2) Certification of Buses for Rollover as per AIS-031 using CAE Methods 3) Calibration Lab 4) 4 Degree of Freedom (4DOF) HCV Cabin Shaker Test 5) Jounce and Squirm Test Rig for Seat Testing 6) Sound Package Tuning for Automotive Interiors 7) Photometric Services at Safety & Homologation Laboratory 8) ARAI Signed MoU with Loughborough University, UK for Research, Post Graduate and Doctoral Programmes in Automotive Engineering 9) Inauguration of ARAI-Regional Centre South (ARAI-RCS) at Chennai 10) Bus Body Accreditation by Automotive Research Association of India 11) Pressure Pulsation Testing for Engine Crankcase 12) Towing Dynamometer 13) Flash News 14) ARAI signs MOU with ISA, Sweden 15) Online Submission and Tracking of CMVR Type Approval Certification 16) Automotive Crash Test 17) Strategic Tie up of ARAI with CCT, Korea 18) Wheel Force Transducer for Passenger Cars and SUVs 19) Material Compatibility Study with Gasoline and Ethanol Blended Fuel 20) Development of EURO V Compliant CNG Injection Engine 21) Structural Dynamics Lab Your Partner in Vehicle Development 22) ARAIs Participation in Automotive EXPOs
Alternative Fuel Engine Development at ARAI
Development of alternatively fueled engines has become vital in order to meet the increasingly stringent emissions norms being implemented globally. Furthermore, alternative fuels provide a cost benefit, due to the lower costs of production of these fuels. Compressed Natural Gas (CNG), Liquefied Petroleum Gas (LPG) and Hydrogen-CNG blended fuel (HCNG) are promising alternative fuels in India. The Engine development lab at ARAI has developed several CNG engines for Indian OEMs ranging from 2 stroke 3 wheeler engines to heavy duty commercial engines. Various sub-systems of the baseline SI/CI engine, such as the air-intake system, combustion bowl, CR, the exhaust system, after treatment device are reviewed and suitably modified to achieve the target specifications. ARAI has experience of developing CNG/LPG engines with carburetion and injection kit fuel technologies and has completed several projects with reputed suppliers such as Landi-Renzo, AFS, Vialle, BRC, Lovato, Impco, Omnitek, ad Vanaz. Fuel system parts such as 1 st
stage reducer, 2 nd stage reducer, mixer are also suitably modified & optimized to achieve target specifications.
Figure 1 A CNG Bus engine developed by ARAI and the CNG HCV The CNG engines & vehicles developed by ARAI have passed current emission norms with comfortable margins in CO & NMHC+ NOx emissions. Most of the ARAI developed engines have been commercialized and are successfully running in the field. Figure 1 shows a CNG Bus engine developed at ARAI. As exhibited by the results, Closed loop control of CNG engines results in a large reduction in NOx and PM emissions as compared to diesel engines. CNG Injected engine can meet Euro-IV norms easily and have superior performance as compared to carbureted engines. The charge stratification in the CNG combustion chamber permits extremely lean combustion without high cycle-by-cycle variations with high combustion efficiency.
ARAI has expertise in development of LPG engines. Liquefied Petroleum Gas (LPG) is a prominent alternative fuel with well developed distribution infrastructure and increasing number of Gasoline engines are now being converted to run on LPG considering the fuel economy and low exhaust emissions. ARAI has developed several bi-fuel (LPG/Gasoline) and dedicated LPG engines ranging from single cylinder two wheeler engines to advanced 4 cylinder passenger car engines. Optimization with LPG kit includes emission optimization on to give equivalent mileage on Gasoline. Figure 2 shows a typical LPG engine developed by ARAI.
Figure 2 A Single Cylinder LPG Engine Developed by ARAI
Traditionally CNG vehicles have been developed in India in variety of segments and have contributed to cleaning the ambient conditions of cities like Delhi. However the persistent NOx levels are becoming a hotly debated issue. One of the solutions to this crisis is the addition of Hydrogen to CNG. The Hydrogen + CNG fuel referred to as HCNG has the potential to lower emissions including NOx as compared to CNG and is considered to be the first step towards promotion of a Hydrogen economy. ARAI is developing a 6-Cylinder HCNG naturally aspirated engine using the lean burn concept of combustion. The six cylinder engine was chosen due to its importance for urban bus transportation. In this study the lean burn combustion concept has been evaluated for varying HCNG blends. The HCNG engine has potential to meet Euro-IV and beyond norms with Injection technology. It is also expected that HCNG fuel blends reduce NOx emissions by approximately 50%, non-methane hydrocarbons by 58%, and total hydrocarbons by 23% and CO 2 by 7% as compared to CNG. No PM emissions are observed in CNG or HCNG engines.
Figure 3 HCNG Engine Under Development at ARAI ARAI is fully equipped and has the expertise to undertake development projects for all types of CNG, LPG & HCNG engines for the automotive industry.
Certification of Buses for Rollover as per AIS-031 using CAE Methods
ARAI has completed number of projects on evaluation of strength of bus superstructure for rollover analysis as per AIS-031 using computer simulation and validated the results by physical rollover test. Following are the major activities carried out in the process: Classification of bus models into different families and to arrive at the worst case of the family: ARAI has prepared a methodology for classification of bus models into different families and to arrive at the worst case of the family, based on different engineering parameters and if needed, use of CAE methodology. This facilitates substantial time and cost saving by minimizing the number of physical tests. Generation of input parameters viz. material properties and joint characteristics: Before carrying out the simulation, it is necessary to measure physically all the relevant mechanical parameters (including stress-strain curve, etc) of the material and also that of the joints used in the bus. In the case of joints, they get simulated and validated with the physical data collected using test facilities at ARAI. The validated model of the joints is used for simulation.
Computer Simulation Physical Testing Loading area Constraint area
Joint Simulation and Experimental Validation
Determination of vehicle CG by experimental method using method prescribed in ECE R 66: ARAI have a test setup for determination of vehicle CG by experimental method, which is an important input for FE model generation of buses.
Generation of detailed FE model and Rollover analysis of bus using non-linear FE software: ARAI has developed a methodology for generation the FE model and rollover analysis of bus using non-linear FE software, which has been closely correlated by physical rollover tests. CAE methodology is now very well developed and is widely deployed for evaluation of impact scenarios like the bus rollover. The methodology is proven to generate the necessary confidence to complete the design sign-off.
Experimental CG Determination
FE Model of Bus
Rollover Simulation and Experimental Validation Suggestion of structural modifications to meets rollover requirement: In case the baseline design does not meet the rollover requirement, ARAI can suggest suitable optimum and practical modifications to enable the design to meets rollover requirements. The entire methodology results in speeding up the development cycle for bus manufacturers. Following papers are published by ARAI on the above topic: SAE Paper No. 2009-26-001: Certification of Buses as per AIS-031/ ECE-R66 Using CAE Methods by Joseph Philip, Chopade, S. E., Mahajan R. S., Raju S, at Symposium on International Automotive Technology (SIAT) 2009, ARAI, Pune, India
Automated Process Tool for Pre & Post Processing of Bus Roll-Over Analysis in Compliance with AIS 031/ ECE R66 by Mahajan R. S., Presented at Hyperworks Technology Conference, 08 at Bangalore, India, along with Rishi Shah, Altair Engineering (I) Pvt. Ltd.
Calibration Lab
Calibration Lab at ARAI is well equipped to serve calibration needs of the automotive, component and allied industry. The laboratory has NABL accreditation as per ISO 17025. In addition to discrete calibration services, Calibration Lab undertakes full calibration contracts such as calibration of test cell instruments, production line, etc. It also undertakes turnkey calibration jobs and onsite calibration services are covered under NABL Accreditation. The facilities cover parameters such as : Temperature Pressure Electrical Acceleration Mass & Balances
Sound Pressure Level Miscellaneous, such as RPM, Load, etc.
Highlights National / International Traceability NABL Accreditation
On-site calibration facility Expert Manpower
Various facilities of Calibration provided by Lab 1) Temperature Calibration
Primary Calibration using Fixed Points: Mercury (-38.8344C) TPW (0.01C) Ga (29.7646C) Indium (156.5985C) Tin (231.928C) Zinc (419.527C) Aluminum (660.323C) Reference cells with their maintenance bath are used for calibration of SPRTs, PRTs and Reference Temperature Sensors.
Secondary Calibration by Comparison Method: Comparison Calibration Range: -50C to 1000C.
NABL 2) Mass, Weighing Balance and Load Cell Calibration
Reference Equipment: Set of E1 class Weights Set of E2 class Weights Set of F1 class Weights Micro-Balance Weighing Balances
Standard Weight Set and range 1mg to 200g 500g to 5kg 10kg to 20kg 0.001mg to 2g 0 to 220g, 5kg, 12kg, 150kg Calibration of fractional weights 1mg to 50 kg and balances up to 150 kg.
Load Cells Up to 100 kN
NABL
3) Pressure Calibration
Reference Equipment Dead weight Tester Portable Pressure calibrating system
Standard Weight Set and range Range -1 to 50 bars Range -1 to 1000 bar Calibration of pressure gauges, vacuum gauges, compound gauges, pressure indicating systems, pressure transmitters, etc.
NABL 4) Accelerometer, Sound Level and Speed Calibration
Calibration of ICP, Piezoelectric, Piezoresistive or Capacitive Type Accelerometers using Secondary Accelerometer Calibration up to 60 g in operating range 3 Hz to 10 kHz.
Also facility for calibration of Sound Level Meters, Sound Analyzers, etc. using Multifunction Acoustic Calibrator for A, C and Linear Weighing from 31.5 Hz to 16 KHz.
In-house and on-site calibration for Speed Sensors / Tachometers and Pulse Engine Tachometers.
NABL 5) Electrical Calibration
NABL
Reference Equipment Precise Calibrator, 8 and 6 Digit DMM, Frequency Standards, etc. Calibration of Precise Multi meters, Digital Process Calibrators, Temperature Controllers, Timers, different types of Generators and Counters, Oscilloscopes, Meggers are carried out.
Parameters (For Source & Measure)
DC / AC Voltage DC / AC Current Resistance Frequency Time Temperature Indicator 0 to 1000 V (Source), 0 to 10 KV (Measure) 0 to 20 A 1 to 100 M 1 Hz to 225 MHz 0.1 Minute to 24 Hrs All type of thermocouples & RTDs
4 Degree of Freedom (4DOF) HCV Cabin Shaker Test
With unique blend of resources, facilities and manpower supported by capabilities in the most advanced technology at Structural Dynamics Laboratory (SDL) of ARAI, our customers benefit from the unrivalled expertise. SDL team applies their knowledge and experience for helping customers to create world-class products. Operating across the whole range of transport technologies, SDL provides particular expertise in all aspects of durability. From initial concept through to production start, SDL is being able to provide latest simulation and development tools and techniques. SDL has been supporting Automotive Industry in vehicle development process for more than 20 years, helping customers to design, develop and produce higher quality products with greater speed and lower cost. SDL engineers thrive on diverse and technically challenging projects and are always able to offer customers innovative approach or solution. Operating at the forefront of vehicle development, SDL has completed number of successful projects. Recently SDL has developed cabin simulator to sign off durability in laboratory.
For durability evaluation of cabin, full vehicle test such as four-poster, multi axis test, etc. where input is given at wheels, were being used. This new cabin test rig is designed where various cabin modes are produced. There are independent multi axis motions possible (Vertical, Pitch, Roll, Yaw, Lateral and Longitudinal), but simultaneously reproducing all of them requires significant complexity in data acquisition, as well as test rig design and operation.
SDL has developed 4DOF cab shaker test rig to produce motion vertical, pitch, roll and longitudinal. In this test rig four vertical actuators and one longitudinal actuator are used. The vertical actuators are mounted under the corners of the cabin using a pseudo frame. The longitudinal actuator is mounted at the cross member.
Lateral restraints are used to keep the specimen upright during dynamic operation of the test rig. The objective to this restraint is to stabilize the specimen in an upright position without producing forces and displacements. The picture given below shows schematic of set up at ARAI.
Rig Specifications Cabin Load Capacity: 1T Frequency: 40Hz. Test Specifications: Simulation of Road Load Data Durability: Accelerated durability testing by removing non damaging portion of data of given correlation.
Structural Dynamics Laboratory (SDL) of ARAI is dedicated to product development in the automotive sector, offering engineering, testing and homologation services to the industry world-wide. SDL undertakes global vehicle development projects for the principal manufacturers and has consolidated its position as a reference in the sector.
Based on the global Automotive Roadmap of certification and development, SDL has its own roadmap of introducing new services, which has unique combination of research projects, specialist engineering skills, world class engineering facilities, development test facilities and homologation facilities.
Validation testing on seats and seat structures is one of the major activities carried out at SDL. Validation testing is an important part of design process for seat and seat structures. Validation tests are performed to determine if design requirements are met. These validation tests are classified as, Functional test Reliability test Homologation and Safety related test Testing for interface and compatibility Development tests on sub-assembly components
The development tests conducted so far were as per various International standards and specifications. SDL has now taken another step towards enhancement of its developmental test facility in seat testing area by installation of the Jounce and Squirm Test Rig. Jounce and Squirm Test Rig for Seat Testing
Jounce and Squirm test rig is designed to simulate an occupant sitting on a seat, twisting and / or bouncing. The seats are mainly evaluated for trim degradation including fabric tears, cuts, rips, wear, etc. and functionality. The seat cushion (or back) is fixtured to a table and fitted with an arrangement where it can be deflected. The cushion (or back) is loaded by foam to simulate jouncing action. While this body form is loading the seat is rotated left and right about a pivot point to simulate squirm action. This test is done on all types of automotive, train and bus seats.
SDL has installed a custom built Jounce and Squirm test rig using pneumatic actuators, servo motors and Programmable logic controllers. The rig can be used for Jounce only, Squirm only and Jounce and Squirm Tests. The rig can test 2 occupants simultaneously. The specifications of the rig can be summarized as below: Jounce Load : Max 150 Kg per occupant (2 occupants simultaneously) Jounce operating cycles Rate : 100 cpm Squirm Angle : Max 45 degree Squirm Cycle Rate : 10 cpm
Load and frequency at the load application is adjustable to suit specific requirements of the customer.
Sound Package Tuning for Automotive Interiors
Recent trends in automotives show increasing use of acoustic materials for interior noise control. Automotive noise control involves many aspects of vehicle design. Vehicle development team has a challenge of balancing the conflicting requirements of mass reduction and acoustical performance enhancement. Acoustical performance of dash insulator and carpet contribute significantly in the vehicle interior noise.
ARAI has developed new engineering methods and new multi-layer materials to solve automotive noise problems. Study has emphasized to get noise reduction by use of a typical sandwich insulator (for dash insulator and carpet), which consists of a steel panel, porous de-coupler and heavy layer. Noise reduction mainly depends upon sound transmission loss of the sandwich insulator, which is evaluated as per SAE J 1400. Unfortunately, this sandwich insulator acts as a mass-spring-mass system which resonates between 100 Hz to 500 Hz in the same frequency range as the engine firing frequency. The aim is to tune the system attenuation at resonance, while maintaining performance at middle and higher frequencies. Effectiveness of these products was enhanced to meet the requirements with proper selection of decouplers, heavy layer mass per unit area and use of simulation tool.
NVH Lab at ARAI, jointly with OEMs and acoustic material manufacturers, could diagnose and provide quick engineered solutions to improve the vehicle interior noise.
0 10 20 30 40 50 60 70 80 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 S o u n d T r a n s m i s s i o n L o s s ,
d B One third octave frequency band, Hz Dash Insulator_Diesel Vehicle Dash Insulator_Petrol Vehicle Steel sheet_0.8 mm Resonant Frequency
Sound transmission loss of dash insulators evaluated at ARAI as per SAE J 1400
Photometric Services at Safety & Homologation Laboratory
Safety & Homologation Laboratory (SHL) of ARAI operates as the longest serving independent NABL / ISO 17025 accredited laboratory for Photometry in India. Since 1998, SHL has been the source for accurate and timely photometric testing. The laboratory is accredited by National Accredited Board for laboratory (NABL), which is equivalent to ISO 17025 in the field of Optics and Radiometry. This lab is also certified for ISO 9001, ISO 14001, OHSAS 18001 and continually reviews, monitors and updates its measuring techniques and processes which help in achieving shorter turnaround times, greater accuracy and quality results for our Clients. SHL ensures to provide all services related to photometry with the state-of-the-art test facility. The laboratory provides consultancy services for R&D projects related with lighting, signaling and related areas. This laboratory has also been providing calibration services to all lighting and signaling device manufacturers and also to the other testing agencies notified under CMVR.
Gonio-Photometer
Venturing into new areas of services in Photometry SHL undertakes any form of photometric testing that may be required within its sphere of competency. Recently, SHL ventured into the following new areas of photometric testing. a) Aeronautical Lighting Devices b) Destination Boards for Buses c) Road Signs / Road Studs and Retro-Reflective Sheets Aeronautical Lighting ARAI recently completed assessment of Aeronautical lighting systems as per the specifications of International Civil Aviation Organization (ICAO) and MIL standard for one of our customers. This involved the following experiments.
a) Measurement of light intensity as per ICAO b) High temperature as per MIL-STD-810E c) Low temperature as per MIL-STD-810E d) Salt fog test as per MIL-STD-810E
Aviation Warning Light with control unit Unit under climatic test Destination Board for Buses
SHL is currently conducting assessment of LED based destinations boards as per customer specifications. Destination Boards are evaluated for their resistance to damage from vibration induced stresses, resistance to water and dust penetration, resistance to heat and cold, effect of corrosion, life test etc. To assess these parameters the following tests are being conducted as per customer specifications -
a) General specifications for dimensions, brightness variation, etc. b) Environmental tests such as : i. Dry Heat test ii. Cold test iii. Damp Heat test iv. Vibration test
v. Salt Spray test vi. IP test vii. Life test for LEDs
Front / Rear Destination Boards Internal Display Board
Driver Control Unit
Unit under hot/cold/damp heat test Unit under vibration test
Road Signs / Road Studs / Retro Reflective Sheets
SHL has also taken up testing services for road signs, road studs, retro Reflective sheets, etc. as per national and international standards like ASTM D 4956 or SAE J 845. a) Day time colour b) Adhesion test c) Gloss value d) Co-efficient of retro reflection
Road pavement markers are tested for their coefficient of luminous intensity as per ASTM D 4280-04
Triangle Sign Board LED Pilot Lamp Delineators
Road Stud / Pavement Marker ARAI Signed MoU with Loughborough University, UK for Research, Post Graduate and Doctoral Programmes in Automotive Engineering In addition to utilizing state-of-the-art technology, laboratories and highly-trained personnel, ARAI recognizes the need to develop a new generation of engineers to meet the demands of the automotive industry, not just in India but across the globe. Its objective is to develop a World-class Eco-friendly Academy at ARAI for Masters, Doctoral and Professional Improvement programs in Automotive Engineering in collaboration with National and International Universities. ARAI has embarked upon a programme of building up human resources by commencing educational programmes in Automotive Engineering. It has started the Academy for M.Tech. (Automotive Engineering), in collaboration with VIT University, Vellore in 2004. The success of this collaboration has prompted ARAI to look into the development of specialized programs in various fields of automotive technology with the leading Universities abroad.
Shri Shrikant Marathe, Director-ARAI (right) and Prof Richard Stobart of LU sign the MoU With this background, ARAI has signed an MoU with Loughborough University located at Leicestershire, UK on 4 th July 2009. The MoU reflects our mutual interest in research, education and enterprise in the area of automotive engineering, and as a contribution to international co- operation. During the visit of a team from Loughborough University to ARAI, training workshop on a 5-day module called Professional Improvement Programme on Powertrain Engineering was conducted at ARAI, Pune.
Based on the present system in the Universities, credits are proposed for each module so that engineers can attend various modules and sum up the credits required for Masters or Doctoral Programs. ARAI Academy proposes to start the following programs through LU from September 2010: Course Duration No. of Seats M. Sc. (Full Time) in Automotive System Engineering 18 months 25 Seats M. Sc. (Part Time) in Automotive System Engineering 36 months 25 Seats Ph. D. (Full Time) in Automotive System Engineering 03 years 05 Seats Ph. D. (Part Time) in Automotive System Engineering 05 years 05 Seats
Each taught module would entail intensive residential study week at ARAI together with work on prepared programme, material and assignments requiring access through email and internet. The modules at ARAI would be taught jointly by in-house faculty of ARAI and LU with an approximate proportion of 50:50.
This would be a very good opportunity for engineering professionals to join this program on part time basis without leaving their present jobs. The projects can be done at the same organization where they are working. However, they would be required to visit Loughborough University at UK for 6 weeks and undergo some modules, orientation, campus recruitment, industrial visit, etc.
Inauguration of ARAI-Regional Centre South at Chennai
In an effort to expand the business activities of ARAI in the southern region of India, ARAI has opened Regional Centre South (RCS) at Chennai on 12 th August 2009. As a Chief Guest at the Inaugural Function, Dr. V. Sumantran, Former President of ARAI and Vice Chairman of M/s. Hinduja Automotive Ltd, inaugurated ARAI-RCS Office in the presence of Mr. R. R. G. Menon, Executive Director of M/s. Ashok Leyland Limited and Mr. Srivathsa Ram, Managing Director of M/s. Wheels India Limited were the special invitees. Representatives of automobile, component and allied industry were present on this auspicious occasion.
In his welcome speech Mr. Shrikant R. Marathe, Director of ARAI, explained the need to strengthen the R&D base in India and widen the horizon of operations to expand the business further. While indicating the major role being played by ARAI in design, development and certification of automobiles and auto components, Mr. Marathe informed ARAIs readiness to support the industry in meeting the challenges ahead. ARAI will not have any facilities at their Regional Centre South, but only the office to co-ordinate development and testing work of all our customers in the southern part of India. Our Engineers at ARAI-RCS will interact with the customers, understand their requirements and co-ordinate their assignments with ARAI Head Office at Pune for better and timely execution. In his Inaugural Address, Dr. Sumantran appreciated the timely initiative taken by ARAI to support the automotive industry in southern part of the country, in all their needs, especially the development work. He informed that in last five years automobile industry has not only grown in volume, but also technologically. He further insisted that the R&D and Testing Facilities in the country need to be upgraded in line with the requirements of the industry. He appreciated that the dedicated team work by ARAI boosts confidence of the Indian Auto Industry. He wished all the success to ARAI in all its endeavours.
The function concluded with vote of thanks by Mr M. V. Ramachandran, Senior Assistant Director and In Charge of Regional Centre South office.
Contact details of ARAI-RCS are given below :
Mr. M. V. Ramachandran, Senior Assistant Director The Automotive Research Association of India Regional Centre South (ARAI-RCS) Ground Floor, AP/68 AF-Block, Second Street Anna Nagar West Chennai 600 040 Telefax: 044- 26191804 Mobile: 9840294777 E-Mail: araircs@md4.vsnl.net.in; ramachandran.dts@araiindia.com
Bus Body Accreditation by ARAI
To keep pace with the dynamic requirements for mobility and simultaneously catering to added concerns of safety and comfort for mass transportation, Government of India has taken up, on priority, the key issue of streamlining and harmonizing bus body building; with an intent of evolving universal procedure for design and type approval of buses and as a corollary bring the unorganized private bus body building sector under one gambit.
Addressing all these issues, Technical Committees have formulated AIS-052 : Code of Practice for Bus Body Design and Approval as well as AIS-063 : Requirement of School Buses, which are in the process of being notified shortly. Simultaneously, Ministry of Road Transport & Highways (MoRTH) has issued S.O. 425 (E) dated 23rd March 2007, laying down procedural norms for Accreditation of Bus Body Builders as well as formulation of Zonal and National Accreditation Boards.
Accreditation is a process of evaluating, assessing and approving the capabilities and capacities of a Bus Body Builder to consistently produce specified quality of bus bodies by the competent authority. Accreditation process basically calls for an administrative and technical audit at the premises of bus body builder, to assess their design and development capabilities (technical expertise and qualified manpower) along with available land, plant and equipment, ascertaining usage of quality products backed by genuine material and parts, availability of minimum in-house facilities, viz. production assembly and fabrication unit, paint shop, final product inspection facilities, etc., uniformity in the construction with due regard to safety and comfort, in consonance with the Code of Practice for Bus Body Design and Approval, AIS-052.
ARAI is well-equipped to carry out evaluation of buses, as per AIS-052 as well as AIS-063. Additionally, based on the technical expertise and qualified manpower, ARAI has been allocated the secretariat of North and East Zonal Accreditation Boards for Bus Body Accreditation.
So far, ARAI has evaluated twelve bus body manufacturing units in the North Zone. Evaluation of four bus body builders from the East Zone is in the offing.
As accreditation of Bus body builders vide S.O 425(E) dated 27 th March 2007 is in vogue, applicants from North and East Zone may kindly send applications in the prescribed format specified under said S.O., to:
Shri S.S. Sandhu, Deputy Director (Vehicle Evaluation Lab) Secretariat, Zonal Accreditation Boards (North & East) Member, National Accreditation Board The Automotive Research Association of India (ARAI), S. No. 102, Vetal Hill, Off Paud Road, Kothrud, Pune 411 038, Maharashtra, India Tel: 020-3023 1370; Mobile: 099754 92653; E Mail: sandhu.vel@araiindia.com
Pressure Pulsation Testing for Engine Crankcase
Development and testing of products calls for development and modeling of own designs as well as validate performance and durability of prototypes. Meeting customer requirements successfully now requires reliable component testing and validation strategy that generates accurate component test data that can be shared directly with customers. Weighing such factors carefully with time constraints, realistic approach must be adopted for testing of components according to specific circumstances. Considering all these aspects, our Structural Dynamics Lab (SDL) has developed in-house component test cell, especially for development of engine components.
Demands for Structural Testing of Engine Components
Structural testing plays an important role in development and validation of engine components. Structural Dynamics Lab equipped with the state-of-the-art facilities cater to structural evaluation requirements of engine manufacturers. Structural testing at SDL for evaluation of Engine and its Components: Fatigue testing of various engine components for evaluation of fatigue strength, determination of fatigue life, comparative study of components, simulation of failure modes, etc. Experimental stress measurement on components during service condition and testing Fatigue Testing of bolts by S-N curve Evaluation, Staircase method, Weibull Analysis
Series of ARAI Update will demonstrate variety of development projects that we are ready to undertake specifically for engine components. To start with, this issue of ARAI Update covers development of crankcase.
Need for pressure pulsation test on engine crankcase
To confirm structural adequacy of cylinder block for the designed peak firing pressure under cyclic loading To check for any leakage between the block and head due to failure of gasket at the peak pressure Check for strength of cylinder head bolts To validate CAE model of cylinder block To identify critical locations on cylinder block.
The test rig designed and developed by has following advantages
Few components are required for the test Lower cost Time required will be less as compared to running of engine on the test bed Tests with higher factor of safety are possible Different engine components can be simultaneously validated in design stage, before testing of engine, thus total engine development time can be reduced. Selection of critical locations for mounting of strain gauges and strain values can be recorded before, during and after completion of test.
Test set up for Inline - Cylinder Engine Test set up for V Type - Cylinder Engine
Cyclic Pressure variation recorded during the pressure pulsation test. General test requirements and procedure
The aim is to carry out pressure pulsation test on engine crankcase for required pressure variation in two adjacent cavities at 180 out of phase pressure cycles at estimated frequency for 10 million cycles each. Peak cylinder pressure is used for pressure pulsation test.
Fixtures like steel manifold block, etc. was designed and fabricated for carrying out the test.
Design of Manifold block for two main purposes
a) To seal 2 adjacent cylinder block cavities like cylinder head and to incorporate hydraulic circuit for oil flow to and from servo - valve attached to it.
b) Provide pressure transducer connection for test cylinder cavities. The manifold block was designed to incorporate cylinder head bolts used in the engine.
Test Procedure
1. Clean and assemble crankcase with engine connecting rods, crankshaft and one steel piston each in 2 adjacent cylinder cavities.
2. Lock crankshaft at flywheel end to prevent rotation such that steel pistons in the cavities will be at Top Dead Centre (TDC).
3. Assemble hydraulic manifold block on 2 adjacent cylinder cavities with engine cylinder head gaskets.
4. Tighten cylinder head bolts up to required torque levels.
Components required during testing
1) Cylinder block 2) Flywheel 3) Flywheel locking arrangement 4) Modified piston 5) Sealing arrangement 6) Cylinder head bolts 7) Gasket between block and head
8) Crankshaft 9) Connecting rod 10) Oil sump 11) Fabricated stand 12) Connection for lubrication inlet 13) Provision for plugging oil galleries
Towing Dynamometer
Unlike Engine / Chassis Dynamometers, Towing Dynamometer is a trailer mounted eddy current dynamometer which is attached to the test vehicle and by adjusting the eddy current, the driver of the test vehicle can adjust the load requirement (draw bar pull), to simulate varying test conditions, on the field, either in constant load or constant speed mode. Following are some of the tests that can be conducted using the Towing Dynamometer, which give more realistic test results, under controlled loading of subject vehicle a. Engine Cooling Performance by simulating extra load on the engine viz. increasing draw bar pull. b. Transmission Component Evaluation c. Gradeability Simulation without physically putting on dead load on test vehicle. This test can be done on a straight level track instead of climbing a gradient. d. Fuel Consumption Simulation of extra GVW by increasing the draw bar pull of the vehicle. e. Failure Analysis f. Vehicle Heating and Cooling Systems and g. Tyre Testing by increasing draw bar pull in such a way up to skidding / slipping point of tyres.
Being extensively used worldwide for development of prototype, the Towing Dynamometer could also be used for study of various parameters viz. efficiency of a engine cooling system, loading of transmission and drive axle to assess the design sufficiency.
In 2004, the Vehicle Evaluation Laboratory (VEL) has procured Towing Dynamometer Model RS 40K from M/s. DynoMotive LLC, USA, having the following specifications: Model : RS40K Length : 270 (6,856 mm) Width : 96 (2,438 mm) Height : 72 (1,829 mm) Weight, Dry : 14,900 lb (6,760 kg) Weight, with Ballast : 21,200 lb (9,619 kg) Load Cell : 11,240 lb (50,000 N) Overload Protection : 500 lb (40,000 N) Max. Drawbar Pull : 11,240 lb (50,000 N) Max. Continuous Hp : 410 HP (305 kW) Max. Speed : 68 mph (110 km/h)
Additional Features
Programmable facility for loading and monitoring through drivers cabin Compatibility with Indian tyres Output Device (Strip Chart Recorder to plot Drawbar Pull Vs Speed Vs Time) with user definable inputs.
Special Feature
The special feature of this Towing Dynamometer is that loading is electrically operated, which entails in considerable savings of time. Besides, loading can be adjusted according to pre- programme, which ensures repeatability of trials.
FLASH NEWS ARAI and Romax Technology (UK) have signed an MOU to provide engineering services to the Indian automotive industry in the following areas: NVH analysis and testing Transmission Control Unit (TCU) Development Transmission matching and optimization Finite Element Analysis of Transmission components
Design validation and upgradation Design and analysis of Gearbox, Engine Gear train, Chain and Belt Drives, Clutch, Rear-axle, Differential and Drive Shaft Design of Automotive transmission system and industrial Gearbox Gear Failure Analysis
New Services from ARAI:
Winter Testing Fire Risk assessment of Vehicles ARAI and ISA (Invest in Sweden Agency) have established closer relationship by signing a MoU with the understanding to work closely in number of areas related to Automotive Sector. ISA is a government agency responsible to the Ministry for Foreign Affairs, Government of Sweden to facilitate business and investment opportunities in Sweden. The co-operation between ARAI and ISA in various areas relating to advanced automotive technology and services will meet the emerging demands of the Indian Automotive Industry.
The subsequent visit of Director of ARAI, Mr. Shrikant R. Marathe and Sr. Deputy Director, Mr. D J Kulkarni in August 2009 to several organizations in Sweden has established working arrangements with them within a very short period. Through these arrangements, ARAI is now in a position to offer following services to the Indian Automotive Industry. 1. Winter Testing Facilities Dynamic handling and ride comfort to check Noise, Vibrations and Harshness, suspension rattling etc. Snow chain test particularly for all wheel drive vehicles Extreme maneuverability and tyre testing Gradeability tests Anti spin, mixed track test with polished ice and asphalt tracks Transmission test for slippages on 10-27 degrees slopes Cobblestone and severe track for checking vibrations, noise etc Heated asphalt and polished ice track having split coefficient of friction particularly to test brake systems and ESP tests. Hilly terrain with extreme bends to test reliability, durability and manouverability checks.
The above facilities will be useful to - OEMs Electronic system manufacturers Automotive component and sub-system manufacturers Tyre manufacturers
2. Fire testing facilities including Fire Risk assessment of vehicles
3. Along with ISA and other Swedish manufacturers, ARAI is planning a demonstration project to operate a public transport bus on bio-gas as a renewable fuel for urban sustainability.
Online Submission and Tracking of CMVR Type Approval Certification
With immense pleasure we share with you that ARAI website www.araiindia.com is revised, with a user-friendly newer version, incorporating custom built advanced features as highlighted below: Virtual Tour With single click of a Virtual Tour button, ARAI customers can have a quick tour to the state-of-the-art facilities and capabilities of ARAI as well as diversified activities in specialized R&D as well as Homologation Certification areas.
Online Submission of Type Approval Application This feature enables ARAI customers to submit hassle-free paperless application online through web access with a single click. ARAI customers are allowed to submit Type approval documents / specifications through a secured Online System Architecture. Unique login IDs and passwords provided to the customers will enable them securely submit their applications online through ARAI website. On submission of application from any destination all over the world, customer will receive an acknowledgement via email, confirming Apex Number for respective document submission. Innovative Tracking System Latest status on CMVR Type Approval Certification updated from time to time is accessible through ARAI Website. With this advanced system, online applications can be tracked at any point of time to know the status of CMVR certification. Customers unique login IDs and passwords enable them to online access / check status on certification of their vehicles online maintaining security of their products.
TA-Admin Group look forward to welcome you and have further interaction via email ta-admin@araiindia.com CMVR Type Approval Handbook
CMVR Type approval Handbook is available as a priced publication under Downloads. It contains all that one would wish to know about the Indian Type Approval System for Automotive Vehicles, Components, Generator Sets, Construction Equipment Vehicles, Tractors and any other equipment / vehicles covered under Central Motor Vehicles Rules (CMVR), 1989 as amended from Time to Time.
Automotive Crash Test With the experience gained over the years and the know-how developed in the area of automotive crash testing, ARAI has developed expertise to carry out crash tests to check the performance of security devices / barriers against automotive crash. ARAI has successfully carried out a certification test for Tire Ripper, a security device, by performing actual crash test at customers site. This otherwise would have required testing at the facilities abroad. The testing was possible with the state-of-the-art portable electronic vehicle propulsion and control system available with ARAI.
ARAI is geared up to take similar tasks at given site. For further details contact: director@araiindia.com
Strategic Tie up of ARAI with CCT, Korea
ARAI and China Certificate Technology (CCT), South Korea, specializing in China Compulsory Certificate (CCC), China Security and Protection certificates (CSP), State Radio Regulatory Commission (SRRC) have entered into an MOU to promote component certification and vehicle homologation for the manufacturers from South Korea as per the Central Motor Vehicles Rules applicable in India.
CCT is an authorized representative of ARAI in South Korea to promote ARAIs business. Wheel Force Transducer for Passenger Cars and SUVs
Structural Dynamics Lab (SDL) of ARAI has recently acquired a 16 wheel force sensor used for measurement of spindle forces and moments on a rotating wheel; a major constituent in modern vehicle development cycle. Kistler make RoaDyn S635 measuring wheel has a modular, highly versatile design for mounting on different wheel hubs and rim geometries of vehicle. Simultaneous data of three spindle forces in longitudinal (Fx), lateral (Fy) and vertical (Fz) direction along with three moments Mx, My and Mz can be acquired precisely. The same WFT can be used for non-spinning application on MTS 329 test rig available at SDL. Signals from WFT can be used directly for simulating acquired spindle forces. With this sensor, vehicle instrumentation, vehicle testing / development time will be reduced substantially.
Typical Applications
Measuring operating loads during typical vehicle driving maneuvers Input data for design of new components and verification of design loads Measuring test stand control data for road simulators Investigation of vehicle behavior in specific or critical driving situations Input data for fatigue calculations and numeric simulations
Material Compatibility Study with Gasoline and Ethanol Blended Fuel Study project on evaluation of effect of 10% ethanol blended gasoline (E10) fuel versus commercial gasoline (E0) on polymeric materials (Elastomers and Plastics) used in automotive components is undertaken by ARAI. Few common elastomers and plastics used in automotive components are being tested as per the guidelines given in the standard, SAE J 1748 for non-metal compatibility study. Change in material properties like volume/swell, weight, appearance, tensile strength, elongation, impact resistance and hardness shore A will be measured after immersion of materials in the fuel in a periodic manner to evaluate impact of E10 fuel on materials relative to gasoline.
Development of EURO V Compliant CNG Injection Engine
Use of CNG as an automotive fuel results in significant reduction in vehicular pollutants such as CO, HC, NOx and PM. Additionally, use of CNG results in reduction in emissions of greenhouse gases (CO 2 ), owing to lower Carbon-to-Hydrogen ratio of the methane (CH4), as compared to other hydrocarbon fuels. ARAI has developed several CNG and LPG engines ranging from 2-stroke single cylinder engine to multi cylinder 4- stroke engines with fuel kits ranging from elementary carburetion to sophisticated multi-point fuel injection systems. The CNG engines and vehicles developed by ARAI have passed current and upcoming emission norms with comfortable margins in CO and NMHC+ NOx emissions. The CNG engines developed by ARAI have been commercialized and are successfully running on multiple vehicles in the field. ARAI work on gaseous fuel engine development has been lauded at various international forums. We have also undertaken HCNG (Hydrogen + CNG) engine development program.
The CNG Injection Engine recently developed for one the OEMs is meeting Euro V norms with sufficient margin. This engine has superior performance with specific power output of over 20 kW/l as compared to contemporary CNG engines. The charge stratification in CNG combustion chamber permits extremely lean combustion without high cycle-by-cycle variations with high combustion efficiency. Various design modifications are carried in the base SI engine for upgradation to achieve Euro V Emissions Norms. Simultaneous improvements were obtained in fuel efficiency by modifications in various sub-systems of the engine, such as fuel-system, ignition-system, air-intake system and combustion parameters.
ETC cycle and Successful Regression Analysis
ETC cycle and Successful Regression Analysis Salient features of engine are as follows: State-of-the-art injection technology Tuned Intake manifold Optimized combustion bowl for squish Effective utilization of swirl Centrally located spark plug Dual intake valve Palladium based catalytic converter Specific power output over 20 kW/l Flat torque curve over engine range Fast response thereby meeting ETC comfortably
Euro-V CNG Engine
0 1 2 3 4 CO THC Nox Achieved performance Euro IV limit Euro V Limits
Emission Performance of CNG Engine over ETC Cycle With the development of CNG engine, ARAI has achieved competency to carry out development assignments for CNG, LPG and HCNG engines to meet Euro-V and beyond norms.
Structural Dynamics Laboratory Your Partner in Vehicle Development Operating across whole range of vehicle development technologies, our Structural Dynamics Lab (SDL) provides particular expertise in vehicle development and Optimization Cycle for Indian Road Driving Conditions.
Starting from initial concept to launch of vehicle and even for further development plans, vehicle manufacturers have to pass through several different stages. Backed with innovative approach, experience and expertise developed over the years in handling diverse and technically challenging projects, our engineers are able to offer to our customers appropriate solutions at every stage.
Testing, a key element of total engineering services, comprise design, development and validation. Extensive knowledge is applied for development of wide range of vehicles, systems and individual components of the vehicle.
SDL has unique combination of specialist engineering skills and world class / renowned engineering facilities. This Group serves the customers right from component manufacturers to worlds largest vehicle OEMs. Working together in tandem, customers are provided with the assistance to optimize designs, improve productivity and bring quality products to market at faster pace.
Through wide variety of domains, wherein work has been carried out at SDL, as well as currently ongoing research activities based on futuristic long term technological outlook, we are in a position to offer comprehensive end-to-end solutions to execute the same with the highest level of quality and with optimal time schedules to meet global targets.
SDL has recently completed an assignment for one of the OEMs, right from development of virtual model, validation to full vehicle. ARAI worked hand in hand with the OEM for design, development and manufacture of high quality products with greater speed and lower cost. The project scope included: Measurement of Road Profile Validation of virtual model
Road load data acquisition on roads, tracks and mines
Chassis System Evaluation Development of test load specification for vehicle durability Measurement of wheel loads Estimation of duty-cycle for drive train Measurement of cabin loads Ride comfort Evaluation Identification of critical areas
Evaluation of chassis frame Finalization of test scheme for its durability aspects Full vehicle validation on 6 poster rig
Evaluation of Cabin Finalization of test scheme for its durability aspects Cabin validation on multi axis rig
Evaluation of chassis frame Chassis frame validation on multi axis rig
ARAIs Participation in Automotive EXPOs ARAIs state-of-the-art facilities and capabilities in design, development , testing and certification of automobiles and automotive components are showcased in different exhibitions held in India. This could help ARAI to reach out to the automobile, component and allied industry within India and abroad and strengthen business relations to cater to the requirements of the industry as a whole. ARAI presentations in the Technology Theatres received sound response.
ARAIS Support to International EXPOs ARAI had supported following overseas Exhibitions : Automotive Forum 2010, Shanghai DEC-ASIA diesel emission conference, Beijing
A AU UT TO O E EX XP PO O 2 20 01 10 0 New Delhi, 5-11
January 2010
Business meeting at ARAI Stall
ARAI Stall at Auto Expo 2010
A AU UT TO OM MO OT TI IV VE E T TE ES ST TI IN NG G E EX XP PO O Hyderabad, 2-4
February 2010 Business meeting at ARAI Stall
ARAI Presentation at Technology Theatre
A AU UT TO OM MO OT TI IV VE E E EN NG GI IN NE EE ER RI IN NG G S SH HO OW W Pune, 8-10 February 2010
Interaction with Visitors at ARAI Stall
Inaugural Function
Interaction with Visitors at ARAI Stall
Inaugural Function
B BA AN NG GA AL LO OR RE E I IN NT TE ER RN NA AT TI IO ON NA AL L A AU UT TO OM MO OT TI IV VE E E EX XP PO O 2 20 01 10 0 11-14 March 2010
The Automotive Research Association of India Survey No. 102, Vetal Hill, Off Paud Road, Kothrud, Pune 411 038 (India) Tel.: +91-20-3023 1101, 2543 1284
For Information contact: Shrikant R Marathe, Director, ARAI director@araiindia.com