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In the coming years, moving towards a hundred percent electric vehicles will be one of the key areas in the automotive industry. The main advantages of using e-mobility are operational flexibility, lower carbon emission and regenerative energy. Thermal management in an e-vehicle plays a vital role for the reliability of the system and any thermal failure can cost a significant amount of money to a company per vehicle. Inverter assembly is widely used to convert Direct Current (DC) to Alternating Current (AC) in the e-mobility platform to operate the motor for vehicle propulsion. It consists of various electronic transmitters, controllers, capacitors, and semi-conductors which will emit an enormous amount of heat during their operation. Since inverters are highly temperature sensitive in nature, it is necessary to improve the temperature distribution in the device. For this reason, adequate cooling system and ventilation is inevitable to keep the components operational.

Pneumatic valves are widely used in heavy commercial vehicles’ air braking systems. These valves are mainly used in the braking system layout to maintain the vehicle stability during dynamic conditions. Rubber components are inevitable in valves as a sealing element, and it is very difficult to predict the behavior due to its nonlinear nature. Basically, this valve efficiency is defined in terms of performance and response characteristics. These characteristics are determined in the concept stage itself using 1D simulation software. AMESim software has a variety of elements to use in a unique way for performance and response behavior prediction. For pneumatic valves, 1D analysis is an effective method and it gives good correlation with actual test results. During the modelling of pneumatic valves, some of the contacts between rubber and metals are controlled by various parameters such as damping, contact stiffness and desired phase angle.

Manufacturing suspension systems is not a new or upcoming process, it has been in the market for years but still, the survival of the fittest plays a key role for the respective manufacturer. So, the main objective of the vehicle suspension system is to improve ride comfort, road handling and vehicle stability. A suspension system plays a vital role in a smooth and safe riding experience. So, an analysis of the suspension system should be done, and the results should be in the standard range. In this paper, the simulations of a quarter and half car passive spring and air suspension were analysed for ride comfort and suspension travel by mathematical modelling of the quarter-and-half car with the help of a system of equations.

Air Supply Unit (ASU) serves as the pneumatic source for the air suspension system in the passenger car segment. The ASU is an electrically driven oil-free compressor with integrated air dryer to deliver dry air to the suspension system. Solenoid valve, Height Sensor and ECU adjusts the pressure in bellow based on the vehicle load condition. During the lab test, pressure was not building up in the compressor due to delivery valve failure. The type of valve in asu is reed valve type, it is mostly used in the micro compressors due to its low cost, simple structure and light weight configuration. The reed movement is based on the pressure difference between the inlet and the compression chamber. Failure analysis is carried out based on the finite element analysis to identify the root cause, the root cause identified is optimized to prevent the failure.

In recent days the usage of Electro - Hydraulic Control Unit (EHCU) is increased acutely in light passenger vehicle applications apart from the passenger cars. The main advantage of using electro - Hydraulic control unit (EHCU) is operational flexibility, consistent performance customization, increase durability and lower running cost. During running, the mechanical load is converted into the electronic signal by using transmitter. The electronic devices are highly responsive when compared with mechanical devices, so, it is necessary to reduce the Noise, Vibration and Harshness (NVH) in the system. As per the recent trend, the NVH pollution should be as low as possible in the vehicle. It is necessary to maintain the NVH in minimum level in the electronic device to meet the overall performance of the system. The vibrational isolator is one of the key components used in Electro – Hydraulic Control Unit to reduce the noise and vibration implication of the system.

Braking system components generally are safety critical products. Commercial vehicles braking systems are of highly safety critical as they pose a serious threat to life and property. Therefore, a system must be designed and validated to minimize the effects of component failure of these portfolios of products. In order to avoid accidents due to brake failures, this paper mainly focuses on analysis of loss of pneumatic fluid pressure in the components of the braking systems. Leakage of pneumatic fluid pressure through the sealing in braking system is one of the major reasons for the failure of the brakes in the vehicles. The aim of the present study is to simulate the lab failure and improve the design using finite element analysis. Also, the optimized design is validated by experimentally. A finite element model is developed in Ansys Workbench to study the behavior of the sealing ring under assembly conditions.

In recent days, the usage of disc brake is increased acutely in commercial vehicle applications apart from the passenger vehicles. The main advantage of using disc brake is reducing the stopping distance, temperature and wear between the disc and pad. During the braking, kinetic energy of the vehicle is converted into thermal energy due to the friction between disc and pad. To maintain the temperature between the disc and pad is critical for the overall performance of the disc brake and safety of the vehicle. The process of vehicle braking is a dynamically thermal structure coupling problem which is complex in nature. In this study, temperature between the disc and pad is determined using Finite Element Analysis for two different pad configurations. As per recent vehicle norms by the government the axle load is increased by 20 % which requires increased braking force and will leads to high temperature in the disc pad interface.

Lift axle is essentially provided in commercial vehicles to increase the vehicle’s load-carrying capacity. The axle is lowered in the case of a high payload and the load is evenly distributed among the wheels both on fixed axles and the lift axle. This ability to lift the axle implies better maneuverability in turns, better fuel consumption, and less wear and tear on the tires and brake shoes. Also, it will reduce the damage to the road surfaces. This lowering and lifting of the lift axle are controlled by a series of valves together called the Lift Axle Control System (LACS). This LACS must consider the vehicle load condition, the ignition state, and gear state to decide if the axle must be lifted or lowered. This paper deals with the modeling and simulation of the LACS system at the vehicle level and optimize the design for the respective desired design solution.

Generally the brake system products are mounted on chassis with brackets which are subjected to dynamic loads due to road undulations. Exhaust brake is used to restrict the engine exhaust flow passage and thereby creates a back pressure in the engine for reducing the engine speed. This in turn reduces the vehicle speed. This is widely used in the vehicles operating in the hilly areas. This product is mounted on the exhaust passage and the air cylinder sub-assembly which actuates the exhaust brake is mounted on a bracket. Automotive industries perform durability tests on vehicles to reduce the failure on end-user environment. An assembly which has cleared the durability test got failed on addition of a spring into the assembly. The inclusion of spring is for enhancing the performance of the overall assembly.

Reliable sealing solutions are extremely important in commercial vehicle industry because sealing failures can cause vehicle breakdown, damage of equipment or even accident, incurring expenses that are substantially higher than the costs of just replacing the damaged seals. Consequently, new seal designs must be experimentally verified and validated before they can be implemented. In this study, Mooney - Rivlin hyper elastic material model is used to simulate the sealing behavior during dynamic conditions. The seal under study is a large diameter lip seal made of Neoprene® rubber (NBR) A finite element model to study the response of the seal under dynamic conditions was developed. The analysis took into account the mating parts dimensions and the lip seal parameters. Three designs were proposed and verified. The seal design is optimized using non-linear FEA and validated. Results include contact pressure, deflection and strain experienced by the seal during actuation.

This paper presents a systematic procedure for design and evaluation of snap fit for Quadruple System Protection Valve (QSPV) piston assembly. The QSPV piston is assembled with housing by means of snap joint. Snap joints are a very simple, economical and rapid way of joining two different components. All types of snap joints have in common the principle that a protruding part of one component, e.g., a hook, stud or bead is deflected briefly during the joining operation and catches in a depression (undercut) in the mating component. After the joining operation, the snap-fit features should return to a stress-free condition. The joint may be separable or inseparable depending on the shape of the undercut; the force required to separate the components varies greatly according to the design. It is particularly important to bear the following factors in mind when designing snap joints: Mechanical load during the assembly operation and force required for assembly.