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Powertrain Modelling of a Fuel Cell Three-Wheeler for the Indian Roads

PES University-Abhishek Puthige, Sharanabasappa Patil
  • Technical Paper
  • 2019-28-2513
Published 2019-11-21 by SAE International in United States
The three wheeled vehicles are extremely popular in the Indian subcontinent and are constantly posting a positive growth in sales. Given this trend and their polluting nature they can be noted as sizeable contributors to the air quality issues plaguing the metropolitans. With the nation aiming at eradicating the use of internal combustion engines (ICE) in passenger transportation by the year 2030, there have been attempts to convert ICE three-wheelers to battery electric three-wheelers. However, the battery electric three-wheelers, which are quite commonly used for end-mile connectivity, serve to highlight the demerits of the technology pertaining to their range, charge cycles, power to weight ratio, and efficiency. Hydrogen based fuel cells are gaining traction as a potential alternative to batteries due to their efficient and clean power generation. The present paper aims to develop and recommend an optimized power management strategy along with a driveline model for addressing intra-city connectivity in a typical Indian city. The simulation models, considering a parallel hybrid electric three-wheeler with a Proton Exchange Membrane fuel cell as the prime mover,…
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Equivalent Radiated Power driven optimization for driveline housings using simulation tools to cut-down the project time

VE Commercial Vehicles, Ltd.-Suresh Kumar Kandreegula, Hemant Nishad, Dheeraj Singh, Kunal Kamal
  • Technical Paper
  • 2019-28-2533
Published 2019-11-21 by SAE International in United States
In the field of Automotive industry, being competitive makes you succeed. Industry is moving towards advancement day by day. New technologies to improve fuel efficiency, crash resistance, vehicle noise levels have been trending. At VECV, we have traditionally worked on CAE of driveline housings (clutch housing & transmission housing) based on static, dynamic and transient loadings. Currently, weight optimization technique depends on the structural and dynamic loading conditions, but do not consider acoustic concerns. Powertrain housings are highly prone to vibrations and leads to high level of noise. Noise has been constant issue in the casting components associated to driveline. There have been lot of research going on to reduce the level of noise and vibrations in the vehicle driveline, which ultimately leads to fuel efficiency and ergonomic benefits. Low noise generation can also lead to saving of lot of resources deployed to dampen the noises. In order to capture the acoustic responses of the system and to improve the design based on acoustic responses, a comprehensive analysis of newly developed driveline housings (clutch housing…
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Improved Performance of Electric Vehicles with Supercapacitor

Spel Technologies Private Limited-Rajendrakumar Laxminarayan Sharma
  • Technical Paper
  • 2019-28-2468
Published 2019-11-21 by SAE International in United States
Background: Due to Environmental concern worldwide, Mobility is under pressure to shift gear from fossil fuel to Electric. This is Rebirth of Electric Mobility is with state’s initiative, but it is facing bigger challenges than the 1900s era. Fossil fuel vehicles have already carved the benchmark on ease of range per charge, and time of charge (filling of fossil fuel), which needs to be at least matched by Electric Vehicles. The success of electric vehicles will not only be driven by state policy but also by performance and Economic Viability. While at this introduction level state is trying best to offset cost by way of subsidy/tax-sops offering. So, in clear terms “Performance of Electric Vehicles” need to be addressed and enhanced to put them in main stream in place of fossil fuel vehicles. In last 100 years there has been significant technological development in Motors, and Energy Storage, which is base of Electric mobility. Motors have fared well on technological development front, but energy storage has been struggling to keep pace with this Power hungry…
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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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EV Charging Concept for the Indian Market

Robert Bosch Engineering & Business Solutions, Ltd.-Tarang Garg, Viswanatha Lingala, Prabhakar G
  • Technical Paper
  • 2019-28-2502
Published 2019-11-21 by SAE International in United States
Predominantly the biggest question that haunts the EV Market is the charging infrastructure that should eventually ease the nervousness of the consumers and allowing EV to penetrate the Indian market with changes done within urban areas and highways. There are multitude of options available ranging from onboard charging via home charging point to a Fast DC off board charger that can be used to charge an EV. There are multiple factors that can be used to evaluate the options and their pros / cons. Some of these factors are: • Cost, time to charge, health of battery, charging and discharge rate of the battery, etc… • Convenience and availability of charging point • Ease of operation including payment • Safety and Security • Ambient temperature in which charging is done There are mainly these categories of charging options: • Residential charging based on a home charging point. The charger is mounted on the vehicle (onboard) and the EV cable can be connected to the home plug point. This method of charging could result in heating…
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High Durable PU Metallic Monocoat System for Tractor Sheet Metal Application

Mahindra & Mahindra, Ltd.-Rahul Lalwani, Sudhir Sawant, Yogesh keskar, Nitin Pagar
Mahindra Research Valley-Vinay Kumar
  • Technical Paper
  • 2019-28-2541
Published 2019-11-21 by SAE International in United States
In sheet metal painting for various applications like tractor and automobiles, most attractive coating is metallic paints. It is widely applied using 3 coat 2 bake or 3 coat 1 bake technology. Both options, results in high energy consumption, higher production through put time and lower productivity in manufacturing process. During various brainstorming and sustainability initiatives, paint application process was identified to reduce burden on environment and save energy. Various other industry benchmarking and field performance requirement studies helped to identify critical quality parameters. There was collaboration with supplier to develop monocoat system without compromising any performance and aesthetic properties. This resulted in achieving better productivity, elimination of two paint layers, substantial reduction in volatile organic content, elimination of one baking cycle and energy saving.Metallic mono-coat formulated using strong polyurethane resins and latest technology pre-coated aluminum pigment for achieving metallic effect in finish. With new resin technology, further reduction in baking temperature and energy is possible.
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Potential for Emission Reduction and Fuel Economy with Micro & Mild HEV

AVL List GmbH-Franz Murr, Ernst Winklhofer, Michael Weissbaeck, Gerald Teuschl
  • Technical Paper
  • 2019-28-2504
Published 2019-11-21 by SAE International in United States
The development of modern combustion engines (spark ignition as well as compression ignition) for vehicles compliant with future oriented emission legislation (BS6, Euro VI, China 6) has introduced several technologies for improvement of both fuel efficiency as well as low emissions combustion strategies. Some of these technologies as there are high pressure multiple injection systems or sophisticated exhaust gas after treatment system imply substantial increase in test and calibration time as well as equipment cost.With the introduction of 48V systems for hybridization a cost- efficient enhancement and, partially, an even attractive alternative is now available. An overview will be given on current technologies as well as on implemented test procedures. The focus will be on solutions which have potential for the Indian market, i.e. solutions which can be implemented with moderate application effort for currently available compact and medium size cars. The possibilities of 48V technologies for fuel economy and emission reduction will be discussed. Simultaneously, tools for testing and calibration at power train testbed as well as for on-road application will be presented.Furthermore, it…
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Rapid Prototyping and Implementation of traction motor drive for E- Mobility

Altair Engineering India Pvt Ltd.-Srikanth R, Sreeram Mohan
  • Technical Paper
  • 2019-28-2472
Published 2019-11-21 by SAE International in United States
Objective / Question: Is it possible to extend the envelope of simulation driven design and its advantages to development of complex dynamic systems viz. traction motor drives? The objective that then follows is how to enable OEM/Tier-1s to reduce wastes in the process of traction motor controller design, development, optimization and implementation. Motor control design to validation process is time consuming and tricky! Additionally, the requirement of software knowledge to write code to implement drive engineer's control ideas. The challenges here are - to name a few - algorithm for real time, addressing memory constraints, debugging, comprehending mathematical overflows, portability & BOM cost. These introduces wastes in parameters like time, cost, performance, efficiency and reliability. Methodology: Developing a new traction motor controller for E Mobility takes 18 - 24 months typically. 2 distinct activities take place in a loop. One is the motor drive engineer who has good understanding of the motor, requirement demands on the motor & digital control of the motor and the second is the software engineer who has a good understanding…
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High Rigidity and Light Weight Bumper Material Development in India

Honda Cars India Limited-Manu Sharma
  • Technical Paper
  • 2019-28-2553
Published 2019-11-21 by SAE International in United States
Vehicle weight reduction becomes important at the view point of fuel efficiency improvement and CO2 reduction in India also as well as developed countries.With this background, High tensile and Super high tensile steel application has become increasing.Similarly, weight reduction of big plastic parts like bumper face is one of the most important items, so Honda has developed Thin-wall and light weight bumper face.In the development of light weight bumper, rigidity, impact strength and flowability which are main requirement are contradictory property. It is necessary to develop new material to achieve this technical concern.Moreover, we verified part shape and thickness optimization to achieve part requirement.Established high property material and part manufacturing technology were applied for current CITY firstly, and it has been expanded to other models sequentially to contribute weight reduction for Honda vehicles.In this report, we report the analysis and verification result example of high rigidity and light weight bumper material development in India.
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Experimental Investigation on Performance and Emission Characteristics of a Single Cylinder CRDI Engine Fueled with Diesel-Methanol Blend

Sridhar Sahoo, Chinmay Nayak, Srinibas Tripathy, Dhanajay Srivastava
  • Technical Paper
  • 2019-28-2380
Published 2019-11-21 by SAE International in United States
Diesel engine is widely used for its high thermal efficiency and better fuel efficiency. However, increasing usage of petroleum fuel and environmental degradation motivates to use renewable biofuel as a replacement to conventional diesel. Biofuel produced from non-edible sources can be used as a partial substitute of diesel for the significant growth of fuel economy and reduction of environmental pollution. Methanol can be implemented as a blend fuel in the diesel without affecting engine design. In this paper, we study the effect of diesel-methanol blends and injection parameters in particular, start of injection (SOI) and fuel injection pressure (FIP) on a common rail direct injection (CRDI) diesel engine performance and emission were investigated. Four blends were prepared by mixing diesel with methanol (5%, 10%, 15% and 20% by mass) and adding a certain amount of oleic acid and Iso-butanol to get a stable blend. Experiments were performed at an engine speed and load of 1500 rpm and 15 Nm, respectively. FIP governs air-fuel mixture preparation and fuel atomization which control combustion behavior of the engine,…
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