Strategic & Frugal technology approach meet the stringent CPCB-IV+ Emission norms

2026-26-0059

To be published on 01/16/2026

Authors Abstract
Content
In CPCB-IV+ Emissions regulations NOx & PM are reduced by 90% from CPCB-II limits in the power band 56 <kW ≤ 560. Obvious technology approach adopted by industry to meet this requirement is, introduction of CRDI fuel injection system & DOC+SCR+ASC aftertreatment technology, leading to substantial modifications at both engine & genset level. It results into huge development expenditure as well as high incremental product cost, timelines and increased in the total cost of ownership. This paper describes the frugal technology approach to keep development cost, product cost, development time to the minimum using electronically governed, high pressure mechanical fuel injection equipment while comfortably achieving target CPCB-IV+ emission levels. 1D-thermodynamic & 3D-combustion simulation approach was adopted to predict the engine out emissions and to optimize combustion hardware. This was followed by Virtual Test Bench (VTB) or closed loop HiL system simulation to integrate the engine & after-treatment plant models, actuators, sensors, ECU, ACU and GCU. In VTB lab, all the corresponding software's communication was established and verified most of the NCD functionalities before moving on to the actual test bed activities. The matured dataset from VTB and hardware selected through simulation were further taken up on the engine testbench and engine out calibration and Tailpipe/ SCR calibration were carried out. Thermal management for Aftertreatment were also taken care during engine calibration. Through this approach, engine out and tail pipe emissions achieved with single hardware combination and OBD activities completed smoothly. During this development there were challenges like high back pressure, thermal management & oil consumption etc. which we could overcome through integrated design & development approach involving benchmarking, data analysis, inputs from suppliers etc. Through this approach CPCB-IV+ emission norms could be met with min.50% margin on NOx emissions, min.30% margin on PM emissions and NCD regulations met with single NCD family, while maintaining best in class fuel & DEF consumption levels. This approach also helped in completing the entire development in just 12 months.
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Citation
Arde, V., Juttu, S., Kadam, A., Gothekar, S. et al., "Strategic & Frugal technology approach meet the stringent CPCB-IV+ Emission norms," SAE Technical Paper 2026-26-0059, 2026, .
Additional Details
Publisher
Published
To be published on Jan 16, 2026
Product Code
2026-26-0059
Content Type
Technical Paper
Language
English