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To reduce the Body in White (BIW) mass, it is necessary to expand the application of Advanced High-Strength Steels (AHSS) to complex shaped parts. In order to apply AHSS to complex shaped parts with thinner gauge, high formability steel is required. However, higher strength steels tend to display lower elongations, compared with low/medium strength steels. Current AHSS are applied to limited parts for this reason. The new 1.2GPa material, with high formability, was developed to solve this issue. The mechanical property targets for the high elongation 1.2GPa material were achieved by precise metallurgical optimization. Many material aspects were studied, such as formability, weldabilty, impact strength, and delayed fracture. As the result of this development, 1.2GPa AHSS has been applied to a new vehicle launched in 2013.The application of this material was the 1st in the world, and achieved a 11kg mass reduction.

Many papers have mentioned, in passing, a phenomena that is known as “airtightness”, which is one factor that hinders automobile doors from closing. It also causes the eardrums of any passengers in the vehicle to be temporarily pressurized when the door is closed. However, few documents have considered this phenomena in detail. In this paper, we investigate the magnitude of “airtightness” as it affects ear pressure and examine its relationship to such factors as the volume of the passenger compartment, door's opening area and its inertial moment. Finally, we utilized estimation methods to predict its influence on the force required to close the door and the amount of the resultant air draft.

A light weight,multifunctional plastic reinforcement has been developed for the outer body panels of vehicles. This new plastic reinforcement,composed mainly of polyvinylchloride resin, epoxy resin and an organic foaming agent, provides a 63% weight reduction over conventional plastic reinforcements, while adding the damping function to outer body panels. This paper introduces the process followed in developing the new plastic reinforcement and describes its characteristics. This new plastic reinforcement is already employed in the Nissan S-Cargo model, and it will be adopted in other passenger car models to be released in the near future.

A robotic driver has been designed on the basis of an analysis of a human driver's action in following a given driving schedule. The self-learning algorithm enables the robot to learn the vehicle characteristics without human intervention. Based on learned relationships, the robotic driver can determine an appropriate accelerator position and execute other operations through sophisticated calculations using the future scheduled vehicle speed and vehicle characteristics data. Compensation is also provided to minimize vehicle speed error. The robotic driver can reproduce the same types of exhaust emission and fuel economy data obtained with human drivers with good repeatability. It doesn't require long preparation time. Thereby making it possible to reduce experimentation work in the vehicle development process while providing good accuracy and reliability.

This paper describes a simple engine model at idling and it applies particularly to idle speed control. Through linearization in the neighborhood of the nominal operating points (650 rpm), the engine is expressed as a reduced-order constant coefficient state variable (2 state) model. It was produced through the system order-reduction method. The strategy for controlling idle speed uses the Linear Quadratic and Integral (LQI) optimal control theory. The tracking controller was designed using a state variable engine model, and the performance index was minimized. Since state variables are artificially introduced, they are not directly accessible. Therefore, they must be estimated in accordance with a stored dynamic model (i.e. observer), in which the engine dynamic behavior is estimated on the basis of a state variable model which represents the engine's internal states, in determining controlling values.

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.

This paper explains the specific measures taken to develop the body and underfloor of the newly developed Electric Vehicle for the purpose of reducing drag. Additionally, the headlamps and fenders were designed with innovative shapes to reduce wind noise that occurs near the outside mirrors. As a result of utilizing the aerodynamic advantages of an electric vehicle to maximum effect, The newly developed Electric Vehicle achieves a class-leading drag coefficient and interior quietness.

An electric vehicle (EV) has less powertrain energy loss than an internal combustion engine vehicle (ICE), so its aerodynamic accounts have a larger portion of drag contribution of the total energy loss. This means that EV aerodynamic performance has a larger impact on the all-electric range (AER). Therefore, the target set for the aerodynamics development for a new EV hatchback was to improving AER for the customer’s benefit. To achieve lower aerodynamic drag than the previous model’s good aerodynamic performance, an ideal airflow wake structure was initially defined for the new EV hatchback that has a flat underbody with no exhaust system. Several important parameters were specified and proper numerical values for the ideal airflow were defined for them. As a result, the new EV hatchback achieves a 4% reduction in drag coefficient (CD) from the previous model.

Car rust has been a big problem. To improve the effectiveness of rustproofing, car materials and some methods are being developed. Sealing the seams of body panels is one important method. But the sealing operation is a difficult process and it is not easy to maintain quality standards for workmen and automatized systems. To overcome this problem, we developed an automatic robot sealing system with following features: 1. The system can be easily installed on an existing conveyor and follows the line conveyor in synchronization during sealing operation. 2. Small robots can cover wide area inside the vihecle. 3. New sealant supply controllers can regurate the supply rate in response to speed and motion of robots with a high accuracy. This system has already been installed in the Murayma plant and has proved successful in achieving a high quality sealing result.

This paper deals with the development of plastics recycling technology, which is one key to resolving environmental and natural resource problems and encouraging recycling activities. Bumpers are among the heaviest plastic auto parts, so the technology for recycling bumpers is strongly required. Paint remaining on bumpers causes the strength of the recycled material to decline and degrades its surface quality. Therefore, unless the paint is removed, it is impossible to use recycled material to manufacture new bumpers. This hampers recycling efforts and results in low-value recycled material. Consequently, it is essential to develop a simple paint removing without chemical substances for practical plastics recycling at low cost. Two topics are discussed in this paper. The first concerns the mechanism of paint removal and the development of a technique for utilizing that mechanism.

Use of high strength steel (HSS) could be an important consideration in achieving competitive weight and safety performance of the body-in-white (BIW). This study covers key technical issues in the application development. Many aspects were studied such as formability, weldability and impact strength for application of this grade to the BIW. One of the key issues is spot weldability, especially in the assembly of heavy gauge materials for structural parts. The spot weld strength appears not to satisfy the target for some HSS applications, when hardness of the nugget is high. The relation between weld strength and the chemical composition of steel sheets was studied, because hardness can be controlled by chemical composition and welding conditions. It was found that using lower carbon content or carbon equivalent compared to conventional grades could improve weld strength.

There are strong demands for vehicle weight reductions so as to improve fuel economy. At the same time, it is also necessary to ensure crash safety. One effective measure for accomplishing such both requirements conflicting each other is to apply advanced high strength steel (AHSS) of 780 MPa grade or higher to the vehicle body. On the other hand, higher strength steels generally tend to display lower elongation causing formability deterioration. Nissan Motor Corporation have jointly developed with steel manufacturers a new 980 MPa grade AHSS with high formability with the aim of substituting it for the currently used 590 MPa grade high-tensile steel. Several application technologies have been developed through the verifications such as formability, resistance spot weldability, crashworthiness, and delayed fracture.

Evaluations of dummy injury readings obtained in regulatory crash tests and new car assessment program tests provide indices for the development of crash safety performance in the process of developing new vehicles. Based on these indices, vehicle body structures and occupant restraint systems are designed to meet the required occupant injury criteria. There are many types of regulatory tests and new car assessment program tests that are conducted to evaluate vehicle safety performance in side impacts. Factoring all of the multiple test configurations into the development of new vehicles requires advanced design capabilities based on a good understanding of the mechanisms producing dummy injury readings. In recent years, advances in computer-aided engineering (CAE) tools and computer processing power have made it possible to run simulations of occupant restraint systems such as side airbags and seatbelts.

It is considered that door mirror drag is composed of not only profile drag but also interference drag that is generated by the mixing of airflow streamlines between door mirrors and vehicle body. However, the generation mechanism of interference drag remained unexplained, so elucidating mechanism for countermeasures reducing drag have been needed. In this study, the prediction formulas for door mirror drag expressed by functions in relation to velocities around the vehicle body were derived and verified by wind tunnel test. The predicted values calculated by formulas were compared with the measured values and an excellent agreement was found. In summary, new prediction formulas made it possible to examine low drag mirror including profile and interference drag.

The progress of computer technology and CAE methodology makes it possible to simulate dummy injury readings in vehicle crash simulations. Dummy neck injuries are generally more difficult to simulate than injuries to other regions such as the head or chest. Accordingly, improving the accuracy of dummy neck injury data is a major concern in frontal occupant safety simulations. This paper describes the use of an advanced airbag modeling methodology to improve the accuracy of dummy neck injury readings. First, the following items incorporated in the advanced airbag model are explained. (1) The Finite Point Method (FPM) is used to simulate the flow of gas. (2) A folding model is applied to simulate the folded condition. (3) The fabric material properties used in the simulation take into account anisotropy in the fiber directions and the nonlinear, hysteresis characteristics of stiffness.

This paper describes the magnetic circuit design of a coaxial AC motor system, comprising one stator and two rotors, and the test results obtained for a prototype motor. The rotors of the motor share the same stator core and coils, and each rotor uses its magnetic part as a yoke. Magnetic flux linkage of each rotor was determined in consideration of the maximum torque/power conditions and maximum motor speed. Finite Element Method were utilized to design a magnetic circuit for achieving the magnetic flux linkage specification. Tests conducted with a prototype motor showed that the torque characteristics can be divided into magnetic torque and reluctance torque, just like an ordinary IPM motor. Each torque level was improved through field-weakening control. The combined torque obtained when the two rotors were driven simultaneously approximately equaled the sum of the individual torques when the rotors were driven independently.

A simulation system has been developed for making comprehensive predictions and assessments of the various and interrelated indices of vehicle performance. This system draws upon a data base containing information on the characteristics of the different units making up a vehicle. The system includes fuel economy and emissions calculation programs incorporating a large number of evaluation items. It also features an acceleration calculation program by which the transient characteristics of a turbocharger can be studied and a vehicle exterior noise program that makes accurate predictions of the pass-by noise level during acceleration. Equipped with a large number of calculation functions the system is an effective tool for improving total vehicle performance.

Engines in Japan have higher output versus small displacement (bhp/liter) and require low phosphorus content in the engine oils to meet the most stringent exhaust emission regulation in the world. The market survey of typical API SF oils in Japan showed that the average phosphorus content was approximately 0.07 %. Under such circumstances engine oils provide good performance with the usage of secondary zinc di-alkyldithiophosphates (Zn DTP) for valve train wear protection, addition of friction modifiers for fuel economy, etc.

An electric vehicle (EV) is promising as clean energy powered vehicle, due to increased interest in fuel economy and environment in recent years. However, it requires to meet unique safety performance such as electric safety. Nissan has developed a new electric vehicle which achieves electric safety in addition to maintaining enough cruising distance and cabin space. This was achieved by I he development of an all-new platform for electric vehicles. The electric safety was enhanced by the protection of high-voltage components based on consideration of component layout and body structure, high-voltage shutdown by impact sensing system and prevention of short circuit by fuse in the battery. As an example of the protection of high-voltage components, the battery which locates under the floor was protected by elaborative packaging and multi-layer protection structure.

At Nissan we have developed a new parallel hybrid system for rear-wheel-drive hybrid vehicles. As the main components of the hybrid system, both the motor and the inverter have been developed and are manufactured in house to attain high power density for providing responsive acceleration, a quiet EV drive mode and improved fuel economy. Because the motor is located between the engine and the transmission, it had to be shortened to be within the length allowed for the powertrain. Therefore, new technologies have been developed such as high-density, square-shaped windings and an optimized magnetic circuit specially designed for concentrated winding motors. The inverter is sized to a 12V battery, which it replaces in the engine compartment. Despite its compact size, the inverter must have rather large current capacity to drive a high-power motor. Heat management is critical to the design of a small but high-power inverter.