The Advanced Technologies
for Next-Generation Productsof Mitsubishi Heavy Industries

YUTAKA OZAWA*1

1. Introduction

2. Advanced technologies in new fields

Mitsubishi Heavy Industries, Ltd. (MHI) develops
new products in new fields including solar cells, intelligent robots, and semiconductor manufacturing
equipment. This paper describes the features of leading-edge technologies in new fields such as
nanotechnology, quantum mechanics, electronics, andIT, which play a major role in the development stage ofthese new products. A description is also given of therelation between the advanced technologies and the new
products. MHI has basic core technologies that havebeen accumulated through the development of MHI’s
core products including aircrafts, engines and turbines,
and ships, specifically in the fields of structure, vibration, tribology, fluid dynamics, combustion, and heattransmission. The paper also gives a brief overview ofthese core technologies focusing on the background ofefforts to enhance their level and their utilization in
product development.

2.1 Nanotechnology
Nanotechnology is the technology of creating new functions through the control of materials and structures atatomic and molecular levels. In Japan, the Council for Science and Technology Policy of the Cabinet Office adopted
the subject of “Nanotechnology-Materials” in fiscal 2001 as
one of the four science and technology fields to be the focus
of national emphasis. Thus, nanotechnology is confidently
expected to become a key technology in the 21st century.
Fig. 1 shows the impact of nanotechnology on society.
From around the 1950s, microprocessing technology, precision analysis technology, computation science, and othernew technologies have shown significant progress basedon dramatic advances in physics, chemistry, biology, andother scientific fields. As a result, various types ofnanotechnology (nanoscience) have appeared in the fields
of materials, manufacturing technologies, semiconductors,
electronics, bio-technologies, and other fields. Technologi-

Electronics

EnergyNanoelectronics
Semiconductors

Environment

IT

Nanosimulation
Biotechnology,
medical treatment

Semiconductor
devicesNanoinstrumentation

Nanodevices
Nanobiotechnology

Micromachines

Structures andfunctional materials

Mechatronics

Nanofabrication

Nanomaterials
Nanoscience

Chemistry

Physics

BiologyFig. 1 Impact of nanotechnology on society
Nanotechnology has been applied in many fields including materials, manufacturing technologies, semiconductors, and biotechnology, based on physics, chemistry, biology, and other fields. Thus, the technology
revolution utilizing nanotechnology has begun in a wide range of fields such as IT, electronics, medical
treatment, environment, and energy.

Mitsubishi Heavy Industries, Ltd.
Technical Review Vol.40 No.6 (Dec. 2004)*1 Advanced Technology Research Center, Technical Headquarters
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cal revolutions in the fields of IT and biology utilizing
nanotechnology have already been proceeding apace. Furthermore, rapid technological innovation is expected toproceed utilizing nanotechnology in wide range of otherfields such as electronics, environment, energy, and medical treatment, as well.
The current state of application of nanotechnology in
MHI’s materials technology and catalyst technology is outlined below.
(1) Material technology
Materials are one of the fundamental technologies
of nanotechnologies. MHI has been investigated the application of nanometals, carbon nanotubes, nanoparticles, and other nanomaterials to industrial products. Among these new materials, nanometals (metallic
materials provided with new characteristics by using
nanotechnologies) have drawn attention as heat resisting and corrosion resisting materials applicable toboilers and turbines for power generation plant owing
to their excellent strength and anti-corrosion characteristics. Specifically, MHI has been developing a new
precipitation hardening stainless steel that has improved strength and toughness for rotor blades of steam
turbines. Structure controlling technologies are utilized
in the material to disperse and precipitate fine intermetallic compounds in several nm size. In addition, MHI
has joined "the Nanometal Project" of New Energy andIndustrial Technology Development Organization(NEDO) to promote basic researches on ultrahigh purity Cr-Fe alloys that contain nonmetallic impurity
elements such as C, N, O, P, and S at levels as low as
100 ng/g or less. (This impurity level corresponds to Fe>
99.9995 mass% in case of pure iron. On the other hand,the purity of conventional pure iron is from 99 to 99.9
mass%. ) The alloy is expected to become an epoch-making heat resisting and corrosion resisting material thatcan be applied in severely corrosive environments in
waste incinerator boilers, coal gasification plant, chemical plants, etc.
(2) Catalyst technology
Advanced technology in the field of catalysis has beendeveloped, including the control of micropores in catalyst supports and the nano-sizing of catalytic active
metals. It is said that shrinking the particles down tonanosize improves the activity, as well as increase thesurface area of the catalyst (1). Hence, MHI has been
studying how to improve catalyst activity by applying
various methods such as the sol-gel, the coprecipitation,and colloids method.
In the field of flue gas treatment, in which catalysts
are actively applied, the requirement for performanceof catalysyts has become higher for both grid and offgrid power plants, incineration plants and vehicles in
keeping with recent changes in environmental regulations. In response to these increasing requirements, MHI
has developed and practically applied a high-grade catalyst preparation technology. Fig. 2 shows an example ofa catalyst used for reduction of NOx in flue gas. The
catalyst activities has been improved by controlling thearrangement of the atoms composing the catalyst.
The development of polymer electrolyte fuel cells(PEFCs) has been accelerating around the world focusing on high efficiency and low-emission products forstationary power sources and for automobiles. MHI has
developed a 1 kW system for a stationary type PEFC
using natural gas that is the most compact system in
the world. In addition, MHI has also developed an electrode catalyst for the system. That is, catalytic activity
is doubled compared with conventional catalysts by controlling the size of the platinum particles on the carbon
support to several nanometers and by arranging the particles in an optimum pattern. With the growing trend
in PEFC applications and the increase in the amount ofsuch units being shipped in the future, an emphasis
has been placed on reseach for replacement of platinum,
which is the definite mineral resource. Accordingly, theenhancement of technological development is expectedin the fields that rely on the use of platinum as a catalyst
to find suitable ways of reducing platinum consumption
based on the catalytic function of platinum, the designand development of alternate catalysts, and the production of catalysts that utilize self-organization technology.

DeNOx catalyst (honeycomb-type catalyst)

Example of catalyst crystal
structure

Fig. 2 A V4Cr2O13 composite oxide in a honeycomb-type catalyst for DeNOx:
Arrangement of crystal structure
Photograph shows the arrangement of Cr layer-O layer-V layer-O layer (C-axis)
in the composite oxide structure of the honeycomb catalyst (70 mm square,
400 mm in length, and 5 mm in pitch) for low temperature DeNOx system.

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Technical Review Vol.40 No.6 (Dec. 2004)2

2.2 The field of quantum mechanics
Many advanced technologies have been adopted in products produced by MHI in order to attain higher grade andhigher added value in the products. The main performance
characteristics of many products were obtained throughthe use of phenomena based on Newtonian mechanics. In
the fields of energy and the environment, which have been
gaining greater prominence at MHI, however, a growing
number of new products have appeared that rely on quantum mechanics based phenomena for their main
performance characteristics.
(1) Energy
A typical example of new technological developmentin the energy field is solar cells. In this field, diversification of energy sources is desired. In response, MHI
has developed thin film amorphous silicon type solar
cells utilizing solar rays, which are representative of
natural energy. Solar cells utilizing the characteristics
of silicon semiconductors require special technology toconvert solar rays spanning the entire visible spectrum
from ultraviolet to infrared light to electricity at low
cost and high efficiency. At present, technological development has been proceeding from amorphous silicon
type solar cells to tandem type solar cells (combinationof amorphous silicon with fine crystals) that have increased efficiency. Technological development fully
utilizes the most advanced technologies in the quantum
field, particularly in the control of grain growth in thinfilm silicon semiconductors, the control of band gap
width, and large area film-forming technology. Development work is proceeding under the collaboration ofindustry, academia, and government with the aim of attaining greater increases in efficiency and reductions
in cost.
(2) Environment
In the field of the environment, there is an increasing demand for the removal of trace substances such as
those represented by dioxins that are highly toxic. Existing chemical analysis technologies cannot adequately
respond to this demand, and a need arose to develop a
new "ultrahigh sensitivity and high speed analyticaltechnology for toxic substances" that can detect themquickly on site. Responding to the need, MHI has developed a high-resolution analytical technology that canquickly analyze trace amounts of toxic substances. The
newly developed analytical technology uses vacuum ultraviolet light to efficiently ionize very small amounts
of toxic substances, in order to enrich these substanceson site and to separate them from other substancespresent. This analytical technology is realized by a timeof-flight mass spectrometer (TOFMS) that uses an
ion-trap. At present, MHI expects to apply the analytical technology to the monitoring of toxic generation
sources in waste incinerators or other facilities. In the
future, however, MHI intends to develop the technology

for application to continuous monitoring of the global
environment through the compact design of devices, inorder to contribute to the safety and comfort of residents.
(3) Semiconductors
Semiconductor manufacturing equipment, which
are also a new field of products produced by MHI, areproducts whose core operation relies on quantum mechanics based phenomena. When forming thin films
on the surface of a semiconductor such as silicon, thesemiconductor manufacturing equipment must be capable of securing the band gap of the semiconductormaterial in order to prevent any leakage in current
due to tunnel currents, for example. The equipment
must also be capable of decreasing dielectric constantsin the film and of preventing the diffusion of metallic
elements. To do this, MHI adopted the most advanced
film-forming technology available. In addition, MHI
has developed an exclusive film-forming technology
called the "chloride reduction film-forming method."
The technology is expected to contribute to the acceleration of developments in a wide range of fields,
including ultra LSIs, in terms of the refinement ofdevice structures and realizing significant improvements in performance.
As described in sections (1) through (3) below, thedevelopment of technology and improvements in performance in these products essentially rely on thedevelopment of technologies in the quantum mechanics
field in order to achieve proper product performance. At
the same time, however, the creation and developmentof fundamental technologies to support basic technologies should also be emphasized. Quantum mechanics isoften compared with Newtonian mechanics. It can besaid that Newtonian mechanics stands on a macroscopic
and visible foundation, while quantum mechanics may
be said to be the invisible "controlling principle of the
microscopic world." Thus, in this way Newtonian mechanics and quantum mechanics can be said to differ
from each other. However, the above-mentioned products reflect the principle in visible form, so engineering
reliability can only be attained with the support of macroscopic world technologies. Hence, what is referred toas high-grade technology based on Newtonian mechanics is absolutely necessary in order to achieve any
improvements in performance and reliability as well as
any reductions in cost. Examples of these supporting
technologies include vacuum technology, heat and structure technology, and chemical analysis technology. These
supporting technologies in particular are ones in which
MHI has accumulated extensive experience over a long
period of many years. By fusing advanced technologies
with supporting technologies, MHI is making every effort to provide products that meet the most demandingneeds of its customers.
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Technical Review Vol.40 No.6 (Dec. 2004)3

2.3 Electronics technology
Reflecting recent trends towards maturation andupgrading society and industry, the products of MHI
are required to have levels of performance, precision,and function that will allow them to overcome the limits of existing technologies in every application.
Electronics technology is one such technology where
major breakthroughs have been made that surpass
previous limits. In this regard, MHI has successfully
developed electronic devices and applications thatsimulate five major functions of the human body.
These include systems and sensors that gather andrecognize information to control systemic response
similar to the sensory organs; information and communication engineering resembling the nerve
network; microelectronics and computing systems resembling the brain; power electronics resembling themuscles; and system controls which govern movement,
knowledge, learning, and reasoning, thus administrating individual organs. Based on this scheme, MHI
re-organizes existing technologies for further upgrading and enhancement. The following is a brief overview
of the activities of MHI in these core technologies anda reflection of core technologies thus far developed in
the products of MHI.
(1) Sensing technology
A number of issues have become increasingly important in various aspects of the development stageof sensing technology. These include such things as
the need for greater speed and scope of non-destructive inspection technologies and techniques thatwere developed through inspections of power generation plants and facilities. Issues in instrumentation technology together with image processing include the need to improve robustness to cope
effectively with disturbances and the need to quantify judgment criteria. Issues of concern in new
fields such as microsensing and biometrics include
the securing of greater product reliability.
It is expected that non-destructive inspection
technology will show further improvements throughthe adoption of multidimensional arrays for ultrasonic flaw detection, thereby contributing tosecuring enhanced product reliability and widening the business of after-sale service of plants.
Furthermore, efforts are underway to develop image instrumentation and image recognition
technologies that are robust to variations in theenvironment, as well as to develop advanced spectroscopic technology for color measurement, which
will be applied to autonomous machine systems
having high-level judgment functions and to highlevel inspections such as adhesion inspections using
infrared light. In addition, the development of differentiation technology centering on optic fiber

sensors is expected in laser-applied instrumentation technology.
(2) Information and communication engineering
Electronic toll collection (ETC) systems at expressways and electronic road pricing (ERP)systems in urban areas are systems of automatically collecting tolls from vehicles that enter a tollarea using radio communication. Issues of particular concern to these types of systems include thedevelopment of low cost and highly reliable communication technology and the development ofhighly functional moving image recognition technology capable of detecting the approach of avehicle and identifying the type of vehicle involved.
Switching communication waves to high frequency
waves will allow the communication to transfer signals at high speed and greater capacity. Suchdevelopment will make it possible to realize the fineand detailed control of machines moving at highspeed, and will lead to the application to precision
sensors. In addition, the study of energy transfer
technology using radio waves is in the development
stage. Once these technologies are established, it
will be possible to realize machines that can be operated completely wirelessly.
(3) Microelectronics
The development of exclusive processors that integrate intelligent processing and parallel
processing with the most advanced LSIs has been
an issue of great interest in improving performancein decision-making and image compression. Investigations are also moving ahead on the applicationof commercially produced components in the fieldsof aviation, space, and defense. To realize such applications, however, it is absolutely essential that
there be satisfactory means of improving the reliability of such commercial components, including
improvements in the ability to withstand a wide
range of environmental conditions, the adoption of
duplex circuit systems, and the adoption of effective self-recovery functions.
Efforts are thus underway to develop machineswith intelligent processors in keeping with progress
being made in the development of autonomous dispersion functions in machine products. Thea c t u a l i z a t i o n o f s u p e r- s m a l l d e v i c e s u t i l i z i n gnanotechnology, as well as of super-small and highfunctional devices utilizing Radio Frequency Micro
Electro Mechanical Systems (RF-MEMSs) is expected in this field.
(4) Power electronics
The need to adopt build in custom motors has
been increasing. In this regard, MHI has alreadydeveloped the exclusive technologies necessary forachieving size-reductions, increased efficiency, andMitsubishi Heavy Industries, Ltd.
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cost-reductions for custom motors and power converters, applications of which have already beenrealized in various products. One issue confronting both motors and power converters is the needto increase the operating efficiency of the equipment.
Electromagnetic drive mechanisms are fully expected to be integrated in various machine products
as a component in the future. No concept of components such as a motor or generator exists in the
power electronics field. That is, once a machine isfabricated, the functions of motor and generator are
included in the machine. In other areas, the actualization of new types semiconductors such as SiC,
which achieves significant energy savings in a device, can be expected.
(5) System control technology
A major area of concern in the field control systems
development is compatibility between the machine system and humans and the realization of an effective
man-machine interface (placing the human at the core,
while establishing a natural and intelligent relation
between the computer and human).
In the future, the rapid development of IT technologies including digitization, distributed operation,and remote operation, together with the response to
their use will steadily expand into an ever-wider rangeof fields. On the other hand, with the current tendency towards ever-greater emphasis on service andsolution-oriented approaches, maintenance service
technologies for machines equipped with operational
support and diagnostic capabilities, as well as machines and plants developed based risk assessment
will find a greater range of applications as technologies that increase the added value of these and similar
products. In addition, the development and application of technologies that realize functions that
resemble the five human senses, including the devel-

opment of innovative technologies capable of changing the intrinsic qualities of a machine, can be
expected to proceed centering on Intelligent Transport Systems (ITS) and robots.
In this regard, MHI intends to focus on promoting
the introduction of miniature, ultrahigh efficiency, andintelligent (energy saving, time saving, resource saving, efficiency increasing) technologies, along with
communication technologies. The focus will be on realizing a sensuality assessment technology capableof dealing with sensitivity and feeling, together withhumanoid processing technology.
2.4 IT field
The business of computing and contents supply services
that are closely related to living, entertainment, medical
treatment, welfare, and security, accelerates in emerging
advanced information technologies and broadband generation.
The progressing information technologies (IT) since the1980s has become a core technology of "Transportation &Distribution," "Environment & Social facility," and "Services," which are major business areas emphasized by MHI,
as shown in Table 1
1. The applications of the newest advanced technologies and future technologies to MHI
products are described in this section.
(1) Application to mechanical systems
Technologies related to computers, communication,
man-machine interface, and artificial intelligence are
the driving forces to create new highly value added products and the creation of service businesses such asmachines with operational support maintenance andmonitoring services in machines, plants, transportationand logistics systems. The extending effect by the
progress of these technologies on the mechanical systems that support MHI's core business areas isextremely large.
Specifically, MHI has already commercialized thereal-time operation monitoring technology for plant andTable 1 Progress of IT-related Technologies and Business Areas of MHI
Technology field
Computers,
Communication
Artificial Intelligence

Sensors

The 1980s

The 1990s

PCs (1st period)
Low speed modem

PCs (2nd period),Internet

Wearable, Wireless,Broadband

Knowledge
engineering

Probability models,
Data mining

Autonomous
distributed system,
Reinforcement learning

Visible ray, X-rays

Infrared ray,
Microwaves

The 2000s

The 2010s
Ubiquitous,
Self-repair type
Common sense
reasoning
Sub-terawave
Sub-terawaves

Business Areas of MHI: Home use robots,
Next generation
machine tools: ITS

Human I/F

Keyboard, CRTs

VR

AR, Telepresence
telepresence
AR,

Cyber I/F

Robotics

Industrial robots

Harsh environment
robots: Autonomous
distributed
material handling

Personal robots

Intelligent robots

Micromachines

Nanotechnology: Plant maintenance& inspection: Surveillance,
Security

Manufacturing,
Materials

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Integrated screen for total basin monitoring screen

WEB display
Example screen forwater level trend monitoring
Cell-phone
PC

Internet
Pump station
Sluice way
Garbage sweeper
Outer water level
Inner water level
Monitoring at any time and any place

Fig. 3 Wide area remote monitoring and control system for a drainage pump station
IT is applied to realize remote monitoring at any time and any place for laborsaving.

mechanical systems using the high-speed communicaFig. 3),
3 the operational support oftion of the Internet (Fig.
injection molding machines that apply control technology and intelligent processing technology, andoperational technology to prevent unstable combustionin combustors. Autonomous control technology, reinforcement learning technology, and other types oftechnologies are expected to be developed further to (a)have functions capable of modifying the internal structure of a system by itself and create new structures
through interactions with complex and dynamic environments, and (b) achieve evolution toward machines
which have functions to conduct self-repair and self-organization as like as organisms. And hence, MHI isactively engaged in promoting technological development under consideration of the progress towards thecreation of intelligent-oriented mechanical systems.

(2) Innovation of foundation in information-oriented society
and development of robots as an intelligent machine(a) Ubiquitous network society
A society with an information network that allows
people to access at any time and any place by various methods and which allows people to use the network freely intheir living environment under unconsciousness is referred
to as an ubiquitous network society, shown in Fig. 4
4. In
the ubiquitous network society expected to appear within
the next decade or so years, the barriers and spatial distance between the real world and the virtual world will
be removed, and people will observe and control distantreal objects as if they exist right before their eyes. The
impact on industry, society, and living such as the operation and maintenance of facilities and plants, medical
treatment and nursing, education and art, as well ashouse automation can be expected to be extremely large.

Network allowing people to freely utilize all kinds of services at any place without stress

Ubiquitous environmental plane

Ubiquitous platform

Ubiquitous appliancesMultilayer/multilink/multimodalCore network

Ubiquitous content

Access network
Flexible super-broadband

Ubiquitous flexible broadband
Advanced distributed
processing
systemAdvanced distributed
processing system

Ubiquitous agents
Ubiquitous sensor network
Accurate positioning(position information)

Ubiquitous teleportation(2)

Fig. 4 Concept of ubiquitous network (2010)

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SpaceFrom narrow area and single point towide area and multiple points
Post IT inovation originated from Japan"Network robots"• Availability in wide area such as outdoors and natural environment increases.
• Linking between many points crossing space boundaries becomes available.

Operation

From separate operation to linked operation• Cooperation and linking between many machines become possible.
• Mutual support on functions and capacities becomes possible.

Function

Establishment of intelligent-orientedsocial life style at house and office

From specific function to multifunction capability• Information transmission and sharing of information beyond the physicaldistance become possible.
• Remote communication between human and robot and between robots
becomes possible.
• Remote control and remote operation become possible.

Use

Contributing to various social issues(aging, medical treatment and nursing,working, etc.)

From limited use to general use• Module-combination and tailor-made robots for each use are realized.
• Flexible design responding to changes in use becomes possible.
• Various functional modules widen the range of choices.

Extensionality

Creation of new businesses
in the 21st century

From pre-extension to post-extension• Users can extend functions at need.
• Functions and applications develop synchronously with social diffusion process.
Fig. 5 Effect of realization of "Network robots"(3)(b) Fusion between networks and robots (intelligent
machines)
The term "robot" in this category consist of a broadconcept that not only includes what is referred to as
physical robots, but also includes various functions
that are embedded into the surrounding environment(actual machines and facilities such as rooms androads) as well as functions such as information-basedhousehold electric appliances which deal with information in a virtual space. Accordingly, the concept
overlaps the future of intelligent mechanical systems
in the ubiquitous network society, which are one of
the targets in MHI's products. The effects of realizing such a new robot, called Network Robots are given
in FigFig.. 5 . As can be seen in the figure, the information owned by individuals can become informationcommonly shared by society. This can be expected tofacilitate the transition from individual robots (intelligent machines) to autonomously cooperative robots
as a group (intelligent machines).
(c) Home use robot as a target of MHIMHI has developed a robot capable of providing
support for daily life called “wakamaru,” (4) which isable to live symbiotically with humans. MHI is making an effort to solve such issues as realizing
conversation capabilities with humans in various
scenes, image and speech recognition technology robust against noise, safety against informationhacking, and communication technologies including
real-time receiving and remote operation of dynamic
scenes and voices, in order to create a “Network Robot” that is capable of leading the ubiquitous network
society described above.

3. Enhancing the level of fundamental core technologies
3.1 Structure, strength, and vibration technologies
Structure, strength, and vibration related technologies
are fundamental core technologies for products essential
to acquiring the satisfaction of customers. To ensure theprompt and effective delivery of good products to customers, MHI emphasizes three technologies in this field. The
following sections presents an overview of how these advanced technologies positively affects products.
(1) Large-scale structural analysis technology
MHI continually strengthens the technologies it usesin the analysis of large-scale structures by linking thesetechnologies with three-dimensional CAD design techniques that are being progressively developed by thedesign section. By establishing structural analysis models and increasing the speed at which structural analyses
are performed, large-scale and precision structural
analysis can be conducted at high speed, which servesto optimize products.
Fig. 6 shows an example of a structural analysis carried out on a die head of an injection molding machine.
The use of such repeated precision structural analyses
during the design stage make it possible to attain optimized product designs.
(2) Multibody dynamics technology
Multibody dynamics technology is a technology inwhich strength assessments are conducted at the component level. It takes into consideration the total
dynamic behavior of a product structured by multiple
components. Linking with 3-D CAD during the productdevelopment stage, a digital mockup of the subject product is fabricated so that the computer can confirm thefunctions and performance of the product.
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Fig. 7 shows a model that was used in the development stage of a forklift. The combined analysis of thehydraulic system and control system made it possible
to quickly confirm the driving performance of the subject forklift. Since the verification is done using a digital
mockup, the period of experimental verification is shortened by approximately 30%.
(3) Robust design technology
Applying quality engineering using the Taguchi

Method, MHI has developed products with highly robust levels, that is to say, which are capable of enduring
the variations of actual working environments. Fig
Fig.. 8shows an analytical example of a structure to prevent
folding at the edges in a paper-folding machine of a newspaper offset press. A highly robust paper folding machineis attained by combining the analysis technology, which
simulates the dynamic behavior of the papers with quality engineering techniques using the Taguchi Method.

Elements:
1.5 million elements
Structural analysis model
3-D CAD modelFig. 6 Die head of injection molding machine
The structure analysis model linked with 3-D CAD data gives precise structural analysis.

Mast (internal)

Head guard
Seat

Mast (external)

Steering rod

WeightRear tireEngine cover
Mainframe
Fork, backrest

Rear axle
EngineFront tire
Tilt cylinder

Front axle

T/M Knuckle arm

Fig. 7 Multibody dynamics model of forklift truck
Combined analysis of control system and hydraulic system is conducted using a
multibody dynamics model, and the performances are verified using a computer.

Folding drum

Guide
Paper

Folding roller
Fig. 8 Analysis of mechanism to prevent edge folding in paper folding machine
Nonlinear dynamic analysis on the behavior of papers in a paper folding machine isconducted using the parameters of fluctuations in paper travel speed and of paperfeed speed at the folding rollers. The data thus obtained are rearranged and evaluatedusing quality engineering to increase the stability of the operation.

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3.2 Tribology
Tribology is a field that handles machine elements suchas bearings, gears, and seals, which are utilized in MHI
products. Tribology plays an important role in supporting
the performance and reliability of the products.
Since MHI produces a large variety of products and mostof them are tailor made, it is difficult to verify products ofeach kind by the repeated fabrication of prototypes. Consequently, MHI has developed analytical models forevaluating performance of machine elements based on theoretical model of fluid and solid dynamics, and validates
them with experiments. Then MHI adopts the analyticalmodels to simulate the actual machine. By maintaining
the analysis technology at the most advanced level, tribology contributes to effective product development.
In the sliding bearings inside an engine, for example,
analysis was applied in a practical manner taking into account the effects of fluid, heat, and structural deformation.
Furthermore, consideration of the relation between the
bearing gap and the amount of lubricant present, both ofwhich vary with time, has made it possible to predict the

Exhaust side

peak value and the peak position of local high pressure, as
illustrated in Fig. 9
9. Such analysis contributes to the improvement of engine reliability.
In the case of roller bearings, MHI has developed ananalysis model that considers the 3-D motion of balls, which
is owned by only a limited number of bearing manufacturers. Integral analysis of the bearing and the peripheral
structures makes high speed and high face pressure limit
Fig
design possible (Fig
Fig.. 1010). Adding to common standard computational methods such as those specified by American
Gear Manufacturers Association (AGMA), MHI has also
developed an exclusive analytical method for gears to predict actual damage limits, thus allowing compact limit
Fig
design (Fig
Fig.. 11 ).
As described above, MHI has been quite successful inextending analysis to areas where only experience could
previously make predictions.
Continued progress in these fundamental technologies
is expected to play an essential role even more intensively
in improving the performance and reliability of products
both now and in the future.

Cam side

Developed to plane

Upper metal
Pmax:
34 MPaLower metal
Cam side

Upper metalU
Exhaust side
Oil groove

Pmax:
56 MPaCam side
Exhaust side

Oil-film pressure distribution
derived from conventionalelastohydrodynamic
lubrication analysis

Oil-film pressure distribution derived
from the elastohydrodynamic lubrication
analysis considering the time history of
the filling ratio of the oil film

Fig. 9 Computation of oil-film pressure distribution in an engine bearing
Conventional EHL analysis gives only 34 MPa of the maximum oil-film pressure. Considering the time history ofoil filling ratio, however, actual local high pressure of 56 MPa is predicted.
Rotor headContact pressure: Thrust unloaded side
: Thrust loaded side
(Stress)
Large

215 m
m

0
Bearing

60 120 180 240 300 350
Angle (deg)FEM model

Pressure distribution

Heel side
Small

Fig. 10 Structure of windmill bearing and rotor head;pressure distribution derived from the combined analysis of
FEM of the structure with the numerical model of the bearing
Elastic deformation in the structure around the bearing distorted contactpressure distribution and the maximum contact pressure significantly increased
compared to the pressure calculated for the bearing installed in a rigid housing.
However, the structural optimization design using the combined analysis of
FEM and the bearing model made only 7% of maximum pressure deviationfrom the pressure in the rigidly supported case.

Contact face

Toe sideFig. 11 Bending stress analysis on a spiral bevel gear
Contact computation on the created tooth profile was given by FEM
considering the dynamic load effect during high-speed meshing.
The bending strength can be estimated on the basis of the stressactually applied to the tooth.

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3.3 Fluid technology
Fluid technology is essential to develop many of the
700 kinds of MHI products that are currently available.
In particular, owing to the rapid progress in the recent
development of computational fluid dynamics (CFD),
which is a kind of numerical simulation technology, theanalysis of complex flow states has become possible.
Such analysis was not possible just a few years ago.
Fluid technology has progressed "from two dimension
to three dimension," "from non-viscous fluids to viscous
fluids," "from steady states to unsteady states," "fromparts to whole structures," and "from simple shapes tocomplex shapes." This section introduces several examples which apply the technology in order to further
understand current advanced technologies. Fig. 12 shows
an example of a kind of supporting system for disastercountermeasures, or a system for evaluating gas diffusion and exposure utilizing a weather prediction model.
The system is currently used in Comprehensive Nuclear
Emergency Response Training, National Disaster Prevention and Countermeasures, and other programs inJapan. Fig. 13 shows a precision analytical method thattakes into account the influence of the hull, ladder, propeller, and free surface of a ship. The method is appliedin the design of high fuel-efficiency ship shapes. Fig. 14
shows an analysis technique that can grasp weak compression waves inside a nozzle utilizing an advanced
precision numerical method. The analysis develops a
nozzle that generates decreased fluctuations. Fig. 15
shows a 3-D analysis of the heat flow inside an automobile cabin. The analysis computes the temperature,humidity, and air velocity around a passenger from thesense of heat and cold, thus evaluating the comfort levelof the passenger.
As shown in Figs. 12 to 15, fluid technology is appliedin a broad range of fields from weather prediction on a
global basis, to ships, supersonic wind tunnels, and vehicles. MHI will continue to develop its Center of
Excellence (COE) with the aim of maintaining and advancing CFD technology at the highest level in the world.

Fig. 13 Integrated fluid analysis of hull and propeller
Analysis to determine the effect of the hull, ladder, propeller, and freesurface significantly improve the accuracy of flow field computation.
The method is applied here to the design of a high fuel-efficiency ship
shape.

Fig. 12 Prediction of smoke diffusion from Mt. Usu.
MHI developed a system for evaluating gas diffusion and exposure utilizing
a weather prediction model as a supporting system for disaster countermeasures. The system is being used in Comprehensive Nuclear Emergency
Response Training, National Disaster Prevention and Countermeasures,and other similar programs.

Fig. 15 Evaluation of comfort levels for air-conditioning in
an automobile
A method for evaluating comfort levels was established by focusing
on the sense of heat and cold for a passenger. Through the 3-D
analysis of heat flow in the cabin, the temperature, humidity, andair velocity around the passenger are computed, which are thenentered into the evaluation method to determine the level of comfort.

Fig. 14 Mach-number contour in a supersonic wind tunnel (the scale in the radial direction is magnified by a factor of ten)
MHI has developed a nozzle that generates decreased fluctuations by grasping the weak compression waves inside a nozzle using
an advanced precision numerical method, and utilizing CFD.

Mitsubishi Heavy Industries, Ltd.
Technical Review Vol.40 No.6 (Dec. 2004)10

3.4 Combustion and heat transfer technologies
Combustion and heat transfer technologies are core technologies that support MHI products in the energy andenvironment fields. Among these technologies, energy
transfer technology converts thermal energy into higher
efficient electric power. The thermal energy transfer has
been at the forefront of the structuring of new cycles, newproduct development combined with conventional cycles,
and new energy development including the solar cells andfuel cells mentioned earlier.
Combustion is an important technology for responding
to global environmental problems. For example, the operating temperature of industrial gas turbines has raised fromthe 900 oC level to the 1 500 oC level in order to increase thethermal efficiency. In this case, MHI has achieved a decrease in NOx generation levels from conventional levelsof several hundreds of ppm to several tens of ppm applying
the fuel lean premixed combustion technology. MHI was
the first company in the world to successfully apply thefuel lean combustion technology to a commercial combustion system. The development of this technology required
the establishment of a technology for securing a stable combustion state under a fuel lean premixed combustion
condition through a careful analysis of the flow dynamics
and chemical reactions occurring in the combustor. Fig
Fig.. 16shows an example of the direct measurement of the distribution of NOx generated in a combustor by means of thelaser-induced fluorescence (LIF) method. Although diesel
engines are driven in an intermittent combustion state,
MHI has successfully attained reduced emission combustion through the refinement of heavy oil droplets and the
optimization of flow inside the cylinder, as described indetail in a separate article. In addition, MHI has been engaged in the study of artificial liquid fuels such as DME(dimethyl ether), and the environmentally compatible combustion technologies for various fuels including coal, which

has the largest reserves among fuels currently in use.
Heat transfer is an important technology closely related
to the thermal efficiency and reliability of boilers, steam
generators in atomic power plants, and other facilities. In
this regard, MHI promotes experimental and analyticalstudies to analyze such phenomena as increasing the performance of high performance of heat transfer in the tubes,
the prediction of critical heat flux, and solving flow instability. As shown in Fig
Fig.. 17
17, which is an example of the CFD
results, MHI has been conducting various studies to analyze the behavior of bubbles using the particle method
aimed at the microscopic approach in order to predict theboiling phenomenon that appears in the tube bundles ofsteam generators. The inlet temperature of a high temperature gas turbine of the latest design reaches levels as
high as 1 500 oC. The reliability of the turbine blades operated in such a high temperature gas environment is ensured
through the use of high grade cooling technologies. An example of the cooling technology is film cooling, in which
the cooling air is guided to flow along the surface of theturbine blade. Efficient film cooling hole configuration isrequired to minimize the mixing of cooling air with themain gas stream on the blade surface. In this regard, optimization of air ejection is attained by detailed analysis of
the mixing between the film-cooling air and the main gas
stream, as shown in Fig
Fig.. 18
18. One example of exposure to

Low NOx combustion flame with aquartz combustor

Fig. 17 Particle method analysis of Weatherhead experimental data

1.0

0.5

r (mm)

0
50
100
150

0.0

Intensity of NOLFIF emissions

Hot main gas stream(room temperature for the experiment)

Cooling air (hot air for the experiment)

1.0 (Cooling
air temp.)

0 (Main gas
stream temp.)

0

50 100 150 200250 300
X (mm)
Fig. 16 Distribution of NOx in a premixed Low NOx combustor

Fig. 18 LES analysis of film cooling:
mixing of air-film with main gas stream

Mitsubishi Heavy Industries, Ltd.
Technical Review Vol.40 No.6 (Dec. 2004)11

higher temperatures is the case of a reusable launch vehicle (RLV). On returning to the earth, the airframe of the
RLV is exposed to high temperature plasma. The body ofspace shuttle is provided with a thermal protection system, in which it is covered with thermal insulation tiles toprotect the airframe from the high temperature plasma.
Heat transfer technology contributes significantly to theaviation and space fields through the application of tests
simulating the state of heating of the airframe in a surrounding high temperature fluid flow, and through the useof CFD predicting the heating state. As described above,
MHI is continually making efforts to contribute to the conservation of the global environment and the developmentof energy conversion/thermal-control technologies ranging
from very low temperatures to ultrahigh temperaturesusing combustion and heat transfer technologies.

leading-edge fundamental core technologies including
structural, fluid, combustion, and heat transfer technologies, and described the application of these coretechnologies in the 700 kinds of products produced by MHI.
Placing these advanced technologies as a first step, MHI
will continue to create new fields and new products, anddeliver the world’s top-level core products to customers by
successively adopting innovative advanced technologies
occurring around the world.
References(1) M. L. Satter, P. N. Ross, Ultramicroscopy, 20, 21 (1986)(2) The Report of “Study Group on the Future Direction of Ubiquitous Network Technology” by MPHPT
http://www.soumu.go.jp/joho_tsusin/policyreports/
chousa/yubikitasu/(3) The Report of “Study Group on Network Robot Technology”
by MPHPT
http://www.soumu.go.jp/joho_tsusin/policyreports/chousa/
netrobot/index.html(4) Asano, S. et al., New Technology for Intelligent Robot,
Mitsubishi Juko Giho Vol. 40 No. 6 (2003) p.328

4. Conclusion
This article has presented a brief review of some of theprospects for technological innovation proceeding in newtechnological fields such as nanotechnology, IT, and the like.
This has included a review of some of the applications of
the resulting technologies to the development of products
by MHI in new fields such as solar cells, robots, amongst
others, as well as further for the future development ofthese technologies. The article also briefly described the

Yutaka Ozawa

Mitsubishi Heavy Industries, Ltd.
Technical Review Vol.40 No.6 (Dec. 2004)

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