GM Honors Top Innovators of 2003

DETROIT, Michigan May 25, 2004; General Motors honors its top innovators of 2003 at the 28th annual "Boss" Kettering Awards ceremony today.

The "Boss" Kettering Award is GM’s highest award for recognizing GM technical inventions and innovations. Its purpose is to honor individuals who have developed outstanding inventions and innovations that have demonstrated identifiable and substantial benefit to General Motors during the previous year. Awardees join an elite and prestigious group of GM innovators, 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 names of "Boss" Kettering Award winners for 2003.

Advanced Hydroforming Operation This patented GM innovation advances the processes to clamp and pierce hydroformed tubes, which lowers cost, increases volume capacity and reduces cycle time. In the hydroforming die operation, compact seal units are mated with locator assemblies for placing and clamping pre-bent tubes to ready them for final forming and hole piercing. The assemblies have been adapted to enable the clamps to remain in position, eliminating the need to retract during processing. New punch configurations have been developed to expand piercing capabilities and improve hole quality. Required holes or slots can be pierced into the part while in the hydroforming die, eliminating some post-hydroforming operations. This innovation was first demonstrated on the 2002 Chevrolet TrailBlazer, GMC Envoy, Oldsmobile Bravada, Chevrolet Corvette and the Cadillac DeVille as a die retrofit.

The Advanced Hydroforming Operation team includes Mike Ghiran, Roman Gmurowski and Tom Winterhalter of Metal Fabricating Division in Sterling Heights, Mich; Ben Kaufman, Terry Kent and Boris Shimanovski of Metal Fabricating Division in Pontiac, Mich; Mike Lovell and Tom Malone of Metal Fabricating Division in Troy, Mich; Paul Oberski of Metal Fabricating Division in Warren, Mich; and Sanjay Shah of Vehicle Operations in Warren, Mich.

Canister Powder Paint Delivery This industry first innovation uses a two-canister system to apply color-specific powder paint to automotive external and internal surfaces. As one canister is in use for the painting process, the second is purging the powder from the previous job and readying for the next, allowing continuous operation in an inline system, rapid color changes and a mere eight-seconds between paint jobs. This innovation was implemented in October 2003 at the GM Baltimore Assembly plant to apply color powder primer to certain exterior surfaces of the 2004 Chevrolet Astro and GMC Safari vans. It was also selected for use in the new paint shop at the GM Lordstown complex in Ohio for the application of color-specific powder primer to interior surfaces of the 2005 Chevrolet Cobalt.

The Canister Powder Paint Delivery team includes Dr. Sheila Kia, Chris Murphy, Brian Prylon, Fred Blair and Frank Rauch of Paint & Polymers Engineering in Warren, Mich.

FaultFinder: Model-Based Approach for Advanced Engine Diagnostics This model-based approach for advanced engine diagnostics uses algorithms and ingenious applications of existing hardware to detect and diagnose faults on emission-related components of automotive engines. The GM-patented diagnostic approach requires no additional sensors or other hardware, reduces false-alarm rates, improves vehicle repair rates and dealership effectiveness. This innovation has been implemented in the 2004 Chevrolet Malibu featuring ECOTEC 2.2-LITER 4-cylinder engines; Cadillacs featuring the Northstar 4.6-liter V-8 engines; and Chevrolet Colorado and GMC Canyon mid-size trucks.

The FaultFinder: Model-Based Approach for Advanced Engine Diagnostics team includes Thomas Ting and Dr. Man-Feng Chang of GM Research & Development in Warren, Mich; John Van Gilder of GM Powertrain in Warren, Mich; and Dr. Mark Costin of GM Powertrain in Milford, Mich.

Hidden Passenger Air Bag Door This method of providing a hidden passenger air bag door is an industry first. This patented, technological advancement produces an integral instrument panel air bag door without secondary manufacturing operations, eliminating the need for cutting and scoring equipment and requisite production processes. The result is a high-quality, low-cost vehicle interior surface that hides the air bag door yet optimizes air bag deployment. This innovation was first introduced by GM on the 2003 Cadillac CTS and the 2004 Cadillac SRX.

The hidden passenger air bag door method innovator is William Barnes of GM Product Development in Warren, Mich.

Integrated Remote Start System Integrated Remote Start is the first such system developed and implemented by an original equipment vehicle manufacturer. It also is the first ever to integrate powertrain, vehicle and content theft control systems to provide superior levels of safety and security over existing aftermarket remote start systems. Vehicle and content security systems remain active during a remote start and the system will shut off the engine if the powertrain control system detects engine problems. Integrated Remote Start is currently offered on the 2004 Chevrolet Malibu and Malibu Maxx, and will be offered on many future GM vehicles.

The Integrated Remote Start System team includes Kerfi Katrak of GM Powertrain in Milford, Mich; Dave Bodenmiller, Scott McCullough, Terry Meehan, Dave Proefke, Dave Thatcher, Tom Utter and Lisa Weber of GM Product Development in Warren, Mich.

Mechanization of Hydra-Matic Six-Speed Front-Wheel-Drive Transmissions This new family of six-speed automatic transmissions, jointly developed with Ford Motor Company, features a new architecture with optimal steps between gears and a wider gear ratio span to improve fuel economy by as much as 4 percent compared to a traditional four-speed automatic transmission. Featuring a compact design, the new 6-speed will be capable of higher torque capacity when compared to most existing front-wheel-drive transmissions such as 4-speed automatics and continuously variable transmissions. Production is scheduled to begin in 2006 for GM front-wheel-drive and all-wheel-drive passenger cars and sport-utility vehicles.

The Mechanization of Hydra-Matic Six-Speed Front-Wheel-Drive Transmissions team includes: Chi-Kuan Kao, Joseph Lee, Dr. Madhu Raghavan and Dr. Patrick Usoro of GM Research & Development in Warren, Mich; Dan Coffey of GM Powertrain in Wixom, Mich; Joel Maguire, Paul Stevenson, Scott Wittkopp and Paula Armstrong of GM Powertrain in Ypsilanti Township, Mich.

Rapid Modeling and Analysis This fully automatic, near real-time finite element model building and analysis tool is used for computer simulation of vehicles, subsystems and components. Currently Rapid Modeling and Analysis (rMA) is used for modeling and analysis of sheet metal parts, including body-in-metal vehicle subsystems. This innovative tool can simulate the response of a structure automatically, usually without manual intervention and within hours of a design being completed. It reduces the time to create a finite element model from the usual 4 to 12 weeks, down to approximately eight hours and at the same time yields more accurate answers than with traditional methods. GM plans to roll out rMA globally.

The Rapid Modeling and Analysis innovator is Vinod Kanodia of GM Product Development in Warren, Mich.

RiBeTT: Software Subsystem (Ring) Behavioral Test Tool This innovation dynamically tests the behavior of powertrain controls software subsystems (rings) as soon as the software is available, which is typically months before embedded controller and vehicle evaluations are ready to begin. This software tool emulates the embedded controller operating system to detect between 75 and 90 percent of software subsystem problems earlier and more effectively than traditional methods. Test results allow conclusions about eventual real-world software behavior to be made with high confidence, potentially reducing cost and development time, and improving quality.

The RiBeTT: Software Subsystem (Ring) Behavioral Test Tool team includes Dan Bolstrum, Doug Constance, Trent Haines, Mike Kropinski, Alex Makris, Mike Turley and Mike Wisbiski of GM Powertrain in Milford, Mich

Two-Mode, Compound-Split Electromechanical Transmission This innovation represents a competitive breakthrough in hybrid technology for GM. The system integrates planetary gearing with electrical machines to achieve high efficiency in a compact parallel hybrid transmission. The two-mode arrangement decouples the engine from the vehicle to allow full continuously variable transmission operation and regenerative braking. The result is reduced fuel consumption and dramatically lower emissions while preserving a high level of performance. First applied during 2003 in city transit coaches, the two-mode transmission architecture is scalable from large transit buses to passenger vehicles.

The Two-Mode, Compound-Split Electromechanical Transmission innovator is Mike Schmidt of GM Powertrain in Indianapolis, Indiana.

VehSim: Virtual Chassis / Driveline Controls and Integration This software simulates the chassis and driveline controls and integration environment, which reduces the need for expensive hardware development and testing. VehSim is a key technical enabler for accelerating the global vehicle development process for GM and its alliance partners. It provides an extremely user-friendly graphic user interface with state-of-the-art graphic and window-based technologies. This cost-effective, easy to use computer program seamlessly integrates with existing controls software and has the ability to share models and controls with simulation software commercially available to suppliers. VehSim is a versatile, common design tool suitable for use from research and development through product development.

The VehSim: Virtual Chassis / Driveline Controls and Integration team includes Steve Chin, Kevin Deng and Yong Lee of GM Research & Development in Warren, Mich; and Bob Nisonger of GM Product Development in Milford, Mich.

Adaptive Forward Lighting This innovation is a vehicle-front exterior lighting technology that provides additional exterior lighting functionality in addition to the standard fixed position low and high beam headlights. Adaptive Forward Lighting (AFL) provides Dynamic Curve Light, Cornering Light and Main Beam Headlights (where both low and high-beams can be projected through one single Xenon bulb per headlight). With AFL Curve Light, the projected headlamp pattern "follows" the road that the vehicle is traveling, while the Cornering Function illuminates the path toward which the vehicle is turning. AFL was first introduced in the 2003 Opel Signum, Vectra Sedan, Vectra GTS and Vectra Caravan.

The Adaptive Forward Lighting team includes Wolfgang Gottwald and Thorsten Lachenmaier of GM Adam Opel AG in Rüesselsheim, Germany

Fuel Additive for Flex Fuel Vehicles This patented innovation is a fuel additive originally developed for ethanol-fuel and flex-fuel (gas/ethanol) vehicles to clean aluminum hydroxide deposits from the fuel filter and dissolve sludge from inside the intake manifold. Launched in the Brazilian market in June 2003, profit opportunities exist through licensing agreements with suppliers to distribute to other original equipment vehicle manufacturers and fuel stations.

The Fuel Additive for Flex Fuel Vehicles innovator is Djalma Mello of GM do Brasil in São Caetano do Sul, SP, Brazil.

Meriva Flex Space Concept FlexSpace enables maximum freedom for configuring a vehicle interior. All seating possibilities can be arranged within seconds, without tools and without removing seats. With this innovative concept, a five-seater can be quickly and effortlessly transformed into a spacious four, three or two-seater with a generous load area and increased legroom for rear occupants. In addition, the Meriva interior offers an optional, industry-first Travel Assistant. This multipurpose storage box can be latched onto the rear side of the folded center seatback and contains an adjustable armrest and two cup holders in addition to storage space.

The Meriva Flex Space Concept team includes Horst Baltes, Winfried Ehrhard, Jurgen Pache and Michael Polster of GM Adam Opel AG in Rüesselsheim, Germany; Albino Marques and Claudemir Pereira of GM do Brasil in São Caetano do Sul, SP, Brazil.

Signum Flex Space Concept Travel Assistant The Signum FlexSpace concept allows vehicle occupants to arrange rear seating and loading area configurations to suit individual needs. This innovation makes it possible to choose between maximizing legroom, loading area space or a combination of the two. Seating and cargo possibilities can be arranged quickly, without tools or seat removal. Additionally, as a dealer option, the Signum interior offers an industry first, multifunctional Travel Assistant, which affords even greater versatility and comfort by offering rear passengers two folding tables, a cooler, a trashcan, cup holders, a 12-volt power outlet and a holder for a DVD player.

The Signum Flex Space Concept Travel Assistant team includes Gerhard Herbold, Karl-Josef Jagus, Claudia Kilburg, Andrew Leuchtmann, Michael Polster, Werner Renneisen, Volker Stein, Thomas Uhlendorf and Horst Webler of GM Adam Opel AG in Rüesselsheim, Germany.