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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
Higher latent heat of vaporization of ethanol deteriorates low ambient temperature starting of engines with ethanol blended fuels. In case of flex fuel vehicles, cold starting becomes very critical on account of higher ethanol content. This case study highlights how pivot table based analytics were effectively employed to enhance engine start strategy during the development of small commercial vehicle running on E20 and E85 fuel blends. The approach showcases how structured data interpretation can significantly support development work in Flex Fuel calibration. The analysis is focused on various critical engine start events such as first crank success, failure to start, battery voltage behavior, and post-start stability across a range of coolant temperatures, particularly below 20°C. Real world test data was categorized using data analysis based on parameters such as crank RPM, battery voltage during cranking, fuel, phase detection status, throttle input, and spark advance, and start
Undre, ShrikantKulkarni, DeepakThonge, RavindraUpadhyay, RajdipKanchan, Shubham
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
India’s commitment to carbon neutrality is significantly shaping the future architecture of commercial vehicle powertrains. While the use of CO₂-free technologies such as battery-electric drivetrains has already been successfully demonstrated across various applications, challenges related to limited range and the lack of high-power charging infrastructure continue to hinder widespread adoption, particularly for productivity-critical commercial vehicles. This has shifted the spotlight toward sustainable fuels, which offer the advantage of fast refueling times. Among these, hydrogen internal combustion engines (H₂ ICE) have gained increasing attention in recent years. In regions such as the European Union, the primary motivation for hydrogen is CO₂ reduction. In contrast, for markets like India, hydrogen also presents a strategic opportunity for reducing dependency on fossil fuel imports. Over the past four years, multiple performance and emission development projects across various H
Arnberger, AntonDanninger, AloisMannsberger, StefanBreitegger, Bernhard
Engine radiated noise has complex behavior since the diesel engine assembly comprises several components with varied dynamic speeds. The engine noise performance for the open station tractor is a crucial contributor to noise and needs to be optimized. Various engine noise sources have been researched, including structural like the engine block, intake, exhaust, and timing gears. Reducing noise in diesel powertrains by structural improvements entails limiting vibrations and preventing noise transfer from the engine. This can be accomplished by increasing the rigidity of the engine block and other structural components, as well as optimizing structural designs. Local adjustments to structural components have become a significant strategy for reducing noise and vibration problems. Design enhancements in structural components can be predicted and optimized for NVH. NVH testing helps validate changes in engine structure stiffness and assess acoustic improvements. Coupled with simulations
Kamble, PranitBaviskar, ShreyasGhale, GuruprasadChatterjee, DipankarPrabhakar, Shantanudhobale, VishwajeetBendre, ParagThakur, SunilKunde, Sagar
There is continuous push from the legislation for stringent fuel economy and emission regulations while the modern customers are demanding more engaging driving experience in terms of performance and refinement. To meet this Tata Motors has developed an advanced 1.2L 3-cylinder turbocharged gasoline direct injection engine. This next-generation powertrain delivers optimum efficiency, reduced emissions, superior performance with refined NVH characteristics. The key features used to enable these demanding requirements includes a 35 MPa fuel injection system, Miller Cycle operation and electrically actuated variable nozzel turbocharger (VNT). A uniquely designed BSVI complaint (WLTP ready) exhaust after-treatment system with Four-Way Conversion Catalyst (FWC+TM) ensures optimum emission control. A centrally mounted variable cam phaser minimizes pumping losses. The lightweight yet rigid all-aluminum engine structure, featuring an integrated structural oil sump, enhances durability and
Hosur, ViswanathaGhadge, Ganesh NarayanJoshi, ManojJadhav, AashishPanwar, Anupam
This paper explores the requirement of multi speed – multi motor torque vectoring in a battery electric commercial truck. The area of focus was to compare the vehicle performance and range of a BEV truck with conventional central drive single motor configuration with the same vehicle consisting of a multi speed – multi motor torque vectoring control strategy. Through this exercise, we have analysed the motor power and torque requirements to meet the vehicle performance along with the required reduction ratios. A MATLAB based vehicle model is used to simulate the effect of multi motor operation on the vehicle range. Also simulated the effect of torque vectoring control algorithm on the vehicle performance like steady state cornering(SSC), Double Lane change (DLC), Off road dive Cycle, vehicle stability and turning circle diameter(TCD).
Pethkar, ShivanandS, SrivatsaGhosh, Sandeep
In automotive safety systems, Time to Collide (TTC) is traditionally used to trigger warnings in auto-emergency braking systems. However, TTC can lead to premature or inaccurate warnings as it is calculated based on the relative speed and distance between the ego and an obstacle. TTC does not consider the vehicle’s braking dynamics, such as brake prefill lag which varies across different vehicles, maximum deceleration, and the effectiveness of braking systems and assumes constant speed which may not always be realistic. We propose Time to Brake (TTB) as a more effective parameter for driver warnings. TTB directly relates to the action a driver needs to take—braking. It provides a clear indication of when braking should begin to avoid a collision, whereas TTC only tells us about the possibility of a collision. To calculate TTB we utilize the brake profile, which incorporates both deceleration and system jerk for improved accuracy. The proposed warning time is the sum of variable brake
Singh, Ashutosh PrakashKumawat, HimanshuGupta, Sara
Mass Mobility Systems are critical for a sustainable and progressive society. As the world confronts the serious challenges of global warming and urban traffic congestion, efficient mass mobility solutions become critical in reducing carbon footprints and enabling equitable access. Advancement in mass mobility is not limited to electric buses alone but also includes innovations across conventional ICE vehicles, autonomous vehicles, trains, and other integrated transport networks. Safety and accessibility for users remain critical to the sustainability of future mass mobility concepts. The COVID-19 pandemic exposed vulnerabilities in public transportation, highlighting the urgent need for safer and more resilient systems. Road safety, passenger well-being, and hygienic standards must be deeply embedded into future mobility solutions. Furthermore, strong last-mile connectivity will be essential to ensure that mass mobility truly meets the needs of all citizens. An effective Mass Mobility
Vasudevan, MKumar S, AshokSridevi, MKumar, RajivKumar, Om
This research investigates the dynamic characteristics of an electric two-wheeler chassis through a combined experimental and numerical approach, and understands the contribution of battery towards overall behaviour of the frame in a structural manner. The study commences with the development of a detailed CAD model, which serves as the basis for Finite Element Analysis (FEA) to predict the chassis's natural frequencies and mode shapes. These numerical simulations offer initial insights into the structural vibration behavior crucial for ensuring vehicle stability and rider comfort. To validate the FEA predictions, experimental modal analysis is performed on a physical prototype of the electric two-wheeler chassis using impact hammer excitation. Multiple response measurements are acquired via accelerometers, and the resulting data is processed to extract experimental modal parameters. The correlation between the simulated and experimental mode shapes is quantitatively assessed using the
Das Sharma, AritryaIyer, SiddharthPrasad, SathishAnandh, Sudheep
As vehicles are becoming more complex, maintaining the effectiveness of safety critical systems like adaptive cruise control, lane keep assist, electronic breaking and airbag deployment extends far beyond the initial design and manufacturing. In the automotive industry these safety systems must perform reliably over the years under varying environmental conditions. This paper examines the critical role of periodic maintenance in sustaining the long-term safety and functional integrity of these systems throughout the lifecycle. As per the latest data from the Ministry of Road Transport and Highways (MoRTH), in 2022, India reported a total of 4.61 lakh road accidents, resulting in 1.68 lakh fatalities and 4.43 lakh injuries. The number of fatalities could have been reduced by the intervention of periodic services and monitoring the health of safety critical systems. While periodic maintenance has contributed to long term safety of the vehicles, there are a lot of vehicles on the road
HN, Sufiyan AhmedKhan, FurqanSrinivas, Dheeraj
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
As urban population continues to grow, the safety of Vulnerable Road Users (VRUs) particularly in the presence of Heavy Good Vehicles (HGVs) has emerged as a critical concern. Research indicates that VRUs are at a 50% higher risk of fatal injury in collisions involving HGVs compared to passenger cars. To address this issue, this study proposes a novel pedestrian protection system that integrates LiDAR (Light Detection and Ranging) technology with a reusable airbag system to mitigate the severity of collisions. The proposed solution adopts a twofold approach for enhancing VRU protection in scenarios involving HGVs. In both approaches, LiDAR sensors are used to generate a real-time 3D model of the vehicle’s surroundings, enabling accurate VRU detection and predictive collision analysis. Scenario 1: When vehicle speed exceeds the first threshold and a collision is unavoidable, the onboard ECU activates front lid actuators, extending the vehicle's front lid which can be retracted back to
Patil, UdaySriharsha, ViswanathPillai, Rajiv
Electric motor benchmarking is often constrained by limited availability of motor-specific data, particularly when dealing with commercially available or third-party electric motors. This paper presents a streamlined and scalable methodology for characterizing unknown E-Motors using a configurable universal inverter platform. The proposed approach is specifically designed for OEMs and Tier 1 suppliers seeking to evaluate performance metrics such as torque accuracy, peak and continuous capability, efficiency, and control behavior—without prior access to key motor parameters or simulation data. A central challenge in this context is the stepwise electromagnetic characterization required to determine the phase current needed for accurate speed and torque control, especially under a Maximum Torque per Ampere (MTPA) or Maximum Torque per Watt (MTPW) strategy. As this requirement is highly dependent on the motor’s topology and electromagnetic properties, most conventional approaches rely on
Kanya, BenjaminDuchi, FrancescoRavi, Abhishek
Occupant Safety systems are usually developed using anthropomorphic test devices (ATDs), such as the Hybrid III, THOR-50M, ES-2, and WorldSID. However, in compliance with NCAP and regulatory guidelines, these ATDs are designed for specific crash scenarios, typically frontal and side impacts involving upright occupants. As vehicles evolve (e.g., autonomous layouts, diverse occupant populations), ATDs are proving increasingly inadequate for capturing real-world injury mechanisms. This has led to the adoption of computational Human Body Models (HBMs), such as the Global Human Body Models Consortium (GHBMC) and Total Human Model for Safety (THUMS), which offer superior anatomical fidelity, variable anthropometry, active muscle behaviour modelling, and improved postural flexibility. HBMs can predict internal injuries that ATDs cannot, making them valuable tools for future vehicle safety development. This study uses a sled CAE simulation environment to analyze the kinematics of the HBMs
Raj, PavanRao, GuruprakashPendurthi, Chaitanya SagarNehe, VaibhavChavan, Avinash
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
The objective of the present study is to examine trends in occupant kinematics and injuries during side impact tests carried out on vehicle models over the period of time. Head, shoulder, torso, spine, and pelvis kinematic responses are analysed for driver dummy in high speed side impacts for vehicle model years, MY2016-2024. Side impact test data from the tests conducted at The Automotive Research Association of India (ARAI) is examined for MY2016-2024. The test procedure is as specified in AIS099 or UNECE R95, wherein a 950kg moving deformable barrier (MDB) impacts the side of stationary vehicle at 50km/hr. An Instrumented 50th percentile male EUROSID-2 Anthropomorphic Test Device is positioned in the driver seat on the impacting side. Occupant kinematic data, including head accelerations, Head Injury Criterion (HIC15), Torso deflections at thorax and abdominal ribs, spine accelerations at T12 vertebra, and pelvis accelerations are evaluated and compared. The “peak” and “time to
Mishra, SatishBorse, TanmayKulkarni, DileepMahajan, Rahul
This study focuses on enhancing energy efficiency in electric vehicle (EV) thermal management systems through the development and optimization of control logic. A full vehicle thermal management system (VTMS) was modeled using GT-Suite software, incorporating subsystems such as the high voltage battery (HVB), Electric powertrain (EPT), and an 8-zone cabin. Thermal models were validated with experimental data to ensure accurate representation of key dynamics, including coolant to cell heat transfer, cell-to-ambient heat dissipation, and internal heat generation. Control strategies were devised for Active Grille Shutter (AGS) and radiator fan operations, targeting both cabin cooling and EPT thermal regulation. Energy consumption was optimized by balancing aerodynamic drag, fan power, and compressor power across various driving conditions. A novel series cooling logic was also developed to improve HVB thermal management during mild ambient conditions. Simulation results demonstrate
Chothave, AbhijeetKumar, DipeshGummadi, GopakishoreKhan, ParvejThiyagarajan, RajeshPandey, RishabhS, AnanthAnugu, AnilMulamalla, SarveshwarGangwar, Adarsh
Automobile emissions refer to the gases and particles released into the atmosphere by vehicles during their operation. These emissions contribute to environmental pollution and have an impact on human physiology and environment. This paper assimilates findings from a comprehensive research study examining tyre wear and its Indian perspective. Tyre wear understood as a factor affecting road safety, environmental health, and economic sustainability. The study identifies factors affecting tyre wear and provides overview regarding tyre wear generation in India, encompassing road infrastructure, vehicle characteristics, driving patterns, and environmental factors. Moreover, it examines the adverse effects of these particles on human health, such as respiratory ailments and cardiovascular diseases, as well as their impact on ecosystems. This paper delves measures to measure tyre wear and safeguard both environmental and public health. It also covers the tyre wear measurement methodologies to
Joshi, AmolKhairatkar, VyankateshBelavadi Venkataramaiah, Shamsundara
In its conventional form, dynamometers typically provide a fixed architecture for measuring torque, speed, and power, with their scope primarily centered on these parameters and only limited emphasis on capturing aggregated real-time performance factors such as battery load and energy flow across the diverse range of emerging electric vehicle (EV) powertrain architectures. The objective of this work is to develop a valid, appropriate, scalable modular test framework that combines a real-time virtual twin of a compact physical dynamometer with world leading real-time mechanical and energy parameters/attributes useful for its virtual validation, as well as the evaluation of other unknown parameters that respectively span iterations of hybrid and electric vehicle configurations, ultimately allowing the assessment of multiple chassis without having to modify the physical testing facility's test bench. This integration enables a blended approach, using a live data source for now, providing
Kumar, AkhileshV, Yashvati
The road infrastructure in India has complex navigational challenges with most of the road unstructured especially in rural areas. Decision-making becomes a challenge for drivers in unpredictable environments such as narrow roads, flooded roads and heavy traffic. In this paper, an Augmented Reality based ML-Algorithm for Driver Assistance (ARMADA) has been proposed that improves awareness to safely maneuver in these conditions. The methodology for development and validation of this Augmented Reality (AR) based algorithm contains multiple steps. Firstly, extensive data collection is conducted using real time recording and benchmark datasets like Berkeley Deep Drive (BDD) and Indian Driving Dataset (IDD). Secondly, collected data are annotated and trained using an optimal machine learning (ML) model to accurately identify the complex scenario. In third step, an ARMADA algorithm is developed, integrating these models to estimate road widths, detect floods and provide seamless driver
Anandaraj, Prem RajSivakumar, VishnuThanikachalam, GaneshL, RadhakrishnanMotoki, YaginumaSelvam, Dinesh Kumar
The clutch is a mechanical device that connects and disconnects engine power to the drivetrain through the clutch disc and cover assemblies. The disc, with friction material linings is mounted on the transmission shaft, transmits power when clamped between the flywheel and cover assembly. During operation, wear occurs due to speed differences and slippage between the engine and transmission. Clutch performance is evaluated under repeat restart conditions on steep gradients to assess thermal durability and reliability in commercial vehicles. The repeat restart test on a 12% gradient replicates truck launches under full load, where excessive slippage generates heat that may lead to friction material wear or failure if critical temperature limits are exceeded. To address the high cost and time of physical testing, a 1D thermal simulation was developed using GT Suite. The model replicates 90 repeat vehicle launches on a 12% gradient in first gear, integrating driver inputs and drive cycles
Munisamy, SathishkumarChollangi, DamodarMane, Sudhir
The growing demand for Electric Vehicles (EVs) has highlighted the importance of efficient and accurate simulation tools for design and performance optimization. The architecture of electric vehicles is distinct from that of internal combustion engine vehicles. It consists of on-board charger, DC-DC converter, Lithium ion battery pack, Inverter, electric motor, controllers and transmission. The battery pack supplies electric current to the traction motor, which then converts this electrical energy into mechanical energy, resulting in the rotational motion needed to drive the vehicle. Wide range of Multi-physics is involved in the simulation which involves Power electronics, Electromagnetics, Fluid Mechanics, Thermal engineering. This paper presents an integrated simulation and range prediction methodology for Electric Vehicles (EVs) using the Reduced Order Model (ROM) approach. The methodology includes simulation in both 3D and 1D domain. CFD simulation is performed to understand the
Shandilya, AnandKumar, Vivek
In the assessment of parts subjected to impact loading, the current process relies on static analysis, which overlooks the significant influence of high strain rate on material hardening and damage. The omission of these effects hinders accurate impact simulations, limiting the analysis to comparative studies of two components and potentially misidentifying critical hot spot locations. To address these limitations, this study emphasizes the importance of incorporating the effects of high strain rate in impact simulations. By utilizing the Johnson-Cook material calibration model, which includes both material hardening and damage models, a more comprehensive understanding of material behavior under dynamic loading conditions can be achieved. The Johnson-Cook material hardening model accounts for the strain rate sensitivity of the material, providing an accurate representation of its behavior under high strain rate conditions. This allows for improved prediction of material response
Pratap, RajatApte, Sr., AmolBabar, RanjitDudhane, KaranPoosarla, Shirdi Partha SaiTikhe, Omkar