Browse Topic: Measurements

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Verification of the Impact of Coefficient of Drag Variation due to Natural Wind on Fuel Consumption based on Actual Driving Data2025-01-8778To be published on 04/01/2025
It is often assumed that the actual fuel economy on public roads is affected by natural wind and that this could be contributing to discrepancy between catalog fuel economy and actual fuel economy, owing to the increased yaw angle and drag coefficient (CD). However, the impact of yaw characteristics alone on fuel economy during actual driving has not been verified or proven as it is difficult to obtain actual driving data under uniform conditions. For this reason, shape optimization is normally performed at zero-yaw through the aerodynamic development phases. In this paper, two vehicles with different yaw sensitivity characteristics are driven simultaneously, and fuel economy measurements are performed simultaneously with ambient airflow, environment, and vehicle conditions, and the results where the conditions of the two vehicles match are extracted to clarify the impact of the differences of yaw characteristics on fuel economy. The obtained results matched the values predicted by
Onishi, Yasuyuki, Nichols, Larry, Metka, Matt, masumitsu, Yasutaka, Inoue, Taisuke
Technical Paper
Quantifying the uncertainty in bicycle-computer speed measurements2025-01-8701To be published on 04/01/2025
The goal of this study is to quantify the uncertainty in bicycle computer measurements of speed. We acquired 100+ hours of data at 1-second intervals simultaneously from three Garmin Edge 530 computers mounted to the same handlebars during road cycling in rural and urban environments. Each computer recorded speed data using a different method: One unit was paired to a Garmin GSC 10 speed-and-cadence sensor (wheel rotation based), a second unit was paired to Garmin Speed Sensor 2 and Cadence Sensor 2 (accelerometer based), and a third unit was not paired to any remote sensors and relied on the device’s GPS position to calculate speed (GPS based). Based on these data, we generated probability distributions that quantify the uncertainty in the accelerometer based and GPS based speed measurements. This study provides foundational information regarding the appropriate methods to quantify the uncertainty in bicycle-computer speed data and to probabilistically interpret these data for
Booth, Gabrielle R., Siegmund, Gunter P.
Technical Paper
3D CHT Simulation of Oil-Cooled Electric Motors: A Comparative Study of Standard and Paperless Designs2025-01-8181To be published on 04/01/2025
Conjugate heat transfer (CHT) analysis of cooling in an electric motor, featuring both the standard and the paperless stator designs, was conducted using the CFD package Simerics-MP+ to assess the predictive accuracy of the numerical simulations. The condition investigated involved the motor running at 14,000 RPM. The high rotor speed was modeled using a novel hybrid approach for mesh rotation to make the problem more tractable. The two immiscible fluids, oil and air were modeled using the interface capturing, volume of fluid (VOF) method. The traditional CHT approach is computationally expensive for electric motor cooling applications due to the heat transfer time scale differences between the fluid and the solid. Temperature changes in solids occur over a much slower time scale owning to their higher thermal inertia compared to fluids. Therefore, we model the fluid and solid domains separately and use a mixed-time scale approach to exchange the heat transfer data between them. The
Varghese, Joel, Srinivasan, Chiranth, Chen, Yawei, Bhunia, Srijohn, Schlautman, Jeff
Technical Paper
Deformation Behavior and Springback Analysis of Anti-Collision Beam on Bending Forming2025-01-8247To be published on 04/01/2025
Since aluminum alloys (AA) are widely used as structural components across various industries, higher requirements for shape-design, load-bearing, and energy-absorption capacity have been put forward. In this paper, we present the development of a numerical model, integrated with a compensation method, that effectively predicts processing defects in the anti-collision beam of a vehicle, resulting in a marked improvement in its forming quality. Specifically, different constitutive models are investigated for their applicability to the beam, enabling a precise evaluation of its structural performance under large deformation. The Johnson-Cook failure model is introduced to better characterize the fracture behavior of the beam under severe structural damage. The three-point bending experiment served as a rigorous examination, demonstrating good consistency between the experimental and simulation results. Furthermore, a prediction model for assessing the forming quality during the bending
Zhang, Shizhen, Meng, Dejian, Gao, Yunkai
Technical Paper
Investigation of Skin Friction Topology on the AeroSUV Using GLOF Meter2025-01-8782To be published on 04/01/2025
In this study, the aerodynamics and skin flow field of a 1/5 scale SUV vehicle model called “AeroSUV” were experimentally investigated. The aerodynamics and skin flow field investigations were carried out in the wind tunnel at Hiroshima University with a Reynolds number ReL = 1.2×10^6, baseline yaw angle β = 0° and crosswind conditions β = 5°, 10° and 15° for two rear ends, Estateback and Fastback. The results provide aerodynamic information and detailed skin flow field information for a standard middle-class SUV vehicle with different rear ends, which is important for automotive design. By applying GLOF measurements to automotive aerodynamics, the skin friction topology was revealed in detail as skin flow field information that is useful for understanding the physics of the flow. The skin friction topology clearly shows the separation lines, reattachment lines, and focus points associated with the separation flow, longitudinal vortices and recirculation vortices of this vehicle model
Hijikuro, Masato, Shimizu, Keigo, Nakashima, Takuji, Hiraoka, Takenori
Technical Paper
CAATS - Automotive Wind Tunnel Calibrations2025-01-8762To be published on 04/01/2025
Wind tunnel calibration is necessary for repeatable and reproducible data for all industries interested in their output. Quantities such as wind speed, pressure gradients, static operating conditions, ground effects, force and moment measurements, as well as flow uniformity and angularity are all integral in an automotive wind tunnel’s data quality and can be controlled through appropriate calibration, maintenance, and statistical process control programs. The purpose of this technical paper is to (1) provide a basis of commonality for automotive wind tunnel calibration, (2) help customers and operators to determine the calibration standards best suited for their unique automotive wind tunnel and, (3) complement the American Institute of Aeronautics and Astronautics recommended practice R-093-2003(2018) Calibration of Subsonic and Transonic Wind Tunnels as specifically applied to the automotive industry. This document compiles information from various automotive wind tunnel customers
Bringhurst, Katlynn, Best, Scott, Nasr Esfahani, Vahid, Senft, Victor, Stevenson, Stuart, Wittmeier, Felix
Technical Paper
Accuracy of Time Stamps in Digital and Network Video Recorders2025-01-8690To be published on 04/01/2025
Video analysis plays a major role in many forensic fields. Many articles, publications, and presentations have covered the importance and difficulty in properly establishing frame timing. In many cases, the analyst is given video files that do not contain native metadata. In other cases, the files contain video recordings of the surveillance playback monitor which eliminates all original metadata from the video recording. These “video of video” recordings prevent an analyst from determining frame timing using metadata from the original file. However, within many of these video files, timestamp information is visually imprinted onto each frame. Analyses that rely on timing of events captured in video may benefit from these imprinted timestamps, but for forensic purposes, it is important to establish the accuracy and reliability of these timestamps. The purpose of this research is to examine the accuracy of these timestamps and to establish if they can be used to determine the timing
Molnar, Benjamin, Terpstra, Toby, Voitel, Tilo
Technical Paper
Structural Weld Optimization with Efficient Approach of DFSS2025-01-8248To be published on 04/01/2025
Structural Weld Optimization with Efficient Approach of DFSS Abstract In automotive engineering, welds are frequently used to join or connect various parts of structures, frames, cradles, chassis, suspension components, and body. These welds usually form the weakest material link for durability and impact loads, which are measured by lab-controlled durability and crash tests, as well as real-world vehicle longevity. Consequently, designing robust welded components while optimizing for material performance is often prioritized as engineering challenge. The position, dimensions, material, manufacturing variation, and defects all affect the weld quality, stiffness, durability, impact, and crash performance. In this paper, the authors present best practices based on studies over many years, a rapid approach for optimizing welds, especially seam welds, by adopting Design For Six Sigma (DFSS) IDDOV (Identify, Define, Develop, Optimization, and Verification) discrete optimization approach. We
Qin, Wenxin(Daniel)
Technical Paper
A Novel Hybrid Approach for Segmenting Driver Based on their Driving Style2025-01-8205To be published on 04/01/2025
Drivers present a diverse landscape with their distinct personalities, preferences, and driving habits influenced by many factors. While drivers exhibit a wide range of behaviors, identifiable patterns in driving styles enable the classification of drivers into discrete segments. Discrete segmentation provides a practical and effective way to categorize and address the differences in driving style. The segmentation approach offers many benefits, including simplification, measurement, proven methodology, customization, and safety. Numerous studies have investigated driving style classification using real-world vehicle data. These studies employed various methods to identify and categorize distinct driving patterns, including naturalist differences in driving and field operational tests. This paper presents a novel hybrid approach for segmenting driver behavior based on their driving patterns. We leverage vehicle acceleration data to create granular driver segments by combining event
Chavan, Shakti Pradeep, Chinnam, Ratna Babu
Technical Paper
A Sensitivity Study of Frequency Response Method for Setting Bearing Preload Due to Uncontrollable Parameters2025-01-8520To be published on 04/01/2025
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. One open problem is the design of the production controller which relies on a detailed sensitivity study of the system frequency response to changes in the bearing and system design parameters. Recently, an analytical model was developed for multi-row tapered roller bearings
Gruzwalski, David, Mynderse, James
Technical Paper
OPTIMAL INVESTIGATION ABOUT CAB OF BSC RACING CAR BASED ON ERGONOMICS2025-01-8669To be published on 04/01/2025
In the Baja competition, the racing cars need to run under a variety of complex off-road conditions such as pebble road, shell pit, the road with many broken stones, hump, water puddle and so on，in the endurance race，the driver even has to drive continuously for four hours. In the process of this high-intensity and high-concentration race, the irrational designs of cab in ergonomics will easily cause the driver's visual and handling fatigue, so that the driver's attention is not concentrated，and cause the security accidents. Moreover, the lower back pain, sciatic nerve discomfort, lumbar spine diseases and other occupational diseases are basically caused by uncomfortable driving posture and unreasonable manipulation interface, and these have a lot to do with unreasonable ergonomic designs. In order to solve the unreasonable designs of the cab in ergonomics and improve the safety and comfort of the driver, first of all, establish the overall model of BSC racing car in Catia to obtain a
Liu, Yuzhou, Liu, Silang
Technical Paper
Application of Model-based Horizon Prediction to Enhance Control Algorithm Performance by Compensating for Time Delays in Automotive Drivelines2025-01-8574To be published on 04/01/2025
Accurate estimation of crucial quantities in automotive drivetrain systems is essential for optimizing performance, durability, and emissions. However, the presence of time delays, arising from tasks scheduling and communication latency between control units, can significantly hinder the effectiveness of advance control algorithms. Closed-loop performance is often limited by the equivalent time delay between the control action command, its effect on the system, and the measurement of the reaction. Frequently, commands and measurements originate from different sources, requiring precise coordination to accurately estimate the driveline response. This paper presents a novel model-based approach that integrates Kalman filtering with horizon prediction techniques to effectively address time-delay compensation. By leveraging the descriptive capabilities of physics-based models, the proposed method enables to overcome synchronization misalignment between commands, actuations and measurements
Rostiti, Cristian, Patel, Nadirsh, Catkin, Bilal
Technical Paper
Integrated design for body in white fabricated by additive manufacturing and its mechanical performance analysis2025-01-8613To be published on 04/01/2025
With the development of additive manufacturing technology, the concept of integrated design has been introduced and deeply involved in the research of body design. In this paper, by analyzing the structural characteristics of the electric vehicle body, we designed a body in white with the additive manufacturing process, and analyzed its mechanical properties through finite element method. According to the structural characteristics of the body, the integrated structure was modeled in three dimensions using CATIA. For the mechanical properties of the body, the strength and stiffness of the body structure were simulated and analyzed based on ANSYS Workbench. The results show that for the strength of the body, the maximum stress of the simulation results was compared with the permissible stress, and the maximum stress was calculated to be less than the permissible stress under each working condition. For the body stiffness, the displacement of the body deformation was used to measure, and
Xu, Cheng, Zhang, Tang-yun, Wang, Tao, Wang, Liangmo, Cao, Can
Technical Paper
Innovative Methods for Predicting Material Stress-Strain Curves Based on Transfer Learning and Artificial Intelligence2025-01-8317To be published on 04/01/2025
The mechanical properties of materials play a crucial role in predicting performance across various applications. However, traditional methods for measuring these properties often involve complex, resource-intensive, and time-consuming tests, which may be impractical in certain situations. The Small Punch Test (SPT) is a small-sample detection technique for evaluating material mechanical properties, characterized by its "non-destructive" nature: applying localized loads to small specimen samples and measuring the resulting deformation. While SPT can obtain load-displacement curves for specimens, it cannot directly reflect material mechanical properties and relies on empirical formulas for estimation. To address this challenge, we designed a specialized SPT experiment and fixture, and established a Finite Element Method (FEM) model. We developed a multi-fidelity model capable of predicting the mechanical properties of steel and aluminum alloys, representing a novel machine learning
Zou, Jie, Li, Shanshan, Huayang, Xiang, Chen, Yechao
Technical Paper
Design and Optimization of a Novel Aluminum-Intensive Spaceframe-Based Electric Mailvan Prototype Driven by CAE2025-01-8323To be published on 04/01/2025
Despite the known advantages of aluminum in terms of its lower density and comparable strength-to-weight as well as stiffness-to-weight ratios as those of steel, superior recyclability and high residual value, etc., there are only a handful of vehicles in global markets, mostly outside the reach of the common man, made primarily of aluminum. As cost of material and joining of parts is a deterrent in large scale adoption of aluminum as a material of choice for vehicle body design, a novel architecture is necessary for minimizing weight, maximizing performance and lowering cost of tooling. Additionally, a lightweight vehicle cannot be behind in terms of crash safety compared to its predominantly steel body-based counterparts. With these objectives in mind, a novel aluminum-intensive electric mailvan based on a spaceframe body architecture comprised mainly of low-cost extrusions has been designed and prototyped primarily driven by CAE. The design methodology consists of selective testing
Deb, Anindya, Karthika, M R
Technical Paper
Optimized Stiffness Design of Rubber Bushings with Metal Inserts2025-01-8322To be published on 04/01/2025
Rubber bushings play a critical role in the overall vehicle handling and stability of vehicles. In the paper, a method is proposed to optimize the design of rubber bushing with metal inserts for four-directional stiffness: radial stiffness, axial stiffness, yaw stiffness and torsional stiffness. Firstly, the Ogden model is used as the material constitutive model of the rubber bushing, and the finite element analysis method for the calculation of the static stiffness of the bushing is established according to this model. The static stiffness calculation model of the bushing is verified through the measured six-directional stiffness of the bushing's. A multi-objective optimization model is then established, targeting the anisotropic stiffness as design objectives, and a genetic algorithm is employed to solve the model. According to the optimization results, a prototype rubber bushing with metal inserts was manufactured. The radial stiffness, axial stiffness, yaw stiffness and torsional
Liu, Sheng, Shangguan, Wenbin, Lei, Xiao, Yin, Lifeng
Technical Paper
Telematics-based Managed EV Charging: A pilot case study for utility bulk and distribution grid services2025-01-8122To be published on 04/01/2025
Growth in the EV market is resulting in an unprecedented increase of electrical load from EV charging at the household level. This has led to concern for electric utilities' ability to upgrade electrical distribution infrastructure at an affordable cost and sufficient speed that can keep up with EV sales. Adoption of EVs in the California market has outpaced the national average and offers early insight for other regions of the United States. The Sacramento Municipal Utility District (SMUD) partnered with two Distributed Energy Resource (DER) aggregators, the OVGIP (recently formed as ChargeScape) and Optiwatt, to deliver a vehicle telematics-based active managed charging pilot. This pilot was launched in Summer 2022, with approximately 1,200 EVs enrolled over two years including Tesla, Ford, BMW, and GM electric vehicles. The goal of this pilot was to evaluate the business case for mitigating EV grid impacts and delivering additional grid services providing both EV drivers and the
Liddell, Chelsea, Schaefer, Walter, Dreffs, Kora, Moul, Jacob, Kay, Carol, Aswani, Deepak
Technical Paper
A Time-Aware Shaper-Based Method for Addressing Traffic Bursts and Out-of-Order Induced by IEEE 802.1CB in In-Vehicle Networks2025-01-8079To be published on 04/01/2025
The trends of intelligence and connectivity are continuously driving innovation in automotive technology. With the deployment of more safety-critical applications, the demand for communication reliability in in-vehicle networks (IVNs) has increased significantly. As a result, Time-Sensitive Networking (TSN) standards have been adopted in the automotive domain to ensure highly reliable and real-time data transmission. IEEE 802.1CB is one of the TSN standards that proposes a Frame Replication and Elimination for Reliability (FRER) mechanism. With FRER, streams requiring reliable transmission are duplicated and sent over disjoint paths in the network. FRER enhances reliability without sacrificing real-time data transmission through redundancy in both temporal and spatial dimensions, in contrast to the acknowledgment and retransmission mechanisms used in traditional Ethernet. However, previous studies have demonstrated that, under specific conditions, FRER can lead to traffic bursts and
Luo, Feng, Ren, Yi, Zhu, Yian, Wang, Zitong, Guo, Yi, yang, zhenyu
Technical Paper
Numerical Comparison of TPMS Structures for the Design of an Automotive Engine Oil Cooler2025-01-8155To be published on 04/01/2025
Triply Periodic Minimal Surfaces (TPMS) structures offer the possibility of reinventing structural parts and heat exchangers to obtain higher functional efficiency and lighter or even multi-functional components. As crescent global climate concern has led to increasingly stringent emissions regulations, the adoption of TPMS represents a resourceful tool for OEMs to downsize and lighten mechanical parts, thereby reducing the overall vehicle’s weight and fuel consumption. In particular, TPMS structures are gaining growing interest in the heat exchanger field as their morphology allows them to naturally house two separate fluids, thus allowing heat transfer without mixing. Moreover, TPMS-based heat exchanger can provide countless possible design configurations. These structures are obtained by the periodic repetitions in the three spatial dimensions of a specific unit cell with defined dimensions and wall thickness. By tuning their characteristic parameters, the structure can be tailored
Torri, Federico, Berni, Fabio, Martoccia, Lorenzo, Marini, Alessandro, Merulla, Andrea, Giacalone, Mauro, Colombini, Giulia
Technical Paper
Automotive fatigue load spectra: modelization, identification and applications2025-01-8240To be published on 04/01/2025
Fatigue design is invariably of prior concern for the automotive industry, no matter of the evolution of the mobility market: at first because carmakers have to stay compliant with general structural integrity requirements for reliability, notably applicable to the chassis system, then due to the endless competition for lightweighting in order to mitigate product costs and/or enhance vehicle efficiency. In the past, this key performance was often tackled by basic reference load cases, making use of the simplest signal content, e.g. sinus functions, to practice constant amplitude loads on test rigs and for computations, respectively. Nowadays, full time series coming from proving ground measurements, or any corresponding virtual road load data computations, may be applied to feed complex vehicle computations for virtual assessment and complex test facilities for final approval, under variable amplitude loads. In between, the concept of load spectra (i.e. distribution of amplitudes with
Facchinetti, Matteo Luca, Tjhung, Tana, Jaffre lng, Sébastien, Datta, Sandip, Hayat lng, Romain, Guo, Mingchao
Technical Paper
Finite Element Simulation and Experimental Study of the In-Mold Graining Process2025-01-8330To be published on 04/01/2025
In-Mold Graining (IMG) is an innovative production technology applied to the skin wrapping of automotive interior components. In the design of automotive interior components of door panels and instrument clusters, to overcome process-related problems, such as the thinning of grain patterns and excessive reduction in thickness, simulation of the skin vacuum forming process is required. The Thermoplastic Olefin (TPO) skin material is investigated in this paper, and a viscoelastic mechanical model for this material is established. Dynamic Mechanical Analyzer (DMA) is utilized to perform scan for frequency and temperature, and the tested data is used to obtain key model parameters of the viscoelastic constitutive model. Based on the experimental data, the study explores how to calculate the relaxation time spectrum to describe the viscoelastic properties of TPO material during the vacuum adsorption process. Numerical simulation of the vacuum adsorption process of TPO material is conducted
Chai, Bingji, Guo, Yiming, Xie, Xinxing, Zhang, Qu
Technical Paper
A Sensitivity Study of Frequency Response Method for Setting Bearing Preload Due to Manufacturing and Design Variation2025-01-8518To be published on 04/01/2025
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. One open problem is the design of the production controller which relies on a detailed sensitivity study of the system frequency response to changes in the bearing and system design parameters. Recently, an analytical model was developed for multi-row tapered roller bearings
Gruzwalski, David, Mynderse, James
Technical Paper
Evaluation of Several Tesla Dashcam Angles for Model 3 and Y Via Reverse Project Photogrammetry2025-01-8700To be published on 04/01/2025
Tesla Model 3 and Model Y vehicles come equipped with a standard dash-camera feature with the ability to record video in four directions called TeslaCam. Additional views have been known to be recorded under specific circumstances, often triggered in impacts, and available to some owners through data requests to Tesla. Prior research into TeslaCam either did not fully explore all known camera views across multiple vehicles or the metadata associated with genuine copies of TeslaCam video. Testing and analysis of real-world crashes revealed a reliable methodology to conducting photogrammetry analysis utilizing the front, rear, and side cameras found on Tesla Model 3 and Model Y vehicles, how to verify the likelihood of any copy of TeslaCam being a genuine original video discovered during the course of an investigation, and how to examine ever changing video properties as new software becomes available for the vehicles. Moving and stationary Tesla vehicles captured frames of GPS
Jorgensen, Michael, Swinford, Scott, Imada, Kevin, Farhat, Ali
Technical Paper
A Method for Calculation Flow Resistivity of Kapok Fiber Felt2025-01-8246To be published on 04/01/2025
The flow resistivity is a critical parameter for evaluating the acoustic performance of the porous materials. Accurate determination of flow resistivity is essential for predicting the characteristic impedance and propagation constants of materials. In this paper, a method is proposed to calculate the flow resistivity of kapok fiber felt, aiming to accurately assess the flow resistivity of kapok fiber felt. Based on the dual-porosity equivalent model of kapok fiber felt, it is hypothesized that the flow resistivity is divided into two components. One part from the large pores between fibers, and the other part from the hollow structures within kapok fibers and the micropores on the fiber walls. The contribution of the large pores between fibers to the flow resistivity is calculated using the Tarnow_S model. Meanwhile, the hollow pores within the kapok fibers and the micropores on the fiber walls are represented as an equivalent pore. The slip effects are considered, and experimental
Lin, Jiaman, Kang, Yingzi, Xie, Xinxing, Zhang, Qu, Yang, Shanmiao, Shangguan, Wen-Bin
Technical Paper
Consideration of Factors Influencing Closed Jet Wind Tunnel Blockage Corrections for Road Vehicles2025-01-8771To be published on 04/01/2025
Experimental studies of wind tunnel blockage for road vehicles have usually been conducted in model wind tunnels. Models have been made in a range of scales and tested in a working section of fixed size. More recently CFD studies of blockage have been undertaken, which allow a fixed vehicle size and the blockage is varied by changing the cross section of the flow domain. This has some inherent advantages. A very recent database of drag and lift coefficients for different road vehicle shapes and simple bodies examined in a closed wall tunnel with a wide range of blockage ratios has become available and provides some additional insight into the blockage phenomenon. This paper shows how some of the parameters influencing blockage can be derived from the CFD data and provides some tentative proposals for correcting the measured drag and lift coefficients
Howell, Jeff, Gleason, Mark, Butcher, Daniel
Technical Paper
Dynamic Testing and Analysis of Autocycle Vehicles for Accident Reconstruction2025-01-8687To be published on 04/01/2025
The Autocycle is a style of vehicle that most often utilizes a reverse-tricycle design with two front wheels and a single rear wheel. Modern autocycles in the United States are often utilized in a recreational role. This work presents physical measurements of two modern autocycles for use in accident reconstruction and pursues a deeper understanding of the unique attributes and handling associated with these vehicles. Vehicles were used to measure physical properties and subjected to cornering tests presented herein, and the data is compared to that for a conventional automobile. Observations on tire scuff marks are made from cornering tests unique to these vehicles. Strengths and challenges with this type of vehicle design are presented for various use cases as compared to conventional automobiles. Data and knowledge from this study will aid accident reconstruction efforts and act as a stepping stone for future work
Warner, Wyatt, Swensen, Grant, Warner, Mark
Technical Paper
Study on measuring viscosity and density of lubricating oil with a wire resonator system2025-01-8472To be published on 04/01/2025
The paper focuses on the principle of metal wire resonators, the development, and validation of a model for measuring liquid viscosity and density, alongside the optimization design of the resonator. Initially, an in-depth analysis of the operational mechanism of metal wire resonators is conducted, followed by the establishment of both mechanical and electrical models. These models are then interlinked to derive the critical parameter correlations between them. By refining the electrical model, a more precise electrical measurement model is formulated and experimentally verified for accuracy.Furthermore, by reducing the order of hydrodynamic functions, a simplified model applicable for measuring liquid viscosity and density using metal wire resonators is constructed. This model is validated using two sets of publicly available data, with calculated results affirming the correctness and simplicity of the derived theoretical model. By simplifying the principle of model 1, the calibration
Shan, Baoquan, Shen, Yitao, Yang, Jianguo, Zhang, Zhaoying, Wu, Dehong, Zhao, Yingke
Technical Paper
A Novel Nonlinear Model Predictive Control Strategy for a Class of Nonlinear Systems with Multiple Actuators’ Response Time-Delays2025-01-8028To be published on 04/01/2025
This paper investigates the problem of nonlinear model predictive control (NMPC) strategy for a class of nonlinear systems with multiple actuators’ response time-delays. Considering the response time-delays of the actuators when constructing NMPC problem will usually greatly increase the scale of the optimization problem. To address these problems, a novel NMPC strategy is designed. At the first stage, the NMPC strategy is designed for the nonlinear system without actuator’s response time-delay, which will not increase the scale of the optimization problem. The optimal control sequence solved by NMPC is polynomial fitted into a time-continuous polynomial function, which is used as the reference signal of the actuators’ response time-delay models. At the second stage, combining inverse model and inverse Laplace transform techniques, a novel inverse model compensation control (IMCC) strategy is designed for actuators’ response time-delays, which can track the reference signal without
Wang, Bin
Technical Paper
Liquid Viscosity Decoupling Measurement Based on U-Shaped Tungsten Wire Sensor2025-01-8460To be published on 04/01/2025
In this paper, based on the cylindrical flow theory of incompressible viscous fluids and the equivalent circuit model of resonant sensing elements, a theoretical model for the measurement of liquid viscosity with a U-Shaped tungsten wire resonance sensor was established. This model can measure the liquid viscosity independently without liquid density or coupled detection of liquid density. The experimental results show that the decoupling of liquid viscosity and its density can be achieved at Re<1. The liquid viscosity is strongly linear with the resonant conductance. The viscosity measurement error is less than 7.24% in the viscosity range of 7.235cP to 85.2cP
Shan, Baoquan, Shen, Yitao, Yang, Jianguo, Wu, Dehong
Technical Paper
A deep learning framework for time series prediction of passenger motion sickness based on vehicle dynamics data2025-01-8104To be published on 04/01/2025
Technology development for enhancing passenger experience has been gaining attention as autonomous vehicles (AVs) provide new opportunities for human-vehicle interaction. A new possibility for occupants of AVs is performing productive tasks as they’re relieved from the task of driving. However, it has been shown that non-driving-related tasks cause a conflict between the visual and vestibular sensory systems and can, consequently, lead to Motion Sickness (MS). To develop MS mitigating technologies, it’s advantageous to design a tool that can predict when MS is likely to occur. However, there is currently a lack of in-vehicle systems that are capable of estimating a passenger's MS state in real-time. Furthermore, the lack of real-time physiological data from vehicle occupants constrains the types of sensory data that can be used for estimation under realistic implementations. To address this, a computational model was developed to predict the MS score for passengers solely based on the
Kolachalama, Srikanth, Sousa Schulman, Daniel, Kerr, Bradley, YIN, Siyuan, Wachsman, Michael Ben, Pienkny, Jedidiah Ethan Shapiro, Jalgaonkar, Nishant M., Awtar, Shorya
Technical Paper
A Novel Approach to develop the Exhaust Backpressure Measurement System for Automotive Application2025-28-0168To be published on 02/07/2025
Backpressure is one of key acoustic performance evaluation criteria of exhaust muffler (or Silencer) /EATS (Exhaust after treatment system) as well as for the exhaust system. Exhaust back pressure is an important parameter for fuel efficiency of a vehicle. Typically, the engine manufacturer specifies an upper limit for this. Usually, exhaust back pressure is measured during the driving condition of the vehicle at maximum power condition of the engine either on road or on chassis dynamometer. Both these methods, need a lot of preparatory works, test setup arrangement, 3 or more manpower and special skills. In this research, authors are tried to develop a new backpressure measurement set up for automotive vehicle application, which is simple and innovative, to fulfill the backpressure test requirement. In this design, mainly following devices are used namely Pitot tube, Compressed air, Manometer (or pressure gauge), Thermocouple, Fluke thermometer, along with standalone exhaust layout
Mandal, Goutam, Biswas, Sanjoy
Technical Paper
OPTIMIZED DESIGN AND ANALYSIS OF A HIGH-PERFORMANCE, TRACK-FOCUSED QUAD BIKE FOR THE INDIAN MARKET2025-28-0061To be published on 02/07/2025
A comprehensive approach to the optimized design and analysis of a track-focused quad bike specifically tailored for the Indian market. The design process integrates multiple critical factors, including driver ergonomics, aesthetics, and strategic component placement, to establish the optimal vehicle dimensions. The primary objective is to ensure comfort, functionality, and visual appeal while addressing the unique demands of the Indian terrain and user preferences. A meticulous selection process for tires and suspension geometry is conducted using the advanced Optimum Kinematics software. This optimization ensures that the vehicle can adeptly handle a variety of road conditions, providing superior performance and stability. The vehicle’s core structure features a space frame chassis, engineered to minimize tubing and facilitate ease of fabrication, contributing to both weight reduction and structural integrity. A robust 600cc 4-cylinder engine is selected, emphasizing an optimal power
Thanikonda, Praveen Kumar, Shaik, Amjad, Tappa, Raju, Ratlavath, Ramu, Navar, Adarsh, Challa, Ajith Kumar
Technical Paper
Data-Driven Optimization of Titanium Grade 7 Machining for Automotive Applications2025-28-0143To be published on 02/07/2025
Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in materials that conduct electricity, irrespective of their level of hardness. With the rising demand for superior products and the necessity for quick design modifications, decision-making in the industrial sector becomes increasingly complex. This study specifically examines Titanium Grade 5 and suggests creating prediction models through regression analysis to estimate performance measurements in ECM. The experiments are formulated based on Taguchi's ideas, utilizing a multiple regression approach to deduce mathematical equations. The Taguchi method is utilized for single-objective optimization in order to determine the ideal combination of process parameters that will maximize the material removal rate. ANOVA is a statistical method used to determine the relevance of process factors that affect performance measures. The suggested prediction technique for Titanium Grade 5 exhibits
Natarajan, Manikandan, Pasupuleti, Thejasree, Kumar, V, Krishnamachary, PC, Somsole, Lakshmi Narayana, Silambarasan, R
Technical Paper
Advanced Parameter Forecasting for Titanium Grade 19 Machining in Automotive Applications2025-28-0045To be published on 02/07/2025
Electrochemical machining (ECM) is a remarkably effective technique for producing detailed designs in materials that can conduct electricity, regardless of their level of hardness. As the desire for high-quality products and the necessity for rapid design changes grow, decision-making in the industrial sector becomes increasingly intricate. This work focuses on Titanium Grade 9 and proposes the development of prediction models using regression analysis to estimate performance measurements in ECM. The experiments are designed using Taguchi's methodology, employing a multiple regression approach to produce mathematical equations. The Taguchi technique is utilized for the purpose of single-objective optimization in order to determine the optimal combination of process parameters that will optimize the rate at which material is removed. ANOVA is a statistical method used to assess the relevance of process factors that impact performance indicators. The suggested prediction technique for
Pasupuleti, Thejasree, Natarajan, Manikandan, Ramesh Naik, Mude, Silambarasan, R, D, Palanisamy
Technical Paper
Taguchi-Grey Hybrid Method for Enhanced Advanced Machining of Cupronickel Alloys2025-28-0041To be published on 02/07/2025
Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in materials that conduct electricity, independent of their level of hardness. With the growing demand for superior products and the increasing necessity for quick design modifications, decision-making in the manufacturing industry becomes increasingly complex. The primary objective of this work is to concentrate on Inconel 718 and suggest the creation of predictive models through the utilization of a Taguchi-grey technique for the purpose of multi-objective optimization in ECM. The trials follow Taguchi's principles and utilize a Taguchi-grey relational analysis (GRA) technique to maximize numerous performance indicators concurrently. This involves optimizing the pace at which material is removed while decreasing the roughness of the surface and obtaining precise geometric tolerances. ANOVA is a statistical method used to determine the importance of process factors that influence these
Natarajan, Manikandan, Pasupuleti, Thejasree, C, Navya, Somsole, Lakshmi Narayana, Silambarasan, R
Technical Paper
Automation of a Quarter-Car Suspension Test Bench2024-36-011512/20/2024
This paper aims to describe a quarter-car suspension test bench automation process to be utilized in an academic environment. The project is made up of pneumatic system modeling and control system design. An analysis of the bench’s pneumatic system is carried out. This pneumatic system is composed of a pneumatic actuator and a proportional directional control valve, which are responsible for generating the road profile. It is proposed a model to compensate the non-linearities present in the pneumatic system measurement process and the disturbances caused by the under test suspension system, as well as a control strategy for small displacements of the load through linear control approaches, which provide the necessary flexibility to directly influence the parameters affecting the dynamics of the excitation system platform’s displacement, thereby reducing the complexity of the controller design to be adopted. Furthermore, analyses are conducted on the effectiveness of the control in
Siqueira, Matheus Amaral, Gomes, Pedro Carvalho, Teixeira, Evandro Leonardo Silva, Fortaleza, Eugênio Libório Feitosa, Morais, Marcus Vinicius Girão
Technical Paper
Assessing Road Load Predictions: A Comprehensive Review and Comparative Analysis of Real-World versus Numerical Simulation2024-36-015712/20/2024
Road loads, encompassing aerodynamic drag, rolling resistance, and gravitational effects, significantly impact vehicle design and performance by influencing factors such as fuel efficiency, handling, and overall driving experience. While traditional coastdown tests are commonly used to measure road loads, they can be influenced by environmental variations and are costly. Consequently, numerical simulations play a pivotal role in predicting and optimizing vehicle performance in a cost-effective manner. This article aims to conduct a literature review on road loads and their effects on vehicle performance, leveraging experimental data from past studies from other researchers to establish correlations between measured road loads and existing mathematical models. By validating these correlations using real-world measurements, this study contributes to refining predictive models used in automotive design and analysis. The simulations in this study, utilizing five distinct empirical
Pereira, Leonardo Pedreira, Braga, Sérgio Leal
Technical Paper
SAE TOMORROW TODAY: Scaling Connected Vehicles with Over-The-Air Updates1349212/18/2024
As the automotive world shifts toward fully software-defined vehicles (SDVs), many OEMs are hesitant to embrace a consumer-driven model for over-the-air (OTA) updates. Enter Sibros, a company offering holistic OTA software that enables automakers to achieve scalable, software-defined mobility. By providing AI-powered insights that deliver continuous product and service enhancements, OEMs can harness Sibros' single no-code platform to monitor, control and optimize SDVs, thus accelerating time-to-market, reducing code defects and enabling hundreds of connected vehicle use cases at global scale. This presents unique value for consumers, OEMs, commercial fleet operators, and even off-road sectors like agriculture and mining. To learn more, we sat down with Hemant Sikaria, CEO & Co-Founder, Sibros, to discuss the impact of his company's groundbreaking technology, how insurance and regulation come into play, and the importance of robust security measures to ensure the responsible growth of
Hineman, Marcie
Podcast
Low-Cost Fusion Odometry Algorithm Based on 4D Radar and Pseudo-LiDAR: Bridging the Gap between 4D Radar and Images in 3D Space2024-01-703112/13/2024
Recently, four-dimensional (4D) radar has shown unique advantages in the field of odometry estimation due to its low cost, all-weather use, and dynamic and static recognition. These features complement the performance of monocular cameras, which provide rich information but are easily affected by lighting. However, the construction of deep radar visual odometry faces the following challenges: (1) the 4D radar point cloud is very sparse; (2) due to the penetration ability of 4D radar, it will produce mismatches with pixels when projected onto the image plane. In order to enrich the point cloud information and improve the accuracy of modal correspondence, this paper proposes a low-cost fusion odometry method based on 4D radar and pseudo-LiDAR, 4DRPLO-Net. This method proposes a new framework that uses 4D radar points and pseudo-LiDAR points generated by images to construct odometry, bridging the gap between 4D radar and images in three-dimensional (3D) space. Specifically, the pseudo
Huang, Minqing, Lu, Shouyi, Zhuo, Guirong
Technical Paper
Brake Rotor Thickness Variation and Lateral Run-Out MeasurementsJ3111_202412 (Current)12/12/2024
This SAE Recommended Practice is derived from common methods used within the industry and is not intended to validate a given design or configuration. This SAE Recommended Practice applies to vehicles below 4540 kg of gross vehicle weight rating
Brake NVH Standards Committee
Recommended Practice
Automatic Hose Cutting Machine for Small Scale Industries2024-01-521712/10/2024
The goal of this work is to increase the accuracy and efficiency of hose cutting operations in small scale industries is by designing and building an automatic hose-cutting equipment. The device uses a computer-controlled system to autonomously cut pipes of various sizes and lengths. By means of a stepper motor-driven, rapidly spinning blade, the cutting process is accomplished. Additionally, the machine has sensors that measure the hose's length and modify the cutting position as necessary. Premium components and materials are used in the machine's construction; these are chosen for their performance and longevity. The device is able to boost cut precision and raise industry production all around from 100% to 190% efficient system thereby decreasing labor and time needed for hose cutting operations
Feroz Ali, L., Manikandan, R., Madhankumar, S., Sri Hari, P., Suriya Prakash, T., Vishnu Doss, G.
Technical Paper
The Application of a Chemical Inhibitor in an Effort to Prevent the Scaling of Ferrous Carbide2024-01-523012/10/2024
The properties of organic nitrate ester that inhibit scale formation were investigated in order to acquire a better understanding of ferrous carbide precipitation from supersaturated solutions. When the scale inhibitor was present, precipitation rates were much lower than when it was missing, even at very low concentrations. When the temperature and time are increased simultaneously, more scale is deposited. The effect of nitrate ester on scale deposition demonstrates that the inhibitory dosage is relatively low at low temperatures but rapidly increases when exposed to high temperatures. The inhibitor is thought to alter the shape of the first crystals by binding to dynamic growth sites and inhibiting the threshold level of development
Sandeep, Ch, Srinivasan, V. P., Raja Kumar, G., Anandan, R., Shanthi, C., Selvarajan, L.
Technical Paper
AI-Based Smart Vehicle Parking System2024-01-524212/10/2024
This project presents the development of an advanced Autonomous Mobile Robot (AMR) designed to autonomously lift and maneuver four-wheel drive vehicles into parking spaces without human intervention. By leveraging cutting-edge camera and sensor technologies, the AMR integrates LIDAR for precise distance measurements and obstacle detection, high-resolution cameras for capturing detailed images of the parking environment, and object recognition algorithms for accurately identifying and selecting available parking spaces. These integrated technologies enable the AMR to navigate complex parking lots, optimize space utilization, and provide seamless automated parking. The AMR autonomously detects free parking spaces, lifts the vehicle, and parks it with high precision, making the entire parking process autonomous and highly efficient. This project pushes the boundaries of autonomous vehicle technology, aiming to contribute significantly to smarter and more efficient urban mobility systems
Atheef, M. Syed, Sundar, K. Sham, Kumar, P. P. Prem, Karthika, J.
Technical Paper
Definition and Measurement of Transfer Case Speed-Dependent Parasitic LossJ2985_202412 (Current)12/06/2024
This SAE Recommended Practice covers transfer cases used in passenger car and light truck applications. Transfer cases are of the chain, geared, manually and electronically shifted types although other configurations are possible. The operating points (speeds, temperatures, etc.) were chosen to mirror those of the United States Environmental Protection Agency Vehicle Chassis Dynamometer Driving Schedules (DDS
Drivetrain Standards Committee
Recommended Practice
Impact of Time Aligned Measurement Parameters on Brake Specific Emissions2024-28-013212/05/2024
As per global emissions legislation requirements running test cycles and reporting brake specific emissions is the key requirement. Engine gaseous emissions measurement is mandatory requirement for ON Highway and OFF Highway applications for transient duty cycles during testing at test cells. To meet the stringent emission limits is one of the challenging tasks considering the nature of transient duty cycles with accurate measurement of lower emission values. Calculating accurate results is critical since there are several factors which impacts the accuracy of calculated results especially for transient tests measurement as various engine measurement parameters are involved in calculating the brake specific emission results and time alignment of the various parameters are needed. As per latest regulatory test methods (Euro VI, BS VI, EPA), there is guidance on measuring the time lag through an experiment method and accounting the same during the results calculation, however during
Patil, Rahul Chandrakant, Rajopadhye, Sunil, Mudassir, Mohammed, Mokhadkar, Rahul, Phadke, Abhijit Narahari, Bharambe, Niraj, Dhuri, Santosh
Technical Paper
Validation Methodology of Different Driver Monitoring Systems Using a Modular Motion Drive Simulator2024-28-026312/05/2024
In India, Driver Drowsiness and Attention Warning (DDAW) system-based technologies are rising due to anticipation on mandatory regulation for DDAW. However, readiness of the system to introduce to Indian market requires validations to meet standard (Automotive Industry Standard 184) for the system are complex and sometimes subjective in nature. Furthermore, the evaluation procedure to map the system accuracy with the Karolinska sleepiness scale (KSS) requirement involves manual interpretation which can lead to false reading. In certain scenarios, KSS validation may entail to fatal risks also. Currently, there is no effective mechanism so far available to compare the performance of different DDAW systems which are coming up in Indian market. This lack of comparative investigation channel can be a concerning factor for the automotive manufactures as well as for the end-customers. In this paper, a robust validation setup using motion drive simulator with 3 degree of freedom (DOF) is
Raj, Prem raj Anand, Selvam, Dinesh Kumar, Thanikachalam, Ganesh, Sivakumar, Vishnu
Technical Paper
Correlation Study for Radial Lash in Sliding Bushings of a Steering System2024-28-024912/05/2024
Investigation of clunking noise in a steering system fitted into a test vehicle indicated radial lash in sliding bushings, which are press fitted into housings, as one of the possible causes for clunk. To study the behavior of sliding bush under the influence of assembly clamp loads, manufacturing tolerances and road loads, sliding bushings are modelled in more detail in the steering system finite element models. Further for correlating the bushing measurements from test vehicle to the finite element model, a radial lash output is derived which is not directly available in finite element software. Finally, the correlated model is used to assess the updated design and check for radial lash improvement
Badduri, Jaideep, Pandey, Ashish
Technical Paper
Electromagnetic Interference Measurement Study from Various Electric Drive Train2024-28-013812/05/2024
The article presents radio frequency electromagnetic emission measurement results from a Vehicle semi-anechoic chamber (VSAC) with different electric drivetrains under loading conditions. The measurements are conducted based on AIS 004 part-3 and CISPR 12 standard guidelines in which radiated broadband emissions in the frequency range of 30 MHz to 1 GHz using quasi-peak detector is measured [1, 2, 3]. Categories of vehicles such as Two-wheeler and three-wheeler drivetrains are selected for this study. Typically, the measurements are done with no road loading condition as per standard recommendation. However, in this paper, we studied the effects of loading conditions with the help of a chassis dynamometer. The study examines and discusses how various vehicle architectures behave under different conditions
Mulay, Abhijit B, M, Gokul, Patel, Jinay M
Technical Paper
Navigating Future Horizons with Leading-Edge Exterior Lamps2024-28-019112/05/2024
Automotive “Exterior Lighting” systems are subject to stringent regulatory requirements and vehicle manufactures internal standards to meet the functional and aesthetic requirement of various vehicle classes. Exterior Lighting systems have grown increasingly due to complexity in design to meet customer demands. Traditionally, validation of lighting system is dependent on physical testing and associated vehicle hardware, particularly Body Control System (BCM). This traditional approach presents several challenges, including dependency on mature vehicle hardware and software, difficulties in integration testing and synchronization across various lamps, and this may compromised design validation quality. To address these challenges, this paper proposes a novel approach leveraging digital simulation of lamps validation methodology through a real time hardware simulation system. Enabling independent testing and validation of exterior lighting systems in a controlled virtual environment. The
Joshi, Vivek S., Mandloi, Prince, Ghanvat, Hemant, Bolij, Aarti
Technical Paper
An Innovative Method to Measure Tapered Roller Bearing Preload in Manual Transmission & Identification of Crucial Influencing Parameters2024-28-019712/05/2024
In manual transmission, bearing preload is a vital factor for optimum durability and performance of tapered roller bearings (TRB). To achieve better optimization of bearing preload, a precise measurement method is a minimum requisite. This technical paper investigates multiple ideas and develops a novel methodology for accurate bearing preload measurement, overcoming the challenges produced by the complexity of transmission design. This paper provides a systematic approach to bearing preload measurement in manual transmission along with identification of key parameters responsible for influencing bearing preload, such as rigidity and fit of the components. A comprehensive experimental study at both part level and system level was conducted to quantify the effects of above-mentioned parameters on preload and transmission performance. Furthermore, the paper explores the effect of bearing preload optimization on the durability performance of the transmission unit
Gaurav, Kumar, Kumar, Arun, Singh, Maninder Pal, Dhawan, Soumil, Singh, Kulbir, Kumar, Krishan, Singh, Manvir
Technical Paper
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