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The Benefits of Hybrid Electric Drive for Military Operations

2012-03-27
Hybrid Electric Drive (HED) provides the potential to improve military vehicle capabilities beyond the well understood fuel economy benefits. Additional HED benefits for military operations can be realized in the areas of mobility, survivability, lethality, power generation and maintainability. General Dynamics Land Systems (GDLS) continues to demonstrate significant advantages that HED can offer to military vehicle platforms. This presentation will focus on the advanced military capabilities provided by HED utilizing in-hub wheel motors and include a summary of GDLS demonstrator vehicles with integrated HED. Presenter Andrew Silveri, GENERAL DYNAMICS LAND SYST
Video

ICE Evolution and Hybridization

2012-03-27
In Oct. 2011, Nissan announced its new six-year environmental plan, Nissan Green Program 2016 (NGP 2016), that includes initiatives to lead fuel efficiency: 35% fuel economy improvement compared with 2005 on a corporate average for all Nissan vehicles sold in Japan, China, Europe and the United States. To achieve this target, we`re planning to launch products delivering class-leading fuel efficiency such as an all-new FWD hybrid model, Introducing a next-generation continuously variable transmission (CVT). In this session, Nissan`s apploach for fuel erfficiency is presented with internal-conbustion powered technology evolution and hybridization, referring to new FWD hybrid system. Presenter Taiichi Onoyama, Nissan Motor Company, Ltd.
Video

Electric Drive Technology Futures – Economics, Consumer Responses, and Social Benefits

2012-03-27
The rapid pace of recent progress in vehicle electrification technologies points to a bright future for electric-drive vehicles, but uncertainty regarding future technical trajectories and uncertainty in consumer response make possible a multitude of electric-drive vehicle futures. This presentation will examine a range of these possible electric-drive futures as a function of different technology and pricing scenarios. An exploration of initial conditions, market uptake, and resulting social benefits will show how HEV and PEV technology enable the attainment of stringent vehicle efficiency goals and unlock potential for lower-carbon futures. Presenter Jacob Ward, Department Of Energy
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Smart and Connected Electrification at Ford

2012-03-27
Electrification is becoming a means of sustainable transportation to address global climate change and environmental concerns by reducing the dependency on fossil fuels for personal transportation; and to use renewable energy for transportation. Ford has incorporated Electrification as an important part of the company's sustainable strategy to provide sustainable transportation that is affordable environmentally, socially and economically. While offering customers Power of Choice for a wide range of Electrification products, Ford continues to exploit the potentials of Electrification by taking advantage of the advanced information technology to create smarter and greener vehicles customers want and value. This presentation will highlight some of the on-going research and development on smart and connected Electrification. Presenter Ming Lang Kuang, Ford Motor Co.
Video

SAE Standards to Support Electro-Mobility

2012-03-27
Presentation will concentrate on a brief overview of SAE International including history, international focus and SAE electro-mobility ground vehicle standards development activities. The new era of mobility and the driving forces behind it including converging technologies and today�s drive toward �green� will be discussed. Also, standards and technology enablers for vehicle electrification including, the global landscape for EV charging standards and next generation charging method approaches will be reviewed. Additionally, an overview of SAE global EV Battery Standards and activities including industry/government collaborative efforts to develop lithium ion rechargeable energy storage system safety standards will be provided. Presenter Keith Wilson, SAE International
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The Utility and Fuel Consumption of Hybrid and Electric Vehicles

2012-03-27
There are now a wide variety of Hybrid and Electric Vehicles in or near production. They reduce or displace petroleum consumption with of various combinations of conventional IC engine, mechanical transmission, liquid fuel storage, electrical energy storage, electrical and electro-mechanical energy conversion, and vehicle-to-grid energy interface. These Electrified types of vehicles include Mild Hybrid, Full Hybrid, Plug-In Hybrid, Extended Range Electric, and Battery Electric. Some types differ in their actual usability for the real mixes of driving trips, and further that differ in their effectiveness to reduce or displace fuel in actual real world driving use. Vehicle size is also a factor in total vehicle utility in transporting people. If we may segment drivers by their driving needs, in each segment, we see a particular type of electrified vehicle that is better suited than others at minimizing fuel cost and petroleum consumption for the purposes of transporting people.
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The Challenges of Electrification in Premium Luxury Vehicles

2012-03-27
JLR is on track to develop stop-start, parallel hybrid and plug-in parallel hybrid vehicles in the next few years. Plug-in hybridization is arguably the most suitable technology for large, premium luxury vehicles for the foreseeable future. Range_e is a UK based demonstrator for a plug-in hybrid system and has brought into sharp focus the attribute issues and wider challenges that need to be taken into consideration when moving towards production. Presenter Paul Bostock, Jaguar Land Rover
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Letters to the Editor: How Readers Responded to Motor Trend's 2011 Car Of The Year

2012-03-23
Motor Trend Magazine�s selection of the Chevrolet Volt as its 2011 Car-Of-The-Year saw the publication inundated with responses, the vast majority of these polarized between astute praise and bewildering condemnation. Here, I will read you some of our best Volt Car-Of-The-Year reader mail. And along the way, offer a few of my own responses � including thoughts on how the gulf between these contentious camps of enthusiasts might eventually be bridged. Presenter Kim Reynolds, Motor Trend Magazine
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Long-term Technology Issues and Projections

2012-03-23
Conventional hybrids have been marketed in the US for over a decade, with very high quality scores and high consumer satisfaction. However, their cost is still too high for mass market acceptance and their sales continue to be almost entirely to early adopters. This presentation will discuss mainstream consumer discounting of future fuel savings and how much they might be willing to pay, then focus on the potential for future hybrid efficiency improvements, synergies with other technologies, and cost reduction. The future cost reduction and efficiency benefits of the input powersplit and the P2 (parallel twin-clutch) hybrid systems are compared and projections offered through 2030. Presenter John German, International Council On Clean Transport
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New Solutions for One Shot Hand Held and Robot Drilling of CFRP/Titan and -/Aluminium Stack Drilling in H8 Quality for Aerospace Applications

2012-03-23
This article characterizes the special features of drilling of CFRP/Titanium and -Aluminium stacks. Simplified theoretic models will show how CFRP/Titanium stacks should be machined without scratches and burn marks contacting carbon. Low axial forces and smart chip removal technology are the main characteristics of the drilling tool technology, optimized to reach H8 quality in one shot operation. Presenter Peter Mueller-Hummel, Cutting Tools Inc.
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High Volume Production of Fiber Reinforced Thermoplastic Parts

2012-03-23
With the increased demand for high volume, cost-effective, fiber-reinforced thermoplastic parts, the lack of high throughput systems has become more pronounced. Thermoforming as a method to generate complex shapes from a flat preform is dependable and fast. In order to use readily available, standard unidirectional impregnated thermoplastic tape in this process, a flat perform must be created prior to the thermoforming step. Formerly, creating the preform by hand layup was a time consuming and therefore costly, step. Fiberforge�?s patented RELAY� technology overcomes the challenges of handling thermoplastic prepreg tape and provides a solution through the automated creation of a flat preform, referred to as a Tailored Blank?. Producing a part for thermoforming with accurate ply orientation and scrap minimization is now as simple as loading a material spool followed by a pressing a start button. Presenter Christina McClard, Fiberforge
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Prepreg Slit Tape and Fiber Placement: Developing High Performance Material Delivery Systems for High-Output AFP Lines

2012-03-23
Presented by: Dan Ott Web Industries Director, Business Development, Advanced Composites Market With the growth of Fiber Placement technology as a preferred automation technology in aerospace manufacturing and the rapid growth of new production line installations, it is crucial to provide material in a form which meets all necessary specifications and supports the optimum productivity available from this major capital investment made by the producer of the parts. Achieving these goals happnes when the part designer, AFP machine builder, and the slit tape producer design the best process and format which provides smooth, efficient and rapid delivery of the prepreg slit tape to the Fiber Placement laydown head. Tape size (width), slit width tolerance, spool shape and size, density of prepreg on the spool, spool change-over and handling processes all play a factor in productivity, and creating (or inhibiting) the best ROI on a full-scale AFP production line.
Video

Ford: Driving Hybrid Efficiency

2012-03-23
Hybrid vehicles in the modern era were developed with a strong primary goal to increase fuel efficiency in the North American market. Over the last 15 years, this market has expanded from zero sales to as high as 3% of total US sales. Most recently, the portfolio of competitive offerings with HEV propulsion systems has grown even more to about 30 models on sale today. Some interesting features and attributes have evolved thru this wider array of products giving the customer much more choice of which characteristics to select to match their needs. Ford�s 3rd generation HEV system will be offered for sale this fall. With it, we have continued our focus on the Fuel Efficiency as the driving force for our efforts. The overall process for the system engineering and some of the relevant subsystem and component contributors to the Fuel Efficiency improvement reflected in the 2013 Model Year Fusion and CMAX Hybrids will be presented. Presenter Charles Gray, Ford Motor Co.
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Exploring the Manual Forming of Complex Geometry Composite Panels for Productivity and Quality Gains in Relation to Automated Forming Capabilities

2012-03-23
In a variety of industries there is a growing need to manufacture high quality carbon fibre epoxy matrix composite structures at greater production rates and lower costs than has historically been the case. This has developed into a desire for the automation of the manufacture of components, and in particular the lay-up phase, with Automated Tape Laying (ATL) and Fibre Placement (AFP) the most popular choices. When used for large primary structures there are such potential gains to be had that both techniques have seen rapid implementation into manufacturing environments. But significant concerns remain and these have limited their wider adoption into secondary structure manufacturing, where manual forming of woven broadgoods is dominant. As a result the manufacture of secondary structures is generally explored for costs reduction through drape simulation and lower cost materials.
Video

Orbital Drilling Machine for One Way Assembly in Hard Materials

2012-03-23
In Aeronautic industry, when we launch a new industrialization for an aircraft sub assembly we always have the same questions in mind for drilling operations, especially when focusing on lean manufacturing. How can we avoid dismantling and deburring parts after drilling operation? Can a drilling centre perform all the tasks needed to deliver a hole ready to install final fastener? How can we decrease down-time of the drilling centre? Can a drilling centre be integrated in a pulse assembly line? How can we improve environmental efficiency of a drilling centre? It is based on these main drivers that AIRBUS has developed, with SPIE and SOS, a new generation of drilling centre dedicated for hard materials such as titanium, and high thicknesses. The first application was for the assembly of the primary structure of A350 engine pylons. The main solution that was implemented meeting several objectives was the development of orbital drilling technology in hard metal stacks.
Video

Incorporating AFP Material Delivery Technology on Commercially Available Robot Machine Platforms

2012-03-23
: Fiber Placement equipment has historically been very large and very expensive. Therefore, the AFP process has been mostly exclusive to the larger aerospace companies of the world. In order to achieve more widespread use of the AFP process, a wider variety of machine configurations must be offered and cost of the equipment must be decreased. Commercially available, articulated robotic arms have been identified as an attractive, low cost option for AFP machine platforms. However, incorporating AFP material delivery technology with robotic arms has many challenges. These challenges relate to both hardware and software issues. This presentation will address the technical challenges of using robots as a machine platform for the AFP process and review the current status of this composites lamination equipment technology. Presenter Frederic Challois, Coriolis Composites
Video

A350XWB Fiber Placement Spars; From R&D Conception Phase to Serial Production

2012-03-23
At the end of 2006, two MTorres engineers visited the plant of Airbus UK in Filton receiving a new challenge: Find a more efficient way to manufacture Carbon Fiber Spars for the new A350 program. The range of possibilities were wide: manual infusion methods (RTM, RIM, RFI...), Automatic Taping & hot forming, or the new technology proposed, Fiberplacement or AFP. Two (2) options were considered: hot forming+ATL and AFP (both using prepeg technology.) The usage of a flat lay-up + hot forming technology was used in the only Airbus program that used carbon fiber for the wing manufacturing so far, the A400M. The expected greater complexity of A350 spar created doubts on the feasibility of using the above process, while the AFP technology, consisting of laying up directly on the final shape of the spar, also raised questions of technical feasibility, apart from the economic ?business case?, in case the productivity of the cell was not big enough. A ?Spar team?
Video

RFID on Aircraft Parts - Industry Initiatives, Testing Standards, and Best Practices for Storing Maintenance History Information Directly on Aircraft Parts

2012-03-22
The aerospace industry has long sought a solution for storing maintenance history information directly on aircraft parts. In 2005 leading airframe manufacturers determined that passive Radio Frequency Identification (RFID) technology presented a unique opportunity to address this industry need. Through the efforts of the Air Transport Association (ATA) RFID on Parts Committee and SAE International testing standards and data specifications are in place to support the broad adoption of passive RFID for storing parts history information directly on aircraft parts. The primary focus of the paper will be on the SAE AS-5678 environmental testing standard for passive RFID tags intended for aircraft use. Detail will be provided to help aerospace manufacturers understand their role and responsibilities for current programs and understand how this may impact their parts certification process.
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Automating AFP Tuning Using a Laser Sensor

2012-03-22
Electroimpact Automatic Fiber Placement (AFP) machines lay-up composite parts by accurately placing carbon fiber tow (strips of impregnated carbon fiber) on a mould. In order to achieve high accuracy at high speeds, the processes of feeding and cutting tows must be tuned. Historically, the tuning has been a time-consuming, manual process. This paper will present a methodology to replace manual measurements with an automated laser, improve measurement speed by an order of magnitude, improve accuracy from +/? 0.020? (manual) to +/? 0.015? (laser), and eliminate human error. Presenter Joshua Cemenska, Electroimpact Inc.
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Business Model for Successful Commercialization of Aircraft Designs

2012-03-21
In any new aircraft development program there are many important design decisions that determine profitability potential. The key to making new aircraft profitable is to design features that will command more money than the cost to provide them within the market's ability to absorb them. The business model in this paper shows how to predict or find: 1) the costs to provide various aircraft features; 2) the values that aircraft buyers place on these features; 3) the amount of money that buyers have to commit to them, 4) the open spaces in the market in which to place new designs and 5) the predicted profits from new designs. In this process, this paper extends previous work on the law of value and demand, which states that attributes determine value; value determines price; and that price determines demand. This four-dimensional, non-negative system hosts a business model that describes the features needed to enable aircraft designs to go from concepts to profitable assembly lines.
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