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Technical Paper

Estimating drive cycle for E-rickshaws using real world operating scenarios and for overall powertrain improvements.

2019-11-21
2019-28-2497
E-Rickshaws are popular and convenient mode of transportation for last mile connectivity and are typically used for short distance(<10Km) commute. As per recent reports there are more than 1.5million e-rickshaws plying on Indian roads and approx. 10,000 vehicles are adding every month. Owners of these vehicles are inclined towards the overall range these vehicles can give on a single charge. Range can be improved by using efficient powertrain. Range can also be improved by optimized Battery Management systems and Controllers. Though there are certain evaluation criteria (such as curtailed Indian Drive Cycles) which can be used for efficiency estimations, manufactures are more interested in extending the range in real world scenarios. Hence, availability of real-world drive cycle is imperative. Through this paper, we have attempted to derive a typical drive cycle by collecting road data of various types of e-Rickshaws under different environment conditions.
Technical Paper

Review of architecture and control strategies of Hybrid Electric and Fuel Cell Technology for Automotive Application

2019-11-21
2019-28-2509
Well-functioning and efficient transport sector is a requirement for economic and social development in the 21st century. Another side of this transport sector is responsible for a many negative social and environmental effects, like a significant contribution to global greenhouse gas emissions, air pollution and reduction in fossil fuels resources. It is need of time to shift to a greener and low carbon economy and for that it is necessary to improve the ways in which energy is produced and used. Other energy sources like battery, fuel cells (FC), supercapacitors (SC) and photovoltaic cells (PV) are the alternative solutions to the conventional internal combustion engines (ICE) for automobiles. Development of Hybrid electric vehicles (HEV) along with other cleaner vehicle technologies like Fuel cell electric vehicles (FCV), battery electric vehicles are continuously increasing in the list of green energy options.
Technical Paper

Potential for Emission Reduction and Fuel Economy with Micro & Mild HEV

2019-11-21
2019-28-2504
The development of modern combustion engines (spark ignition as well as compression ignition) for vehicles compliant with future oriented emission legislation (BS6, Euro VI, China 6) has introduced several technologies for improvement of both fuel efficiency as well as low emissions combustion strategies. Some of these technologies as there are high pressure multiple injection systems or sophisticated exhaust gas aftertreatment system imply substantial increase in test and calibration time as well as equipment cost. With the introduction of 48V systems for hybridization a cost-efficient enhancement and, partially, an even attractive alternative is now available. An overview will be given on current technologies as well as on implemented or simulated vehicle concepts for light duty gasoline and diesel powertrains.
Technical Paper

Engine Fuel Economy Optimization for different Hybrid Architectures using 1-D Simulation technique

2019-11-21
2019-28-2496
In order to improve fuel economy of the 3.3 litre tractor model, various kinds of engine hybridization is studied. This paper presents a methodology to predict engine fuel consumption using 1-D software by coupling Ricardo Wave and Ricardo Ignite. Engine fuel consumption and emission maps are predicted using Ricardo WAVE. These maps are used as an input to IGNITE for predicting cumulative fuel consumption. There is good agreement within 10% deviation between simulated cumulative fuel consumption and experimental cumulative fuel consumption. Same calibrated model is used further for studying series hybridization, parallel P1 type and Parallel P2 type of hybridization. A design of experiment (DOE) model is run for different electric motor sizes, battery capacity and battery state of charge condition, to understand their effects on overall engine fuel consumption and cycle soot emission. Model predicts overall significant reduction in cumulative fuel consumption and soot emission.
Technical Paper

Impact of Vehicle Electrification on Brake Design

2019-11-21
2019-28-2499
Electric vehicles have come full circle from being primary vehicle type in 19th century (much before IC powered vehicles) to 21st century where major stake holders in mobility have announced plans towards vehicle electrification. Apart from battery & powertrain system, braking system is area which will undergo major changes because of vehicle electrification. But Why? Major keywords are regenerative braking, increased vehicle weight, no or insufficient vacuum from engine and silent powertrains. This paper tries to outline potential impact on hydraulic brake system & its component design for M1 and N1 category of four wheelers with advent of vehicle electrification. Needless to say extent of change will vary depending upon extent of electrification and extent of recuperation during regenerative braking. Extent of electrification depends upon whether vehicle is range extender type hybrid vehicle, plug in hybrid vehicle, battery electric vehicle, fuel cell vehicle etc.
Technical Paper

FI system of single cylinder Engine for motorcycle

2019-11-21
2019-28-2527
In India, due to the progress of air pollution problem in major cities, exhaust emission regulations had been planned to become stricter for motorcycles as so as automobile. And effective date has been also announced. The fuel supply system to small displacement engines of motorcycles used to be a carburetor, however, to meet the regulations it should be replaced by electronic fuel injection (FI). This paper introduces "i-Beat II system", the FI system for small motorcycles developed by Mikuni, meant for single cylinder and small displacement gasoline engine which accounts for more than 90% of the motorcycle market.  We developed adaptable FI system for motorcycles with simplified structure of the system, more suitable logic for single cylinder engine, and then achieved emission regulation also better drivability, fuel consumption.
Technical Paper

HANDLING EXCEPTIONAL SITUATION OF AN AUTONOMOUS VEHICLE

2019-11-21
2019-28-2526
In autonomous vehicle world human safety takes highest priority. And most researchers agree that machines won't be able to completely take over driving duties for years or even decades. "Today's autonomous vehicles can drive relatively well in typical settings, but they fail in exceptional situations - and it's those situations that are the most dangerous," said Walter Lasecki, an assistant professor of computer science and engineering. "Designing autonomous systems that can handle those exceptional situations could take decades, and in the meantime, we're going to need something to fill the gap. Few companies have introduced human safety drivers in autonomous vehicles which has cost advantage compared to traditional ride sharing services. Combining human and artificial intelligence in autonomous vehicles could push driverless cars more quickly toward wide - scale adoption.
Technical Paper

Miniaturized and sleek protective device

2019-11-21
2019-28-2535
A miniaturized and sleek protective device M. Priyanka, Mahindra&Mahindra, India D. Boobala Krishnan*, Mahindra&Mahindra, India T.Vijayan, Mahindra& Mahindra, India Keywords-Fuse, Lightweight. Research and/or Engineering Questions/Objective: Now-a-days there is lot of advancement coming in automobiles. Earlier the electronics were used in engine and engine compartment areas. Now all hydraulics and transmission have been operated by electronics. The role of electronics like sensors, actuators increasing day by day for lifting and moving operations. With increase in electronics circuit, there is complex in wiring harness and packaging space for fuse box is premium Limitations: Limitations of placing other devices. Occupy more space and weight in the vehicle. Packing constraint due to vibration and thermal management issues. Methodology: Two different fuse of same rating can be given in one fuse and we can reduce the wire size.
Technical Paper

Equivalent Radiated Power driven optimization for driveline housings using simulation tools to cut-down the project time

2019-11-21
2019-28-2533
In the field of Automotive industry, being competitive makes you succeed. Industry is moving towards advancement day by day. New technologies to improve fuel efficiency, crash resistance, vehicle noise levels have been trending. At VECV, we have traditionally worked on CAE of driveline housings (clutch housing & transmission housing) based on static, dynamic and transient loadings. Currently, weight optimization technique depends on the structural and dynamic loading conditions, but do not consider acoustic concerns. Powertrain housings are highly prone to vibrations and leads to high level of noise. Noise has been constant issue in the casting components associated to driveline. There have been lot of research going on to reduce the level of noise and vibrations in the vehicle driveline, which ultimately leads to fuel efficiency and ergonomic benefits. Low noise generation can also lead to saving of lot of resources deployed to dampen the noises.
Technical Paper

Challenges of fuel economy determination with gaseous fuels

2019-11-21
2019-28-2512
The importance of fuel economy (FE) has significantly increased for new technologies like hydrogen fuel cells or compressed natural gas (CNG) engines. Regarding conventional combustion engine driven vehicles, the current gap between the official CO2 emissions and the real-world emissions on the road is quite big. One main reason for this gap might be a non-authentic test environment for combustion engines in comparison to real road conditions. New standards like the world harmonized driving cycle (WLTC) try to reduce the above-mentioned gap. Such standards underline the importance of complex speed and torque profiles. It appears that steady state consumption measurement is not sufficient anymore. Replacing the conventional vehicle engine by a fuel cell system does not eliminate this performance requirements on the measurement equipment. Performance testing methods are well known for conventional liquid fuels. However, new media like hydrogen or CNG represent new challenges.
Technical Paper

Development of Dedicated Lubricant for Hydrogen Fueled Spark Ignition Engine

2019-11-21
2019-28-2511
Hydrogen has low ignition energy ensures easy ignition of the ultra-lean mixture of H2+air also. The flame speed of hydrogen is about five times higher than methane and gasoline which allows hydrogen fuelled IC engines to have relatively reduced cyclic variations than that of with methane and gasoline. High flame speed also helps to make the combustion closer to constant volume which enhances the thermal efficiency of hydrogen fuelled IC engine. High octane number of hydrogen makes it suitable for its application in Spark ignition (SI) engines. Since the hydrogen combustion in spark ignition engine generates water which can interfere with the lubricant performance, different lubricant is to be developed for this purpose. In this background, the present work is aimed at the development of dedicated lubricant for hydrogen fuelled SI engine. This paper presents the various parameters required for evaluating different lubricants for hydrogen fuelled genset.
Technical Paper

Compensation of Signal Offset, Amplitude Imbalance and Imperfect Quadrature in Rotor Position Sensor Signals for Motor Drives

2019-11-21
2019-28-2524
In recent years, the use of the electric motors in automotive applications such as electric power steering (EPS), hybrid and electric vehicles has increased. In these fields, rotor position information plays and important role in the field- oriented control concept. It performs a transformation from the stator reference frame to the rotor reference frame and vice versa. This is nothing but the Park and inverse Park transformation. They are typically used to provide accurate absolute rotor position in high-performance motor drive systems because their robustness and reliability make them particularly suited to Automotive Environment. Hence, greater accuracy of these sensor signals is required. However, in reality, the output signals include the position error in the sensor itself as well as error in the sensor signal conditioning circuits.
Technical Paper

Powertrain Modelling of a Fuel Cell Three-Wheeler for the Indian Roads

2019-11-21
2019-28-2513
The three wheeled vehicles are extremely popular in the Indian subcontinent and are constantly posting a positive growth in sales. Given this trend and their polluting nature they can be noted as sizeable contributors to the air quality issues plaguing the metropolitan cities. With the nation aiming at eradicating the use of internal combustion engines (ICE) in passenger transportation by the year 2030, there have been attempts to convert ICE three-wheelers to battery electric three-wheeler. However, the battery electric three-wheelers, which are quite commonly used for end-mile connectivity, serve to highlight the demerits of the technology pertaining to their range, charge cycle, power to weight ratio, and efficiency. Hydrogen based are fuel cells gaining traction as a potential alternative to batteries due to their efficient and clean power generation.
Technical Paper

IMPROVE NVH CHARACTERISTICS OF ENGINE OIL PAN BY OPTIMIZATION & LIGHT WEIGHING WITH DEEP LEARNING PROCESS

2019-11-21
2019-28-2552
Recent Years “NVH” is gaining lots of attention as the perception of vehicle quality by a consumer is closely aligned to NVH Characteristics. Demand on Vehicle Light weighting to compliance the environmental norms with powerful engines challenging the “Vehicle NVH”, powertrain induced noise will be continued to be a primary factor for all IC engine vehicles. Component level NVH refinement is necessary to control the overall NVH characteristics of vehicle with lighter Vehicle goal. Current Paper works starts with physical testing the Engine oil pan of the most popular vehicle and build an equivalent simulation model by reverse engineering the design and match similar performance trend in simulation model. After building baseline simulation model, conduct shape, topology, gauge and material optimization to improve weight and performance of Oilpan.
Technical Paper

Development of Diesel Particulate NOx Reduction DPNR System for Simultaneous Reduction of PM and NOx in Diesel Engines

2019-11-21
2019-28-2554
The Diesel Particulate NOx Reduction (DPNR) system is used for simultaneous reduction of PM and NOx in diesel engine. DPF is used to trap particulate matter in diesel engines. NOx absorber technology removes NOx in a lean (i.e. oxygen rich) exhaust environment for both diesel and gasoline lean-burn GDI engines. The NOx storage and reduction catalyst is uniformly coated on the wall surface and in the fine pores of a highly porous filter substrate. Combination of these two components in the DPNR results in a compact size of the system. The base diesel engine model validated with pressure crank angle diagram and performance parameters such as Indicated mean effective pressure. This base engine’s exhaust emission is given as an input to the DPNR system. The surface reaction is connected to the DPF through chemcon template. The surface reaction is NOx storage and reduction chemical kinetics like Lean NOx Trap. The modelling of DPNR and Base engine is done using GT-SUITE.
Technical Paper

Computerized Experimental Investigation on Performance & Exhaust Emission of Twin Cylinder Adiabatic Diesel Engine coated with YSZ

2019-11-21
2019-28-2548
The fuel consumption and performance of the Internal Combustion engine is improved by adopting concepts of an adiabatic engine. An experimental investigation for different load conditions is carried out on a water-cooled, constant-speed, twin-cylinder diesel engine. This research is intended to emphasize energy balance and emission characteristic for standard uncoated base engine and adiabatic engine. The inner walls of diesel engine combustion chamber are thermally insulated by a top coat of Metco 204NS yttria-stabilized zirconia (Y2O3ZrO2) powder (YSZ) of a thickness of 350 mm using plasma spray coating technology. The same combustion chamber is also coated with TBC bond coats of AMDRY 962 Nickle chromium aluminum yttria of thickness of 150 mm. The NiCrAlY powder specially designed to produce coating’s resistance to hot corrosion.
Technical Paper

Design and Development of Constant speed diesel engine up to 20 bar BMEP with Inline FIS

2019-11-21
2019-28-2549
Design and Development of Constant speed diesel engine up to 20 bar BMEP with Inline FIS Remesan CB, Sanjay Aurora, Vasundhara V Arde, Vishal Kumar, Om Prakash Yadav, Piyush Ranjan Eicher Engines (A unit of TAFE Motors & Tractors Ltd.) Abstract Development trend in diesel engine is to achieve more power from same size of engine. With increase in brake mean effective pressure (BMEP), the peak firing pressure will also increase. The methodology to control the peak firing pressure on higher BMEP is the major challenge. We achieved better SFC with CPCB II emission targets on a constant speed engine. This study involves a systematic approach to optimize combustion parameters with a cost effective and robust inline Fuel Injection System. This paper deals with the strategies applied and experimental results for achieving the power density of 25kW/lit with Inline FIP by keeping lower Peak firing pressure.
Technical Paper

MASS OPTIMIZED HOOD DESIGN FOR CONFLICTING PERFORMANCES

2019-11-21
2019-28-2546
MASS OPTIMIZED HOOD DESIGN FOR CONFLICTING PERFORMANCES Santosh Swamy, Gulshan Noorsumar, Shivakumar Chidanandappa General Motors Technical Center, India Keywords Hood; Head Injury Criterion (HIC); Stiffness; Shape optimization; Multi-Disciplinary Optimization (MDO) Research and/or Engineering Questions/ Objective The objective of this work is to obtain a light weight hood which has least possible mass, and at the same time meets all contradicting performances of pedpro (pedestrian protection) and structural stiffness disciplines. Passenger vehicles have stringent safety norms from pedpro perspective to meet child and adult head injury criteria (HIC). These pedestrian safety requirements often conflict with structural stiffness performance criteria which pose a challenge for most automotive OEMs. Therefore, there is a growing need for mass optimization and performance balancing to meet both the requirements simultaneously.
Technical Paper

Analysis of occupant dynamics and optimization of Driver airbag performance against all FMVSS208 frontal impact cases using validated Finite element Methodology

2019-11-21
2019-28-2545
Several people die every year due to vehicle accidents. Federal Motor Vehicle Safety Standards (FMVSS) are U.S. federal regulations stating design, structure, performance, and durability necessities for vehicles. The objective of a crash test for FMVSS No. 208 is to measure how well a passenger vehicle would protect its occupants in the event of a frontal crash. FMVSS 208 consists of series of tests including different impact surface type as well as occupant sizes. It also covers the belted and unbelted occupant behavior at the time of front impact. Each test scenario has different ways to injure the occupant. Airbags are the part of passive safety equipment family in any automobile and play an imperative role to reduce the occupant head and chest injuries at the time of crash or accidents. This study covers the evaluation of airbag performance in all FMVSS 208 load cases using validated Finite Element Methodology (FEM).
Technical Paper

Passenger "Sleeper Bus" Structure, an Optimization Study using Finite Element Analysis

2019-11-21
2019-28-2537
Sleeper buses are increasingly used as connectivity between cities and remote areas with sleeping comfort for passengers. During the normal operation, the bus body is subjected to several loads, external loads from the road (i.e. crossing over a speed bump, breaking & cornering). Moreover, there is a substantial possibility that these loads may lead to a structural failure. Hence, it is necessary to determine stresses occurred in the bus body to ensure its integrity under these driving scenarios. During the accident, rollover/front/rear/side impact, energy absorbing capacity of bus body structure is crucial for safety of passengers. The objective of this study is to reduce weight of bus structure while maintaining cost & safety as constraint. 3D Model prepared in NX and finite element model created in hypermesh ,LS-dyna/optistruct used as solver and post processing done in hyperview. In this study, fully loaded bus with passengers as well as maximum language mass, considered.
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