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Technical Paper

A Prediction Method of Vehicle Vibration caused by the Drive Torque Fluctuation at Takeoff

2007-08-05
2007-01-3499
Clutch judder phenomenon is known as a vehicle vibration caused by the drive torque fluctuation from the clutch unit at takeoff. In this paper, a novel strategy for improving clutch judder phenomenon caused by the movement/tolerance between mechanical parts comprising the clutch system is introduced. In order to simulate the movements of the clutch system and of the vehicle drivelines precisely, we used numerical analysis software and have achieved high-grade prediction of the clutch torque fluctuation and the vehicle vibration. Using this method, we have developed a high-quality clutch system that enables smoother clutch engagement, and at the same time, development efficiency has been improved.
Technical Paper

Development of High-Strength Carbo-Nitriding Process

2001-10-01
2001-01-3373
One of the problems concerning T/M is conventionally how “Improving the input torque as the engine gets higher power” and “Making product lighter in weight and more compact to improve the fuel consumption” can be realized at the same time. To realize these things at the same time, it is needless to say that the gears must be stronger. For the “pitting fatigue strength” which is quoted as a problem lately, the fatigue mechanism has not been clarified, yet. Therefore, it is now a big problem how to achieve high strength. In the meantime, we tried to develop the production engineering for “finer crystal grains” and “fine-dispersion precipitation of carbo-nitrides,” and succeeded in improving “pitting fatigue strength” remarkably. Such results will be reported in the following sections:
Technical Paper

Development of New Aisin Transmission for Medium Duty Truck and Bus

1994-11-01
942283
AISIN SEIKI CO., Ltd. Started the production of electronically controlled hydraulic automatic transmissions for medium-duty trucks and buses in 1989. The number of vehicles on the Japanese market in which this system is adopted is increasing steadily. After re-examining market needs, AISIN SEIKI CO., Ltd. has newly developed an electronically controlled hydraulic automatic transmission A580 which focuses on improved input capacity, driving performance and fuel economy for medium-duty trucks and buses and lessens learnt from experience.
Technical Paper

Development of Robust Motor Servo Control for Rear Steering Actuator Based on Two-Degree-of-Freedom Control System

1999-03-01
1999-01-0402
Rear steering system can improve vehicle stability using active control of the rear wheel angles. For designing the rear steering system, environmental conditions, performance deterioration due to aging and component variation as a result of manufacturing tolerance under mass production must be taken into consideration. We have applied two-degree-of-freedom (2DOF) feedback control with feedforward control for the motor servo control so that the rear steering actuator can track the target rear steering angle accurately and stably. The control system is designed based upon a nominal mathematical model and its variation range. As a result, the rear steering actuator can be controlled with excellent performance and high reliability. This paper describes the mathematical model construction in the frequency domain and a robust motor servo controller design based on 2DOF feedback control with feedforward control.
Technical Paper

Development of Roll-Forming Technology With Gradual Cross-Sectional Change

1997-05-12
971741
As a process that enables the high-speed and continuous forming of lengthy materials with a constant cross-sectional configuration, roll forming offers much higher productivity than the stamping process. However, in case a change must be made to the shape of the cross section, the material must normally be stamped or joined with a part containing a separate shape. This affects productivity, increases the number of pieces, and degrades the material's appearance. This report describes the roll-forming technology that we developed, in which the cross section of the material can be changed gradually. This method adopts a system which uses a movable and rotatable roll-stand that enables high-speed, continuous roll-forming processes.
Technical Paper

Development of Switched Reluctance Motor for EV Traction System

2001-03-05
2001-01-0957
Switched Reluctance Motor (SRM) mainly has two advantageous characteristics such as no magnet and simple construction. These characteristics contribute lower cost and higher reliability compared with other motor systems such as brushless permanent magnet motors or induction motors. However, acoustic noise and output torque ripple should be improved when the SRM is applied to a traction system for passenger electric vehicle since these characteristics directly affect vehicle quietness and drivability. In this paper, we describe a system configuration of the SRM traction system for passenger electric vehicle. The SRM traction system includes an electric motor, transmission gears and power inverter module. Then, an approach to improve acoustic noise and output torque ripple is introduced. Generation mechanisms of acoustic noise and output torque ripple are analyzed.
Journal Article

Development of the All-Surface Plated Smart Handle Through In-Vapor Deposition Technology

2016-04-05
2016-01-0543
There are such outside door handles called smart handles which have a transmitting antenna, a lock/unlock sensor, and a sensor detection circuit, with which operation of door lock is possible just by "touching" the electrostatic-capacitance type sensor of the handles.As the design of the outside handles, body color painting and Cr plating are adopted. However, if plating is applied over the entire surface of a smart handle, electromagnetic waves transmitted from the antenna will be blocked since plating material is electrically conductive. In addition to this, touching a part other than the sensor may change the electrostatic-capacitance of the sensor, which results in unwanted functioning of the lock/unlock sensor. Because of this, only part of the handle, which does not hinder the transmission of electromagnetic waves and does not cause unwanted functioning, is covered by plating, that is called, "Partially plated specifications" (Figure 1).
Technical Paper

Development of the Inspective Devices Using 3D Visual Sensor for Measuring Volume of the Piston Combustion Chamber at Production Line

1994-03-01
940665
Automating the inspection of the piston combustion chamber volume is difficult and prevents establishing an unmanned machining process of the piston in the future. So, we developed an inspection technique which uses a Range Finder, non-contact visual sensor, and calculate the chamber volume by integrating 3D position data. We applied this real-time measurement technique which enables 100 % inspection to our production lines. Then, we developed the “Defect Free Production Line”, which calibrates itself by feeding back the measured volume data to the machining process. Our paper will explain this inspection technique and our “Defect Free Production Line”.
Technical Paper

Development of the Quick Response Tandem Brake Booster

1997-02-24
971110
Responsiveness is one of the main characteristics of a brake booster. The design of a tandem booster, with its two boosting chambers, has a negative influence on high responsiveness. This report, using the CFD method for the air flow analysis, shows the way we found the most suitable air passage within the space of the given design of the current production tandem booster.
Technical Paper

Drive Train Vibration and Acoustic Noise Reduction Control of Switched Reluctance Motor for Electric Vehicle

2002-06-03
2002-01-1887
Switched Reluctance Motor (SRM) mainly has two advantageous characteristics such as no magnet and simple construction. These characteristics contribute lower cost and higher reliability compared with other motor systems such as brushless permanent magnet motors or induction motors. However, SRM has disadvantages that are its torque ripple and acoustic noise in particularly. Moreover, the resonance frequency mode of a motor system is excited by torque ripple, and drive train vibration is caused. These noise and vibration should be suppressed when the SRM is applied to a traction system for passenger electric vehicle since these characteristics affect vehicle quietness and drivability. In this paper, we describe an approach to suppress drive train vibration and acoustic noise.
Technical Paper

Evaluation of Production Systems Using Artificial Intelligence - Application to Doorlock Assembly System

1995-02-01
950821
As a part of our process engineering (planning) steps and in order to shorten the initial flow control after the implementation of a production system, we have been adopting countermeasures for defects that have been forecasted by the application of FMEA. However, due to this having to be done with limited information (which is dependent upon the skill level of the operator) and due to the fact that the effects of each particular countermeasure are not fully understood, we cannot be certain that the measures implemented during the planning stages are thorough enough. The current situation is that countermeasures for most issues are being handled during the initial flow control stages based on the trial-and-error method. Given this situation, normally, it would take us more than three months from the time of line-off (start of production) to achieve our target rate of capacity utilization.
Technical Paper

Experimental Study of Reduction Methods for Clutch Pedal Vibration and Drive Train Rattling Noise from Clutch System

1993-11-01
932007
When a clutch pedal is operated, the clutch pedal vibration and interior noise are mostly affected by the dynamic characteristics of the clutch cover assembly. We achieved a high correlation between vehicle test data and results using this method when exciting not only clutch system but also the engine system. Finally, we developed an excitation method to evaluate the dynamic characteristics of the clutch cover assembly.
Technical Paper

Newly Developed Long-Life Potentiometer for Automobiles

1993-10-01
932868
Aiming at improved reliability and cost reduction of position sensors for automobiles, we tackled with the challenge of developing long life contact type potentiometer which has a simple construction and cost advantage. We made clear the wear characteristics of the resistor materials and the mechanism how noise occurs, and developed a long life, low noise resistor material, and the double - layer resistor structure which has excellent characteristic in durability. We also clarified the ways of using brushes according to applications through the investigation of the relationship between the contact shape and the amount of wear of the resistor. Based on these investigation, we have developed a highly reliable throttle position sensor and a long life vehicle height sensor.
Technical Paper

Sensor-Less Position Control System for Memory Seat

2003-03-03
2003-01-0095
We have developed Sensor-less Memory Seat system that requires no position sensors such as Hall ICs etc.. It detects the rotation of DC motor by current ripple signals in motor operating current. The developed Sensor-less position control system can attenuate a wide frequency variation of Motor current noise which varies depending on motor condition and convert small current ripples to Pulse signals in proportion to the rotation of DC motor. We realized low cost position control method for use in Memory Seat system.
Technical Paper

Study on Stabilization Friction Coefficient of Disc Brake Pads in Cold Condition

1997-10-06
973030
Resolving the brake squeal that occurs under various environments is a major topic, and a resolution method is eagerly anticipated. We focused on the phenomenon that, amid various environmental conditions, squeal occurs easily when an automobile has been left standing in a cold environment. We checked the details focusing on the friction coefficient (hereafter, μ). As a result, we found that μ increases when squeal is generated, and that the sliding surface film contributes to the μ behavior. We studied measures to be taken to increase the μ in cold conditions.
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