Transportation Energy Data Book: Edition 28

Davis, Stacy Cagle; Diegel, Susan W; Boundy, Robert Gary

doi:10.2172/970887

Cited by 61 publications

(44 citation statements)

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“…This increased diversity can be seen in fi gure 1, showing material decomposition in American automobiles over the latest 40 years [13,14]. Notably, the plastic and plastic composites as well as aluminum content have grown with time, while regular steel proposes a smaller portion of the materials with each year (from ~54 per cent to ~35 per cent) [13,14]. Looking at this shift for the industry, it seems like advances in material and manufacturing technology, along with increased demands on sustainability, enable new materials to be introduced and used increasingly in mass-produced vehicles.…”

Section: Automotive Industry Challengesmentioning

confidence: 96%

“…Material distribution (in %) of an average American car by year (adapted from [13] and [14] Production system challenges To be able to introduce new materials, the production system needs to be taken into account. The production system can be defi ned as "the people, equipment, and procedures that are organized for the combination of materials and processes that comprise a company's manufacturing operations" [15].…”

Section: Figurementioning

confidence: 99%

“…Effi cient knowledge gathering 4,6,7,9,13,14 Understanding the production system's eff ect on the product 1,3,4,6,7,12 Understanding the product's eff ect on the production system 3,5,6,7,9,10,11,14,15 …”

Section: Aspects To Analyze Insights From Case Studiesmentioning

confidence: 99%

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Introducing New Materials in the Automotive Industry: Managing the Complexity of Introducing New Materials in Existing Production Systems

Henriksson¹

2017

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Passenger vehicles are central to Western society, and contribute to a signifi cant part of our greenhouse gas emissions. In order to reduce emissions, the automotive industry as a whole is working to reduce mass in passenger vehicles in order to reduce energy consumption. One way to reduce mass is to introduce lightweight materials in the body of the vehicle. This research aims to explore the relationship between product and production system when introducing new materials.Besides a theoretical review and an industry-centered technological mapping, four case studies have been conducted during the course of this licentiate thesis. Two case studies were conducted with engineering design students working as development teams, one case study with the author as the developer and fi nally one case study in an industrial environment at a product owning company with in-house production.The goal of the case studies has been to increase the collective knowledge of how product development decisions aff ect production development decisions, and vice versa, when developing passenger vehicles in new materials.In the following analysis of case study outcomes, a number of factors important for introducing new materials are discussed. The relationship between product and production is investigated, both in terms of how the production system aff ects the product and how the product aff ects the production system. The outcome from this analysis is a mapping of important factors for automotive industry companies to understand and identify when looking at introducing new materials in existing production systems. Finally, a suggestion for future research eff orts is presented. ACKNOWLEDGEMENTS

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Section: Automotive Industry Challengesmentioning

confidence: 96%

Section: Figurementioning

confidence: 99%

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Introducing New Materials in the Automotive Industry: Managing the Complexity of Introducing New Materials in Existing Production Systems

Henriksson¹

2017

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“…Figure 2 shows that further material differentiation is a continuing trend. Notably, the plastic and plastic composites as well as aluminum content have grown with time (from around six per cent to nine and ten), while regular steel proposes a smaller portion of the materials with each year (from ~44 per cent to ~39 per cent) [4,5]. Advances in material and manufacturing technology along with increased demands enables new materials to be introduced, and used increasingly in mass produced vehicles.…”

Section: Figure 1 Vehicle Mass Divided Per Subsystem (After [1])mentioning

confidence: 99%

An Outlook on Multi Material Body Solutions in the Automotive Industry - Possibilities and Manufacturing Challenges

Henriksson¹,

Johansen²

2016

SAE Technical Paper Series

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In the automotive industry, mass reduction and lightweight design is a continuing trend that does not show signs of declining. When looking at where to reduce weight in a vehicle, the body is a preferential subsystem due to its large contribution to overall mass and the stability of body composition over a specific model range. The automotive industry of today moves toward a greater differentiation in materials that compose a car, which can be seen in the several different multi material vehicle bodies that have been introduced by manufacturers in recent years. But while mixing materials may contribute to a good compromise between weight reduction and vehicle cost, it also proposes a number of challenges that need to be addressed. Among other material factors, the different coefficients of thermal expansions might introduce new stresses during painting and curing. Joining processes and possible chemical reactions between materials also needs to be taken into account, the same with the question of whether to integrate or differentiate different functions in a system. If the manufacturing plant uses mixed model assembly lines, design of end effectors for gripping multiple different materials is another challenge not previously encountered in this context. In this paper, a number of production and manufacturing related challenges are discussed, and the authors highlight different areas where the requirements of design engineering tools needs to be evaluated for these new multi material concepts and design decisions in order for automotive manufacturers to ensure future market competitiveness. IntroductionAt the moment, large emphasis in industry is put on reduction of energy consumption. This is especially true in the automotive industry. A vehicle's energy consumption can be divided into three discrete phases: production phase, use phase and end of life phase. The production phase will include everything up until delivery to the first user, the use phase will consist of the cars "life" as a driven vehicle and end of life includes disassembly, reuse and recycling. While development is not mentioned anywhere in these three phases (and occurs before the first phase, production, is initiated), decisions made during the development of a vehicle will affect energy consumption in both production, use and end of life. Therefore, it is interesting to look at what can be done during development that will reduce energy consumption in later phases. The automotive industry and its different stakeholders currently focus on energy savings, and one way of achieving this is by reducing the fuel consumption of a vehicle. The fuel consumption of a vehicle can be described as in equation 1 [1]. The denotation can be seen in table 1.

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“…While the AFDC reports 2,403 propane stations in the United States, this number pales in comparison to the number of gasoline stations available to the public, at roughly 164,000 in 2007 (Davis et al 2009). As previously noted, the Clean Cities Program and industry are trying to address this issue by building refueling infrastructure, which will link cities together in key markets.…”

Section: Adequate Number Of Refueling Stationsmentioning

confidence: 99%