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SARDOU SAS has developed highly stressed composites parts for 35 years. SARDOU SAS and QUALITY INDUSTRIAL PRODUCT invented composite coils springs in 2002. Developing composite coils springs, we have faced a big challenge, how to increase the short life expectancy of this highly stressed structure? We have identified that the weak point, in composite coils springs, is its epoxy matrix. In fact, during heavy loading, the matrix undergoes micro cracks. Then, during fatigue, micro cracks propagate and merge, transforming the matrix into a fine powder. The composite coil suspension springs, using, classic epoxy, where ruined after only 100,000 cycles in the best cases. The fact to integrate “functionalized silica aggregates”, in the matrix, enable the springs to exceed 1,000,000 cycles, with the same spring design. In addition, the spring stiffness has increased by 6% and the thermal set has reduced by 1.6%.

This paper presents information on new technology which has made the Composite Coil Spring a practical Reality. The light weight and low cost nature of this novel component presents very interesting possibilities for reducing the weight of automotive models. The experimentation with composite materials which was focused on developing practical components with viable manufacturing methods began in our company 1983. The first episode was with very strong torsion members for truck applications. This was followed by development of a unique “C” spring design in 1993 (reported in SAE paper 2000-01-0100). This paper deals with the new successor to these earlier designs, the “Composite Coil Spring”. This paper identifies the manufacturing process that has been developed and patented to provide composite Coil springs cost effectively. The paper also presents the physical properties of the springs which are made from thermoset Epoxy, and E type glass fibers.

This paper presents information on new technology which has made aerodynamic rotating shroud composite cooling fans a practical reality. This paper will describe the design methodology which creates an aerodynamic blade for just the required performance of the system. The design tool has shown to more than 90% accurate for air flow performance in lab validation tests. This paper describes applying this fan matching software to an application involving railroad switcher locomotives. The new fans are compared to the predecessor fans, and the notable performance improvement is shown. The heavy demand on cooling systems now and in the future will find a very attractive solution in the high performance low noise rotating shroud composite fan system.

Our organization has developed since 1992 a numerical model in order to compute fan performances. As we have observed lack of noise efficient prediction tool, we have aimed to an integrated model, which enable us to fully optimize fans, pressure and noise of fans. This paper shows some examples of our model optimization features. The fans that this model defined are interesting for energy efficiency; and so, it's possible to reduce energy consumption as well as in drive installed power requirement.

Composite C Springs for suspension have been developed by our company since 1993. This paper show some examples of our C springs manufacturing, realization, testing and optimization features. We will start our presentation by an analysis of reasons why Composite Compression Springs (patented) perform well compared to leaf springs. Then we will give examples of some development programs we have successfully carried out from study up to vehicle road testing. The C Springs have been tested in static measuring bench, in fatigue and in relaxation machine. C Springs have been (and are), also road tested. More than hundreds of thousand of kilometers have been achieved with success (near exhaust pipes). We will present examples of spring integration giving a dramatic weight reduction, as well as ride and handling improvement. We will also introduce cost evaluations showing that Composite Compression Springs save money as well as weight on a vehicle.

Our organization has developed since 1992 a numerical model in order to compute fan performances. As we have observed lack of noise efficient prediction tool, we have aimed to an integrated model, which enable us to fully optimize fans, pressure and noise wise. This paper show some examples of our model optimization features. Our numerical model compute noise versus mass flow as well than pressure versus mass flow. This model is valid for axial as well as for centrifugal or mixed flow fans and fans for auto cooled traction motors (clock wise and anti-clock wise rotation). Thank to our model and our expertise, we have developed ultra low noise fans for a lot of applications. Some of which are described in the paper. An important point is that the fans we develop are interesting for energy efficiency; and so, money savings are possible as well in energy consumption than in drive installed power requirement.

This paper show some examples of our C springs manufacturing, realization, testing and optimization features. Composite C Springs have been developed by our company Since 1993. We will start our presentation by an analysis of reasons why Composite Compression Springs (patented) perform well compared to leaf springs. Then we will give examples of some development programs we have successfully carried out from study up to vehicle road testing. The C Springs have been tested in static measuring bench, in fatigue and in relaxation machine. C Springs have (and are), also road tested. More than hundred of thousand kilometers have been achieved with success (near exhaust pipe). We will present examples of spring integration giving a dramatic weigh reduction, as well than ride handing improvement. We will also introduce cost notions showings that Composite Compression Springs save money as well as weight on a vehicle.

Our organization has developed since 1992 a numerical model in order to compute fan performances. As we have observed lack of noise efficient prediction tool, we have aimed to an integrated model, which enable us to fully optimize fans, pressure and noise wise. This paper show some examples of our model optimization features. Our numerical model compute noise versus mass flow as well than pressure versus mass flow. This model is valid as well for axial than for centrifugal for mix flow fans and fans for auto cooled traction motors (clock wise and anti-clock wise rotation). Thank to our model and our expertise, we have developed ultra low noise fans for a lot of applications. Some of them are described in the paper. An important point is that the fans we develop are interesting for energy efficiency; and so, money savings are possible as well in energy consumption than in drive installed power requirement.