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Currently, there is a growing demand for application of plastic coverings for motorcycles in the market. Accordingly, decorative features for plastic coverings are increasingly important to enhance the attractiveness of exterior designs of those motorcycles. Under these circumstances, the magnetically formed decorative painting had been adopted to a mass-production model sold in Thailand in 2008. Magnetically formed decorative painting is a method in which the design patterns are formed by painting a material that contains flakes movable along with magnetic fields, while applying magnetic sheets in the ornamenting design shapes underneath the part being painted. It offers a three-dimensional appearance even though its surface has no protrusions or indentations. The degree of three-dimensionality on the paint surface appearance was defined as “plasticity” [1] (a term used in pictorial arts).

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.

Exhaust heat recovery units that use a thermoelectric element generate electricity by creating a temperature difference in the thermoelectric element by heating one side and cooling the other side of the thermoelectric circuit (module). In this case, the general structure does not directly join the thermoelectric module with the heat sink, and instead presses the thermoelectric module against the heat sink using bolts or other means in order to prevent thermoelectric element damage due to the difference in linear expansion between the cooled and heated sides of the thermoelectric module. However, this poses the issues associated with a complex, heavy and expensive structure. Therefore, a new vacuum space structure was devised that houses the thermoelectric module in a vacuum chamber and presses the module against the heat sink using atmospheric pressure.

A sports car exhibits many challenges from an aerodynamic point of view: drag that limits top speed, lift - or down force - and balance that affects handling, brake cooling and insuring that the heat exchangers have enough air flowing through them under several vehicle speeds and ambient conditions. All of which must be balanced with a sports car styling and esthetic. Since this sports car applies two electric motors to drive front axle and a high-rev V6 turbo charged engine in series with a 9-speed double-clutch transmission and one electric motor to drive rear axle, additional cooling was required, yielding a total of ten air cooled-heat exchangers. It is also a challenge to introduce cooling air into the rear engine room to protect the car under severe thermal conditions. This paper focuses on the cooling and heat resistance concept.

Glass fiber reinforced plastic of polyamide is applied as one of the materials used for the high strength exterior parts of a motorcycle, such as a rear grab rail or a carrier, to which both strength and good exterior appearance are required. However, Glass Fiber reinforced Polypropylene (PPGF), which is relatively inexpensive material, has a property that the contained glass fibers are prone to be exposed at the surface and, therefore, the requirements for good appearance are hardly met by using PPGF. In this study, Heat and Cool molding method (H&C molding) was employed to realize a cost reduction by using PPGF yet without applying painting process, and the established method was applied to mass production while fulfilling the requirements for a good exterior appearance. In H&C molding, the metal molds are heated up by steam and cooled down by water after molding.

Vehicles are required durability in various environments all over the world. Especially water resistance on flooded roads is one of the important issues. To solve this kind of problem, a CFD technology was established in order to predict the water resistance performance of the vehicle at the early development stage. By comparison with vehicle tests on flooded roads, it is clarified the following key factors are required for accurate prediction; the vehicle velocity change, the vehicle height change and the air intake flow rate. Moreover, these three key factors should be appropriately determined from vehicle and engine specification to predict water intrusion for flooded roads at the early stage of development. In this paper, a methodology which determines appropriate analysis conditions mentioned above for flooding simulation from vehicle and engine specification is described. The methodology enables us to determine whether the vehicle provides sufficient waterproofness.

A hybrid simulation model in the transient bench was developed to realize the characteristics of the transient behavior and the fuel economy equivalent to that of a real vehicle. The motors and the batteries that were main components of the hybrid vehicle system were simulated as constructive modules, the functions of which have the integrated control and the input/output (I/O) function with real components. This model enabled us to accommodate a variety of auxiliary (AUX) I/O flexibly. The accuracy of the model was verified by the transient characteristics of the engine and the fuel economy result through correlation with a mass-produced vehicle. Furthermore, the flexibility of the model to a variety of AUX I/O was examined from the simulation test of the vehicle equipped with the waste heat recovery (WHR) system.

Simulation was employed to estimate the fuel economy enhancement from the application of an exhaust heat recovery system using a thermoelectric generator (TEG) in a series hybrid. The properties of the thermoelectric elements were obtained by self-assessment and set as the conditions for estimating the fuel economy. It was concluded that applying exhaust system insulation and forming the appropriate combination of elements with differing temperature properties inside the TEG could yield an enhancement of about 3% in fuel economy. An actual vehicle was also used to verify the calculation elements in the fuel economy simulation, and their reliability was confirmed.

Several processes, such as casting, forging, and pressing, were used in the manufacturing of the Honda NSX's aluminum chassis. For casting, a high grade method which utilizes program control of mold temperature was developed and put into practical use. For optimum forging, a selection of cold and hot processes were investigated and a process to save energy during processing was pursued. As a result, an overall weight reduction of approximately 50% was achieved.

A new brake system, able to make efficient use of regenerative braking while maintaining excellent brake feel, has been developed to increase the fuel economy of hybrid vehicles. A hydraulic servo was used as a base to enable mechanical operation of the service brakes; solenoid valves and brake fluid pressure sensors were added to this base to make it possible to control brake line pressure as demanded. The use of a stroke simulator in the hydraulic servo prevents brake feel from being affected by the control of the brake pressure. In addition, high-accuracy brake pressure control that functions cooperatively with the regenerative brakes is enabled, resulting in stable braking effectiveness.

A compact, low-cost fuel pump module has been developed for use in motorcycles with a small-displacement engine. Various considerations are given to make the module as compact as possible. The pump motor, which is one of the major component parts, is down-sized specifically for applications to small-displacement engines. The pressure regulator uses a simple construction consisting only of a ball and a spring without a diaphragm. Especially noteworthy is that with the volume reduced by approximately 40% from the conventional pressure regulator while using the construction that reduces self-excited vibrations caused by fuel pressure pulsations, the pressure regulator contributes significantly to the down-sizing and cost reduction of the module. Furthermore, the down-sized module remarkably reduces the size of fuel pump mount surface, allowing a modification from the flat-surface sealing to the radial sealing.

As a result of recent EPA (U.S. Environmental Protection Agency) gasoline permeation control regulations, the fuel tanks on motorcycles and ATVs (All-Terrain Vehicles) are required to change to lower gasoline permeation performance on 2008 models. Therefore, we determined to use a multilayer plastic fuel tank. There are some molding issues that are peculiar to motorcycle and ATV fuel tanks. First, when the insert is blow molded, there is a reduction in welding strength. Second, peeling of the adhesion occurs on impact in the inserted parts. Third, saddle shapes with large ductility deformation are easy to be punctured during molding. Finally, the appearance of the fuel tank is not acceptable. In order to address the first issue, the welding performance, the drawdown of parison and the melting damage of insert parts were balanced, focusing attention to the temperatures of the parison and the insert.

A hexavalent-chromium-free metal gasket for PWC engines was developed to correspond to the ELV (End of Life Vehicle) directive. In order to enhance the adhesive property, the ion capture to trap the chloride ion, an anti-rust pigment to reform the chemical coating, and an inorganic sealer to stop the passage of chloride ion were added to the adhesive and rubber raw material. A good adhesive property and rubber physical property was obtained through the addition of an anticorrosive pigment. The rubber vulcanization condition in the manufacturing process was reviewed. As a result, without modifying the current compound coating line for mass-production, a gasket with a blistering resistance more than hexavalent chromium conversion coating equivalence and coating adhesion was developed when using salt water for engine cooling.

In recent years, the increased use of electric power steering in vehicles has increased the importance of issues such as making systems more compact and lightweight, and dealing with increased development man-hours. To increase development efficiency, the use of a “Hardware in the loop simulator” (HILS) is being tested to shift from the previous development method that relied on a driver's subjective evaluation in an actual vehicle test to bench-test development. Using HILS enables tasks such as specification studies, performance forecasts, issue identification and countermeasure proposals to be performed at an early stage of development even when there is no prototype vehicle. This report describes a case study of using HILS to solve the issues of reducing the load by adjusting the geometric specifications around the kingpin and eliminating the tradeoff by adding a new EPS control algorithm in order to make the electric power steering (EPS) more compact and lightweight.

The Vehicle Stability Assist (VSA) system can generate sufficient forces to rapidly change the vehicle's motion. We can use this capability to effectively control the vehicle's behavior, but we must pay careful attention to ensure its reliability. The VSA system should be precisely tuned for each vehicle's characteristics in order to satisfactorily control performance without any unnecessary intervention or any excessive warnings. Usually extensive field tests are necessary to precisely tune the VSA system. This paper presents a practical method to tune the VSA system with Hardware-In-the-Loop (HIL) simulations in the final stage of its development. Due to the application of this procedure, both high control capabilities and reliability of the VSA system can be achieved.

Increasing the strength of materials is effective in reducing weight and boosting structural part performance, but there are cases in where the residual strain generated during the process of manufacturing of high-strength materials results in a decline of durability. It is therefore important to understand how the residual strain in a manufactured component changes due to processing conditions. In the case of a connecting rod, because the strain load on the connecting rod rib sections is high, it is necessary to clearly understand the distribution of strain in the ribs. However, because residual strain is generally measured by using X-ray diffractometers or strain gauges, measurements are limited to the surface layer of the parts. Neutron beams, however, have a higher penetration depth than X-rays, allowing for strain measurement in the bulk material.

An attempt was made to apply the index U* in detail analysis of load paths in structural joints under static load, using as examples coupling structures of two joined frames with hat-shaped sections, and T-beam joint structures each including spot welds, both of which are widely used in automotive body structures. U* is a load path analysis index that expresses the strength of connection between load points and arbitrary points on a structure. It was possible to identify areas making up load paths by means of the magnitude of U* values, and to clarify the areas that should be coupled in order to achieve effective load transfer to contiguous members. In addition, because it is possible to determine whether or not each section of a structure possesses the potential for load transfer using U* analysis, the research also demonstrated that U* could be used as an indicator of joint structures providing efficient load transfer.

A multi-body simulation coupled with a tire model enables the prediction of forces generated on a vehicle when driven over a rough road profile. As the durability of a vehicle depends on these generated forces, the accuracy of the predicted forces is a crucial factor in assessing durability. A new test setup has been used to evaluate the accuracy of the simulation. Due to good reproducibility, the results from physical testing and simulation can be compared in the time domain. This time domain comparison makes it possible to detect any problems associated with the simulation which need to be improved. This new evaluation method is very suitable to full vehicle simulations involving rough road profiles. It was also confirmed that the suspension model with tire model evaluated in this project had an adequate capability for curb strike simulation by a full vehicle.

Lane departure prevention systems are able to detect imminent departure from the road, allowing the driver to apply control to prevent lane departure. These systems possess enormous potential to reduce the number of accidents resulting from road departure, but their effectiveness is highly reliant on their level of acceptance by drivers. The effectiveness of the systems will depend on when they are providing driving assistance, what level of laxness in terms of maintaining contact with the steering wheel is allowed on the part of the driver, and what level of assistance the system provides. This paper will discuss research on the minimum necessary contact and contact strength with the steering wheel on the part of the driver when a lane departure prevention system is in operation.

A multi-use road simulator for reproducing various road loads on motorcycles and buggies has been developed on a test bench by using computer-controlled hydraulic actuators. The device is controlled by a low-priced personal computer and an interface system with custom software. An unique feature is the capability to simulate loads related to such phenomena as the bottoming of suspension and the movement of a telescopic type front fork on the road.