2013 Finalists

2013

1. BorgWarner Thermal Systems

   Visctronic High-Speed Reservoir System

   Nearly all vehicles have electronically controlled cooling fans that turn on when needed, reducing drag on the engine. BorgWarner’s Visctronic system matches the fan’s operation more precisely with the engine’s needs, saving fuel and reducing noise, vibration and harshness.
   Visctronic fan drives utilize BorgWarner’s proven viscous technology with precise electronic control. The fan drive is controlled by the engine’s control module for precise fan speed modulation. Visctronic fan drives provide better engine cooling and improved fuel economy with minimum parasitic loss. The Visctronic fan drive’s ability to better control engine temperature effectively provides the cooling needed for low tailpipe emission requirements and lowers average fan speed and horsepower during cooling resulting in lower noise, greater economy, and improved driver comfort. All of which make it an ideal choice for passenger car, sport utility vehicles (SUVs), and light trucks around the world.

2. Hirotec America Inc.

   Hirotec Robotic Rear Wheelhouse Roller Hemming System

   Wheelhouse hemming pinches together the edges of a vehicle’s underbody and fender. Hirotec’s robots read the vehicle without complex machine vision. And one robot station can achieve high-quality, low-cost hems on various vehicles.
   As a total hemming solutions provider with over 80 years of experience, HIROTEC AMERICA offers our customers a reliable and flexible rear wheelhouse robotic roller hemming application. Our unique hemming approach can significantly improve wheel safety conditions, finished hem quality, and enhanced corrosion resistance.

   Choosing HIROTEC AMERICA as your wheelhouse roller hemming specialist will provide:
    A flexible hemming system that can achieve a variety of hems on multiple models in a single hemming cell, which reduces the need for costly additional tooling.
    Push/pull roller hemming head, featuring multiple roller configurations that can accommodate a variety of finished hem conditions, such as flat, rope, or cap.
    Simple yet robust design that does not require vision technology, which translates to significantly lower costs for our customers.

3. Tweddle Group Technologies

   Tweddle Connect Telematics Solution

   The telematics software allows motorists to connect mobile phones to a vehicle’s center stack. This reduces driver distraction because motorists can enjoy certain apps in the vehicle without handling their cell phones. Tweddle’s system can be adapted to many phones and automakers’ hardware.

   Utilizing innovative connectivity, content aggregation and user authentication solutions, Tweddle’s connected services platform offers OEMs and Tier 1 suppliers a comprehensive and dynamic solution that supports multiple vehicle connection strategies (Bluetooth, WiFi, and Embedded Cellular). The platform leverages advanced database, access control and network solutions based on proven information technologies and industry standards. Our suite of tools and customization services include:
   • Access to Tweddle’s custom/stable APIs for service queries, user management and information access
   • A patent-pending access control methodology
   • A base set of content features from recognized partners such as Bing, OpenTable, MovieTickets.com, STATs, Pandora, iHeart radio, Slacker and more…
   • Integration with OEM backend systems for vehicle authentication and user management
   • E-Commerce (B2B and B2C)
   • New vehicle owner on-boarding wizard
   • Customizable mobile application portal that supports most in-market handsets offered with a data plan
   • Bluetooth connectivity software based on published Bluetooth SIG and Web standards
   • Interoperability testing of in-market handsets (to support phone connectivity strategy)
   • HMI design (both mobile and in-vehicle)
   • Application publishing

4. Halla Visteon Climate Control Corp.

   New Assembly Method Between Shaft And Swash Plate

   The shaft and swash plate of Halla’s air-conditioning compressor rub against each other, so they are coated with Teflon. To prepare surfaces for Teflon, such parts are typically sandblasted, anodized or treated with phosphates. Halla prepares the surface with lasers, which improves adhesion of the Teflon, removes a small burr created by machining and reduces pollution because lasers don’t use harmful chemicals.

5. Magna Powertrain

   eRAD for Plug-In Hybrids

   Volvo wanted a plug-in hybrid version of the V60 wagon, so the automaker added Magna’s electric rear-axle drive, or eRAD, which uses an electric motor to power the car’s rear wheels. The car’s diesel powertrain drives the front wheels. Drivers can choose electric power, diesel or a combination. This method economically combines an internal combustion engine with an electric motor to create a four-wheel-drive vehicle.

6. Nartron

   iQ Power Solid-State Touch-Screen Systems

   Typical vehicle touch screens respond only to finger tapping. This technology responds to finger taps, slides and pinches, like many smartphones.

7. BorgWarner Emissions Systems

   Advanced Compact Brushless Actuator

   BorgWarner’s electronic device reduces emissions of oxides of nitrogen in diesel engines by precisely controlling valves on gas recirculators, waste gates, turbochargers and exhaust throttles. It replaces metal gears with plastic ones, reducing weight and vibration for better efficiency and durability.
   BorgWarner Emissions Systems products focus on air management and emissions control for passenger cars, light trucks and commercial vehicles. Engineered to lower emissions, improve fuel economy and enhance vehicle performance, BorgWarner’s advanced technologies include exhaust gas recirculation (EGR) modules which consist of the valve, cooler, tubes and by-pass valve, as well as other products such as secondary air systems, tubular products, advanced actuators and integrated system solutions.

8. Visteon Corp.

   Reconfigurable Instrument Cluster With Illuminated Mechanical Gauge Rings

   The Visteon instrument cluster can show different displays for various brands, nameplates and trim levels using the same hardware. All circuitry is printed on a single board, cutting manufacturing costs and complexity.

9. Telenav

   Scout for Cars

   Many drivers unsafely use the navigation app on their smartphones while behind the wheel. Scout for Cars enables a motorist to operate a smartphone’s nav app on a vehicle’s infotainment system. The navigation app appears on a vehicle’s center stack screen while the smartphone stays safely in the motorist’s pocket.
   Scout for Cars connects the car with your phone and the cloud. With the growing use of smartphones and mobile services, consumers increasingly want and expect to access their personal information in the car. With current tools, drivers must deal with multiple apps and interfaces and constantly re-enter information on the go, which compromises the experience. Telenav provides solutions that make the transition from phone to car a seamless, safe and efficient experience.
   Telenav’s Scout for Cars solutions include:
   • Scout for Cars: Brought In — Allows the in-vehicle display to interact with the Scout™ mobile app via Bluetooth®, MirrorLink, USB or Wi-Fi.
   • Scout for Cars: Built In — An embedded platform that connects the car to Telenav’s mobile services.

10. Delphi Automotive

    Myfi Connected Navigation Radio

    The infotainment system lets automakers mix and match features such as HD radio, satellite radio, USB connections or navigation in one compact package. Dealers can add features by downloading additional software. The system has an energy-saving, lightweight design.
    With more than six decades of audio system integration experience and the ability to pioneer emerging technologies for the vehicle environment, Delphi is helping provide drivers and passengers the entertainment and connectivity they want in their vehicles. We combine this expertise with specialized audio technologies to provide distinctive, quality products that achieve the highest levels of performance.

11. Preh GmbH

    Fanless Interior Temperature Sensor

    Sensors to measure cabin temperatures have long needed fans. Preh’s fanless sensor uses a thermistor — an electronic part whose resistance changes with temperature — and software. The device is less expensive and more durable than a sensor with a fan. It can be built into the climate control system or placed in the cabin.

12. Mahle GmbH

    Monotherm Steel Pistons For Passenger Car Diesel Engines

    Aluminum pistons are the standard for diesel engines. Mahle’s forged steel piston and accompanying pin assembly are lighter than an aluminum assembly. And the steel piston operates with 5 percent less friction than aluminum, helping automakers to meet goals for carbon dioxide reduction.

13. Federal-Mogul Corp.

    High Performance Aluminum Diesel Pistons

    Federal-Mogul used innovative manufacturing methods such as die cooling to create strong aluminum pistons that can handle the higher thermal and mechanical loads of downsized diesel engines.

14. Takata Corp.

    Front Center Airbag

    Takata, with General Motors’ assistance, developed an airbag that inflates between the left and right front seats. The airbag, mounted in the right side of the driver’s seat, protects the driver and front-seat passenger in side-impact crashes.

15. Delphi Automotive

    Fourth-Generation Manifold Air-Pressure Sensor

    The first generation of Delphi’s pressure sensor, the size of a computer mouse, required 28,900 square feet of manufacturing floor space. Today’s fourth generation is the size of a small tooth and requires 6,269 square feet of space. Delphi can now produce more accurate custom sensors on a single assembly line while lowering warranty problems from 51 problem parts per million to less than 10 with this sensor.

16. Valeo Lighting Systems

    BiLED Module

    Two multichip LEDs are used for the low beam, and a third is activated for the high beam. No mechanical movement, necessary in some xenon headlights, is needed to project the high beam. Because light-emitting diodes generate little heat, the module uses a lightweight plastic lens, adding flexibility for designers.

17. Lear Corp.

    Lear Crafted Comfort Connect

    Seat makers typically use convex surfaces to hold leather in place and prevent wrinkling. But stylists now want different shapes. Also, traditional processes usually preclude large, sculpted surfaces. To solve these problems, Lear used a combination of advanced manufacturing processes: infrared heating, computer-aided temperature feedback and new adhesive and laminate chemistries.

18. Fulton Innovation

    eCoupled Wireless Power For Vehicles

    Motorists can wirelessly charge mobile phones or other electronic devices by placing them on a charging surface.

19. Delphi Automotive

    Delphi Vehicle Sound Generator

    Congress has passed a law requiring EVs and hybrids to make sounds warning pedestrians of the vehicles’ presence. The device emits signals and can create distinctive sounds for different brands.

20. BorgWarner Turbo Systems Winner!

    Regulated 3-turbocharger System (R3S)

    First launched on 2012 M Series X6, X5 and 550 sedan, BorgWarner’s Regulated 3-turbocharger System (“R3S”) helps BMW set new Diesel performance and fuel economy benchmarks with the highest output per liter in a production Diesel vehicle. (280 kW/381 HP and 740 Nm/546 lb-ft torque) Beyond simply adding an additional turbo, BorgWarner worked with BMW to develop a new sealing approach to minimize the parasitic pumping loses and intake fouling that were key obstacles to serial/parallel turbo applications.

21. Brose North America, Inc. Winner!

    Brose Hands-free Liftgate Opener

    Shoppers arriving at their car with arms full have surely wished their rear lift gate could open automatically. The challenge was to design a hands-free system that would open reliably but only when desired. A BMW-Daimler-VW consortium concluded that a non-contact kicking motion might work; Brose made it work.

    Using standard proximity sensors, Brose created an electronic profile of a kicking motion that allows people of all sizes to signal opening yet cannot be triggered accidentally by a dog fetching a ball or a child swinging their legs while sitting in the rear. The Brose hands-free solution can be installed on any vehicle that has a keyless entry system and an electronic latch release. First launched on the BMW 5-series in 2011, it is now available on the Ford Escape and C-Max and the Mercedes SL and will soon launch with other OEMs.

22. Continental Automotive Systems, Interior Division, Body and Security Winner!

    Tire Pressure Monitoring System: Localization on Synchronized Emissions (LocSync)

    Regulators require a low tire pressure indicator but until now showing the pressure of individual tires required additional sensors and was typically a premium feature. Using a clever software solution Continental’s LocSync has changed that game, allowing OEMs to implement premium functions on standard systems.

    The LocSync software tracks the differential slip of wheels in normal driving using existing vehicle sensors. It can then correlate sensor output to to associate individual valve stem pressure sensors to the correct wheel location. Continental’s LocSync system is standard on the 2012 Chrysler Dodge Dart and 2011 Hyundai Sante Fe, and will launch on vehicles of multiple North American, Asian and European brands over the coming two years, allowing them to offer premium functionality on entry-level vehicles.

23. Continental Automotive, Chassis & Safety Division, ADAS Business Unit Winner!

    24GHZ ISM Band Short Range Radar

    Taking Short Range Radar (SRR) to a new level, Continental Automotive has developed a Blind Spot Detection (BSD) and Rear Cross Traffic Alert (RCTA) system that out performs anything currently in the market today. The product innovation is superior with regard to speed, distance and angle. Both Toyota and Ford gave high accolades to this product and praised it with regard to ‘zero missed warnings’ and ‘zero false alarms’ during BSD and RCTA testing. Toyota also applauded the product innovation because it meets all global Short Range Radar safety requirements.

    This product innovation has been selected for the Lexus ES, RX and LS, Toyota RAV4, Avalon and Sienna as well as the Jeep Grand Cherokee, Ford F-150, Ford Mustang and Ford Explorer.

24. Dana Holding Corp. Winner!

    Diamond Series Driveshafts

    Introduced by Peterbilt (Paccar) for heavy hauler and vocational applications, Dana’s Spicer® Diamond Series™ is an industry first one-piece aluminum driveshaft that allows truck owners to save up to 100 pounds per vehicle. Dana developed a hydro-formed football shape and adapted rocket science joining techniques to weld lightweight aluminum tubes to durable steel end fittings removing up to 36% of a HD truck’s traditional two-piece driveshaft weight and simplifying assembly line installation.

25. Delphi Automotive Winner!

    F2E Distributed Pump Common Rail System

    The F2E distributed pump common rail system enables the efficient introduction of common rail fuel injection technology, and Class-leading 3000 bar rail pressure performance, to an existing Electronic Unit Injector (EUI) diesel engine architecture with minimal modification.

    The combination of unmatched high pressure and highly efficient hydraulic design enabled Delphi to demonstrate 50% smoke reduction and up to 5% fuel consumption improvement while attaining required low NOx levels. The F2E modular system fits completely under the rocker cover and is driven by the engine camshaft. The enclosed installation and efficient pump design yields a measurable -2dB(A) NVH benefit. The new modular system is comprised of pumping and non-pumping injectors, which can be deployed in varying proportion according to the engine performance requirements.

26. Federal-Mogul Corp. – Powertrain, Bearings and Ignition Winner!

    IROX® – Highly Effective Coating for Engine Bearings

    To meet customer demands and government regulation vehicle OEM’s are seeking improved fuel efficiency and reduction of CO2. They are looking at many options such as turbocharging, downsizing, hybrids and engine stop-start management strategies. Each of these increases mechanical loads and lubrication challenges for engine bearings.

    Federal-Mogul addressed these challenges by developing an innovative polymer coating for bearing shells. Called IROX®, the new technology reduces friction and withstands the increased mechanical loads and addresses the lubrication challenges by protecting bearing shells and crankshaft from damage where metal-to-metal contact would otherwise occur. In these applications, it is estimated that the IROX® overlay can increase bearing shell life by more than five times.

    IROX® extends the applicability of existing aluminum and copper based bearings as well as the use of cost-efficient crankshaft materials, like nodular cast iron, to higher specific loads. These innovative metal sleeve bearings provide OEM’s a design alternative for many powertrains that provide improved fuel efficiency and reduce CO2 Emissions.

27. GPM GmbH< Winner!

    Electro-Hydraulic Controlled Flow (ECF) Water Pump

    OEMs face unprecedented engineering challenges to improve the efficiency of internal combustion engines, ICEs,

    ICEs exhibit high levels of fuel consumption and emissions at cold start. The goal is to reach operating temperature as soon as possible. Existing mechanical driven constant flow water pumps circulate coolant during warm-up, dissipating heat from the engine delaying the time to reach optimal temperature.

    GPM GmbH solves this problem with its Electro-Hydraulic Controlled Flow Water Pump, ECF. The ECF is the first mechanically driven water pump capable of continuous flow control. It enables the fastest possible engine warm-up and can be an important part of an ICE thermal management strategy.

    A unique axial piston “pump within a pump” uses coolant to generate the hydraulic pressure to actuate a flow control slider. The pump also eliminates all external control valves with the only connection being the control signal.

    For Volkswagen’s TDI Engine, ECF implementation contributed to a 2% improvement in fuel efficiency and CO2 reduction.

28. Halla Visteon Climate Control Corp. Winner!

    Metal Seal Fitting

    Zero HVAC leaks is a goal for all OEM’s, especially as the need to reduce refrigerant emissions grows. Halla Visteon’s new zero-leak Metal Seal Fitting takes the industry a big step in that direction. Indeed SAE now uses the MSF as the “zero leak” standard, qualifying for US environmental credits.

    The Halla Visteon Metal Seal Fitting maintains its zero leak capability in the real world of assembly plants, where contaminants, misalignment, and tightening errors can cause other fittings to leak. In service, a shop mechanic can retighten the Halla Visteon MSF without losing the full refrigerant charge, rather than needing to replace the fitting, delivering lower costs to the customer and lessening the environmental impact. First launched on the Ford Taurus and Lincoln MKS/MKZ, it will be standard on all Ford vehicles beginning with MY2012.

29. PPG Industries Inc. Winner!

    PPG Andaro Tint Dispersions

    With Andaro Tint Dispersions, PPG has achieved a brilliance and clarity of automotive color previously attainable only with fragile organic dyes used on show and concept cars. Andaro consists of pigments ground to nano-scale particles combined with a proprietary technology to prevent particle agglomeration, providing reduced light scattering and more absorption. It is applicable by existing paint shop processes, requiring no additional OEM capital investment. Ford and Chrysler are the first customers to adopt Andaro.

30. Valeo Winner!

    Air Intake Module with Integrated Water Charge Air Cooler (for Diesel emissions reduction applications)

    Valeo’s new water charged air cooled intake module, code named WCAC, has several innovative enhancements compared to the traditional air-to-air coolers, including higher cooling efficiency in a smaller package, performing as a structural part of the air intake module. Plus the WCAC system integrates the throttle body, a high pressure EGR valve and an EGR distribution channel within the manifold outlet flange.

    The integrated EGR valve mixes exhaust gases with cooled charged air for homogenous distribution into the cylinder heads. The module is assembled directly onto the cylinder head for shorter charge air routing, reducing turbo lag during acceleration. The WCAC’s coolant plates are comprised of a specially developed aluminum alloy material that is resistant to EGR corrosion. Introduced first on the Volkswagen 4 cylinder 1.6 and 2.0 L TDI modular engineers, the WCAC played an important enabling role in meeting worldwide emission regulations, and in downsizing of the engine for improved fuel consumption without loss of power.

31. Federal-Mogul Corp. Powertrain – Sealing – Southfield Winner!

    Injection Molding of High Modulus Bonded Pistons Used in High Pressure Transmissions

    Increasing hydraulic pressures and reduced packaging space in new generation dual clutch and automatic transmissions have triggered the need for higher tensile strength and higher modulus (stiffer) elastomer lips on bonded pistons to resist deflection and wear. But the higher viscosity of materials satisfying these requirements inhibits flow in the injection molding process.

    In addition to a new material formulation Federal Mogul has developed tooling and manufacturing processes that overcome this limitation, and successfully produce pistons that enable transmission manufacturers to reach their design goals. Higher productivity, lower scrap rates, and an industry leading doubling of modulus are the result.

32. Schuler Inc. – Hydroforming Division Winner!

    Hydroforming and Global Die Standardization Process

    Schuler has created a hydroforming process that delivers a more economical approach to a global standard process for hydroform component production. The process delivers a global die design, stabilized and lower cost die development, increased material utilization and a leading edge ability to process emerging high strength steels. The new die development process creates a die that can produce the same parts, with the same process, on the same dies, anywhere in the world. These simple, yet revolutionary process improvements make hydroforming more economical than ever before, allowing more freedom for automakers to apply this technology for new light weight designs and better structural integrity. To make this concept a reality, Schuler collaborated with Ford Motor Company. Through this collaboration, Schuler trained 200 Ford team members, helping the company achieve new innovative structural designs with greater cost savings, higher material utilization and improved structural integrity for their current and future platforms.

33. Hughes Telematics, Inc. Winner!

    Automotive Software Remote Update Technology

    Today’s cars run up to 100 million lines of software code on as many as 70 to 100 electronic control units, ECU’s. Software related recalls cost $75 to $100 per vehicle plus time and inconvenience to the driver.

    As vehicle codes become more advanced auto manufacturers can expect annual costs in the hundreds of millions for software recalls. The Automotive Software Remote Update Technology (ASRUT) developed by Hughes Telematics Inc.(HTI) provides a significantly lower cost alternative by “re-flashing” the vehicle remotely. Instead of 1:1 vehicle repairs ASRUT is capable of 1:thousands of vehicle updates and with no driver intervention. Instead of visiting a service center to upload software patches vehicles will remotely download and install the upgrades through their telematics systems over cellular-data networks in minutes.

    HTI’s initial application of this technology is exclusive to the Telematics Control Unit (TCU). HTI will leverage the technology to remotely add new features to the Mercedes-Benz mbrace™ telematics service offering. The full application of this technology to both updating existing code or adding new services will benefit both automotive manufacturers and consumers by making auto software updates cheaper, easier and more reliable.

34. BMW Manufacturing Co., LLC for their partnership with BorgWarner Turbo Systems

    Regulated 3-turbocharger System (R3S)

    The BMW’s early support and continuing efforts for Borg Warner’s 3 stage turbocharger system formed the basis of deep collaboration partners resulting in a system that advances turbo sealing, performance, charge cooling, emissions and airflow management. The Euro-6 emissions compliant turbo system is in BMW’s first M-Series vehicles powered by a diesel.

35. General Motors for their partnership with Takata

    Front Center Airbag

    GM and Takata filed joint patent applications addressing ways to minimize the side impact injuries using a front and center air bag system. GM teams worked with the Takata engineers without interruption for 5 years to commercialize this unique air bag system.

36. Mercedes-Benz USA for their partnership with Hughes Telematics Inc.

    Automotive Software Remote Update Technology

    MBUSA worked hand in hand with Hughes Telematics Inc. to develop the process management and necessary controls to create ways to remotely update vehicle software as well as add services to vehicles over the air without dealership visits to bring simplicity and cost savings to the evolving automotive telematics technology.

37. Toyota Motor Corporation for their partnership with Continental Automotive

    24GHZ ISM Band Short Range Radar

    Toyota collaborated in a variety of complex phases with Continental Automotive, Chassis and Safety Division to refine and commercialize a new rear corner radar system that has zero false alerts and zero missed warnings for both blind spots and rear cross traffic alerts.

38. Volkswagen AG for their partnership with Valeo

    Air Intake Module with Integrated Water Charge Air Cooler

    VW had short development lead times for their new worldwide diesel engine and worked closely with Valeo Thermal using weekly on site meetings in multiple locations and joint international project management processes to secure timely 2012 launches.