Wednesday - SAE

Wednesday - SAE



Integration is king, says Queen

In a week that brings engineers

together from all over the world,

and dares to put competitors not

only under the same roof but often

in the same room or on the same

stage, James Queen, Vice President,

GM North America Engineering,

General Motors, Corp. talked

at yesterday afternoon’s keynote

address in the AVL Technology

Theater about integration. He

touched upon the topic at several

different levels.

“Beyond any individual company,

it is important to have an

industry coalition of OEMs and

suppliers working together,”

Queen said. “Cooperation is

absolutely essential for exchanging

business and technical information

for advancing our industry.”

Queen added that “the SAE

World Congress is the most

important international forum”

for enabling such cooperation, as

well for “growing future generations

of successful engineers and

technical leaders.”

Wednesday, March 10, 2004


Industry taking active stance on safety

Diminishing returns from

passive safety features has

the automotive industry, as

well as its regulators,

turning to active safety

features. One of the

biggest obstacles associated

with this evolution is

public acceptance of active

safety features. As several

speakers noted at

Tuesday’s session, “Electronic

Active Safety

Systems: How Far Can We

Go?” the typical driver is

loath to let the vehicle’s

onboard computers decide for

them what it should do in dangerous


It’s not an insurmountable

problem, though, as evidenced by

the fact that drivers already have

given up some degree of control

with antilock braking systems.

Other systems beginning to make

their way into production vehicles

include adaptive cruise control,

brake assist, and electronic stability

control—where a vehicle’s

General Motors’ James Queen spoke at

Tuesday afternoon’s keynote on

Technical Integration. “It’s a great time

to be an engineer in the automotive

business,” he said.

Integration is also important

within a company, he stressed, and

in the past, too often forgotten.

“An entire organization can be

improved by integrating the efforts

of different departments,” said

Queen. He provided the example

Thomas Gillespie (far right), moderated

Tuesday’s “Electronic Active Safety Systems: How

Far Can We Go?” panel, which featured (from

left to right) Delphi’s Richard Lind, Denso’s

Hiroshi Fujinami, Ford’s Susan Cischke, and

NHTSA’s Joseph Kanianthra.

computers determine how to help

drivers in certain circumstances

and then do so via braking. Future

technologies could involve an even

greater level of automatic vehicle


Joseph Kanianthra, Associate

Administrator for Applied Research

at the U.S. National Highway

Traffic Safety Administration

(NHSTA), said drivers are responsible

for about 90% of fatal

accidents, and vehicle defects

See INDUSTRY, Page 17

The Ford Shelby Cobra concept, revealed in January 2004 at the North

American International Auto Show, is on display at the Ford Motor Co. booth

adjacent to the AVL Technology Theater. Powering the Shelby Cobra is an allaluminum

6.4-L V10 that produces 605 hp (451 kW) at 6750 rpm and 501 lb•ft

(679 N•m) at 5500 rpm without supercharging or turbocharging. Many of the

car’s components are borrowed from the Ford GT, including the rear-mounted

six-speed transaxle and the slightly modified suspension system, steering rack,

rear rails, and bumper beam. Its seven-spoke BBS wheels are wrapped by BF

Goodrich Z-rated racing slicks, 275/40R18 in front and 345/35R19 in the rear.

Software issues head list for

embedded system design

Software is becoming a product differentiator in vehicle design, so

creating and testing code is emerging as a key issue. Panelists discussing

“Embedded Controls Development Challenges for the Future” in the AVL

Technology Theater on Tuesday weren’t shy about shining the spotlight

on software. “Hardware has become a commodity. The most exciting

features today and in the future come from software,” said Deepak Goel,

Manager of Body and Security Subsystems at Ford Motor Co.

One of the key areas of development is in auto code generation,

which is growing in usage even though many automotive designers view

it with skepticism.

“Auto coding still has a lot of issues to debate, but I think it’s got a

great future,” said Herbert Hanselmann, CEO for dSpace. He added that

the technology has advanced significantly in recent years, but that is

unknown in many areas. “One of the really big things we have to do is

educate people,” he said.

Automatically generated code is generally easier to debug, and

modules can be re-used in future designs. Though a machine’s approach

is more structured

than hand-coded

software, design

teams cannot rely

on it being done

correctly every time.

It must be examined

on the system

extensively before

managers sign off

on the design. “You

need to have even

better testing and

diagnostics when

you use code

Software issues were a hot topic for (l-r) Jason Fortier,

Jack Little, Herbert Hanselmann, and Deepak Goel

Tuesday afternoon in the AVL Theater.

See SOFTWARE, Page 17

Today’s Congress


• Keynote Presentation

High Performance Cars - A

Passion for Performance

From Muscle Cars to Soccer

Moms: Redefining High


J. T. Battenberg III, Chairman

of the Board, Chief Executive

Officer & President, Delphi Corp.

9:00 a.m.

AVL Technology Theater

• Business Panel on Poland

9:00 a.m.-10:30 a.m.

Dana Technical Innovation Forum

• High Performance Cars - A

Passion for Performance

The Team Approach to the

Design of High Performance


10:00 a.m.

AVL Technology Theater

• Spotlight on Austria: Styria

On the Cutting Edge of

Automotive Technology

10:45 a.m.-12:15 p.m.

Dana Technical Innovation Forum

• Keynote Presentation

Market Impact of High

Performance Vehicles

Phil Martens, Group Vice

President, Product Creation,

North America, Ford Motor Co.


AVL Technology Theater

SAE Annual Business Meeting

1:00-1:15 p.m.

Dana Technical Innovation Forum

• High Performance Cars - A

Passion for Performance

New Vehicle Engineering -

The Ford GT

1:30 p.m.

Dana Technical Innovation Forum

• Innovative Applications of

Materials - Selecting the Right

Combination of Materials and

Manufacturing Processes to

Save Time, Weight, and


1:30 p.m.

AVL Technology Theater

• IMechE / SAE Exchange

Lecture: Getting Fun

Out of Diesel

John Mardell, Chairman,

IMechE Automobile Division

3:30-4:30 p.m.

Cobo Center, D2-13/14

• New Product Design and

Development - How Lean Can

We Get? More new models,

less product lead time, more

focus on initial product quality

all add up to higher product

design and development costs.

How can the industry use new

technology to solve this


3:30 p.m.

AVL Technology Theater

• 19th Cliff Garrett

Turbomachinery Engineering

Award Lecture

4:00-5:00 p.m.

Cobo Center, M2-30

• International Reception

5:30-7:30 p.m.

Cobo Center, Promenade Room


Continental-Teves CEO Wolfgang Ziebart chats with Mattias Rabe, Executive

Director of Group Research with Volkswagen.

Two-time CART Championship racing driver Gil de Ferran meets with VP and

Technical Director of Toyota Racing Development, Peter Spence.

Robert LeFort, President, Infineon

North America, moderated the

“Embedded Control Development”

panel in the AVL Technology Theater

on Tuesday.

Susan M. Cischke, Vice President of

Environmental Safety Engineering for

Ford Motor Co., discussed electronic

active safety systems with fellow AVL

Technology Theater panelists.

Larry Denton, President & CEO, Dura Automotive Systems, presented the

company’s business strategy at a press conference.

Former Detroit Lions great and NFL Hall of Famer Barry Sanders signs autographs

to benefit the Boy Scouts in the Motorola booth on Tuesday.

Chassis integration key to

safety improvements

Electronic stability control (ESC) systems provide huge safety benefits, but

the U.S. consumer needs to know that, said Wolfgang Ziebart, Deputy

Chairman of Continental AG’s Executive Board, who gave the Active

Safety keynote address held in the AVL Technology Theater Tuesday

morning. ESC’s performance has improved greatly since its introduction

nearly a decade ago, he added, but further integration with other vehicle

systems will provide even better safety and performance benefits.

The National Highway Traffic Safety

Administration (NHTSA) says that in

2002, auto-related fatalities in the U.S.

alone were nearly 43,000, and nearly 3

million people were injured. While the

data released last July by NHTSA shows

fatalities at a 10-year high, injuries are

at an all-time low. Ziebart believes this

indicates the concentrated focus on

passive systems such as airbags and

seatbelts is reducing the severity of

injuries in accidents, but that crash

avoidance is taking a back seat. So,

active systems such as ESC must

become a primary focus of the industry

Wolfgang Ziebart, Deputy

Chairman of Continental AG’s

Executive Board, sees the linking

of active and passive systems as

the key enabler to improved

vehicle safety.

and a personal choice by consumers to

prevent accidents from occurring in

the first place. It is the responsibility of

engineers to develop systems that

assist the driver in recognizing and

See CHASSIS, Page 17

Visualizing sound for quieter cars

Automotive designers and engineers will be able to make quieter

vehicles if they can see sound. That’s the concept behind a

startup that uses technology to create 3-D models allowing

developers to see where noise is generated or “leaking” into the

vehicle cockpit.

The startup, SenSound LLC, has licensed what it calls acoustic

holography developed at Wayne State University. The testing

and analysis technology lets designers of planes, trains, automobiles,

and consumer products “see” where unwanted sound is

generated and how it travels through space and time.

“To reduce noise, you need to know its sources and paths,”

said Sean Wu, a Wayne State professor who is Chief Technology

Officer at the startup.

He noted that the SenSound technology is much faster than

the analysis tools being used today. “If you use lasers, it’s very

time consuming. It can take all day to figure out what’s causing

brake squeal. We provide more information and do it in one

minute,” Wu said.

The technology can detect sounds across the full spectrum of

noise. “We can go up to 6000, even 7000 Hz,” said Sergio Maza,

SenSound President.

The acoustic holography system uses a variety of microphones

that are positioned near the object being tested such as a car

door or brake drum. The microphones can detect exactly where

noise is being generated. “We can distinguish between two small

holes located only 1.4 cm (0.5 in) apart,” Maza said.

Terry Costlow

Editorial staff

AEI editorial staff for the Show Daily

can be reached during show hours at

Booth 1859.

Kevin Jost

Editorial Director

Jean L. Broge

Associate Editor

David Alexander

Associate Editor

Patrick Ponticel

Assistant Editor

Ryan Gehm

Assistant Editor

Jennifer Newton

Assistant Editor

Carey Cyphert

Editorial Assistant

Kami Buchholz

Detroit Editor

Contributing Editors

Terry Costlow

Jenny Hessler

Linda Trego

Wayne Silvonic

Production Manager

Contributing Artists

William L. Schall Jr.

Christian Bonicky

Wednesday, March 10, 2004


Powering the future

The dominant power source for at

least the next 10 years remains the

internal combustion engine, but the

reigning technology after that

timeframe is debatable.

Tomorrow’s technology may be

defined by a frantic fuel-cell takeoff.

The solid oxide fuel cell (SOFC) being

developed by Delphi may be just

such an application. “By increasing

power, reducing packaging, and

eliminating the battery, SOFC adds

the most near-term value for electric

propulsion,” said Jean Botti, Chief

Technologist at Delphi’s Innovation

Center, during the “Powering The

Future” panel in the AVL Technology

Theater on Monday.

Mike Rosenberg, Director of

Corporate Relations for Ballard

Power Systems, rallied for fuel cells

that use hydrogen “because it’s a

manufactured fuel.” He added that

hydrogen fuel cells are no longer in

the research and development stage

as fleet demonstrations are in

progress. “We think fuel cells are the

ultimate solution,” Rosenberg added.

Powering the Future panelists were

(from left to right) Toyota’s Kazuo

“Joe” Tomita; Ballard’s Mike Rosberg;

GM’s Robert Purcell; DaimlerChrysler’s

Reginald Modlin; Delphi’s Jean Botti;

and moderator Ken Baker of Altarum.

Hybrid-electric vehicles (HEVs)

are in the power-source mix.

“HEVs will occupy carefully

defined market niches,” said

Reginald Modlin, Director of

Environmental & Energy Planning

for DaimlerChrysler, citing high

fuel economy or performance

enhancers, or a combination of

both reasons, as the primary

appeal factors for such vehicles.

Rather than predict the future,

Robert Purcell, Group Director of

Planning & New Business Development

for GM Powertrain, said

partnering for tomorrow is one

way to address the fundamental

challenges inherent with the

technology adoption. The General

Motors/Ford front-wheel-drive sixspeed

automatic transmission is a

prime example of how partnering

with other companies can prove

out a technology until it’s commercially

viable. Technologies that

become industry standards are not

the “low-volume exclusive

programs,” said Purcell.

According to Purcell, the future

means more industry collaboration

such as the GM Powertrain

Advanced Hybrid System II, which

has accumulated more than one

million miles in a city bus application.

Purcell invited companies to

partner on the system, which “we

intend to be an industry standard.”

In the meantime, today’s

vehicles are a “very, very evolved

product,” said Kazuo “Joe”

Tomita, Senior Vice President of

Technical & Regulatory Affairs for

Toyota Motor North America, Inc.

Tomita’s believes that, in choosing

future powering technologies, a

reality check is necessary. “The

painful reality is that, unless clean

technologies can be sold in

volume, they will do nothing to

improve air quality. A companion

truth is that products must be

profitable or “do-gooders go


Kami Buchholz

16 4

Wednesday, March 10, 2004

Each day, Show Daily editors highlight some of the top products

and technologies on display at the SAE 2004 World Congress.

Design analysis

SolidWorks Corp. has upgraded its

COSMOS finite-element analysis applications,


and COSMOSMotion, making the suite 10

to 15 times faster than comparable

applications and enabling solvers to use

processor cycles more efficiently. Users

can test assembly behavior without fully

modeling component connectors, such as pins and springs, up front. Analysis

is simplified with the addition of usability features that simulate processes

such as heat regulation using a thermostat with simple menu-driven

commands that replace manual computations. Additional visual and

reporting features enable users to extract more precise results from their

analyses. Improved integration with SolidWorks 3D mechanical design

software enables COSMOS users to analyze designs without re-entering data

and switching between applications.

Booth 2306

Motor generator system

TM4’s motor generator system is an

onboard generator and a powertrain

equipped with an integral differential. The

system uses a magnetic clutch to transform

vehicles into a series hybrid, parallel hybrid,

or an electric vehicle equipped with a range

extender. It also features a smart controller,

an onboard battery charger, and a bi-directional 12-V dc/dc converter

to supply vehicle auxiliaries.

Booth 2653

Simulation environment

Link for ModelSim from The MathWorks

is a direct co-simulation interface that

integrates MATLAB and Simulink systemlevel

design environments into the

hardware design flow for field programmable

gate array and application-specific

integrated circuit development. It provides a link where users can set up an

environment between MATLAB, Simulink, and Mentor Graphic’s HDL

simulator, ModelSim, for bi-directional co-simulation, verification, and

visualization. The link supports PE and SE versions of ModelSim and supports

multiple simultaneous ModelSim instances and multiple HDL entities from

within one Simulink model or MATLAB function.

Booth 2217

CFD design software

Fluent’s FloWizard is computational fluid

dynamics (CFD) software that employs the

use of a wizard to guide users through the

design decision process step-by-step with

basic terminology. It can simulate laminar

or tubular flow, with or without heat

transfer, and features special options such as moving belts and conducting

walls. It is suitable for first-pass analyses early in the product development

cycle and potentially eliminates designs that do not meet basic performance

guidelines early on. All geometry, case, data, and mesh files are fully

compatible. FloWizard automatically detects erroneous or questionable

inputs and outputs and will notify users. In addition, multiple users can view

the same information from different locations.

Booth 1642

Plastic oil module

An oil module with a complete

plastic housing developed by


cooperation with Audi AG will be

used in the new 2.0-L, four-cylinder,

FSI direct-injection petrol engine of

Volkswagen and Audi. The module

is used to control oil circulation, the

filtration and cooling of the engine

oil, oil pressure control, and

crankcase ventilation. A heat

exchanger flange mounted onto the

module keeps the filtered oil cool,

and capable of lubrication, while the

module relieves the crankcase

ventilation by reducing the oil share

in the blow-by gases with a

labyrinth separator.

Booth 2035

Wednesday, March 10, 2004


Inside development of the Ford GT

Ford Motor Co.’s 30-person

engineering team faced an array of

obstacles in designing and

developing the GT supercar, not

the least of which was a deadline

from CEO Bill Ford that the first

three cars needed to be ready in

time for the company’s centennial

in June 2003. The compressed

timeframe drove nearly every other

significant decision regarding the

car. The other primary constraint

was the need to maintain exterior

styling that diverged little from the

2002 concept car, even though the

concept car was drawn with little

consideration of production issues.

Basic problems like providing for

windows that open, and keeping

the car from lifting off of the

ground at high speeds, were at

Ford says the GT’s engine cover contains the single largest section of carbon

fiber in any production car. The composite inner portion is bonded to an

aluminum skin.

odds with the styling as it was

originally created. The extremely

low 44-in (1120-mm) height made

packaging a headache, while the

GT’s iconic roof cut-outs for the

doors undermined stiffness.

Ford and its partners will

provide a comprehensive insidelook

at the car’s development at

1:30 p.m. in the Dana Technical

Innovation Forum. The first job was

to create a plan for exactly how

the company would build the car

in such a short period of time. “We

had 30 days to put together a

complete plan for how we could,

in 15 months, completely develop

the car,” said Fred Goodnow, Ford

GT Design, Engineering and

Launch Manager. “We produced a

half-inch thick binder charting the

timing, the engineering and the

manufacturing of the car. We went

from concept to production in 22

months. A lot of people have tried

to do things faster before without

doing things differently. But when

you do that, you compromise


Ford relied heavily on suppliers

to develop the car. “We went with

major suppliers who had experience

with this type of car for the body,

interior, and powertrain,” said

Goodnow. Mayflower Vehicle

Systems, Inc., Ove Arup &

Partners Detroit Ltd., and Saleen

Inc. contribute to the car’s chassis

and body, Lear Corp. provided the

interior, Roush Industries did the

engine design and dyno work, and

Ricardo UK Ltd. helped with the

transaxle. “For a lot of the small bits

on the car, our guys were working

directly with the [smaller] suppliers,”

he said.

Kevin Jost

Publish your book

with SAE

Today from 8:00 a.m. to 5:00

p.m. during SAE 2004 World

Congress, SAE’s book publishing

staff will be on hand in Room

W1-53 in Cobo Center to speak

with prospective authors about

writing a book with SAE. Please

stop by for more information.


Wednesday, March 10, 2004

Ansys develops strategic problem solving

According to the company,

high-performance CFD (computational

fluid dynamics) is

achieved in CFX-5, from Ansys,

Inc., by application of a cohesive

strategy in six key technology

areas: meshing, accuracy,

reliability, speed, physics, and

flexibility. Details of how these

features all come together are

available at Booth 846.

The meshing strategy is

flexible, because no single

strategy is ideal for every case.

Four element types—

hexahedral, tetrahedral, wedge

evolved over a 20-year period,

rooted first in CFX-TASCflow and

now in CFX-5. This is the only

linear solver available in the

program. It is fully automatic,

fully scalable (linear increase in

CPU time with problem size), and

insensitive to mesh aspect ratio.

All of this means the user

experiences fewer problems in

getting the desired computation

to run from start to end.

The latest version of CFX-5 will

be released in April, 2004 and

will contain many new features

that build upon high performance.

Turbulence model

control, one-way fluid-structure

interaction, and moving mesh are

just some of the new capabilities.

David Alexander

With CFX-5 from Ansys, Inc., a fully

transient turbulence model can solve

large eddy simulation of flow behind

a cylinder.

or prism, and pyramid—are

available, and from these

building blocks almost any style

of mesh is possible. The

program supplies its own

hybrid meshing technology,

and the result is near-automatic

best-practice CFD meshes that

resolve the geometry and the

boundary layer.

It also supports a large

number of external grid

formats. Combinations of

multiple mesh styles in a single

analysis can be done using the

general grid interface (GGI)

technology in CFX-5, developed

over a 12-year period in CFX-

TASCflow. For example, a hex

mesh created with ICEM Hexa

can be connected to a hybrid

unstructured mesh created with

the mesher.

A CFX-5 simulation involves

the solution of a set of coupled

nonlinear equations. The

nonlinear solution is obtained

by repeatedly updating and

solving a set of linearized

equations. There are many

approaches to achieve reliable

convergence, but the coupledmultigrid

method stands out.

The CFX multigrid-method has

Wednesday, March 10, 2004

See Us at SAE Show Booth #2143


Engineers from China tackle hybrids

Although there are some hybridelectric

vehicles on the road today,

the ac technology is being tackled

like there’s no tomorrow.

That is the case even in China,

where the levels of production of

conventional vehicles is booming

and where the latest technologies

are, for the most part, imported. The

world’s most populous country is

trying to get up to speed in terms of

hybrid-electric and other advanced

automotive technology. Participation

in the SAE World Congress is one

way to expedite the process, so it’s

not surprising to see engineers from

China in Cobo Center this week.

There will be a heavy concentration

of Chinese engineers at a

Wednesday technical session on

hybrid powertrains beginning at

9:00 a.m. in Room D3-17/18. One of

the papers at the session, Parametric

Design of a Parallel Hybrid

Powertrain for a Transit Bus, will be

presented by Minghui Liu, of the

Research and Development Center

of FAW (First Auto Works) Corp,

China’s largest car manufacturer.

Co-authoring the paper are two

other Chinese engineers, both from

Jilin University of Technology.

Five of the session’s eight papers are

authored by Chinese engineers.

In his paper, Liu says, “In

concept design and prototype

development of parallel hybrid

power train for transit bus one of

the main concerns is to determine

the appropriate parameters of

power train components. Utilizing

the developed off-line simulation

model of a parallel hybrid

powertrain, the study on the

influence of components’ parameters

on acceleration performance

and fuel economy of a transit bus

is completed."

The “guideline strategies of

parametric design of a parallel

hybrid powertrain for a transit

bus” are brought forward in the

paper: “Given the condition of

propulsion requirement, the

parametric design for this transit

bus are performed targeting

minimizing fuel consumption. It is

the conclusion that the appropriate

components’ parameters determined

by means of parametric

design can make parallel hybrid

transit bus achieve much better

acceleration performance and

much lower fuel equivalent

consumption than that of baseline

transit bus.”

Patrick Ponticel

Focus & select your business sessions...

The AVL Technology Theater at the SAE 2004 exhibition is industry’s

world stage for executive strategy steering the business in a complex

global marketplace.

ZF is taking to the road

At the Transmission & Driveline

Systems Symposium – New

Transmission Systems technical

session yesterday, researchers from

ZF discussed the design of the

company’s CFT30, a continuously

variable transmission (CVT) with a

chain driven variator that will be

used in the 2004 models of the

Ford 500, the Ford Freestyle, and

the Mercury Montego.

ZF’s CFT30 continuously variable

transmission was designed specifically for

six-cylinder automotive applications. It will

soon be on the market in several 2004 Ford


According to ZF, the CFT30 is

the first CVT that uses a chain drive

in a front-transverse installation

combined with a torque converter

for enhanced launch performance.

The transmission can handle the

310 N•m (230 lb•ft) available with

more recent six-cylinder engines. It

employs fully electronic controls

and can achieve better performance

and fuel economy results

than some recent four-speed

automatic transmissions and

some new six-speed

transmissions in the same

vehicle, claims ZF.

Located on the primary

axis of the CFT30 is the

torque converter, the

radial piston pump, the

planetary gear set for

reverse gear, and the

primary pulley. On the

secondary axis is the

secondary pulley with the

integrated park gear and

the transfer gear. A

transfer axis and a

conventional differential

axis follow. The final drive

can be varied in a range by

using different transfer

gear sets. The design of

the transmission negates

the need for a mechanical

torque sensor or any

mechanical feedback of

the sheave position.

Jean L. Broge

Ford’s Scheele to

keynote at SAE 2004

World Congress


Nick Scheele, President and Chief

Operating Officer of Ford Motor

Co., will deliver the keynote speech

at the SAE 2004 World Congress

Annual Banquet: Driven to Dream

on March 11, 2004. The banquet,

which will close the four-day event,

will be held at 7:00 p.m. in the

Renaissance Ballroom at the Marriott

Renaissance Center Hotel in

downtown Detroit.

Since assuming his current

position on October 30, 2001,

Scheele has been responsible for

Ford’s global automotive business.

Prior to his current position, he was

Group Vice President, Ford North

America, a job he assumed in

August 2001.

Scheele also

served as

Chairman, Ford

Europe, from

January 2000

through July

2001, and he

was Chairman

and CEO of

Jaguar Cars Ltd. Nick Scheele

from 1992 to

1999. Under his leadership, Jaguar’s

sales doubled and the company

regained its place as one of the

world’s top marques in brand image,

product quality, and customer


Scheele’s career at Ford began in

Europe in 1966 where he held

several successive senior purchasing

appointments in Ford’s British and

European operations before moving

to the U.S. in 1978. In 1988, Scheele

became President of Ford of Mexico,

where he directed manufacturing

and marketing operations.

In June 2001, the British Queen

awarded Scheele a knighthood. He

was awarded the Order of St.

Michael and St. George for services

to British exports. He serves on the

Advisory Board for the British

American Chamber of Commerce

and is on the Executive Committee

of the Society of Motor Manufacturers

and Traders.

Tickets for Thursday’s Banquet

can be purchased in Congress


Stop by the

SAE Bookstore for

your copy of the

Worldwide Automotive

Supplier Directory—

only $179!


Wednesday, March 10, 2004

Korea Autoparts & Accessories Show scheduled for October 2004

The first International Korea

Autoparts & Accessories (KOAA)

Show organized by S. Trade and

EASTEXPO in cooperation with

SAE will be held in Seoul, Korea, at

the Seoul Trade Exhibition Center

(SETEC) from October 27-29, 2004.

The Ministry of Commerce,

Industry and Energy, and the

Gyeonggi Provencial

Government are also event


Event organizers estimate participation

of more than 300 companies,

and will feature an operational

match-making section for

major purchasers; a technology and

marketing conference; and a cyber

KOAA show for those who are

unable to attend the show in Korea


This new annual event is held in

cooperation with SAE as part of an

Attention Nonmember


Enjoy all the technology

of next year’s World

Congress FREE!

MOU (memorandum of understanding)

recently signed by leaders of S.

Trade, SAE, and the Korea Trade

Center encouraging mutual

participation in each others’

exhibitions. SAE will organize

technical or management sessions

for the KOAA Show 2004, and the

society will also have the opportunity

to organize technical training

sessions at the event—all as a part

of the MOU.

S. Trade is a nonprofit Trade

Promotion Foundation specializing

in shows, matchmaking

business between South Korea

and U.S. companies, and international

auto parts.

For more information on the

event, please contact Brian Kim,

Director of S. Trade-Detroit Office, at,

248.223.0266, or 248.355.4911.

Jennifer Newton

Did you know that $100 of your

SAE 2004 full-conference registration

fee can be used as payment

for a year’s worth of membership?

That’s a year’s worth of SAE

membership and all the benefits

that it brings—for free! Plus, as a

member, you’ll gain access to all

the technology that is the World

Congress—for free at SAE 2005!

• Do it now

Submit a completed membership

application at the registration

desk when you pay the

non-member registration fee

on site. Member benefits, such

as 20% off SAE Bookstore

purchases, begin immediately!

• Do it later

Pick up an application at the

registration area or download

an application from the SAE

Web site and send the completed

application—with proof

of SAE 2004 registration fee

payment—to SAE World


Do it…and save!

SAE International

400 Commonwealth Drive

Warrendale, PA 15096

Wednesday, March 10, 2004


PPG pioneers

spray-on bedliner

The first application of PPG’s

Durabed is on a pickup truck bed,

but the protective coating system

might find additional uses.

“We are investigating other

applications for this unique

coating system,” said Dennis

Taljan, Director of Global Technology,

Automotive OEM

Coatings for PPG Industries.

Available as optional equipment

on the Nissan Titan,

Durabed is the result of a more

than one-year development

program. “During that time,

many technical challenges were

successfully resolved to create a

two-component polyurethane

coating that can be applied with

a high-speed process,” according

to Taljan.

The bedliner is applied

robotically after the vehicle leaves

the factory’s paint area. Beds are

removed from the trucks and sent

via conveyor to the bedliner

application area. They are coated

with the material, and then

carried by conveyor back to the

original vehicle before it arrives at

final assembly.

“The bedliner process is

relatively short since no bake time

is involved. The cure is ambient,

and the material is touchable

within minutes,” Taljan explained,

adding, “A significant

challenge was to slow the front

end of the cure process so that

the material would not cure in

the gun, and then hasten the

cure rate toward the end to

provide the desired consistency in

texture and gloss.”

In contrast to drop-in bedliners,

spray-on bedliners create an

airtight seal. “Drop-in bedliners

can move around in the bed and

create noise. This movement can

also result in abrasion and/or

scratching of the paint film. Water

can become trapped between the

drop-in bedliner and the truck

bed. And the combination of

trapped water and scratched

coatings film can lead to corrosion,”

according to Taljan.

Durabed’s surface texture is

accomplished “per customer

specifications via control of the

application process. The material

is applied in two coats. The

second coat is a dust coat that

provides the texture,” Taljan

explained. PPG’s Durabed is not

available in the aftermarket.

“Durabed is formulated for use in

an automotive OEM assembly

plant,” noted Taljan.

Kami Buchholz

Wednesday, March 10, 2004

SAE strengthens OEM coalition for the World

Congress—General Motors, BMW AG, Toyota

to host events from 2005 through 2007

SAE has reached agreements with

the host companies for its 2005

through 2007 SAE World Congress

events. General Motors Corp.

previously agreed to host the SAE

2005 World Congress, while BMW

AG (Bayerische Motoren Werke)

will now host the 2006 World

Congress event, and Toyota

Motor Corp. will host in 2007.

SAE in recent years has sought

to build a strong coalition of OEM

support and international representation

for its flagship event, held

each year at Cobo Center in

Detroit, MI.

General Motors has hosted the

SAE World Congress many times

over its 58-year history. BMW AG

became the first ever Europeanbased

manufacturer to host the

event when it did so in 2000.

Toyota Motor Corp. will become

the first manufacturer with

headquarters in Asia to host when

it takes the reins in 2007.

“Having host company agreements

from such top-notch

companies on three continents this

far in advance is a terrific development

for SAE World Congress.

With Ford’s great support this

year, with Phil Martens’ serving as

General Chairperson, Group Vice

President, Product Creation, Ford

North America, General Motors

hosting the SAE centennial

meeting next year, and then to add

companies the caliber of BMW AG

and Toyota in ’06 and ’07 is a best

case scenario for us” said Dave

Amati, Director of Automotive

Business for SAE. “When we are

able to actively engage companies

like these in a leadership role for

SAE World Congress, we’re finding

the event itself continues to

transform into something very

special,”Amati added.

Jim Queen, Vice President, North

American Engineering for General

Motors Corp., is the General Chair

for the SAE 2005 World Congress.

General chairs have not yet been

announced by BMW AG and Toyota

for the 2006 and 2007 SAE World

Congress events. Below are the

dates for the next three SAE World

Congress events:

SAE 2005 World Congress –

Sponsored by General Motors

Corp.: April 11-15, 2005

SAE 2006 World Congress –

Sponsored by BMW AG: April 3 -

7, 2006

SAE 2007 World Congress –

Sponsored by Toyota Motor

Corp.: April 16-20, 2007

All SAE World Congress events

will be held at Cobo Center in

downtown Detroit, MI.

High-resolution camera

Flir Systems’ thermovision A40V is a solution for industrial product and

process monitoring as well as security applications. The camera features highresolution

IR imaging; multiple connectivity interfaces; a maintenance-free,

longwave microbolometer detector, standard Ethernet connection; real-time

14-bit digital video output; plug-and-play setup; and multiple independent

target spots and alarms selected from menu-driven configuration controls.

The camera’s onboard software and electronics can discriminate temperature

variations as small as 0.8°C (33°F). The A40V was designed to operate

unattended for long periods in harsh industrial environments.

Booth 1429

Microscopy camera

Developed through collaboration with the

National Institute of Advanced Science

and Technology, the FocusScope from

Photron is a microscopy camera system

that significantly increases the depth of

focus displayed. Via a high-speed sensor

and extremely high-speed image

processing techniques, the FocusScope

has increased the depth compared to a

traditional system up to one hundred microns. A piezoelectric actuator

physically moves the objective lens full-scale at a rate of thirty times per

second while the camera records at 1000 frames per second resulting in

approximately thirty frames per second, each with a different focal point. In

real time the camera processor analyzes each of the frames to find those

sharply focused pixels and then integrates those pixels, along with the other

29 for that second, into a single “all-in-focus” image for display and

recording. Through adoption of Gauss’ law, the system produces the relevant

three-dimensional (X, Y, and Z) topographical image data, along with

imagery with a much greater field of focus than is available through conventional

microscope-mounted cameras, and all in real time. It features a C-

mount lens mount that can mount on practically any microscope to produce

512 by 512 pixel resolution imagery. All-in-Focus and Depth Image data are

output via BNC cables, while a three-meter CameraLink cable is used for the

digital output connection between the camera and Digital Interface Unit.

Booth 426


The SAE 2004 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.

Marking system

EFD, Inc.’s MicroMark precision-spray

marking system produces consistent spots

and stripes from 5 to 30 mm (0.2 to 1.2 in)

wide. It reduces downtime on automated

and semi-automated production lines.

Typical applications include color-coding to

differentiate between similar components,

pass-fail status indication, and designation as

to whether a process has been performed. A

precision-spray valve and low-volume lowpressure

air are used to make the uniform

spots and stripes without mist. A high-transfer efficiency and quick cutoff

improve part appearance and cleanliness, while a short microburst of air

after each shot keeps the nozzle from clogging and reduces maintenance.

A microprocessor-based controller simplifies system setup and operation

and can be interfaced with a programmable logic controller.

Booth 1245

Scanning technique

X-ray Computed

Tomography (X-ray

CT) from Hitachi is

an X-ray scanning

technique that

performs dimensional


density analysis, and integrity analysis of assemblies. The technique is

suitable for reverse engineering components and for the non-destructive

testing of components to improve quality and accelerate the engineering

process, thus reducing component development time and decreasing

costs. The technology includes StereoCooker software for CT dimensional

analysis and FeatureMaker to convert CT data to CAD data. Typical

automotive applications for the program include cylinder blocks, heads,

transmissions, and other powertrain components. X-ray CT technology is

applicable for materials such as aluminum, steel, plastics, and composites;

trial scans are available.

Booth 351

Test calibration

MTS Systems Corp. offers the

computer-aided engineering

(CAE) Calibrator software

product for their NASTRAN users

that leverages test and other

external data to interactively

compare, correlate, calibrate,

and automatically update CAE

models for structural dynamics.

The software ensures that a CAE

model’s performance matches

test data, other CAE models, and user-entered design targets. Beta testing

of CAE Calibrator confirms it updates models instantaneously, eliminating

the manual effort that is often required to implement design changes in

real models. Automated and interactive studies or iterations on potential

changes are also accomplished more quickly. The software will synchronize

orientation, scaling, and results and will update designs in the NASTRAN

input deck automatically.

Booth 621

Keypad technology

GM Nameplate offers an electroluminescent

(EL) keypad technology that integrates

EL lighting with elastomers to create highly

functional, lightweight, switch units that

use fewer components than conventional

keypads with light pipes or light dams and

mechanical switches. The keypads operate

at temperature ranges from -30 to +80°C (-

22 to +176°F) with a voltage range of 20-

200 V ac and a frequency of 50-3000 Hz.

Advantages include no light pipes to design

or mold, a 0.012-in (0.3-mm) flexible light

source, reduced power consumption, sealed top-surface, laser-etched

graphics, variable tactile response from the dual-layer elastomer

construction, and different day and night graphic colors.

Booth 1152

Test rig

A test rig from Aries Ingenieria Y

Sistemas, S.A. complies with

existing test protocols as well as

the new head-restraint testing

protocol proposed by the National

Highway Traffic Safety Administration.

The system is based on

electrical actuators and includes a

complete control system to

program force-loading profiles. Its

features include a high-precision

laser adjustment system, a

compact heavy-duty mechanical

design, and many possibilities of

test configuration, including open

code for the user.

Booth 432

Casting impregnation

The continuous flow impregnation

system from Godfrey & Wing

fulfills the need for direct-coupled

casting impregnation within

automotive manufacturing

facilities. It is based on a dry

vacuum- and pressure-process

where vacuum cycles work on the

part, not the air surrounding the

part, and resin is maintained in its

purest form, not entrained with air

or water. The part experiences a

significant positive pressure, and

recovery and conservation of resin

is used in lieu of recycling. Resin is

prevented from entering the

plant’s waste stream through

efficient recovery, negating the

need for additional equipment and

chemicals to process specialty

resins. Through automated,

repeatable handling, the system

processes the most complicated,

highly machined parts without the

risk of damage or contamination.

Booth 2652


Wednesday, March 10, 2004

Polyethylene resins

Raprex resins from Ion Beam

Applications (IBA) and its

subsidiary IBA Advanced Applications

provide improved physical

properties without the use of

chemical cross-linking agents. Use

of the resins precludes the need for

chemical additives. The crosslinking

is achieved before forming

the finished parts through radiation

processing of the base

polyethylene resin. The resins are

available in three grades: extrusion

grade raprex 200 for pipe, tubing,

containers, and profiles; injection

molding grade raprex 200 for tote

bins, pump housings, industrial

clamps, and luggage handles; and

film grade raprex 300 for steel pipe

sleeves, and timber pole sleeves.

Booth 1712

Refrigeration systems

Cryogenic industrial freezers from

Russells Technical Products Inc. are

capable of maintaining temperatures

as low as -120°F (-85°C). The

company's expanded product line

includes heavy-duty industrial freezers

for the heat-treat industry. Standard

sizes range from 15 ft 3 to 60 ft 3 (0.42

m 3 to 1.7 m 3 ) in chest-type and frontopening

configurations. Load

capacities range from 100 lb to 2000

lb (45 kg to 900 kg) and up. Options include microprocessor programming,

cycle timers, Nema 12 electrical, and disconnects.

Booth 744

Metering pumps

Metering pumps from Thomas

Magnete allow for high meteringprecision

with an exactly defined

swept volume and minimum noise.

The solenoid armature in the

pumps is simultaneously the pump

plunger. With no electrical current, all cavities are filled with fuel. When

current is fed to the coil, the armature displaces the piston against a

spring. The pump plunger raises a valve ball and expels the medium from

the pump while closing the supply apertures. When the current is

switched off, the spring presses the armature and piston back. This

induces a sub-atmospheric pressure in the pump space, and the fuel

enters through the reopened supply apertures.

Booth 2041

Snap rings

Smalley Steel Ring Co.’s

snap rings are made by coiling

flat wire, producing a snap

ring that has no protruding

ears or burrs to interfere with

performance. The rings are

stocked in carbon steel with

diameters ranging from 0.5 in

to 11 in (13 mm to 279 mm).

Special designs are available

and can be economically produced in stainless steel because coiling

produces no scrap. The rings can withstand high loads and impact


Booth 1653

Isolation systems

AirLock enclosure systems

from Simplex Isolation

Systems are modular

cleanrooms used for paint

lines, transmission and engine

assembly areas, and manufacturing

and assembly of

electronic controls and dash

components. They provide

contamination control, and

are available for use as modular dividers. Both soft-wall and hard-wall

models are offered, and each can be latched together depending on

intended use.

Booth 654

Wednesday, March 10, 2004


Pneumatic tools

BAND-IT pneumatic tools from

Idex Corp. provide a fast, highspeed,

uniform application of

stainless steel ties and clamps

with extended service life and

low maintenance. Features

include heavy-duty cut-off and

tensioning components, a long-life valving system, easy access to

maintenance components, and low-line pressure requirements.

Booth 1730


Lightweight CVJ

High-precision CVJ components

from IFA Maschinenbau GmbH

feature an eight-ball design for

reduced weight, lower centrifugal

forces within the CVJ and shaft,

reduced friction and vibrations,

and steady running. Centering by

the plug-in connection provides

axial separation from vibrations

caused by engine, gear, and

differential; and reduction of

assembly effort and time. Components

include the IHF-IFA High

Speed Fix Joint and the IHP-IFA

High Speed Plunge Joint.

Booth 2335

Rapid prototyping

The FDM vantage rapid

prototyping system from Stratasys

Inc. allows the use of hightemperature,


engineering thermoplastics. The

system comes standard with ABS

and polycarbonate thermoplastic

modeling materials. The polycarbonate

offers high tensile-strength

and flex-strength, a hardness

exceeding ABS, a high heatdistortion

temperature, dimensional

stability, and durability

sufficient for rapid manufacturing

applications. The system comes

with the firm’s WaterWorks watersoluble

supports for ABS modeling,

which allows users to dissolve

model-support material rather than

remove it by hand.

Booth 737

System engineering

Imagine Software Inc.’s

AMESim fluid power

engineering and simulation

software is a complete

system-engineering platform

that allows the engineer to

model complex multidomain

systems, run

simulations, and perform indepth

analysis. The package

includes 19 libraries and an increasing number of interfaces to packages

such as MATLAB/SimuLink and ADAMS. New libraries are incorporated

for air conditioning, two-phase flow, and planar mechanical. The air

conditioning library provides steady-state and transient simulation,

multiple refrigeration components, predictive modeling, and geometric

editing. The two-phase flow enables steady-state and transient simulation,

multi-fluid functionality, complex design capability, and time and

frequency domain analysis. The planar mechanical library is for mobile

hydraulic applications.

Booth 2052

Design and simulation software

Version 6.1 from

Integrated Engineering

Software is a 2-


symmetric design and

simulation software

package that includes

magnetostatics, electrostatics,

and eddy currents. It features the hybrid BE-FE method that

combines the strengths of both the boundary-element method (BEF)

and the finite-element method (FEM). Users can choose which solver

best suits their application. The BEM handles open-region problems

more effectively, allowing accurate field calculations, and requires a

small amount of data to be stored for each solution. The FEM addresses

non-linear problems, and the solution time is quick if the calculation

region is small.

Booth 1275

Non-contact measurement device

FARO Technologies’ FARO ScanArm

is a seven-axis contact/non-contact

measurement device with a fully

integrated laser scanner. Users can

collect simple-point variations with the

arm’s hard probe at a rate of more

than 13,000 points per second, and

then laser-scan the sections requiring

larger volumes of data. The ScanArm

has a feature that samples an object’s surface and adjusts the scanner’s

settings to ensure optimal scanning. It can be used for such non-contact

measurement applications as inspection, cloud-to-CAD comparison,

rapid prototyping, reverse engineering, and 3-D modeling.

Booth 1301

Eddy current instrument

Zetec, Inc.’s InSite-HT eddy current instrument

verifies proper hardness, case depth,

and material mix at production line speeds.

The system features intuitive controls, menudriven

display, built-in language selection,

and automatic voltage switching. The system

can be used for basic bench-top or complex

multi-station inline inspection, and reliably sorts parts with single- or

multiple-defects at high sample rates. It is available in 2-, 4-, and 8-coil

versions and operates in 32°F to 113°F (0°C to 45°C).

Booth 864

Wednesday, March 10, 2004

Headlamp adhesive

ADCO Products, Inc.’s Köramelt 107 is a hot-melt moisture-cure

headlamp adhesive that features a wider adhesion spectrum, higher

strength values, and lower application temperatures. Köramelt 107

offers rapid green strength development that enables users to remove

work-in-process capital and free up plant space. The product is offered

in cartridges, pails, or drums and is easily applied using a variety of

processing equipment.

Booth 1535

Dispensing system

The Ultra TT Automation Series

from EFD is a convenient automated

tabletop assembly process

that combines accurate programming

with closed-loop dc servo

control and powerful drive motors

for fast, precise positioning of the

dispensing tip. Benefits include

improved productivity, process

consistency, and less scrap and

rework. Benchtop bonding, gasketing, and filling operations can all be

programmed using a Palm handheld. Graphic user interface software

provides improved control of positioning and dispensing parameters. The

systems are offered with either 325 x 325 mm (13 x 13 in) or 525 x 525

mm (21 x 21 in) work envelopes and are fully compatible with a wide

range of dispensing valves and syringe reservoirs.

Booth 1245

Software infrastructure

Decomsys and 3Soft offer TimeCore, a standard software module that

features a comprehensive set of building blocks for the construction of a

software infrastructure in embedded real-time systems that demand faulttolerance

and a synchronous time-driven approach. TimeCore can be

incorporated in third party design processes and will streamline the

development process to reduce costs, according to the companies. A

getting-started-guide minimizes the learning effort and decreases

common mistakes, while standardized software components increase the

overall test coverage of the application.

Booth 1327

CAN card

The PXI 3051 is a CAN card from

Göpel Electronics that offers

additional functions over its

predecessor, the PXI 3050. The PXI

3051 does not require special

plugs because a 25-pole connector

sends and receives all signals. Two

ports on the basis board and two

on the PXI card realize the higher

hardware performance. Each

channel is a 32-bit CAN controller

so the card can be used with

improved efficiency. An input and

output line is available for each

port, allowing trigger functions to

be called on the unit under test or

enabling further measurement

instrumentation. The trigger line

also can be used via the PXI bus.

The PXI 3051 features onboard

tools such as network management,

while its software offers

extended ramp functions for the

output of messages.

Booth 2401

CFD software

Pointwise, Inc.’s Gridgen Version

15 is meshing and pre-processing

software for computation fluid

dynamics (CFD). Features of this

version include minimizing a user’s

interaction with large and

complex meshes, Native CAD

readers, and improved solver

interfaces. Tools include a CADstyle

layer manager, pick masks,

and grid groups. Re-extrusion, a

new tool for continuing the

extrusion process for a mesh,

includes complete recall of all

attributes and has the ability to

backup the extrusion as well as

continuing forward. A qualitybased

smoothing technique

increases the number of extrusion

steps by a factor of two and the

extrusion distance by a factor of

three or four.

Booth 1016

Light modeling

The CATIA V5-integrated SPEOS

software from OPTIS unites optics and

CAD, allowing users to simulate

photometric and colorimetric characteristics

while the visual ergonomics

application simulates and analyzes the

interaction between the part and its

lighting environment. The product

appeals to designers and integrators of

dashboards, exterior lighting, car interiors, switches and controls,

electronics systems, and LCD displays because it allows them to work on

the lighting and optics while remaining in the CATIA V5 environment.

Booth 2712

Steel products

Topia Corp.’s products are

made of high-tension steel.

Exhibited is a steering hanger,

which shows the extremely

short lead time for product

delivery. The firm can manufacture

the component in only 20 days—from receiving design data until the

product is ready for shipment.

Booth 556

Catalytic converter material

Unifrax Corp. has combined its

magnesia-silicate Isofrax 1260°C

(2300°F) fiber with an advanced

paper-manufacturing process to

maximize the performance of its

IsoMat AV catalytic converter support

mat. IsoMat AV offers thermal stability

with a continuous use temperature of

700°C (1290°F), and is engineered to meet the performance requirements

associated with typical catalytic converter applications.

Booth 1013

Wednesday, March 10, 2004


Rubber lubricant gel

P-80 THIX from International Products Corp., is now offered in a

smaller, 200-ml (7-oz) container. P-80 THIX is a thixotropic gel designed

to lubricate rubber parts, and has a flip-top lid, making use simpler in

some assembly and manufacturing tasks. The gel formula is useful when

parts are in an overhead assembly line, or aligned vertically to the floor.

The new smaller size can be applied directly from the bottle.

Booth 1652

Multilayer film

Senotop is a multilayer film from Senoplast

with a base layer of styrol-acrylinitril with acrylic

modified rubber (ASA), and polycarbonate (PC)

blend and a UV-stable co-extruded top layer in

solid and metallic colors. The carrier blend

material combines the processability and UV

resistance of ASA with the advantages of PC,

including stiffness at high temperature and

strong impact behavior. The top layer offers

improved surface finish with high gloss, chemical resistance, and resistance

to scratch and wear. The Senotop film surface displays equal performance

when compared to automotive standard paints. It is thermoformed on

vacuum-forming machines and is trimmed and reinforced by injection

molding with thermoplastic, with or without glass filling, or by polyurethanefoam

technologies. Senotop is suitable for vehicle roofs, interior parts, wind

deflectors, mudguards, and bumpers.

Booth 1327

Simulation software

Ansoft’s ePhysics allows users to couple thermal and

stress simulation to the electromagnetic solution generated

by Maxwell 3D and HFSS and is offered as an add-on

to these products. A multiple analysis environment created

for the electrical engineer, ePhysics performs a complete

virtual simulation of a design. Its thermal feature provides

a steady-state thermal and transient analysis capability,

including convection and radiation and one-way coupling

between ac magnetic and thermal, while a static stress

capability offers one-way coupling between electrostatic,

magnetostatic, ac, and thermal solvers.

Booth 2214

Circuit chip

AdvanTech International offers

the Tamagawa Seiki Smartcoder

AU6802N1 resolver-to-digital

integrated circuit (IC) chip. Both the

Smartcoder IC and the Singlsyn

variable-reluctance resolver were

developed for automotive applications

that require absolute position

and speed sensing and/or operate

in severe environmental conditions,

including steering angle, throttle

position, automatic clutch, suspension,

pedal position, and x-by-wire

sensor vehicle applications. The IC

chip was designed to facilitate

acceleration at both the high and

low speed electric motor/generator

applications inherent in hybrid

vehicle powertrains. Features

include a compact size of 10 x 10

mm (0.4 x 0.4 in) and an operating

temperature range of -40 to

+125°C (-40 to +257°F).

Booth 1735

High-speed camera

The FASTCAM-X 512 PCI from

Photron USA provides high-speed

imaging capabilities as fast as

32,000 frames/s with a maximum

achievable resolution of 512 x 512

pixels at speeds up to 2000

frames/s. The 512 PCI is available

in both 30-bit color and 10-bit

monochrome configurations and in

two models: 2000 and 32,000

frames/s. Two memory sizes are

offered with 1.3 gigabytes as

standard, providing capacity for

more than 4000 full-resolution

images. An available PCI expansion

system allows the PCI card to be

placed in a cradle for easy connection

to a laptop computer. The

camera is designed to run under

Windows NT 4.0, 2000, and XP.

Booth 426

Environmental testing

Temptronic Corp.’s TP04300B ThermoStream

and interchangeable ThermoChamber compact

environmental test chamber offer fast temperature

cycling, thermal shock testing, and environmental

testing of electronic control units, sensors, critical

electronics, printed circuit boards, and other assemblies

at -80 to +225°C (-112 to +437°F). The

portable, modular system can be used at the

benchtop, design lab, or production station, offering

a cost- and time-efficient alternative to large

chambers or ovens. Features include finer temperature

control directly at the sensor, configuration for testing different sensors

or assemblies, and portability for sharing among multiple users. The test

chamber offers a touchscreen including graphing and datalogging capabilities.

ThermoStream can be directly connected to a user’s application via a

flexible extender thermal air hose that reaches up to 6 ft (1.8 m) or with a

compact ThermoChamber attached directly to the ThermoStream base.

Booth 848

Imaging system

Redlake has added the HG-LE high-speed

digital camera to its MotionXtra family of

imaging systems. Built on the technology of

the HG-100K, the HG-LE offers a highquality,

mid-performance solution featuring

a fast frame rate of 1500 frames/s at 752 x

752 resolution. Two tiers of performance are

offered, and a 5-ms electronic shutter eliminates motion blur during the

recording of very-high-speed events. The self-contained HG-LE’s rugged

design enables it to withstand forces up to 100 g in any axis, making it

suitable for automotive crash, airbag deployment, and component safety

testing. Two basic models allow customers to choose either color or

monochrome according to application needs.

Booth 622


Wednesday, March 10, 2004

INTEGRATION...Continued from Page 1

of engineering and purchasing departments, which in the past have

had a reputation of working against each other more than with

each other.

“Today, engineering and purchasing are more closely interfacing

with each other as well as suppliers to benefit all,” he said. “Our

engineers have come to understand that purchasing is an enabler, not

an obstacle, in vehicle development. And, conversely, purchasing has a

much greater understanding of the engineering processes required to

create great cars and trucks.”

No matter on what level technological integration occurs, internally

or externally, it ultimately comes down to each individual person to

make it succeed throughout all the levels. “[GM] challenges its engineers

daily to develop innovative function engineering solutions that

improve people’s lives,” said Queen. “The most advanced technologies

in the world can result in customer dissatisfaction if they aren’t properly

integrated and user-friendly.”

In the long run, “the integration of functional technology will be the

key performance differentiator between companies that lead and those

that fall by the wayside,” said Queen.

Jean L. Broge

Owens Corning sounds the right notes on muffler filler

The use of absorptive mufflers is

growing in North America, much

to the delight of Owens Corning

(Booth 2561). The company is a

major supplier of glass-fiber

filler for the application. Nissan

is using it on its new Titan pickup


The path of exhaust pipes through the

muffler determines the level and type

of sound attenuation achieved in

reflective type mufflers (left side),

while glass fiber does the job in

absorptive types (right side).

There is no filler in reflective

types, sound attenuation/

modification being achieved via

the geometry of the exhaust pipe

circuit through the muffler body.

Reflective-type mufflers

generally run hotter than absorptive

types, meaning heat shields

are necessary in more cases with

the former, Hires said. Another

advantage of absorptive types is

that they are better able to deal

with the wider range of high

frequencies produced by vehicles

using displacement-on-demand

engine technology, he added.

Patrick Ponticel

INDUSTRY...Continued from Page 1

attribute for 3%. He said an effective way to convince drivers that

new technologies “know” better than do humans what steps should

be taken in crash situations is to set up a rating program for the

technologies. It could be similar to, or part of, NHTSA’s New Car

Assessment Program in which the agency rates vehicles for their

ability to protect passengers in frontal impacts, side impacts, and

rollovers. A new rating program could also be established to assess

various active-safety systems.

Ford Vice President of Environmental and Safety Engineering

Susan Cischke said a key to successful integration of new active

safety technologies into vehicles is making sure they are not too

difficult for drivers to understand and take advantage of.

Denso (Booth 1716) is concentrating on the sensor technologies

behind new active safety systems. For frontal collision avoidance, it is

developing radar, millimeter-wave, and optical sensing systems, said

Hiroshi Fujinami, a member of the Board at Denso and General

Manager of the company’s Safety and Chassis Systems Product Division.

Patrick Ponticel

CHASSIS...Continued from Page 3

avoiding crashes, Ziebart added, and suppliers and vehicle manufacturers

need to provide consumers with information about these advances.

Continental has been working to demonstrate the safety potential of

networking passive and active vehicle systems. Its “30-meter car” is

comprised of such components and systems as linked tires, air springs,

variable dampers, and electrohydraulic brakes to form an optimized overall

system that allows stopping distance from a speed of 100 km/h (62 mph)

to be cut from 39 to 30 m (128 to 98 ft).

The company’s goal is the total integration of key safety components.

Its latest ESC-based project, called the Active Passive Integration Approach

(APIA), links existing systems such as ABS, ESC, airbag control, and

adaptive cruise into one network, with other active and passive safety

components to be added later. The key APIA component is additional

software in the brake ECU that detects traffic hazards, determines the

probability of an accident, and initiates a staged response to protect

occupants and other road users if necessary.

The next stage in ESC development will be to include “electric steer

assisted steering” driven conventionally by a hydraulic pump, with an

epicyclical gear unit powered by an electric motor. ESC can be augmented

in the APIA by active rollover protection, which rapidly applies the brakes

with a high burst of pressure to the appropriate wheels to interrupt the

rollover before it occurs. Advanced pre-crash sensors will play a key role in

detecting crash events before they occur and preparing safety systems for

optimal response. Lane-keeping support will be enabled by cameras that

detect unintentional deviation from a lane by warning the driver via

vibrations in the steering wheel.

Kevin Jost

Wednesday, March 10, 2004

The transition from reflective

mufflers to absorptive ones in

Europe began about 20 years ago

and today about 60% of mufflers

sold there are of the absorptive

type. The percentage in North

America is only about 10% since

the market experience with glass

packs from years ago was a

negative one, with the fiber often

being blown out. That is not an

issue with Owens Corning’s

Silentex product, which is a

continuous strip, said Howard

Hires, Business Manager for

Owens Corning North America.

SOFTWARE...Continued from

Page 1

generation,” said Jason Fortier,

Global Vice President of Embedded

Control Tools at ETAS.

Hanselmann echoed that view by

saying, “Code generation will not

be a push-button technology.”

One thing that will help

software regardless of how it is

created is to reduce the complexity

of writing unique code for each

platform. “Standardization and

reuse are absolutely key, but that’s

easy to say and difficult to do,”

said Robert LeFort, the panel

moderator from Infineon Automotive

and Industrial.

Modeling is among the other

development issues that will

change the way vehicles and

subsystems are designed in the

future. It will change the process

because errors and problems can

be found early in the process, but

the payoff can be worthwhile.

“Modeling can lengthen design

time, but it shortens overall time to

production,” said Jack Little, CEO

at The MathWorks.

Terry Costlow


Removing hexavalent chromium

Henkel Technologies’ (Booth 927) Alodine 4595 is a chrome-free

aluminum wheel pretreatment that offers enhanced corrosion protection

and paint adhesion, as well as eliminates legacy cost, according to the

company. Made from a blend of organic polymers and inorganic metals,

Alodine 4595 does not require additional manufacturing process steps,

such as extra rinse and pretreatment stages. The technology was implemented

in December 2003 by one of Henkel’s wheel-manufacturing

customers, with four additional customers expected to begin using it by

the end of this year.

Jean L. Broge

Dura gives windows a lift

At a press conference on

Tuesday, Larry Denton,

President and CEO of Dura

Automotive Systems, Inc.,

outlined his plans for the

future. One key aspect of his

strategy was investment in

new technology. Some of

Dura’s ideas are on display in

Technology Salon A.

An example of alternative

thinking is a new window-lift

system that offers OEMs a

lightweight alternative to

traditional window regulators.

Made from a lightweight, selflubricating,

proprietary, highstrength

polyamide material,

Performance engineering for all

The UK Trade & Investmentsponsored

Performance Engineering

Pavilion, located at the center of the

show floor, made its SAE World

Congress debut on Monday. “This

year you will see a theme throughout

the show: performance engineering,”

said Robert Chalker,

Director of Sales and Marketing for

SAE. “We believe hard-core, cuttingedge

engineering is often initiated in

the performance sector of our

business,” continued Chalker, and

from there it “trickles down” into

more mainstream passenger


According to Jeremy Burne,

Automotive Sector Specialist for

UK Trade & Investment (Booth

2042), the organization was

interested in sponsoring such a

pavilion because the UK has a

successful history in motorsports

and performance engineering. The

pavilion hosts a number of UK

companies, including Cosworth

Technology (Booth 1947),

Prodrive (Booth 1946), and Lotus

Engineering (Booth 1933).

The UK has “a tradition of

supporting independent design

and engineering firms that provide

The RackLift power window regulator from

Dura Automotive Systems eliminates most of

the traditional mechanism to free up space

inside the door cavity.

Dura’s RackLift system is fully recyclable and provides a 10 to 14 lb (4.5 to

6.5 kg) mass savings when installed on a four-door vehicle. Its electromechanical

lift mechanism uses a dual rack-and-pinion configuration that

eliminates unwanted horizontal side forces as well as the need for overpowered

motors that are prevalent in current automotive window systems.

The window-lift systems are engineered to be applicable for OEM

factory installation or as an integral part of a complete door module.

In addition to the dual-rail rack with an attached base housing, RackLift

consists of a high-efficiency and lightweight drive motor, drive gear, slave

gear, and appropriate glass-attachment device, such as glass clamps. The

base-motor-gear assembly drives the glass up and down the all-plastic rack.

RackLift is compatible with one-touch-up and express-down, and

incorporates anti-pinch safety technology. Other advantages of the technology,

according to Dura, are reduced travel time, fewer components, noise

reduction, and simplified installation.

A major OEM will feature RackLift in a MY2005 vehicle.

David Alexander

engineering [expertise] to vehicle

manufacturers,” said Burne. “It’s

not just about making fast cars; it’s

about…the business processes and

specialized knowledge, the ability

to solve problems quickly, and the

ability to tackle [unique] projects.”

Burne believes that independent

design and engineering firms will

be used for more projects in the

near future as automakers continue

to move into low-volume,

niche markets. One of the main

reasons for this trend, he noted, is

that performance companies tend

to be “smaller, more flexible, and

faster working” than traditional

Tier 1 and 2 suppliers.

“There’s a pool of resources and

knowledge that is performance

engineering, and you can apply it to

whatever you want,” said Burne.

Vehicles such as BMW’s Mini and

some of Chevrolet’s small passenger

cars make use of performanceengineering

principles, he said, as

do Chrysler Group vehicles

powered by the Hemi engine,

noting that Ricardo (Booth 2222)

was involved with the design of the

V8 as part of an extended team.

Ryan Gehm

Exhibit Directory


The following is a Directory update

as of March 9, 2004.

NuForm Rolling Corp.

315 Nantucket Blvd.

Scarborough, Ontario M1P 2P2


Booth 1315

Nuform roll forms parts for the entire vehicle such as seat

track, window regulators, crash beams, chassis and door

beams. Using strict tolerances, hot rolled, cold rolled, HSLA

and Martinsite material. Nuform has a proven track record

with leading Tier 1 companies and manufactures over 10

million parts a year.

Ove Arup & Partners Detroit Ltd.

1625 West Big Beaver Rd., Suite C

Troy, Michigan 48084 United States

Booth 1945

Arup Vehicle Design Group provides vehicle styling,

structural analysis, manufacturing analysis, software and

methods development services to the world automotive

industry from engineering centres in the UK, Detroit and

Tokyo. Services provided range from concept design and

development studies through to structural and production

feasibility assessments.

Safety trails cost

atop DuPont/SAE


Thirty-three percent of respondents

to the 10th annual DuPont

Automotive/SAE Survey said only

cost is of more concern than safety

in the design of next-generation

vehicles. Surveyed were

preregistrants for the SAE 2004

World Congress. Ranking behind

cost and safety (13%) were

alternative powertrains (12%) and

fuel economy (12%).

Respondents also indicated that

they believe safety is the vehicle

feature that consumers most want

to see improved. Sixty-six percent of

respondents said safety is among the

top-five consumer concerns; while

47% believe vehicle performance is

a top-five concern. Next came

entertainment technology (37%),

fuel-efficient vehicles (16%), and

cleaner powertrains (25%).

At a Tuesday morning press

conference, Diane Gulyas, Group

Vice President of DuPont Electronic

and Communication Technologies,

briefly reviewed the survey and

spoke about how her company is an

enabler of safety through its ceramic

substrate and other technologies.

She said her division is growing more

than any other DuPont Automotive

unit as electronic safety-related

content in vehicles climbs steeply

and steadily. Gulyas cited a Strategy

Analytics Inc. study to show that

there will be more demand for safety

than for any other vehicle system.

DuPont is showing some of its

safety-related technologies in Booth

1643. Blind-spot detection is an area

of concentration for the company,

and headup and occupant-sensing

technologies are among others

being studied intently at DuPont.

Patrick Ponticel


Wednesday, March 10, 2004

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