Browse Topic: Measurements

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CFD-Based Investigation of Fuel Tank Sloshing: Crash Safety and Noise Concerns2026-01-0490To be published on 04/07/2026
A computational study using the Volume of Fluid (VOF) method in SimericsMP+ was conducted to investigate fuel sloshing in automotive fuel tanks under both crash and sudden stop conditions. The SEALs method was employed to rapidly generate the fuel tank mesh, enabling efficient simulation setup. At the outset, a benchmark sloshing case was simulated and compared against experimental data, showing excellent agreement to validate the simulation method. This simulation method was then applied to the fuel tank sloshing scenarios mimicking crash and sudden stop conditions. The study initially focused on a crash scenario where fuel waves impact valves, pumps, and other internal structures. Capturing these localized impact forces is critical for evaluating the risk of component failure and potential leakage. A baffle-equipped tank was simulated and compared with sensor data. Results show that the computed shock forces on valves and baffles closely matched the measurements, demonstrating the
Jia, Kun, Rahman, Ashique
Conjugate Heat Transfer Modeling for Predicting Thermal Behavior of X76 Emotor Windings2026-01-0118To be published on 04/07/2026
A computational study based on a conjugate heat transfer (CHT) method in SimericsMP+ was performed to predict the winding temperatures in an X76 emotor. In this study, the thermal load was represented in the simulation through the solution of electromagnetic equations in SimericsMP+, where heat generation was driven by root-mean-square (RMS) current, while liquid cooling was applied at flow rates ranging from 1 LPM to 6 LPM. Simulations were conducted to measure the temperature on three thermocouple locations on each side of the winding crown and weld regions under steady operation. The computational strategy employed a loosely coupled approach. A fluid-only simulation was first carried out to establish stable flow conditions, followed by coupling with solid conduction where the winding acted as the heat source. The predicted temperature distributions were then compared with test data. Results obtained show good agreement, with differences remaining within an acceptable range, thereby
Jia, Kun, Schlautman, Jeff, Srinivasan, Chiranth
A Comparison of Road Grade Preview Signals from Lidar and Maps2026-01-0026To be published on 04/07/2026
Road grade can impact the energy efficiency, safety, and comfort associated with automated vehicle control systems. Currently, control systems that attempt to compensate for road grade are designed with one of two assumptions. Either the grade is only known once the vehicle is driving over the road segment through proprioception, or complete knowledge of the oncoming road grade is known from a pre-made map. Both assumptions limit the performance of a control system, as not having a preview signal prevents proactive grade compensation, whereas relying only on map data potentially subjects the control system to missing or outdated information. These limits can be avoided by measuring the oncoming grade in real-time using on-board lidar sensors. In this work, we use point returns accumulated during travel to estimate the grade at each waypoint along a path. The estimated grade is defined as the difference in height between the front and rear wheelbase at a given waypoint. Kalman filtering
Schexnaydre, Logan, Poovalappil, Aman, Robinette, Darrell, Bos, Jeremy
CFD Investigation of Oil Ingestion and Aeration in a V6 Engine Oil Pan During Vehicle Maneuvers2026-01-0279To be published on 04/07/2026
A computational investigation was carried out using SimericsMP+ to analyze oil distribution and aeration behavior in a V6 engine oil pan during severe vehicle maneuvers. The model accounted for the crankshaft/camshaft rotations and piston motions, which allows for capturing realistic oil distribution in cylinder head drainbacks, engine bay and sump after initializing the crankcase with prescribed oil levels to establish baseline aeration prior to applying dynamic maneuver profiles. Of particular interest was the response of the main oil gallery (MOG) pressure and the exposure of the oil pickup tube during kickoff conditions at multiple fill levels. Both a baseline configuration and a modified sump featuring a containment “doghouse” were examined. Results obtained from the kickoff maneuver show complete uncovering of the pickup tube in the baseline design, leading to unstable lubrication. The first doghouse design only delayed pickup tube uncovering briefly, as oil pooled at the rear
Jia, Kun, Rahman, Ashique, Pandey, Ashutosh
Methodology for generating off-road tracks for powertrain simulation of off-road passenger vehicles2026-01-0275To be published on 04/07/2026
For off-road driving, particularly on steep grades and over barriers, the engine torque is a key design criterion of off-road vehicles. In conventional powertrains with combustion engines, mechanical all-wheel-drive systems combined with differential locks are used to distribute the torque demand between the front and the rear axle based on wheel-specific traction. With the growing market share of electric powertrains, off-road applications are becoming increasingly relevant for electric passenger cars. In comparison to conventional powertrains, electric all-wheel-drive configurations do not have a mechanical torque transfer between the two axles. If one axle experiences low traction, the second axle can rely on its own torque capability only. Transfer of unused torque of the slipping axle to the other one is not possible. The challenge, therefore, is to specify the right torque requirements for each axle for off-road driving while avoiding an over-dimensioning and high powertrain
Martin, Michael, Winkelheide, Jonas, Hartmann, Lukas, Sturm, Axel, Henze, Roman
Defect Depth Characterization via Thermally and Pneumatically Induced Shearography for Nondestructive Component Inspection in the Automotive Sector2026-01-0205To be published on 04/07/2026
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
Bastgen, Valentin, Plaßmann, Jessica, Petry, Christopher, von Freymann, Georg, Schuth, Michael
Investigation of the Blockage Phenomenon in Closed Wall Wind Tunnels During the Testing of Bluff Automotive Bodies with Small Wakes in Yawed Configurations2026-01-0607To be published on 04/07/2026
The difficulties of testing a bluff automotive body of sufficient scale to match the on-road vehicle Reynolds number in a closed wall wind tunnel has led to many approaches being taken to adjust the resulting data for the inherent interference effects. But it has been very difficult to experimentally analyze the effects that are occurring on and around the vehicle when these blockage interferences are taking place. The present study is an extension of earlier works by the author and similarly to those studies uses the computational fluid dynamics analysis of five bodies that generate relatively small wakes to examine the interference phenomena in solid wall wind tunnels and the effects that they have on the pressures, and forces experienced by the vehicle model when it is in yawed conditions up to 20 degrees. This is accomplished by executing a series of CFD configurations with varying sized cross sections from 0.4% to 14% blockage enabling an approximation of free air conditions as a
Gleason, Mark, Riegel, Eugen
Self-Supervised Gaussian-Based Framework for Robust Static-Dynamic Decomposition and Real-Time Urban Scene Reconstruction2026-01-0010To be published on 04/07/2026
We propose a self-supervised Gaussian-based framework that enhances the robustness and efficiency of static-dynamic decomposition and high-fidelity reconstruction in autonomous driving scenarios. Existing approaches demonstrate promising performance but remain prone to noisy motion segmentation, overfitting on sparse LiDAR observations, and degraded accuracy in low-texture or distant regions, resulting in unstable geometry. To address these challenges, our method introduces a feature fusion module that jointly exploits image semantics and geometric cues, enabling more reliable motion prior extraction under noise and illumination variations. A cross-sequence geometric consistency constraint is further designed to regularize reconstruction across temporal and viewpoint changes, ensuring physically coherent scene representations. In addition, we formulate an efficient Gaussian parameter optimization strategy that constrains scale and normal updates, preventing unrealistic ellipsoid growth
Feng, Runlei, Wang, Ning, Zhang, Zhihao
An Enhanced Canny-Based Vision System for Vanishing Point Detection in Camera Calibration and Sun Glare Mitigation for ADAS2026-01-0016To be published on 04/07/2026
Abstract— Edge detection is fundamental for intelligent vehicle applications, directly supporting ADAS functions such as lane detection, obstacle recognition, and scene understanding. The conventional Canny edge detection method exhibits notable shortcomings, especially in color-image processing, adaptive threshold selection, and preserving edge integrity under noisy conditions. In this study, we present an enhanced Canny edge detection framework tailored for ADAS-oriented intelligent vehicle systems, incorporating a quaternion-based weighted averaging scheme for color preservation, adaptive thresholds derived from gradient-amplitude histograms, multiscale edge localization via scale multiplication, and a novel gravitational-field-intensity operator for improved gradient robustness. Moreover, we extend the method to vanishing-point estimation an essential ADAS capability by performing precise intersection calculations combined with clustering techniques such as DBSCAN and RANSAC
Uppala, Rohit Raj, Kaye, Murali, Zadeh, Mehrdad, TAN, Teik-Khoon
The Effects of Collision-Related Power Loss on Toyota Safety Sense 3.0 Event Data2026-01-0548To be published on 04/07/2026
Toyota vehicles equipped with Toyota Safety Sense (TSS) can record detailed information surrounding various driving events. Often, this data is employed in accident reconstruction to better understand the dynamics of a collision. TSS data is comprised of three main categories: Vehicle Control History (VCH), Freeze Frame Data (FFD), and image records. During an event, it is possible that a vehicle undergoes a catastrophic power loss from the damages sustained during the event. In this paper, the effects of a sudden power loss on the VCH, FFD, and images are studied. Events are triggered on a TSS 3.0 equipped vehicle by driving toward a stationary target. After system activation, a total power loss is induced, triggered on the instrument cluster “BRAKE” alert message, at various delays after activation. This testing studies various signals recorded across VCH, FFD and image data including vehicle speed, measured accelerations and time and date. This testing also compares the acceleration
Getz, Charles, Yeakley, Adam, DiSogra, Matthew
Quantifying Accuracy and Robustness to Guide Fidelity Selection for Multi-fidelity Vehicle Dynamics Models2026-01-0149To be published on 04/07/2026
Accurate and reliable simulation models are essential for design, development, and performance evaluation during virtual vehicle testing. However, fidelity assessment and validation remain a challenge. While error metrics are used to evaluate simulations, they alone do not capture how reliable predictions are, or how robust models are to varying driving scenarios and modeling assumptions. This work develops a systematic quantitative approach for evaluating vehicle dynamics model fidelity, moving beyond traditional visual or qualitative comparisons. A dimensionless fidelity metric is proposed that integrates error and uncertainty into a single measure, enabling objective accuracy assessment of variable-fidelity simulations. This framework supports fidelity selection in vehicle dynamics, providing clearer insight into tradeoffs between computational cost and achievable accuracy, and advancing the goal of reliable virtual testing. This approach is demonstrated on an open-loop vehicle
Emara, Mariam, Balchanos, Michael, Mavris, Dimitri
Displacement measurement in impact tests based on machine vision2026-01-0477To be published on 04/07/2026
Contact measurement is difficult to arrange sensors under various impact tests. And the method of measuring displacement by machine vision has significant advantages. This paper proposes a displacement measurement method based on machine vision. Firstly, YOLO (You Only Look Once) v5 is used to automatically extract the recognition targets in various test scenarios. Secondly, the extracted recognition target graphics are processed by image enhancement and threshold segmentation technology. Then, the geometric shape of the processed graphics is identified by edge detection technology, and the scale factor is calculated. Finally, the displacement of the target structure is calculated through coordinate transformation in multiple coordinate systems. The results show that for a single recognition target, the relative error between machine vision and sensor measurement is within 5%, and for multiple recognition targets, the relative error between machine vision and industrial software
Sun, Jiawei, Du, Dan, Zhang, Bin
From Static Ground to Moving Ground Wind Tunnels: Feature Selection for Reliable Estimation of Drag Coefficient Discrepancies2026-01-0203To be published on 04/07/2026
Moving ground wind tunnels offer a more accurate test environment for ground vehicle drag coefficient measurement due to their highly realistic representation of the boundary layer phenomenon. However, historically most vehicles have been tested on static ground wind tunnels. As a result, the measured drag coefficient of these vehicles may not be sufficiently realistic for certification purposes. Therefore, it is valuable to build statistical models to estimate moving-ground wind tunnel drag coefficient by using information from a static-ground wind tunnel and other relevant vehicle characteristics such as presence of aerodynamic devices (spoilers, air dams, etc.). However, to build accurate statistical models, appropriate predictive features must be identified as a first step. In this paper, an aerodynamic feature selection study has been conducted to identify vehicle characteristics that contribute to drag coefficient estimation discrepancies between a static- and a moving-ground
Singh, Yuvraj, Jayakumar, Adithya, Rizzoni, Giorgio
Progressive optimization path planning method for intelligent mobile agent in unstructured environment2026-01-0253To be published on 04/07/2026
Due to the presence of cluttered obstacles and irregular road edges in most operation scenarios, this poses significant challenges for the autonomous mobile operation of intelligent agents. To address the challenges of such unstructured scenarios, this study proposes a progressive optimization path planning method for intelligent mobile agents. Firstly, to eliminate the blind search behavior of the traditional RRT algorithm, a dynamic target bias function is introduced to guide the RRT to search as close to the target point as possible, obtaining the initial planned path. Secondly, to improve the comprehensive performance of the path planning, an iterative artificial potential field optimization algorithm is developed to iteratively update the initial planned path to obtain a progressively optimized path. Finally, different scale scenarios are designed to verify the effectiveness of the proposed method. The result shows that the method proposed in this study can significantly improve
Zeng, Yongping, Zeng, Dequan
Automotive Crash Dynamics Modeling Accelerated with Machine Learning2026-01-0568To be published on 04/07/2026
Crashworthiness assessment is a critical aspect of automotive design, traditionally relying on high-fidelity finite element (FE) simulations that are computationally expensive and time-consuming. This work presents an exploratory comparative study on developing machine learning-based surrogate models for efficient prediction of structural deformation in crash scenarios using the NVIDIA PhysicsNeMo framework. Given the limited prior work applying machine learning to structural crash dynamics, the primary contribution lies in demonstrating the feasibility and engineering utility of the various modeling approaches explored in this work. We investigate two state-of-the-art neural network architectures for modeling crash dynamics: MeshGraphNet, a graph neural network that is widely employed in physics-based simulations, and Transolver, a transformer-based architecture with a physics-aware attention mechanism designed to maintain linear computational complexity with respect to geometric
Nabian, Mohammad Amin, Chavare, Sudeep, Akhare, Deepak, Ranade, Rishikesh, Cherukuri, Ram, Tadepalli, Srinivas
Aerodynamic Proximity Effects Between the DrivAer and AeroSUV Standard Models, Part 1 – Same-Lane Interactions2026-01-0605To be published on 04/07/2026
Road-vehicle platooning is traditionally defined as close-distance longitudinal following in laterally-aligned formation. In this paper, the effects of aerodynamic interactions on the drag of a two-vehicle system are examined by considering the influence of separation distance, cross winds, vehicle size and shape. Testing was undertaken at 30% scale in a large wind tunnel with road-representative freestream turbulence. Separation distances of 0.5, 1.0, and 2.0 vehicle lengths were examined over a range of yaw angles between ±15deg. A highlight of the current study is the characterization of platoon drag-reduction benefits for different sizes and shapes of the lead and follower models, by using a DrivAer model and an AeroSUV model, each with slant-back (Notchback or Fastback) and square-back (Estateback) variants, providing four distinct model pairings. Drag reduction for the lead model appears to be affected mainly by the size of the follower vehicle, while the follower model shows a
McAuliffe, Brian, Ghorbanishohrat, Faegheh
Experimental Validation of a Multi-Row Tapered Roller Bearing Analytical Model for Relating Preload to Frequency Response Characteristics2026-01-0008To be published on 04/07/2026
Roller bearings are used in many rotating power transmission systems in the automotive industry. During the assembly process of the power transmission system, some types of roller bearings (e.g., tapered roller bearings) require a compressive preload force. Those bearings' rolling resistance and lifespan strongly depend on the preload set during the installation process. Therefore, accurate setting of the preload can improve bearing efficiency, increase bearing lifespan and reduce maintenance costs over the life of the vehicle. A new method for bearing preload measurement has shown potential for both high accuracy and fast cycle time using the frequency response characteristics of the power transmission system. An open problem is experimental validation of the multi-row tapered roller bearing analytical model. After validation, the analytical model can be used to predict the assembled system damped natural frequency for a desired bearing preload. This work presents the experimental
Gruzwalski, David, Mynderse, James
Digital Twin Aerodynamics Model Validation for HALO Wind Tunnel2026-01-0610To be published on 04/07/2026
A simulation-based aerodynamics model of the Honda Automotive Laboratories of Ohio (HALO) Wind Tunnel, a three-quarter open-jet (ground plane) configuration opened in 2022 for full-scale automotive testing, is under development to support data fusion for more accurate surrogate models in vehicle engineering programs. The objective is to demonstrate that a matched set of boundary values between the physical wind tunnel and the three-dimensional numerical model yield correct responses for several key flow field quantities, starting with the baseline empty tunnel case: (1) streamwise static pressure distribution, (2) evolution of the free shear layers downstream of the nozzle exit plane, and (3) ground-plane boundary layer development. Pressure-based measurement probes were deployed in these regions using a four-axis overhead traverse to acquire validation data in the large facility, including instrument verification between a 14-hole probe and Pitot-static rake. Detached eddy simulation
Patel, Sajan, Disotell, Kevin, Eagles, Naethan
Comparing the Dynamic Response of a Rolling Tire using Data Collected using a 3D Scanning Laser Doppler Vibrometer2026-01-0592To be published on 04/07/2026
Detailed tire response data is necessary to advance vehicle safety, and monitor real time tire health. This study presents a non-contact experimental method to measure the vibratory characteristics of a tire subject to shaker excitation and road rolling forces. A Global Electric Motorcars (GEM) E4 electric vehicle was mounted on a chassis dynamometer to simulate loading conditions in a controlled environment. Scanning laser vibrometry (SLDV) was employed to capture out of plane velocity responses across the tire surface using a three independent laser configuration. This technique enables visualization of mode shapes under static and dynamic excitation. The results from SLDV identified the tire’s dominant resonant frequencies and corresponding operating deflection shapes under both static and dynamic conditions at different velocities. The dynamic measurements revealed that the harmonics of rotational frequency dominated higher order structural responses. Incorporating a reference
Gower, Adam, Baqersad, Javad, Gupta, Arjun
Noninvasive Loss Breakdown of an Electric Drive Unit2026-01-0448To be published on 04/07/2026
Techniques exist to precisely measure the electromechanical efficiency in an electric drive unit (EDU, defined here as the combined motor and geartrain). While total drive unit efficiency is an important metric, it does not quantify the different loss sources in the EDU. Due to the tight packaging in production EDUs, it’s impractical to mount a torque transducer between the electric machine and gearbox to separate the losses from these components. Additionally, this approach does not separate the winding, core, and mechanical losses present in the electric machine. In this work, we developed a noninvasive approach to distinguish winding, core, and mechanical losses for EDUs containing synchronous electric machines. To separate the effects of these losses, mechanical output power was held constant at several test points while varying the stator’s current amplitude and angle. By maintaining the mechanical power at a constant value and varying the stator current, the core and winding
Woods, Tyler, Gross, Michael, Drallmeier, Joseph
AirCARE: Assessing the Impact of an Integrated Air Purification System on Vehicle Thermal Management2026-01-0272To be published on 04/07/2026
The increasing concentration of atmospheric pollutants in urban environments necessitates innovative solutions to mitigate their impact on public health and the environment. This work presents the AirCARE project, which investigates the integration of a catalytic converter and a particulate filter with a vehicle's radiator to create an active air purification system. The primary objective is to evaluate the feasibility and performance implications of this integrated system on the vehicle's thermal management. A comprehensive methodology combining computational modeling and experimental testing was employed. A 1D longitudinal vehicle model was developed to simulate the powertrain's heat generation and the cooling system's performance under various representative driving conditions. This model allows for a parametric study of the radiator, assessing the impact of the additional components on its heat exchange efficiency. Concurrently, experimental tests were conducted on a radiator to
de Carvalho Pinheiro, Henrique, Sartoretti, Enrico
Data-Driven Objective Road-Driving Classification For Durable Design Of Vehicles2026-01-0181To be published on 04/07/2026
Durability development in the automotive industry depends on a clear understanding of how road surfaces and driving characteristics affect structural road loads and fatigue. Traditionally, road surface classification has been subjective (e.g., city, highway, rural), and done through driving instrumented vehicles over a small selection of roads. The variations in driving characteristics that are often consequent to the road surface quality is rarely accounted for in designing vehicle level durability tests. This makes it difficult to establish targets for the durability testing that accurately match the wide variations in real-world roads and driving across the market of vehicles. This paper presents a data-driven approach to objectively classify road surface and driving characteristics using metrics derived from existing vehicle and road response metrics like Vibration Dose Value (VDV), International Roughness Index (IRI) and statistical estimates of vehicle speed and acceleration
Shaurya, Shubham, Ramakrishnan, Sankaran, Demiri, Albion, Khapane, Prashant
A Correction Method to Estimate Wake Effects for Aerodynamic Performance Metrics2026-01-0601To be published on 04/07/2026
Wake effects modify the aerodynamic performance of a road vehicle when driving in traffic. Analysis of wind-tunnel measurements conducted in flows with wake characteristics, using a traffic-wake-simulation system, suggests that conventional uniform-wind performance coefficients can be scaled, using wake-flow-field information, to predict the influence of wake effects. This paper presents a flow-field-averaging method that estimates a dynamic-pressure correction and yaw-angle correction for application to uniform-wind data, to account for changes in performance due to wake effects. This first-order method is shown to provide reasonably-good accuracy when reverse correcting the wind-tunnel wake-effects measurements. Drag-coefficient data for light-duty-vehicle models, which showed wake effects exceeding 20%, were corrected to within 5% of uniform-wind values, while data for heavy-duty-vehicle models, which showed wake effects exceeding 15%, were corrected to within 2% of uniform-wind
McAuliffe, Brian
Introduction to Catesby Aero Research Facility, CARF, the coast-down tunnel proving ground.2026-01-0611To be published on 04/07/2026
This paper reports on the Catesby Aero Research Facility (CARF), which began commercial use in 2019, and provides an overview of the facility and related technologies, particularly details on the vehicle-mounted component force measurement devices. CARF is a proving ground that was renovated from a former railway tunnel approximately 2.74km long and is now covered with high-quality tarmac. The road surface quality was designed to be at least as good as that of SUBARU's proving ground, and the standards were achieved using British construction technology. The course is almost straight, but there is a slight incline. The course specifications are: blockage 40m2, road width 6m (maximum 8.4m), flatness σ<0.5mm, and gradient 0.57%.In particular, compared to outdoor coastdown trucks, its overall length allows for continuous measurement right up to the stop, giving it a significant advantage in repeatability.At the same time, Subaru's newly developed six-component force sensor built into the
Shimoyama, Hiroshi
Bias and uncertainty in the time, position, and speed data of consumer-grade GPS devices2026-01-0544To be published on 04/07/2026
The goal of this study is to quantify the accuracy and uncertainty of position and speed measurements acquired by a wide range of consumer-grade GPS-enabled devices while road cycling. We acquired position and speed data simultaneously from 13 consumer devices (e.g., phones, watches, bicycle computers) at their maximum sampling rate (typically 1 Hz) during 10 hours (thirty 20 minute sessions) and 150 km of road cycling in a suburban environment. The position data from these devices were compared to real-time kinematic (RTK) data acquired using a differential GPS system and the speed data from these devices were compared to speed data acquired with high-resolution wheel rotation sensors (23,040 pulses per revolution) synchronized with the RTK data. Based on these comparisons, we generated probability distributions for the errors in the position and speed measured by each of the consumer devices. This study provides foundational data needed to quantify the accuracy and uncertainty across
Booth, Gabrielle R., Mitchell, Alan L., Siegmund, Gunter P.
Impedance Characterization of an Automotive Battery Pack2026-01-0381To be published on 04/07/2026
Parasitic inductance and capacitance of the battery pack can affect the performance of the electric powertrains. Characterizing these parasitic phenomena in an automotive battery pack is therefore crucial to ensuring performance and reliability. In this work, geometric models of a production automotive battery pack are developed to simulate the parasitic inductance of the busbar system, the parasitic inductance of individual modules, and other critical components. For these simulations, several assumptions and simplifications are introduced to reduce model complexity, while preserving the main electromagnetic behavior of the system. The impact of the different components on the battery pack impedance is investigated to evaluate parasitic capacitances, thereby simulating the worst-case scenario. Laboratory procedures are developed to accurately measure parasitic impedance, providing a reliable comparison between experimental data and analytical models and supporting the overall validity
Misley, Marco, D'Arpino, Matilde, ZHU, Di, Zhang, Liwen
AI Smart Timer-Based Power Control and Energy Monitoring System for Home Appliances2026-28-0060To be published on 02/12/2026
The paper presents the design and implementation of an AI-enabled smart timer-based power control and energy monitoring solution for household appliances. The proposed system integrates real-time sensing of electrical device parameters with cloud artificial intelligence for predictive analytics and automatic control. Continuous measurement of voltage, current and power consumption of the connected appliances are performed for analysis of the usage patterns. The appliance operation is completely automated by choosing between the best option which is the user-defined schedule or the load shifted schedule recommended by AI. The AI recommendation depends on peak demand of the day and the current load requirement thereby aiding approximate smoothening of daily load curve and improving load factor. The data collected is transmitted to the cloud for real-time and historical data collection, for prediction of consumption patterns, anomaly detection, and clustering appliances according to their
D, Anitha, D, Suchitra, Jain, Utsav, Maity, Souvik, Dinda, Atish
Analysis and Optimization of Noise and Vibrational Performance of an Electric Axle2026-26-03401/16/2026
As the electric mobility landscape evolves, there is a growing emphasis on addressing the Noise, Vibration, and Harshness (NVH) challenges associated with electric drivetrains. The absence of an IC engine in EVs shifts the focus to other noise contributors such as gear meshing, electric machine operation, and structural vibrations. Despite the known influence of micro-geometry on gear dynamics, current optimization practices often rely on empirical adjustments or standard guidelines without fully utilizing advanced computational methods to predict and optimize NVH performance. There exists a pressing need for a systematic approach to analyze and optimize gear micro-geometry to reduce noise and vibration in high-speed e-axle applications. This research aims to bridge that gap by investigating the relationship between micro-geometry optimization and NVH characteristics of an e-axle. Through detailed modelling and optimization techniques, this research aims to identify optimal gear micro
Ankit, Priyadarshi, Kulkarni, Krishna, Momin, Vaseem
Development of a Fuel Injector Driver for Accelerated Testing2026-26-05641/16/2026
This paper presents the design of a cost-effective fuel injector driver designed for accelerated testing of injectors. The driver simulates injection patterns across a wide range of vehicle operating conditions and can be programmed with injection maps for different engines, test cycles based on drawing specifications, pre-defined engine running profiles, and manual control, where the user defines PWM frequency and duty cycle. It also enables remote operation through a Wi Fi access point. An injector driver-based test setup was developed to study wear and evaluate leakage tendency in an injector design. To simulate extended field usage in a short timeframe, an accelerated operating cycle was derived using telematics data. Injector samples were tested with periodic leak rate measurements. Conducting such tests at vehicle level or on engine test bench would involve significant time and cost. This setup is an effective tool for rapid comparative analysis across supplier design, enabling
Bhatt, Pancham, Agrawal, Adheesh, Kuchhal, Abhinav
Development of an Optimized XCP Software Stack for Real-Time Validation of Vehicle Control Units Using Next-Generation Communication Protocols2026-26-01901/16/2026
With the rapid adoption of electric vehicles (EVs), ensuring the reliability, safety, and cost-effectiveness of power electronic subsystems such as onboard chargers, DC-DC converters, and vehicle control units (VCUs) has become a critical engineering focus. These components require thorough validation using precise calibration and communication protocols. This paper presents the development and implementation of an optimized software stack for the Universal Measurement and Calibration Protocol (XCP), aimed at real-time validation of VCUs using next-generation communication methods such as CAN, CAN-FD, and Ethernet. The stack facilitates read/write access to the ECU’s internal memory in runtime, enabling efficient diagnostics, calibration, and parameter tuning without hardware modifications. It is designed to be modular, platform-independent, and compatible with microcontrollers across different EV platforms. By utilizing the ASAM-compliant protocol architecture, the proposed system
Uthaman, Sreekumar
26SIAT-1032-Experimental Frequency-Based Substructuring for Full-Vehicle NVH Characterization in Electric Vehicles2026-26-03091/16/2026
The area of electric vehicles (EV) has fully arrived with almost every OEM enhancing electric vehicles in their portfolio. However, regarding its business potential numerous challenging engineering questions have risen. Especially vehicle NVH development needs to be rethought as masking noise from classical internal combustion engines (ICE) are gone. At the same time the frequency content of electric engines falls in the best human audible range, creating high potential for annoying tonal acoustic issues. With NVH design requirements now pushed up into the kilohertz range, many classic development strategies fail or lack efficiency. VIBES Technology’s answer to this challenge is what we call Hybrid Modular Modelling (HMM). This modelling strategy combines test-based and numerical simulation throughout the vehicle development cycle. Using best of both worlds, HMM allows accurate virtual (part / system) design and optimization on full vehicle level. Here HMM is based on the latest
Kohlhofer, Daniel, Pingle, Pawan Sharad, de Klerk, Dennis
Comprehensive Evaluation of Bolster Behaviour: Field Data Insights for Design Modifications2026-26-04971/16/2026
Bogie suspension systems are becoming increasingly popular in tipper vehicles to enhance their performance and durability, especially in demanding environments like construction and mining areas [1]. Bolsters contribute significantly to the overall performance and durability of the bogie suspension systems of tipper vehicles by evenly distributing the loads across the whole suspension system. They act as shock absorbers and negate the impact caused by the rough terrains and heavy loads, thereby reducing stress on individual components and maintaining the structural integrity of the vehicle. Bolsters also help in improving the ride comfort and to maintain the position of the suspension system [2]. This study focuses on the comprehensive testing and evaluation of bolsters to understand their modes and displacement data derived from field data. The primary objective is to analyse the performance and behaviour of bolsters under various operational conditions. Critical manners of
V Dhage, Yogesh, Kolage, Vikas
Optimizing Vehicle Dynamics: A Methodology for Reducing Correlation Gaps2026-26-00911/16/2026
Final design choices are frequently made early in the product development cycle in the fiercely competitive automotive sector. However, because of manufacturing tolerances design tolerances stiffness element fitment and other noise factors physical prototypes might show variations from nominal specifications. Significant performance differences (correlation gaps) between the digital twin representation produced during the design phase and real-world performance may result from these deviations. Measuring every system parameter repeatedly to take these variations into account can be expensive and impractical. The goal of this study is to identify important system parameters from system characteristic data produced by controlled dynamic testing to close the gap between digital and physical models. Dynamic load cases are carried out with a 4-poster test rig where vehicle responses are captured under controlled circumstances at different suspension locations. An ideal set of digital model
Verma, Rahul Ranjan, Goli, Naga Aswani Kumar, Prasad, Tej Pratap
Virtual Prototyping: Accelerating Traction Motor Development for Commercial Electric Vehicles2026-26-01521/16/2026
This paper presents the virtual prototyping of traction motor in commercial EV to make an early prediction of the performance parameters of the machine without spending an enormous cost in building a physical structure. A 48/8 slot-pole configuration of IPMSM is used to demonstrate the electromagnetic and thermal co-simulation in ANSYS MotorCad. The core dimensions were determined using permanent-magnet field theory. From those, a two-dimensional finite-element (2D FEM) model of the interior permanent magnet (IPM) motor was simulated using Ansys Motor-CAD electromagnetic simulation tool. The influence of geometrical parameters on the performances of traction motor are evaluated based on FEM. The temperature distribution have been analyzed under steady and transient operating conditions. Alongside, the effects of saturation, demagnetization analysis, and the impact of PM flux linkage on inductances are also considered in this paper. At last, the simulation and analytical results of the
Murty, V. Shirish, Rathod, Sagarkumar, Gandhi, Nikita, Tendulkar, Swati, Kumar, Kundan, Thakar, Dhruv, Sethy, Amanraj
Auto Braking System for Preventing Commercial Vehicle Overloading2026-26-00321/16/2026
Overloading in vehicles, particularly trucks and city buses, poses a critical challenge in India, contributing to increased traffic accidents, economic losses, and infrastructural damage. This issue stems from excessive loads that compromise vehicle stability, reduce braking efficiency, accelerate tire wear, and heighten the risk of catastrophic failures. To address this, we propose an intelligent overloading control and warning system that integrates load-sensing technology with real-time corrective measures. The system employs precision load sensors (e.g., air below deflection monitoring via pressure sensors) to measure vehicle weight dynamically. When the load exceeds predefined thresholds, the system triggers a multi-stage response: 1 Visual/Audio Warning – Alerts the driver to take corrective action. 2 Braking Intervention – If ignored, the braking applied, immobilizing the vehicle until the load is reduced. Experimental validation involved ten iterative tests to map deflection-to
Raj, Amritesh, Pujari, Sachin, Londhe, Mahesh, Shirke, Sumeet, Shinde, Akshay
Comprehensive Technology Framework for Effective and Early Leveraging of Test Assets2026-26-05271/16/2026
The automotive industry is undergoing a significant technological transformation, which is continually impacting the methods used to test the functionalities, delivered to end consumer. This includes the ever-growing need to embed software-based functions to support more and more end user functionality, while at the same time retaining existing and well-established functions, all within short development timelines. This presents both opportunities and challenges, with greater potential for reuse or leverage of test assets, although the actual percentage of leverage on real world projects is practically less than anticipated for a multitude of reasons. This paper collates the various factors which effect the practical leverage of test assets from one project to another, including various workflows and the interaction across components amongst applications lifecycle management systems. Alongside, it describes the current practices of basis analysis in isolation in combination with
Venkata, Parameswaran, Kulkarni, Apoorva, RAJARAM, Saravanan, Ganesh, Chamarthi
Development of Door Impact Loads Using Pedal Force Sensor and First Principles2026-26-05381/16/2026
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 or getting into cab etc. Design of these doors and their latches involve a knowledge of the loads arising when the door is shut which usually involves 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 ~8 times. For these problems, structures
Valkunde, Sangram, Ghate, Amit, Gagare, Kiran
Real-Time Helmet Detection and Closed-Loop Enforcement System for Two Wheelers2026-26-06501/16/2026
Asian countries capture a significant share of global two-wheeler usage, with India consistently ranking among the top three countries. 2 wheelers are a significant portion of road traffic and contribute heavily to the national burden of road fatalities. Despite regulatory mandates, helmet non-compliance remains widespread due to limited enforcement reach and behavioural inertia. The current strategies for enforcement, such as traffic policing or external camera-based surveillance, are reactive, infrastructure-dependent, are ineffective at scale. To address these limitations, we propose system that will detect if the user is wearing the helmet. The system is designed and packaged to be integrated into the 2-wheeler directly and then execute functions in real-time for helmet noncompliance. The software algorithm is an AI-powered, vision-based system that leverages deep learning techniques for helmet detection. This model is enforced with a custombuilt dataset accommodating cultural and
Kandimalla, Om Mahalakshmi, Shah, Ravindra, Karle, Ujjwala
Multi-Band Frequency Approach to Correlate Proving Ground and Road Simulator for an Electric Two-Wheeler2026-26-05561/16/2026
Real-world usage subjects two-wheelers to complex and varying dynamic loads, necessitating early-stage durability validation to ensure robust product development. Conducting a full life-cycle durability testing on proving grounds is time-consuming, extremely difficult for the riders involved, and costly, which is why accelerated testing using rigs such as the road simulator system have become a preferred approach. The use of road simulators necessitates, accurately measured inputs and precise simulation to ensure proper actuation of the rig, thereby enabling realistic representation of road undulations. This paper covers two important aspects essential for achieving an accurate and clear representation of road simulation in a 4-DOF road simulator, encompassing both longitudinal and vertical simulations at the front and rear of the vehicle. The first aspect involves the development of an instrumentation strategy for the two-wheeler, with careful identification of directionally sensitive
Ganju, Shubham, V, Vijayamirtharaj, Prasad, Sathish, R S, Mahenthran
Novel Approach for Predicting Steering Rack Load Using Multi-Body Simulation2026-26-03781/16/2026
In the initial stages of a vehicle development program, the sizing of various components is a critical deliverable. The steering system, in particular, requires a precise estimation of the rack load for the appropriate sizing of the rack and assists units. Accurately predicting the load on the system during the early stages of development is challenging, especially in the absence of benchmark or legacy data. Commonly used processes for estimating parking steering effort often employ simplistic approaches that may fail to account for parameters such as tire size, vertical stiffness, and steering geometry, leading to reduced accuracy. This paper introduces an advanced methodology for predicting steering rack loads, which incorporates considerations such as contact patch size and pressure variation, as well as the tire jacking effect. The methodology involves mathematical modeling of the contact patch using mesh-grids, utilizing common inputs available in the early stages of vehicle
Shirke, Umesh, Dabholkar, Aniruddh, Bardia, Vivek, Srivastava, Harshit, Prasad, Tej Pratap
An Analysis of Material Damping Characteristics: A Comparison of Oberst Bar Method and Center Impedance Method and their Relationship to Component Level for EV Application2026-26-03171/16/2026
Damping materials exhibit advantageous mechanical and acoustic characteristics that enhance the structural integrity of systems. These materials find extensive applications across various industries, including automotive, aerospace, and building acoustics, and are widely employed in the development of soundproofing materials. The damping characteristics of materials primarily pertain to the dissipation of vibrational energy, the reduction of oscillations, and the controlling and subsequent attenuation of vibration-induced noise emanating from structures. To improve both structural integrity and acoustic performance, it is crucial to accurately assess the damping properties of these materials. The Oberst bar test method is a standard method used in the automotive, railway and building industry for initial optimization of damping material However, questions have arisen about the degree to which the outcomes of the Oberst test truly reflect real-world applications. Numerous experimental
Kamble, Prashant Prakash, Joshi, Manasi, Jain, Sachinkumar, Harishchandra Walke, Nagesh
Wheel Side Load Calculation using the Strain Measurement on Swingarm and Duty Cycle Development2026-26-05831/16/2026
Typically duty cycle development for any component carried out in the absence of direct acting load will be based on the measured strain from the RLDA and comparing it with the rig level testing. The biggest drawback from such an approach is the fact that the selected loads can be drastically different from the actual experienced peak load from the actual RLDA. This happens because the strain gauges will have sensitivity toward all three directional loads and sometimes due to complex structure design uni directional sensitive locations are difficult to find out or strain gauge. This will lead to over predicting the loads in some cases and the selected load may end up yielding the component in a single cycle itself. This paper discusses the method employed to calculate the loads at the input load location using the strain gauges which are cross sensitive and using that input loads to select the loads for the testing of the component. Also it talks about the constraints it faces while
Anandh, Sudheep, Prasad, Sathish, R S, Mahenthran
Accurate Component Load Prediction with Hybrid Test-FEA Approach2026-26-03661/16/2026
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
Pratap, Rajat, Apte, Sr., Amol, Babar, Ranjit
Durability Validation of Full Vehicle Structures Using Strain Correlation and RLDA-Based Simulations2026-26-05231/16/2026
Durability validation of full vehicle structures is crucial to ensure long-term performance and structural integrity under real-world loading conditions. Physical test strain and finite element (FE) strain correlation is vital for accurate fatigue damage predictions. During torture track testing of the prototype vehicle, wheel center loads were measured using wheel force transducers (WFTs). In same prototype strain time histories were recorded at critical structural locations using strain gauges. Preliminary FE analysis was carried out to find out critical stress locations, which provided the basis for placement of strain gauges. Measured loads at wheel centers were then used in Multi Body Dynamics (MBD) simulations to calculate the loads at all suspension mount points on BIW. Using the loads at hard points transient analyses were performed to find out structural stress response. Strain outputs from the FE model were compared with physical measurements. Insights gained from these
Jaju, Mayur, Dokhale, Sandeep, Gadre, Nilesh, Patil, Sanjay
A Case Study of Emission Optimization using Machine Learning2026-26-02291/16/2026
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
Dhayanidhi, Hukumdeen, Balasubramanian, Karthick, A, Akash
Effects of Battery Integration in Modal Behaviour of Electric Two Wheeler Frame2026-26-03101/16/2026
This research investigates the dynamic characteristics of an electric two-wheeler chassis through a combined experimental and numerical approach, and understands the contribution of battery towards overall behaviour of the frame in a structural manner. The study commences with the development of a detailed CAD model, which serves as the basis for Finite Element Analysis (FEA) to predict the chassis's natural frequencies and mode shapes. These numerical simulations offer initial insights into the structural vibration behavior crucial for ensuring vehicle stability and rider comfort. To validate the FEA predictions, experimental modal analysis is performed on a physical prototype of the electric two-wheeler chassis using impact hammer excitation. Multiple response measurements are acquired via accelerometers, and the resulting data is processed to extract experimental modal parameters. The correlation between the simulated and experimental mode shapes is quantitatively assessed using the
Das Sharma, Aritrya, Iyer, Siddharth, Prasad, Sathish, Anandh, Sudheep
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-05011/16/2026
Manufacturing tolerances play a critical role in the quality and functionality of components, particularly those made from rubber. Even slight deviations in dimensions can cause significant issues such as improper fit and reduced performance, leading to increased costs and project delays. This is especially true for rubber grommets, which are nonlinear elastic components commonly used as sealants, gaskets, and insulation covers in automotive and industrial applications. Typically manufactured from EPDM rubber with varying Shore hardness, grommets must maintain precise geometry to ensure sealing integrity and protect adjacent parts. Dimensional inaccuracies can result in failures such as buckling or misalignment, compromising both functionality and durability. This study proposes a digital simulation methodology for early-stage evaluation of grommet robustness, reducing reliance on physical prototypes. Using a stochastic design of experiments (DOE) approach, the influence of critical
Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, Pathan, Eram
Machine Learning Approach to ISO Road Class Prediction Using Multiple Linear Regression2026-26-06671/16/2026
The inertial profiler methodology is traditionally employed in RLDA (Road Load Data Acquisition) to measure road profiles and classify test routes into ISO road classes. However, this approach demands significant time and effort during instrumentation. Also, during data acquisition, laser height sensor data is affected especially during adverse conditions such as rainy seasons or on surfaces with improper reflectivity. Additionally, substantial resources are required for data processing to convert raw measurements into road classifications. To address these challenges, an initial attempt was made to establish a relationship between axle acceleration responses and road profiles, enabling axle acceleration measurements during RLDA to predict ISO road classes. However, this approach relied on a simple linear model that considered only axle acceleration responses, rendering the predictions susceptible to inaccuracies due to varying parameters such as vehicle speed. To overcome these
P, Praveen Kumar, P, Dayalan, Sriramulu, Yoganandam
Advancement in Analytical Characterization of NBR: Py-GC-MS as an Alternative to NMR for Acrylonitrile Quantification2026-26-05461/16/2026
Nitrile Butadiene Rubber (NBR), known for its superior resistance to hydrocarbon oil, low gas permeability, and excellent thermal stability, finds extensive use in seals, O-rings, conveyor belts etc. Importantly, these performance attributes are chiefly governed by acrylonitrile content in NBR. Analytical characterization of raw NBR is relatively straightforward using conventional techniques such as elemental analysis (CHNS) and liquid state 13C NMR. In contrast, the analysis of vulcanized NBR presents considerable challenges due to its crosslinked structure, which renders it insoluble in most organic and inorganic solvents, thereby restricting direct molecular-level analysis. While solid-state 13C NMR is an established technique for structural characterization in rubber vulcanizates, its high-cost curbs routine industrial analysis. In this study, Pyrolysis-Gas Chromatography-Mass Spectrometry (Py-GC-MS) technique has been explored as a robust, precise, cost-effective alternative
Samanta, Rajyasree, Ghosh, Debojit, Anjana, Kanhaiya, Sen, Amit, Guria, Biswanath, Chanda, Jagannath, Samui, Barun, Ghosh, Prasenjit, Mukhopadhyay, Rabindra
Risk Assessment of Cold Side Components Using Quick Modal Analysis Correlation Technique2026-26-04411/16/2026
Modal analysis is performed to determine the natural frequencies and mode shapes of a structure or system. It helps engineers understand how a system vibrates and how external forces, such as mechanical loads, might excite unwanted resonances. To check the stresses due to vibration inputs, certain G levels are assumed, and stresses are scaled to those vibration levels. This gives an understanding of the stresses of components with respect to its EFR limit and design margins are calculated. But, assumed acceleration levels in pre-prototype stage level can over predict or under predict the design margins. A quick modal analysis correlation technique can be used by using test measured accelerations conducted at prototype stage of the program. In this work, a modal analysis correlation technique is used to perform risk assessment of intake manifold. The intake manifold failed due to high vibration levels which were not captured from high cycle fatigue analysis with assumed G-level. In the
Bale, Shrikant Bhaskar, Bawache, Krushna
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