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2017

Story: Fuel economy, autonomous-drive ideas win big at PACE 2017
Click or tap to see more detail about each winner

» Continental Corp. -- One-box approach to braking is lighter, simpler

One-box approach to braking is lighter, simpler

Company: Continental Corp.

What: MK C1 electronically controlled braking

Innovation: Because newer vehicles provide little or no vacuum power to operate braking, Continental developed a vacuumless approach that integrates the tandem master cylinder, brake booster and modulation system in a one-box package. The system requires fewer components and allows for a tunable brake pedal.

Judge's Citation: Continental has developed the first electronically controlled braking system called the MK C1. It is faster, lighter and simpler than conventional systems. As new, highly efficient diesel, gasoline and hybrid-electric powertrains have limited or no vacuum, this approach addresses the need for efficient braking. It simplifies installation by reducing components with significant packaging (250+ cubic inches) and weight reduction of three to four kilograms, or a 30-40 percent reduction. In addition, the MK C1 braking system responds to the requirement of advanced driver assistance systems to react more quickly than traditional vacuum systems. It has built-in autonomous braking capability by decoupling the driver brake and providing tunable pedal feel. Also, the new Continental vacuum-less "by-wire" braking can fit in the same under-the-hood location as other systems and reacts more quickly.

First Customer: Alfa Romeo	Web site: www.continental-automotive.com

» Continental Structural Plastics -- A composite challenges aluminum panels

A composite challenges aluminum panels

Company: Continental Structural Plastics

What: TCA Ultra Lite lightweight composite

Innovation: Continental has made its TCA (Tough Class A) Ultra Lite 1.2 composite material a rival to large aluminum body panels by cutting its weight, reducing its cost and improving its surface quality. The innovations make this composite material more attractive than aluminum on low-volume vehicles.

Judge's Citation: Innovations in the 1920s propelled steel stampings into the material of choice for auto bodies, enabling today's beautiful painted surfaces. While inexpensive, steel is heavy, and with the focus on fuel mileage car makers are turning to costly alternatives such as aluminum to save weight. Through a series of game changing innovations Continental Structural Plastics, now part of Teijin, transformed sheet molding compound (SMC) into a paintable and light-weight material that in many applications is a cost-effective alternative to metallic body parts. First commercialized on the 2016 Corvette, CSP's TCA Ultra Lite is now in use by multiple OEM platforms on three continents.

First Customer: General Motors	Web site: cspplastics.com

» Dana -- High-speed transmission pumps sealed with steel

High-speed transmission pumps sealed with steel

Company: Dana

What: Multi-Layer Steel Transmission Pump Gasket

Innovation: Dana developed a five-layer steel transmission pump gasket that can perform securely under pressure up to 480 pounds per square inch. This thin multilayer-steel approach replaces traditional elastomeric seals to support the higher-pressure operating characteristics of new eight-, nine- and 10-speed transmissions.

Judge's Citation: A transmission pump gasket that allows for the manufacturing of transmissions with greater gear ratios resulting in better fuel efficiency and improved operating performance. The Dana gasket allows for more shifts that are smoother and quicker under increased operating pressures with a spin loss reduction of up to 40 percent.

First Customer: General Motors	Web site: dana.com

» Dayco -- Activac eliminates electric vacuum pump

Activac eliminates electric vacuum pump

Company: Dayco

What: Activac vacuum generation system

Innovation: Dayco's Activac is an aspirator-driven vacuum-generating system made of lightweight plastic parts and hoses for brake power that eliminates the need for electric vacuum pumps.

Judge's Citation: The Dayco Vacuum Generation System, ACTIVAC, is an innovative and game changing technology that eliminates the need for a vacuum pump on today's vehicles, resulting in weight reduction, cost savings and fuel economy improvements. This highly efficient and better performing technology was developed for gasoline and diesel engines and can be adapted to not only brake systems but many other systems on the platform.

First Customer: Ford	Web site: dayco.com

» Delphi Automotive -- Taking 360-degree sensing to a higher fidelity

Taking 360-degree sensing to a higher fidelity

Company: Delphi Automotive

What: 76 GHz Short Range Radar for 360-Degree Sensing

Innovation: Delphi developed a higher performing but more affordable 360-degree sensing system using 76 gigahertz. The enhancement and special antenna can work in complex and cluttered environments and discriminate among multiple stationary and moving objects or pedestrians at greater distances.

Judge's Citation: Delphi's 76GHz Short Range Radar (SRR) for 360 degree sensing is the only SRR on the market that supports features to actively control the vehicle with high precision. The Delphi 76Ghz SRR with its unique antennae and wave form radar provides high performance and is cost competitive with 24GHz. It is universally recognized by OEMs as the best performing SRR system and is a critical enabler for advancing automated vehicle development. The technology is being adopted by other markets, mining, agriculture, aerospace (robots) virtually anything that moves.

First Customer: BMW	Web site: delphi.com

» Denso -- Common rail allows higher pressures, more control

Common rail allows higher pressures, more control

Company: Denso

What: Fourth-generation diesel common rail

Innovation: The latest innovation of Denso's diesel common rail system operates at the high pressures of current diesel engines while incorporating a feedback system that can precisely vary combustion timing and fuel spray. This enables a significant improvement in performance needed to meet stringent new emission rules.

Judge's Citation: Denso used three innovations that address the problems presented by ultra-high pressure common rail systems, the increased temperature of fuel, the high load in the area where the pressure is applied and the ability to operate accurately and avoid seizure on the high pressure application surface. Denso's I-Art technology allows the system to assure precise fuel delivery under extremely high pressure and accurate multiple injection timing. Their unique "feedback" system is a computer in a very bad environment. Other feedback systems only measure the time of injection while the Denso system measures that plus the spray variations needed based upon fuel variability characteristics.

First Customer: Toyota	Web site: denso.co.jp

» Giffin -- A vortex pulls paint from the air

A vortex pulls paint from the air

Company: Giffin

What: ELITE Wet Scrubbing Technology

Innovation: By creating a controlled vortex of air in a paint booth, Giffin has improved the process of removing overspray from the air. The customizable innovation means lower energy consumption, less booth cleaning and less paint shop investment.

Judge's Citation: Efficiently �scrubbing� paint overspray is a longstanding problem in the automotive industry. In an assembly plant existing systems cost millions of dollars a year to filter and condition air for temperature and humidity before being exhausted through the paint booths, while using copious amounts of water in the scrubbing process. GIFFEN used computational fluid dynamics to analyze existing venture scrubbers and developed a new vortex approach. The �ELITE Wet Scrubber� has been installed in assembly and parts plants, where it eliminates unscheduled down time for cleaning. In the typical assembly plant it lowers particulate emissions by 40 tons a year, reduces scrubber energy usage by 23 percent, cuts carbon dioxide by 4000 tons per year while using 50 percent less water.

First Customer: General Motors	Web site: giffininc.com

» GKN Driveline -- Integrated e-axle simplifies hybrid design

Integrated e-axle simplifies hybrid design

Company: GKN Driveline

What: Co-axial electric axle

Innovation: GKN's integrated co-axial electric axle and electric motor system simplifies the design of plug-in hybrids. The electric motor's output is used as the transmission input shaft, resulting in a smaller and lighter electric drivetrain.

Judge's Citation: GKN has developed an integrated co-axial electric axle and electric motor system that enables OEMs to design and build fuel-efficient plug in hybrid electric vehicles on global platforms. The innovation has launched on the Volvo XC90 T8 Twin Engine plug-in hybrid SUV, and fits in the same space as the rear wheel drive module on the conventional XC90 AWD driveline. It is the first disconnecting eAxle on a premium SUV, enabling pure electric drive or all-wheel drive mode, in conjunction with the internal combustion engine. By using the electric motor�s output shaft and the transmission�s input shaft, the result is a smaller, lighter and higher performance electric driveline.

First Customer: Volvo	Web site: gkndriveline.com

» JTEKT Toyoda Americas Corp. -- Gear cutting gets faster in a smaller footprint

Gear cutting gets faster in a smaller footprint

Company: JTEKT Toyoda Americas Corp.

What: High-Speed Axis Synchronization with multipurpose machining capabilities

Innovation: JTEKT Toyoda has integrated the gear manufacturing work of five machines into one process. The result, incorporating a rotary table that took 10 years to develop, allows for high-speed synchronization to produce parts with greater accuracy, less cost and less waste.

Judge's Citation: Improved productivity through high speed machining:skive, turn, mill, bore and drill in one set up which eliminates concentricity and run-out issues while maximizing floor space utilization. This machining center has revolutionized how gears are manufactured.

First Customer: Torsen Machines	Web site: toyoda.com

» NVIDIA -- A vehicle supercomputer the size of a license plate

A vehicle supercomputer the size of a license plate

Company: NVIDIA

What: In-Car Artificial Intelligence Supercomputer

Innovation: It is no bigger than a license plate, but NVIDIA's new autonomous driving control system, DRIVE PX 2, is capable of processing 24 trillion operations a second as it monitors a 360-degree view of a drive. It also uses deep learning to continually respond to driving conditions, a key step toward vehicle autonomy.

Judge's Citation: Today's development of self - driving cars are predominantly computer vision-based, which has limitations. Therefore, there is need for technology to pull in other sensors besides cameras, like LIDAR, radar, and ultra-sonic. Also, tackling the infinite permutations that a driver needs to react to is a very complex programming challenge. NVIDIA has introduced the DRIVE PX 2 as the 1st In-Car Artificial Intelligence (AI) Supercomputer which can tackle these challenges. DRIVE PX2 uses Deep Learning (AI) and advanced Graphics Programming for 360 degree situational awareness. It provides an open development platform with processing power equivalent to 150 MacBook Pros, in the size of a license plate. It delivers 24 trillion operations per second.

First Customer: WEpod autonomous shuttle	Web site: nvidia.com

» Sanhua Automotive -- Valve can take on higher pressures

Valve can take on higher pressures

Company: Sanhua Automotive

What: Electronic Expansion Valve

Innovation: Sanhua's valve will allow heating and air conditioning systems to address the higher pressures that will come with new refrigerants that have been mandated. The valve also can handle dual applications for cooling and vehicle heat pumps.

Judge's Citation: The SANHUA Automotive Electronic Expansion Valve EVX replaces conventional valves with accuracy and control not seen before in mobile air conditioning and chiller systems. SANHUA�S innovation not only outperforms traditional valves but will operate with all of today�s refrigerants, including very high pressure R744 (CO2) systems. SANHUA�S superior performing EVX boosts the coefficient of performance by more than 10 percent, resulting in reduced compressor loads, improved fuel economy, better reliability, and enhanced system NVH quality.

First Customer: Confidential	Web site: sanhuaautomotive.com

» Schaeffler -- An electromechanical path to vehicle stability

An electromechanical path to vehicle stability

Company: Schaeffler

What: Electromechanical Active Roll Stabilizer

Innovation: Schaeffler's electromechanical approach to active roll control ensures that a vehicle does not tilt sideways when cornering at high speeds, resulting in greater driving comfort and stability.

Judge's Citation: Traditionally, RIDE and HANDLING are viewed as a tug-of-war where vehicle engineers trade-off one to get the other. To provide stability, engineers use roll stabilizers (AKA: Anti-Sway Bar) to increase vehicle stiffness and mitigate the tipping sensation in turns but this results in a harsh ride over rough roads. Hydraulic anti-sway bar disconnect systems appeared several years ago, but their sluggish response times and high vehicle lifecycle costs effectively limited their application to SUVs and other high CG vehicles. Schaeffler's electromechanical roll stability solution eliminates hydraulics, and by offering both 12v/48v options brings the ride and comfort advantages of an anti-sway bar disconnect system to a wide range of performance, luxury and mainstream vehicles. Launched on the 2016 BMW 7-Series, Schaeffler's electromechanical Active Roll Stabilizer ("eARS") has been adopted as a new standard for multiple brands spanning ultra-luxury, high performance, and hybrid vehicle programs. eARS modular architecture, tunable elastomeric coupler, internally developed touch-less torque sensor, and 12v/48v capabilities afford OEMs the ability to minimize application engineering timing/costs for bringing Mode Decoupling to a broader array of vehicles. eARS marks Schaeffler's expansion from its traditional metal forming foundation, showcasing new competencies in electronics, software development, software application engineering/validation/lifecycle management, placing the company squarely in the realm of mechatronic innovation.

First Customer: BMW	Web site: schaeffler.com

» Schaeffler -- High-rev shifting gets easier

High-rev shifting gets easier

Company: Schaeffler

What: One-way transmission clutch

Innovation: Using lighter-weight stamped components in place of machined parts, Schaeffler has created a one-way clutch that allows for smoother shifting with no lurching at high rpms. The innovation is beneficial for rear-wheel vehicles and critical for new 10-speed transmissions.

Judge's Citation: The Schaeffler One Way Transmission Clutch Assembly, has made it possible to usher in a new age of fuel-efficient and smooth-operating automatic transmissions for rear drive vehicles. The highly-sophisticated and electronically-controlled 10 speed transmission developed by both Ford Motor and GM required a one way clutch that could operate at 16,000 RPM, have zero backlash, be lower in drag, lighter in weight, and stronger than any clutch on the market. Schaeffler took on the challenge and delivered an innovative design and production process that met all of those requirements. For that effort, their new OWC has become a vital component of the best-selling vehicles in America.

First Customer: Ford and General Motors	Web site: schaeffler.com

2016

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» Valeo -- Water-cooled condenser

Water-cooled condenser

Company: Valeo

What: Cooling with water, saving fuel

Innovation: Valeo's condenser uses water, not air, to liquefy air-conditioning refrigerant vapor. Water is a more efficient coolant than air, saving fuel. Water condensers also permit flexible packaging under the hood because they can be placed in various locations.

Judge's Citation: Valeo Powertrain Thermal Systems has developed and introduced to market a water-cooled condenser to liquefy air conditioning refrigerant vapor. The unit can be located anywhere in the vehicle. Water cooling provides many design and operating advantages over air cooling. Principal among them are the elimination of the large air radiator from the front of the vehicle, which improves the efficiency of engine cooling ... the engine radiator is no longer shielded by the air conditioning radiator; freeing up space in the front end for design flexibility in crash absorption performance; and reducing fuel consumption by as much as six percent when the air conditioner is running. Water cooling reduces system pressure fluctuations providing improved comfort stability. Mass production began in July, 2015 on BMW's B-engine platform.

First Customer: BMW	Web site: valeo.com

» Valeo -- Electric supercharger

Electric supercharger

Company: Valeo

What: Goodbye, turbo lag

Innovation: A supercharger driven by an electric motor that allows faster response time and eliminates the lag effect associated with turbocharging. It is the first electric-driven compressor that will be in mass production and is designed for 12-volt and 48-volt systems.

Judge's Citation: Valeo�s electric supercharger is the first electric driven compressor that will be in mass production. The use of an electric motor allows a faster response time and therefore eliminates the �turbo-lag� effect that is perceived today on traditional turbocharged engines. Designed for both 12V and upcoming 48V applications, Valeo�s electric supercharger integrates its own electronic control unit connected via CAN bus to the vehicle. With the electric supercharger, the turbocharger can be tuned to work in a specific area and therefore achieve a higher turbo efficiency. This product is key technology enabler for the trend in engine downsizing (and further improve fuel efficiency) without compromise to vehicle performance.

First Customer: Audi	Web site: valeo.com

» Faurecia Emissions Control Technologies -- Exhaust System Adaptive Valve

Exhaust System Adaptive Valve

Company: Faurecia Emissions Control Technologies

What: Less exhaust noise, better fuel economy

Innovation: Faurecia has developed a device for mitigating undesirable low-frequency exhaust noise that results when automakers use fuel-saving technologies such as cylinder deactivation and multispeed transmissions. The Exhaust System Adaptive Valve is a spring-loaded, self-regulating valve that presents exhaust gas flows with a variable restriction, suppressing low-frequency acoustic energy. This innovation allows automakers to extend the range of the cylinder-deactivation mode, further improving fuel economy.

Judge's Citation: Driven by CAFE fuel economy requirements, OEM�s have incorporated fuel saving technologies such as cylinder deactivation and high gear count with lower displacements. These strategies present challenges of increased low frequency noise that is readily apparent unless additional measures are taken. Unlike traditional approaches Faurecia�s Adaptive Valve� enables fuel-saving powertrain strategies while offering refined NVH with reduced package space (10-15L) and system mass (5-10 Kg). The Adaptive value addresses NVH concerns by presenting gas flow with a variable restriction. This suppresses low frequency acoustic energy. This extends the operating range of the cylinder deactivation mode, yielding further improvements to fuel efficiency beyond what is possible without the value. It also eases the transition in and out of cylinder deactivation modes, making it imperceptible to vehicle occupants. The Adaptive Valve� was initially launched on General Motor�s Full Size Hybrid. Other products and OEMs are adopting the Adaptive Valve� technology.

First Customer: General Motors	Web site: faurecia.com

» Federal-Mogul Corp. -- Hybrid induction-welding for steel pistons

Hybrid induction-welding for steel pistons

Company: Federal-Mogul Corp.

What: A path to lighter pistons, smaller diesel-engine blocks

Innovation: Federal-Mogul figured out how to induction-weld two forgings together to produce steel pistons for small-bore diesel engines. This allows the use of shorter, lighter pistons. Automakers have the option of designing a shorter engine block or using longer connecting rods, which improves fuel economy.

Judge's Citation: Manufacturers are moving from aluminum to steel in the production of pistons for light vehicle diesel engines to take advantage of the cost, mass, durability, and heat tolerance properties of steel. Steel pistons are assembled from two pieces, crown and skirt, joined at the cross section of the crown where the cooling gallery is located. This process requires simultaneous welding of two concentric surfaces. Until now this has been done by friction welding; twisting the surfaces together until a bond has been established by inertia. However, friction welding creates bulge, flash and debris in the cooling gallery; and it is not feasible for smaller bore sizes where curl on the mated surfaces obstructs the gallery. To solve these problems Federal Mogul Powertrain has developed a hybrid induction welding technique (HIW), wherein the concentric surfaces are heated by electrical induction and then mated in a brief back-and-forth rotation. This process minimizes bulge and flash, leaving a clean unimpeded cooling gallery, with flexibility in the choice of steel material combinations. Engine efficiency is improved by two to five percent. Market acceptance has been exceptional.

First Customer: Ford	Web site: federalmogul.com

» Delphi Automotive -- Dual Role Hub

Dual Role Hub

Company: Delphi Automotive

What: Smoothing the integration of iPhones, CarPlay

Innovation: Delphi developed an application-specific integrated circuit to control communication with iPhones and eliminate integration challenges posed by Apple's CarPlay software. CarPlay is set up to be the sole host device providing music, messaging and navigation to a car's head unit. Delphi created a USB port that allows the iPhone and car radio to be identified as host devices simultaneously.

Judge's Citation: When Apple announced CarPlay�, iPhone users couldn�t wait to buy a car with an infotainment interface that was intuitive and mirrored how their IPhone worked. The problem with the CarPlay� integration came when a driver wanted to access music on another device, play video on a passenger�s tablet or listen to music on a passenger�s Android phone. The iPhone running CarPlay� wanted to operate as the sole �host� device taking control from the car radio and denying access to other devices. Delphi solved it � at a lower cost, in a smaller package and with all functionality - by developing a custom USB ASIC chip, allowing the iPhone and car radio to be recognized as �host� devices simultaneously. Delphi's Dual Role Hub solved this vexing problem by developing a �Smart Media USB Hub�, that allows not just only a single Apple device, but allows any device plugged into the multi-port hub system to be a "host." Now one passenger can watch a movie on an SD card, while another watches a movie off a handheld, while the driver uses the system for navigation, phone conversations, or just listens to their music. Delphi developed an amazingly elegant and cost effective solution for a complicated problem in the world of vehicle infotainment systems. Delphi will capture 40 percent of GM, Ford, and Chrysler products globally, representing 10 million units and their technology is ready to reach every OEM around the globe!

First Customer: General Motors	Web site: delphi.com

» FTE Automotive -- Electronic oil pump

Electronic oil pump

Company: FTE Automotive

What: A smaller, lighter oil pump

Innovation: The compact, lightweight pump can operate on demand to move oil from a transmission oil pan to a distribution system at the top of the gearbox. The pump is a key part of a "dry sump" lubrication system that eliminates the need for the gears to dip into oil in the pan. That reduces friction and increases overall efficiency while reducing carbon dioxide emissions.

Judge's Citation: The majority of transmissions use a "splash lubrication" method to provide lubrication to gear sets. These transmissions have an oil pan that is always filled, with gears that dip into the oil. But turning gears in oil generates friction, which degrades transmission efficiency. In a dry sump system the gears do not dip into the oil. A pump is used to direct the fluid out of the pan into a distribution tank located on top of the transmission. Oil flows by gravity onto the gears. Dry sump lubrication systems have existed for years, using positive displacement pumps driven mechanically or by electric motor. FTE's new EP20 features an inexpensive, lightweight, low pressure centrifugal pump, which can be switched on or off on demand, and which provides real time diagnostics to the TCU through its integrated LIN controller. Most of the components are composed of plastic materials, which is novel in that a portion of the pump assembly is nested inside the transmission and subject to a corrosive environment. First application is Audi's 7-speed DCT.

First Customer: Audi	Web site: fte-automotive.com

» Koito Manufacturing Co. -- Dual-function LED headlamp

Dual-function LED headlamp

Company: Koito Manufacturing Co.

What: A smaller, lighter LED headlight

Innovation: Koito designed an LED light source that can generate a headlamp's high and low beams. By integrating the LED, heat dissipater and circuitry into one unit, Koito produced a headlight that is 70 percent smaller and 60 percent lighter. The low-cost LED is therefore suitable for small cars, SUVs and luxury vehicles.

Judge's Citation: Before Koito innovated a standardized compact dual beam LED unit, the high beam � low beam LED applications needed to use multiple LEDs and two lens systems. These systems were large, costly, heavy and did not enable standardization. Koito�s innovation LED Compact Family, is uniquely enabled by two patented inventions: sub-reflectors which provides very high light spread and reach, plus an internal mechanical light shaping mechanism, which doesn�t need to shade. Thus this dual beam LED unit doesn�t waste generated light and it uses a single LED for all modes of operation. The result, is a single compact unit can employ single beam, AFS Adaptive Front-lighting System, and also a dual beam ADB Adaptive Driving Beam.

First Customer: Toyota	Web site: koito.co.jp

» Bosch -- Linear Force Solenoid

Linear Force Solenoid

Company: Bosch

What: New solenoid design eliminates transmission components

Innovation: The solenoid can take control of transmission components, eliminating hydraulic and other parts often used to transfer force in current gearbox designs. The solenoid enables manufacturers to develop more efficient, high-speed transmissions without increasing weight.

Judge's Citation: With the rapidly increasing use of 8 to 10 speed transmissions for fuel efficiency, shift quality and shift speed become even more important. Bosch has addressed these and other transmission needs with their electromagnetic Linear Force Solenoid (LFS) replacing the hydraulic pilot valves in transmission clutch actuators. The LFS eliminates the efficiency losses and concerns with oil contamination of pilot valves, while helping to squeeze more gears and their controls into the tightly-limited transmission space. The LFS also enables modifying the transmission shift characteristics under software control. This saves months of time in optimizing the shift quality of new transmissions, compared to the iterative substitution of different pilot valves previously required. The Bosch LFS was first used on a 2014 Daimler 9-speed transmission, with subsequent applications in Ford and GM 9-speed transmissions.

First Customer: Daimler	Web site: bosch.com

» Gentex Corp. -- Full Display Mirror

Full Display Mirror

Company: Gentex Corp.

What: Rearview mirror displays video images

Innovation: A Gentex-designed rearview mirror displays a video image of the road behind the vehicle, eliminating blind spots. It can be used as a conventional automatic-dimming mirror, or with the flick of a switch it activates a liquid crystal display that provides an unobstructed and expanded rear view.

Judge's Citation: The Gentex Full Display Mirror (FDM) is an intelligent rear vision system using a custom, externally mounted camera and a mirror-integrated video display to optimize a vehicle's rearward view. The Gentex FDM is an important advancement in rear vision safety offering 300 percent more vision than an ordinary mirror and provides bi-modal functionality. The Gentex system is the first and only hybrid FDM. With the flip of a switch, the mirror goes from a standard mirror mode and enters a display mode and a clear, bright LCD display appears through the mirror's reflective surface. Additionally, during nighttime driving, digital light sensors interact with each other to automatically darken the mirror when glare is detected.

First Customer: Cadillac	Web site: gentex.com

» Magna Closures -- Electronic door latch

Electronic door latch

Company: Magna Closures

What: Electronic door latch is driven by single control unit

Innovation: Magna's SmartLatch has an electronic control unit that governs features such as passive entry, "soft" door-closing, the exterior keypad and the door's LED lighting. These items previously required several ECUs, so SmartLatch reduces weight, complexity and cost. If the car suffers a power loss, supercapacitors provide backup electricity so that motorists can open the doors. Because of the reduction in components, doors with SmartLatch can be thinner and lighter in weight.

Judge's Citation: Magna Closures has developed the SMARTLATCH, the first fully electronic side door latch in the market. The SMARTLATCH removes all mechanical latch system components, replacing them with smaller, lighter wire harnesses and push buttons. The new system includes an onboard ECU that includes power backup capabilities and provides additional functions like diagnostic, LED control, passive entry, crash and post-crash safety and capability for a soft close function for automatic door cinching. The new double pawl mechanical strength module also is able to reduce drastically the energy and loads required to release the door in all situations. Locking noises and high handle efforts are eliminated creating a quiet and smooth operation inside and outside of the vehicle. The SMARTLATCH benefits include potential weight savings of up to 11%, cost savings of up to 8%, improved safety with automatic door unlatching post-crash, a reduced number of components, sound quality improvement and the flexibility to be used in any type of car.

First Customer: BMW, Lincoln	Web site: magna.com

» Faurecia Automotive Seating -- Cover Carving Technology for seats

Cover Carving Technology for seats

Company: Faurecia Automotive Seating

What: Technology allows for 3-D shapes on seats

Innovation: Cover Carving Technology combines polyurethane foam spraying with molding to create two component offerings: a sculpted cover for seat surfaces and sculpted light panel for the seat-back panels. Foam is sprayed onto a scrim, which is then placed in a press and cut to the shape of the part. The technology has a number of benefits, including improved durability, lighter weight and new freedom for designers to create 3-D shapes for seat fronts and backs.

Judge's Citation: Driven by CAFE fuel economy requirements, OEM�s have incorporated fuel saving technologies such as cylinder deactivation and high gear count with lower displacements. These strategies present challenges of increased low frequency noise that is readily apparent unless additional measures are taken. Unlike traditional approaches Faurecia�s Adaptive Valve� enables fuel-saving powertrain strategies while offering refined NVH with reduced package space (10-15L) and system mass (5-10 Kg). The Adaptive value addresses NVH concerns by presenting gas flow with a variable restriction. This suppresses low frequency acoustic energy. This extends the operating range of the cylinder deactivation mode, yielding further improvements to fuel efficiency beyond what is possible without the value. It also eases the transition in and out of cylinder deactivation modes, making it imperceptible to vehicle occupants. The Adaptive Valve� was initially launched on General Motor�s Full Size Hybrid. Other products and OEMs are adopting the Adaptive Valve� technology.

First Customer: Renault	Web site: faurecia.com

» GKN Driveline -- Lightweight constant velocity joint

Lightweight constant velocity joint

Company: GKN Driveline

What: Rear sideshaft trims weight and size

Innovation: GKN's constant velocity joints for rear sideshafts - developed for rear-wheel-drive luxury cars - trims 9.3 pounds per vehicle, reduces package size by approximately 10 percent and increases torque capacity.

Judge's Citation: For GKN's new Constant Velocity Joint (CVJ) and accompanying sealing and side shaft technology. At the heart of GKN's premium sideshaft technology is a newly designed CVJ that has raised the bar across the industry for performance and weight. The company's new CVJ is 25% lighter, 10% smaller and able to handle up to 27% more torque than what it replaces. Encompassing a new internal design geometry this CVJ has changed the rules of the game in an area of automotive technology that has seen few significant improvements over the past several decades.

First Customer: BMW	Web site: gkn.com

» Ichikoh Industries -- MonoLED light source

MonoLED light source

Company: Ichikoh Industries

What: A standardized, replaceable LED cuts cost

Innovation: Ichikoh has developed an LED that fits into a standardized socket, which lowers cost and allows the replacement of the LED alone. LEDs usually are built into a single module that must be replaced if repairs are needed. The lower cost of the company's MonoLED also makes it more attractive to use LED lamps in vehicles in lower price ranges, not just premium models.

Judge's Citation: Ichikoh has developed a LED socket (called MonoLED) that can be inserted into a lightening assembly without needing an enclosure. To make the socket viable, Ichikoh created a heat radiation socket using carbon containing resin, resulting in 45% lower cost than standard LED lighting units, 91% smaller in size, 31% lower power consumption, and most importantly, an LED that fits into a traditional automotive bulb socket. The Ichikoh LED socket approach is gaining market share because it is lower cost and because the thermal management solution allows more flexibility in a small form factor.

First Customer: Toyota	Web site: ichikoh.com

2015

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» Continental Automotive -- Multiapplication unified sensor element

Multiapplication unified sensor element

Company: Continental Automotive

What: 1 sensing device, many powertrain uses

Innovation: Continental developed a sensing device that can be programmed to act as five powertrain sensors. For example, a camshaft position sensor can become a crankshaft position sensor via a programming change. An added bonus: The element does not require rare-earth materials. It uses ferrite magnets, which cost 70 percent less than the magnets used by a typical sensor.

First Customer: 2.0-liter gasoline direction injection and 2.4-liter turbo direct injection engines in the Hyundai Sonata and Santa Fe Sport and Kia Optima and Sorento, January 2014	Web site: conti-online.com

» Federal-Mogul Corp. -- DuroGlide piston ring coating

DuroGlide piston ring coating

Company: Federal-Mogul Corp.

What: Piston coating reduces friction up to 20%

Innovation: Federal-Mogul's DuroGlide piston ring coating cuts friction up to 20 percent. The coating is a durable carbon material with properties of diamond that resists abrasions and scuffing. Fuel savings can be up to 1.5 percent.

First Customer: Volkswagen 1.6-liter and 2.0-liter BlueMotion models, 2014	Web site: federalmogul.com

» GKN Driveline -- Two-speed gearbox for electrified vehicles

Two-speed gearbox for electrified vehicles

Company: GKN Driveline

What: 2nd gear saves fuel for electrified vehicles

Innovation: The typical electric powertrain uses a one-speed electric-drive transmission, which takes the vehicle to a certain speed, then disconnects. GKN's two-speed eTransmission allows optimal powertrain performance with electric propulsion for high speeds, too. In the BMW i8, which goes from 0 to 60 mph in 4.4 seconds, the eTransmission, guided by innovative computer controls, stays engaged with the vehicle's six-speed automatic transmission up to the vehicle's programmed limit of 155 mph.

First Customer: BMW i8, 2014	Web site: gkn.com

» Osram Opto Semiconductors -- Oslon black flat multichip family

Oslon black flat multichip family

Company: Osram Opto Semiconductors

What: Less expensive LEDs for mass-market cars

Innovation: LEDs create elegant auto lighting. But the diodes and related parts are complex electronic devices that have been restricted mainly to luxury vehicles because of high costs. Osram's family of LEDs, by reducing complexity and cutting manufacturing costs, are suitable for mass-market vehicles.

First Customer: Audi, 2015	Web site: osram-os.com

» BorgWarner -- Limited-slip differential for front-wheel drive

Limited-slip differential for front-wheel drive

Company: BorgWarner

What: Improved traction for fwd vehicles

Innovation: When a drive wheel hits a slippery spot, such as ice, the limited-slip differential sends torque from the wheel on ice to the wheel with better traction. BorgWarner, working with VW Motorsport, devised a cost-effective limited-slip differential for fwd vehicles. It uses BorgWarner's controls and clutch actuation to operate the front differential.

First Customer: Volkswagen Golf GTI, November 2013	Web site: borgwarner.com

» Continental AG -- Printed circuit board for transmission control units

Printed circuit board for transmission control units

Company: Continental AG

What: Low-cost substrate for transmission computers

Innovation: Computer control units for transmissions typically use ceramic substrates. But ceramic is expensive and time consuming to cure. Also, the same substrate cannot house logic circuits, which perform operations on data, and power circuits, which transfer and control higher amounts of electricity. Continental's nonceramic substrate solves these and other problems.

First Customer: Mercedes-Benz seven-speed transmission, February 2012	Web site: conti-online.com

» Denso Corp. -- Standardized HVAC unit

Standardized HVAC unit

Company: Denso Corp.

What: Standard HVAC units for many vehicles

Innovation: Most vehicle heating, ventilation and air conditioning units are designed for specific models. Denso's standardized unit can be used in a variety of models, cutting design and tooling costs. The innovation also reduces the unit's size, weight and power consumption.

First Customer: Toyota, December 2013	Web site: densocorp-na.com

» Magna Closures -- PureView seamless sliding window

PureView seamless sliding window

Company: Magna Closures

What: Elegant rear window

Innovation: A typical pickup's rear window has two panes of glass that slide on an exterior track. Magna's single panel slides inside the rear window. It gives the rear window a clean, elegant appearance, and it reduces manufacturing complexity.

First Customer: 2015 Ford F-150	Web site: magna.com

» Federal-Mogul Powertrain -- MicroTorq seal for rotating shafts

MicroTorq seal for rotating shafts

Company: Federal-Mogul Powertrain

What: Seal for shafts cuts friction losses

Innovation: The elastomeric seal for today's high-pressure and high-heat crankshafts and other rotating shafts reduces friction losses up to 80 percent compared with competitive seals. It is customizable for different engines and boosts fuel economy by about 0.15 mpg.

First Customer: Volvo, August 2013	Web site: federalmogul.com

» Mahle GmbH -- Evotec 2 lightweight piston

Evotec 2 lightweight piston

Company: Mahle GmbH

What: Cooling gallery makes piston more durable

Innovation: The piston for gasoline engines combines lightweight aluminum and high structural strength. A key feature is an advanced cooling gallery to increase durability and performance.

First Customer: Audi, February 2012	Web site: mahle.com

» Nvidia Corp. -- Tegra visual computing module

Tegra visual computing module

Company: Nvidia Corp.

What: Programmable computer keeps infotainment fresh

Innovation: Consumers want up-to-date software and entertainment in their autos on a par with their smartphones. Nvidia's programmable computer module for auto infotainment and navigation accepts software updates and new features after it is installed in a vehicle.

First Customer: Tesla Model S, June 2012	Web site: nvidia.com

» Sika Automotive -- Adhesive for mixed material bonding

Adhesive for mixed material bonding

Company: Sika Automotive

What: Flexible adhesive holds i3 together

Location: BMW needed to bond the i3's carbon fiber-reinforced plastic body to an aluminum chassis. Sika's adhesive flexes after curing, maintaining the bond as the plastic and aluminum expand at different rates with changing temperatures. The adhesive is still strong to withstand crashes.

» Valeo Electrical Systems -- Efficient alternator

Efficient alternator

Company: Valeo Electrical Systems

What: Alternator eliminates voltage drop, boosting efficiency

Innovation: Auto alternators universally use diodes to change alternating current into direct current. Valeo uses transistors, which eliminate voltage drop and boost fuel economy. The alternator's efficiency is increased by 10 percent, or the equivalent of 0.7 mpg.

First Customer: 2016 Audi A6	Web site: valeo.com

» FTE automotive GmbH -- 2Polymer hydraulic gear shift actuator

2Polymer hydraulic gear shift actuator

Company: FTE automotive GmbH

What: Lightweight gear shifter for Audi

Innovation: The polymer actuator, mainly for double-clutch transmissions, uses hydraulic pressure to shift gears. With high-tech plastics, the module is 35 percent lighter than comparable units that use steel and aluminum. Using polymer facilitates molding-in cavities for sensors and connectors. That's not feasible with machined aluminum.

First Customer: Audi, June 2014	Web site: fte-automotive.com

2014

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» Continental AG -- Pressure sensor for pedestrian protection

Pressure sensor for pedestrian protection

Company: Continental AG

What: Simple sensors protect pedestrians

Innovation: When an auto strikes a pedestrian, the impact is reduced when the vehicle's hood lifts slightly. Continental uses two air-pressure sensors connected to an air tube across the front of the vehicle to help lift the hood. Previous systems used as many as seven sensors and other related equipment.

First Customer: Mercedes-Benz in Europe, 2011	Web site: conti-online.com

» Delphi Automotive -- ErgoMate connector

ErgoMate connector

Company: Delphi Automotive

What: Quick, easy connection

Innovation: Autos have a staggering number of wires that come together in large bundles that need connectors. Delphi's connector uses a geared cam and slider. Workers can snap together the bulky bundles with a simple push from one hand.

First Customer: Chrysler Group, 2010	Web site: delphi.com

» Schaeffler Group -- Torque converter with pendulum

Torque converter with pendulum

Company: Schaeffler Group

What: Pendulum reduces engine vibrations

Innovation: Downsized engines tend to vibrate more than larger ones. Schaeffler developed a pendulum, operated by centrifugal force and mounted to the torque converter, that cancels vibrations from the engine.

First Customer: Ford Transit, 2013	Web site: schaeffler.com

» Dow Automotive Systems -- Betamate structural adhesive for untreated aluminum

Betamate structural adhesive for untreated aluminum

Company: Dow Automotive Systems

What: Epoxy eliminates expensive treatment of aluminum

Innovation: Adhesives for aluminum typically require treated metal and lengthy heat curing. Dow's Betamate epoxy creates a long-lasting bond without heat curing even with untreated aluminum, cutting labor, material and capital costs.

First Customer: Kenworth T680 and Peterbilt 579 cabs, 2012	Web site: dowautomotive.com

» Robert Bosch -- Spray enhancements in gasoline direct injection

Spray enhancements in gasoline direct injection

Company: Robert Bosch

What: Lasers drill better fuel-injector spray holes

Innovation: Bosch uses lasers to drill spray holes with precise shapes in fuel injectors. This improves fuel atomization and mixing with air. The holes can reduce unburned hydrocarbons during startup by as much as 20 percent.

First Customer: Audi, 2011	Web site: bosch.us

» Valeo � Driving Assistance Product Group -- Backup protection

Backup protection

Company: Valeo � Driving Assistance Product Group

What: High-tech sensing gives drivers better view behind auto

Innovation: Valeo's system helps avoid accidents when vehicles are backing. The system integrates data from a rearview camera and ultrasonic sensors to provide extra rear object detection.

First Customer: Unavailable	Web site: valeo.com

» BorgWarner Transmission Systems -- Eco-launch solenoid for transmissions

Eco-launch solenoid for transmissions

Company: BorgWarner Transmission Systems

What: Better valve reduces lurch in stop-start engines

Innovation: When a stop-start engine stops, the transmission fluid begins to lose pressure. This can cause the auto to lurch when the engine and vehicle restart. A hydraulic accumulator can efficiently maintain the pressure. BorgWarner engineers developed a solenoid valve for accumulators that is quiet and allows high flow.

First Customer: General Motors, 2013	Web site: borgwarner.com

» ArcelorMittal and Magna Cosma International -- Laser-welded, hot-stamped door ring

Laser-welded, hot-stamped door ring

Company: ArcelorMittal and Magna Cosma International

What: Steel teamwork saves weight on Acura MDX

Innovation: Teamwork was essential for this innovation, a strong, lightweight door ring for an auto body. Honda R&D Americas designed the door ring. ArcelorMittal provided the steel blank and laser welding. Magna Cosma International developed the hot stamping for the laser-welded blank. The ring cut 8.6 pounds from the vehicle's weight.

First Customer: 2014 Acura MDX	Web site: arcelormittal.com magna.com

» BASF Corp. -- High-gloss black interior door switch bezels

High-gloss black interior door switch bezels

Company: BASF Corp.

What: New resin eliminates expensive painted trim

Innovation: Ford wanted to replace painted interior plastic parts with molded-in-color ones to cut costs and environmental hassles. The challenge, though, was to achieve high gloss and scratch resistance in frequently handled parts. BASF, working on a tight deadline, developed a resin with adequate scratch resistance.

First Customer: 2013 Ford Fusion	Web site: basf.com

» ZF Friedrichshafen AG -- Nine-speed automatic transmission for front- and all-wheel-drive cars and crossovers

Nine-speed automatic transmission for front- and all-wheel-drive cars and crossovers

Company: ZF Friedrichshafen AG

What: Simple and compact transmission saves fuel

Innovation: The transverse-mounted transmission provides a wide spread of gear ratios. This keeps engine rpms in optimal range, increasing fuel efficiency. The design is also simple and compact. For instance, two of the four planetary gear sets are nested together.

First Customer: Range Rover Evoque, 2013	Web site: zf.com

» Autoliv Inc. -- Pedestrian protection airbag

Pedestrian protection airbag

Company: Autoliv Inc.

What: Airbag protects pedestrians

Innovation: In a collision with a pedestrian, an exterior airbag is triggered to cover the hazardous lower parts of the windshield and A pillars.

First Customer: Volvo V40, 2012	Web site: autoliv.com

» Hella KGaA Hueck & Co. -- LED matrix beam headlights

LED matrix beam headlights

Company: Hella KGaA Hueck & Co.

What: Constant high-beam light without glare

Innovation: Innovation: Hella's headlights cast the equivalent of high-beam illumination constantly at night. A camera and computer track vehicles and send on and off signals to each headlight's 25 light-emitting diodes, or LEDs, eliminating glare. The system can create nearly 1 billion light combinations and has no moving parts.

First Customer: Audi A8, 2013	Web site: hella.com

» Henkel Adhesive Technologies -- Bonderite 2798 for coating aluminum

Bonderite 2798 for coating aluminum

Company: Henkel Adhesive Technologies

What: Coating for aluminum reduces sludge

Innovation: Automakers use zinc phosphate to clean and prepare vehicle surfaces for paint. But if a vehicle uses lots of aluminum, sludge can build up in the preparation baths, which is expensive to remove and send to landfills. Bonderite 2798 coats aluminum with zirconium, a metal resistant to corrosion, which significantly reduces sludge.

First Customer: 2013 Ford F-150	Web site: henkelna.com

» Federal-Mogul Corp. -- New bearings get the lead out

New bearings get the lead out

Company: Federal-Mogul Corp.

What: Lead-free bearings for high-performance engines

Innovation: For more than a century, hazardous lead has been used in engine and other bearings. Federal-Mogul replaced lead with an alloy of copper, nickel and silicon.

First Customer: Select BMW and Mercedes-Benz cars, 2008	Web site: federalmogul.com

» TI Automotive -- Flexible process can produce a variety of fuel tanks

Flexible process can produce a variety of fuel tanks

Company: TI Automotive

What: Flexible manufacturing process for blow-molded plastic fuel tanks

Innovation: Before blow molding is completed, this process places fuel-delivery components of different sizes and configurations inside the tank. This enables a single blow molder to produce plastic fuel tank variants for diesel, flex-fuel, gasoline and hybrid powertrains.

First Customer: Mercedes-Benz S class, 2013	Web site: tiautomotive.com

2013

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Product

Manufacturing Process and Capital Equipment

Information Technology

Hughes Telematics, Inc. – Atlanta, Ga. - Automotive Software Remote Update Technology

Innovation Partnership Winners

2012

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Product

Manufacturing Process

Innovation Partnership Award

2011

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Product

MAHLE - Stuttgart, Germany - Electrical Waste Gate Actuator

OSRAM Opto Semiconductors GmbH - Regensburg, Germany - OSTAR Headlamp - LED Headlamp Light Source

Robert Bosch GmbH - Stuttgart, Germany - Bosch P2 Parallel Full Hybrid System

Schaeffler Technologies - Troy, Mich. - INA Lightweight Balance Shaft with Roller Bearings

Manufacturing Process

Takata Corporation - Auburn Hills, Mich. - Vacuum Folding Technology

Innovation Partnership Award

2010

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Product

Product-Europe

Manufacturing Process and Capital Equipment

Information Technology and Services

Siemens PLM Software - Plano, Texas - Teamcenter In-Vehicle Software (IVS) Management System

Innovation Partnership Award

2009

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Product

Product-Europe

Manufacturing Process and Capital Equipment

Information Technology and Services

Innovation Partnership Award

2008

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Product

Product Europe

Manufacturing Process & Capital Equipment

Information Technology and Services

Delphi Corporation and Sirius Satellite Radio � Kokomo, Indiana - Sirius Backseat TV

2008 Innovation Partnership Awards

2007

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Product

Product Europe

Manufacturing Process & Capital Equipment

Information Technology

Innovative OEM Collaborator Awards

2006

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Product

Product Europe

Manufacturing Process & Capital Equipment

Information Technology

CogniTens Inc. - OptiCell Non-Contact Measuring System

Innovative OEM Collaborator Awards

2005

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Product

Product Europe

Manufacturing Process & Capital Equipment

Siemens VDO Automotive, Powertrain Fuel Components - DEKA VII Low Pressure Electronic Gasoline Fuel Injectors

Information Technology & Services

i2 Technologies, Inc. - Optimal Scheduler

Innovative OEM Collaborator Awards

2004

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Product Innovation

Product Europe

TRW Automotive Inc. +++ Active Control Retractor (ACR)

Process

Information Technology

2003

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Product Innovation

Product Europe

Siemens VDO Automotive - Piezo Common Rail Diesel Direct Injection System

Manufacturing Process & Capital Equipment

Information Technology & Services

Perceptron Inc. - AutoGauge FMS In-Process Measuring System

2002

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Product Innovation

Europe

Information Technology

Engineous Software Inc. - iSight software

2001

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Product Innovation

Information Technology/Internet

Management Practice

ZF Industries Inc. - Ergonomically based job assignment employee rotation process

Manufacturing Proess

Nucap Industries - NUCAP Retention System

Europe

Open Category - Enduring Innovations

Shape Corporation +++ Tubular High Strength Swept Bumpers

Open Category - Environmental

BASF Corporation, Coatings and Colorants Division - Integrated Process

2000

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1999

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1998

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Benteler Automotive Corp.
Cooper Automotive/Wagner Lighting
Durr Industries
Eaton Corporation, Spicer Clutch Division
Gentex Corporation
Johnson Controls, Inc./Prince

1997

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1996

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Cherry Corporation, Electrical Products
Delco Electronics Corporation
Fayette Tubular Products Incorporated
Gage Products Company
Progressive Tool and Industries Company (PICO)

1995

AP Technoglass Company
Dana Corporation, Spicer Driveshaft Division
Gentex Corporation
Johnson Controls, Inc.
Phillips Service Industries Inc.

Contact Us

For questions regarding the program or sponsorship opportunities, contact:
Ellen Dennehy, Director of Relationship Marketing
Phone: (313) 446-6039
Email: edennehy@autonews.com

For registration questions, contact:
Shauna Vercher-Morrow, Special Events Manager
Phone: (313) 446-0479
Email: sverchermorrow@autonews.com

Lyndsey Walworth, Marketing Coordinator
Phone: (313) 446-6041
Email: lwalworth@autonews.com

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2014

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2013

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2006

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2005

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2004

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2003

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Story: Fuel economy, autonomous-drive ideas win big at PACE 2017
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