Wednesday

Wednesday, April 16

daily 3

Official publication

From the Editors of:

Mahindra tech chief has heavy hybrid history

Automobile funding provided by:

Today’s Congress Highlights • Financial Strategies: Delivering Competitive Advantage to your Customers 9:30 a.m - 10:15 a.m. SAE Executive Business Theater

Recently named Chief Technology Officer at Mahindra & Mahindra Ltd. of India, Arun Jaura poses here with the Scorpio diesel-hybrid SUV now under field testing in India.

Arun Jaura will not call himself an expert in hybrid vehicle technology—“‘Expert’ is a dangerous word,” he said—but he knows enough about it that Ford

The Tank Automotive Research, Development and Engineering Center (TARDEC) held its first Advanced Planning Briefing for Academia yesterday, hoping to forge relationships with academia that could help the

See Aftermarket should not be an afterthought, Page 3

Participate in the Technology Trip Ticket Program

Car Give Away

Motor Co. named him Vehicle Engineering Manager for the Escape Hybrid several years ago. And his current employer, See Mahindra, Page 24

U.S. military searches for a few good colleges

“There’s a disconnect sometimes between what the consumers are really looking for and what the OEMs want to give,” said DUB Publishing’s President and CoFounder Myles Kovacs. “[Dub is] collaborating with the OEMs to help shorten the curve.”

1

Win a Dodge Nitro!

Patrick Ponticel

World Congress

Wednesday, April 16

www.sae.org/congress

U.S. military retain its technical leadership. Copying a longstanding program for industry that has helped the military leverage development in the automotive See U.S. military, Page 25

• Will Fuel Economy Sell and Can We Afford it? What Concepts are Rising to the Top and How Much of a Cost Increase do they Represent? 9:30 a.m - 11:30 a.m. FEV Powertrain Innovation Forum • Finance: Secrets to Making Money in the Auto Industry 10:15 a.m - 12:00 p.m. SAE Executive Business Theater • The Changing Values of the Global Customer 10:30 a.m - 12:30 p.m. AVL Technology Leadership Theater • Alternative Fuels: Does the Model Work? What are the Powertrain-related Technical Challenges? 1:30 p.m - 3:30 p.m. FEV Powertrain Innovation Forum • Globalization is 24/7 2:30 p.m - 4:30 p.m. AVL Technology Leadership Theater • International Networking Reception 5:00 p.m. - 6:30 p.m. Exhibit Hall, Cobo Center

TARDEC hopes universities can provide technology to help in the design of military vehicles of the future.

Visit us at Booth 1001

End-to-End AUTOSAR Development dSPACE’s SystemDesk and TargetLink® deliver: AUTOSAR system and software architecture design and simulation AUTOSAR Runtime Environment (RTE) generation Integration with Elektrobit EB tresos® Functional behavior modeling of AUTOSAR software components AUTOSAR-compliant production code generation for Simulink® Generation of SWC descriptions for tool interoperability

Complete tool chain. In multiple production programs. Helping drive the standard as an AUTOSAR Premium Member. Achieve AUTOSAR compliancy with confidence

dSPACE www.dspaceinc.com

Phone: 248-295-4700

[email protected]

SAE 2008 World Congress Daily

Wednesday, April 16

3

Aftermarket should not be an afterthought “Designers and engineers can actually build more waste into a product in one afternoon than an army of manufacturing engineers can take out in an entire lifecycle of that vehicle,” said John Waraniak, Vice President of Vehicle Technology at SEMA, driving home the point that OEMs need to collaborate with the aftermarket upfront to achieve what he calls “lean customization.” At yesterday’s “Designing for the Customer” session in the FEV Powertrain Innovation Forum, several examples were presented by OEM executives of how they considered accessorization early in the development process, one being the Mazda CX-9 roof rack. Compared to a previous roof rack Mazda did for the Mazda6 station wagon, which was a late addition to the program and involved a lot of time and disassembly work to install, the CX-9’s rack was considered at the Vehicle Program Approval stage. “At that point, we began earnest work with Mazda Japan—the platform team—to provide proper roof-structure

provisions for my engineering team here to develop a North American accessory roof rack with a SEMA member,” said Jack Stavana, Group Manager of Accessory Operations at Mazda North America. That aftermarket supplier is JAC Products, and the provisions included six attachment points in the roof with “doors.” The end result is a high-quality roof rack with much quicker installation. “In this case, because of the growth of our accessory business at Mazda, Japan frankly was more willing to listen to us and get more provisions built into the cars upstream,” said Stavana, noting that the CX-9 averages about $800/vehicle for accessories. Mobile electronics is a significant piece of the accessorization pie, said Waraniak, particularly with the popularity of PDAs, navigation, and entertainment options. But there are some challenges in this area as well. “The aftermarket can do the electronics a lot easier than we can; there’s a lot of federal rules, a lot of things you can’t do in a

car, so we have to be very careful because we can spoil it for everybody if we try to be too aggressive with in-car electronics,” said Ralph Gilles, Vice President of Design and Specialty Vehicles at Chrysler. And though performance is thoroughly ingrained in the customization landscape, the topic of “green customization” inevitably rose to the surface. Waraniak noted that at this year’s SEMA show there will be a “green zone” for environmentally friendly aftermarket technologies. “SEMA is not the Hells Angels of the auto industry,” he said. “There’s a lot of green aspects…. [But] once emissions are pretty much under control [with advanced-technology vehicles such as] hybrids and extended-range electrics, you’re going to see a whole rebirth of performance again.” On the topic of standards, panelists agreed that it will be a challenge to establish more stringent guidelines for the aftermarket. “You’ve got to imagine a company the scale of [some of] these aftermarket companies— there’s just no way you can put

these products through the same type of testing that an OE can,” said Michael J. Chetcuti, CEO of Quality Metalcraft. “They’re coming out to market [with products] within weeks after the concept and for a fraction of the engineering dollars. As far as the performance specs, that’s pretty easy to hit; but the safety and long-term durability are pretty difficult.” A General Motors executive agreed. “If we sell a vehicle with aftermarket parts like Brembo brakes, for example, we expect those parts to meet OEM requirements, OEM validation,” said Ken Morris, Executive Director of Vehicle Integration at GM. “When you talk about strictly aftermarket, I think it will be a challenge not only on component-level validation but vehicle-level validation, vehicle dynamics, all of those things. How many of the companies that are currently in business have the wherewithal to manage that kind of validation?” Ryan Gehm

Moskowitz advocates integrating customers into early research Howard Moskowitz sells blue elephants, and automotive engineers are on his target list of buyers. As the author of Selling Blue Elephants, Moskowitz says it is possible to create great products before customers even know they want the products. Selling products is all about “understanding the algebra of the customer’s mind,” according to Moskowitz, President of Moskowitz Jacobs Inc., a research and consulting firm in White Plains, NY. Moskowitz, who gave the keynote speech in the SAE Executive Business Theater on Tuesday, believes engineers can benefit from being in tune with customers at a prod-

uct’s idea stage. According to Moskowitz, customers do not know what they want until they see it. So, if customers can see various versions of a product at the concept stage, they can provide valuable feedback to engineers. “Engineers know best what to do, but customers know best how to evaluate,” said Moskowitz. Integrating end-users into the innovation and research process, said Moskowitz, enables rapid feedback on the ideas. Moskowitz illustrated his point by talking about how a spaghetti-sauce company created a variety of sauces to please the masses. Knowing it could control what

ingredients were in the sauce, the company “systematically changed the variables—the six major ingredients. It created combinations of those ingredients,” and then had customers taste the choices, he said. Mathmodels were used to track the impressions, making the process somewhat akin to dialing in a new product. Moskowitz says technical aids can assist the creative thought process. “Identify ideas from different areas/products by mixing and matching the combinations by experimental design. Mash these ideas into new vignettes, and rate the combinations as

See Moskowitz, Page 24

Howard Moskowitz said in his Tuesday morning keynote speech that testing a number of ideas/concepts is a smart way to approach product development.

4

Wednesday, April 16


Michigan Tech preps for Challenge X Challenge X wraps up its final competition year this May when 17 North American collegiate teams drive modified 2005 Chevrolet Equinox SUVs in a contest that puts the spotlight on re-engineering the stock vehicles for greater energy efficiency and fewer emissions. “No two teams have more than a handful of components that are the same on the vehicle,” said Todd Cimermancic, Michigan Tech’s Challenge X Team Leader, as he drove Michigan Tech’s Challenge X Equinox on Jefferson Avenue toward the SAE 2008 World Congress at Cobo Center on Tuesday morning. Other college teams modified the SUVs via hybrid-electric, plugThe Michigan Tech University team has been cruising the streets of downtown Detroit to promote the upcoming Challenge X competition sponsored by General Motors and the U.S. Department of Energy.

Editorial staff

AEI editorial staff for the Show Daily can be reached during show hours at booth 964.

KEVIN JOST Editorial Director

JEAN L. BROGE Senior Editor

LINDSAY BROOKE Senior Editor DARLENE FRITZ Associate Editor

PATRICK PONTICEL Assistant Editor

Ryan Gehm Assistant Editor

MATT MONAGHAN Assistant Editor

MATTHEW NEWTON Assistant Editor

KAMI BUCHHOLZ Detroit Editor

CONTRIBUTORS Terry Costlow Jenny Hessler Bruce Morey Jennifer Shuttleworth Linda Trego Paul Weissler

WAYNE SILVONIC Production Manager

GRAPHIC DESIGNERS William L. Schall Jr. Lucy Matyjaszczyk

in, or fuel-cell-powered propulsion systems using alternative fuels such as biodiesel, ethanol, or hydrogen. Cimermancic and Doug Sarsen, the only members on the 15-person Michigan Tech team involved since the first year of Challenge X, have high hopes for the team’s parallel through-the-road hybrid that sports a 2.0-L four-cylinder Ford engine, instead of the 3.4-L V6 fitted on the 2005 Equinox, and a Cobasys nickel metal-hydride battery pack. Since last year’s Challenge X competition, the team has worked to shave 20 lb (9.1 kg) from the vehicle. “We tried to get the vehicle closer to the stock

weight, which is about 3860 lb,” said Cimermancic. The team also revamped the vehicle’s entire exhaust system (including the catalyst and muffler), reworked on the cooling system, and made changes to the hybrid system’s control strategy to improve the fuel economy and the vehicle’s performance. Last year, the vehicle recorded 22 mpg in the combined-drivecycle competition, but the SUV had achieved 38 mpg on the combined highway/city drive cycle in pre-competition testing. Unlike past Challenge X competitions, this year’s event will include a 300-mi (483-km) trek on public roads in New Jersey, New York, Maryland, and Wash-

ington, D.C. The 17 vehicles have “to survive the entire trip,” said Cimermancic. In addition to the real-world drive, the competition entails fuel economy, emissions, ride quality, and performance tests as well as an autocross. Cimermancic, Sarsen, and fellow students are spending time at Michigan Tech’s display (booth 2761) during World Congress. Michigan Tech and several other universities are showcasing various competition vehicles (including Formula SAE and SAE Baja) at their exhibits, which are located near the SAE Executive Business Theater. Kami Buchholz

Cars don’t drive themselves—unless properly asked It’s asking a lot of a car to drive itself. But some engineers and computer scientists, such as Woody English, are not shy about asking. At the SAE International booth (964), nearly lost amid an array of self-driving SUVs that participated in the Defense Ad-

vanced Research Projects Agency’s Urban Challenge, English is asking for attention to SAE’s efforts in laying part of the groundwork for an autonomous future. “This whole thing we call unmanned systems is still in its infancy,” said English, President of DeVivo Automated Systems

Technology. “We still have to get our heads around what it’s going to mean in the future at the more ‘consumer’ production level. Right now, we’re just emerging from the laboratories.” Deployments of unmanned ground vehicles currently are See Cars, Page 6

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Wednesday, April 16


Reaction Design speeds, refines combustion-chemistry simulation Stringent near-term emissions and fuel-efficiency standards are driving engine designers and fuel providers toward more efficient combustion cycles. Using simulation to help understand design decisions

The Chemkin-Pro multizone engine model uses segmentation to practically model combustion processes spatially.

Cars ... Continued from Page 4

either commercially experimental or military in nature. Some units are being deployed in Iraq by the U.S. Army. “What’s going over into theater are ‘onesy-twosies,’ or they’re very ‘early’ and not very autonomous systems,” English said.

DeVivo Automated Systems Technology President Woody English served as test director for Team AutonomousSolutions:TED in the DARPA Urban Challenge. Rigged with an array of vision and laser sensors, TED (Toyota Highlander) used the JAUS message set—as did all of the other SUVS on display at the SAE International booth (964).

To get the ball moving toward fuller autonomy, SAE in 2004 formed the AS-4 Committee – Unmanned Systems. The committee is all about message sets—the commands and data for information transfer between unmanned systems elements. An application would be the controller sending a request to

in engines and aftertreatment seems only natural. “What our software does is allow an engineer to understand what is going on inside the engine cylinder,” said Bernie Rosenthal, CEO of Reaction Design, Inc. “Simulation is important in reducing cost,” said Rosenthal. “Prototyping even a single-cylinder engine can range from tens of thousands up to millions of dollars before you get one piece of data out of that test cell. We are finding companies are more open to embracing simulation before they commit to bending metal.” He added that people have used combustion and reaction simulations in the past, typically using a single fuel as a model. However, the emissions standards of today require more accurate modeling, he said. On the other hand, actual fuels are too complex to simulate

directly since they are composed of hundreds of components. Computer run time could stretch into weeks with this approach. The Chemkin software models ‘pure’ fuel mixtures with surrogate mixtures to simulate real fuels. The model accurately predicts factors such as ignition delay, knocking tendency, flame speeds, pollutant emissions, sooting tendency, density, viscosity, and heating value. Computational fluid dynamics (CFD) does not support the level of detailed chemistry required to simulate accurately these combustion performance criteria. The new multizone engine model in the software compensates by segmenting the cylinder volume into reaction zones. Each zone models detailed chemistry mechanisms while maintaining an accurate representation of the cylinder geometry.

the vehicle for status—what is your speed, your position, your orientation? “And back would come all of that information,” English said. The message set is not code; rather, “it’s a structure—a welldefined structure down to the bit level that would move data through a transmission media,”

English explained. Various transmission media can be used. The acronym JAUS (joint architecture for unmanned systems) is used to identify the message set and the SAE standards that define them. Three SAE JAUS standards have been published and three are works in progress. The acronym goes back to the mid-1990s, “when attention was brought to the fact that all of the unmanned ground vehicles were being developed somewhat in a vacuum,” English said. “The Army’s Robotic Systems Joint Program Office thought it would be a great idea to standardize the interoperability aspects of those vehicles.” The resulting JAUS group initially formed as a small government-only outfit that met two to four times per year. It later was opened up to the general public and its scope was broadened to include possible marine and aerospace applications.

See Reaction, Page 8

Patrick Ponticel

Reaction Design’s new software tool, Chemkin-Pro, increases the speed of accurate combustion simulation to meet the needs of engineers designing clean, efficient engines and aftertreatment systems.

Patrick Ponticel

SAE World Congress April 14 – April 17, 2008 Cobo Center, Detroit

Booth 1971

Equal to the sum of our parts. As experts at developing Hybrid Drivelines, Hub Motors and Electric Propulsion and Energy Systems, we develop our progressive hybrid-electric propulsion technology through maintaining and nurturing four key core competencies. We focus on these four things so that we can excel at one thing: creating cost effective, sustainable solutions to moving the world forward.

Motor Design & Controls

Using topology and architecture, we develop optimal electromagnetic, electric, thermal and mechanical designs based on our customers’ requirements.

Energy Storage Systems

We create custom energy storage package designs and electronics hardware and software, then use modeling, chemistry and testing to ensure maximum life and performance.

Vehicle Controls

Our chassis driveline control systems incorporate ABS, TCS and yaw control into our electric propulsion solutions for improved vehicle dynamics and safety.

Systems Engineering

We engineer a completely vertical chassis system, ensuring that our motor design, energy storage and vehicle controls work together to provide optimal systems architecture and performance at the lowest possible cost.

We’re changing the way the world moves. Come with us.

1613 Star Batt Drive Rochester Hills, MI 48309 | Phone: (248) 606-0606 | Fax: (248) 606-0601 | www.bluwavsystems.com

8

Wednesday, April 16


Powertrain odyssey to diversity At the end of 2007, the U.S. government mandated that by 2020 passenger vehicles—on a fleet-wide basis—achieve 35 mpg, which represents a 40% hike from today. At the start of 2008, oil roared past $100 a barrel, signaling the first time that history recorded a price in triple digits.

Change is a constant in the world of automobiles, so how can the industry survive and thrive? “We need a united and coordinated strategy,” Margo Oge, Director of the Office of Transportation & Air Quality, U.S. EPA, told an SAE 2008 World Congress audience

Honda’s Yuji Kawaguchi, Executive Chief Engineer of Honda R&D Co. Ltd., said that the FCX Clarity hydrogen fuel-cell vehicle has twice the energy efficiency of a hybrid-electric vehicle.

Reaction ... Continued from Page 6

The accomplishments of the Model Fuels Consortium (MFC) inspired the technology, led by Reaction Design to create more accurate combustion simulations. Current members of the MFC include Chevron, Conoco Phillips, Cummins, Dow Chemical, Ford, General Motors, Honda, l’Institut Français du Pétrole, Mazda, Mitsubishi Motors, Nissan, PSA Peugeot Citroën, Oak Ridge National Laboratory, Petrobras, Saudi Aramco, and Toyota. Currently scheduled to end in 2008, the MFC will immediately be followed by a new MFC II consortium. The MFC II will continue work on modeling particulate and soot emissions models, a particular challenge according to Rosenthal. The MFC II will run to 2011. “As oil hovers near $100 a barrel, alternative sources

such as oil from shale becomes economically attractive,” said Rosenthal. “We will need to understand how to control emissions from fuels such as these as they become viable.” Membership in the consortium has its benefits. Members have exclusive rights to the data for two years and they help correlate the simulation by providing test facilities and test runs, which is incorporated using a sophisticated design-of-experiments methodology. “With many different fuel and engine options in development or already available, designers need one simulation tool that

attending the “Powertrain Diversity” session in the AVL Technology Leadership Theater. Automotive industry leaders are pursuing a variety of near-, mid-, and long-term powertrain solutions including advancing the internal combustion engine and moving the performance meter on hybrid-electric vehicles. But fuel-cell vehicles are frequently considered the holy grail of energy diversification. Yuji Kawaguchi, Executive Chief Engineer of Honda R&D Co. Ltd., noted that the Honda FCX Clarity hydrogen fuel-cell vehicle has twice the energy efficiency of a hybrid-electric vehicle and three times the energy efficiency of a gasoline-enginepowered vehicle. Honda officials plan to lease the FCX Clarity, starting this summer, to a few southern California citizens. J. Gary Smyth, Director of Powertrain Systems, General Motors Research and Development, said that GM’s Project

Driveway represents another milestone along the route of proving out the production viability of hydrogen-powered vehicles. More than 100 people will drive a Chevrolet Equinox fuel-cell SUV—powered by GM’s fourth-generation fuel-cell propulsion system—beginning this year. Drivers in New York, Los Angeles, and Washington, D.C., will give feedback on their impressions of the fuel-cell vehicle. Although fuel-cell vehicles are considered zero-emissions vehicles, various powertrain technologies can be designed to elicit greater fuel-efficiency and lower greenhouse gas emissions. “Detroit has always been home to dreamers and believers,” Oge said, adding that the researchers and engineers working on the powertrains of tomorrow may very well create “the next great industrial revolution.”

quickly and accurately predicts the way various fuel mixtures will interact with different engine designs,” said Rosenthal. The new software makes use of an innovative high-speed solver engine. It is said to cut the time required for solution convergence by five to 10 times over previously available combustionsimulation codes. These results are visible using a new, interactive visual display, called the Reaction Path Analyzer, that also shows which reaction paths are dominant and helps designers determine opportunities for mechanism reduction. A new particle-tracking mod-

ule tracks particle growth from inception to oxidation to predict number and size statistics. The new particle-tracking tool also features a user-programmable module called Uncertainty Analysis, which allows designers to evaluate how their inputs propagate through a simulation, helping define tolerances and safety margins and increasing the accuracy of the simulation. A typical internal combustion engine model that would take 53 min in Chemkin 4.1 now takes 3 min in Chemkin-Pro.

Standards Hot Spot open to attendees

Kami Buchholz

Bruce Morey

A Standards Hot Spot and Technical Committee Lounge, sponsored by HCL, will be offered during the SAE 2008 World Congress, Monday through Thursday. Located in the Brule A room at the Marriott Renaissance Center, the lounge will offer refreshments, wireless Internet access, SAE materials, and SAE staff support. A prize drawing will take place at noon on Wednesday for those who enter their business card into the marked box in the room.

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Wednesday, April 16


AEI 2008 Tech Awards Instrument panel testing

Intelligent towing

For more information, visit booth 1001

and less complex than other towing systems, IntelliTow improves the safety of vehicles and trailers by providing drivers with real-time information about the trailer’s performance. The system’s circuit-specific, real-time diagnostics notify the driver when a failure occurs with trailer lighting and battery charge circuits through an in-dash messaging system. The solid-state outputs offer diagnostic feedback for short and open circuit for running lights, right turn/brake lights, left turn/brake lights, reverse, and battery outputs.

dSPACE offers simulation technology to assist in verifying the functionality of in-vehicle instrument panels through automated monitoring. The solution combines a real-time, hardware-in-the-loop simulator with an integrated camera-based system to perform continuous instrument cluster monitoring at a rate of 20 to 50 frames per second—removing the human-error factor from the testing and development process. Using a digital signal processor integrated into the camera, the system generates image algorithms to monitor the vehicle’s speed gauge, engine rpm, temperature, fuel level, and the driver messages displayed on an LCD screen, such as speed, temperature, and service information. Software generates automatic test reports. The company plans to extend the automated testing capability to other information systems, such as navigation, climate control, and collision warning.

Soy-based interior

The United Soybean Board (USB), in partnership with Ford and Lear, has helped make flexible foam technology a reality in Ford vehicles. The soy-based flexible foam, which uses a 5% soy-based polyol, is incorporated into seatbacks and seat cushions in the 2008 Ford Mustang as well as the 2008 F-150, Expedition, and Lincoln Navigator. The 2009 Escape is slated as the next application for this eco-friendly material. Ford plans to work with John Deere and its seat supplier, Sears Manufacturing, to bring this greener alternative to traditional seat foam to fields and even backyards nationwide. The environmental advantages of soy foam include: reduction of CO2 emissions; less energy used to produce; up to 24% renewable content; and less dependency on volatile energy markets. The use of soybean oil instead of petroleum is done without compromising the durability, stiffness, or performance of the foam. For more information, visit booth 2125

Diesel engine simulation

LMS Imagine’s AMESim software is an integrated platform that offers complete 1-D simulation to model and analyze multidomain, intelligent systems and to predict their multi-disciplinary performance. The components of the model are described by analytical models representing the system’s hydraulic, pneumatic, electric, or mechanical behavior. The system allows engineers to design complete diesel engine systems and components, including fuel-injection systems, advanced valvetrains, lubrication circuits, engine cooling systems, and engine controls. For more information, visit booth 2645

IntelliTow from Yazaki is an intelligent towing system that combines electronics, power switching, and connectors for what the company deems “a smarter, safer towing experience.” Designed to be lighter


Warm-forming presses

Interlaken Technology’s Warm Forming Press Systems for production manufacturing and metals research provide companies the capability to develop new ways to form aluminum, magnesium, and steel panels into innovative shapes intended to help augment designs. The systems can form aluminum and magnesium at elevated temperatures to 350°C (662°F). Higher-temperature solutions are available. Features such as highly detailed logos or threads can be incorporated into part designs. In addition, much larger parts can be formed on a smaller system due to the lower forming pressures required. The Warm Forming Press has a small footprint and fits well into a workcell environment. For more information, visit booth 1000

3D PLM will Put You on the Fast Track Dassault Systèmes is a visionary partner providing automotive suppliers and manufacturers with the powerful tools they need to transform their business and drive innovation. Our software solutions – including CATIA, DELMIA, ENOVIA, SIMULIA and 3DVIA – enhance business processes, foster innovation, facilitate seamless collaboration across the global supply chain and bring new products to market faster. Visit Booth #1550 to see these interactive demonstrations: • • • • •

CATIA PLM Express for Auto Suppliers CATIA V5 Knowledge Templates Body-In-White (BIW) Planning Final Assembly Planning Design for Manufacturability

• • • •

ENOVIA Automotive Platform Abaqus Unified FEA CATIA Analysis Simulation Lifecycle Management

You’ll learn first hand how to improve quality, reduce costs and streamline your product development cycle. Plus, don’t forget to enter our daily drawing to win an iPod Nano.

Dassault Systèmes is the proud sponsor of this year’s SAE International Car Giveaway, the Dodge Nitro. The 2008 Dodge Nitro was designed using Dassault Systèmes CATIA V5.

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Wednesday, April 16


What’ s New from the exhibitors

Induction hardening and tempering

The CrankPro system from Inductoheat is a nonrotational, compact induction hardening and tempering system for crankshafts. The system uses advanced SHarP-C technology, which eliminates the need to rotate or move the inductor or the crankshaft during heating and quenching cycles. The stationary method of heating without crankshaft rotation provides several practical benefits, such as simple operation, superior reliability, and cost reduction. Other technological advantages include short heat times (Þ

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Booth #1544

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Booth #1245

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PARK SUPPLIERS Peter Zhou

Peter Schmitt

6ViÊ*ÀiÃìÌ C&U USA INC.

6*ÊÕÌÌÛiÊ->iÃ]Ê ÕÃiÃÃÊ/À>ÃvÀ>Ì Dassault Systèmes

Booth #2036

UÊÊ ÕÌLiÊLi>À}Ã]ÊÃ«iV>Êìi«Ê}ÀÛiÊ Ê L>ÊLi>À}Ã UÊÊ />«iÀi`ÊÀiÀÊLi>À}ÃÊvÀÊÌÀ>ÃÃÃ UÊÊ 7iiÊÕLÊLi>À}ÃÊvÊÌiÊwÊÀÃÌ]ÊÃiV`Ê>`Ê Ê ÌÀ`Ê}iiÀ>ÌÃ UÊÊ iiÀ>ÌÀÊLi>À}Ã]ÊÜ>ÌiÀÊ«Õ«ÊLi>À}Ã]Ê Ê É ÊVÕÌVÊLi>À}Ã UÊÊ /iÃiÀÃ]ÊiiìÊÀiÀÊLi>À}ÃÊvÀÊi}iÊ Ê ÀV}Ê>ÀÃ

Booth #1550

UÊÊ /ÊvÀÊÛÀÌÕ>Ê«À`ÕVÌÊìÃ} UÊÊ ÊvÀÊÛÀÌÕ>Ê«À`ÕVÌ UÊÊ "6ÊvÀÊV>LÀ>ÌÊ>`ÊLÕÃiÃÃÊ Ê «ÀViÃÃÊ>>}iiÌ UÊÊ Î 6ÊvÀÊÎ ÊiÊviiÊiÝ«iÀiViÃâ

Dr. Andrew Brown, Jr., P.E.

ÝiVÕÌÛiÊ ÀiVÌÀÊEÊ

ivÊ/iV}ÃÌ Delphi Corporation

Booth #1237

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Dan Wohletz

Jeff Mihalic

Bob Rossiter

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Booth #1745

UÊÊ µÕiViÁÊ >Ì}Ê iV>Ã UÊÊ «Ã«>ÌiÊ ìÀÌiÁÊ ÛiÀÃÊ >Ì}Ã UÊÊ -ÌÀÕVÌÕÀ>Ê-ÕÌÃÊ>`Ê>ÃiÌ}ÊÌiV}iÃ UÊÊ ÀÊi>ÌVÕÀi`Ê>ìÃÛiÃÊÌÊÀÌi«iÀ>ÌÕÀi Ê VÕÀ}ÊÌÜV«iÌÊÃÌÀÕVÌÕÀ>Ê>ìÃÛiÃ

Booth #2044

UÊÊ ÌiÀiÌÊiÀÀÕÃÊÀÕ«ÊqÊ Ài`Ê>`Ê Ê VÀi`Ê`ÕVÌiÊÀÊV>ÃÌ}ÃÊ UÊÊ ÌiÀiÌÊ* * TMÊ*ÀiÃÃÕÀiÊ ÕÌiÀÊ*ÀiÃÃÕÀiÊ Ê >ÃÌ}®ÊÀÕ« UÊÊ ÌiÀiÌÊ iÊ >ÃÌÊÀÕ«ÊqÊÃi`]Ê>Vi`Ê Ê >`Ê>ÃÃiLi`ÊV>ÃÌ}ÃÊÊ>}iÃÕ]Ê Ê ÕÕÊ>`Ê`Ê,iÃÌÀ>ÌÊ-ÞÃÌiÃ UÊÊ /Ê`Ê-i>Ì} UÊÊ vÀÌÊ,iÃÌÊqÊi>`Ê,iÃÌÀ>ÌÃ UÊÊ ÞLÀ`Ê*ÜiÀÊ iVÌÀVÃ UÊÊ ÛiÌÒÊi>À½ÃÊ>ÞÊvÊ*ÀiÕÊi>ÌiÀ UÊÊ -`Ê-Ì>ÌiÊ->ÀÌÊÕVÌÊ ÝÊ-Î

Dick Heilman

Sal Scuderi

ÀiVÌÀ]Ê >ÀiÌ}ÊEÊ-ÌÀ>Ìi}VÊÀÜÌ PPG

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Booth #1751

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Booth#1337

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Alastair Deane

George R. Perry

-iÀÊ6ViÊ*ÀiÃìÌÊÊ /iV}Þ The Timken Company

Booth #1837

Booth #1737

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" Yazaki North America

Booth #1536

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16

Wednesday, April 16



and centrifugal blowers that use a new technology to control and monitor motor operation. The product lineup includes baseline brushless products that can be tailored to meet unique and specific applications and customer requirements. With motor power ratings that range from 250 to 1000 W over the course of the product entry, the concept provides a more robust and more reliable as well as less costly alternative to current brushless motor technology. Standard features of the brushless motor fans and blowers include: sealed, water-resistant motor; locked rotor protection; over-voltage protection; over-current protection; over-temperature protection; and reverse-polarity protection.

Displays and touch panels

United Radiant Technology provides medium-sized TFT modules and touch panels suitable for the automotive, medical, industrial, portable handheld, and consumer-electronics applications. The company features a 3.5-in, backlit LED with an active area of 70 x 53 mm; a 4.3-in, backlit LED with an active area of 95 x 54 mm; and a 5.7-in, backlit CCFL with an active area of 115 x 86 mm. United Radiant Technology’s touch panels are available in 4-in with an 87 x 49-mm active area and 7-in with a 153 x 93-mm active area. For more information, visit booth 1324


tection function. The ECU is operated via microcontroller and several power stages (from four up to eight, suitable for diesel engines between four and eight cylinders). It is implemented with a custom intelligent power switch featuring short circuit to ground, over-current, and overtemperature protection. The module is controlled by pulsewidth-modulated input signal and includes diagnostic output.

and deploying machine vision applications without programming. Using this menu-driven software, engineers can build complex machine vision applications incorporating not only vision algorithms but also state-based execution with looping and branching using the built-in state diagram editor. For more advanced applications, the cameras also integrate with LabVIEW software and the full NI library of image processing and machine vision algorithms such as edge detection, pattern matching, 1-D and 2-D code reading, and optical character recognition. For more information, visit booth 1501


Fuel-cell fleet

More than 100 Chevrolet Equinox petroleum- and emissionsfree fuel-cell electric vehicles have been sent to Los Angeles, D.C., and New York for market testing. Drivers will provide feedback on their experience and help define GM’s future fuel-cell technology and marketing plans as part of its “Project Driveway” initiative. Various drivers will have access to the electric Equinox and the hydrogen fuel needed to make electricity onboard for three months, and will be required to report their experiences. GM plans to take what it learns and apply it to the advancement of electric-drive vehicles such as the Chevy Volt with E-Flex (flexible electricity) system. The Equinox electric vehicle is a functional crossover powered by the company’s fourth-generation fuel-cell propulsion system. For more information, visit booth 1045

Expandable power amplifiers

Turbo engine

In an effort to reduce fuel consumption and emissions while improving power and torque, FEV introduces the Spray Guided Turbo engine. The 1.8-L I4 has direct injection centrally located in the combustion chambers for a clean burn. Benefits include improved cold starts, reduced oil dilution, and enhanced use of flex fuels. The Spray Guided Turbo engine delivers 160 kW (214 hp) of power and 320 N·m (236 lb·ft) of torque and supports homogenous and lean-burn concepts while approaching diesel brake mean effective pressure levels, according to the company. For more information, visit booth 1625

Diesel engine control module

The fast glow plug diesel engine control module from Nagares features a reverse battery pro-

Smart cameras

The NI 1722 and NI 1742 Smart Cameras from National Instruments are embedded devices that combine an industrial controller with an image sensor and integrate with NI vision software to offer image processing directly on the cameras, making them suited for applications such as locating parts, inspecting packaging, verifying assembly, and reading 1-D and 2-D codes. The cameras come with Vision Builder for Automated Inspection, an interactive software environment for configuring, benchmarking,

AR RF/Microwavable Instrumentation offers the expandable and upgradeable high-power W series amplifiers. Available in 1000W1000C (1000 W/80-1000 MHz) today, then when future specs demand higher-power customers can add another 1000W1000C amplifier and a combiner to make a 2000-W unit—up to 4000 W. The units can be used independently and can also be brought together when extra power is needed. For more information, visit booth 1300

Extreme visualization software Computational Engineering International’s EnSight 2008 software includes several additions to its visualization product. An option to add CAD file importers to access native CAD files without the use of the original CAD system, a FLUENT direct

•

Hybrid Efficiency with Supercharged Power in a Low Cost Package

• • •

Exceeds Future Emissions and CAFE Standards Today Patented in Over 50 Countries Licensing to Engine Manufacturers Worldwide

COME SEE US AT: SAE WORLD CONGRESS BOOTH #1337

www.scuderigroup.com | airhybridblog.com

18

Wednesday, April 16



interface, and the introduction of chameleon mode are some of the new features. The CAD readers offered include CATIA V5 and V4, IGES, and Parasolid. The FLUENT direct data reader offers improved speed, robustness, and capability. The new FLUENT beta reader features: faster data loading; SOS support for large models and distributed computations and convenience specifically related to quickly uncompressing zipped files; availability of a list of variables for parts; and the ability to load a single part. For more information, visit booth 1212

Modeling and simulation

CPU Technology showcases its SystemLab PS platform simulator that is capable of modeling and simulating an entire suite of automotive electronic control units in real time. By using SystemLab PS, designers and development engineers are able to simulate and validate all of the electronics of an automobile in real time, including hardware and software, prior to any hard-

ware integration. The visibility and control, combined with the high-fidelity models running the actual software code at real-time speeds, offer improvements in testing, debugging, and time to market. SystemLab PS is a complete high-productivity solution that includes hardware, enterprise software, virtual model development, custom library elements, training, and support. For more information, visit booth 1230

Nano-indentation testing

The tabletop instrument from CSM Instruments combines the advantages of the standard nanoindentation tester into a small, cost-effective instrument that is suited to routine nano-indentation testing where a full platform system may not be appropriate. It is upgradeable with optional technical features like the sinus mode (dynamic mechanical analysis) and can be configured with a range of displacement stage options and integrated video microscope. It features a load range of 0.1 to 500 mN, a load resolution of 0.04 µN, a maximum depth of 200 µm, along with a nano-indentation head assembly with referencing system and a Berkovich indenter. For more information, visit booth 403

Composite DPF

The SiC composite diesel particulate filter (DPF) from Ceramiques Techniques et Industrielles (CTI) and IFP is produced using a cost-effective

patented manufacturing process that enables the production of many different sizes and shapes. Featuring filtration efficiency to target Euro 5 and 6 emissions limits, the SiC provides high thermal conductivity leading to an efficient and complete regeneration. The DPF also offers chemical resistance to acids and ash, high durability even after harsh aging treatments, and good adhesion to washcoat formulations proposed by catalyst manufacturers. According to CTI, the SiC filter is three to four times under the limit of Euro 5 emissions standards of 5 mg/ km on MVEG cycles. It has been used for many years on buses and trucks with trouble-free servicing, says CTI.


Mobile safety kit

DC Safety provides eco-friendly first-aid and driver-essentials kits to help vehicle manufacturers fulfill safety and preparedness requirements while at the same time supporting environmentally conscious initiatives. In addition to the automotive industry’s commitment to passenger travel safety, personal safety is also being recognized by OEMs as more manufacturers provide invehicle first-aid kits to custom-

ers. Custom-designed to meet specific OEM requirements, the kits use natural materials with non-zipper, flapped construction and are made of durable Duck fabric with natural loop and toggle closures. Logo branding is done with nontoxic paint or embroidery. A “Quick Guide to First Aid and CPR” is included with each kit to help address minor injuries. For more information, visit booth 731

Data-collection system

DTS’ TDAS G5 M-24 is a full-featured crashworthy datacollection system that supports 24 channels of sophisticated data-collection technology in a 24 x 44 x 74 mm (.94 x 1.7 x 2.9 in) package. As a stand-alone, modular DAS, it offers virtually unlimited channel capabilities, according to the company. Designed for easy integration into all sizes of crash-test dummies and other tight-to-fit spaces, each module features intuitive software controls, comprehensive self-diagnostics that assist in identifying issues before critical testing, and a 100-Mbit ethernet communications protocol. The TDAS G5 products also offer versions with greatly extended memory and a high-bandwidth option up to 40 KHz. For more information, visit booth 408

Military tire wheel

The carbon-fiber polyurethane solid tire from American Engineering Group (AEG) is a military tire wheel (MTW) assembly for future tactical and combat vehicles that places emphasis on handling, traction, and cornering tire performance for light trucks. The LT225/35R19 solid tire features a lower-than 0.35

Modular-System:

PM-METALIT™ plus SCR results in SCRi™

Modul 1: Particle separation in partial flow filtration

Oxicat

PMMETALIT™

PM - METALIT™ enables continuous particulate reduction for series production (e.g. FUSO, Hyundai, MAN) and Retrofit.

PM reduction [%]

80 60 40

Improvement with increasing PM-METALIT™ length

20 0

74.5

150

PM-METALIT™ length [mm]

300

Modul 1+2: Urea Oxicat

at Visit us

255 H T O BO hall Wayne in located

Homepage: www.emitec.com E-mail: [email protected]

LS- and PE-Design™

PMMETALIT™

PM-METALIT™

SCR cat

LS-Design®

• PM-METALIT™ in double function: Partial flow PM-filtration and hydrolysis catalyst as mixer. • SCR-catalyst behind continuous PM-filtration. Turbulent structures allow more compact systems. SCRi = Selective Catalytic Reduction integrated

Gesellschaft für Emissionstechnologie mbH · Hauptstr. 128 · D - 53797 Lohmar · Tel. +49 2246 1090 · Fax +49 2246 109 109 Emitec, Inc. · 3250 University Drive, Suite 100 · Auburn Hills, Michigan 48326 · Tel. +1 248 276 6430 · Fax +1 248 276 6431

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Wednesday, April 16


What’ s New from the exhibitors more than twice the visible light of a conventional glass roof to provide an open-air look inside the vehicle. The roof glass technology provides the equivalent of more than 50 SPF ultraviolet protection, according to PPG.

aspect ratio; a rim width of 7.0 in; a tread width of 7.6 in; and an overall diameter of 25.0 in. With a speed rating of 80 mph (129 km), AEG strives to eliminate tire blowouts with its integrated carbon-fiber ring wheel MTW assembly. The solid one-piece wheel and tread system’s rim is bonded to soft polyurethane elastomer that provides the shock-absorbing property of a traditional pneumatic tire. The MTW’s vertical and lateral stiffness can both be optimized, pushing the performance envelope in various military applications. For more information, visit booth 615

Reflective windshield By reflecting IR energy away from the vehicle, PPG Industries’ Sungate-coated glass keeps drivers cool and reduces the necessity for air-conditioning. In testing, automobiles equipped with Sungate windshields achieved up to 4% better fuel economy; the coated glass decreases the amount of solar energy entering the vehicle, thereby reducing interior heat buildup, lessening the load for the air conditioner and resulting in lower fuel consumption and greenhouse gas emissions. Ford has plans to feature a fixed-glass panoramic roof using Sungate infrared reflective technology that will reject more than 95% of the sun’s energy while allowing


Description data tool

Vector CANtech has extended the functional features for ODX by releasing Version 5.5 of the CANdelaStudio tool for creating diagnostic description data. Users can visualize ODX data from various perspectives in the integrated EffectiveODX viewer either before import or after export. For developers, the combination of ODX import and export simplifies migration of existing diagnostic data to ODX. Independent of the import/export functionality, the EffectiveODX viewer also can be used to view ODX data from any source. Benefits include the ability to create diagnostic descriptions in ODX 2.0.1 and ODX 2.1.0 formats. For more information, visit booth 1319

Variable compression ratio

FEV’s two-step variable-compression-ratio mechanism is suited for medium and heavyduty truck engines. The system

handles peak cylinder firing pressures of 180 bar and allows adjustments of compression ratio from 14:1 to 17:1 within the engine map. It offers potential for significant fuel economy improvements. Characteristics include carry-over piston and piston pin design, and eccentric suspension of the piston pin in the conrod. Compression ratio adjustment is achieved by exploiting gas and mass forces. Hydraulic cylinders in the conrod support eccentric moments. A 3/2-way valve is adapted to control compression ratio, externally actuated by cam disc. Actuation of the cam disc unit occurs via a small electric motor. For more information, visit booth 1625

Pressure-indicating sensor film

Sensor Products’ Pressurex tactile pressure indicating sensor film comes in the form of a thin Mylar sheet, physically similar in thickness to paper. Measuring pressure from 2 to 43,000 lb/in2 (14 to 300,000 kPa), the sensor is very thin, allowing it to conform to curvaceous surfaces or invasive intolerant environments. When placed between two contacting surfaces, the film instantaneously and permanently changes color. This color change is directly proportional to the actual pressure applied. Precise pressure magnitude is easily determined by comparing the resultant color intensity to a color correlation chart, which is conceptually similar

to interpreting litmus paper. Used by NASCAR’s Joe Gibbs Race Team, applications for the pressure-indicating sensor film include engine gaskets, clamping, catalytic converter canning, brakes/clutches, lamination, door seals, tire tread footprints, and impact. For more information, visit booth 2551

Rapid heat delivery

EnviroHeater from Testa Creative Solutions improves the time it takes an engine to reach optimal operating temperature. As a direct result of rapidly reaching this temperature, the EnviroHeater not only quickly delivers heat to the passenger compartment of a vehicle, but offers other benefits such as reduced fuel consumption and decreased vehicle emissions. The reduction in engine warm-up time is especially important in diesel vehicles, which traditionally take longer to warm up. The EnviroHeater’s closed-loop operation comes into effect much sooner, reducing vehicle emissions. According to the company, the EnviroHeater is a cost-effective, lightweight heating unit that easily installs into a vehicle’s existing heating system. For more information, visit booth 2461

“Automobiles are free of egotism, passion, prejudice and stupid ideas about where to have dinner. They are, literally, selfless. A world designed for automobiles instead of people would have wider streets, larger dining rooms, fewer stairs to climb and no smelly, dangerous subway stations.” — P.J. O’Rourke

The Michigan Economic Development Corporation salutes the SAE in its quest to advance automotive and alternative energy technologies. As the global capital of automotive research and development, Michigan is where alternative energy solutions come to life. For more information, stop by the MEDC booth or visit our new website at MichiganAdvantage.org/sae.

MichiganAdvantage.org/sae

22

Wednesday, April 16



Steel fasteners

The Fontana Group manufactures alloy steel fasteners at 10 plants worldwide and serves the automotive, agricultural, and heavy-duty truck industries. Recent product lines have expanded to include more complex ‘special’ and ‘critical’ as well as standard fasteners. The group also is a provider of customtailored logistic programs that offer a mix of options and tools to design, implement, and execute technology and engineering programs. Fontana’s Logistic Division serves North and South America as well as Europe. For more information, visit booth 2358

Filter improvements

GVS Filter Technology offers automotive filters and components using thermoplastic materials for ABS systems, low- and high-pressure gasoline injection systems, high-pressure common rail diesel, automatic transmissions, throttle valves, and fuel tanks. Fuel and diesel injection systems feature improved performance and filter surface in small spaces, while updated materials and screen range offer various flow capacities depending on specifications. The company’s filters for various hydraulic systems protect from dirt particle contamination and offer highvolume production of more than 100,000,000 zero-defect units per year. GVS nonwoven gradient filtration material improves barriers to protect parts from liquid and dust and increases retention and flow rates, according to the company. For more information, visit booth 1406

Paint pretreatment

Adhesive, sealant, and surface treatment manufacturer Henkel has expanded testing of its Bonderite conversion coating process at Ford’s Twin Cities production facility. The Bonderite non-phosphate automotive conversion coating process for multi-metal bodies improves vehicle assembly pretreatment productivity by shortening the process and reduces environmental impact, according to the company. The coating streamlines the paint pretreatment process and eliminates the pretreatment sludge, landfill requirements, and wastewater treatment problems associated with conventional zinc-phosphate pretreatments. Bonderite conversion coating is free of phosphate, volatile organic compounds, and CO2-equivalent emissions, resulting in minimal environmental impact. It is applied at room temperature to decrease natural resource requirements. For more information, visit booth 1745

Physical modeling

Maplesoft has partnered with Toyota to produce advanced physical modeling tools to help the company move to a modelbased development (MBD) product development process. Initially used in the design, simulation, and implementation of control systems, the MDB concept creates a computer-based model to analyze, test, improve, and optimize before building the physical system. Features include physical modeling based on a symbolic approach, control system design, and improved quality and time-to-market. Physical

modeling requires a computational symbolic approach to represent real-world physical systems. The software offers a computation engine to derive, solve, and simplify complex sets of equations as well as to develop advanced mathematical models and create technical applications. The software’s document environment also makes solutions more readable and understandable for re-use. For more information, visit booth 1201

Simulation software

Mercury Computer Systems’ Avizo software delivers 3D simulation visualization and data analysis capabilities to address advanced simulation post-processing and testing challenges with an intuitive workflow and graphical user interface. A comprehensive, scalable application framework addresses 3D scientific and industrial data visualization, processing, analysis, and presentation, and delivers high-quality 3D graphics capabilities, including flow data, scalar, vector, and tensor visualization; image segmentation; 3D reconstruction; and quantification tools. Suitable for managing multiphysics data in all visual simulation fields, Avizo’s open architecture allows users to create custom components such as file readers and writers, computation modules, and visualization modules. Avizo 5 is available for Linux and Windows 32- and 64-bit environments, with support for additional platforms planned. For more information, visit booth 1112

Six Sigma software

Quality Companion 2 process improvement software was designed by Minitab to help Six Sigma professionals manage, plan, execute, document, and report on projects. The three elements critical to Six Sigma success—organization, practical tools, and expert guidance—all are linked by the software. At the start of a project, Quality Companion’s Project Roadmap feature lets users plan out every phase in detail. The software’s coach function is available for guidance, and analysis capture tools help summarize the results of statistical analyses. An included tool lets professionals create presentations from inside the application, and all related documents are maintained in one file. Benefits include a streamlined project workflow; linked tools to improve analysis, reporting, and presentations; and standardized projects throughout the organization. For more information, visit booth 2517

Brushless dc motors

Moving Magnet Technologies offers a family of 3-phase brushless dc motors with mechanical output from 10 to 200 W under standard 12-V automotive supply. Features include up to 80% efficiency, low detent, and

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Wednesday, April 16



ripple torque. Design simplicity decreases production time and costs. In an automotive electric pump, the motors’ non-contact feature enables immersion of the rotor into the application’s fluid, be it water, fuel, or oil, and allows for a more compact integration than with a traditional dc motor. Custom designs are available based on the application requirement. For more information, visit booth 2645

Diesel particulate filter testing

INDUSTRIAL MICROHYDRAULICS

The Cambustion DPG is a diesel-fueled system used for diesel particulate filter (DPF) testing. The device allows a soot composition similar to that of many diesel engines and offers the capability to study different fuels such as biodiesel. Computer control of the burner, airflows,

Mahindra... Continued from Page 1

and temperatures ensures good repeatability of soot output. The system preheats the DPF to the loading temperature, thus allowing temperature and filtration effects to be separated and affording better evaluation of filtration performance of different media. A range of monitoring techniques to study DPF efficiency in real time can be fitted to the DPG, and results can be recorded into the automatically generated test report. The unit can regenerate a filter, allowing studies such as maximum soot load tests. For more information, visit booth 1517

Precision Safety Screens

Lee Self-Retaining Screens Protect Components from Rogue Contamination

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Innovation in Miniature

The Lee Company 0ETTIPAUG2OAD 7ESTBROOK #4 [email protected]

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Mahindra & Mahindra Ltd., recently named him Chief Technology Officer responsible for hybrid and other advanced technologies being pursued by the Indian company. Hybrid expert or not, Jaura yesterday found himself on the receiving end of a prestigious award from SAE International: The SAE Fellow Grade of Membership. Jaura carved a few minutes out of his busy SAE Congress schedule Tuesday to talk about Mahindra’s hybrid activities. One of its hybrid products, a Scorpio SUV with a diesel engine, is on display at FEV’s booth (1625). Jaura noted that Mahindra worked closely with FEV on the diesel-hybrid Scorpio, which in about two years will go on sale in India. The vehicle is a full parallel hybrid based on the conventional diesel-powered Scorpio that was launched in November 2007, and has all of the corresponding functions: start-stop, torque augmentation, regenerative braking, and electric launch with an initial period of EV operation. The electric motor, sandwiched between the engine and the transmission, is rated at 15 kW continuous and 30 kW max. The 2.2-L I4 engine was developed from the ground up by Mahindra. It uses a secondgeneration common-rail fuelinjection system developed in cooperation with Bosch, and

Moskowitz... Continued from Page 3

if they are actual products,” Moskowitz said, promoting the notion of identifying up front what does and does not excite people. Learning what “specifically drives the customer to respond” is key to product creation, ac-

employs a nickel metal-hydride battery. “When you have an electric motor between the engine and the transmission, the biggest thing that the driver is going to feel is when it switches between electric and engine,” Jaura said. “The way we have calibrated it, there is a very seamless transition.” The vehicle already performs “fantastically” in this respect, he said, adding that there will be refinements in calibration right up to launch. The calibration challenge is especially difficult when dealing with diesel engines, said Jaura. He noted that India is diesel-centric, and the fuel sells for less than gasoline. The diesel-hybrid Scorpio is expected to get 20% better fuel economy than the conventional version, with a similar reduction in CO2 emissions. Mahindra is also working on mild hybrid, biofuel, and hydrogen-combustion technologies, according to Jaura. He said several mild-hybrid products will reach market in India within months. The hybrid Scorpio is envisioned as an India-only product for the short term. Mahindra plans to export a nonhybrid pickup truck to the U.S. next year. As chief of product development until six weeks ago, Jaura was intimately involved in the vehicle’s development. It will meet federal Tier 2 Bin 5 and applicable FMVSS standards. Patrick Ponticel

cording to Moskowitz, who added that feedback can occur in a matter of weeks, especially if the Internet is utilized. “All combinations of ideas are valid, although some will prove more appealing than others. That’s what your job is to find,” said Moskowitz. Kami Buchholz

SAE 2008 World Congress Daily U.S. military... Continued from Page 1

and other industries, TARDEC is reaching out to the nation’s universities. Collegiate researchers can help fill in gaps in the military’s long- and short-term technology roadmap while also providing benefits that industry can’t address. “We’re also looking at workforce development. We hope to find ways to engage them so the core competencies we need can be fulfilled,” said Paul Skalny, Director of the National Automotive Center at TARDEC. The half-day presentation at Cobo Hall saw solid turnout, prompting plans for a second

Wednesday, April 16 meeting for academia. “We had over 30 universities and more than 150 people. This went so well that next year we’re already expecting 300 to 400 people,” Skalny said. The SAE is a close partner helping the military connect with industry and academia, he added. The military is looking for technology in three key areas: power and energy, thermal management, and survivability. Power and energy includes engines and batteries, with the latter playing a key role for both powering remote stations and bringing hybrid vehicle technology to help fuel supplies last longer.

Thermal management focuses on reducing heat in systems as well as keeping soldiers comfortable as they travel, while survivability addresses the many aspects involved with keeping vehicles moving and protecting their occupants. Another emerging area, robotics, may also benefit from research conducted at universities. Program directors hope that attendees can help the U.S. Army advance its technologies in all these areas. “We hope to end up with some single-point partnerships that address gaps in our basic and applied research. We also expect to see multi-university

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research programs that address gaps in our portfolio,” Skalny said. While the military searches for new technologies, it’s also looking at ways to keep its fleet of vehicles operating. Various techniques can be used to predict potential problems. “Condition-based maintenance is our term for prognostics that let us get to the point that we can efficiently tell when a vehicle is poised to break down so we can repair it and keep it running,” Skalny said. Terry Costlow

Tackling the innovation vs. cost conundrum How do you increase the level of innovation in your products and services when the pressures to reduce cost are relentless? And how can mature OEMs and suppliers compete successfully with low-cost companies from emerging markets? These questions were tackled head-on Tuesday morning in the SAE Executive Business Theater in a session titled, “Cost Down/ Innovation Up: Minimizing Cost While Maximizing Performance, Innovation and Quality”. Robustly configured and properly managed, global product development (PD) will reduce the auto industry’s program costs 12-18% while dramatically improving cycle times, said ZF North America President Julio Caspari. But for companies still building their global-PD processes, potential pitfalls abound, including intellectual property piracy. Then there are the roadblocks: Lack of global architectures, lack of a standard bill of material and process design, and inadequate native skillsets, among many other issues. “Recently, we [ZF] had to discuss vehicle dynamics with some developing-market engineers—

then we realized none of them had even driven a car,” Caspari noted. Caspari cited ZF’s new 8HP eight-speed automatic transmission, to enter production later this year, as an example of how innovative design and engineering delivered a product with greater performance and value— and lower complexity—than the six-speed unit it replaces. “Health, space, economy, and wealth are the critical factors for innovation” moving forward, explained Bernd Wiedemann, former CEO of Volkswagen’s Commercial Vehicles (and founder of SAE Brasil). Major opportunities for the auto industry will come within the next decade, as 40% of the world’s population will be concentrated in “megacities” where creative answers to personal mobility will find eager markets. Connectivity, the drive to zero emissions, low NVH, infotainment, and even privacy glass, are features OEMs will favor as they innovate for the new market, he said. Analyst J Ferron and Gerhard Buschmann, Executive Vice President for Diesel Engines at IAV, both asserted that one solu-

tion for tackling the innovation/ cost conundrum is to directly link design engineers with the customer, as the “adaptive”

industries such as consumer electronics do. Lindsay Brooke

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Wednesday, April 16


Docter Optics shows improved lenses Visitors to booth 700 will see the world’s first all-LED headlights for a production SUV from the Cadillac Escalade Platinum. What makes these LED headlights so special is that the high beam, low beam, and daytime running lights are projected through seven free-form lenses developed by Docter Optics in collaboration with headlight manufacturer Hella. Each LED illuminates a specific area in the beam pattern, but the LED module generates the entire light pattern. Of the seven lenses, there are six different types that provide the pattern. Some lenses have a more circular shape and others have a more rectangular shape depending on function. Each geometry is calculated to project light to a certain area within the beam pattern. For the low beam, five LEDs are used. The high beam consists of two additional LEDs per headlamp. State-of-the-art software was used to generate the free-form surfaces based on the required light distribution. Packaging constraints and thermal management of the headlamp were some of the other problematic engineering issues that were resolved. An electrical fan is needed to create the necessary airflow inside the headlamp to dissipate

The all-LED headlamps of the Cadillac Escalade Platinum feature seven freeform lenses developed by Docter Optics in collaboration with headlight manufacturer Hella.

the heat from the LEDs. In recent years, Docter Optics says it has significantly improved the technology required for high-precision molding of optical glass components. That means projection lenses can

Exhibitor Directory Addendum

The following is a Directory update as of April 14, 2008

Hubei Chuwei Axle Incorporated Company No 188 Jiaotong Ave Suizhou City Hubei Provinve 441300 China www.hbchuwei.com.cn Booth 1118 Business mainly produces main reductor assembly, brake assem-

bly, front and back bridge assembly and all kinds of pedal parts for Dongfend series. Front and back carbridge assembly consists of EQ1092, EQ1118, EQ1141G and EQ1240G etc. Spare parts of more than 160 kinds mainly consist of Dongfend, Yiqi, Jianghuai, Style series.

now be economically produced in virtually any shape or form. That also applies to free-form lenses, which the company says are especially important for leading-edge automotive applications from conventional Xenon

high-intensity-discharge headlights to new LED technology. It enables automaker designers to work with their counterparts at headlight manufacturers to turn many more drawing board ideas into production reality. Doctor Optics is also showing new reflection-free Auto-Tessar brand camera lenses that meet the optical needs of the engineers designing advanced driverassistance systems. The miniaturized camera lenses are said to be the first that use optical design to eliminate distracting reflections caused, for example, by light from oncoming traffic. The potential for errors caused by veiling glare and reflections is reduced to near zero, which makes the systems more reliable and eliminates or reduces the need for electronic componentry. The new Auto-Tessar camera lenses fill a gap in the market, taking experience and expertise gained by Docter Optics in the area of sophisticated high-end optics for development of special-purpose lenses for high-tech aerospace, defense, and biometric applications. The Auto-Tessar camera lenses are part of a special booth demonstrator.

SAE Member Lounge open

Kevin Jost

Throughout the SAE 2008 World Congress, SAE International members can visit the SAE Member Lounge, located in Room W2-60 at Cobo Center. The lounge will be open Monday through Wednesday from 8 a.m. to 5 p.m., and April 17 from 8 a.m. to 2 p.m. A continental breakfast will be available Monday through Thursday, from 8 a.m. to 10 a.m. Sandwiches will be available for lunch from noon until 2 p.m. Monday through Wednesday. Proof of membership is required to access the Member Lounge.

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Naturally Innovative

Innovation drives sustainability. Sustainability means future viability. Henkel offers sustainable technologies and solutions that benefit customers by reducing costs while achieving superior quality and productivity. As environmental sustainability becomes a greater corporate responsibility, Henkel’s products help our customers deliver on the legal, social, and financial requirements of their customers and the environment. For more information on Henkel at the SAE World Congress, call 866.332.7024; visit www.henkelatSAE.com; or stop by booth #1745.

TM

® ®

® and ™ designate trademarks of Henkel Corporation or its Affiliates. ® = registered in the U.S. Patent & Trademark Office. © Henkel Corporation, 2008. All rights reserved. 4967 (2/2007)