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Physical and Virtual Simulation of Lightweight Brake Drum Design for Heavy Duty Commercial Vehicles Using Alternate Material Technologies

VE Commercial Vehicles Ltd.-Suresh Kumar Kandreegula, Himanshu Deshmukh, Shivdayal Prasad, Sonu Paroche, Ashesh Anil Shah
Published 2018-10-05 by SAE International in United States
Brake drum in commercial vehicles is very important aggregate contributing towards major weight in brake system module. The main function of brake drum is to dissipate kinetic energy of vehicle into thermal energy, as a results in braking operation major load comes on brake drum. Hence this is very critical component for vehicle safety and stability [1].Objective of this paper is to increase the pay load, which is utmost important parameter for commercial vehicle end customers. To achieve the light weighing target, alternate materials such as Spheroidal graphite iron (SGI) has been evaluated for development of brake drum. Many critical parameters in terms of reliability, safety and durability, thickness of hub, wheel loading, heat generation on drum, manufacturing and assembly process are taken into consideration. The sensitivity of these parameters is studied for optimum design, could be chosen complying each other’s values.Digital thermal performance evaluated in house, fine-tuned and verified by correlating with test data available for existing cast iron design and then applied for new design with alternate materials. In two different designs around…
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Design and Development of Hybrid Single Rod Gear Shift Lever (SRGSL) System With Extra Degree of Freedom

VE Commercial Vehicles Ltd.-Naveen Tripathi, Aravally Patel, Hemant Nishad, Suresh Kumar Kandreegula
Published 2018-04-03 by SAE International in United States
Manual Gear shifting mechanism is a customer touch point in vehicle driving conditions and it is a frequently used functional part of the vehicle. Inherent challenges exist to develop a gear shifting system that achieves better comfort shifting gears in manual transmissions, i.e. gear shift levers should be comfortable, efficient and reliable. There are several traditional concepts available for designing a mechanical interface for gear shift system like cable GSL (Gear Shift Linkages), mechanical GSL, engine mounted SRGSL (single rod gear shift linkages), directly transmission mounted GSL. All are having pros and cons over another.A unique attempt is made to provide an efficient single rod type gear actuation system for commercial vehicle where one end is directly mounted on the cowl floor of the bus/Truck and another end is connected to transmission lever. Spherical ball mechanism is used for shifter lever mounting on cowl floor and lower part of this lever is connected to single rod through a yoke type mechanism. This paper is about the design & simulation part of this hybrid type single…
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Background and Technology Approach for Development and Testing of Auto-Tire Inflation System for Reducing Tire Wear in Commercial Vehicle

VE Commercial Vehicles Ltd.-K U Syed Taj Yaser, Sourabh Jadhav, Aashish Bhargava
Published 2018-04-03 by SAE International in United States
The reduction of tire wear in vehicle is one of the major challenges for engineers. Under-inflated tire can cause reduction in tire life along with decrease in driving stability of vehicle. Efforts have been taken to develop a low-cost auto-tire inflation system integrated in vehicle for reduction in tire wear as well as to avoid periodic checks of tire pressure. This paper deals with the technology and design approach required in the development of auto-tire inflation system for commercial vehicle. This system should have the fundamental role of not only monitoring the tire pressure but also inflating the tire to the recommended level of pressure whenever the pressure is reduced below the recommended level.Different approaches have been worked out for integration of system on vehicle with least modification in existing design. For system control, cost effective and innovative method of using two-way solenoid valve, pressure transducer and electronic control unit is employed for monitoring and regulating tire pressure. Innovative sealing system has been used for fail safe and leakage free mechanism. Precautions are also taken care to…
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Development, Performance Analysis and Optimization of Parallel Hydraulic Hybrid System for City Bus Application

VE Commercial Vehicles Ltd.-K U Syed Taj Yaser, Rupesh Bakatwar, Aashish Bhargava, Sanjay Tiwari
Published 2018-04-03 by SAE International in United States
One of the key requisites for a sustained mobility development is to have an efficient public transport system. Fuel efficiency and emission control are extremely important in this respect. By the very nature of city driving, it is obvious that city traffic results in frequent vehicle start and stops; which involves huge waste of vehicle kinetic energy. Every time vehicle moving from idle, needs a bigger input of power and every time the brakes are applied, all energy built up disappears again, wasted in the brake pads as heat.An effort has been taken to recuperate vehicle kinetic energy, hydraulically during braking events and utilize it to assist the vehicle during acceleration. Hydraulic based hybrid vehicle working on the principle of regenerative braking is one of the most fuel-efficient technologies for city application. Parallel hydraulic hybrid vehicle has been developed and optimized for fuel efficiency gain at vehicle level.Objective of this paper is to study behavior, performance and optimization of hydraulic hybrid vehicle in city application. This paper deals with evaluation of simulation, integration, calibration and…
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Manual Gear Shifting Mechanism Integrated with Cabin Tilting Provision by Providing Telescopic Rod Type Arrangement with Cam and Follower Mechanism

VE Commercial Vehicles Ltd.-Naveen Tripathi, Aravally Patel, Suresh Kumar Kandreegula
Published 2018-04-03 by SAE International in United States
In manual driven vehicle, gear change mechanism is a component that is too often taken granted but it is one of the most important feature of the vehicle. Customer touches, feels the entire vehicle through gear shift mechanism hence it must be quick and smooth in action, efficient and totally reliable. In cab over engine type truck configuration, the mechanical single rod is preferable and best efficient option for gear shift mechanism. In conventional single rod design, one end of gear shifting linkage is mounted on the engine through bracket and the lever comes inside from the cabin, beside the driver seat for changing the gears. Another end of this linkage is connected to vehicle transmission shift lever. In this conventional design, gear shift lever is having huge induced vibration, which is irritating and frustrating in nature.And during the cabin tilting at its axis, a cut out is required on cabin floor which allows cab tilting when GSL is mounted on engine. Sealing this cut out from engine heat, hot air and noise is a…
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Design and Development of Active On-Board Alcohol Detection System with Safety Features for Commercial Vehicles

VE Commercial Vehicles Ltd.-Rupesh Bakatwar, K U Syed Taj Yaser, Sourabh Jadhav, Aashish Bhargava
Published 2018-04-03 by SAE International in United States
Drink & drive has caused the increased rate of commercial vehicle accidents in the world due to the slow response to judgment and reasoning. According to research study 70% accidents are happened due to drunk & drive, it causes loss of human life and economic damage. Research has proven that drunk drivers exhibit aggressive driving behavior and apply more force during braking. While public health awareness and legal restrictions can assist in educating and discouraging people from drunk & drive, a more fool-proof method is not available in the market for commercial vehicles. Currently, a low cost, fail-safe onboard alcohol detection, and vehicle safety system is the need of the hour.This paper deals with the design & development of a low cost active onboard breath alcohol detection system and it’s on vehicle validation. Further, it explains the type of alcohol detection sensor used, controller design, logic programming and system packaging. An accurate, precise and contactless alcohol detection system and advanced safety features are the key highlights.The system has been validated on the vehicle, to check…
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Innovative Approach of Wedge Washer to Avoid Bolt Loosening in Automotive Applications

SAE International Journal of Passenger Cars - Mechanical Systems

VE Commercial Vehicles Ltd.-Suresh Kumar Kandreegula, Rahul Jain, Shivdayal Prasad, Rahul Machiya, Avinash Mandyam
  • Journal Article
  • 06-11-01-0004
Published 2017-10-08 by SAE International in United States
Automotive vehicle includes various systems like engine, transmission, exhaust, air intake, cooling and many more systems. No doubt the performance of individual system depends upon their core design. But for performance, the system needs to be fastened properly. In automotive, most of the joints used fasteners which helps in serviceability of the components. There are more than thousands of fasteners used in the vehicle. At various locations, we found issue of bolt loosening and because of this design intent performance has not met by the system. During product development of ECS (Engine cooling system), various issues reported to loosening the bolt. The pre-mature failure of bolt loosening, increases the interest in young engineers for understanding the behavior of fastener in vehicle running conditions. This paper focuses on the design of wedge shape of washer to avoid bolt loosening. Further, the paper is reinforced with FEA simulation for understanding the behavior of the bolt loosening. The joint in ECS is tested experimentally and FE simulated using simulation tools with various methods under different vibration conditions like…
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FEM based Approach for Design and Development of Exhaust System Flex Connector and Experimentally Validated

VE Commercial Vehicles Ltd.-Suresh Kumar Kandreegula, Sayak Mukherjee, Rahul Jain, Shivdayal Prasad, Kamal Rohilla
Published 2017-03-28 by SAE International in United States
Flex Connectors are intended for mitigating the relative movement of exhaust system components along the axis of the system arising from the thermal expansion due to intermittent engine operation. Flex connectors must not be installed in locations, where they will be subjected to destructive vibration. Hence, the stiffness of the flex connector plays an important role, while designing or selecting the right design.It consists of a multi-ply bellows combined with an inside and an outside steel braid. The liner is included to reduce the temperature of the bellows and improve flow conditions. The braid is included for mechanical protection and to limit the possible extension of the joint. It has only axial translational motion.Instead of conventional approach, Finite Element Method has been adopted to align the project time plan (design and development time), to predict the static and dynamic stress levels along with the vertical, lateral and torsional frequencies for defining the design parameters (stiffness) of the flex connector suitable for the operating environment. Then, this flex connector has been tested under VECV standard durability…
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Experimental Study and Design to Overcome the Problem of Flickering Issues in Electrical Components in Automotive Vehicles

VE Commercial Vehicles Ltd.-Gaurav Gupta, Ujjwal Modi
Published 2017-03-28 by SAE International in United States
Flickering problems in automotive vehicles have been observed from long time. After assessing numerous vehicles it was observed that whenever the hazard lights in a vehicle are activated, it leads to flickering problems in lights/small electrical components. This paper is to provide the solution for flickering snags in electrical components in a vehicle. The lights that are analyzed to be flickering/wavering are generally small loads such as LEDs in the bus roof area, small parking lamps, LEDs used in instrument clusters, cabin lamps, etc. The flickering in lights can turn out to be very unappealing at certain times. This absurd behavior can lead to extreme discomfort to the passengers and can also be a source of major distraction to the driver. This study presents the design & development for a vehicle platform & implementation that assesses the problem. Because of abrupt behavior of flasher circuits, voltage surges are observed, leading to flickering problems. This prevalent problem can be solved by adopting a streamlined process in the architecture by proper load distribution, appropriate grounding, filter circuits,…
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Design and Optimization of Web Fillets for Commercial Vehicle Crankshaft for Improving SCF and Theoretically Correlated

VE Commercial Vehicles Ltd.-Suresh Kumar Kandreegula, Sayak Mukherjee, Sonu Paroche, Diwakar Ayyar, Umashanker Gupta
Published 2016-04-05 by SAE International in United States
Crankshaft is one of the critical components of an engine (5C: cylinder head, connecting rod, crankshaft, camshaft and cylinder block). It is subjected to repetitive and dynamic loads due to cyclic operation of an engine and inertia forces. Due to uneven mass distribution, failure zones occur near fillets and holes in journal locations during operation of the engine. Hence, this topic was chosen because of increasing interest in higher payloads, lower weight, higher efficiency and shorter load cycles in crankshaft equipment.Calculation of Crankshaft strength consists initially in determining the nominal alternating bending and nominal alternating torsional stresses, which multiplied by the appropriate SCF (Stress Concentration Factor), result in an equivalent alternating stress. This equivalent alternating stress is then compared with the fatigue strength of the selected crankshaft material. This comparison will show whether or not the crankshaft concerned is dimensioned adequately. Hence, SCF is main focus point. The present study emphasizes on a CAE based approach for prediction of SCF for crankshaft web fillets. Using FE Solver (Optistruct), the dimensions and shape of the web…
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