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Combustion and Emissions for Engineers

2019-12-09
Public awareness regarding pollutants and their adverse health effects has created an urgent need for engineers to better understand the combustion process as well as the pollutants formed as by-products of that process. To effectively contribute to emission control strategies and design and develop emission control systems and components, a good understanding of the physical and mathematical principles of the combustion process is necessary. This seminar will bring issues related to combustion and emissions "down to earth," relying less on mathematical terms and more on physical explanations and analogies.
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

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

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

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

LIFE CYCLE ASSESSMENT OF A PASSENGER VEHICLE TO ANALYSE THE ENVIRONMENTAL IMPACTS USING CRADLE TO GRAVE APPROACH

2019-11-21
2019-28-2581
OBJECTIVE: Climate change is primary driver in the current discussions on CO2 reduction in the automotive industry. Current Type approval emissions tests (BS III, BS IV) covers only tailpipe emissions, however the emissions produced in upstream and downstream processes (e.g. Raw material sourcing, manufacturing, transportation, vehicle usage, recycle phases) are not considered in the evaluation. The objective of this project is to assess the environmental impact of the product considering all stages of the life cycle, understand the real opportunities to reduce environmental impact across the product life cycle. METHODOLOGY: As a part of environmental sustainability journey in business value chain, Life-cycle assessment (LCA) technique helps to understand the environmental impact categories. To measure overall impact, a cradle to grave approach helps to assess entire life cycle impact throughout various stages.
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

Steering and Handling Performance Optimization Through Correlation of Objective - Subjective Parameters and Multi-body Dynamics Simulation

2019-11-21
2019-28-2412
RESEARCH OBJECTIVE: Automobile Industry has driven through the ages with continuous development with innovative technologies and frugal engineering. Expectation of customer is also increasing through the generations. To meet the customer demand for performance and be best in market, OEM needs to deliver best performance of vehicle with cost effective and short development process. Steering and Handling of vehicle is one of major customer touchpoints and needs to be tuned to achieve various conflicting requirements. The objective of this research is to optimize the steering and handling using correlation between three major methods of evaluation. METHODOLOGY: Methodology for optimization of steering and handling performance using correlation between subjective evaluation, objective measurement and multi-body-dynamic simulation is presented.
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

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

PMSM motor drive for Electric Vehicle applications

2019-11-21
2019-28-2475
To control air pollution in urban areas and to reduce carbon print in the cities, nowadays EV’s are preferred over IC engine vehicles. Earlier Electric vehicles used DC motor and Induction motors. But Brushless Permanent Magnet motors are preferred over Induction motor for EV’s due to their High Torque density, high-power density and highly efficiency. Prevalent Electric vehicles today have Brushless DC motors. Compared to BLDC, PMSM motor have smoother control and negligible torque ripplesThus, PMSM motor is preferred over BLDC for Electric Vehicle, because of its sinusoidal back emf which results in smoother control, and results into smoother and more comfortable driving experience to users. Methodology Sensor based field-oriented control (FOC) is implemented in 48 V 5kW Interior PMSM motor. . To start the Synchronous motor initial position of the rotor magnetic field should be known.
Technical Paper

Performance & efficiency Improvement of Electric Vehicle Power train

2019-11-21
2019-28-2483
Introduction: The advent of electric mobility is changing the conventional mobility techniques and their application in automobiles across all segments. This development comes with challenges ranging across varied sub -systems in a vehicle including Power Train, HVAC, Accessories, etc. Objective: This paper would concentrate on the Power train related sub systems & improvement of the same both in terms of Efficiency & Performance. Methodology: The electric power train consists of three major sub parts: 1. Motor Unit 2. Controller with Power electronics 3. Battery Pack with BMS We would concentrate on improving the overall efficiency and performance of all these subsystems while they perform in vehicle environment and work in tandem by deploying following techniques: a. Improved Regenerative Braking for converting vehicles Kinetic energy into electrical energy using specific algorithms and control techniques b.
Technical Paper

Design analysis of a retrofit system for an electric two wheeler

2019-11-21
2019-28-2482
Two wheelers are the major mode of single transport in the metros of India. They contribute about 70 % of the auto market unit wise. Also it is proved from the research that for per unit energy consumption they contribute more to the environment emission. Conventional IC engine based energy supply unit can be replaced with an electric DC motor with chargeable battery as the energy source for the two wheelers present in the market. In the current research, engine is replaced with the motor, batteries and controller. The above system is placed on the space emptied by the conventional engine, The design developed is tested on different gradients for identifying the motor torque for minimum and maximum resistances available on the road. The paper provides an insight on the of the torque requirements based on variable resistances required for two wheelers. Also the system will be used as a retrofit for the existing IC engine bikes to be converted in electric bikes.
Technical Paper

Changes in user experiences of electric vehicles

2019-11-21
2019-28-2489
Research Objective The objective of the paper is to research what are the changes in experiences being brought about due to the advent of Electric Vehicles (EVs). EVs are silent, have less complex propulsion system, and have free space under the hood, amongst other things. Each change brings about both good and bad experiences across the spectrum of users. Some of the bad experiences can be safety incidents leading to death as well. Researching the areas that are harmful to end users, including pedestrians, will be our focus area. Methodology Our methodology will look at the changes at the vehicle architecture level which are inherent to the EV design. Research how are the experiences so far due to these changes. Are these just inconveniences or safety hazards? EVs have excellent NVH characteristics. A farmer may love a silent tractor, but a racing enthusiast may not like a relatively silent sports car.
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

Experimental investigation on performance and emission characteristics of a single cylinder CRDI engine fuelled with a diesel-methanol blend.

2019-11-21
2019-28-2380
The diesel engine is widely used for its high thermal efficiency and better fuel conversion efficiency. However, increasing usage of petroleum fuel and environmental degradation motivates to use renewable biofuels as a replacement to conventional diesel. Biofuels produced from non-edible sources can be used as a partial substitute of diesel for the significant growth of fuel economy and reduction of environmental pollution. Methanol can be implemented as a blended fuel in the diesel without affecting engine design. In this study, the effect of diesel methanol blends and injection parameters such as fuel injection pressure (FIP)and start of injection (SOI) on a common rail direct injection (CRDI) diesel engine performance and emission were investigated. Four blends were prepared by mixing diesel with methanol (5%, 10%, 15% and 20% by mass) and adding a certain amount of oleic acid and iso-butanol to get a stable blend.
Technical Paper

Effect of Gasoline-Ethanol blends and CNG on GDI engine to reduce cost of vehicle ownership

2019-11-21
2019-28-2379
A major challenge for combustion development is to optimize the engine for improved fuel economy, reduce greenhouse gases. Stringent CAFÉ and emission norms require the customer to pay higher capital on vehicles. To offset the cost of ownership- cheaper and alternative energy sources are being explored. Ethanol blend with regular Gasoline and CNG are such alternative fuels. The study was carried on turbo-charged gasoline direct injection engine. The effect of ethanol on engine and vehicle performance is estimated and simulated numerically. The work is split into three stages: first the base 1D engine performance model was calibrated to match the experimental data. In parallel, vehicle level Simulink model was built and calibrated to match the NEDC cycle performance. Second, the thermal efficiency of the ethanol blend is calculated as a linear function of theoretical Otto cycle efficiency.
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

EMISSION REDUCTION OF A DIESEL ENGINE FUELED WITH BLENDS OF BIOFUEL UNDER THE INFLUENCE OF 1,4-DIOXANE AND RICE HUSK NANO PARTICLE.

2019-11-21
2019-28-2387
Research Objectives. In this modern era increase in Pollution became a huge impact in the lives of all living creatures, in this automobile tends to be one of the major contributors in terms of air pollution thanks to their exhaust emissions. The objective of the present study is to reduce the amount of harmful pollutants emitted from the automobiles by the utilization of a biofuel further influenced by two additives (liquid and a Nano additive). Methodology In this study, first the bio oil is extracted, Then the biofuel is mixed with diesel fuel at different proportions of 20%, 40% by volume. Experiments are carried out in a direct injection compression ignition engine, which is a stationary test engine manufactured by Kirloskar, connected to a computer setup. The emission values in the exhaust gases are obtained using AVL exhaust gas analyzer.
Technical Paper

Approach for CO2 Reduction in India’s Automotive Sector

2019-11-21
2019-28-2388
India has gone through a lot of transformation over the last decade. Today it is the 6th largest and one of the fastest growing economies in the world. Rising income level, increased consumerism, rapid growth in urbanization and digitization have attributed to this change. Government focus on “Make in India” for promoting trade and investment in India have ensured that India emerge as one of the largest growing economies in the world. The automotive industry played a pivotal role in the manufacturing sector to boost economic activities in India. The passenger car market has increased 3 times over the last decade and it has led to increased mobility options for many people across India. However, this has put concerns on the country’s energy security and emission levels. According to IEA’s recent report on global CO2 emission, 32.31 Gt of CO2 emissions were from fuel combustion in 2016, out of which transport sector contributed ~25%.
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