Browse Topic: Design Engineering and Styling

Items (46,184)

Interpretable Tire Force Modeling for Formula Student Vehicle Dynamics and Lap Time Applications

2026-01-0762To be published on 07/01/2026

Accurate tire models are a key enabler for vehicle dynamics simulation, control design, and lap time optimization, particularly in the context of Formula Student race cars, where vehicle setups and tire characteristics differ significantly from production vehicles. State-of-the-art tire models, such as Pacejka’s Magic Formula, provide high accuracy but rely on predefined functional structures and a large number of parameters, which limits interpretability and adaptability to new tire compounds. This paper presents a data-driven approach for deriving compact and physically interpretable tire force models using symbolic regression. The proposed method employs an intelligent tree search to systematically explore the space of mathematical expressions and identify models that optimally balance prediction accuracy and structural simplicity. In contrast to black-box machine learning approaches, the resulting models consist of explicit mathematical expressions that enable physical

Anselment, Marcel, Borowski, Julian, Rudolph, Stephan

Numerical Analysis of Pre-Ignition Factors in Hydrogen Engines

2026-01-0740To be published on 07/01/2026

Numerical analysis was conducted to investigate abnormal combustion, a major challenge in efforts to improve hydrogen engine efficiency. Focusing on two factors that induce abnormal combustion—surface reactions and lubricating oil—numerical analysis examined the potential for each to trigger abnormal combustion. Furthermore, since it was confirmed that the self-ignition prediction using a detailed chemical reaction mechanism deviates from experiments at temperatures around 800K, attempts were made to improve this issue. As a result, it was confirmed that surface reactions affect the chemical species ratio near the wall surface but have little effect on flame propagation. Regarding lubricating oil, two possibilities were investigated: the lubricating oil itself self-igniting and becoming an ignition source for the hydrogen mixture, and deposits generated from the lubricating oil generating heat and becoming an ignition source. We investigated two possibilities: the lubricating oil

Moriyoshi, Yasuo, Yamane, Taichi, Wang, Zhiyuan, Kuboyama, Tatsuya

Methodology for Battery System Optimization and Evaluation Using Format Flexible Pouch Cells

2026-01-0749To be published on 07/01/2026

Electrification using battery systems is one of the most relevant solutions regarding ecological challenges within multiple application cases such as mobility, tools or stationary power supply. Nonetheless besides recent achievements in some cases battery systems are still lacking behind operational requirements compared to conventional propulsion systems, therefore limiting the potential of electrification. Especially when purpose design possibilities are limited. Besides improving properties of cell materials, better usage of the available installation space offers potential for overall optimization of the battery system. The development of battery systems is complex, as it involves multiple system levels and domains, along with a wide range of design options and architectures. Battery cells that can be manufactured in flexible formats offer the potential to make more efficient use of available installation spaces. At the same time, these additional degrees of freedom increase design

Müller-Welt, Philip, Bause, Katharina, Spohn, Hannes, Albers, Albert

Key Modeling Considerations for Reliable FEM-Based Demagnetization Evaluation of IPMSM

2026-01-0741To be published on 07/01/2026

The reduction of heavy rare earth elements such as dysprosium and terbium, which are associated with high cost, geopolitical risk, and sustainability concerns, is a key objective in the electromagnetic design of IPMSM for traction applications. As these elements are the primary contributors to magnet intrinsic coercivity, their minimization increases the risk of irreversible demagnetization of the permanent magnets. In IPMSM designs with reduced heavy rare earth content, it is therefore necessary to operate close to the demagnetization limit of the permanent magnets and accurately identify them. Consequently, precise and reliable finite element based prediction of demagnetization robustness is essential for systematic and material efficient machine design. This paper investigates the key factors required for reliable assessment of demagnetization robustness in IPMSM using electromagnetic FEM. Unlike existing literature, which typically neglects the accuracy of magnet material data

Malner, Max, Naumoski, Hristian, Gretzinger, Stefan, Izquierdo, Patrick, Kulzer, Andre Casal

Mind the Gap: Quantifying Behavioral Fidelity in CARLA using Naturalistic Drone Data

2026-01-0771To be published on 07/01/2026

The rapid advancement of autonomous driving systems, particularly SAE Levels 3 and 4, requires rigorous validation strategies to ensure safety during handover and fallback procedures. Although virtual environments provide the necessary scalability, the simulation-reality gap poses a significant risk to the reliability of human-in-the-loop (HITL) assessments. This paper presents a comprehensive, empirical investigation into the transferability of human driving behavior from the Car-Learning-to-Act (CARLA) simulation environment to real-world traffic situations. Using the exiD dataset, which comprises high-precision, drone-recorded, naturalistic trajectories from German highways, we systematically reconstructed distinct traffic scenarios. These scenarios included lane changes, cut-in maneuvers, and curve navigation. Twenty-five participants navigated these scenarios in a driving simulator. The study employed a robust, multidimensional analytical framework to compare the simulated

Rebling, Patrick, Alphan, Metehan, Nenninger, Philipp

Towards a Smarter E-Bike: Enhancing Energy Efficiency through Adaptive Speed Control

2026-01-0736To be published on 07/01/2026

This paper presents the development of a speed controller for e-bikes, designed as part of an energy-adaptive assistance system. The controller provides riders with appropriate support along planned routes, based on the available battery capacity. The control concept is intended for integration into existing commercial e-bikes without requiring extensive modifications to the drive system. Therefore, the rider remains part of the control loop, adjusting the support mode according to instructions from the controller. The speed controller is implemented as a rule-based state machine, enabling comprehensible design and parameterization Since the rider must manually switch between support modes while riding, the control logic incorporates hysteresis and dead times to ensure stability, prevent oscillations and avoid frequent mode switching. The user interface is a smartphone application that issues visual and audio instructions for switching support modes. An initial, system-independent

Rauch, Yannick, Simmann, Gabriel, Schneider, Manuel, Goss, Christian, Kriesten, Reiner

CFD Optimization of Multi-Pass Serpentine Flow Distributors for PEM Fuel Cells

2026-01-0746To be published on 07/01/2026

Polymer electrolyte membrane (PEM) fuel cells represent one of the most promising solutions for decarbonizing powertrain technologies, as they can be employed as carbon-free electrical power source. However, performance degradation during their operating lifetime - caused among other factors by non-uniform reactant distribution and improper membrane humidification, which may lead to the formation of local hot spots - remains a significant challenge. Computational fluid dynamics (CFD) tools represent an effective approach for investigating the transport of oxygen and hydrogen within the cell and for optimizing the geometry of PEM fuel cell flow distributors. Thus, they can be exploited in order to improve the uniformity of current density and temperature distributions over the cell active area. In this work, a serpentine flow field PEM fuel cell is considered as test case. The distributor consists of a multi-pass serpentine flow-field composed of repeated sets of five parallel channels

Bulgarini, Margherita, Della Torre, Augusto, Montenegro, Gianluca, Baricci, Andrea, Mereu, Riccardo, Lalangui Gallegos, Jose A., De La Morena, Joaquin

Identifying and mitigating resonance effects in HV Powernets

2026-01-0742To be published on 07/01/2026

HV Power nets of electric vehicles consists of various HV components such as batteries, inverters, auxiliaries and cables. During in-vehicle testing, multiple failures of an auxiliary inverter were observed, caused by resonance issues within the component filter. Initial investigations revealed that these resonances, absent during manufacturer testbench evaluations, were influenced by the vehicle power net and its impedance characteristics. To better understand the underlying causes and identify preventative measures, extensive simulations were performed. The results demonstrate a diminishing influence of the power net capacitance when significantly larger than the component capacitance. Also they highlight the critical impact of cable inductance on the component resonance frequency when comparable to the component’s inductance. A simplified electrical equivalent circuit was used to derive an equation predicting the resonance frequency as a function of the component’s capacitance

Schmiel, Fabian, Aurand PhD, Tobias, Koehnlechner, Benjamin, Zimmer PhD, Markus

Multi-Scale Modelling of Localized Battery Degradation in Heavy-Duty Series Hybrids: From Electrochemical Impedance Spectroscopy to Powertrain and Battery Pack Performance

2026-01-0747To be published on 07/01/2026

The operational efficiency of heavy-duty hybrid electric vehicles (HEVs) is intrinsically linked to the health and power capability of the battery pack. Traditional battery management systems often rely on bulk State-of-Health (SOH) metrics, failing to account for localized degradation and the resulting current imbalances within parallel-connected modules. Recent literature emphasizes that cell-to-cell variations and thermal gradients can lead to a 6% reduction in accessible energy and a 5.2% acceleration in degradation rates due to heterogeneous current distribution. This study addresses these gaps by presenting a multi-scale modelling framework that translates cell-level electrochemical degradation features into system-level powertrain optimization. Initially, a thorough experimental campaign was conducted on LFP cells, using accelerated cyclic and thermal aging at 25°C and 60°C. High-fidelity battery parameters were extracted from EIS data using fractional-order equivalent circuit

Safavi, Seyed Reza, Homayouni, Hooman, Shoa, Tina, Wang, Jason, McTaggart-Cowan, Gordon

Dynamic Wireless Charging for Electric Vehicles

2026-01-0748To be published on 07/01/2026

This paper investigates the electromagnetic and circuit-level performance of an inductive power transfer (IPT) system for dynamic wireless charging of electric vehicles (EVs). Key design parameters affecting power transfer efficiency (PTE) are explored. A simplified Series-Series (SS) compensated IPT model using Double-D coil geometry and shielded ferrite backing was developed using MATLAB software. The framework has been built around variations of air gap, lateral misalignment, load resistance, and operating frequency. The results show that PTE is highly sensitive to spatial alignment, with a significant efficiency loss at air gaps greater than 10 cm and misalignments beyond 15 cm. Both parameters can cause a compounded nonlinear effect on the PTE, thus a 3D surface plot was used to confirm the simultaneous effects of both parameters. Load resistance analysis revealed an optimal range around 10–15 Ω, while frequency analysis showed a peak efficiency near 85 kHz, in alignment with SAE

Abdelrahman lng, Marwan, Sodre, Jose Ricardo

From Wind Tunnels to an AI-Supported Data-Driven Development Ecosystem How Software Transforms Aerodynamic Testing into a Strategic Asset

2026-01-0767To be published on 07/01/2026

Despite advances in CFD, wind tunnel testing remains indispensable for aerodynamic validation, correlation, and homologation. Increasing configuration complexity, shortened development cycles, and stringent result robustness and documentation requirements demand a shift from isolated facilities to integrated, data-driven ecosystems within the overall development and company-wide test processes. We present a software-centric approach integrating wind tunnel operations into a strategic element of the Digital Thread. By orchestrating test planning, execution, data acquisition, and documentation within a unified framework, experimental data becomes reusable across projects and traceable for compliance and homologation. The interaction between CFD and physical testing is important. Such systematically improves simulation models with wind tunnel tests. And CFD results guide efficient test matrix definition. Extended measurement methodologies include automated actuation of active aerodynamic

Jacob, Jan D.

Feasibility study on the mechanical adjustment of the vibration behaviour of a powertrain test rig for validating longitudinal vehicle shuffle

2026-01-0735To be published on 07/01/2026

Vehicle manufacturers use Hardware-in-the-loop (HiL) approaches to validate overall vehicle characteristics, including those dependent on the powertrain, at an early stage of vehicle development. A powertrain test rig is a typical example. In the specific setup, the vehicle engine and side shafts are mechanically coupled to the load machines of the test rig, eliminating the physical influence of the rims, tires and vehicle body. Adapting a specimen to the test rig changes some characteristics. This affects the specimen's vibration behaviour, making it more challenging to validate comfort-related characteristics. A particular example is longitudinal vehicle shuffle; the powertrain's first torsional natural frequency causes it. The natural frequencies of the real vehicle and device under test differ significantly, so a road-matching approach is not directly feasible. To account not only for tire-road contact but also for the missing vehicle mass, some scientific studies propose a purely

Hübner, Carl, Prokop, Günther

Production-Ready Automated ECU Calibration using Residual Reinforcement Learning

2026-01-0780To be published on 07/01/2026

Electronic Control Units (ECUs) have played a pivotal role in transforming motorcars of yore into the modern vehicles we see on our roads today. They actively regulate the actuation of individual components and thus determine the characteristics of the whole system. In this, the behavior of the control functions heavily depends on their calibration parameters which engineers traditionally design by hand. This is taking place in an environment of rising customer expectations and steadily shorter product development cycles. At the same time, legislative requirements are increasing while emission standards are getting stricter. Considering the number of vehicle variants on top of all that, the conventional method is losing its practical and financial viability. Prior work has already demonstrated that optimal control functions can be automatically developed with reinforcement learning (RL); since the resulting functions are represented by artificial neural networks, they lack

Kampmeier, Andreas, Badalian, Kevin, Koch, Lucas, Lee, Sung-Yong, Andert, Jakob

Vision-Language Model Training for Code Generation from Requirements and Model-Based Artifacts

2026-01-0770To be published on 07/01/2026

Recent advancements in Vision-Language Models (VLMs) have opened new possibilities for bridging the gap between Systems Engineering artifacts and automated code generation. Traditional Large Language Models (LLMs) are primarily trained on textual data and generic code repositories, which limits their ability to interpret graphical engineering artifacts such as Simulink block diagrams or system architecture models. In safety-critical domains like the automotive industry, these graphical models are central to development workflows and must remain closely aligned with textual requirements and implementation code to ensure traceability, compliance, and functional correctness. This paper proposes a VLM-centered multimodal training framework for code generation that integrates textual requirements, graphical model-based artifacts, and annotated source code into a unified learning process. By leveraging models which combine vision encoders with language backbones, the approach enables the

Padubrin, Marcel, Kulzer, Andre Casal, Guerocak, Erol

Low-Temperature Internal Heating of Lithium-Ion Cells by Zero-Mean Square-Wave Current Excitation: Thermal Response and Aging Effects

2026-01-0753To be published on 07/01/2026

Lithium-ion batteries commonly used today may only be charged at temperatures above 0 °C. However, the heating elements currently used to warm the battery packs make the battery heavier and more complicated in design. In addition, heat is transferred from outside into the cell, causing the temperature inside the cell to rise slowly. The aim is to heat the cells without additional components by applying alternating current and without significantly accelerating aging. To this end, a series of measurements were carried out at temperatures between 0 °C and -20 °C and at frequencies between 50 Hz and 10 mHz. A square wave signal and an amplitude of 5 A were kept constant in all measurement series. The cells were heated for 30 minutes and then cooled for 60 minutes. After every 50 heating cycles, the state of health (SOH) of the cells was determined, and a total of 400 heating cycles were carried out. Aging due to heating is independent of temperature and frequency, with the SOH ending at

Raiber, Stefan, Allmendinger, Frank, Degler, David, Parschau, Anke

Passive Thermal Management of Battery Disconnect Units for Fast-Charging Electric Vehicles: A Comparative Study of Phase Change Material Heat Transfer Configurations

2026-01-0759To be published on 07/01/2026

Reducing charging time remains a critical challenge for the widespread adoption of electric vehicles (EVs). Limited charging infrastructure availability, combined with the long duration required for battery recharging, significantly affects user acceptance. As a result, fast-charging technologies are increasingly being introduced in both newly designed EV platforms and existing vehicles through retrofitting solutions. Despite their benefits, fast-charging systems impose substantial thermal loads on vehicle components, charging stations, and associated power electronics. Excessive heat generation can compromise performance, reliability, and safety, making effective thermal management a key design concern. Within the high-voltage architecture, the Battery Disconnect Unit (BDU) plays a vital role by monitoring and controlling the connection of the battery to the powertrain and charging system. Traditionally, BDUs are designed for conventional charging power levels; however, higher

Salameh, Georges, Goumy, Guillaume, Frecinaux, Anthony, Ratajczack lng, Christelle, Palluel PhD, Marlène, Noiseau lng, Pascal, LARDEUX, Sébastien

Numerical Analysis of Directly Injected Hydrogen into a High-Pressure Chamber

2026-01-0745To be published on 07/01/2026

Due to the historical use of fossil fuels, the transportation sector has been one of the major producers of greenhouse gas (GHG) emissions and harmful pollutants. Because of its high specific energy content and the potential for zero carbon-based emissions, Hydrogen Internal Combustion Engines have emerged as an option for decarbonizing heavy-duty transportation. However, injecting high-pressure gas into pressurized combustion chambers induces complex compressible flow phenomena, including choked flow and under-expanded supersonic jet structures, which challenge conventional modeling approaches. Accurate prediction of the resulting fuel-oxidizer mixing process is critical for optimizing engine performance and emissions. This study conducts a numerical investigation of transient hydrogen injection into a high-pressure argon environment, benchmarking a 2D axisymmetric Computational Fluid Dynamics (CFD) model against high-fidelity experimental optical measurements. Utilizing Ansys Fluent

Castilla Batun, Uriel Isaac, Alzahrani, Fahad

Integrated DC Boost Charger in Post-800V Architecture with Open-End Winding Machine – Magnetic-Domain Modelling and Torque Analysis

2026-01-0739To be published on 07/01/2026

Next-generation powertrain architectures proposed within EU Horizon projects adopt operating voltages above 800 V, providing improvements in efficiency as well as reductions in copper usage and system weight. However, post-800 V vehicles must remain backward compatible with existing 400 V and 800 V charging infrastructure, which requires the installation of an additional onboard DC boost charging unit on the vehicle. This paper proposes an integrated DC boost charging solution that reutilizes the open-end winding electric machine and the traction inverter of the electric powertrain, enabling backward compatibility while further reducing system cost and weight. In charging mode, the electric machine is repurposed as a passive inductive component, imposing a strict requirement of stationary operation with zero torque generation, which fundamentally differs from the driving mode characterized by rotor rotation and electromagnetic torque production. Consequently, conventional electric

Wang, Haoran, Kallur-Krishnamoorthy, Rajesh, Neuhaus, Christoph, Andert, Jakob

Optimization of a Halbach array for torque ripple reduction in a Yokeless And Segmented Armature axial flux machine

2026-01-0754To be published on 07/01/2026

This paper presents the optimization of a Halbach magnet array applied to an axial flux machine (AFM) in a 12-pole, 18-slots yokeless and segmented armature (YASA) topology, evaluated in the torque–speed characteristics diagram. AFMs offer significant advantages in terms of compact design and high torque density compared to other permanent magnet machine topologies. However, noise, vibration, and harshness (NVH) performance is strongly influenced by cogging torque, electromagnetic torque ripple, and tooth forces. While Halbach magnet arrays are well established in high-performance radial flux machines, only limited research has investigated their influence in AFMs. A Halbach array concentrates magnetic flux on one side of the magnet arrangement, leading to increased air-gap flux density and a more sinusoidal magnetic field distribution. By using a Halbach array, the magnetic field distribution in the air gap becomes more sinusoidal, thereby reducing harmonic components. Previous

Müller, Karsten, Schulz, Fabian, Bremer, Martin, Burkhardt, Yves, De Gersem, Herbert

Bridging Simulation And Reality: Incorporating Seal Contact Detachment Into Stick–Slip Prediction

2026-01-0714To be published on 06/20/2026

Preventing stick–slip in virtual vehicle development combines virtual displacement data with experimental sliding tests. If the calculated relative displacement at a contact exceeds the distance of two stick–slip impulses, that contact could be a potential noise source. Such risks can be mitigated only by design changes or alternative sealing concepts. Stick–slip tests provide the experimental reference, showing how often a frictional pairing produces impulses over a defined sliding distance. The basis for this assessment is Multibody Dynamics (MBD) simulations, which compute component deformations during virtual drives and derive relative displacements at contact interfaces (e.g. in the sealing gap between body and closure), representing the theoretical sliding distance that enables stick–slip effects. Yet, this combined approach has overlooked a critical factor: the deformability of automotive seals. Due to their elastomeric properties and geometry, seals can elastically follow

Strangfeld, Martin, Fritz, Susanne, Weber, Jens, Rosell, Anneli

High-Fidelity NVH Analysis Model Development Process for EV Traction Motors Based on Experimental Correlation

2026-01-0685To be published on 06/20/2026

This study presents a high-fidelity NVH (Noise, Vibration, Harshness) analysis model development process for EV traction motors. The proposed process consists of two main components: Path refinement through structural stiffness tuning, and Source refinement, focused on the motor’s excitation mechanisms. Model accuracy was validated through comparison of simulation results with dyno test data, with particular focus on the 24th-order electromagnetic vibration observed in an 8-pole, 48-slot motor. Path refinement was achieved through modal correlation between experimental results and finite element (FE) analysis. Nine modal test and simulation stages were conducted, ranging from individual components to the complete motor assembly. Mode shapes were compared using the Modal Assurance Criterion (MAC), and natural frequencies were matched within a 5% error margin by adjusting FE material properties. For the 24th-order electromagnetic vibration, simulation results agreed with test data within

Kim, Donghee, Kim, Dong-Jun, Lee, SangHan, Kim, Seon Hyeong, Hwang, Seung Gyu, Valente, Giorgio, Parisouz, Shahriar, Halse, Christopher

NEW CORRELATION APPROACH FOR BODY DISTORTION OF A COMPLETE VEHICLE USING MBD AND TEST RESULTS

2026-01-0680To be published on 06/20/2026

By using a fully trimmed vehicle body as flexible body (MNF model) in a complete vehicle Multibody Dynamics (MBD) analysis, the simulation setup gets considerably closer to the test conditions compared to only using a linear FEM approach. Since the MBD analysis includes the nonlinear behavior of the wheel suspension, the gravity and the rigid body modes of the vehicle, it brings the correlation between simulation and test to a new and more comprehensive level. As correlation criteria, the results of the so-called Multi Stethoscope (MSS) are used. The MSS captures the time history of distortion in all body openings and cross sections and enables a detailed stiffness evaluation of the body using the so-called Opening Distortion Fingerprint (ODF). The ODF gives the quasi-static response while the Operational Deflection Shape (ODS), which is another result of the MSS measurements, reflects the dynamic response. Apart from the different individual steps of this new correlation approach, the

Lindkvist, Lisa, Olger, Emma, Piiroinen, Petri, Karypidis, John, Pena, Milton, Bäcklund, Jesper, Appelgren, Peter, Marberg, Henrik, Ugale, Pravin, Weber, Jens

Standardized Equivalent Tire Load measurements delivered by suppliers to an OEM enabling consistent and comparable simulation input.

2026-01-0699To be published on 06/20/2026

Part- or component-level tests are commonly performed by Tiers and OEMs to investigate the NVH behavior and loading mechanisms. However, because test bench dynamics differ from those of the actual vehicle environment, correlating measured sound, acceleration, and forces between bench and vehicle often proves challenging. Blocked forces offer a way to address this issue, as they provide test bench– and vehicle–independent load representations, effectively enabling different Tiers to deliver consistent load data, which OEMs can then to better tune excitation and noise transmission on their vehicles. This paper focuses on 2 test bench compensation techniques, involving pure test and a simulation models of the tire, to obtain accurate blocked-forces. The compensation techniques are validated on four testbenches of different companies.

Reichart, Ron, de Klerk, Dennis

Single microphone sound source localisation in partially known environments using sequential spatial sampling

2026-01-0681To be published on 06/20/2026

Sound source localization is a fundamental capability for environmental awareness in a wide range of applications, including automotive or automated vehicles. Microphone-array-based signal processing techniques are widely used for this task. However, achieving sufficient localization accuracy often requires a large number of microphones and wide array apertures, which can be incompatible with limited installation space and cost constraints. Moreover, standard array-processing methods often rely on free-field transfer functions. In environments with reflections, diffraction, and scattering, particularly under non-line-of-sight conditions, this mismatch can degrade both accuracy and interpretability. This paper presents a methodology for sound source localization in partially known environments that addresses these challenges by combining two ideas. First, the method reduces sensor requirements by exploiting sequential pressure measurements acquired at different spatial locations along a

Pirro, Giovanni Battista, Nijman, Eugene, Deckers, Elke, Denayer, Hervé

Frequency Based Substructuring as Key Enabler for New NVH Root Cause Analysis Types in FE Simulations

2026-01-0710To be published on 06/20/2026

Noise, vibration, and harshness (NVH) performance is critical in the automotive development process, yet identifying the true root causes of unwanted dynamic behavior remains a challenge in full vehicle or system‑level finite element (FEM) models. This work demonstrates how frequency based substructuring (FBS) provides an efficient framework for understanding NVH and facilitates new root cause analysis types and processes. To begin, we prove the high numerical accuracy of the FBS algorithm deployed in the BETA CAE software by comparing its results with those obtained without substructuring. Then we illustrate how FBS supports new root cause analysis types, starting with a new variant of transfer path analysis (TPA). While standard TPA assesses the paths between only two system components, the new expanding TPA is a multi-step process that identifies the most critical path across all components in a fully automated way. Furthermore, if the FBS workflow starts with a modal representation

Herbst, Markus

Transmission Loss of Vehicle Components Using Virtual SEA: Validation and Modeling Challenges

2026-01-0705To be published on 06/20/2026

In the automotive industry, controlling noise transmission through vehicle components is essential for passenger comfort and regulatory compliance. Traditionally, Transmission Loss (TL) is estimated using simplified CAD-based metrics, which lack accuracy at high frequencies and for complex assemblies. This study presents an industrial application applying the Virtual SEA (Statistical Energy Analysis) method to evaluate TL for firewall. Modeling complex vehicle components introduces challenges, such as representing fluid-structure and trim interactions, with spatially varying trim thicknesses. The study discusses strategies for subsystem adaptation and analytical trim modeling, highlighting the importance of managing untrimmed zones and spatial averaging effects. The proposed workflow integrates laboratory measurements of trim materials, advanced subsystem definition, diffuse sound field excitation and radiation in free conditions. Virtual SEA results are systematically validated

Orselli, Joseph, Jacquemin, Gaetan

A High-Performance Computing Strategy for Acoustic Encapsulation Modeling of Electric Vehicle Subsystems Using Coupled BEM–PEM–FEM Methods

2026-01-0694To be published on 06/20/2026

Electric vehicle subsystems, including powertrains, electric motors, and gearboxes, pose new challenges in achieving stringent acoustic performance targets for both interior and exterior noise. These challenges are intensified by increasingly demanding customer expectations regarding interior acoustic comfort, which encompasses the reduction of intrusive noise sources and the enhancement of overall sound quality across a broad frequency spectrum. A primary concern associated with electric vehicles subsystems is the generation of high-frequency tonal noise, commonly referred to as whine noise, which can significantly impact acoustic performance and passenger comfort. High-frequency whine noise propagates through multiple transmission paths and can be effectively attenuated at the source through encapsulation strategies, which also contribute to broadband noise reduction across a wide frequency spectrum. To predict the acoustic performance of encapsulation, a coupled simulation approach

Amichi, Kamel, Calloni, Massimiliano

Robustness Analysis for A Computationally efficient Virtual Sensing Framework in time-domain for Exterior Vibroacoustics problems

2026-01-0721To be published on 06/20/2026

Reconstruction of acoustic radiation from vibrating structures is central in vibroacoustic, as full-field sound information is essential for identifying radiation mechanisms and improving structural-acoustic performance. Conventional microphone-based measurements are limited by spatial sampling constraints and high experimental cost, while purely numerical approaches such as Finite Element Method (FEM) simulations, particularly in the frequency domain, offer flexibility but are strongly affected by parameter uncertainties, discretization errors, and imperfect boundary conditions. To overcome these drawbacks, this work develops a hybrid time-domain framework that couples vibration measurements with FEM-based acoustic models. The FEM model is reduced using Krylov subspace projection, yielding a compact state-space representation that captures the dominant vibroacoustic modes while remaining computationally efficient for sequential data assimilation. The acoustic radiation domain is

Dong, Luyao, Cai, Yinshan, Denayer, Hervé, Deckers, Elke

Experimental Validation of Frame-Dependent Gyroscopic Frequency Splitting in a Freely Rotating Tire Using Wireless MEMS Accelerometers and Scanning Laser Doppler Vibrometer

2026-01-0700To be published on 06/20/2026

Gyroscopic effects split circumferential traveling-wave resonances of rotating structures into forward and backward branches. This work first analyzes the splitting in the co-rotating (Lagrangian) frame to provide physical intuition for the evolution of the two branches with spin speed. A transformation to the inertial (Eulerian) frame is then derived, showing that the observed frequencies are shifted by a kinematic Doppler-like term that acts with opposite sign on the forward and backward waves, leading to different Campbell-diagram slopes depending on the observation frame. The resulting framework is validated experimentally on a freely rotating, unloaded tire using two complementary sensing modalities: wireless on-tire accelerometers (co-rotating view) and a scanning laser Doppler vibrometer (inertial view). A frequency-domain SVD-based identification (FDD/ODS-SVD) is used to extract poles and deformation patterns over a range of spin speeds, enabling Campbell diagrams in both

del Fresno Zarza, Javier, Naets, Frank

Holistic sound package design for optimal NVH and carbon footprint of a BEV

2026-01-0708To be published on 06/20/2026

Vehicle sound packages are usually designed to provide a given level of vehicle NVH comfort, under weight and cost constraints. Optimal comfort results can be obtained by considering the interaction of all the parts as a full physical system. So far, extensive research has already been performed and published on optimizing vehicle sound packages to achieve effective noise reduction at lowest cost and weight. Nowadays, due to the urgency of the transition to carbon neutrality, sound packages must also address the reduction of the full vehicle life cycle carbon emissions. Sound package components should use materials that have a low emission impact during production and that are suitable for recycling at the end of the vehicle’s life. This entails reconsidering the material solutions chosen for the sound package as a whole, rather than for each individual component. This article describes the design process of a sound package involving NVH, sustainability, and weight/cost requirements

Courtois, Theophane, Cardillo, Marco, Criscione, Mattia, Gerges, Youssef, Massocco, Andrea

Impact of door dynamics on vehicle interior low-frequency vibro-acoustics.

2026-01-0679To be published on 06/20/2026

Interior acoustics represent an essential component of driving comfort in electric vehicles. Numerical simulation is an effective approach for assessing design concepts and enhancing acoustic performance. However, a fully coupled vibro-acoustic model for an entire vehicle remains computationally infeasible. Our approach couples mechanical and acoustic modal models on non-conforming interfaces in the low-frequency range, allowing independent mode combinations. Modal coupling reduces the computational effort significantly from full-order systems with millions of degrees of freedom to a selection of modes of the acoustic and mechanical systems. Modal models of the vehicle structure are derived from laser-vibrometer measurements while the interior acoustics are simulated numerically. Since laser measurements are restricted to the vehicle’s exterior surfaces and vibro-acoustic coupling occurs between the inner structural surface and the interior fluid, the structural behavior of the

Gutbrod, Manuel, Gabriel, Christoph, Müller, Gregor Johannes, Toth, Florian

Towards Realistic Stick-Slip Testing: Efficiently Mapping Material Behaviour across a wide Range of Loading Conditions

2026-01-0713To be published on 06/20/2026

To minimise noise caused by interior components rubbing against each other, automotive materials are usually tested in advance with the established stick-slip method according to VDA standard 230-206. This procedure is widely used for soft materials, upholstery and plastics. However, it is limited to constant climatic and selected loading conditions. Contrary, in real application, changing climates and dynamic excitations can nevertheless trigger noise issues even in materials rated as suitable in the prior tests. To address this gap, a new test method has been developed that evaluates the stick-slip behaviour of material combinations for a wide range of loading and climatic conditions. Conducted in a climate chamber with a standard stick-slip bench, the procedure applies sinusoidal excitations, dynamic climatic shifts and advanced data analysis. In addition to the usual results the new method also evaluates realistic scenarios such as starting a vehicle in different seasons or sudden

Fritz, Susanne, Strangfeld, Martin

Vibro-Acoustic simulation for vehicle audio design

2026-01-0670To be published on 06/20/2026

Acoustic user interfaces and audio experiences are among the leading comfort factors in new vehicle interior designs. OEMs are more and more focusing on loudspeaker design and positioning, to provide the most immersive experience to the customers. The industrial target is to be able to predict the performance of an audio system in early design phases. This paper presents a methodology to model source-receiver transfer functions in a full-scale vehicle cabin and investigates the installation effect of the speakers in a real car door. A hybrid methodology is developed to be able to model the loudspeaker in different environment.

Zerrad, Mehdi, Errico, Fabrizio, Mordillat, Philippe

Early-Stage BIW Design Evaluation Using Higher-Order Beam–Shell Hybrid Models

2026-01-0674To be published on 06/20/2026

Achieving favorable NVH and durability performance in the vehicle requires sufficient static and dynamic stiffness of the Body-in-White (BIW). Virtual development of BIW performance targets in the early stages is essential to minimizing costly modifications in later phases. In the automotive industry, full-scale finite element models are widely used for this purpose, offering high fidelity and enabling virtual performance evaluation. However, their complexity and the significant computational resources they demand limit their practicality for early-stage sensitivity and optimization studies. Beam-based models offer a faster alternative, but conventional formulations based on Euler or Timoshenko theory often fail to capture the complex deformation behaviors of thin-walled structures typical of BIW designs. This limitation generally leads to poor correlation with detailed models unless artificial joint flexibility is introduced. To address these challenges, we propose a hybrid modeling

Kim, Jin Hong, Gang-Won, Jang

Dynamic characterisation and modelling of Electric Cables under representative load conditions

2026-01-0676To be published on 06/20/2026

Electric high voltage (HV) cables are commonly used in automotive applications and very prominently in electrified vehicles. These cables are potential flanking transmission paths for structure-borne sound in a broad frequency range and must therefore be included in the NVH design process. Electrical high voltage cables exhibit non-linear mechanical characteristics, when exposed to significant bending the internal geometry of the cable will change and a curvature dependent bending stiffness will result. The electrical cables envisaged in the current publication feature a helically wound stranded aluminium wire core. This conductive core is covered by, in sequence, a silicone rubber insulation, a braided aluminium wire shield with aluminium foil to minimize electromagnetic interference and a silicone rubber outer sheath. An extensive measurement campaign was carried out to dynamically characterize cable specimen of different lengths and cross sections in terms of multi-degree of freedom

Nijman, Eugene, Buchegger, Blasius, Böhler, Elmar, Zeller, Bernhard, Rejlek, Jan, Faksa, Lukáš, Lukavsky, David

Development of a Convolutional Autoencoder-Based Unsupervised Classification and Visualization Model for Extracting Feature Frequency in C-EPS Fault Diagnosis

2026-01-0717To be published on 06/20/2026

In the automotive industry, deep learning models such as convolutional neural networks, autoencoders, and transformers have been actively studied to improve defect detection rates in End-of-Line (EOL) processes. However, applying these approaches to the field of Noise, Vibration, and Harshness (NVH) faces several practical challenges. ① Difficulty in securing sufficient training data and risk of overfitting due to longer evaluation times compared to other data types. ② Label imbalance caused by the relatively small amount of defective data. ③ Reduced labeling accuracy due to human error. ④ Decreased model robustness under domain shifts such as jig variations, evaluation environments, signal-to-noise ratio (SNR), and the occurrence of new abnormal noises. ⑤ Constraints in application due to compatibility issues with existing evaluation equipment. To address these issues, this study proposes an unsupervised learning-based method for classifying operating noise data of Column-type

Park, Jun-Seo, Jo, Hyeon-Choel, Cho, In-Je, Seo, Jae-Yong, Yoo, Seong-Sik

Joint estimation of inputs and states for multi-axis vibration environment testing

2026-01-0683To be published on 06/20/2026

Monitoring the states of a structural dynamic system is often challenging, as direct measurements are costly or even infeasible. Estimating “hard-to-measure” quantities from a limited set of output-only data is therefore of great interest and useful for the application of Structural Health Monitoring (SHM) systems. This work proposes a virtual sensing methodology for state estimation in structural dynamics based on a tuned Kalman Filter, combined with a model order reduction technique to ensure low computational cost. The approach aims to overcome the limitations of dense embedded physical sensor networks by reconstructing unmeasured responses from limited measurements. The methodology is validated numerically and experimentally on a notched aluminum beam, representative of an overhanging automotive component, subjected to multi-directional base excitations on a 3D shaker to emulate realistic operating conditions.

Salazar Colunga, Rodrigo, Pandiya, Nimish, Dindorf, Christian, Naets, Frank

AI-Based Package Tray Design Method for Controlling Acoustic Modes in a Sedan

2026-01-0716To be published on 06/20/2026

• In this study, we propose a methodology for predicting the acoustic modes and natural frequencies of a sedan using artificial intelligence and demonstrate the feasibility of controlling its acoustic characteristics by modifying the hole distribution of the package tray. In typical sedan structures, the cabin cavity and trunk cavity are acoustically coupled through holes in the package tray. The distribution of these holes significantly affects the natural acoustic modes and frequencies of the vehicle. However, once the exterior shape of the vehicle is finalized during the design phase, options for structural modifications to mitigate noise issues caused by these modes become extremely limited. To address this challenge efficiently, we develop a deep learning-based neural network model trained on data derived from a simplified acoustic analysis model of a sedan that includes a package tray. Finite element analysis is performed to generate acoustic modes and natural frequencies, which

Lee, Jin Woo, Cho, Jaeho, Nam, Younsic, Han, Yongha

A Modular Method for Certified Virtual Validation of NVH Performance in Automotive Platforms

2026-01-0684To be published on 06/20/2026

This work presents a modular engineering methodology (DigPhBalance - Digital Physical Balance) for the virtual validation of Noise, Vibration, and Harshness (NVH) performance in automotive development. The approach addresses the inefficiency of repeated physical testing across vehicle variants by introducing a structured two-phase process—Launcher and Reskin—centered on quantitative performance indicators with formal acceptance thresholds. In the Launcher phase, a digital replica of the base vehicle is built and iteratively correlated with physical test data. Validation is governed by objective indicators of confidence, conformity, and correlation, each evaluated against predefined thresholds. Once validated, the model becomes a certified reference, enabling its reuse across derivative configurations in the Reskin phase. Physical testing is only required if indicators fall below threshold, with a final gate test on pre-series vehicles ensuring industrial robustness. DigPhBalance

Celiberti, Lucia, Camia, Andrea

Methodology Development for EDM Vibro-acoustic Assessment using Simulation Measurement Comparison and RCA

2026-01-0691To be published on 06/20/2026

The virtual development of Electric Drive Modules (EDM) for Battery Electric Vehicles (BEVs) requires proven and predictive methodologies. One part of the development investigates the vibro-acoustic assessment for low and high frequencies over the targeted operating range. The efficient usage of such a methodology requires the understanding of the accuracy and the validity of the achievable results as well as the derivation of suitable improvement measures for goals that have not been achieved. The usage of reference data from experimental investigations and a detailed root-cause analysis (RCA), to directly link a specific response and behavior to the excitations, modal content and transfer functions, is an essential and non-trivial part of the methodology development. This paper describes the development of such a methodology using the example of a new EDM virtual model for Noise, Vibration and Harshness (NVH) analysis, the simulation approach, validation, and evaluation procedure. It

Klarin, Borislav, Pevec, Denis, Resch, Thomas, Esposito, Sara, D'Alessandro, Vincenzo, Spanu, Giorgio

High-frequency mount characterization: a comparison of methodologies

2026-01-0693To be published on 06/20/2026

The rapid electrification of the automotive industry introduces new challenges in noise, vibration, and harshness (NVH). In particular, in a virtual prototyping phase of the e-vehicles development, the rubber mounts are often one of the key elements to be considered when analysing the structure borne noise contributions. Having an accurate experimental characterization of the mount dynamic stiffness curves is therefore very relevant. However, conventional mount characterization methods are often pushed to their limits, partly due to the use of stiffer bushings, and partly because the frequency range of interest is extended toward higher frequencies. When using inverse substructuring, the dynamic stiffness curves can be obtained from frequency response function measurements. The required test setup consists of excitations and responses, located on each side of the mount via dedicated fixtures. The measured frequency response functions are reduced into 6 degrees of freedom representation

Bianciardi, Fabio, Forrier, Bart, Minervini, Domenico, Barbieri, Marco, Janssens, Karl

Development and Standardization of a Compensation Method for Measurement Equipment Effects to Improve Blocked Force Accuracy in Physical Tires

2026-01-0698To be published on 06/20/2026

Although the tire system is not developed in-house but supplied by tire manufacturers, it is a critical component that significantly affects overall vehicle performance, including NVH. To ensure the supplied tires meet vehicle performance targets, our company provides detailed development guidelines, defining block force—closely related to road noise—as a key NVH performance index. As virtual tire development is introduced, manufacturers will submit block force data from virtual models with initial tire designs, enabling early prediction of tire and vehicle-level performance. However, this approach is still under evaluation, with unresolved challenges such as the absence of clear block force target-setting methods and limited accuracy in current virtual evaluations. To address this, we propose using block force measurements from mass-produced or prototype tires as a basis for data-driven target setting and as a reference to enhance virtual model accuracy. Since block force data is

Ahn, Youngeun, Kang, Min Kyoo, Kim, Yong Dae, Reichart, Ron, Kim, Yonghun, Han, Inhyuk, Ji, Unjin, Lee, JeongHwan

Mid-High frequency structure-borne transmission in full vehicles trimmed body models using a reverberant finite element approach

2026-01-0706To be published on 06/20/2026

The simulation of structure-borne energy flow within a full vehicle trimmed body at mid and high frequencies has always been a challenge due to the large computational cost associated with standard deterministic simulations. This is a particularly pressing problem given that the electrification of the vehicles is extending the presence of structure-borne sources to higher frequencies. While the improvement of computational hardware has allowed OEMs to shift the limit of standard Finite Element (FE) approaches to higher frequencies, no methods have been proposed in the literature that tackle the full frequency range for industrial-sized problems. In this paper, a simulation methodology that uses wave-based processing of the original low-frequency finite element input deck to compute the coupling loss factors is proposed to model structure-borne noise in complex systems at mid and high frequencies. The methodology is validated against numerical and experimental data.

Errico, Fabrizio, Legault, Julien, Mordillat, Philippe, Zerrad, Mehdi

Best-in-Class NVH Optimisation for Electric Powertrains, Holistic Front-Loading Approaches

2026-01-0689To be published on 06/20/2026

Achieving best-in-class Noise, Vibration, and Harshness (NVH) in electric powertrains demands a paradigm shift in development methodology. This paper presents a holistic, front-loaded approach to NVH optimisation, leveraging simulation models, machine learning, and target cascading to deliver superior results. By attacking NVH at the source, and integrating data-driven techniques early in the design cycle, significant reductions in development time and reliance on traditional testbed loops are realised. Machine learning algorithms are utilised to accelerate root cause analysis and refine simulation accuracy, while target cascading ensures alignment of system-level performance objectives down to subsystem contributions. Combined, these strategies enable rapid and robust NVH optimisation, setting the benchmark for next-generation electric powertrain development. several application and real life exmaple are shown.

Mehrgou, Mehdi, Garcia de Madinabeitia, Inigo, Graf, Bernhard, Gojo, Josef

A New Approach to Identify Rigid Body Rotations When Measuring the Body Distortion of a Full Vehicle

2026-01-0682To be published on 06/20/2026

The Opening Distortion Fingerprint (ODF) is a method to evaluate the overall body stiffness of a vehicle using the Multi Stethoscope (MSS). Using the MSS, the time history of distortion in diagonals located at all body openings and cross sections of a vehicle are captured. Evaluation of the ODF is applicable in both test and Multibody Dynamics (MBD) simulation. It has been found that the Evaluation-line (E-line) method, which is used for the distortion calculation, gives valid results in the absence of large rotations originating from rigid body modes that occur at low frequencies. The E-line method measures the relative displacement between two points in a local coordinate system. One straightforward way of identifying the frequency at which the large rotations start to make the E-line results invalid, is to compare the distortion in the local z-component (pointing in the direction of the diagonal) of the E-line method with the total distance (i.e. the total deformation of the

Olger, Emma, Lindkvist, Lisa, Piiroinen, Petri, Karypidis, John, Pena, Milton, Bäcklund, Jesper, Appelgren, Peter, Marberg, Henrik, Ugale, Pravin, Weber, Jens

Feasibility of Hybrid Dynamic Substructuring for Structural Modifications in Automotive Suspension Subsystems

2026-01-0697To be published on 06/20/2026

Recent advancements in system-level NVH (Noise, Vibration, and Harshness) development methodologies have improved target cascading and enabled more efficient system-level optimization. Dynamic substructuring facilitates the virtual integration and modification of multiple subsystems and the prediction of changes in overall transfer functions. In practical automotive applications, advanced frequency-based substructuring has been applied to virtually modify system parameters—such as mass and stiffness—at multiple points in a target system, allowing prediction of the resulting effects and optimization of parameter changes without physical intervention. This study extends the methodology by introducing an enhanced substructuring approach capable of addressing not only basic parameter modifications but also large-scale structural changes. The proposed process involves identifying the characteristics of a base system assembly and a target subsystem, decoupling the subsystem from the assembly

Cho, Munhwan, Boelens, Jelle, Reichart, Ron, de Klerk, Dennis, Ahn, Jiho

Validation of an adaptive order Finite Element model for transmission loss simulation of trimmed automotive structures

2026-01-0707To be published on 06/20/2026

Vehicle electrification and increasing demands for driving comfort present significant challenges for designing effective noise control treatments in modern vehicles. Lightweight, low-emission designs often compromise acoustic efficiency. One way of compensating this is through the use of multi-layer ‘trim’ material configurations to mitigate noise across a wider frequency range. Traditional 3D finite element models, while accurate and even needed to capture the full dynamic behaviour, become computationally prohibitive for complex automotive structures like firewalls, which feature intricate shapes, high curvature, and material compression. This computational burden limits design exploration and timely noise performance predictions. This paper introduces the use of an innovative adaptive higher-order finite element method to address these challenges. The method utilizes a fixed finite element discretization of trim components and surrounding acoustic fluid, incorporating an automated

Van Genechten, Bert, Vansant, Koen, Purohit, Bimal, Effinger, Veronika

Simulation and Analysis of Flow and Acoustic Induced Structural Vibration

2026-01-0696To be published on 06/20/2026

For analysing flow and acoustic induced structural vibration, a run time fully coupled framework combining a hybrid CFD-CAA approach with a modal response simulation was validated and presented at the ISVNH 2022 (SAE Technical Paper 2022-01-0938). In this contribution we show the application of this method on a production vehicle, simulating the flow and acoustic induced vibration of the bonnet. The simulation setup of this study resolves the geometry of the vehicle including the complex details of the bonnet structure, the frunk and the engine compartment. The FEM model for the modal analysis of the bonnet takes into account the complex boundary conditions at the bearings and provides the eigenmodes relevant for the low frequency range. Simulations are conducted in an undisturbed wind tunnel setup and the resulting vibrations are compared to acceleration measurements under wind tunnel and road conditions. Due to the employed hydrodynamic acoustic split approach, the relevance of the

Schwertfirm, Florian, Ocker, Joerg, Hartmann, Michael

A Self-Learning Framework for NVH CAE Analysis

2026-01-0718To be published on 06/20/2026

The vibro-acoustic performance of a vehicle is a critical factor in customer perception of quality and comfort. Optimizing for Noise, Vibration, and Harshness (NVH), particularly road noise, presents a persistent challenge in the automotive development cycle. While modern FEM analysis is essential, the increasing complexity and sheer volume of CAE simulation data often overwhelm manual interpretation, potentially leading to prolonged development times or sacrifices in resulting comfort quality. To address these challenges, this paper introduces the application of CDH/ACE (Autonomous Computational Experiments), a framework that combines conventional CAE simulation workflows with machine learning in an iterative cyclic process. This creates a self-learning and self-correcting system that autonomously defines, performs, and learns from computational experiments. By building predictive models from simulation data, the framework intelligently guides the design exploration to achieve

Visser, Rene

NoiseSphere: An AI-Based Approach for Dynamic and Large-Scale Noise Mapping

2026-01-0719To be published on 06/20/2026

Noise pollution is a major environmental and health challenge, yet its strong spatial and temporal variability makes comprehensive mapping highly complex. Current approaches under the European Noise Directive (END) provide only partial coverage and often lack temporal dynamics. The NoiseSphere project, fundet by the Austrian Research Promotion Agency FFG, develops an AI-based methodology for dynamic, large-scale noise prediction and mapping. A machine learning model is trained on heterogeneous data sources, including semantically enriched Sentinel-2 satellite imagery, OpenStreetMap road data, floating car data (traffic density and speed), and existing noise maps. The model is refined through integration of noise emission data and validated using targeted in-situ measurements. Two case studies, one located in an urban environment (Graz) and the other one in a rural region near Linz demonstrate the model’s applicability across contrasting settings. By combining remote sensing, traffic

Girstmair, Josef

Items per page:

1 – 50 of 46184