SAE offers new credential program for engineers
SAE International is introducing a personnel credentialing program that enables engineers, product development technicians, and associated personnel to earn a Certificate of Competency or Certification in the Design Review Based on Failure Modes (DRBFM) methodology. Created by industry professionals for industry professionals, the program was developed and segmented into three distinct levels to meet the needs of specific personnel. Exam questions align with the body of knowledge to address each of the three levels. The DRBFM Process and Application Certificate of Competency is designed for individuals who require training and validation of knowledge in DRBFM process methodology. Job roles include product engineers, manufacturing engineers, quality engineers, supplier quality engineers, validation and test engineers, and facilitators, trainers, and consultants in all industries. This credential requires completing an open-enrollment training course and passing an online exam. Registration is now open for the December 2012 offering of this program. For more information, contact SAE International at certification@sae.org or visit https://www.saecredentialingalliance.org/go/drbfm.
Gentherm to adapt passenger-car thermoelectric generator to heavy vehicles
Gentherm has received a $1.55 million contract modification from the U.S. Department of Energy (DOE) to apply the technology in its thermoelectric generator (TEG) for passenger cars to a similar program for heavy vehicles. The TEG technology, which converts waste heat from gas exhaust into electric energy, has the potential to improve passenger-car fuel efficiency by as much as 5%, the company claims. The grant is an add-on to the $8 million award from the DOE in August 2011 for converting thermoelectric heat to power for passenger cars and extends the technology to heavy military vehicles. With this new project, the U.S. Army Tank Automotive, Research, Development and Engineering Center (TARDEC) becomes a key partner to Gentherm, joining passenger-car partners Ford and BMW. With completion expected by early 2015, the project will scale up the fully functional passenger-car TEG (working prototypes have been delivered to BMW and Ford) and integrate it with a 15-L diesel engine to provide fuel economy improvement and ignition-off auxiliary power for combat vehicles. This add-on leverages the existing program technology for large diesel engines, providing a new solution for military heavy vehicles, Class 8 trucks, marine, and industrial power generating equipment.
Other related articles include: http://www.sae.org/mags/aei/10647 and http://www.sae.org/mags/aei/7916.
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Gentherm's automotive thermoelectric generator (shown), which converts unused waste heat to electricity, is now being scaled up to suit heavy vehicles.
Navistar, JAC one step closer to Chinese engine joint venture
Navistar International Corp. and Chinese truck maker Anhui Jianghuai Automobile Co. Ltd. (JAC) recently received formal approval from China’s National Development and Reform Commission (NDRC) to move forward with their commercial-engine joint venture, first announced in September 2010 when the companies signed an agreement. The JV will provide JAC with access to Navistar’s Euro IV and Euro V compliant technology, and also sets the stage for global export opportunities of JAC’s light-, medium-, and heavy-duty commercial trucks. Navistar has established a central China office in Shanghai, as well as satellite offices in Beijing and Hefei. In Hefei, product development engineers from both companies have been collaborating on engine and vehicle design. Construction also has started on a 93,000-m2 (1 million-ft2) machining and assembly facility, R&D center, and administrative offices in Hefei to support the new venture. Products slated for the JV include Navistar’s MaxxForce 3.2-, 4.8-, and 7.2-L, and JAC’s 2.8-L 4DA1 engines. Now that the JV has received its business license, Navistar and JAC planned to formally submit their commercial truck joint venture application to the Chinese government this fall.
Tier 4 small diesels coming from MHI
Mitsubishi Heavy Industries, Ltd. (MHI) has announced the production schedule for its new Tier 4 small diesel engines in the output range of 19 to 74 kW (25 to 99 hp). The Tier 4 compliant D03CJ and D04CJ will begin production in 2013; the Tier 4 interim D04EG is currently available, and the Tier 4 final version will be available in 2015. These engines will be suitable for a variety of construction, agricultural, and industrial equipment, such as compressors, generators, welders, off-highway equipment, material handling, etc.
Compared to the previous Tier 3 compliant models being replaced, the D03CJ (1.655 L) and D04CJ (2.207 L) offer a smaller displacement, while output has been increased. The three-cylinder D03CJ produces up to 41 kW (55 hp) and 165 N·m (122 lb·ft) at 1800 rpm. The four-cylinder D04CJ produces a maximum of 55 kW (74 hp) and 230 N·m (170 lb·ft) at 1800 rpm. Fuel efficiency is reportedly 16% better than the previous engines.
The new Tier 4 interim, four-cylinder D04EG (3.331 L) delivers up to 74 kW (99 hp) and 375 N·m at 1600 rpm, with a power density of 0.22 kW/L. Compared with the Tier 3 engine it replaces, the D04EG offers 12% improved fuel economy. To achieve Tier 4 final compliance in the 57- to 74-kW (76- to 99-hp) range, MHI currently plans to incorporate a selective catalytic reduction (SCR) system.
All three new engine models are equipped with high-performance turbochargers, manufactured at the same plant that the engines are produced. Combined with a new optimized common-rail system, the engines achieve an enhanced power density that increases output up to 50% compared with the previous Tier 3 compliant engines, MHI claims.
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The D03CJ (pictured) and D04CJ both feature an optimized common-rail system with a diesel particulate filter (DPF) and diesel oxidation catalyst (DOC) for Tier 4 compliance.
Allison and Dana license Fallbrook's NuVinci transmission technology
Dana Holding Corp. and Allison Transmission will use Fallbrook Technologies' Continuously Variable Planetary (CVP) technology in new products under a "strategic relationship" announced by the three companies Sept. 13. Fallbrooks' NuVinci CVP is a traction-based class of continuously-variable transmission that is scalable and adaptable. In the basic design, a set of rotating balls is located between the input and output components. Tilting the balls changes their contact diameters and varies the speed ratio. Compared to other current technologies, Fallbrook claims its is less complex, scales and packages more easily, and costs less to manufacture. Under the deal, Allison has exclusive rights to use the Fallbrook CVP technology to develop and commercialize primary drivetrain transmissions for Allison's end markets, which could include commercial vehicles, military applications, and certain off-highway and large stationary equipment. Under a separate agreement, Dana will hold an exclusive license to engineer and produce transmission components and other advanced powertrain solutions for passenger and certain off-highway vehicles in the end markets that Dana serves. For end markets Allison Transmission serves, Dana and Allison have signed a letter of intent to explore a strategic alliance through which Dana would exclusively manufacture transmission components with NuVinci CVP technology for Allison. Full-scale production of transmissions with NuVinci-equipped components in Dana's off-highway markets is expected within the next three to five years, while implementation in passenger and commercial vehicles is anticipated before the end of this decade.
Eaton, NREL team to reduce hybrid-electric-vehicle battery size
Eaton Corp. is developing a power control system for hybrid-electric vehicles (from passenger cars to commercial vehicles) with the goal of reducing by 50% the size of the battery needed. The company on Aug. 27 announced that the work is part of a $2.8 million project funded jointly by Eaton and the U.S. Department of Energy, the latter of which is contributing $2 million. The project is being led by Eaton's Innovation Center team in Southfield, MI, which will work with a team from the DOE's National Renewable Energy Laboratory (NREL)—the former offering expertise in intelligent power management and the latter expertise in battery modeling and prognostics. Specifically, the project aims to significantly downsize the battery through a combination of duty-cycle learning and model-based supervisory optimal control design. Using advanced physics-based battery models developed in partnership with NREL, the hybrid vehicle supervisory controller dynamically balances fuel economy and the health of the downsized battery pack to maximize vehicle performance while minimizing the impact on battery life.
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Using advanced physics-based battery models developed in partnership with NREL, the hybrid vehicle supervisory controller dynamically balances fuel economy and the health of the downsized battery pack.
Parker acquires Indian hydraulics business
Parker Hannifin Corp. announced in mid-July that it had acquired the hydraulics manufacturing division of PIX Transmissions Ltd. based in Nagpur, India. PIX manufactures a range of hydraulic and industrial hose, hose assemblies, and fittings primarily used in general engineering, marine, agriculture, mining, construction, and HVAC markets. Terms of the transaction were not disclosed. The acquired business has annual sales of approximately $13 million, employs 470 people, and includes a recently upgraded $25 million manufacturing plant in Nagpur. The division will be integrated into Parker's Fluid Connectors Group, and sales will be reported as part of the International Industrial Segment. “The acquisition of the PIX hose and fittings business will allow us to solidify our position in India, which is a strategically important growth market, while establishing an important base to support growth in the region,” said Bob Bond, President of Parker's Fluid Connectors Group.
Cummins broadens SCR dosing via Hilite acquisition
Cummins Inc. has acquired the emissions control assets of Hilite International in Marktheidenfeld, Germany, and made them part of Cummins Emission Solution (CES), positioning the company to serve all major market applications with a Cummins doser. The selective catalytic reduction (SCR) dosing system developed by Hilite will complement existing Cummins aftertreatment technology, including controls, sensors, catalysts, substrates, and packaging. As part of the acquisition, 133 former Hilite employees have joined Cummins; for now, the business will continue to operate from the plant at Marktheidenfeld. “This acquisition puts Cummins in a strong position to meet the needs of current customers and grow into new markets, especially as an increasing number of regions around the world adopt tougher emissions standards,” said Srikanth Padmanabhan, Vice President and General Manager of CES.
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.
New ETI project to increase heavy-duty vehicle efficiency
The Energy Technologies Institute (ETI), working with Romax Technology, Castrol Ltd., and ANSYS Inc., has announced a £2.5 million project to reduce parasitic losses and increase the efficiency of heavy-duty vehicles (HDVs). The project will focus on improving vehicles’ overall system design, including gears, bearings, surface treatments, lubricant flow, and lubricant composition. Parasitic losses in the lower drivetrain system can account for more than 10% of overall vehicle energy losses; the goal is to cut this loss by 50%. ETI plans to use the technologies developed in this project on a variety of HDVs, including buses, tractors, backhoe loaders, and wheeled loaders. “When we launched our HDV efficiency program, we stated a belief that HDV carbon dioxide emissions could be reduced by up to one-third,” said Chris Thorne, Program Manager for Heavy Duty Vehicles at ETI. “This next phase of the program aims to take us closer to that end objective.”
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