BorgWarner Drivetrain Systems
eGearDrive Electric Drive Transmission
For the generations of tomorrow, we are engineering eGearDrive® electric drive transmissions. Adaptable, high torque, fast-to-market technology, so efficient it helps drivers get more miles from every charge. eGearDrive® transmissions are accelerating the growth of electric powertrains from roadsters to delivery vans.
Clarion Corporation of America
Ford Motor Company’s Next Generation Navigation System
This major evolution for in-vehicle, real-time interface between audio, graphics and data became a reality because of the close relationship between Clarion Corp of America and Ford Motor Company during an extended product development process. The combined efforts created a series of firsts in integration, real time information feeds, voice recognition multi-language software and Human Machine Interface (HMI). Along the way Clarion and Ford reworked the rules of collaboration in that they successfully operated together dealing with other global software and electronics companies such as Microsoft and Sirius. The working relationships established by the joint development teams provide a model for future technologies and in-vehicle software efforts.
Electronically Scanning Radar
For the first time, adaptive cruise control, early collision warning and a host of related safety features will be affordable for all vehicle classes. Achieving multimode long- and short-range radar in a single box, Delphi’s innovative design represents a significant breakthrough in cost/performance and manufacturability.
Delphi Packard Electrical and Electronic Architecture
Delphi Halogen-Free 0.13 mm2 Cable
Delphi’s exceptionally thin cable insulation allowed the supplier to create a wiring-harness cable that is one-third the size of the previous minimum that could stand up to a vehicle’s harsh underhood environment. Delphi’s cable allows the weight and bundle size of a wiring harness to be slashed with no sacrifice in performance.
DURA Automotive Sysytems Inc.
Horizonal Sliding Rear Window with Defrost
As pickup trucks have evolved from basic work vehicles to family oriented luxury transportation, with larger cabs and more comfort features, light truck manufacturers have sought to differentiate themselves by offering customers unique comfort and safety features. With a target buyer demographic as much urban as rural, a defrost feature on the rear sliding window has become a necessity. Dura is the first to offer a solution in the form of the Heated Power Sliding Rear Window.
Dura’s horizontal sliding rear window with defrost incorporates the defrost capability without compromising design or degrading styling esthetics. It provides the customer with the highest level of satisfaction, convenience and safety; clearing the rear window in minutes in the most severe winter conditions. As the rear window with defrost has become the standard for passenger cars and SUVs, Dura’s defrost feature will become the standard for pickups.
Federal-Mogul Corporation (Nasdaq: FDML) has developed an innovative, environmentally-friendly product that helps General Motors eliminate noise in a vehicle’s cabin using recycled waste packaging and other by-products normally discarded at a vehicle manufacturing plant. QuietShield(R) GRN’s (Green Non-woven) first application will be in the 2010 Buick LaCrosse luxury sedan, to be introduced at the North American International Auto Show on January 11. Cardboard packaging used by manufacturers, in this case from General Motors’ Marion Metal Stamping plant in Marion, Indiana, is recycled into QuietShield GRN and is used as eco-friendly acoustical padding in the LaCrosse’s headliner to reduce noise in the passenger compartment. Importantly, QuietShield represents a lower cost solution to provide acoustical padding versus traditional products, in addition to reducing landfill utilization and waste disposal costs.
Meridian Lightweight Technologies Inc.
Single Piece Cast Magnesium Liftgate Inner Panel
“Light-weighting” is an increasingly important requirement in the automotive world as governments continue to raise the bar on fuel efficiency. As a Tier 1 preferred supplier, Meridian initially worked on a development project for the Ford U152. While the magnesium casting developed did not make it onto the vehicle several years ago, Meridian proved that it was possible to use magnesium as a substitute for steel as a liftgate inner structure. Now in production on the Lincoln MKT, the magnesium tailgate inner is the largest die cast magnesium closure panel globally. It not only saves substantial weight but it also functions as the primary structural load carrying component of the liftgate assembly meeting stringent crash performance requirements, integrates six separate parts into one inner panel casting, allows for increased passenger headroom, is 100% recyclable and meets the acceptance criteria for Class A die cast surfaces.
Super High Power Elecrocoat
Electrodeposited coatings (Ecoat) have been in broad use in a variety of industries for over 50 years. An Ecoat system applies a DC charge to an auto body immersed in a bath of oppositely charged particles. A film builds on the surface of the part which coats and insulates the metal. PPG has introduced new paint chemistry for E Coat systems that achieves “super high throw”, allowing paint to penetrate recesses and coat interior surfaces without excess paint on exterior surfaces. PPG’s innovation has eliminated over 1 pound of paint per vehicle, and provides significant costs savings from reduction of paint, capital equipment and increased line rates. In one year, PPG and Toyota have launched super high throw electrocoat at eleven plants North America and Europe.
TI Group Automotive Systems LLC
Dual Channel Single Stage (DCSS 39-50) Electric Fuel Pump
With its innovative geometry of two sets of turbine blades in parallel on a single impeller, the dual channel, single stage, pump achieves greatly increased dynamic operating range to accommodate a wide range of conventional and flex-fuel powertrains. Its 20% higher efficiency affords lower electrical demand and longer life. The DCSS is enjoying rapid acceptance by a number of auto manufacturers.
The significant fuel economy, safety, and ease of use advantages of Automatic Manual Transmissions (“AMT”) are displacing traditional manual 5-18 speed transmissions in ever increasing numbers of commercial vehicles outside of the US. Introduced on the China National Heavy Truck Corp. (CNHTC) flagship model, Wabco’s (Westinghouse Air Brake Company) configure to order OptiDrive™ system improves vehicle control and safety while enhancing the driver’s effectiveness. It also significantly contributes to decreased fuel consumption and reduced maintenance cost for the vehicle’s powertrain while increasing vehicle efficiency and environmental protection.
OptiDrive’s modularity and reliance on advanced electronics enables a rapid low-cost development cycle that allows Wabco to go into markets and product segments that previously could not support AMT up-front investment costs. Since its introduction in late 2008, OptiDrive has been adopted and is in development with multiple commercial vehicle makers in Europe, China, and India.
Continental – Regensburg & NGK Insulators
Smart NOx Sensor
Jointly developed by Continental and NGK Insulators, Ltd., the Smart NOx Sensor is the first on-board sensor capable of direct measurement of NOx, in ppm levels. Using the Smart NOx Sensor, vehicle and engine makers like Daimler and Cummins can meet EPA 2010 and Euro V emissions requirements while providing customers better fuel economy and eliminating the unpleasent ammonia odors associated with of competitive urea based exhaust treatment strategies.
While outwardly similar to traditional 02 sensors on OBD/OBD2 installations, the Smart NOx sensor operates at 4x higher temps and measures current at nano amp levels and is currently the only sensor capable of supporting Stratified Charge Gasolene Direct Injection and urea dosing optimization.
Delphi Corporation Powertrain Systems Division
Delphi Direct Acting Piezo Injector
Delphi’s Powertrain Systems team has created a technology superior to common rail technology because it allows better control of injection with very short injector duration and very short separation between each injection. This direct injection piezo innovation represents a significant step in diesel direct injection possibilities offering unique capabilities that reduce particulates or NOX by 30%, a game changer that is required for the new generation of low NOX diesel engine processes. This key innovation increases power by 8% and decreases fuel consumption by 4% even as it avoids or minimizes the use of complex and expensive deNOX aftertreatment systems. With the assistance of this new injector, Mercedes was able to achieve both higher power and 20% reduced fuel consumption by replacing a 6-cylinder with a 4 cylinder engine on its 2009 C- and E-class vehicles.
Dow Automotive Systems
Providing high performance adhesion to a vast range of materials, BETAMATE™ structural adhesives can help improve vehicle durability and reduce weight while providing cost savings. BETAMATE structural adhesives replace welds and mechanical fasteners, helping reduce fatigue and failure commonly found around spot welds and fasteners.
Bayonet Connection System for Profile Wiper Blades
First introduced in limited use in 2004, today the Bayonet Connection System is the choice of more than 70% of all new blade/arm designs becoming the defacto industry standard. With easy guide and positive snap and click, the Bayonet Connection system not only improves both the security of connection and ease of removal, it also improves the grip and rotational angle compared to other existing connector systems still available today.
Rieter Automotive Management AG
Rieter Ultra Silent
Most vehicle underbody noise-deadening panels use short glass fibers for stiffness and adhesives to create a sandwich structure. But that raises environmental problems during installation and makes recycling difficult. Rieter eliminated glass fibers and adhesives and came up with a fiber-based product that is extremely lightweight, acoustically tunable, stiff, temperature-resistant and cost-effective.
Robert Bosch LLC
Long Range Radar (LRR3)
Bosch’s LRR3, the world’s first application of a silicon-germanium (SiGe)-based 77 gigahertz (GHz) radar sensor, is a major step in bringing semiconductor-based radar technologies to the automotive mass market. In addition to being the key component for adaptive cruise control (ACC), LRR3 enables advanced safety functions like Bosch’s predictive collision warning (PCW), emergency braking assist (EBA) and automatic emergency braking (AEB). The first commercial production application of LRR3 launched was in September 2009 on the 2010 Porsche Panamera.
Robert Bosch LLC
VSS, Vehicle Stability System for a 3-Wheeled vehicle
Bosch Engineering Group collaborated closely with Bombardier Recreational Products to develop the Vehicle Stability System for the Spyder, BRP’s first road vehicle. Bosch had to learn to work with a small, fast-paced development organization that had no prior experience with stability and traction control systems, while developing software to utilize existing sensors while dealing with the dynamics of a light-weight 3-wheel design. BRP in turn had to learn about the interrelatedness of systems and to convey the “sporty” experience users expected of its products. Bosch and BRP collaborated closely throughout the project, to develop a 6 sensor system that was tuned to provide the ability to handle aggressive riding yet provide the margin of safety that would make the Spyder appeal to its target purchasers.
Wheel Bearing with Face Spline
Wheel bearing with face spline Schaeffler’s design replaces traditional radial splines with self-centering axial splines where the wheel bearing meets the half-shaft. This allows easier, faster assembly and the transfer of greater torque while improving noise, vibration and harshness. It also cuts weight by 1.3 pounds per axle.
Valeo Lighting Systems
BeamAtic Premium ADB (Adaptive Driving Beam)
Imagine shining a flashlight at a fellow camper, who holds up his hand to block the beam glaring in his eyes. You can see him — and by shading his eyes, he is no longer blinded by your light. Valeo’s newest headlights achieve a similar effect by combining a camera, moving masks and advanced software to block out just that portion of the beam that would glare into other vehicles, while illuminating everything else. The new headlights allow you to drive with your high beams in traffic.
ZF Getriebe GmbH
ZF 8HP 8 Automatic Transmission
Designed to work with both conventional gas and diesel engines that are available today, ZF’s new transmission is also easily adaptable to the new hybrid power trains of tomorrow. Taking up the same size package as their previous PACE Award winning Six-Speed Automatic Transmission, this new innovative transmission represents another significant milestone in fuel consumption, performance and package flexibility over existing technology available today.
Durr Systems, Inc.
Durr’s EcoDryScrubber is a paint overspray retrieval system requiring no water. Its purpose is to provide a new technology for paint overspray capture that reduces operating costs per unit manufactured. One of the key benefits of the EcoDryScruber is that because of its extremely efficient filtration capability, up to 95% of paint booth process air is re-circulated. By re-circulating air, energy consumption in the paint spray booth is reduced by 60% and in the entire paint shop by 30%. Emissions of carbon dioxide can be reduced up to 5,200 tons per year.
The paint spray absorptive agent is inexpensive, readily available, powdered limestone; which is recycled after use as a commodity in other industries such as cement making. EcoDryScrubber does not limit advances in paint coating technology, since it provides unlimited flexibility for use with any process and material.
EcoDryScrubber has won immediate and wide acceptance, notably in Volkswagen’s Chattanooga, Tennessee, plant starting in 2010.
DuraBowl Piston Reinforcement Process
Engine makers all use lightweight low cost aluminum pistons in modern Diesel engines. Demands for higher performance, lower emissions, and better fuel economy in the next generation of Diesels are all driving higher operating temperatures, and higher cylinder pressures that go beyond the limits of the traditional aluminum piston. Transitioning to steel pistons is prohibitively expensive, so engine makers are aggressively seeking solutions and exploring workarounds to extend the capabilities of aluminum pistons.
Originally launched on the Mercedes 2.2L Diesel, Federal-Mogul’s provides an answer with their low-cost fully automated TIG welding based DuraBowl(R) process that remelts the highly stressed combustion bowl area to create a aluminum piston with over six times the durability of conventional aluminum pistons. A second dimension the DuraBowl innovation is the proprietary in-line Eddy control testing process that validates the microstructure and integrity of the DuraBowl process in every piston prior to delivery to the OEM. DuraBowl pistons will be found in Diesel engines from six different engine makers in two to twelve liter configurations.
High Precision Electro-Erosion Machining
Federal-Mogul developed an extension of electro-chemical machining that for the first time makes this approach feasible for high volume automotive production. The first application is machining the wrist pin hole of Monosteel® pistons for diesel engines. This allows the piston to tolerate pressures above 200 bar without a bushing – and at lower production cost, which helps open the design envelope for diesel engines. The machined surface holds tolerances within a 4-micron band; the tiniest high spot will form a pressure point that diminishes engine life, and that can lead to catastrophic failure. To do this, the Federal-Mogul team started from the basic science to modify the prior art of electro-chemical machining so substantially that they chose to call it electro-erosion machining. The process is applicable to other ultra-high tolerance machining of suitable geometries.
Aquence® Autodeposition and Co-Cure Paint Process
Henkel developed an autodeposition process using a chemical bath to replace e-coat for the anti-corrosion coating of vehicles and parts. After low-temperature drying, a topcoat is applied and both coats are cured and cross-linked in a single drying oven. This process uses less paint, less energy, less floor space, and gives better corrosion resistance than comparable wet-on-wet processes using an e-coat base, and with 70-80% lower capital cost. The ability to mix polymers in the emulsion used for deposition gives superior corrosion resistance. Any surface that is wetted is coated, which with the right paint formulation, gives better corrosion resistance in holes, on edges, and in odd-geometry cavities. Because chemical deposition stops at the right thickness when the reaction is complete, a more uniform coating is obtained using simpler paint equipment and controls. In addition, with water-based paints it reduces volatile emissions to near zero and eliminates the sludge attendant upon phosphate pretreatment for e-coat, which also reduces operating cost and downtime. The process with two coats is in production at several locations. Autodeposition with co-cure is believed to be a superior platform from which to achieve the goal of the industry, a three-coat application with one curing oven for all three.
International Automotive Components Group North America
IAC Manufacturing Process: Two-Step Panoramic Headliner for 2009 Toyota Venza
Manufacturing process for two-step, panoramic headliner IAC designed a headliner with a large sunroof — and a new, automated manufacturing process to make it. The combo cut weight, cost and manufacturing complexity compared with traditional, labor-intensive headliners of that size.
Johnson Controls GmbH Automotive Experience & Nordenia Deutschland Gronau, GmbH
PP Thin Film
Engineered plastic panels abound in modern vehicles including door panels, kick panels, consoles, side panels, and seat backs; the more plastic panels are used in a vehicle, the greater their impact on perceived quality, durability and cost. Based on a technology developed for pet food packaging, Johnson Controls (JCI) in a close collaboration with NORDENIA DEUTSCHLAND developed a molded polypropylene (“PP”) Thin Film process, that provides automakers like BMW, Volvo, and Opel the superior durability, perceived quality, and reduced environmental impact, of higher cost filmed coatings at a price equal to or lower than painted plastics.
The close collaboration between JCI and Nordenia resulted in a new automated manufacturing process that integrates thin film technology, deep drawing, back injection molding, laser cutting and the edge wrapping processes to manage parameters such as gloss, and grain texture uniformity, to increase the customer’s perception of the part.
RobScan Optical scanning allows RobScan’s laser beam to jump from one weld spot to the next while the robot arm moves without stopping. At one automaker that uses it, throughput has increased up to 15 times compared with resistance spot welding.
Siemens PLM Software
Teamcenter In-Vehicle Software (IVS) Management System
The Siemens In-Vehicle Software Management system addressed and solved the increasing number of vehicle variations that manufacturers face with the growth of distributive electronic systems. As the number of electronic control units expands, then lines of software code and interdependencies between competing suppliers within vehicles expands. The current number of lines of code is about 10 million in a typical vehicle. By 2015, 100 million lines of code will be within “connected vehicle.” Siemens and Ford have created a software management system permitting them to monitor every vehicle variation on a global basis down to the VIN (vehicle identification number). This innovation extends the lifetime control Ford has of its global fleet by leveraging existing software management processes that also maintain security protocols for firewalls between competing suppliers to all model types.