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Since an automotive headlamp is very complicated structure, CFD (Computational Fluid Dynamics) had the problem of being very difficult. Especially, if radiation is taken into consideration, the memory required for calculation is huge. In the present study, the first aim was to develop the new calculation technology that was called FSI-DM, that is a unique technique, in which the calculation mesh generated in the fluid were made discontinuous on the solid and fluid surface. In this FSI-DM, radiative heat transfer was calculated with using the coarse mesh generated on the solid surface to reduce memory size in order to use practical, and it enable us to predict velocity and temperature on the inner parts of an automotive headlamp comparatively accurately. Next, FSI-DM was further extended so that it would be able to be applied for moisture condensation on the lens surface.

In order to improve thermal endurance, mechanical durability and ventilation performance in a headlamp, it is important to understand heat transfer and flow in an automotive headlamp. Especially in a design stage, understanding natural convection inside the headlamp will make it possible to shorten its development period, which can be fulfilled by Computational Fluid Dynamics (CFD). In the present study, a newly-developed method called Surface Heat Transfer (SHT) method, that is a unique technique for making an accurate estimate of temperature and velocity in the automotive headlamp without involving the couple of the fluid mechanics and the structural mechanics (the coupled fluid solid interaction), was investigated for practical use. An evaluation of SHT method was performed, and CFD results were compared with the experimental results. Consequently, the temperature results by CFD were within ±10 degrees as compared with the experimental results.

Sensors which can detect minimal acceleration such as ± 9.8 m/sec2 in longitudinal and lateral direction of a vehicle, for DC to 20 Hz range, are required to control ABS (anti-lock braking system) or suspension system. To fulfill these requirements, we have developed a one-dimensional acceleration sensor, using magnetic fluid, to control the vehicle. In 1992, we submitted a paper on this sensor at the SAE International Congress and Exposition. Based on this one-dimensional acceleration sensor, we have developed an acceleration sensor which can detect two dimensional acceleration using a single inertia mass. This sensor is compact and can detect minimal acceleration with high accuracy. Spring and damping functions were obtained via the adoption of magnetic fluid, as in the case of the former one-dimensional acceleration sensor. This sensor can sustain mechanical shocks.

In vehicle control systems such as ABS (anti-lock braking system) or active suspension control, sensors for detecting longitudinal and/or lateral acceleration of vehicles (acceleration of up to ± 9.8 m/s2, with frequency range of DC to 20 Hz) is necessary. The principle of acceleration detection for this sensor is as follows. A permanent magnet levitates steadily in magnetic fluid by the action of the magnetic field generated by the magnet itself. The magnet moves by the application of acceleration on the mass of the magnet. This change of position of the magnet is detected by the Hall element, and thus acceleration is measured as an electrical signal. This sensor consists of only magnetic fluid, a permanent magnet, housing, a pair of Hall elements and an electronic circuit.