An orientation about Vehicle Inspection

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An orientation about Vehicle Inspection

• Anil Chhikara
• MLO
• Transport Department

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Contents

• Transport Scenario of Delhi
• Vehicle Inspection history and achievments
• Signification of vehicle tests

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Typical progress of Delhi Transport

• Delhi population increase is three folds but the
• vehicle increase is about 17.5 times during
  the same period .
• Delhi average traffic speed is about 16kms/hr ,
  the lowest in the country and in central Delhi
  it is even less than 10 kms/hr at peak hrs .
• Delhi has 21 area coverage for roads, best in
  India, better than any global city ,but
  congestion is worst in the country .
• 90 of the road space is occupied by 35 of the
  total travelers of cars and two wheelers .
• The road length per 1000 vehicles reduced from
  12 kms to six kms from 1990 to 2006 .
• Road expansion has reduced from 71 to 3 since
  last four decades .
• It is estimated that daily 2 hrs delay is
  experienced by individuals and loss of fuel waste
  due to congestion and idling is around Rs
  20,000 millions per annum .

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Modal split of a typical city transport
The chart shows decline of bus passenger
ridership and potential to shift passengers to AR
and taxies
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Distance travel matrix
source IIT Delhi
85 people have 10 kms or less travel distance ,
Short distance transport is left unattended.
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Random , unorganized traffic and multidirectional
transport
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organized traffic with ITS application
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Vehicle Inspection chronicle

• Vehicle inspection every year took place since
  1914 in Delhi with Delhi Police for pvt. and
  transport vehicles.
• MVI was called as Patrol Inspector who was from
  traffic police who was responsible to inspect the
  vehicles.
• Since 1940 the DMVR was published where the only
  Transport vehicle was mandated to be checked
  every six months .
• Prior to 1955 the Motor Vehicle Act and Railway
  Act was dealt jointly . After 1955 full fledged
  Transport department started functioning .
• The provision of Fitness certifications and
  cancellation of fitness started .

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Vehicle Fitness Regime in Delhi

• The vehicle fitness inspection was carried out
  twice in year by Board of Inspector which
  included one traffic inspector and one MVI .
• The vehicle inspection was continued at Yamuna
  Bank and was carried out very specifically ,
  stringently but visually . Vehicle owner fear
  was much as of today in vehicle maintenance .
• In 1987 the pollution checking of vehicle was
  started of all vehicles.
• In 1991 the vehicle inspection unit was
  established where the emission check and brake
  test were carried out . The brakes dynamometers
  got buried in concrete by 1997. No maintenance
  provisions were made during that time .

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• In 1996 MORTH granted one test lane , was not
  used at all and got obscured into concrete . Also
  no maintenance program was provisioned and the
  equipment testing were non starter .
• In 2005 two test lanes and in 2007 one more test
  lanes was installed where the passenger vehicles
  were tested . The department had to bear a big
  cost of repairs and delays in repairs.
• However the testing was conducted under stringent
  control parameters resulting up scaling of
  quality of vehicles particularly in brakes ,
  emission , cat converter, silencer , emergency
  hand brakes , speed governors , body finishing
  quality , seating comfort , headlamp , tail lamp
  functioning , steering play , noise reduction,
  wipers, CNG safety , overall cleanness , power
  transmission efficiency etc.
• The passenger vehicles aesthetics were so
  improved to the new buses finish and there was a
  drop of fatal accidents by 20 in 20062008.
• The vehicle owner was to fill the check sheet
  after his self evaluation as pre inspection as
  the failure rate initially was 70 reduced to 20
  .
• The vehicle operator was informed about the
  performance of his vehicle and necessary prior
  information were made available to him before the
  vehicle was produced for inspection.

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• The automated test lane inspection procedure was
  carried out for the first time in India and was
  appreciated by media as well national wide
  transport agencies.
• The transparency in testing was maintained and
  customer satisfaction level was very high .
  People encouragement was also seen that vehicle
  owner wanted the tests be conducted voluntarily.
• The cost of tyre wear , fuel saving due to
  controlled emission , reduction of fear of
  accidents due to correction of steering play/
  joint play / sideslip , overall brake performance
  

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• The number of fatalities was declined by 20 by
  passenger vehicles during 2007-8.
• The ratio of inspectors and vehicles was
  1/20,000 and now it is 1/1,00,000 also inspector
  population was 1/80,000 which is now 1/1,50,000.
  This ratio is the lowest in the country on other
  side the work pressure is increasing .

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• Significance of Inspection and
• Maintenance /Certification System

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IM and IC

• There is a practice worldwide that in use
  vehicles are maintained through the machines
  performance results. This vehicle maintenance
  regime is called as Inspection and Maintenance
  (IM) system and is organized by the dealers
  workshops of the automotive manufacturers.
• The performance rating of vehicle when measured
  through the set of machines to conform the
  statutory provisions and issuance of
  roadworthiness certificates is called Inspection
  and Certification (IC) system.

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IM system

• Under this system test equipments are installed
  in a lane and the vehicle testing is done
  sequentially and the test report is prepared
  through software. The database of the vehicle is
  stored in the computer hardware . This data can
  be transmitted on line along with the procedure
  can be surveyed on web support . The practice is
  made that the tests be accomplished without human
  intervention.

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IC system

• When legislation is made that the certificate of
  road worthiness is granted upon the basis of the
  test reports is called the Inspection and
  Certification system . The test equipments for
  IM and IC can installed be at one place or
  other , depends upon the authorities .
• In general at the stations array of machines
  perform the various test of the vehicles .
  Visual inspection observations are also recorded
  in computers and the drivers need to be trained
  to synchronize the operations with remote
  controls or manual operations .

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Various test at glance

• Pre Inspection of vehicles
• Vehicle data entry
• Emission test .
• Noise test
• Side slip
• Weight measurement of axles
• Brake testers
• Speed rollers test and speed governor test
• Joint play testers
• Head lamp testers
• Suspension testers

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Individual Vehicle Tests
Exhaust Emissions Test

• This is an unloaded test Exhaust Emissions Test
  mode, using a certified gas analyzer, as per
  Indian standard TAP 115 / 116 requirements,
  specifically for spark ignition vehicles. This
  test is similar to the Pollution Under Control
  (PUC) test, currently used in India. HC and CO
  are measured and if they are below the
  prescribed limits for that vehicle, the vehicle
  shall be assigned a passing result, otherwise a
  Fail will be recorded. In this program , as a
  fraud protection measure, a CO2 and O2 is be
  incorporated in the test procedure .

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• In addition, Air Fuel ratio the LAMBDA (?)
  (for CNG/LPG/Gasoline), requiring an O2
  measurement. The emissions analyzers includes the
  capability to measure CO, HC, CO2, O2, and engine
  RPM to the range and accuracy. This enhanced
  measurement requires engine to run at normal idle
  and high idle so the behavior of emission can be
  tested at variable speeds. This prevents also
  tempering of the tests by non recording of the
  emission measurement at tailpipe leakage. In
  anticipation of future requirements the emissions
  analyzer shall have the capabilities for addition
  of Nitric Oxide (NO) measurement and dynamometer
  interface.

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• Diesel Test
• This is an unloaded test mode using the Pollution
  Under Control (PUC) test currently used to test
  diesel vehicles. This test use the PUC procedure
  and specified smokemeter (certified as per Indian
  requirement) (TAP Document) however, the test
  equipment of incorporates a different test
  sequence, such as the SAE J1667, the EU snap
  acceleration tests .The free accelerations at
  the maximum rpm ( 25 _), engine temperature
  above 60 C the smoke density is measured . In
  case of measurement at load , the dynamometers
  are also installed to check the behavior of smoke
  at load conditions.

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• Sideslip Test
• The equipment shall measure the toe, either in or
  out, of a vehicle as it drives across the
  plate(s). The measurement is a linear
  displacement perpendicular to the longitudinal
  axis of the vehicle. Excessive toe indicates out
  of alignment with respect to the vehicles
  manufacturers specification, which results in
  excessive tire scrub and/or wear, and constitutes
  a failure.

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• Weight Measurement
• This measurement, used for vehicle classification
  and/or brake and suspension test use, can be done
  either with a separate scale, or integrated with
  another piece of equipment, such as the
  suspension and brake tester. Weight is measured
  per wheel and appropriately summed to achieve the
  axle weights and total vehicle weight. The load
  sensors are used to convert the weight to digital
  form .

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• Suspension Test
• The suspension test shall use the appropriate
  parameters, such as vehicle weight, and dynamic
  shock/strut damping measurements during the test
  to determine whether the vehicle suspension
  system is road worthy. The actuator plates
  vibrates the axles and damping forces are
  measured in . The test holds good in LMV
  passenger cars .

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• Brake Test
• The brake test shall use a roller type brake
  tester. The performance of the brake testers
  shall conform to established standards such as EU
  standards.
• The brake test shall measure braking force of
  wheels individually as well as the parking brake
  via a set of load cells. Multiple comparisons of
  measured forces shall be performed to determine
  pass/fail results for each of the parameters.

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• Wheel and Tire Initial Resistance / Vehicle
  Coasting Force
• This test shall check the vehicles wheels for
  abnormally high rotational force prior to testing
  braking forces. A high rotational force can be an
  indication of suspension misalignment, wheel
  bearing failure, or low tire pressure (among
  other concerns), and constitutes a failure.

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• Magnitude Braking Force
• After the initial resistance check, the braking
  force shall be measured at each wheel to check
  the amount of braking force available in Newtons.
  A set amount of brake force is available per unit
  of weight of the vehicle if not, the magnitude
  brake force is considered a failure for that
  wheel. The system shall be capable of providing a
  display of the brake force as a visual reference
  for manual analysis.

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• Left-to-Right Brake Force Difference
• Using the previously measured brake forces, the
  difference from left to right braking forces
  shall be calculated for each axle. An abnormally
  high number indicates steering wheel pull when
  the brakes are applied which, above a certain
  value, is a safety concern and considered a
  failure.

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• Warped Rotor and/or Drum Out-of-Roundness
• From the previously measured brake forces, an
  abnormally high variance in the amplitude shall
  indicate a drum or rotor that is out-of round or
  warped, and classified as a failure. It shall be
  possible to display and print a plot of the brake
  force as a visual reference and manual diagnosis.

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• Brake system proportioning
• From the previously measured brake forces, the
  difference in measured brake forces on each axle
  shall be compared to ensure that the vehicle
  braking proportioning system is working properly
  and anomalies displayed and printed as a failure
  or advisory.

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• Parking Brake
• This is a repeat of magnitude braking force
  measurement only using the parking brake. The
  system shall be capable of providing a plot of
  the brake force as a visual reference for manual
  analysis. In case of pneumatic system the braking
  performance is checked to enable the vehicle to
  stop. This brake is also called as fail safe
  brake as well as emergency brake.

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• Headlight test
• The headlight test shall measure the intensity
  and vertical and horizontal alignment of the
  headlamps. To enhance throughput, it is preferred
  that the test shall be automatic to the extent
  that once the test is initiated the headlight
  system shall automatically position itself using
  appropriate sensors and motors. Low levels of
  intensity, deviations of aim angles, and headlamp
  height outside defined standards shall constitute
  a failure.

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• Noise Test
• The noise test shall use a device that measures
  the decibel (dB) level of the vehicles sound to
  classify a vehicles contribution to noise
  pollution. Excessive noise measurement above a
  predetermined threshold can be indicative of a
  vehicle malfunction (such as a hole in the
  exhaust ) and constitutes a failure. The passerby
  noise as well as higher noise indicates the
  malfunctioning of engine.

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• Speedometer Test
• The speedometer test shall use a device that
  accurately measures the vehicle wheel speed while
  the vehicle speed is maintained constant. During
  this test, the operator enters the speed from the
  vehicle speedometer and the constant speed
  indicated by the speedometer tester is compared
  to the vehicle speedometer displayed speed
  entered by the vehicle operator. A pass/fail is
  determined based on the comparison to established
  acceptance limits. The speed governor speed
  characteristics are also captured in the database
  to check speed governor performance at simulated
  conditions .

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Joint Play Test

• Joint play is a visual check requiring a joint
  play device that forces movement of the
  structures while allowing the inspector to
  inspect the steering and suspension mechanisms.
  The results of the visual inspection shall be
  entered by the inspector manually at the
  appropriate data entry terminal. The results will
  then be incorporated into the VTR ( Vehicle Test
  Report ).

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• Visual Checks Contd.
• The pass/fail results of the visual inspection
  shall be entered by the inspector at the
  appropriate data entry terminal and incorporated
  into the VTR. The menu for the visual inspection
  items shall be displayed at the data entry
  terminal and the inspector shall have the option
  of selecting pass or fail at either the data
  entry terminal or a remote control unit.

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Visual Checks Contd

• The system configured such that an authorized
  individual can set the individual criteria to be
  pass/fail or advisory. The visual inspections may
  include tire tread depth measurement, the current
  Indian CNG and LPG inspection procedure and gas
  leak detection. It is desirable, to interface
  these measurement devices into the computer
  system. The visual aesthetics , permit conditions
  , wipers, turn signals , oil leakage , tail pipe,
  wheel nut , body , seats , paintings , windows ,
  vibrations are entered in the database.

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• Future Capabilities
• Without jeopardizing the throughput performance
  and reliability, the test system hardware and
  software architecture should be flexible and
  expandable to enable easy future field addition
  of new tests. These could include new petrol and
  diesel loaded mode emissions tests, automated
  tire tread depth measurement, enhanced brake
  tests, steering wheel play , clutch slippage ,
  and on-board diagnostic (OBD I, II ) checks etc.

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• Thanking You
• Anil Chhikara