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In the automotive industry, external aerodynamic evaluations in digital environments are commonly conducted using simplified, large box tunnels with vehicle being static. These approaches are computationally efficient and ensure faster turnaround time. To closely replicate physical wind tunnel testing or real-world conditions, these simulations are often augmented with moving ground and rolling tire configurations. While such setups provide valuable directional feedback for aerodynamic drag improvements, they frequently exhibit significant discrepancies when compared to physical wind tunnel test data. It is observed that key factors such as wind tunnel blockage effects, boundary layer suctions, when not properly accounted for, distort the local flow field dynamics and introduce errors in the simulations. With OEMs aiming to accelerate time-to-market for new vehicle launches, many aspire to minimize reliance on physical testing and maximize use of digital methods for design sign-off
Sharma, Sandeep KumarChalipat, SujitMaiyya, Sandeep
Transportation industry is facing a growing challenge to reduce its carbon footprint and utilize the carbon neutral, more environmentally sustainable fuels to comply with the goal of carbon neutrality. Implementation of carbon free fuels such as Hydrogen, Ammonia and low carbon fuels such as Methanol, Ethanol can significantly reduce the greenhouse gas emissions, but these fuels are suitable for SI engine architecture due to their high-octane ratings. Hydrotreated Vegetable Oil (HVO) is one of the few fuel solutions available today with a high Cetane rating (70-80), that can be used as a drop-in fuel in the existing CI engines, with minimal modifications. The main constituent of HVO is pure alkane and it can be produced from feedstocks such as vegetable oils, animal fats, various wastes and by-products. A closed cycle 3-D CFD combustion simulation using a detailed chemistry-based solver has been conducted with the HVO, on a three cylinder, naturally aspirated water-cooled CI engine at
Tripathi, AyushMukherjee, NaliniNene, Devendra
In the automotive industry, during the early phase of development, numerical prediction of strength and durability of chassis parts become crucial as these predictions help in design optimization, selecting the appropriate material and identifying potential issues before physical prototypes are built. One of the crucial simulation requirements is the prediction of accurate load carrying capacity or bucking load of axle links. When it comes to the sheet metal axle links there is a deviation in the hardware test and CAE results for load carrying capacity due to the non-integration of forming effects in the numerical simulation, resulting in overdesign of parts, increased costs and development time. This study aims to address these challenges by integrating forming effects experienced by the part during forming process into static strength simulations. These effects include plastic straining, which contributes to material strain hardening and local thickness changes that lead to thinning
R B, GovindSelvaraj, Nirmal Velgin
Leakage of oil through breathers can be a serious concern in electric vehicle (EV) gearbox or transaxle units, especially due to the complexities presented by the small housing space and rotational components, which are running at relatively high speeds compared to conventional transmission units. Predicting the oil leakage from the transmission unit is another concern. Traditional methods are mostly centered on developing individual breather compartments, resulting in excess material usage, additional weight, and increased cost of manufacturing. To eliminate oil leakage through the air breather, the oil channelization technique used involves integrated oil deflection baffles, low-friction return channels, an oil accumulation cavity with cover, and strategically optimized airflow paths/vents. This design provides a number of benefits, such as increased gearbox reliability, minimized risk of component failure, and reduced maintenance needs, with all of these and a compact, cost
Ekshinge, Mahesh ShivajiAgrawal, DeveshPandey, Ankit KumarBhandari, Kiran Kamlakar
This paper explains the method of precooling of electric vehicle from grid connected charger reduce load on HVAC and improve the range. HVAC systems are integral part of a commercial EV bus. With the rise of ambient temperatures during various seasons, the load on HVAC System is increasing. Once an Electric vehicle is released from a depot for service, with an initial soaked up ambient vehicle, the HVAC system demands peak power for cooling the interiors which consumes a lot of battery power thus affecting the range. That cause the additional energy consumption required for precooling, which cannot be estimated as it is highly dependent on ambient temperature and range of the vehicle is also dependent on HVAC consumption during summer and peak loads. This paper is proposing a method that uses a special precooling mode which is activated depending on the selection of the vehicle route based on backend application running on cloud. The Application in the cloud checks if the vehicle is
Ganguly, SutanuShukla, AmishaJain, SarikaPatil, RohanSahu, PritishYadav, AnkitMarskole, DeepaAmancharla, Naga Chaithanya
Driver-in-the-Loop (DIL) simulators have become crucial tools across automotive, aerospace, and maritime industries in enabling the evaluation of design concepts, testing of critical scenarios and provision of effective training in virtual environments. With the diverse applications of DIL simulators highlighting their significance in vehicle dynamics assessment, Advanced Driver Assistance Systems (ADAS) and autonomous vehicle development, testing of complex control systems is crucial for vehicle safety. By examining the current landscape of DIL simulator use cases, this paper critically focuses on Virtual Validation of ADAS algorithms by testing of repeatable scenarios and effect on driver response time through virtual stimuli of acoustic and optical warnings generated during simulation. To receive appropriate feedback from the driver, industrial grade actuators were integrated with a real-time controller, a high-performance workstation and simulation software called Virtual Test
Sharma, ChinmayaBhagat, AjinkyaKale, Jyoti GaneshKarle, Ujjwala
Global emission norms are getting very strict due to combat the harmful pollutants from internal combustion engine. Hence internal combustion engine (ICE)-based agricultural tractors need to introduce complex after-treatment systems and fuel optimization to provide same or higher value to farmers as cost of these systems drive the overall cost of the product. Engineers around the world are building Electric vehicles to combat the problem and has range issues due to design constraints & Hybrid tractors have emerged as a promising intermittent solution. It helps in combining the advantages of respective ICE and electrification solutions while reducing overall vehicle emissions and enhances operational flexibility. This paper presents a modular thermal modes system developed for a hybrid electric tractor platform where a downsized diesel engine operates at optimal efficiency DC generator used to charge the battery & DC converter is used to charge the auxiliary battery. Battery which is
K, SunilD, MariNatarajan, SaravananKumawat, Deepakrojamanikandan, ArumughamK, MalaV, SridharanMuniappan, BalakrishnanMakana, Mohan
As atmospheric CO₂ concentrations continue to rise at unprecedented rates, the urgent need for breakthrough technologies that can efficiently capture carbon directly from the air and convert it into sustainable synthetic fuels has never been clearer. While numerous capture and conversion methods have been propose, many remain at an early stage of development, facing significant challenges such as low energy efficiency, limited scalability, and high operational costs. This lack of technological maturity underscores a vast, largely untapped potential for innovation and transformative advancement. In response to this gap, the present study compiles and critically examines a wide spectrum of emerging capture and conversion technologies. Through a detailed exploration of their functionalities, potentials, advantages, and challenges, the paper accumulates a comprehensive and well-informed dataset. This holistic understanding not only reveals key bottlenecks but also identifies promising
Jain, GauravPremlal, PPathak, RahulGore, Pandurang
Cylinder Deactivation technology is explored as an effective mechanism for enhancing the fuel economy and reducing emissions in internal combustion engines. The current exercise focuses upon the feasibility of Cylinder Deactivation technology in a 3-cylinder, 3.3-liter naturally aspirated, water-cooled diesel engine from the off-highway tractor application. A meticulous 1D thermodynamic simulation with individual cylinders deactivated one by one, has proved that deactivating the second cylinder yields the most favorable fuel economy, emissions and engine balancing, particularly at the loads lower than 54% and across all engine speeds. Upon deactivating the cylinders at Top Dead Centre (TDC) and Bottom Dead Centre (BDC), it has been concluded that the most effective deactivation point occurs at TDC, where the minimum air mass is trapped inside the cylinder. This results in a reduction of pumping and friction losses by maximum 34% and an increase in brake thermal efficiency by maximum 26
Choudhary, VasuSaini, SanjayMukherjee, NaliniNene, Devendra
The penetration of ADAS in automotive markets is increasing rapidly. However, their effectiveness and acceptance are significantly influenced by regional driving behaviours and infrastructure. This study explores the interaction between naturalistic driver behaviour in India and the operational characteristics of ADAS systems (FCW, ACC, LCF and BSD) with focus on cars. Using real-world driving data collected from Indian roads, the research aims to highlight the divergence between ADAS design assumptions often based on structured Western traffic environments and the complex, dynamic nature of Indian traffic, characterized by frequent human negotiation, informal road practices, and different vehicle types. The study characterizes multiple driver’s driving pattern through naturalistic driving and ADAS systems behaviour in corresponding situations, notably how they adapt to unstructured Indian scenarios such as lane ambiguity, pedestrian unpredictability, traffic flow unpredictability and
Sankpal, Krishnath NamdevMagar, AkshayKhot, AnkushKulkarni, AlokPerez, Marc
A passenger vehicle's front-end structure's structural integrity and crashworthiness are crucial to ensure compliance with various frontal impact safety standards (such as those set by Euro NCAP & IIHS). For a new front-end architecture, design targets must be defined at a component level for crush cans, longitudinal, bumper beam, subframe, suspension tower and backup structure. The traditional process of defining these targets involves multiple sensitivity studies in CAE. This paper explores the implementation of Physics-Informed Neural Networks (PINNs) in component-level target setting. PINNs integrate the governing equations into neural network training, enabling data-driven models to adhere to fundamental mechanical principles. The underlying physics in our model is based upon a force scheme of a full-frontal impact. A force scheme is a one-dimensional representation of the front-end structure components that simplifies a crash event's complex physics. It uses the dimensional and
Gupta, IshanBhatnagar, AbhinavKumar, Ayush
Mounting strategies for vehicles with panoramic sunroofs remains a challenge owing to its high complexity to balance cost, performance and assembly efficiency. Achieving efficient and reliable headliner mounting solutions is one of the conundrums where cost optimization must go together with uncompromised performance. Traditional methods like Dual Lock Fasteners (DLFs), have set high benchmarks for robustness but at the cost of increased manufacturing complexity and expense . In pursuit of a more economical and production-friendly alternative, various plastic clip designs were explored. However, these solutions posed significant challenges during validation due to the stringent requirements for mounting feasibility, tolerance management, and long-term durability This paper introduces a novel hybrid plastic-metal clip solution that addresses those challenges comprehensively. [2] The new design achieves precise tolerance control, ensuring reliable headliner installation under varying
D, GowthamKumarasamy, Raj GaneshShoeb, MohdChauhan, Aarti
Computer-Aided Engineering (CAE) users often follow traditional meshing and contact generation processes, which are time-consuming, repetitive, and heavily dependent on user experience and perspective. The method described herein presents a system for generating a mesh and contact interfaces that ensures standardized and consistent output for a model. The process stores multiple mesh configurations, each containing a set of predefined geometric parameters to create standardized mesh for users. The process begins by receiving data for a CAD model of an object and capturing user input through a graphical user interface (GUI). Users specify parameters such as body type, global mesh size, and a selected mesh configuration from the available options. Using these inputs, the system generates a mesh for the model, incorporating the selected mesh configuration The contact automation process offers multiple key features for enhancing FEA simulations. It classifies contact types based on user
Dabadgaonkar, AnandKamble, Amardeep
Powertrain is the most prominent source of Noise and Vibration in the vehicle. Improvement in Powertrain Noise and Vibration is a multifaceted topic due to the complex architecture of the powertrain and the critical role of calibration in defining combustion inputs. Hence, a method to clearly distinguish these aspects is required in order to address the exact problem and decide on course of actions to improve NVH performance of powertrains. This paper discusses a post-processing technique through which experimentally acquired ICE Powertrain Noise can be further segregated in order to identify and address the root source. The segregation methodology requires as input - noise, vibration and cylinder pressure values at various torque conditions across multiple operating points. A MATLAB based code developed by the authors is used to generate correlation between the Cylinder Pressure, Torque and Noise Parameters. The transfer coefficient at every frequency point is calculated using
K J, KishorKulkarni, ShriramRawat, UdeshyaPisal, SangramNaidu, Sudhakara
The electrification of transportation is revolutionizing the automotive and logistics sectors, with electric vehicles (EVs) assuming an increasingly pivotal role in both passenger mobility and commercial activities. As the adoption of EVs rises, the necessity for precise range estimation becomes essential, especially under diverse operational circumstances, including vehicle and battery characteristics, driving conditions, environmental influences, vehicle configurations, and user-specific behaviors. Among the varying factors, a key fluctuating one is user behavior—most notably, increased payload, which significantly affects EV range. A key business challenge lies in the significant variability of EV range due to changes in vehicle load, which can affect performance, operational efficiency, and cost-effectiveness—especially for fleet-based services. This research aims to tackle the technical deficiency in forecasting electric vehicle (EV) range under various payload conditions
Khatal, SwarajGupta, AnjaliKrishna, Thallapaka
The need for energy is ever increasing, though the dependency on renewable energy have increased, it is not sufficient to cater the demand. India is one of fastest developing country which depends on coal 55% for its total energy need. To achieve coal digging & transportation an underground mining vehicle has gained high importance. Underground mine environment is inherently dangerous due to various factors, including explosive and toxic gases, dust, and the potential for collapses. Thereby vehicles running in coal mines requires extreme safety features to safeguard its operator & coal mine workers. In India the Directorate General of Mines Safety (DGMS) under Government of India circulates notification to Manager of Coal and Metalliferous Mines & OEM, concerned about the minimum safety evaluations to be taken care for the mining trucks. It has been observed that there are significant inconsistencies in design practices for mining vehicles, with the presence of multiple, unverified
Babar, SagarAkbar Badusha, A
The transition to electric vehicles (EVs) has brought about significant advancements in automotive technology, with inverters playing a crucial role in converting DC power from the battery to AC power for the electric motor. Ensuring the functional safety of these inverters is paramount, as any failure can have severe implications for vehicle performance and passenger safety. This case study explores the successful implementation of ISO 26262 standards in the development and validation of EV traction inverters. This paper begins by outlining the functional requirements and safety goals specific to EV inverters, followed by a detailed analysis of the potential hazards and risks associated with their operation. Using ISO 26262 as a framework, we describe the systematic approach taken to identify, assess, and mitigate these risks. Key methodologies such as Hazard Analysis and Risk Assessment (HARA), Failure Mode and Effects Analysis (FMEA), and Fault Tree Analysis (FTA) are employed to
Ramachandra, ShwethaV, Sushmitha
With the expansion of compressed natural gas (CNG) filling station in India, bi-fuel vehicles are gaining popularity in recent times. Bi-fuel engine runs on more than one fuel, say in both CNG and petrol. Hence, the engine must be optimized in both the fuel modes for performance and emissions. However, due to the inherent differences in combustion characteristics: ignition dynamics and fuel properties, they pose a significant challenge in case of detection of misfires. Misfires are caused because of faulty injection systems and ignition systems and incorrect fuel mixture. Accurate detection is essential as misfires deteriorate the catalysts performance and may impacts emission. Misfires (or engine roughness) is calculated from engine crankshaft speed signal. In this study, the effectiveness of crankshaft-based misfires detection method, comparison of misfire signals magnitude in bi-fuel modes and practices developed for accurate detection of misfires is presented.
Thiyagarajan, AbhinavN, GobalakrishnanR, Hema
Meeting the stringent emissions norms of CEV stage V for medium BMEP engines, CI engines present significant challenges, particularly concerning cold startability. Low ambient temperatures and pressures intensify the cold start difficulties which are characterized by prolonged cranking, incidences of misfiring, compromised transient response and overall engine performance. This paper highlights the strategies and technologies employed to enhance cold start and transient performance of medium BMEP engines under such demanding environmental conditions. Investigations were conducted up to an altitude of 4500m and ambient temperatures as low as-20°C, utilizing only air heater at intake manifold as the sole cold start aid. This cost effective approach is integrated with an optimized combustion chamber design, along with minimal pilot injection timing and quantity to facilitate smooth ignition and stable combustion during cold start. The paper also explore the techniques to improve the
Saxena, HarshitLokare, PrasadSanthosh, AjithGandhi, NareshShinde, Prashant
Over the last few years, notable progress has occurred in electric vehicle (EV) technology. Inverters are key components for electric vehicles (EV). Various PWM strategies have been implemented by OEMs over past years. For most of PWM scheme timing calculation & Lengthy algorithm increases complexity. The proposed a novel Pulse Width Modulation (PWM) control technique for generating inverter lag switching times in multi-level inverters. The proposed Space Vector PWM (SVPWM) method eliminates the need for sector and region identification by utilizing sampled values of reference phase voltages, thereby reducing computational efforts and complexities. The scheme can generate N-level PWM signals and offers flexibility to operate with fewer levels, including operation in the overmodulation range. The sampled magnitudes reference phase voltages are converted into timing signals that are subsequently processed by an algorithm to modify modulating signals. These modulating signals are
Bhanabhagvanwala, Prem Kiritkumar
Electric vehicles (EVs) have surged in popularity in recent years due to their environmental benefits. The influence of range on air conditioning (AC) power consumption is a critical concern for electric vehicle (EV) owners, particularly in warmer climates. Overcoming obstacles such as a limited vehicle range is necessary for the increased use of electric-powered automobiles. Cabin heating and cooling demand for climate control consumes more energy from the main battery and has been revealed to significantly reduce vehicle range. During peak cooling or heating, the overall power consumption of the AC system takes almost 50% of the energy used for traction. The average reduction in driving range caused by air conditioning (heating and cooling) approximates 33%. The energy usage of an electric vehicle can be considerably decreased by switching the climate control setting to economy mode. The AC system will operate more effectively, enabling the vehicle to save energy and extend its range
Mulamalla, Sarveshwar ReddyAnugu, AnilE A, MuhammedUmmiti, KumarM, NisshokChoudhary, Ankit
The proliferation of wireless charging technology in electric vehicles (EVs) introduces novel cybersecurity challenges that require comprehensive threat analysis and resilient design strategies. This paper presents a proactive framework for assessing and mitigating cybersecurity risks in wireless charger Electronic Control Units (ECUs), addressing the unique vulnerabilities inherent in electromagnetic power transfer systems. Through systematic threat modeling, vulnerability assessment, and the development of defense-in-depth strategies, this research establishes design principles for creating robust wireless charging ecosystems resistant to cyber threats. The proposed framework integrates hardware security modules, encrypted communication protocols, and adaptive threat detection mechanisms to ensure operational integrity while maintaining charging efficiency. Experimental validation demonstrates the effectiveness of the proposed security measures in preventing unauthorized access, data
Uthaman, SreekumarMulay, Abhijit BGadekar, Pundlik
The growing environmental, economic, and social challenges have spurred a demand for cleaner mobility solutions. In response to the transformative changes in the automotive sector, manufacturers must prioritize digital validation of products, manufacturing processes, and tools prior to mass production. This ensures efficiency, accuracy, and cost-effectiveness. By utilizing 3D modelling of factory layouts, factory planners can digitally validate production line changes, substantially reducing costs when introducing new products. One key innovation involves creating 3D models using point cloud data from factory scans. Traditional factory scanning processes face limitations like blind spots and periodic scanning intervals. This research proposes using drones equipped with LiDAR (Light Detection and Ranging) technology for 3D scanning, enabling real-time mapping, autonomous operation, and efficient data collection. Drones can navigate complex areas, access small spaces, and optimize
Narad, Akshay MarutiC H, AjheyasimhaVijayasekaran, VinothkumarFasge, Abhishek
Nowadays, Printed Circuit Board (PCB) design is facing critical challenges like high heat dissipation, increased cost, densely populated components and reduced life span. In view of the above, present study is focused on temperature prediction, thermal management, and optimization of component allocation (e.g. mosfet) in PCB. Heat flow occurring from traces to different copper layers in the PCB can cause adverse effects such as thermal run away/PCB warpage. Here, transient thermal analysis is carried out in an in-house developed PCB which is placed inside a sheet metal enclosure. Initially, thermal prediction to explore thermal regimes in the PCB is performed with the help of a commercially available software Altair Simlab ElectroFlo 2024.1. Temperature across all the components of the PCB as well as at the enclosure is simulated which is found to be beneficial in identifying the critical hotspots. In addition to the above, thermal measurements are performed in the lab with the help of
Rajasekharan, JayakrishnanML, SankarPrasad, Suryanarayana
Robust validation of Advanced Driver Assistance Systems (ADAS) considering real-world conditions is a vital for ensuring safety. Mileage accumulation is a one of the validation method for ensuring ADAS system robustness. By subjecting systems to diverse real-world driving environments and edge-case scenarios, engineers can evaluate performance, reliability, and safety under realistic conditions. In accordance with ISO 21448 (SOTIF), known hazardous scenarios are explicitly tested during robustness validation in combination of virtual and physical testing at component, sub system and vehicle level, while unknown hazards may emerge through extended mileage by running vehicles on roads, allowing them to be identified and classified. However, defining a mileage target that ensures comprehensive safety remains a significant engineering challenge. This paper proposes a data-driven approach to define mileage accumulation targets for validating Autonomous Emergency Braking Systems (AEBS
Koralla, SivaprasadRavjani, AminTatikonda, VijayGadekar, Ganesh