Browse Topic: Optimization

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Electrode-Level Modeling of Thermal Decomposition Reactions as a Foundation for Multiscale Thermal Runaway Analysis in Lithium-Ion Batteries2025-01-0523To be published on 11/25/2025
Thermal runaway in lithium-ion batteries represents a critical safety challenge, particularly in high-voltage battery systems used in electric vehicles and stationary energy storage. A comprehensive understanding of the multi-scale processes that initiate and propagate thermal runaway is essential for the development of effective safety measures and design strategies. This study provides a structured theoretical overview of the thermal runaway phenomenon across four hierarchical levels: electrode, single cell, module, and high-voltage battery system. At the electrode level, thermal runaway initiation is linked to electrochemical and chemical degradation mechanisms such as solid electrolyte interphase decomposition, separator breakdown, and internal short circuits. These processes lead to highly exothermic reactions that, at the cell scale, can result in rapid temperature increases, gas generation, and overpressure. On the module and system levels, thermal runaway can propagate through
Ceylan, Deniz, Kulzer, André Casal, Winterholler, Nina, Weinmann, Johannes, Schiek, Werner
Cellular energy architecture to secure resilient energy supply for critical infrastructure2025-01-0516To be published on 11/25/2025
Introduction of renewable energy systems offers the opportunity to achieve energy self-sufficiency or autarky in addition to contributing towards carbon neutrality by reducing the dependency on energy logistics. Amidst growing geo-political conflicts, the scenario of energy shortage or disruption of energy logistics is a major threat, especially for Europe due to the significant reliance on import of primary energy. Achieving autarky, however, requires a distinction between energy consumers that need uninterrupted energy supply and consumers that could potentially be cut-off during energy shortages to avoid prohibitive costs resulting from over sizing the system. Critical infrastructure such as hospitals, communication systems, emergency services and key mobility nodes like fuelling stations and charging points needed to sustain the services provided by them, always need uninterrupted energy supply. The architecture in current tools for optimising the design and operation of
Vijay, Arjun, Thaler, Bernhard, Köcheler, Valentin, Oppl, Thomas, Trapp, Christian
Data-Based Modeling of Power-Split Hybrids Using Cascaded Neural Networks2025-01-0522To be published on 11/25/2025
Power-split hybrid powertrains represent one of the most advanced and complex types of powertrain systems. The combination of multiple energy sources and power paths offers great potential but results in complex interactions that require improved strategies for optimal efficiency and emission control. The development and optimization of such operating strategies typically involve algorithms that demand fast computational environments. Traditional high-accuracy numerical simulations of such a complex system are computationally expensive, limiting their applicability for extensive iterative optimizations and real-time applications. This paper introduces a data-based approach designed specifically to address this challenge by efficiently modeling the dynamic behavior of power-split hybrid powertrains using cascaded neural networks. Cascaded neural networks consist of interconnected subnetworks, each specifically trained to represent individual drivetrain components or subsystems. This
Frey, Markus, Itzen, Dirk, Yang, Qirui, Grill, Michael, Kulzer, André Casal
Development of Vibration Fixtures for Automotive Testing, a combined analytical and FEA-Based Approach2025-28-0258To be published on 11/06/2025
The thermal performance of battery chargers plays a crucial role in ensuring their reliability, safety, and efficiency. The proposed research work elaborates the best use case of convergent divergent Venturi effect to improve the air velocity near the housing and establish proper temperature distribution inside the charger. This approach helped eliminating the hot spots within the charger, thereby improving heat reliability in the extreme temperature's conditions, safeguarding the thermal run-away effect within the charger. Various strategies have been utilized to reduce the hotspots in the design inclusive of decreasing potting conductivity, using various fan configurations and improving the mechanical housing design by way of providing design improvement using the Venturi effect in the fin design. The thermal analysis of a 3.3kW battery charger has been performed using ANSYS tool. The primary objective of this research is to analyze the heat distribution and identify hot spots in
Shinde, Pramodkumar, Shah, Viren
Assessing Excavator Quick Couplers: A Customer-Centric Study to Application Suitability2025-28-0268To be published on 11/06/2025
In the fast-paced world of construction, the demand for machine Uptime is paramount. Various construction machines play crucial roles in applications such as digging, loading, landscaping, and demolition. One critical component that significantly enhances machine uptime for these operations is the quick coupler. This innovative attachment facilitates rapid tool changes, enabling operators to switch between attachments seamlessly. It also boosts operator safety by eliminating frequent interaction between the operator and the attachments. Additionally, the ease of replacing attachments ensures that operators can easily use the correct attachment for specific tasks optimizing overall attachment usage. This paper aims to study the trade-off between breakout force and productivity when using quick couplers. This research assists customers in determining whether to utilize quick couplers based on their specific application requirements. The findings of this study are designed to help
Bhosale, Dhanaji Haridas, PARAMESWARAN, SANKARAN, Narayanan, Arun
Optimizing the Structural simulation process of Automobile Airvent knob design to evaluate the sustainability for human accidental sliding load2025-28-0289To be published on 11/06/2025
The research work elaborated the structural integrity of airvent by skipping the assembly level snap fit analysis of knob to reduce computational complexity of air vent knob sliding test post stopper. During assembly, the strain based mechanical breakage prediction of airvent sliding knob snaps is investigated in prestressed condition. The function of airvent knob is to rotate the vertical fins to divert the air flow as per comfort in intended direction identified by passenger. The airvent knob slides on central horizontal fin on a grove feature provided. Post sliding the knob to extreme end it gets stopped at end of grove feature of H fin. The sliding knob is assembled by compressing it against a silicon rubber elastomer inlay. The compression of inlay produces a constant tension on the knob snaps. The knob assembly has to sustain a passenger accidental and abrupt sliding loads while in stopped condition. The knob snaps in this press fit condition are the weak link in the accidental
Shah, Viren
Advanced Compliance Risk Assessment Using Big Data from Leverage Fleet Intelligence2025-28-0343To be published on 11/06/2025
In-Use compliance regulations globally mandate that machines meet emission standards in the field, beyond dyno certification. For engine manufacturers, understanding compliance risks early is crucial for technology selection, calibration strategies, and validation routines. This study focuses on developing analytical and statistical methods for compliance risk assessment using Leverage Fleet Intelligence (LFI) data, which includes high-frequency telematics data from over 500K machines, reporting 1300 measures at 1Hz frequency. Traditional analytical methods are inadequate for handling such big data, necessitating advanced methods. We developed data pipelines to query measures from the Enterprise Data Lake (A Structured Data storage system), address big data challenges, and ensure data quality. Regulatory requirements were translated into software logic and applied to pre-processed data for compliance assessment. The resulting reports provide actionable insights on NOx sensor activity
Arya, Satya Prakash, Shekarappa, Kiran
Comprehensive Warranty Data Analytics: A Blend of Conventional & Advanced Methods2025-28-0299To be published on 11/06/2025
In today’s competitive landscape, industries are relying heavily on the use of warranty data analytics techniques to manage and improve the warranty processes. Warranty analytics is important since it provides valuable insights into product quality and reliability. It must be noted here that by systematically looking into the warranty claims and related information, industries can identify patterns and trends that indicate potential issues with the products. This analysis helps in early detection of defects, enabling timely corrective actions that improve product performance and customer satisfaction. This paper introduces a comprehensive framework that combines conventional methods with advanced machine learning techniques to provide a multifaceted perspective on warranty data. The methodology leverages historical warranty claims and product usage data to predict failure patterns, identify root causes, and optimize warranty policies. By integrating these diverse methods, the framework
Quadri, Danishuddin S.F., Soma, Nagaraju
Enhanced PTO motor operation modes in Electric tractor2025-28-0239To be published on 11/06/2025
This paper is about optimized way of operation of PTO motor (Auxiliary motor) in Electric tractor using 3 different modes - Low Idle mode, Loader mode and PTO mode. These modes will provide benefit to user by improved battery range, comfort/less fatigue while using loader operation and improved performance or productivity while using PTO operated implements.
sundaram, Pavithra, M, Rojer, Natarajan, Saravanan, Joshi, Priyanka
Design Optimization of Rolling Resistance Product Development Using Linear Regression2025-28-0314To be published on 11/06/2025
Simulation, physical testing, and a combination of both is an indispensable tool for developing reliable product designs in the automotive industry. Engineers rely on this integrated approach to thoroughly explore design possibilities and fine-tune products for varying configurations. Drawing insights from existing designs, engineers can effectively tackle important design challenges, such as reducing rolling resistance. This study introduces a pragmatic solution, leveraging simulation and real-world test data, and demonstrates the effectiveness of employing Linear Regression (LR) techniques for improving rolling resistance in vehicles. Integrating LR algorithms into the design process enables swift and cost-effective optimization of parameters, offering a quicker pathway for product development.
ALTHI, Tirupathi Rao, Manuel, Naveen, K, Manu
A Load Cell-Free Solution for Weighing2025-28-0346To be published on 11/06/2025
The agricultural industry increasingly demands innovative solutions to enhance efficiency and productivity, while minimizing overhead costs of an advanced system. Large farms cultivating forage crops for the Dairy and Livestock sectors require high-quality, dense bales that retain their nutritional value. Bale weight serves as a critical parameter for assessing production yields, managing inventory and facilitating fair trade in the industry. Traditional weighing systems reliant heavily on load cells, can pose limitations in terms of cost, complexity and maintenance. This paper presents an advanced model-based weighing system de-signed specifically for balers machine. It utilizes mathematical models and dynamic torque monitoring techniques to accurately estimate the weight of bales just after the baling process. The Bale weight calculation is achieved by measuring reverse pressure experienced during bale handling and monitoring the pitch angle to compensate for measurements over
Kadam, Pankaj
‍AI Negotiator: Intelligent Chatbot for Seamless Negotiations2025-28-0347To be published on 11/06/2025
Negotiating with suppliers is a critical yet challenging task. More negotiation you do more value you create. Traditional negotiation methods often involve extensive manual effort, prolonged timelines, and inconsistent outcomes. These inefficiencies can lead to suboptimal agreements, higher costs, and strained supplier relationships. The problem is further exacerbated by the complexity of managing multiple suppliers, each with unique terms, conditions, and negotiation dynamics. The introduction of a negotiation chatbot tool, leveraging advanced language models (LLMs), addresses these challenges by automating and optimizing the negotiation process. This tool is designed to interact with suppliers in a natural, conversational manner, understanding and responding to their queries and proposals effectively. By utilizing LLMs, the chatbot can analyze vast amounts of data used for negotiation like Spend file, Material/Energy/Labour indices, identify patterns, and generate strategic responses
Panda, Dinesh Abhimanyu
Analysis Led Design (ALD) Approach for Development of Air Filter Mount Casting Component in Mower Machine2025-28-0278To be published on 11/06/2025
With the current industrial trend, where demand for reduced weight & cost, optimal shape and reduced assembly time is of prime importance, structural optimization has become need of the hour. Traditionally, structural optimization is largely analysis driven, however with analysis led design (ALD) democratization, it has now equally been shared by design engineers. In this paper, a casting component was developed as an alternative to engine air filter bracket weldment used in wide area mower machines through analysis led design (ALD) approach. The 11 piece weldment assembly of engine filter bracket along with high cost and complex assembly, had significant warranty claims. To overcome these challenges, weldment was converted into a single piece ductile iron casting. Complex design shapes and optimal design opportunities often make casting components an ideal optimization problem. In order to obtain optimal casting design shape along with sufficient load bearing capacity, generative
Patil, Prafull Pratap, Kazi, Mohseen Vahab, Gandhi, Mitesh
E-Motor thermal management using 2D-3D coupling2025-28-0225To be published on 11/06/2025
In the electrical machines, detrimental effects are resulted often due to the overheating, such as insulation material degradation, demagnetization, decreased lifetime and efficiency of the motor and Joule losses. Hence, it is vital to optimize the reliability and performance of the electric motors (E-Motor) and to reduce the maintenance and operating costs. This study brings the analysis capability of CFD for the air-cooling of an E-Motor powering on E-Machines. With the aggressive focus on electrification across automotive industry, there is an increasing need of CFD modeling to perform virtual simulations of the E-Motors to determine the viability of the designs and their performance capabilities. The thermal predictions are extremely vital as they have tremendous impact on the design, spacing and sizes of motors. With this study using Ansys Fluent - Maxwell coupling, a complete 3D CFD with CHT modeling of an Electric Motor, including all the key components like the windings, rotor
Singh, Bhuvaneshwar, Tirumala, Bhaskar, Badgujar, Swapnil, HK, Shashikiran
Design and Development of a Cost-Effective Reversible Cooling Fan for Agricultural Tractors.2025-28-0261To be published on 11/06/2025
Agricultural tractors require self-cleaning and cooling technology, especially in hot and dusty environments. This study introduces a novel reversible fan system designed which is incorporating a manually operated lever-type connection mechanism as an alternative to conventional pneumatic systems. Traditional reversible fans often rely on pneumatic actuators for blade rotation control, which can introduce complexity, maintenance challenges, and energy inefficiency. The proposed design replaces pneumatic components with a mechanically optimized lever linkage system, enabling users to manually reverse the fan’s airflow direction with minimal effort. This innovation enhances operational simplicity, reduces dependency on compressed air systems, and low costs as compared to conventional type reversible fan. The lever mechanism, engineered for ergonomic usability, ensures rapid switching between sucker and pusher modes, optimizing the fan’s utility in applications such as dust removal
Debbarma, Respect, Parwal, Mahendra, Baghel, Anand
Additive Manufacturing for Custom Off-Highway Vehicle Components: Enhancing Performance and Sustainability2025-28-0250To be published on 11/06/2025
Off-highway vehicles (OHVs) operate in challenging environments that demand high-performance components that can withstand extreme conditions. This paper explores the use of additive manufacturing (3D printing) to produce custom, lightweight components for OHVs, offering significant advantages over traditional manufacturing methods. By utilizing advanced materials and CAD/CAM software, this approach enables the creation of complex, optimized designs that reduce vehicle weight, enhance fuel efficiency, and improve overall performance. Additionally, 3D printing reduces material waste and shortens production times, making it an ideal solution for producing tailored components with minimal environmental impact. The use of rapid prototyping further accelerates the design and testing process, enabling faster iteration and optimization of vehicle parts. This innovation not only improves OHV functionality but also aligns with sustainability goals by minimizing resource usage and reducing the
Vashisht, Shruti
Multi-Objective Design Optimization and Pugh Matrix Analysis to Develop Exhaust Tail Pipe Mounting for EU6 Heavy Trucks2025-28-0293To be published on 11/06/2025
Mainly Pass by Noise (PBN), exhaust backpressure, durability & reliability; exhaust brake performance, aesthetics (if visible from outside chassis), cost, weight and safety are the key performance evaluation criteria of any Automotive Exhaust System. Introduction of different Exhaust Aftertreatment System/Devices (EATS) call for additional emissions evaluation for Exhaust System from EU4 (or BS-IV) onwards. In Engineering Function (R&D), key focus is given on above performance parameters of any design and development or New Product Introduction (NPI) process. This paper covers a critical problem faced by downstream function of NPI process and its resolution through Design of Experiments (DoE) and Pugh Matrix Analysis based on QDCFSS (Quality, Design, Cost, Feature, Safety and Sustainability). Design for Assembly (DFA) is critical event specially at the pre-launch production phase. It has the dependency with design, parts (piece to piece variations- like dimension, material property
P, Balu Mukesh, Biswas, Sanjoy, Rokade, Aditya
Traction voltage level in two-wheeler: considerations on e-motor performance2025-32-0093To be published on 11/03/2025
The electric power of most electric two-wheelers on the market ranges between 2 and 12 kW. For this power range, the traction voltage level is mostly between 48V and 96V. There appears to be no strong correlation between electric power and traction voltage, suggesting that the current voltage choice is rather arbitrary. This paper briefly describes the e-motor model used in this study and introduces variations of four design parameters: DC voltage, maximum phase current, e-motor active length, and the number of turns in the e-motor winding. The consequences of these variations on peak performance, continuous performance, and efficiency maps are presented. Specific cases of parameter combinations are also studied. Two e-motors designed for 48V and 96V systems will be compared, showing that size, cost, and performance (power and losses) are equivalent. Additionally, the paper discusses how increasing the maximum phase current rating of the inverter can improve e-motor power in a 48V
Albert, Laurent
Development of an Artificial Calibrator for Shift Program Optimization to Enhance Fuel Efficiency2025-32-0082To be published on 11/03/2025
The calibration of automotive electronic control units is a critical and resource-intensive task in modern powertrain development. Optimizing parameters such as transmission shift schedules for minimum fuel consumption traditionally requires extensive prototype testing by expert calibrators. This process is costly, time-consuming, and subject to variability in environmental conditions and human judgment. In this paper, we introduce an artificial calibrator – a software agent that autonomously tunes transmission shift maps using reinforcement learning (RL) in a Software-in-the-Loop (SiL) simulation environment. The RL-based calibrator explores shift schedule parameters and learns from fuel consumption feedback, thereby achieving objective and reproducible optimizations within the controlled SiL environment. Applied to a 7-speed dual-clutch transmission (DCT) model of a 1.5 L Mild Hybrid Electric Vehicle (MHEV), the approach yielded significant fuel efficiency improvements. In a case
Kengne Dzegou, Thierry Junior, Schober, Florian, Rebesberger, Ron, Henze, Roman
Design optimization and calibration of a single-cylinder, motorcycle engine for integration into a novel Formula SAE electric hybrid powertrain2025-32-0045To be published on 11/03/2025
The Formula SAE competitions often drive changes in the automotive research field by developing, implementing and emphasizing new technologies for both on-road and on-track applications and by training future engineers, mechanics, logistics and administrative personnel. In this work, the adaptation of a motorcycle, single-cylinder engine for the installation in an electric hybrid car for Formula SAE races is described, focusing on the design of intake and exhaust parts and on the development of the fully open-access Engine Control Unit code. In the first part of the work, the 1-D model of the engine is developed and used to design the intake and the exhaust parts needed to make the Formula Student car rules compliant. In particular, the intake manifold and the intake ducts have been designed with the assistance of the engine model to optimize the engine response under transient conditions and to maximize the power. On the other hand, the exhaust line was designed to increase the
Brusa, Alessandro, Fabbri, Pietro, Shethia, Fenil, Bassani, Davide, Petrone, Boris, Cavina, Nicolo
Machine Learning-Enhanced Electrical Circuit Model Parametrization for Battery Cells: Reducing Experimental Workload Through GITT Testing with Altair RapidMiner®2025-32-0097To be published on 11/03/2025
This study addresses the challenge of reducing the experimental workload involved in characterizing battery cell behavior as a function of state of charge and temperature. Galvanostatic Intermittent Titration Technique tests were carried out in a climate chamber across a wide temperature range, from -20 °C to 70 °C, with 10 °C intervals. The voltage and current response data collected from these tests were used to train several machine learning algorithms. The trained models could then be used to predict the cell voltage response every 5 °C from -15 °C to 55 °C. While the models were experimentally validated at 15 °C, 25 °C, and 35 °C, the predicted voltages across this range contribute to enhancing the characterization process. In particular, the inclusion of these predicted voltage profiles—combined with the experimental data collected every 10 °C from -20 °C to 70 °C—allows for the creation of more accurate lookup tables for the parameters of the equivalent circuit model. These
Giuliano, Luca, Peretto, Lorenzo, Canella, Nicholas, Nefat, Damir
Development of CAE Technology for the Design Support of Piston Pin Circlip2025-32-0015To be published on 11/03/2025
This study focuses on the technology for establishing design criteria for the piston pin circlip (hereinafter referred to as "circlip"), which is a component that holds the engine piston pin. The circlip is assembled into the piston by compressing it to the size of the piston circlip groove. However, in high-revving engines, the inertia forces caused by engine rotation can cause the circlip to disengage from the groove, potentially leading to the piston pin falling out and damaging the engine. To prevent this, it is possible to compress the circlip more and increase the reactive force acting on the groove to prevent falling out. However, this countermeasure raises concerns about the deterioration of the assemblability of the circlip. Therefore, it is necessary to establish evaluation criteria that prevent the circlip from disengaging and deteriorationg the assemblability of the circlip. To enable appropriate design of the circlip during the engine specifications review phase, we
Ishizuka, Atsushi, Watanabe, Naoto
Dome Profile Optimization and Stress Analysis of Type IV Composite Cylinders using a CLT-based MATLAB Program and FEA Validation2025-28-0374To be published on 10/30/2025
Type IV composite pressure (CP) vessels composed of a plastic liner and composite layers require special design attention to the dome region. The cylindrical portion of the composite cylinder is wrapped with composite layers consisting of the 900 hoop layers and low-angle helical layers, whereas the dome surface carries helical layers only. The winding angle of the helical layers being a constant over the cylindrical portion starts to vary from the cylinder-dome junction toward the boss at the top continuously. Along with the winding angle, the composite thickness also varies continuously resulting in a maximum thickness at the top crown region. The complete analysis and layer-wise stress prediction of Type IV composite cylinders for service pressures up to 70 MPa was analyzed by the Classical Lamination theory (CLT)-based MATLAB program. The MATLAB program developed in this work for the dome initially performs the dome profile generation through the numerical integration of the dome
R. S., Nakandhrakumar, Tandi, Ronak, M, Ramakrishnan, Raja, Selvakumar, Elumalai, Sangeethkumar, Velmurugan, Ramanathan
Optimizing Electric Vehicle Motor Testing with Fine Gaussian SVM and Bilayered Neural Network.2025-28-0397To be published on 10/30/2025
Electric vehicles are shaping the future of the automotive industry, with the drive motor being a crucial component in their operation. Ensuring motor reliability requires rigorous testing using specialized test benches to validate key performance parameters. However, inefficiencies in the helical gear configuration within these test systems have led to frequent malfunctions, affecting production flow. This study focuses on optimizing the motor test bench by refining critical design parameters through vibration signal analysis and machine learning techniques. Vibrational data is collected under different gear configurations, utilizing an accelerometer integrated with a Data Acquisition (DAQ) system and MATLAB-based directives for seamless data collection. Machine learning classifiers, including Fine Gaussian SVM and a Bilayered Neural Network, are applied to categorize signals into normal and faulty conditions, both with and without a 0.25 KW load. The analysis reveals that SVM
S, Ravikumar, Sharik, N, Syed, Shaul, V, Muralidharan, D, Pradeep Kumar
Optimization of Coolant Circuit Layout to Prevent Cavitation in Battery Electric Trucks Using Simulations.2025-28-0354To be published on 10/30/2025
In the design of battery electric trucks, efficient thermal management is crucial to ensure optimal performance and longevity of the vehicle’s components. This study focuses on the layout optimization of the coolant circuit to avoid cavitation issues in the coolant pump of a battery electric truck. Initially, we designed the electric truck's coolant circuit layout and conducted preliminary simulations to predict flow behavior and thermal efficiency. However, during prototype testing, cavitation was identified at the inlet of the coolant pump, affecting the system’s performance. To diagnose the issue, we performed several rounds of simulations, analyzing flow dynamics and pressure drops within the circuit. Based on the simulation results, we optimized the coolant layout, adjusting component positioning and flow paths to reduce the risk of cavitation. Subsequent tests confirmed that the optimized layout resolved the cavitation problem, leading to improved pump performance and enhanced
Garg, Ravi
Design & Validation of High-Altitude Test Rig for ATS & component level testing2025-28-0367To be published on 10/30/2025
New regulation standards on engine pollutant emissions are widening the engine operating conditions subjected to type approval tests to prevent from the gap between regulated and real-driving emissions. In this regard, ambient temperature and driving altitude are new boundaries to be considered. Although the basis of the impact of these variables has been studied concerning the engine performance, new challenges appear to meet the emission limits and the aftertreatment conversion efficiency. When operating at high altitude (up to 6000 ft) in a wide range of ambient temperature (range -5° C to 50°C), Particular focus is put on the modelling of the DEF Dosing. Starting from a sea-level calibration, the proposed methodology accounts for mechanical criteria as well as the impact on the engine raw emissions and exhaust flow properties to define new calibration setting for altitude operation. The paper focuses on developing an altitude rig to simulate the test conditions and helps enable
Rath, Jagannath Prasad, Varpe, Pradnya, Magar, Vijay, JAHAGIRDAR, RADHIKA
Integration and Evaluation of Different Thermal Loops through Simulation for Improved Defrost and Range of an Electric Truck2025-28-0417To be published on 10/30/2025
The rapid advancement in thermal management for electric vehicles (EVs) is driven by the need to reduce battery load and enhance EV range. Unlike conventional platforms, EV thermal management is complex due to temperature sensitivity and the numerous components involved. Powertrain components, such as the motor and transmission, operate at higher temperatures, while the battery and passenger cabin require distinct thermal conditions. This necessitates a carefully modelled thermal layouts that considers the diverse thermal needs of each component. The primary objective of this study is to improve the existing thermal layout of EVs, aiming for a more efficient design and evaluating its benefits through simulation. Utilizing the 1D commercial software GT-SUITE, the research integrates different layouts of EV’s and study the hydraulic and thermal feasibility. Integrations are based on operating temperatures, flow, and pressure requirements, while ensuring thermal comfort in the cabin and
Patel, Vedant Umang, Koti, Shivakumar, Gurdak, Michael, singh, Ramanand
Integrated Topology, Shape and Size optimization - Application in Automotive Design and Manufacturing.2025-28-0375To be published on 10/30/2025
CAE (Computer Aided Engineering) optimization plays a pivotal role in various industries to gain a competitive edge. CAE optimization is essential in several industries, such as automotive, aerospace and consumer electronics, etc., concentrating on enhancing component structural design. The process helps in addressing complex design challenges, including weight reduction, material usage efficiency and operational effectiveness. This paper presents applications for an integrated form shape, size and topology optimization approach of structural systems by using CAE tools. For the present study, CAD (Computer Aided Design) was prepared using CATIA V5 followed by meshing in Altair Hyper-works software. Hyper-mesh (Optistruct) was used as a solver tool. Modal analysis was performed to extract the natural frequencies of vibration and respective mode shapes. According to the results of the frequency response function study performed on the automobile air conditioning condenser, based on low
Mehra, Akanksha, Parayil, Paulson
CFD Simulation Techniques for Optimizing Operating Torque in HVAC Kinematics2025-28-0369To be published on 10/30/2025
This abstract presents a comprehensive overview of the methodology employed in leveraging CFD for optimizing HVAC kinematics, focusing on reducing the operating torque by improvising the flap geometry. The aim here is to utilize the CFD simulation in order to predict the torque generated on the actuator motor connected to the flap when the flap is placed in high speed airflow and based on this value work out an optimized geometry of the flap, since its geometry plays a significant role when it comes to determining the torque values. This torque is generated because of the force acting on the flap which is acting as a buffer in the path of airflow. The torque generated should be less than the stall torque of the actuator motor in order for smooth performance/movement of the flap. Initial geometry of the flap generated a torque of around 95 Ncm which was much higher than the stall torque of actuator motor. So in order to bring these torque values within the working range of actuator
Madaan, Ashish, Kumar, Ravi, Behera, Suresh, Chauhan, Arpit
Automotive AC System Design and Validation Methodology at Vehicle-Level2025-28-0434To be published on 10/30/2025
Abstract: Modern mobility solutions increasingly rely on HVAC systems due to growing transport demands, traffic congestion, and harsh environmental conditions. These systems, comprising a compressor, evaporator, condenser, and thermal expansion valve, require adequate airflow for optimal performance. Insufficient airflow, caused by factors like undersized ducts, improper fan settings, clogged filters, or high static pressures from duct restrictions, significantly hinders cooling capacity. The objective of this study is to develop a predictive model for passenger vehicle AC system performance under controlled environmental conditions. Discrepancies between predicted and desired performance will trigger a structured problem-solving process involving iterative testing, root cause analysis, and the development of corrective measures. The improvements will be focused on the vehicle-level HVAC design, adhering to customer specifications. This research will also establish an experimental
Meena, Avadhesh Kumar, Agarwal, Roopak, Sharma, Kamal, Kishore, Kamal
Improvement in Shift Quality in an Automated Multi-Speed Transmission of a Battery Electric Vehicle through Optimization of Required Shift Force2025-28-0386To be published on 10/30/2025
In heavy-duty Battery Electric Commercial Vehicles, developing multi-speed transmissions with smaller traction motors is crucial for achieving necessary gradeability and improving operational efficiency. However, understanding the shifting process in electric vehicles, which lack physical clutches to disengage the transmission from the traction motor during gear shifts, presents a unique challenge. Traditional methods for estimating shift forces are not applicable, creating a new challenge for the industry. The rise of electric vehicles offers opportunities to optimize various aspects of mechanical powertrains, particularly through designing compact shift systems with smaller actuators for automated gear shifting. During gear shifts, the goal is to optimize the required shift force to match the load capacity of a smaller actuator, as failure to do so may result in unsuccessful shifts. This paper evaluates and proposes a methodology for estimating the required shift force in an
Sharma, Saurabh
ML-Based System Level Optimization of EV Cooling Circuit2025-01-0376To be published on 10/07/2025
Efficient thermal management is vital for electric vehicles (EVs) to maintain optimal operating temperatures and enhance energy efficiency. Traditional simulation-based design approaches, while accurate, are often computationally expensive and limited in their ability to explore large design spaces. This study introduces a machine learning (ML)-based optimization framework for the design of an EV cooling circuit, targeting a 5°C reduction in the maximum electric motor temperature. A one-dimensional computational fluid dynamics (1D-CFD) model is utilized to generate a Design of Experiments (DOE) matrix, incorporating key parameters such as coolant flow rate and heat exchanger dimensions. A Radial Basis Function (RBF) neural network is trained on the simulation data to serve as a surrogate model, enabling rapid performance prediction. Optimization is performed using the Non-Dominated Sorting Genetic Algorithm II (NSGA2), yielding three distinct design solutions that meet the thermal
Paul, Kavin, Ganesan, Arul, Mansour, Youssef
Automated Calibration of Heavy-Duty Low NOx Aftertreatment System Controls using Physics-Informed Machine Learning and Global Optimization Methods2025-01-0402To be published on 10/07/2025
Heavy duty diesel engines provide a robust power plant for transportation applications both on highway and off road. Control of criteria pollutants such as particulate matter and NOx at tailpipe for these applications based on standards set by regulatory bodies such CARB and EPA is critical. SwRI has demonstrated the capability to achieve 0.02 g/bhp-hr. Tailpipe NOx standard through application of a model-based controls in EPA and CARB funded projects. This control mechanism enables precise urea dosing for both steady and transient conditions by leveraging the estimated ammonia storage state in a dual dosing system using chemical kinetics-based SCR observer models. This controller is highly nonlinear, with a significant amount of controller tuning and up to 55 calibratable parameters. To improve the accuracy and reduce the time required for calibration of this controller, this work proposes the deployment of a PINN-based SCR plant model in conjunction with a Genetic Algorithm-based
Chundru, Venkata Rajesh, Rajakumar Deshpande, Shreshta, Sharp, Christopher, Gankov, Stanislav
Simulation-Based System-Level Design Optimization for Formula SAE Vehicles2025-01-0380To be published on 10/07/2025
System-level design decisions in Formula SAE (FSAE) vehicles drive all downstream subsystem designs, yet these decisions are often based on historical precedent or anecdotal evidence rather than rigorous analysis. This work presents a simulation-driven methodology to support data-informed decisions early in the design process, specifically examining how overall vehicle parameters—such as engine power, vehicle mass, aerodynamic drag and lift, wheelbase, and track width—influence performance in a representative FSAE endurance scenario. Two types of lap-time simulation tools were used in this study: OpenLAP, a point-mass simulator, and ChassisSim, a transient 3D vehicle dynamics simulator that incorporates suspension geometry, yaw response, weight transfer, and steering effects. Initial simulations with OpenLAP were used to rapidly identify trends and guide early design decisions, while ChassisSim was used for detailed sensitivity analyses and to validate system-level trade-offs in a more
Hernandez, Andy Jose, Bachman, John Christopher
Optimal Control Strategy for BEV with CVT Using Dynamic Programming Method2025-01-0407To be published on 10/07/2025
Optimal Control Strategy for BEV with CVT Using Dynamic Programming Method Authors: Hanqing Zhao, Yasuo Moriyoshi, Tatsuya Kuboyama Abstract Battery electric vehicles (BEVs) equipped with high-speed, low-torque motors can benefit greatly from the use of continuously variable transmissions (CVTs). This study aims to reduce energy consumption by adjusting the CVT ratio to ensure that the motor operates in its optimal efficiency range during both traction and regenerative braking, while delivering the required power with minimal power loss. A detailed mathematical model of a dual motor, single CVT EV powertrain and transmission structure was developed to establish an optimal control problem aimed at minimizing energy consumption. Three methods were compared to evaluate their effectiveness: (1) The basic simulation method, which directly uses the existing control map to control the CVT ratio based on torque, vehicle speed, and motor speed; (2) The steady-state method, which searches all
Zhao, Hanqing, Moriyoshi, Yasuo, Kuboyama, Tatsuya
Applying Specialized System Analysis for Brake by Wire in Software Defined Vehicles: The Development of a System Analysis Tool (SAT)2025-01-0355To be published on 09/15/2025
The emergence of Software Defined Vehicles (SDVs) has introduced significant complexity in automotive system design, particularly for safety-critical domains such as braking. A key principle of SDV architecture is the centralization of control software, decoupled from sensing and actuation. When applied to Brake-by-Wire (BbW) systems, this leads to decentralized brake actuation that demands precise coordination across numerous distributed electronic components. The absence of mechanical backup in BbW systems further necessitates fail-operational redundancy, increasing system complexity and placing greater emphasis on rigorous system-level design validation. A comprehensive understanding of component interdependencies, failure propagation, and redundancy effectiveness is essential for optimizing such systems. This paper presents a custom-built System Analysis Tool (SAT), along with a specialized methodology tailored for modeling and analyzing BbW architectures in the context of SDVs
Heil, Edward, Zuzga, Sean, Babul, Caitlin
Research on Validation and Research Platform for Automotive Air-Conditioning Control Strategy2025-01-505809/10/2025
In order to improve the efficiency of verification and optimization of control strategies for air-conditioning systems, a thermal management platform is established based on a rapid control prototyping (RCP) approach in the article. The platform is composed of a HVAC hardware bench, a real-time control system, and a control software model. This article describes the overall architecture of the platform, the control strategy, and an efficient method for development and optimization of air-conditioning control strategies. The cooling and heating modes of the air conditioner are tested. The results show that the control strategy can be directly modified via the platform to improve the performance of the whole system. The experimental results show that after modifying the control strategy, the cooling effect of the air conditioner is optimized and the cooling time is reduced by 10.6%. The CLTC cycle is also tested in this work to verify the dynamic control performance of the air
Liu, Shuqi, Yu, Yilong, Wang, Wei, Wang, Yuan, Zhang, Yilun, Xu, Xiang
Design of a High-Speed Pure Synchro-Reluctant Machine with Asymmetrical Poles for Automotive Applications2025-24-012909/07/2025
In this article, the authors present the various choices made to design a magnet free and directly recyclable pure synchro-reluctant (Pure-SynRel) machine with asymmetrical poles operating at a maximum speed of ~21,000 rpm dedicated to automotive. This project focused on identifying design levers and optimizing the magnetic circuit to address three well-known challenges of this topology that limit its application as an automotive traction machine. These challenges include: maximizing the power factor to reduce inverter rating and cost, minimizing sources of NVH (noise, vibration, and harshness) and torque ripples, and ultimately maximizing efficiency to bridge the performance gap with magnet-based technologies (PMaSynRel). The sizing of stator components—such as the choice of winding (concentric or distributed, full or fractional pitch, round or hairpin wire)—and rotor components (e.g., the number of pole pairs, shape, and number of barriers) are explained. Additionally, the
Applagnat-Tartet, Antoine, Milosavljevic, Misa, Delpit, Pierre
What Materials for an Electrical Motor with a High-Power Density?2025-24-012609/07/2025
The rapid development of electric mobility leads to improve the performance of all the powertrain components. There is still a high need to maximize their efficiency for autonomy reasons, but weight and volume are critical parameters for automotive, aeronautic or train applications. This paper focuses on electrical machines, especially the permanent magnet synchronous axial flux motors (PMSAFM) which offer advantages in terms of power density and volumetric electromagnetic torque. The paper proposes a panorama of solutions for designing such a motor, with an application case to 100 kW – 10000 rpm, and an objective of 12 kW/kg at steady state. Obtaining such a power density can be obtained by optimizing the design, by boosting the current, using a high DC voltage, choosing a high-performance electrical steel and adapted permanent magnets, etc). For the PMSAFM topologies several configurations can be considered, and the authors show that a double rotor PMSAFM surface-mounted magnets
Lecointe, Jean-Philippe, Hebri, Mohamed, Bauw, Grégory, Fawaz, Sara, Duchesne, Stéphane, Zito, Gianluca, ABDELLI, Abdenour, ARSLANE, Idir
Enabling Near-Zero Emissions and Superior Efficiency in Large-Bore, Medium-Speed Engines with a Hydrogen-Argon Power Cycle2025-24-000109/07/2025
Combustion engines operating on a hydrogen-argon power cycle (H-APC) offer potential for superior thermal efficiency with true zero exhaust emissions. The high specific heat ratio of argon allows extrapolation of the theoretical efficiency of the Otto cycle to almost 90%. However, this potential is significantly constrained by challenges in combustion control, excessive thermal loading, and system integration, particularly regarding argon recovery. This study investigates these trade-offs, within the context of real-world engine-based peaking power plants. An experimentally validated 1D-simulation model of a prototype Wärtsilä 20 DF engine serves as reference for analysis of a retrofit incorporating a closed-loop argon cycle, with dedicated H₂ and O2 injectors, a water condenser and water separator. Engine performance is evaluated at reference operating point of 75% load, considering pre-ignition, peak pressure and exhaust temperature constraints, condenser limitations, and impurity
Ahammed, Sajid, Ahmad, Zeeshan, Mahmoudzadeh Andwari, Amin, Kakoee, Alireza, Hyvonen, Jari, Mikulski, Maciej
New Hybrid Powertrain Architectures for European Passenger Car Market2025-24-009709/07/2025
This study presents a comprehensive methodology for the design and optimization of hybrid electric powertrains across multiple vehicle segments and electrification levels. A full-factorial simulation framework was developed in MATLAB/Simulink, featuring a modular, physics-based vehicle model combined with a backward simulation approach and an ECMS (Equivalent Consumption Minimization Strategy) -based energy management algorithm. The objective is to evaluate three hybrid powertrain architectures, namely Series Hybrid (SH), Series-Parallel Hybrid with a single gear stage (SHP1), and Series-Parallel Hybrid with a double gear stage (SHP2), across three vehicle classes (Sedan, Mid-SUV, Large-SUV), four different internal combustion engines (ICEs), and three application types (HEV, PHEV, REEV). More than 10,000 unique configurations were simulated and filtered through a two-step performance requirements analysis. The first phase assessed individual vehicle-level performance targets, while
Amati, Nicola, Marello, Omar, Mancarella, Alessandro, Cavallaro, Davide, Ianni, Luca, Cascone, Claudio, Paulides, Johannes JH
Thermal Characterisation of a High-Power Lithium-Ion Pouch Cell and Surface Temperature Prediction for Motorsport Applications2025-24-014209/07/2025
Accurate cell thermal characterisation is vital for battery modelling and thermal management, especially in motorsport, where minor temperature estimation errors can have severe consequences. Conventional methods for determining key thermal parameters, such as the specific heat capacity, often require costly calorimeters or destructive testing. Recent studies propose an alternative approach using a 1D lumped thermal network to solve the thermal balance of a heat-generating cell. However, these studies often overlook critical aspects of the heat generation equation, particularly the entropic term, which is essential for capturing nonlinear thermal behaviour, especially under dynamic cycling conditions. This study presents a cost-effective approach for rapid cell thermal characterisation and accurate surface temperature prediction. A pouch LCO cell was first tested to determine the entropic coefficient, followed by experiments under two convective conditions to evaluate its specific heat
Sciortino, Davide Domenico, Schommer, Adriano, Costa, Andre
Multi-Objective Optimization of the Energy Management Strategy for Hybrid Electric Vehicles -Examination of Sensitivities between Fuel Consumption, Electric Driving and Driving Comfort2025-24-010309/07/2025
The combination of the electric drive and the internal combustion engine (ICE) in hybrid electric vehicles (HEV) requires the implementation of an Energy Management Strategy (EMS). The task of the EMS is to split the driving demand between the two energy converters. The design of the EMS in charge-sustaining operation is commonly targeted at the minimization of fuel consumption. For in-vehicle implementation of the EMS, supplementary objectives, such as the electric driving (ED) experience or the driving comfort, influenced by the frequency of state shifts, are considered. Therefore, this work extends the framework for EMS optimization from the fuel-optimal design to multi-objective target spaces. First, the general multi-objective optimal control problem (MOOCP) is formulated. In a next step the central target space for EMS calibration consisting of fuel consumption, ED time and number of ICE starts is considered and the resulting MOOCP is solved using Dynamic Programming (DP). The
Ehrenberg, Bastian, Engbroks, Lukas, Schmiedler, Stefan, Geringer, Bernhard, Hofmann, Peter
Optimum Design and Sizing Approach for a Series-Hybrid Vehicle2025-24-009909/07/2025
The need to reduce pollutant emissions has pushed the automotive industry towards sustainable mobility promoting new technological solutions, among which the use of hybrid powertrains stands out. The development of a hybrid architecture is very complex and demands proper components sizing and the determination of optimized power-split strategies among different power sources, for example: Internal Combustion Engine (ICE), electric generator/motor and batteries. Moreover, the experimental analysis regarding performance and emissions requires that the whole propulsive system must be set up on the test bench, hence, negatively affecting the cost of the entire design phase. In this scenario, an optimum design and sizing approach for a series-hybrid electric vehicle (S-HEV) is proposed aiming at a design cost reduction. The presented procedure relies on numerical modelling of the hybrid powertrain and on the optimization of the fuel consumption and the driving range. The series-hybrid
Lisi, Leonardo, Saponaro, Gianmarco, Episcopo, Domenico, Torresi, Marco, Camporeale, Sergio Mario
DLR Tire and Road Wear Particle Emission Testing Methodology–Collection System Influence and Repeatability Assessments2025-24-009209/07/2025
Tire and road wear particles (TRWP) have emerged as air quality hazardous matters and significant sources of airborne microplastic pollution, contributing to environmental and human health concerns. Regulatory initiatives, such as the Euro 7 standards, emphasize the urgent need for standardized methodologies to quantify TRWP emissions accurately. Despite advancements in measuring tire abrasion rates, critical gaps persist in the characterization of airborne TRWP, particularly regarding the influence of collection system design and influencing parameters on measurement accuracy and repeatability. This study addresses these challenges by designing a controlled methodological framework that aims to minimize the influencing effects and ensure comparability in TRWP emission quantification results. At the German Aerospace Center (DLR) dynamometer testbench in Stuttgart, Germany, a methodical framework was established to ensure the repeatability and comparability of TRWP measurements
Celenlioglu, Melis Seren, Epple, Fabius, Reijrink, Nina, Löber, Manuel, Reiland, Sven, Vecchi, Roberta, Philipps, Franz
Optimal Design of Electric Motors for Automotive Applications2025-24-013209/07/2025
The paper describes how, exploiting AI, it is possible to design electric motors for automotive applications. Both traction motors and motors for auxiliary functions are dealt with. Given the requested performance of the motor (objective functions) and the constraints, the design variables defining the motor are derived by means of a multi-objective programming approach. Usually, tenth of either objective functions or design variables are considered. Aspects related both to electromagnetic and mechanical performance are taken into account, in a multi-physics framework. The issues referring to thermal, structural and noise-vibration-harshness are considered for defining the Pareto-optimal sets both in the design variable domain and in the objective function domain. Such domains can be found by either supervised learning or reinforced learning, two well-known AI algorithms. Basic constraints related to manufacturing are included in the optimization process. A couple of examples are
Guidotti, Giacomo, Barri, Dario, Soresini, Federico, Ballo, Federico, Gobbi, Massimiliano, Di Gerlando, Antonino, Mastinu, Gianpiero
Improve Modeling, Control, and Health Monitoring of an e-Motor Applying an Integrated Flux Sensing Array: Concepts and Design2025-24-012509/07/2025
Knowing the magnetic flux inside an electric machine can provide valuable information, as it allows for monitoring the actual behavior of the motor during operation. This leads to more accurate torque delivery and enables prognostic and state-of-health analyses. By integrating Hall-effect sensors inside an e-motor, it is possible to measure the magnetic flux and gain all the benefits from this information, such as accurate torque, rotor position and speed, and magnets' temperature. This paper describes the design of an e-motor with an integrated flux sensing array (ISA), including all surrounding models and software solutions for efficient motor control, integrating health monitoring and failure prevention. The focus is on the analyses performed to estimate the magnetic flux linkage and determine the optimal sensor placement, the control architectures that can benefit from a more accurate flux estimation, and the design of the e-machine to integrate the flux sensors. The aim is to
Capitanio, Alessandro, Sala, Giada, Esmaeilnia, Ali, Garcia de Madinabeitia, Inigo, Pastore, Andrea, Tranchero, Maurizio, Franceschini, Giovanni, Saur, Michael
Understanding and Qualifying Hydrogen Combustion Related Phenomena for Low-Carbon Mobility2025-24-005709/07/2025
The reduction of the overall greenhouse gas and pollutant emissions from ground vehicles is mandatory to fight against global warming and health issues. Moreover, regarding the increasing demand related to the population growth, the energy requirement for mobility may significantly increase during coming years. Meeting greenhouse gas emission targets is not only about commitment to regulations but also fundamentally about enhancing human well-being. Consequently, the diversification of low-carbon energy sources is of huge interest. The use of Hydrogen (H2) as a sustainable energy source in ground transportation is an alternative or a complementary solution to the full electric vehicles. Hydrogen for mobility can be used in two types of energy converters: The Proton-Exchange Membrane Fuel Cell or the H2 adapted Internal Combustion Engine (H2-ICE). This last has the advantage of its strong maturity with the reuse of existing production infrastructures from conventional ICE and low raw
Laget, Olivier, Bardi, Michele, Quintens, Hugo, Giuffrida, Vincent, Bramoullé, Clément, Sikic, Ivan
Simulation Driven Thermal Optimization of an Innovative Battery System2025-24-013809/07/2025
BATSS project objective is to design a safe, effective and sustainable battery pack. To achieve this, the battery system (BS) will be mechanically, electrically and thermally optimized using cutting edge technology. Consequently, the battery system includes innovative 4695 cylindrical cells and advanced thermal management, carried out with the Miba FLEXCOOLER®. This work focuses on the BS thermal optimization using system simulation tools. First a simplified version of the BS is simulated with all physical phenomena involved in thermal behavior to identify first order parameters. It appears that various BS component and heat transfer can be neglected in comparison with the heat transfer due to cooling system. Then the simulation of the full battery system is conducted under nominal condition. Cooling system appears to be performant as it allows a controlled averaged temperature and very low cell-to-cell temperature variability. Finally, impact of both design and operating parameters is
Chevillard, Stephane, Popp, Hartmut, Galarza, Igor, Petit, Martin
A Novel Mechanical Model Simulating a Pavement Deflection Measuring System for Non-Invasive Pavement Monitoring Based on a Reliability-Based Optimization Algorithm02-18-03-002509/04/2025
This article presents a novel mechanical model for simulating the behavior of pavement deflection measuring systems (PDMS). The accuracy of the model was validated by comparing the acceleration of the new model with the data achieved through experimental tests fusing a deflection measurement system mounted on a Ford F-150 truck. The experimental test for the PDMS is carried out on a random road profile, generated by an inertial profiler, over a 7.4-mile (12 km) loop around a lake near Austin, Texas. Integrating a reliability-based optimization (RBO) algorithm in a PDMS aims to optimize system parameters and reduce vibrations effectively. The PDMS noises and uncertainties make it crucial to use a robust system to ensure the stability of the system. This article presents a robust algorithm for considering the uncertainties of PDMS parameters, including the damping coefficients and spring stiffness of the supporting brackets. Moreover, it considers the variation of system parameters, such
Yarmohammadisatri, Sadegh, Sandu, Corina, Claudel, Christian
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