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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
Hydrogen Fuel Cell Electric Vehicles (FCEVs) represent a significant trajectory in vehicular decarbonization, harnessing the inherently high energy density of diatomic hydrogen within electrochemical conversion systems. When sourced via renewable pathways, such hydrogen facilitates propulsion architectures characterized by zero tailpipe emissions, enhanced energy efficiency, and extended operational range profiles. Realizing peak systemic efficacy necessitates the synergistic orchestration of high-fidelity fuel cell stack design, resilient compressed gas storage modalities, and nuanced energy governance protocols. To reduce transient stressors and guarantee long-term electrochemical stability, employing multi-scale modeling and predictive simulation, combined with constraint-aware architectural synthesis, is crucial in handling stochastic driving conditions spectra. This study develops a high-fidelity mathematical plant model of a hydrogen Proton Exchange Membrane (PEM) fuel cell
Mulik, Rakesh VilasraoE, PorpathamSenthilkumar, Arumugam
Growing population in Indian cities has led to packed roads. People need a quick option to commute for both personal trips and business needs. The 2-3 Wheel Combination Vehicle is a new, modular solution that switches between a two-wheeler (2W) and a three-wheeler (3W). Hero has designed SURGE S32 to be a sustainable and flexible transportation option. It is world’s first class changing vehicle. The idea is to use a single vehicle for zipping through city traffic, making deliveries, or earning an income. Manufactured to deal with the challenges of modern life, this dual-battery convertible vehicle can easily transform from a two-wheeler to a three-wheeler and vice versa within three minutes. The Surge S32 is a versatile vehicle that replaces the need for multiple specialised vehicles. By lowering the number of vehicles on the road, it decreases road congestion, reduces emissions, and improves livelihoods. It powers by electricity, ensuring sustainability in all aspects. The current
Ali Khan, FerozGupta, Eshan
Growing global warming and the associated climate change have expedited the need for adoption of carbon-neutral technologies. The transportation sector accounts for ~ 25 % of total carbon emissions. Hydrogen (H2) is widely explored as an alternative for decarbonizing the transport sector. The application of H2 through PEM Fuel Cells is one of the available technologies for the trucking industry, due to their relatively higher efficiency (~50%) and power density. However, at present the cost of an FCEV truck is considerably higher than its diesel equivalent. Hence, new technologies either enabling cost reduction or efficiency improvement for FCEVs are imperative for their widespread adoption. FCEVs have a system efficiency around 40-60% implying that around half of the input energy is lost to the environment as waste heat. However, recapturing this significant amount of waste heat into useful work is a challenge. This paper discusses the feasibility of waste heat recovery (WHR
P V, Navaneeth
Hydrogen Internal Combustion Engine (HICE) has the promise of zero carbon solution for the mobility industry. The key beneficiary would be the medium and heavy-duty segment of transportation which are likely to adapt the battery electric or fuel cell electric solution in longer term. This particular segment of engines need high low end torque, peak torque and rated power which cannot be compromised. Additionally, a competitive thermal efficiency w.r.t diesel engines would be advantageous. Direct Injection (DI) of hydrogen gives higher specific power and thermal efficiency as compared to Port Fuel Injection (PFI). This study focuses on the performance characteristics of these technology routes to aid in the HICE development process. Current work involves the use of 1-D thermodynamic simulation using GT-SUITE for modeling the performance of HICE. Both predictive and non-predictive methodologies of modeling the combustion were employed. Initially, the model validation of the PFI engine
Parthiban R, VarunKarthikeyan, K RNarayana Reddy, JParamasivam, PrakashManjunath, MKumar D, KishoreN R, VaratharajSuresh, KG, Yogesh BolarSadagopan, KrishnanPandey, Sunil Kumar
Air pollution is profligate becoming a serious worldwide problem with the increasing population and its subsequent demands. Diesel, Gasoline, Natural Gas, Propane, etc., are some of the traditional fuels used in the power generation sectors. Diesel fuel, popularly utilized for backup power in critical operations, is valued for its swift activation time. This makes diesel generators a preferred choice for commercial properties and hospitals requiring reliable emergency power. Moreover, natural gas, distributed through local utility grids, provides a convenient and readily available fuel source for generators, eliminating the need for on-site fuel storage. On the other hand, CPCB has instructed to modify the emission regulations for genset engines for decarbonization and development clean fuel. The change from CPCB II to CPCB IV+ standard shows the commitment of the Indian government towards environmental sustainability and COP26. Pondering to the stringent emission norms, researchers
Bandyopadhyay, DebjyotiSutar, Prasanna SDhar, Rit PrasadSonawane, Shailesh BalkrishnaRairikar, Sandeep DThipse, Sukrut SSingh, SauhardMishra, Sumit KumarBera, TapanBadhe, RajeshTule, ShubhamAghav, YogeshLakshminarasimhan, Krishna
During parking conditions of vehicles, the state of the battery is uncertain as it goes through the relaxation process. In such scenarios, the battery voltage may exceed the functional safety limits. If we cross the functional safety limits, it is hazardous to the driver as well as the occupant. In this case, relaxed voltage plays a crucial role in identifying the safe state of the battery. To estimate the relaxed cell voltage there are methods such as RC filter time constat modeling and relaxation voltage error method. The problem with these solutions is the waiting time and accuracy to determine the relaxation voltage. In this manuscript, a solution is proposed which ensures the above problem is reduced. To achieve the reduction of relaxation voltage estimation time, a python sparse identification of nonlinear dynamics (PySindy) is used which identifies and fits an equation model based on observing the battery characteristics at different SOC and temperatures. The implementation is
Pandey, PriyanshuNilajkar, AnkurPanda, Abinash
The world is moving towards data driven evolution with wide usage tools & techniques like Artificial Intelligence, Machine Learning, Digital Twin, Cloud Computing etc. In automotive sector, the large amount of data being generated through physical and digital test evaluations. Computer-Aided Engineering (CAE) is one of the highest contributors for data generation as physical testing involves high cost due to prototypes & test set-up. The Automotive Noise, Vibration & Harshness (NVH) field is advancing exponentially due to new stringent regulatory norms & customer preferences towards comfort, where digitally advanced techniques are playing a key role in the revolution of NVH. Data generation through CAE tool is a crucial aspect of Engineer’s daily activities and selecting such appropriate CAE software and solvers is critical, as it influences user interface experience, accuracy, solution time, hardware requirements, variability expertise, Design of Experiments ability, and integration
Hipparge, VinodMasurkar, NikitaArabale, VinandBillade, Dayanand
This paper presents the virtual prototyping of traction motor in commercial EV to make an early prediction of the performance parameters of the machine without spending an enormous cost in building a physical structure. A 48/8 slot-pole configuration of IPMSM is used to demonstrate the electromagnetic and thermal co-simulation in ANSYS MotorCad. The core dimensions were determined using permanent-magnet field theory. From those, a two-dimensional finite-element (2D FEM) model of the interior permanent magnet (IPM) motor was simulated using Ansys Motor-CAD electromagnetic simulation tool. The influence of geometrical parameters on the performances of traction motor are evaluated based on FEM. The temperature distribution have been analyzed under steady and transient operating conditions. Alongside, the effects of saturation, demagnetization analysis, and the impact of PM flux linkage on inductances are also considered in this paper. At last, the simulation and analytical results of the
Murty, V. ShirishRathod, SagarkumarGandhi, NikitaTendulkar, SwatiKumar, KundanThakar, DhruvSethy, Amanraj
Over the last few years, notable progress has occurred in electric vehicle (EV) technology. Inverters are key components for electric vehicles (EV). Various PWM strategies have been implemented by OEMs over past years. For most of PWM scheme timing calculation & Lengthy algorithm increases complexity. The proposed a novel Pulse Width Modulation (PWM) control technique for generating inverter lag switching times in multi-level inverters. The proposed Space Vector PWM (SVPWM) method eliminates the need for sector and region identification by utilizing sampled values of reference phase voltages, thereby reducing computational efforts and complexities. The scheme can generate N-level PWM signals and offers flexibility to operate with fewer levels, including operation in the overmodulation range. The sampled magnitudes reference phase voltages are converted into timing signals that are subsequently processed by an algorithm to modify modulating signals. These modulating signals are
Bhanabhagvanwala, Prem Kiritkumar
Automotive displays have become an essential part of modern vehicles, not just for aesthetics but also for improving safety and user interaction. As cars get smarter, the industry is leaning heavily into advanced display technologies to provide drivers and passengers with clearer, more responsive visuals. Technologies like Active Matrix LCDs (AMLCDs) and AMOLEDs are now common in dashboards, infotainment systems, digital clusters, and even head-up displays. These display types are popular because they offer great brightness, vibrant color, and wide viewing angles — all of which are important in a car, where lighting conditions can change constantly. But to make these displays work effectively, a solid backplane is critical. That’s where technologies like amorphous silicon (a-Si) and low-temperature polysilicon (LTPS) come in. Among these, LTPS has gained popularity due to its ability to support high-resolution, high-refresh-rate screens, thanks to its higher carrier mobility. Still
Sinha Roy, DebarghyaDuggal, AnanyaSingh, Ujjwal Kumar
The transition to electric vehicles (EVs) has brought about significant advancements in automotive technology, with inverters playing a crucial role in converting DC power from the battery to AC power for the electric motor. Ensuring the functional safety of these inverters is paramount, as any failure can have severe implications for vehicle performance and passenger safety. This case study explores the successful implementation of ISO 26262 standards in the development and validation of EV traction inverters. This paper begins by outlining the functional requirements and safety goals specific to EV inverters, followed by a detailed analysis of the potential hazards and risks associated with their operation. Using ISO 26262 as a framework, we describe the systematic approach taken to identify, assess, and mitigate these risks. Key methodologies such as Hazard Analysis and Risk Assessment (HARA), Failure Mode and Effects Analysis (FMEA), and Fault Tree Analysis (FTA) are employed to
Ramachandra, ShwethaV, Sushmitha
For regions with cold climate, the range of an electric bus becomes a serious restriction to expanding the use of this type of transport. Increased energy consumption affects not only the autonomous driving range, but also the service life of the batteries, the schedule delays and the load on the charging infrastructure. The aim of the presented research is to experimentally and computationally determine the energy consumption for heating the driver's cabin and passenger compartment of an electric bus during the autumn-winter operation period, as well as to identify and analyze ways to reduce this energy consumption. To determine the air temperature in the passenger compartment, a mathematical model based on heat balance equations was used. This model was validated using data from real-world tests. The research was conducted at a proving ground under two conditions: driving at a constant speed and simulating urban bus operation with stops and door openings. The causes of heat loss in
Kozlov, AndreyTerenchenko, AlexeyStryapunin, Alexander
In recent years, the automotive industry has been looking into alternatives for conventional vehicles to promote a sustainable transportation future having a lesser carbon footprint. Electric Vehicles (EV) are a promising choice as they produce zero tail pipe emissions. However, even with the demand for EVs increasing, the charging infrastructure is still a concern, which leads to range anxiety. This necessitates the judicious use of battery charge and reduce the energy wastage occurring at any point. In EVs, regenerative braking is an additional option which helps in recuperating the battery energy during vehicle deceleration. The amount of energy recuperated mainly depends on the current State of Charge (SoC) of the battery and the battery temperature. Typically, the amount of recuperable energy reduces as the current SoC moves closer to 100%. Once this limit is reached, the excess energy available for recuperation is discharged through the brake resistor/pads. This paper proposes a
Barik, MadhusmitaS, SethuramanAruljothi, Sathishkumar
India's electric 2-wheeler (E2W) market has witnessed fast growth, driven by lucrative government policies. The two-wheeler segment dominates the Indian automotive market, accounting for the largest share of total sales. Consequently, the manufacturers of 2-wheelers are developing new electric vehicles (EV) tailored for the Indian market. However, the Indian EV market has witnessed multiple fire accidents in recent years, raising safety concerns among consumers and industry stakeholders. These incidents highlight key weakness in battery thermal management systems (BTMS), particularly during charging. Most existing E2W BTMS relies on passive (natural) air cooling, which has been associated with fire incidents due to its inefficiency in heat dissipation, particularly during charging in India's high-temperature environment. Therefore, it is imperative to build thermally viable and economical BTMS for the growing E2W vehicles with fast charging capability. FEV is actively developing the
Raut PhD, AnkitHiremath, Vinodkumar SEmran, AshrafGarg, ShivamBerry, Sushil
Highway Pilot (HWP) systems, classified as SAE Level 3 Automated Driving Systems (ADS), represent a potential advancement for safer and more efficient highway drives. In this work, the development of a connected HWP prototype is presented. The HWP system is deployed in a real test vehicle and designed to operate autonomously in highway environments. The implementation presented in this paper covers the complete setup of the vehicle platform, including sensor selection and placement, hardware integration and communication interfaces for both autonomous functionality and Vehicle-to-Everything (V2X) connectivity. The software architecture follows a modular design, composed of modules for perception, decision-making and motion control to operate in real-time. The prototype integrates Vehicle-to-Vehicle (V2V) communication, such as Cooperative Awareness Messages (CAM), to enhance situational awareness and improve the overall system behaviour. The modular structure allows new functionalities
Domingo Mateu, BernatLeiva Ricart, GiselaFacerias Pelegri, MarcPerez, Marc
Transportation industry is facing a growing challenge to reduce its carbon footprint and utilize the carbon neutral, more environmentally sustainable fuels to comply with the goal of carbon neutrality. Implementation of carbon free fuels such as Hydrogen, Ammonia and low carbon fuels such as Methanol, Ethanol can significantly reduce the greenhouse gas emissions, but these fuels are suitable for SI engine architecture due to their high-octane ratings. Hydrotreated Vegetable Oil (HVO) is one of the few fuel solutions available today with a high Cetane rating (70-80), that can be used as a drop-in fuel in the existing CI engines, with minimal modifications. The main constituent of HVO is pure alkane and it can be produced from feedstocks such as vegetable oils, animal fats, various wastes and by-products. A closed cycle 3-D CFD combustion simulation using a detailed chemistry-based solver has been conducted with the HVO, on a three cylinder, naturally aspirated water-cooled CI engine at
Tripathi, AyushMukherjee, NaliniNene, Devendra
During vehicle launches in 1st gear, a lateral shake (undulation) and a pronounced metallic hitting noise were observed in the underbody. The noise was identified as the propeller shaft's second universal joint (UJ) yoke striking the fuel tank mounting bracket. Sensitivity to these issues varied with acceleration inputs: light pedal input during a normal 1st gear launch on a flat road resulted in minimal undulation, whereas wide open throttle (WOT) conditions in 1st gear produced significant lateral shake and intensified hitting noise. Further investigation revealed that the problem persists across all gears and occurs consistently during normal driving conditions, with continuous impact between the propeller shaft yoke and the fuel tank mounting bracket. Extensive experimental measurements at the vehicle level indicated that these issues were primarily caused by the center-mounted propeller shaft joint deviating from its central position and rotating eccentrically under torque. This
Sanjay, LS, ManickarajaKumar, SarveshKanagaraj, PothirajSenthil Raja, TB, Prem PrabhakarM, Kiran
Controlling the source vibrations in internal combustion engines is a crucial approach to minimizing the vibration levels experienced by the driver. The driver's subjective perception of vibration is primarily dictated by the vehicle's low-frequency response (<100 Hz). In an IC engine used in agricultural tractor applications, the primary sources of vibration include (a) 1st order inertial force, (b) couples generated by rotating and reciprocating components such as the piston assembly, connecting rod, and crankshaft, and (c) in-cylinder combustion. In this study, an order ranking analysis was conducted on a single-cylinder, air-cooled, naturally aspirated tractor engine within the driver’s operating range to identify the dominant contributors to source vibrations. The 1st order inertial force was observed to be the dominant contributor to the engine's vibration levels. Subsequently, an attempt was made to mitigate the unbalanced forces by implementing counterweight-based balancing
Bhuntel, AjayRajput, SurendraRawat, Ashish
The rising demand for high-performance 4x4 electric vehicles (EVs) has necessitated development in Noise, vibration and harshness (NVH) optimization, especially in critical components such as compressor bracket. This study focuses on NVH optimization of a dual-stage compressor bracket, comparing its performance against conventional single stage isolation bracket. The dual-stage bracket is evaluated for isolation effectiveness, modal frequency alignment, and overall NVH performance, while ensuring compliance with stiffness targets. Additionally, dual-stage design meets stringent stiffness requirement, confirming structural integrity under dynamic loads. Modal analysis results reveal that the dual-stage configuration effectively shifts critical frequencies away from operational ranges, reducing resonance risks. The results highlight the dual-stage bracket's ability to address NVH challenges in high-performance 4x4 EVs, offering a robust solution for improving cabin comfort and vehicle
Hazra, SandipTangadpalliwar, Sonali
Tire noise reduction is important for improving ride comfort, especially in electric vehicle due to lack of engine noise and majority of the noise generated in-cabin is from tire-road interaction. Therefore, the tire tread pattern contribution is one of the important criteria for NVH performance apart from other structurally generated noise and vibration. In this work a GUI-based pitch sequence optimization tool is developed to support tire design engineers in generating acoustically optimized tread sequences. The tool operates in two modes: without constraints, where the pitch sequence is optimized freely to reduce tonal noise levels; and with constraints, where specific design rules are applied to preserve pattern consistency and manufacturability. The key point to be considered in this pitch sequence is that it should be reducing the tonal sound and equally spread i.e., the same pitch cannot be concentrated on one side which may lead to non-uniformity. So, the restriction is that
Sampathraghavan, LakshmiRamarathnam, Krishna KumarMantripragada PhD, Krishna TejaRamachandran, Neeraj
When the flow of fluid within a high-pressure line is abruptly halted, pressure pulsations are generated. This phenomenon is known as the water hammer effect. This may lead to significant stress and, in the worst-case scenario, results in various types of failures within the highly pressurized system. Similar issues are observed in diesel high pressure fuel line where pressure is well above 1600 bar. Due to multiple injections on-off events, pressure pulsation gets created inside high pressure fuel lines (HPFL) which leads to problems such as high strain on high pressure fuel lines, mechanical damage, uneven fuel injected quantity, vibration beyond specification limits for rail pressure sensors or in worst case extreme noise. This is due to high pressure pulsation which occurs when fluid/fuel natural frequency resonates with structural HPFL natural frequency. In this work, A comparative FEA analysis is conducted to evaluate strain in two distinct high-pressure fuel lines, with pressure
Bawache, Krushna RameshSethy, Girija Kumari
One can witness the constant development and redevelopment of cities throughout the world. Construction equipment vehicles (CEVs) are commonly used on the construction site. However, the noise pollution from construction sites due to the use of CEV has become a major problem for many cities. The construction equipment employed is one of the main causes of these elevated noise levels. The construction workers face a potential risk to their auditory health and well-being due to the noise levels they are exposed to. Different countries have imposed exterior and operator’s ear noise limits for construction equipment vehicles, enabling them to control noise pollution. In this study, three vehicles were selected and checked for NVH performance and found that the operator ear noise level of the identified vehicle is 6 dB(A) higher than the benchmark vehicle level in dynamic conditions, when tested as per ISO 6396. Similarly, there was another vehicle having exterior noise 2 dB(A) higher than
Shinde, GauravJawale, PradeepJain, SachinkumarHarishchandra Walke, Nagesh