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In CFD (Computational Fluid Dynamics) verification of vehicle aerodynamics, detailed velocity measurements are required. The conventional 2D-PIV (Two Dimensional Particle Image Velocimetry) needs at least twice the number of operations to measure the three components of velocity ( u,v,w ), thus it is difficult to set up precise measurement positions. Furthermore, there are some areas where measurements are rendered impossible due to the relative position of the object and the optical system. That is why the acquisition of detailed velocity data around a vehicle has not yet been attained. In this study, a detailed velocity measurement was conducted using a 3D-PIV measurement system. The measurement target was a quarter scale SAE standard vehicle model. The wind tunnel system which was also designed for a quarter scale car model was utilized. It consisted of a moving belt and a boundary suction system.

Crankshafts of motorcycles require high strength, high reliability and low manufacturing cost. Recently, a reduction of Pb content in the free-cutting steel, which is harmful substance, is required. In order to satisfy such requirements, we started the development of Pb-free free-cutting steel which simultaneously enabled the omission of the normalizing process. For the omission of normalizing process, we adjusted the content of Carbon, Manganese and Nitrogen of the steel. This developed steel can obtain adequate hardness and fine microstructure by air-cooling after forging. Pb-free free-cutting steel was developed based on Calcium-sulfur free-cutting steel. Pb free-cutting steel is excellent in cutting chips frangibility in lathe process. We thought that it was necessary that cutting chips frangibility of developed steel was equal to Pb free-cutting steel. It was found that cutting chips frangibility depend on a non-metallic inclusion's composition, shape and dispersion.

A numerical calculation method, which enables the analysis of gear train behavior including non-linear elements in a motorcycle engine, was established. During the modeling process, it was confirmed that factors such as bearing distortion, radial bearing clearance and elastic deformation of a tooth flank could not be neglected because they effect the rotation behavior. To keep a high accuracy, those factors were included in the simulation model, after they were converted into the rigidity elements along the rotational direction of each gear model. In addition, the model was combined with a crankshaft behavior calculation model for a driving and excitation source. A time domain numerical integration method was used to perform the transient response simulation across a wide range of engine speeds. A jump phenomenon of response behavior of the driven gear was predicted that is a characteristic of non-linear response. The phenomenon was also observed in a physical test.

Variable-valve-actuation mechanism is considered to be one of the most suitable solutions to realize the compatibility between higher power output and performances in the practical speed range. A new variable-valve-actuation mechanism named “Shuttle Cam” was designed and studied. In this mechanism which was applied to a conventional motorcycle engine with rocker arms and gear-train-driven valve system, the cam gears move along the idler gear. And cam shafts simultaneously slide along the rocker-arm slipper surfaces which are concentric with the idler gear. Consequently valve lift varies continuously in accordance with the alteration in the rocker-arm lever ratio and the cam phasing changes simultaneously in accordance with the cam gear rotation. Result of the experiments has confirmed that the mechanism functions accurately even at high speeds up to 10,000 rpm and some improvements were achieved in power output, fuel consumption, idling quality, and exhaust-noise level.

Early activation of catalyst by quickly raising the temperature of the catalyst is effective in reducing exhaust gas during cold starts. One such technique of early activation of the catalyst by raising the exhaust temperature through substantial retardation of the ignition timing is well known. The present research focuses on the realization of quick warm-up of the catalyst by using a method in which the engine is fed with a large volume of air by feedforward control and the engine speed is controlled by retarding the ignition timing. In addition, an intake air flow control method that comprises a flow rate correction using an adaptive sliding mode controller and learning of flow rate correction coefficient has been devised to prevent control degradation because of variation in the flow rate or aging of the air device. The paper describes the methods and techniques involed in the implementation of a quick warm-up system with improved adaptability.

Manganese oxides show high catalytic activity for CO and HC oxidation without including platinum group metals (PGM). However, there are issues with both thermal stability and resistance to sulfur poisoning. We have studied perovskite-type YMnO₃ (YMO) with the aim of simultaneously achieving both activity and durability. This paper describes the oxidation activity of PGM-free Ag/i-YMO, which is silver supported on improved-YMO (i-YMO). The Ag/i-YMO was obtained by the following two methods. First, Mn⁴+ ratio and specific surface area of YMO were increased by optimizing composition and preparation method. Second, the optimum amount of silver was supported on i-YMO. In model gas tests and engine bench tests, the Ag/i-YMO catalyst showed the same level of activity as that of the conventional Pt/γ-Al₂O₃ (Pt = 3.0 g/L). In addition, there was no degradation with respect to either heat treatment (700°C, 90 h, air) or sulfur treatment (600°C to 200°C, total 60 h, 30 ppm SO₂).

To enable non-throttling operation of gasoline S.I. engine, we have manufactured engines equipped with a newly developed Hydraulic Variable-valve Train (HVT), which can vary its intake-valve closing-timing freely. The air-intake control ability of HVT engine is equivalent to conventional throttling engines. Combustion becomes unstable, however, under non-throttling operation at idling. For the countermeasure, newly designed combustion chamber has been developed. The reduction of pumping loss by the HVT depends on engine speed rather than load, and amounts to about 80 % maximum. A conventional engine-management system is not applicable for non-throttling operation. Therefore, new management system has been developed for load control.

This research investigated the mechanism of the effects of hydraulic dampers, which are attached to vehicle body structures and are known by experience to suppress vehicle body vibration and enhance ride comfort and steering stability. In investigating the mechanism, we employed quantitative data from riding tests, and analytical data from simplified vibration models. In our assessment of ride comfort in riding tests using vehicles equipped with hydraulic dampers, we confirmed effects reducing body floor vibration in the low-frequency range. We also confirmed vibration reduction in unsprung suspension parts to be a notable mechanical characteristic which merits close attention in all cases. To investigate the mechanism of the vibration reduction effect in unsprung parts, we considered a simplified vibration model, in which the engine and unsprung parts, which are rigid, are linked to the vehicle body, which is an elastic body equipped with hydraulic dampers.

A dual piston Variable Compression Ratio (VCR) engine has been newly developed. This compact VCR system uses the inertia force and hydraulic pressure accompanying the reciprocating motion of the piston to raise and lower the outer piston and switches the compression ratio in two stages. For the torque characteristic enhancement and the knocking prevention when the compression ratio is being switched, it is necessary to carry out engine controls based on accurate compression ratio judgment. In order to accurately judge compression ratio switching timing, a control system employing the Hidden Markov Model (HMM) was used to analyze vibration generated during the compression ratio switching. Also, in order to realize smooth torque characteristics, an ignition timing control system that separately controls each cylinder and simultaneously performs knocking control was constructed.

The new automatic transmission, A-HMT (Advanced Hydro-Mechanical Transmission) has been developed for the Honda ATV (All Terrain Vehicle), which is for wide applications such as utility, recreation, etc. The A-HMT system features high performance, durability and reliability attained by improving the structures from the original hydro-mechanical automatic transmission used for the scooter called “Juno”, which Honda had produced many years ago, working on the same principle. In addition to it, by applying the electronic control system, the highly responsive driveability that suits the requirements of ATV's has been realized. The A-HMT is installed in the new 500 cm3 ATV, FOURTRAX FOREMAN RUBICON, which has been introduced in the USA market since June 2000.

Traditionally, the suitability of wireless terminals for automotive use has been evaluated by conducting repeated driving tests in actual environments. However, this method of evaluation has long presented issues, and the implementation of the method itself is today becoming increasingly challenging. A method of evaluating the suitability of terminals for onboard use by generating virtual radio wave environments on a PC has therefore been developed by applying a two-stage method to multiple-input multiple-output (MIMO)-over-the-air(OTA) evaluation. The radio wave propagation characteristics necessary for the generation of these virtual radio wave environments are set using the multiple signal classification method incorporating an RF recorder. The research discussed in this paper used these methods to analyze the effect of the multipath distortion rate on sound quality in the reception of FM broadcasts.

In this research, a material model was developed that has orthotropic properties with respect to in-plane damage to support finite element strength analysis of components manufactured from a randomly oriented long-fiber thermoplastic composite. This is a composite material with randomly oriented bundles of carbon fibers that are approximately one inch in length. A macroscopic characteristic of the material is isotropic in in-plane terms, but there are differences in the tension and compression damage properties. In consideration of these characteristics, a material model was developed in which the damage evolution rate is correlated with thermodynamic force and stress triaxiality. In-plane damage was assumed to be isotropic with respect to the elements. In order to validate this material model, the results from simulation and three-point bending tests of closed-hat-section beams were compared and found to present a close correlation.

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.

An electric servo brake system applied for use on electric vehicles was applied for use on plug-in hybrid vehicles in order to achieve fuel-savings together with good brake feel and enhanced operability for plug-in hybrid vehicles. The electric servo brake system is made up of highly accurate braking pressure control that functions cooperatively with regenerative brakes together with a structure in which pedal force is not influenced by braking pressure control. The configuration of these components enabled good braking feel even when the power train was being switched from one drive mode to another. Automated pressurization functions that are intended for plug-in hybrid vehicles and that operate with electric servo brake systems were also developed. These developed functions include stall cooperative control that functions cooperatively with the power train, regenerative coordinate adaptive cruise control, and hill-start assist.

The technology to estimate engine load using the amplitude of crankshaft angular velocity variation during a cycle, which is referred to as “Δω (delta omega)”, in a four-stroke single-cylinder gasoline engine has been established in our former studies. This study was aimed to apply this technology to the spark advance control system for small motorcycles. The cyclic variation of the Δω signal, which affects engine load detection accuracy, was a crucial issue when developing the system. To solve this issue, filtering functions that can cope with various running conditions were incorporated into the computation process that estimates engine loads from Δω signals. In addition, the system made it possible to classify engine load into two levels without a throttle sensor currently used. We have thus successfully developed the new spark advance system that is controlled in accordance with the engine speed and load.

A combustion flame visualization system, for use as an engine diagnostics tool, was developed in order to evaluate combustion chamber shapes in the development stage of mass-produced spark ignition (S.I.) engines. The system consists of an image converter camera and a computer-aided image processing system. The system is capable of high speed photography (10,000 fps) at low intensity light (1,000 cd/m2), and of real-time display of the raw images of combustion flames. By using this system, flame structure estimated from the brightness level on a photograph and direction of flame propagation in a mass-produced 4-valve engine were measured. It was observed that the difference in the structure and the propagation of the flame in the cases of 4-valve and quasi-2-valve combustion chambers, which had the same in the pressure diagram, were detected. The quasi-2-valve configuration was adopted in order to improve swirl intensity.

The atomization of molten aluminum when injected during high-pressure die casting is analyzed to determine its effect in enhancing the strength of the product being cast. In the previously reported first step of this study, molten aluminum was injected into open space and its atomization was observed photographically. Now in the second step of the study, a simulation is conducted to determine how the molten aluminum becomes atomized at the injection nozzle (gate) and how this atomized material flows and fills the cavity. A new simulation method is developed based on large-eddy simulation coupled with the volume-of-fluid method. The simulation system is verified by comparing its output with photographs taken in the first step of the study. Simulations are then conducted using an approximation of a real cavity to visualize how it is filled by the atomized molten aluminum.

An analytic technology able to rapidly and accurately predict oil flows and churning torque in a transmission has been developed. The new method uses the finite difference method for analysis; with regard to wall boundaries it reproduces the shapes of physical objects by imparting boundary information to cells. This has made it a simple matter to treat the rotation and meshing of the gears, which form oil flows, and has also reduced the calculation cost. Tests of single-phase and multi-phase flows and churning torque were conducted in order to verify the accuracy of the new method. Calculation results for the flow velocity fields produced by rotating bodies, the trajectory of oil, and the behavior of the surface of the fluid displayed a good correlation with test results. Considering air entrainment in the oil, the ability of the method to reproduce these phenomena at high speeds of rotation was also increased.

Using stabilizing yaw-moment diagrams, the authors analyzed three methods of active chassis control for their effect and effective ranges during cornering maneuvers. The following results were obtained: controlling the transverse distribution of driving and braking forces cancels the changes in a vehicle's dynamic characteristics caused by acceleration and deceleration. Controlling the distribution of roll stiffness is only effective in ranges with high lateral acceleration, and the effect varies depending on the longitudinal weight distribution. Controlling the rear wheel steering angle is most effective in a range with a small side slip angle, but this effect decreases with an increase in the angle, especially during deceleration.

This paper will discuss the stress reduction of the worm wheel for an electric power steering (EPS) system. The research discussed in this paper focused on the worm wheel, the EPS component that determines the maximum diameter of the system. If the stress of the worm wheel could be reduced without increasing in size, it would be possible to reduce the size of the worm wheel and EPS system. In order to reduce the stress of the worm wheel, the conventional design method has extended the line-of-action toward outside of the worm wheel to increase the contact ratio of the gears and these method lead to an increase in the outer diameter. In order to address this issue, past research proposes the basic concept to extend line-of-action toward the inside of the worm wheel. And this new meshing theory was named MUB (Meshing Under Base-circle) theory. In this paper, characteristics of meshing of the gear formed by MUB theory are determined in more detail.