Index Issue 2018-2019

Centre of Excellence for E-Mobility

Calibration of EMI/EMC Testing related Instruments under NABL

Development of Aluminium Superstructure City Bus – a Step towards Greener Environment

Vehicle Development Test Facility (VTC 05)

Virtual Calibration: BS VI with Improved Quality at Reduced Time and Cost

FAST : Experience Center for Futuristic Adaptive Smart Techniques

ARAI and CSIR-NCL join hands for Collaborative Research

Automotive Lighting Conference 2018

Electronic Stability Control (ESC) System Test Facility

Heavy Duty Vehicle Energy Audit and Sensitivity Analysis for Fuel Consumption Improvement

Development of Diesel-Ethanol Engine for HCV

Thermal Management of Lithium-ion Battery Pack for EVs

Vehicle and Systems Integration for xEV Technology Demonstrator

ARAI’s Designation as “Foreign Motor Vehicle Testing Institute” by NTSEL (National Traffic Safety and

Environment Laboratory) National Agency for Automobile and Land Transport Technology, Japan

ARAI Efforts for Methanol Economy

ARAI Development Pedestrian Headform Finite Element (FE) Model for World-wide Industry Use

Electric Vehicle Battery Management System (EV-BMS)

“MAKE IN INDIA” initiative for Design, Manufacturing and Supply of 3-D H-Point Machine as per SAE J826

Symposium on International Automotive Technology (SIAT) 2019 – Brief Overview

Center of Excellence for E-Mobility

In line with National Electric Mobility Mission and thrust of Government of India on Electric Mobility, rampant

growth in Electric Vehicle development is envisaged in India.

ARAI, the premier Automotive R&D, Testing and Certification Institute in India, has geared up to support the

automotive industry for development, evaluation and certification of Electric Vehicles (EVs). In line with this,

ARAI has set up comprehensive state-of-the-art Center of Excellence (CoE) for Electric / Hybrid Electric

vehicles (2-Wheelers, 3-Wheelers, Passenger cars, Buses and Commercial vehicles) and their components

such as traction batteries, motors, controllers, chargers, etc.

We believe that, considering technological advances and stringent regulatory norms, automotive designers will

be compelled to move towards EVs and in particular electrification of powertrains.

This center will support Government’s Electric Mobility Mission to scale up Electric Vehicles (EVs) in India and

automotive vehicle and component manufacturers. We can be partner for vehicle and component

manufacturers providing active help in product development and analyzing field failures along with evaluation

of design, functionality and certification.

List of Facilities under Center of Excellence for E-Mobility:

100 kW DC Power Supply-cum-Battery Emulator

250 kW DC Power Supply-cum-Battery Emulator

150 kW motor test bed

220 kW motor test bed

250 kW battery pack level tester

Battery Module Level Tester

Battery Cell performance test system with environmental chamber

HCV chassis dynamometer

Facility Installed at ARAI Homologation and Technology Centre, Chakan (Near Pune, India):

150 kW Electric motor test bed:

It facilitates complete development, testing, verification and validation of electric drives and is useful for

determining and analyzing electrical, mechanical and thermal characteristics. Tests such as functionality,

reliability, endurance and cold startability are conducted under real operating conditions.

Includes Calibration of Key Parameters:

Impedance Insertion Loss Return Loss First peak current Current at Different ns (e.g. @30 ns, 60 ns, etc.) Rise / Fall Time Air discharge DC voltage

Pulse Amplitude Pulse Width Repetition frequency Burst duration Burst period Open circuit voltage / Short circuit current Front time

Parameter Range CMC

Impedance 10 KHz to 230 MHz (2.72 Ω to 200 Ω) ±7.3% to ±14 %

Insertion Loss 9 KHz to 6 GHz (0.1 dB to 65 dB) 0.63 dB

Return Loss 9 KHz to 6 GHz (1.0023 to 3.5 ) ±7.3% to ±13 %

Different types of Immunity Generators:

1. ESD Simulators Calibration:

Calibration of EMI/EMC Testing related Instruments under NABL

Parameter Range CMC

Contact Discharge Current I pk and I at tns ±2kV to ±30 kV (0.15 A to 112.5A)

±4.86% to ±8.2%

Rise/fall time 0.7 to 1ns ±6.96% to ±7.45%

Air discharge DC voltage ±( 2-30kV) ±2.69%

2. EFT Generators, CDN:

Parameter Range CMC

Amplitude ±25 V to ±4KV ±3%

Time 5 ns ±4%

Width 50 ns & 150 ns ±4%

Repetition Frequency 4 KHz to 120 KHz ±4%

Burst Duration 0.7 ms to 18 ms ±4%

Burst period 300 ms ±4%

3. Combination Surge Wave Generator, CDN :

Parameter Range CMC

Open Circuit voltage

Voltage ±0.5 KV to ±5 KV ±3%

Front/Rise Time 1.2/1 µs ±4%

Width 50 µs ±4%

Short Circuit current

Current ±0.25 KA to ±2KA ±5%

Front/Rise Time 8/6.4 µs ±4%

Width 20/16 µs ±4%

4. Voltage Dips / Interruption Generator:

Parameter Range CMC

Amplitude 0-100% ±3%

Time 10 ms- 5 Sec ±4%

5. Voltage Drop Simulator:

Parameter Range CMC

Amplitude 0 to 60 V & 0 to 40 A ±1% & ±4%

Time 1 ms to 10 ms ±4%

Width 5 ms to 5 sec ±4%

6. Micro-Pulse Generator:

Parameter Range CMC

Amplitude 20 to 600 V ±3%

Time 1 µs to 60 µs ±4%

Width 1.75 ms to 6 ms ±4%

7. Load Dump Generator:

Parameter Range CMC

Amplitude 20 to 200 V ±3%

Time 5 ms to 10 ms ±4%

Width 40 ms to 400 ms ±4%

Reference Equipment Used

Digital Storage oscilloscope, ENA series Network Analyzer, HV Differential Probe, Current monitor probe,

ESD Target Different types of respective loads and attenuators, etc.

Pollution due to fossil fuel combustion is the primary concern for India and vital area to be addressed. Large

population of automobiles has significant impact on climate change. Urban population is most affected due to

these GHG emissions and significant number of them are getting health disorders. Even though there have

been significant improvements in powertrain technology, particularly fuel efficiency, this has not been enough

to neutralize the effect of increasing urban vehicular population.

In order to address above need, ARAI has designed and developed 12m, Low Entry city bus prototype with

environment-friendly material, Aluminium. Bus design meets all the regulatory requirements, addressing

engineering challenges of strength and durability under Indian road conditions, human comfort and fuel

efficiency improvement.

Light weighting through aluminum can be directly adapted for EV and HEV to compensate increased weight

due to electrification and hybridization. Lighter the structure better the battery life. Significant improvement in

charging frequencies is observed with lightweight structures for Electric vehicles.

Why City Bus?

Power required to move vehicle has direct co-relation with the mass of the vehicle. It follows that any

reduction in the mass of the vehicle would mean lesser power requirement for its movement. In realistic

driving situations where there are several start and stops over a certain period of time, like in case of city

transit buses, quantum of benefit increases over a large number of cycles. It is thus logical to target city bus

for light weighting for reduction in fuel consumption. Mass of bus has functional relationship with fuel economy

and emissions, given that powertrain and drivetrain efficiency remains constant.

Looking at the city buses in India, it is found that major weight of bus is of its super structure, which is made of

steel. Reduction in weight of this structure will take a step ahead towards greener environment. 1 kg

aluminium used as against steel can reduce 20 kg of CO2 emissions over the life of a vehicle. Aluminium can

be recycled (up to 97%) and after end of vehicle life this aluminium property gives push to achieve cleaner

environment along with recycling cost benefit.

Development of Aluminium Super Structure City Bus – A Step towards Greener Environment

Light weighting of bus using Aluminium - ARAI experience:

Aluminium bus design and development from concept to compliance carried out by ARAI-CAE team.

Measured road load data of Indian cities was used while designing bus superstructure for city application.

Virtual validation of design carried out using simulation technique. Integration of aluminium superstructure with

steel chassis was carried out using mechanical fasteners. Aluminium bus body is free from welding and Heat

affected zone (HAZ) is absent, this feature makes superstructure more durable.

Aluminium super structured bus prototype has following salient features:

37% lighter superstructure for its class of buses

Improved fuel economy

Fully bolted bus structure design - Simple and fast assembly

Durable for Indian road load conditions

Meets Strength (UBS-II), NVH (AIS:153) & Bus Body Code (AIS:052) requirements

Improved corrosion resistance

Easy adoptability for EV, HEV & CNG bus application

While embarking on accelerated growth of automobile, use of lighter material such as aluminium need to be

increasingly used in vehicle to curb GHG emissions. Use of aluminium for public transport buses on a large

scale is now feasible for addressing stringent fuel consumption regulations while maintaining structural

integrity, comfort and safety.

Background:

Methanol is a fuel, which can be derived from high ash coal or natural gas or biomass. Methanol contains less

carbon and hence can be used as a fuel in SI engine vehicles.

Recently Ministry of Road Transport & Highways, Govt. of India, vide GSR 490(E), has notified M-15 and M-

100 as automotive fuels. BIS is developing Indian specifications for M-15 and M-100 fuels. Further studies on

methanol on locomotives, marine applications and cooking stoves are planned. A seminar was held in ARAI

in April 2017 for promotion of methanol economy in India. ARAI will play an important role in field validation,

vehicle trials and certification of vehicles developed as per BS-VI emission norms. Scope of the study

proposed by ARAI to Department of Heavy Industry, Govt. of India, is as follows:

SCOPE

Evaluation of a Physio-chemical characteristics of Methanol

Establishing effect on fuel economy and benefit of emission reduction in MPFI Engines for 15%

Methanol-gasoline blend on chassis dynamometer / engine dynamometer at ARAI.

Field trials for establishing fuel efficiency, emission reduction, compatibility and durability of engine

components using Methanol.

Engine Durability Studies for Methanol.

PHYSICO-CHEMICAL STUDIES

For these studies, following test fuels may be used

Neat Gasoline +15% Methanol

Oil companies have been supplying gasoline in India conforming to BIS 2796 specification. Blending of 15%

Methanol will affect physico-chemical characteristics of the fuel. All the test fuels to be tested as per BIS

specification for following parameters:

Colour

Copper Strip Corrosion

Density

Distillation

Anti-knock Index / Octane number

Sulphur Content

Existing Gum content

Potential Gum content

Reid Vapour Pressure

Vapour Lock Index

ARAI Efforts for Methanol Economy

Establishing Effect on Fuel Economy and CMVR Trials

Testing to be carried out using 15% Methanol blends on chassis dynamometer basis (vehicles below 3.5 tons)

on IDC / WMTC Cycle, for compliance to BS-IV and BS-VI norms.

CMVR Trials to be conducted on proto vehicle (2-Wheeler & 4-Wheler) using 15% methanol blend

Range

CSFC

Driveability

Gradeability

EMI/EMC

Acceleration

Cold Startability

Cooling Trials

Field Trials Planned

It is necessary to conduct field trials on a fleet of 10 passenger cars with blends of 15% Methanol.

The vehicles will have to be tuned by the manufacturer for operation with blends. Apart from

startability and drivability tests mentioned above, the fleet of vehicles may be run daily over a fixed

route of about 100 km, for total of at least up to 1,00,000 km. After every 10,000 km run, following

tests will be conducted:

1. Fuel Economy as per Indian Driving Cycle (IDC) on chassis dynamometer at ARAI , at

constant speeds of 40, 60 and 100 km.

2. Normal Fuel Economy tests for fleet may be conducted by topping up method.

3. At the end of the trials, vehicle engines may be inspected by for any adverse effects

Engine Durability Studies

Durability testing for 500 hours on engine basis with 15% gasoline-methanol blend for SI Engines.

Durability includes periodic FTP for 100 hours and will be followed by strip down of engine and

metrology on all parts.

Certification of upgraded METHANOL Vehicles for BS-IV and BS-VI emission norms

ARAI is capable to certify upgraded methanol M-15 vehicles against BS-IV and BS-VI emission

norms. Application in standard CMVR format be submitted to ARAI for certification.

It is a matter of pleasure to announce that in July 2018, NTSEL (Japan) granted to ARAI (India) accreditation

for test item, viz. “Japan Motorcycle Exhaust Gas Emission Test”, carried out as per TRIAS31-J044(2)-01.

Objective

Objective of this accreditation is to establish relationship between National Traffic Safety and Environment

Laboratory (NTSEL) and The Automotive Research Association of India (ARAI) as designated Testing

Institute, regarding designation of foreign motor vehicle testing institutes for utilizing ARAI test data.

Designation

Means a designation made by NTSEL to provide examination services, in which results of tests conducted by

Testing Institute in foreign country are utilized, so that NTSEL may smoothly provide examination services

Regarding type designation of vehicles manufactured in foreign country.

Effect of Designation

As ARAI has been designated, NTSEL may provide examination services, utilizing the results of tests conducted by ARAI regarding the test item so designated.

Criteria for Designation

NTSEL designated ARAI for applied test item according to enforcement procedure for “designation of Foreign

Motor Vehicle Testing institutes for utilizing their data” as per NALTEC Rule No. 28 dated 1st April 2016, based

on written application and accompanying document. NTSEL verified the scope of test item, in which ARAI is

considered to have technical capabilities to properly provide the test services.

On site survey by NTSEL

NTSEL has visited the premises of ARAI and surveyed its machinery equipment and other facilities used for

the test services, and the procedure for such services in order to confirm whether ARAI complies with the

criteria.

NTSEL Audit Team with ARAI officials

ARAI Designation as “Foreign Motor Vehicle Testing Institute” by NTSEL (National Traffic Safety and Environment Laboratory) - National Agency for Automobile and Land Transport Technology, Japan

Developed Sustainable Co-relation between VTC 05 and NABL Accredited Reference Lab

Chassis Dynamometer Specifications

• Maximum permissible axle load (kg): 4500

• Roller diameter: 48” (1219.2 mm)

• Maximum distance between rollers (mm): 2744

• Minimum distance between rollers (mm): 914

• Base inertia (kg):1209

• Inertia simulation range (kg): 454 - 5448

• Nominal minimum permanent motoring power

(kW): 150

• Speed range (km/hr): 0-200

Vehicle & Fuel Categories:

• Quadri-cycles

• Passenger cars

• Vans and LCVs corresponding to M1, M2,

and N1 with reference mass not

exceeding 2610 kg.

• 3-Wheelers

• Fuels: Compatible for diesel, gasoline,

CNG, LPG, Methanol, Ethanol, DME, Bio-

fuels and other alternative fuels, including

Bi-fuel, dual fuel, HCNG, etc.

iGEM System

• Puma Based System

• Open architecture – Flexible and easy to

configure

• Automation software includes cycles up to Euro

6 (WLTP).

- Dynamic Gear Shifting as per WLTP.

- Downscaling of Test Cycle.

- Battery current monitoring and calcualtion.

Applications

• BS VI Emission development and testing

• Vehicle development testing and OBD

calibration

• Powertrain friction force measurement

• Driveline Oil Evaluation

• Vehicle testing using various national,

international and customized driving

cycles

• Dynamic road gradient simulation

• Constant speeds fuel consumption tests

Vehicle Development Test Facility (VTC 05)

Emission System Specification

• Exhaust gas sampling system : CVS-CFV

• CVS Flow: 4 to 30 m3/min with gasoline/diesel separation

• Venturi sizes 4, 6, 8 and 12; flow rates from 4 to 30 m3/min in steps of 2 m3/min

• Heated bag double cabinet for 12 bags (35ᵒ C)

• CO, CO2, THC, CH4, NO2 and NO, NOx concentration

• Background particulate measurement for GDI and diesel

• Particle number counting

• PM measurement equipment

• Emission measurement equipment – dilute bench

• GDi tunnel

Range of Calibration Gases

• Carbon monoxide (COL) : 0–5000 ppm

• CO2: 0-0.5 to 6%

• THC: 0-1000

• CH4: 0-1000 ppm

• NO: 0-1000 ppm

• NOx: 0-1000 ppm

Virtual Calibration : BS VI with Improved Quality at Reduced Time and Cost

BS VI norms being stringent on emissions, demand significantly higher calibration efforts. It is required to improve performance as well. This demands increased number of labels to be calibrated with increased complexity due to after-treatment and diagnostics.

In addition to this, RDE requirements call for extended range calibration. All these requirements lead to

calibration efforts on engine / chassis dyno as well as vehicle. Therefore, calibration using virtual test bed

becomes essential to frontload the activities as shown in Figure 1.

Figure 1 : BS VI Calibration Efforts

Key Aspects of Calibration with VTB

Calibration not dependent on weather, location and prototype availability

Improved calibration quality with high reproducibility and good extrapolation capability

Concept definition, calibration robustness investigation

Minimized usage of expensive test facilities

Reduced number of prototypes resulting into faster time to market

Virtual Calibration Lab at ARAI

Virtual Calibration Lab set up at ARAI has AVL Virtual Test Bed (VTB) with semi-physical engine and after-

treatment model, PUMA open test bed controller with CAMEO DOE tool. Calibration environment is exactly

same as that of real calibration test bed.

Figure 2 Virtual Test Bed System

Extensive performance trials and emission prediction at standard and non-standard operating conditions

have been taken as described below. It is observed (as shown in Figure 3), that steady-state trends are

captured very well for exhaust temperature, BSFC, NOx and SootSat standard operating conditions. Also, for

cycle emissions for steady-state and transient, comparison of measured and VTB output for NOx and soot

are shown in Figure 4 and Figure 5.

Figure 3 Steady state results at standard conditions

Figure 4 Legislative results, WHSC and WHTC cycle

Figure 5 : Cycle Emissions at Standard Operating Conditions

Steady-state trends with non-standard operating conditions are captured well for exhaust temperature, BSFC,

NOx and Soot. With this, the extrapolated ambient conditions can be simulated in Virtual Calibration Lab,

which we are unable to create in real test bed environment (figure 6). Transient results with non-standard

operating conditions show 2% deviation for engine-out NOx prediction as shown in figure 7. Cycle emission

predictions for non-standard operating conditions are shown in Figure 8.

Figure 6: Steady State Results at Non-standard Conditions

Figure 7: Non-standard Results at 95 kPa and 25 deg C

Figure 8 : Cycle Emissions at Non-standard Operating Conditions

These results show evaluation potential of VTB in ARAI Virtual Calibration Centre in the area of concept

investigation, function development, calibration, robustness investigation, etc. with following benefits:

Reduction of concept risk

Reduction of engineering loops

Evaluation of HW, which is not physically available

Realistic Plant Model for software development

Early check of control functions and Initial Calibration

Calibration no matter of prototype availability

Shifting work to cost effective test environments

Enlarged validation space and high degree of automation

Evaluation of vehicle performance, RDE and ambient trials

Avoidance of false OBD in the field

Optimizing tolerances and system sensitivity

In-field and post SOP support in case of calibration changes

FAST : Experience Center for Futuristic Adaptive Smart Techniques

Automotive sector all over the world is rising rapidly. Every now and then, new vehicles are coming up, with

various advancements. The major trend in today’s automotive focuses on light weighting, energy efficiency,

high structural performance of components, structural durability, safety and vibration control. Our automotive

industry is a progressing sector and to keep this flow going, new methods and technologies need to be

developed to meet the requirements, which cannot be countered solely by the existing techniques. Thus, need

for smart and intelligent materials in automotive industry is rising rapidly.

Smart Materials have been in and around, but have not been explored in Auto-industry. These materials

possess ability to change their physical properties in a specific manner, in response to specific stimulus input

like heat, light, voltage. These materials, along with supporting methods / techniques, could be used

effectively for the growth of the automotive industry.

Experience Center for Futuristic Adaptive Smart Techniques (FAST)

Experience Center for Futuristic Adaptive Smart Techniques (FAST) is an initiative of ARAI to step-up energy

efficient and smart automobiles for sustainable future. This Centre was inaugurated at the hands of

Prof. Ashwini Kuwar Nangia, Director, National Chemical Laboratory.

Applications and proof of concepts, developed by applying adaptive tools of smart structures and materials;

like Piezoelectric Materials, Shape Memory Alloys and techniques of Active Vibration Control, energy

harvesting, Structural health monitoring, Adaptive control. Numerous automobiles applications can be

developed. This is one of the platforms of ARAI to showcase and encourage ‘Design in India’ concept.

Applications developed under this Lab have also been published and awarded in FISITA 2018 and SAE.

This lab works on Adaptive and Smart Techniques that involves various concepts such as Model Order

Reduction, Adaptive Filter designs, Active control strategies, Complex system modelling. These concepts are

carried out along with Smart Structures such as Piezo-electric Materials, Shape Memory Alloy, Inertial Mass

Actuators, Magneto-rheological fluids, etc. These techniques will allow to achieve High durability, Improved

Safety, Control over vibrations, Structural Health monitoring, Energy Harvesting and Light-weighting of

automotive components and systems.

Active Vibration Control of Steering Wheel Switchable Anti-roll Bar

One can experience various concepts of smart structures and adaptive controls from this Centre, which

includes Active vibration control of automotive components, Structural Health monitoring of wheel rim,

switchable stabilizer bar and many more. In order to have an insight of smart structures and systems, special

e-learning modules have also been developed which briefly guides the viewer. This is a total course of 2 (two)

hours, which includes six different modules.

The center appeals to Automobile Engineers, students and enthusiasts, to experience and collaborate, for

development of techniques for Energy efficient and smart automobiles towards sustainable future.

Memorandum of Understanding has been signed between ARAI and NCL to research on various areas of

mutual interests.

ARAI is presently working with CSIR- National Chemical Laboratory (NCL) to develop testing methodology

and advanced characterization techniques for various commercially available batteries. Battery chemistry is an

important parameter in predicting life span and also end use of battery.

Harmful effects of fossil fuels on environment and their depletion have led to an increased demand of alternate

resources for transportation. With recent developments in Electric and Hybrid Electric Vehicles, demand from

automotive industry towards high performance EVs is increasing and Lithium ion battery is the heart of the EV.

Material to be used for battery needs to be understood and characterized to meet stringent performance

requirements. Battery testing and recycling becomes an important domain for research in electric mobility

sector.

Aim of this work is to establish database for battery analysis, using various characterization techniques. This

data will be used for battery material analysis in future and also for efficient reuse after its end of life in EV.

This work includes use of techniques with focus on state of charge, state of health and state of safety on

Lithium based batteries. It is envisaged that battery testing and analysis related research for EV application

will significantly help the team to understand life span of battery and its hazards and environmental

implication.

The team is working collaboratively on electrical aspect of batteries. Battery characterization is done by both

destructive and non-destructive techniques. Destructive techniques aim at study of material characterization of

new and damaged cells. In destructive characterization surface morphology is tested by Scanning Electron

Microscopy (SEM) and Transmission Electron Microscopy (TEM) is used to study electrode material subjected

to various conditions. X-Ray Diffraction (XRD) and X-ray photoelectron spectroscopy (XPS) is used to analyze

the elements present in the electrodes of battery.

In non-destructive characterization, Cyclic Voltammetry (CV) graph conveys whether the cell health.

Galvanostatic Charge-Discharge (GCD) study is being used to calculate actual capacity of the cell.

Electrochemical Impedance Spectroscopy (EIS) study gives impedance of cell at various levels of frequencies

through Nyquist and the Bode plot. Tomography study is used to observe internal structure of battery in non-

destructive way. The aim is to establish methodology for cell characterization with the facilities available at

ARAI and CSIR-NCL and understand the factors affecting cell capacity, SoH and SoS due to different

conditions and to develop expertise in battery material characterization for automotive application.

ARAI and CSIR-NCL Join Hands for Collaborative Research

Destructive Characterization

SEM TEM XRD XPS

Non-Destructive Characterization

Tomography EIS plots

Moreover, to mitigate harmful effects of battery waste on the environment, both the Institutes are

jointly working on R3 concept (Reduce, Reuse and Recycle).

ARAI and NCL together have embarked on a journey to provide solution to efficient and

environment-friendly battery technology for future generation E-mobility

Automotive Lighting Conference 2018

ARAI and SAEINDIA–Western Section jointly organized Automotive Lighting Conference on 10th and 11th

August 2018 at ARAI, Pune. This conference focused knowledge sharing and received large participation

from the industry and academia.

This conference was a congress of the best minds in the industry, wherein delegates from Vehicle

manufacturers (2-W, 3-W, 4-W, Tractors, CEVs, EVs), automotive and non-automotive lighting manufacturers,

Test agencies, material suppliers, etc. participated. This two-day event was inaugurated by Mr. Balraj Bhanot,

former Deputy Director General, Department of Heavy Industry (Government of India) and Former Director –

ARAI.

The very first technical session was presented by Mr. Mark Jarvis, aptly known as ‘Innovation Guru’ of Uno

Minda. Mr. Jarvis focused on innovation in the lighting industry and shared his knowledge on industrial design

aspects thereof.

Mr. Vineet Sahni, expressed his views on the very sought after and debatable subject, viz. Preparedness of

India for changing Technology trend in Automotive Lighting Technology. Mr. C. S. Singh further touched upon

Technology Challenges in India.

Fundamentals of Lighting Devices and Light Sources, and making of Affordable LED headlamps and

evolution of Lighting over time was presented in detail by technical experts Michael Willacker, Blanco

Salvatore, Tetsuya Mikami and Tony Bergen.

OEM perspective and real world light evaluation issues were addressed by Mr. Jayprakash of Mahindra

Research Valley. Mr. Ramashankar Pandey spoke on the crucial topic of Arresting Alarming Road Deaths -

Prioritizing Technology, Awareness and Regulation. Mr. M. Siva of ARAI presented indigenous Adaptive Front

Lighting Solution for lowering glare and better visibility.

Mr. Bandal shared his global view and his knowledge on Global Regulations for Automotive Lighting for

China, Brazil, Indonesia, Europe and FMVSS. Mr. M. M. Desai elaborated on EMC Requirements for

automotive lighting technologies and measurement. Mr. N. B. Dhande presented ARAI’s profile to the

participants, summarizing the activities and role of ARAI in Automotive testing, R&D, consultancy as well as

formulation of Indian Standards. The event concluded with Vote of Thanks by Mr. S. S. Nibandhe, Deputy

Director – ARAI Chakan Operations.

The number of participants for this event was well over 170 and feedback received was very encouraging.

The conference succeeded in accomplishing the very purpose of knowledge sharing and providing platform

for exchange of thoughts among the experts / participants.

CAE Lab of ARAI has developed Pedestrian Headform Finite Element (FE) Model for Adult and Child as per

Automotive Industry Standard (AIS) 100/Global Technical Regulation No 9 (GTR 9) considering its mandatory

implementation in India effective1st October 2019 for all car models.

Material characteristics and material model is developed, along with Livermore Software Technology

Corporation (LSTC). This head-form is correlated as per calibration method specified in AIS 100. The same

FE model was impacted on the vehicle bonnet and results found to be in good agreement with experimental

results in terms of deformation and Head Injury Criteria (HIC) values. These validated FE head-forms are

recognized by LSTC and are now available for industry use. Such FE head-form models will help to promote

research and development in the field of pedestrian safety for initial design evaluation of vehicle front

structures.

FE Model Headform Development:

Development process started with 3-D CAD generation of physical head-forms using the blue light scanning

facility at ARAI. Using CAE tools, each component of Headform was converted into corresponding FE Model.

Suitable material models were developed and assigned to each component in FE model. The developed FE

Model was correlated using the calibration tests specified in AIS 100.

Conversion of Physical head-form into 3-D CAD

Comparison of Simulation and Test Results for Child Headform Calibration

Accuracy of FE model of head-form was further corroborated, in terms of deformation and HIC, by physical

head-form impact test on a representative passenger vehicle.

ARAI Developed Pedestrian Head form Finite Element (FE) Model for World-wide Industry

Use

Time plots showing FE Headform Impact on Passenger Vehicle

After successful completion of above extensive exercise, ARAI is now equipped to take up development and

evaluation of vehicle front structures for pedestrian safety.

Paper titled “Development of Pedestrian Headform Finite Element (FE) Model using LS-DYNA® and its

validation as per AIS 100/GTR 9” will be presented at the 12th European LS-DYNA Conference 2019,

Koblenz, Germany.

Electric Vehicle Battery Management System (EV-BMS)

Electrification in India is being driven by air quality and energy dependency. Given the Government’s desire to

reduce air pollution and develop EV technology, battery technology will continue to be the significant driver of

EV penetration in India.

Lithium-Ion Batteries constituting a large component of total EV cost, it is inevitable to localize battery

manufacturing to achieve lower costs and in turn affordable xEVs, ensuring minimum cost for consumers.

Although the factors like cost and guaranteed performance over extreme environmental conditions and

maximizing output requirement, are some of the major challenges for Lithium-Ion batteries. It is necessary to

have battery management system, which dynamically optimizes its performance in every possible use case

and environment.

To do so ARAI has integrated software, electronics, materials, mathematics and test validation knowledge to

develop an Optimized performance BMS technology solution with following features:

Monitoring of every cell Voltage, pack current and temperature

Cell balancing (Passive)

State of Charge (SoC) and State of Health (SoH)

Thermal Management

Compatible with wide range of lithium-ion cells

Failure detection and Diagnostics

Modular and Scalable Architecture

Software development using Model based design tools and techniques

Advanced Estimation Techniques for State of Power (SoP) and State of Safety (SoS)

State-of-the-art GUI for Monitoring, Configuration and Calibration

Advanced Kalman filter Estimation techniques for SoC, SoH

Active Monitoring and De-rating on basis of SoC, SoH and SoS.

The complete solution consists of following:

1. Model Based control software

2. Modular and Scalable Hardware platform

3. Interactive User Interface

The software and hardware platform is scalable and provides flexibility to end users with master/slave

topology, which allows multiple units to be connected together to support up to 800 VDC systems. The

solution is designed to accommodate wide range of lithium-ion battery chemistries.

The software algorithm is designed to monitor current, voltage and temperature of the cells in the battery

pack. It calculates and estimates 4 important states of the energy source (SOC, SOH, SOP, and SOS) using

advanced Kalman filter estimation methods. The software is developed in MATLAB Simulink environment

and is verified and validated in Model in Loop (MIL) environment. Interface of the control strategy with

different type of Battery packs has been tested.

The hardware is designed with highest levels of safety using automotive-grade components. It is qualified for

TRL 8 and validated for automotive test compliance of EMI/EMC (RE, RI, CE, and CI) as per AIS 004 Part 3,

Electro static Discharge Test and Environmental Tests for Temperature, Humidity and Vibration.

The UI Platform is equipped with customizable diagnostic software via CAN and serial interface, which

manages pack diagnostics, data logging, and provides rapid parameter modification and firmware upgrades.

Electronic Stability Control is an active safety system that detects probable lose controls of a vehicle and

automatically mediates by braking any of the four wheels and / or reducing engine torque to help driver stay

on course. The new generation M1 category vehicles are equipped with very effective safety devices, like

ABS, ESC, EBD, ADAS, BAS, ACC, AEBS, LDWS etc.,

Vehicle Evaluation Laboratory (VEL) of ARAI has successfully introduced this new service for carrying out

performance evaluation of Electronic Stability Control Systems fitted on M1 and N1 Category Vehicles, by

employing state-of-the-art instrumentation. These ESC tests are carried out as per the test prescriptions in

AIS 133, which specify performance and the equipment requirements for assessment of the system, under

CMVR. This Standard applies to all vehicles of Category M1 and N1, which are fitted with ESC system. With

this expertise developed at VEL, ESC performance tests can also be conducted as per the test prescriptions

in ECE R 13H, FMVSS126 for the purposes of export homologation. Roll-over (Fishhook) and Sine-dwell tests

are also possible with the ESC measuring system.

Special Instrumentation and Relevant Tests:

Following high precision instruments are employed for carrying out tests to meet the requirements of the

Standard :

a) Steering Robot (ABD SR60 Torus)

b) GPS Based Data Acquisition System (Racelogic - VBOX)

c) Foot Pedal Brake Force Meter

d) Inertial Measurement Unit

e) Out Triggers

f) Weather station

g) Riding gears and safety gadgets necessary for the tests

The test vehicle is fitted with appropriately designed out-triggers and instruments for data acquisition. Out-

triggers are well-constructed, keeping in view the weight limiting factor, overall safety requirements of the test

personnel and vehicle spin or loss of control during testing. The out-riggers are so designed that they do not

interfere during normal driving of the vehicle.

Fitment of Outriggers on Test Vehicle

Electronic Stability Control (ECS) System Test Facility

Fitment of Steering Robot on Test Vehicle

Initial Setting of ESC Evaluation System

The following trials are conducted to evaluate performance of ESC System:

a) Brake Conditioning

b) Tyre Conditioning

c) Slowly Increasing Steer Procedure

d) Sine with Dwell Test of over steer Intervention and Responsiveness

e) ESC Malfunction Detection

f) Post Data Processing – Calculations for Performance Metrics

Sine with Dwell Test of Over-steer Intervention and Responsiveness

Sample data acquired during test

Data Acquisition and Analysis:

The test parameters acquired, after conducting trials as per requisite standards can be precisely analyzed.

The above graph depicts sample data acquired during the tests. Such tests can also be performed at VEL as

development assignment necessary for finalizing specifications of ESC supported braking system.

Specifications of Steering Robot used for ESC Evaluation:

a) Diameter of Steering wheel: Outside - 326mm to 386mm and / or inside - 294mm to 354mm

b) Max torque: 85Nm at 1300°/s

c) Rated torque: 60Nm at 1850°/s

d) Max velocity: 2500°/s at up to 20Nm

e) Angle resolution: 0.001° (approx.)

f) System Angle Accuracy: ±0.2°

g) Environmental: 0 to 45°C

Heavy Duty Energy Audit and Sensitivity Analysis for Fuel Consumption Improvement

Introduction Heavy Commercial Vehicles have major role in national economy, however, these vehicles have significant

share in CO2 emissions. EUROPE, USA, CANADA, CHINA, JAPAN, etc. are working on various

technological improvements to reduce CO2 emission by improving fuel economy, which also benefits in

reducing overall fleet operational cost. Vehicle energy audit and sensitivity analysis of key parameters help in

understanding their influence on overall fuel consumption. Vehicle energy audit plays key role in identifying

potential areas for improvement in fuel economy and parameter wise contribution in CO2 emissions. Figure

below shows vehicle sub-systems and their contribution, which impact on Tank to Wheel (TTW) efficiency.

Improving TTW efficiency by carrying out vehicle energy audit has become focussed for development.

Heat Rejection

Losses

ExhaustHeat Losses

Gas Exchange +

Friction Losses

EngineLosses

Air Drag

Rolling Resistance

Auxiliary losses

Axle &Tyre Losses

Drivetrain losses

Tan

k to

Wh

eel

Eff

icie

ncy

Combustion Losses

Fuel

En

ergy

(100

%)

In this carefully developed methodology, duty cycle was prepared from the real usage pattern. From the duty

cycle condensed drive cycle is prepared and fuel consumption by simulation is correlated on the developed

drive cycle. For this, important component level characteristics are acquired by testing on the test rigs. This is

followed by energy audit and parameter sensitivity analysis for improvements in TTW efficiency. Significant

advantage of this methodology is better correlation with improvements in field fuel consumption.

Transmission Testing: Torque loss is mapped at different output torque and speed. From this, individual

gear efficiency map generated at defined warm up conditions is shown in below Figure 1

Engine Testing: Engine test procedure determines maximum power capabilities of engine, motoring torque

necessary to drag the engine at certain rotational speed and fuel consumed by the engine when running at

defined operation points. Fuel map to characterize fuel consumption of engine is determined at steady-state

operation. Correction factors are applied for vehicle energy audit in transient operation. Additionally,

component level power losses also assessed. Fuel map figure shows schematic picture of fuel map and that

of WHTC load points in this map in 1 Hz resolution.

Engine and Components Power Consumption Engine Fuel Map Generation considering transient

Tire Rolling Resistance Coefficient (RRC): Rolling resistance is one of the major contributors for TTW

efficiency. Selected vehicle tires are tested for RRC as per ISO 28580.

.

Min.

Min.

Max.

6th Gear Efficiency Map

Inpu

t To

rque

(Nm

)

Input Speed (rpm)

Top gear efficiency map

Benefits of Vehicle Energy Audit

Drive cycle based energy audit shows contribution of different vehicle sub-systems for field fuel

consumption.

With the cost benefit analysis parameters can be ranked for higher TTW improvement.

Reduction in field trials, cost and time in identifying potential areas for fuel efficiency and TTW.

Vehicle Model

Energy Distribution

Development of Diesel-Ethanol Engine for HCV

Background

Using bio-ethanol blended diesel fuel for automobile can significantly reduce diesel usage and exhaust

greenhouse gases. Bio-ethanol can be produced by alcoholic fermentation of sucrose or simple sugars. The

main drawback is that ethanol is immiscible with diesel fuel over a wide range of temperatures, and the

hygroscopic nature of ethanol leading to phase separation in blend. Unlike gasoline, which is miscible with

anhydrous ethanol, diesel is immiscible with ethanol. Diesel-ethanol blend does not mix properly and situation

of phase separation, lower Cetane number, lower lubricity and high corrosion arises. To mix ethanol with

diesel, proper additive is necessary to stabilize and improve properties of blend. Presence of water in

amalgams favors separation of ethanol phase. As water content increases, separation occurs with lower initial

ethanol content. Consequently, stability zone becomes narrower. On the contrary, as additive is added to

blends, stability zone becomes broader.

Diesel-ethanol blends commonly known as E-diesel are prepared with different Ethanol proportion such as

5%, 7.7%, 10%, 12.5% and 15%. Effect of each blend is studied for engine performance, emissions and

durability. Method for diesel-ethanol blend preparation with different additives to improve stability, lubricity and

combustion efficiency is established. The scope of work includes finding effect of ethanol blended diesel fuel

on in-use vehicles complying to BS IV norms.

Objectives

To evaluate Emission and Power performance of ethanol blended diesel by comparing base diesel

engine Performance for BS IV emission norms.

To evaluate vehicle performance of ethanol blended diesel by comparing base diesel vehicle

performance

Work Approach

6-cylinder, 5.67-liter heavy duty diesel engine with below mentioned specification was selected for carrying

out base performance and emission testing on diesel and further evaluating diesel-ethanol fuel blend.

Engine type Inline, 4-Stroke, Compression Ignition

Displacement 5.67 liter

Number of cylinder 6

Method of air aspiration TCIC

Fuel injection system CRDI

After treatment device DOC+POC

Among E-diesel, it was found that 7.7% and 10% of ethanol by volume and remaining diesel with 2%

Solubilizer by volume is a promising blend in respect of performance and emission characteristics, Cetane

number improvement and offers greater benefit than other blends.

Blender Used – Solubilizer

Solubilizer was used for diesel-ethanol blending. Effect of Solubilizer on diesel-ethanol blend is as follows:

E- Diesel without solubilizer E-Diesel with solubilizer

1. Compounds in Solubilizer are readily decomposed to give free radicals and thus enhance rate of chain

initiation in diesel-ethanol combustion.

2. Solubilizer raises Cetane number of diesel-ethanol blend.

3. They promote fast oxidation of fuels and thus improve their ignition characteristics.

4. It maintains stability of diesel-ethanol blend for a longer period.

5. Solubilizer has good lubrication characteristic and is, therefore, beneficial for engines when firing with

diesel-ethanol blend.

6. Solubilizer acts as hydrophilic to bond to immiscible liquids together.

Baseline Simulation

1-D simulation was carried out on 6-Cylinder Engine model to check feasibility of working pressures with

Diesel-Ethanol fuel. Baseline diesel engine was unaltered for this work. Simulation was carried out on diesel

and 7.7% E-Diesel fuel and check for maximum combustion pressure generated. Maximum pressure

generated was 3.56% more than that for commercial diesel fuel, which is within the tolerance limit of engine.

Once performance was validated for simulation, various trials for E-Diesel blends were carried out for

performance, emissions and durability.

The optimized blend was decided based on emissions measured during engine dyno testing for ESC and

ETC cycles. The optimum blend was decided as 7.7% Ethanol with 2% Solubilizer. Durability trials were

conducted for 500 hours on optimized Ethanol-Diesel Blend of 7.7%. There were no abnormalities / failures

observed. Power and Torque before and after durability is within tolerance zone. Smoke results show

reduction of almost 37% as compared to commercial diesel smoke readings which is a significant

achievement.

Cost Impact

Elements Rate(Rs.)/ltr Mix Ratio Revised Rate (Rs.)/ltr

Diesel 74.25 90.30% 67.04

Ethanol 52.43 7.70% 4.03

Solubilizer 100 2% 2

Total (Rs.) 73.07

Savings in fuel cost (Rs.) 1.18

Total savings, if 7.7% E-Diesel used, is around Rs. 1.18 (* fuel prices vary daily. Data based on the prices

based in Pune City).

Also if heating value is considered, CO2 released per gram of fuel, 7.7% E-Diesel will emit lesser CO2 (~ 13%)

less than commercial diesel fuel.

Vehicular Trials:

Tests like Gradeability, CSFC and Acceleration, were conducted on commercial diesel and 7.7% Diesel-

Ethanol Blend.

For commercial diesel and 7.7% diesel-ethanol blend, test results were satisfactory and vehicle passed 70

slope.

For the speed of 40 km/h and 60 km/h, CSFC measured with 7.7% E-Diesel is comparable with commercial

diesel.

Acceleration performance of 7.7% E-Diesel blend has 3% less acceleration than that of commercial diesel

because of ignition delay due to presence of Ethanol.

Achievements

ARAI team received best technical paper award for Paper No. 2019-26-0089 presented in Symposium on

International Automotive Technology, 2019 (SIAT 2019).

Thermal Management of Lithium-ion Battery Pack for EVs

Development of electric vehicles is prime focus of automobile sectors due to ever-increasing pollution and

constant increasing pressure on demand of resources, due to less efficiency of conventional drives. Electric

vehicles hold upper hand over conventional vehicles in efficiency and pollutant emission scenarios. Battery is

the most vital component of EV. Implementation of efficient thermal management is critical to ensure risk free

and long life of battery pack. Batteries being electro-chemistry in nature are inherently sensitive to

temperature variations. Performance of batteries heavily relies on operating temperature and distribution of

temperature within the pack. Variations in temperature within a pack leads to capacity fading, increase in

internal resistance and affects battery life to a great extent. ARAI developed competency in evaluation of

Lithium-ion battery pack through simulation to verify suitability to Indian conditions (driving as well as

environmental) and designing of thermal management system for the same.

Lab testing of batteries at various load/drive cycles and controlled environment is carried out using BITRODE

lab facility available in ARAI. Some of the load cycles used to carry out lab testing are Hybrid Pulse Power

Characterization (HPPC), Pune City Cycle (PCC), Maharashtra Industrial Development Corporation (MIDC)

and Worldwide Harmonised Light Vehicle Test (WLTC). Surface temperature, along with voltage of battery, is

mapped in lab testing of battery.

Cell level modeling of battery is carried out by electrochemistry as well as equivalent circuit modelling (ECM)

method using commercially available software. Electrochemistry method implies defining of battery using

chemistry of battery, geometrical and chemical properties of material, generating 1-D model and scaling it to

3-D, whereas ECM develops equivalent circuit of battery to predict thermal behaviour of battery.

Result of cell level simulation is correlated with physical testing of cell. Correlation assures prediction of

temperature in the module and pack to be accurate and fare enough to rely on it.

Module and pack level analysis helps in determining heat points and temperature gradient within the pack.

Predicting temperature at these levels assists design of thermal management system (TMS) without much

fuss. The simulation competency in thermal domain provides capability to predict performance of thermal

management system at specified driving and environmental conditions prior to implementation on vehicle.

Onus to drive the dream of e-mobility rest upon the batteries. Insight of the working characteristics of the

battery helps us to explore the ways to enhance performance of batteries, along with providing prescribed

safety for its operation. Culprit for almost every huddles in the progress of battery being the temperature,

competency to determine temperature and take decisive steps towards creating control environment for

operation of the batteries is the utmost motive of ARAI.

With more emphasis on electrification and hybridization of vehicles, there is a need for expertise in integration

of various electrical and mechanical systems for prototype vehicles. ARAI developed proficiency in vehicle

and system integration for electrification/hybridization. ARAI exhibited competency by demonstrating 2-

Wheeled, 3-Wheeled and 4-Wheeled electric and hybrid electric vehicle.

Several following engineering factors, that are essential to ensure that safe, reliable and robust vehicle, are

addressed by our experienced team.

Mechanical Integration

In conversion of vehicle into electric, all electrical component mountings for integration of motor, motor

controllers, battery, etc. are designed and validated using virtual validation technique. Additions /

Modifications in exiting transmission system based on hybrid configuration are also validated.

Electrical and Electronic System Integration Electrical Integration of Motor and Motor Controller Unit (MCU), Supervisory Controller Unit (SCU), Safety system interlocks, Sensors and actuator, fault indication system, cooling system and CAN communication Interface. Developed an interface between supervisory control unit, motor control unit and electrical and electronics systems present in the vehicle.

Vehicle and Systems Integration for xEV Technology Demonstrator

Selecting right subsystems for EV operations Selection process for electrical system of vehicle began with creating list of necessary, desired and optional functionalities for vehicle. Selected functionalities were then grouped into individual functional systems, based on which technical specification and selection of sub-system is done.

Vehicle high voltage system and Functional safety Developed a high voltage interlock system (HVIL), pre-charge circuit, safety system interface, Emergency shutdown and high voltage junction module for the safe operation of the vehicle under any high voltage potential fault.

Vehicle dynamics, crash safety and Strength analysis for electrification/hybridization Due to addition of number of components, weight of vehicle increases. These modifications call for validation of HEV for various parameters such as power requirement, battery sizing, motor selection, electronics packaging, weight distribution, vehicle dynamics, crash attributes, durability and Noise, Vibration and Harshness (NVH). While developing xEV technology demonstrator, ARAI developed competency in evaluating converted xEV in strength and durability, NVH, crash attributes and vehicle dynamics aspects.

Control Strategy Development and Calibration Model in Loop testing is done on baseline and hybrid diesel vehicle on PCC drive cycle and different operating conditions. Supervisory controller was designed in Simulink and AMESim is used to build plant model as it provides easy-to-use user interface. Real time simulation is carried out in Dspace real time testing for different test cases. Control strategy was aimed at making engine work in its best efficient zone by improving engine operating point while making use of motor to supply power wherever and whenever required. Also, if extra power was generated by engine to be in its efficient zone, surplus power was provided to charge the battery, which was limited by batteries charging rate. Calibration process is used to learn gain and offset for each two potentiometer of accelerator pedals.

Testing and validation Dyno trials were taken on different drive cycle and operating conditions, effect of hybridization/ electrification on ride and handling parameters and supervisory control strategy check by torque split between motor and engine unit.

Our teams have extensive expertise in development of number of technology demonstrator vehicles, across

wide range of vehicle categories ranging from L to M category vehicles. (2 and 3 wheelers, passenger cars,

LCVs, etc.). We also have certified high voltage engineers specifically for working on xEV Technology.

ARAI designed and manufactured 3-D HPM complying with SAE J826. HPM dimensions and weights are

calibrated in ARAI laboratory. With the “Make in India” initiative, 3-D H-Point machine is totally designed,

manufactured in-house and it is being used by the auto industry for testing applications. Various fixtures for

connected services and use of H-Point machine are available.

Back and cushion pans of 3-D HPM are representations of adult male. 3-D HPM specific parts include

followings. Please refer figure 1.

A. Cushion Pan and Back Pan

B. Thigh Bar

C. Head Room Probe

D. Upper Leg & Lower Leg

E. Shoe Assembly

F. Torso & Buttock Weight

G. Thigh Weight

H. Leg Weight

I. Movable storage box

Cushion Pan and Back Pan: Constructed of reinforced plastic and metal, these separate back and cushion

pans simulate human torso and thigh and are mechanically hinged at H-point. The unique part includes H

Point Button, Thigh weight pad and Cushion Pan level indicator.

Thigh Bar: Thigh bar is attached to cushion pan. It is also attached to upper leg assembly.

Head Room Probe: Graduated sliding probe is hinged from H-point to measure head room in the

compartment. Quadrant is fastened to probe to measure torso angle. An adjustable thigh bar, attached to

cushion pan, establishes thigh centre line and serves as baseline for hip angle quadrant.

Upper Leg & Lower Leg: Upper leg is attached to Thigh Bar and Lower leg segments, also adjustable in

length, are connected to cushion pan assembly at knee joining T-bar, which is lateral extension of adjustable

thigh bar. Quadrants are incorporated in lower leg segments to measure knee angles.

Shoe Assembly: Shoe and ankle assemblies are used to measure angular relation to lower leg segment.

Torso & Buttock Weight: Total 10 weights are loaded to Torso weight hanger and H point weight hanger.

Thigh Weight: Total 2 weights are loaded on thigh weight pad.

Leg Weight: Total 2 weights are loaded on leg weight hanger.

“MAKE IN INDIA” initiative for Design, Manufacturing and Supply of 3-D H-Point Machine

as per SAE J826

Movable Storage Box: Industrial customized case made of Plywood and Aluminium sheet composite with

HDPE black foam lining.

Lower leg, thigh bar, shoe, cushion pan, back pan and head room probe are all separate parts. This greatly

improves ease of installation and storage of components. For easy movement, supply includes specially made

movable storage box for easy storage and movement of components.

Figure 1

ARAI 3-D H-Point Machine

Widely acclaimed by global automotive fraternity, SIAT is a benchmark biennial international event, organized

by ARAI since 1985, that serves as forum for exchange of ideas and brainstorming for the automotive

industry, with participation of eminent experts worldwide in various automotive arenas.

The recently concluded 16th edition of SIAT, viz. SIAT 2019, organized by ARAI in association with SAE

International (USA), SAE INDIA and NATRiP, from 16-18 January 2019, at Oxford Golf Resort – Hill Top,

Bavdhan, Pune (India) is viewed upon as a memorable event!

Theme of SIAT 2019 was “Empowering Mobility – Safe & Intelligent Way”

SIAT 2019 focused on recent advances in various automotive areas, such as Safety, Emissions, Engines,

Noise, Electric Mobility, Electronics, Intelligent Transportation, Vehicle Dynamics, Materials, Alternate Fuels,

Simulation and Modelling. It also brought to fore innovative ideas and solutions in automotive technologies to

meet future challenges.

SIAT EXPO 2019

SIAT EXPO 2019, organized in concurrence with SIAT 2019, accommodated 129 Indian and overseas

component manufacturers, equipment suppliers and service providers to showcase wide spectrum of their

products and services across 241 stalls.

Symposium on International Automotive Technology (SIAT) 2019 – Brief Overview

Unique Features & Highlights of SIAT 2019

Chief Guests at the Event

The three-day Symposium was graced with the presence of eminent VVIPs, viz. Dr. A.R. Sihag, Secretary,

DHI (Inauguration Function), Shri Nitin Gadkari, Hon’ble Minister for Road Transport, Highways, Shipping &

Ganga Rejuvenation (Theme Session) and by Shri Anant Geete, Hon’ble Minister for Heavy Industries &

Public Enterprises (Valedictory Session).

Inaugural Function (16-Jan-2019) by Dr. A. R. Sihag

Theme Session (17-Jan-2019) by Shri Nitin Gadkari

Valedictory Function (18-Jan-2019) by Shri Anant Geete

National / International Participation

SIAT 2019 witnessed participation of over 1500 Indian and overseas delegates (representing over 15

countries) along with presentation of 113 technical papers and 40 keynotes in 30 Technical Sessions spread

over 3-days.

SIAT 2019 received overwhelming response in terms of delegates, paper presentations, keynote addresses,

plenary addresses as also for Panel Discussions as well, whereby organizers were obliged to draw a cut-off

line thereof.

Technical Papers / Keynotes / Plenary Addresses:

SIAT 2019 also witnessed quality of Technical Papers, enriched Keynotes and the crowd pulling Plenary

Sessions.

Of total 237 papers shortlisted, best 113 Technical Papers were presented in across 30 Technical Sessions in

6 parallel halls across three days, on 22 diversified topics as enumerated below –

Active and Passive safety

Advanced Driver Assistance Systems (ADAS)

Advanced Powertrain Technology

Advanced Vehicle Dynamics

Agricultural Tractors

Alternative Fuels

Autonomous Vehicles

Construction Equipment Vehicles

Electric & Hybrid Electric Vehicular Technology

Emission Measurement & Control Technology

End of Life & Recycling

Harmonization of Regulations

Intelligent Transportation Systems (ITS)

Materials & Manufacturing

Noise, Vibration & Harshness (NVH)

Public Transportation System

Simulation & Modelling

Structural Reliability

Testing & Evaluation Techniques

Tyre Technology

Vehicular Electronics

Vehicular Systems

Overall 40 Keynotes, based on aforementioned deliberated topics, were delivered, spread across three days,

prior to initiation of respective Technical Sessions.

Additionally, 11 eminent Plenary Speakers presented their thoughts, during two Plenary Sessions scheduled

during first two days of the Event. The speakers elaborated on various topics such as futuristic Mobility

solutions, climatic change, tyre emissions, changing trends, future beyond EV, etc., which were corroborating

with the theme of SIAT 2019, viz. “Empowering Mobility – Safe & Intelligent Way”.

Delegates were showered with enriched “Panel Discussion” on topic “Collaborative Research and

Development for Futuristic Mobility Solutions” wherein experts from various domains and streams, comprising

of top industrialists, distinguished researchers, Governmental Officials, enthusiastic academicians and

Director - ARAI participated and discussed about futuristic research and development in a collaborative

manner.

ARAI been declared as “Centre of Excellence for Methanol”:

Methanol is a low carbon bio-fuel produced from high ash coal or biomass or natural gas and is

environmentally-friendly as it produces low CO2. M-15 is a blend of 15% methanol and 85% Gasoline. Use of

blended fuel M-15 in BS-IV cars can result in lowering down GHG emissions by 10-12% thereby improving

urban air quality. Notification# GSR 490 for use of M-15 fuel has been issued by Ministry of Road, Transport

and Highways. Considering the national requirement to conduct research and development of technologies for

adopting alternate fuels in India, Shri. Nitin Gadkari, Hon’ble Minister (Road Transport & Highways) has

suggested ARAI to develop Centre of Excellence for Methanol. Addressing the automotive fraternity during

the Theme Session in SIAT 2019, Hon’ble Minister further indicated that the Centre will address the need for

development and certification for Methanol and DME transportation vehicles including 2-wheelers, 3-wheelers,

passenger cars, SUVs, small commercial vehicles, light and heavy commercial vehicles. The centre will also

cater to development and certification of Methanol and DME engines for various applications such as genset,

off-highway, marine and agricultural tractors.

The proposed centre at ARAI will consist of an upgraded chassis dynamometer capable of measuring

performance and emissions from vehicles below 3.5 tons. It will also be equipped with an engine test cell

having an engine dynamometer of capacity 350 kW for development and certification trials on engines of

vehicles above 3.5 ton. Methanol fuel analysis laboratory capable of fuel characterization, quality evaluation,

material compatibility, fuel additive testing and catalyst evaluation is proposed to be established. Methanol

and DME fuel station, including methanol and DME storage facility is envisaged with all safety protocols.

Methanol and DME component evaluation facility, which will focus on evaluation of methanol fuel pumps,

injectors will also be established.

The Centre will also host technical cell, which will co-ordinate development of methanol and DME standards,

file for IPR, assist with collaborations with international organizations and local industry, provide consultancy

to small scale and big enterprises as well as provide training to various stakeholders. This Centre will act as a

common platform for the stakeholders such of Methanol producers, Users, Research Institutes / Academia,

OEMs, Oil Manufacturing Industry, Additives manufactures, Policy makers / Regulators, Respective Ministries,

etc. for knowledge dissemination, testing, training and research activities. It can act as one-stop-solution using

collaborative approach. This Centre will undertake projects of national importance to provide directional input

for policy making and will be identified as Research Centre to carry out industry sponsored projects.

M15 3-Wheeler developed by ARAI

Mrs. Rashmi Urdhwareshe, Director, ARAI

director@araiindia.com

The Automotive Research Association of India

Survey No. 102, Vetal Hill, Off Paud Road, Kothrud, Pune 411 038 (India) Tel.: +91-20-3023 1101, 3023 1111 Fax: +91-20-3023 1104

Technical Reference Bulletin: Technical Reference Bulletin (TRB), comprising of technical articles,

advertisements, etc. was published to commemorate SIAT 2019. This Bulletin comprised of technical articles,

contributed to automotive enthusiasts, on various domains. It provided an opportunity for sharing various

advancements in automotive technology.

Student Poster Presentation Competition: SIAT 2019 also hosted “Student Poster Presentation

Competition” for Under Graduate / Post Graduate engineering students and Ph.D. research scholars from

various Universities in three categories, viz. Automotive Safety, Sustainable Mobility and Smart Vehicles.

Awards: As a token of appreciation as also to encourage quality and technical content, Industry sponsored

Awards were given away to Technical Papers, Exhibitory Booths and Student Poster Presentations, as

enumerated below:

Technical Papers (Specified Category)

Technical Papers (Open

Category)

Exhibition Stalls (Best

Display)

Student Poster Presentation Competition

a. Best Technical Paper on Exhaust Emission

b. Best Technical Paper on Safety

c. Best Technical Paper on Simulation & Modelling

d. Best Technical Paper on Electric Mobility

e. Best Technical Paper on Environmental Pollution

f. Best Oral Presentation

a. First Prize b. Second

Prize c. Third

Prize

a. First Prize b. Second

Prize c. Third Prize

a. First Prize b. Second Prize c. Third Prize

On Sustainable

Mobility Safe Mobility Smart Mobility

SIAT 2019 Sponsors