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This specification covers a corrosion-resistant steel in the form of investment castings homogenized and solution and precipitation heat treated to 180 ksi (1241 MPa) tensile strength.
AMS F Corrosion and Heat Resistant Alloys Committee
This paper presents an innovative in-lab accelerated testing approach for chassis-mounted components, with a particular focus on the cooling module of commercial vehicles. The proposed method simulates real-time data acquired from field operations and replicates all critical chassis modes, including torsion. Additionally, real-time coolant circulation at specified pressure and temperature maintenance are feasible during durability testing, enhancing the realism of the test environment. The cooling modules, comprising the radiator, intercooler, and charge air cooler (CAC), often experience failures due to various multi-axial inputs and chassis modes. This paper introduces an innovative methodology for replicating field conditions in the lab, utilizing seven servo-hydraulic actuators to simulate multi-axial inputs. The accuracy of in-lab simulation for the acceleration levels at input and response locations of the cooling module exceeds 90%. This makes it a preferred choice for test
V Dhage, YogeshSatale, Sunil
The transition to electric vehicles is a significant change as the world moves toward sustainable objectives, and thus the effective usage of energy and batter functioning. However, accurate battery modelling and monitoring is still challenging due to its highly nonlinear behaviour because of its dependencies with temperature variations, aging effects, and variable load conditions. To address these complexities, there are smart battery management systems that monitor the key parameters like voltage, current, temperature, and State of Charge, ensuring safe and efficient battery operation. At the same time, this may not completely capture the battery's dynamic aging behaviour. Here, digital twin emerges as the powerful solution, which replicates the complete physical system into a virtual platform where we can monitor, predict and control. This research paper shows the digital twin solution framework developed for the real-time monitoring and prediction of key battery parameters and
G, AyanaGumma, Muralidhar
In current scenario, demand for alternate energy is increasing due to depletion of fossil fuels and countries working to achieve carbon neutrality by 2050. Hydrogen being a cleaner fuel, many OEMs across the world started to work on various strategies like hydrogen combustion engine and fuel cell. Passenger vehicles like buses are at the lookout for fuel cell technology at faster rate than other commercial vehicles. In fuel cell vehicles, cooling system design is critical & complex since it includes fuel cell cooling, Power electronics cooling & battery cooling. In this paper, cooling system design of a Fuel cell electric bus for inter-city application is demonstrated. Radiators and Fans are designed considering overall heat rejection and Coolant inlet temperature requirements of components. Cooling system circuit and pump is decided to meet the coolant flow rate targets. Flow simulation and thermal simulation done with the help of simulation models built using software KULI to predict
M S, VigneshKiran, Nalavadath
The HVAC (Heating, Ventilation, and Air conditioning) system is designed to fulfil the thermal comfort requirement inside a vehicle cabin. Human thermal comfort primarily depends upon an occupant’s physiological and environmental condition. Vehicle AC performance is evaluated by mapping air velocity and local air temperature at various places inside the cabin. There is a need to have simulation methodology for cabin heating applications for cold climate to assess ventilation system effectiveness considering thermal comfort. Thermal comfort modelling involves human manikin modeling, cabin thermal model considering material details and environmental conditions using transient CAE simulation. Present study employed with LBM (Lattice-Boltzmann Method) based PowerFLOW solver coupled with finite element based PowerTHERM solver to simulate the cabin heat up. Human thermal comfort needs physiological modelling; thus, the in-built Berkeley human comfort library is used in simulation. Human
Baghel, Devesh KumarKandekar, AmbadasKumar, RaviDimble, Nilesh
In last two decades, Farm customer expectation on cabin comfort has been increased multifold. To provide the best-in-class customer experience in terms of comfort without adding cost and weight is bigger challenge for all NVH Engineers. It is evident from literature survey that cabin tractors with better comfort is well accepted by customers in US and European Market. Apart from engine excitation, customer has become more sensitive to customer-actuated-accessory noises due to overall reduction in cabin noise in last 2 decades. This paper presents the study conducted on HVAC blower noise in 30HP cabin tractor. Tactile vibrations and cabin noise is not acceptable when AC is switched on due to low frequency modulating nature in frequency range of ~65Hz and 130Hz. The investigation is carried out systematically considering each component of Source-Path-Receiver model. HVAC blower unit as source is diagnosed in detail to understand root cause. Strong dominance of first order of blower been
K, SomasundaramChavan, Amit
Any agricultural operation (such as cultivation, rotavation, ploughing, and harrowing) includes both productive and non-productive activities (like transportation, stops, and idling) in the field. Non-productive work can mislead the actual load profile, fuel consumption, and emissions. In this project, a machine learning-based methodology has been developed to differentiate between effective operations and non-productive activities, utilizing data collected in the field from data loggers installed on the machinery. Measurements were conducted on various machines across the country in all major applications to minimize the influence of any individual sample deviation and to account for variability in customer operating practices. Few critical parameters such as Engine Speed, Exhaust Gas Temperature, Actual Engine Percentage Torque, GPS Speed etc.) were selected after screening and analyzing more than 100 CAN and GPS parameters. The critical parameters were subsequently integrated with
Maharana, Devi prasadGangsar, Purushottamgokhale, VarunPandey, Anand Kumar
Integrating advanced technologies into modern vehicles has led to an increasing focus on Functional Safety (FuSa), especially for the Automotive Integrated Cluster Module (ICM) to ensure the safety of the driver and passengers. This paper highlights the need to bring certain ICM components under an Automotive Safety Integrity Level B (ASIL-B) context using Classic AUTOSAR. This paper discusses the challenges faced and the solutions implemented for achieving compliance with ISO 26262 standards along with the Classic AUTOSAR framework. We are proposing a standardized and structured methodology for the design of the components in compliance with the key safety principles, including Freedom from Interference (FFI), execution under privileged levels, and integrity verification, particularly by adopting Classic AUTOSAR frameworks. This paper also presents the Functional Safety (FuSa) goals for these components and also extend to their configuration management and updating strategies within
Singh, IqbalKumar, Praveen
A passenger vehicle's front-end structure's structural integrity and crashworthiness are crucial to ensure compliance with various frontal impact safety standards (such as those set by Euro NCAP & IIHS). For a new front-end architecture, design targets must be defined at a component level for crush cans, longitudinal, bumper beam, subframe, suspension tower and backup structure. The traditional process of defining these targets involves multiple sensitivity studies in CAE. This paper explores the implementation of Physics-Informed Neural Networks (PINNs) in component-level target setting. PINNs integrate the governing equations into neural network training, enabling data-driven models to adhere to fundamental mechanical principles. The underlying physics in our model is based upon a force scheme of a full-frontal impact. A force scheme is a one-dimensional representation of the front-end structure components that simplifies a crash event's complex physics. It uses the dimensional and
Gupta, IshanBhatnagar, AbhinavKumar, Ayush
Modern automotive systems are becoming increasingly complex, comprising tightly integrated hardware and software components with varying safety implications. As the demand for ISO 26262 compliance grows, performing efficient and consistent Hazard Analysis and Risk Assessment (HARA) across these layers presents both methodological and practical challenges. Traditional approaches often involve performing HARA for an item (where item maybe a system or a combination of systems), which can lead to update of HARA for every new feature addition in an item, which in turn may lead to analysis of same functions in multiple HARAs leading to inconsistent risk categorization, redundancy, or even conflicting safety goals. Therefore, this paper proposes a unique HARA methodology which consolidates the list of functions from various systems and performs the HARA for the grouped functions (hereby referred to as Cluster HARAs). For example, Electrical power steering, Electric pump powered hydraulic
Somasundaram, ManickamVijayakumar, Melvin
As the brain and the core of the electric powertrain, the traction inverter is an essential part of electric vehicles (EVs). It controls the power conversion from DC to AC between the electric motor and the high-voltage battery to enable effective propulsion and regenerative braking. Strong and scalable inverter testing solutions are becoming more essential as EV adoption rises, particularly in developing nations like India. In India, traditional testing techniques that use actual batteries and e-motors present several difficulties, such as significant safety hazards, inadequate infrastructure, expensive battery prices, and a shortage of prototype-grade parts. This paper presents a comprehensive approach for traction inverter validation using the AVL Inverter TS™ system incorporating an advanced Power Hardware-in-the-Loop (PHiL) test system based on e-motor emulation technology. It enables safe, efficient, and reliable testing eradicating the need for actual batteries or mechanical
Mehrotra, SoumyaChhabra, Rishabh
Special vehicles such as off-road vehicles and planetary rovers frequently operate on complex, unpaved road surfaces with varying mechanical parameters. Inaccurate estimation of these parameters can cause subsidence or rollover. Existing methods either lack proactive perception or high precision. This article proposes a fusion framework integrating a visual classifier and a dynamics observer for stable, accurate estimation of road surface parameters. The visual classifier uses an adaptive segmentation system for unpaved roads, leveraging a large-scale vision model and a lightweight network to classify upcoming road surfaces. The dynamics observer employs an online wheel-–ground interaction model using stress approximation, integrating strong tracking theory into an unscented Kalman filter for real-time parameter estimation. The fusion framework performs integration of the classifier and observer outputs at data, feature, and decision levels. An adaptive fading factor and recursive
Zhang, ChenhaoXia, GuangZhang, YangZhou, DayangShi, Qin
Overloading in vehicles, particularly trucks and city buses, poses a critical challenge in India, contributing to increased traffic accidents, economic losses, and infrastructural damage. This issue stems from excessive loads that compromise vehicle stability, reduce braking efficiency, accelerate tire wear, and heighten the risk of catastrophic failures. To address this, we propose an intelligent overloading control and warning system that integrates load-sensing technology with real-time corrective measures. The system employs precision load sensors (e.g., air below deflection monitoring via pressure sensors) to measure vehicle weight dynamically. When the load exceeds predefined thresholds, the system triggers a multi-stage response: 1 Visual/Audio Warning – Alerts the driver to take corrective action. 2 Braking Intervention – If ignored, the braking applied, immobilizing the vehicle until the load is reduced. Experimental validation involved ten iterative tests to map deflection-to
Raj, AmriteshPujari, SachinLondhe, MaheshShirke, SumeetShinde, Akshay
India’s severe road safety challenges, marked by high accident rates and fatalities, necessitate innovative solutions like Advanced Driver Assistance Systems (ADAS) to align with SIAT 2026’s theme, “Innovative Pathways for Safe and Sustainable Mobility.” This paper synthesizes recent studies to explore ADAS’s role in enhancing safety and sustainability in India’s unique traffic environment. Technologies such as automatic emergency braking, lane departure warnings, and driver monitoring systems show promise in reducing crashes caused by human error, a leading factor in road incidents. However, India’s complex road conditions—unmarked lanes, dense urban traffic, and prevalent two-wheelers—pose significant challenges to ADAS effectiveness. There developed is a strong public support recently for ADAS, with many Indian road users recognizing its safety benefits and advocating for its integration into vehicles especially passenger vehicles. Despite growing adoption by automakers like Tata
Neelakanthu, KarraSreenivasulu, TKumar, OmHaregaonkar, Rushikesh SambhajiKumar, Rajiv
Robust validation of Advanced Driver Assistance Systems (ADAS) considering real-world conditions is a vital for ensuring safety. Mileage accumulation is a one of the validation method for ensuring ADAS system robustness. By subjecting systems to diverse real-world driving environments and edge-case scenarios, engineers can evaluate performance, reliability, and safety under realistic conditions. In accordance with ISO 21448 (SOTIF), known hazardous scenarios are explicitly tested during robustness validation in combination of virtual and physical testing at component, sub system and vehicle level, while unknown hazards may emerge through extended mileage by running vehicles on roads, allowing them to be identified and classified. However, defining a mileage target that ensures comprehensive safety remains a significant engineering challenge. This paper proposes a data-driven approach to define mileage accumulation targets for validating Autonomous Emergency Braking Systems (AEBS
Koralla, SivaprasadRavjani, AminTatikonda, VijayGadekar, Ganesh
In era of Software Defined Vehicle (SDV), the whole ecosystem of automobile will be impacted. So, it is going to through several challenges for testing activities. In electric vehicle, most critical component is traction battery, which is controlled and operated through battery management system (BMS). BMS is an electronic system, where is going to function as per software of BMS. And in SDV, software is a key element, which is continuously keep on updating on regular basis. So, it means some of BMS functionalities, features or performance may be also altered on each time on software update, which may impact battery’s operating condition, if some scenario is not evaluated during earlier testing then there are it may bring battery out of safe operating area, which may significant impact battery safety, performance or cycle-life. In this paper, we are exploring that different testing requirements for EV Batteries, which may be part of testing practices under era of SDV. Here we will
Bhateshvar, Yogesh KrishanMulay, Abhijit B
This paper elucidates the implementation of software-controlled synchronous rectification and dead time configuration for bi-directional controlled DC motors. These motors are extensively utilized in applications such as robotics and automotive systems to prolong their operational lifespan. Synchronous rectification mitigates large current spikes in the H-bridge, reducing conduction losses and improving efficiency [1]. Dead time configuration prevents shoot-through conditions, enhancing motor efficiency and longevity. Experimental results demonstrate significant improvements in motor performance, including reduced thermal stress, decreased power consumption, and increased reliability [2]. The reduction in power consumption helps to minimize thermal stress, thereby enhancing the overall efficiency and longevity of the motor.
Patil, VinodKulkarni, MalharSoni, Asheesh Kumar
Original Equipment Manufacturers (OEM’s) are focusing on the fuel economy of passenger cars to meet the next generation emission norms. Few techniques such as downsizing engines, raising lubricant temperature, reducing combustion time and regulating the start-stop system of engines are various efforts being considered by Automobile OEMs to attain fuel efficiency along with next generation emission norms. On the other hand, lubricants used for such engines are also to be modified accordingly to meet more fuel efficiency. Lowering viscosity along with addition of friction modifiers for normalizing frictional losses is widely practiced as the most economical techniques. To achieve this lubricant formulator and additive manufacturers have moved towards modern base oils and advanced additive technologies. This study is done to understand key parameters which reduce friction and increase fuel economy using same viscosity grade oils. In the current study, we have formulated different low
Vabbina, Shiv KumarKatta, LakshmiJoshi, RatnadeepChaudhary, RameshwarSeth, SaritaBhardwaj, AnilArora, Ajay Kumar
Increasing ethanol blending in gasoline is significant from both financial (reducing dependency on crude oil) and sustainability (overall CO2 reduction) points of view. Flex Fuel is an ethanol-gasoline blend containing ethanol ranging from 20% to 85%. Flex Fuel emerges as an exceptionally advantageous solution, adeptly addressing the shortcomings associated with both gasoline and ethanol. Performance optimization of Flex Fuel is a major challenge as fuel properties like knocking tendency, calorific value, vapour pressure, latent heat, and stoichiometric air-fuel ratio change with varying ethanol content. This paper elaborates on the experimental results of trials conducted for optimizing engine performance with Flex Fuel for a 2-cylinder engine used in a small commercial vehicle. To derive maximum benefit from the higher octane rating of E85, the compression ratio is increased, while ignition timing is optimized to avoid knocking with E20 fuel. For intermediate blends, ignition timing
Kulkarni, DeepakMalekar, Hemant AUpadhyay, RajdipKatkar, SantoshUndre, Shrikant
Generally, in an electric sports utility vehicle with rear mounted powertrain the mass distribution is greater in the rear compared to front. This higher rear to front weight distribution results in oversteer behavior during high-speed cornering deteriorating vehicle handling & risking passenger safety. To compensate this inherent oversteer nature of such vehicles & produce understeer behavior, the steering rack is placed frontwards of the front wheel center for toe-out behavior due to lateral compliance during cornering. This compensation measure results in lower Ackermann percentage resulting in higher turning circle diameter deteriorating vehicle maneuverability. This paper proposes a design to obtain ideal understeer gradient with minimal turning circle diameter through utilization of split link technology with a McPherson Strut based suspension framework & frontwards placed steering rack. This suspension is utilized in our Mahindra Inglo platform. This paper elaborates on how
Nadkarni, Ameya RavindraMhatre, NitijPatnala, AvinashNAYAK, Bhargav
Automotive displays have become an essential part of modern vehicles, not just for aesthetics but also for improving safety and user interaction. As cars get smarter, the industry is leaning heavily into advanced display technologies to provide drivers and passengers with clearer, more responsive visuals. Technologies like Active Matrix LCDs (AMLCDs) and AMOLEDs are now common in dashboards, infotainment systems, digital clusters, and even head-up displays. These display types are popular because they offer great brightness, vibrant color, and wide viewing angles — all of which are important in a car, where lighting conditions can change constantly. But to make these displays work effectively, a solid backplane is critical. That’s where technologies like amorphous silicon (a-Si) and low-temperature polysilicon (LTPS) come in. Among these, LTPS has gained popularity due to its ability to support high-resolution, high-refresh-rate screens, thanks to its higher carrier mobility. Still
Sinha Roy, DebarghyaDuggal, AnanyaSingh, Ujjwal Kumar
With increasing demand for improving the vehicle Ride and Handling (R&H) performance, the synergy between vehicle subsystems such as suspension, chassis, brakes & tyres play a major role towards it. In this regard, the interaction between wheel rim width and tyre performance characteristics is a key focus area in vehicle development process. Detailed research is being conducted worldwide to understand their dynamics of interaction and based on the tested data, vehicle manufacturers make the design selection. In this context, the proposed study aims to provide a in-depth analysis of how variations in wheel rim width affect key tyre performance parameters such as lateral force characteristics, damping property, tyre footprint, and pinch cut resistance. Also, the subsequent influence on vehicle-level performance parameters such as R&H, braking, steering, and durability is captured. Based on these analysis, appropriate wheel rim size selection is done which is most optimal for the project
Singh, Ram KrishnanPaua, KetanSundaramoorthy, RagasruobanLenka, Visweswaraahire, ManojAdiga, Ganesh N
The penetration of ADAS in automotive markets is increasing rapidly. However, their effectiveness and acceptance are significantly influenced by regional driving behaviours and infrastructure. This study explores the interaction between naturalistic driver behaviour in India and the operational characteristics of ADAS systems (FCW, ACC, LCF and BSD) with focus on cars. Using real-world driving data collected from Indian roads, the research aims to highlight the divergence between ADAS design assumptions often based on structured Western traffic environments and the complex, dynamic nature of Indian traffic, characterized by frequent human negotiation, informal road practices, and different vehicle types. The study characterizes multiple driver’s driving pattern through naturalistic driving and ADAS systems behaviour in corresponding situations, notably how they adapt to unstructured Indian scenarios such as lane ambiguity, pedestrian unpredictability, traffic flow unpredictability and
Sankpal, Krishnath NamdevMagar, AkshayKhot, AnkushKulkarni, AlokPerez, Marc