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Next Generation Power Distribution Unit in Wiring Harness

Mahindra & Mahindra, Ltd.-Boobala Krishnan D, Himanshi Dua, T Vijayan, Apurbo Kirty
  • Technical Paper
  • 2019-28-2571
Published 2019-11-21 by SAE International in United States
With the exponential advancement in technological features of automobile’s EE architecture, designing of power distribution unit becomes complex and challenging. Due to the increase in the number of features, the overall weight of power distribution unit increases and thereby affecting the overall system cost and fuel economy. The scope of this document is to scale down the weight and space of the power distribution unit without compromising with the current performance.The concept of next generation power distribution unit in automobiles is achieved using miniaturization of its sub-components which involves replacing the mini fuses and JCASE fuses with LP mini and LP JCASE fuses respectively. The transition doesn’t involve any tooling modification and hence saves the tooling cost. Furthermore, to address stringent weight and space targets, LP mini fuses and LP JCASE fuses were further replaced with micro-2 fuse and M-case fuse respectively. Similarly, Micro relay and Mini relay were replaced with Ultra micro and high current micro relay respectively.We took MPV segment vehicle for our initial testing and validation and it has been observed to…
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Mechanical Property Evaluation of Paper Honeycomb reinforced Plastics

Hyundai Motor India Engineering Pvt Ltd.-Vignesh Balaji S G, Pradeep S, Aakash S K
  • Technical Paper
  • 2019-28-2538
Published 2019-11-21 by SAE International in United States
Mechanical Property Evaluation of Paper Honeycomb Reinforced Plastics Vignesh Balaji S G, Pradeep Hyundai Motor India Engineering Pvt. Ltd, Chennai. India Key Words: Paper Honeycomb, Epoxy Composites, Mechanical Properties, Tensile, Impact & Flexural Test Research and/or Engineering Questions/Objective : Composite Materials are widely being used in many engineering applications because of their desirable properties & Cost, Weight Effectiveness. They are widely being used as their Strength-Weight Ratio is Higher than any Other Material. Paper Honeycomb Material is basically a paper made of honeycomb shapes enforced between layers of Glass Mat. This paper deals with the evaluation of Tensile Strength, Flexural (Three-Point Bending) Strength & Flexural Modulus, Impact Strength of Paper Honeycomb Reinforced Epoxy Composites. The Scope of this Material defines the quality of Paper Honeycomb Reinforced Composites which can be used for Automotive Trim Parts. Methodology: Before beginning the tests, the specimens should be prepared and the steps for the preparation of paper honeycomb reinforced epoxy composites are shown below: 1. Mould Preparation 2. Mixing of Epoxy and Hardener with a ratio of 10:1 3.…
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Antirodent Corrugated tube Development for Fuel tube Rat bite

Hyundai Motor India Engineering Pvt Ltd.-Gurupackiam Lakshmanaraj
  • Technical Paper
  • 2019-28-2536
Published 2019-11-21 by SAE International in United States
Rat damages in automobiles/food crops/house hold things are extensive in India. Cases of Rat damages to Car Fuel tubes (plastic) and subsequent fuel leak problems are increasing in India.To protect the Fuel tube from rat bite , a more robust and easy assemble protection method is discussed. Hence Antirodent corrugated tubes are considered to protect fuel tube from rat bite. Antirodent masterbatch (3% ) were added to the corrugated tubes and lab test were done in CAZRI. Antirodent corrugated tubes tested with 2 different species showed better results compared to standard corrugated tubes
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Characterization and Durability of Mold-In-Color Engineering Plastics

Mahindra & Mahindra, Ltd.-Sandeep Kumar Shukla
  • Technical Paper
  • 2019-28-2542
Published 2019-11-21 by SAE International in United States
Plastics are prone to photo oxidative and thermal oxidative degradation under usage conditions due to their chemical nature. From sustainability and cost standpoint, there is an increasing focus on Mold-In-Color (MIC) plastic materials. Simultaneously customer’s expectations on the perceived quality of these MIC parts has been increasing with attractive color and glossy appearance.A study was conducted to analyze the product quality and durability aspects over a prolonged exposure to accelerated weathering condition. Material selected for this study were injection molded specimens of ABS and PC-ABS used in automotive passenger vehicles.Comparative analysis was conducted before and after weathering exposure at defined intervals by using Fourier Transform infra-red spectrometer (FTIR), differential scanning colorimetry (DSC), universal testing machine (UTM), Izod impact tester and microscope to understand the impact on their chemical and mechanical properties.
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Miniaturized and sleek protective device

Mahindra & Mahindra, Ltd.-Priyanka Marudhavanan
  • Technical Paper
  • 2019-28-2535
Published 2019-11-21 by SAE International in United States
A miniaturized and sleek protective device M. Priyanka, Mahindra&Mahindra, India D. Boobala Krishnan*, Mahindra&Mahindra, India T.Vijayan, Mahindra& Mahindra, India Keywords-Fuse, Lightweight. Research and/or Engineering Questions/Objective: Now-a-days there is lot of advancement coming in automobiles. Earlier the electronics were used in engine and engine compartment areas. Now all hydraulics and transmission have been operated by electronics. The role of electronics like sensors, actuators increasing day by day for lifting and moving operations. With increase in electronics circuit, there is complex in wiring harness and packaging space for fuse box is premium Limitations: Limitations of placing other devices. Occupy more space and weight in the vehicle. Packing constraint due to vibration and thermal management issues. Methodology: Two different fuse of same rating can be given in one fuse and we can reduce the wire size. By this method we can save many fuses and reduce the fuse box size. An optimized fuse box minimizes the length of circuit. It translates the system into less plastics. This type of system is highly useful in systems such as ECU…
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End-of-Life Vehicles in India-Regulatory Perspectives

International Centre for Automotive Technology-Vijayanta Ahuja, Shakti N Khanna
  • Technical Paper
  • 2019-28-2580
Published 2019-11-21 by SAE International in United States
This paper discusses the areas affected during and beyond the recycling of the End-of-Life Vehicle (ELV). While the scrap of the vehicle shall be crushed and re-utilised from scrap metal (ferrous and non-ferrous), this paper also discusses potential usage of the components for remanufacturing by the respective OEMs. It further discusses how non-metallic parts such as plastics may be recycled. A complete framework committed to such a comprehensive approach shall not only reduce the impact on the environment but will also provide a more affordable and responsible alternative to the industry. While doing that, the economic and environmental impact on the industry and the un-organised sector has to be considered whilst also ensuring that a model with shared responsibility is established to dispose/ recycle any such ELV responsibly. The paper in its true spirit aims at effectively implementing the 3 Rs - Reduce, Reuse and Recycle - Reduction of waste and virgin natural elements, Reuse of working and efficient spares for remanufacturing purposes and Recycling of the scrap material. Older vehicles, conforming to lenient emission…
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Accounting the variabilities into squeak and rattle predictions

Altair Engineering India Pvt Ltd.-Hari Krishna Reddy, Chandan Ravi, Rongali Praveen
  • Technical Paper
  • 2019-28-2402
Published 2019-11-21 by SAE International in United States
Squeak and Rattle (S&R) are the dominant undesired noises which adjudge the perceived quality of a vehicle. It's a foremost problem which needs to be identified and eliminated at a design stage to develop a robust vehicle, which also aids in pacifying the physical testing and warranty claim costs. A Finite Element model of the complex plastic dashboard has been analyzed to identify risks and the root cause of S&R problem under dynamic and static loading conditions, using E-line methodology. These complex transient problems are highly influenced by various parameters like gap variability, temperature, the coefficient of thermal expansion, thickness, and material properties. This paper elaborates the detailed investigation conducted using stochastic simulations to evaluate the individual and combined impact of each parameter on S&R performance
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Employing natural plant based fiber in interior automotive parts for cost & weight benefit

Vivekanandhan-Vivekanandhan Venkatesan Balaguru
  • Technical Paper
  • 2019-28-2559
Published 2019-11-21 by SAE International in United States
The Automotive industry is in ever more need for a lesser weight car due to progressively stringent emission norms and the demand of customer to have better mileage. It can be a gargantuan challenge for automotive manufacturers to search for lesser weight material to meet both customers as well as regulatory norms. But in some cases such lower weight material can increase the cost and adding a expensive material which increases overall cost to a price sensitive market like India is not favorable. One such solution is using the indigenous plant fiber (Jute) in combination with propylene (PP) to make Interior plastics components. Jute a vegetable fiber also referred to as "the golden fiber" has high tensile strength, low extensibility and is well established in fabric, packing, agriculture, construction industries. The biodegradable Jute lesser weight & abundance (India is the leading manufacturer of the Jute) can be utilized in making automobile trim parts in India. Through this paper we will have insight of the natural fiber based plastic components the benefits (lesser weight, Less GSM…
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Simulation of Softening and Rupture in Multilayered Fuel Tank Material

General Motors Technical Center India-Vijaya Kumar R L, Biswajit Tripathy, Jayaraj Radhakrishnan
  • Technical Paper
  • 2019-28-2557
Published 2019-11-21 by SAE International in United States
Multi-layered, high-density polyethylene (HDPE) fuel tanks are increasingly being used in automobiles due to advantages such as shape flexibility, low weight and corrosion resistance. Though, HDPE fuel tanks are perceived to be safer as compared to metallic tanks, the material properties are influenced by service temperature. At higher temperatures (more than 80oC), plastic fuel tanks can soften, sag and eventually spill out the fuel, while the extreme cold (less than -20°C) can lead to potential cracking problems. Damage may also occur due to accidental drop while handling or due to an impact from a flying shrapnel. This can be catastrophic due to flammability of the fuel. The objective of this work is to characterize and develop a failure model for the plastic fuel tank material to simulate damage and enhance predictive capability of CAE for chassis and safety load cases. Different factors influencing the material properties such as service temperature, rate of deformation, state of stress etc. were considered to develop a characterization and modelling strategy for the HDPE fuel tank material. Samples cut-out from…
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Pearl-Like Coating Enhances Lightweight Armor

  • Magazine Article
  • TBMG-35453
Published 2019-11-01 by Tech Briefs Media Group in United States

By mimicking the outer coating of pearls (nacre or mother of pearl), researchers created a lightweight plastic that is 14 times stronger and eight times lighter (less dense) than steel. It could be applicable to vests, helmets, and other types of body armor as well as protective armor for ships, helicopters, and other vehicles.