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Design of Roof Rack Rails with Cost and Weight Optimization

Maruti Suzuki India Ltd-Abhishek Softa, Anuj Shami, Rajdeep Singh Khurana
Published 2017-03-28 by SAE International in United States
The fuel efficiency of a vehicle depends on multiple factors such as engine efficiency, type of fuel, aerodynamic drag, and tire friction and vehicle weight. Analysis of weight and functionality was done, to develop a lightweight and low-cost Roof rack rail.The Roof rack rail is made up of a lightweight material with thin cross section and has the design that allows the fitment of luggage carrier or luggage rack on the car roof.In starting this paper describes the design and weight contribution by standard Roof rack rail and its related parts.Secondly, the selection of material within different proposed options studied and a comparison of manufacturing and design-related factors.Thirdly, it has a description of the design of Roof rack rail to accommodate the luggage carrier fitment on the car roof. Moreover, optimizations of Roof rack rail design by continuous change in position, shape, and parts used.Finally, the detail of the lightweight and cost effective Roof rack rail design. Cause and countermeasure detail of the surface defects occurred in parts during mass production. Moreover, a realization of…
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Novel Approach towards Fuel Tank Heat Shield Design

Maruti Suzuki India Ltd-V N Bhasker, Abhinav Agarwal, Abhishek Sharma, Avisek Das, Nirajkumar Mishra
Published 2017-03-28 by SAE International in United States
Vehicle heat management has become a serious concern due to escalating under-hood and exhaust temperatures. Compact vehicle packaging caused by downsizing has further magnified this concern. In an automobile, fuel is stored in a metallic or plastic fuel tank. In addition to fuel storage, temperature inside fuel tank has to be maintained at a certain limit in order to control high fuel evaporation rate and prevent deterioration of parts. The fuel tank surface temperature is governed by heat rejection from the engine, exhaust system and heat radiated from the road. Generally, mechanical shielding has been found to be an efficient defense to the heat management problem. However ‘what to shield’, ‘where to place the shield’ and ‘how to shield’ are the major challenges. This paper describes a methodology followed to reduce temperature on fuel tank surface by varying material, geometry and layout of heat shields. Computational Fluid Dynamics (CFD) of different iterations were carried out and correlated with actual vehicle test to determine the most effective shielding arrangement between exhaust system and fuel tank.
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Methodology to Study the Effect of Variation of Suspension Characteristics on Body Durability

Maruti Suzuki India Ltd-Mani Shankar, I V N Sri Harsha, K V Sunil, Ramsai Ramachandran
Published 2017-03-28 by SAE International in United States
In an automobile, road loads due to tire-road interaction are transferred to vehicle body through suspension. This makes suspension a critical component from the body durability perspective. During vehicle design and development, optimization of suspension parameters to suit ride and handling performance is a continuous and iterative process. These changes on suspension can affect vehicle body durability performance. This paper tries to establish a process to evaluate the effect of changes in suspension parameters on body durability, thus helping in understanding the impact of these changes.The process starts with virtual model building in Multi Body Dynamics software. The base line model is correlated with testing using fatigue at some critical locations on Body in White (BIW). Once correlated, Design of Experiments (DOE) approach is used on suspension parameters like spring properties, damper properties etcetera to identify critical parameters that will affect the magnitude of loads on the body-suspension attachment points. These loads are further used to evaluate effect on durability of the body using Finite Element Method (FEM) approach.
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Design of Front Structure of Vehicle for Pedestrian Headform Protection

Maruti Suzuki India Ltd-Abhishek Sinha, Rajdeep Singh Khurana
Maruti Suzuki India, Ltd.-Kamlesh Yadav
Published 2017-03-28 by SAE International in United States
Vehicle Hood being the face of a passenger car poses the challenge to meet the regulatory and aesthetic requirements. Urge to make a saleable product makes aesthetics a primary condition. This eventually makes the role of structure optimization much more important. Pedestrian protection- a recent development in the Indian automotive industry, known for dynamics of cost competitive cars, has posed the challenge to make passenger cars meeting the regulation at minimal cost. The paper demonstrates structure optimization of hood and design of peripheral parts for meeting pedestrian protection performance keeping the focus on low cost of ownership. The paper discusses development of an in-house methodology for meeting Headform compliance of a flagship model of Maruti Suzuki India Ltd., providing detailed analysis of the procedure followed from introduction stage of regulatory requirement in the project to final validation of the engineering intent. The paper presents the impact of major limitations, such as, usage of common platform, aesthetics of hood, height of hood and layout of safety devices present below the hood -on design of hood for…
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Analysis of Potential of Sailing Functionality in Indian Driving Conditions

Maruti Suzuki India Ltd-Arnab Ghosh, Abhishek Bhatia, Srinidhi Suresh
Published 2016-02-01 by SAE International in United States
Sailing Function allows a vehicle to roll freely without traction force, using an automated powertrain/clutch control strategy- when power demand from internal combustion engine is low. Currently in AMT/MT, during coasting phase with clutch and gear engaged, ECM requests a ‘Fuel-Cut’ - where additional vehicle kinetic energy is spent in overcoming Engine friction losses (loss as heat from friction). To avoid this, the drivetrain can be disconnected from Engine - by actuating the clutch, or engaging neutral or both -popularly called sailing - thereby increasing rolling distance. This study focusses on the various aspects of developing a sailing strategy suitable for Indian Conditions - driving pattern, road and traffic conditions. Sailing timeshare - or the amount of time spent in this state was evaluated in flat and hilly driving conditions. Estimation is made about the potential impact of this technology on real world fuel economy of the vehicles, in comparison to the conventional Fuel cut based technology, Idle Start Stop technology and Coasting start stop technology. The impact of this technology on the driver -…
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New Control Strategies to Avoid Pre-Ignition in Higher CR Engines

Maruti Suzuki India Ltd-Thiyagu Raghavan Ranjith Kumar, Ajay Narayan Yadav
Published 2016-02-01 by SAE International in United States
Presently, lot of research is going on, to improve the thermal efficiency and there by the Fuel Economy of vehicles. Increasing the compression ratio to improve on the performance is an option. The compression ratio is a factor that influences the performance characteristics and FE of internal combustion engines. When targeting high output levels at low engine speeds, undesired combustion events called pre-ignition can occur. These pre-ignition events are typically accompanied by very high cylinder peak pressures which can lead to severe damage of engine component. The application engineer needs to optimize this undesired combustion event. This paper describes a systematic application developed to reduce pre-ignition. A case study was done to identify the pre-ignition phenomenon by using in-cylinder measurement. The paper also explains how air, fuel, injection angle and spark can help to avoid pre-ignition.
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An Experimental Study of Mechanism of Body Panel Vibration in Booming Noise Reduction of Passenger Vehicles

Maruti Suzuki India Ltd-Joydeep Chatterjee, Harveen Talwar
University of Petroleum Energy Studies-Srishti Garg
Published 2016-02-01 by SAE International in United States
In a typical passenger vehicle, there can be different types of noises generated which are broadly categorized as Interior Noise and Exterior Noise. The interior noise sources can be further classified into noises which can be Structure Borne or Air Borne. One of the major sources of both structure borne and airborne noise generation is the powertrain of the vehicle. The structure-borne noise and vibrations generated from the powertrain is usually transferred to the vehicle body through its attachment points to the body and the powertrain driveline. These induced body vibrations can sometimes cause the acoustic cavity of the passenger cabin to go into resonance which results in an annoying and disturbing noise for the passengers, called Booming Noise. Very often, one or more than one vehicle body panels show a dominant contribution in inducing this acoustic cavity resonance. In this research, the backdoor of the selected passenger cars were identified to be one of the primary contributors in causing the booming noise phenomena. The objective of this research was to study the mechanism of…
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Interior Noise Reduction in a Passenger Vehicle through Mode Modulation of Backdoor

Maruti Suzuki India Ltd-Ninad Pimpalkhare, Gaurav Kumar, Yuva Kishore Vaddi, Chetan Prakash Jain
Published 2016-02-01 by SAE International in United States
Inside cabin of a passenger car, low frequency booming noise still presents a major hurdle for NVH engineers to fine tune a vehicle. Low frequency booming noise is presently taken care with addition of mass damper and large reinforcements. These conventional countermeasures add weight to the vehicle as well as increase the overall production cost. The study presented in this paper proposes a countermeasure model that not only reduces the booming noise but also avoids any weight and cost addition. It has been focused for low frequency booming noise around 30 ∼ 40 Hz. Within the range mentioned, one of the major reasons for booming noise in hatchback models is the bending resonance of backdoor. By modifying the mode of the backdoor in such a manner that it cancels the effect of bending on the vehicle acoustic cavity, improvement can be achieved in terms of sound pressure level at the driver’s right ear location (DREL). Present study utilizes an innovative approach to change the bending mode of the backdoor into twist mode. This has been…
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Research on Source of Noise during Adjustment of Automotive Seating Head Restraint and its Countermeasure

Maruti Suzuki India Ltd-Nishant Kataria, Kota Nageswara rao Puli, Pankaj Maheshwari, Sandeep Raina
Published 2016-02-01 by SAE International in United States
In automotive seating, there are multiple applications wherein parts have relative motions. During the relative motion of parts, noise is generated due to friction which can be irritant to the end user. This paper focuses on, one such application where conventional noise reduction solutions like grease application are not very effective. Typically, Seats can have two types of Head Restraint, a) Adjustable, b) Non Adjustable. In Adjustable type of Head restraint, during adjustment by the end user, head restraint rod rubs against the metal plate inside the locking guide. This creates friction and that in turn results in noise. The paper focuses on understand the phenomenon of noise, identifying the root cause and studying about potential solutions to reduce the noise to acceptable level. In this paper, parameters affecting the noise are studied and evaluated. Major parameters considered are: 1Surface texture of frame2Surface finishing operations of frameFigure 1Head Restraint fitted in Guides
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Design Optimization of Hood System for Pedestrian Headform Protection

Maruti Suzuki India Ltd-Kamlesh Yadav, Ruhi Thakur
Published 2016-02-01 by SAE International in United States
Hood is the closure provided in the frontal portion of the vehicle for covering the engine room. Any component disposed in the frontal portion of the vehicle becomes important because of aesthetic as well as regulatory requirements. Introduction of new regulations like pedestrian protection brings new challenges for the original equipment manufacturers and the governing authorities. Introduction of Pedestrian Protection regulation, a recent development in the automotive industry, has thrown several questions in front of original equipment manufacturers.This work explains the procedure to address such question and the learning associated with it. With an attempt to comply Pedestrian regulation, following were the major challenges: 1Common Platform and Engine2High Hood Styling3Limited freedom to increase vehicle front overhang4Location of hood switchWith above mentioned constraints, a team of design, evaluation and testing set forth its aim to make the Hood system pedestrian headform compliant while giving priority to styling and common platform. Also the location of safety device, hood switch, can’t be changed which becomes a major constraint in reducing the HIC values as the gap required for…
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