Your Destination for Mobility Engineering Resources

Announcements for SAE Mobilus

Browse All

Recent SAE Edge™ Research Reports

Browse All 177

Recent Books

Browse All 718

Recently Published

Browse All
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 technology solves a long-standing ergonomic and aesthetic problem in automotive and consumer interface design, as the use of mechanical switches disrupts the clean look of modern interiors and tends to attract dust and wear. Currently available technologies, such as capacitive touch buttons and mechanical push switches, do not provide the corresponding tactile feedback or clear indication of touch, and usually contain visible openings that interrupt the design flow. Moreover, traditional switches are made up of multiple built-in components, which results in complicated construction and difficult maintenance. To address these drawbacks, we propose a Seamlessly Integrated, Selectively Elevated Fabric Switch that remains flush with the surface when not in use and automatically rises to form a tactile interface when required. The system is a multi-layer construction consisting of an outer fabric upholstery layer, a tactile actuation membrane, and a smart electromagnetic actuator layer
Mohunta, SanjayPanchal, GirishPuthran, Shaunak
The pressing global need for de-fossilization of the transport sector, especially within the heavy-duty segment, has intensified the exploration of alternative clean fuels. In this context, methanol gained traction due to their renewable production pathways, carbon-neutrality, and are being highly promoted by the Indian government to reduce CO2 emissions. Dual direct injection compression ignition (DDICI) is an effective combustion strategy to use methanol in heavy-duty engines, which combines the advantage of high-efficiency compression ignition with the clean-burning potential of methanol. In contrast to spark-ignited premixed methanol engines, this strategy involves a diffusion combustion of the methanol flame, thereby eliminating knocking and enabling running with high compression ratios. This experimental and numerical study presents a comprehensive investigation into the DDICI strategy using methanol as primary fuel and diesel as a pilot for ignition assistance. The work
Singh, InderpalDhongde, AvnishRaut PhD, AnkitGüdden, ArneEmran, AshrafBerry, Sushil
India has emerged as the world’s largest market for motorized two-wheelers (M2Ws) in 2024, reflecting their deep integration into the country’s transportation fabric. However, M2Ws are also a highly vulnerable road user category as according to the Ministry of Road Transport and Highways (MoRTH), the fatality share of M2W riders rose alarmingly from 27% in 2011 to 44% in 2022, underlining the urgency of understanding the circumstances that lead to such crashes. This study aims to investigate the pre-crash behavior and crash-phase characteristics of M2Ws using data from the Road Accident Sampling System – India (RASSI), the country’s only in-depth crash investigation database. The analysis covers 3,632 M2Ws involved in 3,307 crash samples from 2011 to 2022, representing approximately 5 million M2Ws nationally. Key variables examined include crash configuration, collision partner, road type, pre-event movement, travel speed, and human contributing factors. The study finds that straight
Govardhan, RohanPadmanaban, JeyaJethwa, Vaishnav
Accidents during lane changes are increasingly becoming a problem due to various human based and environment-based factors. Reckless driving, fatigue, bad weather are just some of these factors. This research introduces an innovative algorithm for estimating crash risk during lane changes, including the Extended Lane Change Risk Index (ELCRI). Unlike existing studies and algorithms that mainly address rear-end collisions, this algorithm incorporates exposure time risk and anticipated crash severity risk using fault tree analysis (FTA). The risks are merged to find the ELCRI and used in real time applications for lane change assist to predict if lane change is safe or not. The algorithm defines zones of interest within the current and target lanes, monitored by sensors attached to the vehicle. These sensors dynamically detect relevant objects based on their trajectories, continuously and dynamically calculating the ELCRI to assess collision risk during lane changes. Additionally
Dharmadhikari, MithilS, MrudulaNair, NikhilMalagi, GangadharPaun, CristinBrown, LowellKorsness, Thomas
This paper presents a novel structural solution for side impact protection of high-voltage battery packs in electric trucks. While electric vehicles offer benefits like zero emissions and independence from fossil fuels, in turn present challenges in meeting crashworthiness standards and safety regulations. The device addresses the critical need for effective battery protection & styling of battery electric vehicles. The integration of a hybrid corrugated panel system with plastic side fairings is innovative, combining crashworthiness with aerodynamic and aesthetic benefits. The crash protection features two hat-section steel channels at the top and bottom and corrugated steel sheet with alternating ridges is attached to these channels. Corrugated panels are enforced with help of backing strips. This assembly is mounted on shear plates at both ends, secured to the vehicle's frame rail. During a side impact event, the plastic side fairings absorb the initial impact, crumpling easily. If
Badgujar, PrathameshDevendra, AwachareHansen, Benjamin
Vehicle door-related accidents, especially in urban environments, pose a significant safety risk to pedestrians, infrastructure and vehicle occupants. Conventional rear view systems fails to detect obstacles in blind spots directly below the Outside Rear View Mirror (ORVM), leading to unintended collisions during door opening. This paper presents a novel vision-based obstacle detection system integrated into the ORVM assembly. It utilizes the monocular camera and a projection-based reference image technique. The system captures real-time images of the ground surface near the door and compares them with calibrated reference projections to detect deviations caused by obstacles such as pavements, potholes or curbs. Once such an obstacle is detected the vehicle user is alerted in the form of a chime.
Bhuyan, AnuragKhandekar, DhirajJahagirdar, Shweta
The paper aimed to improve the accurate quantification of driver drowsiness and to provide comprehensive, evidence-based validation for a Vision-Based Driver Drowsiness and Alertness Warning System. Advanced quantification of driver drowsiness is designed to enhance distinction of true positive events from False Positive and False Negative events. Methodology to pursue this included assessing inputs such as facial features, driver visibility, dynamic driving tasks, driving patterns, driving course time and vehicle speed. The system is programmed to actively learn Eye Aspect Ratio (EAR) reference and adapt personalised EAR threshold value to process EAR frames against the learnt threshold value. This method optimized the data frames to enhance the evaluation and processing of essential frames, thereby reducing delays in the processor and the Human-Machine Interface (HMI) warning module. Comprehensive validation is systematically conducted within a controlled test track environment to
Balasubrahmanyan, ChappagaddaAkbar Badusha, A
This study presents a data-driven approach aimed at enhancing the correlation between physical test data and Computer-Aided Engineering (CAE) simulations, with an emphasis on adapting the standard CAE model's response to minimize any gaps relative to the response of a given test specimen. Leveraging historical test data, machine learning techniques are used to categorize responses into distinct bands, effectively capturing the inherent variability observed in real-world scenarios. This categorization step recognizes patterns across a wide range of test data, forming the foundation for closely matching and adapting CAE models to new, unseen hardware data. In typical automotive simulation workflows, tuning a standard CAE model to match new hardware test data involves iterative parameter adjustments and simulations. This process can be time-consuming and often lacks predictive insight into the necessary modifications. The approach developed in this study addresses this challenge by
Khopekar, MariaArya, BibhuSridhar, RaamMohan, PradeepKurkuri, Mahendra
With the rise of EVs, researchers are focusing on optimizing busbar design to meet the demands of high energy density, fast charging, and compact battery packs. The busbar design starts by selecting the material and the cross-sectional area required based on the rated current requirement. The width matches or may exceed the battery cell terminal size, whereas the length is optimized such that it is packaged within the given space constraints. The research also highlights the risk of busbars to oxidation and corrosion, which increases resistance and decreases conductivity for which plating/coating techniques are applied to improve the surface finish, overall durability, conductivity and in some cases the surface hardness, while minimizing the heat loss. Using simulations and experimental validation, the study examines three key design parameters: the weld diameter for busbar welded joints, electrical resistance, and contact resistance. A detailed analysis investigates how the weld
Nogdhe, YogeshSingh, Shobit KumarPaul, JibinMishra, MukeshMenon, Praveen
Refined NVH performance of a vehicle is a mark of premium quality. Achieving the desired NVH performance in different vehicle operating conditions is always a Herculean task and early stage “CAE design recommendations” play crucial role in overall vehicle design development. This becomes tougher when the program is very much cost, weight and timeline sensitive. This paper explores simulation approach for addressing a major noise issue for a vehicle running at a constant speed on a rough road. While working on any issue, the first and the most critical step is to identify the exact root cause of the issue. Hence, we propose a detailed full vehicle level “contribution analysis (CA) + transfer path analysis (TPA)” methodology (everything done through the simulation) and then go for the design recommendations to improve the performance. We used road excitation power spectral density (PSD) as the input at all the four wheels (spindle locations) calculated through MBD software. The first
Mahajani, MihirNascimento, FabioAdinarayana Reddy, KodidelaMatyal, MahanteshTenagi, IrappaSardar, Chenna
The number of female drivers in India is increasing alongside the rapid growth of the Indian automotive industry. A driving comfort survey conducted among female drivers revealed that many of them experienced discomfort when wearing safety belts—while driving and as front-seat passengers. This discomfort is primarily due to a phenomenon referred to as “neck cutting.” The root cause of neck cutting is likely related to vehicle design, which is traditionally based on Anthropometric Test Devices (ATD’s) representing the 5th, 50th & 95th percentile (%tile) of the global population. However, a literature review indicated that the anthropometric dimensions of the Indian populations are generally smaller than those of the global for the respective candidate. To validate the neck-cutting issue, various female candidates were asked to sit in the Driver’s seat for physical measurements trials. Accordingly, methodology was developed to quantify neck cutting parameters objectively. A correlation
Kulkarni, Nachiket AChitodkar, Vivek VEknath Chopade, SantoshMahajan, RahulYamgar, Babasaheb S
This study addresses one of the challenges in the energy transition of heavy-duty vehicles by converting a diesel Refuse Collection Vehicle (RCV) into a hydrogen-powered prototype. The research is part of the VeH2Dem project funded by NextGenerationEU and focuses on dimensioning the complete hydrogen propulsion system for a RCV, including the energy storage capacity, without compromising payload or operational functionality. The development of the propulsion system is based on a comprehensive analysis of operational data extracted from fleet management systems, complemented by detailed instrumental monitoring of various collection routes. This methodology ensured that the prototype inherits performance equivalent to the original internal combustion engine vehicle across all evaluated scenarios. The vehicle performance objectives were established following a comparative analysis with solutions currently available in the RCV market, incorporating statistical analyses to ensure continuous
Cano, PabloBarrio, RobertoRoche, Marinade-Lima, DanielaBatista, SaraBertolí, Xavier
The safety of vulnerable road users, particularly pedestrians, cyclists, and motorcyclists, is a paramount concern in automotive design and regulation. In India, the situation is particularly alarming, with pedestrians being the second highest victims of road accidents, as evidenced by over 32,825 reported pedestrian accidents and 4,836 cyclist fatalities in 2022, excluding two-wheeler motorcyclists. On a global scale, the prevalence of such incidents has prompted European countries to introduce new regulatory requirements, such as ECE R127.03. This regulation encompasses the evaluation of pedestrian head form impacts on windshields, assessing the typical behavior of glass through jerk criteria following initial contact, in conjunction with the existing Head Injury Criterion (HIC) evaluation for pedestrian head forms. These criteria’s are meticulously designed to ensure that both acceleration and jerk remain within safe limits to reduce the severe risk of severe injury to head of
Kumar, RitikA, Rajesh
Functional Mock-up Units (FMUs) have become a standard for enabling co-simulation and model exchange in vehicle development. However, traditional FMUs derived from physics-based models can be computationally intensive, especially in scenarios requiring real-time performance. This paper presents a Python-based approach for developing a Neural Network (NN) based FMU using deep learning techniques, aimed at accelerating vehicle simulation while ensuring high fidelity. The neural network was trained on vehicle simulation data and trained using Python frameworks such as TensorFlow. The trained model was then exported into FMU, enabling seamless integration with FMI-compliant platforms. The NN FMU replicates the thermal behavior of a vehicle with high accuracy while offering a significant reduction in computational load. Benchmark comparisons with a physical thermal model demonstrate that the proposed solution provides both efficiency and reliability across various driving conditions. The
Srinivasan, RangarajanAshok Bharde, PoojaMhetras, MayurChehire, Marc
The clutch is a mechanical device that connects and disconnects engine power to the drivetrain through the clutch disc and cover assemblies. The disc, with friction material linings is mounted on the transmission shaft, transmits power when clamped between the flywheel and cover assembly. During operation, wear occurs due to speed differences and slippage between the engine and transmission. Clutch performance is evaluated under repeat restart conditions on steep gradients to assess thermal durability and reliability in commercial vehicles. The repeat restart test on a 12% gradient replicates truck launches under full load, where excessive slippage generates heat that may lead to friction material wear or failure if critical temperature limits are exceeded. To address the high cost and time of physical testing, a 1D thermal simulation was developed using GT Suite. The model replicates 90 repeat vehicle launches on a 12% gradient in first gear, integrating driver inputs and drive cycles
Munisamy, SathishkumarChollangi, DamodarMane, Sudhir
Water leakage is a common issue in vehicles, especially during water testing. It often occurs due to a gap between the seal bulb and the closure panel. This gap can result from variations in flange angle, flange curvature, closure surface, or seal bulb height. This study focused on how flange curvature affects seal bulb height and sealing performance. A Computer-Aided Engineering (CAE) method was used, supported by tests on physical samples. Multiple simulations were done using different flange curvatures. Results showed that with a constant Side View Flange Angle (SVFA) of 150°, increasing the Flange Curvature Radius (RZX) reduced seal bulb deformation. The optimal flange curvature radius was found to be 250 mm, where the bulb compression was 1.2 mm. Sharp or tight flanges caused the bulb to deform more, reducing contact and sealing force. To reduce this deformation, a hollow tube was inserted inside the seal bulb. The hollow tube used had an internal diameter of 10 mm and an external
Kumar, SauravNeelam, RajatChowdhury, AshokPanchal, GirishLathwal, Sandeep
This research analyzes the significance of air extractor on car door closing effort, especially within the context of highly sealed cabins. The goal is to measure their effectiveness in lowering pressure-induced resistance, study how the cut-out cross section and location affect performance, and its contribution to vehicle premium feel. Current vehicle design trends prioritize airtight cabin sealing for improving aerodynamic efficiency, NVH performance. This causes a problem in door closing operation. Air trapped while closing door creates transient pressure pulses. This pressure surge creates immediate discomfort to user i.e., Popping in Ears and requires high door closing force, and long-term durability problems in hinges and seals. In properly sealed cabins, air pressure resistance can contribute to 25% to 40% of total door closing force. Air extractors, usually installed in the rear quarter panels or behind rear bumpers, serve as pressure relief valves, allowing for a smoother
P, SivasankarSankineni, Vikhyath RaoShah, SahilMarimuthu, Anbarasan
In emerging markets, especially in India and other similar countries, the growing traffic density on the roads leads to different types of accidents, including frontal head-on collisions, rear-end collisions, side-impact collisions, collisions with fixed objects such as electric poles, trees, road guard rails, road dividers, and accidents involving pedestrians, cyclists, and two-wheelers. These accidents could be due to over speeding, distracted driving, violation of traffic rules, and inadequate road infrastructure etc. Providing the necessary safety restraint systems (Airbags and Seat belts) in vehicles and ensuring their robust functionality in different real-world accident scenarios will be challenging for vehicle manufacturers. It is high time to redefine the traditional collision-sensing architecture strategies with a logical approach based on a thorough study of available accident data statistics, types of objects, and scenarios leading to severe accidents. Among these, rear-end
KOVALAM, SUNIL KUMAR
This study presents an integrated vehicle dynamics framework combining a 12-degree-of-freedom full vehicle model with advanced control strategies to enhance both ride comfort and handling stability. Unlike simplified models, it incorporates linear and nonlinear tire characteristics to simulate real-world dynamic behavior with higher accuracy. An active roll control system using rear suspension actuators is developed to mitigate excessive body roll and yaw instability during cornering and maneuvers. A co-simulation environment is established by coupling MATLAB/Simulink-based control algorithms with high-fidelity multibody dynamics modeled in ADAMS Car, enabling precise, real-time interaction between control logic and vehicle response. The model is calibrated and validated against data from an instrumented test vehicle, ensuring practical relevance. Simulation results show significant reductions in roll angle, yaw rate deviation, and lateral acceleration, highlighting the effectiveness
Duraikannu, DineshDumpala, Gangi Reddi
Real-world crashes involve diverse occupants, but traditional restraint systems are designed for a limited range of body types considering the applicable regulations and protocols. While conventional restraints are effective for homogeneous occupant profiles, these systems often underperform in real-world scenarios with diverse demographics, including variations in age, gender, and body morphology. This study addresses this critical gap by evaluating adaptive restraint systems aligned with the forthcoming EURO NCAP 2026 protocols, which emphasize real-world crash diversity and occupant type. Through digital studies of frontal impact scenarios, we analyze biomechanical responses using adaptive restraints across varied occupant demographics, focusing on head and chest injury (e.g., Chest Compression Criterion [CC]). This study used a Design of Experiments (DOE) approach to optimize occupant protection by timing the actuating of these adaptive systems. The results indicate that activating
satija, AnshulSuryawanshi, YuvrajChavan, AvinashRao, Guruprakash
This study introduces a novel in-cabin health monitoring system leveraging Ultra-Wideband (UWB) radar technology for real-time, contactless detection of occupants' vital signs within automotive environments. By capturing micro-movements associated with cardiac and respiratory activities, the system enables continuous monitoring without physical contact, addressing the need for unobtrusive vehicle health assessment. The system architecture integrates edge computing capabilities within the vehicle's head unit, facilitating immediate data processing and reducing latency. Processed data is securely transmitted via HTTPS to a cloud-based backend through an API Gateway, which orchestrates data validation and routing to a machine learning pipeline. This pipeline employs supervised classifiers, Support Vector Machine (SVM), K-Nearest Neighbors (KNN), and Random Forest (RF) to analyze features such as temporal heartbeat variability, respiration rate stability, and heart rate. Empirical
Singh, SamagraPandya, KavitaJituri, Keerti
The present disclosure is about combating Thermal runaway in Electric, Plug-in Hybrids and mild hybrid vehicles. This paper comprises of high-Voltage Battery pack containing Battery cells electrically coupled with Shape Memory Alloy along with Busbars. These connectors (Shape Memory Alloy) are programmed to operate in two states: First to electrically connect the cells with the busbars, second to disconnect the individual cells from electric connection beyond the threshold temperature. This mechanism enables the Battery cells to rapidly prevent the Battery from the Thermal runaway event which is caused from the cell level ensuring the Battery safety mechanically. Additionally, the Battery pack includes the cell monitoring system and Battery Monitoring System to enhance the above invention with regards to the safety of the vehicle. This configuration is implementable and retrofittable into existing battery systems, offering a robust solution to the challenges posed by prolonged vehicle
Reginald, RiniRout, SaswatVENKATESH, MuthukrishnanChauhan, Ashish JitendraSelvaraj, Elayanila
With increased deterioration of road conditions worldwide, automotive OEMs face significant challenges in ensuring the durability of structural components. The tyre being the primary point of contact with the road is expected to endure harshest of impacts while maintaining the other performance functions such as Ride & Handling, Rolling resistance, Braking. Thus, it is considered as the most challenging component in terms of design optimization for durability. The current development method relies on physical testing of initial samples, followed by iterative construction changes to meet durability requirements, often giving trade-off in Ride & Handling performance. To overcome these challenges, a frugal simulation-based methodology has been developed for predicting tyre curb impact durability before vehicle-level testing so that corrective action can be taken during the design stage.
Sundaramoorthy, RagasruobanLenka, Visweswara