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Accuracy of numerical simulation has to be evaluated through the actual phenomenon such as experiment or measurement and then it can be employed to design the air-conditioning system of car cabin at the development phase. Scaled model of vehicle cabin was created by the Society of Automotive Engineers of Japan (JSAE) and the experiment was performed to obtain the detailed information of heat transfer characteristics inside the cabin under the non-isothermal condition. The sheet heaters were put to the inner surface of the acrylic cabin and they supplied certain amount of heat. The temperatures of inner and outer surface and air were measured to evaluate the thermal environment of the cabin. The results lead to enhancement of the data of the standard model of the cabin.

Considerable amounts (400 ∼ 600 thousand tons) of waste vegetable oil in Japan are still flushed down the drain every year. Utilization of waste vegetable oil for diesel fuel leads to two advantages for environmental protection, to reduce CO2 emission from engines and to avoid water pollution of rivers. In this study, combustion characteristics of waste vegetable oil methyl ester (WME) are investigated in detail by not only engine test run but also observation of burning flames in a visual engine. As results indicate, WME shows rather better combustion state in the visual engine and lower smoke emission from a high-speed DI test engine than gas oil. Moreover, by emulsifying WME with water, further improvement of combustion and more than 18 % reduction of NOx emission is carried out.

Test and validation of control systems for hybrid vehicle power trains provide a unique set of challenges. Not only does the electronic control unit (ECU), or pair of ECUs, need to smoothly coordinate power flow between two or more power plants, but it also must handle the power electronics' high-speed dynamics due to PWM signals frequently in the 10-20 kHz range. The trend in testing all-electric and hybrid-electric ECUs has moved toward using field-programmable gate arrays (FPGAs) as the processing node for simulating inverter and electric motor dynamics in real time. Acting as a purpose-built processor colocated with analog and digital input and output, the FPGA makes it possible for real-time simulation loop rates on the order of one microsecond.

It is well known that tire pressure lower than normal reduces the safety of the vehicle. In consideration of active safety, a new tire pressure warning system for Advanced Safety Vehicle (ASV) has been developed. This involves the four mechanical pressure sensors, a simple structure on each wheel. This system can independently detect pressure of each tire with a high degree of precision under a broad range of vehicle speeds, and requires no adjustment. This paper describes the principle and the performance of this system.

With the popularization of easy driving in Japan, the quest to improve the fuel economy and vehicle performance of a small car with a torque converter automatic transmission (AT) has led to the development of the Electro Continuously Variable Transmission (ECVT). The Subaru ECVT which combines an electronically controlled magnetic powder clutch with the van Doorne's steel belt drive system employs a couple of conventional synchromeshes as a means of forward/reverse change-over mechanism and simple hydraulic control valves. This combination has realized smoothness and quick response of CVT operation and provides a compact size for the CVT with the weight of 45.4 kg. Fuel economy of Subaru Justy ECVT car with the one liter engine is thus improved by 15 to 20 % in Japanese 10-mode test cycle and at the 60 km/H constant speed respectively in comparison with that of three speeds torque converter AT.

For the 1990 model year Fuji Heavy Industries will introduce Subaru “Legacy” with a newly designed horizontally opposed 4-valve engine series including a 2.2 Lt for the US market. The new engine series which has been named “Boxer” to symbolize power has been designed and developed making the best use of the advantages of horizontally opposed engines and our twenty three years experience in producing them. The major advantages of horizontally opposed engines are low noise and vibration, with high specific power and design flexibility which are well featured in these new engines. This paper is intended to provide a brief overview of the new engine program with descriptions of unique design features.

Coating has been recently considered as having good potential for use in preventing in-cloud icing on the leading edge of the lifting surfaces of an aircraft in cold climates. In terms of wettability, a coat may exhibit hydrophobicity or hydrophilicity depending on its specific properties. The same applies to the ice adhesion strength, which may be either high or low. It is thus necessary to determine which type of anti-icing or de-icing coat would be appropriate for a particular application in order to fully utilize its specific properties. Notwithstanding, a coat is incapable of preventing ice accretion by itself, and a perfect icephobic coat is yet to be developed. Coating is also sometimes applied to the surfaces of electrical heaters and load-applying machines to enable them to function more effectively and use less energy. The coating used for an electric heater, for instance, should be hydrophobic because of the need for rapid removal of molten water from the surface.

The low frequency noise, vibration and harshness (NVH) characteristics play a critical role in the design of vehicle Body-In-White (BIW) structures. Lower order modes influence the structural reliability of the vehicle as well as its ride and handling characteristics. Special consideration is given to ensure that they are spaced apart and not coincident with the frequencies of other vehicle subsystems (e.g. engine and chassis). The added stiffness required to improve the NVH characteristics comes at a cost: increased BIW mass, which affects vehicle dynamics, fuel economy, and point mobilities/structural inertances. This paper documents a procedure to balance BIW build cost, mass and structural performance through an integrated optimization process.

The authors worked in the Engine Department at Nakajima Aircraft Co. from 1936 to 1945. Nakagawa was in the Engine Design Department, where he was involved in designing the air-cooled, radial double-row 14-cylinder 1,100 hp Sakae Model 20 engine and the radial 18-cylinder 1,800 - 2,000 hp Homare engine. Mizutani was a field engineer for these two engines and other engines. During that period we gained much experience in fuel and lubrication systems. Before the authors joined Nakajima, the company's engine development team had already developed a carburetor-based fueling system, which was subsequently used in all Nakajima engines. From 1941 on, all newly designed engines had to use 87-92 motor octane fuel by order of the Army and Navy. It was a very difficult task to change the engine specifications to meet this requirement, particularly for the Homare engine, which was initially designed for 100-octane fuel. The authors explain various steps taken to overcome this difficulty.

Fuji Heavy Industries Ltd. has introduced a new electronically controlled full-time 4WD automatic transmission system for Subaru. This system consists of the newly developed computer controlled 4-speed automatic transmission which drives front wheels directly and a multi-plate transfer clutch system which transmits the regulated torque to the rear wheels. Various sensor signals such as front and rear wheel speeds, throttle opening and gear position are sent to the transfer clutch electronic control unit, and the transfer clutch is actively controlled to provide the optimum traction distribution of the front and rear wheels under any road conditions.

“Do not let an accident happen” - SUBARU believes this is the ultimate safety measure and has been actively working on the establishment of active safety technology such as the commercialization of an autonomous driving support system. The advancement of the technology needs the development of the interface between the driver and vehicle (human-machine interface). This study examined whether intonated voice can be applied to warning. The results indicated the effectiveness of intonated voice as a means of providing auditory information and warning to drivers.

The mixture formation by fuel spray impingement (OSKA system) was applied to a small direct-injection diesel engine in order to reduce the wall quenching- induced emissions, i.e., the emissions of THC and soluble organic fractions (SOF). Experiments were carried out using a single-cylinder engine, fitted with various piston cavity geometries, ran under a wide range of compression ratios and fuel injection specifications. The piston cavity was designed as a centrally located reentrant type. The combination of the high squish flow and the weak penetration of the OSKA spray was very effective in reducing harmful emissions. A short ignition delay, under the retarded fuel injection timing, was obtained because of the high compression ratio. The OSKA DI diesel engine showed reduced NOx, smoke, and THC emissions without deterioration of the fuel consumption compared to modern DI diesel engines used in automotive applications.

This paper introduces a development of pedestrian protection analyzing technologies and its practical application to an actual automobile. The analyzing technologies have two types, an analyzing tool for initial design stage utilizing Microsoft Excel and a crash analyzing software MADYMO, and a large scale FEM (Finite Element Method) utilizing a crash analyzing software PAM-CRASH. These technologies were applied to an actual car development to study the efficient structure. In this paper, a development of a bumper structure with high leg protection performance is reported. The developed bumper was tested and evaluated on an actual vehicle and was proven to have high leg protection performance. The leg protection analyzing technology could estimate the leg injury of a actual vehicle test within 10% prediction error.

Behaviors of shock waves in knocking phenomena were observed in detail and influences of low temperature reaction on the flame and spontaneous ignition of end gas were investigated through experiments using high-speed direct and schlieren photography. As a result, it was found that light emission of shock waves, that is an indicator of pressure, rose when the shock waves collided with the cylinder wall and that pressure waves arose by low temperature reaction before knocking occurrence. Flame oscillation was caused by pressure waves. It is presumed that pressure waves influence spontaneous ignition.

Unlike the conventional bleed-air method, using electro-thermal anti-/de-icing methods to completely evaporate all of the supercooled water droplets that collide with the leading edge wing surface of aircraft flying in a freezing environment is not easy in terms of technical feasibility and energy efficiency[1]. If the leading edge is warm enough to stay free from frozen water droplets, the water moves backward while still maintaining the liquid phase. The droplets may freeze somewhere on an unheated surface after being halted for some reason and stick on the surface. Ice gradually accumulates as this process is repeated. Therefore, liquid water must be removed from the surface as soon as possible if the electrothermal method is employed for icing prevention. One answer to this problem is coating the surface with a superhydrophobic paint.

This paper details the air-fuel mixing process in a gasoline direct injection (DI) engine. Laser measurement techniques such as particle image velocimetry (PIV) and laser induced fluorescence (LIF) were employed on the optical engine with a transparent cylinder to analyze the in-cylinder flow and fuel vapor concentration. In addition, firing tests were conducted using an actual engine. Test results showed that the multi-stage injection is effective for air-fuel mixing and improvement of combustion stability.

Adhesively bonded structures, that is, metal to metal bonding of cabin and wing skin and honeycomb sandwich panel of pressure bulkhead, are used in newly developed general aviation pressurized piston twin aircraft, Rockwell/Fuji Model 700. This paper presents the design consideration of each bonded structure showing the advantages of bonding, and its quality control procedure used in subject aircraft.

A new combustion method of high compression ratio SI engine was studied and proposed in order to achieve higher thermal efficiency of SI engine comparable to that of CI engine. Compression ratio of SI engine is generally restricted by the knocking phenomena. A combustion chamber profile and a cranking mechanism are studied to avoid knocking with high compression ratio. Since reducing the end-gas temperature will suppress knocking, a combustion chamber was considered to have a wide surface at the end-gas region. However, wide surface will lead to high heat loss, which may cancel the gain of higher compression ratio operation. Thereby, a special cranking mechanism was adopted which allowed the piston to move rapidly near TDC. Numerical simulations were performed to optimize the cranking mechanism for achieving higher thermal efficiency. An elliptic gear system and a leaf-shape gear system were employed in the simulations.

To avoid knocking phenomena, a special crank mechanism for gasoline engine that allowed the piston to move rapidly near TDC (Top Dead Center) was developed and experimentally demonstrated in the previous study. As a result, knocking was successfully mitigated and indicated thermal efficiency was improved [1],[2],[3],[4]. However, performance of the proposed system was evaluated at only limited operating conditions. In the present study, to investigate the effect of piston movement near TDC on combustion characteristics and indicated thermal efficiency and to clarify the knock mitigation mechanism of the proposed method, experimental studies were carried out using a single cylinder engine with a compression ratio of 13.7 at various engine speeds and loads. The special crank mechanism, which allows piston to move rapidly near TDC developed in the previous study, was applied to the test engine with some modification of tooling accuracy.

In the initial design stage, it is important to discuss what kind of body concept is effective from a viewpoint of environment burden reduction. This paper describes the importance of both weight reduction and recycling through conducting LCA (Life Cycle Assessment) for four kinds of body structures. In addition, using each software, DFMA (Design for Manufacture and Assembly), DFE (Design for Environment) and LCA to parts unit, each effectiveness was discussed through the assessment of the material-hybrid body.