Impacting the South’s Automotive Industry showcase... · Impacting the South’s Automotive Industry Clay Walden, ... Testing • Five Instron ... compression, and torsion setups

Impacting the South’s Automotive Industry

Clay Walden, Ph.D.

Director & Research Professor

Center for Advanced Vehicular Systems - Extension

Mississippi State University

Presentation at the Southern Automotive Conference

Chattanooga, TN; October 11, 2012

Computational Fluid Dynamics

• Mesh generation • Simulation tools • Energetics • Thermal mgmt • Aerodynamics • Chemically reacting flow • Multidisciplinary design optimization • Fluid-structure interaction • Uncertainty analysis

Advanced Vehicle Systems

• Automotive Electronics • Hybrid technologies • IC Engines • Dynamometer • Noise, vibration and harshness • Emissions

Engineering Mechanics &

Materials Science • Multi-scale experimentation • Materials characterization • Materials processing • Nano/microstructure

analysis • Lightweight materials • Bio-materials • Particulate materials • Engineering informatics • V&V • Biomechanics • Cyberinfrastructure

CAVS Extension (Canton, MS)

CAVS Research (Starkville, MS)

Human Factors • Human factors • Ergonomics • Product lifecycle mgmt

Computational Engineering & Science

in Mechanics • Multi-scale modeling • Material models • Theoretical mechanics • Design optimization • Uncertainty analysis • Bio-inspired design • Process modeling • Manufacturing

Professional Development

• Rapid Problem Solving • Lean Certification • Six Sigma (Green Belt, Black Belt) • Welding for Engineers • Instrumentation & Diagnostics • Simulation Modeling

Technology Transfer & Field Engineering

• Lean Transformation • Quality Improvement • Kaizen Events • Simulation Modeling • Product Launch • Plant Layout • Quality Engineering • Solid Modeling • Innovation Engineering

K-12 Initiative • STEP Robotics Competition • Near Space Balloon • Summer Engineering Experiences

CAVS is an interdisciplinary center comprised of engineering, research, development, and technology transfer teams

focused on enhancing human and payload mobility.

Innovative Use of Lightweight Materials

CAVS is a leader in the use of lightweight materials for automotive applications.

Mechanical Testing

• Five Instron loading frames with various static and cyclic loading capacities and temperature control settings

• An Instron multi-actuator system for component or subsystem structural testing

• Hysitron Triboscope nanoindention system

• Fullam in-situ SEM fatigue testing

• Hopkinson bars systems with individual tension, compression, and torsion setups

• Trilion optical strain measurement system

• Questar QM100 long focal microscope with a power pak

• Q-panel salt-fog corrosion tank

• Engine and chassis dynomometers

• Shock/vibration

• Taylor-Hobson Talysurf CLI 2000 gauge system with 3-d surface measurement

• X-Ray Tomography • ZEISS optical stereological

microscope • VJ 1000 X-ray inspection system • JEOL6500F high performance SEM

with EBSD and EDS capability • JEOL JEM-100CX II transmission

electron microscope • STRUERS metallographic set Manufacturing Equipment: • Injection molding machine; twin

extruder • HAAS CNC mill and lathe • Powder metallurgy

Materials Characterization

Developing Technologies for Improving Quality … “Clear Vision” Student Project

• Transferred technology to Nissan

• Integrated measurements from vehicle (e.g., VIN), test results into plant wireless network

• World-wide standard

Real World – Undergraduate … Student Engineering Design Projects … resulting in increased testing capability … increasing vehicle quality.

• Challenge X – A 4 year competition that challenged

students to re-engineer a 2005 GM Equinox to minimize energy consumption and emissions while maintaining or exceeding stock vehicle performance.

– First Place overall in Years 3 & 4: National Champions!

• EcoCAR – A 3 year competition where students re-

engineered a 2009 Saturn Vue by minimizing energy consumption and reducing greenhouse gas emissions while maintaining its utility, safety, and performance.

– The MSU team chose their architecture as a plug-in, extended range hybrid that runs on B20 biodiesel!

– First Place overall in Year 2 • EcoCAR2

– A 3 year competition where students are re-engineering a 2013 Chevrolet Malibu.

– The MSU team chose their architecture as a Parallel-Series Plug-In Hybrid Electric Vehicle.

– First Place overall in Year 1

Support for Student Led Design Teams … National Champions!

Overview CAVS Extension

Making a Difference (NIST-MEP Client Surveys)

Economic Impact: $5.5 Billion

3,300 jobs created or retained

Through … On site Projects and Professional

Development Workshops (e.g., Lean Six Sigma, Problem Solving, Kaizen Events, Simulation Modeling, Solid Modeling,

Finite Element Analysis …)

Recent Successes Prototype to Full Scale production (9 mo.)

80% Improvement in Plant Quality

400% Increase in Plant Throughput (3 mo.)

2010 Recipient of University Economic Development Award of Excellence

Southern Growth Policy Board Innovation Award for Mississippi (2012)

Team Building

Instrumentation & Diagnostics

Problem Solving Methodologies

Supporting Professional Development Training … “Enhancing On-the-Job Problem Solving”

Rapid Problem Solving Statistical Process Control Lean Certificate Fundamentals of Welding Introduction to Gage R&R Simulation Modeling Ergonomics Essentials Introduction to Minitab

Vehicle Communications

& Diagnostics

Fundamentals of Mechanical

Drive Systems

Vehicle Dynamics and Safety

Testing & Instrumentation I & II

Sound & Vibration Diagnostics

Leadership

Communications

Coaching

Resolving Conflict

Supporting Change

Program Highlights • Automotive & High Growth Industries

• 27 Prof. Development Courses / 71 Classes; 654 Participants

• 100 Industry-University Projects + Coaching

• Benefits $2M / year

Targeting Gap

0% 10% 20% 30% 40% 50% 60% 70%

Low Skills

Medium Skills

High Skills

Automotive Manufacturing Skills

MS Automotive Cluster Nation

5.8%

10.5%

Nissan North America

SEC Electro Coating

Tower Automotive

Hunter Engineering

Hol-Mac Corporation

IMS Autrans

M-Tek

Anel

Harrison Mfging

Johnson Controls

Bad Boy Enterprises

Martin Rea

Calsonic Kansei

Unipres Southeast

Shiloh Industries

Hagemeyer NA

Yates Services LLC

PACCAR Engine Co

Minact Logistical

PPG

PKUSA

Northrop Grumman

Cox MHP

Ergon Refining

Peavey Electronics

T & L Specialty

PFG

Precision Optics

Thysenkrupp

DTI

ABB Kuhlman

Howard Industries

Viking Range

Milwaukee Tools

Eaton Aerospace

Parker Hannifin

GECOM

JMAA

Manufacturers (42)

Supporting Electric Car Start-Up … Company Background:

• “Start-up” electric car manufacturer located in Horn Lake, MS.

• Targeting initial creation of 150+ jobs

Project Results

• CAVS Research team – efforts focused on battery testing; and collaborations on next generation vehicles.

• CAVS Extension team – responsible for the design of the assembly line and other support processes.

• Targeting production “kick-off” of “MyCar” in late 2012.

Supporting Launches of New Models …

• Over 20 different simulation models have been developed by our CAVS Extension team in collaboration with Nissan and Tier 1 suppliers over the last 2 years.

• Supporting the growth in the Central Mississippi automotive Cluster (NV, Xterra, Frontier).

Support for Ground Vehicles …. Navistar

• Publication of “First Ever” MEP “National Case Study”

• MSU played a major role in the launch of Navistar Defense’s armored vehicle plant in West Point, MS. Key activities included design and implementation of the manufacturing processes and overall production system. Major vehicle launches have included the KBR armored cab, multiple MRAP versions, and TACOM vehicle. Supplier development involving over 12 Mississippi Small manufacturers.

• From prototype to full-scale production peak employment 1,050 at the plant. … average employment over 500 employees across 5 years.

• Total Impact from all of CAVS Extension’s work … over $4B in economic impact (3rd party survey reported by MEP). Documented savings of dozens of lives in Iraq due to increased protection from the threat of IED’s

Student Technology Exchange Program (STEP)

• K-12 Outreach … Introduces high school students to critical technologies used in the automotive industry (e.g., Robotics and PLCs).

• Students have regular access to Nissan’s Training Center. • STEP provides Pre-college Admission opportunities & tours of

manufacturing facilities (e.g., Tower, JCI, and SEC). • Participants: Students are drawn from the following school districts -

Canton City, Jackson Public Schools, Madison County, and Leake County.

• Results: After 5 years 210 students have “graduated”; • 100% High School Graduation vs. 72% statewide • 84% of students have continued education in university/community

college/military • Community Support: Numerous businesses & community

organizations have supported the program (e.g., Nissan, Entergy, …) • Sponsors have given over $32K in grants and scholarships. • Developing Summer Student Internships within automotive industry.

Entergy

Nissan

Oak Ridge National Laboratory Automotive R&D priorities and collaborations Presented by Dr. Claus Daniel Deputy Director, Sustainable Transportation Program 865-946-1204 [email protected]

New technologies and processes for:

• Safe, secure, and affordable vehicles for passengers and freight

• Domestic production of transportation fuel

• Reducing environmental impacts of transportation

• Predictable, reliable transport schedules

Accelerating electrification

• Wireless power transfer

• Advanced battery materials, processing, and modeling

• Battery manufacturing R&D

Efficient vehicles

• Lightweighting • Advanced

electric/ combustion, and hybrid powertrains

• Trucks as well as autos

Alternative fuels

• Drop-in biofuels for legacy cars

• Renewable fuels for advanced engines

• Natural gas

Intelligent systems and operations • Managing

congestion • Efficient

operations in commercial vehicles

• Data for decision-making

• Communications

4 Managed by UT-Battelle for the U.S. Department of Energy S&TCommittee_1101

Sustainable transportation R&D in diversity of technologies

ORNL Battery Manufacturing Facility The nation’s largest open-access battery manufacturing R&D facility…

●Pouch cells of up to 66x99x12mm and 6Ah ●Focus on manufacturing R&D, drying, alternative heating technologies, solvent less processing, alternative assembly methods, new cutting, materials handling, and filling methods ●Production yield issues

●700 sq ft dry space with <0.5% R.H.

●700 sq ft adjustable 1-15% R.H. ●Co-located with MDF and NTRC ●Accessible off-site location

specifically designed for industrial collaborations

Power Electronics & Electric Machinery

● Efficient and robust power electronics packages and new electric drive motors that do not require rare-earth materials

● Stationary and dynamic wireless power transfer technology at the prototype vehicle scale

● Highly-efficient/cost-effective inverter/converter technologies

● Performance verification of new WBG devices; new power electronics topologies and packages that make full use of WBG attributes

Lightweight body and chassis Light metals (Mg, Ti), ICME Joining technology Low cost carbon fiber Composite manufacturing

Propulsion materials ● Robust bulk materials, coatings and

surface treatment for wear ● Materials synthesis and manufacturing

methods ● Energy recovery (e.g. thermoelectrics, hi-

temp materials for turbochargers) ● Emissions catalysts

Materials Development

Low Cost Carbon Fiber Technology Carbon fiber technology for energy

and national security applications. Low-cost and high-performance fibers Fast, energy efficient processing Capability to evaluate micrograms of

candidate materials and produce up to 25 tonnes/year

Produce fibers for large-scale material and process evaluations by composite manufacturers

Train and educate workers Grow partnerships with US industry

Construction funded through the 2009 American Recovery & Reinvestment Act

Innovative emissions diagnostics enabled commercialization of clean diesel engine

Decade of “low-temperature combustion research. Demonstrated DOE program engine efficiency goals

Exhaust after-treatment research and characterization contributions to clean diesel commercialization

Extensive experiments and data for low-temperature combustion modes

Clean Fuels & Powertrains

Over the past 3 summers, students have participated in the following automotive-related research areas: Additive Manufacturing - Polymers Additive Manufacturing - Robotics Battery Research and Development Biofuels Fuels, Engines and Emissions Intelligent Transportation Systems Low Cost Carbon Fiber Sustainable Manufacturing

Volkswagen Distinguished Scholars Program

Managed by UT-Battelle for the U.S. Department of Energy

Thank you for the opportunity to share parts of ORNL’s portfolio in

Transportation Technology R&D

1 CAVT - University of Alabama

CAVT A University of Alabama

Research Center

University of Alabama Center for Advanced Vehicle Technologies

The Center for Advanced Vehicle

Technologies http://cavt.eng.ua.edu

Vision Promote development

of efficient, safe, economical, durable, and environmentally-conscious vehicles

to meet the mobility needs of America

through discovery, research and education

CAVT Instrumented Ford Hybrid Escape



Research Center

Center for Advanced Vehicle Technologies

• CAVT was established late 1998 by Transportation Equity Act for the 21st Century (TEA-21)

• Initially funded by US DOT/AL DOT (~$8 M over 10 years) • Current funding from government grants and industry • CAVT coordinates UA faculty research, educational activities

and outreach in the automotive area. • CAVT is not a stand-alone, bricks-and-mortar center, but does

have several affiliated laboratories on campus.



Research Center

CAVT Research Focus Areas • Powertrains

– Engines and combustion – Electrical drives and hybrids – Noise and vibrations – Thermoelectric efficiency enhancement

• Energy storage and fuel cells – PEM and SOFC fuel cells – Battery

• Materials and manufacturing – Light weight materials: Composites, alloys – Surface science – Manufacturing processes

• Electronic systems – Embedded systems – Vehicle to vehicle communications



Research Center

CAVT Research Facilities

• CAVT has a large wet lab in Shelby Hall dedicated to fuel cell research and used mainly by faculty in Chemistry and Chemical and Metallurgical and Materials Engineering.

• A hemi-anechoic chamber is operated in the AIME Building • Major new Engines and Combustion Lab in brand new South

Engineering Research Center.

South Engineering Research Center



Research Center

SERC Engines and Combustion Lab

• 6 convertible combustion/ engine test cells

• Full heavy-duty dilution tunnel • 4WD 700 hp chassis dyno • Cold start capability • High-flow ventilation

• Conditioned combustion air • Fuel service • Laser safety • Clean assembly area • Dedicated instrumentation

areas



Research Center

New 650 hp diesel-rated engine dynamometer



Research Center

Major Instrumentation

• Standard 5-gas analyzers • Cambustion high speed NOx analyzer • TSI EEPS high speed particulate sizer • Thermoelectron FTIR analyzer • Fast response mass spectrometer • High response time constant volume

combustion apparatus • Various laser capabilities- PIV, LDV,

LIBS, rainbow schlieren, PDPA, LII • Various high speed data acquisition

systems • High accuracy fuel metering system

CAVT supports automotive engineering education!



Research Center

Major Engines Research Themes

• Engine emissions reduction • Alternative engine and combustion fuels

(hydrogen, natural gas, dual fueling) • Hybrid electric powertrains and controls • Biofuels (biodiesel, DME, glycerol, alcohols) • Utility engines • Combustion of difficult to burn waste fuels • Development of combustion diagnostic methods • Combustion simulation



Research Center

Recent Personnel Addition to CAVT!

TUSCALOOSA, Ala. — Dr. Bharat Balasubramanian, long-time automotive technology researcher and development engineer at Daimler AG, joined the faculty in The University of Alabama College of Engineering, bringing decades of industry experience into the classroom and labs. Balasubramanian retired earlier this year as vice president of group research and advanced engineering responsible for product innovations and process technologies after nearly 40 years as a research and development engineer for the Mercedes-Benz brand in Stuttgart, Germany. At UA, he will be a professor with an appointment in both the mechanical engineering and electrical and computer engineering departments. He was also named executive director of the Center for Advanced Vehicle Technologies, or CAVT, a cross-discipline research center focused on automotive innovation.

http://uanews.ua.edu/wp-content/uploads/2012/10/Balasubramanian-Bharat.jpg�


Questions? cavt.eng.ua.edu 205-348-9090

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Vehicle Infrastructure Energy Infrastructure

Information Infrastructure

Transportation Infrastructure

Human Operator

A Central Theme: Systems Integration

Human-Machine Interface

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Advanced Powertrains – Vision at CU-ICAR

• Advanced engine concepts

• Powertrain integration, flexible drivelines

• Hybrid propulsion

• Electrification and connectivity

Pursue research in four strategic areas:

Advanced Conventional

Electric Vehicle, PHEV

Hybrid Electric vehicle

IC Engine

Energy Conversion, Storage

New architectures, Light Weight

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Vehicle Electronics – Vision at CU-ICAR

• Vehicle electronic systems integration

• Electromagnetic compatibility

• Electromagnetic modeling

Pursue research in three strategic areas:

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Manufacturing and Materials – Vision at CU-ICAR

• New manufacturing systems

• Continuous process improvement

• Sustainable manufacturing

• Advanced materials characterization, processing, and manufacturing


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Vehicle Performance – Vision at CU-ICAR

• Vehicle dynamics

• Advanced driver assistance systems

• Human factors and HMI

• HIL and on-road testing


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• Power Connectivity

• Communication Connectivity

• Human-machine Interface

Pursue research in three strategic areas:

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Vehicle-to-Vehicle Connectivity and Vehicle-Infrastructure Vision at CU-ICAR

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7-Poster with Climate Chamber

4-Wheel Chassis Dyno/Anechoic Chamber 500hp Engine Test Cell

Full Vehicle CMM

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Full Vehicle EMC Chamber

Advanced Machining Centers

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2011/2012 Research Partners include:

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Lessons Learned to Date - Generalized • Some challenges associated with typical demographic model:

manufacturing operations in the Southeast and R&D either in Midwest or Europe/Asia

• Market surveys have revealed that Tier 1 and 2 suppliers have need

for greater materials/root cause testing and services

• Emphasis from motorsports companies tends to be on short-term data acquisition type of activities and not longer-term “traditional” research relationships

• Strong focus on workforce development needs – collaboration with technical college systems essential

• Potential benefits for all could be realized through a more regional approach to R&D

Documents

Impacting the South’s Automotive Industry showcase... · Impacting the South’s Automotive Industry Clay Walden, ... Testing • Five Instron ... compression, and torsion setups