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FEA Beyond Basics Thermal Analysis

2019-12-16
Finite Element Analysis (FEA) is a powerful and well recognized tool used in the analysis of heat transfer problems. However, FEA can only analyze solid bodies and, by necessity thermal analysis with FEA is limited to conductive heat transfer. The other two types of heat transfer: convection and radiation must by approximated by boundary conditions. Modeling all three mechanisms of heat transfer without arbitrary assumption requires a combined use of FEA and Computational Fluid Dynamics (CFD).
Technical Paper

Automobile Exhaust Emmision Control- A review

2019-11-21
2019-28-2382
Since the 20th century increase in the number of cars in the major cities is been a point of concern because of the toxic gasses being emitted from the engine of an automobile. These gasses are polluting the atmosphere and degrading the air to breathe. The main gasses responsible for the degradation of air quality are carbon monoxide, hydrocarbon and oxides of nitrogen. There is a necessity to find ways to reduce the pollution emitted into the atmosphere from the automobile. The source of emission is either evaporation from fuel tank or carburetor which is easy to be dealt with or harmful gasses due to improper combustion which is a concern for the environment. The two ways to reduce these emissions are, modification in the engine to minimize the production of harmful gases and to treat the harmful gasses emitted from the engine before blowing it into the atmosphere from the exhaust. Catalysts help to break harmful gasses into smaller compounds that are environment-friendly.
Technical Paper

Low Voltage Powertrain in Light Electric Vehicles

2019-11-21
2019-28-2467
Engineering objective Light Electric Vehicles (LEV) with Li-ion batteries suffer from short battery life and poor efficiency, due to low grade electronics. Battery management systems (BMS) cannot always keep the pack in balance, and after cell voltages drift, capacity of the pack diminishes and some cells may destruct, causing a fire. The paper describes a novel approach to LEV powertrains using parallel connected battery cells & control methodology that keep cells in balance naturally, thereby eliminating BMS and hence safer to use. Li-Ion cells with different chemistries can be used and superior thermal management reduces temperature rise, resulting in longer battery life. Methodology Based on the original invention by the author, the system circuit schematics was designed and simulated using OrCAD PSpice. After obtaining results from the simulation, the first prototype device was constructed and tested in laboratory.
Technical Paper

Thermal Management of Li-Ion Battery Pack using GT-SUITE

2019-11-21
2019-28-2500
Objective It is very important to simulate the battery pack being built to understand its behavior when used in applications especially Electric vehicles (EV). All Li-Ion cells are not the same. They need to be characterized before building any battery pack. Hence modeling the battery pack to simulated its performance in the actual conditions becomes important. Methodology To understand the behavior of cells in the on-field environment, they are tested at various conditions like different rates of charging/discharging, various depth of discharge (DOD), ambient temperature, etc. HPPC test is also performed on cells to derive its RC model equivalent model. GT Suite simulation software is used to model the Li-Ion cell using the testing data. Depending on the pack configuration, the modeled cell is connected in the required series and parallel configuration, to study the battery pack with respect to aging, performance and cooling requirements.
Technical Paper

Electric Vehicle Thermal Management System For Hot Climate Regions

2019-11-21
2019-28-2507
ELECTRIC VEHICLE THERMAL MANAGEMENT SYSTEM FOR HOT CLIMATE REGIONS Rana Tarun*, Yamamoto Yuji, Kumar Ritesh, Bhagatkar Shubhada Pranav Vikas India Private Limited, India Key Words Electric Vehicles (EV); Battery Thermal Management System (BTMS); COP; Electric Vehicle Thermal Management System (EVTMS); BTMS and HVAC System Integration; Thermal System Performance Comparison; Active Liquid Cooling; EV Battery Cooling Research and/or Engineering Questions/Objective Electric Vehicles is the need of time to limit global warming and it is in application at a wide scale in colder or mild climate regions where ambient temperature is limited to mild or moderate level. Its application (Heat pump, CO2) is constrained to cold climates only due to securing better COP for heating function, sacrificing cooling COP of the existing system when operated in Hot Climate Regions, thus limiting its application to nearly half of the automotive user-base.
Technical Paper

Thermal Challenges in Automotive Exhaust System through Heat Shield Insulation

2019-11-21
2019-28-2539
While advanced automotive system assemblies contribute greater value to automotive safety, reliability, emission/noise performance and comfort, they are also generating higher temperatures that can reduce the functionality and reliability of thesystem over time. Thermal management and insulation are extremely important and highly demanding in BSVI, RDE and Non-IC engine operating vehicles. Passenger vehicle and Commercial vehicle exhaust systems are facing multiple challenges such as packaging constraints, weight reduction andthermalmanagement requirements.Frugal engineering is mandatory to develop heat shield in the exhaust system with minimum heat loss. The focus of the paper is to design, develop and validate heat shield products with different variables such as design gap, insulation material, sheet metal thickness and manufacturing processes. 1D and 3D computational simulations are performed with different gaps from 3 mm to 14 mm are considered.
Technical Paper

Replacing twin electric fan radiator with Single fan radiator

2019-11-21
2019-28-2381
Downsizing is one of the crucial activities being performed by every automotive engineering organization. The main aim is to reduce – Weight, CO2 emissions and achieve cost benefit. All this is done without any compromise on performance requirement or rather with optimization of system performance. This paper evaluate one such optimization, where-in radiator assembly with two electric fan is targeted for downsizing for small commercial vehicle application. The present two fan radiator is redesigned with thinner core and use of single fan motor assembly. The performance of the heat exchanger is tested for similar conditions back to back on vehicle and optimized to get the balanced benefit in terms of weight, cooling performance and importantly cost. This all is done without any modification in vehicle interface components except electrical connector for fan. The side members and brackets design is also simplified to achieve maximum weight reduction.
Technical Paper

Accounting the variabilities into squeak and rattle predictions

2019-11-21
2019-28-2402
Squeak and Rattle (S&R) are the dominant undesired noises which adjudge the perceived quality of a vehicle. It's a foremost problem which needs to be identified and eliminated at a design stage to develop a robust vehicle, which also aids in pacifying the physical testing and warranty claim costs. A Finite Element model of the complex plastic dashboard has been analyzed to identify risks and the root cause of S&R problem under dynamic and static loading conditions, using E-line methodology. These complex transient problems are highly influenced by various parameters like gap variability, temperature, the coefficient of thermal expansion, thickness, and material properties. This paper elaborates the detailed investigation conducted using stochastic simulations to evaluate the individual and combined impact of each parameter on S&R performance
Technical Paper

Occupant Controlled Ventilation

2019-11-21
2019-28-2461
Keywords-Coolant,Ventilation Research and/or Engineering Questions/Objective: Number of Occupants is the major parameter when we consider Air Conditioning System. The number of person who stays in the room may vary in the same way the person who travels in the automobile also vary throughout the distance. This is more prevalent in transportation system like bus, train and where lot of people will travel together and where dropping station in the vehicle is too frequent.In this type,operating A.C has to be varied Methodology: . Instead the number count in the vehicle will be monitored from time to time. Based on the number of count, the cabin has to be cooled or heated and accordingly corresponding power has to be drawn by the compressor from the engine. This human count can be detected based on the number of CO2 sensor located in the cabin. the amount of fresh air that should be added to a cabin can be controlled by a carbon dioxide level transmitter.
Technical Paper

Vehicle Interior cleanliness tracker

2019-11-21
2019-28-2466
The future of mobility is being driven towards fully autonomous driving. As a result, people spend majority of the time in vehicles for chores other than driving. The focus of automotive makers shifts towards providing best-in-class passenger comfort. One of the least focused area in passenger comfort is vehicle interior cleanliness which requires periodic human intervention. An intelligent vehicle can outsmart a human by self-caring to maintain the cleanliness elements on floor, seat and roof. This paper addresses subjects like wetness, dirt and stains in the vehicle interior utilizing the capability of Interior sensing platform. An internally mounted camera in the vehicle can capture images of the interior and apply image processing techniques to identify the subjects mentioned above. The wetness on the floor mats can lead to moldy odor, corrosion, failure of the electronic components in the car.
Technical Paper

Noise & Vibration challenges in an Electric Vehicle (Bus), its effect and possible reduction techniques

2019-11-21
2019-28-2493
Ikshit Shrivastava1, Kiranpreet Singh2 1,2 International Centre for Automotive Technology (ICAT), Gurugram, India Introduction: Noise and Vibrations is a vast field of study and has been a constant challenge to Acousticians and designers. IC engines have been in existence since almost 125 years and have given enough room & time to acousticians and engineers to develop materials and tune powertrains to minimize Noise and Vibrations from vehicles. With the advent of technology to evolve alternate fueled powertrains to reduce emissions emitted by IC engines, lot of research is being carried out to develop powertrains particularly in the area of Hybrids & Electrics. Substantial investments are being made by OEMs worldwide on researching xEV domain to tap new motor/ battery technologies for vehicles. Since the technology in xEVs is majorly different, the problems associated with them are also different.
Technical Paper

Coupled Electro-Chemical and Thermal Modeling for Cylindrical Lithium-ion Batteries

2019-11-21
2019-28-2488
The shift over of the automobile sector from the ICE to the electric drives is imminent due to arising global issues of pollution and ever rising pressure on the demand of the natural resources due to lower efficiency of the ICE drives. This has led to uprising of the Lithium-ion batteries, with addition of the burden of living to expectation of clean energy and higher efficiencies. Alongside, with limitation in the availability of the lithium-ion batteries they carry a hefty price tag with them, hence causing huddles in the research. Lack of research leads to failure of batteries and may cause life threatening situations when operating in the vehicle. In order to insight the working of the cylindrical lithium-ion batteries under different driving and environmental conditions a methodology is developed for the coupled electro-chemical and thermal phenomenon. This allows anticipating the behaviour of the battery under different conditions that influence its performance.
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

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

Development of high power density diesel engine for constant speed application

2019-11-21
2019-28-2566
Engine up gradation for higher power rating involves challenges that require hardware changes which not only increase cost but also demand higher space. This paper focuses on the up gradation of a 4 cylinder 4.9l CRDi engine from 24.03 kW/L to 30.75 kW/L by adjustment of various parameters to meet both emission and performance targets. Various challenges like higher exhaust temperature, increased peak firing pressure etc. were met using the proper calibration strategy. To meet SFC targets and keep peak firing pressures, exhaust temperatures within desired limits, different operating points for EGR, main injection timing, rail pressure have been optimized. The operating points for optimization were determined by conducting various drive trials on different type of load conditions in test bench. Calibration strategy involved the safe limits of NOx, soot, CO emissions, fuel consumption.pfp, and exhaust temperature.
Technical Paper

Combustion Optimization and In-cylinder NOx and PM Reduction by using EGR and Split Injection Technique

2019-11-21
2019-28-2560
Nowadays, the major most challenge in the diesel engine is the oxides of nitrogen (NOx) and particulate matter (PM) trade-off, with minimal reduction in Power and BSFC. Modern day engines also rely on expensive after-treatment devices, which may decrease the performance and increase the BSFC. In this paper, combustion optimization and in-cylinder emission control by introducing the Split injection technique along with EGR is carried out by 1-D (GT-POWER) simulation. Experiments were conducted on a 3.5 kW Single-cylinder naturally aspirated CRDI engine at the different load conditions. The Simulation model incorporates detailed pressure (Burn rate) analysis for different cases and various aspects of ignition delay, premixed and mixing controlled combustion rate, the injection rate affecting oxides of nitrogen and particulate matter.
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