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Training / Education

Applied Brake Controls ABS, TCS, and ESC

2020-01-27
Experience the vehicle dynamic enhancements afforded by anti-lock brakes (ABS), traction control (TCS), and electronic stability control (ESC) with this highly interactive two-day seminar. Designed to get you out of the classroom and on to the test track, a total of six 60-minute structured learning experiences behind the wheel will vividly illustrate the benefits, limitations, and ultimate compromises that must be made when designing and implementing modern brake control systems.
Training / Education

Principled Negotiation

2019-12-12
This highly interactive workshop focuses training on negotiation strategy and skills. This is not the manipulative, win-lose negotiation approach frequently taught today, where the winner eventually spends time and effort protecting his negotiated advantage against erosion, while the loser continually exploits loopholes and shortcuts to recover lost ground. Traditional negotiation is a wary dance based on mistrust, the true cost of which is lost in quality and brain fatigue - usually for someone other than the negotiator - over the life of the agreement.
Training / Education

Fundamentals of Vehicle Suspension Design

2019-12-05
The design and development of vehicle suspensions significantly influences vehicle handling and ride comfort. Suspension system design excellence follows the basic laws of physics using design synthesis techniques, a methodical process for suspension geometry development. Suspension geometry is the foundation of vehicle performance from which high-confidence suspension components and tunings can be developed. Suspension component design continues to move toward mass and cost efficient designs with high levels of stiffness being essential to achieving design requirements.
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

A new appraisal of the thermomechanical behaviour of a hybrid composite brake disc in a formula vehicle

2019-11-21
2019-28-2572
A new appraisal of the thermomechanical behaviour of a hybrid composite brake disc in a formula vehicle Research Objective This paper presents a hybrid composite brake disc with reduced Un Sprung Weight clearing thermal and structural analysis in a formula vehicle.Main purpose of this study is to analyse thermomechanical behaviour of composite brake disc for a formula vehicle under severe braking conditions. Methodology In the disk brake system, the disc is a major part of a device used for slowing or stopping the rotation of a wheel. Repetitive braking of the vehicle leads to heat generation during each braking condition. Based on the practical understanding the brake disc was remodelled with unique slotting patterns and grooves, using the selected aluminium alloy of (AA8081) with reinforcement particle of Silicon carbide (SiC) and Graphite (Gr) as a hybrid composite material for this proposed work.
Technical Paper

FABRICATION AND WEAR CHARACTERISTICS BASALT FIBER REINFORCED POLYPROPYLENE MATRIX COMPOSITES

2019-11-21
2019-28-2570
Generally brake pads are manufacturing by use of asbestos materials, these materials are chemically harmful and toxic, affects human health. The present investigation fabricates polypropylene composites with mixing constant volume [5 Vol.%] of alumina nano particles and different volume percentages [0%, 5%, 10% & 15%] of basalt fibre by hand layup compression technique. The wear characteristics of polypropylene matrix composites were tested by dry sliding condition using pin on disc apparatus configuration with hardened steel counter-face at elevated temperature. The load was applied 30N to 70N with the interval of 20N and varying of sliding speed 300 rpm to 900rpm with the interval of 300rpm for the time period of 0-180 sec. The wear rate was decreases with addition of alumina nano particle and also increases the frictional force for the effect of basalt fibre content present in the composites. The co-efficient of friction was increases from 0.1 to 0.66 under normal loading condition.
Technical Paper

Design & analysis of 2 point aluminum upper control arm in modular multi link rear suspension system

2019-11-21
2019-28-2564
In current automobile market, due to the need of meeting future CO2 limits and emission standards, demand for hybrid systems is on the rise. In general, the requirements of modern automobile architecture demands modular chassis structure to develop vehicle variants using minimum platforms. The multi-link modular suspension system provides ideal solution to achieve these targets. To match ideal stiffness characteristics of system with minimum weight, aluminum links are proving a good alternative to conventional steel forged or stamped linkages. Design of current 2-point link (Upper Control Arm) is based on elasto-kinematic model developed using standard load cases from multi body dynamics. CAD system used is CATIA V5 to design upper control arm for rear suspension. This arm connects steering knuckle & rear sub frame. For Finite Element Analysis we used Hyperworks CAE tool to analyze design under all load cased & further optimization is done to resolve highly stressed zones.
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

Semi-autonomous parking assist system (SA-PAS)

2019-11-21
2019-28-2529
This paper describes the Semi-autonomous parking assist system (SA-PAS) developed using combination of high accuracy position sensing and electronic power steering. A real-time system that helps driver to identify the parking space and assist to perform maneuvers. Parking is often a difficult task, especially for inexperienced drivers. Starting with the problem of having to find a suitable parking spot, to then maneuvering in to it without colliding with anything or anyone, while trying avoiding disturbing the surrounding traffic. The numbers of vehicles are rapidly increasing as compared to the expansions of roads and parking spaces. Therefore, effective use of the existing spaces is needed (by making them narrower), which can cause inconvenience to many drivers. Semi-autonomous parking assist system searches for suitable space and steers the vehicle into it, while driver has to control the gear shifter, accelerator and brakes.
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

Compensation of Signal Offset, Amplitude Imbalance and Imperfect Quadrature in Rotor Position Sensor Signals for Motor Drives

2019-11-21
2019-28-2524
In recent years, the use of the electric motors in automotive applications such as electric power steering (EPS), hybrid and electric vehicles has increased. In these fields, rotor position information plays and important role in the field- oriented control concept. It performs a transformation from the stator reference frame to the rotor reference frame and vice versa. This is nothing but the Park and inverse Park transformation. They are typically used to provide accurate absolute rotor position in high-performance motor drive systems because their robustness and reliability make them particularly suited to Automotive Environment. Hence, greater accuracy of these sensor signals is required. However, in reality, the output signals include the position error in the sensor itself as well as error in the sensor signal conditioning circuits.
Technical Paper

An Energy Harvesting E-SHOCK for Future Mobility

2019-11-21
2019-28-2506
India has emerged as the world’s biggest market for Two-wheelers and Four-wheeler. Besides rising incomes and growing infrastructure in all areas, one big reason for the spurt in sales has been ease of zipping in and out of chaotic city traffic along with road irregularities and potholes. Furthermore, the efficiency increase in the Shock absorber within the vehicle have high demands to use of regenerative solutions, in which e-system can be employed as to recover part of the energy otherwise dissipated in form of heat. The Smart e-Shock can charge battery and illuminate accessories of vehicle. Also, the e-shock can provide the various damping characteristics by changing the Electric load on to it to make system as Semi-Active Suspension. This Smart e-Shock system is based on unique and patented concept of constraining the reciprocating motion of the shock absorber in to a single sense of rotation of e-system and the energy is recuperated and given to the battery from the e-system.
Technical Paper

Impact of Vehicle Electrification on Brake Design

2019-11-21
2019-28-2499
Electric vehicles have come full circle from being primary vehicle type in 19th century (much before IC powered vehicles) to 21st century where major stake holders in mobility have announced plans towards vehicle electrification. Apart from battery & powertrain system, braking system is area which will undergo major changes because of vehicle electrification. But Why? Major keywords are regenerative braking, increased vehicle weight, no or insufficient vacuum from engine and silent powertrains. This paper tries to outline potential impact on hydraulic brake system & its component design for M1 and N1 category of four wheelers with advent of vehicle electrification. Needless to say extent of change will vary depending upon extent of electrification and extent of recuperation during regenerative braking. Extent of electrification depends upon whether vehicle is range extender type hybrid vehicle, plug in hybrid vehicle, battery electric vehicle, fuel cell vehicle 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

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

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

C123 Methodology for concept design of the Chassis Frame

2019-11-21
2019-28-2534
Objective This paper explores the usage of Altair simulation driven concept process, C123 for developing the chassis frame of the SUV along with Multidisciplinary optimisation tool. C123 process is useful for strategic & systematic usage of optimisation to generate design alternatives, trade-off information, best balanced designs, design sensitivities, to actively support the concept development process on daily basis. Methodology C123 is used for developing initial concept design of the chassis frame of the SUV. C123 process is independent of vehicle architectures, manufacture process (e.g. extrusions, sheet metal) & material selection (e.g. metals, composites, mixed etc.) and platform sharing strategy. C1 process is used for identification of optimum Structural Layout, C2 is for rapid optimum Sizing of idealized Sections, C3 is used for detailed optimum Sizing of Manufacturable Sections. Automatic process is used for handling pre and post processing process very efficiently.
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