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Technical Paper

AUTOMOTIVE VEHICLE TRANSMISSION SYSTEMS

2019-11-21
2019-28-2521
Abstract:At present there are a few types of transmission system available in automated industry, there might some variation in transmission system but the basic working and principle is still the same. Many big automotive manufacturers use different technologies in their transmission system but they still use the same basic principle in their transmission systems. This new technology which is brought by Koenigsegg has changed the way people think about transmission system. This new transmission system is known as Koenigsegg Direct Drive and is currently used by one automotive manufacturer and in one vehicle only, but it soon might change the way it is now.
Technical Paper

Employing natural plant based fiber in interior automotive parts for cost & weight benefit

2019-11-21
2019-28-2559
The Automotive industry is in ever more need for a lesser weight car due to progressively stringent emission norms and the demand of customer to have better mileage. It can be a gargantuan challenge for automotive manufacturers to search for lesser weight material to meet both customers as well as regulatory norms. But in some cases such lower weight material can increase the cost and adding a expensive material which increases overall cost to a price sensitive market like India is not favorable. One such solution is using the indigenous plant fiber (Jute) in combination with propylene (PP) to make Interior plastics components. Jute a vegetable fiber also referred to as "the golden fiber" has high tensile strength, low extensibility and is well established in fabric, packing, agriculture, construction industries. The biodegradable Jute lesser weight & abundance (India is the leading manufacturer of the Jute) can be utilized in making automobile trim parts in India.
Technical Paper

To establish the correlation in between Computer Aided Engineering & physical testing of automotive parts returnable case (Stacktainer).

2019-11-21
2019-28-2569
Automotive returnable cases (Stacktainers) are being used to transport the automotive parts through surface & seaways. No automotive manufacturer wants to spend money on woods, paper & cardboard again and again, it`s better to pay once for robust & reusable cases. these provide better protection to parts from its manufacturing to assembly line of vehicle. While transporting, any kind of crack or failure of returnable cases may lead to loss of money, human & time. To ensure the safety, these pallets have to be validated for vibrations coming from surface irregularities, sea waves & load due to stacking of cases one above other. The objective of this study is to establish a correlation in between the physical testing & simulation in Computer added Engineering (CAE) of automotive returnable case (Stacktainers). There are different types of tests considered to validate the returnable case, rough road evaluation, Multi-axial Vibration & strength evaluation.
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

Improved update-over-the-air solution through standardization of ‘software/firmware package format and flash jobs’

2019-11-21
2019-28-2435
This paper investigates and proposes the possibilities of standardizing the software/firmware package format and flash jobs in order to provide the possibility of productizing the update-over-the-air solution regarding on-board vehicle components and make use of it in all OEMs with minimum configuration changes and customization. The update-over-the-air solution in the automotive sector is provided by various suppliers and needs to be customized to meet various OEMs requirements. Possible Variants of OEM requirements are: • Variant 1 o Customer Portal + Backend + vehicle on-board components solution from supplier • Variant 2 o Customer Portal + Backend solution from OEM o Vehicle on-board components from supplier • Variant 3 o Backend from OEM o Customer Portal + vehicle on-board components from supplier ODX, VBF, and many other formats from OEMs include software/firmware packages.
Technical Paper

Paper Title : Connectivity in 2wheeler: Opportunities & Challenges

2019-11-21
2019-28-2437
Abstract: Future of Mobility is mainly driven by 3 main pillar viz Connected , Electrified and Automated Driving. With advancement in Communication Technology supplemented by huge customer Base , Connectivity has proven to deliver better Services to the End-user. The next step in this journey would be to connect the so called “Things” and the Things that we want to connect is the 2 wheeler in the Mobility domain This paradigm shift in the Mobility Landscape is expected to bring plethora of opportunities on one side as well as new challenges that were never witnessed in the realm of Mobility in the Past. This paper focuses on Opportunities in terms of Location Based services, Vehicle Management, Data Analytics, Infotainment , and possible Business scenarios and Models as well as challenges in Terms of Security and Data Ownership Methodology: Analysis of OEM and Supplier strategies/approaches and upcoming trends in connectivity and electrification.
Technical Paper

Entry Level Connected Infotainment Unit with Smartphone and vehicle integration

2019-11-21
2019-28-2434
As we transition towards Internet of Things (IoT) - humans are connected to each other & outside world through the smartphone. Customers tend to use smartphones for varied purposes ranging from communication to entertainment. However, the concern of distraction exists due to poor visibility & accessibility of the phone's screen in driving condition. One of the repercussion of being connected to smartphone particularly in driving condition includes higher number of road accidents due to distraction. This paper explains one of the key initiatives taken by Maruti Suzuki India Limited to address the same.
Technical Paper

Optimization of An EV Controller Design For A Three Wheeler BOVs - EMC Approach

2019-11-21
2019-28-2474
Introduction: The advent of electric mobility is changing the conventional mobility techniques and their application in automobiles across all segments. Three wheeler Battery Operated Vehicles (BoVs) are a special category of electric vehicles (EVs) as far as EMC compliance is concerned. The problem mainly lies with the open body design and cost cutting measures being exercised by the manufactures which makes Electromagnetic compatibility (EMC) compliance challenging. Objective: Though it is sometimes possible to resolve EMC malfunctions related to motor power cable, cables & wiring harness etc. using external techniques post design stage, but controller being a closed and typical element makes it difficult to improve against EMC malfunctions using external techniques. This paper would concentrate on the controller design parameters and improvement of the same in terms of Electromagnetic compatibility (EMC) and performance efficiency at the design stage itself.
Technical Paper

Analysis Of GaN Based BLDC Motor Drive For Automotive Application

2019-11-21
2019-28-2471
Objective Automotive sector is rapidly moving towards electric vehicle. BLDC motor is gaining popularity in the field of electric vehicle due to its high torque to weight ratio and simple control. In this paper we will focus on Switching loss characterization of 3 kW GaN based BLDC drive for electric vehicle. To improve efficiency of drive gallium-nitride based power transistor is used instead of Si MOSFET. GaN devices enable the design of inverter at higher frequencies with improved power density and efficiency as compared to traditional Si MOSFETs. Methodology In this paper commercially available GaN devices compared with Si MOSFETs. The power devices, which are selected for the performance comparison, are EPC2022 GaN by EPC, GS61008P GaN by Gan System and SiDR668DP Si MOSFET by Vishay. The Switching losses analytically predicted in MATHCAD tool and then compared with SPICE simulation losses. Double pulse test circuit is used to find out power losses of power transistors.
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

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

Thumb Design and Optimization for Backhoe Loader

2019-10-11
2019-28-0109
Product Engineering organizations are committed to provide solutions with right quality and value to customers. Value improvement and efficient product improvement are key considerations for product engineering. In this paper, Author outlines the summary of Thumb Design and Optimization for Backhoe Loader. This project goal was to come up with own thumb design. The Backhoe thumb attachment was previously a Proprietary Design of the supplier which had two major limitations, limited opportunity of design improvements for resolving customer issues and higher total cost. The paper covers details about overcoming these limitations. In Backhoe loaders, for multiple variants of machines, four different thumbs are used. Small and mid-backhoe machine classes use 4-tine and 2-tine thumb depending upon customer applications. The design team targeted an external customer requirement of a more compact design and internal requirement of accelerating design improvement cycle time.
Technical Paper

Prototype design of a small scale thermionic energy generator for waste heat recovery in hybrid electric vehicle.

2019-10-11
2019-28-0027
The sustainability of energy generation is primarily based on the effectiveness of the methods used for minimizing the wastes and optimum utilization of available energy resources. Mobility and its ease is therefore being an essential component of development. Automotive technology is an area where methods are explored in recent times to provide sustainable solution for reduction of fuel consumption and carbon emission by switching to hybrid technology and electric vehicles where regeneration of energy plays an important role. At present the research is focused on achieving methods of solid state conversion of heat into electricity but its limited to thermoelectric which has lower conversion efficiency. A comparative analysis of the direct energy convertors shows that thermionic energy conversion stands better with a higher conversion efficiency.
Technical Paper

Fault Detection in Single Stage Helical Planetary Gearbox using Artificial Neural Networks (ANN) with Histogram Features

2019-10-11
2019-28-0151
Abstract Drive train failures are most common in wind turbines. Lots of effort has been made to improve the reliability of the gearbox but the truth is that these efforts do not provide a life time solution. Majority of failures are caused by bearing and gearbox. It also states that wind turbine gearbox failure causes the highest downtime as repair has to be done at Original Equipment Manufacturer [OEM]. This work aims to predict the failures in planetary gearbox using fault diagnosis technique and machine learning algorithms. In the proposed method the failing parts of planetary gearbox are monitored with the help of accelerometer sensor mounted on the planetary gearbox casing which will record the vibrations. A prototype has been fabricated as a miniature of single stage planetary gearbox. The vibrations of healthy gearbox, sun defect, planet defect and ring defect under loaded conditions are obtained. The signals show the performance characteristics of gearbox condition.
Technical Paper

Mathematical Modelling of Door Shut-line Definition in CATIA

2019-10-11
2019-28-0107
Door shut-line definition is the first vital step in car body door engineering and depends on the hinge position, hinge shape, manufacturing capabilities and other parameters. In the design process, once the hinge axis definition is finalized door shut-line is defined which should satisfy two major requirements. The requirements are clearance between the door outer surface with its surrounding components (like hinges, fender, other door etc.) and assembly feasibility. The above conditions must be checked on different locations of the door as well as w.r.t different openings of the door. The paper presents a mathematical model to determine the door shut-line position with great computational efficiency. This method propounds closure engineer with parameters to define the shut-line rather than cumbersome manual iterative process. Instead of following an iterative approach to determine a limit for the shut-line, paper presents a mathematical formulation with an implicit equation.
Technical Paper

Design and development of intake ports for 2-valve & 4-valve configurations for heavy duty off-highway Diesel Engine

2019-10-11
2019-28-0042
Keywords - Four valve intake port design, steady flow test, CFD numerical simulation, off-highway engines Abstract: Future emission limits for off-highway application engines need advanced power train solutions to meet stringent emissions legislation, whilst meeting customer requirements and minimising engineering costs. Development of diesel engines for off-highway application for different power segments need different intake port design solutions to optimise in-cylinder flow structure for efficient combustion. With adaptation of low pressure mechanical fuel injection system, intake port development becomes an important stage for reduction of emission formation at the source and improvement in fuel economy. In this paper, intake port design and development process is elaborated for two different power ratings of 75 hp and 120 hp of off-highway engine. 2-valve and 4-valve configurations are deployed for the same cylinder bore size.
Technical Paper

A Case Study on the Importance of Implementing an Obsolescence Material Management in an Aerospace Manufacturing Supplier Industry Environment

2019-10-11
2019-28-0145
Obsolescence Material management plays an important and vital role in today’s modern Aerospace manufacturing, Aerospace Maintenance, Repair and Overhaul industry as well as Aerospace Distributors. Aerospace vehicles have a considerable longer product life-cycle when compared to any other consumer goods like automobile and electronics industry. With the advent of new, disruptive technologies, many sources and supplies of materials including COTS and Standard catalogue parts, components and goods, which are widely used in an Aerospace manufacturing environment, are diminishing at a considerable rate and thus result in their obsolescence before the end disposal of the product life cycle. It is one of the leading causes to the sale of counterfeit and fraudulent parts and components, which can result in considerable deterioration of Quality and Cost to Customer.
Technical Paper

Development of a Simulation Model for Computing Stable Configurations for Off–Road Vehicle

2019-10-11
2019-28-0126
Off-highway vehicles operate under complex duty cycles which consist of handling varying terrain conditions under dynamic loads. A challenge for the equipment operator is to maintain stability of the vehicle during various field operations. The operator must make judgement calls on whether terrain and loading conditions are suitable for vehicle stability. In view of the increasing emphasis being placed on operator comfort and vehicle autonomy, a methodology to predict the degree of vehicle stability in varying terrains and dynamic loads will be an aid in designing safer vehicles. In this paper, we describe a mathematical model capable of predicting the longitudinal overturning behavior of off-highway vehicle. A mathematical kinematic and dynamic model of the system is developed using Newton-Euler approach. This yields a system of non-linear equations which are solved iteratively using commercial software to predict stability for varying terrains and dynamic loads.
Technical Paper

Design and Implementation of Digital Twin for Predicting Failures in Automobiles using Machine Learning Algorithms

2019-10-11
2019-28-0159
The drastic technological advancements in designing autonomous vehicles and connected cars lead to substantial progression in the commercial values of automobile industries. However, these advancements force the Original Equipment Manufacturers (OEMs) to shift from feedback-based reactive business analysis to operational-data based predictive analysis thereby enhancing both the customer satisfaction as well as business opportunities. The operational data is nothing but the parameters obtained from several parts of an automobile during its operation such as, temperature in radiator, viscosity of the engine oil and force applied over the brake disk. These operational data are gathered using several sensors implanted in different parts of an automobile and are continuously transmitted to backend computers to develop Digital Twin, which is a virtual model of the physical automobile.
Technical Paper

Step & Repeat: Reduce Derivative Aircraft Development Risk with Design Reuse

2019-09-16
2019-01-1871
Designing derivative aircraft is a complex process with potentially large amounts of program risk. In this paper we present new technologies such as digital interface control documents, and generative design that can transform this process. Employing these types of technologies makes the process more verifiable and repeatable. The paper explains how the technologies can be adopted from the early definition of components & LRUs, to their aggregation into reusable subsystems, as well as the automation and validation processes that can be built around them to reduce the associated complexity and program risk.
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