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“Spotlight on Design” features video interviews and case study segments, focusing on the latest technology breakthroughs. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. Fuel efficiency, or simply put, how to get more mileage out of the same amount of fuel has become one of the main goals to be achieved by new automotive technologies in the future, thanks in part to new government regulations. In the episode “Fuel Efficiency: Racing toward CAFE 2025” (21:24) AVL engineers show simulation and testing being used to design more fuel efficient vehicles, including the equipment that actually analyzes fuel economy.

For internal combustion engines and industrial machinery, it is well recognized that the most cost-effective way of reducing energy consumption and extending service life is through lubricant development. This presentation summarizes our recent R&D achievements on developing a new class of candidate lubricants or oil additives ionic liquids (ILs). Features of ILs making them attractive for lubrication include high thermal stability, low vapor pressure, non-flammability, and intrinsic high polarity. When used as neat lubricants, selected ILs demonstrated lower friction under elastohydrodynamic lubrication and less wear at boundary lubrication benchmarked against fully-formulated engine oils in our bench tests. More encouragingly, a group of non-corrosive, oil-miscible ILs has recently been developed and demonstrated multiple additive functionalities including anti-wear and friction modifier when blended into hydrocarbon base oils.

With automotive electrification, the electric machines show a tendency to share or even replace the dominant role of internal combustion engines in future vehicles. Besides the design and innovation of different electric machines to meet the needs of powertrain and drivetrain performances, high volume production becomes a challenging topic and an un-avoided requirement. Flexible line and sharing line will help the variation of production rate and volume, while the dedicated unique line contributes to large scale of E-motor production. Supplier chain from raw materials, parts to processes has to be built from ground-zero or low grade to mature stage within quality specification and time limitation. Multi function skills, cross area technologies and complex management etc are all required for E-motor manufacturer to grow up with component and equipment suppliers. Reducing cost, improving quality and guaranteeing safety are always the thematic series.

This presentation will introduce the overall goals of the EcoCAR competition in brief, and will go into the third and final year of the competition in detail. The final year of competition saw teams refining and testing their student-built advanced technology vehicles including hybrids, plug-in hybrids, hydrogen fuel cell PHEVs and one battery electric. Important events, such as the Spring Workshop chassis dynamometer testing event at the U.S. Environmental Protection agency, as well as significant competition results, such as vehicle performance, consumer acceptability and efficiency will be presented. Presenter Patrick Walsh

This paper forms the third of a series and presents results obtained during the testing and development phase of a dedicated range extender engine designed for use in a compact class vehicle. The first paper in this series used real world drive logs to identify usage patterns of such vehicles and a driveline model was used to determine the power output requirements of a range extender engine for this application. The second paper presented the results of a design study. Key attributes for the engine were identified, these being minimum package volume, low weight, low cost, and good NVH. A description of the selection process for identifying the appropriate engine technology to satisfy these attributes was given and the resulting design highlights were described. The paper concluded with a presentation of the resulting specification and design highlights of the engine. This paper will present the resulting engine performance characteristics.

Automakers, suppliers, public agencies, interest groups and others are increasingly embracing the environment as one of the dominant forces in the US automotive market. All parties have a strong vested interest in understanding how environmental concerns will influence design, production, marketing and usage of tomorrow�s vehicles. A common need of all parties is independent and actionable information to enable them to make better decisions and have the greatest chance of being successful in this uncertain future. Four factors - an uncertain economic climate; a constantly changing governmental regulatory system; advancements in powertrain technology; and ever-present environmental concerns - continue to shape the automotive landscape. While automakers are focused on developing alternative powertrains and alternative fuel options for an increasingly �green� vehicle market, J.D.

Simulation-based tolerance analysis is the accepted standard for dimensional engineering in aerospace today. Sophisticated 3D model-based tolerance analysis processes enable engineers to measure variation in complex, often large, assembled products quickly and accurately. Best-in-class manufacturers have adopted Quality Intelligence Management tools for collecting and consolidating this measurement data. Their goal is to completely understand dimensional fit characteristics and quality status before commencing the build process. This results in shorter launch cycles, improved process capabilities, reduced scrap and less production downtime. This paper describes how to use simulation-based approaches to correlate the theoretical tolerance analysis results produced during engineering simulations to actual as-built results. This allows engineers to validate or adjust as-designed simulation parameters to more closely align to production process capabilities.

Presented by: Dan Ott Web Industries Director, Business Development, Advanced Composites Market With the growth of Fiber Placement technology as a preferred automation technology in aerospace manufacturing and the rapid growth of new production line installations, it is crucial to provide material in a form which meets all necessary specifications and supports the optimum productivity available from this major capital investment made by the producer of the parts. Achieving these goals happnes when the part designer, AFP machine builder, and the slit tape producer design the best process and format which provides smooth, efficient and rapid delivery of the prepreg slit tape to the Fiber Placement laydown head. Tape size (width), slit width tolerance, spool shape and size, density of prepreg on the spool, spool change-over and handling processes all play a factor in productivity, and creating (or inhibiting) the best ROI on a full-scale AFP production line.

There are worldwide activities in developing guidelines and standards for fiber optic sensors. Fiber optic sensors (FOS) are increasingly demanded for structural health monitoring purposes and for measurement of physical and chemical quantities because of their specific features. However, they are not yet widely established for practical use due to a lack of guidelines and confirmed standards. Therefore, there are few groups worldwide which are very active in developing standards for use of FOS in different fields, particularly driven from aircraft industry, oil industry or the necessity to provide sensor systems for health monitoring of structures with a certain level of risk. The benefits of guidelines and/or standards on the way to well-validated and well-specified sensor systems will be presented by means of related examples. The presentation will also give an overview on the state-of-the-art and most relevant activities. Results achieved are discussed.

In Aeronautic industry, when we launch a new industrialization for an aircraft sub assembly we always have the same questions in mind for drilling operations, especially when focusing on lean manufacturing. How can we avoid dismantling and deburring parts after drilling operation? Can a drilling centre perform all the tasks needed to deliver a hole ready to install final fastener? How can we decrease down-time of the drilling centre? Can a drilling centre be integrated in a pulse assembly line? How can we improve environmental efficiency of a drilling centre? It is based on these main drivers that AIRBUS has developed, with SPIE and SOS, a new generation of drilling centre dedicated for hard materials such as titanium, and high thicknesses. The first application was for the assembly of the primary structure of A350 engine pylons. The main solution that was implemented meeting several objectives was the development of orbital drilling technology in hard metal stacks.

At the end of 2006, two MTorres engineers visited the plant of Airbus UK in Filton receiving a new challenge: Find a more efficient way to manufacture Carbon Fiber Spars for the new A350 program. The range of possibilities were wide: manual infusion methods (RTM, RIM, RFI...), Automatic Taping & hot forming, or the new technology proposed, Fiberplacement or AFP. Two (2) options were considered: hot forming+ATL and AFP (both using prepeg technology.) The usage of a flat lay-up + hot forming technology was used in the only Airbus program that used carbon fiber for the wing manufacturing so far, the A400M. The expected greater complexity of A350 spar created doubts on the feasibility of using the above process, while the AFP technology, consisting of laying up directly on the final shape of the spar, also raised questions of technical feasibility, apart from the economic ?business case?, in case the productivity of the cell was not big enough. A ?Spar team?

The foundation of many production aircraft assembly facilities is a more dynamic and unpredictable quantity than we would sometimes care to admit. Any tooling structures constructed on these floors, no matter how thoroughly analyzed or well understood, are at the mercy of settling and shifting concrete, which can cause very lengthy and costly periodic re-certification and adjustment procedures. It is with this in mind, then, that we explore the design possibilities for one such structure to be built in Belfast, North Ireland for the assembly of the Shorts C-Series aircraft wings. We evaluate the peak floor pressure, weight, gravity deflection, drilling deflection, and thermal deflection of four promising structures and discover that carefully designed pivot points and tension members can offer significant benefits in some areas.

The sustainable use of energy and the reduction of pollutant emissions are main concerns of the automotive industry. In this context, Hybrid Electric Vehicles (HEVs) offer significant improvements in the efficiency of the propulsion system and allow advanced strategies to reduce pollutant and noise emissions. The paper presents the results of a simulation study that addresses the minimization of fuel consumption, NOx emissions and combustion noise of a medium size passenger car. Such a vehicle has a parallel-hybrid diesel powertrain with a high-voltage belt alternator starter. The simulation reproduces real-driver behavior through a dynamic modeling approach and actuates an automatic power split between the Internal Combustion Engine (ICE) and the Electric Machine (EM). Typical characteristics of parallel hybrid technologies, such as Stop&Start, regenerative braking and electric power assistance, are implemented via an operating strategy that is based on the reduction of total losses.

Plugin Hybrid Electric Vehicles (PHEV) have a large battery which can be used for electric only powertrain operation. The control system in a PHEV must decide how to spend the energy stored in the battery. In this paper, we will present a prototype implementation of a PHEV control system which saves energy for electric operation in pre-defined geographic areas, so called Green Zones. The approach determines where the driver will be going and then compares the route to a database of predefined Green Zones. The control system then reserves enough energy to be able to drive the Green Zone sections in electric only mode. Finally, the powertrain operation is modified once the vehicle enters the Green Zone to ensure engine operation is limited. Data will be presented from a prototype implementation in a Ford Escape PHEV Presenter Johannes Kristinsson

Transmission of light through automotive topcoat and primer layers can lead to degradation of the underlying electrocoat layer and to topcoat delamination. In order to protect against this, it is critical that transmission of both ultraviolet wavelengths and certain visible wavelengths be effectively blocked by the topcoat and primer layers. The clearcoat, basecoat and primer each have their own role and combine to protect against light transmission. The transmittance of these combined layers is typically measured by the Integrating Sphere UV-Visible Spectrophotometer. It would both simplify measurement of the topcoat systems and allow better system modeling if these layers could be measured separately and combined mathematically. We demonstrate here that absorbing and reflecting pigments can be effectively modeled using the Beer-Lambert law while results for scattering pigments are consistent with the Kubelka-Munk theory.

ISO 26262 is the actual standard for Functional Safety of automotive E/E (Electric/Electronic) systems. One of the challenges in the application of the standard is the distribution of safety related activities among the participants in the supply chain. In this paper, the concept of a Safety Element out of Context (SEooC) development will be analyzed showing its current problematic aspects and difficulties in implementing such an approach in a concrete typical automotive development flow with different participants (e.g. from OEM, tier 1 to semiconductor supplier) in the supply chain. The discussed aspects focus on the functional safety requirements of generic hardware and software development across the supply chain where the final integration of the developed element is not known at design time and therefore an assumption based mechanism shall be used.

Using pressure sensitive adhesive tapes to achieve economy and efficiency in automotive assembly

ISO 26262 is the first comprehensive automotive safety standard that addresses the safety of the growing number of electric/electronic and software intensive features in today's road vehicles. This paper assesses the standard's ability to provide safety assurance. The strengths of the standard are: (1) emphasizing safety management and safety culture; (2) prescribing a system engineering development process; (3) setting up a framework for hazard elimination early in the design process; (4) disassociating system safety risk assessment from component probabilistic failure rate. The third and fourth strengths are noteworthy departure from the philosophy of IEC61508. This standard has taken much-needed and very positive steps towards ensuring the functional safety of the modern road vehicles. SAE publications from industry show a lot of enthusiasm towards this standard.

Those who are concerned about access to rare earths and other critical minerals for EV powertrains are focused on the exact wrong problem. Mr. Thomas discusses why it's control of process technology, not the raw ores themselves, that dictates cost, availability and performance. Presenter Lawrence B. Thomas, Primet Precision Materials

As an annual subscription, the Wiley Cyber Security Collection Add-On is available for purchase along with one or both of the following: Wiley Aerospace Collection Wiley Automotive Collection The titles from the Wiley Cyber Security Collection are included in the SAE MOBILUS® eBook Package. Titles: Network Forensics Penetration Testing Essentials Security in Fixed and Wireless Networks, 2nd Edition The Network Security Test Lab: A Step-by-Step Guide Risk Centric Threat Modeling: Process for Attack Simulation and Threat Analysis Applied Cryptography: Protocols, Algorithms and Source Code in C, 20th Anniversary Edition Computer Security Handbook, Set, 6th Edition Threat Modeling: Designing for Security Other available Wiley collections: Wiley SAE MOBILUS eBook Package Wiley Aerospace Collection Wiley Automotive Collection Wiley Computer Systems Collection Add-On (purchasable with the Wiley Aerospace Collection and/or the Wiley Automotive Collection)