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Windshield Defrosting Analysis: A Numerical and Experimental Approach

Maruti Suzuki India Ltd.-Chandan Kumar, Mohan Makana, Felix Regin, Amit Garg, Durga Prasad Pedamallu
Published 2019-10-11 by SAE International in United States
The outside visibility through the windshield and ORVM visibility through the side glasses are critical for safe driving. The frost deposition on the Windshield and side glasses in the cold climatic condition impairs the outside and ORVM visibility during driving and hence leads to an unsafe driving condition. In India, the regulation AIS-084 governs the defrosting standard. The defrosting performance evaluation by testing cannot be performed at concept stage when the vehicle prototype is not available. It also increases the cost of vehicle development due to increase in the number of prototype used for testing.This paper explains about the in-house developed CFD methodology to evaluate the windshield defrosting performance of the vehicle in the concept stage when no vehicle proto is available and cost of countermeasure for defrosting performance improvent is very less. This methodology is implemented for some of the existing models. The results of CFD simulations are compared to the experimental data using a correlation study and the correlation coefficient of numerical and experimental measurements were reported. CFD simulation was in good agreement…
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A New Analytical Model for Clutch System Modeling and Design Optimization

Maruti Suzuki India Ltd.-Rahul Shandilya, Vikas Rawla
Published 2019-04-02 by SAE International in United States
In manual transmission vehicles, Clutch has direct interaction with the driver and plays a significant role in defining the drivability and NVH of a vehicle. These key performance factors depend on the interaction of diaphragm and cushion springs of a clutch. For an automobile manufacturer, it’s essential to optimize the characteristics of these springs based vehicle performance requirements. A state of the art analytical model has been developed by modeling the diaphragm and cushion spring with exponential equations. Based on these models, response functions for release load, torque build-up, and pressure plate lift have been derived. Results achieved from these response functions are correlated with test data. Key contributing factors for peak clutch pedal load, vehicle launch acceleration, and disengagement point have been identified by sensitivity analysis. Multi-objective optimization is performed to select optimized parameters for vehicle performance improvement
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Seat Belt Reminder Sensor Selection for Optimized Performance and Driver Convenience

Maruti Suzuki India Ltd.-Parth Sharma, Abhilash Choubey, Mohd Azal, Rajesh Pal, Pankaj Maheshwari, Kotanageswararao Puli
Published 2019-04-02 by SAE International in United States
Use of safety belts inside a vehicle is necessary to ensure the safety of passengers as well as drivers. To promote the use of seat belts, a seatbelt reminder system is utilized. This system incorporates a sensor for checking seat occupancy for the passenger seat. Activation of these sensors depends on various parameters like seat pad shape, seat upholstery, vehicle H-point, a load on the seat, etc. In this study, the load factor on the seat is studied. The load on the seat may come from occupants or due to the objects placed on the seat. The detection of objects as an occupant may result in false seat belt reminder alarm and cause inconvenience to the customers. Subjective analysis and surveys, covering a broad range of market population, were done to identify such objects. Consequently, performance requirements were determined to facilitate sensor optimization and selection.
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Study for Manufacturing a Cost Effective, Light Weight, Single Piece Injection Molded Spoiler

Maruti Suzuki India Ltd.-Tarun Gupta, Nilesh Rathod
Published 2019-01-09 by SAE International in United States
Today automotive sector has become very dynamic. There is renewed emphasis on safety through adoption of new regulations, electric vehicles are on the verge of replacing ever evolving engine technology, emission norms are getting stringent year by year & several companies are trying to make vehicles more efficient by adoption of new light weight or high strength materials and altering manufacturing methods.In one of the new vehicle programs, there was focus on vehicle styling. In order to improve the styling, back door spoiler was to be considered from design stage itself.Back door spoiler is added in high speed vehicles for creating a downward force to improve the vehicle hold on road. However, nowadays in passenger vehicles that purpose has been subsided and spoiler is given in automotive vehicles for aesthetics or giving vehicle a sporty appearance. For instance in our case it was given to augment aesthetics.This would have resulted in additional cost and weight. Hence, challenge was to introduce it in minimal cost and weight and still it should pass all performance criteria.Each and…
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Effectiveness of Vehicle Cool Glove Box and Analysis of Parameters Effecting Cool Glove Box Performance

Maruti Suzuki India Ltd.-Sandeep Kumar Reddy Janampally, Rajaprasad Lingampelly, Vijay Bhaskar Sonti
Published 2018-04-03 by SAE International in United States
People needs and expectations from vehicles have changed. One of the need is to maintain the temperature of beverages without use of any external source. Cool Glove Box is a feature in which cool air from automotive HVAC system is used to maintain the temperature of the beverages in passenger vehicles. There are various parameters which play a vital role in maintaining the temperature of the beverages and to reduce the rise in temperature. The effectiveness of cool Glove Box is tested in vehicle in an environmental controlled chamber and impact of various parameters which affects the performance are studied. The Glove Box with cooling feature located on bottom of instrumental panel with good sealing and having high air flow directly from HVAC unit will have good cooling performance.
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Passenger under Foot Structure and its Efficacy:-Analytical & Experimental Evaluation

Maruti Suzuki India Ltd.-Prashant Kumar, Sameer Srivastava, Arnab Sandilya, Kapil Kumar Pandey, Pavan Pabba
Published 2018-04-03 by SAE International in United States
Increasing customer expectations of comfort and convenience inside the vehicle has resulted in OEMs working on various solutions to improve interior ergonomics and overall layout. One of the key areas of focus has been the ease of ingress into and egress from the vehicle. But with increased sharing of platforms in OEM Model Lineup, due to obvious benefits like cost and common tooling/parts, it is very difficult to achieve improved results in different vehicles (like Hatchback, Notchback, SUV etc.) but with same underpinnings.One of the commonly used approaches is provision of false flooring via floor pads for front / Rear Passengers for easy Egress-Ingress. Floor Pads are used to maintain similar comfort levels across different vehicles sharing common platform and to maintain similar relationship between Foot resting positions and Side Sill.Various materials like Synthetic felts, Polyurethane (PU) foam blocks, Rubber blocks, expanded polypropylene etc. are used to this end as solid structures placed below carpet. Other than that Synthetic resin structures are also used for the mentioned purpose. Of the various requirements for any solution…
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Study and proposals for improving static comfort in automotive seating

Maruti Suzuki India Ltd.-Ankush Kamra, Sandeep Raina, Pankaj Maheshwari, Abhishek Agarwal, Prasad Latkar
Published 2017-03-28 by SAE International in United States
Automotive seating is designed by considering safety, comfort and aesthetics for the occupants. Seating comfort is one of the important parameters for the occupant for enhancing the overall experience in a vehicle. Seating comfort is categorized as static (or showroom) comfort and dynamic comfort.The requirements for achieving static and dynamic comfort can sometimes differ and may require design parameters such as PU hardness to be set in opposite directions. This paper presents a case wherein a base seat with good dynamic comfort is taken and an analysis is done to improve upon the static comfort, without compromising on the dynamic comfort. The study focuses on improving the initial comfort by considering various options for seating upholstery.
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Effect of PVC Skin and Its Properties on Automotive Door Trim Inserts

Maruti Suzuki India Ltd.-Mahendra Beera, Dinesh Pahuja, Arpit Kapila, Rajat Handa, Sandeep Raina
Published 2017-03-28 by SAE International in United States
Plastic plays a major role in automotive interiors. Till now most of the Indian automobile industries are using plastics mainly to cover the bare sheet metal panels and to reduce the weight of the vehicle along with safety concerns. Eventually Indian customer requirement is changing towards luxury vehicles. Premium look and luxury feel of the vehicle plays an equal role along with fuel economy and cost. Interior cabin is the place where aesthetics and comfort is the key to attract customers. Door Trims are one of the major areas of interiors where one can be able to provide premium feeling to the customer by giving PVC skin and decorative inserts. This paper deals with different types of PVC skins and its properties based on process constraints, complexity of the inserts. Door trim inserts can be manufactured by various methods like adhesive pasting, thermo-compression molding and low pressure injection molding process etc. Considering process feasibility and PVC skin manufacturing constraints, it will be a challenge to decide the specifications of the PVC skin to achieve good…
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Determining the Parameters of Feeling for a Mechanism of Seat Adjustment

Maruti Suzuki India Ltd.-Abhilash CHOUBEY, RAJESH PAL, Kotanageswararao Puli, Pankaj Maheshwari, Sandeep Raina
Published 2017-03-28 by SAE International in United States
The seating system is an inseparable part of any automobile. Its main function is not only to provide a space to the user for driving but also to provide support, comfort and help to ergonomically access the various features and necessary operations of the vehicle. For comfort and accessibility, seats are provided with various mechanisms for adjustments in different directions. Typical mechanisms used for seating adjustment include seatback recliners, lifters (height adjusters), longitudinal adjusters, lumber support, rear seat folding mechanism etc. These mechanisms can be power operated or manual based on vehicle/market requirements. For manual mechanisms, the occupant adjusts the position of seat by operating the mechanism with his/her hand. Often comfort to the occupant during operation is limited to the operating effort of the mechanism. However, as will be shown through this study, operating effort is only one of the parameters which provide overall comfort feeling. Given similar operating effort, there are other parameters that have been identified to contribute to the overall feeling of mechanism’s adjustment. The parameters which affect the operation feeling…
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Effects of Ageing on Aesthetics Performance of Automotive Non-Woven Fabrics

Maruti Suzuki India Ltd.-Sameer Srivastava, Sandeep Raina, Kapil Kumar Pandey, Arnab Sandilya, Shankar Bose, Kumar Vivek
Published 2016-04-05 by SAE International in United States
The aim of the research was to explore and establish aspects that affect ageing of non-woven fabrics used in automobiles. One of the most vulnerable parts in a vehicle, at the behest of the customer, is the Floor Carpet. Original Equipment manufacturers are continually binging at doable options for providing low cost carpets that are functionally and aesthetically durable throughout the vehicle life. [1] Car interiors, especially carpet, must remain in impeccable condition to uphold a good resale value.Targeting the analysis of causes that affect ageing of non-woven fabric material will form the core study of the literature to follow. The establishment of which shall ascertain some viable solutions to augment quality of the contemporary non-woven automotive carpet.
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