Cultivating the Next Generation of Engineers for the Electrification of Mobility

University and technical college students build Formula-style racing cars from scratch and compete in areas such as performance, vehicle concept, design, and cost. This event, known as “Student Formula” and organized by the Society of Automotive Engineers of Japan, serves as a gateway for young engineers aiming to work in the automotive industry.

Since its inception in 2003, this competition has enabled students to build formula-style racing cars, gaining extensive practical knowledge beyond mechanical and electrical engineering. They have tackled challenges such as improving performance, reducing costs, and enhancing product quality. Student teams spend about a year on design, manufacturing, and testing before the competition day.

The 2024 competition took place from September 9 to 14 at Aichi Sky Expo (Aichi International Exhibition Center), featuring 75 participating teams. DENSO contributed 18 employees as executive committee members, who were involved in the event's operation and judging. Notably, their support for students extended beyond the competition period and continues to this day.

One of the key supporters is Shinichi Nino. Nino was seconded from DENSO to MIRISE Technologies Corporation, a joint venture established by Toyota Motor Corporation and DENSO Corporation in 2019 to accelerate the development of automotive semiconductors. Additionally, he has been sharing information about the “principles of electrification” on his X, YouTube, and blog, working on disseminating and teaching technology alongside his duties.

Nino is primarily responsible for supporting the EV (electric vehicle) class in the Student Formula. Amidst the global shift towards EVs, a preliminary EV class competition was held in 2012. In the 2024 competition, 21 out of 75 teams chose the EV class.

To support teams tackling the EV class, DENSO, led by Nino, provides technical guidance to university students and offers EV motors and inverters(*) free of charge to nine universities (as of November 2024). Regarding the importance of guiding students, Nino says the following.

※These products are essential for efficiently utilizing the electricity stored in an EV's battery and ensuring excellent mobility. They convert the direct current (DC) supplied by the battery into alternating current (AC) and control the voltage and frequency of the AC to adjust the motor's rotation speed and torque.

“If student teams can effectively utilize the inverters and motors provided by DENSO, they can participate in the competition, but to aim for top positions, they need to further enhance the performance of these products. Many students don't know where to start when they actually face the products. To guide these students, we have started visiting universities directly." (Nino)

While visiting and instructing at ten schools, including the University of Tokyo and Sophia University, supported by DENSO, Nino realized that although students are acquiring knowledge, opportunities to actually create and assemble things are decreasing. Nino analyzes this situation as follows:

"I feel that fewer students understand the mechanisms and principles behind the products we provide and engage in monozukuri. This may be due to the reduced opportunities to directly interact with physical objects.

This trend is driven by the development of simulation technology. In traditional manufacturing, changes at the component level were necessary to verify the performance and safety of products. Now, this can be done by simply manipulating variables on a simulator, which saves money, eliminates danger, and speeds up the process.

However, some aspects cannot be verified by simulation alone. For example, even if calculations show no issues, the actual product may break under unexpected loads during testing. This intuition is difficult to develop through simulation alone. While simulation is important, we also emphasize the 'sense' that cannot be obtained through detailed calculations, helping students understand the true essence of manufacturing." (Nino)

During the event, students from various universities visited the DENSO booth. We showcased a variety of technologies and equipment, including electrification products, EV systems used in FIA World Endurance Championship (WEC) racing cars, demo machines for Advanced Driver Assistance Systems (ADAS) and their supporting software, as well as generative AI robots. Our goal was to let visitors experience the future and the evolving landscape of manufacturing.

On that day, Nino was actively engaging with students at the booth, explaining the principles of electrification technology with a mock-up.

“Many people believe that running a hybrid car's motor requires a large battery and high voltage to generate a significant current. However, you can actually operate a hybrid motor with just a single dry cell battery.

To demonstrate this principle, I created a 'hand-cranked three-phase inverter.' This device, which uses simple switches without any electronic circuits, helps explain the principle of inverters to many students through hands-on demonstrations." (Nino)

A university student who visited the booth said, "I have been interested in three-phase inverters for a long time, and I was impressed to see them in action." They added, "Given the challenges of electrification and automation in mobility, I believe it is up to us, the younger generation, to take on these responsibilities." Another student from a different university also shared their thoughts by saying:

“Seeing an incredibly fast EV up close made me realize that the EV class has great potential, but I also thought it wouldn't be easy to make the switch. However, at the DENSO booth, I learned about the principles of EVs, and it inspired me to take on the challenge myself and give it a try.”

As part of his technical guidance, Nino has continued to support teams from the University of Tokyo and Sophia University in transitioning to the EV class.

As mentioned earlier, in the 2024 competition, 21 out of 75 teams chose the EV class. However, shifting from the conventional ICV (internal combustion vehicle) that they have been developing to the EV class is not easy.

First, since the Student Formula competition is held annually, shifting to the EV class requires completing the EV machine from scratch within a year. Although the competition has an official "EV Parts Information Support" page and various companies provide parts, it remains challenging for students to proceed independently. This is because, unlike conventional internal combustion vehicles (ICVs), EVs have unique aspects—such as equipment layout, control unit methods, parts selection, and battery production—that require starting from scratch due to the absence of inherited technology and know-how.

Additionally, the team's captain is concerned about the potential drop in rank during their term if they switch to the EV class, which also hinders the transition.

In response to this situation, Nino notes that it has only been in the past one to two years that company engineers have actively become involved and started supporting the shift to EVs.

One of DENSO's supported teams is the "University of Tokyo Formula Factory" (hereafter referred to as the "University of Tokyo Team"). The team transitioned to the EV class in 2023, with the goal of winning the EV division. In the 2023 competition, they successfully completed the race in their first year of the EV shift, achieving an overall rank of 25th, including ICV, and securing 3rd place in the EV class.

This year (2024), the team achieved an overall ranking of 15th and secured 3rd place in the EV class, demonstrating steady progress. Despite the challenges of transitioning to EVs, the University of Tokyo Team achieved excellent results in their first year. According to Nino, this success is attributed not only to the large number of members in the team but also to the students' proactive learning attitude. So, what efforts has the University of Tokyo Team been making? Team leader Motozawa shares the following insights.

“Originally, there were two teams at the University of Tokyo: the ICV team and the EV team. The ICV team faced a significant issue when the engine they were using was discontinued, meaning they wouldn't be able to run if the current one broke. Additionally, many students in the EV team were more interested in electrical technology than the car itself, making it challenging to build the entire vehicle. Meanwhile, the organizers of the student formula competition began promoting EVs, which we saw as a great opportunity to merge the teams and focus solely on the EV class." (Motozawa)

Regarding the approach that includes technical guidance, Motozawa reflects:

"Since the specifications of the inverter changed from what was previously provided, it was helpful that we could ask questions as needed and receive answers each time. Mr. Nino came to the university and held an 'Inverter Class,' where he explained the structure and internal circuits of the inverter. He even answered very basic questions in great detail, which was extremely helpful." (Motozawa)

“In 2024, as the University of Tokyo Team enters its second year since shifting to the EV class and steadily climbs the ranks, what changes in technology and experience have occurred over the past year?”

“In the first year, 2023, we encountered numerous challenges due to our lack of experience, and it took a considerable amount of time to complete the machine. However, our meticulous approach to building the machine paid off, allowing us to finish without any malfunctions. This year, we are implementing small improvements such as miniaturizing the circuit board, organizing the wiring, and installing a display. The experience we gained in the first year has been invaluable, enabling everyone to work more quickly and efficiently." (Motozawa)

And when asking about the “decline in hands-on opportunities” mentioned by Nino, he responded as follows.

“At the University of Tokyo, first and second-year students primarily focus on general education courses, which involve a lot of classroom learning. Therefore, opportunities to learn hands-on, like in the student formula competition, become a significant advantage when moving on to specialized courses.

In the Department of Mechanical Engineering, there are many hands-on activities, but in my department, Aerospace Engineering, simulations are more common, and there are fewer opportunities for practical, hands-on experience.

Of course, society is shifting towards digitalization, but society cannot function without skills. Especially in today's world, I believe there is great value in learning through hands-on activities." (Motozawa)

Learning by doing and utilizing simulations are key principles at DENSO. The former, known as "Genchi Genbutsu," and the latter, referred to as "Sakidori," are integral parts of the DENSO Spirit. These guiding principles are positioned as crucial elements for contributing to the future of society.

Therefore, we aim to continue supporting the Student Formula, which seeks to “foster students' comprehensive monozukuri skills.” We plan to maintain our support to help participating schools achieve excellent results in the Student Formula and to increase the number of EV class teams.

For DENSO, cultivating the next generation of engineers is essential for a carbon-neutral future. Skilled engineers, led by Nino, create practical opportunities for students, and this commitment to shaping the future of technology is expected to drive the future of mobility electrification.