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Design, Simulation and Validation of Front End Auxiliary Drive (FEAD) Mounting Bracket for Electric Powertrain Application

VE Commercial Vehicles Ltd-Kamal Rohilla, Suresh Kumar Kandreegula, Saurabh Agrawal, Jasvir Bisht, Pungaraj Muthaiah
Published 2019-01-09 by SAE International in United States
The main driving force behind recent innovations in automotive sector is the need to decrease the dependability on fossil fuels and move towards alternative sources for energy. While there is still substantial scope for improvement in conventional diesel and petrol engine based powertrains, the inherent dependency on limited and rapidly depleting carbon based fuels make their long term usage impractical highlighting the need for alternative non-conventional powertrain setups.In the recent past, electric powertrains have come out as favorable alternative as they are extremely flexible in adopting to scenarios where energy for use might be drawn from multiple sources such as solar power, hydroelectric, nuclear reaction, etc. The advantages can further be magnified by adopting the electric power based powertrains in mass transportation application such as bus application. However, the adoption of electric power based powertrains requires a complete redesign of powertrain mounting architecture.This study is specifically focused on redesigning the Front End Accessory Drive (FEAD) mounting bracket for bus application. The new design will also include the provision for the mounting of prime mover (electric…
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Simulation and Validation of Propeller Shaft Mounting Brackets for Heavy Duty Commercial Vehicles

VE Commercial Vehicles Ltd-Suresh Kumar Kandreegula, Kamal Rohilla, Naveen Sukumar, Kunal Kamal
Published 2017-07-10 by SAE International in United States
A propeller shaft is a mechanical component of drive train that connects transmission to drive wheels/axle with the goal to transfer rotation and torque. It is used when the direct connection between transmission and drive axle is not possible due to large distance between their respective assigned design spaces. In commercial vehicles especially in heavy duty (GVW/GCW>15 tons) a single piece propeller shaft is seldom used due to its inherent disadvantages and therefore, most if not all, of the setups consists of multiple pieces of propeller shaft which are directly mounted on to frame cross members with the help of mounting brackets. As such the mounting bracket assembly undergoes various dynamic and static loading conditions and should be able to withstand these loads.This paper will focus on the FEA analysis of propeller shaft mounting assembly system. Furthermore, these results will be correlated with physical tests results collected from test rig and physical vehicle testing. The design of mounting system is of high importance in commercial vehicle sector as the failure of mounting assembly will result…
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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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Design & Development of Single Rod Gear Shift Lever (SRGSL) for HD Commercial Vehicles with Experimental Correlation

VE Commercial Vehicles Ltd-Suresh Kumar Kandreegula, Kamal Rohilla, Gaurav Paliwal, Naveen Sukumar, Naveen Pratap Tripathi
Published 2016-09-27 by SAE International in United States
Three on the tree, four on the floor. The gear change mechanism is a component that is too often taken for granted but it is one of the more important features of the vehicle. It must be quick and smooth in action, efficient and totally reliable. Modern driving conditions demand that the driver makes frequent gear changes and a mechanism that is temperamental or inaccurate can be both frustrating and dangerous as well as physically tiring. The gear changing mechanism starts, quite obviously, with the gear lever.Most stem from the fact that a gear lever must move in two planes, forward and back and then from side to side to move across the gear "gate". A good many drivers think of gear changing as one simple action. This is more a tribute to the design of gear changing mechanisms than a reality. There are multiple gear selector mechanisms that are available for use in commercial vehicle industry. The selection of the most favorable mechanism has historically relied on the application and packaging constraints. However, driver…
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