eMobility Development using 1D Simulation

Electric motor, battery capacity & transmission system sizing & selection for target vehicle performance and all electric range (AER) with multiple driving cycles

Integrated drivetrain, cooling & HVAC systems to check sufficiency of radiator, fan, pipe length, pump to meet desired temperature under different load modes (grade, vehicle speed)

Existing LT & HT cooling circuits performance prediction and sizing of radiators, fans & pumps to keep temperature within limits under hot ambient temperatures for driving cycles

Finalize tire radius, axle wheel drive ratio, transfer case ratio, and wheel drive mechanism (4WD/ 2WD) for time to accelerate for vehicle speed & distance, gradability, range and max vehicle speed

Gear ratio of the higher rating engine is optimized for fuel economy for NEDC cycle; and there is an improvement of 12% in vehicle fuel consumption

Radiator sizing, pump & fan selection to eliminate engine overheating under hot ambient air conditions and partially blocked grills and radiator front

Optimization of radiator features, pump capacity and fan airflow requirements to achieve the 57% increase in heat heat load of the upgraded engine

Performance and emissions development of turbocharged diesel engine through optimization of turbocharger, port design, EGR system and injection system

Various options - 4-valves, camshaft profile, turbocharger, EGR flow and intake & exhaust system pipe diameter - are investigated and target 35% power upgrade could be achieved

Select the best turbocharger based on altitude capability, emissions, fuel economy, mechanical design limits, surge margin and turbocharger efficiency

Develop power derate table with altitude and ambient temperature conditions without violating limits of mechanical design, compressor surge and emissions

Determine optimal camshaft profile for minimum BSFC and at the same time max ManVolEff without violating mechanical design constraints

Maximize and balanced power and torque output at specific engine speed through optimization of port design and camshaft profile for both intake & exhaust sides

Investigate feasibility to meet BS-VI emission norms & impact on performance through intake port design, compression ratio, cylinder bore & injection system

  Engine model NOx prediction capability development through calibration at steady state operating points and validation for the 8-mode Non-Road Steady Cycle (NRSC)

Proper combustion model development to capture transient capability. Estimate load step capability meeting ISO requirements - speed droop, recovery time, smoke limit, etc

Exhaust muffler modeling and TL correlation with measured data for one design. Predict TL for the remaining 3 designs and select the one with best TL characteristics

Optimize exhaust muffler design to achieve target acoustic curves for multiple microphones at relevant engine orders and with minimum back pressure

Predict TL of baseline dirty air duct system with three existing Helmholtz resonators and optimize resonator features to attenuate at three different frequencies

 Optimize air intake system pipe, number of resonators, resonator geometric features to meet intake orifice noise, air mass flow rate and pressure drop

Optimize dirty air duct, airfilter box, clean air duct, & turbocharger outlet air duct using a set of resonators at each section and porous pipes to meet stringent TL & intake orifice noise

Complete lube system model & steady state simulation for oil flow, power consumption, bearing load, max pressure, temperature rise and minimum oil film thickness (MOFT)

Steady state impact of main bearing groove variables – width, depth & extent of groove angle on MOFT, oil flow & power loss at peak torque, max speed & rated power

Transient simulation and investigate impact of initial oil temperature and oil type on lubrication system priming, temperature rise and power consumption

    Crankshaft design based on analysis of balancing, torsional & bearing. Comparison between modified & benchmark design. Balancing of forces & moments

FRM preparation, steady state & transient response validation with reference data, incorporate input & output signals, check compatibility with Simulink

 MVEM preparation using neural network, steady state & transient response validation with reference data, incorporate input & output signals, check compatibility with Simulink