THURSDAY - SAE International

THURSDAY
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The right formula
”You’re hired” are words that
several former Formula SAE competitors
heard after they graduated
from college.
”Without this organization, I
wouldn’t have been able to meet
the people, and get the jobs,” said
Eric Weber, who landed a job with
Honda’s performance development
group before taking his current
job with Mitsubishi‘s motorsports
operation doing engineering support
work for the company’s World
Rally Team.
In his first week at Rochester
Institute of Technology (RIT), Weber
joined the Formula SAE team.
That decision proved invaluable
when Weber—while talking about
the racecar’s fuel injection—impressed
the judges, who were
Honda engineers.
Another RIT alumni said that the
networking opportunities that arise
from participating in Formula SAE
are great for student engineers and
employers. “It’s critical in developing
and identifying engineering
SAE065: SAE Collegiate Design Series competitions prepare engineers well to hit
the ground running at automotive companies, according to “Heroes of Formula
SAE” panelists.
See FORMULA, Page 17
India panelist eschews ‘mindless growth’
That India has the potential to become more like the U.S. in terms of the
size of the automotive market was a point of agreement among participants
of a Wednesday afternoon FEV Technology Forum panel discussing
that Asian country’s prospects.
But at least one panelist brought to mind the saying: ”Be careful what
you wish for; you just might get it.”
India Panel participants, including Syed Shahed (second from right), discussed the
great potential of the Asian country—both good and bad.
See INDIA PANELIST, Page 17
Research success through collaboration
“It’s not just about pure research.
Rather, it’s about development success,”
said Dr. Burkhard Göschel,
Member of the Board of Management
of BMW, during his keynote
address in the AVL Technology Theater
on Wednesday. BMW assesses
research and development success
according to two critical factors: the
output of innovations and the efficiency
of the development process.
“Partnerships provide the
required freedom to set [global]
standards in our fields of core
competence,” said Göschel. “We
focus corporate resources on fields
of development that contribute
to strengthening the brand and
differentiating it from competitors.
Partnerships offer us access to
further innovations and provide the
opportunity to rapidly integrate them
into our vehicle concepts.” He added that the application of industry-wide
standardized components offers significant cost benefits resulting from
economies of scale.
BMW adopts different working models depending on the scope and
objectives of the cooperation. The company supports industry-wide partnerships
with other OEMs and Tier 1 suppliers to establish standards and
interfaces. Partnerships with other OEMs make sense for the development
of complex components such as engines. And internal resources can be
freed up through the use of integration and system partners.
Dr. Göschel will be the SAE 2006 World Congress General Chairperson.
David Alexander
Andersson talks buying power
General Motors makes a majority
of its annual $85 billion in global
purchases in its home country.
”Fifty-nine percent of what we
spend globally goes back to companies
with U.S. headquarters,” Bo
Andersson, Vice President of Global
Purchasing and Supply Chain for
General Motors, said during a
Wednesday afternoon keynote address
to an AVL Technology Theater
crowd.
GM annually pays $64 billion
to North American-based suppliers.
On a more geographic-specific
tally, $12 billion goes to Michiganbased
suppliers. In contrast, China
accounts for a mere $200 million
in export purchases, according to
Andersson.
All of the money coming from
GM coffers goes to 3500 global
suppliers who collectively account
for 160,000 part numbers on a
daily basis. Since suppliers are supporting
21 major global launches,
Dr. Burkhard Göschel, Board of
Management, BMW, said that the
BMW Group aims in the long term to
develop and enable the world’s best
partner network in the automobile
industry.
“Technology is critical to GM,” according
to GM’s Bo Andersson. “We need
technology that offers customers value,
not technology for technology sake.”
it is vital that new programs have
the right quality at the right time
for the right cost, according to the
purchasing czar.
Of course, a flawless launch
does not happen by chance. “This
is teamwork. Typically, 50% is GM,
and typically 50% is the responsibility
of the supply base,” said
Andersson.
Today’s Congress
Highlights
• Keynote Address: Military
Mobility—Lessons Learned
and Challenges for the Future
General Benjamin S. Griffin,
Commanding General, U.S. Army
9 a.m.
AVL Technology Theater
• Technology Licensing—A
Faster, Cheaper, Better Way to
Market
9 a.m.
FEV Innovation Forum
• Industry’s Role in the
Global Military Mobility
Challenge—Sustainability,
Maintainability, Rapid
Deployment
10 a.m.
AVL Technology Theater
• Keynote Address
Dr. Samuel W. Bodman,
Secretary, U.S. Department of
Energy
Noon
AVL Technology Theater
• Pre-Banquet Industry
Networking Reception
5 p.m.
GM World, Marriott Renaissance
Center
• SAE 2005 Annual Banquet:
The Future Starts Today
Principal speaker: G. Richard
Wagoner Jr., Chairman & CEO,
General Motors
7 p.m.
Renaissance Ballroom, Detroit
Marriott Renaissance Center
Remember to pick up your
FREE SAE World Congress
TV DVD today in the bins
located outside of each
exhibition hall entrance.
Achieving the best cost does not
happen by luck either. Andersson
cited various examples of suppliers
who made changes that brought
about cost savings. In one instance,
the relocation of a seat-side airbag
to a door translated to a 27%
cost savings. Andersson said the
recent project was accomplished in
16 weeks and that, in the future,
several vehicles will adopt this packaging
method.
In another example, 30 process
steps were eliminated from a paint
See ANDERSSON, Page 17
Thursday, April 14, 2005 1

FORMULA... Continued from Page 1
creativity, talent, and passion,” said
Lynn Bishop, a Director of Engineering
at Pratt & Miller Engineering.
Bishop noted that Pratt & Miller has
37 staff engineers, with 16 having a
Formula SAE connection.
Alba Colon, current Chevrolet
Program Manager for the NASCAR
Nextel Cup Series, was a founding
member of the Formula SAE team
at the University of Puerto Rico.
She landed her first automotive-related
job, as data-acquisition engineer
at General Motors, from her
Formula SAE involvement. “There’s
so much you learn in one year,”
Colon said to the professional and
student engineers in the audience
during the “Heroes of Formula
SAE” panel in the FEV Innovation
Forum this week at the SAE 2005
World Congress.
Mark Coffill, Manager of Simulation
and Chassis Development for
Dodge Motorsports, participated
in Formula SAE while attending
Western Michigan University. He
also encourages young engineers
to join the Formula SAE ranks. “Get
involved,” said Coffill, “That’s the
most important thing you can do.
Start the networking.”
The chief vehicle engineer for
Ford SVT relished his Formula
SAE activities from two different
SMARTER DUMMIES... Continued from Page 3
campuses, Brown University
and Cornell University. While at
Brown, Jay O’Connell helped build
a racecar in 15 weeks. “It was the
lightest car at the event—409 lb,”
said O’Connell. The 40-hp (30-kW)
entry placed third out of 20 entries
in the competition years before
Formula SAE moved well past 100
teams.
Erich Heuschele, a Western
Michigan University graduate, still
enjoys getting behind the wheel of
a racecar. “Formula SAE sparked my
interest in racing,” said Heuschele,
a vehicle dynamics specialist for
DaimlerChrysler‘s SRT (Street and
Racing Technology). His years-long
passion for racecar driving includes
several SCCA titles, including the
1996-98 SCCA Pro Racing Neon
Challenge Champion. “Formula
SAE stirred my passion for racing
to the point where it became my
personal hobby,” he said.
Marques McCammon, Director
of Product and Business Planning
for ASC, participated in SAE Mini
Baja while attending North Carolina
A&T. “Whether it’s Formula
SAE or SAE Mini Baja, participation
teaches you how to take the theoretical
and make it practical,” said
McCammon.
Kami Buchholz
has three sensors,” said Arp. “These units have a battery so that if the
cable breaks, data won’t be lost.” Along with their new memory capacity,
the dummies are also capable of some signal processing.
Dummy maker First Technology Safety Systems Inc. is also using
compact data-acquisition modules inside its robots, making it possible to
put 120 sensors in a dummy. The company’s previous model had only 64
sensors.
First Technology uses a data-acquisition unit that measures 25 x 54 x
84 mm (1.0 x 2.1 x 3.3 in), about the size of a cigarette pack, said Z. Jerry
Wang, Senior Project Manager at First Technology. Those modules also
store data from sensors.
The data-acquisition modules use the same connections, so they can
be interchanged. Each sensor now has an individual identification number,
dramatically simplifying setup.
Though dummy technology is moving forward, the new models are not
expected to see rapid acceptance.
“If you’re building a new facility, these new dummies are very desirable,”
said Bill Hurley, Market Development Manager at the Center for
Advanced Product Evaluation, a testing facility in Westfield, IN. “But this is
a capital intensive business, if you’ve already got your platform set up, it’s
difficult to justify the expense of replacing it.”
Terry Costlow
SAE 100 grand prize winners
To view the list of 100 early registrants for the SAE 2005 World Congress
who won an SAE 100th anniversary leather jacket, and the one
person who won a trip for two to New York City, visit the SAE Store in
Wayne Hall or check out www.sae.org. Winners should go to the SAE
Store to provide size and shipping instructions for their prize.
ELECTRONICS... Continued from Page 3
Modeling can reduce the number
of prototype vehicles and make
tests of these prototypes more
efficient. “We can weed out a lot
of bad designs before they make it
to the test track or wind tunnel,”
Landon said.
The cost savings that arise
when modeling replaces prototype
testing are substantial. “Prototype
testing can cost several thousand
dollars per hour of testing. Simulation
time on the computer is more
or less free,” said Peter Schoeggl,
Vice Head of Product Line Racing at
INDIA PANELIST... Continued from Page 1
That cautionary note was sounded
by Syed Shahed, Vice President
of Honeywell, Garrett Engine
Boosting Systems (and former
SAE President). Speakers preceding
Shahed painted a promising picture
for the developing country—one
where larger cars with larger-displacement
engines fill the streets.
The second-to-last speaker, Shahed
was discomfited enough by what
he viewed as the “spirit” of those
presentations (i.e., that India should
strive to be like the U.S.), that he
said, “I’m not sure the world could
afford it.”
He went on to say that he has
no emotional or logical reason to
want to deny to the citizens of his
homeland the same “quality of
life” that he enjoys as an executive
in Los Angeles. But if India did rise
to the same standard of living as is
enjoyed by Americans, “It would be
ANDERSSON...
Continued from Page 1
procedure. The process makeover
means a reduction in lead-time by
six months, less complexity, and
lower costs to the supplier and GM.
While purchasing decisions
certainly have a lot to do with cost,
innovative ideas still get noticed.
“Technology is critical to GM.
We need technology that offers
customers value, not technology for
technology sake,” said Andersson.
For suppliers who worry that an
innovative idea will land in competitor
hands, Andersson said, “We are
not shopping your technology.”
However, to protect unique technology,
patents and/or information
shields are worthwhile options. If a
supplier has what Andersson refers
to as “sensitive technology,” that
supplier may want to hold back
some of the proprietary information.
Kami Buchholz
AVL. Engineers can run thousands
of simulations, often at night so the
results are ready the next workday.
Come race day, electronic
technology inside the vehicle has
already made a big impact in these
racers. “A typical F1 car has more
than 150 sensors, plus a number of
very high-speed actuators including
the ignition and injector,” said Peter
Waeltermann, Lead Applications
Engineer at dSpace GmbH.
But as electronic controls move
deeper into the engines, it won’t
take as many people to maintain
a global disaster” for the environment,
he said.
In the question-and-answer
period shortly after his presentation,
someone from the audience asked
why he prefers that India remain
underdeveloped. Why not instead
focus on limiting or rolling back
development in the U.S. and letting
India catch up?
In response, Shahed clarified his
position to say that what he does
not want to see is “the same kind of
mindless growth” as has occurred
in the U.S. And he added that what
has happened in the U.S. in this
regard “is an indictment of myself.”
The focus in India should be on
sustainable technologies that will
help the country grow its automotive
industry in a way that is environmentally
beneficial not only for
itself but for the world at large. With
this focus, environmentally friendly
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the vehicle to the peak levels needed
during a race. “A F1 team today
needs about 100 people. Once F1
cars have standard electronics, that
100 will go down to five or 10,”
Schoeggl said.
The benefits can ripple out to
passenger cars over time. “F1 is at a
stage where high-tech products can
be put to the test. Much of it may
carry over to the passenger car,”
said Ravi Gopinath, Vice President
of Engineering and Industrial Services
at Tata Consultancy Services.
Terry Costlow
technologies developed in India can
be marketed to other nations.
It is important, Shahed continued,
that the country’s very diverse
road-transportation mix be taken
into account when companies
develop vehicles and vehicle technologies.
Safety is especially at issue
because bicycles and motorcycles
make up a large percentage of the
vehicle population. There is heavy
pedestrian traffic in this “urban
mobility mélange,” as well, he said,
so small “urban” cars are in order.
Many of the other speakers
spoke about how fast the country
is developing and how great the
opportunities are for investment by
foreign automakers and suppliers.
The country graduates more than
250,000 engineering students/year
and has about 13,000 engineering
colleges.
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Thursday, April 14, 2005
17

AVL assesses driveability
SAE 2005 World Congress attendees
have the opportunity to experience
the driving characteristics of a
Formula One racecar in a simulator
demonstrating AVL-DRIVE software.
AVL (Booth 2179) partnered with
FCS, a spin-off of Fokker Aircraft
that produces electric motion platforms
for the simulation industry,
“so we could have something
dynamic to demonstrate our
software,” said Philip Marson, AVL
Technical Expert for Drive Quality,
Vehicle Applications. The simulator
is not part of the product offering
but is available through FCS.
Though DRIVE software is more
commonly used for the passengercar
market, “For this SAE show, it
makes far more sense to demonstrate
the version that we use to
AVL partnered with FCS, specifically
for the SAE World Congress, to
demonstrate AVL-DRIVE software on
a platform that offers realistic motion
cues for an F1 racecar.
calibrate a world-class F1 car because it is significantly more interesting,”
added Marson.
For passenger cars, custom sensors are added to the vehicle to measure
everything the driver is feeling—all the loads, vibrations, and noises
that affect the senses. These inputs are fed through a model that filters
them to match responses of the human body. “We then take data from
the vehicle, it all gets processed, and that generates a score relative to the
best-in-class vehicle for that particular driving mode,” said Marson.
The DRIVE tool can be broken down to offer assessment for different
vehicle models—e.g., compact, large, luxury, and sports cars—because
customers in each segment have different performance expectations—not
just for speed, but luxury, quietness, vibration, quality of gearshift, response
of pedal, etc.
Ryan Gehm
Ricardo makes WAVE
Ricardo (Booth 2234) has released a new version of its widely used WAVE
engine performance and gas dynamics simulation software. Called v7, it
has been developed to enhance accuracy and reduce solution times. The
system includes advanced model-generation tools, multi-processor-based
solutions, enhanced emissions simulation capabilities, and improved preand
post-processing.
The RCAT 3D Catalyst model in WAVE v7 was developed by Ricardo for higher accuracy
in emissions simulation.
According to Ricardo, the system has several key innovations.
WaveMesher facilitates the creation of “consistent and accurate” WAVE
models directly from CAD data. WaveBuild3D provides a CAD environment
that enables users to build solid, 3-D models that can be automatically
meshed for use in WAVE. Run Distribution is described as being a new innovation
offering “the potential to unleash the power of a multi-processor
or network computer system.” RCAT 3D Catalyst, is a 3-D catalyst model
that brings “new levels of accuracy and resolution to emissions simulation.”
WAVE’s mission capabilities also include a new 1-D model for wallflow
diesel particulate filters. A new Element Manager allows centralized
creation and management of model elements.
Stuart Birch
Axeon unveils
embedded system
At the SAE 2005 World Congress,
Axeon and Infineon launched
an embedded machine-learning
system based on Axeon’s Vindax
technology integrated with the
Infineon Powertrain Starter Kit
(PSK) and Triboard development
platforms.
Vindax technology comprises a
methodology, an algorithm, and
processor architecture that enables
real-time, multivariable, nonlinear
problem solutions to be formulated
through development tools
and deployed in FPGA or IP core
products.
“This is Axeon’s first embedded
platform with Infineon, and
reinforces our commitment to
drive the Vindax architecture to
the heart of future automotive
embedded systems,” said Axeon
CEO, Hamish Grant. “Together
we will be able to address some
of the most complex issues found
in current and future powertrain
architectures.”
The learning system/PSK
combination will allow Tier 1 and
OEM application developers to
use hardware neural networks to
solve challenges such as classification,
function approximation, and
change detection. Applications developed
with the system can have
significant cost benefits combined
with improved solution accuracy
and increased system reliability.
“In automotive, we’re increasing
the complexity of the data
because of legislative requirements
(OBD, for example),” said Colin
Turnbull, Vice President of Marketing
for Axeon. “You expose [the
system] to legacy data, and the
system will continue to learn until
you stop [the process].”
Axeon is demonstrating its
integration work at Booth 1115,
where the Vindax-Triboard combination
is used to implement a
virtual mass airflow sensor. The
integration uses a daughtercard
hosting a 256 processing element
array and support logic interfaced
directly to the external port of the
Tricore on the PSK or Triboard via
the system expansion connectors.
The demonstration shows how
a machine-learning system can
be used to replicate the output of
an actual mass airflow meter with
a high degree of accuracy. The
virtual sensor provides additional
powertrain system functionality
and allows output calibration of
the physical sensor via the electronics
system.
Kevin Jost
Protective coatings from Henkel
A new automotive coating for ferrous parts that uses a unique application
process, and a new powertrain sealant aimed at helping automakers meet
emissions legislation represent key technologies on display by Henkel
(Booth 1135) at the SAE 2005 World Congress. The company is spotlighting
its ACC 900 Series of coatings, which gained the approval of major
automakers in 2004 for use on targeted applications.
“ACC 900 is used on several automotive applications, including frame
and chassis, steel wheels/pulleys, and interior components such as seating
and safety restraints,” said Kevin Woock, Business Director of Organic
Coatings and Integrated Services for Henkel. “The performance qualities
of ACC 900 Series coatings have already earned material and performance
specifications from OEMs and their metal component suppliers.”
The coatings use Henkel’s autodeposition coating process, which essentially
eliminates the need for several material-handling and pre-treatment
steps. “Fewer manufacturing steps translate into shorter cycle times, lower
operating costs, and improved productivity,” said Woock. “The autodeposition
process for Henkel ACC coatings reacts directly to ferrous metals and
therefore does not require chemical conversion coating, reducing environmental
impact and eliminating the need for extra treatment equipment
and manufacturing steps. The process has the additional environmental
benefit of eliminating toxic heavy metals such as lead, chrome, nickel, and
cadmium from the final rinse phase.”
Henkel’s exhibit also features Loctite 5810, a one-component, room
temperature cure polyacrylate sealant containing calcium carbonate, organosilane,
plasticizer, and condensation catalyst.
In a tangible way, the new sealant provides an additional means of
meeting emissions requirements. “The U.S. federal government is making
and implementing policies and regulations on U.S. vehicle manufacturers
to lower emissions not only from the tailpipe, but also those that emanate
from the vehicle powertrain,” said Mark Neuenschwander, Marketing/Business
Development Manager for Loctite Gasket Products at Henkel. “The
5810 polyacrylate (fixed in place) sealant has better permeation resistance
of oil/fuel vapor than other liquid sealants used today. This assists the carmaker
to meet new emissions legislation requirements.”
Kami Buchholz
Biodiesel offers real-world applications
Is biodiesel fuel “for real”? Absolutely, explained Greg Olweg, Agriculture
Communications Manager for the United Soybean Board, which is, as
you would expect, looking for new applications for the product.
Of the 20 billion pounds of soybean oil produced annually, he said,
more than 90% is used for edible purposes. The remainder is available for
other uses, and it could provide 250 million gallons of biodiesel fuel. The
price of biodiesel is about 20% higher than petroleum-based diesel fuel,
he said, but for some ultra-low-emission needs, such as mining and for
vehicles operated in national parks (where air quality is important), it is
preferred.
“If it spills, it’s just as if some ordinary cooking oil were spilled,” said
Olweg during the SAE 2005 World Congress.
Although 250 million gallons is not significant in total diesel fuel usage
terms, biodiesel will make a big difference when low-sulfur fuel is introduced
nationwide in 2006, Olweg explained. The soybean oil, as an additive
of up to 5% in petroleum-based diesel fuel, provides the lubricating
effect of the removed sulfur.
Volkswagen AG, he pointed out, has agreed to extend full warranty
coverage to diesel engines running on fuel with a biodiesel content of up
to 5% in all its U.S. market diesels. (The company is the leading seller of
diesel automobiles in the U.S., with annual sales of nearly 40,000.)
Biodiesel is said to reduce particulate emissions and carbon monoxide
(compared with petroleum-based diesel fuel). VW and Archer Daniels
Midland are engaged in a joint research project to develop and demonstrate
the advantages of blends of 20% biodiesel, 80% petroleum-based
diesel fuel.
The supply of soybean oil can readily be expanded, Olweg said, by
growing genetically modified soybeans, because they would not be subject
to the health concerns raised for human consumption.
Paul Weissler
18
Thursday, April 14, 2005

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Each day, Show Daily editors highlight some of the top products
and technologies on display at the SAE 2005 World Congress.
Vehicle dynamic
simulation
Mechanical Simulation’s Car-
Sim 6 software offers a variety
of environmental conditions and
vehicle behaviors for a consistently
close agreement between simulation
and road testing. Enhanced
to run faster and easier than the
previous solution, the package
allows engineers to simulate the
dynamic behavior of light vehicles.
The software animates simulated
tests and generates more than 500
output variables that can be plotted
Simulation process automation
MSC.SimManager 2004 r2 from MSC.Software automates the execution of simulation processes, captures all intermediate
and resulting data, and increases the effective use of simulation by delivering critical product performance knowledge early in
the design cycle. The software enables engineers to assess and compare the performance of multiple design configurations
rapidly and consistently. Enhancements help engineers set up simulation processes, conduct simulations, evaluate results, and
iterate through multiple “what-if” scenarios. Emphasis is placed on support for key IBM technologies including WebSphere
Application Server, DB2 Universal Database, and the AIX 5L operating system; support for Red Hat Linux on Intel-based servers;
a Web-based report generator; and advanced capabilities for execution and interactive configuration of Trade Studies.
Booth 1106
AVL Competence Network:
Optimising your Product Creation Process
and analyzed with other software,
including the “fishhook test” conducted
by the National Highway
and Traffic Safety Administration.
CarSim 6 runs on Windows
desktop and laptop PCs. The more
than 75 enhancements made in the
software include an upgraded and
extended graphical user interface
and database with more than
40 new features, extended math
models with over 25 new features
including extended nonlinear and
asymmetric suspension kinematics
and alternate tire models, and
extended event management that
allows interactive variables to act
as triggers to simulate complicated
test sequences.
Booth 1721
Quiet brake
modulator
The Quiet
Brake Modulator
(ADS-
V1) from
ADVICS is a
high-pressure
gear pump
that features reduced operational
noise. It provides enhanced vehicle
dynamics and comfort. Safety is
increased thanks to expanded brake
control area and function. The
system is used on vehicles including
the Celsior, Crown, Harrier, Camry,
Ipsum, Raum, and Vitz.
Booth 1461
AVL Advanced Simulation Technologies
AVL Instrumentation & Test Systems
AVL Powertrain Engineering
Networking
We combine the worlds of simulation,
engineering and testing to increase your
process efficiency.
Connecting
We bring together ideas, people and effort
within a global partner and affiliate network
to ensure best quality results.
Interacting
We understand and handle the correlation
and interactivity between engine, powertrain
and vehicle to minimize your development risks.
Integrating
We offer integrated solutions along the whole
development process - from math to lab to
road - to speed up your SOP
AVL NORTH AMERICA INC.
AVL POWERTRAIN ENGINEERING INC.
47519 HALYARD DRIVE, PLYMOUTH, MICHIGAN 48170
PHONE: +1 734 414-9600, FAX: +1 734 414-9690
WWW.AVL.COM/NAI
AVL LIST GMBH
HANS-LIST-PLATZ 1, A-8020 GRAZ, AUSTRIA
PHONE: +43 316 787-0, FAX: +43 316 787-400
WWW.AVL.COM
Please visit us at the AVL booth, Nr. 2179
to the right of the AVL Technology Theater.
Thursday, April 14, 2005
5

AHSS tube hydroforming
AUTO21 researchers are addressing
the formability issues required to
introduce advanced high-strength
steel (AHSS) tubes, such as dualphase
DP600, into lightweight
automotive structures. AHSS tube
is much stronger than conventional
and mild steel tube, allowing thinner
walls and lower weight; however, its
formability is lower, requiring more
care in processing. In particular, the
study examines the impact of tube
pre-forming operations, such as
tube bending, on the subsequent
hydroformability of AHSS tube. A
collaborative effort is under way
with researchers from McMaster
University, Queen’s University,
and University of Sherbooke to
study the fundamentals of damage,
formability, and texture evolution
in DP600, while large-scale testing
is done using an instrumented
rotary draw-mandrel tube bender
and 1000-t hydroforming press
at the University of Waterloo.
Industrial partners include steel
and tube manufacturers Dofasco,
NovaTube, and Stelco;
lubricant supplier DA Stuart;
Eagle Precision Technologies,
a tube bender supplier; and
CANMET Materials Technology
Laboratory, a Canadian government
laboratory. This research
team is presenting four papers
in the Sheet/Hydro/Gas Forming
Technology & Modeling session at
SAE 2005.
Booth 1020
Innovative Ideas…Proven Results
Camera system
The Phantom v4.3 camera
system from Vision Research
features the SR-CMOS (complementary
metal oxide semiconductor)
sensor, which triples the
sensitivity of previous models.
All image sizes (aspect ratios)
selected during setup are centered
on the sensor’s midpoint;
the continuously adjustable resolution
feature permits screen
size adjustment in 16 x 8 pixel
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increments. The slightly smaller
v4.3 includes Gigabit Ethernet
to simplify camera network
communications and speed file
transfers. The SR-CMOS sensor
is designed exclusively for
high-speed usage. It offers the
advanced features inherent in
previous designs, including the
on-chip circuitry that provides
true snapshot shutter capabilities,
auto exposure, and pixellevel
Extreme Dynamic Range
control to extend picture quality
in harsh lighting conditions.
The system offers a recording
speed to 1000 fps. Maximum
frame rate is 90,000 pps. Both
color and monochrome cameras
provide 10-bit image depth for
extended image quality.
Booth 539
6
Please visit us at SAE Show Booth# 1815
Thursday, April 14, 2005

The SAE 2005 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.
CAE tool
CEI’s EnSight 8 software contains
several enhancements including
a more intuitive graphical user
interface, dozens of new features,
more direct readers, and additional
lighting and special effects. Analysis
of complex transient data sets is
eased with new tracking features.
The software enables view tracking
in different viewports and fixed to a
moving model. New icons provide
easier access to advanced functions,
and parts list menus reduce the
number of mouse clicks needed to
perform common tasks. A dialog
TPO/TPV foaming processes
An AUTO21 researcher is advancing
the use of thermoplastic
olefin/thermoplastic vulcanizates
(TPO/TPV) foaming processes for
automotive components. Since both
materials have polypropylene (PP)
as the major matrix where foaming
occurs, investigation of the foaming
behavior of PP is the required first
step. To control the foaming process,
information about the solubility of
the blowing agent in the PP matrix is
necessary. Researchers are working
on these critical issues to be able to
conduct the TPO and TPV foaming
projects better. The TPO foaming
project is supported by a Tier One
automotive supplier, who expects to
see savings of $20-30 million/year
once successfully implemented. Also
under study is the processing of
nylon/nanocomposites for automotive
applications.
Booth 1020
box controls color and provides sliders
to adjust transparency, shading,
and lighting parameters. A VCRlike
interface automatically plays a
flipbook animation after loading.
With the click of a button, the
software automatically recognizes
and loads files from major solvers
including ABAQUS, ANSYS, Crunch,
Fluent, Permas, Adams, and Patran.
Users can create visually realistic
scenes with features such as ray
tracing, control of positioning for a
second light source, and the ability
to display a bitmap image in the
background.
Booth 1814
Self-powered siren
The Self
Powered Siren
from Cobra
Automotive
Technologies
is an electronic
siren with internal
battery and
piezo speaker
assembly. The device features a fourpin
connection; is LIN or proprietarycomline
compatible; and contains
a central fixation bolt. Mass is 160
g (5.6 oz) and dimensions are 110
x 80 x 40 mm (4.3 x 3.1 x 1.6 in).
The unit produces high sound-pressure
level, buzzer, and jingle-tones.
It complies with Thatcham requirements
and European directive 95/54/
EC and 95/56/EC.
Booth 853
Thursday, April 14, 2005
7

Gantry robot
The gantry robot APAC from
AccuPlace aids with fully automatic
assembly tasks using adhesive
components. It is suitable for batch
processes or can be integrated into an
assembly line. Feeding of the adhesive
components from the reel is implemented
by up to four robot modes
RM3065 integrated into the APAC.
This permits feeding of up to four different
adhesive components, allowing
the execution of complex assembly
tasks. Custom-made vacuum chucks to handle the delicate adhesive components
are the only hardware required to change from one product to
another. Standard linear drive X-Y axes and optional servo Z and U axes ensure
that even the most complex assembly steps with different orientation
changes and multiple height placements can be achieved. PC-based control
with a powerful ARSIC software system supports the adhesive component
assembly tool. Optional vision systems ensure accurate assembly, even of
parts with critical tolerances. Various transport systems such as dual try
shuttle, SMEMA conveyor belt systems, or tray handling unit are available
in custom designs.
Booth 1047
Assembly monitoring
Promess’ PC-AMS (programmable
control, assembly monitoring system)
is the fourth in a series of systems
to perform online quality evaluations
of press-fit, insertion, staking,
crimping, and other operations. The
multi-channel monitoring system
consists of a microprocessor-based
electronic unit that monitors signals
from force and position sensors
mounted on an assembly machine.
Using a “taught-in” master as the
standard for acceptance, the system
monitors, in real time, both the force
and position sensors mounted on the
machine to measure key attributes of
each assembly produced. As they are measured, the attributes are analyzed
and compared to those of the “taught master.” The system provides multichannel
(non-synchronous) monitoring, built-in data acquisition, and data
point storage. It also can monitor multiple windows.
Booth 820
EGR meter
ECM’s Exhaust Gas Recirculation
(EGR) 4830 Analyzer is a fast EGR
meter suitable for diesel engine
development, calibration, and testing.
Ceramic sensors placed in the
intake and exhaust of the diesel
engine are used to determine both
mass- and volume-based percentage
EGR. Intake and exhaust percentage
O² and pressures are also
reported by the analyzer. EGR is a
key parameter used to control the
NOx emissions of diesel engines;
the EGR 4830 analyzer facilitates
this measurement due to its high
response time and ease-of-use.
Booth 706
Supply-chain tool
The Virtual Engineer from Modern Engineering is a Web-based tool that establishes an ideal collaborative
working environment for supply-chain engineering professionals and the tools necessary for implementing lean
manufacturing solutions. The software integrates internal and external supply chain participants to form a broad,
global communication network. This system allows for the effective management and dissemination of current
engineering data, files, and drawings across the supply-chain network—from suppliers, service providers, plant
managers, engineers, and designers to skid loaders, material handlers, assemblers, transporters, and warehouse
personnel. The product includes 10 integrated modules that cross-manage activities of the supply chain engineering
function: program management, financial cost and tracking, data part plan, containerization, logistics, material
flow, processing, placarding, experimentation, and notification. A key feature is its ability to forecast “what-if”
scenarios and associated costing models to understand the implications of changes and identify corrective actions.
Another important feature is the data ownership and exchange functionality: if containerization engineers alter
package dimensions, all other parties working with that data are notified of the change and the data are updated
in real time.
Booth 1038
Torque transducers
Maintenance-free rotating torque transducers
from PCB Piezotronics use noncontact
rotary transformers to send excitation voltage
to, and receive measurement signals from,
the rotating strain gauge sensor. The units
are suitable for use in dynamometers and
in torque studies on fuel pumps, hydraulic
motors and pumps, combustion engines,
driveshafts, transmissions, fans, and electric motors. The design eliminates
the need for replacing worn brushes, which is required with conventional
slip-ring-type rotating torque sensors. The standard Series 4100 rotary
transformer torque sensors offer capacities from 50 oz·in to 100,000 lb·in
(0.35 N·m to 11.3 kN·m) full scale and maximum speeds to 20,000 rpm. In
addition to the torque output signal, an optional pickup provides an output
proportional to speed.
Booth 827
8
In-House Check Valve vs. Lee Chek ®
(Find the parts, coin the seat, assemble
the parts, stake in place, test)
Why fuss with the in-house approach when Lee Chek Valves install in less time, work more
reliably, last longer, and cost less?
Lee Chek features include:
For a free Lee Chek valve, email your application to
IMHEngr@theleeco.com or call 800-LEE-PLUG and
• 100% Performance Tested
ask for the IMH Applications Engineer.
• Quick, Automated Installation
• 2.5, 5.5 and 8 mm Diameters
Innovation in Miniature The Lee Company
• New "Press-In" Models for Plastics
Westbrook CT
Tel: 800-533-7584
• Restrictor Check Models Available
www.TheLeeCo.com/imh4
Please visit us at SAE Booth #1417
(Pre-assembled, autoinsertable,
100% tested)
CAN bus
measurement
CSM’s family of measurement
modules provides a solution for
temperature, voltage, current, and
pressure measurement applications.
The wide operating temperature
range up to 125°C (257°F) and an
IP rating of IP 65 (optionally IP 67)
make the modules suitable for road
trials and test stands as well. Their
small size, low power consumption,
and CAN bus communication enable
the modules to be installed even in
the smallest gaps inside the engine
compartment. Short cable connections
to the sensors reduce interferences
and cabling efforts. The CSM
Thermo-Scan MiniModul comes with
eight inputs for thermocouples type
K. Each input is provided with its
own cold junction compensation to
allow a maximum on measurement
accuracy. The CSM AD-Scan Mini-
Modul includes four bipolar analog
measurement inputs.
Booth 553
Thursday, April 14, 2005