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There are such outside door handles called smart handles which have a transmitting antenna, a lock/unlock sensor, and a sensor detection circuit, with which operation of door lock is possible just by "touching" the electrostatic-capacitance type sensor of the handles.As the design of the outside handles, body color painting and Cr plating are adopted. However, if plating is applied over the entire surface of a smart handle, electromagnetic waves transmitted from the antenna will be blocked since plating material is electrically conductive. In addition to this, touching a part other than the sensor may change the electrostatic-capacitance of the sensor, which results in unwanted functioning of the lock/unlock sensor. Because of this, only part of the handle, which does not hinder the transmission of electromagnetic waves and does not cause unwanted functioning, is covered by plating, that is called, "Partially plated specifications" (Figure 1).

Over the past decades, the automotive industry has made significant efforts to improve engine fuel economy by reducing mechanical friction. Reducing friction under cold conditions is becoming more important in hybrid vehicle (HV) and plug-in hybrid vehicle (PHV) systems due to the lower oil temperatures of these systems, which results in higher friction loss. To help resolve this issue, a new internal gear fully variable discharge oil pump (F-VDOP) was developed. This new oil pump can control the oil pressure freely over a temperature range from -10°C to hot conditions. At 20°C, this pump lowers the minimum main gallery pressure to 100 kPa, thereby achieving a friction reduction effect of 1.4 Nm. The developed oil pump achieves a pressure response time constant of 0.17 seconds when changing the oil pressure from 120 kPa to 200 kPa at a temperature of 20°C and an engine speed of 1,600 rpm.

Resolving the brake squeal that occurs under various environments is a major topic, and a resolution method is eagerly anticipated. We focused on the phenomenon that, amid various environmental conditions, squeal occurs easily when an automobile has been left standing in a cold environment. We checked the details focusing on the friction coefficient (hereafter, μ). As a result, we found that μ increases when squeal is generated, and that the sliding surface film contributes to the μ behavior. We studied measures to be taken to increase the μ in cold conditions.

Recently, plastic air intake manifold (PAIM) has been adopted into gasoline and diesel engines as standard equipment. The advantages of the PAIM are light mass weight, low cost, high thermal-insulation efficiency and reduction of air pressure loss compared with a metal air intake manifold. However, in order to bring the advantages of the PAIM into play, many issues including static burst, noise and vibration, and so on should be settled in its design process. In this paper, the performance prediction and application example of PAIM are introduced.

Switched Reluctance Motor (SRM) mainly has two advantageous characteristics such as no magnet and simple construction. These characteristics contribute lower cost and higher reliability compared with other motor systems such as brushless permanent magnet motors or induction motors. However, acoustic noise and output torque ripple should be improved when the SRM is applied to a traction system for passenger electric vehicle since these characteristics directly affect vehicle quietness and drivability. In this paper, we describe a system configuration of the SRM traction system for passenger electric vehicle. The SRM traction system includes an electric motor, transmission gears and power inverter module. Then, an approach to improve acoustic noise and output torque ripple is introduced. Generation mechanisms of acoustic noise and output torque ripple are analyzed.

Sport Utility Vehicles (SUV) and light duty trucks have gained in popularity for the last several years and the demand for more car-like behavior has increased, accordingly. Two areas for potential improvement are vehicle stability and maneuverability while parking. 4WS (4 wheel steering system) is known as an effective solution to stability and low speed maneuverability. In this paper, we identify a new systematic design method of two degree of freedom vehicle state feedback control algorithm that can improve vehicle stability, and show its control effects for a SUV with trailer towing. Low speed maneuvering is improved when the rear tires are steered in negative phase relative to the front tires. However with a large rear steer angle at low speed, the vehicle's rear overhang tracks a wider swing-out path than a 2WS vehicle. For this concern, we propose a new swing-out reduction control algorithm.

Exhaust emission regulation has become stricter year by year because of the global movements of environment protection. In consequence, turbocharger application to diesel engines became indispensable. Especially a variable geometry turbocharger (VGT) is perceived as the essential item. Of late years, the diesel engine has a trend of higher exhaust temperature to increase specific output. At the same time, needs of the turbocharger application to the gasoline engine has been rising again in order to reduce the size. In spite of this trend of the emission temperature increment, VGT of the variable nozzle vane type which is commonly available in the current market has problems of high temperature resistance due to its complex structure. AISIN SEIKI has developed a variable flow turbocharger (VFT), which is able to resolve those problems.

Recently two-mass flywheels have adopted in various types of engines to decrease torsional engine vibrations. A two-mass flywheel has a resonance frequency below the idle speed. Thus, it must be provided with an energy dissipating mechanism to avoid a resonance problem. Consequently, flywheel's damping effectiveness at practical engine speeds is decreased because the energy dissipating mechanism restricts relative displacement of the two-mass flywheel. In this work, a new prototype two-mass flywheel was evaluated and found to be effective in improving two important qualities of such devices; (1) its ability to decrease torsional vibrations (2) its ability to avoid resonance problems during engine startup.

A new variable displacement pump has been developed. This pump can variably change its discharged flow rate in accordance with the revolution changes of an automotive engine from idling engine speed to 6000rpm. It can quickly discharge oil necessary for controlling the autmotive active suspension system. This pump is of a swash plate, axial piston type which controls optimal fluid flow in time by using a pressure sensing control valve. Further, in order to improve the quietness in the vehicle system, the pulsation of the pump pressure was reduced and this pump's utility was realized for automobile use. This is a report on how the pump was introduced for commercial automobile use.

An active suspension system controls a spring constant and an attenuater in real time using a power supply. Generally, the hydraulic pressures are used for transmitting the power. Therefore, a highly reliable and inexpensive control system has been required for a commercial use. This has been achieved by developing a mechanical fluid servo valve which comprises a simple combination of a solenoid valve and a spool valve. The technical problem of the valve vibrations has been solved through the numerical analyses, the fluid flow visualization tests and the vehicle tests.

Recently, for the aspects of ecology and economy, fuel efficiency improvement demand has been increased globally. And, various types of hybrid systems have been suggested. In response to this market demand, AISIN SEIKI has been developing Synchronizer-less hybrid automated manual transmission (HV-AMT) system aiming excellent transmission efficiency, excellent agility, and shift change quality like a step automatic transmission (AT). This hybrid system is constructed based upon a parallel 2-axis manual transmission (MT) which originally has high transmission efficiency. The synchronizer system of a MT is replaced by a Dog clutch system which does not spoil the transmission efficiency and never makes failure in synchronization. This Dog clutch system includes a modified detent function, a shift actuator of linear motor, advanced function controls for a clutch and a shift actuator.

This paper reports the results of a study into a preview control that uses the displacement of the road surface in front of the vehicle to improve for front and rear actuator responsiveness delays, as well as delays due to calculation, communication, and the like. This study also examined the effect of a preview control using the eActive3 electric active suspension system, which is capable of controlling the roll, pitch, and warp modes of vehicle motion.

Aiming at improved reliability and cost reduction of position sensors for automobiles, we tackled with the challenge of developing long life contact type potentiometer which has a simple construction and cost advantage. We made clear the wear characteristics of the resistor materials and the mechanism how noise occurs, and developed a long life, low noise resistor material, and the double - layer resistor structure which has excellent characteristic in durability. We also clarified the ways of using brushes according to applications through the investigation of the relationship between the contact shape and the amount of wear of the resistor. Based on these investigation, we have developed a highly reliable throttle position sensor and a long life vehicle height sensor.

Automating the inspection of the piston combustion chamber volume is difficult and prevents establishing an unmanned machining process of the piston in the future. So, we developed an inspection technique which uses a Range Finder, non-contact visual sensor, and calculate the chamber volume by integrating 3D position data. We applied this real-time measurement technique which enables 100 % inspection to our production lines. Then, we developed the “Defect Free Production Line”, which calibrates itself by feeding back the measured volume data to the machining process. Our paper will explain this inspection technique and our “Defect Free Production Line”.

Development of a system which utilizes technology for the recognition of a vehicle's surroundings. Research is currently taking place in many countries, the goals of which are to improve a vehicle's safety and convenience by reducing driver strain through the automation of the recognition, judgment, and operation capabilities that are needed when driving an automobile. To recognize the vehicle's surroundings, we have adopted an image sensor system which offers superior three-dimensional recognition capabilities. In this paper, we will introduce a inter vehicle distance control system which controls the vehicle's throttle and braking functions by detecting the position of the driving lane and the distance to the vehicle in front based on the images obtained by a CCD camera.

Brake noise problem is one of the most common customer complaints regarding brake systems. With a focus on low frequency squeal, we have studied the vibration modes of brake caliper. In the present study, we achieved the reduction of low frequency brake squeal through modal analysis of mounting brackets.

In this paper, we discuss vehicle directional stability and introduce advanced stability control (ASTC) to stabilize the vehicle during severe cornering. Vehicle behavior in a transient steering condition during severe cornering was analyzed by computer simulation. It was found that applying an external yaw moment makes the vehicle more stable. The effect of controlling the brake force response is also evaluated by simulation to determine the brake actuator response criteria. The actual vehicle test was performed with a pylon slalom using a hydraulic brake actuator. It is verified that the ASTC stabilizes the vehicle for transient steering maneuvers.

This active-drive wheel speed sensor, developed by the high-frequency magnetic system, enables detection of very slow wheel speeds - hitherto difficult to accomplish with any conventional type of Magnetic Pick up - by applying the eddy current effect through the high-frequency magnetic field. The following report presents an analysis of the magnetic circuit which integrates the magnetic-field generating coil with the detection rotor, and the unique circuit system which ensures strength against eccentricity of the wheel rotor and air gap variations, etc.

Drive train components (transmission, differential gears, etc.) can be made smaller and lighter if the excessive torque exerted on them can be reduced during the quick start of a vehicle. An orifice put in the hydraulic clutch piping path is an effective method. However, increased oil viscosity at low temperatures (0°C or below) makes the “pedal feel” worse. In order to increase the orifice diameter for better “pedal feel”, a shape memory alloy spring, for operation at low temperatures, was developed by adding cobalt to the nickel-titanium alloy. Consequently, a Variable-Orifice valve, using the shape memory alloy spring, is practical.

While exhaust gas emission standards are becoming severe, turbochargers which have a good performance and wide operating range are required. At Aisin Seiki, we have started development of the SJ (swirl jet) turbocharger to cope with these requirements without increasing costs. In this paper, we describe the features and effects of the SJ turbocharger.