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Technical Paper

Modal Model Correlation of Commercial Vehicle Frame

Design decisions based on the virtual simulations leads to reduced number of prototype testing. Demonstrated correlation between the computer simulations and experimental test results is vital for designers to confidently take simulation driven design decisions. For the virtual design evaluation of durability, ride, handling and NVH performance, demonstration of correlation of structural dynamic characteristics is critical. Modal correlation between CAE and physical testing validates the stiffness and mass distribution used in the FE model by correlating mode shape and mode frequency in the desired frequency range. The objective of this study is to arrive at a method for establishing modal correlation between CAE and experimental test for a bare frame and thereby enabling evaluation of design iterations in virtual environment to achieve modal targets.
Technical Paper

Remnant Life Estimation of Automotive Components by Resonance Fatigue Method

In today’s commercial vehicle scenario, designing and developing a component which will never fail throughout its lifespan is next to impossible. For a long time especially in the field of automotive, any crack initiation shall deem the component as failed and the design requires further modification. This paper deals with studying the failure of one such component and understanding the effect the crack has on the overall life of the component i.e. understanding the remnant life of the component. The component under study was gear shift lever bracket and is mounted on the engine exhaust manifold. It experiences two types of loads: inertial load due to the engine vibration and gear shift load. Frequent failures were observed in the field and in order to simulate it at lab, an accelerated test approach was adopted. The engine operating speed was used to identify the possible excitation frequency which the component might experience.
Technical Paper

A Modular High Frequency Stable Orthogonal Road Load Exciter for Validation of Automotive Components

The commercial vehicle industry is evolving faster with the rise in multifarious aspects deciding a company's progress. In the current scenario, vehicle performance and its reliability in the areas of payload, fuel economy, etc. play vital roles in determining its sustenance in the industry, in addition to reducing driver fatigue and improving comfort levels. Test quality and time is the key to assure and affirm, smooth and quick launch of the product into the market. This paper details on the design of Multi-Axis road data simulator which entails realistic loads onto the components for capturing meaningful information on behavior of the product and recreate the field failure modes. The design was conceptualized keeping in mind both cost (for initial installation and running cost) and time for testing without loss in the convergence factor.
Technical Paper

A Systematic Approach of Improving Reliability Process through Development and Application of On-Board Diagnostics System, for Commercial Vehicle

This paper describes a methodology for design and development of On-Board Diagnostic system (OBD) with an objective to improve current reliability process in order to ensure design & quality of the new system as per requirement of commercial vehicle technology. OBD is a system that detects failures which adversely affect emissions and illuminates a MIL (Malfunction Indicator Lamp) to inform the driver of a fault which may lead to increase in emissions. OBD provides standard and unrestricted access for diagnosis and repair. Below given Figure 1 shows the working principle of OBD system. The exhaust emission of a vehicle will be controlled primarily by Engine Control Unit (ECU) and Exhaust Gas After Treatment Control (EGAS CU). These two control units determine the combined operating strategies of the engine and after treatment device. Figure 1 Modern Control Architecture for OBD System in Commercial vehicle [1]
Journal Article

Development and Analysis of an Electric Vehicle Controller for LCV

This paper describes the system architecture together with control and diagnostics features of an indigenously developed electric vehicle controller for Light Commercial Vehicle. The key functions of vehicle controller include power management, driveline controls, regeneration and vehicle mode controls. In particular this paper presents vehicle's operational strategy in economy, normal and performance modes based on the vehicle speed and SOC. It also has feature to enable vehicle operation in reduced performance mode at low battery voltages. The battery fault predictor algorithm is also described in detail that is used to control discharge current to prevent sudden dip in SOC and to increase battery life. The vehicle control strategy is modeled & simulated using MATLAB™ environment and results for a specific test case are validated with embedded controllers-in-the-loop in a test-bench environment.
Technical Paper

Potential Weight Saving in Buses Through Multi Material Approach

Vehicle light-weighting of late has gained a lot of importance across the automotive industry. With the developed nations like the U.S. setting stringent fuel economy targets of 54.5 mpg by 2025, the car industry's R&D is taking light weighting to a whole new level, besides improving engine efficiency. The commercial vehicles on the other hand are also gradually catching up when it comes to using alternate material for weight reduction. This paper will discuss light-weighting in the context of buses though. For a typical bus, the contribution of shell structure weight in the bus body weight is more than 40%. This qualifies as the area with a huge potential for weight saving. On the other hand the shell structure forms the base skeleton of the bus body providing it with adequate strength and stiffness for meeting both functional (bending & torsional stiffness) and passive safety requirements (rollover compliance).
Technical Paper

A Holistic Approach to Aerodynamics of Intercity and Interurban Buses

The aerodynamic drag of cars, trucks and buses have been closely examined over the years. Many of them focus on the front end and to some extent on rear end of the vehicles [1]. Of course these are the two surfaces that contribute to more than 85 % of the total drag. This is because these surfaces are almost normal to the direction of air flow and hence create enormous pressure differences and hence drag. A lot of optimization has also gone into these, by way of reducing the sharp corners at ‘A’ pillars, introducing aerodynamic dome and even ‘boat tail flap plates’ [2-3] for some trailers. However, part of the vehicle that has not received sufficient attention in aerodynamic drag considerations is the ‘transverse outer profile’ of vehicle. This transverse outer profile is nothing but the cross sectional profile formed by the vehicle's sides, roof and their integration.
Technical Paper

Development of World's 1st Mechanical Inline Pump Engine Meeting BSIII Emission Norms with Technology of Exhaust and AT

The automotive industry is one of the industries that have visibility suffered a strong demand for higher environmental performance. This industry have enjoyed years as the main source of employment and economic growth, today it is being pointed out as one of the major contributors to air pollution in urban centers. Indeed the benefits of automobile provide the means of gaining access to life's necessities and employment and a source of pleasure. However, despite these benefits there are environmental burdens as well: local air pollution, greenhouse gas emissions, road congestion, noise, mortality and morbidity from accidents and less open space to roads. Thus companies in the sector have been trying different strategies to overcome these challenges Evaluation of Emission development for commercial vehicles had always been great challenge to continuously migrate from one level of emission norm to other maintaining the business continuity.