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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).
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

Determining the State Of Health [SOH] of Li Ion cell

2019-11-21
2019-28-2579
“NuGen Mobility Summit-2019” Paper Title : Determining the State Of Health [SOH] of Li Ion cell Authors: Sushant Mutagekar, Ashok Jhunjhunwala, Prabhjot Kaur Objective Cells age with life. This aging is dependant on various factors like charging/discharging rates, DOD of operation and operating temperature. As the cell ages it undergoes power fade (ability to deliver required power at particular State of Charge [SOC]) and capacity fade (the charge storage capacity of cell). In an Electric Vehicle it is important to know what power shall be demanded from a battery irrespective of what its current SOC is and number of cycles it has undergone. With minimal accuracy and less computational power, it is difficult for a Battery Management System [BMS] to accurately determine SOH; the paper proposes a a precise model that may help.
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

Design improvements in advanced automotive batteries using AI

2019-11-21
2019-28-2505
Introduction: The advent of electric mobility is changing the conventional mobility techniques and with this comes challenges to improve the performance of battery to optimize power consumption in electric vehicles. Objective: This paper would focus on the optimization of battery performance incoherent with vehicle power consumption behavior in terms of efficiency using decision-making ability based on given input signals
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

Performance of Switched Reluctance Motor for Small Electric Vehicle in Urban Mobility

2019-11-21
2019-28-2501
Small electric vehicles are challenging in nature while designing the power train and especially the mounting of batteries within the volume available. In this research, power train of small electric vehicle is designed and it is compared with the electric vehicles. The designed vehicle should meet the requirements of urban car so that it can be preferred in urban mobility. Emphasis is given on studying performance parameters such as motor speed, torque for different urban driving cycles by altering the motor and its no. of poles. Battery pack is designed to fit under the front hood of the vehicle whereas motor is fitted at the rear. Range is estimated using Simulink and it is validated with mathematical calculation using Peukert method performed in MATLAB. It is concluded that the designed vehicle with Switched Reluctance Motor 6/4 configuration of 15 kW, 110 Nm is sufficient to meet the urban car in 2020 targets. NCA battery is preferred for range improvement.
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

EV Charging Concept for the Indian Market

2019-11-21
2019-28-2502
Predominantly the biggest question that haunts the EV Market is the charging infrastructure that should eventually ease the nervousness of the consumers and allowing EV to penetrate the Indian market with changes done within urban areas and highways. There are multitude of options available ranging from onboard charging via home charging point to a Fast DC off board charger that can be used to charge an EV. There are multiple factors that can be used to evaluate the options and their pros / cons. Some of these factors are: • Cost, time to charge, health of battery, charging and discharge rate of the battery, etc… • Convenience and availability of charging point • Ease of operation including payment • Safety and Security • Ambient temperature in which charging is done There are mainly these categories of charging options: • Residential charging based on a home charging point. The charger is mounted on the vehicle (onboard) and the EV cable can be connected to the home plug point.
Technical Paper

Design and Development of Industrial Automotive Battery Management system

2019-11-21
2019-28-2498
Battery operated vehicle need accurate management system because of its quick changes in State of charge (SOC) due to aggressive acceleration profiles and regenerative braking. Li-ion battery needs control over its operating area for its safe working. So, the main objective of the proposed system is to develop a BMS having algorithms to estimate accurate SOC, predict degradation parameters, balance individual cells, manage cell temperature, and provide safe area of operation defined by voltage and temperature. Proposed methodology uses Model-based Design approach wherein nonlinear behavior of battery is modeled as Equivalent Circuit Model to compute the SOC and degradation effect on battery to decide the end of life of battery, also performing inductive Active balancing on cells to equalize the charge. proposed algorithms communicate with the vehicle ECU through CAN to assist the driver for runtime estimation, time for battery swapping, Alerts.
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

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.
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