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DENSO started a pilot demonstration of on-site methanation as “CO2 circulation plant” as proactive initiative for CO2 capture and storage/utilization (CCUS) technologies toward achievement of carbon neutrality by 2035 in our own business. The CO2 circulation plant was designed to capture CO2 primarily generated by the plant and recycle it as an energy source of the facility. We also started work on the development of electric swing CO2 adsorption (ESA) technology to achieve low-energy CO2 capture.

Safety assurance is a central concern for the development and societal acceptance of automated driving (AD) systems. Perception is a key aspect of AD that relies heavily on Machine Learning (ML). Despite the known challenges with the safety assurance of ML-based components, proposals have recently emerged for unit-level safety cases addressing these components. Unfortunately, AD safety cases express safety requirements at the system level and these efforts are missing the critical linking argument needed to integrate safety requirements at the system level with component performance requirements at the unit level. In this paper, we propose the Integration Safety Case for Perception (ISCaP), a generic template for such a linking safety argument specifically tailored for perception components. The template takes a deductive and formal approach to define strong traceability between levels.

A response surface model of a diesel spray, parameterized by the internal geometries of a nozzle, is established in order to design the nozzle geometries optimally for spray mixing. The explanatory variables are the number of holes, the hole diameter, the inclined angle, the hole length, the hole inlet radius, K-factor and the sac diameter. The model is defined as a full second-order polynomial model including all the first-order interactions of the variables, and a total of 40 sets of numerical simulations based on D-optimal design are carried out to calculate the partial regression coefficients. Partial regression coefficients that deteriorate the estimate accuracy are eliminated by a validation process, so that the estimate accuracy is improved to be ±3% and ±15% for the spray penetration and the spread, respectively. Then, the model is applied to an optimization of the internal geometries for the spray penetration and the spray spread through a multi-objective genetic algorism.

Increased interest in global warming issues requires rapid improvements in reduction of CO2 emissions. The automotive industry is placing high importance on improving fuel economy performance across their entire product lines. Charging Management System is a necessary element towards fuel economy improvement. Many of today's charging management systems perform at least two important functions: improving efficiency based on vehicle motion, and detecting battery state of charge. These systems become more complicated as more components (i.e. generators, current sensors and ECU) and software are added. Therefore, it is difficult to develop charging management systems for an entire product line and difficult to retrofit the system for vehicles already in production. A stand-alone charging management system solves these issues. This system is independent of the other vehicle systems. The software for improving fuel economy is installed in the generator or current sensor.

Many accidents occur today when distant objects or roadway impediments are not quickly detected. To help avoid these accidents, longer-range safety systems are needed with real-time detection capability and without requiring a line-of-sight (LOS) view by the driver or sensor. Early detection at intersections is required for obstacle location around blind corners and dynamic awareness of approaching vehicles on intersecting roadways. Many of today's vehicular safety systems require short LOS distances to be effective. Such systems include forward collision warning, adaptive cruise control, and lane keeping assistance. To operate over longer LOS distances and in Non-LOS (NLOS) conditions, cooperative wireless communications systems are being considered. This paper describes field results for LOS and NLOS radio links for one candidate wireless system: 5.9GHz Dedicated Short Range Communications (DSRC).

We propose a novel millimeter wave radar system and object detection algorithm for automobile use by using advanced null scanning method. Generally, null scanning method can achieve a higher resolution and a more compact sensor size compared to beam scanning method, but needs huge computing power. We introduced the theory of forgetting factor into it and developed a new null scan algorithm. It achieved a high lateral object separation ability of less than 3 degree, and a quick response under feasible computing power in simulation and test vehicle. These technologies enable compact and high performance radar for advanced safety system.

Carbon brushes for automotive starters are used under severe conditions of high electric current density, high contact pressure and high sliding velocity. Therefore lead has traditionally been added to brushes to improve performance and durability. Lead is an environmental hazardous substance. In the EU, the law prohibits adding lead to brushes for electric motors which is installed on new automobiles in and after January 2005. In order to develop the lead free carbon brush for starters, we analyzed the effect and selected substitutive substance of lead. Adding lead to the brush reduces the electric resistance increase of the brush in high-temperature and high-humidity atmosphere and in high-temperature atmosphere. Furthermore lead reduces the wear amount of brush. We developed the lead free brush surpassing the lead addition brush in performance and durability by addition of lead alternatives silver and zinc.

A recent trend in the making of automotive engines, where high efficiency and low emissions need to be considered, is to mount multiple parts around the motor in order to improve overall engine efficiency. As a result of modern technology, the engine head and surrounding space have an excessive amount of parts. To accommodate the congested engine compartment, it is desirable to reduce the size of the spark plug. Small size spark plugs have the problem of poor resistance to carbon fouling and are subject to side sparks if carbon fouling occurs. This results from a reduced insulating gap between the center electrode and the housing achieved by reducing the size of the spark plug. By using visualization of flame growth and electric field strength analysis, we have conducted studies on insulator temperatures and spark behaviors in search of the optimal specifications.

Increasing electric loads in a vehicle causes over-discharge of a battery and drag torque due to an alternator. This paper gives a system concept of vehicle electric power flow management to solve these issues. Its primary function includes preserving electricity in a battery, stabilizing electric bus voltage, interfacing with vehicle torque control system, and improving fuel economy. The key point to realize such a system is a unified structure. It offers ‘Plug and Play’ function for electric power management components. Newly developed Vehicle Electric Power Flow Management System (VEF ) totally controls electric power flow in a vehicle. VEF contains an Electric Power Manager and its functional sub-systems, and controls them with the key parameter ‘electric power’. The sub-system includes Generation, Storage, Conversion, and Distribution to the loads.

Up to now, while automobile electric packages have demanded the high density for small and light products, electric leaks, which have occurred due to condensation, have been a major problem. To prevent any electric leaks, a conformal coating on the electric parts (ex. ECU: Electronic Control Unit) has been needed, but in general the design rules of the conformal coating (ex. Application area) is vague. Therefore, DENSO demands to clear the design rules of conformal coating electric package for higher reliability. To meet the demand, DENSO has developed a condensation simulation method using CAE that can show the occurrence condition of condensation fast and accurately. In the result, DENSO has been able to get the design rules where to need the conformal coating in the electric package for automobiles.

Spark plugs with higher ignitability are continuously in great demand to realize high fuel efficiency and low emissions. To meet this demand, DENSO launched the Iridium Spark Plug in 1997, which realized the two characteristics that had been conventionally difficult to achieve concurrently-high ignitability and long life. The development of this product was enabled by miniaturizing the center electrode, produced using DENSO's original, highly wear-resistant iridium alloy (featuring a high melting point and excellent oxidation resistance). While spark plugs are now required to have a longer service life, they are also required to be higher in ignitability, as exhaust gas regulations have been tightened recently. However, the effort to miniaturize the center electrode is reaching a limit.

We have achieved significant weight reduction for the MS (Multi-Tank Super Slim Structure) Evaporator (1)currently in production at DENSO CORPORATION. The evaporator of HVAC unit, located in the instrument panel, is a component of the aluminum heat exchanger used in automotive air conditioners. The new evaporator uses thinner quad-layer sheet material, thanks to optimization of the electrical potential among its outer filler metal, intermediate anodic layer and core. The evaporator is thus lighter than conventional evaporators, but retains equivalent corrosion resistance.

In view of the shorter development period for new automobiles, we have developed a computer-aided engineering (CAE) system to aid in commensurately speedy development of automotive air conditioners. This system consists of three tools: one that calculates various design specifications instantaneously, one that enables designers to easily examine air-conditioner shape, and one that converts shape data into calculable model data to enable 3D (three-dimensional) processing. Effective use of these tools cuts air-conditioner development lead time to half that of the conventional process.

Recently, automotive semiconductor devices need miniaturization. One of the most important technologies is the package which encapsulates devices. In addition, the outer shape of the package is needed to change according to the mounted space. Conventional devices are mounted in the case, and encapsulated with potting resin. However this package structure is difficult to miniaturize because the case size limit. This report describes the development of the packaging technology for miniature and particular outer shape. The devices are set in the cavity and molded to one package. The three-dimension flow simulation is applied to analyze the flow in the cavity. The results of simulation correspond with experimental results. The cavity structure and the mold resin can be optimized by the simulation.