Browse Topic: Design Engineering and Styling

Items (44,850)

Optimization of Active–Passive Integrated Evaluation Weighting for Pedestrian Protection

2026-01-0577To be published on 04/07/2026

Pedestrians, as the most vulnerable road users, largely determine the severity of traffic accidents through the extent of their injuries. Traditional vehicle safety evaluations have primarily emphasized passive safety. However, with the widespread implementation of active safety technologies such as Automatic Emergency Braking (AEB), passive-only assessments no longer adequately reflect a vehicle’s true pedestrian protection performance.This study employed finite element models of a sedan and an SUV to analyze changes in pedestrian head and lower limb injury metrics before and after AEB intervention, thereby quantifying the associated injury-mitigation benefits. The results show that AEB reduced the maximum head injury value (HIC15) by about 50%, lowering the proportion of severe head injuries from 0.217 to 0.118. Conversely, braking-induced pitch effects increased the proportions of severe femur and tibia bending moment injuries to 0.235 and 0.294, respectively, making them higher

shi, Xinxin, YE, BIN, Liu, Yu, Zhan, Zhenfei, Sun, Bowen, Zhao, yuanyi, zhu, lei

Correlating CFD and experimental vehicle aerodynamics using multi-fidelity simulation approaches

2026-01-0595To be published on 04/07/2026

The automotive industry faces several challenges requiring faster product development, where numerical simulations and digitalization are key enablers to reduce time to market and development costs. Numerical methods require both short turnaround times and high-fidelity results. Capturing small differences across vehicle designs, by accurately predicting complex flow phenomena is crucial for aerodynamics optimization. The disruptive and fast development of GPGPU computing hardware, promising accelerated turnaround times at lower costs, found its natural position in this landscape. This paper describes simulation approaches with increasing fidelity applied to a set of variants of a Stellantis estate production car: these include geometrical, yaw angle and ride height changes, and all were tested in wind tunnel test facilities. Correlation between aerodynamics CFD simulations using Simcenter STAR-CCM+ and wind tunnel measurements is verified by comparing drag trends, pressure probes and

Landi, Simone, Altmann, Peter, Cannavacciuolo, Ciro, Johannesson, Mani, Borowiec, Grzegorz, RIBES, Charles, Guzman, Arturo, Miretti, Luca

Thermo-Mechanical Analysis of 1U CubeSat Structures using ANSYS: Insights for Mobility Applications

2026-01-0145To be published on 04/07/2026

Particularly for small satellites like CubeSats, the growing commercialization and downsizing of space technology have brought both new opportunities and problems in the areas of heat management and structural design. A Single Unit (1U) CubeSat structure's design and simulation analysis are presented in this work, with an emphasis on the structure's mechanical and thermal performance during launch and orbit. The CubeSat platform, which is frequently constructed using commercial off-the-shelf (COTS) components, needs robust and lightweight structures that can handle mechanical loads and high temperature changes. In order to conduct mechanical stress loading (MSL) and thermal analysis (TA) on a 3D CubeSat model, this work uses ANSYS in a simulation-driven manner. Geometry modeling, meshing, boundary condition application, and simulation of important space environment elements including microgravity, solar radiation, and launch-induced stresses are all part of the process. The findings

Hussain, Muzammil, Azeem, Naqash, Adeel, Muhammad

CFD-Based Investigation of Fuel Tank Sloshing: Crash Safety and Noise Concerns

2026-01-0490To be published on 04/07/2026

A computational study using the Volume of Fluid (VOF) method in SimericsMP+ was conducted to investigate fuel sloshing in automotive fuel tanks under both crash and sudden stop conditions. The SEALs method was employed to rapidly generate the fuel tank mesh, enabling efficient simulation setup. At the outset, a benchmark sloshing case was simulated and compared against experimental data, showing excellent agreement to validate the simulation method. This simulation method was then applied to the fuel tank sloshing scenarios mimicking crash and sudden stop conditions. The study initially focused on a crash scenario where fuel waves impact valves, pumps, and other internal structures. Capturing these localized impact forces is critical for evaluating the risk of component failure and potential leakage. A baffle-equipped tank was simulated and compared with sensor data. Results show that the computed shock forces on valves and baffles closely matched the measurements, demonstrating the

Jia, Kun, Rahman, Ashique

Exploring Bionic Twisted TPMS Designs for Improved Energy Absorption

2026-01-0243To be published on 04/07/2026

Triply periodic minimal surface (TPMS) lattice structures have emerged as a promising class of customizable mechanical metamaterials owing to their outstanding potential in lightweight design and multifunctional engineering applications. However, previous studies have mainly concentrated on global parameters such as wall thickness, cell size, and periodicity, while the local deformation and pre-deformation characteristics of unit cells, particularly the twist effects along specific directions, have not been systematically investigated. To address this gap, a bioinspired twisted design strategy was proposed in this study, in which controllable pre-twist was introduced along the build direction to tailor the energy absorption behavior of lattice structures. Twisted lattice specimens with different twist angles were fabricated using selective laser melting, and their mechanical properties were comprehensively examined through numerical simulations and experimental validation. The results

Liu, Zhe, Lian, Yuehui, Li, Youguang, Guo, Pengbo, Zhong, Gaoshuo

A Holistic Approach to Pre-Chamber Design, Integration, and Operational Optimization

2026-01-0310To be published on 04/07/2026

As internal combustion engines continue to play a critical role in hybrid on-road and numerous non-road applications, there is a continued push to increase efficiency and minimize tailpipe emissions. However, reduced investment in new engine architectures means retrofittable technologies are favored to continue incremental performance improvements to existing engine platforms. To maintain the relatively low capital cost of engine-based powertrains, these technologies must be low-cost and compatible with the diverse mix of fuels that may be encountered across various market segments in the future. Pre-chambers have shown significant potential for improving spark-ignited engine performance across a wide range of engine sizes, from motorsport applications to stationary power, and operating conditions, from stoichiometric operation to ultra-lean. Understanding the degree to which this central combustion technology must be tailored to optimize its performance with a variety of fuels and

Peters, Nathan, Pothuraju Subramanyam, Sai, Hoth, Alexander, Bunce, Mike

Leveraging Large Language Models for CAD Automation and Multi-Objective Optimization of Automotive Heat Exchangers

2026-01-0506To be published on 04/07/2026

The design of automotive heat exchangers is a critical challenge, requiring the careful balance of thermal performance, aerodynamic efficiency, structural integrity, and manufacturability. Traditional design processes rely heavily on manual CAD modeling and iterative simulations, which are both time-intensive and computationally demanding. Recent advances in artificial intelligence, particularly in Large Language Models (LLMs) and Transformer-based architectures, open new possibilities for automating these tasks. This work introduces a novel framework that integrates LLMs with CAD kernels to generate parametric heat exchanger geometries directly from natural language descriptions. The models are automatically exported into standard formats for computational fluid dynamics simulations and seamlessly incorporated within a multi-objective optimization pipeline. By coupling natural language-driven CAD automation with advanced optimization techniques, the framework enables rapid exploration

Chaudhari, Prathamesh, Tovar, Andres

Simplified Thermal Runaway Propagation Modeling to Enable Mass-Optimized Battery Pack Design

2026-01-0404To be published on 04/07/2026

This paper presents a simplified approach to model thermal runaway propagation in a multi-cell battery pack, with the goal of designing a safe and lightweight pack for mass-sensitive applications. The key parameters which characterize single-cell thermal runaway, including heat release profile, apparent cell emissivity and mass loss, were extracted from empirical nail penetration tests. This characterization was used to drive a three-dimensional thermal model of a 19-cell hexagonal sub-pack with a center trigger cell. To enable rapid design exploration, a symmetry-based computationally simplified domain was used for a full-factorial Design of Experiments (DOE) varying cell spacing, epoxy thickness, heat spreader thickness, and cup geometry. The DOE results were used to identify dominant heat-transfer mechanisms, capture main and interaction effects, and determine mass-efficient design levers governing peak-neighbor cell temperature during propagation. Insights from the DOE study

Kalyankar, Apoorv, Owen, Elliot, Strohmaier, Kyle, Mardall, Joseph

Assessing Energy Use, Cost, and Emissions of Small Regional Rail Vehicles: Methodology and Case Study on a German Track

2026-01-0419To be published on 04/07/2026

The decarbonization of regional rail remains a pressing challenge in the European Union, where nearly half of the 200,000 km network remains unelectrified. Lightweight, single-car railbuses historically provided efficient service on such lines, but modern replacements are scarce. This work evaluates a standardized 30-ton, 16 m railbus platform for unelectrified regional service, focusing on propulsion system design and trade-offs between range, cost, and emissions. A MATLAB/Simulink drive-cycle model was developed to simulate energy consumption under realistic operating conditions. The Erfurt–Rennsteig route in Germany (130 km round trip, gradients up to 6 %) was selected as a representative case study. The model incorporates sub-models for traction motors, lithium-ion batteries (LFP and LTO), fuel storage, fuel cells, and ICE gensets across multiple fuel options (diesel, gasoline, methane, ethanol, methanol, HVO, FAME, and hydrogen). Battery lifetime is estimated using a combined

Ahrling, Christoffer, Tuner, Martin, Gainey, Brian, Torkiharchegani, Amir, Scharmach, Marcel, Hertel, Benedikt, ALAKÜLA, Mats

Is Implicit Knowledge Enough for LLMs? A RAG Approach for Tree-based Structures

2026-01-0111To be published on 04/07/2026

Large Language Models (LLMs) are effective at generating responses using contextual information, which is especially useful when working with structured data like code. Retrieval-Augmented Generation (RAG) enhances this capability by retrieving relevant documents to supplement the model’s context. However, the best way to represent retrieved knowledge—particularly for hierarchical structures such as trees—remains underexplored. In this work, we introduce a novel method to linearize tree-structured knowledge, making it suitable for storage in a knowledge base and direct use with RAG. We compare this approach to applying RAG on raw, unstructured code, evaluating both the accuracy and quality of the generated responses. Our results show that while response quality is comparable between the two methods, our linearized approach reduces the number of vector documents by almost 4x. Without any loss of generality, we applied and benchmarked our method to a specific automotive use case, that is

Gupte, Mihir, Giusto, Paolo, S, Ramesh

CAE-based Electro-Thermal Characterization and Design Optimization of Automotive Inverter Busbars

2026-01-0642To be published on 04/07/2026

High power density demands in automotive inverters need precise thermal management to ensure efficiency, reliability and extended component lifetime. This paper presents a systematic, integrated electro-thermal workflow utilizing Computer-Aided Engineering (CAE) tools to characterize and optimize internal inverter components by directly linking electrical performance to thermal behavior. The methodology comprises three main steps: first, detailed frequency-dependent electrical parameters (RLCG, Z, S) and current density maps are extracted using computational calculations by ANSYS HFSS and ANSYS Q3D Extractor. Second, these parameters inform comprehensive power loss calculations (conduction, dielectric, switching), which are then mapped onto detailed 3D thermal fields using Computational Fluid Dynamics (CFD) through ANSYS Icepak. Finally, the results are analyzed to identify critical components and inform targeted design modifications. The workflow's effectiveness is demonstrated

Oliveira, Felipe, Aguiar, Cláudio, Justino, Marco, Tarrago, Vinicius, Almeida, Oberti

Extreme Scale Automotive Aerodynamic Simulations

2026-01-0597To be published on 04/07/2026

Achieving an optimal balance between simulation accuracy and computational efficiency remains a central challenge in automotive aerodynamics. While the adoption of AI and machine learning (ML) methods in vehicle development is expected to grow significantly, the demand for highly scalable, computationally efficient, and accurate computational fluid dynamics (CFD) methods persists. The emergence of GPU technology presents new opportunities to deliver cost-effective, high-fidelity, scale-resolving simulations to industrial users. A comprehensive evaluation of Simcenter STAR-CCM+’s parallel scalability and accuracy across extensive CPU and GPU resources was executed on the Frontier supercomputer at Oak Ridge National Laboratory. Steady-state and transient aerodynamic scalability simulations were executed using the DrivAer notchback vehicle configuration. Simulation accuracy was evaluated through transient simulations employing the SST-DDES turbulence model on an initial mesh of 200

Larsson, Torbjörn, Grover, Ronald O., Landi, Simone, Altmann, Peter, McManus, Liam, Dowding, Steven

Propulsion System Design Considerations for HEV versus EV Applications

2026-01-0641To be published on 04/07/2026

The design and development of EVs and HEVs has become a growing issue recently due to concerns about pollution and dependence on non-renewable fossil fuels. Accordingly, General Motors (GM) has an evolving vehicle electrification plan over the past several decades and into the future to deliver low-cost and efficient EVs and HEVs. Propulsion system requirements for the applications of EV and HEVs are quite different and therefore, the design principles and directions are also distinct between these cases. From micro-hybrid and full plug-in hybrid applications to full EV applications, design requirements, strategies and outcomes can widely vary. Continuous and peak duty are substantially different depending on the application of the vehicle. Motor operational duty is significantly higher for EV compared to the electric motor of a hybrid electric vehicle. Motor torque, power and efficiency requirements are also higher for EV motors, which greatly influences the choice of motor type and

Momen, Faizul, Jensen, William, Das, Shuvajit, Chowdhury, Mazharul, Alam, Khorshed, Anwar, Mohammad, Reinhart, Timothy

Designing an e-SUV to Meet Global Front Crash Safety Standards

2026-01-0580To be published on 04/07/2026

Vehicle crashworthiness has improved tremendously over the past 20 years with increasing scenarios being defined and assessed by governments and nonprofits every few years. Bodies such as NTHSA, IIHS and EuroNCAP created safety ratings to distinguish objectively which vehicles are the safest for consumers. In doing so, automotive OEMs must spend more resources and design additional crash safety features onto their vehicles, often making them heavier in the process. As a result, negatively impacting the driving range of an electric vehicle. At Lucid Motors, through a holistic and first-principles approach, CAE simulations were used to guide the design of the Lucid Gravity to pursue highest possible crash safety ratings and battery protection while minimizing weight on the vehicle structure. By keeping the weight low, the Lucid Gravity Grand Touring was able to achieve an estimated EPA-rated range of 450 miles, which is groundbreaking for a full size 3-row electric SUV. This paper

Ng, Meng

Research on Intelligent Vehicle Fleet Longitudinal Control Based on Fuzzy Model Predictive Control

2026-01-0040To be published on 04/07/2026

Addressing the challenge of balancing tracking efficiency and stability in longitudinal cooperative control of intelligent vehicle platoons, this paper proposes a hierarchical control strategy integrating fuzzy logic with Model Predictive Control (MPC). The upper-layer controller, based on the platoon's longitudinal dynamics model, formulates an optimization objective function that considers both tracking performance and ride comfort. A fuzzy logic system is introduced to adaptively adjust the weighting coefficients within the MPC objective function in real-time based on the prevailing tracking state, outputting an optimal desired acceleration. The lower-layer controller, utilizing an inverse longitudinal dynamics model incorporating the engine's universal characteristic map and a brake system model, accurately translates the desired acceleration into throttle opening or brake pressure via a Proportional Integral Derivative (PID) control algorithm. To validate the control strategy, a

Li, Ye

Conjugate Heat Transfer Modeling for Predicting Thermal Behavior of X76 Emotor Windings

2026-01-0118To be published on 04/07/2026

A computational study based on a conjugate heat transfer (CHT) method in SimericsMP+ was performed to predict the winding temperatures in an X76 emotor. In this study, the thermal load was represented in the simulation through the solution of electromagnetic equations in SimericsMP+, where heat generation was driven by root-mean-square (RMS) current, while liquid cooling was applied at flow rates ranging from 1 LPM to 6 LPM. Simulations were conducted to measure the temperature on three thermocouple locations on each side of the winding crown and weld regions under steady operation. The computational strategy employed a loosely coupled approach. A fluid-only simulation was first carried out to establish stable flow conditions, followed by coupling with solid conduction where the winding acted as the heat source. The predicted temperature distributions were then compared with test data. Results obtained show good agreement, with differences remaining within an acceptable range, thereby

Jia, Kun, Schlautman, Jeff, Srinivasan, Chiranth

Optimization of Lightweight Gear Blanks to Improve NVH for an Electric Drive Unit

2026-01-0001To be published on 04/07/2026

A single-speed electric drive unit (eDU) with multi-stage reduction can have high gear whine due to high pitch-line velocity in the absence of engine masking noise. A comprehensive investigation is conducted focusing on the optimization of the first-stage transfer gear blanks to improve NVH performance and reduce mass for EV applications. A multibody dynamic model of the eDU was constructed, incorporating asymmetric gear blank geometry, shaft elasticity, bearing stiffness, and housing flexibility, in order to characterize realistic operating conditions and simulate gear contact mechanics with high fidelity and computational efficiency. NVH excitation sources, including static transmission error and dynamic meshing force, were systematically evaluated for solid and slotted gear configurations. Based on a DOE optimization study, an 8-slot gear blank design is selected to balance mass reduction, stress, NVH, and manufacturing requirements. Micro-geometry optimization was conducted for the

He, Song, Du, Isaac, Li, Bo, Bahk, Cheonjae, Grguras, Zachary, Baladhandapani, Dhanasekar, Patruni, Pavan Kumar

Analysis of the Impact on Ride Comfort from Splitting the Unsprung Mass in Vehicle Modeling

2026-01-0212To be published on 04/07/2026

The study was conducted to investigate the differences in ride comfort analysis between treating the unsprung mass as a whole and modeling it separately. A classical two-degree-of-freedom single-wheel vehicle vibration model and a three-degree-of-freedom single-wheel vehicle vibration model with split unsprung mass were established, with their state-space descriptions determined. The fundamental vibration response quantities of both models were identified, and time-domain simulations under random road excitation were performed using Matlab/Simulink. The results indicate that the two modeling approaches exhibit minimal differences in ride comfort analysis for the sprung mass, but there are certain differences for the unsprung mass. Additionally, for the three-degree-of-freedom single-wheel vehicle vibration model with split unsprung mass, the axle-to-wheel mass ratio was introduced to analyze the changes in the fundamental vibration response quantities when the unsprung mass increases

Jie, Li, Wei, Deng

Characterizing the Impact of C-V2X PC5 Radio on Cooperative Driving Automation in Hardware-in-the-Loop Experiments

2026-01-0077To be published on 04/07/2026

The SAE J3216 standard defines Cooperative Driving Automation (CDA), which has gained increasing attention in recent years as an umbrella framework encompassing a wide range of automated vehicle applications enabled by Vehicle-to-Vehicle (V2V) and Vehicle-to-Infrastructure (V2I) technologies. However, limited research has investigated how Cellular Vehicle-to-Everything (C-V2X) technology affects CDA applications, especially the agreement seeking operations. This work presents a hardware-in-the-loop (HIL) experimental study designed to evaluate the Argonne CDA controller under varying C-V2X radio transmission frequencies and message configurations. A three-vehicle car-following scenario was implemented in the Argonne-developed Roadrunner Simulator, incorporating CDA agreement-seeking operations, vehicle powertrain models, and V2V communication modules. The CDA messages were then exchanged through two actual C-V2X radios with realistic communication impairment caused by the hardware

Zhan, Lu, Hyeon, Eunjeong, Misra, Priyash, JEONG, Jongryeol, Di Russo, Miriam, Das, DEBASHIS, Stutenberg, Kevin

Computational Modeling and Optimization of Shape Memory Polymer-Based Energy Absorbers

2026-01-0573To be published on 04/07/2026

Shape memory polymers (SMPs) provide tunable thermomechanical properties and enable the design of recoverable crash structures for automotive applications. This paper introduces a computational framework for the design and optimization of SMP-based crash absorbers with periodic auxetic microstructures. A finite element (FE) model is developed and validated against experimental data reported in the literature. The model is used to simulate crushing and recovery behavior under different temperature conditions. A parametric study is performed by varying key microstructural features, including wall thickness, cell size, and cell shape. Structural performance is evaluated in terms of specific energy absorption (SEA), peak force, and recoverability under axial crush loading. To efficiently explore the high-dimensional design space, surrogate models based on machine learning are constructed, and multi-objective optimization is carried out to identify Pareto-optimal designs that balance

Zhu, Yingbo, Zhu, Feng, Deb, Anindya

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

2026-01-0614To be published on 04/07/2026

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

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

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

2026-01-0588To be published on 04/07/2026

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

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

Integrating Optimization and Model Fidelity Selection Methods for Real-Time Driver-in-the-Loop Vehicle Simulators

2026-01-0621To be published on 04/07/2026

Automotive OEMs perform extensive prototype testing to configure vehicles for objective criteria (performance), and subjective criteria (handling and comfort). To reduce testing time and costs, OEMs rely on real-time Driver-In-the-Loop Simulators (DIL) running complex Multi-Body Dynamics (MBD) models. Recent advances in simulation technology have increased model accuracy but also operating costs, possibly limiting the viability of real-time DIL applications. Running high fidelity MBD models in real-time is computationally intensive and often requires re-configuration, CAE model de-contenting, solver setting optimization, which can introduce significant analysis errors. This presents a core challenge: selecting model fidelity levels that result in computationally efficient simulations, while maintaining sufficient predictive accuracy. This study introduces a methodology that integrates optimization algorithms with decision-making techniques to select the right fidelity within a

Balchanos, Michael, Emara, Mariam, Zarate Villazon, Angel, Mavris, Dimitri

A Control Method for Dual Motor Redundant Steer System based on Zeroing Neural Networks

2026-01-0581To be published on 04/07/2026

In the process of driving a vehicle, the steering system directly determines the vehicle's travel path and direction, serving as the physical basis for precise control in autonomous driving. Whether it is lane keeping, turning, or obstacle avoidance, high responsiveness of the steering control is required to execute the commands of the decision-making system. This study focuses on the dual-motor steer-by-wire (SBW) system, addressing the tracking issues arising from factors such as dual-motor coupling. A control strategy for coordinated dual motor drive in an autonomous driving steering system based on dual-motor redundancy is proposed. A dynamic model of the steer-by-wire system is constructed, and the software algorithm employing a zeroing neural network for the dual-motor redundant steering is used to solve the synchronization issues of the dual-motor system, based on the concept of cross-coupled control. Finally, simulation analysis was performed on the MATLAB simulation platform

Yang, Lingang, xiong, min, Zeng, Dequan, Petitti, Antonio, Nawaz, Aamir, Linh, Nguyen Vu, Hu, Yiming, Yu, Yinquan, CARBONE, GIUSEPPE, GAO, LETIAN, Jiang, Xiaomeng

Backward Fuzzy Driving Control for 6×4 Off-Road Vehicles

2026-01-0148To be published on 04/07/2026

Offroad autonomous vehicle systems must be able to operate across unstructured and variable terrain while avoiding obstacles. This presents significant challenges in vehicle and control system design, especially for less conventional platforms such as 6x4 vehicles. While forward driving autonomy has developed and matured in recent years, effective reverse navigation remains an under-explored area of vehicle co-design. Reversing 6x4 vehicles have limited rear steering authority, an extended wheelbase, and asymmetric traction, which introduce complex dynamics into any control system that is used. To address this need, a robust and experimentally validated fuzzy logic control architecture for 6x4 reverse navigation was developed during the course of this project. This architecture incorporates both near-field and long-range path data with adaptive outputs controlling steering and velocity based on a rule base that covers the whole vehicle state space. This method has low computational

Dekhterman, Sam, Patterson, Albert, Sreenivas PhD, Ramavarapu, Norris, William, Soylemezoglu PhD, Ahmet, Nottage PhD, Dustin

A Dataset for Visual Classification of Buldging Pouch Battery Cells

2026-01-0393To be published on 04/07/2026

The rapid advancement of lithium-ion battery technologies, particularly pouch cells, has driven significant growth in electric vehicles, mobile devices, and renewable energy storage. However, pouch cells are especially susceptible to mechanical deformation and failure, including bulging caused by internal gas formation—a common indicator of cell aging or imminent failure. In this study, we developed a dataset of bulging pouch battery cells to support real-time diagnostics and safety monitoring in industrial and laboratory environments.

Alkawasmie, Mohammad, Farooqui, Saad, Algalham, Dheya, Rahman, Mahfilur, Challa, Karthikeya, Maxim, Bruce, Shen, Jie

Impact of Core Glue Coverage and Stacking Factor on Glue-laminated Motor Material Properties and Its NVH Behavior

2026-01-0439To be published on 04/07/2026

The influence of core glue coverage and stacking factors on the mechanical properties of core material is investigated in this study. As these structural attributes of the motor directly affect the mechanical behavior of the e-drive system, such as the NVH and durability performance, their influence on NVH is also analyzed under electromagnetic loads. With the unit-cell method previously proposed for predicting laminated motor core material properties, the material used in the finite element analysis (FEA) model for the glue-laminated motor core is homogenized over the laminations and idealized macroscopically as a transversely isotropic material. A numerical FEA method to quantify the effect of the glue coverage rate and stacking factor in a statistical or averaged sense to establish their relationship with the linear transversely isotropic properties. The glue is assumed to be evenly distributed over the lamination plane, and changes in the in-plane and out-of-plane elastic modulus

Nie, Zifeng

Simultaneous Multi-Material Part and Reinforcement Topology Optimization With Structural Performance Objectives

2026-01-0174To be published on 04/07/2026

Within the automotive industry, the demand for lightweight yet structurally sound systems continues to increase, driven by environmental regulations and performance targets. Furthermore, as manufacturers continue to introduce new electric vehicle platforms, overall vehicle energy efficiency is increasingly achieved through weight reduction. In recent decades, topology optimization (TO) has emerged as a leading design tool for generating high-performance structures that satisfy lightweighting requirements through efficient material distribution within a defined design space. In structural design, TO can be leveraged to yield optimal configurations of both a base structure and an applied surface reinforcement material, allowing additional design freedom in the pursuit of stiff, lightweight design solutions. However, conventional TO frameworks are limited in how they couple these two design domains and are not well suited to optimize both simultaneously without compromising solution

Hronowsky, Benjamin, Kim, Il Yong

Application of Fatigue Damage Criteria to CAE-Based Fatigue Life Prediction of a Welded Chassis Component

2026-01-0232To be published on 04/07/2026

In recent years, computer-aided engineering (CAE) has become an essential practice in design and durability analysis of industrial components such as weldments. The current analytical trend for CAE-based fatigue life prediction of weldments includes procedures based on design guidelines, mesh-sensitive methods (e.g., local strain-life approach) and mesh insensitive methods (e.g., Volvo and Verity methods). As an inherent characteristic of weldments, the geometry of the weld is often simplified in failure analysis and important hotspots such as start/stop of the weld beads are not considered in designing process. However, such critical locations cannot be avoided in complex welded structures. Therefore, incorporating main geometrical details of the weld can improve the accuracy of critical regions identification and damage calculation using mesh-sensitive CAE-based methodologies. Herein, a framework for life prediction of welded components including the weld geometry is discussed and

Razi, Ahmad, Kim, Dooyoung, PARK, Jaehong, YOUK, Wansoo, Fatemi, Ali

Real-time Parameter Optimization for Eco-driving Control in Connected and Automated Vehicles Using Reinforcement Learning

2026-01-0041To be published on 04/07/2026

This paper introduces a novel methodology to enhance the energy efficiency of eco-driving controllers in Connected and Automated Vehicles (CAVs) by leveraging Reinforcement Learning (RL) techniques for real-time parameter optimization. Traditional eco-driving strategies rely on fixed control parameters, which limit adaptability across diverse traffic and road conditions. To address this, we apply continuous action space RL algorithms, specifically Deep Deterministic Policy Gradient (DDPG) and Proximal Policy Optimization (PPO), to dynamically tune four key parameters within a model predictive control framework that is grounded in Pontryagin’s Maximum Principle (PMP). These parameters influence acceleration, braking, cruising, and intersection-approach behaviors, making them critical for achieving optimal eco-driving performance. Our study employs Argonne National Laboratory’s RoadRunner simulator, a Simulink-based environment designed for high-fidelity CAV analysis, incorporating

Zhang, Yaozhong, Ammourah, Rami, Han, Jihun, Moawad, Ayman, Shen, Daliang, Karbowski, Dominik

Research on electro-hydraulic compound braking coordinated control strategy based on sliding mode control

2026-01-0631To be published on 04/07/2026

Hydraulic braking torque and motor braking torque are the main sources of braking torque of new energy vehicles. Hydraulic braking converts vehicle kinetic energy into heat dissipation, and motor braking converts vehicle kinetic energy into electric energy to achieve energy recovery. In the process of vehicle braking, when the wheels tend to lock, it is easy to cause vehicle instability, which seriously threatens the safety of driving.Therefore, how to coordinated the braking torque of the two braking systems to ensure the vehicle braking safety and energy recovery efficiency is still an urgent problem to be solved. In this paper, the electric vehicle equipped with electro-hydraulic compound braking system is taken as the research object, and the electro-hydraulic compound braking coordinated control strategy considering the general braking state and emergency braking state is proposed. Firstly, a 3-DOF vehicle longitudinal dynamic model is established according to the vehicle dynamic

Zhao, Gaoming, Zhao, Bingquan, Zhao, Binggen, He, Chengkun, Zhang, Xiaoyang

Path Following Strategy for Multi-Axle Vehicles via Nash Game-Based Coordinated Control of AFS and DYC

2026-01-0629To be published on 04/07/2026

Due to their complex structure and large inertia, multi-axle hub electric drive vehicles often suffer from response delays and insufficient control sensitivity. To improve path tracking accuracy and handling stability under high-speed and low-adhesion conditions, this paper proposes a coordinated control strategy that integrates a three-dimensional stability assessment with a Nash game-based approach for active front steering (AFS) and direct yaw moment control (DYC) systems. A path tracking control model tailored for multi-axle vehicles is developed, and a robust Tubular Model Predictive Control (Tube-MPC) method is employed to enhance trajectory tracking performance under model uncertainties and external disturbances. Within the prediction horizon of Tube-MPC, the system continuously evaluates whether the vehicle state remains within the stable region. If the state exceeds this region, a Nash game-based coordination mechanism is activated to formulate a multi-objective control game

Lv, Xin, Liu, Zuyang, Shen, Yanhua, Wang, Kaidi

Simulate, Validate, Repeat: Streamlining Testing with Record, Replay, & Simulation

2026-01-0082To be published on 04/07/2026

As autonomous systems mature, the ability to test, validate, and debug them efficiently has become as critical as the underlying software and algorithms. This paper outlines an approach to enabling simulation, record and replay, and time control native to the development and validation process. The underlying application brings deterministic control, scalable recording, and simulator integration into one cohesive development workflow, enabling faster iteration, smarter testing and deployment. This approach uses a unified testing pipeline, across MiL, SiL, and HiL, supporting flexible testing and integration through interchangeable data feeds, recordings, or simulation inputs. The same application used to test in simulation can run unchanged on a vehicle, greatly accelerating iteration and de-risking deployment. Virtual time support systems allow for executing faster or slower than real time, while preserving correct behavior and deterministic timing. Built on ROS 2’s rosbag2 framework

Phillips, Chris

Trajectory Prediction Model for Autonomous Vehicles in Highway Scenarios Based on Spatiotemporal Interaction Feature Extraction

2026-01-0027To be published on 04/07/2026

Accurately predicting the future trajectories of surrounding vehicles is one of the core tasks in autonomous driving, and its precision is directly related to the safety and reliability of decision-making, path planning, and control execution. However, challenges such as the complexity of traffic participants’ behaviors, the variability of interactions, and the highly dynamic nature of traffic environments make it difficult for existing methods to effectively model spatiotemporal dependencies and achieve accurate long-term prediction in dynamic scenarios, thus limiting their applicability in real-world settings. In this paper, we propose a Transformer-based trajectory prediction model with a spatiotemporal attention mechanism to extract and effectively model vehicle motion and spatial interactions. Specifically, the temporal attention module captures the motion patterns of the target vehicle across the time dimension, while the spatial attention module constructs vehicle interactions

Zhang, Lijun, Hu, Xingyu, Meng, Dejian, zhu, Zhehui

Vehicle Test Platform with Experimentally Correlated Tire Model for Torque Vectoring Control

2026-01-0622To be published on 04/07/2026

This paper presents a testing platform for torque vectoring controls utilizing a 10 degree of freedom (DOF) vehicle simulation and a ⅕ scale radio control test vehicle. These vehicle simulations or “Digital Twins” have been widely adopted throughout the automotive industry for their lower operating costs and ease of implementation. Virtual models are not perfect representations of reality, however, and physical testing is still necessary to validate systems for use in the real world. This is especially true when testing safety-critical features such as Advanced Driver Assist Systems (ADAS). As a result, a simulation environment working in conjunction with a test vehicle represents an optimal hybrid approach. In this work, a 1/5 scale radio controlled vehicle with torque vectoring capability is designed and assembled. A high fidelity vehicle model is then constructed in the Matlab/Simulink environment to model test vehicle behavior. The test vehicle features independent suspension for

Petersen, Nicholas Conner, Robinette, Darrell

Integrated Effects of Suspension Geometry and Tire Pattern Design on Vehicle Pull Reduction under Acceleration in High-Performance and Electric Vehicles

2026-01-0593To be published on 04/07/2026

Torque steer is a phenomenon that is more prominently observed in high-performance vehicles and electric vehicles (EVs). This phenomenon occurs primarily due to asymmetric driveshaft angles, drivetrain structure, and suspension geometry. Additionally, tire characteristics, particularly lateral force (Tire Lateral Force), also play a significant role in affecting torque steer. Tire lateral force is strongly influenced by the contact patch dynamics and the geometric design of the tire tread pattern. This study focuses on analyzing the impact of tire tread pattern geometry on the relationship between torque steer and tire lateral force in such vehicles. Specifically, lateral force response variations (dfy/dfx) resulting from tread pattern block deformation were derived through finite element (FE) simulations. These simulations enabled the establishment of an analytical method for tread pattern evaluation and optimization. The developed characteristic parameter was validated by comparative

Yoon, Youngsam, Jang, Dongjin, Kim, Hyungjoo, Lee, Jaekil

BEV drivetrain parameters sensitivity for efficient and effective active damping controls modeling

2026-01-0004To be published on 04/07/2026

Effective active damping control is critical for Battery Electric Vehicle drive quality. Central to this control is open loop frequency response function between actuator (motor torque) and response (motor speed). While many driveline parameters influence the system dynamics, sensitivity analysis reveals that only a few of them significantly shape the resonance frequency and amplitude of crucial low frequency driveline modes. In this study, an orthogonal array-based sensitivity analysis is conducted and validated using 1D simulation tool as Amesim. The results show that identifying the most influential parameters enables meaningful model simplification without loss of accuracy, guiding quick and efficient modelling to help design control system. This approach provides engineers with a practical framework to focus on critical variables of driveline torsional system, reduce model complexity, and implement effective active damping controls strategies.

Sharma, Pranjal, Kolluri, Murali Mohan, Lin, Chihang

Mitigation of Sensor-Level Cyber-Physical Attacks on Electric Vehicle Powertrains: A Simulation-Based Study

2026-01-0091To be published on 04/07/2026

Electric vehicles (EVs) rely extensively on sensor feedback for safe and efficient powertrain operation. However, this dependency introduces cyber-physical vulnerabilities, especially when sensor signals are maliciously manipulated. This paper presents a simulation-based investigation into sensor-level cyberattacks on a mid-sized EV powertrain model developed in MATLAB/Simulink. The study quantifies mechanical consequences and evaluates mitigation strategies to enhance system resilience. Four representative attack scenarios were simulated. Speed sensor spoofing led the controller to misinterpret vehicle velocity, causing a 41% overshoot beyond the 50 km/h setpoint. False data injection into torque/current sensors triggered an unintended torque surge of approximately 20%, resulting in inverter current saturation within 2 seconds. Battery temperature spoofing delayed thermal protection, allowing a deviation of 1.5 °C/min beyond safe operating limits. A hybrid attack combining frozen

Tariq, Usama, Sahandabadi, Sahereh, Dianat, Ali

Vehicle Health Monitoring and Failure Prognosis through Edge-Based Component Wear Tracking

2026-01-0094To be published on 04/07/2026

Traditional vehicle maintenance has relied primarily on mileage-based schedules and periodic visual inspections, approaches that often fail to account for variations in driving conditions, component quality, and usage patterns. These conventional methods typically result in either unnecessary premature replacements or unexpected component failures, leading to increased operating costs and unplanned downtime. Reactive maintenance strategies prove particularly problematic for critical wear components like clutch assemblies, brake systems, and suspension parts where undetected degradation can cause secondary damage. This paper presents an advanced monitoring system that shifts from scheduled maintenance to actual condition-based servicing through real-time wear measurement. The solution implements a network of distributed sensors that directly track critical parameters: ultrasonic measurement of clutch plate thickness, resistive wear sensors for brake pads, linear potentiometers for

Saraswat, Shubham, Vishe, Prashant

Safety-Constrained Control of Nonlinear Mobility Systems Using Reference Governor

2026-01-0033To be published on 04/07/2026

Ensuring safe operation and reliable control of mobility systems remains a significant challenge, particularly for nonlinear and high-dimensional applications subject to external disturbances with hard constraints and limited computational resources in real-time implementations. A reference governor (RG) can enforce constraints using an add-on scheme that preserves the pre-stabilizing controller while balancing the need to satisfy other requirements, including reference tracking and disturbance rejection. Thus, in this paper, we exploit RG-based strategies focusing on nonlinear mobility systems. While the method is generalizable to other applications, such as waypoint following for autonomous driving, the flight dynamics of a quadrotor system with twelve states are used as an example. We implement a disturbance rejection RG to satisfy safety constraints and track set points. To handle nonlinearity, we propose an optimal strategy to quantify the maximum deviation between the nonlinear

Dong, Yilong, Li, Huayi

A Comparison of Road Grade Preview Signals from Lidar and Maps

2026-01-0026To be published on 04/07/2026

Road grade can impact the energy efficiency, safety, and comfort associated with automated vehicle control systems. Currently, control systems that attempt to compensate for road grade are designed with one of two assumptions. Either the grade is only known once the vehicle is driving over the road segment through proprioception, or complete knowledge of the oncoming road grade is known from a pre-made map. Both assumptions limit the performance of a control system, as not having a preview signal prevents proactive grade compensation, whereas relying only on map data potentially subjects the control system to missing or outdated information. These limits can be avoided by measuring the oncoming grade in real-time using on-board lidar sensors. In this work, we use point returns accumulated during travel to estimate the grade at each waypoint along a path. The estimated grade is defined as the difference in height between the front and rear wheelbase at a given waypoint. Kalman filtering

Schexnaydre, Logan, Poovalappil, Aman, Robinette, Darrell, Bos, Jeremy

CAE Acceleration With Machine Learning For Results Prediction

2026-01-0488To be published on 04/07/2026

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

Dangare, Anand Manohar, Kulkarni, Mandar

Research on Economy Mode Control Algorithm for Pure Electric Tractor with Powered Trailer

2026-01-0425To be published on 04/07/2026

This research presents a comprehensive investigation into the electrification development pathway and energy-saving optimization methodologies for commercial tractor vehicles. Given the pivotal role that commercial vehicles play in modern logistics and transportation sectors, their propulsion systems are undergoing a fundamental transition from traditional internal combustion engines toward more sustainable hybrid and pure electric architectures. Simultaneously, the emerging trend of trailer electrification has gained considerable attention, where conventional trailers are retrofitted with motorized axles to form cooperative powertrain systems, demonstrating substantial energy-saving potential as confirmed by multiple research studies. Utilizing an integrated Trucksim and MATLAB/Simulink co-simulation platform, this study developed sophisticated vehicle dynamics models, detailed electric drive system models, and advanced battery models, which were subsequently integrated to establish a

tong, zi yu, Zheng, Hongyu, Li, Gang

Acoustic simulation for a vehicle audio system across the full audible frequency

2026-01-0226To be published on 04/07/2026

Audio system is an important part of vehicle cabin for various purposes. In vehicle development process, it need be tuned for optimal acoustic performance. Traditionally, this process is performed physically on vehicles. In this paper, a methodology is developed to simulate the acoustic performance of the audio system across the full audible frequency range. To quantify the effectiveness, the p/v acoustic transfer functions of the sound pressures at passengers’ ears over the voltage inputs are measured for 12 different speakers in a production vehicle. As the sound perceived by the passengers depends on both the source and the path, the effort of the numerical study mainly concentrates on two aspects: characterization of the loudspeaker parameters and representation of cabin environment. The speaker parameters are characterized from the sound radiation data measured in 2pi chamber. To represent the vehicle cabin, pure finite element model is applied under 1k Hz while a hybrid FE-SEA is

Yang, Wenlong, Patra, Suresh, Hawes, David, Shorter, Phil

Optimizing EV Battery Models for Full Vehicle Simulations

2026-01-0389To be published on 04/07/2026

The increasing adoption of electric vehicles (EVs) demands accurate yet computationally efficient battery models that can be integrated into full vehicle simulations. At the cell level, mechanical battery models often employ fine-scale elements to capture localized deformation and failure phenomena. While such detailed discretization enables high-fidelity predictions, it also imposes significant computational costs that become prohibitive when scaling up to pack-level or full-vehicle crash and durability simulations. This research addresses the challenge by systematically simplifying cell-level mechanical models to reduce computational burden while preserving predictive accuracy. We propose an approach in which larger elements and reduced complexity representations are introduced without compromising the model’s ability to replicate experimentally observed behaviors. The methodology emphasizes model validation against targeted loading conditions, ensuring that the essential mechanics

Sahraei, Elham, Brar, Bavneet, Parmar, Dhruv, Muralidharan, Umachandran

AI-Powered Requirements Engineering & Design Optimization of Electric Powertrains

2026-01-0500To be published on 04/07/2026

The development of electric vehicle powertrains is driven by diverse and often conflicting requirements. In early development phases, these requirements are often vague, incomplete, and continuously refined and subject to change as development progresses. Moreover, powertrain designs must be competitive regarding multiple key performance indicators (KPIs) such as performance, cost, energy efficiency, and package integration. This challenges engineers to concurrently develop the powertrain design alongside the requirements on which the design is based on. Managing this combination of uncertain requirements and multi-KPI design optimization represents a complex challenge in automotive engineering. The present work introduces a requirements engineering approach based on OPED (Optimization of Electric Drives). OPED digitalizes the transition from requirements to technical solutions by integrating parametric system models with an AI-based evolutionary optimization algorithm. This enables

Hofstetter, Martin, Lechleitner, Dominik

Finite-time multi-target tracking based on the super-twisting algorithm

2026-01-0254To be published on 04/07/2026

This paper focuses on multi-agent systems with known boundaries of complex disturbance factors, where the specific disturbance factors include parameter uncertainties and external perturbations. A finite-time hierarchical control algorithm based on the super-twisting algorithm is proposed to solve the finite-time multi-target tracking control problem.Firstly, the Euler-Lagrange dynamic equations are adopted to model the multi-agent system, and the control objectives of the considered problem are put forward simultaneously. Secondly, by utilizing the super-twisting algorithm and a tracking error observer, a finite-time hierarchical control algorithm is designed, which consists of a local layer algorithm and an estimation layer algorithm. Then, stability analysis is conducted on the estimation layer algorithm: the finite-time stability of the closed-loop system for the estimation layer is derived via the Lyapunov stability principle. Subsequently, stability analysis is performed on the

Tong, Gang

The Impact of Fuel Injector Deposits on Fuel Consumption: Correlations & Consequences for Modern Compression Ignition Engines

2026-01-0343To be published on 04/07/2026

Fuel injector cleanliness has been identified in the literature as the key factor for maintaining performance in modern compression ignition engines. Fuel injector nozzle deposits have been shown to restrict the mass of fuel that can be injected, resulting in power loss under full load. Several published studies have also investigated changes in fuel economy brought about from fuel injector nozzle deposits, but the majority of these have failed to demonstrate an unambiguous link between fuel economy and fuel injector nozzle deposits. In this paper, we present previously unpublished data from multiple platforms, including light- and heavy-duty, and from vehicle and stationary engine tests, with each showing a strong link between the formation of fuel injector nozzle deposits and associated losses in full-load power and increased brake specific fuel consumption (BSFC). A requirement for a tractable method is that it should be short enough to economically enable multiple repeats to

Smith, Alastair

Effects of the Spark Location and Timing in a Heavy-Duty Hydrogen-Fueled Engine

2026-01-0331To be published on 04/07/2026

The use of hydrogen in internal combustion engines offers a promising route to low-carbon propulsion in heavy-duty transportation. However, its distinct combustion characteristics as high flame speed, wide flammability limits, and susceptibility to abnormal combustion, necessitate careful engine and ignition system design. This study investigates the combined influence of spark plug location and ignition timing on the performance of a heavy-duty Volvo Diesel engine modified to operate in a spark-ignited mode with hydrogen fuel at low compression ratio under different load conditions. Three-dimensional computational fluid dynamics simulations with detailed hydrogen chemistry, including diffusive-thermal effects, were conducted to evaluate flame development, combustion efficiency, and heat release under different loads. Model validation against combustion behavior and jet characteristics from a low-pressure, high-mass-flow direct injector is also presented. The results demonstrate that

Menaca, Rafael, Shakeel, Mohammad Raghib, Panithasan, Mebin, Liu, Xinlei, Qahtani, Yasser, AlRamadan, Abdullah, Cenker, Emre, Silva, Mickael, Pei, Yuanjiang, Turner, James, Im, Hong

Designing Military Vehicles For A Battlefield Characterized by Drones

2026-01-0262To be published on 04/07/2026

The modern battlefield is increasingly characterized by the use of small drones. As such, military vehicles must now be designed to account for this threat. This paper presents a model-based systems engineering approach to identify vehicle vulnerabilities and generate new vehicle requirements to mitigate them. This approach uses a standard set of SysML diagrams. A vehicle’s primary roles are captured in a series of use-cases. Each use-case is characterized by a sequence of activities performed by the vehicle. These activity sequences are captured in an activity diagram, which can be used to wargame how a drone could exploit the vehicle at each phase. Each exploitation is assigned a likelihood and severity, which feed into a risk index. This risk index is then used to prioritize each vulnerability. From these vulnerabilities, a set of operational requirements can be derived, which then informs the development of system requirements. As the system matures, the physical system

Ells, Alec, Werntz, Bryson, Saulsberry, Taylor, Wilkinson, Cooper, Mittal, Vikram

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