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“Spotlight on Design: Insight” features an in-depth look at the latest technology breakthroughs impacting mobility. 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. The quality of fluids used in aviation, such as oil or fuel, is an extremely important safety issue. One way to reliably monitor fluids is through the use of special measurement sensors. In the episode “Fluid Measurements and Avionics” (9:13), an engineer at Meggitt demonstrates the capabilities of time-domain reflectometry sensors, explaining how they are assembled and used. The business case for monitoring oil and fuel degradation, and how to proactively take advantage of preventative maintenance is also explained.

“Spotlight on Design: Insight” features an in-depth look at the latest technology breakthroughs impacting mobility. 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. Extreme environment sensors require extreme environment cables that can reliably perform in temperatures up to 2300° F, withstand intense vibration, and have extraordinary strength. In the episode “Sensors: Noise Avoidance and Cable Manufacturing” (8:53), an engineer at Meggitt Sensing Systems demonstrates the intricate process of developing cable for sensors used in these situations.

“Spotlight on Design: Insight” features an in-depth look at the latest technology breakthroughs impacting mobility. 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. Automated driving is made possible through the data acquisition and processing of many different kinds of sensors working in unison. Sensors, cameras, radar, and lidar must work cohesively together to safely provide automated features. In the episode “Automated Vehicles: Converging Sensor Data” (8:01), engineers from IAV Automotive Engineering discuss the challenges associated with the sensor data fusion, and one of Continental North America’s technical teams demonstrate how sensors, radars, and safety systems converge to enable higher levels of automated driving.

“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. In the episode “Diagnostics and Prognostics: Proactive Maintenance and Failure Prevention” (21:04), Delphi engineers explain how they leverage the growing number of sensors and computing power in vehicles to diagnose and proactively solve emerging mechanical or electronic problems, before a breakdown occurs. This video also looks at the next generation of automotive telematics, with HEM Data demonstrating how in-vehicle data acquisition is used to monitor the inner workings of vehicles.

The CAN protocol has served the automotive and related industries well for over twenty-five (25) years now; with the original CAN protocol officially released in 1986 followed by the release of CAN 2.0 in 1991. Since then many variants and improvements in CAN combined with the proliferation of automotive onboard microprocessor based sensors and controllers have resulted in CAN establishing itself as the dominant network architecture for automotive onboard communication in layers one (1) and two (2). Going forward however, the almost exponential growth of automotive onboard computing and the associated devices necessary for supporting said growth will unfortunately necessitate an equivalent growth in the already crowded wired physical infrastructure unless a suitable wireless alternative can be provided. While a wireless implementation of CAN has been produced, it has never obtained real traction within the automotive world.

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 the growing use of carbon fiber composite structure in Aircraft Manufacturing, the challenge of drilling carbon fiber stacked with Titanium has become a focus point. Due to the abrasive nature of the carbon fiber (CF), cutting tool life is relatively short when drilling carbon fiber stalked with Titanium. A common drill wear indicator is exit burr formation in the Titanium. As drilling tools wear due to the abrasive nature of the CF, the exit burr in the in the Titanium increases. This study seeks to understand the factors that lead to tool wear and exit burr formation. A correlation may be made relating drilling thrust forces with exit burr formation. Different cutting tools geometries and materials are studied using a high speed camera to attempt to understand the factors influencing exit burr formation. Findings are optimized and tested. Decreasing exit burr in the drilling of CF and Titanium may increase tool life thereby reducing tool costs to airframe manufacturers.

Use of airborne high resolution digital sensor imagery is ever increasing. Color HDTV, infrared cameras and radar are examples of such sensors. And they are becoming increasingly used for mission purposes by the military, police, customs and coast guard onboard helicopters and fixed wing aircraft. These users have requirements for onboard presentation, analysis and storage. Use of weather radars and other similar types of sensors are flight oriented applications in major types of aircraft. Another application is the integration of cockpit and cabin surveillance systems onboard commercial airlines. Cabin surveillance systems, growing from cockpit door cameras to complete cabin surveillance, will use several cameras. The purpose is to acquire and store imagery from un-normal events including unruly passengers and eventual terrorists. The primary intentions are security awareness in the cockpit as well as collecting evidence for a potential prosecution.

With the increased demand for high volume, cost-effective, fiber-reinforced thermoplastic parts, the lack of high throughput systems has become more pronounced. Thermoforming as a method to generate complex shapes from a flat preform is dependable and fast. In order to use readily available, standard unidirectional impregnated thermoplastic tape in this process, a flat perform must be created prior to the thermoforming step. Formerly, creating the preform by hand layup was a time consuming and therefore costly, step. Fiberforge�?s patented RELAY� technology overcomes the challenges of handling thermoplastic prepreg tape and provides a solution through the automated creation of a flat preform, referred to as a Tailored Blank?. Producing a part for thermoforming with accurate ply orientation and scrap minimization is now as simple as loading a material spool followed by a pressing a start button. Presenter Christina McClard, Fiberforge

Probabilistic methods are used in calculating composite part design factors for, and are intended to conservatively compensate for worst case impact to composite parts used on space and aerospace vehicles. The current method to investigate impact damage of composite parts is visual based upon observation of an indentation. A more reliable and accurate determinant of impact damage is to measure impact energy. RF impact sensors can be used to gather data to establish an impact damage benchmark for deterministic design criteria that will reduce material applied to composite parts to compensate for uncertainties resulting from observed impact damage. Once the benchmark has been established, RF impact sensors will be applied to composite parts throughout their life-cycle to alert and identify the location of impact damage that exceeds the maximum established benchmark for impact.

With the increased usage of Carbon Fiber Reinforced Plastics (CFRP) in the aircraft industry, there has been increased pressure to improve cutting tool life. Tungsten carbide tools were the first to be applied to CFRP materials. Poly Crystalline Diamond (PCD) tools also became an acceptable material to be used as a cutting tool material. In recent years, Chemical Vapor Deposition (CVD) diamond tools have become more popular as a cutting tool material for CFRP. This study compares these possible cutting tool materials in the drilling of CFRP. Wear is measured as well as hole quality. Life is determined by common industry standards with regard to fiber break out in a common CFRP material. An economic analysis is conducted in order to determine cost per hole. Presenter Christophe Petit

This session covers topics regarding new CI and SI engines and components. This includes analytical, experimental, and computational studies covering hardware development as well as design and analysis techniques. Presenter Joshua Styron, Ford Motor Co.

Watlow and EmiSense Technologies, LLC are commercializing an improved electronic particulate matter (PM) sensor that has real-time measurement capability and improved sensitivity. To demonstrate the capability of this improved sensor of on board diagnostics (OBD) for failure detection of diesel particle filters (DPF), independent measurements were performed by university of California Riverside (UCR) and by Southwest Research Institute (SwRI) to characterize the engine PM emissions and to compare with the PM sensor response. In situ PM measurements from PM sensors correlate well with real-time gravimetric measurements. In addition, particle size and particle number data are presented and discussed.Due to an improved design update, the sensitivity of the sensor could have been significantly increased.

Sensing exhaust gas temperature is a key component in diesel after treatment systems for both control and diagnostics. Accuracy varies significantly depending upon the sensing technology and implementation in the system. Prior published work has demonstrated that resistance based temperature sensors are not able to achieve the system accuracy required for advanced diagnostics over the life of the emission system. This presentation will show that it is feasible to achieve better than �10�C end of life system accuracy by means of active thermocouple technology. Results from tests at Michigan Technological University will be used to illustrate diagnostic uncertainty related to the application of temperature sensors and a specific DOC/DPF example will be used to show the benefits of accurate temperature based diagnostics. Presenter D. P. Culbertson, Watlow Gordon

Rapid control prototyping (RCP) is a widely used technique for verifying a controller's functional behavior. Typically, RCP uses a target processor with ample processing power and memory, which makes the technique attractive for engineers exploring new concepts. Presenter Thomas Erkkinen, MathWorks Inc.

Software content within commercial vehicles is growing exponentially. Emissions requirements, multiplexed communications, hybrid-electric technologies, active suspensions and smart sensors are amongst the technologies driving the increase in embedded code. Presenter Christoph Braeuchle , MKS Software, Inc.

These advanced checks have resulted in development of many new diagnostic monitors, of varying types, and a whole new internal software infrastructure to handle tracking, reporting, and self-verification of OBD related items. Due to this amplified complexity and the consequences surrounding a shortfall in meeting regulatory requirements, efficient and thorough validation of the OBD system in the powertrain control software is critical. Hardware-in-the-Loop (HIL) simulation provides the environment in which the needed efficiency and thoroughness for validating the OBD system can be achieved. A HIL simulation environment consisting of engine, aftertreatment, and basic vehicle models can be employed, providing the ability for software developers, calibration engineers, OBD experts, and test engineers to examine and validate both facets of OBD software: diagnostic monitors and diagnostic infrastructure (i.e., fault memory management).

This paper presents an extension of our earlier work on Cummins Vehicle Mission Simulation (VMS) software. Previously, we presented VMS as a Windows based analysis tool to simulate vehicle missions quickly and to gauge, communicate, and improve the value proposition of Cummins engines to customers. Presenter Nagesh Belludi, Cummins Inc.

When vehicles share certain information wirelessly via Dedicated Short Range Communications (DSRC), they enable a new layer of electronic vehicle safety that, when needed, can generate warnings to drivers and even initiate automatic preventive actions. Vehicle location and velocity provided by Global Navigation Systems (GNSS), including GPS, are key in allowing vehicle path estimation. GNSS is effective in accurately determining a vehicle's location coordinates in most driving environments, but its performance suffers from obstructions in dense urban environments. To combat this, augmentations to GNSS are being contemplated and tested. This testing has been typically done using a reference GNSS system complimented by expensive military-grade inertial sensors, which can still fail to provide adequate reference performance in certain environments.