Thoracic injuries, most frequently rib fractures, commonly occur in motor vehicle crashes. With an increased reliance on human body models (HBMs) for injury prediction in various crash scenarios, all thoracic tissues and structures require more comprehensive evaluation for improvement of HBMs. The objective of this study was to quantify the contribution of costal cartilage to whole rib bending properties in physical experiments. Fifteen bilateral pairs of 5th human ribs were included in this study. One rib within each pair was tested without costal cartilage while the other rib was tested with costal cartilage. All ribs were subjected to simplified A-P loading at 2 m/s until failure to simulate a frontal thoracic impact. Results indicated a statistically significant difference in force, structural stiffness, and yield strain between ribs with and without costal cartilage. On average, ribs with costal cartilage experienced a lower force but greater displacement with a longer time to

Schaffer, Rose, Kang, Yun-Seok, Marcallini, Angelo, Pipkorn, Bengt, Bolte, John H, Agnew, Amanda M

Digital Twin-Enabled Fault Detection for Suspension Systems in Autonomous Mining Haulage Vehicles

2024-36-0170

12/20/2024

Autonomous vehicles for mining operations offer increased productivity, reduced total cost of ownership, decreased maintenance costs, improved reliability, and reduced operator exposure to harsh mining environments. A large flow of data exists between the remote operation and the ore haul vehicle, and part of the data becomes information for the maintenance sector which it monitors the operating conditions of various systems. One of the systems deserving attention is the suspension system, responsible for keeping the vehicle running and within a certain vibration condition to keep the asset operational and productive. Thus, this work aims to develop a digital twin-assisted system to evaluate the harmonic response of the vehicle’s body. Two representations were created based on equations of motion that modeled the oscillatory behavior of a mass-damper system. One of the representations indicates a quarter of the ore transport truck’s hydraulic system in a healthy state, called a virtual

Rosa, Leonardo Olimpio, Branco, César Tadeu Nasser Medeiros

Sensitivity Analysis of the Thickness Mapping and Local Stiffness for Bumper Grille Structural Simulations

2024-36-0102

12/20/2024

In recent decades, thermoplastics have become fundamental materials for the automotive industry, due to characteristics such as low density and increased possibility of manufacturing parts into complex geometries. Correlate the mechanical behavior of parts made with these materials, between virtual and physical testing, still poses a challenge that can be explained by the inherent nature of polymeric compounds, which generally exhibit a complex microstructural composition. This study uses a Bumper Grille made of Acrylonitrile Styrene Acrylate (ASA) as case study. This part is a fundamental external vehicle component, not only for safety criteria, but also for consumer satisfaction. To analyze the structural behavior of a vehicle components such as a Grille, Computer Aided Engineering (CAE) tools with the Finite Element Method (FEM) are commonly applied, in which a good understanding of the analysis setup and physical properties used to define the model are essential. For models built

Ferreira, Gabriel Ramos, Souza Silva, Paulo, Soares, Annelise Heidrich Pietro, Maciel, Ronei Santos, Carvalho, Gimaézio Gomes, Sanchez, Jorge Romero

Battery Development for Vehicles: Integration of 3D Finite Element Method and CFD for Effective Thermal Management

2024-36-0163

12/20/2024

With the growing demand for electric vehicles (EVs), ensuring the safety and efficiency of battery systems is critical. This paper presents a methodology integrating 3D Finite Element Methods (FEM) and Computational Fluid Dynamics (CFD) to analyze battery systems, effectively mitigating thermal runaway phenomena. By combining FEM and CFD, our methodology provides a comprehensive approach to assess thermal management strategies within battery systems. This integration enables engineers to accurately simulate thermal behavior, predict hotspots, and optimize cooling strategies, thereby mitigating the risk of thermal runaway. Furthermore, our methodology minimizes the reliance on costly and time-intensive physical prototypes and testing. By leveraging virtual simulations, engineers can rapidly iterate through design modifications, assess their impact on thermal performance, and make informed decisions early in the development process. This article demonstrates the efficacy and accuracy of

Melo, Caiuã Caldeira, Araujo, Pedro Henrique, Castro Orefice, Fabio, Cury, Davi Machado, Vieira, Tiago Augusto Santiago, Abdu, Aline Amaral Quintella, Monteiro, Henrique Carlos

Study of the Stress Concentration Factor in PPS/C Type Composite Using FEA and Analytical Method

2024-36-0072

12/20/2024

The use of parts with notches or some geometric discontinuity is common in the industrial field. In the aerospace industry, it is common to use components made of composite materials with holes for fixing components. Thus, understanding the behavior of these materials, especially when they present holes or geometries that act as stress concentrators, becomes crucial to assess the possible reduction in strength due to presence of these notches. This study aims to determine the stress concentration factor in circular-hole composite laminates made of PPS (Polyphenylene Sulfide) with 5 HS carbon fiber. For determining stress concentration factor, analytical methods using the point stress criterion, computational numerical simulation through FEA (finite element analysis), and experimental validation of proposed model were used. Mechanical tests of specimens with dimensions adapted from ASTM D3039 standard were performed, which were instrumented using strain gauges in the transverse and

De Almeida, Fernando Cristian Soares, Oliveira, Geraldo Cesar Rosario, Guidi, Erick Siqueira

Optimizing Side Impact with Metaheuristics coupled with Penalty Methods

2024-36-0036

12/20/2024

In the automotive industry, a good vehicle is one that not only provides comfort and adequate on-road performance but also ensures safety for its users. Therefore, various standards have been created to qualify and ensure that cars meet minimum requirements. Assays include frontal and side impact tests. However, physical tests end up being costly if performed frequently, and thus, increasing the correlation between these and computational simulations has been explored in recent years. Within the computational scope, given the nonlinear nature of the functions involved in such studies, the use of metaheuristics (MH) with constraint handling techniques (CHT) has been employed to obtain better results for such scenarios. In this work, three MH algorithms are used: Archimedean Optimization (AOA), Sine-Cosine Algorithm (SCA), and Dung Beetle Optimization (DBO). They are coupled with CHTs of the penalty methods (PM) type in their most basic character, such as Static Penalty Method (SPM

Souza Silva, Paulo, Dezan, Daniel Jonas, Ferreira, Wallace Gusmão

DOE Tool Applied on a Skid Plate: A Case Study

2024-36-0090

12/20/2024

In recent years, the automotive industry has been undergoing constant evolution, and to keep up with market trends, it’s necessary to seek better performance in the shortest time possible. Therefore, CAE (Computer Aided Engineering) becomes one of the most efficient tools for this purpose, as it can predict failures and/or improvements virtually before the start of tooling manufacturing. Thus, optimization, a process in which the best value of a parameter is obtained, becomes essential in the CAE field. In this work, Design of Experiments (DOE) will be applied, a methodology that, using applied statistics, plans, conducts, analyzes, and interprets controlled tests, evaluating predefined parameters from different areas. A light vehicle skid plate will be the case study, impacting disciplines such as durability, NVH (Noise, Vibration and Harshness), and aerodynamics, in virtual analyses such as stiffness, vibration modes, and water fording. Using the resources provided by Renault, this

dos Santos Magalhães, Daniella Fernanda, Moura, Vitor Loic, Braga Junior, Francisco Estevanato, Andrade Barbosa, Samuel França Moura, Theulen Mueller, André Marcelo

Loss Function Curve to Quantify Customer (Dis)Satisfaction for Rear Opening Width Lower for Notch Back Vehicle

2024-36-0051

12/20/2024

During the early phase of vehicle development, one of the key design attributes to consider is the trunk. Trunk is the pillar that is responsible for user’s accommodate their baggage and make into customer needs in engineer metrics. Therefore, it is one of the key requirements to be considered during the vehicle design. Certain internal vehicle trunk characteristics such as the trunk height and length are engineer metrics that influence the occupants’ perception for trunk. One specific characteristic influencing satisfaction is the rear opening width lower for notch back segment, which is the subject of this paper. The objective of this project is to analyze the relationship between the rear opening width lower with the occupant’s satisfaction under real world driving conditions, based on research, statistical data analysis and dynamic clinics

Santos, Alex Cardoso, Silva, Gustavo, Genaro, Piero, Terra, Rafael, Pádua, Antônio, Benevente, Rodrigo, Lourenço, Sergio

PDCA-Guided Development of Fuzzy Logic Controller for Autonomous Vehicle Cruise Control and Collision Avoidance

2024-36-0188

12/20/2024

The advancement of the automotive industry towards automation has fostered a growing integration between this field and automation. Future projects aim for the complete automation of the act of driving, enabling the vehicle to operate independently after the driver inputs the desired destination. In this context, the use of simulation systems becomes essential for the development and testing of control systems. This work proposes the control of an autonomous vehicle through fuzzy logic. Fuzzy logic allows for the development of sophisticated control systems in simple, easily maintainable, and low-cost controllers, proving particularly useful when the mathematical model is subject to uncertainties. To achieve this goal, the PDCA method was adopted to guide the stages of defining the problem, implementation, and evaluation of the proposed model. The code implementation was done in Python and validated using different looping scenarios. Three linguistic variables were used, one with three

Branco, César Tadeu Nasser Medeiros, Santos, Rafael Celestino

Evaluation of Superficial Damage of Mechanical Components through Digital Image Analysis Using Deep Learning Framework

2024-36-0034

12/20/2024

Mechanical component failure often heralds superficial damage indicators such as color alteration due to overheating, texture degradation like rusting or false brinelling, spalling, and crack propagation. Conventional damage assessment relies heavily on visual inspections performed by technicians, a practice bogged down by time constraints and the subjective nature of human error. This research paper delves into the integration of deep learning methodologies to revolutionize surface damage evaluation, addressing significant bottlenecks in diagnostic precision and processing efficiency. We detail the end-to-end process of developing an intelligent inspection system: selecting appropriate deep learning architectures, annotating datasets, implementing data augmentation, optimizing hyperparameters, and deploying the model for widespread user accessibility. Specifically, the paper highlights the customization and assessment of state-of-the-art models, including EfficientNet B7 for

Cury, Rudoniel, Gioria, Gustavo, Chandrasekaran, Balaji

Advanced Design Validation Planning Techniques for Commercial Vehicle E-Axles

02-17-04-0024

12/16/2024

Design validation plays a crucial role in the overall cost and time allocation for product development. This is especially evident in high-value manufacturing sectors like commercial vehicle electric drive systems or e-axles, where the expenses related to sample procurement, testing complexity, and diverse requirements are significant. Validation methodologies are continuously evolving to encompass new technologies, yet they must be rigorously evaluated to identify potential efficiencies and enhance the overall value of validation tests. Simulation tools have made substantial advancements and are now widely utilized in the development phase. The integration of simulation-based or simulation-supported validation processes can streamline testing timelines and sample quantities, all the while upholding quality standards and minimizing risks when compared to traditional methods. This study examines various scenarios where the implementation of advanced techniques has led to a reduction in

Leighton, Michael, Tuschkan, Alwin, Playfoot , Ben

Research on the Pull Drift Compensation Control Algorithm based on Steer-By-Wire Systems

2024-01-7052

12/13/2024

SBW(Steer-by-wire) is a steering system that transmits the driver’s request and gives feedback to the driver through electrical signals. This system eliminates the mechanical connection of the traditional steering system, and can realize the decoupling of the steering wheel and the road wheel. In addition, this system has a perfect torque feedback system, which can accurately and delicately feedback the road surface information to the driver. However, vehicle driving deviation is one of the most common failure modes affecting vehicle performance in the automotive aftermarket, this failure mode can exacerbates tire wear, reducing their life cycle, at the same time, the driver must apply a counter torque to the steering wheel for a long time to maintain straight-line travel during driving. This increases the driver’s operational burden and poses safety hazards to the vehicle’s operation. Based on the steer-by-wire system and vehicle driving deviation characteristics, this paper proposes

Xiangfei, Xu, Qu, Yuan

Redundant Brake Boost Control Strategy of Integrated Electro-hydraulic Braking System

2024-01-7038

12/13/2024

The traditional braking system has been unable to meet the redundant safety requirements of the intelligent vehicle for the braking system. At the same time, under the change of electrification and intelligence, the braking system needs to have the functions of braking boost, braking energy recovery, braking redundancy and so on. Therefore, it is necessary to study the redundant braking boost control of the integrated electro-hydraulic braking system. Based on the brake boost failure problem of the integrated electro-hydraulic brake system, this paper proposes a redundant brake boost control strategy based on the Integrated Brake Control system plus the Redundant Brake Unit configuration, which mainly includes fault diagnosis of Integrated Brake Control brake boost failure, recognition of driver braking intention based on pedal force, pressure control strategy of Integrated Brake Control brake boost and pressure control strategy of Redundant Brake Unit brake boost. The designed control

Dexing, Lao, Luping, Yan, Qinghai, Sui, Long, Cao, Shang, Gao, Zhigang, Chen, Mingxing, Ren, Zhicheng, Chen

A Driving Behavior Decision Method Based on Gradient Boosting Tree Algorithm

2024-01-7030

12/13/2024

In order to reduce the incidence of traffic accidents and improve passengers’ driving experience, intelligent driving technology has attracted more and more attention. The core content of intelligent driving technology includes environment perception, behavior decision-making and control follow-up. Simulating driver’s behavior decision-making based on multi-source heterogeneous environment information is the key to liberate drivers and become the focus and difficulty of intelligent driving technology. Aiming at this key problem, this paper presents a design method of driving behavior decision maker based on machine learning after fuzzy classification of historical data. Firstly, 1000 sets of driving environment-decision results database are generated randomly according to driving rules and driving state. A fuzzy classification rule is established to classify driving environment information such as speed and relative distance. Then, a driving behavior decision maker is designed based on

Li, Hongluo, Xia, Hongyang, Huang, Yongxian, Xu, You, Xu, Wei

Biofidelity Assessment of the GHBMC M50-O Seated in a Honda Accord Seat in a Rear-Facing Configuration during a High-Speed Frontal Impact

09-12-03-0014

12/10/2024

Vehicles equipped with automated driving systems (ADS) may have non-traditional seating configurations, such as rear-facing for front-row occupants. The objectives of this study are (1) to generate biomechanical corridors from kinematic data obtained from postmortem human subjects (PMHS) sled tests and (2) to assess the biofidelity of the Global Human Body Models Consortium (GHBMC) 50th male (M50-O) v6.0 seated in an upright (25-deg recline) Honda Accord seat with a fixed D-ring (FDR) in a 56 km/h rear-facing frontal impact. A phase optimization technique was applied to mass-normalized PMHS data for generating corridors. After replicating the experimental boundary conditions in the computational finite element (FE) environment, the performance of the rigidized FE seat model obtained was validated using LSTC Hybrid III FE model simulations and comparison with experiments. The most recent National Highway Traffic Safety Administration (NHTSA) Biofidelity Ranking System (BRS) method was

Pradhan, Vikram, Ramachandra, Rakshit, Stammen, Jason, Kracht, Corey, Moorhouse, Kevin, Bolte, John H., Kang, Yun-Seok

Autonomous Mobile Robot for Gas Leak Localization

2024-01-5226

12/10/2024

LIDAR-based autonomous mobile robots (AMRs) are gradually being used for gas detection in industries. They detect tiny changes in the composition of the environment in indoor areas that is too risky for humans, making it ideal for the detection of gases. This current work focusses on the basic aspect of gas detection and avoiding unwanted accidents in industrial sectors by using an AMR with LIDAR sensor capable of autonomous navigation and MQ2 a gas detection sensor for identifying the leakages including toxic and explosive gases, and can alert the necessary personnel in real-time by using simultaneous localization and mapping (SLAM) algorithm and gas distribution mapping (GDM). GDM in accordance with SLAM algorithm directs the robot towards the leakage point immediately thereby avoiding accidents. Raspberry Pi 4 is used for efficient data processing and hardware part accomplished with PGM45775 DC motor for movements with 2D LIDAR allowing 360° mapping. The adoption of LIDAR-based AMRs

Feroz Ali, L., Madhankumar, S., Hariush, V.C., Jahath Pranav, R., Jayadeep, J., Jeffrey, S.

Investigating Mechanical Performance of Load Vehicle Brake Liners Enhanced with Nanomaterials Using Finite Element Analysis

2024-01-5210

12/10/2024

This study investigates into the mechanical performance of load vehicle brake liners that have been enhanced with nanomaterials, employing Finite Element Analysis (FEA). The analysis involves a detailed investigation of structural, thermal, and wears characteristics to evaluate the overall performance of the brake liners. This research aimed to reduce the stress and pressure exerted on vehicle brakes during braking by conducting a comprehensive stress analysis of the braking system. Finite Element Analysis serves as a powerful tool for simulating and assessing the behavior of complex structures under varying conditions. In this research, the study employs FEA techniques to model and analyze the load vehicle brake liners, considering the incorporation of nanomaterial’s, with a special emphasis on materials like Al2O3.The aim is to gain a profound understanding of how these nanomaterial’s influence and improve the mechanical aspects of the brake liners

Kumar, N. Mathan, Thillikkani, S., Kannan, S., Soundararajan, S., Bharti, Kundan

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

2024-28-0260

12/05/2024

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

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

Writing an Effective Technical Safety Concept in Accordance with ISO26262

2024-28-0207

12/05/2024

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

Cheni, Dileep Kumar, Desai, Priyanka Pradeep

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

2024-28-0268

12/05/2024

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

Sahoo, Jyoti Prakash, Sarma, Neelam Kumar

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