Browse Topic: Body structures

Items (4,725)

Innovation Powered by High-Fidelity Multiphysics Modeling: A Holistic System Optimization of BorgWarner’s Next Generation Integrated Drive Modules

2026-01-0497

To be published on 04/07/2026

In the stringent market of BEV, the development of integrated Drive Modules (iDM) fitting environmental and customer needs is mandatory. It is important to extract the best from the less. To achieve those goals, a deep insight into complex multiphysics phenomena occurring in an iDM has been achieved by accurate and validated models. This engineering methodology is applied through the development of BorgWarner products, comprising non-exhaustively iDM 180-HF, Externally Excited Synchronous Machine and Multi-Level Inverter. The paper will review the methodology development for deeper understanding involving in-house technical excellence and complemented by strategic partnerships with academic institutions and start-ups. It will present the approach of integrating advanced multiphysics models with high-quality experimental validations, specifically on loss evaluation on electrical machines and inverters. Complex models involving multiphysics such as thermal/fluid coupling or electric

Leblay, Arnaud, Bourniche, Eric, Bossi, Adrien, David, Pascal, Nanjundaswamy, Harsha

A Study on the Relationship between Impact Conditions and Head Injury Criterion (HIC) in Powered-Two-Wheeler to Car Crashes

2026-01-0571

To be published on 04/07/2026

Road Traffic crash statistics highlight the importance of reducing fatalities among Powered-Two-Wheeler (PTW) riders, and suggest the necessity of a robust method to evaluate PTW crashworthiness performance. The objective of this study is to clarify the relationship between impact conditions and the Head Injury Criterion (HIC) to establish a fundamental basis for determining representative crash configurations for safety. A total of 1,272 PTW-front to car-side impact simulations were conducted by using production car and PTW models. HIC was used as a metric indicating likelihood of head injury. Velocities, impact angle, and impact locations were varied to create response surfaces. The surfaces were evaluated in terms of their accuracy in identifying the representative impact conditions. In addition, head trajectories were analyzed to clarify the kinematics until head impact. The Finite Element (FE) simulations produced the following findings. The HIC distribution by Head Impact Target

Yanaoka, Toshiyuki, Gunji, Yasuaki, Zulkipli, Zarir Hafiz, Matsushita, Tetsuya, Carroll, Jolyon, Puthan, Pradeep, Mohd Faudzi, Siti Atiqah, D-Wing, Kak, Miyazaki, Yusuke

Development of a System for Enhancing Regression Using Shape Generation AI for Hood Stiffness

2026-01-0499

To be published on 04/07/2026

This study proposes a method to enhance regression models by shape generation AI. The approach focuses on automatically identifying regions within the design space where the model’s prediction accuracy is low. Once these regions are identified, new and diverse sample shapes are automatically generated by the shape generation AI and incorporated into the training dataset. The regression model is then retrained to improve its performance. By iteratively repeating this cycle of exploration, shape (FE mesh) generation, and model updating, the model’s reliability and accuracy across the entire design space are progressively enhanced. This method addresses data sparsity issues common in complex design tasks and enables better generalization to underrepresented regions. The effectiveness of the proposed system was demonstrated through a case study involving hood outer panels in automotive design. The results showed that adding AI-generated shapes improved prediction accuracy, particularly in

Taniguchi, Mashio

Design, Fabrication, and Assessment of a User-Friendly Suspension System for a 2025 BAJA Vehicle

2026-01-0588

To be published on 04/07/2026

A suspension system was designed, fabricated, and tested following a systems design approach by an SAE Off-road Team from a North Midwest university. Compared to previous suspensions, the new suspension system is more reparable and contains a minimal number of custom parts, while still maintaining sufficient strength to withstand dynamic loads experienced when operating the vehicle. Modifications were also made to fit the newly designed vehicle body frame. As an integral part of the team’s 2025 Baja vehicle, the redesigned suspension system contributed to the vehicle’s improved performance during the 2025 SAE (Society of Automotive Engineers) Baja Competition. This paper presents a detailed account of the design, development, and fabrication process of the suspension system. The final design was tested and evaluated via both computer simulations and physical tests, whose efficiency and reliability were finally demonstrated by the team’s improved ranking in the 2025 Baja SAE Competition

Liu, Yucheng, Anderson, Matthew, Larson, Cody, Rodgers, Joshua, Seberger, Aaron, Letcher, Todd

Development and Application of CAE Methods for Predicting Snow Accumulation on Floor Undercovers During Snowy Road Driving.

2026-01-0482

To be published on 04/07/2026

This study presents a simulation method for reproducing slush accumulation on underbody components, with a particular focus on the floor undercover, during vehicle operation on slush-covered roads. As electrified vehicles become increasingly important in the pursuit of carbon neutrality, the adoption of aerodynamic undercovers to improve driving range has accelerated. However, these components are exposed to various environmental stresses, including water, chipping, and especially snow and slush, which can lead to damage and performance degradation. While previous research has addressed water and chipping stresses through simulation, studies on slush-induced stress have been limited. To address this gap, the Moving Particle Semi-implicit (MPS) method was applied, incorporating a power-law model to represent the non-Newtonian flow characteristics of slush. Parameter identification was conducted through steel ball drop tests and tire scattering tests, ensuring both qualitative and

Matsuura, Tadashi, Annen, Teruyuki, Harada, Takeyuki, Ueno, Shigeki, Asai, Mikio, Watanabe, Haruyuki

CAE Acceleration with Machine Learning for Results Prediction

2026-01-0488

To be published on 04/07/2026

Industries are following a tedious product development cycle for developing their product. In product development major steps includes design ideas, Drawings, CAD, CAE, Testing and design improvement cycle. This is a monotonous process and takes time which impacts on its time to deliver product and cost on development. Now a days industries are fast growing and targeting to reduce development cycle time and cost. AI&ML is impacting almost all areas in the industry and significantly reducing efforts time and cost. To make use of AI&ML in CAE, Altair Physics AI is an effective tool. To ensure the design of product traditional way is to develop a CAD of the product, develop, perform CAE and analyze performance. If we consider CAE procedure it is time consuming process which includes FEA model build, applying boundary conditions, running simulation and analyzing results which could take minutes to hours. By using ML with Physics AI we can make predictions on new design of the product in

Dangare, Anand Manohar, Kulkarni, Mandar

Design and Simulation Analysis of an Integrated Honeycomb-Filled Front Bumper for a Special Vehicle

2026-01-0475

To be published on 04/07/2026

In frontal collisions of automobiles, the bumper beam at the front of the vehicle plays a crucial role in absorbing energy and protecting the vehicle body during a collision. To enhance the collision resistance of a specific type of special vehicle with a non-load-bearing body structure, this paper focuses on this type of vehicle and conducts a study on the design and collision performance of an integrated vehicle front bumper - anti-collision beam structure based on aluminum alloy additive manufacturing technology. A novel bumper structure is proposed, which integrates the front bumper and the front anti-collision beam of the vehicle and is integrally formed using aluminum alloy additive manufacturing technology. This integrated structure is directly connected to the vehicle frame. Firstly, based on the appearance of the special vehicle body and the form of the front anti-collision beam of traditional passenger vehicles, an integrated design of the vehicle front bumper- anti-collision

王, Xufan, Yuan, Liu-Kai, Zhang, Tangyun, Wang, Tao, Zhang, Ming, Wang, Liangmo

Investigation of the Blockage Phenomenon in Closed Wall Wind Tunnels during the Testing of Bluff Automotive Bodies with Small Wakes in Yawed Configurations

2026-01-0607

To be published on 04/07/2026

The difficulties of testing a bluff automotive body of sufficient scale to match the on-road vehicle Reynolds number in a closed wall wind tunnel has led to many approaches being taken to adjust the resulting data for the inherent interference effects. But it has been difficult to experimentally analyze the effects that are occurring on and around the vehicle when these blockage interferences are taking place. The present study is an extension of earlier works by the authors and similarly to those studies uses the computational fluid dynamics analysis of five bodies that generate small wakes to examine the interference phenomena in solid wall wind tunnels. This focuses on the effects on the pressures, and forces experienced by the vehicle model when it is in yawed conditions up to 20 degrees. This is accomplished by executing a series of CFD configurations with varying sized cross sections from approximately 0.4% to 14% blockage enabling an approximation of free air conditions as

Gleason, Mark, Riegel, Eugen

HaloBus: Edge Computing-Enabled Real-Time Boarding and Exit Detection for Enhanced Transportation Safety Using Lightweight AI

2026-01-0555

To be published on 04/07/2026

This paper proposes HaloBus, an innovative, edge-computing solution designed to mitigate this risk by detecting student boarding and exiting in real time using lightweight AI based methods. A persistent challenge in elementary school transportation is the issue of missing students after they exit their buses, which disproportionately impacts low-income households. Current safety systems place the burden of implementation on individual households, often requiring independent methods. Common methods include applications on a personal device or a small tracker. However, not everyone can afford these options, and ensuring child safety is a primary concern for parents and caregivers. That is why HaloBus was invented. The system employs YOLOv5us—an Ultralytics-enhanced, anchor-free, split-head architecture that offers a superior accuracy speed trade-off. By providing real-time, on-device alerts, HaloBus enables immediate intervention to prevent a student from being left behind, thereby

Getz, Grayson, Zadeh, Mehrdad, Tan, Teik-Khoon

Acoustic Improvements to a Passenger Service Unit Panel with Core Filler and Facesheet Patches using Topology Optimization

2026-01-0511

To be published on 04/07/2026

Passenger comfort is becoming the forefront of luxury private jets where noise needs to be kept to a minimum. One source of structure-borne noise is the vibration of the Passenger Service Unit (PSU) panel. These vibrations originate from the outer skin, excited by turbulent boundary layer, and are transmitted through the fuselage frame to the PSU panel. This panel resides overhead of passenger seating, it is composed of a corrugated honeycomb core sandwiched between thin face-sheets. This paper presents a systematic approach to improve the vibro-acoustic performance of a honeycomb core sandwich structure by employing core filler and facesheet patches. Topology Optimization (TO) is used to determine the optimal layouts of these design modifications. The vibro-acoustic performance of the PSU panel with facesheet patches and core filler is evaluated using a frequency response analysis in the commercial finite element solver OptiStruct. The effectiveness of vibration reduction will be

Russo, Connor, Whetstone, Isobel, Patel, Anuj, Wotten, Erik, Kim, Il Yong

Jute-Polyester Trim as a Novel Vehicle Upper Interior Head Impact Safety Countermeasure

2026-01-0567

To be published on 04/07/2026

A significant fraction of annual global human mortality is caused by severe head injuries resulting from vehicle crashes. In order to ensure upper interior head impact safety in vehicles, stiff upper body pillars are covered with plastic trims often along with internal countermeasures such as fin-type monolithic ribs. In the study being reported here, a consistent Computer-Aided Engineering (CAE) procedure employing explicit nonlinear finite element analysis has been demonstrated for predicting headform impact safety of a steel A-pillar component covered with a novel jute-polyester trim. Using simulation as mentioned combined judiciously with test data and physical reasoning, a number of jute-polyester trim configurations are considered by varying the number of jute plies, and packaging space between trim and A-pillar inner panel. Additionally, jute-polyester trims with internal ribs are considered. The current study reinforces the potential of a jute polymer composite as a vehicle

Karthika, M R, Deb, Anindya, Zhu, Feng

Air Bind Energy Prediction in Door Closing Event Through CFD & Its Accuracy Validation with Physical Test

2026-01-0483

To be published on 04/07/2026

In the automotive industry, the perceived quality of a vehicle is heavily influenced by the ease and effort required to close its doors (which is governed by total door closing energy), particularly when all windows and other doors are closed. A major contributor to increased door closing energy is the air bind energy, a phenomenon caused by the rapid compression of trapped air within a sealed vehicle cabin during door closure. Studies have shown that this transient event leads to a significant rise in cabin pressure. This study presents a Computational Fluid Dynamics (CFD) method to evaluate the impact of air bind energy on door closing during the early stages of vehicle design. By simulating the cabin pressure dynamics during door closure, the research identifies key parameters influencing the air bind energy, such as door closing velocity, pressure relief valve and airflow escape paths. Other mechanical factors like hinge friction, check arm, and door seal etc. are excluded from the

Jagtap, Rohit, Parida, Shaswati, Pimpalkhare, Ninad, Khanna, Susheel, Pasunurthi, Shyam Sundar

ProGuard: A Real-Time Preemptive Artificial Intelligence-Based Anti-Pinch System for Bus Entryways on Low-Power Edge Devices

2026-01-0100

To be published on 04/07/2026

This paper proposes ProGuard, a novel approach to preemptive pinch detection systems for buses. ProGuard utilizes state-of-the-art AI object detection algorithms to identify potential pinching events in bus entryways before pinching occurs. Modern conventional anti-pinch systems, such as pressure sensors or hall effect sensors, often rely on mechanical contact before triggering. While these systems are established safety mechanisms, they are reactive and therefore require some level of pinching before triggering. This reactive approach presents numerous safety concerns for passengers, especially when considering children on school buses. Existing preemptive detection methods, such as infrared or ultrasonic sensors, solve the problems presented by these reactive detection systems. However, these systems either lack the range or environmental resilience needed for reliable operation in buses. The critical nature of anti-pinch systems requires a robust and reliable solution that can adapt

Bradley, Hudson, Zadeh, Mehrdad, Tan, Teik-Khoon

Elucidation of Flow Mechanisms Modulating Vehicle Wind Noise by Using Large-Scale CFD Simulation

2026-01-0614

To be published on 04/07/2026

In vehicle development, noise reduction is critical for ensuring passenger comfort. As electric vehicles become prevalent and engine noise is minimized, wind noise becomes more noticeable. Modulated wind noise, which causes a sense of fluctuation due to atmospheric turbulence, wind gusts, and preceding vehicle wakes, can cause significant discomfort. This noise is characterized as a high frequency sound above 1 kHz, modulated at low frequencies owing to the wind velocity and direction fluctuating at several Hz. The mechanisms behind wind noise modulation are not fully understood, and no established countermeasures have been developed. This is because wind noise perceived through the side window is primarily caused by the A-pillar vortex and door mirror wake, which coexist as complex turbulent flows around the vehicle. Therefore, identifying the source of modulated wind noise around vehicles under fluctuating wind conditions is difficult. This study aims to identify the source of the

Tajima, Atsushi, Hirata, Takumi, Ikeda, Jun, Kamiwaki, Takahiro, Wakamatsu, Junichi, Tsubokura, Makoto

Integrated Welding Simulation and Experimental Characterization of Weld-Metal and Heat-Affected-Zone Strength in AA6063-T6

2026-01-0230

To be published on 04/07/2026

In the context of automotive lightweighting and efficient manufacturing, welding is a key joining method for aluminum body structures due to its maturity, versatility, and cost effectiveness. This study investigates MIG butt welding of AA6063-T6 sheets using a sequential thermo-mechanical finite element model with a double-ellipsoid heat source. Thermocouple histories and macroscopic metallography of the weld-pool morphology are used to validate the predicted temperature field, and post-weld deformation measured by a coordinate measuring machine is compared with the simulation to confirm overall model reliability. Hardness mapping across the joint partitions the material into weld metal (WM), heat-affected zone (HAZ), and base metal (BM). Miniature tensile specimens extracted along the weld provide local mechanical properties, from which linear strength–hardness relations are established. Building on these results, a five-material equivalent strength model covering WM, HAZ-I, HAZ-II

Shao, Jiyong, Meng, Dejian, Xiang, Yao, Gao, Yunkai

Determining Video Frame Capture Rate through Reverse Engineering

2026-01-0543

To be published on 04/07/2026

The timing of video recordings, along with the spatial positioning of objects, is a fundamental parameter for calculating the speed time history. If the task involves determining the average speed of an object moving at approximately constant speed, it may be acceptable to average the speed over several to a dozen frames, using the fps (frames per second) parameter as the basic time unit.. However, if the objective is to compute speed from individual frames, the reliability of the timing becomes crucial. Without access to DVR hardware documentation, proprietary algorithms, or software – and considering the frequent hardware modifications and software updates - the most effective way to solve the problem is through a reverse-engineering approach. This study discusses several aspects of timing analysis, including: (1) making a test recording of a calibrated LED lightboard; (2) analyzing the relationship between the lightboard time and the presentation time stamp (pts) extracted from the

Wach, Wojciech

SUNRISE - A Harmonised Safety Assurance Framework For Connected, Automated Mobility Systems

2026-01-0060

To be published on 04/07/2026

Safety assurance of Cooperative, Connected, and Automated Mobility (CCAM) systems is a crucial factor for their successful adoption in society, yet it remains a significant challenge. The SUNRISE project has consolidated previous and on-going efforts, and developed a harmonised Safety Assurance Framework (SAF) designed to operationalise the UNECE New Assessment/Test Method (NATM), targeting a wide range of stakeholders including (but not limited to) certifiers, regulators, manufacturers, suppliers, researchers, and assessors. It incorporates a scenario-based approach, underpinned by the system’s Operational Design Domain (ODD) and behaviour for safety assessment. In line with NATM, the SAF consists of multiple pillars: the Audit of manufacturer processes and Safety Management Systems, In-Service Monitoring and Reporting (ISMR) to ensure continued safety during deployment, and Performance Assurance to generate and evaluate safety evidence pre-deployment. While all pillars are integral

Zhang, Xizhe, Khastgir, Siddartha, de Vries, Stefan, Hillbrand, Bernhard, Op den Camp, Olaf, Bolovinou, Anastasia, Bourauel, Bryan, Ehrenhofer Gronvall, John Fredrik, Menzel, Thaddäus, Nieto, Marcos, Stettinger, Georg, Jennings, Paul

Ultra-Low Latency Video Pipeline Optimization for Perception-Centric Autonomous Systems

2026-01-0022

To be published on 04/07/2026

Autonomous platforms such as self-driving vehicles, advanced driver-assistance systems (ADAS), and intelligent aerial drones demand real-time video perception systems capable of delivering actionable visual information at ultra-low latency. High-resolution vision pipelines are often hindered by delays introduced at multiple stages—sensor acquisition, video encoding, data transmission, decoding, and display—undermining the responsiveness required for safety-critical decision making. This study introduces a holistic system-level optimization framework that systematically reduces end-to-end video latency while maintaining image fidelity and perception accuracy. The proposed approach integrates hardware-accelerated encoding, zero-copy direct memory access (DMA), lightweight UDP-based RTP transport, and GPU-accelerated decoding into a unified pipeline. By minimizing redundant memory copies and software bottlenecks, the system achieves seamless data flow across hardware and software

Indrakanti, Rama Kiran Kumar

OFEODM: An Vehicle Onboard Fast and Efficient Object Detection and Distance Prediction Model

2026-01-0017

To be published on 04/07/2026

Object detection and distance prediction have advanced significantly in recent years. The YOLO toolbox has released its 11th version, along with numerous variants that have been applied across various fields. Meanwhile, the Detection Transformer (DETRs) has repeatedly set new state-of-the-art (SOTA) records in the field of object detection. Depth Anything also released its second version last year, further pushing the boundaries of distance detection. Although these models achieve impressive performance, they often require substantial computational resources. However, for the algorithms intended for real-world applications and deployment on onboard devices, computational efficiency are extremely critical. Inference time per frame is a critical factor in ensuring an algorithm’s reliability and feasibility. Designing a model that operates in real time without sacrificing accuracy remains an extremely challenging problem, and extensive research is ongoing in this area. To address this

Li, Taozhe, Wang, Hanchen, Hajnorouzali, Yasaman, Xu, Bin

Wind-Tunnel Investigation of Snow/Ice Drag on a 30%-Scale DrivAer Model

2026-01-0604

To be published on 04/07/2026

Wind-tunnel tests were conducted using a 30%-scale DrivAer model, in estateback and notchback rear-geometry configurations, to investigate aerodynamic performance changes associated with snow and ice buildup on passenger vehicles. Around 20 snow/ice accumulation patterns were tested, at a Reynolds number of 2.8 × 106 based on model wheelbase, for each of the notchback and estateback variants. 5 additional patterns were tested on the estateback with roof-rack support bars. Snow accumulation was modelled with foam, while ice accumulation was simulated with aluminum tape hand-formed to the desired shape. A simulated full-scale snow thickness of 58 mm on the hood, roof and trunk increased the wind-averaged drag coefficient by 16% for both model variants. With 90 mm of snow, the drag of the estateback variant increased by 19%. Drag changes increased with, but were not proportional to, snow thickness. Chamfered front and rear edges, representing windblown shapes, reduced the drag penalty

de Souza, Fenella, McAuliffe, Brian

Effects of Vehicle Speed, Category, and Front-End Design on Full-Body Injury Risks of a Midsized Male Pedestrian

09-14-01-0017

3/28/2026

This study investigated how vehicle front-end geometry, impact speed, and vehicle category influence injury risk to a midsize male pedestrian. Eighty-one generic vehicle (GV) models representing sedans, sport utility vehicles (SUVs), pickup trucks, and minivans sold in the United States were developed by morphing three base models using an automated pipeline. Front-end parameters that were varied included ground clearance (GC), bumper height (BH), hood leading-edge (HLE) height, hood length (HL), bumper lead angle (BLA), hood angle (HA), and windshield angle (WSA). Each vehicle impacted the Global Human Body Models Consortium 50th percentile male simplified pedestrian (GHBMC M50-PS) model at 30, 40, and 50 kph, totaling 243 simulations. Boundary conditions followed the European New Car Assessment Program (Euro NCAP) pedestrian test protocol. Thirty-five injury metrics were extracted across the head, neck, thorax, abdomen, pelvis, and lower extremities. Linear mixed-effects regression

Poveda, Luis, Miller, Logan E., Edwards, Colin C., Pollock, Madeline, Armstrong, William M., Hsu, Fang-Chi, Gayzik, Scott F., Weaver, Ashley A., Stitzel, Joel D., Devane, Karan S.

Failure Cause Analysis of Valve-Regulated Lead-Acid Battery on Fire in Communication Equipment Room

2026-01-7022

2/27/2026

This paper carried out the fire failure analysis of valve-regulated lead-acid battery in communication equipment room. Through disassembly and observation of the battery and iron frame of battery cabinet in the area of fire origin, we obtained the key residual traces and used the physical and chemical analysis methods such as macroscopic/microscopic morphology, EDS, X-ray and metallographic, it was finally judged that the leakage of the battery electrolyte lead to the connection of the battery electrode plate and the iron frame and subsequently the electric heating fault caused the fire accident. Furthermore, we put forward some suggestions according to the existing problems, which may contribute to the prevention of similar failures.

Guo, Yuhang

Design evolution of Novel Subframe for a Multilink Rear Suspension of an e-SUV

2026-28-0007

2/12/2026

As there is a major shift in customer demand for energy efficient transportation, electric vehicle development has taken prominence worldwide as they provide pollution free and noise free mobility. The subframe being an important structural component of the chassis system, the designers always find it challenging to provide best-in-class rear subframe (RSF) optimized in terms of cost and weight within the available packaging space especially in an electric sport vehicular boundary. The main function of rear subframe is to transmit forces to BIW without deflections hence for this it should be very stiff. At the same time, it should be light in weight and simpler to industrialize. In the present work, the design evolution of a novel sub-frame assembly for a multilink rear suspension of a born electric sports utility vehicle (e-SUV) platform is detailed. With increased rear axle weight contributed by the battery weight and rear mounted motor, the design evolution of the rear subframe (RSF

Nidasosi, Basavraj Maruti, J, Ramkumar, Nayak, Bhargav, Mani, Arun, M, Sudhan

Accidental Dooring Warning and Assist System

2026-28-0053

2/12/2026

Dooring accidents occur when a vehicle door is opened into the path of an approaching cyclist, motorcyclist, or other road user, often causing serious collisions and injuries. These incidents are a major road safety concern, particularly in densely populated urban areas where heavy traffic, narrow roads, and inattentive behavior increase the likelihood of such events. To address this challenge, this project presents an intelligent computer vision based warning system designed to detect approaching vehicles and alert occupants before they open a door. The system can operate using either the existing rear parking camera in a vehicle or a USB webcam in vehicles without such a feature. The captured live video stream is processed by a Raspberry Pi 4 microprocessor, chosen for its compact size, low power consumption, and ability to support machine learning frameworks. The video feed is analyzed in real time using MobileNetSSD, a lightweight deep learning object detection model optimized

C, Jegadheesan, T, Karthi, Gurusamy, Varun Sankar, Balraj, Tharun, Murugaiya, Tamilselvan

Establish Relation of Car Door Window Glass Opening on Door Assembly Dynamic and Vibrational Behavior

2026-01-5006

2/2/2026

Window glass is a component of the side door assembly of cars. It provides a clear vision for passengers and outsiders. It functions as a temporary opening and ventilation system for the car. It is a part of a car’s aesthetics; it adds stiffness to the door and protects the occupants from different weather conditions. The objectives of this study were to understand the effect of fully and partially opened or closed window glass on the dynamic behaviors of door assemblies and to develop a process to assess these dynamic behaviors. An assessment methodology was developed to determine the effects of various window glass positions on the dynamic behavior of the door assembly. An authenticated finite element (FE) model was used to complete this investigation. The finite element model of the door assembly was validated by correlating the modal frequencies with their corresponding mode shapes. The correlated FE model with the window glass fully closed was called the baseline (W0), and eight

Jadhav, Pandurang Maruti, Waghulde, Kishor B., Bhortake, Rupesh V.

Accelerating down the road to AUTONOMY

26TOFHP02_02

2/1/2026

Commercial success of the autonomous truck may be closer than we think. The last half decade has brought the best of times and worst of times for the commercial autonomous truck sector. While some perceived pillars of this technology have fallen, others have continued to carry the weight of bringing driverless trucks closer to commercialization. Consolidation was inevitable given the volume of speculative investment that brought a tidal wave of capital to various startups. Even so, some industry experts and Wall Street investors wondered if the autonomous truck sector might collapse entirely.

Wolfe, Matt

Side Crash Pressure Sensor Response Prediction: CPM Approach

2026-26-0413

1/16/2026

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

Method and System of Detecting Obstacle around Vehicle Door

2026-26-0026

1/16/2026

Vehicle door-related accidents, especially in urban environments, pose a significant safety risk to pedestrians, infrastructure and vehicle occupants. Conventional rear view systems fails to detect obstacles in blind spots directly below the Outside Rear View Mirror (ORVM), leading to unintended collisions during door opening. This paper presents a novel vision-based obstacle detection system integrated into the ORVM assembly. It utilizes the monocular camera and a projection-based reference image technique. The system captures real-time images of the ground surface near the door and compares them with calibrated reference projections to detect deviations caused by obstacles such as pavements, potholes or curbs. Once such an obstacle is detected the vehicle user is alerted in the form of a chime.

Bhuyan, Anurag, Khandekar, Dhiraj, Jahagirdar, Shweta

Advanced Driver Assistance for Sunroof Misuse: Alarm Trigger and Speed Limiting System

2026-26-0041

1/16/2026

Sunroof-equipped vehicles are gaining rapid popularity in India, especially among young and urban users. However, unsafe practices like occupants protruding through the sunroof during driving have led to increasing injuries and fatalities, particularly in sudden braking or collisions. This behavior, prohibited under the Motor Vehicles Act, remains an overlooked safety risk in today’s vehicles. This paper presents an industry-first innovation: an Automated Safety Alarm and Speed Control System designed to detect and prevent sunroof misuse. Using integrated photoelectric and infrared beam sensors, the system detects human extension beyond the sunroof boundary while the vehicle is in motion. Upon detection, it triggers a tiered safety response: an immediate dashboard warning, an audible alert if vehicle speed exceeds 15 km/h and an active speed limiter that restricts vehicle speed to 20 km/h until safe conditions are restored. This marks a shift from passive warnings to active vehicle

Padmanapan, Gopi, Yadav, Sanjeev

Experimental Evaluation of Metro Rail Bogie Frame through Bench Testing

2026-26-0561

1/16/2026

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 an 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 initial design phase. This helps to verify and evaluate the design and validate the quality of metro rail frame as per the requirement specified in EN13749:2021 European standard in early design stages.

Tormal, Uday Bapurao, Sinnarkar, Nitin, Shinde, Vikram

Wireless Charger Packaging in Peculiar Rear Door Trim Profile

2026-26-0270

1/16/2026

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

Accelerating Sunroof System Development with Modular Hardware-in-the-Loop Testing

2026-26-0519

1/16/2026

This paper presents a novel Hardware-in-the-Loop (HiL) testing framework for validating panoramic Sunroof systems independent of infotainment module availability. The increasing complexity of modern automotive features—such as rain-sensing auto-close, global closure, and voice-command operation—has rendered traditional vehicle-based validation methods inefficient, resource-intensive, and late in the development cycle. To overcome these challenges, a real-time HiL system was developed using the Real time simulation, integrated with Simulink-based models for simulation, control, and fault injection. Unlike prior approaches that depend on complete vehicle integration, this methodology enables early-stage testing of Sunroof ECU behavior across open, close, tilt, and shade operations, even under multi-source input conflicts and fault conditions. Key innovations include the emulation of real-world conditions such as simultaneous voice and manual commands, sensor faults, and environmental

Ghanwat, Hemant, Lad, Aniket Suryakant, Joshi, Vivek, More, Shweta

Automotive Body Structures’ Section and Joint Enhancement towards NVH Performance

2026-26-0331

1/16/2026

A primary focus of an automotive architecture development is to efficiently distribute the mass, energy, and stiffness throughout the body structure. The car body structure is integrated with load carrying members, pillar structures, panels, and joints. These structural members play a significant role in meeting the body in white (BIW) performance within weight targets. The initial development stage of the vehicle architecture has a flexibility to change the sections and joints as compared to the later stages. An effective utilization of the primary stage of the design will minimize the efforts during the later stage of the performance improvements. One of the critical performance metrics of the BIW is noise vibration and harshness (NVH). For better NVH performance, the BIW must meet certain stiffness and mass requirement that is specific to the vehicle configuration and type. A good design strategy of the section parameters of structural members along with stiffer joints will assist

Senthilkumar, Vibeesh, Raghuvanshi, Jayeshkumar, Lakshe, Shailesh

Challenges in Head-Up Display (HUD) Design for Modern Connected Vehicles: Balancing Functionality with Structural Integrity in an NVH Landscape

2026-26-0354

1/16/2026

A more recent focus on driver comfort and the increasing demand for wide range of information availability make automotive Original Equipment Manufacturers (OEMs) provide advanced features such as Head Up Display (HUD) system. Even though HUD projects vital information onto the windshield/glass, its structural integration comes with significant vibration challenges, leading to display instability and haziness. This paper discusses the significant design parameters influencing the functional effectiveness of HUD system. The structure considered for analysis is the HUD assembly and its integration in vehicle. Cross Car Beam (CCB) turns out to be the critical component of the vehicle structure susceptible to road excitations. Although it’s mass dampens the vibrations inherently, due to the low mass of the HUD, relative oscillation between its projector, mirror, and either the windshield or display causes image distortion This paper investigates in detail the role of HUD structural

Vardhanan K, Aravindha Vishnu, Naidu, Sudhakara, Titave, Uttam

Innovative Inverted Cross Car Beam Design for Optimized Packaging of Advanced Driver Assistance Technologies in Global Vehicles

2026-26-0051

1/16/2026

The integration of Advanced Driver Assistance Systems (ADAS) into modern vehicles necessitates innovative solutions for interior packaging that balance out safety, performance, and ergonomic considerations. This paper introduces an inverted U-shaped steel tube cross car beam (CCB) as a superior alternative to traditional straight tube designs, tailored for premium vehicle instrument panels. The U-shaped geometry overcomes the limitations of straight tube beams by creating additional packaging space for components such as AR-HUDs, steering columns, HVAC systems, and electronic control units (ECUs). This geometry supports efficient crunch packaging while accommodating ergonomic requirements like H-point, eyeball trajectory, and cockpit depth for optimal ADAS component placement. The vertical alignment of the steering column within the U-shaped design further enhances space utilization and structural integrity. This study demonstrates that the inverted U-shaped CCB is a transformative

Mahajan, Ajay Senu, Regatte, Ganesh, Nagarjuna, Kamisetti, Sahoo, Sandeep, Udugu, Kumaraswamy, JC, Sudheera

Crash Pulse Characterization for the Passenger Vehicle Fleet in India

2026-26-0029

1/16/2026

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

Effect of Pipe Bending by Rotary Tube Bending Process on Durability of Frame Structure

2026-26-0370

1/16/2026

Automobile frames, particularly trellis frame structures, are engineered for superior dynamic performance, with stiffness being a paramount consideration1. These frames frequently utilize welded tubes, a manufacturing process made more complex by the necessity of bending tubes to precise angles to meet packaging and assembly requirements2. This bending, however, induces residual stresses that can substantially compromise the frame's durability3. This investigation employs a detailed finite element simulation to analyse the structural deformation and residual stresses that arise during the bending of Cold Electric Welded (CEW) annealed round pipes4. A comprehensive 3D mechanical model, incorporating realistic tooling and contact interactions, was developed to accurately simulate shape change, ovality, and wall thickness redistribution during the bending process5. CEW pipes, unlike their Electric Resistance Welded (ERW) counterparts, possess minimal initial forming stresses, and the

Rajwani, Ishwar, Khare, Saharash

Development of Door Impact Loads Using Pedal Force Sensor and First Principles

2026-26-0538

1/16/2026

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 or getting into cab etc. Design of these doors and their latches involve a knowledge of the loads arising when the door is shut which usually involves 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 ~8 times. For these problems, structures

Valkunde, Sangram, Ghate, Amit, Gagare, Kiran

Packaging the HPTS Airbag in a Second-Row Seat

2026-26-0033

1/16/2026

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 Automotive industry, safety features are very important, one of the topmost features which falls in this category is airbags. The driver and passenger safety during high impact collisions and sudden crashes is the key objective of airbag. This safety is provided by the airbag with its automatic deployment. The inflatable airbag is engineering in a way to respond very quickly during a collision and furnish necessary cushioning to decrease the impulse and enhance the safety of the passenger. The technology has been practiced widely upon many vehicles' seats. However, the present work highlights a novel approach of packaging the HPTS air bag in second row seat. This Air bag unit is

Buradkar, Rajat, Bose, Karthik, Jadhav, Deepika, Balakrishnan, Gangadharan

Optimizer Sunshade Packaging with Half Aluminum Cassette and Metal Pull Bar

2026-26-0597

1/16/2026

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 packaging of Sunshade in door trim system. Traditional sunshade design, often bulky and increasingly incompatible with the trend towards compact design and packaging. The car sunshade is a shield that is placed on a car side window and used for regulating the amount of light entering from the car window and helps improve the passenger comfort inside the cabin. Car Interior components, specifically plastic and seats are based on thermal stress properties. When we expose these parts to direct contact with sunlight, humidity and ambient temperature above threshold limit, the interior plastic parts can start to soften and melt. Due to this, they start emitting harmful chemicals which cause anemia and poor immune systems. So, the Sunshade, in addition to protecting

Palyal, Nikita, D, Gowtham, Bhaskararao, Pathivada, Bornare, Harshad, Ritesh, Kakade

Optimization of Frontal Impact Force Scheme to Accelerate the Target Setting Process for Development of Front-End Structures in Vehicles

2026-26-0001

1/16/2026

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

Unique Hybrid Panoramic Headliner Clip with High Tolerance to Replace Dual Lock Fasteners

2026-26-0299

1/16/2026

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. [2] The new design achieves precise tolerance control, ensuring reliable headliner installation under varying

D, Gowtham, Kumarasamy, Raj Ganesh, Shoeb, Mohd, Chauhan, Aarti

Analysis of Energy Consumption for Heating City Electric Buses and Ways to Reduce It

2026-26-0156

1/16/2026

For regions with cold climate, the range of an electric bus becomes a serious restriction to expanding the use of this type of transport. Increased energy consumption affects not only the autonomous driving range, but also the service life of the batteries, the schedule delays and the load on the charging infrastructure. The aim of the presented research is to experimentally and computationally determine the energy consumption for heating the driver's cabin and passenger compartment of an electric bus during the autumn-winter operation period, as well as to identify and analyze ways to reduce this energy consumption. To determine the air temperature in the passenger compartment, a mathematical model based on heat balance equations was used. This model was validated using data from real-world tests. The research was conducted at a proving ground under two conditions: driving at a constant speed and simulating urban bus operation with stops and door openings. The causes of heat loss in

Kozlov, Andrey, Terenchenko, Alexey, Stryapunin, Alexander

Analysis of Door Seal Compression and its Influence on NVH Performance in Heavy-Duty Vehicle

2026-26-0339

1/16/2026

This study focuses on the effect of door seal compression prediction and its impact on structure borne NVH in trucks. Customer perception of vibrations are envisaged as quality criteria. It is necessary to determine the contribution of seal stiffness due to seal compression under closed condition of the door rather than considering stiffness of the door seal under uncompressed conditions. The dynamic stiffness of door seal is determined from analysis of non-linear type. The simulations are built using the Mooney - Rivlin model. The parameters influencing the compression of door seals in both two – dimension and three – dimension, are identified from the analysis. This involves contemplating the appropriate 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. As a part of next step, the compressed

L, Kavya, Ramanathan, Vijay

A Scientific Approach to Identify the Source of Intermittent Steering Rattle Noise and Implementing the Design Solutions

2026-26-0346

1/16/2026

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

Optimization of Air Extractor for Improved Door Closing Effort and Perceived Premium Feel

2026-26-0592

1/16/2026

This research analyzes the significance of air extractor on car door closing effort, especially within the context of highly sealed cabins. The goal is to measure their effectiveness in lowering pressure-induced resistance, study how the cut-out cross section and location affect performance, and its contribution to vehicle premium feel. Current vehicle design trends prioritize airtight cabin sealing for improving aerodynamic efficiency, NVH performance. This causes a problem in door closing operation. Air trapped while closing door creates transient pressure pulses. This pressure surge creates immediate discomfort to user i.e., Popping in Ears and requires high door closing force, and long-term durability problems in hinges and seals. In properly sealed cabins, air pressure resistance can contribute to 25% to 40% of total door closing force. Air extractors, usually installed in the rear quarter panels or behind rear bumpers, serve as pressure relief valves, allowing for a smoother

P, Sivasankar, Sankineni, Vikhyath Rao, Shah, Sahil, Marimuthu, Anbarasan

Methodology for Optimizing the Bench Testing of Steering I-Shaft Using Vehicle Level Data to Reduce Overall Product Development Time and Cost

2026-26-0560

1/16/2026

Steering I-shaft with rubber coupling (or hardy disc) is an important part of complete steering system mainly in body on frame (BOF) 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 (Body in white) 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 of 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

Kabdal, Amit

Comprehnsive Measurement and Evidential Evaluation of Driver Drowsiness and Alertness Warning System

2026-26-0520

1/16/2026

The paper aimed to improve the accurate quantification of driver drowsiness and to provide comprehensive, evidence-based validation for a Vision-Based Driver Drowsiness and Alertness Warning System. Advanced quantification of driver drowsiness is designed to enhance distinction of true positive events from False Positive and False Negative events. Methodology to pursue this included assessing inputs such as facial features, driver visibility, dynamic driving tasks, driving patterns, driving course time and vehicle speed. The system is programmed to actively learn Eye Aspect Ratio (EAR) reference and adapt personalised EAR threshold value to process EAR frames against the learnt threshold value. This method optimized the data frames to enhance the evaluation and processing of essential frames, thereby reducing delays in the processor and the Human-Machine Interface (HMI) warning module. Comprehensive validation is systematically conducted within a controlled test track environment to

Balasubrahmanyan, Chappagadda, Akbar Badusha, A

A Novel Approach to Deep Drawing Using Hybrid System and Pneumatic-Assisted Forming

2026-26-0301

1/16/2026

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 suitable for

Chava, Seshadri Reddy, Singh, Prakhar, Dhanajkar, Narendra, Roy, Amlan, Raju, Gokul

An Outer Waist Seal with Integrated Glass Wiping Mechanism for a Window Frame of a Vehicle

2026-26-0011

1/16/2026

This invention solves a significant safety issue where drivers have low visibility of the Outside Rear View Mirror (ORVM) in the case of rain, fog, dust or ice formation on the Side Door Window Glass (SDWG). Currently developed methods, such as hydrophobic finishing or films and heated window glass on the doors, provide temporary or weak results, and thus, a more successful and dependable method is demanded. In order to address this problem, we have modified the Outer Waist Seal, which includes a Glass Wiping Mechanism in it. Outer Waist Seal is a type of weather strip fixed on the bottom of the side window of a vehicle on the panel of the door. It does not allow the flow of heavy water, dust and debris into the door cavity, besides supporting the glass on the window when it is in a movement process. The stationary fixed arm of this system is coupled with a rotating arm and an attached wiper blade powered by a low-speed-high-torque motor and interfaced with the Body Control Module (BCM

Neelam, Rajat, Chowdhury, Ashok, Panchal, Girish, Kumar, Saurav

Items per page:

1 – 50 of 4725