In- Wheel Motors BRABUS EV

Vol. 190 • Issue 3 ai-online.com • autoindustry.us • peace









IDZs

smoothing the path

In-Wheel Motors

provide power to new

to investment

BRABUS EV

Major expos for

the auto industry









FAST-TRACKING

3-D sensors open up new

dimensions in design



Green lubricants and

ECU

DEVELOPMENT

catalyst honeycombs

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Manufacturers can think about creating a portfolio of powertrains, from

hybrids to PHEVs to EVs, simply by resizing the battery and using the same

vehicle and the same in-wheel motor drivetrain technology. Page 60

- Bob Purcell, chief executive officer Protean Electric.

contents





AUTOMOTIVE INDUSTRIES (ISSN 1099-4130)

Volume 190 Number 3 • September 2011









contents

Published Quarterly by Automotive Industries Ltd • Issue date: Q3 2011

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PO Box 1510, Versailles, KY 40383, USA Editorial comment - Being green is the cost (and opportunity) of doing business .......................... 4

Automotive Industries is published by: AI Insider - Australian ethanol producer replacing grain with algae ................................................ 6

Automotive Industries Ltd. BMW builds its DNA into new “i” range ........................................................................................ 8

Publisher: John Larkin

jal@autoindustry.us Wabco – Suspended on air ........................................................................................................ 12

+1 313 262 5702 (IP 5101888888) ixetic – Traditional oil pump is moved, and becomes a vacuum pump as well ............................. 14

Mobile Quality Control Editor: Ed Richardson

edrich@siyathetha.com • +27 (0) 41 582 3750

Editing: Claire Warneke

Mercedes-Benz – Future technologies ....................................................................................... 16

BASF – Cars love chemistry ....................................................................................................... 20

claire@siyathetha.com • +27 (0) 41 582 3750

Circulation Management: Dave Sweeney Norma – New generation fluid transport systems for diesel SCR technology .............................. 22

support@sandscirculation.com

+1 859 879 8420

Rhodia – “Game-changing” materials reduce vehicle weight....................................................... 24

Finance: Ben Adler FCA Songwon – Thermoplastics get tougher and more colourful ....................................................... 26

Deliver information to the production line ben@autoindustry.us

+44 (0) 20 8458 7130 DSM – Plastics for better living ................................................................................................... 28

and improve the bottom line. Business Development - Asia Pacific: Yogesh Rudra

yogirud@autoindustry.us

CES – OEMs, suppliers signing up for consumer electronics shows ........................................... 30

+91 9810 440 916 austriamicrosystems – 3-D sensors open up new dimensions in design ..................................... 36

Press Releases and Advertising Enquiries: Cinterion – Connectivity is greening transport ............................................................................. 38

Enquiries should be sent to the AI Team via the contact details below

The GaugeFlex system is a multi-module solution GaugeFlex, the only wireless STEVE BARCLAY DOE - Investing for a cleaner world ............................................................................................ 42

Engineering & Design Press Releases and Advertising Enquiries

mobile gauging solution, is: Axeon – Battery recycling and reuse .......................................................................................... 48

that converts inspection data instantly to actionable steve.barclay@autoindustry.us

+91 8800 839 040 (IP 5101888999) MOST takes automotive technology into new industries ............................................................. 50

information. It enables workers to automatically analyze, Rugged - Mobile device is sealed NICK PALMEN

Engineering & Design Press Releases and Advertising Enquiries Synopsis – Fast-tracking ECU development ............................................................................... 54

to IP54 standards and withstands nickpalmen@autoindustry.us

track, research and chart data captured at the point of multiple 4’ drops to concrete. +44 (0) 20 8764 9696 (IP 5101401836)

Renesas – Single MCU caters for multiple infotainment standards .............................................. 56

JAMES HILTON Integrys – Natural Gas network coming on stream ..................................................................... 58

activity. It wirelessly delivers the information, allowing Shows Press Releases and Advertising Enquiries

Flexible - With both 1D and 2D jah@autoindustry.us

Protean Electric – “Re-inventing” the in-wheel drive system ........................................................ 60

plant operators to make immediate adjustments, address barcode scanning capability, the

+44 (0) 1142 811 014 Automechanika Shanghai – Gateway to still accelerating Chinese market................................... 64

CLINTON WRIGHT

problems and prevent production lots from falling out device can be used throughout Environmental Technologies Press Releases and Advertising Enquiries Moroccan auto industry moving into top gear ............................................................................ 68

cew@autoindustry.us PaintExpo – Growing Eurasian auto market attracts major trade fair ........................................... 70

of specification. The GaugeFlex system is helping the manufacturing facility. +44 (0) 7852 722 602

JON KNOX NPE2012 – Lower costs benefit both exhibitors and visitors....................................................... 72

manufacturing operations around the world execute Convenient - The only rugged

Fuels & Future Fuels Press Releases and Advertising Enquiries

J.Knox@autoindustry.us

LiqTech International – Taking pole position in the race to develop DPF technology ahead of regulations ...... 76

quality control, production control and inventory control device that weighs less than 10 +34 (0) 690 276 463 Croda Lubricants – Naturally more efficient lubricants................................................................. 78

ALAN TRAN

ounces and has a full 3.5” color Vehicle Systems - Interior Press Releases and Advertising Enquiries Frauenthal – Catalytic SCR technology goes mobile ................................................................... 80

more effectively. The question is not whether you can display, so it’s light and easy to use. AlanTran@autoindustry.us S&P Capital IQ – Toyota: understanding exposures at times of crisis .......................................... 82

+ 44 20 3129 8361 (IP 5101401831)

afford to deploy the GaugeFlex mobile quality control ROB WHITE Thermamax – Keeping heat and sound inside the system .......................................................... 86

Versatile - Works with digital Vehicle Systems - Exterior Press Releases and Advertising

solution, but rather: Can you afford not to? Enquiries

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“...because lean always starts at the waste!”

Automotive I n d u s t r i e s 3

Being green is the

intro cost (and opportunity)

of doing business

There is a saying in the Automotive industry, which goes means looking at all aspects of a facility and creating a plan that

something along the lines of “don’t talk to me about quality. will positively impact the environment. It’s a continuous process

Talk to me about price and delivery. Quality is a given. With- that is ever changing and ensures that best practices are used

out it, we would not be having this conversation”. and shared across the globe in Ford’s manufacturing sites”.

The gist is that any supplier to the auto industry starts at The company has invested in renewable energy generation at a

ISO9001 and continuously improves their quality standards from number of its sites.

there. Quality is not a nice-to-have. It is the ticket to the game. China has made it government policy. The vision is captured in

ISO14001 and green credentials have reached that tipping point. three key documents – the “12th National Economic and Social









E20001-F10-P301-X-7600

To use one of the cliché’s of the age, it is “being built into the Development Five – Year Plan” drafted by the ministry of science;

DNA” of the OEMs and, therefore, their suppliers. Volkswagen the “Guiding Catalogue of Industrial Structure Adjustment

has branded it “BlueMotion,” and its commitment to green- (2010 edition)” modified by the State Development and

ness extends to the design of new plant and equipment. This Reform Commission; and the “Saving and New Energy Vehicle

means that architects, engineers and equipment manufacturers Development Program” of the ministry of Industry and Information

wanting to do business with VW world-wide will also have to think Technology all have a direct impact on the Chinese auto sector.

green – along with the various Tiers of component suppliers. In short, the vision is for China to be the world’s leading producer

General Motors says “when we develop new vehicles, of “new energy” vehicles by 2020, with the focus on

our designers and engineers work to find ways pure electric drive technology. Government grants

to improve the impact our products will have of RMB 100-bn (US$16-bn) are available to

on the environment throughout their entire support development.

lifecycle. We look at everything from the The rest of the world is in the same race,

materials that go into our vehicles and the and the winner will be the planet. Other

winners will be innovative companies

which are able to bring green solutions

to the auto industry. Opportunities are

not limited to the traditional suppliers

Increased Energy Efficiency

Editor, Ed Richardson

who are helping develop more efficient

power trains, electric power trains, for Fixed-Speed Drives

and sophisticated engine management

manufacturing processes used to build systems. They include the design and SIRIUS Industrial Controls: Energy and cost savings in the automotive industry

them, to energy consumption on the road building of factories, the development

and the recyclability of our vehicles at the of bio-based materials, anything that

end of their useful life,” says the company. contributes to cleaner manufacturing, more

Toyota has developed a “life cycle efficient logistics services, and recycling solutions.

assessment” tool, which covers the full life-cycle of What will stimulate exciting innovation and

a vehicle, from design through production to use and final investment is that the opportunities lie all along the

disposal. Production is governed by the “five Rs” - refine, reduce, automotive value chain. The green philosophies adopted by the

reuse, recycle and recover energy. Gains include a reduction in the OEMs – as with their commitment to quality – extends to all their

use of water per vehicle by 20% since 2003, the company’s North suppliers. Pollution and the unsustainable use of resources are

American plants have cut landfill waste by 96% since 1999, and no longer hidden through outsourcing. OEMs are becoming as

the end of life recovery/recycling rate is over 90%. diligent as their critics in their search for environmental efficiencies.

Ford says green production is “more than just recycling paper The next step, for true sustainability, is to find ways to create

and turning the lights off at the end of the day; being green sustainable jobs while keeping the world mobile. AI



CONGRATULATIONS Will Schumacher of GM - You are the winner of the Automotive Industries Reader Survey! Soon

you will be receiving the iPad2. We appreciate your feedback about your experience with Automotive Industries!



AUTOMOTIVE INDUSTRIES and Rutgers, the State University of New Jersey, have put together a digital

library of back issues of AI from the early 1900’s (high res and low res) of approximately 230,000 images

of the print publication. This archive, which documents the birth of the auto industry to the present, is

available to AI subscribers. Go to AI’s homepage www.ai.com and click on the “AI Library” link or visit

www.ai-online.com/100YearLibrary

siemens.com/sirius/energysaving

4 to read full version of AI stories go to www.ai-online.com

UK • USA • GERMANY



Ai insider



Australian

ethanol producer replacing

Reconsider the Wheel

grain with algae By: Bob Brooks

Increased power, improved fuel efficiency,

The Manildra Group, Sydney, Australia, the largest Austra- when savings are applied from productive use of CO2 rather than

ease of integration and the freedom to

lian producer of ethanol (300 000 metric tons/yr), has con- being taxed as a pollutant. Another advantage is the Algae Tec design – Protean Drive™ In-Wheel Motors

cluded an agreement with Algae Tec to provide facilities at system can use either salt or fresh water.

Manildra’s largest ethanol plant for demonstration at scale Although pilot operation of the system has validated Algae Tec’s expand your options in the development of

of the Algae Tec system for making bio ethanol. A full scale

module is scheduled for start up by the end of Q1, 2012.

performance, all eyes are now on the full scale modular unit being

constructed at a Manildra ethanol facility. With 40 total locations in

hybrid/electric powertrains.

Based on information from Earl McConchie, managing director of SE Asia, Australia and the U.S., Manildra could be a large supplier

Algae Energy, (subsidiary of Algae Tec) Cumming, Georgia, Manildra of non food related ethanol. To learn more about how we turned the

is moving ahead with the Algae Tec system for two primary reasons. McConchie believes growth in World population, increases

One is to eliminate the use of food commodities (now primarily in the standard of living in eastern parts of the globe, reluctance in-wheel motor inside out, visit Protean

wheat) as raw material for making ethanol. The second is the Algae to use food product for fuel and price increases from dwindling Electric at ProteanElectric.com.

Tec system’s productive use of CO2, which is a waste product from supplies of petroleum all combine to enhance the outlook for fuel

Manildra plant operations. Australia is reportedly planning to impose made from algae. Algae Tec’s target for algae based fuel is 8-10

taxes on CO2 released into the atmosphere. million metric tons/yr by 2022; said to represent over 2 billion

Manildra is a one million tons/year user of wheat to produce gallons/yr of biofuel.

flour, starch, gluten, protein, glucose and syrup, as well as If measured performance of the initial production module at

ethanol. McConchie says Manildra is focused on the advantages scale next year validates the firm’s data from its pilot operation

of Algae Tec’s photo bioreactor system packaged in 40 ft. and depending on competitive systems, the 2 billion gallons/yr

modular containers (the same size as shipping containers). The forecast may be conservative. Next will be the question of who

algae solution is cultivated in separated layers fed with CO2. will participate with Algae Tec in the commercialization of the

Solar energy via fiber optics from remote parabolic solar energy firm’s algae system applied to the economic production of diesel

collectors provide distributed energy to each layer for optimum and aviation jet fuels which have larger potential than ethanol.

algae growth. By this means, large algae oil or ethanol yields can McConchie reports that discussions are in progress with several

be realized for a given bioreactor foot print. The yield per acre is firms. Surely this is driven forward by expressed desire of the

said to be very high. military and air lines actively seeking replacement of petroleum

While the subject of Algae Tec’s product cost was not with biofuel. Helping to drive demand is the standard now

discussed recently, the firm earlier indicated to Automotive approved for hydro processed aviation bio jet fuel set by an

Industries that basic cost is expected to be something less than ASTM International Committee. The approval for new aviation

$2/gal and certainly below the current cost of either petroleum or biofuel is an annex to the alternative fuel specification D7566,

food commodity based fuel. Unknown is just how this will work out reported by Biodiesel Magazine. AI







AI Insider Bob Brooks is a member of the

Society of Automotive Engineers and long-time

automotive technology journalist specializing

in powertrains and fuels. +1 248 740 5580

info@proteanelectric.com



6 to read full version of AI stories go to www.ai-online.com

innovation









BMW builds its DNA

into new “i” range By: Nick Palmen







BMW expects to launch purpose-designed and built elec- Secondly, we will offer a wide range of ConnectedDrive

tric and hybrid vehicles within the next two years. They will applications. BMW ConnectedDrive stands for safety, comfort and

be very different to the current pilot fleet of electric Minis, infotainment. One feature is Real Time Traffic Information, which

and driving enthusiasts will still have power and accelera- continuously calculates updated traffic information in real time.

tion on tap. Automotive Industries (AI) went to the Frankfurt Drivers are able to react in due time to avoid congested areas by

Motor Show to find out more. changing their route. The display shows the roads around you in

But first, we asked Klaus Draeger, Member of the colors – green, red or yellow including the different lanes in both

Board of Management of BMW AG for Development, directions. We are also introducing different lines for the 1

what the new BMW 1 Series offers in terms of Series. We have Urban Line and Sport Line – and, of

innovation and efficiency. course, we will have the M sports package from

Draeger: Since we launched the 1 Series next year.

BMW in the premium compact segment it AI: Will we see any of the new 1 Series

technologies in the new 3 Series?

Draeger: 1 Series and 3 Series are

from the same family. If we have 1 Series

Klaus Draeger, Member of the models with turbo charged engines,

Board of Management of BMW then we will have the 3 Series with turbo

AG for Development. charged engines. The same applies

for the automatic gearbox and the

ConnectedDrive applications, So, yes,

we will find a lot of these technologies in

has sold over one million units all around the 3 Series.

the world. The new 1 Series is a continuation AI: What more is the new M5 going to

of this premium car segment for BMW. Of offer than its predecessor?

course, there are changes – the new car is a little Draeger: There are two significant differences.

bit longer and wider, with a little bit longer wheelbase We have greatly improved fuel economy, and we

giving more legroom at the rear as well as bigger luggage achieved this with even more power and more torque. The new

compartment. It is still a real premium compact car, but is more M5 can clearly be seen as a better sedan for a long distance driving

like a well trained athlete. than its predecessor. There is now no compromise between a

In terms of innovations, there are two areas where we’ve made sports car and a car for cruising over long distances.

huge progress. One is in terms of EfficientDynamics – we will only AI: What approach do you take with the BMW i3 and

offer turbo charged engines with an entry of 1.6l BMW twin power BMW i8 Concept?

turbo technology. They all feature direct injection sitting in a central Draeger: First we have to talk about the brand. BMW is a

position between the four valves, delivering very good response very strong brand, enhanced by BMW M, our well established

and efficiency. In addition, we have 8-speed Stepronic gearbox sub-brand for exclusive and highly sporty cars. But we see more

with auto start/stop function and ECO PRO mode, which is a new and more customers with a great interest in having a premium

mode that gives the driver a chance to save up to 15-20% in fuel. car which fulfils their expectations in terms of sustainability even



8 to read full version of AI stories go to www.ai-online.com

BMW’s “i” concept is aimed at those who want driving performance while reducing their impact on the environment.









Premium

battery, the electric motor, the electronics and also carries the





3

front and the rear axles. Mounted on top is the Life module,

which is a body-in-white (BIW) basically made from very light and

strong carbon fiber. This architecture gives us liberties in interior

and exterior design, making the BMW i models extraordinary

and easy recognizable. The biggest achievement certainly is the







Mobility. Dynamics. Innovation.

extremely low weight. The intelligent mix of materials gives us an

advantage of 250-300kg compared to converting a conventional

vehicle to an electric one.

AI: You have a joint venture with SGL Carbon for production

better than today’s models can. These are people who want to of carbon fiber. What are the advantages for BMW?

show to the outside world that they care. We believe that with our Draeger: We have used carbon fiber in conventional vehicles

“i” sub brand, we can deliver a specific product for customers we for quite some time. You can see carbon fiber components on

were probably not going to reach with a conventional product. the high performance products like M3 & M6. Some of them are

So, the BMW i sub-brand is for customers looking for maximum structural parts, others are exterior like the carbon fiber roof on the

sustainability in premium products. M3. But as we expect to have a quite substantial usage of carbon

The two new products i3 and i8 are basically two bookmarks – fiber in the future, we decided to set up the joint venture thus

i3 Megacity 100% electric vehicle (available with a range extender securing our supply. SGL has a great carbon fiber competence,

later), and the all new BMW i8 plug-in hybrid sports car, where and is therefore an ideal partner. Combining the SGL expertise

we combine a powerful turbo-charged three-cylinder engine on with the BMW know-how gives us a head start.

the rear axle with an electric motor on the front axle. The BMW i8 AI: When do you plan to launch the i3 and the i8?

can drive in three different modes – purely electrical, combining Draeger: We will launch the BMW i3 in late 2013 and the

electrical and gasoline, and gasoline alone for long distance. The BMW i8 in 2014.

fuel consumption will be under 3 l/100km with the acceleration AI: What is the future of the BMW’s i family, can we expect

and the performance of a BMW M3.

AI: What new technologies can we see for the first time

any models between i3 and i8?

Draeger: There are a lot of opportunities as well as a lot of

Innovative and efficient aggregates for steering, chassis

and suspension, gears, brakes and air conditioning.

in i3 and i8? ideas. But first let’s see the take off of the two cars then of course

Draeger: We are convinced that it is not ideal to convert a we can add further vehicles to fill the strategic gap we deliberately

conventional car into an electric vehicle since you will always end decided to leave in between.

up with a compromise. You have an empty engine compartment AI: What is the future of the Mini’s front wheel drive platform?

with just a small electric motor, and there is never sufficient space Draeger: We do not want to have BMW competing with Mini.

for the battery in the area where the fuel tank is situated. We are taking the opportunity to bring really different cars on the

So, what we need is a purpose-built architecture designed same architectural characteristics to the market. We are able to

around the necessities of electric mobility, especially with introduce derivatives in terms of length, in terms of width and

designated space for the battery and the electric motor. The also in terms of height, but a Mini will remain a Mini. In addition,

BMW i models have what we call a Life-Drive-Architecture. The there is some space for new BMW models based on front wheel

so called Drive module is an aluminum frame that holds the drive architecture. AI



10 to read full version of AI stories go to www.ai-online.com

innovation

Air suspension

for everyone By: Nick Palmen









Air suspension is becoming increasingly popular for premium and luxury vehicles, with nearly all the

major carmakers replacing all four steel spring systems on the corners with air springs. Features

that add value for customers include optimum ride height that is independent of vehicle load, which

can be achieved with a less complex rear axle air suspension. BMW has achieved this advancement

and decided to equip its new 5 Series Touring and Gran Turismo models with rear axle air suspension

as a standard feature. Electronic control unit and air supply unit for rear axle air suspension are standard equipment for the new BMW 5 Series Touring.



Automotive Industries (AI) asked Helge Westerkamp, a stronger suspension to be able to carry heavier payloads and not the load situation. These features can be realized with both the AI: What have been the major breakthrough achievements

sales and marketing leader of WABCO Car Systems, about kneel too deep when fully loaded. The downside is an uncomfortable rear axle air suspension and 4-corner system approaches. in WABCO´s air suspension history for passenger cars?

WABCO’s product portfolio for electronic suspension ride when the car is empty. Air suspension is the ideal solution because AI: What competing technologies are available to Westerkamp: The first application was the VW Passat in

systems as well as the content delivered into new BMW 5 the air spring pressure is automatically adjusted by a compressor. compensate height change due to load variation? 1986, where WABCO introduced its oil free compressor technology

Series Touring and Gran Turismo vehicles. The effect is always optimum ride height, independent of vehicle load, Westerkamp: Theoretically, there are four different physical plus the electronic control module for a rear levelling system. After

Westerkamp: WABCO introduced its first electronic air and a spring characteristic that is softer at lower loads and stiffer at principles available. First, air suspension; second, hydraulic a series of further applications i.e. for Landrover, Mercedes and

suspension system in 1986 for commercial vehicles. Meanwhile, higher payload. Nature has made it simple for us. suspension; third, mechanical adjustment of the spring base plate Audi, we launched in 2000 the first mechatronic air supply unit

it has become a standard in Europe on buses and the majority of AI: What is today’s market penetration and what future with an electric drive; and fourth, electromechanical suspension for several General Motors SUVs. The innovation was to integrate

trucks and trailers. The breakthrough for passenger cars in Europe trend do you see for air suspension? following the principle of a loudspeaker. Only the first two have made all air supply components, including electronic control, into one

happened in 1998 with the introduction of air suspension in the Westerkamp: Today only around two per cent of all light it into automotive series production, the others are too complex and device in order to realize a plug-and-play solution for the OEMs.

Mercedes S-class where WABCO developed its first generation vehicles are equipped with air suspension. The share between rear expensive. For rear axle systems, the main competing technologies In 2006, we introduced air suspension into the compact class

high-power, oil free compressor as the heart of a system axle and 4-corner systems is similar. Nearly all carmakers have been air suspension and self-leveling shock absorbers. for PSA C4 Picasso vehicles as the full system supplier. Another

that could pressurize air up to 16 bar in a single offer air suspension on their premium vehicles. The AI: What are the main differences between rear highlight was the launch of the Audi A8 in 2010, where WABCO

stage. In the following years, additional system functionality is increasingly enhanced through air suspension and self-levelling shock developed the complete air supply system including

components were added to the portfolio additional features such as damper control absorbers and what effect does it have the first electronic control unit for air suspension

including complex electronic control units or switchable air spring characteristics. for the end-customer? plus damper control with FlexRay technology.

for air suspension in combination with Rear axle air suspension offers some of Westerkamp: Air suspension AI: What other technologies is WABCO

the most important features while being directly compensates height change focusing on for the future?

less complex than a 4-corner system. when the vehicle is loaded. The Westerkamp: As a technology leader for

We are convinced that this feature will height sensors measure the deviation vehicle control systems for commercial vehicles,

Helge Westerkamp,

become more and more standard on from optimal ride height and the WABCO is experienced in all kinds of safety

sales and marketing leader

station wagons and minivans. The time electric control unit operates the related systems like ABS, rollover prevention, driver

of WABCO Car Systems.

will soon pass when families are riding compressor in order to inflate the air assistance systems, and many more. We have

low toward summer vacation with springs accordingly. The driver gets development and production capabilities across

fully loaded vehicles. Today’s high-tech direct feedback. The self-levelling shock the globe and we are expanding our capabilities

damper control. The delivery content vehicles can no longer permit a hanging absorber needs movement of the vehicle’s to embrace several new technologies. This

for BMW is the electronic control unit appearance. BMW has recognized this body relative to the road in order to pump expertise can also be adapted to the passenger

plus the complete air supply unit including early and decided to put air suspension as hydraulic oil within the damper into a load- car world. For commercial vehicles, we have

compressor, air dryer, valveblock, brackets, standard on its recently launched 5 Series carrying volume. Consequently, the vehicle a clear path to enhance vehicle efficiency and

isolation and air intake. Touring and Gran Turismo. must drive to create body movement and environmental sustainability by 20% through

AI: What is the technical difference between AI: Which features of air suspension do pump itself up. On even roads, this can WABCO products. Our vision is to improve

rear axle air suspension versus normal steel suspension? customers value most? take a couple of hundred meters and the advanced safety and driver effectiveness,

Westerkamp: The problem with steel suspended vehicles is Westerkamp: WABCO has carried out a global consumer driver gets very limited feedback. Also, and reduce the number of commercial vehicle

always the compromise between comfort and limited overall wheel survey, asking passenger car drivers about their perception of air active features – like trailer connect or easy accidents by 50% by 2020. AI

travel. The effect is that a vehicle with soft suspension, which is fully suspension. An interesting outcome is how end-customers rank loading with on-demand height reduction

loaded, has very limited wheel travel left to compensate for road the different features of air suspension. The analysis of the data while parked – can only be realized with an air

undulations. This becomes critical, particularly for vehicles with high allowed us to set up a top 10 list of air suspension features. It clearly suspension system. We see the market moving The compressor drive, which is the

payload such as station wagons or minivans. These vehicles need identified improved comfort and vehicle ride height independent of toward air suspension for new vehicle generations. heart of the WABCO system.



12 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 13

innovation



Traditional oil pump

is moved, and becomes a

vacuum pump as well By: Nick Palmen Tandem Oil Vacuum Variable-Transmission-Pump Switchable Vacuum



In the constant quest for improved safety, better fuel con- using conventional vane pump technology. Our new solution is

sumption and lower CO2 emissions, the industry is having much more efficient. We can mechanically control the oil volume

to take a critical look at all components, even the seemingly and the oil stream. We control the displacement of the pump, which

immovable and insignificant. One such is the oil pump. makes it possible to save a significant amount of energy on the

Automotive Industries (AI) asked Georg Wolf, CEO of transmission. The pump is on when it is needed to cool down the

ixetic, what is unique about the new ixetic tandem pump motor or to shift gears, and off if you are cruising on the highway.

launched at the Frankfurt Motor Show. AI: Is the pump suited for both automatic-transmission

Wolf: Until now oil pumps have been connected directly to and dual-clutch gearbox applications?

the camshaft. But, engines have had to become “flatter” in order Wolf: Both require a pump for hydraulic functions such as

to meet the standards for better pedestrian safety. Our solution is clutch actuation, converter supply and the cooling and lubrication

a tandem pump. Located in the oil sump, it supplies the engine of transmission components. The pump can be used in normal

with oil for lubrication and cooling, and is also a vacuum transmissions and wet double clutch. The savings are

pump. The vacuum pump, which is connected to again 2.0g of CO2 per km.

the brake booster, can be switched on and off AI: What are your efforts / plans in the ABOVE: Test Car i miEV

as needed. The oil pump can be controlled field of electric mobility? LEFT: Heating Cooling Unit 2.0

fully-variably or in steps, depending on Wolf: First of all there is electrification

of the powertrain, which requires the AI: Is your globalization strategy on track?

electrification of the pump functions. Wolf: The first steps we took after our independence from

At present, we have electrical vacuum Schaeffler Group was to restructure the company completely.

Georg Wolf, pumps and electrical transmission The system takes care of the entire thermal management of We built a new plant in Bulgaria. In parallel, we started the

CEO of ixetic. pumps to allow for functions such as the an electrically-driven vehicle. This includes the cooling of electric internationalisation of the company by going to India. We have

stop/start function. motors and lithium-ion batteries, as well as the air conditioning of our first contract there already. The next step was to go to China.

Then there is the fully electric car. the interior. It is highly efficient, and the exchange of heat between That has been achieved with a contract in the Shanghai area from

Many years ago we started with the the individual units is virtually loss-free. The heart of the system is a European customer. Next on the list is North America. We have

customer needs. This means that the pump development of the CO2 technology, a small heating/cooling module in which carbon dioxide (R744) contracts with transmission producers like ZF and Chrysler who

delivers either fixed amounts of oil at different which was later stopped by the OEMs. We circulates as an environmentally-friendly refrigerant. A special are expecting an answer from us as to when we are going to be

volume levels, or optimally adjusts the amount are applying this CO2 knowledge to full electric compressor was designed for this purpose. Thanks to a standard ready for production in North America. Our target is 2013.

supplied in line with requirements. cars. One of the biggest problems with electric interface, the module can be seamlessly integrated into every AI: What else can we expect from ixetic in the future?

AI: What benefits does this offer OEM’s? cars is the driving range. There was a report last mass-produced vehicle. Wolf: When we became independent, we had an older

Wolf: Around 10% less space is required than using year in Germany by TUV where they compared different We see a big future CO2, because as a refrigerant it can work product portfolio, which consisted mainly of steering pumps. Now

two individually-driven units, despite the presence of a patented electric vehicles under certain conditions, and what they found in very low temperatures down to -20C, which of course is not we have fully converted to electric systems. We have a completely

mechanical clutch integrated into the drive shaft. The pump was that in cold conditions the driving range is reduced by half. possible with other refrigerants. This is our contribution to electro new product portfolio for the next five years. We are extremely

requires little more space than a conventional vacuum pump. We have a solution in a production-ready thermal management mobility, and we are totally convinced from a technical stand active on the engine side, with vacuum pumps and oil pump

Tests have shown that, with defined shifting strategies and driving system that significantly increases the range of electric vehicles. point that we are ready for production. Our thermal module can applications - solo or tandem, electric pumps for CO2 reduction

cycles, the savings are 4%, or 5g of CO2. So the benefits are In practical tests the system enabled a Mitsubishi i-MiEV and a be used for heating and cooling in other industries like trains, or transmissions. We produce many different vacuum pumps for

saving room in the engine compartment and CO2 reduction. Smart fortwo electric drive vehicle to cover significantly more miles or heating and cooling tooling machines. The big difference to 6-8 cylinder engines and, as we have engine downsizing at the

AI: You have also introduced the world’s first demand- per battery charge. previous CO2 systems is that our system is completely closed. moment, there is a big focus on four-cylinder engines. We also

dependant variable cartridge-type transmission pump. A standard Mitsubishi i-MiEV and a smart fortwo electric drive No servicing is needed. have a completely new business on the transmission side, and

How does this work? vehicle were retrofitted with the modular thermal management AI: Is ixetic able to meet the demand? are working with most of the well-known transmission companies.

Wolf: At the end of 2004 we started to introduce the vane system. In August 2011, the company successfully demonstrated Wolf: The design is finalised. There is no really a challenge There will be new products like the thermal module for the electric

pumps in transmission applications, and we are now the world the range of the i-MiEV increased as a result. In the tests, the in the production of the parts. The only thing that is missing is a car. We are also looking for business on the non-automotive side

leader in vane-type transmission pumps. We are very much remaining range with our concept was 85%, without heating contract. We are ready for series production, and expect to start for products in the powertrain area. ixetic’s strength is in our

involved with the latest developments with ZF, Daimler and Chrysler output being impaired, compared to that of a standard vehicle. in two to three years. technical expertise in the area of electrification. AI



14 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 15

innovation









Future technologies at

Mercedes-Benz By: Nick Palmen



Mercedes-Benz customers and the motor industry were your content on the fly. Every six months to one year we will be

given a view into the technological direction being taken by introducing new services. Many of them will be free of charge.

the premium car maker at the 2011 Frankfurt Motor Show. In the context of reducing driver distraction, the other feature we

Automotive Industries (AI) was there, and asked will be introducing offers much more natural interaction with the head

Prof. Bharat Balasubramanian - vice president product unit and connectivity. We are showcasing some of these technologies

innovations and process technologies at Daimler what key in the F 125!. One is gesture recognition. If you are sitting in the rear

issues other than green technologies and emission control seat looking at the TV monitor you can scroll, you can pause, you

are influencing the future of the automobile. can select the program that you want. Similarly, on the driver’s side,

Balasubramanian: I think we have two other very key we have a special touch pad that not only recognizes touch but also

issues. One is the inclusion of driver assistance systems, including your gesture for up to 20mm above the pad.

autonomous driving, and the second area will be “digital lifestyle”- The third area of gesture recognition is the opening and closing

adding premium connectivity and infotainmant to the driving of the doors of the F 125! You open it with the swipe of you hand

experience of the customer. upwards, and you close it with a swipe downwards. If you want

AI: Will new media will have a central role in to stop the door at some point, you just press your hand

tomorrow’s car? forward. Inside the vehicle, the instrument panel

Balasubramanian: Yes. It is very much a generates a 3-D picture. We have cameras

central role for the simple reason of the digital analyzing the position of your face so you

lifestyle. People are so used to using their don’t need special 3-D-spectacles. If you

smartphones for a variety of applications move your head the system automatically

adjusts the stereoscopic picture for your

position and then you can integrate multi

Bharat Balasubramanian - vice layered information three dimensionally

president product innovations and into a rich visual experience.

process technologies at Daimler. AI: How is the innovation process

structured at Daimler?

Balasubramanian: We always ana-

besides normal telephoning that they will lyze global trends and what the competition

demand this type of interaction in the vehicle. are doing, benchmark it, and then create spe-

AI: What possibilities do you see for cial focus areas where we generate innovation.

Daimler in the areas of connectivity and Current focus areas include the road to emission-

infotainment? free mobility - we are an innovation leader here – the

Balasubramanian: We have a vision called “@ road to accident-free driving, and infotainment and con-

your COMAND” which focuses on four areas - sensory perfection, nectivity. Beyond that, we also do a lot of work in lighting technology,

seamless experience, natural handling, and remote convenience. in aluminum, and carbon fiber. Almost 80% of the innovations have

Because of constant connectivity with the Cloud, the driver has some form of electronics, but on the materials side you do not need

seamless access to all the media he or she normally uses. We it. In our lightweight strategy, we have the full aluminum body for the

have data transferring from your telephone to our Daimler vehicle AMG SLS. For the SLS E-CELL it is a mixture of carbon fiber for the

backend server, which prepares the content for you in such a way battery case coupled with aluminum space frame structure.

that you do not experience any driver distraction. The tedious AI: How important is supplier innovation for Mercedes?

synchronization of different communication and entertainment Balasubramanian: We have very close relationship with our

devices is also completely eliminated. There are a lot of features key suppliers. In some areas we generate the innovations together

that you can have including Facebook, Twitter, Google Panoramia, with them - generally the idea for the system integration and

etc. This is a very powerful feature because it lets you upgrade functionality comes from us. The suppliers also generate ideas



16 to read full version of AI stories go to www.ai-online.com

INSPIRING MOBILITY

The cockpit of the F 125! - showcasing the next generation of Daimler technology.

on the cost side - how to get the cost down to acceptable level AI: How does the new B-class concept differ from the

to the final customer. It is a joint effort and in many of these areas old one?

(especially in the safety areas), we allow the supplier to license Balasubramanian: There are two major changes. The last

this patent also to others, as we did with the anti-lock braking generation B-Class had a sandwich floor concept, which we

systems, ESP, air-bags, etc. removed in the new one. Secondly, we changed the position of

AI: What processes do you have in place to deal with the engine and placed it in front of the front axle. This allowed us to

quality assurance and customer expectations? utilize the modules and aggregates that we have in the C-Class. It’s

Balasubramanian: We follow customer research and trends almost the same engine designed for longitudinal and transverse

in all big market areas closely. Above and beyond that, we have very mounting. Removing the sandwich floor allows us to have much

focused and intensive testing procedures. I would think that there is more design freedom - we will have five different body versions.

no other company in the world with the range and in-depth testing This is the first variant with the high seating position - not because

that we do for all these features. That might be part of the reason that, we have a sandwich, but because there are traditional Mercedes-

for some innovations, someone else comes to the market earlier. We Benz customers who prefer the high seating position. The rest

are sure that the functionality we offer works in a very wide range of of the cars will all be coming with low seating positions. With our

use cases. When we have product on the market we closely follow module strategy, we have been able to introduce into the B-Class

customer feedback, we analyze the different countries with the help high-end safety systems, including the forward collision warning

of JD Power in the US and in Germany for example. system and collision mitigation with the help of radar systems, lane

AI: Is the future of the automobile electric or internal keeping assist with a mono camera, we have PRE-SAFE etc. So

combustion? the things available in the E- and S-Class have been cascaded

Balasubramanian: I think we will see both technologies. The down to the B-Class. It is a major step forward to get a B-Class

internal combustion engine will remain with us for many decades. with all this technology.

We will have improvements in internal combustion technology like AI: Are the new advanced technologies seen in the new









PHOTO GILLES DEFAIX

we are showing in the new 6- and 8- cylinder engines with direct SLK55 & SLS AMG Roadster exclusive only to the segment?

fuel injection and lean burn solutions, multi stage charging etc. Balasubramanian: The SLS AMG Roadster has a full

At the same time, we will have a hybridization of the drive train in aluminum chassis and body. You’ll see something similar in the

various ranges - from low to high power, and finally zero emission coming years on the Mercedes-Benz cars. Other than that what

technologies like fuel cells and full battery electric vehicles. you see in both areas is a lot of sharing, the only difference is that

AI: Smart has always been a pioneer in matters of urban AMG positions its vehicle in the very sporty corner and we are

mobility and at Frankfurt you introduced the smart forvision more in the area of cultured sportiness, but the technologies are

concept vehicle jointly developed with BASF. What did BASF’s very similar and shared between the two companies.

material and system competence bring to this project? AI: What else can we expect in terms of innovation from

Balasubramanian: BASF is very strong in materials. It is Daimler in the future?

an impressive example of what can be achieved by two leading Balasubramanian: You can see all the innovations for the

companies from two different sectors working together. There are so future in the F 125!. One is the new form of hydrogen storage

many innovations - for example the roof of the car has got power- with very small tanks with a capacity of 7.5 kg of hydrogen. The Rhodia is a specialty chemical company committed to sustainable development and a long-standing partner of the

generating solar cells based on organic chemical dyes, and the wheel second is in the high-voltage battery, where we are talking about automotive industry. With unique expertise in polymer materials, inorganic chemistry and catalytic processes, Rhodia’s

rims are made of fiber reinforced plastics saving about 3kg. The body the next generation of lithium batteries with half to one-third in strength in innovation is a constant source of inspiration helping to meet the new challenges of sustainable mobility:

panels and the chassis are made of special plastic components weight, compared to current technology of the same capacity.

making the vehicle lighter and with a greater driving range. Gesture recognition, on-line speech recognition modules, 3D

AI: What new technologies are we going to see in series displays and the materials and fabrics like the ones in F 125!,

production first? Carbon fiber hybrid doors to reduce the weight. These are all

Balasubramanian: New to series production is the paint, in our book of innovations many of which you will see in the Solutions to preserve Enabling emission Materials &

natural resources control systems competencies

the infrared light reflecting material, and the wheel rim technology. coming years. AI and limit CO2 emissions for better air quality for enhanced safety





18 to read full version of AI stories go to www.ai-online.com

innovation









New seat materials

provide greater comfort

with less weight.









Cars love chemistry By: Nick Palmen

The smart forvision – the result of a collaboration between BASF and Daimler.



smart’s new forvision vehicle has been described as a The three pillars we were focusing on were lightweight aluminum. Thanks to short hardening times, the Baxxodur resin future system supplier we will be able to support our customers

“showcase” of technologies for sustainable and holistic construction, temperature management and energy efficiency. systems from BASF are also suitable for producing larger volumes. in the electromobility field.

electric mobility of the future. AI: What did BASF’s material and system competence AI: What is your contribution in terms of temperature AI: By how much is it possible to extend the range of a

Unveiled at the 2011 Frankfurt Motor Show, it offers a bring to the vehicle in terms of lightweight design? management? battery-electric driven vehicle using your expertise?

platform in which the researchers and designers “intentionally Fischer: The key lightweight materials are: the first all-plastic Fischer: We introduced a heat shield that has not yet been Fischer: The total of all technologies integrated in the concept

realise a mixture of visionary materials and technologies in wheel rim suitable for large volume production. It consists of long- used for automotive applications. It consists of a new kind of vehicle make a significant contribution to increasing the range.

the concept vehicle - some of these are still at a laboratory glass-fibre-reinforced Ultramid Structure. The weight saving in infrared-reflective film from BASF applied in the windscreen and This is always at the centre of discussions relating to battery-

stage, while others have a realistic chance of entering series comparison to aluminium is three kilograms each, so we are side windows, protecting the car interior from heating up. The electric driven vehicles. With maximum energy efficiency, intelligent

production,” says the company. already talking about 12kg of weight savings. The metal-free film is integrated between the panes of the safety temperature management and consistent lightweight construction

Much of the innovation is the result of a second is the all-plastic lightweight seat developed glass, and ensures that the infrared rays are effectively reflected. it is possible to increase the range by up to 20%.

partnership between Daimler and BASF, with combining various BASF materials that not only Thanks to its high transparency in the visible range, it can also be AI: Which of the technologies that were on show at the

the focus on energy efficiency, lightweight save weight - and thus energy - but also applied to tinted windows and guarantees an unprecedented level IAA are ready for a series production, and when can we

design and temperature management. provide more comfort. The load-bearing of reflection of sunlight and heat. Unlike metalized films, which expect them in the marketplace?

part is made of the polyamide Ultramid, a are already used in some vehicles, the new film reflects only the Fischer: It varies from product to product and from application

one-piece self-supporting seat shell that infrared rays of the sun. Radio waves for GPS, Bluetooth, mobile to application. Very promising is the all-plastic wheel rim. Regarding

leads to a significant reduction in weight. phones or toll collection pass through the glass unhindered. the seat, we have four products already, namely Ultramid, Steron,

Dr. Christian Fischer,

With the help of e-textile technology, the AI: One factor slowing market adoption of electric Luquafleece and Elastoflex - and we can offer other possibilities.

president Polymer Research

seat heating can be directly integrated in vehicles is the relatively short driving range associated with The light-reflecting coating including so-called “cool pigments”, is

at BASF.

textiles and be near the body. This means current batteries. How will your new generations of cathode more or less close to launch. It is very promising that we can offer

there is heat directly under a breathable materials increase driving distance? quite a number of innovations to the market in the short to mid-

seat cover made of Steron. The seat Fischer: Batteries are the key technology for the term. For the mid to long-term are energy efficient applications

Automotive Industries (AI) asked climate is regulated through the use of electromobility of the future. Over the next five years, BASF such as OLED modules and organic color solar cells.

Dr. Christian Fischer, president Poly- Luquafleece moisture absorbers without the will be investing a three-digit million Euro sum in researching, This was our intention from the very beginning, to offer the right

mer Research at BASF how well the use of electrical energy. Elastoflex soft foams developing and the producing battery materials. Part of the mix between close to series production realistic technologies and

partnership works. in the seats save up to 20% of the weight, and at investment is being channelled into the construction of a products that are really visionary. That’s why Daimler and BASF

Fischer: We’ve worked very closely with Daimler the same time offer ergonomic advantages through production plant for advanced cathode materials in Elyria, Ohio. chose the name “forvision”. It is a visionary concept, but not

for a number of decades. After all, BASF is the largest different hardness zones. These are the main features of This new facility is scheduled to supply the market with cathode science fiction.

chemical supplier to the automotive industry with sales last year the seat. materials for the production of high-performance lithium-ion AI: What are your plans for the future?

alone of close to eight billion Euro. Our key strengths compared to In addition to the tridion passenger cell, components such batteries from mid-2012. In addition, BASF has entered the field Fischer: For us, the automotive industry is - and will remain – a

others are that we both have very broad product and technology as the doors are made of carbon-fibre-reinforced epoxy resin. of electrolyte development. High-quality tailored electrolytes are key sector. The automotive industry is really eager to bring innovations

portfolios. In the joint project with Daimler we have successfully The use of such materials enables a weight saving of more than essential for battery performance. We are also researching future to the market, and plastics have a bright future in the car - not only for

developed a holistic approach for the electric mobility of the future. 50% to be achieved compared with steel or 30% compared with battery concepts such as lithium sulphur and lithium-air. As a weight reduction, but also for acoustic management. AI







20 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 21

innovation







The Norma Urea system. “ During the market implementation of our first generation



of electrical heated plastic urea tube systems - which was



already a big step compared to heated elastomer systems





New generation fluid transport - our engineers gained valuable experience about the



disadvantage of externally heated urea lines.

”

systems for diesel SCR technology Generation2 of the Normaflex Urea

fluid transport system.

By: Nick Palmen



Patented in the United States in 1957, selective catalytic first generation of electrical heated plastic urea tube systems - and can be formed accordingly. Furthermore, the pressure loss is & induction, ancillary systems and industrial fluid connector

reduction of noxious exhaust gases using ammonia as the which was already a big step compared to heated elastomer similar to externally heated systems. applications. For our customers in industries like passenger

reducing agent is now coming into its own. systems - our engineers gained valuable experience about the Due to the fact that the heating element is directly inside vehicle, truck and heavy equipment, engine manufacturing,

Development of SCR technology continued in Japan and the disadvantage of externally heated urea lines. Based on this the media, we were able to reduce the power consumption railway, aviation, ship building and white goods manufacturing,

US in the early 1960s, with research focusing on less expensive knowledge, they started to develop a solution that combines the by about 50% versus standard systems on the market. In we offer individually developed solutions. Clamps, couplers,

and more durable catalyst agents. Urea SCR systems use diesel advantage of plastic tubes with their narrow space geometries addition, the heating time can also be considerably reduced. connectors and fluid transporting pipe systems are set up from

exhaust fluid (DEF) as a reductant. DEF is typically a blend of and low weight with the features of short de-icing times and low Another big advantage is that we can partially avoid heating our modular system of components. The broad knowledge of our

32.5% urea and 67.5% deionized water. It is injected into the electrical power consumption. the Quick Connectors - which reduces power consumption, engineers based in our technology centers in EMEA, Americas, and

diesel exhaust stream ahead of a SCR catalyst. When the urea AI: How does this compare with what is available? weight, complexity and also costs. Further cost reductions Asia creates a basis for design-to-cost solutions. At the same time

makes contact with the hot exhaust gases, ammonia (NH3) is Kraus: Standard electrical heated urea transport lines as were achieved by the fact that we can use our standard pipes we can support our customer’s requirements to meet new legal

released. The ammonia initiates a reaction where NO and they are used in the market today are designed with the and Quick Connectors, and therefore our manufacturing requirements while downsizing their internal combustion engines or

NO2 molecules are broken down (reduced) into electrical heating element on the outside of the technology. This results in a very high manufacturing process implementing alternative drives like hybrids or electrical motors. AI

nitrogen, oxygen, and water. One of the biggest transport tube or hose. This means that the stability from the very beginning, which from a quality point of

challenges has been that DEF freezes at 120 F heat is not where it is needed, as you have to view is important.

(-110 C). The Norma Group, a global market transfer the heating power through the wall AI: What were the biggest challenges?

of the hose or the pipe into the urea fluid. Kraus: As the urea fluid has a very low viscosity and a tendency

As elastomer hoses and plastic tubes to creep out of every possible void, the sealing of the heating rod

are excellent insulators, a lot of power at the interface to the Quick Connector proved challenging. In

gets lost, which leads to longer de- the end, by following the proven sealing design of the SAE J0244

Thomas Kraus, NORMA Group Vice

freezing times, which is a key feature interface, we were able to establish a robust seal between the

President Business Development

of the system that the OEMs need to heating rod and Quick Connector.

Europe, Middle East, Africa.

minimize. We turned this around. Our AI: What are the next steps?

heating element is now directly in the Kraus: The Normaflex Urea GEN2 pipes systems have already

urea fluid. This means that the heating been in winter and summer tests at various global OEMs. Some of

rod is in the inside of the transport pipe. the approval tests are still ongoing, but we are also in the middle

leader in Engineered Joining Technology, is This required the development of a, now of the first series launch, which is going to happen in September

one of the pioneers in the development and patented, Quick Connector to establish the 2011. After that, our PD department will start a new project to

production of automotive urea fluid transport electrical connection from outside to inside the develop UREA GEN3, as we have already talked with some of our

systems. It recently launched the next generation tube system. customers about additional features that are needed to achieve

of electrically heated urea pipes designed to overcome AI: What are the advantages of the new EURO6 and EURO7 solutions. Couplings for the new generation Normaflex

the problem of DEF freezing. generation of Normaflex urea systems to the customers? AI: What other products and systems does your com- urea fluid transport system.

Automotive Industries (AI) asked Thomas Kraus, NORMA Kraus: First, it needs to be mentioned that our modified pany offer?

Group Vice President Business Development Europe, Quick Connectors still fit to the standard SAE spigots. Therefore, Kraus: Besides the standard clamping and connecting

Middle East, Africa to tell us more about the new system. no changes are necessary to the customer interfaces. The free technology of approximately 35,000 articles for all kinds of

Kraus: Creating a new generation of urea transport systems diameter inside the transport pipe is still the same as in the old industries, trades and private fields of application, our Engineered

is the logical consequence of our tag line: “Customer Value versions, without an increase in the outer diameter. This means Joining Technology business unit develops individual as well as

through Innovation”. During the market implementation of our the pipe has the same flexibility as a standard nylon fluid pipe standardized solutions for emission control, cooling, air intake





22 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 23

innovation

Seat: replacement of metal

parts for cushion modules.









The 2020 Rhodia objective for body

in white: replace metal with weight-

“Using TiersTechnyl ranges also

enables

our

manufacturers and

saving plastics components.



car makers to get easy access to



“Game-changing” materials weight reduction through metal

substitution without sacrificing



reduce vehicle weight By: Nick Palmen

performance or safety.

”

Specialty chemical developer and producer Rhodia has resistance, combined with design freedom and short time cycles. the most cost-effective solution. Predictive simulation includes the AI: What other solutions for lightweight vehicles can we

teamed up with global auto component supplier Faurecia Using our Technyl ranges also enables Tiers manufacturers and manufacturing process and charting behavior under various oper- expect from Rhodia in the future?

to develop the next generation of lightweight automotive car makers to get easy access to weight reduction through metal ating conditions. It is the best way to find optimal weight/perfor- Hincker: A huge weight reduction on car structure in 2020

seat structural components using polyamide-based high- substitution without sacrificing performance or safety. mance ratio and therefore the most cost-effective solution. We of- could be possible with thermoplastic composites. Evolite by

performance engineering plastics. AI: Is there a shift in your automotive strategy? fer systems for designers developed by leading R&D researchers; Technyl, our breakthrough PA composite range, provides an

“As the global automotive industry continues to make significant Hincker: We have provided Technyl engineering plastics high-performance toolsets, featuring advanced behavior models optimal balance between lightweight and performance, and is

progress in sustainability, Rhodia is proud to play an important role to the automotive industry for decades. Over time we have supported by DIGIMAT, and end-user assistance. suitable for both continuous glass and carbon fibers applications.

by supplying innovative technologies that address top challenges systematically developed more and more high-performance MMI Confident Design, in which our complete Technyl Positioned as a high performance, cost-competitive and recyclable

such as weight reduction, rolling resistance and air quality,” says materials for under-the-hood parts like air intake manifolds, rocker database is loaded, provides for precise predictions of the glass material, Evolite is designed for a wide range of applications.

Jean-Pierre Clamadieu, Chairman and CEO of Rhodia. covers, and oil pans – in the process reducing weight fiber behavior during the molding process – and from that the These include transport seating, car bumper beams and front-end

“Faurecia is working with game-changing materials with our performance compounds. mechanical performance of the final application. As an example, structures, and body-in-white.

– developed by Rhodia – and structural seating The new standards designed to reduce CO2 using MMI to design a crash resistance application will save on Evolite’s matrix has the lowest viscosity of any polyamide.

concepts to meet the substantial challenges emissions through improved fuel consumption time-consuming and expensive prototyping, while optimizing the This performance is key to offering outstanding impregnation,

which the automotive industry faces in have dramatically accelerated the demand quantity of material required. resulting in higher reinforcement rates – of up to 62%. Parts

producing lighter vehicles. This partnership for lightweight solutions. Our ambition now AI: Would that reduce the time from conception made in Evolite show excellent strength and toughness,

is to enable our customers to respond through to part manufacturing? enhanced crash resistance and very good ageing properties.

to this trend by providing solutions for Hincker: Of course. Our predictive simulation service eliminates In addition, material fluidity increases the competitiveness of

semi structural applications. We’ve numerous steps in part design, so reducing development time and the process dramatically, thanks to faster production rates

François Hincker, President of started this year with seat structure improving cost efficiency. than thermoset technologies.

Rhodia Engineering Plastics. components. AI: Does it help OEMs and their suppliers to reduce AI: Rhodia has teamed up with Faurecia to jointly develop

The ultimate objective: to provide material usage (cost) and weight? next-generation lightweight seat structural components

structural parts, such as body in white, to Hincker: The industry is always looking for ways of improving using polyamide materials. When will we see the results in

is expected to help car makers comply with reach the target of 95g CO2 / km by 2020. cost effectiveness, supporting sustainable development, fast-tracking series production?

ever more stringent emissions regulations Our innovative thermoplastic composite design improvements, and reducing time to market. Polyamide can Hincker: The seat cushion structural components jointly

worldwide” says Patrick Koller, Executive Vice- range Evolite by Technyl – which is still under play a key role in meeting these very ambitious goals. By replacing designed by Faurecia and Rhodia are currently in advanced

President of Faurecia Automotive Seating. development - will be Rhodia’s EP proposal to metal in many under-the-hood and structural parts, plastics parts development, with series production expected in 2014- 2015.

Automotive Industries (AI) asked François achieve this target. Thanks to its high fluidity, complex reduce car weight, and so CO2 emissions. Due to its excellent Beyond this important milestone, both companies will extend their

Hincker, president of Rhodia Engineering Plastics, structures can be formed with low production cycle times. mechanical properties, high temperature and chemical resistance, cooperation to further explore new innovative solutions to help

where Rhodia is represented around the world. AI: What are you doing to combine high-performance polyamide offers very interesting recycling alternatives, and also meet automotive OEMs needs for lightweight solutions. AI

Hincker: We are particularly well positioned in fast-growing materials with advanced simulation services like MMI? greater flexibility and creativity in design. With a proven 50-year

regions. Some 38% of our sales are in Asia, and 18% in Latin Hincker: Our advanced MMI Confident Design simulation track record, the constantly-evolving Technyl has become a market Technyl® is a registered trademark of Rhodia.

America. Under the brand name Technyl, we offer polyamide package offers our customers a very competitive advantage. MMI reference for lightweight materials, thanks to its cost effectiveness/ Evolite™ is a registered trademark of Rhodia.

products and advanced services that answer very demanding Confident Design is a unique service package developed with performance ratio in the compound market; offering ideal injection Confident Design™ is a Rhodia Trademark.

requirements as fluid resilience, mechanical performance, fire e-Xstream Engineering and its DIGIMAT software, and therefore process capabilities for mass production; and its easily recyclability. DIGIMAT™ is an e-Xstream Engineering trademark.



24 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 25

Thermoplastics

innovation

get tougher and

more colorful By: Lenny Case



A newly-developed range of high heat, low color distortion and low emission additives for

thermoplastics has been developed to meet ever-stricter regulations, together with greater

customer expectations.

The range was developed by South Korean firm Songwon 2009, we took backward integration a step further by investing in Automotive Industries (AI) asked Dieter Morath, quality assurance system which is needed due to the variability

Industrial, which produces additives and stabilizers for the PVC an isobutylene plant based on proprietary technology. In order to executive vice president sales, and member of the of secondary polymer streams - we work with integrated and

industry, polyurethane, polyester diol, antioxidant, alkyl phenol, enhance our competiveness and to consolidate our position as Songwon International Group Executive Committee, what external compounding companies to solve issues not covered by

biphenol, flocculants, super-absorbent polymer, agrochemical, tin partner of choice for the polymer industry, we have now decided new applications for thermoplastics in motor vehicles are the larger polymer producers

intermediary, and other products. Songwon has manufacturing to integrate the production of Songnox 1076 into Maeam. This will possible with the development of the new range of additives. AI: What other new products and applications are in the

facilities in Ulsan, South Korea, where it started producing create the best possible manufacturing platform for this product Morath: Over the medium term, the requirements for greater pipe-line?

additives for the PVC industry in the mid 1960’s and antioxidants in line with our strategy to maximize backward integration and durability of PP parts in automotive plastics engineering will Morath: Carbon fiber sheet technologies for

for the polymer industry in the mid 1980’s. economies of scale. We believe that Maeam is now the biggest continue to rise – in under the hood applications in particular. automotive light weight engineering.

Songwon says market demands for improved performance and plant in the world dedicated to key antioxidants based on a fully The new Songwon High Heat OPS Range offers our customers a This is foreseen as a future mega trend in automotive car body

durability in end-use applications have driven the requirements for integrated manufacturing process,” says Jongho Park, chairman complete toolbox for designing tailor-made solutions to meet the engineering and production. It addresses the need for continuous

total service life and average operating temperature to new levels. and CEO of Songwon Industrial. requirements of longer service life and/or durability under harsh reduction of weight and consequently CO2 emissions related to the

Existing systems based on phenolic antioxidants and thioesters Songwon has also been extending its global product range to conditions. Sophisticated automotive plastic parts may well be consumption of petrol. There is a long way to go when comparing

are in danger of not meeting more stringent requirements that are include Hindered Amine Light Stabilizers (HALS), Benzotriazole replaced by PP as the performance standards increase. The range the current process cost based on the operating cycle with today’s

being introduced. There is already a need for materials such as filled UV Light Absorbers, and key niche antioxidants to serve specific of products also addresses the goal of the automotive industry to state-of –the-art steel and aluminum based manufacturing. But we

or unfilled Polypropylene (PP), which are typically injection molded application needs. Globally, the company has increased its reduce the overall level of volatile organic compounds. The new at Songwon believe that the development path forward can only

in thicker wall sections, to offer longer life cycles. Environmental, presence by establishing subsidiaries in other countries. Songwon Songwon High Efficiency OPS Range on the one hand, aims at be shaped together with the polymer additives industry. We work

Health and Safety standards have also become stricter, with a key International has been operational from July 1, 2006 covering base stabilization packages already up-stream allowing lowered on new solutions together with the resins producers to make these

focus on the reduction of emissions. EMEA and Americas. Songwon China, a wholly owned concentration levels in e.g. PP resins through more efficient necessary process & quality innovations happen.

Songwon says it has created a significant win- subsidiary of Songwon Industrial, and based in stabilization packages. On the other hand this new range also

win solution. The additives outperform current Hong Kong, is the investment arm into an offers concepts for formulations targeting lowered emissions of Light –weight materials

industry standards by more than 50%, and are increasing number of Songwon entities in VOC and/or smell/odor during service life. In order to achieve weight reduction, the (wall) thickness of

able to meet these standards with reduced China. Songwon Shanghai Trading is the parts gets below the point where (rigid) foam replaces complete

main operational company. UV Packages solid parts. As thinner parts in general have a lower service

Songwon Baifu Chemical is a joint In addition Songwon offers new stabilization concepts life than thicker parts (oxygen migration) and additionally the

venture with Tangshan Baifu Chemical for achieving superior UV protection, both for exterior and complex foaming processes exclude “traditional” stabilization

Dieter Morath, executive vice

to manufacture and sell thioester interior automotive PP applications. The new Songwon UV packages, new stabilizer solutions must be developed in order

president sales, and member of

antioxidants. It will have a fully backward OPS range has been designed in particular for protection of for this to be implemented.

the Songwon International Group

integrated capacity of 6,000 tons. A surface properties like gloss and surface crazing under severe

Executive Committee.

full analytical laboratory is being built in weathering conditions, when containing fillers, or other additives E-Mobility

Shanghai, and will be operational by the like flame retardants, etc. This is another mega trend we may anticipate for the automotive

additive loadings. This, in turn, generates end of 2011. “We are very pleased with design & engineering process with plastics. For certain car series the

the additional benefits of low color distortion the progress we have made in China in Recycling E-Mobility Century might change the requirements under the hood

- often a problem when higher loadings are such a short time. The commitment we made Songwon offers complete process and stabilization know-how completely because the classical combustion engine will be phased

required. Lower loadings have a direct and to customers in China has been recognized to the entire recycling value chain that systematically collects and out over time – either partly, in combination with an electric motor,

positive effect on emissions. and we are being rewarded by growth and long reworks plastic waste streams. By adding the tailored Songwon or with other alternative engines, or even completely. At the same

Songwon has steadily been increasing its global term business commitments. This is driving the need Recycling OPS additives package at the end of the recycling time the need for light weight engineering will become accelerated

presence and capacity. In 2010, the company announced for extended services, such as the analytical laboratory, chain enables up-grading of waste stream material to a new and only be achieved with plastics. In other words, the demand for

the expansion of its antioxidant capacity from 55,000 tons to and the extension of our product range. Songwon Baifu will be automotive PP compound with remarkable durability similar to plastics engineering in automotive will again become accelerated!

80,000 tons a year. This will be on stream from August 2011. influential in China and will provide world class thioester antioxidant that of prime materials. And this will only be possible by using specialty chemicals called

The expansion is the result of the consolidation of the Songnox products to our other key regions. We are also establishing long term AI: How does Songwon work with OEMs to develop new antioxidants which is Songwon’s speciality.

1076 production into Songwon’s new fully backward integrated relationships with home based suppliers to ensure a secure stream of components? AI: What are your strategies in Asia, the Americas and

Maeam plant. “In 2006 we made a commitment to customers to raw materials, intermediates and finished products that meet our high Morath: We define projects and solutions for next generation Europe with regard to the automotive market?

drive reliability of supply and competitiveness through economies standards and competitive market position. “Our recently announced cars matching future demands together with the recycling industry. Morath: We are a global player, and in our dealings with

of scale and backward integration from a state of the art facility. Songwon and HPL Joint Venture for Polymer Stabilizers will create It is our objective to achieve performance levels that are similar global players we have learned that the fundamental drivers

Maeam was dedicated to producing key antioxidants, with critical production capabilities in India which is another step to expand our to prime materials –with similar quality performance / material are the same everywhere. We monitor trends and issues, and

intermediates fully integrated into the manufacturing process. In product range and expand our global network“ says Park. properties. Futhermore we support the industry by setting up a proactively find solutions. AI



26 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 27

Plastics for

RIGHT: When Philips Electronics

innovation developed a new lamp that can

outlast the life of a car, Mercedes-

Benz engineers were able to

simplify the design of the rear light

unit as there was no longer any need

to access it to change the bulb.









better living

The German auto maker selected

Stanyl, a plastic developed by

DSM Engineering Plastics. STANYL

is able to deal with the extreme

temperature conditions, and is as

By: Lenny Case durable as the lamps.





Plastics are being given a makeover as their use grows in vehicles and aircraft, where they have helped to create the world’s AI: Tell us about the thinking behind the Bright Science. Devits: DSM Engineering Plastics has a wide product portfolio

vehicle design and component structure. Already, plastics fastest, most fuel-efficient light aircraft. Brighter Living™ brand. of polyamide 6, high temperature polyamide 4-6, thermoplastic

account for 50% of the materials used by the automotive Our composite resins’ ability to take punch way above their Gambade: The re-brand has been extremely helpful in polyesters, and copolyester elastomers. Akulon nylon compounds

industry – but just 10% of the weight. weight is why they are increasingly being used for key applications, conveying to the outside world – not to mention our 22,000 global are utilized in a host of interior and exterior applications, including

Suppliers of plastics are now being challenged to develop such as the Renault Clio fender support system. However, we are employees - our transformation from a chemical company to a life air intake manifolds, door handles, airbag canister housings,

sustainable and recyclable materials that meet ever greater going further than just strength, performance and light weight. We sciences and materials sciences one. Our strategy is based on pedals and brackets, etc. Arnite is a dimensionally stable polyester

performance standards. In response to this trend, Life sciences also lead the industry in terms of developing materials that use using our expertise to find solutions to three global trends: shifts product line for critical applications such as brake booster valve

and material sciences company Royal DSM earlier this year bio-based, rather than fossil-based ingredients. Palapreg ECO P in wealth and population; climate change and energy usage; and bodies. Stanyl polyamide 6 is utilized in demanding under-the-

launched a new brand – Bright Science. Brighter Living to inculcate 55-01 contains 55% bi-renewable content - the highest bio-based health and wellness. hood components such as timing system guide faces and

a new culture within the company, its clients and suppliers. The content on the market today. We have been able to achieve this AI then asked Koen Devits, president of DSM Engineering tensioner arms, front end accessory drive bushings and pulleys,

rebranding “signaled the first step in the transformation of DSM without making any sacrifice in terms of processing standards or Plastics Americas how important plastics are to the electronic throttle control and VIS gears, auto connectors and

from a chemical company into a life sciences and materials product performance. automotive sector. control modules, and transmission bearing cages.

sciences company, says Feike Sijbesma, CEO and AI: How does DSM work with its OEM customers Devits: The automotive industry is working very hard to improve Being a life science company, as well as a materials company,

chairman of the DSM managing board. to develop customized products? fuel economy by looking for ways to reduce mass. They are also we have developed bio-based solutions to meet demanding

DSM Composite Resins develops high quality Gambade: Working with our partners is maximizing space by reducing the size of components. Materials under-the-hood temperature needs with EcoPaXX ,a new PA4-10

UPR resins such as vinyl esters that are used critical if we are to achieve the right blend of that withstand wear and friction will translate into improved fuel product manufactured from castor bean oils. We have extended

for the production of fiber-reinforced plastics innovation to suit their needs. We need to economy and lower carbon footprints. Engine technology is our Stanyl product portfolio with Stanyl ForTii which improves

know exactly what performance criteria they driving improved fuel economy with the implementation of turbo dimensional stability with lower CLTE and significantly reduced

are looking for. Likewise, our business needs systems, which require higher temperature materials. Increased water absorption. With our customers demanding higher

Feike Sijbesma, CEO to be sustainable, so we need to work electronics content also requires high strength and heat temperature performance, for applications like turbo

and chairman of the DSM with our downstream customers to ensure resistant materials that take up less space. With charger applications, our Stanyl Diablo product

managing board. that the market is ready for any innovation an increasing focus on safety, systems require technology increases thermal stability out to

that originates from us. This collaboration high strength ductile materials to absorb 5,000 hrs and retains our high temperature

starts at conception and continues through energy to meet demanding standards. Using product performance.

or non-reinforced filled products in end-use development to product testing and, finally, plastics also makes it easier to manufacture

applications such as building & infrastructure, marketing. We also work with OEMS on longer- complex designs, which helps push

tanks & pipes, cure-in-place pipes, automotive range projects. For example, as the automotive production costs lower. Wilfrid Gambade, DSM business

and wind turbine blades. industry increasingly looks to electric cars, light AI: What DSM a preferred supplier director, composite resins Europe

Automotive Industries (AI) asked Wilfrid weight and air resistance reduction will be vital as they to automotive OEMs? and global markets.

Gambade, DSM business director, composite will directly impact on the performance and lifetime of the Devits: DSM Engineering Plastics

resins Europe and global markets to tell us more about the battery. Materials are key to the success of these future trends, and is a financially strong global supplier.

company’s automotive sector products. we need to be able to demonstrate to our OEM customers that our Research & Technology scientists develop AI: What are your global plans?

Gambade: When we talk to OEMs, the message we are innovation delivers a core component of their own product. new products to meet and exceed the stated Devits: DSM is vertically integrated from

hearing loud and clear is the need to improve the performance AI: How are you expanding globally? requirements of automotive design engineers. caprolactam and PA6 polymer in Europe, the

and reduce the emissions of the vehicles they are producing. This Gambade: Our strategy is based on four growth drivers: high Our strength is in application development. US, and China. DSM compounds engineering

need is becoming increasingly urgent in the context of recent growth economies, innovation, sustainability and partnerships and We have application development engineers and plastics in Europe, US, China, India, and Japan. We

legislation such as – in Europe – the EU’s vehicle CO2 emissions acquisitions. We are currently enjoying robust growth in high-growth business development managers that work directly with have recently announced a compounding joint venture to

targets and the EU End of Life Vehicle Directive. It is our job to economies such as China and India, where we recently entered into our customers to help select and optimize component design. supply in Russia, and we are looking to expand compounding

help OEMs meet these new requirements, and we are focusing a joint venture with Kemrock Industries. In terms of innovation, we They are application and material experts. Our global development operations in Brazil by the end of this year. Our customers are

on innovations that help OEMs make their cars lighter, stronger have already mentioned our commitment to develop smarter, lighter centers use computer aided design capability to further optimize global. We will supply locally. AI

and better performing. For example, our Turane resins strengthen and stronger materials, are dedicated to being the sustainability product design.

parts while being very easy to process and cost-effective - thanks leader in our industry. At the corporate level, DSM is placed number AI: Tell us about your product portfolio, and how you plan Palapreg® is a registered trademark.

to fast processing speeds. They are already being used in racing one in the Dow Jones Sustainability Index. to expand it. Brighter Living™ is a trademarked name.



28 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 29

OEMs, suppliers

innovation









signing up for consumer

electronics shows By: James Hilton









Automotive OEMs are showing more and more interest in The 44th International CES was so successful that a year

technology shows, as mobility becomes as much a factor before the 2012 edition of the show, the 2012 International 75,000

of IT convergence as manufacturing and design excellence. net square feet of exhibit space CES iLounge Pavilion - sponsored

In 2011, Ford chose the International Consumer Electronics by iLounge.com - sold out in less than two hours.

Show (CES) to unveil its first electric car – the Ford Focus Electric. Automotive Industries (AI) asked Shapiro what will be

At the same show, major technology trends emerged including new for the OE, telematics and international automotive

the launch of more than 80 tablets, wireless 4G LTE, connected community at the 2012 International CES.

TV technologies and smart appliances. Shapiro: Major automakers are increasingly participating in

There will be more OEM and automotive presence at the 2012 CES. In addition to the well-known companies, electric vehicles will

International CES, which will be held from January 10 to January be a major trend at the 2012 International CES. They will be featured

13, 2012 in Las Vegas, Nevada. Produced by the Consumer prominently in the GoElectricDrive TechZone on the show floor.

Electronics Association (CEA), CES is the world’s largest Attendees will see innovative electric vehicles and technologies

tradeshow for consumer technology. Keynote from start-ups and major car manufacturers, including

speaker in 2012 will be Steve Ballmer, chief advancements in smartphone integration, smart

executive officer of Microsoft Corporation. grid technology and more.

“We are pleased to welcome Microsoft back Innovative aftermarket products will also

be huge at the 2012 CES, with everything

from Internet radio, safety and vehicle

navigation to audio. Pioneer’s Aha Radio

and AppRadio have done very well in

Gary Shapiro, president and the aftermarket and we can expect to

CEO, the Consumer Electronics see more mobile apps announced at

Association (CEA). the show. Connected aftermarket on-

board diagnostic (OBDII) solutions for

car dealers will be big in 2012. We are

also seeing more devices provided for

to the CES keynote stage. From mobile to driver monitoring, stolen vehicle recovery,

desktop to gaming and beyond, Microsoft family tracking, insurance services and

has a significant impact on all aspects of roadside assistance. Aftermarket mirrors will

the consumer technology industry, and Steve be big in 2012 with enhanced back-up cameras,

Ballmer’s keynote is a great way to kick off the exciting navigation and other driver services. In-vehicle

2012 International CES,” says Gary Shapiro, president and entertainment trends will emerge at the 2012 CES including

CEO of CEA. more Android-based head units and an increase in television

The 2011 International CES saw more than 140,000 choices, including over-the-air digital TV.

technology attendees with 31,677 of them being from outside AI: Tell us about the iLounge pavilion – what will be some

the US. “The 2011 International CES was the must-attend event of the innovations, concepts, themes, new technologies

of 2011 and featured astounding innovative debuts including that will be showcased there?

Android Honeycomb, Ford’s Electric Focus, Motorola’s Atrix and Shapiro: The iLounge Pavilion at the 2012 CES will be the

Microsoft’s Avatar Kinect,” says Shapiro. largest in our history, spanning 75,000 net square feet. Experiencing



30 to read full version of AI stories go to www.ai-online.com

Cisco CEO John Chambers, Xerox Chairman and CEO Ursula Burns, GE Chairman and CEO Jeffrey Immelt join the 2011

International CES keynote line up as participants in the Innovation Power Panel.





50% growth over its 2011 CES footprint, iLounge is now the largest

dedicated exhibition of iPod, iPhone and iPad related products and

services in the world. Cutting edge products and technologies for

the next generation of iPad, iPhone and iPod offerings from more





Sustainable materials

than 250 companies will be on display in the iLounge Pavilion to be

previewed by top retailers, vendors and more than 5,000 press and

analysts. Attendees can expect the launch of new products including

the latest accessories, fashion cases, plug-ins and more.







for automotive.

AI: What are some of the iPhone/smart phone

technologies and applications that are driving the growth

trend in the automotive market?

Shapiro: Internet radio apps will be a huge driver in 2012

and many will be announced at the 2012 International CES,

along with navigation apps that will continue to drive growth in

the marketplace.

AI: What are some of the current trends in automotive

vehicle electronics and multimedia systems?

Shapiro: Streaming audio from the head unit is a major trend From under-the-hood and powertrain

in the in-vehicle market. Products and services such as Slacker,

Highlights from the Mobile Apps Showdown at 2011 CES

Pandora, MOG, Spotify, Livio Radio are driving growth. Audio is

where apps producers had two minutes to demo their app,

applications to exterior panels such as

still a major component to the driving experience and as such,

and an applause-o-meter measured audience enthusiasm

attendees can expect to see a strong showing from speaker

to determine the winners. deck lids, head lamp reflectors, and

manufacturers at the 2012 CES.

AI: What are some of the awards and market announce-

ments that we can expect at the 2012 International CES? of course, CNET will host its ever-popular Best of CES at the

motor encapsulations DSM materials

Shapiro: The 2012 CES Innovations Design and Engineering 2012 show.

Awards will be announced in November, and the honorees will AI: What is the impact and what are the market help build lighter, stronger, safer,

be on display at the upcoming 2012 CES. The Innovations implications for the next generation of electronic products

Awards program honors the top products and services across for vehicle manufacturers and suppliers? and more sustainable vehicles.

32 consumer technology product categories. A new awards Shapiro: To sum it all up, the car will meet the cloud at the 2012

program for the 2012 CES is the International Academy of CES and attendees can expect to see a bigger role for wireless Learn more at www.dsm.com.

Web Television (IAWTV) Awards. The IAWTV Awards program carriers and off-board content and service providers. The market

is the first awards show within the Web television industry is moving faster than it ever has before and the traditional supplier

to be presented by content creators, for content creators. network is beginning to change to keep up with the marketplace.

From studio content producers to YouTube celebrities, those Attendees at the 2012 CES will see greater visibility from software

successfully creating entertainment for digital platforms will be and service companies, as roles are changing within the automotive

celebrated across 33 categories. The UK’s Stuff Magazine will market and systems are changing to accommodate smartphone

again produce the Hot Stuff Awards at CES, featuring the top integration, larger displays, embedded telecommunication

ten must-have products as chosen by their editorial team. And modules, Wi-Fi, Bluetooth and USB connections.



32 to read full version of AI stories go to www.ai-online.com

All in one.

AS5410 – a new dimension

in linear position sensing



Multiple 3D Hall cells

Attendees view exhibits in the Central Hall of the 2011 International CES.

Automotive Industries also spoke to Karen Chupka,

Senior Vice President, Events and Conferences at CEA,

AI: What are some of the benefits for companies exhibiting

at the Eureka Park TechZone – how does the pavilion help

Configurable output

and asked her how she rated the response to the 2012

International CES.

Chupka: The 2012 International CES is shaping up to be our

showcase their technologies?

Chupka: Eureka Park provides a platform for young

companies, small start-ups and entrepreneurs to showcase their

characteristic

best show yet. We are expecting more than 140,000 attendees innovations at the world’s largest business event for consumer





High accuracy

at the 2012 show, which will feature more than 2,700 exhibitors technology. Every major technology milestone started with an

across more than 1.6 million square feet of exhibit space. That’s idea, and we want to provide the next generation of innovators

over 33 football fields of consumer technology innovation! We with an opportunity to launch their technologies to the world at

are also excited to have automakers, such as Ford, Audi and CES. Turnkey exhibit space within Eureka Park is provided at a

Mercedes at the 2012 CES. special rate in order for these young companies to be able to

AI: What do you expect visitor and exhibitor numbers to participate in the world’s largest consumer technology tradeshow.

be at the 2012 event? AI: What are some of the innovations at the 2012

Chupka: We are expecting more than 140,000 industry International CES?

professionals from 140 countries to attend the 2012 CES. The Chupka: More than 20,000 new products will launch at the

2012 show is expecting a record number of new product launches 2012 CES, spanning 15 product categories and more than 1.6

with more than 2,700 exhibitors showcasing their latest products million net square feet of exhibit space. Trends for the 2012 CES

and services. will include connected TVs, the latest in-vehicle and electric vehicle

AI: How much international attendance do you expect at technologies, mobile consumer devices and 3D innovations.

the 2012 CES? AI: The International CES has always been known for

Chupka: Some 30,000 attendees from outside the United their keynote speakers - tell us what the 2012 edition of the

States are expected to attend the 2012 CES. show has on offer in this respect. What will the conference

AI: Tell us a little about the Eureka Park TechZone and program be like and how many speakers are expected at

what visitors and exhibitors can expect from this pavilion. the conference?

Chupka: The inaugural Eureka Park TechZone is a dedicated Chupka: Ballmer’s CES keynotes are always thrilling and

area at the 2012 CES showcasing innovative start-ups and a great way to kick off. Our full schedule of CES keynotes will

entrepreneurs. In partnership with the National Science Foundation, be available in the fall. Our CES conference program will be

more than 30 companies signed up to exhibit in Eureka Park within announced in the coming weeks, but we expect 500 industry

a few weeks of the launch. Eureka Park, located at The Venetian, leaders to speak at this year’s CES with 200 conference sessions

is designed to benefit budding entrepreneurs, start-ups and small slated for the 2012 show. AI

companies looking to gain footing in the consumer technology

market. This area will be a hot spot for venture capitalists, CES® is a registered trademark.

investors, media and industry professionals looking for the next All 2012 International CES awards can be found online at

big thing in technology. http://www.cesweb.org/awards.



34 to read full version of AI stories go to www.ai-online.com www.austriamicrosystems.com/5410

innovation





3-D sensors

open up new dimensions

in design By: Steve Barclay This image shows where the ICs from austriamicrosystems AG can be used.





Advances in integrated sensor technology are freeing up we can do whatever is required by the application with the same AI: What has the reaction been to the AS54xx from your magnet. Moreover, the 3D Hall solution’s output remains stable even

system and vehicle designers from the constraints of hav- sensor array, just by changing the post-processing,” said Bernd automotive customers? when the device is subject to external stray magnetic fields. This

ing to work in only one or two dimensions. Gessner, General Manager Automotive, austriamicrosystems, in Gessner: The idea for such a product was more or less feature is a worldwide first, and is the result of a special differential

One of the leaders in the field is Austrian firm austriamicrosystems, an earlier interview with AI. logical, because there was a clear need for it from our target and measurement architecture that includes several 3D Hall sensor

which has just released a number of new high-performance analog Programming of the AS54xx’s internal EEPROM enables lead customers. For example, long distance linear measurement elements. With four preset basic operating modes which are

integrated circuits (ICs) for the automotive market. The company the conversion of a wide range of geometries, including curved - up to 40 mm - is possible with our 3D Hall encoders, and opens selectable via an SPI port, the AS5410 3D Hall encoder offers quick

makes ICs for the automotive, consumer, communications, movements, non-linear scales, and tilted chip/magnet geometries, up a completely new area of solutions. Several sensors can now and easy configuration. All signal conditioning is on chip, including

industrial and medical industries. It recently launched its first 3D into a linear output signal. In order to achieve a perfectly linearized be replaced by one single part. Some of the benefits include compensation for temperature effects.

Hall magnetic encoder family, called the AS54xx series. output of up to 0.5 % accuracy, the AS54xx position sensor less board space, easier printed circuit board design, simplified The AS5410’s unique differential architecture makes it perfect

According to austriamicrosystems, the AS54xx enables the first provides an internal linearization table with 33 base points. All communications and high reliability. for use in position sensing applications that include not only

true 3-axis differential measurement of a magnetic field to cover high reliability and high temperature EEPROM blocks are fully Another usage example would be a dashboard application. dust, dirt and moisture but also unwanted magnetic fields. The

absolute linear and off-/on-axis and three-dimensional tilt sensor automotive qualified and are designed for harsh environments, To combine rotation, tilt and push button functionality normally unique AS54xx family of 3D Hall magnetic encoder ICs is a

applications. The new three-dimensional Hall element is able to making them ideal for designs in automotive, medical and requires different kinds of sensors. With the 3D Hall device, fundamental addition to austriamicrosystems’ current magnetic

provide absolute and highest resolution angular or linear industrial applications. Many products, such as power one sensor is enough. So our customers start to realize what

output data. This new flexibility enables solutions metering systems, motor control units, engine they can do with our new devices. Despite the fact that they

for formerly unsolved sensing problems in management systems and many more, will can save board space and costs, it is also possible to start the

benefit from ultra high reliability over a wide implementation of new applications.

temperature range up to 170°C by using AI: What are main applications your 3D Encoder was

a proven PMOS-based NVM technology, designed for?



“ To combine rotation, tilt and

push button functionality

requires different kinds of sen-

says the company.

Automotive Industries

asked Gessner what makes the

3D Hall encoder unique?

(AI)

Gessner: Our first target applications are any kind of long

distance linear measurements like you can find, for example, in

clutch applications, pedal applications or gear boxes. Second, we

have a strong focus on on/off axis position sensors, like steering

sors. With the 3D Hall device, Gessner: Our new 3D Hall angle sensors or any kind of application where the access to the





”

encoders open a new chapter, a end of a shaft is limited. Last, but not least, we are focusing on

one sensor is enough. new dimension in position sensing multi-axis-tilt applications like joystick, navigation knobs and similar

systems. In the past, we have been applications, where the measurement of all three axes is required.

Bernd Gessner, General Manager limited to measuring just one axis of Since the devices are very flexible, we expect more applications to

Automotive, austriamicrosystems. the magnetic field. Now, with a new core be developed over the next couple of years.

approach, which was developed together AI: Can you tell us about the AS5410, the 3D Hall encoder

with the Fraunhofer Institute in Germany, we you introduced this June?

industrial and automotive applications. The AS54xx have maximum flexibility because we are able Gessner: The AS5410 linear position sensor is the first

series was developed in cooperation with Fraunhofer to measure all three axes of the magnetic field at formally introduced product from the world’s first fully-featured 3D

Institute for Integrated Circuits IIS in Germany - license the same time. For system designers, this eliminates many Hall platform. The unique 3D Hall sensor solution senses absolute The AMS 3D Hall operates in three dimensions.

holder of the HallinOne technology. limitations. Because this new encoder covers absolute linear, on/ position in automotive and industrial applications, and provides the

“3D Hall encoders use a different technology. Instead of off-axis as well as multi-axis tilt measurements, it can be used highest resolution position information available. The AS5410 allows

measuring only one direction of the magnetic field, we are now for different sensing applications. From a logistical perspective, absolute position sensing of a simple two-pole magnet immediately sensor product portfolio with a focus on both the automotive and

measuring all three axes. So, with the right algorithm, we can this offers a huge benefit for sourcing. What we maintain from after starting up the device, without the need for a prior reference industrial markets. Beyond the AS5410, a portfolio of 3D Hall

use the three dimensions to do linear measurement, off-axis our existing portfolio of technology is our differential measurement run within the application. Position sensing is possible even with encoder products is being developed to operate up to 150°C

measurement (where the magnet does not have to be on top technique to ensure high robustness as well as performance over very small magnets: for example, a travel distance of 40 mm does and from a supply up to 18 V to address the needs of the most

of the IC) and joystick applications. With the three dimensions, high temperatures. not pose a problem for a small, 4 x 4 x 3 mm NeFeB (neodymium) demanding applications. AI



36 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 37

innovation









Connectivity is

greening transport

By: Alan Tran





Transportation is at a crossroads, where the pace and challenges of modern life are creating an ur-

gent need for change. Almost 70% of the world’s population resides in urban areas, and increasing

traffic has produced congestion problems, safety concerns, noise pollution and an unprecedented

increase in CO2 emissions. Cinterion’s new AH3 Module.





The good news is that innovation and advancements in The vehicle is equipped with the latest M2M telematics Just as you are finishing your last bite of pasta, you receive Gemalto and Cinterion are meeting associated security challenges

automotive, energy and wireless technologies are converging to system, which is always-on and continually gathering and another text that says your car is fully charged and ready for travel. head-on with the industry’s first Machine Identity Module, or

provide solutions to relieve traffic congestion, improve road safety delivering information vital to safe and efficient travel. In this case, Unfortunately, several miles down the road, your vehicle runs over MIM technology. MIMs serve the same basic functions as SIM

and reduce environmental impact. Field-proven telematics solutions your car automatically received data updates from embedded a sharp object, punctures a tire and spins off the road inflating the cards. They define subscriber identity and information, they are

are being applied in new and inventive ways to reduce the impact. road sensors that indicate weather and road conditions and vehicle’s airbag. Your vehicle automatically sends a message to personalized and updated over the air, they ensure security via user

suggested alternative routes based on an embedded the nearest Public Safety Answering Point (PSAP), communicating authentication with mobile network operators and they provide a

Green, Clean, Intelligent Transportation GPS navigation solution. vital information such as time of accident, location of vehicle, secure environment for software applications. However, MIMs

Intelligent M2M communication technology, As you approach your final destination, a list vehicle description, Vehicle Identification Number (VIN), registered are ruggedized and offer M2M optimized features to ensure an

in all its forms, has the power to change the of potential charging stations is displayed owner, etc. Emergency roadside assistance is dispatched within extended lifetime even under the severe environmental conditions

future of transportation. With the rise of on the screen along with service station minutes to get you on the road as soon as possible… of extreme temperature, excessive vibration and high humidity

hybrid and Electric Vehicles (EVs) such descriptions, estimated wait times, often associated with automotive M2M applications.

as Toyota’s Prius, Nissan’s Leaf and directions and a list of local restaurants The Future Is NOW









“

and other attractions for each Sound futuristic? Not so, says Holger Lenz, Director of Business

location. You select a renewable- Development at Cinterion. “All this technology exists today and is M2M is a crucial enabling

Holger Lenz, director powered recharging station with being integrated in many places around the world. The three main

of business development fast charging capabilities and a challenges to wide scale adoption and a seamlessly-connected

at Cinterion. nearby Italian restaurant. You pull intelligent transportation system are interoperability, security and technology in the building of the

into the charging stall, plug in your infrastructure development.”



EV charging infrastructure.

”

vehicle, receive a text with walking Government agencies and global industry coalitions such

Mitsubishi’s MiEV, the opportunities for instructions to the restaurant and as ERTICO, Europe’s Intelligent Transportation System (ITS)

positive transformation are remarkable. head off for a meal. M2M technology organization, ITS Russia and others are working together to define

But how does it all work? invisibly and securely manages all industry standards for open-ended technology platforms that can Gemalto’s new MIMs are available as a removable plug-in

…Imagine driving in your new electric charging station tasks including vehicle connect our world in unprecedented ways. The European eCall component or a fixed solderable chip embedded in telematics

powered car along a curvy stretch of road and user authentication, start and stop initiative and Russia’s ERA-GLONASS projects are good examples solutions during manufacturing. Since soldered MIMs can’t be

on a cold night when the dashboard screen commands, transmission of usage data, of successful programs that are promoting transportation safety removed and replaced, new provisioning services, or ‘Last Stage

and voice activated prompt simultaneously deliver payment procedures and more. No need to dig and efficiency by enabling vital cellular communication across Personalization’ (LSP), are now available to simplify the integration

a warning message: “Icy road conditions ahead next 2 through a purse or pocket for the credit card and no international boarders and different wireless networks. and manufacturing process for OEMs. LSP occurs when mobile

miles, reduce speed and proceed with caution or choose one of need for interaction with a display screen - all of the charging As the “Internet of Things” proliferates and society moves network operator (MNO) subscription information is securely

the following alternative routes.” station tasks are achieved automatically with M2M. toward interconnected transportation and smart grid systems, transferred to the MIM during the last stage of the manufacturing





38 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 39

process. LSP gives customers full flexibility in choosing a carrier road signs give drivers real-time updates on road conditions AI: What are some of the innovations made to

because the device is not MNO-specific until LSP occurs, even so routes can be altered to shorten time on the road. The US Gemalto’s MIMs?

when the MIM is already integrated in a closed device. Environmental Protection Agency (EPA) estimates that the use of Lenz: OEMs and device vendors are now able to select

The development of a widely-distributed intelligent transportation M2M technology and complementary ITS solutions that help guide the feature set best suited to individual solutions, value chains,

infrastructure has picked up tremendous momentum in the last driving behavior can save up to 20% in fuel consumption overall. industries and customer requirements. MIMs are standalone

two years as technological innovation, network ubiquity and The National Highway Traffic Safety Administration (NHTSA) innovative products – the first identification security modules

MNO motivation have converged to offer an undeniably strong estimates that each American driver travels about 12,000 miles that were specifically designed and ruggedized to meet the

business case for implementing M2M. Cinterion is working with a year, combining to spread approximately 5.48 metric tons of special requirements of M2M solutions. Due to the wide variety

customers around the world on solutions such as RWE’s award- CO2 pollution into the atmosphere. A 20% reduction in fuel of telematics systems with varying vertical market requirements

winning Smart-Station, an EV charging infrastructure that provides consumption means 2.4 pounds less CO2 in our atmosphere per and value chain specifics, a “one MIM fits all” offering is not

convenient charging at six times the speed of traditional electric person, which is significant. possible. Instead, individual MIM features and advantages

outlets and three times faster than competing charging stations. AI: How do your products help the global automotive OEM are packaged for different categories of use to increase

RWE’s Smart-Stations are powered by Cinterion’s award-winning and transportation industries meet current challenges? customization and flexibility.

M2M modules and are already deployed in public spaces, parking Lenz: Cinterion has an entire portfolio of automotive-grade MIMs are available in two form-factor families – as plug-

lots, homes and businesses in 14 European countries. products specifically designed to meet the special requirements ins or as solderable quad flat components. Both families are

Cinterion – a Gemalto company since 2010 - is the global of the industry, and they are all manufactured according to standardized and compliant to the ETSI 2FF or the ETSI MFF Cinterion’s new AH3 Module.

leader in Machine-to-Machine (M2M) modules - the embedded TS16949 and VDA2 quality standards. Our sixth generation of specifications. M2M Plug MIMs have the same dimensions as

component that allows vehicles, traffic signs, curbside electric dedicated automotive modules, including AC75i / AC65i and traditional mobile phone SIMs, but offer additional M2M-specific M2M optimized MIMs operate in a similar way, but offer new

charging stations and more to communicate with one another over AGS3, offer advanced telematic features and are prepared to features. The M2M Plug version is based on a highly durable provisioning services known as Last Stage Personalization,

cellular networks. Cinterion (formerly Siemens Wireless Modules) meet the requirements of the European eCall initiative. AGS3 M2M security controller chip, which is resistant to extreme or LSP, that allow personalization to occur when the

works with partners around the world to develop next-generation was the first automotive module with Land Grid Array (LGA) conditions of temperature, high humidity and shock. The M2M device is shipped. LSP can be integrated in an assembly

M2M solutions. technology for flexible soldering and process manufacturing chip offers a long lifespan with an extended number of write line manufacturing process, or existing inventory can be

Automotive Industries (AI) asked Holger Lenz, director precision. All Cinterion modules are fully type approved including cycles and improved endurance of non-volatile memory. In personalized for a specific customer or project just before

of business development at Cinterion, how the company’s global mobile network operator pre-approvals. They are the ideal addition to the M2M chip, a dedicated Java operating system shipping in a three-way collaborative approach between

vision of M2M-enabled technologies help reduce the impact building blocks for applications such as electronic road tolling, handles and controls all the MIM tasks and provides software telematics OEMs, MNOs and Gemalto-Cinterion. And LSP is

of traffic on the environment. telematics and fleet management as well as emergency call, features to extend the life of the MIM and the longtime availability just the beginning of a whole new category of complementary

Lenz: M2M is a crucial enabling technology in the deployment breakdown or roadside assistance. Cinterion’s 7th generation of of stored data such as authentication keys. provisioning services to optimize and simplify specialty wireless

of the electric vehicle charging infrastructure. In addition, M2M automotive-grade products is currently under development and The M2M Quad MIM has the same ruggedized M2M chip device design and development.

technology is the foundation of smart meters, a crucial component will bring HSPA+ broadband communication to the connected and the extended temperature ranges of the plug version. The AI: What are some of the new technologies your company

of smart grid solutions that can seamlessly integrate sustainable cars of the next generation. difference in Full M2M Quad is the standardized ETSI MFF2 form- will be launching soon?

energy sources like solar, wind and hydropower into the traditional AI: What are some of the challenges automotive factor with a much smaller size of only 5x6 mm compared to the Lenz: Cinterion has recently launched its 7th generation of

electricity grid. EVs and associated technology are the most obvious telematics systems face? 15x25 mm footprint of a plug-in card. With the solderable MIM, dedicated automotive modules – the AH-series. The new modules

ways M2M is greening up the auto industry, but if you look at many Lenz: Telematics systems for automotives are designed and the telematics device printed circuit board - PCB - can be smaller are Cinterion’s first automotive-grade HSPA+ product for OEM

different types of M2M solutions at work in the transportation manufactured to meet rigorous quality standards and ensure and the plug-in SIM cardholder can be eliminated, which reduces customers and Tier-1 suppliers. The AH-series will offer broadband

industry, most of them also have a positive environmental impact. product longevity even under harsh environmental conditions and hardware costs. In addition, automated assembly by machines is connectivity with speeds up to 14.4 MBit/s for downlinks and up

For example: M2M-powered fleet management solutions help fleet on rough roads. Unfortunately, these devices are equipped with possible, eliminating inadvertent damage during device handling. to 5.76 Mbit/s for uplinks. Designed with a common board-to-

managers optimize routes. They cue drivers in real time to maintain the same SIM cards specified for mobile phones and consumer Telematics devices no longer need to be opened by field people board connector scheme for forward compatibility, automotive

consistent and safe speeds and cut out idle time. The same is connected devices, which often don’t meet the specific needs to plug-in the SIM card, and instead, are sealed at factory and customers currently using AC65i or AC75i modules can easily

true for onboard telematics solutions and GPS systems that help of telematics systems. Gemalto is meeting this challenge with shipped as a complete unit. And since the solderable MIM stays migrate to the AH-series by reusing most parts of their existing

drivers optimize routes and speed. Solutions like M2M-enabled dedicated MIMs cards. with the same telematics device through its lifespan, the need for hardware designs. The AH-series meets specific automotive

PIN codes is eliminated, increasing ease of use for both OEMs temperature requirements with its thermal optimized design

and system integrators alike. and large heat dissipation area on the backside of the module.

AI: What makes MIM technology particularly suitable for Additional features such as integrated A-GPS, eCall inband







“

automotive use?

Cinterion will soon launch its 7th generation of dedicated modem, advanced antenna diagnostics and SIM Access Profile

Lenz: M2M-optimized embedded MIMs and complementary (SAP) are included to meet all requirements of current and future

provisioning services offer OEMs increased durability to expand the automotive applications. To support worldwide implementations

automotive modules – the AH-series. The new modules are lifespan of telematics systems. They also enable new opportunities and global roaming, the AH-series supports five 3G frequency

for device manufacturers to offer related services. Traditional SIM bands as well as quad-band 2G coverage for EDGE and GPRS

Cinterion’s first automotive-grade HSPA+ product for OEM cards are personalized by the card manufacturers on behalf of a connectivity fallback. AI







”

mobile network operator. Specific SIM information - the MSISDN

customers and Tier-1 suppliers. and IMSI numbers for instance - are mapped by the MNO to For more information, please visit www.cinterion.com, www.

individual customers and used for identification and monthly billing. facebook.com/cinterion, or follow @cinterion on twitter.



40 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 41

Croda Lubricants

Investing for a

innovation



Leading the way naturally



cleaner world By: Jon Knox



Perfad™ 3000 Series

Billions of dollars are being invested into reducing the reliance of the United States on

fossil fuels, with spin-offs for the motor industry around the world as batteries become Polymeric Friction Modifiers for Engine Oils

more efficient and lose weight, as do the cars they are powering.

l Proprietary high performance additives providing outstanding friction

In a ground-breaking partnership with the private sector, the technical targets and roadmaps, and evaluate R&D progress.

Vehicle Technologies Program of the Office of Energy Efficiency The 21st Century Truck Partnership aims to cut pollution from

reduction in oil-based systems

and Renewable Energy in the United States Department of Energy trucks and buses while they safely and cost-effectively move l Increased oxidative stability compared to traditional small molecule

(DOE) has invested US$2.4-billion in new battery and electric- larger volumes of freight and greater numbers of passengers.

friction modifiers

drive component manufacturing and vehicle deployment projects. Again, the critical goal is to dramatically reduce dependence

These include battery and power electronics manufacturing on imported oil. l Highly effective zero SAP lubricity agents

facilities, PHEV, and electric vehicle (EV) demo projects, as well Automotive Industries (AI) asked Patrick Davis,

as education projects. program manager of the Vehicle Technologies l Increased fuel economy in challenging GF-5 engine oil tests

As the largest single investor in these technol- Program office at the US Department l Protect surfaces and reduce wear by building thick lubricant films under

ogies, the program is designed to jumpstart of Energy what makes the Vehicle

U.S. manufacturing capacity. The program’s Technologies Program so critical boundary conditions

fiscal year 2011 budget is approximately today?

$300 million, which supports research Davis: Our dependence on

imported petroleum is one of our Reference Oil + 0.5% Friction Modifier (100°C)

greatest economic and national

Patrick Davis, Program Manager, security risks, and a primary driver for 0.10 Reference Oil

Vehicle Technologies, Energy the Vehicle Technologies Program.

0.09 + 0.5% Perfad 3000

Efficiency and Renewable Energy, Our nation imports more than 50%

U.S. Department of Energy. of the petroleum we use, and we 0.08 + 0.5% Perfad 3050









Coefficient of Friction

export capital of about $400 billion 0.07 GMO (Conventional FM)

per year (about $1 billion per day) to

for hybrid drivetrains, advanced bat- pay for this imported petroleum. This 0.06

teries, lightweight materials, advanced is not sustainable in the long-term. 0.05

combustion and fuels, vehicle systems Moreover, transportation accounts for 0.04

integration, and deployment activities. approximately two-thirds of our petroleum

The program supports the mission of the use, and on-road vehicles are responsible 0.03

DOE to strengthen America’s energy security for about 80% of our transportation energy 0.02

through public-private partnerships. America imports needs. The Vehicle Technologies Program supports

0.01

more than half of the oil it consumes – 69% of which is used a broad range of advanced technologies that can significantly

for transportation. While the program supports a portfolio of improve vehicle efficiency and reduce petroleum consumption, 0

advanced vehicle technologies, including advanced combustion, such as advanced combustion, materials technologies, and 0.01 0.1 1

materials, and fuels technologies, its’ focus on electric-drive fuel and lubricant technologies. These solutions are critical to

Log Speed m/s

technology aims to reduce costs through three complementary reducing our dependence on imported petroleum in the near

component and system-level technology routes: term. Addressing this challenge over the longer term, however,

The program works through two major government-industry requires fuel substitution, such as through vehicle electrification.

endeavors – U.S. DRIVE (Driving Research and Innovation The Vehicle Technologies Program supports a robust effort to

for Vehicle efficiency and Energy sustainability); and the 21st accelerate the development of advanced batteries and other

Century Truck Partnership. U.S. DRIVE facilitates frequent and electric-drive components and systems, with a focus on reducing

detailed technical information exchange among government cost and improving performance to facilitate the widespread use

and industry experts, who discuss critical R&D needs, develop of electric-drive vehicles.



www.crodalubricants.com

42 to read full version of AI stories go to www.ai-online.com

The energy to drive change.









“ The Vehicle Technologies Program supports

a broad range of advanced technologies that

can significantly improve vehicle efficiency and

reduce petroleum consumption

AI: How would you rate the work of the program so far?

”

identify possible solutions, and evaluate progress toward jointly-

Davis: The Vehicle Technologies Program has an excellent developed technical goals. It also prevents duplication of efforts

record of success. A few examples: between government and industry and ensures that publicly-

• The batteries in all leading hybrids today contains DOE battery funded research delivers high-value results and overcomes high-

technology risk barriers to technology commercialization.

• The Vehicle Technologies Program has reduced cost of PHEV/ AI: What is most important – speeding up the popularity

EV Lithium Ion battery to $650/kWh (a 35% reduction from the of EVs and HEVs, improved battery storage solutions or the

2009 baseline of $1,000/kWh) search for alternative fuels?

• The Vehicle Technologies Program and Argonne National Davis: The Vehicle Technologies Program maintains a balanced

Laboratory (ANL) developed breakthrough battery technology portfolio that includes advanced combustion, lightweight materials,

licensed to multiple automotive manufacturers/suppliers – this and fuels technologies, as well as batteries, power electronics,

cathode technology results in much smaller and lighter battery and electric motors needed for electric-drive vehicles. All of these

cells and potentially lower-cost batteries advanced technologies contribute to petroleum reduction by

• Program-sponsored R&D enabled engine manufacturers either improving vehicle efficiency or by fuel substitution. These

to improve diesel engine efficiency by 5% since 2002 (has technologies are not mutually exclusive, either. For example,

saved 2.4 billion gallons of diesel fuel worth more than vehicle lightweighting can increase the efficiency of the full

$7.6 billion – more than 60 times the Vehicle Technology range of vehicles and powertrains, and using advanced internal

Program’s $123 million investment in commercial engine combustion engines in hybrid electric vehicles and plug-in hybrid

R&D from 1999 to 2007) electric vehicles will enable even greater fuel savings benefits.

• Program-supported light-duty engine R&D at Argonne AI: How does your program work in allocating resources

National Laboratory, University of Wisconsin, and Sandia or setting priorities?

National Laboratory demonstrated engine technology that can Davis: We work to maintain a steady balance across the portfolio For more than 20 years, Delphi has had a proven track record innovating

potentially improve the fuel economy of engines by over 75% of technologies the program supports, while also considering the alternative energy technology. Now, we’re continuing tradition with our Power

AI: How does this public-private enterprise model works? importance of both near-term and longer-term technologies and

Davis: The Vehicle Technologies Program seeks stakeholder their relative potential for reducing dependence on petroleum. With Electronics product line. With high-value hybrid electric vehicle technology

and public input in many different ways. Among them are our regard to vehicle classes, the program’s support of light-duty vehicle

like HEV controllers, DC/DC converters, inverters, battery management

public-private partnerships for research and development, technologies generally reflects their significant contribution to highway

which provide an important framework for frequent and detailed transportation energy use, compared to other vehicle classes: light- systems and energy storage systems, we can drive costs down for you,

interaction with industry to discuss R&D needs, obtain industry duty vehicles account for 76% and heavy trucks account for 19% of

input on research targets and roadmaps, and evaluate progress U.S. highway transportation energy use (buses and medium trucks your customers and the environment. From components to integrated systems,

toward those targets. Each partner organization is engaged at account for the remaining 5%). It is important to note, however,

let us customize the reliable solution that works for you. delphi.com/hybrid

multiple levels, so there is steadfast commitment from leadership, that much of the Vehicle Technologies Program budget supports

management, and technical staff. We operate by consensus, the development of technologies applicable to both light-duty

allowing all partners to have a voice in decision-making if they so vehicles and heavy-duty vehicles, such as advanced combustion,

choose. Although partners participate regularly in detailed technical hybridization, and lightweight materials. In addition, historically the

discussions, each organization makes its own independent balance between R&D and deployment has strongly favored R&D.

decisions regarding project management and funding. Our Roughly 10% of the program’s annual budget supports vehicle

partnership framework helps to accelerate technical progress, as deployment efforts, focusing primarily on facilitating local partnerships

it allows peers in the technical community to regularly discuss that can significantly leverage Federal funding to both accelerate

pre-competitive, technology-specific R&D needs and challenges, market penetration of commercially-available advanced vehicle HEV Controllers DC/DC Converters Inverters Battery Management Systems On-board Chargers





44 to read full version of AI stories go to www.ai-online.com

IARC

2012

technologies and raise awareness of other petroleum reduction to discuss R&D needs, develop goals and technology roadmaps,

strategies among the driving public. and evaluate progress toward technical targets.

AI: How environmentally viable do you think EVs are when AI: What are some of the critical milestones of the U.S.

considering the power generation options available today? DRIVE endeavor?

Davis: Although battery electric vehicles (BEVs) produce Davis: The Partnership sets research targets for key metrics 12 t h International Automobi le

zero tailpipe emissions, from a well-to-wheel perspective their in each of its focus areas, and each of the Partnership’s technical Recycl ing Cong ress IARC 2 012

environmental attributes depend on the source of electricity used teams has a roadmap with a comprehensive set of detailed

to charge the vehicle. While a focus of the Vehicle Technologies technical targets. As part of the transition from FreedomCAR and

March 21 – 23, 2012, Budapest, Hungary

Program is to accelerate the development of electric drive Fuel to U.S. DRIVE, we are updating those key partnership targets RAW

The next top quality congress in ELV recycling will focus on: HE

vehicles, parallel efforts are underway in other areas within the and each of the teams is updating its technology roadmap and









T

n How do car manufacturers and the industry close the recycling loop?

Department of Energy to address emissions of power generation the technical targets therein. Examples of current targets include LS

New cars and new recycling technologies ERIA

n

technologies. These efforts focus on renewable electricity reducing the cost of advanced lithium-ion batteries to $300/kWh n Where are the new cars sold? – Where are they going to be recycled? MAT

generation, as well as technologies for clean electricity generation by 2014, reducing the cost of advanced electric-drive systems n Best available recycling technologies

from conventional resources. (advanced power electronics and electric motors) to $12/kW by T









E

n Reports about illegal export of wrecked vehicles DEBA

AI: Tell us a little about the FreedomCAR and Fuel 2015, and reducing the cost of automotive fuel cell systems to n Hybrid vehicle dismantling and parts reuse

Partnership initiatives. $30/kW by 2017. n European ELV Directive – A monster with no teeth?

Davis: The Department of Energy has a long history of AI: What are the critical breakthroughs of the 21st n Recycling – High-tech or low-cost technology?

partnering with industry to advance the development of light-duty Century Truck Partnership? An exhibition area is integrated into the conference facility, where vendors meet their clients.

vehicle technologies. Beginning with the partnership for a New Davis: The partnership accomplishments include the design Cocktail receptions and a networking dinner create an excellent atmosphere to get in touch with

Generation of Vehicles (PNGV) in the 1990s, this relationship has of a diesel electric hybrid drive train that has seen production in your business partners, friends and competitors.

evolved over time in terms of membership, scope, and technical thousands of transit buses, increasing heavy duty diesel engine Plant tours to leading recycling companies and car manufacturers in the vicinity of Budapest are

emphasis. FreedomCAR, and later the FreedomCAR and Fuel efficiencies - while meeting stringent federal emissions regulations offered to all participants.

partnership, was part of that evolution. In May 2011, on behalf of - and teaming with NASA and the national labs to explore new

the partnership, DOE announced the transition from FreedomCAR approaches to commercial vehicle aerodynamics. These elements

ICM AG, Schwaderhof 7, 5708 Birrwil, Switzerland, www.icm.ch, info@icm.ch, +41 62 785 10 00

and Fuel to the next-generation partnership, called U.S. DRIVE and more have recently been brought together in four industry

(Driving Research and Innovation for Vehicle efficiency and Energy teams under the DOE SuperTruck Initiative to develop and

sustainability). demonstrate Class 8 tractor trailer systems with a 50% higher

Like the FreedomCAR and Fuel Partnership, U.S. DRIVE is a non- freight hauling efficiency.

binding and voluntary government-industry partnership focused AI: What will be the focus of your program in the next

on pre-competitive research of advanced automotive and related five years?

energy infrastructure technologies, and partners include DOE and Davis: We will continue our support of a broad portfolio of

automotive, energy, and electric utility companies. At the heart of advanced vehicle technologies, with an emphasis on research

the partnership are twelve technical teams that bring together the to overcome key cost and performance barriers to technology

foremost technical experts from U.S. DRIVE partner organizations commercialization and market penetration. AI





Partnerships in action

DOE has a long history of working with industry, academia, and demonstrations of homogeneous charge

national laboratories to research, develop, and demonstrate compression ignition. This demonstrated up to a

advanced vehicle technologies. Examples include: 15% fuel economy improvement over comparable spark

ignition engines

• A new cathode material was developed and transferred to • Since 1987, DOE has sponsored more than two dozen

industry in 2011 by Argonne National Laboratory with multiple university-level competitions, providing engineering students

industry licenses. The material has unique combination of an opportunity to conduct hands-on research and development.

lithium- and manganese-rich mixed-metal oxides that will lower EcoCAR 2: Plugging In To the Future kicked off workshop held

battery cost and extend electric vehicle operating range. September 2011.

• High temperature traction drive inverter developed by Delphi • Working with Argonne National Laboratory and General

using an advanced packaging concept enabling cost reductions Motors, developed the next-generation vehicle modeling

through reduced silicon utilization. In addition, they achieved tool called Autonomie, which builds on the success of the

significant decreases in volume, weight, and part count. Powertrain Systems Analysis Tool and uses a plug-and-play

• Internal combustion engine research done in the Vehicle architecture to analyze the performance and efficiency

Technologies Program resulted in one of the first public of a variety of powertrains technologies. AI







46 to read full version of AI stories go to www.ai-online.com

innovation

Battery partnerships

in action By: Jon Knox





An electric vehicle pack that offers a 35% improvement in vehicle (EV) and hybrid electric vehicle (HEV) applications. Its blue-

range has been developed by Axeon in a project co-funded chip clients include Rolls-Royce (for which it produced the world’s

by the UK Government’s Technology Strategy Board. most powerful passenger EV battery), JaguarLandRover, and

The battery uses Lithium Nickel Cobalt Manganese (NCM) also a European manufacturer of premium supercars, as well as

chemistry, which theoretically requires 50% less volume and manufacturers of fully electric urban delivery vehicles.

30% less mass when compared to Lithium Iron Phosphate large- The company provides turnkey battery design, development,

format prismatic cells. The battery also integrates an automotive assembly and test capability throughout the product life cycle,

battery management system (BMS) that works with multiple cell backed up by its global sourcing capability and “cell-agnostic”

chemistries, has active balancing and delivers diagnostic and approach. Axeon is independent of cell suppliers, allowing it to

prognostic information to the vehicle control system. This new deploy the best cell for a particular application. It has, however,

battery represents a real step forward in the development of electric developed strategic partnerships with leading global cell

vehicles and is highly versatile, being suitable for applications for manufacturers, including the US’s A123 and Dow Kokam, with

many vehicle manufacturers and across a wide range of platforms, whom it has collaborated on a number of projects.

according to the company. Axeon says its “cell agnosticism” gives it a wide variety of

Axeon says its “expertise and deep understanding” of cell battery chemistries from which to choose, and the experience to

electrochemistry is enhanced by its’ manufacturing and testing engineer an optimized solution based on that chemistry. It works

capabilities, which have been developed over several years of the with lithium-ion chemistries, choosing the most appropriate variety

manufacture of both of its own EV battery designs, and managing for a particular application. For example, its batteries for urban

the manufacture and complete system integration of batteries delivery vehicles have typically deployed lithium iron phosphate,

for several customers to their design. Axeon recently managed a though this chemistry is also being used in high power applications.

complete build-to-print project of an EV battery for a major US cell Axeon’s battery and charger systems are designed and

manufacturer with a European automotive customer. manufactured to full automotive standards, incorporating all the

Axeon is Europe’s leading designer and manufacturer of exacting requirements of packaging design, thermal management,

advanced lithium-ion battery systems for a variety of electric electronics, testing and vehicle integration. AI









Axeon’s battery

and charger

systems are

designed and

manufactured to

full automotive

standards.



Battery Recycling

Axeon is one of six British companies to receive a share of statistically-robust process for determin-

nearly £500,000 funding from the Technology Strategy Board ing when batteries have reached their end of life

for feasibility studies into the recycling and re-use of batteries and are ready to be recycled.

for hybrid and electric vehicles. In addition to researching the “The issue of end-of-life for batteries in hybrid and

recycling process, the project will look at how to determine electric vehicles is incredibly important to OEMs and

end-of-life, which is still a major issue with automotive car buyers alike, particularly in respect of the economic

batteries for both manufacturers and consumers. and environmental considerations. Our project will

Establishing a battery recycling industry will improve help to define industry standards and best practice

environmental efficiency, create jobs in the UK automotive for battery recycling, which will be key to the mass

supply chain, boost materials supply and ensure materials commercialisation of battery-powered vehicles,”

are dealt with safely. Axeon will also develop a thorough and says Axeon CEO Lawrence Berns. AI





48 to read full version of AI stories go to www.ai-online.com

In the exhibition area

during ICA 2011 on

November 17 in Tokyo, the

MOST Cooperation and

innovation various members will show

the latest MOST solutions

and applications.









Most150 goes into

serial production By: Lenny Case







The latest MOST generation is about to enter into serial production, with Daimler and C





Audi leading the field in multimedia integration using MOST150. M







Y





The MOST150 Electrical Physical Layer Sub-Specification “We very much acknowledge this major effort and invited CM



Rev. 1.0 based on coaxial was launched recently. “This MOST150 speakers from the automotive electronics industry to contribute

MY

coax physical standard complements the existing MOST150 to the conference program. We look forward to presentations

optical physical layer in the infotainment domain, especially for on the latest MOST designs, solutions, experiences, research CY





OEMs who have stringent preferences in the electrical physical results, and future outlooks,” says Christian Thiel, Administrator CMY



layer. In addition, this new standard opens the way into other of the MOST Cooperation.

vehicle domains, as this physical layer is able to provide bi- MOST150 is heading towards implementation. “The newest

K







directional communication and power supply on the same MOST generation is about to hit the road and the MOST

cable,” says Wolfgang Bott, Technical Coordinator of the Cooperation is proud that core partner members Audi

MOST Cooperation. and Daimler will be the first carmakers to integrate

MOST150 is a multi-channel network MOST150 into series production vehicles. This

(control data, synchronous and packet reflects MOSTCO’s path of success, with

channel) which allows the parallel usage of fast-growing acceptance of this de-facto

automotive network standard by key

carmakers worldwide.

Daimler and Audi were the first

Dr. Wolfgang Bott is carmakers to integrate MOST150 into

Technical Coordinator of series production vehicles. The decision

the MOST Cooperation. to integrate MOST150 into the Audi

A3 series was taken in 2010, and the

Volkswagen Group said it would roll

out the technology into all its brands,

all these services through one network. It including volume cars like the Golf and Top

provides an isochronous channel for video class vehicles like the Audi A8.

data transmission, among others. It also MOST150 is based on the well-proven tech-

enables IP data communication, providing the nologies of MOST25. Therefore the vehicle harness,

automotive-ready Ethernet channel according to existing mechanisms for the transmission of multimedia

IEEE 802.3. with freely configurable bandwidth from 0 to data, and established application interfaces can be reused. In ad-

nearly 150 Mbit/s. dition, MOST150 has the capacity to realize infotainment systems

The MOST Cooperation will host the 12th MOST with an up-to-date set of features and a full-fledged multi-seat sys-

Interconnectivity Conference Asia on November 17, 2011 in tem. With the new packet channel, which is compatible with Ether-

Tokyo, Japan. The focus of the conference will be on MOST150. net, MOST150 enables the seamless integration of consumer elec-



50 to read full version of AI stories go to www.ai-online.com

SUSTAINABLE

PROTECTION OF Care for the air.

OUR ENVIRONMENT



CERAM´s homogeneously

extruded SCR-Catalysts show

longest durability and widest

operation range: This leads to

sustainable emissions control

technology on all our roads.



‘MOST150 – next step: rollout’ - Carmakers Audi and

Daimler prove MOST150 to be ready for mass production.





tronics systems, Internet-based services, and established standards of carmakers’ activities, as well as know-how and lessons learned

from the IT industry. from running MOST150 serial development. Further presentations

There are over 110 vehicle models on the road using the MOST will introduce latest MOST devices and systems including optical

infotainment backbone. The MOST Cooperation will demonstrate connectors, test solutions and ongoing specification activities

various aspects and application features based on MOST150,” such as High-bandwidth Content Protection (HDCP) on MOST.

says a spokesman for the MOST Cooperation. An outlook into the MOST future, together with a perspective on

Automotive Industries (AI) asked Dr. Wolfgang Bott, possible future MOST Technology aspects and applications will

Technical Coordinator of the MOST Cooperation, to tell our round off this high quality conference program.

readers about third-generation MOST technology that is AI: What are some of the new challenges facing the

rolling out. MOST150?

Bott: Due to its consistent further development of the existing Bott: The integration of a new network is always coupled

MOST25 and MOST50 transmission technology, MOST150 offers with high investment and is a risky project. But, the risk with

clear benefits, including an increase in bandwidth, an Ethernet MOST150 is as small as possible as the migration from existing

channel for the transmission of IP data, isochronous streaming for the MOST25 is rather an evolution than a revolution. MOST150

transmission of video streams, packet data transmission, synchronous allows carmakers to continue the use of POF and LEDs as light

streaming for transmitting multichannel audio, and a control channel to sources. They can continue to use their established optical wire

transmit control commands to peripheral devices. MOST150 allows harness and assembly processes which makes the transition

the parallel usage of all these services through one network. to higher bandwidth networking with MOST150 a smooth

Consequently, MOST150 meets the requirements not only for procedure. The same holds at device level. The applications

the traditional areas of entertainment and information, but also can stay the same, only the network interface controller needs

for the new domains of mobile connectivity, connected services, to be exchanged.

and driver assistance. MOST150 offers the technology and the AI: Tell us a little about the time line of the roll out of the

audio/video capability for next generation automotive infotainment latest MOST150 developments.

features and devices such as head units, rear seat entertainment, Bott: First use of MOST150 will be with the start of production

amplifiers, TV-tuners and video displays. In addition, it is ready for of the new Audi A3 series in 2012. Following this, the technology will

new features like Internet access devices, iPods, cameras, video roll out successively through each of the series in the Volkswagen

processing units, and many more. group. This contains the vehicle construction sets MQB (modular

AI: What will be some of the core issues vis a vis MOST150 transverse construction set) and MLBevo (modular longitudinal

that will be highlighted at the MOST Interconnectivity construction set). Daimler also confirmed that MOST150 has

Conference in Tokyo this November? successfully passed comprehensive evaluation and is ready for

Bott: Highlights will include a MOST150 implementation mass production. Daimler will start MOST150 in Mercedes-Benz WWW.FRAUENTHAL.NET

update and sharing of experiences, including evaluation and results S-Class vehicles in 2013. AI

Porzellanfabrik Frauenthal GmbH | Gamserstraße 38 | A- 8523 Frauental

T +43 (0) 3462 2000 0 | E info@frauenthal.net

52 to read full version of AI stories go to www.ai-online.com

innovation





Fast-tracking

ECU development By: Lenny Case





Automotive OEMs are constantly looking for ways to speed up the development of networked cars.

A critical component of these cars - the electronic control units or ECUs - need to be developed and

Virtualization can speed up the development of increasingly complex systems.

tested quicker and more accurately than ever before.

“Electronics continue to infiltrate all aspects of automotive design Serughetti: OEMs are rallying to position themselves for the automotive the necessary abstraction to enable applications to be Virtualizer product. Finally, the Saber products are used for net-

as consumer demand for safety, performance, fuel efficiency, four automotive megatrends – safety, environment, connectivity developed independently from the hardware. In theory that enables work design, power design and wire harness design – i.e. for the

and reliability continues to grow. Automotive design relies on an and mobility for everyone. interoperability and flexibility across platforms and allows the level of system-aspects at the OEM side.

efficient exchange of design information across the supply chain. In the context of those trends, OEMs are differentiating with the testing, which eventually increases reliability. Bottom line - most of our tool technologies strive towards

Electronic design incorporates semiconductor, FPGA, PCB, sub- user experience provided to end customers, provide improved AI: How do you see the automotive industry adapting to virtualization of the development process. Instead of waiting for

system, system, and software design. Integrating all these aspects functionality for similar cost and have to navigate a complex landscape standards like AUTOSAR? hardware prototypes, Synopsys products augment those flows

of electronics requires careful attention to component design and of governmental regulations. They have to manage the care complexity Serughetti: Some regional intricacies aside, we see adoption with simulation techniques, virtualizing the development flow,

system interactions to reduce costs and warranty recalls, meet and quality at the vehicle level and meet the legislative requirements. of AUTOSAR across the board with OEMs requiring it for most achieving better time to market, more testing and increased

performance specification, and enhance vehicle reliability,” says Their Tier 1 suppliers are facing high price pressures, have new ECU developments - if not all. Adoption will require better product robustness.

the US$1.4-billion company Synopsys. to deal with demands for high quality measured with standards coordination amongst the development community. Just like in AI: Tell us your company’s work in embedded

The California-headquartered company supplies software, IP like ISO26262, and are trying to innovate within an increasingly the early days of Linux and Android, a variety of parallel versions electronics solutions.

and services used in semiconductor design and manufacturing. networked environment and interfaces to other systems in the and incarnations do exist. Agreeing on the appropriate AUTOSAR Serughetti: As a development tool provider, we are

Earlier in 2011, Mazda chose a Synopsys solution to verify its car. IC suppliers are facing significant price pressures combined versions will be crucial to enable the desired effects of openness mostly an enabler. Besides our semiconductor IP for interfaces,

ECUs. “We selected Synopsys’ CoMET-METeor virtual prototyping with high quality requirements and innovation at the system level. and flexibility across platforms. processors and peripheral components, which directly play in

solution because of its cycle-accurate modeling and high-speed Overall, the increased software content, combined with concerns AI: What solutions does Synopsys offer automotive embedded systems, our tools enable embedded development -

simulation capabilities”, says Hisayoshi Naito, general manager, around safety and design robustness, requires starting development electronics designers and developers? from the early portioning tasks using architecture design, through

vehicle development division, Mazda. The design tool is used as early as possible. The prototyping of systems in hardware requires Serughetti: We offer a comprehensive set of development software development on virtual prototypes to hardware/software

by Mazda to create accurate models for normally dangerous live augmentation by virtualizing significant portions of the development solutions for OEMs, Tier 1s and semiconductor providers. With integration on FPGA prototypes - to software regression testing

tests and difficult to reproduce conditions, and to enhance levels process, from architecture design through early software development, complexities continuing to grow at the rates they do, reuse has become and fault injection techniques for ISO26262 compliant testing.

of safety, reliability and quality. power and network design, combined simulation of the mechanical essential. We offer pre-defined building blocks for both software and AI: How will the quality of automotive electronics be

Synopsys says Mazda will save time and costs by decreasing and electronic worlds and eventually to hardware/software integration hardware. Good examples are our SONIC Focus software building improved?

the number of tests on real automobiles and hardware-in-the-loop and software testing. blocks to enhance the passenger audio experience, and the building Serughetti: Consumer demand for safer, reliable, high

simulation (HILS) test equipment. Virtual prototyping is used to AI: What progress is being made in the development blocks which accelerate semiconductor development – the industry quality products will only grow, as will government regulations

develop and debug designs in the pre-silicon environment months. of reliable advanced software apps that provide flexibility refers to them as Semiconductor IP. to formalize safety and reliability. Virtualization of more and

“Today’s automotive makers struggle with the added complexity of across platforms? Great examples here are our offerings in the area of Ethernet, which more of the development processes will become crucial, as it

millions of lines of software code affecting everything from energy Serughetti: Some features like “where is my car?”, “remote includes the latest AVB capabilities for Audio Video Broadcasting allows more effective, earlier software development and testing,

use to safety features. Achieving system validation and software diagnostics”, “cabin climate conditioning” or “telling my navigation via Ethernet. Our USB and SATA offerings are accelerating chip and directly enables compliance for standards like ISO26262.

development earlier in the flow and with higher quality is crucial system to look up my last Google maps search” can be implemented development, especially in the infotainment domain. Our embedded AI: How important is the automotive business for

to an automobile’s success in the end market,” says John Koeter, today. Other attractive apps, like the virtual valet, will require more memory solutions together, with our ARC processors, round up the Synopsys?

vice president of marketing for the Solutions Group at Synopsys. technology advances like autonomous driving to find adoption IP portfolio. Serughetti: With our strong foundation in the chip and

Automotive Industries (AI) spoke to Marc Serughetti, first. Apps are somewhat shielded from the actual hardware using On the development tools side, we provide AUTOSAR-aware systems hardware development markets, as complexity grows

director of automotive business, and asked him what abstraction layers like operating systems. Just like Android for software analysis to enable OEMs and Tier 1s to assess different we need to serve new, higher levels of abstraction. In this area

challenges face ECU developers. wireless and consumer application domains, AUTOSAR provides in mappings of their software into target hardware architectures. Our application specificity becomes much more important. The

virtual prototypes are used for the development of software, for automotive application domain, along with wireless and consumer





“ Just like Android for wireless and consumer application domains, software testing and hardware/software integration. FPGA proto- applications, is an important area for Synopsys in general, and the

typing plays a role here too. The virtual prototypes representing Solutions Team in particular. AI

AUTOSAR provides in automotive the necessary abstraction to enable the electronics of the ECU, can be connected to our mechanical









”

simulation solutions as well, to allow co-simulation of the mechani- AI readers can find out more on the Synopsys system-level

applications to be developed independently from the hardware. cal motor combustion effects in our Saber products in conjunc-

tion with the actual software running on an ECU simulation in our

design blog: “A View from the Top” at

http://www.synopsysoc.org/viewfromtop





54 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 55

innovation



Single MCU caters

“

They’ll only need one MCU, which can

control the car networking based on several

for multiple infotainment standards, and that significantly reduces the

standards By: Lenny Case

usual number of microcontrollers.

”

Developers of in-vehicle infotainment systems are faced product roadmaps - to handle all real-time networking and system display audio application field, Renesas offers a device series - be available for all the 4th generation P, D and F-Series families.

with two conflicting challenges, one from customers who control tasks. Since power management and diagnostics are also SH726x – that provides connectivity solutions, i.e. the link of audio Even though AUTOSAR is not a mandatory requirement in the

expect the systems to be able to do more and more, and important functions for multimedia applications, the Sx4-H offers functionality with USB and Bluetooth and 2D graphic solutions and field of car infotainment yet, AUTOSAR drivers for the networking

the other from OEMs, which need to eliminate complexity the required interface peripherals (like AD converters, Ethernet), at reduces external components to a minimum. Supported by a rich interfaces will be available for the S-Series. Due to the compatible

as much as possible. an excellent low power/high performance ratio. software application package which can be adapted to customer V850 platform concept, Renesas Electronics is able to offer fast

Automotive Industries (AI) asked Michael Hannawald, AI: What are Renesas Electronics strengths in the fields needs, Renesas offers specific expertise to integrate customer and easy adaptation to the S-Series.

Head of Marketing, Automotive Business Group, Renesas of in-vehicle infotainment and embedded electronics? requirements into an optimized solution. AI: How has the production of microcontrollers been

Electronics Europe, how the Renesas X4 generation V850 Hannawald: Renesas Electronics has a long history in the Renesas’ R-CAR series, based on ARM’s Cortex A9 RISC impacted by the devastation caused by the Japanese

MCUs – the S-series for in-vehicle infotainment automotive sector. Our strengths include a strong market processors, offers a scalable roadmap from single- and dual- earthquake and tsunami?

solutions are meeting this challenge. and customer focus, as well as consolidation of glob- up to quad-core systems. These implement both 3D and 2D Hannawald: By April 6, 2011, Renesas Electronics had seven

Hannawald: The main differentiator is al market requirements into a consistent, scalable graphic cores, a rich application feature set, and various hardware of its eight affected Japanese facilities back in operation. The big

the multimedia gateway functionality, which and software compatible product roadmap, acceleration functions for audio, video and pictures. They put a challenge for Renesas Electronics has been working to get its Naka

copes with the increased demand for data with the focus on software re-usability for strong focus on efficient, highest data bandwidth oriented system wafer fab back to operational levels, which was worst affected

in the multimedia system and performs the customer. With the increased system architectures, boosting the performance of the devices even by the earthquake and tsunami in March. Naka represented 15%

complexity and high level operating sys- further. Since performance requirements in this application field of the company’s total production, and  50% of Naka’s output

tems in car infotainment, we also focus are evolving rapidly, Renesas offers enough headroom for future is microcontrollers - over half of which go to the automotive sector.

Michael Hannawald, Head on providing a full range of software so- requirements. Various operating systems will be supported, The first wafers were put through the fab in June. The company

of Marketing, Automotive lutions from simple device drivers and including open architectures like Linux, together with graphic moved production from the Naka fab to other Renesas fabs and

Business Group, Renesas qualified AUTOSAR MCAL packages drivers and rich software application packages. to foundries to help maintain the supply chain. The relatively high

Electronics Europe. to production-ready multimedia com- The synergy with our subsidiary Renesas Mobile Company inventory levels pre-quake have been an important factor. In fact,

ponents and SDKs. Paired with in-depth (RMC) enables us to quickly react to market requirements and 70% of orders were shipped from inventory until May/June. 

the networking/transfer of control and technical knowledge and an acclaimed research future market trends, like LTE (Long Term Evolution). All On June 10, 2011, Renesas Electronics released an updated

multimedia data between the different customer support team, this attests to this will keep us at the top position in the automotive in-vehicle production schedule for its Naka wafer fabrication factory in

systems in the car. For example, it allows Renesas’ dedication and commitment to the infotainment market segment. Hitachinaka, Ibaraki. Having resumed mass production at both

the link between different interfaces like MOST, automotive market. Together with the excel- AI: What has Renesas Electronics’ role been in promoting the 200- and 300-mm wafer fabrication lines, the key highlight

Ethernet and CAN at high transfer rates. To lent mass production quality level, Renesas has the MOST Cooperation standards? of the new schedule is that Renesas expects it will be capable of

prevent any delay in transfers, the real-time behavior of achieved the number one position among suppliers of Hannawald: Renesas is seeing increased interest in this significantly advancing the schedule by one month, from the end

the MCU is essential, and this is one of the proven, key assets microcontrollers to the automotive sector. interface from OEM and Tier 1 - and not only for premium cars. of October to the end of September, when the supply (shipment)

of the proprietary 32-bit V850E2 RISC-CPU core. AI: What is Renesas Electronics’ expertise in providing This is why MOST is part of our networking oriented system capacity will return to pre-earthquake levels. Renesas Electronics

AI: How is this product going to help OEMs looking to advanced embedded design technologies for in-vehicle controllers V850ES/Sx4-H, the Dashboard (D-Series) and the will continue to focus all possible efforts on the recovery work at the

offer more infotainment solutions at lower costs? infotainment solutions? R-Car SOC device families. Naka factory. The company expresses gratitude for all the support

Hannawald: They’ll only need one MCU, which can control Hannawald: Renesas Electronics offers a broad product AI: What efforts has Renesas Electronics put into pushing it received from companies outside the Renesas Group, which

the car networking based on several standards, and that portfolio from low end audio system control up to a quad-core the AUTOSAR standards? helped to speed up the resumption of operation and advance the

significantly reduces the usual number of microcontrollers. The navigation application processor. Renesas Electronics’ standard Hannawald: Renesas has been a pioneer in that it has production schedule.

V850E2/Sx4-H Series is the most suitable supplement to today’s audio system control devices (Sx3 Series), and the newly established AUTOSAR support for all of its products for automotive Thanks to the efforts mentioned above and the cooperation of

car infotainment head units, communicating with connectivity available Sx4-H with multimedia gateway functionality, are the control applications. Even the former 3rd generation was equipped our business partners in the automotive industry, Renesas was

and/or navigation devices - like Renesas’ SH726x and R-Car de-facto standard for audio system control applications. In the with a full Autosar support package. AUTOSAR support is or will able to reduce the delivery impact to a minimum. AI





56 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 57

LEFT: Integrys Energy Group is

headquartered in Chicago, Illinois, where its

regulated natural gas utility Peoples Gas

innovation Pinnacle CNG provides delivers safe, reliable natural gas to more

compressed natural gas as a than 800,000 homes and businesses.

transportation fuel for the City of

Austin, Texas, and its residents. BELOW: Trillium USA serves the City of

Berkeley, California, fleet on the city’s site,

which is also open to the public.









Natural Gas network

coming on stream By: Jon Knox



Demand for Natural Gas-powered vehicles is growing low and stable long-term natural gas prices, the environmental the fuel side, the industry is in full agreement that natural gas fuels is not an easy task for any fleet, let alone the average

strongly. According to U.S. Natural Gas Vehicle (NGV) As- benefits of a clean-burning, low-carbon fuel, and an increasing prices in the U.S. will continue to be low relative to petroleum consumer. Our strategy focuses on presenting customers with

sociation, more than 12 million NGVs are in use worldwide, supply of competitively priced NGV products for consumers. But for the foreseeable future. The experts have shown that the U.S. everything they need to evaluate CNG – the vehicle, a refueling

with 110,000 of those in the United States. The International perhaps one of the biggest reasons the market is ready is that has vast domestic reserves of natural gas, and technology has solution and excellent customer service. The key is to make it easy

Association of Natural Gas Vehicles estimates that more CNG is a comfortable choice when compared with gasoline and advanced to the point where we can develop these resources for the customer. Presenting an integrated platform that covers

than 50 million NGVs, or about 9% of the world’s transpor- diesel. Gasoline and diesel are driven by global market demand safely and cost effectively. everything from the vehicle to the refueling solution eliminates the

tation fleets, will be on the road within the next 10 years. and can be affected by disruptions related to that. Moving toward Regarding the availability of NGV products for consumers, we need for customers to have to figure it out on their own. Their

On September 1, 2011, a major step toward making natural something more predictable is attractive to customers. have seen an increased interest by manufacturers in NGVs, and we business is running their business. Ours is to present them with

gas a mainstream transportation fuel in the U.S. was taken. The Our strategy aims to build market share through our are confident this trend will continue. Most of the automobile, truck a cost-effective turnkey solution that makes their business more

Integrys Energy Group — a U.S. Fortune 500 company — acquired demonstrated capability in the energy delivery business, and by and engine manufacturers have NGV products available overseas, efficient and profitable.

Salt Lake City, Utah-based Trillium USA and Midland, Texas-based capitalizing on the proven expertise of Trillium USA and Pinnacle but there has been little interest in bringing these products to the AI: What are some of Trillium’s and Pinnacle’s strengths

Pinnacle CNG Systems from Wagner & Brown. Trillium USA, the CNG. The acquisition provides Integrys with the resources it needs U.S. up to this point. We believe this is at least in part driven by that will help Integrys achieve this plan?

second largest provider of compressed natural gas (CNG) in the to execute a customer-focused CNG strategy immediately. The a lack of available refueling infrastructure to support consumer Radtke: Certainly, an important factor in our decision to

U.S., is now coupled with Pinnacle CNG, a manufacturer companies provide 20 years of experience, and bring to confidence, and regulatory barriers that increase the cost of the acquire the two companies was their reputation within the industry,

and provider of CNG fueling solutions, under a new the portfolio a network of existing refueling stations, vehicle. We see both barriers being addressed. and with their customers. Their attention to detail, ability to deliver

division, Integrys Transportation Fuels, LLC. operating infrastructure, and a market reputation Our strategy is to eliminate this chicken-and-egg dilemma customer-focused solutions and exceptional level of customer

“Expansion into this business (CNG) is built on their years of demonstrated capability by deploying additional infrastructure, increasing consumer service sets them apart.

consistent with our mission of providing and reliable performance. Today, Trillium confidence and paving the way for more rapid NGV adoption. On From a technical perspective, the companies have a

customers with the best value in energy USA and Pinnacle CNG provide fuel for the regulatory front, the USEPA has taken steps to reduce the cost demonstrated expertise in developing reliable systems for a wide

thousands of natural gas-fueled vehicles, of bringing NGVs to the U.S. market, but the real key is increasing range of customers. From the high-capacity, fast-fueling needs of

amounting to about 45 million gasoline consumer demand so as to reduce vehicle costs on a per-unit transit agencies and large trucking operations, to the less intensive

Mark Radtke, Executive Vice gallon equivalents of CNG annually. basis. We see it this way: With the spread between natural gas time-fill operations of the refuse and school transportation sector,

President and Chief Strategy Going forward, the goal is to build on and petroleum fuels growing, and additional refueling solutions to both large and small unattended retail sites - these companies

Officer for Integrys. the expertise of these two companies bolstering consumer confidence, NGV adoption rates will rise. This cover the spectrum. In our view, it was the perfect combination of

and expand our presence across the will result in demand for more NGV components, which can be skills and capabilities.

U.S. This will mean a continued focus on delivered at more competitive prices to manufacturers, allowing We also learned in our research that exceptional customer

and related services. Our decision to enter Trillium’s and Pinnacle’s very successful them to deliver a lower per-unit cost to consumers. This cycle will service in the CNG industry goes a long way. While not all

this market is in response to customer business lines, which include transit, retail accelerate as NGVs move into the mainstream over the coming customers demand what we call “on-site” service, being there

needs, and is complementary to our existing fuel sales, and proprietary customer fueling decade, thereby allowing for a more diverse and cost-effective “on-demand” when the customer needs assistance clearly

skill sets in regulated and non-regulated solutions, while adding new resources in line-up of NGV in the U.S. distinguishes Trillium USA and Pinnacle CNG from the pack.

natural gas and electric services,” said Charlie growth markets to service fleets through networks AI: How will your strategy integrate with the OEMs and Lastly, as a company, Integrys takes great pride in the values

Schrock, Chairman, President and Chief Executive of efficient and well-operated stations. their distributors? we have established for our business and employees. These

Officer of Integrys. AI: How optimistic are you about the growth of CNG in Radtke: Our strategy with OEMs, qualified vehicle include integrity, innovation, safety, collaboration, respect for

Automotive Industries (AI) asked Mark Radtke Executive the U.S. transportation industry? manufacturers (QVMs) and distributors is to continue working our employees and customers, customer service, providing

Vice President and Chief Strategy Officer for Integrys to tell our Radtke: Everything we see in terms of market fundamentals jointly with them to deploy both vehicles and CNG infrastructure value for our owners, and supporting the communities which

readers about the Integrys strategy in the CNG fuel market. points to a rapid adoption of the fuel in transportation in the into various markets. Trillium USA and Pinnacle CNG have we live and work in. These same values are and have been

Radtke: All signs point to CNG becoming a mainstream near term. The primary drivers for NGV adoption are the spread excellent working relationships with these groups that we will espoused by Trillium USA and Pinnacle CNG throughout their

transportation fuel for the country in the next decade. These between petroleum fuels and CNG, and the availability of continue to foster and expand. We believe providing the customer 20-year history. In addition to everything else, this made the

include a vast supply of domestic natural gas, forecasts for efficient and cost-effective NGV products for consumers. On with a complete, turnkey solution is vitally important. Changing companies a great fit into the culture of Integrys. AI



58 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 59

innovation



“Re-inventing” the

in-wheel drive system By: Jon Knox



A team of British and American entrepreneurs and engineers would like you to reconsider every-

thing you know about in-wheel motors – and take a look at their approach which, they believe, has

turned past designs “inside out”.

Protean Electric is an advanced technology company that has customers. We partnered with them to build two different kinds of

redesigned and re-engineered the in-wheel electric motor. Protean’s performance drivetrains, both displayed at the 2011 Frankfurt Motor

approach – turning the wheel motor “inside out” and putting the show. The first BRABUS EV sedan, called the “High-performance

rotor on the outside – gives the motor great power density, and Four-wheel-drive Full Electric Car,” is based on the Mercedes-Benz

allows Protean to package the inverter and power electronics E-Class. Its all-new EV system has a peak combined 320 kW (430

inside each motor to improve vehicle packaging. These in-wheel hp) and 3,200 Nm (2,350 ft.-lbs.) torque from pure electric power

motors improve fuel economy and performance, and can be easily using four direct-drive Protean Electric motors, one in each wheel.

integrated into a broad range of vehicles. Protean’s system can The second BRABUS is a hybrid drive vehicle, with two in-wheel

increase fuel economy by over 30% depending on the size of the motors and an internal combustion engine all driving the rear wheels.

battery and the driving cycle. Protean is based in the United States Each in-wheel motor adds 80 kW (110 hp) and 800 Nm (590 ft.-lbs.)

and the United Kingdom. of peak torque to each rear wheel. This gives the sedan a combined

Automotive Industries (AI) asked Bob Purcell, Protean electric motor and internal combustion engine acceleration of 0-100

Electric’s chief executive officer to explain how advanced km/hr (0-62 mph) in 7.4 seconds. The car is impressive. It will

the technology is for an in-wheel electric drive. accelerate from 60-120 km/hr (37-75 mph) of 5.6 seconds. This is

Purcell: There is simply nothing else like it. We turned that the new definition of performance, done efficiently and responsibly.

model inside out, putting the rotor on the outside and Partnering with BRABUS on these vehicles was very

cool for us and really demonstrates the flexibility and

diversity of our in-wheel motors.

AI: What response did the Ford F150

pick-up truck retrofitted with your in-

wheel drives evoke at the SAE World

Congress in April this year in Detroit?

Purcell: That was a great opportunity for

Protean Electric. It gave the international forum

of engineers and business people a chance to

see how easy it is to integrate our in-wheel mo-

The Vivaro plug-in hybrid on the road. tors into a vehicle. Near our display, we featured

RIGHT: In-wheel motor. the Ford F150 pick-up during the ride and drive

sessions, and I believe everyone was impressed with

the stator and electronics on the inside. That simplicity the quiet performance of our direct drive motor system.

of design creates more power density per motor and much AI: What has been the industry response to the

simpler vehicle integration. Rather than using one large inverter Vivaro plug-in hybrid?

to control the motor, Protean Electric has a patented distributed Purcell: We have had a sensational industry response to

architecture that uses eight self-contained sub-motors that work the Vivaro ever since we showed the vehicle in May at the 2011

together. Delivering 81kW (110hp) per in-wheel motor, it’s the Michelin Challenge Bibendum in Berlin. Fleets especially love the

highest power density drive system we know of and it all fits in a concept. The Vivaro is powered by a conventional diesel engine

conventional 18-inch road wheel. for the front wheels and two Protean Electric motors retrofitted

AI: Please tell us about your most recent vehicle to the rear axle. The driver has the advantage of being able to

announcement with BRABUS, the luxury performance tuner. switch between multiple operating modes: two- or four-wheel

Purcell: This was really an exciting project for us. BRABUS is drive operation, or an electric torque assist Through-The-Road-

the largest independent automobile tuner in the world. They make Hybrid. The Protean-equipped Vivaro van can achieve an effective

very exclusive high-performance automobiles for very discerning 60 percent fuel economy improvement in charge depleting mode



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The Brabus hybrid – a joint project by Protean Electric and high-end car customizer Brabus.



(electricity + diesel) as compared to charge sustaining mode (diesel IC engine smaller and more fuel efficient. Manufacturers can think

only). Source: SAE “Recommended Practice for Measuring the about creating a portfolio of powertrains, from hybrids to PHEVs

Exhaust Emissions and Fuel Economy of Hybrid-Electric Vehicles, to EVs, simply by resizing the battery and using the same vehicle

Including Plug-in Hybrid Vehicles” (J1711 JUN2010). and the same in-wheel motor drivetrain technology. Finally, with the

AI: What has Protean drawn from the data taken as a motor out of the way and with no drive shafts or gear boxes or

result of the partnership with Millbrook testing ground with differentials, just think how automotive designers now have new

the Vauxhall Vivaro TTRH (through the road hybrid)? freedom like never before to create exciting vehicles.

Purcell: The main benefit of the testing has been to get real AI: What do you think is the future of hub-mounted motors?

world third party validation of our technology and systems. We have Purcell: With the capability of today’s power electronics and the

now run for over 10,000 km, including a 100-hour Pave simulation, packaging innovation of Protean Electric’s distributed architecture

with very few problems. The vehicle has also gone through a design, the time is right for in-wheel motors to be used in high

comprehensive set of prototype validation tests and in most cases, volume. The use of electric motors to improve the fuel efficiency of

passed with flying colors. That’s about where we want to be. cars and trucks is going to increase exponentially. The low cost and

We are on a path to be fully certified and validated to automotive high power density of the Protean Drive in-wheel motor design is

standards. So, in short, we have learned a lot about the control well suited for the near-term introduction of in-wheel motors in new

system integration and how our IP is involved in developing through- vehicles and the retrofitting of existing vehicle fleets.

the-road plug-in hybrids like the Vivaro. AI: What is Protean’s strategy in popularizing its

AI: What are the benefits for OEMs in using the technologies in the USA and Europe? Do you think markets

Protean Drive? outside these regions are also ready for the Protean Drive?

Purcell: The Protean Electric motors offer several advantages. Purcell: We have active programs underway in the USA,

The first is about speed to market and avoiding development costs. Europe and Asia. We believe the 81kW (110hp) motor designed

Since the motors and motor control electronics are in each wheel, for an 18-inch road wheel is the best place to start. That size and

there are few if any modifications necessary for the body structure, power is applicable to a wide range of retail and fleet vehicles used

transmission, or drivetrain components. This avoids expensive in all three regions. The fuel saving benefits of the Protean Electric

re-tooling of large body panels and drivetrain components and in-wheel motor will encourage the retrofitting of light commercial

minimizes disruption in the vehicles final assembly process. If the vans and trucks in the near-term. The motor’s power density makes

Protean Drive system is used to augment the existing powertrain, it also well suited to provide enhanced performance for vehicles for

there is no need for changes to major engine emission components. both Europe and the USA markets. Beyond that, we see interest

Development engineers can use the Protean Drive on board a ranging from the most common cars to special applications like

vehicle with a conventional IC engine, allowing them to make the delivery vans, EVs, taxis and police cars. AI





Technology Pioneer

Protean Electric has been awarded the prestigious Technology Pioneers award by the World Economic Forum for

its in-wheel motor, electric drive system for cars and trucks.

The 2012 class of Technology Pioneers, announced in September in Switzerland, comprise 25 of the most innovative

technology start-ups from around the world.

“We are honored to be named a World Economic Forum Technology Pioneer - recognition that our in-wheel motor de-

sign is a ‘game changer’ for integrating electric propulsion into the world’s cars and trucks,” said Bob Purcell, chairman

and CEO of Protean Electric.

“We believe our system has the potential to bring electric drive to many of the world’s vehicle markets.” AI





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innovation









Gateway to still accelerating

Chinese market By: Clinton Wright





Asia’s largest trade fair for automotive parts, accessories, and fuel cell vehicles will be exempt from tax and conventional

equipment and services continues to grow as it mirrors the hybrids will also qualify for a 50% exemption.

expansion and diversification of the Chinese automotive In addition, the National Development and Reform Committee

market. (NDRC) of China launched a pilot program to promote the country’s

In 2010, China’s automobile market saw the highest ever annual automotive parts remanufacturing industry to help establish a

sales in global history with 18.06 million vehicles registered. As a sustainable economy. Included in the remanufacturing list are

result, China’s automotive products market exceeded RMB500- engines, transmissions, generators, starters, steering, compressors,

billion (US$78-bn) in 2010. For 2011, the China Association oil pumps, water pumps and transmission shafts.

of Automobile Manufacturers predicts that car sales in Much of the technology needed to drive this

China will grow by 10%. Industry analysts expect growth will be on show at Automechanika

Shanghai 2011, which will run from December

7 to December 10 at the Shanghai New

International Expo Center. The fair is

expected to attract 3,600 exhibitors,

Fiona Chiew, group which is 15% more than at the 2010

manager, trade fairs, edition of Automechanika Shanghai.

Automechanika. Having gained a strong foothold in the

automotive industry, the 2010 show drew

50,561 visitors representing 130 countries

and regions, an increase of 31% compare

the automotive product market to be worth to 2009. Exhibitor numbers rose by 29% with

RMB650-bn (US$102-bn) - and reach RMB1- 3,115 exhibiting companies from 27 countries

trillion (US$157-bn) within three years. In addition, the and regions showcasing their latest automotive

automotive electronic products market is estimated to products and services in 138,000 square meters

reach RMB240-bn (US$97-bn). with an annual growth of 26%. covering 11 permanent and six temporary halls.

Automotive safety systems, car-care and maintenance services are This year, the show has received strong support from the

predicted to witness an even bigger growth. China Aftermarket Forum or CAF, an industry group consisting

The Chinese government is taking green initiatives in its of Automotive Aftermarket Suppliers Association (AASA) and the

12th five-year plan which involves investments of RMB4-trillion Motor & Equipment Manufacturers Association (MEMA) members

(US$470-bn) to support the development of nine industries, with operations in China.

including alternative energy vehicles and environmentally friendly Companies like Affinia, Arvin Meritor, Brembo, BorgWarner,

new materials. By 2012, automobile production in China is Bosch, Continental VDO, ContiTech, Corghi, Dana, Dayco, Delphi,

expected to exceed 20 million units, with alternative energy Febi Bilstein, Federal Mogul, Graco, ITW, Liqui Moly, Mahle,

vehicles accounting for 10%, or more than two million units of Mann+Hummel, NTN-SNR, Osram, Panasonic, PCL, Philips,

total production. To encourage the use of green and sustainable Schaeffler, SPX, Stanley, TRW Automotive and ZF have confirmed

vehicles in Beijing, the Vehicle and Vessel Tax Law has been their participation in Automechanika Shanghai 2011, according to

revised. From January 1, 2012, electric vehicles, plug-in hybrids the organizers.



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Demonstrating equipment at Automechanika Shanghai. Talking business at Automechanika.





The vibrant automotive sector in China has seen numerous sourcing platform for global automotive companies who want to

companies investing in the country. Recently, the Volkswagen do business in China.

Group received the go ahead for two more plants at Yizheng in AI: What are some of the new features of the 2011 show?

Jiangsu Province in eastern China and Foshan in Guangdong Chiew: This year, in addition to the established parts

Province in southern China. Each plant will have an annual capacity and maintenance equipment sectors, we will have a new hall

of 300,000 vehicles and production is due to start in 2013. dedicated to accessories, tuning and car care. We will also have a

This year, Automechanika Shanghai will feature a new “remanufacturing pavilion” fully supported by the Automotive Parts

automotive accessories product hall to meet an increasing Remanufacturers Association (APRA) and The China Resource

domestic demand resulting from the booming car sales in Recycle Association Remanufacture Committee (CRRARC), plus

China. “Exhibitors will showcase their latest products ranging a “new energy zone” reflecting the new industry trends.

from vehicle electrics and electronics, car care and lubricants AI: Tell us a little about the growing number of exhibitors

to decoratives and tuning. In addition, to help exhibitors at Automechanika Shanghai – what do you attribute the

explore the potential of the fast growing eco-friendly vehicle increase to?

and renewable energy markets under the strong support Chiew: We expect to have 3,600 exhibitors this year. This is a

from the Chinese government, this year’s show will set up 15% increase compared to the last show. There are various areas

remanufacturing and new energy vehicle product zones,” says where we see the increase in exhibitors numbers: Firstly, more

Messe Frankfurt, the show organizers. overseas companies joining us – we will have first time pavilions

Automotive Industries (AI) asked Fiona Chiew, group from Japan and India. Secondly, more world leading brands are

manager, trade fairs, Automechanika, what makes joining us - BorgWarner, Mann+Hummel, NTN-SNR, Osram,

Automechanika Shanghai so important to automotive Panasonic and Philips are all first time exhibitors. Lastly, we have

companies. more exhibitors from the repair and maintenance sector, as well as

Chiew: Automechanika is a trusted trade fair brand for the the accessories and tuning sector.

automotive industry. Within a short span of eight years, we have AI: How many visitors are you expecting at this year’s event?

built up Automechanika Shanghai to be the largest automotive Chiew: We expect to have more than 60,000 professional

trade fair in China and Asia. It is now the annual trading and buyers visit the show this year. AI







Automechanika Frankfurt

Automechanika Shanghai is one of 13 global Automechanika fairs held in Asia, Europe, North America, South Amer-

ica and Africa. The fair is organized by Messe Frankfurt (Shanghai) Co Ltd and the China National Automotive Industry

International Corporation or CNAICO.

Messe Frankfurt is already gearing up for the 2012 edition of Automechanika which will be held in Frankfurt from the 11th

to the 16th of September, 2012.

Registration is open for next year’s show. AI







66 to read full version of AI stories go to www.ai-online.com

Final checks on

Renault’s Somaca

production line.



innovation









Moroccan auto industry Quality checking at Renault’s Somaca plant in Morocco.









moving into top gear By: Michael Stewart

LEFT: Assembly at Renault’s

Somaca plant in Morocco.





Morocco is on track to become a leading destination for to 10% of the total investment to help automotive facilities set up. the deployment of its manufacturing footprint in a country where 4. Competitive platform for export due to competitive wages

automotive investments. The country’s automotive sector The government also has set in place training programs tailored to passenger vehicles are playing an increasingly important role in the compared to Europe.

has witnessed a boom over the past five years. Recent in- the needs of the automotive sector. national economy as well as in the daily lives of Moroccans. I am AI: Please explain AMDI’s strategy when trying to attract

vestments in Morocco’s automotive sector include a one Morocco’s strategy as far as the automotive sector is concerned confident about the development of our new site in Kenitra and I foreign investors to Morocco’s auto industry.

billion Euro investment by Renault. The French company is revolves around boosting investments from automotive suppliers would like to express my gratitude to the Moroccan government Fihri: Our strategy is centered around developing a good

setting up a new plant which will produce 400,000 vehicles who are looking to invest in low-cost countries. Plus, the country for the welcome they have given us and for their efficient support.” value proposition: world class infrastructure (industrial zones, free

annually. The plant is expected to create around 36,000 di- wants to establish itself as a manufacturer of specialty vehicles Earlier, in 2002, Delphi invested around US$4-million in Tangiers zones, Tangiers Med Sea Port, Highways…), competitive human

rect and indirect jobs. such as trucks, buses and coaches. AMDI is a leading force in to boost the manufacture of automotive components in Morocco. resources, attractive set of incentives and duty-free access to one

In a testimonial posted on the Moroccan Agency for Investment promoting the automotive sector in the country. In March 2011, Automotive Industries (AI) asked Ahmed Fassi Fihri, billion consumers. Then, promotion and communication are also

Promotion (AMDI) website, Renault says: “Having settled in AMDI made a presentation to leading car-makers in France. investment promotion manager of AMDI, what makes crucial. For the first time this year, we launched a communication

Morocco for 80 years, Renault is the leader of the Moroccan car It told OEMs that Morocco has created integrated industrial Morocco an ideal destination for automotive manufacturers? campaign in four European countries using television and

market with its brands Renault and Dacia. Already holder of a areas which it calls platforms in Tangiers and Kenitra. These Fihri: First, Moroccan economic fundamentals have been specialized press (automotive among others). In parallel, AMDI

production unit in Casablanca (SOMACA), the Group launched industrial integrated platforms are called P2i, and were created strong over the last decade, with a GDP growth around 5%, a regularly organizes conferences and road shows in our target

in 2008 the construction works of a vast industrial complex in for automotive manufacturers. The P2i program helps automotive controlled inflation below 2% and a public debt reduced to 47% markets to present our automotive value proposition to foreign

Tangier. The decision to install the Renault Project at Tanger Med companies rent or buy real estate and buildings or get customized of GDP. Second, thanks to the numerous free trade agreements, investors. Our strategy is also based on the use of commercial

in Morocco was based on several factors: facilities in Tangiers and Kenitra. The logistics on offer include Morocco allows duty free access to a market of one billion agents, i.e. companies with strong knowledge of the auto

Prospects related to the automotive sector in Morocco with a optimal connectivity to major ports, airports and highways. consumers - a market representing 60% of world GDP. industry and the target countries, which help us reach the auto

rapid growing equipment rate and an attractive domestic market. The services offered under the P2i program include those that As far as auto industry is concerned, our proximity with the manufacturers and present to them our value proposition.

The wide trade zone to which Morocco provides access because fall in the general infrastructure category such as helping set up European market (less than 10 miles separating Morocco and AI: Tell us about the country’s free trade zones aimed

of its geographical proximity to several European and African infrastructure, maintenance, security etc. In addition, there are Spain) allows access to a huge potential market within few days at automotive manufacturers, and how successful they

countries and opportunities offered by the Agadir Agreement. general services such as telecom, food, health services, banking for equipment manufacturers: 4.2 million vehicles are produced have been?

Good infrastructure conditions through primarily the Tangier Med and so forth. These areas also offer services such as business less than three days away from Morocco. Fihri: Investors in free trade zones benefit from incentives

port and the dedication of space (13 hectares) to the exportation centers, recruitment agencies, travel agencies and so forth. Our value proposition is based on four pillars: ranging from complete exemption from the Corporate tax for

of Renault vehicles. Advanced services such as engineering, logistics, and recycling 1. Infrastructure with two integrated industrial platforms with free the first five years (and 8.75% for the following 20 years), VAT

“Solid wage and fiscal competitiveness that allows Morocco to are also offered. The P2i program also offers training programs zone status dedicated to the automotive sector. exemption both on Imports & Exports, no taxes on dividends, no

target the competitiveness levels of Romania. Support of public with specialized training institutes aimed at the automotive sector. 2. Human resources and training support: creation of a Specialized restriction in capital repatriation and convertibility, free transactions

authorities and presence of a financial partner for the Renault The P2i program streamlines clearances by offering a One Stop Automotive Institutes with the participation of international in foreign currencies and simplified custom procedures.

Tanger Méditerranée Project (The Caisse de Depot et de Gestion Shop for automotive investors. automotive training, coupled with very attractive training Two free trade zones are actually dedicated to the auto

contributes by up to 48% to Renault Tanger Med Project). And A few years back, Faurecia, Europe’s second-ranking incentive schemes adapted to the needs of the automotive industry: Atlantic Free Zone in Kenitra and Tangier Automotive City

finally, the Free Zones in Tangier and Tetouan which facilitate the automotive equipment supplier, invested 10-million Euro in sector players and their suppliers. in Tangier. These are still in the construction phase, and we expect

installation of vendors near the industrial complex.” Kenitra to set up an automotive seating trim cover production 3. Attractive set of incentives: State subsidies of up to 20% of the first hand over before the end of 2011. Commercialization has

The Moroccan government has chalked out a strategy to further plant. The facility provides seat trim covers to Renault-Nissan professional building costs and 10% of equipment costs for started and reached very promising levels: in Kenitra, more than

boost the industry. The plan includes attractive incentives such as a and Volkswagen in Europe. At the time of the setting up the machinery investment exceeding 220,000 Euro, complete 40 companies expressed interest; and in Tangiers, the Renault

5-year corporate tax exemption for automotive companies setting facility, Patrick Koller, then Faurecia’s executive vice president for exemption from Corporate Tax for the first five years, and suppliers are definitely willing to invest and benefit from the free

up shop in the country. Plus, the government offers aid worth up automotive seating said: “With this new plant Faurecia is pursuing 8.75% for the following 20 years in the free zone. zone status. AI



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innovation





Growing Eurasian

auto market attracts

major trade fair By: Steve Barclay Over 300 exhibitors took part in the 2010 PaintExpo.







Europe’s biggest specialist coatings fair, PaintExpo, will be PaintExpo’s organizer, FairFair, was founded by Haussmann in Haussmann says the event functions as a link between and so on. The demand for white goods is also growing. The

staged in Eurasia for the first time. Planned to be held every 2006. PaintExpo is organized in partnership with JOT (German manufacturers for whom they promote sales, and users to whom exhibition program will reflect these special requirements.

two years in Turkey, PaintExpo Eurasia will be held from trade journal for surface finishing). It is a biennial event – the fourth it provides information and procurement sources, creating added AI: What do you attribute the growing interest in Paint-

October 6 to October 8 2011 at the Istanbul Expo Center. PaintExpo will be held in Karlsruhe, Germany between April 17 and value for both groups of customers. Expo 2012?

It is being organized by FairFair in collaboration with Turkish April 20, 2012. According to FairFair, over 260 companies from Automotive Industries (AI) asked Haussmann what made Haussmann: The basics are the good concept - the clear

technical trade fair specialist company Artkim Fuarcılık. According 19 countries have already signed on as exhibitors. Haussmann the company decide to take PaintExpo to Turkey. focus on coating technologies, and catering for all steps in the

to the organizers, Turkey, as well as many other countries on the attributes the high levels of international interest in participation Haussmann: PaintExpo in Germany attracts both a large process chain: Industrial wet painting, powder coating and coil

shores of the Eastern Mediterranean and Black Sea, are having to the extensive investment requirements for companies with in- number of trade visitors from German-speaking countries, and coating are presented from pre-treatment up to final inspection.

to upgrade their technology. “This applies in particular to the house painting facilities, and job-shop coaters. more and more international painting specialists. Nevertheless, Practically, all relevant market and technology leaders are on site.

field of industrial coating. In order to secure a competitive edge, “This is being triggered by ever stricter requirements regarding the economic growth of Turkey and neighboring countries in the Decision-makers from companies with in-house coating facilities

companies in the region with in-house painting operations, and efficiency, quality, flexibility and environmental protection, as well Middle East is faster than we can bring all those potential visitors and job-shop coaters are able to collect relevant information for

job-shop painters, need to apply coatings in higher quality, in a as by new materials and material combinations. PaintExpo to Germany. Taking the main idea of PaintExpo, and slightly process and cost optimization in one trade fair visit. Due to this,

more ecologically friendly manner, faster and more cost- is the number one information and procurement adjusting it to this economic region was the solution welcomed PaintExpo is becoming increasingly popular with every edition and

effectively. This results in strong demand for top platform for users, due to the fact that it presents by our existing customers, and many manufacturers from Turkey. attracts more and more international exhibitors and visitors.

quality technology,” says Jürgen Haussmann, the world’s most comprehensive offerings AI: Will PaintExpo Eurasia continue as a biennial event in AI: What are some of the latest paint technologies that

managing director of FairFair. ranging from pre-treatment right on up to Turkey or do you plan to host the event in other countries will be showcased at the PaintExpo 2012 in Germany?

final inspection,” says Haussmann. in the region? Haussmann: We know that several new products are

The third PaintExpo held in April Haussmann: Istanbul is a hub for domestic and international currently under development. They are concerned with energy

2010 in Karlsruhe, saw exhibitor flights. The fairground, Istanbul Fuar Merkezi, also known as CNR and material savings, and higher process flexibility. In the pipeline

numbers grow by 14% compared Expo, is easy to access from the airport. Business people from our are also technologies to reduce the necessary process steps by

Jürgen Haussmann, to 2008, and visitors were up by target region are used to travelling to Istanbul for trade fairs. Several combined methods. Many of them will help users comply with even

managing director 8% to a total of 6,397, despite the exhibitors and many users of industrial coating technologies are more restricted VOC-regulations, which are expected in future.

of FairFair. economic downturn. “PaintExpo is located in and close to Istanbul, so our decision for Istanbul was AI: What numbers do you hope to reach in 2012 with

very well accepted by our customers well thought out. We do not expect any change of the location in exhibitors as well as visitors?

and other interested parties because the near future. Haussmann: Since the beginning of PaintExpo we have

it offers an extremely clear-cut AI: What will be some of the differences in terms of focused on quality more than on quantity. Though an increase of

picture of the entire coatings industry. products/issues/technologies in PaintExpo Eurasia as about 10% or even 15% may be expected, which means roughly

PaintExpo Eurasia will cover all aspects of All of the relevant companies from all compared to the fair in Germany? 370 exhibitors and more than 7,000 expert visitors.

the coating process. Istanbul, located where fields of industrial coating technology are Haussmann: There are some smaller differences related to the AI: Any other international editions of PaintExpo planned

Europe and Asia meet, is considered the most represented here. We’re very satisfied with local economy. The automotive sector is growing because many in the future?

important trade fair location by visitors from Turkey the quantity and the quality of the visitors again global car and commercial vehicle manufacturers are building new Haussmann: We are fair organizers, and of course, we are

and its neighboring countries, he says. The fair will cater for this year,” said Martin Weidisch of J. Wagner, which has plants or increasing their production capacity in Turkey. The reasons thinking about launching new trade fairs. But, right now, it’s much

the automotive industry and its suppliers, coating job-shops, participated in all three events. for this include rising domestic demand, and the strategic location too early to talk about it. And PaintExpo Eurasia has started so well

commercial vehicles industry, the aviation and aerospace industry “Visitors who attend PaintExpo are a dream-come-true for of Turkey for exports into neighboring countries. This has another that the development of this fair is currently our focus of attention.

among many other sectors. Visitors will find out how to cut material anyone who’s involved with customer consultation. All of them positive effect for PaintExpo Eurasia, because many automotive It is also our company guideline not to start too many new projects,

costs by reducing paint consumption, increase product quality are engineers, technicians or process engineering experts – suppliers establish themselves around the car manufacturers. and perhaps fail with all of them. Sustainable development of one

and process flexibility, optimize coating processes while cutting exactly the kind of people we want to hook up with. We’re able Other examples are the current construction boom, which results new project brings more satisfied customers and pays off in the

energy usage and to prepare to meet upcoming governmental to discuss things with them at a highly technical level,” said in a rising demand for coated metal and glass parts for facades of long term. But be sure, as soon as we are going to launch a new

volatile organic compound (VOC) regulations. Achim Trefz, assistant sales manager from SATA & Co. KG. skyscrapers, as well as for internal products like boilers, radiators trade fair, AI will receive this information first. AI



70 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 71

Orlando’s Lower costs

innovation

benefit both exhibitors and What makes us what we are is our code!

visitors to NPE2012 By: James Hilton







NPE2012,” the world’s largest plastics industry trade show & Suppliers Center, will be made up of plastics molding and

and conference,” is shaping up to be the biggest ever, thanks extrusion firms, as well as companies that supply them. Another

to a combination of the growing use of plastics in the auto new pavilion will focus on advanced manufacturing techniques,

and other industries, as well as costs that have been saved such as rapid product development and automation. These are in

by moving the expo from Chicago to Orlando, Florida. addition to other technology pavilions returning after 2009. They

“Many exhibitors are taking bigger booths than they did at our include pavilions focusing on advanced materials, bioplastics,

2009 show in Chicago and plan to operate more equipment on energy efficiency and conservation, sustainability, thermoforming,

the show floor. They’ve told us that the lower costs of exhibiting fluoropolymers, and moldmaking.

in Orlando have enabled them to justify investing in more space, Throughout the NPE2012 trade show and the co-located

while the simpler logistics and work rules there have encouraged events, two innovative technology sectors will be more strongly

them to bring more machinery,” said Gene Sanders, SPI senior

vice president in charge of trade shows and conferences.

The triennial event is solely owned and produced by SPI: The

present than ever before at NPE. One of these will be bioplastics,

which have been the target of extensive new investment and

product development since NPE2009. The other will be alternative

GEICO’S CODE BE INNOVATIVE

Plastics Industry Trade Association, and will run from April 1 to energy systems, including new battery systems for automotive, C



April 5, 2012. The event is attracting a growing presence from the plastics for use by designers of wind turbines, and films, sheets,

M

automotive sector, which is switching to plastics in order to reduce sealants, and other components for photovoltaic energy systems.

weight. Fuel tanks, wire harnesses, instrument panels, and even new AI: How do you think the change of location has helped Y





molded windshields will be at the show. SPI is expecting a “surge” in exhibitors and attendees? CM



visitors from countries like China and Brazil for the NPE2012 event. Carteaux: Exhibitors have already purchased more exhibit

At NPE2009, 228 exhibitors came from China, including companies space than was occupied at NPE2009. The reason for this

We are a strong innovation-oriented

MY







in four Chinese-sponsored multi-exhibitor pavilions—the most such enthusiastic response is that, in comparison with Chicago, Orlando CY





pavilions ever at an NPE. Similarly, an increased number of

Brazilian plastics professionals will be at NPE2012 to find

provides cost and logistical advantages. A systematic

comparison by SPI has indicated that the move to

CMY business constantly integrating new

ways to increase productivity, create new product Orlando makes possible these average savings: K

technologies and methods to satisfy

values, and expand business with companies

from around the world, says SPI.

48% on utilities for booths; 19% on on-site hauling

(“drayage”) and rigging services for exhibitors;

our customer’s demands while

23% on lodging; and 11% on travel.

Savings on travel, food, and lodging

building a better future and

Bill Carteaux, will benefit attendees as well. These concentrating our efforts in advanced

SPI president and CEO. economies, combined with the greater

proximity of Orlando to Latin America,

energy saving and enviromentally

seem certain to result in a significant sustainable solutions.

Automotive Industries (AI) asked Bill increase in Latin American attendance.

Carteaux, president and CEO of SPI: At recent NPEs, Latin Americans have

The Plastics Industry Trade Association, already accounted for more than one-fourth

to describe some of the innovations for of international attendance. The relocation to

NPE2012 – apart from the new venue. Orlando strongly favors further growth. Orlando is Pardis Innovation Center is Geico’s R&D facility where the latest technologies

Carteaux: SPI has expanded the “Technology served by nonstop flights from twelve Latin American are developed and experimented in order to satisfy Customers’ critical

expectations.

Central” concept that it introduced at NPE2009. Technology destinations, and there are 65 direct flights to Miami from

Central will also feature a Technology Theater, where exhibitors destinations in Latin America and the Caribbean. Airfare and travel

can schedule 30-minute presentations, product demonstrations, times are less than flights to Chicago. In addition to this influx from

or seminars. A large segment of the exhibit floor and a wealth Latin America, we are looking forward to once again attracting

of adjacent meeting space will be dedicated to displaying or international attendees from more than 100 countries elsewhere

presenting new technology in formats that put multiple groupings in the world.

of innovative developments together in one place. We have AI: What are some of the automotive-related technologies

added new specialized technology pavilions, each made up of that will be highlighted at NPE2012?

multiple exhibitors involved in a particular industry sector. They Carteaux: It is difficult to generalize about innovative plastics

will include those for flexible vinyl, medical plastics, and adhesives technologies for automotive, simply because the components in www.geico-spa.com

and sealants. Another new pavilion, called the Processors which plastics are used, or could be used, are vast in number



Original coating plants for the vehicle industry.

72 to read full version of AI stories go to www.ai-online.com

marine propulsion power generation

automotive commercial vehicles







Tmax products:

approved by

FAR LEFT: Items leading OEM/



Applied thermal design.

Molded on NPE Tier1!

Exhibit Floor.







Exhaust gas system

LEFT: Collected

Scrap Stored at NPE

Recycling Center.





and diverse in their performance requirements. Certain themes, productivity, enhance product quality and consistency, and, Exhaust emission standard

Exhaust gas temperature

however, will be evident in any NPE2012 exhibit or conference wherever possible, develop capabilities and services that set them

presentation that focuses on automotive. apart from competing companies. NPE2012 will be a showcase

Obviously one of these will be weight reduction for fuel for the latest plastics technologies available for helping to meet

economy. Similarly, automotive manufacturers can always expect

to discover new technologies that save on component production

costs through such techniques as parts consolidation, multi-

these goals. The next opportunity to see all these developments in

one place at one time will not come along in the United States until

three years later—at NPE2015.

Acoustics

material molding or extrusion, and elimination of painting in favor of

cosmetically enhanced part surfaces. Typically these innovations

require improvements in raw materials, processing techniques,

AI: What is the current state of the plastics industry in

the US and what role does it play in the automotive sector?

Carteaux: Virtually every type of plastics material system is in

Thermamax!

and toolmaking—all of which will be amply represented at commercial use for automotive components, involving practically

NPE2012. Specific innovations for automotive applications that every type of processing equipment. More than 330 pounds of

one can expect to discover at NPE2012 include new biopolymer plastics are used in the typical vehicle.

compounds that can help automotive manufacturers increase the Plastics is the third-largest US manufacturing industry, with

“green’ content of vehicles. Replacement of the diverse materials current annualized shipments amounting to around $350-billion.

often found in multi-part components with single-material systems In 2009 (the last year for which whole-year figures are available),

that facilitate recycling, or systems that are recyclable because suppliers to the industry accounted for an additional $73-billion

they consist of compatible polymers. Replacement of EPDM and in shipments. The total number of persons employed by the

other thermoset rubbers with TPEs, reducing fabrication costs plastics products and supply sectors was 1.4 million jobs.

and permitting parts consolidation through coextrusion or over- There were 17,348 plastics facilities operating throughout the

molding with other thermoplastics. country. Manufacturers of plastics products spent $7.8-billion

AI: What are some of the reasons why NPE2012 is a on capital equipment.

must-attend for automotive companies? AI: How will NPE2012 help address the new challenges

Carteaux: Among companies that design and manufacture facing the industry?

parts or subassemblies for automotive use, competition is Carteaux: NPE2012 will provide attendees with an opportunity

more intense than ever. Yes, the industry is recovering, but it is to discover the latest technologies for solving problems involving

a slow recovery, and in North America especially, the market for cost control, productivity, vehicle weight reduction, sustainability,

automotive components is still smaller than it was before the great passenger safety, new consumer values, proliferation of electronic

recession of 2007-2009. To stay competitive in this market— devices, and other critical factors for competing in today’s

better, to prevail in it—manufacturers need to cut costs, boost automotive industry. AI





Exhaust emission standards? Part of the solution is in the exhaust system! Combine

Parallel events









www.fischerziegler.com

standards compliance with 100% performance, optimum balance and excellent design!

Leading developers and manufacturers use our insulation technologies to retain

Three events will be co-located with NPE2012.

ANTEC 2012, sponsored by the Society of Plastics Engineers (SPE), is the world’s largest plastics technical exhaust gas energy and to reduce undesirable noise on downstream components (SCR,

conference. The 2011 edition of this annual event provided attendees from 40 countries with access to more than DOC, DPF, etc.). Thermamax can help you too. Just give us a call!

700 original, peer-reviewed technical presentations covering every sector of the plastics industry.

SPI’s ‘Business of Plastics’ conference will begin with a keynote presentation on Sunday, April 1 and be followed by

+49 621 32235-0 | www.thermamax.com

half-day sessions on Monday through Thursday. Presenters will focus on the business implications of their topics rather

than conducting a technical discussion. SPI is planning for presentations on timely topics of broad interest to plastics

professionals, such as bioplastics, sustainability, medical and healthcare markets, and issues involving regulation,

safety, or industry advocacy. THERMAMAX.

The 2nd International Plastics Design Competition is open to entrants from all nations. The competition will showcase Leading technologies supporting exhaust gas treatment.

innovative applications by designers and processors serving appliance, automotive, medical device, packaging,

and other consumer and industrial markets. AI



( Understanding Temperature. )

74 to read full version of AI stories go to www.ai-online.com

innovation



Taking pole

position in the race to develop

DPF technology ahead

of regulations By: Lenny Case





Increasingly stringent emission regulations are forcing OEMs to redesign DPF and catalyst

technology in the middle of a model life, and also for after-market support of their vehicles Close-up showing the honeycomb structure and washcoat

already on the road. of a Liqtech substrate.



One of the specialists in the fast-track development of DPFs and says. The extra storage capacity of the filter secures a lower asked what makes the company’s ceramic membranes and

oxidation catalysts is Danish firm Liqtech International (formerly back-pressure over time, increases the time between service catalytic coating solutions innovative.

CoMeTas). It develops, manufactures and markets catalysts and intervals and thereby the lifetime of the filter. Mathiasen: Liqtech International differentiates itself to its

diesel particulate filters for engine emission control for both the “We are well aware that there is strong competition from larger competitors through a very flexible product development

OEM and after markets. other materials, such as cordierite or alumina titanate, and that approach, which enables us to customize products very fast.

Liqtech has developed a portfolio of catalyzed DPFs (cDPF) regular SiC filters for many applications are “over-engineered” That goes for both the diesel particulate filters, which can

based on its proprietary washcoat technology and metal in terms of durability. However, our new asymmetric design, be specifically dimensioned and produced for a particular

oxide composition. The coating can be optimized for low soot with optimized hydraulic diameters in the channels and excess application, and also for the catalysts which can be modified to

combustion temperature, catering for low and high NO2 levels. storage capacity, combines low initial back-pressure, with meet exact customer requirements.

High NO2 ratios are required for optimal function in durability and constant lower back-pressure even Examples of Liqtech’s International catalyst portfolio. AI: Tell us about the work Liqtech is doing developing

an SCR system. In the retrofit segment, Liqtech when the filter is loaded with soot and ash,” says ceramics and catalysts.

recommends zone coatings which make it the company. Mathiasen: Our Innovation and Technology group is really

possible to balance regeneration and NO2 For the automotive segment, the company the heart of our business and the most important key to our past,

performance according to the specific also offers a range of pre-catalysts for DPF present and future growth. There is a large demand in the market

systems. The portfolio includes pre-catalysts for fast, flexible and reliable development, that allows customers

for CRT, cCRT, FBC and post-injection to bring a unique product to the market based on their specific

Dina Mathiasen, Head of systems.. “Our current focus is on metal needs in terms of dimensioning and formulations. We are currently

Emission Technologies Division, pre-catalyst for HC-injection systems working on a variety of different products that we are looking

Liqtech International. for OEM use. Generally, our binder forward to presenting to the market.

technology for metal substrates can be AI: How would you describe Liqtech’s automotive

applied to all oxidation catalysts, including capabilities and future objectives?

hydrolysis catalysts for SCR. In 2012, our Mathiasen: Our core competency is definitely within smaller,

requirements of the region in which the state-of-the-art SCR catalyst will also be specialized applications.

vehicle is being sold and used. “It is our commercially available,” says the company. AI: What are Liqtech’s plans for further global growth?

philosophy that for all our customers we verify It has built up extensive expertise and Mathiasen: The current plans include a catalyst production

whether or not our standard coatings are the knowledge in designing 3-way catalysts for the facility in North America early in 2012, and hopefully in East Asia

right choice. We are happy to make the necessary aftermarket in Europe and South America. All catalysts Researchers in the Liqtech laboratories. for both diesel particulate filters and catalysts by the end of the

modifications to the formulation to secure it fits the system are based on the company’s wash-coating formulation same year. Besides that, we are expanding our sales activities to

perfectly,” says the company. and production. We aim to provide recommendations and quotes is a plug and forget solution for simple reduction of odor and ensure local presence in all our strategic markets. However, for

“The Liqtech International portfolio includes SiC DPFs, and within 48 hours and general lead time on prototypes after receiving smoke in applications where a DPF can not be applied because of our catalyst products, we also respect that for some applications,

we are very proud to present our new asymmetric design. substrates is less than one week,” says the company. high sulfur levels,” says the company. situations and places, it is not feasible to do the production

From a back-pressure, durability and soot load capacity point “For regions with high-sulfur levels, we have developed a DOC Automotive Industries spoke to Dina Mathiasen, Head in-house and we also license our washcoat and production

of view this product will be attractive in many applications,” it Survivor coating with very high sulfur tolerance. The DOC Survivor of Emission Catalyst Division Liqtech International, and technology to new partners. AI





76 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 77

innovation

“As a supplier to a highly

technical industry, we must

Naturally more develop and supply products

which deliver real, tangible



efficient lubricants

benefits to our customers and

By: Lenny Case

ultimately to the consumer.

”

LEFT: Perfad 3000 Series - friction reduction graph.

Lubricants are playing an increasingly important role as continued toughening of global legislation

sets challenging targets that require components to retain key performance characteristics and

properties over extended periods of time.

AI: Give us an idea of the kind of R&D being done. the desired viscometric and noack properties it is necessary for Later in 2011, we plan to launch some new products which can be

High-performance base fluids and additives developed by Nottingham: Research and development is the key to the formulators to use synthetic base fluids such as Gp III and used as seal swell agents. These products will be based on renewable

UK-based Croda Lubricants, for example, offer qualities such as future growth and prosperity. Croda is a global company with Group IV base fluids, often in combination with synthetic esters. and sustainable raw materials and will deliver similar or better seal swell

reduced coefficient of friction, excellent anti-wear capability, zero or manufacturing, sales offices and research laboratory facilities Esters are of interest to formulators due to their high viscosity performance than phthalate esters. For many years phthalates have

reduced sulfated ash, phosphorus and sulfur (zero or low SAPS), across the globe, including the USA, Brazil, Japan, China, index properties, their excellent low temperature flow properties been used in the lubricants industry, but their use is coming under ever-

low volatility, superior thermal stability, increased oxidation stability, Singapore, India, France, Holland, Spain and the UK. Croda and their outstanding Noack volatility properties. increasing scrutiny due to their poor toxicological and environmental

high viscosity indices, clean burn and low deposit formation. Lubricants is one of nine business units operated by Croda, and AI: What is the significance of Croda getting the HX-1 profiles. Croda’s new products will be non-harmful to humans and

Automotive Industries (AI) asked Chris Nottingham, our research facilities are located in New Castle Delaware, Hull UK registration for the Priolube 3970? aquatic organisms and will be substantially biodegradable.

vice president of Croda Lubricants to tell us more about and at Cowick Hall, UK. Nottingham: For many years, formulators of lubricants for use We are also continuing to develop products for the industrial

the technology. At these facilities we have synthesis labs for the development in the food preparation industry, for example, bakeries, have had to lubricants market sector. Biodegradability, low environmental

Nottingham: Croda is very proud of the fact that it is a world and preparation of new products, and applications laboratories rely on mineral oil and PAOs as base fluids. Whilst these base fluids and human toxicity, controlling friction and minimizing wear are

leader in specialty chemicals derived from natural and sustainable in which we can evaluate the intrinsic properties of our products, have their uses, they also have their limitations. For example, they all key desirables in applications such as wind turbine lubricants,

raw materials. As a supplier to a highly technical industry, we must across a wide range of industrial and automotive applications, do not possess the desired oxidation and thermal stability properties metal rolling fluids, metal cutting and deformation fluids and

develop and supply products which deliver real, tangible benefits including engine oils and transmission fluids (for example, wet required for use in higher temperature chain lubrication. hydraulic fluids. We will take the knowledge that we have gained

to our customers and ultimately to the consumer. This is achieved clutch fluids for dual clutch transmissions). Priolube 3970 is an important step forward in that it is an from automotive applications and adapt our ideas and products

through a combination of a deep understanding of the technical AI: Tell us about Croda’s natural solutions for friction oxidatively and thermally stable ester and it has proven to be the to deliver solutions and competitive advantage to our industrial

and regulatory needs that are placed upon the industry through modification, viscosity and anti-corrosion. first of a number of ester base fluids that are considered acceptable lubricant customers.

the introduction of new specifications and environmental Nottingham: More than 70% of the raw materials by the NSF as HX-1 ingredients. Since registering Priolube 3970 AI: How would you describe Croda Lubricants’ automotive

regulations, and through close collaboration with our used in our products are renewable. Croda Croda has been successful in gaining H1-X approval from the NSF identity and personality?

customers, namely, the lubricating oil formulators. Lubricants has for many years been a leader in for Priolube 3966, Priolube 3999. Croda has also been successful Nottingham: Ask an engine oil formulator what they want,

the development of products which are derived in having one of its anti-corrosion additives approved as an HX-1 and they’ll usually tell you lower friction and friction durability.

from renewable raw materials, but we also ingredient, namely Crodasinic O. Ask a transmission fluid formulator what they want and they’ll tell

consider the impact that our products may AI: What are some of the future natural solutions you you controlled friction within defined limits and friction durability.

have on the natural environment. Many of expect to launch? At Croda we think about how we can assist our customers in

Chris Nottingham, our products are therefore designed to Nottingham: The main industry driver for the foreseeable controlling and managing the frictional and wear properties of their

vice president of Croda be biodegradable and have low toxicity future is improving fuel economy and reducing emissions for formulations.

Lubricants. towards aquatic organisms. In addition to vehicles powered by internal combustion engines. AI: Tell us about your new tagline and identity “Leading

being a leading supplier of friction modifiers, Croda will continue to work on friction modifiers and low the Way Naturally”.

Croda has a very broad range of esters (more viscosity base fluids for both engine oils and for transmission Nottingham: “Leading the way naturally” is a reflection of

than 100) which can be used as lubricant fluids. Whilst positive strides have been made in the industry in both our corporate strategy and the strategy of Croda’s Lubricants

An example of our current new product base fluids and lubricity additives, perhaps the recent years, there is still a desire to reduce the amount of sulfated business. Croda Lubricants is an innovator. We have a long track

development activities includes the design of new, broadest range of any supplier worldwide. ash, phosphorus and sulfur (SAPs) that is used in engine oils. record of being an industry leader in many of our chosen markets, be

unique polymeric friction modifiers, Perfad 3000 and Each product is different, and is tuned for a Croda will therefore continue to develop new SAPs-free products they automotive applications or industrial applications. Whilst other

Perfad 3050. These two products can reduce the frictional particular application. For example, low viscosity esters that can be used to reduce friction and to reduce wear in engines, companies may follow a strategy of imitation through the manufacture

characteristics of engines oils to levels previously unachievable can be used in the formulation of low viscosity engine oils. In the and products that can be used to enhance the performance of of me-too products, Croda will continue to develop new and ground

with conventional organic friction modifiers, which results in search for fuel efficiency, the OEMs are demanding lower viscosity conventional additives, such as ZDDP. In the area of transmission breaking products and to work closely with our customers to find

significant improvements in fuel economy and reduced exhaust engine oils, for example, 0W or 5W oils, to reduce energy loss fluids, we will continue to develop friction modifiers and lubricant solutions to their problems. We are constantly looking to develop

emissions. Croda’s new polymeric friction modifiers may also through churning of the lubricating oil in the engine. base fluids that can be used to control friction and friction durability, new technologies and solutions to meet the changing needs of

provide increased engine durability through reduced wear, an area Conventional base oils, such as Group I and Group II mineral oils to ensure good fuel economy, equipment durability and driver the lubricants markets and we aim to do this by continuing to use

that we are exploring further. are not suitable for these new low viscosity engine oils. To achieve comfort through-out the lifetime of the vehicle. renewable and sustainable resources, responsibly. AI







78 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 79

Catalytic SCR

innovation

technology goes The making of

mobile By: Lenny Case

Porzellanfabrik

Porzellanfabrik Frauenthal was founded in 1921 and

is a specialist in honey-comb ceramics. Initially,

Designers and manufacturers of catalytic and ceramic honeycombs and plates are being challenged

the company manufactured high voltage insulators

by the adoption of selective catalytic reduction (SCR) technology in vehicles after its success in sta- made of porcelain.

tionary applications. It was sold to the Swedish EUROC group, and in

1985 started manufacturing SCR catalysts. In 1990, a

“The real challenge for vehicles was the development of a showed that our homogeneous, vanadium containing catalysts

management-buy-out took place. Through strategic

new geometry. An extreme increase in cell density was needed did not damage aquatic organisms or cause cancer in approved

expansion and acquisition the new brand name CERAM

to accommodate a reasonable catalyst volume in the limited test series,” says the company.

was established. The CERAM group is now the world’s

space of a vehicle. Pioneering work was done in manufacturing “Of course, the automotive market of these products is strongly

second largest manufacturer of porcelain insulators. In

the new tools with ten thousands of high precision cells instead dependent on the political landscape. Wherever the legal situation

2001, the insulator division was sold to American investor

of a few hundred for stationary operations. All this R&D had to be is requiring tougher emission limitation, more vanadium-containing

group The Riverside Company and Porzellanfabrik

accompanied by adjusting the necessary processing parameters catalysts will be needed. This is the case particularly in those markets

Frauenthal was taken over by Frauenthal Holding. Since

of the catalytic mass,” according to Porzellanfabrik Frauenthal, where only high sulfur containing fuel is available. Our type of catalyst

then, catalysts and non-catalytic honeycombs have

which is part of the Austrian Frauenthal Holding AG. is completely resistant to sulfur compounds. For this reason, we see

become the company’s main business. The Austrian

Porzellanfabrik’s SCR diesel catalyst, developed for commercial a market boom in the emerging markets within the next a few years”,

group Frauenthal Holding is a group of industrial

vehicles, successfully entered into series production in 2005. says newly-appointed managing director Chaohong Zhu.

companies with 13 production sites in Europe, and

Diesel catalysts yield a nitric oxide reduction of up to 90% in the Automotive Industries (AI) asked Zhu what plans the

sales and representative offices in the United States,

exhaust gases of today’s diesel engines. The various company had to popularize SCR technology.

China and South Korea. The Frauenthal Group, headed

forms of usage range from low-temperature Zhu: As a company used to working with

by Frauenthal Holding AG, which has three divisions -

reduction of nitric oxides up to full load operation OEMs, as well as canners, we regularly inform

industrial Honeycombs, comprising Porzellanfabrik

in motor vehicles. This SCR-system requires our existing and potential clients about results Porzellanfabrik Frauenthal is committed to green technology.

Frauenthal, which produces ceramic honeycombs that

a mix of an additional reducing agent. we’ve achieved and what we are planning

are used as SCR catalyzers for flue gas purification at

to do in the next steps. A lot of fruitful

thermal power stations, waste incinerators and other

contacts also came through “word-of-

large combustion plants, as well as heat exchangers and

Chaohong Zhu, mouth-recommendations”. In parallel

foundry filters.

managing director with this, we intend to actively participate

The Automotive Components Division, consists of truck

of Porzellanfabrik in relevant government projects during

component suppliers, which manufacture leaf springs,

Frauenthal. their preparation phase, and in other

suspension arms, stabilizers, braking system air reservoirs,

related professional organizations.

U-Bolts and diesel catalysts for automotive manufacturers

AI: What are some of the new

An example is a 32.5% urea solution in Europe. Finally, there is the Wholesale Plumbing Supplies,

products launched by your company

marketed under the trade name “AdBlue”. made up of the SHT Haustechnik Group, which distributes

recently and what impact have they had

For really tough conditions such as very hot a number of third-party brands in Austria, as well as its own

on the market?

regeneration temperatures behind particle traps, Prisma and SaniMeister brands. AI

Zhu: Developing temperature stabilized

the company has developed a stabilized new catalyst catalysts recipes combined with bigger diameters, high

type. “Additionally, we fully investigate the limits of our cell densities and thin walls are the most challenging projects Porzellanfabrik Frauenthal’s variety of catalyst diameters.

traditional series catalysts as they are well proven in all conditions. we have been working on. Meanwhile, we are well on our way to

The advantage of SCR-systems for automotive applications lies in produce diameters of up to 13” in 400cpsi – fully homogenous for this reason that we continue investing in resourcing for our for development programs – especially if those are linked with

the considerable reduction of fuel consumption up to 7%, as it is extruded - not too far in the future. Research and Development Team and in our production capacity. customized new catalyst formulations. But, we are flexible enough

possible to efficiently optimize diesel engines,” says the company. AI: Where is the fastest growth for SCR catalyst technology? AI: Please tell us a little about Porzellanfabrik Frauenthal’s for any reasonable adaptation and modification. Our goal is

SCR-catalysts are homogeneous extruded honeycombs Zhu: In our opinion, the fastest growth will come from emerging plans for further expansion across the world? customer satisfaction. Our reaction time is fast!

containing titanium, tungsten and vanadium. They are the leading markets like Brazil, Russia, China and India. With the upcoming Zhu: Whenever the necessary volume for the smallest self- AI: What are some of the new technologies/products in

technology for nitrogen oxide reduction in stationary applications emission regulations (similar to Euro V in Europe) big markets for sustaining production unit has been established, we are prepared the pipeline from your company?

particularly in Japan and US and, according to the company, SCR will be created. The question for us now is not whether, but to follow our clients to the relative market. We are, of course, Zhu: Besides dimensional development, we are developing

the market is still growing. “There is a lot of public discussions when! The timing for the big market demand depends mainly on flexible enough to work with which local system suppliers in new catalyst recipes capable of delivering good performance in

about the possible loss of vanadium in the environment if catalysts the regulatory situation in the related markets. regions in which the OEMs are active. This is particularly important sophisticated EURO VI/US 2010 exhaust after-treatment systems

are installed into mufflers of vehicles. We take our responsibility AI: How does your company adapt technologies to in the emerging markets. in regards to NOx performance – no matter if the performance

seriously, and have comprehensive projects running at well known different regions? AI: What are some of the current issues facing SCR is required at low or high exhaust gas temperatures. At the end

and specialized external organizations. Toxicological behavior Zhu: As a flexible company we are used to follow our catalyst technology, and how is Porzellanfabrik Frauenthal of the day our customers must have the choice out of several

of the catalyst as a whole, as well as biologic influence of the customers´ requirements. This gives them the freedom to choose dealing with these issues? solutions to find the optimum for their individual application – and

separate ingredients, has been investigated. The results clearly solid, robust and cost effective technical solutions. It is precisely Zhu: One of the most challenging issues is the short timelines this is what we are targeting and striving for. AI



80 to read full version of AI stories go to www.ai-online.com Automotive I n d u s t r i e s 81

Successful Superior Supreme Supportive Sure Surprising Sustainable Swift Songwon Scientific Secure Select Seamless Sensational Sensible Serious Skilled Service Sign





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at times of crisis

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Salient

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an announcement

financial arrangements that can easily be disrupted by external (CDS) market – spiked on March 15th followingSincere Skilled Smart Solid Solutions Solving Sophisticated Special Specific Speedy Spirited Splendid Spontaneous Stable Steadfast Stepchanging Sterling Stew

circumstances. Toyota’s experience neatly demonstrates the by TEPCO – the operator of Fukushima nuclear power plant which Superior Supreme Supportive Sure Surprising Sustainable Swift Songwon Scientific Secure Select Seamless Sensational Sensible Serious Service Signific

breadth of impact from an event of the scale of Japan’s March was shut down in the wake of the tsunami – that it was to initiate

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Swift with Japan’s

impact events – such as a tsunami or sovereign debt crisis – it still at levels below what would usually be associated Songwon Scientific Secure Select Seamless Sensational Sensible Serious Service Significant Sincere Skilled Smart Solid Solutions Solving Sophisticat

is critical that counterparties have access to a sufficient breadth sovereign credit rating. Steadfast Stepchanging Sterling Stewardship Strategic Striking Strong Studious Sturdy Successful Superior Supreme Supportive Sure Surprising Susta

and depth of financial information, and that these datasets are Exposure to related industries and sectors

sufficiently integrated to allow for what we call cross-asset class Sensational Sensible Serious Service Significant Sincere

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Exposure to an entity’s securities in Miyagi Prefecture, one of the worst-affected areas alongside Skilled Smart Solid Solutions

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Defining exposure to a company the size of Toyota is complex. Fukushima and Iwate Prefectures. The damage led to significant

Toyota is the ultimate obligor to over 1,000 securities, and many of production cuts that – certainly, in the opinion of analysts from

these are issued by its subsidiaries, or their subsidiaries. Some are

even issued by a separate entity but linked to Toyota by obligation.

Standard & Poor’s – could erode Japanese automakers’ market

shares and competitive positions. Estimates suggest that Toyota

Songnox®

To resolve this issue, analysts require access to a large universe will suffer a production loss as high as 400,000 vehicles – adding Basic and Specialty Antioxidants

of securities data. This can be achieved through products such further volatility to the company’s probability of default on its fixed-

as CUSIP Global Services’ CABRE Directory, which organizes income securities. Songnox® oPS

securities according to issuers, obligors and counterparties. Exposure to downgrades One pack systems

Using this data counterparties are then able to instantly account While credit ratings and measures of probability of default speak

for their exposure in the event of a crisis. As we saw with Toyota, to the longer term prospects for an entity’s credit risk, CDS spreads Songlight®

every security linked to an entity can be heavily impacted. For and share prices speak to shorter term market and volatility risk. Hindered Amine Light Stabilizers

instance, the company’s share price fell 21% by March 15th, while Recent events show these indicators can influence or be influenced

the risk premium on much of its issued debt in the bond markets shot by the performance of each other. The most robust analysis now SongSorb®

upwards. Meanwhile, Japan’s sovereign credit rating was revised by understands that exposure to market sentiment as a response to UV Light Absorbers

Standard & Poor’s to a negative outlook and the cost of insuring these triggers must be considered alongside exposure to the events

against a Japanese sovereign default dramatically increased. themselves. Certainly, counterparties and credit analysts must Songbrite™

Exposure to the sovereign understand that every element of exposure has consequences Optical Brighteners

Many corporates are significantly affected by the credit health of for the entire company and for the company’s counterparties. By

the states they operate in – especially if, like Toyota, they are highly extension, missing or inaccurate data may also represent exposure. SongStab™

centralized businesses, with much of their operations – as well as In order to effectively mitigate the dynamic nature of risk, the ability Acid Scavengers

those of its counterparties – based in one country. Six weeks following to look across an entity’s entire financial profile is therefore essential

the tsunami, and as a result of the likely negative impact to Japan’s – exploiting and cross-referencing all available data. AI SongStab™

PVC Stabilizers

This chart shows SongCat™

the correlation Tin Intermediates

between Toyota’s

share price SongCiZer™

and probability Plasticizers

of default.



www.songwonind.com

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Keeping heat LiqTech International Emission Technologies

innovation





diesel particulate filters and emission catalysts





and sound inside

the system By: Ed Richardson





Technology developed to control heat and sound for luxury heat away from the car body. The breakthrough is that we have

sports cars is now going mainstream as OEMs and their developed a way of providing better insulation performance with

Tier 1 suppliers strive to comply with more stringent emis- thinner insulation. Internal temperatures of up to 1,000 degrees “We are a young, dynamic company with an im-

sion regulations. C are kept to an external 100 degrees C by just few millimeters pressive track record and growth rates, but we still

Mannheim Germany – based Thermamax Hochtemper- of insulation This means we improve performance, reduce weight

aturdämmungen is one of Europe’s leading suppliers of high- and keep more heat in the exhaust – which reduces emissions and remain true to our core values and commitment to

temperature insulation systems. Founded in 1976, its products improves fuel consumption. This solves a number of problems, the supply customized products fast.”

are found in most street-legal high-performance sports most important of which is the performance of the exhaust

cars - and a growing number of passenger vehicles. system, which relies on high temperatures in order to

“Through the early integration of the high-temper- meet the emission standards. Another benefit to CEO of Liqtech International, Lasse Andreassen

ature and acoustic insulation in the planning the OEMs is that designers and engineers now

process, our customers save both develop- have more space for other components.

ment time and costs,” says Thermamax. What impact are the new emission

regulations are having on the industry,

and on Thermamax?

Markus Formanski, Formanski: It is very exciting. The

Thermamax business unit regulations have transformed a “nice to

manager (automotive). have” product into a “must have” product.

In many applications, the exhaust system

will only meet the standards if fitted with

The company also helps its customers our insulation products. What this means

understand how individual components for Thermamax is that we have gone from a

behave when subjected to heat and how niche supplier to high-end street-legal sports

the component and the insulation harmonize cars to a much wider range of vehicles. We

under full load by offering field simulation of the have invested in people, systems and equipment

thermal conditions in the exhaust system using various in order to meet this increased demand.

insulation constructions in the in-house hot-gas test facility or AI: How do your solutions help automotive OEMs

thermographic recordings. meet the increasingly stringent emission norms?

In response to the need to reduce exhaust emissions across Formanski: OEMs are happy to deal with us because we have

the spectrum in Europe and other markets, Thermamax has a very long history. We continued to invest in new technologies

invested over Euro 2.4-million in new machines and technologies. and systems even during the downturn. Their attitude to us is

A large percentage of its yearly turnover is channeled back into changing because they know that some of their systems will not

research and development in order to improve products and work without our solutions.

employee training. AI: Are there any unique challenges?

Automotive Industries (AI) asked Markus Formanski, Formanski: OEMs sometimes do not see the big picture – by Denmark USA Korea Brazil

Thermamax business unit manager (automotive) what was keeping the heat inside the pipe, we are impacting on the whole

LiqTech International A/S LiqTech North America, Inc. Liqtech Asia Av. Das Américas 19.019

unique about their system. car environment. The insulation also helps deaden the sound

Formanski: Basically, the principal is that we retain the heat entering the cabin. In some companies, this leads to a failure Industriparken 22 C 1804 Buerkle Road 160-5, Seokchon-Dong, Recreio dos Bandeirantes

inside the pipe – unlike the conventional heat shield, which keeps to adopt the technology quickly because of inter-departmental 2750 Ballerup, Denmark MN 55110, White Bear Lake, Songpa-ku Rio de Janeiro, Brazil

+45 44986000 USA Seoul, 138-844, Korea + 55 21 24900715

sales@liqtech.com +1 651 7735850 +82 24137992 jan@cometas.com.br

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Exhaust temperature >800°C, surface temperature

on insulation 500°C. Limited available space and high reduced by a factor of three. Limited available space

demands on avoidance of heat loss in order to optimize (no beading/fold), many indentations in the insulation

the light-off characteristics. allowing 0mm, flush with component.





differences. One department does not want to have to pay for a

solution which results in savings for another department.

AI: Let’s talk technology again – what is different about

your manufacturing processes?

Formanski: We are different to most of competitors in that

we start with the design of the fiber. Other companies buy in

the fiber and build their solutions around what is available in the

market-place. We do not design the fibers by ourselves, but work

closely with our customers to come up with a solution. We have

almost everything in-house, starting from foundation research to

prototyping to the production lines for producing high volumes of

textiles and metal components.

AI: How do you work with Tier 1 and other suppliers?

Formanski: We are very flexible, and set up the logistics line

to suit our customers. In some cases we deliver the materials to

the Tier 1 supplier, who then applies them to the parts. In others Cone insulation‚ “Integraldämmung” on SCR catalyst.

we supply the insulation. We can also supply fully assembled System temp. 750°C. Objective: maintain system

components just-in-time to the Tier 1 customer. temperature and optimize light-off.

AI: How does the technology assist with sound deadening?

Formanski: We have developed a sound deadening product In April 2011, Thermamax was presented with the Caterpillar

that is heat resistant up to 1,000 degrees C. Our products can also Supplier Quality Award for reliability and the excellent quality of the

combine sound and heat deadening properties, and are tuned to insulation components supplied. Our processes and components

the frequency of noise generated by the component. Gas and are certified to ISO/TS 16949:2009; DIN EN ISO 9001:2008 and

diesel engines produce different frequencies of noise. We achieve module D of code 96/98/EG of ship’s gear; and EN ISO 3834-2

this by using different layers – each of which has its own task, such (welding process) quality standards, as well as the ISO14001:2008

as reducing noise, absorbing or reflecting heat. The technology environmental standard. In addition, Thermamax is a member of

is so efficient that an OEM project team we were working with to VDA, VDMA, and supplies a number of leading companies.

reduce the ambient noise in a diesel-powered car was pleasantly AI: What are your plans to expand your business to

surprised when we were able to reduce levels in a current project meet demand?

by up to 4dB at once – they were used to dealing in increments of Formanski: Our Mannheim plant is located in the centre

0.1dB or 0.2dB. of Europe, and is being expanded to meet demand across the

AI: Tell us about Thermamax’ quality control standards. continent. We are able to produce and assemble high volumes for

Formanski: OEMs and Tier 1 companies who work with us automotive series components such as manifolds, turbochargers,

for the first time are pleasantly surprised at the level of quality – pipes etc. High-end 3-d laser robots are being installed in order to

from the functional prototype in early stage. We are often told that meet the required production and quality levels. We have the ability to

the prototypes look like serial production parts. Quality begins with grow further organically – we have the people and the space. In the

the sourcing of raw materials, and constant in-house testing. We United States, our Chicago plant is ready for serial production, with

have our own test benches for the materials and designs in order initial capacity of 100 000 units a year. And, when there is a need to

to reduce the time to market. expand, we do it. We will respond to the needs of our customers. AI





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