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P001_ADEU_MAR10.qxp:Layout 1 4/3/10 19:02 Page 1 The pan-European magazine of the SAE International Launch issueMarch 2010 ■ Lightweight strategies under the microscope ■ Ford’s EcoBoost delivers 20% fuel savings ■ NVH Testing: sound engineering gets serious ■ Innovation and collaboration at SAE World Congress Lightweight champion. The all-new XJ fully exposed P002_ADEU_MAR10 3/3/10 11:49 Page 1 DUAL CLUTCH TRANSMISSION TECHNOLOGY IS MOVING THE INDUSTRY FORWARD. ARE YOU MOVING WITH IT? Maybe it’s the fact that in the time you read this, a Dual Clutch Transmission could switch gears 40,000 times. Perhaps it’s the fact that DCTs appeal to more buyers by combining impressive fuel-economy, the smooth ride of an automatic and the speed of a manual. It could be the fact that leading clutch suppliers estimate they’ll quadruple DCT sales by 2014. Or maybe it’s the fact that by 2015, 10% of all passenger cars will have them. DCTFACTS.COM gives you endless reasons to believe that DCTs are the future generation DCTFACTS.COM of transmissions. And the more you know about them, the further ahead you’ll get. P003_ADEU_MAR10.qxp:Layout 1 4/3/10 19:27 Page 3 Contents Vol.1 Issue.1 12 Cover feature 5 Comment Jaguar’s green technology Design Jaguar is synonymous with sporting elegance and collaboration will refinement – and now also high tech materials and drive recovery green endeavour. Ian Adcock gets the inside story from the all new XJ’s engineering design team 6 News 18 Spotlight on Phil Hodgkinson Performance hybrids Phil Hodgkinson talks with Ian Adcock about Jaguar Land Rover’s future engineering strategy Renault bids for 22 Engine technology CO2 leadership EcoBoost set to cut fuel consumption by 20% Ford’s EcoBoost is about more than cutting engine MultiAir set to capacity and adding direct injection, turbocharging grow and twin variable camshafts. Automotive Design reveals the technology behind the headlines A8 proves its credentials 24 SAE preview Collaboration and innovation 29 The SAE 2010 World Congress is set to offer more focused technology and cost-saving solutions, says SAE Columnist International’s Matt Monaghan Thinking globally, acting 26 NVH testing locally Sound engineering Kevin Jost, SAE Engineers are using ever advanced tools to create the International sounds of today’s vehicles. SAE International’s Bruce editorial director, Morey reports on the technology and processes contemplates the 30 automotive Question time industry’s The future is in alloys globalisation Robert Georg of Novelis talks with Ian Adcock about weighty matters and aluminium developments 38 60 second 32 Electrical technology interview Lightening the electronic load Audi leads the After years of attempts to scale back the burgeoning way in aluminium- weight and complexity of automotive wiring, a new intensive cars, so way is emerging. Keith Howard reports what does the 34 Lightweight solutions future look like? We asked Dipl-Ing Weight watchers’ new answers Heinrich Timm, While the big news in automotive weight reduction is head of Audi’s invariably around the body structure, moves are Lightweight underway to transform vehicle components’ Design Centre contribution. March 2010 www.automotivedesign.eu.com 3 P004_ADEU_MAR10 2/3/10 09:28 Page 1 The Essential Automotive Technology Event April 13-15, 2010 Cobo Center Detroit, Michigan USA New Solutions—New Congress Network. Collaborate. Innovate. How will you benefi t from attending? &G¾DJFOUMZBTTFTTUIFTVQQMZDIBJO° BUUIFFYDMVTJWF²*OOPWBUPST0OMZ³ FYIJCJUJPO "DDFTTTVCKFDUNBUUFSFYQFSUT Host Company: #FODINBSLBOEOFUXPSLXJUIZPVSQFFST &YQFSJFODFBOFYDJUJOH3JEFBOE%SJWF Tier One Strategic Partner: 1MVT EPJUBMMJOBDPOEFOTFEEBZ TDIFEVMF www.sae.org/congress Event theme: Ecollaboration P100163 P005_ADEU_MAR10.qxp:Layout 1 4/3/10 19:24 Page 5 Comment Editor in Chief: Ian Adcock [email protected] Web Editor: John Challen Design collaboration [email protected] Sub Editor: Brian Wall [email protected] Editorial Director: Kevin Jost, SAE International. will drive recovery [email protected] Contributing Editors: William Diem, Andrew English, Paul Horrell, Keith Howard, Tony Lewin, Bruce Morey Automotive OEMs stand accused of Art Editors: Martin Cherry, Neil Young squandering the earth’s resources and Illustrator: Phil Holmes Production Manager: Nicki Mckenna polluting the planet. This is an industry in need [email protected] of new ideas, methods and business models, Print Advertising Coordinator: Linda Risch along with eco-friendly materials and designs. [email protected] Tel: 001 724-772-4039 Only by working with strategic partners and Publisher: Ed Tranter sharing innovative engineering concepts will [email protected] those OEMs find the right solutions. That’s Circulation Manager: Chris Jones [email protected] why ‘e-collaboration’ is the theme of the SAE 2010 World Congress (see page 24), which Advertisement Sales USA looks set to attract leading auto design engineers from around Marcie Hineman the world. The industry knows that design engineering solutions [email protected] are at the heart of the sector’s recovery. Hence the thirst for new Germany Sven Anacker Ralf Gerbracht technologies, techniques and ways of working. To satisfy that [email protected] demand, SAE International is collaborating with Findlay Media Tel: +49.202.27169.17 Fax: +49.202.27169.20 France to deliver this new magazine, Automotive Design, to 20,000 Marc Jouanny engineers in the European hotbed of automotive development. [email protected] Published six times a year, each issue will focus on a T: +33 1 435 53397 particular engineering theme, with features from acknowledged Automotive Design experts, plus interviews with industry leaders, as well as news Tel: 01322 221144 Fax: 01322 221188 and product briefs from our editors in Europe and the USA. www.automotivedesign.eu.com Between publications, our website will be updated daily with [email protected] industry news; while videos, white papers and an international ISSN 2043-0299 supplier directory will provide further essential information. The site’s searchable technology library – comprising material Published: March, May, July, from Findlay Media’s European Automotive Design magazine September and November by AD Media Europe archive and selected features from SAE International’s Hawley Mill, Hawley Road, Dartford, Kent, DA2 7TJ Automotive Engineering International – provides an unmatched Copyright 2010 AD Media Europe. Annual subscription (6 issues per year) reference resource for European design engineers. for readers in the UK is £45, Meanwhile, in this first issue, we focus on lightweight overseas is £66, and airmail is £86. technologies – among the keys to meeting future emissions Origination: legislation – with an exclusive insight into the all-new Jaguar XJ’s CTT, Walthamstow, London E17 6BU. aluminium-intensive structure and in-depth interviews with the Printed in England by people behind the concept. Plus, we talk to Phil Hodgkinson, Warners Midland plc Jaguar Land Rover’s director of product development, who describes his ambitious plans for these iconic British brands. Moving on? If you change jobs or your company moves, please contact To guarantee your personal copy of Automotive Design, and [email protected] to continue to receive regular electronic newsletters, register now on receiving your copy of Automotive Design. www.automotivedesign.eu.com. We hope you enjoy the results of our own collaboration – and that Automotive Design serves to help you in all of yours. Ian Adcock, Editor in Chief March 2010 www.automotivedesign.eu.com 5 P006_ADEU_MAR10.qxp:Layout 1 4/3/10 19:40 Page 6 News Performance hybrids show the way Lotus, Ferrari and Porsche each launched innovative hybrid technology solutions at the Geneva Salon, aimed at making high performance cars more acceptable by reducing Lotus 414E emissions and improving fuel consumption, Hybrid without detracting from their performance. While the Lotus and Ferrari systems are based on road-going cars, Porsche is developing its hybrid technology on the race track in a 911GT3. for instance, at high speed when the 414E Hybrid was the second of three Ferrari 599 HY-KERS batteries are fully charged. By keeping the stages of hybrid development. “The Don’t be misled into thinking Ferrari has clutches open, the engine and propshaft are third stage might be replacing the engine with adapted its F1 Kinetic Energy Recovery System disconnected, allowing for up to 10km electric- a small gas turbine as a generator.” for road use, explained technical director Franco only, low-speed, stop-start commuting. Cimatti, “In this case, KERS refers to A motor generator powered from the Porsche 911 GT3 R Hybrid the energy captured under braking and used batteries replaces the alternator to power the Although the car uses a Williams-developed, to recharge the 80kWh lithium batteries.” air-conditioning and power steering pumps. F1-type KERS flywheel, it now has a lifetime of Cimatti predicted another three years one million storage cycles, significantly more development, mainly on battery-engine than any battery, according to Hartmut Kristen, management. Although displayed in a front- Porsche’s head of motorsport. This has been engined car, the architecture can be deployed achieved by use of ceramic bearings, while in mid-engined Ferraris as well. locating it flat on the floor ensures the system only has to cope with rotational masses. Lotus 414E Hybrid “We are still
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