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New CEC Gasoline Direct Injection Fuels Test – Comparison of Deposits and Spray Performance from New and Used injectors.

Afton Chemical, Ltd.-Jonathan James Pilbeam
  • Technical Paper
  • 2019-28-2392
To be published on 2019-11-21 by SAE International in United States
The use of deposit control additives in European market gasoline is well documented for maintaining high levels of engine cleanliness and subsequent sustained fuel and emissions performance. Co-ordinating European Council (CEC) industry fuels tests have played a crucial role in helping to drive market relevant, effective and low-cost deposit control additives into European market fuels. Until now, there has not been a Gasoline Direct Injection engine test available to fuel marketers in any market globally. However, a new CEC engine test is currently being developed to address that gap. Based on an in-house VW injector coking test, it shows promise for becoming a useful tool with which to develop and measure the performance of deposit control additives. A key requirement of industry tests should be to replicate issues seen in consumer vehicles, thereby providing a platform for relevant solutions. For this paper, injectors from the new VW injector coking test in a clean and coked state were compared to injectors from vehicles in the market in respect of deposit geometry, elemental composition and injector spray…
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Digital Twins for Prognostic Profiling

Altair Engineering India Pvt Ltd-Painuri Thukaram
Altair Engineering India Pvt , Ltd.-Sreeram Mohan
  • Technical Paper
  • 2019-28-2456
To be published on 2019-11-21 by SAE International in United States
Digital Twins for Prognostic Profiling Authors: Sreeram Mohan*, Painuri Thukaram**, Panduranga Rao*** Objective / Question: Ability to have least failures in products on the field with minimum effort from the manufacturers is a major area of focus driven by Industry 4.0 initiatives. Amidst traditional methods of performing system / subsystem level tests often does not enable the complete coverage of a machine health performance predictions. This paper highlights a workable workflow that could be used as a template while considering system design especially employing Digital Twins that help in mimicking real-life scenarios early in the design cycle to increase product’s reliability as well as tend to near zero defects. Methodology: With currently available disruptive technologies , systems are integrated multi-domain 'mechatronics' systems operating in closed-loop/close-interaction. This poses great challenges to system health monitoring as failure of any component can trigger catastrophic system failures. It may be the reason that component failures, as per some aerospace reports, are found to be major contributing factors to aircraft loss-of-control. Essentially, it is either too expensive or impossible to…
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Development of a Graphical User Interface (GUI) Based Tool for Vehicle Dynamics Evaluation

Mahindra & Mahindra Ltd-Saravanan Muthiah
Mahindra & Mahindra, Ltd.-Divyanshu Joshi
  • Technical Paper
  • 2019-28-2397
To be published on 2019-11-21 by SAE International in United States
Title Development of a Graphical User Interface (GUI) Based Tool for Vehicle Dynamics Evaluation Authors Mr. Shubham Kedia, Dr. Divyanshu Joshi, Dr. Muthiah Saravanan Mahindra Research Valley, Mahindra & Mahindra, Chennai Objective Objective metrics for evaluation of major vehicle dynamics performance attributes i.e. ride, handling and steering are required to compare, validate and optimize dynamic behavior of vehicles. Some of these objective metrics are recommended and defined by ISO and SAE, which involve data processing, statistical analysis and complex mathematical operations on acquired data, through simulations or experimental testing. Due to the complexity of operations and volume of data, evaluation is often time consuming and tedious. Process automation using existing tools such as MS Excel, nCode, Siemens LMS, etc. includes several limitations and challenges, which make it cumbersome to implement. In the current work, a GUI based post-processing tool is developed for automated evaluation of ride, handling and steering performance. Methodology This work is about development of a centralized platform for quantification, visualization and comparison of ride, handling and steering performance metrics from testing and…
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Improved update over-the-air solution through standardization of ‘software/firmware package format and flash jobs’

Elektrobit India-Pavithra Kumaraswamy
  • Technical Paper
  • 2019-28-2435
To be published on 2019-11-21 by SAE International in United States
This paper investigates and proposes the possibilities of standardizing the software/firmware package format and flash jobs in order to provide the possibility of productizing the update-over-the-air solution regarding on-board vehicle components and make use of it in all OEMs with minimum configuration changes and customization. The update-over-the-air solution in the automotive sector is provided by various suppliers and needs to be customized to meet various OEMs requirements. Possible Variants of OEM requirements are: • Variant 1 o Customer Portal + Backend + vehicle on-board components solution from supplier • Variant 2 o Customer Portal + Backend solution from OEM o Vehicle on-board components from supplier • Variant 3 o Backend from OEM o Customer Portal + vehicle on-board components from supplier ODX, VBF, and many other formats from OEMs include software/firmware packages. With variant 1, these different formats are converted into one supplier proprietary format and is saved in backend and understood by the vehicle on-board components for re-programming of target ECUs. With variant 2 and variant 3, these different OEM formats have to be…
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DEVELOPMENT OF A FLEET MANAGEMENT SYSTEM FOR AN OFF-HIGHWAY VEHICLE

Research & Devlopment Institute-JAGANNATHAN VASU
  • Technical Paper
  • 2019-28-2439
To be published on 2019-11-21 by SAE International in United States
DEVELOPMENT OF A FLEET MANAGEMENT SYSTEM FOR AN OFF-HIGHWAY VEHICLE V.Jagannathan 1.a* , B.Jaiganesh 2.b & S.Sudarsanam 3.c Mahindra & Mahindra Limited, Mahindra Research Valley, Mahindra World City, Anjur PO, TN, India Corresponding author Email- V.JAGANNATHAN@mahindra.com Managing an off-highway vehicle fleet during validation is a challenging task. Complexity is acquainted when more than 100 vehicles with different horse power (hp) & with different product configuration working across India and other parts of countries. Traditionally, a tractor validation involves data collection such as usage hours (Hour meter reading on cluster), locations etc. which are recorded in spread sheet and updated to the respective project owners on daily basis through mail communications. A manual recording and consolidation of tractors validation status is prone to error, reiterative work, consumes more resource and effort. Moving towards digitalization, IT enabled system for updating the tractor validation status on daily basis was added with advantage of huge data storage capacity, history data retrieval and data access anytime & anywhere, a step ahead to traditional method but with few limitations of not…
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THE NEED OF PERSONALIZATION AND OPPORTUNITIES IN AUTONOMOUS VEHICELS AND SHARED MOBILITY

General Motors Tech Center India-Suresh Dayakar, Vijayasarathy Subramanian, Keshava Reddy, Vijaykumar Shiramgond
  • Technical Paper
  • 2019-28-2520
To be published on 2019-11-21 by SAE International in United States
Shared mobility and Autonomous shared mobility take major share in Mobility 4.0. Personalization in a shared mobility will play a significant role in customer engagement in Autonomous world. In case of personal vehicle each customer will have their own personal settings in their own vehicle; in case of Autonomous shared mobility or shared mobility, we can satisfy individual customer need only by personalizing the vehicle for each individual user needs. This will give a cognitive feel of personal vehicle in a shared environment. We need technologies in improving vehicle interior and exterior systems and design to address personalization. We will be discussing on feasible opportunities of personalization and with illustrations in Vehicle Interior Cabin Space, Seat comfort, Compartments, Vehicle interior & Exterior Access / Controls. The summary will have design concept that will have personalization solutions satisfying each critical customer integration for all identified zones of vehicle exterior and interior. This approach of Design Thinking of identifying personalization need and enabling integrated design solution will help to improve customer satisfaction and engagement in Autonomous /…
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An IMPC based Parking Assistance System with Interactive Searching Function

FinitronX-Qianyu Ouyang, Xianzhe Jia
  • Technical Paper
  • 2019-01-2614
To be published on 2019-10-22 by SAE International in United States
This paper summarizes progress and outcome from our research projects on IMPC-based parking management system, including parking motion planning and control strategy, as well as a searching strategy for parking spot. To predict future parking parameters, we proposed a practical framework which integrates anticipatory techniques with a model predictive approach that robustly models the stochastic parking environment. The framework is able to take into account the interactions between vehicle subsystems, and can optimize trajectory under complex traffic patterns in real-world scenarios. Adaptive model predictive control is utilized to optimally minimize a cost function regarding performance, energy efficiency and drivability with regard to surrounding vehicle states. Dynamic programming was used to solve the control objective under multiple constraints, which yielded superior performance in comparison with convex programming. An original navigation system was developed for leading user to the parking spot in case of forgetting exact location, which is characterized in that swift location and path are generated by BLE-based sensor fusion. After successful parking action, the system beacons the parking location and transmits data to mobile…
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Tool Condition Monitoring in Face Milling Process Using Decision Tree and Statistical Features of Vibration Signal

B S Abdur Rahman Crescent Institute of Science & Technology-Pradeep Kumar Durairaj, Muralidharan Vaithiyanathan
  • Technical Paper
  • 2019-28-0142
To be published on 2019-10-11 by SAE International in United States
In milling process, the quality of the machined component is highly influenced by the condition of the tool. Hence, monitoring the condition of the tool becomes essential. A suitable mechanism needs to be devised in order to monitor the condition of the tool. To achieve this, condition monitoring of milling tool is taken up for the study. In this work, the condition of the tool is classified as good tool and tool with common faults in face milling process such as flank wear, worn out and breakage of the tool based on machine learning approach using statistical feature and decision tree technique. Vibration signals of the milling tool are obtained during machining of mild steel. Statistical features are extracted from the obtained signal, in which the important features are selected using decision tree. The selected features are given as the input to the same algorithm. The output of the algorithm is utilized for classifying the different conditions of the tool. The experimental results show that the accuracy of decision tree technique is at the acceptable…
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Experimental Study on Tool Wear and Cutting Temperature during Machining of Nimonic C-263 and Waspaloy Based on Taguchi Method and Response Surface Methodology

Sri Sairam Engineering College-Vetri Velmurugan Kannan
Vellore Institute of Technology-Venkatesan Kannan, Devendiran Sundararajan
  • Technical Paper
  • 2019-28-0144
To be published on 2019-10-11 by SAE International in United States
Nickel based materials of Nimonic C-263 and Waspaloy are used nowadays for aerospace applications owing to its superior strength properties that are maintained at a higher temperature. Tool wear and cutting temperature in the vicinity of cutting edge are two essential machinability characteristics for any cutting tool. In this regard, this study is pursued to examine the influence of factors on measuring of tool wear (Vba) and cutting temperature (Ts) during dry machining of two alloys studied experimentally based on Taguchi method and response surface methodology. Taguchi’s L16 orthogonal array is used to design the experiment and a PVD (TiAlN), CVD (TiN/Al2O3/TiCN) coated carbide inserts are used on turning of two alloys. The factor effect on output responses are studied using analysis of variance, empirical models, and responses surface 3D plots. To minimize the response and to convert into one single optimum level, responses surface desirability function approach is applied. The results show that progress of flank wear associated with Waspaloy is faster that of Nimonic C-263 due to high cutting temperature for Waspaloy that…
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Vision Based Surface Roughness Characterization of Flat Surfaces Machined with EDM

BSA Crescent Institute of Science & Technology-Mahashar Ali, Siddhi Jailani, Mangalnath Anandan, Vignesh Pavithran
Vellore Institute of Technology-Murugan Mariappan
  • Technical Paper
  • 2019-28-0148
To be published on 2019-10-11 by SAE International in United States
Surface roughness measurement is an important one in any manufacturing next to dimensions. In this investigation, a vision system and image processing tools were used to develop reliable surface roughness characterization technique for Electrical Discharge Machined surfaces. A CMOS camera with red LED light source were used for capturing images of EDMed surfaces. A separate signal vector generated for all the images from its image pixel intensity matrices. The mean, skewness and kurtosis were obtained from the signal vector. The mean, skewness and kurtosis of the images signal vector correlates very well with the stylus measured hybrid roughness parameters Rda and Rdq. Hence the technique may be preferred for online surface roughness characterization of Electrical Discharge Machined (EDMed) surfaces.