THURSDAY

THURSDAY

Technology Theater Sponsored by:

VISIT

www.sae.org/congress FOR THE ONLINE VERSION Technology, partnerships drive sustainability

Weinberger SpeedCam Visario cameras help to make the most of crash testing. The vehicle shown is a Mini Cooper after a 35-mph (56-km/h) offset crash into a barrier. With 2 GB of solid-state DRAM, approximately 400 frames are stored at a rate of 1000 frames per second in AVI format. Each frame has a resolution of 1536 x 1024 pixels using a typical shutter speed of 200 ms. The camera uses a megapixel CMOS sensor and the compact design is suitable for use in harsh environments such as shock and vibration. In a crash-test environment, cameras would be mounted all around the impact site, and some mounted on board the vehicle.

Development that meets the present needs of society without compromising the ability of future generations to meet their own needs must be based in technology and science, said George Hamilton, Vice President of Automotive Materials, Dow Automotive, during his Wednesday keynote address, The Challenge of Managing Sustainable Development. “New business growth through investments in R&D is closely related to sustainable development,” Hamilton said. “Sustainability begins on the lab bench as scientists develop innovative technologies.”

SAE 2003 President begins term Dr. Jack E. Thompson, DaimlerChrysler’s Director of Computer Aided Engineering and Concept Development, will officially begin his role as SAE 2003 President tomorrow at the Board of Directors meeting. Thompson began his career working as an Atomic Energy Commission subcontractor to Los Alamos Laboratory before moving to Detroit, where he began his 38-year (and counting) career with Chrysler.

Dr. Jack E. Thompson

Thompson has held a number of positions with Chrysler over the years, initially as a product engineer in the Vehicle Structures Department where he progressed to manager of the department. He has also served as Program Manager for an electric vehicle research project; Manager of Advance Manufacturing Feasibility; and Director of Advance Manufacturing Planning. For a few years in between his manufacturing work, Thompson returned to product engineering as Chief Engineer of Advance Vehicle Engineering at Chrysler Central Engineering. His team handled advance engineering work on the first Chrysler minivan. Thompson was also named first Director of the Chrysler Technology Center Development handling all aspects of building the new facility. Thompson then became Executive Engineer in the Large Car Platform. He went on to serve as Director of Advance Engineering

See PRESIDENT, Page 3

AEI Show Daily Thursday, March 6, 2003

Keynote Speaker George Hamilton

For sustainable development to be effective, there must be partnerships between companies and industries. “The automobile provides huge social benefits,” he said. “Automobile usage, however, poses challenges—fuel efficiency, tailpipe emissions, greenhouse gas emissions, and recycling, to name a few—that [must be addressed].” Dow is addressing these challenges, Hamilton said, by helping to make cars lighter and more fuel efficient as well as finding ways to address passenger safety through innovative foams and structural adhesive. For example, the company’s Betafoam solution has not only been used as an acoustical absorbing and sealing system, but also in a variety of components for crash and energy-management applications, including many on the Cadillac CTS, he said. The need to reduce the environmental impact of products throughout their entire lifecycle presents another opportunity for collaboration, said Hamilton. One initiative Dow is addressing is the end-of-life vehicle (ELV) regulations in Europe,

See TECHNOLOGY, Page 18

Today’s Congress highlights • Putting Vehicles on a HighProtein Diet: the Challenge of Making Lighter, Safer Cars SAE Technology Theater 8:00-9:30 a.m. • Safer Vehicles Through New Technology: Where Engineering a Miss is a Big Hit SAE Technology Theater 10:00-11:30 a.m. • Keynote Address: John Plant TRW Automotive The Safety Revolution: As Safe as Possible 11:30 a.m.-Noon • Managing Driver Distraction in a Focused Approach SAE Technology Theater 1:00-2:30 p.m. • Automotive Electronic Systems Reliability Panel Discussion: Global Strategies and Business Opportunities: Satisfying the Long-Term Demand for Electrical/ Electronic Service Parts Room D3-16/17/18 1:00 p.m. • SAE Annual Banquet Detroit Marriott Renaissance Center Renaissance Ballroom 7:00-9:00 p.m.

Aisin grows in North America One of Japan’s leading suppliers, Aisin, is now a conglomerate of 121 companies with worldwide sales in 2002 of $11.4 billion. In North America, 22 of its companies combined for total sales of $1.1 billion. Plans for growth in North America include building automatic transmissions in North Carolina—the first such Aisin plant outside of Japan—and increasing aluminum casting production at the Kentucky plant by 50% to meet demand. Six-speed transmissions are rapidly becoming popular for the improved fuel economy and better driving characteristics they provide. Aisin is supplying both manual and automatic versions for front- and rear-wheel drive, and the transaxle for the hybrid Ford Escape. Advics is the chassis products division within the Aisin The new Aisin six-speed automatic transmission for light trucks provides better fuel economy and engine braking. group, the name being derived from ADVanced Intelligent Chassis Systems. “We are the only company that provides a complete brake system from pedals to pads,” said Gordon Daig, Vice President, Advics. The Toyota Sienna minivan features the Advics braking system, which supports adaptive cruise control. It also has a mechanical brake booster that provides extra power for emergency events. David Alexander

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Reginald Modlin, Director, Environment & Energy Planning, DaimlerChrysler Corp. talks to Neil Schilke, SAE 2001 President and GM Director of Engineering, Corporate Staffs, on the exhibit hall floor.

Herb Everss, CEO of GlobalEmergent, meets with Klaus Dohring, Program Manager, Transportation, Siemens VDO Automotive. Detroit Mayor Kwame Kilpatrick (center) meets with Dennis Wind, Director, U.S. Army TACOM National Automotive Center, and six junior ROTC cadets from Northwest High School in Detroit.

Visteon’s Giavanna Palazzolo, Manager of Corporate Public Affairs, and Gary Mayo, Global Director of Environmental Affairs, speak with David Cole, President, Altarum, before a Technology Theater presentation on sustainable development.

PRESIDENT...Continued from Page 1 for Large Car until 1995 when he assumed his current role. Each new SAE President brings specific goals to the job. Thompson, a 38-year SAE member, plans to devote his Presidential energy to three important initiatives: Knowledge Transfer, Systems Engineering, and Digital Development Process. He approaches his Knowledge Transfer focus with a goal of developing a knowledge database for sharing practical experience, on-the-job lessons learned, best practices not learned in college or from reading a book, and tapping experience of Fellow and/or retired members. His focus of Systems Engineering addresses the time and effort directed toward trade-offs between conflicting goals. According to Thompson, specific training programs that deal with these principles need to be designed. As for the Digital Development Process focus, Thompson

explained that industry can no longer afford the expense or the time required to develop designs using physical prototypes. With industry’s pace of change accelerating, he wants to ensure SAE members stay current with the latest analytical methods and understand the shortcomings and benefits of each. Also at tomorrow’s Board meeting, The Boeing Co.’s Bob Spitzer will begin his three-year term as the newly implemented Aerospace Vice President. This position is the result of a Blue Ribbon Panel’s conclusion that to stay relevant and strong in all the industries it serves, SAE needed to get closer to them. The resolution to this challenge SAE faced was to add three industrysector Vice President positions— aerospace, automotive, and heavy-duty—beginning in 2003, 2004, and 2005, respectively, Spitzer being the first. Jennifer Newton

Sustainable development “a very grand challenge” Protecting the environment and conserving the earth’s natural resources is an imperative for the automotive industry, participants in yesterday’s Sustainable Development panel acknowledged, but so is making money. Balancing those two competing interests is proving to be “a very grand challenge” in the view of panelist Thomas Gottschalk, Executive Vice President and

General Counsel, General Motors Corp. It’s also his opinion that technological innovation is the best lever to achieve that balance. But the automotive industry’s responsibility goes beyond that, Gottschalk said, requiring it to explore the issues of traffic congestion and alternative forms of transportation more thoroughly.

Editorial staff AEI editorial staff for the Show Daily can be reached during show hours at Booth 601, (313) 393-4469. Kevin Jost Editor Jean L. Broge Associate Editor Dave Alexander Associate Editor Patrick Ponticel Assistant Editor Jennifer Newton Assistant Editor Ryan Gehm Assistant Editor Kami Buchholz Detroit Editor Contributing Editors Linda Trego Terry Costlow Wayne Silvonic Production Manager Contributing Artists

Participants in Wednesday’s sustainability panel in the Technology Theater were, from left, DaimlerChrysler’s Bernard Robertson, Visteon’s Gary Mayo, Altarum’s David Cole, General Motors’ Thomas Gottschalk, DuPont’s William Hsu, and Ford’s Sue Cischke.

Christian Bonicky, William L. Schall Jr. Lucy Matyjaszczyk

See SUSTAINABLE DEVELOPMENT, Page 18 AEI Show Daily Thursday, March 6, 2003

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Doing business in China The move from a planned to a market-driven economy puts China on course to become a worldwide vehicle-producing contender. “By 2010, China will be number three in terms of light vehicle production globally,” said

Michael Robinet, Vice President of Global Forecasting for CSM Worldwide, during Monday’s Original Equipment Supplier Association (OESA)-sponsored panel discussion on China’s automotive industry.

European, Japanese, Korean, and U.S.-based automakers have established manufacturing locales in the Communist country as a means of increasing their worldwide market share. For many years, China’s automotive market

seemed destined to remain highly restricted. But since December 2001, more than 2300 laws and regulations have been amended and approximately 830 laws have been abolished to comply with WTO (World Trade Organization) rules.

“There’s a great opportunity, but tread with caution,” advised Timothy Donovan, Executive Vice President, General Counsel and Managing Director of Tenneco Automotive’s International Group, citing excess capacity and corresponding pricing pressures as one of many expected market trends. One source of overcapacity is the supply base. Donovan estimates that 1000 companies in China offer ride-control products. “They don’t present that much competition (to Tenneco) because they lack advanced technologies,” said Donovan, who believes many of the companies eventually will cease to exist or focus on the aftermarket. China’s automotive landscape includes more than 100 vehicle assemblers. “I think—at this stage of the game—the Koreans are the fiercest competition,” said Nancy Gougarty, General Motors Global Customer Director for Delphi, adding that Korean automakers and part suppliers typically “don’t over-engineer.” Taken as a whole, China’s “market is coming of age, modernizing, and achieving better economies of scale,” said Robinet. Doing business in China often requires a nimble approach to production. “There is usually only a six-month timeframe—after receiving an order—to get ready for production,” said John Wehrenberg, Senior Director of Asian Operations for ArvinMeritor. According to Wehrenberg, tooling, manufacturing, and processes must be ready in six months, which is the usual time frame in North America for building the tooling. “That’s just some of the market dynamics,” he said. Kami Buchholz

Exhibit Directory Addendum The following is a Directory update, as of March 5, 2003.

New exhibitor TES International LLC 1000 W. Maple Rd., Ste. 103 Troy, MI 48084-5361 United States www.tes-inet.com [email protected]

Booth 2516 Founded in 1994 to provide innovative, cost-effective solutions to our customers’ most challenging thermal/CFD and structural design problems. This is accomplished through a unique combination of theoretical, analytical and real-world expertise of our personnel. Engineers hold advanced degrees in mechanical engineering, with extensive experience in aerospace, automotive and electronics thermal and structural applications. Also license the leading electronics cooling software Electroflo featuring coupled electrical/thermal and patented radiation solver.

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Each day, Show Daily editors highlight some of the top products and technologies on display at the SAE 2003 World Congress.

Vehicle component simulator Southwest Research Institute (SwRI) engineers have developed a test apparatus capable of simulating vehicle powertrain operations in the laboratory. The apparatus uses hardware-in-theloop technology and a softwarecontrolled simulator to determine how a powertrain or related component would perform if it were integrated into a vehicle. The engineers designed and constructed a test system that simulates the operation of a transmission under a wide range of real-world conditions. (The

image shows a portable cold box being used to test a transmission under low-temperature conditions and varying grade angles.) Similar test systems can be

42-V auxiliary power unit developed to test engines, electric motors, hybrid-vehicle battery packs, and other equipment under a variety of road and environmental conditions. Using the RAPTOR VSM powertrain simulation software, researchers can perform numerous driving cycles to simulate driving conditions and eliminate some fleet testing. The apparatus can simulate stop-andgo traffic, roll and grade angle, heat rejection, aerodynamic drag, varying temperatures, and other parameters. Booth 2227

Motors and generators The traction characteristics of Technologies M4 (TM4) drive systems, which include electrically actuated ABS and traction control, make them especially suitable for launch and wheel assist applications. The distributed control system and direct drive features provide independent wheel control in both acceleration and braking. The firm’s integral electric motor and gearbox/ differential units are suitable for most EV, HEV, or FCEV applications. Paired with power converters and electronic controls, the units are efficient and contribute to a system overall efficiency over 96%. The company produces a range extender for EVs or generator for series hybrid vehicles. The generator can also be used to assist as a starter for an ICE. In addition, TM4 develops power converters and electronic control systems for generators and motors, including power inverters, vehicle control devices, and energy flow management systems. Booth 2848


Aria Power Products presents the experimental installation of its AAPU system in a 2003MY Lincoln Navigator. The system incorporates the compact Sytec two-cylinder 500-cc3 engine, harnessed to a 5-kW highefficiency permanent-magnet generator with combined AC starter. APP has commissioned Prodrive UK to perform the design and assembly of the installation. The installation displays the feasibility of mounting the engine as an under-slung unit, cross-member located rearwards of the rear axle in its own enclosure. The generator is located in an environmentally separated compartment of this enclosure. The fuel and coolant systems of the AAPU are integrated into the main vehicle systems. The prototype Power Management System—which controls the AAPU start-stop system relative to power demand, battery condition, output rectification, and control—is installed in its own cabinet on the Navigator’s rear load deck. This housing also incorporates a 36-V battery in a separately vented, 12-V, fan-cooled compartment. The dual-voltage electrical system specification showcases three 42-V features representative of future applications of the technology, including drive motors for the rear HVAC compressor and powerassisted steering pump, and the main vehicle power unit cooling fan. All other onboard electrical applications are powered via a dc/dc converter at 12 V while a rear-bumper-mounted connection socket allows the connection of either a 110-V or 220-V inverter for powering satellite electrical appliances. Booth 2741

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Variable-compression-ratio engine technology FEV’s Variable Compression Ratio (VCR) technology helps avoid the compromise that is necessary with fixed compression ratio in supercharged engines that

feature extended load ranges. It is based on the concept of an eccentric crankshaft bearing. Rotation of the eccentric bearing leads to a vertical position change

of the crank-train relative to the cylinder head and thus a continuous change in the compression ratio. The company has developed a demonstration vehicle

that features the VCR concept. A highly boosted, four-cylinder turbocharged SI engine was redesigned for the eccentric positioning of the crankshaft.

The vehicle has undergone several thousand kilometers of test driving and has exhibited neither damage nor unusual wear. As a result of careful combustion tuning, the compression ratio can be adjusted to its maximum/retaining position. Even during continuous driving at 140 km/h (87 mph), the compression ratio can remain at a relatively high value of 14. FEV has subcontracted to the EPA to help develop an in-cylinder NOx control methodology that simplifies after-treatment technologies while meeting 2007/ 2010 emissions standards. This Ultimate Clean Diesel Engine technology opens the door for cost-effective diesel powertrains that meet the federal Tier 2 standards. Booth 1817

Stop by the SAE Bookstore for your copy of the Worldwide Automotive Supplier Directory Special Congress Price $179 — Save over 50%

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The SAE 2003 World Congress provides industry suppliers the opportunity to showcase their products, services, and technologies to the global automotive community. Show Daily editors review what some exhibiting companies are displaying this year.

Axle components

Standards and regulations

SG Automotive manufactures axle components, brake components, spindles, and upper and lower control arms for light-duty trucks, light-duty buses, SUVs, and heavy-duty buses, as well as

InterRegs’ International Automotive Regulations CD is a comprehensive resource of up-to-date automotive manufacturing regulations that is referred to by automotive homologation, engineering, and R&D divisions globally. InterRegs covers over 50 countries and subjects including FMVSS, EC Directives, and emissions, all available on CD and online. InterRegs also presented the SAE/InterRegs Standards & Regulations

Award for Young Engineers to its winner at the annual Honors Convocation that took place on Tuesday. The SAE/InterRegs Award is given annually to a practicing engineer involved in standards, regulations, or conformity assessment systems that improved safety or reduced emissions in a mobility product. Booth 1367

independent suspension system parts for passenger cars. Manufacturing processes include hot and cold forging, stamping, powdered-metal work, casting both aluminum and steel, welding, CNC machining, heat treating (carborizing and nitriding), and gear cutting and lapping. ISO 9001 and QS-9000 certification is provided. Booth 2749

Recycling services In 2002, Amazon Environmental, Inc. opened its fourth facility in Lima, OH, to provide clients with the

option of 100% recycling (zero landfilling) of industrial paint sludge, wastewater treatment sediment, leftover latex paints, and chemically similar materials. The firm produces Processed Latex Pigment cement additive from non-reusable paints and makes and markets highquality recycled paint from reusable leftovers. Since 1995, Amazon has recycled 28,000 ton (25,400 t) of materials that otherwise may have been disposed of in landfills. The company operates recycling facilities in California and Minnesota as well as the new Ohio location. Booth 2175


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Brushless dc motor control

Differential pressure sensor

TTTech Computertechnik’s TTPBy-Wire Box controls brushless dc motors and high-power actuators. A DSP option enhances control functions of dc motors. The developer can choose between six-step motor control and advanced sinusoidal mode control of the brushless dc motor. This control method produces low levels of acoustic noise and low motor torque ripple. Development work is facilitated via support for rapid prototyping with motor control blocks for the MATLAB/Simulink environment. The unit is based on TTP technology and is suited for rapid prototyping of reliable by-wire systems. The MPC555 PowerPC microprocessor used as a host CPU for the TTP communication controller provides enhanced processing power. The TTP-C2 communication controller (AS8202) and the TTPTools software development suite provide the facilities needed to integrate several TTPBy-Wire Boxes into a hard, real-time architecture. The system works with 12- to 42-V power supplies and can be upgraded for future high-speed TTP communication controllers.

Kavlico’s Model P321 OEM dieselengine exhaust gas differential pressure sensor comes in pressure ranges of 0-5 through 0-10 psi and withstands high common line

Booth 1427.11

Rugged modules

Gas analyzers

Sony Ericsson’s rugged family of GSM/GPRS modules is comprised of interchangeable products for telematics and telemetry applications

California Analytical Instruments, Inc. manufactures gas analyzers commonly used for exhaust emissions research. These analyzers include flame ionization detectors, chemiluminescent (CLD), and nondispersive infrared. The analyzer techniques are combined with a unique software package to provide complete emissions analysis systems. The firm’s new microprocessor-based gas-analyzer product line includes the heated CLD with a selfcontained chiller to provide both wet and dry measurement capabilities. Booth 2362

Testing services

pressures (100 psi) in a highvibration, high-soot, and acid-rich environment while continuously providing high-output voltage accuracy. The sensor measures pressure drops across an orifice and provides the control system with a proportional measurement that is used to regulate EGR flowrate, which then reduces NOx formation. Key to the device’s high performance is the ceramic, variable-capacitance sensing element with programmable ASIC on hybrid circuit for reliable signal conditioning.

using TDMA, CDMA, and GSM cellular technologies. In addition to full voice and traditional SMS and data capabilities, the CDMA units are fully 1xRTT packet data capable, as are the GSM products with GPRS. They meet extreme operating temperature and vibration/shock resistance requirements for use in harsh environments, with a standard form factor for telematics and telemetry applications. Two versions are available, supporting either dual-band 900/1800 MHz (GM41) or 850/1900 MHz (GM42).

Booth 2101

Booth 3245

Bodycote Materials Testing offers a comprehensive range of outsourced services to the North American automotive industry from a network of 14 accredited laboratories in North America and over 40 laboratories worldwide. The Engine Technology Group’s test facilities are recognized by the Environmental Protection Agency and California Air Resources Board as being capable of conducting both on-road U.S. Federal Test Procedures as well as off-road emissions testing. Projects conducted by the Engine Technology Group include engine performance, development, durability, calibration, and emissions certification for heavy-, medium-, and light-duty engine manufacturers and aftermarket suppliers. The Vehicle Dynamics Group specializes in accelerated durability testing

using advanced servo-hydraulic simulation equipment. Facilities include a six-post heavy-dutyvehicle road simulator, four-post medium-duty road simulator, and a four-post light-duty road simulator climate chamber. Multiaxis simulation testing is also offered for large-component testing, as well as a spindlecoupled cab shake facility for medium- and heavy-duty trucks. Booth 1261

Inspection tools Everest VIT’s tools for the automotive industry allow problems to be diagnosed without disassembly. These include the 3.9-mm (0.15-in) diameter XL PROT, fiberscopes, and

rigid borescopes. The tools have been used to locate squeaks and rattles, inspect for water leaks, check anti-corrosion wax within closed sections of body shells, view inside structure parts during crash testing, examine the insides of gasoline and diesel engines, perform prolonged engine and transmission endurance tests without disassembling the power unit, inspect brake master cylinders, and check diesel fuel injector assemblies and crankshaft oil pipes for blockages. Booth 2335

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Crystal oscillators

CMOS technology

Two families of high-stability, temperature-compensated crystal oscillators (TCXOs) from C-MAC MicroTechnology have a clipped sinewave output offering current consumption down to 1.5 mA. Based upon the company’s fourth-

The 90-V mixed-signal CMOS technology from austriamicrosystems is well matched for any high-voltage (HV) application for automotive and industrial applications such as analog sensor front ends and even future 42-V automotive applications. A full set of HV and mixed-signal devices including HV NMOS, PMOS, DMOS, vertical and lateral bipolar transistors, NJFETs,

capacitors, and resistors are provided to enable leading-edge designs and products. The process is complemented by a special version of the “HIT-KIT” EDA tool featuring accurate silicon-proven models and a powerful and easyto-use design environment. Booth 1427.2

order analog temperature compensation ASIC, known as Pluto, the CFPT-9005/9008 and CFPT-9057/ 9061 devices can be specified with tight frequency stability and low jitter. Besides compensating for the standard frequency-to-temperature characteristics of the crystal, the device uses analog circuitry that compensates for non-linearity and temperature dependence in the pulling response of the oscillator. When matched to the characteristics of an individual oscillator, this circuitry delivers high stability over the temperature range, even when the oscillator frequency needs to be adjusted by several parts per million (ppm) to track an external frequency source or to correct for device aging. Thus, the units deliver temperature compensation better than ±0.3 ppm from -20 to +70°C (-4 to +158°F) without introducing granularity. Booth 2101

Welding simulation The latest release of SYSWELD from ESI Group considers all aspects of material behavior, design, and process to simulate continuous

welding, resistance welding, quenching, induction hardening, thermo-chemical treatment, and surface treatment. Completely redesigned to suit the needs of experts and non-experts, the system reduces cost and lead time. It is available on PC and Unix platforms. Booth 2303


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Miniature gears for air vents Wave Drive miniature precision gear units from Oechsler AG electrically adjust air vents for cars. This feature provides interior designers more freedom, eliminating wheels and knobs that are mechanically connected to the vent. They can be incorporated in customizing solutions such as keyless go and driver recognition. The actuators are integrated in the flap shaft and thus save valuable space in the dashboard area. They consist of a dc or stepper motor combined with gearboxes, providing a reduction ratio of 400:1 in a compact volume. They measure 12.2 mm (0.5 in) in diameter by 9 mm (0.35 in) in length, and have a mass of less than 1 g (0.03 oz).

Strain and stress analysis The Grid Analyzer Model 100 from FMTI Systems Inc. will automate strain and stress

Booth 2146

Process management The egip Process Engine from egip Software AG is a Web-based business solution for comprehensive corporate process management that integrates process, multi-project, workflow, innovation, and knowledge management. The software offers the range of practically oriented functionalities for consistent modelling, transparent controlling, efficient realization, and automated documentation of business processes. The egip Modeller, which runs on the Web as a Java Applet, allows the user to concentrate efficiently on visual process design without taking care of inconsistencies or loops. The corporate process technology with built-in consistency leads to cost savings in the maintenance of enterprise-wide processes. Due to the flexible modular concept, processes can be dynamically adapted to the ever-changing environment of the company, thus achieving a continuous improvement of all processes. By generating projects directly from the processes, egip provides an efficient tool for process-oriented multiproject management that meets all the requirements of modern quality management standards. Booth 2043

analysis in sheet-metal-forming operations. With the grid analyzer, the traditional Circle Grid Analysis is faster and more accurate than using conventional techniques. The consistency of the strain measurements for a typical electro-etched grid is about 0.5% in engineering strain units with a processing time of about 2 s per data point. The system supports several grid patterns including those drawn by hand. The system automatically generates Forming Limit Curve, Forming Limit Diagram, and production strain analysis reports. Data and images are easily exported for inclusion in all reports. The grid analyzer comes complete with software designed for the analysis of single and multi-operation processes. Booth 1370

Waterproof sealing DSG-Canusa’s DERAY Coldmelt II system is designed to provide waterproof sealing as well as resistance to thermal, chemical, and mechanical damage to wire harnesses. It uses a two-piece custom-designed grommet and a soft butyl rubber component to prevent water and other fluids from leaking between wires in a wire bundle, and possibly causing failures of electrical connections. The butyl rubber creates a reliable seal between wires in large bundles, without the use of heat and adhesives, preventing damage to wire jackets. The grommet replaces the costly over-molding process commonly used in sealing wire bundles in car body feed-through areas. Installation time is reduced as this system can be installed at the sealing area rather than being fed along the entire harness. In addition, it is installed during the harness assembly process, eliminating the need for a separate manufacturing process away from the assembly area. Available in operating temperatures from 85 to 135°C (185 to 275°F), the material is resistant to all common automotive fluids and meets the requirements of Ford, BMW, DaimlerChrysler, and many other major car manufacturers. Booth 2800

Active hood An active hood from Concept Technologie GmbH is a system for passive safety in the vehicle’s front area. By lifting the hood, more free space is gained, which can be used for deformation of the hood. The deformation of the head impact zone allows the effective energy to be absorbed, thus preventing the pedestrian’s head from being exposed to a greater force. The system consists of a leaf spring, locking mechanism, and trigger mechanism. In the event of an accident with a pedestrian, the

system is activated, and the hood is transferred to the active position. The movement between the two positions is completed in 40 ms. The locking mechanism can absorb deformation energy. Booth 1427.3

Valve coating Future F1 valvetrain requirements can be met today with a new jointly developed DLC coating from Hyromecanique Et Frottement (HEF)-Del West

Europe. The new hybrid PVD/ PACVD coating increases valvetrain life by a factor of two or more. Work continues to be done to have the technology available and cost-effective for the high volumes of present-day automotive engines. Booth 1371

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Composites technology Curv technology from Curv Composites, a part of Amoco Fibers and Fabrics Co., uses 100% polypropylene composite for light weight, thermoformability, and ease of

Automotive forum focuses on innovations for Welsh automotive industry The automotive industry in Wales, which employs nearly 30,000 people, is the largest manufacturing sector in the UK. Home to Ford and Toyota’s engine production

facilities, as well as 200 other automotive supply chain companies, Wales is a leading destination for the automotive industry and produces many technical advances each year.

The Welsh Automotive Forum (WAF) was established to support the flourishing industry. Founded by Chairman Garel Rhys, the WAF is responsible for monitoring the global

automotive technology sectors in order to disseminate new trends, innovations, and advancements back to the companies in Wales. Booth 1934

recycling. A new product application is an underbody shield developed in partnership with a major OEM. This part is undergoing extensive road testing in Europe. Curv fits well with this application because not only is it lighter in weight than conventional underbody materials, but it also has considerably higher resistance to impact and abrasion. It never becomes brittle, even at extreme temperatures. Other applications under investigation include lightweight load floors, tonneau covers, and areas of interior trim. Booth 3300

Embedded electronics Electronic Concepts & Engineering, Inc.’s embedded electronics and real-time software development services include specific expertise in hybrid-electric-vehicle control systems, transmission and engine controls, wired and fiber-optic CAN network systems, and vehicle data

recorders. A new multi-purpose I/O Processing Unit (IPU) that is designed for control, data acquisition, and/or test applications features digital, analog, and power inputs/outputs, serial communication, a programmable processor, wired and fiber-optic CAN network interfaces, and ruggedization to operate in extended temperatures and harsh environments. The IPU may be implemented as a standalone unit or a network node in a distributed system. Booth 1713


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Turbochargers for commercial-duty engines Holset Turbochargers’ latest turbocharging technology for commercial-duty engines is encapsulated in the E-Range introduced in 2002, including advanced turbocharging designs such as variable geometry turbine (VGT). Models on display include the HE500V (12- to 16-L engines) with pneumatic actuation (pictured), and the HE300V (6- to 8-L engines) with electric actuation of the VGT, Turbocompound (the Scania DTC12 system), cast titanium, and machined from solid forged-aluminum compressor wheels. Also on display are various turbocharger control components that enable Holset turbochargers to be interfaced with the engine ECU, including DCON and ICON valves for VGT turbochargers and Command valves for wastegate turbochargers. An Iveco Cursor 13 engine with the Holset VGT represents the first application of the VGT turbo that was developed over a period of 10 years in partnership with Iveco engineers in Turin. A Cummins ISB engine that was developed by Gale Banks Engineering working in close cooperation with Holset Turbochargers is also on display. Booth 2753

Transmission controller

Measurement platform

Smart child seat

IAV’s transmission controller is the newest addition to its Prototyping Controller Line. The design of automotive-compliant, rapidprototyping controller hardware and software for prototype and low-volume production has always been an integral part of IAV’s automotive electronics division. This expertise makes the firm’s controllers (universal controller, engine controller, and transmission controller) valuable tools for development, demonstration, and evaluation. The transmission controller’s core runs with a 16-bit controller at 40 MHz. It has 512 k flash memory and 32 k nonvolatile fast RAM. The power stages are designed to deal with fast and powerful actuators, e.g., electric motors or control valves. The base software is an OSEK-compliant RTOS. Its development tool chain consists of a graphic tool, design tool, compiler tool, flash tool, as well as a measurement and calibration tool using CCP. IAV owns the intellectual property for transmission control software for automated manual transmissions.

The Cronos PL measurement platform from imc DataWorks is suitable for research and in-vehicle testing. It consists of configurable hardware and ready-to-use software that adapts quickly to changing engineering needs. An innovative portable hardware platform allows for both self-contained and PC Ethernet operation at a low cost per channel. Integrated DSP enables real-time signal conditioning, analysis, and feedback control to optimize information collection. Cronos PL can synchronize and correlate measurement of all signal parameters—analog, digital, and CAN bus. Flexible PC software

The TattleTale child car seat from New Lenox Baby Products adds a new dimension to child safety. Using sensors to monitor when the child seat is properly installed in

Booth 1344

provides full data visualization and calculation capabilities, with COM extensions for development of specialized applications. To adapt to changes in testing requirements, Cronos PL can be easily expanded with compact CANSAS modules to form a complete distributed measurement system. Booth 1721

the vehicle, if the child is sitting in the seat properly, and if the child releases the child seat buckle, the TattleTale will audibly alert parents if a problem exists. The smart child seat helps with proper installation by using an audible voice when the seat is properly installed by announcing “Buckle fastened, vehicle belt tight.” During the ride, the system continuously monitors itself and the secured child, precisely pinpointing problems that may occur so they can be quickly resolved. The seat has a five-point harness system, making it difficult for the child to climb out. The smart child seats are offered in two versions: toddler and booster seats. They will work with traditional twoand three-point vehicle seatbelt systems and are compliant with new FMVSS 213 child seat regulations. In addition to portable child seats, the TattleTale smart child seat principles are being evaluated for integrated child seat applications. Booth 2617

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Interactive wiring diagrams TTA International’s advanced ActiveSchematics provides Interactive Wiring Diagrams in CGM and SVG format. It is possible to load netlists directly into ActiveSchematics. The wiring diagrams are drawn in a specially developed authoring system. The

software enables engineers to use the circuit diagram illustration to explain the required details for performing fault isolation diagnostics graphically. By following defined steps, connections can be highlighted to check for fault isolation, making it

Copper rod alloys possible to perform guided diagnosis with the circuit diagram. Thus, all circuit-diagram-related information such as pin number, connector codes, and location does not have to be copied into the diagnosis information. Booth 3129

The Copper Rod Alloys for Machined Products CD-ROM from Copper Development Association is an alloy selection guide for copper and copper alloy rod, bar, and shapes used for machined parts. The CDROM is organized to help the designer, engineer, or purchasing manager specify the proper alloy for the intended application. It presents data on all copper rod metals, but emphasis is on freecutting brass. It demonstrates how material cost, machining cost, design, and scrap value influence the total cost of machined parts. Booth 236

Windows-based tactile sensor system Sensor Products Inc.’s Topaq pressure analysis system provides a unique perspective of the distribution and actual magnitude of pressure between any contacting or impacting surfaces. Topaq is typically used by automotive engineers and technicians to interpret pressure measurements obtained from the use of pressure-indicating sensor film such as the company’s Pressurex, which changes color in proportion to the amount of pressure applied to it.

The Windows-based Topaq system scans and interprets the exposed film and produces digitally enhanced images and statistical reports, which can be saved, printed, and exported for analysis in other software packages. The system can be used to ensure accurate interfacial spacing and membrane placement in fuel-cell stacks (pictured), among other applications. For more information, circle 1810

Drive system Somaloy powders from North American Höganäs, Inc. are used in automotive actuators, ABS systems, cooling fans, power steering, and electrical vehicles. Manufacture of Transverse Flux Machines (TFMs) is now a commercially viable solution. Voith’s ELVO drive system features a 150-kW motor and incorporates a TFM in an environmentally friendly diesel electric system for city buses in Germany. This non-polluting propulsion system can switch between diesel and electric propulsion, and batteries can be recharged during diesel propulsion to boost operational range. A 60-kW drive for electric-hybrid and fuel-cell vehicles provides not only the high continuous torque necessary, but also the environmental and economic benefits gained from electrical machines. The system features high power density, low weight, and efficiencies up to 95%. Booth 1374

Microprocessor chips VindAX microprocessor chips from Axeon help solve nonlinear problems such as engine management and emissions, voice recognition technology, and noise cancellation. Ford and Lotus Engineering

are using the VindAX rapid prototyping station to aid in reducing emissions harmful to the engine and environment, and create an alternative to software-driven systems for voice recognition. Features include small hardware neural networks, increased training algorithm resolution, update after classification, and 3-D visualization that allows the user to analyze characteristics within the data. Booth 1927


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Temp. & humidity test chamber

Data acquisition

VXI controller

Tenney’s T2 chamber can simulate a wide range of temperature and humidity conditions while using minimal floor space. These chambers are well suited for use in electronics and military quality assurance and reliability testing and production processes. The temperature range is -75 to +200°C (-103 to +392°F) and includes removable access panels to the refrigeration system, control system, and optional accessories. The new design allocates space within the cabinet’s interior for all standard options, which improves the mobility of the unit as well as the overall appearance.

Validyne Engineering’s MC170-L portable signal conditioning system accepts plug-in amplifiers for sensors used in automotive testing such as strain gages, LVDTs, variable-reluctance pressure sensors, frequency signals, and dc voltages. Portability and versatility make the unit suitable for vehicle testing, flight testing, and engine test stands. It operates on +10 to +24 V dc vehicle power. The device comes complete with its own dataacquisition software package for any PC or laptop computer running Windows 95/98 or NT. Programming for Visual Basic 6.0 and

KineticSystems Co.’s V153 VXI Slot-0 Controller expands on the capabilities of its predecessors—the V151 and V152, the industry’s first VXI Controllers with embedded PowerPC technology—by offering clock speeds of up to 1.26 GHz and memory options up to 512 Mb. The V153, a single-width, C-size VXI bus module, takes advantage of the Pentium III CISC-based architecture to provide a powerful real-time computing environment. It is a suitable replacement for older, lower-capacity embedded processor controllers, such as those using 68030-based technology operating at 25 MHz. The increased memory provides greater data buffering capacity for expanded data acquisition and control capability without placing correspondingly higher demand on the host computer. The V153 will operate under either Linux (available with real-time extensions) or Windows 2000 Operating Systems. In most applications, the V153 is an embedded PC, which includes a USB port, keyboard, mouse, and SVGA port. Other connection options include one PMC card option for fast/wide SCSI and IEEE488, and features include two 16-bit and two 32-bit programmable counters/timers, voltage sensors, watchdog timer, and status LEDs.

Booth 1236

Softwire is also available. An optional plug-and-play 200-kHz A/D interface card makes the laptop a portable, real-time data-acquisition instrument. Booth 452

Compact environmental chamber The ThermoFixture compact environmental chamber from Temptronic is a compact environmental test chamber for the fast, convenient testing of sensors, ECUs, sample parts, and critical electronics at precise temperature from -80 to +225°C (-112 to +437°F) at the benchtop or test station. With precise temperature control directly at the sample or PC board case, the ThermoFixture chamber provides uniform temperature control across the PC board, ECU, or sensor to be tested. Suitable for thermal cycling, thermal shock, environmental testing, or any thermal test application, the system performs with fast temperature change rates using the ThermoStream highvolume thermal airstream system. For a turnkey, one-step solution, the chamber is available with fixturing directly to the customer’s test station to provide a controlled thermal test environment at the test site. The portable device can also be located beside or near the test station, a convenient alternative to testing in ovens with long test cables. An optional probethrough window enables probing/testing of a PC board or subject while at precise temperature. Booth 844

Measurement and calibration system The CANape graph measurement and calibration system from Vector CANtech, Inc. is a software application providing multivariate data acquisition, analysis, and parametric calibration at the ECU level with complete access to userselected values in the ECU’s RAM. Through its unique combination of features, the software can reduce subsystem and ECU development cycle time by streamlining the development process. Its rich feature set and ASAM-compliant standardization (CCP and XCP protocols) allow the low-cost extension of powerful calibration techniques typical in powertrain systems to less complex electrical subsystems such as those found in body and chassis applications.

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An off-line mode allows work to proceed if hardware is temporarily unavailable. The software is vehicle-network-aware; thus, it can support measurement and calibration functions across distributed control systems involving multiple ECUs. It runs under Microsoft Windows (98, ME, NT, 2000, XP). Booth 2601

Booth 936.1

Quote preparation VisiQuote Version 5.0 from QStrat Inc. is an integrated and secure quote preparation application. It is an off-the-shelf, enterprise-ready quoting solution designed to meet the needs of automotive component suppliers. The software offers an industrial-strength alternative to costly internally developed and divergent spreadsheet/database quotation systems, with the potential to interface with other enterprise systems via XML. NetVQ is a secure, browser-based quote tracking and quotation process management application hosted by QStrat and offered securely via the Internet as an application service. It is designed to meet the quotation process requirements of automotive component suppliers and provides enhanced quote tracking and quotation process management. NetVQ Client Host is identical in functionality to NetVQ and is provided as a host installed at a client location, allowing larger clients to manage and control the NetVQ application within their existing corporate network. Booth 1321.1


Vehicle/road simulation TNO Automotive has developed a facility in which a vehicle can be tested in laboratory conditions, while realistic road conditions are being simulated. In the VEHIL hardware-in-the-loop test facility, the complete intelligent vehicle is placed on a chassis dynamometer, with each wheel supported by one of the four drums of the dynamometer. The vehicle is able to ride and brake as if on the road. The dynamometer simulates road behavior based on a simulation model of the test vehicle. Maximum speed is 250 km/h (155 mph). Realistic emergency braking can be simulated up to 150 km/h (93 mph) for most vehicles. The chassis

dynamometer can accommodate very small vehicles as well as trucks and buses up to a mass of 12,000 kg (26,450 lb). Other road users are represented by “moving bases,” which are designed to perform every conceivable 2-D course with simultaneous longitudinal, lateral, and yaw movement. A central controlling computer creates a virtual relative world for the test vehicle and coordinates the interaction between chassis

dynamometer and moving bases. The software provides an intermediate step between simulation and full-scale road tests. Booth 424

Dynamometers and assembly systems

Lighting catalog

Cirrus Technologies offers four core engineering competencies for the vehicle assembly line and laboratory: electrical test systems, rolling roads including dynamometers, wheel and tire assembly systems, and special-purpose automotive test and assembly systems. Recently Cirrus completed a major noise, vibration, and harshness (NVH) chassis dynamometer project in a semi-anechoic chamber for testing a range of Saab passenger automobiles, including the latest 9-3 sport sedan (pictured). Full details of this installation at the Saab Technical Center in Sweden are on display. In addition, Cirrus manufactured and installed an axle production line for Delphi that was 75 ft (23 m) long, consisting of individual build stations, and was designed to operate as a continuous application 24 hours a day, 7 days a week. Delphi can now assemble and set thousands of rear axles per week for midsize automobiles.

The 2003 Supplement Catalog from Hamsar Diversco Inc. features product additions including Micro Line and compact auxiliary lamps, rectangular work lamps, utility lamps for exterior and interior applications, twin beam work lamps, a new type of rear lighting, mechanical and solid-state flashers, and an updated daytime running light application guide. The catalog complements the firm’s existing line of electronics, which also includes relays, bulbs, and backup alarms.

Booth 1835

Booth 3126

Direct injection system Orbital Engine Corp.’s air-assist direct-injection system (OCP) delivers inherent advantages such as enhanced fuel atomization, multiple injection strategies, and low-spray-penetration velocities. Recent testing has shown that the OCP system can overcome the typical hurdles such as poor cold startability, limited load range, and high knock sensitivity faced by the use of heavy hydrocarbon fuels in conventional SI engines. Booth 2644

Data acquisition The Fluke 2680A data-acquisition system is designed for small to large multi-channel applications requiring reliable Ethernet communications. It features 120-channel capability,

flexibility, and scalability to 2000 universal channels per system. An optional OPC server allows integration to existing application software. The front-end chassis style system has six slots, allowing users to custom build a complete datalogging system. Five of the slots can accommodate any combination of 20-channel universal input modules compatible to the 2680 Series. The sixth slot may be used for an additional analog input module or for an available digital I/O relay module that adds an additional element of control. Booth 936.2


See US at SAE Show Booth #712

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Self-piercing fasteners

Film-to-digital scanner

The headed FAS-NER self-piercing, flush-mounted fastener from AKH joins dissimilar metals and thicknesses. The system is a simple punch and die operation, which automatically feeds, punches, inserts, and locks the unit to produce a solid joint in one high-cycle operation. The device is available in zinc-plated steel and high-strength aluminum and can be pre-painted to match the product. The one-step operation results in improved holding strength.

Visual Instrumentation Corp.’s high-resolution automatic 16-CVS film-to-digital scanner is designed to transfer 16-mm (0.63-in) high-speed data film captured in automotive safety applications, including fullscale vehicle barrier, Hi-g sled, airbag deployment tests, and related safety testing applications. The 16-CVS automatic scanner handles both color and monochrome films with digital resolution up to 4.2 million pixels per image frame. Once captured, these digital images are easily transferred to most popular file formats including AVI, TIFF, JPEG, and MPEG2 for analysis, presentation, distribution, archival, and other formats as required. Options include Visual Fusion 2-D/3-D motion analysis software. When included with the 16-CVS, users have a complete and fully integrated turnkey system. Visual Fusion detects and tracks moving objects in a series of images and provides position, velocity, angle, acceleration, and size vs. time. It also handles NTSC & PAL video formats and provides users with advanced motion analysis software.

Booth 2927

Booth 514

Heat treating The Alfe heat-treating system combines the reliability and flexibility of a distributed automation system with the high integration of a centralized system. The system integrates control, networking, and visualization, reducing the time and cost to integrate multiple controllers. Ability to reuse tags throughout the control system has reduced programming time. Greater reliability allows production capacity to meet or exceed previous levels. The integrated automated processing system uses a RAD (RSView32 Active Display) server that stores all information, then makes it accessible to operators from seven operator interface stations to monitor the heat-treating system, track batches, and control temperature. Operator interface stations also provide connection points for badge readers

and bar-code printers used to identify operators and their respective access settings. All activities are logged and tracked to a specific user and time. The touch-screen controls play a major role within the daily functions and operations for the heat-treating process and can improve productivity, quality, and security, as well as decrease labor and training costs. Booth 2845

Sealants Sinterseal 100 from Ultraseal International is a low-cost sealant for the powdered metal industry. Traditionally, cast components are impregnated to seal them against leaks, which if left untreated would cause them to fail in service. Sintered parts have different properties that require impregnation for one or more different reasons. The sealant helps with increased machinability, surface coating pretreatment, and pressure integrity. The firm also has a new corrosion inhibitor, DB100, which is a nitrile-free detergent for aluminum alloys and protection on ferrous parts. The company also produces front-loading impregnation equipment that provides short cycle time due to small chamber size, eliminates overhead crane and walkways, and automates the entire process to ensure quality and cleanliness. Booth 2615

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See US at SAE Show Booth #2405

CAESAR technology showcased During the show, SAE 2003 World Congress attendees can see the latest technology for creating accurate, innovative, and comfortable designs. It’s called CAESAR (Civilian American and European Surface Anthropometry)—a 3-D anthropometric database that is revolutionizing current design methods. Imagine having access to 3-D model scans that can be manipulated to allow additional measurements. This database has many advantages over the old measurement systems using tape measures, anthropometers, and other similar instruments. Hundreds of thousands of points in three dimensions are on the human body surface in a few seconds, providing tremendous detail about the surface shape. The 3-D locations of measurements relative to each other enable easy transfer to Computer-Aided Design (CAD) or Manufacturing (CAM) tools. The resulting scan is independent of the measurer, making it easier to standardize. In addition to the scans, this database contains a rich cache of anthropometric information: 99 univariate measures—59 from the scans and 40 using traditional measurements. Plus extensive demographic data permits you to create a sample tailored to your target market. The sample includes men and women, ages 18-65, in the United States and Canada—the NATO member nations with the largest, most diverse populations. Representatives include samples for various weights, ethnic groups, gender, geographic regions, and socioeconomic status. It includes three scans per person (one standing, two seated poses). Data collection methods were standardized and documented so the database can be consistently expanded and updated. CAESAR was created as the result of a comprehensive research project that brought together numerous industries including apparel, aerospace, and automotive along with the government and military to collect the most extensive sampling of consumer body measurements for comparison. SAE now offers this product to the mobility industry.


Fuel cells, hydrogen may be ready by 2015 The development of fuel-cell vehicles and the infrastructure needed to support them will be a huge endeavor, one that will take at least a decade before making any significant impact. The effort will require cooperation at all different levels, according to the panelists discussing Fuel Cell Initiatives: Powering Up at the State, Regional, or International Levels. Some partnerships are already being forged. The U.S. Department of Energy’s (DOE) FreedomCAR and the California Fuel Cell Partnership are among the largest, with the latter including international partners. These efforts, along with those in other states and countries such as Austria, should propel fuel cells into commercial usage during the next decade. “I think things will start coming on line around 2015,” said Patrick Davis, Technology Development Manager for Hydrogen Fuel Cells and Infrastructure at the DOE. He added that some form of alternative technology will be necessary to close the growing gap between the amount of fuel that becomes available each year and the amount of fuel needed in the U.S. Transportation accounts for about two thirds of U.S. fuel consumption making it the primary area for research here. One of the keys will be to make fuel cells price competitive with gasoline and diesel engines. Panelists also predicted that hydrogen will also play a role in a similar timeframe. By 2010, Murray Davis, Chief Technology Officer at DTE Energy Technologies, predicted that, in certain instances, hydrogen will be price competitive with gasoline priced at $6 per gallon when measured on the cost of a 300-mi (483-km) trip. However, when the technology exists for creation of hydrogen fuels at local sites, the price will fall below the prices of today’s gasoline, he predicted. Panelists suggested that trucks and buses should lead in the commercialization effort, since they consume more fuel per vehicle. However, the real value will come when private cars convert, since their huge numbers mean they consume more fuel than larger vehicles. Terry Costlow

Gasoline engine still king The main messages from The Road to Tomorrow’s Gasoline Engines panel were that gasoline engines still have a lot of room for improvement and that they will remain a core powertrain technology, particularly in North America, for years to come. Though the gasoline engine will remain the powerplant of choice in North America, Daniel Kapp, Chief Engineer of Ford Motor Co.’s Powertrain Operations said, “alternative approaches will continue to play an increasingly significant role.” According to Kapp, the gasoline engine will be a core technology for another 30 years or more, while the modern clean diesel will be vital for the next 40 plus years. He referred to hybrids as a “supplementary” technology, hydrogen-fueled internal combustion engines as a “bridging action” to a potential hydrogen economy, and fuel cells as the potential “end game,” with volume impact coming 20 years or so down the road. Franz Pischinger, President and CEO of FEV Motorentechnik GmbH, noted displacement on demand (DOD) and several variable valvetrain concepts are technologies to improve both the performance and fuel economy of gasoline engines through minimization of pumping

losses. He said that cam phasing can reduce fuel consumption by about 4%, fully variable intake valve lift and timing by about 10% (a method BMW is putting to use in its new engines), camless electromagnetic intake and exhaust valvetrains (including oscillating cylinder deactivation) by about 18%, and DOD (cylinder deactivation) by 8%. Pischinger also mentioned downsizing (possibly combined with variable compression ratio), direct injection, the introduction of roller bearings, and low-friction design as other engine technologies that can enhance future gasoline engines. “In Europe, there is intensive development work going on with all of these technologies,” he said. Similarly, Ford’s Kapp noted advanced valvetrain systems as significant technology, as well as advanced combustion systems as a means to further improve efficiency. Takehisa Yaegashi, Senior General Manager of Toyota Motor Corp.’s Powertrain Planning

Department, emphasized the importance of hybridization, stating that it is key for the advancement of all powertrain technologies on their path toward “the ultimate ‘eco’ car.” Hybridization will allow the internal-combustion-engine vehicle to stay competitive in the future, he said, by enabling a total energy efficiency that is comparable to the fuel-cell hybrid vehicle.

Yaegashi predicts the percentage of Toyota and Lexus vehicle sales that will be hybrids in the 2005 to 2010 time frame will be about 5%, though its current hybrid sales account for “barely “ 0.5%. He believes that hybrids will become more economically competitive in the future, making them more attractive to potential customers. Ryan Gehm

42 volts and fuel cells Vehicle accessories on today’s luxury cars typically require 2-3 kW of electrical power, but luxury cars produced in 2010 are predicted to consume more than 8 kW for accessory loads. “Cars are becoming very hungry relative to their need for electrical power,” Frank Preli, Vice President of Engineering for UTC Fuel Cells, a United Technologies Co., said during Tuesday’s 42-volt electrical systems and fuel cells panel discussion. UTC Fuel Cells and BMW are working on a 42-volt auxiliary power unit (APU) that will be fitted on a 7 Series in the coming months. “UTC has been working on PEM (Proton Exchange Membrane) APUs with BMW since 1998,” said Preli. Delphi continues its work on APU technology. “42-volt is the nominal voltage for Delphi’s fuel cell APUs presently in development,” said Jean Botti, Chief Technologist of Delphi’s Innovation Center. While APUs represent a viable power source solution, not everyone shares the same viewpoint on the technology’s value. Tom Moore, Vice President of Liberty and Technical Affairs for DaimlerChrysler, favors APUs for certain applications, but he disagrees that fuel cell APUs are the right solution for high-volume passenger cars in the nearterm “because it’s an expensive way to make a modest amount of power.” General Motors’ Hy-Wire concept vehicle via the AUTOnomy program combines fuel-cell propulsion and 42-volt technology. “42-volt enables driveby-wire, which allows re-interpretation of the interior design,” said Christopher Borroni-Bird, Director of Design and Technology Fusion and the AUTOnomy Program Director for GM. Borroni-Bird expects to see a gradual rollout of select drive-by-wire technologies in the next five to 10 years. Will 42-volt electrical systems replace 12-volt technology? “I’m not sure the 42-volt system is nearly as imminent as once thought,” said Moore, who believes 12-volt architecture can survive. “You really have to manage it smarter and smarter.” One reason for his 12-volt stance: a change would affect more than 100 vehicle items, ranging from dome lamp to power seat control. “I don’t think we’ll be abandoning 12 volts for a long time,” Moore predicted. Kami Buchholz


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The SAE Technology Theater is an important new component of the SAE World Congress. Its sessions, featuring industry leaders from around the world, will be open to all SAE World Congress attendees including those registered for the exhibit only. The SAE Technology Theater will be located on the exhibit floor adjacent to special technology displays from major Original Equipment Manufacturers. If you have a question for a speaker, send it via e-mail to [email protected].

Putting Vehicles on a High-Protein Diet: the Challenge of Making Lighter, Safer Cars 8:00-9:30 a.m. Lightweight materials technology will be a significant enabler allowing vehicle designs to meet personal transportation needs of the future. Successful vehicle platforms will use an array of materials and processes—a combination of traditional, evolutionary, and revolutionary materials and processes. Speakers will focus on the interaction between these materials technologies to achieve the desired objectives of speed to market, manufacturing flexibility, occupant safety, energy reduction, air quality and vehicle recycling, all with minimal cost. Don Goodwin, Vice President, Scientific Labs and Proving Grounds, DaimlerChrysler - Moderator Tom Moore, Vice President, Liberty and Technical Affairs, DaimlerChrysler Charles Wu, Director, Manufacturing and Vehicle Design Research Lab., Ford Motor Co. Steve Denner, Vice President Research and Technology, National Steel and Chairman of the AISI Committee on Manufacturing Technology Eric F. M. Winter, President, ALCOA Automotive Engineering Luis Lorenzo, Global Director, Applied Development & Engineering Alan I. Taub, Executive Director – Science, GM Research and Development, General Motors Corp. Len W. Miller, Vice President of Technology, Meridian Global Technology Centre

Safer Vehicles Through New Technology; Where Engineering a Miss is a Big Hit 10:00-11:30 a.m. New applications of automotive electronics including active stability control, vision systems, and crash avoidance technology offer engineers a new arsenal of weapons to protect tomorrow’s drivers and passengers. How will this new technology impact vehicle design and safety? Mark Chernoby, Director, NVH & Energy Management, DaimlerChrysler - Moderator David Robinson, President, Electrical and Electronics Division, Bosch Automotive Group Josef Pickenhahn, Vice President, Brake Engineering, TRW Automotive Bruce Wrenbeck, North American Director of Safety Electronics and Restraint Systems, Chassis and Car Body Division, Siemens VDO Automotive Craig G. Naylor, Group Vice President, DuPont Performance Materials William L. Kozyra, President, Continental Teves North America Jean Botti, Chief Technologist - Innovation Center, Delphi Corp.

Keynote Address: John Plant, President and CEO, TRW Automotive The Safety Revolution: As Safe as Possible

11:30 a.m.-Noon Never before have engineers had so many opportunities to apply new materials and technology. How will they decide what to do next?

Managing Driver Distraction in a Focused Approach 1:00-2:30 p.m. The next generation of vehicles will offer even more capability as work places and entertainment centers, combined with a host of new communication, driving, and navigation aids. Managing the interfaces with these new benefits to minimize driver distraction will be a challenge to vehicle and systems designers. Barry H. Kantowitz, Director, The Transportation Research Institute of the University of Michigan - Moderator Kit Green, Executive Director of the Transportation Imaging Laboratory, Wayne State School of Medicine, and Fellow, Neuroimaging, Department of Radiology James Geschke, Vice President & General Manager, Electronic Business, Johnson Controls, Inc. Charles Eger, Director, Office of Driver Safety, Motorola Andrew Brown Jr., Director of Engineering, Delphi Delco Electronics Systems Joseph N. Kanianthra, Associate Administrator for Applied Research, National Highway Traffic Safety Administration, U.S. Department of Transportation

Invest.UK, the sponsor of today’s Technology Theater, was created to enable technology exchanges and potential partnerships between UK companies in the automotive sector and the U.S. industry. Five UK companies are represented at the show this week. SIRA Ltd. is showing its vehicle performance and emissions monitoring system, which monitors vehicle and driver performance, together with both internal and external emissions levels. Torotrak has developed an infinitely variable transmission (IVT) that can cut fuel consumption on SUVs and trucks by up to 20%. The IVT is featured on the UK Department of Trade and Industry Foresight Vehicle at Booth 2032. Coretex Structures has developed carbon-composite technology for the volume manufacture of lightweight automobiles, trucks, and trailer assemblies. TRL Ltd. is featuring work on biomechanics and injury prevention, as well as its in-depth research on transportation infrastructure, safety, and environmental issues such as noise and vibration, air quality and emissions, alternative fuels, and soil and water pollution. The Center for Transport Studies at Imperial College is highlighting new research initiatives including geomatics, the design and testing of high performance navigation and positioning systems, and real-time monitoring of vehicle and driver performance. A free trip to the UK on the Concorde can be won from Invest.UK by completing a questionnaire at Booth 1931.

TECHNOLOGY

SUSTAINABLE DEVELOPMENT...Continued from Page 3

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The failure of the industry to clearly define goals and priorities for global sustainable development has limited progress to date, according to Bernard Robertson, Senior Vice President-Engineering Technologies and Regulatory Affairs, DaimlerChrysler Corp. “Engineers are good at solving problems if they know what the problem is,” he said. Visteon’s Gary Mayo, Global Director of Environmental Affairs, said it will be consumers, not the industry, who ultimately determines what is acceptable in terms of energy efficiency. Sue Cischke, Ford Vice President of Environmental and Safety Engineering, acknowledged that her company doesn’t claim to have the whole answer to the challenge of sustainable development. It’s a challenge for OEMs to continue developing emerging technologies for better fuel economy and lower emissions while at the same time devoting resources to getting the most out of current technologies. Moderator David Cole, President of Altarum, said the industry must do a better job of educating the public about the extent of the problems and about the limits of technology. If better informed, the public will demand more appropriate solutions. A fact that gets little attention in the debate over greenhouse gas emissions is that water vapor is a much greater culprit than CO2 emissions, Cole said. Patrick Ponticel

which aim to reduce the environmental burdens from ELVs and assist conservation efforts of materials by making recycling more complete. “To us, this means simplifying the complex mix of materials used to make vehicles,” he said. “We’re developing polymers that are compatible with other plastics and enhance the properties of the recycled mixtures even after several cycles of reuse.” He noted that Dow has developed thermoplastic panels made of long-glass-fiber polypropylene for use as underbody protection that can help automakers meet the recycling portion of the European ELV legislation, which begins in 2005. Ryan Gehm

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See Us at SAE Show Booth #2665
