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Technical Paper

Computer Vision and Monocular Camera System for Cost Efficient Autonomous Vehicle

2019-11-21
2019-28-2518
The positioning of the sensors on vehicle will play a critical role in autonomous cars, it improves the performance of overall system by all the means and make it cost effective by reducing a total system cost. This paper contributes in deciding the best position of camera location on the vehicle with complete geometric and system calculation based on the maximum speed of vehicle, hardware processing speed, camera parameters, actuation and control time, Blind spot detections, maximum Height of objects, etc. The paper presents the technologies and datasets used for lane lines and other object detections. It focusses on newly proposed technique and its calculations to decide the best location of monocular camera sensor on the vehicle by considering all other parameters of autonomous vehicle system. It enhances the performance of overall system as well as reduces the system cost which takes us closer to the futuristic dream of efficient and low-cost autonomous vehicle.
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

Self-Sensing, Lightweight and High Modulus Carbon Nanotube Composites for Improved Efficiency and Safety of Electric Vehicles

2019-11-21
2019-28-2532
Carbon Composites (CFRP) have been touted to be an essential component of future automobiles due to their mechanical properties and lightweight. CFRP has been adopted successfully for secondary and primary structures in Aerospace industry. In Automobiles, they are incorporated in models like the BMW i-series. CFRP suffers from 2 major problems. Delamination of Composites leads to catastrophic and rapid failure which could be dangerous in passenger vehicles. Delamination occurs whenever there is a shock on the composite. Secondly, Composites need regular expensive maintenance to ensure that the material is intact and will not compromise passenger safety. Carbon Nanotubes in composites have shown a substantial increase in delamination resistance. A 0.1wt% addition of HiPCO® Single-walled Carbon Nanotube provides both self-sensing and improved fracture resistance.
Technical Paper

High Durable PU Metallic Monocoat system for tractor sheet metal application.

2019-11-21
2019-28-2541
In sheet metal painting for various applications like Tractor, Automobile, most attractive coating is metallic paints and it is widely applied using 3 coats 2 bake or 3 coat 1 bake technology. Both options, results in high energy consumption, higher production throughput time & lower productivity in manufacturing process. During various brainstorming & sustainable initiatives, paint application process was identified for alternative thinking to reduce burden on environment & save energy. Various other industry benchmarking & field performance requirement studies helped us identify the critical to quality parameters. We worked jointly with supplier to develop mono-coat system without compromising the performance & aesthetical properties. This results in achieving better productivity, elimination of two paint layers, substantial reduction in volatile organic content, elimination of one baking cycle and energy saving.
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

MOLD IN COLOR DIAMOND WHITE ASA MATERIAL FOR AUTOMOTIVE EXTERIOR APPLICATION

2019-11-21
2019-28-2562
In this paper, mold in color diamond white ASA material has been explored for front bumper grill, fender arch extension and hinge cover applications. Other than aesthetic requirements, these parts have precise fitment requirement under sun load condition in real world usage profile. Structural durability of the design was validated by virtual engineering. Part design and material combinations with better tooling design iterations were analysed by using mold flow analysis. Complete product performances were validated for predefined key test metrics such as structural durability, thermal aging, cold impact, scratch resistance, and weathering criteria. This part met required specification. This mold in color ASA material-based parts has various benefits such as environmentally friendly manufacturing by eliminating environmental issues of coating, easily recycled, and faster part production because intended color achieved in one step during molding.
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

Aerodynamic analysis of electric passenger car using wind turbine concept at front end

2019-11-21
2019-28-2396
Electric passenger car with floor battery usually have its front boot space empty and the space is used as additional luggage storage. Since it is completely closed, it is an adding factor to the drag coefficient of the vehicle. This space can be utilized to capture the wind energy to reduce the drag coefficient and generate electricity. Based on this, the objective of the work is to perform an aerodynamic analysis of an electric passenger car using wind turbine placed at the front. An active front grill shutters will be used to optimize the aerodynamic drag at different vehicle speeds. Initially the aerodynamic analysis of a basic electric car model is performed and then it is validated with the scaled model by using wind tunnel testing. The modified model with a wind turbine and an active grill shutters is analyzed, considering different parameters such as number of turbine blades, height of wind turbine, angle of attack, vehicle speed (60-120 kmph).
Technical Paper

Aerodynamic analysis of commercial vehicle using active vortex generators concept

2019-11-21
2019-28-2409
Any physical body being propelled through the air has drag associated with it. Drag will be created on the surface of the vehicle due to the flow separation at the rear end. In aerodynamics the flow separation can often result in increased drag particularly pressure drag, to delay the flow separation, the vortex generators are used on the roof end of the vehicle just before the point of flow separation. The objective of this project is to perform aerodynamic analysis of commercial vehicle using active vortex generators concept. First, the aerodynamic analysis of a baseline commercial vehicle model is performed and same is validated with the scaled model by using a wind tunnel test. Further analysis has been done by using active vortex generators concept with variation of angle of attacks for vehicle speed of 50, 70, 90 kmph. Also, analysis has been carried out for six different yaw angles. The simulation is carried out with the use of ANSYS Fluent.
Technical Paper

Aerodynamic Analysis of a Passenger Car to Reduce Drag using Active Grill Shutters and Active Air Dams

2019-11-21
2019-28-2408
Active aerodynamics can be defined as the concept of reducing drag by making real-time changes to certain devices such that it modifies the airflow around a vehicle. Using such devices also have the added advantages of improving ergonomics and performance along with aesthetics. A significant reduction in fuel consumption can also be seen when using such devices. The objective of this work is to reduce drag acting on a passenger car using the concept of active aerodynamics with grill shutters and air dams. First, analysis has been carried out on a baseline passenger car and further simulated using active grill shutters and air dams for vehicle speed ranging from 60 kmph to 120 kmph, with each active device open from 0° to 90°. The improved model obtained is then subjected to variations in yaw angle ranging from -18° to +18°. The optimized model is then validated for a scaled down prototype in a wind tunnel.
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

Affect of Tyre inflation on Rolling Resistance of Tyre

2019-11-21
2019-28-2415
Rolling resistance refers to the various forms of resistance against driving force when the vehicle is in motion. Several factors contribute to rolling resistance, including wind drag on the car, acceleration resistance generated by inertia force when speeding up, and resistance on the tyres. Tyre inflation pressure plays vital role on Coefficient of Rolling Resistance (RRC) of Tyre consequently vehicle mileage. Low or High tyre pressure is not good for driving comfort, safety of vehicle well as for environment. Petroleum Conservation Research Association ( PCRA ) has taken good initiative in direction to Tyre Star marking based on RRC values of Tyre.
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.
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