Technical Papers - SAE Mobilus

SAE Technical Papers are written and peer-reviewed by experts in the automotive, aerospace, and commercial vehicle industries and provide the latest advances in technical research and applied technical engineering information.

Items (118,414)

DESIGN AND DEVELOPMENT OF STEERING BASED ADAPTIVE HEADLIGHT SYSTEM

2024-28-0272To be published on 12/05/2024

Driving at night presents numerous challenges, particularly on curved roads where visibility is a significant concern. Despite only a quarter of driving occurring at night, over half of driving accidents happen during this period, highlighting the need for better illumination solutions. Traditional headlamp systems often fail to adequately light curved roads, increasing accident risks. To address this issue, Adaptive Front Lighting Systems (AFS) have been developed. The goal is to design a prototype AFS that integrates seamlessly with existing fixed headlamp systems, prioritizing accuracy, reliability, and component availability to ensure its feasibility and effectiveness. AFS represents a significant innovation in automotive lighting technology, specifically targeting the limitations of conventional headlamps in illuminating curved roads. Unlike static headlamps, which emit a fixed beam pattern regardless of driving conditions, AFS dynamically adjusts the headlamp intensity based on

T, Karthi, G, Manikandan, P C, Murugan, S, Sakthivel, N, Vinu, P, Dineshkumar

Review of Integrated Thermal Management system for electric vehicle

2024-28-0227To be published on 12/05/2024

Electric vehicles use Li-ion batteries due to their high energy and power densities. Working of Li-ion batteries is very sensitive to temperature thus thermal management system becomes very important to provide safety and performance under different working conditions. This paper review different integrated thermal management system developed for electric vehicles. integrated thermal management content Battery thermal management, cabin thermal management and Electric drive thermal management. These systems share some common objectives and common parts so integrating these systems will help to optimize the number of components in the electric vehicles thermal management system. The integrated thermal management system also helps to optimize the weight and use of waste heat to heat the cabin or battery which will also help in optimization of energy consumed by the thermal management system and range improvement. But integrating different systems which content refrigerant and coolant

Mhaske, Pramodkumar Chimaji

An Intelligent estimation of Dynamic Vehicle mass for Electric Vehicle

2024-28-0229To be published on 12/05/2024

Dynamic Vehicle mass is one of the most critical parameters in the automotive controls such as battery management, transmission shift scheduling, distance-to-empty predictions and most importantly, various active and passive safety systems. This work aims to find out Dynamic Vehicle mass for Electric Vehicles in a real time transient driving conditions. The work proposes a real-time approach in finding Dynamic vehicle mass where accumulated Energy based vehicle performance, an improvement to the vehicle dynamics equation, has been employed for consistent and accurate results. Factors affecting vehicle mass such as road grade, dynamic friction coefficient, driving pattern, wheel slip etc. have been considered for model optimization. Here recursive Bayesian state estimator has been used for finding vehicle mass as a constant state variable while time varying forgetting factors are used to nullify the impact of major losses. Algorithm is auto tuned using Machine Learning techniques to

Pandey, Suchit, Sarkar, Prasanta, Sawhney, Chandan, Kondhare, Manish, Joshi, Pawan, CH, Sri Ram

A Design Synthesis Approach to Improve HVAC Acoustic Performance of Passenger Vehicles

2024-28-0221To be published on 12/05/2024

Noise induced by the Heating, Ventilation and Air conditioning (HVAC) system inside a vehicle cabin can cause significant discomfort to passengers and, in turn, affect the brand image in a competitive automotive market. HVAC acoustic performance has become more prominent with the ongoing transformation from Internal Combustion (IC) to Electric Vehicle (EV) segments. For this reason, acoustic quality is increasingly prioritized as a key design issue throughout the entire development process of the HVAC system. This paper covers the design synthesis considering air handling unit-induced airborne and structure-borne noise of a dashboard-mounted HVAC system to achieve better NVH refinement inside vehicle while maintaining thermal performance. This study began by analyzing HVAC-induced blower motor, impeller, air ducts, vents, and recirculation suction noise from the vehicle level to subsystem level and eventually at the component level. At the subsystem level, major noise source

Titave, Uttam Vasant, Naidu, Sudhakara, Kalsule, Shrikant

A novel methodology for Cascading Vehicle level fuel tank slosh noise performance to component level

2024-28-0271To be published on 12/05/2024

Slosh, a phenomenon occurring in a vehicle's tank during movement, significantly contributes to noise and vibration issues, often reaching 25dB above idle levels. Existing methods lack a standardized approach to quantify and address this dynamic, short-duration noise. This paper introduces a novel methodology to bridge this gap. This approach standardizes the generation of the slosh phenomenon by establishing vehicle-level acceleration, braking, and driving profiles. Noise and vibration data capture, along with boundary conditions and event parameters, categorizes slosh noise into Hit and Splash noise, differentiated by distinct driving profiles and frequency content. A dedicated test rig designed that replicates these conditions at the subsystem level. Vehicle speed and braking profiles are translated into rig-specific acceleration and deceleration profiles, enabling consistent data capture for correlation with vehicle-level results. Computational Fluid Dynamics (CFD) analysis

Titave, Uttam Vasant, Zalaki, Nitin, Vardhanan K, Aravindha Vishnu, Naidu, Sudhakara, Virmani, Nishant

Rear Twist Beam optimization by cross beam and bush orientation technique to meet performance targets

2024-28-0269To be published on 12/05/2024

Born Electric SUVs generally feature a high center of gravity (CG) with greater rear axle weight. They use sophisticated multi-link suspension, which offers large scope for ride comfort and handling optimization. The development costs and time associated with the process will position the vehicle in a premium segment. Usually, the twist beam (RTB) is used in lower rear axle weight category vehicles due to its simple design and cost effectiveness. This study showcases exploration for implementation of RTB on higher weight category vehicles, which usually uses multi-link suspension. The limitation of the twist beam is to exhibit lateral force compliance oversteer during cornering, due to large moment arm from wheel center to twist beam bush. Lack of lateral stiffness when compared to multi-link suspension causes delayed rear axle yaw response. It also has reduced scope in ride-handling optimization due to its simple structure and kinematics. So, in order to maximize the performance

Prabhakara Rao, Vageesh, Rasal, Shraddhesh, Asthana, Shivam, M, Sudhan, Vellandi, Vikraman

Optimization of Console Armrest Design for Reduction of G-values in Head Impact Testing

2024-28-0212To be published on 12/05/2024

Head injuries from interior impacts during vehicle accidents are a significant cause of fatalities in India. Data from the National Crime Records Bureau (NCRB) for 2023 reveals that approximately 15% of the total 150,000 road fatalities were due to head impacts on vehicle interiors, resulting in about 22,500 deaths. Thus, head impact protection in a car crash is a key during the design of vehicle interiors. IS 15223 and ECE R21 provides specific guidelines for head impact testing of instrument panels and consoles in vehicles to ensure compliance with safety standards and minimize the risk of head injuries during collisions. By systematically addressing each aspect of IS 15223 and ECE- R21 in the design, testing, and documentation phases, manufacturers can ensure that console armrests are optimized for safety. This approach not only helps meet regulatory standards but also enhances overall occupant protection in vehicles during collisions. The objective of this paper is to design a

Malhotra, Deepak, Vaishnav, Suresh, Sureshkumar Presannakumari, Rajasilpi, Mangal, Gautam, Keshri, Amit

Multiple Pathways to decarbonize PV Sector

2024-28-0127To be published on 12/05/2024

The cumulative accumulation of greenhouse gases (GHGs) historically has resulted in the current problem of global warming. This is further compounded by developed nations, therefore, to fill this gap enhanced global actions are decided. Considering Country's development need, available resources, government boost for agriculture, A holistic approach for 4W PVs is taken considering well to wheel emissions, as there are other ways to reduce tank to wheel emissions but may not be very effective for overall country's GHG reduction. Major emissions in vehicle use are calculated based on Carbon intensity of various fuels & optimum pathway for Indian scenario is prepared & discussed in the paper considering all aspects CO2 reduction, development & motorization need This paper explains multiple pathways for PV Sector to be considered to meet country's GHG needs

Sarna, Nishant, Jaiswal, Harsh, Rani, Abha, Dwivedi, Vipin, Vashisth, Ajay, Bhat, Anoop

Drag Prediction of an Electric Cargo Scooter

2024-28-0173To be published on 12/05/2024

Drag prediction is a very important stage in the design of an electric cargo scooter. Early knowledge of the drag forces will enable designers to accurately estimate the motor power, size, battery pack size, vehicle range, and the maximum speed of the vehicle. In the present paper we present a simulation-based methodology to estimate the drag forces and drag coefficient accurately and to identify possible design changes to optimize and reduce them. The main advantage of simulation-based method is reducing the number of prototypes built during the initial design stages and reducing wind tunnel tests. Future variants also will not require any wind tunnel measurements as they can be accurately predicted using the established process. Reynolds Averaged Navier Stokes (RANS)-based steady state Computational method is utilized. The study includes mesh independence, inlet velocity independence, and Turbulence model independence

Balachandran, Karthik, Das, Alok, Shinde, Pranav

Powering Sustainable Mobility: Electric and Hybrid Vehicles Leading the Way

2024-28-0137To be published on 12/05/2024

Electric vehicles (EVs) have emerged as a pivotal solution for sustainable mobility amidst escalating global environmental challenges. According to the International Energy Agency (IEA) report, under current energy, climate, and industrial policies, EVs are projected to account for half of all global car sales by 2035. Furthermore, the report estimates that global electric car sales could reach approximately 17 million units by 2024, highlighting the rapid evolution and significance of EVs. The adoption of EVs extends beyond passenger cars to encompass two-wheelers, three-wheelers, and commercial vehicles (light, medium, and heavy), illustrating a burgeoning trend in electrification across various modes and geographies. This report provides a detailed case study on automotive vehicle electrification, examining its impact across different transportation sectors. Government policies, initiatives, standards, and regulations play a crucial role in accelerating this evolution. The report

Thorat, Jalindar Sukhadev, Kumar, Dharmendra, Sandhu, Jivraj Singh

MBSE for SDV: A Framework for Efficient Resource Allocation and System Behavior in Software-Defined Vehicles

2024-28-0255To be published on 12/05/2024

Emergence of Software Defined Vehicles (SDVs) presents a paradigm shift in the automotive domain. In this paper, we explore the application of Model-Based Systems Engineering (MBSE) for comprehensive system simulation within the SDV architecture. The key challenge for developing a system model for SDV using traditional methods is the document centric approach combined with the complexity of SDV. This MBSE approach can help to reduce the complexity involved in Software-Defined Vehicle Architecture making it more flexible, consistent, and scalable. The proposed approach facilitates the definition and analysis of functional, logical, and physical architecture enabling efficient feature and resource allocation and verification of system behaviour. It also enables iterative component analysis based on performance parameters and component interaction analysis (using sequence diagrams

Navas, Akhil, Paul, Annie

Dynamic modeling of torque & emissions: Digital twin to simulate combustion process and exhaust emissions for diagnostics & prognostics applications

2024-28-0172To be published on 12/05/2024

A large fraction of today’s energy consumption is attributable to the transportation sector. Therefore, further development of internal combustion engines has a huge potential to reduce environmental impact through modelling complicated, fast and unsteady phenomena including the changes of emission gases concentration and output torque observed during diesel emission and combustion process. This paper presents research on the emission and combustion characteristics of a heavy vehicle diesel engine, elaborating an engineered framework for prognostics/diagnostics, state monitoring, and performance trending of heavy-duty vehicle engine and after treatment system (ATS). The proposed framework leverages advanced simulation and modeling methodologies to ensure precise predictions and diagnostics. By integrating physics-based models with data-driven techniques, the framework accurately models engine and exhaust system behaviors under various operating conditions. For exhaust system, framework

Singh, Prabhsharn, Thakare, Ujval, Hivarkar, Umesh

Comprehend Dynamic Behaviour of Vehicle Body for Refined NVH Performance

2024-28-0265To be published on 12/05/2024

Modal performance of a vehicle body often influences tactile vibrations felt by passengers as well as their acoustic comfort inside the cabin at low frequencies. This paper focuses on a premium hatchback’s development program where a design-intent initial batch of proto-cars were found to meet their targeted NVH performance. However, tactile vibrations in pre-production pilot batch vehicles were found to be of higher intensity. As a resolution, a method of cascading full vehicle level performance to its Body-In-White (BIW) component level was used to understand dynamic behavior of the vehicle and subsequently, to improve structural weakness of the body to achieve the targeted NVH performance. The cascaded modal performance indicated that global bending stiffness of the pre-production bodies was on the lower side w.r.t. that of the design intent body. To identify the root cause, design sensitivity of number and footprint of weld spots, roof bows’ and headers’ attachment stiffness to BIW

Titave, Uttam Vasant, Zalaki, Nitin, Naidu, Sudhakara

Best Practices in Sensor Selection for Object detection in Autonomous Driving: A Practitioner’s Perspective

2024-28-0218To be published on 12/05/2024

Object detection is one of the most important aspects in Autonomous Driving (AD) application. This depends on the strategic sensor’s selection and placement of sensors around the vehicle. The sensors should be selected based on various constraints such as range, use-case, and cost limitation. This paper introduces a systematic approach for identifying the optimal practices for selecting sensors in AD object detection, offering guidance for those looking to expand their expertise in this field and select the most suitable sensors accordingly. In general, object detection typically involves utilizing RADAR, LIDAR, and cameras. RADAR excels in accurately measuring longitudinal distances over both long and short ranges, but its accuracy in lateral distances is limited. LIDAR is known for its ability to provide accurate range data, but it struggles to identify objects in various weather conditions. On the other hand, camera-based systems offer superior recognition capabilities but lack the

Maktedar, Asrarulhaq, Chatterjee, Mayurika

Active Hydro-pneumatic Suspension Active Disturbance Rejection Sliding Mode Control to Improve Vehicle Stability

2024-28-0215To be published on 12/05/2024

Hydro-pneumatic suspension is widely used because of its desirable nonlinear stiffness and damping characteristics. However, the presence of parameter uncertainty and high nonlinearity in the system, lead to unsatisfactory control performance of the traditional controller in practical applications. Therefore, A novel stability control method for active hydro-pneumatic suspension (AHPS) is proposed. Firstly, a nonlinear mathematical model of the hydro-pneumatic suspension considering the seal friction is established based on the hydraulic principle and the knowledge of hydrodynamics. On the basis of the established hydro-pneumatic suspension nonlinear model, a vehicle dynamics model is established. Secondly, an active disturbance rejection sliding mode controller (ADRSMC) is designed for the vertical, roll, and pitch motions of the sprung mass. The extended state observer (ESO) is used to estimate the lumped disturbance caused by the nonlinearity and uncertainty of the model, which is

Niu, Changsheng, Liu, Xiaoang, Jia, Xing, Gong, Bo, Xu, Bo

Reliability assessment of Audio generating devices- Horn

2024-28-0178To be published on 12/05/2024

Due to increase in vehicular traffic on Indian roads honking frequency of horn have enormously increased especially in city driving conditions and during pick traffic hours. The current electro mechanical horns has mission life of 1 lac cycles in reference to Indian standards (IS 1884). But with increased usage pattern motivated us to recheck / validate efficacy of this requirement. The studies carried out revels the average horn blow frequency of 3 per kilometer for normal usages vehicles. When same is extrapolated to category based usage i.e. public transport vehicles, self-owned vehicle usage pattern, average horn blowing frequency comes to 5 times per kilometer which corresponds to 4.03 Lac cycles for vehicle mission life of 2.4 Lac Kms of vehicle. This advocates us to review the validation test specifications suitable to customer usage pattern to improve upon component reliability. It allows us early-stage prediction of failure / issues during development stage itself with

Joshi, Vivek S., Jape, Akshay

Characterization of Cut and Chip Damage in Ultra Low Rolling Resistance Tire for Electric Vehicles

2024-28-0175To be published on 12/05/2024

Since the inception of battery driven electric vehicles in the automotive world, there has been a constant challenge in maximizing the range of an electric vehicles through various means including battery technology, vehicle weight optimization, low drag coefficients etc. The tires being a viscoelastic composite material have now become a vital to the range performance of an EV. The rolling resistance of a tire is now become a hotter topic than ever. The rolling resistance coefficient (RRC) is the measure of energy loss during rolling due to viscoelastic dissipation in the tire. The viscous dissipation in tire arises due to hysteresis in the various components of a tire including tread, sidewall, inner liner, apex etc rubber compounds. The internal friction between layers of body ply, steel belts and tread crown ply also contribute to the internal heat generation. Therefore, the development of ultra-low RRC tires is a serious challenge for tire engineers. Nevertheless, the recent

Mishra, Nitish, Singh, Ram Krishnan

Precise and robust SoC estimation using adaptive filters-based techniques for Electric Trucks

2024-28-0152To be published on 12/05/2024

The traction for zero emission vehicles in the transportation industry is creating a focus on Battery Electric vehicles (BEV) as one of the potential alternate powertrain sources. To the relevance of electric trucks, the range estimation and optimum energy prediction & utilization brings utmost importance. Battery management system (BMS) controller is needed for optimized and safe operation of high voltage (HV) battery. For correct behavior of battery management system, it is important to accurately estimate the state of charge (SoC). SoC is an important and decisive factor for deciding operating limits such as current limits, voltage limits & battery operational range (charge-discharge interval). Inaccurate State of Charge (SoC) estimation can accelerate battery aging and cause damage to components, affecting energy throughput. Current state of art deploys coulomb counting technique for SoC calculation, this approach encounters the challenges like sensor noises and initial SoC error

Kumar, Raman, AHMAD, MD SAIF, Challa, Krishna, Ranjan, Ashish, Bayya, Madhuri

Evaluation of Dynamic Load Coming on E-Driveline Due to Bump and Study its Effect on Motor Mountings and Battery Position

2024-28-0171To be published on 12/05/2024

During the development of E-Driveline, it is observed that loading failure encountered with On-highway vehicle’s E-Drivelines has increased in comparison with traditional driveline. The major cause of these failures is motor and battery reaction loads acting on driveline in electric vehicles. The main source of load generation is acute dynamic reaction coming from road conditions i.e., bumps, potholes, ditch, uneven surfaces and get transferred to motor or batteries through the E-Driveline. The uneven distribution of motor and battery loads in vehicle will amplify the dynamic reactions which may lead to severe failures. It will be useful if we predict the dynamic loads in early design and simulation stage for accurate solution. This work is based on development of multi body dynamic modeling and simulation approach to predict loads coming on to E-Driveline due to road conditions and correlate it with test setup of actual vehicle running on these road conditions. After the correlation

Deshmukh, Shardul, Nikam, Vinod

Simulation methodology for hydrogen concentration and dilution strategy in a hydrogen fueled internal combustion engine

2024-28-0220To be published on 12/05/2024

Manufacturers of internal combustion engines are changing their focus to non-conventional fuels like hydrogen in response to the worrying global warming situation. When compared to conventional fuels like gasoline or diesel, the use of gaseous hydrogen fuel in an internal combustion engine powered by hydrogen can lessen the engine's negative environmental effects. But occasionally, hydrogen can leak to the engine top cover through the high-pressure fuel injection system or as blowby within the crankcase. Static zones may emerge as a result of these H2 leaks. Potential explosion or fire can result when the H2 concentration in these stagnation zones is more than 4% and triggers a minimum ignition energy of 0.02 mJ. A CFD simulation methodology incorporating multi-species model, piston, and crank motion is developed to estimate the H2 concentration within crankcase. The blowby values are determined from the experimental measurement and used as the inputs. The dilution strategy and system

Sahu, Abhay Kumar, Nagawade, Shubham, Veerbhadra, Swati

Evaluation of Mechanical Properties of Reduced Stress Localized Aluminium Composites for Automobile Applications

2024-28-0241To be published on 12/05/2024

The modern-day development in the field of mobility demands the development of advanced engineering materials for various engineering applications. Composite materials play a pivotal role in the advancement of mobility by achieving overall weight reduction and thereby contributing to the sustainability of the environment. Metal matrix composites has played a crucial role over the last few decades in the automotive industry replacing the conventional metal in achieving a better strength to weight ratio. Metal matrix composites can be a combination of a metal and a ceramic combined at a macroscopic level to achieve better mechanical and tribological properties at a reduced weight to strength ratio. Aluminium being one of the largest metals widely used in automobiles, are gradually being replaced with Aluminium metal matrix composites. Aluminium – silicon carbide composite is a key interest among the researchers due to the attractive mechanical and tribological properties that enhance the

Novel UWS mist injection technique for SCR performance improvement

2024-28-0133To be published on 12/05/2024

The present study aims to meet the Euro-VII compliance applicable for internal combustion engines (diesel and hydrogen) by improving the performance of selective catalytic reduction (SCR) system using a novel UWS mist generation technique. The SCR system helps to convert the harmful NOx emission into harmless by-products by injecting the UWS, which is converted into ammonia (NH3). Despite the proven technology, there are several challenges presented in the existing system which degrade the SCR performance: (i) incomplete droplet evaporation (ii) solid deposit formation (iii) non uniformity of NH3 distribution at the catalyst entrance. The past studies shows that the droplet size plays a major role in this context. Further, it is noted that the smaller size droplets are desirable to overcome the impediments and enhance the efficiency of SCR application. Therefore, the current work numerically investigates the effect of mist (contains very fine size droplets) injection on the droplet

Venkatachalam, Palaniappan, Shiva, Shashidhar, Govindarajan, Vaishali, Soni, Prerna, Patidar, Sachin

Low Cycle Thermo-Mechanical Fatigue Life of Solder Joints using Cohesive Zone Model

2024-28-0253To be published on 12/05/2024

A temperature dependent cohesive zone model considering the thermo-mechanical fatigue loadings are used to simulate and predict the failure process of solder joint interface in power electronics modules. Cohesive Zone Models (CZMs) are gaining popularity for modeling the fracture and fatigue behavior in various class of materials such as metals, polymers, ceramics, and their composite materials. Unlike the traditional fracture mechanics which considers concept of infinitesimal crack, CZMs assume a fracture process zone in which external energy is distributed in vicinity to propagating crack. In order to predict the fatigue-fracture process under thermo-mechanical cyclic loading, a damage accumulation variable is utilized. The calculation of damage is performed using a progressive mechanism, and the cohesive zone model is updated to reflect the present level of damage. The existing cohesive forces are influenced by both the current damage status and the extent of separation

Singh, Praveen Kumar, Sahu, Abhishek, Chirravuri, Bhaskara, Miller, Ronald

Parametric Analysis of Relationship between Tyre and Braking Performances in Electric Vehicle

2024-28-0180To be published on 12/05/2024

Braking Performance is a measure of stopping distance & stability of the vehicle. When it comes to Electric vehicle, balancing Tyre performances i.e RRc, Traction, Tyre life & NVH characteristics is a challenge due to higher axle weights, higher moment of inertia and higher instantaneous torque. This study presents the Braking performances of EV intended tyres at various contact surfaces with different coefficient of friction in both Dry & Wet conditions. Impact of Tyre design attributes like Tyre tread Pattern, contact patch, Tread Compound, Tyre Constructions & Characteristics studied on 5 different tyres of Standard and Ultra High-Performance tyres on Braking performances. This paper contains the study & analysis of 1) Footprint Analysis with respect to Shape of the footprints , Pressure distribution, Land-sea ratio, Contact Area 2)Tyre tread design such as Grooves ,Ribs & Sipes design and Pitch length 3) Compound property studies like Hardness, Modulus ,Tensile strength ,Tear

V, Padmasri, Vellandi, Vikraman, Sundaram, Raghupathi, Singh, Ram Krishnan, P, Praveen, Chittibabu, Santhosh

Virtual recording generation using Generative AI and Carla Simulator

2024-28-0261To be published on 12/05/2024

A Field Operation Test (FOT) and Use case scenario recording capture is very expensive due to the amount of necessary material (vehicles, measurement equipment, headcount, data storage capacity/complexity, trained drivers/professionals) and all-time robust working vehicle setup is not available, mileage is directly proportional to time, along with that it cannot be scaled up due to physical limitations. During the early development phase, ground truth data is not available, and data that can be reused from other projects may not match 100% with current project requirements. All event scenarios/weather conditions cannot be ensured during recording capture. Carla is an autonomous open-source driving simulator, used for the development, training, and validation of autonomous driving systems, by integrating generative AI, particularly Generative Adversarial Networks (GANs) and Retrieval Augmented Generation (RAG) which are deep learning models, the process of creating synthetic data, and

Sehgal, Vishal, Sekaran, Nikhil

An Experimental Study of White Deposit formation on IG coil in SI Engine

2024-28-0206To be published on 12/05/2024

This paper primarily focuses on the ignition coil (IG) by enclosing factors like vibration of surrounding components, temperature etc. IG coils are the components which convert low battery voltage into high voltage required to generate the flashover between the electrodes on the spark plug so that combustion cycle can be started. Considering the importance of IG coils in engine operation which has a direct impact on the engine performance. Any failure in the IG coils is judged as a critical failure and encompasses severe repercussions. This paper intends to capture one such issue of White deposition on IG coils. White deposit was observed in IG Coils during new model development in bench level durability test. Failure investigation was carried out using various techniques such as vibration analysis, thermal analysis, white deposit chemical analysis etc. for identifying the root cause. Possible countermeasures were identified, and the issue was resolved by hardware design optimization

Patel, Hardik Manubhai, Gupta, Vineet, Chand, Subhash, Kumar, Nitish

Development of an Assessment Methodology for synchronizer ring (CuZn Alloy) wear durability

2024-28-0185To be published on 12/05/2024

An optimized gear shift feeling throughout the life of a MT Gearbox is one of the major challenges during transmission development. Synchronizer ring’s function during its intended life play important role to get optimized gear shifting effort. Any undesired synchronizer ring (CuZn Alloy) wear causes high effort in gear engagement during vehicle running and discomfort to the driver. High wear rate reduces the life span on synchronizer ring. Current paper explains the experimental approach for study of critical parameters on synchronizer ring wear and Coefficient of friction (COF) under controlled temperature environment on test bench. Gear shift loading conditions based on Reflected Inertia (kgm2), shifting time (sec), shifting load (N) on gear knob and speed difference (rpm) between gears were calculated on synchronizer ring level and accordingly the loading conditions such as sliding speed (m/s), axial pressure (N/mm2) and synchro energy (J) were decided. As synchro wear rate and

Singh, Paramjeet, Yadav, Sanjay Kumar

A Simulation-based Methodology for Optimizing correlation of Brake Disc temperature

2024-28-0183To be published on 12/05/2024

Brake disc thermal capacity is a key factor for brake performance and brake part life. Hence it is very important to optimize the correlation of brake disc for thermal capacity by considering the critical parameters. Optimization algorithm is used to optimize the critical parameters to achieve the correlation. A front loading tool is developed to optimize the brake disc keeping target thermal capacity via optimization algorithm

Negi, Ayush Singh, Kochhar, Raman

Data-Driven Analysis of Road Infrastructure for automotive applications

2024-28-0179To be published on 12/05/2024

Road infrastructure has a significant impact on the performance of the truck components which includes components like ATS, turbocharger and other components whose performance depends on the region of vehicle operation. Therefore, it is important for research and development teams to analyze the road infrastructure of the region in which trucks are going to be operated in the future, this helps the teams to make decision on component specification which will exactly cater the customer need in those regions and suggest the optimal design of the component. This paper shows a method to summarize and visualize the road infrastructure particularly focusing on length of road segment and its elevation profile distribution and other is an analysis on continuous road segments (without intersections) and their truck speed limit which will help engineers to identify critical routes & locations in those regions and choose precise parameters for their system using statistical data driven approach

Thakur, Shivam, Salunke, Omkar, Ambuskar, Mandar, Pandey, Lokesh

Vehicle underbody small parts detection using Computer vision

2024-28-0190To be published on 12/05/2024

Manual installation of vehicle underbody small parts is tedious task which sometimes results in incomplete & inaccurate installation. Based on process quality guidelines, this comes under potential defect category at End of line inspection area for which few hours of manual efforts are required for identifying location of error & doing rework activity. Existing deep learning & image comparison method falls short in identifying error location. To overcome this challenge, deep learning algorithm with co-ordinate system developed which comprises of identifying plurality of entities present in test and reference image and indexing it as a small part & a hole. This further comprises of determining 2D position in terms of X and Y co-ordinate of each indexed hole & small parts between reference & test image. By seamless integration of deep learning-based part detection with coordinate constraints logic, our system enables real-time identification of incorrectly assembled parts or the absence

Dhumal, Abhishek Trimbak, Mishra, Jagdish, Tote, Anuj, Nurukurthi, Lakshmi, Kumar, Prakash

Strategic Utilization of Digital Twins for examining elastic attack surfaces and replicating attack scenarios for Vulnerability analysis on road vehicle components

2024-28-0256To be published on 12/05/2024

With the advent of trending software-centric architecture for vehicles, the complexity of judging the vehicle's software behavior increases the exploitation of missed, overlooked, or untreated vulnerabilities. More and more often, automotive products are targeted for many malicious reasons. Automotive security incident management does include continuous monitoring of incidents and vulnerabilities, but it poses challenges in reproducing those attacks and revalidating the security goals. It lacks visualization of the attack scenarios, attack vectors, and knowledge required to replicate and reproduce the attack. If the visualization of the vulnerable path is traceable, then attack scenarios, attack vectors, and the knowledge required to demonstrate the attack for vulnerability assessment can be achievable with fixed timelines. Architecture that supports digital twins to promote vulnerability assessment is most appreciative. The vision of this paper is to provide a theoretical approach to

Venkatachalapathy, Sreenikethana

Study of impact forces on wheel rim from pothole impacts and improvement of flange design to eliminate wheel bend

2024-28-0262To be published on 12/05/2024

Typically, an automotive passenger car wheel rim can withstand gradual loading contributed from the vehicle during cornering and high-speed maneuvering and as per the standard as well as customer requirements wheel has to withstand some impact forced contributed from radial and inclined loading. But in some cased wheel rim may not withstand the impact forces generated during impact on potholes and curbs with high-speed maneuvering. This Study helps to understand the impact on wheel rim and the forces acting on the rim flanges during pothole impact and high-speed curb impact. For Electric vehicles, always unsprung mass contributes for lesser range and the wheel rim design contributes huge for the aero drag. Due to this the wheel rim weight plays an active role for vehicle performance and dynamics. In this study author tends to explain about the design of the rim flanges considering the impact forces the wheel rims are exposed to during pothole impact. Also, In this study, road load data

Thiyagarajan, Sriram, Jithendhar, A, Singh, Ram Krishnan, Sundaram, Raghupathi, Paua, Ketan

Driver comfort improvement for a deep mine tipper vehicle for sustained fatigue free persistent driving

2024-28-0208To be published on 12/05/2024

Drivers of heavy commercial tipper vehicles are required to work in the application of carrying heavy loads as well as the rough terrain in off-road conditions. Due to the nature of the application, the primary vehicle/chassis suspension and the cabin suspension are designed to take higher tonnages of load carrying capacity as well as to withstand the rigors of the tough off road terrain conditions. The primary objective of the vehicle and cab suspension design is to enhance the vehicle durability and endurance life suitable for the application. This results in the drivers being subjected to continuous or intermittent exposure of comprehensive magnitudes of low frequency high amplitude whole-body vibration. Short term impact of such vibration results in blurred vision, headache, dizziness and fatigue, etc Prolonged exposure to such vibration has been associated with disorders of the lumbar spine and the connected nervous system. This effectively poses a critical occupational hazard to

Venkatesh, Srinivasa, Prabhakaran, Baskaran

Enhanced Crash Box Energy Absorption: Impact of Single Screw Integration - A Finite Element Analysis Study

2024-28-0214To be published on 12/05/2024

This study proposes a novel energy absorber design by incorporating a screw into the groove of crash boxes and evaluates its performance using finite element analysis (FEA). The methodology integrates CAD modelling, material characterization, and detailed analysis of simulation data to assess the influence of single screw integration on crash box performance. LS-Dyna simulation is employed to investigate the behaviour of Aluminium Alloy 5052 (Al5052) crash boxes with screws in the groove. Results from FEA reveal key performance indicators such as displacement, stress, strain, internal energy, and acceleration across various crash box thicknesses. Analysis of the data demonstrates that as the thickness of the crash box increases, there is a trend of decreasing displacement, stress levels, and acceleration. The presence of the screw leads to reductions in stress levels and acceleration across different thicknesses of crash boxes, indicating superior performance. These findings suggest

R, Teddy Samuel, Mayakrishnan, Jaikumar

Relevance of Autonomous Vehicles in the Indian Context

2024-28-0122To be published on 12/05/2024

Autonomous vehicles (AVs) are positioned to revolutionize transportation by eliminating human intervention through the use of advanced sensors and algorithms, offering improved safety, efficiency, and convenience. In India, where rapid urbanization and traffic congestion present unique challenges, AVs still hold significant promise. This technical paper discusses the relevance of autonomous vehicles in the Indian context and the challenges that need to be addressed before the widespread adoption of autonomous vehicles in India. These challenges include the lack of infrastructure, concerns regarding road safety, software vulnerabilities, adaptability to change towards autonomous vehicles, and the management of traffic. The paper also highlights the government's initiatives to encourage the development and adoption of autonomous vehicles, the ideology behind the legal framework, and the required changes in terms of technological advancements and urban planning. In a brief manner, this

Mishra, Adarsh, Mathur, Gaurav

Leveraging welding spot Quality Control using computer vision system

2024-28-0264To be published on 12/05/2024

Spot welds are integral to automotive body construction, influencing vehicle performance and durability. Spot welding ensures structural integrity by creating strong bonds between metal sheets, crucial for maintaining vehicle safety and performance. It is highly compatible with automation, allowing for streamlined production processes and increased efficiency in automotive assembly lines. The number and distribution of spot welds directly impact the vehicle's ability to withstand various loads and stresses, including impacts, vibrations, and torsion. Manufacturers adhere to strict quality control standards to ensure the integrity of spot welds in automotive production. Monitoring spot weld count and weld quality during manufacturing processes through advanced inspection techniques such as Image processing by YOLO V8 helps identify the number of spots and quality that could compromise safety Automating quality control processes is paramount, and machine vision offers a promising

Kadam, Shubham Narayan, Dolas, Aniket, Mishra, Jagdish

Trailer Disengage confirmation Alarm System for Electric Subsystems

2024-28-0213To be published on 12/05/2024

This paper presents a Trailer-Tractor Disengage Alarm System (TTDAS) designed to enhance safety in electrical connections between the tractor and trailer of commercial vehicles. The proposed system addresses the critical issue of unintentional disengagement of electrical connections, which can lead to hazardous situations on the road. The system employs sensor technologies and intelligent algorithms to continuously monitor the status of the electrical connection between the tractor and trailer. In the event of a disconnection, the system activates a robust alarm mechanism to promptly notify the driver, mitigating the risk of accidents and ensuring the safety of both the vehicle and other road users. Key features of the Trailer Disengage Confirmation Alarm System include real-time monitoring, rapid response time, and compatibility with various trailer configurations. The paper details the system architecture, including the integration of sensors, control units, and the alarm mechanism

Singh, Amandeep, Kumar, Pradeep, Suresh, Karthikrajan, Kotian, Pradeep, T, Thirunavukkarasu, Chitreddy, Bharath, R, Sunilkumar

Impact Of Time Aligned Measurement Parameters On Brake Specific Emissions

2024-28-0132To be published on 12/05/2024

As per global emissions legislation requirements running test cycles and reporting brake specific emissions is the key requirement. Engine gaseous emissions measurement is mandatory requirement for ON Highway and OFF Highway applications for transient duty cycles during testing at test cells. To meet the stringent emission limits is one of the challenging tasks considering the nature of transient duty cycles with accurate measurement of lower emission values. Similarly calculating accurate results is critical since there are several factors which impacts the accuracy of calculated results. As per regulatory test methods, there is guidance on measuring the time lag through an experiment method and accounting the same during the results calculation, however during dynamic conditions, the time lags will vary and influence the calculated results. This paper focuses on understanding critical parameters which leads to variations in dynamic condition of time lag of measured emissions

Patil, Rahul Chandrakant, Rajoapdhye, Sunil, Mudassir, Mohammed, Mokhadkar, Rahul, Phadke, Abhijit Narahari, Bharambe, Niraj, Dhuri, Santosh

A method on HPR critical route identification and evaluation in electric trucks

2024-28-0150To be published on 12/05/2024

Heavy-duty vehicles, particularly those towing higher weights, require a continuous/secondary braking system. While conventional vehicles employ Retarder or Engine brake systems, electric vehicles utilize recuperation for continuous braking. In a state where high voltage battery of electric vehicles is at 100% of its designed capacity, at such scenario if vehicle travels on a route which has brake requirement, all this recuperated energy generated from the vehicle operation is passed on to high performance brake resistors(HPR) and this energy gets converted from electrical energy into waste heat energy. This study focuses on a method for identification of such a routes, which are critical for Brake Resistors, by analyzing the elevation data of existing charging stations, the route’s slope distribution, and the vehicle’s battery SOC. In the results entire method is demonstrated with the example of all the charging stations of Switzerland. This method has a significant applications in

Thakur, Shivam, Salunke, Omkar, Ambuskar, Mandar, Pandey, Lokesh

Securing CAVs : Exploring ZTA potential and implementation challenges

2024-28-0274To be published on 12/05/2024

Zero-Trust Architecture (ZTA) is emerging as a fundamental cybersecurity solution across various industries. Built on the principle of "never trust, always verify," ZTA mandates continuous authentication and authorization of every access request, employing techniques such as multifactor authentication (MFA), micro-segmentation, and real-time monitoring to safeguard data from external threats. Connected and autonomous vehicles (CAVs) are rapidly increasing in popularity. However, their growing reliance on complex software, extensive data storage, and enhanced connectivity introduces significant cybersecurity vulnerabilities. Traditional perimeter-based security measures are insufficient to address these sophisticated and evolving threats. This paper examines the application of ZTA principles to secure in-vehicle systems in CAVs. It explores several key technical aspects, including: - Micro-segmentation: Implementing micro-segmentation to isolate network segments within the vehicle

Pratyaksh, Pratyaksh, Uthamalingam, Padmini

Smart Testing Methodology For Air Suspension System Of Buses

2024-28-0201To be published on 12/05/2024

In the fast growing automotive sector, reliability & durability are two terms of utmost importance along with weight and cost optimization. Therefore it is important to explore new technology which has less weight, low manufacturing cost and better strength. It also seek for a quick, cost effective and reliable methodology for its design validation so that any modification can be made by identifying the failures. This paper presents the rig level real world usage pattern simulation methodology to validate and correlate the vehicle level targets for micro strain, wheel forces and displacement on suspension components like optimized Z spring, torque rods, pan hard rod & mounting brackets of newly developed light weight two bellow air suspension for buses. The newly developed suspension consist of two air bellows instead of four air bellows along with unique Z spring which replaces conventional parabolic leaf spring and specially designed to take forces in vertical as well as longitudinal

Tangade, Atul Bandu, Babar, Sunil, Bankar, Milind Achyutrao, Mehendale, Ravindra, Dhumal, Kailas, Bhusari, Deepak, Sonawane, Ravindra, Shinde, Saurabh

ADVANCE METHOD OF MEASURING TCD "TURNING CIRCLE DIAMETER" FOR VEHICLE

2024-28-0267To be published on 12/05/2024

Turning circle diameter (TCD) of vehicle is critical parameter which is used to determine the turning capability of vehicle. TCD is the smallest circular turn that a vehicle can make of given drive track. The TCD mainly depends on vehicle wheel lock angles, wheelbase, and geometric architecture of vehicle. The Regulation certification requirement of steering system, states that the maximum TCD should be less than 24m & TCCD 25m (M&N category). (IS 12222:2011 & R79). This invention relates to measuring the TCD of vehicle Vehicle's TCD is measured in plenty of open space. Road wheel is steered to full lock condition either in left or right and driven at low speed. Outer side wheel mark is traced on ground with help of chalk, or some other means and final trace mark is measured with tape from center. This is popular and most used TCD measurement, this process involves lot of manual intervention, time consuming, safety concern and has more room for error. Our proposed solution : The

Yadav, Satyendra, Ojha, Vijay, Chatterjee, Anupam, Saikrishna, VNL, Karthik, V

Phenomenological modelling of radar sensor and realization of noise effects

2024-28-0199To be published on 12/05/2024

The rapid advancement in the autonomous vehicle industry has underscored the critical role of sensors in identifying and tracking traffic participants. Among these sensors, radar plays a pivotal role due to its ability to function reliably in various weather and lighting conditions. This paper presents a phenomenological radar sensor model designed to simulate the behavior of real radar systems under diverse scenarios, including noisy environments and accidental situations. As the complexity of autonomous systems increases, relying solely on on-road and bench testing becomes insufficient for meeting stringent safety and performance standards. These traditional testing methods may not encompass the wide range of potential scenarios that autonomous vehicles might encounter. Consequently, virtual environment modeling has emerged as a crucial tool for validating driving functions, assistance systems, and the strategic placement of multiple sensors. In contrast to high-fidelity radar models

Hanumanthaiah, Manjunath, S, Girish, Durairaj, Priya

CAE simulation based structural assessment of steering wheel

2024-28-0200To be published on 12/05/2024

The structural integrity of the steering wheel is important for vehicle operations. It is subjected to various load conditions during the vehicle motion and thus becomes important to understand various aspects of the same which includes stiffness, natural frequency, regulatory requirements i.e body block test, head form impact test. Simulation plays an important role in structural integrity and design validation requirement at design stage itself. This paper discusses modelling and simulation of steering wheel at both armature level and at complete steering wheel level. As armature is critical from structural strength and stiffness point of view, certain simulations like modal analysis are performed first at armature level and design iterations were done to achieve the natural frequency target. List of simulations performed includes modal analysis, bending rigidity, static compression, bending stiffness, body block test and head form test as per AIS -096 etc. Simulation results which

Rathore, Gopal Singh, Kumar, Ankit, Chauhan, Adesh Kumar, Das, A.P., Sahu, Hemanta Kumar

Deployment of Continuous Integration and Continuous Testing in Mobility For Software Qualification

2024-28-0198To be published on 12/05/2024

Title: Deployment of Continuous Integration and Continuous Testing in Mobility For Software Qualification Abstract: In the rapidly evolving field of automotive engineering, the drive for innovation is relentless. One critical component of modern vehicles is the automotive ECU. Ensuring the reliability and performance of ECU is paramount, and this has led to the integration of advanced testing methodologies such as Hardware-in-the-Loop (HIL) testing. In conjunction with HIL, the adoption of Continuous Integration (CI) and Continuous Testing (CT) processes has revolutionized how automotive ECU are developed and validated. This paper explores the integration of CI and CT in HIL testing for automotive ECU, highlighting the benefits, challenges, and best practices. Continuous Integration and Continuous Test (CI/CT) are essential practices in software development. Continuous integration process involves regularly integrating code changes into the main branch, ensuring that it does not

Hande, Sheetal Vikram, Mandava, Balaji Bharath

Anomaly Detection in Fleet Vehicle Data and Statistical approach to develop Engine System OBD thresholds

2024-28-0195To be published on 12/05/2024

On-Board-Diagnostics are crucial for ensuring the proper functioning of Vehicle’s emission control system by continuously monitoring various sensors and components. When the failure is detected, the Check Engine Light (CEL) is triggered on Vehicle’s dashboard, alerting the driver to seek professional service to address the issue. However, the task of developing the Diagnostics strategies and perform robust calibration is a challenging and time consuming. Model in Loop Testing and Simulation is a technique used to understand and estimate the behavior of system or sub system. The diagnostics model can be tested and refined within the model-based environment allowing a complex system to be efficiently regulated. Model in loop framework could be used at various stages of development from very early in the design phase to later stages of series developments through vehicle fleet data. This framework allows an early identification and correction of errors and bugs. In this paper, the

Kumar, Amit, Hegde, Karthik, Challa, Krishna, H, YASHWANTH

Automotive 5G : Roadmap and Challenges

2024-28-0217To be published on 12/05/2024

The advent of 5G technology is set to revolutionize the automotive industry, enabling a host of new applications that align with emerging automotive megatrends such as connectivity, autonomy, and enhanced user experiences. This paper provides an overview of the roadmap for integrating 5G into the automotive sector and examines the challenges that must be addressed to realize its full potential. 5G's high-speed, low-latency communication capabilities are pivotal in advancing vehicle-to-everything (V2X) connectivity. This facilitates real-time data exchange between vehicles, infrastructure, pedestrians, and networks, supporting applications such as advanced driver assistance systems (ADAS), autonomous driving, and intelligent traffic management. Enhanced V2X communication enables vehicles to make faster, more informed decisions, thereby improving safety and efficiency on the roads. Moreover, 5G technology enables enhanced in-car experiences through high-bandwidth applications like

Rajappa, Yashavanth

A novel experimental approach for taper roller bearing preload measurement in manual transmission to optimize the durability and performance

2024-28-0197To be published on 12/05/2024

In manual transmission units, taper roller bearing preload is vital factor for enhancing the durability and performance. To achieve better optimization of bearing preload, precise measurement method is a minimum requisite. This technical paper investigates the multiple methods and develops a novel methodology for accurate bearing preload measurement, overcoming the challenges produced by the complexity of transmission designs. The study also identifies key parameters responsible for influencing bearing preload, including rigidity & fit of the parts involved. A comprehensive experimental study at part level & system level was done to quantify the effects of these parameters on preload levels and transmission performance. Furthermore, the paper explores the effect of bearing preload optimization on durability as well as efficiency of transmission unit. In conclusion, this paper contributes a systematic approach to bearing preload measurement in manual transmission units. By enhancing

Gaurav, Kumar, Kumar, Arun, Singh, Maninder Pal, Dhawan, Soumil, Singh, Kulbir, Kumar, Krishan, Singh, Manvir

Development of an Automated Testbench for Functional Testing of Dosing Unit

2024-28-0202To be published on 12/05/2024

Increasingly stringent emission regulations continue to be legislated around the world to signifi-cantly minimize pollutants released to the air by internal combustion engines. After Treatment Systems (ATS) meant for reducing oxides of nitrogen (NOx) in the exhaust into non-harmful species have evolved at a rapid pace over the past two decades. Stringent emissions requirements have driven complex ATS architecture through sensors to measure delta-pressure, NOx, and tem-peratures. Accurate and precise performance of individual components as well as the integrated ATS is required to ensure regulatory compliance and efficient performance. Both of which require substantial amounts of performance and validation testing. Manufacturers have been developing the ability to accurately and efficiently test the ATS components. To meet the norms for tail pipe or stack emissions of NOx in ‘as new’ condition and during the entire ‘emissions useful life (EUL)’ of the ATS, all components of an ATS must

RAUT, Pratiksha C, Ottikkutti, Pradheepram, Phadke, Abhijit Narahari, Magar, Vijay A.

Development of a Method to Model Flexible Hose in FE Linear Dynamics Simulations

2024-28-0254To be published on 12/05/2024

Linear dynamics simulations are performed on engine components to ensure structural integrity under dynamic loading. The FE model of the engine assembly must be prepared accurately to avoid under or over design of the engine components. Flexible hoses are present at pipe routings and modeling them in simulations is a challenge because the stiffness of the composite is not known. Current method includes using linear mass and spring elements instead of the hose with assumed stiffness, which leads to lack of confidence in the FE model. The hose under study in this paper is a rubber composite with a knitted reinforcement layer. This work involves a multiscale modelling approach using Representative Volume Element (RVE) for homogenization of yarn and rubber material properties to model composite hose in FEA. A RVE geometry is created which is a unit cell representation of the composite consisting of the knitted yarn and surrounding rubber. Orthotropic elastic properties are established at

Ashodiya, Jay Virendra, Jayachandran, Janarthanan, Santhosh, B

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