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Multiphysics for Everyone MULTIPHYSICS FOR EVERYONE The evolution of computational tools for COMSOL MULTIPHYSICS ® numerical simulation of physics-based systems has reached a major milestone. APPLICATION BUILDER Custom applications are now being developed by simulation specialists using the Application Builder in COMSOL Multiphysics®. APPLICATION With a local installation of COMSOL Server™, applications can be deployed within an entire organization and accessed worldwide. Make your organization truly benefi t from the power of analysis. comsol.com/application-builder © Copyright 2016 COMSOL. COMSOL, the COMSOL logo, COMSOL Multiphysics, Capture the Concept, COMSOL Desktop, COMSOL Server, LiveLink, and Simulation for Everyone are either registered trademarks or trademarks of COMSOL AB. All other trademarks are the property of their respective owners, and COMSOL AB and its subsidiaries and products are not affi liated with, endorsed by, sponsored by, or supported by those trademark owners. For a list of such trademark owners, see www.comsol.com/trademarks. AUTOMOTIVE ENGINEERING® LE MANS 2016! Racing’s most ruthless test of speed and efficiency New Ford GT-R: First crack at Le Mans— good enough to win? 3 new approaches to ICE efficiency Multi-material design for strength & mass reduction June 2016 magazine.sae.org/auto MATLAB SPEAKS MACHINE LEARNING With MATLAB you can use clustering, regression, classification, and deep learning to build predictive models and put them into production. mathworks.com/machinelearning @2016 The MathWorks, Inc MathWorks, The @2016 CONTENTS FEATURES REGULARS 18 A 24-hour battle of speed and 2 Editorial Henry, Elon and the mastery of manufacturing efficiency COVER STORY At Le Mans this month, amped-up hybrid prototype racecars from Audi 4 Technology Report and Toyota face a revamped Porsche 919 hybrid, while Ford hopes to 4 How Porsche met cooling challenges on the new recapture glory with its new GT-R. 4-cylinder Boxster | POWERTRAINS 8 Brembo brake-by-wire will be production- 24 Pushing the ICE forward, gradually ready before 2020 | CHASSIS POWERTRAINS 12 Powering up the new stop-start systems | Emergent technologies from BorgWarner, Eaton and Mahle aim for ELECTRONICS greater efficiency in gasoline and diesel engines. 15 Google talks self-driving vehicle development | 28 Smile, you’re on Magna camera! ELECTRONICS 17 Ford upgrades dyno sleds to handle 2017 ELECTRONICS Super Duty diesel’s might | TESTING Magna Electronics is rapidly expanding production of its made-in-U.S.A. onboard cameras to keep pace with booming OEM demand for safety 35 Global Vehicles and vehicle-autonomy vision-systems technology. 35 Second time a charm for Honda’s unibody Ridgeline pickup? 31 Multi-material body solutions: 37 Jaguar puts a brave Pace on testing its new Possibilities and manufacturing crossover challenges MATERIALS 40 Focus RS: Ford and GKN create an AWD The body-in-white is a prime target for lightweighting and many masterpiece automakers are pursuing unique and effective multi-material approaches, 42 Product Briefs Spotlight: CAD/CAM/CAE but improved design tools and processes might yield greater gains. 46 What’s Online ON THE COVER 47 Companies Mentioned, Upcoming, Two of Ford’s new GT-R endurance racers run in tight formation. Ad Index The GT-R “endured” a rough start to the 2016 season but quickly found a groove, winning its first race, a two-hour sprint in California, 48 Q&A in early May—an immense confidence-builder as the GT-R heads to Kauaki Shingo’s background is in mechanical its first-ever appearance in world-famous crucible of the Le Mans engineering and internal-combustion engines— 24-hour endurance race this month. making him a perfect candidate to develop the world’s most popular electrified car. The Assistant Chief Engineer of the 2016 (fourth-generation) Follow us on social media Toyota Prius spoke with Automotive Engineering at the car’s North American media launch. Automotive Engineering®, June 2016, Volume 3, Number 5. Automotive Engineering (ISSN 2331-7639) is published in February, March, April, May, June, August, September, October, and November by Tech Briefs Media Group, an SAE International®, 261 Fifth Avenue, Suite 1901, New York, NY 10016 and printed in Mechanicsburg, PA. Copyright © 2016 SAE International. Annual print subscription for SAE members: first subscription, $20 included in @SAEAutoMag @saeaei SAE Magazines dues; additional single copies, $30 each North America, $35 each overseas. Prices for nonmember subscriptions are $115 North America, $175 overseas. Periodicals postage paid at New York, and additional mailing offices. POSTMASTER: Please send address changes to Automotive Engineering, P. O. Box 47857, Plymouth, MN 55447. SAE International is not responsible for the accuracy of information in the editorial, articles, and advertising sections of this publication. Readers should independently evaluate the accuracy of any statement in the editorial, articles, and advertising sections of this publication that are important to him/her and rely on his/her independent evaluation. For permission to reproduce or use content in other media, contact [email protected]. To purchase reprints, contact [email protected]. Claims for missing issues of the magazine must be submitted within a six-month time frame of 17 the claimed issue’s publication date. The Automotive Engineering title is registered in the U.S. Patent and Trademark Office. Full issues and feature articles are included in the SAE Digital Library. For additional information, free demos are available at www.saedigitallibrary.org. (ISSN 2331-7639 print) (ISSN 2331-7647 digital) Audited by AUTOMOTIVE ENGINEERING June 2016 1 NY, NJ, OH: EDITORIAL Ryan Beckman +1.973.409.4687 Bill Visnic [email protected] Editorial Director [email protected] PA/DE: Desiree Stygar Lindsay Brooke +1.908.300.2539 Editor-in-Chief [email protected] [email protected] Midwest/Great Lakes: EDITORIAL Ryan Gehm IN, MI, WI, IA, IL, MN Associate Editor [email protected] Chris Kennedy +1.847.498.4520, x3008 Patrick Ponticel [email protected] Membership Editor [email protected] Midwest/Central Canada: KS, KY, MO, NE, ND, SD, ON, MB Elon, Henry, and the mastery of manufacturing Lisa Arrigo Bob Casey Custom Electronic +1.847.223.5225 “Do you want to make a bet on Musk’s fans is easy; cranking them out in vol- Products Editor [email protected] [email protected] latest pronouncement?” asked my friend ume is the tough part. Rocky Mountain States/NM: CO, ID, MT, UT, WY, NM the Tier 1 supplier engineer, whose com- Jumping from 50,000 units to Contributors Tim Powers +1.973.409.4762 pany is part of Tesla’s supply chain. 500,000 units is a 900% increase. If Musk Kami Buchholz [email protected] Detroit Editor “I’m betting against it,” he followed, pulls that off, it would be a rare and his- Southern CA, AZ, NV: Stuart Birch Tom Boris “because they haven’t yet proved toric feat. I pulled a book I wrote in 2008, European Editor +1.949.715.7779 they’re capable of big volumes. When Ford Model T: The Car that Put the World Jack Yamaguchi [email protected] Asia Editor Northern CA, WA, OR, they increase product complexity and on Wheels, off the shelf to look at Henry Western Canada: volume at the Fremont plant it stumbles Ford’s accomplishment. From 1910 to Steven Ashley, Dan Carney, Craig Pitcher Terry Costlow, Richard Gardner, +1.408.778.0300 in end-of-line quality. Product is de- 1914, annual output at the new Highland John Kendall, Bruce Morey, [email protected] Jennifer Shuttleworth, Linda Trego, layed. They’re still teething while talking Park plant skyrocketed from 19,050 cars Paul Weissler like they’re big boys.” to 202,667—a 968% increase in four International DESIGN Europe – Central & Eastern: Not being a betting kind of guy, I ac- years. And that was just the start of a Sven Anacker knowledged that this was sound logic. colossus that was churning out over two Lois Erlacher Britta Steinberg Creative Director +49.202.27169.11 Then I added: “My concern is not with million Model Ts annually by 1922. [email protected] Ray Carlson [email protected] Tesla’s ambition for such a huge produc- If Musk can execute his Tesla plan by Associate Art Director Europe – Western: tion leap—from 50,000 Model S and X 2018, comparisons to Henry Ford will Chris Shaw +44.1270.522130 units built in 2015 to 500,000 units includ- inevitably be made. Both men built bil- SALES & [email protected] ing Model 3 in 2018. They plan to double lion-dollar empires and were global dis- MARKETING China: that again, to 1 million units, by 2020. ruptors. Both were dictatorial leaders. Joe Pramberger Alan Ao Publisher +86.21.6140.8920 Ford became an instant folk hero when [email protected] [email protected] he announced the $5 work day. Musk’s Marcie L. Hineman Japan: Global Field Sales Manager Shigenori Nagatomo fans treat him like a rock star. [email protected] +81.3.3661.6138 [email protected] But his manufacturing vision relies on Debbie Rothwell Marketing Director South Korea: finding veteran production engineers to [email protected] Eun-Tae Kim +82-2-564-3971/2 ramp up volume ten-fold in two years. Martha Tress [email protected] Unfortunately for Tesla, Musk hasn’t Recruitment Sales Manager +1.724.772.7155 been able to keep vice presidents in [email protected] Integrated Media Model 3 and Model T makers: Musk and Ford charge of manufacturing around long Consultants enough to create that robust structure. REGIONAL Angelo Danza +1.973.874.0271 “My biggest concern is this: Elon Musk Indeed, according to my supplier friend SALES [email protected] has yet to create a sufficiently robust and experts familiar with the Fremont Patrick Harvey North America +1.973.409.4686 manufacturing organization to pull it off.” operation, Tesla has been a “revolving New England/Eastern Canada: [email protected] ME, VT, NH, MA, RI, QC Readers of this magazine who follow door” for manufacturing experts.
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