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Engine mounts are an integral part of the vehicle that helps in reducing the vibrations generated from the engine. Engine mounts require a simple yet complicated amalgamation of two very different materials, steel and rubber. Proper adhesion between the two is required to prevent any part failure. Therefore, it becomes important that a comprehensive study is done to understand the mating phenomenon of both. A good linking between rubber and metal substrate is governed by surface pretreatment. Various methodologies such as mechanical and chemical are adopted for the same. This paper aims to present a comparative study as to which surface pretreatment has an edge over other techniques in terms of separation force required to break the bonding between the two parts. The study also presents a cost comparison between the techniques so that the best possible technique can be put to use in the commercial vehicle industry.

BSIV implementation for commercial vehicle in pans India effectively from April 2017. It’s very challenging job for performance and emission engineer to meet engine performance & fuel economy with stringent emission norms for high power and torque density HD diesel engine. In Altitude, lack of air availability & combustion energy passes by mechanical waste gate, lead to lower boost at partial load in waste gate region; which in turn leads to poor engine performance & fuel efficiency and higher turbo speed. To control the turbocharger design speed limit various methodologies adopted like engine derating or optimizing the combustion parameters leads to poor vehicle performance. Combustion parameter optimsation is having limited scope for turbocharger speed control.

Vehicle life and performance is affected by many factors when in use. The most influential being the vibrations generated especially when the vehicle is in motion. These vibrations are directly experienced by the driver, whose performance goes down, if under continuous influence of these vibrations. This increases the fatigue and greatly reduces the return on investment done by the customer. There are two major sources of vibrations, the engine and the road on which the vehicle moves. To prevent such issues engine mounts are used in vehicles, which may seem simple but perform a critical role, of providing comfort to the driver. Therefore, it becomes important that thoroughly designed and examined mounts are being used in the vehicle. This paper focuses on the methodology to be followed for design and validation of an engine mount used in heavy duty vehicles.

The Mounting system of component plays a major role in determining the structural durability, compatibility and synchronization of the systems with respect to each other. The major function of Engine mounts is to isolate the engine from the chassis and to align the power-train system of vehicle according to needs. Here we exclusively deal with the failure case of a Heavy duty commercial vehicle Engine Mounts and its optimization. We do formulate a theoretical calculation for the estimation of engine loads, Center of Gravity (C.G) and characteristics of existing engine mount followed by a failure root cause analysis based on design and transmissibility parameters. This is then correlated with data from Computed Aided Engineering and Matlab for analysis of the existing model which is compared to the experimental transmissibility from Road load data Acquisition (RLDA). This is to validate the conditions and propose optimizations to reduce critical failures.

Diesel exhaust is a complex mixture of combustion products of diesel fuel, and the exact composition of the mixture depends on the nature of the engine, operating conditions, lubricating oil, additives, emission control system, combustion parameters and fuel composition. In a diesel engine, NOx (NO & NO2) and PM (Particulate Matter) are the most critical constituents for the emission legislation. In order to control the PM emission of diesel engine and comply with increasingly stringent exhaust legislation, more information is required on the components and genesis of PM. In general, PM from diesel engines is classified into two fractions: Insoluble Organic Fraction (ISOF) and Soluble Organic Fraction (SOF). In this experimental study, a series of 13 mode ESC cycle were run on a light duty diesel engine after optimization of combustion parameters (Injection Pressure, Injection Timing, Multiple Injections, EGR rate, etc) in successive tests and PM component was analyzed.

The hybrid structure of Engine Mounts made of rubber casing with cast iron reinforcing. Use of two materials made it unique both in application and testing. The rubber provides damping for engine vibrations and the cast iron provides necessary strengthening to hold the heavy engine in place. In this research paper the FEA (Finite Element Method) methodology is being discussed to evaluate and optimize the design analysis to enhance overall engine mount capacity. The existing and modified designs are validated and considerable improvement is being observed in modified design in physical testing. Accurate modeling of engine mounts assembly is presented in this paper. FEA analysis results have good correlation with physical validation for both designs. Impact of design parameters of rubber mounts has been presented.

The main emphasis for a commercial vehicle design which was focused on fuel-economy and durability does not fulfill the increasing customer expectations anymore. Commercial vehicle designers need to focus on other vehicle aspects such as steering, ride comfort, NVH, braking, ergonomics and aesthetics in order to provide car like perception to truck, bus drivers and passengers during long distance drives. Powertrain mounting system must perform many functions. First and foremost, the mounting system must maintain & control the overall motion of the powertrain, to restrict its envelope reasonably, thereby avoiding damage to any vehicle component from the potential impact. This requires the mount to be stiff. Second the mount must provide good vibration isolation to have a comfortable ride to the vehicle occupant. This requires the mount to be soft.

In an electric vehicle, engine is replaced with battery and transmission is replaced with traction motor. Thermal management of electric battery and motor became a necessary evaluation step in the design and development process of electric vehicles. The temperature of the traction motor coolant is required to be maintained below 600C to ensure proper functioning of the system. Coolant takes away heat from traction motor, motor controller along with an on-board charger in battery charging and discharging conditions. In this paper the cooling unit selection for the total required heat rejection from all three components is analytically calculated and thermal management methodology of liquid-cooled Electric Motor is being studied and documented with the help of numerical simulation. The results are further validated with test results in Electric bus for city application.

Turbocharging has become an important method for increasing the power output of diesel engines. A perfectly matched turbocharger can increase the engine efficiency and decrease the BSFC. For turbocharger matching, engine manufacturers are dependent on the turbocharger manufacturers. In this paper, an analytical model is presented which could help engine manufacturers to analyze the performance of turbocharger for different load and ambient condition using compressor and turbine map provided by turbo manufacturers. The analytical model calculates the required pressure at inlet and exhaust manifold for fixed vane turbocharger with waste gate using inputs like BSFC, lambda, volumetric efficiency, turbocharger efficiency and heat loss, that are available with the engine manufacturer.