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Tearing down the global barriers Steering systems are becoming increasingly sophisticated, as Ian Adcock discovers when talking to the men leading Nexteer's European expansion €1.1 billion worth of Bentley luxury Bentley's Bentayga is the first in a new generation of luxury cross-overs. Ian Adcock reveals its engineering secrets Goal: "virtual" perfection Should simulations be 100% accurate?

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.

E-business: the new game in town With the initial formation of Covisint in February 2000, and with other online ventures established over the past couple of years, the automotive industry has thrown its chips into the B2B e-commerce game. The following is an update on how the industry is faring now that its cards are on the table. Simulation: redefining the development process Just as companies sought to shorten the development cycle with intergrated product teams, they do so again with up-front computer-aided analysis and simulation. New connections for automobiles Thanks to innovative technologies and applications, flexible circuitry is helping drive new trends, such as modularity, in automotive design, according to Sheldahl. NAIAS highlights: production Since becoming an international event in 1989, the North American International Auto Show in Detroit has hosted 620 North American and worldwide vehicle introductions.

Semiconductors flex their muscles Makers of semiconductors see the automotive market as a prime opportunity for growth. The first part of this article looks at this growth from the perspective of semiconductor industry leader Motorola. The second part highlights some recent semiconductor product introductions. 2002 supplier technology As automakers increase outsourcing, suppliers are taking on more responsibility for developing increasingly complex systems and components. This special edition of Tech Briefs highlights some of the many supplier contributions to 2002 passenger cars. Vision sensors and the intelligent vehicle Advancements in CMOS imaging sensors have enabled Delphi engineers to adapt low-cost, high-quality cameras for a variety of applications in integrated safety systems. The reborn Thunderbird Taking cues from the 1955 model, the 2002 car benefited from Ford's modern platform and systems engineering as well as C3P computer modeling techniques.

Spark-ignition engine trends In the face of growing competition from diesels and alternative power sources, some of the latest prototype and production gasoline-fueled engines show how continued engineering development is meeting demands for more power, reduced fuel consumption and emissions, and more efficient packaging. Expanding supplier capabilities through consolidation The pace of consolidation in the automotive industry has slowed somewhat, but its importance has not diminished. Raymond A. Morris named SAE Executive Vice President THe 27-year SAE veteran promises to focus on the needs of the customer and to become better acquainted with the Detroit automotive industry.

NAIAS production vehicles Editors review the engineering highlights of the show's production-vehicle introductions. BMW 7 Series: AEI's Best Engineered Vehicle for 2002 With help from its suppliers, BMW has produced a vehicle that blazes the engineering trail with innovations that will influence passenger vehicles for years to come. Developments in fuel cells Automotive engineers are concentrating on providing quick startup, cost reduction, mass manufacturability, and crash safety. AEI Tech 2002 Awards Automotive Engineering International editors highlight the top products and technologies that were displayed at the SAE 2002 World Congress. Introducing S.M. Shahed, SAE President for 2002 From humble beginnings, S.M. Shahed carves out a seat at the society's top spot. Urea selective catalytic reduction Testing by Ford researchers of a small-diesel emissions-control system proved successful in meeting ULEV emissions standards.

Fuel-cell commercialization The technology race is on to market the next revolution in automotive propulsion, with the first vehicles in limited quantities coming from Toyota and Honda by the end of the year. Telematics technology trends Analysts at the Telematics Research Group explain the computer, communications, and automotive electronic component advancements that will influence systems development. No end in sight to electronics' growth The biennial Convergence conference on transportation electronics, hosted by DaimlerChrysler, will explore the interplay of electronics with mechanical and other systems to improve vehicle safety, performance, and convenience. Making contacts Engineers at AMI DODUCO reveal their latest research and developments on critical automotive electrical contact reliability.

Tech Highlights: 2002 Mondial de L'Automobile European editor Stuart Birch gives a run down of some of the significant vehicle and technology debuts at the Paris Motor Show, beginning with the French automakers. Supply-chain trends With increased responsibility for modules and warranties, automotive suppliers are finding innovative ways to manage their supply chains. Sports car racing technology Le Mans series race car engineering reach a high-water mark in 2002, but will likely recede in 2003. Innovation at DaimlerChrysler Chairman and CEO Jurgen Schrempp believes that in the next 15 years, car technology and design will move ahead more rapidly than at any time in the past half century--and that almost everything except the basic four-wheel layout could change. Escape Hybrid is a showstopper Ford in 2003 will launch the world's first production hybrid-electric SUV, which will be the subject of much discussion at this month's 2002 SAE International Truck & Bus Meeting & Exhibition.

Bending light Lighting technology is becoming more intelligent and adaptive as OEMs and suppliers develop systems that are more integrated into vehicle electronics systems for greater performance and safety. Top technologies of the year The world's automakers and suppliers were busy in 2002 equipping production vehicles with significant new technology. The editors review some of those significant "game changing" innovations for the past model year. Testing on the move Advances in mobile data acquisition, such as those from HBM, have helped engineers move the testing of vehicles from the laboratory to the road. Producing an all-new powertrain Ford and International each revamped a plant to build a new powertrain for Ford's super-duty trucks and Excursion sport utility vehicle. Making plastic parts New ways of forming plastics for automotive components were revealed at an annual contest sponsored by the Society of Plastics Engineers.

Engine strategies and engineering Top powertrain executives from DaimlerChrysler and General Motors talk about their companies' views and plans for the future. Greater performance, better efficiency, and reduced emissions are the highlights of the latest crop of internal combustion engines from their companies and others. Educating engineers The automotive and academic worlds are teaming to ensure that the industry's future is full of qualified engineering talent. OEM production systems enable flexibility Building multiple models on the same production line is a Japanese innovation--one that U.S. automakers are hurrying to implement. Executives abound at SAE 2003 World Congress Re-tooled to increase the presence of OEMs and to make it easier for attendees to get the information they need, this year's Congress offers a great return on investment for engineers and related automotive industry professionals who spend time in Detroit's Cobo Center March 3-6.

NAIAS production vehicles The strength of light trucks and crossovers in North America was on display as a majority of the all-new vehicles debuting at the events were for those segments of the industry. This special edition of Global Vehicles provides highlights of new-vhielce technology for 2003 and beyond. Volvo XC90: AEI's Best Engineered Vehicle for 2003 The new model raises the safety and environmental compatability bars for SUVs. Leading the way Fuel-cell vehicles from Toyota and Honda are hitting the streets for customer use in both Japan and the U.S. AEI Tech 2003 Awards Automotive Engineering International highlights the top products and technologies (submitted as of February 18) from the SAE 2003 World Congress. Introducing Dr. Jack E. Thompson, SAE President for 2003 A change agent with early roots in the automotive industry gets in the Society's driver seat.

Phantom materializes BMW's Rolls-Royce Motor Cars unveils its first model, an aluminum-bodied sedan with rear-hinged rear doors and a new V12. Protecting the cabin from powertrain NVH OEMs are getting help from suppliers such as Collins & Aikman and Bayer in damping NVH, thanks to innovation in plastics. Forced induction Environmental pressures prompt renewed interest in turbochargers and superchargers. Collaboration software emerges Interactive product development tools that can decrease design time and cost, enhance quality, and improve engineering processes are now widely available. Validated virtual testing DaimlerChrysler and MTS Systems have verified that component load histories can be predicted before prototypes are built. Automation: a tool, not an end Toyota and its suppliers try to strike a balance between automation and manual labor at their U.S. plants.

Product is king in North America As it does every year, AEI takes a look at automotive industry trends in the three major regions of the world, beginning in this issue with a look at the North American industry and how domestic OEMs and suppliers are shaping its future. Europe will be the focus in June, Japan in August. A powerful mix Traditional and not-so-traditional power sources will share the roads in North America as OEMs and suppliers continue to research and develop a variety of advanced propulsion technologies. Consumer research drivers interior trends OEMs are giving suppliers greater responsibilities not only for delivering vehicle interiors, but also for consumer research that leads to compelling interior designs. Body and chassis developments Advanced technologies are enabling light trucks and SUVs to close the ride, handling, and safety gap with passenger cars.

New York revival More than 20 of the 30 new vehicle introductions at this year's New York International Auto Show were world debuts, and cars took center stage for the first time in a while at a North American auto show. Safety first Consumers say safety is priority one, but deaths on the highway are rising as government regulators impose tougher--and more costly--safety standards on automotives. Ford turns 100 Pausing to celebrate its many technical achievements of the past century, Ford maintains its focus on being an innovation leader for the next 100 years. Hi-tech Europe Europe's automotive industry is set to apply technology to a greater degree than ever before. Diesels and DCTs Turbodiesel engines may soon power half the cars sold in Europe, and as European roads become ever more crowded, dual-clutch and automatic transmissions are becoming more attractive propositions.

No hands with Bluetooth A major effort is underway to implement the wireless specification in cars and cell phones to reduce driver distraction. Sensors proliferate The boom is light on wireless, heavy on intelligence. Water and heat in the fuel-cell balance Researchers from the National Renewable Energy Laboratory, Millenium Cell, and DaimlerChrysler are working on a sodium borohydride system tha thas the potential to meet FreedomCAR's weight-percent hydrogen-storage targets. Far East optimism Asia's Big Three--Toyota, Honda, and Nissan-- relied to a large extent on their global presence to post strong profits in 2002 as they and other Far East automakers prepare for an upswing in their economies. Models of choice Seven of the eight Japanese passenger car/light truck manufacturers offer various configurations of compacts, which are taking off in Asia.

Concepts from 2003 Tokyo Motor Show Environmental, safety, and information technology were strongly emphasized in an impressive array of fuel-cell, hybrid, and pure electric concept cars. LEDs shine on The lighting technology's compact size, power, and durability excite designers who still long for flexibility in interior and exterior styling. GM, software, and electronics At its annual media preview of new models, the company demonstrated how its technology investments will pay off in more features, for more people, in more market segments. Plastics roll into new territory From structural members to Class A surfaces, plastics continue to find increasingly broad application in the automotive industry. 2003 technology in review AEI editors look back at some of the most significant production-intent innovations introduced over the past year. Forging ahead in metal forming Crude though the means may have been, humans began making and shaping metal several millenia ago.

The chain in China North American suppliers must confront some challenging supply-chain issues as they take aim at what could potentially become the world's largest automotive market. Visteon researches composite truck chassis The company used computer analysis extensively in a research project aimed at reducing the mass and complexity of a chassis structure while increasing strength and stiffness. Simulation goes beyond engineering Computational fluid dynamics simulation and visualization software vendors are introducing products to extend the value of CFD throughout the product life cycle, according to Acuitiv Software. Ford still riding Six Sigma quality horse Ford is combining Six Sigma with kaizen events at its plants around the globe to coax new ideas from its hourly workers in hopes of closing the gap with perennial vehicle-quality leader Toyota.

Technical highlights from Geneva The high-profile event combined new technology, fresh design, debuts of major production models, and styling concepts in a compact venue. North American technology trends Every year in the May issue, Automotive Engineering International explores the major technology trends defining the auotmotive industry in North America. In June, it will do the same Europe, and in August Asia. Internal-combustion engineering Despite a century of refinement, the gasoline engine still has untapped potential, say industry executives. Body building The quest for light, quieter, and safer cars and light trucks influences the design and engineering of most vehicle areas--body not excluded. Chassis integration keeps the rubber on the road U.S. OEMs and Tier 1 suppliers are collaborating to deliver the latest technology for performance and safety, but integration stays in-house.

Success by design Toyota is working to differentiate itself from the competition by continually evolving its unique design philosophy. China overcapacity overstated? Automakers and suppliers are taking a "build it and they will come" approach to capacity in China. Challenges aplenty in China From an underdeveloped infrastructure to insufficient policing of intellectual property rights, government and industry leaders in China are dealing with a multitude of challenges--and opportunities--as vehicle sales soar. Testing adapts Growing vehicle complexity, globalization, and other industry trends are prompting companies to focus more on automation and standardization in their test programs. Lightweight vehicle engineering Demand for performance and fuel economy make materials once considered too expensive increasingly attractive.

Ultracapacitors charge ahead The limitations of current energy-storage solutions could encourage consideration of these alternative solutions, but more engineering work needs to be done to reduce costs. Technology for all Automotive industry executives expect high-end technologies, once considered only for inclusion in luxury cars, to increasingly make their way into entry- and mid-level vehicles in the very near future. Convergence continues A lot of automotive electronics ground has been covered at the Convergence conferences past, and there's more to come at this year's show in October. Fueling the next generation As hydrogen joins the battle for automotive power with gasoline and diesel, the future could be more choices rather than one winner.