AutoBrochure_CSIRO innovations.pdf

8/14/2019 AutoBrochure_CSIRO innovations.pdf

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Innovation for the Automotive Industry

Louie Douvis/FairfaxPhotos





CSIRO is addressing the important issues facing the automotive

industry with active programs in environmental sustainability and newmaterials through to vir tual design and manufacturing systems.

Our capabilities in action

CSIRO has decades of demonstrated expertise in automotive

materials and manufacturing technology, from mathematical

modelling and computer aided visualisations to welding and

advanced composite materials.

Casting technologies

T-Mag™

T-Mag™, an innovative magnesium

casting technology, enables super-light

magnesium alloys to be cast into high

integrity, high strength automotive

components which are cost-competitive

with those made from aluminium or steel.

T-Mag Pty Ltd, a joint venture between

CSIRO and three Australian companies,

is taking T-Mag™ technology to the global automotive industry.

Advanced thixotropic metallurgy

CSIRO’s Advanced Thixotropic

Metallurgy (ATM) heralds a new age

of quality high pressure die casting.

ATM is particularly suited to aluminium

or magnesium alloys. It offers lower costs

and improved quality in products such as

safety critical automotive components.

Mathematical modelling

Our specialists in simulation,

mathematical problem solving and

information visualisation cover:

• nite-element modelling

• adaptive supply networks

• whole-of-life modelling

• human-vehicle interfaces

• planning and operations optimisation

• exible virtual enterprises

• passenger cabins as smart spaces.

Safety systems

CSIRO’s Safe-T-Cam system

monitors heavy vehicle trafc

on Australia’s highways.

Our award-winning RoadCrack

system is used to assess the integrity

of the road surface from a vehicle

travelling at normal highway speeds.

> CSIRO’s casting technology

makes components made of

super-light magnesium alloys an

economically viable alternative.

> CSIRO has specialists in simulation,

mathematical problem solving

and information visualisation.

Advanced materialsCSIRO has considerable expertise in

• textiles

• light metals

• sustainable manufacturing

• heat recovery

• visual inspection

• autonomous vehicles

• adaptive supply networks.

Technology already used by automotive

manufacturers and suppliers includes:

• advanced composite fabrication

• textiles and bres

• polymer coatings

• bonding techniques.

We also work with component suppliers.

For example, we collaborated with a

leading manufacturer to produce new

high strength alloys for bearings.



Lightweighting

We are leaders in using light metals such

as aluminium, magnesium and titanium.

Our recent breakthrough in heat

treatment of aluminium alloys has

the potential benet of lower vehicle

mass and higher crash safety.

Other research is pioneering twin-roll

cast and nished-rolled magnesium sheet.

Rapid design

CSIRO’s virtual design and engineering

technology can more than halve the time

from concept car to production vehicle.

It integrates the design, engineering and

manufacturing processes and signicantly

reduces the need for prototyping.

For example, our augmented reality

tools such as haptics (the ability to

touch in virtual reality) can be used

to visualise assembly processes.

Environmental sustainability

Drawing on our long-term capabilities

monitoring air pollution, CSIRO performs‘well-to-wheel’ analysis of alternative fuels

to examine their climate-friendly status.

With the rise of electried vehicles,

CSIRO is developing cleaner methods of

electricity generation and smart ways of

integrating distributed sources of energy.

> CSIRO develops sophistocated

power and control electronics.

> CSIRO’s UltraBattery and supercapacitors.

Energy storage

CSIRO is a world leader in designing

technologies to deliver safer, lighter,

more powerful and longer lasting

mobile energy storage devices.

Supercapacitors

Supercapacitors are electrochemical

capacitors that offer very high

capacitance in a small package.

CSIRO’s supercapacitor stores a large

amount of charge and release it very

quickly. This makes them ideal for short

term, high energy applications such

as whan an electric car accelerates.

UltraBattery

CSIRO’s UltraBattery integrates a

supercapacitor with a lead acid battery.

In comparison with conventional hybrid

electric vehicle systems, the UltraBattery:

• lasts four times longer

• produces 50 per cent more power

• is about 70 per cent cheaper.

Lithium battery

Our breakthrough research on room

temperature ionic liquids is spearheading

our development of a rechargeable

lithium metal battery that is:

• safe

• works over a wide temperature range

• delivers 25 per cent more energy

than a contemporary lithium

ion battery of the same size .

Our strengths include a team of internationally

recognised experts and a longstanding reputation forexcellence in technology and business innovation.

Meeting future challenges

Improving core technologies and tackling the

big issues for a sustainable future.

Fuelling future transport

We are exploring the feasibility ofalternative road fuels and assessing

possible biophysical, social and economic

impacts of their production and adoption.

This work covers:

• biofuels

• synthetic fuels (coal to liquid

and gas to liquid conversion)

• hydrogen as a fuel source.



< This artist’s impression of the

Duoleta shows that radical appearance

is not required to achieve functional

and environmentally friendly objectives.

Concept vehicles

Together with our par tners CSIROhas been involved in the planning,

development and production of low fuel

consumption, low emissions vehicles.

ECOmmodore

CSIRO’s collaboration with Holden

began with the development

and demonstration of the

ECOmmodore in 2000.

This was one of the world’s rst family-

size parallel hybrid petrol-electric cars.

It performs like a conventional V6,

but with half the fuel consumption.

The ECOmmodore has a combination

of rst generation CSIRO

supercapacitors and specially designed,

‘valve regulated’, high power lead-acid

batteries. These are controlled by an

electronic energy management system

which controls the hybrid powertrain.

aXcessaustralia

Also developed in 2000, the

aXcessaustralia low emission vehicle

was a low-cost petrol-=electric

series hybrid concept vehicle.

It used technology from CSIRO

and more than 80 Australian

component manufacturers.

It could halve fuel bills and slash

air pollution by up to 90 per

cent and was acclaimed at motor

shows around the world.

On the road

The development of alternative vehicle technology is

driven by, among other things, rising fuel prices and

the need to reduce greenhouse gas emissions.

Duoleta

In late 2005, CSIRO was part of anAutoCRC conceptual development

investigating the technical and

commercial feasibility of producing in

Australia an ultra lightweight vehicle with

low fuel consumption and low emissions.

The Duoleta concept drew on petrol

engine technology, avoiding the high cost

and complexity of hybrid powertrains.

The study found such a car could

be made with features such as:

• fuel consumption <4 L per 100 km

• 0 – 100 km/h less than 10 s

• crash performance equal to

the best car of its size

• suitable for freeway and local road

• high manoeuvrability

• seating for 4 with 4 doors.

The Duoleta was designed for :

• export

• ease of disassembly and

high recyclability

• ultra-low drag coefcient (<0.25)

• ultra-low kerb weight (~700 kg).

The Duoleta concept revealed unrivaled

performance and fuel consumption

and very low CO2 emissions.

> The ECOmmodore was one of

the world’s rst family-size parallel

hybrid petrol-electric cars.

> The aXcessaustralia low

emission vehicle.



For further information about partnering

with us:

Light Metals Flagship

Mr Sam Tartaglia

Phone: +61 3 9545 2964

Email: [email protected]

Web: www.csiro.au/ lightmetals

For further information about light alloys:

CSIRO Materials Science and

Engineering

Mr Barrie Finnin

Phone: +61 3 9545 2951


Web: www.csiro.au/cmse

For further information about low emission

transport:

Energy Transformed Flagship

Dr John Wright

Phone: +61 2 4960 6080


Web: www.csiro.au/et

Documents

AutoBrochure_CSIRO innovations.pdf