Fuel Efficiency improvement is ongoing Challenge. It is becoming more and more challenging with every upgrade of emission. In last two decade the significant improvement have taken place improving basic engine, hardware systems, technology , presentation discusses how to merge all ideas in main stream and include in validation of upcoming norms say BSVI in India. Its not economical to keep doing small improvements and validating.

1. Fuel Efficiency Improvement
Quest for excellence continues with ever increased challenges

2. Fuel Efficiency:
• Fuel Efficiency improvement is ongoing Challenge.
• It is becoming more and more challenging with every upgrade of
emission.
• In last two decade the significant improvement have taken place.
• Engine level BSFC improvement by 10%
• Nox – PM reduction by 90%
• Increase in Specific output
• Also adding cost significantly and reducing weight

3. Fuel Efficiency & Physics:
• Energy can not be created not can it be destroyed, it can only change from
one form to other.
• Fuel – chemical energy converted in to useful work with dissipation in
Cooling and Exhaust remains.
• However % Efficiency of Conversion is improving.
• Useful energy at reduced emission is the requirement.
INPUT OUTPUT
• Fuel – Chemical energy Power – Mechanical energy
• Air induction Exhaust
• Cooling Medium ( oil / Air / Water ) Cooling medium – Elevated temp

4. Few Prevailing Facts :
• Driving Habit can impact as high as up to 30%
• New Tyre burns more fuel as high as up to 5 – 6% compared to worn ones.
• More the speed more the Fuel burns.
• Under inflation of Tyres consumes more fuel than over inflation.
• Lower the idle lower the Fuel gets consume.
• Prolong idle consumes more fuel.
• Aero dynamic resistance impacts FE at higher speeds.
All Facts are governed by Physics

5. Major elements affecting fuel Efficiency of the System :
1. Prime mover : Engine
2. Medium - Vehicle
3. Road on which vehicle moves / Gradient
4. Load / Weight of the vehicle being carried
5. Speed of the vehicle ( designed / habit )
6. Ambient Conditions
7. Wind Resistance
8. Users Habits
Optimizing Vehicle speed as per road ,
load in min BSFC Zone

6. Fuel Energy
100%
Exhaust
30%
HT 20% IHP 50%
Gas Ex.2.5%
Friction 1.5%
Acc. 2.5%
BHP 43.5%
Fuel Energy
100%
Exhaust
24%
HT 26% IHP 50%
Gas Ex.4%
Friction 1.5%
Acc. 2.5%
BHP 42%
Fuel Energy
100%
Exhaust
20%
HT 22% IHP 58%
Gas Ex.2%
Friction 1.0%
Acc. 2.5%
BHP 52.5%
Heat Balance : Engine Level : YOY( Year on Year )
1998 2008
Advanced
Effect of High Pressure Pump,
CEGR,

7. Sl. No. Heading Areas
1 Pistion , Ring, Pin Pack
2 Cyclinder Bore
3 Bearing Sizes
4 Seals
5 De Speeding
6 Thermal Efficiency Thermal Equillibrium : Optimise Cooling
7 Fluids Oil, Coolant , Friction inhibitors
8 Air Induction System Reduced pressure drop
9 Minimise restriction
10 Exhaust System Reduced back pressure
11 Minimise EGR
12 Electric Controls for Water pump
13 Thermostat
14 Turbo
15 EGR
15 Losses reduction / On demand Oil Pump
16 Water Pump
17 Clutch
18 Fuel Pump
19 FAN
20 Alternator
21 Air Conditioning
22 Architectural changes Block, Head, Brackets
23 Reciprocating mass Valves, Push rod,
24 Rotating masses Flywheel, Pulleys , Fan , Drives
12
Optimise power consumption
Weight reduction
Turbo Improvements
Engine
Friction Reduction
Thermal Efficiency improvement
Friction modifiers
Air Induction system
Engine Level
Improvements :
Application Specific
Calibration could give
min. 3 % fuel
Efficiency Improvements.

8. Vehicle
Sl. No. Heading Areas
Rolling Resistance
1 Weight reduction
2 Tyre rolling resistance
3 Tyre Air pressure
4 Bearing Lubrication
5 Skewness of axles
Aerodynamics
6Cd reduction Application specific kit beside basic Cd
Optimised Drive train selection
7Selection of drive train Transmission, Axle ratio
Minimum restriction
8 Air Intake , Exhaust , Fuel system
9 Cooling system
Accessory loads
10Battary Chraging Optimised Accessory load
11 Air conditioning optimisation
12 Air compressor load
Vehicle Parameter optimisation
12Low idle : min Matching drive line / NVH
13Speed zone Possibility of modes
14Driveability On demand power / Eco mode
15 Twin Axle if possible
Vehicle level parameters contributing to FE :

9. • Aero Dynamics : Cd : Co-efficient of drag does matter at
moderate speed 45-50 kmph and above.
• Applications on commercial vehicle calls for further restrictions
which can be answered by specific attachment to reduce drag.
• Mirrors , external attachments contributes to Cd and impact FE
• Cargo size , shape , type impacts drag and hence FE.
Vehicle level parameters contributing to FE :

10. • It is said that good and bad driving habit can impact as high as
up to 30% on fuel efficiency.
• Road conditions and geographical conditions .
• With flexibility available thro’ Electronic common rail engine ,
smart calibration can be answer !!
User Behavior contributing to FE :

11. Way forward :
• Taking stock of situation.
• Brain storm and arrive at ideas.
• Make time plan and compare with parent plan , if any
• All Tests & Validation is very much tedious and costly affair.
• Prepare master idea list and target impact .
• Combine with Base program .