Shaving weight to enhance performance and cut down carbon footprint

To enhance performance and comply with BSIV emission norms DICV did much more than simply fit an exhaust gas after-treatment SCR system to the trucks. So, after adding all the new systems, how DICV managed to price the trucks competitively? Company sources told Auto Components India that every kilogram of steel that is take out of the truck is money. The engineering team at DICV thus indulged in weight shaving even as they added BSIV tech and hardware to the truck. The team went through the entire truck including every nut and bolt to evaluate weight reduction. Over 400 kg worth of weight was shaved to incorporate BSIV hardware.

Depending on the nature of each truck model, the engineering team turned to value analysis where functions of different parts were analysed. Material analysis too was carried out. On the lighter trucks the weight reduction is achieved in between 200-300 kg, the move led to the team choosing materials that would balance cost and weight. Material and design change played a crucial role, but also the non-load bearing members. Claimed the source that the grade of material was improved in such applications, reducing their thickness and in-turn weight. Without sacrificing performance or reliability, the company is said to achieve weight saving through the use of superior grade material. In many application areas, the use of ‘Domex 650’ high strength steel was resorted to. This steel grade is being used by many bodybuilders to build containers in North India, the source claimed. The cost of this steel grade is high, but leads to substantial weight saving. The Domex cold forming steels are also thermomechanically rolled where the heating, rolling and cooling processes are carefully controlled. To increase fuel efficiency, DICV compartmentalised the function of engine and the after-treatment system. SCR was chosen since it reduces the engine effort to meet the tighter emission norms. The chemical process is limited to the after-treatment system. SCR is often looked upon as an advanced active emissions control technology system that injects AdBlue into the exhaust gas stream while the engine is in operation. Reducing (Nitrogen Oxide) NOx emission primarily, the SCR helps to achieve better fuel efficiency by putting hardly any burden on the engine. Engine performance is thus not compromised. NOx flows into the SCR system for reduction reactions to take place in an oxidizing atmosphere. SCR reduces the level of NOx using ammonia as a reducing agent within a catalyst system. For the chemical reaction Diesel Exhaust Fluid (DEF) is used as a reducing agent that reacts with NOx to convert the pollutants into nitrogen, water and less amount of CO2. DEF also enables the engine to use less EGR and higher oxygen levels for better combustion. With the use of SCR, NOx can thus be reduced by up to 90%. The system helps to seek a desirable balance between fuel efficiency and emissions.