Browse Topic: Measurements

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A Load Cell-Free Solution for Weighing2025-28-0346To be published on 11/06/2025
The agricultural industry increasingly demands innovative solutions to enhance efficiency and productivity, while minimizing overhead costs of an advanced system. Large farms cultivating forage crops for the Dairy and Livestock sectors require high-quality, dense bales that retain their nutritional value. Bale weight serves as a critical parameter for assessing production yields, managing inventory and facilitating fair trade in the industry. Traditional weighing systems reliant heavily on load cells, can pose limitations in terms of cost, complexity and maintenance. This paper presents an advanced model-based weighing system de-signed specifically for balers machine. It utilizes mathematical models and dynamic torque monitoring techniques to accurately estimate the weight of bales just after the baling process. The Bale weight calculation is achieved by measuring reverse pressure experienced during bale handling and monitoring the pitch angle to compensate for measurements over
Kadam, Pankaj
Development of Door Impact Loads Using Frugal use of "Pedal Force Sensor"2025-28-0283To be published on 11/06/2025
The first step in designing or analyzing any structure is to understand “right” set of loads. Typically, off-road vehicles have many access doors for service/getting into cab etc. Design of these doors and their latches involve a knowledge of the closing loads when the door is shut mostly with an impact of varying magnitudes. In scenarios of these impact events, where there is sudden change of velocity within few milliseconds, produces high magnitude of loads on structures. One common way of estimating these loads using hand calculations involves evaluating the rate-of-change-of-momentum. However, this calculation needs “duration of impact”, and it is seldom known/difficult to estimate. Failing to capture duration of impact event will change load magnitudes drastically, e.g. load gets doubled if time-of-impact gets reduced from 0.2 to 0.1 seconds and subsequently fatigue life of the components in “Door-closing-event” gets reduce by ~7 times. For these problems, structures are usually
Valkunde, Sangram, Ghate, Amit, GAGARE, KIRAN
Method to determine the instantaneous Temperature rise and current offset for a continuously fluctuating current in a current measurement device.2025-28-0294To be published on 11/06/2025
This research proposes a method to accurately determine the instantaneous temperature rise and current offset in a current measurement device subjected to continuously fluctuating currents, while considering the ambient temperature conditions within an electric vehicle (EV) junction box. The study addresses the critical need for precise current measurements in EVs, where varying loads and environmental conditions can impact the performance and safety of electrical systems. The method involves the development of a comprehensive mathematical model that accounts for the dynamic interplay between the fluctuating current, temperature changes, joule heating and ambient conditions within the EV junction box. By incorporating thermal dynamics and electrical characteristics, the model aims to provide a nuanced understanding of the temperature rise and current offset phenomena. Special emphasis is placed on considering the effects of ambient temperature variations, which play a significant role
r, Sudarshan, Cheran, Abhinav, Rao, Sudarshan, Chandran, Praveen
Exhaust emissions tests of small gasoline engines used as drives for power generators and handheld machinery2025-32-0072To be published on 11/03/2025
The paper presents the results of the investigations on the exhaust emissions carried out under real operating conditions of gasoline small engines. During the operation of these devices the authors measured the exhaust emissions: CO, HC, NOx and CO2. For the measurements the authors used a portable exhaust emission analyzer (PEMS). The presented method is a new solution in determining of the exhaust emissions from such engines. In the paper the results of exhaust emissions measurement has been presented. Moreover, some remarks according to measurement method has been presented. The obtained results were compared with the applicable emission requirements. Besides, based on the performed investigations, the authors attempted an evaluation of the possibilities of the use of the measurement method for development works and legislation related to the reduction of the emission from small gasoline engines.
Lijewski, Piotr, Markiewicz, Filip, Fuc, Pawel, Dobrzynski, Michał
Analysis of injected mass shot-to-shot dispersion and injection rate profile for a PFI injector in actual operating conditions2025-32-0019To be published on 11/03/2025
In order to improve engine emission and limit combustion instabilities, in particular for low load and idle conditions, reducing the injected fuel mass shot-to-shot dispersion is mandatory. Unfortunately, the most diffused approach for the hydraulic analysis of low-pressure injectors such as PFIs or SC R dozers is restrained to the mean injected mass measurement, since the use of conventional injection analysers is unfeasible. In the present paper, an innovative injection analyser is used to measure the injection rate and the injected mass of each single injection event, enabling a proper dispersion investigation of the studied system. The proposed instrument is an inverse application of the Zeuch’s method, which in this case is applied to a closed volume upstream the injector, with the injector being operated with the prescribed upstream-downstream pressure differential. Further, the injector can inject freely against air, thus enabling simultaneous analyses of the resulting spray
Postrioti, Lucio, Maka, Cristian, Martino, Manuel
Machine Learning-Enhanced Electrical Circuit Model Parametrization for Battery Cells: Reducing Experimental Workload Through GITT Testing with Altair RapidMiner®2025-32-0097To be published on 11/03/2025
This study addresses the challenge of reducing the experimental workload involved in characterizing battery cell behavior as a function of state of charge and temperature. Galvanostatic Intermittent Titration Technique tests were carried out in a climate chamber across a wide temperature range, from -20 °C to 70 °C, with 10 °C intervals. The voltage and current response data collected from these tests were used to train several machine learning algorithms. The trained models could then be used to predict the cell voltage response every 5 °C from -15 °C to 55 °C. While the models were experimentally validated at 15 °C, 25 °C, and 35 °C, the predicted voltages across this range contribute to enhancing the characterization process. In particular, the inclusion of these predicted voltage profiles—combined with the experimental data collected every 10 °C from -20 °C to 70 °C—allows for the creation of more accurate lookup tables for the parameters of the equivalent circuit model. These
Giuliano, Luca, Peretto, Lorenzo, Canella, Nicholas, Nefat, Damir
Experimental analysis of wheel bearing friction losses under realistic driving cycles on a component and roller test bench2025-32-0100To be published on 11/03/2025
The ongoing electrification of vehicle powertrains brings attention to components with a minor contribution to overall friction losses in research and development. To optimize the overall energy efficiency, it is essential to analyze and reduce the losses in these components. Wheel bearings are of particular interest in this context, as their friction losses affect both the driving and recuperation phases. These losses are dependent on temperature, mechanical loads and the bearing mounting situation into the vehicle. The analysis of friction losses and their dependency on the factors mentioned above is usually conducted by measurements on component test benches to allow an isolated evaluation. In contrast, the friction losses of the complete drive system are measured on powertrain or roller test benches. In this context, the factors affecting the losses in wheel bearings may deviate from the measurements obtained on component test benches. The purpose of this paper is to analyses the
Hartmann, Lukas, Erxleben, Lars, Rebesberger, Ron, Henze, Roman, Sturm, Axel
Establishing the method for simulation of electric potential in cooling water passages of outboard motors2025-32-0008To be published on 11/03/2025
Producing 3D models of cooling water passages of outboard motors, and calculating distribution of electric potential on the water passage surfaces using BEM, we have developed the new method for simulation of electric potential distribution. The outboard motor is a propulsion system attached to the transom of the boat with steering function. As the water around the boat is drawn in for cooling of the engine, the engine parts are susceptible to severe corrosion. As a means to help prevent corrosion, a part referred to as the anode metal, which has a lower natural potential, is provided. Such a method is called the sacrifice protection because the anode metal corrodes before the engine parts due to the difference of electric potential. Since anti-corrosion currents occur preferentially to areas close to the anode metal, the anode metal is required to be located at the most effective place for corrosion protection. However, there are certain restrictions in the layout of anode metal from
Shibuya, Ryota, Suzuki, Hiroki
Development of CAE Technology for the Design Support of Piston Pin Circlip2025-32-0015To be published on 11/03/2025
This study focuses on the technology for establishing design criteria for the piston pin circlip (hereinafter referred to as "circlip"), which is a component that holds the engine piston pin. The circlip is assembled into the piston by compressing it to the size of the piston circlip groove. However, in high-revving engines, the inertia forces caused by engine rotation can cause the circlip to disengage from the groove, potentially leading to the piston pin falling out and damaging the engine. To prevent this, it is possible to compress the circlip more and increase the reactive force acting on the groove to prevent falling out. However, this countermeasure raises concerns about the deterioration of the assemblability of the circlip. Therefore, it is necessary to establish evaluation criteria that prevent the circlip from disengaging and deteriorationg the assemblability of the circlip. To enable appropriate design of the circlip during the engine specifications review phase, we
Ishizuka, Atsushi, Watanabe, Naoto
DEVELOPMENT OF TEMPERATURE SENSOR FOR AUTOMOTIVES2025-28-0394To be published on 10/30/2025
The paper presents a micro-electromechanical system (MEMS) temperature sensor that has been designed using COMSOL Multiphysics 6.0 software for use in predicting the temperature of automotive parts. Due to its versatility, the shape of this design employs a meander, and this involves joule heating physics. It can measure temperatures ranging from -200°C to 600°C. It clearly shows the variation of resistance with temperature. For this design, copper material is used because of some advantages: high electrical conductivity, thermal conductivity, and mechanical strength, which help in withstanding harsh climate conditions in the stratosphere. This sensor works based on the principle of temperature dependence of resistance; that is, the resistance of the material increases or decreases based on temperature.
P, Geetha
ML-Based System Level Optimization of EV Cooling Circuit2025-01-0376To be published on 10/07/2025
Efficient thermal management is vital for electric vehicles (EVs) to maintain optimal operating temperatures and enhance energy efficiency. Traditional simulation-based design approaches, while accurate, are often computationally expensive and limited in their ability to explore large design spaces. This study introduces a machine learning (ML)-based optimization framework for the design of an EV cooling circuit, targeting a 5°C reduction in the maximum electric motor temperature. A one-dimensional computational fluid dynamics (1D-CFD) model is utilized to generate a Design of Experiments (DOE) matrix, incorporating key parameters such as coolant flow rate and heat exchanger dimensions. A Radial Basis Function (RBF) neural network is trained on the simulation data to serve as a surrogate model, enabling rapid performance prediction. Optimization is performed using the Non-Dominated Sorting Genetic Algorithm II (NSGA2), yielding three distinct design solutions that meet the thermal
Paul, Kavin, Ganesan, Arul, Mansour, Youssef
Further Investigation of Disc Pad Compression Deformation during ISO Compressibility and Dynamic Modulus Measurements under Relatively Low Pressures2025-01-0334To be published on 09/15/2025
In an earlier publication, it was reported that the pad compressibility measured under 160 bars on NAO formulas keeps decreasing with increasing number of repeated measurements due to unrecoverable residual deformation of the friction material combined with increasing moisture adsorption, which increases the hardness of the friction material. This current investigation was undertaken to find out if this same phenomenon occurs for NAOs under a low pressure of 100 bars during compressibility measurements and under 700N during dynamic modulus measurements. In all cases, it is found that the same phenomenon occurs, meaning that friction materials become permanently compressed without full recovery, making them harder to compress and raising up the modulus. The dynamic modulus of friction material attached to a backplate is found to be lower as compared with the friction material without the backplate, which is caused by more rapid moisture adsorption of friction material pads without a
Sriwiboon, Meechai, Rhee, Seong Kwan, Sukultanasorn, Jittrathep
Brake System Homologation: A Holistic, Simulation-Based Approach2025-01-0351To be published on 09/15/2025
With the introduction of the Euro 7 regulation, non-exhaust emissions – particularly those arising from brake and tire abrasion – will be regulated and subject to emission limits for the first time. This presents significant challenges not only for OEMs striving to meet these targets within the given timeframe, but also for suppliers, who must develop innovative solutions for the precise measurement, analysis, and mitigation of these emissions. To address this, it is essential to establish and industrialize new testing methodologies as structured, scalable, and cost-efficient processes. Beyond pure measurement capability, service providers in this domain are increasingly expected to serve as feedback mechanisms – identifying process limitations, proposing targeted improvements, and thereby enabling continuous development in line with evolving technical and regulatory requirements. In this context, AVL is pursuing a holistic development strategy that integrates brake emission
Grojer, Bernd
Improving the Comparability of Brake Wear Solid and Total Particle Number Emission Measurement2025-01-0362To be published on 09/15/2025
Brake wear emissions are a significant contributor to particle mass (PM) emissions originating from road transport. In Europe, this is taken into consideration by including emission limits for brake wear particles in the legislation. UN GTR (United Nations Global Technical Regulation) No.24 is a technical description of how to measure the particle number (PN) and PM emissions of brakes. PN measurement includes solid particle number (SPN) and total particle number (TPN), meaning excluding and including the volatile particle matter, respectively. In this study, we examine over 500 TPN and SPN emission factors, in terms of SPN-TPN ratio. To interpret the emission factor data, we present results of a characterization of SPN and TPN measurement instruments in a laboratory setting. We discuss the benefits of using a flow splitter in the PN measurement and present an experimental demonstration of its suitability for measurement of brake wear PN. Combining the results of this investigation
Martikainen, Sampsa, Pramstrahler, Madlen, Weidinger, Christoph, Rainer, Andreas, Engler, Dieter, Huber, Michael
The Challenges of Measuring Residual Brake Drag using Different Test Apparatuses and Methods to Mitigate Inaccuracies2025-01-0343To be published on 09/15/2025
As automotive manufacturers have tried to set themselves apart by reducing emissions, and increasing vehicle range/fuel economy by eliminating any energy loss from inefficiencies on the vehicle, the brake corners have been an area of interest to reduce off-brake torque to zero in all conditions. Caliper designers can revise some attributes like piston seal grooves, and pad retraction features to reduce drag, but even if a caliper is designed perfectly in all aspects, trying to measure it in a reliable and repeatable manner proves to be difficult. There are many ways to measure brake drag all with ranging complexity. Some of the simplest measurements are the most repeatable, but it excludes the majority of the vehicle inputs. The most vehicle representative testing requires the most complex equipment and comes with the most challenges. This paper will focus mainly on the different ways residual brake drag can be measured, the benefits and challenges to each of them, the problems trying
Retting, Joshua
SAE TOMORROW TODAY UNPLUGGED - Why Robo-Taxis Are Losing the Battle for Energy1353309/08/2025
The staggering energy demands of AI data centers are set to consume 12% of America's electricity by 2028 -- and tech giants are investing billions to secure supply. This leaves robo-taxi operators fighting for scraps in an energy market dominated by hyperscalers who are set to spend $322 billion combined this year alone. In this Unplugged episode of SAE Tomorrow Today, host Grayson Brulte breaks down why energy is the real roadblock to autonomy and whether bold solutions like natural gas-powered depots could change the game for robo-taxi developers struggling to scale. Have your own thoughts on this topic? We'd love to hear from you! Share your comments, questions or ideas for future topics with Grayson on Twitter or send them to podcast@sae.org. Follow SAE on LinkedIn, Instagram, Facebook, Twitter, and YouTube. Follow host Grayson Brulte on LinkedIn, Twitter, and Instagram.
Patterson, Lori
Heat Flux Temporal Variation and Turbulent Structures on Diesel Flame-Impinged Wall by Comparing High-Speed Infrared Thermography and MEMS Sensor Measurements2025-24-003909/07/2025
For further elucidation of the extremely complex mechanism of wall heat transfer during diesel flame impingement, heat flux measurement results based on two different relatively new approaches, high-speed infrared thermography and Micro Electro- Mechanical Systems (MEMS) heat flux sensor, were compared. Both measurements were conducted on the chamber wall impinged by a diesel flame achieved in constant volume combustion vessels under similar experimental conditions. Infrared thermography was conducted using a high-speed infrared camera (TELOPS M3k, 13,000 fps, 128×128 pixels), allowing the capture of time-series temperature and heat flux distributions on the wall surface with a spatial resolution of 70 μm (9 mm / 128 pixels). This high-resolution imaging also enables detailed estimation of near-wall turbulent structures, which are considered to significantly influence the heat flux distributions. The MEMS sensor is composed of closely aligned (520 microns separated) multiple highly
Shimizu, Fumika, Morooka, Masato, Aizawa, Tetsuya, Dejima, Kazuhito, Nakabeppu, Osamu
Optimum Design and Sizing Approach for a Series-Hybrid Vehicle2025-24-009909/07/2025
The need to reduce pollutant emissions has pushed the automotive industry towards sustainable mobility promoting new technological solutions, among which the use of hybrid powertrains stands out. The development of a hybrid architecture is very complex and demands proper components sizing and the determination of optimized power-split strategies among different power sources, for example: Internal Combustion Engine (ICE), electric generator/motor and batteries. Moreover, the experimental analysis regarding performance and emissions requires that the whole propulsive system must be set up on the test bench, hence, negatively affecting the cost of the entire design phase. In this scenario, an optimum design and sizing approach for a series-hybrid electric vehicle (S-HEV) is proposed aiming at a design cost reduction. The presented procedure relies on numerical modelling of the hybrid powertrain and on the optimization of the fuel consumption and the driving range. The series-hybrid
Lisi, Leonardo, Saponaro, Gianmarco, Episcopo, Domenico, Torresi, Marco, Camporeale, Sergio Mario
DLR Tire and Road Wear Particle Emission Testing Methodology–Collection System Influence and Repeatability Assessments2025-24-009209/07/2025
Tire and road wear particles (TRWP) have emerged as air quality hazardous matters and significant sources of airborne microplastic pollution, contributing to environmental and human health concerns. Regulatory initiatives, such as the Euro 7 standards, emphasize the urgent need for standardized methodologies to quantify TRWP emissions accurately. Despite advancements in measuring tire abrasion rates, critical gaps persist in the characterization of airborne TRWP, particularly regarding the influence of collection system design and influencing parameters on measurement accuracy and repeatability. This study addresses these challenges by designing a controlled methodological framework that aims to minimize the influencing effects and ensure comparability in TRWP emission quantification results. At the German Aerospace Center (DLR) dynamometer testbench in Stuttgart, Germany, a methodical framework was established to ensure the repeatability and comparability of TRWP measurements
Celenlioglu, Melis Seren, Epple, Fabius, Reijrink, Nina, Löber, Manuel, Reiland, Sven, Vecchi, Roberta, Philipps, Franz
Improve Modeling, Control, and Health Monitoring of an e-Motor Applying an Integrated Flux Sensing Array: Concepts and Design2025-24-012509/07/2025
Knowing the magnetic flux inside an electric machine can provide valuable information, as it allows for monitoring the actual behavior of the motor during operation. This leads to more accurate torque delivery and enables prognostic and state-of-health analyses. By integrating Hall-effect sensors inside an e-motor, it is possible to measure the magnetic flux and gain all the benefits from this information, such as accurate torque, rotor position and speed, and magnets' temperature. This paper describes the design of an e-motor with an integrated flux sensing array (ISA), including all surrounding models and software solutions for efficient motor control, integrating health monitoring and failure prevention. The focus is on the analyses performed to estimate the magnetic flux linkage and determine the optimal sensor placement, the control architectures that can benefit from a more accurate flux estimation, and the design of the e-machine to integrate the flux sensors. The aim is to
Capitanio, Alessandro, Sala, Giada, Esmaeilnia, Ali, Garcia de Madinabeitia, Inigo, Pastore, Andrea, Tranchero, Maurizio, Franceschini, Giovanni, Saur, Michael
Understanding and Qualifying Hydrogen Combustion Related Phenomena for Low-Carbon Mobility2025-24-005709/07/2025
The reduction of the overall greenhouse gas and pollutant emissions from ground vehicles is mandatory to fight against global warming and health issues. Moreover, regarding the increasing demand related to the population growth, the energy requirement for mobility may significantly increase during coming years. Meeting greenhouse gas emission targets is not only about commitment to regulations but also fundamentally about enhancing human well-being. Consequently, the diversification of low-carbon energy sources is of huge interest. The use of Hydrogen (H2) as a sustainable energy source in ground transportation is an alternative or a complementary solution to the full electric vehicles. Hydrogen for mobility can be used in two types of energy converters: The Proton-Exchange Membrane Fuel Cell or the H2 adapted Internal Combustion Engine (H2-ICE). This last has the advantage of its strong maturity with the reuse of existing production infrastructures from conventional ICE and low raw
Laget, Olivier, Bardi, Michele, Quintens, Hugo, Giuffrida, Vincent, Bramoullé, Clément, Sikic, Ivan
A Novel Mechanical Model Simulating a Pavement Deflection Measuring System for Non-Invasive Pavement Monitoring Based on a Reliability-Based Optimization Algorithm02-18-03-002509/04/2025
This article presents a novel mechanical model for simulating the behavior of pavement deflection measuring systems (PDMS). The accuracy of the model was validated by comparing the acceleration of the new model with the data achieved through experimental tests fusing a deflection measurement system mounted on a Ford F-150 truck. The experimental test for the PDMS is carried out on a random road profile, generated by an inertial profiler, over a 7.4-mile (12 km) loop around a lake near Austin, Texas. Integrating a reliability-based optimization (RBO) algorithm in a PDMS aims to optimize system parameters and reduce vibrations effectively. The PDMS noises and uncertainties make it crucial to use a robust system to ensure the stability of the system. This article presents a robust algorithm for considering the uncertainties of PDMS parameters, including the damping coefficients and spring stiffness of the supporting brackets. Moreover, it considers the variation of system parameters, such
Yarmohammadisatri, Sadegh, Sandu, Corina, Claudel, Christian
Smart Capsule Designed to Study GI TractTBMG-5377309/01/2025
Engineers have developed a smart capsule called PillTrek that can measure pH, temperature, and a variety of different biomarkers. It incorporates simple, inexpensive sensors into a miniature wireless electrochemical workstation that relies on low-power electronics. PillTrek measures 7 mm in diameter and 25 mm in length, making it smaller than commercially available capsule cameras used for endoscopy but capable of executing a range of electrochemical measurements.
High-Pressure Hydrogen Flows through Single- and Multi-Hole Nozzles: A Computational Study13-06-03-002409/01/2025
Efficient propulsion technologies that utilize alternative fuels are becoming increasingly critical to achieve high efficiency at the vehicle scale while fulfilling global regulations in terms of emissions and criteria pollutants. In this scenario, hydrogen (H2) represents an important and appealing part of the solution due to its molecular composition and unique physical and chemical properties. With reference to internal combustion engines, much research is needed to overcome technical challenges that make H2 use not yet viable at the industrial scale. This work focuses on the computational modeling of some of the fundamental aspects of H2’s physical behavior, which can be useful to the development of high-pressure H2 injection systems. Computational fluid dynamics simulations are discussed with the goal of understanding the near- and far-nozzle behavior of H2 using single- and multi-hole nozzles. This study presents the validation of the computational framework against literature
Torelli, Roberto, Park, Ji-Woong, Pei, Yuanjiang
Thin Film Sensor for Ultra High-Temp MeasurementTBMG-5371809/01/2025
Innovators at NASA Johnson Space Center have developed a thin film sensor that measures temperatures up to 1200 °F, and whose prototype successor may achieve measurements up to ~3000 °F — which was the surface temperature of the Space Shuttle during its atmospheric reentry.
Toothbrush-Shaped Ultrasound Allows for Gum MonitoringTBMG-5377609/01/2025
A toothbrush-shaped ultrasound transducer can provide a less invasive screening for gum disease. In proof-of-concept demonstrations on animal tissues, the device produced measurements similar to those of a manual probe.
Optimizing Engine Coolant Hose Joint Performance through Taguchi Design of Experiments and Computer-Aided Engineering Analysis2025-01-505007/15/2025
This article presents a design of experiments (DOE) approach to analyze automobile engine coolant leakage from hose joints. The data includes force measurement at hose joints through physical validation and computer-aided engineering (CAE) simulation results. The proposed approach involves utilizing digital validation data, which simulates the entire experiment using CAE. The novelty of this approach lies in its reliance on digital validation data rather than conventional physical measurements, thus providing cost and time savings for the organization. In this study, the authors investigated the force at the coolant hose joint, which results in oil leakage as the response variable. Nine independent factors were evaluated in this experiment. The study concluded through the identification of critical parameters and opposed regression model to predict force at hose joints.
Koulage, Dasharath Baliram, Mondal, Kanchan, Manerikar, Dattatray Shriniwas
Data-Driven Analysis of Vehicle Lateral Control in the Country Road Domain2025-01-026807/02/2025
The optimization and further development of automated driving functions offer significant potential for reducing the driver's workload and increasing road safety. Among these functions, vehicle lateral control plays a critical role, especially with regard to its acceptance by end customers. Significant development efforts are required to ensure the effectiveness and reliability of this aspect in real-world conditions. This work focuses on analyzing lateral vehicle control using extensive measurement data collected from a dedicated vehicle fleet at the Institute of Automotive Engineering at the Technical University of Braunschweig. Equipped with state-of-the-art measurement technology, the fleet has driven several hundred thousand kilometers, allowing for the collection of detailed information on vehicle trajectories under various driving conditions. A total of 93 participants, aged between 20 and 43 years, contributed to the dataset. These measurements have been classified into
Iatropoulos, Jannes, Panzer, Anna, Arntz, Martin, Prueggler, Adrian, Henze, Roman
Experimental Investigation of Factors Influencing Thermal Runaway in Lithium-Ion Battery Cells2025-01-030607/02/2025
Experimental testing in automotive development sometimes relies on ad hoc approaches like ‘One Factor at a Time’, particularly in time- and resource-limited situations. While widely used, these approaches are limited in their ability to systematically capture parameter interactions and system complexities, which poses significant challenges in safety-critical applications like high-voltage battery systems. This study systematically investigates the factors influencing thermal runaway in lithium-ion battery cells using a statistical full-factorial experimental design. Key parameters, including state of charge, cell capacity and heating trigger power, have been analyzed under controlled conditions with an autoclave setup, enabling precise measurement of thermal and mechanical responses. The use of automotive-grade lithium-ion cells ensures relevance for next-generation applications. By employing factorial regression and statistical analysis, the study identifies critical temperatures
Ceylan, Deniz, Kulzer, André Casal, Winterholler, Nina, Weinmann, Johannes, Schiek, Werner
Comprehensive Optical and Numerical Investigation of Hydrogen Jet Formation for a Commercial Gasoline Hollow-Cone Injector2025-01-031307/02/2025
Hydrogen produced from renewable sources offers the opportunity to reduce future emissions and enable CO2-neutral mobility by both adapting existing internal combustion engines (ICE) and developing new combustion engine systems. One challenge of hydrogen direct injection (DI) ICE is to optimize the mixture formation to ensure low engine out emissions as well as high efficiencies. In the study presented in this paper, a conventional piezo hollow-cone gasoline injector, commonly used in passenger car series, was adapted for high-pressure hydrogen direct injection applications. Therefore, optical measurements within a low pressure chamber (LPC) were conducted using a high-speed Schlieren imaging measurement technique to visualize the injection behavior and jet pattern at various injection conditions. The visualization of density gradients during the injection process showed a slightly decreased relative gaseous penetration length (GPL) of 4% for hydrogen in comparison to helium while the
Fleischmann, Maximilian, Mirsch, Niklas, Ghanoum, Mohamad, Morcinkowski, Bastian, Adomeit, Philipp, Pischinger, Stefan
Automated Test Process for Highly Configurable Software-Defined Mobility Systems in CI/CD2025-01-029707/02/2025
In the pursuit of customizability and evolvability of vehicle functions, manufacturers shift towards software-defined vehicles to enable flexible customization and over-the-air updates. This results in multiple variants and versions of a vehicle model. While shifting to software-defined vehicles (SDVs) adds value and flexibility for customers, manufacturers struggle with homologating new and updated functionality because existing testing processes do not scale for high-frequency release cycles that limit available testing resources. Overcoming this challenge by using a coherent test process designed for testing continuously evolving variant-rich systems will be one of the key enablers. This paper presents an innovative end-to-end pipeline for efficient and comprehensive testing of variant-rich vehicle functionality tailored to an application in continuous development. Our transferable test pipeline employs sample-based variant selection, a software-in-the-loop environment for executing
Hettich, Lennard, Pett, Tobias, Nägele, Ann-Therese, Schindewolf, Marc, Eriş, Halit, Wagner, Stefan, Sax, Eric, Schaefer, Ina, Weyrich, Michael
Wearable Lactation Pads Detect Chemicals in MilkTBMG-5344107/01/2025
Engineers have developed a smart lactation pad that can quantify a wide range of chemicals in breast milk in real time. This work is pioneering the first wearable, rapid sensor for at-home measurement of chemicals in breast milk, addressing an important technology gap for improving the health of the mother and the baby.
Comparison of Methanol and Gasoline Fuel Spray Vaporization Using Direct-Injection Technology2025-01-022506/16/2025
Considering the large opportunity to reduce net lifecycle carbon emissions through the use of renewable methanol, we address spray technologies needed to overcome the challenge of wall wetting and poor vaporization for methanol and the need for improved computational modeling of these processes. High-speed extinction imaging followed by computed tomography reconstruction is utilized to provide three-dimensional liquid volume fraction for reference fuel injectors, to be used for model validation activities. The first injector is the symmetric 8-hole Spray M injector for the Engine Combustion Network, and the second injector is an asymmetric 6-hole injector designed for lateral-cylinder mounting. The degree of plume interaction and vaporization are characterized at representative injection conditions, showing substantially higher concentrations of liquid for methanol than gasoline even with preheated fuel temperatures (90 degrees C). In light of higher injected mass requirements for
Wan, Kevin, Clemente Mallada, Rafael, Buen, Zachary, White, Logan, Oh, Heechang, Dhanji, Meghnaa, Pickett, Lyle
Test and Measurement: Regulatory Updates and Strategic ImplicationsTBMG-5329106/01/2025
Wearable Sensors Provide Real-Time Measurements of Sweat Rate and Electrolytes and Metabolites in SweatTBMG-5322206/01/2025
Researchers developed wearable skin sensors that can detect what’s in a person’s sweat. Using the sensors, monitoring perspiration could bypass the need for more invasive procedures like blood draws and provide real-time updates on health problems such as dehydration or fatigue. The sensor design can be rapidly manufactured using a roll-to-roll processing technique that essentially prints the sensors onto a sheet of plastic.
The Growing Connectivity Dimensions in Medical TechnologyTBMG-5328306/01/2025
Tape-Based Robot Reaches Far When ExtendedTBMG-5321606/01/2025
It’s a game a lot of us played as children — and maybe even later in life: unspooling measuring tape to see how far it would extend before bending. But to engineers at the University of California San Diego, this game was an inspiration, suggesting that measuring tape could become a great material for a robotic gripper.
Development of an Intelligent Instrumented Tire for Real-Time Hydroplaning Risk Estimation10-09-03-002705/21/2025
This study introduces an innovative intelligent tire system capable of estimating the risk of total hydroplaning based on water pressure measurements within the tread grooves. Dynamic hydroplaning represents an important safety concern influenced by water depth, tread design, and vehicle longitudinal speed. Existing intelligent tire systems primarily assess hydroplaning risk using the water wedge effect, which occurs predominantly in deep water conditions. However, in shallow water, which is far more prevalent in real-world scenarios, the water wedge effect is absent at higher longitudinal speeds, which could make existing systems unable to reliably assess the total hydroplaning risk. Groove flow represents a key factor in hydroplaning dynamics, and it is governed by two mechanisms: water interception rate and water wedge pressure. In both the shallow water and deep water cases, the groove water flow will increase as a result of increasing the longitudinal speed of the vehicle for a
Vilsan, Alexandru, Sandu, Corina, Anghelache, Gabriel, Warfford, Jeffrey
A Study on Active Sound Design and Control Method for Vehicle Interior Hybrid Noise to Enhance Sound Quality2025-01-001105/05/2025
With the current popularity of new energy vehicles and the continuous development of intelligent cabin technology, the demand for acoustic comfort within automotive cockpit is increasing. A multi-channel feedforward active sound design and control method was proposed to improve the sound quality of the hybrid broadband road and narrowband order noise inside the test vehicle. The method selectively designed the target amplitudes for broadband noise and narrowband noise in the vehicle to satisfy passengers comfort, mainly including the sound design phase and the control phase. During the sound design phase, objective sound quality parameter analysis was first conducted on the noise of the prototype vehicle, followed by an subjective evaluation of the sound quality with rating scale method. An active acoustic design strategy focusing on comfort, motivation sense were proposed, including a formula for the target amplitude of adjustment order and sound pressure level. The sound quality was
Liu, Xuexian, Xu, Wenxuan, Li, Rubin, Lu, Lu
Pass-By Noise Comparison of Two Test Facilities with Vehicles Operating in Electric Mode2025-01-000505/05/2025
Outdoor test facilities for light vehicle exterior noise regulatory measurement need to have surfaces certified to meet ISO 10844. A recent study considered plug-in-hybrid vehicles operating purely in electric mode to compare results at two facilities, both certified. This emphasizes the pavement contribution. Overall results are generally similar, with a few differences which are discussed.
Sorenson, Steve, Shao, Guangxin
GPU-Accelerated Aeroacoustic Simulations of HVAC Duct Configurations2025-01-013305/05/2025
Large eddy simulations (LES) of two HVAC duct configurations at different vent blade angles are performed with the GPU-accelerated low-Mach (Helmholtz) solver for comparison with aeroacoustics measurements conducted at Toyota Motor Europe facilities. The sound pressure level (SPL) at four near-field experimental microphones are predicted both directly in the simulation by recording the LES pressure time history at the microphone locations, and through the use of a frequency-domain Ffowcs Williams-Hawking (FW-H) formulation. The A-weighted 1/3 octave band delta SPL between the two vent blades angle configurations is also computed and compared to experimental data. Overall, the simulations capture the experimental trend of increased radiated noise with the rotated vent blades, and both LES and FW-H spectra show good agreement with the measurements over most of the frequency range of interest, up to 5,000Hz. For the present O(30) million cell mesh and relatively long noise data collection
Besem-Cordova, Fanny M., Dieu, Donavan, Wang, Kan, Brès, Guillaume A., Delacroix, Antoine
Effects on Motorcycle Response Data Using Wheel Force Transducers2025-01-009405/05/2025
Wheel Force Transducers (WFT) are precise and accurate measurement devices that seamlessly integrate into any vehicle. They can be applied in numerous vehicle applications for both on-road and in laboratory settings. The instrumentation requires replacing an original equipment manufacturer (OEM) wheel with a custom WFT system which is specific to the wheel hub design. An ideal design will minimally impact a vehicle's dynamics, but the vehicle system is inherently modified from the mass of the measurement device. Research and technical documentation have been published which provide conclusions explaining reduction in the unsprung mass reduces dynamic wheel load. However, there doesn’t appear to be clear compensation techniques for how a modified unsprung mass can be related to the original system, thus allowing the WFT signals to be more accurate to the OEM wheel forces. An experimental study was performed on a prototype motorcycle to better understand these differences. An
Frisco, Jacob, Larsen, William, Rhudy, Scott, Oosting, Nicholas, Laurent, Matthew
Characterize the Sound Field Generated from a Vehicle Horn by Pellicular Analysis2025-01-005805/05/2025
To predict the sound field produced by a vehicle horn requires a good source representation of it in the full vehicle model. This paper investigates the characterization of a physical vehicle horn by an inverse method called pellicular analysis. To implement this method, firstly an acoustic testing is performed to measure the sound pressure radiated from the horn at a certain number of microphone locations in a free field environment. Based on the geometry of a virtual horn, the locations of each microphone and measured sound pressure data, pellicular analysis is adopted to recover a set of vibration pattern of the virtual horn. The virtual horn and the recovered vibration information are then incorporated in a full vehicle numerical model to simulate its exterior sound field. The validity of this approach is confirmed by comparing the prediction for a horn in a production vehicle to the corresponding physical test which is required to meet the Brazilian regulation CONTRAN 764/2018.
Yang, Wenlong, Melo, Andre
Snap-Fits Evaluation for Minimizing the Squeak & Rattle in Automotives2025-01-009105/05/2025
The world of plastic products has been growing due to its versatile properties and has become an intrinsic and fundamental part of engineering for new products. The most important aspects contributing to this spectacular growth are the design and assembly, making sure that plastic parts are designed optimally. The safety requirements have been increased due to the safety ratings and thus interior parts must provide more absorption and protection to occupants. The main connection types used in the plastic parts are heat stakes and snap fits. The purpose of a good snap fit is not only to have a high retention effort but also to present ergonomic characteristics with optimal insertion and extraction effort because each part requires a different function. With the time-dependent loading, the material will redistribute its internal energy thereby performing a time-related flow leading to reduced pretension thus decreasing stiffness. This paper presents an analytical and numerical method for
Michael Stephan, Navin Estac Raja, C M, Mithun, Mohammed, Riyazuddin, R, Prasath
New System for the Measurement of Sound-Insertion Loss on Small Samples: A Comparison with ASTM-E2611 and ASTM E90 Test Procedures2025-01-011605/05/2025
This article follows a companion article [1] presented at the SAE NVC 2021, in which a new system for the measurement on small samples of the normal-incidence Insertion Loss (IL) of multilayers used for the manufacturing of automotive sound package parts was first introduced. In addition to simplifying the evaluation of the sound-insulation of multi-layers used to produce sound-package components, the system aims at overcoming the limitations of the test procedure based on the ASTM E2611 standard. In this article, the latter point is demonstrated by comparing the insertion loss results obtained with the new system with those obtained with the test procedure based on the ASTM E2611 standard on a few multilayers commonly used for the manufacturing of automotive sound package parts. Results indicate that the data obtained by means of the newly developed system are more meaningful, practically usable and less prone to edge-effects, compared to those obtained according to the ASTM E2611
Ruggeri, Giulio, Bertolini, Claudio, Horak, Jan
Design of a Reactive-Style Muffler for a Formula SAE Race Car2025-01-002405/05/2025
The noise generated by high-performance vehicles like Formula SAE (FSAE) race cars, presents a significant challenge in adhering to strict competition noise regulations. In this study two muffler designs were created: muffler design 1 and 2. Each design utilized two chambers to generate destructive interference, targeting two dominant exhaust frequencies of the Honda CBR600RR engine to maximize transmission loss and reduce sound pressure levels (SPL) below the FSAE-mandated range of 103 dBC at idle and 110 dBC at all other operating conditions. For each design, the exhaust noise and muffler performance were simulated using GT-Suite, allowing for an evaluation of noise attenuation across engine speeds. Experimental testing was conducted to validate the GT-Suite model and assess the effectiveness of muffler design 1. This testing involved measuring the SPL with a calibrated microphone, both with and without the designed muffler. Muffler design 1 was based on the dominant exhaust
Labao, Kai, Middleton, Nicholas, Nuszkowski, John
Designing Rubber Flaps for Resonance Management: High-Frequency Tuning in Electric Vehicles Using AI/ML Approaches2025-01-012505/05/2025
High-frequency whine noise in electric vehicles (EVs) is a significant issue that impacts customer perception and alters their overall view of the vehicle. This undesirable acoustic environment arises from the interaction between motor polar resonance and the resonance of the engine mount rubber. To address this challenge, the proposal introduces an innovative approach to predicting and tuning the frequency response by precisely adjusting the shape of rubber flaps, specifically their length and width. The approach includes the cumulation of two solutions: a precise adjustment of rubber flap dimensions and the integration of ML. The ML model is trained on historical data, derived from a mixture of physical testing conducted over the years and CAE simulations, to predict the effects of different flap dimensions on frequency response, providing a data-driven basis for optimization. This predictive capability is further enhanced by a Python program that automates the optimization of flap
Hazra, Sandip, Khan, Arkadip
Feasibility of In-Situ Vehicle-Level Sound Transmission Loss Measurement to Guide Dash Pass-Through Grommet Selection2025-01-012205/05/2025
Noise transmission through the vehicle dash panel plays a critical role in isolating passengers from noise sources within the motor bay of the vehicle. Grommets that contain electrical harness routing as well as HVAC lines are examples of dash panel pass-throughs that should be selected with care. Acoustic performance of these components is generally characterized in terms of measured quantities such as noise reduction (NR), sound transmission loss (STL), and insertion loss (IL). These measurements need to be carried out per SAE or ASTM standards in appropriate anechoic or reverberant chambers as this is important for consistency. This work explores an in-situ measurement of the grommet STL performance in the vehicle environment. It utilizes a repurposed vehicle with its cabin retrofitted to serve as an anechoic chamber and its frunk acting as a reverberant chamber. Results of this in-situ measurement are then compared to measurements following industry standards to discuss the
Joodi, Benjamin, Jayakumar, Vignesh, Chang, Michael, Geissler, Christian, Pilz, Fernando, Conklin, Chris
Methodology for Sound Quality Metric Development2025-01-007005/05/2025
While many individual technical descriptors exist to quantify and describe different kinds of acoustic phenomena, they each only describe the technical aspects of a sound itself without considering any additional non-acoustic context. Human perception, however, is greatly informed by this context. For example, humans have different expectations for the sound of an electric razor than they do for an internal combustion engine, despite both objects being able to be described by sound pressure level or a measure of roughness. No single technical descriptor alone works in all contexts as a gold standard which objectively determines whether a sound is “good.” Jury tests, however, are a great aid towards gaining a measure of this context. When seeking to effectively quantify the sound quality of a device, it is necessary to combine the perceptive information from the results of a jury test alongside one or more technical descriptors in order to provide a meaningful method of evaluation. The
Thiede, Shane
Hybrid 3D Sound Intensity Measurements and Simulations Applied to a Truck Rear Axle2025-01-010505/05/2025
This study presents a novel methodology for optimizing the acoustic performance of rotating machinery by combining scattered 3D sound intensity data with numerical simulations. The method is demonstrated on the rear axle of a truck. Using Scan&Paint 3D, sound intensity data is rapidly acquired over a large spatial area with the assistance of a 3D sound intensity probe and infrared stereo camera. The experimental data is then integrated into far-field radiation simulations, enabling detailed analysis of the acoustic behavior and accurate predictions of far-field sound radiation. This hybrid approach offers a significant advantage for assessing complex acoustic sources, allowing for quick and reliable evaluation of noise mitigation solutions.
Fernandez Comesana, Daniel, Vael, Georges, Robin, Xavier, Orselli, Joseph, Schmal, Jared
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