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A compact and high performance electric motor, called the 3D motor and designed to achieve output torque density of 100 Nm/L, was developed for use on electric vehicles and hybrid electric vehicles. The motor adopts an axial flux configuration, consisting of a disk-shaped stator sandwiched between two disk-shaped rotors with permanent magnets. It also adopts 9-phase current with a fractional slot combination, both of which increase the torque density. The rated torque output of this high power-density motor is achieved by applying a hybrid cooling system comprising a water jacket on the outer case of the stator and oil dispersion into the air gaps. The mechanical strength of the rotors against centrifugal force and that of the stator against torque exertion were confirmed in mechanical experiments. Several measures such as flux barriers, a chamfered rotor rim, parallel windings, and radially laminated cores were adopted to suppress losses.

For a numerical model of vibro-acoustic coupling analysis, such as a vehicle noise and vibration, both structural and acoustical dynamic characteristics are necessary to replicate the physical phenomenon. The accuracy of the analysis is not enough for substituting a prototype phase with a digital phase in the product development phases. One of the reasons is the difficulty of addressing the interior acoustical characteristics due to the complexity of the acoustical transfer paths, which are a duct and a small hole of trim parts in a vehicle. Those complex features affect on the nodal locations and the body coupling surface of acoustic mode shapes. In order to improve the accuracy of the analysis, the physical mechanisms of those features need to be extracted from experimental testing.

The ways in which vehicles are used in the field are continually becoming more diverse. In order to provide the optimum solution with respect to performance and weight, it is necessary to be able to assure vehicle endurance reliability with a high degree of accuracy in relation to the manner of use in each market. This situation has increased the importance of accurately quantifying the ways in which vehicles are used in the field and of designing vehicles with sufficient endurance reliability to match the usage requirements. This report presents a “market model” by which the manner of usage in the field can be treated quantitatively using combinations of environmental factors that influence the road load, drive load and corrosion load, representing typical loads vehicles must withstand.

Since interior noise has a strong effect on vehicle salability, it is particularly important to be able to estimate noise levels accurately by means of simulation at the design stage. The use of sensitivity analysis makes it easy to determine how the analytical model should be modified or the structure optimized for the purpose of reducting vibration and noise of the structural-acoustic systems. The present work focused on a structural-acoustic coupling problem. As the coefficient matrices of a coupled structural-acoustic system are not symmetrical, the conventional orthogonality conditions obtained in structural dynamics generally do not hold true for the coupled system. To overcome this problem, the orthogonality and normalization conditions of a coupled system were derived by us. In this paper, our sensitivity analysis methods are applied to an interior noise problem of a cabin model.

Achieving a multi-cylinder engine with excellent noise/vibration character sties and low friction at the main bearings requires an optimal design not only for the crankshaft construction but also for the bearing support system of the cylinder block. To accomplish that, it is necessary to understand crankshaft system behavior and the bearing load distribution for each of the main bearings. Crankshaft system behavior has traditionally been evaluated experimentally because of the difficulty in performing calculations to predict resonance behavior over the entire engine speed range. A coupled crankshaft-block analysis method has been developed to calculate crankshaft system behavior by treating vibration and lubrication in a systematic manner. This method has the feature that the coupled behavior of the crankshaft and the cylinder block is analyzed by means of main bearing lubrication calculations. This paper presents the results obtained with this method.

Engines that not only produce less noise but also provide good sound quality have been in increasing demand recently. Discomforting noise can sometimes be heard, however, during acceleration as the engine reaches higher levels of power and speed. This paper presents the results of a study into the bending vibration of the crankshaft-flywheel system, which clarify the mechanism producing discomforting noise during acceleration. Based on that study, a flexible flywheel has been developed which effectively reduces crankshaft bending vibration that is closely related to the frequency range of the discomforting noise. As a result, acceleration sound quality is greatly improved.

The durability test with road-load input is necessary for evaluating durability of body and chassis structure in automotive applications. This paper shows the method to analyze road-load input to a suspension system for development of a simple component level bench test. This method enables the extraction of the essential inputs to evaluate the durability of suspension parts using the transfer function (frequency response function) measured by Multi-axial Road Simulator and wheel force transducers. These extracted inputs contribute to development of a new realistic component bench test.

Recently, it has been very important to reduce the noise, especially the Squeak and Rattle noise, for improving customer appeal of passenger vehicles. The Squeak and Rattle noise occurring inside the car cabin during vehicle operation is an especially large problem. This paper describes a newly developed measurement technology that uses the developed signal processing using the Beam-forming method and vibration sensor to identify the Squeak and Rattle noise sources, making it possible to determine effective countermeasures quickly. This new technology is used to identify all Squeak and Rattle noises at a time among many different noises, for example Wind noise, Engine noise and Road noise occurring during vehicle operation, and is expected to shorten substantially the time needed for noise analysis and contribute to quality improvements.

This paper describes a newly developed HC-adsorption three-way catalyst and adsorption system that reduce cold-start HC emissions with high efficiency. This system is the first of its kind anywhere in the world to be implemented on production vehicles. An overview is given of the various improvements made to achieve higher cold-start HC conversion efficiency. Improvement of conversion performance was accomplished by (1) increasing the thermal stability of the HC adsorbent, (2) improving desorbed HC conversion efficiency and durability and (3) optimizing the geometric surface area (GSA) of the substrate. Concretely, the thermal stability of the adsorbent was improved by enhancing the high-temperature durability of zeolite. Improvement of desorbed HC conversion efficiency was accomplished by improving the OSC material so as to match the temperature rise characteristic and usage temperature of the catalyst.

Eliminating squeal noise generated during braking is an important task for the improvement of vehicle passengers' comfort. Considerable amount of research and development works have been done on the problem to date. In this study, we focused on the analyses of friction self-excited vibration and brake part resonance during high frequency brake squeal. Friction self-excited vibration is caused by the dry friction between pads and rotor, and occurs as a function of their relative sliding velocities. Its vibration frequency can be calculated in relation to the mass and stiffness of the pad sliding surface. Frequency responses of the brake assembly were measured and the vibration modes of the pad, disc and caliper during squeal were identified through modal analysis. Further study led to the development of a computer simulation method for analyzing the vibration modes of brake parts. Analytical results obtained using the method agreed well with the corresponding experimental data.

This paper describes the motor and inverter system developed for the Nissan LEAF that has been specifically designed as a mass-produced electric vehicle. The system produces maximum torque of 280 Nm and maximum power of 80 kW. The motor achieves a small size, high power, and high efficiency as a result of adopting the following in-house technologies. The magnetic circuit design was optimized for an interior magnet synchronous motor to attain the maximum performance figures noted here. The material technologies of the rotor and the stator facilitate high efficiency and the production technology achieves high density winding. The cooling mechanism is optimally designed for a mass-produced electric vehicle. The inverter incorporates the following original technologies and application-specific parts to obtain cost reductions combined with reliability improvements. The power module has an original structure with the power devices mounted directly on the busbars.

This paper describes the HMI, navigation and telematics systems developed specifically for the Nissan LEAF electric vehicle to dispel drivers' anxieties about operating an EV. Drivers of EVs will need to understand various new kinds of information about the vehicle's operational status that differ from conventional gasoline-engine vehicles. Additionally, owing to the current driving range of EVs and limited availability of charging stations, drivers will want to know acccurate the remaining driving range, amount of power and the latest information about charging station locations. It will also be important to ensure that people unfamiliar with EVs will be able to operate them easily as rental cars or in car-sharing systems without experiencing any inconvenience.

The Hybrid FE-SEA method has been used to create fast/efficient model of structure-borne noise in a fully trimmed vehicle from 200Hz to 1kHz. A joint paper is presented which highlights the method and modelling process along with extensive validation results. This paper describes the use of the model to analyze structure borne noise in the full vehicle, design and evaluate the impact of counter-measures. One of the key attributes of the Hybrid FE-SEA method is the ability to predict noise transfer paths in the vehicle. First, results from a Noise Path Analysis are used to identify key contributors to interior noise in the 200Hz-1kHz frequency range. Next potential design strategies for reducing interior noise are introduced along with implications on the model. Finally, sample prediction results illustrating the impact of design changes on interior noise levels are shown along with preliminary experimental validation results.

Nissan has added ball bearings to its “High-flow Ceramic Turbocharger”(1) (introduced in 1987) to improve acceleration response by reducing friction loss. The following programs were carried out in applying ball bearings to the turbocharger: Optimum bearing size and material were selected to assure long life; lubrication techniques were employed to achieve compatibility between acceleration response and durability; a thrust support system was designed to assure that the ball bearings endure thrust load which varies in direction and magnitude during engine operation; and the squeeze film damper was optimized to keep the turbocharger silent. These innovations have resulted in a practical ball-bearing turbocharger, which has been installed in Nissan's most recent Skyline model(released in May 1989). This is the first time a ball-bearing turbocharger has been applied to a passenger car.

This paper presents Nissan's new four-valve-per-cylinder direct injection (DI) diesel engine series consisting of a 2-liter class and 3-liter class. These engine series provide substantially improved power output along with lower noise and vibration levels, which have been traditional drawbacks of DI diesel engines. Nissan developed this engine series in response to the heightened need in recent years for passenger-car DI diesel engines with superior thermal efficiency, a characteristic advantageous for reducing CO2 emissions.

This paper describes an experimental modal synthesis method for determining the noise characteristics of coupled acoustic-structural systems. This method was developed to provide an essential tool for analyzing passenger compartment noise levels. With this method, it is possible to obtain the coupled acoustic-structural parameters directly from experimental measurements of noise and vibration. The resulting modal parameters provide the basis for predicting how structural modifications will affect interior noise characteristics. This paper presents the theory on which the method is based and gives examples of its application to passenger compartment noise analyses.

This Paper Presents the world's first active noise system for production vehicle implementation. Adopted in the new middle size FF car model, this epoch-making system dramatically reduces the booming noise caused by the second-order harmonic of engine revolution. This is accomplished by using an adaptive control theory based on digital signal processing technology and a digital signal processor (DSP). The system basically employs a multiple error filtered-x LMS algorithm, to which an new algorithm was added to achieve the maximum noise reduction effect under a condition of stable control in a compact system for production vehicle application.

Increased attention has been directed toward noise and vibration characteristics of vehicles in recent years and the performance requirements in this area continue to become more rigorous every year. The acceleration noise in a frequency range of 250 ∼ 800Hz caused by powerplant vibration is important, and there is a need to reduce this noise level. In addition to reducing noise and vibration, however, there is also a growing need to achieve further weight reductions. Consequently, it is essential to reduce the weight of a powerplant without increasing its vibration levels. This make it necessary to predict powerplant vibration characteristics accurately at the planning and design stage so that suitable specifications can be determined. Specifications for reducing powerplant vibration have traditionally been found by experimentation. However, in powerplant excitation tests it has not been possible to take into consideration the effect of the crankshaft system on powerplant vibration.

This paper presents a new refrigeration lubricant for use with the HFC-134a retrofit refrigerant in automotive air-conditioning systems originally designed to use the CFC-12 refrigerant, one of the regulated CFCs scheduled to be phased out. This new retrofit lubricant provides high lubricity and excellent performance characteristics as a result of adopting a newly developed PAG base oil with a block polymer structure and a new antiwear additive formulation. In retrofit systems, it assures sufficient durability for wobble-plate-type variable displacement compressors, which experience severe lubrication conditions.

The target performance of a new engine has to be obtained under various restrictions such as cost and weihgt. It is particularly important to predict the engine noise and vibration performance at an early stage. For this purpose the analytical methods have been developed, which include the prediction of the absolute noise and vibration level by inputting a given exciting force into the model. These methods were applied to the development of the new engine. As a result, the characteristics of an aluminum cylinder block were used effectively to achieve a new lightweight V6 engine with low noise and vibration levels.