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Technical Paper

Automobile Navigation System with Multi-Source Guide Information

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.
Journal Article

Development of Aluminum Wire for Low-Voltage Automotive Wiring Harnesses

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.
Journal Article

Development of High Strength Aluminum Wires for Low-Voltage Automotive Wiring Harnesses

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.
Technical Paper

Development of a Drill Bit for CFRP/Aluminum-Alloy Stack: To Improve Flexibility, Economical Efficiency and Work Environment

In the expansion of composite material application, it is one of the most important subjects in assembly of aircraft structure how drilling of composite/metal stack should be processed in an efficient way. This paper will show the result of development of a drill bit for CFRP/Aluminum-alloy stack by Kawasaki Heavy Industries (KHI) and Sumitomo Electric Hardmetal (SEH). In order to improve workability and economic performance, the drill bit which enables drilling CFRP/Al-alloy stack: at 1 shot; from both directions; without air blow and coolant (just usual vacuuming); was required. A best mix drill bit which has smooth multi angles edge and pointed finishing edge was produced as a result of some trials. Developed drill bit achieved required performance and contributed to large cost reduction, labor hour saving, production speed increase and work environment improvement.
Technical Paper

Development of a Method to Predict Fatigue Failure Life of Junction Block Bracket Using CAE

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.
Technical Paper

Diesel Particulate Filter Made of Porous Metal

A diesel particulate filter (DPF) using porous metal for a filter, due to its high thermal conductivity, and a radiation heater for a regeneration device, due to its uniform distribution of temperature, has been developed. When high trapping efficiency is required, filter thickness should be increased. However, the thicker filter has a problem of low regeneration efficiency caused by the declination of temperature in the direction of thickness in the filter. In order to improve regeneration efficiency, a filter-heater structure which achieves uniform distribution of temperature was designed by using computer simulation and confirmed good regeneration efficiency of this structure in the experiment.
Technical Paper

Estimation and Measurement of Travel Time by Vehicle Detectors and License Plate Readers

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.
Technical Paper

Friction Characteristics Evaluation of Carbon/Carbon Composite Produced by Carbon Powder Sintering Method

We have developed a new Carbon/Carbon composite (C/C) manufacturing process called the “Carbon Powder Sintering Method [1] (C.P.S.M.)”. This study was conducted to evaluate the friction characteristics of C/C manufactured by the C.P.S.M. as compared with C/C manufactured by conventional methods using a dynamometer. In general, C/C shows a high friction coefficient at a high temperature, but shows a low friction coefficient at room temperature. There is a transition temperature point between both friction coefficients. As a result of this study, it was found that the transition temperature of the C.P.S.M. C/C is lower than for any other conventional C/C.
Technical Paper

High-Speed Machining of Titanium by New PCD Tools

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.
Technical Paper

In-Tunnel Traffic Flow Measuring System Using ITV Cameras

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.
Technical Paper

Joining of Si3 N4 Turbine Rotor and Metal Shaft

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.
Technical Paper

Lubrication Pump Made of Rapidly Solidified Aluminum Alloy for High Performance Engine

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.
Technical Paper

Rotary Car Air Conditioner Made with P/M Al-Si Wrought Alloys

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.
Technical Paper

The Development of P/M Complicated Shape Helical Gears

Recently, powder metal parts have been used in a lot of automobiles. One typical powder metal part is a helical gear. Compacting helical gears is much different from conventional compacting, because a part of the tool rotates on its own axis. The important points are as follows: (1) how to guide the upper punch into a die smoothly and to fit in it, (2) how to rotate the die/punch smoothly in order that the part of gear trains may not be broken by twisting stress during pressing process and (3) how to prevent green compacts from having crack/lamination. The larger the helix angle, the more difficult its compacting. The compacting of complicated shapes such as helical gears with an irregular shape or another helical gear is more difficult. Powder metal helical gears are produced because powder metal is suitable for mass production at low cost. Most powder metal helical gears are simple shapes such as helical gears only outside or inside.
Technical Paper

Valve Spring with High Fatigue Resistance for Automotive Engine

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.