Ongoing Technological Developments to Attain Higher Goals for the Next Generation

Transcription

1 Section 1 Product Development 1 Ongoing Technological Developments to Attain Higher Goals for the Next Generation It is important for us to improve the environmental performance of our products to enable our customers to use the products without being concerned about the impacts caused by these products to the global environment. In their lifecycles, our products tend to cause the largest environmental impacts while they are in use, and we need to reduce such impacts. To meet this requirement, Honda is striving to build a better relationship between people, the earth, and our products by setting severe voluntary standards for environmental conservation, including cleaner exhaust gases and higher fuel efficiency. Reduction of CO2 emissions Reduction of air pollutants Improvement of environmental performance Practical use of alternative energies 11

2 column Full-scale Efforts towards the Century of the Environment: Decision to Replace Various Engines with New-Generation i-series Engines Honda, hoping to make its most popular engines in each class the World s No. 1 Engines at the beginning of the 21st century, is now developing the new-generation i-series engines. Towards the Century of the Environment, we are pursuing higher goals with all our strength, utilizing the unsurpassed skills of our product development department. 1 To meet the next-generation engine. Exhaust gases from these two 2 Honda s decision to develop requirements engines were 50% or less than the 2000 a new engine Heading the world, Honda unveiled a CVCC engine that met the criteria of the Muskie Act (the U.S. exhaust gas regulations) in 1972, and has long been taking measures to achieve cleaner exhaust gas. In the latter half of the 1990s, various international agreements were made, including the Kyoto Protocol, which accelerated the global movement towards environmental conservation. Accordingly, people increasingly demanded higher fuel economy to reduce CO2 emissions from automobiles as part of efforts to reduce global warming. Under such circumstances, Honda began developing two new types of engines: a 1.0- liter engine as the main power train for the Honda IMA System used for Honda s hybrid car, the Insight; and a 2.0-liter DOHC engine for Honda s sports car, the S2000. The former achieved the ultimate high fuel economy of 35 km per liter in the mode and the latter achieved the ultimate power of 250 horsepower from a 2.0 liter exhaust gas emission standards and the S2000 became the first automobile to meet the 2000 emission standards. Also, these engines were light and compact, enabling a more flexible design. As a result, the aerodynamic performance and the energy absorbing ability of the crushable zone were improved. Thus these engines have greatly contributed to the provision of products that are excellent in handling, fuel economy, and safety. Honda, while developing such technologies to achieve ultimate functions, made a new, challenging decision: to introduce the new-generation designs to various engine classes, to be the world s No. 1 in terms of power, clean energy, and fuel economy. The development and production departments would need to cooperate together to accomplish the substantial work of developing a new engine, which requires the creation of hundreds of new parts, including the cylinder block and cylinder head, which serve as the framework of the engine. Honda, however, decided to commence this difficult task, thinking it impossible to achieve the high goal that it had set for the next generation by simply improving existing engines. The first objective was downsizing the engines by 10% in terms of weight, improving their fuel economy by 20%, and increasing their output by 10%. For their specifications, the following three issues were decided: to change the engine s revolving direction, which had previously been set reversely from general engines, to install all the engines sideways; and to develop new transmissions for these engines. As for application technologies, Honda s concept about the replacement of engines Environmental goals in the Century of the Environment Replacing all engines with new-generation engines Contribution to society Contribution to customers Joy of driving Overwhelmingly excellent running performance Insight Ultimate power Clean Ultimate fuel economy S2000 High-level combination Targets to be achieved to make Honda s new-generation engines World s No. 1 Clean performance : to reduce exhaust emissions to the utmost limit Fuel economy : to improve fuel economy by 10 to 20% compared with previous engines Compactness : to downsize the engines by 10 to 15% in terms of weight to make them the world s most compact Output : to achieve torqueful performance in the whole speed area Production technology : to achieve higher production efficiency and more innovative production Comfort 12

3 Automobiles it was decided to adopt the optimal technologies for each engine, not using the same technologies for the engines for different models. Thus we started to develop the ultimate gasoline engines, using diverse application technologies and all our skills, including the advanced technologies accumulated in the development of the Insight and S Newly developed engines As the first result of these efforts, Honda unveiled a 2.0-liter i-vtec engine in The new-generation, 2.0-liter, 4-cylinder gasoline engine was characterized by its high performance and light and compact design, and was used for the STREAM. For this i-vtec engine, a lean-burn combustion method was adopted as a result of trials and tribulations for improving fuel economy, environmental performance, including cleaner exhaust gas, and driving functionality. The second product of the newgeneration engine series was the 1.3-liter i-dsi engine used for the Fit. This engine achieved a high fuel economy of 23 km per liter in the mode, and was equipped with two ignition plugs per cylinder. The i signifies intelligent engine and Honda plans to replace various engines with its new i-series engines. Production innovation and 4 synergies Honda then decided to replace existing engines with new-generation engines as a part of its production line reforms, in order to improve the efficiency and flexibility of its production bases within and outside Japan for the manufacturing of products with higher qualities as well as for the further reduction of its environmental impact. Traditionally, at Honda factories, different engines were manufactured by different production lines and the line and factory operation rate differed depending upon order quantities. If, however, the production lines were improved to increase the number of engine types that one production line could handle, more popular products could be manufactured by multiple lines, and production could be allocated to various factories. Thus, more options could be provided and the needs of customers could be met more flexibly, leveling the work load and improving the production efficiency of each production line at all Honda factories across the world. To manufacture multiple engine types on one production line, however, careful consideration must be given to the production process, even as early as the engine design stage. The replacement of engines was therefore an important decision to promote production line reforms. As a result, for the STREAM and the Fit, which had become very popular with customers, we were able to establish production systems to fully meet customers needs. Pursuing diversified possibilities 5 for power trains There are presently two types of engines in the i-series : the 1.3-liter in-line 4-cylinder i-dsi engine and the 2.0-liter in-line 4- cylinder i-vtec engine. The i-dsi engine corresponds to 1.2 to 1.5-liter engines and the i-vtec engine corresponds to 2.0 to 2.4-liter engines. We are now planning to expand the application of these new engines to other models. Also, we are rapidly developing new engines with other displacements. By 2005, all other Honda models, in addition to the STREAM and the Fit, will be equipped with i-series engines, and thereby all Honda s objectives concerning cleaner exhaust emissions and higher fuel economy will be achieved (see figure below). In addition to the sophistication of gasoline engines, we will also aggressively take other environmental measures, reducing CO2 emissions from diesel engines, expanding the application of hybrid engines, and developing power trains for the next-generation technologies including fuel cells. Also, for motorcycles and power products, we will take the necessary measures to reduce their environmental impacts. Environmental goals for automobiles to be achieved by ) To achieve clean emissions of 50% or less of the 2000 emission standards for all models by 2002 To reduce the total HC and NOx emissions from new automobiles by approximately 75% by 2005 To obtain ULEV certification for most of Honda passenger vehicles from the Ministry of Land, Infrastructure and Transport by 2005 To achieve the 2010 fuel economy criteria for all the weight categories by 2005 To improve the average fuel economy by approximately 25% by 2005 (compared with the 1995 level) 2) 1) These goals are all domestic goals to be achieved within Japan. 2) Already achieved in Influence of engine replacement Engine replacement exerts great influence over many elements, including the design, performance, and production system of an automobile. In order to replace our engines in various classes, all the departments in the company would have to cooperate together. 13

4 Cleaner Exhaust Gas Steady Improvement of Engines to Achieve Cleaner Exhaust Gas Honda has been developing environmental technologies, giving first priority to the reduction of exhaust emissions and setting its own high goals for each of the periods. We developed CVCC engines in the 1970s, and released LEV-spec engines and met the highest emission standards such as ULEV and SULEV standards for the first time in the world in the 1990s. Also, we introduced the i-series new-generation engines towards the 21st century. Further accelerating the progess in environmental technologies, we will provide the world with greener vehicles. Cleaner exhaust gas target for 2005: To reduce the total exhaust emissions of HC and NOx by approximately 75% for new vehicles by 2005 (compared with 1995)* To achieve a clean performance that exceeds the 2000 exhaust emissions standards of Japan by 50% or more for all vehicles* To obtain certification as Ultra Low Emission Vehicle (ULEV) from Japan s Ministry of Land, Infrastructure and Transport for most Honda models* *Targets for Japan To disseminate automobiles with cleaner exhaust emission technology 1972 CVCC Honda LEV Announcement in 1972 of the CVCC technology to meet ahead of others the U.S. exhaust emissions standards called the Muskie Act, which was said to be impossible to comply with. Release in Japan in 1973 of the CIVIC CVCC using the latest CVCC technology CIVIC CVCC (Released in 1973) Honda LEV Improved combustion at engine start, when the engine is cold. Also, by keeping exhaust emissions at a high temperature, it is made possible to quickly maximize the catalyzer s cleaning ability. First applied to CIVIC FERIO (put on sale the in 1997) Met the LEV standards Met the ULEV standards for the first time in the world Announcement of the new-generation, 2-liter, 4-cylinder gasoline engine i-vtec S2000 (put on sale in 1999) Met the SULEV standards* for the first time in the world The world s strictest clean exhaust gas standards for gasoline-powered vehicles) Approved as the first vehicle meeting the exhaust emission standards for year Improvement with the times, starting with CVCC 1) 2 Meeting the LEV 2), ULEV 3), and SULEV 4) standards for the first CO, HCs, and NOx contained in exhaust gases time in the world may cause photochemical smog and acid rain, In 1995, in its pursuit of the ultimate and exert diversified influences on people. technologies, Honda unveiled the ultra low Honda has been giving the first priority to emission engine to meet ahead of others in the reduction of these substances and the world the ULEV standards of California, improving its exhaust gas cleaning which were said to be the strictest in the technologies. Following the movement of the world. (In 1997, in the U.S., we released an times, we have entered benchmarking Accord equipped with this engine.) technologies for low emission engines in the At the same time, we were developing the market, including CVCC, Honda LEV, and Honda LEV technology, which reduced the DOHC i-vtec technologies. We have also CO, HCs, and NOx contained in exhaust been conducting research to comply with emissions to one-tenth of the levels set by our high, voluntary environmental standards Japan s automobile exhaust emissions in addition to the environmental regulations regulations for 1978, and released the implemented in different countries. products equipped with the technology 1) CVCC: Compound Vortex Controlled Combustion 2) LEV: Low Emission Vehicle 3) ULEV: Ultra Low Emission Vehicle 4) SULEV: Super Ultra Low Emission Vehicle 5) i-vtec: Intelligent-Variable Valve Timing & Lift Electronic Control System within Japan. This marked the start of the distribution of products having clean performances much higher than those of the standard products marketed at that time. The technology was subsequently applied to nine remodeled Honda automobiles. In 1999, the ULEV technology was further improved to meet ahead of others in the world the SULEV standards of California. 3 Progress to i-vtec 5) and to the Excellent Low Emission level Subsequently, in Japan in 2000, the Ministry of Land, Infrastructure and Transport implemented the Low Emission Vehicles Approval System. Under the system, vehicles are classified as Good, Excellent, or Ultra low emission vehicles. Honda, by inputting the new-generation DOHC i-vtec engine, obtained certification as Excellent low emission vehicles (achieving emissions that are 50% or less of the emission standards for 2000) for almost all its models other than light trucks as of October By 2005, we intend to obtain the certification as Ultra low emission 14

5 NOx regulations in Japan and the U.S.* Automobiles U.S. CARB regulations (for NOx) Unit: g/mile Regulations for the emission of NOx enacted in Japan Unit: g/km (regulations in 1972) g/mile 0.40 LEV LEV (regulations in 1975) (regulations in 1977) 1.00 (regulations in 1980) 0.40 (regulations in 1982) Tier I TLEV LEV Honda LEV (CIVIC) ULEV ULEV (Accord) LEV ULEV SULEV Meeting SULEV standards (regulations in 1973) CVCC (first CIVIC) 1.20 (regulations in 1975) CVCC-1 (CIVIC) 0.85 (regulations in 1976) Over 1 ton 0.60 (regulations in 1976) 1 ton or below 0.25 (regulations in 1978) CVCC + oxidation catalyzer (CIVIC, Accord, Prelude) Regulations in 2000 J-TLEV Honda LEV S2000 J-LEV J-ULEV 0.08 Regulations in g/km *The regulations cannot simply be compared between Japan and the U.S., because the units and test methods differ DOHC i-vtec CIVIC G Accord 20E STREAM Progress of VTEC, exhaust systems, and catalyzers In addition to Honda s unique VTEC, more precise control of in-take valve timing has realized low exhaust gas, high fuel economy, and higher torque performance. Also, the adoption of a rear dual exhaust system and a NOx absorbing catalyzer for leaner burn has made it possible to comply with the Excellent Low Emission Vehicle certification level set by the Ministry of Land, Infrastructure and Transport. Ultra Low Emission Vehicle certification level To obtain Ultra Low Emission Vehicle certification for most models Reducing HC and NOx emissions by achieving cleaner exhaust gas for new vehicles Total HC and NOx emissions from new vehicles (shown in a percentage to the level of 1995) (%) -75% Sales quantity (in Japan) 800,000 vehicles (Fiscal year) vehicles (achieving the emissions that are 25% or less of the emission standards for 2000) for most of our passenger vehicles. We started the sale of Ultra low emission vehicle-certified CIVIC and CIVIC FERIO in October 2001 and have also obtained the ULEV certification for the CIVIC Hybrid, Accord, and Accord Wagon. 4 Honda has been improving its exhaust gas cleaning technologies based on a consistent approach: to completely combust the gasoline in a highly efficient engine and to clean the exhaust gas by the use of threeway catalyzers. This approach requires the combustion control according to changing external conditions and running conditions. Honda has been trying to meet the requirement step by step by increasing the sophistication of Noise reduction Implementing careful measures to reduce the noises caused by automobiles Noises caused by automobiles include engine noise, air intake and exhaust noise, and noise caused by the friction between tires and roads. Honda is reducing such noises to improve the quietness performance of its automobiles. Specifically, we have improved the engine intake and exhaust system, applied sound absorbing materials to the engine compartment, and improved silencers and mufflers. We are thus implementing considered measures for noise reduction. Automobile noise reduction technologies Engine Adoption of silent chains for the timing belt Improved parts rigidity Air exhaust system Adoption of a large-capacity silencer Adoption of a double catalyzer cover computer technology and by conducting research to pursue the possibilities of increasing catalyzer density and the use of new materials. We will further continue to Air intake system Centralized air intake system Adoption of a large-capacity air cleaner with a muffler Use of sound absorbing materials Road noise reduction measures Adoption of low noise tires make these efforts to provide customers with automobiles of ever higher clean performances. 15

6 Improvement of Fuel Economy Honda s Unique Approach to Improve Fuel Economy to Reduce CO2 Emissions: Input of New-Generation Engines and Hybrid Systems Honda, as its approach to the remarkable improvement of fuel economy, has developed the VTEC mechanism that enables high fuel economy as well as high output, a hybrid car that achives the world s highest fuel economy, and the transmissions that enable the effective transmission of power. We also introduced new-generation i-series engines. In the 21st century, we will accelerate the development of environmental technologies to further reduce the emission of CO2 from vehicles. Fuel economy improvement target for 2005 To achieve by 2005 the new fuel efficiency standards of Japan for 2010 for all weight categories* To improve the average fuel economy by approximately 25% (compared with 1995)* Targets for Japan Improvement of engine efficiency VTEC Features two cams on a single camshaft one for the high-speed range and the other for low-and mid-speed ranges. By using either of these cams according to driving conditions, the engine achieves superior fuel economy while delivering high power output. VTEC-E Features two intake valves, one of which is suspended at low engine revolutions. Through this, the engine achieves fast but stable lean combustion with high fuel economy. New VTEC Developed by combining the advantages of the VTEC engine, which produces an excellent balance of power and fuel economy, with the intake valve suspension mechanism for VTEC-E engines that achieve superior fuel economy. 3-stage VTEC Optimizes intake valve timing and lift in three stages (low, medium, and high speeds), and achieves the highest fuel economy and power output in the 1.5-liter engine class. First applied to the INTEGRA (put on sale in 1989) First applied to the CIVIC (put on sale in 1991) First applied to the Accord (put on sale in 1993) First applied to the CIVIC (put on sale in 1995) 1 Combust gasoline with no waste. Use the derived energy as driving power to the greatest possible degree. These are the objectives that every engine design pursues. For example, the VTEC engine released in 1988 achieved high power output and high fuel economy through the use of two alternate cams mounted on a single camshaft one for the high-speed range and the other for lowand mid-speed ranges. Honda further improved the VTEC technology, and subsequently in 1999 unveiled the i-vtec engine as the most advanced VTEC engine. Through technological renovation such as the sophistication of combustion controls by an intelligent system and drastic downsizing (through lighter and more compact design), we combined higher fuel economy and 16 cleaner exhaust gas with the joy of driving in a sophisticated manner. The i means intelligent and by 2005 we intend to upgrade all our engines in various classes to intelligent engines as the i series. In 2001, we developed the 1.3 liter i-dsi * engine and adopted it in the Fit. * i-dsl : Inteligent Dual & Sequential Ignition 2 Honda Multimatic S The efficient transmission of power generated by highly efficient engines contributes to greater fuel economy. Honda has therefore also been making efforts to improve power transmission efficiency. We equipped the 6th generation CIVIC released in 1995 with an innovative automatic transmission called Honda Multimatic, together with the 3-stage VTEC engine to greatly improve its fuel economy. Honda Multimatic is a continuously variable transmission composed of two of Honda s own pulleys and a special metal belt. In 1998, we further developed the Honda Multimatic S, improving fuel economy compared with that of the Honda Multimatic by adopting the PROSMATIC, which optimizes the timing for speed changes, widening the pulleys, and by improving the precision of oil pressure control. The Honda Multimatic S has also been applied to the HR-V, Fit, and CIVIC Hybrid. 3 In 1999, Honda developed a hybrid system to improve the fuel economy of gasolinepowered vehicles to the utmost limit, and released the Insight, in which the Honda integrated motor-assist (IMA) system was installed. The IMA system uses a gasolinepowered engine as its primary power source

7 Automobiles 1999 The Insight, running 35 km on a liter of gas 2001 The CIVIC Hybrid, running 29.5 km on a liter of gas With higher combustion efficiency, the lighter and more compact 1-liter lean-burn VTEC engine, the highly efficient motor-assist system, the light aluminum body and with better aerodynamic performance, the model achieves the world s highest fuel economy, running 35 km on a liter of gas (10 15 mode/5-speed transmission). With the combination of the Honda IMA system, the newly developed 1.3-liter, i-dsi cylinder idling VTEC engine, the DC brushless motor, and of the Honda Multimatic S, the model achieves among the highest fuel economy for massproduction gasoline-powered vehicles for 5 passengers, running 29.5 km on a liter of gas (10 15 mode) Annoucement of the new-generation, 2-liter, 4-cylinder gasoline engine i-vtec The STREAM, running 14.2 km on a liter of gas Equipped with the DOHC i-vtec engine, the model achieves the highest fuel economy in the class, running 14.2 km on a liter of gas (10 15 mode) >> Continuously variable transmission >> Automatic transmission Honda Multimatic In combination with the 3-stage VTEC engine, the transmission improves the fuel economy of automobiles by 20% compared with those equipped with traditional transmissions. Honda Multimatic S With higher efficiency, the transmission improves the fuel economy of automobiles by 8% compared with those equipped with the Honda Multimatic. and a motor as an auxiliary power source. The Insight, with this system, runs 35 km (10 15 mode) on a liter of gas, which represents the world s highest fuel economy for a massproduction gasoline-powered vehicle. The Insight was ranked as No. 1 in the U.S. Environmental Protection Agency (EPA) s fuel economy ranking consecutively for four years (as of October 2002). Furthermore, in 2001, we released the CIVIC Hybrid installed with the new Honda IMA system. We are thus applying higher fuel economy technologies to our standard products, contributing to environmental improvement through our products chosen by a greater number of customers in various product categories. DOHC i-vtec The ultimately compact engine intelligently and extremely precisely controls combustion. Direct-control 5-speed AT* Compared with the Accord equipped with a 4-speed AT (put on sale in 1998),the fuel economy is improved by approximately 7%. AT: Automatic transmission Improvement by 30%, exceeding the objective of improving average fuel economy by approximately 25% (in March 2002)* Target for Japan Improvement of average fuel economy Further improvement of fuel economy Honda is reducing the emission of CO2, which causes global warming, by improving the fuel economy of its vehicles in all the classes. We have improved the fuel economy by 30%, exceeding the objective of improving the average fuel economy by approximately 25% by 2005 (in March 2002) % The Fit, running 23 km on a liter of gas Through a combination of the i-dsi engine and Honda Multimatic, this model achieves the world s highest fuel economy. Change in the average fuel economy i-dsi engine By the use of twin plugs, which is revolutionary for a 1.3-liter engine, the engine comes close to the ideal engine, which is fast and enables complete combustion Application of i-series engines to various classes (Fiscal year) modes 17

8 Practical Use of Alternative Energies Use of Clean Energy Vehicles in Our Daily Lives for the Future Honda, to popularize clean energy vehicles characterized with extremely low CO2 and other emissions, has improved the performance of electric and natural gas vehicles. Also, by utilizing the technologies accumulated in the development process, we promoted the practical use of fuel cell vehicles. In July 2002, our fuel cell vehicle became the first in the world to obtain an approval for commercialization from the U.S. government. Furthermore, we obtained an approval for the car also in Japan and started its sales in a limited quantity both in Japan and the U.S. Next-generation technology target: To introdue fuel cell electric vehicles into the market by 2002 Practical use of alternative energies Electric vehicle Experimental fuel cell electric vehicles Experimental fuel cell electric vehicle New-type Dream Honda has been participating in the World Solar Challenge. The model won massive victories in the competitions held in 1993 and Honda EV Plus In mode, the model runs 220 km on a single charge. Its specially designed body is roomy enough to seat four adults comfortably Developing new-generation vehicles based on a complete understanding of the characteristics of alternative energies Natural gas vehicle High-pressure gas storing technology FCX-V1 FCX-V2 Type that uses pure hydrogen as fuel, which is stored in a hydrogenabsorbing alloy Type that retrieves hydrogen from methanol by the use of a reformer Motor drive technology Energy management technology for the Insight CIVIC GX The model reduces CO2 exhaust emissions by approximately 20% compared with gasoline-powered vehicles. Further, it nearly eliminates CO, HCs, and NOx from the exhaust gas. High-pressure gas storing technology New CIVIC GX The model features a newly designed engine, longer cruising range, and more space for passengers. (Put on sale in 2001) FCX-V3 More suitable for practical use with improved accelerating ability from standstill and higher fuel economy 1 Honda EV Plus, which is powered by natural gas Honda believes that the value of environmentfriendly technologies will increase through the use of such techologies by a greater number of people. Based on this belief, we have been developing alternative energy vehicles giving the first priority to the improvement of their performance to make it comparable to that of vehicles currently available on the market, including speed, accelerating ability, and safety in the event of a collision. For example, we started to develop the technologies for electric vehicles (EVs) in the latter half of the 1980 s and released the Honda EV Plus in 1996 and the natural gas-powered CIVIC GX in Subsequently in 2000, we released the remodeled and improved CIVIC GX as the New CIVIC GX. All of these products embody Honda s efforts to achieve a performance comparable to that of traditional models, including a longer cruising range and more space for passengers. Further, since 1990, we have been participating in a world solar car race as a challenge to new technologies. The race provided us with an opportunity to increase the sophistication of various technologies for higher energy efficiency and provide feedback to EV technologies. We utilize the technologies accumulated through diversified methods in combination for the development of fuel cell electric vehicles. of the electrolysis of water, creates electricity that runs the motor. Fuel cells generate electricity by a chemical reaction that occurs at a low temperature, and the energy conversion efficiency is as high as 60%. In addition, the reaction produces only water and generates almost no CO or NOx. Honda has been developing two types of fuel cell electric vehicles: one is a type that uses pure hydrogen as fuel, stored in a hydrogenabsorbing alloy, and the other is a type that uses methanol as raw material and retrieves 2 Development of fuel cell electric hydrogen from the methanol using a reformer. vehicles as the FCX Series 3 Launch of FCX-V3 test runs Honda unveiled experimental fuel cell electric on public roads vehicles named the FCX-V1 and FCX-V2, and their prototype FCX in This vehicle uses fuel cells as its power source. The chemical reaction between hydrogen and oxygen, whose principle is just the opposite In 2000, Honda released the FCX-V3 that installed a stack manufactured by Balard and used high-pressure hydrogen as fuel. The riding capacity was improved from two to four by downsizing the system. In 2001, the FCX- 18

9 Automobiles Using clean energy for producing hydrogen Honda established a hydrogen production and fueling station within its research institute in Los Agneles in the U.S. to generate hydrogen for fuel cell vehicles from water by the use of solar energy. It started experimental operation in July The station utilizes solar power in order not to emit CO2 in the process from the production and saving to the supply of hydrogen. At the station, solar cells are used to generate electricity and the electricity is used to extract hydrogen from water. The extracted hydrogen is pressurized and supplied to fuel cell vehicles, and recycled as water. Hydrogen manufacturing and supply station FCX-V4 With a more compact power unit, the cruising range is prolonged from 180 km to 315 km. To be comparable to the performance of models available in the market, the performance of the model was improved regarding the maximum speed, acceleration, and safety in case of collision. FCX In July 2002, the FCX becomes the first fuel cell electric vehicle in the world to obtain EPA and CARB certifications required for sales in the U.S. It achieves a powerful accelerating ability from standstill, a maximum running speed of 150 km/h, and a cruising range of 355 km through the improvement of the motor torque performance by approximately 15% from that of the experimental FCX-V4, as well as by the improvement of the medium-and high-speed output characteristics. Introducing a fuel cell electric vehicle in to the market V4, which is an experimental fuel cell electric vehicle achieving a maximum speed of 140 km/h and a cruising range on a single charge of 315 km, which are comparable to the performance of vehicles available on the market, was developed. We have already started test runs on the public roads for the FCX-3 and FCX-V4, both in the U.S. and in Japan. We are also developing peripheral technologies, including the experimental operation of a hydrogen production and fueling station, which produces hydrogen through the use of solar power without emitting CO2. 4 Obtaining approval to commercialize The FCX, and starting its limited sale both in the U.S. and in Japan Honda continued the development of the FCX to intraduce it in to the market at the end of As a result, in July 2002, the FCX became Drive motor Conceptual diagram of the fuel cell electric vehicle Ultra capacitor the first car in the world to obtain an approval for commercialization from the U.S. government. In October of the same year, American Honda Motor Co., Inc. reached a basic agreement with the city of Los Angeles on the world s first sale of fuel cell vehicles. Also in Air supply system Fuel cell stack Cooling system Humidification High-pressure hydrogen tank Humidification Japan, the FCX was approved by the Minister of Land, Infrastructure and Transport in November, and the leasing of the vehicle was started both in the U.S. and in Japan in December Honda is determined to further develop the FCX as a next-generation clean vehicle. 19

10 Cleaner Exhaust Gas Applying 4-Stroke Engines to All Types of Motorcycles, from Large Motorcycles to Scooters Honda, since its foundation, has been developing motorcycles equipped with 4-stroke engines that are clean and excellent in fuel economy. In recent years, we have accelerated the application of 4-stroke engines to scooters, including the GIORNO Crea. Also, we decided to expand the application of programmed fuel injection (PGM-FI) systems that had been limited to large motorcycles, including the application to cheaper 50cc products by Thus we are promoting the improvement of environmental performance for all the classes. Cleaner exhaust gas target for 2005: Reduction of total HC emissions from new Honda motorcycles to one-third by 2005 (compared with the 1995 levels)* Average of total emissions in Japan, the U.S., Europe, and Thailand Exhaust gas cleaning technologies for large motorcycles 1951 Traditional use of 4-stroke engines since its adoption in the Dream E model Mainly developing clean, fuel efficient, and quieter 4-stroke engines 1998 HECS3 VFR800FI Secondary air injection system PGM-FI 1999 Advanced exhaust gas cleaning technologies for motorcycles HECS3*: (3-way catalytic converter system) Remarkably reduces the CO, HC, and NOx contents of exhaust gases by combining the 3-way catalyzer with the O2 sensor that precisely controls the air-fuel ratio for cleaner fuel combustion. Honda Evolutional Catalyzing System 3 Secondary air injection system Sends air to the exhaust port to combine oxygen with exhaust gas. This promotes the combustion of unburned gas to reduce CO and HC emissions. PGM-FI (Programmed fuel injection) system An electronic control unit (ECU) controls the air-fuel ratio according to operational situations and thereby reduces the emission of air pollutants. Exhaust gas cleaning technologies for scooters LEAD First compliance with the domestic exhaust emissions regulations for motorized bikes with engines by the adoption of more efficient 2- stroke engines and oxidation catalyzers Further increase in the number of scooters in which 4-stroke engines ( Clean 4 engines) are used idle stop GIORNO Crea Adoption of a water-cooled 4-stroke 50 cc engine Adoption of the world s first idle stop system for a mass-produced motorcycle in the GIRONO Crea Deluxe 1 Advanced exhaust gas cleaning technologies for high performance motorcycles The world s first exhaust emissions regulations for motorcycles were adopted in the United States in Since then, other countries have followed suit. Japan has introduced motorcycle exhaust emission regulations in stages since Even before such regulations were established, Honda has been developing its very own technologies to achieve cleaner exhaust gases. These technologies are used in a variety of its motorcycles. For example, with the PGM-FI, which is a light and compact fuel injection system that provides optimal air-fuel ratio, we have achieved cleaner combustion. Furthermore, we introduced a secondary air injection system to inject fresh air into the exhaust gas immediately after it is discharged from the combustion chamber to promote the combustion of unburned gas. In 1998, we equipped the VFR800FI (made for the European market) with a 3-way catalytic converter system called HECS3, which Honda developed independently. As a result, we have complied with the exhaust emissions regulations in Europe, the U.S., and Japan, achieving emissions far below the regulation standards. 2 Adoption of exhaust gas cleaning technologies in larger to smaller motorcycles To introduce exhaust gas cleaning technologies for automobiles to compact motorcycles, we needed to solve a number of problems in terms of technologies and cost. Despite these difficulties, Honda has been transferring its advanced technologies, such as PGM-FI, to motorcycles, first targeting large motorcycles and then gradually expanding the target to include smaller ones. For example, the SILVER WING, released in 2000, is equipped with PGM-FI for the first time as a 600 cc model, which has reduced the CO and HC contained in the exhaust gas to approximately half of the regulation standards. 3 Introduction of Clean 4 * technologies to scooters to make their exhaust gases cleaner Honda has also been making efforts to achieve cleaner exhaust gases for scooters, which are popular as a simple means of transportation and are sold in large quantities. For example, in 1998, we adopted the oxidation catalyzer that we independently developed to the LEAD to reduce its CO and HC emissions to half or one-third of those 20

11 More advanced exhaust gas cleaning technology for the new GOLD WING and the VFR Motorcycles For the GOLD WING, which was fully remodeled in August 2001, and the VFR, fully remodeled in January 2002, we have achieved cleaner exhaust gases by greatly increasing the number of cells in the HECS3 3- way catalytic converter system from 100 to 300 cells. As a result, their CO and HC emissions are now one-tenth of the domestic regulation standards and NOx one-fourth, which represents the world s highest environmental performance. Cleaner exhaust gas (g/km) CO HC 100 cells 300 cells NOx New VFR VFR 2001 model New VFR GOLD WING idle stop The SILVER WING Equipped with PGM-FI for the first time as a 600 cc model Sale of 125 cc and 150 cc scooters equipped with PGM-FI in Europe in the spring of 2003 Gradual adoption of the system in small scooters also in Asia (including Japan) FORZA S idle stop idle stop Crea Scoopy i SMART-Dio Deluxe idle stop Idle stop system from the previous model. Starting with the GIORNO Crea, equipped with a water-cooled 4-stroke 50 cc engine released in June 1999, we have also been introducing our advanced exhaust gas cleaning technologies to scooters, naming 4-stroke engines characterized with four advantages (clean, silent, economical, and tough) Clean 4. We have applied watercooled 50 cc engines to scooters, although the adoption of such engines is said to be difficult for scooters with small displacements. Combined with the adoption of very small air injection systems, the CO and HC emissions from these scooters have been reduced to approximately half of the regulation standards. To reduce exhaust emissions and to improve fuel economy, we are also dynamically introducing the idle stop system, which automatically stops the engine when the motorcycle comes to a standstill (e.g. at traffic lights) and restarts the engine when the rider opens the throttle. Clean 4 : Clean (efficient gasoline combustion), Economy (high fuel economy), Silent (high quietness), and Tough (high durability) 4 Applying the PGM-FI system to 50 cc motorcycles Although the PGM-FI system is indispensable for automobiles, the application of this system is limited to large motorcycles because it is difficult to apply it to cheaper motorcycles in terms of cost and technology. Despite the difficulty, Honda is determined to apply the PGM-FI system to some of its 50 cc models by 2005 as part of its efforts to set the standards for motorcycles in the 21st century. The engine automatically stops when the motorcycle comes to a standstill. When the rider opens the throttle, the engine smoothly restarts and allows the rider to proceed. The system employs electronic controls to automatically stop the engine when the motorcycle comes to a standstill, such as at traffic lights. When the rider opens the throttle, the engine restarts and allows the rider to proceed. Due to the system, fuel economy has been improved by approximately 5.1% compared with models not equipped with this device. (Measured by Honda based on the assumption that the motorcycles are running in urban areas.) Many models are equipped with the idle stop system, including the GIORNO Crea Deluxe, the Crea Scoopy i, the FORZA S, and the FORZA ST. 21

12 Improvement of Fuel Economy Continuous Development of Technologies to Improve Fuel Economy, Focusing on Motorcycles with the Fuel Efficient 4-Stroke Engines Since its sale in 1958, the Super Cub has been loved by people all over the world. With its history of evolution and improvement that extends over 40 years, this product has achieved a high fuel economy, running 75.4 km 1) 130 km 2) on a liter of gas. Honda has been improving the fuel economy of its motorcycles and scooters, mainly focusing on 4-stroke engine technologies, to provide a satisfactory lineup of products with less CO2 emissions and better economical efficiency. 1) Measured internally by Honda at a specified driving mode (ECE R40) 2) Measured at a constant speed of 30 km/h Fuel economy improvement target for 2005: To improve the average fuel economy* by 30% or more by 2005 (compared with 1995 levels) Average fuel economy for Japan, the U.S., Europe, and Thailand Progress in technologies for higher fuel economy Water-cooled, 4-stroke 50 cc engine World s first water-cooled 50 cc engine. The installation of the water cooling system on a 50 cc engine is made possible by downsizing and integrating the cooling system components. Various technologies, including the more compact combustion chamber, have contributed to the improvement of fuel economy. GIORNO Crea (51.8 km/l 1) /71.3 km/l 2) ) This model is equipped with a newly developed watercooled, 4-stroke 50 cc engine as well as with the idle stop system (for the first time as a 50 cc motorcycle). 1) Measured internally by Honda at a specified driving mode (ECE R40) 2) Measured at a constant speed of 30 km/h Crea Scoopy (75.0 km/l 2) ) The model is equipped with a more efficient and more compact engine. The body weight is reduced by the improvement of components and of the die-cast frame. Weight reduction, downsizing, and friction reduction technologies Technologies to make motorcycles lighter and more compact >> ACG starter The ACG starter used for scooters has been improved and its weight reduced by adopting a new operating method. >> Highly rigid aluminum die-cast frame For the GIORNO Crea, we have reduced the weight through the adoption of highly rigid aluminum die-cast frames. Furthermore, for the Crea Scoopy, we have achieved a further weight reduction by using the frames developed for the GIRONO Crea for the front part, after making some modifications to the frame, and by designing new frames for the rear part. >> Resin radiator tank We have adopted resin as the material for the radiator tank. Through these technologies, the weight of the engine alone has been reduced by 4 kg and the weight of the entire body by 6 kg. Technology to reduce friction We have reduced friction by optimizing the specifications of engine parts using computers and by improving the precision of machining technologies. Highly rigid aluminum die-cast frame Resin radiator tank 1 From the GIORNO Crea to the 2 Improvement of the water-cooled, Crea Scoopy 4-stroke 50 cc engine As the Clean 4 series, Honda is introducing scooters with high environmental performance into the market. One of the important themes for these scooters is economy or the improvement of fuel efficiency. The Crea Scoopy, released two years after the GIORNO Crea in 1999, represents Honda s efforts for further improvements of the new models for fuel economy. Honda adopted a newly developed watercooled, 4-stroke 50 cc engine for the GIORNO Crea. The water cooling system stabilizes combustion and improves the compression ratio, thereby contributing to higher fuel economy. The Crea Scoopy, through improvement of the 4-stroke 50 cc engine and of various devices, including the starter, has been made more compact. Further, Honda has used computer technology to optimize the 22 specifications of engine components, has improved the precision of the machining technologies and reduced friction to increase the output and improve fuel economy. To further improve fuel economy, we are now developing a small fuel injection system for motorcycles to optimize the air-fuel ratio, and are making efforts for the practical use of various technologies to provide more advanced scooters. 3 Improvement for the reduction of body weight The reduction of body weight greatly contributes to the improvement of fuel economy. In September 1998, Honda, jointly with its other cooperative suppliers, developed a welded structure made of aluminum die cast and extruded aluminum materials (this technology is known to be difficult), and in the same year adopted highly rigid aluminum die-cast frames for the CBR 600F. These frames were subsequently applied to other models, including the GIORNO Crea. For the Crea Scoopy, the frames for the GIORNO Crea were applied to the front part after making some modifications to the frames and new frames were designed for the rear part to further reduce the body weight. Also, the material for the radiator tank was changed to resin. As a result, the entire body weight has been reduced by 6 kg.

13 Motorcycles Noise reduction Analyzing various noise sources and implementing careful noise reduction measures Honda employs a computer-assisted sound source analysis technology to promote research for the prevention of any noise from motorcycles. Based on accumulated research results, we succeeded in realizing significant noise reduction for the LEAD and the VTR 250, released in January These models complied with Japan s noise regulations enacted in October 1998, ahead of other models. In the remodeling process, we have been taking further noise reduction measures, including the reduction of noise from the drive chains and tires. Noise reduction measures for motorcycles Air exhaust system Larger muffler capacity High capacity sound-abatement system Use of glass wool Use of punching divider Driving system Lighter chain Low-noise tire tread pattern Morris damper for drive and driven sprockets Noise reduction technologies used for the VFR Engine >> Through the adoption of the V4 VTEC engine, two of the four valves are suspended at low rpm. This lowers the sound pressures level inside the combustion chamber. >> A silent chain drive was adopted for the camshaft. Air intake system Larger air cleaner capacity Two-chamber structure Air intake resonator Engine Improved gear accuracy New combustion chamber shape Noise-proof engine cover Sound prooting and sound absorbing in aterials Vibrating system Rubber engine mount Drive system >> The newly developed Silent Cross Chain and a drive sprocket developed specially for the chain are utilized. Technologies to Pursue New Possibilities for Motorcycles Focusing on Alternative Energies for Creating New Lifestyles and New Pleasures Honda, in the pursuit of new possibilities for motorcycles, has been developing and releasing products that use energy sources other than gasoline. For example, we released an electric scooter using electricity, which has attracted much attention as a clean energy vehicle, and subsequently unveiled concept models for the next generation. Also, we are increasing our lineup of electric motor-assisted bicycles, which are becoming quite popular. Electricity-powered motorcycles CUV ES Charged by a 100-V power supply. The model runs 60 km on a single charge, which takes eight hours. RACOON Released as a transportation method with little environmental impact. The model has increased the possibilities for motorcycles. Anyone can easily operate and enjoy it. Electric motor-assisted bicycle Electric scooter MOBIMOBA e-dax Electric motor-powered commuter scooter introduced as a concept model at the Tokyo Motor Show. STEP COMPO The first electric motor-assisted bicycle that adopts the aluminum die-cast monocoque frame. The cruising range is almost doubled compared with the RACOON COMPO. RACOON COMPO The first electric motor-assisted bicycle that can be folded. 1 Electric scooter CUV ES Honda has been developing electricitypowered scooters since the latter half of the 1980s. In 1994, we released a small scooter called the CUV ES as an electric scooter adopting a low-vibration DC brushless motor that produces very little operating noise. The built-in charger can recharge the battery on household 100-V power supply and the scooter runs 60 km on a single charge, which takes eight hours. Since the release of the CUV ES, we have been continuously pursuing the possibilities for new-generation motorcycles and have introduced various experimental motorcycles at motor shows, etc. 2 Lineup of electric motor-assisted bicycles In 1995, Honda released an electric motorassisted bicycle, the RACOON, which uses electricity as an auxiliary power source. In 1998, we released the RACOON COMPO, adopting highly rigid aluminum frames. The RACOON COMPO is made foldable by the reduction of the battery weight. In 2000, we totally remodeled the RACOON to reduce its weight by 3.5 kg compared with the previous model. Furthermore, in 2001, we released the STEP COMPO, further improving the RACOON by the addition of an ECO mode. The cruising range of the STEP COMPO is almost double compared with that of the RACOON COMPO. Honda will provide the products with little environmental impact that meet the various needs of society by aggressively developing products that use alternative energies, such as electricity. 23