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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.

Understanding in-use fleet operating behavior is of paramount importance when evaluating the potential of advanced/alternative vehicle technologies. Accurately characterizing real world vehicle operation assists in properly allocating advanced technologies, playing a role in determining initial payback period and return on investment. In addition, this information contributes to the design and deployment of future technologies as the result of increased awareness regarding tractive power requirements associated with typical operating behavior. In this presentation, the concept of vehicle duty cycles and their relation to advanced technologies will be presented and explored. Additionally, current research attempts to characterize school bus operation will be examined, and existing computational analysis and evaluation tools associated with these efforts discussed. Presenter Adam Duran, National Renewable Energy Laboratory

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.

Many manufacturing companies want to apply AFP technology to complex high-curvature part shapes. As new AFP machine technologies are developed to specifically apply material over complex shapes, new and innovative NC programming approaches are needed to successfully, reliably, and accurately apply material with good consolidation, while meeting the fiber direction and coverage requirements. A big issue with AFP is the production rate vs. part complexity. Most complex shapes can be created with a single .125? wide strip (tow) of material. But the production time would be impractically long. So machine builders create 6, 8, 16, even 32 tow AFP heads, and use the widest tow possible for the highest laydown rates. But then wide compaction rollers on these systems have difficulty consolidating material over curved surfaces, and the minimum steering radius of wider tows challenge the software?s ability to meet the layup requirements.

Automakers, suppliers, public agencies, interest groups and others are increasingly embracing the environment as one of the dominant forces in the US automotive market. All parties have a strong vested interest in understanding how environmental concerns will influence design, production, marketing and usage of tomorrow�s vehicles. A common need of all parties is independent and actionable information to enable them to make better decisions and have the greatest chance of being successful in this uncertain future. Four factors - an uncertain economic climate; a constantly changing governmental regulatory system; advancements in powertrain technology; and ever-present environmental concerns - continue to shape the automotive landscape. While automakers are focused on developing alternative powertrains and alternative fuel options for an increasingly �green� vehicle market, J.D.

Alyson Lyon, Executive Leadership Coach, explains how the most successful people manage their time. Members can view the full version by logging into the Member Connection here Not a Member? Get a taste of the Member Connection and join at connection.sae.org.

Watch for tips from experts in the mobility industry on how to live in harmony. Members can view the full panel session by logging into the Member Connection here Not a Member? Join us today at sae.org/join.

The presentation describes the aerodynamic development and optimization process of the three different new models of the Audi A6/A7 family. The body types of these three models represent the three classic aerodynamic body types squareback, notchback and fastback. A short introduction of the flow structures of these different body types is given and their effect on the vehicle aerodynamic is described. In order to achieve good aerodynamic performance, the integration into the development process of the knowledge about these flow phenomena and the breakdown of the aerodynamic resistance into its components friction- and pressure drag as well as the induced drag is very important. The presentation illustrates how this is realized within the aerodynamic development process at Audi. It describes how the results of CFD simulations are combined with wind tunnel measurements and how the information about the different flow phenomena were used to achieve an aerodynamic improvement.

Simulation-based tolerance analysis is the accepted standard for dimensional engineering in aerospace today. Sophisticated 3D model-based tolerance analysis processes enable engineers to measure variation in complex, often large, assembled products quickly and accurately. Best-in-class manufacturers have adopted Quality Intelligence Management tools for collecting and consolidating this measurement data. Their goal is to completely understand dimensional fit characteristics and quality status before commencing the build process. This results in shorter launch cycles, improved process capabilities, reduced scrap and less production downtime. This paper describes how to use simulation-based approaches to correlate the theoretical tolerance analysis results produced during engineering simulations to actual as-built results. This allows engineers to validate or adjust as-designed simulation parameters to more closely align to production process capabilities.

Over the past several years, new recommended practices for testing plug-in vehicles have been developed by SAE standards committees. At first only proprietary or prototype vehicles were available to validate new procedures. However, with the recent availability of Chevy Volt and Nissan Leaf, these test procedures were put to the test in Argonne�s National Laboratory�s dynamometer test facility. Procedures for the Volt were according to the SAE J1711 procedures. The Leaf was tested according to procedures still under development in the SAE J1634 task force. Identified were aspects of the tests that were successful and areas where more development is needed. As described in SAE J2841, the Volt results were analyzed using a �utility factor� to estimate in-use expectations of electric-only miles.

This study evaluates utilizing an accelerated test method that correlates customer interaction with a vehicle seat where bagginess and wrinkling is produced. The evaluation includes correlation from warranty returns as well as test vehicle results for test verification. Consumer metrics will be discussed within this paper with respect to potential application of this test method, including but not limited to JD Power ratings. The intent of the test method is to aid in establishing appropriate design parameters of the seat trim covers and to incorporate appropriate design measures such as tie downs and lamination. This test procedure was utilized in a Design for Six Sigma (DFSS) project as an aid in optimizing seat parameters influencing trim cover performance using a Design of Experiment approach. Presenter Lisa Fallon, General Motors LLC

As a result of recommendation from the Augustine Panel, the direction for Human Space Flight has been altered from the original plan referred to as Constellation. NASA's Human Exploration Framework Team (HEFT) proposes the use of a Shuttle Derived Heavy Lift Launch Vehicle (SDLV) and an Orion derived spacecraft (salvaged from Constellation) to support a new flexible direction for space exploration. The SDLV must be developed within an environment of a constrained budget and a preferred fast development schedule. Thus, it has been proposed to utilize existing assets from the Shuttle Program to speed development at a lower cost. These existing assets should not only include structures such as external tanks or solid rockets, but also the Flight Software which has traditionally been a ?long pole? in new development efforts. The avionics and software for the Space Shuttle was primarily developed in the 70's and considered state of the art for that time.

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

A series of flight tests were conducted to design and evaluate a Combined Vision System (CVS) that integrates a forward looking infrared video image with synthetic vision on a primary flight display. System features included colorizing the video image to mesh with the synthetic terrain background, decluttering the approach symbology to facilitate the detection of the approach lights and runway markings, creating a semi-transparent IR sky to ensure continuous situational awareness of the surrounding terrain, and annunciating the decision height to facilitate the transition to the actual runway environment. Over 100 approaches were flown during three flight test sessions. For the first flight test session pilots reviewed early CVS proofs of concept on Honeywell's Citation Sovereign.

“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. Fuel efficiency, or simply put, how to get more mileage out of the same amount of fuel has become one of the main goals to be achieved by new automotive technologies in the future, thanks in part to new government regulations. In the episode “Fuel Efficiency: Racing toward CAFE 2025” (21:24) AVL engineers show simulation and testing being used to design more fuel efficient vehicles, including the equipment that actually analyzes fuel economy.

“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.

“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 “Composite Materials: Advanced Materials and Lightweighting” (30:20), Molded Fiber Glass Companies, known for its deep involvement in the creative development of the molded fiberglass process for the Corvette, demonstrates the manufacturing of sheet molded composite for fiberglass parts. Tanom Motors introduces the Tanom Invader, a blend between an automobile and a motorcycle made exclusively with composite materials. Finally, Euro-Composites demonstrates the manufacturing of honeycomb core material made out of aramid paper and phenolic resin used in aircraft structures.

“Spotlight on Design” features video interviews and case studies, focusing on technology breakthroughs, hands-on testimonials, and the importance of fundamentals. Viewers are virtually taken to industry labs and research centers to learn how design engineers solve real-life problems. These challenges include enhancing product performance, reducing cost, improving quality and safety, while decreasing environmental impact, and achieving regulatory compliance. In the episode “Automotive Charging Infrastructure: Vehicle and Grid Integration” (21:00), engineers from NextEnergy and an infrastructure expert from General Motors explain how technologies are rapidly converging to power electric vehicles and support the overall electric grid. This episode highlights: How the fast expansion of charging infrastructure is changing the way electric and hybrid-electric vehicles are gaining the confidence of consumers.

“Spotlight on Design” features video interviews and case studies, focusing on technology breakthroughs, hands-on testimonials, and the importance of fundamentals. Viewers are virtually taken to industry labs and research centers to learn how design engineers solve real-life problems. These challenges include enhancing product performance, reducing costs, improving quality and safety, while decreasing environmental impact, and achieving regulatory compliance. In the episode “Additive Manufacturing: 3D Printing in the Automotive Industry” (20:00), engineers from Fiat Chrysler Corporation (FCA) explain the importance of using 3D printing to test multiple design scenarios and develop solutions that can be quickly evaluated on test tracks. And Local Motors shows how it builds a vehicle from the ground up with a 3D printer, and without a traditional assembly line.

In “The Impact of Additive Manufacturing in Automotive Applications”, a professor from Kettering University explains why additive manufacturing will be a game changer for car makers, and how process control is one of the biggest challenges ahead. An engineer at Local Motors in Arizona shows how the company builds its cars using a large-scale 3D printer, including how a variety of materials is being evaluated for optimal performance in this type of application. The episode highlights: The expected positive impact of AM on smaller car makers and suppliers The key difference between small 3D printers and large-scale ones The need to find the best possible material combination so vehicles that are #D-printed are as safe as traditional ones Also Available in DVD Format To subscribe to a full-season of Spotlight on Design, please contact SAE Corporate Sales: CustomerSales@sae.org or 1-888-875-3976.