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Temperature management in both residential environments and commercial vehicle cabins are rapidly evolving toward intelligent, interconnected climate-control ecosystems. However, current systems operate in isolation, with no mechanism for synchronizing thermal comfort preferences between a user’s smart home and the cabin environment of a truck used for either personal mobility, last-mile delivery, or commercial logistics. This disjointed control results in inconsistent comfort experience, unnecessary HVAC energy consumption, and the inability to anticipate user needs based on transition patterns (e.g. leaving a cool home for a hot truck cabin) between home and vehicle. To address this technical challenge, this research paper provides bidirectional communication temperature-synchronization framework in which a smart-home HVAC app communicates seamlessly with the truck’s cabin climate-control system, integrating user-specific comfort profiles(such as temperature preferences, real-time cabin and home temperature, humidity levels, HVAC operating states, outside weather forecasts, trip start times, thermal-soak estimates etc.) and environmental prediction models to maintain consistent thermal comfort across both environments. Based on user’s comfort profile, our framework derives the Comfort Deviation Index (CDI), Transient Temperature Gradient (TTG) and applies predictive algorithms to precondition the cabin or home environment accordingly. The AI technique Long Short-Term Memory (LSTM) network is used for forecasting temperature transitions across home-to-vehicle. Our technique becomes even more pronounced in small-haul trucks that operate under frequent stop-and-go conditions, where rapid cabin temperature fluctuations are common. There is currently no existing research or framework that enables seamless temperature synchronization between a user’s home environment and the truck cabin. A smart-home–to-cabin synchronization approach would fill this gap by intelligently accounting for outside weather, trip duration, thermal soak, and energy-efficiency constraints. Additional challenges include ensuring secure communication over cloud and edge networks, managing latency constraints for real-time actuation, and preventing conflicts between home HVAC automation and automotive HVAC control logic
Prajapati, Saurav, Sagar, Kshitij Singh, B. S., Sanchitha
High-voltage (HV) cables and connector terminals in electric vehicles (EVs) are susceptible to high current loads. Due to high current, there is excessive temperature rise near the terminals and crimping region inside the connectors. Excessive temperature beyond critical limits may pose risks to connected components and compromise passenger safety. Conventional cooling approaches are often energy-intensive and rely on active thermal management systems, which may not always be suitable for high power applications. Therefore, there is a need for a localized, rapid, and reliable passive thermal management strategy that can be retrofitted into existing connector designs with some structural modifications that would provide significant safety enhancements. This study proposes a novel approach by incorporating phase-change material along with solid fins inside the connector. The PCM has been placed co-axially surrounding the terminals of the connectors and enclosed inside a casing to ensure no direct contact with the connector components. The fins are also enclosed inside the same casing with projections going into the PCM. The PCM acts as heat storage unit, delaying the time for the peak temperature to rise and the fins distribute the heat rapidly inside the PCM. The objective is to maintain the terminal temperature below 100°C with 125 A current rating. A 3-D transient thermal analysis was performed on a CAD model encompassing PCM with solid fins inside the female connector. A comparative analysis between a traditional connector to a fin enhanced PCM connector showcased a drastic delay in temperature rise (acting time) by 115 seconds. Furthermore, the slope of rise in temperature decreased significantly beyond 100°C, slowing the rapid heating of the terminals. Thus, a passive sustainable system is designed for localized thermal management of HV Connectors.
Neogi, Angshuman, Singh, Jitendra, Kumar, Ashutosh
The Software-Defined Vehicle (SDV) paradigm is reshaping automotive electronic architectures by enabling continuous software rollout & artificial intelligence (AI) evolution on platforms over the total service life of the hardware. This creates a fundamental challenge for electronic control unit (ECU) design: to enable sustained deployment, adoption & maintenance of AI models over vehicle’s lifetime. This paper presents a technology independent framework for integrating AI lifecycle management into SDV ECU architectures, while decoupling AI & software innovation from hardware constraints. It further discusses the role of scalable computing platforms based on high-performance CPUs, GPUs & SoCs, in supporting increasing AI workloads over time. In addition, the evolution of AUTOSAR-based hardware abstraction mechanisms is examined as an enabler for software portability & hardware independence. The discussed framework addresses key lifecycle aspects, including AI model deployment, versioning, rollout strategies & long-term maintainability within established automotive safety, cybersecurity frameworks. The presented work contributes to future-ready SDV systems capable of sustaining continuous AI innovation over extended operational lifetime.
Ghosh, Sayantan, Anudeepika K., Durga, Nagaraju, Yamuna
Oil canning, characterized by localized buckling and surface waviness in thin metal panels, is a critical quality parameter in the automotive industry. Since outer panels serve both structural and aesthetic functions, even minor surface distortions can adversely affect perceived vehicle quality. Traditionally, evaluation of oil canning relies on extensive nonlinear Finite Element simulations. For example, assessing a single hood design variant may requires thousands of nonlinear Finite Element analyses. Considering multiple design iterations across major vehicle panels including hood, roof, doors, fenders, and trunk, the total number of simulations can exceed tens of thousands, leading to substantial computational cost and development time. Consequently, this conventional approach is both time intensive and resource demanding. To address these limitations, advanced Machine Learning techniques are employed to significantly reduce simulation effort as well as accelerate design exploration. Initially, a deep learning based one-dimensional Reduced Order Model is developed to predict load–displacement response and oil canning propensity for a given panel. Indentation points on the hood panel are selected using a space filling Latin Hypercube sampling method. The Machine Learning based one-dimensional Reduced Order Model is trained by using 300-500 indentation points and validated using approximately 40-50 unseen indentation points. The verification is performed on multiple hood geometries. The predicted results demonstrate strong correlation with Finite Element generated load–displacement curves with that of ML based 1-dimensional reduced order model. Furthermore, to enable rapid design exploration across different panel geometries, a dataset of 40 different hood designs is utilized. A geometric deep learning approach is applied to cluster panel geometries, and the resulting representations are used within a 3-dimensional deep neural network tool Ansys SimAI™ to predict oil canning propensity and quantify it using the canning ratio. Validation study is carried out on unseen panel geometries, and the Machine Learning predicted oil canning zones show good agreement with Finite Element identified critical regions. The proposed Machine Learning framework reduces prediction time from hours to minutes, offering a scalable and cost-effective solution for early-stage design evaluation and mitigation of oil canning in automotive panels.
Sarnobat, Rajvardhan Vilasrao, Kumar, Dinesh, Jawale, Akshay, Balaji, Ananya, Kulkarni, Shreya
The automotive industry is leaning heavily into virtual testing to speed up vehicle design and cut physical prototyping costs. However, checking if a simulation matches a real car still relies on older, rigid math formulae and manual checks. This makes virtual testing less reliable for highly dynamic driving maneuvers, required in vehicle design. To address this, following paper introduces an automated software framework built to accurately measure the differences between physical test data and virtual simulations. The methodology was validated using a lightweight off-road prototype at the National Automotive Test Tracks (NATRAX) on a custom-engineered track inducing high-fidelity roll, pitch, and yaw excitations. To guarantee accuracy, an identical digital twin of this complex topography was constructed within a high-fidelity vehicle-dynamics simulation environment. The system features an algorithmic engine that automatically reads, cleans, and synchronizes distinct physical and virtual telemetry streams. Initial validation using standard metrics like NRMSE, RMSE, and S&G proved insufficient, failing to quantify errors in data exhibiting non-linear temporal shifts caused by stochastic human driver latencies. To overcome these limitations this study applies Windowed Dynamic Time Warping (DTW) to operationalize the ISO/TS 18571:2024 standard. This approach leverages the optimal warping path to extract continuous, vector-based error profiles, isolating phase and amplitude inconsistencies across the entire event. This automated framework significantly reduces correlation time by transitioning from subjective scalar scores to high-resolution diagnostic error vectors. By quantifying dynamic fidelity through this automated, high-precision DTW computational tool, the methodology validates virtual models as robust predictive tools, allowing simulation data to yield results comparable to physical benchmarks. This capability enables faster vehicle development by allowing rapid evaluation of multiple parameters in a virtual environment. It supports performance fine-tuning with reduced physical testing and can be integrated into automated workflows for repeatable data correlation, improving validation efficiency and reducing time.
Umorya, Divyansh, Pithadia, Chirag, S. J., Srihari, Jaiswal, Manish, Hardiya, Karan, Marmat, Hemant
As automotive architectures evolve toward Software Defined Vehicles (SDVs) and high levels of driving automation, traditional safety analysis techniques rooted in hardware reliability require significant adaptation. The Classical Event Tree Analysis (ETA), a cornerstone of ISO 26262 functional safety compliance, relies on static, binary branching logic where each function either fails or succeeds. While highly interpretable and effective for modelling random hardware failures, classical ETA struggles to capture the dynamic, non-linear interactions, temporal degradation, and complex human-machine interface (HMI) dependencies that are characteristic of modern Advanced Driver Assistance Systems (ADAS) and autonomous vehicles. This paper proposes State Dependent Event Tree Analysis (SD-ETA), a methodological extension designed to integrate discrete state vectors and temporal dependencies into the classical ETA framework. SD-ETA assigns probabilities to the branches for the dynamic nonlinear interactions, temporal degradation, and complex human-machine interface (HMI) dependencies instead of binary values, thereby allowing the system state (comprising vehicle physics, environmental conditions, and driver attention metrics) to dynamically update based on the outcomes of the preceding nodes. This approach retains the visual hierarchy and regulatory familiarity of standard event trees while significantly enhancing model fidelity for Safety of the Intended Functionality (SOTIF) scenarios governed by ISO 21448. To demonstrate the necessity and utility of this methodological evolution, this paper presents a comparative case study analysing a system operating under degraded environmental conditions. The quantitative application reveals that while classical ETA predicted a relatively low collision risk by treating sensor performance as a static binary state, the dynamic SD-ETA simulation exposed a critical hidden safety gap, calculating a higher collision probability due to compounded latency and degraded physical operating parameters. Ultimately, SD-ETA equips safety practitioners and automotive regulators with a modernized, time-aware framework to accurately evaluate the complex, interacting risks of autonomous systems without sacrificing the transparency required for rigorous safety certification.
Sharma, Dhiraj Mohan, Mutagi, Megha, Reddy, Kakarla Subba
Children dying in hot cars is not a new problem. Since 1998, more than 1,000 children have died this way in the United States alone — roughly 37 every year. That number has barely been reduced, which tells something alarming: the solutions built so far aren't solving it completely. Door-based reminders are a good example of why. They trigger when a rear door opens, but opening a door doesn't confirm a child was left behind. Single-sensor setups have their own gaps too; no single sensor handles every real-world scenario reliably on its own. Multi-sensor systems get closer, but most use rigid threshold-based rules that fall apart the moment conditions deviate — a sleeping infant barely moves, a child under a blanket reads completely differently on a thermal sensor. This paper proposes Smart-ROPS (Smart Rear Occupant Protection System), an embedded ML architecture that targets these specific failure modes without needing expensive hardware or complex software. Four sensor types feed the system: millimeter-wave radar, CO₂, thermal infrared, and ultrasonic. Data from these passes through three layers — the Perception Layer handles initial sensor fusion, the Processing Layer runs a decision tree as the primary classifier, and when confidence is low, a shallow neural network steps in for ambiguous cases. If a risk is confirmed, the Intervention Layer manages the response: starting with a smartphone alert and cabin ventilation, escalating to emergency services if needed. This is presented as an architectural design contribution — hardware prototyping and real-world testing are left for future work.
Shrimal, Harsh
Overtaking another vehicle on a two-lane road can turn dangerous within a few seconds, especially when the gap to an oncoming vehicle is short or that vehicle is moving fast. Many driver-assistance systems rely on a simple, fast rule called the Overtake Safety Margin formula to decide whether an overtaking maneuver is safe, without running a full traffic simulation. This study checks the formula's reliability using a physics-based simulator that models three vehicles: the car overtaking, the car being overtaken, and the oncoming car. One million generated overtaking scenarios were evaluated using both the OSM formula and the kinematic simulator to identify cases where the formula classified a maneuver as SAFE while the simulator predicted an UNSAFE outcome. These mismatches, called blind spots, represented 3.98% of the evaluated scenarios and were concentrated in high oncoming-speed, short-gap situations, pointing to a specific weakness rather than random error. To catch these blind spots automatically, a small and efficient machine-learning model, a micro-transformer, was trained on the simulator's results. It reached 96.3% overall accuracy and correctly flagged 86.9% of the formula's blind spots, outperforming LightGBM, which detected 73.2%. The model's confidence scores were well calibrated, so they can be trusted to trigger an extra safety check when needed. An uncertainty-based search then used these confidence scores to find risky scenarios efficiently: 187 of the 500 most uncertain cases turned out to be unsafe, about 9.4 times more effective than random selection. Finally, the 30 highest-priority cases were replayed in the CARLA driving simulator, and 27 were confirmed to reproduce unsafe outcomes. Together, these results show that pairing a fast rule-based formula with a calibrated learning-based monitor can catch dangerous situations the formula alone would miss, supporting the safety documentation required for automotive safety-of-the-intended-functionality standards.
Sekaran, Nikhil, Sehgal, Vishal
Accurately predicting Thermal and Flow parameters in Battery Pack Thermal Management System is very important to ensure maximum system efficiency, long range and vehicle safety. Traditionally, conventional Computational Fluid Dynamics (CFD) methods are used to get detailed insights into these parameters. But these methods remain computationally very expensive, which limits their application in real-time predictions. This study presents an alternate structured simulation framework that combines CFD fundamentals with Physics-Informed Neural Networks (PINNs) to enable fast and efficient prediction of thermal and flow behavior. PINNs incorporates the governing partial differential equations (PDEs) - mass, momentum and energy – directly into the neural network's loss function, enabling efficient learning with limited dependency on training datasets. In this study, we present a PINN framework trained on limited datasets derived from general CFD simulations of flow and Conjugate Heat Transfer (CHT) cases for a battery pack. The trained PINN model is then validated against a separate set of test datasets obtained from independent studies, across key performance parameters including pressure drop, velocity, temperature distribution, and hotspot location. Comparative analysis indicates that the proposed PINN framework predicts key parameters within 5% deviation from test dataset values. The PINN model also significantly reduces computational time from 5-8 hours per case for traditional detailed CFD to 2-3 seconds. Additionally, the PINN framework requires only a closed-volume CAD geometry and does not rely on 3D-mesh. Limited data can be used to speed up the training process, thereby eliminating the time associated with pre-processing, repeated model setup for different cases, and subsequent corrections. Findings from this study demonstrate PINNs as a potential surrogate modelling tool for real-time thermal monitoring and rapid design iteration in battery cooling systems. This reduces dependency on computationally expensive simulations, thereby reducing development cycles and faster time for customers. This work shows a scalable physics-informed neural-network framework that can be extended beyond battery systems to other components at system and vehicle levels.
Sarkar, Shantanu, Lakshmanan, Yoganathan, A., Raju
Rapid electrification of the automotive industry has significantly increased the functional complexity and safety expectations of Battery Management Systems (BMS) used in electric vehicles. While Model-in-the-Loop (MIL) testing remains a standard practice for early-stage verification of control algorithms, it is inherently limited in its ability to represent real time execution effects and physical hardware interactions. Critical BMS functions, including protection timing validation, sensor interface behavior, contactor actuation logic and fault detection mechanisms are strongly influenced by hardware characteristics such as signal conditioning, analog to digital conversion, execution latency, and nonlinear component behavior, which cannot be accurately captured in a software only environment. This paper presents the application of Hardware-in-the-Loop (HIL) testing as an essential validation methodology for safety critical BMS functions by interfacing the production intent BMS controller with a real time simulated battery environment. The proposed HIL setup enables realistic interaction between embedded software and physical I/O interfaces, allowing systematic evaluation of BMS behavior under normal operating conditions as well as controlled electrical, thermal, and communication fault scenarios. Key validation aspects include protection of response timing, robustness of fault handling logic, and system behavior under transient and abnormal conditions. The study demonstrates that HIL testing effectively bridges the validation gap between MIL simulations and vehicle level testing by enabling early identification of hardware–software integration issues. This approach enhances confidence in functional safety readiness, reduces development risk, and supports compliance with established automotive development workflows. The presented methodology aligns with established automotive development practices and provides a practical framework for robust BMS validation at bench level prior to vehicle level.
Patowary, Suman, Kumar, Aashish, Choudhary, Abhilash, Kumar, Abhishek, Bora, Abhijit
Brake squeal in heavy-duty S-cam drum brakes remains a persistent NVH challenge, primarily driven by friction-induced modal instabilities. Existing studies on drum brake squeal mitigation largely emphasize geometric modifications, stiffness tuning, or the application of damping treatments, while the influence of directional stiffness characteristics of friction linings remains insufficiently explored. This research presents a novel, material-centric approach by modelling the brake lining as a transversely isotropic material, characterized by six independent elastic constants, and systematically quantifying their influence on squeal-prone unstable modes using Complex Eigenvalue Analysis (CEA). A validated finite-element model of a production S-cam drum brake assembly is developed and correlated through experimental modal analysis, ensuring close agreement between predicted and measured natural frequencies and mode shapes. The validated model is then integrated with a Design of Experiments (DOE) within commercially available FEA software to quantify both main effects and higher-order interactions across practical ranges of in-plane and out-of-plane elastic moduli and shear constants. To enhance the predictive accuracy of the surrogate models, a subsequent sampling–fit study is conducted, significantly improving the coefficient of determination (R2) of the response surfaces. The refined surrogate models are employed within a Global Response Surface Methodology (GRSM) framework to perform multi-parameter optimization aimed at minimizing squeal propensity under representative operating conditions. Finally, complex eigenvalue analysis quantifies the impact of the optimized transversely isotropic property combinations on modal stability, establishing a predictive, optimization-driven methodology for robust, noise-free drum brake design. The study culminates in the identification of an optimized transversely isotropic elastic-constants signature for the friction lining, providing actionable targets for friction material formulation and reinforcement alignment. Unlike prior research focused on isotropic material assumptions or component-level design changes, this first-of-its-kind methodology advances the state of the art by enabling friction material– centric NVH optimization for heavy-duty drum brake systems.
Philip, Rony, Muralidharan, Sudharsan, Mohanam, Gopalakrishnan
Finite Element Analysis (FEA) plays a vital role in accelerating product development and reducing overall engineering costs. Accurate simulation of powertrain components requires extensive preprocessing of solid models. Detailed contact definitions and bolt representations are required to properly evaluate screw joints. Pipe joints present similar challenges, as they often incorporate various types of nuts and connectors. As a result, engineers spend a significant amount of time manually modelling these joints. Automating the modelling process is difficult due to the high variability in bolt sizes and pipe joint designs. This paper proposes AI-based models to automatically classify these components and extract their distinctive geometric features. Because bolts and pipe joints have wide feature variations, developing a generalized AI model requires a large dataset which is often hard to obtain. To address this limitation, this paper explores strategies for generating smaller, specialized AI models tailored to each unique joint type. This study describes the development of deep learning neural network models capable of learning distinguishing features of different joint configurations from limited training data. A multilayer graphical neural network architecture is employed, enabling efficient extraction and representation of these unique geometric characteristics. The proposed models can robustly generalize different joint types while maintaining high classification accuracy and reliable feature detection despite constrained training data availability. Automated workflows have been implemented in commercially available preprocessing tools to validate the proposed AI methodology and demonstrate its effectiveness in practical engineering applications. The integration of AI model automation in preprocessing tools significantly reduces engineering effort and repetitive manual preprocessing steps. This work highlights the potential of hybrid AI models to accelerate CAE workflows and provides scalable framework for future automation in FEA.
Jayachandran, Janarthanan, Agarwal, Deepak
EV fleets in the EU/US region are owned by a fleet manager who manages the entire fleet operation. Currently, the telematics ECU transmits a significant amount of information that can be used to our advantage for vehicle–route assignment. The beneficiaries of this solution would be the fleet managers, who will receive an optimized vehicle–route plan, and the drivers, who will be able to see their entire week’s schedule. This can be achieved using models and applications in operations research, which take in EV vehicle parameters and provide an optimal solution. Existing fleet and vehicle control strategies typically rely on fixed actuation limits or rule-based logic that are configured without direct awareness of fleet-level objectives or task-specific requirements. As a result, vehicles may operate inefficiently, experience unnecessary energy consumption, or incur accelerated component aging. There is therefore a need for a system in which fleet and task information directly influence vehicle actuation in a dynamic and coordinated manner. This approach enables fleet operators to reduce energy cost, battery degradation, and unplanned downtime by dynamically aligning vehicle actuation with actual task and fleet needs rather than static calibrations. It improves fleet utilization and scalability by allowing vehicles to automatically adapt their energy and power behavior as operational conditions change. As electrified and mixed fleets grow and complexity increases, such optimization-driven actuation becomes critical for achieving cost-efficient, reliable, and sustainable fleet operations. The scheduling is modelled in three distinct layers that is vehicle-task scheduler, charging scheduler, human driver scheduler, thereby ensuring a clean modular design.
Anavekar, Abhishek Anil, Bhowmick, Saikat
Commercial vehicles predominantly employ drum brakes because of their low cost, robustness, and simple construction. However, with the increasing push toward quieter powertrains, particularly in electric commercial vehicles, brake squeal has become a dominant noise source. The inherent complex and chaotic nature of brake squeal makes its prediction and suppression especially challenging. Traditional squeal mitigation strategies, such as modifying component mass and stiffness or using materials with higher native damping (e.g., cast iron), are inherently constrained in their capacity to mitigate instability. In such scenarios, constrained layer damping (CLD) shims have proven to be an additional, effective and practical solution in disc brakes, which is motivating growing interest in extending similar concepts to drum brake applications. A key challenge in adopting shims for drum brakes lies in identifying and achieving the required damping level necessary to suppress squeal while adhering to stringent packaging, manufacturability, and cost constraints of foundation brakes. Establishing a clear relationship between squeal propensity, noise intensity, and target damping is therefore essential. While past CLD studies discuss layer-thickness effects in generic structures and caliper brakes, no work applies thickness optimization to brake shims in a drum brake assembly. This paper presents a systematic and target-driven framework for the design of CLD shims for drum brake applications. The approach initially defines the damping requirement for squeal suppression using system noise metrics and dynamic stability evaluations. Based on this requirement, a design optimization approach is employed to determine the appropriate thickness distribution of the individual shim layers, while accounting for practical constraints such as packaging limitations, material feasibility, and manufacturing considerations inherent to foundation brake systems. The optimized CLD shim configurations obtained through this process are subsequently integrated into the drum brake assembly and evaluated using complex eigenvalue analysis. The simulations utilized a validated FE model of the S-cam drum brake assembly, whose accuracy was established through experimental modal analysis–based correlation. The results indicate that the proposed target-based shim design methodology leads to a measurable improvement in modal damping and system stability, thereby demonstrating its effectiveness as a practical and robust approach for brake squeal mitigation in drum brake systems.
Muralidharan, Sudharsan, Philip, Rony, Mohanam, Gopalakrishnan
The longitudinal dynamics during braking of articulated heavy vehicles is primarily governed by coupled load transfer mechanisms, yet the isolated influence of hitch location on axle load distribution and braking response remains insufficiently quantified. This study investigates the sensitivity of hitch height variation of a twin-axle tractor with a single-axle on the axle loads and consequently braking performance. A rigid-body longitudinal dynamics model is utilised and evaluated against a high-fidelity multibody simulation across a structured test matrix spanning friction levels and trailer loading conditions. Results show that hitch location primarily affects braking behaviour through redistribution of axle normal loads via hitch-induced pitching moments. A 400~mm increase in hitch height produces up to 5% variation in drive axle load in the unladen case, rising to approximately 16% under laden conditions. Longitudinal hitch variation yields comparable sensitivity in drive axle load, with increased influence on steer axle loading, while trailer axle load remains largely unaffected. Despite these variations, the overall braking metrics such as stopping distance and steady-state deceleration exhibit limited sensitivity to hitch location under most operating conditions. However, near friction limits, hitch-induced load redistribution significantly alters axle-wise friction utilisation and wheel lock sequence, steer axle-first at low deceleration and rear-axle-first at higher deceleration. The results demonstrate that while hitch location has a secondary effect on overall braking efficiency, it plays a critical role in stability-relevant behaviour mainly in the laden vehicle configurations. These findings highlight the importance of accounting for hitch-induced coupling in load-aware braking strategies for articulated vehicles.
Devadiga, Shravan S., Mandal, Indra, Gaurkar, Pavel, Vivekanandan, Gunasekaran, Sivaram, Sriram, Shankar Ram, C. S.
Modern vehicles increasingly rely on software-intensive functions, which continue to drive the growth and complexity of Electronic Control Units (ECUs). Conventional architectures based on single core or statically partitioned multicore microcontrollers are becoming inadequate for meeting emerging requirements such as deterministic real time performance, high communication throughput, synchronized time bases, and secure message handling. This paper introduces a software driven multicore consolidation approach that enables multiple ECU functions to be integrated on a single high-performance microcontroller while maintaining essential attributes of safety, determinism, and responsiveness. The proposed architecture emphasizes the co-location of dependent software modules to reduce cross core communication overhead and enhance runtime efficiency. By leveraging AUTOSAR compliant multicore Basic Software (BSW) stacks, including Communication, NVM, STBM, Diagnostics, and OTA, the system supports improvements in timing accuracy, data throughput, and task synchronization. In addition, core-specific communication channel assignment, interrupt-based routing, HSM supported secure frame handling, and multicore enabled NVM with a master–satellite design collectively contribute to more efficient CPU utilization and reduced latency under high load communication scenarios. The approach supports key industry relevant capabilities (e.g., runtime remote software updates, sensor fusion) and enables efficient handling of high-volume communication activity, making it adaptable for emerging multicore ECU architectures in next generation vehicles. The theoretical analysis presented in this paper describes how the proposed software driven consolidation can reduce system overheads, improve the organization of multicore workloads, and support more structured parallel execution. The study further highlights that a well-designed multicore software strategy can serve as a practical and scalable direction for future automotive electronics, supporting higher levels of feature integration and communication flexibility, along with lower CPU load compared to traditional multicore ECU implementations. Considerations for future enhancements in software component grouping and communication stack adaptability are also discussed.
Sadhu, Santosh, Toshniwal, Sachin
In current and futuristic electronic designs, ensuring the accuracy and reliability of electrical circuits over all component parameter variation and operating condition, requires validation across multiple domains - mathematical modelling, simulation, and physical measurements. Before committing to physical board fabrication, simulation has become a critical step in the circuit design process. With increasing design complexity, engineers rely heavily upon simulation tools to predict circuit behavior, optimize performance, and reduce the number of design iterations. The effectiveness of simulation lies not only in its ability to provide accurate representations of real-world circuit behavior, but also capturing key electrical characteristics such as voltage levels, frequency response, accurate modeling of component tolerances and coefficients, etc. It should also excel in efficiency-allowing rapid iteration, testing under varied conditions, evaluation of multiple scenarios without excessive computational costs, and quick comparisons of design alternatives. This paper presents an advanced semiconductor derating methodology that addresses the limitations of conventional approaches through automation. The derating algorithm has been developed and implemented using Maple (Mathematics based Tool) to generate precise worst-case values of semiconductor component parameters adjusted for specific circuit operating conditions. This automated tool significantly enhances both the efficiency and accuracy of mathematical analysis results, providing engineers with more reliable performance predictions for electronic circuit design. This paper also presents a comparative study that analyzes and correlates the performance of an electrical circuit obtained through worst-case mathematical analysis using internal tool, simulations using industry-standard tools, and the result collected during internal testing of the product. The objective is to evaluate how closely theoretical predictions and simulations align with real-world behavior and to identify factors contributing to any discrepancies.
Mishra, Anshul, M. S., Suhas
Autonomous Emergency Braking (AEB) is a safety-critical Advanced Driver Assistance System now mandated for commercial vehicles in India.to reduce crash frequency and severity. This paper presents a structured, simulation-based V&V approach for camera-based AEB that integrates TTC braking evaluation, Forward Collision Warning assessment, and real-time object detection validation. High-fidelity tools Hexagon VTD & ROD, and MATLAB Roadrunner are employed to generate photorealistic, India-specific scenarios capable of modelling detailed road geometry, marked and unmarked lanes, mixed traffic behavior, and diverse environmental and weather conditions. Scenario-driven testing enables frame-accurate, end-to-end assessment of detection, decision-making, and actuation without requiring access to internal algorithms (black-box validation). Across representative scenarios, the test campaign achieved up to 90% accuracy in detecting relevant targets. This validation aligns with AIS & MoRTH guidance, and adheres to UN Regulation (UN R131), while incorporating applicable ISO 26262 functional safety principles. Requirement traceability matrices are used to evaluate system behavior under sensor degradation, misclassification, and other critical edge-case conditions prevalent in Indian driving environments. The proposed methodology enables consistent, repeatable, and regulation aligned validation of camera based AEB systems, supporting safer and more reliable commercial vehicle deployment in India.
S., Nagabhushana N., P., Gururaaj, M. L., Sankar
To comply with increasingly stringent emission norms and simultaneously enhance engine efficiency, durability, and power output, continuous improvements in engine performance have become essential for modern automotive engineering. However, these advancements often result in unintended consequences, particularly in the form of elevated noise and vibration (NV) levels, which negatively impact overall vehicle refinement and customer comfort. Managing NV without compromising performance has therefore emerged as a critical challenge in contemporary powertrain development. The study addresses the optimization of NV characteristics while maintaining engine functionality through a hybrid approach. This method combines transfer path of noise and vibration with a detailed evaluation of engine electronic control unit (ECU) parameters. By combining these analytical techniques, critical contributors to NV were identified, enabling the formulation of a targeted countermeasure strategy. Experimental validation was carried out on the engine intake system under controlled conditions to assess the effectiveness of proposed solutions. Results indicate that modifications to the intake system significantly reduce noise levels at the engine intake side, thereby improving acoustic comfort without adversely affecting combustion efficiency or power delivery. Furthermore, systematic optimization of ECU parameters contributed to smoother engine operation and reduced vibrational excitation across multiple operating points. The findings demonstrate that accurately targeting the appropriate engine subsystem and employing an integrated analytical-experimental framework can achieve balanced performance and acoustic refinement. This work highlights the effectiveness of integrated analytical and experimental methods for achieving balanced performance and acoustic refinement in advanced engines.
Singh, Karamdeep, Uniyal, Ravinder, Yadav, Manish, Mishra, Durga Prasad
The rapid evolution of automotive electronics has pushed traditional vehicle electrical and electronic (E/E) architectures to their limits. Conventional designs, characterized by point-to-point wiring harnesses, distributed domain-specific ECUs, and communication buses such as LIN, CAN, and Ethernet, impose significant drawbacks in terms of vehicle weight, integration complexity, and long-term scalability. As the industry moves toward the Software-Defined Vehicle (SDV) paradigm, there is a compelling need to rethink the foundational principles governing in-vehicle connectivity. This paper proposes a wireless-centric SDV architecture in which non-functional-safety-relevant sensors and actuators communicate over standardized wireless protocols, eliminating the need for their associated physical wiring. By decoupling these peripheral nodes from the wired backbone, the proposed architecture reduces harness bulk, lowers vehicle mass, minimizes redundant compute hardware, and significantly reduces integration cost. Safety-critical systems including those governing powertrain, braking, and steering are explicitly retained on hardwired, deterministic communication channels in compliance with ISO 26262 functional safety requirements. This paper additionally defines explicit assumptions and fallback behavior governing that wired/wireless boundary. The architectural framework is evaluated against key SDV design objectives such as modularity, over-the-air (OTA) updateability, and feature scalability, assessed qualitatively against published engineering precedent, with a structured validation roadmap defined to quantify latency, reliability, and coexistence performance in follow-on work. The analysis demonstrates that a hybrid wired-wireless topology can substantially simplify vehicle E/E architecture while maintaining the reliability and latency guarantees demanded by automotive-grade systems. This work contributes to a structured transition roadmap for OEMs and Tier-1 suppliers seeking to adopt SDV principles without compromising vehicle safety or regulatory compliance, together with an explicit protocol-selection framework and a functional-safety argument for the wired/wireless boundary.
Hebbale Ramkumar, Ramya, Sarkar, Dibas
Modern day vehicles are equipped with multiple features to enhance user experience, increased safety and continuous over the air updates for upgradability and updatability of vehicles over lifetime. The implementation of every embedded automotive software feature consumes microcontroller resources (like RAM and ROM) which are highly critical and need careful handling. In an SDV architecture, where continuous software upgrades and updates are enabled, optimal feature handling becomes necessary. The microcontroller resources chosen during the development phase often reaches the threshold limit even before series production. In such scenarios, software feature enhancement/updates are challenging. When the memory is limited and becomes a constraint for installing newer features / upgrades, OEM has minimal provision to enhance or introduce new features. The paper presents framework to OEM to get a summary of how to manage functionality in a vehicle variant depending on specific demographic location and user preferences. The summary of the functionality usage is reported to end user in the vehicle system.
Chandrashekar, Sandhya, Hubli, Ashwini
Automotive industry is currently experiencing a major transition towards Software-Defined Vehicles (SDV) to facilitate seamless new feature integration via over the air (OTA) update. SDVs integrate more than 50 + ECUs with more than 400+ software functions, leading to significant software complexity and a substantial need for comprehensive bench level testing to prevent software issues at vehicle level. To address these challenges, a robust and edge case focused test specification is essential, ensuring maximum requirement coverage across all scenarios while incorporating insights from past bugs and field issues. Currently, the automotive industry faces challenges in producing high-quality test specifications mainly focusing on functional testing (both positive and negative scenario), fault injection testing, ISO standards testing, network management testing which often exceed 2,000 + test cases for SDV features in parallel with maintaining consistency over time, ensuring maximum system-requirement coverage, and meeting project milestones. This paper introduces a new method to overcome above said problems. We provide a comparative study involving our proposed method with other methods to show the efficacy of the proposed method.
Arumugam, Jayalakshmi
As the global automotive industry pivots toward sustainable mobility, reducing vehicle curb weight remains a paramount objective for enhancing energy efficiency and range. This paper presents a robust and comprehensive methodology for the light weighting of a two-wheeler chassis through the integration of Design of Experiments based optimization and Power Spectral Density durability analysis. The study begins by establishing a baseline durability profile for the vehicle using frequency-domain durability simulations under random vibrational loading, ensuring a benchmark for structural integrity. To explore the design space effectively, frame tube thicknesses are parameterized, and a Design of Experiments design matrix is constructed using Modified Extensible Lattice Sequence technique. This design matrix is solved, and a response matrix is built. These two matrices are combined, and appropriate curve-fitting techniques are applied to construct a Reduced Order Model. This mathematical surrogate model enables the rapid evaluation of the frame’s response under varying frame thickness combinations, thereby avoiding computationally expensive traditional Finite Element Analysis iterations. The optimum combination of frame tube thicknesses is identified using the Global Response Surface Method. This configuration minimizes the overall mass of the vehicle while strictly maintaining predefined durability and safety targets. The final optimized frame is evaluated by a secondary Power Spectral Density durability analysis to validate the accuracy of the surrogate model’s predictions. The integration of this metamodel-based design approach results in a significant reduction in structural weight. Ultimately, this framework accelerates the design cycle by developing a lightweight, cost-effective, and durable structure, thereby minimizing the overall time-to-market for sustainable automotive products.
Chettiar, Alfred Selvamani, V., Vinothkumar, S., Deepak, Praveen, Kannan
The brake pedal assembly is a critical load bearing automotive component that must perform reliably under severe service conditions, especially during emergency braking events. Structural assessment is commonly carried out using computationally intensive non-linear finite element analysis, which can limit rapid design iterations during early product development. This study presents a physics informed surrogate modelling framework for predicting displacement and von Mises stress responses of a brake pedal directly from unstructured three dimensional mesh geometry. A structured dataset was created through parametric morphing and a Design of Experiments approach by varying pedal arm angle, pedal moment length, flange/web thickness, and combined geometric conditions. The simulation database was developed using conventional solvers and the generated cases were used to train Physics Artificial Intelligence based on the Transformer Neural Simulator architecture. The trained model showed close agreement with conventional solver results for both peak response values and contour distributions. For representative testing cases, predicted displacement and stress responses remained within acceptable engineering tolerance compared with the finite element baseline. After training, the PhysicsAI workflow reduced the prediction turnaround time compared with the conventional solver workflow. The results suggest that Design of Experiments driven datasets combined with geometric deep learning can provide an efficient workflow for rapid brake pedal structural assessment during concept development and iterative design studies.
N., Rengarajan, Praveen, Kannan, Philip Thomas, Febin
Automotive E/E architecture is getting transition from distributed ECUs to high performing Zonal architectures. Traditional diagnostic methodologies based on Unified Diagnostic Services (UDS/ISO 14229) is being followed for providing failure analysis. It is difficult when debugging complex software and to find issues where lies exactly at modular level called “stack trace”. This could provide solutions for software bugs, failures or even container-level crashes in Software-Defined Vehicle (SDV). This paper provides a remote diagnostic framework that makes use of the ISO 17978 (SOVD) standard to visualize a “Vehicle-wide Crashlytics” as analogous to modern mobile application analytics with Firebase SDK. Also, the comparison of failure management with traditional diagnostic method to handling fault management in remote framework with both ISO 17978 (SOVD) and ISO 20077/20078 (Remote Diagnostic) is made. It also speaks how methodology can be formed for software logs capturing and traces execution triggered by function software level anomalies. Also, the constrains such as V2X bandwidth and data is monitored and controlled with Diagnostic Saliency Algorithm that helps to determine only relevant telemetry is transmitted via 5G or V2N. This framework proposal is checked with a simple application failure scenario, which leads to the reduction in “Mean Time to Repair” (MTTR) for software bugs. The reduction in MTTR is achieved since actionable root cause of software issue is shared directly from vehicle’s run-time environment. Future development of vehicle functions (SaaS) is expected to be integrated with SOVD and cloud-native observability patterns. This is much needed towards the scalable and quick development and deployment of applications into Vehicle as Digital Hub.
Kalirajan, Vignesh, Annamalai, Viswachandar, Balakrishnan, Arun Shankar