Browse Topic: Materials handling

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Experimental Study on Partitioned Fruit and Vegetable Storage in Ships2026-99-15039/11/2026
After an investigation into a fruit and vegetable storage compartment on a ship, this paper proposes a method for creating different temperature zones within a single storage unit. To perform this approach, a top perforated plate air supply system should be implemented, and storage panels should act as partitions to make temperature control more accurate in different zones within the same compartment. This method ensures that fruits and vegetables can be stored for the best flavor at suitable temperatures, enabling fewer separate storage units on the ship. According to the experimental results, this solution can preserve various types of fruits and vegetables under different conditions during long trips, deal with the challenge of chilling or freezing injury due to mixed storage, and save the cold storage capacity on the ship. The proposed method has significant value in engineering applications.
Xie, Zhihao, Cui, Yonglong, Duan, Wenli, Li, Kun, Li, Qi, Wei, Shuaiju
Exploration of the Minimum Safe Transverse Distance for Ships Passing Through the Pier of Huangpu River Tidal Barrier Based on the Boundary Element Method2026-99-15469/11/2026
The Huangpu River tidal barrage is in a navigable reach where the quay wall greatly restrains the flow. Earlier studies focused on ship-structure interaction, but there aren’t many hard numbers on safe passing distance near the barrage pier. The purpose of this paper is to determine the lowest safe lateral gap for large vessels and to provide an engineering means of ascertaining the clear width of the main channel. A 20,000-ton oil tanker is used as the test vessel. Using the boundary element method (BEM), a 3D model is constructed to simulate the interactions between the ship and the pier under varying speeds, draft depths, and lateral offsets. Simulations were conducted for different speed levels, draft depths, and lateral offsets to observe the flow and the ship’s movement. Changes in side forces, yawing moments, and bow angles were recorded over time, and their maximum values were determined. Sensitivity and uncertainty analyses were also performed to evaluate how input variations affect the results and to assess model stability. Based on these results, simple limits were established for the three measures to serve as safety rules. Using these rules, the clear width of the main channel was calculated. The results indicate a minimum safe lateral distance of 14 m and a suggested channel width of 202 m, deviating by only 0.5 m, or approximately 0.25%, from the theoretical value of 202.5 m. These findings can also be applied in practice for pier layout and the determination of speed limits in narrow channels.
Guan, Keping, Yu, Min, Zhan, Qingan
Linkages and Propagation Mechanisms of Risk Sources during Electric Vehicles Transportation2026-99-15289/11/2026
This study addresses safety issues in three representative logistics scenarios for electric vehicles (EVs) as cargo-car carriers, roll-on/roll-off (Ro-Ro) vessels, and containers. To address the heterogeneity across these modes, we develop an integrated “process–spatiotemporal load–risk factor” framework that embeds operational steps and confinement conditions into the indicator system, overcoming the limitations of single-scenario or single-factor studies in explaining chain-type propagation. Building on process mapping and spatiotemporal load characteristics, we develop a risk indicator system spanning “person-equipment-transported object-operation & environment-system management.” Expert judgments are then analyzed using an integrated DEMATEL-ISM approach to quantify inter-factor linkages and transmission pathways. The results indicate that regulatory oversight and carrier-side emergency equipment constitute the deep root causes of thermal runaway. The most hazardous transmission route is “regulatory oversight, procedural compliance and skill-experience match”, while “battery type, road/sea conditions and hoisting impacts” forms the shortest path. These findings reveal weaknesses in management and equipment that are amplified by operational execution and limited personnel capability, ultimately precipitating severe transportation incidents.
Yuan, Libo, Jiang, Huifu, Qin, Xiao
Dimensional Adaptability and Traffic Organization Analysis of Ships in Group Lockage2026-99-15109/11/2026
Aiming at the technology of electric intelligent working boat towing 4 ships in group lockage during the construction period of the Gezhouba Shipping Capacity Expansion Project, this paper, starting from ship dimensions, conducts an adaptability analysis on electric intelligent working boat towing ships in group lockage for all ships passing through Gezhouba No. 1 and No. 2 Ship Locks throughout 2024, based on the two-dimensional packing model, ship lock chamber scheduling model and algorithms, navigation scheduling rules and safety management regulations, the results show that ships unsuitable for being towed in group lockage through Gezhouba No. 1 Ship Lock account for approximately 26% of the total number of ships passing through it, while those unsuitable for being towed in group lockage through Gezhouba No. 2 Ship Lock account for approximately 57% of its total passing ships. Meanwhile, ships passing through the three Gezhouba ship locks on a specific day are selected, and an adaptability analysis on the dimensional suitability of electric intelligent working boat towing these ships in group lockage is carried out under the scenario where these ships only pass through Gezhouba No. 1 and No. 2 Ship Locks. The results show that the number of ships with suitable dimensions for group lockage accounts for the majority of the ships passing through the locks on a selected specific day. On this basis, combined with the operation modes of Gezhouba No. 1 and No. 2 Ship Locks, an analysis is carried out on the traffic organization, potential risks, corresponding countermeasures, and the required quantity of electric intelligent working boats for towing ships in group lockage, targeting the three main collaborative operation modes. The results can provide a basis for the future practical application of electric intelligent working boat towing ships in group lockage during the construction and operation periods of the Gezhouba Shipping Capacity Expansion Project.
Huang, Shaowen, Yang, Xi, Wang, Jian
Optimization of Order Picking in an AMR-Assisted Picker-to-Parts System2026-99-15679/11/2026
With global retail sales expanding and same-day delivery demand on the rise, efficient order picking operations in warehouses have become critical to success. To improve order picking processes, warehouse managers increasingly rely on autonomous mobile robots (AMRs), which improve the performance of traditional picker-to-parts systems. This paper investigates an AMR-assisted picker-to-parts system in which a set of customer orders must be fulfilled. The orders are first batched, and the resulting batches are assigned to individual pickers. Each picker works in a batch-by-batch manner, manually retrieving items from picking aisles and handing over the completed batch to an AMR waiting at the cross aisle. After receiving a full batch, the AMR transports it to the designated depot before returning to serve the next batch. The objective is the minimization of the total tardiness of all orders. The problem is formulated as a mixed-integer programming (MIP) model, and several effective heuristic algorithms are developed. Extensive computational experiments are conducted to evaluate the performance of the proposed algorithms and compare them with a commercial MIP solver.
Jin, Bo, Peng, Jianxin
An Improved Genetic Algorithm for Multimodal Hinterland Empty Container Repositioning Considering Demurrage and Detention charges2026-99-15279/11/2026
The imbalance of global trade exacerbates the mismatch between supply and demand of empty containers, requiring rapid repositioning from import to export regions, so empty container repositioning has long been a focus of research. Compared to maritime repositioning, hinterland empty container repositioning is more complex because it occurs over a sophisticated multimodal transport network. Rail and inland waterways typically offer high capacity at lower cost, and hinterland container operators often consolidate containers and move them in batches to achieve economies of scale. In addition, demurrage and detention (D&D) charges, imposed on operators for delayed container returns, have remained high in recent years. Traditional hinterland empty container repositioning approaches that focus solely on transportation costs often overlook these time-related penalties, leading to higher total repositioning costs. To address this, we first develop a generic hinterland empty container repositioning optimization model that integrates both transportation costs and demurrage and detention charges while capturing batch-based dispatching characteristics observed in practice. Second, due to the model’s non-convex and combinatorial nature, traditional solvers struggle to provide efficient solutions. We further develop an improved genetic algorithm (GA) to solve this non-convex MINLP problem. The results of numerical experiments showcase the benign performance of our improved GA. Finally, we conduct a real-world case study based on a 2025 operation in China. The results demonstrate that minimizing transportation costs alone results in higher total repositioning expenses, while jointly optimizing transportation and D&D costs leads to more balanced and cost-effective repositioning strategies. This highlights the practical necessity of incorporating D&D considerations into HECR decision.
Yu, Mingzhu, Yang, Haoran, Zhang, Lingge
Design and Simulation of Mobile Straw Carbonization Equipment2026-99-12659/4/2026
Straw is one of the major biomass energy sources. It has low economic benefits by conventional disposal methods, such as returning to the field, using as feed, pressing into block fuel, gasification power generation, papermaking, and manufacturing building materials. With the surplus of crop straw, a large amount of straw resources will be burned, resulting in severe resource waste, soil structure damage, and air pollution. Straw carbonization technology and equipment are effective measures to solve the problem of straw surplus. This paper proposes a mobile straw carbonization technology, studies the principles and processes of straw carbonization, and designs a high-efficiency mobile carbonization equipment that can be used in the field to reduce the costs of straw collection, transportation, and storage and realize the transformation of straw from waste to valuable resources. A mathematical model for the pyrolysis process of straw pellets was established. The structure of the mobile straw carbonization equipment was designed based on the research on the mechanism of straw pyrolysis and carbonization. A multi-layer sleeve rotary structure of the reactor is adopted, and the furnace body solves the problem of uneven heating of carbonization with a mixed feeding design of screws and scrapers. Simulation and experiments were conducted using corn straw as the raw material to analyze the variation law of temperature inside the furnace and verify the feasibility of the equipment designed for straw carbonization.
Shang, Chunmin, Yu, Jiadong
Simulation of Gas Diffusion in Nanoscale Microchannels at the Parallel Seam-Weld Interface2026-99-04198/28/2026
Driven by the stringent service conditions of aviation, aerospace, and military equipment, parallel seam welding, as an advanced resistance-welding packaging process, has been widely applied in ceramic-metal packages that require high hermeticity, owing to its excellent sealing performance and reliability. In this study, targeting the hermeticity failures that appear in parallel seam-welded ceramic packages after temperature cycling, molecular dynamics simulation is used to systematically investigate helium diffusion in nanoscale interfacial microchannels and its effect on hermeticity. On the LAMMPS platform, a three-region model is constructed that includes a helium-charging region, a wall-channel region composed of Fe, Ni, and Au, and a vacuum leak region. The Lennard-Jones potential is used to describe interatomic interactions, and a thermal-cycling environment conforming to MIL-STD-883, with a temperature range from -50°C to +125°C, is simulated to represent actual service conditions. The simulation results show that when the channel diameter is less than or equal to 1.2 nanometers, the number of leaked helium atoms remains constant at approximately 22 and is not affected by temperature; when the diameter is greater than or equal to 1.6 nanometers, the leakage exhibits significant temperature dependence. For example, in a 2.6-nanometer channel, 212 atoms leak at 423 K and 176 atoms at 223 K. Both leakage flux and leak rate increase markedly with channel size. OVITO analysis confirms that helium diffusion exhibits molecular-flow characteristics; at very small apertures, atomic escape efficiency is limited by the frequency of collisions with the wall. These findings provide insight for improving hermetic packaging and reliability of critical electronics used in aviation, aerospace, and military equipment.
Li, Xiangyang, Gong, Yubing, Zheng, Xianling
Experimental Study on the Crack Sensitivity of Storage Tank Bottom Plate Welded Joints in Hydrogen Sulfide Environments2026-99-04238/28/2026
This study investigates the cracking problems observed on the surface of T-joint welds and shell welds of storage tanks used for storing crude oil containing trace amounts of hydrogen sulfide (H2S) in a certain oilfield. Tests were conducted on Q235 and Q345R welded joints using electrodes with different hydrogen contents to evaluate their susceptibility to cold cracking, hydrogen-induced cracking (HIC), and sulfide stress corrosion cracking (SSC), as well as the effects of post-weld hydrogen removal treatment. The results show that no delayed cold cracks occurred in any welded joints of either Q235 or Q345R. Both materials exhibited hydrogen-induced cracking (HIC) on the cross-section, and the hydrogen removal treatment had little effect on improving HIC resistance. The overall HIC sensitivities of Q235 and Q345R were similar, both showing susceptibility to hydrogen absorption and internal cracking in the wet H2S environment. In contrast, SSC tests revealed that low-hydrogen welds exhibited no fractures or cracks, whereas high-hydrogen welds developed surface cracks. After hydrogen removal treatment, no SSC cracks were found in any specimens, regardless of electrode type. Therefore, for storage tanks operating in H2S-containing environments, the combination of low-hydrogen electrodes and post-weld hydrogen removal treatment is recommended to improve weld reliability and ensure operational safety.
Kang, Chun, Deng, Yufa, Zhang, Penggang, Han, Xiaochun, Huang, Mingji, Deng, Banghui, Li, Qiang, Zhang, Shuxin
Dynamics of Quayside Container Cranes with Anti-Wind Devices under Strong Winds2026-99-03198/14/2026
Quayside container cranes (QCCs), essential for cargo handling in seaport operations, are particularly vulnerable to damage under strong wind conditions. This study investigates the wind-induced dynamic behavior of QCCs equipped with active anti-wind systems, focusing on the mechanisms that govern cable stress and sliding instability. A five-degree-of-freedom mathematical model is established, incorporating nonlinear cable stiffness, restricted sliding through a Kelvin-Voigt collision model, and a combined Stribeck-Coulomb friction model for the wheel-rail interface. Parametric studies are conducted to evaluate the influence of three key factors, the anti-wind cable diameter, the sliding displacement of the QCC wheel, and the wheel-rail friction coefficient, on cable stress responses. The results show that increasing the cable diameter and friction coefficient significantly reduces peak cable stress, whereas greater sliding displacement increases stress accumulation and structural vulnerability. Sensitivity analysis reveals that cable diameter has the most dominant effect on cable stress, followed by sliding displacement and friction coefficient. This work might provide theoretical foundations for the design and optimisation of wind-resistant QCC structures, as well as for the development of more reliable anti-wind protection systems in extreme conditions.
Xiang, Lei, Ji, Huanyu, Liu, Zhiwei, Wang, Ziyou, Xu, Xinyue
Finite Element-Based Structural Optimization for UAV Storage-Launch Container2026-99-01647/31/2026
To fulfill the multi-tube launch requirements for a specific folding-wing UAV, this study improves the structure of the existing storage-launch container. Based on the finite element method, a parametric model of the container is established, and a multi-condition mechanical analysis is carried out for various storage, transportation, and launch conditions. The difference between the first six natural frequencies of the free mode and the prestressed mode is compared and analyzed. The modal analysis model considering prestress is used to identify the optimization area of the container. The variable density method (SIMP) is used to optimize the topology of the container, with the volume of the container as the constraint condition and the minimum strain energy as the optimization goal. The optimization results show that the first-order modal natural frequency of the container is increased by 108%, and the first six natural frequencies are increased to a safe range, which effectively avoids the resonance risk. At the same time, the quality is reduced by 29%, and good optimization results are achieved.
Yuan, Weiyang, Ji, Yuguo, Liu, Zhipeng, Yu, Wenxin
Design of a Fully Automated Tea Packaging System Based on an Improved Genetic Algorithm2026-99-01137/31/2026
Manual operations in traditional tea packaging lines often suffer from low productivity, safety risks, and inconsistent labeling quality. To overcome these limitations, this study develops a fully automated tea packaging system guided by an improved genetic algorithm. The system integrates five functional modules—bag feeding, bag opening, material filling, sealing, and labeling—into a seamless workflow. By applying the optimization capability of the improved genetic algorithm, the system achieves better coordination among modules, higher adaptability to different bag shapes and sizes, and improved operational efficiency. Experimental validation demonstrates that the proposed design not only simplifies the packaging procedure but also enhances precision, reliability, and production speed. The system provides a flexible and intelligent solution applicable to a wide range of tea packaging requirements.
Guo, Hui, Zhao, Zhikai, Yuan, Weilong, Lin, Lin, Yu, Yunchang, Gao, Jiashun
Research on Sealing and Vibration Reduction Performance of Large Sized Packaging Box2026-99-02027/31/2026
With the continuous development of large precision equipment, the reliability requirement for long-distance transportation is also constantly increasing. Large packaging box with sealing and vibration reduction performance is crucial during transportation. This article introduces the sealing measures for large-sized packaging box, as well as the sealing structure design methods for key parts, vibration reduction measures and the selection and design of vibration dampers. The designed packaging box has been used for long-distance transportation of various types of equipment and the reliability of sealing and vibration reduction performance has been verified in practical applications, providing reference for the design of similar packaging boxes.
Zhang, Ruoyu, Jiang, Shouli
Parameter Identification for the Dynamics Model of a Robotic Grasping Process Based on SFOA2026-99-01237/31/2026
To precisely simulate the nonlinear dynamic characteristics of a robotic arm grasping cylindrical objects from storage units, this study establishes a dynamic model of the robotic grasping process incorporating Coulomb and viscous friction models to characterize frictional properties. Furthermore, to effectively identify unknown parameters in the dynamic model, a parameter identification method based on the Superb Fairy-wren Optimization Algorithm (SFOA) is proposed. The root-mean-square error (RMSE) between the displacement responses from the dynamic model and the experimentally acquired displacement data serves as the optimization objective. Multiple sets of experimental data are utilized to identify the unknown parameters of the dynamic model. The results demonstrate that when the identified parameters are applied to the dynamic model, the goodness-of-fit between the model’s response displacement data and the experimental displacement data exceeds 0.999. This validates the effectiveness and accuracy of the proposed method for identifying unknown parameters in dynamic models.
Shen, Shaofeng, Yang, Liu, Wang, Zihan, Han, Qunyi
Identification of Uncertain Parameters in the Dynamics Model of a Rotary Storage Mechanism Using the Stellar Oscillation Optimization Algorithm2026-99-01487/31/2026
The rotary storage mechanism is a critical component responsible for transferring cylindrical units. To accurately simulate the nonlinear dynamics characteristics of the rotary storage mechanism, a dynamics model incorporating uncertain parameters is established based on the Lagrange method. Utilizing an optimization approach, uncertain parameters of the rotary storage mechanism are identified based on test data. The Stellar Oscillation Optimization (SOO) algorithm is employed, which balances exploration and exploitation by simulating the periodic expansion and contraction of stars to achieve optimal solutions. The results show that the output of the identified dynamics model under two operating conditions closely matches the test data, validating the accuracy of the model and the effectiveness of the identification process. This provides strong support for subsequent reliability analysis and fault diagnosis studies of the rotary storage mechanism.
Li, Ang, Chen, Guangsong, Huang, Peng, Li, Hanning
Design and Application of Simulation-Based Lifting Tool for Fabric Truck Roller Replacement2026-99-01377/31/2026
In the process of replacing the rollers of the fabric cart of the tobacco storage cabinet, in order to solve the problems of low replacement efficiency and high safety risk.This article proposes a specialized lifting tool for fabric cart rollers with a self-locking and adopts the screw lifting structure, which facilitates roller maintenance operations, and conducts SolidWorks Simulation calculations and dynamic simulation methods. Jinan Cigarette Factory fine cigarettes special line leaf silk temporary storage cabinet fabric car roller replacement, for example, the results show that: the average operating personnel reduced by 50%, the replacement time from 6.7h to 1.2h, efficiency increased by 458%, This innovation significantly reduces the labor intensity of maintenance personnel and ensures a safe and reliable replacement process.
Zhang, Lei, Xue, Yifei, Zhang, Ge, Sun, Yanzhao, Wang, Hongbin, Cheng, Linfeng
Development and Performance Validation of a Maintenance Platform for 10kV Switchgear Trolleys2026-99-02047/31/2026
With the development of the power industry, 10kV switchgear (circuit breaker switches) are increasingly widely applied in power grids. When performing power-off maintenance or testing on 10kV switchgear (circuit breaker switches) at substations, maintenance personnel require transport carts to move the equipment to suitable locations for operation. Traditional transfer carts suffer from structural design flaws and significant shortcomings. These include difficulty operating in the confined spaces of switchgear cabinets, high risks associated with manual handling, low efficiency in secondary transfers, and poor adaptability across multiple workstations. These issues collectively pose safety hazards during power-off maintenance or testing. When operating in a 3m×5m high-voltage room, traditional maintenance carts achieve less than 0.5 units transported per hour, with equipment damage rates reaching 3% annually due to drops, resulting in low work efficiency. To address these challenges, a 10kV switch cart maintenance platform has been developed. This standardized equipment facilitates 10kV switch cart maintenance, supporting the intelligent upgrade of power grid operation and maintenance.
Yang, Sen, Zhou, Han, Su, Hainan, Yu, Xin, Hu, Yutao, Wang, Xisheng
Fault Diagnosis of Packaging Machine Bearings Based on EEMD-CNN-BiLSTM2026-99-16017/24/2026
During the high-speed operation of packaging machines, if the abnormal components evolve into faults, the packaging machines often stop for inspection or even damage, causing production stagnation and huge economic losses. If key variables are predicted and faults are identified before the evolution of packaging machine failures, it is of great significance to ensure equipment safety and reduce maintenance costs and losses for enterprises. The purpose of fault prediction is to use the information modeling of equipment historical data to output the changes in key features before component failures in the future. Firstly, for the redundant data of multiple measurement points of the same variable in the packaging machine process variables, Pearson correlation analysis is used to obtain more accurate variable data. We reuse adaptive empirical mode decomposition (EEMD) for signal processing and feature extraction, reduce redundant information, use convolutional neural network (CNN) models for spatial feature learning, and then use bidirectional long short-term memory models to capture temporal dependencies of CNN information for capturing time series data. A model is established on the normal training set to fit the normal state of the packaging machine, identify different types and degrees of equipment fault characteristics through normal test set data, and send the predicted results of the equipment state to the fault classifier for judgment to determine whether to issue a fault warning. The results indicate that this article has validated the effectiveness of the model in fault feature extraction and high-precision fault classification through training on equipment status data.
Wu, Aimin, Liu, Shixian, Zhao, Lihui, Liu, Zhao, Wu, Tao, Li, Lianbing
Design and Dynamic Simulation of a High-Speed Conjugate Parallel Indexing Cam Mechanism2026-99-16257/24/2026
The cam mechanism, as an extremely important transmission method in mechanical transmission, is widely used in automatic machinery and automatic control devices. In small and medium-sized high-speed automatic guns, high-speed camshafts are often used to achieve intermittent movement of the supply and transport of ammunition during high-speed shooting. Due to the possible vibrations, wear, and instability that may occur during the movement of high-speed camshafts, the design of camshafts needs to meet the requirements of continuous third-order derivatives of the curve, while minimizing angular acceleration as much as possible. This article focuses on the design requirements of a high-speed intermittent motion mechanism, with continuous angular velocity and angular acceleration as design constraints. It establishes segmented function motion equations for the acceleration, deceleration, and uniform speed sections of a high-speed conjugate parallel indexing cam while ensuring that the design cam curve does not have knots. The theoretical profile and the actual profile of the cam, considering roller radius offset, are calculated. Based on this, dynamic simulations are carried out on the acceleration and deceleration sections of the cam roller, and the structural response considering structural elastic deformation and contact collision conditions is obtained. The calculations show that the cam and roller meet the structural strength requirements during high-speed motion. Experimental verification shows that the structure is stable and reliable during high-speed motion.
Wang, Shuman, Qin, Yanhui, Ning, Bianfang
Design of A Steerable Pressure Vessel Transfer Device2026-99-16377/24/2026
A rotatable pressure vessel transfer device has been designed to meet the positioning requirements of pressure vessels in old factory buildings with limited lifting space or insufficient crane lifting capacity, as well as small factory buildings with limited overall space. The device consists of a main driving rail car, a cable reel, a control box, and a towed transport car. In order to test the load-bearing capacity, passability, and stability of the transfer device for hill parking, experiments were conducted at the factory. The experimental results show that under full load conditions, the transfer device can park stably on the sloping track without any sliding phenomenon. The curved track passes smoothly without any jamming or derailment, meeting the design requirements.
Chen, Jinshan, Sun, Ye, Zhu, Jialei, Liang, Xiaodong, Wang, Hongfei
Analysis and Experimental Research on The Impact of the BangBang Valve Switch on the Flow Rate of the Storage and Supply System2026-99-16157/24/2026
This article focuses on a wide range of high-precision storage and supply systems. Under the rated flow rate of 2.928 mg / s of the proportional flow controller, the instantaneous flow fluctuation range of the BangBang valve reaches 2.963 mg / s, exceeding the control accuracy requirement of 1% for the proportional flow controller. By establishing mathematical models of the BangBang valve, proportional valve, and proportional flow controller for simulation analysis, the trend of the simulation results is consistent with the experimental results. Furthermore, considering the spatial layout and weight of the storage and supply system, this paper proposes a method to improve the accuracy of flow output by adding 180 mL of air capacity between the proportional valve and the proportional flow controller. Ultimately, the maximum flow fluctuation of the proportional flow controller at the moment of the BangBang valve opening and closing is 2.941 mg / s, which meets the control accuracy of the proportional flow controller. Moreover, the error between the output flow rate of the proportional flow controller and the rated working flow rate is minor after increasing the air capacity.
Li, Zhong, Li, Zongliang, Yan, Zelong, Huang, Tiankun
AI Drones Bring Real Time Intelligence to Warehouse AutomationTBMG-554416/29/2026
Labor shortages and supply chain volatility are putting additional pressure on warehouse operations to be faster and more adaptable. “In this environment, real-time visibility becomes foundational. Physical AI enables warehouses to operate with a continuously updated understanding of their environment, allowing them to respond quickly to disruptions and optimize performance,” Joseph Mirabile, Vice President of Operations at Gather AI, a Pittsburgh-based startup developing drone-powered inventory solutions.
Spatial Optimisation of Inner Dash Acoustic Performance Using Reciprocal Holography2026-01-07126/20/2026
As acoustic requirements for NVH trim components become increasingly constrained by mass, cost, and sustainability targets, traditional approaches to inner dash design based on spatially averaged Transmission Loss (TL) metrics are reaching their practical limits. In fully built vehicles, the acoustic performance of the inner dash is governed by its global insulation capability but also by strong spatial heterogeneity and its interaction with spatially distributed noise sources such as the power unit, gearbox, and tyre-road excitation. This paper presents a test-based methodology for the spatial optimisation of inner dash acoustic performance using reciprocal holography. By applying a calibrated sound power source within the vehicle cabin and measuring the reciprocal response in the engine bay and wheel-arch regions, a high-resolution spatial Transmission Loss “hologram” of the inner dash is obtained under in-situ conditions. The resulting spatial data enables the identification of localised acoustic weak points that are not observable using conventional testing methods. To bridge the gap between passive component characterisation and real-world vehicle operation, the spatial TL hologram is subsequently evaluated using representative operational source sound power data to prioritise acoustically relevant regions. This enables the transmitted acoustic energy to be evaluated under realistic driving conditions. The holographic data is then coupled with a parametric acoustic model of the inner dash system, allowing localised mass redistribution to be optimised using a genetic algorithm while respecting packaging and manufacturing constraints.
Harry, Evan, Eandi, Giacomo
Ergonomic Assessment of Glove-Box Design in Passenger Vehicles for the Indian Scenario15-19-02-00096/10/2026
Passenger vehicles experience severe packaging constraints around the instrument panel, rendering glove-box operation a critical yet ergonomically underexplored interaction. Although glove-box interaction occurs frequently during routine vehicle use, its potential implications for ergonomic risk remain largely unexamined in existing automotive research. To isolate the influence of driver-side packaging constraints from component-level design effects, this study adopts a comparative evaluation of driver and co-driver glove-box interaction as a built-in control condition. This study introduces a discomfort-based evaluation framework that integrates Digital Human Modeling with India-specific anthropometric datasets. A composite loss-function scoring model is developed to quantify functional usability differences across four glove-box configurations, defined by variations in latch placement (center or side) and storage-bin mechanisms (fixed or rotating). Indians are utilized to assess reachability and visibility during glove-box interaction. Ergonomic performance is analyzed through reach and visibility metrics for both latch actuation and storage-access tasks. For the co-driver, all configurations exhibit 0% loss, confirming that usability remains unaffected. In contrast, the driver assessment reveals pronounced limitations. Center-mounted latches prove inaccessible from a neutral seated posture, reflecting an approximate loss function of 55%. Among the side-latch alternatives, the rotating-bin configuration achieves the lowest discomfort score (41%), supported by more favorable access posture and smoother hand-entry alignment. The findings specify that ergonomic limitations stem primarily from driver-side packaging constraints rather than inherent flaws in the glove box unit. Based on the reach and visibility loss values obtained through the developed framework, the Side-Latch + Rotating-Bin configuration emerges as the most suitable design option for passenger-vehicle layout. The proposed methodology offers a practical decision-support tool for early stage ergonomic evaluation of glove-box configurations in passenger vehicles.
Jujjavarapu, Sreeram, Kota, Srinivas, Kotkunde, Nitin, Jasti, Naga Vamsi Krishna
Heavy-Duty Nonroad Material Handler Electrification, Part 1: Real-World Drive Cycle Development02-19-03-00156/10/2026
Knowing a detailed operating cycle is critical for developing and testing equipment. Operating cycles can be separated by two clear distinctions: (1) regulatory or non-regulatory and (2) application at the engine-only or full machine level. The Environmental Protection Agency’s (EPA) Nonroad Transient Cycle (NRTC) may be a good representation of engine use in many types of equipment, but there is a gap in standardized and validated drive cycles specifically for nonroad material handlers. Lacking a standardized drive cycle makes it difficult to accurately benchmark machine performance and validate new powertrain technologies. The objective of this investigation is to illustrate the development of a custom drive cycle augmented with real-world customer use data that serves multiple purposes: (1) understand the range of operation and utilization that formulated inputs for electrified architecture analysis and (2) develop a repetitive and consistent maneuver to establish baseline energy consumption enabling equivalent comparison to future electrified prototype builds. This article presents a solution specifically for a 23-ton nonroad material handler in which material handling, machine transport, and extended idle were homologated to form representative short cycles defined by machine velocity and hydraulic cylinder position. The most intensive material handling short cycles had a load factor of 40% and an average fuel rate of 16 L/h. Combined with a visual aid, the short cycles exhibited low variability, having less than 5% root mean square (RMS) error in lift and reach position with respect to the average. The machine’s performance on these short cycles at the Advanced Power Systems Research Center (APSRC) was compared to results from two real-world customer locations operating the instrumented test machine in a cyclical manner, and for similar ground conditions were found to be comparable in fuel consumption.
Czarnecki, Alexander, Goodenough, Bryant, Worm, Jeremy, Robinette, Darrell, LaTendresse, Phil, Westman, John
Research on Temperature Measurement Requirements for Seasonal Thermal Energy Storage Water Pits2026-99-17055/22/2026
Solar seasonal thermal energy storage technology is an important means to solve the problem of seasonal uneven distribution of solar resources, and as the core component, the thermal storage capacity of the water pit directly affects the performance of the whole system. Accurately mastering the water pit temperature is essential for scientifically evaluating its thermal storage capacity. Based on the thermal storage water pit simulation software developed in the laboratory, this study focuses on determining the optimal number of temperature measurement points required for seasonal thermal energy storage water pits under an accuracy requirement of ±0.1°C, and establishes the mathematical relationship between the number of measurement points and the height-diameter ratio (H/D) as well as the inlet position. The proposed method can cover the temperature measurement point design for cylindrical and frustum-shaped water pits, and can also be referenced for prism-shaped configurations. Combined with the thermal performance analysis of the Huangdi City Phase II seasonal thermal energy storage project, the applicability of the mathematical relationship has been verified. The optimal number of measurement points obtained in this study provides effective suggestions for the scientific design of water pit temperature measurement systems.
Niu, Pengbin, Ma, Jianfu, Wang, Fangxing, Qi, Shiyu
Overcoming the Carbon Neutrality Bottleneck: Multidimensional Innovations and Future Prospects of Carbon Capture, Utilization, and Storage (CCUS) Technology2026-99-17365/22/2026
As the global pursuit of carbon neutrality accelerates, carbon capture, utilization, and storage (CCUS) technology is emerging as a critical strategic pillar for achieving significant emission reductions and facilitating the transition to green development. This review systematically summarizes the principal technological pathways and recent advances in carbon capture, resource utilization, and storage within CCUS systems, with particular attention to innovative directions including advanced adsorption and separation materials, synergistic catalytic conversion, biological carbon sequestration, and mineralization-based storage. By examining representative engineering practices and industrialization cases both domestically and internationally, this paper summarizes the major challenges currently facing CCUS, including material costs, energy consumption, environmental risks, and large-scale deployment. The positive impacts of interdisciplinary integration, process system optimization, and policy coordination on the commercialization of CCUS are also discussed. The review indicates that overcoming bottlenecks in core materials and process technologies, improving regulatory frameworks and market mechanisms, and establishing clustered industrial ecosystems are essential for CCUS to spearhead the forthcoming low-carbon energy and green industrial revolutions. This paper envisions future development trends for CCUS technology, highlights its multidimensional strategic value for global carbon governance, energy security, and the circular economy, and offers theoretical references and cutting-edge insights for scientific research, policy formulation, and industrial decision-making in related fields.
Wang, Yingfei
Design And Analysis of Low-Temperature Liquid Nitrogen Tank Car2026-99-17125/22/2026
The design and analysis of the wave plate of the tank body of the low-temperature liquid nitrogen tank car are carried out. According to the design method of the empirical formula, the 0.43 MPa low-temperature mobile liquid nitrogen tank body wave plate with the working temperature of -196°C to -178°C is optimized. According to the analysis and design standards, the stress distribution law of the mobile liquid nitrogen tank body under the forward impact condition is analyzed by the method of numerical analysis. The results show that the stress value will gradually increase near the junction of the tank body and the support, and the parts such as the head, the pad, the angle steel ring, and the Z3848 glass steel pipe meet the requirements of the analysis and design standards. At the same time, the first six orders of the natural mode vibration frequency of the tank body are analyzed, which provides a reliable and effective data analysis for the optimization design of the low-temperature liquid nitrogen tank body wave plate.
Ding, Xuqiang, Ni, Yiwei, Gu, Chen, Yan, Dongdong, Xu, Zhiquan, Wang, Qi
Fatigue Resistance of High-Pressure Hydrogen Storage Vessels with Aluminum Liner2026-99-07315/15/2026
Although carbon fiber-reinforced aluminum-lined hydrogen storage vessels (Type III) exhibit outstanding specific strength and specific stiffness, the constraints imposed by their design parameters on fatigue performance and ultimate load-bearing capacity remain incompletely elucidated. We propose a fatigue life prediction method for high-pressure vessels that couples progressive damage in the fiber composite with cumulative damage in the metallic liner, aimed at forecasting the fatigue performance of Type III pressure vessels under cyclic loading. Furthermore, a finite element analysis systematically investigates the influence of key design parameters, for nominal pressure, liner diameter and liner thickness, on fatigue performance and ultimate load-bearing capacity. Results indicate that fatigue life significantly decreases with increasing nominal pressure and liner diameter, with nominal pressure exerting a more pronounced effect. Notably, altering the autoclave pressure alone cannot achieve a synergistic design that balances high load-bearing capacity and high fatigue life when the burst safety factor equals 2.25. More interestingly, we discover that appropriately increasing the pressure vessel's safety factor or liner thickness enables synergistic optimization of the overall structure. These findings provide reliable design approach for the structural design and life assessment of composite hydrogen storage pressure vessels.
Bi, Zhihai, Zhang, Qian
Automotive Engineering: May 202626AUTD055/14/2026
Forvia Hella ready with ADB, but NHTSA test stands in the way A demonstration ride shows the glare-free, game-changing power of adaptive driving beams, already available in Europe. An approval test from NHTSA is proving difficult for OEMs to pass. Sharper validation without brute force How CERTUS reshapes AV testing. Simulation-driven battery development From material selection to system-level performance. How simulation unlocks efficient and innovative motor design Engineers are still at the heart of the development process as simulation tools become great levelers. Engineering in the second quarter of the 21st Century Building a trusted digital twin and decision-centric simulation ecosystem. Engineering in the second quarter of the 21st Century Building a trusted digital twin and decision-centric simulation ecosystem. Independent materials testing for OEM validation How validated data provides the foundation for approved components. Editorial All the ways: Learning via print in a digital era The Navigator Uber wants a piece of every robotaxi Bosch Shows off its first U.S. electrolyzer in support of hydrogen research Engineering better reusable bulk containers for the industry The dawn of agentic autonomy in factories Some Automakers Retreat from North American EV Market Enabling certified GoogleTest for safety-critical embedded software Toyota expands all-electric bZ 'family' First Drive: 2026 Subaru Outback Wilderness Product Briefs Spotlight: Testing & simulation, semiconductors Q&A TMMK president: Solar and bright, quieter factory floor help production
Unidirectional Carbon Fiber Tape Epoxy Repair Prepreg, Vacuum Curing Part 3 - Purchasing Specification for Unidirectional Carbon Fiber Tape Epoxy Repair PrepregAMS6885/3 (Current)5/7/2026
This Purchasing Specification, AMS6885/3, specifies the batch release and delivery requirements for unidirectional carbon fiber tape epoxy prepreg used for repair. This specification is applicable only when the unidirectional carbon fiber tape epoxy prepreg is used as part of the repair system defined in AMS6885 and AMS6885/1. This specification also defines the procedure and requirements for storage life extension of materials purchased against this specification. It is only applicable for materials qualified against AMS6885 (refer to PRI-QPL-AMS6885) and shall be carried out within the responsibility of the purchaser and under control of its Quality organisation.
AMS CACRC Commercial Aircraft Composite Repair Committee
Performance Analysis and Data Processing for the High Solidity Test Campaign in the Jet Propulsion Lab 25-ft Space Simulator (Presentation Only)F-0082-2026-03335/5/2026
Historical rotor designs for Earth and Mars have typically landed at thrust-weighted solidities of ∼0.1-0.15 as a best compromise of performance and weight. Comprehensive analysis predicts that high solidity rotor designs of more than twice this range have the potential to significantly increase the lift capability of future Mars explorers severely limited by packaging and weight. However, there is limited existing experimental data of high solidity rotor designs at representative densities to quantify the efficiency impact and verify models of the aerodynamic environment. Therefore, the Mars Exploration Program (MEP) funded a joint test campaign between NASA's Jet Propulsion Laboratory, NASA Ames Research Center, and AeroVironment, Inc.to validate performance predictions for low- and high- solidity rotor variants at Mars pressures. Experimental setup, test matrix, data processing, data quality, and performance results for the High Solidity Test (HST) campaign are presented and discussed.
Schatzman, Natasha, Bowman, Belen, Karras, Jaakko, Fillman, Michael, Gehlot, Vinod, Mier-Hicks, Fernanco, Fjaer Grip, Havard, Sahragard-Monfared, Gianmarco, Johnson, Wayne, Langberg, Sara, Lottman, Paige
Full State Feedback Controller for a HelicopterF-0082-2026-00415/5/2026
Full state feedback offers theoretically guaranteed multi-axis stability, making it superior to conventional PID controllers. There is however one drawback, a full state controller has a mathematical difficulty if the B matrix is not square and thus not invertible. This is the case for helicopters with 6 degrees of freedom and 4 inceptors. Variations of linear quadratic regulators are a work around, however complexity dramatically increases. Best would be a direct solution to the original problem. This is the breakthrough result of this paper. This paper documents an approach which removes the analysis roadblock by partitioning the 6 x 6 system "A" matrix into two groups of 4 x 4 matrices. The 4x4 matrices are individually stabilized with full state gain matrices. One matrix is designated “Driver Matrix” which provides actuator commands. The other matrix is designated "Reference Matrix" which provides references. The two matrices are coupled together by requiring that the driver matrix follow references generated by the reference matrix. With each matrix individually stabilized, the coupled combination is also stabilized. Computation of flight dynamics states (u, v, w, p, q, r) is shared between the matrices. Initial results are very encouraging, showing an originally sluggish, heavy lift helicopter having now concise decoupled responses to pitch and roll commands. Stability derivatives are recomputed during flight allowing coverage over the whole flight envelope. A handling qualities task has been defined to relocate a 40 ft standard seaborne container directed by a pilot in a ground control station. Cooper Harper ratings of this task have demonstrated favorable Level 1 handling qualities if use is made of an automated lateral repositioning command.
Mouritsen, Stephen, Piasecki, Fred
A Shipping Container That Builds 50 Interceptor Drones a DayTBMG-551365/1/2026
Sensofusion Helsinki, Finland
Experimental and Kinetic Modeling Study of Aged Natural Gas Three-Way Catalyst Performance2026-01-03734/7/2026
The applicability of three-way catalyst (TWC) models for system-level aftertreatment simulations under transient operating conditions of natural gas engines depend on accurate integration of reaction kinetics as a function of the air-fuel equivalence ratio lambda(λ). A comprehensive global kinetic model has been developed for an aged commercial three-way catalyst (TWC), incorporating key reaction pathways including oxidation of CO, CH₄, C₂H₆, and H₂; reforming of CH₄ and C₂H₆; the water-gas shift reaction; and NO reduction via CO and H₂. The model also accounts for oxygen storage capacity (OSC) and its dynamic interaction with CO and H₂. To calibrate kinetic parameters, systematic bench-scale flow reactor experiments were conducted under lean, stoichiometric, and rich conditions. Performance metrics focused on CH₄ and C₂H₆ oxidation and reforming across varying O₂ and CO concentrations, and NO reduction with CO and H₂ under different oxygen levels. Experimental results revealed that CO suppresses the reforming of CH₄ and C₂H₆. NO conversion was observed between 150°C and 600°C, with H₂-driven reduction producing NH₃, N₂, and N₂O depending on lambda (λ). Under rich conditions, complete NO conversion occurred from 150°C, while lean conditions showed reduced NO conversion at elevated temperatures due to H₂ oxidation. NO reduction with CO initiated at 250°C, achieving full conversion under rich conditions. The model accurately captures the influence of λ on NO reduction with both H₂ and CO, predicts NH₃ formation under rich conditions, and simulates H₂ generation via the water-gas shift reaction above 400°C. It successfully reproduces λ sweep data (λ = 0.95–1.02) and demonstrates CO inhibition effects on H₂ oxidation and NO reduction. This global model is validated with dithering reactor data and qualitatively captures key trends in data which aids in catalyst sizing, calibration robustness and the system level modeling of end of useful life parts. Further validation of the current developed model with lean-rich cycle tests confirms the model’s ability to predict NOx slip at the onset of rich cycles impacting the ability to accurately predict NOx emissions during engine braking events in system level models.
Raj, Richa, Kim, Mi-Young, Aigbiremolen, Grace, Srinivasan, Anand
Impact of Hydrothermal Aging and Chemical Poisoning on NOx Reduction Performance of SCR – A Simulation Study2026-01-03724/7/2026
Diesel aftertreatment systems continue to play a critical role in compliance of tailpipe criteria pollutant compliance for commercial transportation applications. Quantification of performance of the aftertreatment system in particular Selective Catalytic Reduction component as a function of aging is critical in ensuring real world tailpipe NOx standard for aged systems. As part of A2CAT-II consortium at Southwest research Institute this aspect of the production AT system was studied for different aging conditions using a set of DAAAC aged components. The performance of these aged components was quantified through a set of steady state reactor tests and transient ECTO burner lab tests that simulate on engine performance. The data was collected at 0, 33 and 100% equivalent aging conditions and this data was used to develop a GT suite-based model with a set of inhibition factors to simulate the loss of Ammonia Storage Capacity and reduced SCR reaction rates caused by thermal load and chemical poisons. A quantitative and qualitative discussion of the degradation mechanism is presented based on the inhibition factors determined as part of the simulation study. Primary mechanism of performance degradation for fully aged component consisted of a 12% drop in ammonia storage capacity and a 10% and 12% drop in standard and fast SCR reaction rates leading to reduced NOx conversion rate. Due to catalyst degradation up to 11% reduced NH3 oxidation rate was observed which led to increased NOx conversion for temperatures above 350C. These trends can have a significant impact of systems designed for ultra low NOx standards by EPA and CARB which require precise control over NOx conversion of the system.
Chundru, Venkata Rajesh, Sharp, Christopher, Gankov, Stanislav, Eakle, Scott
Target Cascading Kinematics and Compliance Tables to Suspension Design2026-01-05844/7/2026
During the initial design phase, automotive Original Equipment Manufacturers (OEMs) require the adaptability to examine various suspension system architectures while maintaining focus on the specific performance objectives. Those requirements are expressed by Kinematics and Compliance (K&C) look-up tables and represent the footprint of what the suspension should look like in real-world applications. However, translating those requirements into the full geometric hardpoint layout is not straightforward. This process often relies on trial-and-error approaches, making it time consuming and requiring significant expertise. This challenge, known as ”target cascading,” remains a major hurdle for many engineers. The main objective of this paper is to cascade the suspension requirements from K&C look-up tables to hardpoint locations by adopting an automatic workflow and ensuring respect for constructive and feasibility constraints. Design space exploration was conducted using a robust optimization methodology leveraging a Reduced-Order Model (ROM) of a MacPherson suspension. Feasible designs are ensured by incorporating physical constraints such as roll center variation, scrub radius range, tie rod inclination, packaging limitations and relative hardpoint influence. The usage of ROM significantly accelerates the optimization cycle, reducing the computation time from 2 days to 3 hours.
Brigida, Piero, Di Carlo, Paolo, Di Gioia, Niccolò, Geluk, Theo, Tong, Son, Alirand, Marc, Gorgoretti, Davide, Occhineri, Marco, Tassini, Nicola, Berzi, Lorenzo
Impact of Hydrogen on Methane and Pollutant Emissions over Three-Way Catalysts with Natural Gas–Hydrogen Blends2026-01-03574/7/2026
Blending natural gas (NG) with hydrogen (H₂) can improve combustion and engine performance while potentially facilitating the catalytic conversion of methane and other pollutants, resulting in cleaner tailpipe emissions. This study evaluates the impact of H2 on the conversion of methane, CO, and NOx emissions on a commercial three-way catalyst (TWC) in a flow reactor using synthetic gas mixtures that simulate stoichiometric engine exhausts with NG or NG+H₂ combustion. The work examines whether, and how, the additional amount of H₂ in the exhaust stream affects the conversion efficiency of methane and other pollutants. Experiments were conducted with both degreened and aged catalysts under controlled conditions, systematically varying temperature, the air-to-fuel equivalence ratio (λ), and λ modulation. Test conditions covered λ values from 0.996 to 1.000 to represent nominally stoichiometric engine operation with different λ modulation amplitudes, as well as a range of temperatures to inform control strategies for effective CH₄, CO, and NOₓ reduction. Overall, the results show that hydrogen addition significantly improves the conversion efficiency of CH₄ and NOₓ, particularly at temperatures below 500 °C. More significantly, this study highlights that exhaust gas composition, operating temperature, λ management, and the oxygen storage capacity of the TWC all play major roles in affecting the tailpipe emissions from NG and NG+H₂ combustion.
Prikhodko, Vitaly, Wang, Min, Park, Yeonshil, Chen, Hai-Ying, Pihl, Josh
Protection of Megawatt-Scale DC Fast Charging Infrastructure for Heavy-Duty Vehicles: Ultra-Fast DC Breaker Development, Testing, and Future Roadmap2026-01-04004/7/2026
Direct Current (DC) fast charging enables supply of megawatt (MW) scale DC power to the large battery systems of Heavy-Duty Electric Vehicles (HDEVs), such as electric trucks, buses, ferry and construction machinery. This contrasts with Alternating Current (AC) charging, which is limited by the capacity of the On-Board Charger (OBC) that converts AC to DC to charge the battery. In DC fast charging, however, the Electric Vehicle Supply Equipment (EVSE) delivers DC power directly to the HDEVs, bypassing the OBC. The feasibility of fast DC charging has been driven by advancements in semiconductor technology offering higher voltage and current handling capabilities as well as improvements in battery energy density. Ongoing research indicates continued growth in both semiconductor power handling and battery storage capacity, further strengthening the case for fast DC charging. Key benefits include significantly higher charging efficiency, drastically reduced charging times, and lower driver fatigue. However, unlike AC systems, DC based charging infrastructure presents unique protection challenges. These challenges arise from the absence of natural current zero-crossings of DC current and the limited commercial availability of pure DC breakers. This paper presents a concise review of existing protection technologies applicable to DC fast-charging infrastructure, identifying critical gaps in current approaches and evaluating potential solutions for Low Voltage (LV, <1.5 kV) and Medium Voltage (MV, 1.5–35 kV) DC applications. Then a downsized 10 kW prototype of an Ultra-Fast Active Resonance Current Source-Based Hybrid DC Circuit Breaker (UFRDCB) has been developed and experimentally validated as a proof of concept. The prototype successfully interrupts a 1 kA continuous DC current in less than 500 μs, and the corresponding test results are presented and discussed. Finally, the paper outlines a forward-looking roadmap for advancing protection technologies that are critical to the safe and reliable operation of megawatt-scale DC fast-charging infrastructure for HDEVs in the United States and globally.
Rahman, Md Rakib-Ur, Dobrzynski, Daniel
In-Use Life Digital Twin (Redundant Storage) and Swappable Use Case for Battery Durability2026-01-03974/7/2026
As regulatory frameworks for zero-emission vehicles (ZEVs) and battery electric vehicles (BEVs) continue to evolve, there is growing emphasis on monitoring battery durability and usage throughout the vehicle lifecycle. These regulations increasingly specify the use of data monitors and tracking mechanisms to assess battery health and performance. In addition, regulations require anti tampering mechanisms especially for monitors that have external write access. Historically, regulations focused primarily on vehicle warranty; however, with the introduction of battery durability monitors, clarity is needed for the new battery durability monitors. More specifically if the battery durability monitors track with the lifetime of the vehicle or if they follow the lifetime of the battery. Furthermore, current regulations provide no guidance on high-voltage (HV) traction battery service strategies or methods to protect monitors from tampering by external customers. This paper will classify battery durability tracking parameters (DIDs) according to whether they align to the lifetime of the vehicle or the battery itself. Building on this classification, a service strategy is proposed that considers typical vehicle architectures: when the battery management Electrical Computer Unit (ECU) is fully integrated with or separated from the high voltage traction (HV) battery. The outlined service strategy not only supports regulatory compliance, but also enhances data integrity by mitigating the risk of tampering with monitored parameters through a Digital Twin framework. More specifically, the Digital Twin framework introduces redundant storage of critical information in multiple storage locations such as ECUs and then a mechanism for correlating that critical information to determine a mismatch. This approach anticipates future requirements for tamper-proofing and ensures secure, reliable tracking of battery durability metrics through redundant ECU storage.
Laskowsky, Patricia, Bunnell, Justin, Zettel, Andrew, Albarran, Josue
Multi-Stage Packaging and Routing Optimization for Automotive Component Layout, Wire Harness and Duct Route Design2026-01-05074/7/2026
Modern vehicle design involves complex considerations and tradeoffs between system integration and layout which have a direct impact on performance, efficiency, and cost. The placement of equipment including control boards, motors, and fans as well as the routing of ducts and wire harnesses poses a time-consuming and intricate problem for design engineers. This paper presents an automated methodology to determine the optimal component packaging configuration, duct routing, and wire harnessing layout to maximize component packing density and minimize the total routing length. A two-stage optimization framework has been developed where the first stage packages the components within the design space with considerations for space utilization, component overlap, proximity relationships, point-to-point accessibility, and component mounting. The second stage implements a custom A* path-finding algorithm and gradient based optimization to determine the optimal route layout between port points. The objective of this work – using A* and gradient based optimization - is to minimize the total length of the duct work and harness layout while respecting proximity, overlap, and accessibility considerations. This paper outlines the methodology and real-world application through the design optimization of an automotive dashboard.
LeFrancois, Richard, Kim, Il Yong
Forensic Acquisition and Analysis of Unsupported Lexus Infotainment Modules via CMD42 Bypass and Data Carving2026-01-05404/7/2026
Crashes involving passenger vehicles increasingly include vehicles equipped with infotainment systems that are unsupported by commercial vehicle system forensics hardware and software. Examiners facing these systems must overcome challenges in acquiring and analyzing user data, requiring an understanding of both digital forensics principles and the proprietary characteristics of the modules. This paper presents a methodology for acquiring data from previously unsupported Lexus infotainment modules, including techniques to bypass CMD42 security locks on SD cards and extract data. Once acquired, the paper outlines methods for analyzing user data through data carving techniques, enabling recovery of information from binary images even when the full file system cannot be reconstructed. Emphasis is placed on maintaining the integrity of the evidence and validating findings through controlled testing. These validation procedures ensure that the recovered information is both accurate and admissible, providing examiners with actionable intelligence relevant to crash reconstruction and related investigations. A detailed case study demonstrates the application of these methods on an exemplary Lexus infotainment module, illustrating the technical process of bypassing security restrictions, recovering user data, and analyzing the information to uncover relevant insights. Key considerations include correlating extracted data, verifying data integrity, and adapting general forensic principles to a previously unexamined platform. By sharing these findings, the paper provides a roadmap for examiners encountering unsupported vehicle systems, offering practical guidance for overcoming security mechanisms, performing advanced data recovery, and validating results through documented testing. Lessons learned from this work contribute to the broader understanding of automotive digital forensics and underscore the importance of innovative approaches when confronting emerging technologies and proprietary storage protections.
Burgess, Shanon
Noninvasive Loss Breakdown of an Electric Drive Unit2026-01-04484/7/2026
Techniques exist to precisely measure the electromechanical efficiency in an electric drive unit (EDU), defined here as the combined motor and geartrain. While total drive-unit efficiency is an important metric, it does not quantify the different loss sources in the EDU. Due to the tight packaging in production EDUs, it’s impractical to mount a torque transducer between the electric machine and gearbox to separate the losses due to these components. Additionally, this approach does not separate the winding, core, and mechanical losses present in the machine. In this work, we developed a noninvasive approach to distinguish winding, core, and mechanical losses for EDUs containing synchronous electric machines. To separate the effects of these losses, mechanical output power was held constant at several test points while varying the stator’s current amplitude and angle. By maintaining the mechanical power at a constant value and varying the stator current, the core and winding losses were excited independently of the mechanical loss. We combined the resulting data with an equivalent-circuit model (ECM), including separate resistors representing the winding and core losses, as well as a flux-linkage map (providing the voltage for the ECM) to separate and quantify the individual losses. As validation, we implemented this approach on a 2022 Ford F-150 Lightning rear EDU. The Lightning EDU showed lower total efficiency during regenerative operation, rather than tractive, which is unusual, since core losses are typically lower when generating rather than motoring. The loss breakdown revealed that the machine’s core losses exhibited the usual behavior and that its winding losses were symmetric about zero torque, as expected. The EDU’s greater overall loss when generating was solely due to asymmetrical mechanical losses.
Woods, Tyler, Gross, Michael, Drallmeier, Joseph
Lightweight Bubble Sheet Panel To Reduce Inverter Noise and Vibration for Electric Vehicles2026-01-04424/7/2026
Inverters are typically integrated into electric drive units for electric vehicles (EVs) to reduce packaging size and cost. However, coupled vibrations from the electric motor and gears are transmitted to the inverter, which can become a dominant noise source due to its large radiative panel. Metal panels are required for electromagnetic interference (EMI) compliance, yet these covers usually lack sufficient stiffness or damping for noise control. Adding ribs and applying damping treatments result in excessive mass, cost, and packaging challenges. A new bubble sheet panel design has been developed to enhance the structural strength and damping performance of the inverter cover while significantly reducing its mass. A thin sheet of aluminum is welded onto the cover in an optimized pattern that enhances stiffness and damping performance while accommodating packaging requirements. The welding pattern can include logos or artistic designs to improve the panel’s appearance. The metal sheets are blown apart between the welds to form a 3D structure that is three times stiffer and twice as strong as a flat monolithic sheet of the same thickness. The composite dual bubble sheets can effectively reduce structural vibration. Damping materials, such as liquid-applied sound deadener (LASD), can be injected into the bubble sheet cavities to significantly improve its damping performance. Prototype bubble sheets have been designed, analyzed, and tested for an integrated inverter used in front-wheel-drive (FWD) electric drive unit for EV applications. Analysis and modal tests show a reduction of 10 to 15 dB at panel resonances with close to 30% reduction in mass. The bubble sheet panel is installed on an integrated inverter and tested in the electric drive unit. Sound power measurements confirm a reduction of up to 10 dB in inverter panel vibration.
He, Song, Bobel, Andrew, Naismith, Gregory, Yi, Wenwen, Patruni, Pavan Kumar
Effect of Exhaust Gas Components on Oxygen Storage Capacity Measurements of Automotive Catalysts2026-01-03604/7/2026
Three-way catalytic converters (TWC) are one of the most popular methods to help reduce harmful tailpipe emissions emitted from internal combustion (IC) vehicles. To help improve conversion efficiency, TWCs can store and release oxygen via an oxygen storage capacity (OSC) mechanism. During engine control unit (ECU) calibration, on board OSC measurements are correlated to TWC and vehicle emissions to monitor emissions performance throughout the full useful life (FUL) of the vehicle. It is known that different test conditions, including temperature, space velocity and background gases in the exhaust stream affect OSC measurement, potentially altering the calculated OSC values and thus the perceived level of OSC and emissions preformance during operation. This study utilises an OMEGA test bench to complete OSC measurements on the full-scale automotive catalyst samples to quantify the effects of different background gases including carbon monoxide, hydrocarbons and nitric oxide on OSC measurements, concluding that all background gases studied affect measured OSC values. The study revealed that hydrocarbons had the largest effect on OSC measurement increasing OSC values by up to 50%. It was concluded that the increase in OSC measurement with injected hydrocarbons was due to the breakdown of hydrocarbons on the catalyst surface during rich periods of operation increasing the amount of oxygen required to fully oxidise the catalyst resulting in a larger perceived OSC measurement. During the initial ECU calibration original equipment manufacturers (OEM) should consider these effects on OSC measurement and understand how this will affect perceived OSC and vehicle emissions performance for FUL and onboard diagnostics (OBD) applications. This will help ensure emissions compliance and guide optimized catalyst and engine calibrations.
Mc Grane, Liam, Douglas, Roy, Irwin, Kurtis, Woods, Andrew, Elliott, Matthew, Istrate, Oana, Nockemann, Peter
EDITORIAL: It's war o'clock again26AUTP04_044/1/2026
This year will mark my 20th year trying to understand the automotive industry as a journalist. A full understanding is, of course, an impossible task. The global scale, the endless levels of complexity, the billions of consumers and dollars and components. But it's been an enjoyable mission, one that has a 0% chance of becoming boring any time soon, even if I might want the ups and downs to stop being quite so dramatically high and low. As I write this in mid-March, the U.S. is still launching attacks at Iran with nothing but ever-changing threads of reasoning attached. The resulting chaos has shot gas prices in the U.S. back to what they were at this time of year in 2024, according to AAA, and governments from Japan to the UK are searching for ways to intervene and keep gas prices under some semblance of control. The Danish energy minister suggested people there avoid driving their cars unless it is “strictly necessary.” And yet, a fair number of analysts now find more things to worry about in the Middle East than they can point to areas of security. Without a doubt, the war's tendrils have already begun reaching into food production (apparently around fertilizer sourcing), health care (at least one apparent Iran-connected hack), and the auto industry, with initial supply chain questions revolving around aluminum and plastics, is the sense I'm getting. In the U.S., spot shipping rates have jumped almost 30% in recent weeks, which will only worsen the financial troubles OEMs and suppliers are facing in getting vehicles to customers.
Blanco, Sebastian
Breakthrough in Carbon-Based Battery Materials Improves Safety, Durability, and PowerTBMG-548554/1/2026
This research demonstrates a new way to make carbon-based battery materials much safer, longer lasting, and more powerful by fundamentally redesigning how fullerene molecules are connected. Today’s lithium-ion batteries rely mainly on graphite, which limits fastcharging speed and poses safety risks due to lithium plating. These research findings mean progress toward safer electric vehicles, longer-lasting consumer electronics, and more reliable renewable-energy storage.
EP40: Structural Epoxy Used for Steel Bonding in Marine ApplicationsTBMG-549274/1/2026
To reduce its environmental impact and pollution, the shipping industry is investigating methods to construct more lightweight ships. One potential method is using adhesive bonding techniques to replace traditional welding and riveted joints on ships to fabricate lighter ships with smaller carbon footprints. However, adhesives age and deteriorate when exposed to moisture, high temperatures, and ultraviolet light. This makes it necessary to understand how they age in maritime environments to determine whether they can truly replace traditional welding techniques.
Alternate Catalyst for DOC in a Catalytic Converter2026-28-00162/12/2026
Emission norms have become much more stringent to reduce emissions from vehicles. Diesel engines in particular are the predominant contributors to higher emissions. Diesel Oxidation Catalyst (DOC) in diesel engine catalytic converter systems is the crucial component in reducing harmful emissions such as Carbon Monoxide (CO) and unburnt Hydrocarbons (HC). DOCs often rely on expensive noble metals like platinum, palladium, and rhodium as catalyst materials. This significantly raises the cost of emission control units. The proposed idea is to explore MnO2-CeO₂ (Manganese Oxide, Cerium Oxide) as an alternative catalyst to traditional DOC materials. The goal is to deliver effective oxidation performance while reducing overall system cost. MnO2-CeO₂ catalysts are promising because of their good low-temperature activity, oxygen storage capacity, and redox behavior. These features are helpful for diesel engines that operate under various conditions. They improve the oxidation of CO and HC, even during cold starts or at lower exhaust temperatures. The catalyst was successfully synthesized and applied to a honeycomb substrate, resulting in a fabricated catalytic converter prototype. Quantitatively, the fabricated MnO₂–CeO₂ coated prototype demonstrated a 43% reduction in CO, 47% reduction in HC, 27% reduction in NOx, and 41% reduction in PM during low-temperature exhaust testing (150 – 400 °C) during testing on a 1.5 L diesel engine. The results were based on repeated experimental runs using an uncoated substrate as baseline. The work also focuses on material accessibility and environmental sustainability by using non-noble, widely available metal oxides. The hypothesis of this study is that a MnO₂–CeO₂ catalyst synthesized via co-precipitation can deliver meaningful low-temperature oxidation performance at significantly lower cost compared to PGM-based DOCs. Thus, the project contributes a significant step toward developing more accessible and sustainable emission control technologies for the automotive industry.
C, Jegadheesan, T, Karthi, Rajendran, Pawan, Muruganantham, Kowshiik, S, Vaitheeshwaran
A New Approach Enabling Intuitive Robotic Helpers for Household, Workplace, and Warehouse settingsTBMG-545452/1/2026
For a robot, the real world is a lot to take in. Making sense of every data point in a scene can take a huge amount of computational effort and time. Using that information to then decide how to best help a human is an even thornier exercise.
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