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It has been required recently that diesel engines for passenger cars meet various requirements, such as low noise, low fuel consumption, low emissions and high power. The key to improve the noise is to reduce a combustion noise known as “Diesel knock noise”. Conventional approaches to reduce the diesel knock are decreasing combustion excitation force due to pilot/pre fuel injection, adding ribs to engine blocks or improving noise transfer characteristics by using insulation covers. However, these approaches have negative effects, such as deterioration in fuel economy and increase in cost/weight. Therefore, modification of engine structures is required to reduce it. We analyzed noise transfer paths from a piston, a connecting rod, a crank shaft to an engine block and vibration behavior during engine operation experimentally, and identified that piston resonance was a noise source.

Lateral distance from the center of a driver's seating position to the gas and brake pedals is one of the main design factors that relates to the ease of stepping on the pedals from one and the other. It is important to keep a certain distance between the pedals to prevent erroneous operations or to reduce the driver's anxiety. In this paper, we explain that the distance between the pedals is affected by the driver's seating height. In other words, if the driver sits lower, the accuracy of stepping on the pedals from the gas pedal to the brake pedal will increase compared to the higher seating position. In addition, we found out that providing auxiliary parts for the leg support enhances the accuracy of the pedal operations.

We have proposed a human mimetic machine, using electronics control technology, which is quasi-human like an android equipped with volition as a new technical concept for man-machine systems. This machine determines the driver's physiological and psychological conditions and, in response, controls surrounding stimuli, such as sounds and vibrations. In this way, the relationship between the driver and the vehicle is made more human like. To determine the significance of the human mimetic machine, we have been developing a biofeedback vigilance control system, which maintains an optimum vigilance level during driving by controlling stimuli. In the first stage of the study, we have developed an accurate method to determine vigilance level using multiple regression analysis of electroencephalograms.

An Advanced driving simulator has been developed at Mazda Yokohama Research Center. The primary use of this simulator is to research future driver-vehicle systems. In an emergency situation, a driver must respond rapidly to perceived motion and visual stimulus to avoid an accident. In such cases, because the time delay associated with the perception of motion cues is shorter than visual and auditory cues, the driver will strongly rely upon perceived motion to control the vehicle. Hence, a driving simulator to be used in the research of driver-vehicle interactions in emergency driving must include a high performance motion system capable of large amplitude lateral motion. The Mazda simulator produces motion cues in four degrees of freedom, provides visual and auditory cues, and generates control feel on the steering wheel. This paper describes the merit of the large amplitude motion system and the features of this newly developed driving simulator.

A method to inspect the rattle generated in a vehicle cabin has been developed. In the method, the waveform of overall in-cabin noise is analyzed using Wigner distribution, a kind of time-frequency analysis, and the rattle component of the waveform is condensed and separated from the background shake noise. Then the rattle component is classified into three levels, strong, middle and not detected, using a neural network. Fuzzy inference is also used to select normal waveform data. Experimental results show that the correct classification ratio of the method is more than 90%, which equals the ability of skilled inspectors.

A technique to strengthen body frame with a polymeric structural foam has been developed with benefits of reducing vehicle weight and improving drivability and fuel economy. The idea of this new technology was evolved from the concept that body frame strength will increase drastically if the body frames are prevented from folding on collision. The energy of a collision impact would be effectively absorbed if weak portions of body frames are reinforced by a high strength structural foam. The new technology composed of the high strength structural foam and a light-weight frame structure with partial foam filling is reported here.

In recent years, improving fuel efficiency and collision safety are important issue. We have worked on a new construction method to develop body structure which is light weight and strong/stiff. We adopt multi type Tailor-Welded Blanks (TWB) which is formed after welding several steel sheets for ATENZA (MAZDA 6), NEW DEMIO (MAZDA 2), and RX-8. This is a technology to consistently improve of such product properties and to reduce costs. Laser welding is a common TWB welding method, but for further equipment cost reductions and productivity improvements, we have developed a higher welding speed and robust plasma welding and introduced this to mass production. We introduce this activity and results in this report.

Effects of split injection, with a relatively short time interval between the two sprays, on the spray development process, and the air entrainment into the spray, were investigated by using laser induced fluorescence and particle image velocimetry (LIF-PIV) techniques. The velocities of the spray and the ambient air were measured. The cumulative mass of the ambient air entrained into the spray was calculated by using the entrainment velocity normal to the spray boundary. The vortex structure of the spray, formed around the leading edge of the spray, showed a true rotating flow motion at low ambient pressures of 0.1 MPa, whereas at 0.4 MPa, it was not a true rotating flow, but a phenomenon of the small droplets separating from the leading edge of the spray and falling behind, due to air resistance. The development processes of the 2nd spray were considerably different from that of the 1st spray because the 2nd spray was injected into the flow fields formed by the 1st spray.

On board multiplexing communication system is regarded as a necessary technology for the future of electronic system in automobiles. Many companies are developing multiplexing systems and the ISO and SAE are active in establishing standards for communication protocols. The proposed communication protocol specifications have different specifications. Consequently, no compatible evaluation standards existed, and it was difficult to compare one protocol to another. Therefore, to assist the standardization activities of the IS0 and SAE, we have developed an evaluation method for distributed multiplexed communication systems and evaluated each of the proposed protocols using this method. These evaluations were performed from the point of view of the future users of these systems. In this paper we present the results of the experiments on distributed multiplexed communication systems each of which consists of communication IC and the proposed physical layer.

Mazda has developed new-generation V6 engines. The new V6 series comprises 2.5-litre, 2.0-litre and 1.8-litre engines. The development objective was to ensure high output performance for excellent “acceleration and top-end feel”, while satisfying “Clean & Economy” requirements. The engines also had to have a pleasant sound. Mazda selected for these engines a short stroke, 60° V-shaped 24 valve DOHC with an aluminum cylinder block. Various techniques are adopted as follows: Combustion improvement and optimization of control to achieve high fuel economy and low emissions Improvement of volumetric efficiency, inertia reduction of rotating parts and optimization of control to achieve excellent “acceleration and top-end feel” Adoption of a high-rigidity, two-piece cylinder block and crankshaft and weight reduction of reciprocating parts to achieve a pleasant engine sound Material changes and elimination of dead space to achieve a compact, lightweight engine

Lean-burn technology is now being reviewed again in view of demands for higher efficiency and cleanness in internal combustion engines. The improvement of combustion using in-cylinder gas flow control is the fundamental technology for establishing lean-burn technology, but the great increase in main combustion velocity due to intensifying of turbulence causes a deterioration in performance such as increase in heat loss and N0x. Thus, it is desirable to improve combustion stability while suppressing the increase in main burn velocity as much as possible (1). It is expected that the fluid characteristics of the in-cylinder tumbling motion that the generated vortices during intake stroke breake down in end-half of compression stroke will satisfy the above requisition. This study is concerned with the effects of enhancing of tumble intensity on combustion in 4-valve S. I. engines.

For both notchback-type and fastback-type models, it has been found that critical geometries which increase the aerodynamic drag exist, and the time-averaged wake patterns basically consist of an arch vortex behind the rear window and trailing vortices in the wake. The unsteady characteristics of the wake seem to be directly related to aerodynamic drag. However, the unsteady characteristics of these wake patterns for notchback and fastback cars were not clear. The purpose of present paper is to clarify these phenomena. We try to analyze experimentally the unsteady characteristics by measuring the velocity fluctuations in the wake, the pressure fluctuations on the trunk deck and the drag-force fluctuations acting on the model. At the same time, the analysis of the numerical simulation was made by using the same numerical model as the experimental model. The computed flow visualization behind the rear window showed a fluctuating arch vortex.

Both NOx and unburned HC were reduced by changing the direction of the flame propagation. It is generally said that the optimum ignition position of spark ignition engine is in the center of combustion chamber. However by igniting arround the chamber and propagating the flame toward the center, a smooth heat release pattern due to the decrease in the flame area and a decrease in the unburned gas entering the ring crevise can be anticipated. These effects of this combustion process, which was named the surrounding combustion process (SCP), were experimntally confirmed using the constant volume combustion vessels and the spark ignition engine equipped with six spark plugs per cylinder. Next, the steps for decreasing the number of ignitions TCre considered, and additional three spark plugs for SCP were installed in the four valve pentroof combustion chamber. With this engine, the NOx reduction and the capability of SCP to further improve the lean burn engine fuel economy were confirmed.

The “R26B” 4-rotor rotary engine is a powerplant that brought a Mazda racing car to victory in the 1991 Le Mans 24-hour endurance race. This engine was developed to achieve high levels of power output, fuel efficiency, and reliability, as required of endurance racing engines. This paper describes the basic structure of the engine, including a 3-piece eccentric shaft that represents a major technological achievement incorporated in the engine, as well as other technological innovations employed for the enhancement of the engine's power output and reliability, and for reducing its fuel consumption. These innovations include a telescopic intake manifold system, peripheral port injection, 3-plug ignition system, 2-piece ceramic apex seal, and a cermet coating on the rubbed surfaces of the housings.

The thermal fluid field in a vehicle cabin model is analyzed by the mesh free method as well as mentioned in the Part 1. This paper focuses on the steady state indoor climate in the vehicle cabin including the effect of the buoyancy, the heat generation of the driver and heat conduction through the vehicle body surface under the maximum air-cooling condition soaked in a climate chamber in the summer condition for the demonstration of the mesh free method without not only the deformation of the 3D-CAD model but mesh generation. The solar radiation distribution and heat generation through the exhaust pipe from the engine room are simply included in the analysis. Simulated results are compared with experiments in the conditions of both moving and idling states. As a result, no significant difference in air temperature between simulation and experiments can be obtained in both conditions.

Mazda announced that all customers who purchase Mazda cars are provided with the joy of driving and excellent environmental and safety performance under slogan of "Sustainable Zoom-Zoom" long-term vision for technology development. The purpose of this study is to develop a new approach of Life Cycle Assessment (abbreviated to LCA) to be applied to clean energy vehicles and new car models. The improvement of both environmental performance, e.g., fuel consumption, exhaust emissions, vehicle weight reduction, and LCA that is a useful methodology to assess the environmental load of automobiles for their lifecycles has become more important. LCA by inventory analysis, for RX-8 Hydrogen RE as a rotary engine vehicle used hydrogen as clean energy, was carried out and disclosed the world for the first time. LCA for new Mazda 5 was carried out as the portfolio of all models, previously only the specific model equipped with fuel efficiency device based on ISO14040.

In previous Life Cycle Assessment (LCA) methods, environmental burden items to be analyzed, prior to a life cycle inventory analysis, were assumed as the main factors of environmental problems regardless of the product category. Next, the life cycle inventory analysis, in which the total amount of environmental burden items emitted during the life cycle of a product was calculated, and an environmental impact assessment were performed. The environmental impact assessment was based on the initially assumed environmental burden items. The process, in other words, was a particular solution based on this assumption. A general solution unconstrained by this assumption was necessary. The purpose of this study was to develop a general method of LCA that did not require such initially assumed environmental burden items, and to make it possible to perform a comprehensive environmental impact assessment and strategically reduce environmental burden of a product.

First, this paper describes a measurement of the human back-backrest interface contours and a reduction procedure of the measured contours to reconstruct the statistical back contours of American 50 and 95-percentile male. Second, the paper illustrates the difference of the back contour between the statistical male drivers and SAE 3-D Manikin. Finally, the advantage of using the back contour model in experiment is given. The AM 50 back contour model was used as a loader to obtain the backrest pressure distribution and proved an excellent tool for backrest comfort evaluation.

In order to expand the applicable range of in-vehicle LANs down to popular cars, drastic cost reduction is essential. In addition, an in-vehicle LAN with high transmission rate and advanced functioning is extremely important for the further spreading of vehicle electronics intended to enhance vehicle intelligence. We developed the Protocol for Automotive Low and Medium Speed Network (PALMNET) as an in-vehicle LAN system and put it into practical use in 1990. Based on this, we developed a new communication protocol and three ICs for an in-vehicle LAN called the Advanced Protocol for Automotive Local Area Multiplexing Network (Advanced PALMNET), which satisfies the above-mentioned requirements and covers the medium-to-low transmission rate (up to 125kbps) to high rate (up to 1Mbps).

The planar laser induced fluorescence (PLIF) technique was applied to two dimensional visualization of OH radicals in a combustion flame. A frequency doubled Nd:YAG laser pumped dye laser was used to form a laser light sheet which excited the OH X2Π-A2Σ transition. A fluorescence image of the OH radical and a visible image of a combustion flame were simultaneously imaged by a pair of CCD cameras with image intensifiers. Measurement of the OH radical in the combustion flame could be carried out by using this PLIF technique without Mie scattering lights from soot particles and other optical disturbances. The PLIF technique was employed to study the OH radical in the combustion chamber of a spark ignition (S. I.) engine using gasoline as fuel. Measurements of the OH radical fluorescence were carried out under various operating conditions of mass burned fraction, swirl ratio and air-fuel ratio.