Hydrogen's Future Under the Spotlight
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P001_ADEU_NOV11_Layout 1 28/11/2011 14:32 Page 1 The pan-European magazine of SAE International November/December 2011 That’s Infotainment! E-AVB has arrived ABS drives move to cut road deaths Lighter con rods step up efficiency A LOT OF HOT AIR? HYDROGEN’S FUTURE UNDER THE SPOTLIGHT P002_ADEU_NOV11 16/11/11 17:05 Page 1 P003_ADEU_NOV11_Layout 1 28/11/2011 14:34 Page 3 Contents 18 12 Spotlight on Bernard Gilmont 5 Comment Ian Adcock talks with the European Aluminium Association director about light weighting and 6 improved vehicle efficiency News • LA Show News 18 Cover feature • F1-inspired Hydrogen: The Power Broker aerodynamics for Andrew English on the challenges of storing latest Honda Civic hydrogen, using metal-organic frameworks • Lighter, smaller differential 22 22 Infotainment Bridging the gap • Injectors improve In an Automotive Design exclusive, Richard Yarrow efficiency reveals the secrets behind Harman’s interconnected infotainment technology 17 The Columnist 24 The SAE’s Testing and validation operating Testing times structure Graham Pitcher on why Electromagnetic David Schutt, SAE Compatibility (EMC) testing is becoming ever International CEO, more complex on the importance 32 of the Society’s 28 Electronics board structure Integrating intelligence OEMs are another step closer to fully automated cars. 36 Question Time Meanwhile, one concept of driver assistance is the Mark Fletcher European HAVEit intelligent transport project talks with Chuck Grindstaff about 32 Materials Siemens’ latest PLM Saving weight saves fuel software Mahle develops ultra-lightweight connecting rod 39 60 second 34 Technology Review interview Mortal combat Isaac Litman CEO Ian Adcock assesses some of TRW’s latest safety Mobileye in the systems to see where they are heading spotlight November/December 2011 www.automotivedesign.eu.com 3 P004_ADEU_NOV11 16/11/11 16:31 Page 1 ©TRW Automotive 2011 JUST THINK: SIDE PROTECTION SYSTEMS FOR EVERY CAR IN BRAZIL. TRW’s low-cost, scalable technologies are raising the bar of safety worldwide. Cognitive Safety Systems from TRW can help protect more drivers, passengers and pedestrians worldwide. TRW’s Smart Thinking – the safety everyone deserves. ADVANCED THINKING / SMART THINKING / GREEN THINKING http://cognitivesafetysystems.trw.com P005_ADEU_NOV11_Layout 1 29/11/2011 09:24 Page 5 Comment Editor in Chief: Ian Adcock [email protected] Web Editor: John Challen [email protected] Sub Editor: Brian Wall [email protected] Editorial Director: Kevin Jost, SAE International. [email protected] Contributing Editors: Steven Ashley, Ryan Borroff, Lindsay Brooke, Kami Bucholz, William Diem, Cash injection will fire Andrew English, Mark Fletcher, Paul Horrell, Keith Howard, John Kendall, Tony Lewin, Bruce Morey, Lou Reade Art Editors: Martin Cherry, Neil Young up automotive industry Illustrator: Phil Holmes Production Manager: Nicki Mckenna [email protected] Publisher: Ed Tranter Manufacturing and engineering have often [email protected] been overlooked industries in the UK, as Circulation Manager: Chris Jones [email protected] successive governments and the private Advertisement Sales sector concentrated their efforts, in terms of Europe/UK John Gordon both manpower and finance, into service International Sales Manager industries. [email protected] UK, Benelux, Italy and Scandanavia It was, therefore, heartening to see that a Chris Shaw Chris Shaw Media Ltd / SAE International Publishers large tranche of the last round of the British Representative Tel: +44 (0) 1270 522130 government’s £950 million (€1.1 billion) M: +44 (0) 7983 967471 Regional Growth Fund has been targeted at manufacturing and, [email protected] Germany in particular, the automotive sector. Sven Anacker, Ralf Gerbracht [email protected] The headlines were grabbed by the likes of Bentley, Getrag- Tel: +49.202.27169.17 Fax: +49.202.27169.20 USA Ford, Aston Martin and Lotus, but it was reassuring to see that Print Advertising Coordinator: companies further down the automotive food chain, such Linda Risch [email protected] Calsonic-Kansei, Ceram Research, Federal-Mogul, TRW, MIRA Tel: 001 724-772-4039 Marcie Hineman and Zytek also benefited. [email protected] Japan It’s particularly good news for Lotus, as the grant will fund a Shigenori Nagatomo second factory and assembly line at Hethel, dismissing fears that Akutagawa Bldg, 7-7 Nihonbashi Kabutocho Chuo-ku, Tokyo 103-0026 JAPAN the sports car maker could go overseas for additional Tel: +81.3.3661.6138 Fax: +81.3.3661.6139 production facilities. [email protected] When you include the likes of JCBamford, Cummins, Automotive Design Cummins Turbo Technologies and Pirelli, it is a positive and Tel: 00 44 (0)1322 221144 Fax: 00 44 (0)1322 221188 timely boost for the vehicle industry as a whole. www.automotivedesign.eu.com [email protected] While this is obviously good news for employment in the UK, ISSN 2043-0299 it sends out a wider message to the European and, indeed, Published: January, March, May, July, global automotive industry that the UK is a good place to invest September and November by AD Media Europe in for manufacturing or to come to for world-class engineering Hawley Mill, Hawley Road, Dartford, Kent, DA2 7TJ Copyright 2011 AD Media Europe. and innovation. Annual subscription (6 issues per year) for readers in the UK is £45, At present, manufacturing accounts for 11.1% of the UK’s overseas is £66 and airmail is £86. GDP and 74% of all business expenditure on UK R&D. Bentley, Origination: CTT, Walthamstow, London E17 6BU. for instance, is the 18th largest investor in R&D nationally and Printed in England by Warners Midland plc the third biggest R&D investor in the UK’s automotive sector. Moving on? If you change jobs or your There’s plenty of innovation in this issue as well, including the company moves, please contact current status of advanced hydrogen storage technologies and a [email protected] to continue receiving your copy of Automotive Design. European exclusive on Harman Kardon’s Ethernet Audio Video Bridging (E-AVB); technology designed to enable different and multiple networks within a car to communicate with each other. Ian Adcock, Editor in Chief November/December 2011 www.automotivedesign.eu.com 5 P006_ADEU_NOV11_Layout 1 28/11/2011 14:37 Page 6 To boldly go... Land Rover has given a glimpse of a range of new technologies it is considering for use on its DC100 Concept Defender replacement, slated for launch in 2015/16, as well as other models in its line-up. The aim is to reduce the challenges inherent in on-road/off-road vehicle design, such as traction-enhancing attributes, long wheel travel, high ground clearance and soft suspension, which are compromised in the interests of on-road ride and handling. “The original Defender had adaptability and versatility,” says Mike Boyd, Land Rover's chassis and vehicle research manager, “and we want to keep that, but with 365 days’ useability.” The idea is that the basic vehicle can be up-rated with plug-in advanced systems. Chief amongst these will be an enhanced version of Land Rover’s Terrain Response system, which takes the normal inputs of drag, slip, boulder-strewn landscape, for example. the vehicle that is the key to making this suspension movement and steering angle, Another development is using sound work.” Land Rover is also working with three engine and road speed, and uses a probability navigation and ranging (sonar) to predict the tyre suppliers on the development of a range matrix in the software to estimate what the depth of water as the vehicle enters it. This of new tyres, including airless, self inflating surface is and the best combination of engine, would enable the systems to prepare the and tyres that can pneumatically deploy transmission and suspension settings to vehicle for fording by raising the suspension or spikes. The auto spike versions carry ice traverse it. “This is a patented Land Rover adjusting its attitude, for example. It could also spikes below the surface of the tread blocks development,” he points out. “It is being driven advise the driver of the most appropriate with a tiny air pocket beneath, which can be now in our research vehicles.” speed and gear to negotiate the hazard and pumped up using the tyre’s air pressure. Ultimately, a twin camera set up at the warn if the water is too deep. The company is also contemplating a front of the vehicle could even predict the “Wadeaid software detects the attitude sophisticated, twin clutch-based freewheel surface before the vehicle arrives on it and of the vehicle and depth of the water,” he system, which would isolate drive to the rear advise the driver how best to steer through a explains, adding: “It is detecting the attitude of axle and its propshaft at steady speeds on a Ford slashes development costs Under the show’s bloodsucking lighting, Ford's new Escape looked boxily anodyne. That ‘bold’ front seems as bold as a Walmart shopping trip, but the company is clear about the savings it has made, combining the development of two vehicles – the North American Escape and European Kuga – into one. Both vehicles share almost everything and, according to Martin Smith, executive design director of Ford of Europe, only small trim changes will denote the Kuga version, which debuts at next year’s Geneva Show. of prototypes we have to build. From an a vehicle like this, if we were doing it for just “It’s far more effective to make one vehicle investment perspective, this is basically a one market,” he says. for two markets,” says Gunnar Herrmann, Ford’s copying process, so we are saving in the order The result is a telescoped development C-car vehicle line director. “We’re looking at of 20% there.” He says another benefit is in the timing, which has enabled Ford to roll out over engineering efficiency savings of the order of technologies that Ford is able to offer on both half of its proposed C-segment line-up across 40% and a lot of that is in the reduced number vehicles.