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The efficiency of the NOx Storage and Reduction (NSR) catalysts used in the aftertreatment of diesel engine exhaust gases can potentially be increased by using reactive reductants such as CO and H₂ that are formed during in-cylinder combustion. In this study, a multi-dimensional computational fluid dynamics (CFD) code coupled with complex chemical analysis was used to study combustion with various fuel after-injection patterns. The results obtained will be useful in designing fuel injection strategies for the efficient formation of CO.

The authors developed a low-speed in-vehicle network for the body control system on passenger cars, where the most remarkable effects to reduce the number of wire harnesses could be expected. First, the authors analyzed the body control system to clarify the specifications required to build a low-speed in-vehicle network. Then the authors worked out optimum communication protocol, placing emphasis on cost reduction which is the key to expanding the applications of the low-speed in-vehicle network over wider fields. The low-speed in-vehicle network was evaluated for its performance through simulation and on-vehicle tests, and proved the practical validity of the concept. It was also verified that introducing the low-speed in-vehicle network has a satisfactory effect to reduce the number of wire harnesses.

In the field of automotive body electronic control such as control of door locks, power windows, and wipers, there is a growing need of multiplexing communication to reduce the amount of wire harnesses. To meet this need, we developed a multiplexing communication protocol particularly suited to the body electronic control. Based on the developed protocol, we designed a communication control IC and a simple driver/receiver circuit with a few discrete components. The bus access method of the communication is the CSMA/CD with nondestructive bit arbitration, and its bit rate is 5 kbps. Its transmission media is a single wire. The communication IC has a multiplexing control block and a serial I/O block for an interface with a host CPU. It was fabricated using CMOS technology and has a chip of 2.6mm x 3.0mm in size that contains about 5,000 transistors. The driver/receiver circuit consists of one transistor, one capacitor and several resistors.

Development of a new battery system for Toyota Estima Hybrid, the world's first minivan hybrid vehicle, has been completed. The battery pack that consists of 30 nickel metal hydride battery modules is compactly arranged under the 3rd seat in the cabin along with components such as the battery cooling blower and the ducts. This arrangement was designed in consideration of user's vehicle use, passengers' comfort and efficient battery-cooling performance.

To meet the requirements for higher horsepower and torque as well as lower fuel consumption and emissions, we have developed a new “Intelligent Variable Valve Timing (VV-i)” system. It gives continuously variable intake cam phasing by up to 60 degrees crank angle (CA) . This system not only increases WOT output by optimizing intake valve closing timing but also reduces fuel consumption and NOx/ HC emissions under part load by increasing intake and exhaust valve overlap on 4 stroke Spark Ignited engines. VVT-i has been applied to optimize a new 3-liter inline 6 engine for higher torque and at the same time better fuel economy with continuous and wide-range cam phasing.

A new experimental method, that enables to estimate the body and driveline sensitivity to unit transmitting error of a hypoid gear for automotive rear axle gear noise, has been developed. Measurements were made by exciting the tooth of the drive-pinion gear and that of the ring gear separately using the special devices designed with regard to simulation of acceleration and deceleration. The characteristic of this method is to estimate the forces at the contact point of the gears. Estimation of these forces is carried out under the condition that the higher stiffness is provided by the tooth of the drive-pinion gear and that of the ring gear, compared with the stiffness of the driveshafts and that of the propeller shaft etc., and relative angular displacement of the torsional vibration between the teeth of the drive-pinion gear and those of the ring gear is constant.

To avoid knocking phenomena, a special crank mechanism for gasoline engine that allowed the piston to move rapidly near TDC (Top Dead Center) was developed and experimentally demonstrated in the previous study. As a result, knocking was successfully mitigated and indicated thermal efficiency was improved [1],[2],[3],[4]. However, performance of the proposed system was evaluated at only limited operating conditions. In the present study, to investigate the effect of piston movement near TDC on combustion characteristics and indicated thermal efficiency and to clarify the knock mitigation mechanism of the proposed method, experimental studies were carried out using a single cylinder engine with a compression ratio of 13.7 at various engine speeds and loads. The special crank mechanism, which allows piston to move rapidly near TDC developed in the previous study, was applied to the test engine with some modification of tooling accuracy.

A discomforting noise can sometimes be heard in a vehicle passenger compartment during acceleration which can be annoying to passengers. We call this noise a “rumbling noise”. A detailed study of the rumbling noise spectrum has clarified the generating mechanism of the rumbling noise and the relation between the spectral structure and the tone. In order to analyze the rumbling noise, we simulated it with electrically synthesized noise. This method showed that at the times when the noise is heard there are always more than three discrete harmonics which are half an order harmonics of the engine revolution. The sensation of discomfort depends on the phase, frequency and magnitude of each frequency component. To evaluate the noise quantitatively, we also analyzed the shape of the time domain noise envelope. The envelope shape has a good correlation with the feelings of discomfort.

Brake squeal is caused by dynamic instability, which is influenced by its dynamic unstable structure and small disturbance of friction force variation. Recently, FE Analysis of brake squeal is applied for brake design refinements, which is based on dynamic instability theory. As same as the refinement of brake structure is required for brake squeal reduction, the refinement of pad materials is also required for brake effectiveness and brake squeal reduction. It is well known that friction film, which is composed of polymers like phenol formaldehyde resin and so on, influences for friction coefficient. Therefore it is expected that the refinement of polymers in pad materials enable higher brake effectiveness and less brake squeal. In this paper, Molecular Dynamics is applied for the friction force variation of polymers in pad materials. The MD simulation results suggest the reduction method of friction force variation of polymers.

In the field of automobile disk wheels, demands for aluminum wheels have been increasing for the reason of ride comfort and better appearance. And over 90 percent of luxurious passenger cars are equipped with aluminum wheels. This trend is spurred also by the demand for higher fuel efficiency for the cause of environmental protection, which calls for weight reduction of automobiles. This paper reports our research on manufacturing light-weight, high-quality aluminum cast wheels; covering the entire process from basic design to casting, and placing emphasis on the following three points. 1) Determination of optimum wheel configuration through computer simulation 2) Selection of optimum material composition 3) Optimization of the thin plate casting conditions Combination of the above technologies developed for the purpose of weight reduction resulted in the weight reduction of approximately 20% over the conventional aluminum wheels.

It is well known and a common experience among drivers that controllability and stability of a car-trailer combination is affected when an articulated Heavy Goods Vehicle overtakes. In this paper, aerodynamic effects to a car-trailer combination when it is overtaken by an articulated HGV, have been analyzed experimentally using 1/20 scale models in wind tunnel, and a method to suppress this phenomenon has been investigated. The dynamic behaivor of a car-trailer combination is simulated by a simple mathematical model. The result shows that a car-trailer combination can be stable following the addittion of aerodynamic devices to each side of the vehicle. This simulated result is verified by the on-read test.

Technologies of 4WD chassis dynamometers (CHDY hereinafter) have advanced dramatically over the past several years, enabling 4WD vehicles to be tested without modifying their drive-train into 2WD. These advances have opened the use of 4WD-CHDY in all fuel economy and emission evaluation tests. In this paper, factors that influence the accuracy of fuel economy tests on 4WD CHDY are discussed. Fuel economy tests were conducted on 4WD CHDY and we found that most of the vehicle mechanical loss is the tire loss and that stabilizing the tire loss of the test vehicle is essential for the test reproducibility.

The present paper describes an application of non-parametric shape optimization to disc brake squeal phenomena. A main problem is defined as complex eigenvalue problem in which the real part of the complex eigenvalue causing the brake squeal is chosen as an objective cost function. The Fre´chet derivative of the objective cost function with respect to the domain variation, named as the shape derivative of the objective cost function, is evaluated using the solution of the main problem and the adjoint problem. A selection criterion of the adoptive mode number in component mode synthesis (CMS), which is used in the main problem, is presented in order to reduce the computational error in complex eigenvalue pairs. A scheme to solve the shape optimization problem is presented using an iterative algorithm based on the H1 gradient method for reshaping. For an application of the optimization method, a numerical example of a practical disc brake model is presented.

The vehicle requires high brake performance and mass reduction of disc brake for vehicle fuel economy. Then disc brake will be designed by downsizing of disc and high friction coefficient pad materials. It is well known that disc brake squeal is frequently caused by high friction coefficient pad materials. Disc brake squeal is caused by dynamic unstable system under disturbance of friction force variation. Today, disc brake squeal comes to be simulated by FEA, but it is very difficult to put so many dynamic unstable solutions into stable solutions. Therefore it is very important to make it clear the influence of friction force variation. This paper describes the development of experimental set up for disc brake squeal basic research. First, the equation of motion in low-frequency disc brake squeal around 2 kHz is derived.

This study used finite element (FE) simulations to analyze the injury mechanisms of driver spine fracture during frontal crashes in the World Endurance Championship (WEC) series and possible countermeasures are suggested to help reduce spine fracture risk. This FE model incorporated the Total Human Model for Safety (THUMS) scaled to a driver, a model of the detailed racecar cockpit and a model of the seat/restraint systems. A frontal impact deceleration pulse was applied to the cockpit model. In the simulation, the driver chest moved forward under the shoulder belt and the pelvis was restrained by the crotch belt and the leg hump. The simulation predicted spine fracture at T11 and T12. It was found that a combination of axial compression force and bending moment at the spine caused the fractures. The axial compression force and bending moment were generated by the shoulder belt down force as the driver’s chest moved forward.

Methyl esters of saturated/unsaturated higher aliphatic acids (FAMEs) and a FAME of waste cooking oil (WCOME) were heated at 120°C in an air gas flow. The samples were analyzed before and after heating, using six different methods including electrospray ionization mass spectrometry. As a result, the samples after heating were found to contain low molecular weight aliphatic compounds and oligomers of the FAME. Based on the chemical structure of these oxidation products, reaction schemes were proposed for the deterioration of FAMEs. In addition, two unsaturated FAMEs containing 2,6-di-t-butyl-p-cresol (BHT) were similarly heated and analyzed to examine the effect of BHT on the oxidation of these FAME.

Hybrid vehicles (HVs) are becoming more widely used. Since HVs supplement engine drive with motor power, the lubricant oil temperature remains at a lower level than in a conventional gasoline vehicle. This study analyzed the effect of cylinder bore temperature and lubricant oil temperature on engine friction. The results showed that, although the lubricant oil temperature was not relevant, the bore temperature had significant effect on piston friction. It was found that raising the temperature of the middle section of the cylinder bore was the most effective way of reducing piston friction.

In the direct injection spark ignition gasoline engine (D-4), thin fan-shaped high-dispersion, high-penetration and high-atomization spray formed by the slit nozzle generates a stratified mixture cloud without depending on a strong intake air motion, subsequently realizing stable stratified charge combustion. To improve fuel economy further in actual traffic, the region of stratified charge combustion in torque-engine speed map must be expanded by improving spray characteristics. Since the fuel flow inside the nozzle has a large effect on the spray characteristics, it was clarified this effect by visual analysis of the fuel flow inside the nozzle using an enlarged acrylic slit nozzle of 10 magnifications. Consequently, it was found that vortices are generated frequently within a sac even in the case of steady state conditions. The effect on the spray characteristics is corresponding to the vortex scale.

A new automatic transmission, engineered from concept for “intelligent” and “anti-aging” (long life), has been designed and developed for TOYOTA's luxury passenger car, LEXUS LS400. This system, which has resulted in silky-smooth shift quality without changes in the long term, is composed of a transmission computer that interacts with engine computer, a number of sensors, an electronically controlled hydraulic unit with linear solenoid valves and assorted devices. As new control logic being developed with the aid of computer simulation to achieve distinction, the hydraulic and engine controls are combined in this system. There is a “feedback control”, where the clutch pressure is controlled according to the rate of acceleration and compensated for dispersion to applied pressure, engine torque and/or the coefficient of dynamic friction of clutches, and at the same time engine torque is reduced by retarding ignition timing.

The effect of GTL diesel fuel on organic materials used in fuel delivery systems of vehicles was investigated. Specimens made from 16 kinds of organic materials were immersed in GTL diesel fuels synthesized at Refinery-A and Refinery-B (referred to as GTL-A and GTL-B, respectively) and then subjected to tensile testing. The tensile test results revealed that elongation of the nylon sample immersed in GTL-A was extremely small, about 4% of that of untreated nylon. In the light of this finding, the GTL diesel fuels and nylons before and after immersion test were analyzed in detail using about 20 analysis methods to determine the cause for poor elongation. The following points were found. (1) GTL-A consisted of low molecular-weight paraffins. (2) GTL-A had low molecular-weight i-paraffins. (3) The nylon immersed in GTL-A contained low molecular-weight paraffins. (4) The paraffins in the nylon immersed in GTL-A were richer in i-paraffins than the original GTL-A.