MOBILITY ENGINEERINGTM AUTOMOTIVE, AEROSPACE, OFF-HIGHWAY A quarterly publication of and Indian Air Force Getting greener HCCI vs. conventional acquisition engine technologies Dassault Aviation Rafale fighters Student competitions • Baja SAEINDIA highlights • Rise of the underdogs Volume 2, Issue 2 June 2015 ME Molex Ad 0615.qxp_Mobility FP 4/29/15 8:00 PM Page 1 Decades of automotive experience and innovations developed for the consumer and telecom industries give Molex the right expertise to help you develop the next generation of vehicles. What will we make together? molex.com/automotive CONTENTS Features 38 Getting greener AUTOMOTIVE 49 Slick solutions for friction POWERTRAIN reduction AUTOMOTIVE POWERTRAIN To meet upcoming fuel economy and emissions regulations, Suppliers and engine designers are attacking every the developmental homogeneous charge compression potential source of internal friction—no longer a “low- ignition (HCCI) engine shows promise, but pursuit of more hanging fruit”—as the battle to squeeze more mechanical conventional engine technologies may be the better path. work from less fuel intensifies. 40 Highlights of Baja SAEINDIA 53 Hydraulics still in control of STUDENT COMPETITIONS off-highway needs OFF-HIGHWAY The 2015 event, the 8th edition with the theme of Beyond ELECTRONICS | HYDRAULICS Boundaries, was won by the College of Engineering, Pune. Engineers continue to master electronic controllers and software to help systems manage engine speeds and 43 Rise of the underdogs STUDENT boost efficiency to the ultimate benefit of both OEMs and end users. COMPETITIONS Problem-plagued effort last year spurs Baja SAE team from VIT University of India to overhaul itself and its car. Cover 45 Testing reality in an increasingly The Indian Air Force plans to complex design space acquire 36 Rafale fighters. AEROSPACE SIMULATION The cover image shows a single-seater in full “Air-Air” Digital simulation tools have transformed the designing and configuration and a two-seater testing of new aircraft, as well as the way they are in mixed configuration. manufactured and sustained. follow us @SAEAutoMag MOBILITY ENGINEERING JUNE 2015 1 CONTENTS Departments Denso displays more compact HVAC design 4 Editorial 26 AUTOMOTIVE INTERIORS High-voltage developments 27 Automakers see possibilities, limits for gesture 6 Focus controls AUTOMOTIVE ELECTRONICS Building the SAEINDIA brand 28 The quest for the self-cleaning car AUTOMOTIVE BODY 8 SAEINDIA News 30 Brunel pursues ultrasound for ‘greener’ production of aluminum alloys AUTOMOTIVE MATERIALS 8 AWIM National Olympics held in Chakan 31 MTU develops new turbine blade material in record 10 KLU hosts National Student Convention time AEROSPACE MATERIALS 12 New 3D printing event 32 Lightweight steel is stronger than titanium 13 Industry News AUTOMOTIVE | AEROSPACE MATERIALS 34 Automatic collision avoidance added to inspection 15 Technology Report software AUTOMOTIVE SIMULATION 15 Schaeffler developing novel powertrain for 2015/2016 35 X-ray testing for large composites AEROSPACE FIA Formula E season MOTORSPORTS POWERTRAIN TESTING New yeast strain enhances biofuel production 16 36 NanoSteel powder alloys advance 3D printing of ENERGY high-hardness parts MANUFACTURING 17 Cummins in production with ‘simplified’ Tier 4 Final 37 Altair optimizes 3D-printed structures for complex, engines OFF-HIGHWAY POWERTRAIN lightweight designs MANUFACTURING 18 Aerojet Rocketdyne gets a boost from additive manufactured components AEROSPACE PROPULSION 56 Global Vehicles 19 Military technologies aid the fight for improved 56 Next-gen NSX: A twin-turbo, multi-material off-highway efficiencies OFF-HIGHWAY ELECTRONICS Ferrari-fighter 21 Audi details piloted driving technology AUTOMOTIVE 60 Cabin key to Komatsu America’s new T4F hydraulic ELECTRONICS excavator 22 Flight vision system for rotary-wing aircraft AVIONICS 61 New XF moves to Jaguar’s aluminum architecture 23 Counterfeit electronic parts: Manufacture of and 63 Companies Mentioned avoidance AEROSPACE ELECTRONICS 63 Ad Index 24 Johnson Controls presents interior concept for autonomous driving at 2015 NAIAS AUTOMOTIVE 64 Q&A INTERIORS Michael Tinskey, Ford’s Global Director of Vehicle 25 Portable shade proposed for cooler interiors Electrification and Infrastructure AUTOMOTIVE 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 JUNE 2015 MOBILITY ENGINEERING ME Altair Ad 0615.qxp_Mobility FP 5/5/15 12:35 PM Page 1 EDITORIAL EDITORIAL Kevin Jost Editorial Director [email protected] Asit K. Barma SAE India Editor C. V. Raman ED, MSIL High-voltage developments [email protected] Arun Jaura The concept of higher-voltage vehicle electrical Validation Manager for Controlled Power VP, SAEINDIA [email protected] networks between those for 12-V conventional and Technologies, because 48-V hybrids are cur- Bala Bharadvaj 200- and 600-V full hybrids and electric vehicles is rently the most cost-effective way of meeting MD, Boeing R & T [email protected] not new, with development experiencing fits and stringent CO2 emissions in the buildup to 2020 Mathew Abraham starts over the past few decades. However, tight- European regulations. This is compounded Sr. GM, Mahindra [email protected] ening efficiency and emissions regulations and potentially by a shift from the current NEDC to Dr. Venkat Srinivas increasing demand for onboard electrical power the more aggressive WLTP test. Vice President & Head - Engineering & Product Development, Mahindra & means that higher voltages, in the form of supple- Electric engine boosting could benefit from Mahindra Truck and Bus Division [email protected] mental 48-V subsystems, are nearing production. 48-V networks. Hyundai and Kia are developing Jean L. Broge One sign of this was on display at the 2014 Los a mild-hybrid diesel powertrain using an electric Managing Editor [email protected] Angeles Auto Show. The Audi Prologue show car, supercharger in conjunction with a 48-V net- Lindsay Brooke which provided a glimpse of the company’s work. According to Bloore, electric boosting Senior Editor [email protected] design future, also more quietly previewed a new using energy recuperated, rather than lost in fric- Ryan Gehm 48-V electrical system coming to future Audis. tion from the brakes, not only reduces emissions, Associate Editor [email protected] The company attributed some of the large but also can have a positive impact on vehicle Zach Nocera Editorial Assistant show car’s relatively low fuel consumption and performance and drivability. Patrick Ponticel CO2 emissions to the new 48-V system. Powered The rapidly growing interest in 48-V networks Membership Editor [email protected] by a belt starter generator, the set up enables was also discussed at the SAE International 2015 Lisa Arrigo mild powertrain hybridization with brake-energy Hybrid & Electric Vehicles Technologies Custom Electronic Products Editor recovery. The displacement of high-wattage Symposium held in Los Angeles in February. Dr. [email protected] loads to more efficient 48-V networks is Mazen Hammoud, Ford’s Chief Engineer for Contributors expected to be the next step in the development Electrified Powertrain Systems and SAE Fellow, Kami Buchholz Detroit Editor of a new generation of mild hybrid vehicles. said that the 48-V working voltage is the best com- Stuart Birch In addition to improved fuel economy and promise for mild hybridization. (See http://articles. European Editor Jack Yamaguchi reduced emissions, 48-V systems could poten- sae.org/13908.) Asian Editor tially save costs on new electrical features and Although the higher voltage provides no real Steven Ashley help better address the emerging needs of future electric-only drive capability, there is better Dan Carney Terry Costlow drivers. A new report from Autelligence on 48-V capacity for capturing braking regen energy, and Richard Gardner Jenny Hessler automotive electrification analyzes the technol- it’s a good stop-start enabler, Hammoud said. A John Kendall Bruce Morey ogy and provides an outlook on future introduc- mild hybrid can provide more than 3% increased Jennifer Shuttleworth Linda Trego tions. The report notes that the new technology engine-off time versus a 12-V stop-start vehicle Paul Weissler is “extremely economical because it can be easily in real-world driving conditions. In addition, DESIGN integrated into an existing vehicle architecture according to ECE-R 100 regs for direct current Lois Erlacher and the small 48-V battery means battery costs under 60 V, shock protection is not required for Art Director are reasonable,” said Christopher Breitsameter, 48 V, helping to lower cost. Ray Carlson Associate Art Director Head of Business Development and Strategy, The consensus of global forecasts suggests Continental Powertrain Division. that 48-V mild hybrids will soon come to domi- SALES & Challenges to 48-V system implementation nate the market. Compared with 200-600 V full MARKETING remain. At the 2nd International Conference