Sustainable Automotive Technologies 2011 (eBook)

Preface 6
TABLE OF CONTENTS 8
I EVALUATING SUSTAINABILITY 12
A HOLISTIC APPROACH TO SUSTAINABILITY EVALUATIONS IN THE AUTOMOTIVE INDUSTRY 13
1 Introduction 13
2 Sustainability in the Automotive Industry 14
3 A Holistic View on Sustainability 15
4 The Sustainability Checklist 17
5 Summary and Next Steps 18
References 20
II TECHNOLOGIES FOR PRODUCTION 21
FLEXURAL CREEPING ANALYSIS OF POLYURETHANE COMPOSITES PRODUCED BY AN INNOVATIVE PULTRUSION PROCESS 22
1 Introduction 22
2 Manufacturing process 23
3 Experimental work 24
4 Approach for a theoretical analysis 25
5 Core benefits and application of pultrusion profiles 26
6 Conclusion 27
References 27
MANUFACTURING MICROSTRUCTURED SURFACES FOR AUTOMOTIVE APPLICATIONS 28
1 Introduction 28
2 Superhydrophobic Silicone Micropillars 29
3 Tools for Superhydrophobic Polymer Microstructures 29
Acknowledgments 32
References 32
THE FIRST WATER BASED PRETREATMENT SYSTEM FOR DIRECT GLAZING 33
1 Introduction 33
2 Sika HydroPrep-1: Properties 34
3 Comparison of time to bonding 35
4 General Overview of Ecological Study Results 35
5 Sika’s VOC-free Bonding Concept 36
6 Application of Water-based activator 37
Conclusion 38
HYBRID COMMAND ISSUING IN A 2-DOF SERVOMECHANISM OPERATED UNDER VISION-BASED FEEDBACK CONTROL 39
1 Introduction 39
2 Hybrid Command Generation Protocol 40
3 Simulation Results 44
4 Conclusion 45
Acknowledgements 46
References 46
ALTERNATIVE METHODS TO INCREASE THE LONG TERM PERFORMANCE OF LASER-WELDED COPPER ALUMINUM CONNECTIONS FOR ELECTRONIC APPLICATIONS IN MOBILE SYSTEMS 47
1 Introduction 48
2 Experimental setup 51
3 Results of the welding tests 51
4 Characterization of the welded samples 53
5 Conclusions and outlook 54
Acknowledgment 55
References 55
III COMBUSTION ENGINES AND FUELS 56
INVESTIGATION AND OPTIMIZATION OF BIODIESEL CHEMISTRY FOR HCCI COMBUSTION 57
1 Fuels Evaluated 57
2 Description of Engine 58
3 Experimental Plan 60
4 Data Analysis 60
5 Conclusions 63
References 64
NEW POTENTIAL OF OLD WANKEL-TYPE MACHINES 65
1 Rotation machines, their geometry and topology 65
2 The Efficiency of Wankel Machines 67
3 Planetary Piston Machines with 2nd Order Piston Symmetry (PPM2) 68
4 Desired Qualities of a Seal 70
Acknowledgements 70
References 71
RPM – ROTARY PISTON MACHINES: NEW CLASS OF INNOVATIVE MACHINES 72
1 Introduction 72
2 Current state of the art 73
2.1 Schematical functional principle 73
2.2 Key benefits 74
2.2.1 Combustion 75
2.2.2 Lightweight construction issues 75
2.2.3 Economic value 76
3 Applications 76
References 77
IV HYDROGEN AND ELECTRIC VEHICLE TECHNOLOGIES 78
INDUCTIVE POWER TRANSFER SYSTEM INTEGRATION FOR BATTERY-ELECTRIC VEHICLES 79
1 Introduction 79
2 Drive cycles 81
3 Simulation Model 82
4 ICPT Track Positioning 82
5 Vehicle Mass Compounding Effects 84
6 Conclusion 87
References 87
PERFORMANCE COMPARISON OF HYDROGEN FUEL CELL AND HYDROGEN INTERNAL COMBUSTION ENGINE RACING CARS 88
1 Introduction 88
1.1 The case for hydrogen vehicles 88
1.2 Formula H 89
2 Vehicle Comparison Methodology 89
2.1 Lap Simulation 89
2.2 Tyre Grip 90
2.3 Vehicle Specifications: H2ICE Benchmark Vehicle 91
2.4 Vehicle Specifications: Fuel Cell Vehicle 92
3 Vehicle Comparison Results 92
4 Conclusions 94
References 94
V MATERIALS AND STRUCTURES 95
DESIGN OF BASIC STRUCTURAL COMPOSITE ELEMENTS 96
1 Introduction 96
2 Material Properties of Unidirectional Composites 97
3 The “Lug” Load Introduction Element for Several Helicopter and Space Applications 98
4 The Cross Section of the “Flexbeam” of the Helicopter EC 135 100
5 Spring Elements for Reducing Vibrations of a Helicopter 100
6 The Open Net Face Sheet for Sandwich Structures 101
7 Summary 102
Acknowledgements 102
References 103
ENHANCING SUSTAINABILITY THROUGH THE TARGETED USE OF SYNERGY EFFECTS BETWEEN MATERIAL CONFIGURATION, PROCESS DEVELOPMENT AND LIGHTWEIGHT DESIGN AT THE EXAMPLE OF A COMPOSITE SEAT SHELL 104
1 Introduction 104
2 Development of a Lightweight Seat Shell 105
3.1 The Seat Shell Development in Detail 105
3.2 Analyses of the Resource Efficiency of the Seat Shells 108
4 Summary 110
Acknowledgments 111
References 111
SUSTAINABLE DESIGN OF A SIDE DOOR REINFORCING ASSEMBLY – EXPLORATORY OPTIMISATION 112
1 Introduction 112
2 FEA Model 113
2.1 Side Door Reinforcing Assembly 113
2.2 Requirements and Specifications 114
3 Exploratory Optimisation 114
3.1 Description of Parameters 114
3.2 Description of Constraints and Objectives 115
3.3 Optimisation Scheduler 116
4 Optimisation Findings 117
4.1 Factor Analysis 117
4.1.1 Effects of Configuration Input Parameters 117
4.1.2 Effects of Material Input Parameters 118
4.1.3 Effects of Geometry Input Parameters 118
4.2 Optimal Design 119
5 Conclusion 120
References 121
RESEARCH AND DEVELOPMENT OF ANEW AND SUSTAINABLE COMPOSITE:“NATURAL STONE LAMINATE” 122
1 Introduction 122
2 Approach 123
3 Production 124
4 Experimental and numerical investigations and validation 125
4.1 Bending behavior 125
4.2 Acoustic testing 126
5 Outlook 128
References 128
VI VEHICLE SYSTEMS 129
IN-WHEEL COUPLED SUSPENSION AND DRIVE: DESIGN, DEVELOPMENT, AND MODELING 130
1 Introduction 131
2 Kinematic Synthesis and Operational Modes 131
3 Drive Sizing and Tradeoffs 133
4 Simulation 134
5 Conclusion 136
References 136
OPTIMISATION OF AUTOMOTIVE SEAT KINEMATICS 138
1 The design problem 138
2 Fundamental model 139
3 Simulation 140
4 Simulation results 141
5 Conclusion 143
References 143