MOBILITY ENGINEERINGTM AUTOMOTIVE, AEROSPACE, OFF-HIGHWAY A quarterly publication of and Electrifying launch Volvo bringing hybrid bus technology to India Crankshaft reliability Integrated design, simulation, and testing Volume 3, Issue 1 Autonomous vehicles March 2016 Societal impacts ME Saint-Gobain Ad 0316.qxp_Mobility FP 1/4/16 12:50 PM Page 1 Anything for a quiet ride We believe seat adjustment systems are there to enhance driver comfort, not to make distracting noises during driving. By dampening structure-borne vibrations in the seat height adjustment system Saint-Gobain helps you deliver a quieter drive. We can also reduce component wear for a longer life. It’s just one of the ways our teams are working with the world’s automotive engineers to improve the driving experience. Find out how we’re making a difference on every scale: makingabigdifference.com [email protected] CONTENTS Features 40 Autonomous vehicles: impact 52 Touch and go AEROSPACE AVIONICS on society AUTOMOTIVE ELECTRONICS Avionics developments are changing life in the cockpit and Self-driving technology offers plenty of promise, but not at airborne work stations. everything about autonomous vehicles will be a panacea. 56 Improving heavy-duty engine 42 Crankshaft reliability by component efficiencies integrated design, simulation, OFF-HIGHWAY POWERTRAIN and testing AUTOMOTIVE POWERTRAIN Cylinder deactivation can improve fuel economy by using a This testing method is proven and beneficial for the design reduced number of cylinders that operate at higher loads and development of the crankshaft and could be applied and thermal efficiency, while other cylinders are turned off, to other critical engine components, thereby extending to when the engine operates at partial load conditions. A system reliability. switching roller finger follower is one of the technologies that help make it work. 45 New Engines 2016 AUTOMOTIVE POWERTRAIN Highlighting the design, engineering, and technologies Cover inside some of the most competitive gasoline and light- Volvo is bringing its hybrid bus duty diesel ICEs. technology to India in the first half of 2016, promising a fuel-consumption benefit of 39% compared to diesel. MOBILITY ENGINEERING MARCH 2016 1 CONTENTS Departments Secondary loop and heat pump climate control 4 Editorial 26 under evaluation once more AUTOMOTIVE INTERIORS 6 Focus 27 SABIC showcases customizable sheet, 3D seat for 8 SAEINDIA News aircraft interiors AEROSPACE INTERIORS 8 SAENIS Efficycle 2015, 15th-18th October 2015 28 Ford looks to spread Corning’s new lightweight 10 Inauguration of Division Offices, 13th October and Gorilla Glass beyond the 2017 GT AUTOMOTIVE BODY November 2015, Chennai & Madurai 30 2016 Civic structure employs ‘first’ partial in-die soft 12 Technical talk, 30th October 2015, Bangalore zones AUTOMOTIVE BODY & CHASSIS 12 AWIM Master Teacher Training Program 2015, 12th 31 UCLA researchers develop new strong and lightweight December 2015, Bangalore metal nanocomposite AEROSPACE MATERIALS 13 AWIM Regional Olympics 5th December 2015, Pune 32 GT350 Mustang features novel composite structural component AUTOMOTIVE MATERIALS 14 Lecture Meeting, 19th December 2015, Chennai 33 Crash testing advances on many fronts 14 SINE 2015, 13th-24th December 2015, Pune AUTOMOTIVE TESTING 16 AWIM Regional Olympics, 19th and 30th December 34 Evaluating new forestry machines in a fraction of the 2015, Tirunelveli and Chennai time OFF-HIGHWAY SIMULATION 17 Industry News 36 Aurora Flight Sciences, Stratasys debut at Dubai 17 Rockwell Collins expands India operations jet-powered, 3D printed UAV AEROSPACE SIMULATION 17 Tech Mahindra buys controlling stake in Pininfarina 36 Surface Generation speeds composites throughput with one-shot stamp-forming process AUTOMOTIVE 17 HydraForce strengthens electrohydraulic-controls MANUFACTURING position in India 38 GE scanner enhances defect detection for industrial 18 Magneti Marelli opens plant to produce automated CT AEROSPACE MANUFACTURING manuals 38 Hot-stamping process from Schuler employs 18 Volvo launches first hybrid buses in India flexible ‘pressure controlled hardening’ AUTOMOTIVE MANUFACTURING 19 Technology Report 19 Low-friction techniques push advanced city-car 60 Global Vehicles project toward 84-mpg target AUTOMOTIVE 60 BUDD-e concept forecasts what VW zero-emission POWERTRAIN van could be in 2019 21 Clean-sheet design for Proterra’s all-electric city bus 61 Airbus looks to expand military product lines OFF-HIGHWAY PROPULSION 63 Companies Mentioned, Ad Index 22 GE’s clean-sheet turboprop engine to launch with Textron Aviation AEROSPACE PROPULSION 64 Q&A 23 OTA reflashing: the challenges and solutions Navistar CIO Terry Kline talks about the company’s AUTOMOTIVE ELECTRONICS vehicle connectivity strategy and its new over-the-air 24 Clamoring for a connection AVIONICS reprogramming technology 25 HMIs offer something for everyone COMMERCIAL VEHICLE INTERIORS © SAEINDIA and SAE INTERNATIONAL reserves all rights . No part of this publication and/or website may be reproduced, stored in a retrieval system or transmitted in any form without prior written permission of the Publisher. Permission is only deemed valid if approval is in writing. SAEINDIA and SAE International buys all rights to contributions, text and images, unless previously agreed to in writing.In case of Address/addressee not found return to SAE INDIA, No 1/17Ceebros Arcade, 3rd Cross, Kasturba Nagar, Chennai -600 020. Telefax: 91-44-2441-1904, Phone: 91-44-4215 2280. 2 MARCH 2016 MOBILITY ENGINEERING ME Smalley Ad 0316.qxp_Mobility FP 1/29/16 10:30 AM Page 1 HOW DO I KNOW IF I’M TALKING TO AN ENGINEER OR A SALESMAN? Ask Smalley. We have nothing against sales people. But when it comes to differentiating Inconel from Elgiloy or overcoming dimensional variations within a complex assembly, wouldn’t you rather work with an engineer? Our customers would. That’s why they collaborate directly with our world-class team of Smalley engineers—experienced professionals whose only focus is helping you specify or design the ideal wave spring, Spirolox® retaining ring or constant section ring for your precision application. Smalley wave springs reduce spring operating height by 50%, saving space and weight, axial spaces. We offer more than 4,000 stock sizes in carbon and stainless steel. Visit smalley.com Smalley Coil Spring for your no-charge Wave Spring test samples. THE ENGINEER’S CHOICE™ EDITORIAL EDITORIAL Bill Visnic Editorial Director [email protected] Asit K. Barma SAE India Editor C. V. Raman The links between phone and car won’t be ignored ED, MSIL [email protected] At January’s North American International Auto development of autonomous-driving technol- Arun Jaura VP, SAEINDIA Show (NAIAS), Detroit’s winter weather played ogy. Without the society-imploding implica- [email protected] its typical role, but decidedly not to script was tions of autonomous vehicles (AVs), Bala Bharadvaj MD, Boeing R & T the buzz that refused to go away: that despite automakers and suppliers probably wouldn’t [email protected] several magnificent concept cars and formida- have much of notice at CES beyond oversized Mathew Abraham ble production vehicles on display in Detroit, dashboard screens with still-frizzy versions of Sr. GM, Mahindra [email protected] many automakers and technology suppliers Android Auto and Apple CarPlay. Instead, this Dr. Venkat Srinivas actually had revealed their vision of the “real” year’s CES championed concept-car reveals of Vice President & Head - Engineering & Product automotive future a week earlier at the serious import, such as Volkswagen’s BUDD-e Development, Mahindra & Mahindra Truck and Bus Division Consumer Electronics Show (CES). and—make your own believability determina- [email protected] In effect, many insisted that not only has CES tion—Faraday Future’s FFZERO1 concept. There Lindsay Brooke Editor-in-Chief amplified its profile to the point that it rivals any was a raft of production or near-production [email protected] of the auto industry’s international shows, but innovations from major suppliers such as Ryan Gehm Associate Editor that CES has quickly eclipsed “traditional” auto Bosch, ZF, Harman, and Continental. [email protected] shows as the place to get the first glimpse of And GM used CES—not the Detroit show—to Patrick Ponticel bleeding-edge automotive technology. stage the first (albeit brief) public drives of the Membership Editor [email protected] For now, though, I still get the whiff of Chevrolet Bolt electric vehicle, surely one of the Lisa Arrigo slightly more flash than substance with CES, company’s most pivotal models of the last 50 Custom Electronic Products Editor particularly in terms of how the auto industry years. That says all you need to know about [email protected] cadences new technology. For example, how the automotive sector has acknowledged Contributors Faraday Future, the mysterious and much-dis- the impact of CES. And it demonstrates the Kami Buchholz Detroit Editor cussed electric-vehicle startup that’s either links between the automotive and consum- Stuart Birch vaporware or the next-and-even-better Tesla, er-electronics industries are rapidly tightening. European Editor rests its production-vehicle future on a “skate- Development of autonomous technology has Jack Yamaguchi Asia Editor board” modular vehicle architecture that stampeded from being a closely-watched con- Steven Ashley appears to be a reboot of General Motors’ cept when pushbutton start