Browse Topic: Electronic control systems

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ECU Flashing and the Software Defined Vehicle2026-01-0112To be published on 04/07/2026
In recent years, the use of software-defined platforms has become increasingly prevalent. As a result, flashing electronic control units (ECUs) has become an important factor in ensuring efficiency, quality, and compliance in vehicle production. Conventional approaches, such as final end-of-line flashing, are increasingly unsuitable for the growing amounts of data, complex dependencies, mixed physics and protocols, and traceability requirements. This SAE paper presents the current trends and challenges in ECU flashing. It highlights in particular the impact of the exponential growth in software payloads and the necessary migration to offline and parallel workflows. This can only be achieved through closer integration with automated and robot-assisted production, taking into account the requirements of cybersecurity and verifiability. It also addresses the shift toward end-to-end flashing ecosystems, where updates are performed not only on the assembly line, but also in warehouses
Wells, Michael
From Propane to Pi: Affordable AI-Driven Solutions for Sustainable Bus Heating.2026-01-0164To be published on 04/07/2026
The design of an affordably luxurious school bus means improving passenger comfort while greatly decreasing energy usage and emissions. The key consideration is to replace traditional propane heating with an electric heated-seat system and supported by green electricity/energy efficient smart power management. The system is designed from a 24V/48V battery system; to a Smart Energy Cube - a portable dock in power module requiring solar, battery and grid connection. Seat heating is only applied to seats that are occupied. The on-board image processing models (YOLOv5/YOLOv8, OpenCV, TensorFlow Lite) are run on affordable/portable microcomputers capable of detecting the number of occupied and available seats e.g. Raspberry Pi. There is one bottle neck when using the Raspberry Pi in the experiments to validate concept, when using low/medium power frame rates of ~ 1 fps for Raspberry Pi 3; to 7-8 fps with a Raspberry Pi 5. As a baseline, there is still potential for improvement and
Chikkala, Daney Bhargav, Zadeh, Mehrdad, TAN, Teik-Khoon, Ponnam, Jitin, BATTE, JAI RATHAN
Passive Soot Regeneration Observations on a GPF-equipped vehicle for PM exhaust emission control.2026-01-0366To be published on 04/07/2026
The gasoline particulate filter (GPF) will be a common technology adopted by EPA Tier4 emission compliant vehicles, starting as early as model year 2017 in North America. For those Tier-4 compliant gasoline-powered powertrains, their GPF solutions will require that the captured soot can be safely removed through passive oxidation. This clean-out process is driven by occasional fuel-cut events, such as engine motoring, which would provide an excess of oxygen in the exhaust gas flow to the hot, soot-loaded GPF. Here, a study has been conducted where a modern vehicle with a 3L engine displacement was upfitted with appropriately sized GPFs for soot capture in the dual-bank exhaust line. These GPFs were weighed to track their soot-load trends between representative real-world driving routes, where sensor data and ECU parameters were recorded. Thus, characterization of the passive soot regeneration process in the GPF was linked to the preceding exposure of gaseous flow temperatures, oxygen
Craig, Angus, Warkins, Jason
Simulation of Conjugate Heat Transfer using the Lattice Boltzmann Method2026-01-0135To be published on 04/07/2026
Flow simulation with conjugate heat transfer, which involves fluid flow, conduction, and radiation in solid components, is a critical capability that helps engineers design and evaluate cooling systems for heat-generating components such as brakes, powertrains, batteries, and power electronics for both gasoline and electric vehicles. For this study, we utilize PowerFLOW™, featuring its novel native thermal solver, which models both fluid and solid domains within a single model. For the flow domain, we use the Lattice Boltzmann Method with VLES turbulence modeling based on the RNG k-epsilon method. And for the solid domain, the finite volume method with second-order accuracy for thermal conduction and a surface-to-surface radiation for the surfaces. This approach not only leads to a more integrated and streamlined workflow but also enables an accurate modeling of conduction and radiation. In this study, we demonstrate the accuracy of the conjugate heat transfer simulation methodology
Mukutmoni, Devadatta, Shock, Richard, Li, Han, Wanderer, John
Implementation and evaluation of a method to defend in-vehicle networks using SAE J1939-91C to authenticate network messages between multiple ECUs.2026-01-0092To be published on 04/07/2026
The objective of this paper is to understand the effort required to integrate the hardware and software of in-vehicle cybersecurity systems. The in-vehicle cybersecurity method discussed is the SAE J1939-91C, which involves Network formation, Rekeying, and secure Message Exchange between Electronic Control Units (ECUs). The SAE J1939-91C network security protocol operates over a CAN-FD network to perform necessary cryptographic operations and key generation. To evaluate the method, test vectors were created to validate SAE J1939-91C key generations and cryptographic operations on the simulated ECU in-vehicle network system hardware. The evaluation results provide a benchmark for network system performance that can be used in a system test bench to assess compliance with the SAE J1939-91C standard and to test the standard's effectiveness in ambiguous edge cases. In the future, this benchmark could be utilized in "Plugtests" to assign test scores to non-uniform SAE J1939-91C
Zachos, Mark, Medam, Krishna Teja
The Simple Complexity of Reverse Engineering a Vehicle CAN Bus2026-01-0070To be published on 04/07/2026
Automotive Original Equipment Manufacturers (OEMs) closely guard information about their products due to the significant investment in vehicle research and development. However, advancing automotive innovation often requires insights from existing systems to improve safety, efficiency, and performance. The Controller Area Network (CAN) bus remains the industry standard for communication between electronic control units (ECUs), yet CAN message specifications are typically proprietary and undocumented. This paper presents a case study involving the reverse engineering of CAN messages from a 2025 Toyota Grand Highlander powertrain. By capturing and analyzing communication between a diagnostics tester and the vehicle’s ECUs and replicating the communication, substituting A CAN case and software in place of a diagnostics tester, we were able to reverse engineer the vehicle's CAN bus, demonstrating a practical methodology for decoding and interpreting CAN traffic without prior access to
Bolarinwa, Emmanuel, Peters, Diane
Integration and Validation of Adaptive Cruise Control Algorithm Across Different Modes2026-01-0076To be published on 04/07/2026
This paper presents the integration and validation of Adaptive Cruise Control (ACC) algorithms on a student-team-developed vehicle as part of the U.S. Department of Energy EcoCAR EV Challenge. The competition provided each team with a 2023 Cadillac Lyriq, which was modified to an all-wheel-drive configuration and re-architected to support the development of Level 3 autonomous features including Adaptive Cruise Control (ACC), Automatic Intersection Navigation (AIN), Lane Centering Control, and Automatic Parking. The major contribution of this work is the development of ACC with Vehicle-to-Infrastructure (V2I) integration, highlighting the end-to-end implementation of the ACC algorithm and its interaction with key actuation systems in the modified vehicle architecture. In the team’s approach, the ACC algorithm encompassed multiple applications: conventional cruise control to maintain speed, adaptive cruise control to respond to a lead vehicle, and initial deceleration handling for
Gupta, Ishika, Midlam-Mohler, Shawn, Estrada, Tyler, Tambolkar, Pooja
Innovative Smart Switch Architecture Catering to 12 Volts to 48 Volts Battery Bus Requirements2026-01-0064To be published on 04/07/2026
Electronics is rapidly entering all automotive subsystems, performing control and monitoring tasks apart from making the entire vehicle intelligent.. Interface with the external automotive ecosystem needs careful attention during the system design. It defines how seamlessly the electronic unit interacts with the rest of the vehicle. It needs to do so in an effective manner without compromising on cost and other automotive application constraints. This paper focuses on the “ smart switch building block” that forms the heart of an automotive output interface echo system. Its importance stems from the fact that a smart switch is an indispensable building block for any electronic control system driving external loads. As various novel electrical and electronics architectures are entering various vehicle segments need for a single reusable solution that will cater to 12 Volts to 48 Volts battery buses is increasingly being felt. However, no prevalent solution meets this requirement. Even
Vaidya, Vishwas Manohar
Methods of Highly Repeatable Lubricant Testing for Electric Vehicles: Universal Motor Control and Statistical Test-Variation Analysis2026-01-0421To be published on 04/07/2026
This paper describes a systematic approach to evaluate lubricants for hybrid and electric vehicles (xEVs) that can detect impacts on efficiency as low as 0.1 percentage points. Two testing methods were developed to evaluate lubricants' efficiency effects: (1) on a complete vehicle (using the manufacturer's hardware and motor control) and (2) on a standalone drive unit (using custom power electronics and control). A Monte Carlo simulation was used to analyze the resulting data to determine the detection limits of the vehicle test method. To evaluate the effectiveness of the test stands and the data-analysis method, a Tesla Model 3 electric drive unit and a Chevrolet Bolt battery electric vehicle (BEV) were characterized for system efficiency. For the Bolt mounted on a hub driven chassis dynamometer, this method is capable of detecting a change in the drive unit's electromechanical efficiency between baseline and candidate fluids of <0.4 percentage point (pp) with 95% confidence at most
Luo, Yilun, Gross, Michael, Kostan, Travis
Lightweight Bubble Sheet Panel To Reduce Inverter Noise and Vibration for Electric Vehicles2026-01-0442To be published on 04/07/2026
Inverters are typically integrated into electric drive units for electric vehicles (EVs) to reduce packaging size and cost. However, coupled vibrations from the electric motor and gears are transmitted to the inverter, which, due to its large radiative panel, becomes a dominant noise source. Metal panels are required for electromagnetic interference (EMI) compliance, yet these covers usually lack sufficient stiffness or damping for noise control. Adding ribs and applying damping treatments results in excessive mass, cost, and packaging challenges. A new, patented bubble sheet panel design has been developed to enhance the structural strength and damping of the inverter while significantly reducing its mass. A thin sheet of aluminum or magnesium is welded onto the cover in an optimized pattern that enhances stiffness and damping performance while accommodating packaging requirements. The welding pattern can include logos or artistic designs to improve the panel’s appearance. The metal
He, Song, Bobel, Andrew, Naismith, Gregory, Yi, Wenwen, Patruni, Pavan Kumar
Noninvasive Loss Breakdown of an Electric Drive Unit2026-01-0448To be published on 04/07/2026
Techniques exist to precisely measure the electromechanical efficiency in an electric drive unit (EDU, defined here as the combined motor and geartrain). While total drive unit efficiency is an important metric, it does not quantify the different loss sources in the EDU. Due to the tight packaging in production EDUs, it’s impractical to mount a torque transducer between the electric machine and gearbox to separate the losses from these components. Additionally, this approach does not separate the winding, core, and mechanical losses present in the electric machine. In this work, we developed a noninvasive approach to distinguish winding, core, and mechanical losses for EDUs containing synchronous electric machines. To separate the effects of these losses, mechanical output power was held constant at several test points while varying the stator’s current amplitude and angle. By maintaining the mechanical power at a constant value and varying the stator current, the core and winding
Woods, Tyler, Gross, Michael, Drallmeier, Joseph
ZSI Impedance Source inverter integrated XFC ( Extreme fast charging ) for Electric Vehicle2026-01-0438To be published on 04/07/2026
This paper presents the application of an inverter named Improved Enhanced-Boost Quasi-Z-Source Inverter in AC-connected extreme fast charging (XFC) stations for electric vehicles (EVs), with the goal of reducing conversion stages and enhancing system efficiency. Currently, XFC stations are a focus of development due to their potential to match the refueling time of traditional fuel stations. AC-connected systems offer greater reliability for XFCs compared to DC-connected systems as they tend to have better fault tolerance and are less sensitive to power fluctuations. However, this increased reliability comes at the cost of greater complexity due to the need for multiple conversion stages—such as AC to DC and DC to the required voltage—making the overall system more intricate and potentially less efficient than DC-connected counterparts. The Improved Enhanced-Boost Quasi-Z-Source Inverter addresses this challenge by consolidating the DC-DC and DC-AC conversion stages into a single
SAILESH, DILEEP, Sanaboyina, Prudhvi, Chhagar, Rohnitsingh, Satyanarayan, Swapna
An Efficient Approach to Key Negotiation in an Automotive Environment2026-01-0087To be published on 04/07/2026
Negotiating Keys for applications such as message authentication within a vehicle presents many problems as, in designing the algorithm; the algorithm must be able to be utilized by small, fixed-point processors. In addition, if there is a desire to do this algorithm in the manufacturing environment, there are severe time constraints placed on how long this algorithm can take, as there are strict station time requirements, which are expensive to change, and any time utilized in the plant can negatively affect vehicle throughput. Additionally, negotiating these keys between many ECUs can greatly increase the time required to negotiate a common key using standard multi-party Diffie-Hellman. Timing would also be an issue in the case of using pair-wise Diffie-Hellman for encryption and distribution of keys utilizing a key master. To solve these problems in multi-party key negotiation, we have utilized the Elliptic Curve variation of the Burmester-Desmedt (ECBD) algorithm. ECBD is
Van Dam, Theo, Mazzara, Bill
Low-Cost Packaging of SiC Power Modules for EV Traction Inverters2026-01-0119To be published on 04/07/2026
The increasing demand for efficient and cost-effective power electronics in electric vehicle (EV) traction inverters necessitates innovative power module designs. This paper presents a novel SiC power module packaging focused on low-cost fabrication and assembly.. The proposed design features a simplified sandwich structure consisting of a lead frame, the innovative epoxy composite deposited on a high-performance cold plate. The novel epoxy composite eliminates the critical solder connection typically found between the DBC/AMB and the cold plate. This significantly streamlines the thermal path by reducing the number of material layers and interfaces between the SiC chip and the coolant. As a result, the integrated stack-up achieves significantly low junction-to-coolant thermal resistance (Rth) while delivering substantial cost savings related to power module module packaging. This work provides the details on the power module prototype fabrication steps and functionality including the
Chen, Yu, Mena-Garcia, Javier, Chen, Hao, Xiao, Kewei, Gupta, Man Prakash, Degner, Michael
CAE-based Electro-Thermal Characterization and Design Optimization of Automotive Inverter Busbars2026-01-0642To be published on 04/07/2026
High power density demands in automotive inverters need precise thermal management to ensure efficiency, reliability and extended component lifetime. This paper presents a systematic, integrated electro-thermal workflow utilizing Computer-Aided Engineering (CAE) tools to characterize and optimize internal inverter components by directly linking electrical performance to thermal behavior. The methodology comprises three main steps: first, detailed frequency-dependent electrical parameters (RLCG, Z, S) and current density maps are extracted using computational calculations by ANSYS HFSS and ANSYS Q3D Extractor. Second, these parameters inform comprehensive power loss calculations (conduction, dielectric, switching), which are then mapped onto detailed 3D thermal fields using Computational Fluid Dynamics (CFD) through ANSYS Icepak. Finally, the results are analyzed to identify critical components and inform targeted design modifications. The workflow's effectiveness is demonstrated
Oliveira, Felipe, Aguiar, Cláudio, Justino, Marco, Tarrago, Vinicius, Almeida, Oberti
Advanced Integrated Chassis Control for Improved Energy Efficiency and Driving Experience in Electric Vehicle Applications2026-01-0643To be published on 04/07/2026
Complexity of modern ground vehicles grows constantly, since car manufacturers want to provide functionality, while customers are expecting innovation and recent technologies to be integrated into the latest models released to the market. Recent advances in hard- and software opened the gates for new means of vehicle control and operation. Especially the transition to electric propulsion systems and decoupled chassis actuators offer completely new opportunities of dynamics control and manipulation. This paper presents an approach for integrated chassis and vehicle motion control in (battery) electric vehicle applications by using new and innovative controllers as well as mechatronic chassis systems. In several experiments on public roads with a fully instrumented vehicle demonstrator, that features in-wheel based rear-wheel drive and a hybrid brake-by-wire-system, the proposed control is tested under real environmental and traffic conditions with respect to aspects like energy
Heydrich, Marius, Mitsching, Thomas, Ivanov, Valentin
Propulsion System Design Considerations for HEV versus EV Applications2026-01-0641To be published on 04/07/2026
The design and development of EVs and HEVs has become a growing issue recently due to concerns about pollution and dependence on non-renewable fossil fuels. Accordingly, General Motors (GM) has an evolving vehicle electrification plan over the past several decades and into the future to deliver low-cost and efficient EVs and HEVs. Propulsion system requirements for the applications of EV and HEVs are quite different and therefore, the design principles and directions are also distinct between these cases. From micro-hybrid and full plug-in hybrid applications to full EV applications, design requirements, strategies and outcomes can widely vary. Continuous and peak duty are substantially different depending on the application of the vehicle. Motor operational duty is significantly higher for EV compared to the electric motor of a hybrid electric vehicle. Motor torque, power and efficiency requirements are also higher for EV motors, which greatly influences the choice of motor type and
Momen, Faizul, Jensen, William, Das, Shuvajit, Chowdhury, Mazharul, Alam, Khorshed, Anwar, Mohammad, Reinhart, Timothy
Look-ahead Information based Predictive Cruise Controller for Energy Efficient Powertrain Operation of Heavy-Duty Electric Trucks2026-01-0039To be published on 04/07/2026
Heavy-duty electric trucks represent a growing innovation in the transport and logistics sector, aiming to reduce emissions and reliance on fossil fuels. A major challenge with battery electric trucks is the long recharging time which takes significantly longer than refueling conventional diesel trucks. This limitation highlights the importance of optimizing powertrain operations to reduce energy losses and maximize efficiency. One effective approach is implementing optimal speed control through a predictive cruise controller. By anticipating road conditions, traffic, and elevation changes, the predictive cruise controller can adjust the truck’s speed in real time to minimize energy consumption, enhancing the range and reducing the need for frequent charging. Many problem formulations for electric trucks focus primarily on minimizing the energy required at the wheels, often overlooking the impact of powertrain efficiencies. This simplification neglects critical factors such as the
Safder, Ahmad Hussain, Villani, Manfredi, Khuntia, Satvik, Nelson, James, Meijer, Maarten, Ahmed, Qadeer
Accelerating Electrification Through Modular Propulsion: GM’s Strategy for BEV and BET Platforms2026-01-0410To be published on 04/07/2026
General Motors continues to advance its electrification strategy through the development of scalable Battery Electric Vehicle (BEV) and Battery Electric Truck (BET) platforms. This paper highlights GM’s latest BEV and BET products that leverage shared Drive Unit (DU), Rechargeable Energy Storage System (RESS), and integrated power electronic (IPE) components across multiple vehicle programs. By adopting a modular and commonized propulsion architecture, GM achieves significant benefits in manufacturing efficiency, cost optimization, and product flexibility. The shared DU, RESS, and IPE components are engineered to meet diverse performance requirements while maintaining high standards of energy efficiency, thermal management, and durability. This approach enables rapid deployment of electrified solutions across various segments, from passenger vehicles to full-size trucks, without compromising on capability or customer experience. The paper outlines the technical rationale behind
Liu, Jinming, Sevel, Kris, Anwar, Mohammad, Oury, Andrew, Welchko, Brian, Gagas, Brent
Comparative Analysis of Flux Linkage Characterization Methods for Automotive Permanent Magnet Traction Motors: A Critical Review and Performance Evaluation Framework2026-01-0441To be published on 04/07/2026
Accurate flux linkage characterization is essential for the design, control, performance and efficiency optimization of permanent magnet (PM) traction motors in automotive applications. Precise knowledge of flux linkage across varying load, speed, and temperature conditions directly impacts torque production, field-weakening capability, overall drive system efficiency and torque security. This paper presents a critical review and classification of flux-linkage characterization methods, encompassing offline laboratory mapping, standstill signal injection, self-commissioning inverter-only routines, and online real-time estimation. Each method exhibits distinct trade-offs in terms of accuracy, robustness to inverter nonlinearities, temperature adaptability, cost, and scalability for production and in-vehicle use. With the increasing complexity of automotive electrified traction systems, understanding these trade-offs is crucial for optimal motor design and control. To enable systematic
Khan, Ahmad Arshan, Haddad, Reemon, Kim, Jay, Hermann, Justin, Mohamadian, Mustafa
Innovation Powered by High-Fidelity Multiphysics Modeling: A Holistic System Optimization of BorgWarner’s Next Generation Integrated Drive Modules2026-01-0497To be published on 04/07/2026
In the stringent market of BEV, the development of integrated Drive Modules (iDM) fitting to environmental and customer needs is mandatory. It is important to extract the best from the less. To achieve those goals, a deep insight of complex multiphysics phenomena occurring in an iDM has been achieved by accurate and validated models. This engineering methodology is applied through the development of BorgWarner products, comprising non-exhaustively iDM 180-HF, Externally Excited Synchronous Machine and Multi-Level Inverter. The paper will review the methodology development for deeper understanding involving in-house technical excellence and complemented by strategic partnerships with academic institutions and start-ups. It will present the approach of integrating advanced multiphysics models with high-quality experimental validations, specifically on loss evaluation on electrical machines and inverters. Complex models involving multiphysics such as thermal/fluid coupling or electric
Leblay PhD, Arnaud, Bossi, Adrien, Bourniche, Eric, DAVID, Pascal, Nanjundaswamy, Harsha
Engine Park Angle Control via Electric Machine Under Varying Deceleration Constraints2026-01-0445To be published on 04/07/2026
Accurate control of the engine park angle during Autostop in hybrid vehicles is critical for enabling rapid and smooth Autostarts, reducing start-up vibrations, and enhancing overall driving comfort. However, in real-world scenarios, the available torque for engine positioning is often limited by competing driver torque demands, battery discharge constraints, and the state of charge (SoC). Under these conditions, conventional position-speed control strategies frequently fail to achieve the desired precision. This paper introduces an adaptive control strategy for the electric machine (EM) that drives the internal combustion engine, ensuring precise alignment of the crankshaft at a predefined angle to optimize restart conditions. Upon receiving an engine shutdown request, the proposed controller computes an adaptive deceleration profile that respects the EM’s torque and deceleration limits while guiding the crankshaft toward the target park position. The core of the approach lies in
Purohit, Punit, ACHIR, Ali, Bhakare, Allwyn
CAN-Based Model Interface Standardization and Model Integration Framework2026-01-0081To be published on 04/07/2026
With the rapid increase in the complexity of automotive electronic control systems and advancements in software-defined vehicles, the efficient integration of diverse simulation models has become a critical requirement in vehicle development. Virtual testing (VT) and scenario-based validation are now considered essential for safety certification and regulatory compliance. However, current modeling practices are often hampered by inconsistencies in signal definitions, repetitive manual processes, and the inherent complexity of integrating various development environments and tools, which can lead to time-consuming workflows and an increased risk of errors. Engineers typically match controller and plant model signals by hand or rely on limited automation solutions that may lack scalability and robustness for large-scale, collaborative simulation environments. In this study, we propose a CAN-based integration framework that incorporates a standardized interface library and a Python-based
Lee, Bokyung, Lee, Jin Hwa, Kim, Donghwan, Han, Woojin, Cho, Yoonho, Kim, Wonho
Control Strategy and Dynamic Characteristics of a Hydrogen Opposed-Cylinder Free-Piston Engine Generator2026-01-5017To be published on 02/23/2026
Free-piston engine generator (FPEG), as a novel energy conversion device, has the advantages of good fuel adaptability and high energy utilization. Combustion variation between cycles poses a significant challenge to the running control of an FPEG. A hierarchical control strategy, including motion, combustion, and generation power controllers, is designed in this paper to achieve the stable and efficient running of a hydrogen-fueled opposed-cylinder FPEG prototype. Piston motion is controlled by adjusting the generation current, which is adjusted through iterative learning using piston displacement feedback and adaptive control using piston velocity feedback. Generating power is regulated by controlling the throttle opening angle, which is adjusted through iterative learning. A multidisciplinary joint mathematical model is developed to simulate the dynamic characteristics and verify the control strategy. The simulation results reveals that the dead center position accuracy can be
Wang, Jiesheng, Liu, Liang, Xu, Zhaoping
Airport Electrical Power System HarmonicsAIR5387 (Current)2/17/2026
This SAE Aerospace Information Report (AIR) is intended to cover all airport 50 or 60 Hz electrical systems as well as all electrical utilization equipment that is attached to those systems.
AGE-3 Aircraft Ground Support Equipment Committee
In-Service Reliability Data of Continuously Active Ball Screw and Geared Flight Control Actuation SystemsAIR5713A (Current)2/13/2026
This Aerospace Information Report (AIR) has been written to provide in-service reliability data of continuously active ball screw and geared flight control actuation systems.
A-6B3 Electro-Mechanical Actuation Committee
Development of Smart Climate Control with Multiple Level Auto Calibrations2026-28-00082/12/2026
Electric Vehicles (EVs) are rapidly transforming the automotive landscape, offering a cleaner and more sustainable alternative to internal combustion engine vehicles. As EV adoption grows, optimizing energy consumption becomes critical to enhancing vehicle efficiency and extending driving range. One of the most significant auxiliary loads in EVs is the climate control system, commonly referred to as HVAC (Heating, Ventilation, and Air Conditioning). HVAC systems can consume a substantial portion of the battery's energy—especially under extreme weather conditions—leading to a noticeable reduction in vehicle range. This energy demand poses a challenge for EV manufacturers and users alike, as range anxiety remains a key barrier to widespread EV acceptance. Consequently, developing intelligent climate control strategies is essential to minimize HVAC power consumption without compromising passenger comfort. These strategies may include predictive thermal management, cabin pre-conditioning
Mulamalla, Sarveshwar Reddy, SV, Master Eniyan, M, Nisshok, Anugu, Anil, E A, Muhammed, Guturu, Sravankumar
Automotive Ethernet Proxy-Based Security Architecture in Vehicle Computers2026-28-01212/12/2026
Modern vehicles require sophisticated, secure communication systems to handle the growing complexity of automotive technology. As in-vehicle networks become more integrated with external wireless services, they face increasing cybersecurity vulnerabilities. This paper introduces a specialized Proxy based security architecture designed specifically for Internet Protocol (IP) based communication within vehicles. The framework utilizes proxy servers as security gatekeepers that mediate data exchanges between Electronic Control Units (ECUs) and outside networks. At its foundation, this architecture implements comprehensive traffic management capabilities including filtering, validation, and encryption to ensure only legitimate data traverses the vehicle's internal systems. By embedding proxies within the automotive middleware layer, the framework enables advanced protective measures such as intrusion detection systems, granular access controls, and protected over-the-air (OTA) update
M, Arvind, Praneetha, Appana Durga, Remalli, Ravi Teja
Common Mode Voltage Reduction in Quasi-Z Source Inverter for Electric Vehicle Applications Using MBPWM Technique2026-28-01022/12/2026
Unlike traditional voltage source or current source inverters, ZSI/qZSI can boost and invert DC power in a single stage, making them attractive for applications like EVs where battery voltage may vary. Common mode Voltage (CMV) is the voltage between the neutral point of the motor and ground. High CMV in motor drive systems can cause: Higher leakage currents, Electromagnetic interference (EMI), Insulation stress, bearing currents, leading to premature motor failure. Reducing CMV is essential for reliable and safe EV operation. Pulse-width modulation (PWM) is used to control the QZSI output voltage. The QZSI offers several advantages over traditional inverters, including improved efficiency, reduced cost, and increased reliability. The proposed system is designed to reduce the CMV through a combination of passive LC filtering and shoot-through (ST) modulation techniques. The LC filter is designed to attenuate high-frequency components of the CMV while the ST modulation is used to
N, Kalaiarasi, R, Rajarajeswari, D, Anitha
Aircraft Lightning ZoneARP5414B (Current)2/6/2026
This SAE Aerospace Recommended Practice (ARP) defines lightning strike zones and provides guidelines for locating them on particular aircraft, together with examples. The zone definitions and location guidelines described herein are applicable to Parts 23, 25, 27, and 29 aircraft. The zone location guidelines and examples are representative of in-flight lightning exposures.
AE-2 Lightning Committee
PRODUCT BRIEFS26AUTP02_172/1/2026
Multiphysics Analysis of Heat Sink Designs for Efficient Thermal Performance in Power Electronics Systems2026-26-04461/16/2026
The thermal management capability of power electronic (PE) systems has a critical impact on the performance and efficiency of electric, fuel cell, or hybrid vehicles. Bus bars, high resistance sensor devices, semiconductor switches, power capacitors are the primary components, which make a major contribution in total heat generation in electrical drive unit. As PE packaging sizes are projected to become smaller, the challenge of managing increased heat dissipation becomes more critical. This paper numerically compares six different cooling strategies to determine the best possible thermal management scenario. A coupled physics co-simulation framework is used to analyze a 35W motor inverter integrated with water cooled heat sink. A multi-physics finite element model, integrating fluid, electrical, and thermal fields, is employed to analyze heat generation within the PE system and the associated cooling mechanisms. The power losses from the inverter system are dynamically computed in 1-D
Singh, Praveen Kumar, Natarajan, Nesamani, Murali, Sariki
Driving Performance Impact Analysis on EV Components for Efficient, Safe, and Intelligent Mobility2026-26-06551/16/2026
Electric vehicles (EVs) are the cornerstone of sustainable transportation, but their performance and component longevity are heavily influenced by driving behaviors. This study proposes a comprehensive analytical framework to assess how different driving styles affect the operational health of key EV components such as the battery pack, motor, and DC-DC converter. Various driving styles such as aggressive, moderate, and economical are discriminated against using dynamic vehicle operation signatures including acceleration and braking intensity, turning profiles, and load variations. These behavioral patterns are reflected in the electrical responses, namely current and voltage waveforms across power electronic systems. By analyzing these electrical signatures, a range of KPIs can be estimated for each component, offering insights into their operational stress and degradation trends. Experimental analysis using real-time EV datasets validates the framework’s ability to predict and
Deole, Kaushik, Kumar, Pankaj, Hivarkar, Umesh
Achieving Robust Sensing Performance for Six-Airbag Systems: Design Approaches and Validation Techniques for Side Sensing2026-26-00301/16/2026
The proposal of GSR 16(E) in India promotes six airbags in passenger vehicles, aiming to enhance occupant safety. In parallel, the new Bharat New Car Assessment Program (BNCAP) outlines performance protocols that demand robust airbag deployment strategies to achieve a five-star safety rating. One of the critical challenges in meeting both regulatory and consumer safety expectations is the optimal packaging of the airbag Electronic Control Unit (ECU) and its associated impact sensors. These must perform reliably across regulatory tests, BNCAP protocols, and real-world accident scenarios. The location of side acceleration ‘g’ side impact sensors—whether mounted on the side sill, B-pillar, C-pillar, or door structures—is pivotal to achieving consistent and timely side airbag deployment. These sensors must also demonstrate immunity to false triggers or missed events in both static and dynamic misuse and abuse conditions. Ensuring robust sensor performance under these varied conditions is
Kudale, Shailesh, Rao, Guruprakash, wayal, Virendra, Goswami, Tarun
Proactive AI-Enhanced Cybersecurity for Next-Gen Automotive Infotainment ECU2026-26-06191/16/2026
With the rapid advancement of connected vehicle technologies, infotainment Electronic Control Units (ECUs) have become central to user interaction and connectivity within modern vehicles. However, this enhanced functionality has introduced new vulnerabilities to cyberattacks. This paper explores the application of Artificial Intelligence (AI) in enhancing the cybersecurity framework of infotainment ECUs. The study introduces AI-powered modules for threat detection and response, presents an integrated architecture, and validates performance through simulation using MATLAB, CANoe, and NS-3. This approach addresses real-time intrusion detection, anomaly analysis, and voice command security. Key benefits include zero-day exploit resistance, scalability, and continuous protection via OTA updates. The paper references real-world automotive cyberattack cases such as OTA vulnerability patches, Connected Drive exploits, and Uconnect hack, emphasizing the critical need for AI-enabled proactive
More, Shweta, Kulkarni, Shraddha, Kumar, Priyanshu, Ghanwat, Hemant, Joshi, Vivek
Accelerating Sunroof System Development with Modular Hardware-in-the-Loop Testing2026-26-05191/16/2026
This paper presents a novel Hardware-in-the-Loop (HiL) testing framework for validating panoramic Sunroof systems independent of infotainment module availability. The increasing complexity of modern automotive features—such as rain-sensing auto-close, global closure, and voice-command operation—has rendered traditional vehicle-based validation methods inefficient, resource-intensive, and late in the development cycle. To overcome these challenges, a real-time HiL system was developed using the Real time simulation, integrated with Simulink-based models for simulation, control, and fault injection. Unlike prior approaches that depend on complete vehicle integration, this methodology enables early-stage testing of Sunroof ECU behavior across open, close, tilt, and shade operations, even under multi-source input conflicts and fault conditions. Key innovations include the emulation of real-world conditions such as simultaneous voice and manual commands, sensor faults, and environmental
Ghanwat, Hemant, Lad, Aniket Suryakant, Joshi, Vivek, More, Shweta
Multi-Physics Simulation and Reliability Analysis of Onboard EV Charger2026-26-04991/16/2026
The rapid advancement of electric vehicle (EV) technology has created a demand for reliable and Thermal - efficient electronic components for power electronics and control systems on printed circuit boards (PCBs). The research looks at the overall simulation and study of a PCB for Electric Vehicles, including how it handles heat, stress, and reliability in real working conditions like considering casing (Heat Sink) in which PCB is held, into the simulation. We have used numerical based methods (reliability), Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) methods to simulate heat performance looking at steady-state and changing load profiles common in EV powertrains. We ran structural and thermal simulations to check the PCB's toughness against heat expansion and shaking loads often seen in cars. We also did a reliability check looking at heat cycling life for PCB components, and possible ways it could break to guess long-term toughness. The results show critical
Kanbarkar, Suraj Omana, Deore, Uday, Patil, Nishikant, Nayak, Shibabrata
Resilient Design Strategies for Wireless Charger ECUs: A Proactive Threat Analysis and Risk Assessment Framework for Ensuring Cybersecurity in EV Charging Ecosystems2026-26-01731/16/2026
The proliferation of wireless charging technology in electric vehicles (EVs) introduces novel cybersecurity challenges that require comprehensive threat analysis and resilient design strategies. This paper presents a proactive framework for assessing and mitigating cybersecurity risks in wireless charger Electronic Control Units (ECUs), addressing the unique vulnerabilities inherent in electromagnetic power transfer systems. Through systematic threat modeling, vulnerability assessment, and the development of defense-in-depth strategies, this research establishes design principles for creating robust wireless charging ecosystems resistant to cyber threats. The proposed framework integrates hardware security modules, encrypted communication protocols, and adaptive threat detection mechanisms to ensure operational integrity while maintaining charging efficiency. Experimental validation demonstrates the effectiveness of the proposed security measures in preventing unauthorized access, data
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
Integrated Powertrain Domain Controller Using Wide Band Gap Devices for EV Applications2026-26-00551/16/2026
The rapid evolution of electric vehicles (EVs) has amplified the demand for highly integrated, efficient, and intelligent powertrain architectures. In the current automotive landscape, EV powertrain systems are often composed of discrete ECUs such as the OBC, MCU, DC-DC Converter, PDU, and VCU, each operating in isolation. This fragmented approach adds wiring harness complexity, control latency, system inefficiency, and inflates costs making it harder for OEMs to scale operations, lower expenses, and accelerate time-to-market. The technical gap lies in the absence of a centralized intelligence capable of seamlessly managing and synchronizing the five key powertrain aggregates: OBC, MCU, DC-DC, PDU, and VCU under a unified software and hardware platform. This fragmentation leads to redundancy in computation, increased BOM cost, and challenges in system diagnostics, leading to sub-optimal vehicle performance. This paper addresses the core issue of fragmented control architectures in EV
Kumar, Mayank, Deosarkar, Pankaj, Inamdar, Sumer, Tayade, Nikhil
Achieving Full ASIL-B Level Functional Safety (FuSa) for Automotive Clusters2026-26-00081/16/2026
Integrating advanced technologies into modern vehicles has led to an increasing focus on Functional Safety (FuSa), especially for the Automotive Integrated Cluster Module (ICM) to ensure the safety of the driver and passengers. This paper highlights the need to bring certain ICM components under an Automotive Safety Integrity Level B (ASIL-B) context using Classic AUTOSAR. This paper discusses the challenges faced and the solutions implemented for achieving compliance with ISO 26262 standards along with the Classic AUTOSAR framework. We are proposing a standardized and structured methodology for the design of the components in compliance with the key safety principles, including Freedom from Interference (FFI), execution under privileged levels, and integrity verification, particularly by adopting Classic AUTOSAR frameworks. This paper also presents the Functional Safety (FuSa) goals for these components and also extend to their configuration management and updating strategies within
Singh, Iqbal, Kumar, Praveen
Electric Vehicle Battery’s Testing Challenges in Era of Software Defined Vehicle2026-26-01591/16/2026
In era of Software Defined Vehicle (SDV), the whole ecosystem of automobile will be impacted. So, it is going to through several challenges for testing activities. In electric vehicle, most critical component is traction battery, which is controlled and operated through battery management system (BMS). BMS is an electronic system, where is going to function as per software of BMS. And in SDV, software is a key element, which is continuously keep on updating on regular basis. So, it means some of BMS functionalities, features or performance may be also altered on each time on software update, which may impact battery’s operating condition, if some scenario is not evaluated during earlier testing then there are it may bring battery out of safe operating area, which may significant impact battery safety, performance or cycle-life. In this paper, we are exploring that different testing requirements for EV Batteries, which may be part of testing practices under era of SDV. Here we will
Bhateshvar, Yogesh Krishan, Mulay, Abhijit B
AI Based Models as Virtual Sensors to Replace Real Sensors2026-26-06711/16/2026
Artificial Intelligence and Machine learning models have a large scope and application in Automotive embedded systems. These models are used in the automotive world for various applications like calibration, simulation, predictions, etc. These models are generally very accurate and play the role of a virtual sensor. However, the AI/ML models are resource intensive which makes them difficult to execute on largely optimized automotive embedded systems. The models also need to follow safety standards like ASIL-D. The current work involves creating a Global DoE with ETAS ASCMO to generate data from a 125cc single to create AI/ML model for the engine outputs like Torque, T3, Mid-cat temperatures etc. The created models were validated across the operating space of the engine and found to have good accuracies. With ETAS Embedded AI Coder, the torque and T3 prediction AI models were converted to embedded code which can be easily used as a virtual sensor in real time. Using these AI models
Chouhan, Vineet Singh, Bulandani, Saurabh, Kumar, Alok, Varsha, Anuroopa, P R, Renjith
Cross-ICA Trust Mechanism in Automotive Cybersecurity2026-26-06151/16/2026
With the increasing complexity and connectivity in modern vehicles, cybersecurity has become an indispensable technology. In the era of Software-Defined Vehicles (SDVs) and Ethernet-based architectures, robust authentication between Electronic Control Units (ECUs) is critical to establish a trust. Further, the cloud connected ECUs must perform authentication with backend servers. These authentication requirements often demand multiple certificates to be provisioned within a vehicle, ensuring secure communication between various combinations of ECUs. As a result, a single ECU may end up storing multiple certificates, each serving a specific purpose. This work proposes a method to limit the number of certificates required in a given ECU without compromising security. We introduce a Cross-Intermediate Certificate Authority (Cross-ICA) Trust Architecture, which enables the use of a single certificate per ECU for inter-ECU communication as well as backend server authentication. In this
Venugopal, Vaisakh, Goyal, Yogendra, Raja J, Solomon, Rai, Ajay, Rath, Sowjanya
Robust Validation of Rotary Switch with TFT Display in Hardware in Loop Simulation2026-26-05401/16/2026
Modern automotive systems are increasingly integrating advanced human-machine interfaces, including TFT displays, to enhance driver experience and functionality. Ensuring the reliability of these systems under diverse operating conditions is critical, especially given their role in vehicle control. This paper presents a Hardware-in-the-Loop (HIL) testing methodology for validation of rotary switch with TFT display. The HIL setup simulates real-world vehicle conditions, including CAN communication, power fluctuations and user interactions, enabling early detection of potential failure modes such as display flickering or communication loss. The results demonstrate improved robustness and reliability of the gear selection switch, supporting its deployment across multiple vehicle platforms.
Bhuyan, Anurag, Jahagirdar, Shweta, Khandekar, Dhiraj
Dynamic Diagnostic Controller Architecture for Scalable and Adaptive Zonal Based Vehicle Platforms2026-26-06891/16/2026
The rapid evolution of in-vehicle electronic systems toward zonal based architectures introduces a new layer of complexity in automotive diagnostics. Traditional architectures, built on Controller Area Network (CAN) and Local Interconnect Network (LIN) protocols, operate on a uniform Real-Time Operating System (RTOS), enabling simplified and consistent diagnostic workflows across Electronic Control Units (ECUs). However, next-generation platforms must accommodate diverse communication protocols (e.g., CAN, LIN, DoIP, SOME/IP) and heterogeneous operating systems (e.g., RTOS, Linux, QNX), resulting in fragmented and inflexible diagnostic processes. This paper presents a Diagnostic controller that addresses these challenges by enabling unified, scalable, and adaptive diagnostic capabilities across modern vehicle platforms. The proposed system consolidates protocol handling at the application level, abstracts diagnostic complexities, and allows cross-platform communication through
Mukherjee, Soumyadeep, Raman, Kothanda
Automotive Cybersecurity Measures in ECU Production2026-26-06281/16/2026
Modern vehicles use a network of Electronic Control Units (ECUs) that transmit over thousands of signals. The production of these ECUs is fraught with cybersecurity challenges that can lead to significant vulnerabilities, which pose risks not only to the suppliers but also to Original Equipment Manufacturers (OEMs) and end users. The automotive industry increasingly relies on sophisticated electronic systems but there is a lack of standardized approach to ensure implementation of robust cybersecurity measures during ECU production. It is imperative to establish effective safeguards against potential threats to ensure vehicle and passenger safety. This paper proposes a comprehensive approach to enhancing cybersecurity in ECU production. Key measures include the activation of cybersecurity protections in production units, secure flashing at plant and memory upload process, effective plant password generation, and securing the debug interface to prevent unauthorized access. By
Kulanthaisamy, Nagarajan, M S, Tejaswini, Sankar, Ganesh
Unique Methodology to Cluster and Reuse the “Hazard Analysis and Risk Assessment” for Different Electrical/Electronic Systems of an Automobile2026-26-00041/16/2026
Modern automotive systems are becoming increasingly complex, comprising tightly integrated hardware and software components with varying safety implications. As the demand for ISO 26262 compliance grows, performing efficient and consistent Hazard Analysis and Risk Assessment (HARA) across these layers presents both methodological and practical challenges. Traditional approaches often involve performing HARA for an item (where item maybe a system or a combination of systems), which can lead to update of HARA for every new feature addition in an item, which in turn may lead to analysis of same functions in multiple HARAs leading to inconsistent risk categorization, redundancy, or even conflicting safety goals. Therefore, this paper proposes a unique HARA methodology which consolidates the list of functions from various systems and performs the HARA for the grouped functions (hereby referred to as Cluster HARAs). For example, Electrical power steering, Electric pump powered hydraulic
Somasundaram, Manickam, Vijayakumar, Melvin
Advanced SVPWM Techniques for Multi-Level Inverters: Enhancing Performance and Reducing Complexity2026-26-01471/16/2026
Over the last few years, notable progress has occurred in electric vehicle (EV) technology. Inverters are key components for electric vehicles (EV). Various PWM strategies have been implemented by OEMs over past years. For most of PWM scheme timing calculation & Lengthy algorithm increases complexity. The proposed a novel Pulse Width Modulation (PWM) control technique for generating inverter lag switching times in multi-level inverters. The proposed Space Vector PWM (SVPWM) method eliminates the need for sector and region identification by utilizing sampled values of reference phase voltages, thereby reducing computational efforts and complexities. The scheme can generate N-level PWM signals and offers flexibility to operate with fewer levels, including operation in the overmodulation range. The sampled magnitudes reference phase voltages are converted into timing signals that are subsequently processed by an algorithm to modify modulating signals. These modulating signals are
Bhanabhagvanwala, Prem Kiritkumar
A Digital Twin Framework for Real-Time Optimization of Solar-Integrated Energy Systems2026-26-04181/16/2026
In the context of increasing global energy demand and growing concerns about climate change, the integration of renewable energy sources with advanced modelling technologies has become essential for achieving sustainable and efficient energy systems. Solar energy, despite its considerable potential, continues to face challenges related to performance variability, limited real-time insights, and the need for reactive maintenance. To overcome these barriers, this work presents a Digital Twin framework aimed at optimizing solar-integrated energy systems through real-time monitoring, predictive analytics, and adaptive control. This work presents a Digital Twin framework designed to address the challenges of designing, operating, maintaining, and estimating renewable energy systems, specifically solar power, based on dynamic load demand. The framework enables real-time forecasting and prediction of energy outputs, ensuring systems operate efficiently and maintain peak performance across
R, Akash, Burud, Priti Raju, Gumma, Muralidhar
Standard SWS Requirement-Based Integration Testing for Classic AUTOSAR Modules2026-26-05071/16/2026
In the development of the automotive electronic control unit (ECU), to keep performance at the desired level, what remains constant is to verify, evaluate, and validate electronic control units. Nowadays, Cars have multiple ECUs even in the range of fifty. Software is validated by a tester using a target ECU, Controller Area network (CAN) communication, and some Input/Output simulation techniques. Also, in some applications, a virtual environment is created for testing. In this paper, the method of Integration testing of Automotive Open System Architecture (AUTOSAR) modules is presented with AUTOSAR software specification as its input. This makes standard test cases as SWS remains the same for AUTOSAR standard release. It enables a platform to efficiently test all layers of AUTOSAR base software (BSW) modules after integration. For the demonstration, TriCore micro controller TC377TX from Infineon is used. Same controllers are usually used in the development of automotive ECUs for
Kelkar, Renu, Patil, Vardhman
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