Browse Topic: Engine components

Items (22,993)
This Aerospace Recommended Practice (ARP) outlines the causes and impacts of moisture and/or condensation in avionics equipment and provides recommendations for corrective and preventative action.
AC-9 Aircraft Environmental Systems Committee
In order to control the engine performance which is driven by the strict emission regulations and customer request for the improved fuel economy, precise air intake measurement and fuel control system are essential. In the modern engines, the mass air flow sensor (MAF) acts an important role which provides a precise estimation of air flow from the clean side ducting of air intake system to engine control unit module (ECU). The hot wire mass air flow sensor are mounted on the clean side of the air intake system in order to protect the sensing element from the contamination and to extend their lifespan as well as maintain its accuracy. It is essential to maintain a steady and a uniform airflow at the sensing element of the MAF sensor for reliable sensor reading at different engine speeds and varying engine load. However, the physical limitations of engine packaging inside the engine bay, limits the sensor placement. Incorrect sensor mounting can lead to errors in the airflow estimation
Sonone, Sagar DineshZope, MaheshKale, VishalPadmawar, HarshadSridhar, SKolhe, Vivek MPanwar, Anupam
The maximum power is recorded with Gasoline than CNG and Hydrogen fuel. The maximum exergy and energy efficiency is with Hydrogen, followed by CNG and then Gasoline. Hydrogen fuel has a maximum potential to convert into energy. The maximum energy destruction of 48.7kW for gasoline fuel at 3000 rpm and followed by CNG and hydrogen. The maximum entropy generation of 85.5 W/K with Gasoline and 60.72 W/K and 29.39W/K for CNG and hydrogen engine respectively at 10000 rpm. The entropy generation rate increase with engine speed. The highest rate of heat release is from hydrogen fuel, followed by Gasoline and CNG.
Shinde, Apurwa BalasahebKadam, Tusharkarunamurthy, KSHINDE, DR BALU
This paper presents the methodology and outcomes of modifying a 1.2L naturally aspirated (NA) engine to enable flex-fuel compatibility, targeting optimal performance with ethanol blends ranging from E20 to E100. Ethanol is being increasingly promoted due to its potential to reduce greenhouse gas emissions and to provide an additional source of income for farmers. As per the road map for Ethanol blending released by Govt. of India, there has been continuous increase in blending of ethanol in gasoline. An initial target of 20% ethanol blending in gasoline by April 2025 has already been achieved. This work is in alignment with the broader push for development of flex-fuel vehicles, which necessitates engine adaptations capable of operating on varying ethanol blends. The primary objective was to upgrade the engine, which can give optimum performance with both lower range of ethanol blends starting from E20 as per IS 17021:2018 standard till higher blends of up to E100 as per IS 17821:2022
Tyagarajan, SethuramalingamPise, ChetanKavekar, PratapAgarwal, Nishant Kumar
This study focuses on enhancing energy efficiency in electric vehicle (EV) thermal management systems through the development and optimization of control logic. A full vehicle thermal management system (VTMS) was modeled using GT-Suite software, incorporating subsystems such as the high voltage battery (HVB), Electric powertrain (EPT), and an 8-zone cabin. Thermal models were validated with experimental data to ensure accurate representation of key dynamics, including coolant to cell heat transfer, cell-to-ambient heat dissipation, and internal heat generation. Control strategies were devised for Active Grille Shutter (AGS) and radiator fan operations, targeting both cabin cooling and EPT thermal regulation. Energy consumption was optimized by balancing aerodynamic drag, fan power, and compressor power across various driving conditions. A novel series cooling logic was also developed to improve HVB thermal management during mild ambient conditions. Simulation results demonstrate
Chothave, AbhijeetKumar, DipeshGummadi, GopakishoreKhan, ParvejThiyagarajan, RajeshPandey, RishabhS, AnanthAnugu, AnilMulamalla, SarveshwarGangwar, Adarsh
Turbochargers play a crucial role in modern engines by increasing power output and fuel efficiency through intake air compression, thereby improving volumetric efficiency by allowing more air mass into the combustion chamber. However, this process also raises the intake air temperature, which can reduce charge density, lead to detonation, and create emissions challenges—such as smoke limits in diesel engines and knock in gasoline spark-ignited (GSL) engines. To mitigate this, intercoolers are used to cool the compressed air. Due to packaging constraints, intercoolers are typically long and boxy, limiting their effectiveness, especially at low vehicle speeds where ram air flow is minimal. This study investigates the use of auxiliary fans to enhance intercooler performance. Two methodologies were adopted: 1D simulation using GT-Suite and experimental testing on a vehicle under different fan configurations—no fan, single fan, and dual fans (positioned near the intercooler inlet and outlet
Patra, SomnathHibare, NikhilGanesan, ThanigaivelGharte, Jignesh Rajendra
With the increasing tonnage of electric heavy commercial vehicles, there is a growing demand for higher power and torque-rated traction motors. As motor ratings increase, efficient cooling of the EV powertrain system becomes critical to maintaining optimal performance. Higher heat loads from traction motors and inverters pose significant challenges, necessitating an innovative cooling strategy to enhance system efficiency, sustainability, and reliability. Battery-electric heavy commercial vehicles face substantial cooling challenges due to the high-pressure drop characteristics of conventional traction system cooling architectures. These limitations restrict coolant flow through key powertrain components and the radiator, reducing heat dissipation efficiency and constraining the operating ambient temperature range. Inefficient cooling also leads to increased energy consumption, impacting the overall sustainability of electric mobility solutions. This paper presents a novel approach of
Dixit, SameerPatil, BhushanGhosh, Sandeep
India’s commitment to carbon neutrality is significantly shaping the future architecture of commercial vehicle powertrains. While the use of CO₂-free technologies such as battery-electric drivetrains has already been successfully demonstrated across various applications, challenges related to limited range and the lack of high-power charging infrastructure continue to hinder widespread adoption, particularly for productivity-critical commercial vehicles. This has shifted the spotlight toward sustainable fuels, which offer the advantage of fast refueling times. Among these, hydrogen internal combustion engines (H₂ ICE) have gained increasing attention in recent years. In regions such as the European Union, the primary motivation for hydrogen is CO₂ reduction. In contrast, for markets like India, hydrogen also presents a strategic opportunity for reducing dependency on fossil fuel imports. Over the past four years, multiple performance and emission development projects across various H
Arnberger, AntonDanninger, AloisMannsberger, StefanBreitegger, Bernhard
Agricultural operations in hilly, uneven & slopy terrains demands high levels of operator focus, effort and skill. However, todays farming ecosystem across the globe is affected by 2 major scenarios: the aging workforce in the agricultural sector and the ever-growing problem of distraction due to mobile device and social media use. These issues compromise safety during operations such as start stop maneuvers, parking on slopes, and maneuvering in confined & narrow areas. Stringent emission norms are also being mandated across developed and developing countries as a measure to reduce Global Greenhouse house gas emissions. These measures are indeed necessary for sustainability but has increased overall tractor purchase and operating costs without improving safety & operator comfort. There has been a trend seen around the world in terms of poor sales post Emission implementation. Registration of Older tractors without these stringent emission norms were also witnessed in Developed
M, RojerT, GanesanP, VelusamyNatarajan, SaravananV, Mathankumartripathi, ShankarNarni, KiranHaldorai, RajanDevakumar, Kiran
Hydraulic engine mounts are widely used in automotive applications to reduce vibration and noise transmission from the engine to the vehicle body by providing high damping at low frequencies and low damping/stiffness at higher frequencies. This is achieved by allowing sufficient clearance between components inside the hydro mount, activating hydraulic damping only with sufficient amplitude inputs. However, this inherently leads to the generation of parasitic noises emanating from hydraulic engine mounts which significantly degrade the Noise, Vibration, and Harshness (NVH) performance of vehicles, presenting a considerable challenge in the automotive industry. This encompasses phenomena such as cavitation, arising from the formation and subsequent collapse of vapor bubbles within the working fluid due to localized pressure drops below the vapor pressure, and membrane hitting, resulting from the dynamic interaction between the fluid and the elastic membrane within the mount. Both noise
Agrawal, AdheeshVineeth, SekharanGhosh, ChiranjitSaxena, AkshanshParmar, AashishSeenivasan, GokulramNandal, AbhishekDhankhar, Dinesh SinghKhan, Prasenjit
Engine braking is a deceleration technique that leverages the internal friction and pumping losses within the engine. By closing the throttle and potentially selecting a lower gear, the engine creates a retarding force that slows the vehicle. This practice contributes to better fuel economy, decreased brake system load, and improved vehicle handling in specific driving scenarios, such as steep declines or slippery road surfaces. To alleviate stress on their primary braking systems and prevent overheating, heavy vehicles frequently incorporate engine-based braking. While older trucks relied on simple exhaust brakes with a butterfly valve to restrict exhaust flow, these had limited impact. Hence contemporary heavy vehicles almost exclusively use more advanced engine braking technologies. Traditionally, our heavy-duty vehicles use Exhaust brake system to elevate the braking performance on hilly terrains. Hence an improved sample of Engine brake was developed for enhanced braking
M, Vipin PrakashRajappan, Dinesh KumarR, SureshN, Gopi Kannan
Balance towards various Vehicle attributes often faces design contradictions, particularly in Noise, Vibration, and Harshness (NVH) optimization. Traditional approaches rely on trade-offs, but TRIZ (Theory of Inventive Problem Solving) offers a structured methodology to resolve contradictions innovatively. This paper presents TRIZ-based solutions for 2 key NVH challenges: (1) exhaust systems requiring noise reduction while maintaining low engine back-pressure, (2) engine mounts requiring both softness for vibration isolation and hardness for durability & vehicle stability, By applying TRIZ principles such as separation, mechanics change, etc. and using Thinking Tools such as thinking in time & scale, novel solutions are proposed to achieve superior performance without traditional compromises. These case studies demonstrate how TRIZ enhances automotive NVH refinements by enabling systematic innovations. This also explores benefits of Frugal Engineering for profitable launch of new
A, Milind Ambardekar
Internal Combustion Engine (ICE) is the heart of an Automobile. The failure of any critical component of the ICE engine will directly affect the performance of the vehicle. The gaskets are among the many vital parts of an IC engine that are essential in ensuring appropriate sealing to prevent gas and liquid leakage and maintain optimal engine efficiency. Engines use a variety of gasket types to accommodate various sealing requirements. Among them the exhaust manifold gaskets are one of the critical gasket elements in ICE engines. Exhaust Gasket acts as a seal between cylinder head and extremely hot exhaust manifold, which prevents the leakage of hot exhaust gases produced during typical engine operating condition. The gaskets are crucial components because they endure extremely high mechanical loads from the exhaust manifold sliding and banana-shaped bending brought on by thermal expansion, as well as extremely high thermal loads from the high exhaust gas temperatures, which are more
Reddy, RajavardhanR B, GovindKulkarni, SanjeevPalve, ChandrakantMueller, Frank Oliver
Modern automotive powertrains are increasingly adopting engine downsizing and down speeding to meet stringent emission regulations and improving fuel efficiency However, these changes result in higher torsional vibrations excitation amplitudes and NVH (Noise, Vibration, and Harshness) refinement more challenging. With growing customer expectations for premium driving experiences conventional clutch is no longer sufficient. To meet the NVH performance targets of the vehicle Dual Mass Flywheels (DMFs) are used In DMF due to lower stiffness and inertia separation there is a greater advantage on torsional filtration in normal drive and idle condition. But the torsional resonance frequency of the connected DMF is lower than the idle RPM. Engine startup is a key drawback with DMF equipped vehicles. The proper tuning of starter motor performance & DMF stiffness is required to cross the resonance zone faster otherwise it will lead to DMF to stay in the resonance zone for a longer time leading
Jayachandran, Suresh KumarVijayaragavan, ThirupathiM, DevamanalanKanagaraj, PothirajAhire, ManojVellandi, Vikraman
Thermo-mechanical fatigue (TMF) is a critical durability concern for cylinder heads in internal combustion engines, particularly under severe cyclic thermal and mechanical loads. TMF-induced damage often initiates in geometrically constrained regions with high thermal gradients and can significantly reduce component life. As performance demands increase, understanding and mitigating TMF becomes essential to ensure the structural integrity and long-term reliability of engine components. This study presents a simulation methodology for evaluating thermo-mechanical fatigue (TMF), a temperature-dependent low-cycle fatigue (LCF) mechanism that arises from repeated thermal expansion and contraction under mechanical constraints, leading to cyclic plastic deformation and damage. The methodology consists of two key phases. Phase I involves global finite element (FE) simulations both thermal and structural to obtain temperature and displacement fields under rated and idle engine conditions
Ghotekar, SunilKumbhar, Dipak MadhukarPendse, Ameya
The increasing adoption of ethanol-blended fuels, such as E20 (20% ethanol and 80% gasoline) and E85 (85% ethanol and 15% gasoline), necessitates a comprehensive understanding of their compatibility with automotive engine components to ensure durability and operational reliability. Fuel compatibility is particularly critical for components in direct contact with ethanol-rich fuels, as improper material selection or insufficient testing can lead to corrosion, material degradation, and compromised engine performance. This study focuses on evaluating the behavior of sintered materials extracted from potential fuel-contact part of automotive engine when exposed to E20 and E85 fuels. Testing was conducted in accordance with the SAE J1747 standard, which provides a systematic approach for assessing corrosion resistance and material degradation in fuel environments. Following the exposure tests, post-test evaluations included visual inspection to identify surface changes and Scanning Electron
Karthikeyan, C.Venugopal, SivakumarGopalan, Vijaysankar
Engine radiated noise has complex behavior since the diesel engine assembly comprises several components with varied dynamic speeds. The engine noise performance for the open station tractor is a crucial contributor to noise and needs to be optimized. Various engine noise sources have been researched, including structural like the engine block, intake, exhaust, and timing gears. Reducing noise in diesel powertrains by structural improvements entails limiting vibrations and preventing noise transfer from the engine. This can be accomplished by increasing the rigidity of the engine block and other structural components, as well as optimizing structural designs. Local adjustments to structural components have become a significant strategy for reducing noise and vibration problems. Design enhancements in structural components can be predicted and optimized for NVH. NVH testing helps validate changes in engine structure stiffness and assess acoustic improvements. Coupled with simulations
Kamble, PranitBaviskar, ShreyasGhale, GuruprasadChatterjee, DipankarPrabhakar, Shantanudhobale, VishwajeetBendre, ParagThakur, SunilKunde, Sagar
Customers in off-highway industry are increasingly seeking high-performance capabilities for their tractors due to increasing penetration of mechanisation and labour scarcity. One effective solution to achieve enhanced performance is turbocharging of engines, while meeting emission and highly dynamic transient response of tractor field applications. The process of selecting and validating a suitable turbocharger for tractor field application suitability is significantly time and resources consuming activity due to extensive testbed and field trials. This study focuses on the selection of turbocharger for tractor engines through analytical calculations to freeze key parameters like lambda, boost pressure ratio & temperature within boundaries of exhaust temperature and turbo efficiency maps to deliver best field transient performance and fuel consumption. The selected parameters are further validated under real-world transient operating conditions, involving tractors and their implements
Kumar, Harish KumarRawat, SaurabhDogra, DaljitSinghSingh, SachleenSingh, Amarinder
The inclusion of the cabin in HVAC simulations gained more importance with the introduction of BEV’s. Thermal management and efficiency being in the forefront, exploration for the possible opportunities to reduce the energy consumption for meeting the comfort of passengers gained importance. The energy consumed by the Electric coolant or air heaters for heating the cabin at extreme cold ambient temperatures to deliver similar comfort to that of an ICE version is 2 to 3 times that of the energy required for cooling the cabin in a high ambient condition. Even during the sizing of HVAC system, if traditional method of ambient or fresh air conditions is considered for calculating the requirements, the result is we would require a product which will have unrealistic performance demand. Hence to explore different possibilities for studying the system, usage of recirculation air was considered as one of the options. This paper talks about the approach followed in creating the cabin model in
Veerla, EswarSubramanian, Karthik
The study emphasizes on development of Diesel Exhaust Fluid (DEF) dosing system specifically used in Selective Catalytic Reduction (SCR) of diesel engine for emission control, where a low pressure pumpless DEF dosing system is developed, utilizing compressed air for pressurizing the DEF tank and discharging DEF through air assisted DEF injection nozzle. SCR systems utilize Diesel Exhaust Fluid (DEF) to convert harmful NOx emissions from diesel engines into harmless nitrogen and water vapor. Factors such as improper storage, handling, or refilling practices can lead to DEF contamination which pose significant operational challenges for SCR systems. Traditional piston-type, diaphragm-type, or gear-type pumps in DEF dosing systems are prone to mechanical failures leading to frequent maintenance, repairs, and costly downtimes for vehicles. To overcome the existing challenges and to create a more reliable and simple DEF delivery mechanism the pumpless DEF Dosing system is developed. The
M, HareniGiridharan, JyothivelA.l, SureshV, YuvarajRajan, Bharath
In a conventional powertrain driven by Internal combustion (IC) engines, various sensors are used to monitor engine performance and emissions. Along with physical sensors, virtual sensors or modelled values of key parameters play an important role for enabling various diagnostics strategies and engine monitoring. Conventional strategies for modelling incorporate the use of regression models, map-based models and physics-based models which have few drawbacks in terms of accuracy and model calibrations efforts. Data driven models or neural networks have fairly better accuracy and reliability for estimating complex parameters. Representing the neural network with a mathematics-based model would help to eliminate drawbacks associated with conventional modelling approach. The proposed methodology uses artificial intelligence technique called artificial neural network (ANN) for estimation of temperature at turbine inlet (TTI) in typical diesel engine. The data driven model is built in Python
Jagtap, Virendra ShashikantShejwal, SanketMitra, Partha
Air suction in a naturally aspirated engine is a crucial influencing parameter to dictate the specific fuel consumption and emissions. For a multi-cylinder engine, a turbocharger can well address this issue. However, due to the lack of availability of continuous exhaust energy pulses, in a single or two-cylinder engine, the usage of turbocharger is not recommended. A supercharger solution comes handy in this regard for a single or two-cylinder engine. In this exercise, we explore the possibility of the usage of a positive displacement type supercharger, to enhance the air flow rate of a single cylinder, naturally aspirated, diesel engine for genset application, operating at 1500 rpm. The supercharger parametric 3D CAD model has been prepared in Creo, with three design parameters i.e. (a) Generating radius, (b) depth of blower and (c) clearance between lobes & lobe and casing. The optimum roots blower design is expected to fulfil the target boost pressure, power consumption and
Satre, Santosh DadasahebMukherjee, NaliniRajput, SurendraNene, Devendra
Maximizing vehicle uptime and reducing maintenance costs are critical objectives in modern automotive systems, making efficient resource utilization a top priority. One of the key factors is engine oil life or degradation, which directly affects the engine performance, longevity, and overall vehicle efficiency/fuel economy. Most vehicles tracks engine oil life solely on a fixed mileage interval while few uses dedicated sensor, which is costly and requires service and maintenance. As the engine oil degrades, it reduces Oil Total Acid Number (TAN) increases while Oil Total Base Number (TBN) decreases. It is recommended that maximum usable life of the engine oil is up to the crossover point between oil TAN and TBN (as the engine oil degrades). Vehicle driving pattern governs the occurrence of crossover points with respect to vehicle mileage. Based on this fundamental concept, an XG-Boost machine-learning algorithm is trained using vehicle Controller Area Network (CAN) channels and varying
Dusane, MangeshTade, VilasIqbal, Shoaib
Oil pressure, the most fundamental to engine's performance and longevity, is not only critical to ensure that the engine components are properly lubricated, cooled, and protected against wear and contamination, but also ultimately contributing to reliable engine performance. Due to several factors of engine such as, rotational fluctuation, aeration, functioning of hydraulic components there are fluctuations in oil pressure. In engines, with a crank-mounted fixed displacement oil pump (FDOP), these inherited pressure fluctuations cannot be eliminated completely. However, it is very necessary to control the abnormal oil pressure fluctuation because abnormal pressure fluctuation may lead to malfunction of hydraulic component functioning like variable valve timing (VVT), hydraulic lash adjuster (HLA) and dynamic chain tensioner which can further cause serious issues like excessive or sudden load drops, unstable engine performance, valve train noise, improper valve lift operation etc. In
Kumar, AshokChoubisa, ManasKumar, RaviPathak, Mehul
The present work demonstrates a Fluid-Structure Interaction (FSI) based methodology that couples a Finite Volume Method (FVM) and Finite Element Method (FEM) based tools to estimate air guide deformation, thereby predicting accurate aerothermal performance. The method starts with a digital assembly step where the assembly shape and the induced stress due to assembly is predicted. A full vehicle Aerodynamic simulation is performed to extract the surface pressure on the air guide which is then used to estimate the extent of deformation of the air guides. Based on the extent a subsequent Aerodynamic simulation may be carried out to predict thermal efficiency. Comparison against pressure data and deflection data extracted from the wind tunnel experiments of vehicles has shown reasonable match demonstrating the accuracy and usefulness of the method.
Gadasu, RavishastriChoudhury, SatyajitUmesh, Acharya VaibhavKumar, SaravananYenugu, SrinivasaZander, DanielBeesetti, SivaHattarke, Mallikarjun
Controlling the source vibrations in internal combustion engines is a crucial approach to minimizing the vibration levels experienced by the driver. The driver's subjective perception of vibration is primarily dictated by the vehicle's low-frequency response (<100 Hz). In an IC engine used in agricultural tractor applications, the primary sources of vibration include (a) 1st order inertial force, (b) couples generated by rotating and reciprocating components such as the piston assembly, connecting rod, and crankshaft, and (c) in-cylinder combustion. In this study, an order ranking analysis was conducted on a single-cylinder, air-cooled, naturally aspirated tractor engine within the driver’s operating range to identify the dominant contributors to source vibrations. The 1st order inertial force was observed to be the dominant contributor to the engine's vibration levels. Subsequently, an attempt was made to mitigate the unbalanced forces by implementing counterweight-based balancing
Bhuntel, AjayRajput, SurendraRawat, Ashish
Engine noise mitigation is paramount in powertrain development for enhanced performance and occupant comfort. Identifying NVH problems at the prototype stage leads to costly and time-consuming redesigns and modifications, potentially delaying the product launch. NVH simulations facilitate identification of noise and vibration sources, informing design modifications prior to physical prototyping. Early detection and resolution of NVH problems through simulation can significantly shorten the overall development cycle and multiple physical prototypes and costly redesigns. During NVH simulations, predicting and optimizing valvetrain and timing drive noise necessitates transfer of bearing, valve spring, and contact forces to NVH simulation models. Traditional simulations, involved continuous force data export and NVH model evaluation for each design variant, pose efficiency challenges. In this paper, an approach for preliminary assessment of dB level reductions across design iterations is
Rai, AnkurDeshpande, Ajay MahadeoYadav, Rakesh
There is a scarcity of research in literature regarding the determination of Plenum Opening Area of cowl box. The area of the plenum opening in the cowl box significantly affects the airflow rate in fresh airflow modes, such as face and defrost modes, as well as issues related to water ingress. Primarily, the size of the plenum opening is determined by the necessary HVAC airflow rate. This study aims to investigate how the plenum opening area impacts both airflow discharge and the water ingress issue in the HVAC module. A novel approach is introduced in this research to determine the optimal plenum opening area of the cowl box, taking into account both airflow rate and water ingress concerns. The ANSYS FLUENT software is utilized to analyze airflow discharge in both face and defrost modes, while the SPH (Smooth Particle Hydrodynamics) based Preonlab tool is employed for water ingress analysis. Airflow discharge is evaluated for various plenum opening sizes in both modes, and the area
Baskar, SubramaniyanMahesh, AGopinathan, Nagarajan
In today’s fast paced and competitive automotive market, meeting the customer’s expectation is the key to any OEM. This has led to development of downsized high performance engines with refinement as an important deliverable. However developing such high output engines do come with challenges of refinement, especially higher torsional vibrations leading to transmission noise issues. Hence, it becomes important to isolate the transmission system from these high torsional vibration input. To address this, one of the most common method is to adopt Dual Mass flywheel (DMF) as this component dampens torsional vibrations and isolates the transmission unit from the same. While Dual Mass Flywheel assemblies do great job in protecting the transmission units by not allowing the oscillations to pass through them, they do have their own natural resonance frequency band close to the engine idle (low) engine speeds, which must be avoided for a continuous operation otherwise it may lead to Dual Mass
Raiker, Rajanviswanatha, Hosur CJadhav, AashishJain, OjaseJadhav, Marisha
Increasing ethanol blending in gasoline is significant from both financial (reducing dependency on crude oil) and sustainability (overall CO2 reduction) points of view. Flex Fuel is an ethanol-gasoline blend containing ethanol ranging from 20% to 85%. Flex Fuel emerges as an exceptionally advantageous solution, adeptly addressing the shortcomings associated with both gasoline and ethanol. Performance optimization of Flex Fuel is a major challenge as fuel properties like knocking tendency, calorific value, vapour pressure, latent heat, and stoichiometric air-fuel ratio change with varying ethanol content. This paper elaborates on the experimental results of trials conducted for optimizing engine performance with Flex Fuel for a 2-cylinder engine used in a small commercial vehicle. To derive maximum benefit from the higher octane rating of E85, the compression ratio is increased, while ignition timing is optimized to avoid knocking with E20 fuel. For intermediate blends, ignition timing
Kulkarni, DeepakMalekar, Hemant AUpadhyay, RajdipKatkar, SantoshUndre, Shrikant
This paper presents an innovative in-lab accelerated testing approach for chassis-mounted components, with a particular focus on the cooling module of commercial vehicles. The proposed method simulates real-time data acquired from field operations and replicates all critical chassis modes, including torsion. Additionally, real-time coolant circulation at specified pressure and temperature maintenance are feasible during durability testing, enhancing the realism of the test environment. The cooling modules, comprising the radiator, intercooler, and charge air cooler (CAC), often experience failures due to various multi-axial inputs and chassis modes. This paper introduces an innovative methodology for replicating field conditions in the lab, utilizing seven servo-hydraulic actuators to simulate multi-axial inputs. The accuracy of in-lab simulation for the acceleration levels at input and response locations of the cooling module exceeds 90%. This makes it a preferred choice for test
V Dhage, YogeshSatale, Sunil
An optimal engine lubrication system, encompassing engine oil and an oil cooler, is critical for thermal management and minimizing frictional losses. This system ensures adequate lubrication and cooling of engine components, thereby maintaining optimal performance. This study investigates the implications of oil cooler removal in a 45HP inline engine tractor. Various validation trials were conducted, including high ambient temperature tests under worst-case conditions, high coolant temperature scenarios, and a rigorous tractor killer test. In the latter, the tractor underwent 100 hours of operation on a PTO bench at maximum engine RPMs. Despite an observable increase in lubricant oil temperature during these tests, the tractor did not exhibit any component seizure or failure. The findings aim to determine whether the inclusion of an oil cooler is essential for the engine's operational reliability. This research offers valuable guidance for optimizing hardware selection and cost
Gupta, DeepakKumar, PankajSingh, ManjinderSingh, GagandeepKumar, MunishSingh, HarpreetSingh, Maninder
In the era of Software Defined Vehicles, the complexity and requirements of automotive systems have increased knowingly. EV Thermal management systems have become more complicated while having multiple functions and control strategies within software frameworks. This shift creates new challenges like increased development efforts and long lead time in creating an efficient thermal management system for Electric Vehicles (EV’s) due to battery charging and discharging cycles. For solving these challenges in the early stages of development makes it even more challenging due to the unavailability of key components such as fully developed ECU hardware, High voltage battery pack and the motor. To address this, a novel framework has been designed that combines virtual simulation with physical emulation at the same time, enabling the testing and validation of thermal control strategies without fully matured system and the ECU hardware. The framework uses the Speedgoat QNX machine as the
Chothave, AbhijeetS, BharathanS, AnanthGangwar, AdarshKhan, ParvejGummadi, GopakishoreKumar, Dipesh
This paper presents the design, structural analysis, structural test validation and risk assessment done by Cummins to evaluate the structural integrity of Light Duty engine cylinder head for a Medium Wheelbase (MWB) pick-up truck. Initially, Cummins used the 2.5L and 3.0L (4-cylinder) engines that have standard power ratings based on existing requirements, but rising market demands for more power, fuel efficiency, lower cost and weight, and future emission compliance led to customer requirements for 15% uprate for 2.5L and 22% uprate for 3.0L from the same base engine. The increase in power requirement possesses challenges on critical components, especially cylinder heads in terms of thermal and structural limits. Multiple analysis led design iterations were performed using cutting edge CAE software such as Ansys, Dassault Systems fe-safe, and PTC Creo to ensure the structural integrity of the cylinder head under high thermal and mechanical loads, and to keep design margins within
Pathak, Arun JyotiAdiverekar, VaidehiSingh, RahulBiyani, Mayur
The Indian farmers choice of agriculture tractor brand is driven by the ease of operation and fuel efficiency. However, the customer preference for operator comfort is driving many tractor OEMs for improvement in noise and vibration at the operator location. Also, the compliance to CMVR regulation for noise at operator ear location and vibration at operator touch point location are mandatory for all the tractors in India. NVH refinement development of the tractor plays a critical role in achieving the regulated noise level and improved tactile vibration In presented work, the airborne sources such as exhaust tail pipe, intake snorkel and cooling fan are quantified by at tractor level through elimination method. The detailed engine level testing in engine noise test cell (hemi anechoic chamber) is carried out to estimate the contribution of engine components to overall noise. The outcome of Noise source identification (NSI) has revealed silencer, timing gear cover and oil sump to be
Gaikwad, Atul AnnasahebHarishchandra Walke, NageshYadav, Prasad SBankar, Harshal
The scale of worldwide population presents its own set of difficulties, especially in densely populated cities. Almost every individual has some form of personal transport, which leads to congestion and limited parking space. Automotive manufacturers are scaling down the size of vehicles to resolve these issues to some extent. This paper is based on the NVH development of a single cylinder diesel engine vehicle. It provides an insight into the comprehensive vehicle level NVH refinement approaches adopted. The NVH characteristics of benchmark two-cylinder diesel and baseline vehicle were measured and analyzed for target setting. The performance of each subsystem such as engine mounting, vehicle structure, intake and exhaust was evaluated, and gap analysis was performed against set targets. It was found that the engine mounting system and vehicle structure were inefficient in isolating the excitation forces. The design and location of the mounting system was evaluated using CAE and
Ghale, Guruprasad ChandrashekharBaviskar, ShreyasBendre, ParagKamble, PranitBhangare, AmitTHAKUR, SUNILKunde, SagarWagh, Sachin
Validation of hydrogen-fuelled internal combustion engine (H2 ICE) is critical to assess its feasibility as sustainable transportation with zero carbon emissions. This experimental analysis conducted on Ashok Leyland’s 6cylinder 2V engine to evaluate the engine performance & durability with hydrogen fuel. Combustion behaviour of hydrogen ICE needs to be closely monitored during continuous operation of validation testing, due to its unique properties compared to other conventional fuels. During engine run, a pre-ignition source can cause knock event leading to instant failure of critical parts like piston assembly, spark plug, liner, valves & cylinder head. Also, hotspots inside IMF leads to backfire affecting the air intake & fuel injection assembly. This study emphasizes the significance of precise instrumentation of thermocouples across engine on cylinder head, intake manifold & exhaust manifold, to detect performance detoriation and combustion abnormalities causing knocking
Vasudevan, SindhujaJ, Narayana ReddyBolar, Yogesh GaneshPandey, SunilN, HarishN R, VaratharajKarthikeyan, KKumar D, Kishore
Battery Electric Vehicles (BEVs) necessitate highly efficient thermal management strategies, as cabin heating directly consumes energy from the finite traction battery, potentially reducing driving range significantly. Early-stage design evaluations of warmup performance commonly rely on one-dimensional (1D) simulations due to their computational speed and efficiency. The accuracy and predictive capability of these models are critically dependent on how well they represent blower operation and account for temperature-induced variations in air density. This fidelity is essential because engineers depend on warmup simulations to set HVAC targets that will deliver real-world comfort and defrost performance within stringent range constraints. Earlier, warmup simulations employed a Constant Mass Flow (CMF) approach, which simplifies computations by assuming a fixed air density at a standard reference temperature. However, this approach contrasts with real-world blower behavior, where
Subramanian, Karthik
In last two decades, Farm customer expectation on cabin comfort has been increased multifold. To provide the best-in-class customer experience in terms of comfort without adding cost and weight is bigger challenge for all NVH Engineers. It is evident from literature survey that cabin tractors with better comfort is well accepted by customers in US and European Market. Apart from engine excitation, customer has become more sensitive to customer-actuated-accessory noises due to overall reduction in cabin noise in last 2 decades. This paper presents the study conducted on HVAC blower noise in 30HP cabin tractor. Tactile vibrations and cabin noise is not acceptable when AC is switched on due to low frequency modulating nature in frequency range of ~65Hz and 130Hz. The investigation is carried out systematically considering each component of Source-Path-Receiver model. HVAC blower unit as source is diagnosed in detail to understand root cause. Strong dominance of first order of blower been
K, SomasundaramChavan, Amit
The Indian automobile industry is experiencing a significant shift, propelled by environmental necessities and national climate obligations set at the CoP26 summit, aiming for a 45% decrease in CO₂ emissions by 2030 and reaching carbon neutrality by 2070 [1]. Transportation continues to be a significant source of air pollution; consequently, India is enhancing its regulatory frameworks with BS VI Stage 2 regulations, CAFE Phase III norms set for 2027, and CAFE Phase IV by 2032 [2]. Furthermore, the transition from MIDC to WLTP driving cycle is meant to increase the accuracy of the efficiency and emissions assessments [2]. To comply to these upcoming regulations, the automotive industry is moving toward producing high efficiency engines in India. A naturally aspirated (NA) 1.5L, 4-cylinder inline gasoline engine was selected from Indian market for this study. Maximum Brake Thermal Efficiency (BTE) of this engine is around 37%. Assessment of new technologies were performed by
Garg, ShivamFischer, MarcusEmran, AshrafJagodzinski, BartoschFranzke, Bjoern
The performance and longevity of Li-ion batteries in electric vehicles are significantly influenced by the cell temperature. Hence, efficient thermal management techniques are essential for battery packs. Simulation based optimization approaches improves the efficiency of the battery pack thermal management during the early stage of product development. In this paper, a simulation-based methodology has been introduced to increase the heat transfer from/to coolant via cooling plate as well as to reduce the heat transfer from/to the external environment. The heat transfer coefficient between cooling plate and coolant needs to be enhanced to achieve efficient heat transfer through cooling plate, without exceeding the coolant pressure drop the target limit. A one-dimensional simulation methodology described in this work analyzed numerous design of experiments for coolant layout without performing CAD iteration loops and optimized the cooling channel width, height and number of channels to
U, ReghunathP S, Shebin
Automotive driveline design plays an important role in defining a vehicle’s Noise, Vibration and Harshness (NVH) characteristics. Driveline system, responsible for torque transfer from the engine/transmission to the wheels, is exposed to a wide spectrum of vibrational excitations. The industry’s shift toward turbocharged engines with fewer cylinders while maintaining the equivalent torque and power has led to increased low-frequency torsional vibrations. This paper presents some key design considerations to drive the NVH design of a driveline system using linear dynamic FE simulations. Using an E-W All-Wheel Drive driveline architecture with independent suspension as a case study, the influence of various subsystem modes on driveline NVH performance is examined. The paper further explores the strategies for vibration isolation, motion control, and mode management to identify the optimal bushing rates and its location. Furthermore, it examines the ideal bushing specifications for
Joshi, Atul KamalakarraoSubramanian, MANOJ
This paper presents Nexifi11D, a simulation-driven, real-time Digital Twin framework that models and demonstrates eleven critical dimensions of a futuristic manufacturing ecosystem. Developed using Unity for 3D simulation, Python for orchestration and AI inference, Prometheus for real-time metric capture, and Grafana for dynamic visualization, the system functions both as a live testbed and a scalable industrial prototype. To handle the complexity of real-world manufacturing data, the current model uses simulation to emulate dynamic shopfloor scenarios; however, it is architected for direct integration with physical assets via industry-standard edge protocols such as MQTT, OPC UA, and RESTful APIs. This enables seamless bi-directional data flow between the factory floor and the digital environment. Nexifi11D implements 3D spatial modeling of multi-type motor flow across machines and conveyors; 4D machine state transitions (idle, processing, waiting, downtime); 5D operational cost
Kumar, RahulSingh, Randhir
In recent times, the governments are pushing for stringent emission regulations. These regulations call for reduction of pollutants as well as monitoring of engine components which are critical for emission control. Monitoring these emission critical engine components are to be done in real world driving conditions. The In-Use Performance Ratio Monitoring (IUPRm) framework quantifies how often onboard diagnostic systems check these components within defined boundaries for each vehicle. IUPRm is divided into several monitoring groups like catalyst monitoring, oxygen sensor monitoring, exhaust gas recirculation (EGR) monitoring, gasoline particulate filter monitoring and others. These groups are differentiated based on fuel type, engine technologies and exhaust treatment system configurations. For an Automotive manufacturer analyzing these parameters across large vehicle fleets is a complex and data intensive task. To address this, a user-friendly application was developed in-house
Ghadge, Ganesh NarayanJadhav, MarishaHosur, Viswanatha
In alignment with its carbon reduction commitments, India is transitioning towards higher ethanol-blended fuels, with E20 set for nationwide implementation by 2025. Ethanol is a renewable, domestically produced biofuel produced through fermentation of biomass such as sugarcane, corn. It possesses a higher octane rating and oxygen content compared to conventional gasoline, making it a favorable additive for improving engine performance and reducing emissions. This study investigates the impact of E20 fuel on performance parameters of a 694 cc MPFI , water-cooled, twin-cylinder gasoline engine. For deriving maximum benefits of increased Octane rating of E20, compression ratio was increased to 12.5:1. Experimental analysis was conducted to assess the changes in combustion behavior, brake specific fuel consumption (BSFC), torque output, engine out emissions and thermal efficiency when operating on E20 compared to baseline gasoline (E10). Base results indicate that E20 promotes more
Kulkarni, DeepakMalekar, Hemant AThonge, RavindraKanchan, Shubham
In current scenario, demand for alternate energy is increasing due to depletion of fossil fuels and countries working to achieve carbon neutrality by 2050. Hydrogen being a cleaner fuel, many OEMs across the world started to work on various strategies like hydrogen combustion engine and fuel cell. Passenger vehicles like buses are at the lookout for fuel cell technology at faster rate than other commercial vehicles. In fuel cell vehicles, cooling system design is critical & complex since it includes fuel cell cooling, Power electronics cooling & battery cooling. In this paper, cooling system design of a Fuel cell electric bus for inter-city application is demonstrated. Radiators and Fans are designed considering overall heat rejection and Coolant inlet temperature requirements of components. Cooling system circuit and pump is decided to meet the coolant flow rate targets. Flow simulation and thermal simulation done with the help of simulation models built using software KULI to predict
M S, VigneshKiran, Nalavadath
There is continuous push from the legislation for stringent fuel economy and emission regulations while the modern customers are demanding more engaging driving experience in terms of performance and refinement. To meet this Tata Motors has developed an advanced 1.2L 3-cylinder turbocharged gasoline direct injection engine. This next-generation powertrain delivers optimum efficiency, reduced emissions, superior performance with refined NVH characteristics. The key features used to enable these demanding requirements includes a 35 MPa fuel injection system, Miller Cycle operation and electrically actuated variable nozzel turbocharger (VNT). A uniquely designed BSVI complaint (WLTP ready) exhaust after-treatment system with Four-Way Conversion Catalyst (FWC+TM) ensures optimum emission control. A centrally mounted variable cam phaser minimizes pumping losses. The lightweight yet rigid all-aluminum engine structure, featuring an integrated structural oil sump, enhances durability and
Hosur, ViswanathaGhadge, Ganesh NarayanJoshi, ManojJadhav, AashishPanwar, Anupam
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