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Frame structure durability development methodology for various design phases

FCA Engineereing India Pvt Ltd-Venkatesh Naik
FCA Engineering India Pvt Ltd-RAGHAVENDRA BYALI
  • Technical Paper
  • 2020-01-0196
To be published on 2020-04-14 by SAE International in United States
It is a challenging task to find an optimal design concept for a truck frame structure given the complexity of loading conditions, vehicle configurations, packaging and other requirements. In addition, there is a great emphasis on light weight frame design to meet stringent emission standards. This paper provides a framework for fast and efficient development of a frame structure through various design phases, keeping durability in perspective while utilizing various weight reduction techniques. In this approach frame weight and stiffness are optimized to meet strength and durability performance requirements. Fast evaluation of different frame configurations during the concept phase (I) was made possible by using DFSS (Design For Six Sigma) based system synthesis techniques. This resulted in a very efficient frame ladder concept selection process. Frame gauge optimization during the subsequent development phase (II) utilizing a newly developed damage based approach greatly reduced the number of design iterations relative to a typical stress based approach. In the light weighting phase(III) that followed, a method was established to effectively locate and optimize lightening holes using fatigue…
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New Seven Speed DCT transaxle and effect of angular positioning of shaft in layout.

Satyam Venture Engineering Services-Muralidhar Bhat
  • Technical Paper
  • 2020-01-0429
To be published on 2020-04-14 by SAE International in United States
This paper presents about new concept developed on 7 speed DCT transaxle for transverse application and a torque capacity of 200 Nm to 360 Nm. How current 6 speed DCT can modified to 7 speed with packaging benefit is discussed. In this paper, discussions are focused about torque carrying parts of transaxle only. Here only single countershaft is used giving lot of packaging advantage and at first glance layout looks like four speed layout, but it is compact layout. Further in this paper effect of angular position of shaft in layout is discussed.. Position of shafts in transaxle layout effects the stress, bending moment and displacement induced in shaft. Detailed study on effect of change in angle with respect to Bending moment, Stress in shaft, Cylindrical roller bearing (CRB) and Deep Groove Ball Bearing (DGBB) Bearing reaction force analysis, life calculations are computed.
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Virtual verification of light reflection for cluster and Side Mirror in real time scenario

VE Commercial Vehicles Ltd-Manas Bhatnagar, Jyotiranjan Biswal, Saurabh Sharma
  • Technical Paper
  • 2020-01-0568
To be published on 2020-04-14 by SAE International in United States
In the very world of automotive sector trends are changing at a very fast pace, due to continuous expectation changes by user and new regulatory requirement comes on paper with a very stringent timeline. In current situation manufacturer had to wait for mock up for concept selection and physical proto build to conclude open points of design verification, this complete process take more than a year to make design mature enough for further build. In VECV we have created Cluster design standard to meet the different level of cluster illumination & reflection at virtual level. We are defining the cluster light illumination based on our rigorous study on cluster reflection impact on side glass, windscreen and mirror. Accordingly we package our mirror to minimize the impact of cluster reflection on mirror visibility. With the help of virtual verification of cluster and Side mirror inter co-relation of packaging, we reduced the major time loss and cost required for developing proto build. Different options of mirror and cluster can be verified in quick session. With the help…
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Optimum positioning of FIP drive system for Type-II BSVI engine based on coupled 1d “Valve-train – Chain drive” Dynamic analysis

VE Commercial Vehicles, Ltd.-Kaarthic Kaundabalaraman, Hemantkumar Rathi, Jasvir Singh Bisht
  • Technical Paper
  • 2020-01-1020
To be published on 2020-04-14 by SAE International in United States
The automotive industry is gearing up to meet the accelerated emission compliance changes posed by the government. This transition to eco-friendly system would also necessitate an automotive engineer to retain the engine packaging as compact and simple as possible. The packaging layout considered should not be at the expense of deteriorating engine performance. The work started with concept level layout development, with the aim of having simplified system with minimum number of components. The engine on which the work was carried out was 4cylinder 3Liter with OHC configuration A number of layouts were developed which included gear type, belt drive and integrated shaft arrangement for driving FIP. Each of these concepts were brainstormed with cons and pros, based on which two concepts were initially proposed for driving FIP system (i) Front Driven FIP (ii) Rear Driven FIP. The difference between the two layouts was that in the latter case the FIP system was directly driven through Exhaust Camshaft with gear type arrangement. For the above two proposed layouts, dynamic evaluation was done up-to Max intermittent…
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Parametric Modelling and Performance Analysis of HVAC Defroster Duct Using Robust Optimization Methodology

FCA Engineering India Pvt Ltd-Nagababu Garikipati
FCA Engineering India Pvt, Ltd.-Mohsin Khan
  • Technical Paper
  • 2020-01-1250
To be published on 2020-04-14 by SAE International in United States
Thermal comfort and safety of automotive passengers are the most important factors in the development of the automotive HVAC system. HVAC system is responsible for the demisting and defrosting of the vehicle’s windows and for creating/maintaining a pleasant environment inside the cabin by controlling airflow and temperature. Fog or ice which forms on the windshield is the main reason for invisibility and leads to major safety issue to the customers while driving. It has been shown that proper clear visibility for the windshield could be obtained with a better flow pattern and uniform flow distribution in the defrost mode of the HVAC system and defrost duct. Defroster performance has received significant attention from OEMs to meet the specific global performance standards of FMVSS103 and SAE J902. Therefore, defroster performance is seriously taken into consideration during the design of HVAC system and defroster duct. The HVAC unit provides hot air to the defroster duct which is blowing high velocity air to the windscreen to clear the frosting. Currently as a traditional defrost duct design process, multiple…
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Design of Valve Body Integrated Direct Acting Control Solenoids

FCA US LLC-Zhe Xie
  • Technical Paper
  • 2020-01-0965
To be published on 2020-04-14 by SAE International in United States
This paper studies the latest trend in transmission hydraulic controls development which involves the integration of the solenoid hydraulic element into the hydraulic valve body and attaching the magnetic part of the solenoid to the assembled valve body. This practice has been adopted by multiple automotive OEMs. Integrated direct acting control solenoids are key enablers for OEMs to meet more stringent fuel economy requirements in competitive environments. In the meantime, there are unique challenges in both integration and packaging due to the limited useful stroke of the armature and the fact that the solenoid armature can only act upon the spool valve in an outward motion. Both normally low and normally high functionality can be achieved with direct acting solenoids, but there are more challenges for the normally high functionality, especially spool valve porting and high hysteresis. This paper uses analytical methods to link the challenges to physical interactions between the magnetic and hydraulic parts of direct acting solenoids, and introduces design principles and best practices to address them in the design phase.
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Air Induction Impact on Turbocharger Noise and Thermodynamic Performance

FCA US LLC-Shadi Saeed, Brian Butler, Mark Likich, Jeff Orzechowski
FEV Europe GmbH-Tobias Zimmermann PhD
  • Technical Paper
  • 2020-01-0426
To be published on 2020-04-14 by SAE International in United States
The trend of improved FE and performance has led to industry growth of turbocharged engines and as a result, the need to address their undesirable attributes. This presents some unique engineering challenges as customer expectations for NVH, and other vehicle-level attributes, trend higher over time as well. Noise attenuation specific to turbocharged engines is uniquely challenging due to the types of noises they produce. Of specific concern, flow interaction between the induced air and compressor through a range of thermodynamic conditions can often result in objectionable "whoosh" noises within the Air Induction System (AIS). The traditional method for attenuation of this type of noise has been to use resonators which adds cost, weight and requires packaging space which is often at a premium in the under-hood environment. By improving our understanding of the root cause of the compressor whoosh noise, we hope to develop system design strategies that can prevent unwanted noise from being generated and avoid the need for traditional noise attenuation solutions. To investigate different flow metrics and their impact on compressor noise…
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Validation Testing of Lithium Battery Performance-Based Packaging for use in Air Transportation (SAE G-27)

National Research Council Canada-Khalid Fatih, Manuel Hernandez
Transport Canada-Ian Whittal, Kiran Shoib
  • Technical Paper
  • 2020-01-0042
To be published on 2020-03-10 by SAE International in United States
The SAE G-27 committee was tasked by ICAO to develop a performance-based packaging standard for lithium batteries transported as cargo on aircraft. The standard details test criteria to qualify packages of lithium batteries & cells for transportation as cargo on-board passenger aircraft. Lithium batteries and cells have been prohibited from shipment as cargo on passenger aircraft since 2016. This paper summarizes the results of the tests conducted by Transport Canada and National Research Council Canada to support the development of this standard with evidence-based recommendations. It includes a description of the test specimens, the test set up, instrumentation used, and test procedures following the standard as drafted to date. The study considered several lithium-ion battery and cell chemistries that were tested under various proposed testing scenarios in the draft standard. The aim was to assess the feasibility of proposed tests, and to determine whether the tests are able to accurately capture hazards which may arise from a catastrophic battery or a cell failure within the package. Laboratory results were also simulated with Computational Fluid Dynamics…
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Development of a test rig to evaluate the performance of Front-End Accessory Drive systems

VIBROACUSTICA-Celso Kenzo Takemori, Diego Wilian da Silva, Edmar Baars
ZEN S.A. Indústria Metalúrgica-Alvaro Canto Michelotti, Lucas Figueiro Berto, Pedro Palma Pastorelli, Andre Francioso Ferreira
  • Technical Paper
  • 2019-36-0296
Published 2020-01-13 by SAE International in United States
The increased adoption of downsized engines along with higher electrical demand is generating a challenge to the Front-End Accessory Drive (FEAD) system functioning and validation. One alternative to speed up the validation of potential design solutions is the in-vehicle experimental tests approach. Nevertheless, experimental data collection during in-vehicle FEAD evaluation imposes some challenges due to, for instance, packaging space constraints and sample rate required to capture the dynamic events during vehicle operation, among others. In order to overcome this limitation, the objective of this research is focused in the development of a customized test rig that emulates FEAD layout of an actual automobile in a simulated operating condition. This equipment could contribute in research studies focusing in critical performance parameters, allowing complete data acquisition and evaluation of potential design trade-offs that could maximize overall performance of the system, as the test rig could also allow the study of the impact of different layouts or operational configurations in the overall system efficiency. Therefore, the test rig design intent is to have a configurable layout that can…
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Packaging for SiC Sensors and Electronics

  • Magazine Article
  • TBMG-35699
Published 2019-12-01 by Tech Briefs Media Group in United States

Innovators at NASA’s Glenn Research Center have developed a planar, modular package that protects electronics and sensors more effectively in high-temperature conditions than previously available methods. Lack of reliability at high temperatures, due to poor packaging, have discouraged the global application and large-scale commercialization of high-temperature electronics and sensors.

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