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PPG Industries, the world's leading manufacturer of transportation coatings, recently completed a study of consumer opinions regarding the importance of coatings and color as they relate to new car purchases. The goal of the study was to identify premium color consumers who place a large importance on vehicle color, what vehicles they purchase and how satisfied they are with the current color offerings. The internet based study consisted of approximately 1,340 U.S. consumers who have either purchased a new vehicle in the past two years, or are planning to purchase a vehicle within the next two years. Results from this study will be presented and those consumers identified by demographics. Presenter Michael Millar, PPG

Listen in as Dr. Ravi Rajamani discusses his new book, the history of electric flight, and electric propulsion. Learn more at books.sae.org/t-135.

Can you become a visionary or are you born one? How does a visionary capture an opportunity and makes it a successful business? Are engineers more qualified to solve technical problems or run companies? SAE's "The Visionary's Take" addresses these and many other questions, by talking directly with those who have dared to tackle difficult engineering problems, and create real-life products out of their experience. In these short episodes, Sanjiv Singh and Lyle Chamberlain, respectively CEO and Chief Engineer from Near Earth Autonomy, talk about their experience in creating a brand-new company in the UAV world. Founded in 2011, Near Earth Autonomy brought together a group of engineers and roboticists, looking for unconventional solutions to very hard logistics problems, presenting danger to human life. The answers were developed by pushing technology to a higher level, testing quickly and often, and keeping an open mind to alternative ways of framing engineering challenges.

Can you become a visionary or are you born one? How does a visionary capture an opportunity and makes it a successful business? Are engineers more qualified to solve technical problems or run companies? SAE's "The Visionary's Take" addresses these and many other questions, by talking directly with those who have dared to tackle difficult engineering problems, and create real-life products out of their experience. In these short episodes, Sanjiv Singh and Lyle Chamberlain, respectively CEO and Chief Engineer from Near Earth Autonomy, talk about their experience in creating a brand-new company in the UAV world. Founded in 2011, Near Earth Autonomy brought together a group of engineers and roboticists, looking for unconventional solutions to very hard logistics problems, presenting danger to human life. The answers were developed by pushing technology to a higher level, testing quickly and often, and keeping an open mind to alternative ways of framing engineering challenges.

We're working to solve the STEM crisis and building the next generation of engineers and scientists with our Kindergarten-College programs supported by the SAE Foundation: - A World In Motion (AWIM) Kindergarten-8 - Collegiate Design Series (CDS) College Help us inspire curiosity in STEM: find out more at saefoundation.org today.

In “Simulation Tools for Engine Design” engineers from Ricardo Software discuss the use of simulation software in new powertrain development. Another engineer, this time from General Motors, talks about how simulation tools helped them solve the challenge of fuel flow reversion while designing the new turbocharged Cadillac V6 engine. This episode highlights: The challenge of simulating complex and combined systems in one vehicle An example of how a library of components in a software package can be chosen to form a specific system and analyzed How computational fluid dynamics simulation tools were used to help redesign a new planum Also Available in DVD Format To subscribe to a full-season of Spotlight on Design, please contact SAE Corporate Sales: CustomerSales@sae.org or 1-888-875-3976.

“Spotlight on Design” features video interviews and case studies, focusing on technology breakthroughs, hands-on testimonials, and the importance of fundamentals. Viewers are virtually taken to industry labs and research centers to learn how design engineers solve real-life problems. These challenges include enhancing product performance, reducing costs, improving quality and safety, while decreasing environmental impact, and achieving regulatory compliance. In the episode “Additive Manufacturing: 3D Printing in the Automotive Industry” (20:00), engineers from Fiat Chrysler Corporation (FCA) explain the importance of using 3D printing to test multiple design scenarios and develop solutions that can be quickly evaluated on test tracks. And Local Motors shows how it builds a vehicle from the ground up with a 3D printer, and without a traditional assembly line.

“Spotlight on Design” features video interviews and case studies, focusing on technology breakthroughs, hands-on testimonials, and the importance of fundamentals. Viewers are virtually taken to industry labs and research centers to learn how design engineers solve real-life problems. These challenges include enhancing product performance, reducing cost, improving quality and safety, while decreasing environmental impact, and achieving regulatory compliance. In the episode “Engine Development for Performance and Efficiency” (22:00), engineers from Ricardo and General Motors explain the importance of lessons learned on the race tracks, how using the appropriate design and simulation tools expedite development, and present the new testing frontiers now available with 3D printing.

“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.

“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. Just how prevalent is the problem of counterfeit electronic parts? What are the consequences of using sub-par components in safety or mission critical systems? The Federal Aviation Administration estimates that 2% of the 26 million airline parts installed each year are counterfeit, accounting for more than 520,000 units, maybe more.

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.

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.

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

Since 2006 Oak Ridge National Labs (ORNL) and the Pacific Northwest National Labs (PNNL) have conducted research of injection molded long glass fiber thermoplastic parts funded by U.S. DOE. At DOE's request, ACC's Plastics Division Automotive Team and USCAR formed a steering committee for the National Labs, whose purpose was to provide industry perspective, parts materials and guidance in processing. This ACC affiliation enabled the plastics industry to identify additional key research requirements necessary to the success of long glass fiber injection molded materials and their use in the real world. Through further cooperative agreements with Autodesk Moldflow and University of Illinois, a new process model to predict both fiber orientation distribution and fiber length distribution is now available. Mechanical property predictive tools were developed and Moldflow is integrating these models into their software.

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.

The need for light-weighting of automotive structures has spurred on a tremendous amount of interest in and development of low cost carbon fiber composite materials and manufacturing. This presentation provides a description of the commercial carbon fiber concept compared to traditional aerospace and specialty carbon fiber products. A specific update is presented on the development and commercialization of new low cost carbon fiber based on lignin / PAN precursor technology. The second focus of the presentation is on carbon fiber composite manufacturing processes, including carbon SMC, RTM, prepregs, and thermoplastic processes. Advantages and disadvantages of these processes are discussed, especially related to low cost manufacturing. Presenter George Husman, Zoltek Companies Inc.

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.

There is a need to accelerate the automotive industry's alert notification and distribution process for quality, reliability, counterfeit, and safety issues that reside in specific electronic components or circuit card assemblies. This paper describes an alert procedure for an entire supply chain that can improve operational efficiency and reduce the costs associated with responding to and resolving those issues. Interoperability: Ability to work with each other. It is frequently unnecessary for separate resources to know the details of how they each work. But they need to have enough common ground to reliably exchange messages quickly without error or misunderstanding. Presenter William Crowley, QTEC Inc.