A REPORT ON Power Performance Measurement Of TWO WHEELERSBYRitwik Sahoo Vikram Bhansali Digvijay Verma 2009A4PS281G 2009A4PS265G 2008B4AB717P

AT HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD MANESAR A PRACTICE SCHOOL 1 STATION OF

BIRLA INSTITUTE OF SCIENCE AND TECHNOLOGY, PILANIJULY, 2011

[1]

A REPORT ON Power Performance Measurement of TWO WHEELERSBY RITWIK SAHOO VIKRAM BHANSALI DIGVIJAY VERMA 2009A4PS281G 2009A4PS265G 2008B4AB717P

Prepared in partial fulfillment of the Practice School I Course No. BITS C221 ATHONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD MANESAR

A PRACTICE SCHOOL 1 STATION OF

BIRLA INSTITUTE OF SCIENCE AND TECHNOLOGY, PILANIJULY, 2011

[2]

List of ContentsCertificate and Acknowledgement Executive Summary Introduction to HONDA HMSI Vision Introduction to Engineering Quality Major Components of Emisssion Lab Chassis Dynamometer Emission Analyzer Principles of Measurement and Analysis of Gaseous Emissions Various Activities of EQ Annexure 4 5 6 8 10 12 12 13 14 16 18

[3]

CERTIFICATE This is to certify that this project report is submitted by Mr. Ritwik Sahoo, Mr. Vikram Bhansali and Mr. Digvijay Verma to BITS Pilani University is a bonafied record of work carried out by them under my supervision.Date:Ritwik Sahoo Vikram Bhansali Digvijay Verma SIGN: Mr. Abhishek Gupta HOD, EQ

ACKNOWLEDGEMENTWe are grateful to Mr. Abhishek Gupta, DM ,Head of Department - EQ, HMSI for giving me this opportunity to gain experience at the organization and for giving me invaluable guidance right at start. I extend my gratitude to Mr. Dhananjai Dabral and Mr Vipul Bhatia without the help of whom; this report would not have been possible. I would also like to thank Mr. George, Mr. Amrinderpal, Mr.Ashish Negi for their help they have given me to complete my project. I would also like to thank Mr. William Joe, my PS- I Instructor from BITS Pilani, for being a constant source of guidance for me. Ritwik Sahoo Vikram Bhansali Digvijay Verma[4]

BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE PILANI (RAJASTHAN) Practice School Division

Executive SummaryStation: Honda Motorcycles and Scooters India Pvt Ltd Centre: Manesar Duration: From: 23rd May 2011 Till: 30th June, 2011 Date of Submission:1st July, 2011

Title of the project POWER PERFORMANCE MEASUREMENT OF TWO WHEELERS Guide: Mr. ABHISHEK GUPTA Designation: Dy. Manager, Engineering Quality PS Faculty: Mr. William Joe Keywords: Power, Performance, Fuel Economy, Emission, Chassis Dyno, Analyser

AbstractThis project report aims at the study of the components of Emission Lab and their working principles. The various performance tests like Power Test, HHML FE Test Vmax Test, M/E Test etc are correlated to the theoretical concepts. It shows the similarities and dissimilarities between theoretical and practical approaches of the performance and quality check for two wheelers.

Signature of Faculty

Signature of Student

Date: 1st July, 2011

[5]

HONDA MOTORCYCLES AND SCOOTERS PVT. LTD. (HMSI)

Honda Motorcycles and Scooters India Pvt. Ltd. (HMSI), a wholly owned subsidiary of Honda Motor Company Ltd. was incorporated on 20th August 1999 to manufacture two wheelers in India. Its Symbol wings is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in the lifestyle of the people of India. It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards. Hondas commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions. Ever since its establishment in 1999, HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people. In a short span of ten and half [6]

years, HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India. While endeavoring to meet and exceed the expectations of the customers, the critical importance to providing the product, technology and service that not only benefits the customer but also the society in areas such as environment preservation and riding safety is also realized. It is believed at HMSI that by meeting these expectations, HMSI will enhance the quality of life through products and services that reflect the spirit of today. Bringing joy to people and contributing to social development will continue to be the principles that will guide HMSI in future. It came into mass production with Honda Activa in 2001. Since then, the company has continued to grow in the Indian market along with regularly providing world class, advanced and technically sound products. Living up to its illustrious line age of excelling in the manufacture of two wheelers of global quality, HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Eterno, Dio, Unicorn and Shine. Apart from outstanding sales, Honda also caters its customers with excellent service and spare parts support. The HMSI factory is spread over 52 acres, with a covered area of about 85,815 square meters at Manesar, Gurgaon district of Haryana. The foundation stone for the factory was laid on 14th December 1999 and the factory was completed in January 2001. The initial installed capacity was 100,000 scooters per year, which has reached 6,00,000 scooters by the year by 2007 and motorcycle capacity shall be 4,00,000 per annum. The total investment outlay for the initial capacity was Rs. 215 crores and now the accumulated investment is 800 crores. HMSI mainly deals with: Manufacturing and sales of two wheelers. Manufacturing and sales of two wheelers engines. Service and sales of spare parts and accessories. Export of Honda products (CBU, Engine & Parts).

[7]

HMSI VISION:

HONDA LOGO:

2.3 HONDA GLOBAL NETWORK:

Honda has 5 operating regions and 1 R& D centre Honda Motor Corporation Limited, Japan Honda North America Incorporation, USA Asian Honda Motor Corporation Limited, Thailand Honda R&D, China Honda Motor Limited Association, Brazil Honda Motor Europe Limited, UK

HONDA OPERATION IN INDIA:

Honda Motor Company, Japan with its headquarters in Tokyo, has manufacturing operations in 32 countries with 109 production bases. The company principal of Honda Worldwide is dedication to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction. It has three business divisionsnamely 2-wheelers, 4-wheelers and power products. Apart from HMSI that manufactures 2-wheelers, the other business [8]

divisions in India include Honda Siel Cars India Limited (HSCI) and Honda Siel Power Products Limited (HSPP) 1. HMSI Factory at Manesar, Gurgaon:

The HMSI factory is spread over 52 acres, with a covered area of about 85,815 square meters at Manesar, Gurgaon district of Haryana. The foundation stone for the factory was laid was 100,000 scooters per year, which has reached 6, 00,000 scooters by the year by 2007 and motorcycle capacity shall be 4,00,000 per annum. The total investment outlay for the initial on 14th December 1999 and the factory was completed in January 2001. The initial installed capacity was Rs. 215 crores and now the accumulated investment is 800 crores.

[9]

Introduction to Engineering Quality

Honda is world renowned for its Quality, one point out of many which separates it from rest. Engineering Quality is one of the most important departments of HMSI. It is an vital part of the Organization since it helps maintain the quality of Honda two wheelers with an engineering aspect. The Quality of vehicles includes the following aspects: Performance, Durability and Machinability. It mainly deals with performance tests of two wheelers and also the working of Emission Lab. Fuel Economy

Emission

Performance

Power

Accelaration

[10]

MAJOR COMPONENTS OF EMISSION LAB

Chassis DynamometerA chassis dynamometer measures power delivered to the surface of the "drive roller" by the drive wheels. The vehicle is often parked on the roller or rollers, which the vehicle then turns and the output is measured. Chassis dynos can be fixed or portable. Modern chassis dynamometers can do much more than display RPM, horsepower, and torque. With modern electronics and quick reacting, low inertia dyne systems, it is now possible to tune to best power and the smoothest runs, in real time. Emissions development and homologation dynamometer test systems often integrate emissions sampling, measurement, engine speed and load control, data acquisition, and safety monitoring into a complete test cell system. These test systems usually include complex emissions sampling equipment (such as constant volume samplers or raw exhaust gas sample preparation systems), and exhaust emissions analyzers. These analyzers are much more sensitive and much faster than a typical portable exhaust gas analyzer. Response times of well under one second are common and required by many transient test cycles. Because of frictional and mechanical losses in the various drivetrain components, the measured rear wheel brake horsepower is generally 15-20 percent less than the brake horsepower measured at the crankshaft or flywheel on an engine dynamometer.

[11]

Principle:

Road Load Equation.

The behavior of a vehicle under road conditions is described by road load equations (RLE). The RLE is a fundamental requirement of a true chassis dynamometer which has to resist the torque being produced at the vehicle drive wheels in such a way as to simulate real-life resistance to vehicle motion. It is necessary to have a clear understanding of this control model before studying the various types of machines coming under the heading of chassis dynamometers or rolling roads. The RLE is the formula that calculates the change in torque required with change of vehicle speed in order to simulate the real-life performance of a given vehicle; it defines the traction or braking force that is called for under all possible conditions, which include steady travel at constant speed on a level road; hill climbing and descent; acceleration, over-run and braking; transitions between any of the above; effects of atmospheric resistance, load, towed load, tyre pressure, etc. The road load equation for a given vehicle defines the tractive force or retarding force, F (Newton), that must be applied in order to achieve a specified response to these conditions. It is a function of the following parameters: 1. Vehicle specific: Mass of vehicle M kg Components of rolling resistance a0 N Speed dependent aV N Aerodynamic bV2 N 2. External: Speed V m/s

The usual form of the road load equation is:

F = Mg +aV+bV2+MdV/dtwhere M dv/dt = force to accelerate/brake vehicle Components of Chassis Dynamometer Roller Cooling fan Exhaust fan Fly wheel

[12]

Emission AnalyserEmissions of many air pollutants have been shown to have variety of negative effects on public health and the natural environment. Emissions that are principal pollutants of concern include:

Hydrocarbons - A class of burned or partially burned fuel, hydrocarbons are toxins and are a major contributor to smog, which can be a major problem in urban areas. Prolonged exposure to hydrocarbons contributes to asthma, liver disease, and cancer. Regulations governing hydrocarbons vary according to type of engine and jurisdiction; in some cases, "non-methane hydrocarbons" are regulated, while in other cases, "total hydrocarbons" are regulated. Carbon monoxide (CO) - A product of incomplete combustion, carbon monoxide reduces the blood's ability to carry oxygen; overexposure (carbon monoxide poisoning) may be fatal. Nitrogen oxides (NOx) - Generated when nitrogen in the air reacts with oxygen at the high temperature and pressure inside the engine. NOx is a precursor to smog and acid rain. NOx is a mixture of NO and NO2. NO2 destroys resistance to respiratory infection.

The two wheelers are tested for THC, CO and NOx as per the Emission Norms set by Government of India. The emission norm prescribed for Indian two wheelers is followed as per BSIII according to which the : HC + NOx CO 1.0 g/ km 1.0 g/ km

[13]

Principles of measurement and analysis of gaseous emissionsNon-dispersive Infrared Analyzer (NDIR): It is called non-dispersive because all the polychromatic light from the source passes through the gas sample before going through a filter in front of the sensor, whereas dispersive instruments, found in analytical laboratories, filter the source light to a narrow frequency band before the sample. The CO2 molecule has a very marked and unique absorptance band of infrared (IR) light that shows a dominant peak at the 4.26_m wavelength which the instrument sensor is tuned to detect and measure. By selecting filters sensitive to other wavelengths of IR, it is possible to detect other compounds such as CO and other hydrocarbons at around 3.4_m . Note that the measurement of CO2 using an NDIR analyser is cross-sensitive to the presence of water vapour in the sample gas.

Chemiluminescence detector (CLD) Chemiluminescence is the phenomenon by which some chemical reactions produce light. The reaction of interest to exhaust emissions is NO + O3

NO + O NO + O + photon2 2 2 2

The nitrogen compounds in exhaust gas are a mixture of NO and NO2, described as NOx. In the detector, the NO2 is first catalytically converted to NO and the sample is reacted with ozone which is generated by an electrical discharge through oxygen, at low pressure in a heated vacuum chamber. The light is measured by a photomultiplier and indicates the NOx concentration in the sample.[14]

Flame Ionization Detector (FID) The FID has a very wide dynamic range and high sensitivity to all substances that contain carbon. The operation of this instrument shown schematically in Fig. 16.7 depends on the production of free electrons and positive ions that takes place during the combustion of hydrocarbons. If the combustion is arranged to take place in an electric field, the current flow between anode and cathode is closely proportional to the number of carbon atoms taking part in the reaction. In the detector the sample is mixed with hydrogen and helium and burned in a chamber which is heated to prevent condensation of the water vapour formed.

[15]

Various activities done in Emission Lab are :1. Sampling for Vehicles: The vehicles are taken from the mass production. They undergo a series of tests: a. Accustom : The vehicle is made to run for 150 km. b. Soaking : The vehicle is soaked in an cool environment for 6 to 30 hours in soak room as per government norms. c. Pre-Checking : The physical testing of minor components are done such as tyre pressure, brakes, clutch, throttle etc. d. Mounting : The vehicle is mounted on the chassis dynamometer. The front wheel is clamped and the rear wheel is put on the roller of the dynamometer. Depending on the distance between the front and the rear wheel mounting differs from vehicle to vehicle. e. CVS Connection : Control Volume Sampling connection is done for emission Test. 2. Mass Emission (M/E) Test :

M/E Type I IDC Type II IDLE

IDC: It is an acronym for Indian Driving Cycle. This cycle is used for all domestic vehicles. For export vehicles other cycles are followed. For domestic vehicles BS III emission limit is followed while for export vehicles, Euro emission limits are followed. 3. Hero Honda Motorcycle Ltd. (HHML) Test: This is a fuel economy test. HHML driving cycle is followed in Honda. This cycle varies from company to company.

[16]

4. Power Test:: This test measures the power available at the wheels. The vehicles speed is varied from minimum to maximum at full throttle and the power delivered at the wheels is measured. The power obtained is checked against the specifications .

5. New Model / Trial Events: The new model vehicle undergoes a series of trials T1 and T2 and then preproduction PP1 and PP2 before finalizing it for Mass Production. The tests mentioned for Sampling Vehicles are also done for them. New Models are also tested for Vmax and constant speed fuel economy and acceleration. 6. Competitor Vehicles: The Research and Development Department gets the vehicles of other companies from their respective dealers for testing against their own vehicles of same cubic capacity. 7. II source: Whenever a vendor is not able to meet the demands of the company, the company takes the help of other vendors products to meet their requirements. It finally compares all the vendors products and chooses the best one for Mass Production.

[17]

AnnexureMethods of collecting information Desk Review Personal Observations Focus Group Differentiation Equipment Manuals E-book- Engine Testing by A J Martyr Internet-www.wikipedia.org

List of persons contacted Mr. Abhishek Gupta, Head of Department Mr. Dhananjay, Head of section Mr. Vipul Bhatia, Executive Mr. Amrinderpal Mr. George Mr. Ashish Negi Mr. Monu Mr. Ashok Mr. Virender Mr. Robin Guleria

[18]

RITWIK SAHOO| 2009A4PS281G DOB: 7th February, 1992 Gender: Male Mob: +91 9654606479 Email: ritwiksahoo@gmail.com

Objective To secure a rewarding career in an organization that enables me to utilize my good communication skills, man and technical knowledge in an enriching environment. . Experience Street Art Painting which requires technical as well as creative thinking and art skills Took computer night classes for mess workers for one semester Manager of a 3 day workshop Fuel Cell Development, in Quark 2011 where I managed a team of five. Manager of a 2-day workshop Adobe Flex Workshop, Quark 2010. Held the responsibility for holding the 2011 and 2010 Campus Elections Came 12th Position in Full Throttle competition in Techfest 2011,IIT Bombay. Currently Events Head for Quark 2012. Currently interested and studying in the field of Computational Fluid Dynamics.

Educational Qualifications Key Skills

CBSE X BoardExam CBSE XII Board Exam BE(hons) Mechanical Engineering

92.2% 87% 7.76(CGPA)

Proficient in Engineering Drawing and Engineering graphics. Languages: C ,Java, Python, PHP Softwares: Intimate -Netbeans, Matlab, Pro E, Catia, Autodesk Maya 2011, Autodesk 3DS Max 2011, AutoCAD PSPICE, Microsoft Office, ANSYS Familiar - Adobe Photoshop, Fireworks, Flash, Dreamweaver, After Effects OS- Ubuntu, Windows Technical Art Direction Efficient Managerial Skills Social Media Marketing 3D Modeling Artist Mathematical and Analytical skills

Positions of Responsibility/Honour

Events Head, Quark 2012 (2011- till date) Member, Department of Controls Quark (2009-2011) Member, Election Commission (2010-till date) Member, Arts and Deco (2009-2011) Member, Computer Graphics Club (2010-till date) Member, Abhigyan (2009-2010)

Interests and Hobbies

Computational Fluid Dynamics Animation and Computer Graphics Volleyball and Badminton Math Programmer Reading novels and Listening to Music

[19]

VIKRAM BHANSALI| 2009A4PS265G

DOB: 15th august, 1990 Gender: Male

Mob: +91 9657282379 Email: vbhansali7@gmail.com

Objective To secure a rewarding career in an organization that enables me to utilize my good communication skills and technical knowledge in an enriching environment. . Educational Qualifications Key Skills

SSC X Board Exam (AP) Vizag INTERMEDIATE Board Exam (AP) Vizag BE(hons.) Mechanical Engineering

2007 2008-09 CGPA

91% 97.4% 8.18

Vidyodaya High School Sri Chaitanya Junior College BITS Pilani Goa Campus

Auto-cad , C programming, PSPICE, MS Word, MS Excel Efficient Managerial Skills Mathematical and Analytical skills

Positions of Responsibility/Honour

Member of DOFAM(DEPARTMENT OF FINANCE & ASSET MANAGEMENT) 2nd Topper of Andhra Pradesh inter 1st year board exam Has done a computer project on CHAOS GAME in MATLAB

[20]