Browse Topic: Manufacturing

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Potential and Challenges of Next Generation Fuel Cell Powered Heavy-Duty Long Haul Trucks2025-01-0525To be published on 11/25/2025
Vehicle manufacturers are to reduce the CO₂ emissions of new trucks dramatically within the next decade. That requires to consider emission-free/neutral vehicles in the fleet mix. Especially for the application of heavy-duty (HD) long haul trucks, fuel cell powered trucks demand a holistic concept for the integration of the entire powertrain, its auxiliaries and the complete vehicle’s energy management. Key topics and takeaways: - Challenges of mechanical, thermal, EE and functional integration - Importance of predictive energy management for cost-efficient operation and lifetime optimization - Achievements in the latest fuel cell system developments and its impact on truck integration - Potential of further fuel cell stack improvements
Döbereiner, Rolf, Schörghuber, Christoph, Schenk, Alexander, Schubert, Thomas, Stöckl, Bernhard
Simulative temperature determination of an electric machine from test bench tests2025-01-0520To be published on 11/25/2025
One of the most important components of an electric vehicle is the drive motor. Induction motors are often used for this purpose. Power losses occur during the operation of these motors, particularly at high speeds. Among other things, this power loss corresponds to the sum of winding losses, iron core losses and mechanical losses. The power losses generate heat, causing the temperature in the rotor and stator to rise. The increase in temperature of the components inside the motor can lead to premature wear and fatigue failure. To prevent overheating, the motors are air or water cooled. Water cooling can be achieved by jacket cooling, for example. In this case, the heat generated is dissipated directly by forced convection. However, the cooling jacket makes it difficult to determine the temperature inside the motor. Determining these temperatures is necessary to prevent the motor from fatiguing prematurely. The temperatures that occur inside the motor during operation are of particular
Schamberger, Stephanie, Reuss, Hans-Christian
Monitoring of Long drill wear status through Vibration analysis using Time and Frequency domain2025-28-0252To be published on 11/06/2025
Hard carbon steel is used for drilling deep holes, such as C19, which has dimensions of 630 mm in length, 50 mm in breadth, and 125 mm in depth. Long twist drills with a diameter of 8 mm are used. Such drills are manufactured with larger helix than the traditional drills for increasing penetration efficiency. But, Prediction of long drill & tool replacement strategies during metal cutting are mostly depend on conservative estimation given by manufacturer's catalog. Hence, long drill while drilling cam shaft in automobile applications may be underutilized or over utilized. Now a day, Diagnostics software in advanced CNC machines are indicating hours of utilization of tools in bar chart. On the other hand, Utilization of long drill wear beyond the recommended range affects the quality of workpiece. As a result, several researchers have proposed the reliable approach of vibration-based online monitoring of drill flank wear over the past 20 years. In these works, the vibration sensor is
R. S., Nakandhrakumar, Raja, Selvakumar, Elumalai, Sangeethkumar, Velmurugan, Ramanathan, M, Ramakrishnan
Automated Offboard system to measure the volume of harvested material2025-28-0331To be published on 11/06/2025
Problem Statement: Measuring the volume of harvested material behind the machine can be beneficial for various agricultural operations, such as baling, dropping, material decomposition, cultivation, and seeding. This paper aims to investigate and determine the volume of material for use in various agricultural operations. This proposed methodology can help to predict the amount of residue available in the field, assess field readiness for the next production cycle, measure residue distribution, determine hay readiness for baling, and evaluate the quantity of hay present in the field, among other applications which would benefit the customer. Solution Statement: • TO Improve the agricultural production system. • By – Measuring the volume of harvested material • Using – Remote Sensing and IoT Technology: System is going to use Onboard camera and satellite image to determine the volume of materials. The system collects data from the capture device during runtime to obtain information
Singh, Rana Shakti
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
Design for automation for Construction equipment fabrication and welding.2025-28-0248To be published on 11/06/2025
Over the past 25 years, the heavy fabrication and construction equipment industry has experienced significant development. With the global increase in demand for construction equipment, companies face immense pressure to produce more products in less time and at competitive prices. Additionally, new challenges have emerged as the younger workforce is reluctant to acquire essential skills such as heavy metal fabrication, heat treatment, welding, and painting. The increased demand has forced companies to operate in three shifts, but they struggle to find workers willing to work the third shift. Recruiting and retaining a workforce to meet the heightened demand has become a major challenge. Automation in manufacturing processes is the only viable solution to address these challenges. However, the implementation of automation projects in heavy fabrication and construction equipment factories has been slow. A significant challenge is that the products being produced were originally designed
Saseendran, Unnikrishnan, Bhorge, Pankaj
Assessing Excavator Quick Couplers: A Customer-Centric Study to Application Suitability2025-28-0268To be published on 11/06/2025
In the fast-paced world of construction, the demand for machine Uptime is paramount. Various construction machines play crucial roles in applications such as digging, loading, landscaping, and demolition. One critical component that significantly enhances machine uptime for these operations is the quick coupler. This innovative attachment facilitates rapid tool changes, enabling operators to switch between attachments seamlessly. It also boosts operator safety by eliminating frequent interaction between the operator and the attachments. Additionally, the ease of replacing attachments ensures that operators can easily use the correct attachment for specific tasks optimizing overall attachment usage. This paper aims to study the trade-off between breakout force and productivity when using quick couplers. This research assists customers in determining whether to utilize quick couplers based on their specific application requirements. The findings of this study are designed to help
Bhosale, Dhanaji Haridas, PARAMESWARAN, SANKARAN, Narayanan, Arun
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
Transformative Deep Learning for Image Colorization with Machine Learning-Based Classification2025-28-0317To be published on 11/06/2025
Imagine a user opening a technical manual, eager to troubleshoot an issue, only to find a mix of stark black-and-white illustrations alongside a few color images. This inconsistency not only detracts from the user experience but also complicates understanding. For technicians relying on these documents, grayscale graphics hinder quick interpretation of diagrams, extending diagnostics time and impacting overall productivity. Producing high-quality color graphics typically requires significant investment in time and resources, often necessitating a dedicated graphics team. Our innovative pipeline addresses this challenge by automating the colorization and classification of existing grayscale graphics. This approach delivers consistent, visually engaging content without the extensive investment in specialized teams, enhancing the visual appeal of materials and streamlining the diagnostic process for technicians. With clearer, more vibrant graphics, technicians can complete tasks more
Khalid, Maaz, Akarte, Anurag, Kale, Aniket, Rajmane, Gayatri, Nalawade, Komal
Technology Driven Solutions for Effective Tool Management.2025-28-0249To be published on 11/06/2025
IoT is revolutionizing the asset tracking industry, transforming it from manual entries in spreadsheets and logs to real-time, data-driven, foolproof solutions that boost manufacturing efficiency. Technical advancements are occurring in the IOT architecture. Leveraging a combination of cost-effective sensors such as LoRa -WAN and UWB provides data precision and accuracy by replacing traditional benchmark hardware solutions. Protocols like MQTT and Kafka enhance the data connectivity layer, enabling rapid data flow and logging, instantaneous insights, and agile decision-making. In the context of manufacturing, real-time indoor tracking ensures that equipment, tools, and products are located more accurately, resulting in improved operational matrices like productivity, availability, etc. This aligns with digital LEAN manufacturing principles such as Continuous Improvement (CI), Equipment Utilization factor, and just-in-time inventory management.
Patel, Shravani Prashant
Strength Analysis of Additive Parts with Variation in Infill Percentage for ABS Materials2025-28-0251To be published on 11/06/2025
In John Deere additive manufacturing, one of the significant challenges in additive manufacturing is determining the optimal infill percentage, as it directly affects the mechanical strength of printed components. Designers often find it difficult to decide on this percentage due to the lack of clear guidelines and empirical data. This study addresses this gap by investigating the strength characteristics of additive ABS30 material parts with varying infill percentages, specifically ranging from 10% to 100% (full solid). Despite existing literature, there is a notable absence of comprehensive studies on the relationship between infill percentage and strength, primarily due to the complexities involved in creating and exporting accurate infill models from additive manufacturing software. To tackle this issue, we developed CAD models designed for tensile, compression, and bending tests as per ASME, incorporating line infill patterns at various infill percentage. We then performed virtual
Salgar, Manojkumar, Patil, Anup
A Load Cell-Free Solution for Weighing2025-28-0346To be published on 11/06/2025
The agricultural industry increasingly demands innovative solutions to enhance efficiency and productivity, while minimizing overhead costs of an advanced system. Large farms cultivating forage crops for the Dairy and Livestock sectors require high-quality, dense bales that retain their nutritional value. Bale weight serves as a critical parameter for assessing production yields, managing inventory and facilitating fair trade in the industry. Traditional weighing systems reliant heavily on load cells, can pose limitations in terms of cost, complexity and maintenance. This paper presents an advanced model-based weighing system de-signed specifically for balers machine. It utilizes mathematical models and dynamic torque monitoring techniques to accurately estimate the weight of bales just after the baling process. The Bale weight calculation is achieved by measuring reverse pressure experienced during bale handling and monitoring the pitch angle to compensate for measurements over
Kadam, Pankaj
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
E-Motor thermal management using 2D-3D coupling2025-28-0225To be published on 11/06/2025
In the electrical machines, detrimental effects are resulted often due to the overheating, such as insulation material degradation, demagnetization, decreased lifetime and efficiency of the motor and Joule losses. Hence, it is vital to optimize the reliability and performance of the electric motors (E-Motor) and to reduce the maintenance and operating costs. This study brings the analysis capability of CFD for the air-cooling of an E-Motor powering on E-Machines. With the aggressive focus on electrification across automotive industry, there is an increasing need of CFD modeling to perform virtual simulations of the E-Motors to determine the viability of the designs and their performance capabilities. The thermal predictions are extremely vital as they have tremendous impact on the design, spacing and sizes of motors. With this study using Ansys Fluent - Maxwell coupling, a complete 3D CFD with CHT modeling of an Electric Motor, including all the key components like the windings, rotor
Singh, Bhuvaneshwar, Tirumala, Bhaskar, Badgujar, Swapnil, HK, Shashikiran
Advanced End-of-Line Routines for Genset Fault Diagnostics: Integrating Catalyst and Component Aging Detection2025-28-0308To be published on 11/06/2025
Advanced end-of-line (EOL) testing is crucial for making sure the next generation of generator sets (gensets) stay both reliable and up to code. This paper introduces new diagnostic methods that combine real-time data collection, automated testing scripts, and targeted operating zones. The goal is to catch any immediate production issues and also spot early warning signs of catalyst or engine aging. By placing gensets in carefully controlled environments that closely reflect their real-world operating conditions, these EOL tests can detect subtle performance problems that ordinary spot checks often miss. A standout feature of this approach is using specialized testers to run specific load points and temperatures, allowing for faster evaluations of potential catalyst wear, diesel particulate filter (DPF) buildup, and other types of long-term deterioration. By applying predictive algorithms and comparing results to baseline data from new components, these advanced routines can identify
Kumar D, Ajay, Menon, Anand, Itagi, Ravi, Patel, Prateek, JOHNSON, JEEVAN
Evaluating the Influence of Material Properties and Hardness on Tightening Torque2025-28-0255To be published on 11/06/2025
A Crawler Dozer is a tracked machine that uses a mounted blade at the front to move materials. Different blades (S-blade, U-Blade, Angle blade, PAT blade) are used for moving large amounts of soil, debris, and stones. Each blade is designed for a specific requirement/application. The blades are equipped with ground engaging (GET) tools, such as cutting bits or a set of cutting bits, to help protect the shovel and other earthmoving tools from wear. Torquing hardened plates of bolted joint components is essential to ensure uniform load distribution and prevent premature failure. Therefore, selecting the proper torque is an important parameter. This study focuses on analyzing various parameters that impact the final torque on the hardened surface. This will help understand the torque required for specific joints. Several other parameters considered in this study include hardware material, coefficient of friction, end bit and cutting-edge material, and their hardness. Understanding the
PARAMESWARAN, SANKARAN POTTI, Bhosale, Dhanaji, Kumar, Rajeev
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
A unit Product Energy mapping framework2025-28-0247To be published on 11/06/2025
Combining energy management and value stream mapping In today's industrial landscape, manufacturing plays a central role in driving economic growth. However, this crucial sector is also a major contributor to global energy consumption and greenhouse gases (CO2eq) emission. Energy management focuses on the systematic use of management and technology to improve energy performance in a selected site, such as a building, facility, or an entire organization. It requires that energy procurement, energy efficiency and renewable energy y be integrated proactive and incorporated in order for it to be fully effective. Value Stream Mapping (VSM), a widely used tool of Lean Manufacturing, is a type of symbolic model that graphically enables the end user to observe the material and information flow as a product or service travels through a value chain. The model represents the flow of resources such as materials, information and personnel along with their interactions, beginning with a sales order
Sumbe, Ankita Surendra, Kumar, Rahul, Shrivastava, Swapnil
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
Mechanical complex assembly2025-28-0262To be published on 11/06/2025
Title: Two weldments assembled using four or more bolts. Abstract consists of study on Two weldments assembled using four or more bolts. Assembly preload stress effect on weld area of subassembly. There are three different assembly fits. 1. Clearance fit. 2. Interference fit. 3.Transition fit. Preload stress on weldments generated are different for three different fits of assemblies. In industry interference & Transition fits required special tooling to assemble parts together. Ergonomically it is not practice using interference fit. In case of interference fit: We need to assemble part with applying hammer. In that case when apply torques on bolted joint. Preloads on assembly is adequate. This joint is good joint. Clearance fit: Preloads Stresses on joints will be higher & severe based on size of gap in between joining surfaces. These types of stresses will cause crack generation on welded are of sub-assembly. Further in cyclic load crack propagates. Clearnce fit and Shims: We can
Kazi, Mohseen Vahab, Gandhi, Mitesh
Enhancing Tractor Operator Comfort and Safety Through Advanced Drive Assistance Features2025-28-0216To be published on 11/06/2025
This paper explains the role of Advanced drive assistance features that have been designed to increase comfort, operational efficiency, and safety in an electric tractor. Prime goal is to address the challenges faced by the operators currently in a variety of agricultural and utility applications. Hill hold and electric parking brake work in tandem to offer unparalleled safety by eliminating the fear of tractor roll back in uneven terrain and surfaces both in launch and normal operational scenarios. Cruise and Creep control in a combination have been designed to reduce operator fatigue and increase productivity.
M, Rojer, sundaram, Pavithra, Natarajan, Saravanan, devakumar, Kiran, Muniappan, Balakrishnan
Enhanced PTO motor operation modes in Electric tractor2025-28-0239To be published on 11/06/2025
This paper is about optimized way of operation of PTO motor (Auxiliary motor) in Electric tractor using 3 different modes - Low Idle mode, Loader mode and PTO mode. These modes will provide benefit to user by improved battery range, comfort/less fatigue while using loader operation and improved performance or productivity while using PTO operated implements.
sundaram, Pavithra, M, Rojer, Natarajan, Saravanan, Joshi, Priyanka
Analysis of simulators for designing network architecture in Wireless Sensor Network(WSN) applications2025-28-0338To be published on 11/06/2025
Recent advancements in energy-efficient wireless communication protocols and sensor technologies have led to the development of wireless sensor network (WSN) applications in diverse industries. Wireless sensors are crucial in both smart factory applications and in introducing autonomy in harsh environment agricultural operations, where traditional wiring systems have higher chances of failure. These WSNs are generally designed using Bluetooth Low Energy (BLE), ZigBee, and Wi-Fi communication protocols, depending on the range and reliability requirements of the application. The design of these WSN applications also depends on several factors. First, the environment in which devices operate varies with the industries and products they are employed in. Second, the energy availability for these devices is limited, so higher signal strength for transmission and retransmission significantly reduces the lifetime of these nodes. Finally, the size of networks is increasing, making scheduling
Periwal, Garvit, Koparde, Prashant, Sewalkar, Swarupanand
Eyes of Robot operating system for future hands2025-28-0246To be published on 11/06/2025
In today’s competitive market, factories need to harness their full potential by smart and adaptive thinking to keep up with changing technology, demand, and manufacturing process. This demands multiple product manufacturing on same line, less time for changeovers and robotic automations for efficiency improvements. Each custom automation piece requires human efforts for development and maintenance. Robot programming is major pain area for industries requiring skilled professionals and adapting to shifting market demands. Enabling ROS with Cameras for learning natural/traditional way of manufacturing for Robots and incorporating that to program them will reduce manual efforts, skilled professionals and help factories in sustainability, highest customization, and even higher quality. Enabling ROS with Camera to capture -> connect -> compile -> create for reducing development time and increasing efficiency. This will help industries to manage even the complex product portfolio on a
Hepat, Abhijeet
Predictive Maintenance Solution with Real-Time Insights and Cost Estimation for Machine Health Management2025-28-0302To be published on 11/06/2025
This paper introduces a comprehensive solution for predictive maintenance, utilizing statistical data and analytics. The proposed Service Planner feature offers customers real-time insights into the health of machine or vehicle parts and their replacement schedules. By referencing data from service stations and manufacturer advisories, the Service Planner assesses the current health and estimated lifespan of parts based on metrics such as days, engine hours, kilometers, and statistical data. The user interface displays current part health, replacement due dates, and estimated replacement costs. For example, if air filter replacement is recommended every six months, the solution uses manufacturer advisories to estimate the remaining life of the air filter in terms of days or engine hours. It also suggests replacement dates, suitable part options, replacement costs, and available service slots through an operator guidance mobile app and portal. The solution features a 360-degree view of
Chaudhari, Hemant Ashok
A Framework for network protocol selection for Smart Factories2025-28-0245To be published on 11/06/2025
In the current phase of Industry 4.0, the selection of appropriate network protocols is a critical factor in enabling real-time data, high-speed motion control, and IT-OT connectivity in smart factories. Yet, selecting the right network protocols for smart factories remains a complex challenge, as no single protocol suits all 05 layers of the automation pyramid, from field-level sensors layer to enterprise layer. This paper explores how network protocols can be mapped to different layers of the automation pyramid, ranging from sensor layer (L0) to enterprise-level data layer (L4). For example, Profinet is shown to be highly effective for time-critical applications such as robotic assembly and motion control due to its deterministic, real-time Ethernet capabilities. Meanwhile, IO-Link offers a, point-to-point solution with its diagnostic capabilities for intelligent sensors and actuators, making it ideal for IoT-driven data collection. Other protocols, such as EtherCAT and OPC UA, each
Tarapure, Prasad
Implementing Generative AI into Realtime Visualization Workflow2025-28-0324To be published on 11/06/2025
The development of 3D models is a critical component of the asset creation workflow in industries. However, traditional modeling techniques often demand extensive manual input, particularly in the areas of modeling, retopology, and texturing. To address challenges, we propose the integration of generative AI technologies into the 3D modeling workflow, aiming to enhance efficiency and streamline processes. This paper presents a comprehensive methodology that leverages advanced algorithms, machine learning techniques, and specialized software to automate repetitive tasks associated with 3D asset creation. By harnessing the power of generative AI, we aim to significantly reduce the manual effort required to produce high-quality 3D models, thereby accelerating the overall development timeline. The aim is to enter a prompt/Image as input to get a fully developed Model. Through a series of experimental implementations, we are aiming to demonstrate the effectiveness of our proposed framework
Arunachalam, Haripriya, GUMASTE, Amey, Kumar, Pravin
Advanced Manufacturing Processes – Construction Equipment’s2025-28-0243To be published on 11/06/2025
With the global increase in demand for construction equipment, companies face immense pressure to produce more products in a competitive & sustainable way by utilizing advanced manufacturing technologies. Additionally, the need for data analytics and Industry 4.0 is increasing to take better decision early in the development cycles and during the production phase. Advanced manufacturing processes & adopting Industry 4.0 is the only viable solution to address these challenges. However, the implementation of advanced manufacturing processes in heavy fabrication and construction equipment factories has been slow. A significant challenge is that the products being produced were originally designed for conventional manufacturing processes. When factories are becoming smart and connected through Industry 4.0 solutions, companies must reconsider many established assumptions about advanced manufacturing processes and its benefits. To maximize efficiency gains, improve safety standards, and
Bhorge, Pankaj, Saseendran, Unnikrishnan, RODGE, SOMESHWAR
Additive Manufacturing for Custom Off-Highway Vehicle Components: Enhancing Performance and Sustainability2025-28-0250To be published on 11/06/2025
Off-highway vehicles (OHVs) operate in challenging environments that demand high-performance components that can withstand extreme conditions. This paper explores the use of additive manufacturing (3D printing) to produce custom, lightweight components for OHVs, offering significant advantages over traditional manufacturing methods. By utilizing advanced materials and CAD/CAM software, this approach enables the creation of complex, optimized designs that reduce vehicle weight, enhance fuel efficiency, and improve overall performance. Additionally, 3D printing reduces material waste and shortens production times, making it an ideal solution for producing tailored components with minimal environmental impact. The use of rapid prototyping further accelerates the design and testing process, enabling faster iteration and optimization of vehicle parts. This innovation not only improves OHV functionality but also aligns with sustainability goals by minimizing resource usage and reducing the
Vashisht, Shruti
Analysis of Artificial Intelligence in biofuel industry: A case study2025-28-0341To be published on 11/06/2025
Increasing reservations about the consumption of fossil fuels due to their detrimental impact on our ecosystem has led to an increased focus to look for renewable alternative. In the last decade, biofuels have attracted much attention as a promising replacement for fossil fuel-based diesel, especially in the transportation sector. Biofuels are non-toxic, environmentally friendly, and carbon-free fuel that can be made from naturally available resources. Biofuel production and its further utilization requires identifying unknown parameters having nonlinear relationships between each other. Accurate and better predictive tools are required at different stages during its usage. AI technique is one such tool that can provide support during production and utilization. The same is utilized to design handle, control, optimize, and monitor the system. The present research investigates the different areas of AI usage which makes use of production modeling methods, machine learning for better
Vashist, Devendra
Design and Fabrication of Micro-Hybrid Agricultural Machine2025-28-0220To be published on 11/06/2025
Agriculture remains the backbone of India’s economy, with a majority of farmers operating on small and fragmented landholdings. However, most agricultural machinery available in developed nations is unsuitable for these conditions due to high costs and large sizes. To address these challenges, this project introduces the Design and Fabrication of a Micro-hybrid Agricultural Machine (Mini-tractor)—a 7 HP, multi-purpose, off-road agricultural vehicle tailored for small-scale farmers. The mini-tractor is designed to perform various farming operations, including ploughing, weeding, cultivation, and pesticide spraying. A key innovation in this system is the integration of solar-powered spraying technology, reducing dependency on fossil fuels and lowering operational costs. Its modular design allows easy attachment and detachment of implements, making it highly versatile for different agricultural tasks. Additionally, the mini-tractor can be used for local transportation and material
Wagh, Shrutika Suryabhan
Development of Integrated Forming of New "NMAX" YECVT Parts Using the Plate Forging Method2025-32-0005To be published on 11/03/2025
Yamaha Motor Engineering Co., Ltd. provides plastic processing technology based on fuel tank press forming technology, and is developing various plastic processing methods, including forging, and developing mold equipment to realize them. This time, the core parts of the YECVT unit mounted on Yamaha Motor Co., Ltd.'s small premium scooter "NMAX" were not made by welding individual parts to each other, but by integrally forming them from a single thick plate using the cold forming method, resulting in lightweight, compact, high-strength, high-precision parts. By incorporating a composite plastic processing method that takes advantage of the characteristics of the material while making full use of analysis technology and mold technology, we were able to develop a composite plastic processing method (plate forging method) that creates new added value and mass produce it. In addition,this development has made it possible to achieve a thickness increase of 1.7 times the standard material
Hongo, Hironari, Tamaru, Shogo, Uda, Shinnosuke
Clean cuts, clear conscience: Advanced engines, optimized tools, eco-friendly fuels2025-32-0087To be published on 11/03/2025
Handheld outdoor power equipment is used worldwide to shape and maintain the environment and are daily assistants in forestry, operated under very demanding environmental conditions. In the power tool sector, as elsewhere, the shift from petrol to battery-powered products is already well underway, especially for consumer applications. However, internal combustion engines will continue to be indispensable for professional users of power tools, who place the highest demands on their equipment in terms of performance and energy density. These power tools are often used in remote locations and thus far away from a possible charging infrastructure. To make a contribution to climate protection, biofuels and RFNBOs are necessary. The continuous optimization of engine technology and its overall system, including cutting tools (saw chain set, cutting wheel, etc.) is an important development goal of STIHL. The interaction between the saw chain, guide bar and power train are essential for optimal
Beck, Kai W., Maier, Georg, Müller, Matthias, Lux, Thomas, Kölmel, Armin, Lochmann, Holger, Melder, Jens
Higher-strength, higher-toughness die cast wheel material using recycled aluminum2025-32-0007To be published on 11/03/2025
In an attempt to reduce CO2 release from the alloy wheel production, we have developed such an aluminum alloy for casting that satisfies necessary property requirements using recycled aluminum and without heat treatment. The wheel is a critical safety item of the vehicle requiring higher toughness and strength. In many wheels, virgin aluminum containing small amounts of impurities are used to maintain toughness, and the heat treatment (T6), in which quick heating and cooling are conducted after the casting, is applied to provide ensure strength. At the start of this project, we focused on two wheel-manufacturing processes; the production of virgin aluminum and the heat treatment, from which a large amount of CO2 is released. The change from the virgin to the recycled material allows reduction of CO2 release to 1/9. The issue in the use of recycled material is that impurities grow in the metal structures as an intermetallic compounds and lower toughness. To deal with the said issue, we
Suzuki, Noritaka
Development of CAE Technology for the Design Support of Piston Pin Circlip2025-32-0015To be published on 11/03/2025
This study focuses on the technology for establishing design criteria for the piston pin circlip (hereinafter referred to as "circlip"), which is a component that holds the engine piston pin. The circlip is assembled into the piston by compressing it to the size of the piston circlip groove. However, in high-revving engines, the inertia forces caused by engine rotation can cause the circlip to disengage from the groove, potentially leading to the piston pin falling out and damaging the engine. To prevent this, it is possible to compress the circlip more and increase the reactive force acting on the groove to prevent falling out. However, this countermeasure raises concerns about the deterioration of the assemblability of the circlip. Therefore, it is necessary to establish evaluation criteria that prevent the circlip from disengaging and deteriorationg the assemblability of the circlip. To enable appropriate design of the circlip during the engine specifications review phase, we
Ishizuka, Atsushi, Watanabe, Naoto
Safety Critical Series Arc Detection and Measurement in Medium and High Voltage DC Grids2025-32-0012To be published on 11/03/2025
Direct current (DC) systems are increasingly used in small power system applications ranging from combined heat and power plants aided with photovoltaic (PV) installations to powertrains of small electric vehicles. A critical safety issue in these systems is the occurrence of series arc faults, which can lead to fires due to high temperatures. This paper presents a model-based method for detecting such faults in medium- and high-voltage DC circuits. Unlike traditional approaches that rely on high-frequency signal analysis, the proposed method uses a physical circuit model and a high-gain observer to estimate deviations from nominal operation. The detection criterion is based on the variance of a disturbance estimate, allowing fast and reliable fault identification. Experimental validation is conducted using a PV system with an arc generator to simulate faults. The results demonstrate the effectiveness of the method in distinguishing fault events from normal operating variations. The
Winkler, Alexander, Mayr, Stefan, Grabmair, Gernot
Enhancing Cabin Air Quality: Challenges, Impact and Advanced Climate Control Solutions2025-28-0433To be published on 10/30/2025
Cabin air quality plays a crucial role in ensuring passenger comfort, health and driving experience. There have been growing concerns over poor cabin air quality resulting from multiple factors, including infiltration of external pollutants such as particulate matter, volatile organic compounds, emissions from vehicle interior materials, microbial contamination and inadequate ventilation. Therefore, maintaining optimal air quality inside vehicle cabin has become a critical aspect of vehicle climate control systems. Additionally, high humidity levels inside the cabin contribute to mold growth and fogging of windows, further compromising both air quality and visibility. This review explores such factors contributing to poor cabin air quality, where the severity of these issues ranges from mild discomfort and allergic reactions to long-term respiratory ailments. To mitigate these challenges, automotive manufacturers and researchers have implemented various air purification and filtration
Sharma, Shrutika
Demisting system to secure the outside rear-view mirror visibility without a dedicated side demister2025-28-0383To be published on 10/30/2025
Efficient demisting of automotive side windows is crucial for maintaining visibility and ensuring passenger safety, particularly in adverse weather conditions. Conventional systems often employ dedicated side demisters, which increase system complexity, and production costs and vehicle weight. This study explores an alternative approach to side glass demisting by utilizing airflow from the front defroster system, eliminating the need for separate side demisters. The Study leverages optimized airflow dynamics and strategic design of defroster to direct a portion of the air towards the side glass. Computational Fluid Dynamics (CFD) simulations and actual vehicle tests to analyze the airflow patterns, temperature gradients, and defogging efficiency of this configuration. Results indicate that the front defroster airflow can effectively clear mist from the side windows, achieving comparable performance to conventional side demisters. Key design parameters, including defroster geometry
Kushwaha, Mayank, Bhangale, Shekhar, Mittal, Sachin, Kumar, Mukesh, Umbarkar, Shriganesh
Structural and thermal behavior prediction of chiller by using CAE simulation2025-28-0396To be published on 10/30/2025
Heat exchangers are critical components in various industrial applications, enabling efficient energy transfer between fluids. Chiller (Plate-type heat exchanger), with its compact design and high thermal performance, have gained significant attention in industries such as HVAC, power generation, and chemical processing. This study presents a comprehensive thermo-structural analysis of a chiller generated due to varying fluctuating temperatures and vehicle vibrations using Computer-Aided Engineering (CAE) tools. The analysis involves modeling the heat exchanger geometry, including the alternate chiller plates, to capture the complex geometries. Advanced simulation techniques such as Computer- Aided engineering (CAE) and Finite Element Analysis (FEA) are employed to investigate the thermal behavior under varying operating conditions, including flow rates, inlet temperatures, and pressure drops. Key parameters like pulsation pressure test, temperature distribution, dynamic stress
Jaiswal, Ankit, Parayil, Paulson
Artificial Intelligence application in biodiesel production and usage for better resource utilization2025-28-0385To be published on 10/30/2025
Increasing reservations about the consumption of fossil fuels due to their detrimental impact on our ecosystem has led to an increased focus to look for renewable alternative. In the last decade, biodiesel has attracted much attention as a promising replacement for fossil fuel-based diesel, especially in the transportation sector. Biodiesel is a non-toxic, environmentally friendly, and carbon-free fuel that can be made from any kind of vegetable oil or fat. Biodiesel production and its further utilization requires identifying unknown parameters having nonlinear relationships between each other. Accurate and better predictive tools are required at different stages during its usage. AI technique is one such tool that can provide support during production and utilization. The same is utilized to design handle, control, optimize, and monitor the system. The present research investigates the different areas of AI usage which makes use of production modeling methods, machine learning for
Vashist, Devendra, KUMAR, VIVEK
Noise mitigation techniques in vehicle HVAC system2025-28-0378To be published on 10/30/2025
Noise produced by Heating, Ventilation, and Air Conditioning (HVAC) systems in automobiles considerably influences passenger comfort and the overall driving experience. As automotive manufacturers strive to improve the acoustic environment within vehicles, the reduction of HVAC system noise has emerged as a significant concern. The main sources of noise in HVAC systems consist of fan operation, compressor vibrations, and airflow turbulence occurring within ducts. This paper investigates several technical strategies to diminish HVAC system noise, emphasizing advanced methods such as Campbell diagrams, waterfall charts, and techniques for system optimization One significant approach for noise mitigation is the utilization of Campbell diagrams, which serve as essential instruments for pinpointing resonant frequencies in HVAC components. By graphing frequency in relation to rotational speed, engineers are able to identify critical resonance points and devise solutions to either avoid or
Trivedi, Arpita, Kumar, Ravi, Madaan, Ashish, Shrivastava, Pawan
Optimizing Electric Vehicle Motor Testing with Fine Gaussian SVM and Bilayered Neural Network.2025-28-0397To be published on 10/30/2025
Electric vehicles are shaping the future of the automotive industry, with the drive motor being a crucial component in their operation. Ensuring motor reliability requires rigorous testing using specialized test benches to validate key performance parameters. However, inefficiencies in the helical gear configuration within these test systems have led to frequent malfunctions, affecting production flow. This study focuses on optimizing the motor test bench by refining critical design parameters through vibration signal analysis and machine learning techniques. Vibrational data is collected under different gear configurations, utilizing an accelerometer integrated with a Data Acquisition (DAQ) system and MATLAB-based directives for seamless data collection. Machine learning classifiers, including Fine Gaussian SVM and a Bilayered Neural Network, are applied to categorize signals into normal and faulty conditions, both with and without a 0.25 KW load. The analysis reveals that SVM
S, Ravikumar, Sharik, N, Syed, Shaul, V, Muralidharan, D, Pradeep Kumar
Maximizing Range with Advanced Air Conditioning Optimization and Energy Management2025-28-0364To be published on 10/30/2025
Widespread adoption of electric vehicles (EVs) is hindered by "range anxiety," a major concern for consumers. A primary contributor to this issue is the significant energy consumption of the Heating, Ventilation, and Air Conditioning (HVAC) system, which can account for 15-40% of a vehicle's total energy demand, directly reducing its practical driving range. Using the 1D simulation tool GT-SUITE, this research provides a comparative analysis of two distinct HVAC architectures: a conventional air-cooled condenser (ACC) and a proposed liquid-cooled condenser (LCC). The performance of both hardware systems was evaluated under two control strategies a Proportional-Integral (PI) controller and a basic On/Off controller—to identify the optimal configuration. The results advocate that optimizing the system's architecture and control logic yields a substantial improvement in the Coefficient of Performance (COP) ranging from 47% to 128% compared to the baseline ACC/On-Off configuration, with a
T R, Rakshith, Yadav, Ankit
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
Reactivity Retention of Modern Converters for Stringent Emission Control2025-01-0401To be published on 10/07/2025
The push for environmental protection and sustainability has led to strict emission regulations for automotive manufacturers as evident in EURO VII and 2026 EPA requirements. The challenge lies in maintaining fuel efficiency and simultaneously reducing the carbon footprint while meeting future emission regulations. Modern internal combustion engines typically employ various in-cylinder emission reduction techniques along with a multi-stage exhaust after-treatment system to comply with emission standards. Three-way catalyst has been the primary workhorse for the automotive industry for exhaust after-treatment in stoichiometric burn engines, owing to its exceptional conversion efficiency and single-stage simultaneous reductive and oxidative emission mitigation. However, fuel and lubricant-borne sulfur and phosphorus compounds have been shown to have a significant long-term effect on the activity of three-way catalysts, particularly during the lean-rich transitions and oxygen storage
Sandhu, Navjot Singh, Yu, Xiao, Jiang, Chuankai, Ting, David, Zheng, Ming
The Challenges of Measuring Residual Brake Drag using Different Test Apparatuses and Methods to Mitigate Inaccuracies2025-01-0343To be published on 09/15/2025
As automotive manufacturers have tried to set themselves apart by reducing emissions, and increasing vehicle range/fuel economy by eliminating any energy loss from inefficiencies on the vehicle, the brake corners have been an area of interest to reduce off-brake torque to zero in all conditions. Caliper designers can revise some attributes like piston seal grooves, and pad retraction features to reduce drag, but even if a caliper is designed perfectly in all aspects, trying to measure it in a reliable and repeatable manner proves to be difficult. There are many ways to measure brake drag all with ranging complexity. Some of the simplest measurements are the most repeatable, but it excludes the majority of the vehicle inputs. The most vehicle representative testing requires the most complex equipment and comes with the most challenges. This paper will focus mainly on the different ways residual brake drag can be measured, the benefits and challenges to each of them, the problems trying
Retting, Joshua
Effect of Casting Microstructure on the Mechanical Performance of Recycled EN AC-43200 Al-Si Alloy2025-01-0357To be published on 09/15/2025
This work investigates the influence of casting microstructure on the mechanical performance of ad hoc samples of recycled EN AC-43200 Al-Si alloy. Three batches are produced by modifying the casting process parameters (i.e., molten alloy temperature and in-mold cooling conditions) to obtain different casting microstructures. Room temperature tensile and high-cycle fatigue tests, coupled with metallography, X-ray tomography, and fatigue fracture surface analysis, are performed to elucidate the relationship between microstructural characteristics and mechanical properties of the investigated alloy. The findings indicate that casting pores and intermetallic precipitates play a pivotal role in influencing the mechanical behavior and performance of cast, recycled EN AC-43200 Al-Si alloy. Additionally, an inverse correlation between secondary dendrite arm spacing (SDAS) and both tensile properties and fatigue life is established.
Pavesi, Arianna, Barella, Silvia, D'Errico, Fabrizio, Bonfanti, Andrea, Bertasi, Federico
Automated Gaseous Nitrocarburizing Controlled by PotentialsAMS2759/12C (Current)09/10/2025
This specification covers the requirements for producing a continuous compound zone (white layer) with controlled extent of porosity by means of a gaseous process, automatically controlled to maintain nitriding and carburizing potentials that determine properties of the nitrocarburized surface. Automatic control is intended to ensure repeatability of nitrogen and carbon content of the compound zone, which influences properties such as wear and corrosion resistance, ductility, and fatigue strength.
AMS B Finishes Processes and Fluids Committee
SAE TOMORROW TODAY UNPLUGGED - Why Robo-Taxis Are Losing the Battle for Energy1353309/08/2025
The staggering energy demands of AI data centers are set to consume 12% of America's electricity by 2028 -- and tech giants are investing billions to secure supply. This leaves robo-taxi operators fighting for scraps in an energy market dominated by hyperscalers who are set to spend $322 billion combined this year alone. In this Unplugged episode of SAE Tomorrow Today, host Grayson Brulte breaks down why energy is the real roadblock to autonomy and whether bold solutions like natural gas-powered depots could change the game for robo-taxi developers struggling to scale. Have your own thoughts on this topic? We'd love to hear from you! Share your comments, questions or ideas for future topics with Grayson on Twitter or send them to podcast@sae.org. Follow SAE on LinkedIn, Instagram, Facebook, Twitter, and YouTube. Follow host Grayson Brulte on LinkedIn, Twitter, and Instagram.
Patterson, Lori
Influence of Geometric Parameters on the Performance of TPMS-Based Heat Exchangers2025-24-001509/07/2025
Advancements in additive manufacturing (AM) technology have enabled the use of Triply Periodic Minimal Surface (TPMS) lattice structures to integrate thermal and structural functions into a single component. These structures offer advantages such as weight reduction, compactness and enhanced heat dissipation, making them promising for automotive, aerospace and electronics applications. TPMS structures, characterized by zero mean curvature and periodic crystalline geometry, have recently gained significant research attention thanks to their potential in thermal management. Among various TPMS geometries, the gyroid and diamond structures stand out for their thermal and fluid dynamic performance. This study explores the influence of cell geometry, unit cell size, and wall thickness on the efficiency of TPMS-based heat exchangers, as these parameters are crucial for their technical feasibility. Using Computational Fluid Dynamics (CFD) simulations, a comparative analysis is conducted for a
Cordisco, Ilario, Torri, Federico, Berni, Fabio, Testa, Veronica, Giacalone, Mauro, Fontanesi, Stefano
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