Browse Topic: Failure analysis

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Controllability and Driving Automation2025-01-8679To be published on 04/01/2025
A key challenge for manufacturers of automotive systems, hardware components and software products with no contribution to driving automation is the stringent requirements imposed on elements while being integrated into vehicles with driving automation. The result is increased development cost and low reusability. For such elements or components with no contribution to driving automation, their functions and failure modes remain unchanged when comparing vehicle integration with and without driving automation. The influence of driving automation is not accounted for in the current approach of classifying risk while conducting a Hazard Analysis and Risk Assessment (HARA). Functional safety standards for on-road vehicles rely on human intervention as a parameter to classify risk. Since current safety standards for on-road vehicles are not inclusive of driving automation concepts, classification of risk, based on existing definitions of parameters such as controllability, leads to
Shah, Mihir, Ibarra PhD, Ireri
Technical Paper
Design Validation of Automotive Inverter Components: the importance of Fatigue Simulations2025-01-8639To be published on 04/01/2025
Vibration qualification tests are currently indispensable for vehicle manufacturers and their suppliers. Carmakers’ specifications are therefore conceived to challenge the mechanical endurance of car components in the face of numerous in-service detrimental phenomena: fatigue damage, shocks or accidents, and mechanical degradation. In the automotive industry, components are commonly qualified by means of a test without failure, the goal being to determine whether it will or not "pass" customer requirements. Validation of new or newly designed components is obtained via bench test and structural simulation. Simulation has gained traction in recent years because it represents the first step of the design validation process. In particular, Finite Element Analysis simulations are so powerful that they not only justify physical testing (shaker tests) on prototypes but enable engineers to optimize the design and predict the durability of the part. This paper illustrates how FEA simulations
Durai, Arumugapandian, LEON, Renan, Bonato, Marco, RAJA, Antony, KUMAR, Lalith, NIWA, Takehiro
Technical Paper
Deformation Behavior and Springback Analysis of Anti-Collision Beam on Bending Forming2025-01-8247To be published on 04/01/2025
Since aluminum alloys (AA) are widely used as structural components across various industries, higher requirements for shape-design, load-bearing, and energy-absorption capacity have been put forward. In this paper, we present the development of a numerical model, integrated with a compensation method, that effectively predicts processing defects in the anti-collision beam of a vehicle, resulting in a marked improvement in its forming quality. Specifically, different constitutive models are investigated for their applicability to the beam, enabling a precise evaluation of its structural performance under large deformation. The Johnson-Cook failure model is introduced to better characterize the fracture behavior of the beam under severe structural damage. The three-point bending experiment served as a rigorous examination, demonstrating good consistency between the experimental and simulation results. Furthermore, a prediction model for assessing the forming quality during the bending
Zhang, Shizhen, Meng, Dejian, Gao, Yunkai
Technical Paper
Application of AI/ML based Image Analytics in Auto Component Fracture Analysis2025-01-8228To be published on 04/01/2025
This paper introduces an innovative digital solution for the categorization and analysis of fractures in Auto components, leveraging Artificial Intelligence and Machine Learning (AI/ML) technologies. The proposed system automates the fracture analysis process, enhancing speed, reliability, and accessibility for users with varying levels of expertise. The platform enables users to upload images of fractured parts, which are then processed by an AI/ML engine. The engine employs an image classification model to identify the type of fracture and a segmentation model to detect and analyze the direction of the fracture. The segmentation model accurately predicts cracks in the images, providing detailed insights into the direction and progression of the fractures. Additionally, the solution offers an intuitive interface for stakeholders to review past analyses and upload new images for examination. The AI/ML engine further examines the origin of the fracture, its progression pattern, and the
Sahoo, Priyabrata, Rawat, Sudhanshu, Garg, Vipin, Naidu, Garima, Sharma, Amit, Narula, Rahul, Bindra, Ritesh, Khera, Pankaj, Goel, Pooja, MONDAL, ARUP
Technical Paper
A framework for modeling mechanically induced thermal runaway in lithium-ion batteries2025-01-8134To be published on 04/01/2025
Battery safety is a paramount concern in the development of electric vehicles (EVs), as failures can lead to catastrophic consequences, including fires and explosions. Ensuring the reliability and robustness of lithium-ion cells under various conditions is essential for the widespread adoption of EVs. With the rapid global adoption of EVs, understanding how battery cells perform under extreme conditions such as mechanical or thermal abuse is crucial for ensuring safety. This study investigates the dynamic behavior of lithium-ion pouch cells under mechanical abuse conditions, focusing on improving safety measures in EV battery systems. Our research systematically examines the response of these cells at different states of charge (SOC), through controlled dynamic tests. These tests, which involve varying strain rates and punch geometries, offer significant insights into the mechanical thresholds that lead to cell failure. By analyzing the data, we gain a deeper understanding of the
Patanwala, Huzefa, kong, Kevin, Challa, Vidyu, Darvish, Kurosh, Sahraei, Elham
Technical Paper
Aggressive Autonomous Control on Snow and Ice2025-01-8040To be published on 04/01/2025
In cold and snowy areas, low-friction and non-uniform road surfaces make vehicle control complex. Manually driving a car becomes a labor-intensive process with higher risks. To explore the upper limits of vehicle motion on snow and ice, we use an existing aggressive autonomous algorithm as a testing tool. We built our 1:5 scaled test platform and proposed an RGBA-based cost map generation method to generate cost maps from either recorded GPS waypoints or manually designed waypoints. From the test results, the AutoRally software can be used on our test platform, which has the same wheelbase but different weights and actuators. Due to the different platforms, the maximum speed that the vehicle can reach is reduced by 1.38% and 2.26% at 6.0 m/s and 8.5 m/s target speeds. When tested on snow and ice surfaces, compared to the max speed on dirt (7.51 m/s), the maximum speed decreased by 48% and 53.9%, respectively. In addition to the significant performance degradation on snow and ice, the
Yang, Yiming, Bos, Jeremy P.
Technical Paper
Using CAN Electrical Signals for Cybersecurity and Harness Diagnostics2025-01-8080To be published on 04/01/2025
This paper describes a novel invention which is an Intrusion Detection System based on fingerprints of the CAN bus analogue features. Clusters of CAN message analogue fingerprints can be associated with each ECU on the network. During a learning mode of operation, fingerprints can be learnt with the prior knowledge of which CAN identifier should be transmitted by each ECU. During normal operation, if the fingerprint of analogue features of a particular CAN identifier does not match the one that was learnt then there is a strong possibility that this particular CAN identifier’s message is symptomatic of a problem. It could be that the message has been sent by either an intruder ECU or an existing ECU has been hacked to send the message. In this case an intruder can be defined as a device that has been added to the CAN bus OR a device that has been hacked/manipulated to send CAN messages that it was not designed to (i.e. could be originally transmitted by another device). It could also
Quigley, Christopher, Charles, David
Technical Paper
Design of A Differential Braking Controller Based on Road Reaction Force Estimation to respond to Steering System Failure in Autonomous Driving Situations2025-01-8797To be published on 04/01/2025
As the electrification of chassis systems accelerates, the demand for fail-safety strategies is increasing. In the past, the steering system was mechanically connected, so the driver could respond directly to some extent. However, the Steer-By-Wire system is composed of the column and rack bar as electrical signals, so the importance of response strategies for steering system failure is gradually increasing. When a steering system failure occurs, a differential braking control using the difference in braking force between the left and right wheels was studied. Recently, some studies have been conducted to model the wheel reaction force generated during a differential braking. Those studies linearly modeled the reaction force generated at the kingpin axis. Since actual tires and road surfaces are nonlinear and cause large model errors, model-based control methods have limited performance. Also, in previous studies assumed that the driver normally operates the steering wheel in a failure
Kim, Sukwon, Kim, Young Gwang, Kim, SungDo, Moon, Sung Jin
Technical Paper
Applications of Advanced High-Strength Steels for Automotive Structures – Haulage Load body for EV2025-01-8219To be published on 04/01/2025
To develop a Light weight Load body structure for Electric haulage vehicle application without affecting strength & durability of the product. Conventional haulage Load body given for diesel vehicle application weight is approximately 20% of vehicle Kerb weight. Payload carried by customer does not get affected much. Electric vehicle Kerb weight is comparatively higher than diesel vehicle, due to battery packs & its mounting structures. So the payload carried by customer is getting affected. Hence Load body weight must be reduced to 10-15% of Kerb weight. By considering past field failure data, customer loading pattern, durability trials & CAE static structural analysis, light weight Load body is designed with optimized sections & HSS material. To delight the customers, Number of Floor cross members & sideboard pillars not reduced which is their first impression before buying any haulage vehicle. Multiple iterations & design failure mode effective analysis was done before finalizing
Lakshminarayanan, Karthik
Technical Paper
Dynamic Tailgate Water Management Simulation Using Smoothed Particle Hydrodynamics2025-01-8625To be published on 04/01/2025
Tailgate opening can cause rain that has settled on its surfaces to run off onto the customer or into the rear load space, causing annoyance. Relatively small adjustments to tailgate seals and encapsulation can effectively mitigate these effects. However, these failure modes tend to be discovered relatively late in the design process as they, to date, need a representative physical system to test – including ensuring that materials used on the surface flow paths elicit the same liquid flow behaviours (i.e. contact angles and velocity) as the production vehicle surfaces. In this work we describe the development and validation of an early-stage simulation approach using a Smoothed Particle Hydrodynamics (SPH) Code (PreonLab). This includes its calibration against fundamental experiments to provide models for the flow of water over automotive surfaces and their subsequent application to a tailgate system simulation which includes fully-detailed surrounding vehicle geometry. This approach
Gaylard, Adrian Philip, Weatherhead, Duncan
Technical Paper
Validation of Elastomeric SLA Control Arm Bushing Fatigue Life Under Multi-Channel Road Load Input2025-01-8235To be published on 04/01/2025
The rapid virtualization of engineering workflows for elastomer parts calls for the pairing of robust simulation capabilities with correspondingly thorough validation. Continuing prior work, which established a simulation workflow for simulating fatigue performance of elastomeric bushings operating under a full schedule of 6 channel (3 forces + 3 moments) road load histories, the present report presents the results of an experimental program comparing predicted and measured fatigue performances for an SLA control arm bushing. The experimental fatigue testing program was conducted on a servo-hydraulic 3 axis test rig. The rig was designed to provide radial (cross-car), axial (for-aft), and torsional inputs into the bushing. The test schedule was comprised of 11 virtual test track events. The individual events were run using remote parameter control playback of virtual road load data acquisition signals. Four bushings were operated under the subject loading schedule. Bushings were tested
Mars, WILL, Barbash, Kevin, Wieczorek, Matthew, Pham, Liem, Braddock, Scott, Steiner, Ethan, Strumpfer, Scott
Technical Paper
Brittle or Ductile – or Both? The Role of Print Orientation on the Mechanical Properties of PLA Samples Built by Material Extrusion Additive Manufacturing2025-01-8335To be published on 04/01/2025
The automotive industry leverages Material Extrusion (MEX)-based Additive Manufacturing (AM) to reduce lead time and costs for prototypes, rapid tooling, and low-volume customized designs. For effective design, the mechanical and physical properties of a material need to be known. This paper examines the impact of print orientation on the tensile properties of Polylactic Acid (PLA), selected for its ease of use and accessibility. Double-angle builds were included. Dog bone samples were designed to the ASTM D638 tensile testing standard and printed solid with a 0.2mm layer height, two outer walls, and a 45° raster-fill angle, with layers alternating by 90°. A nomenclature was developed to represent rotations around the X, Y, and Z axes. Testing was conducted on the MTS Criterion Model 43, 50 kN system. From the experimental stress-strain curves, the Young’s modulus, and yield, ultimate, and fracture stresses, in relation to build orientation, were extracted. Notable differences can be
Strelkova, Dora, Urbanic, Ruth Jill
Technical Paper
Light weight Haulage Load body for Sustainable Mobility applications2025-01-8216To be published on 04/01/2025
To develop a Light weight load body structure for Electric haulage vehicle application without affecting strength & durability of the product. Conventional haulage load body given for diesel vehicle application weight is approximately 20% of vehicle Kerb weight. Payload carried by customer does not get affected much. Electric vehicle Kerb weight is comparatively higher than diesel vehicle, due to battery packs & its mounting structures. So the payload carried by customer is getting affected. Hence load body weight must be reduced to 10-15% of Kerb weight. By considering past field failure data, customer loading pattern, durability trials & CAE static structural analysis, light weight load body is designed with optimized sections & HSS material. To delight the customers, Number of Floor cross members & sideboard pillars not reduced which is their first impression before buying any haulage vehicle. Multiple iterations & design failure mode effective analysis was done before finalizing
Lakshminarayanan, Karthik
Technical Paper
A data-driven synthetic population approach to estimate multi-noise lifetime durability loads for the sustainable design of electric vehicles2025-01-8295To be published on 04/01/2025
Designing for the durability of motor vehicles requires accounting for various stress factors, including tractive loads, thermal loads, and structural loads. For electric vehicle propulsion systems, it's crucial to consider not just the magnitude of these loads but also their temporal sequence throughout the vehicle’s lifespan. The order and timing of these loads influence factors such as charge and discharge cycles, and active motor heating, which ultimately impact the damage to components like the cell and the inverter. Traditionally, lifetime loads for durability assessments are derived from a single user load profile that represents a cumulative damage equivalent to the desired warranty threshold. This profile is typically based on historical usage data, user scenarios, and industry experience but may not capture the diverse failure modes of different propulsion components. This approach also adds material mass, size, and capacity increasing lifecycle emissions, reducing
Ramakrishnan, Sankaran, khapane, Prashant
Technical Paper
Image-based Machine Learning Methods in Materials Microstructure and Failure Analysis2025-01-8324To be published on 04/01/2025
Image-based machine learning (ML) methods are increasingly transforming the field of materials science, offering powerful tools for automatic analysis of microstructures and failure mechanisms. This paper provides an overview of the latest advancements in ML techniques applied to materials microstructure and failure analysis, with a particular focus on the automatic detection of porosity and oxide defects and microstructure features such as dendritic arms and eutectic phase in aluminum casting. By leveraging image-based data, such as metallographic and fractographic images, ML models can identify patterns that are difficult to detect through conventional methods. The integration of convolutional neural networks (CNNs) and advanced image processing algorithms not only accelerates the analysis process but also improves accuracy by reducing subjectivity in interpretation. Key studies and applications are further reviewed to highlight the benefits, challenges, and future directions of
Akbari, Meysam, WANG, Andy, Wang, Qigui, Yan, Cuifen
Technical Paper
Maintenance and Updates in Manufacturing Software Architecture: The Power of Automation Playbooks2025-01-8332To be published on 04/01/2025
High-efficiency manufacturing relies heavily on an extensive suite of software applications, including those for order handling, quality control, trace management, PLC communication, Andon boards, and scheduling. This reliance is particularly pronounced in facilities operating under tight schedules with stringent production targets and close collaboration with Just-In-Time (JIT) suppliers. Ensuring the continuous operation of these software systems is crucial; any downtime can result in delayed or lost units, potentially leading to significant revenue losses amounting to millions annually. Regular patching and rebooting of servers and applications are essential to maintaining system uptime, as the risk of failure increases with prolonged operation. Therefore, frequent resets and health checks are necessary, but these processes are both complex and time-consuming due to the multitude of servers and narrow scheduling windows involved. The integration of automation into these maintenance
Jan, Jonathan, Preston, Joshua
Technical Paper
Usability and scalability of performing software FMEA integration with software architecture design2025-01-8200To be published on 04/01/2025
Software FMEA is one of the several safety analysis tools that can be used during software development process to analyze software defects and their effects and take preventive measures to improve the reliability of software and the products that contain them. Nevertheless, software FMEA is subjective to the knowledge and experience of the performing organization and has limitations in that it is not quantitative, and in some cases, software FMEA is sometimes mistakenly perceived as a just formal procedure. In addition, in order to perform software FMEA, it is necessary to analyze customer requirements, and then system and software architecture design. However, the actual software development practice is often not very systematic. This paper presents a new method for integrating software architecture design and software FMEA. Among seven steps of software FMEA presented in AIAG-VDA 2019, the core concept of this integrated methodology is to add a new signal analysis process between
Han, PoongGyoo
Technical Paper
Virtual Evaluation of Stator Failure Modes using Multiphysics Analysis Approach2025-01-8627To be published on 04/01/2025
The modern luxurious electric vehicle (EV) demands high torque and high-speed requirements with increased range. Fulfilling these requirements gives rise to the need for increased electric current supply to motors. Increased amperage through the stator causes higher copper loss resulting in high temperature generation across the motor components and its casing. In most of the cases. stator is mounted on the casing through interference fit to avoid any slippage during operation conditions. High temperature across the stator and casing causes significant thermal expansions of the components which is uneven in nature due to the differences in corresponding coefficient of thermal expansion (CTE) values. Casings are generally made of aluminium and tends to expand more having higher value of CTE than that of steel core of stator which may give rise to a failure mode related to stator slippage. In this paper, we are exploring the effect of high amperage through the hairpin with the help of a
Karmakar, Nilankan, Prasad, Praveen
Technical Paper
Matchit: A Domain-Adaptable Information Extraction and Categorization Tool for Enhanced Decision Making2025-01-8107To be published on 04/01/2025
This paper presents Matchit, a novel method for expediting issue investigation and generating actionable insights from textual data. Recognizing the challenges of extracting relevant information from large, unstructured datasets, Matchit leverages Large Language Models (LLMs) to automatically identify and categorize key information into distinct topics, each representing a different aspect of the issue under investigation. This process offers two key functionalities: fully automatic topic extraction based solely on input data, providing a concise overview of the problem and potential solutions, and user-guided extraction, where domain experts can specify the type of information or pre-defined categories to target specific insights. This flexibility allows for both broad exploration and focused analysis of the data. Matchit's efficacy is demonstrated through its application in the automotive industry, where it successfully extracts repair diagnostics from diverse textual sources like
Wang, Lijun, Arora, Karunesh
Technical Paper
A Time-Aware Shaper-Based Method for Addressing Traffic Bursts and Out-of-Order Induced by IEEE 802.1CB in In-Vehicle Networks2025-01-8079To be published on 04/01/2025
The trends of intelligence and connectivity are continuously driving innovation in automotive technology. With the deployment of more safety-critical applications, the demand for communication reliability in in-vehicle networks (IVNs) has increased significantly. As a result, Time-Sensitive Networking (TSN) standards have been adopted in the automotive domain to ensure highly reliable and real-time data transmission. IEEE 802.1CB is one of the TSN standards that proposes a Frame Replication and Elimination for Reliability (FRER) mechanism. With FRER, streams requiring reliable transmission are duplicated and sent over disjoint paths in the network. FRER enhances reliability without sacrificing real-time data transmission through redundancy in both temporal and spatial dimensions, in contrast to the acknowledgment and retransmission mechanisms used in traditional Ethernet. However, previous studies have demonstrated that, under specific conditions, FRER can lead to traffic bursts and
Luo, Feng, Ren, Yi, Zhu, Yian, Wang, Zitong, Guo, Yi, yang, zhenyu
Technical Paper
Comprehensive mechanical characterization of prismatic lithium-ion cells2025-01-8129To be published on 04/01/2025
As electric vehicles (EVs) become increasingly prevalent, ensuring the safety of their battery systems is paramount. Lithium-ion batteries, the cornerstone of modern EV technology, present unique safety challenges due to their high energy density and the potential for catastrophic failure under certain conditions. The importance of understanding and mitigating these risks cannot be overstated, particularly as the industry strives to meet growing global demand while adhering to stringent safety standards. Battery safety is not just a technical concern but a critical factor in public acceptance and the widespread adoption of EVs. This study presents an extensive series of experimental tests conducted on prismatic cells from two different manufacturers. These tests include flat punch, hemispherical punch, and three-point bending tests, all designed to assess the cells’ structural integrity and failure modes. Key areas of interest include the behavior of the cell casing, jellyroll, and
Patanwala, Huzefa, Song, Yihan, SONAR, Mahesh, Belur Sheshadri, Anantharam, Sahraei, Elham
Technical Paper
Market Research & Analysis of failures due to environmental gases in Automotive Electronics and integration of learnings in development testing2025-01-8255To be published on 04/01/2025
Automotive industry is growing rapidly with innovations leading to increase in new features and improving the Quality of vehicles. These new components are developed with the available design standards across global OEMs. This Quality research paper aims to address the need of revision of design standards due to environmental factors prevailing in India. With the increase towards autonomous mobility, the number of electronics is also increasing, and this involves hardware & software evaluation. The hardware testing is a point of concern due to increase in the failure rate from the markets. Environment changes are very much evident with the growing economies and OEMs are developing the components with innovation, but if the basic design standards are not revised in parallel with the changing environment, the issues will continue to trouble the end customers. The failed cases data received from across the country was analyzed and observed that the cases are majorly reported from urban
MARWAH, Ramnik, Pyasi, Praveen, Bindra, Ritesh, Garg, Vipin
Technical Paper
Predicting Forming Limit of Hot Stamping Boron Steel using a Modified Zener-Hollomon Parameter based Ductile Failure Criterion2025-01-8225To be published on 04/01/2025
This study combines a recently proposed ductile failure criterion with a modified Zener-Hollomon parameter to predict the forming limit of a boron steel at hot stamping temperatures. The Zener-Hollomon parameter is modified to include a parameter that accounts for the non-linear variation of strain rate during hot stamping. The combined ductile failure criterion takes into account the critical damage at localized necking or at fracture as a function of strain path, initial sheet thickness and strain rate variation. The process of determining various parameters in the failure criterion is explained. The capability of the ductile failure criterion is demonstrated by predicting forming limit of a boron steel in an isothermal Nakajima dome test. The criterion is further demonstrated by predicting fracture in hot stamping a B-Pillar part (NUMISHEET Benchmark #3 2008
Sheng, ZiQiang, Mallick, Pankaj
Technical Paper
Introducing the ML FMEA: The Next Step in Machine Learning Safety2025-01-8078To be published on 04/01/2025
Several challenges remain in deploying Machine Learning (ML) into safety critical applications. We introduce a safe machine learning approach tailored for safety-critical industries including automotive, autonomous vehicles, medical automation, industrial robotics, and aerospace. Aiming to fill a perceived gap within Artificial Intelligence and ML standards, the described approach integrates ML best practices with the proven Process Failure Mode & Effects Analysis (PFMEA) approach to create a robust ML pipeline. The solution views ML development holistically as a value-add, feedback process rather than the resulting model itself. By applying PFMEA, the approach systematically identifies, prioritizes, and mitigates risks throughout the ML development pipeline. The paper outlines each step of a typical pipeline, highlighting potential failure points and tailoring known best practices to minimize identified risks. As an additional contribution, a populated ML FMEA template is provided
Schmitt, Paul, Pennar, Krzysztof, Lopez, Jerry, Bijelic, Mario, Seifert, Heinz Bodo
Technical Paper
Leaf Spring Suspension System: MBD Model Building, Simulation, and Validation2025-01-8288To be published on 04/01/2025
Title: Leaf Spring Suspension System: MBD Model Building, Simulation, and Validation The leaf spring suspension is a critical component of the chassis system, providing benefits such as improved ride quality, stable handling, and load-carrying capability. However, if a leaf spring fails, it can cause the vehicle frame and body to drop onto the wheel assembly, rendering the vehicle immobile. Therefore, it is crucial to identify leaf spring failures early in the product development cycle to save time, effort, and costs associated with market launch and development. Simpack, an MBD tool for the simulation of leaf spring system is used in this paper. Four types of spring models are available: Simbeam Flexible Spring, Multi Mass Spring, SMM Simbeam and SMM Multi Mass. Simbeam flexible spring approach is used here. Linear and non-linear beam modeling approaches are available, with linear flexible elements using the Euler-Bernoulli or Timoshenko hypothesis. Substructures and communicators are
Apte, Ameya P., Gawade, Tushar, Muralidharan, Sandeep, M, Kathikeyan, Wong, Jason
Technical Paper
Data Driven Quantitative Evaluation of Safety Controllability for Highly Automated Vehicle2025-01-8281To be published on 04/01/2025
With the development of Highly Automated Vehicles (HAVs), it is essential to ensure their safety even in the presence of system faults or function inefficiency. Safety controllability refers to the ability to manage and control the vehicle, ensuring that it remains safe even in the presence of faults with unexpected conditions. This study proposed a data driven method to evaluate quantitatively safety controllability for HAVs. Safety analysis is conducted to identify the potential hazard events. Considering system function and architecture, the failure modes of the vehicle hazards are identified with critical scenarios. Based on the identified failure modes, fault injection tests are conducted with critical scenarios. Furthermore, the improved Analytic Hierarchy Process (AHP) can be explored to quantitatively evaluate the safety controllability based on fault injection test results. In particular, this study focuses on the case study to forecast the effect of faults on safety
Ye, Xiaoming, Yang, Yanding, Li, Lingyang, Zhang, Yaguo, Wang, Yongliang
Technical Paper
Trajectory Tracking Fault-tolerant Control for Distributed Drive Electric Vehicles Considering Steering Actuator Faults2025-01-8299To be published on 04/01/2025
Trajectory tracking control is a key component of vehicle autonomous driving technology. Compared with traditional vehicles, Distributed Driven Electric Vehicle (DDEV) is an ideal vehicle for trajectory tracking control because of its high space utilization, redundant control freedom and fast system response. However, the chassis execution system of DDEV has a relatively large number of sensors, which significantly increases its probability of failure. In this paper, we propose a trajectory tracking fault-tolerant control method for DDEV considering steering actuator faults. Firstly, we establish the dynamic model of the steering actuator and the trajectory tracking model of DDEV. The model is linearized and discretized by using Taylor series expansion and forward Euler method. Next, considering multi-objective constraints such as motion comfort, actuator saturation and road adhesion boundary, the trajectory tracking control strategy of DDEV is designed by using model predictive
Chen, Zhicheng, Teng, Yuhan
Technical Paper
Forced Vibration Analysis of Cracked Functionally Graded Beams2025-28-0169To be published on 02/07/2025
This study investigates the forced vibration characteristics of functionally graded material (FGM) beams with square cross-sections featuring V-shaped cracks. FGMs, characterized by a gradual transition in mechanical composition from a ceramic to a metallic surface, offer unique advantages in various engineering applications due to their non-uniform microstructure, which imparts varying material properties throughout the structure. This research employs ANSYS Workbench to conduct a comprehensive numerical analysis, focusing on evaluating the frequencies and mode shapes of cracked FGM beams under simply supported boundary conditions. The analysis delves into the impact of three critical crack parameters: crack opening width, crack depth, and crack location. The findings highlight that the crack opening width significantly influences the vibrational frequencies of the FGM beam. Specifically, as the crack opening width increases from 0.002 meters to 0.01 meters, the frequencies decrease
D, Manish, C V, Prasshanth, N, Suhas, Bhaskara Rao, Lokavarapu
Technical Paper
Method Development for Virtual Validation of Tractor Three-Point Linkage for customer practices in Haulage application2025-28-0069To be published on 02/07/2025
This paper discusses the design and analysis of the Three-point linkage of an agricultural tractor for uncommon abusive usage practices during haulage applications. Some operators use the Three-point linkage for additional traction to navigate gradient surfaces, which requires additional wheel torque to overcome road slope when the trailer is attached. These maneuvers induce higher loads on Three-point linkage components, such as the lower link, lift rod, and powertrain components, which may lead to structural failures. A virtual simulation and lab-level test methodology need to be established to simulate the usage pattern upfront and predict potential failures. Multi-body dynamics (MBD) simulation was deployed to simulate the physics and extract realistic loads for Computer Aided Engineering (CAE) analysis. Data acquisition was carried out to record the strain levels during the uncommon haulage usage practices, which will be used for further studies. CAE analysis has been carried out
Kumar, Yuvaraj, Perumal, Solairaj, V, Ashok Kumar, Savsani, Smitkumar, Subbaiyan, Prasanna Balaji, Bhandwalkar, Anand, V V H Krishna Prasad, Tadikamalla
Technical Paper
Design and Test methodology development of Retainer plate in Forward and Reverse mechanism of Tractor Transmission2025-28-0079To be published on 02/07/2025
ABSTRACT: In the Automobile tractor- transmission system plays major role to transfer power from Engine to final drive through gear box enabling Forward/reverse(F/R) movements during field operations and transportation conditions. The F/R retainer plate with idler gear, shaft is located between clutch housing and transmission gear box housing. If the retainer housing plate gets failure, then power will not be able to transfer from engine to transmission gear box main drive. In one of the tractor model Retainer plate failures was observed during field testing. To simulate the failure mode from field to lab condition, the resultant forces and angle were calculated based on the gear torque and gear ratio of the drive line assembly. The resultant loads were applied on Idle gear shaft assembly through servo actuator in cyclic mode at FTL lab. The failure was observed in the Retainer plate and location of failure was matching with Field failure. CAE Virtual simulation was carried out for
V, Saravanan, Mani, Suresh, Kumar, Sasi, More, Amit, Dumpa, Mahendra Reddy
Technical Paper
Actuators, Linear Mechanical, General Specification GuideARP5812 (Current)01/09/2025
This SAE Aerospace Recommended Practice (ARP) establishes design, manufacturing performance and test requirements for linear mechanical actuators intended to be used for linear motion applications in response to manual or automatic power control system inputs. It is applicable, but not confined to, ball screws, sliding contact screws, roller screws, helical splines, rack and pinion assemblies, and skewed roller actuators. It is a reference for preparing detail specifications for mechanical actuators compatible and applicable to military or commercial aircraft systems
A-6B3 Electro-Mechanical Actuation Committee
Recommended Practice
LEDs and Aircraft ApplicationsARP6253A (Current)01/09/2025
This document presents minimum criteria for the design and installation of LED assemblies in aircraft. The use of "shall" in this specification expresses provisions that are binding. Nonmandatory provisions use the term "should
A-20C Interior Lighting
Recommended Practice
Comparison of Bending Properties in Paired Human Ribs with and without Costal Cartilage2024-22-000612/20/2024
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
Journal Article
Digital Twin-Enabled Fault Detection for Suspension Systems in Autonomous Mining Haulage Vehicles2024-36-017012/20/2024
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
Technical Paper
Evaluation of Superficial Damage of Mechanical Components through Digital Image Analysis Using Deep Learning Framework2024-36-003412/20/2024
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
Technical Paper
Research on the Pull Drift Compensation Control Algorithm based on Steer-By-Wire Systems2024-01-705212/13/2024
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
Technical Paper
Redundant Brake Boost Control Strategy of Integrated Electro-hydraulic Braking System2024-01-703812/13/2024
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
Technical Paper
Autonomous Mobile Robot for Gas Leak Localization2024-01-522612/10/2024
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.
Technical Paper
Strategic Utilization of Digital Twins for Examining Elastic Attack Surfaces and Replicating Attack Scenarios for Vulnerability Analysis on Road Vehicle Components2024-28-025612/05/2024
As vehicles adopt software-centric architectures, assessing vehicle software behavior becomes more complex, which can lead to the exploitation of overlooked or untreated vulnerabilities. Using these backdoors, attacks frequently targeted automotive products for malicious reasons. Automotive security incident management involves continuous monitoring of incidents and vulnerabilities. However, it faces challenges in reproducing attacks and revalidating security goals. The lack of visualization of attack scenarios, and vectors, and the knowledge required to replicate attacks hinders vulnerability assessment. The proposed approach aims to improve vulnerability assessment and document residual risks. It promotes replicating attack scenarios using cyber digital twins to support threat modeling, risk assessment, and threat analysis. The research paper focuses on utilizing digital twins for cybersecurity incident response, threat monitoring, and vulnerability exploitation by examining elastic
Venkatachalapathy, Sreenikethana
Technical Paper
An Experimental Study of White Deposit Formation on IG Coil in SI Engine2024-28-020612/05/2024
This study meticulously examines the ignition coil (IG), a pivotal component in engine operation, which transforms the low voltage from the battery into the high voltage necessary for spark plug electrode flashover, initiating the combustion cycle. Considering the importance of IG coils in engine operation which has a direct impact on the engine performance. Any failure in the IG coils is judged as a critical failure and encompasses severe repercussions. The paper details an investigation into the issue of ‘White Deposition’ on IG coils. White deposit was observed in IG Coils during new model development in bench level durability test. A comprehensive failure analysis was conducted, employing vibration analysis, thermal analysis, and chemical analysis of the white deposits to ascertain the root cause. Subsequent to identifying the root cause, the study elaborated on hardware design enhancements as a solution. These design changes were rigorously tested on engine benches, confirmed for
Patel, Hardik Manubhai, Gupta, Vineet, Chand, Subhash, Kumar, Nitish
Technical Paper
Reliability Assessment of Audio Generating Devices- Horn2024-28-017812/05/2024
The increase in vehicular traffic on Indian roads has led to a significant rise in the frequency of horn usage, particularly in city driving conditions and during peak traffic hours. Existing electro-mechanical horns are designed to have a mission life of 100,000 cycles according to Indian standards IS 1884 [1]. However, the intensified usage patterns have prompted a re-evaluation of the efficacy of these requirements. Studies reveal that the average horn blow frequency for normal usage vehicles is approximately three times per kilometer. When extrapolated to various usage categories, such as public transport and privately owned vehicles, observed increase in average horn blowing frequency per kilometer. When extrapolated, this corresponds to more than 4 lakhs cycles for a vehicle mission life of 2.5 lakhs kilometers. This insight drives the need to review and update validation test specifications to better align with customer usage patterns, thereby enhancing component reliability. By
Joshi, Vivek S., Jape, Akshay
Technical Paper
Writing an Effective Technical Safety Concept in Accordance with ISO262622024-28-020712/05/2024
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
Technical Paper
Utilization of FEA Based Fluid Pressure Penetration Technique for Understanding Fluid Leakage Phenomenon from Mechanical Fittings2024-28-024712/05/2024
In demanding automotive coolant applications characterized by extreme pressure and temperature conditions, a variety of Mechanically Attached Fittings (MAFs) are offered by multinational corporations (MNCs). These engineered fittings have been designed to meet the rigorous requirements of various industries, providing a cost-effective and reliable means to seal engine/motor coolant hose joints. Mechanical fitting assemblies are critical in various engineering systems and are used for connecting various fluid-carrying locations. Understanding leakage phenomena from MAFs is essential for ensuring their reliability and efficiency. This study explores the deployment of Fluid Pressure Penetration Technique (FPPT) available in Abaqus FEA software to comprehensively analyze leakage paths in mechanically joined fittings. The FPPT offers a systematic approach to model fluid penetration behavior within fitting joints under many loading conditions. By utilizing Abaqus software, a powerful finite
Aher, Ravi Kautik, Jivani, Chinmay, Olesnavich, Michael, Lima, Jose, Pillai, Pramod
Technical Paper
Smart Logistics Junction to Supervise the Material Handling Equipment Movements at the Intersection2024-28-026012/05/2024
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
Technical Paper
PREDICTING THE LIFE OF MILITARY VEHICLE COMPONENTS IN THE PRESENCE OF DEFECTS2024-01-320011/15/2024
ABSTRACT When the components of a military vehicle are designed, consideration is given to long term durability under repeated mission applications. In reality, surface and subsurface defects have always existed in weldments, forgings, and castings. These defects came from the manufacturing process or nucleated during the life of the vehicle. These defects may grow under repeated operations, resulting in ultimate failure of parts well before the design life is achieved. In such situations, a design based on crack initiation alone will not suffice, and a fracture mechanics based fatigue should also be included to predict the design life of a part accurately. In this paper a methodology is given on how to predict the available design life given the presence of defects in different parts of a military vehicle. An example will be provided with the process to demonstrate each step of the process
Porter, William De
Technical Paper
UTILIZATION OF MODEL-BASED APPROACHES IN CONDITION BASED MAINTENANCE PROGRAMS2024-01-366811/15/2024
ABSTRACT All CBM+ solutions must establish a business case considering cost of implementation and sustainment of value with a quantifiable return on investment. The business case must be traceable to specific failure modes, associated failure effects, criticality, and risk. Risk is not limited to safety and operational risks. Predictive systems by definition return both true and false predictions representing operational and financial risk from high false positive rates. There is also risk of losing operator confidence in predictive systems when there is a high false positive rate. All of these risks must be quantified and considered in the design and development of CBM+ systems. Model based approaches are effective in accelerating development, defining advanced functional characteristics, and efficiently testing dynamic effects of complex systems. CBM+ maintenance strategies rely on performance of complex systems
Nelson, David, Banghart, Marc
Technical Paper
MECHANICAL BEHAVIOR AND FATIGUE STUDIES OF RUBBER COMPONENTS USED IN TRACKED VEHICLES2024-01-320711/15/2024
ABSTRACT In this study, a styrene butadiene rubber, which is similar to the rubber used in road wheel backer pads of tracked vehicles, was investigated experimentally under monotonic and fatigue loading conditions. The monotonic loading response of the material was obtained under different stress states (compression and tension), strain rates (0.001/s to 3000/s), and temperatures (-5C to 50C). The experimental data showed that the material exhibited stress state, strain rate and temperature dependence. Fatigue loading behavior of the rubber was determined using a strain-life approach for R=0.5 loading conditions with varying strain amplitudes (25 to 43.75 percent) at a frequency of 2 Hz. Microstructural analysis of specimen fracture surfaces was performed using scanning electron microscopy and energy dispersive x-ray spectroscopy to determine the failure mechanisms of the material. The primary failure mechanisms for both loading conditions were found to be the debonding of particles on
Brown, H.R., Bouvard, J.L., Oglesby, D., Marin, E., Francis, D., Antonyraj, A., Toghiani, H., Wang, P., Horstemeyer, M.F., Castanier, M.P.
Technical Paper
Analysis of Spinal Compression and Energy-Absorbing Seats in Blast Environments2024-01-312011/15/2024
Summary Combat vehicle designers have made great progress in improving crew survivability against large blast mines and improvised explosive devices. Current vehicles are very resistant to hull failure from large blasts, protecting the crew from overpressure and behind armor debris. However, the crew is still vulnerable to shock injuries arising from the blast and its after-effects. One of these injury modes is spinal compression resulting from the shock loading of the crew seat. This can be ameliorated by installing energy-absorbing seats which reduce the intensity of the spinal loading, while spreading it out over a longer time. The key question associated with energy-absorbing seats has to do with the effect of various factors associated with the design on spinal compression and injury. These include the stiffness and stroking distance of the seat’s energy absorption mechanism, the size of the blast, the vehicle shape and mass, and the weight of the seat occupant. All of these
Eridon, James
Technical Paper
Challenges Faced By System Integrators: From a System Simulation Approach2024-01-334811/15/2024
ABSTRACT In today’s competitive market, OEMs are racing towards developing more efficient vehicles without sacrificing on its performance. In this process, they’re forced to evaluate new technologies and designs in various subsystems. Most of the sub-systems today have become “intelligent”, which means that the controllers have become quintessential for the system’s behavior. Equally important are the physical behavior of the plant that needs to be controlled. These two independent groups have their own design and development cycle and the challenge for the companies have been in bridging the gap so as to identify potential failure modes. This paper discusses an Architecture-driven Model Based Development process that can address the challenges posed during the development. Three key enabling technologies – Imagine.Lab System Synthesis, Imagine.Lab SysDM & Imagine.Lab AMESim are leveraged in this process
Radhakrishnan, Karthikeyan, Padmanaban, Ramesh, Paike, Ravindra, Vijay, Hari
Technical Paper
A FAULT-TOLERANT HYBRID ELECTRIC VEHICLE POWERTRAIN2024-01-341811/15/2024
Abstract This paper presents a fault-tolerant powertrain topology for series hybrid electric vehicles (SHEVs). The introduction of a redundant phase leg that is shared by three converters in a standard SHEV drive system allows to maximize the reliability improvement with minimal part-count increase. The new topology features fast response in fault detection and isolation, and post-fault operation at rated power throughput. The operating principle, control strategy, and fault diagnostic methods are elaborated. The substantially improved reliability over the standard topology is verified by the Markov reliability model. Time-domain simulation based on a Saber model has been conducted and the results have verified the feasibility and performance of the proposed SHEV drive system with fault-tolerant capability. The experimental results from a prototype have further validated the robust fault detection scheme and excellent post-fault performance
Song, Yantao, Wang, Bingsen
Technical Paper
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