Browse Topic: Manufacturing

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Life-Cycle Assessment of a Composite vs. a Metallic Bipolar Plate for Fuel Cell Applications: More Sustainable while Maintaining Same Performance Standards?2025-01-0298To be published on 07/02/2025
Faced with one of the greatest challenges of humanity – climate change – the European Union has set out a strategy to achieve climate neutrality by 2050 as part of the European Green Deal. Life Cycle Assessment (LCA), which among other aspects identifies climate change effects, is an important tool to assess the environmental characteristic of sustainable technologies or products to fulfill this ambitious target. In this context, research is presented that examines the ecological sustainability impacts of a metallic vs a composite bipolar plate made of innovative graphite-compound based foils for fuel cell applications. A bipolar plate is a central component of the fuel cell stack to ensure efficiency and durability. For this purpose, a LCA is performed for both bipolar plate materials. This assessment follows the methodology of DIN EN ISO 14040/44 and the EU Product Environmental Footprint framework. Focusing on cradle-to-gate system boundary conditions, the research emphasizes the
van Sloun, Andreas, Schroeder, Benedikt, Kexel, Jannik, Schmitz, Maximilian, Balazs, Andreas, Walters, Marius, Koßler, Silas, Pischinger, Stefan, Joemann, Michael
Technical Paper
Evaluation of Static and Dynamic stiffness of rubber grommet by experimental and FEA method2025-01-0274To be published on 07/02/2025
Vibration control is most important in automotive applications and generally rubbers are used to dampen these vibrations due to their inherent nature and low-cost manufacturing methods. Now to select a rubber material shore hardness is considered in engineering applications, but to additionally control the behaviour we need to understand its static and dynamic stiffness. These values help to determine the vibration isolation obtained by these rubbers. In this paper, we will discuss methods to calculate the static and dynamic stiffness of rubber grommets using experimental methods and FEA modelling. As elastomers have non-linear material properties various material modelling techniques in FEA are used to capture multiple phenomena like creep, fatigue and dynamic conditions. Rubber compounding is used to improve the physical and chemical properties which in turn would give desirable linear characteristics. Certain guidelines and thumb rules are used in the rubber industry for different
Khamkar, Prasad Subhash, Gaikwad, Vikrant C
Technical Paper
In Situ Observation of Different Soot Layers in a Model Filter Channel During Its Regeneration2025-01-0312To be published on 07/02/2025
To keep the air clean, wall-flow particulate filters are predominantly used in the exhaust gas after-treatment systems of combustion engines to remove reactive soot and inert ash particles. These filters consist of parallel porous channels with alternately closed ends, effectively separating particles by forming a layer on the filter surface. However, the particulate layer increases the pressure drop, requiring periodic regeneration. During regeneration, soot oxidation breaks up the particulate layer, while resuspension and transport of individual agglomerates may occur. These phenomena are influenced by gas temperature and velocity, as well as dispersity and the reactivity of the soot particles. Sustainable fuels can produce different types of soot with different reactivities and dispersities, therefore this study focuses on the influences of soot dispersity and reactivity by varying the reactive particle system. A model wall-flow filter channel is used for the investigation, enabling
Desens, Ole, Hagen, Fabian P., Meyer, Jörg, Dittler, Achim
Technical Paper
Commercial Vehicle’s Exhaust Front Pipe Reliability Improvement through Virtual Simulation and Experimental Validation2025-01-0209To be published on 06/16/2025
The exhaust front pipe is a critical structural component in commercial vehicles, ensuring the leak-proof flow of exhaust gases into the exhaust after-treatment system while withstanding engine and frame vibrations. To isolate these vibrations, the front pipe is equipped with a flex connector capable of enduring various displacements at frequencies between 8-25 Hz. The position of the flex connector relative to the engine crank axis significantly impacts its structural reliability over its service life. This paper compares the existing design, which features a horizontally positioned flex connector, with a modified design that positions the flex connector vertically and changes the material from SS-304 to SS-321. Finite element analysis was conducted using Nastran software. The fatigue life of the existing flex connector design is approximately 1015 cycles. In contrast, the improved design demonstrates a fatigue life of 1727 cycles, representing a 70% increase in durability compared to
Chandel, Kushal, Paroche, Sonu, Namdev, Akhilesh, Jain, Shailendra, Patil, Keyur
Technical Paper
Morphology Experiment of Icing Effect on Spray Propagation2025-01-0222To be published on 06/16/2025
The working conditions of combustion systems have been going extreme under the desire of human beings exploring the unknown. Cold environments can be a significant impact on the spraying of fuel not only by changing the fuel properties including viscosity and surface tension, but also by freezing the parts. In the present study, methanol spray from a commercial injector is studied via high-speed imaging, with the liquid fuel being frozen to sub-zero degrees at the injector tip. It is observed that water components from the environment will freeze at the injector tip, creating crystal structures on the surface. During the injection, the ice components will be flushed by the liquid, and the spray morphology of the starting cycle will be strongly altered, resulting in wider spray angles, much shorter penetrations, and particle structures can be observed in the downstream of the flow field. The results of the experiment provide a clear view and quantified evaluation of the freezing impact
Zeng, Tingxi, Wang, Shangning, Zhang, Yijia, Hung, David, Xu, Min
Technical Paper
Techno-Economic Analysis of an Integrated E-Methanol Production Plant Utilizing First and Second Generation Biomass Resources2025-01-0182To be published on 06/16/2025
Building upon foundational research utilizing Aspen Plus modeling for e-methanol production from sugar cane and sugar beet biomass, this study advances by incorporating a comprehensive techno-economic assessment (TEA) of an integrated e-methanol production system. The established integrated system converts biomass into ethanol through fermentation and synthesizes e-methanol using both captured CO2 and syngas derived from biomass residue gasification. The approach optimizes dual utilization of CO2 and biomass thereby fostering a circular carbon economy. The TEA quantifies capital expenditures (CAPEX), operational expenditures (OPEX), and levelized costs of energy (LCOE), providing a detailed economic analysis of the potential for commercializing e-methanol. Additionally, a sensitivity analysis is conducted to evaluate the impact of variable factors such as feedstock prices, process yields, and energy costs on the economic outcomes. This sensitivity analysis is crucial for understanding
Fernandes, Renston Jake, Shakeel, Mohammad Raghib, Nguyen, Ducduy, Im, Hong G., Turner, James W.G.
Technical Paper
New system for the measurement of sound-insertion loss on small samples: a comparison with ASTM-E2611 and ASTM E90 test procedures2025-01-0116To be published on 05/05/2025
This article follows a companion article presented at the SAE NVC 2021, in which a new system for the measurement on small samples of the normal-incidence Insertion Loss (IL) of multilayers used for the manufacturing of automotive sound package parts was first introduced. In addition to simplifying the evaluation of the sound-insulation of multi-layers used to produce sound-package components, the system aims to overcome the limitations of the test procedure based on the ASTM E2611 standard. In this article, the latter point is demonstrated by comparing the insertion loss results obtained with the new system with those obtained with the test procedure based on the ASTM E2611 standard on a few multilayers commonly used for the manufacturing of automotive sound package parts. Results indicate that the results obtained by means of the newly developed system are more meaningful, practically usable and less prone to edge-effects, compared to those obtained according to the ASTM E2611 test
Ruggeri, Giulio, Bertolini, Claudio, Horak, Jan
Technical Paper
Identification and Evaluation of Passthroughs That Affect the Acoustic Performance of a Dash System2025-01-0121To be published on 05/05/2025
This paper discusses a systematic process that was developed to evaluate the acoustic performance of a production electric vehicle dash system. The production dash panel was tested under different configurations to understand the importance of passthroughs in the acoustics of the dash system. Results show that often the performance of the passthroughs strongly affects the overall performance of the dash system and this may become the limiting factor to increase the system STL. The dash with passthroughs was then extensively tested to understand the acoustic strength of different passthroughs and to understand how these passthroughs affect the overall performance of the dash system. Subsequently a test procedure based on flat panel tests was developed so the OEM can develop target values and the suppliers can provide test results of their passthroughs that are meaningful and useful to the OEM to help build an acoustically competitive vehicle.
Saha, Pranab, Baack, Gregory, Geissler, Christian, Kaluvakota, Srikanth, Pilz, Fernando
Technical Paper
Application of Hybrid SEA in Vehicle NV Package Optimization2025-01-0050To be published on 05/05/2025
As India’s economy expands and road infrastructure improves, the number of car owners are expected to grow substantially in the coming years. This market potential has intensified competition among original equipment manufacturers (OEMs) to position their products with a focus on cost efficiency while delivering a premium user experience. Noise and Vibration (NV) performance is a critical differentiator in conveying a vehicle's premiumness, and as such, NV engineers must strategically balance the achievement of optimal acoustic performance with constraints on cost, mass, and development timelines. Traditionally, NV package optimization occurs at the prototype or advanced prototype stage, relying heavily on physical testing, which increases both cost and time to market. Furthermore, late-stage design changes amplify these challenges. To address these issues, this paper proposes the integration of Hybrid Statistical Energy Analysis (HSEA) into the early stages of vehicle development
Rai, Nitesh, Mehta, Makrand, Ravindran, Mugundaram
Technical Paper
Subjective Development of EV Propulsion Noise to Drive Product Differentiation2025-01-0067To be published on 05/05/2025
The frequency and amplitude content of powertrain noise is motor torque and speed dependent and tends to influence the driver’s subjective perception of the vehicle. This provides manufacturers with an opportunity to drive product differentiation through consideration of powertrain noise in early stages of the development cycles for electric vehicles (EVs). This paper focuses on the evaluation of customer preference and perception of acoustic feedback from different powertrain design options based on targeted powertrain orders and expected wind and road masking during high acceleration maneuvers. A jury study is used to explore customer feedback to a two-stage gearbox design with AC permanent magnet motor order combinations. The subjective influence of order spacing, dominant frequency content and the number of audible orders is studied to understand aural perspective product differentiation opportunities.
Joodi, Benjamin, Jayakumar, Vignesh, Conklin, Chris, Pilz, Fernando, Iyengar, Shashank, Weilnau, Kelby, Hodgkins, Jeffrey
Technical Paper
Experimental Investigation on Genetic Algorithm optimized Proportional Integral Derivative Based Active Suspension System2025-01-0014To be published on 05/05/2025
In this work, Genetic Algorithm (GA) optimized Proportional Integral Derivative (PID) controller is employed. The PID gain values are optimally tuned based on the objective function formulated using the Integral Time Absolute Error (ITAE) criteria of various suspension measures like vehicle body displacement, suspension and tire deflections. The proposed GAPID controller is experimentally validated through the 3-DOF quarter-car test rig model. The fabricated model with passive suspension system (PASS) and active suspension system (ACSS) provided with an electrical actuator as base excitation is pictured. The schematic representation of the fabricated test set-up with and without ACSS is also illustrated. Further, simulation and experimental response of the fabricated model with and without ACSS are compared. It is identified that the proposed GAPID controller attenuates the sprung mass acceleration by about 41.64 % and 29.13 % compared with PASS for the theoretical as well as
A, Arivazhagan, Kandavel, Arunachalam
Technical Paper
Mode Shape Identification Using Graph Neural Networks for Vehicle Structure Design2025-01-0131To be published on 05/05/2025
This paper introduces a novel, automated approach for identifying and classifying full vehicle mode shapes using Graph Neural Networks (GNNs), a deep learning model for graph-structured data. Mode shape identification and naming refers to classifying deformation patterns in structures vibrating at natural frequencies with systematic naming based on the movement or deformation type. Many times, these mode shapes are named based on the type of movement or deformation involved. The systematic naming of mode shapes and their frequencies is essential for understanding structural dynamics and “Modal Alignment” or “Modal Separation” charts used in NVH analysis. Current methods are manual, time-consuming, and rely on expert judgment. The integration of GNNs into mode shape classification represents a significant advancement in vehicle modal identification and structure design. Results demonstrate that GNNs offer superior accuracy and efficiency compared to current labor intensive manual modes
Tohmuang, Sitthichart, Swayze, James L., Fard, Mohammad, Fayek, Haytham, Marzocca, Piergiovanni, Bhide, Sanjay, Huber, John
Technical Paper
Plug-in hybrid and range extender NVH – Challenges and Solutions2025-01-0101To be published on 05/05/2025
The automotive industry continues to develop new powertrain and vehicle technologies aimed at reducing overall vehicle-level fuel consumption. While the use of electrified propulsion systems is expected to play an increasingly important role in helping OEM’s meet fleet CO2 reduction targets, hybridized propulsion solutions can play a vital role in the electrification strategy of vehicle manufacturers. Plug-in hybrid and range extender vehicles show unique NVH challenges due to their different possible operation modes. First, the paper outlines different driveline architectures for PHEV and range extenders. Given the multiple general architectures, as well as operation modes which typically occur for these vehicles, characterizations and source-path analysis of these vehicles can be more complicated than conventional vehicles. In the following steps, typical NVH related challenges are highlighted and potential solutions for NVH optimization are discussed. While the overall noise levels
Wellmann, Thomas, Ford, Alex, Pruetz, Jeffrey
Technical Paper
Do EVs Snore?2025-01-0074To be published on 05/05/2025
As EV and PHEV adoption continues to increase more people will have direct experiences with these quieter vehicles in their daily lives. Topics such as 'propulsion sound' via Active Sound Design (ASD) and bystander safety through Acoustic Vehicle Alerting Systems (AVAS) have been discussed widely for many, many years...but who is talking about Charging Noise? Charging noise is a less spoken about topic because most EV / PHEV owners will charge their vehicles at their home, in their garage or their driveway, overnight when they are sleeping. Because of that people do not think much about charging noise. But anyone who has plugged in their car overnight will tell you a strange cacophony of sounds come from the car...and some can be downright concerning. In this paper data from several production EVs were measured during their normal charging cycle. Binaural recordings made inside and outside the vehicle are analyzed using psychoacoustics metrics to see what sounds would cause the most
Marroquin, Marc, Bray, Wade
Technical Paper
A Comparative Analysis of Fault Diagnosis by vibration signals for Critical Gear Components in Electric Vehicle Motor Testing Machines Using Machine Learning Algorithms2025-01-0040To be published on 05/05/2025
Electric vehicles (EVs) represent the future of the automobile industry, with the drive motor being a crucial component in modern EVs. To ensure optimal performance, a motor testing machine is used to verify the essential parameters of these electrical motors. This machine regularly evaluates electric motor characteristic curves and their electromagnetic behavior under different conditions. However, it has been observed that flaws in the testing machine's helical gear arrangement frequently cause malfunctions and suboptimal performance, affecting the efficiency of the electric vehicle production line. This research project aims to improve the motor test bench apparatus by modifying critical design parameters using machine learning and vibration signal analysis methods. Vibration signals are recorded at various gear settings, and statistical features are extracted from these signals. These signals are then classified using classifiers such as Naive Bayes and Decision Trees. Machine
S, Ravikumar, Sharik, N, Syed, Shaul, V, Muralidharan, D, Pradeep Kumar
Technical Paper
Improving the Sound Transmission Loss of Wire Harness Pass Throughs2025-01-0118To be published on 05/05/2025
Abstract Improving the Sound Transmission Loss of Wire Harness Pass Throughs For years the NVH community has known that openings in the dash sheet metal, such as holes to pass wire harnesses through, create an acoustical weak point that limits the potential noise reduction of the dash insulation system. These pass throughs can also be a source of water leaks into the vehicle’s interior. With the combustible engine and now electric inverter power plants, the need to seal this area is vital. By molding a lightweight barrier that draws through the fiber/absorber interior decoupler and dash sheet metal which mates to a secondary seal molded into an outer engine dash decoupler, the two opposing molded barriers meet in the engine compartment and compress together forming a seal around the wire harness. This male/female molded seal replaces the conventional snap in grommet and eliminates noise/water leaks. The system Sound Transmission Loss (STL) is equivalent to similarly insulated sheet
Check, James, Moritz, Charles
Technical Paper
Impact of tripod joint pressing load variation on drive shaft rattling in passenger car2025-01-0097To be published on 05/05/2025
In today’s fast changing and competitive automotive world, vehicle NVH plays an important role in customer’s perception of the brand. A silent cabin with lower noise levels is a desired attribute in a modern car. In such a scenario, abnormal noises arising because of manufacturing variations and tolerances of components can impact the brand image of any automotive company negatively. This paper presents an investigation into a noise issue arising from the right-hand (RH) drive shaft of an automotive vehicle while driving on rough roads at approximately 30 km/h. Various technical measurements, including rotational backlash and dimensional assessments, were conducted, all of which were found within specification. However, axial play between the tripod spline and the mid-shaft spline was identified during disassembly. Further analysis revealed that material localization was the only change point in the RH drive shaft manufacturing process. The fit interference between the tripod spline
Dhankhar, Dinesh Singh, Mishra, Ashish, Kirti, Viplav, Rana, Deepak, Bhardwaj, Ashish, Singh, Karanveer
Technical Paper
Leveraging Vision Language Models and Prompt Engineering for Bearing Defect Classification from Vibration Signals2025-01-0127To be published on 05/05/2025
Bearings are fundamental components in automotive systems, ensuring smooth operation, efficiency, and longevity. They are widely used in various automotive systems such as wheel hubs, transmissions, engines, steering systems etc. Early detection of bearing defects during End-of-Line (EOL) testing and operational phases is crucial for preventive maintenance, thereby preventing system malfunctions. In the era of Industry 4.0, vibrational, accelerometer, and other IoT sensors are actively engaged in capturing performance data and identifying defects. These sensors generate vast amounts of data, enabling the development of advanced data-driven applications and leveraging deep learning models. While deep learning approaches have shown promising results in bearing fault diagnosis, they often require extensive data, complex model architectures, and specialized hardware. This study proposes a novel method leveraging the capabilities of Vision Language Models (VLMs) and Large Language Models
Chandrasekaran, Balaji, Cury, Rudoniel
Technical Paper
Pass-by Noise Contribution Analysis of an Agricultural Tractor2025-01-0134To be published on 05/05/2025
There is an increasing effort to reduce noise pollution across different industries worldwide. From a transportation standpoint, pass-by regulations aim to achieve this and have been implementing increasingly stricter emissions limits. Testing according to these standards is a requirement for homologation but does little to help manufacturers understand why their vehicles may be failing to meet limits. Using a developed methodology such as Pass-by Source Path Contribution (SPC, also known as TPA) allows for identification of dominant contributors to the pass-by receivers along with corresponding acoustic source strengths. This approach is commonly used for passenger vehicles, but impractical for off-highway applications, where vehicles are often too large for most pass-by-suitable chassis dynamometers. A hybrid approach is thereby needed, where the same techniques and instrumentation used in the indoor test are applied to scenarios in an outdoor environment. This allows for
Freeman, Todd, Engels, Bret, Thuesen, Ben
Technical Paper
Saw-Tooth Ramps for the Suppression of Flow-Acoustic Coupling in a High-Frequency Silencer for Turbocharger Compressors2025-01-0023To be published on 05/05/2025
The ported shroud casing treatment for turbocharger compressors is desirable for mitigating broadband/whoosh noise and enhancing boost pressures at low to mid flow rates. Yet, it is accompanied by elevated narrowband noise at the blade-pass frequency (BPF). Compressor BPF noise occurs at high frequencies where wave propagation is often multi-dimensional, rendering traditional planar wave silencers invalid. An earlier work introduced a novel reflective high-frequency silencer (baseline) targeting BPF noise in the 8-12 kHz range using an “acoustic straightener” that promoted planar wave propagation along arrays of quarter-wave resonators (QWRs). The design, however, faced challenges with high-amplitude tonal noise generation at specific flow conditions due to flow-acoustic coupling at the opening of the QWRs, thereby compromising the noise attenuation. The current study explores two QWR interface geometries that weaken the coupling, including linear and saw-tooth ramps on the upstream
Sriganesh, Pranav, Selamet, Ahmet
Technical Paper
Drilling Methods for Controlling Exit Burr Height in CRES Material Stacks2025-01-0169To be published on 05/02/2025
The Electroimpact Automatic Fan Cowl Riveter uses two novel drill processes to control exit burr height and achieve the required hole quality in CRES (Corrosion-Resistant Steel, also called stainless steel) material stacks. Both processes use piloted cutters on the OML side, and two different tools are used in a backside spindle on the IML side of the component. The first process uses a shallow-angle shave tool in the IML spindle to directly control the exit burr height after it is produced by the OML spindle and is called the “burr shave” technique. The second process uses a countersink tool in the IML spindle and produces an “intermediate countersink” after the pilot hole is drilled by the OML spindle, but before the final hole diameter is drilled. These drill processes were able to achieve the required hole quality in a challenging CRES material stack, which allows the machine to be qualified for one-up assembly of the component.
Schultz, Rich, Peterman, Randy, Luker, Zachary, Murakonda, Sai Krishna
Technical Paper
Enhancing Efficiency in Aerospace Manufacturing through AI Agent Based Bearing Diagnostics System2025-01-0158To be published on 05/02/2025
Industrial bearings are critical components in aerospace manufacturing, where their failures can result in costly downtime. Traditional fault diagnosis typically depends on time-consuming on-site inspections conducted by specialized engineers. This research introduces an innovative Artificial Intelligence application that functions as a virtual maintenance technician, empowering on-site personnel to perform preliminary diagnoses. By reducing the dependence on specialized engineers, this technology aims to minimize downtime. The AI system leverages large language models to guide the inspection process, answer queries from a comprehensive knowledge base, analyze defect images, and generate detailed reports with actionable recommendations. Multiple deep learning algorithms operate as backend APIs to support this functionality. This study details the architectural design of the expert system and provides a real-time simulation of its workflow, demonstrating its potential to enhance
Chandrasekaran, Balaji
Technical Paper
Comparison of Different Joining Techniques as a Benchmark for Integrally Joined Thermoformed Components Based on Tailored rCF Organosheets2025-01-0170To be published on 05/02/2025
Climate-neutral aviation requires resource-efficient composite manufacturing technologies and viable solutions for the reuse of carbon fibers (CF). In this context, thermoplastic composites (TPC) can make a strong contribution. Thermoforming of TPC is an efficient and established process for aerospace components. But it’s efficiency could be further increased by integration of joining processes, which would otherwise be separate steps. In this work, a two-step thermoforming process for hollow box structures, particularly uplift structures, is presented. The starting point are two organosheets. First, one of the organosheets, intended for the bottom skin of the uplift structure, is thermoformed. After cooling, the press opens, the organosheet remains in the press and an infrared heater is pivoted in, to locally heat up just the joining area. Meanwhile, a second organosheet, intended for the top skin, is heated and thermoformed and simultaneously joined to the lower skin, thereby forming
Vocke, Richard, Seeßelberg, Lorenz, Focke, Oliver, Dietrich, Jan Yorrick, Jobke, Katrin, Albe, Christopher, May, David
Technical Paper
Material Adapted Method for the Repair of Curved Thermoplastic Composite Structures by Induction Welding of Patches2025-01-0165To be published on 05/02/2025
Thermoplastic fiber-reinforced polymer composites (TPCs) are gaining importance in aviation due to their high strength, stiffness, and recyclability. To maximize their potential, efficient repair methods are needed to maintain aircraft safety and structural integrity. This article introduces a novel repair technique for damaged TPC structures, involving the insertion of a repair patch with a susceptor material. The susceptor consists of a material with high electrical conductivity and magnetic permeability and therefore reacts stronger to the electromagnetic field than the composite, even if it is carbon fiber based. This means that the thermal energy is specifically concentrated in the repair area. The susceptor can be placed on the patch surface or in the welding zone. The process begins by identifying and preparing the damaged area, followed by precise scarfing. Care is taken to ensure that the surrounding material remains intact and that an exact stepped structure is created, which
Geiger, Markus, Glaap, Anton, Schiebel, Patrick, May, David
Technical Paper
Segment Manipulator Retrofit2025-01-0159To be published on 05/02/2025
A segment manipulator machine was in service nineteen years. Many of the control components were out of date and hard to obtain. Customer engaged Electroimpact to upgrade using the latest state-of-art controls. The program from the previous control system could not be reused. A “layup mandrel” is a form that is used to lay carbon fiber. The layup mandrel for a wide body aircraft fuselage section consists of six segments. The mandrel is made up of segments so that it can be assembled and disassembled from the inside. The segments are Crown, Upper Left, Upper Right, Lower Left, Lower Right, and Keel. For each build the mandrel is assembled with a segment manipulator machine, wound with carbon fiber tape, clad, and baked in an autoclave. Then the mandrel is disassembled with a segment manipulator machine leaving the cured carbon fiber shell behind. The segments are refurbished and brought to the assembly area on segment carts for the next build. Segments each weigh in the vicinity of 3000
Luker, Zachary, Donahue, Michael
Technical Paper
Semi-Automatic Riveter G39 Replacement2025-01-0160To be published on 05/02/2025
Zieve, Peter, Reznicek, Jeffrey
Technical Paper
Approach to Optimize the Airplane Boarding Process by using Image Recognition and Stochastic Simulation to Predict Overhead Bin Fill Levels2025-01-0164To be published on 05/02/2025
In single-aisle aircraft, the available storage space for carry-on baggage is inherently limited. When the aircraft is fully booked, this often results in insufficient overhead bin space, necessitating last-minute gate-checking of carry-on items, which delays the boarding process and reduces operational efficiency. A promising approach to mitigating this issue involves the integration of computer vision technologies with an appropriate data storage system and stochastic simulation to enable accurate and supportive predictions that enhance planning. In this work the YOLOv8 image recognition algorithm is used to identify and classify each passenger’s carry-on baggage into categories such as handbags, backpacks and suitcases. This data is then linked to passenger information stored in the NoSQL database MongoDB, which included seat assignments and the number of carry-on items per passenger. Stochastic simulation is applied to predict the occupancy levels of overhead storage bins across
Bergmann, Jacqueline, Hub, Maximilian
Technical Paper
Image Processing-Based Chip Detection by KIZKI Algorithm and Its Optimization2025-01-0168To be published on 05/02/2025
The process of producing aircraft parts involves the drilling of aluminum alloys. This creates a large amount of chips, which are removed using air, but sometimes they still remain within the holes. This is checked by inspectors through visual inspection. However, the quality of human inspection varies based on skill level and fatigue. Thus, image-based inspection should be used to stabilize and further improve inspection quality. This study aims to build a framework for chip detection based on image processing. Taking into account on-site implementation, the system must have low installation and running costs and be standalone. Therefore, we adopt the KIZKI algorithm, which satisfies these conditions. KIZKI means awareness in Japanese. This is a model of human peripheral vision and saccades. It does not require training like AI and can achieve high-speed and high-performance detection using a low-performance computer. In other words, there is no need for a computer with an expensive
Iinuma, Marin, Sato, Junya, Tsuji, Masahiko
Technical Paper
Development of NOx Storage Catalyst and Investigation of Deterioration Mechanism for Small Powertrains2024-32-009704/18/2025
In response to the evolving landscape of exhaust gas regulations for small powertrains, reducing NOx emission is increasingly important. This study deeply investigated the feasibility of a NOx storage catalyst (NSC) containing cerium oxide (CeO2) and barium oxide (BaO) for reducing NOx emission. The key functions, NOx storage and reduction performances were evaluated, and deterioration mechanisms were explored through performance evaluations and physical property analyses. The findings revealed a strong correlation between the size of CeO2 crystals and NOx storage performance at low temperature, such as those encountered during city driving conditions. Conversely, at high temperature, such as those during highway driving conditions, NOx storage performance correlated well with sulfur deposition, suggesting that the formation of barium sulfate (BaSO4) contributes to the deactivation. This experiment also showed a strong correlation between NOx reduction performance and BaSO4 formation
Nakano, Fumiya, Koito, Yusuke
Technical Paper
Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions2024-32-003804/18/2025
The arc welding process is essential for motorcycle frames, which are difficult to form in one piece because of their complex shapes, because a single frame has dozens of joints. Many of the damaged parts of the frames under development are from welds. Predicting the strength of welds with high reliability is important to ensure that development proceeds without any rework. In developing frames, CAE is utilized to build up strength before prototyping. Detailed weld shapes are not applicable to FE models of frames because weld shapes vary widely depending on welding conditions. Even if CAE is performed on such an FE model and the evaluation criteria are satisfied, the model may fail in the actual vehicle, possibly due to the difference between CAE and actual weld bead geometry. Therefore, we decided to study the extent to which the stresses in the joint vary with the variation of the weld bead geometry. Morphing, a FE modeling method and design of experiment method, was utilized to
Hada, Yusuke, Sugita, Hisayuki
Technical Paper
Optimal Porous Electrode Structures in All-Vanadium Redox Flow Batteries2024-32-008504/18/2025
To address the pressing issue of electrical fluctuations from renewable energy technologies, an energy storage system (ESS) is proposed. The vanadium redox flow battery (VRFB) is gaining significant attention due to its extended lifespan, durability, thermal safety, and independent power capacity, despite its high cost. Key components of the VRFB include a membrane, carbon electrode, bipolar plate, gasket, current collector, electrolyte, and pump. Among these, the carbon electrode and bipolar plate are the most expensive. Reducing capital costs in VRFB systems is crucial for advancing clean energy solutions. Conventional flow field designs like interdigitated flow field (IFF), serpentine flow field (SFF), and parallel flow field (PFF) are used to feed the electrolyte into the VRFB cell, necessitating thicker bipolar plates to avoid cracking during the machining process. This study focuses on optimizing the flow-through (FT) design, which eliminates the need for machining on bipolar
Aiemsathit, Poramet, Sun, Pengfei, Alizadeh, Mehrzad, Laoonual, Yossapong, Charoen-amornkitt, Patcharawat, Suzuki, Takahiro, Tsushima, Shohji
Technical Paper
Reducing the Waste of Plating Solution for Magnetostrictive Torque Sensors2024-32-000604/18/2025
The power assist system of an electric bicycle uses a magnetostrictive torque sensor to detect the pedal force based on the magnetic properties of the crankshaft, which change according to stress. Fe–Ni alloy plating is used to coat the surface of the crankshaft with a magnetic film to enhance the magnetostrictive effect. However, the sensor performance decreases as the plating solution degrades, which necessitates replacement of the plating solution. In this study, experiments were performed to investigate how to prevent or mitigate degradation of the plating solution to reduce waste. The amounts of carbon and sulfur in the magnetic film were found to increase with degradation of the plating solution. The carbon derived from organic reducing agents and their decomposition products, and the sulfur derived from stress relievers and their decomposition products. A method was developed for reducing the amounts of carbon and sulfur in the magnetic film, which would help maintain the sensor
Ohnishi, Hiromichi
Technical Paper
Development of Higher Clarity Injection Molded Windscreen for Motorcycles2024-32-004004/18/2025
The windscreen is one of the key elements to enhance passenger comfort of touring motorcycle. The clarity through the windscreen should not discomfort the rider. The discomfort we discuss here mainly refers to three factors: the “distortion,” the “blur,” and the “transparency.” Introduced in this paper is the technical measures to achieve sufficient clarity by the injection molding method. Firstly, with respect to the “distortion,” we determined the main cause was local unevenness of plate thickness. As the uneven thickness were related to the accuracy of the die, we clarified the tolerable zone and carried out higher precision machining of the die to satisfy the requirements. Regarding the “blur,” we analyzed the refractive power of the windscreen and found the main cause of blur is the microscopic roughness on the surface. As the microscopic roughness were attributable to the die surface, we clarified the tolerable zone and established the polishing conditions satisfactory for the
Yamada, Atsushi, Endo, Sakae
Technical Paper
Study on Flex Fuel Compatible Coatings for Automotive Fuel Tank2024-32-007604/18/2025
Reducing CO2 emissions is now a major focus in India heading towards net zero emissions by 2070. India is the 3rd largest automobile market in the world and the transportation sector is the 3rd largest CO2 emitter. In this direction, it is necessary to reduce the carbon footprint from the automobile sector to combat climate change. The adoption of sustainable biofuels such as ethanol will enable us to reduce emissions, as ethanol is carbon neutral fuel. However, vehicle manufacturers are facing challenges in manufacturing flex fuel compatible parts in the vehicle mainly fuel systems. Ethanol has both nonpolar and polar bonds, making it miscible to both gasoline and water, thereby water contamination is inevitable in ethanol blend fuels. In addition, control of ethanol contamination by sulfates and chlorides during ethanol production is challenging. Thus, ethanol blend fuels are considered more corrosive and tendency towards deposit formation than normal gasoline fuels. Design and
Pandi, Dinesh Babu, Shanmugam, Gomathy Priya, Nagarkatti, Arun, Gopal, Manish, Anbalagan, Prathap
Technical Paper
A Study on Optimal Combinations of Winding and Cooling Methods for Downsizing Power Units in Motorcycles2024-32-000704/18/2025
In commercially available electric motorcycles, there is a notable shift in the cooling method, moving from air cooling to water cooling, and in the winding method, moving from concentrated winding to distributed winding, as the output increases. This shift occurs around 8 to 10 kW. However, there is a paucity of empirical investigations examining these combinations to ascertain their optimality. In order to verify this trend, a verification model has been constructed which allows for the comparison of the capacity and weight of the motor and cooling system according to the vehicle’s required output and thermal performance. A comparison and verification of the combinations of winding methods (concentrated winding or segment conductor distribution winding) and cooling systems (water-cooled or air-cooled) was conducted using the model that had been constructed. In the motor designed for this study, when the maximum output of the vehicle was 35 kW or less (European A2 license), the total
Otaki, Ryota, Tsuchiya, Teruyuki, Sakai, Yu, Yamauchi, Takuya, Shimizu, Tsukasa
Technical Paper
Sustainable Design of Automotive Batteries2025-01-000104/18/2025
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
Dependency of Gear Honing Machine Processing Accuracy on Machine Vibration and the Vibration Reduction Considering Contribution2024-32-002004/18/2025
In recent years, accurate gear processing is required for various products to improve efficient power transmission and small noise and vibration. On the other hand, the accuracy tends to be worse by high speed processing for increasing production efficiency. Therefore, we investigated relationship between gear honing machine vibration and the accuracy. The vibration acceleration of the honing machine was measured at various conditions, and the gear accuracy was measured after processing. As results, the accuracy was observed to be affected by both the original gear accuracy before honing processing and the gear secondary rotational vibration of the machine in operation. Subsequently, we applied transfer path analysis (TPA) to investigate which directional force in operation increased the vibration. As the results, the contribution from the input force at gear processing point along normal direction was the main contributor. Then, vibration transmission characteristics of the machine
Hanioka, Hiroaki, Ogawa, Yunosuke, Yoshida, Junji, Onishi, Yoichi, Kurokawa, Yasuhiro
Technical Paper
Hose Assembly, Convoluted Polytetrafluoroethylene, Metallic Reinforced, Low Pressure, Up to 400 °F, AircraftAS1227C (Current)04/14/2025
This SAE Aerospace Standard (AS) defines the requirements for a convoluted polytetrafluoroethylene (PTFE) lined, metallic reinforced, hose assembly suitable for use in aerospace fluid systems at temperatures between -65 °F and 400 °F for Class 1 assembly, -65 °F and 275 °F for Class 2 assembly, and at operating pressures per Table 1. The use of these hose assemblies in pneumatic storage systems is not recommended. In addition, installations in which the limits specified herein are exceeded, or in which the application is not covered specifically by this standard, shall be subject to the approval of the procuring activity.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Technical Standard
Gaseous NitrocarburizingAMS2759/13A (Current)04/14/2025
This specification covers the engineering requirements for producing a continuous compound zone (white layer) on parts by means of a gaseous, low-temperature, carbon-enriched nitriding process.
AMS B Finishes Processes and Fluids Committee
Material Specification
Electron-Beam Welding For Fatigue Critical ApplicationsAMS2680D (Current)04/14/2025
This specification defines the procedures and requirements for joining metals and alloys using the electron-beam welding process.
AMS B Finishes Processes and Fluids Committee
Material Specification
CAATS – Automotive Wind Tunnel Calibrations2025-01-876204/01/2025
Wind tunnel calibration is necessary for repeatable and reproducible data for all industries interested in their output. Quantities such as wind speed, pressure gradients, static operating conditions, ground effects, force and moment measurements, as well as flow uniformity and angularity are all integral in an automotive wind tunnel’s data quality and can be controlled through appropriate calibration, maintenance, and statistical process control programs. The purpose of this technical paper is to (1) provide a basis of commonality for automotive wind tunnel calibration, (2) help customers and operators to determine the calibration standards best suited for their unique automotive wind tunnel and, (3) complement the American Institute of Aeronautics and Astronautics recommended practice R-093-2003(2018) Calibration of Subsonic and Transonic Wind Tunnels as specifically applied to the automotive industry. This document compiles information from various automotive wind tunnel customers
Bringhurst, Katlynn, Best, Scott, Nasr Esfahani, Vahid, Senft, Victor, Stevenson, Stuart, Wittmeier, Felix
Technical Paper
Comparison of Vortex Identification Methods on Base Wake Structures in Bluff Body Flows2025-01-877604/01/2025
In this work, a modified Ahmed body with both upsweep and downsweep was used to create a complex wake. The time-averaged streamline topology revealed that the wake was composed primarily of a torus past the vertical base and two pairs of streamwise-oriented vortices on the upper and lower slant edges. Several vortex identification methods including three-dimensional (3D) (Q−, λ2−, Ω−criteria, and Liutex method) and two-dimensional (2D) (Γ1−criterion) methods were compared to determine the effectiveness in identifying complex wake structures. Of the 3D methods analyzed, none produced wholly satisfactory results. The Q− and λ2−criteria were plagued by well noted issues; failing to separate shear from rotation and threshold sensitivity which led to inconsistently identifying the weaker torus. The Ω−criterion addressed all of these concerns, especially identifying the torus consistently. However, the identified torus structure did not reflect the physical structure observed using the
Aultman, Matthew, Duan, Lian
Technical Paper
Robust Design of Automotive Inverter Components using Tests and Simulations2025-01-863904/01/2025
Vibration qualification tests are indispensable for vehicle manufacturers and suppliers. Carmakers’ specifications are therefore conceived to challenge the mechanical endurance of car components in the face of numerous in-service detrimental phenomena: In automotive industries, components are commonly qualified by means of a test without failure, the goal being to determine whether it will or not "pass" customer requirements. Validation of newly designed components is obtained via bench test and structural simulation. Simulation has gained traction in recent years because it represents the first step of the design validation process. In particular, FEA simulations are powerful to predict the dynamic behavior of physical testing on prototypes, enable engineers to optimize the design and predict the durability. This paper illustrates how FEA simulations were applied to product validation in the pre-serial phase to optimize manufacturing process. In particular, we will focus on the PCB of
Duraipandi, Arumuga Pandian, Leon, Renan, Bonato, Marco, Raja, Antony Vinoth, Kumar, Lalith, Niwa, Takehiro
Technical Paper
Dynamic Tailgate Water Management Simulation Using Smoothed Particle Hydrodynamics2025-01-862504/01/2025
Opening a tailgate can cause rain that has settled on its surfaces to run off onto the customer or into the rear loadspace, causing annoyance. Relatively small adjustments to tailgate seals and encapsulation can effectively mitigate these effects. However, these failure modes tend to be discovered relatively late in the design process as they, to date, need a representative physical system to test – including ensuring that any materials used on the surface flow paths elicit the same liquid flow behaviours (i.e. contact angles and velocity) as would be seen on the production vehicle surfaces. In this work we describe the development and validation of an early-stage simulation approach using a Smoothed Particle Hydrodynamics code (PreonLab). This includes its calibration against fundamental experiments to provide models for the flow of water over automotive surfaces and their subsequent application to a tailgate system simulation which includes fully detailed surrounding vehicle geometry
Gaylard, Adrian Philip, Weatherhead, Duncan
Technical Paper
A Sensitivity Study of Frequency Response Method for Setting Bearing Preload Due to Uncontrollable Parameters2025-01-852004/01/2025
A new method for bearing preload measurement has shown potential for both high accuracy and fast cycle time using the frequency response characteristics of the power transmission system. One open problem is the design of the production controller, which relies on a detailed sensitivity study of the system frequency response to changes in the bearing and system design parameters. Recently, an analytical model was developed for multi-row tapered roller bearings that includes all appropriate bearing and power transmission system design parameters. During the assembly process, some of the parameters related to the roller positions cannot be controlled. These parameters include the actual position of the first roller compared to the vertical axis, the relative position of the rollers between the bearing rows, and others. This work presents a sensitivity analysis of the effects of those uncontrollable parameters on the analytical model. The sensitivity study determines the percentage change
Gruzwalski, David, Mynderse, James
Technical Paper
A Review of Warm Forming for Steels: History, Methodology and Emerging Trends2025-01-881404/01/2025
Many manufacturing techniques and processes have been implemented over the years to improve the formability of sheet metals. Warm forming of sheet metals is one such established method. However, it is more commonly and successfully applied to aluminum grades. The re-evaluation of less-used metal forming technologies, such as warm forming and sheet hydroforming for steel are responses to the challenges posed by competitive processes like large castings and the geometry requirements of new BEV parts. By understanding the effects of elevated temperatures (above or below recrystallization temperatures) on different steel grades and the impact of various heating methodologies, the industry can adapt and optimize these proven techniques for modern applications. This paper is a thorough summary of the effect of elevated temperatures on various grades of steel. Different heating techniques, their cycle times and effects on final forming feasibility are contrasted. The effect of chemistry
Kella, Caroline, Wormald, Tom
Technical Paper
Lattice Based Localized Energy Absorber for Improved Vulnerable Road User Performance for a Vehicle2025-01-872304/01/2025
A passenger vehicle hood is designed to meet Vulnerable Road User (VRU) regulatory requirements and consumer metric targets. Generally, hood inner design and its reinforcements, along with deformable space available under the hood are the main enablers to meet the Head Impact performance targets. However, cross functional balancing requirements, such as hood stiffness and packaging space constraints, can lead to higher Head Injury Criteria (HIC15) scores, particularly when secondary impacts are present. In such cases, a localized energy absorber is utilized to absorb the impact energy to reduce HIC within the target value. The current localized energy absorber solutions include the usage of flexible metal brackets, plastic absorbers etc. which have limited energy absorbing capacity and tuning capability. This paper focuses on usage of a novel 3D printed energy absorbers, based on various kinds of lattice structures. These absorbers are either sandwiched between the inner and the outer
Kinila, Vivekananda, Agarwal, Varun, V S, Rajamanickam, Tripathy, Biswajit, Gupta, Vishal
Technical Paper
Fundamental Science on Oxygen Storage Capacity of Cerium Complex Oxides for Advanced On-Board Diagnostics (2) Quantitative Observation of Oxygen Released from Cerium Complex Oxides2025-01-847604/01/2025
In order to comply with the tightening of global regulations on automobile exhaust gas, further improvements to exhaust gas control catalysts and upgrades to on-board diagnostics (OBD) systems must be made. Currently, oxygen storage capacity (OSC) is monitored by front and rear sensors before and after the catalyst, and deterioration is judged by a decrease in OSC, but it is possible that catalyst deterioration may cause the rear sensor to detect gas that has not been sufficiently purified. It is important to observe the activity changes when the catalyst deteriorates in more detail and to gain a deeper understanding of the catalyst mechanism in order to create guidelines for future catalyst development. In this study, we used a μ-TG (micro thermogravimetric balance) to analyze in detail how differences in design parameters such as the type of precious metal, detection temperature, and mileage (degree of deterioration) affect the OSC rate in addition to the OSC of the ceria-based
Hamada, Shota, Uegaki, Shinya, Tanabe, Hidetaka, Nakayama, Tomohito, Jinjo, Itsuki, Kurono, Seita, Oishi, Shunsuke, Narita, Keiichi, Onishi, Tetsuro, Yasuda, Kazuya, Matsumura, Daiju, Tanaka, Hirohisa
Technical Paper
European Initiatives Addressing High Efficiency and Low-Cost Electric Motors for Circularity and Low use of Rare Resources2025-01-880604/01/2025
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, greenhouse gas 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
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
Integrated Design for Body in White Fabricated by Additive Manufacturing and its Mechanical Performance Analysis2025-01-861304/01/2025
With the development of additive manufacturing technology, the concept of integrated design has been introduced and deeply involved in the research of body design. In this paper, by analyzing the structural characteristics of the electric vehicle body, we designed a body in white with the additive manufacturing process, and analyzed its mechanical properties through finite element method. According to the structural characteristics of the body, the integrated structure was modeled in three dimensions using CATIA. For the mechanical properties of the body, the strength and stiffness of the body structure were simulated and analyzed based on ANSYS Workbench. The results show that for the strength of the body, the maximum stress of the simulation results was compared with the permissible stress, and the maximum stress was calculated to be less than the permissible stress under each working condition. For the body stiffness, the displacement of the body deformation was used to measure, and
Xu, Cheng, Zhang, Ming, Wang, Tao, Zhang, Tang-yun, Cao, Can, Wang, Liangmo
Technical Paper
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