Browse Topic: Interiors, Cabins, and Cockpits

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Simulation-Based Investigation and its Experimental Validation of the Thermal Behaviour of a Battery Electric City Bus2025-01-0266To be published on 07/02/2025
Electrification of city busses is an important factor for decarbonisation of the public transport sector. Due to its strictly scheduled routes and regular idle times, the public transport sector is an ideal use case for battery electric vehicles (BEV). In this context, the thermal management has a high potential to decrease the energy demand or to increase the vehicles range. The thermal management of an electric city bus controls the thermal behaviour of the components of the powertrain, such as motor and inverters, as well as the conditioning of the battery system and the heating, ventilation, and air conditioning (HVAC) of the drivers’ front box and the passenger room. The focus of the research is the modelling of the thermal behaviour of the important components of an electric city bus in MATLAB/Simscape including real-world driving cycles and the thermal management. The heating of the components, geometry and behaviour of the cooling circuits as well as the different mechanisms of
Schäfer, Henrik, Meywerk, Martin, Hellberg, Tobias
Technical Paper
Optimized Cabin Heating Strategy for Battery Electric CEP Vehicles2025-01-0263To be published on 07/02/2025
Electromobility is gaining significance in the CEP (Courier, Express, and Parcel) sector, as parcel service providers increasingly rely on zero-emission vehicles to improve their CO2 balance. A general disadvantage of electric vehicles is the reduced range under cold operating conditions due to the higher energy demand for cabin heating. Another CEP-specific effect which affects the energy demand and thermal cabin comfort is the frequent door opening during the parcel delivery. Additionally, the vehicle cabin cools down during the driver’s absence because the cabin heating is turned off. Despite an acceptable level of thermal comfort must be maintained during the driving phases. This paper proposes an optimization-based strategy for the cabin heating of battery electric CEP vehicles. The objective is to maximize the cabin temperature during the driving phases compared to a baseline heating strategy while maintaining a desired energy consumption. For this purpose, a nonlinear model
Rehm, Dominik, Krost, Jonathan, Meywerk, Martin, Czarnetzki, Walter
Technical Paper
Metamaterial application to automotive glass for vibration reduction and reduced noise transmission2025-01-0119To be published on 05/05/2025
A metamaterial which, attached to the edge of a panel, reduces vibration results in reduced noise transmission into a vehicle. In this particular case, the metamaterial is designed to be attached to the edge of a glass panel and can reduce panel vibration and noise transmission due to wind or other sources into the vehicle interior. Acoustic transmission loss and panel vibration assessments show the benefit of this approach.
Sorenson, Steve, Li, Xiaopeng, Moore, Jaime, Robison, Scott
Technical Paper
Feasibility of In-Situ Vehicle-Level Sound Transmission Loss Measurement to Guide Dash Pass-Through Grommet Selection2025-01-0122To be published on 05/05/2025
Noise transmission through the vehicle dash panel plays a critical role in isolating passengers from noise sources within the motor bay of the vehicle. Grommets that contain electrical harness routing as well as HVAC lines are examples of dash panel pass-throughs that should be selected with care. Acoustic performance of these components is generally characterized in terms of measured quantities such as noise reduction (NR), sound transmission loss (STL), and insertion loss (IL). These measurements need to be carried out per SAE or ASTM standards in appropriate anechoic or reverberant chambers as this is important for consistency. This work explores an in-situ measurement of the grommet STL performance in the vehicle environment. It utilizes a repurposed vehicle with its cabin retrofitted to serve as an anechoic chamber and its frunk acting as a reverberant chamber. Results of this in-situ measurement are then compared to measurements following industry standards to discuss the
Joodi, Benjamin, Jayakumar, Vignesh, Chang, Michael, Geissler, Christian, Pilz, Fernando, Conklin, Chris
Technical Paper
Flow-Induced Noise Prediction and Validation of a Heavy-Duty Electric Vehicle's HVAC System Using the Lattice Boltzmann Method2025-01-0057To be published on 05/05/2025
Within automobiles, the HVAC is a critical system to regulate the occupants’ thermal comfort. However, at its high operating speeds, it can contribute significantly to the overall sound levels perceived by the cabin occupants, impacting their experience. This is especially true in the case of electric vehicles due to their overall quieter operation. This work has the intention to validate HVAC noise predictions using computational fluid dynamics (CFD) simulations. In addition, CFD simulations provide detailed flow field insights which are essential to identify and rank the main noise sources, and it ultimately allows a better understanding of the physical mechanisms of noise generation on similar systems. These insights are very difficult, if not impossible, to obtain with physical testing and are key to designing a quiet and efficient HVAC system. Sound levels were measured experimentally at eight different locations inside of a Class-8 Nikola TRE hydrogen fuel cell electric semi
Ihi, Rafael, Fougere, Nicolas, Passador, Stephen, Woo, Sangbeom, Kim, James, Desouky, Mohamed
Technical Paper
Data-Driven Machine Learning Approach for Rattle Risk Mitigation2025-01-0126To be published on 05/05/2025
In the modern automotive industry, squeak and rattle issues are critical factors affecting vehicle perceived quality and customer satisfaction. Traditional approaches to predicting and mitigating these problems heavily rely on physical testing and simulation technologies, which can be time-consuming and resource-intensive, especially for larger models. In this study, we propose a data-driven machine learning approach to mitigate rattle risks more efficiently. In this study, a floor console model has been evaluated using the traditional simulation-based E-line method to pinpoint high-risk areas. Data generation is performed by varying material properties, thickness, and flexible connection stiffness using the Modified Extensible Lattice Sequence (MELS) sampling algorithm, creating a diverse and comprehensive dataset for generating a machine learning (ML) model. Utilizing the dataset, the top contributing variables were identified for training the ML models. Various machine-learning
Parmar, Azan, Rao, Sohan, Reddy, Hari Krishna
Technical Paper
Designing Rubber Flaps for Resonance Management: High-Frequency Tuning in Electric Vehicles Using AI/ML Approaches2025-01-0125To be published on 05/05/2025
High-frequency whine noise in electric vehicles (EVs) poses a significant challenge, affecting customer perception and the overall vehicle experience. One primary source of this undesirable noise is the interaction between motor pole resonance and the resonance of the engine mount rubber. This paper presents an innovative method for predicting and tuning the frequency response of engine mounts by precisely adjusting the dimensions of rubber flaps, specifically their length and width. The proposed solution employs a dual approach: fine-tuning rubber flap dimensions and utilizing machine learning (ML) techniques. An ML model, trained on historical data, predicts how varying flap dimensions impact frequency response, providing a data-driven foundation for optimization. This prediction capability is enhanced by a Python program that automates the optimization process using a linear combination formula, efficiently addressing resonance issues. By integrating ML insights with the linear
Hazra, Sandip, Khan, Arkadip
Technical Paper
Research on NVH Performance of Pulse Heating System of One Vehicle2025-01-0078To be published on 05/05/2025
When the ambient temperature is too low, the performance of the lithium-ion battery will deteriorate, and the car will have the problems of difficult charging, fast power consumption, and even difficult to start, so the battery needs to be heated before use to provide a comfortable working environment for the lithium-ion. The high-frequency pulse heating system can quickly and evenly raise the temperature of the battery, but there is noise during operation, which affects the NVH performance of the vehicle itself, and its noise comfort needs to be further optimized. Firstly, the high-frequency pulse heating system is discussed in detail, and the parameters affecting the NVH performance are explored. Secondly, NVH tests and subjective and objective evaluations were carried out based on different system parameters, relevant data were collected to establish a model, the influence degree of each parameter was demonstrated, and the best parameter combination was determined. Finally, the
Yun, Zhao, Shouhui, Huang, Hu, Zhongxun, Hui, Hui, Zhou, Changshui, Teng, Charlie
Technical Paper
Tonal noise investigation of automotive HVAC systems : a hybrid method2025-01-0027To be published on 05/05/2025
There is no need to recall how the electrification trend of transport facilities has tightened the requirements around acoustic comfort. Within the automotive industry, these targets are more challenging for Heating, Ventilation and Air Conditioning systems for which passengers are in the foreground of noise emissions. The complexity of the requirements and specifications set by car manufacturers and suppliers stems from a dual aspect. First is quantitative based on the sound pressure level, whether it's the overall level or 1/3 octave band spectra. The second is purely subjective based on the perceived noise quality by stakeholders and final customers worldwide. During development phases, low frequency tone noises are frequently encountered on these systems which might induce discomfort to the passengers. The experimental investigations usually point to an aerodynamic origin, which prompted this research activity. The purpose of this work is to analyze and understand the mechanism of
Bennouna, Saad, Alaoui, Mohamed, Henner, Manuel
Technical Paper
Cabin noise modeling for seat location variation using AI and Machine Learning2025-01-0129To be published on 05/05/2025
Analyzing acoustic performance in large and complex assemblies, such as vehicle cabins, can be a time-intensive process, especially when considering the impact of seat location variations on noise levels. This paper explores the use of AI and machine learning to streamline this analysis by predicting the effects of different seat configurations on cabin noise, particularly at the driver’s ear level. The study begins by establishing a baseline simulation of cabin noise and generating training data for various seat location scenarios. This data is then used to train an AI model capable of predicting the noise impact of further seat adjustments. These predictions are validated through detailed simulations. The paper discusses the accuracy of these predictions, the challenges encountered, and provides insights into the effective use of AI and machine learning in acoustic analysis for cabin noise, with a specific emphasis on seat location as a key variable. Keywords: Acoustic analysis, AI
Kottalgi, Santosh, He, Junyan, Banerjee, Bhaskar
Technical Paper
GPU-Accelerated Aeroacoustic Simulations of HVAC Duct Configurations2025-01-0133To be published on 05/05/2025
Large eddy simulations of two HVAC duct configurations at different vent blade angles are performed with the low-Mach (Helmholtz) flow solver ``Fidelity CharLES'' for comparison with aeroacoustics measurements conducted at Toyota Motor Europe facilities. The pressure fluctuation time history is recorded on a Ffowcs Williams-Hawking (FW-H) surface to predict the sound pressure level at specific locations, corresponding to the positions of four near-field and four far-field microphones. The A-weighted 1/3 octave band delta sound pressure level (SPL) between the two vent blades angle configurations is computed and compared to experimental data. Overall, the simulations capture the experimental trends and the LES spectra show good agreement with the experimental measurements over the frequency range of interest (i.e. 1000Hz to 5000Hz).
Besem-Cordova, Fanny M., Dieu, Donavan, Wang, Kan, Brès, Guillaume A., Delacroix, Antoine
Technical Paper
High-resolution option for the Sottek Hearing Model Tonality enables accurate order analysis2025-01-0093To be published on 05/05/2025
The Sottek Hearing Model provides a comprehensive framework for understanding the nuances of sound perception, including such aspects as loudness, tonality, roughness, fluctuation strength, sharpness, and impulsiveness. The principal model was first published more than three decades ago as part of a doctoral thesis. Over the past few decades, the model has been refined and recently standardized in the international standard ECMA 418-2. This standard addresses several psychoacoustic parameters, including a new approach to time-varying loudness based on a nonlinear combination of partial tonal and noise loudness. This is the preferable approach because the loudness of tonal components (i.e., tonal loudness) may have a more pronounced impact on loudness perception than the loudness caused by other components (i.e., noise loudness). Other standardized parameters include tonality and psychoacoustic modulation analyses. These comprise roughness, which is employed to evaluate rapidly
Sottek, Roland, Bray, Wade
Technical Paper
Active noise control with head tracking system2025-01-0012To be published on 05/05/2025
In active noise control, the control region size(zone of control) decreases as the frequency increases, so that even a small moving of the passenger's head causes the ear position to go out of the control region. In order to increase the size of the control region, many speakers and microphones are generally required, but it is difficult to apply it in a vehicle cabin due to space and cost constraints. In this study, we propose moving zone of quite actvie noise control technique. An 2D images based head tracking system captured by a camera to generate the passenger's head coordinates in real time with deep learning algorithm. In the controller, the control position is moved to the ear position using a multi-point virtual microphone algorithm according to the generated ear position. After that, the multi-point adaptive filter training system applies the optimal control filter to the current position and maintains the control performance. Through this study, it is possible to secure the
Oh, ChiSung, Kang, Jonggyu, Kim, Joong-Kwan
Technical Paper
Underbody contribution simulation for vehicle wind-noise.2025-01-0026To be published on 05/05/2025
Wind noise is one of the largest sources to the interior noise of modern electric and hybrid vehicles. This noise is encountered when driving on roads and freeways from medium speed and generate considerable fatigue for passengers on long journeys. Aero-acoustic noise is the result of turbulent and acoustic pressure fluctuations created within the flow. They are transmitted to the passenger compartment via the vibro-acoustic excitation of vehicle surfaces and underbody cavities. Generally, this is the dominant flow-induced source at low frequencies. The transmission mechanism through the vehicle floor and underbody is a complex phenomenon as the paths to the cavity can be both airborne and structure-borne. This study is focused on the floor contribution to wind noise of different type of vehicles (SUV and Sport car), whose underbody structure are largely different. Aero-Vibro-acoustic simulations are performed to clarify the transmission mechanism of the underbody wind noise and
Mordillat, Philippe, Zerrad, Mehdi, Errico, Fabrizio
Technical Paper
Interconnected and Data-Driven Aircraft Cabin Systems: Consistent Integration of ARINC 853 Messaging Standard into Model-Based Aircraft Systems Development2025-01-0174To be published on 05/02/2025
Increasing digitalization of the aircraft cabin, driven by the need for improved operational efficiency and an enhanced passenger experience, has led to the development of data-driven services. In order to implement these services, information from different systems is often required, which leads to a multi-system architecture. When designing a network that interconnects these systems, it is important to consider the heterogeneous device and supplier landscape as well as variations in the network architecture resulting from airline customization or cabin upgrades. The novel ARINC 853 Cabin Secure Media-Independent Messaging (CSMIM) standard addresses this challenge by specifying a communication protocol that relies on a data model to encode provided and consumed information. This paper presents an approach to integrate CSMIM-specific communication concepts into a Model-Based Systems Engineering (MBSE) framework using the Systems Modeling Language (SysML). This enables a streamlined
Giertzsch, Fabian, Blecken, Marvin, God, Ralf
Technical Paper
Enhancing Airworthiness Security: SysML-Based Approach to Modelling Security Scope Definitions2025-01-0172To be published on 05/02/2025
Airworthiness certification of aircraft requires an Airworthiness Security Process (AWSP) to ensure safe operation under potential unauthorized interactions, particularly in the context of growing cyber threats. Regulatory authorities mandate the consideration of Intentional Unauthorized Electronic Interactions (IUEI) in the development of aircraft, airborne software, and equipment. As the industry increasingly adopts Model-Based Systems Engineering (MBSE) to accelerate development, we aim to enhance this effort by focusing on security scope definitions – a critical step within the AWSP for security risk assessment that establishes the boundaries and extent of security measures. However, our findings indicate that, despite the increasing use of model-based tools in development, these security scope definitions often remain either document-based or, when modeled, are presented at overly abstract levels, both of which limit their utility. Furthermore, we found that these definitions
Hechelmann, Adrian, Mannchen, Thomas
Technical Paper
Approach to Optimize the Airplane Boarding Process by using Image Recognition and Stochastic Simulation to Predict Overhead Bin Fill Levels2025-01-0164To be published on 05/02/2025
In single-aisle aircraft, the available storage space for carry-on baggage is inherently limited. When the aircraft is fully booked, this often results in insufficient overhead bin space, necessitating last-minute gate-checking of carry-on items, which delays the boarding process and reduces operational efficiency. A promising approach to mitigating this issue involves the integration of computer vision technologies with an appropriate data storage system and stochastic simulation to enable accurate and supportive predictions that enhance planning. In this work the YOLOv8 image recognition algorithm is used to identify and classify each passenger’s carry-on baggage into categories such as handbags, backpacks and suitcases. This data is then linked to passenger information stored in the NoSQL database MongoDB, which included seat assignments and the number of carry-on items per passenger. Stochastic simulation is applied to predict the occupancy levels of overhead storage bins across
Bergmann, Jacqueline, Hub, Maximilian
Technical Paper
MBSE Framework for Developing Data-Driven Passenger Services in Aircraft Cabins2025-01-0171To be published on 05/02/2025
The aircraft cabin plays a crucial role in airline differentiation strategies, particularly when introducing novel, data-driven services. These services aim to enhance the passenger experience during the flight and to improve cabin crew efficiency in order to reduce workload and ensure continued growth of airline revenue. Digitalization and extensive exchange of information across the entire aircraft transport system have emerged as key enablers for these services. The development of aircraft and aircraft systems that realize these services is characterized by a multi-level development process. Various development levels are considered to initially identify the functions of an aircraft in the air transport system, refine its systems and break them down into their components until a level of detail is reached that allows the implementation of the component functions. In addition to the high complexity, a major challenge in this development is to ensure traceability and consistency
Blecken, Marvin, Giertzsch, Fabian, God, Ralf
Technical Paper
Evaluation of Hybrid Aeroacoustics Models for HVAC Duct Noise Predictions2025-01-5032To be published on 05/01/2025
This study evaluates the effectiveness of two hybrid computational aeroacoustic methods—Lighthill wave model and perturbed convective wave model—in simulating HVAC duct noise in the automotive industry. Using component-level acoustic testing of a Ford HVAC duct, simulations were conducted at varying airflow rates to assess the accuracy of both models in predicting duct noise. The Lighthill wave model, suitable for noise analysis in regions outside turbulent flow areas, showed a good correlation with experimental data, especially in the frequency range of 100 Hz–5000 Hz, but sometimes struggled with pseudo-noise effects at low frequencies near turbulent regions. The perturbed convective wave model, which is suitable for noise analysis anywhere in the flow domain, underpredicted sound pressure levels at low frequencies as well. Both models underpredicted high-frequency noise (>5 kHz) due to insufficient mesh and time-step sizes. Despite these limitations, the Lighthill wave model
Nam, Jee-Whan, Mendel, Marc, Golberg, Igor
Technical Paper
Dynamic Nonlinear Viscoelastic Measurements of Vehicle Seat Components for Ride Comfort Evaluation2024-32-005104/18/2025
Ride comfort is an important factor in the development of vehicles. Understanding the characteristics of seat components allows more accurate analysis of ride comfort. This study focuses on urethane foam, which is commonly used in vehicle seats. Soft materials such as urethane foam have both elastic and viscous properties that vary with frequency and temperature. Dynamic viscoelastic measurements are effective for investigating the vibrational characteristics of such materials. Although there have been many studies on the viscoelastic properties of urethane foam, no prior research has focused on dynamic viscoelastic measurements during compression to simulate the condition of a person sitting on a seat. In this study, dynamic viscoelastic measurements were performed on compressed urethane foam. Moreover, measurements were conducted at low temperatures, and a master curve using the Williams–Landel–Ferry (WLF) formula (temperature–frequency conversion law) was created.
Kamio, Chihiro, Yamaguchi, Takao, Maruyama, Shinichi, Hanawa, Kazuto, Iwase, Tsutomu, Hayashi, Tatsuo, Sato, Toshiharu, Mogawa, Hajime
Technical Paper
Minimum Performance Standard for Airborne Head-Worn Display (HWD)AS7377 (Current)04/14/2025
This SAE Aerospace Standard (AS) specifies minimum performance standards for airborne head-worn display (HWD) to be used as a head-up display (HUD) equivalent in fixed wing (14 CFR Parts 23 and 25) aircraft. While this document may be applied to rotorcraft using an HWD for piloting functions (14 CFR Parts 27 and 29), additional performance standards may be required. This AS covers basic display requirements but does not include specific application requirements. Specific applications can include flight instrumentation, navigation, engine and system status, alerting, surveillance, communication, terrain awareness, weather, enhanced vision, synthetic vision, and other formats. This document covers criteria for conformal HWD systems that are intended for use in the flight deck by the pilot or copilot. Display minimum performance characteristics are specified for standard and other environmental conditions for the purpose of product qualification. Figure 1 defines the HWD System Scope for
A-4HUD Head-up Display Subcommittee
Technical Standard
Air Conditioning Service Procedures for Off-Road Work Machines and Agricultural Tractors Using HFC-134a or HFO-1234yf RefrigerantJ3126_202504 (Historical)04/14/2025
This SAE Recommended Practice is intended to provide technicians with safe and efficient techniques and general equipment recommendations for servicing mobile air conditioning systems in off-road, self-propelled work machines as defined in SAE J1116 and tractors and machinery for agriculture and forestry as defined in ASABE standard ANSI/ASAE S390. Both refrigerants HFC-134a (R-134a) and HFO-1234yf (R-1234yf) are covered. Many service procedures are similar for both refrigerants, but recovery, recycling, charging, and electronic leak detection tools can be unique to each refrigerant.
HFTC6, Operator Accommodation
Recommended Practice
Driver Seating Accommodation and Steering Wheel Location ModelsJ3099_202504 (Current)04/14/2025
This practice presents methods for establishing the driver workspace. Methods are presented for: Establishing accelerator reference points, including the equation for calculating the shoe plane angle Locating the SgRP as a function of seat height (H30) Establishing seat track dimensions using the seating accommodation model Establishing a steering wheel position Application of this document is limited to Class-A Vehicles (Passenger Cars, Multipurpose Passenger Vehicles, and Light Trucks) as defined in SAE J1100.
Human Accom and Design Devices Stds Comm
Recommended Practice
Development of a New Concept Structure for 4-Way Electric Headrest Adjustment2025-01-862004/01/2025
At present, electric head restraints have been developed locally, so overseas mechanisms are used. In this study, two concept mechanisms were developed, and in addition, one patent for a wing-out head restraint mechanism was additionally applied. The new mechanism has had an excellent effect on cost reduction and improvement of operating noise compared to the current one.
Yu, Sanguk
Technical Paper
Research on the Thermal Performance of Thick Film Heater for Electric Vehicle Battery2025-01-815404/01/2025
A specific thick film heater (TFH) for electric vehicles is investigaed in this study, and its three dimensional heat tansfer analysis model is estab-lished. The heat transfer and fluid performance of the TFH is analyzed using a computational fluid dynamics soft-ware. The performance of TFH is measured on a test bench, and the measured data is used to validate the developed model. Using the established model, the heating efficiency of TFH is studied for different inlet temperatures and flow rates, and the influence of the fin spoiler structure on TFH heating efficiency and the heating board temperature is investigated. The result indicates that the spoiler structure has a large effect on the board heating temperature, but has little effect on the heating efficiency. An orthogonal experimental design method is used to optimize the design of the fins and water channels, and the purpose is to reduce the board heating temperature for preventing over burning. Under the 25°C inlet
Guan, Wenzhe, Guo, Yiming, Wu, Xiaoyong, Wang, Dongdong, Shangguan, Wen-Bin
Technical Paper
Effects of Aging on PVC-Based Instrument Panel Skin for Passenger Airbag Deployment Analysis2025-01-832104/01/2025
Plasticized polyvinyl chloride (PVC) has many applications in automotive industry including electrical harnesses, door handles, seat and head rest covers, and instrument panel (IP) and other interior trim. In IP applications, the PVC skin plays a critical role in passenger airbag deployment (PAB) by tearing along the scored edge of the PAB door and allowing the door to open and the airbag to inflate to protect the occupant. As part of the IP, the PVC skin may be exposed to elevated temperatures and ultraviolet (UV) radiation during the years of the vehicle life cycle which can affect the PVC material properties over time and potentially influence the kinematics of the airbag deployment. Chemical and thermal aging of plasticized PVC materials have been studied in the past, yet no information is found on how the aging affects mechanical properties at high rates of loading typical for airbag deployment events. This paper compares mechanical properties of the virgin PVC-based IP skin
G, Karthigan, Savic, Vesna, Ravichandran, Gowrishankar
Technical Paper
Development of Ceramic Humidity Regulator (CHR) Using Honeycomb Type PTC Heater to Improve Electric Vehicle Driving Range in Winter2025-01-817704/01/2025
With Rapid growth of Electric Vehicles (EVs) in the market challenges such as driving range, charging infrastructure, and reducing charging time needs to be addressed. Unlike traditional Internal combustion vehicles, EVs have limited heating sources and primarily uses electricity from the running battery, which reduces driving range. Additionally, during winter operation, it is necessary to prevent window fogging to ensure better visibility, which requires introducing cold outside air into the cabin. This significantly increases the energy consumption for heating and the driving range can be reduced to half of the normal range. This study introduces the Ceramic Humidity Regulator (CHR), a compact and energy-efficient device developed to address driving range improvement. The CHR uses a desiccant system to dehumidify the cabin, which can prevent window fogging without introducing cold outside air, thereby reducing heating energy consumption. A desiccant system typically consists of two
Hamada, Takafumi, Shinoda, Narimasa, Konno, Yoshiki, Ihara, Yukio, Ito, Masaki
Technical Paper
Modeling Virus Infection Risks in Automobile Cabin2025-01-817604/01/2025
In the post Covid era, risk of infection in conditioned space is getting attention and has generated a lot of interest for the design of the new systems and strategies for the management and operations of the existing HVAC systems. Risk management plays a key role where the amounts of outside air and recirculated airs can be used to mitigate the propagation of the virus within the conditioned space. In other words, ventilation plays a huge role within the conditioned space along with strategies based on UV irradiation, ionization and use of highly efficient filters. Different air purification systems have been created by the researchers based on the titanium oxide-based UV photocatalysis system, filters with MERV ratings higher than 11 (ASHRAE Standard 52.2) and HEPA filters. Recent ASHRAE standard 241 (2023) on infectious diseases recommends using high ventilation rates within the conditioned space to reduce virus concentration, and hence, to reduce the risk of infection. Determining
Mathur, Gursaran
Technical Paper
Analysis of Coolant Flowing and Heat Transfer Performance in High Voltage Heater System2025-01-819404/01/2025
A method for performance calculation and experimental method of a high voltage heater system in electric vehicles is proposed. Firstly, heater outlet temperature and pressure drop of the heater are used as metrics to compare simulation results with experimental data, thereby validating the established model. Then, simulations are performed on two heater flow channel configurations: a cavity flow channel and a cooling fin flow channel. It is observed that the latter significantly reduces the heating plate temperature. This reduction enhances the protection of heating elements and extends their operational lifespan, demonstrating the advantages of incorporating cooling fins into the flow channel structure. The optimization variables for multi-objective optimization include the fin unit length, fin height, fin thickness, fin width, and spacing between two adjacent rows of fins. The optimization objectives include pressure drop, heat transfer efficiency, and heating plate temperature
Gong, Ming, Wang, Xihui, Wang, Dongdong, Shangguan, Wen-Bin
Technical Paper
Demonstration of Model Predictive Control to Optimise Cabin Thermal Comfort in a Battery Electric Vehicle2025-01-814504/01/2025
The focus on thermal system efficiency has increased with the introduction of electric vehicles (EV) where the heating and cooling of the cabin represents a major energy requirement that has a direct impact on vehicle range in hot and cold ambient conditions. This is further exacerbated during heating where EVs do not have an engine to provide a source of heat and instead use stored electrical energy from the battery to heat the vehicle. This paper considers two approaches to reduce the energy required by the climate control and hence increase the range of the vehicle. The first approach considers minimizing the energy to keep the passengers comfortable, whilst the second approach optimizes the heating and ventilation system to minimize the energy required to achieve the target setpoints. Finally, these two approaches are combined to minimize both the passenger’s demand and the energy required to meet the demand. This paper covers the development process from simulation to
Fussey, Peter, Dutta, Nilabza, Milton, Gareth, Ma, He
Technical Paper
An Experimental Investigation of the Liquid Jet Breakup Characteristics in a Vaporizer under Equivalent Operating Conditions of a Microturbine Combustion Chamber2025-01-845804/01/2025
This study experimentally investigates the liquid jet breakup process in a vaporizer of a microturbine combustion chamber under equivalent operating conditions, including temperature and air mass flow rate. A high-speed camera experimental system, coupled with an image processing code, was developed to analyze the jet breakup length. The fuel jet is centrally positioned in a vaporizer with an inner diameter of 8mm. Airflow enters the vaporizer at controlled pressures, while thermal conditions are maintained between 298 K and 373 K using a PID-controlled heating system. The liquid is supplied through a jet with a 0.4 mm inner diameter, with a range of Reynolds numbers (Reliq = 2300÷3400), and aerodynamic Weber numbers (Weg = 4÷10), corresponding to the membrane and/or fiber breakup modes of the liquid jet. Based on the results of jet breakup length, a new model has been developed to complement flow regimes by low Weber and Reynolds numbers. The analysis of droplet size distribution
Ha, Nguyen, Quan, Nguyen, Manh, Vu, Pham, Phuong Xuan
Technical Paper
A Wide Belt Correction Strategy for Belt-Whip and Wheel Ventilation Drag2025-01-877004/01/2025
The increased importance of aerodynamics to help with overall vehicle efficiency necessitates a desire to improve the accuracy of the measuring methods. To help with that goal, this paper will provide a method for correcting belt-whip and wheel ventilation drag on single and 3-belt wind tunnels. This is primarily done through a method of analyzing rolling-road only speed sweeps but also physically implementing a barrier. When understanding the aerodynamic forces applied to a vehicle in a wind tunnel, the goal is to isolate only those forces that it would see in the real-world. This primarily means removing the weight of the vehicle from the vertical force and the rolling resistance of the tires and bearings from the longitudinal force. This is traditionally done by subtracting the no-wind forces from the wind at testing velocity forces. The first issue with the traditional method is that a boundary layer builds up on the belt(s), which can then influence a force onto the vehicle’s
Borton, Zackery
Technical Paper
Finite Element Simulation and Experimental Study of the in-Mold Graining Process2025-01-833004/01/2025
In-Mold Graining (IMG) is an innovative production technology applied to the skin wrapping of automotive interior components. In the design of automotive interior components of door panels and instrument clusters, to overcome process-related problems, such as the thinning of grain patterns and excessive reduction in thickness, simulation of the skin vacuum forming process is required. The Thermoplastic Olefin (TPO) skin material is investigated in this paper, and a viscoelastic mechanical model for this material is established. Dynamic Mechanical Analyzer (DMA) is utilized to perform scan for frequency and temperature, and the tested data is used to obtain key model parameters of the viscoelastic constitutive model. Based on the experimental data, the study explores how to calculate the relaxation time spectrum to describe the viscoelastic properties of TPO material during the vacuum forming process. Numerical simulation of the vacuum forming process of TPO material is conducted using
Chai, Bingji, Guo, Yiming, Xie, Xinxing, Zhang, Qu
Technical Paper
Real-Time PMV Thermal Comfort Index Observer Based on Artificial Neural Networks for Infrared Heating Panel Control2025-01-813904/01/2025
Improving electric vehicles’ range can be achieved by integrating infrared heating panels (IRPs) into the existing Heating Ventilation and Air-Conditioning system to reduce battery energy consumption while maintaining thermal comfort. Localized comfort control enabled by IRPs is facilitated by thermal comfort index feedback to the control strategy, such as the well-known Predicted Mean Vote (PMV). PMV is obtained by solving nonlinear equations iteratively, which is computationally expensive for vehicle control units and may not be feasible for real-time control. This paper presents the design of real-time capable thermal comfort observer based on feedforward artificial neural network (ANN), utilized for estimating the local PMV extended with IRP radiative heating effects. The vehicle under consideration is equipped with 12 heating panels (zones) organized into six controller clusters that rely on the average PMV feedback from its respective zone provided by a dedicated ANN. Each of six
Cvok, Ivan, Yerramilli-Rao, Isha, Miklauzic, Filip
Technical Paper
Emissions Savings from Efficient Mobile Air-Conditioning (MAC) Systems in Passenger Vehicles2025-01-815604/01/2025
Mobile Air-Conditioning (MAC) systems are a substantial source of energy consumption and CO₂ emissions in passenger vehicles, particularly for electrified vehicles under real-world operating conditions. Enhancing the efficiency of such systems is imperative to achieving greater energy efficiency and maintaining occupants’ comfort. In recognition of their significance, MAC systems can be classified as eco-innovative technologies under EU Regulation 2019/631, effective from 2025. This study lays the groundwork for a methodology to calculate CO₂ savings from eco-innovative MAC systems in passenger cars. The approach compares CO₂ emissions between baseline and eco-innovative vehicles under active and inactive MAC systems. Literature-derived indicative ambient conditions are applied to reflect realistic MAC usage scenarios in Europe. The testing protocol follows the WLTP procedure under controlled ambient conditions, including temperature, humidity, and solar irradiation, which can either
Di Pierro, Giuseppe, Currò, Davide, Gil-Sayas, Susana, Fontaras, Georgios
Technical Paper
Occupant Responses in High-Speed Rear Sled Tests: Focus of Initial Position, Seat Strength and ATD Size2025-01-873104/01/2025
The National Highway Safety Administration (NHTSA) recently published an Advanced Notice of Proposed Rulemaking (ANPRM) to evaluate seat performance in rear impacts [1]. The ANPRM was issued partially in response to two petitions requesting an increase in seatback strength requirements and high-speed testing with various size Anthropometric Test Devices (ATDs). To better understand the effect of these requests, this study evaluates ATD responses with two high-speed rear sled conditions, three occupant sizes and various seat designs. Seat designs varied from modern conventional seats with yielding properties to stronger and stiffer seats represented by seat integrated restraint (SIR) designs, and rigidized SIR seats. Twenty-four rear sled tests were analyzed. The tests were matched by crash severity, seat designs (strength), ATD sizes and initial postures (nominal/in-position, leaned forward and leaned outboard). The test data and videos were reviewed to identify time coinciding with
Parenteau, Chantal, Burnett, Roger
Technical Paper
Overview of Seat Design Changes and Performance2025-01-872904/01/2025
The National Highway Traffic Safety Administration (NHTSA) published an Advance Notice of Proposed Rulemaking (ANPRM) to update the Federal Motor Vehicle Safety Standard (FMVSS) 207. Part of the ANPRM is to assess the merit of conducting quasi static body block seat pull tests and conducting FMVSS 301 rear crash tests at 80 km/h or higher with a 95th percentile ATD lap-shoulder belted in the front seats and limiting seatback deflection to 15 to 25 degrees. Prior to updating regulations, it is important to understand the seating design history and implications. This study was conducted to provide a historical background on seat design and performance using literature and test data. One objective was to first define the terminology used to describe occupant kinematics in rear crashes. Secondly, seat design evolution is then discussed. Third, test methods and test results were summarized, and fourth, the field performance are synopsized and discussed with respect to 2nd row occupant
Parenteau, Chantal, Burnett, Roger, Davidson, Russell
Technical Paper
Investigation of the Blockage Phenomenon in Closed Wall Wind Tunnels During the Testing of Bluff Automotive Bodies with Large Wakes in Yawed Configurations2025-01-878604/01/2025
The difficulties of testing a bluff automotive body of sufficient scale to match the on-road vehicle Reynolds number in a closed wall wind tunnel has led to many approaches being taken to adjust the resulting data for the inherent interference effects. But it has been very difficult to experimentally analyze the effects that are occurring on and around the vehicle when these blockage interferences are taking place. The present study is an extension of earlier works by the author and similarly to those studies uses the computational fluid dynamics analysis of three bodies that generate large wakes to examine the interference phenomena in solid wall wind tunnels and the effects that they have on the pressures, and forces experienced by the vehicle model when it is in yawed conditions up to 20 degrees. This is accomplished by executing a series of CFD configurations with varying sized cross sections from 0.4% to 14% blockage enabling an approximation of free air conditions as a reference
Gleason, Mark, Riegel, Eugen
Technical Paper
Power Loss Estimation in Poly-V Belts for Micro and Mild Hybrid Powertrains Using the Generalized Maxwell Model2025-01-831604/01/2025
In modern automotive powertrains, the front-end accessory drive represents a crucial subsystem that guarantees the proper functioning of micro and mild hybrid configurations and auxiliary vehicle functionalities. The motor/generator (12 V or 48 V), the air conditioning compressor and other accessories rely on this subsystem. Therein, the poly-V belt is the main transmission mechanism. From an efficiency standpoint, its behavior is usually represented through slip and elastic shear phenomena. However, the viscoelastic nature of the compounds that constitute the belt layers demand a more detailed approximation of the loss mechanisms. The quantification of such losses allows evaluating the performance of the e-machine integrated in the powertrain. This work models the belt through a lumped-parameter time-domain model, where domains are discretized into multiple elements and represented through the generalized Maxwell model. Loss contributions due to bending, stretching, compression and
Galluzzi, Renato, Amati, Nicola, Bonfitto, Angelo, Hegde, Shailesh, Zenerino, Enrico, Pennazza, Mario, Staniscia, Emiliano
Technical Paper
A Novel Co-Simulation Framework for Optimizing Human Thermal Comfort and Energy Consumption in a Vehicle2025-01-819104/01/2025
A major portion of the energy consumed in a vehicle is spent on keeping the occupants thermally comfortable in all environmental conditions when the heating, ventilation, and air-conditioning (HVAC) system is turned on. Maintaining the thermal comfort of a passenger is critical in terms of fuel consumption and emission for internal combustion engine (ICE) vehicles. In electrified vehicles, where range is of major concern, this gains further-more importance. SC03 is a test defined by the US Environmental Protection Agency (EPA) to measure tailpipe emissions and fuel economy of passenger cars with the air-conditioner on. The current study would focus on this drive cycle on an ICE vehicle. The co-simulation framework would include a 1D thermal system model, associated thermal controls, a vehicle cabin model, and a human thermal model. 1D model will be predicting the energy consumption via compressor power, refrigerant pressure and temperature across the loop, component heat rejection, etc
Natarajan, Shankar, Balasubramanian, Sudharsan
Technical Paper
Modeling and Control Strategies of the Thermal Management System for Electric Vehicles2025-01-819004/01/2025
The electric vehicle thermal management system is a critical sub-systems of electric vehicles, and has a substantial impact on the driving range. The objective of this paper is to optimize the performance of the heat pump air conditioning system, battery, and motor thermal management system by adopting an integrated design. This approach is expected to effectively improve the COP (Coefficient of Performance) of cabin heating. An integrated thermal management system model of the heat pump air conditioning system, battery, and motor thermal management system is established using AMEsim. Key parameters, such as refrigerant temperature, pressure, and flow rate at the outlet of each component of the system are compared with the measured data to verify the correctness of the model established in this paper. Using the established model, the impact of compressor speed on the heating comfort of the cabin under high-temperature conditions in summer was studied, and a control strategy for rapid
Zhang, Min, Li, Liping, Zhou, Jianhua, Huang, Yu, Zhen, Ran, Shangguan, Wen-Bin
Technical Paper
Battery Thermal Management System for PHEV by using Air Conditioning Heater System2025-01-817204/01/2025
Toyota Motor Corporation pursuing an omnidirectional strategy that includes battery electric vehicle (BEV), plug-in hybrid electric vehicle (PHEV), and fuel cell electric vehicle (FCEV) to accelerate electrification. One of the technical challenges with our xEV batteries which feature good degradation resistance and long battery life, is that regenerative braking cannot be fully effective due to the decrease in regenerative power in some situations, such as low battery temperature. For the electrified vehicles with an internal combustion engine such as PHEVs, the solution has been running the engine to increase deceleration through engine braking during coasting. PHEVs are expected to extend their cruising range and enhance EV driving experience as "Practical BEVs". While increasing battery capacity and enhancing convenience, the restrictions on EV driving opportunity due to low battery temperature may negatively affect PHEV’s appealing. As an alternative, introducing a battery heater
Hoshino, Yu
Technical Paper
A Co-Simulation Methodology for Predicting Occupant Thermal Comfort for Cabin Cooldown and Warmup Scenarios2025-01-818804/01/2025
Achieving and maintaining thermal comfort for vehicle cabin cool down and warm up is a challenging task. Keeping the passenger comfortable in all driving scenarios needs a properly sized system. Predicting thermal comfort in a virtual environment consisting of thermal system and vehicle cabin gives us the opportunity to size the system components to maintain thermal comfort. These studies could then be extended to develop comfort-based control strategies that help us achieve a system optimized for performance. The present study focuses on developing a co-simulation methodology for predicting thermal comfort in a vehicle for hot and cold ambient conditions. Key to proper system sizing would be to capture the cabin thermal loads accurately. Traditionally, either a 1D or 3D cabin model is used for assessment of thermal comfort. Both these cabin models have their own applications and limitations. A 1D-3D cabin model along with the developed co-simulation methodology in this work addresses
Balasubramanian, Sudharsan, Natarajan, Shankar
Technical Paper
Control Trajectory Optimization of Electric Vehicle Heat Pump-Based Cabin Heating System2025-01-814404/01/2025
Optimal control of battery electric vehicle thermal management systems is essential for maximizi ng the driving range in extreme weather conditions. Vehicles equipped with advanced heating, ventilation and air-conditioning (HVAC) systems based on heat pumps with secondary coolant loops are more challenging to control due to actuator redundancy and increased thermal inertia. This paper presents the dynamic programming (DP)-based offline control trajectory optimization of heat pump-based HVAC aimed at maximizing thermal comfort and energy efficiency. Besides deriving benchmark results, the goal of trajectory optimization is to gain insights for practical hierarchical control strategy modifications to further improve real-time controllers’ performance. DP optimizes cabin inlet air temperature and flow rate to set the trade-off between thermal comfort and energy efficiency while considering the nonlinear dynamics and operating limits of HVAC system in addition to typically considered cabin
Cvok, Ivan, Deur, Josko
Technical Paper
Coordinated motor speed control design for seat systems2025-01-806904/01/2025
Automotive seating systems have become increasingly sophisticated, providing consumers with more flexible configurations and comfort functionalities. Traditional power seating, which relied on a few motors to adjust the seat position, has evolved into more technically advanced reconfigurable systems equipped with additional feedback sensors and actuators. These advancements include features such as Easy Entry, Zero Gravity, Stadium Swivel, IP Nesting, Auto Lumbar/Bolster Adjustment and Power Long Rails. All the features indicate that the overall control of seating systems now resembles robotic arm control or multi-body control, involving numerous coordinated movements. In this paper, we propose a novel control strategy for the coordinated speed control of multiple motors. Unlike traditional seating controls, which typically use direct switches or open-loop systems, we introduce a feedback approach that incorporates Kalman-filter-based speed estimation using raw signals directly from
Yang, Hanlong, Li, Miranda
Technical Paper
Automatic Generation of HVAC Ducting System Designs Using Topology and Shape Optimization2025-01-865604/01/2025
In this paper, the topology and shape optimization of a vehicle Heating, Ventilation, and Air Conditioning (HVAC) system is presented. The CFD and optimization methodologies are implemented within AcuSolve™ software. The topology optimization algorithm computes the geometry, where the design domain is parameterized with a field of porosity design variables which indicates the material, fluid or solid, throughout the domain. The optimization is performed using the continuous adjoint approach by the Galerkin Least Squares solver on which the AcuSolve™ solver is based. The design is further improved by using shape optimization. To optimize the geometrical shape, a combination of smooth perturbations, in terms of so called morph shapes, are used to deform the geometrical shape in the optimization algorithm. To this end, a parameterization of the design space is done using a moderate number of design variables, each associated with a morph shape. The two optimization phases are connected by
Papadimitriou, Dimitrios, Sandboge, Robert
Technical Paper
A Reconfigurable Backrest Surface for Investigating Preferred Seat Configurations2025-01-861104/01/2025
A reconfigurable experimental seat is useful for seating comfort research and allows researchers to investigate the effects of seat parameters and to propose quantitative guidelines for improving seat comfort. Since 2017, Gustave Eiffel University has such an experimental seat which allows us to carry out parametric studies on the geometric dimensions of a seat and to understand the role of the contact force, particularly that in shear force. Equipped with force and positioning sensors, all contact forces and seat position can be measured. More specifically, it is equipped on the seat with a matrix of 52 cylinders, each adjustable in height and each equipped with a three-axis force sensor. These cylinders make it possible to vary the contact surface of seat pan and measure the distribution of contact forces. More recently, a new system with a matrix of 263 hydraulic cylinders was designed and manufactured to better study the comfort of the backrest in replacement of the three-support
Wang, Xuguang, Beurier, Georges
Technical Paper
Aeroacoustic Noise Prediction of Passenger Car HVAC by Using CFD and Validation with Test Result2025-01-862904/01/2025
The advancement of automotive industry demand compact size of HVAC with better cabin comfort. To achieve this, HVAC has to be optimized in all the aspects such as in shape & size, thermal comfort as well as in noise comfort. from an HVAC perspective, aeroacoustics noise is more significant due to its intensity at higher speeds and frequencies. Since HVAC is mounted inside the cabin, noise can transfer directly inside cabin. To avoid this, noise reduction or noise controlling is of very important. This is possible with HVAC design and simulation at the initial level and acoustic prediction after the CFD/CAA analysis. The present paper describes the aeroacoustic simulation of one of the HVAC to predict the noise during face mode. For that, 1-D simulation has been done initially to find the porosity of heat exchangers and coupled with a CFD solver. STAR CCM+ software is used for the CFD analysis. Transient simulation is performed with compressible fluid using a moving mesh approach. To
Kame, Shubham, Parayil, Paulson, Goel, Arunkumar
Technical Paper
Integrated Body Structure to Accommodate Manual and Power Door Sunshade Variants in a Vehicle2025-01-861604/01/2025
Door sunshade in a vehicle has proven to be very comfortable and luxurious feature to the customers. Luxury vehicles provide power sunshade which is electrically operated with the activation of a switch, whereas cost conscious vehicles provide manual sunshade which requires manual coiling and uncoiling. This study is to develop a door panel structure that can accommodate both the manual sunshade and power sunshade, thereby serving both cost conscious as well as luxury seeking customers. Manual sunshade consists only of cassette, pull bar, spindle mechanism and hooks whereas the power sunshade consists of cassette, pull bar, spindle mechanism, flap mechanism, bowden cable mechanism, actuator and motor. Due to this difference in package, it becomes difficult to accommodate both variants of sunshade into the same body system. However, this study helps in developing a common body structure by ways of effective packaging, modifying the cable and actuator mechanism and critical packaging of
S M, Rahul, d, Anantha, Kakani, Phani Kumar
Technical Paper
User Experience for Digitalized and Smart Cockpits and Cabins of Next-gen MobilityEPR202500603/31/2025
This SAE Edge Research Report explores advancements in next-generation mobility, focusing on digitalized and smart cockpits and cabins. It offers literature review, examining current customer experiences with traditional vehicles and future mobility expectations. Key topics include integrating smart cockpit and cabin technologies, addressing challenges in customer and user experience (UX) in digital environments, and discussing strategies for transitioning from traditional vehicles to electric ones while educating customers. User Experience for Digitalized and Smart Cockpits and Cabins of Next-gen Mobility covers both on- and off-vehicle experiences, analyzing complexities in developing and deploying digital products and services with effective user interfaces. Emphasis is placed on meeting UX requirements, gaining user acceptance, and avoiding trust issues due to poor UX. Additionally, the report concludes with suggestions for improving UX in digital products and services for future
Abdul Hamid, Umar Zakir
Research Report
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