AN AUTONEWS 04-16-07 B 1 AUTONEWS 4/10/2007 3:43 PM Page 1 ENGINEERING INSIGHT APRIL 16, 2007 • 16A 110000 CCCoolCoolooooll ttthingsthingshhiinnggss

hink there’s nothing new under the We know it when we see it. It can be high- sun? How about this collection of tech, low-tech or no-tech. Tinnovations — from headlights that Thousands of cool things can be found in see around a bend to a voice-recognition modern and trucks and in automotive system that handles explicit commands such factories. as “find Thai restaurant.” Here’s just a sampling — a mere 100 — in no How do we define cool? Well, put it this way: particular order. AN AUTONEWS 04-16-07 B 2 AUTONEWS 4/10/2007 3:44 PM Page 1

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An end to 3 parallel-parking panic The Lexus LS 460 parks itself. As you cruise slowly through a parking lot, front-bumper Pop-up tweeters sensors search for open spots. Shift into 1 The optional Bang & Olufsen stereo in reverse, and the backup monitor displays the the S8 makes you want to stay in the targeted parking space. Confirm the parking long after that big shuts down. Bang & spot, release the brake and let go of the Olufsen specializes in high-glitz home steering wheel. The car automatically swings electronics equipment that sounds good and into the parking spot. looks spectacular. With the S8, the Danish company ventures into car audio. Slide into the driver’s seat, turn the key and, magically, a tweeter rises out of the dashboard on each side, right by the A-pillars. The tweeters are It makes the grade augmented by 12 other speakers, including a 2 Driving on a steep, unstable grade is a true test of an off-roader’s skill. Land subwoofer, and the whole system gets its Rover’s Gradient Release Control helps a driver’s confidence by holding the vehicle in power from a 1,100-watt amplifier. All that place on steep uphill or downhill inclines, even after the driver’s foot is off the brake. fancy optional gear comes at a price: about That allows the driver to be more poised when applying the accelerator — rather than $6,300. having to stab at it. GRC, developed by Continental Automotive Systems, makes its first appearance on the 2008 LR2.

Deep tracks Thoroughly modern milling 4 The MyGIG system 6 Because mass-production cast cylinder that offers on its heads are so expensive to mill, tolerances of Sebring and several as much as plus or minus 1.2 mm have been other vehicles comes with accepted. But Linamar Corp.’s 5-Axis contour a 20-megabyte hard drive milling does a lot better than that. Combustion capable of holding MP3 chambers and intake and exhaust ports are songs, photos and machined to tolerances of plus or minus navigation system software. You’re so vein 0.004 mm. And the process costs a fraction of Chrysler says 1,600 MP3 5 Hitachi Ltd.’s door the estimated $2,500 per for songs take up less than locks identify car owners custom milling. Engine horsepower and half the hard disc. There’s by the patterns of veins in efficiency rise, while noise, vibration and a Gracenote search engine their fingers. When used harshness decrease. Linamar’s system was to find song information for personal computer first used on the LS7 V-8 engine that powers from the most popular of security, the system scans the 2006 Chevrolet Corvette ZO6. 4 million CDs it has on file. finger veins on the palm side. But gripping a car’s door handle deforms those veins. So Hitachi scans veins behind the fingernails instead. Wireless 7 wonder Let’s say you have spent hours 9 programming Kenny G, Yanni, Barbra Streisand and Krokus into your iPod. Now you Compression want to take it in the car with you. No problem, if you own one of the makes impression 30 car brands that are Bluetooth- By changing the enabled. The wireless compression ratio of an communication system lets engine, fuel economy can electronic devices such as cell be increased and emissions reduced without affecting phones, music players and performance. FEV Engine Technology Co., of Auburn Hills, Mich., laptops communicate with each is a pioneer in variable compression ratio . The FEV other without plugs or cables. It Soooo cool system raises and lowers compression by pivoting the crankshaft also allows voice-activated 8 The Chrysler group calls it the Chill Zone, a cooled storage electronically. Several cars have performed well in durability devices to work seamlessly bin that is standard on several models. The bin, on the passenger tests. FEV has several development contracts. without the driver pressing any side of the instrument panel, can hold as many as four 12-ounce buttons. beverage cans. A vent at one end of the bin pushes cold air around the cans when the air conditioner is on. AN AUTONEWS 04-16-07 B 4 AUTONEWS 4/10/2007 3:45 PM Page 1

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Threefold improvement 10 The new BMW 3-series convertible solves a huge problem common to cars with folding metal hardtops: lack of space. When the top is down on cars such as the Mercedes- Benz SLK, Mazda Miata or Pontiac G6, little cargo room remains. But BMW’s roof, from German supplier Edscha Convertible Roof Systems, folds flat upon itself in three layers, leaving ample room for a suitcase or other large items.

Back-seat TV 12 If the kids are bored with the 11 same old DVDs they play in the rear of the , help is on the way. Chrysler rolled out Sirius Back Seat TV at the New York See that sign? auto show this month. The system will be offered first on the 2008 Chrysler Town Slow down! & Country and Grand Caravan Toyota is developing a . It operates with a SiriusConnect system that uses a SC-V1 Audio/Video Tuner that will be camera to recognize a connected to back-of-the-headrest school-zone sign. If you monitors. Rear-seat occupants can watch are speeding, it then TV while the car is moving. Front seat automatically slows the occupants also can also watch on their car to no more than the MyGIG hard-drive screen when the vehicle legal limit. is stationary with the in Park. Chrysler and Sirius will offer a menu of channels with an emphasis on kids.

14 Active all- wheel torque BorgWarner Where’s that Less friction, runs great engineers have 15 matched an all- cupholder? 13 Engines lose about 6 percent of their wheel-drive system While driving at night, steaming fuel’s energy to friction as parts rub against each to modern safety Starbucks cup in your hand, how other. The 350Z’s engine cuts friction 25 controls, including many times have you searched percent and thus boosts fuel efficiency about 3 electronic stability blindly for the cupholder? The Dodge percent. It uses a hydrogen-free, diamondlike carbon control, to create an electronically controlled torque unit Caliber features illuminated coating plus special engine oil for piston rings, valve that actively manages traction. The system improves cupholder rings that glow bluish lifters and other parts. The coating and oil bind better performance and stability at high speeds and on slippery green, helping you make a perfect to create a smoother film between parts. surfaces. It was first used on the Porsche 911 Turbo, landing every time. introduced in March 2006.

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A TRUSTED PARTNER TO THE AUTOMOTIVE INDUSTRY AN AUTONEWS 04-16-07 B 6 AUTONEWS 4/10/2007 3:46 PM Page 1

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17 Battery of the future Lithium ion batteries hold four times the power of the nickel- metal batteries they will replace in hybrid vehicles. Look for Toyota to introduce lithium ion batteries in the 2009 Prius.

Fast-delivery piezo 16 Diesel engines with piezo injectors run much smoother and quieter than diesels with old-fashioned, spring-loaded, electromechanical injectors. Siemens VDO and Bosch Automotive have the first piezo injectors in production. Siemens’ are in the new Ford Super Duty pickup’s 6.4-liter twin- turbo engine. Bosch’s piezo injectors Fuel-efficient are in diesels in the Jeep Grand 18 Cherokee and Mercedes-Benz E320. pocket rocket Siemens also has gasoline piezo In a world of high fuel prices, the injectors on the new BMW 335i. 1.4-liter Volkswagen Golf GT may be the performance car of the future. Zero to 60 mph takes 7.6 seconds, and fuel economy is about 50 mpg. VW has equipped the with a supercharger for off-the-line acceleration and a for extra passing power.

Listen up 19 Voice recognition is coming of age. In some Acura vehicles you can operate the air conditioner, radio, phone and navigation system without taking your eyes off the road. In the TL, for example, the voice-recognition system from Alpine Electronics can be taught to recognize explicit commands such as “find Thai restaurant.” Then you can tell the system to call the See the light restaurant so you can make a reservation. 22 The Lexus LS 600hL has the world’s first LED low-beam headlamps, built by Koito Manufacturing Co. Ltd. of . The LEDs, or light emitting diodes, are Weld done scarcely larger than a penny, yet they 21 Dacia’s low-automation plant in Pitesti, Romania, uses jigs and crank out gobs more light than manual welding for the point at which a vehicle’s floorpan, sides and roof are halogens or standard bulbs. Each joined. The problem with manual spot welds is that they often aren’t flat on headlamp housing holds nine LEDs Quiet the surface, making a failed crescent-shaped weld that is weak. The Pitesti in the cluster — three in the low- 20 jigs use 3-inch tubes that indicate where the welds are supposed to go. The beam headlamp, two in the lower riot welding guns have long, slender tips on them that fit directly into the holes, low-beam lamp, two in the side- With its high-pressure, direct and — Voila! — the welds not only are in exactly the right spot for strength marker lamp and two in the front fuel-injection system; special but are guaranteed to make square, perfect contact. clearance lamp. The five low-beam pistons and low weight, the lamps require only 58 watts and will 3.6-liter V-6 coming this fall in the last the life of the vehicle. revamped 2008 Cadillac CTS is one of the most advanced engines General Motors has built. At 300 hp, it’s also the most powerful production V-6 GM has yet produced. It’s quiet, too. An insulator that fits on the end of the fuel injectors reduces noise from the injectors, which operate at more than 1,700 pounds per square inch. 24 Who says the electric Pay attention! car is dead? 23 The Lexus LS 600hL has a steering-column- Take the bones of a Lotus Elise, fill it mounted driver monitor that checks not only whether the with the electrical engineering driver is drowsy but whether he or she is paying attention to knowledge of castoff aerospace the road. The system, made by ’s Seiki Co. Ltd., engineers, fuel it with Silicon Valley has six infrared sensors that work even in the dark. If venture capital cash and start sensors detect an imminent problem and the monitor building cars in Albuquerque, N.M. determines that the driver is not paying attention, the manufacturer Tesla system will sound an alert and tap the brakes as a warning. Motors says its initial run of 100 two- seat roadsters, priced at $100,000, is sold out. Next up: a sedan. AN AUTONEWS 04-16-07 B 8 AUTONEWS 4/10/2007 3:48 PM Page 1

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Unexpected 25 gain The of the Escape Hybrid is so quiet that Ford engineers were able to detect and reduce other noises. That led to upgrades in the gasoline- powered Escape. Be aware, clean air 26 Carmakers can make Earth-friendly cars, but driver behavior is the key to cleaning the air. That’s where simple “eco- meters” come in. According to Nissan’s research, installing a gauge that shows mpg on the instrument panel makes drivers want to boost their fuel economy. The result: a 7 percent drop in emissions.

Just right 27 The 2007 Chrysler Sebring sedan and the 2008 sedan and Sebring convertible have cupholders in the center console that can cool a beverage to 35 degrees Fahrenheit or heat it to 140 F. Look for this feature to appear on more vehicles.

Roll control 28 Lots of automakers have traction control systems, but none is so boldly named as Volvo’s Roll Stability Control. The Volvo system, developed by Continental Automotive Systems, uses a gyroscope to determine the risk of a rollover. When Roll Stability Control determines that a roll may be imminent, it cuts engine torque and applies brake force to one or more wheels. During a high-speed parking- lot test of an XC90, notorious car thrasher Jay Koblenz couldn’t even force a spinout, much less lift a Boss…we have a problem. wheel off the ground.

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CALL TODAY TO SEE HOW ANX MANAGED SERVICES CAN PROVIDE YOU WITH PEACE OF MIND. (877) 488-8ANX Torque 29 in the road Honda’s Super Handling All-Wheel Drive doesn’t just shift torque from front to rear, as other systems do. It shifts the torque from side to side as 2000 Town Center · Suite 2050 · Southfield, Michigan · WWW.ANX.COM · (877) 488-8ANX well. Honda says the system reduces on dry pavement. It is used on the Acura RL and MDX. AN AUTONEWS 04-16-07 B 10 AUTONEWS 4/10/2007 3:53 PM Page 1

16J • APRIL 16, 2007 INSIGHT ------100 Cool things------31 Letting gravity do the work Most car fuel cells are aligned horizontally. They push hydrogen and oxygen through a membrane, producing electricity to turn the A glove box wheels and water as a 30 to match your thirst byproduct. Honda decided not to push. It shrank the fuel cell The glove box of the D:5 minivan, sold to fit it vertically into the former in Japan, heats or cools food and drinks. It can hold driveshaft hump down the a small water bottle lying on its side. Need more space? center of a car. Gravity pulls the Remove the glove box’s false bottom, and it is large water through the fuel cell. enough for two one-liter bottles standing side by side.

Wherever in the world you compete, Michigan can give you the upper hand. 622 IN A SERIES OF THOUSANDS

When Toyota put the pedal to the metal, they arrived in Michigan.

In 1977, Toyota opened its Technical Center (TTC) from a converted auto garage in Ann Arbor, Michigan Brake-through to be close to the Environmental Protection Agency. 32 The electronic parking Since then, they’ve put the pedal to the metal and brake system on , Jaguars and have become Toyota’s key research and development a few other cars eliminates the facility for all of North America. The facility does cables and levers that have been everything from engineering individual parts to used since the 1940s. The driver engineering and designing complete Toyota vehicles pulls a small handle and an electric for the North American market. And today, TTC is motor on the caliper squeezes the moving forward again…in Michigan. brake pads against the disc. The brakes can be programmed to keep a Thanks to the Michigan Economic Development car from rolling backward or to Corporation, TTC is breaking ground on an engage when the driver turns off the ignition. Suppliers include TRW, additional 700-acre campus in the Ann Arbor area. Continental, Dura Automotive and The expansion will house another 400 engineers. Siemens VDO. And, the Senior Executive Administrator at Toyota Technical Center, Bruce Brownlee, says it couldn’t have happened in a better location. After all, Michigan is home to the most skilled engineering talent, top research universities and a high concentration of automotive suppliers.

But this isn’t just an automotive story. In Michigan, your high-tech business could have access to the $2 billion 21st Century Jobs Fund, centrally located technology clusters, tax incentives and so much more. Michigan is also ranked #2 among all states for patents awarded to public universities.

So, if you’re looking to move your business forward, look no further. Because wherever in the world you compete, Michigan can give you the upper hand. Let the Michigan Economic Development Corporation show you how. Call 800 878 7722 or click on Reinventing michigan.org/biz. 33 the wheel Placing motors in the hub of the wheel would allow engineers to do away with brakes, , transmissions and driveshafts. Wheel hub motors free space that normally would be used to house the drivetrain and would enable four- Bruce Brownlee wheel drive and four-wheel steering. Senior Executive Administrator Engineers are working to make Toyota Technical Center them watertight, keep them cool and make them weigh less. GM’s michigan.org/biz Sequel fuel cell vehicle has motors in the rear hubs.

MED11606_ToyotaAutoNews_F1.indd 1 11/20/06 1:24:19 PM AN AUTONEWS 04-16-07 B 11 AUTONEWS 4/10/2007 3:54 PM Page 1

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Gleaming wheels 34 Thanks to Alcoa Wheel Products’ Dura-Bright forged wheel treatment technology, brake dust and road grime can be rinsed off aluminum wheels. Scrubbing isn’t necessary. Dura-Bright is a corrosion-inhibiting chemical that penetrates the aluminum surface. It was adopted first by Pittsburgh’s transit system and now is used by most makers of heavy trucks Grape is the answer for allergies and trailers. Automakers are testing the 35 Most air filters catch particles as small as 10 microns. They don’t block diesel 36 system on cars and trucks. soot (1 micron) or cedar pollen or dust mites (0.3 to 0.5 micron). Nissan’s filter is impregnated with natural grape seed polyphenol. It bonds with certain allergens to remove The advantages them from cabin air. Also, its natural electrostatic charge traps 0.5-micron particles. are manifold By integrating the exhaust manifold into the cylinder head, Lotus reduces engine mass; Ethanol makes car go faster cuts build cost; speeds 37 Fill up your flex-fuel vehicle with , and assembly time; reduces noise, you’ll probably notice a little extra kick when you put the vibration and harshness; and pedal to the metal. The blend of 85 percent ethanol and achieves 20 percent quicker 15 percent gasoline contains octane of about 105, catalyst light-off. The compared with 87 for regular unleaded. A flex-fuel vehicle windshield de-mists faster, too, has an engine computer that senses the amount of and lower thermal stresses octane in the fuel and tunes the engine accordingly. improve durability.

How to test a hydrogen engine 38 Ford Motor Co. engineers want to know how well regular car engines would hold up over time when burning gaseous hydrogen. But it isn’t easy to pile tens of thousands of miles on hydrogen-powered internal combustion engines. That’s because you can count on one hand all the IN THIS ECONOMY filling stations in the country that dispense hydrogen. So Ford built a test fleet of 25 E-450 airport shuttle outfitted with hydrogen-fueled, 6.8- liter V-10 engines. The shuttle vans will begin running this summer in YOU’RE THINKING OVERHEAD. Ottawa and Orlando, Fla. The test will last three years. SO ARE WE.

Smart storage 39 At less than nine feet long, the new ForTwo isn’t a car that We manufacture the world’s most innovative, technically-advanced can afford to waste any space. That’s why it’s available with an ingenious and competitively-priced roof systems. Visit us at www.webasto.com drop-down tailgate that conceals a compartment containing not just a first-aid kit but also a warning triangle, high-visibility jacket, spare bulbs, flashlight, ice scraper — and even an umbrella. AN AUTONEWS 04-16-07 B 12 AUTONEWS 4/10/2007 3:56 PM Page 1

16L • APRIL 16, 2007 INSIGHT ------100 Cool things------40 Jag’s blue-light special Jaguar’s C-XF , which debuted at this year’s Detroit auto show, has a jewellike power button that pulses like a heartbeat on the center console. When it is pushed, aluminum rings lower from the center console to reveal the gear shift Order in the trunk knob. As the engine starts, a blue 41 Nissan has a patent light sweeps around the cabin; pending on the Sentra’s Divide-N-Hide the entire roofline illuminates trunk system. Lockable storage with a muted blue light; and a compartments let owners stow grocery final blue light shines from the bags and other loose bits and pieces front grille, signifying the car’s instead of allowing the stuff to slip and ignition. slide around. 44 Turning Tahoe into fuel-sipper This heavy-duty hybrid gearbox may be the most complex transmission ever installed in an automobile. The Two- Mode — co-developed by General Motors, DaimlerChrysler and BMW — will give big SUVs such as the Chevrolet Tahoe and a 25 percent boost in fuel economy. Watch for it in the Tahoe and Durango this fall.

Pedestrian-friendly 42 fronts Notice the full-frame grilles on the latest Safety burst Volkswagen and Audi vehicles. They’re 43 The rear seat in the Ford Interceptor concept is made of softer material, have more equipped with inflatable safety belts that fill with air during a empty space behind them and are crash. A strap of airbag material in the seat belt webbing inflates designed to deform quickly. They conform into a cylindrical shape when front airbags deploy. The idea is to with the European Union’s new spread forces from a vehicle crash over a broader section of the pedestrian safety regulations. body than traditional seat belts.

:a^b^cViZ Best of both worlds 45 One technology showing promise for reducing emissions and boosting fuel economy is Homogeneous Charge Compression 5HFXUULQJ Ignition. An HCCI engine combines the best features of gasoline and diesel engines. The gasoline and air mixture is ignited by compression — like a — rather than a spark plug. The engine runs on a 3UREOHPV leaner mix than a regular engine, and that reduces oxides of nitrogen. Nearly all the world’s major automakers are developing the technology.

,QFUHDVH3URÀWV ,PSURYH&XVWRPHU6DWLVIDFWLRQ 46 8QGHUVWDQGLQJ5RRW&DXVHDQG6\VWHPLF&RUUHFWLRQ$FWLRQ Continuous 4HISPUBLICTRAININGISBEINGTAUGHTBYANINTERNATIONALLYRECOGNIZEDAUTOMOTIVEEXPERTANDWILLGIVEYOUTHETOOLSYOUNEEDTO improvement lND4RUE2OOT#AUSEINYOURSYSTEMSANDTAKEPROPER#ORRECTIVE!CTIONTOPREVENTRECURRINGPROBLEMS Just when you thought the continuously variable )NVESTMENT/NE $AY4RAINING transmission would never catch on in the United $ATES !PRIL *UNE 3EPTEMBERAND/CTOBER States, Nissan and Audi ,OCATION(OLIDAY)NN3ELECT,AKE%ASTBROOK 'RAND2APIDS -) have revamped the fuel- #ONTACTUSAT  FORDETAILS saving gearbox and made it work with higher- displacement engines. The secret: stronger belts in the case of the )3/\)3/43\)3/\/(3!3 and a more robust chain for the . Both use improved hydraulic and 4AHOE$RIVE 3UITE 'RAND2APIDS -) 4OLL&REE&AX computer controls. Ford and General Motors tried and failed with CVTs. But %MAILINFO ASRWORLDWIDECOM 7EBWWW!32WORLDWIDECOM make no mistake — the nonshifting gearbox is here to stay. The biggest suppliers of CVTs are , a Japanese company, and Germany’s ZF Group. AN AUTONEWS 04-16-07 B 14 AUTONEWS 4/10/2007 3:28 PM Page 1

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Keyless goes 48 Easy does it 47 It’s a rite of passage: Get a classless pickup, drop the tailgate, hear it slam. Radio-controlled key systems For the 2007 Tundra redesign, Toyota that allow drivers to start a installed a gas strut, hidden behind a vehicle by pressing a button on taillamp, so the tailgate eases down on the instrument panel no longer its hinges, rather than slamming. It’s a are a feature for expensive cars nice touch for the neighbors of the only. For example, Nissan’s contractor who loads his truck at 5 a.m. Intelligent Key System now is The strut also makes raising the tailgate in the $13,000 Versa. a two-finger affair.

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Manage customer expectations An extra twist 49 The Lexus LS 600hL’s Active Stabilizer Suspension System from Japan’s Aisin Seiki Co. Ltd. has the front and rear stabilizer bars Control internal inventory levels equipped with electric motors (actually, 46-volt actuators) that provide torsional twist based on steering angle and vehicle speed. The system reduces vehicle roll and enhances cornering characteristics. It even comes in sport mode. Strengthen your supply chain Simple Siemens 50 Siemens VDO has developed an electronic braking system that does away with Control customer inventory levels hydraulic lines, master cylinders, brake boosters and other hardware. The system uses 12-volt Avoid delivery penalties electric motors to move metal wedges that squeeze the brake pads against the rotors on systems. Stopping distances are shorter and assembly is simplified. Meet deadlines Siemens has several development contracts.

pmcAMERICA is the Automotive partner you are looking for to help streamline your production and accelerate your profi ts. Virtually real 51 RTT USA Inc. has created software that makes virtual three- dimensional vehicle prototypes from computer-aided design data. The computer-generated, photo-realistic prototypes can be manipulated and shown with unlimited colors and materials. Users can see One Towne Square the vehicle in detail and under varying light conditions — even at night. And unlike cumbersome and expensive clay modeling, these prototypes take just Suite 1580 days to produce. Southfield, MI 48076 (248) 359-3000 Read on pmc-america.com The Engineering Insight continues with 49 more cool things on Page 32D. AN AUTONEWS 04-16-07 B 18 AUTONEWS 4/10/2007 3:58 PM Page 1

32D • APRIL 16, 2007 INSIGHT ------100 Cool things------Mild, but not meek 52 Fuel economy gains usually The rest come in small increments. It’s rare that 53 one simple bolt-on device can raise fuel of the story economy 20 percent. But the electric Part 2 of the motor/generator used on the Saturn One small step, 100 Cool things Vue and Saturn Aura Green Line mild one giant leap Engineering hybrids does just that. A Vue Green Line Insight is EPA-rated at 32 mpg on the highway. Ford’s new Super Duty starts here. The cost to consumers is less than pickup comes with a Part 1 is on $2,000. The downside: The Green Lines sturdy fold-away step Pages 16A-16N. don’t drive solely on electric power, as and grab handle does a Toyota Prius. concealed in the leading edge of the tailgate. The step — which is easily deployed and can support 1,000 pounds — makes climbing into the bed with an armful of cargo a lot easier.

Let there be ambient light 55 In the 2007 Mercedes-Benz S class or CL, just under the wood and chrome trim that encircles the center stack, a row of soft fiber-optic lights give the car its ambience. The driver can adjust the brightness or turn How about a back rub? off the system. Chrysler and Ford are using colored lights on consoles, and in 54 The rear seat of the Lexus LS 460L is patterned after a business-class airplane seat. It reclines, kicks Ford’s Mustang, the driver can change the color of the instrument lights. out an ottoman, has heating/cooling/massage, a swivel-out table and an infrared sensor of the occupant to ensure proper climate control. A nine-inch DVD screen makes going out to the movies redundant.

August 21–23, 2007 Rock Financial Showplace, Novi, Mich.

• OEM Purchasing Executive panel discussion • 10 conference tracks featuring 50 sessions: – Changing culture in quality • Supply chain and thought-leader general sessions – Co-opetition – Dr. Barry Nalebuff – Emerging health, safety and environmental issues Yale School of Management – Global/joint efforts – Laurie Harbour-Felax – Global supply chain Harbour-Felax Group – Global supply chain interoperability – Daniel Burrus Burrus Research Associates, Inc. – PLM case studies – PLM strategic approaches in automotive • Hear about and discuss emerging issues facing the Save $200! global automotive supply chain – Update on quality Save $200! – Warranty Pre-register by • Exhibit hall featuring product demonstrations and July 31, 2007 global business solutions July 31, 2007 www.aiag.org (248) 358-3003 AN AUTONEWS 04-16-07 B 20 AUTONEWS 4/10/2007 4:03 PM Page 1

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Taking the sting 57 out of whiplash The Japan-market Lexus LS 460 flashes its hazard lights if its rear bumper’s radar determines it will be rear-ended within 1.5 seconds. If the approaching vehicle doesn’t slow, sensors find the driver’s head. The driver’s headrest extends forward up to 2.4 inches, to just shy of the driver’s head. The goal: reduce whiplash injuries.

New 58 bearings The humble roller bearing used in hubs and axles has not changed for decades. But FAG, a division of Germany’s LuK Group, and Timken Co. have developed dual- Pushing the pushrod row bearings that use 59 Huge pushrod 505-hp V-8 engines less space than aren’t supposed to get 16 mpg city and 26 on the Slimming the Super Duty traditional tapered roller highway. But the 7.0-liter V-8 in the Corvette Z06 56 At almost 8 feet wide, Ford’s new Super Duty pickup bearings. They also does. What’s the secret? A huge reduction of cuts a wide swath. But with the press of a button, the truck can get reduce friction. friction in the engine, creative use of gearing and skinnier. The optional door-mounted power mirrors can be folded generous use of such lightweight materials as against the body or retracted 3 inches. aluminum, magnesium and carbon fiber.

WHAT IS DRIVING THE AUTOMOTIVE INDUSTRY TO INVEST BILLIONS IN MISSISSIPPI?

Located in the heart of the Southern Auto Corridor, Mississippi boasts many valuable resources for the automotive industry. Among them is the Center for Advanced Vehicular Systems. This facility, located on the campus of Mississippi State University, is dedicated to developing methods that efficiently yield high-quality vehicles. But that’s not the end of the story. If you are interested in revving up your business, call us. We can tell you all you need to know about doing business in Mississippi. Contact us at 800 528 5196 or www.mspower.com. CALL US. AN AUTONEWS 04-16-07 B 22 AUTONEWS 4/10/2007 4:04 PM Page 1

32H • APRIL 16, 2007 INSIGHT ------100 Cool things------From out 61 of nowhere Side-mounted cameras on the Volvo S80 peek behind for any Mettle cars that might be lurking in 60 to the pedal blind spots. If a vehicle is present, an orange light Wouldn’t it be cool to have a trained appears on the windowsill as a off-roader sitting next to you — instructing warning. The optional device, how to stomp or feather the gas pedal called the Blind Spot depending on whether you were driving over Information System, can be snow, mud, rocks or sand? All turned on and off. vehicles come with “Terrain Response” software, designed by Land Rover’s engineers, which does just that. Using a radial dial on the center console, the driver selects the picture that matches the driving conditions, and the engine and transmission controls are remapped accordingly.

‘Suicide doors’ 62 that think The wide-opening, forward-hinged rear doors on the Rolls-Royce Phantom may be the highest-tech portals on the road. These “suicide We don’t just talk about performance doors,” which enable easy ingress and egress, are electronically controlled. And they can’t be opened from the inside while the car is going faster than 2.5 mph.

Feel the noise 63 Quadrascan Driven by a culture of performance and ingenuity, we Technologies Inc., of Brentwood, we live it. Tenn., has patented a device that will produce virtually every machined vehicle component help automakers hear wind noise for the automotive industry. Our powertrain groups before it happens, either at the r&d share best in class processes and the unrivalled stage or on the assembly line. Using engineering expertise of McLaren Performance transmitters placed inside vehicles Technologies. We excel at collaborating internally, as they go down the production line, and with our customers, to design and build products an ultrasonic scanner captures any sound waves that leak from the car. of the highest quality and precision. Catch a wave, correct the leak, stop the noise. Our ability to deliver a diverse line of value-added solutions – from parts, to modules, to fully assembled systems – is what defines us as a world-class manufacturer, and your supplier partner of choice.

Welcome to the new vision of Linamar. A vision powered by the most enterprising and passionate people working in our industry.

Surround sound 64 The Toyota FJ Cruiser’s audio system has a pair of NXT SurfaceSound transducers that convert the vehicle’s entire headliner into a speaker diaphragm. Forget 12- inch woofers, this is a 72-inch speaker membrane. The headliner doesn’t create huge sound. But it does complement the FJ’s conventional speakers, creating a broad, omni-directional dispersion of Mozart — or Metallica. AN AUTONEWS 04-16-07 B 23 AUTONEWS 4/10/2007 4:05 PM Page 1

INSIGHT APRIL 16, 2007 • 32I ------100 Cool things------Choose 65 your ride With drive-by-wire systems, like that on the Chevrolet Sequel, you can tune the handling of your car to fit your mood. Let’s say you want to take the Corvette to work in the morning. All you’ll do is turn Straighten up a knob to stiffen the 66 A camera mounted on the suspension and sharpen the rearview mirror or grille reads the lines in response of the steering and the road. When the car drifts too close to brakes. If you want the the center or the edge, the driver hears a supersupple Cadillac ride beep or feels a slight vibration in the along the way, you’ll turn the steering wheel or seat. The lane departure knob in the other direction. warning system, which debuted in 2005 Look for complete by-wire on the Infiniti FX, helps drivers stay systems to appear about between the lines. Suppliers include 2020. Delphi, Visteon, TRW and Continental.

Clutchless, 67 not shiftless Want to flash through the gears like a Formula One driver? Audi and Volkswagen are leading the way with their six-speed direct-shift gearboxes that can be shifted either by paddle shifters on the steering wheel or the gearshift lever on the console. Other carmakers are not far behind. What makes the direct-shift gearbox seem more like a real is the dual- clutch system that enables the car to accelerate with virtually no delays between shifts. The exhaust makes an ever-so-pleasing boy racer popping noise after you hit the next gear just right.

Our keyless entry and start systems turn hands-full into hands-free. Incoming! A PAssive Start and Entry (PASE) System from With more experience than anyone in passive start 68 The same kind of radar Siemens VDO could help customers decide on and entry systems, we minimize time to market and that tracks missiles is being adapted your brand. There’s no more fumbling for a key or cut costs by avoiding common design pitfalls and to cars and trucks. Valeo Raytheon standard remote fob. As the driver approaches the sharing other onboard RF system components. Systems’ multibeam radar blind- vehicle, a smart fob carried in a pocket or purse zone radar sensor will protect drivers PASE is another example of innovative Siemens VDO unlocks the doors and trunk, and prepares for push- electronics that help carmakers sell cars the world over. from traffic in blind spots. The radar button starting. Hands-free PASE can also adjust determines the direction and speed Give your customers a helping hand; call 248-209-4000. mirrors, seats, HVAC, and infotainment systems to www.usa.siemensvdo.com of an object using two devices, one the driver’s tastes. on each rear side corner of the vehicle. When traffic is detected, the system illuminates an icon in the side-view mirror to inform the driver. Software distinguishes between vehicles and roadside structures. ©2007 Siemens VDO Automotive, Corp The first use will be on three North American vehicles in mid-2007. AN AUTONEWS 04-16-07 B 24 AUTONEWS 4/10/2007 4:07 PM Page 1

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Ford goes capless 69 Ford Motor Co. plans to do away with the fuel filler cap on Ford, Lincoln and Mercury vehicles starting in 2008. Ford gave Illinois Tool Works’ capless system a dry run on the 2005- Seeing around the bend 06 GT supercar. Inside the fuel filler 72 Ford Motor Co. engineers are working on a neck is a rubber flapper valve that keeps better idea for swiveling headlights, which will most the tank sealed, except when the fuel likely debut on its Lincoln brand. Headlights nozzle is filling the tank. automatically illuminate toward bends in the road. Instead of the mechanical system used by others, Ford is close to perfecting an electronic system that uses sensors in the steering wheel to activate a series of lights on the front and side of the vehicle.

Let’s talk 70 Vehicle-to-vehicle communications can help avoid accidents. Nissan and General Motors are working on communication systems Taking a dim view that enable cars to detect each other Pedal power and help the drivers avoid collisions in 71 Electrically adjustable pedals boost safety and 73 Automatically dimming rearview mirrors perilous situations, such as blind comfort. Ford Motor started the trend in 1999, equipping the Ford have been a hot ticket for years — so why not put them intersections and turning across Taurus and Mercury Sable with brake and accelerator pedals that everywhere? Audi did on the 2007 TT coupe. A three- oncoming traffic. Warning lights and could be moved forward or back by pressing a button on the dash. mirror system from Gentex Corp. dims the glare from beeps alert drivers before the danger is Some GM vehicles now also feature them. the rearview and driver- and passenger-side mirrors as obvious. bright lights hit them. 74 Reverting to form General Motors is working on technology that could allow cars to repair themselves after minor accidents. GM scientists are close to perfecting plastics and metals that revert to their original shape when heat or electricity is applied. Got a parking lot ding? No problem. Just aim your blow- dryer at it and bingo, the dent is gone. The technology can also be used to open and close vents, such as those on a grille. AN AUTONEWS 04-16-07 B 25 AUTONEWS 4/10/2007 4:09 PM Page 1

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Feels like the 75 first time

“One of the main decision makers for high-end vehicles is how the switches feel,” says Barbara Wilson, an engineer in Ford’s Interior Harmony Group. Ford wants each button, switch and knob to work and feel as if it were designed as a complete set — requiring the same amount of pressure and movement. The redesigned 2008 Escape is Ford’s first vehicle that has all controls, lighting and sound Jaguar’s light touch harmonized. 76 Lotus founder Colin Chapman’s idiom for increasing performance was “Add lightness.” Lotus’ brethren at Jaguar are taking it to heart, using aluminum for the body-in-white and panels for the XJ sedan and XK coupe. While a pricey alternative to steel, aluminum saves hundreds of pounds of weight, thereby increasing acceleration and fuel economy.

Easy button 78 Press a button in the rear cargo area of the Ford Expedition and the split third-row rear seats automatically fold flat Hot sauce into the floor — a nifty feature that 77 Thirteen 2007 General Motors vehicles offer Microheat makes loading cargo easy. Inc.’s HotShot heated windshield wiper fluid system. The Pressed again, that same button system sprays fluid heated to 149 degrees F onto the windshield to clear raises the seats. Ford is the only frost and ice. Ford plans to install the system on a sedan in 2010. automaker to offer the system.

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32L • APRIL 16, 2007 INSIGHT ------100 Cool things------Thinking outside 79 the boxes Engine well in front, fuel tank far in back, people in between. That three-box layout rules in car design. Breaking the rules, innovative cars such as the (shown), Honda Fit and Smart maximized interior space by rearranging their engines and fuel tanks.

Red-hot design 80 Red rivers of lava light run down the back end of the Volvo XC60 concept, which was at the Detroit auto show in January. Volvo’s Gothenburg, Sweden, design studio bent and twisted the fixtures to flow around the vehicle’s curvy hips.

Swivel ’n Go 82 The Chrysler group, which surprised and delighted minivan enthusiasts with Stow ’n Go seating, has added a clever feature: Swivel ’n The current trend Go. Not only do the seats fold flat into the floor, 81 If General Motors builds the Chevrolet Volt hybrid — and if it but each seat in the second row swivels 180 works as well as GM claims — some drivers theoretically might never have to degrees. Second-row occupants can talk face to buy a drop of gasoline for it. The low-slung Volt is designed to travel about 40 face with third-seat passengers. A portable table miles on electric power alone — more than enough range for most Americans allows them to play games. to commute to and from work. The Volt uses a turbocharged three-cylinder engine to power a generator that keeps a lithium ion battery pack charged. Corvette-like Grinding systems on 83 cornering ZF Group’s electronic suspension system has computer-controlled the cutting edge. shocks that virtually eliminate body Let us introduce you to a world of opportunities and a roll during cornering. The JVTWYLOLUZP]LWHJRHNLVMILULÄ[ZHULU[PYLYHUNL continuous damping control of solutions from a single provider. system is used on such high- TYROLIT offers the complete end cars as Rolls-Royce, product range for all automotive Ferrari and Maserati. applications. But GM makes Grinding and Honing of: damping control Learning from crashes • Components optional on four 85 These days about 90 percent of new cars and • Transmission Components inexpensive trucks have a black box. The data recorders capture loads • Fuel Injection Systems models, including the Astra of information during a crash, including the vehicle’s • Camshafts/Crankshafts hatchback. For about $500, the system makes speed, position of the steering wheel and brake system • Valves • *=1VPU[Z the Astra handle like a Corvette. performance. They help automakers design safer cars and help investigators piece together details of an accident.

Chicken-and-egg solution 84 It’s chicken or egg. Which will come first: hydrogen-powered cars or hydrogen fuel pumps? Mazda’s dual-fuel, rotary-engine RX-8 car has two tanks: gasoline and hydrogen. If you run low on hydrogen, flip a button and switch to gasoline until you can find a hydrogen station. Call it the oyako domburi solution. ;@9630;>PJRTHU0UJ‹*HWP[HS(]L‹6HR7HYR40 ;LS ‹-H_  That’s a Japanese dish that *05*055(;0;@9630;‹+PZUL`:[‹*PUJPUUH[P6/ ;LS ‹-H_   ;@9630;*HUHKH‹ ,K^HYKZ)S]K‹4PZZPZZH\NH653;>;LS‹ ‹-H_   translates as “mother and child bowl” because it combines both chicken www.tyrolit.com pieces and an egg over rice. AN AUTONEWS 04-16-07 B 27 AUTONEWS 4/10/2007 4:22 PM Page 1

INSIGHT APRIL 16, 2007 • 32M ------100 Cool things------87 Hybrid made simple Hybrids have to be complex — or do they? Zytek’s Smart ForFour-based prototype uses an electric motor up to 40 mph and a diesel for higher speeds. The two-speed gearbox selects a low ratio for electric and high for Cloud of suspicion diesel. No costly 86 OK, it won’t show up as a factory- clutches, no fancy installed Cadillac option anytime soon. But FlashFog, epicyclics or continuously from Arias Tech Ltd. in Mississauga, Ontario, is still a variable transmissions — cool antitheft gadget. A thief tries to start your car, just a seamless transfer of and, in just a few seconds, FlashFog fills the cabin torque between the two with a harmless vapor that is so thick, he can’t sources of power. possibly drive anywhere.

Triple play 89 The smoke 88 Here’s the trifecta of clears environmentally friendly technology You could drive behind a in one vehicle: a fuel cell, electric new diesel vehicle, such as motor and lithium ion batteries with the 2008 Jeep Grand plug-in recharge capability. In Cherokee, and not even January, Ford showed the futuristic know it. The cleaner diesel powertrain in the Airstream concept fuel that began arriving at vehicle at the Detroit auto show. In fuel pumps last summer reduces the amount of sulfur from March, a running version installed in 500 parts per million to 15. That cuts harmful emissions, a appeared at the White such as soot and oxides of nitrogen. In other words, you’ll House, where President Bush no longer see black smoke. The clean fuel is triggering the inspected the crossover with Ford return of the diesel in North American cars. Eight CEO Alan Mulally. Ford calls the automakers promise new diesels by 2010. powertrain HySeries Drive. AN AUTONEWS 04-16-07 B 28 AUTONEWS 4/10/2007 4:36 PM Page 1

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The screen 90 91 scene How do you present a lot of information to drivers without Keeping your causing sensory overload? Try a reconfigurable display — a screen distance that, with a press of a button, can Active cruise control has show everything from radio controls been around since the late and air conditioner settings to 1990s. But Mercedes-Benz has taken the technology further with navigation routes and data about the its Distronic Plus system. Instead of just slowing the car when a vehicle’s condition. Mercedes-Benz vehicle ahead gets too close, Distronic Plus, from Bosch, can be uses reconfigurable screens in many tuned to stop the car. Want to see how it works? Go to: vehicles. The system in the CLK autonews.com/distronicplus. Look for the technology to filter coupe is an example of how versatile down into nonluxury vehicles. these screens have become.

Warning stripes 92 White stripes painted on the floor of Fiat’s assembly plant in Tychy, Poland, mark the beginning and end of each workstation on the line. They indicate the boundaries Ecotec: King within which each employee does his 94 or her task. About a meter from the of horses end of each station, a red line is The 260-hp, 2.0-liter version of painted. Says a foreman: “If I see an the Ecotec four-cylinder engine, employee consistently working in the used in the Saturn Sky Red Line last meter of his station … I know and Pontiac Solstice GXP, holds something is wrong — his air gun is General Motors’ record for not adjusted right, or he doesn’t output per liter. No regular- have the right parts — and I can help production GM engine has ever him fix it before we have a quality developed more than 130 hp per problem.” liter — not the fire-breathing V-8s of the muscle-car era or even the wildest Corvette engines.

2-stage boosters 93 Any safety-conscious parent knows what a nightmare child seats can be, with different designs needed The 8 for each age group. Volvo’s dual-height booster cushions, integrated in the rear seats of the new V70 station wagon, 95 promise optimum seat belt geometry for children weighing 33 to 80 pounds — and an end to loose seats forgotten at works great home or buried in the trunk. Road rage relief The eight-speed automatic 97 No need to wait for transmission in the Lexus LS 460 — your AM news radio station to an industry first — helps the huge broadcast its abbreviated “traffic on 4,244-pound luxury sedan post That ain’t the sixes” if you have XM respectable fuel economy numbers: 96 NavTraffic. XM Satellite Radio has 19 mpg city and 27 mpg on the paint linked to the navigation displays in highway. And it’s a mechanical The Trax is one of three Acura, Lexus, Infiniti, Nissan and marvel. Not only is the eight-speed Chevrolet minicar concepts that Cadillac vehicles to superimpose the same size as the six-speed it General Motors unveiled this real-time traffic flows onto maps of replaces, but the new gearbox month at the New York auto local highways. Color coding shows adjusts its shifting based on driving show. To reduce costs color is traffic speed along stretches of conditions, driver habits and internal added to the thermoplastic used highway. Accident, construction and wear. for the front and rear fascias, other data also are displayed, bumpers, rocker panel molding showing the exact locations. XM and side fenders. That way the NavTraffic is installed for 50 major trim does not need to be painted. metro markets. Multijob Clean diesel 99 100 Shooting an ammonialike acid fob called urea into the exhaust Shushing Volvo’s Personal Car system of a diesel vehicle is an inexpensive way 98 Communicator key fob to reduce the discharge of oxides of nitrogen, the the shaft does more than lock and smog precursor known as NOx. Look for It’s just a pickup prop shaft, but unlock the car. Within Mercedes-Benz to install urea injectors first, in oh, what a feeling. Toyota chose a about 325 feet, the fob the 2009 model year. bimetallic shaft from Dana Corp. can tell you whether the to cut drive noise on the vehicle is locked, if the redesigned 2007 Tundra pickup. alarm has been triggered Contributors Dana’s combination of steel and and even if someone is Richard Truett, James B. Treece, Mark Rechtin, aluminum lets the shaft work with inside the car. That last Rick Kranz, Lindsay Chappell, Bradford Wernle, less mass, meaning less function is done with a Tony Lewin and Jesse Snyder vibration and a smoother rotation. highly sensitive The result: a quieter ride. heartbeat sensor.