Browse Topic: Body structures

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SUNRISE - a harmonised Safety assUraNce fRamework for connected, automated mobIlity SystEms2026-01-0060To be published on 04/07/2026
The SUNRISE project develops and demonstrates a harmonised Safety Assurance Framework (SAF) for Connected, Cooperative and Automated Mobility (CCAM) systems. The framework has been created in close alignment with the UNECE New Assessment/Test Method (NATM), and past and on-going international projects and initiatives. It also aligns with standardisation efforts in various standardisation bodies such as ISO, ASAM, SAE, and BSI. At the core of the SAF lies the Performance Assurance flow, which structures how safety evidence is generated and assessed. This flow is organised into three interconnected blocks: Scenario, Environment, and Safety Argument. The Scenario block encompasses the creation, formatting, and storage of scenarios that can be retrived to cover the system’s Operational Design Domain (ODD) and behaviour. The Environment block addresses the concretisation of test cases, their allocation across virtual, proving-ground, and real-world environments, and their execution. The
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
OFEODM: An Onboard Fast and Efficient Object Detection and Distance Prediction Model2026-01-0017To be published on 04/07/2026
Object detection and distance prediction have advanced significantly in recent years. The YOLO series has released its 11th version, along with numerous variants that have been applied across various fields. Meanwhile, the Detection Transformer (DETR) 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 algorithms intended for real-world applications and deployment on onboard devices, computational resources are limited and valuable. 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
Determining Video Frame Capture Rate through Reverse Engineering2026-01-0543To 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 an object’s average speed over several to a dozen frames, the average inter-frame interval can be used 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 file metadata; (3) investigating frequency interference occurring when recordings are
Wach, Wojciech
Integrated Welding Simulation and Experimental Characterization of Weld-Metal and Heat-Affected-Zone Strength in AA6063-T62026-01-0230To 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
Ultra-Low Latency Video Pipeline Optimization for Perception-Centric Autonomous Systems2026-01-0022To 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
Wind-tunnel investigation of snow/ice drag on a 30%-scale DrivAer model2026-01-0604To 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 million 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
Innovation Powered by High-Fidelity Multiphysics Modeling: A Holistic System Optimization of BorgWarner’s Next Generation Integrated Drive Modules2026-01-0497To be published on 04/07/2026
In the stringent market of BEV, the development of integrated Drive Modules (iDM) fitting to environmental and customer needs is mandatory. It is important to extract the best from the less. To achieve those goals, a deep insight of 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 PhD, Arnaud, Bossi, Adrien, Bourniche, Eric, DAVID, Pascal, Nanjundaswamy, Harsha
Elucidation of Flow Mechanisms Modulating Vehicle Wind Noise by using Large-Scale CFD Simulation2026-01-0614To 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, causes 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. However, 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
Tajima, Atsushi, Hirata, Takumi, Ikeda, Jun, Kamiwaki, Takahiro, Wakamatsu, Junichi, Tsubokura, Makoto
Design, Fabrication, and Assessment of a User-Friendly Suspension System for a 2025 BAJA Vehicle2026-01-0588To be published on 04/07/2026
A suspension system was designed, fabricated, and tested following a systems design approach by the Desert Hare Off-road Team from South Dakota State University (SDSU). 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
Liu, Yucheng, Anderson, Matthew, Larson, Cody, Rodgers, Joshua, Seberger, Aaron, Letcher, Todd
Design and Simulation Analysis of an Integrated Honeycomb-filled Front Bumper for a Special Vehicle2026-01-0475To 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-impact beam structure based on aluminum alloy additive manufacturing technology. A novel bumper structure is proposed, which integrates the front bumper and the front impact 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 impact beam of traditional passenger vehicles, an integrated design of the vehicle front bumper-impact beam structure is carried out and
王, Xufan, Yuan, Liu-kai, Zhang, tangyun, Wang, Tao, Zhang, Ming, Wang, Liangmo
A Study on the Relationship between Impact Conditions and Head Injury Criterion (HIC) in Powered-Two-Wheeler to Car Crashes2026-01-0571To 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
Yanaoka, Toshiyuki, GUNJI, Yasuaki, Zulkipli, Zarir Hafiz, Matsushita, Tetsuya, Carroll, Jolyon, Puthan, Pradeep, Mohd Faudzi, Siti Atiqah, D-Wing, Kak, Miyazaki, Yusuke
A study on Crack propagation characteristics of interlaced holes for key automotive components.2026-01-0186To be published on 04/07/2026
Aiming at the engineering problem that the stress interference of interlaced holes dominates crack propagation and directly affects driving safety in the hole group structure of key components such as chassis and body frame in the automotive field, in order to accurately reveal the quantitative influence of key parameters of interlaced hole placement (crack deflection Angle, longitudinal hole spacing) on the crack evolution of automotive hole group components, This study adopts the approach of numerical simulation combined with variable control to conduct systematic analysis. Taking an aluminum alloy thin plate with two relatively initial cracks (a commonly used structural material for automobiles) as the research object, multiple sets of typical interlocking hole structure variable models of automotive components covering different crack deflection angles and longitudinal hole spacings were constructed in the ABAQUS software. The J-integral was calculated by the circumscribed line
Chen, Yechao, Zhan, Zhenfei, Tang, Weiqin, Yang, Yutong, Gan, Yuan, Yan, Kaibo, HUANG, Shiyao
HaloBus: Edge Computing‑Enabled Real‑Time Boarding and Exit Detection for Enhanced Transportation Safety Using Lightweight AI2026-01-0555To 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 are forced upon the individual households with their own methods. Common methods include applications on a personal device or a small tracker. However, not everyone can afford these options, and every parent deserves to feel like their child is safe. That is why HaloBus was invented. The system employs YOLOv5u—an Ultralytics‑enhanced, anchor‑free, split‑head architecture that offers a superior accuracy–speed tradeoff. By providing real-time, on-device alerts, HaloBus enables immediate intervention to prevent a student from being left behind, thereby shifting the focus from reactive post-incident
Getz, Grayson, Zadeh, Mehrdad, TAN, Teik-Khoon
ProGuard: A Real-time Preemptive Artificial Intelligence-Based Anti-Pinch System for Bus Entryways on Low-Power Edge Devices2026-01-0100To 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
Development of a System for Regression Model Enhancement Utilizing Shape Generation AI2026-01-0499To 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
CAE Acceleration With Machine Learning For Results Prediction2026-01-0488To 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. AIML is impacting almost all areas in the industry and significantly reducing efforts time and cost. To make use of AIML 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 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
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
Optimization of Frontal Impact Force Scheme to Accelerate the Target Setting Process for Development of Front-End Structures in Vehicles2026-26-00011/16/2026
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
Packaging the HPTS Airbag in a Second-Row Seat2026-26-00331/16/2026
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
Wireless Charger Packaging in Peculiar Rear Door Trim Profile2026-26-02701/16/2026
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 Testing2026-26-05191/16/2026
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
Crash Pulse Characterization for the Passenger Vehicle Fleet in India2026-26-00291/16/2026
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
Optimizer Sunshade Packaging with Half Aluminum Cassette and Metal Pull Bar2026-26-05971/16/2026
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
Development of Door Impact Loads Using Pedal Force Sensor and First Principles2026-26-05381/16/2026
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
Effect of Pipe Bending by Rotary Tube Bending Process on Durability of Frame Structure2026-26-03701/16/2026
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
Unique Hybrid Panoramic Headliner Clip with High Tolerance to Replace Dual Lock Fasteners2026-26-02991/16/2026
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 It2026-26-01561/16/2026
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 Vehicle2026-26-03391/16/2026
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
Side Crash Pressure Sensor Response Prediction: CPM Approach2026-26-04131/16/2026
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
Challenges in Head-Up Display (HUD) Design for Modern Connected Vehicles: Balancing Functionality with Structural Integrity in an NVH Landscape2026-26-03541/16/2026
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
Experimental Evaluation of Metro Rail Bogie Frame through Bench Testing2026-26-05611/16/2026
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
Method and System of Detecting Obstacle around Vehicle Door2026-26-00261/16/2026
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 System2026-26-00411/16/2026
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
An Outer Waist Seal with Integrated Glass Wiping Mechanism for a Window Frame of a Vehicle2026-26-00111/16/2026
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
Optimization of the Hood Ro-dip CED Process Through Strategic Support Rod Placement at Multiple Locations for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing2026-26-04861/16/2026
The Ro-dip Cathodic Electrodeposition (CED) process is new 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 pressure and drag forces on large surface panels of BIW like hood. For maintaining consistent gaps and 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 structure supports through strategic optimization of support rod placement and quantity within the Ro-dip CED paint shop system. This Paper underscore the importance of tailored fixture design in the Ro-dip CED process, offering a scalable solution for automotive manufacturers aiming to improve quality while reducing costs associated with dimensional
Tile, Vikrant, Unadkat, Siddharth, Askari, Hasan, Jadhav, Devidas
Developing Advanced CAE Model for Door Glass Regulator Operating Noise Reduction through TEST-CAE Correlation2026-26-03111/16/2026
In recent decades, Computer-Aided Engineering (CAE) has become increasingly critical in the early stages of vehicle development, particularly for performance improvement and weight optimization. At the core of this advancement lies the accuracy of CAE models, which directly impacts design insights and reliable TEST-CAE correlation. Yet, accurately replicating real-world physical systems in virtual environments remains a significant challenge. This research introduces a structured methodology for improving correlation in door system models. It focuses specifically on reducing glass regulator operating noise, a common design issue that can lead to unwanted sounds and passenger discomfort. Traditional CAE models often fail to predict this problem, exposing the limitations of virtual-only validation. To address this gap, the study proposes a modal correlation-based approach aligned with actual assembly stage conditions. This strategy enables more precise assessment of the glass regulator’s
Panuganti, Naresh Kumar, Choi, Seungchan
Prediction of Trimmed Body Noise Transfer Function Based on BIW Response Using Machine Learning2026-26-06401/16/2026
This work focuses on the prediction of Trimmed Body Noise Transfer Function (NTF) using Glazed BIW (body in white) structural model characteristics by leveraging Machine Learning (ML) technique. Inputs such as Glazed BIW (GBIW) attachment dynamic stiffness, Body Panel Vibration Transfer Functions (VTF) and Driver Ear level NTFs are employed to predict Trimmed Body NTF for a particular hard point. An iterative process of performing design modifications on the BIW to verify its effect on BIW performance and therefore on Trimmed body NTF is undertaken. BIW geometric parameters are varied in an organized manner to generate hundreds of data points at GBIW level which are provided as input to the train the ML model to predict the trimmed body level NTF. The outcome provides crucial insights of how the trimmed body NTF is closely related to the GBIW design characteristics. This ML approach of predicting trimmed body NTF based on GBIW characteristics provides critical insight about GBIW design
Kulkarni, Prasad Ramesh, Bijwe, Vilas, Kulkarni, Shirish, Sahu, Dilip, Inamdar, Pushpak
Optimization of Air Extractor for Improved Door Closing Effort and Perceived Premium Feel2026-26-05921/16/2026
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
A Scientific Approach to Identify the Source of Intermittent Steering Rattle Noise and Implementing the Design Solutions2026-26-03461/16/2026
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
A Novel Approach to Deep Drawing Using Hybrid System and Pneumatic-Assisted Forming2026-26-03011/16/2026
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
From Physical Prototypes to Virtual Simulations: Advancing Automotive Latch Validation with nanoFluidX2026-26-04751/16/2026
Automotive door latches play a crucial role in occupant safety and user experience. The mechanisms utilized as latching systems in automotive doors are designed to hold the doors in a closed position relative to the body of a vehicle and can be grouped into three major categories: hood/frunk latches, lift gate latches, and side door latches. These mechanical systems vary in design across vehicle models, but all must withstand harsh environmental conditions, including water intrusion. Therefore, their requirements and validations include rigorous testing that ensures the continued functionality of the device after being subjected to extreme environmental conditions, such as cold, heat, and humidity. Rainfall in winter months leads to ice storms where water freezes instantly upon contact with cold surfaces leading to ice formation on structures. In some cases, water can penetrate latch systems, freezing the latch systems with the risk of potentially making them inoperable. Currently
Chaudhari, Abhijit, Srikanth, Praveen, Takabi, Behrouz, Calamaco, Eli, Estrada, Ignacio, Huerta Rodriguez, Sergio
Methodology for Optimizing the Bench Testing of Steering I-Shaft Using Vehicle Level Data to Reduce Overall Product Development Time and Cost2026-26-05601/16/2026
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 System2026-26-05201/16/2026
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
Design of the BIW Structure for Battery Pack Protection in Case of Side Pole Impact2026-26-00251/16/2026
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
Optimized Panel Design for Reducing Seal Squeak and Chucking in Door & Body Seals2026-26-03411/16/2026
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
3D Multi-Object Tracking Based on Probability Distribution and State Regression2025-01-731412/31/2025
In previous multi-object tracking paradigms, a complex data association strategy is generally needed to achieve accurate matching for detections and trajectories. In this paper, a novel end-to-end 3D multi-object tracking (MOT) framework is proposed based on probability distribution and state regression. Firstly, this framework does not rely on complex data association strategies; instead, it derives the accurate position of an object in the current frame directly by regression based on the prior information of the object’s trajectory. Secondly, a probability grid sampling strategy is then adopted to expand the regression search range of the trajectory in an adaptive manner, thereby reducing the uncertainty of the trajectory states caused by consecutive predictions. Lastly, to eliminate overlaps of trajectories, a trajectory interaction module is introduced to retain trajectories with higher confidence. Experiments are conducted on the KITTI and Waymo datasets. The results demonstrate
Liang, Zheng, He, Jiawei, Ji, Pan, Huang, Mingguang, Cheng, Hao, Fu, Chunyun
LLS-SMGSC: A Lidar Localization System Based on Simplified Maps Integrated with Global Search Capabilities2025-01-730312/31/2025
To address the issues of large storage requirements in maps and the dependence of localization accuracy on initial pose estimation, this paper proposes a novel relocalization method named LLS-SMGSC, which is based on simplified maps integrated with Global Search capabilities. Firstly, we partition the map-based on grid size to reduce memory usage. Next, we voxelize the point cloud and map and extract surfel. Then, a coarse-to-fine hierarchical alignment module between the initial frame and maps to estimate the initial global pose. Finally, unmanned platform pose is estimated by the Normal Distribution Transform (ndt) algorithm. Experiments demonstrate that LLS-SMGSC achieves the highest localization accuracy in both unstructured and structured environments while maintaining computational efficiency.
Quan, Zhiheng
Analysis of the Structural Alignment during the System Conversion of Continuous Beam Bridges with High Piers, Long Spans and Wide Box Girders2025-99-022412/23/2025
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
Experimental Investigation of Stress Distribution Characteristics in Surrounding Rock during Unloading in Oblique Upper Crossing Tunnel2025-99-024212/23/2025
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Wu, Hao, Qin, Shuzhen, Li, Guofeng, Dong, Tianwen, Shi, Yongyue
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