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GM Honors Top Innovators of 2004


May 2005
 Filed under: GENERAL MOTORS CORPORATE Car News | GENERAL MOTORS CORPORATE Headlines
DETROIT, Michigan. - General Motors honored its top innovators of 2004 at the 29th annual "Boss" Kettering Awards ceremony last week. The "Boss" Kettering Award is GM's highest award for recognizing GM technical inventions and innovations. Its purpose is to honor individuals from every region of the globe whose outstanding inventions and innovations have demonstrated identifiable and substantial benefit to General Motors during the previous year. Awardees join an elite group at GM, becoming part of a tradition of innovation stretching back to GM's earliest days.
The prestigious internal award is named for the legendary Charles F. "Boss" Kettering, who launched GM's Research and Development organization in 1920. A prolific inventor himself, Kettering held more than 140 patents.

Following are descriptions of the innovations and the "Boss" Kettering Award winners for 2004.

ADVANCED AUTOMATIC CRASH NOTIFICATION

Advanced Automatic Crash Notification (AACN), an industry first, makes emergency information available to 911 centers so that they can send the appropriate life-saving personnel and equipment to crash scenes faster. Using a collection of sensors, AACN automatically calls an OnStar advisor if the vehicle is involved in a qualified frontal, rear or side-impact crash, regardless of air bag deployment. AACN provides crash severity information to OnStar advisors, who relay it to 911 dispatchers. AACN systems can determine the severity of crash, direction of impact, air bags deployed, multiple impacts and rollover (if equipped with appropriate sensors).

The Advanced Automatic Crash Notification team includes Dr. Jasmin Jijina, Dan McGarry, and Matt Przybylski all of OnStar in Detroit, Michigan; and Tom Mercer, Vipul Modi, and Brian Sychta all of GM Product Development in Warren, Michigan.

ADVANCED DIGITAL DIE TECHNOLOGY

This leading digital die technology was developed for line die forming simulations to predict and resolve potential failures and quality problems. It allows for digital validation of stampings before physical die construction and tryout and improves the quality of stamping components, sub-assemblies, and vehicle assembly. The innovation shortens line die tryout time and significantly improves the robustness of the stamping process. This innovation strengthens GM's global technology and business leadership in math-based die engineering and math-guided stamping manufacturing.

The Advanced Digital Die Technology team includes Dr. Venkat Aitharaju, Dr. Jennifer Dong, Dr. Norman Goan, Jeff Gress, Dr. Ramesh Joshi, Dr. CT Wang, Dr. Si Xu, and Dr. Jimmy Zhang all of GM Manufacturing & Labor Relations in Pontiac, Michigan.

AERODYNAMIC SHAPE DEVELOPER

Aerodynamic Shape Developer (ASD) is a software program for estimating aerodynamic drag information for new vehicles. It utilizes information taken from existing tests to allow a user to dynamically represent and modify simplified vehicle concepts on a computer screen. The user can instantaneously determine the effects of vehicle shape and shape changes on aerodynamic drag. ASD is currently capable of modeling cars, SUVs, vans and pickups.

The Aerodynamic Shape Developer team includes Dr. Constantinos Koromilas of GM R&D and Strategic Planning in Warren, Michigan, and Dr. Sanjay Kumarasamy of GM Product Development in Warren, Michigan.

AUTO-GENERATION OF ELECTRICAL CONTROLS DESIGN

The GM-EPLAN CAE Tool provides for rapid and accurate generation of controls hardware designs, reducing both design costs and lead times. Based on commercial EPLAN electrical CAE software, GM's customized application uses standard data templates to produce detailed schematics, interconnect diagrams, panel layouts, fluid power circuits and Bills of Material. EPLAN's object-oriented database handles the routine controls design tasks, while GM's innovative eDrawing application and other utilities automatically generate GM standard detail design graphics and reports; significantly reducing effort and improving accuracy of the output.

The Auto-generation of Electrical Controls Design team includes Aaron Dunlap, and Jim Jenkinson both of GM Manufacturing & Labor Relations in Pontiac, Michigan; Dr. Sushil Birla of GM R&D and Strategic Planning in Warren, Michigan; Jerry Cinpinski, Daniel King and James Tucker all of GM Manufacturing & Labor Relations in Warren, Michigan, and Peter Mueller of GM Product Development in Rüsselsheim, Germany.

AUTOMATIC CODE GENERATION FROM MODELS

This innovative method allows production software source code to be automatically generated and integrated into a production environment quickly and error free. Currently, automotive production source code is manually generated by software engineers who translate requirements to code, a process that is time consuming and subject to errors. Automatically generating code offers improvements in time, quality, and cost.

The Automatic Code Generation From Models team includes Joe Dulzo, Hamid Esfahan, Jerry Kortge, Mike Kropinski, Satish Kumar, Michael Lucido, Onassis Matthews, Mike Steele, and Cheryl Williams all of GM Powertrain in Milford, Michigan.

CLUTCH-TO-CLUTCH SHIFT CONTROL SYSTEM

This innovation consists of groundbreaking control logic and the hydraulic hardware necessary to control clutch-to-clutch transmissions with world-class shift quality. These methods enable five- and six-speed transmissions to be integrated with various engines and platform combinations with significantly reduced calibration effort. Included is FAST Learn, an algorithm that compensates for initial build variation, allowing the control logic to deliver excellent shift quality right out of the vehicle assembly plant and over the life of the transmission through adaptive learning. The control logic with reduced calibration effort minimizes development cost, time, and improves overall quality.

The Clutch-to-Clutch Shift Control System team includes Jeff Cole, Martin Dadel, Kevin Kluemper, Scott Kluemper, Chuck Long, Phil McCauley, Scott Mundy, and Jeff Runde all of GM Powertrain in Indianapolis, Indiana; and Greg Hubbard of GM Powertrain in Milford, Michigan.

DISPLACEMENT ON DEMAND

Displacement on Demand (DOD) saves fuel by using only half of the engine's cylinders during most normal driving conditions. The system automatically and seamlessly reactivates the other cylinders when the driver needs the engine's full capabilities for brisk acceleration or load carrying. DOD enables GM to market vehicles with improved fuel economy while simultaneously meeting performance, emissions, noise, vibration and harshness, as well as customer expectations.

The Displacement on Demand team includes Tom Bolander, Dr. Chuck Folkerts, Dr. Greg Matthews, and Alex Roberts all of GM Powertrain in Milford, Michigan; Bill Albertson, Jim Hicks, Allen Rayl, and Fred Rozario all of GM Powertrain in Pontiac, Michigan, and Jeff Allen of GM Powertrain in Warren, Michigan.

DUAL TANK SIMULTANEOUS FILL SYSTEM

This innovation allows for one fuel filler neck to be utilized in a two-fuel tank system. Through the incorporation of a "Y" joint, customers fill both tanks just as they would in a single tank system. As vehicle packaging of large fuel systems becomes more difficult, this invention facilitates the ability to have large on-board fuel capacity utilizing two fuel tanks in a reliable cost-effective fill system. It provides more flexibility in packaging, with no cost disadvantage for GM. Transparent to the customer, it provides ease of use, reliability, and consistent fuel fills.

The Dual Tank Simultaneous Fill System innovator is Dr. Akram Zahdeh of GM Powertrain in Pontiac, Michigan.

FLEXPOWER TECHNOLOGY

Flexpower Technology (ethanol/gasoline fuel blend vehicle operation) is a new technology jointly developed with GM Powertrain, Delphi and Bosch. It consists of a high-tech engine management system able to control all combustion engine functions for best operation when using alcohol, gasoline, or any percentage of blends involving both fuels.

The Flexpower Technology team includes Jorge Bersani and Adolpho Pilato Junior both of GM Product Development in São Caetano do Sul, SP, Brazil; and Luiz Henrique Riedel, José Luiz Minelli and Fernando Pio all of GM Product Development in Indaiatuba, SP, Brazil.

HYBRID POWERTRAIN ELECTRIC MOTOR INTEGRATION

This unique, compact powertrain integration of an electric motor has allowed GM to produce the world's first hybrid full-size truck with minimal impact to the basic vehicle architecture and assembly processes. Selection of a downsized torque converter provides space for the electric machine to be packaged concentrically around it in roughly the same diameter and length as the standard larger torque converter. In turn, the electric machine smoothes out driveline torque disturbances to enable early torque converter clutch lockup, which negates the inherent disadvantages, such as overheating, of a smaller torque converter.

The Hybrid Powertrain Electric Motor Integration team includes Dave Evans of GM Powertrain in Milford, Michigan, and Keith Van Maanen of GM Powertrain in Troy, Michigan.

IDSplus INTERACTIVE DYNAMIC DRIVING SYSTEM

A joint innovation project between Opel Advanced Engineering and GM R&D was initiated and then transferred to Opel Product Engineering. It is an example of outstanding teamwork encompassing multiple disciplines of chassis control, vehicle dynamics, math-based control design, vehicle test & validation. The team worked creatively and effectively to functionally integrate different chassis control systems from multiple suppliers and to enhance overall vehicle active safety and performance.

The IDSplus team includes Dr. Youssef Ghoneim of GM R&D and Strategic Planning in Warren, Michigan; and Dr. Christian Bielaczek, and Thomas Jenny both of GM Product Development in Rüsselsheim, Germany.

KNOWLEDGE-BASED DIE TOOLING INNOVATION

Knowledge-based die tooling is a digital technology that supports the design process by reducing delivery time and increasing productivity in tooling engineering for metal fabrication. The innovation is comprised of three key elements: an optimizing system for tooling design and implementation of a die template, a web-based supplier collaboration system, and a 3D design-based intelligent CAM system for 2D machining. The innovation allows for die design standardization through template utilization.

The Knowledge-based Die Tooling Innovation team includes Bak Se-Jin, Hyun Ji-Won, Ju Sang-Yul, Kwon Sung-Oh, Lee In-Seok, and Song Myeong-Hwan all of GMDAT in Incheon, South Korea.

OVAL - GENERAL MOTORS VIRTUAL AERO LAB

GM Virtual Aero Lab (OVAL) is a new software environment that speeds up the common simulation process for external aerodynamics by incorporating a high degree of automation and improved user-friendliness. Using OVAL, the working time for one simulation can be reduced, resulting in a much faster turnaround for the computation of multiple body variants. OVAL is a key enabler for virtual aerodynamic optimization of vehicles. It supports standardized workflow for use in all GM regions and allows a global sharing of math models and standardized procedures and deliverables.

The OVAL - General Motors Virtual Aero Lab team includes Silvestre Artiaga Hahn, and Frank Werner both of GM Product Development in Rüsselsheim, Germany.

RAPID RETARD PROCEDURE FOR ENGINE TORQUE

This innovation provides a means for rapidly determining the effects of ignition timing on engine torque throughout the full dynamic range of vehicle engine operation. Increasingly complex engine torque control algorithms are used to facilitate the management of engine torque for transmission shift quality and traction control. Discrete changes in spark advance result in immediate changes in engine output. Historically the response of engine torque to spark advance has been determined through steady-state dynamometer testing. This requires that the engine be stabilized at each operating point prior to acquiring data. This is time consuming and places unrealistic constraints on the range of testing. The new procedure utilizes measured engine combustion parameters to allow testing of extremely short duration, thus improving productivity and removing the unrealistic constraints on testing.

The Rapid Retard Procedure for Engine Torque team includes Joe Kelly, Dr. Dave Lancaster, Sean Slade and Ray Sroka all of GM Powertrain in Warren, Michigan.

ROOF RAIL

Roof Rail is an industry-first, stainless steel Class-A exterior surface application of hydroforming technology. This innovation utilizes existing hydroforming technology to form a steel tube into a one-piece roof rail in order to replace the multi-part standard systems in use. While the first tryouts to hydroform a roof rail were made over a decade ago, it is the integrated design that allowed the application of this technology to the base car. As a result, the roof moldings used in combination with prior roof rails have been eliminated. This technology saves costs, yet allows a very sporty design of the vehicle.

The Roof Rail team includes Helmut Huerter, Bernhard Mathes, Richard Stahlhut and Tobias Stever all of GM Product Development in Rüsselsheim, Germany.

THICK FILM THERMOFORMED EXTERIOR MOLDING

This technology is a low-cost, fast-to-market, thermoforming process that when married to a colored-matched capped plastic sheet, allows for the fabrication of a truly Class-A automotive part. The final formed part possesses superior chip resistance and low temperature impact performance. Utilizing a low cost thermoform fabrication method with aluminum reduces tooling costs when compared to steel tools. Additionally, the molding process is very flexible and can be installed at any assembly plant thus reducing shipping and mutilation costs.

The Thick Film Thermoformed Exterior Molding team includes Mike Balogh and Chuck Mentzer both of GM R&D and Strategic Planning in Warren, Michigan; Chuck Buehler, Cathy Ostrander and Mike Szymberski all of GM Product Development in Warren, Michigan; and Steve Schmidt of GM Manufacturing & Labor Relations in Warren, Michigan.

THROUGHPUT ANALYSIS AND IMPROVEMENT SYSTEM

The Throughput Analysis and Improvement System, through innovative applications of GM-developed standard tools, data, and processes, has dramatically improved the throughput performance of GM plants. Key elements include: new algorithms and methods for the fast, analytic approximation of throughput; a new hybrid simulation algorithm providing fast and accurate analysis of throughput in complex manufacturing systems; a novel system architecture which encapsulates analysis algorithms in an environment that is expandable to provide throughput analysis in support of a variety of business needs; a flexible user interface for manufacturing system design applications; a new web-based data collection and reporting system to enable in-plant operations improvement; and an industry-first throughput improvement process coordinating the use of the above innovations. Applying these innovations resulted in reduced non-scheduled overtime, higher productivity, less process waste, and fewer missed production targets.

The Throughput Analysis and Improvement System team includes Dr. Jeffrey M. Alden, Craig Jackson, Dr. Bill Jordan, and Dr. Jonathan H. Owen all of GM R&D and Strategic Planning in Warren, Michigan; Mark G. Emeott, Todd Meredith, John Rabaey, and Dr. Demet Wood all of GM Manufacturing & Labor Relations in Warren, Michigan; Ted Costy of GM Global Purchasing & Supply Chain in Warren, Michigan; Dr. David Vander Veen of GM Product Development in Warren, Michigan; and Richard D. Hutton of GM Manufacturing & Labor Relations in Rüsselsheim, Germany.

TORQUE-RIPPLE-FREE ELECTRIC POWER STEERING

Torque-Ripple-Free Electric Power Steering (TRF-EPS) is a world-class fuel-efficient electric power steering technology using advanced electronic control to provide smooth steering control. This novel technology reduces the steering vibration due to torque ripple and improves fuel economy. It enabled implementation of electric power steering on GM mid-size vehicles, an industry-first in North America. TRF-EPS simplifies the vehicle assembly and service process by eliminating the hydraulic pump, hoses, and fluid handling while reducing warranty costs associated with hydraulic fluid leakage and pump noise.

The Torque-Ripple-Free Electric Power Steering innovator is Dr. Chandra Namuduri of GM R&D and Strategic Planning in Warren, Michigan.

General Motors, the world's largest automaker, has been the global industry sales leader since 1931. Founded in 1908, GM today employs about 321,000 people around the world. It has manufacturing operations in 32 countries and its vehicles are sold in 200 countries. More information can be found at www.gm.com.

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