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The process for setting the marketability targets and achievement methods for automotive interior quietness (as related to air borne noise above 400Hz, considered the high frequency range) was established. With conventional methods it is difficult to disseminate the relationship between the performance of individual parts and the overall vehicle performance. Without new methods, it is difficult to propose detailed specifications for the optimal sound proof packages. In order to make it possible to resolve the individual components performance targets, the interior cavity was divided into a number of sections and the acoustic performance of each section is evaluated separately. This is accomplished by evaluating the acoustical energy level of each separate interior panel with the unit power of the exterior speaker excitation. The applicability of the method was verified by evaluating result against predicted value, using the new method, during actual vehicle operation.

Cabin quietness is one of the important factors for product marketability. In particular, the importance of reducing road noise is increasing in recent years. Methods that reduce acoustic sensitivity as well as those that reduce the force transferred from the suspension to the body (the suspension transfer force) are used as means of reducing road noise. Reduction of the compliance of the body suspension mounting points has been widely used as a method of reducing acoustic sensitivity. However, there were cases where even though this method reduced acoustic sensitivity, road noise did not decrease. This mechanism remained unclear. This study focused on the suspension transfer force and analyzed this mechanism of change using the transfer function synthesis method. The results showed that the balance between the body's suspension mounting points, suspension bush, and suspension arm-tip compliance is an important factor influencing the change in suspension transfer force.

In brake squeal analyses using FE models, minimizing the discrepancies in vibration characteristics between the measurement and the simulation is a key issue for improving its reproducibility. The discrepancies are generally adjusted by the shape parameters and/or material properties applied to the model. However, the discrepancy cannot be easily adjusted, especially, for the vibration characteristic of the disc model of a motorcycle. One of the factors that give a large impact on this discrepancy is a thermal history of the disc. That thermal history includes the one experienced in manufacturing process. In this paper, we examine the effects of residual stress on the natural frequency of motorcycle discs. The residual stress on the disc surface was measured by X-ray stress measurement method. It was followed by an eigenvalue analysis. In this analysis, we developed a unique method in which the residual stress was substituted by thermal stress.

When a vehicle drives over road seams or a bumpy surface, low-frequency noise called drumming is generated, causing driver discomfort. The generation of drumming noise is closely related to the vibration characteristics of the suspension, body frame, and body panels, as well as the acoustic characteristics of the vehicle interior. It is therefore difficult to take measures to get rid of drumming after the basic vehicle construction has been finalized. Aiming to ensure drumming performance in the drawing review phase, we applied the Finite Element Method (FEM) to obtain acoustical transfer functions of the body, and Multi Body Simulation to get suspension load characteristics. This paper presents the results of the study of drumming prediction technology using this hybrid approach.

Currently, car bodies require further weight reduction in order to support increasing fuel economy requirements. An efficient way for light weight body design is to include body member size as a design variable in addition to part thickness. However it is currently difficult for finite element (FE) models to change member size even using current morphing techniques. To break through this challenge, a hybrid modeling approach was developed which combines shell and beam element representations of body structural members. The original member shell element thickness was decreased by 40%. Then the stiffness reduction caused by this change is offset by beam elements incorporated inside these members. These beams can represent the stiffness change due to new cross sectional dimensions or orientations without changing the original shell elements, thus avoiding modeling instabilities that can occur from morphing.

As the electric vehicle (EV) market expands and we enter the period of fully fledged diffusion of the vehicles, evaluation of battery performance when secondhand vehicles are sold and when batteries are put to alternative uses will become increasingly important. However, the accurate measurement of battery performance for the purpose of battery evaluation represents a challenge when the batteries are fitted in a battery pack consisting of multiple cells. The authors therefore formulated a degradation estimation model for the evaluation of battery performance based on battery usage history. To formulate the model, parameters expressing the internal state of the battery are estimated from the battery's usage history; battery capacity is estimated with consideration of these parameters.

We had developed Electric Servo Brake System, which can control brake pressure accurately with a DC motor according to brake pedal force. Therefore, the system attains quality brake feeling while reflecting intentions of a driver. By the way, “Build-up” is characteristics that brake effectiveness increases in accordance with the deceleration of the vehicle, which is recognized as brake feeling with a sense of relief as not to elongate an expected braking distance at a downhill road due to large-capacity brake pad such as sports car and large vehicles. Then, we have applied the optical characteristic control to every car with Electric Servo Brake System by means of brake pressure control but not brake pad. Hereby, we confirmed that the control gives a driver the sense of relief and the reduction of pedal load on the further stepping-on of the pedal. In this paper, we describe the development of brake feel based on the control overview.

In this research, a material model was developed that has orthotropic properties with respect to in-plane damage to support finite element strength analysis of components manufactured from a randomly oriented long-fiber thermoplastic composite. This is a composite material with randomly oriented bundles of carbon fibers that are approximately one inch in length. A macroscopic characteristic of the material is isotropic in in-plane terms, but there are differences in the tension and compression damage properties. In consideration of these characteristics, a material model was developed in which the damage evolution rate is correlated with thermodynamic force and stress triaxiality. In-plane damage was assumed to be isotropic with respect to the elements. In order to validate this material model, the results from simulation and three-point bending tests of closed-hat-section beams were compared and found to present a close correlation.

Titanium alloy for forging and pure titanium material for exhaust systems have been developed. The forging alloy will be applied to production of lightweight motorcycle frames and the pure titanium will be applied to improve engine performance. The materials have been made inexpensive by the use of off-grade sponge that includes many impurities for production of titanium ingot. Stable characteristics have been obtained by controlling oxygen equivalent after setting the volume of tolerable impurities by considering mechanical properties and production engineering. In spite of low-cost, the material provides the same design strength compared to conventional material, and enables parts production with existing equipment. A review of manufacturing and surface treatment processes indicated a reduction in the price of titanium parts produced with this new material.

Honda has been taking measures since the late 1990s to address three issues raised by the automobile, from air pollution, which was already a matter of regulation, to the additional issues of global warming and energy. With observation of recent trends in society, what had been our concern about these three matters appears to have gradually been turning into certainty instead. Meanwhile, the demand for automobiles is expected to increase with the population growth in newly emerging countries, economic growth, and other such factors. At present, with automobiles dependent on oil for the greater part of their energy, it has become a challenge to secure a stable supply of reasonably priced oil while the global warming perspective requires reduction of CO2 emissions. This article will review the history of development of the fuel cell vehicle (FCV) equipped with the next-generation power plant capable of simultaneously providing the solutions demanded for all three automobile issues.