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Engine mount design & failure analysis in commercial vehicle and a correlation between virtual & physical validation.

VE Commercial Vehicles Ltd.-Mahendra Parwal
VE Commercial Vehicles, Ltd.-Arushi Dev
  • Technical Paper
  • 2020-01-0491
To be published on 2020-04-14 by SAE International in United States
Vehicle life and performance is affected by many factors when in use. The most influential being the vibrations generated especially when the vehicle is in motion. These vibrations are directly experienced by the driver, whose performance goes down, if under continuous influence of these vibrations. This increases the fatigue and greatly reduces the return on investment done by the customer. There are two major sources of vibrations, the engine and the road on which the vehicle moves. To prevent such issues engine mounts are used in vehicles, which may seem simple but perform a critical role, of providing comfort to the driver. Therefore it becomes important that thoroughly designed and examined mounts are being used in the vehicle. This paper focuses on the parameters and methodology to be followed for design and validation of an engine mount used in heavy duty vehicles. Case study has been presented to show the failure cases in an engine mount, especially the separation of rubber and metal bonding. Importance of surface pre-treatments to have better bonding has been discussed…
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Optimum positioning of FIP drive system for Type-II BSVI engine based on coupled 1d “Valve-train – Chain drive” Dynamic analysis

VE Commercial Vehicles, Ltd.-Kaarthic Kaundabalaraman, Hemantkumar Rathi, Jasvir Singh Bisht
  • Technical Paper
  • 2020-01-1020
To be published on 2020-04-14 by SAE International in United States
The automotive industry is gearing up to meet the accelerated emission compliance changes posed by the government. This transition to eco-friendly system would also necessitate an automotive engineer to retain the engine packaging as compact and simple as possible. The packaging layout considered should not be at the expense of deteriorating engine performance. The work started with concept level layout development, with the aim of having simplified system with minimum number of components. The engine on which the work was carried out was 4cylinder 3Liter with OHC configuration A number of layouts were developed which included gear type, belt drive and integrated shaft arrangement for driving FIP. Each of these concepts were brainstormed with cons and pros, based on which two concepts were initially proposed for driving FIP system (i) Front Driven FIP (ii) Rear Driven FIP. The difference between the two layouts was that in the latter case the FIP system was directly driven through Exhaust Camshaft with gear type arrangement. For the above two proposed layouts, dynamic evaluation was done up-to Max intermittent…
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Predication & Correlation of Bearing Preload With Rotational Torque In Wheel End Bearing System

VE Commercial Vehicles, Ltd.-Suchit Sharma, Prasad S. Warwandkar
  • Technical Paper
  • 2020-01-0951
To be published on 2020-04-14 by SAE International in United States
Wheel end bearing is one of the critical components of the vehicle as it shares the loads & wheels rotate on it.In wheel end ,taper roller bearings are used .This would help to withstand both vertical & lateral loads imparted during cornering. Also taper roller bearings are used in pair of two so that overall impact of lateral forces during straight running would be nullified. In wheel end bearing systems, 02 bearings are kept at distance w.r.t to each other based on position of load line & would share the total portion of load accordingly. Also life of bearings is dependent on whether the bearings are packaged & operating in play or preload. This paper focuses on various aspects of bearings life & how it vary with respect to Play & Preload. Also a methodology is developed to measure the overall preload of bearing system. Two different bearing systems one with distance piece & second without distance piece is considered. Stiffness of bearings & distance piece are measured out at different loads. Considering these stiffness,…
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Design and Optimization of a Muffler integrated with an Adaptive Quarter Wave Tube for Noise Reduction in Commercial Vehicles

VE Commercial Vehicles, Ltd.-Arun Cherkkil, Ajay Rathor
  • Technical Paper
  • 2020-01-0507
To be published on 2020-04-14 by SAE International in United States
With rising concerns on internal combustion engine noise levels in commercial vehicles, it is necessary to attenuate noises present in specific frequency bands. This can be achieved with the implementation of a quarter wave tube on the present exhaust system. Historically such passive attenuators have been efficient only at specific engine speeds and exhaust gas temperatures. A new exhaust flow actuated adaptive quarter wave tube design is proposed here which can give significant noise attenuation at various engine operating conditions. The proposed design eliminates the requirement of complex electronic actuating mechanisms for the adaptive quarter wave tubes and replaces the same by perforated diaphragms and spring loaded trap door mechanisms, which are more robust and effective. The module can be integrated with the turbo S-flow muffler which is installed on most of the commercial vehicles. A design is conceptualized and developed using CAD tools. The performances for various combinations of quarter wave tube and muffler lengths are compared using Finite Element Analysis. A comparative study on the transmission losses achieved by the current muffler design…
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Piston Bowl Design Optimization to Improve Low Load Torque in BS-VI Diesel Engine based on Multi-dimensional Combustion Simulation

VE Commercial Vehicles, Ltd.-Anish Appukuttan, Jasvir Bisht, Kaarthic Kaundabalaraman, Hemantkumar Rathi
  • Technical Paper
  • 2020-01-0241
To be published on 2020-04-14 by SAE International in United States
In cylinder combustion and emission characteristics are dependent on piston bowl geometry design. Properties like local AF ratio inside the cylinder, in-cylinder fuel air mixing and flame front movement are influenced by piston bowl shape and design. These properties in turns affect the combustion behaviour and the power developed by the diesel engine. In this study piston bowl geometry optimization of a LMD diesel engine is carried out to improve the torque and BSFC output at low to rated operating zones. The optimized bowl geometry is also incorporated in the engine and validated on the test bed. In this work, commercially available CFD code AVL FIRE is used for combustion simulation and bowl geometry optimization. The validation of in-cylinder combustion simulation of a 2L Turbocharged LMD BS-VI diesel engine with base piston bowl geometry is carried out with the available test data. The validation of combustion simulation is performed for four engine operating speed points covering rated torque to rated power operating condition. Four key piston bowl geometry parameters were selected for the optimization study…
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Height Adjustment in School Bus Seat to Improve Comfort of Children with Different Age Group

VE Commercial Vehicles Ltd.-Sujit Banginwar
VE Commercial Vehicles, Ltd.-Ravi Joshi
  • Technical Paper
  • 2020-01-0871
To be published on 2020-04-14 by SAE International in United States
Seats are one of the critical component of School Bus for children comfort & safety. Seat Foam thickness, its shape, Cushion width & seat height will play a vital role in comfort. Fatigue is the most common cause due to uncomfortable seating and its due to only one type of seat available in school bus to accommodate different height children. Here different height means, a school has children from class nursery to Senior secondary. Fatigue will cause impact on child health & there overall development. The topic was chosen because of increasing interest in children comfort & safety in school buses. The Present method is making one standard seat with cushion height from bus floor is 450mm. In this case, its generally suitable for children height of 4.5 feet to 5.5 feet. It was found that children range of height from 3 feet to 4feet, it is very difficult for them climb on the seat. A unique arrangement has been design in seats, which will allow flexibility to adjust height of the seat for children…
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Flexible Anti-Vibration Stability Cab Mount System for Commercial Vehicles

VE Commercial Vehicles, Ltd.-Krishna Achanta, Bhuvaneshwar Sharma, Subrat Bhanja, Narendra Behera
  • Technical Paper
  • 2020-01-1087
To be published on 2020-04-14 by SAE International in United States
Present day truck cab suspension comprises fully floating linkage type cab suspension to facilitate ride comfort. Fully floating cab has certain limitations in terms of stability of cab in dynamic articulations during vehicle running especially in off-road terrain applications. Presence on linkages leads to more wear and tear of joints and bushes which will in turn provide detrimental effect on vibration levels of cab that affects ride comfort and of cab for occupants. There is a dire need to develop a system that provides improvement in lateral and vertical stability of cab without compromising ride comfort of occupants. Durability of the product also to be met till life of vehicle. Anti-Vibration Stability Cab Mount is a unsymmetrical mount designed by compounding of elastomeric(rubber) metal bonded outer sleeves sandwiched between multistage inner mount bonded on aluminum casing. Cabin front supports are hinged to mount along with housing providing proper alignment to cab after assembly. This mount is assembled under pre-compression to felicitate sufficient stiffness in roll, pitch and yaw motions of cab during dynamic motions. Polymer…
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Ride-Comfort Analysis for Commercial Truck Using MATLAB Simulink

VE Commercial Vehicles, Ltd.-Subrat Bhanja, Krishna Achanta, Pranay Jain, Sumit Bharti
ARAI Academy-Sarnab Debnath
  • Technical Paper
  • 2019-28-2428
Published 2019-11-21 by SAE International in United States
Ride Comfort forms a core design aspect for suspension and is to be considered as primary requirement for vehicle performance in terms of drivability and uptime of passenger. Maintaining a balance between ride comfort and handling poses a major challenge to finalize the suspension specifications. The objective of this project it to perform ride- comfort analysis for a commercial truck using MATLAB Simulink. First, benchmarking was carried out on a 4x2 commercial truck and the physical parameters were obtained. Further, a mathematical model is developed using MATLAB Simulink R2015a and acceleration- time data is collected. An experimentation was carried out on the truck at speeds of 20 kmph, 30 kmph, 40 kmph and 50 kmph over a single hump to obtain actual acceleration time domain data. The model is then correlated with actual test over a single hump. This is followed by running the vehicle on Class A, B & C road profiles to account for random vibrations. Similarly, a simulation is done on MATLAB Simulink and a correlation is established between simulated and actual…
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Model Based Design of Chassis-Frame with MATLAB

VE Commercial Vehicles, Ltd.-Rishabh Singh Parihar, Gaurav Sharma, Nitinkumar prabhakar Patil, Yogendra Aniya
  • Technical Paper
  • 2019-28-2429
Published 2019-11-21 by SAE International in United States
In the current commercial vehicles market, ride-comfort and handling are crucial parameters for the customer and end user. There are various aspects which determine the vehicle behavior. One of aspects is the structural rigidity of the vehicle, which has its own effect on vehicle dynamics. To meet the required stiffness of the main structural component of the vehicle i.e. chassis frame, FEA analysis has to be done in current methodology. The number of iterations have to be done to build an appropriate model with low weight, which can meet the design requirements. At first, conceptual design mock-up unit is to be developed then FEA (CAE) analysis to be done on it. If any design criteria are not met, then this cycle repeats again until it fulfils the required stiffness.Today, the direct stiffness procedure is the basic principle of almost every FEA software package. In this paper, computer code based on MATLAB software is provided and presented for the analysis of the chassis frame using the direct stiffness method. The code, models a structure of the…
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An analysis of the Fuel Cell Pack with Different Drive Cycles

VE Commercial Vehicles, Ltd.-C Venkatesh Chandrasekar, L R Amruth Kumar
  • Technical Paper
  • 2019-28-2510
Published 2019-11-21 by SAE International in United States
In the view of an eco-friendly environmental future, the major automotive manufacturers are making a move towards electric mobility. The electric vehicle helps to achieve Zero-emission. However, there are some limitations too. The zero-emission Battery electric vehicle (BEV) can provide a limited range only; the market penetration is getting difficult because of an energy storage capability. The addition of an electric vehicle with a fuel cell unit and a hydrogen supply unit can increase the range and the energy capacity of the system. Fuel cell electric vehicle (FCEV) system is faster to refill compared to plug-in Battery electric vehicle (BEV).This study deals with a behavioral analysis of Polymer Electrolyte Membrane (PEM) Fuel cell; with different drive cycles. In this, a fuel cell model developed and simulated in the SIMULINK environment with different drive cycle and results were obtained. The fuel cell controls also were analyzed for the city start/stop cycle.The results obtained from the different drive cycles simulations were analyzed and discussed in this paper. Also, the fuel cell system behavioral analysis experimented on the…
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