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This study investigates if particulates from a GDI engine can be significantly suppressed by use of ultra-high injection pressures under 2 different engine conditions known to be associated with high particulate numbers (PN): warm-up and transients. Experiments were carried out in a single-cylinder GDI engine equipped with an endoscope connected to a high-speed camera to enable combustion visualization. To mimic the warming-up, the coolant temperature was varied between 20 °C and 90 °C. A Diesel injector with modified nozzle was used and the injection pressures were varied between 400 and 1500 bar. The results revealed that increasing the fuel injection pressure decreased engine out HC and PN under warming-up conditions. However, the coolant water temperature was the most dominant factor affecting the emissions. For coolant temperature of 20 °C, the use of 1500 bar fuel injection pressure in comparison to lower fuel pressures resulted in significantly lower PN.

In hot climate regions, there is demand for improved thermal comfort for rear occupants in vehicles not equipped with a rear air conditioner. One solution to this challenge is a circulator mounted on the ceiling. The circulator is a product designed to enhance thermal comfort for occupants by circulating the air in the cabin. The conventional circulator design, which employs a cross flow fan with a large cross section, juts into the cabin space, because it is difficult to package. Consequently, the challenge for the circulator is to provide thermal comfort for rear occupants while taking up the minimum cabin space under the ceiling. To solve this challenge, that is, to enable a substantially thinner structure, while retaining the same level of air flow delivered as before for the same thermal comfort as the conventional circulator, we divided the structure into an air outlet and an air blower.

Continuous improvement of gasoline engine emissions performance is required to further protect the global environment and also the impact of emissions on a local level. During real world driving, transient engine operation and variation in fuel injection, airflow, and wall temperature are key factors to be controlled. Due to the limited opportunity for optimization of engine control, generation of a well-mixed fuel spray is necessary to create a suitable combustion environment to minimize emissions. Optimum spray performance achieves minimum surface wetting as well as promoting evaporation and diffusion if wetting occurs. Improvement in spray homogeneity is an important step to achieve this. Higher fuel pressure is initially considered to achieve improvements, as it is expected to improve mixture formation by reduction of wall wetting due to high atomization and lower penetration, as well as improvement in spray homogeneity.

One of the main features of 48 V vehicles is the ability to coast at high speeds with the Internal Combustion Engine (ICE) off. This can be realized due to the high torque and power the 48 V motor-generator provides which allows a quick and smooth re-cranking of the ICE. The coasting feature reduces the fuel consumption depending on frequency and duration of the coasting events. This depends in turn on driving pattern, driving style, State-of-Charge of the 48 V and 12 V batteries and the air-conditioning (A/C) system. In summer, if the A/C runs with a mechanical belt-driven compressor, the cabin inlet air temperature from the evaporator inevitably increases during each coasting event as the ICE turns off and cannot operate the compressor. If the evaporator temperature reaches a certain threshold at which the cabin comfort is noticeably affected, the ICE is re-cranked for resuming air-conditioning.

To comply with increasing fuel efficiency regulations, a low temperature radiator (LT radiator) is required to cool the charge-air system of a turbocharged engine. These engines are important to use for environmentally-friendly cars. Since heavy-duty and high-performance cars demand high cooling performance, the main radiator alone is typically insufficient in meeting the vehicle’s cooling requirements. An additional radiator installed in the front of the wheel-well is required to meet the extra cooling demand. In order to install this radiator in the front of the wheel-well, guaranteed performance in the limited packaging space and impact resistance of the leading tube edge are required. We developed the Supplementary Inner-Fin Radiator (SIR) which achieves the compact, high-performance, and durability requirements by use of an inner-fin tube (I/F tube). The purpose of this paper is to report our design approach and product specifications of the SIR.

As a method of maintaining thermal sensation and comfort inside a passenger compartment, not only a conventional HVAC system but also a combination of a HVAC system and other devices such as seat heaters, a steering wheel heater, ventilation seats are increasing. This research developed a method to evaluate thermal sensation of a human body when using these various thermal control devices. This method can evaluate the heat balance of the human body by calculating the amount of heat exchange between a human body and the external environment, and it takes into consideration the influence of heat exchange by heat conduction with seats or a steering wheel. The human thermal model is made by dividing a human body into various segments, and it is the model that considers heat transport by blood flow for each segment.

The coming Diesel powertrains will remain as key technology in Europe to achieve the stringent 2025 CO2 emission targets. Especially for applications which are unlikely to be powered by pure EV technology like Light Duty vehicles and C/D segment vehicles which require a long driving range this is the case. To cope with these low CO2 targets the amount of electrification e.g. in form of 48V Belt-driven integrated Starter Generator (BSG) systems will increase. On the other hand the efficiency of the Diesel engine will increase which will result in lower exhaust gas temperatures resulting in a challenge to keep the required NOx reduction system efficiencies under Real Drive Emissions (RDE) driving conditions. In order to comply with the RDE legislation down to -7 °C ambient an efficient thermal management is one potential approach. Commonly utilized means to increase exhaust gas temperature are late injection and/or intake throttling, which enable sufficient NOx reduction efficiency.

A methodology for simulating effect of international variations in fuel compositions on spray combustion is proposed. The methodology is validated with spray combustion experiments with real fuels from three different countries. The compositions of those fuels were analyzed through GC×GC and H-NMR. It was found that ignition delay times, flame region and flame luminosity were significantly affected by the compositional variations. For the simulation, an evaporation surrogate consisting of twenty two species, covering basic molecular types and a wide range of carbon numbers, is developed. Each species in the evaporation surrogate is then virtually converted to a reaction surrogate consisting of n-hexadecane, methylcyclohexane and 1,2,4-trimethyl benzene so that combustion reactions can be calculated with a published kinetic model. The virtual species conversion (VSC) is made so as to take over combustion-related properties of each species of evaporation surrogates.

Recent electric vehicles use Li-ion batteries to power the main electric motor. To maintain the safety of the main electric motor battery using Li-ion cells, it is necessary to monitor the voltage of each cell. DENSO has developed a battery Electronic Control Unit (ECU) that contributes greatly to the reduction of the cost and the improvement of the reliability of the system. Each manufacturer has been developing a dedicated IC for monitoring the voltages of each cell of a battery. However, since the number of cells that can be monitored is limited, more than one IC is required to measure the voltages of a large number of cells. The increase in the number of ICs and the amount of insulator leads to the rise in system cost. DENSO has developed a dedicated IC that uses a proprietary high-breakdown voltage process, and which enables monitoring up to 24 cells with a single IC chip.

The Diesel engine performance was drastically improved since the introduction of the Common Rail system in 1996. Over the years, the Common Rail technology was continuously improved to reduce the fuel consumption, engine-out emissions and enhance the drivability. However further technical improvement steps for a precise control of combustion are required to satisfy the increasing stringent worldwide emissions limits and to contribute to attractively performing Diesel powered vehicles. Common Rail injectors significantly contribute to improve the combustion. This improvement can be achieved by precisely controlling the injected fuel quantity and increasing the injection pressure. In addition to those features, a more rectangular injection rate, the capability of stable multiple injections at shorter intervals and the control of the spray shape, are required to achieve an optimized fuel mixture.

Gasoline direct injection (GDI) systems are a main development focus for global environment issues and energy security. At the same time, it is also important to challenge further development of Multi point injection (MPI) systems for a simple and robust combustion system responding to global fuels ,required for the growing automotive markets in emerging countries, especially in the A, B vehicle segments. This paper focuses on reducing wall wetting in cold conditions and maximizing mixture cooling by fuel vaporization (preventing knocking) in high load conditions as key development points of MPI systems. We propose a dual MPI system enhancing direct flow of spray into the combustion chamber to gain part of the benefit of GDI in addition to the homogeneity advantage of an MPI system. This dual MPI system requires finer atomization with at the same time robustness against intake airflow.

In recent years, from a viewpoint of global warming and energy issues, the need to improve vehicle fuel economy to reduce CO2 emission has become apparent. One of the ways to improve this is to enhance engine thermal efficiency, and for that, automakers have been developing the technologies of high compression ratio and dilute combustion such as exhaust gas recirculation (EGR), and lean combustion. Since excessive dilute combustion causes the failure of flame propagation, combustion promotion by intensifying in-cylinder turbulence has been indispensable. However, instability of flame kernel formation by gas flow fluctuation between combustion cycles is becoming an issue. Therefore, achieving stable flame kernel formation and propagation under a high dilute condition is important technology.

This study reports on a new generation ECS (Ejector Cycle System) which includes a highly efficient ejector and a novel system configuration. The ejector is working as a fluid jet pump that recovers expansion energy which is wasted in the conventional refrigeration cycle decompression process, and converts the recovered expansion energy into pressure energy and raises the compressor suction pressure. Consequently, the ejector system can reduce power consumption of the compressor by using the above mentioned pressure-rising effect and improve energy efficiency of the refrigeration cycle. The ejector consists of a nozzle, a suction section, a mixing section and a diffuser. The objective of this study is to improve actual fuel economy of all vehicles by ejector technology. The previous generation ECS was reported in 2012 SAE World Congress1. Now, a new generation ECS has been successfully developed and released in the market for Mobile Air Conditioning systems as of 2013.

Diesel common rail injectors are required to utilize a higher injection pressure and to achieve higher injection accuracy in order to meet increasingly severe emissions, less fuel consumption, and higher engine performance demand. In addition to those requirements, in conjunction with optimized nozzle geometry, a more rectangular injection rate and stable multiple injections with shorter intervals are required for further emissions and engine performance improvement by optimizing the combustion efficiency.

In recent years, the spread of eco-car has led to the demand for adaptation to low heat source, high efficiency and low noise in vehicle air conditioner. On the other hand, larger interior space of vehicle to assure passenger comfort is demanded, so that the car air-conditioner is required to be smaller. Therefore, we adopted 2-layer HVAC for the air conditioner which can respond to a low heat source. At the same time we have developed the compact high-efficiency 2-layer blower fan for HVAC in order to enable the 2-layer HVAC to be mounted on eco-car with smaller space than conventional HVAC. Generally, because axial flow velocity increases resulting from downsizing of the blower, the ununiform velocity distribution in the axial direction and the turbulent flow between fan blades occurs. It causes the efficiency decrease. To satisfy both downsizing and high-efficiency of the 2-layer blower, we have developed new technologies which can make the flow uniform between fan blades.

Humidity sensors used in automatic windshield defogging controls contribute to the improvement of fuel consumption. The optimum control of air conditioning systems can be realized by adding humidity information to conventional systems which have used only temperature information. While resistive humidity sensors have been widely used, their sensing range and responsiveness are observed as issues. Resistive sensors cannot function at a humidity range of around 100% RH as well as at a low temperature range, and have a low response rate to sudden changes in humidity. It is considered that resistive humidity sensors will be replaced with capacitive ones which have a wide sensing range and high responsiveness.

The number of idle-stop vehicles is rapidly increasing in recent years, and air-conditioning technologies that extend engine stopped time while maintaining the cabin comfort are required. When the engine stops during idle- stop mode, the air conditioner also stops functioning. To maintain cabin comfort, the engine is restarted to work the air-conditioning cycle, which reduces the fuel saving effects. As a countermeasure, a cold storage air conditioning system has been proposed. The system extends engine non-operation time by using cold storage for generating cool air while the engine is stopped. We have integrated this technology into an evaporator, which is used in the air-conditioning cycle, and the system has a short cold storage period and a necessary cold release period. This report describes its concept and effects.

Recently, diesel engine manufacturers have been improving the tolerance of fuel injection quantity and timing in response to the strengthening of emissions regulations and the introduction of various kinds of diesel fuels. This paper describes the Intelligent Accuracy Refinement Technology (i-ART) system, which has been developed as a way of achieving substantially improved tolerances. The i-ART system consists of a fuel pressure sensor installed in the injectors. It calculates the injection quantity and timing at high speed using a dedicated microcomputer designed for pressure waveform analysis. As the injector can directly measure the fuel injection pressure waveform for each injection, it can compensate the injection quantity and timing tolerance at any time. Toyota Motor Corporation has introduced this system in Brazilian market vehicles. In Brazil, the PROCONVE L6 emissions regulations will be introduced in 2012, and the market also uses various kinds of diesel fuels.

Ejector Cycle® development has been under way to improve refrigeration cycle performance and increase its efficiency in light of global environmental conservation. Ejector Cycle® can be applied to cool boxes that cool drinks using the refrigeration cycle of the vehicle air-conditioning system. We commenced deliberating Ejector Cycle® application to improve cool box system performance. Difficulties associated with the cool box include the decline in cabin air-conditioning performance due to simultaneous operation of the cabin air conditioning and cool box. We have solved this problem by using an ejector to achieve continuous operation with two evaporator temperatures in the same system. Furthermore, we have configured the cycle to be suitable for vehicle air-conditioning systems, designed a high-efficiency two-stage variable ejector, and addressed various system problems.

With the economic development of countries around the world led by BRICs(Brazil, Russia, India, China), the total number of automobiles in the world continues to rise. From the standpoint of preserving limited petroleum resources and reducing CO2 emissions, improved fuel consumption is necessary if we are to continue enjoying the use of automobiles. In Europe, significant development of diesel engine technology as a power source for automobiles has taken place to reduce fuel consumption and to enhance the “Fun to Drive” experience, and market share of diesel engines has increased in this area. However, with increasing environmental awareness worldwide, all areas of the globe are seeing tightened regulations for not only fuel consumption, but also exhaust emissions, including those for PM(Particulate Matter) and NOx. Of these regulations, the requirement for vehicles to satisfy the US Tier 2 Bin 5 rating, regardless of whether they are gasoline or dieselpowered, is the most stringent.