Browse Topic: On-board energy sources

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System Validation & Verification Plan Template - ARP4754A - AFuzionARP4754A_PL_009 (Current)To be published on 08/13/2201
Test IR Report 61626IR616261_202606 (Current)6/16/2026
test
Automotive Electronic Systems Reliability Standards
Hydrogen Fuel Quality for Fuel Cell VehiclesJ2719_202605 (Current)5/8/2026
This standard provides background information and a hydrogen fuel quality standard for commercial proton exchange membrane (PEM) fuel cell vehicles. This report also provides background information on how this standard was developed by the Hydrogen Quality Task Force (HQTF) of the Interface Working Group (IWG) of the SAE Fuel Cell Standards Committee.
Fuel Cell Standards Committee
Fuel Cell Vehicle TerminologyJ2574_202605 (Current)5/8/2026
This SAE Information Report contains definitions for hydrogen fuel cell powered vehicle terminology. It is intended that this document be a resource for those writing other hydrogen fuel cell vehicle documents, specifically, Standards or Recommended Practices.
Fuel Cell Standards Committee
Direct Deposition of Nickel Abrasion Guards on to Carbon Filled Composite Rotor Blade StructuresSM-2026-VLADA-51991/27/2026
Composite materials have become widely adopted in commercial aviation, as aerospace manufacturers look to use them to drive weight reduction and improved fuel efficiency in new aircraft designs. In the case of aircraft rotary blades, the poor wear properties of these materials have necessitated the development of metal leading edge guards that can provide critical protection against erosion and impact damage during flight. Electroforming has been a leading process for the manufacture of these protective guards, with nickel parts providing excellent wear resistance that significantly extends the service life of the rotary blade assembly. Currently there has not been a focus on utilizing direct electrodeposition of metal on to carbon filled epoxy composite structures, as traditional plating-on-plastics approaches require considerable effort in surface preparation and normally do not provide adequate adhesion to the underlying structure. Alpha Metalcraft Group has been working in
Cazzaniga, Luigi
REPLACING DIESEL ENGINES WITH CNG ENGINES – IMPACT ON EMISSIONS, BASED ON CHASSIS DYNAMOMETER TESTS OF MEDIUM AND HEAVY-DUTY BUSES2026-26-01271/16/2026
Abstract This paper compares carbon dioxide, carbon monoxide, methane and nitrogen oxide emissions from medium and heavy-duty buses using diesel, diesel-hybrid, and CNG powertrains. Comparisons are made using results from chassis dynamometer-based tests with driving cycles intended to simulate a wide range of operating conditions. Tail pipe emissions are measured by diluting the vehicle exhaust in a full-scale dilution tunnel by mixing with conditioned air. Samples are drawn through probes of raw exhaust, diluted exhaust and measured using laboratory grade emission analyzers. Emissions measurements include carbon dioxide, carbon monoxide, nitrogen oxides, and hydrocarbons including methane. Fuel consumption for liquid fuels is measured using weighing scales, while a gas flow meter is used for measuring CNG. Experimental data from 20 buses tested on a chassis dynamometer over the last 8 years is analyzed and a comparison of results from similar buses but with the differently fueled
Iyer, Suresh
Wheel Corner Module Energy Losses and Potential Improvements2026-26-00961/16/2026
With the inevitable shift of automotive industry towards E-mobility and mandatory fuel efficiency targets, there is a need to evaluate the energy losses in the vehicle & identify potential areas of improvement. Energy losses are calculated for different components in the corner module system of a passenger car. Contribution of losses (Resistances) from respective component are depicted using simple analytical models. Potential energy saving improvements were identified and analyzed basis emerging technologies in respective areas.
Raghatate, Kumar Shreyas, Vedartham, Raghavendra, Khanger, Rakesh, Bisht, Arun
Fuel Cell Electric Vehicles: Method for Characterization of Onboard Power Management System and Defining Vehicle Level Attributes2026-26-05701/16/2026
Fuel Cell and Battery Pack/Capacitors are two power sources on-board a Fuel Cell Electric Vehicle. Each having it's own set of boundary conditions and ideal operating conditions in order to deliver expected performance over the intended useful life. Such a dual power source architecture poses a challenge of optimally balancing power delivery from Fuel Cell and Battery Pack/Capacitor in order to ensure health of both these important aggregates of vehicle over it's intended useful life. Therefore, a method and tool for characterizing the Power Management System of Fuel Cell Electric Vehicle is required during development and validation. "Aggregate Sizing" and "Calibration of Power Control Strategy" are significant factors for optimum life of Fuel Cell powered vehicle without compromising performance. Although the former is mainly a design decision, the latter is crucial during testing and validation to achieve the design objective and avoid unwanted failures. Distribution of load catered
Deshmukh, Naval, Ganguly, Sutanu, Sindgikar, Pavan, Jain, Sarika
Development of Flex fuel Vehicle for Indian Market2026-26-01171/16/2026
This paper presents the methodology and outcomes of modifying a 1.2L naturally aspirated (NA) engine to enable flex-fuel compatibility, targeting optimal performance with ethanol blends ranging from E20 to E93. The road map for Ethanol Blending released by Govt of India call for progressively increase in ethanol blending in gasoline, with a target of 20% by April 2025. Ethanol is promoted as a renewable fuel due to its potential to reduce greenhouse gas emissions and provides an additional source of income for farmers. This work is in alignment with the broader push for development of flex-fuel vehicles, which necessitates engine adaptations capable of operating on varying ethanol blends. The primary objective was to retain the performance with E20 while mitigating the fuel consumption penalties when the vehicle is operating on higher ethanol concentrations upto E93. The engine upgrade incorporated key modifications, including optimizing the compression ratio, implementing Variable
Tyagarajan, Sethuramalingam, Pise, Chetan, Kavekar, Pratap, Agarwal, Nishant Kumar
Evaluation of Intercooler Effectiveness with No Fan, Single Fan, and Dual Fan: A Simulation and Experimental Study2026-26-05791/16/2026
Turbochargers play a crucial role in modern engines by increasing power output and fuel efficiency through intake air compression, thereby improving volumetric efficiency by allowing more air mass into the combustion chamber. However, this process also raises the intake air temperature, which can reduce charge density, lead to detonation, and create emissions challenges-such as smoke limits in diesel engines and knock in gasoline spark-ignited (GSL) engines. To mitigate this, intercoolers are used to cool the compressed air. Due to packaging constraints, intercoolers are typically long and boxy, limiting their effectiveness, especially at low vehicle speeds where ram air flow is minimal. This study investigates the use of auxiliary fans to enhance intercooler performance. Two methodologies were adopted: 1D simulation using GT-Suite and experimental testing on a vehicle under different fan configurations-no fan, single fan, and dual fans (positioned near the intercooler inlet and outlet
PATRA, SOMNATH, HIBARE, NIKHIL, Ganesan, Thanigaivel, Gharte, Jignesh Rajendra
Design and Optimization of Air Intake Manifold for 4cylinder 4valve Turbocharged CNG Engines: Enhancing Performance Metrics and Emission Compliance2026-26-01241/16/2026
This study presents the development and optimization of an air intake manifold for a 3-liter, 4-cylinder, 4-valve turbocharged engine operating on Compressed Natural Gas (CNG). The intake manifold plays a critical role in determining engine performance, directly influencing parameters such as power output, brake-specific fuel consumption (BSFC), and emissions. A systematic design methodology was adopted, starting with standard design repository, which were refined through iterative improvements focused on manifold volume, runner geometry, injector location, and fuel injection pressure. Computational Fluid Dynamics (CFD) simulations were conducted to evaluate the influence of manifold geometry and injector positioning on air-fuel mixing. The analysis assessed three potential injector locations: the tangential port, the swirl port, and a common upstream point where air splits into individual intake runners. Among these, the common upstream point consistently demonstrated superior air
Lomada, Balaji, Vasudevan, Sindhuja, RAVI, HARIKRISHNAN, N, Harish, UG, Remesh
Advancing Sustainable Mobility: Transitioning to Zero-Emission Electric Vehicles with BEVs and FCVs2026-26-01641/16/2026
The transportation and mobility sector is undergoing a profound transformation, with a growing emphasis on sustainability and minimizing the environmental impact of transportation. Among the most significant trends is the transition to electric vehicles (EVs) in the form of Battery and Fuel cell, which produce zero emissions without any harmful gases release in nature. This review highlights several infrastructure-related issues and critical factors that could drive India's transportation sector toward adopting electric vehicles. It also delves into the fundamental understanding of e-mobility, shedding light on the daily challenges and barriers it faces. Furthermore, the study explores research aspects, including the strategies, methods, and tools used for electric vehicles to complete the research on Battery electric vehicles (BEV) and also comparative analysis with Fuel cell vehicles (FCVs). The shift BEVs has been driven by decreasing battery costs and advancements in charging
Kumar, Dr. Vijay Bhooshan
Performance Analysis of Hydrogen Fuel Cell Electric Vehicle for Intercity and Intracity Applications2026-26-02661/16/2026
Hydrogen Fuel Cell Electric Vehicles (FCEVs) are emerging as a sustainable solution to reduce greenhouse gas emissions in the transportation sector, in line with the Paris Agreement and global net-zero emission goals. This paper presents a comprehensive performance analysis of the FCEV powertrain under intercity and intracity driving conditions. The study focuses on key parameters such as fuel cell system efficiency, energy consumption, hydrogen usage, and overall drivetrain response. Using simulation models validated with real-world driving data, the performance of the powertrain is evaluated across varying speed profiles, vehicle loads, and driving cycles. The analysis also considers the impact of auxiliary load including HVAC systems and consumption of other electric components on the powertrain efficiency and energy balance. Results highlight that the FCEV powertrain performs efficiently during intercity driving due to stable speed conditions and low stop-start frequency, while
Patil, Nikhil Nivrutti, Gawhade, Ravikant, Gadve, Dhananjay, Saurabh, Saurabh, Bhardwaj, Rohit, Ahmed, Yasir, Amancharla, Naga Chaithanya
Testing Methodology to Calculate the Fuel Economy in Km/Kg of Hydrogen Fuel Cell Electric Vehicle (FCEV) based on Current (Ampere) Method and Flow Method2026-26-02481/16/2026
The globe is looking headlong to set up new benchmarks for the reduction of GHG (Green House Gases) considering short-term and long-term strategies. Efforts in the Internal Combustion Engines (ICE) domain have been accelerating to find an alternative way to reduce harmful emissions. Hydrogen is considered as a promising fuel to leapfrog this transition. Hydrogen fuel can be categorized into vast mobility areas viz. ICE and Fuel Cell Electric Vehicle (FCEV). Hydrogen fuel has attracted global attention from engine researchers due to the crude oil crisis and its rise in prices in recent years. This will serve the nation's goal towards carbon neutrality. Hydrogen has a few advantages such as less fueling time, higher heating value and more efficiency making it an eye-touching fuel for the automotive industry. In the contemporary FCEV segment, many fuel cell technologies have evolved, wherein the development of Proton Exchange Membrane (PEM) fuel cell technology has taken a new height for
JOSHI, ASHISH RAJENDRA, Kandalgaonkar, Siddhesh, Pawar, Yogesh
Advancing Circular Economy in India's Automotive Sector: Challenges and Sustainable Solutions2026-26-02381/16/2026
This research examines the fundamental principles of the Circular Economy in relation to the automotive industry in India, a sector that plays a vital role in the country's economy. However, it also presents significant challenges concerning energy consumption and environmental impact. The circular economy framework offers a transformative approach throughout a vehicle’s lifecycle, guiding the automotive industry toward a more sustainable transportation system. One of the key strategies defined by the global automotive commission for decarbonizing this sector involves increasing the recycled plastic content in vehicles to 20-25% by 2030. This target necessitates the recovery of plastics from end-of-life vehicles, though these materials are rarely integrated into compounds today. The automotive industry's reliance on plastics has grown substantially due to their lightweight properties, which enhance fuel efficiency, reduce CO₂ emissions, and improve versatility and mechanical
Kumar, Vijay Bhooshan
Total cost of ownership analysis of fuel cell and hydrogen-powered commercial vehicles for cost competitiveness with ICE and BEV2026-26-02541/16/2026
Worldwide, the automotive industry is pivoting towards electrification and zero-emission vehicles (ZEV) to address greenhouse gas emissions and to meet net-zero emission goals. Although pure electric vehicles with rechargeable high-voltage batteries seem to be the most popular choice to achieve climate goals, hydrogen-powered vehicles are also seen by many as a viable technology to clean up the transportation sector. Hydrogen fuel cells and fuel cell-powered vehicles have been in development for a long time, and hydrogen internal combustion engines (ICE) have seen rapid development in the past few years. While the technological feasibility of hydrogen fuel cells and H2 ICE is being proven, mass adoption of these technologies depends, along with other factors such as hydrogen infrastructure, upon financial feasibility as well. This paper presents a systematic analysis of the total cost of ownership (TCO) of hydrogen-powered vehicles, especially fuel cell electric vehicles. Different
Jacob, Joe, Chougule, Abhijeet
1D Simulation Approach for Common Rail Injection Systems for a Marine 2 Stroke Diesel Engine2026-26-03951/16/2026
This study presents a comprehensive 1D simulation approach of an automotive solenoid-based diesel fuel injector and a common rail injection system for a marine engine using Simcenter AMESim. The injector model was developed to analyse the injection rate and total injected fuel at various solenoid actuation durations (1.2 ms and 2.0 ms) and common rail pressures. The experimental results from a well-established research study are used for validating the simulation results of the solenoid-based injector. The model demonstrates strong agreement at higher rail pressures (above 1000 bar) and solenoid actuation times. Building on this validated injector model, a detailed marine common rail system was developed incorporating key hydraulic components: a check valve to maintain pressure inside the rail, flow limiting valves to prevent overpressure in the fuel injector, and a combination pressure relief valve. The simulation was used to study rail pressure dynamics at full engine load for
Bhoware, Yash, Pise, Uday, Saha, Dipta, Gaikwad, Nilesh
Effect of the Flow Forming Process on the Mechanical properties and Microstructure of GDC & LPDC cast aluminum alloy wheels.2026-26-02981/16/2026
Aluminum alloy wheels have become the preferred choice over steel wheels due to their lightweight nature, enhanced aesthetics, and contribution to improved fuel efficiency. Traditionally, these wheels are manufactured using methods such as Gravity Die Casting (GDC) [1] or Low Pressure Die Casting (LPDC) [2]. As vehicle dynamics engineers continue to increase tire sizes to optimize handling performance, the corresponding increase in wheel rim size and weight poses a challenge for maintaining low unsprung mass, which is critical for ride quality. To address this, weight reduction has become a priority. Flow forming [3,4], an advanced wheel production technique, offers a solution for reducing rim weight. This process employs high-pressure rollers to shape a metal disc into a wheel, specifically deforming the rim section while leaving the spoke and hub regions unaffected. By decreasing rim thickness, flow forming not only reduces overall wheel weight but also enhances strength and
Singh, Ram Krishnan, Medaboyina, HarshaVardhan, G K, Balaji, Gopalan, Vijaysankar, SUNDARAM, RAGHUPATHI, Paua, Ketan
Experimental evaluation of Energy and Exergy of Hydrogen, CNG and Gasoline fuelled High-Speed Spark Ignition Engine2026-26-02581/16/2026
HIGHLIGHTS The maximum power is recorded with Gasoline than CNG and Hydrogen fuel. The maximum exergy and energy efficiency is with Hydrogen, followed by CNG and then Gasoline. Hydrogen fuel has a maximum potential to convert into energy. The maximum energy destruction of 48.7kW for gasoline fuel at 3000 rpm and followed by CNG and hydrogen. The maximum entropy generation of 85.5 W/K with Gasoline and 60.72 W/K and 29.39W/K for CNG and hydrogen engine respectively at 10000 rpm. The entropy generation rate increase with engine speed. The highest rate of heat release is from hydrogen fuel, followed by Gasoline and CNG.   ABSTRACT- The analysis was performed on a single Cylinder, Multivalve, Electronic Fuel Injection, high-speed motor fuelled engine with Gasoline, CNG and Hydrogen to assess energetic and exegetic performance. The engine was evaluated from 3000 rpm to 10000 rpm on each of the three fuels. All tests are led at Wide Open Throttle condition.The Gasoline and CNG
shinde, Apurwa Balasaheb, SHINDE, DR BALU, Kadam, Tushar, karunamurthy, K
Development of high BMEP natural gas engine with knock mitigation2026-26-01211/16/2026
The stringent emission norms over the past few years have driven the need to use low carbon fuels and after treatment technology. Natural gas is a suitable alternative to diesel for heavy duty engines with applications in power generation and transportation sectors. Stoichiometric combustion mode offer the advantages of complete combustion and low carbon dioxide emissions. The combination of turbocharging and cooled exhaust gas recirculation (EGR) technology enhances the power density along with reduced exhaust emissions simultaneously. However, there are several constraints in the operation of natural gas spark ignition engine such as exhaust gas temperature (EGT) limit of 750 °C, sufficient before turbine (BT) pressure for EGR drivability, boost pressure (2.5 bar), peak cylinder pressure limit and knocking. These limits may restrict the brake mean effective pressure (BMEP) of the engine. In the present study, tests were conducted on a V12, 24 litre, dedicated heavy duty natural gas
Khaladkar, Omkar, Marwaha PhD, Akshey
Thermal Shock Test Rig for CNG Shut-off Valve2026-26-05261/16/2026
In Automobile, Gasoline Engines are being used along with electrically operated shut-off valve installed at the roof of bus in case of higher capacity of CNG systems. In order to start/ stop CNG supply from cylinder for running of engine/ safety/ servicing an electrical operated ignition switch/ key controlled CNG Shut-Off Valve is placed just after the cylinders. There have been few failures of these CNG shut-off valves in field application. On investigation, it was observed that the CNG shut-off valve gets failed due to water ingress in coils from the cracks on surface generated due to spray of water (due to daily washing of bus and rain) on heated shut-off valves. In order to validate this field failure and subsequent validation of modified design, a need was felt to use a test rig which can exactly simulate the water spray based thermal shocks. However, there was no low cost facility available to simulate the field service condition for validation. Therefore, a low cost test set-up
Srivastava, Pravin Kumar, Vivekanand, Vivekanand, Kumar, Satish
Key Parameters for Turbocharger selection & experimental validation for Off-Highway Applications2026-26-01041/16/2026
Customers in off-highway industry are increasingly seeking high-performance capabilities for their tractors due to increasing penetration of mechanisation and labour scarcity. One effective solution to achieve enhanced performance is turbocharging of engines, while meeting emission and highly dynamic transient response of tractor field applications. The process of selecting and validating a suitable turbocharger for tractor field application suitability is significantly time and resources consuming activity due to extensive testbed and field trials. This study focuses on the selection of turbocharger for tractor engines through analytical calculations to freeze key parameters like lambda, boost pressure ratio & temperature within boundaries of exhaust temperature and turbo efficiency maps to deliver best field transient performance and fuel consumption. The selected parameters are further validated under real-world transient operating conditions, involving tractors and their implements
RAWAT, SAURABH, KUMAR, HARISH KUMAR, Singh, Amarinder, Singh, Sachleen, Dogra, DaljitSingh
Combustion noise quality improvement in a common rail Diesel Engine at Low idle for Agriculture Tractor2026-26-03291/16/2026
Vehicle level NVH performance plays major role in customer comfort criteria. Tractor low idle rpm Sound Quality can be one of the parameter which influences customer purchasing decision based on comfort criteria. Modern diesel engines with stringent emission norms together with fuel economy requirements pose challenges to noise control. Common rail engine technology has advantage of precise fuel delivery and combustion control which needs optimization to achieve the conflicting requirements of noise, emission and fuel efficiency. Engine noise at low idle condition is dominated by combustion noise which depends on rate of pressure rise inside the cylinder during combustion. The important parameters which influence cylinder pressure rise are fuel injection timing, pilot injection quantity and its separation, rail pressure and EGR valve position. The study is carried out to understand which combustion parameter is most influencing to achieve better sound quality of engine. Taguchi design
p, Priyadarshan, Chavan, Amit, A, Kannanswamy, Patil, Sandeep, Chaudhari, Vishal V
Engine and After-treatment optimization using Simulation tools2026-26-00571/16/2026
To achieve world-class engineering quality and reduce the effort and cost associated with conventional techniques, it is essential to incorporate digital validation during the development and validation phases. This research paper explores the methodologies and applications of advanced simulation tools for creating models of engines and their sub-components using MATLAB/Simulink, parameterizing these systems with AVL CruiseM, and operating them using ETAS Labcar-Operator. The paper provides an in-depth analysis of optimizing engine and after-treatment parameters, demonstrating their impact on performance and environmental compliance. It presents a series of simulation case studies that illustrate the effects of different parameter settings on the efficiency and emission levels of diesel passenger and commercial vehicle engines. These case studies highlight the overall workflow of model-based system development, emphasize various development milestones, and correlate these with actual
Shukla, Saurabh, Shilledar, Aneesh
Ethanol Blended Diesel Fuel: Solution towards Carbon emission reduction and Sustainable Heavy Duty Transportation2026-26-01261/16/2026
Government of India has set up an ambitious net zero carbon emission target by 2070 in COP 26. To meet this target and to ensure energy security and energy sustainability, emphasis is being made to phase out petroleum derived fuels i.e. petrol, diesel etc. through sustainable alternatives. With all the environmental concern of diesel fuelled vehicles, it is a challenge to phase out them completely specifically from Heavy duty application due to their inherent attributes of high torque, efficiency and high range. Therefore, most pragmatic solution lies in reduction of carbon emission through fuel intervention and retain the characteristics of diesel fuelled vehicles. Efforts are under progress to explore the possibility of utilization of ethanol as blend in diesel fuels. This research work is focus on development and evaluation of ethanol blended diesel fuel in heavy duty engines. The ethanol and diesel are not miscible naturally so suitable agent was developed to make homogeneous
Mishra, Sumit Kumar
Numerical study of a hydrogen ejector with regulated inlet for extended PEMFC operating range in automotive application2026-26-02491/16/2026
Hydrogen recirculation is a key requirement for enhancing fuel efficiency and anode stability in Proton Exchange Membrane Fuel Cell (PEMFC) systems, particularly in automotive applications. Effective hydrogen recirculation is critical for maintaining high efficiency and fuel utilization. A hydrogen recirculation ejector equipped with a regulated pressure inlet, aimed at eliminating the need for mechanical pumps while maintaining optimal hydrogen utilization. The passive operation of the ejector eliminating the need for rotary components which significantly improves system reliability and reduces failure modes commonly associated with moving parts. This work presents a numerical investigation of a hydrogen recirculation ejector featuring a regulated pressure inlet, with the objective of extending its operating range across varying fuel cell power levels. A combination of 1D system-level modelling and 2D multi-species Computational Fluid Dynamics (CFD) simulations was employed to
Khot, Ranjit Uttreshwar, T P, Muhammad, Chougule, Abhijeet
Design & analysis of Dual Mass flywheel during Engine startup condition in 3 Cylinder Gasoline application2026-26-03491/16/2026
Modern automotive powertrains are increasingly adopting engine downsizing and down speeding to meet stringent emission regulations and improving fuel efficiency However, these changes result in higher torsional vibrations and excitation amplitudes makes more challenge in NVH (Noise, Vibration, and Harshness) refinement. With growing customer expectations for premium driving experiences conventional clutch are no longer sufficient. To meet the NVH performance targets of the vehicle Dual Mass Flywheels (DMFs) are used In DMF due to lower stiffness and inertia separation there is a great advantage on torsional filtration in normal drive and idle condition. but the resonance frequency of the connected DMF is lower than the idle RPM. Engine startup is a key drawback with DMF equipped vehicles. The proper tuning of starter motor performance & DMF stiffness is required to cross the resonance zone faster otherwise it will lead to DMF to stay in the resonance zone for a longer time leading to
Jayachandran, Suresh kumar, Vijayaragavan, Thirupathi, M, DEVAMANALAN, Kanagaraj, Pothiraj, ahire, Manoj, Vellandi, Vikraman
Design and Validation of UDS Application Software for Fuel Cell Electric Vehicle within AUTOSAR Framework2026-26-02531/16/2026
Affordable and clean energy has been one of the major objectives adopted by United Nations under the 2030 Agenda for Sustainable Development. In this direction, fuel cell electric vehicles have gained popularity in recent times due their efficiency and environmental friendliness. Fundamentally, it uses compressed hydrogen from the vehicle-mounted tank and combines with ambient air to generate DC electricity. Water is created as a by-product and expelled through the tailpipe. The technology being integrated on powertrain architecture, along with battery pack can prove to be an efficacious approach for zero emission automotive system. However, hydrogen being the primary fuel, and being stored at high pressure, the system involves handling and potential hazards of hydrogen, and possibility of explosions due to hydrogen leaks. Hence, safety is the key issue in handling fuel cell vehicles. This paper discusses about role of Unified Diagnostic Services (UDS) in providing safety and
PRASAD, Dr. P SHAMBHU, Jacob, Joe, Hadke, Tanmay, Wagh, Priyanka, Achanur, Mallappa
Failure Prevention of Permanent Deformation in HNBR Elastomeric Diaphragms Used in CNG Valve Applications2026-26-02941/16/2026
Hydrogenated nitrile butadiene rubbers (HNBR) and its derivatives have gained the significant importance in automotive compressed natural gas (CNG) valve applications. In one of the four-wheeler CNG valve application, HNBR elastomeric diaphragms are being used for their excellent sealing and pressure regulation properties. The HNBR elastomeric diaphragm was developed to sustain CNG pressure more than 10 bars. However, it was found permanently deformed under 4 bar pressures. In the present work, a set of experiments were carried out in order to find out the primary root cause of diaphragm permanent deformation and preventing the failure for safe usage of the CNG gas. HNBR diaphragm deformation investigation was carried out using advanced qualitative and quantitative analysis method such as Soxhlet Extraction Column, Fourier Transform Infrared Spectroscopy (FTIR), Differential Scanning Calorimetry (DSC), Optical Microscopy (OM), Scanning Electron Microscopy (SEM) and Thermogravimetric
Patil, Bhushan Gulab, NAIKWADI, AMOL, Mali, Manoj, Tata, Srikanth
The Creation of the 245/90R16 Tire Size for Commercial Vehicles 8.5T -12T in the 16-Inch Tube-Type Category – A Global First2026-26-06021/16/2026
This project introduced a brand-new tire size—245/90R16—for the first time globally in the 16-inch tube-type category, designed specifically for commercial vehicles with Vehicles 8.5T -12T gross vehicle weight (GVW). The main goal was to create a compact vehicle that can carry more payload, reduce overall weight, and improve fuel efficiency with use of rear single tyre instead of twin tyre in 8.5T. This helps customers lower their operating costs and improve vehicle performance, especially on narrow roads. The new tire supports high load capacities: up to 2300 kg for single tire use and 2180 kg for dual tire fitment. It enables a new type of vehicle to be developed—an 8.5-ton GVW vehicle with rear single tires—offering better payload capacity without increasing the size of the vehicle. By using this new tire, the kerb weight of the vehicle is reduced, which increases the payload and helps improve fuel economy. It also helps lower the cost of the vehicle by allowing the use of lighter
Pawar, Dhondiram Dnyandeo, Shaikh, Matin, ambekar, Prasad
Material Compatibility Studies of Ethanol Blended Diesel2026-26-01291/16/2026
The Government of India has mandated biofuel blending in automotive fuels to reduce crude oil imports and support the national economy. As part of this initiative, Oil Marketing Companies (OMCs) have begun nationwide blending of E20 fuel (20% ethanol in petrol). Ethanol supply is expected to exceed demand by the end of 2025 due to initiatives like the Pradhan Mantri JI-VAN Yojana (ethanol from waste grains). Alternative applications for ethanol are being explored; one promising approach is its use as a co-blend with diesel fuel. However, ethanol’s low cetane number and poor lubricity present challenges for direct use in diesel engines without modifications. This study explores ethanol diesel (ED) blends for unmodified diesel engines. ED blends demonstrated reduced emissions while maintaining performance comparable to conventional diesel. To further address concerns related to materials compatibility of ED blends with fuel system components, particularly plastomers (e.g., hoses, seals
Johnpeter, Justin P, Chakrahari, Kiran, Chakradhar, Maya, Arora, Ajay, Prakash, Shanti, Pokhriyal, Naveen Kumar
Data-Driven Prediction of Global Automotive Trends: Forecasting Fuel Economy and CO₂ Emissions Using Machine Learning2026-26-06431/16/2026
In the pursuit of cleaner transportation and environmental sustainability, the global automotive industry is undergoing rapid transformation. This study leverages historical multi-decade vehicle data to develop predictive models for fuel economy and CO₂ emissions across a wide range of vehicle technologies. By utilizing advanced machine learning algorithms in Python and integrating insights through Power BI visualizations, the project identifies key correlations between vehicle attributes—such as weight, powertrain, and footprint—and their environmental performance. Results highlight the increasing impact of electric vehicle adoption, hybridization, and light weighting on overall emissions reduction. These insights help forecast the direction of fuel economy standards, emission patterns, and technology shifts across manufacturers and vehicle types. Beyond technical predictions, the study offers a decision-support framework for global policymakers, automotive designers, and
Hazra, Sandip, Tangadpalliwar, Sonali, Hazra, Sanjana
Performance Evaluation and Optimization of Engine Brake System using Chassis Dynamometer2026-26-05111/16/2026
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
M, Vipin Prakash, Rajappan, Dinesh Kumar, R, Suresh, N, Gopi Kannan
Development of above 500 kW Diesel Engine & After treatment System to meet CPCB-IV+ Emission Norms2026-26-02341/16/2026
The CPCB-IV+ emission compliance for genset application is applicable with effect from 1st July 2023 as per as per GSR 804(E). The CPCB-II to CPCB-IV+ changeover in very stringent in emission front by almost 90 % emission reduction. It's a significant advancement in environmentally sustainable powertrain technology. To meet the CPCB-IV+ Emission, combustion development & ATS technology plays an important role. First is the base engine need to optimize enough with combustion & associated parts. Second is the after treatment system which will carry the battle further to the engine emission with 10% minimum engineering target. This paper present the systematic approach followed to meet CPCB-IV+ emission norms for upgradation of 21 liter TCIC engine for the power range (56 <P ≤ 560). Here the challenge is that we don't want to major changes in the existing CPCB-II FIE recipe & meet the CPCB-IV+ emission with ECU calibration & ATS system calibration with its potential. Here interesting
RANE, Vikas, Jagtap, Shailesh, Gothekar, Sanjeev, Pawar, Narendra V, Khedkar, Prasad, KAGADE, SAMADHAN, Kendre, Mahadev, G Bhat, Prasanna, Thipse, S
Manufacturing process advancement in CNG Exhaust Valve to prevent seat wear issue2026-26-02781/16/2026
Exhaust Valve CNG market share increased in India in recent years demanding for more durable and reliable CNG Engine. While in current scenario durability is one of the major concerns for CNG engine. Major issue faced in CNG powertrain is high wear at Exhaust valve CNG face due to excessive wear. In Current practice T400 Sintered material layer is deposited at Valve face which is very critical to achieve less wear at valve face. Due to manufacturing variability high level of variation is found mechanical properties of T400 deposit which is very critical for Exhaust Valve CNG performance. In this paper all important process parameters are discussed for achieving consistent Exhaust Valve CNG T400 deposit quality. Each process parameter detail impact on T400 material is studied and explained to achieve consistent quality of T400 deposit leading to robust design of Exhaust Valve CNG.
Poonia, Sanjay, KUMAR, CHANDAN
A Comparative Journey Towards Sustainable Energy: CNG and Bio-Diesel Fuels in India2026-26-01161/16/2026
India being highly populated and developing country, the demand for various alternative fuel is increasing drastically. It is driven by the need to reduce dependency on traditional fossil fuels & reduce impact on environmental issues like Greenhouse gas, emissions & pollution. The potential options, CNG (Compressed Natural Gas) & Bio-diesel which are becoming increasingly popular and important. Biodiesel, a renewable fuel which is produced from waste materials & crops which grown repeatedly & easily available while CNG is more sustainable than diesel as natural gas is a cleaner-burning fossil fuel in comparison to coal or oil. This paper will focus on comparison between basic properties of Diesel, CNG & Bio- Diesel. In this study will also be focusing on survey of various Government initiatives, polices & infrastructural development which are evolving to encourage the usage of CNG & Biodiesel. These fuels are emerging as promising alternative contenders to traditional diesel. It has
Bondada, Nandita, Baruah, Labanya, Mokhadkar, Rahul
The viability of Ammonia in the Automotive sector: Challenges and Opportunities2026-26-01281/16/2026
Ammonia has become an attractive alternative fuel for automotive use because of its high energy density, carbon-free combustion, and possibility of sustainable production. The work examines the viability of ammonia as a fuel for internal combustion engines (ICEs) and fuel cells in automotive applications. Ammonia presents a number of benefits, such as being capable of being produced from renewable energies and having the possibility to diminish reliance on fossil fuels. However, disadvantages such as ammonia's lower energy content per volume, NOx emission possibility, and need for engine adjustment remain significant challenges. The paper covers the combustion characteristics of ammonia and how it behaves in traditional ICEs and in emerging fuel cell technology. It also addresses the necessary infrastructure for the production, storage, and distribution of ammonia to be used in automotive applications. Through comparative testing and comparison with conventional fuels by experimental
Jadhav, Ajinkya, Bandyopadhyay, Debjyoti, Sutar, Prasanna S, Sonawane, Shailesh Balkrishna, Rairikar, Sandeep D, Thipse, Sukrut S
Development of a CNG-Diesel Dual Fuel Tractor with Mechanical Fuel Injection System2026-26-01141/16/2026
Identification of renewable and sustainable energy solutions remains a key focus area for the engine designers of the modern world. An avenue of research and development is being vastly dedicated to propelling engines using alternate fuels. The chemistry of these alternate fuels is in general much simpler than fossil fuels, like diesel and gasoline. One such promising and easily available alternate fuel is compressed natural gas (CNG). In this work, a 3-cylinder, 3-liter naturally aspirated air-cooled diesel engine from the off-highway tractor application is converted into a CNG Diesel Dual fuel (CNG-DDF) engine. A comparative performance shows that the thermal efficiency is up to 5% lower with CNG-DDF with respect to diesel. However, it has shown the benefit of 44% in Particulate Matter (PM), while retaining the same NOx + NMHC levels as baseline diesel engine. The cycle average CO emission was found to increase by 40% simultaneously, which has been controlled by an oxidation catalyst
Choudhary, Vasu, Mukherjee, Nalini, KUMAR, SANJEEV, Tripathi, Ayush, Nene, Devendra
For CNG and FFV fuel application robustness improvement of Exhaust Valve2026-26-01251/16/2026
Today, globally, automotive manufacturers are striving to meet the increasing demand for fuel economy, high performance, and silent engines. The fundamental approach to achieving these requirements is through designing low friction mechanisms, resulting in less wear and higher durability. The demand for CNG vehicles has surged exponentially in recent years, prompting increased government focus on alternative fuels such as CNG and hydrogen. These dry fuels lack lubricating properties, unlike conventional fuels like petrol, diesel, and biofuels, which are wet and liquid. Consequently, the operations and failures associated with these fuels differ. The materials and designs of engine parts, such as fuel lines, ECU, exhaust valves, and cylinder heads, vary depending on the fuel used. This study discusses the countermeasures adopted to address the high seat and guide wear in cylinder heads and valves. The investigation focuses on material, design, and manufacturing process improvements
Poonia, Sanjay, KUMAR, CHANDAN
Investigation of Engine Oil Dilution by E100 Fuel Under Diverse Operating Conditions in Passenger Vehicles2026-26-01221/16/2026
The adoption of alternative fuels like Ethanol is increasing due to stricter emission regulations in various global regions. Indian government is also promoting to develop FFV¹ technology specifically for Indian driving conditions. The government moved up its goal of reaching a 20% blending rate from initial 2030 timeline to 2025. Plans are in place to bring E-85 and E-100 Vehicles into India in areas where there is an excess of ethanol.. However, there are challenges associated with this target. Using pure ethanol to power a vehicle can lead to various concerns, including deposition on engine parts, wear of critical components, and fuel contamination of engine oil, such as fuel dilution. Compared to gasoline, ethanol has lower calorific value resulting in less energy per gallon than gasoline during combustion, which means to produce same amount of energy 33% more ethanol injection is required. This higher fuel injection can result in higher oil dilution in comparison to gasoline
Yadav, Vimal, Attri, Mayank, pathak, Mehul
Navigating Towards a Sustainable Future: India's Automotive Sector and the Path to Net Zero Emissions2026-26-01181/16/2026
This study examines the evolving landscape of India's automotive sector in the context of the global push for net-zero emissions. As the world's third-largest automotive market, India is poised to play a significant role in this transition. The country's automotive sector is expected to experience rapid growth, with its market size projected to expand from USD 437 billion in 2022 to USD 1.8 trillion by 2030. The study highlights the importance of diverse mobility solutions, such as electric vehicles, green hydrogen, and alternative fuels like bio-CNG and ethanol, in addressing transportation challenges and reducing greenhouse gas emissions. The Indian government's comprehensive approach to promoting green mobility, while balancing the needs of a large and diverse population of 1.4 billion people, is a key focus of this research. Through a detailed analysis of economic, social, energy, regulatory, and technological factors, this study provides insights into the current dynamics
Seshan, Vivek, Bandyopadhyay, Debjyoti, Sutar, Prasanna S, Sonawane, Shailesh Balkrishna, Rairikar, Sandeep D, Thipse, Sukrut S, De Castro Gomez, Daniel J.
Data analysis -Driven Calibration Enhancement for Alternative Fuel Engine Start2026-26-01231/16/2026
In the pursuit of improving cold-start performance in alternate fuel vehicles, data analysis has become a cornerstone for driving informed calibration decisions. Cold start is very critical for flex fuel vehicles since it has higher latent heat of vaporization and lower vapor pressure compared to gasoline. Ethanol blend fuels deteriorate engine starting at low ambient temp. This case study highlights how pivot table based analytics were effectively employed to enhance engine start strategy during the development of small commercial vehicle running on E20 and E85 fuel blends. The approach showcases how structured data interpretation can significantly support development work in Flex Fuel calibration. The analysis concentrated on various critical engine start events such as first crank success, failure to start, battery voltage behavior, and post-start stability across a range of coolant temperatures, particularly below 20°C. Real-world test data was segmented using data analysis based
Undre, Shrikant, Kulkarni, Deepak, Thonge, Ravindra, Upadhyay, Rajdip
Establishing a High-Pressure Direct Injection Hydrogen Engine Test Facility with Integrated Ammonia Fuel Capability: Technical Considerations, Safety Framework, and Best Practices2026-26-02671/16/2026
The transition toward zero-carbon propulsion technologies has highlighted the urgent need for specialized test infrastructure to support hydrogen and alternative fuel research. This paper presents the conceptualization, design, and operation of a High-Pressure Direct Injection (HPDI) Hydrogen Internal Combustion Engine (H2 ICE) test facility with integrated ammonia fuel testing capability, marking a significant advancement in India’s sustainable automotive research efforts. Drawing from practical experience, it outlines crucial technical specifications, safety protocols, and best practices for establishing robust, adaptable, and secure testing environments. Addressing the industry’s need for dedicated infrastructure, it is engineered for adaptability across various engine types—including heavy-duty, light-duty, and multi-utility vehicles—while aligning with global technical standards. Key technical considerations include the use of a transient dynamometer that features an advanced
Dhyani, Vipin, Kurien, Caneon, Subramanian, Balaji, Khandai, Chinmayananda, Muralidharan, M
3D CFD simulation methodology for safe and efficient hydrogen refueling for hydrogen internal combustion engines2026-26-02521/16/2026
As conventional fossil fuels are on the verge of depletion, the search for alternative fuel for automotive applications has intensified. Among these, hydrogen stands out due to its high energy content per unit mass, high octane number, and compatibility with Internal combustion engines (ICE). However, the volatility of hydrogen (H2) presents challenges, particularly during the refueling process, where uncontrolled temperature rise occurs because of negative Joule-Thomson (JT) effect. This brings an alarming bell for the safety of fueling stations, vehicles and mankind. This paper investigates the physics involved in hydrogen tank filling, focusing on maintaining the hydrogen gas temperature below 85 °C during the process. A 3D Computational Fluid Dynamics (CFD) analysis was performed to model the temperature and pressure behavior of hydrogen during filling. The study provides insights into the optimal fill rates, temperature distribution, and the evolution of peak temperature locations
Khanna, Gourav, Veerbhadra, Swati, Sahu, Abhay Kumar
Modelling of Turbulent Combustion of Liquid Ammonia in Dual Fuel CI Engine2026-26-04421/16/2026
Combustion of fossil fuel results in CO2 emission which is considered to be a leading cause of global warming. Alternative fuels with little or no carbon foot is being actively considered. Direct combustion of ammonia is being actively investigated as it is considered to be a carbon neutral fuel that does not emit CO 2 . It is one of the largest industrially produced chemicals and is easy to store and transport with a well-established supply-chain system. Compared to conventional fuels, ammonia has inferior combustion properties like high ignition delay, low flame speed and a high propensity to produce NOx due to the availability of fuel bound nitrogen. This study uses numerical simulations and a chemical kinetic model to examine the combustion characteristics of ammonia and diesel blend in a dual fuel compression ignition IC engine. Both liquid ammonia and diesel are directly injected into the cylinder, with ammonia as the primary fuel and diesel as a pilot to initiate combustion. An
Warghat, Ketan Vinayak, Prabhakaran, Dinesh, Banerjee, Sayak, kolhe, Pankaj, Banerjee, Raja
Analysis of the Indian Patent Landscape on Alternative Fuels with a focus on Hydrogen Fuel Cells and Hydrogen Internal Combustion Engines2026-26-02621/16/2026
This paper presents an analysis of the Indian patent landscape concerning alternative fuels, with a specific focus on hydrogen fuel cells and hydrogen internal combustion engines (H2 ICEs). The study aims to provide insights into the innovation trends, key players, white spaces and technological advancements, in this evolving sector within the Indian context. The study is based on the granted patents and disclosures in the said area, and also focuses on the key problems and solutions. Based on a review of patent publications from January 2024 to March 2025, it was observed that a significant number of patent records pertain to the broader domain of hydrogen internal combustion engine disclosures. Specifically, 540 extended families patent publications were screened focusing on hydrogen internal combustion engine as a domain of disclosure. Further analysis revealed that greater 75 % of applicants were from the industry sector, indicating a strong commercial interest in these
Nikam, Mahesh Suresh, Sutavane, Ila, V, Ajay, Aghav, Yogesh
A 3D CFD Combustion Evaluation of Hydrotreated Vegetable Oil (HVO) as a Potential Alternate Fuel for the Future CI Engines2026-26-01131/16/2026
Transportation industry is facing the growing challenge to reduce its carbon footprint and utilize the carbon neutral, more environmentally sustainable fuels to comply with the goal of carbon neutrality. Implementation of carbon free fuels such as Hydrogen, Ammonia and low carbon fuels such as Methanol, Ethanol can significantly reduce the greenhouse gas emissions, but these fuels are suitable for SI engine architecture due to their high-octane ratings. Hydrotreated Vegetable Oil (HVO) is one of the few fuel solutions available today with a high Cetane rating (70-80), that can be used as a drop-in fuel in the existing CI engines, with minimal modifications. The main constituent of HVO is pure alkane and it can be produced from feedstocks such as vegetable oils, animal fats and various wastes and by-products. A closed cycle 3-D CFD combustion simulation using a detailed chemistry-based solver was conducted with the HVO, on a three cylinder, naturally aspirated water-cooled CI engine at
Tripathi, Ayush, Mukherjee, Nalini, Nene, Devendra
There is ‘NO ALTERNATE TO ALTERNATE FUELS’2026-26-01081/16/2026
Alternate Fuels are to be redefined as current definition says any fuel other than Diesel or Petrol. CNG / LNG / LPG / Bi-fuels / Synthetic fuels / Electric energy and Hydrogen fuel are various alternate fuels; many more are expected to add mainly Solar energy in future. CNG / LNG / LPG are alternative fuels but from fossil fuels category. Renewable Fuels are fuels produced from renewable resources. Examples include: biofuels Hydrogen fuel and fully synthetic fuel (also known as electro fuel). Electrical energy & Hydrogen energy produced from conventional way can be classified as non-renewable fuels. Interestingly, Bio-fuels and Synthetic fuels are produced from the waste. Therefore, these fuels serve dual purpose - consumption of waste and generation of energy. While studying the fuels, we need to understand one more thing how these fuels are used, this is explained as below. The Alternative fuel choice is not easy as there are many things involved to be considered. We need to take
KUMATHEKAR, RAJESH RAMDAS
Combustion dynamics and performance optimisation using higher HCNG blends for decarbonising the Gas Genset sector2026-26-02511/16/2026
Air pollution is profligate becoming a serious worldwide problem with the increasing population and its subsequent demands. Diesel, Gasoline, Natural Gas, Propane, etc., are some of the traditional fuels used in the power generation sectors. Diesel fuel, popularly utilized for backup power in critical operations, is valued for its swift activation time. This makes diesel generators a preferred choice for commercial properties and hospitals requiring reliable emergency power. Moreover, natural gas, distributed through local utility grids, provides a convenient and readily available fuel source for generators, eliminating the need for on-site fuel storage. On the other hand, CPCB has instructed to modify the emission regulations for genset engines for decarbonization and development clean fuel. The change from CPCB II to CPCB IV+ standard shows the commitment of the Indian government towards environmental sustainability and COP26. Pondering to the stringent emission norms, researchers
Bandyopadhyay, Debjyoti, Sutar, Prasanna S, Dhar, Rit Prasad, Sonawane, Shailesh Balkrishna, Rairikar, Sandeep D, Thipse, Sukrut S, Singh, Sauhard, Mishra, Sumit Kumar, Bera, Tapan, Badhe, Rajesh, Tule, Shubham, Aghav, Yogesh, Lakshminarasimhan, Krishna
Development of an Software Algorithm Based Semi-automated Data Acquisition System for Gasoline Vehicle Calibration on Chassis Dynamometer2026-26-05351/16/2026
Vehicle level testing is one of the crucial part of the calibration development. In this, chassis dynamometer is used to collect the vehicle level data. Different engine and vehicle level parameters are logged at various speed and load points covering the entire engine operational zone. This data acquisition is a repetitive activity and covers over 30-40% of the total testing duration. This phase includes base calibration verification, transient development, and emissions-related calibrations, all of which follow a standardized and repetitive sequence. However, these tasks are predominantly performed manually, leading to potential human error and inefficiencies. This paper presents a novel and comprehensive algorithm developed using INCA FLOW software; the first of its kind for this application. Here, crucial vehicle data acquisition activities are identified, mapped into detailed steps. The algorithm introduces a semi-automated, stepwise process for data acquisition during chassis
Kavekar, Pratap Chandrashekhar, Tyagarajan, Sethuramalingam, Agarwal, Nishant Kumar, Shaikh, Wasim, Karadi, Subramanya
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