By Anirban Ghosh
Here are the edited excerpts from the presentation.
Actors in the commercial vehicle industry face great challenges because vehicles are their winning machines. Owners need to control all vehicle-related cost factors such as finances, fuel, tires, payload, uptime, vehicle uptime, compliance with changing regulations, etc. Virtual product development is the key to responding to these and others. challenges of the CV industry. The use of virtual engineering is not only for internal combustion engine vehicles, but also for electric mobility which will be the future of the industry.
Fuel is the highest cost factor unlike many other countries. Compared to 38% in India, it is only 10% in Europe. For BS-VI fuel compliance, virtual product development has been the key that has helped us. This ensured that in a small window of development time we could ensure BS-VI compliance of new VECV vehicles. With the support of the Volvo Group, we have introduced several new variants to the market.
Benefits of virtual product development
The benefits of virtual product development include a robust design concept before investing in a physical concept, early verification of vehicle performance, fewer prototypes resulting in less cost and time to market. Time to market can be reduced by 30% by following virtual simulation and testing processes.
For vehicles with internal combustion engine, gasoline, CNG or diesel, virtual product development helps with fuel efficiency (engine and transmission analysis), emissions (EATS optimization), sustainability analysis from vehicle and powertrain systems, to driving productivity (driving control, handling, NVH analysis), crash and safety analysis and payload optimization.
For fuel efficiency at VECV, the complete vehicle was modeled on the simulation, including driving cycle, environment, vehicle model aggregated with engine model, tire aerodynamics, etc. Using virtual engineering, we were able to establish a correlation of up to 96% between virtual validation of energy efficiency and actual energy efficiency. Today, VECV offers products whose energy efficiency is 4 to 10% higher than that of the competition.
On the emissions side as well, there is a virtual engineering technique, a virtual EATS, which zone to target, what is the sweet spot of the engine for increased efficiency and lower emissions and which zones need to be targeted and all of that is. accomplished on the virtual test bench.
Using virtual engineering, we were able to establish a correlation of up to 96% between virtual validation of energy efficiency and actual energy efficiency. Today, VECV offers products whose energy efficiency is 4 to 10% higher than that of the competition.Rajinder Singh Sachdeva, COO and R&D manager, VECV
Likewise, the actual driving emission cycles become very important. In-service conformity, resulting from BS-VI, vehicle aging conditions are now important parameters along which the quality of a vehicle is measured. And here we have created extensive verification metrics of different variants, aged calibration which is performed on the virtual test bench, limited validation of the most unfavorable combinations is performed and after that we perform real physical tests. Here we can see that 80% of our effort is put in the first step, which is our calibration, 60% in the aged calibration, 50% in the limited validations and only 40% of the effort will be spent on an accumulation. actual physical mileage to ensure in-service compliance. So this is a huge reduction in time, effort and cost, which ensures that all variants comply with BS-VI standards.
A model-based verification on a virtual test bench is performed on the vehicles. Various parameters are modeled like vehicle calibration, environment, drive cycle, EATS aging, NOX emissions and SCR temperature to ensure the vehicle is fully BS-VI compliant.
Likewise for the engine, durability and performance are also measured through the different simulation techniques so that the promised lifespan of the vehicle is established. Even the durability, stability and performance of the transmission are modeled on the simulator and tested.
Road profiles of various Indian roads are incorporated into the simulation and vehicles are tested for durability, damage sustained, chassis life, cabin life, etc. All of this can be accomplished without any actual testing of the vehicle. We can also guarantee maximum driver comfort by using virtual simulation so that the driver can be on the road for maximum hours.
The Indian automotive industry is changing rapidly and today almost 70% of the complete vehicle development can be achieved virtually. In the future, this will increase to 80% to 85% of vehicle development.Rajinder Singh Sachdeva, COO and R&D manager, VECV
Vehicle handling, noise and vibration reduction, steering, improved tire life are all simulated virtually and these inputs help make vehicles safer, more comfortable and more durable. The more kilometers a vehicle travels, the more profit the owner earns. Even safety rules like crash tests can be simulated in a virtual environment.
A lot of weight reduction has been possible using the virtual development process. The unwanted weight has been reduced so that the payload capacity is increased.
Development of electric vehicles
For electric vehicles (EVs), the development of virtual products has made it possible to simulate parts ranging from electric motors to battery cooling circuits. The engine cooling airflow pattern and the temperature variation of the internal battery cells were also simulated. A complete electric vehicle can be modeled where the control system, the battery management system, the performance of the electric vehicle, the range of the vehicle and the variation of the range with temperature are virtually analyzed in the laboratory, which ensures that vehicles meet customer requirements.
While almost everything can now be simulated, from engine efficiency to driver safety, the CV industry faces many challenges. Regulations and standards are changing rapidly and compliance has been tightened. Market dynamics are also changing rapidly. Vehicles must be ready for the implementation of BS-VI Stage II in 2023, the transition to electric mobility, connected vehicles or IoT-enabled vehicles, the development of autonomous trucks or autonomous trucks, FCEV vehicles and other challenges must be met in the CV industry.
In order to meet all these challenges, the development of virtual products is an investment from which the CV industry can greatly benefit. The Indian automotive industry is changing rapidly and today almost 70% of the complete vehicle development can be achieved virtually. In the future, this will increase to 80% to 85% of vehicle development.
With this technology, all customer requirements can be brought to the lab and without spending a lot of time on the prototype and the investment, the requirements can be simulated to ensure that the uptime, fuel efficiency and load capacity of the vehicle are maximum so that the profit the owner earns from the vehicle is maximum. This is the only way to reduce logistics costs which are 12.5 to 13% of GDP. The product must be more productive.