2004 DETROIT AUTOMOTIVE TECHNOLOGY by WesleyL

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									2004 DETROIT AUTOMOTIVE TECHNOLOGY
          CONFERENCE & EXPOSITION




April 17, 2004, Lawrence Technological University, Southfield, MI

                        Sponsored by




        Edited by Ming F. Shi and Sheng-Dong Liu
  2004 DETROIT AUTOMOTIVE TECHNOLOGY CONFERENCE

                        2004 年 底特律汽車技術研討會


                                        PREFACE
It is our pleasure to welcome you to our 2004 Detroit Automotive Technology Conference &
Exposition

The theme of our conference this year is “Advances in Automotive Technology and Career
Development”. The technical sessions cover automotive technologies in the areas of vehicle
noise & vibration, automotive electronics, packaging, six sigma quality system, superplasticity,
hybrid vehicles and auto and steel industry overview. Career development is one of the favored
topics for many Chinese American Engineers. This year’s luncheon program would feature a
keynote speech “Career Development for Chinese American Engineers”, delivered by Dr.
Dazong Wang of GM. In this speech, Dr. Wang would share his views on key elements of career
development and discuss logic framework of career development. The luncheon program also
includes the Ford DCEA Future Engineer Award and two outstanding high school scholarship
award ceremonies. As usual, Exhibitions and social hours for professional networking are also
featured in this conference.

This conference is the results of many weeks’ voluntary work of DCEA board members and
officers, technical presenters, invited speakers and many DCEA members. Lawrence
Technological University has graciously provided the conference facilities and all necessary
supports for this year’s conference. Financial contributions from DaimlerChrysler, Ford Motor
Company and General Motors Corporation are greatly appreciated.

I sincerely wish you have an enjoyable, educational and inspirational conference experience.


Ming F. Shi
President, Detroit Chinese Engineers Association

April 17, 2004




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  2004 DETROIT AUTOMOTIVE TECHNOLOGY CONFERENCE

                     2004 年 底特律汽車技術研討會
                      Lawrence Technological University
     Wayne Buell Management Building, 21000 West Ten Mile Road, Southfield, MI
      勞倫斯技術大學﹐韋恩布爾管理大樓﹐南地市﹐密執安州

                             Saturday, April 17, 2004
                           2004 年 4 月 17 日﹐星期六
                    Detroit Chinese Engineers Association

                            底特律中國工程師協會

Conference Chair:                  Ming F. Shi, US Steel
會議主席:                              石明峰,美钢联公司
Technical Program Chair:           Sheng-Dong Liu, Generalety, LLC
技術委員會主席:                           劉胜棟, 通用科技公司

Technical Program Committee:       Alan Luo, General Motors Corporation
技術委員會                              羅愛華﹐通用汽車公司
                                   Tai Chan, General Motors Corporation
                                   陳大倫, 通用汽車公司
                                   Hua He, General Motors Corporation
                                   何 華, 通用汽車公司
                                   Yilu Zhang, General Motors Corporation
                                   张一璐, 通用汽車公司
                                   Lifeng Xu, Ford Motor Company
                                   徐立峰, 福特汽車公司
                                   Paul Lin, Ford Motor Company
                                   林 群, 福特汽車公司
                                   Connie Yao, DaimlerChrysler Corporation
                                   姚峙聰, 戴莫勒-克萊斯勒汽車公司
                                   Sheila Wang, DaimlerChrysler Corporation
                                   王 倩, 戴莫勒-克萊斯勒汽車公司
                                   Hong Yuan, Denso Corporation
                                   袁 紅, 电装公司
                                   Jie Du, J.D. Power & Associates
                                   杜 杰, 捷迪鮑爾公司

Treasure & Site Coordinator: Kingman Yee, Lawrence Technological University
財務及場址協調                            余景文, 勞倫斯技術大學



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Conference Language:         English
大會語言:                        英語



                                Conference Program

                                        會議議程
9:30am – 10:00am                       Registration and Reception          Atrium
                                       會議注冊                                大廳

10:00AM – 12:00        SESSION I.                                          Room M218
                       分會 1.                                               M218 室
                       Chair: Sheng-Dong Liu, Generalety, LLC
                       主持人: 劉胜棟, 通用科技公司

10:00AM       Vehicle Noise and Vibration - An Overview
              汽车噪音与振动概述
              Hua He, Jian Pang, Gang Sheng, General Motors Corporation
              何华,庞剑,甚刚,通用汽車公司

10:30AM       Consumer Driven 6-Sigma: An Overview
              Larry Lloyd, Generalety, LLC
              基于消费者需求的6倍标准差系统概述
              Larry Lloyd, 通用科技公司

11:00AM       Superplasticity: From Aerospace to Automotive
              Xin Wu, Wayne State University
              超塑性概述 - 从航空业到汽车业
              吴新,伟恩州立大学

11:30AM       Auto/Steel Industry in China
              Ming F. Shi, US Steel Corporation
              中国汽车钢铁工业概述
              石明峰,美钢联公司

12:00 – 1:30pm         Luncheon Program                      University Dining Room
                       午餐會議                                  大學餐廳

   Introduction of DCEA Board, Officers and Guests           Ming F. Shi, President
   Welcome and Overview of DCEA in 2003                      Ming F. Shi
   Recognition of Retired Officers and President for 2003    Ming F. Shi
   Award Ceremony for “Ford Future Engineer Award”           Ford Representative
   Award Ceremony for “Outstanding High School Students”     Alan Luo, DCEA           Past
     President


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                                KEYNOTE SPEECH
                                      主题演讲
                                 Chair: Ming F. Shi
                           主持人: 石明峰,美钢联公司
                 “Career Development for Chinese American Engineers”
                               华裔工程师的职业发展
                      Dazong Wang, General Motors Corporation
                               汪大总,通用汽車公司


1:30PM – 3:00PM      SESSION II.                               Room M218
                     分會 2.                                     M218 室
                     Chair: Hua He, General Motors Corporation
                     主持人: 何華, 通用汽車公司
1:30PM        Hybrid Vehicles
              Goro Tamai, General Motors Powertrain
              混合动力汽车
              Goro Tamai, 通用汽車公司

2:00PM        Research and Education in MEMS and Optoelectronics Packaging in China
              Sheng Liu, Wayne State University
              中国微系统和光电封装的研究与教育
              劉胜, 伟恩州立大学

2:30PM        The Development of Automotive Electronics
              Ming Li, Motorola
              汽车电子产品的开发
              李茗,摩托罗拉公司

3:00pm –3:30pm       Networking (Beverages and Refreshments)           Atrium
                     自由活動 (飲料和甜點)                                      大廳

3:30pm                      Adjourn
                     休會

Registration (Lunch included): Free for DCEA members
注冊(包午餐)﹕                           DCEA 會員免費
                                   $10 for non-DCEA members
                                   非 DCEA 會員$10
                                   $25 for DCEA lifetime membership
                                   DCEA 終身會員費$25




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                       Pre-registration Contacts:
                          大會注冊聯系人:


Tai Chan     陳大倫             tai.chan@gm.com             586-986-2518
Jie Du       杜杰      Jie.Du@powerinfonet.com      248-312-4176
Hua He       何華      hua.he@gm.com                248-685-4055
Paul Lin     林群      qlin@ford.com                313-390-8788
Sheng-Dong Liu 劉胜棟   sliu@generalety.com          734-578-1818
Alan Luo     羅愛華             alan.luo@gm.com             586-986-8303
Ming Shi     石明峰             mfshi@uss.com               248-267-2610
Sheila Wang 王 倩      qw3@daimlerchrysler.com      248 576 5330
Lifeng Xu    徐立峰             lxu1@ford.com               313-323-6615
Connie Yao   姚峙聰             zy@daimlerchrysler.com      248-576-4076
Kingman Yee 余景文              yee@ltu.edu                 248-204-2582
Scarlet Yuan 袁紅      scarlet_yuan@denso.com       586-492-3976
Yilu Zhang   张一璐             yilu.zhang@gm.com           586-986-4717




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                                          SESSION I
                         Chair: Sheng-Dong Liu, Generalety, LLC

                          Vehicle Noise and Vibration - An Overview
                              Hua He, Jian Pang and Gang Sheng
                                  General Motors Corporation

Abstract:
Noise and vibration performance of a vehicle is increasingly linked to customer's perception of
vehicle quality and vehicle appeal. Sizable resources are spent in the industry, from OEMs to
suppliers, to achieve good N&V performance of vehicles. This presentation provides a
systematic overview of N&V in vehicles, the approaches adopted to improve N&V in vehicle
design and development. The presentation also discusses the challenges and opportunities of
N&V as more light-weight parts, hybrid systems and controls are used in vehicles.


Biography:
Dr. Hua He works at General Motors North America Vehicle Development Organization. He is
currently part of the GM Noise &Vibration Expert Team assigned to upfront early vehicle design
with an office in GM Warren Tech Center. Dr. Hua He has been working in the area of noise and
vibration for almost 20 years, with a mix of experience from three continents/countries: China,
Germany and the US. Dr. Hua He earned a Doctorate degree in Acoustics from Massachusetts
Institute of Technology. He is a certified Project Management Professional (PMP) and earned a
MBA degree while working at GM.

Dr. Hua He is actively involved in professional development and community service. He is
currently serving as the vice president of DCEA. He had served, for three years, as a board
director of the Chinese Association of Greater Detroit.


                            Consumer Driven 6-Sigma: An Overview
                                         Larry Lloyd
                                      Generalety, LLC

Abstract:
What is Consumer Driven 6-Sigma and why are so many Fortune 500 companies using it as an
effective method to significantly improve quality and reduce cost? Quite simply, 6-Sigma is a
tool that improves customer satisfaction and shareholder value by reducing variability in every
aspect of a company’s business. It builds on existing processes, provides additional statistical and
analytical tools and offers a disciplined approach that focuses on meeting customer expectations.
6-Sigma allows a company to determine where the variability is in a process and then provides
the tools to reduce variability and improve the process. It’s important to realize that 6-Sigma
ultimately improves the things most companies do anyway and therefore rapidly becomes part of
the company’s “DNA”. It’s not something else they do . . . it is what they do!

Successful 6-Sigma companies find that the methodology improves productivity and shareholder
value by reducing the variability that leads to rework within processes. The improved processes
result in improved customer satisfaction, which increases the likelihood of customers returning to


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buy another of the company’s products. The improved processes also reduce “hidden costs”
(inspections, reworks, recalls). Higher customer loyalty and reduced costs result in increased
shareholder value.

This presentation will provide insights into the following:
. Why it’s important to operate at a 6-Sigma level of quality
. Who uses 6-Sigma and how it’s use has escalated since Motorola’s initial efforts in 1982
. Organizational/philosophical changes that an organization must undergo to successfully
  implement and realize the benefits of 6-Sigma
. Some success stories

Biography:
Larry Lloyd graduated from General Motors Institute (now Kettering University) with a degree
in Mechanical Engineering in 1970. In 1974, he added an MBA from Wayne State University.

Following his graduation from GMI, Mr. Lloyd spent two years working in the Fisher Body
R&D Department at the GM Tech Center. In 1972, he joined Ford Motor Company as a Product
Design Engineer and in 1977 became a Supervisor in the Light Truck Vehicle Programs
Department. From 1972 to 1990, Mr. Lloyd worked in various Light Truck Engineering
departments, including Durability, Cooling and Exhaust Design/Development, and Aerostar
Body Structure Design. In 1988, he was apppointed Program Supervisor for the all-new 1990 1/2
Explorer, which involved design and development coordination and leadership of the vehicle
launch at Louisville, Kentucky.

In 1990, Mr. Lloyd was promoted to 1992 Ranger Program Manager. The program involved
major freshening and FMVSS 208/219 compliance. His next assignment (1992) was Compact
Truck Powertrain Programs Manager in which he coordinated design and development of
Explorer/Ranger/Aerostar 4.0L SOHC engine and A5LDE transmission programs in Germany,
England and France. These new powertrains were successfully launched at Job #1, 1995.

In October, 1994, Mr. Lloyd was transferred from Light Truck Engineering to Car Engineering
and became Vehicle Engineering Manager for the all-new 1994 1/2 Windstar minivan. In this
position, he was responsible for durability, NVH, dynamics, crash testing and packaging and was
the Launch Manager at the Oakville, Ontario Assembly Plant. Mr. Lloyd continued as Windstar
Vehicle Engineering Manager from 1995 through 1999 model years, with 1999 being a major
upgrade/freshening program.

In January, 2000, Mr. Lloyd was appointed North American Car 6-Sigma Deployment Director.
In this capacity, he was responsible for 6-Sigma strategy, deployment and implementation plans
for Mustang, Windstar, Villager, Focus, Taurus and Sable at seven (7) assembly plants and for
1700 Dearborn-based Product Development personnel. North American Car’s first year results
were approximately $88 mil in cost savings and several percentage points improvement in
customer satisfaction for Mustang, Focus and Windstar.

After 30 years with Ford, Mr. Lloyd retired in 2002. Since that time, he has worked as a
financial and legal planning seminar speaker and, most recently, joined Generalety, LLC, as
Chief Program Engineer.




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                     Superplasticity: From Aerospace to Automotive
                                          Xin Wu
            Dept Mechanical Engineering, and Institute for Manufacturing Research
                            Wayne State University, MI 48188

Abstract:
Superplasticity is a phenomenon that at certain temperature and strain rate some materials can be
plastically stretched to hundreds, even thousands of percents of their original lengths without
fracture, at a stress significantly lower than that at room temperature. Scientists were curious
what made these materials so special, and would it be possible we shape engineering materials
this way so complex parts might be made cheap. This scientific curiosity eventually leads to
Superplastic Forming (SPF), a new and very important manufacturing technology. In the past
twenty-five ears there has been a remarkable evolution of SPF in aerospace industry for making
small volume components with very complex geometry and large deformation that otherwise
very difficult to made or require much higher manufacturing cost. The limitation of SPF is it’s
very slow forming speed, making it difficult for large volume production, required for
automotive industry.

Within the last ten years significant progress has been made in high strain rate superplasticity,
and in the development of superplastic materials. It is now clear that the mechanism of
superplasticity is related to grain boundary sliding, which can occur for wide-range materials
with fine-grained and stable microstructures. In order to speed up the forming process without
losing superplasticity or acceptable formability for automotive applications significant efforts
have been made in the areas of material development, tooling, and process/product design. Very
recently GM has disclosed their Quick Plastic Forming process, which allows aluminum
components to be formed with large deformation at a competitive speed and cost to conventional
sheet metal stamping process. In addition, US government has supported an automotive oriented
metal forming technology development, called Hot Metal Gas Forming, with the research base at
Wayne State University. Both forming processes can be considered as the extension of SPF.

Recently it has been found that when materials are refined to a nanometer scale they exhibit
many extraordinary behavior, which are superior than any previously existing materials, for
example, steels with that scale of grain size can be plastically deformed to 0ver 1000%
elongation at high temperature, and after forming and cool to room temperature the strength can
be over 1 GPa. Some new materials such as carbon nanotube is found to have a strength 100
times of steels. The new discovery of the nano-materials provides great opportunity for
superplastic forming at much reduced manufacturing cost and with much improved post-forming
performance.
In this presentation the historical review of the superplasticity, current state-of-the-art, some
personal research results future perspectives will be provided.

Biography:
Dr. Xin Wu got his MS (1980) from University of Science & Technology Beijing, and MS
(1988) & PhD (1991) from the University of Michigan. He was a research faculty member and
served as Co-Director of Ceramic Composite Research Lab (1992-94) and Co-Director of
Material Processing and Stamping Lab at S. M. Wu Manufacturing Research Center (1995-98),
at U of Michigan. In Fall’1998 he joined Wayne State University as a faculty member till now.



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Prior to his graduate study he worked in a steel company in China for several years, and
conducted two-year visiting research at McMaster University, Canada (1984-86). His research
interests are in material processing, manufacturing and characterization, with the expertise in
deformation processing of materials, and published about 40 journal papers, many conference
papers, and two book chapters. He has been closely working with automotive industries on
autobody stamping and subassembly. At WSU he developed a government/industry co-sponsored
program on the development of a new thermally enhanced metal forming technology for
automotive structure manufacturing. Dr. Wu’s teaching activities include teaching and
developing graduate courses of advanced manufacturing series in material forming, cutting,
joining, non-conventional manufacturing, and advanced material testing, and the undergraduate
courses in machine elements design, and the introduction of material science. Dr. Wu is active in
academic societies and organized several symposia, and received “The Best Organizer of
Symposium and Sessions Award (2000)” from ASME and “The Best Paper Award (2001) from
SAE-International.


                                 Auto/Steel Industry in China
                                         Ming F. Shi
                                United States Steel Corporation

Abstract:
Everyone has been well aware of the China’s exceptional economic development since the
1980’s. What no one anticipated, however, was the phenomenal growth of the Chinese auto and
steel industry over the last few years.

In 2003, China has become number three in the world in vehicle production and every major
auto company has entered China market. The questions are: Is it sustainable? Is it accidental?
What will auto industry look like in five year? Who will be the major players?

Like the auto industry, the suddenly increased steel demands in China have resulted in
worldwide raw material shortages and have caused “red hot” steel markets worldwide, including
North America. One presentation from last October’s International Iron & Steel Institute
conference entitled “Vacuum Cleaning the World: China & Steelmaking Raw Materials”. This
title pretty much tells the story of China’s current impact on world steel industry.

This presentation will give an overview on China’s auto and steel industry and some forecasts on
future development.

Biography:
Dr. Ming F. Shi is currently the technical manager of advanced applications technology within
automotive product technology group at the Automotive Center of United States Steel
Corporation. The group consists of leading experts in the industry within the areas of
forming/stamping, computer simulations, structural performance and analysis, welding and
joining as well as materials, structural and mechanical test laboratories.

Ming joined United Steel Corporation in 1997. Prior to that, he worked at Product Applications
Center of National Steel Corporation for 7 ½ years as a leading forming engineer. He has
authored/co-authored more than 40 technical papers in the areas of sheet metal forming, dent
resistance, tailored welded blanks applications, material constitutive modeling and computer



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simulations. He served as an executive board member of North America Deep Draw Research
Group and session organizer and chairman for the body manufacturing and assembly track of
International Body Engineering Conference (IBEC).

Ming received the B.S. in engineering mechanics from Hohai University in Nanjing, China and
the M.S. and Ph.D. in mechanical engineering and engineering mechanics from Michigan
Technological University, Houghton, Michigan.




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                             LUNCHON KEYNOTE SPEECH
                        Chair: Ming F. Shi, US Steel Corporation

                    Career Development for Chinese American Engineers
                                      Dazong Wang
                                General Motors Corporation

Abstract:
Career development is one of the favored topics for many Chinese American Engineers. Dazong
will share his views on key elements of career development. He will also discuss logic
framework of career development followed by Q&A.

Biography:
Dr. Wang began his career with GM in 1985 as a senior research engineer at Research Labs in
Warren, Mich. where he developed a number of computer simulation tools for engineering
development. In 1988, he was transferred to GM Systems Engineering Center and later promoted
to senior staff engineer (GM Fellow). In 1991, he was assigned the manager of Decision and
Design Method Section for the GM Engineering Center in Troy. He developed analytical
decision support tools to support key product and design. He was promoted in 1994 to the
position of chief engineer and country manager for Delphi China. He was instrumental in
establishing three joint ventures, serving as the chairman/director on each of their boards. In
1997, he was appointed director of Vehicle Synthesis, Analysis and Simulation, for Small Car in
Warren. Two years later, he was assigned director of VSAS Vehicle Integration for GM North
America Car Engineering. In 2001 Dr. Wang became Director of Vehicle Architecture and
Design Check for GM North America Product Development, responsible for vehicle design
integration, packaging and mockup for all GM North America car programs, the position held
prior to his current assignment as Director of HVAC/PTC and Thermal Engineering, responsible
for design release of vehicle climate control and powertrain cooling systems. Dr. Wang earned
doctor of philosophy and master of science degrees in mechanical and aerospace engineering
from Cornell University and a master of engineering from Huazhong University of Science and
Technology in China. Dr. Wang serves in a leadership capacity in many social and technical
organizations. He was the founding member and the first president of the Chinese Association of
Greater Detroit and also served as the committee chairman for the America Society of
Mechanical Engineers. Dr. Wang was also instrumental in establishing the Chinese Affinity
Group for the GM's Diversity program.




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                                       SESSION II
                      Chair: Hua He, General Motors Corporation

                                      Hybrid Vehicles
                                         Goro Tamai
                                  General Motors Powertrain

Abstract:
Hybrid electric powertrains combine an internal-combustion engine with an electric drive system
to improve vehicle fuel economy and emissions. Due to environmental and market demands,
hybrid vehicles have been gaining popularity in recent years. An overview of hybrid powertrains
and hybrid vehicle architectures will be presented. Fuel economy mechanisms, IC engine and
electric-motor power balancing, as well as market trends will also be discussed.

Biography:
Goro Tamai received his Bachelor's and Master's degrees in Mechanical Engineering from the
Massachusetts Institute of Technology. He has authored or co-authored several technical papers
(SAE, ASME), authored a book THE LEADING EDGE, AERODYNAMIC DESIGN OF
ULTRA-STREAMLINED LAND VEHICLES, and has over 20 patents issued or pending in
automotive technologies. He is also the recipient of the 2002 SAE Max Bentele Award for
Engine Technology Innovation. He is presently a hybrid-powertrain controls engineer at General
Motors in Milford, Michigan.



        Research and Education in MEMS and Optoelectronics Packaging in China
                                       Sheng Liu
        Mechanical Engineering Department and Institute for Manufacturing Research,
                        Wayne State University, Detroit, MI 48202

Abstract:
A review of research and education in MEMS and optoelectronic packaging research in China is
given in terms of the major institutions, equipment, research topics. The author also discusses
major activities of China in MEMS and optoelectornic packaging.

Biography:
Professor Sheng Liu is the founding director of IMS of HUST and the Electronic Packaging
Lab. and associate professor at Wayne State University, Detroit, Michigan. He obtained his
Ph.D. from Stanford University in 1992. Dr. Liu's past employment includes MARC Analysis
Research Corporation (Palo Alto, CA, a nonlinear finite element company) as consulting
engineer (01/92-05/92) and Chengdu Aircraft Company (China, 01/86-02/88) as a structural
design engineer. Dr. Liu has been working on mechanical and thermal design and analysis of IC,
MEMS, and optoelectronic packaging. Dr. Liu has published more than 220 technical articles,
4 book chapters, edited 5 conference proceedings, invited for more than 100 seminars world
wide, and quite a few keynote/invited lectures. Dr. Sheng Liu once won the prestigious
Presidential Faculty Fellow, ASME EEPD Young Engineer Award, and NSFC Young Scientist
Award in China. He has served a few editoral boards and a few national and international
committees.


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               The Development of Automotive Electronics
                               Ming Li
                            Motorola, Inc.

内容提要: 随着中国汽车站工业的高速发展, 国内市场对汽车电子产品的需求量也快速增
长。国外的汽车制造商迫于降低成本的压力也在积极寻找低成本的汽车电子产品供应
商。国内外的市场需求为中国的汽车零部件厂商提供了一个良好的商机。由于中国汽车
电子工业起步较晚, 产品的设计、开发和生产体系还不很规范。短期内还难与国外成熟的
零部件厂商竞争。

本文根据国外汽车行业的现状介绍汽车电子产品的开发过程。文中将着重介绍汽车电子
产品开发的流程、方法和步骤, 并以汽车发动机控制单元和车体控制单元为例来阐述汽
车电子产品的开发所面临的难题和所需的技术专长。最后将探讨对中国的汽车电子产品
厂商发展策略的一些思考和建议。

作者简介: 李茗, 汽车电子产品技术专家, 现供职于摩托罗拉(美国)的汽车电子半导体产品
的研发部门。李茗在美国从事汽车电子产品的软件开发十余年, 曾先后在克莱斯勒, 福特
等汽车公司开发发动机控制单元、车体控制单元、车载无线通讯及控制单元的软件。李
茗的联系电话是(248-524-2170 USA), 电子邮件地址: ming_li4699@yahoo.com.




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