Authors: Mukesh Kumar, Dr. N K Nath, Dr. R. R. Arakerimath
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This research paper represents Designing of Cost reduced Diesel Exhaust Aftertreatment system against existing Flex Module aftertreatment system. Methods represents the steps to design new cost reduced Aftertreatment system. Study involves how new design is still meeting existing space claim and meeting all performance requirements. Simsolid software were used to calculated Modal and Static structural analysis to compare both the designs & ARAI test facility has been used to validate new deign meets Emission compliance as per BS6 Limit for MHCV Norms.
Aftertreatment is the key elements which treats Engine out Exhaust gas to Emission compliance exhaust gas Out from Aftertreatment system.
For Emerging market Cost is big driver for selling any new product or sustaining existing production due to heavily competition in market, This results, any system we sold to market should be lesser in cost and shall be competitive in price selling to OEM’s. Since current system (Flex ATS system) costs more due to design and Manufacturing complexity.
IV. LITERATURE & PATENT REVIEW
The aftertreatment system or exhaust gas processer plays a very important role in the automotive exhaust systems. A review of the literature survey related to finding cost reduction opportunity based on material change, design modification and commonization technique. In this literature different cost reduction opportunity techniques were taken into consideration, based on system understanding, design change, material change, standardization, modularization.
Following papers are refer for study of aftertreatment system and their configuration.
V. SYSTEM REQUIREMENT
Following parameters or criterions are considered while optimizing cost
VI. CONCEPT DESIGN AND VERIFICATIONS
In this section we will talk about different steps we followed for concept selection and verifications. An exhaust aftertreatment system comprising of DOC, DPF, Mixer and SCR.
To design new After treatment system we need space claim from OEM chassis, Flow and Engine rated condition. New design should meet same/improved Emission limits and passes all structural design requirements.
3. Ideas Evaluation & Verifications
a. Modal Analysis: Modal analysis were performed to check vibrational frequency. First modal frequency for new design is 406.02 Hz whereas for Flex Module it is 382.06 Hz which is improved design as compared to Flex system
b. Static Structural Analysis: Static structural analysis were performed with 10G inertial loading in X, Y&Z directions individually and max stress value is compared with the yield limit of the material. It has been observed that New Design experiences lesser stress than Flex Module.
c. PSD Test: New design verified using Single Axis shaker test using RLDA vibration profile and test has been passed.
d. Emission Verification: New design were verified using Medium Heavy commercial vehicle BS6 Emission transient cycle (WHTC) and this meets emission requirements.
Although it was not easy to complete this project unless I got great company support from Cummins Technology India private Limited Pune & my Industrial guides Mr. Aashish Wadke and Mr. Rajesh Yeole has guided for overall execution.
Newly designed Diesel exhaust Aftertreament system meets all requirement which includes lesser in cost, complexity, Improved in structural performance, Meeting in lesser packaging space claim and finally product offering will be cheaper b/n 5~7% from baseline.
Great books and online library has helped my overall project execution referred from: -  Zoran et al, inventor; Randolph G. et.al, Assignee; Cummins Emission Solutions Inc., Columbus, IN (US). single module integrated aftertreatment module. United States Patent US 10, 092, 879 B2 .2018 oct 9.  AK steel https://www.aksteel.com/  Peter Thorne, Ambati. Commonization and Re-use,2007  K. C. Vora, A. S. Patil and V. G. Halbe Mahindra & Mahindra Ltd., Nasik, India. A Systems Approach to Automotive Exhaust System Development. SAE Paper No. 2003-26-0029.  Harrison et al., inventor; Benjamin Harrison, Assignee; Caterpillar Inc. Exhaust Gas After Treatment Assembly. United states patent US 2010/0186394A1, Jul. 29, 2010  Emun, Y., Quan, G., Kish, J., and Zurob, H., “Comparative Corrosion Evaluation of Ferritic Stainless Steels Utilized in Automotive Exhaust Applications,” SAE Technical Paper 2018-01-1407, 2018, doi:10.4271/2018-01-1407.  S. N. Thakur and J. R. McMillen, M. L. Holly, P. K. Samal, “High Temperature Oxidation/Corrosion Performance of Various Materials for Exhaust System Applications”, SAE Technical paper 2006-01-0605, April 2006.  Heuser, P., Ghetti, S., Rathod, D., Petri, S. et al., \"Bharat Stage VI Solutions for Commercial Engines for the India Market,\" SAE Technical Paper 2017-26-0043, 2017, doi:10.4271/2017-26-0043.  Barman, J., Arora, P., and Patchappalam, K., \"Technology Challenges and Strategies for BS-VI in Commercial Vehicles,\" SAE Technical Paper 2017-28-1937, 2017, doi:10.4271/2017-28-1937  Matthew Baus , Anthony Cook, David Schaller et.al , “Integrating New Emissions Engines into Commercial Vehicles: Emissions, Performance & Affordability,” SAE Technical paper 2006-01-3545 ,2006.  Robert L. Chance, Ronald G. Ceselli , “Corrosiveness of Exhaust Gas Condensates”, SAE Technical paper 830585, May 22,2019  BIS Standard 2062 , “Hot rolled medium and high Tensile structural steel specification”  ASTM Standard B117, “Salt spray corrosion test”  https://www.youtube.com/watch?v=ksUVzAc5tX8&ab_channel=LEARNANDGROW & https://www.youtube.com/watch?v=8riQ9Zt5UWg&ab_channel=ADMETTestingSystems
Copyright © 2022 Mukesh Kumar, Dr. N K Nath, Dr. R. R. Arakerimath . This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.