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C123 Methodology for concept design of the Chassis Frame

Altair Engineering-AshithKumar Shetty
  • Technical Paper
  • 2019-28-2534
To be published on 2019-11-21 by SAE International in United States
Objective This paper explores the usage of Altair simulation driven concept process, C123 for developing the chassis frame of the SUV along with Multidisciplinary optimisation tool. C123 process is useful for strategic & systematic usage of optimisation to generate design alternatives, trade-off information, best balanced designs, design sensitivities, to actively support the concept development process on daily basis. Methodology C123 is used for developing initial concept design of the chassis frame of the SUV. C123 process is independent of vehicle architectures, manufacture process (e.g. extrusions, sheet metal) & material selection (e.g. metals, composites, mixed etc.) and platform sharing strategy. C1 process is used for identification of optimum Structural Layout, C2 is for rapid optimum Sizing of idealized Sections, C3 is used for detailed optimum Sizing of Manufacturable Sections. Automatic process is used for handling pre and post processing process very efficiently. Final refinement of the concept design (C3) will be carried out by considering all the possible critical load cases like Durability, stiffness, Modal Frequency & crash/Impact. Author is also explored usage of advanced high-strength…
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Study of Handling Behavior of a Passenger Vehicle after addition of CNG Tank

Maruti Suzuki India, Ltd.-Lakshmi Narasimha Varma Jelli, Raghav Budhiraja, Akash Goel, Deepak Bakshi, Rakesh K
  • Technical Paper
  • 2019-28-2405
To be published on 2019-11-21 by SAE International in United States
Objective The objective of this paper is to achieve a comparable handling performance from a vehicle fitted with a CNG tank to that of its gasoline counterpart. A validated CarSim model is run through standard handling evaluation tests before and after the addition of CNG tank. The simulation results are used to compare the handling characteristics of the CNG vehicle with the Base vehicle. Further these results are used to tune the suspension parameters to find an optimum set-up for the actual CNG vehicle. The final parameters are then evaluated in the actual vehicle to verify the study. Methodology A mix of Actual Mule vehicle testing backed by quik Car Sim Model. Full car model is first developed using CarSim by using the parameters of the actual base gasoline vehicle. The modeled vehicle is then tested for standard handling maneuvers such Double Lane Change, Constant Radius Constant Speed and Pulse Input. Further the actual vehicle is run through the exact same tests with the same inputs. The results are used to fine tune the CarSim…
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A Philosophy of Full Vehicle Simulation for analysing the Road NVH Problems

Altair Engineering India Pvt Ltd-Azan Parmar
Altair Engineering India Pvt , Ltd.-Hari Krishna Reddy
  • Technical Paper
  • 2019-28-2491
To be published on 2019-11-21 by SAE International in United States
Road and Engine borne noise are the most prominent sources of noise in any commercial vehicle. With advancement in technology and encouraging prospects in hybrid & electric vehicles, road noise can be set aside as the single most dominant source for vehicular NVH problems. In this paper, a full vehicle model is considered for complete NVH simulation with two acoustic and two structural response points. Random road excitations are applied at various vehicle speeds to determine the response characteristics. An elaborate study is conducted to understand the effects of vehicle speed and road conditions on the vehicle. An attempt is also successfully made to diagnose the effects of road excitations on the system behaviour by considering the suitable transfer functions. The methodology can be readily extended to any type of vehicle and speed as the excitations are independent of these parameters. Further, full vehicle model is examined to evaluate the panel and modal participation to the random response obtained
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Suspension hard points optimisation

Altair Engineering-AshithKumar Shetty
  • Technical Paper
  • 2019-28-2419
To be published on 2019-11-21 by SAE International in United States
Objective This paper explores the usage of Altair simulation driven optimisation process, Front Suspension hard points of a sedan Car model are optimised for specific target toe curves using MotionView, MotionSolve and HyperStudy This process gives the optimal hard point values to match the target curves without much iterations. Methodology Parametric Multibody model of the front end of sedan is built in MotionView. To Carry out optimisation HyperStudy is used where few of the suspension hard points which affect the toe curves are chosen as design variable. For the chosen Design variables upper and lower bound limits are specified. Ride, Roll and lateral force tests are performed. Optimisation is performed using HyperStudy where it iterates the suspension hard points to match the target toe curves. Each iteration response can be visualized in HyperStudy and can be compared with the target toe curve. Hyperstudy points the iteration which is closest to the Target curve Advantage • Quick model setup and run time • Parametric model allows quick change in design • Insight at early design stage…
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Design and Development of Industrial Automotive Battery Management system

Dipali Dange, Radhika Ballal L
Assistant professor, COE, Pune-Meera Murali
  • Technical Paper
  • 2019-28-2498
To be published on 2019-11-21 by SAE International in United States
Battery operated vehicle need accurate management system because of its quick changes in State of charge (SOC) due to aggressive acceleration profiles and regenerative braking. Li-ion battery needs control over its operating area for its safe working. So, the main objective of the proposed system is to develop a BMS having algorithms to estimate accurate SOC, predict degradation parameters, balance individual cells, manage cell temperature, and provide safe area of operation defined by voltage and temperature. Proposed methodology uses Model-based Design approach wherein nonlinear behavior of battery is modeled as Equivalent Circuit Model to compute the SOC and degradation effect on battery to decide the end of life of battery, also performing inductive Active balancing on cells to equalize the charge. proposed algorithms communicate with the vehicle ECU through CAN to assist the driver for runtime estimation, time for battery swapping, Alerts. Li-ion cells undergo current tests like pulsed charge-discharge, and transient response is effectively captured with parameter estimation with various degraded cells. Estimated model used in system and build battery stack. Balancing algorithm designed…
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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
To be published on 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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Methodology for failure simulation Using 4 corner 6 DOF Road load simulator of Overhanging Components: An Experimental Approach

Maruti Suzuki India, Ltd.-Naveen Malik, Ayan Bhattacharya, Sahil Jindal, Sayed Zergham Ali Naqvi
  • Technical Paper
  • 2019-28-2404
To be published on 2019-11-21 by SAE International in United States
Nowadays, Road Load Simulators are used by automobile companies to reproduce the accurate and multi axial stresses in test parts to simulate the real loading conditions. The road conditions are simulated in lab by measuring the customer usage data by sensors like Wheel Force transducers, accelerometers, displacement sensors and strain gauges on the vehicle body and suspension parts. The acquired data is simulated in lab condition by generating ‘drive file’ using the response of the above mentioned sensors. For generation of proper drive file, not only good FRF but ensuring stability of inverse FRF is also essential. Stability of the inverse FRF depends upon the simulation channels used. In this paper, an experimental approach was applied for focused failure simulation of engine mount, one of such low correlation zone, with known history of failure. Methodology was established to simulate proving ground loads on engine mount along with simulation of loads at wheel center using a 4 corner 6 DOF road load simulator. Result was verified by endurance run on test rig and matching the nature…
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Development and Testing of Electric Microcar for Indian Cities

VNR VJIET-Amjad Shaik, Srinivasa Rao Talluri, Raju Tappa, Ramu Ratlavath
Published 2019-10-11 by SAE International in United States
Population growth, rapid urbanisation and compounding effects of adding personal vehicles have resulted in increasing the urban air pollution in major Indian cities. Apart from the rising concerns about the urban air pollution, the increasing traffic and lack of parking space difficulties are promoting energy efficient small vehicles. Hence, there is a need to develop a new environmental friendly microcar that relatively affordable and easily manoeuvrable in bigger cities. Electric microcar is one of the most promising options to improve the near term sustainability for personal transportation in cities. This paper mainly presents the development of two seater electric microcar suitable for city driving requirements followed by road test. A mathematical modelling with reference to the urban cycle (Part-one) of modified Indian driving cycle (MIDC) is also carried out for the evaluation of energy and power requirements of electric microcar. The developed electric microcar has been tested on road with the help of the MIDC simulator kit. Results revealed that the developed prototype has demonstrated about 50 km range after one full charge.
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Parametric Calculation and Significance of Engine Dynamic Torque in Performance Benchmarking of a Vehicle

Mahindra Research Valley-Praveen Kumar Ramani, Bharathraj Jayaraman, Sangeetha Ramasamy Thiruppathi
Published 2019-10-11 by SAE International in United States
The automotive industries around the world is undergoing massive transformation towards identifying technological capabilities to improve vehicle performance. In this regard, the engine dynamic torque plays a crucial role in defining the transient performance and drivability of a vehicle. Moreover, the dynamic torque is used as a visualization parameter in performance prediction of a vehicle to set the right engineering targets and to assess the engine potential. Hence, an accurate measurement and prediction of the engine dynamic torque is required. However, there are very few methodologies available to measure the engine dynamic torque with reasonable accuracy and minimum efforts. The measurement of engine brake torque using a torque transducer is one of the potential methods. However, it requires a lot of effort and time to instrument the vehicle. It is also possible to back-calculate the engine torque based on fuel injection quantity and other known engine parameters. Though this calculation method is relatively easy, it is not an accurate method. Moreover, it would not be possible to extract engine information of benchmark vehicles. Since every…
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Roush opens Advanced Durability Lab

Automotive Engineering: October 2019

Kami Buchholz
  • Magazine Article
  • 19AUTP10_12
Published 2019-10-01 by SAE International in United States

The auto industry's steady march toward electrified and automated vehicles has many suppliers affixed to the digital-testing environment rather than using traditional hardware validation.

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