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Efficient thermal management is critical for the reliability and performance of power electronics systems in automotive applications. This work presents a computationally efficient modeling approach for transient thermal simulation of power electronic systems, with a focus on inverter modules using multiple MOSFETs mounted on a printed circuit board assembly (PCBA). A case study of an inverter module comprising six MOSFETs arranged as high-side and low-side pairs for a three phases system mounted on a PCBA, attached to a heat sink is considered. Computational fluid dynamic (CFD) simulations in Ansys® Icepak™ are performed considering different heat transfer mechanisms, including natural convection, forced convection at constant velocity, and forced convection with varying flow velocity. A transient thermal model is developed using the lumped parameter linear superposition (LPLSP) method, a hybrid approach that combines lumped parameter modeling with the principle of linear
Padmanabhan, Neelakantan
The Operator’s Field of Vision (FOV) test, conducted in accordance with IS/ISO 5006:2017, is a vital assessment to ensure the safety and operational comfort of personnel operating Construction Equipment Vehicles (CEVs) / Earth-Moving Machinery. IS/ ISO 5006:2017 defines rigorous guidelines for evaluating the operator’s visibility from the driver's seat, with particular emphasis on the Filament Position Centre Point (FPCP), determined from the Seat Index Point (SIP) coordinates. The test includes assessment of masking areas, focusing on the Visibility Test Circle (a 24-meter diameter ground-level circle around the machine), and on the Rectangular Boundary on which a vertical test object is placed at a height specific to the machine type and its operating mass. These parameters are designed to simulate real-world operating conditions. This paper introduces a portable testing setup developed specifically for conducting the Operator’s FOV test as per IS/ISO 5006:2017. The setup facilitates
Ghodke, Dhananjay SunilTambolkar, Sonali AmeyaBelavadi Venkataramaiah, Shamsundara
This paper focuses on defining the optimal length of rear axle brake lines (flexible polyamide tubes) for commercial vehicles by simulating the lines digitally by considering tube behavior and various axle articulation conditions. Currently, the length of rear axle brake lines are predominantly defined with the help of a physical mockup by articulating axle conditions in a vehicle. This approach requires actual components such as frame, axle, suspension, etc., which consumes considerable time and cost. Through technological advancements, prototyping can be reduced and convergence on digital to build can be achieved through digital simulation. This paper explores tube properties, axle configurations and definitions, and various methods of digitally simulating line articulation. Boundary conditions, space reservations and design criteria for pneumatic routing are defined for the type of line designed. Digital simulation of rear axle brake lines articulation was performed and compared
Duraiswamy, RupeshSankaran, BhargavRaj, Santhosh
Environmental concerns are prompting the global mobility sector to transition towards electrification. Increased research and development in the field of electric vehicles have made them an increasingly efficient and compelling option for reducing greenhouse gas emissions and improving the sustainability of freight transport. Electric vehicles require batteries that offer long range, shorter charging times and high energy efficiency. During long-distance travel, for customer convenience, mobile charging stations have become a trending and highly meaningful solution. For such mobile charging stations, it is essential to ensure the durability and safety parameters of the battery and its structure. For this to happen, it is mandatory that the system possess the strength and stiffness behavior to withstand the various dynamic loads arising from the environment and acting on the vehicle and system. Moreover, the system should maintain a weight that is as low as possible so that it is both
Sonare, PushpeshGaneshan, SubramanianDattawade, Vishal
This paper presents a novel approach to automated robot programming and robot integration in manufacturing domain and minimizing the dependency on manual online/offline programming. Traditional industrial robots programming is typically done by online programing via teach pendants or by offline programming tools. This presents a major challenge as it requires skilled professionals and is a time-consuming process. In today’s competitive market, factories need to harness their full potential through smart and adaptive thinking to keep pace with evolving technology, customer demand, and manufacturing processes. This requires ability to manufacture multiple products on the same production line, minimum time for changeovers and implement robotic automation for efficiency enhancement. But each custom automation piece also demands significant human efforts for development and maintenance. By integrating the Robot Operating System (ROS) with vision-based 3D model generation systems, we address
Hepat, Abhijeet
As global energy demands continue to grow and environmental challenges intensify, Biodiesel stands out as an environmentally sound and technically feasible alternative to curb fossil fuel use and emissions. This study provides an in-depth analysis of the performance and emissions profile of a compression ignition (CI) engine running on a renewable diesel fuel blend made from ethanol and cottonseed (Cs) combinations enhanced with aluminium oxide (Al2O3) nanoparticles. The experimental fuel blends, consisting of 10%, 20%, and 30% cottonseed biodiesel with 5% ethanol and remaining with conventional diesel, were analyzed under varying engine load conditions. The inclusion of ethanol improved fuel atomization due to its lower viscosity and higher volatility, while Al2O3 nanoparticles acted as advanced combustion catalysts, promoting enhanced oxidation rates and thermal efficiency. Among the blends, B10 (10% cottonseed biodiesel) exhibited superior performance metrics, achieving a brake
T, KarthiG, ManikandanSaminathan, SathiskumarM E, ChandhuruS, BavanyaS, Arunkumar
The first step in designing or analyzing any structure is to understand “right” set of loads. Typically, off-road vehicles have many access doors for service or getting into cab etc. Design of these doors and their latches involve a knowledge of the loads arising when the door is shut which usually involves an impact of varying magnitudes. In scenarios of these impact events, where there is sudden change of velocity within few milliseconds, produces high magnitude of loads on structures. One common way of estimating these loads using hand calculations involves evaluating the rate-of-change-of-momentum. However, this calculation needs “duration of impact”, and it is seldom known/difficult to estimate. Failing to capture duration of impact event will change load magnitudes drastically, e.g. load gets doubled if time-of-impact gets reduced from 0.2 to 0.1 seconds and subsequently fatigue life of the components in “Door-closing-event” gets reduce by ~7 times. For these problems, structures
Valkunde, SangramGhate, AmitGagare, Kiran
Alcohol is being considered as an alternative to traditional fuels for compression ignition engines due to their oxygen content and biomass origin. Although alcohol generally has lower cetane numbers, which makes them more favorable for premixed combustion, they also offer potential for lowering emissions in internal combustion engines, particularly when combined with strategies such as exhaust gas recirculation (EGR). This research focuses on enhancing the performance of a single-cylinder, four- stroke diesel engine by introducing ethanol into the intake port during the intake phase. Diesel and rubber seed biodiesel were used as primary fuels and were directly injected into the combustion chamber. The findings indicated that adding ethanol to rubber seed biodiesel, along with 10% EGR, led to improved brake thermal efficiency and a reduction in NOX emissions. The ethanol injection timing and duration were optimized for effective dual-fuel operation. At full engine load, the highest
Saminathan, SathiskumarG, ManikandanBungag, Joel QuendanganT, Karthi
Manufacturers need pragmatic guidance when choosing network protocols that must balance responsiveness, high data throughput, and long-term maintainability. This paper presents a step-by-step, criteria-driven framework that scores protocols on six practical dimensions, real-time behavior, bandwidth, interoperability, security, IIoT readiness, and legacy support and demonstrates the approach on both greenfield and brownfield scenarios. By combining vendor specifications, peer-reviewed studies, and field experience, the framework delivers transparent, weighted rankings designed to help engineers make defensible deployment choices. This paper explores how network protocols can be mapped to different layers of the automation pyramid, ranging from field-level communication to enterprise-level. For example, Profinet is shown to be highly effective for time-critical applications such as robotic assembly and motion control due to its deterministic, real-time ethernet capabilities. Meanwhile
Tarapure, Prasad
This paper introduces an AI-powered mobile application designed to enhance vehicle warranty management through real-time diagnostics, predictive maintenance, and personalized support. The system supports multi-modal inputs (text, voice, image, video), integrates real-time On-Board Diagnostics (OBD) data, and accesses OEM warranty terms via secure APIs. It employs supervised, unsupervised, and reinforcement learning to deliver accurate fault detection, tailored recommendations, and automated claim decisions. Contextual analysis and continuous learning improve precision over time. The application also provides service cost estimates, part availability, and proactive maintenance alerts. This approach improves customer satisfaction, reduces warranty costs, and streamlines aftersales support. Utilizing advanced AI and machine learning algorithms, the application interprets customer queries through multiple input modes—text, voice, video, and image—and retrieves relevant information from the
Ramekar, Vedant MadhavChaudhari, Hemant
Operating tractors on inclined & uneven terrains for prolonged operations presents safety and ergonomic challenges. Applications such as shuttle operations, loader use, or long-duration implement usage prove to be highly critical based on field observations across Mahindra tractor platforms and it requires skill & experience for maneuvering at ease across usage. We identified the need to offload these repeatable tasks from the operator to improve control & offer comfort. This paper explains the role of Advanced drive assistance features developed for Mahindra tractors suited for all prime mover types – ICE, Alternate Fuels including electric. These features include Hill Hold, Electronic parking brake, Cruise control & Creep mode. Each feature is designed to offload frequent manual tasks from the operator and ensure smoother, safer operation. Hill hold and electronic parking brake work in tandem to offer unparalleled safety by eliminating the fear of tractor roll back in uneven terrain
M, RojerSundaram, PavithraNatarajan, SaravananDevakumar, KiranMuniappan, Balakrishnan
Modern vehicle integration has become exponentially more difficult due to the complicated structure of designing wiring harnesses for multiple variants that have diverse design iterations and requirements. This paper proposes an AI-driven solution for addressing variant complexity. By using Convolutional Networks and Deep Neural Networks (CNN & DNN) to generate harness routing using defined specifications and constraints, the proposed solution uses minimal human intervention, substantially less time, and enables less complexity in designing. AI trained modelled systems can generally even predict failures in production methods which also reduces downtime and increases productivity. The new AI system automatically converts design specifications to manufacturable design specifications to avoid confusion with design parameters, by optimizing concepts with connector placements, grommet fittings, clip alignments, and other tasks. The solution coping with the inherent dynamic complexity of
N, Rishi KumaarPatil R, BharathRajavelu, VivekRamachandran, VigneshMohanty, LalitPadmarajan, Vishnu
In the agricultural industry, the logistics of transporting and storing bales, used as cattle feed, pose significant challenges for large scale farms. Traditional storage of bales in barns is labor-intensive, high in capital expenditure and requires multiple trips of transport vehicle on and off the field. Improper handling during this transition can lead to substantial losses in time, resources and loss of hay. This development aims to eliminate the last-mile transportation step, by enabling year-round storage of bales directly in the field. A patented wrapping material, along with strategic orientation of wrapped bales, enhances their resistance to weather conditions. Field experiments demonstrated that this innovative material not only protects the bales from adverse environmental factors but also effectively retains their nutrient and moisture content. A critical aspect of this solution is ensuring the correct orientation of the wrap seams, as the bales are continuously rotated
Kadam, Pankaj
The development of 3D game ready models is a critical component of the asset creation workflow in industries. However, traditional modeling techniques often demand extensive manual input, particularly in the areas of modeling, retopology, and texturing. To address challenges, we propose the integration of generative AI technologies into the 3D modeling workflow, aiming to enhance efficiency and streamline processes. This paper presents a comprehensive methodology that leverages advanced algorithms, machine learning techniques, and specialized software to automate repetitive tasks associated with 3D asset creation. By harnessing the power of generative AI, we aim to significantly reduce the manual effort required to produce high-quality 3D models, thereby accelerating the overall development timeline. The aim is to enter a prompt/Image as input to get a fully developed Model. Through a series of experimental implementations, we are aiming to demonstrate the effectiveness of our proposed
Arunachalam, HaripriyaGumaste, AmeyKumar, Pravin
Tillage, a fundamental agricultural practice involving soil preparation for planting, has traditionally relied on mechanical implements with limited real-time data collection or adjustment capabilities. The lack of real-time data and implement statistics results in fleet managers struggling to track performance, driver behavior, and operational efficiency of the implements. Lack of data on vehicle performance can result in unexpected breakdowns and higher maintenance costs, ensuring compliance with regulations is challenging without proper data tracking, potentially leading to fines and legal issues. Bluetooth-enabled mechanical implements for tillage operations represent an emerging frontier in precision agriculture, combining traditional soil preparation techniques with modern wireless technology. Implement mounted battery powered BLE (Bluetooth Low Energy) modules operated by solar panel based rechargeable batteries to power microcontroller. When Implement is operational turns
Kaniche, OnkarRajurkar, KartikGokhale, SourabhaVadnere, Mohan
The research work elaborated the structural integrity of airvent by skipping the assembly level snap fit finite element analysis of knob to reduce computational complexity of air vent knob sliding test post stopper. During assembly, the strain based mechanical breakage prediction of airvent sliding knob snaps is investigated in non-prestressed condition. The research work proposes a FEM based analysis approach to evaluate the mechanical breakage load of airvent knob assembly for accidental sliding load. This process skips the assembly level snap insertion load case along with silicone rubber pad compression which could serve as the prerequisite simulation. This prerequisite simulation is computationally expensive and complex to solve due to polymer plasticity and silicone rubber elastomer hyper-elasticity and moving frictional contacts between parts. If the accidental sliding load case without considering pre-tension on snaps is simulated, the load causing mechanical failure in the FEM
Shah, VirenWani, DishantMiraje, Jitendra
The evolution of Autonomous off-highway vehicles (OHVs) has transformed mining, construction, and agriculture industries by significantly improving efficiency and safety. These vehicles operate in high dust, uneven terrain, and potential communication failures, where safety is challenged. To guarantee vehicle safety in such situations, a robust architecture that combines AI-driven perception, fail-safe mechanisms, and conformance to many ISO standards is required. In unstructured environments, AI-driven perception, decision-making, and fail-safe mechanisms are not fully addressed by traditional safety standards like ISO26262 (road vehicles), ISO19014 (earth-moving machinery and it is replacing withdrawn ISO 15998), ISO12100 (Safety of machinery) and ISO25119 (agriculture), ISO 18497 (safety of highly automated agricultural machinery), and ISO/CD 24882 (cybersecurity for machinery).These standards mainly concentrate on the reliability of mechanical and electric/electronic systems
Muthusamy, Sugantha
Vibration testing is an essential component of automotive product development, ensuring that components such as engines, transmissions, and electronic systems perform reliably under various operating conditions. The adoption of electronics in the automotive industry, particularly during the 1950s and 1960s, marked a shift in vibration testing approaches, moving from primarily low-frequency tests to methods that could address high-frequency vibrations as well. This evolution highlights the need for effective vibration fixture designs that can simulate real-world conditions, enabling manufacturers to detect potential weaknesses before products are integrated into vehicles. A key aspect of vibration testing is the identification of resonant frequencies within components. The coupled mass-spring-damper system, for example, can exhibit multiple resonances characterized by a Bode Diagram, where the Q factor technique is utilized to assess damping levels. Accurate vibration analysis can be
Shinde, PramodkumarShah, Viren
Turbocharging is a vital technology for enhancing internal combustion engine (ICE) performance and efficiency while enabling engine downsizing to reduce fuel consumption and emissions. This research analyzes turbocharger systems by examining their components—turbine, compressor, intercooler, and waste-gate—and their roles in boosting engine efficiency. It explores how exhaust energy drives the turbine to compress intake air, improving power output. The study evaluates turbocharger impact on fuel economy, emissions, and engine response under various driving conditions. It also considers wheel design, material selection, and durability under high temperatures and speeds. Advanced simulations using CFD and FEA analyze airflow, pressure, and thermal behavior to optimize performance. This research affirms turbocharging’s role in creating high-performance, fuel-efficient, and environmentally sustainable engines, offering insights that support the design of next-generation automotive
Chandrashekar, B. AdityaBhaduria, Abhishek
Off-Highway Vehicles (OHVs) — including mining trucks, construction machinery, and agricultural equipment — contribute significantly to greenhouse gas (GHG) emissions and local air pollutants due to their dependence on fossil diesel. Achieving sustainable development goals in off-highway sectors requires transitioning toward alternate fuels that can reduce CO₂, NOₓ, and particulate matter (PM) emissions while maintaining performance and reliability. This paper comprehensively evaluates alternate fuels such as biodiesel, renewable diesel, compressed and liquefied natural gas (CNG/LNG), liquefied petroleum gas (LPG), hydrogen, and alcohol-based blends. Using insights from Service Bulletins, fuel standards, and the Worldwide Fuel Charter, it discusses fuel properties, engine compatibility, operational challenges, sustainability impacts, economic feasibility, safety considerations, and regulatory aspects. Case studies of alternate fuel deployment in OHVs illustrate practical challenges and
Mulla, TosifThakur, AnilTripathi, Ashish
This paper introduces a comprehensive solution for predictive maintenance, utilizing statistical data and analytics. The proposed Service Planner feature offers customers real-time insights into the health of machine or vehicle parts and their replacement schedules. By referencing data from service stations and manufacturer advisories, the Service Planner assesses the current health and estimated lifespan of parts based on metrics such as days, engine hours, kilometers, and statistical data. This approach integrates predictive analytics, cost estimation, and service planning to reduce unplanned downtime and improve maintenance budgeting, aligning with SAE expectations for review-ready manuscripts. The user interface displays current part health, replacement due dates, and estimated replacement costs. For example, if air filter replacement is recommended every six months, the solution uses manufacturer advisories to estimate the remaining life of the air filter in terms of days or
Chaudhari, Hemant Ashok
Off-highway vehicles (OHVs) routinely navigate unstable and varied terrains—mud, sand, loose gravel, or uneven rock beds—causing increased rolling resistance, reduced traction, and high energy expenditure. Traditional rigid chassis systems lack the flexibility to adapt dynamically to changing surface conditions, leading to inefficiencies in vehicle stability, maneuverability, and fuel economy. This paper proposes an adaptive terrain morphing chassis (ATMC) that can actively modify its structural geometry in real-time using embedded sensors, hydraulic actuators, and soft robotic elements. Drawing inspiration from nature and recent advances in adaptive materials, the ATMC adjusts vehicle ground clearance, track width, and load distribution in response to terrain profile data, thereby optimizing fuel efficiency and performance. Key contributions include: A multi-sensor fusion system for real-time terrain classification Hydraulic actuators and morphing polymers for variable chassis
Vashisht, Shruti
Requirement for Construction Equipment Vehicles (CEVs) in India is continuously growing due to India’s focus on infrastructure development. Technology in the automotive industry has evolved rapidly in recent times and it is also adding new dimensions to the compliance to Electromagnetic Interference, Susceptibility (EMI/EMC) and Safety. EMC and Safety requirements of CEVs are internationally governed by ISO 13766, Part 1 & Part 2. This paper discusses the significance of each aspect specified in these standards and its applicability. Due to nature of work carried out by construction equipment, there is absolutely no scope for compromise on safety for the same. Although Construction equipment standards are based on automotive standards, there are few additional tests which are part of ISO 13766, Part 1 and 2. This paper explains each aspect with practical case study. It also provides general EMC guidelines and precautions to be followed during design validation and product validation
Yeola, MayurNigade, MaheshMulay, Abhijit B