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This specification covers a corrosion-resistant steel in the form of investment castings homogenized and solution and precipitation heat treated to 180 ksi (1241 MPa) tensile strength.
AMS F Corrosion and Heat Resistant Alloys Committee
In emerging markets, especially in India and other similar countries, the growing traffic density on the roads leads to different types of accidents, including frontal head-on collisions, rear-end collisions, side-impact collisions, collisions with fixed objects such as electric poles, trees, road guard rails, road dividers, and accidents involving pedestrians, cyclists, and two-wheelers. These accidents could be due to over speeding, distracted driving, violation of traffic rules, and inadequate road infrastructure etc. Providing the necessary safety restraint systems (Airbags and Seat belts) in vehicles and ensuring their robust functionality in different real-world accident scenarios will be challenging for vehicle manufacturers. It is high time to redefine the traditional collision-sensing architecture strategies with a logical approach based on a thorough study of available accident data statistics, types of objects, and scenarios leading to severe accidents. Among these, rear-end
KOVALAM, SUNIL KUMAR
The present disclosure is about combating Thermal runaway in Electric, Plug-in Hybrids and mild hybrid vehicles. This paper comprises of high-Voltage Battery pack containing Battery cells electrically coupled with Shape Memory Alloy along with Busbars. These connectors (Shape Memory Alloy) are programmed to operate in two states: First to electrically connect the cells with the busbars, second to disconnect the individual cells from electric connection beyond the threshold temperature. This mechanism enables the Battery cells to rapidly prevent the Battery from the Thermal runaway event which is caused from the cell level ensuring the Battery safety mechanically. Additionally, the Battery pack includes the cell monitoring system and Battery Monitoring System to enhance the above invention with regards to the safety of the vehicle. This configuration is implementable and retrofittable into existing battery systems, offering a robust solution to the challenges posed by prolonged vehicle
Reginald, RiniRout, SaswatVENKATESH, MuthukrishnanChauhan, Ashish JitendraSelvaraj, Elayanila
The transportation and mobility sector are undergoing a profound transformation, with a growing emphasis on sustainability and minimizing the environmental impact of transportation. Among the most significant trends is the transition to electric vehicles (EVs) in the form of Battery and Fuel cell, which produce zero emissions without any harmful gases release in nature. This review highlights several infrastructure-related issues and critical factors that could drive India's transportation sector toward adopting electric vehicles. It also delves into the fundamental understanding of e-mobility, shedding light on the daily challenges and barriers it faces. Furthermore, the study explores research aspects, including the strategies, methods, and tools used for electric vehicles to complete the research on Battery electric vehicles (BEV) and also comparative analysis with Fuel cell vehicles (FCVs). The shift BEVs has been driven by decreasing battery costs and advancements in charging
Kumar, Dr. Vijay Bhooshan
In-vehicle communication among different vehicle electronic controller units (ECU) to run several applications (I.e. to propel the vehicle or In-vehicle Infotainment), CAN (Controller Area Network) is most frequently used. Given the proprietary nature and lack of standardization in CAN configurations, which are often not disclosed by manufacturers, the process of CAN reverse engineering becomes highly complex and cumbersome. Additionally, the scarcity of publicly accessible data on electric vehicles, coupled with the rapid technological advancements in this domain, has resulted in the absence of a standardized and automated methodology for reverse engineering the CAN. This process is further complicated by the diverse CAN configurations implemented by various Original Equipment Manufacturers (OEMs). This paper presents a manual approach to reverse engineer the series CAN configuration of an electric vehicle, considering no vehicle information is available to testing engineers. To
Kumar, RohitSahu, HemantPenta, AmarBhatt, Purvish
In the development of high-voltage (HV) batteries, ensuring secure connections between HV conductors and maintaining the safety and performance of the battery pack is paramount. Therefore, In the pursuit of enhancing efficiency and reliability in electrical connections, this paper explores the innovative alternate for a traditional screwing method with a friction locking mechanism for connecting busbars. The novel design reimagines the busbar as a Friction clamp (Female part) that securely holds the male part of the Busbar, significantly increasing the contact surface area up to 50%. This enhanced surface area not only improves electrical conductivity but also addresses heat generation issues associated with traditional screw-based connection. By eliminating the need for screws, the new design streamlines the assembly process, resulting in reduced cycle times and improved overall assembly line efficiency. This study presents the design methodology, performance analysis, and potential
Venkatesh, MuraliRaghu, ArunBhramanna, Amol
As light electric vehicles (LEVs) gain popularity, the development of efficient and compact on-board chargers (OBCs) has become a critical area of focus in power electronics. Conventional AC-DC topologies often face challenges, including high inrush currents during startup, which can stress components and affect system reliability. Furthermore, DC-DC converters often have a limited soft-switching range under light load conditions, leading to increased switching losses and reduced efficiency. This paper proposes a novel 6.6 kW on-board charger architecture comprising a bridgeless totem-pole power factor correction (PFC) stage and an isolated LLC resonant DC-DC converter. The main contribution lies in the specific focus on enhancing startup behavior and switching performance. In PFC converters, limiting inrush current during startup is crucial, especially with fast-switching wide-bandgap devices like SiC or GaN. Conventional soft-start techniques fall short in of ensuring smooth voltage
Patil, AmrutaBagade, Aniket
The present work highlights a case-study that aims to determine the performance (power input/output) and battery temperature on in-house developed e-rickshaw battery pack. With the rise of e-rickshaws in Indian market, the demand for the batteries have also increased and being the largest state-run energy company of India, R&D Centre of Indian Oil Corporation Limited (IOCL) has developed a chemically modified nanomaterial-based lead acid battery. The lab scale experiments, which are not presented in the study due to confidentiality and intellectual property obligations, indicated that the nanomaterial doped lead acid battery pack performs better than the control (reference) and leading commercial batteries in terms of lifecycle, capacity etc. Subsequently, this paper highlights the performance with IOC R&D Centre manufactured 12V/100AH chemically modified (nanomaterial) lead acid battery pack for e-rickshaw on duty cycle developed indigenously based on the city driving experiences. The
Saroj, ShyamsherSithananthan, MKumar, PrashantArora, AjaySundaram, PKalita, Mrinmoy
Path planning is a key element of autonomous vehicle navigation, allowing vehicles to calculate feasible paths in challenging environments for applications like automated parking and low speed autonomous driving. Algorithms such as Hybrid A*, Reeds-Shepp, and Dubins paths are widely used and can generate collision-free paths but tend to create curvature discontinuities. These discontinuities result in sudden steering transitions, which create control instabilities, higher mechanical stress, and lower passenger comfort. To overcome these issues, this paper suggests a path-smoothing technique based on the pure-pursuit algorithm to produce smoothed curve paths appropriate for real-world driving. This method utilizes the practical approach of the original path, but removes sudden transitions that destabilize control. By ensuring smooth curvature, the vehicle undergoes fewer jerky steering actions, improved energy efficiency, less actuator wear, and improved high-speed tracking. This paper
S, ShriniyathiA, JosanaEdwin J, JoelT, AkshayaaM, Senthil VelKumar, Vimal
The light and light signaling devices installation test as per as per IS/ ISO 12509:2004 & IS/ISO 12509:2023 for Earth Moving Machinery / Construction Equipment Vehicles is a mandatory test to ensure the safety and comfort of both road users and operators. Considering the shape and size of construction equipment vehicles, accurate measurement of lighting installation requirements is crucial for ensuring safety and regulatory compliance. The international standard IS/ISO 12509:2004 & IS/ISO 12509:2023 outlines specific criteria for these installation requirements of lighting components, including the precise measurement of various dimensions to ensure optimal visibility and safety. Among these dimensional requirements, the dimension 'E' i.e., the “distance between the outer edges of the machine and the illuminating surface of the lighting device” plays a critical role in the performance of vehicle lighting systems. Traditional methods of measuring this dimension, such as using a
Ghodke, Dhananjay SunilBelavadi Venkataramaiah, ShamsundaraTambolkar, Sonali Ameya
Emission Regulations for NRMM in India have evolved significantly over past two decades. India has progressively adopted stricter standards to align with best practices carried out globally for curbing air pollution. The latest regulations have introduced stringent caps on nitrogen oxides (NOx), and other emission pollutants, ensuring compliance with environmental sustainability goals. Future legislative frameworks are expected to impose even more rigorous emission limits, while incorporating real-world emission monitoring. This will require powertrain manufacturers to integrate advanced after-treatment systems and adopt cleaner combustion technologies to meet compliance standards. To validate compliance with these stringent limits, rigorous testing methodologies are employed. Portable Emission Measurement Systems (PEMS) have become a crucial tool for real-world emission assessment. PEMS technology allows for on-road and field testing of NRMM under actual operating conditions
Rastogi, AadharGarg, VarunRagot, Nicolas
Transportation sector in India accounts for 12% of total energy consumption. Demand of energy consumption is being met by the imported crude oil, which makes transportation sector more vulnerable to fluctuating international crude oil prices. India is mindful of its commitment in 2016 Paris climate agreement to reduce GHG emissions intensity of its GDP by 40% by 2030 as compared to 2005 levels. To fast track the decarbonization of transportation sector, commercial vehicle manufacturers have been exploring other viable options such as battery electric vehicles (BEVs) as a part of their fleet. As on today, BEV has its own challenges such as range anxiety & high total cost of ownership. Range anxiety can be certainly addressed by optimum sizing of electric powertrain, reduction in specific energy consumption (SEC) & use of effective regeneration strategies. Higher SEC can be more effectively addressed by doing vehicle energy audit thereby estimating the energy losses occurring at each
Gijare, SumantKarthick, K.Juttu, SimhachalamThipse, Sukrut S.A, JothikumarJ, Frederick RoystonSR, SubasreeG, HariniM, Senthil Kumar
This paper compares carbon dioxide, carbon monoxide, methane, and oxides of nitrogen emissions from medium and heavy-duty buses using diesel, diesel-hybrid, and CNG powertrains. Comparisons are made using results from chassis dynamometer-based tests with driving cycles intended to simulate a wide range of operating conditions. Tail pipe emissions are measured by diluting the vehicle’s exhaust in a full-scale dilution tunnel by mixing with conditioned air. Samples are drawn through probes of raw exhaust, diluted exhaust and measured using laboratory grade emission analyzers. Fuel consumption of diesel is measured using a weighing scale, while a gas flow meter is used for measuring CNG consumption. Experimental data from 19 buses tested on a chassis dynamometer over the last 8 years has been analyzed and a comparison of results from similar buses with the differently fueled powertrains is presented. Based on these test results, it is shown that replacing diesel engines with CNG engines
Iyer, Suresh
The advancement of electric vehicle (EV) transmission systems is currently a prominent trend aimed at decreasing carbon emissions and providing eco-friendly transportation alternatives. Most of the EV transmissions are single speed, but research conducted on multi speed EV transmissions show higher efficiency, good performance, high speed and torque demand when compared with single speed counterparts. Most of the multi speed EV transmissions that are developed are of non-synchromesh type, which have direct effect on NVH, driving dynamics and durability of drivetrain components. Due to aforementioned factors, gearshift analysis becomes critical for development. Simulation model is developed at early development phase for initial feedback. Using the feedback, drivetrain can be optimized furthermore and test on physical parts can be conducted for final verification. This paper provides a simulation based approach for modelling non-synchromesh two speed EV transmission using Simulation X
Kansagara, SmitThambala, PrashanthSutar, SureshTodtermuschke, KarstenPatel, Hiral
Automotive headlamps in Battery Electric Vehicles (BEVs) are exposed to a wide range of environmental and operational conditions that influence their thermal behaviour. Factors such as solar radiation, ambient temperature, lighting features, and nearby heat sources can significantly impact headlamp temperatures, potentially leading to issues like condensation, material degradation, and reduced optical performance. Accurate thermal modelling using Computational Fluid Dynamics (CFD) is essential during the design phase, but its effectiveness depends heavily on the fidelity of boundary conditions, which are often based on internal combustion engine (ICE) vehicle data. This study investigates the thermal behaviour of BEV headlamps under real-world conditions, focusing on parking and charging scenarios. Temperature measurements were taken at various locations on the lens and housing of a Jaguar I-Pace using thermocouples. The results show that lighting features, particularly the high beam
Nangunuri, Vishnu TejaKapadia, VatsalKovacs, GaborAhmad, Waqas
The Government of India has mandated biofuel blending in automotive fuels to reduce crude oil imports and support the national economy. As part of this initiative, Oil Marketing Companies (OMCs) have begun nationwide blending of E20 fuel (20% ethanol in petrol). Ethanol supply is expected to exceed demand by the end of 2025 due to initiatives like the Pradhan Mantri JI-VAN Yojana. Alternative applications for ethanol are being explored; one promising approach is its use as a co-blend with diesel fuel (ED blends). However, ethanol’s low cetane number and poor lubricity pose challenges for direct use in diesel engines without modifications. ED blends demonstrated reduced emissions while maintaining performance comparable to conventional diesel. To further address concerns related to materials compatibility of ED blends with fuel system components, particularly plastomers that may impact engine durability, a detailed study was conducted using elastomers such as FVMQ, FKM, HNBR, and NBR in
Johnpeter, Justin PChakrahari, KiranChakradhar, MayaArora, AjayPrakash, ShantiPokhriyal, Naveen Kumar
Today, passenger car makers around the world are striving to meet the increasing demand for fuel economy, high performance, and silent engines. Corporate Average Fuel Economy (CAFE) regulations implemented in India to improve the fuel efficiency of a manufacturer's fleet of vehicles. CAFE goal is to reduce fuel consumption and, by extension, the emissions that contribute to climate change. CNG (Compressed Natural Gas) engines offer several advantages that help manufacturers meet and exceed these standards. The demand for CNG vehicles has surged exponentially in recent years, CNG engine better Fuel efficiency and advantage in CAFÉ norms make good case for OEM & Customer to use more CNG vehicle. CNG is dry fuel compared to gasoline. These dry fuels lack lubricating properties, unlike conventional fuels like petrol, diesel and biofuels, which are wet and liquid. Consequently, the operations and failures associated with these fuels differ. The materials and designs of engine parts, such as
Poonia, SanjayKumar, ChandanSharma, ShailenderKhan, PrasenjitBhat, AnoopP, PrasathNeb, Ashish
The stringent emission norms over the past few years have driven the need to use low-carbon fuels and after treatment technology. Natural gas is a suitable alternative to diesel heavy-duty engines for power generation and transportation sectors. Stoichiometric combustion offers the advantages of complete combustion and low carbon dioxide emissions. Turbocharging and cooled exhaust gas recirculation (EGR) technology enhances the power density along with reduced exhaust emissions. However, there are several constraints in the operation of natural gas spark ignition engine such as exhaust gas temperature limit of 780 °C, sufficient before turbine pressure for EGR drivability, boost pressure, peak cylinder pressure limit and knocking. These limits coulld restrict the engine BMEP (brake mean effective pressure). In the present study, tests were conducted on a V12, 24 liters, heavy duty natural gas fuelled spark ignition engine (600 HP) with different EGR and turbocharger configurations to
Khaladkar, OmkarMarwaha, Akshey
This paper presents a novel structural solution for side impact protection of high-voltage battery packs in electric trucks. While electric vehicles offer benefits like zero emissions and independence from fossil fuels, in turn present challenges in meeting crashworthiness standards and safety regulations. The device addresses the critical need for effective battery protection & styling of battery electric vehicles. The integration of a hybrid corrugated panel system with plastic side fairings is innovative, combining crashworthiness with aerodynamic and aesthetic benefits. The crash protection features two hat-section steel channels at the top and bottom and corrugated steel sheet with alternating ridges is attached to these channels. Corrugated panels are enforced with help of backing strips. This assembly is mounted on shear plates at both ends, secured to the vehicle's frame rail. During a side impact event, the plastic side fairings absorb the initial impact, crumpling easily. If
Badgujar, PrathameshDevendra, AwachareHansen, Benjamin
Curtain airbags are the most effective protective systems to prevent severe/fatal head injuries in side collisions with narrow objects such as poles or trees. One of the important parameters of curtain airbags is the inflated zone i.e. the coverage area of the airbag, which decides the extent of head protection for occupants with different anthropometries in different seating rows. EuroNCAP first introduced the concept of Head Protection Device Assessment (HPDA) in 2015., In addition to the performance requirements in the dynamic test, EuroNCAP started assessing the deployed curtain airbag/s for its area coverage and verification of inflated zones for various anthropometries over occupant rows. In India, there is now a near total adoption of curtain airbags as standard fitment by the OEMs. Further, introduction of Bharat NCAP (BNCAP), a Perpendicular Pole Side Impact test is conducted for assessing the effectiveness of curtain airbags in a dynamic test, but currently, does not perform
Jaju, DivyanKulkarni, DileepMahajan, Rahul
The safety of vulnerable road users, particularly pedestrians, cyclists, and motorcyclists, is a paramount concern in automotive design and regulation. In India, the situation is particularly alarming, with pedestrians being the second highest victims of road accidents, as evidenced by over 32,825 reported pedestrian accidents and 4,836 cyclist fatalities in 2022, excluding two-wheeler motorcyclists. On a global scale, the prevalence of such incidents has prompted European countries to introduce new regulatory requirements, such as ECE R127.03. This regulation encompasses the evaluation of pedestrian head form impacts on windshields, assessing the typical behavior of glass through jerk criteria following initial contact, in conjunction with the existing Head Injury Criterion (HIC) evaluation for pedestrian head forms. These criteria’s are meticulously designed to ensure that both acceleration and jerk remain within safe limits to reduce the severe risk of severe injury to head of
Kumar, RitikA, Rajesh
This research analyzes the significance of air extractor on car door closing effort, especially within the context of highly sealed cabins. The goal is to measure their effectiveness in lowering pressure-induced resistance, study how the cut-out cross section and location affect performance, and its contribution to vehicle premium feel. Current vehicle design trends prioritize airtight cabin sealing for improving aerodynamic efficiency, NVH performance. This causes a problem in door closing operation. Air trapped while closing door creates transient pressure pulses. This pressure surge creates immediate discomfort to user i.e., Popping in Ears and requires high door closing force, and long-term durability problems in hinges and seals. In properly sealed cabins, air pressure resistance can contribute to 25% to 40% of total door closing force. Air extractors, usually installed in the rear quarter panels or behind rear bumpers, serve as pressure relief valves, allowing for a smoother
P, SivasankarSankineni, Vikhyath RaoShah, SahilMarimuthu, Anbarasan
This paper presents a comprehensive survey and data collection study on the adaptability of Camera Monitoring Systems (CMS) for passenger vehicles. With the growing demand for enhanced safety, automation, and driver assistance technologies, Camera Monitoring Systems (CMS) has emerged as a key component in modern automotive design. This study aims to explore the current state of camera-based monitoring in passenger vehicles, focusing on their adaptability through survey data collection of various driving population and analysis. This paper evaluates the acceptance of CMS configurations in replacement to conventional rear-view mirrors through Position of Monitor, Clarity, CMS Adaptiveness to eyes, Comfort while turning, Merging into moving traffic, Monitoring Rear Traffic, while Getting Out of Car, while Overtaking, Coverage Area and Overall Acceptance. The findings offer valuable insights for manufacturers, engineers, and researchers working toward the evolution of intelligent vehicle
Sinha, AnkitTambolkar, Sonali AmeyaBelavadi Venkataramaiah, ShamsundaraKauffmann, Maximilian
This paper presents the design, simulation, and evaluation of a low-profile Multiple-Input Multiple-Output (MIMO) antenna configuration, optimized to meet the evolving demands of modernized wireless communication systems, incorporating LTE-Advanced (LTE-A) and emerging 5G Internet of Things (5G-IoT) applications. The antenna’s geometry relies on a novel design comprising staircase-shaped rectangular radiating patches with an integrated stub. This configuration is employed to improve impedance bandwidth and strengthen the isolation between antenna components, which are critical parameters in MIMO system performance. The antenna is fabricated on a Rogers RT/Duroid 5880 substrate, distinguished by its low dielectric loss and high-frequency stability. With a compact physical footprint of 96 × 96 mm2, the proposed design effectively serves the feature of integration into portable and space-constrained wireless devices. The antenna operates effectively across frequency range of 2.13 GHz to
Gupta, ParulPrasad, Anjay