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Replacing Twin Electric Fan Radiator with Single Fan Radiator

Engine Design & Testing-Tushar Warkhade
Tata Technologies, Ltd.-Aashish Bhargava, Gaurav Soni
  • Technical Paper
  • 2019-28-2381
Published 2019-11-21 by SAE International in United States
Downsizing is one of the crucial activities being performed by every automotive engineering organization. The main aim is to reduce - Weight, CO2 emissions and achieve cost benefit. All this is done without any compromise on performance requirement or rather with optimization of system performance.This paper evaluate one such optimization, where-in radiator assembly with two electric fan is targeted for downsizing for small commercial vehicle application. The present two fan radiator is redesigned with thinner core and use of single fan motor assembly. The performance of the heat exchanger is tested for similar conditions back to back on vehicle and optimized to get the balanced benefit in terms of weight, cooling performance and importantly cost. This all is done without any modification in vehicle interface components except electrical connector for fan. The side members and brackets design is also simplified to achieve maximum weight reduction.Further Cooling system performance of engine is evaluated along with Fuel efficiency; results are compared with present configuration.
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Development of Low Cost Lifesaving System for Automotive Vehicles during Road Accidents

Tata Technologies, Ltd.-Sachin Madhukarrao Pajgade, Aashish Bhargava
  • Technical Paper
  • 2019-28-2460
Published 2019-11-21 by SAE International in United States
Vehicular accidents are life-threatening and result in fatal casualties in developing country such as India. According to estimates, traffic accidents kill more people in India than diseases like Cancer and AIDS. More than 150,000 people are killed every year in traffic accidents in India, which works out to 400 fatalities a day, far higher than developed auto markets like the U.S., which had logged about 40,000 deaths in 2016. The World Health Organization estimates road accidents cost most countries about 3 per cent of their gross domestic product.India being the fastest growing economy will be the world’s third-largest car market after China and the U.S. by 2020, according to automobile researchers.According to research study most of death cause due to not getting help on time to the injured person. Research has proven that if injured person is not found any option of help then they also lose the power to fight such critical situation due to psychological effect. When vehicle met accident, people are not getting on time support, this delay is the major cause…
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Optimization of Bio-Diesel Fuel Filter Size Media and Configuration for Longer Service Interval

Tata Technologies, Ltd.-Gaurav Soni, Aashish Bhargava, Sujit Gavade
  • Technical Paper
  • 2019-28-2391
Published 2019-11-21 by SAE International in United States
Bio diesel is one of the most promising fuel which can not only replace the conventional fuels but also environment friendly in terms of Greenhouse gases emission. Adaptation of Bio diesel comes with reduced maintainability and high maintenance cost. Blends of biodiesel and conventional diesel are most commonly used in automotive diesel engines. Biodiesel is most popular choice as an alternate fuel of fossil diesel due to its easy availability, eco-friendly nature and minimum change in existing diesel engine for retro fitment.In this paper efforts have been taken to optimize the life of Fuel filter for bio diesel application. For improving Fuel filter life, modifications carried out in Fuel filter media, size and configuration. Further, Fuel filter tested on Engine test bed and Vehicle to establish the life of filter in real world usage condition. Testing Results were compared with existing diesel fuel filter.
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Optimization of Compression Ratio for DI Diesel Engines for Better Fuel Economy

Tata Technologies, Ltd.-Sujit Gavade, Aashish Bhargava, Gaurav Soni, Chandrakant Deshmukh
  • Technical Paper
  • 2019-28-2431
Published 2019-11-21 by SAE International in United States
Fuel economy is becoming one of the key parameter as it does not only account for the profitability of commercial vehicle owner but also has impact on environment. Fuel economy gets affected from several parameters of engine such as Peak firing pressure, reduction in parasitic losses, volumetric efficiency and thermal efficiency. Compression ratio is one of key design criteria which affects most of the above mentioned parameters, which not only improve fuel efficiency but also results in improvement of emission levels.This paper evaluates the optimization of Compression ratio and study its effect on Engine performance.The parameters investigated in this paper include combustion bowl volume in Piston and Cylinder head gasket thickness as these are major contributing factors affecting clearance volume and in turn the compression ratio of engine. Based on the calculation results, an optimum Compression Ratio for the engine is selected. Further Engine testing carried out with selected Compression ratios and parameters such as Fuel efficiency, In-cylinder pressure, and Brake thermal efficiency and Ignition delay were compared.
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Development of Low Cost Closed Crankcase Ventilation With Oil Mist Separation System on Light Duty Diesel Engine

Tata Technologies, Ltd.-Vishal Kailas Walhekar, Sujit Gavade, Gaurav Soni, Aashish Bhargava
  • Technical Paper
  • 2019-28-2578
Published 2019-11-21 by SAE International in United States
Currently automotive industry is facing bi-fold challenge of reduction in greenhouse gases emissions as well as low operating cost. On one hand Emission regulations are getting more and more stringent on other hand there is major focus on customer value proposition.In engine emission the blow by gases are one of the source of greenhouse gases from engine. Blow-by gases not only consist of unburnt hydrocarbons but also carry large amount of oil. If oil is not separated from these gases, it will led to major oil consumption and hence increase total operating cost of Vehicle.Considering the above challenges, effort taken to develop a low-cost closed crankcase ventilation with oil mist separation system on diesel engine. For cost-effective solution, two different design and configuration of oil mist separation system developed.Further, engine with two different above said configuration has been tested for blow-by gasses and oil consumption measurement on Engine test bed and vehicle to understand the behavior in real environment. Further results compared for both configuration and further actions proposed.
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Development and Optimization of Variable Flow AC Compressor for Commercial Vehicles to Reduce Parasitic Losses and Improving Efficiency of HVAC System

VE Commercial Vehicles, Ltd.-Ankit Kumar Shukla, Aashish Bhargava, Sachin K S, Rajesh Jain
Published 2018-04-03 by SAE International in United States
In the modern era of commercial vehicle industry, passenger and driver comfort is one of the major parameters that improves vehicle running time which leads to fleet owner’s profitability. Air conditioning system is one such system whose primary function is to provide the required cooling inside the cabin in hot weather conditions. An Air-conditioned truck cabin creates a comfortable environment for the driver which increases his efficiency and reduces fatigue.An AC compressor consumes power directly from the engine affecting fuel economy and vehicle performance. With ever increasing demand for energy efficient systems and thermal comfort in automobiles, AC systems should be able to deliver the required cooling performance with minimum power consumption. Therefore, reducing AC power consumption in vehicles is one of the key challenges faced by climate control engineers. Variable AC compressor is a technology to decrease parasitic losses in an engine resulting in higher energy efficiency.The application of Variable AC compressors in commercial vehicles is new in India. Therefore, the objective of this paper is to study the behavior & performance of a…
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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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Performance Analysis & Optimization of Engine Cooling System by Using Electronically Controlled Thermostat for Improving Thermal Efficiency

VE Commercial Vehicles, Ltd.-Rupesh Bakatwar, Kevin Nesamani, Aashish Bhargava, Rajesh Jain
Published 2018-04-03 by SAE International in United States
The engine coolant temperature influences fuel consumption, power, emissions and mechanical load on the components. The optimization of these variables does not permit a fixed temperature value if there are different speed and load states. The optimization requires a temperature range that corresponds to each operating point. A conventional wax thermostat has a wide temperature control range. The start to open and full open temperature values depend on the mechanical properties of the spring and wax material. Hence, there is no control on the coolant temperature band in real time.This paper deals with the performance analysis & optimization of engine cooling system by using electronically controlled coolant thermostat for improving engine thermal efficiency. To integrate this technology with an existing engine, some design modifications have been made in the thermostat housing mounted on the engine cylinder head and radiator inlet hosepipe. An electronic control unit was developed & programmed in-house to control thermostat variable opening with respect to coolant temperature.The system has been evaluated on a vehicle to analyze the effect of raising engine operating…
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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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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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