Browse Topic: Design Engineering and Styling

Items (43,057)

CAE simulation based structural assessment of steering wheel

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

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

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

Phenomenological modelling of radar sensor and realization of noise effects

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

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

Hanumanthaiah, Manjunath, S, Girish, Durairaj, Priya

Investigation on Thermal Performance of Battery Cooling Plate for Lithium-ion Battery

2024-28-0259To be published on 12/05/2024

Electric Vehicles are regarded to be the most effective way to lower emissions of greenhouse gases from transportation industry. Lithium-ion batteries are rechargeable and ideally suited for vehicle electrification due to their high specific energy and energy density in comparison to others. Electric Vehicle performance greatly depends on efficient operation of Li-ion Battery. Battery thermal management plays a crucial role in ensuring the optimum vehicle operation. Heat dissipation from the battery should be dealt with, for safe operation and to prolong the battery life cycle. To achieve the battery’s optimal temperature, an efficient cooling system should be established. Battery cooling plate is an essential component which is necessary for heat transfer from battery pack to coolant. Four different battery cooling plates such as dimple, U shaped, Splitter, Serpentine with varying profiles are modeled for computational fluid dynamics simulation. Models are compared based on pressure

K, Muthukrishnan, S, Saikrishna, K, Keshavbalaje

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

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

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

PATEL, HARDIK MANUBHAI, Gupta, Vineet, Chand, Subhash, KUMAR, NITISH

Smart Testing Methodology For Air Suspension System Of Buses

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

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

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

Correlation Study for Radial Lash in Sliding Bushings of a Steering System

2024-28-0249To be published on 12/05/2024

Investigation of clunking noise in a steering system fitted into a test vehicle indicated radial lash in sliding bushings, which are press fitted into housings, as one of the possible causes for clunk. To study the behavior of sliding bush under the influence of assembly clamp loads, manufacturing tolerances and road loads, sliding bushes are modelled in more detail in the steering system finite element models. Further for correlating the bushing measurements from test vehicle to the finite element model, a radial lash output is derived which is not directly available in finite element software. Finally, the correlated model is used to assess the updated design and check for radial lash improvement

Badduri, Jaideep, Pandey, Ashish

Impact Of Time Aligned Measurement Parameters On Brake Specific Emissions

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

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

Patil, Rahul Chandrakant, Rajoapdhye, Sunil, Mudassir, Mohammed, Mokhadkar, Rahul, Phadke, Abhijit Narahari, Bharambe, Niraj, DHURI, SANTOSH

Application of TOPSIS approach for Optimization on Additive Manufacturing (Fusion Deposition Modeling) of TPU Material: A Systematic Approach for Process Enhancement

2024-28-0232To be published on 12/05/2024

Additive Manufacturing (AM), specifically Fusion Deposition Modeling (FDM), has transformed the manufacturing industry by allowing the creation of complex structures using a wide range of materials. The objective of this study is to enhance the FDM process for Thermoplastic Polyurethane (TPU) material by utilizing the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) optimization method. The study examines the influence of FDM parameters, such as layer height, nozzle temperature, and infill density, on important characteristics of the printing process, such as tensile strength, flexibility, and surface finish. The collection of experimental data is achieved by conducting systematic FDM printing trials that cover a variety of parameter combinations. The TOPSIS optimization method is utilized to determine the optimal parameter settings by evaluating each parameter combination against the ideal and anti-ideal solutions. This method determines the optimal parameter

Pasupuleti, Thejasree, Natarajan, Manikandan, Kiruthika, Jothi, Ramesh Naik, Mude, Silambarasan, R

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

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

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

Deshmukh, Shardul, NIKAM, VINOD

Implementation of a Hybrid Hardware-in-the-Loop (HIL) Test System for Automotive Software Validation and Verification

2024-28-0252To be published on 12/05/2024

The automotive industry relies heavily on software to enhance safety, performance, and user experience. The increasing complexity of automotive software demands rigorous testing methodologies. Ensuring the quality and reliability of this software is critical. In this paper, we propose an innovative approach to software validation and verification using a Hybrid Hardware-In-the-Loop (HIL) test system. Our methodology integrates diverse hardware and software tools to establish a flexible and efficient testing environment. This environment can evaluate the Device Under Test (DUT) with minimal alterations. Our comprehensive solution includes the development of test strategies, plant model simulation, and compliance assurance, all in accordance with automotive standards such as ASPICE and ISO26262. We also introduce a Personality module for the DUT, enabling sequential testing of multiple products using the same HIL setup. This is achieved by loading a DUT-specific signal mapping

Yadav, Vikaskumar, Bhade, Nilesh

Calibrated Accelerated Life Testing (CALT) First Load Determination Using Systematic Step Stress Concept

2024-28-0251To be published on 12/05/2024

Calibrated Accelerated Life Testing (CALT) is a sequential and quantitative method to Accelerated Life Testing (ALT). Its design aims to optimize test efficiency by minimizing both test duration and sample size while estimating product life. In the CALT context, the focus is on testing specimen under three or more distinct stresses or loads to estimate the life span/BX life, which is a crucial parameter in reliability estimation. Determining the first load in CALT typically involves exploratory testing on a limited number of specimens and relies heavily on engineering judgments such as analyzing Finite Element Analysis (FEA) outcomes, referencing test data from comparable designs and materials, and considering stiffness results etc. This often leads to challenges in accurately identifying the first load/stress. To address this issue, we propose a systematic step-stress test approach instead of exploratory testing. This approach aims to efficiently identify the first load in CALT. The

Patidar, Nitin, Soma, Nagaraju

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

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

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

Hande, Sheetal Vikram, Mandava, Balaji Bharath

Parametrized Twist Beam Suspension for Enhanced Ride and Handling : A Design Iteration Approach

2024-28-0181To be published on 12/05/2024

Objective: - The parametrized twist beam suspension is a pivotal component in the automotive industry, profoundly influencing the ride comfort and handling characteristics of vehicles. This study presents a novel approach to optimizing twist beam suspension systems by leveraging parametric design principles. By introducing a parameter-driven framework, this research empowers engineers to systematically iterate and fine-tune twist beam designs, ultimately enhancing both ride quality and handling performance. Methodology: - Affordable vehicles are widely equipped with twist-beam suspensions since they are simple to design, take up less space, and are less expensive to manufacture. It is difficult to design an axle made with twist-beam profiles due to the variety of possible configurations, and the suspension arm and axle beam stiffness must be adjusted. To address the challenges of optimizing the twist beam model, this study presents a simplified optimization model using MSC ADAMS. This

Pakala, Pradeep Kumar, Ganesh, Lingadalu

Optimization of Additive Manufacturing (Fused Deposition Modeling) of PETG Material Using Taguchi Grey Relational Analysis

2024-28-0234To be published on 12/05/2024

Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM), has become a highly promising method for creating intricate shapes using different materials. Polyethylene Terephthalate Glycol (PETG) is a highly utilized thermoplastic that is recognized for its exceptional strength, resistance to chemicals, and effortless processing. This study aims to optimize the process parameters of the FDM technique for PETG material using Taguchi Grey Relational Analysis (GRA). An empirical study was carried out to examine the impact of various FDM process parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on important outcome variables like dimensional accuracy, surface quality, and mechanical properties. The Taguchi method was used to systematically design a series of experiments, while GRA was used to optimize the process parameters and performance characteristics. The results unveiled the most effective parameter combinations for attaining

Natarajan, Manikandan, Pasupuleti, Thejasree, Kiruthika, Jothi, D, PALANISAMY, Silambarasan, R

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

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

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

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

Influences of porosity shapes and sizes on stress and strain fields in the Casted Aluminum using Finite Element Modelling

2024-28-0159To be published on 12/05/2024

Porosity is a common issue in Aluminum casting. The contemporary casting technologies have succeeded to some extent in predicting and controlling the casting defects. It is still impossible to eliminate various defects such as porosity, voids, and inclusions. It is also difficult to predict the exact shape and size of defect. Consequently, a key challenge in designing casted components is to validate durability by predicting accurate stress, strain, and strength by considering casting defects. In the present work, a set of static elastic-plastic finite element analyses (FEA) performed to obtain the stress and strain fields distribution near the voids/pores, and their resultant impact on tensile strength of Aluminum under tensile testing is studied. Using FEA, the stress and strain fields are determined for simple tensile test samples/specimens without and with voids/discontinuities modeled under a uniform displacement applied at a far field. The stress concentration is evaluated as a

T, Kalinga, Sahu, Abhishek, Chirravuri, Bhaskara, miller, Ronald, Xu, Siguang

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

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

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

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

Comprehend Dynamic Behaviour of Vehicle Body for Refined NVH Performance

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

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

Titave, Uttam Vasant, ZALAKI, NITIN, Naidu, Sudhakara

A Simulation-based Methodology for Optimizing correlation of Brake Disc

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

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

Negi, Ayush Singh, Kochhar, Raman

Trailer Disengage confirmation Alarm System for Electric Subsystems

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

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

Singh, Amandeep, KUMAR, Pradeep, SURESH, KARTHIKRAJAN, KOTIAN, PRADEEP, T, THIRUNAVUKKARASU, Chitreddy, Bharath, R, Sunilkumar

A Comprehensive Analysis of Electromagnetic NVH in Electric Powertrain

2024-28-0136To be published on 12/05/2024

In this paper, a comprehensive analysis of NVH in electric powertrains due to electromagnetic sources is presented. The spatial harmonics model of the traction motor, which is dependent on the motor design structure, rotor poles, stator teeth, and slots, is used for the analysis of the electromagnetic forces from the motor in the electric powertrain. The time harmonics model of the injected current of the motor dependent on the drive electrical circuit and control strategy is also considered for the electromagnetic force calculation. A complete workflow of this electromagnetic NVH analysis for electric powertrain covering the spatial harmonics and time harmonics model is presented. The spatial harmonics model result is presented as flux linkage with respect to dq-axes current and rotor position. The time harmonics are also presented by the injected current of the motor. In addition, a set of operating points on the torque-speed boundary of the traction motor is selected and results are

Joshi, Nakul, Kumar, Vinit, Tsoulfaidis, Antonios, Huang, Zhenhua, Schmaedicke, Marcel, Fialek, Gregory, Zhang, Dapu, Wimmer, Joe

Enhancing Bumper & Headlamp Durability: Lightweight Bumper design with Optimized Resonance Frequency

2024-28-0238To be published on 12/05/2024

Lightweight Bumper Design for Enhanced Durability and Natural Frequency The automotive industry continually seeks innovative solutions to improve safety, reduce weight, and enhance performance. In this study, we propose a novel lightweight bumper design that addresses two critical aspects: bumper and headlamp durability and natural frequency optimization. Durability Enhancement: Our design incorporates advanced materials, such as high-strength composites and energy-absorbing polymers, to withstand impact forces. Structural simulations and crash tests validate the improved durability, ensuring protection for both the vehicle and pedestrians. Natural Frequency Optimization: By carefully selecting materials and geometry, we achieve a desirable natural frequency for the bumper system. Proper tuning minimizes vibrations during driving, enhancing ride comfort and stability. Weight Reduction: The lightweight design significantly reduces mass without compromising safety. Weight savings

Pandey, Sudheer, Ganesan, Balaji

Reliability assessment of Audio generating devices- Horn

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

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

Joshi, Vivek S., Jape, Akshay

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

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

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

R, Teddy Samuel, Mayakrishnan, Jaikumar

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

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

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

Kumar, Amit, HEGDE, KARTHIK, Challa, Krishna, H, YASHWANTH

Validation methodology of different driver monitoring systems using a modular motion drive simulator

2024-28-0263To be published on 12/05/2024

In India, Driver Drowsiness and Attention Warning (DDAW) system market is increasing due to anticipation on mandatory regulation for DDAW. However, readiness of the solution to introduce to Indian consumer can be challenging as the validations to meet standard (Automotive Industry Standard 184) for the system are complex and sometimes subjective in nature. Furthermore, the evaluation procedure to map the system accuracy with the Karolinska sleepiness scale (KSS) requirement involves manual interpretation which can lead to false reading. In certain scenarios, KSS validation may entail to fatal risks also. Currently, there is no effective mechanism so far available to compare the performance of different DDAW systems which are coming up in Indian market. This lack of comparative investigation channel can be concerning factor for the automotive manufactures as well as for the end-customers. In this paper, a robust validation setup using motion drive simulator with 3 degree of freedom (DOF

Raj, Prem raj Anand, Selvam, Dinesh Kumar, Thanikachalam, Ganesh, Sivakumar, Vishnu

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

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

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

venkatachalapathy, Sreenikethana

Multidisciplinary and Integrated Approach to Predict Automotive Axle System Efficiency

2024-28-0196To be published on 12/05/2024

In today’s competitive automotive market, customers are now looking for system efficiency as one of the important design parameters of system performance along with durability and reliability. It is essential to ensure products are designed to utilize maximum input power and have better system efficiency. In automotives, transmission and axle systems are power transmitting elements from prime mover to wheels and are one of the main contributors to overall vehicle efficiency. Hence, predicting and assessing overall system efficiency of these aggregates is of paramount importance. System efficiency is driven by component power losses for various speeds and torques, which are arising out of component design parameters, complex interaction within system, operating conditions, lubrication, temperatures etc. To capture multi-physics of speed and torque dependent losses of automotive axle, multidisciplinary and integrated approach is proposed in this paper, Efficiency predictive model is

Dambir, Gaurav

Performance Evaluation of Battery Cooling System for Electric Bus Applications Using MATLAB

2024-28-0145To be published on 12/05/2024

As the electrification of transportation continues to gain momentum, the thermal management of onboard batteries remains a critical aspect to ensure optimal performance, efficiency, and longevity. To address this challenge, we developed a standalone cooling system with a cooling capacity specifically tailored for electric buses. This paper presents a comprehensive analysis of the performance comparison between simulation and testing data for a standalone battery cooling system designed for electric bus applications. The study encompasses two primary components: numerical simulation using MATLAB Simulink and experimental testing. In the experimental phase, rigorous tests were conducted in a laboratory environment to evaluate the system's cooling performance under various operating conditions. Key metrics such as cooling capacity, temperature profile, and power consumption were measured and recorded to assess the system's effectiveness. A detailed numerical simulation model was developed

Suman, Saurabh, Kushwah, Yogendra Singh, SHUKLA, ANKIT

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

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

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

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

Design improvement on cooling plates/tube of BTMS of Electric vehicles by changing internal structure and coolant mass flow rate

2024-28-0203To be published on 12/05/2024

The lithium-ion battery is most common types of batteries in modern electric vehicles. During operation of vehicle and charging of batteries, temperature of the battery cells increases. From any battery, its temperature needs to be controlled and maintained within a defined limit to achieve the maximum efficiency. Considering the overall thermal effect on the battery, a battery cooling system is of great importance in electric vehicles to maintain the temperature of the battery cells inside the battery pack. There are different types of systems for battery cooling but water cooled systems are very popular. It uses mixture of water and ethylene glycol to absorb heat from the battery cells. The coolant circulates through components that surround the cells, such as tubes and cold plates surrounded by cells. The paper involves the study of internal structure of tubes on the temperature variation of battery cell. It involves by changing the design of internal structure of the tube how the

Parayil, Paulson, Ahmad, Taufeeq, Dagar, Aakash, Goel, Arunkumar

Revolutionizing Simulink Model Management with Conduit Frameworks

2024-28-0167To be published on 12/05/2024

This paper presents a comprehensive implementation of various Conduit frameworks designed to manage the hygiene of Simulink models in control systems and enhance them to meet industry standards such as MAB, MISRA, Polyspace, and SERT. The core challenge addressed is the minimization of repetitive work and the elimination of cognitive workload. Beginners often struggle to create Simulink models that adhere to industry standards, and keeping track of all the standards can be challenging Given the complexity and size of these models, manual processing is time-consuming. Our Conduit frameworks help enhance their models for adherence to those standards, improving efficiency by up to 95% and utilizing machine intelligence to process large amounts of code efficiently. The Conduit frameworks also automate non-value-added (NVA) activities, including updates in properties of variables, checking for unwanted data types that develop during internal calculations of Simulink blocks, and variable

Agrawal, Vipul, TE, Harikrishna, N, Prajitha, Kumar, Kosalaraman, Venkat, Harish, Shaji, Anish

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

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

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

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

Comparative Analysis of BIW Subassembly Simulation Techniques: AutoForm vs LS-DYNA

2024-28-0169To be published on 12/05/2024

Abstract Assembly simulation plays a pivotal role in predicting and optimizing the distortion of an assembly, particularly in the automotive industry where precision and efficiency are paramount. In BIW parts assembly, factors such as clamping, mechanical & thermal joining, and loading direction are important. These factors affect the quality of the final assembly. Predicting and optimizing these parameters in the early design stage can help reduce development time, cost and improve the quality of the final product. Currently, LS-DYNA is used for closures like doors, hoods, and fenders. However, preprocessing, calculation, and post-processing time in LS-DYNA is very high, making it unfeasible for the whole BIW. Employing a comprehensive approach, the authors assess the distortion results, preprocessing, calculation, and post-processing time of both simulation techniques. Notably, the study reveals that AutoForm offers over 50%-time savings across all stages compared to LS-DYNA, without

Talawar, Vaishnavchandan, Nalam, Swaroop Raju, DHANAJKAR, NARENDRA, KUMAR, AJAY, pasupathy, vivekanand, Chava, Seshadri

Onboard State of Charge Estimation for LiFePO4 Battery Packs Using a Hybrid Extended Kalman – Particle Filter Algorithm

2024-28-0223To be published on 12/05/2024

In recent years, Lithium Iron Phosphate (LiFePO4) has emerged as a popular choice for Li-ion battery chemistry in electric vehicles and energy storage systems due to its inherent safety, long lifecycles, absence of cobalt and nickel, and reliance on common raw materials. State-of-Charge (SoC) is a derived parameter used for optimal and safe battery operation. The Kalman Filter-based SoC estimator is highly regarded for its accuracy and suitability in Battery Management systems. However, estimators within the Kalman Filter Family requires an accurate initial SoC to deliver precise estimates. Errors in this initial SoC can result in significant inaccuracies, prolonging the time required for the estimator to converge to the true value. The Open Circuit Voltage–SoC (OCV–SoC) method is commonly used to set the initial battery SoC during idle periods. This method proves ineffective in LiFePO4 chemistry due to its flat OCV-SOC profile. Given the critical nature of battery applications, where

Ns, Farhan Ahamed Hameed, Jha, Kaushal, Shankar Ram, C S

Optimization of Wire Electrical Discharge Machining Parameters for Cupronickel Material Using TOPSIS Method

2024-28-0245To be published on 12/05/2024

Wire Electrical Discharge Machining (WEDM) is a widely used manufacturing technique that is employed to shape complex geometries in conductive materials such as cupronickel, which is highly regarded for its resistance to corrosion and ability to conduct heat. The objective of this study is to improve the effectiveness and accuracy of Wire Electrical Discharge Machining (WEDM) for cupronickel material by utilizing the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) optimization method. The study investigates the impact of WEDM parameters, specifically pulse-on time, pulse-off time, and discharge current, on important machining outcomes such as surface roughness, material removal rate. Experimental trials are performed to collect data on these parameters and their corresponding machining characteristics. The TOPSIS optimization method is utilized to determine the most favourable parameter settings by evaluating each parameter combination against the ideal and

Pasupuleti, Thejasree, Natarajan, Manikandan, Kiruthika, Jothi, C, Navya, Silambarasan, R

Development of ANFIS Predictive Model for Wire Electrical Discharge Machining of Cupronickel Material

2024-28-0239To be published on 12/05/2024

Wire Electrical Discharge Machining (WEDM) is an essential manufacturing process used to shape complex geometries in conductive materials such as cupronickel, which is valued for its corrosion resistance and electrical conductivity. The objective of this study is to improve the efficiency and precision of machining by creating a specialized predictive model using an Adaptive Neuro-Fuzzy Inference System (ANFIS) for cupronickel material. The study examines the intricate correlation between process parameters of the WEDM (Wire Electrical Discharge Machining) technique, such as pulse-on time, pulse-off time, and discharge current, and crucial machining responses, including surface roughness, material removal rate. Data is collected through systematic experimentation in order to train and validate the ANFIS predictive model. The ANFIS model utilizes the collective learning capabilities of neural networks and fuzzy logic systems to precisely forecast machining responses by considering input

Pasupuleti, Thejasree, Natarajan, Manikandan, Kiruthika, Jothi, Katta, Lakshmi Narasimhamu, Silambarasan, R.

Optimization and ANFIS Predictive Modeling of Additive Manufacturing (Fused Deposition Modeling) for PLA Material

2024-28-0240To be published on 12/05/2024

Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM), has become a revolutionary technology for creating intricate shapes using different materials. Polylactic Acid (PLA) is a biodegradable thermoplastic that is commonly used in additive manufacturing (AM) because of its environmentally friendly properties, affordability, and ease of use. The objective of this study is to optimize the FDM parameters for PLA material and create predictive models using the Adaptive Neuro-Fuzzy Inference System (ANFIS) to forecast printing performance. An investigation was carried out through experimental trials to examine the impact of important FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical outcomes such as dimensional accuracy, surface finish, and mechanical properties. The utilization of design of experiments (DOE) methodology enabled a methodical exploration of parameters. A predictive model using ANFIS was created to

Pasupuleti, Thejasree, Natarajan, Manikandan, Kiruthika, Jothi, Ramesh Naik, Mude, Silambarasan, R

Optimization of Additive Manufacturing (Fused Deposition Modeling) of PLA Material Using TOPSIS Approach

2024-28-0233To be published on 12/05/2024

Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM), has transformed the manufacturing industry by allowing the creation of intricate shapes using different materials. Polylactic Acid (PLA) is a biodegradable thermoplastic that is commonly used in additive manufacturing (AM) because of its environmentally friendly nature, affordability, and ease of processing. This study aims to optimize the parameters of Fused Deposition Modeling (FDM) for PLA material using the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) approach. The researchers performed experimental trials to examine the impact of important FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical outcomes, including dimensional accuracy, surface finish, and mechanical properties. The methodology of design of experiments (DOE) enabled a systematic exploration of parameters. The TOPSIS approach, a technique for making decisions

Natarajan, Manikandan, Pasupuleti, Thejasree, Kiruthika, Jothi, Katta, Lakshmi Narasimhamu, Silambarasan, R.

Crash Simulation of Steel-Wood Hybrid Road Safety Barrier with Perforated Post Design: Car Test Evaluation

2024-28-0162To be published on 12/05/2024

Research area in Road furniture has become important due to the rising incidence of road accidents and fatalities. Enhancing road attributes such as crash barriers, crash cushions, crash poles, and emergency communication systems can significantly reduce these fatalities. Among these, crash barriers promise particular attention as they serve as immediate safety mechanisms. When a vehicle loses control, crash barriers can effectively mitigate the severity of accidents by restraining the vehicle and preventing more severe outcomes. This paper focuses on the performance of a novel steel-wood hybrid crash barrier with perforated post parallel to vehicles direction, designed to enhance road safety in hilly areas. Utilizing finite element analysis (FEA) in LS-DYNA software, renowned for simulating structural deformation under loading, we evaluated the structural response and crashworthiness of the hybrid barrier under various impact scenarios. Our simulations assessed the barrier's

Bendre, Sagar, Das, Alakendu, Jaiswal, Manish

Utilization of FEA based Fluid Pressure Penetration Technique for understanding Fluid Leakage Phenomenon from Mechanical Fittings

2024-28-0247To be published on 12/05/2024

In demanding automotive coolant applications characterized by extreme pressure and temperature conditions, a variety of Mechanically Attached Fittings (MAFs) are offered by multinational corporations (MNCs). These engineered fittings have been designed to meet the rigorous requirements of various industries, providing a cost-effective and reliable means to seal coolant hose joints. Mechanical fitting assemblies are critical in various engineering systems and are used for connecting various fluid-carrying locations. Understanding leakage phenomena from MAFs is essential for ensuring their reliability and efficiency. This study explores the deployment of Fluid Pressure Penetration Technique (FPPT) available in Abaqus FEA software to comprehensively analyze leakage paths in mechanically joined fittings. The FPPT offers a systematic approach to model fluid penetration behavior within fitting joints under many loading conditions. By utilizing Abaqus software, a powerful finite element

Aher, Ravi Kautik, Jivani, Chinmay, Olesnavich, Michael, Lima, Jose, Pillai, Pramod

Optimizing the Capacity of Dozer Blade with Hydraulic Foldable Wings to Enhance Productivity

2024-28-0268To be published on 12/05/2024

Crawler Dozers play a critical role in global construction, mining and industrial sectors, performing essential tasks like pushing the material, grading, leveling and scraping. In the highly competitive dozer market, meeting the growing demand for increased productivity requires strategies to enhance blade capacity and width. Approximately 70% of dozer operations involve pushing the material and dozing, where blade capacity significantly influences performance. Factors such as mold board profile, blade height, and width impact blade capacity which are crucial for productivity in light applications such as snow removal and dirt pushing. Blade width is also pivotal for grading and leveling tasks. Traditional blade designs, like straight or fixed U-type blades, constrain operator flexibility, limiting overall productivity. The integration of hydraulic-operated foldable wings on both sides of the blade offers the adaptability to adjust blade capacity which also helps to reduce material

Sahoo, Jyoti Prakash, Sarma, Neelam Kumar

Influence of Discrete Load Cases on Optimization of Chain Guide Design of Crawler Dozers under Various Ground Conditions

2024-28-0270To be published on 12/05/2024

The undercarriage is a critical component in machines like Crawlers, Excavators, and Compact Track Loaders. Undercarriage includes vital elements of the machine such as Track Frame, Chain Guides, Rollers, Track Chains, Idler, Carrier Rollers, Final Drive, and Sprockets. Among all the machines, Crawler Dozers encounter harsh environments with various ground conditions. During operations, the chains are subjected to traverse and side loads due to which the chains tend to slip out of the bottom rollers. The chain guide plays a crucial role in assisting and maintaining the chain in the correct position. The forces acting on chain guides are influenced by factors like track chain tension, roller wear, chain link wear, impact loading (especially side impact), and counter rotation, where one track moves forward while the other moves in reverse. This study is focused on analyzing various load cases to determine the necessary number of chain guides, the optimal spacing between each chain guide

Masane, Nishant, Bhosale, Dhanaji, Sarma, Neelam K

Real Time Vehicle State Estimation using Error Map Function

2024-28-0266To be published on 12/05/2024

The estimation of vehicle handling and control parameters in dynamic conditions is challenging due to errors and delays in real-time data logging with low-resolution onboard sensors. These issues significantly impact the performance of vehicle stability and control algorithms, particularly in vehicles under testing. This study presents a statistical approach for real-time vehicle state estimation that addresses the limitations of low-resolution sensors with errors and delays in measured signal. In this study, a real-time (RT) model was developed and trained using an in-house electric SUV to estimate yaw velocity and slip angle. The model leverages other measured signals available from the vehicle’s onboard sensor setup. It integrates an error and delay function with an error predictive model to estimate the targeted parameters' signal response in real time. The RT model introduces an error function method that enhances prediction accuracy by combining the error map value with the error

Kumar, Avinash, Asthana, Shivam, Rasal, Shraddhesh, M, Sudhan, Vellandi, Vikraman

Diesel Exhaust Fluid (DEF) Associated Corrosion Risk Prediction for Aftertreatment System

2024-28-0258To be published on 12/05/2024

Topic Name: Diesel Exhaust Fluid (DEF) Associated Corrosion Risk Prediction for Aftertreatment System. Authors: Tushar S Udhane, Enoch Nanduru, Michael J Warwick, Donald E Willey, Tanishq Parikh, Nikhil Giri. Abstract: With emission regulations becoming increasingly stringent, the integration of Diesel Exhaust Fluid (DEF) in aftertreatment systems has become essential for reducing nitrogen oxide (NOx) emissions in compliance with these evolving standards. DEF dosing is a critical component in Selective Catalytic Reduction (SCR) systems, where it chemically reacts with NOx emissions in the exhaust stream to form harmless nitrogen and water vapor, thus significantly reducing the environmental impact of diesel engines. However, the introduction of DEF presents a challenge of corrosion risk within the aftertreatment system components. This study aims to predict the location of corrosion risks associated with DEF usage in Diesel aftertreatment system by employing a multi-faceted approach

Udhane, Tushar Sudam, Nanduru, Enoch, Warwick, Michael, Willey, Donald, Giri, Nikhil, Parikh, Tanishq

Writing and Effective Technical Safety Concept in accordance with ISO26262

2024-28-0207To be published on 12/05/2024

With the trend of increasing technological complexity, software content and mechatronic implementation, there are increasing risks from systematic failures and random hardware failures, which is to be considered within the scope of functional safety. ISO 26262 series of standards provides guidance to mitigate these risks by providing appropriate requirements and processes. To develop a safe product with respect to above mentioned complexities, it is very critical to develop a safe system and hence a thorough and robust “Technical Safety Concept” is very important to ensure absence of unreasonable risk due to hazards caused by malfunctions of E/E systems. ISO26262-Part 4 provides guidelines for “Product development at the system level”, to design safety-related systems that include one or more electrical and/or electronic (E/E) systems and that are installed in series production road vehicles. Defining requirements at system level for each individual technology and systematically

CHENI, DILEEP KUMAR, Desai, Priyanka Pradeep

Smart Logistics Junction to Supervise the Material Handling Equipment Movements at The Intersection

2024-28-0260To be published on 12/05/2024

This paper presents a work undertaken to simulate the logistics processes in the digital environment using a discrete event simulation software which involves the movements of the Material Handling Equipment [MHE]. MHE movements to the line side involves traffic, where the parts are transported from the supermarket area to the line side based on the part requirement list ordered from the line side. Due to the shared routes for the delivery, the traffic at the intersections is more and if the vehicle scheduling is not streamlined during any failure/stoppage of the vehicle, would result in the blocking of the vehicles causing line stoppage. This work outlines to develop a junction block in the digital environment using a discrete event driven approach where an optimal flow of the vehicles is maintained at the intersections. The Junction block is created based on the succeeding track occupancy level, thus the preceding MHE’s can overtake in case of any blockages based on the priority. The

Surendranath, Sujith, Amasa, Sanjay, Kotegar, Shravan Raj, Venkataramana, Surendhar, Sathiyamoorthi, Gokul

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

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

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

Titave, Uttam Vasant, Vardhanan K, Aravindha Vishnu, ZALAKI, NITIN

DESIGN AND DEVELOPMENT OF STEERING BASED ADAPTIVE HEADLIGHT SYSTEM

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

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

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

Enhancing Testing and Simulation with Virtualized Base Software

2024-28-0248To be published on 12/05/2024

The fusion of virtualized base software with simulation technologies has transformed the methods used for development and system testing. This paper examines the architecture, implementation, and advantages of employing virtualization to improve simulation environments. Virtualized base software enables the creation of isolated, scalable, and replicable settings, essential for executing complex simulations that replicate real-world situations. Utilizing virtualization enhances simulations by making them more efficient, flexible, and cost-effective. The study covers the essential elements of virtualized simulation platforms, such as containerization, network abastraction and virtual drivers. It also analyzes how these components collaborate to create a strong framework for simulating diverse applications, ranging from software testing to hardware emulation. This approach offers several benefits, including better resource utilization, quicker deployment times, and the flexibility to

Shenoy, Ganesh, Malchow, Florian

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