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An Investigation on the Auto-Ignition of Fuel-Air Mixture Induced by Release of Oil-Fuel Droplets from Cylinder-Liner Using Multi-Zone Model

Honda R&D Co., Ltd. Automobile R&D Center-Katsuya Matsuura, Hiroshi Sono
Keio Univ-Yuichi Seki, Keito Negoro, Norimasa Iida
Published 2014-11-11 by SAE International in United States
This study investigated effects of gas inhomogeneity induced by droplets of fuels and oils on the auto ignition timing and temperature in the direct-injection spark ignition (DISI) engine by means of detailed numerical calculation using multi zone model. Recent researchers pointed out that droplets are made of fuels and oils which mix on the cylinder liner and released from the cylinder liner [1]. During the compression stroke released droplets reach the auto ignition temperature before flame propagation induced by spark ignition. It is called Pre-ignition. In combustion chamber, there is inhomogeneity caused by temperature and mixture distribution. In this study, the effects of gas inhomogeneity produced by droplet on the auto ignition timing and temperature have been investigated using Multi-Zone model of CHEMKIN-PRO by changing initial temperature and initial equivalence ratio. Especially, the volume of first ignition zone is focused on.As for fuels, this study used n-heptane to observe the impacts which the gas inhomogeneity has on low-temperature heat release (LTHR). As for calculation conditions, 15 zones model were assumed. Based on the assumption that…
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The Development of Primer Process-less Paint System (4WET Paint System by Using Waterborne Chipping Primer)

Honda R&D Co., Ltd. Automobile R&D Center-Keisuke Kojima, Takeshi Ogawa
Published 2014-04-01 by SAE International in United States
The CO2 emission from automobile plants is large. A majority of this quantity comes from the body painting process. A breakdown of CO2 emissions from the painting process shows the significant impact of painting process equipment such as the oven used to cure paint and the air conditioning facilities used to maintain controlled temperature and humidity on CO2 emissions. It was concluded, therefore, that shortening these processes will effectively promote the reduction of CO2 emissions.Removing the primer process means that the basecoat (BC) and clearcoat (CC), which provide color and marketability, would be applied on the E-coat directly. By the removing the primer several issues are raised such as stone chipping resistance, weather durability, color variation and appearance. By contrast, this 3Wet painting system applies two coats of waterborne basecoat, dividing it up into 1-Base and 2-Base and then CC, in order to achieve both targets, quality and color variation.For severe corrosion areas, chipping primer (CP) is applied to keep chipping resistance before the application of 1-Base. Also waterborne chipping primer is required in VOC…
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Automotive Aerodynamic Design Exploration Employing New Optimization Methodology Based on CFD

SAE International Journal of Passenger Cars - Mechanical Systems

Honda R&D Co., Ltd. Automobile R&D Center-Kenichi Ando, Akio Takamura
PSG Co., Ltd.-Isao Saito
  • Journal Article
  • 2010-01-0513
Published 2010-04-12 by SAE International in United States
Optimization methodology employing CFD for the aerodynamic design of automotive car styling is presented. The optimization process consists of three stages: Design of Experiments (DOE), Response Surface Modeling (RSM), and optimization algorithm execution. RSM requires a number of CFD calculations in order to ensure its accuracy, making it difficult to apply the RSM to aerodynamic design optimization. In order to resolve this issue, Adaptive Multi Stage RSM (AMS-RSM) was conceived. This method provided the response surface its required accuracy and robustness. The optimization process was realized by constructing an automatic optimization system consisting of software.
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New Liquid Surface Conditioner for Low-Temperature Phosphating System Aimed at CO2 Emission Reduction

SAE International Journal of Passenger Cars - Mechanical Systems

Honda R&D Co., Ltd. Automobile R&D Center-Yasuhito Murai, Koichiro Izumi, Tatsumasa Hidaka
  • Journal Article
  • 2010-01-0732
Published 2010-04-12 by SAE International in United States
A new liquid surface conditioner has been developed to improve phosphate coating quality and enable a low-temperature phosphating system designed to reduce CO₂ emissions during the pretreatment processes of automobile production. Phosphate film is formed by a phosphating treatment that provides corrosion resistance for the steel plates that make up auto bodies. In the vehicle body, pocket-shaped structures such as side sills and wheel arches are likely to collect muddy water and form rust. Regarding anticorrosion quality assurance, particular attention must be paid to these pocket structures, in which phosphating solution flows slowly, and a lower solution-volume-to-surface-area ratio contributes less to the phosphating reaction. For this reason, with the conventional liquid surface conditioner, a low-temperature phosphating system cannot coat substrate surfaces sufficiently, which would result in lower corrosion resistance. The new liquid surface conditioner developed in this research improves the phosphate coating quality of substrate surfaces using smaller seed particles, each of which has greater electrostatic charge to improve the stability of the dispersed particles. A combination of the new surface conditioner and a low-temperature…
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Development of Adult and Elderly FE Thorax Skeletal Models

Honda R&D Co., Ltd. Automobile R&D Center-Osamu Ito, Yasuhiro Dokko
PSG Co., Ltd-Kazuki Ohashi
Published 2009-04-20 by SAE International in United States
Accident statistics show that the thorax is one of the most frequently injured body regions in drivers who sustain severe injuries in frontal car crashes. Thoracic injuries are more significant for the elderly than for adults. However, there are no injury assessment tools accounting for differences in anatomical features and material properties between adults and the elderly.The current study developed adult and elderly FE thorax models for investigating thoracic injury mechanisms for each generation. The ages represented by these models were defined as 35 and 75 years old (y.o.), respectively, based on the age distribution from accident statistics. The FE meshes representing the external shapes of the thoracic skeleton were first created based on the thorax CT images of the individuals with approximately average body sizes of males in their 30’s and 70’s. Since the geometry of the created mesh of the 35 y.o. appeared significantly different from the average statistically generated in the literature while that of the 75 y.o. was very close, the mesh of the 35 y.o. was recreated by morphing the…
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Size and Weight Reduction Technology for a Hybrid System

SAE International Journal of Engines

Honda R&D Co., Ltd. Automobile R&D Center-Shinya Kubota, Takeshi Sakurai, Hidenori Okada
  • Journal Article
  • 2009-01-1339
Published 2009-04-20 by SAE International in United States
A small hybrid system was developed for the 2009 model hybrid vehicle. The Intelligent Power Unit (IPU), which consists of a high-voltage battery and a Power Control Unit (PCU), occupies 19% less volume and is 28% lighter than the previous model(1).In order to reduce the size and weight of the IPU, the number of nickel-metal hydride battery modules was reduced, enabling the battery box to be made smaller and lighter. In order to provide the necessary output with fewer battery modules, the length of the battery electrodes was increased, thus raising the output from each battery module. The volume and weight of the PCU were reduced by integrating the inverter, DC-DC converter, and ECU into a single package.The size reduction of the IPU enabled the IPU to be installed at the bottom of the luggage compartment. As a result, the available space in the luggage compartment is the same as that of a conventional vehicle.
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Low Specific-Gravity Body Sealer Containing Resin Balloons

SAE International Journal of Materials and Manufacturing

Honda R&D Co., Ltd. Automobile R&D Center-Masanobu Yaguchi, Kiyoshi Hasegawa
  • Journal Article
  • 2009-01-0571
Published 2009-04-20 by SAE International in United States
A lightweight body sealer that cures at low temperatures was developed. In order to make the sealer lightweight, it is necessary to add light raw materials. In this development, the technique in which the weight reduction effect adds the resin balloon which is high and is easy to fluctuate the thickness and the particle diameter of shell was selected. Two types of resin balloons were used in combination with each other. High pressure-resistant resin balloons made of polyacrylonitrile (PAN) were one type, of which pressure resistance was increased by optimally designing heat-expandable microspheres (raw material), and the other type was high pressure-resistant polyester (PES) balloons. To enable the sealer to cure at low temperatures, it is necessary to use a resin that cures in the specified temperature zone and has the necessary physical properties. To this end, two types of resins, acrylic and polyurethane, were selected as base resin due to their good mechanical properties, when curing at low temperatures, and their versatility. These materials were used to develop a new sealer that can contribute…
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Pedestrian Dummy Pelvis Impact Responses

Honda R&D Co., Ltd. Automobile R&D Center-Masayoshi Okamoto, Akihiko Akiyama, Yukou Takahashi
Published 2009-04-20 by SAE International in United States
In order to investigate pedestrian injury mechanism by representing whole body kinematics of a pedestrian, a pedestrian dummy (POLAR II) has been developed. Previous studies indicated that the original pelvis design needed to be modified from the comparison of POLAR II and PMHS (Post Mortem Human Subject) responses in a pedestrian impact test with a SUV (Sports Utility Vehicle). In addition, according to the results of an in-depth investigation of pedestrian versus SUV or mini-van accidents in the US, pelvis fracture was found to be most frequent in AIS 2+ pelvis and lower limb injuries. Based on these findings, the POLAR II pelvis was modified for improved biofidelity. The modified pelvis design incorporated the flexible ilium (polyacetal resin) and pubic symphysis (rubber material) as opposed to the original pelvis cast in aluminum. The modified pelvis responses were verified against published isolated pelvic PMHS test results in lateral compression of the pelvis. The results showed that the force-deflection responses had good correlation with the published response data for both iliac and acetabulum loading.
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Validation of an FE Lower Limb Model for a Child Pedestrian by Means of Accident Reconstruction

SAE International Journal of Passenger Cars - Mechanical Systems

Honda R&D Co., Ltd. Automobile R&D Center-O. Ito, M. Okamoto, Y. Takahashi
PSG Co., Ltd.-F. Mori
  • Journal Article
  • 2008-01-1240
Published 2008-04-14 by SAE International in United States
Validation of a child FE model is a great challenge due to the lack of sufficient data for children. In their previous study, the authors have developed a methodology for validating a child FE model by reconstructing pedestrian accidents and comparing predicted and observed injuries. However, the study reconstructed only one accident case and more validation cases were needed for enhanced confidence of the estimated material property. The current study therefore reconstructed two additional child pedestrian accident cases. In addition, published 3–point bending test results of child long bones were also used for quantitative assessment of the material property.The accident cases were taken from the PCDS and CIREN databases. Based on the information from the accident data, a multi–body simulation and optimization procedure were used to identify impact conditions. The estimated impact conditions were used to simulate the accident cases using the FE model with failure criteria. The predicted injuries using various sets of material parameters representing individual variation were compared with observed injuries. Published 3–point bending tests for child femora and tibiae were simulated…
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Development of High-performance Diesel Engine Compliant with Euro-V

Honda R&D Co., Ltd. Automobile R&D Center-Ryuta Matsui, Kazuaki Shimoyama, Shigeji Nonaka, Isao Chiba, Shoshi Hidaka
Published 2008-04-14 by SAE International in United States
Honda has newly developed a 2.2 L 4-cylinder turbocharged diesel engine that has achieved high power and lower exhaust gas emissions. This engine is a second generation diesel engine, following the first diesel engine for vehicles at Honda, which was launched in 2004. This engine has realized large reductions in exhaust emissions, to allow compliance with EURO-V standards, and enhancements in output and NV performance. To enhance low exhaust emission performance, this engine adopted a 180 MPa common-rail system and optimized the shape of the combustion-chamber. Moreover, to enhance control accuracy under steady state and transient conditions, a Universal Exhaust Gas Oxygen (UEGO) sensor system was applied, and an electric-controlled EGR valve and electric swirl control valve newly developed. In order to enhance output, a newly developed highly efficient variable nozzle turbine (VNT) was adopted, and intake and exhaust system performance have been enhanced. The maximum power and maximum torque of this engine have been increased to 132 kW/380 Nm from 103 kW/340 Nm, compared to the previous model engine. NV performance is a vital…
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