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This SAE Standard provides performance and general design requirements and related test procedures for a combination tail and floodlamp for use on industrial wheeled equipment that may be operated on public roads.

The three major challenges in the power electronics in hybrid and electric vehicles are: System cost, power density and reliability. High temperature power device and packaging technologies increases the power density and reliability while reducing system cost. Advanced Silicon devices with synthesized high-temperature packaging technologies can achieve junction temperature as high as 200C (compared to the present limitation of 150C) eliminating the need for a low-temperature radiator and therefore these devices reduces the system cost. The silicon area needed for a power inverter with high junction temperature capability can be reduced by more than 50 - 75% thereby significantly reducing the packaging space and power device and package cost. Smaller packaging space is highly desired since multiple vehicle platforms can share the same design and therefore reducing the cost further due to economies of scale.

SAE 2011 High Efficiency IC Engines Symposium - Session 1- Pathways to High Efficiency Presenter Rolf D. Reitz, Univ. of Wisconsin

Real-time simulation of truck and trailer combinations can be applied to hardware-in-the-loop (HIL) systems for developing and testing electronic control units (ECUs). The large number of configuration variations in vehicle and axle types requires the simulation model to be adjustable in a wide range. This paper presents a modular multibody approach for the vehicle dynamics simulation of single track configurations and truck-and-trailer combinations. The equations of motion are expressed by a new formula which is a combination of Jourdain's principle and the articulated body algorithm. With the proposed algorithm, a robust model is achieved that is numerically stable even at handling limits. Moreover, the presented approach is suitable for modular modeling and has been successfully implemented as a basis for various system definitions. As a result, only one simulation model is needed for a large variety of track and trailer types.

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.

The amount of software, computation and logic embedded into the vehicle systems is increasing. Testing of complex real time embedded systems using Hardware in Loop (HIL) simulations across different vehicle platforms has been a challenge. Data driven testing enables a qualitative approach to test these complex vehicle systems. It consists of a test framework wherein the test logic and data are independent of the HIL test environment. The data comprises variables used for both input values and output verification values. This data is maintained in a database or in the form of tables. Each row defines an independent test scenario. The entire test data is divided into three categories, High, Medium and Low. This feature gives the advantage of leveraging the same set of test data from Unit Level Testing phases to the Integration Test phase in the V-Cycle of software development. A data driven test approach helps the reuse of tests across vehicle platforms.

Driver assistance systems (e.g. the emergency brake assist Active Brake Assist2, or ABA2 for short, in the Mercedes-Benz Actros) are becoming increasingly common in heavy-duty commercial vehicles. Due to the close interconnection with drivetrain and suspension control systems, the integration and validation of the functions make the most exacting demands on processes and tools involved in mechatronics development. Presenter Thomas Bardelang, Daimler AG

The number of electronically controlled systems in commercial vehicles is increasing rapidly. Much of this electrical content is controlled using ECUs (Electronic Control Units) which share information using some type of networking technology, such as a CAN bus running the SAE J1939 protocol. Presenter Jeffrey Craig, Vector CANtech Inc.

Propane autogas, the world?s third most-used engine fuel, powers vehicles, transit buses, and now school buses. Blue Bird has recently launched the Next Generation Vision type C school bus, powered by a ROUSH CleanTech liquid propane autogas fuel system and a Ford 6.8L V10 engine. The bus reduces operating costs by up to 40%, greenhouse gas emissions by up to 24%, and maintains the factory horsepower, torque, and towing capacity ratings. Learn about how school districts are saving over $.30 / mile using this clean, domestically-produced fuel. Presenter Brian Carney, Roush CleanTech.

With nearly 220,000 vehicles, the United States Postal Service (USPS) has the largest non-military vehicle fleet in the world. This fleet requires over a billion dollars of fuel annually, and this figure does not include contracted vehicles. As a part of the business strategy, the USPS has embraced and invested in alternative fueled vehicles since 1899, when the first recorded use of an electric vehicle for USPS service was performed as a technology evaluation in Cleveland, OH. As part of a technology evaluation of advanced vehicle systems, the USPS has partnered with the DOE?s Vehicle Technology Program (VTP) to benchmark and quantify the capabilities of five vehicles in meeting specific Urban Route Delivery requirements, both with dynamometer and in-service testing. The all electric vehicle conversions have been developed by established electric vehicle systems manufacturers representing various perspectives on meeting the vehicle specific operation objectives.

With the introduction of the Chevrolet Volt, the Electrification of the Automobile begins in earnest, by offering a car that runs off of grid energy that has mass market appeal. The Volt offers a vehicle which is driven primarily by electricity under ?real world? driving conditions, while not presenting the driver with inconvenient choices about range and recharge time, or the disconcerting experience of a real possibility of becoming stranded. The Voltec powertrain arrangement enables the Volt to be an Extended Range Electric Vehicle, or E-REV and gives full performance utilizing only electrical energy from the grid for most driving, and a seamless transition to gasoline energy for longer and less frequent trips to maintain full vehicle utility. General Motors and its suppliers has had to the lead developments of fundamental component technologies that were not addressed by earlier, more simple hybridization work.

In any new aircraft development program there are many important design decisions that determine profitability potential. The key to making new aircraft profitable is to design features that will command more money than the cost to provide them within the market's ability to absorb them. The business model in this paper shows how to predict or find: 1) the costs to provide various aircraft features; 2) the values that aircraft buyers place on these features; 3) the amount of money that buyers have to commit to them, 4) the open spaces in the market in which to place new designs and 5) the predicted profits from new designs. In this process, this paper extends previous work on the law of value and demand, which states that attributes determine value; value determines price; and that price determines demand. This four-dimensional, non-negative system hosts a business model that describes the features needed to enable aircraft designs to go from concepts to profitable assembly lines.

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.

This presentation will introduce the overall goals of the EcoCAR competition in brief, and will go into the third and final year of the competition in detail. The final year of competition saw teams refining and testing their student-built advanced technology vehicles including hybrids, plug-in hybrids, hydrogen fuel cell PHEVs and one battery electric. Important events, such as the Spring Workshop chassis dynamometer testing event at the U.S. Environmental Protection agency, as well as significant competition results, such as vehicle performance, consumer acceptability and efficiency will be presented. Presenter Patrick Walsh

The foundation of many production aircraft assembly facilities is a more dynamic and unpredictable quantity than we would sometimes care to admit. Any tooling structures constructed on these floors, no matter how thoroughly analyzed or well understood, are at the mercy of settling and shifting concrete, which can cause very lengthy and costly periodic re-certification and adjustment procedures. It is with this in mind, then, that we explore the design possibilities for one such structure to be built in Belfast, North Ireland for the assembly of the Shorts C-Series aircraft wings. We evaluate the peak floor pressure, weight, gravity deflection, drilling deflection, and thermal deflection of four promising structures and discover that carefully designed pivot points and tension members can offer significant benefits in some areas.

The fatty acid methyl esters (FAME's) - in Europe mostly RME (Rapeseed methyl ester) - are used in several countries as alternative biogene Diesel fuels in various blending ratios with fossil fuels (Bxx). Questions often arise about the influences of these biocomponents on the modern exhaust aftertreatment systems and especially on the regeneration of Diesel particle filters (DPF). In the present work different regeneration procedures of DPF systems were investigated with biofuels B0, B20 & B100. The tested regeneration procedures were: passive regenerations: DOC + CSF; CSF alone, active regenerations: standstill burner; fuel injections & DOC. During each regeneration on-line measurements of regulated and unregulated emission components (nanoparticles & FTIR) were conducted. It can be stated that the increased portion of RME in fuel provokes longer time periods to charge the filter with soot.

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.

The Pennsylvania State University is one of 16 North American universities that participated in the EcoCAR advanced vehicle technology competition (http://www.ecocarchallenge.org/). A series-hybrid-electric vehicle based on a General Motors crossover SUV platform has been designed, built and tested for this purpose. The powertrain features a 1.3 L turbodiesel engine running on a B20 fuel system, a 75kW generator directly coupled to the engine and advanced lithium-ion batteries. In this paper, the vehicle architecture and control strategy are detailed and performance predictions (e.g., acceleration, fuel consumption and emissions) are presented. This includes discussion of the development process that led to the selected designs. The predicted performance is compared with data obtained on a chassis dynamometer and during on-road measurements over specified drive cycles. Presenter Shawn Getty

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.

Using pressure sensitive adhesive tapes to achieve economy and efficiency in automotive assembly