Tech 2002 Awards
Electromechanical/electrohydraulic simulation
SIMPLORER from Ansoft is a design suite for electromechanical and electrohydraulic systems used in the automotive industry. It covers a range of applications including onboard power networks, 42-V systems design, and electric and electric-hybrid vehicles. The product combines advanced, non-Spice circuit simulation with a powerful block diagram and a sophisticated state machine simulator. The kernels run simultaneously in a simulator-coupling environment, providing high numerical stability. The coupling technology also provides an open programming interface to include other industry tools. The company's latest release, SIMPLORER 4.2.1, has an extended model generation capability that allows the use of the latest power semiconductor technology. The parameterization process uses SIMPLORER's optimization tool to adapt the model parameters to the required behavior.
Exhaust gas aftertreatment
AVL List GmbH has developed heavy-duty diesel engines complying with Euro 4 emissions legislation without the use of particulate traps or DeNOx catalysts. The technology builds on advanced fuel-injection equipment combined with AVL's combustion knowledge and holistic development approach. A dynamically controlled EGR system is applied. An Oxicat is added to compensate for production tolerances affecting the lube-oil control. Test results show a 20% margin to the legislated emissions limits. On-road fuel consumption is similar to current Euro 3 compliant engines. The technology is also applicable to off-road engines to meet Tier 3 requirements.
Release coatings
DuPont TraSys water-based release coatings are environmentally safe, enabling molders to meet even the most stringent existing and anticipated environmental regulations. TraSys is free of volatile organic compounds and ozone-depleting chemicals. DuPont also has eliminated chlorinated solvents from its release products rather than replace them with carcinogenic solvents or flammable alcohols. The releases are manufactured using highly effective, stable raw materials and are mixed in a unique blending process to yield the desired durability. Product consistency and reliability keep production running smoothly, while competitive pricing, combined with high levels of performance and longevity, provides the most cost-effective release available for elastomer molders.
CFD package
FLUENT 6, which is built on Fluent Inc.'s core unstructured technology platform, expands the automotive applications for CFD simulation, including deicing and water runoff, fuel tank studies, HVAC systems and components, painting, and flow-induced noise. Major enhancements in turbomachinery modeling and underhood thermal analysis provide economical design testing options for automotive engineers. A moving/deforming mesh capability, released in beta form with this version, is one of many building blocks in the release intended to tackle challenging IC engine modeling.
Spinforming systems
Integrated spinforming systems from Hess Engineering are used for high-volume automotive exhaust component production. The precise, economical metal-forming technology can accommodate concentric-, eccentric-, and oblique-axis designs. Benefits include cost savings of 30%, no welding, low tooling cost, high material yield/reduced scrap, weight reduction, flexible manufacturing, and high reliability.
