Browse Topic: Interiors, Cabins, and Cockpits

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An experimental investigation of the liquid jet breakup characteristics in a vaporizer under equivalent operating conditions of a microturbine combustion chamber2025-01-8458To be published on 04/01/2025
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
Development of a new concept structure for 4-way electric headrest adjustment2025-01-8620To be published on 04/01/2025
In car seats, various adjustment mechanisms are provided to accommodate passengers of different body sizes, ensuring a comfortable posture. In premium vehicle models, customer convenience is further enhanced by enabling electric operation for these adjustments. Among these, electric headrest adjustment systems are increasingly being adopted in premium vehicle models. This paper discusses the development of a new 4-way (up/down/left/right) electric headrest concept that aims to improve cost competitiveness while addressing existing quality issues. The current headrest mechanism consists of an X-link structure, where a motor rotates the X-link around its axis to adjust the mechanism forward and backward. However, this design involves many components, resulting in high costs, and the tolerance caused by screw thread gaps at the center of the X-link makes quality assurance difficult. Additionally, the reliance on a lead screw for operation causes issues with play and load concentration. To
Yu, Sanguk
Technical Paper
Development of Ceramic Humidity Regulator (CHR) Using Honeycomb Type PTC Heater to Improve Electric Vehicle Driving Range in Winter2025-01-8177To be published on 04/01/2025
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 power 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 power consumption. A desiccant system typically consists of two
Hamada, Takafumi, Shinoda, Narimasa, Konno, Yoshiki, Ihara, Yukio, Ito, Masaki
Technical Paper
Analysis of Coolant Flowing and Heat Transfer Performance in High Voltage Heater System2025-01-8194To be published on 04/01/2025
A method for performance calculation and experimental method of a high voltage heater system in electric vehicles is proposed. This system is critical for the thermal management of electric vehicle batteries, especially in low-temperature environments. It provides essential heating support to maintain optimal battery performance and safety, thereby improving overall efficiency and reliability.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
Gong, Ming, Wang, Xihui, Wang, Dongdong, Shangguan, Wen-Bin
Technical Paper
Modeling Virus Infection Risks in Automobile Cabin2025-01-8176To be published on 04/01/2025
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 13 (ASHRAE Standard 52.2) and HEPA filters. Recent ASHRAE standard 243 (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
Effects of Aging on PVC-based Instrument Panel Skin for Passenger Airbag Deployment Analysis2025-01-8321To be published on 04/01/2025
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 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 material
G, Karthigan, Savic, Vesna, Ravichandran, Gowrishankar
Technical Paper
Demonstration of Model Predictive Control to optimise cabin thermal comfort in a battery electric vehicle2025-01-8145To be published on 04/01/2025
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
Research on the Thermal Performance of Thick Film Heater for Electric Vehicle Battery2025-01-8154To be published on 04/01/2025
The life of power battery and its discharge efficiency in electric cars will be significantly reduced in a low temperature environment. Therefore, in order to ensure its working mileage and safety, heating the power battery is required. Heat pump air conditioners and PTC-based onboard heaters are usually way to heat the power battery under lower temperature so far. In low temperature environment, due to the lower heating efficiency of the heat pump air conditioner, onboard heaters are widely used in electric cars. A specific thick film heater(TFH) for electric vehicles is investigaed in this study, and its three dimensional heat tansfer analysis model is established. The heat transfer and fluid performace of the TFH is analied using a computational fluid dynamics software. 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
Guan, Wenzhe, Guo, Yiming, Wu, Xiaoyong, Wang, Dongdong, Shangguan, Wen-Bin
Technical Paper
Coordinated Motor Speed Control Design for Seating Systems2025-01-8069To be published on 04/01/2025
Automotive seating systems have become much more sophisticated in terms of providing more flexible configurations and comfort functionalities to the consumer. Regular power seating with a few motors to move and adjust the seat position has turned to be more technical advanced reconfigurable systems with more sensors and actuators, such as Easy Entry, Zero Gravity, Stadium Swivel IP Nesting, Power Long Rails etc. The overall control of the seating becomes more and more like the robotics control with many coordinated movements. In this paper, a novel control strategy is proposed for the coordinated speed controls of multiple motors. Unlike traditional seating controls, other than the open loop controls, a feed-back approach is proposed together with a Kalman-filter based speed estimation via raw signal of Hall Effect sensor. The control of multiple motors at the same time will also be coordinated and synchronized properly, so that the seat will move in coordination, will not only not to
Yang, Hanlong, li, Miranda
Technical Paper
Occupant Responses in High-Speed Rear Sled Tests: Focus of Initial Position, Seat Strength and ATD Size2025-01-8731To be published on 04/01/2025
This study evaluates ATD responses in high-speed rear sled tests with various seat designs. Seat designs included modern conventional seats (non-SIR), second row seat integrated restraints (SIR), and rigidized SIRs. Sixteen tests were conducted with the lap-shoulder belted 50th male Hybrid III ATD at 40 km/h, 10 with nominal position and 6 with the ATD leaned forward. The biomechanical responses were below IARV. Lower neck Nij was higher with SIR than non-SIR seats. Head, lower neck and chest responses were higher in the SIR seats when the ATD was leaned forward. Compared to nominal position, the responses were higher with the forward position, increasing the gap between the head/upper torso and seat/head restraint, irrespective of seat type. Six tests were conducted at 56 km/h with the 5th female Hybrid III, 4 in nominal position and 2 leaned outboard. The biomechanical responses were higher in SIR than non-SIR seats in the nominal position. When the ATD was leaned outboard, the head
Parenteau, Chantal, Burnett, Roger
Technical Paper
Overview of Seat Design Changes and Performance2025-01-8729To be published on 04/01/2025
NHTSA published an ANPRM to update FMVSS 207. This study was conducted to provide a historical background on seat designs and test performance based on literature review and updated prior work. Seat designs have continuously evolved, including changes in seat and head restraint geometry. Most seats today have a conventional design, with D-ring on the B-pillar. Seatbacks have become taller; most are now designed with an open perimeter frame allowing the occupant to pocket while offering load-limiting features. Head restraint have become bulkier cushioning the head early during ride-down. Various methods are used to evaluate seats including quasi-static pull tests, and dynamic sled tests. The pull-tests were conducted with a body block simulating upper torso loading; the results showed a continuous increase in rearward loading strength. Seat strength averaged 10,902 in-lbs in seats with model year (MY) 1989 and older and 28,716 in-lb in MY 2010+, decreasing dynamic seatback rotation
Parenteau, Chantal, Burnett, Roger, Davidson, Russell
Technical Paper
A Co-Simulation Methodology for Predicting Occupant Thermal Comfort for Cabin Cooldown and Warmup Scenarios2025-01-8188To be published on 04/01/2025
Balasubramanian, Sudharsan, Natarajan, Shankar
Technical Paper
Finite Element Simulation and Experimental Study of the In-Mold Graining Process2025-01-8330To be published on 04/01/2025
In-Mold Graining (IMG) is an innovative production technology applied to the skin wrapping of automotive interior components. In the design of automotive interior components of door panels and instrument clusters, to overcome process-related problems, such as the thinning of grain patterns and excessive reduction in thickness, simulation of the skin vacuum forming process is required. The Thermoplastic Olefin (TPO) skin material is investigated in this paper, and a viscoelastic mechanical model for this material is established. Dynamic Mechanical Analyzer (DMA) is utilized to perform scan for frequency and temperature, and the tested data is used to obtain key model parameters of the viscoelastic constitutive model. Based on the experimental data, the study explores how to calculate the relaxation time spectrum to describe the viscoelastic properties of TPO material during the vacuum adsorption process. Numerical simulation of the vacuum adsorption process of TPO material is conducted
Chai, Bingji, Guo, Yiming, Xie, Xinxing, Zhang, Qu
Technical Paper
Vehicle interior audio system noise prediction based on inverse acoustic approach and directivity pattern2025-01-8640To be published on 04/01/2025
Automotive audio components must meet high quality expectations with ever-decreasing development costs. Predictive methods for the performance of sound systems in view of the optimal locations of loudspeakers in a car can help to overcome this challenge. Use of simulation methods would enable this process to be brought up front and get integrated in the vehicle design process. The main objective of this work is to develop a virtual auralization model of a vehicle interior with audio system. A hybrid simulation approach, which combines both the ray based & finite element approach to predict acoustic transfer functions & auralization effects across the audible frequency range on any chosen vehicle variant. In this paper, Acoustic Vehicle Alerting System (AVAS) speaker tested in an acoustic lab is used. The surface vibration pattern over the surface of the virtual speaker is first extracted based on measured sound pressure data. The acoustic response in a free field generated by the
Baladhandapani PhD, Dhanasekar, Thaduturu, Sai Ravikiran, Du, Isaac
Technical Paper
Automatic Generation of HVAC Ducting System Designs using Topology and Shape Optimization2025-01-8656To be published on 04/01/2025
Topology and shape optimization of a vehicle Heating, Ventilation and Air Conditioning (HVAC) system is presented in this paper. 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 means
Papadimitriou, Dimitrios, Sandboge, Robert
Technical Paper
INTEGRATED BODY STRUCTURE TO ACCOMMODATE MANUAL AND POWER DOOR SUNSHADE VARIANTS IN A VEHICLE2025-01-8616To be published on 04/01/2025
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
A reconfigurable backrest surface for investigating preferred seat configurations2025-01-8611To be published on 04/01/2025
A reconfigurable experimental seat is useful for seating comfort research, and allows researchers to investigate on 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. Equipped with force and positioning sensors, all contact forces and seat position can be measured. More specifically, the seat pan surface is composed of a matrix of 52 cylinders, each adjustable in height and each equipped with a three-axis force sensor, while the backrest is composed of three supports. These cylinders make it possible to vary the contact surface 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. As for the seat pan
Wang, Xuguang, Beurier, Georges
Technical Paper
Investigation of the Blockage Phenomenon in Closed Wall Wind Tunnels During the Testing of Bluff Automotive Bodies with Large Wakes in Yawed Configurations2025-01-8786To be published on 04/01/2025
Abstract 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 four bodies that generate large wakes to examine the interference phenomena in solid wall wind tunnels and the effects that they have on the pressures, forces and force increments 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
Gleason, Mark, Riegel, Eugen
Technical Paper
Control Trajectory Optimization of Electric Vehicle Heat Pump-based Cabin Heating System2025-01-8144To be published on 04/01/2025
Optimal control of battery electric vehicle thermal management systems is essential for maximizing 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
Modelling of Vehicle Efficiency Through Thermal System Plant and Controls Integration2025-01-8186To be published on 04/01/2025
Improving the efficiency of Battery Electric Vehicles (BEVs) is crucial for enhancing their range and performance. This paper explores the use of virtual tools to integrate and optimise various systems, with a particular focus on thermal management. The study considers global legislative drive cycles and real-world scenarios, including hot and cold weather conditions, charging cycles, and towing. A virtual vehicle model is developed to include major contributors to range prediction and optimization, such as thermal systems. Key components analysed include high voltage (HV) and low voltage (LV) consumers (compressors, pumps, fans), thermal system performance and behaviour (including cabin climate control), thermal controllers, and thermal plant models. The emergent behaviour resulting from the interaction between hardware and control systems is also examined. The methodology involves co-simulation of hardware and control models, encompassing thermal systems (coolant, refrigerant, cabin
Tourani, Abbas, Price, Christopher, Dutta, Nilabza, Moran Ruiz, Eduardo
Technical Paper
Headliner design considerations to meet safety and regulations2025-01-8245To be published on 04/01/2025
Headliners are one of the largest components inside an automobile, stretching from the front windshield to the rear windshield. Besides its aesthetic purpose, it contributes to multiple other purposes like housing different components, helps in NVH, defines the interior roominess, and plays a crucial role in defining the deployment of curtain airbag. The headliner also plays a role in meeting regulatory requirements like upward visibility and headroom requirements of the occupants. During the deployment of curtain airbag, it is important that the headliner-pillar interface aids in the easy opening of airbag, with the least hindrance. This is defined by multiple factors like the location of headliner-pillar interface in “z” direction, and its distance from the airbag ramp bracket, the position of the inflator, the mountings of the headliner and pillar trims, to name a few. Also, during the deployment of the airbag, it is important that parts such as grabhandle, speaker grilles, etc
Sabesan, Arvind Kochi, D, ANANTHA, Kakani, Phani Kumar
Technical Paper
A Wide Belt Correction Strategy for Belt-Whip and Wheel Ventilation Drag2025-01-8770To be published on 04/01/2025
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
Power Loss Estimation in Poly-V Belts for Micro and Mild Hybrid Powertrains Using the Generalized Maxwell Model2025-01-8316To be published on 04/01/2025
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 and improving its control. 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
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 Consumption2025-01-8191To be published on 04/01/2025
A major portion of the energy consumed in a vehicle is spent on keeping the occupants thermally comfortable in all environmental conditions. 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, blower power, etc. 1D-3D co-simulation approach is used for modeling the cabin. Berkeley human comfort model has been used in recent times to get a subjective
Natarajan, Shankar, Balasubramanian, Sudharsan
Technical Paper
Modeling and Control Strategies of the Thermal Management System for Electric Vehicles2025-01-8190To be published on 04/01/2025
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 System2025-01-8172To be published on 04/01/2025
At Toyota Motor Corporation, we are pursuing an omnidirectional strategy that includes BEVs, PHEVs, and FCEVs 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 starting the engine to increase deceleration through engine braking during coasting. In this context, PHEVs are expected to extend their cruising range and enhance EV driving experience as "Practical BEVs". While several manufacturers including us are increasing battery capacity and enhancing convenience, restrictions on EV driving opportunity due to low battery temperature will affect the appeal of these electrified vehicles. However, introducing a battery heater is considered
Hoshino, Yu
Technical Paper
Optimization and Regression Modeling of Additive Manufacturing (Fused Deposition Modeling) of PETG Material for Automobile applications2025-28-0146To be published on 02/07/2025
Additive Manufacturing (AM) techniques, specifically Fused Deposition Modeling (FDM), have transformed the manufacturing industry by allowing the creation of intricate shapes using different materials. Polyethylene Terephthalate Glycol (PETG) is a thermoplastic that is commonly used in additive manufacturing (AM) because of its advantageous mechanical properties, resistance to chemicals, and ease of processing. PETG is used especially for producing automotive components that require impact resistance, dimensional stability, and good surface finish. It can be used for interior trim parts, protective covers, and exterior components The primary objective of this study is to enhance the FDM process parameters for PETG material and construct regression models that can accurately forecast important performance metrics. An investigation was carried out through experimental trials to examine the impact of FDM process parameters, such as layer thickness, infill density, printing speed, and
Natarajan, Manikandan, Pasupuleti, Thejasree, Shanmugam, Loganayagan, Katta, Lakshmi Narasimhamu, Silambarasan, R, Kiruthika, Jothi
Technical Paper
Optimization and Regression Modeling of Fused Deposition Modeling for TPU Material used in automotive instrument panels2025-28-0142To be published on 02/07/2025
Fused Deposition Modeling (FDM) is a widely recognized additive manufacturing method that is highly regarded for its ability to create complex structures using thermoplastic materials. Thermoplastic Polyurethane (TPU) is a highly versatile material known for its flexibility and durability. TPU has several applications, including automobile instrument panels, caster wheels, power tools, sports goods, medical equipment, drive belts, footwear, inflatable rafts, fire hoses, buffer weight tips, and a wide range of extruded film, sheet, and profile applications.. The primary objective of this study is to enhance the FDM parameters for TPU material and construct regression models that can accurately forecast printing performance. The study involved conducting experimental trials to examine the impact of key FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical responses, including dimensional accuracy, surface quality, and mechanical
Pasupuleti, Thejasree, Natarajan, Manikandan, Sagaya Raj, Gnana, Silambarasan, R, Kiruthika, Jothi
Technical Paper
A Simulation Methodology for Rainwater Ingress into Vehicle HVAC Cowl Box With Design Improvement2025-28-0163To be published on 02/07/2025
Cowl Box is the first element of HVAC air passage and responsible for keeping rainwater away from blower unit without much impacting the HVAC air flow rate. Rainwater ingress to HVAC system affects passenger comfort. The main design objectives to be achieved in the design of HVAC cowl box includes minimizing the pressure drop and eliminating the chances of water ingress in cowl box. There are CFD tools available to study the cowl box pressure drop. However, methods available to study rain water ingress in cowl box are expensive in both mesh preparation and computational time. Using SPH (Smooth Particle based Hydrodynamics) based Preonlab tool, an attempt has been made in this work to study the design improvements of HVAC cowl box to eliminate the chances of flooding during raining. ANSYS FLUENT tool used to study the pressure drop of each design. The objectives of the simulation are to examine the cowl box pressure drop and water ingress quantity into the HVAC module. Designs with
Baskar, Subramaniyan, A, Boopalshanmugam, Raju, Kumar
Technical Paper
LEDs and Aircraft ApplicationsARP6253A (Current)01/09/2025
This document presents minimum criteria for the design and installation of LED assemblies in aircraft. The use of "shall" in this specification expresses provisions that are binding. Nonmandatory provisions use the term "should
A-20C Interior Lighting
Recommended Practice
Simulation Analysis of Seat Ventilation Performance Considering Deformation during Human Occupancy15-18-02-000801/02/2025
The comfort of seats increasingly becomes a crucial factor in the overall driving experience, particularly as vehicles become increasingly integrated into people’s daily lives. Passengers often maintain a relatively fixed posture and have close contact with the seat for extended periods of time, leading to issues such as heat, humidity, and stickiness. In order to enhance the thermal comfort experienced by occupants, manufacturers are no longer satisfied with ensuring the thermal comfort performance of vehicles only through the HVAC system in the cabin, but also developed a microclimate control seat that adjusts the temperature through ventilation between the contact surface of the seat and the human body, trying to improve the thermal comfort of passengers more effectively. However, the ventilation ducts of these seats are commonly designed based on empirical or autonomous standards, and their effectiveness is subsequently assessed through test or simulation, typically under unloaded
Zhang, Tianming, Ren, Jindong, Zhang, Haonan
Journal Article
Experimental Investigation of Spray Characteristics Direct Injected in Atmospheric Ambient Conditions by a Multi-Hole Injector2024-36-015612/20/2024
The aim of the present work was to characterize macroscopic spray parameters of a multi-hole direct injection injector for spark ignition engine applications. The geometry, the position of spray boundaries the overall cone angle, the spray vertical penetration and the vertical spray length were evaluated by processing the spray images recorded at 3300 frames per second. The frequency of recording images was suitable for capturing all the spray developments in all tested conditions. The tested fluid was EXXSOL D60 for simulating ethanol spray characteristics due to its similar properties and due to security reasons. The injector was tested outside the engine and into an open acrylic chamber being injected into atmospheric air conditions of the laboratory. The injection pressure was set up in 100 bar and the simulated engine speed were set up in MOTEC ECU in 3000 rpm, 3600 rpm and 4000 rpm. The injection durations were set up in 3,0 ms for 3000 rpm and 2.3 ms for 3600 rpm and 4000 rpm
Guzzo, Márcio Expedito, Fonseca, Lucas Guimarães, Duarte, Thales Henrique Ramos, Baeta, José Guilherme Coelho, Huebner, Rudolf, Pujatti, Fabrício José Pacheco
Technical Paper
Loss Function Curve to Quantify Customer (Dis)Satisfaction for Rear Chair Height (H30-22024-36-005012/20/2024
In vehicle design, the H point is a theoretical relative location measured in relation to specific characteristics that determines a group of dimensions to define vehicle interior roominess. Based on theoretical H point automakers concept their vehicle and have to make important decisions on vehicle architectural that could result in a bad product for the future customers and during the early phase of vehicle development, one of the key design attributes to consider is in relation to the interior comfort of the user, so that its design and its components enabling a favorable interaction with the occupant. Vehicle interior roominess is one of the key factors for buyers’ satisfaction with certain features such as the shoulder room, headroom and couple distance, among others, may influence the level of satisfaction of the occupants’ comfort. One of these items refers to the rear chair height (H30-2), which is presented while by the distance of rear H-point to the vehicle floor affecting
Santos, Alex Cardoso, Silva, Gustavo, Terra, Rafael, Pádua, Antônio, Benevente, Rodrigo, Buscariolo, Filipe, Lourenço, Sergio
Technical Paper
Magnesium Alloy Hybrid Composite Properties are Featured with Boron Carbide Particle for Automotive Seat Frame Usage2024-01-520712/10/2024
With the advancement of lightweight magnesium-based hybrid composites, are potential for weight management applications. The liquid state stir cast process is the best way to produce complex shapes and most industries are preferred. However, the melting of magnesium alloy and achieving homogenous particle distribution are the major challenges for the conventional stir-casting process, and hot crack formation is spotted due to thermal variations. The main objectives of the present research are to enhance the microstructural and mechanical behaviour of magnesium alloy hybrid nanocomposite (AZ91E) adopted with boron carbide (B4C) and alumina (Al2O3) nanoparticles through a semisolid stir cast technique associated with inert atmosphere helps to limits the oxide formation and reduce risk of magnesium fire. The effect of composite processing and multiple reinforcements on surface morphology, tensile strength, impact strength, and hardness were thoroughly evaluated and compared. The results
Manivannan, S., Venkatesh, R., Kaliyaperumal, Gopal, Karthikeyan, S., Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad, Karthikeyan, N.
Technical Paper
Biofidelity Assessment of the GHBMC M50-O Seated in a Honda Accord Seat in a Rear-Facing Configuration during a High-Speed Frontal Impact09-12-03-001412/10/2024
Vehicles equipped with automated driving systems (ADS) may have non-traditional seating configurations, such as rear-facing for front-row occupants. The objectives of this study are (1) to generate biomechanical corridors from kinematic data obtained from postmortem human subjects (PMHS) sled tests and (2) to assess the biofidelity of the Global Human Body Models Consortium (GHBMC) 50th male (M50-O) v6.0 seated in an upright (25-deg recline) Honda Accord seat with a fixed D-ring (FDR) in a 56 km/h rear-facing frontal impact. A phase optimization technique was applied to mass-normalized PMHS data for generating corridors. After replicating the experimental boundary conditions in the computational finite element (FE) environment, the performance of the rigidized FE seat model obtained was validated using LSTC Hybrid III FE model simulations and comparison with experiments. The most recent National Highway Traffic Safety Administration (NHTSA) Biofidelity Ranking System (BRS) method was
Pradhan, Vikram, Ramachandra, Rakshit, Stammen, Jason, Kracht, Corey, Moorhouse, Kevin, Bolte, John H., Kang, Yun-Seok
Journal Article
Cab Heating Systems Test Procedure and Performance Requirements—Trucks, and Multipurpose VehiclesJ1612_202412 (Current)12/06/2024
This SAE Recommended Practice establishes uniform test procedures and performance requirements for engine coolant type heating systems of enclosed truck cabs. The intent is to provide a test that will ensure acceptable comfort for cab occupants. It is limited to a test that can be conducted on uniform test equipment in commercially available laboratory facilities. There are two options for producing hot coolant in this document. Testing using these two approaches on the same vehicle will not necessarily provide identical results. Many vehicle models are offered with optional engines, and each engine has varying coolant temperatures and flow rates. If the test is being conducted to compare the performance of one heater design to another heater design, then the external coolant source approach (Test A) will yield the most comparable results. If the test is being conducted to validate the heater installation on a specific vehicle model with a specific engine, then using the engine to heat
Truck and Bus Windshield Wipers and Climate Control Comm
Recommended Practice
Bus Body Heating System TestJ2233_202412 (Current)12/06/2024
This SAE Recommended Practice establishes uniform cold weather test procedures and performance requirements for engine coolant type heating systems of bus that are all vehicles designed to transport 10 or more passengers. The intent is to provide a test that will ensure acceptable comfort for bus occupants. It is limited to a test that can be conducted on uniform test equipment in commercially available laboratory facilities. Required test equipment, facilities, and definitions are included. There are two options for producing hot coolant in this recommended practice. Testing using these two approaches on the same vehicle will not necessarily provide identical results. Many vehicle models are offered with optional engines, and each engine has varying coolant temperatures and flow rates. If the test is being conducted to compare the performance of one heater design to another heater design, then the external coolant source approach (Test A) will yield the most comparable results. If the
Truck and Bus Windshield Wipers and Climate Control Comm
Recommended Practice
Rating Air-Conditioner Evaporator Air Delivery and Cooling CapacitiesJ1487_202412 (Current)12/06/2024
The purpose of this SAE Recommended Practice is to establish uniform test procedures for measuring and rating air delivery and cooling capacity of truck and off-road self-propelled work machines used in earth moving, agriculture, and forestry air-conditioner evaporator assemblies. It is the intent to measure only the actual cooling capacity of the evaporator. It is not the intent of this document to rate and compare the performance of the total vehicle air-conditioning system
Truck and Bus Windshield Wipers and Climate Control Comm
Recommended Practice
Driver Selected Seat Position for Class B Vehicles - Seat Track Length and SgRPJ1517_202412 (Current)12/06/2024
This Recommended Practice provides a procedure to locate driver seat tracks, establish seat track length, and define the SgRP in Class B vehicles (heavy trucks and buses). Three sets of equations that describe where drivers position horizontally adjustable seats are available for use in Class B vehicles depending on the percentages of males to females in the expected driver population (50:50, 75:25, and 90:10 to 95:5). The equations can also be used as a checking tool to estimate the level of accommodation provided by a given length of horizontally adjustable seat track. These procedures are applicable for both the SAE J826 HPM and the SAE J4002 HPM-II
Truck and Bus Human Factors Committee
Recommended Practice
A Predictive Controller for Battery Cooling and Air-Conditioning Systems to Tackle the Comfort-Safety-Efficiency Dilemma2024-28-014712/05/2024
The advent of electric vehicles has increased the complexity of air conditioning systems in vehicles which now must maintain the safety and comfort of occupants while ensuring that the high voltage battery temperature is kept within safe limits. This new task is critical due to the influence of the cell and battery pack temperature on the efficiency. Moreover, high temperatures within the battery pack can lead to undesirable effects such as degradation and thermal runaway. Classical solutions to this problem include larger air conditioning components to support worst case scenario conditions where the cooling request from the battery and the cabin happen at the same time. In such conditions, for the safety of the battery, the cooling request is assigned to battery system which may cause discomfort to the passengers due the significant temperature increase in the cabin during such events. The probability of such events happening is certainly dependent on the weather conditions but in
Palacio Torralba, Javier, Kulkarni, Shridhar Diliprao, Shah, Geet, Jaybhay, Sambhaji, Kapoor, Sangeet, Locks, Olaf
Technical Paper
Leak Detection: Stability and Compatibility Criteria of Fluorescent Refrigerant Leak Detection Dyes for Mobile Air-Conditioning SystemsJ2297_202412 (Current)12/05/2024
This SAE Standard applies to dyes intended to be introduced into a mobile air-conditioning system refrigerant circuit for the purpose of allowing the application of ultraviolet leak detection. In order to label any product(s), they shall meet SAE J2297, the certification process as described in SAE J2911 must be followed, and the documentation described in Appendix A shall be submitted to SAE
Interior Climate Control Fluids Committee
Technical Standard
A Design Synthesis Approach to Improve HVAC Acoustic Performance of Passenger Vehicles2024-28-022112/05/2024
Noise induced by the Heating, Ventilation and Air conditioning (HVAC) system inside a vehicle cabin can cause significant discomfort to passengers and, in turn, affect the brand image in a competitive automotive market. HVAC acoustic performance has become more prominent with the ongoing transformation from Internal Combustion (IC) to Electric Vehicle (EV) segments. For this reason, acoustic quality is increasingly prioritized as a key design issue throughout the entire development process of the HVAC system. This paper covers the design synthesis considering air handling unit-induced airborne and structure-borne noise of a dashboard-mounted HVAC system to achieve better NVH refinement inside vehicle while maintaining thermal performance. This study began by analysing HVAC-induced blower motor, impeller, air ducts, vents, and recirculation suction noise from the vehicle level to subsystem level and eventually at the component level. At the subsystem level, major noise source
Titave, Uttam Vasant, Naidu, Sudhakara, Kalsule, Shrikant
Technical Paper
Optimization of Console Armrest Design for Reduction of G-Values in Head Impact Testing2024-28-021212/05/2024
Head injuries from interior impacts during vehicle accidents are a significant cause of fatalities in India. Data from the National Crime Records Bureau (NCRB) for 2023 reveals that approximately 15% of the total 150,000 road fatalities were due to head impacts on vehicle interiors, resulting in about 22,500 deaths. Thus, head impact protection in a car crash is key during the design of vehicle interiors. IS 15223 and ECE-R21 provide specific guidelines for head impact testing of instrument panels and consoles in vehicles to ensure compliance with safety standards and minimize the risk of head injury during collisions. By systematically addressing each aspect of IS 15223 and ECE- R21 in the design, testing, and documentation phases, manufacturers can ensure that console armrests are optimized for safety. This approach not only helps meet regulatory standards but also enhances overall occupant protection in vehicles during collisions. The objective of this paper is to design a console
Malhotra, Deepak, Vaishnav, Suresh, Sureshkumar Presannakumari, Rajasilpi, Mangal, Gautam, Keshri, Amit
Technical Paper
Cabin Emergency Exits Design and Operation - Transport Category AircraftARP488G (Current)12/04/2024
This ARP provides design and performance recommendations for emergency exits in the passenger cabin. This ARP does not apply to Crew Emergency Exits
S-9B Cabin Interiors and Furnishings Committee
Recommended Practice
Cabin Crew StationsARP583L (Current)12/03/2024
This SAE Aerospace Recommended Practice (ARP) provides guidance for the design and location of cabin crew stations, including emergency equipment installations at or near such stations, to enable the cabin crew to perform effectively in emergency situations, including emergency evacuations. Recommendations regarding design of cabin crew stations apply to all such stations; recommendations regarding location apply to those stations located near or adjacent to floor level exits
S-9B Cabin Interiors and Furnishings Committee
Recommended Practice
EDITORIAL: China's warning signs24AUTP12_0412/01/2024
Sometimes, I cringe; sometimes, I just listen and wonder. These past few months have given us all a lot to think about in the automotive space, and it's clear now that the coming years will keep the foot down on the accelerator when it comes to the dramatic changes we've experienced this past decade. One thing that stood out to me in various recent conversations is that there's a widening gulf opening between Chinese automakers and the rest of the world. This isn't exactly news, and this column isn't meant to monger any fears. It's just a bit of off-the-cuff reporting that sheds a bit of light on the level of the challenges we face. As you can read in Chris Clonts' excellent report further in this issue about the warning that Voltaiq's CEO gave at The Battery Show this October, the U.S. is in serious danger of falling well behind Chinese competitors in the EV battery race (Michael Robinette tackles similar ground through a tariff lens in this month's Supplier Eye). But that message was
Blanco, Sebastian
Magazine Article
Location and Operation of Air Brake Controls in Motor Truck CabsJ680_202411 (Current)11/22/2024
This recommended practice shall apply to all on-highway trucks and truck-tractors equipped with air brake systems and having a GVW rating of 26 000 lb or more
Truck and Bus Human Factors Committee
Recommended Practice
Cleaner, Carpet Shampoo TypeAMS1630D (Current)11/22/2024
This specification covers a shampoo type carpet cleaner in the form of a liquid
AMS J Aircraft Maintenance Chemicals and Materials Committee
Material Specification
Night Vision Goggle (NVG) Compatible Light SourcesARP4168B (Current)11/21/2024
This ARP covers three common light sources, incandescent, electroluminescent and light emitting diode that, when NVG filtered, can be used to illuminate NVG compatible aerospace crew stations. It is recognized that many other different light sources can also be used for this purpose. Also see 2.1.1 for other SAE documents that cover particular applications within the crew station environment. This ARP sets forth recommendations for the design of NVG compatible lighting, utilizing these light sources, that will meet the requirements of MIL-L-85762 Lighting, Aircraft, Interior, Night Vision Imaging System (NVIS) Compatible. This also includes the replacement document MIL-STD-3009: Lighting, Aircraft, Night Vision Imaging System (NVIS) Compatible. Although this ARP concentrates on lamp light sources for illumination, the information contained within this ARP may be directly applied to incandescent, electroluminescent and light emitting diode information display devices. Regardless of the
A-20A Crew Station Lighting
Recommended Practice
Safety Considerations for Airplane LavatoriesARP1315E (Current)11/21/2024
This SAE Aerospace Recommended Practice (ARP) establishes safety recommendations for lavatories in transport category airplanes
S-9B Cabin Interiors and Furnishings Committee
Recommended Practice
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