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This paper demonstrates the possibilities of using Automotive waste plastic material from “end of life” vehicles (ELVs), in the Footwear Industry to manufacture shoe components. The study establishes the sustainability of the flow of ELVs, from the European Car Parc and identifies and estimates the quantity of plastic materials potentially available for recycling from ELVs. Four potential materials, Acrylonitrile/butadiene/styrene (ABS), Polypropylene (PP), Polypropylene/ethylene/propylene/diene (PP/EPDM) and Polyamide (PA), were identified and three materials (PP, PP/EPDM and ABS) were reprocessed from ELV components and evaluated by the Footwear Industry. As a result, ABS was recommended as an economically, suitable replacement for HIPS, the current material used for manufacturing shoe heel components.

Pneumatic, manually operated, drilling machines are used to produce a significant proportion of all holes drilled during wing manufacture. Drilling machine design and the manual drilling process has not changed significantly in decades. By employing miniature, low power, electronics and interfacing techniques, a monitoring system has been developed. This system enables improved process control of the manual drilling operation. Machine calibration management, measurement of drill performance, jig drilling error control and asset management are some of the benefits attainable. This project will hopefully encourage others to discover the potential for improving historically established processes, by employing modern technological developments.

As increasing populations set demands for the abundant natural resources of the colder regions, the complex industrial machines of American Industry are expected to build the new railroads, roads, cities, mines, power sources, airports and factories, and operate these activities year round. This paper reviews the basic problems of “winterization” and the design practices, materials and components used with varying effectiveness in “winterizing” construction and associated equipment for use in moderate and extreme cold geographical areas. Several new charts are included which offer design temperature data for the northern United States, Canada, Alaska, Greenland, as well as average January isotherms around the earth. The authors are members of CIMTC Subcommittee XV, “Environment”.

In this paper, remanufacturing will be explored as a feasible option to maintaining the serviceability of electronic modules fitted to vehicles entering their service life from year four (after warranty) and beyond. Understanding the makeup of each module (content, design, and complexity) determines the feasibility of remanufacturing along with its cost effectiveness. Problems exist storing components for many years and engaging in periodic manufacturing is not cost competitive for high content modules. Thus, if reverse capability is not an option, then remanufacturing is a viable solution that, for certain modules, is a cost effective and an environmentally responsible (sustainable) solution to the service parts dilemma.

Estimation of soot deposited on a wall flow type DPF, is a vital information to ensure safe and efficient DPF management. Accuracy in determining mass of soot present inside the DPF ensures a correct regeneration management strategy in-terms of fuel efficiency and DPF safety considering soot overloading and too frequent regenerations. It also ensures an efficient detection of anomalies in the PM filtration mandated by the BSVI/EURO VI legislation as a part of On-board diagnostics. Classical approach of determining soot present inside DPF involves monitoring increase in pressure drop. Real time usage of such a model is limited by the inaccuracy of measuring pressure drop at low exhaust flows. Hence, contemporary engine controllers use pressure drop based models as a failsafe and estimate DPF soot loading by modelling soot release rate due to engine combustion and the rate at which it is oxidized.

This paper describes some of the design solutions adopted in solving two major problems besetting man-powered aircraft in use: that of breakage and storage. It describes work leading up to the building and testing of “Phoenix”, a man-powered aircraft with a polyester-film inflatable wing. The paper deals mainly with aspects relating to the wing design and construction.

Research information on solid lubricants has been compiled for consideration in the possible use of such materials in aircraft electrical equipment. Solid lubricants are capable of lubricating at the maximum temperatures (600° F) for aircraft electrical equipment. Many solids that adhere well to metals may be useful lubricants; those with layer-lattice structure usually give low friction. Solid lubricants are most commonly used as bonded films but the use of fluid carriers and surface reaction products have considerable merit.

The ability to carry cargo efficiently in passenger aircraft has influenced airline economics to the point that optimisation of the freight capacity is mandatory. This document discusses the alternative loading possibilities in defined Lover Deck Compartments and their doors to cater for current and future trends in ULD dimensions. As a result items for study centred on: 1) Optimisation of the available volumes Freight capacity resulting in the selection of “Pallets”-doors for both the Forward and AFT Compartments. Flexibility to meet Freight and Baggage requirements. Possible load arrangements to optimize aircraft C of G 2) Bulk Cargo Compartment Additional LD3 Container position in AFT/Bulk compartment to cater for an uneven number of Baggage container, allowing the carriage of an additional pallet. What is regarded as an optimum is presented.

Combustion concepts for future SI engines try to meet CO2-emission commitments and legislation all over the world. Where the Diesel engine has an advantage by principle, the efficiency of the SI engine has to be improved significantly, while of course the exhaust emissions must not become worse. An approach is to reduce the gas exchange losses using fully variable valve trains on the intake side of the combustion engine. OptiVent is a patented new way of controlling the mass air flow in the cylinder of a combustion engine using opening valves during the compression phase of a four stroke engine. This technology regards a wider range of variability on the valvetrain components of the engine especially for opening the valves more than one time during a cycle. On the other hand it is necessary to combine this technology with direct injection to avoid fuel losses in the exhaust system and raising the exhaust hydrocarbon emission of the engine.

Nisshin Steel Co., Ltd. has developed a new process for the production of a “one-side aluminized steel sheet”. The process utilizes a double layer one-side “stop-off” coating to prevent the molten Al from adhering to the steel surface. The “Stop-off” coating is removed by simple mechanical brushing after hot dipping. The characteristics of this product by above mentioned process are: 1) The steel side was as clean as a conventional cold rolled surface and showed no trace of the “stop-off” layer. Thereby, phosphating and ED painting were performed. 2) In the salt spray test data was obtained from zinc and Al coated steel surfaces; the coatings on both surfaces being of equal thickness.

Engineers doing squeak and rattle testing of instrument panels (IP's) have successfully used large electrodynamic vibration systems to identify sources of squeaks and rattles (S&R's). Their successes led to demands to test more IP's, i.e., to increase throughput of IP's to reflect the many design, material, and/or manufacturing process changes that occur, and to do so at any stage of the development, production, or QA process. What is needed is a radically different and portable way to find S&R's in a fraction of the time and at lower capital cost without compromising S&R detection results.

Engineers have long been restricted in designing and manufacturing one piece, hollow composite components with complex internal geometry. Complex core pulls in the plastic tool, major concessions made in the actual component design or components joined from several pieces were the early means of producing such components. Progressive thinking led to the use of matrix materials such as sand, salt and wax, which provided a measure of flexibility in allowing designed-in undercut areas. These materials, however, lacked the capability to meet the required demands of dimensional accuracy and internal surface, as well as proving themselves unsuitable for high volume production. The concerns for repetitive dimensional accuracy, quality internal surface and high volume production capability has now been satisfied with the use of low melting temperature metal alloys.

This paper presents an innovative brake booster which permits the brake assist function of the electric brake assist system to be implemented with mechanical means. The resultant significant reduction of manufacturing costs enhances the chances for a wide-spread use of this feature in all vehicle classes, thereby making an important contribution to the general improvement of traffic safety. Based on an analysis of the mechanically detectable physical variables for recognizing a panic situation and an evaluation of possible methods of mechanical valve activation, the paper presents a mass production solution and describes its functional properties. In particular, it should be noted that the possibility of controlling the braking pressure within the brake assist function even represents a functional advantage

An two-dimensional axial symmetrical finite volume model will be introduced for the calculation of catalytic converters. It is able to predict transient temperatures and conversion rates in different converter systems according to the driving conditions. Input data are the mass-flow rate, the converter inlet temperature and the raw emissions. The performance of this model is demonstrated on an Indian motorcycle application. Cold start behavior and peak temperatures are investigated. This model has proven to be an effective tool for the preselection of an optimal cost effective catalyst system.

Affordable, efficient and durable catalytic converters for the two and three wheeler industry in developing countries are required to reduce vehicle emissions and to participate in a cleaner and healthier environment. As a contribution Continental Emitec started a comprehensive testing program with a state of the art 180 cc Bharat Stage (BS) III Indian motorcycle. The program consists of testing the state of the art of Metallic substrates with structured foils with various catalyst sizes and positions (original or close coupled). The publication presents a short literature survey and the results of the investigation with a big catalyst volume mounted in underfloor position as well as in close coupled position, gained over the World-wide harmonized Motorcycle Test Cycle, considering the two possible vehicle classifications of this motorcycle, Sub-Class 2.1 and Sub-Class 2.2.

Automotive industry is a major contributor to global carbon dioxide (CO2) emissions and waste generation. Not only do vehicles produce emissions during usage, but they also generate emissions during production phase and end of life disposal. There is an urgent need to address sustainability and circularity issues in this sector. This paper explores how circularity and CO2 reduction principles can be applied to design and production of automotive parts, with the aim of reducing the environmental impact of these components throughout their life cycle. Also, this paper highlights the impact of design principles on End-of-Life Management of vehicles. As Design decisions of Component impacts up to 80% of emissions [1], it is important to focus on this phase for major contribution in reduction of emissions.