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The goal of the present study was to develop a new legform impactor that accurately represents both the impact force (i.e., force between the leg and impacting mass)and leg kinematics in lateral impacts simulating car-pedestrian accidents. In its development we utilized the knee joint of the pedestrian dummy called Polar-2 (HONDA R&D) in which the cruciate and collateral ligaments are represented by means of springs and cables, the geometry of the femoral condyles is simplified using ellipsoidal surfaces, and the tibial meniscus is represented by an elastomeric pad. The impactor was evaluated by comparing its responses with published experimental results obtained using postmortem human subjects (PMHS). The evaluation was done under two conditions: 1)impact point near the ankle area (bending tests),and 2)impact point 84 mm below the knee joint center (shearing tests). Two impact speeds were used: 5.56 m/s and 11.11 m/s.

To investigate the events that could arise when fighting fires in vehicles with carbon fiber reinforced plastic (CFRP) hydrogen storage cylinders, we conducted experiments to examine whether a hydrogen jet diffusion flame caused by activation of the pressure relief device (PRD) can be extinguished and how spraying water influences the cylinder and PRD. The experiments clarified that the hydrogen jet flame cannot be extinguished easily with water or dry powder extinguishers and that spraying water during activation of the PRD may result in closure of the PRD, but is useful for maintaining the strength of CFRP composite cylinders for vehicles.

A simulation has been developed at the Japan Automobile Research Institute to predict the fuel economy of HEVs, which are currently being developed in the advanced clean energy vehicle research and development project of MITI/NEDO (ACE Project). The ACE Project includes six types of HEV. The effect of hybrid components efficiency on fuel economy was evaluated by sensitivity coefficient. The results show that the fuel economy of HEVs can improve that of the base vehicle by two times. The sensitivity coefficient of the battery is largest in the FCEV, while that of the motor is largest in the series or series/parallel HEVs.

Acidified 2,4-dinitrophenylhydrazine (DNPH) solution, or DNPH-impregnated cartridges are commonly used for the collection of automotive exhaust carbonyl compounds. There are some DNPH-carbonyl compounds in not in use DNPH cartridges and DNPH solution. Furthermore, concentrations of automotive exhaust carbonyl compounds are decreasing according to improvement of the purification technology for automotive exhaust. Automotive exhaust carbonyl compounds become to be difficult to be analyzed with DNPH collection method, because of these two reasons. It is thought that reliable analysis of acrolein in automotive exhaust is very difficult because concentration of DNPH-acrolein in extracted solution is not stable. Furthermore, it is found out that DNPH-acrolein in DNPH-cartridge is disappeared for short time storage in this research.

ISO26262 was intended only for passenger cars but can be applied to motorcycles if the Controllability (C) is subjectively evaluated by expert riders. Expert riders evaluate motorcycle performance from the viewpoint of ordinary riders. However, riding maneuvers of ordinary riders have not been confirmed by objective data. For this reason, it is important to understand the basic characteristics of riding maneuvers of both expert and ordinary riders. This study seeks to confirm the compatibility between the riding maneuvers of expert riders and those of ordinary riders. The riding maneuvers and vehicle behavior of four expert riders and 16 ordinary riders were compared using the results of a test assuming normal running.

The hydrogen consumption of fuel cell vehicles (FCV) can be measured by the gravimetric, pressure and flow methods within a ±1% error. These are the methods acknowledged by ISO and SAE [1, 2], but require the test vehicles to be modified in order to supply hydrogen from an external, rather than the onboard tank. Consequently, technical assistance of the vehicle manufacturer is necessary for this modification, while various components in the test vehicle must be readjusted. For these reasons, a measurement method free of vehicle modification is in great demand. The present study therefore developed an “oxygen balance method” which determines the amount of hydrogen that has reacted with oxygen in the fuel cell stack by measuring the oxygen concentration in exhaust gas.

Hydrogen concentration during combustion in a confined space with a ceiling was investigated. The results indicated that steady-state hydrogen concentration was highest at the ceiling surface for all hydrogen flow rates. When hydrogen concentration was 10-20%, weak flame propagation occurred at the ceiling surface, with the most easily burnable spots being dented areas such as seams, pores and creases on the ceiling surface. The unstable and limited nature of flame propagation at the ceiling surface was attributed to the relationship between temperature and hydrogen concentration in a confined space.

A premixed charge compression ignition methanol engine targeting a drastic decrease in NOx emissions and a brake specific energy consumption equivalent to that of a DI diesel engine has been developed (1). The problems of this combustion system are that the brake thermal efficiency decreases, and CO and THC emissions increase due to a deterioration of high load combustion. The purpose of this study is to improve the high load combustion of a premixed charge compression ignition methanol engine using a flash boiling fuel injection technique. The results of this study have shown that the premixed charge compression ignition methanol combustion system using a flash boiling fuel injection technique increases the brake thermal efficiency, decreases CO and THC emissions, while maintaining low NOx emissions in the high load region.

Electric vehicles have become more popular and may be involved in fires due to accidents. However, characteristics of fires in electric vehicles are not yet fully understood. The electrolytic solution of lithium-battery vehicles is inflammable, so combustion characteristics and gases generated may differ from those of gasoline cars. Therefore, we conducted fire tests on lithium-ion battery vehicles and gasoline vehicles and investigated the differences in combustion characteristics and gases generated. The fire tests revealed some differences in combustion characteristics. For example, in lithium-ion battery vehicles, the battery temperature remained high after combustion of the body. However, there was almost no difference in the maximum CO concentration measured 0.5 to 1 m above the roof and 1 m from the side of the body. Furthermore, HF was not detected in either type of vehicle when measured at the same positions as for CO.

The demands of application of dual-axis chassis dynamometers (4WD-CHDY) have increased recently due to the improvement of performance of 4WD-CHDY and an increase in the number of 4WD vehicles which are difficult to convert to 2WD. However, there are few evaluations of any differences between fuel economy and exhaust emission levels in the case of 2WD-CHDY with conversion from 4WD to 2WD (2WD-mode) and 4WD-CHDY without conversion to 2WD (4WD-mode). Fuel economy and exhaust emission tests of 4WD vehicle equipped with a typical 4WD mechanism were performed to investigate any differences between the case of the 2WD-mode and the 4WD-mode. In these tests, we measured ‘work at wheel’ (wheel-work) using wheel torque meters. A comparison of the 2WD-mode and the 4WD-mode reveals a difference of fuel economy (2WD-mode is 1.5% better than that of 4WD-mode) and wheel-work (2WD-mode is 3.9% less than that of 4WD-mode). However, there are almost no differences of exhaust emission levels.

For applying ISO 26262 to motorcycles, controllability classification (C class evaluation) by expert riders is considered an appropriate technique. Expert riders have evaluated commercial product development for years and can appropriately conduct vehicle tests while observing safety restrictions (such as avoiding the risk of falling). Moreover, expert riders can ride safely and can stably evaluate motorcycle performance even if the test conditions are close to the limits of vehicle performance. This study aims to construct a motorcycle C class evaluation method based on an expert rider’s subjective evaluation. On the premise that expert riders can rate the C class, we improved a test procedure that used a subjective evaluation sheet as the concrete C class evaluation method for an actual hazardous event.

ISO 26262, an international functional safety standard of electrical and/or electronic systems (E/E systems) for motor vehicles, was published in November 2011 and it is expected that the scope will be extended to motorcycles in a second edition of ISO 26262 going to be published in 2018. ISO/DIS 26262 second edition published in 2016 has Part 12 as a new part in order to apply ISO 26262 to motorcycle. Proper estimation of Exposure, Controllability, and Severity in accordance with ISO/DIS 26262 Part 12, are key factors to determine Motorcycle Safety Integrity Level. To estimate precise these factors, there would be a case that it might not be appropriate to apply studies done for passenger car to motorcycle, and it would be necessary to apply motorcycle specific knowledge and estimation methods. In our previous studies we clarified these motorcycle specific issues and studied the method for the adaptation.

The SAE Fuel Cell Vehicle (FCV) Safety Working Group has been addressing FCV safety for over 9 years. The initial document, SAE J2578, was published in 2002. SAE J2578 has been valuable as a Recommended Practice for FCV development with regard to the identification of hazards and the definition of countermeasures to mitigate these hazards such that FCVs can be operated in the same manner as conventional gasoline internal combustion engine (ICE)-powered vehicles. SAE J2578 is currently being revised so that it will continue to be relevant as FCV development moves forward. For example, test methods were refined to verify the acceptability of hydrogen discharges when parking in residential garages and commercial structures and after crash tests prescribed by government regulation, and electrical requirements were updated to reflect the complexities of modern electrical circuits which interconnect both AC and DC circuits to improve efficiency and reduce cost.

The SAE FCV Safety Working Group has been addressing fuel cell vehicle (FCV) safety for over 8 years. The initial document, SAE J2578, was published in 2002. SAE J2578 has been valuable to FCV development with regard to the identification of hazards and the definition of countermeasures to mitigate these hazards such that FCVs can be operated in the same manner as conventional gasoline internal combustion engine (ICE)-powered vehicles. J2578 is currently being updated to clarify and update requirements so that it will continue to be relevant and useful in the future. An update to SAE J1766 for post-crash electrical safety was also published to reflect unique aspects of FCVs and to harmonize electrical requirements with international standards. In addition to revising SAE J2578 and J1766, the Working Group is also developing a new Technical Information Report (TIR) for vehicular hydrogen systems (SAE J2579).

We have developed a new propane burner that satisfies the requirements of localized fire test which was presented in SAE technical paper 2011-01-0251. This paper introduces the specifications of this burner and reports its characteristics as determined from various fire exposure tests that we conducted in order to gather data. These tests included temperature and heat flux distribution on cylinder surfaces, which would be useful for the design of automotive compressed fuel cylinders. Our fire exposure tests included localized and engulfing fire tests to compare TPRD activation time, cylinder burst pressure and other parameters between different flame configurations and tests to identify the effects of an automotive compressed fuel cylinder on localized fire test results.

It is becoming more and more necessary to achieve a sustainable low-carbon society by mobility not depending on oil. Electric vehicles are appropriate for such a society, but expensive battery cost and long charging time prohibit the promotion of EVs. One of the solutions is minimizing battery usage by ultra-low fuel efficiency, so we developed an ultrahigh-efficient electric commuter concept car “C-ta”, which requires as small a battery as possible. We assumed that drivers would use the car as a second car for short-distance daily use, such as commuting, shopping, transportation of family, etc. In order to improve fuel efficiency, we mainly considered an ultra-light weight body and chassis, to which CFRP (carbon fiber reinforced plastic) greatly contributes, ultra-low rolling resistance tires, and highly accurate vehicle control technology with four in-wheel motors.

Japan Automobile Research Institute (JARI) have developed the flow method as an easy way of measuring hydrogen consumption of fuel cell vehicles (FCVs) in real-time. A 2004 study on fuel consumption of five models of FCVs, measured by thermal flowmeters and based on gravimetric method, exhibited measurement errors within ±1% range for three models, but the errors were as large as -8% for two models that showed significant pulsation in hydrogen consumption flow. Assuming that the pulsation is the cause of errors in the flow method, we analyzed influences of pulsation in each flowmeter from two points (frequency and amplitude) and found that pulsation indeed caused flowmeter errors. Expansion chambers (Buffers) and throttle valves (regulators) were confirmed to have an effect in attenuating pulsation. Amplitude of pulsation shrunk to one tenths when such pulsation-reducing instruments were introduced between pulsating FCVs and flowmeters and were put to test.

Japan Automobile Research Institute has devised and evaluated the various fuel consumption measurement methods for fuel cell vehicles (FCVs). The examination covers the methods based on measurement of electrical current, hydrogen pressure/temperature, weight and flow rate that are expected to be the same accuracy and convenience as conventional measurement methods such as carbon balance method or fuel flow measurement method. As a result of examining the measurement accuracy for each method with a sonic nozzle used as a standard, it is found that both the pressure method and the weight method fulfill the target accuracy of ±1% and that the flow method is able to improve the accuracy by means of calibration with hydrogen. Also, as a result of applying each method to the fuel consumption test of FCVs, the relative error between the pressure method and weight method is within ±1%.

A biofidelic flexible pedestrian leg-form impactor, called Flex-PLI, was developed by the Japan Automobile Manufactures Association, Inc. (JAMA) and the Japan Automobile Research Institute (JARI). Its latest version is called Flex-PLI 2003. The Flex-PLI 2003 responses have been validated at the component level (thigh, leg, and knee independently) but not at the assembly level (thigh-knee-leg complex). Furthermore, there was no FE Flex-PLI model. This research developed a FE Flex-PLI 2003R model (Flex-PLI 2003R means that the thigh and leg mass of Flex-PLI 2003 is adjusted to AM 50). The FE Flex-PLI 2003R model biofidelity has been evaluated at both the component level and the assembly level, where it demonstrated high biofidelity.

A numerical method specially designed to predict unsteady aerodynamics of road vehicle was developed based on unstructured Large-Eddy Simulation (LES) technique. The code was intensively optimized for the Earth Simulator in Japan to deal with the excessive computational resources required for LES, and could treat numerical meshes of up to around 120 million elements. Moving boundary methods such as the Arbitrary Lagrangian-Eulerian (ALE) or the sliding method were implemented to handle dynamic motion of a vehicle body during aerodynamic assessment. The method can also model a gusty crosswind condition. The method was applied to three cases in which unsteady aerodynamics are expected to be crucial.