Browse Topic: Design Engineering and Styling

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ANALYSIS OF FACTORS INFLUENCING THE EFFICIENCY IMPROVEMENT POTENTIAL OF A WINDING CHANGEOVER IN AN ELECTRIC MACHINE2025-01-0518To be published on 11/25/2025
The winding configuration of an electric machine has a decisive influence on the properties of a traction drive. When designing the electric drive, the optimum compromise must be found between maximum torque, maximum power and high efficiency over a wide operating range. A decisive factor in this design conflict is the choice of the winding configuration. The concept of winding switching offers a way of solving the design conflict and improving the characteristics of the drive through the additional degree of freedom of the variable winding configuration. Switching the number of parallel winding branches in a serial and parallel configuration is a promising approach to overcome the challenge of a high spread between maximum power and high efficiency in customer related driving scenarios of an electric vehicle. The aim of this study is to identify factors influencing the efficiency improvement potential of the winding switching topology under consideration compared to a reference drive
Oestreicher, Raphael, Koenen, Christian, Kulzer, André Casal
Electrode-Level Modeling of Thermal Decomposition Reactions as a Foundation for Multiscale Thermal Runaway Analysis in Lithium-Ion Batteries2025-01-0523To be published on 11/25/2025
Thermal runaway in lithium-ion batteries represents a critical safety challenge, particularly in high-voltage battery systems used in electric vehicles and stationary energy storage. A comprehensive understanding of the multi-scale processes that initiate and propagate thermal runaway is essential for the development of effective safety measures and design strategies. This study provides a structured theoretical overview of the thermal runaway phenomenon across four hierarchical levels: electrode, single cell, module, and high-voltage battery system. At the electrode level, thermal runaway initiation is linked to electrochemical and chemical degradation mechanisms such as solid electrolyte interphase decomposition, separator breakdown, and internal short circuits. These processes lead to highly exothermic reactions that, at the cell scale, can result in rapid temperature increases, gas generation, and overpressure. On the module and system levels, thermal runaway can propagate through
Ceylan, Deniz, Kulzer, André Casal, Winterholler, Nina, Weinmann, Johannes, Schiek, Werner
Cellular energy architecture to secure resilient energy supply for critical infrastructure2025-01-0516To be published on 11/25/2025
Introduction of renewable energy systems offers the opportunity to achieve energy self-sufficiency or autarky in addition to contributing towards carbon neutrality by reducing the dependency on energy logistics. Amidst growing geo-political conflicts, the scenario of energy shortage or disruption of energy logistics is a major threat, especially for Europe due to the significant reliance on import of primary energy. Achieving autarky, however, requires a distinction between energy consumers that need uninterrupted energy supply and consumers that could potentially be cut-off during energy shortages to avoid prohibitive costs resulting from over sizing the system. Critical infrastructure such as hospitals, communication systems, emergency services and key mobility nodes like fuelling stations and charging points needed to sustain the services provided by them, always need uninterrupted energy supply. The architecture in current tools for optimising the design and operation of
Vijay, Arjun, Thaler, Bernhard, Köcheler, Valentin, Oppl, Thomas, Trapp, Christian
Data-Based Modeling of Power-Split Hybrids Using Cascaded Neural Networks2025-01-0522To be published on 11/25/2025
Power-split hybrid powertrains represent one of the most advanced and complex types of powertrain systems. The combination of multiple energy sources and power paths offers great potential but results in complex interactions that require improved strategies for optimal efficiency and emission control. The development and optimization of such operating strategies typically involve algorithms that demand fast computational environments. Traditional high-accuracy numerical simulations of such a complex system are computationally expensive, limiting their applicability for extensive iterative optimizations and real-time applications. This paper introduces a data-based approach designed specifically to address this challenge by efficiently modeling the dynamic behavior of power-split hybrid powertrains using cascaded neural networks. Cascaded neural networks consist of interconnected subnetworks, each specifically trained to represent individual drivetrain components or subsystems. This
Frey, Markus, Itzen, Dirk, Yang, Qirui, Grill, Michael, Kulzer, André Casal
Prognostic Framework for failure analysis and smart farming2025-28-0340To be published on 11/06/2025
Prognostics and Health Management (PHM) for electrical components in tractors represents a transformative approach that harnesses cutting-edge monitoring technologies and predictive analytics to elevate the reliability and efficiency of agricultural machinery. By employing advanced data collection and sophisticated analytics, we achieve real-time monitoring of critical performance parameters such as voltage, current, temperature, and operational cycles, along with field data mapped with GPS coordinates. This capability allows for the early detection of anomalies and potential failures, thereby enhancing operational reliability. Data collected from the machine will be pushed to the server periodically, where advanced AI algorithms will analyze the information to identify possible failures or assess the safety of the machine. This proactive monitoring ensures that any potential issues are flagged in real-time, allowing for immediate intervention and maintenance actions. A comprehensive
Shinde, Ketan Kishor
Machine Learning Model for Predicting Transient Jerk Behavior in Knuckle Boom Loaders2025-28-0332To be published on 11/06/2025
The knuckle boom loader machine experiences a significant issue where rapidly retracting the joystick to the neutral (0) position causes the machine's legs to lift momentarily. This unintended lifting occurs when the joystick is moved back quickly, while gradual movements do not trigger this effect. Addressing this problem is crucial for enhancing both safety and operational efficiency. The primary objective of this project is to develop a machine learning model to predict jerk based on joystick movements. This prediction will aid in creating a model predictive controller (MPC) that suggests optimal joystick positions, thereby reducing unintended lifting. To simulate the knuckle boom loader's response to joystick inputs, a high-fidelity Simulink model developed using Simscape Multibody was utilized. Data were collected through a Design of Experiments (DOE), logging key parameters such as head side pressure, jerk, jerk rate, and lift levels across various joystick positions. The input
Kamaraj, Keerthi Vallarasu
Visibility study for Tractor with Rear Implement2025-28-0320To be published on 11/06/2025
This paper details a process involving digital content creation tools to conduct visibility studies for machinery that utilize vision-based perception system. In this paper we go through the process of preparing over 50 unique tillage implements with Light geometry attached to assess areas of potential sensor occlusion. We optimized the CAD Geometry of the model by removing Duplicate parts, Wiring, Floating geometry. Also, optimization of heavier parts was required and ensuring of high-altitude parts (i.e. SMV, Starfire, Lights, brackets) was important to ensure proper visibility studies. Making sure that the setup of the implement matched that of its corresponding vehicle was also Pertinent. The developed high-fidelity models that are used to Conduct perception occlusion analysis, develop simulations, quickly verify component geometries. Occlusion analyses facilitate cross-team discussions of the perception system coverage and expedite product development. Moreover, the generated high
Kumar, Pravin, GUMASTE, Amey, Rode, Aboli, Goč, Matej
Development of Vibration Fixtures for Automotive Testing, a combined analytical and FEA-Based Approach2025-28-0258To be published on 11/06/2025
The thermal performance of battery chargers plays a crucial role in ensuring their reliability, safety, and efficiency. The proposed research work elaborates the best use case of convergent divergent Venturi effect to improve the air velocity near the housing and establish proper temperature distribution inside the charger. This approach helped eliminating the hot spots within the charger, thereby improving heat reliability in the extreme temperature's conditions, safeguarding the thermal run-away effect within the charger. Various strategies have been utilized to reduce the hotspots in the design inclusive of decreasing potting conductivity, using various fan configurations and improving the mechanical housing design by way of providing design improvement using the Venturi effect in the fin design. The thermal analysis of a 3.3kW battery charger has been performed using ANSYS tool. The primary objective of this research is to analyze the heat distribution and identify hot spots in
Shinde, Pramodkumar, Shah, Viren
Optimizing the Structural simulation process of Automobile Airvent knob design to evaluate the sustainability for human accidental sliding load2025-28-0289To be published on 11/06/2025
The research work elaborated the structural integrity of airvent by skipping the assembly level snap fit analysis of knob to reduce computational complexity of air vent knob sliding test post stopper. During assembly, the strain based mechanical breakage prediction of airvent sliding knob snaps is investigated in prestressed condition. The function of airvent knob is to rotate the vertical fins to divert the air flow as per comfort in intended direction identified by passenger. The airvent knob slides on central horizontal fin on a grove feature provided. Post sliding the knob to extreme end it gets stopped at end of grove feature of H fin. The sliding knob is assembled by compressing it against a silicon rubber elastomer inlay. The compression of inlay produces a constant tension on the knob snaps. The knob assembly has to sustain a passenger accidental and abrupt sliding loads while in stopped condition. The knob snaps in this press fit condition are the weak link in the accidental
Shah, Viren
Assessing Excavator Quick Couplers: A Customer-Centric Study to Application Suitability2025-28-0268To be published on 11/06/2025
In the fast-paced world of construction, the demand for machine Uptime is paramount. Various construction machines play crucial roles in applications such as digging, loading, landscaping, and demolition. One critical component that significantly enhances machine uptime for these operations is the quick coupler. This innovative attachment facilitates rapid tool changes, enabling operators to switch between attachments seamlessly. It also boosts operator safety by eliminating frequent interaction between the operator and the attachments. Additionally, the ease of replacing attachments ensures that operators can easily use the correct attachment for specific tasks optimizing overall attachment usage. This paper aims to study the trade-off between breakout force and productivity when using quick couplers. This research assists customers in determining whether to utilize quick couplers based on their specific application requirements. The findings of this study are designed to help
Bhosale, Dhanaji Haridas, PARAMESWARAN, SANKARAN, Narayanan, Arun
Digital solution using immersive technology for field failure2025-28-0306To be published on 11/06/2025
Warranty claims act as primary source of characterizing field failures across industries, wherein appropriate classification of these claims is critical for further analysis. The classification of warranty claims is a highly laborious effort involving significant man-hours of warranty analysts. This can be highly optimized & made efficient using direct interpretation of the claim data on 3D model using unity game engine. Additionally, the color perception technique using immersive technology (AR/VR) can help to identify the vital few & drive prioritization of the field failures leading to faster problem resolution. The capabilities of UIUX & Advanced Visualization integrated to develop novel method to classify the warranty claims & interpret it on a 3D model using immersive technology which is novel & one of its kind in Industry. Unique characteristics of this tool is it focuses on the warranty claim classification by claim cost & count of claims and presents the heat map (Red-High
Nankery, Vivek, savadatti, Sandeep, Shete, Atul, Apkare, Sanket, Ganapathi, Poongundran
Design Optimization of Rolling Resistance Product Development Using Linear Regression2025-28-0314To be published on 11/06/2025
Simulation, physical testing, and a combination of both is an indispensable tool for developing reliable product designs in the automotive industry. Engineers rely on this integrated approach to thoroughly explore design possibilities and fine-tune products for varying configurations. Drawing insights from existing designs, engineers can effectively tackle important design challenges, such as reducing rolling resistance. This study introduces a pragmatic solution, leveraging simulation and real-world test data, and demonstrates the effectiveness of employing Linear Regression (LR) techniques for improving rolling resistance in vehicles. Integrating LR algorithms into the design process enables swift and cost-effective optimization of parameters, offering a quicker pathway for product development.
ALTHI, Tirupathi Rao, Manuel, Naveen, K, Manu
PTO Clutch Hydraulic Performance Evaluation Methodology Development & Correlation2025-28-0295To be published on 11/06/2025
This paper presents an analysis methodology developed to understand the impact of pressure spikes in off-highway applications, particularly during PTO (Power Take-Off) clutch engagement. These pressure spikes can adversely affect hydraulic subsystem components such as seals, gaskets, and valve operations. Assessing hydraulic system performance through physical trials can be cumbersome, resulting in longer development times and increased costs. To address this, a methodology was developed in a virtual environment to evaluate hydraulic system performance. The virtual method outlined in this paper is created in a 1D environment using an analytical approach to replicate the transient behavior of the system. The hydraulic system primarily includes a relief valve, solenoid valves, a pump, and a clutch. An analytical model was developed for the hydraulic system components with the right fidelity to accurately capture the transient behavior and magnitudes of pressure spikes. This methodology
Memane, Nilesh, Kumar, Suneel, Veerkar, Vikrant
Cooling System Design Approach for Off-Road Vehicles Using CFD and 1D Tools2025-28-0260To be published on 11/06/2025
The average product development cycle spans 3-5 years, involving extensive virtual and physical testing of the machine. Advances in simulation tools have significantly enhanced our ability to identify product solutions early in the design phase. Tools like 1D KULI and Creo Flow simulations offer faster solutions in less time, thereby accelerating the product development cycle. Cooling systems are crucial components of off-highway hybrid vehicles, directly affecting engine efficiency and overall machine functionality. An optimized cooling system ensures the engine operates within safe temperature ranges, preventing overheating and potential damage. Thus, designing an effective cooling system is a vital aspect of machine engineering. 3D Computational Fluid Dynamics (CFD) simulations are essential for evaluating cooling system performance. These high-fidelity simulations provide detailed insights into fluid flow and heat transfer, enabling engineers to predict and enhance cooling
Ukey, Snehal, Tirumala, Bhaskar, Nukala, Ramakrishna
‍AI Negotiator: Intelligent Chatbot for Seamless Negotiations2025-28-0347To be published on 11/06/2025
Negotiating with suppliers is a critical yet challenging task. More negotiation you do more value you create. Traditional negotiation methods often involve extensive manual effort, prolonged timelines, and inconsistent outcomes. These inefficiencies can lead to suboptimal agreements, higher costs, and strained supplier relationships. The problem is further exacerbated by the complexity of managing multiple suppliers, each with unique terms, conditions, and negotiation dynamics. The introduction of a negotiation chatbot tool, leveraging advanced language models (LLMs), addresses these challenges by automating and optimizing the negotiation process. This tool is designed to interact with suppliers in a natural, conversational manner, understanding and responding to their queries and proposals effectively. By utilizing LLMs, the chatbot can analyze vast amounts of data used for negotiation like Spend file, Material/Energy/Labour indices, identify patterns, and generate strategic responses
Panda, Dinesh Abhimanyu
A Load Cell-Free Solution for Weighing2025-28-0346To be published on 11/06/2025
The agricultural industry increasingly demands innovative solutions to enhance efficiency and productivity, while minimizing overhead costs of an advanced system. Large farms cultivating forage crops for the Dairy and Livestock sectors require high-quality, dense bales that retain their nutritional value. Bale weight serves as a critical parameter for assessing production yields, managing inventory and facilitating fair trade in the industry. Traditional weighing systems reliant heavily on load cells, can pose limitations in terms of cost, complexity and maintenance. This paper presents an advanced model-based weighing system de-signed specifically for balers machine. It utilizes mathematical models and dynamic torque monitoring techniques to accurately estimate the weight of bales just after the baling process. The Bale weight calculation is achieved by measuring reverse pressure experienced during bale handling and monitoring the pitch angle to compensate for measurements over
Kadam, Pankaj
Virtual Reality Application in CFD Data Analysis for After Treatment Systems2025-28-0329To be published on 11/06/2025
Virtual reality (VR), Augmented Reality (AR) and Mixed reality (MR) are advanced engineering techniques that coalesces physical and digital world to show case better perceiving. There are various complex physics which may not be feasible to visualize using conventional postprocessing methods. Various industrial experts are already exploring implementation of VR for product development. Traditional computational power is improving day-by-day with new additional features to reduce the discrepancy between test and CFD. There has been increase in demand to replace actual test by accurate simulation approaches. Post processing and data analysis is key to understand complex physics and resolve critical failure modes. Analysts spend considerable amount of time to analyze results and provide directions, design changes and recommendation. There is a scope to utilize advanced features of VR, AR and MR in CFD post-process to find out the root cause of any failures occurred with advanced
Savitha, Bhuduri, Sharma, Sachin
Automating Fault Detection Time Intervals in Automotive Functional Safety Using HIL Simulation2025-28-0274To be published on 11/06/2025
Functional safety is driven by number of standards like in automotive its driven by ISO26262, in Aerospace its driven by DO-178C, and in Medical its driven by IEC 60601. Automotive electronic controllers must adhere to state-of-the-art functional safety standard provided by ISO26262. A critical functional safety requirement is the Fault Handling Time Interval (FHTI), which includes the Fault Detection Time Interval (FDTI) and Fault Reaction Time Interval (FRTI). The requirements for FHTI are derived from Failure Mode Effect Analysis (FMEA) conducted at the system level. Various fault categories are analyzed, including electrical faults (e.g., short to battery, short to ground, open circuits), systemic faults (e.g., sensor value stuck, sensor value beyond range), and communication faults (e.g., incorrect CAN message signal values). Controllers employ strategies such as debouncing and fault time maturity to detect these faults. Numerous FDTI requirements must be verified to ensure
Lengare, Sunil, Yadav, Vikaskumar, Shiraskar, Pallavi
Method development for estimating deflection and fatigue life using flex body-based vibration fatigue2025-28-0266To be published on 11/06/2025
Author: Ajit Wandhare Co-Author: Prasad Kulkarni Abstract: The structural analysis of off-highway machine platforms has traditionally relied on inertial loads and single-point excitation-based vibration fatigue methods, derived from earlier testing. While these approaches provide qualitative insights, they often lead to either under- or over-designed components, resulting in the need for multiple physical builds to address issues related to platform deflection and lifespan. Furthermore, handrail deflection assessments have historically been subjective, allowing for potential inaccuracies in problem identification. This paper investigates the implementation of flex body-based estimation techniques for predicting deflections in both platforms and handrails, as demonstrated in a deflection estimation exercise for a current off-highway machine platform. This innovative methodology enhances the precision of deflection and life predictions during the mule or feasibility stages, enabling
Wandhare, Ajit, S Kulkarni, Prasad
Comprehensive Warranty Data Analytics: A Blend of Conventional & Advanced Methods2025-28-0299To be published on 11/06/2025
In today’s competitive landscape, industries are relying heavily on the use of warranty data analytics techniques to manage and improve the warranty processes. Warranty analytics is important since it provides valuable insights into product quality and reliability. It must be noted here that by systematically looking into the warranty claims and related information, industries can identify patterns and trends that indicate potential issues with the products. This analysis helps in early detection of defects, enabling timely corrective actions that improve product performance and customer satisfaction. This paper introduces a comprehensive framework that combines conventional methods with advanced machine learning techniques to provide a multifaceted perspective on warranty data. The methodology leverages historical warranty claims and product usage data to predict failure patterns, identify root causes, and optimize warranty policies. By integrating these diverse methods, the framework
Quadri, Danishuddin S.F., Soma, Nagaraju
Paint Dip-in and Drain-out Analysis for Off-road Applications Using Low Fidelity Versatile Multi-Phase Simulation Practices2025-28-0244To be published on 11/06/2025
In complex manufacturing processes, reliable simulation tools are essential to supplement expensive prototyping and physical testing, optimizing the design stage efficiently. The manufacturing industry seeks solutions for e-coating, which involves optimizing design parameters like tank dimensions, part trajectory, line speed, and geometrical details. New generation CFD tools, such as Creo Flow Analysis (CFA), offer high accuracy, efficient workflows, and short computational times. The goal is to gain insights into how design parameters affect the process and optimize them. CFA provides powerful Volume of Fraction (VOF) multiphase simulation techniques along with body motions in a user-friendly process, enabling quick verification of painting processes or part designs. Surface coating protects industrial products from corrosion and other environmental influences. Electrophoretic coating (e-coating) is a surface engineering process used to coat metallic components. The paint deposition
Rao, Pooja Dhaval, Tirumala, Bhaskar, soni, Tanushree
Analysis Led Design (ALD) Approach for Development of Air Filter Mount Casting Component in Mower Machine2025-28-0278To be published on 11/06/2025
With the current industrial trend, where demand for reduced weight & cost, optimal shape and reduced assembly time is of prime importance, structural optimization has become need of the hour. Traditionally, structural optimization is largely analysis driven, however with analysis led design (ALD) democratization, it has now equally been shared by design engineers. In this paper, a casting component was developed as an alternative to engine air filter bracket weldment used in wide area mower machines through analysis led design (ALD) approach. The 11 piece weldment assembly of engine filter bracket along with high cost and complex assembly, had significant warranty claims. To overcome these challenges, weldment was converted into a single piece ductile iron casting. Complex design shapes and optimal design opportunities often make casting components an ideal optimization problem. In order to obtain optimal casting design shape along with sufficient load bearing capacity, generative
Patil, Prafull Pratap, Kazi, Mohseen Vahab, Gandhi, Mitesh
Impact of Cooling Airflow and Its Path on Underhood Cooling in Farm Tractors2025-28-0280To be published on 11/06/2025
To ensure the effective operation of engine cooling systems in agricultural tractors, several critical parameters must be considered, including grille opening area and location, grille resistance, front-end blockage, fan speed, and coolant flow rate. While grille design has been moderately explored for highway vehicles, research specific to grille configuration in agricultural tractors remains limited. This study investigates the influence of grille location, grille resistance - modeled using porous inertial and viscous resistance coefficients - front-end blockage, fan RPM, and coolant flow rate on radiator top tank temperature (TTT) using Computational Fluid Dynamics (CFD). The analysis is conducted in two phases: first, the effects of grille opening area and location, grille resistance, and front-end blockage are evaluated under fixed fan speed and coolant flow rate; second, an orthogonal array design of experiments is employed to rank the influence of grille opening area, fan RPM
Subramani, Sridharan, Baskar, Subramaniyan, Gopinathan, Nagarajan
E-Motor thermal management using 2D-3D coupling2025-28-0225To be published on 11/06/2025
In the electrical machines, detrimental effects are resulted often due to the overheating, such as insulation material degradation, demagnetization, decreased lifetime and efficiency of the motor and Joule losses. Hence, it is vital to optimize the reliability and performance of the electric motors (E-Motor) and to reduce the maintenance and operating costs. This study brings the analysis capability of CFD for the air-cooling of an E-Motor powering on E-Machines. With the aggressive focus on electrification across automotive industry, there is an increasing need of CFD modeling to perform virtual simulations of the E-Motors to determine the viability of the designs and their performance capabilities. The thermal predictions are extremely vital as they have tremendous impact on the design, spacing and sizes of motors. With this study using Ansys Fluent - Maxwell coupling, a complete 3D CFD with CHT modeling of an Electric Motor, including all the key components like the windings, rotor
Singh, Bhuvaneshwar, Tirumala, Bhaskar, Badgujar, Swapnil, HK, Shashikiran
Advanced End-of-Line Routines for Genset Fault Diagnostics: Integrating Catalyst and Component Aging Detection2025-28-0308To be published on 11/06/2025
Advanced end-of-line (EOL) testing is crucial for making sure the next generation of generator sets (gensets) stay both reliable and up to code. This paper introduces new diagnostic methods that combine real-time data collection, automated testing scripts, and targeted operating zones. The goal is to catch any immediate production issues and also spot early warning signs of catalyst or engine aging. By placing gensets in carefully controlled environments that closely reflect their real-world operating conditions, these EOL tests can detect subtle performance problems that ordinary spot checks often miss. A standout feature of this approach is using specialized testers to run specific load points and temperatures, allowing for faster evaluations of potential catalyst wear, diesel particulate filter (DPF) buildup, and other types of long-term deterioration. By applying predictive algorithms and comparing results to baseline data from new components, these advanced routines can identify
Kumar D, Ajay, Menon, Anand, Itagi, Ravi, Patel, Prateek, JOHNSON, JEEVAN
Off-Highway Vehicles for Sustainable Development and Empowerment: Innovation and Technology.- Diagnosis2025-28-0301To be published on 11/06/2025
Off-highway vehicles (OHVs) play a crucial role in industries such as agriculture, construction, and mining, contributing to sustainable development and economic empowerment. Ensuring their optimal performance requires a robust customer support system focused on efficient diagnosis and resolution of technical issues. This paper explores the importance of advanced diagnostic techniques in OHVs, emphasizing innovation and technology-driven approaches to minimize downtime and enhance productivity. The evolution of diagnostic tools, from traditional manual inspections to AI-powered predictive maintenance, has transformed customer support in the OHV sector. The integration of telematics, IoT-enabled sensors, and cloud-based analytics allows real-time monitoring of vehicle health, enabling proactive maintenance and reducing unexpected failures. Additionally, remote diagnostics and augmented reality (AR)-assisted troubleshooting empower field technicians with real-time insights, improving
Tripathi, Ashish, Thakur, Anil
Design IQ2025-28-0327To be published on 11/06/2025
Weight and cost are critical parameters in any new product development program, influencing aspects such as homologation and efficiency. Traditionally, tracking these parameters at the machine, subsystem, and module levels involves a manual, time-consuming process. This reactive approach often delays the program and hampers the productivity of design engineers. These challenges can be managed with an automation and simulation. WCOSAP automates the extraction of weight details, identifies outliers, calculates module-level impacts, and predicts future weight changes. This proactive tool eliminates repetitive manual work, enhances data accuracy, and supports dynamic updates. By integrating real-time data and predictive models, WCOSAP enables sound decision-making and proactive weight control during the design phase, ultimately improving efficiency and reducing the need for part revisions. This paper discusses the development, implementation, and benefits of the WCOSAP tool, highlighting
Patil, Vivek, Sahoo, Abhilash, ballewar, Sachin, Chidanandappa, Basavaraj, Chundru, Satyanarayana
Customer Support- Failure and Warranty analysis in Off highway vehicles2025-28-0300To be published on 11/06/2025
Off-highway vehicles (OHVs) play a crucial role in industries such as construction, agriculture, and mining, contributing significantly to global infrastructure and economic development. However, ensuring their reliability and performance requires robust customer support, particularly in failure analysis and warranty management. This paper explores innovative approaches to diagnosing failures, optimizing warranty policies, and leveraging technology to enhance customer support for OHVs. Failure analysis involves systematic root cause identification to prevent recurring issues, minimize downtime, and improve product durability. Advanced diagnostic tools, predictive maintenance strategies, and telematics integration have revolutionized how failures are detected and addressed. By utilizing IoT-enabled sensors and AI-driven analytics, manufacturers can proactively monitor vehicle health, reducing unplanned failures and enhancing service efficiency. Warranty analysis is equally critical
Tripathi, Ashish, Thakur, Anil
Reduction in Product Development Time by Field-to-Lab Simulation2025-28-0282To be published on 11/06/2025
KEYWORDS: Flywheel Inertia, Clutch system, Gear Box, Tractor application, Instrumentation, data analysis, Design and develop new test methodology. ABSTRACT: Puddling is a crucial process in rice cultivation, involving the preparation of the soil in a flooded field to create a soft, muddy seedbed. There are two classifications for puddling: full cage and half cage. Full cage puddling involves replacing the rear wheels of the tractor with steel paddle wheels, which are used to till the rice paddies directly without any additional implement. In the half cage puddling, the rear wheels remain on the tractor, and a smaller cage or paddle wheel is attached to the outside. Considering the field size, the operator often releases the clutch very quickly after a speed or direction change. This generates torque spikes, which are harmful to Transmission Gears and Clutches. This can lead to gear teeth bending fatigue failure due to repeated higher bending stresses. In this paper, a study related to
Pathan, Irfan Hamidulla, Bardia, Prashant
Development of Door Impact Loads Using Frugal use of "Pedal Force Sensor"2025-28-0283To be published on 11/06/2025
The first step in designing or analyzing any structure is to understand “right” set of loads. Typically, off-road vehicles have many access doors for service/getting into cab etc. Design of these doors and their latches involve a knowledge of the closing loads when the door is shut mostly with an impact of varying magnitudes. In scenarios of these impact events, where there is sudden change of velocity within few milliseconds, produces high magnitude of loads on structures. One common way of estimating these loads using hand calculations involves evaluating the rate-of-change-of-momentum. However, this calculation needs “duration of impact”, and it is seldom known/difficult to estimate. Failing to capture duration of impact event will change load magnitudes drastically, e.g. load gets doubled if time-of-impact gets reduced from 0.2 to 0.1 seconds and subsequently fatigue life of the components in “Door-closing-event” gets reduce by ~7 times. For these problems, structures are usually
Valkunde, Sangram, Ghate, Amit, GAGARE, KIRAN
Virtual load sensor methodology for structural verification2025-28-0269To be published on 11/06/2025
Authors - Swapnil Zalte, Prasad Kulkarni, Abhijeet Aundhe, Shikha Gupta, Shubham Darade Large off-highway vehicles, such as combine harvesters, corn heads, and hinged drapers, are complex machines comprised of multiple interacting subsystems. Consequently, capturing the load path through full vehicle finite element modeling poses significant challenges and can be computationally intensive during the design development process. We primarily employ two structural analysis approaches based on the availability of load inputs: • Full Frame Finite Element Model Setup • Subsystem Finite Element Model Setup Just like virtual verification, physical verification can also be performed at both the full vehicle and subsystem levels. The most critical input for both physical and virtual structural verification is load data. Traditionally, we acquire structural loads induced by ground excitations using wheel force transducers. For subsystem finite element models, interface loads are essential, which
Zalte, Swapnil Suresh, S Kulkarni, Prasad, Gupta, Shikha, Aundhe, Abhijeet, Darade, Shubham
Use of the Sound-intensity Method to Identify Acoustic Leakages from Off Highway Machine Cab2025-28-0267To be published on 11/06/2025
The operator station or “cab” in off Highway equipment plays a critical role to provide a comfortable environment for the operator. The cab interfaces with several elements of the off-highway equipment which can create gaps and openings. These openings have the potential for acoustic energy leakage, ultimately increasing sound within the cab. During machine operation, noise generated around the cab conducts inside through these leakages resulting in increased sound levels. Acoustic leakages are among the key noise transfer paths responsible for noise inside the cab. Therefore, before considering noise control treatments it is best to first identify and minimize any leakages from joints, corners, and pass-throughs to achieve required cab noise reduction. In this effort the sound intensity technique is used to detect the acoustic leakages in cab. The commercial test system is used for measuring the sound intensity field over objects. For the cab, an acoustic source is used inside the cab
Pawar, Sachin M., Mandke, Devendra, Fapal, Anand, Cone, Kerry
Novel Methodology for Assessment of Bolted Joints Under Vibration Fatigue2025-28-0287To be published on 11/06/2025
Bolts are one of the most standardized and preferred machine elements for connection and load transfer. On the other hand, since the mechanics of highly stressed bolted joints and the thread fatigue are complex issues, the design and validation of such joints is frequently carried out with major simplifications and assumptions, leading to either over-engineered solutions or to premature failures of the prototypes. Evaluating bolted joint for fatigue is itself complex phenomenon and with vibration loading it adds further challenges in terms modeling and simulation. Proven and most preferred method for vibration fatigue is modal superposition analysis. One major drawback of this method is its inability to include frictional contact. This leads to change in load path, causing incorrect fatigue life evaluation for these joints. In this paper, author presents two different methodologies to evaluate bolts under vibration fatigue capturing correct physics and load path. • Contact optimization
Desale, Amit Nanaji, Singh, Gurwinder, Vhatkar, Rushikesh, Patil, Akhil
Applicability of Machine Learning Techniques to Forecast Remaining Useful Life on Structural Components2025-28-0296To be published on 11/06/2025
Most of the major machines and structural components are designed for fatigue life and at same time it is important to design structural components for no premature fatigue failure. The performance of major machines and structural components are usually tested in controlled environment but in real life components are subjected to fluctuating loads known as fatigue loads which are common causes of failure. Fatigue cracks are common indicators of potential structural failure, and an early stage of crack initiation phase often goes undetected until noticeable performance degradation or failure to the component occurs resulting in a machine downtime. Early detection of Failure and understanding remaining useful life of a component is increasingly more important to customers as it helps in preventive maintenance by timely replacement of a component. This would also result in reducing costs by forecasting time to failure. With recent advancement in science, available data can be analyzed
Velayudhan, Vinod Kumar, ISSRANI, MANOJ, Pawar, Sanket, Goyal, Rakesh
Significance of correlation in the virtual world of structural analysis2025-28-0263To be published on 11/06/2025
In today’s competitive environment, speed to market is important in ensuring success of the product. However, new products cannot be handed over to customers without through verification and validation process. Hence, accelerating this process is the key in getting the product faster to the market. One way to accelerate physical testing is to integrate virtual verification into the workflow. Multiple design options can be evaluated virtually and then the shortlisted design can be sent for physical testing. However, for this integration to work flawlessly and to build trust in the simulation model, it must match the behavior of the physical model ‘exactly.’ How much ‘exact’ is good enough, can be quantified by means of Correlation. This is the important piece for effective testing and simulation integration. This work explores the concept of ‘correlation’ and different approaches of quantifying it. Multiple case studies are used for demonstration purposes. The approach for comparing
Deshpande, Amit Anand, Desale, Amit
Arcing simulation in automatic transfer switches2025-28-0284To be published on 11/06/2025
Automatic transfer switches (ATS) play an important role in the providing uninterrupted power to various applications like data centre, hospitals etc. They can be connected between two utility sources, two gensets or a combination of them. It operates when one of the sources to which load is connected to is not available or the preferred source is up. While they do their job smoothly, they internally see harsh conditions. When one of the sources is active and other ATS is disconnecting, an arc is generated. The arc exists when the air medium breaks into ions and electrons at very high temperatures, typically above 10000K. This arc needs to be quenched quickly to avoid damage to the contacts and current carrying conductors. This paper throws light on an inhouse methodology that is developed using commercial tool Ansys Fluent. The physics of arc consisting flow, thermal and electromagnetic fields are modelled. This paper includes the simulation of arc propagation along with the moving
Badhe, Vivek, Gaikwad, Nikhil Ravindra
Mechanical complex assembly2025-28-0262To be published on 11/06/2025
Title: Two weldments assembled using four or more bolts. Abstract consists of study on Two weldments assembled using four or more bolts. Assembly preload stress effect on weld area of subassembly. There are three different assembly fits. 1. Clearance fit. 2. Interference fit. 3.Transition fit. Preload stress on weldments generated are different for three different fits of assemblies. In industry interference & Transition fits required special tooling to assemble parts together. Ergonomically it is not practice using interference fit. In case of interference fit: We need to assemble part with applying hammer. In that case when apply torques on bolted joint. Preloads on assembly is adequate. This joint is good joint. Clearance fit: Preloads Stresses on joints will be higher & severe based on size of gap in between joining surfaces. These types of stresses will cause crack generation on welded are of sub-assembly. Further in cyclic load crack propagates. Clearnce fit and Shims: We can
Kazi, Mohseen Vahab, Gandhi, Mitesh
Advanced Compliance Risk Assessment Using Big Data from Leverage Fleet Intelligence2025-28-0343To be published on 11/06/2025
In-Use compliance regulations globally mandate that machines meet emission standards in the field, beyond dyno certification. For engine manufacturers, understanding compliance risks early is crucial for technology selection, calibration strategies, and validation routines. This study focuses on developing analytical and statistical methods for compliance risk assessment using Leverage Fleet Intelligence (LFI) data, which includes high-frequency telematics data from over 500K machines, reporting 1300 measures at 1Hz frequency. Traditional analytical methods are inadequate for handling such big data, necessitating advanced methods. We developed data pipelines to query measures from the Enterprise Data Lake (A Structured Data storage system), address big data challenges, and ensure data quality. Regulatory requirements were translated into software logic and applied to pre-processed data for compliance assessment. The resulting reports provide actionable insights on NOx sensor activity
Arya, Satya Prakash, Shekarappa, Kiran
Enhanced PTO motor operation modes in Electric tractor2025-28-0239To be published on 11/06/2025
This paper is about optimized way of operation of PTO motor (Auxiliary motor) in Electric tractor using 3 different modes - Low Idle mode, Loader mode and PTO mode. These modes will provide benefit to user by improved battery range, comfort/less fatigue while using loader operation and improved performance or productivity while using PTO operated implements.
sundaram, Pavithra, M, Rojer, Natarajan, Saravanan, Joshi, Priyanka
Test methodology development for validating engine pulley bolt for accelerated durability2025-28-0234To be published on 11/06/2025
Engine is the prime mover of an automobile. Tractor is also equipped with an engine of higher capacity to meet the power requirement. Apart from powering the wheels, the engine also runs different accessories, such as a water pump, alternator, AC pump, oil pump, and so on. The power from the engine is transferred to accessories via chain drive or belt drive through the crankshaft pulley. During field testing, in one of the tractors, engine pulley mounting bolt failure was reported. The failure resulted in an immediate seizure of the engine, making the tractor standstill in the field. The root cause of the failure was unknown. There was a need to develop a component- or subsystem-level test methodology to address the issue quickly. In the current scope, an attempt was made to develop a subsystem-level laboratory test methodology to simulate the failure mode and to validate the design modifications in an accelerated manner. The failure mode was simulated in the lab, and different design
Chakraborty, Abhirup
Predictive Maintenance Solution with Real-Time Insights and Cost Estimation for Machine Health Management2025-28-0302To be published on 11/06/2025
This paper introduces a comprehensive solution for predictive maintenance, utilizing statistical data and analytics. The proposed Service Planner feature offers customers real-time insights into the health of machine or vehicle parts and their replacement schedules. By referencing data from service stations and manufacturer advisories, the Service Planner assesses the current health and estimated lifespan of parts based on metrics such as days, engine hours, kilometers, and statistical data. The user interface displays current part health, replacement due dates, and estimated replacement costs. For example, if air filter replacement is recommended every six months, the solution uses manufacturer advisories to estimate the remaining life of the air filter in terms of days or engine hours. It also suggests replacement dates, suitable part options, replacement costs, and available service slots through an operator guidance mobile app and portal. The solution features a 360-degree view of
Chaudhari, Hemant Ashok
Simulation of Grade Sensors for Truck Transmission Controllers (Off Highway Application)2025-28-0265To be published on 11/06/2025
The use of 3-axis industrial accelerometers in transmission controllers is prevalent in off-road vehicle applications. To evaluate the performance of heavy vehicles on various grades, simulation is essential prior to actual vehicle testing. This study proposes simulating the grade sensor integrated into the transmission controller using SPI communication and 3-axis industrial accelerometer models on an FPGA. The 3-axis industrial accelerometer, a sensor utilized in truck applications, identifies the x-y-z position and determines the gradient. This sensor is part of the vehicle's transmission controller, which is mounted on the transmission controller PCB. As the vehicle moves and tilts, the sensor calculates the vehicle's gradient. To test software functionality across multiple grades, the ECU typically needs to be physically moved to various grades on vehicle test tracks with different gradients. This proposal aims to replicate test track grades in a lab setting using a Hardware-in
Bhade, Nilesh, Kulkarni, Pallavi
Implementing Generative AI into Realtime Visualization Workflow2025-28-0324To be published on 11/06/2025
The development of 3D models is a critical component of the asset creation workflow in industries. However, traditional modeling techniques often demand extensive manual input, particularly in the areas of modeling, retopology, and texturing. To address challenges, we propose the integration of generative AI technologies into the 3D modeling workflow, aiming to enhance efficiency and streamline processes. This paper presents a comprehensive methodology that leverages advanced algorithms, machine learning techniques, and specialized software to automate repetitive tasks associated with 3D asset creation. By harnessing the power of generative AI, we aim to significantly reduce the manual effort required to produce high-quality 3D models, thereby accelerating the overall development timeline. The aim is to enter a prompt/Image as input to get a fully developed Model. Through a series of experimental implementations, we are aiming to demonstrate the effectiveness of our proposed framework
Arunachalam, Haripriya, GUMASTE, Amey, Kumar, Pravin
Smart Fleet Management for Mechanical Tillage Implements2025-28-0312To be published on 11/06/2025
Tillage, a fundamental agricultural practice involving soil preparation for planting, has traditionally relied on mechanical implements with limited real-time data collection or adjustment capabilities. The lack of real-time data and implement statistics results in fleet managers struggling to track performance, driver behavior, and operational efficiency of the implements. Lack of data on vehicle performance can result in unexpected breakdowns and higher maintenance costs, ensuring compliance with regulations is challenging without proper data tracking, potentially leading to fines and legal issues. Bluetooth-enabled mechanical implements for tillage operations represent an emerging frontier in precision agriculture, combining traditional soil preparation techniques with modern wireless technology. Implement mounted battery powered BLE (Bluetooth Low Energy) modules operated by solar panel based rechargeable batteries to power microcontroller. When Implement is operational turns
Kaniche, Onkar, Rajurkar, Kartik, Gokhale, Sourabha, VADNERE, Mohan
Leveraging AI for Autonomous Simulations in SIL and HIL Frameworks2025-28-0271To be published on 11/06/2025
This paper offers recent ideas and its implementation on leveraging AI for off highway Autonomous vehicle Simulations in SIL and HIL frameworks. Our objective is to enhance software quality and reliability while reducing costs and efforts through advanced simulation techniques. We employed multiple innovative solutions to build a System of Systems Simulation. Physics based models are prerequisite for detailed and accurate representation of the real-world system but it poses challenges due to its computational complexity and storage requirements. Machine learning algorithms were used to create surrogate/reduced order models to optimize by preserving the expected fidelity of models. It helped to speedup simulation and compile model code for SIL & HIL Targets. Built AI driven interfaces to bridge windows, Linux and Mobile Operating systems. Time synchronization was the key challenge as multiple environments were needed for end-to-end solution. This was resolved by using reinforcement
Karegaonkar, Rohit P., AOLE, Sumit, Dasnurkar, Swapnil, Singh, Vishwajeet, SAHA, Soumyadeep
Develop new spray nozzle for off-highway powertrain planetary gearbox lubrication.2025-28-0226To be published on 11/06/2025
In the field of off-highway powertrain systems, efficient lubrication is essential for ensuring the fatigue life and optimal performance of planetary gearboxes. This study presents the development and simulation of a novel spray nozzle designed specifically for planetary gearbox lubrication in off-highway applications. The primary objective of this research is to enhance lubrication efficiency, reduce wear and tear, and improve the overall performance of gearboxes operating under extreme conditions. The developed spray nozzle utilizes advanced simulation techniques to optimize the spray pattern and flow rate, ensuring precise delivery of lubricant to critical areas within the gearbox. Computational Fluid Dynamics (CFD) simulations were employed to analyze the behavior of the lubricant under various operating conditions, including high loads, varying temperatures, and harsh environments. The simulation results demonstrated that the optimized spray nozzle provides consistent and
Singh, Mukesh Kumar, Ghatge PhD, Krishna, Sheelavantar, Sachin, Nair, Aniket
A Measurement method to correlate CFD prediction of air flow velocities across cooling pack for Farm Tractor2025-28-0273To be published on 11/06/2025
An agricultural tractor is a sophisticated machine with a densely packed underhood compartment, presenting unique challenges in airflow management through its heat exchangers. The complexity of the design leads to non-uniform airflow patterns, as the fan-driven system draws air from front, top, and side openings. This variability makes it essential to establish a reliable correlation between test airflow and simulated airflow values. Our investigation has revealed notable differences in the velocity values obtained from the Power Take-Off (PTO) test using various instrumentation. The handheld vane-type anemometer is widely utilized due to its accessibility, affordability, and simplicity. However, it is worth noting that this device can demonstrate discrepancies ranging from 70% to 90% when compared to Computational Fluid Dynamics (CFD) predictions, especially in heavy duty applications. In this study, we have established a robust correlation between the airflow through the heat
A, Boopalshanmugam, Ganesan, Thanigaivel, Reddy, Lakku, Sateesh, Tadi, Gopinathan, Nagarajan
Dynamic Stiffness Simulation Driven Design Changes for Tractor Cab to Mitigate Structure Borne Noise Levels2025-28-0291To be published on 11/06/2025
The dynamic stiffness of mount systems is a critical factor influencing the overall dynamic behavior and vibration isolation capabilities of mechanical assemblies. Effective cab isolation in product design can reduce structure borne noise and tactile vibrations experienced by operators. Detailed dynamic stiffness analysis of mounting brackets coupled with modal analysis using finite element method provide insights into the vibration response and resonant frequencies of components. By systematically varying parameters such as material properties, shape and geometry, the study elucidates the sensitivity of dynamic stiffness to design alternations. This study investigates on dynamic stiffness and their consequential impact on system dynamics on various design alternations by considering the space constraints at mount locations due to components, wiring harness and structural analysis driven solutions. In overall, this paper emphasizes the pivotal role of dynamic stiffness analysis in
Saveenkumar, Valakeerthi, Cone, Kerry, Mandke, Devendra Laxmikant, Fapal, Anand
Optimizing Engine Dynamics & Reliability with Hydraulic Lash Adjusters in Type-5 Valvetrain Systems2025-28-0235To be published on 11/06/2025
The pursuit of optimizing processes and minimizing components has become a central focus in modern powertrain development especially in Off-Highway Vehicles for Sustainable Development. As the automotive industry seeks to upgrade existing engines from older generations with modern technologies, the challenges of integrating advanced valvetrain systems loom large due to their profound impact on engine performance, particularly in terms of timing precision. Among these technologies, Hydraulic Lash Adjusters (HLAs) have emerged as a promising solution, especially in diverse vehicle segments. However, adapting HLAs in Type-5 valve train systems while maintaining existing conditions presents unique challenges. This paper delves into the complexities and benefits of transitioning from mechanically adjusted push rod valve trains to systems controlled by hydraulically operated lash adjusters in a pickup vehicle engine which is an updated tractor engine. Throughout the design and development
John, Shijino Shaji, Bagal, Pratik
Design and Development of a Cost-Effective Reversible Cooling Fan for Agricultural Tractors.2025-28-0261To be published on 11/06/2025
Agricultural tractors require self-cleaning and cooling technology, especially in hot and dusty environments. This study introduces a novel reversible fan system designed which is incorporating a manually operated lever-type connection mechanism as an alternative to conventional pneumatic systems. Traditional reversible fans often rely on pneumatic actuators for blade rotation control, which can introduce complexity, maintenance challenges, and energy inefficiency. The proposed design replaces pneumatic components with a mechanically optimized lever linkage system, enabling users to manually reverse the fan’s airflow direction with minimal effort. This innovation enhances operational simplicity, reduces dependency on compressed air systems, and low costs as compared to conventional type reversible fan. The lever mechanism, engineered for ergonomic usability, ensures rapid switching between sucker and pusher modes, optimizing the fan’s utility in applications such as dust removal
Debbarma, Respect, Parwal, Mahendra, Baghel, Anand
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