SAE 2013 World Congress (2): Supplier Exhibits

New parts/powertrains improve efficiency and reduce fuel use

2013/05/20

Summary

 This report highlights the exhibits of auto parts/material suppliers at the SAE 2013 World Congress held on April 16-18, 2013, in Detroit, the U.S.

 With the theme of the Congress this year, "Achieving Efficiency," participants introduced new technologies and parts/components to reduce vehicle weight, improve powertrain efficiency and reduce fuel consumption through increased electric operations in vehicles. Six OEMs set up their booths as in 2011 and 2012. Visitors slightly increased to approx. 10,000 this year from 9,000 last year and the number of parts/materials suppliers' booths increased slightly from last year to 170.

 With the U.S. auto industry steadily recovering production and sales from Lehman's fall, the Detroit Auto Show, held in January at the same Cobo Hall, showed vibrant atmosphere. In contrast, the venue of the SAE World Congress this year was quiet, far from the Congress six or seven years ago, which was lively with many visitors, vehicles and parts/components exhibits.

Related Reports:  SAE 2013 World Congress (1): OEM Exhibits
North American International Auto Show 2013 (1): US and European OEMs, Asian OEMs


ZF presents resin composite brake pedal and suspension strut of plastic and aluminum

 ZF Group, Tier One strategic partner for the SAE 2013 World Congress, displayed lightweight parts/components using resin and aluminum at a large booth next to the event's host company, Chrysler Group LLC.

Lightweight strut module

 ZF exhibited its prototype of a lightweight suspension strut wheel carrier module. ZF says that it will almost halve the suspension strut's weight by replacing current iron- and aluminum-made struts with those made from Glass Fiber Reinforced Plastics (GFRP), aluminum and High Tensile Strength Steel (HTSS) in order to reduce the unsprung weight, which will improve fuel efficiency and driving performance. For the prototype, ZF formed the strut mount and coil spring from GFRP and cast the strut as a solid aluminum part.

 Currently, ZF is working on the design of the module so that it will be able to supply the parts in an assembled form, instead of shipping them separately to OEMs.

Lightweight suspension strut wheel carrier module
Lightweight suspension strut wheel carrier module
FGRP spring of the lightweight suspension strut wheel carrier module
FGRP spring of the lightweight suspension strut wheel carrier module

 

Resin brake pedal

 ZF exhibited the polyamide resin brake pedal reinforced with glass-fiber and polyamide-fiber sheet, jointly developed with a material supplier. It weighs approximately 50% less than a conventional steel brake pedal. It also costs less as its parts are produced by only one injection molding process.

Resin brake pedal
Resin brake pedal

 

8-speed AT & 9-speed AT

 ZF also presented its 8-speed AT for FR vehicles and the 9-speed AT for transverse engines. The 8-speed AT is currently manufactured at a Chrysler plant in the U.S., under a licensing agreement with ZF, and expected to be mounted on the Chrysler 300, Dodge Charger and Jeep Grand Cherokee. The level of CO2 emission of the 8-speed AT is reduced by 6 to 11 % compared to that of current standard 6-speed AT.

 The 9-speed AT will be manufactured at ZF plant in South Carolina, the U.S., with scheduled installation in the 2014 Jeep Cherokee and other models. This 9-speed AT developed for transverse engines can be installed in both FF and 4WD vehicles. It uses a torque converter with a lockup clutch. This ZF 9-speed AT is a winner of the Top 10 SAE 2013 World Congress Tech Awards.

ZF 8-speed AT for FR vehicles
ZF 8-speed AT for FR vehicles
ZF 9-speed AT
ZF 9-speed AT

 

 



Hitachi Metal America displays a motor material with reduced rare earth

Neodymium magnets with reduced rare earth for electric motor application

 For motors in HV/EV, electric power steering and other actuators, powerful neodymium magnets are used with expensive rare-earth dysprosium added for better temperature resistance. Hitachi Metals and an OEM have jointly developed a dysprosium vapor deposition diffusion technology named DDMagic that efficiently evaporates and diffuses dysprosium on to the boundaries of fine magnetic crystal grains and have successfully reduced the used amount of the rare earth.

 Hitachi Metals also developed a ferrite powder magnet NMF-12 series to replace the neodymium powder magnet used in automotive starter-motors and home appliances' motors. Since 1989 it has produced the NMF-12 in the U.S. as well and is now developing the next-generation ferrite magnet. The new neodymium magnet with reduced dysprosium, currently produced only in Japan, will also be produced in the U.S. from 2013 to be supplied to motor manufacturers and other companies. Although Hitachi Metal has not announced officially, REMI Group and Toshiba are manufacturing motors for the magnet's automotive application in the U.S.

 Hitachi Metal's "dysprosium vapor deposition diffusion technology to reduce dysprosium" won the Top 10 SAE 2013 World Congress Tech Awards.

Explanation of the technology to reduce the amount of rare-earth dysprosium
Explanation of the technology to reduce the amount of rare-earth dysprosium
Neodymium magnets using rare-earth dysprosium
Neodymium magnets using rare-earth dysprosium

 

Heat-resistant cast steel for turbo charger housings and exhaust manifolds

 Hitachi Metals also presented panels explaining its steel castings resistant up to 1,050℃ engine exhaust emissions. OEMs are increasing turbocharger production in order to downsize their engines for better fuel efficiency. Hitachi Metal's austenitic heat-resistant cast stainless steel is used in highly heated turbo-charged engines' exhaust manifolds, turbo housings and turbochargers' waste gates.

 Hitachi Metals predicts that the turbocharger installation ratio in automotive engines produced worldwide, including diesel-powered ones, should rise to almost 50% in 2015 from 22% in 2012 and anticipates a great demand growth for heat-resistant steel castings. (Marklines Note: The ratio of turbocharged engines of all the vehicles produced in North America in model year 2012 was 11.3%.)

Explanation of aluminum wheels and heat-resistant steel castings
Explanation of aluminum wheels and heat-resistant steel castings
Explanation of materials for piston rings and CVT belts
Explanation of materials for piston rings and CVT belts
Explanation of turbine wheels for turbochargers
Explanation of turbine wheels for turbochargers

 

 



SL Corp. presents Around View Monitoring System

 SL Corporation is a global company manufacturing headlights, AT shift levers, brake pedals and other products at its plants in Korea, China, the U.S., India and Slovakia. The Hyundai QZ truck uses SL Corp.'s Around View Monitoring system. Using three separate cameras installed on the left, right and back of the truck and the monitor on the instrument panel, the driver can confirm pedestrians and obstacles around the truck.

 SL Corp. is currently developing an around view monitoring system for a U.S. OEM's passenger cars, which monitors the front, rear, left and right sides of the car with four cameras and for this, application of a high-definition display monitor is under consideration. The system will not only monitor images around the vehicle, but will also assist the driver in parallel parking and pulling over to the curb, detect vehicles in the blind spots and video-record the front view as well.

Explanation of SL Corp.'s Around View Monitoring system
Explanation of SL Corp.'s Around View Monitoring system

 

 



JATCO exhibits two CVTs

 JATCO Ltd. exhibited two types of CVTs jointly developed with Nissan Motor Co., the CVT7 with a sub transmission and the CVT8 for FWD vehicles with 2.0- to 3.5-liter engines. The CVT7 with an auxiliary gearbox (two-step gear change) has successfully improved fuel efficiency by increased gear ratio range to rev down the engine. It is manufactured in Japan and China, and in Mexico from late 2012. Production at JATCO's new Thai plant under construction is also scheduled to start in 2013 to mount the Nissan March made in Thailand.

JATCO CVT7 with an auxiliary gearbox for small vehicles
JATCO CVT7 with an auxiliary gearbox for small vehicles
Features of the CVT7
Features of the CVT7

 

 The CVT8, suitable for 2.0- to 3.5-liter engines, is installed in the Nissan Altima manufactured by Nissan North America, according to JATCO. The CVT8 is produced in Japan and Mexico with a plan to be manufactured in China from 2013. The features of the CVT7 and CVT8 are listed below.

JATCO CVT8 for FWD vehicles with 2.0- to 3.5-liter engines
JATCO CVT8 for FWD vehicles with 2.0- to 3.5-liter engines
CVT8 features
CVT8 features

 

Features Models Production
CVT7 * The auxiliary transmission expands the gear ratio range,  
   providing responsive starting and quieter performance at
   high speeds.
* Downsized with 10% reduction in transmission length and
   13% reduction in overall weight
* 30% lower oil agitation resistance by securing a distance
   between the oil surface and the drive pulley/the belt
Mini and compact cars of Nissan, Mitsubishi and Suzuki manufactured in Japan/Thai-made Nissan March Japan,
China and
Mexico,
and
Thailand
from 2013
CVT8 (CVT8 for 2.0- to 2.5-liter class engines)
10% higher fuel economy achieved through the following 
features

* The gear ratio coverage is expanded by 17% from 6.0 to 
   7.0.
* Friction reduced by approx. 40%(All the CVT8)              
* Wider lock-up range by use of a low-rigidity lock-up 
   damper
* Increased pressure receiving area of the pulley and  
   reduced oil leakage by the downsized oil pump
* Lower oil agitation resistance by setting a baffle plate
* Use of low-viscosity oil
FWD with 2.0- to 3.5-liter engines including the Altima produced by Nissan North America Japan and
Mexico,
and China
from 2013

 

 



Delphi showcases In-vehicle wireless charging system

In-vehicle wireless charging system for cell phones

 Delphi Automotive LLP is currently developing Wireless Charging System for Consumer Devices including cell phones, jointly with a cell phone supplier, Samsung, and other companies. By eliminating cords and adaptors, this system will enable safe charging wherever the device is positioned in the vehicle. Several devices can be charged simultaneously. Although some problems such as creation of standards are yet to be solved, this wireless charging system utilizing electromagnetic resonance is under development with scheduled launch in 2015 vehicle models.

Wireless Consumer Device Charging
Wireless Consumer Device Charging
The system charges devices when putting them in places like the center console
The system charges devices when putting them in places like the center console
The slightly thicker cell phone is compatible with the wireless charging system.
The slightly thicker cell phone (on top) is compatible with the wireless charging system. 
(bottom: ordinary thin cell phone for comparison)

 

Ultra High Pressure Heavy Duty Diesel Common Rail System

 Delphi exhibited the ultra high-pressure common rail system called the F2e System, developed for diesel engines of heavy-duty trucks. It utilizes two types of injectors: "non-pumping" injectors that act like conventional common rail injectors and "pumping" injectors driven by the overhead camshaft. The peak pressure range is from 2,500 bar to 3,000 bar. Production of the F2e System started in 2012 for application in 9- to 16-liter heavy-duty diesel engines with engine cylinder capacity of 1.5 to 2.6 liter. One of the targets of the F2e System is to meet Euro 6 emission standards.

F2e Ultra High Pressure Heavy Duty Diesel Common Rail System
F2e Ultra High Pressure Heavy Duty Diesel Common Rail System
High Pressure Fuel Pump of the F2e System
High Pressure Fuel Pump of the F2e System
Non-pumping injector of the F2e System
Non-pumping injector of the F2e System

 

Delphi Multec Diesel Common Rail System

 Delphi also showed its Multec Diesel Common Rail System, already mounted on the 1.2-liter 3-cylinder diesel engine of a VW compact passenger car since 2010. The plunger fuel pump enables operation up to 2,000 bar and is suitable up to 2.2-liter engines. CO2 emission of the VW Polo, which uses the Multec Diesel Common Rail System, is 87g/km.

Multec Diesel Common Rail System
Multec Diesel Common Rail System
Plunger fuel pump of Multec Diesel Common Rail System
Plunger fuel pump of Multec Diesel Common Rail System
Multec Diesel Common Rail System injectors
Multec Diesel Common Rail System injectors

 

 



Parker Hannifin exhibits Permanent Magnet AC motor and mobile inverter

 Parker Hannifin Corp. exhibited a Permanent Magnet AC motor and a mobile inverter. Both are used for heavy-duty trucks used in construction site, delivery vans, F1 racing cars, fuel-cell vehicles (FCVs), Terex's PHV and others, according to the company.

DC motor
Permanent Magnet AC motor
DC-DC converter
Mobile Inverter

 

 



Pyung Hwa Industrial shows vibration-control systems

 Pyung Hwa Industrial Co. and Pavco, Inc belong to the same business group: Pyung Hwa manufactures and sells fuel filler hoses and hoses to prevent gasoline evaporation, while PAVCO manufactures and sells engine mounts and other vibration-control products. With production facilities in Korea, China and India and a storage facility in Georgia, the U.S., the group supplies their products to Hyundai Kia Automotive Group and GM and exports to Europe for VW and BMW. For Hyundai Kia in the U.S., it is exporting mainly from Korea and India. Approx. 20 billion yen of Pavco's sales consist of 61% by Hyundai Kia, 19% by GM and 20% by exports to Europe, according to the group.

Engine mount
Engine mount
Damper pulley
Damper pulley
Hoses
Hoses

 

 Pyung Hwa is currently developing an electronically-controlled vibration damping system for vehicle application called Active Dynamic Mount System, which is to avoid transmission of engine vibration by setting an engine on the vehicle body via an electronically-controlled engine mount that produces an opposite phase to engine vibration. It is scheduled to be installed in Hyundai's high grade four-door model either this year or the next year.

Explanation of Active Dynamic Mount System
Explanation of Active Dynamic Mount System
Cross-sectional image of the Active Mount
Cross-sectional image of the Active Mount

 

 



Core Molding Technologies further reduces weight of composite resin fender

 Core Molding Technologies Inc., a manufacturer of exterior body panels of medium- to heavy-duty trucks and other products, showcased its front fender under development. Parts molded by compressing thermosetting resin, using a Glass Fiber Reinforced Plastic(GFRP )called Sheet Molding Compound (SMC), are superior in stiffness and tensile strength to those made from thermoplastic resin such as the polypropylene(PP) and common engineering plastics, and lighter than parts made from steel sheet. SMC, therefore, is used for vehicles' body panels and small pickup truck beds, greatly reducing vehicle weight.

 Core Molding Technologies developed Ultra Low Density SMC, a 1.18 sp.gr. density SMC, and molded a front fender for a medium-duty truck. At the Congress, it compared this prototype fender with its 1.9 sp.gr. SMC fender, available on the market. With almost the same appearance and quality, the reduced density SMC prototype weighed 10 lbs., 6 lbs. (approx. 3 kg) lighter than the current product.


 In order to meet the tougher fuel efficiency requirements in the U.S., automobile and truck manufacturers are considering resin body panels and the use of composite in addition to larger application of aluminum, as means of vehicle weight reduction. According to Core Molding Technologies, physical properties of Ultra Low Density SMC are almost the same as currently available SMC. The company will compress SMC into front fenders, apply a primer and supply them to truck manufacturers. Commercial production of the lighter fender will start as early as the end of this year once its quality is confirmed.

Commercially-manufactured front fender of 1.9 sp.gr. Density SMC and the newly developed front fender of the new, ultra-low 1.18 sp.gr. density SMC
Left side:Commercially-manufactured front fender of 1.9 sp.gr. Density SMC
Right side:The newly developed front fender of the new, ultra-low 1.18 sp.gr. density SMC

 

 



Molding compound supplier BMCI introduces encapsulated sensor

 Bulk Molding Compounds, Inc. (BMCI) presented a sensor encapsulated with a fiberglass reinforced thermosetting resin composite. A rotor position sensor for a transmission is used in the harsh environment of high temperature oil. BMCI used its product named BMC (as its company name), thermosetting Bulk Molding Compound superior in heat resistance, dimensional precision and chemical resistance, to encapsulate and injection-mold the rotor position sensor.

 BMC causes no damage to the sensor or to the circuit board when molded into products. Dimensional changes of BMC products from low temperature to over 150℃ are fairly small, which provides an oil-tight and water-tight enclosure. According to BMCI, it is developing BMC- encapsulated sensors to be incorporated into engines and transmissions, jointly with about ten companies. At present, BMC-encapsulated electronics parts including sensors are used in HV/EV motors.

Encapsulated rotor position sensor for a transmission
Encapsulated rotor position sensor for a transmission

 

 



FEV displays Euro 6-compliant engine under development

Euro 6-compliant diesel engine

 FEV Inc. exhibited its diesel engine under development, which satisfies Euro 6 and the U.S. TIER2BIN5 emission standards with less CO2 output. It is equipped with a common rail system with 2,000 bar, a 2-step variable intake valve lift system (VVL) to switch the valve lift between 4.8 and 8.0 mm, water-cooled low pressure/high pressure EGRs, a 2-stage intercooler turbocharger, a variable valve timing system (VVT) on the exhaust camshaft and other devices. With the maximum 220 hp or 100kW/1.0-liter emissions, its fuel consumption is reduced by 17% compared to FEV's previous prototype engine. While the 2-stage turbocharger is already incorporated in its mass-produced engines, the intake VVL and the exhaust VVT are comparatively new technologies, according to FEV.

 FEV is also developing a 1.8-liter gasoline powered 2-stage turbocharged engine with similar new systems, which has successfully generated higher power of 120kW/liter.

Euro 6-compliant clean diesel engine
Euro 6-compliant clean diesel engine
Euro 6-compliant clean diesel engine
Euro 6-compliant clean diesel engine

 

MicroHiL, off-line exhaust emission calibration device

 FEV developed MicroHiL System, a system to simulate driving modes and real car performances in various environmental conditions such as high altitude and cold climates by using a virtual engine model connected to a real time processing ECU in order to search the optimized matching of ECU data. The system, originally developed for OBD (Onboard Diagnostics) system design, has been improved for the calibration of exhaust emissions.

 At present, in order to search the optimized matching of ECU data acquired from environmental test laboratories and actual car driving, detailed ECU parameters are worked through various matching processes at laboratories and on the roads/circuits with real vehicles for final validation. With the MicroHiL, a virtual engine on the computer can try various engine revolutions, fuel injection volumes and simulated input signals from sensors to achieve the optimized matching for an engine and to conform exhaust emissions through semi-automatic processes. It is also capable of debugging the ECU data. The MicroHiL, therefore, reduces calibration times by up to 40%.

 This portable MicroHiL weighs only about 30 to 40 lbs. It is a winner of the Top 10 2013 World Congress Tech Awards.

MicroHiL, off-line exhaust emission calibration device
MicroHiL, off-line exhaust emission calibration device

 

 



AVL presents battery and powertrain simulators

Battery testing simulator

 AVL exhibited a simulation device for environmental testing of batteries on a test bench, without using an actual vehicle. AVL has battery-testing facilities in Europe and the U.S., where influence of thermal environment on batteries can be evaluated. AVL plans to upgrade the simulator by using various parameters including vehicle models, road conditions, and a driver's habits so that the device should be able to simulate a vehicle's actual running performances in the testing laboratory capable of thermal simulation from low to high temperatures. It will also add vehicle body distortion as a parameter and develop the simulation and testing device to be marketed as an integrated system with the software.


 According to AVL, it has developed a lithium-ion battery pack for Mercedes-Benz concept car, EV Coupe-e 800.

Battery testing device on a test bench
Battery testing device on a test bench
Monitor display on simulated conditions
Monitor display on simulated conditions

 

Powertrain simulator

 AVL also exhibited a powertrain simulator that directly connects motors to wheel axes to absorb engine drive and calibrates exhaust emission and fuel efficiency without using a chassis dynamometer. Compared to the system using a chassis dynamometer, with which wheels run on rollers set below the body floor, this simulator has four motors directly connected to front and rear wheel axes to operate the accelerator via computer. Unlike a dynamometer, it does not require an external engine-cooling fan.


 This simulator calibrates exhaust emission and fuel efficiency as well as reproduces the actual driving situation on the test track on a PC, based on recorded engine revolutions, speeds and other conditions. The simulator has already been in use by European OEMs

Powertrain simulator without a chassis dynamometer
Powertrain simulator without a chassis dynamometer

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