The fourth World Solar Challenge (WSC) was held in Australia in October 1996. Honda challenged this race in third times, won again and established a new record.

The new solar car for 1996 WSC was developed as two seater type and greatly improved in running resistance, generated electric power, motor efficiency and others to run faster. It was also improved front view and others, and adopted four wheels to drive safely. For the racing strategy, we evolved the driving method and could drive more efficiently.

The 96Dream developed for the World Solar Challenge has many new mechanisms and new technologies. This paper describes the solar cell module with light weight, low loss and excellent formability.

The substrate is made by polycarbonate with good impact strength and workability, and treated with anti-reflection coating for reduction of energy loss.

As a result, we have achieved 14% weight reduction and 3/4 energy loss compared with 93Dream.

The propulsion motor for “HONDA EV PLUS” has been developed as an electric motor using the type of "DC brushless", which is known as a technology that achieves both high efficiency and high output power density.

The developed technologies include the following items.

(1)Simulation method of magnetic circuit analysis which is capable to design-in efficiency and performance.

(2)The control technology for a motor operation which achieves big torque and high revolution.

(3)Construction of rotor and cooling which achieve high revolution and high output power density.

Also this propulsion motor which was designed by using these has power density more over 1kW/kg and 91% efficiency at Combined Mode achieves most suitable for "HONDA EV PLUS".

Nickel Metal Hydride batteries (Ni-MH) that had been developed since 1991 are applied for HONDA's "EV PLUS" launched on California state in May, 1997. Batteries for EV are quite different from consumer batteries, in particular, temperature condition affects battery performance and cycle life remarkably in accordance with heat generation due to battery itself. Accordingly, heat management technology including the development of battery materials, the structural design of battery module or pack, and installing system is strongly demanded. In this report, battery development logic would be discussed through the heat behavior analysis of Ni-MH batteries which would be decomposed to several factors like battery reaction heat or electric heat etc.

Following current national emission regulations in some European countries, starting from June ’99 a common European regulation for exhaust emissions for motorcycles (97/24/EC Chapter 5) will come into force. HONDA recently presented a newly developed 3-way catalyst system aiming to reduce emission levels to 1/10 of the limit values of this new regulation. These efforts are part of HONDA’s environment strategy that attaches importance to environmental conservation.

HONDA aimed to achieve this objective for the exhaust emission values (CO: 1.3 g/km, HC: 0.3 g/km, NOx: 0.03 g/km) in the ECE40-01 mode, while meeting the development objectives in terms of engine performance and throttle response for the 1998 model of the “VFR 800 FI”. This could be achieved by introducing the exhaust emission reduction system and assuring precise control of the injected fuel amount particularly during acceleration leaning the air-fuel mixture ratio and maintaining a good driveability at the same time. The most appropriate position of the catalyst device was chosen and the secondary air injection system was coupled with the exhaust port. With this system particularly low exhaust emissions were achieved while maintaining the above mentioned overall performance aimed for this model.

Lean-burn is one of the available technology to improve fuel economy arise from development of the engine indicated thermal efficiency. Though it is required not only higher performance and more good fuel economy but also lower NOx emission, leanburn leaves much to be desired. To develop of a new 1.8L lean-burn engine, variable valve timing and lift mechanism (VTEC) and combustion improvement systems under lean mixture operation are introduced. A new 1.8L lean-burn model vehicle achieved 12% more power and 24% better fuel economy and lower exhaust emissions equally against our previous 1.8L vehicle. This engine features the new concept intake port and combustion chamber that designed on the basis of computational fluid analyses. In this paper, technologies and that effects such as improvement of new lean-burn engine and computational fluid analyses results are described.

This paper describes performance and technical features of 2.3L L4 engine developed for '98 USA model new "ACCORD", which has achieved not only high performance, high fuel economy, low noise and vibration but also meets Californian LEV (Low Emission Vehicle) emission standards. Especially, one of Californian market models meets ULEV (Ultra Low Emission Vehicle) standards world-first as mass-produced gasoline engine.

Improvement in noise and vibration performance is one of main concepts in 2.3 liter L4 engine developed for 1998 year model “ACCORD”. Setting 2.2 liter L4 engine for 1994 year model “ACCORD” as base, this target was achieved by optimization of moving parts mainly, by utilization of evaluation methods and simulation technologies.

This paper describes concepts and effects of modifications applied to each parts in order to reduce engine noise and vibration.

It is necessary to observe the in-cylinder phenomena directly for understanding in-cylinder air motion, combustion and evaluation of the numerical simulation. For each purpose, we have developed five types of optically access engine for 1.5L-Civic, 2.2LAccord and Diesel engine.

This paper describes the usage, structure and peculiar technique in design, and introduces the examples of the analyses using these engines.

A new analyzing method which allows to measure quantitative carbon deposits discharge condition and these phenomena by using optically technology for piston top rings half stick condition caused by Combustion Chamber Deposits (CCD), has been developed.

By this method, half stick condition which comes from intermittence reduction phenomenon by top ring gap fluctuation and due to oil film depletion of top ring out side surface, was able to be measured. And the more, the relationship of top rings CCD discharge mechanism and half stick phenomenon was found, and half stick condition was improved by small twist angle of top rings and small real side clearance setting which makes CCD discharge function better.

The research on piston slap has been made mainly for FC cylinder liner, however, it has not been made for FRM one. The purpose of this paper is to clarify the piston slap mechanisms for the FRM liner cylinder block, for the thrust side and anti thrust side under the cylinder temperature condition from cold to hot, by measuring and analyzing the piston slap. Furthermore, using 2-dimensional piston motion simulation, it is confirmed that the slap is accurately estimated by the calculation considering a skirt profile at high temperature condition.

A conventional evaluation method of hardening speed (Touch Free Time) of fluid sealant (hereinafter, we call Gasket in this report) could evaluate only the superficial stiff state of a gasket mono-article. However, we achieved the evaluation method of a portion sealed up in an assembled state by using heat analytic equipment. We propose gasket and flange surface specifications in case of fastening oil pan (steel plate) on aluminum flange from a standpoint of the initial reliance for engine manufacturing process. Also, in order to maintain a long-term reliability we built guidelines of flange shape by analyzing its behavior by the difference of heat expansion rate, and by engine vibrations.

The flexible joint absorbing vibration of exhaust system generally obtains an interlock, since this works as a heat guard and prevents a potential displacement of the flexible joint. The interlock sometimes generates rustle noise owing to the interference construction, and this noise may cause a problem to a development of a vehicle.

In this paper, we suggest to listen to the vibration signal of the interlock, because it is hard to analyze rustle noise by a measured acoustic signal from the view point of the signal to noise ratio. We also propose the analysis method using a short time FFT (Fast Fourier Transform) and a color contour map in order to visually check such vibration.

With this proposed method, the noise generating mechanism and the cause are quantitatively clarified, and the precautions on the design are clearly shown.

A cost-competitive and low fuel consumptive general purpose OHC (Over Head Cam) engine was developed in the field of home-use small engines for lawn mowers, etc. where the side valve engines have been gaining a majority because of their simple structure and relatively low costs. This engine’s unique features are the structure with a built-in timing belt and a common cylinder block both for vertical and horizontal shaft types. Compared with the side valve engines, better performance was obtained in the aspects of clean exhaust gas, fuel consumption, noise, weight and compactness.

We have developed the following two sensors for the Compressed Natural Gas (CNG) engine.

(1) Primary oxygen sensor provides with a catalyst coat to minimize the effect of methane and hydrogen to output of it, and improved in activation of the outer electrode.

(2) Secondary oxygen sensor has the outer electrode which is selectively inert to the methane which effects the detection of oxygen storage capabilities (the condition specified in OBD-II).

The oxygen sensor specification which is to CNG engine, and the evaluation method have been established.

Due to the limit of functions, several methods are used to measure driving speed. In concrete, the limits of speed range and heat toughness need proper use of coil type, which has good heat toughness and less sensitivity for low speed, and semiconductor type, which has enough sensitivity for low speed and lower temperature limit.

Lower speed sensing is required for up to dated control in several usage. Sensor which has adequate heat toughness and low-speed-sensitivity is convenient as parts commonality.

In this report, desirable sensor is developed by adopting garuium-arsenide semiconductor.

The effect of the groove configuration of segment bonded type paper-based wet clutch and porosity of friction materials on dynamic friction property was evaluated in this paper. This evaluation was carried out through a visualization of sliding surface of the clutch disk and a measurement of the automatic transmission fluid permeation speed into the lining at the surface of friction plate. Friction plate configurations with large numbers of grooves (segments) exhibited stable dynamic friction properties with respect to changes in the oil permeability of the friction materials through this evaluation.

We have established reliability evaluation technique of nut tightened condition in power transfer system by which dynamically tightening condition can be quantitatively checked. Slip of tightening parts causes wear of contact faces which causes reduction of tightening force. We also have established technique of estimating such reduction of force.

Additionally, with results from this research, we have made up simulation technique of analyzing the change of tightened condition as operation time passes. This procedure is capable of evaluating reliability of tightened area.

Conventional instrument panel with soft pad (hereafter referred to instrument panel) showed a low recycling rate because it consists of different resin materials e.g. PVC top layer, PP foam pad and styrene resin base material. We tried to apply olefin type resin only, which can be recycled without difficulty, to the instrument panel and have developed the instrument panel recycling technology by which the instrument panel is re-used for that of a new car.

In this paper, we explain about new olefin resin top layer (TPO) which has satisfactory mouldability and good appearance, and the surface treatment technology for it. Also, the modification method of olefin resin base material (PP) for activation to get adhesion development and the recycling technology for re-use of instrument panel material are shown.

The conventional non woven fabric was mainly applied to the items that an artistic design is not claimed so much, such as trunk mat. This paper is the report on the development of non woven fabric Flex Double Dilour (hereafter referred to FDD) which is improved in the quality by technique of fiber material and the new production technique of the two-layer non woven fabric.

FDD is improved in the sense of touch by use of fine cotton fibers and has an improved strength by doubling the layer. It also is available a pattern application by adding some device to the needling method. Consequently, the technology which can offer high freedom of design to the interior items when applying non woven fabric has been established.

In general, conventional frame bodies for scooter is made from a steel material. An aluminum die casting frame body was developed considering superior exterior design, enhancement of production efficiency and reduction of production cost. The developed frame body was successfully reduced to 1/30 of the number of parts and abolished welding portion as compared with a conventional frame body. In the initial development stage, CAD/CAM/CAE unitary data were attempted to use in order to reduce the different of prototype and mass-production frame body. As a result, a development process of aluminum die casting frame body was established in which a clay model was prepared, a construction of die and methodology of casting were studied, and strength and rigidity were confirmed. The variation of weight between the development stage and the mass-production frame bodies was approximately 0.8 % and the variation of rigidity was approximately 3.8 %.

This aluminum die casting frame body was newly applied to SZX50 1998 model.

To apply to the obstacle detecting system for automobile, we have developed the system that makes detection of the relative distance from the vehicle to the obstacle which will have possibility of collision, the relative speed of the vehicle and the size of obstacle using a stereo camera. The exclusive correlative operation hardware and the high-speed algorithm are prepared, and the system has been proved for detection of obstacles at real time by testing in real scenes.

In this paper, we show the explanation for the hardware and the software of the system and the results of experiments.

A new computer simulation model with measurements of the properties for each segment of Hybrid-III lower extremity was developed using ATB (Articulated Total Body) program.

The simulation results were compared to those of component impact tests and sled tests for model validation. High accuracy for tibia axial load and moment was confirmed.

It was found that improvement of friction model is needed while a large friction force is applied on a sole.