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Laser surface treatment machine for Ariane 6 Cryogenic Tanks

Electroimpact-Jeremy FERRER
  • Technical Paper
  • 2019-01-1897
To be published on 2019-09-16 by SAE International in United States
Surface treatment of cryogenic tanks (liquid oxygen and liquid hydrogen) for the Ariane 6 Space Launcher is a critical step for the adhesion of insulation materials. This operation is currently performed by the help of chemical products which are for some of them carcinogenic, mutagenic and repro-toxic. The large tank dimensions require using an important quantity of those products which generate massive recurring costs and health and environment problems. ArianeGroup has previously qualified and patented the Laser Surface Treatment as a replacement solution to chemical process. The aim is to use energy provided by infrared laser beam to modify the top layer of the tank surface. The chosen technology is Nd-YAG pulsed laser. Electroimpact has been chosen to carry out the industrial application. The main components of the laser system are a laser source, to generate the laser beam, an optic fiber to transport the beam and an optic with galvo mirrors to focus and move the laser on the part. The optic scan field is about 50 x 50mm, so it needs to be…
 
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Fast Broadband Curved Insertion Loss Simulation of an Inner Dash Insulator Using a Cylindrical Transfer Matrix Method Spectral Approach

Interac-Gerard Borello
Treves-Arnaud Duval, Mickael Goret
Published 2019-06-05 by SAE International in United States
Middle and high frequency vibro-acoustic simulation of complex shape insulators requires using 3D poroelastic finite elements. This can be applied to either the whole part (up to 2500 Hz maximum) or through singly curved pre-computed Insertion Losses (up to 5000 Hz maximum) to be introduced in large SEA or energy-based models. Indeed, a dependence of the Insertion Loss slopes of noise treatments following the curvature is observed both experimentally and numerically. Beyond frequency range limitations, poroelastic finite element simulations following all curvatures and thickness 3D maps typically take too much time of up to a few hours each. A cylindrical Transfer Matrix Method spectral approach significantly reduces the time for the calculation of singly curved Insertion Losses up to 10 kHz to only a few minutes. This simplifies enormously the SEA modeling effort enabling easier, more precise fully trimmed vehicle middle and high frequency vibro-acoustic simulations. A dash insulator Insertion Loss numerical validation case will be presented comparing the different methods.
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Acoustic Effects of Lightweighting in a Sport Utility Vehicle

Autoneum North America, Inc.-Andrea Lynne Frey
Published 2019-06-05 by SAE International in United States
Weight reduction is a significant concern for automotive manufacturers, and is often achieved by removing as much mass as is safe from the structure of the vehicle. This has a negative effect on the interior acoustics, which has become more and more of an issue as technology has advanced and people expect to be able to do business and consume media in their vehicles. Traditional acoustic treatment tends to be very heavy, which eliminates some of the weight savings.Recently a vehicle study was performed to determine if the current production sound package in a highly-rated sport utility vehicle could be maintained or improved while reducing the weight. This paper presents the results of that study. The study focused on road noise transmitted through the floor (carpet, rear wheelhouse inner and trunk insulation) and engine noise transmitted through the dash (dash inner). Testing was performed both at the vehicle level on the road and at the component level in the laboratory. It was found that the lightweight sound package was highly effective against road noise, but…
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Composite Fuel Tanks, Fuel System Design Considerations

AE-5A Aerospace Fuel, Inerting and Lubrication Sys Committee
  • Aerospace Standard
  • AIR5774
  • Current
Published 2019-05-16 by SAE International in United States
This SAE Aerospace Information Report (AIR) is a compilation of engineering references and data useful to the technical community that can be used to ensure fuel system compatibility with composite structure. This AIR is not a complete detailed design guide and is not intended to satisfy all potential fuel system applications. Extensive research, design, and development are required for each individual application.
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Insulation Sleeving, Electrical, Heat Shrinkable, General Specification for

AE-8D Wire and Cable Committee
  • Aerospace Standard
  • AS23053A
  • Current
Published 2019-04-08 by SAE International in United States
This specification establishes the requirements for various types and colors of electrical insulating sleeving that will shrink to a predetermined size upon the application of heat. This specification includes provisions for demonstrating compliance with qualification requirements (see Section 4 and 7.3), in process inspection, and statistical process control inspections (see 4.4). The continuous operating temperature ranges for the sleeving classes covered by this specification are from -112 to +482 °F (-80 to +250 °C). The continuous operating temperature range for each sleeving class is given in the applicable detail specification.
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INSULATION SLEEVING, ELECTRICAL, HEAT SHRINKABLE, FLAME RETARDED, MODIFIED POLYOLEFIN, FLEXIBLE, CROSSLINKED

AE-8D Wire and Cable Committee
  • Aerospace Standard
  • AS23053/17
  • Current
Published 2019-04-08 by SAE International in United States
No Abstract Available.
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Dielectric Test Methods for Evaluating Sparkplug Insulators

Fram Group Co.-Jing Zheng, Danny R. Overton, Corey Eiden, Philip Paul Treier
Published 2019-04-02 by SAE International in United States
Dielectric testing is essential in developing ceramic insulators for spark plugs used in modern engine platforms. Many test methods are developed for different materials and applications. At Autolite, parallel plate dielectric testing based on the ASTM standard was used for material evaluation. The paper will cover the factors that influence the measurements in these tests as well as a comparison of insulator materials from different spark plug manufacturers. Furthermore, to better evaluate the performance of final product, Autolite developed a proprietary engine dielectric test method for spark plugs. The test method is compared with most conventional tests in the automotive industry, and the performance of spark plugs using Autolite conventional and next gen ceramic will be reported.
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Thermal Modeling and Sensitivity Analysis of a Traction Motor in a Production EV

GAC R&D Center Silicon Valley Inc.-Xiaohui Li, Jin Shang, Bozhi Yang
Guangzhou Automotive Engineering Institute-Linpei Zhu, Xiong Liu, Fei Xiong
Published 2019-04-02 by SAE International in United States
Thermal design is critical to the performance and reliability of electric vehicle’s traction motor which may suffer from issues such as de-magnetization of permanent magnets and aging of insulation layer of copper winding wires at high temperature. In this work, CFD simulation was first conducted using ANSYS FLUENT to study the heat transfer and fluid flow inside the stator-rotor air gap and the end space of an electric traction motor used in a production vehicle (GAC’s pure electric GE3 SUV). To study the effect of air gap thickness, analytical results based on thermo-fluid theory were also computed and compared to CFD results. We then conducted lumped-parameter thermal network (LPTN) simulation of the traction motor. The model consists of 74 nodes, in which each stator end winding was modeled as three-layer structure to capture the inner temperature gradient. A sensitivity analysis was also performed over a range of parameters, e.g., material thermal conductivity, thermal contact resistance at interfaces, stator-rotor air gap thickness, convective heat transfer coefficient at the two end spaces. This systematic work is highly…
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Developing High Dielectric Strength Alumina for Spark Plugs

Fram Group Company-Jing Zheng, Danny R. Overton, Philip Paul Treier
Published 2019-04-02 by SAE International in United States
Engine downsizing and widely adopted Gasoline Turbo Direct injection (GTDi) technology has led to harsher application condition for spark plugs, which demand insulators with higher dielectric strength to meet the new challenges in modern engine platform. To improve conventional alumina insulators, the influences of material properties, such as porosity, grain size, glass chemistry and surface finish, on dielectric strength performance are studied. It is also found that, the manufacturing process can greatly impact the final performance. Hence, the effort in optimizing process variables will be discussed and the performance of resultant Autolite HD95 ceramic will be reviewed against those of several leading manufacturers.
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Fluorinated Ethylene Propylene (FEP) as a Dielectric Material for Multi-Gigabit, Single Pair Ethernet Cable for Automotive

Daikin America Inc.-Daniel Kennefick
Published 2019-04-02 by SAE International in United States
Testing of wire insulation (dielectric) materials for dielectric constant and dissipation factor from -40°C - 150°C is presented. These test results are inserted into known cable attenuation equations to reveal what material is superior within a 1-10GHz frequency band.
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