Here’s a round-up of the latest innovations and automotive tech developments – from the unexpected to the logical development.
Forget the Fuel Tank Cap
Ford’s new Easy FuelTM capless fuel-filler system has an integrated spring-loaded flapper door that allows customers to simply insert the fuel nozzle into the tank to fill up – no screw cap is required. That means no more fumbling to remove and tighten the cap and less fuel odour on customers’ hands or gloves when they’re at the pump.
The spring-loaded flapper door is held closed by two latches that can only be released by a standard-size unleaded fuel nozzle. When the proper nozzle is inserted into the filler neck of the system, the latches release, and the nozzle pushes the spring-loaded flapper door to the open position. When the nozzle is removed, the flapper door automatically is forced closed by the spring.
The fuel filler pipe is then completely sealed, which prevents fuel vapours from escaping and helps reduce evaporative emissions.
“Every time a fuel cap is either lost or not screwed on properly, that equates to evaporative emissions entering the environment,” said Brian Aitken, a Ford fuel systems supervisor. “With Easy Fuel, these scenarios are no longer a problem.”
Easy Fuel also has a patented mis-fuelling inhibitor to reduce improper fuelling and siphoning. The inhibitor consists of a fuel nozzle detector that guides the nozzle to the opening. If a nozzle or foreign tube of a different size – a diesel nozzle or plastic hose, for example – is placed in the filler neck of a gasoline-powered vehicle, the latches will not release. For a diesel-powered vehicle, the inhibitor will keep out the smaller gasoline nozzles.
To protect the fuel filler neck from dirt, dust and debris, Easy Fuel relies on a flexible rubber seal in the body housing. The system also comes with a handy plastic funnel, which is stored with a vehicle’s tyre changing kit, in case someone runs out of fuel and needs to add a gallon or two from a portable container.
“Because fuel cans are not standardised in terms of their nozzle, we needed to make sure customers could easily get fuel into the system if they ran out,” said Aitken. The funnel is the same diameter as an unleaded fuel pump nozzle for a gasoline-powered vehicle.
Digital Thermostat
Traditional “analog” thermostat temperature-control systems for vehicles will soon be a technology of the past if inventor Tom Hollis has his way. Switching to digital can manage critical fluid systems in a way that significantly improves fuel economy, reduces emissions and engine and driveline wear to help extend the life of fluids critical in the operation of engine components.
“When you think of the sophisticated systems in a vehicle today, it comes as a surprise that we still use analog systems to control the interaction of the engine with the radiator system,” said Hollis, director of Advanced Research -- MileageMatrix, Inc.
“After all, those fluids protect the vehicle’s most important operating systems – the engine and driveline – and running them too high or too low simply wastes energy.”
The Digital Rotary Control Valve (DRCV) will provide a “true” powertrain thermal management system that, after mapping, will always allow the engine/transmission to function at their "known" optimum operating temperatures under all driving conditions. The computer-regulated system monitors temperatures at several under-bonnet locations and controls the single DRCV to maintain optimum engine and transmission temperatures, throughout all engine load conditions and extreme ambient temperature ranges.
Developed by Hollis and manufactured by All Service Plastic Molding for MileageMatrix Inc., the component relies on DuPontTM Zytel® HTN PPA resins for the valve body, tube and diverter. The materials’ resistance to continuous exposure to hot long-life coolant up to 130°C, and retention of properties with moisture proved optimal for this application.
“We had to be very sensitive to expansion and contraction because all surfaces are always ‘wet’ and we needed a ‘fluid bearing’ to prevent sticking,” said Hollis.
Critical to the components’ success is its ability to provide precision temperature function between the engine/transmission and radiator.
“Every BTU that exits through the radiator, provides ZERO heat energy value,” said Hollis.
Results from an initial, three-year test program shows fuel economy can improve 8 percent during the winter, and Hollis said they expect year-round fuel economy improvements greater than 5 percent. The component is currently being tested to rigorous OEM specifications.
“The key to improving fuel economy and reducing emissions is getting the engine/transmission fluid temperatures up to optimum operating temperatures fast and maintaining known optimum temperatures,” said Hollis. “Current analog thermostat systems serve the industry well, but this type of digital system can not only meet current cold-start test standards, mostly conducted at 23°C, but they can also optimize performance at a very wide range of ambient temperatures.”
Hollis also noted that engine oil temperature is always maintained well above dew-point, greatly extending the oil-change interval as moisture quickly evaporates. This could result in reduced oil use and fewer used oil filters for disposal.
BMW’s New Wind Tunnel
The BMW Group’s new Aerodynamic Test Centre (ATC) is the world’s most modern facility of its type in the automotive industry. The ATC comprises a wind tunnel allowing analysis of full size vehicles. To reproduce the most important effects and phenomena when driving on the road, the road surface is modelled through a simulation process using no less than five rolling tracks.
A second wind tunnel allows the engineer to move the models tested from one position to the other by means of a control system operating in all directions above the world’s largest wind tunnel rolling road. This allows analysis of vehicle flow conditions under all kinds of circumstances, applying a concept already used for a number of years in motorsport.
The number of scenarios available, as well as the precision of the test processes applied at the ATC, offer a standard quite unique for a facility of this kind. Both wind tunnels are able to generate an air flow velocity of up to 300 km/h or 186 mph, for the first time providing exactly the right, correct physical conditions for the measurement of true-to-scale models.
In all, the BMW Group has invested some Euro 170 million in the construction of the ATC and the facilities/equipment used. The five-floor building is constructed on a piece of land measuring approximately 25,000 square metres or 6.2 acres, located in the immediate vicinity of the Munich FIZ Research and Innovation Centre.
Virtual Instrument Panel
Global automotive supplier Visteon Corporation has launched a reconfigurable instrument cluster on Jaguar Land Rover’s new Range Rover.
Replacing the conventional instrument cluster design, the reconfigurable 12.3-inch full colour Thin Film Transistor (TFT) display integrates multiple functions and operating modes to present on-demand driver information via virtual gauges, graphical displays and a message centre.
By introducing an advanced graphics interface, the reconfigurable cluster presents information to the driver in an innovative way, while helping reduce driver distraction. The cluster redefines the functional role of instrumentation by providing an interface to safely manage the complexity of the Range Rover’s advanced vehicle systems through the reconfigurable message centre, which acts as the information hub for the vehicle.
“The new display technology used by the 2010 Range Rover is a major advance. It gives us tremendous flexibility in presenting information, so that the driver gets precisely the data he or she requires, in all driving conditions,” explains Nick Rogers, chief engineer, new vehicle architecture, Range Rover.
The Range Rover “virtual cluster” is the first production program launched from Visteon’s reconfigurable cluster platform and the latest in its range of clusters with graphic displays. The platform also offers vehicle manufacturers the flexibility to use one hardware solution with multiple graphic applications for easier vehicle differentiation or mid-model refresh.
Intelligent Towbar Wiring Socket
Yazaki North America, Inc. has released IntelliTowTM. The intelligent towing system is the first of its kind to combine electronics, power switching and connectors for a smarter, safer towing experience.
“IntelliTowTM represents a combination of three Yazaki disciplines – solid state power models, advanced connection systems and junction boxes – combined with system diagnostics, intelligence and resettable fusing all in an application where never before used,” said Robert Crumley, executive vice president, technology, engineering and advanced development, Yazaki North America. “Our customers will benefit from fewer parts, simplified wiring, less weight and reduced warranty costs, and the end consumer will gain peace of mind while towing.”
IntelliTowTM improves the safety of vehicles and trailers by providing drivers with real-time information about the trailer’s performance. Through an in-dash messaging system, the system’s diagnostics notify the driver when a failure occurs with trailer lighting and battery charge circuits. Diagnostic feedback is offered for short and open circuit for running lights, right turn/brake lights, left turn/brake lights, reverse, and battery outputs. Electronic braking is a pass-through circuit.
The environmentally resistant module fits in a standard 4 or 7-pin opening and offers standard 4 and 7-pin trailer connectors. The outputs can be controlled using the vehicle communications bus, CAN, LIN, or discrete inputs.
The system is capable of load learning for multiple trailers and is completely submersible for boat launching. The product is designed to greatly reduce terminal corrosion and includes self-resetting smart fusing to avoid intermittent failures.
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