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Students share how SAE Membership has opened doors for their careers, provided educational opportunities and hands-on experiences that has helped them to become a better engineer.

Auto manufacturers have known and surveys confirm that consumers require short payback periods (2-4 years) for investments in fuel economy. Using societal discount rates, engineering-economic generally find substantial potential to increase fuel economy, cost-effectively. This phenomenon, often referred to as the ?energy paradox?, has been observed in nearly all consumers? choices of energy-using durable goods. Loss aversion, perhaps the most well established theory of behavioral economics, provides a compelling explanation. Engineering economic analyses generally overlook the fact that consumers? investments in fuel economy are not sure things but rather risky bets. Future energy prices, real world on-road fuel economy, and many other factors are uncertain. Loss aversion describes a fundamental human tendency to exaggerate the potential for loss relative to gain when faced with a risky bet. It provides a sufficient explanation for consumers?

Transmission of light through automotive topcoat and primer layers can lead to degradation of the underlying electrocoat layer and to topcoat delamination. In order to protect against this, it is critical that transmission of both ultraviolet wavelengths and certain visible wavelengths be effectively blocked by the topcoat and primer layers. The clearcoat, basecoat and primer each have their own role and combine to protect against light transmission. The transmittance of these combined layers is typically measured by the Integrating Sphere UV-Visible Spectrophotometer. It would both simplify measurement of the topcoat systems and allow better system modeling if these layers could be measured separately and combined mathematically. We demonstrate here that absorbing and reflecting pigments can be effectively modeled using the Beer-Lambert law while results for scattering pigments are consistent with the Kubelka-Munk theory.

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.

TAUPE is a collaborative research project co-funded by the European Commission in the framework of the Seventh Framework Programme (FP7). It addresses the aeronautic sector and is composed of 17 partners from 6 European countries. The project lasts 3,5 years (September 2008 ? February 2012), is led by Safran Engineering Services (Labinal, SAFRAN Group) and has a budget of 5.5M?. The project aims to simplify the electrical architecture of aircraft and to reduce the length and mass of cabling by introducing PLC (PowerLine Communication) or PoD (Power over Data) technologies inside the aircraft. Both technologies essentially aim to supply power and data over the same cable.

Our trucks today contain anywhere from XX to XX computers on board, some of these computers have the capability to manage algorithms for the correct operation of up to XX systems. Presenter Jesus Gomez, Daimler Trucks North America LLC

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.

The U.S. Environmental Protection Agency (EPA) contracted with FEV, Inc. to estimate the per-vehicle cost of employing selected advanced efficiency-improving technologies in light-duty motor vehicles. The development of transparent, reliable cost analyses that are accessible to all interested stakeholders has played a crucial role in establishing feasible and cost effective standards to improve fuel economy and reduce greenhouse gas (GHG) emissions. The FEV team, together with engineering staff from EPA's National Vehicle and Fuel Emissions Laboratory, and FEV's subcontractor, Munro & Associates, developed a robust costing methodology based on tearing down, to the piece part level, relevant systems, sub-systems, and assemblies from vehicles ?with and without? the technologies being evaluated.

Software content within commercial vehicles is growing exponentially. Emissions requirements, multiplexed communications, hybrid-electric technologies, active suspensions and smart sensors are amongst the technologies driving the increase in embedded code. Presenter Christoph Braeuchle , MKS Software, Inc.

Can you become a visionary or are you born one? How does a visionary capture an opportunity and makes it a successful business? Are engineers more qualified to solve technical problems or run companies? SAE's "The Visionary's Take" addresses these and many other questions, by talking directly with those who have dared to tackle difficult engineering problems, and create real-life products out of their experience. In these short episodes, Sanjiv Singh and Lyle Chamberlain, respectively CEO and Chief Engineer from Near Earth Autonomy, talk about their experience in creating a brand-new company in the UAV world. Founded in 2011, Near Earth Autonomy brought together a group of engineers and roboticists, looking for unconventional solutions to very hard logistics problems, presenting danger to human life. The answers were developed by pushing technology to a higher level, testing quickly and often, and keeping an open mind to alternative ways of framing engineering challenges.

“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 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 “Engine Development for Performance and Efficiency” (22:00), engineers from Ricardo and General Motors explain the importance of lessons learned on the race tracks, how using the appropriate design and simulation tools expedite development, and present the new testing frontiers now available with 3D printing.

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.

In “Simulation Tools for Engine Design” engineers from Ricardo Software discuss the use of simulation software in new powertrain development. Another engineer, this time from General Motors, talks about how simulation tools helped them solve the challenge of fuel flow reversion while designing the new turbocharged Cadillac V6 engine. This episode highlights: The challenge of simulating complex and combined systems in one vehicle An example of how a library of components in a software package can be chosen to form a specific system and analyzed How computational fluid dynamics simulation tools were used to help redesign a new planum 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.

A key strategy to improving the real-world fuel consumption and emissions of medium and heavy duty vehicles is the hybridization of these applications. Unlike the passenger vehicle market, medium and heavy duty applications are typically comprised of a range of components from a variety of manufacturers. Presenter Monika A. Minarcin, Navistar, Inc. Eric Rask, Argonne National Laboratory Matthew R. Smith, Navistar, Inc.

The Java language is now the most popular programming language for the creation of new software capabilities. Its popularity has resulted in signficant economies of scale, with Java adopted as the primary language of instructional within many university curriculums, an abundance of reusable Java software components and Java software development tools available both from commercial suppliers and as open source technology, a large pool of competent Java developers from which to recruit staff, and a general willingness by senior staff software engineers to invest the effort required to learn this new programming language and technology. This talk describes the special approaches recommended for the use of Java in safety-critical deployments. The talk surveys the current state of the draft JSR-302 Safety Critical Java Specification and describes related experiences with commercially available technologies based on the constraints of early JSR-302 design discussions.

This paper forms the third of a series and presents results obtained during the testing and development phase of a dedicated range extender engine designed for use in a compact class vehicle. The first paper in this series used real world drive logs to identify usage patterns of such vehicles and a driveline model was used to determine the power output requirements of a range extender engine for this application. The second paper presented the results of a design study. Key attributes for the engine were identified, these being minimum package volume, low weight, low cost, and good NVH. A description of the selection process for identifying the appropriate engine technology to satisfy these attributes was given and the resulting design highlights were described. The paper concluded with a presentation of the resulting specification and design highlights of the engine. This paper will present the resulting engine performance characteristics.

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