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This report describes an arc-welding robot system with a vision sensor which Nissan Motor Co., Ltd. has introduced to automate the arc welding line for truck frames. Developed in-house, this system is now in operation on the arc welding line for Nissan Truck frames at Nissan's Kyushu plant. In developing the system, primary emphasis was placed on assuring practicality and high reliability. Included among the prominent features of the system is the capability to detect the welding line of thin panels with a high degree of accuracy and to calculate corrections when needed. To assure the high speed and reliability needed for the production line, the robot and sensor are separated, and the vision sensors are placed at fixed positions. Detection of the welding line and transmission of data to the robots to correct their positions are completed just prior to welding, so as to avoid the effects of noise and the arc flash during welding.

The expanded application of automotive electronics in recent years has increased the number of control switches, thus necessitating the optimization of their layout around the driver and improvement in operability. As an effective means in improving operability, switches mounted on the steering wheel have been developed, placing controls closer to drivers for easier access while driving. However, since the switches rotate along with the steering wheel, recognition and operation of those switches left a few things to be desired. Recently we developed a "steering wheel with a non-rotating center switch pad" where the pad section with the switches are kept stationary. In this paper we describe the general outline of this development.

An important factor in the development of vehicle suspensions has been how to get higher performance from both ride and stability, which are normally in conflict. In addressing this problem, we analyzed the optimum damping forces of shock absorbers for various driving conditions and developed an electronically controlled shock absorber system, which we call “Super Sonic Suspension” based on the results. Through this microcomputer-controlled system, we achieved a great improvement in riding comfort by being able to the damping force much lower than before, based on the results of said analysis. At the same time, stability of the vehicle was also improved by optimumly controlling the damping force for various driving conditions through signals from a newly developed road sensor, which utilizes supersonic waves, and other sensors.

The potentiality of direct injection (DI) diesel engines for passenger cars has been examined by comparing the characteristics of fuel consumption, exhaust emissions and noize levels between a turbocharged DI diesel engine and a turbocharged IDI diesel engine with the same displacement, 4 cylinders and 2 liters. It was observed that improved fuel consumption was obtained as the engine load increased, namely, 10 - 15% in the higher load range and 5 - 10% in the partial load range. In comparison to the IDI engine, the exhaust emissions of the DI engine tended to contain two or three times higher NOx and HC, and also about 30% higher particulates. Further, the noise levels of the DI engine were approximately 2 - 4 dB (A) higher than those of the IDI engine.

Basic vehicle performance, such as Safety, Comfort and Economy, are by dependent on tire performance, and it is the air pressure in the tire which assures this performance. However, tire air has a tendency to leak naturally, making it necessary to check them periodically. Since a deterioration in vehicle performance resulting from a drop on tire air pressure can not be directly felt by the driver, the number of people maintaining their tires sufficiently is relatively few. There have been many tire pressure warning devices developed which advise the driver when the pressure drops below a prescribed level. Differing from conventional devices, the TWD-III features a 7-step digital display (at a pitch of 0.1 kgf/cm2) which shows the pressure of each tire within an optional range, and it also has a flat tire warning function. The employment of echo effect from clystal vibrator resonance precludes the need to attach a power source on the tire.

This paper describes a simple engine model at idling and it applies particularly to idle speed control. Through linearization in the neighborhood of the nominal operating points (650 rpm), the engine is expressed as a reduced-order constant coefficient state variable (2 state) model. It was produced through the system order-reduction method. The strategy for controlling idle speed uses the Linear Quadratic and Integral (LQI) optimal control theory. The tracking controller was designed using a state variable engine model, and the performance index was minimized. Since state variables are artificially introduced, they are not directly accessible. Therefore, they must be estimated in accordance with a stored dynamic model (i.e. observer), in which the engine dynamic behavior is estimated on the basis of a state variable model which represents the engine's internal states, in determining controlling values.

Various radar systems have been proposed as collision avoidance sensors for automatic braking and warning applications. Practical use of laser radar systems is near with the introduction of high power, high reliability laser diodes. Utilizing these new devices, a laser radar system has been adapted for measuring the distance to objects in its path. It was first shown that reflectors on the rear of the automobile possess high reflectivity and sharp directivity. Given these characteristics, a compact laser radar system was tested that employed 12W laser diodes and PIN photodiodes. The maximum range of approximately 100 m was obtained. Furthermore, the ability to discriminate other vehicles from roadside objects was achieved by detecting discontinuity in measured distance data through a microprocessor. These results show that the performance of laser radar is comparable to that of microwave radar.

This Paper describes a computer-controlled power steering system that has been developed and applied to production vehicles. The system provides full power assist at parking speeds, and gradually decreases assistance with increasing vehicle speed to give a normal unassisted “road feel” at highway speeds. The system enables a driver to choose one assistance characteristic among three choices at the flick of a switch, according to the driver's preference and road conditions. A solenoid-operated bypass valve is used to reduce the hydraulic fluid supply to the steering gear, which results in a heavier steering effort. The most suitable valve characteristic curve which corresponds to the increased pressure in the system due to the applied torque is discussed in this study. It is shown that detection of the velocity of steering wheel rotation and extension of the range of characteristics possible are effective ways to ensure good control over the power assistance.

An electronic engine control system that uses a microcomputer has been developed. It combines four control systems - fuel injection, ignition timing, EGR and idle speed control - utilizing the engine speed and intake air quantity for its main parameters. The control circuit is composed of an 8-bit microcomputer combining an 8k byte ROM, RAM, a custom designed input/output LSI, and two hybrid integrated circuits, one has voltage regulators and another has input/output interface circuits. The control program consists of a main program, a fail-safe program for noise protection and a check program for diagnostic functions. The main program uses interrupt techniques to control effectively the four items by one microcomputer. The interrupt requests occur from crankshaft position signal and interval timer signals.

In order to significantly reduce NOx levels by EGR (Exhaust Gas Recirculation), while maintaining good fuel economy and driveability, the EGR flow rate must be properly and accurately controlled under a variety of engine operating conditions. Toward this objective, a new EGR control system was developed. It utilizes a carburetor venturi vacuum for a stable reference signal that represents the engine operating condition and it controls the EGR flow rate by using a feedback principle to obtain sufficient flexibility compatible with several different engines. Its control characteristics were mathematically analyzed. And it has also been confirmed that the system can automatically compensate for the drift in EGR characteristics. This EGR control system has been utilized in Nissan’s emission control systems in order to comply with the 1978 Japanese Emission Standards and the 1980 U.S. Federal and California Emission Standards.

A 24 GHz doppler speed sensor for skid controls has been developed. The microwave sensor is designed using both waveguide and thin-film technologies and assembled into a small integrated unit measuring 27 x 10 x 9 mm. The radar unit and the control circuitry are housed in a waterproof module of 94 x 140 x 78 mm. Part of the casing forms a horn antenna, which radiates a vertically polarized beam incident at 45° on the road surface, when mounted on the vehicle. The error in speed measuring is usually less than 10 percent.

Secondary injection in a diesel engine is defined as the introduction of additional fuel into the combustion chamber after the end of the main injection. It is usually caused by residual pressure waves in the high-pressure pipe line connecting the pump and injector. When these waves exceed the injector opening pressure, secondary injection occurs. Tests revealed that the U.S. Army TACOM single-cylinder engine used in this investigation, fitted with an American Bosch injection system, had secondary injection within the normal engine operating region. The pump spill ports and delivery valve were redesigned to eliminate secondary injection, in accordance with previously reported work. Comparative tests of both the conventional and modified injection systems were run on the same engine, and the effects of secondary injection on engine power, economy, and exhaust emissions were determined.

This paper reviews some of the methods and experience with the DRAM Program, as it has been developed for interactive simulation of realistic mechanical machinery. The Program has been made interactive by increasing solution speed and providing for output of a moving drawing of the mechanism on time shared graphic display terminals. At the same time program generality has been expanded by including effects such as Coulomb friction and impact.

In order to study the potentiality of the modification of the combustion rate for NOx formation control in the spark ignition (SI) engine, the authors first developed a new mathematical model by assuming the stepped gas temperature gradient in the cylinder. The predicted results from this new mathematical model show good coincidence with the experimental data. Second, the authors discuss the effects of the modification of the combustion rate on NOx formation using the new mathematical model. It was concluded that NOx formation in the premixed SI engine would be essentially determined by the specific fuel consumption only, regardless of any modification of the engine combustion rate.

Up to now, drawing of body lines has taken a long time and required skilled workers, and thus has been an obstacle to shortening the time needed to develop a new model. A new on-line system and data file, called the Integrated Body Design System, make body lines lofting easy and speedy, especially in outer panel designs. This on-line system has been developed by: 1. Effective combination of a large computer, a graphic display, a measuring machine, and a numerically controlled drafting machine. 2. Development of software for monitoring a large quantity of data using the technique of list processing.

The Inter-Industry Emission Control (IIEC) Program included the thermal reactor as one of the effective ways of oxidizing HC and CO in the exhaust system. However, this was accompanied by very substantial fuel economy penalties, especially in the case of small engine-low emission concept vehicles. Starting with a new concept aimed at obtaining the HC/CO oxidizing trigger temperature in the thermal reactor by modifying engine settings, the authors arrived at an economical technique of matching the thermal reactor to the engine.

Conclusions based on the airborne experiments with laser radars are summarized in this paper. Details of the equipment and the flight procedures will be displayed during the oral presentation at the conference.