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The conventional internal combustion engines continue to dominate many fields like transportation, agriculture and power generation. Moreover, apprehension over oil price restriction has created an unprecedented demand for fuel economy. Diesel engine is mostly preferred for its higher thermal efficiency, high-torque and outstanding longevity. In recent days with flooded technologies, Uniqueness and the Differentiation of Product play vital role for a successful business in Auto Industry. The present invention is related to the Challenges of Design & Development of Conventional Diesel Engine to meet the stringent emission & performance requirements (BS-IV) of Internal Combustion engines, and more particularly to achieve the targets with conventional Fuel Injection Systems (Non-electronic Fuel Injectors, In-Line Fuel Injection Pump-Governed Electronically) with required sub-systems on IC engine.

In today’s commercial vehicle scenario, designing and developing a component which will never fail throughout its lifespan is next to impossible. For a long time especially in the field of automotive, any crack initiation shall deem the component as failed and the design requires further modification. This paper deals with studying the failure of one such component and understanding the effect the crack has on the overall life of the component i.e. understanding the remnant life of the component. The component under study was gear shift lever bracket and is mounted on the engine exhaust manifold. It experiences two types of loads: inertial load due to the engine vibration and gear shift load. Frequent failures were observed in the field and in order to simulate it at lab, an accelerated test approach was adopted. The engine operating speed was used to identify the possible excitation frequency which the component might experience.

Bio-fuels potentially represent a more environmentally friendly alternative to fossil fuels as they produce fewer greenhouse gas emissions when burned. Ethanol is one such bio-fuel alternative to the conventional fossil fuels. Towards the initiative of sustainable transportation using alternative fuels, it is attempted to develop an ethanol powered engine for commercial vehicles and this paper attempts to explain the 1D thermodynamic simulation carried out for predicting the engine performance and combustion characteristics, as a part of the engine development program. Engine simulation is becoming an increasingly important engineering tool for reducing the development cost and time and also helps in carrying out various DOE iterations which are rather difficult to be conducted experimentally in any internal combustion engine development program. AVL Boost software is used for modeling and simulation.

Powertrain is the major source of noise and vibration in commercial vehicles and has significant contribution on both interior and exterior noise levels. It is vital to reduce the radiated noise from powertrain to meet customer expectations of vehicle comfort and to abide by the legislative noise requirements. Sound intensity mapping technique can identify the critical components of noise radiation from the powertrain. Sound intensity mapping has revealed that oil sump as one of the major contributors for radiated noise from powertrain. Accounting the effect of dynamic coupling of oil on the sump is crucial in predicting its noise radiation performance. Through numerical methods, some amount of work done in predicting the dynamic characteristics of structures filled with fluid. This paper discusses on the capability of numerical approach in predicting the oil sump modal characteristics with fluid-structure interaction and consequent verification with experimental modal test results.

In the emerging commercial vehicle sector, it is very essential to give a product to customer, which is very reliable and less prone to the failures to make the product successful in the market. In order to make it possible, the product is to be validated to replicate the exact field conditions, where it is going to be operated. Lab testing plays a vital role in reproducing the field conditions in order to reduce the lead time in overall product life cycle development process. This paper deals with the design and fabrication of the steering column slip endurance test rig. This rig is capable of generating wear on the steering column splines coating which predominantly leads to failure of steering column. The data acquired from Proving Ground (PG) was analyzed and block cycles were generated with help of data analyzing tools.

CABIN design is continuously undergoing a huge change for reasons of customer comfort on for meeting regulatory requirement. Consequently the strategic design process will not only consider need for high strength structures but a pragmatic research based approach utilizing the latest technology. Though cab structure is built by a sheet metal blank as per the required dimensions, some locations encounter great amounts of stress and must be designed to withstand the same in a durable way. A possible simpler practice would be to add reinforcements in the high stress area or use high strength material for the entire part. However in this approach weight and cost of the component will be increased. As the weight of the Cabin, vehicle increases this will impact fuel efficiency. Attempts have been taken like using composite materials.

Rapid growth in the Indian economy has led to new market trends for commercial vehicles. Customers now expect high levels of comfort from all tactile points in a truck cabin; the gear lever knob is frequently used and its reactions greatly influence how a driver perceives Gear Shift Quality (GSQ) and thereby vehicle quality. The subjectivity of human perception is difficult to measure objectively; therefore this paper represents an objective methodology to correlate customer feedback of gearshift reactions. For the attribute evaluation of a set of intermediate commercial vehicles; detailed subjective appraisals were conducted by expert level assessors for GSQ sub-attributes, and a consecutive objective measurement was performed to investigate and substantiate these vehicle assessments.

In today competitive world, gaining customer delight is the most vital part of an automotive business. Customers’ expectations are high which need to be satisfied limitless, to stay in the business. The major expectation of a commercial vehicle customer is a vehicle without failures which involves lower spares cost and downtime. The significance of a suspension system in the new age automobiles is getting advanced. There have been many improvements in the suspension system especially in leaf springs to provide a better ride comfort, and one such modern era implementation is the Parabolic Spring which comprises of fewer leaves with varying thickness from the center to the ends without inter-leaf friction. Study reveals that parabolic spring exhibits better ride comfort, but less life compared to a conventional leaf spring which leads to the increase in downtime of the vehicle.