Search Results

Injuries to the lower extremities are one of the major issues in vehicle-to-pedestrian collisions. To evaluate pedestrian lower extremity protection, the Transport Research Laboratory (TRL) legform impact tests have been conducted according to the specifications in the EU directive. The TRL legform impactor consists of a tibia and a femur steel shaft connected by deformable knee bars. A Flexible Pedestrian Leg-form Impactor (Flex-PLI), which has flexible femur and tibia, is examined in the Global Technical Regulation (GTR). Previous studies compared the responses of both impactors; however, the relation between the tibia acceleration in the TRL legform impactor and the maximum bending moment in the Flex-PLI (both injury measures are for the tibia fracture) is not understood sufficiently.

This paper proposes Prioritized-CSMA (Carrier Sense Multiple Access) protocol for Japanese vehicle safety communications (VSC). To realize Japanese VSC, we have studied a protocol to carry out Roadside-to-Vehicle (R2V) and Vehicle-to-Vehicle (V2V) communications on single channel because a single 10MHz bandwidth channel on UHF band is allocated for VSC in Japan. In this case, R2V communication requires higher quality than V2V communication, so we have developed a protocol to prevent interference between R2V and V2V communications. The proposed protocol has been evaluated by field experiments and a simulation. The results confirm that the proposed protocol prevents the interference effectively and it has capability to achieve high-quality R2V communication in actual case.

We have developed a novel wafer process for capacitive sensing accelerometer using surface Micro Electrical Mechanical Systems (MEMS) technology and successfully applied to the fabrication process. Our new process combines with a single crystal SOI (Si on Insulator) wafer, high aspect ratio silicon etching and newly developed anhydrous HF/Alcohol etch process of silicon oxides. Although wet conditions such as HF/water etch occurs stiction of mobile structure, our anhydrous HF/Alcohol etch process technology occurs no stiction of mobile structures, because of gas phase (dry) process. In our process, we have achieved smaller-sized sensor chip compared to our conventional 2 axes accelerometer.

In a conventional soldering process, solvents, such as chlorofluorocarbons (CFCs), have been necessary to remove the flux-residue after soldering. A new CFC-free fluxless soldering process has been developed to obtain high sealing ability even in a small soldering area. This new process utilizes a reducing atmosphere with an appropriate load and assembly orientation to solder the parts. Under this fluxless condition, it is found that appropriate loading and good solder-wettability of the upper part increase the wettability of the lower part.

Dimethyl ether (DME) holds promise as an alternative to diesel fuel. However, its physical properties are not similar to those of conventional diesel fuel. The P-V, bulk modulus and viscosity of DME are derived as a function of temperature and pressure. As a result, the Weber and Reynolds number of DME is very large as compared with that of diesel fuel. So, the spray characteristics of DME are not those of a liquid spray but similar to those of gas spray. The spray formation is strongly affected by the fuel flow in the nozzle. The Computational Fluid Dynamics (CFD) and experiments are examined to analyze the fuel flow in the nozzle. The DME physical properties make some difference to the flow in the nozzle, in comparison with those of diesel. As a CFD result, cavitation in the injection nozzle is more frequent with DME than with diesel oil. From experimental results, the temperature in the nozzle sac is higher with DME than with diesel oil.

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 conventional automobile designs, a radiator and a condenser are typically configured and mounted independently of each other. We have developed a smaller and more powerful cooling module by integrating these two products into one piece. The new cooling module has been designed to share the fin material and to have an insulating slit and other means for effective prevention of heat loss that occurs due to thermal conduction between the radiator and the condenser1). In addition, as one of the key techniques for integrating fins, we studied thermal spraying of brazing filler to the tube material and were able to achieve a practical-level cooling module through use of high-performance fins, contributing largely to the efforts to create a more compact, higher performance cooling module.

As automobiles become quieter, wiper operation noise becomes more noticeable. Squeal noise is one type of wiper operation noise. It is a high-frequency self-excited vibration that is easily generated before and after the wiper reverses direction. In analyzing this vibration, squeal noise was observed using a rotary disk system. Then FEM was applied to deduce an equation of motion that reflects the observation results. The equation suggests material and configuration approaches toward reducing squeal noise. Potential measures include improvement in the blade damping coefficient, reduction in the coefficient of friction by surface treatment, and an increase in neck thickness, etc. Implementation of these measures reduced squeal noise.

Dimethyl ether(DME) is a promising new alternative fuel not only diesel fuel but also power generation, fuel cell and city gas. However, the physical properties are not similar to those of conventional diesel fuel. The P-v, bulk modulus and viscosity of DME are derived as a function of temperature and pressure. As a Result, the Weber and Reynolds number of DME is very large as compared with that of diesel fuel. So, the spray characteristics of DME is not the liquid spray but similar to that of gas spray. The spray formation is strongly affected by the fuel flow in the nozzle. The Computational Fluid Dynamics (CFD) and the experiments are examined to analyze the fuel flow in the nozzle. The DME physical properties make some difference of the flow in the nozzle, comparing with those of diesel. As a CFD result, cavitation in the injection nozzle is more frequent with DME than with diesel oil.

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.

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.

We have developed a novel capacitive acceleration sensor fabrication process by applying surface MEMS (Micro Electro-Mechanical System) technology and successfully introduced this process for volume production of a new super slim sensor. The new process uses the ICP-RIE(Inductively Coupled Plasma - Reactive Ion Etching) technology to etch single crystal SOI(Si on Insulator wafers. In this technology, vertical Si etching is followed by, lateral etching along the buried oxide to release the movable electrode. Because of a dry process, the new process does not cause the movable structures to stick to each other. Our process uses only three masks and reduces the sensor chip size to a half that of our conventional capacitive acceleration sensors.

In an effort to protect the earth's environment, emission regulations in the diesel engine field are becoming increasingly strict. One way of meeting these regulations is to atomize the fuel spray by using a fuel injection system with high-pressure injection, which activates engine combustion. With current in-line pump systems, however, it is still possible to satisfy the demand for cleaner emissions by improving the fuel spray, through measures such as reviewing high-pressure injection and initiating improvements in the nozzle. This report describes the new in-line pump system for medium duty diesel engines to meet future emission regulations. In this report, we will describe how analytical technology, such as computer simulation, was used on the pump side to make improvements for higher injection pressure.

The lateral DMOS (LDMOS) had been developed for intelligent power IC[1][2] for ECU (Electric Control Unit). The process and device simulation methodology are used while developing a devices. The physical model and parameter in analytical model are calibrated to enhance the accuracy of the simulation and to reduce lead time and costs.

Through the years, aluminum automotive heat exchangers have been developed in order to have a high performance and a light weight. Therefore, the thickness of the aluminum sheets for the application has been reduced. As the brazeability declines with the reduction in thickness, fins having a thickness under 80μm may be difficult to secure a good brazeability. Therefore, we studied the brazeability to determine the limit of thickness using clad fins from 40 to 80μm. The fillet volume formed at the joints of the fin and tube decreased with the decreasing fin thickness and the Si content in both the filler metals and the core alloys. The suitable range of Si content in the filler metals and the core alloys to obtain a good brazeability decreased with the decreasing fin thickness. When the fins were thinner than the critical values, it was impossible to have a good brazeability.

Conventional methods of physicochemical models require various experts and a high measurement demand to achieve the required model accuracy. With an additional request for faster development time for diagnostic algorithms, this method has reached the limits of economic feasibility. Machine learning algorithms are getting more popular in order to achieve a high model accuracy with an appropriate economical effort and allow to describe complex problems using statistical methods. An important point is the independence from other modelled variables and the exclusive use of sensor data and actuator settings. The concept has already been successfully proven in the field of modelling for exhaust gas aftertreatment sensors. An engine-out nitrogen oxide (NOX) emission sensor model based on polynomial regression was developed, trained, and transferred onto a conventional automotive electronic control unit (ECU) and also proves real-time capability.

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.

Having a light weight, a good heat conductivity and a good brazability, aluminum alloy is widely used for automotive heat exchanger systems. The major problem with Aluminum is perforation of the tube by pitting corrosion and corrosion protection is necessary in the field. In radiator and condenser systems using the the Nocolok brazing process given good corrosion resistance using cathodic protection with sacrificial anode made of Zn-sprayed onto tube or low corrosion potential fins etc. On the other hand, in drawn-cup type evaporators, that are fabricated from brazing sheet tubes in vacuum brazing method and then covered low electro-conductive drain water film in operation, the effect of cathodic protection by the anode fin is limited to a very small area. Therefore, this has been studied to improve self-corrosion resistance of the core in the brazing sheet tube.