Honda gives rare look at R&D center taking on big project under new leader

RAYMOND, Ohio — A mile from a rural highway and past several levels of security is the Honda complex that does some of the heavy lifting — and much of the heavy thinking — for the automaker’s operations throughout North America.

Unlike the Honda assembly plants in Marysville and East Liberty, Honda R&D Americas in Raymond does not give tours to the public. It keeps such a low profile that even its employee count was once a secret.

That began to change in January, when Honda’s top executive announced that the Ohio research center would be in charge of developing a new “supercar,” the Acura NSX. The sports car will be built at a yet-to-be announced location in Ohio.

In light of the center’s highly publicized role with the NSX and other models, company officials opened its doors to The Dispatch for a rare look inside.

The lobby is adorned with 314 plaques representing the patents that Honda obtained based on work at the center.

“It’s like a developmental Petri dish,” said Frank Paluch, senior vice president of automobile development. “We can try new things.”

Automakers tend to do their most-sophisticated research close to their home base, which for Honda is in Japan. Honda is unusual in sending a complicated project so far away.

“It’s a testament to the competence that (the Raymond office) has,” said George Peterson, president of AutoPacific, a research firm in Tustin, Calif.

The heart of the complex is a design room as large as four football fields and filled with hundreds of cubicles for designers and engineers. It’s separated into departments that handle specific aspects of vehicle design.

Everyone is dressed in the Honda uniform: white pants and a long-sleeved white shirt with the person’s first name ironed onto the left breast. This includes the division’s president, whose desk is out in the open with everyone else’s.

Starting on Monday, the new president will be Erik Berkman. Before him, every top executive in the history of the research division came from Honda in Japan. Berkman joined the company in 1982 as an engineer in Marysville. His promotion might signal a growing role for the executives who have spent their careers in North America.

Berkman will oversee a Raymond office that has about 1,300 employees, most of them engineers; 200 more engineers are to be hired in the next few years.

The head count makes this the largest facility of its type in the Americas operated by a foreign-based company. The closest parallel is probably Toyota’s center in Ann Arbor, Mich., which has 1,100 employees.

Honda R&D also has 12 smaller offices in the Americas.

On the levels below the design floor in Raymond, workers make prototype versions of the vehicles and then test them. In this way, the complex is like a miniature assembly plant.
Several of the labs look like sets from a science-fiction movie.

This includes a chamber the size of a small gymnasium whose walls are covered with white foam squares. The walls block out all outside electromagnetic signals, such as those from cellphones, television and radio. In this space, researchers measure the level of electromagnetic activity coming from a vehicle, and they test how it responds when bombarded with intense levels of radio waves.

Elsewhere in the complex, employees maintain a room full of crash-test dummies (officially, they’re called “anthropomorphic test devices”) built to look like women, men and children of various sizes and shapes. Each dummy wears black dress shoes that look as if they came from a thrift store.

The main crash-test space is a long corridor with a slab at one end. Before a crash, workers put on safety glasses and stand behind a series of clear plastic barriers.

“Blink, and you’ll miss it,” one said.

In less than a second, an Odyssey minivan streaks across the room and smacks head-on into the slab. The front crumples, but the rest is almost completely undamaged. Employees wait for a moment and then gather around the wreck to take readings. The room smells like charred nylon, which comes from the material that deploys the airbags.

“Odds are that the occupant would get up and walk out of the car,” said Chuck Thomas, chief engineer for vehicle safety.

Across the hall is a smaller crash-test site that simulates different impact angles. Unlike the main test area, this one doesn’t use whole vehicles. It studies the parts, such as seats and dash components, which get placed in the frame of a vehicle.

The center started in 1991 with a suite of offices that is now the far corner of the complex. At that time, most of the work involved making derivatives of existing models, such as the Accord wagon, which had most of the same components as the Accord sedan.

That changed in 2001 when the office did almost all the development work for the Acura MDX, a completely new model. The center also led the way on the Pilot SUV, the Ridgeline pickup truck and the 2011 redesign of the Odyssey minivan. Of the 18 Honda or Acura models in the current lineup, six were developed at the Raymond office, representing 25 percent of sales.

The NSX is not designed to be a big seller, but it might be the most eagerly awaited vehicle to come out of the center, said Peterson of AutoPacific. The original NSX sold from 1990 to 2005. With a sticker price of about $90,000, the vehicle was a showpiece; sales never topped 2,000 in a year.

The new version will be a gas-electric hybrid, adding another level of complexity to a difficult assignment.

Honda’s CEO, Takanobu Ito, unveiled a preliminary version of the NSX in January, which was when he said the model will be developed and assembled in Ohio.

Paluch, senior vice president at the Honda research center, saw the comments as an affirmation and a challenge.

“Basically, the statement Mr. Ito made is that Honda has grown up its R&D worldwide enough to build a flagship vehicle,” he said.

Source;
http://www.dispatch.com/content/stories/business/2012/04/01/engine-of-design.html

Honda Commits to Finding it's Way Back to Roots

By Chang-ran Kim And Ben Klayman, Reuters

The future of Honda Motor Co. may rest with a pair of contrarian Japanese car engineers working from a drab Tokyo suburb with a hotline to the boardroom. Their mission: just say no.

Honda's creative directors, Toshinobu Minami and Yoshinori Asahi, are out to kill any mediocre car designs rumbling down the pipeline. In short, they have been told to stop anything like the 2012 Civic, a cheapened redesign that prompted critics, consumers and rivals to wonder how Honda had so badly lost its way.

Inside Honda, in both Japan and the United States, that same question has also been asked with urgency.

Honda, many say, slipped into designing cars by committee in recent years and drifted away from the iconoclastic ambitions of its founder.

Honda had become boring.

"Somewhere along the way, we lost the ability to express ourselves more freely," Asahi said. "We have a lot of designers here, and when we ask ourselves, 'Which Honda car would we want to buy?' sometimes some of us draw a blank."

That's a startling admission at a company long praised for the quality and durability of its vehicles - a company that caught U.S. automakers flat-footed in the 1970s with inexpensive, fuel-efficient cars like the original Civic.

Touted four decades ago for its CVCC engine that boasted cleaner tailpipe emissions - as well as inspiring the Civic name - Honda has trailed with advances such as six-speed transmissions and direct fuel-injection systems.

In recent years, Honda's "car guys," the engineers that built the automotive upstart into a powerhouse, were overshadowed by the "bean counters," financial executives more willing to cut corners on vehicle content to shore up margins, insiders say.

That approach looks good on a spreadsheet, but it also carries the risk of a backlash. Consumers can turn on a debased version of a popular car and the resulting publicity can burn a brand - a lesson GM, Ford and Chrysler all learned the hard way in the slide to crisis in 2008.

Ironically, Detroit's willingness to settle for also-ran status in small-car quality created the opening for Honda in the 1970s and 1980s. Now, analysts and industry executives wonder whether Honda can rekindle the underdog ambition of founder Soichiro Honda.

Changes at Honda can't come soon enough after a terrible year. Slow to recover from the earthquake and tsunami in Japan a year ago, Honda's U.S. sales tumbled seven per cent in 2011. By contrast, Nissan bounced back with a 14 per cent sales gain to almost match Honda's market share. Meanwhile, Hyundai Motor Co. and its affiliate Kia Motors Corp. have overtaken Japanese automakers as the benchmark for value-for-money.

"Honda somehow managed to get very, very far away from their engineering discipline," AutoTrends Consulting president Joseph Phillippi said, adding it could take three years for Honda to show it has turned the corner in car development.

Honda's earnings remain supported by a strong finance arm and its leading motorcycle business. In addition, the automaker is taking steps to shift more production to North America to shore up profitability.

In another move that shows the importance Honda attaches to getting it right in the United States, the board last month promoted North America chief Tetsuo Iwamura to become the No. 2 global executive, the first time that job has been based outside Japan.

But behind the scenes, the battle for Honda's automotive soul is being played out in places like Asahi and Minami's sprawling third-floor studio in the Tokyo suburb of Wako. If the upscale Aoyama neighbourhood that houses Honda's headquarters can be likened to New York's Fifth Avenue, then Wako would be a dreary town in New Jersey.

Since September, when they were promoted to fix Honda's car designs, Asahi, 47, and Minami, 44, have been working from Wako with a mission to shake things up. Both worked in the early 1990s on the fourth-generation Accord, a bigger Honda that won praise for its simplicity and a near-indestructible fourcylinder engine.

Honda's creative duo now have a direct line to chief executive Takanobu Ito. Frustrated with the pace of decision-making at Honda, Ito has put himself in charge of Honda's car operations, splitting the core of the company into three units headed by engineers: the Acura brand, mid-sized vehicles and small cars.

Honda is rushing a redesigned Civic to market late this year, essentially a facelift to protect the image of a car that is key to both Honda's future and heritage.

Source;
http://www.calgaryherald.com/business/Honda+will+revamp+after+dent+from+Civic/6245829/story.html

Honda back in the innovation game

By Richard Russell @ Globe and Mail

Although Honda built its reputation in engineering and innovation, in recent years it has strayed from that path – there have been no new engines, transmissions, hybrid, electric or plug-in systems in an era when the competition is bombarding us with new thinking.

Honda Motor president and CEO Takanobu Ito admits the company has had trouble. “The real challenge facing car companies around the world is the speed at which change is taking place. To be honest, we have not been able to keep up as well as we’d like.”

He also heads up Honda R&D and in that role says his first task as president is to push for advanced technologies, advances that will put Honda ahead of the pack in the fields of batteries, hybrids and fuel cells while working on further efficiencies with the internal combustion engine. “We’re hard at work on all of these at once,” he said recently.

The previous day, at the company’s R&D centre in Motegi, 125 km north of Tokyo near the area decimated by the March earthquake and tsunami, we had sampled a steady stream of new innovations that will find their way into an array of new vehicles in the next couple of years.

We drove a variety of new and future vehicles powered by a completely new family of four- and six-cylinder engines. We tried several new transmissions, a truly innovative all-wheel-drive system, various hybrids including one without a transmission, pure electric vehicles and a sleek sedan powered by a fuel cell.

On the engine front, a unique combination of variable valve-timing, twin camshafts and direct injection has been developed allowing engines to run on the fuel-savings Atkinson Cycle without the loss of power or torque previously associated with that method. These include a quartet of new four-cylinder gasoline engines ranging in displacement from 1.0 to 2.4 litres and a new 3.5-litre V6. The new 2.4-litre will first appear in the next Accord, late in 2012, and perhaps the new CR-V shortly afterward.

We drove vehicles powered by a new 148-horsepower, 1.8-litre four that would be right at home in a mid-cycle version of the new Civic being readied for the 2013 model year and a 127-horsepower, 1.5-litre four destined for the Fit. In all cases, these preliminary power figures are on the conservative side but considerably higher than current engines of similar displacement, while consuming 10 per cent less fuel. We also sampled a Civic powered by a potent little 1.6-litre turbo diesel.

Honda engineers have developed a trio of new continuously variable transmissions for small and mid-sized cars. On road and track they exhibited less of the “motor-boating” and “rubber-band” effects associated with CVT transmissions. Only when pressed hard on the track did they assume the CVT propensity to sound like a clutch was slipping.

Honda has also come up with a seven-speed dual clutch gearbox for higher power applications.
All of these engines and transmission will appear in standalone or hybrid applications across a wide range of vehicles of all sizes and shapes in the next two years.

Honda also showed off what it says is the world’s most efficient two-motor hybrid system, one that allows a big family-size car to operate without a transmission with a resulting saving in space and cost. Headed for the North American market next year in the next-generation Accord, it can run on electric or gasoline power or a combination of the two.

The main electric motor produces 221 lb-ft of torque and is used to launch the car, which can run for up to 24 km on battery power alone. The second electric motor is used as a generator to recharge the batteries. At highway speeds, the electric motor drops out and a 134-horsepower gasoline engine takes over.

The IC engine also comes into use to drive the generator and keep the batteries charged, much like the Chevrolet Volt. With the big electric motor able to get the car to cruising speed there is no need for a transmission.

The company also turned us loose on the big oval of the adjacent Twin-Ring Motegi racetrack in an Accord-size sedan equipped with the new V-6 sending 310 horsepower and 265 lb-ft of torque to the front wheels through the seven-speed DSG gearbox and a pair of 27-horsepower electric motors powering the rear wheels.

In addition to the abundance of instant torque when accelerating, one motor is programmed to send more power to the outside wheel in a corner while the other applies negative torque to the inside wheel.

Off-the-line performance can be silent and seamless with the twin electric motors providing the go – or is truly impressive if you get into the throttle and add the V-6 to the equation. Turn-in is exemplary and transient response exceptional thanks to the rear wheels being used to pull the car into the turn. Add to this the ability to get on the power earlier when existing the corner and you’ve got a true sports sedan.

Look for this combination in a forthcoming replacement for the big Acura RL sedan and the replacement for the NSX sports car.

Source;
http://www.theglobeandmail.com/globe-drive/new-cars/auto-news/honda-back-in-the-innovation-game/article2287398/?utm_medium=Feeds%3A%20RSS%2FAtom&utm_source=Home&utm_content=2287398

Honda Commited to fuel economy

by John Leblanc

MOTEGI, JAPAN — Honda, like most of its rival Japanese automakers, has been taking it on the chin of late when it comes to its perceived lack of engineering and product innovation.

With up-to-date features like direct-injected and turbocharged engines and multi-gear or continuously variable (CVT) transmissions more than likely found in rivals from Germany, America or Korea, many customers perceive that Japanese automakers have lost their engineering mojo, or have forgotten how to innovate, after years of being at the top of the sales charts.

The day before it rolled out three concepts at the Tokyo Motor Show that showcased what we may be driving in 2020, Honda unveiled a slew of state-of-the-art technologies at the Twin Ring Motegi Super Speedway that will appear in new cars as early as next year.

The message was clear to the attending media: Honda is back in the business of innovation, and aims to be a leader in fuel economy.

“The first task, when I started as president, was to get ahead of (the competition), particularly in the area of hybrid batteries and fuel cells,” said Honda Motor CEO Takanobu Ito, who’s been with the company since 1978 and took over the top job in 2009.

Ito also said that Honda wants to have "the No. 1 fuel economy in each (vehicle) category within the next three years."

To get there, and under the marketing banner of “Earth Dreams,” the automaker is rolling out a family of new hybrid and gas engines, CVTs, and all-wheel-drive systems, all slated to appear in new models as early as next year.

On the hybrid front, Honda’s new 2013 midsize Accord (due late next year) will receive a plug-in electric hybrid version of the company’s new “two-mode” gas-electric system.

When mated with a four-cylinder engine, Honda is claiming equal power to the existing Toyota Camry Hybrid (200 hp), but better fuel economy than the Toyota’s 4.7L/100 km combined rating.

Technically, Honda’s new two-mode hybrid uses a twin-cam profile. However, instead of using the automaker’s traditional VTEC (Variable Valve Timing and Lift Electronic Control) profile for more power, the hybrid version shifts between an Atkinson cycle (for leaner fuel burning), and the traditional Otto cycle (for more power , depending on the torque load on the engine).

Honda says the system can also be combined with a V6, driven in electric-only mode for up 24 km, electric-and-gas for accelerating, or gas-only for highway cruising.

Once a leader, Honda is catching up to the competition by adding direct-injection and double overhead cams to its mainstream gas engines.

Dubbed “i-VTEC, the new engines promise more power and “at least” a 10 per cent fuel economy advantage over the outgoing powerplants.

For example, the 2013 Accord will get a new i-VTEC 2.4-litre four-cylinder with 181 hp and 177 lb.-ft. of torque (all preliminary ratings), up 4 hp and 16 lb.-ft., respectively, from the existing Accord four.

As well, a new 1.8L i-VTEC, with 148 hp and 133 lb.-ft. (gains of 8 hp and 5 lb.-ft.) may end up in the refreshed 2013 compact Civic, while a new 1.5 i-VTEC with 127 hp and 111 lb.-ft. (10 hp and 5 lb.-ft.) could find a home in the subcompact Fit.

Shying away from CVTs in the past, Honda is now working on three new units — one for mid-sized cars such as the Accord, and two for smaller vehicles such as the Civic and Fit — that will become the base automatic transmissions for all four-cylinder engines.

While competitor CVTs have a "rubber band" feeling similar to a slipping clutch under acceleration, the Honda system I drove at Motegi, in an Acura TSX test mule with the new i-VTEC 2.4, felt more like a traditional torque converter automatic, free of the high-pitch whine usually associated with CVTs.

Honda says the new i-VTEC’s engine control software has been remapped so there is less “hunting” for revs during hard acceleration.

Honda’s premium Acura brand will also see immediate benefits from the automaker’s recommitment to new tech.

“We are not satisfied with the brand’s current positioning. We want to make it more unique and sporty. We want to make it into a ‘high-end’ brand,” said Ito.

The midsize Acura TL sports sedan will receive a new 3.5-litre i-VTEC V6, now with 310 hp and 265 lb.-ft. of torque — 30 more horsepower and 11 more lb.-ft. than the current car’s base six.

More interestingly, Honda also had on hand an Accord engineering test mule that encompassed many of the new technologies that may end up in the oft-rumoured Acura NSX replacement.
Called Electric Super Handling-All-Wheel-Drive, and in the prototype we drove, a new i-VTEC 3.5-litre V6 was mated to an also-new seven-speed dual-clutch auto box with an integrated hybrid-electric motor that also uses the energy from regenerative braking to provide the power boost. All four wheels are independently powered, depending on the car’s cornering and traction needs.

When pressed, Honda engineers told us the hybrid powertrain was rated “well above 300 hp.”
But by the way the car shot forward from rest, my seat-of-the-pants were telling me that that number could be closer to 400 hp.

Speculation in the Motegi paddock was that a new concept car, in the spirit of the Acura NSX super car, would encompass all of the Accord Electric SH-AWD test mule’s new hardware, and is set to appear at next January’s Detroit auto show.

When asked about such a car, Ito replied, “I don’t know. Stay tuned!”

Source;
http://www.wheels.ca/article/801538

Tokyo Motor Show: Honda’s new technology put to the test

By Graeme FletcherTokyo • In terms of North American content, the 42nd edition of the Tokyo Motor Show was a tad thin. However, that is not to say there was little going on. On the contrary, the sprawling show provided a ton of insight into how the world is about to unfold. Honda, a company that has been criticized for being slow to advance its powertrain technology, revealed where it is heading in the next few years, while the long-awaited Subaru/Toyota collaboration finally surfaced in road-going livery.

In Honda’s case, the technology was not only on display at the show, I had the opportunity to put it through its paces. The first is a range of new engines that combine direct injection with Honda’s iVTEC valve-lift system and variable cam phasing. The net result is more power and better economy in all cases. The unit up for testing was the 2.4-litre four-cylinder. It puts out 181 horsepower and 177 pound-feet of torque while being five per cent more fuel-efficient that its predecessor. On the track, this engine pulled strongly over a much broader range — Hondas typically have to be revved to access their twisting power.

The bigger surprise was found in Honda’s intention to shift from traditional automatics toward a range of continuously variable transmissions (CVTs). While I’m not a CVT fan, Honda’s design has two key features going for it. First, unlike most, launch is crisp because the engine’s torque is not reduced to prevent the CVT’s belt from slipping. This brings a significantly stronger tip-in response. More importantly, the shift logic is stepped (as in pre-programmed gears), which means it does not have that really annoying motorboating drone under hard acceleration.

The other engine that would serve Canada very well is an all-new 1.6L turbodiesel. This new engine produces the same output as the current 2.2L turbodiesel (140 hp and 250 lb-ft of torque) it is replacing without sacrificing the linearity and pull that defines the diesel engine. As an aside, driving a European Civic equipped with the 2.2L turbodiesel proved to be a truly rewarding experience — it has fresh looks to go along with the utility of its hatchback design. It would do well in Canada.

The second new technology was a new electric version of Honda’s Super Handling All Wheel Drive (SH-AWD) system. This iteration system uses a 3.5L V6 that’s married to a seven-speed twin-clutch transmission to drive the front wheels, while the rear wheels are driven by two separate electric motors. During cornering, the outside electric motor drives that wheel faster. At the same time, the inner motor applies a negative torque — the slowing effect amplifies turn-in response. The net result is a faster-acting torque vectoring system. The beauty of the system is the manner in which it adds that prized ride-on-rails sensation through a corner. Through the test course, the turn-in proved to be as crisp as it was immediate.

This all-wheel-drive iteration is, in a word, superb. It not only hones the European Accord tester’s handling, it transforms it into a seriously quick ride. Credit goes to two important aspects. First, the new 3.5L V6 is good for 300-plus horsepower; the electric motors then chip in with another 27 hp each. Honda is not saying how much torque they contribute to the fun factor but, based on the low-end grunt, each has to contribute at least 150 lb-ft of torque.

The design is also capable of pulling away under electric power alone. The rear motors drive the car seamlessly until the driver stands on it — then look out. Even in the Accord tester it could almost be described as too much power. The seven-speed twin-clutch also adds to overall driveability — the shifts, which are initiated through paddle shifters, are blindingly quick, which adds to the overall responsiveness.

The engineers were coy about the size of the battery the new SH-AWD system uses, but it will have to be close to a five kilowatt/hour unit. The reason is twofold. First, there must be enough oomph to provide that delicious launch. More importantly, the battery must be large enough to support the SH-AWD functions when needed after said launch. This system is said to be the driving force behind the next-generation NSX. However, if this car were to remain true to its predecessor, it would mean a mid-mounted gasoline engine with the electric motors sitting up front.

Subaru showcased its new BRZ, the lightweight sports car it shares with Toyota. It is powered by Subaru’s traditional flat-four boxer engine and produces 197 hp and 151 lb-ft of torque. Power is relayed to the wheels through a choice of six-speed manual or six-speed manumatic transmission. Inside, the cabin is highlighted by its front sport bucket seats and a tachometer that takes centre stage in the instrument cluster — both speak to the BRZ’s sportier intentions. The layout is also very much 2+2 in nature. Rear-seat leg space is tight. Other anomalies? First, this is a rear-drive car.

When it lands in Canada, the BRZ’s introduction is going to pose a dilemma for Subaru given that the company stresses its advanced symmetrical all-wheel-drive system, which is standard across its lineup. Secondly, it is a stylistic orphan.

Source;
http://life.nationalpost.com/2011/12/01/tokyo-motor-show-hondas-new-technology-put-to-the-test/