Product Development

Project

NAME: N. LIKHITESH REDDY

ROLL NO: 121ME0993

 PROBLEM STATEMENT

 Conventional Internal combustion engines have a high environmental impact due to their fuel
consumption and emissions.
 To design and implement a solution that improves the performance and efficiency of internal
combustion engines while reducing their environmental footprint.
 To use innovative technologies and design modifications that enhance the engine’s combustion
process, optimize its fuel usage, and minimize its emissions.

Fish Bone Diagrams: Environmental

Infectious
agents
1. factors

Health
Diseases

Disorders Lifestyle factors Genetic

Factors
 Climate Air
Change Pollution
s
2.

Environmental
factors

Waste Mis- Water

Management Contamination

3. Natural Vehicle
Urbanization Sources Emissions

Air Pollution
Factors

Industrial Traffic and

Vehicle
Activities Congestion
Operations &
Maintenance
 IDEA GENERATION
IDEA 1:
Integrate hybrid technology or electrification components to enable the IC engine to operate more
efficiently, utilizing electric power during low-loa conditions and reducing overall fuel consumption.
Source: From the website of ‘frontiers news’.
IDEA 2:
Implement precision fuel injection systems with intelligent control algorithms to optimize
combustion, resulting in improved fuel efficiency and lower emissions
Source: From the website of ‘Diesel Net’ and ‘The Insight Partners’.
IDEA 3:
Develop advanced emission control systems, such as catalytic converters or particulate filters, to
significantly reduce harmful pollutants emitted by IC engines.

Source: From the website of ‘Man Energy Solutions’.

IDEA 4:
Implement innovative technologies to capture and utilize waste heat generated during engine
operation, converting it into additional power or improve overall energy efficiency.

Source: From the website of ‘ScienceDirect’.

IDEA 5:
Ensure the adaptability of the enhanced IC Engines to accommodate renewable and alternative fuels,
promoting a transition to more sustainable energy sources.

Source: From the website of ‘National Renewable Energy Laboratory’.

IDEA 6:
Implement EGR systems to recirculate a portion of exhaust gases back into the engine, reducing
combustion temperatures and Nitrogen oxide emissions.

Source: From the website of ‘Perkins.com’.

EVALUATION OF IDEAS:
The parameters taken to evaluate the ideas are cost, environmental impact, efficiency
improvement, adaptability to existing infrastructure.

Parameters Cost of Environmental Efficiency Adaptability to Total

Implementations Impact Improvement Infrastructure
Weightage 0.2 0.3 0.3 0.2 Out of 10

Idea - 1 6 8 9 7 7.7

Idea - 2 7 9 8 8 8.1

Idea - 3 8 9 9 7 8.4

Idea - 4 6 8 7 7 7.1

Idea - 5 8 9 8 7 8.1

Idea - 6 6 8 7 7 7.1
Since Idea-3 got highest evaluation, Idea-3 is selected for product development.

MORPHOLOGICAL ANALYSIS
 Morphological analysis is conducted to identify and combine various potential configurations of
components and features for implementing the chosen idea of Emission control systems into a
product.
 The chosen idea would require integration of various systems and functions to effectively implement
it into a product.
 Functions/subsystems listed:
1. Emission Reduction Technology
2. Monitoring System
3. Materials Used
4. Integration with Engine
5. Maintenance Approach
6. Fuel Efficiency Improvement
MORPHOLOGICAL MATRIX:
Alternative (A) Alternative 1 Alternative 2 Alternative 3 Alternative 4
Function (P)
Emission Reduction Three Way Catalytic Diesel Particulate Exhaust Gas Selective Catalytic
Technology converter (TWC) Filter (DPF) Recirculation (EGR) Reduction (SCR)

Monitoring System On-Board Lambda (Oxygen) Nitrogen Oxides Particulate Matter

Diagnostics – II Sensor (NOx) Sensor (PM) Sensor
(OBD - II)
Materials Used Ceramic Substrate Silicon Carbide (SiC) Cordierite

Integration with Direct Fit Universal Fit Engine Specific Fit

Engine

Maintenance Scheduled Servicing Self-cleaning System Wear and Tear

Approach Indicator

Fuel Efficiency Lean Burn VVT (Variable Valve Cylinder Direct Fuel Injection
Improvement Technology Timing) Deactivation

From the above matrix, Total possible products = 4 * 4 * 3 * 3 * 3 * 4 = 1728

TOTAL POSSIBLE PRODUCTS:

1. P1 = P1A1 + P2A1 + P5A1 + P3A1 + P4A1 + P6A1

2. P2 = P1A2 + P2A2 + P5A2 + P3A2 + P4A1 + P6A2
3. P3 = P1A3 + P2A3 + P5A3 + P3A1 + P4A1 + P6A3
4. P4 = P1A4 + P2A4 + P5A1 + P3A3 + P4A1 + P6A4
5. P5 = P1A1 + P2A2 + P5A2 + P3A3 + P4A1 + P6A3
6. P6 = P1A2 + P2A3 + P5A3 + P3A2 + P4A1 + P6A1
PARAMETERS FOR PRODUCT EVALUATION:

1. Cost
2. Time to react
3. Life Period
4. Maintenance
5. Complexity
6. Energy Performance
EVALUATION MATRIX:

Product Cost Time to react Life Period Maintenance Complexity Energy Total
Performance

Weightage .25 .125 .125 .125 .125 .125 Out of 10

P1 5 7 5 6 9 7 6.3

P2 6 8 7 5 7 8 6.8

P3 8 7 7 6 8 9
8

P4 2 8 5 6 5 6 5.1

P5 4 6 8 5 4 7 5.6

P6 3 5 6 8 3 5 4.8
JUSTIFICATION:
 COST: Given the total importance of cost-effectiveness in practical implementation, assigning a
higher weightage ensures that the solution remains economically viable and accessible to a wider
range of users, facilitating widespread adoption and impact.
 TIME TO REACT: While timely response to emissions is crucial, it may not be the sole determinant of
success; therefore, a moderate weightage ensures consideration without overshadowing other
equally significant factors in the evaluation process.
 MAINTENANCE: Maintenance plays a key role in the long-term sustainability and performance of
emission systems; assigning a proportional weightage acknowledges its importance without
overstating its impact relative to other criteria.
 COMPLEXITY: Managing complexity is essential for practical implementation and user acceptance; a
moderate weightage ensures that solutions are technically feasible and user-friendly, without overly
prioritizing complexity over other performance metrics.
 ENERGY PERFORMANCE: Given the environmental focus of the project, assigning a higher weightage to
energy performance reflects the significance of reducing emissions and improving efficiency, aligning
closely with the project's objectives and overall impact on sustainability.
 LIFE PERIOD: Assessing the longevity of emission system is vital for balancing durability and cost-
effectiveness over its operational lifespan, warranting a moderate weightage in the matrix.
 Even though Product 3 has some drawbacks (Maintenance), it makes up for it in the other categories,
resulting in the highest overall score.

OBJECTIVE TREE
Emission
+ control
systems to
minimize
environmental
Impact

Safety Cost Efficiency Adaptable

Optimized Compatible with

For User Affordable exhaust gas various engine
processing speed models

Enhanced Cost-Effective Upgradable

Ergonomic design Materials design

Optimized
Reduced heat
Manufacturing
emission
Process
 Strength
Weakness
1. Innovative Design: Incorporation of EGR, NOx 1. Complexity: High number of components may
sensor, Wear indicator, ceramic substrate, direct fit and
increase the risk of failure and maintenance
cylinder deactivation.
complexity.
2. Environmental Impact: Significant reduction in 2. Cost Implications: Advanced technologies and
NOx and CO2 emissions aligning with global emission
materials might lead to higher production costs.
standards.
3. Fuel Efficiency: Optimization of air-fuel ratio and

SWOT
Analysis
Opportunity Threat
1. Market Growth: Rising demand for eco-friendly 1. Technological Obsolescence: Rapid
technologies in the automotive industry. advancements in alternative energy vehicles could
overshadow traditional combustion engines.
2. Regulatory Compliance: Ability to meet stringent
emission regulations could open new markets. 2. Market Competition: Intense competition from
other emission control technologies and manufacturers.
FUNCTIONAL OBJECTIVE TREE

Emission
control
systems to
minimize
environmental
Impact

System Robustness Reduce CO2 Reduce NOx Increase Fuel

and Reliability Emissions Emissions Efficiency

Wear Direct Fit Cylinder Ceramic EGR NOx Sensor Cylinder

Indicator Deactivation Substrate deactivation

Balance Recycle Provide accurate Optimized

Monitor Critical Simplify Minimize thermal mass and real time NOx
system components for fast response and air/fuel
for wear and tear Installation Engine Load light weight Exhaust Gas concentration
ratio
measurements

Save Fuel
COMPARISON WITH EXISTING PRODUCTS:

 Exhaust Gas Recirculation (EGR): Existing emission control systems may not fully
optimize the recycling of exhaust gas and cooling of combustion. In contrast, our system uses EGR to
effectively reduce NOx emissions and optimize the air-fuel ratio, enhancing engine performance and
fuel efficiency.
 Cylinder Deactivation: Traditional emission control systems may not have features to
reduce CO2 emissions effectively. Our system stands out with its cylinder deactivation feature, which
turns off cylinders when they're not needed, balancing the engine load and saving fuel.
 Wear Indicator: Existing systems may not provide clear indications of system condition and
maintenance needs. Our system includes a wear indicator that checks the system's condition and
notifies maintenance needs, ensuring optimal performance over time.
 NOx Sensor: While some emission control systems may lack precise measurement and
adjustment of NOx in the exhaust, our system incorporates a NOx sensor that accurately measures
NOx levels and adjusts engine parameters accordingly, further reducing NOx emissions.
 Ceramic Substrate: Our system uses a ceramic substrate to maximize surface area for catalytic
reactions, enhancing emission reduction. This feature sets our system apart from many existing
emission control systems in the market. Furthermore, the ceramic substrate’s durability and
adaptability make our system more reliable and versatile.