P001_ADEU_OCT11.qxp:Layout 1 26/9/11 10:28 Page 1 The pan-European magazine of SAE International September/October 2011 INSIDE IAA FRANKFURT SHOW Full report on key happenings COMPUTING IN ‘THE CLOUD’ Automotive applications STOP-START TECHNOLOGY Focus on low-cost systems INTERNAL COMBUSTION ENGINE: A BORN SURVIVOR P002_ADEU_SEP11 15/9/11 12:19 Page 1 WITHOUT DUAL CLUTCH TRANSMISSION TECHNOLOGY, YOU’RE JUST GETTING LEFT BEHIND. 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_OCT11.qxp:Layout 1 26/9/11 10:29 Page 3 Contents 14 14 Spotlight on Sanjay Ravi 5 Comment Mark Fletcher discovers how The Cloud can help the automotive industry 6 News 20 Cover feature • LCV2011 review Powering Aspirations • Cylinder Ian Adcock reviews technologies at this year’s deactivation Frankfurt motor show launched • Daimler hydrogen 26 Transmission Innovation storage Stop-Start Breakthrough breakthrough 20 Kami Bucholz reports on an innovative Schaeffler • Bosch lambda stop-start for automatics sensor 28 Electronics Right Connections 19 The Columnist Keith Howard asks if the App will take over from the Walking the car key technology walk 30 Manufacturing David Schutt, SAE Overcoming Overspray International CEO, Paul Weissler reports from VW’s radical paint plant on the society’s publications 32 Powertrain programme Shaking up the market 32 Ian Adcock discovers how clever Ford’s newest 42 Question Time EcoBoost engine really is Ian Adcock talks 34 HVAC with Stadco’s Paul Shooting the breeze Meeson about the An insight into the latest heating, ventilation and future of body-in- air-conditioning developments white production 36 Special Report - truck developments Automotive Design reports on truck aerodynamics, 50 60 second hybrids and emissions interview 45 CTI Preview Prof Tim Davis, advisor to We Changing times Predict, on how Automotive Design previews the forthcoming warranty claims can 9th International CTI Symposium assist with design and development September/October 2011 www.automotivedesign.eu.com 3 P004_ADEU_SEP11 22/9/11 10:39 Page 1 Bosch worldwide. Innovative solutions to improve quality of life. As an international leader in technology and services, Bosch is com- mitted to improving quality of life. That is what Bosch employs 283,500 people to do, why it invests some 3.8 billion euros annually in research and development, and why it applies for over 3,800 patents per year. The resulting innovative Bosch products and solutions have one thing in common: they make people’s lives a little better each day. More in- formation at: www.bosch.com P005_ADEU_OCT11.qxp:Layout 1 26/9/11 10:29 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, Long live the internal Lindsay Brooke, Kami Bucholz, William Diem, Andrew English, Mark Fletcher, Paul Horrell, Keith Howard, John Kendall, Tony Lewin, Bruce combustion engine! Morey, Lou Reade Art Editors: Martin Cherry, Neil Young Illustrator: Phil Holmes Production Manager: Nicki Mckenna This latest issue of Automotive Design is [email protected] Publisher: Ed Tranter dominated by one theme: the internal [email protected] combustion engine in all its guises, petrol Circulation Manager: Chris Jones [email protected] and diesel. Doom-mongers have been prophesying its Advertisement Sales Europe/UK demise ever since the latest generation of Gordon Herriot electric vehicles (EVs) started to appear at International Sales Manager [email protected] motor shows around the world. USA But at Frankfurt (the IAA Motor Show), Print Advertising Coordinator: Linda Risch I detected a change in the atmosphere, as developments to [email protected] the internal combustion engine start to deliver fuel economy Tel: 001 724-772-4039 Marcie Hineman improvements that would have been unthinkable five years ago, [email protected] never mind ten. Germany Sven Anacker, Ralf Gerbracht And those improvements aren’t restricted to eco-friendly, [email protected] down-sized engines, such as Ford’s new one-litre EcoBoost Tel: +49.202.27169.17 Fax: +49.202.27169.20 or Kia’s similarly three-cylindered diesel, either. Japan Shigenori Nagatomo Audi has shown off its ‘cylinder on demand’ V8 that it will Akutagawa Bldg, 7-7 Nihonbashi Kabutocho share with Bentley, proving you don’t have to wear a hair shirt Chuo-ku, Tokyo 103-0026 JAPAN Tel: +81.3.3661.6138 to be green. Fax: +81.3.3661.6139 There’s a school of thought that liquid-powered vehicles will [email protected] continue to dominate our roads for the next century, never mind Automotive Design the next couple of decades. And when you get the chairman of Tel: 00 44 (0)1322 221144 Fax: 00 44 (0)1322 221188 Bosch, Franz Fehrenbach, saying: “… there is no immediate www.automotivedesign.eu.com likelihood of electric cars flooding on to the streets” and that he [email protected] doesn’t expect government incentives or intervention “until the ISSN 2043-0299 middle of the next decade”, then isn’t it time to start questioning Published: January, March, May, July, September and November by wholesale vehicle electrification? AD Media Europe By 2025, we could be looking at fleet averages of 3l/100kms Hawley Mill, Hawley Road, Dartford, Kent, DA2 7TJ Copyright 2011 AD Media Europe. for petrol and 2.6l/100kms for diesel. Developing these Annual subscription (6 issues per year) technologies won’t come cheaply. But at a time of financial for readers in the UK is £45, overseas is £66 and airmail is £86. global duress – and how long is it going to take before we see a real recovery? – it will still be cheaper and far less disruptive Origination: CTT, Walthamstow, London E17 6BU. Printed in England by than ramping up electricity generation for EVs. Warners Midland plc KSPG’s Eduard Köhler told me that he considered range Moving on? If you change jobs or your extenders as “a bridge” to EVs; the trouble is, no one has any company moves, please contact idea how long that bridge needs to be or, indeed, what lies on [email protected] to continue receiving your copy of Automotive Design. the other bank. Going by the evidence I saw at Frankfurt, the internal combustion engine has plenty of life left in it yet. Ian Adcock, Editor in Chief September/October 2011 www.automotivedesign.eu.com 5 P006_ADEU_OCT11.qxp:Layout 1 26/9/11 10:30 Page 6 News EV ideas get fast forward Scalextric-style recharging as you race, super- each kilo reduction saving €23 on the cost of the proposing to fit racing circuits with transmitters, high energy-density batteries and miniaturised battery, itself approximately half the cost of the buried under the track surface: the racing cars jet engines to replace costly battery capacity – whole vehicle. Three companies were interested will pick up their power wirelessly as they drive these are just a few of the innovations in taking out a licence to build the T27 and its round, presenting the possibility of long-distance demonstrating that electric and hybrid vehicles gasoline sibling, the T25, said Murray, with one races for electric vehicles, without the need for are once again raising their game and based in the UK. pit stops to recharge or swap batteries. determined to overcome their perceived drawbacks. Ideal internal combustion engine Scaling up All these developments, along with a series Positioning itself as a cost-effective substitute The opportunities for road-going EVs would be of hybrid innovations and new-project for expensive, long-range battery capacity is the significant, too, opening up the potential for presentations, appeared at September’s Bladon jet, a miniaturised axial flow gas turbine unlimited zero-emission range, if sufficient LCV2011, the UK’s premier trade showcase for range extender, which, says managing director charging loops were built into the roads low-carbon vehicles and systems. Paul Barrett, could save 100kg in battery mass. infrastructure. This so-called ‘Scalextric’ Leading the pack, in terms of its public Describing the 75mm diameter gas turbine, with arrangement – nicknamed after the well-known profile, was Gordon Murray Design’s T27, the its single moving part and continuous electric slot-car racing game – is, in many ways, electric version of Murray’s low-cost 1+2 seater combustion process, as the ideal internal the ideal EV scenario, taking the cost of the city car. Boasting an efficiency rating of 71 combustion engine, Barrett claims it had 20 battery out of the vehicle and making EVs much Wh/km, the T27 stands alone, claims Neil times the power density of a piston engine and more affordable. Cheesman of Zytek, GMD’s drivetrain partner, as up to 68% thermal efficiency, as well as clean Battery systems supplier Axeon is no other vehicle had been homologated with a emissions and a multi-fuel capability. remaining tight-lipped about a new cell value below 100 Wh/km. Key to this efficiency, Bladon is now linking the jet to a switched configuration it has devised for a forthcoming he says, were the simplicity of the air-cooled 12 reluctance generator, running in air bearings, electric supercar; rumours in the industry kWh battery pack and the decision to go for a with a power turbine able to step the motor’s suggest that the new battery can pack the light, high-revving motor – a selection made 95,000 rpm down to the maximum of 60,000 exceptional energy density of 5.000 Wh/kg.