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Diesel engines are known for their excellent low-end torque, better drivability, performance, and better fuel economy. The increase in customer demands pushes to deliver higher power and torque along with fuel economy. This requirement puts a great challenge on the overall weight of the engine. This paper explains the holistic approach followed along with optimizing the rocker arm cover to achieve the weight target without compromising on durability and cost in the commercial segment 2.5-liter Diesel Engine. This paper presents a complete overview of the design and development of Rocker Arm (RA) cover to meet Strength, Durability, NVH and Aesthetic in Commercial Engine where base design is in aluminum which is mounted on cylinder head with a separate breather system. From aluminum the base design of Rocker arm cover is optimized to sheet metal where in there is reduction of 43% in weight and cost saving of 13%.

Design and development of high-pressure pipe involves number of design validation plans for robust design in diesel engine. The fundamental behavior of two-cylinder diesel engine with parallel stroke involves high vibration which generates stress on components mounted on crankcase resulting into earlier fatigue failure. In this paper, the innovative approach of using optimized design of vibration damper for resolving high vibration stress concerns in fuel system is discussed. The vibration dampers were designed meeting both performance and durability aspects in two-cylinder diesel engine applicable for both passenger and commercial vehicle. This paper highlights the design approach involving experimental stress measurements and design optimization based on part development feasibility.

Drink & drive has caused the increased rate of commercial vehicle accidents in the world due to the slow response to judgment and reasoning. According to research study 70% accidents are happened due to drunk & drive, it causes loss of human life and economic damage. Research has proven that drunk drivers exhibit aggressive driving behavior and apply more force during braking. While public health awareness and legal restrictions can assist in educating and discouraging people from drunk & drive, a more fool-proof method is not available in the market for commercial vehicles. Currently, a low cost, fail-safe onboard alcohol detection, and vehicle safety system is the need of the hour. This paper deals with the design & development of a low cost active onboard breath alcohol detection system and it’s on vehicle validation. Further, it explains the type of alcohol detection sensor used, controller design, logic programming and system packaging.

One of the key requisites for a sustained mobility development is to have an efficient public transport system. Fuel efficiency and emission control are extremely important in this respect. By the very nature of city driving, it is obvious that city traffic results in frequent vehicle start and stops; which involves huge waste of vehicle kinetic energy. Every time vehicle moving from idle, needs a bigger input of power and every time the brakes are applied, all energy built up disappears again, wasted in the brake pads as heat. An effort has been taken to recuperate vehicle kinetic energy, hydraulically during braking events and utilize it to assist the vehicle during acceleration. Hydraulic based hybrid vehicle working on the principle of regenerative braking is one of the most fuel-efficient technologies for city application. Parallel hydraulic hybrid vehicle has been developed and optimized for fuel efficiency gain at vehicle level.

The reduction of tire wear in vehicle is one of the major challenges for engineers. Under-inflated tire can cause reduction in tire life along with decrease in driving stability of vehicle. Efforts have been taken to develop a low-cost auto-tire inflation system integrated in vehicle for reduction in tire wear as well as to avoid periodic checks of tire pressure. This paper deals with the technology and design approach required in the development of auto-tire inflation system for commercial vehicle. This system should have the fundamental role of not only monitoring the tire pressure but also inflating the tire to the recommended level of pressure whenever the pressure is reduced below the recommended level. Different approaches have been worked out for integration of system on vehicle with least modification in existing design.