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This paper describes an Automobile Navigation System with Multi-Source Guide Information. One of the features of this system is accurate location detection, which uses refined map-matching method incorporating a high accuracy rotation sensor, Fiber Optic Gyroscope (FOG). The system shows the position of the vehicle on a CRT map display and can also provide useful information, such as the locations of hotels, golf courses, etc., by using a CD-ROM disc. In addition to this information, this system can play CD-ROM discs based on the CDCRAFT standard. By means of this standard, software vendors can produce multimedia entertainment, such as a sightseeing guide with voice. Also, this system can display road and traffic information from the roadside radio beacons of the Vehicle Information & Communication System (VICS). This navigation system has been installed in Nissan's 1991 model Cedric, Gloria and CIMA.

The Dynamic Navigation System is an information-providing type navigation and route guidance system. Fundamentally the system is suited for phased implementation. Some measures, however, must be taken in advance to enhance it to the advanced phase. For these measures, information providing data formats, travel time collection methods and small-delay system architecture have been studied. As a result, the flexible data composition for information provision, the on-board travel time measurement for efficient and accurate data collection and the autonomous communication network concept called ‘HYPO NET’ have been proposed.

From the viewpoint of reducing the environmental impacts by automobile emission, improving fuel efficiency is essential. That is why automobiles need to be lightened. However, more and more electrical systems have been necessary in an automobile to ensure safety and comfort. With the increase in the number of electrical systems, the weight of Electrical Distribution System (EDS) also has become increased. In order to reduce the weight of EDS, it was decided to evaluate a change of material from copper to aluminum. In fact, aluminum wires have been used for high-voltage wires, but they have almost never been used for low-voltage wires. SUMITOMO ELECTRIC GROUP developed an aluminum wire that is available for low-voltage wire harnesses and started mass production of the wire from October 2010. In this paper, I'm reporting mainly on our development of a new aluminum alloy that can be used for aluminum wires.

Pollution is worsening in cities. The exhaust gas from vehicles is the main cause of air pollution in cities. The major drawback of the diesel engine is the Particulate Matter (PM) contained in the exhaust fumes which is also said to lead to cancer. For about 20 years many tests have been conducted in order to reduce PM in diesel exhaust gas. However the exhaust gas in present diesel engines contains a significant amount of PM. This is because there is no practical material for the Diesel Particulate Filter (DPF). Conventional ceramic materials have problems such as cracking and melting during regeneration and conventional metal materials lack adequate corrosion resistance for practical use. The authors present a new type of DPF made of metal porous matter (Celmet) which is designed with a thermal construction and simple control system in order to solve the problem of diesel exhaust gas.

The weight of wire harnesses increases with the growing number of systems used in the vehicle in recent years. For the purpose of reducing the weight of wire harnesses, aluminum instead of the conventional copper is getting popular as a wire conductor. The conventional Al wire, however, is not able to be used for small gauge wires such as the sizes of 0.35mm2 and 0.5mm2 and wires used in the engine compartment due to its insufficient conductor strength. For this reason, we tried to develop a stronger aluminum alloy that has conductor strength equivalent to or stronger than that of copper. For the first time in the industry, we have successfully developed a high-strength aluminum alloy wire. Starting with the application of 0.35mm2 wire for engine wire harnesses, we began mass production in April 2015. This paper reports the development of high-strength aluminum alloy that can be used for small gauge wires and wires used in the engine compartment.

We developed a remote control unit (Hereinafter referred to as the controller) employing mainly an eight-directional joystick with push-button function. And it has good operational feeling. As previous joysticks generated operator feeling via springs, so the click sensation could not be felt. We thought that a good click feeling can be obtained by applying rubber contacts to the switch element of the joystick. Additionally, in order to include the push-button functions, we supported the operant unit with biaxial bearing and employed a sliding-knob structure penetrating this operant unit. Also in order to obtain a uniform operator feeling for all eight directions, we applied eight rubber contacts and gave the switches eight contacts. In order to restrain the rise in IC costs with the increase to eight contacts, we introduced an eight-contact four- output switch matrix and a one-contact three-electrode pattern.

With the rapid advances in electronic control within automobiles, the junction block (J/B), primarily used for electrical transmission and electrical wiring, has begun to house electronic control units. It is evolving into an active component with smart functions that also controls vehicle devices, at the core of the wiring harness. We have developed a method using CAE to predict the fatigue failure life of J/B brackets for use as a design-assist tool in the early stage of J/B development. Failure of J/B brackets starts with the repetitive stress generated in the brackets during resonance. This stress is maximum at primary natural vibration which is the lowest frequency during resonance. By accurately estimating the above-mentioned stresses using CAE, we established a method to determine the number of vibrations at which fatigue failure of the J/B bracket would occur (fatigue failure life) from the fatigue failure life characteristics of the material.

We have developed a new type of system to prevent disc brake squealing. The rotor vibration radiates the squeal noise, therefore if the rotor vibration can be stopped electronically, no squeal is generated. Based on this concept, the Electronic Control Canceling System for a Disc Brake Noise ( ECCN ) was developed for the opposed type brake which has four brake pistons. The ECCN consists of four piezoelectric elements and one electronic control unit, and can stop the low-frequency squeal of 2∼4kHz by using a small amount of energy with the noise dynamometer and the test vehicle.

The first SUMITOMO ELECTRONIC ANTILOCK SYSTEM (ALS), a 4-Sensor 3-Channel System for sophisticated FWD vehicles, has been in production since 1987. Further developments have lead to systems suitable for 4W vehicles and compact cars, showing increased control quality and reduced size, weight and production cost. Reliability, one of the major targets in the development of the First system's Electronic Control Unit (ECU) since 1982, was successfully achieved. Recent work has been geared toward reducing the size and production cost of ECU hardware, whilst maintaining the system's reliability. This paper describes the basic design of the current 1987 ECU and further details developments of the hardware.

In 1990, The Japanese National Police Agency (NPA) planned a nationwide two-year research project including field experiments, “Travel Time Estimation and Prediction” aimed at realizing a reliable method of providing travel time information to drivers (1)*. The project was conducted by the Japan Traffic Management Technology Association and three system manufacturers (Sumitomo Electric, OMRON and Matsushita Communication) collaborated on research and experimental work. Several methods of estimating and predicting travel time were developed and evaluated in three major cities (Tokyo, Yokohama and Osaka). Four models, Sandglass, Delay Time, Auto Regressive and Neural Network Models were developed and evaluated using detector and license plate reader information, and field survey data in the three major cities. The first year evaluation results are described here.

Fiber-optic data links have been developed for use in vehicle navigation systems, especially for the communication of CD data. The links consist of transmitters, receivers, and cable assemblies. The transmitters, which include only LEDs, must have driver circuits on their exteriors. In the receiver section, a PD, an amplifier, and a TTL compatible comparator are all integrated into the custom designed IC which is hermetically sealed into an originally developed metal package. Small optical connectors and heat-resistant plastic fiber cords with sufficient reliability and good operability for automotive uses have also been developed.

ABS sensor rings for automotive use are becoming smaller and thinner because of the demand for low cost and light weight. Such small thin parts are easier to break as they must withstand the same severe conditions as larger heavier parts. Superior elongation properties, after corrosion testing, are necessary for avoiding breakage and to obtain superior corrosion resistance. We have, therefore, developed such high performance P/M stainless steel with superior elongation and corrosion resistance. Conventional stainless steel has uniform pores on its inner surface which makes allows water penetration thus making corrosion worse and decreasing elongation. It is possible to increase corrosion resistance by changing pore structure (e.g. decrease continual pores) through the addition of special alloys that accelerate the sintering process.

The paper deals with the end-milling machinability of α-β titanium alloy (Ti-6AI-4V alloy) by new PCD (Polycrystal-line Diamond) cutting tools at high cutting speeds in order to develop a new technology for a high productivity titanium finishing. The main focus of this paper is on investigating the relationships among cutting conditions, PCD tool materials, and tool wear. It was found that the edge engagement time of cutting tools with titanium workpiece has a great effect on PCD tool wear. Compared to cemented carbide tools, PCD tools have a longer tool life, especially at higher cutting speeds. The geometric shape of cutting edges and tool material greatly influences the performance of PCD tools in cutting titanium alloy.

The image processing technology using ITV cameras has been developed as a new type of sensor which can be used for many purposes. Especially, it is hopeful that the improvement of the traffic flow measuring system applying this technology can increase safety in tunnels on expressways. In this paper, we describe about the results of the development of this technology until present. And, the prospect in the future.

The joining process of silicon nitride (S13N4) turbine rotor and steel metal shaft was investigated. The process consists of brazing procedures with multi-layer metallizing and complementary steps involving shrink fitting and non-destructive tests. In the course of the brazing steps, preliminary investigations using small specimens were conducted on the formation of a highly strengthened interface at high temperature and thermal stress reduction, and superior high temperature strength and heat cycle resistance were obtained. Rotary tests at high temperature were successfully completed using the rotor joined by this process.

An internal gear-type pump has advantages compared with an external involute gear-type pump, for example, higher mechanical or volumetric efficiency, considerable reduction of weight and dimension in the oil-pump system[1]. This paper presents characteristics of the internal gear type rotors with a modified trochoidal profile in the oil-pump system, and new P/M(Powder Metallurgy) aluminum alloys which satisfy required wear properties as the lubrication oil-pump rotors. Also, the advantage of high volumetric efficiency and discharge performance and excellent properties of the oil-pump rotor with a modified trochoid profile were combined with a R/S (Rapidly Solidified) aluminum alloy in the scavenging pump for racing car engine. Good results without wear or damage after an actual race are also reported.

We have developed new P/M Al-Si wrought alloys having high strength and high wear resistance for use in the rotors and vanes of rotary car air conditioners. In addition, combined with the development of near-net-shape extrusion technologies, through a joint project with Diesel Kiki Co.,Ltd., we have succeeded in the world's first mass production of rotors made of P/M aluminum wrought alloy. In this paper, the properties and production technology of vanes and rotors made with new P/M Al-Si wrought alloys are presented.

Recently, SiCr clean steel wire for springs on automotive engine valves has been developed. This report describes the characteristics of valve springs subjected to a new manufacturing process using SiCr clean steel wire. The process developed by the authors is as follows: First, form a helical spring with SiCr clean steel wire. Next, quench using the distortion preventing technic --Marquenching--. Temper at a temperature lower than the conventional temperature. Shot peen to the surface layer of the spring. And lastly, polish electrolytically to remove micro surface defects formed through shot peening. Using this new manufacturing process, a valve spring with high fatigue resistance can be produced. At the test stress of 588MPa(τm)±490MPa (τa), the number of cycles to fracture was above 100 million, while the number of cycles to fracture was 4 million using the conventional process with the SiCr clean steel which has the best fatigue resistance for commercial use.

The wheel rotation sensor developed for navigation system is small and light, and generates high output voltage of 0.37V p-p without a prc-amplifier when the gap between the sensor and the multi-polarized magnetic rotor is 2.0mm. The sensor has excellent resistance to environmental conditions. Several simulation tests and car evaluations were carried out and it is confirmed that the sensor generates enough output voltage and satisfies requirements for the system including the decrease of output voltage caused by temperature, gap variation while running, and so on.