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FutureSteelVehicle's (FSV) objective is to develop detailed design concepts for a radically different steel body structure for a compact Battery Electric Vehicle (BEV). It also will identify structure changes to accommodate larger Plug-In Hybrid (PHEV) and Fuel Cell (FCEV) vehicle variants. The presentation will demonstrate seven optimized structural sub-systems that contribute to the program's 35 percent mass reduction goals and meet its safety and life cycle emissions targets. It will explain the advanced design optimization process used and the resulting aggressive steel concepts. Presenter Jody R. Shaw, US Steel

Finding ways to reduce the amount of fuel burned per flight takes top priority in aircraft operations and design. Three experts show how the smallest on-board components can make a huge difference.

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).

Hybrid vehicles are rapidly entering the commercial and consumer marketplaces. However, hybrids introduce safety and service issues many Owners and Service Technicians are not familiar with. Components and systems may be so new existing standards need to be located or new standards developed. Technicians may need to learn new skills, acquire new tools and their service bays modified. Learn as solutions and problems are shared involving servicing hybrid vehicles. Organizer Mark N. Pope,General Motors LLC Arnold Taube,John Deere Company Moderator Mark N. Pope,General Motors Company Panelist Russell George Christ,Deere & Company Mark Quarto,General Motors Company Arnold Taube,DEERE AND CO Organizer Mark N. Pope, General Motors LLC Arnold Taube, John Deere Company Moderator Mark N. Pope, General Motors Company Panelist Russell George Christ, Deere & Company Mark Quarto, General Motors Company Arnold Taube, DEERE AND CO

Trans Tech recently debuted the all-electric eTrans school bus providing a total zero emission school bus. The presentation will demonstrate Smith Electric Vehicles and their history with electric vehicles. The presentation will help ensure that everybody has an idea of what the electric school bus will do and to dispel any rumors about the vehicle. Presenter Brian S. Barrington, Trans Tech. Bus

ECOtality North America, in partnership with the Idaho National Laboratory (INL), Nissan North America, General Motors, and over 40 government, electric utility, and private organizations, has launched a large-scale demonstration of electric vehicle charging infrastructure. This demonstration, called The EV Project, will deploy more than 15,000 level 2 and DC fast chargers in private residence, commercial, and public locations in seven market areas in Arizona, California, Oregon, Tennessee, Texas, Washington state, and Washington, D.C. The EV Project will also include a total of 5,700 Nissan Leaf battery electric vehicles and 2,600 Chevrolet Volt extended range electric vehicles, operated by consumers and fleets in each of the market areas. This demonstration, which is funded by the U.S. Department of Energy�s (DOE) Vehicle Technologies Program, represents the largest ever deployment of electric vehicles and charging infrastructure.

There are many macro drivers that are creating opportunities for transportation electrification. They include the environment, dependence on foreign oil, national security, battery technology and government incentives to name a few. In light of this growing momentum consumers will have choices to where they can charge ? at home, workplace or publicly. Electrical vehicle supply equipment will drive value throughout the supply chain ? installer, building owner, automaker, suppliers, utilities and consumers. Market acceptance will occur when consumer?s needs and wants are met. To meet these needs access to products through multiple channels will be required. Presenter Manoj Karwa, Leviton Manufacturing Co. Inc.

Career development is no longer something you focus on in your twenties and are set for life, it is ongoing and constant. New technologies, globalization and the world-wide competition for jobs demand that we continue to grow our skills and knowledge throughout our life. This session will provide you with tools to help you meet this demand as an engineering professional. Participants will create a personal mission statement and set career goals, identify the best way to research new opportunities and build their network while also crafting a personal brand with consistent messaging. Organizer Martha Schanno, SAE International Panelist Caryn Mateer, Transformational Leaders Intl. Kathleen Riley, Transformational Leaders Intl.

Edgewater Computer Systems Inc. product RTEdge Platform 1.2 is a software toolset supporting proof based engineering, implementation and deployment of software components, built using the RTEdge AADL Microkernel modeling subset. This is a small subset of the AADL component model and execution semantics, covering threads and thread-groups communicating solely through asynchronous event ports and through explicitly shared data ports. Threads behavior is expressed as state machines and dispatch run time semantics is encoded in a Run-time Executive, enforcing pre-emptive priority dispatch based on statically assigned event priorities, with ceiling priority protocol access to shared data. This simple AADL microkernel semantic core can support all dispatch policies, communication and synchronization mechanisms of a fully fledged AADL run time environment, permitting the systematic use of the RTEdge static analysis tools for AADL compliant software components.

Powertrain Systems development is facing unprecedented challenges driven by the convergence of many factors: increasing government regulations for tailpipe emissions, diagnostics and fuel economy, increased competition, shorter development cycles, and tighter program budgets. Using telematics and information technology to automate the evaluation of a system�s robustness enables engineers to focus their time on problem areas during their normal development process and launch with quality. This presentation will use real world examples to detail how this methodology was jointly applied by Control-Tec and Ford Motor Company to identify and improve the system performance of Ford�s Air-Fuel Imbalance Monitor before production. Presenter Bill Leisenring, Control-Tec LLC

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

This presentation shows the SCADE System product line for systems modeling and generation based on the SysML standard and the Eclipse Papyrus open source technology. SCADE System has been developed in the framework of Listerel, a joint laboratory of Esterel Technologies, provider of the SCADE�, and CEA LIST, project leader of the Eclipse component, Papyrus. From an architecture point of view, the Esterel SCADE tools are built on top of the SCADE platform which includes both SCADE Suite�, a model-based development environment dedicated to critical software, and SCADE System enabling model-based system engineering. SCADE System includes Papyrus, an open source component (under EPL license), integrated in the modeling platform of Eclipse. Using this integrated modeling platform, both system and software teams share the same environment for system development. Furthermore, other model-based tools can be added to the environment, due to the use of Eclipse.

The OBD approval process can be a frustrating time for both manufacturer and ARB staff. For manufacturers, a long approval process can sometimes mean accepting deficiencies prematurely in exchange for an approval. For ARB staff, they are inundated with highly technical information which they must review, garner understanding of and then apply their experience to evaluate it for compliance. OBD approval anxiety can be minimized, if not avoided, when manufacturers understand ARB�s expectations. This presentation will take you through some unwritten rules and common pitfalls which can impede the approval process, thus providing a guideline to a less painful and more efficient certification document review and approval. Presenter Mark Frank, Winterpark Engineering Llc

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.

“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. When automotive and aerospace manufacturers look for a material with superior lightweight and strength characteristics, they often look no further than composite materials. In the episode “Composite Materials: New Trends in Automotive Design” (10:20), an engineer from Molded Fiber Glass Research Company demonstrates how they develop and test the properties of composite materials, and an engineer at MirTEQ Incorporated discusses designing molds for an aftermarket composite part.

“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.

Micro-pitting is a fatigue effect that occurs in geared transmission systems due to high contact stress, and monitoring its progression is vital to prevent the eventual failure of the tooth flank. Parameter signature analysis has been successfully used to monitor bending fatigue failure and advanced phases of gear surface fatigue failure such as macro-pitting and scuffing. However, due to modern improvements in steel production the main cause of gear contact fatigue failure can be attributed to surface micro-pitting rather than sub-surface phenomena. Responding to the consequent demand to detect and monitor the progression of micro-pitting, this study experimentally evaluated the development of micro-pitting in spur gears using vibration and oil debris analysis. The paper presents the development of an online health monitoring system for use with back-to-back gear test rigs.

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

: Fiber Placement equipment has historically been very large and very expensive. Therefore, the AFP process has been mostly exclusive to the larger aerospace companies of the world. In order to achieve more widespread use of the AFP process, a wider variety of machine configurations must be offered and cost of the equipment must be decreased. Commercially available, articulated robotic arms have been identified as an attractive, low cost option for AFP machine platforms. However, incorporating AFP material delivery technology with robotic arms has many challenges. These challenges relate to both hardware and software issues. This presentation will address the technical challenges of using robots as a machine platform for the AFP process and review the current status of this composites lamination equipment technology. Presenter Frederic Challois, Coriolis Composites

TERBAN® hydrogenated nitrile rubber (HNBR) is a specialty elastomer used in demanding engineering applications such as the automotive, heavy duty, and industrial markets. It has excellent combination of heat, oil and abrasion resistance in addition to its high mechanical strength, very good dynamic and sealing properties. This paper will present data on aging HNBR for five thousand hours in an aggressive and un-stabilized B30A biodiesel fuel blend (70% ULSD, 30% SME, and an aggressive additive package) and explore the effect of HNBR polymer properties and vulcanizate composition on the performance in such fuel blends. Presenter Victor Nasreddine