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As environmental regulations become more stringent, manufacturers are confronted with the task of product-design considering environmental impacts. Life Cycle Analysis (LCA) is a developing technique that attacks this problem. LCAs provide environmental information for decision making by consumers, manufacturers, and governments. These decisions significantly affect the ability to maximize source reduction, re-use, recyclability, and recycled content. LCAs can aid in diminishing the negative impact a product has on the environment and can be utilized as a partial solution of our nations' (worlds') growing waste management problem. To date, the application of LCAs has varied from product comparison to process development and improvement. The results from these analyses have differed because of differing assumptions and differing choices of boundary conditions. An appropriate Life Cycle Analysis should be consistent across products, locations, and especially across experimenters.

Each year, an estimated 11 million vehicles are scrapped in the United States, generating some 2.5 billion pounds of discarded automotive plastics. The commercial recycling of post-consumer automotive plastics is currently limited to polypropylene battery cases. While some automotive plastic parts such as tail lamps, fenders, bumper covers, wheel covers, and interior trim are reused, the majority of automotive plastics is landfilled. Increasing public pressure is forcing the automotive and related industries to find new ways to divert the plastics away from disposal and into productive uses. In its response to this issue, the American Plastics Council (APC), a joint initiative with The Society of the Plastics Industry, Inc. (SPI), commissioned the “Automotive Plastics Recovery and Recycling Research Project”.

Experimental results on an automatic lane keeping control study are presented in this paper. A magnetic reference system was used to provide the vehicle lateral tracking error as well as future road curvature information and vehicle speed measurement to the vehicle steering controller. The front wheels of the vehicle are steered according to vehicle lateral displacement, future road curvature, vehicle yaw rate and lateral acceleration, and vehicle speed. The control algorithm used to design the feedback and feedforward controllers is known as the Frequency-Shaped-Linear-Quadratic Preview (FSLQ-preview) optimal control design method. The closed loop response of the vehicle was examined under a wide variety of test conditions, including low tire pressure, measurement noise, perturbed reference system, hard braking, and snowy road.

Much attention has focused recently on the recycling of automobiles. Due to the value of their metallic content, automobiles are presently the most highly recycled product in the world. The problem is the remainder of material that is presently landfilled. Automotive shredder residue (ASR, or “fluff”) is made up of a number of materials including plastics, glass, fluids, and dirt. The presence of this mix presents both a problem and an opportunity for the automotive and recycling industries. In order to determine how best to recover the materials that make up ASR, it is first necessary to understand the costs incurred in the present automobile recycling infrastructure: dismantling, shredding/ferrous metal separation, non-ferrous metal separation, and landfilling. Through a technique called Technical Cost Modeling, the costs of the present process are simulated.

We have developed a quick route-finding algorithm for determining the optimal route between two points. We have created a new method for recording on a CD-ROM, using a computer, optimal routes between all major points. The onboard system that we have developed accesses the CD-ROM data to find the route. This method greatly reduces the time needed to find a route.

We have developed a new navigation system which utilizes voice synthesis function, and mounted it on the new model. This paper reports the details of the navigation system. The navigation system was developed with the aim of providing a system which is capable of reducing the load on the driver and helping reach the destination smoothly and more safely than the conventional system.

We have developed a millimeter-wave radar system for advanced automobile applications. This radar system uses digital signal processing technology to analyze the radar signals. It can also measure distance and speed with precision and good stability, and also identify multiple targets.

We have developed a vehicle navigation system with route guidance enhanced by voice messages. This paper describes the human factors engineering study carried out to develop the software specifications for the voice route guidance. Results of experiments for verification of the effectiveness of the system, including objective measurements of drivers' glance behavior and mental workload, will also be reported.

These days, a variety of navigation systems have been developed to provide the driver with necessary information such as vehicle location, direction and destination. An electronic compass is being widely used as a component for such navigation systems (1), (2) and (3). Compared with a conventional magnetic compass, an electronic compass has the following advantages: 1. High vibration durability and quick response. 2. Easy to calibrate and reliable. 3. Sensor and display units can be separated. The electronic compass, however, is accompanied by two serious subjects: the development of a sensitive geomagnetic sensor, and calibration of direction error due to an unexpectedly magnetized vehicle body. First, we developed a new geomagnetic sensor utilizing magnetoresistive elements (MRE) and magnetic lenses. Next, we clarified the magnetic disturbances and defined the mechanism of vehicle magnetization, thereby establishing a simple calibration technique for such magnetization.

Providing the numerous telltale (ICON) or message functions (typically 12 to 20) in current automotive instrumentation is costly and a styling nightmare. This is true even though many of these warnings will never be activated during the vehicle lifetime. The new Miniature Telltale Module provides a compact, low cost solution by combining six telltale functions into one unit. A unique memory feature “stores” the last image selected and allows the input power to be momentary. The use of 2, 3 or 4 modules per instrument cluster allows styling flexibility and simplifies instrument cluster construction including case complexity, tooling leadtime and cost.

The Micro-Miniature Analog Meter Movement is a small, simple and low cost device that has a deterministic input/output relationship. The mechanism is capable of being automatically handled and assembled by standard electronic placement machines, thereby eliminating continual capital investment in specialized assembly line equipment. Significant size reductions in electro-mechanical instrumentation are enabled by this device, including multigauge analog Heads-Up-Displays.

Nu-Tech & Engineering, Inc. has developed a new aftermarket Analog Head Up Display. This new product combines preferred analog instruments with projection heads-up display optics. New technology has allowed multiple analog movements to be contained in a small, low-cost package making HUD technology available to more consumers. The combination of the analog movements with a high intensity VFD light source is the heart of this new product design. A unique mounting configuration for this new display system eliminates “image bounce”. The low-profile package and separately mounted optical combiner easily adapts the system to aftermarket sales and/or dealer installations.

Double Layered Super Twisted Nematic LCD (D-STN) which can be operated by 1/128 duty ratio is presented. Two conflicting requirements; good visibility and a wide operating temperature range are fulfilled through optimization of cell parameters, such as twist angle, pretilt angle of liquid crystal to glass substrate and elastic properties of liquid crystal material. The response time of LCD decreases with increasing temperature. Hence at high temperature, the “frame response” phenomenon is observed and this results in reduction of contrast ratio. We propose multiple line selection (MLS) method for increasing in contrast ratio at high temperature.

The combination of specialty polyolefins and advanced thermoplastic processes offers innovative new approaches to integrated bumper systems. Unique combinations of EA/Beam, EA/Fascia, and complete bumper systems can be achieved utilizing filled and unfilled polyolefins and TPO's with coinjection, gas injection, expanding mold, and other material/design/process combinations. Light weight, low cost, and recyclable one piece bumper systems may be targeted with materials ranging from structural long glass PP to design-flexible TPO skins.

A backlighting system which utilizes a VF Display as the light source allows electro-mechanical instrument clusters to have a laminated construction that reduces their depth to approximately 20% of existing E/M clusters. The VFD light source may contain digital data and/or telltale segments to provide combined functions and reduced cost while tremendously improving quality and reliability. The light distribution system is designed to virtually eliminate lighting development and prototyping leadtime by allowing graphics and pointers to be indiscriminately moved within the cluster without affecting brightness and uniformity. Standardized lighting systems are easily achieved while still maintaining aesthetic flexibility. The backlighting system was developed to utilize flexible, manufacturing processes that allow multiple instrument cluster designs or families to be produced on the same assembly line.

Sheldahl is one of the world's largest suppliers of flexible printed circuits (FPC). Sheldahl has been supplying back can FPCs for automotive instrument clusters for over 25 years. The complexity of today's instrument clusters has required higher density and multifunctional FPCs to add value, reduce part number count, increase reliability, reduce electrical interconnects and reduce cost. This paper will discuss some of the new applications that have come about in recent years as a result of technological advances and integrating more functions into the FPC. Single layer, double layer, double sided plated through hole, rigidized flex and hybrid polyester/polyimide FPCs will be discussed.

Five different engine tests utilizing nonaqueous propylene glycol as the engine coolant were run to examine various aspects of durability and engine performance. This paper reports the results of these engine and bench tests designed to quantify the effects on performance and engine durability. Comparisons are made to baseline engine tests using 50 % aqueous ethylene glycol coolant. Also reported are the data necessary to determine the effects on the size and design of related heat exchangers. Based on these test results, some of the presumed advantages and disadvantages of the use of non-aqueous propylene glycol engine coolants (1) * have been quantified. This work is useful as a basis for further work using total-vehicle systems taking advantage of this innovative technology.

The application of a modeling technique for the study of diesel engine cylinder liner vibrations is presented. The procedure is an analytically based tool for addressing the cavitation erosion problem that occurs on the outer surface of cylinder liners. The modeling approach includes the cylinder liner and the surrounding coolant using a fluid-structure interface between the two. The coolant on the outside of the liner has a large effect on the motion of the liner; therefore, the structural problem and fluid problem cannot be decoupled. An application of the model demonstrates how pressures at the liner-coolant surface are generated from the velocity of the liner and the propagation of pressure waves through the cooling medium. A series of parametric studies demonstrate design alternatives for reducing the minimum pressures that cause cavitation. The parametric studies include variations of liner thickness, water jacket clearance and impact magnitude.

Modeling of liner cavitation corrosion is of increasing significance since new engine design trends could aggravate the problem. Cavitation corrosion is of a complex nature and is affected by numerous coupled factors. A system approach to analyze and assess cavitation corrosion damage is deemed necessary. The approach accounts for the macroscopic and microscopic aspects of the phenomenon that include modeling of piston dynamics, liner transient vibration, pressure wave propagation, bubble dynamics and their effect on material damage. Though detection methods can provide crucial insight of factors that influence the cavitation problem, analysis methods are required at the initial design stage to provide overall engine design optimization and reduce prototype development cost and time. This analytical diagnostic approach provides a powerful tool to give valuable and relatively quick insight in solving engine liner cavitation corrosion problems.

The teaching of design courses for engineering students can be an excellent opportunity for cooperation between industry and higher education. Chronic problems faced in academe (course staffing, project selection) and in industry (design skills of new employees) can be in large part solved by such cooperation. Students can benefit from more meaningful course content and from contact with industrial settings and procedures. This kind of cooperation can work exceptionally well in programs where the students have already had co-operative work experience. The advantages and pitfalls of this kind of cooperation are illustrated by a critical review of a recent industrial sponsorship of a design course for engineering mechanics seniors.