Browse Topic: Product development

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Innovative High-Performance Active Dampers for Effective Mitigation of Helicopter Main Rotor Vibrations2025-01-0163To be published on 04/25/2025
Helicopter vibrations, primarily generated by the main rotor-gearbox assembly, are a major source of concern due to their impact on structural integrity, cockpit instrument durability, and crew comfort. These vibrations are mainly transmitted through the gearbox’s rigid support struts to the fuselage, leading to increased cabin noise and potential damage to critical components. This paper presents a solution for vibration mitigation which involves replacing traditional gearbox support struts with low-weight, high-performance active dampers. Developed by Elettronica Aster S.p.A., these active dampers are designed as electro-hydraulic actuators embedded within a compliant structure. The parallel nested configuration of the system enables high power densities and effective vibration control, significantly reducing the transmission of harmful vibrations to the fuselage. The comprehensive model-based design process is detailed, describing the development and use of a high-fidelity physics
Bertolino, Antonio Carlo, Sorli, Massimo, Porro, Paolo Giovanni, Galli, Claudio
Technical Paper
MBSE Framework for Developing Data-Driven Passenger Services in Aircraft Cabins2025-01-0171To be published on 04/25/2025
The aircraft cabin plays a crucial role in airline differentiation strategies, particularly when introducing novel business and operational processes. These processes aim to enhance passenger experience during flight and to improve cabin crew efficiency in order to reduce workload and to ensure continued growth of airline revenue. Digitalization and extensive exchange of information across the entire aircraft transport system have emerged as key enablers for these processes. The development of aircraft and aircraft systems implementing these processes is characterized by a multi-level development process. Various development levels are considered to initially identify the functions of an aircraft in the air transport system, refine its systems and break them down into their components until a level of detail is reached that allows the implementation of the component functions. In addition to the high complexity, a major challenge in this development is to ensure traceability and
Blecken, Marvin, Giertzsch, Fabian, Hintze, Hartmut, God, Ralf
Technical Paper
Enhancing Airworthiness Security: SysML-Based Approach to Modelling Security Scope Definitions2025-01-0172To be published on 04/25/2025
Airworthiness certification of aircraft requires an Airworthiness Security Process (AWSP) to ensure safe operation under potential unauthorized interactions, particularly in the context of growing cyber threats. Regulatory authorities mandate the consideration of Intentional Unauthorized Electronic Interactions (IUEI) in the development of aircraft, airborne software, and equipment. As the industry increasingly adopts Model-Based Systems Engineering (MBSE) to accelerate development, we aim to enhance this effort by focusing on security scope definitions – a critical step within the AWSP for security risk assessment that establishes the boundaries and extent of security measures. However, our findings indicate that, despite the increasing use of model-based tools in development, these security scope definitions often remain either document-based or, when modeled, are presented at overly abstract levels, both of which limit their utility. Furthermore, we found that these definitions
Hechelmann, Adrian, Mannchen, Thomas
Technical Paper
Interconnected and Data-Driven Aircraft Cabin Systems: Consistent Integration of ARINC 853 Messaging Standard into Model-Based Aircraft Systems Development2025-01-0174To be published on 04/25/2025
Increasing digitalization of the aircraft cabin, driven by the need for improved operational efficiency and an enhanced passenger experience, has led to the development of data-driven services. In order to implement these services, information from different systems is often required, which leads to a multi-system architecture. When designing a network that interconnects these systems, it is important to consider the heterogeneous device and supplier landscape as well as variations in the network architecture resulting from airline customization or cabin upgrades. The novel ARINC 853 Cabin Secure Media-Independent Messaging (CSMIM) standard addresses this challenge by specifying a communication protocol that relies on a data model to encode provided and consumed information. This paper presents an approach to integrate CSMIM-specific communication concepts into a Model-Based Systems Engineering (MBSE) framework using the Systems Modeling Language (SysML). This enables a streamlined
Giertzsch, Fabian, Blecken, Marvin, God, Ralf
Technical Paper
Integrating for Safety – A Proposed Approach to the Integration of Propulsion Battery Systems in Hybrid Electric Aviation2025-01-0148To be published on 04/25/2025
In the last year we have witnessed a notable surge in the designs and in the guidance material for electric and hybrid aircraft. FAA and EASA have continued to evaluate the safety of Propulsion Battery Systems (PBS), with a focus on thermal runaway containment testing. As a result, a harmonization white paper was issued to provide a certification path for Thermal Runaway (TR) Hazards, followed by an EASA certification memorandum on the acceptable approaches for the certification of Electric/Hybrid Propulsion Systems (EHPS). And just recently, an FAA Advisory Circular (draft) was issued for the “powered-lift” aircraft that feature these propulsion battery systems. In spite of the advances made by electric/hybrid aircraft manufacturers and the aviation authorities, there is still a missing piece of the puzzle. Mainly, we are still not confident in our ability to properly integrate the PBS into the EHPS architecture, in such a way where safety is never compromised, no matter the hazard
Hanna, Michael, Walker, Cherizar
Technical Paper
Sustainable Design of Automotive Batteries2025-01-0001To be published on 04/18/2025
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 are the main parameters 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 life-time of the battery. Finally it will round up in an outlook on how batteries will evolve in the future
Braun, Andreas, Rothbart, Martin
Technical Paper
Cloud Based Digital Twin Development for High-Voltage Battery Systems in Commercial Vehicles2025-01-8214To be published on 04/01/2025
Over recent years, BorgWarner has intensified its efforts to explore and leverage trending technologies such as Artificial Intelligence (AI) and Machine Learning (ML) to enhance products and processes. The digital twin technology has potential use cases on system behavior analysis, product optimization and predictive maintenance. As the high-voltage battery is the most valuable component in any electric vehicle understanding the mechanisms of battery aging and failure, along with their dependencies, is crucial for improving performance, battery lifespan, and residual value. A digital twin not only aids in comprehending the impacts of user behavior on the battery's state of health but also facilitates further fault diagnosis and analysis. This paper outlines the development process of a digital twin for a commercial vehicle battery. A cloud-based digital twin demonstrator was developed, which integrates vehicle telemetry data with physics-based battery electric and thermal models, and
Bongards, Anita, Liu, Xiaobing, Beemer, Maria, Gajowski, Daniel, Rama, Neeraj, Shah, Keya, Fallahdizcheh, Amirhossein
Technical Paper
Machine Learning-Based Digital Twin for Optimizing Automotive Components2025-01-8206To be published on 04/01/2025
This paper presents a Digital Twin approach based on Machine Learning (ML), aimed at creating software-based sensors to reduce the auxiliary devices of the vehicle and enabling predictive maintenance, thus reducing carbon footprint. The solution is applied to the Electric Lubrication Oil Pump (ELOP), a crucial component within a vehicle's powertrain system. The proposed ELOP Digital Twin integrates ML-based sensors to estimate critical parameters such as temperature, pressure and flow rate, reducing the reliance on physical sensors and associated hardware. This estimation approach minimizes manufacturing complexity and cost, enhancing energy efficiency during both production and operation. Furthermore, the digital twin facilitates predictive maintenance by continuously monitoring the component's performance, enabling early detection of potential failures and optimizing maintenance schedules. This leads to lower energy consumption and reduced emissions throughout the component's
Khan, Jalal, D'Alessandro, Stefano, Tramaglia, Federico, Fauda, Alessandro
Technical Paper
Digital Twin, A Multiphysics Numerical Tool Chain for Next Generation Electric Drive Design2025-01-8624To be published on 04/01/2025
Following an early adoption phase, the BEV market focus shift towards mass market strategy. This shift has placed greater emphasis on crucial attributes, such as system cost reduction and range extension. System efficiency has always been at the center of the BEV product development, where efficiency metric influenced greatly the range and cost of the vehicle. For example, higher efficiency of an iDM (Integrated Drive Module) reduces the need for bigger battery thus cost reduction, alternatively for a same battery size the end user will benefit with an extended range. BorgWarner adopted Digital Twin technology to optimize iDM within a vehicle ecosystem, Digital Twin is an assembly of high-fidelity physics based numerical tool suites which offer greater degree of freedom to engineers in designing, sizing, optimizing a component vs. system benefit tradeoff, thus enabling most efficient product design within constraints of economics. At BorgWarner we have adopted Analytical System
Bossi, Adrien, Bourniche, Eric, Leblay, Arnaud, David, Pascal, Nanjundaswamy, Harsha
Technical Paper
Model-Driven Systems Engineering Automation with Artificial Intelligence for Robustly Writing Automotive System Requirements2025-01-8658To be published on 04/01/2025
The intensive use of software applications in modern vehicles has highlighted the critical role of Systems Engineering (SE) in the automotive industry. These “computers on wheels” are thoroughly interconnected, by their own connections and with the cloud, due to the advancement of Electronic Control Units (ECU) technologies and the widespread use of sensors transmitting real-time data. This interconnectedness and the level of software abstraction that are known today, significantly escalates the complexity of these systems. This has made it necessary to adopt an approach that is flexible to change, structured, agile, and traceable. The modern approach to SE, now model-based, offers numerous advantages over the previous paradigm, which was predominantly document-based. MBSE (Model-Based Systems Engineering) emerges as a contemporary approach, providing the scalability needed for engineering teams to develop robust products. Its “model-based” essence ensures that the model acts as the
Mendes de Oliveira, Arthur Hendricks, Reis, Pedro Almeida, Anunciação, Gabriel, Vinícius Carlos de Lima, Jonathan, Sarracini Júnior, Fernando, Garcia, Matias Ezequiel
Technical Paper
Digital Twin of an Electric Motor to Predict the Temperature over a Drive Cycle2025-01-8203To be published on 04/01/2025
Abstract: In recent years, simulation-based performance of the models was a very effective way to finalize the model at design stage itself. But simulation-based models are complex owing to more parameters involved hence resulting in more computational time. With the increasing demand of electric vehicles, the development time for electric vehicle (EV) powertrain is reduced substantially thereby increasing pressure on original equipment manufacturers (OEMs) to develop products faster. Digital twin is a platform where replication of physical model is made possible with very limited data to predict the performance of the model hence providing the most accurate results in a very short time. Electric vehicles are the best alternatives for reducing emissions. An Electric vehicle is run by an electric motor which in turn is powered by a battery. Interior permanent magnet synchronous motors (IPMSMs) are the conventional type of motors in electric vehicles because of their high-power density
Shroff, Roopesh, Upase, Balasaheb
Technical Paper
Bimodal Wake Cycling with Turbulent Flow2025-01-8766To be published on 04/01/2025
The vehicle wake region is of high importance when analyzing the aerodynamic performance of a vehicle. It is characterized by turbulent separated flow and large low pressure regions that contribute significantly to drag. In some cases the wake region can oscillate between different modes which can provide engineering challenges during vehicle development. Vehicles that exhibit bimodal wake behavior need to have their drag values recorded over a sufficient time period. When simulating such a vehicle in CFD this can be a problem as the period of oscillation can be very long, on the order of 10’s of seconds or minutes. Running such simulations with sufficient time to capture the average drag would be prohibitively expensive in terms of CPU hour cost during the vehicle design process. As an alternative to running a long simulation it is possible to influence the wake behavior through the use of turbulence. By adding turbulence to the upstream flow the wake can be prevented from settling
DeMeo, Michael, Parenti, Guido, Martinez Navarro, Alejandro, Shock, Richard, Fougere, Nicolas, Razi, Pooyan, Oliveira, Danilo, Lindsey, Craig, Yu, Chenxing, Breglia Sales, Flavio
Technical Paper
The New China Automotive Engineering Research Institute Co., Ltd Full-Scale Aero-acoustic Wind Tunnel2025-01-8779To be published on 04/01/2025
The China Automotive Engineering Research Institute Co., Ltd (CAERI) has completed a new vehicle aero-acoustic wind tunnel (AAWT), which is located in Chongqing, China, and has been in operation for 5 years. To help address Chinese vehicle market’s need to improve fuel economy, reduce exhaust emissions, and decrease product development period, the wind tunnel was designed and implemented to achieve high degree of automation for vehicle test and high accuracy aerodynamic and acoustic test for product development. The CAERI wind tunnel was in operation in August 2019, which has a top speed of 250 kph, a 5-belt rolling road system with a long center belt for proper wake simulation, a test section with very low static pressure gradient, background noise and an overhead traverse both for wind tunnel calibration and customized measurement activities. This paper describes the main facilities of AAWT including some auxiliary equipment. The aerodynamic and acoustic performances of the CAERI
Xu, Lei, Zhu, Xijia, Wang, Qingyang, Bu, Han, Peng, Chao, Shi, Feng, Yang, Chao, Huang, Tao, Zeng, Yi, Zeng, Xiangyi, Wallmann, Steffen, Münstermann, Henning, Wittmeier, Felix, Mercker, Edzard, Blumrich, Reinhard
Technical Paper
Accelerating EV Motor design using MBSE approach2025-01-8660To be published on 04/01/2025
Abstract- Model-Based Systems Engineering (MBSE) enables requirements, design, analysis, verification, and validation associated with the development of complex systems. Obtaining data for such systems is dependent on multiple stake holders and have issues related to communication, data loss, accuracy, traceability which results in time delays. This paper presents the development of new process for requirement verification by connecting System Architecture Model (SAM) with multi-fidelity, multi-disciplinary analytical models. Stakeholders can explore design alternatives at conceptual stage, validate performance, refine system models, and take better informed decisions. The use-case of connecting system requirements to engineering analysis is implemented through ANSYS ModelCenter which integrates MBSE tool CAMEO with simulation tools MotorCAD and TwinBuilder. This automated workflow translates requirements to engineering simulations, captures output and performs validations. System
Upase, Balasaheb, Shroff, Roopesh
Technical Paper
Development of Prediction Model for Vehicle Road Load Using Machine Learning2025-01-8258To be published on 04/01/2025
In the modern automotive industry, improving fuel efficiency while reducing carbon emissions is a critical challenge. To address this challenge, accurately measuring a vehicle’s road load is essential. The current methodology, widely adopted by national guidelines, follows the coastdown test procedure. However, coastdown tests are highly sensitive to environmental conditions, which can lead to inconsistencies across test runs. Previous studies have mainly focused on the impact of independent variables on coastdown results, with less emphasis on a data-driven approach due to the difficulty of obtaining large volumes of test data in a short period, both in terms of time and cost. This paper presents a road load energy prediction model for vehicles using the XGBoost machine learning technique, demonstrating its ability to predict road load coefficients. The model features 27 factors, including rolling, aerodynamic, inertial resistance, and various atmospheric conditions, gathered from a
Song, Hyunseung, Lee, Dong Hyuk, Chung, Hyun
Technical Paper
Material selection of a Parcel shelf for structural performance and Perceived quality improvement through an assessment of wide range composite and sustainable materials.2025-01-8249To be published on 04/01/2025
In passenger vehicles, a parcel shelf is used to conceal luggage in the trunk compartment. Conventionally, materials used in new product development are heavy, making products less competitive in the market. As the automotive industry increasingly prioritizes lightweight products for EV, it is essential to find new alternative materials and technologies that meet performance standards and add value to the product. This research paper focuses on weight optimization, sustainable material section and cost reduction of the parcel shelf without compromising durability, stiffness, and load-bearing capabilities. The proposed material consists of ultra-lightweight composite materials available in various GSM and thicknesses, offering a high strength-to-weight ratio that contributes to: 1. Improved load vs. deflection ratio. 2. Enhanced aesthetics and perceived quality. The proposed material combination and strategy for the parcel shelf will result in a product that is half the weight of
Kinthala, Nareen Kumar, Patnaik, Manga, Khandelwal, Mohit, Kakani, Phani Kumar, Palaniappan, Elavarasan
Technical Paper
Learning-Based Cell Level Battery Digital Twin for Electric Vehicles2025-01-8386To be published on 04/01/2025
Electric vehicles rely on accurate estimation of battery states to operate safely and efficiently. Traditionally, the state estimation is pack level and based on empirical models developed to capture the dynamics of a representative battery pack and hence fall short in accounting for cell-to-cell variations. These variations become more pronounced as the cells age within a battery pack under non-homogeneous mechanical, thermal, manufacturing, and electrical conditions. It is challenging to adapt the traditional physics-based model to changing battery dynamics in real-time. To improve the state estimation at the cell level, a data-driven approach utilizing streamed data from vehicles enabled by connectivity has been shown in this paper. While traditional data-driven approaches result in large models and require large quantities of data for training, the proposed method relies on combining the underlying physics of the electrochemical model with novel data-driven modeling techniques. The
Gupta, Shobhit, Hegde, Bharatkumar, Haskara, Ibrahim, Shieh, Su-Yang, Chang, Insu
Technical Paper
Numerical Model of the Heat-Wait and Seek and Heating Ramp Protocol for the Prediction of Thermal Runaway in Lithium-Ion Batteries2025-01-8127To be published on 04/01/2025
Interest in Battery-Driven Electric Vehicles (EVs) has significantly grown in recent years due to the decline of traditional Internal Combustion Engines (ICEs). However, malfunctions in Lithium-Ion Batteries (LIBs) can lead to catastrophic results such as Thermal Runaway (TR), posing serious safety concerns due to their high energy release and the emission of flammable gases. A better understanding of this phenomenon is essential for reducing risks and mitigating its effects. In this study, a digital twin of an Accelerated Rate Calorimeter (ARC) under a Heat-Wait-and-Seek (HWS) procedure is developed using a Computational Fluid Dynamics (CFD) framework. The CFD model simulates the heating of the cell during the HWS procedure, pressure build-up within the LIB, gas venting phenomena, and the exothermic processes within the LIB due to the degradation of internal components. The model is validated against experimental results for an NCA 18650 LIB under similar conditions, focusing on LIB
Gil, Antonio, Monsalve-Serrano, Javier, Marco-Gimeno, Javier, Guaraco-Figueira, Carlos
Technical Paper
Computer aided engineering for sound propagation in exterior environments2025-01-8631To be published on 04/01/2025
Physical testing is required to assess multiple vehicles in different conditions, specially to validate those related to regulations. The acoustic evaluations have difficulties and limitations in physical test; cost and time represent important considerations every time. Additionally, the physical validation happens once a prototype has been built, this takes place in a later phase of the development. Sound pressure is measured to validate different requirements in a vehicle, horn sound is one of these and it is related to a regulation of united nations (ECE28). Currently the validation happens in physical test only and the results vary depending on the location of the horn inside the front end of every vehicle. In this article, the work for approaching a virtual validation method through CAE is presented with the intention to get efficiency earlier in product development process.
Alonso, Liliana, Cruz, Raciel, Alvarez, Ezequiel
Technical Paper
Tire wear life prediction using machine learning technique2025-01-8757To be published on 04/01/2025
As global warming and environmental problems are becoming more serious, tires are required to accomplish balanced performance such as low rolling resistance, wet braking performance, driving stability, and ride comfort, while minimizing wear, noise, and weight. Furthermore, to respond to the rapid changes in the market environment, there is a strong demand for tire performance prediction and testing methods adapted to MBD. In MBD, Magic Formula and Ftire are used in performance design to predict handling and stability and ride comfort. However, predicting tire wear life, which is affected by both vehicle and tire characteristics, is difficult. And practical prediction method for estimating tire wear life has long been awaited. So, we had proposed an experimental-based tire wear life prediction method that using actual measurement tire characteristics and an abrasive wear volume formula. This method achieves accuracy that can be practically used in the early stages of vehicle
Ando, Takashi
Technical Paper
Highly accurate Machine Learning models for Automotive Crash applications using CAE centric AI/ML Platform2025-01-8719To be published on 04/01/2025
In the automotive industry, there have been many efforts of late in using Machine Learning tools to aid virtual simulation and decrease product development time and cost. As the simulation world grapples with how best to incorporate ML techniques, two main challenges are evident. There is the risk of not knowing if the trained model is sound enough to drive the design. In addition, the complexity of porting simulation data back and forth to a ML software can make the process cumbersome. We would like to put forth a highly accurate and comprehensive one-stop ML workflow that has been implemented within a commercially available CAE driven platform called DEP MeshWorks. MeshWorks is used for rapid concept CAE and CAD model generation and parametrization. The AI platform within Meshworks leverages the inherent best-in-class parameterization capability to help rapidly generate data for training purposes. It is relatively quick to set up a fully parameterized CAE model and vary design
Krishnan, Radha
Technical Paper
European initiatives for User-Centric design of Electric Vehicle2025-01-8807To be published on 04/01/2025
E-mobility is revolutionizing the automotive industry by improving energy efficiency, lowering CO2 and non-exhaust emissions, innovating driving and propulsion technologies, redefining the hardware-software-ratio in the vehicle development, facilitating new business models, and transforming the market circumstances for electric vehicles (EVs) in passenger mobility and freight transportation. Ongoing R&D action is leading to an uptake of affordable and more energy efficient EVs for the public at large through the development of innovative and user-centric solutions, optimized system concepts and components sizing, and increased passenger safety. Moreover, technological EV optimizations and investigations on thermal and energy management systems as well as the modularization of multiple EV functionalities result in range maximization, driving comfort improvement, and greater user-centricity. This paper presents the latest advancements of multiple EU-funded research projects under the
Ratz, Florian, Bäuml, Thomas, Kompara, Tomaž, Kospach, Alexander, Simic, Dragan, Jan, Petra, Möller, Sebastian, Fuse, Hiroyuki, Parades Barros, Esteban, Armengaud, Eric, Amati, Nicola, Sorniotti, Aldo, Lukesch, Walter
Technical Paper
European Initiatives addressing High efficiency and low cost electric motors for circularity and low use of rare resources2025-01-8806To be published on 04/01/2025
The automotive industry is amidst an unprecedented multi-faceted transition striving for more sustainable passenger mobility and freight transportation. The rise of e-mobility is coming along with energy efficiency improvements, CO2 and non-exhaust emission reductions, driving/propulsion technology innovations, and a hardware-software-ratio shift in vehicle development for road-based electric vehicles. Current R&D activities are focusing on electric motor topologies and designs, sustainability, manufacturing, prototyping, and testing. This is leading to a new generation of electric motors, which is considering recyclability, reduction of (rare earth) resource usage, cost criticality, and a full product life-cycle assessment, to gain broader market penetration. This paper outlines the latest advances of multiple EU-funded research projects under the Horizon Europe framework and showcases their complementarities to address the European priorities as identified in the 2ZERO SRIA . The E
Armengaud, Eric, Ratz, Florian, Muñiz, Ángela, Poza, Javier, Garramiola, Fernando, Almandoz, Gaizka, Pippuri-Mäkeläinen, Jenni, Clenet, Stéphane, Messagie, Maarten, D’amore, Lea, Lavigne Philippot, Maeva, Rillo, Oriol, Montesinos, Daniel, Vansompel, Hendrik, De Keyser, Arne, Romano, Claudio, Montanaro, Umberto, Tavernini, Davide, Gruber, Patrick, Ran, Liaoyuan, Amati, Nicola, Vagg, Christopher, Herzog, Matic, Weinzerl, Martin, Keränen, Janne, Montonen, Juho
Technical Paper
AI Enabled Digital Twin of the Traction Motor of an Electric Vehicle2025-01-8564To be published on 04/01/2025
Electric motors are critical component in electric vehicle (EV) & industrial applications. In case of EVs electric motor has a direct impact on the functionality, range and general user experience. Traditional maintenance procedures have several major limitations such as, leave no choice but to use the expensive warranty claims, restricted predictive maintenance, unavailability of useful data, reducing resale value, and ultimately poor customer satisfaction. The process of building a virtual duplicate of an actual motor that can replicate the physical system in real time is known as the Digital Twin (DT) technology. Here, the DT technology-based monitoring and maintenance is initiated on permanent magnet synchronous motor (PMSM) used in traction, thus helping to overcome the drawbacks of traditional maintenance system. To provide a holistic approach to real time motor monitoring, motor management, ensuring enhanced reliability, efficiency, and predictive maintenance capabilities, the
Valiyil, Rinsha, R, Bharath, Nair, Anush, Puthiyapurayil, Shamal, Ravi, Reshma
Technical Paper
Validation of Product Requirements - Specifications Using Field Data and Next Generation Vehicle Design Strategy Using a Calibrated Digital Twin2025-01-8344To be published on 04/01/2025
The engineering design process employs an iterative approach in which proposed solutions are conceived, evaluated and refined until they satisfy a priori requirements - specifications. This iterative cycle generally uses computer aided designs (CAD), engineering analysis (CAE), numerical simulations per operating scenarios, and laboratory or field prototype testing. The availability of product data can be applied to assess the vehicle requirements – specifications to facilitate the next generation design. However, the calibration and use of a digital twin facilitates exploration of tradeoffs between engineering design, product manufacturing, and business demands, plus a desire to shorten the overall time. For instance, digital twin technology enables the swift evaluation of vehicle performance in various configurations and operating conditions. The question arises of how to best integrate digital twin technology into the design process. This paper will review the engineering design
Manvi, Pranav, Suber II, Darryl, Griffith, Kaitlyn, Turner, Cameron, Castanier, Matthew P., Wagner, John
Technical Paper
Correlation of Subjective Assessments and Objective Metrics for On-Center Feeling2025-01-8287To be published on 04/01/2025
Steering feeling plays a critical role in the driving experience and is one of the most significant topics during a new vehicle development process. To reach a consensus for the customers’ satisfaction in both the subjective and objective characteristics in a particular market segment, there have been several studies to investigate the correlations between subjective and objective evaluations of on-center steering feeling. However, it is still not clear how to determine the steering characteristic based on the correlations. In this paper, a series of new correlation between subjective and objective evaluations are built, which focus on steering effort, on-center feel, torque ripple, torque dead band etc. Firstly, we extract a set of objectives metrics from on-center handling test based on ISO 13674-1 2023, which are followed by professional test drivers or tuning experts. Secondly, we list numerical on-center handling tests of vehicles to test and verify the representativeness and
Jin, Ankang, Luo, Kaijie, Yang, Jianyuan, Zheng, Yue
Technical Paper
Research on Digital Twin Model Construction Method for Smart Highway2025-01-717502/21/2025
To facilitate the construction of a robust transport infrastructure, it is essential to implement a digital transformation of the current highway system. The concept of digital twins, which are virtual replicas of physical assets, offers a novel approach to enhancing the operational efficiency and predictive maintenance capabilities of highway networks. The present study begins with an exhaustive examination of the demand for the smart highway digital twin model, underscoring the necessity for a comprehensive framework that addresses the multifaceted aspects of digital transformation. The framework, as proposed, is composed of six integral components: spatiotemporal data acquisition and processing, multidimensional model development, model integration, application layer construction, model iteration, and model governance. Each element is critical in ensuring the fidelity and utility of the digital twin, which must accurately reflect the dynamic nature of highway systems. The
Zhang, Yawen, Cai, Xianhua
Technical Paper
Machine Learning Based Variation Studies for Electric Vehicle Drive Unit Virtual System Models2025-28-017102/07/2025
In electric vehicles development, manufacturing variations pose big challenge in designing various mechanical components as these variations directly impact various customer perceivable performance outputs. If the manufacturing variations can be included in design phase itself, overall robustness of the design can be enhanced. This paper delineates machine learning based methods to include manufacturing variations in designing drive units for electric vehicles. In an electric vehicle, the drive unit transfers power or torque from a battery through an inverter to wheels. The drive units are subjected to different types of loads under various vehicle maneuvers. To evaluate the drive unit system virtually, system level simulations are performed. Traditionally, nominal values of the several inputs such as bearing parameters, gear parameters and clearances etc. are used. However, the drive unit must be designed in such a way that outputs meet target considering all the variations of inputs
Penumatsa, Venkata Ramana Raju, Katha, Venkateswar, Black, Derrick, Jain, Sachin, Maddipati, Seshagiri
Technical Paper
Cloud-Based Monitoring of Lithium-Ion Battery Management Systems for Health Estimation in Manufacturing Industries2025-28-020002/07/2025
The increasing reliance on lithium-ion batteries in manufacturing necessitates advanced monitoring techniques to ensure their longevity and reliability. Cloud technology offers a solution by enabling real-time data collection, analysis, and accessibility, facilitating thorough monitoring and predictive maintenance. Digital twin technology, creating a virtual replica of the physical battery system, provides a platform for simulating real-world conditions and predicting potential issues before they arise. By integrating sensor data and historical usage patterns, the digital twin model can accurately predict battery degradation, aiding in timely maintenance strategies. This proactive approach enhances battery operational efficiency and extends lifespan, leading to cost savings and improved safety. The paper explores using cloud-based monitoring systems to enhance the health estimation and management of lithium-ion batteries. A comprehensive feasibility study on adopting battery digital
Zeeshan, Mohammad, Akre, Vineet
Technical Paper
A reduced-order beam modelling approach of BIW for torsional and bending stiffness optimization2025-28-018702/07/2025
Noise, Vibration, and Harshness (NVH) simulations of vehicle bodies are crucial for assessing performance during the design phase. However, these simulations typically require detailed computer-aided design (CAD) models and are time-consuming. In the early stages of vehicle development, when only high-level vehicle sections are available, designing the body-in-white (BIW) structure to meet target values for bending and torsional stiffness is challenging and often requires multiple iterations. To address these challenges, this study deploys a reduced-order beam modelling approach. This method involves identifying the beam-like sections and major joints within the BIW and calculating their sectional properties (area, area moments of inertia along the plane’s independent axes, and torsion constant). These components form a simplified skeleton model of the BIW. Load and boundary conditions are applied to the suspension mount locations at the front and rear of the vehicle, and torsional and
Khan, Mohd Zishan Ali, Thanapati, Alok, Deshmukh, Chandrakant
Technical Paper
Comparative Study to Identify and Bridge the Gap between Physical and Virtual Durability Testing on a Real Fatigue Acceleration Track and Its Digital Twin of the Vehicle/Surface2025-28-006502/07/2025
India has seen a significant boost in automotive research and development, specific to Vehicle Dynamics active safety systems and ADAS. To develop these systems, without excessive reliance on full working prototypes, vehicle manufacturers are relying on virtual models to better fine tune the design parameters. For this, there is a real requirement of digital twins of the proving grounds. This virtual testing surfaces will help in reducing test costs, test times and increase iteration counts, leading to fine-tuned prototype vehicle and finally a market leading product. National Automotive Test Tracks (NATRAX) is already playing a crucial role in the testing and development of these technologies, on its test tracks. Recognizing the need to assist in virtual testing for Indian automotive manufacturers, NATRAX is taking steps to develop virtual proving grounds to complement physical testing and reduce the development time. This paper targets a comparative analysis of dynamic parameters
S J, Srihari, Umorya, Divyansh, Patidar, Deepesh, Jaiswal, Manish
Technical Paper
Model Based Emissions and NVH Optimization2024-36-005912/20/2024
Throughout the years, the legislations which drive the vehicle development have experimented constant evolutions. Especially when it comes about pollutant emissions and NVH ( Noise, Vibration & Harshness). However, it is complex to understand which calibration strategy promotes the best balance about lowest levels of emissions, vibrations, and noise if considered the number of inputs to be explored, becoming the searching for the optimum calibration a huge challenge for the development engineering team. This work proposes a methodology development in which complex problems can be solved by model based solutions regarding the best balance finding of emissions reduction and noise attenuation. The methodology is based in machine learning approach which provides a virtual behavior of engine phenomena making possible a wider comprehension of the problem and hence the opportunity to explore enhanced solutions. The study case scenario used to apply the method was a 6.4 liters engine which
Ruiz, Rodrigo Peralta Moraes, Santos, Lucas Resende, Nascif, Gabriel Nobre Alves, Oliveira Ribeiro, Douglas, Pereira, Willyan
Technical Paper
Loss Function Curve to Quantify Customer (Dis)Satisfaction for Rear Chair Height (H30-2)2024-36-005012/20/2024
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
Loss Function Curve to Quantify Customer (Dis)Satisfaction for Rear Opening Width Lower for Notch Back Vehicle2024-36-005112/20/2024
During the early phase of vehicle development, one of the key design attributes to consider is the trunk. Trunk is the pillar that is responsible for user’s accommodate their baggage and make into customer needs in engineer metrics. Therefore, it is one of the key requirements to be considered during the vehicle design. Certain internal vehicle trunk characteristics such as the trunk height and length are engineer metrics that influence the occupants’ perception for trunk. One specific characteristic influencing satisfaction is the rear opening width lower for notch back segment, which is the subject of this paper. The objective of this project is to analyze the relationship between the rear opening width lower with the occupant’s satisfaction under real world driving conditions, based on research, statistical data analysis and dynamic clinics.
Santos, Alex Cardoso, Silva, Gustavo, Genaro, Piero, Terra, Rafael, Pádua, Antônio, Benevente, Rodrigo, Lourenço, Sergio
Technical Paper
Loss Function Curve to Quantify Customer (DIS) Satisfaction for Front Door Opening Entrance Height2024-36-005712/20/2024
During the early stages of vehicle development, a crucial design attribute to consider is the access of occupants into the vehicle. Access is essential for ensuring comfortable entry and egress, a key factor in occupant satisfaction. The challenge in development lies in arranging various vehicle dimensions to maintain a competitive level of comfort compared to other vehicles in the same segment. Engineering metrics such as the trimmed opening rearward and forward of the Seating Reference Point (SgRP) significantly influence occupants’ perceptions of access comfort. One specific dimension that directly affects satisfaction is entrance height, the focus of this study. This project successfully correlates the entrance height of a vehicle’s first-row door opening with occupant satisfaction under real-world driving conditions. The research involved statistical data analysis and clinics to validate these findings. The results indicate that greater levels of satisfaction are achieved with
Silva, Gustavo, Santos, Alex Cardoso, Genaro, Piero, Terra, Rafael, Pádua, Antônio, Rossini, Rafael, Benevente, Rodrigo
Technical Paper
Battery Electric Vehicle Design Specifications to Overcome Barriers in Developing Countries2024-36-018912/20/2024
The path towards clean mobility points in the direction of battery electric vehicles (BEVs) as a possible transportation solution. Despite a growing market penetration worldwide, emerging countries are struggling to successfully adopt BEV with current vehicle models. The literature presents an embracing discussion about BEV barriers but lacks into suggesting practical actions into BEV design. Based on a product development methodology and value analysis, this research aims to review factors holding back the BEV adoption in developing countries and to apply these factors into BEV features and design specifications. The literature was systematically reviewed based on the Brazilian case scenario to cast customer requirements for numerical evaluation through the Mudge Method. These were later translated into design requirements and ranked according to their relative importance with the quality function deployment (QFD). The results show that vehicle safety, pricing, and range anxiety are
Colpo, Leonardo R., Nora, Macklini Dalla, Romano, Leonardo N., Glufke, Ronaldo M., Rech, Cassiano
Technical Paper
Digital Twin-Enabled Fault Detection for Suspension Systems in Autonomous Mining Haulage Vehicles2024-36-017012/20/2024
Autonomous vehicles for mining operations offer increased productivity, reduced total cost of ownership, decreased maintenance costs, improved reliability, and reduced operator exposure to harsh mining environments. A large flow of data exists between the remote operation and the ore haul vehicle, and part of the data becomes information for the maintenance sector which it monitors the operating conditions of various systems. One of the systems deserving attention is the suspension system, responsible for keeping the vehicle running and within a certain vibration condition to keep the asset operational and productive. Thus, this work aims to develop a digital twin-assisted system to evaluate the harmonic response of the vehicle’s body. Two representations were created based on equations of motion that modeled the oscillatory behavior of a mass-damper system. One of the representations indicates a quarter of the ore transport truck’s hydraulic system in a healthy state, called a virtual
Rosa, Leonardo Olimpio, Branco, César Tadeu Nasser Medeiros
Technical Paper
A Case Study of Model-Based Systems Engineering Approach Applied in the SAE BRAZIL AeroDesign Competition2024-36-006212/20/2024
Systems Engineering is a method for developing complex products, aiming to improve cost and time estimates and ensure product validation against its requirements. This is crucial to meet customer needs and maintain competitiveness in the market. Systems Engineering activities include requirements, configuration, interface, deadlines, and technical risks management, as well as definition and decomposition of requirements, implementation, integration, and verification and validation testing. The use of digital tools in Systems Engineering activities is called Model-Based Systems Engineering (MBSE). The MBSE approach helps engineers manage system complexity, ensuring project information consistency, facilitating traceability and integration of elements throughout the product lifecycle. Its benefits include improved communication, traceability, information consistency, and complexity management. Major companies like Boeing already benefit from this approach, reducing their product
Azevedo, Marcos Paulo, Lahoz, Carlos Henrique Netto
Technical Paper
Advanced Design Validation Planning Techniques for Commercial Vehicle E-Axles02-17-04-002412/16/2024
Design validation plays a crucial role in the overall cost and time allocation for product development. This is especially evident in high-value manufacturing sectors like commercial vehicle electric drive systems or e-axles, where the expenses related to sample procurement, testing complexity, and diverse requirements are significant. Validation methodologies are continuously evolving to encompass new technologies, yet they must be rigorously evaluated to identify potential efficiencies and enhance the overall value of validation tests. Simulation tools have made substantial advancements and are now widely utilized in the development phase. The integration of simulation-based or simulation-supported validation processes can streamline testing timelines and sample quantities, all the while upholding quality standards and minimizing risks when compared to traditional methods. This study examines various scenarios where the implementation of advanced techniques has led to a reduction in
Leighton, Michael, Tuschkan, Alwin, Playfoot , Ben
Journal Article
Spacecraft System Health Management: Current Practices and Emerging TechnologiesR-56612/12/2024
Ensuring the safe and reliable operation of spacecraft is a complex task that requires advanced technologies and innovative approaches. This comprehensive guide provides a deep dive into the world of spacecraft system health management. From understanding the intricacies of spacecraft systems to exploring cutting-edge technologies like AI and digital twins, this book offers a valuable resource for anyone interested in the field. Key Features: - Clear and accessible language: The book is written for both technical experts and general readers, making it easy to understand complex concepts. - Real-world examples: Case studies and examples from actual missions bring the theoretical concepts to life. - Future-focused: The book explores emerging technologies that are shaping the future of spacecraft health management, giving readers a glimpse into the future of space exploration. Whether you're a seasoned space engineer or simply curious about the wonders of space exploration, this book
Khan, Samir
Reference
Beyond Aviation: Embedded Gaming, Artificial Intelligence, Training, and Recruitment for the Advanced Air Mobility IndustryEPR202402812/12/2024
Recent advancements in electric vertical take-off and landing (eVTOL) aircraft and the broader advanced air mobility (AAM) movement have generated significant interest within and beyond the traditional aviation industry. Many new applications have been identified and are under development, with considerable potential for market growth and exciting potential. However, talent resources are the most critical parameters to make or break the AAM vision, and significantly more talent is needed than the traditional aviation industry is able to currently generate. One possible solution—leverage rapid advancements of artificial intelligence (AI) technology and the gaming industry to help attract, identify, educate, and encourage current and future generations to engage in various aspects of the AAM industry. Beyond Aviation: Embedded Gaming, Artificial Intelligence, Training, and Recruitment for the Advanced Air Mobility Industry discusses how the modern gaming population of 3.3 million
Doo, Johnny
Research Report
SAE Truck & Off-Highway Engineering: December 202424TOFHP1212/12/2024
Demoing clean hydrogen combustion Backed by a consortium of companies, Southwest Research Institute's demonstrator vehicle aims to prove the commercial viability of hydrogen engines for on-road trucks. Improving the ageless ICE Clean-burning fuels, aftertreatment and other innovations place the heavy-duty combustion engine on a low-carbon emissions trajectory. Making software-defined vehicles cyber-secure Virtualization features such as digital twins and virtual patching can accelerate development and make commercial vehicles more agile and secure. Editorial Bauma the big one in 2025 CATL expands battery range for heavy-duty trucks and buses Donaldson's filters aim to keep fuel cells clean Shell's Starship 3.0 NG spotlights efficient powertrain, aero tech Sensata's sensors aid blind spot monitoring for tractor-trailers MTA expands wireless communication, EV tech for trucks Komatsu employs 'slick' battery swapping for underground LHD machine Liebherr, Fortescue reveal towering battery
Magazine Issue
Writing an Effective Technical Safety Concept in Accordance with ISO262622024-28-020712/05/2024
With the trend of increasing technological complexity, software content and mechatronic implementation, there are increasing risks from systematic failures and random hardware failures, which is to be considered within the scope of functional safety. ISO 26262 series of standards provides guidance to mitigate these risks by providing appropriate requirements and processes. To develop a safe product with respect to above mentioned complexities, it is very critical to develop a safe system and hence a thorough and robust “Technical Safety Concept” is very important to ensure absence of unreasonable risk due to hazards caused by malfunctions of E/E systems. ISO26262-Part 4 provides guidelines for “Product development at the system level”, to design safety-related systems that include one or more electrical and/or electronic (E/E) systems and that are installed in series production road vehicles. Defining requirements at system level for each individual technology and systematically
Cheni, Dileep Kumar, Desai, Priyanka Pradeep
Technical Paper
Battery Digital Twin with Edge Deployment2024-28-012012/05/2024
Today's battery 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. 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 devices as a strategy to reduce
Sarkar, Prasanta, Pardeshi, Rutuja, Kharwandikar, Anand, Kondhare, Manish
Technical Paper
MBSE for SDV: A Framework for Efficient Resource Allocation and System Behavior in Software Defined Vehicle2024-28-025512/05/2024
Emergence of Software Defined Vehicles (SDVs) presents a paradigm shift in the automotive domain. In this paper, we explore the application of Model-Based Systems Engineering (MBSE) for comprehensive system simulation within the SDV architecture. The key challenge for developing a system model for SDV using traditional methods is the document centric approach combined with the complexity of SDV. This MBSE approach can help to reduce the complexity involved in Software-Defined Vehicle Architecture making it more flexible, consistent, and scalable. The proposed approach facilitates the definition and analysis of functional, logical, and physical architecture enabling efficient feature and resource allocation and verification of system behaviour. It also enables iterative component analysis based on performance parameters and component interaction analysis (using sequence diagrams).
Navas, Akhil, Paul, Annie
Technical Paper
Dynamic Modeling of Torque & Emissions: Digital Twin to Simulate Combustion Process and Exhaust Emissions for Diagnostics & Prognostics Applications2024-28-017212/05/2024
As a journey to green initiatives, one of the focus areas for automotive industry is reducing environmental impact especially in case of internal combustion engines. Latest digital twin technology enable modelling complicated, fast and unsteady phenomena including the changes of emission gases concentration and output torque observed during diesel emission and combustion process. This paper presents research on the emission and combustion characteristics of a heavy vehicle diesel engine, elaborating an engineered architecture for prognostics/diagnostics, state monitoring, and performance trending of heavy-duty vehicle engine (HDVE) and after treatment system (ATS). The proposed architecture leverages advanced modeling methodologies to ensure precise predictions and diagnostics, using data-driven techniques, the architecture accurately model’s engine and exhaust system behaviors under various operating conditions. For exhaust system, architecture demonstrates encouraging predictive
Singh, Prabhsharn, Thakare, Ujval, Hivarkar, Umesh
Technical Paper
Battery Digital Twin for Electric Vehicle Deployed on Cloud2024-28-015312/05/2024
A BDT (Battery digital Twin) is a virtual representation of a vehicle's physical battery system, combining electrochemical and machine learning models to provide insights into key battery parameters like State of Charge (SOC), State of Health (SOH), Internal Resistance (IR), and Remaining Useful Life (RUL). This BDT model is calibrated using cell testing throughout its degradation process up to 80% SOH, alongside vehicle data for accurate predictions under diverse conditions. By continuously monitoring the battery under various operating scenarios, the BDT aids in effective battery management, identifying cells that degrade more quickly and the likely causes of this degradation. Current and temperature profiles offer insights into battery usage patterns. The BDT aggregates fleet-wide parameters and analyzes individual cell performance, providing critical information on SOC, SOH, IR, RUL, and voltage. Additionally, the BDT includes prognostic capabilities to alert users of potential
Sasi Kiran, Talabhaktula, Kondhare, Manish, Patil, Suyog, Nath, Subhrajyoti, CH, Sri Ram, Tank, Prabhu, Sarkar, Prasanta
Technical Paper
Strategic Utilization of Digital Twins for Examining Elastic Attack Surfaces and Replicating Attack Scenarios for Vulnerability Analysis on Road Vehicle Components2024-28-025612/05/2024
As vehicles adopt software-centric architectures, assessing vehicle software behavior becomes more complex, which can lead to the exploitation of overlooked or untreated vulnerabilities. Using these backdoors, attacks frequently targeted automotive products for malicious reasons. Automotive security incident management involves continuous monitoring of incidents and vulnerabilities. However, it faces challenges in reproducing attacks and revalidating security goals. The lack of visualization of attack scenarios, and vectors, and the knowledge required to replicate attacks hinders vulnerability assessment. The proposed approach aims to improve vulnerability assessment and document residual risks. It promotes replicating attack scenarios using cyber digital twins to support threat modeling, risk assessment, and threat analysis. The research paper focuses on utilizing digital twins for cybersecurity incident response, threat monitoring, and vulnerability exploitation by examining elastic
Venkatachalapathy, Sreenikethana
Technical Paper
Analysis on Test Case Assortment and Priortization Strategy2024-28-017712/05/2024
Agile software development aims to create high-quality products while minimizing waste, reducing project costs. Nevertheless, costs are not decreasing despite shorter project cycles and more compact, flexible teams. One area where consideration is being given to reevaluating the stages in software product development is RT. Regression testing is a form of testing done to assure that changes done in Model do not adversely affect the software's functionality. As software develops, test suites typically expand and may become too expensive to run through in their entirety The initial application might have good set of test cases, and running the entire test suite could make testing more expensive. Three ways for reducing the cost of RT include test instance prioritization, test suite minimizing, and regression test selection. In order to verify that software satisfies customer requirements, identify faults or bugs in the code, and determine how to fix these issues to make the software more
Choudhary, Mukund Kumar
Technical Paper
MAKING SOFTWARE-DEFINED VEHICLES CYBER-SECURE24TOFHP12_0312/01/2024
Virtualization features such as digital twins and virtual patching can accelerate development and make commercial vehicles more agile and secure. There is one sure-fire way to secure commercial vehicles from cyber-attacks. “You just remove the connectivity,” quipped Brandon Barry, CEO of Block Harbor Cybersecurity and the moderator of a panel session on “cybersecurity of virtual machines” at the SAE COMVEC 2024 conference in Schaumburg, Illinois. Obviously, that train has left the station - commercial vehicles of all types, including trains, are only becoming more automated and connected, which increases the risks for cyber-attacks. “We have very connected vehicles, so attacks can be posed not just through powertrain solutions but also through telemetry, infotainment systems connected to different applications and services, and also through cloud platforms,” said Trisha Chatterjee, current product support and data specialist for fuel cell and hydrogen technology at Accelera by Cummins.
Gehm, Ryan
Magazine Article
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