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This SAE Aerospace Recommended Practice (ARP) defines recommended analysis and test procedures for qualification of pneumatically, electrically, manually, and hydraulically actuated air valves. They may be further defined as valves that function in response to externally applied forces or in response to variations in upstream and/or downstream duct air conditions in order to maintain a calibrated duct air condition (e.g., air flow, air pressure, air temperature, air pressure ratio, or air shutoff). Qualification testing performed on the airplane to verify compatibility of the valve function and stability as part of a complete system is outside the scope of this document. Refer to ARP1270 for design and certification requirements for cabin pressurization control system components. As this document is only a guide, it does not supersede or relieve any requirements contained in detailed Customer specifications.
AC-9 Aircraft Environmental Systems Committee
The intent of this report is to encourage that the thermal management system architecture be designed from a global platform perspective. Separate procurements for air vehicle, propulsion system, and avionics have contributed to the development of aircraft that are sub-optimized from a thermal management viewpoint. In order to maximize the capabilities of the aircraft for mission performance and desired growth capability, overall system efficiency and effectiveness should be considered. This document provides general information about aircraft Thermal Management System Engineering (TMSE). The document also discusses approaches to processes and methodologies for validation and verification of thermal management system engineering. Thermal integration between the air vehicle, propulsion system, and avionics can be particularly important from a thermal management standpoint. Due to these factors, this report is written to encourage the development of a more comprehensive system
AC-9 Aircraft Environmental Systems Committee
This SAE Aerospace Recommended Practice (ARP) discusses design philosophy, system and equipment requirements, environmental conditions, and design considerations for rotorcraft environmental control systems (ECS). The rotorcraft ECS comprises that arrangement of equipment, controls, and indicators which supply and distribute dehumidified conditioned air for ventilation, cooling and heating of the occupied compartments, and cooling of the avionics. The principal features of the system are: a A controlled fresh air supply b A means for cooling (air or vapor cycle units and heat exchangers) c A means for removing excess moisture from the air supply d A means for heating e A temperature control system f A conditioned air distribution system The ARP is applicable to both civil and military rotorcraft where an ECS is specified; however, certain requirements peculiar to military applications—such as nuclear, biological, and chemical (NBC) protection—are not covered. The integration of NBC
AC-9 Aircraft Environmental Systems Committee
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
Crash test plays a very crucial role in determining the passenger safety along with driver safety in most modern vehicles. This has become a prominent factor for many buyers to choose a safe car. During crash test, many components tend to fail. Amongst them, the major safety critical component which hampers the drivability of a vehicle is Wheel and Tyre Assembly. With the introduction of low aspect tyres, the failure rate of these assemblies has increased. A very high importance is given to ensure these parts withstand the subject load as it is directly related to function of vehicle. Many methods are available to test the Wheel and Tyre assembly to ensure they pass the crash criteria. We have developed a novel test method which can simulate the crash pattern in the rig/bench level. The method employs a mechanical actuator which can be operated at designated load application to ensure the assembly undergoes the anticipated failure. The process is repeated with different types of
Medaboyina, HarshaVardhanSingh, Ram KrishnanSundaram, RaghupathiJithendhar, Ashokan
To develop a Test Method & Procedure for validating the Tractor clutch system performance & Wear simulation endurance test. Tractor clutch wear simulation test conducted along with transmission by operating clutch in different modes as per RWUP operation. In this test we can validate clutch field failures in short time with improved test accuracy at lab. In one of M&M technology project, Transmission Wet clutch system for higher HP tractors where we don’t have any dedicated test rig/methodology for validating Clutch wear & related failure simulation at lab
D, YashwanthRaja, RUdayakumar, SM, JeevaharanVijayakumar, Narayanan
Sunroof-equipped vehicles are gaining rapid popularity in India, especially among young and urban users. However, unsafe practices like occupants protruding through the sunroof during driving have led to increasing injuries and fatalities, particularly in sudden braking or collisions. This behavior, prohibited under the Motor Vehicles Act, remains an overlooked safety risk in today’s vehicles. This paper presents an industry-first innovation: an Automated Safety Alarm and Speed Control System designed to detect and prevent sunroof misuse. Using integrated photoelectric and infrared beam sensors, the system detects human extension beyond the sunroof boundary while the vehicle is in motion. Upon detection, it triggers a tiered safety response: an immediate dashboard warning, an audible alert if vehicle speed exceeds 15 km/h and an active speed limiter that restricts vehicle speed to 20 km/h until safe conditions are restored. This marks a shift from passive warnings to active vehicle
Padmanapan, GopiYadav, Sanjeev
In the Indian context, introduction of ADAS can play a positive role in improving road safety by assisting the driver and preventing unsafe driver behaviour. Technologies like Automated Emergency Braking (AEB), Lane Keep System, Adaptive Cruise Control, Driver Drowsiness Detection, Driver Alcohol detection etc., if deployed safely and used in a safe manner can help prevent many of the current road deaths in India. Safe deployment and safe use of such ADAS technologies require the systems to operate without failure within their operational design domains (ODD) and not surprise the drivers with sudden or unpredictable failures, to help develop their trust in the technology. As a result, identifying test scenarios remain a key step in the development of Advanced Driver Assistance Systems (ADAS). This remains a challenge due to the large test space especially for the Indian context due to the unpredictable traffic behaviour and occasional road infrastructure. In this paper, we introduce a
Serry, HamidDodoiu, TudorAlakkad, FadiZhang, XizheKhastgir, SiddarthaJennings, Paul
Gears play a critical role in automotive transmission systems. During operation, frictional heat is generated in the intermeshing region due to loading. Effective lubrication and cooling are essential to minimize heat generation and ensure smooth operation. Lubrication failure can lead to a significant local temperature rise, potentially causing gear scuffing—a phenomenon where intermeshed gear teeth weld together and tear apart during rotation—resulting in severe damage and compromised transmission performance. To prevent this, gears are typically lubricated using splash or jet lubrication techniques. This study presents a Conjugate Heat Transfer (CHT) simulation of a jet-lubricated gear pair in an automotive transmission system to predict the local temperature rise due to frictional heating in the intermeshing region of the gears. The paper focuses on implementation of the frictional heat generation on the gear teeth and resultant transient temperature rise in the gear contact region
Ballani, AbhishekVartanian, AleksandrSchlautman, JeffRaj, GowthamSrinivasan, ChiranthMaiti, Dipak
This paper explores the implementation of ISO 21434 Automotive Cybersecurity Assurance Levels (CAL), focusing on enhancing component level cybersecurity for a vehicle. CAL values, which range from 1 to 4, provide a metric for ensuring that assets are protected against relevant threats at various phases of the product life cycle. By identifying parameters in the attack feasibility rating and their severity early in the product life cycle, specifically during the concept phase of ISO 21434, organizations can determine the CAL values. The CAL value serves as a benchmark to determine the level of severity required during the design, development and verification phases of the product life cycle. This paper outlines a method to establish CAL values as per ISO 21434 guidelines. The proposed methodology includes a detailed analysis of threat modeling, which is crucial for identifying and mitigating potential cybersecurity risks. By conducting threat modeling, organizations can systematically
Ghosh, SubhamKhader Batcha, Jashic
O-rings play a critical role in ensuring leak-proof seals in a wide range of engineering systems. Accurate prediction of their compression and relaxation behavior under various material and geometric configurations is essential for optimal design and reliability. This study presents an analysis of machine learning techniques to predict two key performance outputs, compression force and relaxation force (after 10 minutes) trained on computer-aided engineering (CAE) simulation data. The experimental setup was represented in CAE simulation and the results were compared with experimental data conducted at ZF test facilities. Simulation results correlated well with the experimental data (deviation was less than the 5%). To create a dataset for training machine learning (ML) models, realistic ranges for the input parameters such as hardness and geometrical parameters were determined, and simulation data were generated using design of experiments (DOE). Multiple ML models were developed and
Kosgi, DurgaprasadAlva, P PanchamDangeti, VenkataKrishna Pavan
The automotive industry is undergoing a transformational shift with the addition of Virtual ECU in the development of software and validation. The Level 3 Virtual ECU concept will lead to the transformation in the SDLC process, as early detection of defects will have a significant impact on cost and effort reduction. This paper explains the application of a Level 3 virtual ECU which can enable to perform testing in initial period considering the Shift Left Strategy, which will significantly reduce development time. This paper demonstrates various development and validation strategies of virtual ECU and how it can impact project timeline.
Bhopi, AmeySengar, Bhan
Automotive door latches play a crucial role in occupant safety and user experience. The mechanisms utilized as latching systems in automotive doors are designed to hold the doors in a closed position relative to the body of a vehicle and can be grouped into three major categories: hood/frunk latches, lift gate latches, and side door latches. These mechanical systems vary in design across vehicle models, but all must withstand harsh environmental conditions, including water intrusion. Therefore, their requirements and validations include rigorous testing that ensures the continued functionality of the device after being subjected to extreme environmental conditions, such as cold, heat, and humidity. Rainfall in winter months leads to ice storms where water freezes instantly upon contact with cold surfaces leading to ice formation on structures. In some cases, water can penetrate latch systems, freezing the latch systems with the risk of potentially making them inoperable. Currently
Chaudhari, AbhijitSrikanth, PraveenTakabi, BehrouzCalamaco, EliEstrada, IgnacioHuerta Rodriguez, Sergio
This paper presents a bidirectional digital twin developed for the Fischertechnik Smart Factory Kit, enabling real-time simulation and validation of production line modifications prior to actual deployment. The digital twin integrates with a Siemens Programmable Logic Controller (PLC) to mirror real-world operations, capturing live production data and visualizing key factory parameters, such as product, process, and resource metrics within a 3D environment. Engineers can test various optimization scenarios by adjusting robot speed and path, conveyor speeds, part & process sequences, and modifying equipment layout sizes to enhance efficiency. Based on the optimization scenarios, the best-performing configurations are identified using metrics such as throughput, cycle time, and resource utilization. Once validated, these changes are directly deployed to the PLC, ensuring seamless implementation. Beyond capacity optimization, this solution enhances overall production efficiency by
Kumar, RahulSingh, Randhir
PU foam shows a excellent energy absorbing dissipation properties during impact load so it commonly used in car seats, cabin and crash protection system. Specifically, in vehicle seats PU foams play a critical role in protecting occupants during crash scenarios by absorbing energy, distributing forces, and improving seatbelt performance, additionally providing countermeasures for head impact protection. The movement of the seat and the direction of the force during crash testing are highly unpredictable. The material behaviour of PU foam is captured using an isotropic, hyper-elasticity-based constitutive model available in LS-DYNA through MAT_083. This model is designed to take into account the foam's compressibility, sensitivity to strain rates, low Poisson's ratio, and hysteresis. The characterization of a PU foam with a nominal density of 65 kg/m3 was performed using quasi-static compressive testing of 0.01/s and dynamic compressive testing of 1/s,13/s, 120/s, as well as a quasi
Gaurav, Ashish KumarKrishnamoorthy, KunjuVaratharajan, Senthilkumaran
The work demonstrating a novel approach to the optimization of crankshaft design for heavy-duty commercial vehicle engines, specifically targeting non-automotive applications with elevated power ratings. The research focuses on a 6-cylinder, 5.6-litre diesel engine, originally rated at 160 kVA and upgraded to 200 kVA, where the challenge was to enhance the crank-train system’s robustness within existing packaging constraints. By fundamentally altering the crankshaft’s geometry and structural parameters, the new design achieves higher load-bearing capacity while inherently mitigating torsional vibrations, thereby eliminating the need for viscous dampers traditionally used in place of rubber dampers. Advanced simulation tools, notably AVL Excite, employed to iterate and evaluate the balance between crankshaft balance ratio, weight, and torsional behavior. The optimized design then validated through both simulation and physical vibration trials, with sixth-order angular displacement
Khandelwal, MehaKaundabalaraman, KaarthicRathi, Hemantkumar
Commercial vehicle sector (especially trucks) has a major role in economic growth of a nation. With improving infrastructure, increasing number of trucks on roads, accidents are also increasing. As per RASSI (Road Accident Sampling System India) FY2016-23 database, commercial vehicles are involved in 42% of total accidents on Indian roads. Involvement of trucks (N2 & N3) is over 25% of total accidents. Amongst all accident scenarios of N2 &N3, frontal impacts are the most frequent (26%) and causing severe occupant injuries. Today, truck safety development for frontal impact is based on passive safety regulations (viz. front pendulum – AIS029) and basic safety features like seatbelts. In any truck accident, it is challenging rather impossible to manage comprehensive safety only with passive safety systems due to size and weight. Accident prevention becomes imperative in truck safety development due to extremely high energy involved in front impact scenarios. The paper presents a unique
Joshi, Kedar ShrikantGadekar, GaneshDate, AtulKoralla, Sivaprasad
Frontal crash structures play a vital role in occupant safety, but traditional designs often involve a trade-off between structural strength and weight efficiency. In the pursuit of safer and more sustainable mobility, this study explores a physics-based methodology that leverages the principle of dynamic equilibrium to guide the integration of dissimilar materials in front-end vehicle structures. Specifically, examined a novel configuration wherein aluminum High-pressure die cast (single HPDC part) is introduced which covers swan neck region as well as the base of the front longitudinal member, while retaining steel in the frontal crush zone. This arrangement aims to redistribute crash loads and control deformation mechanisms, enabling improved energy absorption without compromising structural integrity. To evaluate the proposed strategy, a series of detailed finite element simulations were conducted using LS-DYNA, a widely adopted tool for vehicle crash analysis. The results reveal
Revanth, GoshikaBhagat, MilindJoshi, VikasMankhair, AbhijitSudarshan, B.SudarshanKollipara, Jahanavi
This paper presents a comparative analysis of road accident datasets from India, the United States, France, and the United Kingdom, utilizing authoritative sources such as Open Government Data (OGD), the National Highway Traffic Safety Administration (NHTSA), GOV.UK, and the French Road Safety Observatory. The research aims to uncover cross-country trends and discrepancies in accident reporting practices and assess whether enhanced documentation can contribute to reducing accident frequency. Effectively reducing the incidence of road accidents necessitates a rigorous understanding of their underlying causal mechanisms, which can only be achieved through comprehensive, data-driven analyses of accident records and systematic parameter comparisons with the Integrated Road Accident Database (iRAD). The primary objective is to identify documentation gaps within the Indian context and propose improvements to ensure comprehensive, high-quality data availability for researchers and
Raj, AswinRaja, DheepanAbhimanyu Shinde, Antriksh
Reducing drag forces and minimizing the rear wake region are the main goals of evaluating exterior aerodynamic performance in automobiles. Various literature and experiments shows that the overall fuel computations of the road vehicle improves significantly with the reduction in aerodynamic drag force. In the road vehicle major components of the drag is due the imbalance in pressure between front and rear of the vehicle. At high vehicle speed, aerodynamic drag is responsible for approximately 30 to 40% of the energy consumption of the vehicle. In the recent year, cost of high-performance computing (HPC) has reduced significantly, which helped computational fluid dynamics (CFD) is an affordable tool to the automotive industry for evaluating aerodynamic performance of the vehicle during developing phase. The vehicles aerodynamic performance is greatly impacted by the dynamic environmental conditions it encounters in the real world. Such environmental conditions are difficult to replicate
Chalipat, SujitBiswas, KundanTare, Kedar
Threat Analysis and Risk Assessment (TARA) is a continuous activity, acting as a foundation of cybersecurity analysis for electrical and electronics automotive products. Existing TARA methodologies in the automotive domain exhibits challenges due to redundant and manual processes, particularly in handling recurring common assets across Electronic Control Units (ECUs) and functional domains. Two primary approaches observed for performing TARA are Manual-Asset-Centric TARA and Catalogue-Driven TARA. Manual-Asset Centric TARA is constructed from scratch by manually identifying the assets, calculating risks by likelihood, and impact determination. Catalogue-Driven TARA utilizes the precompiled likelihood and impact against identified assets. Both approaches lack standardized and modular mechanisms for abstraction and reuse. This results in poor scalability, increased efforts, and difficulty in maintaining consistency across vehicle platforms. The proposed method in this research overcomes
Goyal, YogendraSinha, SwatiSutar, SwapnilJaisingh, Sanjay
State Transport Units (STUs) are increasingly using electric buses (EVs) as a result of India's quick shift to sustainable mobility. Although there are many operational and environmental benefits to this development, like lower fuel prices, fewer greenhouse gas emissions, and quieter urban transportation, there are also serious cybersecurity dangers. The attack surface for potential cyber threats is expanded by the integration of connected technologies, such as cloud-based fleet management, real-time monitoring, and vehicle telematics. Although these systems make fleet operations smarter and more efficient, they are intrinsically susceptible to remote manipulation, data breaches, and unwanted access. This study looks on cybersecurity flaws unique to connected passenger electric vehicles (EVs) that run on India's public transit system. Electric vehicle supply equipment (EVSE), telematics control units (TCUs), over-the-air (OTA) update systems, and in-car networks (such as the Controller
Mokhare, Devendra Ashok