SAE Online Poll: Lightweight materials to most benefit heavy vehicles for upcoming regs
Lightweight materials will make the greatest impact in helping medium- and heavy-duty trucks achieve upcoming greenhouse gas/fuel efficiency regulations, according to respondents to an online poll posted on SAE Off-Highway Engineering Online and Automotive Engineering International Online for two weeks in late November and early December. Lightweight materials were chosen by about 42% of the 64 respondents, hailing from 15 nations.
Automatic engine shutdown (idle reduction) came in second with nearly 22% of the vote, followed by design optimization (17%), aerodynamics (11%), and intelligent electronics (e.g., predictive cruise control) at almost 8%. Low rolling resistance tires did not receive a vote.
Half (32) of the respondents were from the U.S., who likewise selected lightweight materials as the most beneficial technology area at 37.5%. Design optimization and automatic engine shutdown swapped places compared to the overall vote, with 22% and 19%, respectively. Aerodynamics received nearly 16% of the U.S. vote, and intelligent electronics received just over 6%.
India had the second most respondents with 8, and Canada was third with 5. Countries posting a single vote included Pakistan (for design optimization), Singapore (lightweight materials), Malaysia (intelligent electronics), and Sri Lanka (automatic engine shutdown).
Check out our magazine websites often to respond to new poll questions posted by the editors, and feel free to suggest possible poll topics at sohe@sae.org or aei@sae.org.
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Voting results for the poll question: “Which technology area will make the greatest impact in achieving upcoming greenhouse gas/fuel efficiency regulations for medium- and heavy-duty vehicles?”
Detailed FEV study shows the way to major vehicle mass savings
Significant vehicle mass reduction—up to 20%—is achievable if weight reduction is pursued as part of a "full-vehicle approach," according to a study by FEV Inc. released Dec. 13. The company used a 2010 Toyota Venza for its research because that model was used in an earlier, related study. The comprehensive phase-two study by FEV was conducted for the U.S. EPA. The previous study, by Lotus Engineering (go to www.sae.org/mags/aei/8512 to read more), was conducted for the International Council on Clean Transportation. That study did not address mass savings from the powertrain to the extent the new one does, nor did it use advanced CAE tools to judge the impact of mass-savings measures on safety, according to FEV. In both cases, the mass savings were to be achieved with no degradation in safety or other parameters. The new study shows that the body-in-white and closures offered the most mass reduction at 68.32 kg (150.62 lb), followed closely by suspension. Total mass savings of 18.3% (312 kg/688 lb) was achieved, and at a cost savings of $148 from manufacturing efficiencies.
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Advanced CAE tools were used as part of the comprehensive study that resulted in a report of 890 pages.
BMW and Boeing to collaborate on carbon-fiber materials
Two heavyweights in the automotive and aerospace industries are joining minds on lighter materials. BMW and Boeing on Dec. 12 announced they would do joint research on carbon-fiber recycling and share knowledge about the material and its manufacture. As part of the collaboration agreement, the two companies will also share carbon-fiber manufacturing process simulations and ideas for manufacturing automation. BMW in 2013 plans to introduce two models from its new i brand (i3 battery-electric and i8 plug-in hybrid) featuring bodies made of carbon-fiber-reinforced plastic. Boeing's new 787 Dreamliner aircraft is made up of 50% carbon fiber. The collaboration is the first ever between the two companies.
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The bodies of BMW's i brand models will use carbon-fiber-reinforced plastic. (Patrick Ponticel)
SAE considers forming group to look at 1234yf in light of Daimler safety claim
SAE International is working with global automakers to investigate the formation of a new Cooperative Research Program (CRP) regarding 1234yf refrigerant. The formation of the group is in response to a Daimler AG press release on Sept. 25 that questioned the safe use of the refrigerant. The CRP will technically evaluate the findings referred to in the release. SAE International has hosted an organizational meeting to discuss a preliminary scope of research and is actively soliciting OEMs to formally join the new CRP. OEMs wishing to join should contact Gary Pollak at 1-724-772-7196 or gary@sae.org.
GM puts taillights aglow with new LED technology
Working with supplier 3M, General Motors engineers have developed what they claim is an industry-first LED taillight technology that delivers a soft, uniform red glow in a complex and unique shape. It is being deployed first on the MY2013 Buick Enclave, then will be cascaded to other Buick models, the company says. The uniform glow is made possible by 3M's Uniform Lighting Lens technology, which uses a precision engineered, micro-patterned, thermoformable polycarbonate material that provides even illumination around complex shapes with fewer LEDs, reducing both complexity and energy use, according to GM.
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The 2013 Buick Enclave's new taillights use an industry-first Uniform Lighting Lens technology from 3M for a unique look and reduced energy use.
New IIHS test aims to increase protection in frontal crashes
The Insurance Institute for Highway Safety (IIHS) has raised the bar with its new small overlap frontal crash test. With a 50th percentile male Hybrid III dummy in the driver seat, 25% of the car’s front end on the driver side strikes a 5-ft-tall rigid barrier at 40 mph. These small overlap crashes, which affect the outer edges not protected by crush-zone structures, are responsible for a considerable percentage of the 10,000 deaths in frontal crashes each year. The test utilizes three rating categories: structure, restraints and kinematics, and dummy injury measures. Of the vehicles tested, the Volvo S60 performed the best, permitting only a few inches of intrusion into the occupant compartment due to reinforcement of the upper rails and a steel cross member below the instrument panel. Common problems with other vehicles included high occupant compartment intrusion and unsafe occupant motion, including dummies that missed the airbag or moved too far forward toward the A-pillar. After 2013, the IIHS intends to add the small overlap frontal crash test to its list of evaluations for the Top Safety Pick award.
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Of the 11 midsize luxury and near-luxury cars tested, only three scored good or acceptable in the new small overlap frontal crash test from IIHS.
Dow expands composite processing capabilities
Dow Automotive Systems has expanded its capabilities in composite processing technology with two new development facilities—one in Freienbach, Switzerland, and the other in Midland, MI. The labs support global automotive and commercial transportation customers with an emphasis on carbon-fiber composites. The 200-m2 (2150-ft2) Composite Technology Center in Freienbach opened in April and is equipped with a large high-pressure resin transfer molding (RTM) machine for prototype production. It also offers development and testing facilities for resins and related adhesives, as well as an Adhesives Training Center. The Midland tech center, which opened in June, accommodates technologies associated with direct long-fiber processing, prepreg, preforming, compression molding, and laminating. This 465-m2 (5000-ft2) site is co-located with key corporate R&D capabilities including analytical sciences, the Materials Engineering Center, and polymer chemistry and processing related expertise. The two new composite technology facilities are part of Dow Automotive Systems’ strategy to support the industry’s push for more lightweight solutions.
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Dow Automotive Systems' new Composite Tech Center in Freienbach is equipped with a large high-pressure resin transfer molding (RTM) machine for prototype production.
General Motors trials MagneGas alternative metal-working fuel
MagneGas Corp., which converts liquid-based materials into hydrogen-based fuel, removing acetylene from the process, is supplying General Motors with its MagneGas fuel. GM is trialing the fuel in maintenance and metal-working activities at its Grand Blanc Weld & Tool Center in Flint, MI. MagneGas will ship its fuel cylinders from its production facility in Michigan. GM tested MagneGas, assessing its environmental, health, and safety impacts, and found that it cut cleaner, faster, and is more cost-effective than acetylene. GM is working with MagneGas to discuss possible future applications with potential to reduce its environmental impact.
ContiTech expands plastic tubes production in U.S.
ContiTech Fluid Technology is building a competence center for plastic lines in the U.S., its second plastics competence center worldwide after one in Waltershausen, Thuringia, Germany. The company is investing about $11 million in the existing ContiTech Thermopol hose factory in Somersworth, NH, to help meet demand in North America, with the first construction stage recently going into operation. ContiTech says that orders from Ford and Chrysler are already exhausting the capacities of the first plant, which has been in production since January. A second system has been ordered and is expected to be installed in October. The company expects the number of plastic tubes it produces to increase fourfold by the end of 2013 compared to 2012. The Somersworth plant was more than doubled in size two years ago for the extrusion of turbocharger hoses and the assembly of SCR (selective catalytic reduction) hose line systems for diesel engines. Volume assembly of SCR lines for Cummins started in June, and lines for Caterpillar will follow shortly, according to ContiTech. Previously, only silicone hoses were produced in Somersworth. The expansion of the plastics technology operations will see a third, 6700-m2 (72,120-ft2) production hall built on the grounds, and an expected increase in the number of employees from 220 presently to 335 by the end of 2013.
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The blow-molding line at ContiTech’s Somersworth plant in New Hampshire currently produces about 150,000 plastic tubes annually.
MacLean-Fogg forms Engineered Plastics Company
MacLean-Fogg Component Solutions has announced the formation of the new Engineered Plastics Company (EPC)—a merger of its Polymer Technologies business in Whitewater, WI, with EPC of Menomonee Falls, WI. EPC, which has been in operation since 1981, is a plastic injection molding supplier. The new Engineered Plastics Co. will be aligned under the Engineered Components Group of MacLean-Fogg Component Solutions. MacLean-Fogg supplies engineered components, fastener components, and linkage and suspension components to a range of industries including automotive, heavy truck, aerospace, appliance, wind, and mining. Engineered components include cold formed and machined components, horizontal hot-formed components, and engineered functional plastics. Fastener components include Securex and Decorex brand wheel fasteners, high-temperature Lockthread bolts, ESNA locknuts, and a variety of internally threaded fasteners such as Whiz-Lock, Clinch-Lok, and Step-Lok nuts. Linkage and suspension components include aluminum control arms, ball studs, housings, plastics, and PogoStik linkages.
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