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To establish the correlation in between Computer Aided Engineering & physical testing of automotive parts returnable case (Stacktainer).

International Centre For Automotive Tech.-Ashish Singh
  • Technical Paper
  • 2019-28-2569
To be published on 2019-11-21 by SAE International in United States
Automotive returnable cases (Stacktainers) are being used to transport the automotive parts through surface & seaways. No automotive manufacturer wants to spend money on woods, paper & cardboard again and again, it`s better to pay once for robust & reusable cases. these provide better protection to parts from its manufacturing to assembly line of vehicle. While transporting, any kind of crack or failure of returnable cases may lead to loss of money, human & time. To ensure the safety, these pallets have to be validated for vibrations coming from surface irregularities, sea waves & load due to stacking of cases one above other. The objective of this study is to establish a correlation in between the physical testing & simulation in Computer added Engineering (CAE) of automotive returnable case (Stacktainers). There are different types of tests considered to validate the returnable case, rough road evaluation, Multi-axial Vibration & strength evaluation. After conducting the physical test & CAE simulation, a correlation & confidence level up to 90% is established.

Occupant Controlled Ventilation

Mahindra & Mahindra, Ltd.-Priyanka Marudhavanan
  • Technical Paper
  • 2019-28-2461
To be published on 2019-11-21 by SAE International in United States
Keywords-Coolant,Ventilation Research and/or Engineering Questions/Objective: Number of Occupants is the major parameter when we consider Air Conditioning System. The number of person who stays in the room may vary in the same way the person who travels in the automobile also vary throughout the distance. This is more prevalent in transportation system like bus, train and where lot of people will travel together and where dropping station in the vehicle is too frequent.In this type,operating A.C has to be varied Methodology: . Instead the number count in the vehicle will be monitored from time to time. Based on the number of count, the cabin has to be cooled or heated and accordingly corresponding power has to be drawn by the compressor from the engine. This human count can be detected based on the number of CO2 sensor located in the cabin. the amount of fresh air that should be added to a cabin can be controlled by a carbon dioxide level transmitter. When CO2 levels go up, fresh air is added until the CO2 levels…

Load distribution optimization of seatbelt against ECEr-16 using validated finite element approach

anshul satija-Anshul Satija
  • Technical Paper
  • 2019-28-2575
To be published on 2019-11-21 by SAE International in United States
The seat belt system is one of most imperative component of the safety instrument family in a vehicle. The main purpose of seat belt is to minimize the injuries by preventing the occupant from impacting hard interior parts of the vehicle and also the passenger from being thrown-out from the vehicle in case of rollover accidents. The standard three-point belts, mounted to the vehicle in three places, namely anchor, D ring and buckle. The position of D ring is very important to distribute the impact load evenly to the occupants. Very high load in any of these locations could cause breakage of the mountings and also concentrated loading on the occupant chest of pelvis. This study mainly focuses on the seatbelt assembly performance improvement against ECE-R16 sled test. The sled test was carried out first using 28g peak acceleration pulse and measurement of forces at shoulder and anchor position was measured using the load cell. FE (Finite Element) model of the complete seatbelt assemble was developed including buckle, retractor and anchor plate. The simulation was…


Mahindra & Mahindra Ltd-Karthik Govindaraj, K V Balaji, Murukesan Vimalathithan, Gandhi Samir, Ladhe Rajesh
  • Technical Paper
  • 2019-28-2562
To be published on 2019-11-21 by SAE International in United States
In this paper, mold in color diamond white ASA material has been explored for front bumper grill, fender arch extension and hinge cover applications. Other than aesthetic requirements, these parts have precise fitment requirement under sun load condition in real world usage profile. Structural durability of the design was validated by virtual engineering. Part design and material combinations with better tooling design iterations were analysed by using mold flow analysis. Complete product performances were validated for predefined key test metrics such as structural durability, thermal aging, cold impact, scratch resistance, and weathering criteria. This part met required specification. This mold in color ASA material-based parts has various benefits such as environmentally friendly manufacturing by eliminating environmental issues of coating, easily recycled, and faster part production because intended color achieved in one step during molding. Also, it lowers overall production energy footprint, less scrap with no secondary painting, and lower final part cost by eliminating secondary operations.


General Motors Technical Center India-Vijayasarathy Subramanian, Anandakumar Marappan, Biju Kumar, Masani Sivakrishna
  • Technical Paper
  • 2019-28-2525
To be published on 2019-11-21 by SAE International in United States
Shared Mobility is changing the trends in Automotive Industry and its one of the Disruptions. The current vehicle customer usage and life of components are designed majorly for personal vehicle and with factors that comprehend usage of shared vehicles. The usage pattern for customer differ between personal vehicle, shared vehicle & Taxi. In the era of Autonomous and Shared mobility systems, the customer usage and expectation is high. The vehicle needs systems that will control customer interactions (Self-Expressive) & fix the issues on their own (Self-Healing). These two systems / methods will help in increasing customer satisfaction and life of the vehicle. We will be focusing on vehicle Closure hardware & mechanisms and look for opportunities to improve product life and customer experience in ride share and shared mobility vehicles by enabling integrated designs, which will Self-Express & Self-Heal. Vehicle closures having direct human interfaces with components like closures, handle & other hardware's will be tracked for their performance parameters and usage pattern. The performance parameters will be tracked for every customer and mapped to…

CNG injector performance analysis against variation of physical and electrical parameters: An alternate fuel approach

Noida Inst. Of Engineering Tech.-Udit Kaul
  • Technical Paper
  • 2019-28-2389
To be published on 2019-11-21 by SAE International in United States
Authors: Udit Kaul, Mahendarpal and Madhusudan Joshi Organization: International Centre for Automotive Technology, Manesar Introduction: In this paper, a study concerning multi-point CNG injectors (MPCI) or commonly known as injector rail would be presented. Here we would make a detailed analysis regarding the performance of MPCIs due to variation in physical and electrical parameters. In this case multiple MPCIs would be considered and there electrical and dimension parameters would be compared with respect to their performance. The performance comparison would be done based on the common compliance standard under standard laboratory conditions. We would also like to propose the optimal combination of electrical and dimension parameters for better performance. The variables to be considered for the proposed study are: injector valve open/shut timing, injector dimension, voltage levels, solenoid types etc. Key words : multi-point CNG injectors, injector valve, solenoid

Development of high power density diesel engine for constant speed application

TMTL-Rakesh K
  • Technical Paper
  • 2019-28-2566
To be published on 2019-11-21 by SAE International in United States
Engine up gradation for higher power rating involves challenges that require hardware changes which not only increase cost but also demand higher space. This paper focuses on the up gradation of a 4 cylinder 4.9l CRDi engine from 24.03 kW/L to 30.75 kW/L by adjustment of various parameters to meet both emission and performance targets. Various challenges like higher exhaust temperature, increased peak firing pressure etc. were met using the proper calibration strategy. To meet SFC targets and keep peak firing pressures, exhaust temperatures within desired limits, different operating points for EGR, main injection timing, rail pressure have been optimized. The operating points for optimization were determined by conducting various drive trials on different type of load conditions in test bench. Calibration strategy involved the safe limits of NOx, soot, CO emissions, fuel consumption.pfp, and exhaust temperature. By using the same hardware we are thus able to achieve higher power rating for same engine and also meet CPCB 2 emission norms comfortably.

Optimization of An EV Controller Design For A Three Wheeler BOVs - EMC Approach

International Centre For Automotive Tech.-Nikhil Grover
  • Technical Paper
  • 2019-28-2474
To be published on 2019-11-21 by SAE International in United States
Introduction: The advent of electric mobility is changing the conventional mobility techniques and their application in automobiles across all segments. Three wheeler Battery Operated Vehicles (BoVs) are a special category of electric vehicles (EVs) as far as EMC compliance is concerned. The problem mainly lies with the open body design and cost cutting measures being exercised by the manufactures which makes Electromagnetic compatibility (EMC) compliance challenging. Objective: Though it is sometimes possible to resolve EMC malfunctions related to motor power cable, cables & wiring harness etc. using external techniques post design stage, but controller being a closed and typical element makes it difficult to improve against EMC malfunctions using external techniques. This paper would concentrate on the controller design parameters and improvement of the same in terms of Electromagnetic compatibility (EMC) and performance efficiency at the design stage itself. Methodology: This study would concentrate on designing of motor controller for three wheeler EVs, improving and optimizing the EMI/EMC aspects of the design and its performance with the following aspects in mind: 1. Selection of critical…

Computer Vision and Monocular Camera System for Cost Efficient Autonomous Vehicle

Ashish K. Pidurkar
  • Technical Paper
  • 2019-28-2518
To be published on 2019-11-21 by SAE International in United States
The positioning of the sensors on vehicle will play a critical role in autonomous cars, it improves the performance of overall system by all the means and make it cost effective by reducing a total system cost. This paper contributes in deciding the best position of camera location on the vehicle with complete geometric and system calculation based on the maximum speed of vehicle, hardware processing speed, camera parameters, actuation and control time, Blind spot detections, maximum Height of objects, etc. The paper presents the technologies and datasets used for lane lines and other object detections. It focusses on newly proposed technique and its calculations to decide the best location of monocular camera sensor on the vehicle by considering all other parameters of autonomous vehicle system. It enhances the performance of overall system as well as reduces the system cost which takes us closer to the futuristic dream of efficient and low-cost autonomous vehicle.

Steering and Handling Performance Optimization Through Correlation of Objective - Subjective Parameters and Multi-body Dynamics Simulation

Mahindra & Mahindra Ltd-Deva Ranjit Kumar rajarajan, Vinothprakash rajasekar, Shraddhesh rasal, Baskar Anthonysamy, Visweswara LENKA.
  • Technical Paper
  • 2019-28-2412
To be published on 2019-11-21 by SAE International in United States
RESEARCH OBJECTIVE: Automobile Industry has driven through the ages with continuous development with innovative technologies and frugal engineering. Expectation of customer is also increasing through the generations. To meet the customer demand for performance and be best in market, OEM needs to deliver best performance of vehicle with cost effective and short development process. Steering and Handling of vehicle is one of major customer touchpoints and needs to be tuned to achieve various conflicting requirements. The objective of this research is to optimize the steering and handling using correlation between three major methods of evaluation. METHODOLOGY: Methodology for optimization of steering and handling performance using correlation between subjective evaluation, objective measurement and multi-body-dynamic simulation is presented. In first phase, correlation of objective steering & handling parameters is established with subjective evaluation, based on evaluation of various vehicles in SUV segment. The objective parameters which give highest correlation are selected for target setting process. In second phase, Multi-body dynamic(MBD) model is developed in MSC ADAMS and is validated through physical kinematic and compliance data. Components such…