This SAE EDGE Research Report looks at the pros and cons of moving this technology forward and brings recommendations to facilitate a smooth transition from fossil fuel-based to hydrogen-based mobility.Unsettled Issues Concerning the Economics of Fuel Cells and Electric Ground Vehicles discusses the unsettled economic aspects of hydrogen and fuel cell applications in the automotive industry. Lately, the idea of using hydrogen in automotive applications is gaining momentum. While the concept of using clean hydrogen fuel generated from water via electrolysis is nothing new, previous efforts to mainstream the technology failed miserably. About a decade ago, the fuel cell technology, which efficiently converts hydrogen and atmospheric oxygen into electricity, was not as advanced and the fuel cell prototypes were bulky and expensive.Yet, many new fuel cell electric vehicles (FCEVs) have emerged, and hydrogen refueling infrastructure is being built globally. Despite the important steps

Kolodziejczyk, Bart

JLR tackles weight with structural electronics

20AUTP03_1003/01/2020

Ashutosh Tomar, electrical research technical manager at Jaguar Land Rover (JLR) said he has absolute confidence in the potential of structural electronics (SE) now being pioneered by the company. Dubbed LESA (Lightweight Electronics in Simplified Architecture), the technology is expected in upcoming JLR models, though its use in the next-generation Jaguar XJ to be launched in 2020 has not been confirmed. JLR is completing a successful R&D program into printed SE, initially to introduce curved dashboard screens. The company claims an industry first that has the potential to radically alter vehicle interiors, with other applications forthcoming. SE is not a new technology. Decades ago the aerospace industry was considering it as part of aircraft-surface morphing capability to adapt to varying flight conditions.

Birch, Stuart

Technology Impact Forecasting for Multi-Functional Composites

TBMG-3567912/01/2019

To survive within today's stringent economic environment, aircraft design, particularly military aircraft design, has been experiencing a paradigm shift from an emphasis on design for optimum performance to design for system effectiveness. As a consequence, designers and manufacturers are increasingly considering the addition of new technologies to aircraft design to reduce their cost, increase their operating capacities, and optimize new capabilities.

Reducing the High Cost Of Titanium

TBMG-3566712/01/2019

Titanium is neither a precious metal nor rare, yet among industrial metals it has the reputation for being very expensive. It's the fourth most abundant metallic element and the ninth most abundant of all the elements in the earth's crust. Its commercially useful oxide ore occurs in the minerals rutile and ilmenite and numerous iron ores, and exploitable ore deposits are liberally scattered around the world in Australia, Canada, India, Malaysia, Norway, Russia, South Africa and the U.S. But due to its properties and high cost it has often been referred to as unobtanium.

Technology Impact Forecasting for Multi-Functional Composites

19AERP12_0912/01/2019

Multi-functional composites offer a possible solution to the conflicting design goals of making new aircraft lighter, stronger, faster, and more environmentally sustainable. Air Force Research Laboratory, Arlington, Virginia To survive within today's stringent economic environment, aircraft design, particularly military aircraft design, has been experiencing a paradigm shift from an emphasis on design for optimum performance to design for system effectiveness. As a consequence, designers and manufacturers are increasingly considering the addition of new technologies to aircraft design to reduce their cost, increase their operating capacities, and optimize new capabilities. For next generation aircraft design, there are many innovative technologies to be developed that are financially constrained. However, infusion of a new technology (or technologies) are leading to another challenge: how does this new technology affect the aircraft system both in capability and economically?

Reducing the High Cost Of Titanium

19AERP12_0312/01/2019

Application of Multi-Attribute Weighted Gray Target Decision in Automobile Noise Reduction Scheme Evaluation

02-12-03-001407/03/2019

In the selection of automobile noise reduction schemes, the lack of comprehensive quantitative index system and objective evaluation method is a serious problem. In this article, the methods of analytic hierarchy process (AHP) and gray target decision were used to solve the problem. Firstly, AHP and gray target decision method were introduced respectively in detail. Secondly, three automobile noise reduction schemes were illustrated. Four types of data were selected as the decision indexes, and the weight coefficients of all the decision indexes were calculated using the AHP. Then multi-attribute mixed weighted gray target decision model was established. The optimum scheme was obtained by the calculation of the off-target distance and the sorting of the calculation results. The proposed method can quantify the evaluation process and overcome the disadvantages of the traditional analogy method. The example shows that the method is feasible.

Zhao, Zhendong

Manufacturing of Transmission Quill Gear by Sinter Hardening

2019-26-016501/09/2019

Transmission quill gears are hot forged steel parts often used in constant mesh manual transmissions. The quill gear, which helps to transmit the power from input drive shaft to output shaft through driving gears. It’s having external teeth which is positively engaged with driving gear and sleeve. During gear selection sleeve take load from input shaft and transmit to driven gear. Quill gear directly engaged with driving gears on outer surface and bearing in inner surface which needs to have high strength and durability. These properties can be improved by carburization heat treatment in existing design such processes can lead to increased costs. We have developed quill gear through powder metallurgical process and then cooled rapidly in the furnace to get high strength and wear properties. Material composition are optimized to suit for sinter hardening process conditions. Thus, we have succeeded in the development of quill gears via sinter hardening, thus eliminating the forging and

Gunalan, Magendran, Deshmukh, Rahul, Bane, Uttam

Cost Controlling Methodology: Design to Cost

2019-26-007701/09/2019

Current Global Economic scenario is driven by high quality and innovative products and services available at lower cost. With the volatility in the cost drivers market of 3M’s (man, material and manufacturing), Industry needs a methodology which can control cost and assists in increasing research and development efficiencies, robust quality, shared volumes for lower cost and investment, aligned manufacturing sequences and a consistent customer experiences across Global market. This Paper uses the ideology of design to cost as its basis, since a substantial portion of the product’s cost is dictated by decisions with regards to its design. Design to cost is a management strategy and supporting methodologies to achieve an affordable product by focusing on target cost as an independent design parameter that needs to be achieved with the development of a product. The approach emphasizes on Customer Affordability and Competitive Pricing with balance in Product Features. It is a trade-off

Sharma, Himanshu

SUPPLIER EYE

19AUTP01_0701/01/2019

Welcome to 2019, a new year that's already brimming with challenges for mobility-industry suppliers. As they deal with escalating technology investments, unpredictable product-launch cadences, an influx of non-traditional competitors, extreme U.S. import tariffs, and other factors, most suppliers (and their OEM customers) are in a reactive mode to stabilize the bottom line. The tariffs-25% on steel and 10% on aluminum-have been a thorny issue since March 2018. According to IHS Markit, the Steel Producer Price Index in September 2018 was up over 22% year over year, significantly impacting material economics for this metals-intensive industry. Exposure to such unplanned economic price hikes depends upon who is the importer of record, as well as whether or not they're participating in OEM material resale programs.

Robinet, Michael

Design Considerations for Enclosed Turboshaft Engine Test Cells

AIR4989A (Current)11/21/2018

This SAE Aerospace Information Report (AIR) developed by a broad cross section of personnel from the aviation industry and government agencies is offered to provide state-of-the-art information for the use of individuals and organizations designing new or upgraded turboshaft engine test facilities.

EG-1E Gas Turbine Test Facilities and Equipment

Why is Silicone the Material of Choice for Healthcare Tubing?

TBMG-3324411/01/2018

A Paper-Like LCD — Thin, Flexible, Tough, and Cheap

TBMG-3288009/01/2018

Optoelectronic engineers in China and Hong Kong have manufactured a special type of liquid crystal display (LCD) that is paper-thin, flexible, light, and tough. With this, a daily newspaper could be uploaded onto a flexible paper-like display that could be updated as fast as the news cycles. It sounds like something from the future, but scientists estimate it will be cheap to produce, perhaps only costing $5 for a 5-inch screen.

Designing for Mechanical and Signal Integrity in Handheld Medical Treatment Applications

TBMG-2813801/01/2018

Alternate Manufacturing Process for Automotive Input Shafts

2017-01-501310/13/2017

The input shafts are conventionally developed through Hot forging route. Considering upcoming new technologies the same part was developed through cold forging route which resulting in better Mechanical properties than existing hot forging process. It has added benefit of cost as well as environmental friendly. Generally, the part like Input shaft which having gear teeth, splines etc., will be manufactured through Hot forging process due to degree of deformation, availability of press capacity, diameter variations etc., This process consumes more energy in terms of electricity for heating the bar and also creates pollution to the atmosphere. Automotive input shaft design modified to accommodate cold forging process route to develop the shaft with press capacity of 2500T which gives considerable benefit in terms of mechanical and metallurgical Properties, close dimensional tolerances, less machining time, higher material yield when compared to hot forging and metal cutting operation

Magendran, G.

An Integrated Approach for Dynamic Charging of Electric Vehicles by Wireless Power Transfer - Lessons Learned from Real-Life Implementation

2017-01-907604/11/2017

The aim of this paper is to introduce a complete fast dynamic inductive charging infrastructure from the back-office system (EV management system) up to the Electric Vehicle (EV) (inductive power transfer module, positioning mechanism, electric vehicle modifications) and the EV user (User interface). Moreover, in order to assess the impact of the additional demand of inductive charging on the grid operation, an estimation of the 24-hour power profile of dynamic inductive charging is presented considering, apart from the road traffic, the probability of the need for fast charging, as well as the specifications of the proposed solution. In addition, an energy management system is presented enabling the management of the operation of the inductive charging infrastructure, the interaction with the EV users and the provision of demand response services to different stakeholders. The proposed dynamic inductive charging approach has been demonstrated within a real urban environment in order

Marengo, Luca, Karakitsios, Ioannis, Karfopoulos, Evangelos, Bustillo, Aitor, Ponsar, Marc, Del Pozo, Dionisio, Madjarov, Nikolay

Turbulence Models and Model Closure Coefficients Sensitivity of NASCAR Racecar RANS CFD Aerodynamic Predictions

2017-01-154703/28/2017

Cost benefit and teraflop restrictions imposed by racing sanctioning bodies make steady-state RANS CFD simulation a widely accepted first approximation tool for aerodynamics evaluations in motorsports, in spite of its limitations. Research involving generic and simplified vehicle bodies has shown that the veracity of aerodynamic CFD predictions strongly depends on the turbulence model being used. Also, the ability of a turbulence model to accurately predict aerodynamic characteristics can be vehicle shape dependent as well. Modifications to the turbulence model coefficients in some of the models have the potential to improve the predictive capability for a particular vehicle shape. This paper presents a systematic study of turbulence modeling effects on the prediction of aerodynamic characteristics of a NASCAR Gen-6 Cup racecar. Steady-state RANS simulations are completed using a commercial CFD package, STAR-CCM+, from CD-Adapco. Three turbulence models are included in this study: the

Fu, Chen, Uddin, Mesbah, Robinson, Clay, Guzman, Arturo, Bailey, David

Evaluation of Exhaust Heat Recovery System Effectiveness in Engine Friction Reduction and Fuel Economy Improvement for Indian Hatchback

2017-01-015403/28/2017

With the upcoming regulations for fuel economy and emissions, there is a significant interest among vehicle OEMs and fleet managers in developing computational methodologies to help understand the influence and interactions of various key parameters on Fuel Economy and carbon dioxide emissions. The analysis of the vehicle as a complete system enables designers to understand the local and global effects of various technologies that can be employed for fuel economy and emission improvement. In addition, there is a particular interest in not only quantifying the benefit over standard duty-cycles but also for real world driving conditions. The present study investigates impact of exhaust heat recovery system (EHRS) on a typical 1.2L naturally aspirated gasoline engine passenger car representative of the India market. Computational Sciences Experts Group (CSEG) has developed a forward calculating Simulink model of the passenger car in order to calculate the engine loading, engine heat

Uppuluri, Sudhi, R Khalane, Hemant, Naiknaware, Ajay

Exclusive first drive: Torotrak's V-Charge technology

17AUTP02_1102/01/2017

Being the first journalist to test drive the only example of a new piece of technology still in development always concentrates the mind. Doing so in wet and windy weather battering rural roads close to England's North Sea coast brings an added dimension to the experience. But that was how Torotrak demonstrated to Automotive Engineering the potential of its new, CVT-controlled V-Charge pressure charger-a mechanical, gearless, fully variable pressure charger driven by a conventional pulley. It allows compressor speed to vary independent of engine speed. It's designed to provide low-end torque and tackle the effects of turbo-lag on downsized gasoline engines. (See http://articles.sae.org/12401/; also SAE Technical Paper http://papers.sae.org/2015-01-1971/).

Birch, Stuart

Evaluation of Exhaust Heat Recovery System Effectiveness in Engine Friction Reduction and Fuel Economy Improvement

2017-26-003001/10/2017

With the upcoming regulations for fuel economy and emissions, there is a significant interest among vehicle OEMs and fleet managers in developing computational methodologies to help understand the influence and interactions of various key parameters on Fuel Economy and carbon-di-oxide emissions. The analysis of the vehicle as a complete system enables designers to understand the local and global effects of various technologies that can be employed for fuel economy and emission improvement. In addition, there is a particular interest in not only quantifying the benefit over standard duty-cycles but also for real world driving conditions. Present study investigates impact of exhaust heat recovery system (EHRS) on a typical 1.2L naturally aspirated gasoline engine passenger car representative of the India market. CSEG has developed a forward calculating Simulink model of the passenger car in order to calculate the engine loading, engine heat rejection and the exhaust energy being

Uppuluri, Sudhi, M Naiknaware, Ajay, R Khalane, Hemant

Practical Uses of Formal Methods in Development of Airborne Software

2016-01-204409/20/2016

Over the past few decades, advanced methods have been developed for the analysis of digital systems using mathematical reasoning, i.e., formal logic. These methods are supported by sophisticated software tools that can be used to perform analysis far beyond what is practically achievable using “paper and pencil” analysis. In December 2011, RTCA published RTCA DO-178C [1] along with a set of technical supplements including RTCA DO-333 [2] which provides guidance on the use of formal methods towards the certification of airborne software. Such methods have the potential to reduce the cost of verification by using formal analysis instead of conventional test-based methods to produce a portion of the verification evidence required for certification. Formal methods can also be used to find problems earlier in the development process - for example, while the requirements are being developed rather than during system integration when the cost of re-working the requirements and design is much

Joyce, Jeffrey J., Beecher, Scott, Fabre, Laurent, Rajagopalan, Ramesh

Reanalysis of Linear Dynamic Systems using Modified Combined Approximations with Frequency Shifts

2016-01-133804/05/2016

Weight reduction is very important in automotive design because of stringent demand on fuel economy. Structural optimization of dynamic systems using finite element (FE) analysis plays an important role in reducing weight while simultaneously delivering a product that meets all functional requirements for durability, crash and NVH. With advancing computer technology, the demand for solving large FE models has grown. Optimization is however costly due to repeated full-order analyses. Reanalysis methods can be used in structural vibrations to reduce the analysis cost from repeated eigenvalue analyses for both deterministic and probabilistic problems. Several reanalysis techniques have been introduced over the years including Parametric Reduced Order Modeling (PROM), Combined Approximations (CA) and the Epsilon algorithm, among others. It has been shown that the Modified Combined Approximations (MCA) method - an improvement over CA - is the most efficient reanalysis technique for problems

Mourelatos, Zissimos, Haider, Syed F.

Impact of Light-Weight Design on Manufacturing Cost - A Review of BMW i3 and Toyota Corolla Body Components

2016-01-133904/05/2016

OEMs are investigating opportunities to reduce vehicle mass, driven by a need to meet upcoming CAFE targets, increase the range and reduce battery size of EVs. A number of lightweight materials including high strength steels, aluminum alloys, plastics and composites are now in production. To facilitate development of corporate R&D and commercialization plans for new materials, it is beneficial to understand the current manufacturing costs for production components, and their impact on piece price at different volumes. This paper investigates design and cost impact of light-weighting with respect to front door and floor assembly of Toyota Corolla and BMW i3. Toyota Corolla has a traditional steel body and is sold in high volumes while BMW i3 has relatively low annual sales and is primarily made of composite, aluminum and plastic parts. This study identifies good practices by BMW for both light-weighting and low / medium volume production where reduction in tooling costs become

Bubna, Piyush, Wiseman, Marc

Decomposition Technique for Remaining Useful Life Prediction

TBMG-2300510/01/2015

Technology has been developed that provides a way to compute the remaining useful life (RUL) of a component or system. The estimation of the RUL of a degraded or faulty component is at the center of condition-based maintenance, and prognostics and health management. It gives operators a potent tool in decision-making by quantifying how much time is left until functionality is lost. This is especially important for aerospace systems, where unanticipated subsystem or component failure may lead to failure of the system as a whole, which in turn may adversely affect the safety of operation.

Scientific Balloons as Solar Sails

TBMG-22412

07/01/2015

Existing scientific research balloons such as those launched from Wallops Flight Facility could be placed in near- Earth space where they would perform as solar sails, providing relatively inexpensive propulsion systems for interplanetary missions. The balloons would accelerate at rates comparable with the ion drive performance of the NASA Dawn spacecraft, so they would enable unprecedented low-cost access to interplanetary space.