Performance Evaluation and Optimization of Engine Brake System using Chassis Dynamometer

Engine braking is a deceleration technique that leverages the internal friction and pumping losses within the engine. By closing the throttle and potentially selecting a lower gear, the engine creates a retarding force that slows the vehicle. This practice contributes to better fuel economy, decreased brake system load, and improved vehicle handling in specific driving scenarios, such as steep declines or slippery road surfaces. To alleviate stress on their primary braking systems and prevent overheating, heavy vehicles frequently incorporate engine-based braking. While older trucks relied on simple exhaust brakes with a butterfly valve to restrict exhaust flow, these had limited impact. Hence contemporary heavy vehicles almost exclusively use more advanced engine braking technologies. Traditionally, our heavy-duty vehicles use Exhaust brake system to elevate the braking performance on hilly terrains. Hence an improved sample of Engine brake was developed for enhanced braking performance. A study to map the performance of Engine braking at different field conditions was conducted at Chassis Dynamometer Lab on M& HCV Tipper Vehicle model. Conditions are: a) Different speeds/gears. b) Different gradients. Vehicle fitted with improved sample of Exhaust brake is tested on dyno for its performance. Braking power derived & plotted at various Engine speeds and compared with the performance results of existing Engine brake sample. Iterations carried out using various gears at different levels of gradient to simulate real world performance of Engine braking and tested the capabilities of the brake sample to the extreme levels of over speeding engine revolutions. The results obtained from this exercise fortified in evaluating and optimizing the improved sample of exhaust brake and it in turn aided in better performance of the vehicle on road.