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Training / Education

Fundamental Concepts of Turbocharging Modern Engines Current Practices and Trends

2020-06-16
Turbocharging is rapidly becoming an integral part of many internal combustion engine systems. While it has long been a key to diesel engine performance, it is increasingly seen as an enabler in meeting many of the efficiency and performance requirements of modern automotive gasoline engines. This web seminar will discuss the basic concepts of turbocharging and air flow management of four-stroke engines. The course will explore the fundamentals of turbocharging, system design features, performance measures, and matching and selection criteria.
Training / Education

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).
Training / Education

Effective Writing for Engineering and Technical Professionals

2019-11-25
The ability to write concise and unambiguous reports, proposals, manuals, or other technical documents is a key skill for any high-functioning engineer or technical staff person in the mobility industries. Through a combination of class discussions, interactive workshop activities, assignments, checker teams (review teams) and job aids, this course delivers real-life technical writing techniques and tools that can be immediately applied. Attendees discover the importance of knowing their audiences and how to communicate technical information in a "user-friendly" style.
Technical Paper

NEXT GENERATION POWER DISTRIBUTION UNIT IN WIRING HARNESS

2019-11-21
2019-28-2571
Keywords – Miniaturization, Low Profile (LP) Relays, Low Profile (LP) Fuses, Fuse box, Wiring Harness Research and/or Engineering Questions/Objective With the exponential advancement in technological features of automobile’s EE architecture, designing of power distribution unit becomes complex and challenging. Due to the increase in the number of features, the overall weight of power distribution unit increases and thereby affecting the overall system cost and fuel economy. The scope of this document is to scale down the weight and space of the power distribution unit without compromising with the current performance. Methodology Miniaturization involves replacing the mini fuses and J-case fuses with LP mini and LP J-case fuses respectively. The transition doesn’t involve any tooling modification and hence saves the tooling cost.
Technical Paper

A Mathematical Approach to Determine Die Wear during Forging Process and Validation by Experimental Technique

2019-11-21
2019-28-2563
The automotive industry is constantly trying to develop cost effective, high strength and lightweight components to meet the emission and safety norms while remaining competitive in the market. Forging process plays an important role to produce most of the structural components in a vehicle. Precision forging technology is used to produce components with little or no flash leading to elimination of machining process after forging. The load acting on the dies during net or near net forging is very high and leads to wear in the die. In order to have a good die it is important that die wear which is an inevitable phenomenon in a bulk metal forming processes is predicted mathematically. In this study a review on the vast number of studies done in the area of wear and various predictive models is carried out.
Technical Paper

SELF EXPRESSIVE & SELF HEALING CLOSURES HARDWARES FOR AUTONOMOUS AND SHARED MOBILITY

2019-11-21
2019-28-2525
Shared Mobility is changing the trends in Automotive Industry and its one of the Disruptions. The current vehicle customer usage and life of components are designed majorly for personal vehicle and with factors that comprehend usage of shared vehicles. The usage pattern for customer differ between personal vehicle, shared vehicle & Taxi. In the era of Autonomous and Shared mobility systems, the customer usage and expectation is high. The vehicle needs systems that will control customer interactions (Self-Expressive) & fix the issues on their own (Self-Healing). These two systems / methods will help in increasing customer satisfaction and life of the vehicle. We will be focusing on vehicle Closure hardware & mechanisms and look for opportunities to improve product life and customer experience in ride share and shared mobility vehicles by enabling integrated designs, which will Self-Express & Self-Heal.
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

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

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

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

High rigidity and light weight bumper material development in India

2019-11-21
2019-28-2553
Vehicle weight reduction becomes important at the view point of fuel efficiency improvement and CO2 reduction in India also as well as developed countries. With this background, High tensile and Super high tensile steel application has become increasing. Similary, weight reduction of big plastic parts like bumper face is one of the most important items, so Honda has developed Thin-wall and light weight bumper face. In the development of light weight bumper, rigidity, impact strength and flowability which are main requirement are cotradictory property. It is necessary to develop new material to achieve this technical concern. Moreover, we verified part shape and thickness optimization to achieve part requirement. Established high property material and part manufacturing technology were applied for current CITY firstly, and it has been expanded to other models sequentially to contribute weight reduction for Honda vehicles.
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

A review on influence of different flushing methods on Material Removal Rate using EDM.

2019-11-21
2019-28-2543
Electrical release machining (EDM), is a material removal procedure whereby a coveted shape is acquired by utilizing electrical releases (sparks). Material is expelled from the work piece by a progression of quickly repeating current releases between cathode and anode, isolated by a dielectric fluid and subject to an electric voltage. At the point when the voltage between the two terminals is expanded, the power of the electric field in the volume between the anodes winds up more prominent than the quality of the dielectric (in any event in a few spots), which separates, enabling current to stream between the two cathodes. This wonder is the equivalent as the breakdown of a capacitor (condenser). Accordingly, material is expelled from the cathodes.
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

Wiring Harness Optimization towards Wireless Vehicle

2019-11-21
2019-28-2530
Paper Title - Wiring Harness Optimization towards Wireless vehicle Research and/or Engineering Questions/Objective (maximum 100 words)  In current scenario, wiring harness plays a vital role in inter-connecting electrical & electronic components fitted all across the vehicle.  As per cable standard, DIN 72551 or ISO 6722, copper conductors being used in stranded wires against cable cross-section & corresponding weight.  While going complete wire-less requires each component to have its own battery, ground, transmitter & receiver which indeed is a very costly affair to be employed in vehicle as huge development cost is required.  Here I'm suggesting an innovative method to make a vehicle apparently Wire-Less by creating local clusters connected to each other via conventional wiring harness & wire-less module.  Such method will apparently give a look of Wire-less vehicle itself & better advantages in terms of installation, service, troubleshooting, uptime & customer delight.  Moreover, direct benefits of Cost, Weight, FE will also be achieved.
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

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

Powertrain topologies for 2 wheelers : From ICE to Electrification

2019-11-21
2019-28-2480
As Battery cost is expected to see a Downward trend, Electrification of Powertrain in general is expected to pick up and 2wheeler Market is foreseen to be the Flag bearer in this race towards Electrification. In this paper, we would like to emphasize on the Journey of 2wheelers from Conventional Internal combustion Engine to Electrified Powertrains which we foresee in the future. Methodology: EV - Analysis of OEM strategies and upcoming trends in connectivity and electrification. Estimation of current market size of 2Wheeler and segmentation based on different personas. Building survey data based personas around ownership patterns for electric 2Wheelers. Mapping consumer decision process for electric 2Wheelers. Analyse the decision influencers and role of influencers in decision making process. Hybrid - Analysis of different hybrid topologies. Feasibility study via simulation and focus group assessments to evaluate the design. PoC will also be tried to validate the concept.
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