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Managing regulatory content is a complex process for any industry, but particularly for the automotive industry, which is heavily regulated. Several approaches for managing content are discussed along with implications for the industry. The response of an Original Equipment Manufacturer (OEM) to the recent European Parliament End-of-Life Vehicle Directive (EU 2000/53/EC-ELVs)1 is discussed from a North American perspective as well as trickle down expectations for the automotive supply base. Design, sourcing and labeling issues associated with the ELV directive as well as domestic regulations are discussed.

The design of occupant restraint systems in the automotive industry has shifted from an empirical approach to a computer aided analysis approach for many years now. Various finite element software programs have been applied in crash safety analysis, and multi-body dynamics codes have been successfully used where quick system response times were required. Most new vehicle programs are analyzed by the use of finite element tools that were used for previous program projects. Software that has specific occupant protection features may be coupled with these finite element tools, or new vehicle programs may be developed from scratch by using one tool that does all, i.e. a tool where the multi-body dynamics are integrated into the finite element method. Both these approaches will be elaborated as valid tools for occupant protection analysis. At first, the coupling between the finite element crash program LS-DYNA and the F.E.

DKAD is an automated analysis tool for evaluating dynamic characteristics of accessory drives. Rotation response analysis predicts natural frequencies and effects of crankshaft excitation. Lateral response of each belt span shows the effect of pulley run-out and parametric excitation. DKAD systematically allows a user to define a design and its operating conditions and then performs a sequence of analysis to visualize the rotational and lateral responses. It also allows a user to quickly explore and assess alternative designs. Belt layout and associated parameters can be saved in templates for future reference.

Based on the results of “An Evaluation of the Mechanical Properties of Wheel Force Sensors and their Impact on to the Data Collected During Different Driving Manoeuvres” Herrmann et al. (SAE Paper 05M-254) a second, detailed investigation has been started to acquire additional information. In this previous investigation, it has been found out, that a difference in mass can be clearly identified in the signals. The current paper summarizes the results of a detailed investigation, which has been performed at DaimlerChrysler Stress Lab in Auburn Hills, with a fully equipped vehicle - a set of 2/4 Wheel Force Sensors plus several acceleration sensors as well. Through careful research and testing it is expected that the differences in the dynamic behavior can be specified with better accuracy than in the previous study.

This paper will provide an overview of the need, requirements, and constraints governing the development and application of polymer composites in automotive body components. It will discuss the efforts underway to lead and support the technology developments required for the cost-effective application of these new materials in mass-produced vehicles. The requirements and constraints of customer-driven, mass-produced, energy-efficient vehicles with uncompromised cost, capacity and performance, drive careful consideration of an injection-molded thermoplastic approach to a composite automotive body. Recent progress with this approach will be reported and some next steps examined.

An assessment of stamped part quality and launch readiness occurs at many intervals. This paper will focus on dimensional control activities that take place after Stamping Dies are constructed, but prior to producing the stamped parts. Die certification and die repeatability measurements have been performed at DaimlerChrysler and the results are documented. This die certification process provides an opportunity to uncover and resolve die machining issues with respect to the part math model or pre-engineered compensation model prior to producing parts. Additionally, the die repeatability process is performed to determine the ability of the die gaging to locate the incoming in-process material consistently. This paper will explain the die certification and die repeatability processes and share what we have learned. It will describe the processes, the tools, the participants, the sites, the benefits, and the measurement equipment.

During the last several years, significant efforts have been directed toward the development of ultra-clean, gasoline-powered vehicles in the automotive industry. With the coming of increasingly stringent emissions legislation, this development is more critical now than ever before. This has lead to an increase in the technical information available. Advanced Developments in Ultra-Clean Gasoline-Powered Vehicles provides the reader with technical information including a description of fundamental processes, insight on technical issues, key trends, and future R&D directions.