2. Challenge of Emission Regulations
1971-
(2) Development of Electronic Control Technology
- 1967
- Our company identified the “Electronic Fuel Injection (EFI)” system as the key solution for emission control. Developing cutting-edge products through our original methods was the result of our firm belief in pursuing the best technological choices.
From the 1960s to the 1970s, air pollution became a major social issue in the world's leading countries. Governments across the globe began enforcing regulations, urging car manufacturers to implement emission control measures. This movement spread from the United States to Europe, and then to Japan. Technologically, our ultimate solution for emission control was the “Electronic Fuel Injection (EFI)” system, with full-scale research commencing in 1967.
The trigger for this development was an event in the previous year when our pump division engineers, while on an inspection tour in Europe, encountered an Electronic Fuel Injection system developed by Bendix Corporation in a research lab at Hamburg University. This system allowed the CO₂ concentration from the engine to be changed with a single electronic control knob, which was a groundbreaking innovation.
Subsequently, Bosch also entered into a patent agreement with Bendix and ventured into the Electronic Fuel Injection business. These developments spurred our company to begin the full-scale development of the EFI system.
At the first EFI Project Meeting in 1967, our company decided to develop the EFI system using a “four-cylinder independent injection method.” Unlike Bosch's “group injection method,” this approach could meet any requirements from the engine side.
- Deep DiveConcept of Original Methods
- At the time, the director in charge of research and development anticipated that the future would see significant advancements in the integration of electronic components into ICs (integrated circuits), leading to substantial cost reductions in IC prices. Based on this projection, our company proposed the control methods and ECU (electronic control unit) specifications that we believed to be the best for EFI.
While we respected Robert Bosch GmbH as a mentor, we boldly chose the technical direction that we independently assessed and deemed to be the most optimal.
- Deep DiveSelf-Sufficiency in Semiconductor Technology
- During the EFI Project Meeting in 1967, it was decided that we would develop the fuel injection system using our original method. Consequently, we also adopted an original development approach for the ECU (electronic control unit). Not only did we choose to develop the ECU independently, but we also decided to produce the semiconductors used in the ECU in-house. This bold decision underscored our commitment to a self-sufficient and autonomous path.
Later, adjustments were needed due to patent issues regarding our independent EFI approach. In 1970, a contract was signed between Bendix, Bosch, and our company, allowing us to incorporate the technologies from both companies while continuing the development and commercialization of essential components.
- Deep DiveDevelopment of Key Components
- The EFI system is composed of several critical components, including the core ECU (electronic control unit), sensors, injectors, and their associated fuel pumps and air valves. Among these, the injector plays a crucial role by spraying fuel into the intake ports of each engine cylinder. The precision of this component greatly influences the performance of the EFI system, making the establishment of mass production techniques a priority. Development efforts were comprehensive, involving production technology and manufacturing departments. To stabilize quality at an early stage, a pilot production line for injectors was established. Regardless of demand, we maintained the production of 200 units per month to solidify our manufacturing techniques.
Regarding the fuel pump, our company had only mass-produced piston pumps for carburetors, making the development of a dedicated fuel pump for EFI essential. We began by analyzing the drawings of a roller vane pump sent by Robert Bosch GmbH. Challenges included managing the noise generated and achieving the required machining precision for sliding surfaces, as well as efforts to reduce costs.
Despite the potential to address significant social issues, our company, as a parts manufacturer, needed car manufacturers to adopt our products first. We decided to propose our EFI product to Toyota Motor Corporation. This experience reinforced the importance of presenting benefits from the car manufacturer's perspective and making proposals that they could appreciate.
After overcoming these hurdles, we secured approval in 1972 for the mass production of EFI-equipped vehicles by Toyota, paving the way for mass production.
Subsequently, in response to Japan's “1978 Emission Regulations,” which were considered the strictest in the world at the time, our company proposed a new system combining EFI, O₂ sensors, and Three-Way Catalysts. This system finally provided a solution to the challenging social issue of balancing emission reduction with fuel efficiency.
- Deep DiveDevelopment of O₂ Sensors
- Another crucial component in our efforts to meet emission regulations was the development of the O₂ sensor. Our company began working on O₂ sensor development around 1971, following the enactment of the Muskie Act (Clean Air Act Amendments) in the United States.
Ceramic technology is essential for O₂ sensors. In 1955, our company had entered into a technical partnership with Robert Bosch GmbH, which included the production of spark plugs. The insulator technology developed during this partnership became the foundation for the ceramic technology indispensable for automotive electronics.
With support from Toyota Motor Corporation and Toyota Central R&D Labs, Inc., we managed to achieve productization of the O₂ sensor after a six-year development period.
This achievement was not solely due to our company's efforts. We adopted a new collaborative development approach, working jointly with car manufacturers. The determination of our engineers to meet the car manufacturers' desire to enhance vehicle value bore fruit.
Having reached this stage, our company considered the emission control measures to be satisfactorily addressed. Moving forward, we aimed to evolve towards an integrated engine control system to further improve engine performance and fuel efficiency.