You need Photoshop or QuickTime to download and view photos in TIFF format. DENSO approaches modularization from two angles: as a way of combining the functions of two or more components into a single module, and as an integral part of our efforts to make components smaller, lighter, and more functional. With DENSO's all-around strengths across a wide range of automobile components, it is an area where we can excel. DENSO has developed various kinds of modules including front-end modules, cockpit modules, and integrated air/fuel modules.   Front-end Modules   In February 2001, DENSO began supplying its first front-end module (exhibit) to Fiat Auto S.p.A. in Italy, for the vehicle Stilo. The FIAT Stilo front-end module integrates nineteen components into one unit, including a radiator, air-conditioning condenser, shrouded fan, intercooler, oil cooler, front-frame carrier, air intake system, front shroud, bumper fixations, horns and headlamps. In June 2002, DENSO began supplying its latest front-end module (FIG. 1) to Daihatsu Motor Co., Ltd., for the vehicle Copen. The latest front-end module includes a radiator, air-conditioning condenser, fan, intercooler, air cleaner and front-frame carrier. After delivery, the bumper and headlamps are affixed to the DENSO manufactured front-end module by the car maker.   DENSO's front-end modules are lighter and more compact than standards components. Further, by optimizing the entire front-end thermal component zone, DENSO improved the heat exchange efficiencies not possible through improvements on individual components.   Following are the features specifically for the latest front-end module.     The front-frame carrier is formed by a newly developed injection molding process from a light, cost efficient polypropylene (PP) material reinforced with long-fiber glass. The new injection molding process made fiber glass in the carrier about two times longer than that formed by the conventional process, thereby improving strength and rigidity. Also, the new process allowed the carrier to have a desired shape, resulting in improved thermal efficiencies in the heat-exchange components. Changing the carrier material and improving the thermal efficiencies led to approximately 30 percent reduction in weight compared to conventional components including iron-made carrier, while ensuring sufficient rigidity.         DENSO also added an air duct for the air-conditioner condenser to prevent hot air from moving from the engine compartment to the condenser. As a result, it lowered the temperature at the front of the condenser by approximately 5 degrees centigrade when the car idles, and reduced energy needed for air conditioner compressor operation by approximately 13 percent.         The intercooler that operates in conjunction with a turbo charger lowers the temperature of the charge air to the engine, raises the density of that air, and consequently sends more air into the engine. DENSO placed the intercooler in front of the engine taking advantage of better airflow, resulting in 30 percent size reduction of the intercooler, compared to the case where the intercooler is placed directly above the engine.   FIG. 1 Front-end Module for Daihatsu's Copen     Cockpit Modules   DENSO has a product lineup including air-conditioning systems, instrument clusters, and ECUs, which are installed in and on the instrument panel. DENSO also has proprietary expertise not only on design and control systems but also on electrical technology and human machine interface (HMI) technology.   In 2002, DENSO developed a new cockpit module (FIG. 2) by working with its group company in Italy, DENSO Thermal Systems S.p.A. (formerly Magneti Marelli Climatizzazione S.p.A.), which has been supplying cockpit modules to Fiat models since 1997.   The new cockpit modul has the following features.     The cockpit module integrated over 15 components into one unit including an instrument panel, cross car beam, air-conditioning unit, instrument cluster, steering column, air bag, and ECUs and wire harness.         Designing these components as a whole allowed to realize a soft air diffusion at the upper surface of the instrument panel. The soft air diffusion duct blows out the HVAC air toward the windshield glass, as indicated by arrows in FIG. 2, and allows it to progress toward the head of the vehicle passenger forming soft diffusion airflow. The soft diffusion airflow significantly improved passenger comfort. DENSO's control technology in air conditioning system was utilized to realize this soft diffusion airflow.         DENSO developed a new hybrid cross car beam (FIG. 3) that supports several components including a steering wheel and air bag, and secures the rigidity of the vehicle body. Conventionally, the cross car beam was made of steel alone. DENSO's hybrid cross car beam is composed of resin parts made of two different kinds of resins and steel parts that are formed integrally by over molding. The hybrid cross car beam is approximately 10 percent lighter than a conventional one, and eliminated 15 parts.         ECUs are unified into one compact printed circuit board (PCB) junction box, reducing size by 10 percent, reducing the number of wire harnesses by 20 percent, and eliminating parts such as ECU brackets.   Thanks to these developments, DENSO's new cockpit module can be made lighter and smaller than conventional standards components.   In addition, DENSO is developing several cockpit modules targeting specific vehicle sizes. A module developed for compact cars is a topping type (exhibit). The module has minimum functions but allows drivers to selectively install electronic items such as information display, tachometer and wireless phone chargers and change them if necessary. Another cockpit module for luxury cars under development is aimed to integrate various functional components such as a navigation system while providing easier and safer operations using DENSO's HMI technology. DENSO has technological expertise to provide various cockpit modules, complying with customer's needs.   FIG. 2 DENSO's New Cockpit Module     FIG. 3 DENSO's Hybrid Cross Car Beam for Cockpit Module     Integrated Air/Fuel Modules   DENSO began supplying integrated air/fuel modules for the vehicle Liberty manufactured by DaimlerChrysler in September 2001 and for the vehicle Demio manufactured by Mazda Motor Corporation in August 2002.   Following are the features of the integrated air/fuel module for Mazda's Demio (FIG. 4).     The air/fuel module integrated eleven components in one unit including an air cleaner, variable intake control system, air flow meter, throttle body, intake manifold, swirl control valves, injectors and engine ECU. Combining these components in one unit allowed to design an integrated air intake system covering the entire process-from the air inlets to the cylinder head ports. This led to lower air intake noise level and improved engine performance.         Integrating the engine ECU removed the need for a separate ECU case and reduced the volume of wiring.         DENSO adopted DC motors for driving variable intake valves and swirl control valves, instead of conventional vacuum type motors that required several components such as a vacuum tank. This resulted in simplified structure and improved mountability of the valve systems. The variable intake valves and swirl control valves are made of resin, contributing to the lightness of the module.   FIG. 4 Integrated Air/Fuel Module for Mazda's Demio     [Contact] Shinya Omi, Yoko Suga, Miwa Kurokawa Corporate Communications Department of DENSO Corporation, +81-566-25-5594/5592 shinya_omi@denso.co.jp, yoko_suga@denso.co.jp, miwa_kurokawa@denso.co.jp, jennifer_knoll@denso.co.jp http://www.globaldenso.com