Browse Topic: Parts and Components

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Experimental Validation of a Multi-Row Tapered Roller Bearing Analytical Model for Relating Preload to Frequency Response Characteristics2026-01-0008To be published on 04/07/2026
Roller bearings are used in many rotating power transmission systems in the automotive industry. During the assembly process of the power transmission system, some types of roller bearings (e.g., tapered roller bearings) require a compressive preload force. Those bearings' rolling resistance and lifespan strongly depend on the preload set during the installation process. Therefore, accurate setting of the preload can improve bearing efficiency, increase bearing lifespan and reduce maintenance costs over the life of the vehicle. 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. An open problem is experimental validation of the multi-row tapered roller bearing analytical model. After validation, the analytical model can be used to predict the assembled system damped natural frequency for a desired bearing preload. This work presents the experimental
Gruzwalski, David, Mynderse, James
Analyzing Fastened Joints in Hydraulic Dampers using Simulation and Experimental Methods2026-01-0585To be published on 04/07/2026
The main purpose of this study is to develop and validate an accurate calculation model for an unorthodox hydraulic damper piston joint, enabling reliable torque specification and clamp behavior without full prototype iteration. The joint features a bolted interface with a laminated shim stack of many thin disks with varying outer diameters. Analysis of such unorthodox joints are uncommon in literature, making the effects of load distribution truncation in the member stack due to varying outer diameters and surface contact effects between thin members during compression and torquing difficult to quantify. The model discussed in this paper is based on frustum load distribution combined with annular-plate bending and elastic-foundation effects to capture the effects of washer cupping. Concrete outputs of the calculator include member load distribution, bolt and member stiffnesses, torque-to-preload relationships, including friction factors and a variable effective-bearing-diameter, and
Dresen, Gabriel S., Vollmar, Race, Roy Chowdhury, Sourav
Experimental Study on Macroscopic Characteristics of Ammonia Spray under Flash Boiling and Non-Flash Boiling Conditions with Large-Diameter single-hole Nozzles2026-01-0339To be published on 04/07/2026
Ammonia is regarded as a potential alternative fuel, and its spray characteristics are crucial for efficient combustion in engines. For large-bore engines suitable for heavy-duty vehicles or ships, the adoption of large-diameter nozzles is expected to ensure an appropriate fuel flow rate while improving fuel-air mixing efficiency, thereby enhancing in-cylinder combustion performance. This paper conducted an experimental study on the characteristics of liquid ammonia sprays under wide thermodynamic conditions, a wide range of injection pressures, and a wide range of nozzle diameters. The study found that at room temperature, as the ambient pressure increases from 0.1 MPa to 4 MPa, the development of spray penetration slows down. However, at 0.05 MPa, the radial expansion of the near-field spray is greater, and the penetration is slightly behind that at 0.1 MPa. The liquid penetration increases with the increase in ambient temperature. This was because the increase in temperature reduced
Liu, Yi, Zhong, Jie, Hu, Yuchen, Zhu, Wuzhe, yunliang, Qi, QINGCHU, CHEN, Wang, Zhi
Vibration Modeling and Analysis of Pipeline- Clamped Systems for Aircraft Landing Gear2026-01-0215To be published on 04/07/2026
Fluid pulsation within the aircraft landing gear hydraulic pipeline system can lead to severe damage to system structures such as valves, joints, and supports. Previous research has predominantly focused on investigating the vibration characteristics of the pipelines themselves, often neglecting the frequency-dependent characteristics of clamps. For the dynamic modeling of clamped pipeline systems, accurately obtaining the dynamic response of the clamps is of significant importance.This study establishes the vibration differential equations for the hydraulic pipe-clamp rigid-flexible coupling nonlinear system. The frequency-dependent dynamic properties of flexible clamps are considered based on fractional derivative theory, and the parameters of the clamp's dynamic model are identified using a genetic algorithm. Taking into account the flexible constraint of the clamps, a fluid-structure interaction frequency-domain solution method for the hydraulic pipeline-clamp system is
chang, Hailin, Zhu, Hengjia
Noninvasive Loss Breakdown of an Electric Drive Unit2026-01-0448To be published on 04/07/2026
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 from these components. Additionally, this approach does not separate the winding, core, and mechanical losses present in the electric 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
Woods, Tyler, Gross, Michael, Drallmeier, Joseph
Development of A Tire Blowout Experimental Platform for Dynamics and Control Validation2026-01-0202To be published on 04/07/2026
Tires are critical to vehicle dynamics, transmitting traction, braking, and cornering forces to the road. A tire blowout, the sudden and rapid loss of inflation pressure due to puncture or structural failure, can cause severe instability, rollover, or collisions. Understanding vehicle response during blowout events is essential for developing robust safety systems and control strategies. Earlier developed simulation models are used to study and understand vehicle behavior during blowouts, but there is a lack of on-road testing platforms to validate these models experimentally. A custom-built blowout device integrated with a data acquisition system has been developed to address this gap. It consists of multiple solenoid valves mounted on the wheel surface and powered by a 12V supply. All valves are triggered at the same time using an RF remote, producing rapid and synchronized deflation. An Arduino-based actuation system is being developed for individual valve actuation and custom
KANTHALA, Maha Vishnu Vardhan Reddy, Krishnakumar, Ashwin, Lin, Wen-Chiao, Chen, Yan
A Novel Spot Joint Element for Fatigue Evaluation of Spot Welds and Fasteners in Lightweight Automotive Structures2026-01-0182To be published on 04/07/2026
Due to the spot weld and mechanical fastener share the similar characteristics to join sheets together with only differences in deformation behavior around joint region, a novel spot joint element (user-defined element) consists of regular Mindlin shell elements and equations for different kinematic constraints is proposed to simplify the spot joint representation in lightweight automotive structures. The novel spot joint element can not only provide accurate deformation behavior around joint region but also output mesh-insensitive structural stresses at virtual nodes with the use of traction-based structural stress method for fatigue failure analysis. In this investigation, the structural stress distributions around joint peripheral in the lap-shear specimens with spot weld or fastener are first calculated to validate the accuracy of the novel spot joint element. Then, the structural stresses along different cross-sections emanating from joint are also calculated for the specimens
Wu, Shengjia, Zhang, Lunyu, Dong, Pingsha
Design and validation of modern hydrogen and natural gas containers for on board vehicle storage2026-01-0188To be published on 04/07/2026
Ensuring the operational safety of gaseous fuel containers for hydrogen and natural gas vehicles requires robust and validated protective devices capable of responding reliably under diverse operating and accident scenarios. This paper presents the design considerations, test methodology, and validation outcomes for safety subsystems integrated into modern compressed gas storage vessels, with emphasis on pressure relief devices (PRDs), thermal protection systems, and valve assemblies. Drawing on experimental insights from previous studies of hydrogen and natural gas fueling systems and fire-resistance assessments, the work defines safety-critical conditions such as rapid temperature rise during bonfire exposure, localized flame impingement, over-pressurization from fast filling, and mixed-gas operation. A comprehensive validation protocol was established, combining standardized regulatory tests with additional stress profiles replicating service-realistic environments. These included
Flekiewicz, Marek, Flekiewicz, Wojciech
Novel Air System for 300 kW Heavy Duty Fuel Cell2026-01-0434To be published on 04/07/2026
Hydrogen fuel cell powered vehicles for heavy duty trucks is a potential path for reducing heavy duty vehicle emissions in the future. The air handling system delivers the proper amount of air (oxygen) to react with fuel (hydrogen) in the fuel cell to produce power. Air delivery requires significant power and is the largest parasitic loss for a 300 kW fuel cell. Today’s systems use an electric motor to power an air compressor that supplies oxygen to the fuel cell stack. In addition to parasitic power loss, hydrogen fuel cell systems often have reliability issues associated with the air handling system. Reliability is of significant concern for heavy duty applications (especially long-haul applications). This project aims to improve both the electrical power consumption and reliability of hydrogen fuel cell air handling systems to meet the needs of heavy duty on-highway vehicle applications. The air handling is provided by a twin vortices series (TVS) compressor in addition to adding a
Reich, Evan, Swartzlander, Matthew, Wine, Jonathan, McCarthy, James, Miller, Eric, Akhtar, Saad, Reddy, Sharan, Lawy, TJ
Design Optimization and Dimensional Tolerance Improvement of Expanded Polypropylene (EPP) for Enhanced Automotive System Integration2026-01-0248To be published on 04/07/2026
Historically, EPP has required larger dimensional tolerances and much thicker cross-sections than solid plastics produced by injection molding, vacuum forming, and blow molding. This has proved challenging when attempting to incorporate EPP into a wider variety of automotive applications. JSP has developed multiple grades of EPP that achieve tolerances at thinner cross-sections, once considered difficult to attain. These grades expand the potential for automotive applications by combining the established benefits of EPP with improved dimensional precision. This tighter control enables advances in part design and performance, including reduced wall thicknesses, improved surface appearance, reduced weight, lower cost, part consolidation, and more efficient molding with an improved processing window, resulting in faster cycle times and reduced utility consumption. At the vehicle level, these improvements contribute to lighter overall weight for reduced carbon footprint, as well as
Sopher, Steven, Parker, Joshua
Analysis of Failure Causes and Optimisation of Automotive Cycloidal Rotor Pumps2026-01-0184To be published on 04/07/2026
Cycloidal rotor pumps are widely employed in automotive and aerospace industries due to their compact structure, high volumetric efficiency, and minimal flow pulsation. With the advancement of new energy vehicles, rotor pumps are increasingly required to operate reliably under more demanding conditions, including higher rotational speeds, elevated pressures, and more severe operating environments. These requirements place greater emphasis on pump durability and structural integrity. This study investigates a fracture failure of the internal rotor observed during bench testing of a cycloidal rotor pump. Metallographic and physicochemical analyses were conducted on the failed rotor. The results indicated that the fracture was not attributable to material defects. Instead, the failure originated from improperly designed slot locations within the rotor, which created a structural weak point at the slot opening. Additionally, sharp corners introduced during machining of the slots resulted
Li, Meng, Xie, JIa, Qin, Gongyu, Yang, Hanming, Wang, Liangmo
Enhanced CAE Methodology to Predict Bolt Shear Failure using Multi-Layer Approach2026-01-0489To be published on 04/07/2026
Automotive seat system is one of the most complex systems in vehicle for its technical and functional requirements. Seat is designed to meet all regulatory requirements subjecting it to multiple tests with loading patterns which caters to the occupant safety. Varied loading and load path for different test requirements cause seat bolts to experience tensile, compressive, bending moments and shear loading. Shearing along bolt length is one of the common failure modes observed during design validation by physical tests. In the world of CAE, there is an industry approach to find the bolt failures at nut and head for all kind of loads. But shear failures along bolt lengths are not accurately predictable as multiple sheet metal parts will transfer loads unevenly onto bolt length and it becomes challenge to find which component is leading to shear failure. Hence by adding multiple rupture layers across the bolt length shear and its location could be predicted. Further, to resolve the bolt
RJ, Jethendra, Chiu PhD, Li-Ban
A decision-making framework for field manufacturability of vehicle parts in expeditionary environments2026-01-0143To be published on 04/07/2026
Expeditionary environments (such as remote exploration missions, forward military operations, and disaster response zones) demand adaptive manufacturing solutions to support vehicle sustainment in the absence of traditional supply chains. This work introduces a conceptual mathematical framework for modeling the constraints and trade-offs inherent to expeditionary manufacturing, with a focus on vehicle repair and spare parts fabrication using low-energy and simple automated systems including desktop-scale 3D printers and CNC machines. The model integrates key variables such as energy availability, material transport cost, fabrication time, and environmental limitations to support rapid decision-making on part manufacturability and in-field feasibility. A case study involving the on-demand production of some common wear and failure parts on a vehicle, including suspension components and the water pump, is used to demonstrate how this framework can guide the selection of suitable
Mollan, Calahan, Pandey, Vijitashwa, Patterson, Albert E.
Understanding the Effects of Process Parameters on the Dispense Uniformity of Elastomeric Silicone Coating Material for Automotive Manufacturing.2026-01-0239To be published on 04/07/2026
As electric vehicle (EV) manufacturing scales, innovative approaches have been evolving for battery fire protection materials to mitigate thermal runaway hazards, including fire and blast protective coatings. These materials often exhibit high-viscosity and must be deposited with uniform thickness and stable geometry to ensure reliable thermal barriers and battery pack integration. In practice, coating uniformity (uniform thickness, edge fidelity, and minimal sag/run prior to cure) is highly sensitive to dispense conditions, including nozzle slot width, nozzle length, effective dispense height (stand‑off), nozzle sweep speed, and volumetric dispense rate. Establishing robust process understanding early is therefore essential to avoid start‑up scrap, rework, and variability downstream. This paper presents a combined computational and experimental methodology to optimize and de‑risk dispensing of elastomeric battery fire protection (BFP) coatings. We develop a physics‑informed modeling
Hossain, Arif, Repollet Pedrosa, Milton H., Norquest, Kade, Mcmichael, Jonathan, Ng, Sze-Sze, Aradhyula, Pranavi, Thomas, Ryan, Gorin, Craig, Dietsche, Laura, Kenney, James A.
Effect of renewable fuel blends on particulate emissions in warm-up conditions in a GDI engine2026-01-0304To be published on 04/07/2026
Renewable gasoline offers significant benefits in reducing greenhouse gas (GHG) emissions. In this study, five gasolines with different renewable hydrocarbon classes and varying distillation curves were taken to investigate their effect on particle number (PN) emissions in a spark-ignition GDI engine at 10 bar indicated mean effective pressure (IMEP) and 2000 rpm. The engine coolant temperature was varied from 90°C to 35°C to investigate the effect of fuel evaporation on soot formation. Injectors with various spray plume targets and start of injection (SOI) timing (300° and 260° bTDC) were used to assess how different gasolines affect engine performance and to determine engine calibration requirements. A simplified transient cycle examines how engine motoring influences PN emissions for test gasolines. A high-speed camera and endoscope were used to identify the sources of soot during fuel combustion. Simulations were done to assess the quality of fuel-air mixing in support of the
Muniappan, Krishnamoorthi, Dahlander, Petter, Helmantel, Ayolt, Alemahdi, Nika, Lehto, Kalle
Implementation and evaluation of a method to defend in-vehicle networks using SAE J1939-91C to authenticate network messages between multiple ECUs.2026-01-0092To be published on 04/07/2026
The objective of this paper is to understand the effort required to integrate the hardware and software of in-vehicle cybersecurity systems. The in-vehicle cybersecurity method discussed is the SAE J1939-91C, which involves Network formation, Rekeying, and secure Message Exchange between Electronic Control Units (ECUs). The SAE J1939-91C network security protocol operates over a CAN-FD network to perform necessary cryptographic operations and key generation. To evaluate the method, test vectors were created to validate SAE J1939-91C key generations and cryptographic operations on the simulated ECU in-vehicle network system hardware. The evaluation results provide a benchmark for network system performance that can be used in a system test bench to assess compliance with the SAE J1939-91C standard and to test the standard's effectiveness in ambiguous edge cases. In the future, this benchmark could be utilized in "Plugtests" to assign test scores to non-uniform SAE J1939-91C
Zachos, Mark, Medam, Krishna Teja
Development and Preliminary Combustion Experiments of a Prototype Engine with Sleeve Valves Based on the Focusing Compression Principle2026-01-0295To be published on 04/07/2026
Our laboratory has proposed the focusing compression principle which employs pulsed super-multi jets of gas colliding around the chamber center. This principle aims to achieve high thermal efficiency by reducing both exhaust and cooling losses. Exhaust loss is minimized due to relatively-silent high compression. Cooling loss is reduced due to thermal insulation caused by fuel-air mixture being confined to the chamber center and the compressible flow effect. In previous studies, we conducted fundamental gasoline combustion experiments on a proof-of-concept opposed-piston engine which incorporated this principle. This engine featured eight intake nozzles in an octagonal configuration and utilized non-sinusoidal and strongly asymmetric piston movements. The results indicated the possibility of high thermal efficiency based on less knocking under high compression, and the potential for stable combustion under lean-burn conditions. As a next step towards practical application with
NISHIZAWA, Tomohiko, Naitoh, Ken, baba, Shotaro, Ukegawa, Hiraku, Yamada, Sota, Ozono, Yuka, Abiko, Mirei, Suzuki, Yosuke, Hara, Namito, Ito, Yoshikuni, Matsubara, Kosaku, Uenoyama, Kazuyuki
Efficient Embedded Control of Nonlinear Systems for Software-Defined Vehicles: A Case Study Using the Inverted Pendulum2026-01-0075To be published on 04/07/2026
Software-defined vehicles (SDVs) are reshaping automotive control architectures by shifting intelligence to embedded systems, where computational efficiency is paramount. This paper presents the implementation of multiple control strategies such as PID, LQR, and MPC for the inverted pendulum on a cart problem, a canonical example of nonlinear and unstable system control. The objective is to demonstrate how sophisticated control algorithms can be optimized for execution on microcontrollers with limited processing power and memory, reflecting the constraints typical of embedded platforms in SDVs. Each control strategy is implemented with careful consideration of algorithmic complexity, real-time responsiveness, and resource utilization. Performance is evaluated across key metrics including stability, convergence time, and computational load, enabling a comparative analysis that highlights trade-offs between control fidelity and hardware efficiency. The results provide actionable insights
Vupparige, Varun, Pandya, Vidit
Elucidation of Flow Mechanisms Modulating Vehicle Wind Noise by using Large-Scale CFD Simulation2026-01-0614To be published on 04/07/2026
In vehicle development, noise reduction is critical for ensuring passenger comfort. As electric vehicles become prevalent and engine noise is minimized, wind noise becomes more noticeable. Modulated wind noise, which causes a sense of fluctuation due to atmospheric turbulence, wind gusts, and preceding vehicle wakes, causes significant discomfort. This noise is characterized as a high-frequency sound above 1 kHz, modulated at low frequencies owing to the wind velocity and direction fluctuating at several Hz. However, the mechanisms behind wind noise modulation are not fully understood, and no established countermeasures have been developed. This is because wind noise perceived through the side window is primarily caused by the A-pillar vortex and door mirror wake, which coexist as complex turbulent flows around the vehicle. Therefore, identifying the source of modulated wind noise around vehicles under fluctuating wind conditions is difficult. This study aims to identify the source of
Tajima, Atsushi, Hirata, Takumi, Ikeda, Jun, Kamiwaki, Takahiro, Wakamatsu, Junichi, Tsubokura, Makoto
Bearing Fault Diagnosis Method Based on Optimized VMD and Deep Timing Fusion2026-01-0158To be published on 04/07/2026
In the current field of rolling bearing fault diagnosis, two critical challenges persist. First, it is difficult to effectively extract fault features from nonlinear and non-stationary vibration signals. Second, precise diagnosis remains a challenge, especially when distinguishing between different fault types and capturing incipient faults with weak characteristic information. To address these issues, this paper proposes a novel fault diagnosis method based on adaptively optimized Variational Mode Decomposition (VMD) and Deep Temporal Fusion. First, the method improves the traditional Sparrow Search Algorithm (SSA). It enhances SSA’s global optimization capability through strategies like chaotic population initialization and adaptive perturbation. This improved SSA enables efficient global optimization of VMD’s key parameters. Leveraging these optimized parameters, the method decomposes modal signal components with different center frequencies from the vibration signal. This process
Wen, Chao, Zhong, Hong, Wang, Liangmo, Chen, Yong, Gao, Qiang, Li, Yong
The Impact of Fuel Injector Deposits on Fuel Consumption: Correlations & Consequences for Modern Compression Ignition Engines2026-01-0343To be published on 04/07/2026
Fuel injector cleanliness has been identified in the literature as the key factor for maintaining performance in modern compression ignition engines. Fuel injector nozzle deposits have been shown to restrict the mass of fuel that can be injected, resulting in power loss under full load. Several published studies have also investigated changes in fuel economy brought about from fuel injector nozzle deposits, but the majority of these have failed to demonstrate an unambiguous link between fuel economy and fuel injector nozzle deposits. In this paper, we present previously unpublished data from multiple platforms, including light- and heavy-duty, and from vehicle and stationary engine tests, with each showing a strong link between the formation of fuel injector nozzle deposits and associated losses in full-load power and increased brake specific fuel consumption (BSFC). A requirement for a tractable method is that it should be short enough to economically enable multiple repeats to
Smith, Alastair
CAE Acceleration With Machine Learning For Results Prediction2026-01-0488To be published on 04/07/2026
Industries are following a tedious product development cycle for developing their product. In product development major steps includes design ideas, Drawings, CAD, CAE, Testing and design improvement cycle. This is a monotonous process and takes time which impacts on its time to deliver product and cost on development. Now a days industries are fast growing and targeting to reduce development cycle time and cost. AIML is impacting almost all areas in the industry and significantly reducing efforts time and cost. To make use of AIML in CAE, Altair Physics AI is an effective tool. To ensure the design of product traditional way is to develop a CAD of the product, develop, perform CAE and analyze performance. If we consider CAE procedure it is time consuming process which includes FEA model build, applying boundary conditions, running simulation and analyzing results which could take minutes to hours. By using ML with Physics AI we can make predictions on new design of the product in
Dangare, Anand Manohar, Kulkarni, Mandar
Innovation Powered by High-Fidelity Multiphysics Modeling: A Holistic System Optimization of BorgWarner’s Next Generation Integrated Drive Modules2026-01-0497To be published on 04/07/2026
In the stringent market of BEV, the development of integrated Drive Modules (iDM) fitting to environmental and customer needs is mandatory. It is important to extract the best from the less. To achieve those goals, a deep insight of complex multiphysics phenomena occurring in an iDM has been achieved by accurate and validated models. This engineering methodology is applied through the development of BorgWarner products, comprising non-exhaustively iDM 180-HF, Externally Excited Synchronous Machine and Multi-Level Inverter. The paper will review the methodology development for deeper understanding involving in-house technical excellence and complemented by strategic partnerships with academic institutions and start-ups. It will present the approach of integrating advanced multiphysics models with high-quality experimental validations, specifically on loss evaluation on electrical machines and inverters. Complex models involving multiphysics such as thermal/fluid coupling or electric
Leblay PhD, Arnaud, Bossi, Adrien, Bourniche, Eric, DAVID, Pascal, Nanjundaswamy, Harsha
A Helical Compression Spring Fracture under Impact Velocity in Pump Operation by Theoretical Study and FEA2026-01-0271To be published on 04/07/2026
Helical compression springs have been used widely in various industries from automotive, aerospace and heavy-duty industries to electronics and medical devices. In the automotive industry, they appear in many places such as suspension, valvetrain, etc., especially in the discharge check valve of Gasoline Direct Injection (GDI) pump, which is the subject of study due to a recent fracture in lab testing. A theoretical study is conducted first to establish equation governing spring dynamic motion under impact velocity, which can be in high magnitude with surging shock wave along spring axis. A new spring shock wave equation is developed for spring axial motion coupled with coil torsional effect. This newly derived shock wave equation has a broad term than the classic spring formula found in engineering book. In the paper, it proves that the classic spring shock wave equation is only a special case for the new general wave equation discovered. Also, a formula on spring shock wave
Pang, Michael L., GUNTURU, SRINU, Norkin, Eugene
Defect Depth Characterization via Thermally and Pneumatically Induced Shearography for Nondestructive Component Inspection in the Automotive Sector2026-01-0205To be published on 04/07/2026
The following approach introduces a novel method for defect depth characterization using digital Shearography, which is a non-contact, full-field, and material-independent optical interferometric method that enables fast and nondestructive testing (NDT) of components, especially in industrial environments such as the automotive sector. While traditional techniques like computed-tomography, ultrasonic-testing, or thermography can offer depth approximations but they often involve high costs, longer testing times, or limited accessibility. In contrast, the method introduced utilizes various excitation methods in combination with shearographic evaluation to derive procedures for depth estimation of subsurface defects. Recent developments in Shearography have enhanced the method’s robustness and industrial applicability. By detecting the surface deformation behavior in the nanometer range under defined loading, depth-related characteristics of hidden defects can be extracted. Loading can be
Bastgen, Valentin, Plaßmann, Jessica, Petry, Christopher, von Freymann, Georg, Schuth, Michael
ProGuard: A Real-time Preemptive Artificial Intelligence-Based Anti-Pinch System for Bus Entryways on Low-Power Edge Devices2026-01-0100To be published on 04/07/2026
This paper proposes ProGuard, a novel approach to preemptive pinch detection systems for buses. ProGuard utilizes state-of-the-art AI object detection algorithms to identify potential pinching events in bus entryways before pinching occurs. Modern conventional anti-pinch systems, such as pressure sensors or hall effect sensors, often rely on mechanical contact before triggering. While these systems are established safety mechanisms, they are reactive and therefore require some level of pinching before triggering. This reactive approach presents numerous safety concerns for passengers, especially when considering children on school buses. Existing preemptive detection methods, such as infrared or ultrasonic sensors, solve the problems presented by these reactive detection systems. However, these systems either lack the range or environmental resilience needed for reliable operation in buses. The critical nature of anti-pinch systems requires a robust and reliable solution that can adapt
Bradley, Hudson, Zadeh, Mehrdad, TAN, Teik-Khoon
Design and Performance Evaluation of a Dust Contamination Simulation Test Apparatus for Automotive Cameras2026-01-0059To be published on 04/07/2026
In the era of Software-Defined Vehicles (SDVs), sensor integration has become increasingly prevalent, enabling advanced features such as autonomous driving and driver assistance systems. However, contamination from road dust and muddy water poses significant risks to the performance of vehicle camera sensors. Manual methods of applying dust for testing sensor durability are subject to inconsistencies and human error, potentially undermining the validity of test results. To address this, we developed an automated dust deposition apparatus specifically designed for automotive camera systems. This device enables precise and repeatable control over dust application, thereby enhancing the reliability and efficiency of the testing process. The dust contamination simulation apparatus leverages programmable parameters to consistently reproduce various environmental scenarios encountered in real-world driving conditions. Performance evaluations demonstrated that the system achieves uniform dust
Jinhyeok, Gong
Optimization of Lightweight Gear Blanks to Improve NVH for an Electric Drive Unit2026-01-0001To be published on 04/07/2026
A single-speed electric drive unit (eDU) with multi-stage reduction can have high gear whine due to high pitch-line velocity in the absence of engine masking noise. A comprehensive investigation is conducted focusing on the optimization of the first-stage transfer gear blanks to improve NVH performance and reduce mass for EV applications. A multibody dynamic model of the eDU was constructed, incorporating asymmetric gear blank geometry, shaft elasticity, bearing stiffness, and housing flexibility, in order to characterize realistic operating conditions and simulate gear contact mechanics with high fidelity and computational efficiency. NVH excitation sources, including static transmission error and dynamic meshing force, were systematically evaluated for solid and slotted gear configurations. Based on a DOE optimization study, an 8-slot gear blank design is selected to balance mass reduction, stress, NVH, and manufacturing requirements. Micro-geometry optimization was conducted for the
He, Song, Du, Isaac, Li, Bo, Bahk, Cheonjae, Grguras, Zachary, Baladhandapani, Dhanasekar, Patruni, Pavan Kumar
CFD-Based Investigation of Fuel Tank Sloshing: Crash Safety and Noise Concerns2026-01-0490To be published on 04/07/2026
A computational study using the Volume of Fluid (VOF) method in SimericsMP+ was conducted to investigate fuel sloshing in automotive fuel tanks under both crash and sudden stop conditions. The SEALs method was employed to rapidly generate the fuel tank mesh, enabling efficient simulation setup. At the outset, a benchmark sloshing case was simulated and compared against experimental data, showing excellent agreement to validate the simulation method. This simulation method was then applied to the fuel tank sloshing scenarios mimicking crash and sudden stop conditions. The study initially focused on a crash scenario where fuel waves impact valves, pumps, and other internal structures. Capturing these localized impact forces is critical for evaluating the risk of component failure and potential leakage. A baffle-equipped tank was simulated and compared with sensor data. Results show that the computed shock forces on valves and baffles closely matched the measurements, demonstrating the
Jia, Kun, Rahman, Ashique
Prediction of Pressure Pulsation in Brake Line Considering Wave Propagation Characteristics of Fluid Contained in Flexible Hose for Automotive Hydraulic Brake System2026-01-0225To be published on 04/07/2026
Brake pulsation noise caused by fluid-borne vibration, which is generated by pressure pulsations from the pump in the Electronic Stability Control (ESC) modulator, occurs when the control brake function is activated under various driving conditions, such as Adaptive Cruise Control (ACC) and regenerative-friction brake coordination. This noise is particularly noticeable in Battery Electric Vehicles (BEVs), where the background noise from the power source is lower than that of internal combustion engine vehicles. The simulation of pressure pulsations in the brake system requires the excitation force of the pump built into the ESC modulator, the characteristics of valves, and the characteristics of the flexible hose; however, it is extremely difficult to determine these parameters with high accuracy from the design specifications. For this reason, in this study, the pump and valves were experimentally identified, while the flexible hose was represented by a three-element Voigt model to
Koike, Yohei, Komada, Masashi, Yano, Masahiro, Yoshioka, Nobuhiko
Multi-Physics Topology Optimization and Machine Learning Surrogates for Lightweight Cast Automotive Parts2026-01-0510To be published on 04/07/2026
This paper proposes an integrated optimization framework for lightweight cast vehicle structures by combining Multi-Physics Topology Optimization (MPTO) with machine learning (ML)-driven surrogate modeling. Conventional structural optimization approaches often rely on simplified load cases—such as 3 g inertial loading, frame torsion, or bending—rather than capturing the true complexity of performance-critical conditions like crashworthiness and fatigue durability. As a result, designs optimized for a single criterion frequently degrade in other performance areas, leading to costly redesigns or over-engineered solutions. The proposed methodology introduces MPTO through four structured steps that progressively build design fidelity. Step 1 establishes a baseline primitive topology optimization workflow using a standardized package checklist, ensuring that the design domain, boundary conditions, constraints, and key manufacturing rules are consistently defined as the foundation for
Kim, Hyosig, Senkowski, Andres, Gona, Kiran, Saroha, Lalit, Boraiah, Mahesh
CFD Investigation of Oil Ingestion and Aeration in a V6 Engine Oil Pan During Vehicle Maneuvers2026-01-0279To be published on 04/07/2026
A computational investigation was carried out using SimericsMP+ to analyze oil distribution and aeration behavior in a V6 engine oil pan during severe vehicle maneuvers. The model accounted for the crankshaft/camshaft rotations and piston motions, which allows for capturing realistic oil distribution in cylinder head drainbacks, engine bay and sump after initializing the crankcase with prescribed oil levels to establish baseline aeration prior to applying dynamic maneuver profiles. Of particular interest was the response of the main oil gallery (MOG) pressure and the exposure of the oil pickup tube during kickoff conditions at multiple fill levels. Both a baseline configuration and a modified sump featuring a containment “doghouse” were examined. Results obtained from the kickoff maneuver show complete uncovering of the pickup tube in the baseline design, leading to unstable lubrication. The first doghouse design only delayed pickup tube uncovering briefly, as oil pooled at the rear
Jia, Kun, Rahman, Ashique, Pandey, Ashutosh
Multi-stage Packaging and Routing Optimization for Automotive Component Layout, Wire Harness and Duct Route Design2026-01-0507To be published on 04/07/2026
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-star path-finding algorithm and gradient based optimization to determine the optimal route layout between port
LeFrancois, Richard, Kim, Il Yong
In-situ Decoupling and Stiffness Optimization of Resiliently Coupled Assemblies Using FRF-Based Substructuring2026-01-0227To be published on 04/07/2026
Road shake remains one of the most critical NVH challenges in light- and heavy-duty body-on-frame trucks, directly shaping ride comfort and perceived vehicle quality. At the heart of this issue are the body mounts, which govern the transfer of vibration between frame and body. Optimizing these mounts for improved road shake performance is therefore a key objective in NVH engineering. Traditionally, such optimization has relied on finite element analysis (FEA). While highly accurate, FEA—especially when performed with commercial solvers such as NASTRAN—demands enormous computational resources, with complete simulations often requiring hundreds of hours. Each design iteration multiplies this cost, restricting the pace and efficiency of NVH development. Recent methods such as response surface modeling (RSM) and machine learning (ML) have aimed to reduce the burden, yet they remain dependent on large libraries of pre-computed FEA data, inheriting much of the same expense and inflexibility
Haider, Syed, Abbas, Ahmad, Jahangir, Yawar, Maddali, Ramakanth
Predictive Maintenance of EV Drive Unit Oil Pumps via Machine Learning on Fleet Telemetry2026-01-0161To be published on 04/07/2026
The reliability of Drive Unit (DU) oil pumps is critical to the performance and safety of electric vehicles, as these pumps provide essential lubrication and thermal management. However, direct physical sensors for real-time pump health monitoring are absent in current architectures, making early fault detection particularly challenging. To address this limitation, we present a novel, data-driven anomaly detection framework that leverages large-scale customer fleet telemetry and advanced machine learning to identify incipient pump degradation that traditional diagnostic methods often fail to capture. The core of the approach is an XGBoost regression model trained on time-series features—including commanded pump speed, oil temperature, and historical pump current—to predict expected current behavior under nominal conditions. Deviations are quantified using the Mean Absolute Percentage Error (MAPE) between predicted and actual currents, providing a continuous and interpretable measure of
Li, Jingman, Yao, Mengqi, Rahimi, Sahil, Lin, Joanne
Methodology for Shower Water Management in Electric Car Applications2026-28-0068To be published on 02/12/2026
All automotive vehicles with enclosed compartments must pass the shower test standard - IS 11865 (2006). One of the most severe and critical areas of water leakage is “water entry into HVAC (heating, ventilation, and air conditioning) opening”. Excess water flow at high-pressure conditions and seepage during long-time low-pressure conditions could potentially have a significant impact on water entry inside the HVAC suction cutout given on BIW (body in white) and subsequently into the cabin. The present study clearly indicates that for making leak proof HVAC opening (suction interface), it is crucial for the structure of BIW plenum, plenum applique, and its sealing components to be robust enough to effectively collect and divert the water during rainy seasons.
Gunasekaran, Mohanraj, Namani, Prasad, Ramaraj, Rajasekar, Junankar, Ashish, Raju, Kumar
Quantum Meets Agile: Crypto-Agility for a Post-Quantum World2026-28-0127To be published on 02/12/2026
As the automotive industry transitions toward software-defined vehicles and highly connected ecosystems, cybersecurity is becoming a foundational design requirement. A challenge arises with the advent of quantum computing, which threatens the security of widely deployed cryptographic standards such as RSA and ECC. This paper addresses the need for quantum-resilient security architectures in the automotive domain by introducing a combined approach that leverages Post-Quantum Cryptography (PQC) and crypto-agility. Unlike conventional static cryptographic systems, our approach enables seamless integration and substitution of cryptographic algorithms as standards evolve. Central to this work is the role of Hardware Security Modules (HSMs), which provide secure, tamper-resistant environments for cryptographic operations within vehicles. We present how HSMs can evolve into crypto-agile, quantum-safe platforms capable of supporting both hybrid (RSA/ECC + PQC) and fully post-quantum
Kuntegowda, Jyothi
A Nature-Inspired Optimization Approach for Vienna Rectifier Control in EV Fast Charging Applications2026-28-0112To be published on 02/12/2026
The growing adoption of electric vehicles (EVs), particularly those utilizing High-Voltage battery systems, demands fast-charging infrastructure that ensures high efficiency and power quality. The proposed GJO algorithm is employed to optimize the control and switching parameters of the Vienna rectifier, thereby improving harmonic performance and conversion efficiency without altering the converter hardware. This paper focuses solely on control optimization of the Vienna rectifier topology and does not include DC–DC isolation or galvanic separation. Filter components are modeled with equivalent series resistance (ESR) to account for incremental losses. Simulation results demonstrate that the Golden Jackal optimization (GJO) based control reduces input current THD to 2.09%, has a power factor of 0.998, and achieves an efficiency of 98.53%, representing a fractional but consistent improvement over conventional control methods such as SSA, ALO, and PSO. These findings highlight the
R, Mohammed Abdullah, N, Kalaiarasi
Preliminary Design and Analysis of a Dual Throat Fluidic Thrust Vectoring Nozzle for Supersonic Aerospace Application2026-28-0106To be published on 02/12/2026
The Dual Throat Nozzle (DTN) is a unique nozzle configuration that enables fluidic thrust vectoring (FTV), improving aircraft maneuverability while reducing the mechanical complexity of traditional vectoring systems. In this study, a two-dimensional DTN was developed based on a validated NASA Langley model, incorporating a newly designed plenum geometry guided by area expansion ratio principles. Numerical simulations were carried out in ANSYS Fluent using a density-based, steady-state solver with the SST k–ω turbulence model to capture key compressible flow features such as shock waves, flow separation, and jet deflection. Secondary injection rates were determined using choked-flow relations, and a 12-case parametric study was conducted to analyze the effects of Nozzle Pressure Ratio (NPR), injection rate, and injection angle on thrust deflection and efficiency. The simulation results at NPR = 4 with 3% injection showed strong agreement with NASA experimental data, validating the
Suresh, Vignesh, M, Akash, Senthilkumar, Nikil, Sundararaj, Senthilkumar, A, Garry Kiristen, Singh, Swaraj
Virtual Development Kit (VDK) for Software Defined Vehicle2026-28-0120To be published on 02/12/2026
This paper examines the technological and architectural transformations critical for advancing Software-Defined Vehicles (SDVs), emphasizing the decoupling of hardware from software. It highlights the limitations of traditional development models and proposes modern architectural approaches, including MPU-based designs and virtualization techniques, to foster flexible and scalable software ecosystems. Central to this vision is the concept of a Virtual Development Kit (VDK), which enables the design, validation, and scaling of SDVs even before physical hardware is available. The VDK integrates hardware platform emulators, operating systems, software stacks, and middleware optimized for high-performance computing (HPC) environments, providing developers with tools for early-stage testing, debugging, and integration while minimizing dependence on physical prototypes. As the automotive industry increasingly relies on software-defined features as primary drivers of innovation and
Khan, Misbah Ullah, Gupta, Vishal
Research on Characterization Parameters for Engine Valve Clearance Based on Vibration Signals2026-01-50052/2/2026
To address mechanical faults caused by abnormal engine valve clearance, this study investigates the extraction methods of vibration signal feature parameters. A six-cylinder diesel engine test bench was established to collect cylinder head vibration signals under varying rotational speeds, torque loads, and valve clearance conditions. Four time–domain parameters, including peak-to-peak values, rectified average values, standard deviations, and root mean square amplitude, were extracted alongside the energy distribution of frequency bands obtained through wavelet packet decomposition. The correlations between these parameters and valve clearance states were systematically analyzed. The results demonstrated that all parameters exhibited significant increasing trends with elevated rotational speeds, whereas torque variations exerted minimal influence. Abnormal valve clearance induces significant amplitude increases in time–domain parameters. The energy within frequency bands 5–8 (6–12 kHz
Ji, Shaobo, Dong, Yiming, Yue, Yuanhang, Pan, Chi, Liao, Guoliang, Lu, Yueqi
STUD-STEPPED, 1.5 DIA ENGAGEMENT, .375-16 UNJC-3A MOD X .3125-24 UNJF-3A (UNS S66286)AS3490A (Current)1/31/2026
E-25 General Standards for Aerospace and Propulsion Systems
FITTING, ELBOW, 90°, PIPE, INTERNAL THREADAS4856B (Current)1/31/2026
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
HOSE ASSEMBLY, POLYTETRAFLUOROETHYLENE CRES BRAID REINFORCED, 400 °F, 5080 PSI FLARELESS, STRAIGHT TO 45° ELBOWAS5962C (Current)1/31/2026
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
FITTING END, BOLT CLUSTER FITTING, DOUBLE PORT, THROUGH, FLARELESSAS21935A (Current)1/31/2026
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
INSERT, SCREW THREAD, SHORT, SELF-LOCKING, KEY LOCKED, SELF-BROACHING KEYS, UNS S66286AS3651A (Current)1/31/2026
E-25 General Standards for Aerospace and Propulsion Systems
NUT, SELF LOCKING - DOUBLE HEXAGON, EXTENDED WASHER, UNS S66286, SILVER PLATED, UNJ THREADAS3477B (Current)1/30/2026
E-25 General Standards for Aerospace and Propulsion Systems
Aerospace Size Standard for O-RingsAS568F (Current)1/29/2026
This SAE Aerospace Standard (AS) specifies the inside diameters, cross-sections, tolerances, and size identification codes (dash numbers) for O-rings used in sealing applications and for straight thread tube fitting boss gaskets. The dimensions and tolerances specified in this standard are suitable for any elastomeric material provided that suitable tooling is available.
A-6C2 Seals Committee
NUT, SELF-LOCKING, DOUBLE HEXAGON, AMS5709 (UNS N07001), 180 KSIAS3291A (Current)1/28/2026
E-25 General Standards for Aerospace and Propulsion Systems
NUT, SELF-LOCKING, PLATE - 2 LUG, FLOATING, COUNTERBORED, UNS S66286AS3262B (Current)1/28/2026
E-25 General Standards for Aerospace and Propulsion Systems
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