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This specification covers a corrosion-resistant steel in the form of investment castings homogenized and solution and precipitation heat treated to 180 ksi (1241 MPa) tensile strength.
AMS F Corrosion and Heat Resistant Alloys Committee
Balance towards various Vehicle attributes often faces design contradictions, particularly in Noise, Vibration, and Harshness (NVH) optimization. Traditional approaches rely on trade-offs, but TRIZ (Theory of Inventive Problem Solving) offers a structured methodology to resolve contradictions innovatively. This paper presents TRIZ-based solutions for 2 key NVH challenges: (1) exhaust systems requiring noise reduction while maintaining low engine back-pressure, (2) engine mounts requiring both softness for vibration isolation and hardness for durability & vehicle stability, By applying TRIZ principles such as separation, mechanics change, etc. and using Thinking Tools such as thinking in time & scale, novel solutions are proposed to achieve superior performance without traditional compromises. These case studies demonstrate how TRIZ enhances automotive NVH refinements by enabling systematic innovations. This also explores benefits of Frugal Engineering for profitable launch of new
A, Milind Ambardekar
Body-on-frame vehicles are well-regarded for their durability and off-road capabilities, but their structural design often makes them more vulnerable to noise, vibration, and harshness (NVH) issues. Vibrations originating from uneven roads are transmitted through the suspension and steering assemblies, sometimes resulting in rattles or other disturbances. These vibrations can be amplified by the inherent flexibility in the body-to-frame mounting system. In such vehicles, the steering system plays a critical role in driver comfort and is highly sensitive to vibrational inputs from the road surface, especially on coarse or uneven terrain. Occasionally, these inputs result in subtle rattle noises that are perceptible only to the driver and may not be detected under controlled testing environments. This poses a challenge for engineers trying to isolate and resolve such intermittent NVH phenomena. Identifying the source requires a combination of real-world driving evaluations, structural
Ramesh Chand, Karan KumarGopinathan, HaridossKabdal, Amit
Nowadays, customers expect excellent cabin insulation and superior ride comfort in electric vehicles. OEMs focus on fine tuning the suspension system in electric vehicle to isolate the road induced shocks which finally offers superior ride quality. This paper focuses on enhancing the ride comfort by reducing the road excitation which originates mainly due to road inputs. Higher steering wheel vibration is perceived on the test vehicle on rough road surfaces. To determine the predominant force transfer path, Multi reference Transfer Path Analysis (MTPA) is performed on the front and rear suspension. Based on the finding from MTPA, various recommendations are explored and the effect of each modification is discussed. Apart from this, Operational Deflection Shape (ODS) analysis is used to determine the deflection shape on the entire steering system . Based on ODS findings, recommendations like dynamic stiffness improvements on the steering column and steering wheel are explored and the
S, Nataraja MoorthyRao, ManchiSelvam, EbinezerRaghavendran, Prasath
One of agricultural tractors most important aspects is operator comfort. In addition to working long hours, tractor operators may be at risk for health problems due to vibrations and mechanical shocks. The tactile vibrations of a tractor are a major consideration when choosing one for agricultural use. This project's mandate includes a study of tractor vibration control problems. It is essential to investigate the governing system in order to determine the cause of the problem. Evaluating the vibrations transmitted via the tractor and using the design of experiments (DOE) approach to lessen vibrations on particular tactile regions were the study's goals. There are several measures currently under investigation which can be used to reduce the vibrations caused by resonance in this paper, these include reducing the natural frequency so as to be able to avoid resonance with the second order engine frequency and the damping coefficient; this will ensure the amplitude of vibration at
Baviskar, Shreyasdhobale, VishwajeetBhangare, AmitKunde, SagarWagh, Sachin
Connected tail lamps have emerged as one of the key features of modern automotive design. It aligns with current vehicle trends, giving a premium, hi-tech appearance and enhancing visibility for the drivers. (Original Equipment Manufacturers) OEM manufacturer utilizes connected tail lamps as a signature design element to establish and reinforce their brand identity. Assembly and integration of these components poses unique challenges due to Metal-to-plastic interfaces that generate audible noise such as squeak & rattle [1] and affect it affects the perceived quality of an occupant in electric vehicles (EVs). The misalignment of parts concerning geometric dimensioning and tolerancing (GD&T) specifications is addressed, as it contributes to increased micro-sliding between the interface and creates audible creaking sounds. This paper explores the influence of mounting fitment on noise generation and proposes a method to optimize the assembly process to reduce the stick-slip [2
Michael Stephan, Navin Estac RajaC M, MITHUNMohammed, RiyazuddinR, Prasath
This paper presents the development and evaluation of a passive regeneration Diesel Particulate Filter (DPF) system for a 4-cylinder, 3.18-liter naturally aspirated agricultural tractor engine based on the mDI engine family. The primary objective is to significantly reduce particulate matter (PM) emissions while maintaining optimal engine performance and fuel economy. The passive regeneration DPF system leverages the engine's operating conditions to generate sufficient heat for the oxidation of trapped particulate matter, eliminating the need for active regeneration techniques. The paper details the design process, including the selection of DPF material, filter geometry, and integration into the exhaust system. Rigorous experimental testing was conducted to assess the performance of the DPF system under various engine load and speed conditions. Results demonstrate substantial reductions in PM emissions without compromising engine power, torque, or specific fuel consumption. This
Maddali, Varun SumanJidigonti, ShashankKannan, SRamesh, Natrajan
In line with global peers (EU, Japan, etc.), the Automotive Industry Standard (AIS) Committee in India has decided to adopt “World harmonized Light vehicle Test Procedure (WLTP)” for M2 and N1 category vehicles not exceeding 3500 kg and for all M1 category vehicles. As a result, “World harmonized Light-duty vehicles Test Cycle (WLTC)” is set to replace currently applicable “Modified Indian Drive Cycle (MIDC)” in the next couple of years. The draft Corporate Average Fuel Economy (CAFE) III & CAFE IV norms for CO2 emission limits, which are set to be implemented in year 2027 and 2032 respectively refer to a shift to WLTP from MIDC. The latest draft of Central Motor Vehicle Rules (CMVR) for BS-VI emissions is also being revised to use WLTC as test cycle. This migration to WLTC is in sync with the demand for test procedures to replicate real driving conditions more appropriately. Further, the move to WLTC along with stricter emission norms is a major step towards realizing India’s COP26
Pawar, BhushanEhrly, MarkusSandhu, RoubleEmran, AshrafBerry, Sushil
Globally, emission regulations for LDVs (Light Duty Vehicles) are becoming increasingly stringent. In Europe, EU7 regulations will tighten the PN (Particulate Number) requirements by applying PN10 with PN value target 6.0+E11 [#/km] and changing the CF (Conformity Factor) value from 1.5 to 1.34 for RDE (Real Driving Emission). This necessitates the use of GPF (Gasoline Particulate Filter) capable of meeting these PN regulations. Similarly, India is also tightening its PN regulations by referencing European standards. Under the current BS VI Stage 2, in-use compliance test procedures, including RDE measurements using PEMS (Portable Emission Measurement System), necessitate GPFs for GDI (Gasoline Direct Injection) engines. Furthermore, around April 2027, the transition from BS VI Stage 2 to BS VI Stage 3 is expected, with a change of driving cycle from MIDC to WLTC up to Phase 3. Additionally, discussions on BS VII regulations, referencing EU7, have begun, and similar stricter PN
Sugimoto, KentaroOhashi, KenichiMori, ReonMatsumoto, TasukuAoki, TakashiSugiura, SoHibi, Noriyuki
Internal Combustion engines exhibit multi-order vibrations caused by the inertial forces of reciprocating masses. These vibrations induce drivetrain resonance, negatively impacting occupant comfort and the durability of drivetrain components. Torsional vibrations, a critical subset of these oscillations, demand efficient damping mechanisms. Torsional Vibration Dampers are instrumental in minimizing such vibrations by tuning mass and frequency characteristics to prevent resonance. By splitting resonant frequencies into avoidable zones within the engine's operational range, TVD enhance vehicle performance and refinement by dampening the vibrations. Structurally, TVD comprise an inertia ring integrated with a damping medium, such as vulcanized rubber, which attenuates torsional oscillations by permitting controlled oscillation of the inertia ring. This study focuses on the failure investigation and the geometric optimization of oscillating masses of TVD for performance and durability
Wani, Sujit AshokS, ManickarajaKanagaraj, PothirajSenthil Raja, TVellandi, VikramanPatil, Dilip
Noise quality at idle condition is an important factor which influences customer comfort. Modern diesel engines with stringent emission norms together with fuel economy requirements pose challenges to noise control. Common rail engine technology has advantage of precise fuel delivery and combustion control which needs optimization to achieve the conflicting requirements of noise, emission and fuel efficiency. Engine noise at low idle condition is dominated by combustion noise which depends on rate of pressure rise inside the cylinder during combustion. The important parameters which influence cylinder pressure rise are fuel injection timing, pilot injection quantity and its separation, rail pressure and EGR valve position. The study on effect of these parameters at varying levels demand large no of experiments. Taguchi design of experiments is a statistical technique which can be used to optimize these parameters by significantly reducing no of experiments needed to achieve the desired
P, PriyadarshanChavan, AmitA, KannanswamyPatil, SandeepChaudhari, Vishal V
With the increasing demand for DC loads, DC-DC converters have become indispensable in modern power electronic architectures. With high-voltage applications typical DC-DC converter topologies are required which include isolation for safety and voltage level conversion. Among various isolated converter topologies, the flyback converter is widely favored for low-power applications, typically under 100 W, due to its simplicity and cost-effectiveness. Like other DC-DC topologies, the flyback converter can operate in either continuous conduction mode or discontinuous conduction mode (DCM). The work has focused on the design and performance analysis of a flyback converter operating in DCM, with a specific emphasis on magnetic component design and loss evaluation. A 55 W multi-winding flyback converter employing a passive snubber circuit is studied and implemented. The loss analysis is done with switch losses around 3.4W and the coupled inductor core losses around 1.5W and copper losses
S, DenisDeshpande, Prathamesh PravinDeshpande, Rohan
With the increasing tonnage of electric heavy commercial vehicles, there is a growing demand for higher power and torque-rated traction motors. As motor ratings increase, efficient cooling of the EV powertrain system becomes critical to maintaining optimal performance. Higher heat loads from traction motors and inverters pose significant challenges, necessitating an innovative cooling strategy to enhance system efficiency, sustainability, and reliability. Battery-electric heavy commercial vehicles face substantial cooling challenges due to the high-pressure drop characteristics of conventional traction system cooling architectures. These limitations restrict coolant flow through key powertrain components and the radiator, reducing heat dissipation efficiency and constraining the operating ambient temperature range. Inefficient cooling also leads to increased energy consumption, impacting the overall sustainability of electric mobility solutions. This paper presents a novel approach of
Dixit, SameerPatil, BhushanGhosh, Sandeep
This paper introduces a modeling and experimentation methodology for transient analysis of surge protective devices (SPDs) for electric vehicle charging system (EVCS) application. The suggested Surge Protective Device topology is to shield the EV power electronics such as on board charger from surge events generated by the grid during charging, with implementation on the grid-EV interface. A new surge protection circuit is designed to suppress transient overvoltages, with its performance evaluated through simulation. The SPD is evaluated in SPICE simulator in the time domain, including its nonlinear spark over characteristics along with its resistive, capacitive and inductive effects. Equivalent circuit is developed and evaluated by simulation under typical surge conditions. The outcomes prove the topology to be effective in clamping voltage, reducing energy transfer to the EV side, and achieving surge event detection. The contribution of this work lies in the establishment of
CHANCHAL, Kumar Prem ChandraKulkarni, SwanandRajaram Joshi, SanjayPatil, Sagar
In the absence of engine noise, road-induced noise has become a major concern specifically for Battery Electric Vehicles (BEVs), impacting Sound Pressure Level (SPL) for both drivers and passengers. Under the influence of random road load inputs, structural vibrations which transfer from road and tire to suspension to vehicle body, the cabin interior noise, particularly at lower frequencies, is significantly affected. To improve the road-induced low-frequency structure-borne noise behaviour, which frequently perceptible as ‘booming noises’, a study was carried out to assess predominant noise sources present in vehicle and to suggest refinements in reducing the noise levels. By considering random excitations of road profile through tire patch using CD-Tire model, vehicle interior noise was computed. Subsequently, to get insight of dynamic behaviour of vehicle, various diagnostic assessments to understand the influence from structure and paths were deployed. Major contributors from body
Paik, SumanRaghuvanshi, JayeshkumarChaudhari, Vishal VasantraoV, Radhika
The evolution of electric vehicles (EVs) also demands the evolution of powertrain mounting systems to achieve superior Noise, Vibration, and Harshness (NVH) performance. This study presents a comparative evaluation of cradle, saddle and ladder mounting systems in EV applications. Examples of experimental modal analysis and vehicle-level vibration tests were performed in order to evaluate structure-borne noise transmission as well as airborne noise transfer under operating conditions. Important parameters like mount stiffness, isolation efficiency and dynamic load distribution were performed. These findings provide valuable guidance for selecting optimal mount strategies to enhance occupant comfort and acoustic quality in future EV designs. Recommendations for mount system improvements considering evolving EV architectures are also discussed. This work provides a crucial, experimentally-validated framework for selecting optimal mounting architectures, addressing a key gap in the
Hazra, Sandipmore, VishwasNaik, Sarang Pramod
The area of electric vehicles (EV) has fully arrived with almost every OEM enhancing electric vehicles in their portfolio. However, regarding its business potential numerous challenging engineering questions have risen. Especially vehicle NVH development needs to be rethought as masking noise from classical internal combustion engines (ICE) are gone. At the same time the frequency content of electric engines falls in the best human audible range, creating high potential for annoying tonal acoustic issues. With NVH design requirements now pushed up into the kilohertz range, many classic development strategies fail or lack efficiency. VIBES Technology’s answer to this challenge is what we call Hybrid Modular Modelling (HMM). This modelling strategy combines test-based and numerical simulation throughout the vehicle development cycle. Using best of both worlds, HMM allows accurate virtual (part / system) design and optimization on full vehicle level. Here HMM is based on the latest
Kohlhofer, DanielPingle, Pawan Sharadde Klerk, Dennis
The article deals with the issue of identifying structural defects that contribute to the formation of a carbide net during thermochemical treatment of steel parts, which negatively affects the mechanical properties complex of finished products. Based on the available data, a theory has been put forward regarding the influence of the present non-metallic inclusions in the carburizing steels structure on carbide formation process in the hardened layer. As an experimentally the samples have been produced from the varying chemical composition alloy structure carburized steel (0.17-0.23 % C, 0.17-0.37 % Si, 0.80-1.10 % Mn, 1.00-1.30 % Cr, 0.03-0.09 % Ti). During microstructure analysis of the samples it has been establish that non-metallic inclusions, in particular sulfides, contribute to the formation of carbides and carbide net in steel due to their high chemical activity with carbon. Thus, contamination of the metal of carburizing steels with non-metallic inclusions is not only a defect
Runova, IuliiaChatkina, MariiaMusienko, Aleksandr
Transportation sector in India accounts for 12% of total energy consumption. Demand of energy consumption is being met by the imported crude oil, which makes transportation sector more vulnerable to fluctuating international crude oil prices. India is mindful of its commitment in 2016 Paris climate agreement to reduce GHG emissions intensity of its GDP by 40% by 2030 as compared to 2005 levels. To fast track the decarbonization of transportation sector, commercial vehicle manufacturers have been exploring other viable options such as battery electric vehicles (BEVs) as a part of their fleet. As on today, BEV has its own challenges such as range anxiety & high total cost of ownership. Range anxiety can be certainly addressed by optimum sizing of electric powertrain, reduction in specific energy consumption (SEC) & use of effective regeneration strategies. Higher SEC can be more effectively addressed by doing vehicle energy audit thereby estimating the energy losses occurring at each
Gijare, SumantKarthick, K.Juttu, SimhachalamThipse, Sukrut S.A, JothikumarJ, Frederick RoystonSR, SubasreeG, HariniM, Senthil Kumar
As light electric vehicles (LEVs) gain popularity, the development of efficient and compact on-board chargers (OBCs) has become a critical area of focus in power electronics. Conventional AC-DC topologies often face challenges, including high inrush currents during startup, which can stress components and affect system reliability. Furthermore, DC-DC converters often have a limited soft-switching range under light load conditions, leading to increased switching losses and reduced efficiency. This paper proposes a novel 6.6 kW on-board charger architecture comprising a bridgeless totem-pole power factor correction (PFC) stage and an isolated LLC resonant DC-DC converter. The main contribution lies in the specific focus on enhancing startup behavior and switching performance. In PFC converters, limiting inrush current during startup is crucial, especially with fast-switching wide-bandgap devices like SiC or GaN. Conventional soft-start techniques fall short in of ensuring smooth voltage
Patil, AmrutaBagade, Aniket
In-vehicle communication among different vehicle electronic controller units (ECU) to run several applications (I.e. to propel the vehicle or In-vehicle Infotainment), CAN (Controller Area Network) is most frequently used. Given the proprietary nature and lack of standardization in CAN configurations, which are often not disclosed by manufacturers, the process of CAN reverse engineering becomes highly complex and cumbersome. Additionally, the scarcity of publicly accessible data on electric vehicles, coupled with the rapid technological advancements in this domain, has resulted in the absence of a standardized and automated methodology for reverse engineering the CAN. This process is further complicated by the diverse CAN configurations implemented by various Original Equipment Manufacturers (OEMs). This paper presents a manual approach to reverse engineer the series CAN configuration of an electric vehicle, considering no vehicle information is available to testing engineers. To
Kumar, RohitSahu, HemantPenta, AmarBhatt, Purvish
Addressing the critical need for lightweight and safe energy storage solutions in electric vehicles, this paper presents the design and optimization of a novel Composite Metal Hybrid (CMH) battery pack structure. A computer aided simulation using Abaqus software was performed to optimize the weight of battery pack. The structural integrity and crashworthiness of the optimized lightweight design were rigorously evaluated under various load cases like side impact (crush), shock loading and underfloor impact. Modal analysis and load tests addressed, demonstrate the CMH battery pack as a viable and promising lightweight solution for electric vehicle applications. Manufacturing aspects are also discussed to ensure feasibility and integration.
Shah, Bijay KumarSingh, Pundan KumarG., Manikandan
This manuscript introduces a methodology to reduce the DC link capacitor size in pole-phase modulated (PPM) induction motor drives (IMD). Typically, the DC link capacitor (DCLC) occupies around 25 to 30% of the inverter volume and 20% of the inverter material cost. Reducing the DCLC size and cost is essential to lowering the inverter size and cost. This can be accomplished by lowering the DCLC ripple current. The proposed technique suggests adapting phase-shifted triangular carrier waveforms, in all the operating modes of the PPM drive, to significantly reduce the ripple current through DCLC, successively reduces the size and cost of DCLC. Simulations are performed in MATLAB/Simulink on a 9 phase PPM drive to validate the efficacy of the strategy. Though the suggested concept is verified with a 9 phase PPM drive, which is operated in 2 modes, it can be extended to any 3n PPM drive. The results demonstrate a 60% reduction in ripple magnitude, enabling the use of smaller, more reliable
A, Rajeshwari
The transportation and mobility sector are undergoing a profound transformation, with a growing emphasis on sustainability and minimizing the environmental impact of transportation. Among the most significant trends is the transition to electric vehicles (EVs) in the form of Battery and Fuel cell, which produce zero emissions without any harmful gases release in nature. This review highlights several infrastructure-related issues and critical factors that could drive India's transportation sector toward adopting electric vehicles. It also delves into the fundamental understanding of e-mobility, shedding light on the daily challenges and barriers it faces. Furthermore, the study explores research aspects, including the strategies, methods, and tools used for electric vehicles to complete the research on Battery electric vehicles (BEV) and also comparative analysis with Fuel cell vehicles (FCVs). The shift BEVs has been driven by decreasing battery costs and advancements in charging
Kumar, Dr. Vijay Bhooshan