Sustainable Automotive Technologies 2011: Proceedings of the 3rd International Conference

Sustainable Automotive Technologies 2011

Steve Hung ⋅ Aleksandar Subic ⋅ Jörg Wellnitz

Editors

Sustainable Automotive

Technologies 2011

Proceedings of the 3rd International

Conference

123

DOI 10.1007/978-3-642-19053-7

Springer Heidelberg Dordrecht London New York

Library of Congress Control Number: 2011920836

© Springer-Verlag Berlin Heidelberg 2011

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Editors

Professor Steve Hung

Clemson University International Center

for Automotive Research

Greenville

USA

[email protected]

Professor Aleksandar Subic

RMIT University

School of Aerospace

Mechanical & Manufacturing Engineering

Bundoora, Victoria 3083

Australia

[email protected]

Professor Dr.-Ing. Jörg Wellnitz

UAS-Ingolstadt

Marie-Curie-Straße 6

85055 Ingolstadt

Germany

[email protected]

ISBN 978-3-642-19052-0 e-ISBN 978-3-642-19053-7

P.O. Box 71

Cover design: WMXDesign GmbH, Heidelberg

Preface

This third volume of the book on Sustainable Automotive Technologies published

by Springer is a result of extensive investigations undertaken by researchers from

industry, government research institutes, and universities worldwide. The book

includes a selection of 17 papers from the total of 35 contributions presented at the

Conference, coming from Europe, US, Hong Kong, Australia and Columbia. The

contributions that have been selected for publication in this book have been peer

reviewed by an international panel of experts and edited by the Editors appointed

by Springer.

This publication is an important outcome of the 3rd International Conference on

Sustainable Automotive Technologies, ICSAT2011 that was organised in Clem￾son, South Carolina, US by the Clemson University International Centre for

Automotive Research (ICAR), in collaboration with the University of Applied

Sciences Ingolstadt, Germany and RMIT University in Melbourne, Australia. It

follows the successful launch of the first conference in this series that was held in

Melbourne in 2008 and chaired by Professor Aleksandar Subic, and the subse￾quent second conference which was held in Chiemsee in the German Alps and

chaired by Professor Joerg Wellnitz. This third conference in the series is chaired

by Professor Steve Hung. The ICSAT2011 conference has attracted over 100 par￾ticipants from many organisations and countries. The conference has attracted

significant industry support, especially from the local automotive industry hub in

South Carolina, US.

The Editors and their respective universities are proud to announce this publi￾cation that represents an important milestone for the dissemination of knowledge

about sustainable automotive technologies, and in particular about the emerging

and developing green car technologies. With over 900 million vehicles on world

roads today contributing to around 16% of total greenhouse gas emissions (and

rising), the need for strategic research in and rapid development of green cars and

associated sustainable technologies is growing. The book aims to address this

need by highlighting some of the key technologies and practices in this field. It

also aims to provide a balanced view on the range of green car technologies con￾sidered by industry and academia.

The Editors wish to thank all authors, international reviewers and Springer for

their support and contributions without which this publication would not be possi￾ble. We hope that everyone involved with sustainable automotive technologies or

interested in this particular topic will find this book to be a valuable resource go￾ing forward.

The Editors

TABLE OF CONTENTS

I Evaluating sustainability

A holistic approach to sustainability evaluations in the

automotive industry

J. Weber, M. Bowler, T. Kurfess

3

II Technologies for production

Flexural creeping analysis of polyurethane composites produced

by an innovative pultrusion process

S. Bruckmeier, J. Wellnitz

13

Manufacturing microstructured surfaces for automotive

applications

A. Cannon, M. Maguire, R. Hulseman, W. King

19

The first water based pretreatment system for direct glazing

W.-R. Huck

25

Hybrid command issuing in a 2-DOF servomechanism

operated under vision-based feedback control

C. Montes, C. Wong, J. Ziegert, L. Mears

31

Alternative methods to increase the long term performance of

laser-welded copper aluminum connections for electronic

applications in mobile systems

M. Weigl, F. Albert, M. Schmidt

39

III Combustion engines and fuels

Investigation and optimization of biodiesel chemistry for HCCI

combustion

B. Bunting, M. Bunce1, B. Joyce, R. Crawford

51

New potential of old Wankel-type machines

B. Schapiro

59

RPM – Rotary Piston Machines: new class of innovative

machines

E. Wilhelm, J. Wellnitz

67

IV Hydrogen and electric vehicle technologies

Inductive Power Transfer System Integration for Battery￾Electric Vehicles

A. Lorico, J. Taiber, T. Yanni

75

Performance comparison of hydrogen fuel cell and hydrogen

internal combustion engine racing cars

G. Pearson, M. Leary, A. Subic, J. Wellnitz

85

viii

V Materials and structures

Design of basic structural composite elements

H. Bansemir

95

Enhancing sustainability through the targeted use of synergy

effects between material configuration, process development

and lightweight design at the example of a composite seat shell

W. Hufenbach, M. Krahl, R. Kupfer, S. Rothenberg, T. Weber,

P. Lucas

103

Sustainable design of a side door reinforcing assembly –

exploratory optimisation

M. Kajtaz

111

Research and development of a new and sustainable composite:

“Natural Stone Laminate”

L. Müller, J. Wellnitz

121

VI Vehicle systems

In-wheel coupled suspension and drive: design, development,

and modeling

R. Clippard, J. Ziegert

131

Optimisation of automotive seat kinematics

M. Leary, M. Mazur, T. Mild, A. Subic

139

ix

I EVALUATING SUSTAINABILITY

A HOLISTIC APPROACH TO

SUSTAINABILITY EVALUATIONS IN THE

AUTOMOTIVE INDUSTRY

J. Weber, M. Bowler, T. Kurfess

Clemson University International Center for Automotive Research, 4 Research Drive,

Greenville, SC 29607, U. S. A.; Email: [email protected]

Abstract: The influence of sustainability has revolutionized the automotive indus￾try. Although the industry has made countless improvements in this arena, it is

still far from being sustainable. To date the majority of sustainability efforts have

focused on environmental friendliness, both of the cars and the respective produc￾tion processes. However, in order for an automotive corporation to be truly sus￾tainable in the future all business decisions will need to be driven from the view

point of sustainability. A true sustainable solution must be logical economically,

socially, and environmentally, both locally and globally within the corporation.

This approach requires the consideration of the following four domains: mobility

system, phases of the extended life cycle, level of value creation, and sustainabil￾ity perspective. This paper aims to create a structure to allow cause and effect

mapping between decisions made at all points in the vehicle life cycle at all levels

of value creation within a given mobility system in order to determine its true

sustainability. This structure allows decision makers to comprehensively under￾stand, evaluate, and compare products, processes or business alternatives in terms

of their sustainability. This will in effect facilitate localized decisions that make

sustainable business sense locally and globally within the corporation, and ulti￾mately within the automotive industry.

1 Introduction

sustainability by the Bruntland commission in 1987 as the “development that

meets the needs of the present without compromising the ability of future genera￾tions to meet their own needs.” [1] This requires a holistic approach that considers

economic, environmental, and social aspects in the development of everything

from manufactured goods and public policy to corporations and personal lives.

Maintaining an intact environment, a society in physical and psychic health, and

economically successful business are the three main targets which are mutually in￾terdependent and hence all of equal importance (see Fig. 1) [2].

Sustainability, or the ability to sustain or endure, was refined in terms of human

Fig. 1: The Three Spheres of Sustainability [2]

2 Sustainability in the Automotive Industry

In the automotive industry, sustainability has been primarily synonymous with

environmental friendliness, initially of the vehicles and then of their respective

production processes. This is achieved by methods such as life cycle analysis and

design or environmental accounting. For the automakers, environmental friendli￾ness was achieved by complying with the legal requirements, usually at the ex￾pense of undercutting their economic targets. In the past this compliance created a

vehicle that was “green enough” for consumers and therefore green enough for the

manufacturer [3].

Over the last decade however, sustainability has received an increasing amount

of attention. A good indicator of this is the jump of corporate issued sustainability

reports from around 300 in 1996 to over 3,000 in 2009 [4]. There has also been an

emergence of environmental standards, best practices, and rankings such as ISO

14000, European Eco-Management and Audit Scheme (EMAS), and the Dow

Jones Sustainability Index for corporations [5,6]. Since 1999, the Dow Jones

sustainability indexes (DJSI) track the financial performance of the leading

sustainability-driven companies worldwide and provide investors with a financial

quantification of and a ranking in terms of sustainability [7]. Moreover, in the

most recent years tools that allow individuals to calculate their own environmental

impact or assess their personal sustainability have been made easily accessible on

4