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We propose low inductance batteries and enhance power density for a inverter. Conventionally, the capacitors are used for smoothing ripple of the inverter. The low inductance battery which responds at carrier frequency of inverter can reduce the capacity of the smoothing capacitors and enable to enhance power density for the inverter. For reducing the inductance, it is necessary to separately understand the impact of electrochemical reaction under wide range of assumed conditions and structural reaction on frequency characteristics. Furthermore, it is also necessary to design the low inductance batteries based on combining the both of characteristics. However, there are no study focusing on modeling by combining such different domains. Therefore, we made original inductance model inside battery considering frequency characteristics among all materials and structural influence with electromagnetic field analysis simulator.

To increase thermal efficiency of internal combustion engines, dilution combustion systems, such as lean burn and exhaust gas recirculation systems, have been developed. These systems require spark-ignition coils generating large discharge current and discharge energy to achieve stable ignition under diluted mixture conditions. Several studies have clarified that larger discharge current increases spark-channel stretch and decreases the possibility of spark channel blow-off and misfire. However, these investigations do not mention the effect of larger discharge current and energy on the initial combustion period. The purpose of this study was to investigate the relation among dilution ratio, initial-combustion period, and coil specifications to clarify the control factor of the dilution limit.

We have developed a drive cycle (DC) to test Hitachi’s combined battery system (CBS) for electric vehicles (EVs) having battery lifespan enhancements. Conventionally EV batteries consist of high energy density cells, and we call them as energy cells (EC). A major issue with the EVs is high operational costs mainly due to short lifespan of the ECs. CBS almost doubles the EC and thus overall battery system lifespan, as per the evaluation over a WLTP based method. We want to test the CBS under Indian conditions which has predominantly hot weather, and traffic jam scenarios. Battery deterioration and thus its lifespan is sensitive to traffic conditions and ambient temperature. Hence, it was needed to evaluate the CBS over an Indian DC and use 40°C as ambient temperature. However, it was difficult to carry out the tests since there is no standard Indian DC for small / light weight four wheelers.

We have developed a cooperative simulation environment for multiple electronic control units (ECUs) including a parallel executions mechanism to improve the test efficiency of a system, which was designed with multiple ECUs for autonomous driving. And we have applied it to a power window system for multiple ECUs with a controller area network (CAN). The power window model consists of an electronic-mechanical model and a CPU model. Each simulator with a different executions speed operates in parallel using a synchronization mechanism that exchanges data outputted from each simulator at a constant cycle. A virtual ECU simulated microcontroller hardware operations and executed its control program step-by-step in binary code to test software for the product version. As co-simulation technology, a mechanism that synchronously executes heterogeneous simulators and a model of an in-vehicle communication CAN connecting each ECU were developed.

Predicting the vibration of a motor gearbox assembly driven by a PWM inverter in the early stages of development is demanding because the assembly is one of the dominant noise sources of electric vehicles (EVs). In this paper, we propose a simulation model that can predict the transient vibration excited by gear meshing, reaction force from the mount, and electromagnetic forces including the carrier frequency component of the inverter up to 10 kHz. By utilizing the techniques of structural model reduction and state space modeling, the proposed model can predict the vibration of assembly in the operating condition with a system level EV simulator. A verification test was conducted to compare the simulation results with the running test results of the EV.

In recent years, improvement of in-use fuel economy is required with tightening of exhaust emission regulation. We assume that one of the most effective solutions is ACC (Adaptive Cruise Control), which can control a powertrain accurately more than a driver. We have been developing a fuel saving ADAS (Advanced Driver Assistance System) application named “Sailing-ACC”. Sailing-ACC system uses sailing stop technology which stops engine fuel injection, and disengages a clutch coupling a transmission when a vehicle does not need acceleration torque. This system has a potential to greatly improve fuel efficiency. In this paper, we present a predictive powertrain state switching algorithm using external information (route information, preceding vehicle information). This algorithm calculates appropriate switching timing between a sailing stop mode and an acceleration mode to generate a “pulse-and-glide” pattern.

Automotive fuel can be efficiently combusted by injecting it into the cylinders at high pressure to atomize it to pass the regulations for exhaust gas and fuel economy. For this reason, automotive companies have developed direct injection engines, which can inject gasoline into the cylinders directly. Furthermore, the demand for lower-noise high pressure pumps is also increasing from the viewpoint of automotive comfort. Since the valve velocity and noise level will increase as the pressure in fuel pumps increases, noise problems need to be solved under the high pressure conditions. Accordingly, the valve motion should be predicted with high accuracy under operating conditions to evaluate the noise caused by valve impingement. In addition, the squeeze film effect phenomenon will occur in the physical fuel pumps affect the prediction of the noise level caused by valve impingement.

The problem of high fatal accident rates due to drunk driving persists, and must be reduced. This paper reports on a prototype system mounted on a car mock-up and a prototype portable system that enables the checking of the drivers’ sobriety using a breath-alcohol sensor. The sensor unit consists of a water-vapor-sensor and three semiconductor gas sensors for ethanol, acetaldehyde, and hydrogen. One of the systems’ features is that they can detect water vapor from human-exhaled breath to prevent false detection with fake gases. Each gas concentration was calculated by applying an algorithm based on a differential evolution method. To quickly detect the water vapor in exhaled breath, we applied an AC voltage between the two electrodes of the breath-water-vapor sensor and used our alcohol-detection algorithm. The ethanol level was automatically calculated from the three gas sensors as soon as the water vapor was detected.

In previous study, a method of combustion detection for homogeneous charge compression ignition (HCCI) using a crank angle sensor and a knock sensor has been estimated [1]. In addition, an ion-current sensor has been used as a countermeasure against abnormal combustion with downsizing and higher compression ratio engines. An ion-current sensor has been newly adopted in engine systems. In this study, detection performance of combustion conditions in HCCI and spark ignition (SI) using with the ion-current sensor was estimated. The purpose of this study was to confirm detectable combustion conditions using with the ion-current sensor, and to confirm a requirement of applied voltage for the ion-current sensor. A detection signal of the ion-current sensor was changed by combustion style (HCCI,SI). Experimental results showed a heat release rate increased with ion signals increasing approximately at the same time in HCCI and SI.

A recent trend in high-pressure gasoline pumps is increasing the outlet pressure. One of the most important topics for increasing this pressure is improving volumetric efficiency. Therefore, the purpose of this research is to quantify the breakdown of efficiency loss factors and to suggest a new design for improving volumetric efficiency. Authors developed a method of quantifying the efficiency loss breakdown of high-pressure gasoline pumps by using 1D fluid pressure simulation results and conducting evaluation experiments regarding sensitivity. Authors separated pump movement into three phases; suction, compression, and delivery. Authors then investigated the loss factors in each phase. As a result, authors obtained an equation for predicting the final output volume. The equation consists of a limit output volume and other types of leakage volumes.

We developed a thermal calculation 1D simulator for an electric valve timing control system (VTC). A VTC can optimize the open and close timing of the intake and exhaust valves depending on the driving situation. Since a conventional VTC is driven hydraulically, the challenges are response speed and operation limit at low temperature. Our company has been developing an electric VTC for quick response and expansion of operating conditions. Currently, it is necessary to optimize the motor and reduction gear design to balance quicker response with downsizing. Therefore, a coupled simulator that can calculate electricity, mechanics, control, and thermo characteristics is required. In 1D simulation, a thermal network method is commonly used for thermal calculation. However, an electric VTC is attached to the end of a camshaft; therefore, determining thermal resistances is difficult. We propose a method of determining thermal resistances, using both theoretical and experimental approaches.

Recently emissions regulations are being strengthened. An air-fuel ratio cylinder imbalance causes emissions to increase due to universal exhaust gas oxygen (UEGO) sensor error or exhaust gas oxygen (EGO) sensor error. Various methods of reducing an air-fuel ratio cylinder imbalance have been developed. It is preferable for a control system to operate over a wide range of conditions. Our target is to expand the operating conditions from idling to high load conditions. Our approach is to use both an UEGO sensor and a crank angle sensor. A two-revolution frequency component calculated from the UEGO sensor output signal and angular acceleration calculated from the crank angle sensor output signal are used to identify the cylinder where the air-fuel ratio error occurs.

We have achieved injection quantity range enhancement by using the current waveform control technique for direct injection (DI) gasoline injectors. In this study, we developed an injection quantity simulator to find out the mechanism of non-linear characteristics. We clarified the non-linear production mechanism by using the simulator. This simulator is a one-dimensional simulator that incorporates calculation results from both unsteady electromagnetic field analysis and hydraulic flow analysis into the motion equation of this simulation code. We investigated the relation between armature and the injection quantity by using the simulator. As a result, we clarified that the non-linearity was produced by the bounce of the armature in the opening action. Thus, we found that it is effective to reduce the armature bounce to improve the linearity of the injection quantity characteristics.

A technique of estimating particulate matter (PM) from gasoline direct injection engines is proposed that is used to compute mass density and particle number density of PM by using fuel mass in rich mixtures obtained by using non-combustion computational fluid dynamics (CFD). The CFD code that was developed by the authors employed a Cartesian coordinates system as a discretization method and large eddy simulation (LES) as a turbulence model. Fuel spray droplets were treated with the discrete droplet model (DDM). The code was verified with some experimental data such as those obtained from in-cylinder gas-flows with a laser Doppler velocimeter (LDV) and in-cylinder fuel concentration with laser induced fluorescence (LIF). PM emissions from a single-cylinder gasoline direct injection engine were measured with an electrical low pressure impactor (ELPI) to determine the model constants that were required in the estimation model.

The authors developed a multi-swirl type injector characterized by a short spray penetration length and fine atomization to improve exhaust emissions and fuel consumption for port fuel injection (PFI) gasoline engines. In PFI gasoline engines, fuel adhesion to an intake manifold causes exhaust emission. In addition, good mixing of fuel and air causes high combustion efficiency, and as a result the fuel consumption improves. Injectors therefore require two improvements: first, a short spray penetration to avoid fuel adhesion to the intake manifold, and second, a fine atomization spray to generate a good mixture formation of fuel and air. In this study, the authors developed a multi-swirl type injector equipped with multiple orifice holes featuring swirl chambers upstream of each orifice. The key feature of the proposed injector is “involute curve-formed swirl chambers” for generating a uniform thin liquid-film in the orifices.

The cooled EGR system has been focused on as a method for knocking suppression in gasoline engines. In this paper, the effect of cooled EGR on knocking suppression that leads to lower fuel consumption is investigated in a turbo-charged gasoline engine. First, the cooled EGR effect is estimated by combustion simulation with a knock prediction model. It shows that the ignition timing at the knocking limit can be advanced by about 1 [deg. CA] per 1% of EGR ratio, combustion phasing (50% heat release timing) at the knocking limit can be advanced by about 0.5 [deg. CA] per 1% of EGR ratio, and the fuel consumption amount can be decreased by about 0.4% per 1% of EGR ratio. Second, the effect of cooled EGR is verified in an experimental approach. By adding inert gas (N2/CO2) as simulated EGR gas upstream of the intake pipe, the effect of EGR is investigated when EGR gas and fresh air are mixed homogeneously. As a result, the ignition timing at the knocking limit is advanced by 7 [deg.

The robustness control for homogeneous charge compression ignition (HCCI) using a crank angle sensor and a knock sensor has been estimated. On the other hand, an ion current sensor is used as a countermeasure against abnormal combustion with downsized and higher compression ratio engines. This sensor can generally be adopted in engine systems. Therefore, we examined the application of an ion current sensor to robustness control for HCCI. The purpose of this research was to develop a method of detecting combustion conditions to make HCCI engines more robust. Therefore, we evaluated the performance of the ion current sensor. Experimental results comparing ion intensity detection in HCCI. The detection value of the ion current sensor changed based on the form of combustion. Experimental results showed that the heat release rate increased with an increase in ion signals appear during the same time at approximately in both spark ignition (SI) and HCCI.

The internal combustion engines waste large amounts of heat energy, which account for 60% of the fuel energy. If this heat energy could be converted to the output power of engines, their thermal efficiency could be improved. The thermal efficiency of the Otto cycle increases as the compression ratio and the ratio of specific heat increase. If high octane number fuel is used in engines, their thermal efficiency could be improved. Moreover, thermal efficiency could be improved further if fuel could be combusted in dilute condition. Therefore, exhaust heat recovery, high compression combustion, and lean combustion are important methods of improving the thermal efficiency of SI engines. These three methods could be combined by using hydrous ethanol as fuel. Exhaust heat can be recovered by the steam reforming of hydrous ethanol. The reformed gas including hydrogen can be combusted in dilute condition. In addition, it is cooled by directly injecting hydrous ethanol into the engine.

A pioneering approach to implement transfer path analysis (TPA) is proposed in this paper through applying it to an automobile. We propose to use particle velocity as a measure of TPA, in addition to using sound pressure as a conventional measure for TPA. These two quantities together will give a comprehensive and complete definition of sound. Although sound pressure is a scalar, while particle velocity is a vector, it is also proposed that the same technique of the conventional sound pressure TPA should be independently applicable to each component of particle velocity vector. This has been experimentally verified with a study on our test box system. In this paper, we apply the proposed TPA to an actual vehicle to examine its applicability, advantages and limitations. The driving motor sound of a hybrid electric vehicle is chosen as the case study. A tri-axial particle velocity sensor which also measures sound pressure at the same point is utilized in the experiment.

The purpose of this study is to develop model-based methodologies which employ thermo-fluid dynamic engine simulation and multiple-objective optimization schemes for engine control and calibration, and to validate the reliability of the method using a dynamometer test. In our technique, creating a total engine system model begins by first entirely capturing the characteristics of the components affecting the engine system's behavior, then using experimental data to strictly adjust the tuning parameters in physical models. Engine outputs over the full range of engine operation conditions as determined by design of experiment (DOE) are simulated, followed by fitting the provided dataset using a nonlinear response surface model (RSM) to express the causal relationship among engine operational parameters, environmental factors and engine output. The RSM is applied to an L-jetronic® air-intake system control logic for a turbocharged engine.