Browse Topic: Calibration

Items (1,747)
This work introduces a novel parameter measurement model for an infrared detector. Firstly, the models for calculating the parameters of an infrared detector are studied and established, such as hysteresis, repeatability, and sensitivity. Then, experiments are implemented to validate and analyze the aforementioned parameters, demonstrating the accuracy and validity of the parameter computation model. This research has guiding significance for the accurate measurement of the index parameters of infrared detectors, and it is also helpful for the calibration method, error analysis and correction of infrared detectors.
Hu, ChangdeLi, YongQiangMiao, QiGao, SiliLiu, XiangyaoLi, Kunqi
During well testing and killing operations, tubing couplings with a larger diameter than the tubing body significantly increase the flow friction in the casing-tubing annulus, alter the rheological behavior of the kill fluid, thereby affecting operational accuracy and even leading to operational failure in severe cases. Most existing relevant studies focus on the impact of changes in flow area on flow, but ignore the effect of the coupling’s own structural configuration. Moreover, the research conclusions lack verification by downhole measured data, and there is an urgent need to further improve the analysis accuracy. Taking an ultra-deep well in the Xinjiang Oilfield as the engineering background, this paper conducts targeted research: first, a physical model of the flow field in the casing-tubing annulus passing through the tubing coupling is established, and a method for judging and determining the rheological properties of the kill fluid based on the fitting of the physical model and key parameters is proposed; on this basis, a numerical model including the coupling’s structural configuration is established and solved, and the friction calculation equation for the casing-tubing annulus passing through the tubing coupling is obtained through nonlinear fitting; finally, the calculation results of this equation are compared and verified with the measured data and numerical simulation results. The research results show that: under six working conditions, the flow characteristics of the kill fluid all conform to the characteristics of Bingham fluid, which is also consistent with the general flow regime of kill fluid flow; comparing the numerical analysis results of the target well in the Xinjiang Oilfield with the calculation results of the fitting equation, the maximum error, minimum error, and average error of friction analysis under the six working conditions are 14.46%, 0.39%, and 6.15% respectively; the total friction of the casing-tubing annulus in the entire well section calculated based on the theoretical equation is 12.085 MPa, and the relative error compared with the field measured 13 MPa is 7.57%, which meets the engineering accuracy requirements. The equation proposed in this study provides a universal equation for predicting the pressure drop of non-uniform flow in the wellbore, and also has an important reference value for predicting the wellbore pressure in drilling and oil-gas production operations.
Song, ZhitongJiang, WuMi, HongxueCao, YinpingDou, Yihua
The probe is an important component of the precision instrument. During the measurement process, the deformation of the leaf spring directly affects the accuracy of the displacement of the probe. There are many undetermined parameters for the leaf spring, and some parameters have a non-linear impact on the results. This paper proposes a firefly algorithm that combines penalty functions to solve the optimal solution of the objective function for multi parameter leaf springs. Through strategies such as normalizing mapping intervals, setting small populations between cells, and fine-tuning position update formulas, this algorithm quickly obtains the optimal parameters of the leaf spring, and compares it with the orthogonal experimental method to prove the feasibility of this method, providing a certain theoretical reference value for multi parameter solving.
Yu, JianghaoShi, ZhaoyaoSong, Huixu
With the continuous increase in wind turbine power capacity, ultra-long flexible blades face intensified aeroelastic instability risks due to reduced structural stiffness, enhanced modal coupling, and aerodynamic nonlinearity. In addition to the analysis of basic vibration characteristics, this study focuses on energy-related mechanisms of aeroelastic instability under various working conditions. Using a numerical model integrating Dynamic Blade Element Momentum Theory (DBEMT) and Geometrically Exact Beam Theory (GEBT), over 400 time-domain simulations were conducted to characterize instability onset and development. Results reveal four distinct aeroelastic instability regions, each dominated by specific modes. In Region A, flutter dominated by the 2nd flapwise mode is observed. In Region B, flutter dominated by the 1st edgewise mode is observed. In Region C, flutter dominated by the 2nd edgewise mode is observed. While in Region D, where the medial angle of attack (AoA) of the blade has exceeded the stall angle, stall-induced vibration dominated by the 1st flapwise mode is observed. Energy analysis shows aerodynamic work concentration near the blade tip drives instability, with diverse energy exchange patterns across regions. Except for some operating conditions in region C, where instability is dominated by edgewise energy absorption, most aeroelastic instability conditions are dominated by flapwise energy absorption. Torsional degree of freedom contributes minimally to aerodynamic work, but the torsional vibration exerts a notable influence on the AoA. This, in turn, changes the comprehensive aerodynamic forces impacting the blade as well as the general aeroelastic stability. This study clarifies the relationship between operating conditions and energy-driven instability, offering some reference values for the design work and safety assurance of ultra-long flexible blades of the wind turbine.
Wang, SuChen, JiajiaZhou, LeShen, XinLi, ChunDu, Zhaohui
For the large drive mechanisms of the survey platform, aiming to achieve long-life in-orbit rotation lubrication, a study was conducted on the tribological characteristics of a lubrication solution combining molybdenum disulfide (MoS2) coating with the application of perfluoropolyether (PFPE) greases. Validation tests were carried out under vacuum and high-low temperature environments to evaluate the equivalent in-orbit service life of solid lubrication coatings when used in conjunction with vacuum greases. Additionally, the physical properties of the friction pairs under solid-liquid hybrid lubrication conditions were investigated. Using life components equivalent to the actual product state, vacuum high-low temperature life tests under solid-liquid lubrication conditions have been completed to validate long-life lubrication technology. This holds significant guiding and reference value for the design of subsequent long-life spacecraft.
Fu, ZhibinZhang, KaiYang, SiqiZhu, JiahaoQian, ZhiyuanJi, MingZhang, LeiWang, ZhiyiMa, Zhifei
High-precision five-axis machining puts forward strict requirements for the stiffness and position stability of the AC double-angle milling head, especially when the gear transmission system is used under heavy cutting load and complex force coupling conditions. In the actual processing environment, the non-uniform deformation caused by structural coupling and load changes will directly affect the machining accuracy and stability. In order to solve these problems, this paper designs and analyzes a gear-type AC double-angle milling head with a pendulum structure and a layered modular structure. A parametric finite element model was established, and ABAQUS software was used to conduct a static analysis of two typical A-axis directions (0° and 90°), taking into account the internal prestressing force generated by gravity, cutting force, and gear meshing to reflect the typical working conditions. Under the same boundary conditions and load conditions, the influence of different structural materials on the overall stiffness was further studied through comparative analysis. The results show that under the conditions of five-axis linkage machining and positioning machining, the overall deformation of the milling head is maintained within the micron range, which meets the requirements of high-precision machining. The deformation behavior shows obvious dependence on the A-axis direction, reflecting the inherent anisotropic stiffness characteristics of the structure. Compared with the traditional structure, the proposed design has better rigidity performance under combined load conditions and provides practical reference values for the subsequent structural optimization, material selection, and precision control of high-performance five-axis CNC milling heads.
Xie, XinguiYuan, YongchaoQi, QuanLi, Xiangshuai
To address the challenges of binocular vision ranging under complex environmental conditions—such as illumination variations, occlusion, and textureless regions, which result in unreliable and non-robust performance—this paper proposes a multi-source heterogeneous sensor fusion ranging method integrating 4D millimeter-wave radar with the YOLOv5-Monster framework. This method is capable of overcoming the issue of limited ranging accuracy in monocular or binocular vision algorithms under non-ideal imaging conditions. This study achieves high-precision spatial perception through the following specific pipeline: First, Zhang’s calibration method is used to obtain the intrinsic and extrinsic parameters of the binocular camera, and stereo rectification is performed on the raw images. Next, a lightweight YOLOv5 network is employed for object detection, while a high-performance Monster network is utilized to generate dense disparity maps, thereby accomplishing initial depth estimation. To mitigate the inherent depth estimation errors of vision-only systems, 3D point cloud data from a 4D millimeter-wave radar is further introduced. By applying a Kalman filter algorithm, the millimeter-wave radar point cloud and visual outputs are fused, achieving spatiotemporal synchronization and optimal state estimation across modalities and effectively correcting biases in visual ranging. Experimental results show that within the full range of 4 to 150 meters, the relative error of the proposed method remains below 5%. Specifically, the relative errors are 1.25% (absolute error: 0.05 m) at 4 meters, 1.40% at 5 meters, 2.99% at 75 meters, and 4.91% at 150 meters. Compared with the vision-only Monster-YOLOv5 baseline method, the relative error at 150 meters is reduced from 13.16% to 4.91%, representing an accuracy improvement of over 60%. Meanwhile, in terms of long-distance error control, the proposed method significantly outperforms traditional stereo matching approaches such as SGBM+YOLOv5 and BM+YOLOv5, reducing errors by more than 20 percentage points. These results verify that deep multi-modal fusion can enhance environmental adaptability and measurement reliability, providing a high-precision and highly robust solution for distance estimation in intelligent perception systems, which holds important theoretical and engineering significance.
Li, FugaiXie, YuwenSu, HaoLiu, DongleiWu, Qiong
A car seat is one of the most critical components of passive safety. On the basis of the safety of car seats, this paper focuses on optimizing the design of the seat frame and achieving a lightweight design under various dynamic and static loading conditions. The optimization results are verified through physical experiments, which demonstrate the correctness and feasibility of the proposed design method. These experiments also provide research ideas for the optimization design of the seat structure and a certain reference value for the engineering application of the seat.
Shao, YoulinNi, WeiyuChen, Daojiong
Flexible cables are widely used in aircraft and are essential for ensuring the proper functioning of critical systems and flight safety. The design and validation of these cables represent a foundational technology in enabling the transmission of electrical power and signals throughout the entire aircraft. To achieve their intended service life, appropriate protective measures and experimental verification must be implemented. Drawing on the development experience of flexible cables for a specific domestic aircraft model, this paper proposes a combined protection method designed to extend the service life of flexible cables. Experimental analysis demonstrates the practicality and reference value of this approach.
Shi, LiqingHu, HuanghuaGe, Zengwen
The climb gradient along the takeoff trajectory at each point during takeoff reflects the aircraft’s ability to clear obstacles and reach a safe altitude, ensuring the safety of civil flights. Airworthiness regulations specify certain requirements for the single-engine-out climb gradient. Given that the data used in conventional calculation methods are significantly influenced by the flight status during the process, this paper explores two new climb performance calculation methods based on the existing ones. A set of data was calculated, and the resulting errors were all no more than 10%, indicating that both new calculation methods are effective and reliable. Therefore, they provide a certain reference value for the climb gradient calculation of transport category aircraft.
Jiang, TianjunLiu, Tao
This paper presents an innovative study in exploring, evaluating, and implementing deep-learning architectures for the calibration of multimodal sensor systems. The aim of this paper is to leverage the use of sensor fusion to achieve dynamic, real-time alignment between 3D LiDAR and 2D camera sensors. Static calibration methods are tedious and time-consuming, which is why we propose utilizing conventional neural networks (CNNs) coupled with geometrically informed learning to solve this issue. We leverage the foundational principles of extrinsic LiDAR–camera calibration tools such as RegNet, CalibNet, and LCCNet by exploring open-source models that are available online and compare our results with their corresponding research papers. Requirements for extracting these visual and measurable outputs involved tweaking source code, fine-tuning, training, validation, and testing of each of these frameworks for equal comparisons. This approach aims to investigate which of these advanced networks produces the most accurate and consistent predictions. Through a series of experiments, we reveal some of their shortcomings and areas for potential improvements. We find that LCCNet yields the best results among all the models that we validated.
Karramreddy, Venkat Sai RaxitMitchell, Liam
Semi-active suspension systems enhance ride comfort and handling performance by adaptively modulating damping characteristics. However, conventional model-based controllers often fail to maintain optimal performance under uncertain and time-varying vehicle conditions. This article proposes Bayesian Optimization–Tuned Proximal Policy Optimization with Non-Parametric Rewards (BO-NRPPO), a novel reinforcement learning (RL) framework that integrates Bayesian Optimization (BO) with Proximal Policy Optimization (PPO) and a non-parametric reward function (NRF). The proposed approach enables adaptive self-tuning, data-driven reward shaping, and uncertainty-aware policy learning. Moreover, a Trapezoidal Simple Moving Average (TSMA)–based reward normalization scheme is introduced to accelerate convergence and stabilize training. Simulation results across diverse driving scenarios demonstrate that BO-NRPPO outperforms the passive suspension, the classical Linear Quadratic Regulator (LQR), and PPO with parametric rewards. Specifically, compared to the passive suspension and the LQR baseline, BO-NRPPO achieves up to 6.63% and 5.14% improvements in handling stability, respectively. Concurrently, it delivers maximum enhancements of 46.96% and 42.55% in ride comfort over these two baselines. For real-world vehicle applications, this adaptive self-tuning capability significantly reduces the time-consuming manual calibration efforts typically required in chassis development. Furthermore, Hardware-in-the-loop (HiL) validation confirms its real-time applicability and robustness under uncertain driving conditions, highlighting its immense potential as a scalable intelligent suspension control solution.
Chen, GuoyingWang, XinyuWang, JiaqiZhan, XinwangBi, ChenxiaoCong, ShiqiHua, MinSun, TianjunGao, Zhenhai
Acoustic user interfaces and audio experiences are among the leading comfort factors in new vehicle interior designs. OEMs are more and more focusing on loudspeaker design and positioning, to provide the most immersive experience to the customers. The industrial target is to be able to predict the performance of an audio system in early design phases. This paper presents an integrated vibro-acoustic methodology enabling early-stage prediction of loudspeaker performance in real vehicle conditions. The approach combines electromechanical characterization, a hybrid loudspeaker calibrated model valid across the audible range and coupled FEM/BEM/SEA simulations to capture the loudspeaker response in the vehicle’s cabin considering door-installation effects and cabin acoustics. The method is validated experimentally on a rear-door loudspeaker installed in a production vehicle, showing strong correlation with measured SPL. A final application case demonstrates its capability to assess the impact of alternative speaker mounting positions during the design phase.
Zerrad, MehdiErrico, FabrizioMordillat, Philippe
As acoustic requirements for NVH trim components become increasingly constrained by mass, cost, and sustainability targets, traditional approaches to inner dash design based on spatially averaged Transmission Loss (TL) metrics are reaching their practical limits. In fully built vehicles, the acoustic performance of the inner dash is governed by its global insulation capability but also by strong spatial heterogeneity and its interaction with spatially distributed noise sources such as the power unit, gearbox, and tyre-road excitation. This paper presents a test-based methodology for the spatial optimisation of inner dash acoustic performance using reciprocal holography. By applying a calibrated sound power source within the vehicle cabin and measuring the reciprocal response in the engine bay and wheel-arch regions, a high-resolution spatial Transmission Loss “hologram” of the inner dash is obtained under in-situ conditions. The resulting spatial data enables the identification of localised acoustic weak points that are not observable using conventional testing methods. To bridge the gap between passive component characterisation and real-world vehicle operation, the spatial TL hologram is subsequently evaluated using representative operational source sound power data to prioritise acoustically relevant regions. This enables the transmitted acoustic energy to be evaluated under realistic driving conditions. The holographic data is then coupled with a parametric acoustic model of the inner dash system, allowing localised mass redistribution to be optimised using a genetic algorithm while respecting packaging and manufacturing constraints.
Harry, EvanEandi, Giacomo
Addressing climate change requires substantial reductions in CO2 emissions from the transportation sector, where alternative fuels for internal combustion engines play a crucial role. Hydrogen stands out as a compelling energy carrier capable of enabling low-carbon combustion while leveraging existing engine technologies. Its adoption can support a transition toward fuel-flexible powertrains and deliver rapid decreases in exhaust carbon emissions. This approach is particularly relevant for hard-to-abate segments, where full electrification remains challenging. Building on this perspective, this numerical study investigates the modelling behaviour of a heavy-duty port fuel injection (PFI) internal combustion engine fuelled with hydrogen. Initially, the mixture was assumed to be fully premixed to avoid uncertainties related to injection and mixing processes and to significantly reduce computational cost; this assumption was subsequently validated through selected injection simulations. A methodology was then developed to ensure robust model responses by analysing convergence over three consecutive cycles and by appropriately defining the initial and boundary conditions, as well as mesh resolution. Three representative experimental operating points were investigated: full load, maximum power, and cruise conditions. Two combustion modelling approaches were then compared. ECFM, a flamelet-based model, demonstrated its ability to match experimental data through a calibration process that accounts for turbulence-chemistry interactions via the adjustment of model parameters. In contrast, SAGE is a detailed chemistry solver that employs a kinetic reaction mechanism to directly compute reaction rates, without requiring calibration. The comparison highlighted certain limitations of SAGE arising from its underlying approach, whereas ECFM showed more stable and reliable behaviour, albeit with the need for case-specific calibration.
Scopelliti, AlexMisul, Daniela AnnaBaratta, MirkoGallo, AlessandroRapetto, NicolaVargiu, Luca
The paper presents a method for enhancing the static pressure calibration of a high-performance aircraft. Despite the pre-flight calibration using CFD and Wind Tunnel techniques, position errors are generally observed in the free stream parameters, which necessitate further calibration of air data sensors using flight test data. In the present research, the pressure coefficient is estimated as a time-varying parameter in the flight path reconstruction environment implemented using the Extended Kalman Filtering technique. Aircraft kinematic equations were used for the implementation of the state and measurement models, and flight test data from full flight sorties were used in the estimation process. An extensive validation of the on-board air data calibration tables was conducted. Mean values of the static pressure coefficient were updated using data from multiple sorties, each including computed mean errors from three independent sensors. A comparative analysis between the pre-existing and estimated static pressure coefficients was performed to identify specific flight regimes or manoeuvres where further refinement is required. Finally, the accuracy of the estimated true static pressure was validated by comparing the corresponding pressure altitude with radio altimeter readings at low altitudes, demonstrating strong agreement and validating the effectiveness of the proposed calibration refinement method.
TK, Khadeeja NusrathPatel, Dr. Ambalal VJ, Prabhavathi Bhai
Qualification of new aerospace alloys requires extensive mechanical testing to capture anisotropy and ensure reliable performance under complex loading conditions. This process is costly and time-consuming, particularly with emerging manufacturing routes such as additive manufacturing. Advanced yield surface prediction offers a route to reduce test campaigns by linking microstructural features to macroscopic constitutive models. In this work, Digimat is employed as a multi-scale material modeling platform to generate yield surfaces of polycrystalline metals using computational homogenization. Representative volume elements (RVEs) are constructed from experimental texture and grain morphology data, and their response under multiaxial loading is simulated using a crystal plasticity framework. The computed yield loci are then fitted with phenomenological functions (e.g. Yld2000-2D), enabling calibration of anisotropic yield models from virtual testing. As a case study, an AA6016-T4 sheet with strong cube texture is modeled and validated against experimental data, including yield stresses and Lankford coefficients in multiple directions. The predictive capability of the approach is further assessed through a cup drawing simulation in Simufact, where earing behavior is accurately reproduced. These results demonstrate that digital yield surface prediction can capture anisotropic plasticity and provide reliable input to forming simulations while significantly reducing experimental requirements. This capability lays the foundation for more efficient alloy qualification, with direct impact on fatigue and damage tolerance modeling in aerospace applications.
Padhan, ManasUppaluri, RohithLemoine, GuerricSoni, Ganesh
Autonomous Vehicles (AVs) offer unprecedented opportunities to design control strategies that could be able to simultaneously enhance safety, performance, user experience, time efficiency, and the environmental impact of mobility. However, as automation levels increase, a paradigm shift becomes not only necessary but imperative: the integration of human needs into mobility objectives. This includes not only traditional comfort considerations but also minimizing Motion Sickness (MS), a largely under-explored challenge in control strategy design. In recent literature, several methodologies for modeling and mitigating MS have been proposed, yet their integration into vehicle control logics remains limited, often restricted to isolated and specific case studies, with the research area largely unexplored, particularly with respect to the generalization of the proposed methods. This work introduces a theoretically grounded multi-objective Nonlinear Model Predictive Control (NMPC) framework for coupled vehicle–passenger systems, featuring a novel prediction horizon optimization methodology and adaptive conflict resolution strategies for heterogeneous performance metrics to mitigate motion-induced discomfort while ensuring accurate path tracking. Human-centric control design is pursued by embedding increasingly complex vehicle models and MS metrics, further addressing the trade-off between model fidelity and computational feasibility, and introducing a methodological standpoint for selecting the optimal prediction horizon in the presence of heterogeneous and conflicting control objectives, an aspect often overlooked in current literature. An experimental campaign supports model calibration and validation, while multi-scenario simulations demonstrate the framework’s ability to balance tracking performance, computational efficiency, and passenger comfort.
Ponticelli, LorenzoBottiglione, FrancescoRini, GabrieleTimpone, FrancescoSakhnevych, Aleksandr
Deep Reinforcement Learning (DRL) for quadrotor flight control typically relies on Domain Randomization (DR) for sim-to-real transfer, resulting in overly conservative policies that struggle with dynamic disturbances. To overcome this, we propose a novel adaptive control architecture that actively perceives and reacts to instantaneous perturbations. First, we train an optimal outer-loop policy, then replace its reliance on ground-truth disturbance data with a Residual Dynamics Predictor (RDP). The RDP estimates the external forces and moments acting on the aircraft in flight online using only the history of states and control actions. For seamless hardware transfer, we introduce a data-efficient linear calibration bridge and an online thrust correction mechanism that align the simulated latent space with reality using mere seconds of flight data. Real-world validations on a Crazyflie micro-quadrotor demonstrate that our adaptive controller significantly outperforms baselines, maintaining precise trajectory tracking under severe uncertainties including mass variations, asymmetric payloads, and dynamic slung loads.
Saj, VishnuBenedict, MobleKalathil, DileepVemuri, Sushil
The bird strike performance of the flight critical components of a rotorcraft is to be proved. The study investigates the bird strike performance of the cowling structure through experiments and simulations by considering a Building Block Approach. Based on this approach, bird impact tests on a rigid plate and composite panels are performed to validate Smoothed Particle Hydrodynamics method (SPH) bird model and composite material model in LS-DYNA. The composite material properties are obtained from the coupon level test results. After the composite material model is calibrated and validated, the bird strike performance of the cowling structure at critical locations is assessed. A good correlation between the experimental and numerical results was obtained at coupon, sub-component and component levels. The developed composite material modeling technique and validated bird models may be used in showing bird resistances of other airframe components of similar structure of the rotorcraft.
Kambur, ÇağdaşBayhan, Mesut
This paper presents an integrated simulation workflow for aircraft seat development that combines (i) structural dynamics and certification load cases, (ii) occupant comfort and living-space assessment using finite-element digital humans, and (iii) airbag folding, deployment, and calibration using a coupled gas-dynamics solver suited to early-time transients. The workflow is built around a single manufacturing-aware, as-built seat model that is reused across comfort, certification, and restraint-system studies, allowing design iterations to move upstream before design freeze. Each stage is paired with validation or industrial case examples, and the airbag-calibration process is accelerated through reduced-order modeling (ROM) of parameter identification. The result is a practical virtual-seat-development methodology that is sufficiently predictive to de-risk physical testing while remaining fast enough for concept iteration and late-stage compliance support.
Dwarampudi, RameshVaz, Ignatius
Automated Vehicles (AV) pose new challenges in road safety, multimodal interaction, and urban planning, requiring a holistic approach that prioritizes sustainability and protects all road users. The KASSA.AST project addresses this by deploying and evaluating an automated shuttle in southern Austria on three routes. The study area is a Park & Ride zone near a train station, enabling seamless transfers and higher transit use. To assess the safety impacts of the automated shuttle, four Mobility Observation Boxes (MOBs) were deployed. These AI-based systems detect and classify road users, track their trajectories and geospatial coordinates, and identify safety-critical events via Surrogate Safety Measures (SSMs). Over 10 days, a trajectory dataset captured interactions among vehicles and the shuttle. The resulting real-world dataset is a core contribution. This dataset underpins microscopic behavior modeling. Trajectory pairs yield car-following and interaction metrics (relative distance, relative speed, acceleration) to calibrate custom models for realistic mixed traffic. Simulations generate a structured interaction database with time spans, trajectories, conflict points, and SSMs (such as Time-to Collision—TTC, Post-Encroachment Time—PET, and Deceleration-rate-to-avoid-crash—DRAC). These outputs support detailed analysis of shuttle interactions, including near misses. To reveal patterns, clustering identified three interpretable safety-relevant regimes: (i) a low-demand background regime (n = 96) with low speeds and near-zero deceleration demand, (ii) a fast-and-tight regime (n = 33) with reduced TTC, elevated critical-event speeds, and high DRAC/Modified (M)DRAC demand, and (iii) an AV-regulated regime (n = 10) dominated by the shuttle as adversary, showing short TTC but stable moderate speeds (~4 m/s) and conservative headway policies. Ensemble-tree supervised learning reproduced these regimes with high accuracy and revealed that critical-event speeds and counterpart headway are the strongest discriminators, while AV role metadata contributes marginally. This integrated approach—linking field data, behavior modeling, simulation, and machine learning—provides a robust framework for assessing AV safety in urban contexts.
Losada Arias, ÁngelRosenkranz, PaulHula, AndreasAleksa, MichaelSaleh, PeterErdelean, Isabela
Shared Autonomous Electric Vehicles (SAEVs) can enhance urban mobility and efficiency. However, their operational performance is often hindered by the spatio-temporal imbalance between vehicle supply and passenger demand, leading to long wait times. This paper develops a novel repositioning framework where a lightweight CNN, informed by computationally intensive multi-agent simulations, enables real-time strategy deployment. The results show that: (1) An optimized repositioning policy, calibrated via multi-agent simulation, effectively cuts the mean passenger waiting time from 12.0 to 3.0 minutes (a 75% reduction). (2) A lightweight CNN surrogate model enables real-time deployment, reducing the policy computation time from ~4 hours to ~5 minutes (>98% faster). (3) The deep learning surrogate achieves this speed with a negligible performance trade-off, increasing the waiting time by only 0.156 minutes (4.9%) compared to the full optimization.
Shang, KaiWang, Ning
Lane centering is a critical active safety feature whose effectiveness depends on robust design and validation across diverse driving conditions. This paper presents the development of a Lane Centering Controller (LCC) using a structured model-based design workflow in MATLAB and Simulink. A kinematic bicycle model was employed to simulate vehicle dynamics and evaluate an angle based steering controller integrating both feedforward and feedback control paths. The controller was tested across multiple road geometries and speeds up to 65 mph to ensure tracking consistency and stability under nominal and perturbed conditions. Perception noise models for lane curvature and curvature rate were extracted from onboard camera data under controlled conditions, revealing Gaussian characteristics. No filtering was applied, allowing direct evaluation of the controller’s inherent robustness to raw signal variability. The LCC maintained a peak lateral offset within ±0.35 m and lateral jerk within ±9 m/s3, while respecting a steering comfort limit of ±3 Nm, thereby satisfying both functional and driver comfort requirements. The MATLAB based workflow also facilitated requirement traceability and automated test case validation, enabling quantitative comparisons of control response across different speeds and curvature transitions. These results establish a clear link between simulation fidelity and control performance, providing a reference for calibration transfer in higher fidelity environments. The paper concludes with discussion on extending the algorithm to real time Hardware-in-the-Loop (HIL) and Vehicle-in-the-Loop (VIL) platforms, demonstrating scalability toward full vehicle implementation and providing a validated framework for future high speed lane centering development.
Bijinepalli, Ravi TejaTambolkar, PoojaMidlam-Mohler, Shawn
Building upon previous work that successfully employed a Reinforcement Learning (RL) agent for the autonomous optimization of transmission shift programs to enhance fuel efficiency, this paper addresses a critical limitation of that approach: the neglect of human-centric factors. While the prior methodology achieved substantial fuel consumption reductions by training an RL agent in a Software-in-the-Loop (SiL) environment, it did not explicitly account for aspects such as driver comfort and preferences, which are paramount for real-world user acceptance and drivability. This work presents a multi-objective optimization framework extending the artificial calibrator to simultaneously maximize fuel efficiency and enhance driver comfort. The method introduces a modified RL reward function that penalizes undesirable shift behavior to ensure a smooth driving experience (drivability). This new methodology also incorporates a mechanism to capture and integrate driver preferences, moving beyond a purely quantitative fuel-economy-driven objective to a holistic, user-focused calibration. Experimental evaluation demonstrates that the extended framework successfully generates a shift strategy that achieves a favorable trade-off between fuel efficiency and drivability, resulting in a more balanced and practical calibration. The ability to integrate these qualitative factors into an automated, data-driven process represents a significant step forward, promising to accelerate the development of powertrain control systems that are both highly efficient and aligned with the expectations of human drivers. This work lays the foundation for future RL-based calibration tools that are capable of addressing the full spectrum of development objectives, from fuel economy to the subtleties of vehicle drivability.
Kengne Dzegou, Thierry JuniorSchober, FlorianRebesberger, RonHenze, RomanSturm, Axel
With the steady increase in autonomous driving (AD) and advanced driver-assistance systems (ADAS) aimed at improving road safety and navigation efficiency, simulation tools have become a critical part of the development process, allowing systems to be tested while mitigating the risk of physical injury or property damage upon failure. Physics-based simulators are central to virtual vehicle development, yet their control responses often differ from real vehicles, potentially limiting the transfer of controllers and algorithms developed in simulation. As these simulations play an important role in the vehicle design and validation process, a critical question is how well their predicted behavior translates to real-world physical systems. This paper presents a calibration framework for an autonomous vehicle platform that learns the motion characteristics of an experimental vehicle and uses that knowledge to correct the actuator response of a simulation model. The model is trained by collecting training data consisting of angular velocity data recorded during motion sequences from the wheel encoders mounted on the vehicle. After the data is post-processed, a long-short-term memory (LSTM) model is trained that predicts the angular velocity that the physical vehicle would achieve given a sequence of the past 30 command velocities.
Soloiu, ValentinSutton, TimothyMehrzed, ShaenLange, RobinZimmerman, CharlesPeralta Lopez, Guillermo
The push for vehicle development through virtual prototyping and testing in motorsports highlights the critical challenge of tire model selection and calibration, especially when vehicle dynamics must be accurately captured. The calibration process for tire models such as the Pacejka Magic Formula (MF) relies on parameter identification and experimental data fitting. While optimization algorithms have been implemented to calibrate tire models, few studies explore the effects of parameter selection on overall vehicle performance, complicating prioritization for the vehicle’s modeling and simulation strategy. To bridge this gap, this paper leverages optimal control methods to quantify how the variability of MF tire model parameters propagates to the overall vehicle model and impacts lap time prediction accuracy. To achieve this, a subset of parameters critical to combined slip of the MF tire model are varied through a Design of Experiments (DOE). These variations are executed on a flat oval track to simplify the dynamics yet exhibit combined slip characteristics using a fixed vehicle configuration. The minimum lap time problem is solved using collocation methods via Dymos, an optimal control library for multidisciplinary systems. A neural network surrogate model enables an interactive profiler to visualize lap time sensitivity to tire model parameters. The primary contribution of this work is a framework that parametrically connects high-level, vehicle-wide metrics such as lap time to the calibration process and selection of tire models. The parametric and interactive nature of the framework allows high-level insights across the whole design space of tire model parameters. Insights derived from this framework provide a basis to develop a strategy for prioritizing testing and calibration efforts driven by vehicle level impacts of model parameter uncertainties.
Zarate Villazon, Angel M.Brown, IanBalchanos, MichaelMavris, Dimitri
Off-road 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 6×4 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 6×4 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 6×4 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 cost and is robust to terrain changes, wheel slip, and actuator lag. To accomplish this, the controller coevolves with the vehicle design parameters, making this an effective co-design strategy. The vehicle design constraints are embedded into the controller through constraint-aware membership functions and rule tuning, reducing the need for terrain-specific calibration. The architecture is modular and scalable across numerous similar platforms, supporting rapid reconfiguration and vehicle design exploration for future autonomous off-road vehicles such as those used in expeditionary environments.
Dekhterman, Samuel R.Sreenivas, Ramavarapu S.Norris, William R.Patterson, Albert E.Soylemezoglu, AhmetNottage, Dustin
The following approach introduces a novel method for defect depth characterization using digital Shearography, which is a non-contact, full-field, and material-independent optical interferometric method that enables fast and nondestructive testing (NDT) of components, especially in industrial environments such as the automotive sector. While traditional techniques like computed-tomography, ultrasonic-testing, or thermography can offer depth approximations but they often involve high costs, longer testing times, or limited accessibility. In contrast, the method introduced utilizes various excitation methods in combination with shearographic evaluation to derive procedures for depth estimation of subsurface defects. Recent developments in Shearography have enhanced the method’s robustness and industrial applicability. By detecting the surface deformation behavior in the nanometer range under defined loading, depth-related characteristics of hidden defects can be extracted. Loading can be applied thermally, pneumatically, or mechanically. The proposed approach employs dedicated test specimens and a series of calibration measurements to derive a correlation for characterizing defect depth from the temporal progression of thermally induced surface deformation behavior. Pneumatic excitation, in particular the use of negative pressure loading, is also being explored as an alternative loading mechanism. By capturing image sequences during the deformation change between loading conditions of the specimen, this new approach enables both lateral and depth-resolved defect characterization. The method was experimentally validated on representative parts, demonstrating its practical relevance for industrial NDT use cases in which subsurface defect depth directly impacts structural integrity. Shearographic imaging has been well established for lateral defect estimation. The approach presented in this work extends this capability by enabling fast and cost-efficient characterization of defect depth, representing an important step toward more comprehensive three-dimensional defect evaluation.
Bastgen, ValentinPlaßmann, JessicaPetry, Christophervon Freymann, GeorgSchuth, Michael
With the increasing market penetration of automated vehicles, there is a critical need for credible and repeatable methods to quantify their energy impacts. This paper presents a Model-Based Systems Engineering (MBSE)-driven Anything-in-the-Loop (XIL) methodology for quantifying the powertrain energy consumption and potential savings from various controls for automated vehicles in realistic road scenarios while preserving high-fidelity powertrain behavior. The novelty of this approach lies in its use of a unified MBSE backbone (AMBER: Argonne National Laboratory’s [Argonne’s] MBSE-centric platform for transportation energy analysis) to automate the seamless and traceable progression from pure simulation to Vehicle-in-the-Loop (VIL) testing. This work utilizes Argonne's multi-vehicle simulation tool, RoadRunner, which automatically constructs closed-loop road scenarios (road geometry, vehicle sensors, other vehicles, and traffic controls) and connects them to Argonne’s validated, high-fidelity vehicle and powertrain models in Autonomie. The MBSE backbone in AMBER organizes requirements, interfaces, plant and controller models, and test scenarios into a single set of models that is maintained across pure simulation, Software-in-the-Loop (SIL), Processor-in-the-Loop (PIL), and VIL stages. Each stage has a clear role: simulation enables rapid development and validation of advanced models or controls across a large number of scenarios; SIL supports standalone algorithm verification and scenario down-selection; PIL validates real-time execution, inputs/outputs, and timing on the target processor; and VIL provides closed-loop evaluation with a real vehicle under controlled laboratory conditions. AMBER’s automated build and configuration enable rapid retargeting across platforms and repeatable scenario reproduction, making validation fast and cost-effective. To demonstrate its practical application, the workflow is used to validate the functionality and quantify the energy savings of an eco-driving control against a calibrated human driver model. Experiments show strong repeatability and consistent energy gains for the eco-driving strategy while preserving trip time, yielding average energy savings of 7.8% across the evaluated scenarios. Overall, the MBSE-guided XIL workflow shortens development time and reduces test cost by limiting on-road testing and lowering integration risk before track evaluation, while producing credible, closed-loop energy assessments traceable from requirements to test evidence.
Jeong, JongryeolSharer, PhillipDi Russo, MiriamDas, DebashisZhang, YaozhongKarbowski, Dominik
Calibration is a major resource bottleneck and source of risk in powertrain technology development. A promising alternative to the typical design-of-experiments (DoE) approach is the use of a ‘Non-Dominated Sorting Genetic Algorithm’ (NSGA) calibration method, where an iterative process is used to directly identify the Pareto Fronts between performance metrics, for example, net mean effective pressure (NMEP) and NOx emission. The goal of the present work was to develop and demonstrate a fully ‘online’ combustion system calibration method based on an NSGA, where the algorithm operates directly on experimental data rather than empirical models as is typical in the literature. This was completed by first designing an optimal NSGA for combustion system calibration and then demonstrating its use for an experimental combustion system calibration on a single cylinder gasoline engine at one operating condition. Results from the design process here indicate that ‘online’ NSGAs have a strong potential to outperform traditional DoEs in the development of Pareto-optimal engine calibrations; however, NSGA performance is highly sensitive to the specific parameters used in the algorithm logic. The highest sensitivity was to the mutation logic within the genetic reproduction process, and second was the number of genes (calibrations) included in the overall process. Inclusion of both the Primary and Secondary non-dominated Pareto fronts in the set of Pareto-optimal calibrations was found to be critical to the success of the NSGA. When demonstrated for an experimental combustion system calibration the NSGA operated effectively and as expected, continually providing ‘upward’ pressure to generate calibrations that maximize NMEP but also ensure the breadth of the Pareto front (NOx) is scanned with high fidelity. In comparison to a traditional DoE approach, the NSGA was nearly twice as accurate in identifying calibrations along the Pareto front for the same number of total experiments. The Pareto-optimal calibrations developed by the NSGA are reasonable for these operating conditions and in excellent agreement with the literature. The present work strongly motivates and supports further development of NSGA methods for use in more complex systems and situations including for electrified and hybrid powertrains.
Mansfield, Andrew
Trust calibration is vital for safe human–automation interaction but remains largely qualitative. This study develops multiple quantitative frameworks modeling trust as a function of automation reliability. Four progressive models of binary, linear, triangular, and logistic formalize the calibrated trust zone, defining where human reliance aligns with system performance. The framework corrects major misconceptions: that trust is purely qualitative, that low trust–low reliability states are acceptable, and that overtrust and distrust pose equal risk. It establishes a minimum reliability threshold for meaningful trust and identifies distrust as the safer default in high-risk contexts. A case study on an empirical observation of 32 AI applications plotted in the trust–reliability space confirms the analysis, revealing a consistent distrust tendency where reliability exceeds user confidence and other observations. By quantifying trust through reliability, the study reframes it as a controllable safety variable, enabling predictive calibration and adaptive, trust-aware safety architectures for reliable human–AI collaboration.
Wen, HeMounir, Adil
The Formula SAE (FSAE) race track is characterized by a large number of corners, making cornering performance a key factor affecting lap time. Based on the proportional control strategy for rear-wheel steering angles, this paper proposes a steering angle optimization method using a Temporal Convolutional Network (TCN). The TCN model features a faster training speed than traditional sequential neural networks. In addition, dilated convolutions enable an exponential expansion of the receptive field without increasing computational costs, making it particularly suitable for capturing the temporal dependencies of vehicle states. By processing vehicle dynamic parameters including front-wheel steering angle, vehicle speed, yaw rate and sideslip angle, the model calculates the correction value of the rear-wheel steering angle. This correction value is then superimposed with the reference value of the rear-wheel steering angle derived from the proportional control strategy, which serves as the control value for rear-wheel steering. Rear-wheel steering can reduce the turning radius during low-speed driving and enhance the racing car’s stability during high-speed cornering. This method was validated on a typical race track via CarSim-MATLAB co-simulation, resulting in reduced lap time. To meet the real-time computing requirements of FSAE, MATLAB was used to simulate the discretization results of vehicle parameters such as vehicle speed and front-wheel steering angle, generating a Look-Up Table for rear-wheel steering angles, which provides a feasible solution for real-vehicle tests. The racing car is equipped with a manual switch for the driver to operate. The driver can manually turn the rear-wheel steering function on or off when cornering or whenever they deem it necessary.
Liu, Xiyuan
To measure the fuel proportion within the lubricant film, an in-situ Raman spectroscopy technique was employed in a specially modified single-cylinder direct-injection spark-ignition engine. The engine block was engineered for optical access with a fused silica window, enabling a focused laser beam to probe the lubricant film on the engine liner under motoring conditions. The lubricant used was GTL8 base oil with ZDDP additive, and iso-octane was injected as a model fuel to study fuel-lubricant mixing. A calibration curve was established by recording Raman spectra of known mixtures of GTL8 oil and iso-octane. The Raman intensity ratio of the iso-octane peak to the oil peak was used as a quantitative indicator of fuel concentration. During engine operation, Raman spectra were acquired in real time, on a cycle-by-cycle basis, through the optical window. Upon iso-octane injection, its characteristic Raman peak appeared in the spectrum, and the intensity ratio was referenced against the calibration curve to estimate the fuel proportion within the lubricant film. Experimental results demonstrated that the iso-octane signal could be detected during and after injection and this allowed for real-time monitoring of fuel dilution dynamics. The main challenge encountered was high fluorescence from oil, which sometimes obscured the Raman peaks and complicated quantification. Despite this, the technique successfully demonstrated the feasibility of direct, in-situ, and real-time quantification of fuel dilution in engine lubricant films, providing a valuable tool for studying fuel-lubricant interactions under operating engine conditions.
Bolle, BastienAugoye, KobiWong, JanetAleiferis, PavlosHall, JonathanBassett, MikeCracknell, Roger
The Stellantis North America Aero-Acoustic Wind Tunnel (AAWT) has been upgraded with a cutting-edge 5-belt Moving Ground Plane (MGP) system, featuring an 8.5-meter center belt and four Wheel Spinning Unit (WSU) belts with advanced coatings for durability and visibility. The expanded 9.4-meter turntable enables ±90° yaw and supports vehicles with wheelbases from 1800 mm to 4500 mm and weights up to 5000 kg, accommodating the full Stellantis North America product range. The original 2-stage boundary layer control system was retained, with new tertiary slots added for improved flow quality. A high-stiffness, six-component Horiba balance with integrated calibration weights and tractive force measurement ensures accurate and precise measurements. Facility enhancements include a 550 m2 building addition for equipment and vehicle prep, a dedicated compressor container for clean air supply, and a vehicle underbody wash booth for efficient cleaning. Commissioning confirmed that flow quality, axial static pressure distribution, and acoustic background noise meet or exceed system specifications. Operational since October 2024, the upgraded AAWT now delivers world-class aerodynamic and acoustic testing capabilities, with enhanced automation, safety, and efficiency.
Lounsberry, ToddLadouceur, BrentFadler, Gregory
The timing of video recordings, along with the spatial positioning of objects, is a fundamental parameter for calculating the speed time history. If the task involves determining the average speed of an object moving at approximately constant speed, it may be acceptable to average the speed over several to a dozen frames, using the fps (frames per second) parameter as the basic time unit.. However, if the objective is to compute speed from individual frames, the reliability of the timing becomes crucial. Without access to DVR hardware documentation, proprietary algorithms, or software – and considering the frequent hardware modifications and software updates - the most effective way to solve the problem is through a reverse-engineering approach. This study discusses several aspects of timing analysis, including: (1) making a test recording of a calibrated LED lightboard; (2) analyzing the relationship between the lightboard time and the presentation time stamp (pts) extracted from the file metadata; (3) investigating frame skipping and frame timing errors due to frame rate changes; (4) modeling the composite motion of the rolling shutter and the lightboard LEDs; (5) identifying the DVR’s actual frame capture rate; and (6) compensating the timing of the evidentiary recording. Establishing the timing scheme of the test recording enables reliable speed analysis based on two or three adjacent frames of the evidentiary recording, as well as the determination of the velocity time history over a short segment of the recording.
Wach, Wojciech
Torque Vectoring (TV) is a critical control technology for enhancing the vehicle dynamics and stability of electric vehicles equipped with four-wheel-independent-drive (4WID) systems. A central challenge in TV design is managing the trade-off between maximizing handling performance and minimizing energy consumption, a crucial factor for EV range. While numerous advanced TV control strategies have been proposed, a comprehensive and comparative benchmark of foundational controllers evaluated on a platform that captures this trade-off is notably absent from the literature. Among the numerous TV control strategies proposed in literature, they are typically evaluated using simplified vehicle models that neglect the detailed dynamics and efficiency losses of the electric powertrain. This study addresses this gap by presenting a comprehensive comparison of six distinct TV control strategies—PID, LQR, two first-order Sliding Mode Controls (SMC), and two second-order SMCs. The controllers are evaluated on a high-fidelity, multi-domain simulation platform that integrates a detailed 14-DOF vehicle dynamics model with electro-thermal models of the motors and energy storage system. The findings reveal a clear, quantifiable trade-off between control precision and energy efficiency. The LQR and suboptimal SOSM controllers delivered superior yaw rate tracking and vehicle stability but incurred a measurable energy penalty. In contrast, the PID and continuous FOSM controllers provided a robust balance of performance and efficiency. More than an exercise on application of different control methods, this research highlights the necessity of using integrated simulation methodologies for the practical design and calibration of active chassis systems, ensuring that gains in dynamic performance do not come at an unacceptable cost to vehicle range and powertrain reliability.
de Carvalho Pinheiro, HenriqueCarello, Massimiliana
This study systematically investigates methods to enhance the fast-charging capability of lithium-ion batteries through advanced simulation. The electrochemical reaction mechanism, heat generation mechanism, and lithium plating mechanism are analyzed in detail, and an electrochemical–thermal coupled model incorporating a lithium plating sub-model is established. A hybrid parameter identification strategy, combining random search, grid search, and manual adjustment, is employed to calibrate the model across different operating conditions, thereby improving its accuracy in reproducing real battery behavior. Lithium plating is selected as the primary indicator to evaluate fast-charging performance. Based on simulation results, the effects of both operational parameters and structural parameters on lithium plating are thoroughly analyzed. The results indicate that lower charging rates, elevated charging temperatures, higher electrode porosity, and reduced tortuosity are favorable for suppressing lithium plating. These conditions improve the uniformity of lithium deposition while alleviating concentration gradients of lithium ions, thus offering valuable insights for battery material design and practical applications. Furthermore, optimized charging protocols are developed on the basis of conventional strategies and their associated impacts on battery behavior. Two novel approaches—the group-based optimized charging protocol and the adaptive optimization-based charging protocol—are proposed by dynamically adjusting the charging rate according to real-time electrochemical states. Validation on the developed electrochemical–thermal model confirms that the proposed protocols can achieve high-rate charging without inducing lithium plating. As a result, charging time is significantly reduced while ensuring safety and reliability. Overall, this research not only provides a comprehensive methodology for modeling and parameter identification but also offers practical strategies for protocol optimization. With solid-state batteries regarded as a promising future technology, the present work provides a potential basis for their advancement.
Zhao, PeiqiangZhan, WenweiQi, JiYi, Yong
In the context of electro-mobility for commercial vehicles, the failure analysis of a connector panel in a DCDC converter is crucial, particularly regarding crack initiation at the interface of busbar and plastic component. This analysis requires a thorough understanding of thermo-mechanical behavior under thermal cyclic loads, necessitating kinematic hardening material modeling to account for the Bauschinger effect. As low cycle fatigue (LCF) test data is not available for glass fiber reinforced polyamide based thermoplastic composite (PA66GF), we have adopted a novel approach of determining non-linear Chaboche Non-Linear Kinematic Hardening (NLK) model parameters from monotonic uniaxial temperature dependent tensile test data of PA66GF. In this proposed work a detailed discussion has been presented on manual calibration and Genetic Algorithm (GA) based optimization of Chaboche parameters. Due to lack of fiber orientation dependent test data for PA66GF, here von Mises yield criteria based Chaboche NLK model is implemented as a macro-mechanical phenomenological model based on test data with random fiber orientation. After material modelling as described above the thermo-mechanical finite element (FE) simulation has been conducted on Connector panel assembly with temperature cycling from -40°C to 80°C. The assembly under consideration is composed of busbars, insert mold and outer connector body of plastic PA66GF. It is observed from the simulation result that though the equivalent plastic strain is much higher at 80°C in comparison to the same at -40°C, the equivalent von Mises stress is comparatively lower at 80°C than at -40°C because of Bauschinger effect while reversing load, which in turn validates the implementation of proper kinematic hardening material model to address the physical phenomenon. Finally, the FE model is validated through characterized crack initiation site in the plastic component comparing with equivalent plastic strain, von Mises stress and stress triaxiality evaluated from simulated result.
Basu, ParichaySrinivasappa, Naveen
This paper details comprehensive analysis modeling and analysis supporting the development of the Research Aircraft for eVTOL Enabling techNologies (RAVEN). An isolated rotor model was developed in CAMRAD II, and predictions of rotor performance and rotor aeroelastic stability were generated. The rotor stability predictions are part of assessing airworthiness of the RAVEN vehicle. The performance predictions were used to calibrate the surrogate model for the NASA Design of Rotorcraft (NDARC).
Wright, StephenSilva, Christopher
The Exhaust Emission Control is a vital part of automotive development aimed at ensuring effective control of pollutants such as NOx, CO, and HC. The traditional method of calibrating emission control strategies is a highly time-consuming process, which requires extensive vehicle testing under a variety of operating conditions. The frequent updates in emission legislation requires a high-efficiency process to achieve a faster time-to-market. The use of Machine Learning (ML) in the domain of emission calibration is the need of the hour to proactively improve the process efficiency and achieve a faster time-to-market. This paper attempts to explores emerging trend of Machine Learning (ML) based data analysis that have improved the overall process efficiency of emission control calibration. The data generated by automated programs could be used directly in data analysis with minimal or no need for data cleaning. The Machine Learning (ML) models could be trained by historical data from relevant engine platforms to predict the output. The integration of Machine Learning (ML) models with automated measurement processes further enhances the process by enabling model-based calibration development. The use of automated programs and machine learning (ML) models could ensure high accuracy of the emission calibration data. This methodology could significantly reduce the need for volumes of measurements required for data analysis and calibration. This could further help in optimized usage of testing facilities, ultimately saving time and resources. A 70% overall savings in time and resources could be expected with the use of automation and machine learning models. This methodology also supports faster calibration development cycles that would be required for adhering to frequent legislative changes and achieving faster time-to-market.
Dhayanidhi, HukumdeenBalasubramanian, KarthickA, Akash
Artificial Intelligence and Machine learning models have a large scope and application in Automotive embedded systems. These models are used in the automotive world for various applications like calibration, simulation, predictions, etc. These models are generally very accurate and play the role of a virtual sensor. However, the AI/ML models are resource intensive which makes them difficult to execute on largely optimized automotive embedded systems. The models also need to follow safety standards like ASIL-D. The current work involves creating a Global DoE with ETAS ASCMO to generate data from a 125cc single to create AI/ML model for the engine outputs like Torque, T3, Mid-cat temperatures etc. The created models were validated across the operating space of the engine and found to have good accuracies. With ETAS Embedded AI Coder, the torque and T3 prediction AI models were converted to embedded code which can be easily used as a virtual sensor in real time. Using these AI models, accurate predictions can be made on the ECU in real time without an actual sensor, thus paving to remove these sensors and reduce cost per vehicle.
Chouhan, Vineet SinghBulandani, SaurabhKumar, AlokVarsha, AnuroopaP R, Renjith
In the era of Software Defined Vehicles, the complexity and requirements of automotive systems have increased knowingly. EV Thermal management systems have become more complicated while having multiple functions and control strategies within software frameworks. This shift creates new challenges like increased development efforts and long lead time in creating an efficient thermal management system for Electric Vehicles (EV’s) due to battery charging and discharging cycles. For solving these challenges in the early stages of development makes it even more challenging due to the unavailability of key components such as fully developed ECU hardware, High voltage battery pack and the motor. To address this, a novel framework has been designed that combines virtual simulation with physical emulation at the same time, enabling the testing and validation of thermal control strategies without fully matured system and the ECU hardware. The framework uses the Speedgoat QNX machine as the central controller which hosts the control logics and electro-thermal models developed in Simulink and Simscape. Speedgoat is physically connected to a non-functional vehicle equipped with key thermal components such as a radiator cooling fan, AC compressor, HVAC blower, active grille shutters (AGS), valves etc. The heat load for different conditions is emulated using heater carts and vehicle itself. The entire system is designed to be mobile, allowing it to be placed inside a climatic chamber. By controlling all the components through Speedgoat and offering an interactive calibration interface for real time calibration, this framework bridges the gap between simulation and physical testing. It helps in accelerating controls development, optimizes thermal control strategies, ensures energy efficiency, reliability, and cost effectiveness in system design.
Chothave, AbhijeetS, BharathanS, AnanthGangwar, AdarshKhan, ParvejGummadi, GopakishoreKumar, Dipesh
Passenger vehicle users often manoeuvre their cars in diverse and unpredictable driving patterns. The vast and varied terrain of the Indian subcontinent further complicates this scenario, introducing unique challenges due to differences in driving expertise, vehicle usage, and environmental conditions. A specific challenge addressed in this paper arises during different engine temperatures and transient driving conditions—a critical phase for engine calibration to ensure optimal drivability and emissions performance. With current calibration practices, a backfire like abnormal engine noise was observed during certain transient driving patterns. This paper presents a novel calibration methodology designed to eliminate such abnormal noise. The proposed approach involves a step-by-step transient calibration refinement, making the calibration process more robust and adaptable to any driving behaviour. The paper outlines the specific challenges encountered and details the multi-level calibration and validation strategy used to resolve the issue, thereby enhancing overall vehicle drivability performance and customer satisfaction.
Suna, BhagyashreeTyagarajan, SethuramalingamPise, ChetanAishwarya, Amritansh
In the assessment of parts subjected to impact loading, the current process relies on static analysis, which overlooks the significant influence of high strain rate on material hardening and damage. The omission of these effects hinders accurate impact simulations, limiting the analysis to comparative studies of two components and potentially misidentifying critical hot spot locations. To address these limitations, this study emphasizes the importance of incorporating the effects of high strain rate in impact simulations. By utilizing the Johnson-Cook material calibration model, which includes both material hardening and damage models, a more comprehensive understanding of material behavior under dynamic loading conditions can be achieved. The Johnson-Cook material hardening model accounts for the strain rate sensitivity of the material, providing an accurate representation of its behavior under high strain rate conditions. This allows for improved prediction of material response, particularly in terms of plastic deformation and flow stress. Additionally, the Johnson-Cook material damage model considers the progressive accumulation of damage and its influence on the material's failure behavior under impact loading. By incorporating this model, the simulation can accurately capture the initiation and propagation of fractures, providing a more realistic representation of the structural response. This study focuses on the calibration of the Johnson-Cook model for Brittle material and its application in predicting Knuckle failure at the tie rod arm location under impact loads. To validate the predictions of Knuckle failure at the tie rod arm location, the simulation results obtained using the calibrated Johnson-Cook model are compared with physical tests. A test setup capable of delivering high-velocity impacts is utilized in the physical tests. The resulting data from the physical tests, including fracture patterns and impact behavior, are carefully recorded and compared with the simulation results. This study shows that a calibrated Johnson-Cook model is a reliable tool for simulating and predicting Knuckle failure in structures subjected to impact loading. The validation of the simulation results using physical tests adds credibility to the accuracy of the Johnson-Cook model and its suitability for predicting Knuckle failure in practical applications.
Pratap, RajatApte, Sr., AmolBabar, RanjitDudhane, KaranPoosarla, Shirdi Partha SaiTikhe, Omkar
Accurately determining the loads acting on a structure is critical for simulation tasks, especially in fatigue analysis. However, current methods for determining component loads using load cascade techniques and multi-body dynamics (MBD) simulation models have intrinsic accuracy constraints because of approximations and measurement uncertainties. Moreover, constructing precise MBD models is a time-consuming process, resulting in long turnaround times. Consequently, there is a pressing need for a more direct and precise approach to component load estimation that reduces efforts and time while enhancing accuracy. A novel solution has emerged to tackle these requirements by leveraging the structure itself as a load transducer [1]. Previous efforts in this direction faced challenges associated with cross-talk issues, but those obstacles have been overcome with the introduction of the "pseudo-inverse" concept. By combining the pseudo-inverse technique with the D-optimal algorithm, researchers have devised a robust and versatile method for identifying optimal sensor positions (e.g., strain gauges) on the structure where its response can be accurately measured. The pseudo-inverse facilitates the pre-calculation of a calibration matrix, which, when combined with the measured responses, enables the reverse calculation of the loads acting on the structure. This approach offers several advantages over conventional load cascading methods, including higher accuracy in load calculation by minimizing sources of error and the ability to estimate potential errors beforehand. In summary, the integration of the pseudo-inverse technique and the D-optimal algorithm provides an innovative and efficient solution to enhance the accuracy and turnaround time of component load estimations in structural analysis. By utilizing the structure as a load transducer, this method offers a more direct, accurate, and error-aware approach to load calculations, leading to the emergence of robust design solutions.
Pratap, RajatApte, Sr., AmolBabar, Ranjit
Meeting the stringent emissions norms of CEV stage V for medium BMEP engines, CI engines present significant challenges. These stringent norms call for a highly efficient DPF. With the increasing demands for high-performance DPFs, the issue of soot accumulation and cleaning presents significant hurdles for DPF longevity. This paper explores the potential of passive DPF regeneration, which leverages naturally occurring exhaust gas conditions to oxidize accumulated soot, offering a promising approach to minimize fuel penalty and system complexity compared to active regeneration methods. The study investigates engine calibration techniques aimed at enhancing passive regeneration performance, emphasizing the optimization of thermal management strategies to sustain DPF temperatures within the passive regeneration range. Furthermore, the paper aims to expand the applicability of passive regeneration across diverse engine loads common in off-highway applications with effective passive regeneration significantly contributing to overall system efficiency, reduced fuel consumption, and ensuring long-term emissions compliance for CEV Stage V engines.
Saxena, HarshitGandhi, NareshLokare, PrasadShinde, PrashantPatil, AjitRaut, Ashish
Vehicle level EMS tuning is one of the crucial parts of calibration development. In this, vehicle level data is collected by using chassis dynamometer. Main objective of this data collection is to log the engine and vehicle level parameters at various speed and load conditions, covering the entire engine operational zone. This data acquisition process includes verification of base calibration, transient calibration and emissions-related calibration. Due to multiple number of similar acquisition steps this process becomes repetitive in nature and it covers 30-40% of the total calibration duration. All these measurements follow a standardized and repetitive sequence. However, these tasks are predominantly performed manually, leading to potential human error and fatigue. This paper presents a novel and comprehensive algorithm developed using INCA FLOW software; the first of its kind for this application. Here, a systematic development approach is used. First, the crucial vehicle data acquisition activities are identified. Then these activities are mapped into detailed steps. In this paper, an algorithm is proposed which introduces a semi-automated, stepwise process for data acquisition during chassis dynamometer testing, thus significantly reducing the manual intervention. In order to take of the safety conditions, arising due to possible failure modes of failure, safety-monitoring conditions are also introduced. These failures are mainly due to thermal and mechanical limits of the engine, vehicle and human safety while testing. Additionally, a sophisticated data processing algorithm has been designed to significantly reduce manual intervention, improve data accuracy, and streamline the overall calibration development timeline.
Kavekar, Pratap ChandrashekharTyagarajan, SethuramalingamAgarwal, Nishant KumarShaikh, WasimKaradi, Subramanya
Addressing the challenge of optimal strain gauge placement on complex structural joints and pipes, this research introduces a novel methodology combining strategic gauge configurations with numerical optimization techniques. Traditional methods often struggle to accurately capture combined loading states and real-world complexities, leading to measurement errors and flawed structural assessments [9]. For intricate joints, a looping strain gauge configuration is proposed to comprehensively capture both bending and torsional effects, preventing the bypassing of applied loads. A calibration technique is used to create strain distribution matrices and access structural behavior under different loading conditions. Optimization algorithms are then applied to identify gauge placements that yield well-conditioned matrices, minimizing measurement errors and enhancing data reliability. This approach offers a cost-effective solution by reducing the number of gauges required for accurate stress characterization. This concept is extended to both round and complex-shaped pipes to improve fatigue damage prediction using Road Load Data Acquisition (RLDA). The approach addresses geometric complexities and simulates strain behavior under diverse loading scenarios. The optimization focuses on maximizing strain sensitivity in critical regions, minimizing errors, and ensuring robust strain representation while considering RLDA constraints. The unique contribution lies in directly linking optimized strain gauge placement with improved damage calculation. By integrating RLDA, optimized configurations are tested under actual operating conditions, validating numerical models and assessing damage accumulation based on measured strain data. This leads to more realistic damage predictions compared to simplified loading assumptions. The findings demonstrate that optimized placement significantly enhances damage calculation accuracy, crucial for industries like oil and gas, aerospace, and infrastructure monitoring, where RLDA provides valuable insights into real-world loading.
Shingate, UttamYadav, DnyaneshwarDeshpande, Onkar
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