Index Issue 2009-2010

1) Alternative Fuel Engine Development at ARAI

2) Certification of Buses for Rollover as per AIS-031 using CAE Methods
3) Calibration Lab
4) 4 Degree of Freedom (4DOF) HCV Cabin Shaker Test
5) Jounce and Squirm Test Rig for Seat Testing
6) Sound Package Tuning for Automotive Interiors
7) Photometric Services at Safety & Homologation Laboratory
8) ARAI Signed MoU with Loughborough University, UK for Research, Post Graduate and
Doctoral Programmes in Automotive Engineering
9) Inauguration of ARAI-Regional Centre South (ARAI-RCS) at Chennai
10) Bus Body Accreditation by Automotive Research Association of India
11) Pressure Pulsation Testing for Engine Crankcase
12) Towing Dynamometer
13) Flash News
14) ARAI signs MOU with ISA, Sweden
15) Online Submission and Tracking of CMVR Type Approval Certification
16) Automotive Crash Test
17) Strategic Tie up of ARAI with CCT, Korea
18) Wheel Force Transducer for Passenger Cars and SUVs
19) Material Compatibility Study with Gasoline and Ethanol Blended Fuel
20) Development of EURO V Compliant CNG Injection Engine
21) Structural Dynamics Lab Your Partner in Vehicle Development
22) ARAIs Participation in Automotive EXPOs




Alternative Fuel Engine Development at ARAI

Development of alternatively fueled engines has become vital in order to meet the increasingly stringent
emissions norms being implemented globally. Furthermore, alternative fuels provide a cost benefit, due to
the lower costs of production of these fuels. Compressed Natural Gas (CNG), Liquefied Petroleum Gas
(LPG) and Hydrogen-CNG blended fuel (HCNG) are promising alternative fuels in India. The Engine
development lab at ARAI has developed several CNG engines for Indian OEMs ranging from 2 stroke 3
wheeler engines to heavy duty commercial engines. Various sub-systems of the baseline SI/CI engine, such
as the air-intake system, combustion bowl, CR, the exhaust system, after treatment device are reviewed and
suitably modified to achieve the target specifications. ARAI has experience of developing CNG/LPG engines
with carburetion and injection kit fuel technologies and has completed several projects with reputed suppliers
such as Landi-Renzo, AFS, Vialle, BRC, Lovato, Impco, Omnitek, ad Vanaz. Fuel system parts such as 1
st

stage reducer, 2
nd
stage reducer, mixer are also suitably modified & optimized to achieve target
specifications.



Figure 1 A CNG Bus engine developed by ARAI and the CNG HCV
The CNG engines & vehicles developed by ARAI have passed current emission norms with comfortable
margins in CO & NMHC+ NOx emissions. Most of the ARAI developed engines have been commercialized
and are successfully running in the field. Figure 1 shows a CNG Bus engine developed at ARAI. As exhibited
by the results, Closed loop control of CNG engines results in a large reduction in NOx and PM emissions as
compared to diesel engines.
CNG Injected engine can meet Euro-IV norms easily and have superior performance as compared to
carbureted engines. The charge stratification in the CNG combustion chamber permits extremely lean
combustion without high cycle-by-cycle variations with high combustion efficiency.

ARAI has expertise in development of LPG engines. Liquefied Petroleum Gas (LPG) is a prominent
alternative fuel with well developed distribution infrastructure and increasing number of Gasoline engines
are now being converted to run on LPG considering the fuel economy and low exhaust emissions. ARAI has
developed several bi-fuel (LPG/Gasoline) and dedicated LPG engines ranging from single cylinder two
wheeler engines to advanced 4 cylinder passenger car engines. Optimization with LPG kit includes
emission optimization on to give equivalent mileage on Gasoline. Figure 2 shows a typical LPG engine
developed by ARAI.



Figure 2 A Single Cylinder LPG Engine Developed by ARAI

Traditionally CNG vehicles have been developed in India in variety of segments and have contributed to
cleaning the ambient conditions of cities like Delhi. However the persistent NOx levels are becoming a hotly
debated issue. One of the solutions to this crisis is the addition of Hydrogen to CNG. The Hydrogen + CNG
fuel referred to as HCNG has the potential to lower emissions including NOx as compared to CNG and is
considered to be the first step towards promotion of a Hydrogen economy. ARAI is developing a 6-Cylinder
HCNG naturally aspirated engine using the lean burn concept of combustion. The six cylinder engine was
chosen due to its importance for urban bus transportation. In this study the lean burn combustion concept has
been evaluated for varying HCNG blends. The HCNG engine has potential to meet Euro-IV and beyond
norms with Injection technology. It is also expected that HCNG fuel blends reduce NOx emissions by
approximately 50%, non-methane hydrocarbons by 58%, and total hydrocarbons by 23% and CO
2
by 7% as
compared to CNG. No PM emissions are observed in CNG or HCNG engines.




Figure 3 HCNG Engine Under Development at ARAI
ARAI is fully equipped and has the expertise to undertake development projects for all types of CNG, LPG &
HCNG engines for the automotive industry.

Certification of Buses for Rollover as per AIS-031 using CAE Methods

ARAI has completed number of projects on evaluation of strength of bus superstructure for rollover analysis
as per AIS-031 using computer simulation and validated the results by physical rollover test. Following are the
major activities carried out in the process:
Classification of bus models into different families and to arrive at the worst case of the family:
ARAI has prepared a methodology for classification of bus models into different families and to arrive at the
worst case of the family, based on different engineering parameters and if needed, use of CAE methodology.
This facilitates substantial time and cost saving by minimizing the number of physical tests.
Generation of input parameters viz. material properties and joint characteristics:
Before carrying out the simulation, it is necessary to measure physically all the relevant mechanical
parameters (including stress-strain curve, etc) of the material and also that of the joints used in the bus. In
the case of joints, they get simulated and validated with the physical data collected using test facilities at
ARAI. The validated model of the joints is used for simulation.

Computer Simulation Physical Testing
Loading
area
Constraint area



Joint Simulation and Experimental Validation


Determination of vehicle CG by experimental method
using method prescribed in ECE R 66:
ARAI have a test setup for determination of vehicle CG by
experimental method, which is an important input for FE model
generation of buses.


Generation of detailed FE model and Rollover
analysis of bus using non-linear FE software:
ARAI has developed a methodology for generation the FE
model and rollover analysis of bus using non-linear FE
software, which has been closely correlated by physical
rollover tests. CAE methodology is now very well developed
and is widely deployed for evaluation of impact scenarios
like the bus rollover. The methodology is proven to
generate the necessary confidence to complete the design
sign-off.

Experimental CG Determination



FE Model of Bus






Rollover Simulation and Experimental Validation
Suggestion of structural modifications to meets rollover requirement:
In case the baseline design does not meet the rollover requirement, ARAI can suggest suitable optimum
and practical modifications to enable the design to meets rollover requirements.
The entire methodology results in speeding up the development cycle for bus manufacturers.
Following papers are published by ARAI on the above topic:
SAE Paper No. 2009-26-001: Certification of Buses as per AIS-031/ ECE-R66 Using CAE Methods by
Joseph Philip, Chopade, S. E., Mahajan R. S., Raju S, at Symposium on International Automotive
Technology (SIAT) 2009, ARAI, Pune, India

Automated Process Tool for Pre & Post Processing of Bus Roll-Over Analysis in Compliance with AIS
031/ ECE R66 by Mahajan R. S., Presented at Hyperworks Technology Conference, 08 at Bangalore,
India, along with Rishi Shah, Altair Engineering (I) Pvt. Ltd.

Calibration Lab

Calibration Lab at ARAI is well equipped to serve calibration needs of the automotive, component and allied
industry. The laboratory has NABL accreditation as per ISO 17025. In addition to discrete calibration
services, Calibration Lab undertakes full calibration contracts such as calibration of test cell instruments,
production line, etc. It also undertakes turnkey calibration jobs and onsite calibration services are covered
under NABL Accreditation. The facilities cover parameters such as :
Temperature
Pressure
Electrical
Acceleration
Mass & Balances

Sound Pressure Level
Miscellaneous, such as RPM, Load, etc.


Highlights
National / International Traceability
NABL Accreditation

On-site calibration facility
Expert Manpower

Various facilities of Calibration provided by Lab
1) Temperature Calibration





Primary Calibration using Fixed Points:
Mercury (-38.8344C)
TPW (0.01C)
Ga (29.7646C)
Indium (156.5985C)
Tin (231.928C)
Zinc (419.527C)
Aluminum (660.323C)
Reference cells with their maintenance bath are used for
calibration of SPRTs, PRTs and Reference Temperature Sensors.

Secondary Calibration by Comparison Method:
Comparison Calibration Range: -50C to 1000C.

NABL
2) Mass, Weighing Balance and Load Cell Calibration

Reference Equipment:
Set of E1 class Weights
Set of E2 class Weights
Set of F1 class Weights
Micro-Balance
Weighing Balances

Standard Weight Set and range
1mg to 200g
500g to 5kg
10kg to 20kg
0.001mg to 2g
0 to 220g, 5kg, 12kg, 150kg
Calibration of fractional weights 1mg to 50 kg and balances up to 150 kg.





Load Cells Up to 100 kN

NABL

3) Pressure Calibration

Reference Equipment
Dead weight Tester
Portable Pressure calibrating system

Standard Weight Set and range
Range -1 to 50 bars
Range -1 to 1000 bar
Calibration of pressure gauges, vacuum gauges, compound gauges,
pressure indicating systems, pressure transmitters, etc.





NABL
4) Accelerometer, Sound Level and Speed Calibration


Calibration of ICP, Piezoelectric, Piezoresistive or Capacitive Type
Accelerometers using Secondary Accelerometer Calibration up to 60 g in
operating range 3 Hz to 10 kHz.

Also facility for calibration of Sound Level Meters, Sound Analyzers, etc.
using Multifunction Acoustic Calibrator for A, C and Linear Weighing
from 31.5 Hz to 16 KHz.

In-house and on-site calibration for Speed Sensors / Tachometers and
Pulse Engine Tachometers.




NABL
5) Electrical Calibration



NABL

Reference Equipment
Precise Calibrator, 8 and 6 Digit DMM, Frequency Standards, etc.
Calibration of Precise Multi meters, Digital Process Calibrators, Temperature
Controllers, Timers, different types of Generators and Counters,
Oscilloscopes, Meggers are carried out.

Parameters (For Source & Measure)

DC / AC Voltage
DC / AC Current
Resistance
Frequency
Time
Temperature Indicator
0 to 1000 V (Source), 0 to 10 KV (Measure)
0 to 20 A
1 to 100 M
1 Hz to 225 MHz
0.1 Minute to 24 Hrs
All type of thermocouples & RTDs




4 Degree of Freedom (4DOF) HCV Cabin Shaker Test

With unique blend of resources, facilities and manpower supported by capabilities in the most advanced
technology at Structural Dynamics Laboratory (SDL) of ARAI, our customers benefit from the unrivalled
expertise. SDL team applies their knowledge and experience for helping customers to create world-class
products.
Operating across the whole range of transport technologies, SDL provides particular expertise in all aspects of
durability. From initial concept through to production start, SDL is being able to provide latest simulation and
development tools and techniques.
SDL has been supporting Automotive Industry in vehicle development process for more than 20 years, helping
customers to design, develop and produce higher quality products with greater speed and lower cost. SDL
engineers thrive on diverse and technically challenging projects and are always able to offer customers
innovative approach or solution.
Operating at the forefront of vehicle development, SDL has completed number of successful projects. Recently
SDL has developed cabin simulator to sign off durability in laboratory.

For durability evaluation of cabin, full vehicle test such as four-poster, multi axis test, etc. where input is given at
wheels, were being used. This new cabin test rig is designed where various cabin modes are produced. There
are independent multi axis motions possible (Vertical, Pitch, Roll, Yaw, Lateral and Longitudinal), but
simultaneously reproducing all of them requires significant complexity in data acquisition, as well as test rig
design and operation.

SDL has developed 4DOF cab shaker test rig to produce motion vertical, pitch, roll and longitudinal. In this test rig
four vertical actuators and one longitudinal actuator are used. The vertical actuators are mounted under the
corners of the cabin using a pseudo frame. The longitudinal actuator is mounted at the cross member.

Lateral restraints are used to keep the specimen upright during dynamic operation of the test rig. The objective
to this restraint is to stabilize the specimen in an upright position without producing forces and displacements.
The picture given below shows schematic of set up at ARAI.

Rig Specifications
Cabin Load Capacity: 1T
Frequency: 40Hz.
Test Specifications: Simulation of Road Load Data
Durability: Accelerated durability testing by removing non damaging portion of data of given correlation.




Structural Dynamics Laboratory (SDL) of ARAI is dedicated to product development in the automotive sector,
offering engineering, testing and homologation services to the industry world-wide. SDL undertakes global
vehicle development projects for the principal manufacturers and has consolidated its position as a reference in
the sector.

Based on the global Automotive Roadmap of certification and development, SDL has its own roadmap of
introducing new services, which has unique combination of research projects, specialist engineering skills, world
class engineering facilities, development test facilities and homologation facilities.

Validation testing on seats and seat structures is one of the major activities carried out at SDL. Validation testing
is an important part of design process for seat and seat structures. Validation tests are performed to determine
if design requirements are met. These validation tests are classified as,
Functional test
Reliability test
Homologation and Safety related test
Testing for interface and compatibility
Development tests on sub-assembly components

The development tests conducted so far were as per various International standards and specifications. SDL
has now taken another step towards enhancement of its developmental test facility in seat testing area by
installation of the Jounce and Squirm Test Rig.
Jounce and Squirm Test Rig for Seat Testing

Jounce and Squirm test rig is designed to simulate an occupant sitting on a seat, twisting and / or bouncing. The
seats are mainly evaluated for trim degradation including fabric tears, cuts, rips, wear, etc. and functionality.
The seat cushion (or back) is fixtured to a table and fitted with an arrangement where it can be deflected. The
cushion (or back) is loaded by foam to simulate jouncing action. While this body form is loading the seat is
rotated left and right about a pivot point to simulate squirm action. This test is done on all types of automotive,
train and bus seats.

SDL has installed a custom built Jounce and Squirm test rig using pneumatic actuators, servo motors and
Programmable logic controllers. The rig can be used for Jounce only, Squirm only and Jounce and Squirm
Tests. The rig can test 2 occupants simultaneously. The specifications of the rig can be summarized as below:
Jounce Load : Max 150 Kg per occupant (2 occupants simultaneously)
Jounce operating cycles Rate : 100 cpm
Squirm Angle : Max 45 degree
Squirm Cycle Rate : 10 cpm

Load and frequency at the load application is adjustable to suit specific requirements of the customer.


Sound Package Tuning for Automotive Interiors

Recent trends in automotives show increasing use of acoustic materials for interior noise control. Automotive
noise control involves many aspects of vehicle design. Vehicle development team has a challenge of balancing
the conflicting requirements of mass reduction and acoustical performance enhancement. Acoustical
performance of dash insulator and carpet contribute significantly in the vehicle interior noise.

ARAI has developed new engineering methods and new multi-layer materials to solve automotive noise
problems. Study has emphasized to get noise reduction by use of a typical sandwich insulator (for dash
insulator and carpet), which consists of a steel panel, porous de-coupler and heavy layer. Noise reduction
mainly depends upon sound transmission loss of the sandwich insulator, which is evaluated as per SAE J 1400.
Unfortunately, this sandwich insulator acts as a mass-spring-mass system which resonates between 100 Hz to
500 Hz in the same frequency range as the engine firing frequency. The aim is to tune the system attenuation at
resonance, while maintaining performance at middle and higher frequencies. Effectiveness of these products
was enhanced to meet the requirements with proper selection of decouplers, heavy layer mass per unit area and
use of simulation tool.

NVH Lab at ARAI, jointly with OEMs and acoustic material manufacturers, could diagnose and provide quick
engineered solutions to improve the vehicle interior noise.



0
10
20
30
40
50
60
70
80
100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000
S
o
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T
r
a
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B
One third octave frequency band, Hz
Dash Insulator_Diesel Vehicle
Dash Insulator_Petrol Vehicle
Steel sheet_0.8 mm
Resonant Frequency


Sound transmission loss of dash insulators evaluated at ARAI as per SAE J 1400

Photometric Services at Safety & Homologation Laboratory

Safety & Homologation Laboratory (SHL) of ARAI operates as the
longest serving independent NABL / ISO 17025 accredited laboratory
for Photometry in India. Since 1998, SHL has been the source for
accurate and timely photometric testing. The laboratory is accredited
by National Accredited Board for laboratory (NABL), which is
equivalent to ISO 17025 in the field of Optics and Radiometry. This
lab is also certified for ISO 9001, ISO 14001, OHSAS 18001 and
continually reviews, monitors and updates its measuring techniques
and processes which help in achieving shorter turnaround times,
greater accuracy and quality results for our Clients. SHL ensures to
provide all services related to photometry with the state-of-the-art
test facility.
The laboratory provides consultancy services for R&D projects
related with lighting, signaling and related areas. This laboratory has
also been providing calibration services to all lighting and signaling
device manufacturers and also to the other testing agencies notified
under CMVR.


Gonio-Photometer

Venturing into new areas of services in Photometry
SHL undertakes any form of photometric testing that may be required within its sphere of competency.
Recently, SHL ventured into the following new areas of photometric testing.
a) Aeronautical Lighting Devices
b) Destination Boards for Buses
c) Road Signs / Road Studs and Retro-Reflective Sheets
Aeronautical Lighting
ARAI recently completed assessment of Aeronautical lighting systems as per the specifications of International
Civil Aviation Organization (ICAO) and MIL standard for one of our customers. This involved the following
experiments.

a) Measurement of light intensity as per ICAO
b) High temperature as per MIL-STD-810E
c) Low temperature as per MIL-STD-810E
d) Salt fog test as per MIL-STD-810E



Aviation Warning Light with control unit Unit under climatic test
Destination Board for Buses

SHL is currently conducting assessment of LED based destinations boards as per customer specifications.
Destination Boards are evaluated for their resistance to damage from vibration induced stresses, resistance to
water and dust penetration, resistance to heat and cold, effect of corrosion, life test etc. To assess these
parameters the following tests are being conducted as per customer specifications -

a) General specifications for dimensions, brightness variation, etc.
b) Environmental tests such as :
i. Dry Heat test
ii. Cold test
iii. Damp Heat test
iv. Vibration test

v. Salt Spray test
vi. IP test
vii. Life test for LEDs






Front / Rear Destination Boards Internal Display Board

Driver Control Unit



Unit under hot/cold/damp heat test Unit under vibration test

Road Signs / Road Studs / Retro Reflective Sheets

SHL has also taken up testing services for road signs, road studs, retro Reflective sheets, etc. as per national
and international standards like ASTM D 4956 or SAE J 845.
a) Day time colour
b) Adhesion test
c) Gloss value
d) Co-efficient of retro reflection

Road pavement markers are tested for their coefficient of luminous intensity as per ASTM D 4280-04


Triangle Sign Board LED Pilot Lamp
Delineators


Road Stud / Pavement Marker
ARAI Signed MoU with Loughborough University, UK for Research, Post
Graduate and Doctoral Programmes in Automotive Engineering
In addition to utilizing state-of-the-art technology, laboratories and highly-trained personnel, ARAI recognizes
the need to develop a new generation of engineers to meet the demands of the automotive industry, not just in
India but across the globe. Its objective is to develop a World-class Eco-friendly Academy at ARAI for Masters,
Doctoral and Professional Improvement programs in Automotive Engineering in collaboration with National and
International Universities.
ARAI has embarked upon a programme of building up human resources by commencing educational
programmes in Automotive Engineering. It has started the Academy for M.Tech. (Automotive Engineering), in
collaboration with VIT University, Vellore in 2004. The success of this collaboration has prompted ARAI to look
into the development of specialized programs in various fields of automotive technology with the leading
Universities abroad.

Shri Shrikant Marathe, Director-ARAI (right)
and Prof Richard Stobart of LU sign the MoU
With this background, ARAI has signed an MoU with Loughborough
University located at Leicestershire, UK on 4
th
July 2009. The MoU
reflects our mutual interest in research, education and enterprise in the
area of automotive engineering, and as a contribution to international co-
operation.
During the visit of a team from Loughborough University to ARAI,
training workshop on a 5-day module called Professional Improvement
Programme on Powertrain Engineering was conducted at ARAI, Pune.

Based on the present system in the Universities, credits are proposed for each module so that engineers can
attend various modules and sum up the credits required for Masters or Doctoral Programs.
ARAI Academy proposes to start the following programs through LU from September 2010:
Course Duration No. of Seats
M. Sc. (Full Time) in Automotive System Engineering 18 months 25 Seats
M. Sc. (Part Time) in Automotive System Engineering 36 months 25 Seats
Ph. D. (Full Time) in Automotive System Engineering 03 years 05 Seats
Ph. D. (Part Time) in Automotive System Engineering 05 years 05 Seats

Each taught module would entail intensive residential study week at ARAI together with work on prepared
programme, material and assignments requiring access through email and internet. The modules at ARAI
would be taught jointly by in-house faculty of ARAI and LU with an approximate proportion of 50:50.

This would be a very good opportunity for engineering professionals to join this program on part time basis
without leaving their present jobs. The projects can be done at the same organization where they are working.
However, they would be required to visit Loughborough University at UK for 6 weeks and undergo some
modules, orientation, campus recruitment, industrial visit, etc.

Inauguration of ARAI-Regional Centre South at Chennai

In an effort to expand the business activities of ARAI in the southern region of India, ARAI has opened
Regional Centre South (RCS) at Chennai on 12
th
August 2009. As a Chief Guest at the Inaugural Function,
Dr. V. Sumantran, Former President of ARAI and Vice Chairman of M/s. Hinduja Automotive Ltd, inaugurated
ARAI-RCS Office in the presence of Mr. R. R. G. Menon, Executive Director of M/s. Ashok Leyland Limited
and Mr. Srivathsa Ram, Managing Director of M/s. Wheels India Limited were the special invitees.
Representatives of automobile, component and allied industry were present on this auspicious occasion.



In his welcome speech Mr. Shrikant R. Marathe, Director of ARAI, explained the need to strengthen the R&D
base in India and widen the horizon of operations to expand the business further. While indicating the major
role being played by ARAI in design, development and certification of automobiles and auto components, Mr.
Marathe informed ARAIs readiness to support the industry in meeting the challenges ahead. ARAI will not
have any facilities at their Regional Centre South, but only the office to co-ordinate development and testing
work of all our customers in the southern part of India. Our Engineers at ARAI-RCS will interact with the
customers, understand their requirements and co-ordinate their assignments with ARAI Head Office at Pune for
better and timely execution.
In his Inaugural Address, Dr. Sumantran appreciated the timely initiative taken by ARAI to support the
automotive industry in southern part of the country, in all their needs, especially the development work. He
informed that in last five years automobile industry has not only grown in volume, but also technologically. He
further insisted that the R&D and Testing Facilities in the country need to be upgraded in line with the
requirements of the industry. He appreciated that the dedicated team work by ARAI boosts confidence of the
Indian Auto Industry. He wished all the success to ARAI in all its endeavours.

The function concluded with vote of thanks by Mr M. V. Ramachandran, Senior Assistant Director and In
Charge of Regional Centre South office.

Contact details of ARAI-RCS are given below :

Mr. M. V. Ramachandran, Senior Assistant Director
The Automotive Research Association of India
Regional Centre South (ARAI-RCS)
Ground Floor, AP/68
AF-Block, Second Street
Anna Nagar West
Chennai 600 040
Telefax: 044- 26191804 Mobile: 9840294777
E-Mail: araircs@md4.vsnl.net.in; ramachandran.dts@araiindia.com


Bus Body Accreditation by ARAI

To keep pace with the dynamic requirements for mobility and
simultaneously catering to added concerns of safety and comfort for
mass transportation, Government of India has taken up, on priority, the
key issue of streamlining and harmonizing bus body building; with an
intent of evolving universal procedure for design and type approval of
buses and as a corollary bring the unorganized private bus body building
sector under one gambit.



Addressing all these issues, Technical Committees have formulated
AIS-052 : Code of Practice for Bus Body Design and Approval as well
as AIS-063 : Requirement of School Buses, which are in the process
of being notified shortly.
Simultaneously, Ministry of Road Transport & Highways (MoRTH) has
issued S.O. 425 (E) dated 23rd March 2007, laying down procedural
norms for Accreditation of Bus Body Builders as well as formulation of
Zonal and National Accreditation Boards.



Accreditation is a process of evaluating, assessing and approving the capabilities and capacities of a
Bus Body Builder to consistently produce specified quality of bus bodies by the competent authority.
Accreditation process basically calls for an administrative and technical audit at the premises of bus
body builder, to assess their design and development capabilities (technical expertise and qualified
manpower) along with available land, plant and equipment, ascertaining usage of quality products
backed by genuine material and parts, availability of minimum in-house facilities, viz. production
assembly and fabrication unit, paint shop, final product inspection facilities, etc., uniformity in the
construction with due regard to safety and comfort, in consonance with the Code of Practice for Bus
Body Design and Approval, AIS-052.


ARAI is well-equipped to carry out evaluation of buses, as per AIS-052 as well as AIS-063. Additionally, based on
the technical expertise and qualified manpower, ARAI has been allocated the secretariat of North and East Zonal
Accreditation Boards for Bus Body Accreditation.

So far, ARAI has evaluated twelve bus body manufacturing units in the North Zone. Evaluation of four bus body
builders from the East Zone is in the offing.

As accreditation of Bus body builders vide S.O 425(E) dated 27
th
March 2007 is in vogue, applicants from North
and East Zone may kindly send applications in the prescribed format specified under said S.O., to:

Shri S.S. Sandhu,
Deputy Director (Vehicle Evaluation Lab)
Secretariat, Zonal Accreditation Boards (North & East)
Member, National Accreditation Board
The Automotive Research Association of India (ARAI),
S. No. 102, Vetal Hill, Off Paud Road, Kothrud, Pune 411 038, Maharashtra, India
Tel: 020-3023 1370; Mobile: 099754 92653; E Mail: sandhu.vel@araiindia.com


Pressure Pulsation Testing for Engine Crankcase

Development and testing of products calls for
development and modeling of own designs as
well as validate performance and durability of
prototypes. Meeting customer requirements
successfully now requires reliable component
testing and validation strategy that generates
accurate component test data that can be
shared directly with customers. Weighing
such factors carefully with time constraints,
realistic approach must be adopted for testing
of components according to specific
circumstances. Considering all these aspects,
our Structural Dynamics Lab (SDL) has
developed in-house component test cell,
especially for development of engine
components.



Demands for Structural Testing of Engine Components

Structural testing plays an important role in development and validation of engine components. Structural
Dynamics Lab equipped with the state-of-the-art facilities cater to structural evaluation requirements of engine
manufacturers.
Structural testing at SDL for evaluation of Engine and its Components:
Fatigue testing of various engine components for evaluation of fatigue strength, determination of fatigue
life, comparative study of components, simulation of failure modes, etc.
Experimental stress measurement on components during service condition and testing
Fatigue Testing of bolts by S-N curve Evaluation, Staircase method, Weibull Analysis

Series of ARAI Update will demonstrate variety of development projects that we are ready to undertake
specifically for engine components. To start with, this issue of ARAI Update covers development of crankcase.

Need for pressure pulsation test on engine crankcase

To confirm structural adequacy of cylinder block for the designed peak firing pressure under cyclic loading
To check for any leakage between the block and head due to failure of gasket at the peak pressure
Check for strength of cylinder head bolts
To validate CAE model of cylinder block
To identify critical locations on cylinder block.

The test rig designed and developed by has following advantages

Few components are required for the test
Lower cost
Time required will be less as compared to running of engine on the test bed
Tests with higher factor of safety are possible
Different engine components can be simultaneously validated in design stage, before testing of engine,
thus total engine development time can be reduced.
Selection of critical locations for mounting of strain gauges and strain values can be recorded before,
during and after completion of test.

Test set up for Inline - Cylinder Engine Test set up for V Type - Cylinder Engine


Cyclic Pressure variation recorded during the pressure pulsation test.
General test requirements and procedure

The aim is to carry out pressure pulsation test on engine crankcase for required pressure variation in two
adjacent cavities at 180 out of phase pressure cycles at estimated frequency for 10 million cycles each.
Peak cylinder pressure is used for pressure pulsation test.

Fixtures like steel manifold block, etc. was designed and fabricated for carrying out the test.

Design of Manifold block for two main purposes

a) To seal 2 adjacent cylinder block cavities like cylinder head and to incorporate hydraulic circuit for oil
flow to and from servo - valve attached to it.

b) Provide pressure transducer connection for test cylinder cavities. The manifold block was designed to
incorporate cylinder head bolts used in the engine.

Test Procedure

1. Clean and assemble crankcase with engine connecting rods, crankshaft and one steel piston each in
2 adjacent cylinder cavities.

2. Lock crankshaft at flywheel end to prevent rotation such that steel pistons in the cavities will be at Top
Dead Centre (TDC).

3. Assemble hydraulic manifold block on 2 adjacent cylinder cavities with engine cylinder head gaskets.

4. Tighten cylinder head bolts up to required torque levels.

Components required during testing

1) Cylinder block
2) Flywheel
3) Flywheel locking arrangement
4) Modified piston
5) Sealing arrangement
6) Cylinder head bolts
7) Gasket between block and head

8) Crankshaft
9) Connecting rod
10) Oil sump
11) Fabricated stand
12) Connection for lubrication inlet
13) Provision for plugging oil galleries



Towing Dynamometer

Unlike Engine / Chassis Dynamometers, Towing Dynamometer is a trailer mounted eddy current
dynamometer which is attached to the test vehicle and by adjusting the eddy current, the driver of the test
vehicle can adjust the load requirement (draw bar pull), to simulate varying test conditions, on the field, either
in constant load or constant speed mode.
Following are some of the tests that can be conducted using the Towing Dynamometer, which give more
realistic test results, under controlled loading of subject vehicle
a. Engine Cooling Performance by simulating extra load on the engine viz. increasing draw bar pull.
b. Transmission Component Evaluation
c. Gradeability Simulation without physically putting on dead load on test vehicle. This test can be done
on a straight level track instead of climbing a gradient.
d. Fuel Consumption Simulation of extra GVW by increasing the draw bar pull of the vehicle.
e. Failure Analysis
f. Vehicle Heating and Cooling Systems and
g. Tyre Testing by increasing draw bar pull in such a way up to skidding / slipping point of tyres.

Being extensively used worldwide for development of prototype, the Towing Dynamometer could also be used
for study of various parameters viz. efficiency of a engine cooling system, loading of transmission and drive
axle to assess the design sufficiency.



In 2004, the Vehicle Evaluation Laboratory (VEL) has procured Towing Dynamometer Model RS 40K from
M/s. DynoMotive LLC, USA, having the following specifications:
Model : RS40K
Length : 270 (6,856 mm)
Width : 96 (2,438 mm)
Height : 72 (1,829 mm)
Weight, Dry : 14,900 lb (6,760 kg)
Weight, with Ballast : 21,200 lb (9,619 kg)
Load Cell : 11,240 lb (50,000 N)
Overload Protection : 500 lb (40,000 N)
Max. Drawbar Pull : 11,240 lb (50,000 N)
Max. Continuous Hp : 410 HP (305 kW)
Max. Speed : 68 mph (110 km/h)


Additional Features

Programmable facility for loading and monitoring through drivers cabin
Compatibility with Indian tyres
Output Device (Strip Chart Recorder to plot Drawbar Pull Vs Speed Vs Time) with user
definable inputs.

Special Feature

The special feature of this Towing Dynamometer is that loading is electrically operated, which
entails in considerable savings of time. Besides, loading can be adjusted according to pre-
programme, which ensures repeatability of trials.

FLASH NEWS
ARAI and Romax Technology (UK) have signed an MOU to provide engineering services to the Indian automotive industry in
the following areas:
NVH analysis and testing
Transmission Control Unit (TCU) Development
Transmission matching and optimization
Finite Element Analysis of Transmission
components

Design validation and upgradation
Design and analysis of Gearbox, Engine Gear train, Chain and
Belt Drives, Clutch, Rear-axle, Differential and Drive Shaft
Design of Automotive transmission system and industrial Gearbox
Gear Failure Analysis


New Services from ARAI:

Winter Testing
Fire Risk assessment of Vehicles
ARAI and ISA (Invest in Sweden Agency) have established closer relationship by signing a MoU with the
understanding to work closely in number of areas related to Automotive Sector. ISA is a government agency
responsible to the Ministry for Foreign Affairs, Government of Sweden to facilitate business and investment
opportunities in Sweden.
The co-operation between ARAI and ISA in various areas relating to advanced automotive technology and
services will meet the emerging demands of the Indian Automotive Industry.

The subsequent visit of Director of ARAI, Mr. Shrikant R. Marathe and Sr. Deputy Director, Mr. D J Kulkarni in
August 2009 to several organizations in Sweden has established working arrangements with them within a very
short period. Through these arrangements, ARAI is now in a position to offer following services to the Indian
Automotive Industry.
1. Winter Testing Facilities
Dynamic handling and ride comfort to check Noise, Vibrations and Harshness, suspension rattling etc.
Snow chain test particularly for all wheel drive vehicles
Extreme maneuverability and tyre testing
Gradeability tests
Anti spin, mixed track test with polished ice and asphalt tracks
Transmission test for slippages on 10-27 degrees slopes
Cobblestone and severe track for checking vibrations, noise etc
Heated asphalt and polished ice track having split coefficient of friction particularly to test brake systems
and ESP tests.
Hilly terrain with extreme bends to test reliability, durability and manouverability checks.




The above facilities will be useful to -
OEMs
Electronic system manufacturers
Automotive component and sub-system manufacturers
Tyre manufacturers

2. Fire testing facilities including Fire Risk assessment of vehicles

3. Along with ISA and other Swedish manufacturers, ARAI is planning a demonstration project to
operate a public transport bus on bio-gas as a renewable fuel for urban sustainability.



Online Submission and Tracking of CMVR Type Approval Certification

With immense pleasure we share
with you that ARAI website
www.araiindia.com is revised, with a
user-friendly newer version,
incorporating custom built advanced
features as highlighted below:
Virtual Tour
With single click of a Virtual Tour
button, ARAI customers can have a
quick tour to the state-of-the-art
facilities and capabilities of ARAI as
well as diversified activities in
specialized R&D as well as
Homologation Certification areas.


Online Submission of Type Approval Application
This feature enables ARAI customers to submit hassle-free paperless application online through web access
with a single click. ARAI customers are allowed to submit Type approval documents / specifications through a
secured Online System Architecture. Unique login IDs and passwords provided to the customers will enable
them securely submit their applications online through ARAI website.
On submission of application from any destination all over the world, customer will receive an
acknowledgement via email, confirming Apex Number for respective document submission.
Innovative Tracking System
Latest status on CMVR Type Approval Certification updated from time to time is accessible through ARAI
Website. With this advanced system, online applications can be tracked at any point of time to know the status
of CMVR certification. Customers unique login IDs and passwords enable them to online access / check
status on certification of their vehicles online maintaining security of their products.



TA-Admin Group look forward to welcome you and have further interaction via email ta-admin@araiindia.com
CMVR Type Approval Handbook

CMVR Type approval Handbook is available as a priced publication under Downloads. It contains all that one
would wish to know about the Indian Type Approval System for Automotive Vehicles, Components, Generator
Sets, Construction Equipment Vehicles, Tractors and any other equipment / vehicles covered under Central
Motor Vehicles Rules (CMVR), 1989 as amended from Time to Time.


Automotive Crash Test
With the experience gained over the years and the know-how developed in the area of automotive crash
testing, ARAI has developed expertise to carry out crash tests to check the performance of security devices /
barriers against automotive crash. ARAI has successfully carried out a certification test for Tire Ripper, a
security device, by performing actual crash test at customers site. This otherwise would have required
testing at the facilities abroad. The testing was possible with the state-of-the-art portable electronic vehicle
propulsion and control system available with ARAI.

ARAI is geared up to take similar tasks at given site. For further details contact: director@araiindia.com

Strategic Tie up of ARAI with CCT, Korea

ARAI and China Certificate Technology (CCT), South Korea, specializing in China Compulsory Certificate
(CCC), China Security and Protection certificates (CSP), State Radio Regulatory Commission (SRRC) have
entered into an MOU to promote component certification and vehicle homologation for the manufacturers from
South Korea as per the Central Motor Vehicles Rules applicable in India.

CCT is an authorized representative of ARAI in South Korea to promote ARAIs business.
Wheel Force Transducer for Passenger Cars and SUVs

Structural Dynamics Lab (SDL) of ARAI has recently acquired a 16 wheel force sensor used for
measurement of spindle forces and moments on a rotating wheel; a major constituent in modern vehicle
development cycle.
Kistler make RoaDyn S635 measuring wheel has a modular, highly versatile design for mounting on different
wheel hubs and rim geometries of vehicle. Simultaneous data of three spindle forces in longitudinal (Fx),
lateral (Fy) and vertical (Fz) direction along with three moments Mx, My and Mz can be acquired precisely.
The same WFT can be used for non-spinning application on MTS 329 test rig available at SDL. Signals from
WFT can be used directly for simulating acquired spindle forces.
With this sensor, vehicle instrumentation, vehicle testing / development time will be reduced substantially.





Typical Applications

Measuring operating loads during typical vehicle driving maneuvers
Input data for design of new components and verification of design loads
Measuring test stand control data for road simulators
Investigation of vehicle behavior in specific or critical driving situations
Input data for fatigue calculations and numeric simulations

Material Compatibility Study with Gasoline and Ethanol Blended Fuel
Study project on evaluation of effect of 10% ethanol blended gasoline (E10) fuel versus commercial gasoline
(E0) on polymeric materials (Elastomers and Plastics) used in automotive components is undertaken by ARAI.
Few common elastomers and plastics used in automotive components are being tested as per the guidelines
given in the standard, SAE J 1748 for non-metal compatibility study. Change in material properties like
volume/swell, weight, appearance, tensile strength, elongation, impact resistance and hardness shore A will be
measured after immersion of materials in the fuel in a periodic manner to evaluate impact of E10 fuel on
materials relative to gasoline.




Development of EURO V Compliant CNG Injection Engine

Use of CNG as an automotive fuel results in significant reduction in vehicular pollutants such as CO, HC, NOx
and PM. Additionally, use of CNG results in reduction in emissions of greenhouse gases (CO
2
), owing to lower
Carbon-to-Hydrogen ratio of the methane (CH4), as compared to other hydrocarbon fuels. ARAI has
developed several CNG and LPG engines ranging from 2-stroke single cylinder engine to multi cylinder 4-
stroke engines with fuel kits ranging from elementary carburetion to sophisticated multi-point fuel injection
systems. The CNG engines and vehicles developed by ARAI have passed current and upcoming emission
norms with comfortable margins in CO and NMHC+ NOx emissions. The CNG engines developed by ARAI
have been commercialized and are successfully running on multiple vehicles in the field. ARAI work on
gaseous fuel engine development has been lauded at various international forums. We have also undertaken
HCNG (Hydrogen + CNG) engine development program.


The CNG Injection Engine recently developed for one the OEMs is meeting Euro V norms with sufficient
margin. This engine has superior performance with specific power output of over 20 kW/l as compared to
contemporary CNG engines. The charge stratification in CNG combustion chamber permits extremely lean
combustion without high cycle-by-cycle variations with high combustion efficiency. Various design
modifications are carried in the base SI engine for upgradation to achieve Euro V Emissions Norms.
Simultaneous improvements were obtained in fuel efficiency by modifications in various sub-systems of the
engine, such as fuel-system, ignition-system, air-intake system and combustion parameters.



ETC cycle and Successful Regression Analysis

ETC cycle and Successful Regression Analysis
Salient features of engine are as follows:
State-of-the-art injection technology
Tuned Intake manifold
Optimized combustion bowl for squish
Effective utilization of swirl
Centrally located spark plug
Dual intake valve
Palladium based catalytic converter
Specific power output over 20 kW/l
Flat torque curve over engine range
Fast response thereby meeting ETC comfortably

Euro-V CNG Engine


0
1
2
3
4
CO THC Nox
Achieved performance Euro IV limit Euro V Limits

Emission Performance of CNG Engine over ETC Cycle
With the development of CNG engine, ARAI has achieved competency to carry out development assignments
for CNG, LPG and HCNG engines to meet Euro-V and beyond norms.


Structural Dynamics Laboratory Your Partner in Vehicle Development
Operating across whole range of vehicle development technologies, our Structural Dynamics Lab (SDL)
provides particular expertise in vehicle development and Optimization Cycle for Indian Road Driving
Conditions.

Starting from initial concept to launch of vehicle and even for further development plans, vehicle
manufacturers have to pass through several different stages. Backed with innovative approach, experience
and expertise developed over the years in handling diverse and technically challenging projects, our
engineers are able to offer to our customers appropriate solutions at every stage.


Testing, a key element of total engineering services, comprise design, development and validation. Extensive
knowledge is applied for development of wide range of vehicles, systems and individual components of the
vehicle.

SDL has unique combination of specialist engineering skills and world class / renowned engineering
facilities. This Group serves the customers right from component manufacturers to worlds largest vehicle
OEMs. Working together in tandem, customers are provided with the assistance to optimize designs,
improve productivity and bring quality products to market at faster pace.

Through wide variety of domains, wherein work has been carried out at SDL, as well as currently ongoing
research activities based on futuristic long term technological outlook, we are in a position to offer
comprehensive end-to-end solutions to execute the same with the highest level of quality and with optimal
time schedules to meet global targets.

SDL has recently completed an assignment for one of the OEMs, right from development of virtual model,
validation to full vehicle. ARAI worked hand in hand with the OEM for design, development and manufacture
of high quality products with greater speed and lower cost. The project scope included:
Measurement of Road Profile
Validation of virtual model



Road load data acquisition on roads, tracks and mines


Chassis System Evaluation
Development of test load specification for vehicle durability
Measurement of wheel loads
Estimation of duty-cycle for drive train
Measurement of cabin loads
Ride comfort Evaluation
Identification of critical areas


Evaluation of chassis frame
Finalization of test scheme for its durability aspects
Full vehicle validation on 6 poster rig


Evaluation of Cabin
Finalization of test scheme for its durability aspects
Cabin validation on multi axis rig


Evaluation of chassis frame
Chassis frame validation on multi axis rig



ARAIs Participation in Automotive EXPOs
ARAIs state-of-the-art facilities and capabilities in design, development , testing and certification of
automobiles and automotive components are showcased in different exhibitions held in India.
This could help ARAI to reach out to the automobile, component and allied industry within India and abroad and
strengthen business relations to cater to the requirements of the industry as a whole.
ARAI presentations in the Technology Theatres received sound response.

ARAIS Support to International EXPOs
ARAI had supported following overseas Exhibitions :
Automotive Forum 2010, Shanghai
DEC-ASIA diesel emission conference, Beijing




A AU UT TO O E EX XP PO O 2 20 01 10 0
New Delhi, 5-11

January 2010



Business meeting at ARAI Stall

ARAI Stall at Auto Expo 2010

A AU UT TO OM MO OT TI IV VE E T TE ES ST TI IN NG G E EX XP PO O
Hyderabad, 2-4

February 2010
Business meeting at ARAI Stall

ARAI Presentation at Technology
Theatre

A AU UT TO OM MO OT TI IV VE E E EN NG GI IN NE EE ER RI IN NG G S SH HO OW W
Pune, 8-10 February 2010



Interaction with Visitors at ARAI Stall

Inaugural Function




Interaction with Visitors at ARAI Stall

Inaugural Function

B BA AN NG GA AL LO OR RE E I IN NT TE ER RN NA AT TI IO ON NA AL L A AU UT TO OM MO OT TI IV VE E E EX XP PO O 2 20 01 10 0
11-14 March 2010



The Automotive Research Association of India
Survey No. 102, Vetal Hill, Off Paud Road, Kothrud, Pune 411 038 (India)
Tel.: +91-20-3023 1101, 2543 1284

For Information contact:
Shrikant R Marathe, Director, ARAI
director@araiindia.com