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The present work discusses the developed simulation model aimed to predict the heat rejection (HR) performance and external pressure drop characteristics of automotive charge air cooler (CAC). Heat rejection and airside pressure drop characteristics of CAC were predicted for the conditions of different charge air mass flow rates and different cooling air velocities. The lack of detailed research on CAC performance prediction has motivated the development of the proposed simulation model. The present 1-D simulation has been developed based on the signal library of AMESIM application tool. Input parameters for this simulation such as core size, tube pitch, tube height, number of tubes, fin density, louver angle, louver pitch, charge air mass flow rate, cooling air velocity, charge air inlet temperature, and ambient temperature. Heat rejection curve and airside pressure drop of CAC were the output of the present simulation.

This paper discusses the methodology setup for grill opening area prediction at the early development phase of the product development lifecycle, using a commercially available 1D simulation tool- AMESIM. Representative under hood has been modeled using Grill, Condenser, Radiator, intercooler, fan, and engine components. Vehicle velocity is used as an input to derive the airflow passing through the grill and other under-hood components based on ram air coefficient, pressure drop through different components (Grill, Heat exchanger, Fan & Engine). This airflow is used to predict the top tank temperature of the radiator. Derived airflow is correlated with airflow obtained from CFD simulation. A balance has been achieved between cooling drag & fan power consumption at different grill opening areas for target top tank temperature. Top tank temperature has been predicted at two different extreme engine heat rejection operating points.

Currently the Automotive industry demands highly competitive product to survive in the global tough competition. The engine cooling system plays a vital role in meeting the stringent emission norms and improving the vehicle fuel economy apart from maintaining the operating temperature of engine. The airflow through vehicle subsystems like the grille, bumper, the heat exchangers, the fan and shroud and engine bay are called as front-end flow. Front end flow is crucial factor in engine cooling system as well as in determining the aerodynamic drag of vehicle. The airflow through the engine compartment is determined by the front-end vehicle geometry, the CRFM and CAC package, the engine back restriction and the engine compartment geometry including the inlet and outlet sections. This paper discusses the 1D modelling method for front-end airflow rate prediction and thermal performance by 1D method. The underbody components are stacked using heat stack and simulated in pressure mode.

Rotavator is an active tillage implement for breaking the Soil and for the preparation of seed bed for cultivation. The Farmers are currently facing problem due to usage of sub optimal speed of Rotavator which results in more fuel consumption, takes more time for completion of operation. Also, the Current Rental models work on Tractor + Implement as rental combination and customer not able to rent Rotavator as a standalone implement due to non-availability of Tracking information such as hours of utilization on Rotavator. Farmers not able to maintain the service periodicity, if oil change not done in prescribed duration then it may result in improper maintenance and breakdown of the Rotavator. To overcome these problems a smart Rotavator developed consists of an electronic unit fitted on the Rotavator shaft to measure the speed of the shaft rotation and in turn convert to Rotavator speed and also able to convert into Hours of usage based on the starting and stopping of the rotavator.

The adoption of BSVI emission norms for Indian domestic market brought a very stringent window for pollutants. For CI engines, the major impact was in the reduction of NOx by 68% and PM by 82% from BSIV norms. Technologically advanced after treatment systems like SCR / DPF / LNT aid to meet the stringent emission norms. Implementation of high-end after treatment systems in vehicles, requires precise monitoring and fool proof feedback systems. On Board Diagnostics (OBD) makes this possible. OBD is used to monitor the performance of after treatment systems and warn the user in case of deterioration. The challenges in framing OBD strategy increases with more electronic hardware and complex algorithms taking control, to monitor precise information on system performance. For a fool proof OBD monitoring of the exhaust system, a complete understanding of the SCR system and its components in terms of hardware specifications and software functionality is critical.

During the vehicle launch (i.e. moving the vehicle from “0” speed), the clutch would be slowly engaged by the Driver or Transmission Control Unit (in Automatic Transmission/Automatic Manual Transmission vehicle) for smooth torque transfer between engine and transmission. The clutch is designed to transfer max engine torque with min heat generation. During the clutch engagement, the difference in flywheel and gearbox input shaft speed is called the clutch slipping phase which then leads to a huge amount of energy being dissipated in terms heat due to friction. As a result, clutch surface temperature increases consistently, when the surface temperature crosses the threshold limit, the clutch wears out quickly or burns spontaneously. Hence it is crucial to predict the energy dissipation and temperature variation in various components of clutch assembly through virtual simulation.

To comply with the stringent future emission mandates of light-duty diesel engines, it is essential to deploy a suitable combination of emission control devices like diesel oxidation catalyst (DOC), diesel particulate filter (DPF) and DeNOx converter (LNT or SCR). Arriving at optimum size and layout of these emission control devices for a particular engine through experiments is both time and cost-intensive. Thus, it becomes important to develop suitable well-tuned simulation models that can be helpful to optimize individual emission control devices as well as arrive at an optimal layout for achieving higher conversion efficiency at a minimal cost. Towards this objective, the present work intends to develop a one-dimensional Exhaust After Treatment Devices (EATD) model using a commercial code. The model parameters are fine-tuned based on experimental data. The EATD model is then validated with experiment data that are not used for tuning the model.

To meet future emission levels the industry is trying to reduce tailpipe emissions by both, engine measures and the development of novel catalytic emission control concepts. The present study will focus on the Phosphorous impact on Pt based Diesel Oxidation Catalyst after exposure to it over time based on engine oil consumption for lifetime to meet the durability requirements of Indian legislations and Indian OEMs. With BSVI announcement India along with US/Europe will ply their Automobile/Non-Road(>56Kw) engines with Diesel Oxidation Catalysts (DOC), Diesel Particulate Filters (DPF), devices for Selective Catalytic Reduction (SCR) and last but not least an Ammonia Slip Catalyst (ASC). This entire chain of After Treatment system elements play a vital role in emission reduction. Apart from this, these system elements are very much dependent on their preceding system and their performance strongly depend on the previous Catalytic function.

The present study investigates the challenges on performing the on-road regeneration process in Indian road conditions for meeting BS6 emission. There are different types (DPF and SCR) of aftertreatment systems used for meeting BS6 emission. In which, active regeneration (on-road demand) is used to burn the particulate matter accumulated in the diesel particulate filter (DPF). This process must be performed frequently in order to prevent DPF system from over soot loading which leads to damage the DPF. This process is dependent on exhaust temperature, flow of exhaust and availability of oxygen etc. As we know, Indian roads are different from other countries such as European countries. The abnormal soot loading and frequent regeneration lead to many concerns such as oil dilution, performance of the engine and life of DPF system etc.

The tractor usage is growing in the world due to derivative of rural economy and farming process. It needed wide range of implements based on the applications of the customer. The tractor plays a major role in Agricultural and Construction applications. In a tractor, hydraulic system is act as a heart of the vehicle which controls the draft and position of the implement. Hydraulic system consists of Powertrain assembly, 3-point linkage and DC sensing assembly. The design of hydraulic powertrain assembly is challenging because the loads acting on the system varies based on the type of implement, type of crop, stage of farming and soil conditions etc., Hydraulic powertrain assembly is designed based on standards like IS 12207-2019 which regulates the test methods for the system based on the lift capacity of the tractor. In this paper, virtual simulation has been established to optimize the design and perform the test correlation.

In an off-road vehicle, Vehicle Structure plays a major role in passenger safety, Aesthetics, Durability, through a validated construction of canopy structure. This structure is to maintain the shape of the vehicle and to support various loads acting on the vehicle. In present market a safe, Durable, Robust, Waterproof, Noise less, Light weight and cost-effective off-road vehicle will always be a delight for any customer. However, the current conventional way of Soft top vehicle structure use metal brackets and formed sheet parts to create a structure to retain the canopy shape in place. These conventional structures are often heavier and would have many demerits such as heavy weight, Corrosion, Risk of canopy tear due to metallic structure edges and inappropriate draining, water management. Considering this we replaced the heavy metal brackets in to blow molded plastic parts.

The contribution of engine borne noise is the major source of vehicle noise in diesel powered vehicles. The engine noise can be minimized by modification of engine components design and also with different acoustic abatement techniques. The research activities were carried out on 4-cylinder CRDe engine for SUV application. All the emission and performance parameters along with combustion noise was captured continuously for all the part load points from 1000 RPM to 2750 RPM with respect to the different road conditions and driving cycle. This paper targets on reducing the combustion noise at the noise prone zones only on the basis of the injection strategies ensuring no ill effect on the emissions and fuel economy. The first step was the reduction of rail pressure which helped noise levels to be reduced by almost 6 dB at noise zones. Main injection timing retardation was tried at all possible zones which influenced in considerable noise reduction at various zones.

Ground clearance plays a vital role in an off-road vehicle during off roading. Higher the ground clearance, higher is the difficulty during ingress & egress of the vehicle. This brings in the necessity to provide entry-assist grab-handles for vehicle with more ground clearance (>200mm). Entry-assist grab handles alleviates the pain of the occupants during ingress and egress. For entry-assist grab handles’ purpose to be served, it should provide comfortable ergonomic grip & have to take the load of passengers while ingress or egress through-out the complete life cycle of the vehicle. Entry Assist grab handles can be fitted on A-Pillar zone to assist first row passengers & on B-pillar zone to assist second row passenger. Providing entry-assist grab handles on pillar trims make the grab-handles exposed to head-impact zone and hence, in most of the cases, it should pass the head impact regulations framed for respective countries.

In farm tractors, front end loaders are becoming popular attachments for primarily material handling such as loading, moving and unloading of woodchips, sand, gravels etc. It is also used for some severe load application such as tree uprooting and ripping operation which requires validation of loader frame and tractor as well. To validate the design, a standard pull-push test is carried out on tractor with loader in a laboratory. In this test front loader bucket is pushed against a rigidly clamped fixture with full engine throttle and maximum hydraulic cylinder pressure of loader. To avoid surprise failures during the test, a virtual simulation method needs to be developed and validated. In this paper, a method has been proposed by authors for the above objective. A multi-body dynamics model of tractor with loader is created in MSC ADAMS and actual event is simulated using test loads & boundary conditions.

Connected vehicles technology is experiencing a boom across the globe. Vehicle manufacturers have started using telematics devices which leverage mobile connectivity to pool the data. Though the primary purpose of the telematics devices is location tracking, the additional vehicle information gathered through the devices can bring in much more insights about the vehicles and its working condition. Cloud computing is one of the major enabled for connected vehicles and its data-driven solutions. On the other hand, machine learning and data analytics enable a rich customer experience understanding different inferences from the available data. From a fleet owner perspective, the revenue and the maintenance costs are directly related to the usage conditions of the vehicle. Usage information like load condition could help in efficient vehicle planning, drive mode selection and proactive maintenance [1].

The tough emission limits of BSVI norms with very low levels of NOx and PM emissions presents major techno economic challenges for the automobile industry. Combined efforts of pollutants reduction by combustion modification as well as the exhaust after treatment devices could only facilitate to achieve the desired emission targets. selective catalytic reduction technology is a mandatory system which uses ammonia from the aqueous urea solution to react with NOx forming nontoxic by products. The cost spent on aqueous urea solution in addition to the cost of BSVI diesel encounters high operating cost for the vehicle. NOx reduction by SCR too requires adequate quantity of ammonia from the AdBlue. Hence sensible utilization of DEF is essential for reduced running cost of the SCR system. SCR efficiency is higher for higher exhaust temperature and it requires minimum exhaust temperature above which only it operates.

With the implementation of stringent PM emission norms in various countries for diesel vehicles, the legislation demands a PM mass limit as low as 4.5mg/km in the NEDC cycle, starting from Euro5. This makes the usage of Diesel Particulate Filters (DPF) mandatory. The same is going to be mandated for upcoming BSV emission norms in India. Thus it becomes imperative to know the functional aspects of a DPF and their impacts. Basically there are two major functions of a DPF- Soot mass filtration and Soot burning or Regeneration. This paper highlights usage of DPF in Indian context from the perspective of one of the major aspects of DPF regeneration-Regeneration Interval, which is basically governed by vehicle/engine out smoke. Regeneration interval also has direct or indirect influence on life of engine of a vehicle and average fuel economy of a vehicle which will also be touched upon herein.

In order to comply with the stringent future emission mandates of automotive diesel engines it is essential to deploy a suitable combination of after treatment devices like diesel oxidation catalyst (DOC), diesel particulate filter (DPF) and DeNox converter (Lean NOx Trap (LNT) or Selective Catalytic reduction (SCR) system). Since arriving at a suitable strategy through experiments will involve deploying a lot of resources, development of well-tuned simulation models that can reduce time and cost is important. In the first phase of this study experiments were conducted on a single cylinder light duty diesel engine fitted with a diesel oxidation catalyst (DOC) at thirteen steady state mode points identified in the NEDC (New European Driving cycle) cycle. Inlet and exit pressures and temperatures, exhaust emission concentrations and catalyst bed temperature were measured. A one dimensional simulation model was developed in the commercial software AVL BOOST.

The combustion strategies play a key role in emission improvisation and noise reduction on diesel engines equipped for higher emission norus. This paper clearly discussed on the selection of various operating points for optimization and employing of proper calibration strategies like pilot strategy, Main injection timing, EGR type and rail pressure variation for best emission and noise output. Various optimization techniques have been implemented in our study. Since the pilot injection quantity as well as timing are varied in our paper, careful matrix formulation is required to determine the best optimum point. Around 340 points were obtained on varying pilot quantity and pilot separation sweep chosen at single engine speed and load for both the pilots. Out of the above points, 5 sensitive points were selected ensuring the sensitivity of the emissions and noise.

Design and development of high-pressure pipe involves number of design validation plans for robust design in diesel engine. The fundamental behavior of two-cylinder diesel engine with parallel stroke involves high vibration which generates stress on components mounted on crankcase resulting into earlier fatigue failure. In this paper, the innovative approach of using optimized design of vibration damper for resolving high vibration stress concerns in fuel system is discussed. The vibration dampers were designed meeting both performance and durability aspects in two-cylinder diesel engine applicable for both passenger and commercial vehicle. This paper highlights the design approach involving experimental stress measurements and design optimization based on part development feasibility.