11/27/2025

Automotive Vehicles
(BMEE213E)
Module : 7 Vehicle Testing and Standards 5 hours

Venugopal T
Professor
School of Mechanical Engineering

Mudule-7
Module : 7 Vehicle Testing and Standards 5 hours
 Vehicle performance & emission testing: Energy consumption and
emission tests under part load and full load condition of vehicles,
gradeability test, road and track testing methods – testing on chassis
dynamometers, driving cycles.
 Noise, Vibration and Harshness Testing: Standard noise measurement
methods, measurement of vehicle noise- intake and exhaust noise,
combustion noise, mechanical noise, noise from auxiliaries, wind noises,
transmission noises, brake squeal, structure noise.
 Automobile testing standards: Overview and study of testing standards
like; AIS testing standards, Euro Standards, SAE standards. ISO26262
standards.

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Engine Parameters-Energy Balance

Energy Supply

Energy Loss

Unaccounted
Energy Loss

IC Engines-Performance

Input Parameters Parameters to be calculated

 Fuel flow rate (mf)  Indicated Thermal efficiency (ɳ𝒊𝒕𝒉)

 Air flow rate (ma)  Brake thermal efficiency (ɳ𝒃𝒕𝒉)
 Mechanical efficiency (ɳ𝒎)
 Volumetric efficiency(ɳ𝒗 )
 Relative efficiency or efficiency ratio(ɳ𝒓𝒆𝒍 )
 Specific fuel consumption -SFC-(BSFC or ISFC)
Output Parameters  Fuel-air ratio(FAR) or air-fuel ratio (AFR)
 Indicated Mean Effective Pressure (IMEP)
 Torque (T)  Brake Mean Effective Pressure (BMEP)
 Speed (N)  Power density (kW/l)
 Indicated Power (IP)  Heat supply (Qs)
 Brake power (BP)
 Friction power (FP)
 Emissions like HC, NOx,
CO, PM & Smoke

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Heat Balance Test

Vol. Flow

Engine parameters
Fuel-air ratio (FAR)
It is the ratio of mass of fuel to mass of air in the mixture

Air-fuel ratio (AFR)

It is the ratio of mass of air to mass of fuel in the mixture

Specific fuel consumption (S.F.C.)

Mass of fuel consumed per kW developed per hour

𝑚𝑓
S.F.C. = kg/[Link]
𝐵𝑃

where 𝑚𝑓 is mass flow rate of fuel in kg/hr

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Measurement of Fuel Flow

Fuel return
Fuel return
Fuel out
Fuel out
Scale with
Burette

Fuel Pump

Fuel Pump

Weighing Balance
Volume Flow measurement Mass Flow measurement using
using Scale and Burette Weighing Balance

Emission Measurement

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Methods of Measurement

HC - NDIR and FID

CO - NDIR
CO2 - NDIR
NOx - Chemiluminescence,
- Chemical method (self
study)
Aldehyde - FTIR, DNPH

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Origin of Emission Norms

1940
Los Angeles
White or yellow-brown haze
Eyes tear
Smog - "smoke" and "fog,"

Automobile emissions

Carbon monoxide, hydrocarbons, sulphur oxides,

nitrogen oxides, waste heat, and aerosols (liquid
droplets, solid particles, and other various mixtures
of liquids and solids suspended in air).
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Origin of Emission Norms

India
Central Pollution Control Board under the Ministry of
Environment & Forests
USA
United States Environmental Protection Agency
EU
European Union Directive
Japan
Ministry of the Environment
Ministry of Land, Infrastructure and Transport
Ministry of Economy, Trade and Industry
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Indian Emission Standards

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Indian Emission Standards

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Indian Emission Standards

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Indian Emission Standards

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Indian Emission Standards

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Indian Emission Standards

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Indian Emission Standards

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Indian Emission Standards

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Bharat Stage VI
Implemented for vehicles Manufactured after
April 1st 2020 – BS-VI-1(phase 1)

BS-VI-2 (phase 2) – April 1 2023

OBD-On-Board Diagnostic system is must

On-Board Diagnostic
 Circuit continuity for all emission related power
train components (if equipped)
 Distance traveled since malfunction indicator
lamp (MIL) ON
 Electrical disconnection of electronic evaporative
purge control device (if equipped)
 Catalytic converter monitoring
 EGR system monitoring
 Misfire detection
 Oxygen sensor deterioration

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BS-VI and European Fuel Specification

1,3-Butadiene emissions increased with increase in Olefin content

BS IV and VI emission limits for compression

ignition vehicles

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• Category M: vehicles carrying passengers.

• Category N: vehicles carrying goods.
• Category L: 2- and 3-wheel vehicles and
quadricycles.
• Category T: agricultural and forestry tractors
and their trailers.

• [Link]
hp

BS IV and VI emission limits for spark ignition vehicles

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Gradeability Test
 utilized for evaluating wheeled and tracked vehicle
performance on longitudinal and side slopes of varying
degrees of grade.
 evaluating engine, transmission, brake system, and fuel
system performance and vehicle stability and control during
grade and side slope testing.
 The vehicle capabilities for operating on slopes are of
particular interest in conventional and military vehicles; which
must be capable of operating in any tactical situation without
relying on established roadways.
 The evaluation of the gradeability and side slope performance
of a vehicle on calibrated grades provides a means for
determining the adequacy of the equipment, and provides for
an assessment of its tractive effort.

Gradeability Test

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Starting Gradeability

Towing Dynamometer
A Towing Dynamometer (dyno) is an excellent tool to accurately
apply a measured load to a vehicle and to simulate positive or
negative slope while driving around a flat test track. In form, it is
a mechanized trailer that is towed behind the vehicle.

Towing Dynamometers are extremely

efficient tools for testing under real
world conditions taking into account
 frictional losses of the drive train
and the road,
 real world windages
 thermal conditions.

[Link]

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Towing Dynamometer

Drawbar Assembly, Load Cell, Power Supply, Power Absorption Unit (PAU),
Differential, Ballast, Dynamometer Controller

Chassis Dynamometer
 Chassis dynamometer - informally -rolling road
 Mechanical device that uses one or more fixed rollers
 simulate different road conditions within a controlled
environment,
 wide variety of vehicle testing and development purposes

Types :
Based on type of vehicle
 Emissions measurement,
 motorcycles,
 Miles accumulation chassis
 cars,
dynamometer (MACD),
 trucks,
 Noise-Vibration-Harshness (NVH or
 tractors
"Acoustic") Application,
 the size of the roller 25", 48",
 Electromagnetic Compatibility (EMC)
72”
testing, End of line (EOL) tests,
performance measurement and tuning.

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Chassis Dynamometer-Layout

Chassis Dynamometer

[Link]

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Chassis Dynamometer
 It supports tests for various vehicles including four-wheel drive
vehicle, hybrid electric vehicle and electric vehicle, etc.

 Any kind of environment including high temperature, low

temperature, high humidity, low pressure, rain, snow can be
reproduced.

 Various tests including exhaust gas consumption, NVH and

durability are selectable according to the applications.

Noise
Noise is any undesirable sound, usually unpleasant
in nature. Vehicle interior noise is a combination of:
 engine noise
 road noise
 intake noise
 exhaust noise
 aerodynamic noise
 noise from components and ancillaries
 brake noise
 squeaks and other noises

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Noise
Noise or vibration usually originates from outside, interacting with the vehicle
structure in some way (and possibly hence with other noise sources) and then
producing radiated sound inside the compartment. This process is illustrated
in Figure. The interaction with the structure can be either as:
 An airborne noise path – airborne noise from outside the passenger
compartment leaking in to cause airborne noise inside.
 A structure-borne noise path – vibration from outside causing the surfaces
of the passenger compartment to vibrate and radiate noise.
 Direct airborne noise paths are found where there is a lack of sealing
between the interior and the exterior environments (around door seals,
grommets in the bulkhead, etc.).
 Indirect airborne noise paths are found when airborne noise outside
impinges on the surfaces of the passenger compartment, causing them to
vibrate and radiate noise inside.
 The interaction between the noise source and the structure has a filtering
effect on the final interior noise level (see Fig.). For instance, in the case of
indirect.

Noise

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Noise-Vibration- Harshness (NVH)

 Noise is any undesirable sound, usually unpleasant in nature.
 Vibration is any motion, shaking or trembling, that can be felt or
seen when an object moves back and forth or up and down.
 Harshness is a ride quality issue where the vehicle's response to
the road transmits sharply to the customer. Harshness normally
describes a firmer than usual response from the suspension
system.
 Vibration isolators, mufflers and dampers reduce these to
acceptable levels.
 A driver who is unfamiliar with a vehicle can think that some
sounds are abnormal when actually the sounds are normal
for the vehicle type.

Amplitude:
The quantity or amount of energy produced by a vibrating component . An extreme
vibration has a high amplitude. A mild vibration has a low amplitude.
Boom:
Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Buffet/Buffeting:
Strong noise fluctuations caused by gusting winds. An example would be wind gusts
against the side glass.
Buzz:
A low-pitched sound like that from a bee. Often a metallic or hard plastic humming
sound. Also describes a high-frequency vibration. Vibration feels similar to an electric
razor.
Chatter:
A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp:
A short-duration, high-pitched noise associated with a slipping drive belt.
Chuckle:
A repetitious, low-pitched sound. A loud chuckle is usually described as a knock.

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Main Sources of Vehicle Noise

intake and exhaust noise,
combustion noise,
mechanical noise,
noise from auxiliaries,
wind noises,
transmission noises,
brake squeal and
structure noise

Measurement of Vehicle Noise

• Noise is measured in frequency and amplitude using
decibels (DdB) and Sound Level Meters.
• amplitude of noise- can identify the precise force or
energy of the sound wave and the intensity of noise.
• pitch or frequency of noise - in hertz (Hz).

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Measurement of Vehicle Noise

• Sound Level Meters such as condenser microphones - acoustic
measurements.
• The instrument required for noise measuring will vary dependent
on the environment in which the noise occurs.
• noise dosimeters -noise in work and office buildings
• noise monitors -noise, vibration and harshness (NVH) studies in
which environmental noise such as cars and lorries are analyzed.

Measurement of Vehicle Noise

Noise Dosimeter:
 A noise dosimeter - specialized type of sound level meter -to measure
personal noise exposure levels
 Place where it isn’t safe or practical to use a full-sized sound level
meter, such as in areas with a high fire risk or in confined spaces.
 noise dosimeters are light and unobtrusive -people can wear them and
carry on with their work unhindered
 Sound pressure or acoustic pressure is the local pressure deviation
from the ambient (average or equilibrium) atmospheric pressure,
caused by a sound wave
 In air, sound pressure can be measured using a microphone, and in
water with a hydrophone. The SI unit of sound pressure is the pascal
 To find out the direct noise exposure of an employee

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Measurement of Vehicle Noise

Sound Level meter

SLM- generate electric signals proportional to the sound pressure and, via a frequency
correction circuit, displays A-weighted sound pressure levels.

Sound level meters (Class 1& 2)

Class 1 (precision)
Class 2 (standard)

Level linearity error (dB)

±0.8 (±0.5) ±0.6 (±0.3)
(in input level change of 10 dB or less)
Level linearity error (dB)
±1.4 (±1.1) ±1.1 (±0.8)
(Other than the above)
Frequency range (Hz) 20 to 8 kHz 16 to 16 kHz

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Types of equipment used in the testing of

NVH
• Analyzers are electronic devices which can quantify and
assess noise and vibration. Many of these devices are
portable.
• Shakers and controllers provide signal analysis and control of
vibrational noise. Shakers can be built for a range of different
vibrational forces from small (25lbf) to very large (1000lbf).
• Noise dosimeters are specialized sound level meters intended
to measure exposure of a person to noise over time.
• Electromagnetic acoustic transducers (EMATs) are
transducers for non-contact sound generation and reception
using electromagnetic mechanisms.
• Dynamometers measure force, moment of force, or power. In
the case of NHV testing, dynamometers simulate motors and
other mechanical devices to test vibration and noise
characteristics.

Types of equipment used in the testing of

NVH
• Sound level meters are devices used to measure sound
pressure levels. They are used for quantification of almost any
noise in noise pollution studies.
• Microphones are recording devices that can be used to test
noise and sound levels from most sources.
• Accelerometers Static force applied on the sensor due to
gravity → tilt/orientation detection, Force/acceleration
exerted upon the sensor → movement / force detection
• Analysis software includes all computer programs and tools
that provide interface and allow manipulation of outputs from
recorded and testing devices.

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Methods of sound level measurement

1. pressure measurements in the far field

2. pressure measurements in the geometric near
field
3. intensity measurements
4. surface vibration velocity measurements

Interior noise- Measurement procedure

(ISO 5128 – 1980) - BS 6086
 The measurement of noise levels at more than one location, and at least
at the driver’s ear position and one point at the rear of the vehicle.
 Microphones to be horizontal and pointing with their direction of
maximum sensitivity in the direction that an occupant would normally be
looking.
 Microphones to be no closer than 0.15 m to walls or upholstery.
Microphones should be mounted in such a way as to be unaffected by
vibrations of the vehicle.
 Tests shall be carried out with the vehicle being stationary (at idle and at
full engine speed, held for 5 seconds), at various steady speeds in the
range of 60–120 km/hr, and with full-load acceleration from 45% of the
maximum power speed to 90% of the maximum power speed with the
transmission in the highest position without exceeding 120 km/hr.
 Many practitioners make full load accelerations from near idle to near
maximum engine speed in both second and third gears as their standard
interior noise acceleration tests.

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Engine noise
Engine noise is the sum of two elements:
1. combustion noise
2. mechanical noise.

 mechanical noise -engine noise -by spark ignition (gasoline)

engines
 combustion noise - engine noise - by compression ignition
(diesel) engines

Engine noise is dependent on

 engine speed
 engine load

Combustion Noise

Normal combustion Abnormal combustion or knocking

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Combustion Noise

Effect of engine speed on cylinder pressure spectra. NA-DI diesel engine at full load

Mechanical noise
 The crank mechanism (pistons, [Link], crankshaft, bearings)
experiences externally applied forces due to gas forces and
internally generated forces due to its own inertia.
 Piston slap noise increases with engine speed. It also
increases with turbocharging.
 It is mostly controlled by reducing clearance between the
piston and the cylinder-liner.
 Other sources of mechanical noise include:
– timing drive;
– valve train;
– fuel injection equipment.

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Engine noise
 Difficult to measure directly

 measure sound pressure level at specified locations around the engine

and use this for rating engine noise

 The engine is tested either outdoors in a flat, open space or in an

acoustically treated test cell that replicates the outdoor environment
(commonly a semi anechoic cell with large sound-absorbing wedges on
the walls and ceiling and a flat concrete floor).

 The engine is either tested in its bare state (with just enough equipment
to run – pumps and manifolds are fitted but the intake/exhaust noise is
ducted away) or in its fully equipped state (everything fitted including
ancillaries and sometimes full intake and exhaust systems).

 The engine is tested at the maximum power point, at the maximum

torque point, at the point of maximum speed but minimum load and also
at idle.

Semi anechoic cell

Semi-anechoic chamber (SAC):

A shielded enclosure whose internal walls and ceiling
are lined with material that absorbs electromagnetic
energy in the frequency range of interest but whose
floor is truly flat and reflective.

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Aerodynamic Noise
 Aerodynamic (wind) noise - travelling at higher speeds.
 Aerodynamic noise- Aerodynamic excitation of
‘greenhouse surfaces’ on the car (the glass-work and the
roof panel) causing
 Airflow over the underside of the vehicle causing
transmission of airborne sound to the interior, particularly
in the wheel-arch areas.
 Noise transmission through door and glass seals due to
aspiration (leakage) or due to aerodynamic excitation of
doors and glass caused by disturbed airflow over the seals.
 Cavity flows through partially open windows and sunroofs
causing intense low-frequency (below 25 Hz commonly)
noise and buffeting.

Scanning and Multipoint Vibrometer

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Brake Squeal
 Small piece of soft metal- wear indicator- in the brake
pad.
 Brake pad wears to a certain level- wear indicator
begins to rub against the brake rotor -squeaking noise.
 This acts as a warning and indicates your brakes pads
need changing.
 Reasons of Brake squeal
1. Worn or thinning brake pads
2. Dust or debris between your pads and rotors
3. Overnight moisture
4. Personal braking style
5. Lack of lubrication on drum brakes

Brake squeal noise test

 The brake noise -poor customer satisfaction - high
warranty costs
 Brake systems with minimum noise issues desirable
 Brake noise is a very complex problem
 Brake dynamometer- squeal noise test
 Make sure that the brakes will be in the best possible
state when it comes to brake squeal
 It is performed in a noise, vibration and harshness
(NVH) brake dynamometer according to SAE J2521.
 Brake squeal is defined to be between 1 - 17 kHz

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Brake squeal noise test-procedure

 The complete brake system is mounted in a fixture containing a
vehicle corner, i.e. ¼ of the full chassis with suspension.
 Several thousands of brake conditions are tested, among others at
different wheel speed, brake pressure, rotor temperature, various
environmental conditions and brake wear to mention a few.
 A measurement microphone records the brake squeal.
 Accelerometers register vibrations for correlation to the noise.
 3D laser vibrometer or acoustic cameras are sometimes used for
root cause investigations.
 In the case of brake squeal noise exceeding acceptable levels, this
test can be used for testing a range of different brake components.
 This includes modifications of the brake pads, the lining material
composition, pad design, adding shims, mass loading and damping
or modification of the rotor or caliper, including mass loading of the
caliper.

Brake squeal noise test

 Chamfering the ends and/or adding slots to ‘tune’ the

pad that leads to less noise.
 Chamfers and slots change the natural frequency at
NVH Squeal Rig Dynamometer which the pad oscillates,
 It runs quieter than a pad which lacks these features.

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Automobile testing standards

AIS testing standards - Automotive Industry Standards,
the technical automotive standards for India
Euro Standards –European Union countries standards-
Enhanced environmentally friendly vehicle (EEV) -"clean
vehicle"
SAE standards-Society of Automotive Engineers standards
were developed for automotive, aerospace and
commercial vehicles (all over the world)
ISO26262 standards- ensures that a high level of safety is
built into car components from the start. It provides
guidance for the entire automotive safety lifecycle, from
overall risk management to individual component
development, production, operation, service, and
decommissioning

Automotive Industry Standards (AIS)

 AIS stands for Automotive Industry Standards, the technical automotive
standards for India. These are based on the UNECE (United Nations
Economic Commission for Europe) standards.
 AIS certification was introduced in 1989 with the adoption of the India
Central Motor Vehicles Rules (CMVR). In the CMVR, rules and regulations
are published, among other things, in relation to the approval of vehicles,
traffic controls or the production and maintenance of motor vehicles.
 The Automotive Industry Standards (India AIS) are issued by the Ministry
of Road Transport and Highways (MoRTH), which is the ministry
regulating the automotive sector in India.
 TAC is the abbreviation for Type Approval Certificate. TAC is issued for
products that need to meet special technical and safety requirements.
 TAC approval must be obtained before the product is introduced to the
market. The Ministry of Road Transport and Highways is responsible for
issuing the certification.
 Conformity of Production (COP) Certification-as Conformity of Production
refers to the testing of quality assurance in production, one of the most
important steps in the AIS certification process.

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Indian Certification Authorities

AIS certification
There are three certification authorities in India that conduct
the AIS certification. These are:

– International Centre for Automotive Technology (iCAT)

– Automotive Research Association of India (ARAI)

– Automotive Component Manufacturers Association of India

(ACMA)

website: [Link]

Components in AIS certification

Phase 1 – Beginning April, 2009:
•Safety Glass Technical Standard IS 2553
•Brake Hose Technical Standard IS 7079
•Horn Technical Standard IS 1884
•Tire Technical Standard IS 13154
•CNG Regulator Technical Standard ISO 15500
•LPG Vaporizer & Regulator Technical Standard ECE R 67

Phase 2 – Beginning October, 2009:

•Bulb Technical Standard AIS 034

•Speed Limiting Devices Technical Standard AIS 001
•Seat Belt Technical Standard IS 15142
•Wheels (M/N Category) Technical Standard IS 9436/IS 9438
•Luminaires (M/N Category) Technical Standard AIS 012
•Retro Reflectors (M/N Category) Technical Standard AIS 057
•Warning Triangle Technical Standard AIS 022

More components-refer:
[Link]

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Euro Standards
Vehicle inspection
A properly maintained and fully functioning vehicle meeting all safety requirements
is less likely to be involved in a road accident.
Roadworthiness checks not only make sure your vehicle is working properly, they are
also important for environmental reasons and for ensuring fair competition in the
transport sector.
There are 2 types of assessment:
– on-the-spot roadside inspections and
– periodic checks, where owners have to take the vehicle to a specialist centre.

• Under EU law, unannounced roadside inspections of commercial vehicles can be

carried out in any EU country, whether or not the vehicle is registered in the EU.
• These checks cover brakes, emissions and the vehicle's overall condition. Drivers
may also be required to produce recent inspection reports or proof the vehicle has
passed the mandatory roadworthiness test.
[Link]
vehicles/vehicle-inspection_en
[Link]

SAE Standards
SAE International is the world’s leading authority in mobility
standards development. The design of safety, productivity,
dependability, efficiency, and certification is better with
standards.

Standards for Ground Vehicles

[Link]

Search for SAE Standards

[Link]

Standards Under Development

[Link]

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ISO26262 standards

ISO26262 standards- ensures that a high level of

safety is built into car components from the start. It
provides guidance for the entire automotive safety
lifecycle, from overall risk management to
individual component development, production,
operation, service, and decommissioning
Reference website
[Link]
[Link]
tandards

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