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Future diesel engine legislation Tier 4 / Stage V and EU6d demand further improvements to reduce CO2 while keeping the already low NOx emissions levels. For US trucks a more strict limit of 0.2 g/bhp-hr NOx emissions need to be achieved. In this trade-off, system costs and complexity of the after-treatment are defining the constraint in which the common rail fuel injection system layout has to be defined. The increase of rail pressure was in the past the major step to control the soot emissions in view of low engine-out NOx emissions by applying massive EGR. With the on-going development of NOx-aftertreatment by Selective Catalytic Reduction (SCR), conversion efficiencies of up to 97% allow to reduce the EGR usage and rail pressure usage. In that context, the steepness of injection rate, the nozzle flow rate and the injection pressure are remaining parameters to control the NOx emissions.

Automotive manufacturers are working towards protecting the global environment by using filters to reduce particulate matter (PM) emissions from their vehicles. There is a growing demand for sensors that detect the small amounts of PM leaking through these filters, as they can aid in performing on-board diagnostics (OBD) and monitoring the function of these filters. Currently, vehicles predominantly use an electric resistance type PM sensor, which applies a voltage between electrodes, collects PM, and senses the generation of PM path. However, in response to tightening regulations on PM-OBD, the response time of the sensor needs to be optimized. Furthermore, the fast response time must not degrade the poisoning resistance in order to ensure durability. To shorten sensor response time, we have developed a 20 μm-gap electrode structure using a cross-section of laminated alumina sheets with printed electrodes, which can form PM paths at small PM amounts.

Increasingly stringent regulations call for the reduction of emissions at engine startup to purify exhaust gas and reduce the amount of CO2 emitted. Air-fuel ratio (A/F) sensors detect the composition of exhaust gas and provide feedback to control the fuel injection quantity in order to ensure the optimal functioning of the catalytic converter. Reducing the time needed to obtain feedback control and enabling the restriction-free installation of A/F sensors can help meet regulations. Conventional sensors do not activate feedback control immediately after engine startup as the combination of high temperatures and splashes of condensed water in the exhaust pipe can cause thermal shock to the sensor element. Moreover, sensors need to be installed near the engine to increase the catalyst reaction efficiency. This increases the possibility of water splash from the condensed water in the catalyst.

This paper describes an exhaust system using a new air-fuel ratio (hereinafter, A/F) sensor that contributes to low emissions and low fuel consumption of gasoline engines. As the first technical feature, the water splash resistance of the A/F sensor has been substantially improved which allows A/F control to be enabled without delay during engine cold start. To realize this capability, it is important that the sensor characteristics are not affected by the condensed water generated in the exhaust pipe. Therefore, a technique that has the effectiveness of a water splash resistance layer with water repellent function is demonstrated. As the second technical feature, the power consumption of the sensor has been substantially reduced. This is achieved by improving thermal efficiency of the sensor that the element can be activated at a low temperature.

Many ICs are used in various electronic components in automotive applications, such as ECUs (electronic control units) and smart actuators. Automotive ICs required the following features: (1) high integration of analog, digital and output devices; (2) high breakdown voltage for analog devices standing the battery voltage; (3) highly accurate control for analog circuits; (4) susceptibility under harsh operating conditions, such as high ambient temperature and high humidity; and (5) high surge immunity such as ESD (electrostatic discharge) robustness. To meet these requirements, we developed analog and output devices with improved surge endurance based on SOI wafer and trench-dielectric-isolation technologies. Analog circuit applications, especially accurate power management or high-precision solenoid driving, demands stable temperature-compensated output. Load dump and battery-jumping also needs high voltage protection and high noise immunity for these devices.

At present, various efforts are being made in the industrial world to preserve the earth's environment. Automobile industry has to comply with the emission control regulations including NOx and PM and the requirement of reducing CO2 emission from the viewpoint of global warming protection and energy saving. In these situations, diesel engines having a high potential to reduce CO2 emission are attracting much attention. In order to enhance the potential of diesel to reduce CO2 while solving its problems (“slow, dirty, noisy”), common rail systems are vital. DENSO developed an advanced common rail system (CRS) that integrates fuel injectors capable of delivering up to five injection events per combustion cycle at 180MPa injection pressure. This paper describes the injection performance and effects of the 180MPa common rail system and then explains the next generation common rail system.

With regulations on exhaust-gas emissions becoming increasingly tight worldwide, high-accuracy exhaust-gas temperature (EGT) sensors are critical to precisely control the after-treatment systems of diesel engines. In addition, demands for longer sensor probes are growing, to enable the direct measurement of temperature at the core of the diesel particulate filter (DPF). To realize this, improved vibration resistance is required because the extension of the probe involves stronger vibration. An increasing number of turbocharged engines are expected to appear to satisfy fuel-efficiency requirements, and systems equipped with an EGT sensor will become more common for turbocharger protection. Vibration resistance is critical for an EGT sensor installed at the pre-turbocharger position because the sensor will be exposed to heavy vibration generated by the turbocharger. This study introduces a high-accuracy EGT sensor with an anti-resonance structure developed to satisfy these needs.

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.

Increasing electric loads in a vehicle causes over-discharge of a battery and drag torque due to an alternator. This paper gives a system concept of vehicle electric power flow management to solve these issues. Its primary function includes preserving electricity in a battery, stabilizing electric bus voltage, interfacing with vehicle torque control system, and improving fuel economy. The key point to realize such a system is a unified structure. It offers ‘Plug and Play’ function for electric power management components. Newly developed Vehicle Electric Power Flow Management System (VEF ) totally controls electric power flow in a vehicle. VEF contains an Electric Power Manager and its functional sub-systems, and controls them with the key parameter ‘electric power’. The sub-system includes Generation, Storage, Conversion, and Distribution to the loads.

Spark plugs with higher ignitability are continuously in great demand to realize high fuel efficiency and low emissions. To meet this demand, DENSO launched the Iridium Spark Plug in 1997, which realized the two characteristics that had been conventionally difficult to achieve concurrently-high ignitability and long life. The development of this product was enabled by miniaturizing the center electrode, produced using DENSO's original, highly wear-resistant iridium alloy (featuring a high melting point and excellent oxidation resistance). While spark plugs are now required to have a longer service life, they are also required to be higher in ignitability, as exhaust gas regulations have been tightened recently. However, the effort to miniaturize the center electrode is reaching a limit.

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.

Carbon brushes for automotive starters are used under severe conditions of high electric current density, high contact pressure and high sliding velocity. Therefore lead has traditionally been added to brushes to improve performance and durability. Lead is an environmental hazardous substance. In the EU, the law prohibits adding lead to brushes for electric motors which is installed on new automobiles in and after January 2005. In order to develop the lead free carbon brush for starters, we analyzed the effect and selected substitutive substance of lead. Adding lead to the brush reduces the electric resistance increase of the brush in high-temperature and high-humidity atmosphere and in high-temperature atmosphere. Furthermore lead reduces the wear amount of brush. We developed the lead free brush surpassing the lead addition brush in performance and durability by addition of lead alternatives silver and zinc.

A DPNR (Diesel Particulate-Nox Reduction) system is designed to simultaneously remove PM (Particulate Matter) and NOx from the exhaust of diesel engined vehicles. A DPF (Diesel Particulate Filter) is used in the DPNR system to reduce the PM. The DPF must have high PM filtering efficiency, while at the same time having low back pressure. However, filtering efficiency and back pressure have trade off relations. Therefore, it is necessary to optimize the pore distribution in the walls of the DPF to satisfy both characteristics. This paper will explain that optimized control of pore distribution enables both high PM filtering efficiency and low back pressure.

In general, automatic braking uses an electric stability control (ESC) hydraulic unit that can automatically increase the hydraulic pressure in the wheel cylinder (hereinafter called wheel pressure), independent of the driver’s braking operation. The hydraulic unit should have sufficient pressure response to apply autonomous emergency braking (AEB). It was necessary for the hydraulic unit to have a high flow rate for the pressure response. To satisfy the performance requirements of the AEB, a brushless motor, which has a high maximum rotational speed and good response, is adopted for the hydraulic unit. Furthermore, sensorless control, which does not require a rotation angle sensor, has been developed so that the motor size can be small and common to conventional units. The developed sensorless control can switch the driving methods in three states: pre-rotation, low speed, and high speed.

The set-off length (also referred to as the “lift-off length”) is reduced by the re-entrainment of the burned gas by the backward flow surrounding a diesel spray jet produced by a multi-hole nozzle. In the present study, to estimate the equivalence ratio at the set-off length, a means of estimating the amount of burned gas that is re-entrained into the near-nozzle region of the diesel spray jet was established. The results revealed that the suppression of soot formation in quasi-steady diesel spray flames produced by a multi-hole nozzle and a high injection pressure is not attained by reducing the equivalence ratio at the set-off length. Analysis of the amount of soot along the spray axis using a two-color method revealed that the maximum soot amount position appears in a quasi-steady spray flame, after the collapse of the head vortex in which a dense soot cloud is formed. The maximum soot amount position does not change even if the injection pressure varies.

The purpose of this study is to elucidate flame propagation behavior of homogeneous propane-air mixture under application of non-uniform electric field. A needle-shaped electrode was attached to the ceiling and a plate electrode was set at bottom of combustion chamber, so that the electric field was applied in the direction of the chamber's vertical axis. A homogeneous propane-air mixture was supplied at equivalence ratio of 1.0 and was ignited by leaser induced breakdown under atmospheric pressure and room temperature. It was found that the flame front and plate electrode were repelled each other and a thin air layer was formed between the flame and plate electrode when a relatively low positive DC non-uniform electric field was applied to the needle-shaped electrode. It might be thought that the induced current was generated in the flame front, so that the flame front and plate electrode repelled each other.

Reducing vehicle CO2 emissions is an important measure to help address global warming. To reduce CO2 emissions on a global basis, Toyota Motor Corporation is taking a multi-pathway approach that involves the introduction of the optimal powertrains according to the circumstances of each region, including hybrid electric (HEVs) and plug-in hybrid electric vehicles (PHEVs), as well as battery electric vehicles (BEVs). This report describes the development of a new PHEV system for the Toyota Prius. This system features a traction battery pack structure, transaxle, and power control unit (PCU) with boost converter, which were newly developed based on the 2.0-liter HEV system. As a result, the battery capacity was increased by 1.5 times compared to the previous model with almost the same battery pack size. Transmission efficiency was also improved, extending the distance that the Prius can be driven as an EV by 70%.

Toyota Motor Corporation has developed a new battery electric vehicle (BEV) on the dedicated e-TNGA platform for BEVs, which was designed to lower the center of gravity of the vehicle and increase body stiffness. In addition to a full-time 4WD system, another feature of this new BEV is its pleasurable driving experience. A new inverter drive unit was developed for this system. Unlike the previous inverter, the advantage of the new inverter is that it is small enough to be mounted inside the transaxle housing, thereby contributing to the availability of interior and luggage space. The temperature rise of the power semiconductors in the inverter was reduced considerably by the development of a new power semiconductor for BEVs. This enables a parallel layout of two power semiconductors instead of three. The components of the inverter were also downsized. A coreless current sensor was adopted, and capacitors were developed with significantly lower capacitance.