Browse Topic: Product development

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Road Test Emulation: A Data-Driven Calibration Approach2025-01-0521To be published on 11/25/2025
The resource-intensive process of road testing constitutes an elementary part of the development of vehicle software. A significant proportion of explorative tests and adjustments for use in service are conducted during the vehicle test phase. However, the observed trends of decreasing development cycles and increasing system complexity generate a field of conflicts. In order to address this issue, this paper proposes road test emulation as a data-driven approach for continuously adapting vehicle software to the evolving overall system. Therefore, test scenarios equivalent to in-service conditions are determined based on customer data and test drives. These test scenarios enable an emulation of road testing and the analysis of the system in a real-world operational context from the early stages of the product development process. Sensitivity analyses are utilised to generate system-specific data for the vehicle under development, which is then employed to define initial parameter
Martini, Tim, Kempf, André, Winke, Florian, Auerbach, Michael, Kulzer, André Casal
Visibility study for Tractor with Rear Implement2025-28-0320To be published on 11/06/2025
This paper details a process involving digital content creation tools to conduct visibility studies for machinery that utilize vision-based perception system. In this paper we go through the process of preparing over 50 unique tillage implements with Light geometry attached to assess areas of potential sensor occlusion. We optimized the CAD Geometry of the model by removing Duplicate parts, Wiring, Floating geometry. Also, optimization of heavier parts was required and ensuring of high-altitude parts (i.e. SMV, Starfire, Lights, brackets) was important to ensure proper visibility studies. Making sure that the setup of the implement matched that of its corresponding vehicle was also Pertinent. The developed high-fidelity models that are used to Conduct perception occlusion analysis, develop simulations, quickly verify component geometries. Occlusion analyses facilitate cross-team discussions of the perception system coverage and expedite product development. Moreover, the generated high
Kumar, Pravin, GUMASTE, Amey, Rode, Aboli, Goč, Matej
Manufacturing Process Automation for Construction equipment Industry2025-28-0253To be published on 11/06/2025
The adoption of automation in construction equipment manufacturing is becoming increasingly vital for boosting efficiency, productivity, and safety. By taking over repetitive and hazardous tasks, automation helps mitigate labor shortages and allows human workers to concentrate on more complex activities. It ensures consistent quality control, reduces production costs, and provides the flexibility to adapt to changing market demands. Although the initial investment in automation technology can be substantial, the long-term benefits include enhanced workplace safety, lower error rates, and overall cost savings. This paper examines various automation technologies utilized in construction equipment factories and their role in driving the industry's future growth. Key Technologies discussed in this paper: 1. Material handling for construction equipment structures 2. Latest developments in robot welding for construction equipment 3. Cobot welding for high variety, low volume components 4
BHAKUNI, TANUJ, Bhorge, Pankaj, Saseendran, Unnikrishnan
Digital solution using immersive technology for field failure2025-28-0306To be published on 11/06/2025
Warranty claims act as primary source of characterizing field failures across industries, wherein appropriate classification of these claims is critical for further analysis. The classification of warranty claims is a highly laborious effort involving significant man-hours of warranty analysts. This can be highly optimized & made efficient using direct interpretation of the claim data on 3D model using unity game engine. Additionally, the color perception technique using immersive technology (AR/VR) can help to identify the vital few & drive prioritization of the field failures leading to faster problem resolution. The capabilities of UIUX & Advanced Visualization integrated to develop novel method to classify the warranty claims & interpret it on a 3D model using immersive technology which is novel & one of its kind in Industry. Unique characteristics of this tool is it focuses on the warranty claim classification by claim cost & count of claims and presents the heat map (Red-High
Nankery, Vivek, savadatti, Sandeep, Shete, Atul, Apkare, Sanket, Ganapathi, Poongundran
Machine Learning based Off-Road Vehicle Turn identification using Vehicle & GPS Parameters2025-28-0344To be published on 11/06/2025
Identification of different types of turns during field operation of off-road vehicles is critical in the overall vehicle development as it is helpful in identifying & optimizing machine performance, correct duty cycle, fuel economy, stability analysis, accurate path planning, customer usage pattern & designing the critical components, etc. In this study, a machine learning (ML) based methodology has been developed to detect the off-road vehicle turns using vehicle & GPS parameters. Three most common types of off-road vehicles turn conditions e.g., Straight line, Bulb turn, and Three-Point turn have been considered. Different vehicle parameters (like latitude & longitude, compass bearing, yaw rate, vehicle speed, swash plate angle, engine speed, percent load at vehicle speed, raise lower front & PTO channels) generated during field test have been used here. These vehicle parameters are further processed, analyzed and used in ML learning model building. Four ML models e.g., SVM, K-NN
Gangsar, Purushottam
Design Optimization of Rolling Resistance Product Development Using Linear Regression2025-28-0314To be published on 11/06/2025
Simulation, physical testing, and a combination of both is an indispensable tool for developing reliable product designs in the automotive industry. Engineers rely on this integrated approach to thoroughly explore design possibilities and fine-tune products for varying configurations. Drawing insights from existing designs, engineers can effectively tackle important design challenges, such as reducing rolling resistance. This study introduces a pragmatic solution, leveraging simulation and real-world test data, and demonstrates the effectiveness of employing Linear Regression (LR) techniques for improving rolling resistance in vehicles. Integrating LR algorithms into the design process enables swift and cost-effective optimization of parameters, offering a quicker pathway for product development.
ALTHI, Tirupathi Rao, Manuel, Naveen, K, Manu
PTO Clutch Hydraulic Performance Evaluation Methodology Development & Correlation2025-28-0295To be published on 11/06/2025
This paper presents an analysis methodology developed to understand the impact of pressure spikes in off-highway applications, particularly during PTO (Power Take-Off) clutch engagement. These pressure spikes can adversely affect hydraulic subsystem components such as seals, gaskets, and valve operations. Assessing hydraulic system performance through physical trials can be cumbersome, resulting in longer development times and increased costs. To address this, a methodology was developed in a virtual environment to evaluate hydraulic system performance. The virtual method outlined in this paper is created in a 1D environment using an analytical approach to replicate the transient behavior of the system. The hydraulic system primarily includes a relief valve, solenoid valves, a pump, and a clutch. An analytical model was developed for the hydraulic system components with the right fidelity to accurately capture the transient behavior and magnitudes of pressure spikes. This methodology
Memane, Nilesh, Kumar, Suneel, Veerkar, Vikrant
Cooling System Design Approach for Off-Road Vehicles Using CFD and 1D Tools2025-28-0260To be published on 11/06/2025
The average product development cycle spans 3-5 years, involving extensive virtual and physical testing of the machine. Advances in simulation tools have significantly enhanced our ability to identify product solutions early in the design phase. Tools like 1D KULI and Creo Flow simulations offer faster solutions in less time, thereby accelerating the product development cycle. Cooling systems are crucial components of off-highway hybrid vehicles, directly affecting engine efficiency and overall machine functionality. An optimized cooling system ensures the engine operates within safe temperature ranges, preventing overheating and potential damage. Thus, designing an effective cooling system is a vital aspect of machine engineering. 3D Computational Fluid Dynamics (CFD) simulations are essential for evaluating cooling system performance. These high-fidelity simulations provide detailed insights into fluid flow and heat transfer, enabling engineers to predict and enhance cooling
Ukey, Snehal, Tirumala, Bhaskar, Nukala, Ramakrishna
Virtual Reality Application in CFD Data Analysis for After Treatment Systems2025-28-0329To be published on 11/06/2025
Virtual reality (VR), Augmented Reality (AR) and Mixed reality (MR) are advanced engineering techniques that coalesces physical and digital world to show case better perceiving. There are various complex physics which may not be feasible to visualize using conventional postprocessing methods. Various industrial experts are already exploring implementation of VR for product development. Traditional computational power is improving day-by-day with new additional features to reduce the discrepancy between test and CFD. There has been increase in demand to replace actual test by accurate simulation approaches. Post processing and data analysis is key to understand complex physics and resolve critical failure modes. Analysts spend considerable amount of time to analyze results and provide directions, design changes and recommendation. There is a scope to utilize advanced features of VR, AR and MR in CFD post-process to find out the root cause of any failures occurred with advanced
Savitha, Bhuduri, Sharma, Sachin
Method development for estimating deflection and fatigue life using flex body-based vibration fatigue2025-28-0266To be published on 11/06/2025
Author: Ajit Wandhare Co-Author: Prasad Kulkarni Abstract: The structural analysis of off-highway machine platforms has traditionally relied on inertial loads and single-point excitation-based vibration fatigue methods, derived from earlier testing. While these approaches provide qualitative insights, they often lead to either under- or over-designed components, resulting in the need for multiple physical builds to address issues related to platform deflection and lifespan. Furthermore, handrail deflection assessments have historically been subjective, allowing for potential inaccuracies in problem identification. This paper investigates the implementation of flex body-based estimation techniques for predicting deflections in both platforms and handrails, as demonstrated in a deflection estimation exercise for a current off-highway machine platform. This innovative methodology enhances the precision of deflection and life predictions during the mule or feasibility stages, enabling
Wandhare, Ajit, S Kulkarni, Prasad
3D Printed Injection Molding Tool: An unique Approach for New product development2025-28-0321To be published on 11/06/2025
Automotive industry frequently uses 3D printed plastic proto parts during new product development phases as it bypasses the high tooling investment & development time at early part development stage. However for some application, 3D printing technique & its limited material options are not fulfilling the required material properties in the part, resulting poor performance during product testing which may mislead the design engineer during validation process. To overcome this, we introduce a novel approach in constructing injection molding tool by 3D printing the core and cavity using Stereolithography (SLA). This enables production of parts with application-recommended material grades, facilitating traditional validation and increasing stakeholder confidence. This paper compares part quality from 3D printed molds against conventional metallic molds for a gear housing cover, demonstrating a 45% reduction in tooling costs and a 75% decrease in tooling development time. Mold life analysis
Gandhi, Sorna Rajendran
Comprehensive Warranty Data Analytics: A Blend of Conventional & Advanced Methods2025-28-0299To be published on 11/06/2025
In today’s competitive landscape, industries are relying heavily on the use of warranty data analytics techniques to manage and improve the warranty processes. Warranty analytics is important since it provides valuable insights into product quality and reliability. It must be noted here that by systematically looking into the warranty claims and related information, industries can identify patterns and trends that indicate potential issues with the products. This analysis helps in early detection of defects, enabling timely corrective actions that improve product performance and customer satisfaction. This paper introduces a comprehensive framework that combines conventional methods with advanced machine learning techniques to provide a multifaceted perspective on warranty data. The methodology leverages historical warranty claims and product usage data to predict failure patterns, identify root causes, and optimize warranty policies. By integrating these diverse methods, the framework
Quadri, Danishuddin S.F., Soma, Nagaraju
Design IQ2025-28-0327To be published on 11/06/2025
Weight and cost are critical parameters in any new product development program, influencing aspects such as homologation and efficiency. Traditionally, tracking these parameters at the machine, subsystem, and module levels involves a manual, time-consuming process. This reactive approach often delays the program and hampers the productivity of design engineers. These challenges can be managed with an automation and simulation. WCOSAP automates the extraction of weight details, identifies outliers, calculates module-level impacts, and predicts future weight changes. This proactive tool eliminates repetitive manual work, enhances data accuracy, and supports dynamic updates. By integrating real-time data and predictive models, WCOSAP enables sound decision-making and proactive weight control during the design phase, ultimately improving efficiency and reducing the need for part revisions. This paper discusses the development, implementation, and benefits of the WCOSAP tool, highlighting
Patil, Vivek, Sahoo, Abhilash, ballewar, Sachin, Chidanandappa, Basavaraj, Chundru, Satyanarayana
Reduction in Product Development Time by Field-to-Lab Simulation2025-28-0282To be published on 11/06/2025
KEYWORDS: Flywheel Inertia, Clutch system, Gear Box, Tractor application, Instrumentation, data analysis, Design and develop new test methodology. ABSTRACT: Puddling is a crucial process in rice cultivation, involving the preparation of the soil in a flooded field to create a soft, muddy seedbed. There are two classifications for puddling: full cage and half cage. Full cage puddling involves replacing the rear wheels of the tractor with steel paddle wheels, which are used to till the rice paddies directly without any additional implement. In the half cage puddling, the rear wheels remain on the tractor, and a smaller cage or paddle wheel is attached to the outside. Considering the field size, the operator often releases the clutch very quickly after a speed or direction change. This generates torque spikes, which are harmful to Transmission Gears and Clutches. This can lead to gear teeth bending fatigue failure due to repeated higher bending stresses. In this paper, a study related to
Pathan, Irfan Hamidulla, Bardia, Prashant
Bale Wrap orientation tracking for on-field storage2025-28-0279To be published on 11/06/2025
In the agricultural industry, the transportation and storage of bales-dense stacks of hay used as cattle feed-present significant logistical challenges, particularly for large farms. Traditionally, this process involves extensive labor and vehicle movement from the field to storage areas, known as barns. Improper handling during this transition can lead to substantial losses in both time and re-sources. This development aims to eliminate the last-mile transportation step by enabling year-round storage of bales directly in the field. This objective is achieved through the utilization of a patented wrapping material and the strategic orientation of wrapped bales to enhance their resistance to weather conditions. Field experiments demonstrated that this innovative material not only protects the bales from adverse environmental factors but also effectively retains their nutrient and moisture content. A critical challenge was ensuring correct orientation of the wrap seams during the
Kadam, Pankaj
Leveraging AI for Autonomous Simulations in SIL and HIL Frameworks2025-28-0271To be published on 11/06/2025
This paper offers recent ideas and its implementation on leveraging AI for off highway Autonomous vehicle Simulations in SIL and HIL frameworks. Our objective is to enhance software quality and reliability while reducing costs and efforts through advanced simulation techniques. We employed multiple innovative solutions to build a System of Systems Simulation. Physics based models are prerequisite for detailed and accurate representation of the real-world system but it poses challenges due to its computational complexity and storage requirements. Machine learning algorithms were used to create surrogate/reduced order models to optimize by preserving the expected fidelity of models. It helped to speedup simulation and compile model code for SIL & HIL Targets. Built AI driven interfaces to bridge windows, Linux and Mobile Operating systems. Time synchronization was the key challenge as multiple environments were needed for end-to-end solution. This was resolved by using reinforcement
Karegaonkar, Rohit P., AOLE, Sumit, Dasnurkar, Swapnil, Singh, Vishwajeet, SAHA, Soumyadeep
Ensuring The Reliability of Hydraulic Powered Steering System Through Life Data Analysis2025-28-0297To be published on 11/06/2025
The reliability of vehicle steering systems is very crucial to ensure safety, vehicle performance and customer satisfaction. Life data analysis is conducted to analyze how the steering systems are performing in the field and assess whether the steering systems can meet the reliability target when deployed in the field. This article discusses about the systematic process to conduct the field data analysis of Hydraulic Powered Steering System (HPS) from the warranty claim data, usage of Weibull distribution to derive the life characteristic parameters and explains the application of field data analysis results in steering product development.
Ravindran, Mohan, Sugumar, Ganesh
Next-Gen Off-Highway Maintenance by Leveraging Digital Twins2025-28-0336To be published on 11/06/2025
This paper explores how digital twins can be leveraged to enhance the reliability, efficiency, and longevity of off-highway vehicles. It examines the utilization of digital twins to revolutionize maintenance practices, offering a next-generation approach to vehicle health monitoring. By creating dynamic virtual models that mirror physical assets, digital twins enable continuous monitoring and advanced analytics, facilitating timely and accurate predictive maintenance. This approach reduces unexpected breakdowns, optimizes maintenance schedules, and improves overall vehicle performance. The paper delves into the technical aspects of digital twin implementation, the challenges faced, and the substantial benefits realized in the off-highway vehicle sector. Through comprehensive case studies, demonstrate how digital twins can transform maintenance strategies, ensuring that off-highway vehicles are prepared to meet future operational demands with enhanced resilience and efficiency.
Mogal, Masthanvali, Chennamalla, Chandra Shekar
Environmental Factors and Off-Highway Vehicle Safety2025-28-0322To be published on 11/06/2025
Off Highway vehicles recreation has rapidly expanded across the globe hence it is important to consider the safety of off-highway vehicles which is significantly influenced by various environmental factors, which can pose unique challenges and risks. it is important to make sure that the entire vehicle operates safely and reliably even in the toughest conditions. This paper investigates the impact of environmental conditions on the safety and performance of off-highway vehicles, such as construction equipment, agricultural machinery, and mining vehicles. By examining factors such as terrain, weather conditions, visibility, and natural obstacles, the study aims to identify key hazards and propose strategies to mitigate them. The paper explores how advanced technologies, including digital twins and predictive analytics, can be leveraged to enhance safety measures and improve vehicle resilience in diverse environmental settings. Through comprehensive case studies and empirical data, we
Mogal, Masthanvali, Chennamalla, Chandra Shekar
Hybrid Safety Framework for Autonomous Off-Highway Vehicles2025-28-0325To be published on 11/06/2025
The evolution of Autonomous off-highway vehicles (OHVs) has transformed mining, construction, and agriculture industries largely by increasing vehicles efficiency and safety. These vehicles operate in high dust, uneven terrain, and potential communication failure environments where vehicle safety is challenged. To guarantee vehicle safety in such situations, a robust architecture that combines AI-driven perception, fail-safe mechanisms, and conformance to many ISO standards is required. In unstructured environments, AI-driven perception, decision-making, and fail-safe mechanisms are not fully addressed by traditional safety standards like ISO26262 (road vehicles), ISO19014 (earth-moving machinery),ISO12100(Safety of machinery) and ISO25119 (agriculture). These standards mainly concentrate on the reliability of mechanical and electric/electronic systems. Additionally, emerging standards such as ISO21448 (SOTIF) used to detect and mitigate unsafe AI outputs, and ISO8800(AI safety) which
Muthusamy, Sugantha
Development of an Artificial Calibrator for Shift Program Optimization to Enhance Fuel Efficiency2025-32-0082To be published on 11/03/2025
The calibration of automotive electronic control units is a critical and resource-intensive task in modern powertrain development. Optimizing parameters such as transmission shift schedules for minimum fuel consumption traditionally requires extensive prototype testing by expert calibrators. This process is costly, time-consuming, and subject to variability in environmental conditions and human judgment. In this paper, we introduce an artificial calibrator – a software agent that autonomously tunes transmission shift maps using reinforcement learning (RL) in a Software-in-the-Loop (SiL) simulation environment. The RL-based calibrator explores shift schedule parameters and learns from fuel consumption feedback, thereby achieving objective and reproducible optimizations within the controlled SiL environment. Applied to a 7-speed dual-clutch transmission (DCT) model of a 1.5 L Mild Hybrid Electric Vehicle (MHEV), the approach yielded significant fuel efficiency improvements. In a case
Kengne Dzegou, Thierry Junior, Schober, Florian, Rebesberger, Ron, Henze, Roman
Simulation of Hydraulic Retarder using Particleworks2025-28-0382To be published on 10/30/2025
Meshless particle-based simulation methods are increasingly being considered for modeling complex physical systems, particularly those involving large fluid deformations, splashing, and sloshing effects. The effectiveness of these methods, however, depends greatly on the careful selection of simulation models and parameters. This study investigates the capabilities of Particleworks, a CFD simulation tool employing a particle-based Moving Particle Semi-implicit (MPS) solver, in simulating hydraulic retarders used in heavy-duty vehicles (HDVs). Hydraulic retarders utilize viscous drag forces generated by a spinning rotor within a fluid-filled chamber to achieve controlled braking. A dual-rotor, cup-shaped hydraulic retarder operating is analyzed in Particleworks under various conditions, including the use of different working fluids such as transmission oil, coolant, and water. The study also considered thermophysical properties with oil and examined the impact of geometrical
Kumar, Kamal S., Chaudhari, Gunjan
Automotive Battery Thermal Management by Federated Learning methodology - Prognosis of Thermal runaway.2025-28-0408To be published on 10/30/2025
Today's battery thermal management systems include cloud-based predictive analytics technologies. When the first data is sent to the cloud, battery digital twin models begin to run. This allows for the prediction of critical parameters such as state of charge (SOC), state of health (SOH), remaining useful life (RUL), and the possibility of thermal runaway events. The battery and the automobile are dynamic systems that must be monitored in real time for temperature overrun. However, relying only on cloud-based computations adds significant latency to time-sensitive procedures such as thermal runaway monitoring. Because automobiles operate in various areas throughout the intended path of travel, internet connectivity varies, resulting in a delay in data delivery to the cloud. As a result, the inherent lag in data transfer between the cloud and cars challenges the present deployment of cloud-based real-time monitoring solutions. This study proposes applying a thermal runaway model on edge
Sarkar, Prasanta
Approaches for Mechanical Development and Validation of Hydrogen Internal Combustion Engines2025-01-0398To be published on 10/07/2025
Hydrogen Internal Combustion Engines (H2 ICEs) are seen as a viable zero-emission technology that can be implemented relatively quickly and cost-effectively by automotive manufacturers. The changed boundary conditions of a hydrogen-fueled engine in terms of mechanical and thermal aspects require a review and potential refinement of the design especially for the 'piston bore interface' (liner honing, ring and piston design) but also for other engine sub-systems, e.g. the crankcase ventilation system. The influence of oil entry into the combustion chamber is even more important in hydrogen engines due to the risk of oil-induced pre-ignition. Therefore, investigations of the interaction between friction, blowby and oil transfer into the combustion chamber were performed and are presented in this paper. During the investigations experimental tests were carried out on a single cylinder engine ('floating liner') and on a multi-cylinder engine. The 'floating liner' concept allows the crank
Plettenberg, Mirko, Gell, Johannes, Grabner, Peter, Gschiel, Kevin, Hick, Hannes
Passive solution for Battery Disconnect Unit thermal management for electric vehicle fast charging: numerical study and experimental validation2025-01-0420To be published on 10/07/2025
Charging time is a major problem with electric vehicles development and use. The difficulty of finding a charging station and especially the duration needed for a full charge are becoming more and more important topics in electric vehicles selling points. Fast-charging is more and more used on new developed vehicles but also on existing vehicles. One of the limits of fast-charging electric vehicles is the overheating of the different components in the car, the station, and the charging system. One of the key components in this system is the battery disconnect unit. This element is responsible for monitoring, activating and deactivating the high voltage battery system. It is essential to maintain it at convenient temperatures and prevent it from overheating. These components are designed today for normal charging power, but with increasing charging powers and reducing charging time, thermal management of these components become essential. This paper presents a passive way to allow the
Salameh, Georges, Goumy, Guillaume, Chalet, David, Dubouil, Rémi, Frecinaux, Anthony, Palluel, Marlène, Ratajczack, Christelle, Noiseau, Pascal
From Temperature to Wear: A Quantitative Analysis of Tire Influence on Vehicle Cornering Using Handling Key Performance Indicators2025-01-5060To be published on 09/16/2025
Vehicle behavior is strongly influenced by tire performance, as tires serve as the primary interface between the vehicle and the road surface. Since identical vehicles equipped with different tire sets—or even the same tires operating under varying thermal and wear conditions—can exhibit significantly different handling characteristics, this study aims to quantify their impact on both steady-state and transient cornering responses through a dedicated evaluation methodology. To demonstrate the generalization of the proposed approach, three completely different validated vehicle digital twins—a passenger car, a sports car, and a formula car—are analyzed in a virtual environment, employing Vi-Car Real Time for vehicle and scenario representations, and RIDEsuite for tire modeling, considering thermal and wear effects. The simulations were designed using a structured design of experiments approach, resulting in 15 predefined combinations of tire temperature and wear states. Results show
Romagnuolo, Fabio, Aratri, Roberto, De Pinto, Stefano, Farroni, Flavio, Bellis, Sergio Andrea de, Bottiglione, Francesco, Mantriota, Giacomo, Sakhnevych, Aleksandr
Applying Specialized System Analysis for Brake by Wire in Software Defined Vehicles: The Development of a System Analysis Tool (SAT)2025-01-0355To be published on 09/15/2025
The emergence of Software Defined Vehicles (SDVs) has introduced significant complexity in automotive system design, particularly for safety-critical domains such as braking. A key principle of SDV architecture is the centralization of control software, decoupled from sensing and actuation. When applied to Brake-by-Wire (BbW) systems, this leads to decentralized brake actuation that demands precise coordination across numerous distributed electronic components. The absence of mechanical backup in BbW systems further necessitates fail-operational redundancy, increasing system complexity and placing greater emphasis on rigorous system-level design validation. A comprehensive understanding of component interdependencies, failure propagation, and redundancy effectiveness is essential for optimizing such systems. This paper presents a custom-built System Analysis Tool (SAT), along with a specialized methodology tailored for modeling and analyzing BbW architectures in the context of SDVs
Heil, Edward, Zuzga, Sean, Babul, Caitlin
Efficient Simulation Methodology for Caliper Rattle Noise Based on a Reasonably Simplified Model and Integrated NVH CAE Approach2025-01-0348To be published on 09/15/2025
Brake caliper rattle noise is difficult to simulate due to its non-stationary, random, and broadband frequency characteristics. Many CAE engineers have adopted rattle vibration as an alternative metric to quantitative noise levels. Previous rattle noise simulations primarily presented relative displacement results derived from normal mode analysis or vibration dB levels rather than actual noise dB levels. However, rattle noise consists of continuous impact noise, which must account for reflections, diffractions, and refractions caused by transient nonlinear contacts and localized vibrations—especially during extremely short contact events. To accurately simulate impact noise, vibration and acoustic characteristics should be analyzed using a simplified structure, given the numerous mechanisms influencing impact noise generation. The rattle noise can be effectively modeled using LS-Dyna, which incorporates both explicit and BEM solvers. The correlation between test results and CAE
Park, Joosang
New Hybrid Powertrain Architectures for European Passenger Car Market2025-24-009709/07/2025
This study presents a comprehensive methodology for the design and optimization of hybrid electric powertrains across multiple vehicle segments and electrification levels. A full-factorial simulation framework was developed in MATLAB/Simulink, featuring a modular, physics-based vehicle model combined with a backward simulation approach and an ECMS (Equivalent Consumption Minimization Strategy) -based energy management algorithm. The objective is to evaluate three hybrid powertrain architectures, namely Series Hybrid (SH), Series-Parallel Hybrid with a single gear stage (SHP1), and Series-Parallel Hybrid with a double gear stage (SHP2), across three vehicle classes (Sedan, Mid-SUV, Large-SUV), four different internal combustion engines (ICEs), and three application types (HEV, PHEV, REEV). More than 10,000 unique configurations were simulated and filtered through a two-step performance requirements analysis. The first phase assessed individual vehicle-level performance targets, while
Amati, Nicola, Marello, Omar, Mancarella, Alessandro, Cavallaro, Davide, Ianni, Luca, Cascone, Claudio, Paulides, Johannes JH
Methodological Approach to Battery Electric Vehicle Design: Energy-Based Model Development from a Detailed Digital Twin2025-24-009809/07/2025
On the path to the decarbonization of the transport sector, the development of electric vehicles (EVs) is crucial to meeting the targets set by international regulatory bodies. EVs operate with zero tailpipe emissions and offer high energy efficiency and flexibility; however, challenges remain in achieving a fully sustainable electricity supply. In this context, powertrain design plays a fundamental role in determining vehicle performance and mission feasibility, which are strongly influenced by operating conditions and application characteristics, such as driving profiles and ambient temperature. A key challenge is the optimal sizing of components, particularly the battery pack and the electric motor. Therefore, a structured and methodological approach to powertrain design is essential to ensuring an optimal configuration. To this end, the project focuses on an integrated approach based on a master-and-slave modeling framework applied to a light-duty commercial vehicle at two levels
Bartolucci, Lorenzo, Cennamo, Edoardo, Grattarola, Federico, Lombardi, Simone, Mulone, Vincenzo, Tribioli, Laura, Aimo Boot, Marco
Improve Modeling, Control, and Health Monitoring of an e-Motor Applying an Integrated Flux Sensing Array: Concepts and Design2025-24-012509/07/2025
Knowing the magnetic flux inside an electric machine can provide valuable information, as it allows for monitoring the actual behavior of the motor during operation. This leads to more accurate torque delivery and enables prognostic and state-of-health analyses. By integrating Hall-effect sensors inside an e-motor, it is possible to measure the magnetic flux and gain all the benefits from this information, such as accurate torque, rotor position and speed, and magnets' temperature. This paper describes the design of an e-motor with an integrated flux sensing array (ISA), including all surrounding models and software solutions for efficient motor control, integrating health monitoring and failure prevention. The focus is on the analyses performed to estimate the magnetic flux linkage and determine the optimal sensor placement, the control architectures that can benefit from a more accurate flux estimation, and the design of the e-machine to integrate the flux sensors. The aim is to
Capitanio, Alessandro, Sala, Giada, Esmaeilnia, Ali, Garcia de Madinabeitia, Inigo, Pastore, Andrea, Tranchero, Maurizio, Franceschini, Giovanni, Saur, Michael
Products of TomorrowTBMG-5372509/01/2025
SAE BOOKS: From ADAS to SDVs with Plato Pathrose25AUTP09_0409/01/2025
Author's third book delves deeper into SDVs. An experienced engineer with a history in software development and systems engineering, Plato Pathrose is turning from ADAS to SDVs with his latest work. Pathrose's third book, Software Defined Vehicles, will be published in September 2025 with SAE International. “This is both a technology and a business book,” Pathrose told SAE Media. “It aims to offer a comprehensive perspective on one of the most transformative trends in the automotive industry. Software Defined Vehicles explores how software is reshaping the design, function, and value of modern vehicles.” From concept, architecture, and connectivity to over-the-air updates and vehicle personalization, Pathrose's latest book dives deep into the technologies driving this shift. It also addresses the business implications, including new revenue models, ecosystem strategies, and the changing role of OEMs and suppliers.
Blanco, Sebastian
SAE TOMORROW TODAY - Women Breaking Barriers in Aerospace & Beyond1352108/19/2025
Despite decades of progress, the number of women in engineering remains stubbornly low -- especially in aerospace and mechanical engineering. But that isn't stopping the winner of the Aerospace/Defense category in the inaugural Women in Engineering: Rising Star Awards. Heather Cummings is Senior Engineer, Flight Controls & Autonomy for Sikorsky, a Lockheed Martin company. She leads the development of hybrid electric propulsion controls and vehicle management systems for Sikorsky's next-gen HEX and RBW, including groundbreaking work on fully autonomous cargo aircraft. A licensed pilot, Heather is passionate about improving flight safety through automation and mentoring the next generation of aspiring engineers. In this special episode, Heather and Chitra Sethi, Director of Editorial & Digital Content, SAE Media Group, discuss the mission behind the Rising Star Awards, the importance of visibility for women in STEM, and why inspiring the next generation is just as critical as
Hineman, Marcie
How Battery Simulation Is Taking High-Performance EV Development to New HeightsTBMG-5352808/01/2025
In today’s electric age, the definition of ‘high-performance’ is being rewritten, courtesy of electric sports cars, supercars, and hypercars pushing limits that were once thought impossible to reach. Even Formula 1, quite surprisingly to many, has embraced electrification by integrating hybrid electric systems at the pinnacle of motorsport. Every jaw-dropping 0 to 60 mph time or record-breaking lap is backed by a battery system engineered with precision. Increasingly that precision is driven by simulation technology.
Products of TomorrowTBMG-5355708/01/2025
Research on Charging Cables Temperature Field Prediction Based on Finite Element Method and Machine Learning05-18-04-003308/01/2025
With the rapid development of new energy vehicles, high-power charging technology has become an effective way to meet the fast-charging needs of electric vehicles. Temperature control of charging cables is crucial for the safety and efficiency of charging. This article aims to develop finite element method (FEM)-ML to predict the temperature field of the charging cable. First, the initial ambient temperature and maximum current were set as the main influencing factors, and a dataset including various charging parameters and cable temperature fields was built by FEM based on a two-factor, four-level orthogonal design. Then, surrogate models based on the Bayesian optimization (BO) algorithm, multilayer perceptron (MLP) model, and extreme gradient boosting (XGB) model were established to predict the temperature field distribution of high-power charging cables. The results indicated that the XGB model had better prediction performance than the MLP model, with average values of MSE, RMSE
Li, Xilin, Zhan, Zhenfei, Fan, Fuhao, Fu, Yunyou, Shen, Yunlong, Pu, Liangxi, Zhou, Qi, Tang, Weiqin
Transforming Product Development with a Platform-Based Approach to Product Lifecycle Management2025-01-505107/17/2025
The advent of EVs, ride sharing, global events such as the pandemic, chip shortage, and increasing dependency on suppliers are just some factors reshaping the automotive business. Consumer sentiment moving from product to experience resulted in more variants being launched at a record pace. Consequently, product development processes need to be more agile and yet more rigorous while bringing about cohesion and alignment across cross-functional teams to launch vehicles on time, on quality, and in budget. Automotive companies have been using Product Lifecycle Management (PLM) solutions for years to manage CAD, change, and BOMs. With changing business scenarios and increasing complexity of products, the sphere of influence of PLM solutions has expanded significantly over the last decade to manage all aspects of product development. Traditionally PLM software focused on integrating with different authoring tools and managing data in a central repository. The PLM solution had multiple such
Prasad, Ajay
DISRUPT - Decentralized Intelligent System for Road User Prediction and Tracking2025-01-029407/02/2025
We present DISRUPT, a research project to develop a cooperative traffic perception and prediction system based on networked infrastructure and vehicle sensors. Decentralized tracking and prediction algorithms are used to estimate the dynamic state of road users and predict their state in the near future. Compared to centralized approaches, which currently dominate traffic perception, decentralized algorithms offer advantages such as greater flexibility, robustness and scalability. Mobile sensor boxes are used as infrastructure sensors and the locally calculated state estimates are communicated in such a way that they can augment local estimates from other sensor boxes and/or vehicles. In addition, the information is transferred to a cloud that collects the local estimates and provides traffic visualization functionalities. The prediction module then calculates the future dynamic state based on neurocognitive behavior models and a measure of a road user's risk of being involved in
Beutenmüller, Frank, Brostek, Lukas, Doberstein, Christian, Han, Longfei, Kefferpütz, Klaus, Obstbaum, Martin, Pawlowski, Antonia, Rössert, Christian, Sas-Brunschier, Lucas, Schön, Thilo, Sichermann, Jörg
Leveraging AI for Automated Code Generation from Systems Engineering Specifications2025-01-029507/02/2025
The increasing complexity of modern vehicles and the automotive industry's shift towards Software Defined Vehicles (SDVs) require innovative solutions to streamline development processes. Traditional methods of software development often struggle to meet the demands for agility, scalability, and precision in this context. In response, this paper presents a novel approach utilizing Artificial Intelligence (AI), specifically Large Language Models (LLMs), to automate the generation of executable code directly from Systems Engineering (SE) specifications. This novel approach aims to transform how SE requirements are converted into implementation-ready code, reducing the inefficiencies and potential errors associated with manual translation. LLMs trained on domain-specific data are capable of interpreting complex requirements, managing dependencies, and generating consistent and accurate code. By integrating LLMs into the automotive software pipeline, companies can improve productivity
Padubrin, Marcel, Reuss, Hans-Christian, Brosi, Frank, Menz, Leonhard, Guerocak, Erol
Longitudinal Dynamic Metrics for Describing and Developing the Deceleration Behavior of Vehicles in the Concept Phase2025-01-026407/02/2025
The brake system is a critical safety component in motor vehicles. Advances in the electrification of the powertrain and the rise of autonomous driving technologies are significantly impacting the brake system, which allows innovative approaches and necessitating the development of new brake concepts and new deceleration strategies. A major technological advance is the decoupling of the driver from the brake system through Brake-by-wire technology. A crucial attribute of Brake-by-wire systems is the attainment of a concept-independent deceleration behavior. To establish a consistent and brand-specific deceleration behavior in the early development phase, objective metrics and perceptual thresholds are required to describe the desired subjective braking behavior. Moreover, objective metrics are indispensable for the virtual phase of the vehicle development process. This article focuses on deceleration from a straight-ahead drive. To identify objective metrics and perceptual thresholds
Biller, Ralph, Udovicic, Matej, Ketzmerick, Erik, Kirch, Sebastian, Mayr, Stefan, Prokop, Günther, Wagner, Andreas
Development of a Cost Model for ADAS and AD Functions2025-01-026107/02/2025
Computer-aided synthesis and development tools are essential for discovering and optimizing innovative concepts. Evaluating different concepts and making informed decisions relies heavily on accurate assessments of system properties. Estimating these properties in the early stages of vehicle development is challenging due to the depth of modelling required. In order to enable a cost prognosis for driving assistance and automated driving functions including software and hardware properties a cost model was developed at the Institute of Automotive Engineering. The methodology and cost model focuses on multiple combined approaches. This includes a bottom-up approach for the hardware. The costs of the software components are integrated into the model with the help of existing literature data and an exponential regression. For a comprehensive view of the total costs, the model is the model is also supplemented by a top-down approach for estimating the costs of other hardware components. The
Sturm, Axel, Hichri, Bassem, Rohde García, Álvaro, Henze, Roman
Inductance Estimation of an Electric Vehicle2025-01-029307/02/2025
Electric vehicles are no longer a rarity on Europe’s streets. But battery electric vehicles (BEVs) still have a long way to go to be the dominant vehicle type on the streets. In the last years, not only has the number of passenger cars risen, but also the number of electric trucks and heavy-duty vehicles. In 2023 electric trucks have share of 1.5% in the market. [1, 2] For the truck industry higher charging powers are even more important. Due to European regulations drivers of vehicles with more than 3.5t weight or buses with more than 10 passengers must rest for 45 minutes after 4.5 hours of drive. [3] Therefore, higher charging powers were needed, and the Megawatt Charging System (MCS) standard was developed. The voltage level goes up to 1250 V and currents of 3000 A are defined. [4] This allows the battery of heavy-duty vehicles to be completely charged within the driving breaks. As with the upcoming MCS standard, the charging power increases, also the failure risk rises. Higher
Grund, Caroline, Reuss, Hans-Christian
An LLM-Based Multi-Turn Task-Oriented Dialogue System for Machine Learning Algorithm Selection in Data Mining2025-01-028907/02/2025
For the systematic application of machine learning during data mining in product development processes, selecting a suitable algorithm is crucial for success. During an empirical study in the automotive industry, a team applying data mining to develop battery systems for battery electric vehicles was accompanied. Here, it could be observed that data mining tasks are often unique during product development processes and can differ in boundary conditions. Depending on these tasks, suitable machine learning algorithms must be selected. Because of the variety of machine learning paradigms, problems, and algorithms, it is often hard to select a suitable algorithm, especially for inexperienced data miners. This paper presents a large language model (LLM)-based, multi-turn, task-oriented dialogue system to support data miners in selecting machine learning algorithms that are suitable for their specific data mining tasks. This approach, called “Algorithm Selection Assistant” (ASA), enables
Hörtling, Stefan, Bause, Katharina, Albers, Albert
Accelerating Vehicle Usage Analysis: A Methodology for Efficient Clustering2025-01-028707/02/2025
Modern vehicles, increasingly electrified and automated, have effectively become computers on wheels, intensifying product complexity and competitive pressure. Concurrently, increasing digitization offers opportunities to derive customer insights from large-scale vehicle data using Knowledge Discovery in Databases (KDD) and Data Mining (DM). Among these techniques, cluster analysis can reveal hidden subgroups that inform more customer-oriented product solutions. However, cluster analysis lacks a definitive ground truth, making it necessary to test numerous parameter settings, preprocessing steps, and clustering algorithms, and then interpret all plausible results. The complexity of real-world customer data such as heterogeneous, privacy-constrained vehicle usage signals further complicates the selection of appropriate methodologies. Each combination of preprocessing and clustering steps must be analyzed to uncover patterns or groups, significantly increasing the time and manual effort
Wegener, Jan, van Putten, Sebastiaan, Neubeck, Jens, Wagner, Andreas
Upgradeable Mechatronic Systems – Integration of Upgrade Planning and Design for Increasing Sustainability in Vehicle Development2025-01-029007/02/2025
The automotive industry faces the challenge of developing vehicles that meet current customer needs while being future-proof. Surveys conducted for this study show that customers are concerned about the financial risks of essential components such as energy storage systems, mainly due to aging and performance degradation, which significantly affect vehicle lifespans. Based on vehicle developer surveys, a clear need for action was identified. Given the rapid technological advancements in electrified drive systems, there is a need for innovative approaches that can easily adapt to changing requirements. Therefore, this paper presents a strategy combining foresight-based planning of system upgrades with product architecture design to create adaptable and sustainable vehicles through modularity. First, dynamic subsystem characteristics are identified to establish future energy storage technology requirements. Subsequently, future energy storage system technologies are examined to determine
Fehrenbacher, Rüdiger, Kuebler, Maximilian, Zeng, Yunying, Bause, Katharina, Albers, Albert, Nootny, Fabio, Kolbe, Lucia, Jung, Luca
SAE TOMORROW TODAY - Digital Engineering for Defense and Beyond1352007/02/2025
If you were to build the perfect use case for the potential of digital engineering, you would be hard-pressed to choose a better sector than the defense industry. That's why the Pentagon isn't just intrigued by digital engineering-it's made it mandatory. As the U.S. military targets groundbreaking technology improvements that safeguard lives and improve defense capabilities, Ansys is helping connect the dots between people, processes, and technology with the predictive power of simulation. Establishing a digital engineering ecosystem, including digital twins, contributes to the resilience and adaptability of innovations across industries. To learn more, we sat down with Dr. Armond E. Sinclair, Sr. Technical Account Executive for Ansys Government Initiatives, to discuss how digital engineering is enabling smarter decision-making, reducing costs, and accelerating innovation at the Department of Defense (DoD) and beyond. We'd love to hear from you. Share your comments, questions and ideas
Hineman, Marcie
Products of TomorrowTBMG-5323606/01/2025
Sustainable Design of Automotive Batteries2025-01-000105/08/2025
A consequence of the automotive industry's shift to electrification is that a significantly higher percentage of a vehicle's lifecycle CO2 emissions occur during the production phase. As a result, vehicle manufacturers and suppliers must shift the focus of product development from the 'in-use phase only' to optimizing the complete product lifecycle. The proper design of a battery has the highest impact to all other phases following in the life cycle. It influences the selection of materials, the manufacturing, in-use and end of life, respectively the recycling and recycling yield for a circular economy. Using real-life examples, the paper will explain what the main parameters are necessary for designing a sustainable battery. What are the low hanging fruits to be considered? In addition, it will elaborate on the relation as well as the impacts to other KPIs like safety, costs and lifetime of the battery. Finally, it will round up in an outlook on how batteries will evolve in the future
Braun, Andreas, Rothbart, Martin
Experimental Investigation into Modulated Aeroacoustic Cabin Noise Arising from Unsteady Flow Conditions2025-01-002905/05/2025
The unsteady wind conditions experienced by a vehicle whilst driving on the road are different to those typically experienced in the steady-flow wind tunnel development environment, due to turbulence in the natural wind, moving through the unsteady wakes of other road vehicles and travelling through the stationary wakes generated by roadside obstacles. This paper presents an experimental approach using a large SUV-shaped vehicle to assess the effect of unsteady wind on the modulated noise performance, commonly used to evaluate unsteady wind noise characteristics. The contribution from different geometric modifications were also assessed. The approach is extended to assess the pressure distribution on the front side glass of the vehicle, caused by the aerodynamic interactions of the turbulent inflow in straight and yawed positions, to provide insight into the noise generation mechanisms and differences in behaviour between the two environments. The vehicle response to unsteady wind
Jamaluddin, Nur Syafiqah, Oettle, Nicholas, Staron, Domenic
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