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The 1997 F-Series and Expedition Instrument Panel programs were initially launched with steering column and glove compartment knee bolsters constructed of compression molded, glass filled polypropylene. First run capability of the material at production speeds was only 65 percent due primarily to dimensional stability (warp), paint adhesion, and excessive rework issues. A Ford APO (now Visteon) / Dow Automotive† team was formed to seek a replacement material / design for the glass filled polypropylene material which would solve the problems. The new material system had to meet or exceed current FMVSS 208 crash performance standards, provide improved quality and reduce variable and scrap costs all with a minimum tooling investment. Using Dow PULSE™ PC/ABS resin, the team designed / implemented a new knee bolster system in 12 months.

A new type of solar-reflective glass that improves reflection of the near-infrared (NIR) portion of the solar spectrum has been developed. Also developed was a prototype solar-reflective paint that increases the NIR reflection of opaque vehicle surfaces while maintaining desired colors in the visible portion of the spectrum. Both of these technologies, as well as solar-powered parked car ventilation, were tested on a Cadillac STS as part of the Improved Mobile Air Conditioning Cooperative Research Program (I-MAC). Significant reductions in interior and vehicle skin temperatures were measured. The National Renewable Energy Laboratory (NREL) performed an analysis to determine the impact of reducing the thermal load on the vehicle. A simplified cabin thermal/fluid model was run to predict the potential reduction in A/C system capacity. The potential reduction in fuel use was calculated using a vehicle simulation tool developed by the U.S. Department of Energy (DOE).

A fuel vapor system model (FVSMOD) has been developed to simulate vehicle evaporative emission control system behavior. The fuel system components incorporated into the model include the fuel tank and pump, filler cap, liquid supply and return lines, fuel rail, vent valves, vent line, carbon canister and purge line. The system is modeled as a vented system of liquid fuel and vapor in equilibrium, subject to a thermal environment characterized by underhood and underbody temperatures and heat transfer parameters assumed known or determined by calibration with experimental liquid temperature data. The vapor/liquid equilibrium is calculated by simple empirical equations which take into account the weathering of the fuel, while the canister is modeled as a 1-dimensional unsteady absorptive and diffusive bed. Both fuel and canister submodels have been described in previous publications. This paper presents the system equations along with validation against experimental data.

VADSIM-FEA is a comprehensive axle and driveline system finite element (FE) modeling tool developed by Visteon Chassis Axle & Driveline Strategic Business Unit (SBU). By incorporating the best Computer-Aided Engineering (CAE) Practices and SDRC IDEAS software, VADSIM-FEA serves as a user-friendly tool in creating complete driveline system FE models for the purpose of noise, vibration and harshness (NVH) and component structural analyses. The tool was successfully used to generate Independent Rear Suspension (IRS) driveline system FE models as well as its subassemblies resulting in more than 70% reduction in modeling time. VADSIM-FEA makes up-front CAE analyses more efficient in fulfilling VPDS (Visteon Product Development System) objectives.

The auto industry has recently seen a trend in the packaging of metallic and thermoplastic components in “integrated” systems for cockpit modules. The following is a summary of engineering validation of an overmolded cross car beam (CCB) with HVAC system. The design concentrates on meeting the structural demands placed on a CCB constructed using a unique insert-molding process while meeting system demands of packaging and air handling.

A proof-of-concept study has been undertaken to demonstrate the use and potential benefits of actively controlled coolant jets in an IC engine cooling gallery simulator. Results have shown that substantial reductions in coolant volumes are possible and that the control of the liquid/metal surface temperature can be achieved within +/- 0.2°C in response to transient heat flux conditions.

The need for entertainment and information has been a desire ever since people began driving cars. Over the last decade, the entertainment systems for vehicle applications have transformed from a basic audio system to an infotainment and information center similar to what is available in the home or office. The vehicle passenger compartment has already integrated the major innovations available in the home entertainment market, such as Video, Gaming, DVD, MP3, USB, Navigation and Internet connectivity. This rapid growth has been driven by both customer demand and increased affordability. This revolution has driven major changes in vehicle design to accommodate the new concepts and features. Vehicles are now an extension of our homes and offices in terms of convenience, information and entertainment, with content delivered in a safe and pleasant manner for the driver and passengers.

Automotive manufacturers are under pressure to improve the fuel consumption and emissions figures produced by standard drive cycle tests of their vehicles. Drive cycle tests, such as the New European Drive Cycle (NEDC) start with the engine and transmission cold. The fuel consumption is worse for a cold powertrain than when it is at normal operating temperatures and consequently one way of improving both fuel consumption and emissions is by heating the powertrain as quickly as possible. The PITSTOP (Powertrain Integrated Thermal Systems for Thermodynamically Optimised Performance) project brought together several companies to find ways of reducing the powertrain warm up time. Part of the project was to develop a thermal model of the engine that could both simulate the baseline powertrain and predict the potential improvements of alternative thermal management strategies.

The recycling of post industrial ABS and PMMA was investigated. A material compound consisting of 100% post industrial (PI) recycled ABS and multicolored acrylic (PMMA) scrap from a manufacturing plants was blended and extruded. Test samples were injection molded and the test results were correlated to virgin material. Additionally, the material was used in injection molding of rear lamp housings in black and gray colors. The test results and economics are promising.

Motorized throttle valves on conventional spark-ignited engines are designed to have a default position such that when unpowered they go to a fixed position which is between closed-in-bore and wide open. This position allows some, albeit limited, vehicle function in the event of a throttle positioning fault. Described here is a new default positioning mechanism attained by rotating the valve past the conventional operating arc (between closed-in-bore and wide open) through wide open to a partially open position. This default throttle position concept eliminates control difficulties and an undesirable failure mode. The advantages and disadvantages are discussed. Further, the required valve geometry is derived.

A time-efficient throttle flow data collection method is described. It uses a sonic nozzle flow bench to measure air flow as a function of throttle angle and pressure in a manner analogous to on-engine dynamometer throttle flow characterization. Opening each sonic nozzle combination, then recording throttle downstream pressure and computed nozzle flow allows data to be taken in a fraction of the time normally needed. Throttle flow modeling considerations are then discussed.

A series of calibration methodologies have been developed to aid the powertrain engineer in meeting calibration targets throughout the engine development process, i.e. from early engine mapping through to final OBD calibration and vehicle sign off. This paper will present practical examples of the methodologies developed for the base engine mapping phase. The advantages of using design of experiments and advanced statistical modelling to develop empirical models are shown. The models are used to populate the powertrain control module calibration tables as well as for predictive emissions optimisation. The major benefit of the calibration methodologies utilising the model based approach is the ability to evaluate the drive/emissions compromise with no additional testing.