AnnuAl RepoRt 2009

Centre for Automotive Systems Technologies and Testing

The northernmost University of Technology in Scandinavia World-class research and education

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CASTT has developed in several ways, perhaps most importantly in that a growing number of interested parties from Sweden, europe and around the world are now gathering around CASTT and the projects that are being conducted. For example, automotive companies from India are now collaborating with CASTT. The increasing attention that CASTT is receiving in the Gothenburg region is very exciting.

This shows that the automobile testing industry’s efforts to become an accepted part of the Swedish auto industry are paying off.

I look forward with great anticipation to what the CASTT road map project will deliver. It is my hope that this project will provide a map for the continued development of the automobile testing industry and lTu as a bearer of knowledge within the automobile industry.

CASTT is growing project-wise. We are now conducting 12 projects in collaboration with entrepreneurs and automobile companies. on the basis of this strong foundation, I look to the future with great confidence.

Jerker Delsing

Chair, CASTT management group

2009 has been CASTT’s most successful yeAR to date

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cAstt takes on the challenge

Testing is a growing business segment. Greater competition, traffic-safety and environmental concerns are leading to an increased need for testing of both vehicle systems and road systems. Since 2005, CASTT has been working to promote the development of the testing industry.

CASTT brings together entrepreneurs, researchers, teachers, engineers and financiers. From this environment, new offers and new, unique opportunities for testing emerge. All CASTT projects are based on concrete needs in the industry; above all, among the automotive testing companies. The testing companies and, often, their customers, participate in each project, which places high demands on confidentiality.

The work is long-term and CASTT’s activities therefore involve many forms of collaboration including research, development, undergraduate studies, student projects, industry seminars, workshops, continuing education, internships, etc. Common to all projects are the strong links with the automotive testing firms’ current operations and with new business segments within the field of testing.

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Researchers and other experts from different disciplines collaborate within CASTT. Every research problem we address is complex, and a successful solution requires many perspectives and in-depth knowledge in many different areas.

In the research projects, we deal with specific prob-lems, but we also publish scientific articles and describe how the results can be translated into services or prod-ucts. The former provide references and credibility, not least with the research financiers. The latter lead to the positive commercial development of the testing industry, which results in growth and employment.

The goal is more and bigger business. Since the start in 2005, cooperation has grown, as has the industry’s

confidence in, and reliance on, the university. That relation-ship is now bearing fruit. At one time, the offer consisted mostly of test tracks, workshop halls and hotels. Now, for example, for the first time, an assignment with total responsibility for testing has been commissioned by an automaker. Another result of cooperation within CASTT is improved acoustical testing. To develop testing of “squeak and rattle” in vehicles, a new sweep frequency track with a washboard segment laid out according to a specific pattern on the ice is being tested. The acoustical measurements can then be refined and the results will be traceable and comparable.

Now, the challenge is to prolong the testing season with climate-controlled halls and new or improved testing offers.

ReseARcH and DeVelopMent

eDucAtIon The engineering degree programme in automotive sys-tems engineering at Luleå University of Technology was initiated as a result of collaboration within CASTT. There has been, and continues to be, a great interest in this programme among students. Close collaboration with firms in the industry gives the students a broad contact network and enables direct practical application of theo-ry in their studies. The programme also has a very strong research component. Graduate automotive systems engineers are an important asset for companies in this growing sector.

The engineering programme is offered at the Luleå campus and the students’ projects and thesis projects are conducted at the companies. Interaction between the students and companies is beneficial for both parties and contributes to the development of new expertise and new concepts. There are numerous good examples of how student projects have resulted in the commercializa-tion of products and services.

In addition to undergraduate studies, directed courses are given for industry personnel in subject areas identi-fied by the companies.

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RInGs on tHe WAteRCASTT creates

real-time visuali-zation of measure-ment data from vehicles

road To-pography scanning

Micro Climate reporting

event-driven Auto-motive systems

exhaust emissions – Car Test

Tire noise – nokian

intelligent Measurement systems – Car Test

Friction noise – sAAB

remote Vehicle Dynamics

noise, comfort and emissions

Tire Friction on ice

Tire Friction Measurement Methods

sensor for non-Contact road Characterization

Ice and friction

1 – Distributed Automotive Development,

Testing and Validation

2 – remote Vehicle Dynamics

Integration projects

communication and support systems Development

FINANCIER

CASTT is an abbreviation of the Centre for Automotive Systems Technologies and Testing. The centre started with a mandate to develop the automotive testing industry in Norrbotten. CASTT has become an international platform for competence development and cooperation, and has won the confidence and commitment of the industry. The ambition is for CASTT to be made a permanent research centre after its second operating period, 2008-2010.

The projects are based on the needs of the partner com-panies. Automotive testing companies participate in the projects and their customers are sometimes also involved. Each project includes interaction with the undergraduate programme for automotive systems engineers.

Via CASTT, the automotive testing industry gains access to other resources. We work closely with, for example, Test Site Sweden, which is creating a national test arena for ve-hicle safety, with the Swedish Hybrid Vehicle Centre (SHC),

and with the I2 project, which is building a demo environ-ment based on wireless infrastructure along a highway.

CASTT is the foundation from which the testing industry can initiate and co-finance research and development projects that will eventually lead to more and bigger business.

FINANCIER

FINANCIER

FINANCIER CASTT BASIC FUNDING

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GOTHENBURG (Tss and sHC)

LULEå (luleå University of Technology)ARvidsjAUR

ÄLvsBYN

ARjEpLOG (sPgA)

jOkkmOkk

o Arctic Falls AB (Älvsbyn)

o Arctic Track AB (Arvidsjaur)

o Arjeplog Hundspanns-resor (Arjeplog)

o Arjeplog Test Management AB (Arjeplog)

o Cartest AB (Arjeplog)o Cold Climate

Technology (Arvidsjaur)

o Colmis Proving Ground (Arjeplog)

o Continental Teves (Arvidsjaur)

o Galtis AB (Arjeplog)

o Hägglund & Granström (Jokkmokk)

o IceMakers AB (Arjeplog)

o Ice-Track AB (Arvidsjaur)

o Kiruna Test Area (Kiruna)

o Lapice AB (Malå)o Lapland Car Test

(Arjeplog & Arvidsjaur)

o Mats Holmström HB (Arvidsjaur)

o Skellefteå Drive Center (Fällfors)

o Tjintokk AB (Arjeplog)o UB:s Alltjänst AB

(Arvidsjaur)

mALåFÄLLFORs

some automative manufacturers and system and component suppliers active in the winter test region:

o Borg Wagnero Boscho Bridgestono Continental Teveso GKN Drivelineo Haldexo Hyundai Mobiso Knorr Bremseo Magna Powertraino Mandoo Pirellio TRW Automotiveo Unicia Jecso BMWo Ferrario Fiato Fordo General Motorso Land Rovero Porscheo PSAo Renaulto SAABo Scaniao Volvoo VW-group

public authorities and clusters:

o City of Luleåo County

Administrative Board of Norrbotten

o Municipality of Arjeplog

o Municipality of Arvidsjaur

o Municipality of Göteborg

o Municipality of Jokkmokk

o Municipality of Malåo Municipality of

Skellefteå

o Municipality of Älvsbyn

o SHC Swedish Hybrid Vehicle Centre

o SPGA (Swedish proving Ground Association)

o TSS Test Site Sweden

Luleå University of Technology:

o Division of Civil and Environmental Engineering

o Division of Computer Aided Design

o Department of Computer Science and Electrical Engineering

o Division of Functional Product Development

o Division of Machine Elements

o Division of Sound and Vibration

o Project I2 – The Intelligent Inland Road. (CDT, Centre for Distance Spanning Technology and CASTT, Center for Automotive System Technology and Testing)

Test service providers:

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Trainee electRIc cARs and colD clIMAte

“I’m glad I got this chance,” says Jakob Hultkvist, a trainee at the testing company Arctic Falls. Contact with the company was established via CASTT when Jakob did his thesis project. “I’m working with different things during my trainee year, but much of what I do is related to electric cars,” explains Jakob Hultkvist.

Testing of electric cars under cold-climate conditions is a relatively new area. Here, among other things, Jakob works with method development.

“It is a project with Test Site Sweden, where we are putting together a sort of test guide that shows what, how and why we should measure to get correct information in areas such as safety, energy use,

performance, charging and more. The guide will make the measurement results from electric cars comparable to those obtained from fossil-fuel vehicles and will be available to all testing companies,” says Jakob Hultkvist.

Jakob will soon perform a number of tests for a newly-established manufacturer of electric cars. The assignment is a spin-off from the testing methodology project.

“By investing in this development project, Arctic Falls has been in at the start, at a time when more and more electric cars are being introduced. Trainees are an important resource for ventures such as this.”

Whether the trainee period will lead to employment remains to be seen. But one thing is certain: both Jakob and the company have benefitted immensely.

eJAKoB HULTKVIST, TRAINEE, ARCTIC FALLS F

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As a full service winter test supplier to the automotive industry, we continuously need to adapt to its changing conditions. The increased complexity of the technical systems in vehicles, e.g. active safety systems integration of various electronic systems, new types of energy and fuel systems etc., leads to new demands on our tracks and also on our other facilities such as workshops.

Also, the automotive industry is under tough financial pressure and, with shortened lead times, the industry is outsourcing more operations to the winter test providers. This leads to further opportunities for the testing

companies to offer new service packages which, in turn, requires greater engineering expertise and access to more advanced equipment.

Working within the CASTT network, we are assured access to automotive know-how from Luleå University of Technology and CASTT’s international partners. We work with both undergraduate and graduate students, as well as with senior researchers and consultants in various projects. Participating in research projects keeps us at the technological forefront of automotive testing and development – now and in the future.

Test service provider IceMAkeRs ABeLARS SUNDSTRöM, ICEMAKERS F

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All objects start to oscillate at a certain frequency. Interior components and structures in cars are no exception, and when they start to vibrate, the phenomenon is referred to in the auto industry as “squeak and rattle”. In testing, the difficulty is to determine when the noise first becomes audible and the location of its source. A good example of the power of collaboration is that researchers and students from LTU have been able to develop a new test method together with Icemakers. The innovation is a sweep frequency track. By creating a washboard of plywood strips placed at successively narrower intervals, researchers can analyze sound recordings and thereby determine exactly where and when different sounds are produced in the car at different temperatures. The wash-board can also be frozen into the ice, if necessary. The method, which is new for winter testing facilities, is now being refined and will be tested by an automaker.

Continuing education is a concrete example of know-ledge dissemination. Via CASTT, Luleå University of Technology offers a course in materials and vehicles in winter climate conditions. The course, which will be offered annually, was commissioned by Swedish Armed Forces Technical School and the Armed Forces winter unit in Boden. Another example is a course in measurement techniques for both automotive testing companies and stu-dents in the automotive systems engineering programme.

A major industry conference has been held in Arvidsjaur two years running. Within a short time it has become a national forum for the automotive testing industry, the vehicle industry, universities, local municipalities, Vinnova and others with an interest in vehicle testing. This is now an annual event at which research results and current projects are presented.

GooD examples

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Remote Vehicle Dynamics This project explores new ways of using vehicle dynam-ics during winter testing, with the goal to enable new or developed services for service providers and thus render testing more effective for the automotive industry. In gen-eral, service providers want to get closer to their custom-ers in the value chain to provide new or extended servic-es. Service providers find the use of remote technologies, such as fleet management, an important part of their service, especially with respect to the safety of test drivers and overall safety on the test tracks. As well, according to the automotive industry, the possibility of replaying the last run in a 3D environment from logged data in the car enhances these services. The use of steering robots dur-ing winter testing can allow for repeatable and standar-dized testing. However, the studies performed in this project show that the views of companies vary greatly, indicating that further research towards standardized winter testing is necessary. Work to enhance a fleet management solution and a pre-study of using steering robots has been initialized. In addition, a pre-study of a drivability measurement system has been conducted with great success. We believe that, in future, vehicle testing will be standardized even further when the service pro-vider conducts more testing. Hence, tools and methods must be developed to meet this demand.

eCoNTACT: MIKAEL NyBACKA F

Distributed automotive development, testing and validation In this project, technology and methods are developed that enable vehicle testing and validation to be performed in a distributed fashion, using wireless communication networks. This includes technology for remote diagnos-tics, wireless software download and wireless measure-ment data acquisition. Geographical positioning systems for fleet management of test vehicles have also been developed. Moreover, tools and methods for distributed collaborative automotive development using audio, video and data sharing techniques are studied in the context of automotive testing and validation.

The tools and technologies developed in the project are being tested at proving grounds using WLAN com-munication technology and on public roads using GPRS and 3G networks. Since automotive testing facilities are commonly located in remote rural areas, due to the need for extreme climate conditions and privacy, it is important to improve the interaction between developers at auto-motive development sites and test engineers at the prov-ing grounds.

A specific focus is placed on testing and validating electric and hybrid cars through a collaborative effort with the Swedish Hybrid Vehicle Centre. Project partners are Volvo Car Corporation, Alkit Communications AB, Swedish Hybrid Vehicle Centre, Test Site Sweden and Arctic Falls AB.

eCoNTACT: LENNART KARLSSoN F

pRojects

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Reactive programming of event-driven automotive systems The project goal is to improve the testing process of software-based automotive systems through:

• Targeting the testing to functionality, i.e. testing the function to be implemented, instead of struggling with errors (bugs) in code implementation.

• Eliminating hard-to-find software errors, such as mem-ory leakages and pointer errors.

We also strive to improve the product development phase through synchronous simulation in Simulink, where running all embedded software together with a simula-tion model of the vehicle’s electronics and dynamics can validate the functionality. The project encompasses the development of Timber tools, a framework to specify, simulate and analyze the timely behaviour of embedded software.

eCoNTACT: JAN VAN DEVENTER F

Real Time Analysis of Data from Wireless Sensor networks in Automotive Testing This project focuses on wireless sensor technology and its applications in automotive testing. A wireless sensor is used to collect data such as temperatures and acceler-ation in real time from vehicles. The sensor is connected via Bluetooth to a data collection system installed in a vehicle. The data collection unit can perform certain processing on the collected data, and then upload the data to a portal, where it can be further processed and accessed by the automotive engineers. The data can also be visualized in real time for quick, on-line analysis.

The benefit of using wireless sensors in automotive testing is that it makes it easier to set up a test car with-out bothering about a lot of wires for the sensors. For instance, in climate testing, about thirty temperature sen-sors are commonly used, which implies a lot of cabling unless wireless sensors are used. The technology devel-oped in this project is coordinated with the technology development performed in the project “Distributed auto-motive development, testing and validation”.

eCoNTACT: LENNART KARLSSoN F

Roadgrip in winter road conditions The design of safe and reliable non-studded winter tires is challenging due to an inadequate understanding of the involved grip phenomena. There are also gaps in our knowledge of how different winter road conditions affect grip. This research project consists of three parts: road-grip studies, winter tire rubber characteristics and the characterization of winter road surfaces. Equipment and methods to test roadgrip of tires on ice, snow and slush have been developed. The contact area between ice and tire has been studied directly by optical means and indirectly for pressure distribution to understand the slip phenomena. By using different casting techniques, it is possible to measure ice topography with high resolution. Close collaboration with the Swedish Road Administra-tion has resulted in a suggestion for a method descrip-tion on roadgrip tests for production units on the Swed-ish road system.

eCoNTACT: NICLAS ENGSTRöM F

Friction-induced, cold-related noise in automobiles This research project has three main focus areas: • A detailed investigation of the climate influence on the

excitation mechanisms of friction-induced noise from seal surfaces.

• Development of a prediction model based on theoreti-cal modelling verified through experiments.

• Development of a quick and reliable measurement method that can detect transient squeak and rumble sources inside a car.

The intention is for trained test car personnel or auto-motive personnel to use this method. Saab/GME, Vinnova and CASTT co-finance the project, which is run by the Division of Sound & Vibration in cooperation with the Division of Machine Elements and Experimental Mechanics at LTU. The project is being conducted at LTU, Colmis, Icemakers, Saab and at GME’s research facility in Russelsheim.

eCoNTACT: ANDERS åGREN F

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Measurement, identification, assessment and modelling of winter tire noise inside passenger cars The noise caused by studded winter tires is normally more annoying than from ordinary tires. Tire noise inside the car is a product of the generated tire noise and its structural and airborne transfer paths into the car interior. The annoyance that the driver may experience from the tires is not only a product of the level of the sound, but also the sound’s character and the situation in which it is produced. This sound quality aspect is also vital to the total experienced quality of the tire. The project partners are the Division of Sound & Vibration at LTU and Nokian Tyres, Finland.

The project aims to build up the necessary knowledge for tire sound optimization to create tires that are per-ceived as more silent and more comfortable. The project comprises development of methods for subjective and objective measurements of tire loudness and annoyance, development of methods for auralization of interior vehicle tire sound, knowledge about sound quality methodology on tires and examination of the couplings between the resulting cabin noise, the noise transfer paths and the noise excitation by tires. The project is run in cooperation with Icemakers as the test track provider. A test series with five nominally identical cars and a number of tires has been conducted, as well as a series of laboratory tests.

eCoNTACT: ANDERS åGREN F

Reactive programming of event-driven automotive systemsour goal is to improve the testing process of software-based automotive systems through:• targeting the testing to functionality; i.e., testing the

function to be implemented instead of struggling with bugs in the code implementation;

• eliminating hard-to-find software errors such as memo-ry leakages and pointer errors, etc.

We also strive to improve the product development phase through synchronous simulation in Simulink, where the functionality can be validated by running all the em-bedded software together with a simulation model of the vehicle’s electronics and dynamics.

The main and most innovative goal of this project is the development of a holistic, model-based design approach for embedded real-time control systems.

Another important contribution in this project is the development and refinement of the Timber tool suite. The aim is to provide methodologies and tools that improve productivity and shorten development time. A further innovative aspect is the development of automatic traction-control methods for wheel loaders and haulers.

eCoNTACT: PER LINDGREN F

Demonstration of multigas exhaust measurements The project is a demonstration and investigation project in which methodology and equipment for field measure-ments of regulated engine emissions are investigated. A survey and some marketing research are also being done to determine the level of interest in exhaust emis-sion tests in the region. The project is run in cooperation with ETC, Piteå, a commercial partner with expertise in exhaust emission measurements. ETC has invested in equipment that will be used to test emissions for auto-motive companies. A demonstration measurement series was carried out on cold-start exhausts from several automobiles.

Arctic Falls and Mercedes AMG initiated the project, which is run by the Division of Sound & Vibration in cooperation with ETC. Icemakers have also expressed an interest in presenting this service to their customers.

eCoNTACT: MIKAEL NyBACKA F

Microclimate results The project has been conducted in close collabora-tion between industry (test entrepreneurs and SMEs), and researchers and students at LTU. The project has resulted in a prototype system allowing sensor data to be collected (from both mobile and stationary weather stations), stored in a database for processing, and pre-sented to end users. Technology for both stationary and mobile weather stations has been developed in close collaboration with Rajd Systech and is now in a phase of testing. In addition, we have conducted a number of trials for tailoring weather forecasts for the local car test entrepreneurs. These first trials aid our understanding of the customers’ demands and serve as basis for develop-ing future business opportunities for both technology and service providers, as well as for the customers.

eCoNTACT: PER LINDGREN F

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Sensor for Non-contact Road Friction Characterization The aim of the project is to use optical methods to char-acterize winter road conditions that can be used by the automotive and automobile testing companies. Different phases of water (ice, snow and their mixes) have different resonance frequencies, and it has been shown that these differences are greatest at near infrared wavelengths (1-2 µm). Hence, a sensor with three different laser wave-lengths in this span has been developed and tested on real winter roads. The results show that it is possible to distinguish between different road conditions like snow, ice and water on an asphalt road. Further, to determine the surface roughness, a model of light reflection from soils has been applied on the back reflections from as-phalt, resulting in a measure of the roughness, which is an important parameter to correctly determine road fric-tion. In parallel, a stereo camera vision system is under development in order to get an image of the surface topography.

Ideas have also been evoked to combine the results from the surface measurements with additional informa-tion in order to determine the road friction more accu-rately. Such additional information could be, for example, the temperature and whether there is water, snow or ice on the road.

eCoNTACT: MIKAEL SJöDAHL F

eCoNTACTS F

JAN VAN DEVENTER E-mail: Jan.van.Deventer@ltu.sephone: +46 920 491336

NICLAS ENGSTRöME-mail: Niclas.Engstrom@ltu.sephone: +46 920 492381

LENNART KARLSSoNE-mail: Lennart.Karlsson@ltu.sephone: +46 920 491279

PER LINDGRENE-mail: Per.Lindgren@ltu.sephone: +46 920 491092

MIKAEL NyBACKAE-mail: Mikael.Nybacka@ltu.sephone: +46 920 491698

MIKAEL SJöDAHLE-mail: Mikael.Sjodahl@ltu.sephone: +46 920 491220

ANDERS åGRENE-mail: Anders.Agren@ltu.sephone: +46 920 491683

eTHE PRoJECTS ARE CoNDUCTED IN CoLLABoRATIoN WITH THE TESTING CoMPANIES F

Arctic Falls, ATM, Cartest, Colmis and Icemakers

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econoMy

Financial statement CAsTT 2005-2009

income sEk `000 2005 2006 2007 2008 2009 TOTAL

LTU funding 1 610 6 110 8 086 6 504 7 019 22 310

Private companies 260 455 284 890 999

Private foundations 368 45 443 413

other governmental funding 50 2 083 1 972 2 133

Projects, own funding efforts 2 096

TOTAL 1 610 6 370 8 959 8 916 12 420 25 855

Expenditures sEk `000 2005 2006 2007 2008 2009 TOTAL

Personnel costs 590 4 557 6 296 7 170 10 006 18 613

External services 415 1 205 1 153 1 380 1 189 4 153

Equipment 2 148 255 199 51 604

Travel 56 250 423 344 545 1 073

other costs 18 167 320 166 629 671

TOTAL 1 081 6 327 8 447 9 259 12 420 25 114

Result 529 43 512 -343 0 741

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prof. Anders ågrenLuleå University of Technology

E-MAIL:

Anders.Agren@ltu.se

dr. peter jeppssonLuleå University of Technology

E-MAIL:

Peter.Jeppsson@ltu.se

prof. Lennart karlssonLuleå University of Technology

E-MAIL:

Lennart.Karlsson@ltu.se

jerry johanssonArvidsjaurMunicipal commissioner

E-MAIL:

jerry.johansson@ arvidsjaur.se

prof. jerker delsingLuleå University of Technology

E-MAIL:

Jerker.Delsing@ltu.se

Lars HolmgrenSPGA, Managing Director ATM AB

E-MAIL:

lars.holmgren@atmab.com

CASTT is run by a management committee and a group of activity leaders. In addition to executing tasks assigned by the management committee, the activity leaders communicate with project owners, test-service providers and other members of the cooperative network.

CHAirMAn COMMiTTee MeMBers

ACTiViTY leADers PrOJeCT PArTiCiPAnTs

Members of each research and development project are listed in the Project portfolio section of this annual report.

BoARD AnD DIRectoRs

CASTTCentre for Automotive systems

Technologies and Testing

Luleå University of Technology

SE-971 87 Luleå, SWEDEN

phone: +46 (0)920 49 10 00

www.ltu.se/castt

read more about our projects at

www.ltu.se/castt

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Ju · photo: lars H

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ettersson and others · print: luleå Grafiska 10-06/300