Browse Topic: Bodies and Structures

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Design evolution of novel rear sub frame structure for multilink suspension and electric vehicle platform2026-28-0007To be published on 02/12/2026
As there is a major shift in customer demand for energy efficient transportation electric vehicle development has taken immediate significance worldwide as they provide pollution free, noise free mobility environment. In the current work, the authors evaluate novel Rear sub-frame assembly structure with multilink suspension and further for a born electric vehicle platform with increased rear axle weight contribution due to rear motor and battery weight. The Sub Frame is the important structural component of the chassis system. Hence designers face the challenge of providing a best-in-class optimized Rear sub-Frame in terms of cost and weight within the available vehicular boundary. Rear sub-Frame assembly is designed with unique cross member structure and novel motor mounting arrangement on the side member with the given complex hard points or attachments of the suspension linkages, to meet the electric vehicle packaging requirement. Sub frame is designed with light weight to withstand
Nidasosi, Basavraj Maruti, J, Ramkumar, NAYAK, Bhargav, MANI, ARUN, M, Sudhan
Design and Development of Integrated Brake and Bull Cage System for Enhanced Tractor Performance and Sustainability2026-28-0005To be published on 02/12/2026
Conventional tractor transmission systems feature separate Brake and Bull Cage housings, with brakes often being proprietary components and Bull Cage designed by the Original Equipment manufacturer (OE). To optimize design and performance, an innovative integrated system was developed, combining an in-house braking system with a unitized Bull Cage assembly. This robust design reduces part count, eliminates proprietary dependency (except for friction liners), and enhances performance. Virtual simulations performed under RWUP conditions demonstrated enhanced strength and stiffness in the integrated design. In this Integrated Brake & Bull Cage assembly (IBCA) , the braking layout was reconfigured from a 4+1 friction design to a 3+2 configuration which improved balancing, enhancing customer braking experience and increasing contact area by 11%. This adjustment extends friction liner life and boosts mechanical advantage by 7.5%, significantly improving tractor stability and performance
Dumpa, Mahendra Reddy, Dhanale, Swapnil, Perumal, Solairaj, Gomes, Maxson, Redkar, Dinesh, Savant, Kedarnath, V, SARAVANAN
ACCIDENTAL DOORING WARNING AND ASSIST SYSTEM2026-28-0053To be published on 02/12/2026
The term dooring refers to the accidents where a vehicle door is suddenly opened into the path of an oncoming cyclist or motorcyclist. These issues are serious road safety hazards, especially in congested urban areas where people may be careless. This project proposes an intelligent, computer vision based warning system designed to detect the approaching vehicles and alert the occupants in the vehicle before opening the door. The system uses the rear parking camera in vehicles with rear parking system or a USB webcam in vehicles without rear parking system to capture live video feed, which is processed by a Raspberry Pi 4 microprocessor. The system will run a lightweight deep learning model, MobileNetSSD, through TensorFlow Lite. Detected objects are classified in real time, and the relative distance of other vehicles is estimated using bounding box dimensions. If a vehicle is identified within a preset safety distance threshold, a clear visual warning is displayed to prevent door
C, Jegadheesan, T, Karthi, Gurusamy, Varun Sankar, Balraj, Tharun, Murugaiya, Tamilselvan
Ambient Light Reflection Analysis using Dimensional Modelling Tools2026-26-0476To be published on 01/16/2026
The primary motivation is to improve driver safety and visual comfort. This is driven by the need to address the negative impact of ambient light reflecting off Head-Up Displays (HUDs), which can impair visibility through the windshield. There is a need for tools and methods to address this issue proactively during the vehicle design phase. Ambient light reflecting off internal components, specifically the Head-Up Display (HUD), creates unwanted reflections on the windshield. These reflections can obscure the driver's field of view, potentially compromising safety and reducing visual comfort. The extent of this obscuration is influenced by geometrical factors such as the angle of the HUD and the curvature of the windshield, which needs to be analyzed and managed. The study employs a tool-based modeling methodology to trace the pathways of ambient light from its source, reflecting off the HUD, and onto the windshield using a dimensional modeling tool. It focuses on geometrical factors
Muchchandi, Vinod, Akula, Satya Jayanth, Mahindrakar, Pramod, G S, Sharath
Optimization of the Rodip CED Process Suitability through Strategic Fixture System for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing2026-26-0486To be published on 01/16/2026
The Ro-dip Cathodic Electrodeposition (CED) process is latest technology used by Automotive Manufacturers for higher quality corrosion protection in new generation Automobiles. This process involves multiple 360-degree rotation of automotive body in white (BIW) which exert higher hydrostatic forces on large surface panels like Hood. For maintaining consistent gaps & flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel Hood panel while undergoing through this CED process. This study investigates the enhancement of hood panel alignment through strategic optimization of support rod placement and quantity within the Ro-dip CED system. By conducting experimental trials and computational simulations, the research identifies critical deformation points and evaluates the impact of varying support rod configurations on dimensional stability. The outcome results demonstrate that positioning support rods at
Tile, Vikrant, Unadkat, Siddharth, Askari, Hasan, Jadhav, Devidas
Development of Door Impact Loads Using Pedal Force Sensor and First Principles2026-26-0538To be published on 01/16/2026
The first step in designing or analyzing any structure is to understand “right” set of loads. Typically, off-road vehicles have many access doors for service/getting into cab etc. Design of these doors and their latches involve a knowledge of the closing loads when the door is shut mostly with an impact of varying magnitudes. In scenarios of these impact events, where there is sudden change of velocity within few milliseconds, produces high magnitude of loads on structures. One common way of estimating these loads using hand calculations involves evaluating the rate-of-change-of-momentum. However, this calculation needs “duration of impact”, and it is seldom known/difficult to estimate. Failing to capture duration of impact event will change load magnitudes drastically, e.g. load gets doubled if time-of-impact gets reduced from 0.2 to 0.1 seconds and subsequently fatigue life of the components in “Door-closing-event” gets reduce by ~7 times. For these problems, structures are usually
Valkunde, Sangram, Ghate, Amit, Gagare, Kiran
A High-Fidelity Transient Fluid-Structure-Interaction Methodology for Evaluation of Rear Bumper Flutter of a Vehicle2026-26-0410To be published on 01/16/2026
The need for fuel efficient and pedestrian safe cars leads to the use of thinner and lighter car exteriors. Interaction of these exterior car components at high speed with an aerodynamic load can lead to undesirable aero-elastic vibration and flutter. Early identification and mitigation of such vibration can bring significant cost and time benefit, by reducing dependence on prototype testing and recalibration of prototype tooling at later stages. The present work demonstrates a transient Fluid-Structure-Interaction based numerical methodology for estimation of aerodynamic-induced flutter of the rear bumper of an SUV. The proposed method performs coupled-high fidelity transient full vehicle aerodynamic Finite Volume based and dynamic rear bumper structural Finite Element based simulations required for flutter estimation. The method has been put through a two-step validation against experimental wind tunnel test data of a prototype car with modified bumper for the specific test-case. The
Choudhury, Satyajit, Yenugu, Srinivasa, Walia, Rajat, Zander, Daniel, Gullapalli, Atchyut, Balan, Arun, Astik, Pritesh
OPTIMIZER SUNSHADE PACKAGING WITH HALF ALUMINIUM CASSET AND METAL PULL BAR2026-26-0597To be published on 01/16/2026
The automotive industry is advancing rapidly with the integration of cutting-edge technology, aesthetics, and performance. One area that has remained relatively underexplored in the pursuit of sleek, minimalistic interiors is the Sunshade packaging in door trim system. Traditional sunshade design, often bulky and are increasingly incompatible with the trend towards compact. Car sunshade is a shield that is placed on a car side window, and it is used for regulating the amount of light entering from the car window and improves the passenger comfort inside the cabin. Car Interior components specifically plastic and seats based on thermal stress properties. When we exposed these parts direct contact with sunlight, humidity and ambient temperature above threshold limit then interior plastic parts can start softening and melt after that they emit harmful chemical which is caused to anemia and poor immune systems. So, Sunshade protection not only serve to protect passenger comfort inside car
Palyal, Nikita, D, Gowtham, Bhaskararao, Pathivada, Bornare, Harshad, Ritesh, Kakade
The Aerodynamic development of a Compact SUV for FE improvement and compliance with CAFE norms2026-26-0595To be published on 01/16/2026
The Mahindra 3XO is a compact SUV, the first-generation was introduced by Mahindra in 2018. This paper explores some of the challenges entailed in developing the next generation of this successful product, maintaining exterior design cues while at the same time improving its aerodynamic efficiency. A development approach is outlined that made use of both CFD simulation and Coastdown testing at MSPT (Mahindra SUV proving track). Drag coefficient improvement of 40 counts (1 count = 0.001 Cd) can be obtained for the best vehicle exterior configuration by paying particular attention to: • AGS development to limit the drag due to cooling airflow • Front wheel deflector optimization • Mid underbody cover development (beside the LH & RH side skirting) • Wheel Rim optimization • Rear wake control strategy In this paper we have analysed the impact of these design changes on the aerodynamic flow field, Pressure plots and consequently drag development over the vehicle length is highlighted. An
Vihan, Nikhil
Wireless Mobile charger Packaging in Pecuilar Rear Door Trim Profile.2026-26-0270To be published on 01/16/2026
Abstract A mobile wireless charger is a device that charge a smartphone or other compatible gadgets without the need for physical cables. Principle of wireless mobile charger system based on inductive coupling phenomena. The main objective of this paper aims to address the challenge of packaging wireless mobile charger in peculiar door trim profile keeping overall functionality and aesthetic appearance of door trim intact. This paper deals with integration of a wireless charging system within the door trim of a vehicle to provide convenience and advanced functionality. The objective is to pack a wireless charger in door trim meeting the ergonomic target and equilibrium state stability while maintaining sleek and minimalist design of the door trim. The study focuses on innovative packaging solutions related to space optimization in door despite multiple challenges involved. Major challenge lies in packing the unit amidst complex mechanisms such as window regulators, speakers, structural
Palyal, Nikita, D, Gowtham, Bhaskararao, Pathivada, Kumarasamy, Raj Ganesh, Bornare, Harshad
Developing Advanced CAE Model for Door Glass Regulator Operating Noise Reduction through TEST/CAE Correlation2026-26-0311To be published on 01/16/2026
The importance of performance improvement and weight optimization using CAE in the early design stages of vehicle development has been continuously increasing over the past two decades. And, the accuracy of CAE models plays key role, more efforts are required to improve it. Representation of exact physical model in CAE is still a big challenge for achieving an accurate TEST vs CAE correlation. In this research, the procedure and application of door system model correlation were described to reduce the glass regulator operating noise. The function of a regulator in door system is to open and close the glass. The regulator under improper design creates unwanted noise and discomfort to the passenger. In current door CAE Model, we are unable to identify this real time problem. Therefore, this paper discusses how to correlate door system model according to the assembly stage based on modal correlation and it helped in calculating accurate glass regulator operating noise. As a result, the
Panuganti, Naresh Kumar, Choi, Seungchan
UNIQUE HYBRID PANORAMIC HEADLINER CLIP WITH HIGH TOLERANCE TO REPLACE DUAL LOCK FASTENERS2026-26-0299To be published on 01/16/2026
Mounting strategies for vehicles with panoramic sunroofs remains a challenge owing to its high complexity to balance cost, performance and assembly efficiency. Achieving efficient and reliable headliner mounting solutions is one of the conundrums where cost optimization must go together with uncompromised performance. Traditional methods like Dual Lock Fasteners (DLFs), have set high benchmarks for robustness but at the cost of increased manufacturing complexity and expense. In pursuit of a more economical and production-friendly alternative, various plastic clip designs were explored. However, these solutions posed significant challenges during validation due to the stringent requirements for mounting feasibility, tolerance management, and long-term durability This paper introduces a novel hybrid plastic-metal clip solution that addresses those challenges comprehensively. The new design achieves precise tolerance control, ensuring reliable headliner installation under varying Body-in
D, Gowtham, Kumarasamy, Raj Ganesh, Shoeb, Mohd, Chauhan, Aarti
An Outer Waist Seal with Integrated Glass Wiping Mechanism for a Window Frame of a Vehicle2026-26-0011To be published on 01/16/2026
This innovation addresses a major safety concern where drivers experience poor visibility of the Outside Rear View Mirror due to rain, fog, dust, or ice accumulation on the side door window glass. Existing solutions like hydrophobic coatings and heated door window glasses offer limited effectiveness, leading to the need for a more reliable and efficient system. To solve this issue, we have modified Outer Waist Seal by integrating Glass Wiping Mechanism in it. The Outer Waist Seal is a weatherproof strip located at the bottom edge of a vehicle’s side window, attached to the door panel. It prevents heavy water flow, dust, and debris from entering the door cavity while also supporting the window glass during its movement. This system features a stationary fixed arm and a rotating arm with an attached wiper blade, driven by a low-speed, high-torque motor and connected with the vehicle's Body Control Module. Upon activation, the rotating arm with blade wipes the Outside Rear View Mirror
Neelam, Rajat, Chowdhury, Ashok, Panchal, Girish, Kumar, Saurav
Development of Sustainable Textile Solutions Using Recycled and Bio-Based Materials for Automotive Soft Trims2026-26-0236To be published on 01/16/2026
The shift towards sustainable and circular practices in the automotive industry is driving the development of eco-friendly materials for soft trims. This research explores the development and integration of sustainable textile solutions using recycled polyethylene terephthalate (rPET) from post-consumer waste and bio-based fibers such as banana and bamboo in various fabric forms—woven, knitted, and non-woven. Applications studied include seat fabrics, headliners, parcel shelves, and wheel arch liners. rPET textiles demonstrated promising strength, aesthetic appeal, and durability performance, while significantly reducing carbon footprint. Blends of rPET and virgin PET were optimized to balance properties with sustainability targets. Banana fibre, an agricultural by-product abundantly available in India, was explored for headliner substrates and parcel shelves, offering biodegradability and regional sourcing advantages. Bamboo fabrics, known for their natural antimicrobial properties
Deshpande, Sanjana, Borgaonkar, Subodh
Optimization of Propeller shaft design to eliminate Launch Undulation (Lateral shake) and Vibration level2026-26-0334To be published on 01/16/2026
During vehicle launches in 1st gear, a lateral shake (undulation) and a pronounced metallic hitting noise were observed in the underbody. The noise was identified as the propeller shaft's second universal joint (UJ) yoke striking the fuel tank mounting bracket. Sensitivity to these issues varied with acceleration inputs: light pedal input during a normal 1st gear launch on a flat road resulted in minimal undulation, whereas wide open throttle (WOT) conditions in 1st gear produced significant lateral shake and intensified hitting noise. Further investigation revealed that the problem persists across all gears and occurs consistently during normal driving conditions, with continuous impact between the propeller shaft yoke and the fuel tank mounting bracket. Extensive experimental measurements at the vehicle level indicated that these issues were primarily caused by the center-mounted propeller shaft joint deviating from its central position and rotating eccentrically under torque. This
Sanjay, L, S, Manickaraja, Kumar, Sarvesh, Kanagaraj, Pothiraj, Senthil Raja, T, B, Prem Prabhakar, M, Kiran
Design optimization of the propeller shaft and transfer case for high-speed 4WD vehicles2026-26-0343To be published on 01/16/2026
Nowadays, vehicle enthusiasts often vary their driving patterns, ranging from driving at very high speeds to off-roading. Due to these driving patterns, 4WD vehicle demand is continuously growing day by day. A 4WD vehicle used to have better traction control with enhanced stability. The 4WD vehicle performance and reliability at high speed are critically influenced by driveline stiffness and natural frequency. Driveline stiffness and natural frequency are very critical parameter for high-speed vehicles, that significantly influenced by the propeller shaft and transfer case. This study focuses on the design optimization of the transfer case and critical frequency of propeller shafts to enhance vehicle performance at high speeds. The analysis begins with a comprehensive study of the factors affecting power transfer path, transfer case stiffness, critical frequency, including material properties, propeller shaft geometry and the boundary conditions. Advanced computational methods are
Kumar, Sarvesh, Yadav, Sahdev, S, Manickaraja, Sanjay, L, Kanagaraj, Pothiraj, Jain, Saurabh Kumar, Deole, Subodh M
Infotainment-Free Sunroof Control Testing Using National Instruments Framework2026-26-0519To be published on 01/16/2026
Verification of sunroof operation via voice commands conventionally necessitates a fully assembled vehicle platform integrated with an updated Body Control Module (BCM) and infotainment software. This hardware-software dependency presents significant limitations, particularly during the early stages of development, where rapid validation and iteration are critical. Additionally, vehicle availability and software readiness often act as bottlenecks in the validation process. To address this, a novel approach has been developed to simulate sunroof operations—including both physical switch and voice command inputs—using a National Instruments (NI) system. This setup eliminates the reliance on the vehicle’s BCM and infotainment system by simulating LIN commands directly through the NI interface. The integration of the sunroof module with the NI system facilitates comprehensive bench-level testing, including functional validation, endurance evaluation, and abuse case simulation. This
Ghanwat, Hemant, Lad, Aniket Suryakant, Joshi, Vivek, More, Shweta
Rear Wiper Motor with Nozzle Integration for Improved wiping performance and Perceived Quality2026-26-0600To be published on 01/16/2026
In the current modern days of driving, rear wiping performance plays a crucial role in safe driving. This study focuses on improving the rear wiping with add on benefits like improved BSR performance, cost saving and perceived quality. This new concept has the rear wiper motor assembly which accommodates the nozzle also thereby making it a single unified assembly with reduced system complexity. This concept eliminates the complex hose routing of washer system for rear wiping which is usually packaged at spoiler or HMSL. It also helps in improved spray coverage and reduced dry wiping which in turn enhances system reliability with clean & quiet operation. This integrated nozzle concept is much more compact than the available products in the market with minimum number of end items. Also, this design comes with non-return valve which ensures there is no delay in the spray execution. And it improves the cleaning efficiency by maintaining consistent fluid pressure. This concept comes with
Dhage, Prashant, K, Nagarajan, G, Sabari Rajan
Optimization of Air Extractor for Improved Door Closing Effort and Perceived Premium Feel2026-26-0592To be published on 01/16/2026
This research analyses the significance of air extractor on car door closing effort, especially within the context of highly sealed cabins. The goal is to measure their effectiveness in lowering pressure-induced resistance, study how cut-out cross section and location affect performance, and its contribution to vehicle premium feel. Current vehicle design trends prioritize airtight cabin sealing for improving aerodynamic efficiency, NVH performance. This causes a problem in door closing operation. Air trapped while closing door creates transient pressure pulses. This pressure surge creates immediate discomfort to user i.e., Popping in Ears and requires high door closing force, and long-term durability problems in hinges and seals. In properly sealed cabins, air pressure resistance can contribute to 25% to 40% of total door closing force. Air extractors, which are usually installed in the rear quarter panels or behind rear bumpers, serve as pressure relief valves, allowing for smoother
P, Sivasankar, Sankineni, Vikhyath Rao, Shah, Sahil, Marimuthu, Anbarasan
Side Crash Pressure Sensor response Prediction: CPM approach2026-26-0413To be published on 01/16/2026
Side crashes are generally hazardous because there is no room for large deformation to protect an occupant from the crash forces. A crucial point in side impacts is the rapid intrusion of the side structure into the passenger compartment which need sufficient space between occupants and door trim to enable a proper unfolding of the side airbag. This problem can be alleviated by using the rising air pressure inside the door as an additional input for crash sensing. With improvements in the crash sensor technology, pressure sensors that detect pressure changes in door cavities have been developed recently for vehicle crash safety applications. The crash pulses recorded by the acceleration based crash sensors usually exhibit high frequency and noisy responses. The data obtained from the pressure sensors exhibit lower frequency and less noisy responses. Due to its ability to discriminate crash severities and allow the restraint devices to deploy earlier, the pressure sensor technology has
Bhagat, Milind, Narale, Naganath, Mahajan, Ashutosh, Wayal, Virendra, Jadhav, Swapnil
Transforming Headlamp Levelling Compliance Testing Through AI-Powered Predictive Modelling2026-26-0660To be published on 01/16/2026
The process of validating headlamp levelling compliance as per regulatory standards involves physical testing with various vehicle loading conditions. This traditional method is labour-intensive, time-consuming, and consumes significant resources. There is a need for a predictive solution that can simulate and validate headlamp levelling tests virtually, thereby reducing dependency on physical trials. Headlamp levelling compliance is a critical regulatory requirement to ensure optimal visibility and safety under varying vehicle loading conditions. This paper presents an Artificial Intelligence and machine learning-based (AI / ML) solution to simulate headlamp levelling tests virtually/Digitally by using Historical Headlamp designs from past vehicles. By leveraging historical test data and developing regression models, the system predicts headlamp height and dipped beam height for both unladen and laden conditions. Key vehicle parameters such as tire load, overhang, deflection, and
Mandloi, Prince, Joshi, Vivek S., GHANWAT, HEMANT, Ugale, Anand, Munda, Rohit, GHAN, PRAVIN
Packaging the HPTS Airbag in a Second-row bench seat2026-26-0033To be published on 01/16/2026
Seats of modern cars should necessarily meet the regulatory safety norms along with aesthetics and comfort. In the existing passenger cars prevailing across the Indian subcontinent, the measure of safety has been a challenging one. The stringent regulatory norms thereby make the Airbag very promising. In the domain of automotive safety, certain features hold exceptional importance, with airbags taking a forefront position. Their fundamental objective is to provide an advanced level of safety for both the driver and passengers in the unfortunate event of a collision. This is accomplished through the automatic deployment of an inflatable airbag, engineered to swiftly respond during a crash and furnish the necessary sophisticated cushioning to enhance overall passenger safety. The technology has been practiced widely upon a many vehicles seat. However, the present work highlights a novel approach of packaging the HPTS air bag in second row seat. This Air bag unit is fitted in the seat
Buradkar, Rajat, Bose, Karthik, Jadhav, Deepika, Balakrishnan, Gangadharan
Analysis of Door Seal Compression and its Influence on NVH Performance in Heavy-Duty Vehicle2026-26-0339To be published on 01/16/2026
Seals in a truck cabin is one of the major contributors for cabin noise in terms of structure borne as well as air borne noise transfer path. This study emphasizes on the effect of door seal compression prediction and its impact on structure borne NVH in trucks. Vibrations are regarded as quality criteria in the perception of customers. It is necessary to ascertain the contribution of seal stiffness on compression of the seal under closed condition of the door rather than uncompressed conditions. The dynamic stiffness of door seal is calculated by non-linear analysis. The simulations models are constructed using the Mooney - Rivlin theory for both 2D and 3D seals. This encompasses contemplating the relevant seal mounted boundary condition on the body and the door of the vehicle. The stiffness after compression of seal is extracted from this non-linear analysis which is further used to obtain the vibration modes for the doors in the truck cabin. Subsequently, the compressed seal
L, Kavya, Ramanathan, Vijay
A Scientific approach to identify the source of intermittent steering rattle noise and implementing the design solutions2026-26-0346To be published on 01/16/2026
Body-on-frame vehicles are well-regarded for their durability and off-road capabilities, but their structural design often makes them more vulnerable to noise, vibration, and harshness (NVH) issues. Vibrations originating from uneven roads are transmitted through the suspension and steering assemblies, sometimes resulting in rattles or other disturbances. These vibrations can be amplified by the inherent flexibility in the body-to-frame mounting system. In such vehicles, the steering system plays a critical role in driver comfort and is highly sensitive to vibrational inputs from the road surface, especially on coarse or uneven terrain. Occasionally, these inputs result in subtle rattle noises that are perceptible only to the driver and may not be detected under controlled testing environments. This poses a challenge for engineers trying to isolate and resolve such intermittent NVH phenomena. Identifying the source requires a combination of real-world driving evaluations, structural
Ramesh Chand, Karan Kumar, Gopinathan, Haridoss, Kabdal, Amit
The Impact of Color Correlated Temperature (CCT) on Automotive Headlights Performance and Driver Perception2026-26-0130To be published on 01/16/2026
Automotive lighting has been evolved from simple incandescent lamps to advanced LED based AFS and ADB functions. These lighting play crucial role in road traffic enhancing better visibility and safety to driver as well as other road users. Today’s Automotive Headlights use different light sources viz., Halogen, HID (Xenon), LED, and Laser each emitting light at different correlated color temperatures (CCT), measured in Kelvin (K). Color temperature not only influences visibility but also impacts the amount and perception of glare experienced by other drivers. The study was undertaken to evaluate the effect of correlated color temperature of automotive headlamps on driver visibility and comfort during night driving conditions. The experiment was conducted in a controlled laboratory environment using headlamps with different CCTs ranging from 3000K to 6500K. Participants from various age groups and genders were involved to capture diverse perceptions. Studies confirm that both CCT and
Patil, Mahendra G., Kirve, Jyoti, Parlikar, Padmakumar
Method and System of Detecting Obstacle Around Vehicle Door2026-26-0026To be published on 01/16/2026
Modern vehicles are equipped with numerous safety systems focused primarily on active and passive crash protection, but less attention is given to low-speed or stationary scenarios: particularly when occupants exits the vehicle. One common and often underestimated risk occurs when the vehicle door is opened without awareness of nearby obstacles such as walls, poles, or other vehicles. This paper introduces a novel, intelligent solution aimed at enhancing safety during driver egress. The proposed system leverages the existing ORVM (Outside Rear View Mirror) cameras to monitor and measure the surface area adjacent to the vehicle. When the vehicle is parked and the engine is turned off, the system becomes active. As the driver initiates the exit, the system scans for obstructions near the door. If an obstacle is detected within a predefined danger zone, it projects a warning symbol on the Instrument cluster via the puddle lamp and triggers an audible chime to alert the occupant. This dual
Bhuyan, Anurag, Khandekar, Dhiraj, Jahagirdar, Shweta
Design of the BIW Structure for Battery Pack Protection in Case of Side Pole Impact2026-26-0025To be published on 01/16/2026
Electric vehicles (EVs) are becoming more popular than Internal Combustion Engine (ICE) powered vehicles, but their battery and motor components elevate their Gross Vehicle Weight (GVW), posing unique collision risks. Manufacturers strategically mount the high voltage (HV) battery packs under the passenger compartment to lower the Centre of Gravity and shield them from the front impacts. However, side impacts remain a concern, as the battery deformation in such instances could trigger fires or explosions, endangering occupants. To address this, crashworthiness designs adhere to New Car Assessment Program (NCAP) standards, particularly against side pole impact and side mobile barrier impact. Unlike the frontal section of BIW, which typically has larger crush space to absorb the crash energy, extensive design attention is required to the vehicle's side structure to absorb pole impacts without transmitting excessive force to the battery pack. Utilizing aluminium extrusions and sheet
Nivesh, Dharun, Namani, Prasad, Ramaraj, Rajasekar
A Novel Approach to Deep Drawing Using Hybrid System and Pneumatic-Assisted Forming2026-26-0301To be published on 01/16/2026
ABSTRACT: This paper presents a novel Plunger-Integrated Hybrid System aimed at enhancing the efficiency and performance of deep drawing operations in metal forming processes. The proposed hybrid system strategically combines the mechanical strength of metals with the elastic flexibility of polymers, specifically polyurethane rubber, to improve formability and reduce spring-back, two critical challenges in conventional sheet metal forming. A novel two-stage forming technique is employed, an initial drawing operation using a larger radius with polyurethane rubber, followed by final radius formation using the same rubber in conjunction with a pneumatic cylinder. This integrated approach ensures uniform force distribution via the embedded plunger, significantly minimizing forming defects and enhancing the dimensional accuracy of the final components. The solution has been validated using Finite Element (FE) simulation methods, confirming its capability to produce high-quality parts
Chava, Seshadri Reddy, Singh, Prakhar, Dhanajkar, Narendra, Roy, Amlan, Raju, Gokul
Optimized Panel Design for Reducing Seal Squeak and Chucking in Door & Body Seals2026-26-0341To be published on 01/16/2026
Quieter cabins in an automobile are the new era, they provide customers with pleasurable driving experience. Squeak and Rattle are spoil sport for any OEM that aim to improvise customer driving experience. Their nonlinear nature makes it difficult to formulate design frontloading methods. The issue of seals rubbing against the body & door interface is a clear sign of seal squeak & seal chucking. Seals are applied with anti-friction coatings to avoid stick slip phenomena between EPDM and painted panel. Primary root cause for seal squeak is coating erosion. The challenge lies in determining whether the body or the closure side contributes to the seal issue. This paper presents a distinctive approach for identifying the seal squeaking noise and enriches on the new modelling methods for seal interaction with door and body interfaces using FE software. The proposed method was able to highlight the locations along the door-body interface for squeak noise. The approach for reducing the
H, Ravishankar, C M, Mithun, Michael Stephan, Navin Estac Raja, Mohammed, Riyazuddin
Electroluminescent Coating Systems for Heavy-Duty Trucks: Advancing Safety and Sustainability through Smart Surface Technology2026-26-0275To be published on 01/16/2026
As the transportation industry pivots towards safer and more sustainable mobility solutions, the role of advanced surface technologies is becoming increasingly critical. This paper presents a novel application of electroluminescent (EL) coating systems in heavy-duty trucks, exploring to enhance safety and environmental impact through lightweight, energy-efficient lighting integration. EL coatings, capable of emitting light uniformly across painted surfaces when electrically activated, offer a transformative alternative to conventional lighting systems and reflective materials. In the context of heavy-duty trucks, these systems can significantly improve visibility under low-light and adverse weather conditions, thereby reducing the risk of road accidents. Furthermore, illumination achieved without bulky fixtures and without interface gaps contributes to aerodynamic efficiency, fuel economy and reducing carbon emissions. use of this coating system, can optimize tooled up plastic part and
Harel, Samarth Dattatraya, Borse, Manoj, L, Kavya
Crash Pulse Characterization for the Passenger Vehicle Fleet in India.2026-26-0029To be published on 01/16/2026
A crash pulse is the signature of the deceleration experienced by a vehicle and its occupants during a crash. The deceleration-time plot or crash pulse provides key insights into occupant kinematics, occupant restraints, occupant loading and efficiency of the structure in crash energy dissipation. Analysing crash pulse characteristics like shape, slope, maximum deceleration, and duration helps in understanding the impact of the crash on occupant safety and vehicle crashworthiness. This paper represents the crash pulse characterization study done for the vehicles tested at ARAI as per the ODB64 test protocol. Firstly, the classification and characterization of the crash pulses is done on the basis of the unladen masses of the vehicles. The same are further analysed for suitability of mathematical waveform models such as Equivalent Square Wave (ESW), Equivalent Triangular Wave (ETW), Equivalent Sine Wave (ESW), Equivalent Haversine Wave (EHSW) as well as EDTW (Equivalent dual trapezia
Mishra, Satish, Kulkarni, Dileep, Borse, Tanmay, Mahindrakar, Rahula Ashok, Mahajan, Rahul, Jaju, Divyan
Experimental Evaluation of Metro Rail Bogie Frame through Bench Testing2026-26-0561To be published on 01/16/2026
Bogie frame is a main skeleton and structural member in railway system which is carrying all the loads such as Suspensions,Axles,wheels, car body, Motor, Gear box etc. The frame is subjected the exceptional and service stresses in Vertical, Longitudinal, Lateral and twist directions throughout the service life which should be withstand for a life span of 30 years without failure. The purpose of this project is to determine the Structural integrity of the Metro rail bogie frame in consideration with EN13749 standard .This paper is the outcome of bench testing of metro rail bogie frame with the application of multiaxial loading in static and dynamic campaign through which stress data is collected with strain gauge sensors and correlated with the FEA results at design stage. This helps to verify and evaluate the design and validate the quality of metro rail frame as per the requirement specified in EN13749 European standard in early design stages.
Tormal, Uday Bapurao, Sinnarkar, Nitin, Shinde, Vikram
Methodology for optimizing the bench testing of Steering I shaft using vehicle level data to reduce overall product development time and cost.2026-26-0560To be published on 01/16/2026
Steering I-shaft with rubber coupling (or hardy disc) is an important part of complete steering system mainly in body on frame vehicles. Hardy discs are used to dampen the vibrations that transmit to steering wheel through frame, steering gear and I-shaft. They also support to accommodate the variation between frame and BIW of body on frame vehicles. They are made up of rubber or other polymer composites, which have less torsional stiffness as compared to metals. The overall torsional stiffness of steering system reduces since the hardy disc is used in series in steering system, that impacts on the overall performance of steering system. So, during development I shafts with different design, stiffness of hardy discs are used to optimize the steering and NVH performance of vehicle. Considering the development time and cost, each design of I-shaft cannot be validated at vehicle level. The torsional and axial force or displacement of hardy disc is measured at vehicle level on different
Kabdal, Amit
Optimisation of frontal impact force scheme to accelerate the target setting process for development of front-end structures in vehicles.2026-26-0001To be published on 01/16/2026
A passenger vehicle's front-end structure's structural integrity and crashworthiness are crucial to ensure compliance with various frontal impact safety standards (such as those set by Euro NCAP & IIHS). For a new front-end architecture, design targets must be defined at a component level for crush cans, longitudinal, bumper beam, subframe, suspension tower and backup structure. The traditional process of defining these targets involves multiple sensitivity studies in CAE. This paper explores the implementation of Physics-Informed Neural Networks (PINNs) in component-level target setting. PINNs integrate the governing equations into neural network training, enabling data-driven models to adhere to fundamental mechanical principles. The underlying physics in our model is based upon a force scheme of a full frontal impact. A force scheme is a one-dimensional representation of the front-end structure components that simplifies a crash event's complex physics. It uses the dimensional and
Gupta, Ishan, Bhatnagar, Abhinav, Kumar, Ayush
Experimental Investigation of Stress Distribution Characteristics in Surrounding Rock during Unloading in Oblique Upper Crossing Tunnel2025-99-0242To be published on 12/23/2025
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Wu, Hao, Qin, Shuzhen, Li, Guofeng, Dong, Tianwen, Shi, Yongyue
Optimization Design of Typical Vehicle Frame Structure Using Power Flow Transmissibility Objective Function Method — Taking SD160-3 Model as an Example2025-99-0213To be published on 12/23/2025
According to a problem of the vibration and noise suppression of an engineering vehicle cab, a dynamical model of the engine-frame-cab system was established to describe the vibration transmission path. The method of calculation of the vibratory power flow, which is transmitted from the vibration source engine to the cab through the frame and isolators, was deduced. And then an optimization strategy for the frame structure and the corresponding analysis algorithm process were proposed based on the objective function of power flow. The method proposed was validated through an application to a practical example, which would have practical value in the field of vehicle vibration reductions and optimization design of frame structures.
Wang, Qiang, Huo, Rui, Guan, Yanfeng, Zhang, Daokun
Analysis of the Structural Alignment during the System Conversion of Continuous Beam Bridges with High Piers, Long Spans and Wide Box Girders2025-99-0224To be published on 12/23/2025
With the rapid development of the worldwide highway transportation industry, continuous box girder bridges have many advantages, such as superior spanning capacity, reasonable force-bearing performance, and low cost, which give them significant strengths in bridge design. However, to ensure that the structural alignment of the girder meets the design and specification requirements, it is necessary to study the laws of alignment changes of cantilever structures during the construction process. This is to reasonably control the alignment of the main girder structure during construction and ensure that the alignment of the completed bridge is consistent with the design alignment. This paper takes a continuous rigid frame bridge on a certain expressway as the engineering basis. Its superstructure is a three-span prestressed concrete continuous box girder with a span of (88 + 160 + 88) m, a bridge width of 16.5 m, and a maximum pier height of 130 m. The paper analyzes the influence of each
Liu, Xingshun, Ma, Kun, Zhao, Qiang
Aerodynamic Influence of Front Wing Geometry on Formula One Car Performance: A Computational Fluid Dynamics Review2025-36-0043To be published on 12/18/2025
During the development of modern racing cars, many aspects are considered, with one major factor being how air interacts with the structures and enhances performance on the track. Aerodynamics is a concept explored by fluid mechanics that examines the motion of air and other gases and the forces they exert on solid objects moving through them, such as drag and downforce, which are prevalent in aviation and racing categories like Formula 1 (F1). F1 is one of the most internationally renowned single-seater motorsport categories, and its development involves a complex interplay of several highly advanced systems, where aerodynamics plays a central and determining role in the car's performance. Various components compose these cars and contribute to their balance and performance, such as the power unit, suspension, diffuser, and front wing. The front wing, typically made up of one or more airfoils, interacts with several other crucial elements, including the car floor, brake ducts
Freitas, de Camila Mendonça, Telli, Giovani Dambros, Rosa, Josimar Souza
Development of Embedded Electronics with Artificial Intelligence in an Implement for Forklifts2025-36-0012To be published on 12/18/2025
In this article we will discuss the development and implementation of a computer vision system to be used in decision-making and control of an electro-hydraulic mechanism in order to guarantee correct functioning and efficiency during the logistics project. To achieve this, we have brought together a team of engineering students with knowledge in the area of Artificial Intelligence, Front End and mechanical, electrical and hydraulic devices. The project consists of installing a system on a forklift that moves packaged household appliances that can identify and differentiate the different types of products moved in factories and distribution centers. Therefore, the objective will be to process this identification and control an electro-hydraulic pressure control valve (normally controlled in PWM) so that it releases only the hydraulic pressure configured for each type of packaging/product, and thus correctly squeezing (compressing) the specific volume, without damaging it due to
Furquim, Bruno Bueno, Pivetta, Italo Meneguello, Ibusuki, Ugo
A Methodology for Developing Quantitative Satisfaction Curves in Vehicle Design: Bridging Engineering Metrics and Occupant Perception2025-36-0205To be published on 12/18/2025
In vehicle development, occupant-centered design is crucial to ensuring customer satisfaction. Key factors such as visibility, access, interior roominess, driver ergonomics, interior storage and trunk space directly impact the daily experience of vehicle occupants. While automakers rely on engineering metrics to guide architectural decisions, however in some cases doesn’t exist a clear correlation between these quantitative parameters and the subjective satisfaction of end users. This study develops a methodology which addresses that gap by proposing the creation of quantitative satisfaction curves for critical engineering metrics, providing a robust tool to support decision-making during the early stages of vehicle design. Through a combination of clinics, research, and statistical analysis, this project outlines a step-by-step process for developing (dis)satisfaction curves, offering a clearer understanding of how dimensions like headroom, glove box volume, and A-pillar obscuration
Santos, Alex Cardoso, Silva, Gustavo, Benevente, Rodrigo, Padua Silva, Antonio, Lourenço, Sergio Ricardo, Andrade, Cecilia Navas, Sobral, Piero
Impact of Rotor Balancing on Noise and Vibration Levels in Automotive Fuel Supply Modules2025-36-0146To be published on 12/18/2025
Rotor balancing is essential for minimizing vibration and noise in industrial and automotive applications. With increasing consumer demand for quieter vehicle interiors, automotive components are now subject to stricter noise and vibration standards. This study investigates the noise generated by fuel supply modules, which play a critical role in delivering pressurized fuel to engines while maintaining low noise levels. An overview of rotor balancing standards is presented, followed by an analysis of how varying degrees of unbalance influence the vibration and noise characteristics of fuel supply modules. To achieve this, rotors were assembled on electric pump samples with defined upper and lower limits of unbalance and conducted tests at the Robert Bosch Ltda laboratory. Utilizing frequency domain analysis, we examined the vibration and noise signals to identify fundamental and harmonic frequencies, thereby assessing the impact of unbalance on overall performance. Measurements were
Aguiar, Rayssa Moreno Silva, Azevedo Fernandes, Luiz Eduardo, Oliveira Melo, Lazaro Benedito, Laura, Ana, Souza, Lima, Boa, Nathan Barroso Fonte
Enhancing Energy Absorption in Rear Impact Events through Rail Extension Design and Material Variations2025-36-0096To be published on 12/18/2025
Safety improvements in vehicle crashworthiness remain a primary concern for automotive manufacturers due to the increasing complexity of traffic and the rising number of vehicles on roads globally. Enhancing structural integrity and energy absorption capabilities during collisions is paramount for passenger protection. In this context, longitudinal rails play a critical role in vehicle crashworthiness, particularly in mitigating the effects of rear collisions. This study evaluates the structural performance of a rear longitudinal rail extender, characterized by a U-shaped, asymmetric cross-section, subjected to rear-impact scenarios. Seventy-two finite-element models were systematically developed from a baseline configuration, exploring variations in material yield conditions, sheet thickness, and targeted geometric modifications, including deformation initiators at three distinct positions or maintaining the original geometry. Each model was simulated according to ECE R32 regulation
Souza Coelho Freitas, Victor de, Pereira, Romulo Franco, Souza, Daniel Souto de
Vehicle Electrical Architecture: A Review of Wiring Harness Routing Optimization Strategies2025-36-0130To be published on 12/18/2025
The modern vehicle electrical architecture consists, on average, of 30 integrated electronic modules (ABS, infotainment, instrument panel, etc.), also known as Electronic Control Units (ECUs), and approximately 300 peripherals such as sensors (collision, temperature, oxygen, position, pressure, etc.) and actuators (window motor, mirror motor, relays, airbag inflator, windshield wiper, etc.). This increase in component integration imposes significant challenges to system installation and design. The interconnection of multiple devices renders harness design an arduous and time-consuming task, especially when conducted manually, resulting in error-prone and suboptimal outcomes. Such a scenario highlights the pressing need for studies on harness routing optimization in the automotive industry. Historically, wiring harness design practices have transitioned from manual approaches to the adoption of advanced computational tools. This methodological transition encompasses the use of various
Ribeiro, Thiago, Reis, Breno, Barreto, Zeus, Galeno, Antônio, Pereira, Marcelo, Ferreira, Fláavio Fabrício V. M.
Shock Dynamics Analysis of Opening Process of Spring Mechanism for Circuit Breaker2025-99-035412/17/2025
In order to accurately evaluate the strength and stiffness of the key components of the spring mechanism for circuit breakers under strong impact load conditions, and provide strong data support for product design and structural optimization, the impact dynamics analysis method is used to model and simulate the spring mechanism. The dynamic stress test data is used to verify the accuracy of the simulation, and the strength of the key components under impact conditions is obtained. The influence of different stiffness frames on the output shaft offset is analyzed.
Guo, Mingqin, Li, Junfeng, Yin, Tianshuo, Zhang, Pan, Li, Pengzhen, Wang, Pengchao, Ji, Linhao
Multi-Fault Analysis of Aircraft Main Landing Gear Retraction Hydraulic System2025-99-030112/17/2025
Aiming at the common health performance influencing factors of the aircraft’s main landing gear retracting hydraulic system, based on its hydraulic structure, the landing gear retracting control AMESim hydraulic system model is established to carry out the study of the typical faults of the aircraft landing gear retracting hydraulic system, such as injection of the hydraulic pump internal leakage, hydraulic oil contamination, and leakage of the actuator cylinder. The curve diagrams of the simulation results are analyzed, and the conclusions of the influence of typical faults on the boundary conditions on the pressure and flow of the hydraulic system are drawn. The results of the simulation are analyzed, and the effect of typical fault boundary conditions on the pressure and flow of the hydraulic system is concluded, which provides a reference for the study of parameter optimization, fault analysis, and health management of the landing gear in engineering applications.
Yu, Yahui, Cui, Wenhao
Study on the Mechanical Properties of a High-Strength Aluminum Alloy Profiles2025-99-033212/17/2025
Compared to steel, aluminum alloy has the advantages of light weight, high specific strength, corrosion resistance, and easy processing, and is widely used in structures such as aviation, construction, bridges, and offshore oil platforms. All along, Chinese construction aluminum profiles have been produced according to the GB/T5237-XXXX standard, which is determined based on the mechanical performance requirements of doors and windows and the actual processing of aluminum profiles. There are many problems. The author of this article has developed a new product 6063-T56, which has a tensile strength of 240-260Mpa and an elongation rate of not less than 8%, surpassing the latest technology level in Europe. It has been promoted and applied to the aluminum profile production industry in China, improving product performance, reducing production costs, improving production efficiency, and meeting the requirements of the "Aluminum Alloy Doors and Windows Standard" GB/T8478-2020, making
Qiao, Zhou
Qualification Tests of Civil Aircraft Tire2025-99-035112/17/2025
Tire is the only part of the aircraft that contacts the ground, which not only bears the vertical load and lateral load of the whole aircraft, but also provides adequate ground friction to decelerate the aircraft when braking, so the tires are important parts for aircraft take-off and landing. Besides safety concerns, tire physical properties such as vertical, lateral stiffness as static performance and rolling relaxation length, yawed rolling cornering force as dynamic performance are often required by aircraft manufacturers for analyzing aircraft maneuverability. Besides analysis or similarity by experience from other aircraft projects, tires are often qualified by a number of tests, both static and dynamic, to ensure the safety of tires and acquire tire physical performance data.
Ji, Teng
Research on Abnormal Noise in an Inline Six-Cylinder Engine Based on Sound Source Localization and Modal Analysis2025-99-032112/17/2025
This study addresses the abnormal noise issue in an inline six-cylinder engine during acceleration through noise testing and near-field microphone array-based sound source localization, combined with engine modal coupling theory and analytical methods. The results of testing and modal analysis indicate that the overlap of modal parameters between the engine crankshaft system and cylinder block leads to structural resonance under high-speed operation, which is identified as the root cause of the abnormal noise. The diagnostic conclusion was further validated through experimental verification. To mitigate the resonance, a high-stiffness spacer block was added between the vibration damper and crankshaft to adjust the overall modal parameters of the crankshaft system. This optimization effectively avoided resonance, reducing the near-field noise at the engine front end by 3.9 dB(A). The findings provide valuable insights for abnormal noise diagnosis and optimization strategies in engine
Hu, Li, Dong, Jian, Wan, Yeqing, Tian, Ruili, Xu, Maolin, Zhang, Min
Lightweight Design and Optimization of Multi-Terrain Multi-Functional Tracked Amphibious Vehicle2025-99-032412/17/2025
In view of the complex intertidal terrain challenges faced by offshore wind power maintenance, this paper optimizes the lightweight design of multi-terrain tracked vehicles. The structure was optimized by finite element analysis, and the maximum stress was 211.68 MPa ( lower than the safety limit of 230 MPa), and the maximum deformation was 5.25 mm, which ensured the stability and stiffness. Titanium alloy has the advantages of high strength, low density and corrosion resistance, which improves the durability of the frame while reducing the weight of the frame. Advanced manufacturing technologies such as phase transformation superplastic diffusion welding optimize the connection between TC4 titanium alloy and stainless steel. Modal analysis and optimization techniques refine the structural parameters and improve the complex load performance. The research promotes the lightweight of the frame and provides theoretical and technical support for the design of multi-terrain vehicles.
Xu, Han, Xu, Shilin, Ma, Wenbo, Zhu, Wei
Lateral Force Analysis of Clamping Devices and Nose Landing Gear in Cornering Conditions2025-99-030612/17/2025
To further investigate the effects of the clamping mechanism’s tilt angle and the nose landing gear’s turning angle on the lateral force of the nose landing gear during turning with a towbarless tractor, as well as the changes in the lateral force difference between the inner and outer hinges, a three-dimensional model of the towbarless tractor and the aircraft was first created using SolidWorks software. The dynamic simulation of the model under different conditions was then conducted using Adams software, followed by the analysis of the simulation results. The results indicate that introducing a positive clamping angle leads to an increase in the clamping mechanism’s tilt angle and a decrease in the nose landing gear’s turning angle as the turning radius and speed increase. Consequently, the lateral force difference between the inner and outer hinges of the nose landing gear increases, ranging from 40 kN to 70 kN. To ensure the stability of the clamping device and reduce the lateral
Gao, Jianshu, Hao, Shiyu, Liu, Ziao
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