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The public transport in India is gradually shifting towards electric mobility. Long range in electric mobility can be served with High Voltage Battery (HVB), but HVB can sustain for its designed life if it’s maintained within a specific operating temperature range. Appropriate battery thermal management through Battery Cooling System (BCS) is critical for vehicle range and battery durability This work focus on two aspects, BCS sizing and its coolant flow optimization in Electric bus. BCS modelling was done in 1D CAE software. The objective is to develop a model of BCS in virtual environment to replicate the physical testing. Electric bus contain numerous battery packs and a complex piping in its cooling system. BCS sizing simulation was performed to keep the battery packs in operating temperature range.

Transmission of vibration and noise to the occupants and especially driver contributes significantly to the quality perception of the motor vehicle and eventually, it affects the overall ride comfort. These forces mainly reach to customer through tactile locations, i.e. floor, gearshift lever, steering wheel and seat. Showroom/Parking customer drive pattern of a vehicle evinces the steering system and driver’s seat rail vibration as strikingly linked aspect to evaluate human comfort [1]. This paper deals with the study of vibration at steering wheel and seat affecting human comfort at engine idle rpm with AC ON and OFF condition for passenger vehicles. The transmissibility of engine and radiator induced vibrations has been investigated with respect to modal alignment of steering and seat system.

Currently automotive industry is struggling for its sustainability to produce cost effective products with better or same performance. In this study, fuel return line has been converted from Viton/Hypalon material to Epichlorohydrin based material. In initial phase, technical specifications and material properties has been compared. In later phase, components were developed with modified material and validated at Test bed as well as Vehicle level to understand the material behavior in Real world usage. Further, test results were compared and results shows that the new material is able to cater vehicle application requirement in terms of reliability and durability with a good cost saving.

With Continuous increase in demand to reduce weight is forcing Automotive Designers towards finding ways to explore new materials for the Engine components. Currently, Aluminum, Thermoplastics and Composites are widely used in Engine application. This paper examines the potential of a Magnesium alloy Front Cover designed to replace the Cast iron Front Cover in a Light duty Diesel engine. In presented study, a Cast iron Engine front cover is re-designed for Magnesium alloy and components developed. Further Magnesium alloy component tested at vehicle level and it has been demonstrated that a magnesium alloy Front cover can achieve key functional requirements such as Structural durability, Sealing, NVH, while providing substantial Weight saving.

In current scenario, Light Commercial Vehicle segment (7 ton - 9.6 ton) is gradually experiencing a shift in the focus from being just a goods carrier to a vehicle which is developed to take care of driver's safety and comfort in terms of better ergonomics and aesthetics. As compared to their conventional counterparts the new generation Light Commercial Vehicles are better equipped and tuned to cater to the changing needs of the consumers. In view of this, refinement at the sub system level is becoming far more critical. On the same lines, the present work discusses a refined brake system for Light Commercial Vehicles where the conventional pneumatic system is replaced with Dual Air Over Hydraulic (DAOH) to achieve cost and weight advantages without compromising on its performance. However, during the development process, a lot of issues were observed with respect to the braking performance and the brake pedal feel.

Engine Monitoring System (EMOS) plays a crucial role towards engine safety and monitoring for low cost commercial vehicles not equipped with a full-fledged Engine Management System (EMS). The EMOS system mainly focuses on monitoring of coolant temperature, alternator belt failure, and lubrication oil pressure and coolant level indication This paper describes various engineering design considerations for balancing the application requirements with implementation costs. It also highlights some common pit-falls in detecting alternator failures leading to nuisance trips as well as system design considerations involved in matching the gauge indication accuracy with the coolant high temperature trip point. The system designer needs to take into account, difference between alternator belt slippage versus total belt failure condition and implement different control strategies accordingly.

Electric radiator fan is a vital component within IC and EV passenger vehicle cooling system. However, due to its operation, it induces noise and in-cab vibration affecting human comfort level. This paper primarily focus on FMS (Fan Motor Shroud) assembly induced steering wheel vibrations in a vehicle under idle + AC ON condition. The entire NVH performance was cascaded from vehicle level to component level to evaluate for high steering wheel vibration and its transfer path analysis. Unit level vibrations study was also carried out using a rigid rig under controlled conditions. Based on FMS vibration analysis, it was observed that fan blade rotating imbalance leads the high vibrations within system. Thus, a balancing method with higher precision and accuracy was used to measure and balance the fan under all operating conditions. Sensitivity analysis had been carried out for fan imbalanced boundary conditions and operating speeds.

Vehicle thermal management system (VTMS) is a means of monitoring and controlling temperatures of vehicular components and aggregates to within optimum limits, thereby ensuring the proper functioning of the component or aggregate in an automobile. An integrated approach is required for developing VTMS, to satisfy the complex requirements of performance, reliability, fuel economy and human thermal comfort in modern vehicles. Fan motors and blowers play a crucial role in vehicle thermal management. These fan motors/ blower systems need to be designed in a manner such that there is minimum parasitic load on the prime mover. This work comprises performing Transient Powertrain Cooling (T-PTC) and Transient Air-conditioning (T-AC) simulation on a vehicle for prediction of parameters affecting fan operation of Condenser Radiator Fan Module (CRFM) during simulated city drive cycles.