TECHLLIGENT 2009

A NATIONAL LEVEL TECHNICAL SYMPOSIUM Paper Presentation on

Advances in Automobile Engineering

Guide: Dr.R.P.Kate

Authors: Mr. Naresh S.Ahire nareshsahire@gmail.com Cell # 0942085 928 Mr. Samadhan V.Phad samphad@gmail.com Cell # 099!5"499!0

Dr.Babasaheb Ambedkar Techno o!ica "ni#ersit$% &onere. Rai!ad.'() *(+

Abstract
,ith the ad#anced techni-ue emer!in! in automoti#e industr$ the passen!er cars are a so !ettin! more and more re.ined% /ithin a past coup e o. $ears a most each and e#er$ s$stem o. a passen!er car% ri!ht .rom structure% suspension% steerin! to brakin! and i!nition ha#e under!one man$ impro#ements. ,ith the increasin! .ue price the present market demands% cars /hich are .ue e..icient. &ookin! to/ards the same e..orts ha#e been made b$ us to stud$ and present the .actors a..ectin! the .ue consumption o. a car. 0n our paper /e ha#e inc uded ad#anced techni-ue in desi!n ike aerod$namic desi!n o. the car /hich is responsib e .or the dra! .orce. 1actors such as use o. composite materia s to increase the stren!th to /ei!ht ratio and the .riction bet/een the /hee s and the road sur.ace are a so discussed. 2mphasis has been !i#en on the measures to reduce the transmission osses and coo in! osses% /hich make the car3s .ue consumption e#en ess. A so% attempts ha#e been made b$ us to su!!est some bene.icia and re#o utionar$ chan!es% /hich can enab e more .ue 4e..icient car on road incomin! .uture. Throu!h this paper /e are tr$in! to understand the dependenc$ o. the .ue consumption on the di..erent s$stems o. car.

*. 0ntroduction
#n the passenger car the $uel consumption is becoming one o$ the great concerns $or the car manu$acturers as %ell as $or the car o%ners. &ith the constantl' decreasing the $ossils reserves and increasing price o$ the h'drocarbon $uel( the present mar)et demands more $uel* e$$icient cars %ith state o$ art com$ort and driving pleasure. &ith the continuous research and development in the passenger cars various parameters have came into picture %hich e$$ects the per$ormance o$ the car %ith respects to its $uel consumption. +he $uel burnt in the combustion chamber o$ the engine o$ the car releases energ'( out o$ %hich onl' 8, o$ its energ' is utili-ed in moving the car or running the accessories li)e air conditioner or po%er steering the rest o$ the energ' is lost. Car needs energ' to accelerate .overcome inertia/(to push the air against there motion .aerod'namic drag/( and to overcome the $riction $rom tires( %heels and a0les .rolling resistance/( to overcome these obstacles around 85, o$ energ' released $rom burning o$ $uel is e0hausted 1uel provides the energ' in $orm o$ chemical( %hich is burnt .o0idi-ed/ to trans$orm it into heat energ' and engines trans$orm this heat energ' released in combustion into use$ul %or) that turns the vehicle2s %heels rolling.

+A34E #

( Figure 1).

1rom the $igure it is ver' clear that the ma5or part o$ energ' lost is in the po%er generation plant ho%ever the aerod'namic drag( +ransmission losses( pumping losses( cooling losses also contributes the 85, $igure.

). 2ner!$ &osses and 0mpro#ements Re-uired

+he various parameters %hich e$$ects the $uel consumption o$ the car and the possible improvements re6uired in each s'stem7 2.1 Power Plant Losses (Losses in Engine):

Sr. No.

Themes 8educe engine pump losses

0mpro#ements Methods 9irect*in5ection gasoline engine Common rail s'stem diesel engine :ariable cam timing .:C+/

25pected 2..ects

0, 20, ;, .5, 2.5, !.5, 5,

#n the car engine around 80, o$ the energ' released b' the $uel is lost( and the remaining heat energ' is converted into mechanical %or) at the $l'%heel. +he energ' lost is mainl' due to $riction and pumping air into and out o$ the engine. 8educing these losses in the engine %ill increase the $uel e$$icienc' and %ill ma)e the ride cheaper. #mproving the per$ormance o$ various elements can reduce the $uel consumption o$ the engine. +he various themes and improving methods are as $ollo%s along %ith the e0pected e$$ect in the $uel consumption7

2 ; 4

8educe cooling losses #ncrease e$$icienc' o$ e6uipments #mprove $uel e$$icienc' %hen stationar' 8egenerative bra)ing

+hermal storage s'stem <igh e$$icienc' o$ Air*conditioner Anti*#dling $unction

<'brid engines

2.2 Losses due to Drag Force: +he vehicle %hile ascending at a ver' high velocit' e0periences drag $orce due to the impact o$ %ind. =inimi-ing this drag $orce is al%a's a concern %hile designing the pro$ile o$ the car. &hen the %ind stri)es the moving car in the opposite direction the resultant velocit' o$ the %ind is resolved into t%o components i.e. thrust or li$t and the drag $orce.
Thrust! li"t Force #esultant "orce

Correlating the per$ormance o$ vehicles %ith the both $our %heel and t%o %heel drive options sho%s that in $our %heel drive transmission losses to be about 5, higher than rear %heel drive.

+. 6ase Stud$: 7onda 0nsi!ht

+he #nsight is a petrol*electric h'brid t%o*seater coupe that blends a mass o$ ne% technologies to achieve the %orld>s lo%est $uel consumption $or a petrol engine car. +he car has h'brid s'stem $eatures( a high e$$icienc' petrol engine( electric motor( and light%eight 5*speed manual transmission( used in combination %ith a light%eight and highl' aerod'namic aluminium bod'. #t has an outstanding on*road per$ormance( %hich reaches $rom 0 to 90 )mph in 2 seconds and a top speed o$ "0 )mph( %ithout compromising the ultra*lo% $uel e$$icienc' and e0haust emissions. +his increase in the $uel e$$icienc' is due to the $ollo%ing improved $actors in the car7 3.1 Light Weight aterials

Drag Force
1i!. Reso ution o. /ind 1orce

#n the conventional pro$ile o$ the car this drag $orce is high enough to increase the $uel consumption and limit the speed o$ the car ho%ever the research and development in this $ield introduces the aerod'namic design o$ the car %hich allo%s the streamline $lo% o$ %ind over the pro$ile o$ the car and thus minimi-es the drag $orce %hich $urther increases the $uel e$$icienc'.

&eight reducing technologies %ere seen as a )e' $actor in achieving the highest possible $uel econom'. +he use o$ aluminium bod' construction to create a ne% t'pe o$ light%eight aluminium bod' o$$ering a high level o$ rigidit' and advanced sa$et' per$ormance. +he Insight has made optimum use o$ a combination o$ e0truded( stamped and die cast aluminium components and bod' %eight is more than 40 per cent less than a comparable steel bod'. #n this car the components are not onl' light in %eight but also posses a high strength to %eight ratio. 1or e0ample( the connecting rods are not onl' $orged steel( but also case*hardened .or carburised/ $or signi$icantl' increased strength. =agnesium allo' are also used %hich provide a high degree o$ resistance to thermal induced e0pansion $or the engine sump in place o$ aluminium allo'( giving a ;5 per cent %eight reduction. 1or reducing overall vehicle %eight( and in particular unsprung %eight( $ront bra)e callipers and rear bra)e drums made o$ aluminium. Along

2.3 Transmission Losses: +he average rear %heel drive car around 00 bhp loses about !, o$ the engine bhp as transmission losses %here as the losses in the $ront %heel transmission is about 5,.+he 2, reduction in losses over rear %heel drive is because the di$$erential %hich has to turn the drive through 90 degrees at the bac) a0le %hich soa)s up a bit more o$ the engine2s po%er. 1our*%heel drive cars %ill have higher losses because o$ the e0tra di$$erentials and other po%er transmission components. +he t're and main gearbo0 losses %ill be the same though.

%ith the rest o$ the suspension2s aluminium components( these light%eight pieces also help to enhance vehicle handling and ride 6ualit'. ?ther %eight saving technolog' such as use o$ thinner*sleeved c'linder bloc)( %hich also allo%s $or a more compact engine bloc)( brac)et less ancillar' e6uipment( and an increase in plastic parts li)e inta)e mani$old( c'linder head cover( %ater pump pulle'( and the compact :+EC c'linder head also reduces %eight considerabl'. +he Clutch and bra)e pedals are $abricated $rom aluminium to achieve the desired goal. 3.2 Friction #eduction: +he less energ' lost through $riction( the more that can be recovered in the regenerative mode( and an' means o$ reducing $riction is thus o$ vital importance in the 6uest $or lo% $uel consumption. #n order to minimi-e the $rictional losses b' the roc)er arm( the ne% roller t'pe roc)er arm is adapted to the single cam :+EC mechanism( providing a !0 per cent reduction in $riction losses. +he sliding pin used to operate the cam pro$ile s%itchover in the :+EC mechanism is no% integrated %ithin the roller2s inner sha$t $or a lighter and more compact roc)er arm design( thus helping to reduce inertial %eight. #t has also allo%ed the valve spring load to be reduced b' ;0 per cent. +he light%eight aluminium allo' pistons have a minimal s)irt area and the sur$ace o$ the s)irt has been shot*peened. @hot*peening produces a special 2micro dimple2 sur$ace %hich improves the retention o$ the oil $ilm bet%een the piston and the c'linder reducing $riction b' appro0imatel' ;0 per cent. 3.3 $TE%&E Engine:

air*$uel ratios %hich pla's a ma5or role in reducing the $uel consumption. +he )e' to success$ul lean burn operation is overcoming the lengthening combustion time as the mi0ture becomes increasingl' lean. Insights engine substantiall' reduces combustion times compared %ith conventional lean*burn engines( allo%ing much leaner operation and over a greater range o$ engine speeds( to bring substantial improvements in $uel econom'. +he solutions include a ne% s%irl port to enhance the turbulence o$ the mi0ture in the c'linder( a compact combustion chamber and a high compression ratio. :+EC*E .:ariable :alve +iming and 4i$t Electronic Control $or Econom'/ mechanism( in the Insight, %here s%irls are generated b' almost closing one o$ the pair o$ inlet valves at lo%er engine speeds. +he inlet ports are set up in a more vertical direction to generate more po%er$ul s%irls $lo%ing into the c'linder( enhanced b' appro0imatel' 20 per cent both hori-ontall' and verticall'. +he Insight $eatures 5ust one roc)er sha$t %ith the included angle o$ the valves narro%ed $rom 4" to ;0 degrees .comparing $rom conventional :+EC/( allo%ing the high s%irl port shape and the compact combustion chamber to be realised. +his in turn allo%s an increased compression ratio and reduction in $uel consumption.

.$igure 2/

:+EC stands $or :ariable +iming and 4i$t Electronic Control @'stem. #t %as designed to resolve the problem that has traditionall' been $orced to ma)e bet%een lo%*speed tor6ue and high*end horsepo%er. #t lets the engine breathe according to its needs. Insights latest :+EC advances %ith lean burn operation * that is( the use o$ e0ceptionall' high

At high speed the :+EC*E engine activates both o$ its inta)e valves. +he additional valve area satis$ies the high*rpm breathing and po%er re6uirements o$ the engine. +he Insight's engine is 25 per cent more e$$icient and consumes less $uel than a conventional petrol engine.

3.' (erod)namic *er"ormance: +he #nsight2s bod' has been designed to be highl' aerod'namic. #ts coe$$icient o$ drag .Cd/ %hich is 0.25 is one o$ the lo%est amongst the passenger cars in the %orld. #n comparison %ith the other cars it needs around ;2 per cent less po%er to operate at the same speed. Contributing to this outstanding aerod'namic per$ormance are7 .Aerod'namicall' shaped nose( %indscreen. 2.1lat $loor and underbod'. ;.+apered bod' %ith the rear %heels. 0 mm narro%er trac) at

conventional t'res and a 5 per cent reduction in %eight.

'. 6onc usion

Continuous research in the car has provided more $uel e$$icient vehicle on the roads. #mprovements in the pro$ile o$ the car( transmission s'stem( engine c'cle modi$ication has decreased the losses( and more e$$icient utili-ation o$ the $uel is achieved b' reducing the $riction losses. 4oo)ing to%ards the present status o$ the #ndian automobile mar)et %e re6uire to ma)e more $uel e$$icient cars %hich re6uire man' improvements in almost each and ever' s'stem o$ the car. &e are a heading to%ards high speed car %ith a state o$ art com$ort( %hich %ill ma)e car manu$acturers and engineers to %or) more on the aerod'namic pro$ile and use o$ composite material in order to ma)e the car structure light in %eight. 1rom the case stud' o$ <onda>s Insight %hich is an e0cellent e0ample o$ the latest technological advancement in the direction o$ increasing the $uel econom' o$ the car. +his car has incorporated man' advanced $eatures %hich ma)es it ahead o$ its competitors in the race o$ $uel econom'. #mprovement is a continuous process and %e hope to see cars on #ndian roads %ith less $uel consumption b' incorporating the ne% technological advancements.

4.4o%*drag door mirrors. 5.4o% height( small $rontal area and long( tapered roo$line. ".@tra)es at the side* and rear*lo%er edges o$ the Insight's bod' helping to minimi-e drag b' controlling underbod' air$lo%.

!.Aerod'namic rear %heel s)irts and disc*shaped allo' %heels smooth air$lo% around the %heel openings. 8.+he engine air inlet louvers are shaped to e$$icientl' admit cooling air. +he above $eature help in minimi-ing the drag $orce and thus reduces the $uel consumption considerabl'. 3.+ Low rolling&resistance: +he #nsight $eatures speciall' designed t'res mounted on aluminium*allo' %heels. +hese ne% t'res have 40 per cent less rolling resistance than

Re.erences
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