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Determining Worst-Case Execution Time Bounds for Multi-core Processors2025-01-0155To be published on 05/02/2025
Demonstrating deadline adherence for real-time tasks is a common requirement in all safety norms, including ISO 26262 and DO-178C. Timing verification has to address two levels: the code level (worst-case execution time) and the scheduling level (worst-case response time). Determining which methodology is suited best depends on the characteristics of the target processor. All contemporary microprocessors try to maximize the instruction-level parallelism by sophisticated performance-enhancing features that make the execution time of a particular instruction dependent on the execution history. On multi-core systems, the execution time additionally is influenced by interference effects on shared resources caused by concurrent activities on the different cores, which are not controlled by the scheduling algorithm. In the avionics domain, the new FAA AC 20-193 / EASA AMC 20-193 guidance documents formalize predictability aspects of multi-core systems and derive adequate measures for timing
Kaestner, Daniel, Gebhard, Gernot, Huembert, Christian, Pister, Markus, Wegener, Simon, Ferdinand, Christian
Technical Paper
Image Processing-Based Chip Detection by KIZKI Algorithm and Its Optimization2025-01-0168To be published on 05/02/2025
The process of producing aircraft parts involves the drilling of aluminum alloys. This creates a large amount of chips, which are removed using air, but sometimes they still remain within the holes. This is checked by inspectors through visual inspection. However, the quality of human inspection varies based on skill level and fatigue. Thus, image-based inspection should be used to stabilize and further improve inspection quality. This study aims to build a framework for chip detection based on image processing. Taking into account on-site implementation, the system must have low installation and running costs and be standalone. Therefore, we adopt the KIZKI algorithm, which satisfies these conditions. KIZKI means awareness in Japanese. This is a model of human peripheral vision and saccades. It does not require training like AI and can achieve high-speed and high-performance detection using a low-performance computer. In other words, there is no need for a computer with an expensive
Iinuma, Marin, Sato, Junya, Tsuji, Masahiko
Technical Paper
The Why of Development Assurance2025-01-0154To be published on 05/02/2025
In the domain of aircraft certification, Development Assurance is what some would call a useful tool to gain confidence in the development of complex systems, and what others would call a necessary evil. But what does it actually do? Why is it necessary for certification of modern aircraft? What, epistemologically, does it bring to the table? This paper aims to show why development assurance activities, at all levels from aircraft to item, close the epistemological holes created when complex systems are chosen for implementation. It will map the different sources and types of uncertainty encountered in system verification and explain how each type is dealt with within a certification context, working from simple mechanical systems up to complex and highly integrated systems using software and airborne electronic hardware and beyond. It will show that Development Assurance, far from being an arbitrary set of activities, systematically brings personal and corporate expertise to bear to
Laflin, Cory R.
Technical Paper
Enhancing Airworthiness Security: SysML-Based Approach to Modelling Security Scope Definitions2025-01-0172To be published on 05/02/2025
Airworthiness certification of aircraft requires an Airworthiness Security Process (AWSP) to ensure safe operation under potential unauthorized interactions, particularly in the context of growing cyber threats. Regulatory authorities mandate the consideration of Intentional Unauthorized Electronic Interactions (IUEI) in the development of aircraft, airborne software, and equipment. As the industry increasingly adopts Model-Based Systems Engineering (MBSE) to accelerate development, we aim to enhance this effort by focusing on security scope definitions – a critical step within the AWSP for security risk assessment that establishes the boundaries and extent of security measures. However, our findings indicate that, despite the increasing use of model-based tools in development, these security scope definitions often remain either document-based or, when modeled, are presented at overly abstract levels, both of which limit their utility. Furthermore, we found that these definitions
Hechelmann, Adrian, Mannchen, Thomas
Technical Paper
Assignment Criteria for Function Allocation to Commercial Aviation System Security Domains2025-01-0156To be published on 05/02/2025
Aircraft cabin management is characterized by operational and business processes. Both are defined as a logical sequence of activities that occur during the flight. While the operational process includes activities to ensure flight safety, such as take-off, cruise and landing, the business process activities are related to adding value to the customer, i.e. the passenger. They are to be certified by the authority as a part of the aircraft type certification. These processes are defined by the airline and are described as part of the airline’s business model. While the scope of operational processes for passenger safety within the aircraft cabin should remain as unchanged as possible, the increasing competitive pressure on airlines is leading to a constantly rising number of services in the cabin. To prevent compromising cabin safety from increased cabin crew workload during the cruise phase, there is a growing trend toward digitizing operational and business processes. The digitized
Hintze, Hartmut, Blecken, Marvin, God, Ralf, Pereira, Daniel
Technical Paper
A New Test Rig for Electrically Actuated Landing Gear and Brake of a Small Transport Aircraft2025-01-0161To be published on 05/02/2025
Performing highly representative tests of aircraft equipments is a critical feature for gaining utmost confidence on their ability to perform flawlessly in flight under the entire spectrum of operating conditions. This can also contribute to accelerate the certification process of a new equipment. A research project (E-LISA) was performed in recent years, as part of the european funded Clean Sky 2 framework, with the objective of building an innovative facility for testing an electrically actuated landing gear and brake for a small air transport. The project eventually led to the development and construction of an Iron Bird able to reproduce in a realistic and comprehensive way a full variety of landing test cases consistent with certification specifications and landing histories available in the repository of the airframer. The Iron Bird that was eventually developed is a multi-functional intelligent and easy reconfigurable facility integrating hardware and software allowing to
De Martin, Andrea, Bertolino, Antonio, Jacazio, Giovanni
Technical Paper
Innovative High-Performance Active Dampers for Effective Mitigation of Helicopter Main Rotor Vibrations2025-01-0163To be published on 05/02/2025
Helicopter vibrations, primarily generated by the main rotor-gearbox assembly, are a major source of concern due to their impact on structural integrity, cockpit instrument durability, and crew comfort. These vibrations are mainly transmitted through the gearbox’s rigid support struts to the fuselage, leading to increased cabin noise and potential damage to critical components. This paper presents a solution for vibration mitigation which involves replacing traditional gearbox support struts with low-weight, high-performance active dampers. Developed by Elettronica Aster S.p.A., these active dampers are designed as electro-hydraulic actuators embedded within a compliant structure. The parallel nested configuration of the system enables high power densities and effective vibration control, significantly reducing the transmission of harmful vibrations to the fuselage. The comprehensive model-based design process is detailed, describing the development and use of a high-fidelity physics
Bertolino, Antonio Carlo, Sorli, Massimo, Porro, Paolo Giovanni, Galli, Claudio
Technical Paper
Material Adapted Method for the Repair of Curved Thermoplastic Composite Structures by Induction Welding of Patches2025-01-0165To be published on 05/02/2025
Thermoplastic fiber-reinforced polymer composites (TPCs) are gaining importance in aviation due to their high strength, stiffness, and recyclability. To maximize their potential, efficient repair methods are needed to maintain aircraft safety and structural integrity. This article introduces a novel repair technique for damaged TPC structures, involving the insertion of a repair patch with a susceptor material. The susceptor consists of a material with high electrical conductivity and magnetic permeability and therefore reacts stronger to the electromagnetic field than the composite, even if it is carbon fiber based. This means that the thermal energy is specifically concentrated in the repair area. The susceptor can be placed on the patch surface or in the welding zone. The process begins by identifying and preparing the damaged area, followed by precise scarfing. Care is taken to ensure that the surrounding material remains intact and that an exact stepped structure is created, which
Geiger, Markus, Glaap, Anton, Schiebel, Patrick, May, David
Technical Paper
Integrating for Safety – A Proposed Approach to the Integration of Propulsion Battery Systems in Hybrid Electric Aviation2025-01-0148To be published on 05/02/2025
In the last year we have witnessed a notable surge in the designs and in the guidance material for electric and hybrid aircraft. FAA and EASA have continued to evaluate the safety of Propulsion Battery Systems (PBS), with a focus on thermal runaway containment testing. As a result, a harmonization white paper was issued to provide a certification path for Thermal Runaway (TR) Hazards, followed by an EASA certification memorandum on the acceptable approaches for the certification of Electric/Hybrid Propulsion Systems (EHPS). And just recently, an FAA Advisory Circular (draft) was issued for the “powered-lift” aircraft that feature these propulsion battery systems. In spite of the advances made by electric/hybrid aircraft manufacturers and the aviation authorities, there is still a missing piece of the puzzle. Mainly, we are still not confident in our ability to properly integrate the PBS into the EHPS architecture, in such a way where safety is never compromised, no matter the hazard
Hanna, Michael, Walker, Cherizar
Technical Paper
Approach to Optimize the Airplane Boarding Process by using Image Recognition and Stochastic Simulation to Predict Overhead Bin Fill Levels2025-01-0164To be published on 05/02/2025
In single-aisle aircraft, the available storage space for carry-on baggage is inherently limited. When the aircraft is fully booked, this often results in insufficient overhead bin space, necessitating last-minute gate-checking of carry-on items, which delays the boarding process and reduces operational efficiency. A promising approach to mitigating this issue involves the integration of computer vision technologies with an appropriate data storage system and stochastic simulation to enable accurate and supportive predictions that enhance planning. In this work the YOLOv8 image recognition algorithm is used to identify and classify each passenger’s carry-on baggage into categories such as handbags, backpacks and suitcases. This data is then linked to passenger information stored in the NoSQL database MongoDB, which included seat assignments and the number of carry-on items per passenger. Stochastic simulation is applied to predict the occupancy levels of overhead storage bins across
Bergmann, Jacqueline, Hub, Maximilian
Technical Paper
Segment Manipulator Retrofit2025-01-0159To be published on 05/02/2025
A segment manipulator machine was in service nineteen years. Many of the control components were out of date and hard to obtain. Customer engaged Electroimpact to upgrade using the latest state-of-art controls. The program from the previous control system could not be reused. A “layup mandrel” is a form that is used to lay carbon fiber. The layup mandrel for a wide body aircraft fuselage section consists of six segments. The mandrel is made up of segments so that it can be assembled and disassembled from the inside. The segments are Crown, Upper Left, Upper Right, Lower Left, Lower Right, and Keel. For each build the mandrel is assembled with a segment manipulator machine, wound with carbon fiber tape, clad, and baked in an autoclave. Then the mandrel is disassembled with a segment manipulator machine leaving the cured carbon fiber shell behind. The segments are refurbished and brought to the assembly area on segment carts for the next build. Segments each weigh in the vicinity of 3000
Luker, Zachary, Donahue, Michael
Technical Paper
Model-Based Design and Energy Management of an Aeronautical Proton Exchange Membrane Fuel Cell System2025-01-0150To be published on 05/02/2025
The growing demand for air transport requires efficient and sustainable power systems to meet the pressing need for decarbonizing the sector. A hybrid unit, consisting of a proton exchange membrane fuel cell system and a lithium-ion battery, is a suitable option due to the benefits of reduced gravimetric and volumetric impacts, along with the flexibility of energy management strategies. This work addresses, using a model-based approach, the issue of integrating these electrochemical devices into the aircraft’s electrical architecture, considering both design and energy management aspects. Two scenarios are explored to match the DC bus line voltage requirements. In the first, the fuel cell system nominal power is kept constant, while the number of DC/DC converters operating in parallel is assessed by constructing bi-dimensional maps derived from literature. These maps relate the converter’s maximum deliverable power to the input and desired output voltage. The second scenario introduces
Aliberti, Paolo, Sorrentino, Marco, Cuomo, Fabrizio, Napolitano, Ciro
Technical Paper
Short-Time Current Rating of Aircraft Wire2025-01-0145To be published on 05/02/2025
This paper presents a comparative analysis of various short-time current rating formulas, focusing on applications in aircraft wiring. Examining historical formulas developed by pioneers such as W.H. Preece and I.M. Onderdonk alongside modern experimental data provide a comprehensive understanding of short-time current rating formulas. Also, exploring key challenges, such as environmental conditions and material variability in aviation with particular attention to adiabatic methods for current-carrying calculations. The findings of this paper offer practical insights into improving the safety and reliability of an aircraft electrical system with improving the accuracy of short-time current rating predictions.
Fifield, Jon
Technical Paper
Enhancing Efficiency in Aerospace Manufacturing through AI Agent Based Bearing Diagnostics System2025-01-0158To be published on 05/02/2025
Industrial bearings are critical components in aerospace manufacturing, where their failures can result in costly downtime. Traditional fault diagnosis typically depends on time-consuming on-site inspections conducted by specialized engineers. This research introduces an innovative Artificial Intelligence application that functions as a virtual maintenance technician, empowering on-site personnel to perform preliminary diagnoses. By reducing the dependence on specialized engineers, this technology aims to minimize downtime. The AI system leverages large language models to guide the inspection process, answer queries from a comprehensive knowledge base, analyze defect images, and generate detailed reports with actionable recommendations. Multiple deep learning algorithms operate as backend APIs to support this functionality. This study details the architectural design of the expert system and provides a real-time simulation of its workflow, demonstrating its potential to enhance
Chandrasekaran, Balaji
Technical Paper
Powering the Future of Sustainable Flight2025-01-0147To be published on 05/02/2025
Eaton Aerospace is collaborating with original equipment manufacturers (OEMs) on the advancement of technologies to increase aircraft efficiency, enable aircraft electrification, and reduce carbon emissions. Leveraging our expertise as an intelligent power management company, Eaton’s products and research include hydraulic power packs, electromechanical actuation (EMA), thermal management systems, and sustainable aviation fuel (SAF). Eaton Blended Power TM systems improve efficiency through eliminating all centralized hydraulic circuits with distributed power that is provided by a combination of hydraulic power packs and EMA for a More Electric Aircraft (MEA). EMA systems, including electrical synchronization, eliminate the usage of hydraulics and provide additional functionality that benefits the flight efficiency of the aircraft. With MEA comes higher energy and thermal densities, resulting in the need for advanced thermal management. Eaton’s scalable and modular thermal management
Skinner, Jeff, Proul, Margaret, Devan, Stephen, Clendenin, Laura, Hutchinson, Lewis, Masson, Andrew, May, Frank, Momotiuk, Andy, Zuzelski, Chris
Technical Paper
Interconnected and Data-Driven Aircraft Cabin Systems: Consistent Integration of ARINC 853 Messaging Standard into Model-Based Aircraft Systems Development2025-01-0174To be published on 05/02/2025
Increasing digitalization of the aircraft cabin, driven by the need for improved operational efficiency and an enhanced passenger experience, has led to the development of data-driven services. In order to implement these services, information from different systems is often required, which leads to a multi-system architecture. When designing a network that interconnects these systems, it is important to consider the heterogeneous device and supplier landscape as well as variations in the network architecture resulting from airline customization or cabin upgrades. The novel ARINC 853 Cabin Secure Media-Independent Messaging (CSMIM) standard addresses this challenge by specifying a communication protocol that relies on a data model to encode provided and consumed information. This paper presents an approach to integrate CSMIM-specific communication concepts into a Model-Based Systems Engineering (MBSE) framework using the Systems Modeling Language (SysML). This enables a streamlined
Giertzsch, Fabian, Blecken, Marvin, God, Ralf
Technical Paper
Comparison of Different Joining Techniques as a Benchmark for Integrally Joined Thermoformed Components Based on Tailored rCF Organosheets2025-01-0170To be published on 05/02/2025
Climate-neutral aviation requires resource-efficient composite manufacturing technologies and viable solutions for the reuse of carbon fibers (CF). In this context, thermoplastic composites (TPC) can make a strong contribution. Thermoforming of TPC is an efficient and established process for aerospace components. But it’s efficiency could be further increased by integration of joining processes, which would otherwise be separate steps. In this work, a two-step thermoforming process for hollow box structures, particularly uplift structures, is presented. The starting point are two organosheets. First, one of the organosheets, intended for the bottom skin of the uplift structure, is thermoformed. After cooling, the press opens, the organosheet remains in the press and an infrared heater is pivoted in, to locally heat up just the joining area. Meanwhile, a second organosheet, intended for the top skin, is heated and thermoformed and simultaneously joined to the lower skin, thereby forming
Vocke, Richard, Seeßelberg, Lorenz, Focke, Oliver, Dietrich, Jan Yorrick, Jobke, Katrin, Albe, Christopher, May, David
Technical Paper
Semi-Automatic Riveter G39 Replacement2025-01-0160To be published on 05/02/2025
Zieve, Peter, Reznicek, Jeffrey
Technical Paper
Conceptual Design of a Superconducting Aero Electric Engine System2025-01-0146To be published on 05/02/2025
The goal of the development of an electric aircraft engine is to create an aircraft system that achieves ultimate efficiency using hydrogen fuel instead of fossil fuels. Therefore, it is necessary to focus on reducing weight as much as possible, and this paper describes the approach to such fuel cell-powered aircraft. The authors have adopted a superconducting coreless rotating electric machine with an integrated hydrogen tank and are pursuing a target of 70kg or less for the main components of a 2MW rotating electric machine. High-temperature superconducting wires have zero electrical resistance and can carry a very high current density, but the alternating current (AC) loss generated when used in AC has been an issue in their application to rotating electric machines. In 2023, The SCSC cable was developed to be a low-AC-loss, robust, and high current cable concept, in which copper-plated multifilament coated conductors are wound spirally on a core. In addition to using this
Oyori, Hitoshi, Sakurai, Sho, Kusase, Shin, Yoshida, Yukihiro, Yoshinaga, Seiichiro, Nose, Hiroyuki, Amemiya, Naoyuki
Technical Paper
MBSE Framework for Developing Data-Driven Passenger Services in Aircraft Cabins2025-01-0171To be published on 05/02/2025
The aircraft cabin plays a crucial role in airline differentiation strategies, particularly when introducing novel, data-driven services. These services aim to enhance the passenger experience during the flight and to improve cabin crew efficiency in order to reduce workload and ensure continued growth of airline revenue. Digitalization and extensive exchange of information across the entire aircraft transport system have emerged as key enablers for these services. The development of aircraft and aircraft systems that realize these services is characterized by a multi-level development process. Various development levels are considered to initially identify the functions of an aircraft in the air transport system, refine its systems and break them down into their components until a level of detail is reached that allows the implementation of the component functions. In addition to the high complexity, a major challenge in this development is to ensure traceability and consistency
Blecken, Marvin, Giertzsch, Fabian, God, Ralf
Technical Paper
Machine Learning-Based Vision Mapping and Planning for Flexibility in High-Mix Robotic Manufacturing2025-01-0157To be published on 05/02/2025
Industries that require high-accuracy automation in the creation of high-mix/low-volume parts, such as aerospace, often face cost constraints with traditional robotics and machine tools due to the need for many pre-programmed tool paths, dedicated part fixtures, and rigid production flow. This paper presents a new machine learning (ML) based vision mapping and planning technique, created to enhance flexibility and efficiency in robotic operations, while reducing overall costs. The system is capable of mapping discrete process targets in the robot work envelope that the ML algorithms have been trained to identify, without requiring knowledge of the overall assembly. Using a 2D camera, images are taken from multiple robot positions across the work area and are used in the ML algorithm to detect, identify, and predict the 6D pose of each target. The algorithm uses the poses and target identifications to automatically develop a part program with efficient tool paths, including
Langan, Daniel, Hall, Michael, Goldberg, Emily, Schrandt, Sasha
Technical Paper
Designing and Controlling a Hybrid Fuel Cell System for Propelling a Turboprop Aircraft2025-01-0151To be published on 05/02/2025
In the context of aviation sector decarbonization, fuel cell hybrid electric aircrafts are a promising alternative to conventional fuels, presenting opportunities for more sustainable and efficient flight. Hence, the present work is focused on an alternative powertrain architecture, wherein a proton exchange membrane fuel cell system cooperates with a lithium-ion battery to fulfill the electrical power demand of a turboprop-based aircraft. Particularly, a mathematical tool is proposed to evaluate both the components size and performance, while a degradation aware rule-based control strategy guarantees an effective power split between the hybridizing components. Such an energy management approach introduces an idling level and a rate limiter to mitigate degradation associated with start-up/shut-down and transient phases, respectively. Moreover, to have a reliable estimation of the vehicle’s fuel economy, while also guaranteeing the correct components dimensioning, the fuel cell system
De Donato, Angelo, Aliberti, Paolo, Sorrentino, Marco, Cuomo, Fabrizio, Musto, Carmine
Technical Paper
More Electric Engine Technologies Towards the 2040s2025-01-0152To be published on 05/02/2025
Improvement and evolution of all aircraft technologies and the commercialization of new technologies are essential to the carbon-net-zero goal of air mobility. Passenger aircraft are required to provide the ultimate in comfort, economy, and safety, and gas turbine engines will not disappear, while promoting the conversion to SAF and hydrogen fuels. The More Electric Engine (or MEE) concept, which has been proposed since the late 2000s, is one alternative. This paper focuses on the electrification of engine accessories. When the concept of electrification of engine accessories was first presented at Aerotech 10 years ago, the discussion at Aerotech seemed to be negative. Attaching a motor to conventional engine accessories would obviously increase the weight. Next, the conventional engine accessories are centrally controlled and only FADEC is in command, but electrification of engine accessories will increase the cost by adding intelligence to all the accessories. On a more academic
Umeki, Yasuyoshi, Oyori, Hitoshi, Muraoka, Mikio, Suzuki, Tsunehisa, Ogami, Yasuhiro, Yamamoto, Yasuhiko
Technical Paper
Drilling Methods for Controlling Exit Burr Height in CRES Material Stacks2025-01-0169To be published on 05/02/2025
The Electroimpact Automatic Fan Cowl Riveter uses two novel drill processes to control exit burr height and achieve the required hole quality in CRES (Corrosion-Resistant Steel, also called stainless steel) material stacks. Both processes use piloted cutters on the OML side, and two different tools are used in a backside spindle on the IML side of the component. The first process uses a shallow-angle shave tool in the IML spindle to directly control the exit burr height after it is produced by the OML spindle and is called the “burr shave” technique. The second process uses a countersink tool in the IML spindle and produces an “intermediate countersink” after the pilot hole is drilled by the OML spindle, but before the final hole diameter is drilled. These drill processes were able to achieve the required hole quality in a challenging CRES material stack, which allows the machine to be qualified for one-up assembly of the component.
Schultz, Rich, Peterman, Randy, Luker, Zachary, Murakonda, Sai Krishna
Technical Paper
Empirical Inflow Ratio Adjustment for Hovering Open Rotors with Experimental Validation2025-01-0162To be published on 05/02/2025
This study presents empirical modifications of Blade Element Momentum Theory (BEMT) to improve rotor performance prediction for open rotors in hovering conditions. The empirical adjustments were made to the inflow ratio, factoring in the real rotor wake area and estimated induced power losses. A comparison between experimental data and two analytical models, one using an empirical inflow formula and the other a theoretical formula (classical BEMT), was conducted for two rotors. The empirical inflow model demonstrated superior accuracy in predicting thrust and torque. These modifications are applied to the inflow ratio by accounting for the actual rotor wake area and estimated induced power losses. The findings highlight the potential for more accurate performance prediction through the integration of empirical data into theoretical frameworks.
Dayhoum, Abdallah, Ramirez-Serrano, Alejandro, Martinuzzi, Robert
Technical Paper
Sustainable Design of Automotive Batteries2025-01-0001To be published on 04/18/2025
A consequence of the automotive industry's shift to electrification is that a significantly higher percentage of a vehicle's lifecycle CO₂ emissions occur during the production phase. As a result, vehicle manufacturers and suppliers must shift the focus of product development from the 'in-use phase only' to optimizing the complete product lifecycle. The proper design of a battery has the highest impact to all other phases following in the life-cycle. It influences the selection of materials, the manufacturing, in-use and end of life, respectively the recycling and recycling yield for a circular economy. Using real-life examples the paper will explain what are the main parameters necessary for designing a sustainable battery. What are the low hanging fruits to be considered? In addition, it will elaborate on the relation as well as the impacts to other KPIs like safety, costs and life-time of the battery. Finally it will round up in an outlook on how batteries will evolve in the future
Braun, Andreas, Rothbart, Martin
Technical Paper
Procedure for the Calculation of Non-Volatile Particulate Matter Sampling and Measurement System Penetration Functions and System Loss Correction FactorsAIR6504A (Current)04/01/2025
This SAE Aerospace Information Report (AIR) describes a method for assessing size dependent particle losses in a sampling and measurement system of specified geometry utilizing the non-volatile Particulate Matter (nvPM) mass and number concentrations measured at the end of the sampling system.1 The penetration functions of the sampling and measurement system may be determined either by measurement or by analytic computational methods. Loss mechanisms including thermophoretic (which has a very weak size dependence) and size dependent losses are considered in this method2 along with the uncertainties due to both measurement error and the assumptions of the method. The results of this system loss assessment allow development of estimated correction factors for nvPM mass and number concentrations to account for the system losses facilitating estimation of the nvPM mass and number at the engine exhaust nozzle exit plane. As the particle losses are size dependent, the magnitude of correction
E-31P Particulate Matter Committee
Information Report
Design of Fault-Tolerant Control Strategy for Dual-Winding Permanent Magnet Synchronous Motor in Vehicles2025-01-880504/01/2025
Motor drive control is crucial for achieving the performance, reliability, and comfort of electric vehicles. Multi-phase motors, represented by dual-winding permanent magnet synchronous motors (PMSMs), have significant research value in the electric vehicle field due to their high-power drive capabilities and strong fault tolerance. A simple and easily analyzable motor model is essential for achieving high precision in control. This paper employs VSD coordinate transformation (vector space decomposition) based on electromagnetic principles and the positional relationships between windings, treating the multi-phase motor as a whole and mapping various physical quantities to multiple subspaces for simplified analysis. Consequently, a mathematical model for the dual-winding PMSM is established. The vector control system based on VSD coordinate transformation adopts a dual closed-loop structure for speed and current. It focuses on a comparative analysis between traditional two-vector
Gao, ChaoFan, Zheng, Hongyu, Kaku, Chuyo
Technical Paper
Initial Assessment of Component Sizing and Power-Split for Fuel Cell Hybrid Electric Heavy-Duty Trucks2025-01-855004/01/2025
This work presents a computationally inexpensive but effective method for an initial assessment of component sizing and power-split for fuel cell hybrid electric heavy-duty trucks. As a first step, the proposed method employs a prototypical longitudinal vehicle model to generate power demand at every instant of a representative drive cycle. Subsequently, six fuel cell and battery sizing combinations, each providing a peak continuous system power of 400 kW, are identified based on drive cycle power demands, commercially available fuel cell sizes, and Department of Energy (DOE) sizing targets. Ultimately, for each sizing combination, a proportional-integral (PI) controller with anti-windup is implemented to split power between the fuel cell and battery. In this study, the controller is tuned to reduce hydrogen consumption while meeting the instantaneous power demand and maintaining the battery state-of-charge (SOC) between 0.3 and 0.7. The results indicate that increasing the fuel cell
Mandviwala, Ali, Yesilyurt, Serhat, Stefanopoulou, Anna
Technical Paper
Enhanced Sorting Investigation of Retired Lithium-Ion Batteries Based on Electrochemical Impedance Spectroscopy2025-01-813004/01/2025
Given the promising prospects of retired lithium-ion batteries in second-life utilization, enhancing their consistency through a rational sorting process has become a pressing priority. Traditional capacity-based sorting methods have significant limitations as it takes high time costs and fails to provide internal dynamic information about the batteries. To address this, the present study introduces a novel approach by incorporating electrochemical impedance spectroscopy (EIS) into the sorting process. Firstly, principal component analysis (PCA) analysis is applied to extract the first principal component from the EIS data, which has a strong correlation with battery capacity. It serves as a key feature for assessing the residual value of retired batteries. Accurate estimation of battery capacity is then achieved using a simple linear equation: For retired nickel-cobalt-manganese (NCM) batteries, the mean absolute percentage error (MAPE) and root mean squared percentage error (RMSPE
Fan, Wenjun, Wang, Xueyuan, Jin, Yiqun, Jiang, Bo, Zhu, Jiangong, Wei, Xuezhe, Dai, Haifeng
Technical Paper
CL-infoRRT Collision-Avoidance Trajectory Planning for Autonomous Vehicle2025-01-802704/01/2025
To ensure the safety and stability of road traffic, autonomous vehicles must proactively avoid collisions with traffic participants when driving on public roads. Collision avoidance refers to the process by which autonomous vehicles detect and avoid static and dynamic obstacles on the road, ensuring safe navigation in complex traffic environments. To achieve effective obstacle avoidance, this paper proposes a CL-infoRRT planning algorithm. CL-infoRRT consists of two parts. The first part is the informed RRT algorithm for structured roads, which is used to plan the reference path for obstacle avoidance. The second part is a closed-loop simulation module that incorporates vehicle kinematics to smooth the planned obstacle avoidance reference path, resulting in an executable obstacle avoidance trajectory. To verify the effectiveness of the proposed method, four static obstacle test scenarios and four RRT comparison algorithms were designed. The implementation results show that all five
Wu, Wei, Lu, Jun, Zeng, Dequan, Yang, Jinwen, Hu, Yiming, Yu, Qin, Wang, Xiaoliang
Technical Paper
Aspects for the Optimization of Car Production Regarding Efficiency, Availability and Sustainability2025-01-860904/01/2025
Nowadays, more than in the recent decades, the design process for the body in white for passenger cars is driven by efficiency. This results in the enhanced usage of large-scale cast components made of aluminum, for the battery compartment, the front or rear body and other components. While the automotive industry is striving towards even larger structures made with so-called “Giga-Casting”, challenges in the casting and supply chain processes, but also maintenance and repair processes of these large structures, arise. Other tasks to solve might follow from controlling local microstructures, and thus the strength of the parts, when the flow length of the molten metal increases with component size, especially in relation to an increased fraction of recycled aluminum. Within the Fraunhofer-internal project “FutureCarProduction”, focus is directed towards understanding what drives efficiency, availability and sustainability of modern processes for the production of a car body. Moreover
Bleicher, Christoph, Qaralleh, Ahmad, Lehmhus, Dirk, Haesche, Marco, Fernandes Gomes, Leonardo, Pintore, Manuel, Kleinhans, Robert, Sommer, Silke, Tlatlik, Johannes
Technical Paper
RGB2BEV-Net: A PyTorch-Based End-to-End Pipeline for RGB to BEV Segmentation Using an Extended Dataset for Autonomous Driving2025-01-802304/01/2025
In this study, we introduce RGB2BEV-Net, an end-to-end pipeline that extends traditional BEV segmentation models by utilizing raw RGB images with Bird’s Eye View (BEV) generation. While previous work primarily focused on pre-segmented images to generate corresponding BEV maps, our approach expands this by collecting RGB images alongside their affiliated segmentation masks and BEV representations. This enables direct input of RGB camera sensors into the pipeline, reflecting real-world autonomous driving scenarios where RGB cameras are commonly used as sensors, rather than relying on pre-segmented images. Our model processes four RGB images through a segmentation layer before converting them into a segmented BEV, implemented in the PyTorch framework after being adapted from an original implementation that utilized a different framework. This adaptation was necessary to improve compatibility and ensure better integration of the entire system within autonomous vehicle applications. We
Hossain, Sabir, Lin, Xianke
Technical Paper
The Effects of Collision-Related Power Loss on Toyota Safety Sense 2.5+ Event Data2025-01-871304/01/2025
Toyota vehicles equipped with Toyota Safety Sense (TSS) can record detailed information surrounding various driving events, including crashes. Often, this data is employed in accident reconstruction. TSS data is comprised of three main categories: Vehicle Control History (VCH), Freeze Frame Data (FFD), and image records. Because the TSS data resides in multiple Electronic Control Units (ECUs), the data recording is susceptible to catastrophic power loss. In this paper, the effects of a sudden power loss on the VCH, FFD, and images are studied. Events are triggered on a TSS 2.5+ equipped vehicle by driving toward a stationary target. After system activation, a total power loss is induced at various delays after activation. Results show that there is a minimum time required after system initiation in order to obtain full VCH, FFD, and image records. Power losses occurring within this time frame produce incomplete records. Data accuracy is unaffected, even in partial records.
Getz, Charles, DiSogra, Matthew, Spivey, Heath, Johnson, Taylor, Patel, Amit
Technical Paper
A Model for the Design of Automated Vehicle Event Data Recorders2025-01-867804/01/2025
When vehicle accidents occur, investigators rely on event data recorders for accident investigations. However current event data recorders do not support accident investigation involving automated or self-driving vehicles when there is state information that needs to be recorded, for example ADS modes, changes in the ODD that the vehicle operates under, and the various states of vehicle features such as intelligent cruise control, automated lane changes, autonomous emergency braking, and others. In this paper, we propose a model to design new types of event data recorders that supports accident investigations involving automated vehicles when there is state information to be recorded. The model is generic enough to be adapted to any automation level and any set of automated vehicle functional features. The model has been instantiated to a specific ADAS system.
Pimentel, Juan
Technical Paper
Modal Characteristics of Oil-Gas Interconnected Suspension Systems and their Influence on Vehicle Ride Quality2025-01-827104/01/2025
This study focuses on the dynamic behavior and ride quality of three different modes of oil-gas interconnected suspension systems: fully interconnected mode, left-right interconnected mode, and independent mode. A multi-body dynamics model and a hydraulic model of the oil-gas suspension were established to evaluate the system's performance under various operating conditions. The research includes simulations of pitch and roll excitations, as well as ride comfort tests on different road surfaces, such as Class B roads and gravel roads. The analysis compares the effectiveness of the modes in suppressing pitch and roll movements and their impact on overall ride comfort. Results show that the independent mode outperforms the other two in minimizing roll, while the fully interconnected mode offers better pitch control but at the cost of reduced comfort. These findings provide valuable insights for the future design and optimization of oil-gas interconnected suspension systems, especially in
Xinrui, Wang, Chen, Zixuan, Zhang, Yunqing, Wu, Jinglai
Technical Paper
Coordinated Control Strategy for Longitudinal, Lateral, and Vertical Motions of Distributed Electric Vehicles Based on Model Predictive Control2025-01-830004/01/2025
Distributed electric vehicles, equipped with independent motors at each wheel, offer significant advantages in flexibility, torque distribution, and precise dynamic control. These features contribute to notable improvements in vehicle maneuverability and stability. To further elevate the overall performance of vehicles, particularly in terms of handling, stability, and comfort, this paper introduces an coordinated control strategies for longitudinal, lateral, and vertical motion of distributed electric vehicles. Firstly, a full-vehicle dynamics model is developed, encompassing interactions between longitudinal, lateral, and vertical forces, providing a robust framework for analyzing and understanding the intricate dynamic behaviors of the vehicle under various operating conditions. Secondly, a vehicle motion controller based on Model Predictive Control is designed. This controller employs a sophisticated multi-objective optimization algorithm to manage and coordinate several critical
Jia, Jinchao, Yue, Yang, Sun, Aobo, Liu, Xiao-ang
Technical Paper
Deriving Architectural Requirements for SAE J3016 TM Level 3 System from Functional Safety Perspective2025-01-800904/01/2025
Vehicles with SAE J3016TM Level 3 systems are exposed to road infrastructure, Vulnerable Road Users (VRUs), traffic and other actors on roadways. Hence safe deployment of Level 3 systems is of paramount importance. One aspect of safe deployment of SAE Level 3 systems is the application of functional safety (ISO 26262) to their design, development, integration, and testing. This ensures freedom from unreasonable risk, in the event of a system failure and sufficient provisions to maintain Dynamic Driving Task (DDT) and to initiate Minimum Risk Maneuver (MRM), in the presence of random hardware and systematic failures. This paper explores leveraging ISO 26262 standard to develop architectural requirements for enabling SAE Level 3 systems to maintain DDT and MRM during fault conditions and outlines the importance of fail-operability for Level 3 systems, from a functional safety perspective. At a high-level, UN Regulation No. 157 – Automated Lane Keeping Systems (ALKS) is used as a baseline
Mudunuri, Venkateswara Raju, Jayakumar, Namitha
Technical Paper
A Comparison of UAV LiDAR and Terrestrial Laser Scanner Accuracies2025-01-869404/01/2025
The accident reconstruction community frequently uses Terrestrial LiDAR (TLS) to capture accurate 3D images of vehicle accident sites. This paper compares the accuracy, workflow, benefits, and challenges of Unmanned Aerial Vehicle (UAV) LiDAR, or Airborne Laser Scanning (ALS), to TLS. Two roadways with features relevant to accident reconstruction were selected for testing. ALS missions were conducted at an altitude of 175 feet and a velocity of 4 miles per hour at both sites, followed by 3D scanning using TLS. Survey control points were established to minimize error during cloud-to- cloud TLS registration and to ensure accurate alignment of ALS and TLS point clouds. After data capture, the ALS point cloud was analyzed against the TLS point cloud. Approximately 80% of ALS points were within 1.8 inches of the nearest TLS point, with 64.8% at the rural site and 59.7% at the suburban site within 1.2 inches. These findings indicate that UAV-based LiDAR can achieve comparable accuracy to TLS
Foltz, Steven, Terpstra, Toby, Clarson, Julia
Technical Paper
High Performance Computer Based Software Defined Vehicle Hardware in the Loop Testing2025-01-813704/01/2025
Recent years have seen a strong move towards Software Defined Vehicles (SDV) concept as it is seen as an enabler for advancing the mobility by integrating complex technologies like Artificial Intelligence (AI) and Connected Autonomous Driving (CAD) into the vehicle. However, this comes with fundamental changes to the vehicle’s Electrical/Electronic (EE) architecture which require novel testing approaches. This paper presents FEV’s SDV Hardware-In- The-Loop (HIL) test setup which focuses on testing the developed HPC-based software. The functionality of the SDV HIL test setup is demonstrated by testing the software of multiple technologies within the High Performance Computer (HPC) environment like ADAS and teleoperation virtual control units with Over-the-air (OTA) up- dates capability. Test results show the effectiveness of utilizing FEV’s HIL setup in developing and validating the software of SDV platforms.
Obando, David, Alzu'bi, Hamzeh, Carreón Vásquez, Erwin, Alrousan, Qusay, Alnajdawi, Mohammad Sami, Tasky, Thomas
Technical Paper
Validating the Sun System in 3ds Max for Recreating Shadows2025-01-868504/01/2025
Shadow positions can be useful in determining the time of day that a photograph was taken and determining the position, size, and orientation of an object casting a shadow in a scene. Astronomical equations can predict the location of the sun relative to the earth, and therefore the position of shadows cast by objects, based on the location’s latitude and longitude as well as the date and time. 3D computer software includes these calculations as a part of their built-in sun systems. In this paper, the authors examine the sun system in the 3D modeling software 3ds Max to determine its accuracy for use in accident reconstruction. A parking lot was scanned using a FARO LiDAR scanner to create a point cloud of the environment. A camera was then set up on a tripod at the environment, and photographs were taken at various times throughout the day from the same location. This environment was 3D modeled in 3ds Max based on the point cloud, and the sun system in 3ds Max was configured using the
Barreiro, Evan, Erickson, Michael, Smith, Connor, Carter, Neal, Hashemian, Alireza
Technical Paper
Machine Learning-Enabled Optimization of Vehicle Restraint Systems – Demonstration in a Real-World Crash Scenario2025-01-872204/01/2025
Vehicle restraint systems, such as seat belts and airbags, play a crucial role in managing crash energy and protecting occupants during vehicle crashes. Designing an effective restraint system for a diverse population is a complex task. This study demonstrates the practical implementation of state-of-the-art Machine Learning (ML) techniques to optimize vehicle restraint systems and improve occupant safety. An ML-based surrogate model was developed using a small Design of Experiments (DOE) dataset from finite element human body model simulations and was employed to optimize a vehicle restraint system. The performance of the ML-optimized restraint system was compared to the baseline design in a real-world crash scenario. The ML-based optimization showed potential for further enhancement in occupant safety over the baseline design, specifically for small-female occupant. The optimized design reduced the joint injury probability for small female passenger from 0.274 to 0.224 in the US NCAP
Lalwala, Mitesh, Lin, Chin-Hsu, Desai, Megha, Rao, Shishir
Technical Paper
Numerical Model of the Heat-Wait and Seek and Heating Ramp Protocol for the Prediction of Thermal Runaway in Lithium-Ion Batteries2025-01-812704/01/2025
Interest in Battery-Driven Electric Vehicles (EVs) has significantly grown in recent years due to the decline of traditional Internal Combustion Engines (ICEs). However, malfunctions in Lithium-Ion Batteries (LIBs) can lead to catastrophic results such as Thermal Runaway (TR), posing serious safety concerns due to their high energy release and the emission of flammable gases. Understanding this phenomenon is essential for reducing risks and mitigating its effects. In this study, a digital twin of an Accelerated Rate Calorimeter (ARC) under a Heat-Wait-and-Seek (HWS) procedure is developed using a Computational Fluid Dynamics (CFD) framework. The CFD model simulates the heating of the cell during the HWS procedure, pressure build-up within the LIB, gas venting phenomena, and the exothermic processes within the LIB due to the degradation of internal components. The model is validated against experimental results for an NCA 18650 LIB under similar conditions, focusing on LIB temperature
Gil, Antonio, Monsalve-Serrano, Javier, Marco-Gimeno, Javier, Guaraco-Figueira, Carlos
Technical Paper
Developing a Vehicle-in-Virtual-Environment (VVE) Based Autonomous Driving Function Development and Evaluation Pipeline for Vulnerable Road User Safety2025-01-806104/01/2025
Traditional methods for developing and evaluating autonomous driving functions, such as model-in-the-loop (MIL) and hardware-in-the-loop (HIL) simulations, heavily depend on the accuracy of simulated vehicle models and human factors, especially for vulnerable road user safety systems. Continuation of development during public road deployment forces other road users including vulnerable ones to involuntarily participate in the development process, leading to safety risks, inefficiencies, and a decline in public trust. To address these deficiencies, the Vehicle-in-Virtual-Environment (VVE) method was proposed as a safer, more efficient, and cost-effective solution for developing and testing connected and autonomous driving technologies by operating the real vehicle and multiple other actors like vulnerable road users in different test areas while being immersed within the same highly realistic virtual environment. This VVE approach synchronizes real-world vehicle and vulnerable road user
Chen, Haochong, Cao, Xincheng, Guvenc, Levent, Aksun Guvenc, Bilin
Technical Paper
Dynamics Modeling and Lateral Stability of Tank Transport Vehicles2025-01-807504/01/2025
In this paper, the equivalent elliptic gauge pendulum model of liquid sloshing in tank is established, the pendulum dynamic equation of tank in non-inertial frame of reference is derived, and the dynamics model of tank transporter is constructed by force analysis of the whole vehicle. A liquid tank car model was built in TruckSim to study its dynamic response characteristics. Aiming at the problem that the coupling effect between liquid sloshiness in tank and tank car can easily affect the rolling stability of vehicle, the roll dynamics model of tank heavy vehicle is established based on the parameterized equivalent elliptic gauge single pendulum model, and the influence of different lateral acceleration and suspension system on the roll stability is studied. The results show that the coupling effect between the motion state of the tank car and the liquid slosh lengthens the oscillation period of the liquid slosh in the tank, and the amplitude of the load transfer rate of the tank car
Yukang, Guo
Technical Paper
Uncovering Security Flaws in DC Chargers for Electric Vehicles2025-01-811804/01/2025
The added connectivity and transmission of personal and payment information in electric vehicle (EV) charging technology creates larger attack surfaces and incentives for malicious hackers to act. As EV charging stations are a major and direct user interface in the charging infrastructure, ensuring cybersecurity of the personal and private data transmitted to and from chargers is a key component to the overall security. Researchers at Southwest Research Institute® (SwRI®) evaluated the security of direct current fast charging (DCFC) EV supply equipment (EVSE). Identified vulnerabilities included values such as the MAC addresses of both the EV and EVSE, either sent in plaintext or encrypted with a known algorithm. These values allowed for reprogramming of non-volatile memory of power-line communication (PLC) devices as well as the EV’s parameter information block (PIB). Discovering these values allowed the researchers to access the IPv6 layer on the connection between the EV and EVSE
Kozan, Katherine
Technical Paper
Research on Heat Dissipation of Cabinet of Electrochemical Energy Storage System2025-01-819304/01/2025
With the increasingly prominent environmental problems and energy crisis, wind power, solar power and other new energy has been rapid development, and energy storage technology is of great significance to the development of new energy. Compared with the power batteries applied in electric vehicles, battery energy storage systems gather a larger number of batteries and a larger scale, usually up to megawatts or 100 megawatts. During the operation of the energy storage system, the lithium-ion battery continues to charge and discharge, and its internal electrochemical reaction will inevitably generate a lot of heat. If the heat is not dispersed in time, the temperature of the lithium-ion battery will continue to rise, which will seriously affect the service life and performance of the battery, and even cause thermal runaway leading to explosion. It is of great significance for promoting the development of new energy technologies to carry out research on the thermal model of lithium-ion
Chen, Jianxiang, Li, Liping, Zhou, Fupeng, Li, Chuncheng, Shangguan, Wen-Bin
Technical Paper
Leveraging the Automated Mobility Partnership (AMP) to Support the Evaluation of Safety of the Intended Functionality (SOTIF) in Automated Driving Systems2025-01-867404/01/2025
The Automated Mobility Partnership (AMP) is a consortium of industry and academic stakeholders dedicated to advancing Automated Driving Systems (ADS) through a comprehensive suite of tools, datasets, and methodologies. The AMP portal integrates events from over 35 million miles of naturalistic driving data including thousands of annotated crashes and near-crashes and a decade of U.S. police-reported crash data curated by the Virginia Tech Transportation Institute. The portal enables data discovery, visualization, processing, and analysis through secured web access. This paper briefly describes the AMP portal and examines its utility in developing and evaluating the safety of ADS using standardized processes. For the examination, we provide examples based on generic automated driving functions, guided by the Safety of the Intended Functionality (SOTIF) framework. The results show that AMP is instrumental in identifying recorded real-world cases in which the hazardous behavior of a
Antona-Makoshi, Jacobo, Williams, Vicki, Ali, Gibran, Sullivan, Kaye, Terranova, Paolo, Kefauver, Kevin, Hatchett, Alex
Technical Paper
Aggregation of Cervical Loads in Rear Impact Crash Tests and Comparison to Activities of Daily Living2025-01-870804/01/2025
Peak upper and lower neck load data from rear impact crash testing were reviewed, aggregated, and analyzed from over 1,800 tests of existing peer-reviewed literature and research as well as available testing conducted by the Insurance Institute for Highway Safety (IIHS) and the National Highway Traffic Safety Administration (NHTSA). Both human volunteers and anthropomorphic test devices (ATDs) were subjects of the reviewed studies and testing. Peak upper and lower neck axial forces (compression and tension), sagittal shear forces, and sagittal moments (flexion and extension) from available crash testing were reported and analyzed as functions of measured change in velocity (delta-V) ranging from approximately 3 to 60 km/h (1.9 to 37 mph). This load data was then further analyzed for possible trends amongst various testing conditions, such as seat type, ATD used, and subject seating position within the vehicle chassis and seat to develop a simple linear model. The linear regressions
Kazmierczak, Alex, Umale, Sagar, Visalli, Alyssa, Webb, Ella, Kashdan, Aryeh, Randles, Bryan, Welcher, Judson
Technical Paper
Development of a Computer-Less Robotic Platform for ADAS Testing2025-01-806404/01/2025
Testing collision avoidance systems on vehicles has become increasingly complex. Robotic platforms called Pedestrian Target Carriers (PTC) typically require Global Positioning System (GPS), network communications, tuning, and ever-increasing scope to the user interface to function. As an alternative to these complicated systems, but as an improvement to a pulley system pedestrian target carrier, a simplistic robotic platform was developed. An open-loop user interface was designed and developed, and a series of tests were performed to evaluate the effectiveness of the robot in performing basic, repeatable straight-line tests with a vehicle in the loop. Based on testing outcomes, the development of further control algorithms, user requirements, and the prototype improvements are analyzed for future work.
Bartholomew, Meredith, Muthaiah, Ponaravind, Heydinger, Gary, Zagorski, Scott
Technical Paper
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