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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 explains the method of precooling of electric vehicle from grid connected charger reduce load on HVAC and improve the range. HVAC systems are integral part of a commercial EV bus. With the rise of ambient temperatures during various seasons, the load on HVAC System is increasing. Once an Electric vehicle is released from a depot for service, with an initial soaked up ambient vehicle, the HVAC system demands peak power for cooling the interiors which consumes a lot of battery power thus affecting the range. That cause the additional energy consumption required for precooling, which cannot be estimated as it is highly dependent on ambient temperature and range of the vehicle is also dependent on HVAC consumption during summer and peak loads. This paper is proposing a method that uses a special precooling mode which is activated depending on the selection of the vehicle route based on backend application running on cloud. The Application in the cloud checks if the vehicle is
Ganguly, SutanuShukla, AmishaJain, SarikaPatil, RohanSahu, PritishYadav, AnkitMarskole, DeepaAmancharla, Naga Chaithanya
Noise, Vibration, and Harshness performance refinement and long-term vehicle reliability are rapidly evolving in today’s automotive industry and becoming a basic need considering comfort. Engine mounts play a central role in isolating powertrain-induced vibrations. Their deterioration can significantly affect cabin comfort, powertrain integrity, and customer satisfaction. Prior work in this area has primarily focused on direct mount sensors and physical inspection at service centre after failure. While effective in controlled environments, such methods are not scalable, add system complexity and increase vehicle cost due to sudden breakdowns. This paper introduces a novel indirect health monitoring method that leverages a driver seat rail-mounted accelerometer to capture driver specific vibrational responses. By analysing these signals using machine-learning models placed by AIML ECU and domain-specific analytical features, engine mount health is inferred without requiring sensors on
Iqbal, ShoaibDusane, Mangesh
The integration of hydrogen (H2) as a fuel source in internal combustion engines (ICE) necessitates stringent design measures to mitigate leakage risks and ensure operational safety. This study focuses on the design optimization of vanity cover for hydrogen engines. Computational fluid dynamics (CFD) analysis is carried out to assess and control hydrogen leakage through fuel rail connections, injector interfaces and associated high pressure fuel system components. Detailed modelling of hydrogen flow behavior, diffusion characteristics of leaked hydrogen are simulated for worst case scenarios. Design iterations targeted improvement in ventilation pathways, strategic placement of vent holes, and internal flow management to minimize localized hydrogen buildup. The final design achieved hydrogen concentration, which was less than 4% satisfying the Product safety Hazard Analysis (PSHA) threshold for hydrogen engines. This paper validates the critical role of CFD driven design methodology in
Veerbhadra, Swati AshvinkumarSahu, Abhay KumarSingh, Rahul
Electric Vehicles (EV) are increasingly becoming more and more popular in the markets, especially in the commercial vehicle segments. Amidst this, the need to find new elegant methods to perform charging of EV battery becomes extremely crucial. In areas with high demand and limited power capacity, performing charging for multiple vehicles necessitates efficient usage of charging infrastructure, which can’t be guaranteed by the traditional charging methods. Sequential charging is a new state of art technique for managing the charging of multiple EV’s simultaneously connected to a single charging station. Rather than dividing the available power equally among all connected vehicles or charging them one at a time, this technique dynamically allocates power based on various factors such as charging priority, vehicle needs and available infrastructure capacity. Currently, sequential charging can only be implemented by a particular set of chargers that are interconnected via backend and
De, AbirBhattacharya, UllashParihar, Aakash
The adoption of sustainability in electric mobility has made it crucial to investigate environmentally friendly materials. Polymer materials used in automotive application plays very important role in material circularity contributing significant value addition to the overall carbon footprint index. This study discloses the development of recycled polyester textiles derived from PET bottle waste and use for automotive interior parts. The use of recycled textiles is directly helping the organization in scope 3 emissions to get the lower carbon footprint value as it is eliminating the use of fossil fuel resources in making the PET textiles. In this study, the development of 50% recycled PET textile and its feasibility for automotive interior is disclosed in detail. The 50 % recycled PET was tested against automotive critical requirements such as sun load UV resistance, abrasion durability, color migrations, soiling resistance, mechanical and thermal properties. The findings showed that
Palaniappan, ElavarasanVaratharajan, SenthilkumaranBalaji, K VDodiya, Rohanbhai
This comprehensive research presents an in-depth analysis of communication protocols essential for implementing fast charging systems in India's rapidly expanding electric two-wheeler and three-wheeler market. As India witnesses unprecedented growth in electric mobility, with two-wheelers representing over 95% of current EV sales, the establishment of standardized, secure, and efficient charging protocols becomes paramount for widespread adoption. This study examines the current landscape of AC charging methodologies, evaluates the technical and economic feasibility of DC fast charging implementation, and provides detailed comparative analysis of existing international standards including IS 17017-25, IS 17017-31, ChaoJi, and CCS 2.0. The research concludes with strategic recommendations for developing cyber-secure, cost-effective charging infrastructure specifically tailored to meet India's unique market requirements and operational constraints.
Uthaman, SreekumarMulay, Abhijit B
The transition from Internal Combustion Engine (ICE) vehicles to Battery Electric Vehicles (BEVs) introduces significant challenges in drivetrain development, particularly when historical road load data (RLD) is unavailable This study presents a methodology for virtually generating and processing road load data (RLD) to assess the durability of a new 3-speed electric axle (eAxle) design before building a physical prototype. Using AVL Route Studio, we simulated a range of driving conditions including urban, highway, and mixed-terrain routes, covering diverse global scenarios. These simulations produced high-frequency torque and speed data representative of real-world operation. Given that the raw dataset contained millions of points, direct use for fatigue assessment was impractical. To address this, the data was imported into Romax, where it was condensed into an accelerated duty cycle while preserving the cumulative fatigue damage patterns from the original dataset. Unlike
Ligade, PratikKhan, Nuruzzama MehadiKoona, Rammohan Rao
Computer-Aided Engineering (CAE) users often follow traditional meshing and contact generation processes, which are time-consuming, repetitive, and heavily dependent on user experience and perspective. The method described herein presents a system for generating a mesh and contact interfaces that ensures standardized and consistent output for a model. The process stores multiple mesh configurations, each containing a set of predefined geometric parameters to create standardized mesh for users. The process begins by receiving data for a CAD model of an object and capturing user input through a graphical user interface (GUI). Users specify parameters such as body type, global mesh size, and a selected mesh configuration from the available options. Using these inputs, the system generates a mesh for the model, incorporating the selected mesh configuration The contact automation process offers multiple key features for enhancing FEA simulations. It classifies contact types based on user
Dabadgaonkar, AnandKamble, Amardeep
The design and improvement of electric motor and inverter systems is crucial for numerous industrial applications in electrical engineering. Accurately quantifying the amount of power lost during operation is a substantial challenge, despite the flexibility and widespread usage of these systems. Although it is typically used to assess the system’s efficiency, this does not adequately explain how or why power outages occur within these systems. This paper presents a new way to study power losses without focusing on efficiency. The goal is to explore and analyze the complex reasons behind power losses in both inverters and electric motors. The goal of this methodology is to systematically analyze the effect of the switching frequency on current ripple under varying operating conditions (i.e., different combinations of current and speed) and subsequently identify the optimum switching frequency for each case. In the end, the paper creates a complete model for understanding power losses
Banda, GururajSengar, Bhan
The performance, lifespan, safety, and overall cost of high-voltage batteries—central elements in electric vehicles (EVs)—are fundamental to the success of the entire EV industry. These batteries, primarily used as energy storage systems, are especially critical in small commercial vehicles (SCVs), where efficient thermal management directly impacts reliability and durability. This paper presents innovative methods to improve energy efficiency, driving range, charging speed, and cost-effectiveness by combining advanced insulation techniques with thermoelectric cooling systems (TECs). The automotive industry is growing in EV domain and mostly in commercial vehicle application. The major challenge in EV’s is maintaining battery temperature to get optimal performance and best battery warranty. The key strategy of this research is providing insulating materials to stabilize battery temperatures. The thermal insulation minimizes thermal losses and buffers against external environmental
Chormule, Suhas RangraoWarule, PrasadNagpure, RahulJadhav, Vaibhav
In the quest for enhancing electric vehicle performance and safety, this paper presents a comprehensive investigation into the design and performance of high-voltage (HV) battery cooling plates featuring dedicated cooling channels, integrated with structural bottom protection members. The study aims to address the dual challenges of thermal management and crash protection in electric vehicles during bottom impacts. The research evaluates the cooling efficiency and structural resilience of the proposed design through a combination of design iterations, thermal performance evaluation, and crash simulations. Findings reveal that the integrated cooling plates not only maintain optimal battery temperatures under various operating conditions but also significantly improve the vehicle's crashworthiness. It was found that the cooling efficiency of the HV battery plates improved compared to competitor’s design, resulting in a more stable thermal environment for the battery cells. Moreover
Dusad, SagarKummuru, SrikanthJoshi, Amarja
The rapid evolution of modern automotive systems—powered by advancements in autonomous driving and connected vehicle technologies— pose fundamental challenges to design and integration. A specific challenge of these highly interconnected, software-driven systems is in ensuring their safety while avoiding spiralling costs and development times. This challenge calls for a more structured and rigorous approach to safety assurance than traditional methods. Traditional safety cases tend to take a linear, justification-focused approach that mainly focuses on positive assertions —compliance to safety —while giving limited attention to potential weaknesses, or gaps in supporting evidence. This practice may lead to criticism that such arguments are “too positive,” portraying an overly biased or optimistic view of system safety without sufficiently acknowledging areas of unresolved risk. As a result, conventional approaches for developing a safety case may overlook complex interactions
Kumar, AmrendraBagalwadi, SaurabhMcMurran, Ross
Electric vehicles (EVs) are becoming more popular than Internal Combustion Engine (ICE) powered vehicles, but their battery and motor components elevate their Gross Vehicle Weight (GVW), posing unique collision risks. Manufacturers strategically mount the high voltage (HV) battery packs under the passenger compartment to lower the Centre of Gravity and shield them from the front impacts. However, side impacts remain a concern, as the battery deformation in such instances could trigger fires or explosions, endangering occupants. To address this, crashworthiness designs adhere to New Car Assessment Program (NCAP) standards, particularly against side pole impact and side mobile barrier impact. Unlike the frontal section of BIW, which typically has larger crush space to absorb the crash energy, extensive design attention is required to the vehicle's side structure to absorb pole impacts without transmitting excessive force to the battery pack. Utilizing aluminium extrusions and sheet
Nivesh, DharunNamani, PrasadRamaraj, Rajasekar
Passenger vehicle users often manoeuvre their cars in diverse and unpredictable driving patterns. The vast and varied terrain of the Indian subcontinent further complicates this scenario, introducing unique challenges due to differences in driving expertise, vehicle usage, and environmental conditions. A specific challenge addressed in this paper arises during different engine temperatures and transient driving conditions—a critical phase for engine calibration to ensure optimal drivability and emissions performance. With current calibration practices, a backfire like abnormal engine noise was observed during certain transient driving patterns. This paper presents a novel calibration methodology designed to eliminate such abnormal noise. The proposed approach involves a step-by-step transient calibration refinement, making the calibration process more robust and adaptable to any driving behaviour. The paper outlines the specific challenges encountered and details the multi-level
Suna, BhagyashreeTyagarajan, SethuramalingamPise, ChetanAishwarya, Amritansh
With rise of EV adoption globally, electrical system of EV’s are continuously moving towards higher voltage for enabling fast charging capabilities and addressing efficiency. High Voltage electrical safety is a crucial part of safety standards for Electric Vehicles. There are several challenges, when any electrical system operating in High voltage region. This is posing risk for user, it means from design stage these systems should be designed in such a way for safeguarding user. These electric safety concepts are already mapped through different safety standards. In this paper, this high voltage safety related test and functional & constructional requirements will be explored through different EV standards and finally a comparatively analysis carried out.
Bhateshvar, Yogesh KrishanMulay, Abhijit BSantosh Jambhale, MedhaPatil, Sanjay
The customer perception of ride comfort with vehicle performance is the most important aspect in a vehicle design. The ride comfort and vehicle performance are influenced by driveline components i.e. propeller shaft phase angle, inclination angle and critical frequency of the driveline system. The optimization of the driveline system is essential to ensure the efficient and smooth power transfer. Propeller shaft is one of the critical components in the driveline to influence the vehicle performance. Propeller shaft characteristics influenced by several factors like vehicle max torque, propeller shaft joint type, materials properties, UJ phase and inclination angle and shaft unbalance value. The optimization of the above parameter within the tolerance limit enables to meet the required performance standard. Various methodologies are available to optimize these parameters to enhance the vehicle performance and comfort leads to customer satisfactions. This study focuses on the analytical
Kumar, SarveshSanjay, LS, ManickarajaKanagaraj, Pothiraj
In recent times, a standard driving cycle is an excellent way to measure the electric range of EVs. This process is standardized and repeatable; however, it has some drawbacks, such as low active functions being tested in a controlled environment. This sometimes causes huge variations in the range between driving cycles and actual on-road tests. This problem of variation can be solved by on-road testing and testing a vehicle for customer-based velocity cycles. On-road measurement may be high on active functions while testing, which may give an exact idea of real-world consumption, but the repeatability of these test procedures is low due to excessive randomness. The repeatability of these cycles is low due to external factors acting on the vehicle during on-road testing, such as ambient temperature, driver behavior, traffic, terrain, altitude, and load conditions. No two measurements can have the same consumption, even if they are done on the same road with the same vehicle, due to the
Kelkar, KshitijKanakannavar, Rohit
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
This study presents a comprehensive methodology for benchmarking hydrogen and diesel internal combustion Engines, with emphasis on virtual Real-Drive Emission (RDE) test procedures for diesel and hydrogen application. Emission profiles for legal cycles and RDE scenarios are accurately predicted through integration and development of Artificial Neural Networks (ANN) based on Long Short-Term Memory (LSTM) models. Virtual evaluations of Selective Catalytic Reduction (SCR) system performance, Diesel Exhaust Fluid (DEF) dosing accuracy, and exhaust temperature dynamics enabled by integrated data pipelines and physics-based modeling are also explored for holistic prediction of output. Across models, validation demonstrates good prediction accuracy including temperature (R2 > 0.94, RMS error < 25°C), air flow (92% accuracy, RMSE = 28 kg/h), upstream NOx (93% accuracy, RMSE < 10 mg/s), and SCR (TP NOx accuracy = 91.82%, dosing accuracy = 87.73%). This approach has the potential to offer
Shah, Jash VipinS, Manoj KumarRatnaparkhi, AdityaH, Shivaprakash
Electric vehicles are becoming more popular due to the low-cost investment for individual daily usage, such as traveling to nearby places, offices, and schools. There are environmental benefits that make them green and produce less pollution compared to traditional vehicles. Two-wheeler electric vehicles (EVs) have more electronic components compared to two-wheeler internal combustion engine (ICE) vehicles. The major components in two-wheeler EVs are the motor and battery. The traction motor is driven by the battery, Battery is a primary energy source in 2Wheeler electric vehicle. An electric vehicle comprises different major electronic components such as the battery management system (BMS), motor control unit (MCU), human-machine interface (HMI), and, in some cases, a vehicle control unit (VCU) as well. Considering a 48V architecture or less than 60V provides advantages of low system cost as it requires less effort for safety measures. Furthermore, this paper explores diverse
Karunakar, PraveenK R, Amogh
As atmospheric CO₂ concentrations continue to rise at unprecedented rates, the urgent need for breakthrough technologies that can efficiently capture carbon directly from the air and convert it into sustainable synthetic fuels has never been clearer. While numerous capture and conversion methods have been propose, many remain at an early stage of development, facing significant challenges such as low energy efficiency, limited scalability, and high operational costs. This lack of technological maturity underscores a vast, largely untapped potential for innovation and transformative advancement. In response to this gap, the present study compiles and critically examines a wide spectrum of emerging capture and conversion technologies. Through a detailed exploration of their functionalities, potentials, advantages, and challenges, the paper accumulates a comprehensive and well-informed dataset. This holistic understanding not only reveals key bottlenecks but also identifies promising
Jain, GauravPremlal, PPathak, RahulGore, Pandurang