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Experimental and Computational Study on Helical Coil and Straight Type Sub-Cooled Condenser for Air Conditioner in Automobile Vehicle

Keihin Corporation-Junya Washiashi, Jun Liu
Sophia University-Hardeep Singh, Mitsuhisa Ichiyanagi, Edtya Dzieminska, Takashi Suzuki
  • Technical Paper
  • 2020-01-1246
To be published on 2020-04-14 by SAE International in United States
This paper provides the importance of helical coil sub-cooled condenser which has a compact structure, large heat transfer area, and high heat transfer capability in comparison to the straight sub-cooled condenser in the automobile vehicle. The HVAC unit has the largest parasitic load on the engine. Hence, by improving the coefficient of performance of the air-conditioning (A/C) system, the reduction in vehicule emissions is possible. Previous studies explain that there is generation of secondary flow inside the fluid in the circular cross-section of the helical coil. By using the effect of the secondary flow generation, authors tried to enhance the heat transfer rate as it leads to heterogeneous temperature distribution across the periphery of the tube and causes a higher heat transfer. For the purpose of the study, a prototype with a square cross-sectional 2.7 mm × 2.7 mm channel with flat fins towards the outer side has been constructed. Heat transfer characteristics for the square channel helical coil cub-cooled condenser (HCSCC) has been evaluated experimentally and then compared with CFD analysis. During the bench…
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Research on Method of Sensor Fault Detection for OBD-II Compliant Motorcycles Based on Temperature Estimation

Keihin Corporation-Atsushi Watanabe
  • Technical Paper
  • 2019-32-0568
Published 2020-01-24 by Society of Automotive Engineers of Japan in Japan
On-Board Diagnostics II (OBD II), which will be to be introduced into motorcycles in Europe and India, requires that the engine oil and cooling water temperatures be monitored in a rational manner. The rationality of the sensors for engine oil and coolant temperatures (TW sensors) is derived from the ability to detect failure modes such as offset or fixation of unintended output voltage in addition to circuit continuity checks such as sensor harness disconnection and short circuit.The OBD II technology for 4-wheeled vehicles cannot be easily converted to motorcycles with their multiple cooling systems (air-cooled and water-cooled) and multiple heat dissipation structures (full fairings, naked structures, etc.). In previous studies, failures of the TW sensor were detected by estimating the water temperature with high accuracy based on the calorific value of the engine and the amount of heat dissipated. However, in studies considering the implementation of electronic control units (ECUs), it has been reported that such estimations are vulnerable to disturbance (especially from a heater or blower) because it was difficult to estimate water temperature…
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Development of High Productivity and Low Cost Card-Edge Type ECU for Motorcycles

Keihin Corporation-Syuichi TAKIOKA
Honda Motor Co., Ltd.-Yuichi TAKEDA, Daisuke SUGIO, Koji INOSE
  • Technical Paper
  • 2019-32-0516
Published 2020-01-24 by Society of Automotive Engineers of Japan in Japan
To reduce global warming, Honda has been worked on emission reduction and fuel efficiency enhancement by applying fuel injection systems. The productivity enhancement and cost reduction are strongly demanded in developing countries as the market is expanding. To enhance productivity and reduce cost of ECU, application of the semiconductor production method has been started for printed circuits with edge connectors. However, products that fully meet the requirements of us have not been realized so far. The ECU developed this time has a structure shielding the whole PCB package except the edge connector terminals. Thus, the waterproofness required for an ECU has realized, as a standalone component, as the first in the world (by Honda survey). To achieve that, we developed transfer molding dies equipped with a unique mechanism never been applied. Moreover, we developed an epoxy resin that eliminates the after cure process. Thus, productivity of 5 times over conventional was realized with a multi-cavity molding capable of moldings more than 10 pieces at a time. Furthermore, a new waterproof card-edge connector was developed, in…
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EFFECT OF DEAN NUMBER ON HEAT TRANSFER CHARACTERISTICS FOR SQUARE CHANNEL HELICAL COIL SUB-COOLED CONDENSER

Keihin Corporation-Junya Washiashi, Jun Liu
Sophia University-Hardeep Singh, Mitsuhisa Ichiyanagi, Takashi Suzuki
  • Technical Paper
  • 2019-32-0597
Published 2020-01-24 by Society of Automotive Engineers of Japan in Japan
Attribute to high heat transfer rate and less complexity, the Helical coil sub-cooled condenser (HCSCC) can provide the most innovative and unique application for the air conditioning system. In the case of automobiles, reduction in air-conditioning load may diminish the vehicular emission, and power consumption as the air-conditioning load is the most power-consuming components after the engine load. Moreover, to solve the problem, we focus on the helical type heat exchanger. It may play a vital role in reducing the weight and increase the performance of the small engine because of the compact structure and lighter weight. The compressor unit is the most vital component of the refrigeration cycle, but the condenser unit is also one of the most critical devices, and the author tried to reduce the power consumption by enhancing the performance of the condenser. The crucial point of this study is to use HCSCC, which exemplify the effect of subsequent flow generation inside the fluid, and it is known as the Dean's effect. This effect leads to the heterogenous temperature distribution along…
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Development of Voltage Control Unit Using a Coupled Inductor with a New Structure for Plug-In Hybrid Vehicle

SAE International Journal of Advances and Current Practices in Mobility

Keihin Corporation-Satoshi Hashino
Honda R&D Co., Ltd., Automobile R & D Center-Akitomo Komatsuzaki, Tatsuya Choji
  • Journal Article
  • 2019-01-2311
Published 2019-12-19 by SAE International in United States
Honda has developed an electric powertrain for the new model plug-in hybrid vehicle. In order to realize the EV performance, it was necessary to increase the power output of the high-voltage DC-DC converter to boost the battery voltage (referred to as a “Voltage Control Unit (VCU)” below). An interleaved circuit using the newly developed coupled inductor was employed to reduce the magnetic flux leakage to the exterior as the method of increasing the power density of the VCU. The application of the inductor has increased the continuous power density of the VCU approximately 2.8-fold in comparison with the conventional unit employed in previous Honda hybrids.
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Influence of Secondary Flow Generation on Heat Transfer inside the Fin Type Spiral Sub-Cooled Condenser by Experimental and CFD Analysis

Keihin Corporation-Junya Washiashi, Jun Liu
Sophia University-Hardeep Singh, Takashi Suzuki, Mitsuhisa Ichiyanagi
Published 2018-10-30 by SAE International in United States
This paper discusses the compact structure, innovative and unique approach of high performance spiral coil sub-cooled condenser for compact power plant/engine applications. The motivation behind this study is to reduce the engine emission by improving the coefficient of performance for air-conditioning unit. Since the air conditioning system is the most power consumption units after the power plant, so it significantly affects the fuel consumption and the hazardous gas emissions. In the air condition cycle, the condenser unit is addressed as one of the important devices, and thus, the author tried to reduce the energy consumption by improving the performance of the condenser. The most advantage points of this study is to use spiral coil sub-cooled condenser, which elaborates the effect of secondary flow generation inside the fluid and is known as the Dean’s effect. This results in the heterogeneous temperature distribution across the periphery of the tube and lead to a greater heat transfer. The heat transfer characteristics for the tube-fin type with spiral coil and square cross-section have been determined experimentally and then compared…
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Development of High-Power-Density DC-DC Converter Using Coupled Inductors for Clarity Plug-In Hybrid

Keihin Corporation-Satoshi Hashino
Honda R&D Co., Ltd.-Akitomo Komatsuzaki
Published 2018-04-03 by SAE International in United States
Honda has developed an electric powertrain for a 2017 plug-in hybrid vehicle using its second-generation SPORT HYBRID i-MMD powertrain system as a base. The application of the newly developed powertrain system realizes a long all-electric range (AER), allowing operation as an EV for almost all everyday driving scenarios, with dynamic performance making it possible for the vehicle to operate as an EV across the entire speed range, up to a maximum speed of 100 mph. The amount of assist provided by power from the batteries during acceleration has been increased, helping to downsize the engine while also balancing powerful acceleration with quietness achieved by controlling racing of the engine. In order to realize this EV performance with the second-generation SPORT HYBRID i-MMD system as the base, it was necessary to increase the power output of the DC-DC converter, taking restrictions on space into consideration. An interleaved circuit design using coupled inductors was employed as the method of increasing the power density of the DC-DC converter. This circuit design reduced magnetic flux generated in the inductor…
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Spray Characteristics Optimization for Small Motorcycle Engine Using Internal Cylinder Flow Analysis

Keihin Corporation-Yuzuru Sasaki, Nobuhiko Yamaguchi, Akira Arioka
Honda R&D Co., Ltd-Katsunori Komuro, Dai Kataoka, Shunji Akamatsu
  • Technical Paper
  • 2017-32-0017
Published 2017-11-05 by Society of Automotive Engineers of Japan in Japan
In recent times, due to the improvement of internal cylinder flow analysis technology with Computational Fluid Dynamics (CFD), the prediction accuracy of fuel consumption and emission has improved. However, small motorcycles often have complex intake ports which restrict the layout of injectors. Therefore optimization of injection spray to achieve high combustion efficiency and less wall wetting is a challenge. In this study, we predicted fuel consumption and emission performance by the simulation result of air fuel distribution and wall wetting amount with an actual motorcycle engine model. We optimized injector nozzle length, spray angle and spray tip penetration. After the optimization, we evaluated the emission performance and fuel consumption with an actual engine. As a result, we were able to confirm the improvement of fuel consumption and emission performance.
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Research on Misfire Detection Algorithms for Motorcycle Engine Firing at Uneven Intervals

Keihin Corporation-Katsunori Tasaki
  • Technical Paper
  • 2017-32-0052
Published 2017-11-05 by Society of Automotive Engineers of Japan in Japan
Misfire is the condition where the engine does not fire correctly due to an ignition miss or poor combustion of the air fuel mixture, resulting in serious deterioration of tailpipe emissions due to the discharge of unburned gas. In order to prevent further exacerbating environmental problems, misfire detection is obligatory in On Board Diagnosis (OBD) II systems.OBD II technology for passenger cars cannot be easily adopted to motorcycles for several reasons. However, very little research has been reported on misfire detection for an unevenly firing engine in which the degree of contribution to engine output and the variation pattern of angular velocity show a large difference between cylinders, an aspect that is unique to motorcycles.This research focuses on uneven firing V-twin motorcycle engines, to explore misfire detection techniques using variation characters in crank angular velocity.Firstly, algorithms were proposed to be applied either individually or in combination utilizing methodology such as, identifying the portion of the combustion cycle in which combustion characteristics are exhibited for each cylinder from the crank angular velocity variation and to define…
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Vehicle Calibration Techniques Established and Substantiated for Motorcycles

Keihin Corporation-Satoru Kanno, Koichi Tsunokawa , Takashi Suda
Published 2012-10-23 by SAE International in United States
Down-sizing of motorcycle ECU becomes essential requirement because of vehicle load capacity. Furthermore, cost-down is drastically required and components selected in ECU, such as built-in RAM capacity of CPU, are reduced maximally because motorcycle is in low-priced range mostly. The different things of ECU from four-wheeled vehicle affect vehicle calibration in development. It is ideal for using such ECU which has suitable size for vehicle and the minimum built-in RAM capacity of CPU to implement vehicle control, instead of using dedicated development ECU which is in large size and needs additional investment in vehicle calibration for motorcycles. This research has explored techniques for vehicle calibration based on mass-production ECU in order to find particular solution for motorcycles.Vehicle calibration is sequential procedure which adjusts control data of ECU by using PC application software to measure and analyze bench or vehicle test information repeatedly aiming to achieve target performance of vehicle. A typical technique utilized for dedicated development ECU is to reflect all control data deposited in ROM to RAM, and edit RAM data directly. As an…
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