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Steel sector aids sustainability Volvo Group partners with SSAB on 'green steel' for off-highway machines and with Ovako for access to fossil-free hydrogen. CV autonomy: Picking the 'low-hanging fruit' Increasingly automated commercial vehicles offer challenges and opportunities in simulation, data management and standardization. Developing EV-specific lubes As electric-vehicle technology accelerates, dedicated e-fluids are necessary to maintain proper levels of drivetrain performance. Editorial Real-world emphasis on electric Mahle, Liebherr develop active pre-chamber for hydrogen ICE ABS ramps up commercial-vehicle battery-pack assembly Navistar updates A26 engine, improves FE by 4% Bosch debuts new CV-specific electric motor and inverter Western Star adds 'weight sensitive' 47X to vocational lineup Hyundai CE launches next-gen electric forklift Q&A Mahle's Laurent Art discusses thermal-management challenges, solutions for battery and fuel-cell electric commercial vehicles.

Material selection for battery enclosures Mass reduction is the main reason BEV makers choose aluminum for battery enclosures, but cost and thermal requirements favor steel and polymer composites. Startup targets medium-duty EVs Atlis Motors purpose-engineers nearly all the vital components for an electric pickup and platform capable of spanning several market segments. High-voltage hybrids FEV engineers evaluate 48V and high-voltage parallel hybrid architectures for Class 6-7 commercial vehicles. Certain setups show more promise than others. Hemphill's mission: Support the innovation ecosystem Schaeffler America CTO Jeff Hemphill brings impressive technical chops and well-honed communication skills to his new role as 2021 SAE International president.

Engine electronics come of age Changes in global standards, combined with engineering know-how, have resulted in a new generation of clean, quiet, and efficient engines. Operators are rolling in the chips Microprocessors and sensors are being combined to monitor the way that equipment is being used, then help operators to perform better in that environment. Gaining weight Perkins' influence in the off-highway industry grows as it evolves its global engine lines and expands its presence in the U.S. What's new at CONEXPO-CON/AGG, Part 2 of 2 A preview of some of the products and technologies that will be displayed at this year's event, scheduled March 15-19 in Las Vegas, NV. Engineering a career Off-highway companies are challenged not only by the ever-changing technology landscape, but also by finding the engineering talent to help them succeed in it.

Simulating air-conditioning performance A computer program developed by Modine Climate Systems and Modelogics helps determine and optimize air-conditioning system performance. Reduced mass haul-truck design concepts Liebherr Mining trucks adopted a reduced structural mass approach to convert unladen weight directly into payload, while simultaneously incorporating state-of-the-art driveline technology. Optimizing a tractor frame for improved cabin NVH To address an aging agricultural workforce and modern ergonomic guidelines, researchers at Doshisha University and Kubota modeled medium- and large-sized agricultural tractors to reduce vibration and noise and increase comfort. Applying 3d-CAD to turbocharger development Ishkawajima-Harima Heavy Industries has developed a 3d-CAD system for turbochargers. satisfying requirements for digital mockup development.

Lightpipe design According to Breault Research Organization, any off-highway instrument or control that needs illumination is a candidate for a lightpipe to take light from where it is generated to where it is needed. The biodiesel choice Experts from the Natural Biodiesel Board believe it is time to consider alternatives to the current fuel structure. One solution to rising fuel prices is the pursuit of biodiesel fuels. Understanding machining difficulties in gray iron Bosch Braking Systems' engineers look more closely than usual at iron brake rotor samples to give new insights into critical characteristics of the material. Caterpillar mining for customers With commodity prices low, Caterpillar wants to make mining as productive an enterprise as possible for customers.

Increasing the hydroforming knowledge base Tube hydroforming has become a viable economic alternative to various stamping and welding processes in automotive applications. Controlling two-stroke engine emissions With the constant rich operation of two-stroke engines, common design criteria for three-way catalysts fail. DaimlerChrysler technical symposium A year after the merger that created the new corporation, engineers from both groups came together to present a unified technical symposium to review the future direction of the new organization. Here are some highlights of the more significant technical developments. Vertical complex-shape headlamp reflectors Another improvement in lighting technology gives designers increased flexibility in vehicle appearance with no loss in lighting performance. Advances in static and dynamic exhaust system seating Major redesign, combined with minor improvements in simple details, returns significant benefits in sealing.

Body control electronics shapes up The electronics revolution is advancing unabated in vehicle and body control, but the addition of features ranging from electronic power steering to tire pressure monitoring poses numerous challenges for electronics engineers. Telematics comes back on line Interfaces will play a huge role in expected growth. Cadillac XLR The new luxury roadster, designed to go head-to-head with models from Mercedes-Benz, Jaguar, and Lexus, uses an all-new 4.6-L Northstar V8 and innovative features such as adaptive cruise control, Magnetic Ride Control, and keyless access. 2005 Ford GT The company's image vehicle helped develop engineering skills in the race to production. Chrysler Pacifica Safety and infotainment features abound in the upscale 2004 sports tourer. 5 Series changes shape BMW adopted an aluminum/steel hybrid body in the interests of light weight and even weight distribution, and worked with ZF Lenksysteme to introduce active steering.

Finding the right niche As technology, politics, and OEMs struggle to achieve environmental cohesion, small and niche companies are determined to ride out the maelstrom with their ability to adapt, react, succeed, and survive. Jaguar and Land Rover shift Access to technology and engineering takes center stage as the two brands transition from one giant parent to another as Tata takes over from Ford. Aston Martin bonds The company is developing closer ties with Tier 1 suppliers in its new role as an independent. Bentley has secret CO2 plans The company wants to combine luxury and high-performance hallmarks with massive cuts in emissions. Lotus small and manueverable The engineering arm's technology menu--including lightweight, small engines, and high performance--is being sampled across the world. Porsche looks to the future Gasoline hybrid technology, convergence potential, and diesels could be in store for the company.

CO2 changing focus The global economic crisis could trigger novel engineering solutions and the need for comprehensive testing. ZEVs, fuel cells, and high-tech engines Only 10% of cars on Europe's roads by 2020 may be zero-emissions vehicles, but Mercedes-Benz is supporting future ZEV and other advanced technologies with an undiminished R&D budget. Warning signs Design and engineering lead-time tightening may be strangling innovative thinking, says Royal College of Art's Harrow. The decade ahead Renault anticipates that a majority of its powertrains will be downsized to the 0.9- to 1.2-L range and that electric cars will appeal to 30% of the buying public. Automatic for the people Automatic-shifting dual-clutch transmissions are poised to grab share from traditional transmissions thanks to their combination of efficiency and convenience.

Teardown Titan Munro & Associates is leading competitive analysis into the EV age - and spreading the gospel with a global YouTube fan base. Lightweight steel on a (cold) roll A newly developed high-strength steel for cold stamping aims to beat aluminum for EV battery enclosures and other vehicle applications. How EVs and their electronics stick together New adhesives play an increasingly vital role in vehicle structures, battery packs, and in protecting sensitive electronic components from extreme thermal cycling and contaminants. Editorial Farewell and thanks, Mr.

Tesla casts a new strategy for lightweight structures The EV maker boldly invests in the world's largest aluminum die-casting machine to manufacture entire rear underbody structures. Steel the Real Deal Steel's infinite recyclability will help it remain the auto industry's material of choice, insists Tata Steel Europe's CCO. Tesla's Cybertruck is audaciously austenitic A proprietary 301-series stainless steel gives Tesla's first pickup truck unique sales attributes while saving tooling cost. Lightweight design beyond CAD New computational tools enable an integrated data-fusion approach to complex, mixed-materials engineering. An expert from nTopology explains. Editorial Impressions of a rocket launch SAE Standards News New Cooperative Driving Automation standard provides clarity to support advancement of full automation Supplier Eye Now comes product-cadence chaos What We're Driving Can CHAdeMO 3.0 standardize global EV quick-charging?

Weaving a new future for composites In a shift perhaps as prolific as steel to aluminum, woven plastics may finally bring the magic of composites to cost-effective mass-production. New composites target EV applications No longer a low-volume play, the latest composite materials offer EV developers new options for lightweighting, thermal management and structures. Acura TLX is Honda's new body-build benchmark All-new for 2021, Acura's midsize sport sedan gets an exclusive platform to go with its structural, materials and dynamic advancements. Body development leader Jeremy Lucas explains. Schaeffler builds an e-motor powerhouse Armed with state-of-the-art manufacturing and a history of innovation, Schaeffler Group is attacking the e-mobility space, says Daniel Sayre.

Superlight superbike: 2021 Ducati Superleggera V4 Ducati pioneers the first street-legal production motorcycle with a full carbon-fiber chassis, as well as advanced aerodynamics. CFRP technical resources New 2020 SAE Technical papers detail current carbon-composite material developments. Virtual and physical testing of Third-Generation High Strength Steel Evaluating a new high-strength steel's ability to improve an existing stamped-steel production part. Static testing of EV components Firing nails into your latest Li-ion battery pack is but one of many regimens in the comprehensive testing of new electric vehicles.

Software transforms vehicle development Software-defined vehicles are driving major changes in hardware and control architectures. Model-based analysis of e-motor designs Observing the magnetic field distribution, electromagnetic torque, and iron loss distribution allows engineers to optimize specific performance with minimal weight and material costs. NVH simulation meets realism New toolsets help reduce development time and bring sound and vibration data into the real world. Metamaterials R&D targets NVH abatement Nissan readies its lightweight acoustic solution for 2022 production - will Hyundai follow?

AEI Best Engineered Vehicle 2010- Ford Taurus The readers and editors have selected the most significant vehicle of the year. Ford attacks premium sedan segment with all the technology it can muster. Focused on fuel economy Technology is only part of the solution for reducing vehicle energy consumption. In part 2 of AEI's Fuel Efficiency series, vehicle engineers explain why driver behavior is also a key factor. No stopping safety system advances Engineers are focusing on active systems intergration, especially with radars and cameras, more centralized processing, and silicon germanium for 77- GHz systems. Shedding pounds on a magnesium diet Tough CAFE standards are pushing automakers to consider using more lightweight magnesium rather than aluminum, steel, or plastics.

Small car, big project Vehicle Line Executive for the Fiat 500, Joe Grace, talks about bringing the iconic car to North America and the collaboration between engineers in Turin and Detroit that helped make it happen. Girding the grid for EVs Public electric utilities such as Detroit Edison have a virtual role to play in cultivating the electric vehicle market. Progress, new innovations spur GM;s fuel-cell development Fuel-cell program Executive Director Charlie Freese reveals the ongoing technical progress aimed at making FCVs part of GM's production vehicle portfolio later this decade. Planning the future of PLM and 3-D virtual tools The product-development revolution that began with CATIA is only beginning, says Dassault Systemes' CEO Bernard Charles.

Safe and sane Driver distraction, demand for connectivity, and infotainment raise new challenges in combining consumer technologies and cars. Thin on the inside Seat suppliers apply ingenuity to reduce the weight of traditional steel seat frames while trimming away foam to make smaller cars roomier. Early simulation enhances product development While simulating before design may seem to upend the traditional view of product development, many companies are realizing the benefits.

Engine boosting goes full bore Pumping more air into the cylinder is key to solving the CAFE puzzle, and engineers are hard at work figuring out the best ways to do it with turbocharger and supercharger innovation. Building a pathway for autonomous driving Existing safety systems will be augmented by onboard and external inputs; the biggest challenges will be designing the software that makes proper decisions without error and liability concerns. Steel in control Hyundai Steel develops a new 780-MPa grade of hot-rolled high-strength steel for application in a one-piece front lower control arm, displaying the potential for an 8% mass reduction.

Tackling biodiesel's technical challenges Engineers and researchers are working to mitigate biodiesel's negative effects on engine components and aftertreatment systems. Lightweighting with iron Grede throws advanced ultra-high-strength cast ductile iron into the lightweight-materials ring for commercial-vehicle chassis and powertrain applications. Silicon takes over Semiconductor suppliers are altering materials so automakers can add functions and improve reliability.

Bodybuilding 101 The latest designs are pumped up with flagrant use of performance-enhancing substances, such as boron steel, for maximum strength and safety. Prize-winning plastics Lower cost, lighter weight solutions highlight the 2008 SPE Automotive Innovation awards. Mean and green More than a few companies at last month's SEMA Show heralded the eco-friendly side of their products just as highly as the performance side. Setting the standards Automakers along with their supplier partners are now embracing many interfaces and protocols to enable compatibility with consumer electronics devices as well as other advances. Readers' choice: Top technology stories of the year The editors look back at some of the past year's most significant engineering and innovation articles according to readers of Automotive Engineering International and AEI Online. Green victory? The motorsports community contemplates winning races while leaving behind the smallest environmental footprint.