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Technical Paper

A novel approach on range prediction of a hydrogen fuel cell electric truck

2019-11-21
2019-28-2514
A novel approach on range prediction of a hydrogen fuel cell electric truck C.Venkatesh - Manager - Product Development, Sustainable Mobility & Advanced Technologies Abstract: A novel approach on range prediction of a hydrogen fuel cell electric vehicle Abstract: Today's growing commercial vehicle population creates a demand for fossil fuel surplus requirement and develops highly polluted urban cities in the world. Hence addressing both factors are very much essential. Battery electric vehicles are with limited vehicle range and higher charging time. So it is not suitable for the long-haul application. Hence the hydrogen fuel cell based electric vehicles are the future of the commercial electric vehicle to achieve long range, zero emission and alternate for reducing fossil fuels requirement. The hydrogen fuel-cell electric vehicle range, it means the total distance covered by the vehicle in a single filling of hydrogen into the onboard cylinders.
Technical Paper

A DIGITALIZED VALIDATION APPROACH FOR REAL TIME AND REMOTE MONITORING OF AN OFF HIGHWAY VEHICLE PERFORMANCE

2019-11-21
2019-28-2531
A DIGITALIZED VALIDATION APPROACH FOR REAL TIME AND REMOTE MONITORING OF AN OFF-HIGHWAY VEHICLE PERFORMANCE V.Jagannathan 1.a* , B.Jaiganesh 2.b & S.Sudarsanam 3.c Mahindra & Mahindra Limited, Mahindra Research Valley, Mahindra World City, Anjur PO, TN, India Corresponding author Email- V.JAGANNATHAN@mahindra.com Validation of agricultural tractors is necessary to ensure that these machines perform to their expected potential and are aptly matched with implements. Testing these machineries in real-time while performing activities in the field allows a bigger picture to be seen; the performance data incorporates the effects of many external factors (Soil, Climate etc.). Tractor Performance data apprehending is the vital part of validation. Data acquisition of key performance parameters during field validation in different application/different countries is of utmost importance.
Technical Paper

Wiring Harness Optimization towards Wireless Vehicle

2019-11-21
2019-28-2530
Paper Title - Wiring Harness Optimization towards Wireless vehicle Research and/or Engineering Questions/Objective (maximum 100 words)  In current scenario, wiring harness plays a vital role in inter-connecting electrical & electronic components fitted all across the vehicle.  As per cable standard, DIN 72551 or ISO 6722, copper conductors being used in stranded wires against cable cross-section & corresponding weight.  While going complete wire-less requires each component to have its own battery, ground, transmitter & receiver which indeed is a very costly affair to be employed in vehicle as huge development cost is required.  Here I'm suggesting an innovative method to make a vehicle apparently Wire-Less by creating local clusters connected to each other via conventional wiring harness & wire-less module.  Such method will apparently give a look of Wire-less vehicle itself & better advantages in terms of installation, service, troubleshooting, uptime & customer delight.  Moreover, direct benefits of Cost, Weight, FE will also be achieved.
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

Mechanical Property Evaluation of Paper Honeycomb reinforced Plastics

2019-11-21
2019-28-2538
Mechanical Property Evaluation of Paper Honeycomb Reinforced Plastics Vignesh Balaji S G, Pradeep Hyundai Motor India Engineering Pvt. Ltd, Chennai. India Key Words: Paper Honeycomb, Epoxy Composites, Mechanical Properties, Tensile, Impact & Flexural Test Research and/or Engineering Questions/Objective : Composite Materials are widely being used in many engineering applications because of their desirable properties & Cost, Weight Effectiveness. They are widely being used as their Strength-Weight Ratio is Higher than any Other Material. Paper Honeycomb Material is basically a paper made of honeycomb shapes enforced between layers of Glass Mat. This paper deals with the evaluation of Tensile Strength, Flexural (Three-Point Bending) Strength & Flexural Modulus, Impact Strength of Paper Honeycomb Reinforced Epoxy Composites. The Scope of this Material defines the quality of Paper Honeycomb Reinforced Composites which can be used for Automotive Trim Parts.
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

SIMULATION OF SOFTENING AND RUPTURE IN MULTILAYERED FUEL TANK MATERIAL

2019-11-21
2019-28-2557
Research and/or Engineering Questions/Objective Plastic automotive fuel tanks made up of blow molded, multi-layered, high-density polyethylene (HDPE) material can take complex shapes with varying thickness. Accidental drop of fuel tank from a height during handling can lead to development of cracks. Damage can also occur due to an impact during a crash. This can be catastrophic due to flammability of the fuel. The objective of this work is to characterize and develop a failure model for the fuel tank material to simulate damage and enhance predictive capability of CAE for chassis and safety load cases. Methodology Different aspects were considered to develop a characterization and modelling strategy for the HDPE fuel tank. Material properties can be influenced by factors such as, service temperature, rate of deformation, state of stress etc.
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

A Mathematical Approach to Determine Die Wear during Forging Process and Validation by Experimental Technique

2019-11-21
2019-28-2563
The automotive industry is constantly trying to develop cost effective, high strength and lightweight components to meet the emission and safety norms while remaining competitive in the market. Forging process plays an important role to produce most of the structural components in a vehicle. Precision forging technology is used to produce components with little or no flash leading to elimination of machining process after forging. The load acting on the dies during net or near net forging is very high and leads to wear in the die. In order to have a good die it is important that die wear which is an inevitable phenomenon in a bulk metal forming processes is predicted mathematically. In this study a review on the vast number of studies done in the area of wear and various predictive models is carried out.
Technical Paper

STATISTICAL ANALYSIS OF LOW CYCLE FATIGUE PROPERTIES IN METALS FOR ROBUST DESIGN

2019-11-21
2019-28-2576
Objective: In ground vehicle industry, strain life approach is commonly used for predicting fatigue life. This approach requires use of fatigue material properties such as fatigue strength coefficient (σf'), fatigue strength exponent (b), fatigue ductility coefficient (εf'), fatigue ductility exponent (c), cyclic strength coefficient (K′) and cyclic strain hardening exponent (n′). These properties are obtained from stable hysteresis loop of constant amplitude strain-controlled uniaxial fatigue tests. Usually fatigue material properties represent 50th percentile experimental data and doesn't account possible material variation in the fatigue life calculation. However, for robust design of vehicle components, variation in material properties need to be taken into account. In this paper, methodology to develop 5th percentile (B5), 10th percentile (B10) and 20th percentile (B20) fatigue material properties are discussed.
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

Determine Thermal Fatigue Requirements for PEPS Antenna Copper Wire over Vehicle Lifetime with defined Reliability Requirements.

2019-11-21
2019-28-2582
Reliability states the degree to which the result of a measurement, calculation, or specification can be depended on to be accurate. And, tests according to GMW specifications represents a minimum of 15 years of vehicle life time with defined Reliability and Confidence level. In this work, actual number of thermal cycles for Thermal Fatigue tests (Thermal Shock and Power Temperature Cycle) are calculated for Copper Wire whose Coffin Manson exponent is 5. Overstressing the PEPS Antenna under thermal fatigue requirement (defined number of thermal cycles based on Reliability and Confidence requirements) will lead to broken Copper wire which will result in component’s functional failure and thus impossible to continue reliability testing. The objective of this paper is to determine thermal fatigue requirements for Antenna’s Copper wire whose Coffin Manson exponent is 5.
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

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

Effect of variable payload on Vehicle dynamics of Passenger buses in Indian usage conditions

2019-11-21
2019-28-2411
A high impetus from Government on road infrastructure development, is giving a fillip to passenger CV space. This has resulted in making the passenger CV segment lucrative enough, thereby pulling in many operators in the business. The quality of road has immensely improved over a decade, as a result of which the average speed and hence the quantum of distance covered by passenger buses has increased significantly. People are preferring to travel in buses over trains, owing to at par ticket cost, high availability, reduced travel time and also improved level of comfort. Aligned to the market need and the trend, OEM's are offering buses with capable powertrains to cater the need of speed, reduced trip time as well as a lot of attention is also being paid to tune in the comfort level for long hauls. A big chunk of passenger travel is catered by the bus operators especially during major festivals in India.
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