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Global Viewpoints - Europe: Smartening up R&D As every aspect of automotive technology makes rapid advances, R&D becomes ever more complex and faces additional pressures on cost and time. In our annual report from Europe, we spoke to very senior executives about their R&D methods and the demanding criteria they face. LEDs light the way for SuperTruck A research team developed a group of low-energy; high-output LED lamps for forward lighting that could be retrofitted into the truck's current incandescent headlamp housing and lens. Plastic proliferation under the hood Plastic components continue to displace metal engine parts because of cost and weight advantages.

Drivetrains: Challenging the design philosophy A researcher from the Southwest Research Institute focuses on one of the most immediate and dramatic changes of powertrain design: the introduction of CVTs. Elastohydrodynamic lubricants for CVTs In metal-to-metal continously variable transmissions, EHLs momentarily become part of the machinery, allowing for a much higher traction coefficient than is possible with hydrodynamic fluids. Hybrid vehicle dynamics Toyota engineers combined electronic control of the Estima minivan's breaking and driving functions to create its new Vehicle Dynamics Management system, resulting in improved environmental and vehicle performance. Jeep Commander 2 Chrysler Group engineers provide an inside look at one of the pioneering methanol fuel reforming fuel-cell concept vehicles. Improving SUV fuel economy Delphi is pursuing a strategy of engine shutdown and adding torque from an electric motor with its new 42-V integrated starter-generator.

Lighting goes digital Headlights move towards full integration with sensors, adjusting to turns and other driving conditions, while high-intensity discharge and light-emitting-diode technologies see continued growth. 2004 technology in review AEI editors look back at some of the most significant engineering and innovation stories of the past year. The age of digital experience SAE 100 Future look: Automotive historians will remember the beginning of the 21st century as a defining moment in the history of an industry. Simplifying advanced computing SAE 100 Future look: There is no doubt the world is changing. Global competition and sourcing, cost pressures, safety, and environmental concerns are just a few evolving realities facing the automotive industry today.

Solving the driver distraction problem Is voice-recognition technology the silver bullet? No, engineers agree, but it has its place. Succeeding in the alliance game It was General Motors' Arvin F. Mueller, Chairperson of the SAE 2001 World Congress, who came up with "Succeeding in the Alliance Game" as the theme for the March 5-8 automotive engineering event in Detroit. Ferrari 360 aerodynamic development The search for downforce without aerodyamic devices, such as wings or spoilers, led to novel solutions for the car's suspension. Renault's Euro 3 engine Flexible injection systems allowed Renault VI engineers to balance many conflicting priorities in developing Europe's first heavy-duty diesel engine with a fully electronic high-injection-pressure common-rail injection system. Meeting future emissions standards with diesel SUVs AVL List believes that diesel engines could be one way to improve the environmental acceptance of sport utility vehicles.

Military maneuvers Electronics and avionics designers put control in the pilot's hand. Propelling commercial aircraft GE Aircraft Engines calls upon its engineers, and those of its "competitors," to develop a series of next-generation engines. Bonded repairs Aircraft structure repair is process-sensitive, requiring attention to detail, particularly in terms of both composite and metal surface preparation.

Military engines: cost and capability Industry experts provide a glimpse out at the 2020 vision of military propulsion. Manufacturing propellers Dowty Propellers uses a secure data-logging system for its fabrication process.

Marotta turns things around The valve-making company used to have trouble getting product out the door on time, but it has improved its turnaround dramatically via lean thinking. A view from the factory Manufacturing techniques and materials used in other industries may be debuting at aerospace factories near you. Reverse engineering Using digital processes accelerates design and increases manufacturing quality. Fine-tuning aerodynamics The aerospace industry relies on massive amounts of computing power to continually simulate, test, and optimize vehicles for reliability and accuracy.

Quality through closed-loop manufacturing Pratt & Whitney has employed automated part probing as part of its manufacturing process to provide final inspection, data collection and analysis, and process adjustment. A virtual fighter The Boeing Co. and Lockheed Martin Corp. use SGI's Origin 2000 servers and Silicon Graphics Onyx2 visual supercomputers to design their respective Joint Strike Fighter (JSF) demonstrators virtually. Modular aerospace controls Honeywell investigates a commercial off-the-shelf approach to the automated generation of safety-critical software for distributed control systems. Automated fuselage mating Brotje-Automation GmbH has developed an automated alignment facility designed to accurately position and align major aircraft fuselage sections.

Ford's Focus on the fuel cell The company's Aachen research center for advanced powertrain and environmental technologies provided the backdrop for a first drive of its latest fuel-cell prototype. Global viewpoints: Europe embraces the AT-factor The central pillar on which the success of every international automotive company now rests is the AT-factor, which stands for advanced technology. Target-vehicle modeling in crash analysis Ford engineers have refined their computer crash models for simulating vehicle compatibility between light trucks and cars. Reticulated polyurethane foam The new generation of materials has added safety, performance, reliability, and value to a number of automotive applications. Sorting through new automotive technologies Developments in powertrain, interior, and chassis technolgoies are improving the performance of vehicles in all corners of the world, including Europe.

Phantom materializes BMW's Rolls-Royce Motor Cars unveils its first model, an aluminum-bodied sedan with rear-hinged rear doors and a new V12. Protecting the cabin from powertrain NVH OEMs are getting help from suppliers such as Collins & Aikman and Bayer in damping NVH, thanks to innovation in plastics. Forced induction Environmental pressures prompt renewed interest in turbochargers and superchargers. Collaboration software emerges Interactive product development tools that can decrease design time and cost, enhance quality, and improve engineering processes are now widely available. Validated virtual testing DaimlerChrysler and MTS Systems have verified that component load histories can be predicted before prototypes are built. Automation: a tool, not an end Toyota and its suppliers try to strike a balance between automation and manual labor at their U.S. plants.

Then there were two Prevailing sentiment in the Japanese media, and to some extent among the public, is that there are two truly indigenous automobile manufacturers in Japan: the Toyota group of companies and Honda. Others have entrenched themselves in global alliances for much-needed infusions of foreign capital. Cars and light trucks merge As light-vehicle segments blur in function and utlility, Japanese manufacturers are placing body design emphasis on optimum space utilization and crash safety. Chassis trends Technologies in development by Japanese companies include lane keeping, steer by wire, and dynamic stability via hybrid-electric drive. Engines and electric motors The Japanese industry is pursuing a high-tech mix of internal combustion engines, hybrid IC/electric powertrains, and fuel cells.

Broadening horizons Japanese manufacturing continue to diversify, investing in the launch of a domestic premium brand, updating an iconic sports car, and developing a variety of safer micro cars that are gaining popularity all over the world. Today for tomorrow Japanese automotive manufacturers are researching new engine technologies to improve power, efficiency, and emissions. Continental Flying Spur Bentley engineers sought "no compromises" in creating their new GT-based 312-km/h (194-mph) sedan. Material issue Automakers apply advanced materials to stem the rising tide of weight from increasing safety and convenience features. Testing trends This special edition of Testing & Simulation focuses on some of the more innovative technologies designed to satisfy the industry's demanding testing needs. Trading in a socket wrench for a software patch The good old days of taking your car to the repair shop down the street and hoping for the best as Mr.

Seats of power Car users are sitting on more advanced features than ever before, but increasing demands for "comfort" and other considerations have focused industry brainpower on slimmer seat designs, new trim materials, and innovative technology solutions. Big changes for powertrain control Electronics innovations are behind many of the advances in hybrid, diesel, and conventional gasoline engines. Plastic on the outside For many new vehicles, light weight is paramount, and so too is eye-catching design. That's why plastic body panels will become more prevalent. Toyota powers ahead The company's powertrain strategy follows Toyota President Watanabe's dream that a Toyota car be able to cross the American continent with no refueling while cleansing the atmosphere as it travels. The Honda way In the pipeline are a "dedicated hybrid car for family use," a super-clean diesel that meets U.S.

LED-ing the way Headlamps using low-power semiconductors called light-emitting diodes have moved from concept to reality with recent production firsts, but challenges remain in taking the technology mainstream. High-value hybrids The drive to reduce hybrid vehicle cost while boosting efficiency has brought new attention to stop-start and mild-hybrid systems. Sustainability on a small scale Nanotechnology is a new battleground for fighting emissions and making vehicles more environmentally friendly. Sensors inside Suppliers are helping OEMs enhance interior comfort and convenience. CO2: The next big challenge This roundup of recent engineering developments highlights that cutting emissions does not have to mean cutting the fun. Clearing the air Emissions and fuel-efficiency issues emerge collectively as the top concern among engineers attending this year's SAE World Congress.

Spec Formula One The series is moving forward with new rules to reduce cost and make racing more directly relevant to road-car development. Adding foresight Radar and cameras will work together to help drivers avoid accidents. Lexus LS 460:AEI's Best Engineered Vehicle for 2007 The fourth generation of Lexus' global flagship sets new standards in engineering, technical innovation, refinement, and workmanship. Hot off the grid New interest in plug-in hybrids has sparked intense R&D in battery chemistries and systems integration. Digital developments Ever-improving computer-based tools are helping engineers complete more complex designs in shorter time frames with downsized staffs. Illuminating technology Sensor-linked lighting systems, automatic high-beam control, LED headlights, and brand-identifying cabin lighting are enhancing safety, convenience, and the feel-good factor.

Uncertainty quantification The technique is a must for next-generation simulation tools. Oil-pump sizing Researchers from Hinduja Tech investigate options for low friction and power consumption. The future of Indian commercial aviation The growth in traffic that airport modernization has supported has also made a significant contribution to the local and national economies, while the improved infrastructure has been positive for the perception of India in the global market. Driving EVs toward lower cost The race ison to reduce battery and electric-drive systems cost while improving efficiency. Powering on Rolls-Royce's Chief Engineer discusses new technologies that inspire current R&D design and evaluation work as part of its strategic roadmap for future big commercial programs. HMIs extend beyond the cab Telematic functions are being integrated into multi-function user interfaces.

The advent of stop-start technology As environmental concerns grow for R&D teams, OEMs look to bring the strategy further into the mainstream. Recycling opportunities for hybrid/electric vehicle lithium-ion batteries With limited reserves and strict environmental regulations, re-cyclers look to established extraction means to reuse, recycle, and dispose of the used batteries. Cameras look to go the distance Automakers seek vision systems with greater distances, improved reliability, and more functionality, thanks to ruggedized complementary metal-oxide semiconductor technologies. Getting right with composites With composites now a mainstay in most new aircraft de-signs, the engineering emphasis has switched from understanding if they work to thinking through the most efficient way to manufacture them, such as using design-for-manufacturing software.

Integration opens the door Semiconductor suppliers are integrating many functions into power devices while also cutting power consumption in an environment, automotive doors, where 8-bit microcontrollers still hold sway.

The Nano in retrospect A senior graduate student in the Department of Mechanical Engineering at the Indian Institute of Technology looks at the development of the world's cheapest car and its effect on Indian car users. A different riff on your basic two-seat electric car Markus Lienkamp, Chair of Automotive Engineering at the Technical University of Munich, is leading the Visio.M project, a German government-supported R&D effort to produce a low-cost, high-utility electric car that might attract the interest of the middle European mass market. Materials lead the way to vehicle mass reduction Reducing a vehicle's mass opens the door for a downsized engine and transmission, a lighter cradle and body structure, smaller wheels and brakes, as well as a weight-slimmed suspension. The start point for this ripple effect is materials.

Putting electrification to work For fleets, going green is a high priority-but making green is an even higher one. A move to 'more electric' engines Researchers detail a motor control design for the fuel system of a more electric aero engine, focusing on the necessary safety and reliability aspects. 2012-13 Hybrid Vehicles Guide A quick reference to the latest production HEVs and their key specifications.