Motors & Drives Information

In 1949 Nippondenso Co. Ltd. was spun off from Toyota Motor Co. Ltd. with a modest capital base of [yen] 15 million, something less than $150,000 at today's exchange rate. In late 2003, the company now known as Denso Corp. projected record sales of $22 billion for its fiscal year ending in March, putting it comfortably among the top five OE automotive suppliers in the world.

Denso's growth very much parallels Toyota's success. In the years from 1988 to 2000, Denso total sales actually doubled. Though separated from Toyota for more than 50 years, very nearly 50% of Denso's sales are still credited to Toyota.

Conversely, however, that means some $11 billion in sales is to other automakers and engine builders of the world, and Denso is certainly out to win more. It consistently wire accolades from its customers. General Motors, for example, has named Denso supplier of the year For 10 consecutive years.

Denso's engine products are its largest product sector, representing 37% of its business, with climate control at 30%, computer-related products at 14%, with information and communication systems, instruments and small motors accounting For die balance. Information Technology Systems (ITS) are expected to be the largest area of growth in years ahead. The use of pre-crash safety systems and adaptive front lighting systems are also evolving rapidly.
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Japan accounts for 57% of Denso's sales volume, the Americas for 23%, Europe for 12%, with the balance going to Asia, Oceania and other lands.

Following the 2003 Tokyo Motor Show, we received an extensive tour of Denso's R&D center, several engineering and production facilities, and were able to interview key executives and engineering managers about Denso developments and directions.

Our deep dive into Denso revealed a richly textured organization of 90,000 employees all seemingly moving in the same direction to produce world class quality products at the lowest cost with the least possible environmental impact.

"Denso considers environmental protection in all of its activities," said Koichi Fukaya, president and CEO, "including planning, development design, manufacturing, marketing and services. We are developing technologies that will reduce the environmental burden of vehicles.

"We're also tackling higher fuel efficiency, exhaust gas purification and automotive air conditioning systems that have minimal impact on global warming."

Denso's immediate strategy is to maintain its global leadership position in automotive air conditioning, achieve the leadership position in engine and powertrain products, and to further develop its ITS and telematics products, prominently including navigation systems. According to Hiroshi Uchiyama, senior managing director of Denso, the company is very focused on making ITS the third pillar of Denso's product portfolio.

Denso's efforts are backed by a strong commitment to research and development. The company R&D budget is typically in the range of 8% of net sales. The development work is organized into three areas: safety, environment, and information--matching up generally with the three product areas.

Specific product development, however, is separate from pure R&D and is "also budgeted separately. Some 70% of the corporate R&D would be classified as basic research in fields such as materials technology, semiconductors, nanotechnology, telecommunications, energy conversion, and biotechnology.

While most of this activity supports Denso's automotive-related product, the company indicates it will push into new fields if that's where its research takes it.

Denso automotive developments are both frequent and far ranging. In 2003 it introduced a novel new fuel pump, called the model GH, which is half the size of a conventional fuel pump and uses 25% less power. It is driven by a very compact d.c. motor with a high density winding. A highly optimized impeller on the pump helps achieve smooth fuel flow and efficiency.

On the diesel side, Denso has recently introduced a 26,000 psi common rail system, which meets Euro 4 emission regulations without a particulate filter. It is widely applied in Europe by Mazda, Toyota, and Nissan. Ford will adopt the new system in 2005. The system is currently being manufactured in Hungary and will also go into production in Thailand next year.

Denso claims to be the first fuel injection manufacturer to go into production with a common rail diesel injection system. That was in 1995. And this new system is currently the only one in production at the 26,000 psi range. A 29,000 psi system is being developed and it will use piezoelectric technology. That should see production in 2005.

The 26,000 psi bar system makes splitting a second like peeling an onion. Injectors can inject fuel in 0.4 millisecond intervals as precisely as one cubic millimeter per injection. Five multiple injections can be made each combustion stroke, and it may go to seven in the future, the company said.

The system also uses a software compensation method that compensates each injector individually for its manufacturing variance. Each injector has a two dimensional code that is read by the engine ECU and the system automatically compensates each injector by 0.5 cubic millimeters or less during injection.

Chorus Motors plc (OTC: CHOMF) has signed an agreement with Magnetek Inc. (NYSE: MAG) to develop traction drive technology for the underground mining industry. The companies plan to offer complete motor and drive systems for customers who demand the highest performance and reliability in the smallest available package.

Chorus drive and control systems offer unequalled power density in a compact AC unit, together with the ability to switch between high and low torque applications without loss of efficiency, allowing the same system to be used as a generator as well as a traction motor.

Magnetek is a market leader for drives and controls to the underground mining market. It has over 30 years experience in designing and manufacturing industrial power controllers with a range of solutions for the most severe duty equipment as well as custom designs.

"Magnetek is an excellent partner for us," said Isaiah Cox, Chorus's President. "The underground mining market has very rigorous requirements in which reliability and performance are at a premium, and Magnetek will ensure that the products we make will meet and exceed the industry's expectations."

"The Chorus technology allows Magnetek to provide an AC motor and drive package with torque performance equal or greater than the existing Series DC controls," according to Ed Butte, Magnetek VP Product Management. "It also provides a level of redundancy that will allow greater up-time and throughput for our mining customers."

The agreement provides for the development of Chorus® motors for haulage equipment, shuttle cars, and regenerative traction drives, with further products envisaged over time. Marketing, integration, sales and ongoing service and repair contracts will be handled by Magnetek.

In golf, the condition of the green matters. Indeed, in many athletic and recreational activities, ground conditions can make a significant difference. Understanding that, Jacobsen, the Charlotte, N.C., turf equipment manufacturer, has developed a full line of mowers dedicated to maintaining proper ground conditions for golf courses and athletic fields, as well as for professional lawn care, municipal and industrial cutting applications.

As part of that ongoing development, the company recently made a series of improvements to its G-Plex III riding greensmower, which is used primarily to maintain the greens on private and municipal golf courses. "These new features strengthen the position of the G-Plex III," said Quinn Derby, Jacobsen product manger. "Understanding the needs of our customers inspired us to add new features that make the G-Plex III easier to use and maintain."

The improvements included adding a new air purge filter in the engine fuel line. The gasoline version of the GPlex III is powered by a 574 cc two-cylinder OHV Briggs & Stratton Vanguard engine rated 18 hp, while a diesel variation of the G-Plex III is equipped with a 719 cc, three-cylinder Kubota D722 engine rated 18.8 hp. The addition of the new filter, Jacobsen said, prevents engine hesitation on slopes and sharp turns. That improvement is mated with a new 8 gal. fuel tank that has a wider, taller fuel tank neck and larger cap for easier filling and fewer spills. A Donaldson dry-type air cleaner is also installed on the gasoline engine and a Kubota-supplied radiator is used on the diesel mower.
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Jacobsen has also made changes to the hydraulic valves on the G-Plex III mower to ensure consistent front and rear lift phasing is maintained. According to Jacobsen, this helps prevent scalping the turf when lifting or lowering the reels. A Casappa piston pump powers three Cassapa hydraulic gear-type motors--one at each reel--to supply the double-acting cylinders to raise and lower the reels. The power steering is also powered through this circuit.

A separate Sauer-Danfoss hydraulic pump drives the G-Plex III mower's hydrostatic drive system through Parker dual-direction torque motors on each of the drive wheels. Pneumatic tires are also included in the drivetrain, along with hydrostatic brakes and a 6 in. caliper disc parking brake. A third wheel drive system is also offered as an option through the installation of an additional Parker wheel motor to the hydrostatic assembly. Maximum transport speed for the 98 in. long, 74.5 in. wide, 49.4 in. high mower is 7.5 mph. Wheelbase on the machine is 49.7 in.

The cutting system on the G-Plex III rider continues to use three 5 in. diameter x 22 in. long cutting reels equipped with 11 high-manganese carbon steel blades. Overall cutting width of the reels is 62 in., which can be adjusted to cut to a 0.083 to 0.62 in. heights, depending on turf conditions and type of bedknife installed, said Jacobsen. The blades have a cut frequency of 0.05 in./mph, which is matched to the G-Plex III's mowing speed of 3.8 mph (2 mph reverse).

Other changes on the mower included installing what Jacobsen said are more simplified electrical systems, including a new dash panel and electronic controller. Higher quality switches were also added and a new automatic glow plug timer is designed to provide greater reliability, convenience and less downtime in the diesel version of the mower.

The reel controls also have a new pull handle design and are now located on the swing-out center arm. In addition, the mow pedal placement was rearranged and the operator seat has a farther rear adjustment setting.

"With a comfortable operator station, easy-to-use controls, greater visibility and Jacobsen reels, you get an all-around performer with the power to do the tough jobs and the finesse to leave the perfect cut," said Derby. And he added that, "these improvements translate to the operator never having to think about some of these components ever again."

Jacobsen also offers a multitude of accessories through its dealers to customize the G-Plex III mower to the specific application. Options such as smooth and grooved rollers in steel or aluminum are available, as well as brush assemblies and grass catchers.

Quality has been job 1 for top automakers for more than a decade, as Ford Motor Co., General Motors Corp. and DaimlerChrysler AG try to reduce outlays for warranties and improve customer satisfaction. Now those OEMs are making quality just as important for the component makers that supply auto parts.

Much of this effort is centered on APQP (Advanced Product Quality Planning), a process for documenting how suppliers design and deliver components. Software developers including Aras Corp. and Powerway Inc. have been rolling out applications to automate the gathering and distribution of that documentation.

The APQP process takes outsourcing beyond simply requiring a supplier to provide a component that matches a specification. It adds the monitoring of how and when a component is created and delivered to the OEM, thus speeding the supply chain and new-product introduction by ensuring that the OEM and supplier are working on the same schedules.

"Now, instead of delivering just to a specification, the OEM also tells [a supplier] how to design and tool up their factory," said Peter Schroer, chief technology officer at Aras, in Lawrence, Mass. "And they say, 'We're going to monitor you over three years so we know you are completing the project the way we want.' What's new is [the OEMs] are enforcing APQP."
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Aras late last month began shipping its APQP Plus software, which automates the collection of APQP documents, provides a framework for managing APQP compliance projects and integrates with Aras' namesake PLM (product lifecycle management) software.

The new software includes templates for APQP and the Production Part Approval Process auto industry standard. An additional four applications in the suite enable users to manage production, sourcing, other quality issues and tooling. Together, these applications provide document management, engineering change management and cost accounting capabilities.

Indianapolis-based Powerway in March released Version 2.0 of its Powerway.com Web-based APQP software. The upgrade, which is being used by GM and DaimlerChrysler, features enhanced navigation capabilities, additional language support and a new activity log.

Freudenberg-NOK GP, which makes molded rubber components for automobiles, uses Aras' APQP Plus mainly for project management and design management, according to Tom Gill, director of CAE technology and support.

Use of APQP "has been mandatory, but we had been using manual processes," said Gill in Bristol, N.H. "Aras has allowed us to automate a lot of that. We also used this as an opportunity to standardize our processes [among Freudenberg's offices]."

APQP is called a phase-and-gate process, meaning that when suppliers have complied with one step in the process, they can go to the next step. The steps, which cover stages from request for quote to the start of production, are based on several quality standards, including QS 9000.

Freudenberg has broken its APQP compliance into five phases encompassing 60 major steps, Gill said. The phases are quote, product design, process design, validation and launch.

The company, based in Plymouth, Mich., has deployed the Aras APQP software at about 20 sites. By documenting every relevant part of the system, administrators managing the rollout of products have been able to use their time more effectively, Gill said.

"It's improved communication but cut down on meetings," Gill said. "The meetings were used to gather information and disseminate it. Now the project manager can audit [a project] for quality as opposed to dragging information out of people."

Enabling APQP Plus or similar systems to exchange data with PLM systems chosen by the OEMs will probably take some integration work, Gill said, but that's to be expected. "Historically, they pick the systems that work for them, and suppliers adapt," he said.

In deploying collaboration tools such as APQP Plus, integration of the technology is only one hurdle."The culture is the hard part," Gill said. "The software is not the hard part; changing the culture to become more strategic is. Some employees are using the software as intended, [and] that almost came as a surprise—that they are not seeing it as a burden, that they are changing their processes because of the software."

While electronic data generation continues to grow at an 80% annual rate globally, according to IDC, the tape industry is keeping pace with the introduction of larger capacity, faster data transfers, and more scalable products that provide even better returns on investment that provides the protection of your business' data. Unlike their magnetic disk cousins (where the understood physical limits of the medium are continually being challenged and redefined) tape manufacturers have proven that there is at least another 16-fold capacity increase possible by using technologies and materials that are already being tested in their labs.

It is well established that tape is the most cost-effective media for storing large amounts of data. And even as disk capacities have dramatically increased over the past 10 years, the tape industry has continually maintained a capacity advantage over disk; a single tape cartridge can be used to backup the contents of a single hard drive. This has always been the case, and it continues to be the driving imperative behind tape drive and media development.

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The science behind the improvements in tape technology is very impressive, and also very technically sophisticated. Over 40 researchers representing the major tape drive manufacturers, tape media suppliers and many of the leading research universities, collaborated (as part of the Information Storage Industry Consortium--INSIC) to analyze enterprise tape market requirements. The result was the development in 2001 of a 10-year projection for the future of magnetic tape storage. INSIC's work indicates that to remain an economically viable storage solution when compared to disk, tape capacity must grow at a rate comparable to future disk capacity growth on a cost-per-gigabyte basis.

Although disk densities are continuing to rise, the rate of growth is expected to slow as disk recording nears a superparamagnetic limitation. Due to a much lower areal recording density and much greater recording area, tape technology has the potential to grow at a faster rate and as a result improve its cost per gigabyte trends compared to disk. Therefore, when combined with disk in the enterprise storage environment, the tape industry roadmap currently maintains that tape capacity on a single cartridge must achieve 10 terabytes (TB) uncompressed per cartridge by 2011, and must reach 1TB uncompressed on a single cartridge by 2006 on its way to reaching the 10-year goal.

Areal Density

One way to increase storage capacity is to increase the areal density of the medium. Areal density is the number of bits that can be reliably stored on, and retrieved from, a fixed surface size, such as a square inch on the tape or disk. In the mid-1990s, physicists announced the theoretical areal density limit of magnetic disk at 36GB/[in.sup.2], and expected to hit the actual limits somewhere before this theoretical limit. Today, that limit has been surpassed and driven to top-of-the-line enterprise disk drive models of 75GB/[in.sup.2].

Today's mid-range quarter-inch linear tape drives can store data at about .25 to .35 GB/[in.sup.2] on tape media, which is 200 times less than that of a mid-range magnetic hard disk of 65 GB/[in.sup.2] on a 3.5-inch platter. If you consider a half-inch linear tape cartridge, it is 1000 times that of a 3.5-inch platter. The capacity advantage of tape is its large volumetric density of tape in a given cartridge. While this may seem like tape is technically behind disk, tape drive design has kept pace with overall capacity increases, while tape reliability and data retention longevity have increased.

"Disk and tape scientific and engineering advances have been applied to each technology's products," states John Goode, Quantum's Tape Storage Product marketing manager. "These include the development of new, smaller magnetic particles, improved methods of placing these particles on the medium, and smaller, more responsive read/write heads with more parallel data channels."

Greatly improved methods for detecting and recovering from errors have also helped to push the limits of tape and disk capacity. Simple parity schemes have been replaced by complex algorithms, including Partial Response Maximum Likelihood (PRML), to make intelligent decisions on what the recorded content really should be.

As improvements in magnetic media design continue, the developers of tape drives and media have more technology to work with to improve their products. But even if and when magnetic media (particularly disk engineers) do hit the areal density wall, tape engineers will still have many generations of capacity improvements to come, due to the 800:1 ratio in areal density that currently exists between disk and tape design. Another way to look at this would be to say that current tape cartridges contain 800 times the recording surface of a disk drive.