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REVIEW OF THE RESEARCH PROGRAM OF THE PARTNERSHIP FOR A NEW GENERATION OF VEHICLES: SECOND REPORT
Appendix D
United States Council for Automotive Research Consortia
The U.S. automobile industry, through USCAR, has implemented collaborative projects that directly or indirectly support Partnership for a New Generation of Vehicles objectives. These USCAR consortia are:
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REVIEW OF THE RESEARCH PROGRAM OF THE PARTNERSHIP FOR A NEW GENERATION OF VEHICLES: SECOND REPORT
Appendix D
United States Council for Automotive Research Consortia
The U.S. automobile industry, through USCAR, has implemented collaborative projects that directly or indirectly support Partnership for a New Generation of Vehicles objectives. These USCAR consortia are:
Low Emissions Technologies R&D Partnership (LEP)
Automotive Materials Partnership (USAMP)
Supercomputer Automotive Applications Partnership (SCAAP)
CAD/CAM1 Partnership
Natural Gas Vehicle Technology Partnership (NGV)
Advanced Battery Consortium (USABC)
Vehicle Recycling Partnership (VRP)
Auto/Oil Quality Improvement Research Program
Environmental Research Consortium (ERC)
Low Emission Paint Consortium (LEPC)
Electrical Wiring Component Applications Partnership (EWCAP)
1
CAD = computer-aided design
CAM = computer-aided manufacture
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REVIEW OF THE RESEARCH PROGRAM OF THE PARTNERSHIP FOR A NEW GENERATION OF VEHICLES: SECOND REPORT
TABLE D-1 USCAR Consortia Alignment with PNGV Goals
Consortia
Consortia Goal
Aligned PNGV Goal
1995 Accomplishments
United States Automotive Materials Partnership (USAMP)
To develop lighweight materials for improved automotive fuel economy.
Polymer composites (ACC)
Light metals (Al, Mg, metal matrix composites)
Engineered plastics
Cast iron
Steel
Ceramics
Lightweight vehicle
Negotiated cooperative agreement with DOE for $30 M over 5 years
Conducted PNGV Goal 3 composites and aluminum supplier workshops
Successful cart crash of Escort composite front end
Completed design phase of Focal Project II composite pickup box (28% weight save and cost equal to steel plus liner)
Completed second edition of Materials Characterization Test Procedures manual and obtained SAE approval as industry standard
Low Emissions Technologies R&D Partnership(LEP) Engine Support Systems Technologies (ESST)
Identify enabling technologies for improvements in emissions in the following areas:
Fuel preparation and control, combustion and HC control
Cold bag aftertreatment, OBDII, 100K compliance
Evaporative emissions control
Efficient/ low emissions powertrain
Demonstrated feasibility of spray formed tooling using low melting point alloys
Produced test sections of dual wall manifolds to support cold start emissions reduction
Developed hydrous metal oxide materials for NOx reduction catalysts
Developed three new catalyst systems based on Sol-gel/Aerogel technology
Established world-class lean burn and diesel catalyst evaluation facilities at the Oak Ridge National Lab
Environmental Research Consortium (ERC)
To develop common emissions testing instrumentation and methods
Improve the understanding of vehicle and mfg. emission on the environment
Reduce environmental impact of mfg. emissions
Reduce worker exposure to mfg. emissions
Efficient/low emissions powertrain and manufacturing processes
Emissions Research:
Canister purge and modal mini-diluter developed
Prototype instruments developed
Reference ULEV vehicle built
Emissions Assessment:
Georgia Tech/EPA on-road vehicle emissions measured/analyzed
Michigan Remote Sensing Project assessed remote sensing accuracy and high emission vehicle repair effectiveness
Atmospheric Modeling:
Modeling runs identified differences in ground level ozone and agreement on the impact of HC and NOx controls
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United States Advanced Battery Consortium (USABC)
To pursue R&D of advanced energy systems capable of providing future generations of and electric vehicles and hybrids with significantly increased range and performance
Efficient energy storage conversion
Initiated downselect process to manage mid-term and long-term technologies within financial constraints
Received initial lithium polymer demonstration cells
Powering Chrysler/Ford/GM vehicles with mid-term tech. batteries
Phase II program proposal submitted to DOE to cover:
Commercialization of mid-term battery technologies
R&D of long-term battery technologies
PNGV energy storage system proposal process initiated
Low Emissions Paint Consortium (LEPC)
Test and evaluate materials, equipment, and facilities with low emission potential
Develop and demonstrate new low emission processes
Establish common industry database
Focus initially on powder painting technologies
Environmental responsibility
Began construction of $20M powder clearcoat system at Ford Wixom
Participated in powder primer launches at GM and Chrysler plants and established powder primer launch manual
Issued joint mat'l specifications for powder CC and primer
Filed for 2 U.S. patents based on testing at GM
Supercomputer Automotive Applications Partnership (SCAAP)
Develop portable software easily run on a wide variety of high performance computers by automotive design engineers to:
Shorten product lead time to meet environmental standards
Increase the use of advanced materials, such as carbon fiber, in automotive body parts
Efficient vehicle design processes
Released advanced CFD code for aero and engine intake flow dynamics
Developed library of non-linear analytical material models for improved crash simulations
Incorporated auto-grid generation to improve CAE time
Initiated industry benchmarking effort to assess high performance computers
Vehicle Recycling Partnership (VRP)
Reduce the environmental impact of vehicle disposal
Increase the efficiency of component disassembly to enhance vehicle recyclability
Develop mat'l selection and design guidelines
Promote socially responsible/economical solution to vehicle disposal
Achieve 80% vehicle recyclability objective
Established Vehicle Recycling Development Center in Highland Park and initiated technical programs in:
Seat recycling
Fluid reclamation
Disassembly protocols
Airbag dismantling/processing
Time/motion dismantling studies
Developed design guidelines for recycling
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CAD/CAM Partnership
To promote and apply the concepts of feature-based modeling technology to accelerate new product introduction and reduce complexity in automotive design and manufacturing processes
Efficient vehicle design processes
Initiated discussions with Fraunhofer-Berlin on CAD Feature based modeling
Natural Gas Vehicle Technology Partnership (NGVT)
Sponsor the development of pre-competitive fuel storage technologies and gas composition standards to support production of more commercially viable natural gas vehicles by 1998
Develop alt. fuel technologies to support reduced emissions
Established cooperative relationship with Gas Research Institute
USCAR/Gas Industry developed environmental test and specification for storage tanks
Storage tank cost reduction assessment complete resulting in a potential 23% cost savings
Fuel composition emission, performance, and component freeze-up testing 50% complete
Auto/Oil Air Quality Improvement Research Program
To develop data for use by legislators, regulators, and the public on the potential improvements in vehicle emissions and air quality, primarily ozone, from reformulated gasoline, alternative fuels, and developments in automotive technology
Reduced emissions
Demonstrated that changes in gasoline composition will reduce vehicle emissions by 15–25%
Completed all emissions testing for the program
Published 13 tech. papers, including results of reformulated gasoline, ethanol, methanol, and CNG tests
Established database used by government to support environmental decision making
Electrical Wiring Component Application Partnership (EWCAP)
To develop common designs for electrical connectors to reduce cost and complexity, while improving reliability, quality, and serviceability
Affordability
Developed common cigarette lighter specification
Design 95% complete and programmed for ‘97/98 G38 Ford/Chrysler/GM vehicles
Developed electrical connection guidelines and published
Developed common footprint for fuel injector connector
Developed common footprint for ABS module connector
Initiated development of common 1.0mm pin and trailer tow connectors
Strategic Standardization Board (SSB)
Reduction in non-value added product development and manufacturing costs through the standardization of parts, components, and engineering processes across the U.S. auto industry
Affordability
Established forum for industry standardization discussions
Developed process for guiding industry agreements through established standards publishing bodies
Stimulated ANSI to re-evaluate its strategic direction
Commonized 20 nylon standards (down from 120)
Commonized on standard design and process FMEAs
Prioritized parts for joint engineering standardization
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Occupant Safety Research Partnership (OSRP)
To conduct R&D on crash-test dummies and related areas such as modeling, instrumentation, data management and reduction, and subsystem safety test development
Safety and occupant protection
Completed prototype fabrication of next generation side impact dummy (SID-IIs). Testing and evaluation in G42 progress
Continued evaluation of NHTSA advanced dummy thorax
Initiated working group with NHTSA on lower extremity instrumentation
Initiated working group on common crash test instrumentation specifications
Provided by PNGV.
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