Newsletter - July 2015

Opening of expanded Aachen Engineering Centre heralds new era of DENSO innovation
Further demonstrating its European capability to design, develop, engineer and test parts and systems from a vehicle-wide perspective, DENSO AUTOMOTIVE Deutschland GmbH, a subsidiary of Japan-based DENSO Corporation, has expanded its Aachen Engineering Centre (AEC). The opening ceremony took place at the newly expanded site in Wegberg, Germany on 2nd June.

The latest expansion means that AEC has the capacity to serve its European customers in the areas of powertrain, electronics and electrical systems.

At the opening ceremony, new AEC Director Kenzo Yano welcomed guests from DENSO Japan, construction company Takenaka Europe, pm5 Projektmanagement, and all AEC associates present. DENSO Japan (DNJP) Executive Director Yukihiro Shinohara, Head of the Diesel and Gasoline Injection Business Unit, and Katsuhiko Takeuchi, Head of DNJP Diesel Business Unit, hailed the new European powertrain development and shared their vision of further growth. Compared to the original engineering centre, which was opened in 2005, the facilities and offices have been enlarged from 2,110 to 9,500 square metres. AEC became DENSO’s first engineering base for diesel engine component applications outside Japan. It was further expanded in 2010, with powertrain component engineering becoming part of the centre’s expertise. “With the expansion of AEC, we are laying the foundation for our future”, said Masato (Max) Nakagawa, DENSO International Europe’s newly appointed President, CEO & CTO. “We are particularly proud of the all-new electronic laboratory. We can now offer in-house development of hardware and software for engine control units (ECU) used on diesel and gasoline engines.

This laboratory also facilitates the accommodation of electric and hybrid technologies to European specifications. The European region plays a global leadership role in the automotive industry with respect to the creation of advanced technologies and innovative designs. The reinforcement of our local engineering and development capability is key to DENSO’s success.” As an added milestone, AEC associates surprised Mr. Nakagawa with “thank you” messages for 10 years of dedication to AEC and its growth, and a large bouquet of congratulatory flowers, celebrating his promotion and new position within the European DENSO organisation.

DENSO Lambda Sensors: manufacturing expertise meets ceramic craftsmanship
Since launching in 2008 lambda sensors have become an integral part of modern car engines. DENSO explains why this is and how its pioneering sensor technology offers OEMs and the aftermarket optimised efficiency and environmental performance.

The Introduction of EMS
In the old days, the engine of a car was controlled by a so-called open loop control system. The engine could run smooth, rough, or not even at all, and to adjust this required certain changes to various components. These components primarily regulated air and fuel supply, as well as compression, ignition and combustion cycle timings.

The performance of the engine was largely defined by pre-set properties of the carburettor, valve positions and the distributor. Most of these components were electro-mechanical, and to a large extent were subject to wear, vibrations, moisture, heat, and other well-known enemies of such devices. These systems were not only labour-intensive to maintain but also sensitive to malfunctions.

Although such control devices improved in quality and reliability, they proved extremely costly in large-scale production. Longer development times for specific part applications also meant that the original objectives of developing a wider variety of vehicle specifications, creating market demand for fuel efficiency and increasing emission standards were not being efficiently met. The search for a low-cost flexible solution was found by adopting technical design principles from the electronic industry. In the 1970s, vehicle manufacturers started to change their engine control by slowly implementing what is nowadays known as Engine Management Systems (EMS).

Lambda sensors in EMS
Lambda sensors, also referred to as oxygen (or O2) sensors, are the most important sensors for engine control, providing feedback to the Electronic Control Unit (ECU) on how well the engine is performing. The concept behind this is both a simple and brilliant one.

A lambda sensor is an electronic device that measures the concentration of oxygen (O2) in the exhaust gas from an engine, relative to the outside air. The engine ECU uses the signal from the lambda sensor to understand if the engine is running within precise specifications. The most important specification to monitor is the air-fuel ratio. In relation to each other, either too much fuel or air entering the combustion chamber can cause serious long-term engine failure. Both situations can be recognised very reliably and accurately by the lambda sensor. Based on its feedback signal, the engine ECU adjusts the amount of fuel injected into the engine. In order for the sensor to work effectively, it must be located in or near the exhaust manifold. These lambda sensors are known as regulating sensors. The lambda sensor also completes additional functions within modern engine configurations including diagnosing the effectiveness of catalyst converters, referred to as diagnostic sensors.

DENSO Ceramics
DENSO Ceramics Division is a key division of DENSO, creating products based on so-called “Technical Ceramics” that can be found in many applications. Developing, engineering and manufacturing products with these high-tech materials relies on genuine craftsmanship and requires considerable expertise.

DENSO is globally well-known for the superb quality of two other products coming from this division: spark plugs and glow plugs. Those products are both engine actuators, performing an electromechanical task based on unique properties of ceramic materials which consists of electrically insulating and heating while exposed to aggressive internal engine conditions.

However, instead of acting, certain ceramic compounds can also be used to sense specific conditions. As soon as EMS systems emerged, DENSO Ceramics Division recognised the opportunity to develop sensors that convert oxygen concentrations in gasses into an electric voltage. Zirconium dioxide has the ability to do this when heated over 400 degrees centigrade. DENSO was one of the first manufacturers worldwide to develop and produce such sensors, exclusively for the OE business.

Because this type of sensor offered great reliability and accuracy, vehicle manufacturers were able to offer a wider range of engine configurations for specific market demands. Soon, lambda sensors were a standard part of the EMS system.

Since those early years, improvements have been made to activate the sensor faster in order to generally quicken sensor start-up to optimise performance. In the 1980s, the sensor would typically take several minutes to activate, during which time the engine was running on an open-loop basis. The corresponding emissions were then not included in early emission test standards. However, this has gradually changed and today, engine heat-up is included. To shorten the activation time of the sensor under cold start conditions, at first an additional ceramic heater component was built in into the sensor. Later on, this heater was integrated with the sensing element itself. Such advancements mean that for example, the latest generation A/F sensors can provide a reliable signal in less than seven seconds after a cold start.

Other typical examples of engineering solutions are focusing on avoiding premature sensor failure; the most common failure reasons are contamination the and thermal shock. To ensure a long lifetime, DENSO sensors benefit from unique protective measures, such as their coating treatments, double element covers and customised element cover designs.

The latest developments also offer specialised functions for OEMs, and is one of the reasons why DENSO is a supplier of choice to all Japanese brands, and in Europe to Jaguar-Land Rover, Volvo, Renault and Ford.

It’s here!    The latest Starters and Alternators range extension
DENSO announces a further expansion of its OE quality, replacement Starters & Alternators programme, with the addition of 32 new part numbers.

DENSO Europe’s Aftermarket Business Unit has added 20 new Alternators and 12 new Starters to its rotating range, which are available now to its independent aftermarket customers. The new numbers cover an extensive list of makes and applications, including Toyota, BMW, Fiat, Peugeot, Citroën, VW, Jaguar, Land Rover and Audi.

Selected as original equipment by car makers worldwide, the range extension makes the advanced design, OE quality and powerful performance of DENSO’s rotating machines even more accessible to the aftermarket.

Unlike many other brands, the company’s programme of replacement Starters and Alternators offers OE specification, completely new parts, with no remanufactured units – bringing the added customer convenience of no core surcharge or returns. Furthermore, every machine is subjected to DENSO’s rigorous manufacturing and testing processes, to ensure they meet the highest standards of fit and performance.

The new applications cover both new and existing part numbers in the extensive aftermarket programme.

In total DENSO’s programme now includes 217 Alternator part numbers and 1,447 unique OE references covering 1,859 unique applications; and 73 Starter part numbers with 554 unique OE cross references covering over 1,272 unique applications.

“These new references demonstrate our commitment to providing premium quality parts in our widest ever range of Starters and Alternators to the independent automotive aftermarket,” said Kayacan Aya, DENSO Europe Application Engineer.

“Distributors can now offer their customers an even wider selection of the world’s most advanced rotating machines, manufactured by the leading pioneers of advanced Starter and Alternator technology for cars, motorcycles and commercial vehicles.”

Find out more
Further details of DENSO Aftermarket’s expanded Starters & Alternators programme are available online at www.denso-am.eu, in TecDoc or from your local DENSO Aftermarket sales contact.

Coming soon…the new Starters & Alternators 2015 catalogue
The new Starters & Alternators catalogue will be available to all aftermarket customers next month, both in print and online. As well as including full details of DENSO’s new range extension, the new catalogue will also feature all 217 Alternator part numbers and 73 Starter part numbers, between them covering over 3,131 unique applications.