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Platform Development of Fuel Cell Air Compressors and Turbine Expanders2025-01-8547To be published on 04/01/2025
Hydrogen fuel cell is one of paths to achieve carbon neutrality transportation. In the last two decades, significant improvements have been made in compactness, efficiency and durability of fuel cell systems. For heavy duty truck applications, a life span similar to heavy duty diesel engines is required. As a critical component in the fuel cell system, air compressors play an important role to meet fuel cell systems’ high efficiency and durability requirements. In this paper, a holistic approach has been taken to develop a series of airfoil bearing centrifugal compressors for a wide range of applications from forklift, passenger vehicles to commercial vehicles, and achieve high efficiency and durability of one million start-stops. In the new platform development, cooling circuit was optimized so that the external cooling air circuit for the rotor and air bearings is no longer needed, which resulted in 4% efficiency improvement. Hollow rotor structure was adopted to achieve lightweight
Wang, Qianzhen, Yuan, Xixin, Tao, Zhang, Feng, Jin Zeng, Wang, Juan, Xiao, Yong, Zhou, Lei, Xin, Jun
Technical Paper
Development of a new concept structure for 4-way electric headrest adjustment2025-01-8620To be published on 04/01/2025
In car seats, various adjustment mechanisms are provided to accommodate passengers of different body sizes, ensuring a comfortable posture. In premium vehicle models, customer convenience is further enhanced by enabling electric operation for these adjustments. Among these, electric headrest adjustment systems are increasingly being adopted in premium vehicle models. This paper discusses the development of a new 4-way (up/down/left/right) electric headrest concept that aims to improve cost competitiveness while addressing existing quality issues. The current headrest mechanism consists of an X-link structure, where a motor rotates the X-link around its axis to adjust the mechanism forward and backward. However, this design involves many components, resulting in high costs, and the tolerance caused by screw thread gaps at the center of the X-link makes quality assurance difficult. Additionally, the reliance on a lead screw for operation causes issues with play and load concentration. To
Yu, Sanguk
Technical Paper
A systematic review about heat shrink materials using nanomaterials for the automotive industry2025-01-8329To be published on 04/01/2025
Heat shrink polymer sleeves are a type of material used in various industries for their ability to contract and fit snugly around objects when heat is applied. These tubes are typically made from materials like polyolefin or fluoropolymers, which have the property of shrinking when heated. Nanomaterials present many applications and its usage is a remarkable tool aiming to improve many properties of materials. Then, many improvements including increase of performance and price reduction may be done due to its unique properties when nanomaterials are used into heat shrink polymer sleeves. This work presents a systematic review of the state of the art on heat-shrinkable materials for the automotive industry. As a methodology, articles from the last 10 years on the subject were selected. The keywords “heat shrink” AND “nanomaterial” AND “tubes OR sleeves” were used in three different databases. “Scopus”, “Web of Science” and “MDPI”. After using the keywords, articles only in English were
Kerche, Eduardo F., Polkowski, Rodrigo, Horiuchi, Lucas, Goncalves, Everaldo
Technical Paper
Applications of Advanced High-Strength Steels for Automotive Structures – Haulage Load body for EV2025-01-8219To be published on 04/01/2025
To develop a Light weight Load body structure for Electric haulage vehicle application without affecting strength & durability of the product. Conventional haulage Load body given for diesel vehicle application weight is approximately 20% of vehicle Kerb weight. Payload carried by customer does not get affected much. Electric vehicle Kerb weight is comparatively higher than diesel vehicle, due to battery packs & its mounting structures. So the payload carried by customer is getting affected. Hence Load body weight must be reduced to 10-15% of Kerb weight. By considering past field failure data, customer loading pattern, durability trials & CAE static structural analysis, light weight Load body is designed with optimized sections & HSS material. To delight the customers, Number of Floor cross members & sideboard pillars not reduced which is their first impression before buying any haulage vehicle. Multiple iterations & design failure mode effective analysis was done before finalizing
Lakshminarayanan, Karthik
Technical Paper
Thermal Simulation of Ball Bearing in Electric Drive Unit: A CFD Study Using Volume of Fluid and Mixed Timescale Coupled Conjugate Heat Transfer Analysis2025-01-8178To be published on 04/01/2025
The drive unit of electric vehicles is a complex system consisting of an electric motor and a gear train, which work together to provide the necessary power for vehicle propulsion. One essential component within this system is the ball bearing, which supports the rotating components such as gears and shafts. This study focuses on the thermal simulation of a ball bearing within the drive unit conducted using the Volume of Fluid (VOF) method coupled with mixed timescale Conjugate Heat Transfer (CHT) in Simerics-MP+ to reduce the computational time while ensuring accuracy in the analysis. The Computational Fluid Dynamics (CFD) approach considers the geometrical details and clearances of the inner race, outer race, cage, and ball within the ball bearing. By accounting for the relative motions between these components, it can accurately model the film formation of the lubricating oil and its impact on heat removal from the bearing. The simulations are conducted at two different shaft speeds
Ballani, Abhishek, Motin, Abdul, DHAR, Sujan, Ganamet, Alain, Maiti, Dipak, Ranganathan, Raj, Pandey, Ashutosh
Technical Paper
A Sensitivity Study of Frequency Response Method for Setting Bearing Preload Due to Uncontrollable Parameters2025-01-8520To be published on 04/01/2025
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. One open problem is the design of the production controller which relies on a detailed sensitivity study of the system frequency response to changes in the bearing and system design parameters. Recently, an analytical model was developed for multi-row tapered roller bearings
Gruzwalski, David, Mynderse, James
Technical Paper
Effects of Jet Caps on Hydrogen Piezoelectric Injectors for DI Applications: Experiments and 3D-CFD Simulations2025-01-8454To be published on 04/01/2025
The adoption of hydrogen as a sustainable replacement of fossil fuels is pushing the development of internal combustion engines to overcome the technical limitations related to its usage. Focusing on the crucial roles played by the fuel injector in a DI configuration, it must guarantee several targets such as the adequate delivery of hydrogen mass for the given operating condition and the proper mixture formation in the combustion chamber. To these aims, experimental campaigns and computational fluid dynamics simulations can be used as complementary tools to provide a deep understanding of the injector behavior and to drive design modifications in a quick and effective way. In the present work an outward opening piezoelectric injector purposely designed to be fueled with hydrogen is tested in a quiescent vessel on several operating conditions to evaluate its performance in terms of delivered mass flow and jet morphology using the Schlieren imaging technique. To highlight the
Pavan, Nicolò, Cicalese, Giuseppe, Gestri, Luca, Fontanesi, Stefano, Breda, Sebastiano, Mechi, Marco, Vongher, Sara, Postrioti, Lucio, Buitoni, Giacomo, Martino, Manuel
Technical Paper
Dynamic Tailgate Water Management Simulation Using Smoothed Particle Hydrodynamics2025-01-8625To be published on 04/01/2025
Tailgate opening can cause rain that has settled on its surfaces to run off onto the customer or into the rear load space, causing annoyance. Relatively small adjustments to tailgate seals and encapsulation can effectively mitigate these effects. However, these failure modes tend to be discovered relatively late in the design process as they, to date, need a representative physical system to test – including ensuring that materials used on the surface flow paths elicit the same liquid flow behaviours (i.e. contact angles and velocity) as the production vehicle surfaces. In this work we describe the development and validation of an early-stage simulation approach using a Smoothed Particle Hydrodynamics (SPH) Code (PreonLab). This includes its calibration against fundamental experiments to provide models for the flow of water over automotive surfaces and their subsequent application to a tailgate system simulation which includes fully-detailed surrounding vehicle geometry. This approach
Gaylard, Adrian Philip, Weatherhead, Duncan
Technical Paper
Light weight Haulage Load body for Sustainable Mobility applications2025-01-8216To be published on 04/01/2025
To develop a Light weight load body structure for Electric haulage vehicle application without affecting strength & durability of the product. Conventional haulage load body given for diesel vehicle application weight is approximately 20% of vehicle Kerb weight. Payload carried by customer does not get affected much. Electric vehicle Kerb weight is comparatively higher than diesel vehicle, due to battery packs & its mounting structures. So the payload carried by customer is getting affected. Hence load body weight must be reduced to 10-15% of Kerb weight. By considering past field failure data, customer loading pattern, durability trials & CAE static structural analysis, light weight load body is designed with optimized sections & HSS material. To delight the customers, Number of Floor cross members & sideboard pillars not reduced which is their first impression before buying any haulage vehicle. Multiple iterations & design failure mode effective analysis was done before finalizing
Lakshminarayanan, Karthik
Technical Paper
Research on the Gearshift Control in Dual Motor Hybrid System2025-01-8512To be published on 04/01/2025
This paper delineates a shift control approach for a dual motor structure incorporating a drum-type shift lever in a parallel mode, which can be approximately categorized into five stages. In the first stage, the torque of the dual motor and ICE engine is interchanged, and the engine side torque is reverted to zero within the capacity range, with the P3 motor compensating for the torque loss on the engine side. In the second stage, the VCU transmits a request for series connection to the PCM and dispatches a request for the ICE gear position to be in neutral to the PCM. The PCM enters the sequence for the transition from parallel to series and undertakes the action of unloading the C0 clutch torque. Once the C0 clutch torque is completely disengaged, the actual mode is fed back as parallel, and the actual engine gear position is fed back as neutral. In the third stage, upon the PCM's feedback of the actual series connection, the VCU internally conducts a CAN delay judgment and
Jing, Junchao, Liu, Yiqiang, li, Dongfei, Zuo, Botao, Huang, Weishan
Technical Paper
Electric Vehicle Drive Unit Power Losses and Efficiency Estimation: A Coupled 1D Analytical and 3D CFD Approach for High Fidelity Prediction2025-01-8522To be published on 04/01/2025
This study presents a sophisticated approach to accurately estimating the power losses in the electric vehicle drive unit (e-DU) through a combination of 1D analytical models and 3D computational fluid dynamics (CFD). Understanding and accurately estimating these power losses is crucial for enhancing efficiency and range of electric vehicle (EV). The primary focus is on the types of power losses attributable to mechanical contact friction and oil drag within components such as gear meshes, bearings, and seals. The research specifically examines different analytical models for quantifying power losses due to gear mesh contact and bearing friction. These models were validated against experimental test data, allowing for a comprehensive understanding of their accuracy across a range of operational parameters. Additionally, the impact of oil properties and oil jet flow rates on power losses related to gear and bearing drag was analyzed using analytical methods and correlated with CFD
Motin, Abdul, Ganamet, Alain
Technical Paper
Propulsion System Design of Cadillac Lyriq Electric Vehicle2025-01-8566To be published on 04/01/2025
The design and development of EVs and HEVs has become a growing issue recently due to concerns about pollution and dependence on non-renewable fossil fuels. Accordingly, General Motors (GM) has an evolving vehicle electrification plan over the past several decades and into the future to deliver low-cost and efficient EVs. The propulsion system of GM-Cadillac's first electric vehicle, the Lyriq, is designed to deliver significant improvements in both range and peak performance. Its propulsion system uses an optimized drive unit consisting of interior permanent magnet (IPM) motors and silicon traction inverters. The main objective of the drive unit design was to minimize energy loss and cost while maximizing hardware consolidation, range, performance, power density and scalability. Two IPM motors are designed with different stack lengths and number of stator turns, while keeping the rotor design and stator conductor profiles the same. The larger motor is used in rear-wheel drive (RWD
Momen, Faizul, Jensen, William, He, Song, Chowdhury, Mazharul, zahid, Ahsan, Forsyth, Alexander, Alam, Khorshed, Anwar, Mohammad, kim, Young
Technical Paper
Study of the Effects on Plain Bearings in Simulated Corrosion Tests Using Carbon neutral Fuels2025-01-8470To be published on 04/01/2025
Many countries around the world are currently working toward carbon neutrality, which would reduce greenhouse gas emissions to net zero by 2050. As part of our efforts to achieve carbon neutrality, we have developed low friction bearings that contribute to reduced fuel consumption, and high load capacity bearings for increased engine output and longer service life. Meanwhile, Countries around the world are also considering engines that use carbon-neutral (CN) fuels, such as hydrogen and e-fuel, as part of their efforts to achieve carbon neutrality. It was reported that CN fuels differ significantly from gasoline and diesel in the chemical composition of gases produced after combustion. In particular, hydrogen-fueled internal combustion engines generate more water during combustion than gasoline engines, and nitrogen oxides emissions (NOx) have also been observed under some combustion conditions. Dissolution of these substances in engine oil is expected to create a corrosive environment
Kondo, Makoto, Kawaura, Hiroki, Shiroya, Tomoyasu, Watanabe, Airi
Technical Paper
Hierarchical Feature-based Localization using Scene Graphs in Off-road Navigation2025-01-8046To be published on 04/01/2025
While numerous advancements have been made in autonomous navigation for structured indoor and outdoor environments, these solutions often do not generalize well to off-road settings. There are unique challenges in such settings such as unreliable GPS, limited computational and memory resources, and sparse environmental features, making navigation particularly difficult. In our work, we propose a novel data structure called Hierarchical Dynamic Scene Graphs (HDSG) to address these challenges. HDSG captures environmental information at different resolutions, integrating both geometric and semantic features. It enables various navigation tasks such as localization, loop closure, and human interaction through the visualization of environmental features for remote operators. We evaluated the performance of localizing a robot's position within the world frame by comparing compact spatial descriptors extracted from semi-consecutive scene graphs, derived from 3D LiDAR point clouds. Compared to
Alam, Fardifa Fathmiul, Iuricich, Federico, Li, Nianyi, Jia, Yunyi, Li, Bing
Technical Paper
Supervisory Control System Development for a Toyota Mirai FCEV2025-01-8586To be published on 04/01/2025
The performance of a second-generation Toyota Mirai fuel cell was characterized as part of the SwRI internal research program. This data was used to develop a supervisory controller scheme designed to balance the plant for the fuel cell system during steady-state and transient vehicle conditions. This was accomplished using a Supervisory Integrated Controller (SIC) implemented on a Real-time Power Electron- ics Control System (RPECS) with a Simulink-based control algorithm. The actuators of interest are the three hydrogen injectors at anode inlet, air compressor and three air side valves on at the cathode inlet. The FC power measurement and pressure sensor readings at the anode and cathode were utilized as real-time feedback for the controller operation. The aim of the controller was to achieve and maintain the power target set by the hybrid powertrain ECU present on the vehicle, which is responsible for balancing power on the fuel cell and battery over the high-voltage bus. These
Chundru, Venkata Rajesh, Kubesh, Matthew, Legala, Adithya
Technical Paper
Research on Composite Braking Strategy of Pure Electric Commercial Vehicle on Downhill Low-adhesion Road considering Rainfall Intensity2025-01-8813To be published on 04/01/2025
As a distributed wire control brake system, the electro-mechanical brake (EMB) may face challenges due to the need to integrate the actuator in the limited space beside the wheel. During extended downhill braking, especially on wet roads with reduced adhesion, the EMB must operate at high intensity. The significant heat generated by friction can lead to thermal deformation of components, such as the lead screw, compromising braking stability.This paper focuses on pure electric light trucks and proposes a parallel composite braking method. This approach uses an eddy current retarder or motor to provide basic braking torque, while the EMB supplies the dynamic portion of the braking torque, thereby alleviating the braking pressure on the EMB. First, a driver model, tire model, motor model and braking models are developed based on the vehicle's longitudinal dynamics. In addition, the impact of various factors, such as rainfall intensity, road slope, ramp length, road type, and vehicle
Liu, Wang, Zhang, Yu, Xiao, Hongbiao, Shen, Leiming
Technical Paper
Integration of Safety Standards for a Unified Safety Framework for Automated Vehicles2025-01-8717To be published on 04/01/2025
This paper proposes a structured safety framework tailored for the concept phase of Level 2 and Level 3 automated vehicles, addressing the unique challenges posed by these advanced systems. The framework integrates key principles from ISO 26262 and ISO 21448 to create a safety approach that spans hardware reliability, functional safety, and system performance. Central to the framework is a broad analysis that combines methodologies from System-Theoretic Process Analysis (STPA) and Hazard Analysis and Risk Assessment (HARA). This dual approach enables the identification of potential risks arising from both hardware failures and the intended functionalities of the system. The framework further details a combined specification and design process that aligns the strengths of each standard, ensuring robust sensor architectures and reliable decision-making processes. A case study on Adaptive Cruise Control (ACC) with Lane Keeping (LK) is presented to demonstrate the practical implementation
Sari, Ayse Aysu, Soleimani, Morteza
Technical Paper
Accuracy of Mobile of Phone LiDAR on Crashed Accident Vehicles2025-01-8692To be published on 04/01/2025
Apple’s mobile phone LiDAR capabilities can be used with multiple software applications to capture the geometry of vehicles and smaller objects. The results from differing software have been previously researched and compared to traditional ground-based LiDAR. However, results were inconsistent across software applications, with some software being more accurate and others being less accurate. (Technical Paper 2023-01-0614. Miller, Hashemian, Gillihan, Benes.) This paper builds upon existing research by utilizing the updated LiDAR hardware that Apple has added to its iPhone 15 smartphone lineup. This new hardware, in combination with the software application PolyCam, was used to scan a variety of crashed vehicles. These crashed vehicles were also scanned using a FARO 3d scanners, which have been researched extensively for their accuracy. The PolyCam scans were compared to FARO scans to determine accuracy for point location and scaling. Previous research has shown that user variability
Miller, Seth Higgins, Stogsdill, Michael, McWhirter, Seth
Technical Paper
A Sensitivity Study of Frequency Response Method for Setting Bearing Preload Due to Manufacturing and Design Variation2025-01-8518To be published on 04/01/2025
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. One open problem is the design of the production controller which relies on a detailed sensitivity study of the system frequency response to changes in the bearing and system design parameters. Recently, an analytical model was developed for multi-row tapered roller bearings
Gruzwalski, David, Mynderse, James
Technical Paper
Research on Noise Optimization Control based on the New Dead Zone Compensation in Dual Motor Hybrid System2025-01-8516To be published on 04/01/2025
In a three-phase voltage source inverter, in order to prevent the direct short circuit of the upper and lower tubes of the bridge arm and ensure the normal operation of the inverter, microsecond-level dead time needs to be added when the power devices are turned on and off. However, due to the dead-time effect, slight distortion may occur in the inverter within the modulation period, and this distortion will eventually lead to harmonic components in the output current after accumulation, thereby generating torque ripple. Against the above background, implementing dead-time compensation strategies is very important. To compensate for the voltage error caused by the dead-time effect, current polarity determination is required first. Then, the dead time is compensated, thereby indirectly compensating for the voltage error caused by the dead-time effect. Regarding the dead-time compensation time, without changing the hardware, this paper proposes a solution to turn off the dead-time
Jing, Junchao, Zhang, Junzhi, Zuo, Botao, Liu, Yiqiang, Yang, Tianyu, zhu, Lulong
Technical Paper
Research on the Change of Mind Control during Gearshift in Hybrid System2025-01-8509To be published on 04/01/2025
This paper initially delineates the control process of driver-initiated gear changes. The gear-shifting point control module computes the new target gear based on the current updated driving state, and the gear-shifting point decision module assesses the rationality of the new target gear and conveys it to the gear-shifting timing control module. The gear-shifting timing control module selects the reasonable new stage in accordance with the current execution status and outputs the new target gear, coordinating the clutch control module and the brake control module to regulate the clutch engagement/disengagement and the switches of the two clutches. Altering the intention regarding gear changes encompasses gear replacement and variations in power type, which involve the necessary recalculation of the target speed based on the new target gear. Secondly, the conditions for the "change of mind" request in the Speed stage are stipulated, which is the stage where the input shaft speed is
Jing, Junchao, Huang, Weishan, li, Dongfei, Zuo, Botao, Liu, Yiqiang
Technical Paper
Development of a camera-based perspective transform method for quantifying passenger-vehicle driver direct visibility2025-01-8667To be published on 04/01/2025
The Insurance Institute for Highway Safety developed a camera-based perspective transformation method for measuring driver direct visibility. This data collection method captures the driver’s full vertical and 360 lateral field of view (FOV) including pillars, side mirrors, hood and door beltlines. All-around maps of the visible ground points are generated without the need for a physical grid or external curtain setup, which is ideal for field data collection. A rig with standardized eye heights is installed in the driver’s seat to take photos every 15° laterally, with a 130° vertical FOV. The driver’s eye point is measured relative to the vehicle left front corner at ground level then camera lens characteristics are used to complete a perspective transformation, allowing annotated points on the images to be projected onto a virtual ground. This method was compared to a traditional grid method to confirm accuracy, with all forward and side points varying less than 0.6 m distance
Mueller, Becky, Bragg, Haden, Bird, Teddy
Technical Paper
Automatic Generation of HVAC Ducting System Designs using Topology and Shape Optimization2025-01-8656To be published on 04/01/2025
Topology and shape optimization of a vehicle Heating, Ventilation and Air Conditioning (HVAC) system is presented in this paper. The CFD and optimization methodologies are implemented within AcuSolve™ software. The topology optimization algorithm computes the geometry, where the design domain is parameterized with a field of porosity design variables which indicates the material, fluid or solid, throughout the domain. The optimization is performed using the continuous adjoint approach by the Galerkin Least Squares solver on which the AcuSolve™ solver is based. The design is further improved by using shape optimization. To optimize the geometrical shape, a combination of smooth perturbations, in terms of so called morph shapes, are used to deform the geometrical shape in the optimization algorithm. To this end, a parameterization of the design space is done using a moderate number of design variables, each associated with a morph shape. The two optimization phases are connected by means
Papadimitriou, Dimitrios, Sandboge, Robert
Technical Paper
Performing dynamic stress analysis on large-scale models within a practical timeframe by leveraging superelements2025-01-8630To be published on 04/01/2025
This paper addresses the challenge of high hardware requirements for large full-vehicle models with millions of degrees of freedom, which can make dynamic stress simulations for durability impractical due to hardware shortages. To tackle this issue, an approach that reduces runtime without compromising accuracy is essential. The super element technique is proposed, particularly when certain modules remain unchanged across iterations. By leveraging previously solved results for these unchanged modules, the super element technique eliminates the need for solving the entire model in each iteration, thus significantly reducing analysis runtime. The objective of this paper is to outline a modeling strategy that incorporates the super element method and to evaluate its runtime efficiency and accuracy compared to conventional analysis methods. Modal frequency response function analysis is used to demonstrate the methodology. Instead of the traditional Lanczos approach for extracting
Dhangar, Vinaykumar, Badhe, Nitin, salunkhe, Prashant, Hosmath, Anjaney
Technical Paper
INTEGRATED BODY STRUCTURE TO ACCOMMODATE MANUAL AND POWER DOOR SUNSHADE VARIANTS IN A VEHICLE2025-01-8616To be published on 04/01/2025
Door Sunshade in a vehicle has proven to be very comfortable and luxurious feature to the customers. Luxury vehicles provide Power Sunshade which is electrically operated with the activation of a switch, whereas cost conscious vehicles provide manual sunshade which requires manual coiling and uncoiling. This study is to develop a Door Panel structure that can accommodate both the Manual Sunshade and Power Sunshade, thereby serving both cost conscious as well as luxury seeking customers. Manual Sunshade consists only of cassette, Pull Bar, Spindle Mechanism and Hooks whereas the power sunshade consists of Cassette, Pull Bar, Spindle Mechanism, Flap mechanism, Bowden Cable Mechanism, Actuator and Motor. Due to this difference in Package, it becomes difficult to accommodate both Variants of Sunshade into the same body system. However, this study helps in developing a common body structure by ways of effective Packaging, Modifying the cable and Actuator Mechanism and critical packaging of
S M, Rahul, d, ANANTHA, Kakani, Phani Kumar
Technical Paper
Integrated Bracket Design Optimizations to Resolve Issues in Vehicle Prototype Stage2025-01-8614To be published on 04/01/2025
Integrated bracket is a plastic part which packages functional components such as ADAS, Rain Light Sensor and the mounting provisions of auto dimming IRVM. This part is fixed on the windshield of an automobile using double sided 3M tapes and glue. ADAS, rain light sensor and auto dimming IRVM play an important part in the safety of driver, and everyone present in the automobile. The paper takes the readers through a concern faced by the authors that emphasizes the importance of the combination and location of tapes and glues on the integrated bracket. The 3M tapes at the B side of the integrated bracket are used to locate it on the windshield and hold it until the glue's curing time gets completed. If the combination and positions of glue and tapes is not optimum, then the bracket will get peeled off from the windshield causing aesthetic deterioration. This concern came in the prototype stage of a Mahindra SUV. In this concern, the integrated bracket was peeling off from the windshield
Chandravanshi, Priyansh, Dharmatti, Girish
Technical Paper
Optimization Method for Powertrain Mounting Systems Based on Enhanced Genetic Algorithms2025-01-8644To be published on 04/01/2025
A methodology for optimizing natural properties of a powertrain for an electric vehicle has been presented. A model with six-degree-of-freedom was proposed utilizing ADAMS, and the natural frequencies and energy distribution of the powertrain are estimated using the proposed model. The calculated natural frequencies and energy distribution shown that the initial design of mount stiffness does not meet requirements of natural frequency and decoupling ratio, and vibration isolation standards. To overcome the limitations of conventional optimization techniques, a non-dominated sorting genetic algorithm (NSGA) was adopted for the enhancement optimization the mounts parameters. The optimization objectives included the refinement of the decoupling rates and frequency distribution at all mounting directions. Stiffness parameters of the mounts were optimized via the NSGA. The optimized results confirmed significant improvements for powertrain natural characteristics. This study presented an
Jin, Yang, Li, Dewei, Zhao, Yang, Xiao, Lei, Guo, YiMing
Technical Paper
Accurate simulation of Sealing process using a GPU-accelerated Lagrangian differencing dynamics method2025-01-8633To be published on 04/01/2025
A vehicle body is a complex geometric object consisting of many parts. This inevitably creates a lot of seams and gaps through which water, dust, and sound waves can penetrate inside. To prevent corrosion of the body and reduce noise in the car, such gaps are sealed with a special paste with complex non-Newtonian rheological properties. Sealing also has a cosmetic function for visible regions on the finished vehicle, which increases the requirement for quality of the seams. Sealing seams are applied using special robotic arms. Seam length can reach several meters with a height of 0.5-5mm and a width of 5-40mm. In this situation, optimizing the robotic arms paths and the flowrate of expensive sealant can significantly speed up the production process and reduce its cost. Accurate and fast CFD modelling makes it possible to plan the sealing process in advance, which shortens the development cycle of new vehicles and reduces the likelihood of unexpected costs. This paper presents a new
Panov, Dmitrii Olegovich, Peng, Chong, Kotian, Akhilesh, Menon, Muraleekrishnan, Zhu, Huaxiang
Technical Paper
Literature Review and Framework for Identifying Seat Belt Misuse and Misrouting in Frontal Collisions2025-01-8721To be published on 04/01/2025
The effect of seat belt misuse and/or misrouting is important to consider because it can influence occupant kinematics, reduce restraint effectiveness, and increase injury risk. One of the objectives of this study was to identify types of lap-shoulder belt misuse/misrouting and associated injury patterns from a literature review. Belt misuse included shoulder belt only, lap belt only, or shoulder belt under the arm, for example, while belt misrouting included lap belt on the abdomen, shoulder belt above the breasts, or shoulder belt on the neck. The literature review also highlighted the lack of information on the prevalence of belt misuse and misrouting, partially due to assessment complexity. The literature review also identified various methods used to assess misuse/misrouting including testimonies and physical evidence on the occupant (i.e., belt marks/ injury pattern) and on the vehicle interior and/or restraint system (i.e., loading marks). The second objective was to develop an
Gu, Emily, parenteau, Chantal
Technical Paper
Headliner design considerations to meet safety and regulations2025-01-8245To be published on 04/01/2025
Headliners are one of the largest components inside an automobile, stretching from the front windshield to the rear windshield. Besides its aesthetic purpose, it contributes to multiple other purposes like housing different components, helps in NVH, defines the interior roominess, and plays a crucial role in defining the deployment of curtain airbag. The headliner also plays a role in meeting regulatory requirements like upward visibility and headroom requirements of the occupants. During the deployment of curtain airbag, it is important that the headliner-pillar interface aids in the easy opening of airbag, with the least hindrance. This is defined by multiple factors like the location of headliner-pillar interface in “z” direction, and its distance from the airbag ramp bracket, the position of the inflator, the mountings of the headliner and pillar trims, to name a few. Also, during the deployment of the airbag, it is important that parts such as grabhandle, speaker grilles, etc
Sabesan, Arvind Kochi, D, ANANTHA, Kakani, Phani Kumar
Technical Paper
A Wide Belt Correction Strategy for Belt-Whip and Wheel Ventilation Drag2025-01-8770To be published on 04/01/2025
The increased importance of aerodynamics to help with overall vehicle efficiency necessitates a desire to improve the accuracy of the measuring methods. To help with that goal, this paper will provide a method for correcting belt-whip and wheel ventilation drag on single and 3-belt wind tunnels. This is primarily done through a method of analyzing rolling-road only speed sweeps but also physically implementing a barrier. When understanding the aerodynamic forces applied to a vehicle in a wind tunnel, the goal is to isolate only those forces that it would see in the real world. This primarily means removing the weight of the vehicle from the vertical force and the rolling resistance of the tires and bearings from the longitudinal force. This is traditionally done by subtracting the no-wind forces from the wind at testing velocity forces. The first issue with the traditional method is that a boundary layer builds up on the belt(s), which can then influence a force onto the vehicle’s
Borton, Zackery
Technical Paper
Market Research & Analysis of failures due to environmental gases in Automotive Electronics and integration of learnings in development testing2025-01-8255To be published on 04/01/2025
Automotive industry is growing rapidly with innovations leading to increase in new features and improving the Quality of vehicles. These new components are developed with the available design standards across global OEMs. This Quality research paper aims to address the need of revision of design standards due to environmental factors prevailing in India. With the increase towards autonomous mobility, the number of electronics is also increasing, and this involves hardware & software evaluation. The hardware testing is a point of concern due to increase in the failure rate from the markets. Environment changes are very much evident with the growing economies and OEMs are developing the components with innovation, but if the basic design standards are not revised in parallel with the changing environment, the issues will continue to trouble the end customers. The failed cases data received from across the country was analyzed and observed that the cases are majorly reported from urban
MARWAH, Ramnik, Pyasi, Praveen, Bindra, Ritesh, Garg, Vipin
Technical Paper
Assessing the Impact of Mirror Technology on Driver Perception and Safety: Traditional vs. Camera-Based Systems2025-01-8664To be published on 04/01/2025
Camera-based mirror systems (CBMS) are being adopted by commercial fleets based on the potential improvements to operational efficiency through improved aerodynamics, resulting in better fuel economy, improved maneuverability, and the potential improvement for overall safety. Until CBMS are widely adopted it will be expected that drivers will be required to adapt to both conventional glass mirrors and CBMS which could have potential impact on the safety and performance of the driver when moving between vehicles with and without CBMS. To understand the potential impact to driver perception and safety, along with other human factors related to CBMS, laboratory testing was performed to understand the impact of CBMS and conventional glass mirrors. Drivers were subjected to various, nominal driving scenarios using a truck equipped with conventional glass mirrors, CBMS, and both glass mirrors and CBMS, to observe the differences in metrics such as head and eye movement, reaction time, and
Siekmann, Adam, Prikhodko, Vitaly, Sujan, Vivek
Technical Paper
CL-infoRRT collision-avoidance trajectory planning for autonomous vehicle2025-01-8027To be published on 04/01/2025
To ensure the safety and stability of road traffic, autonomous vehicles must proactively avoid collisions with traffic participants when driving on public roads. To achieve effective obstacle avoidance, this paper proposes a CL-infoRRT planning algorithm. CL-infoRRT consists of two parts. The first part is the informed RRT algorithm for structured roads, which is used to plan the reference path for obstacle avoidance. The second part is a closed-loop simulation module that incorporates vehicle kinematics to smooth the planned obstacle avoidance reference path, resulting in an executable obstacle avoidance trajectory. To verify the effectiveness of the proposed method, four test scenarios and four RRT comparison algorithms were set up. The implementation results show that all five algorithms can generate obstacle avoidance trajectories in the four scenarios. However, compared with the comparison algorithms, the proposed method uses fewer nodes. In Scenario 1, the proposed method uses
wu, Wei, lu, jun, Zeng, Dequan, Yang, Jinwen, Hu, Yiming, Yu, Qin, Wang, Xiaoliang
Technical Paper
SPC based Critical Parameters Monitoring of Vendor Supplied Parts by Auto OEM for Quality Control2025-01-8334To be published on 04/01/2025
In Automobile manufacturing, maintaining the Quality of vendor-supplied parts is crucial. This paper introduces a digital tool designed to monitor critical parameters of these parts in real-time. Utilizing Statistical Process Control (SPC) graphs, the tool continuously tracks essential parts and process parameters, predicting potential issues for proactive improvements even before parts are supplied. The tool integrates data from all vendor partners into a single platform, providing a comprehensive view of their performance and the parts they supply. Vendors input data into a digital application, which is then analyzed in the cloud using SPC techniques to predict potential alerts for improvement. These alerts are automatically sent to both vendors and relevant personnel at the OEM, enabling proactive measures to address any quality deviations. 100% data is visualized in an integrated dashboard which acts as a single source of truth for all stakeholders. Real-time monitoring is done
Sahoo, Priyabrata, Bindra, Ritesh, GUPTA, ANKIT, Garg, Vipin, Rawat, Sudhanshu, RAO, AKKINAPALLI VN, Narula, Rahul, Garg, Ishan
Technical Paper
Enhancement in Cabin Comfort and Overall Energy Utilization of an Electric Reverse Trike Car by Optimizing the System Layout2025-01-8150To be published on 04/01/2025
As the emissions norms are getting stringent and stricter, the use of all electric vehicles is widespread and becoming mainstream mobility both in urban and rural areas. However, lack of good charging infrastructure and high energy density cells limiting the overall electric mobility eco-system. Eventually the shorter range and high charging time of the vehicle is becoming the key challenge of e-mobility. Energy consumption by one of the key auxiliary systems e.g. air-conditioning (AC) system is adding further concerns over the range anxiety. It is the most energy consuming system among all others. Hence the need of the hour is to improve and enhance the AC system performance by means of redefining and optimizing the system layout in order to reduce power drawn by system. The present paper evaluates the improvement of cabin comfort and reduce the energy consumption of an electric car AC system by optimizing the layout and position of condenser and compressor. The experiments were
Sen, Somnath
Technical Paper
Investigation of Dimethyl Ether Injection Characteristics in High-Pressure Direct Injection Systems2025-01-8464To be published on 04/01/2025
The majority of transportation systems continue to rely on internal combustion engines powered by fossil fuels. Heavy-duty applications, in particular, depend on diesel engines due to their high brake efficiency, power density, and robustness. Despite significant advancements in diesel engine technology that have reduced emissions and improved efficiency, complex and costly after-treatment systems remain necessary to meet the stringent emission regulations. Dimethyl ether (DME), which can be produced from various renewable feedstocks and possesses high chemical reactivity, is a promising alternative for heavy-duty applications, particularly in compression ignition direct injection engines. Its high reactivity, volatility, and oxygenated composition offer significant potential to address emission challenges while reducing reliance on after-treatment systems. However, DME’s lower energy density requires adjustments in injection parameters (such as injection pressure and duration) or
Cong, Binghao, Leblanc, Simon, Reader, Graham, Yu, Xiao, Zheng, Ming
Technical Paper
Impact of Injector Geometry and Parcel Injection Location on Flash Boiling Spray Simulations of the ECN Spray G Injector2025-01-8462To be published on 04/01/2025
Near nozzle regions of fuel injectors are exposed to rapid phase changes due to flash boiling at ambient condition below fuel’s saturation pressure. So, it is crucial to understand the influence of spray boundary conditions on parcel-based simulations for improved predictions of fuel spray behavior in engine applications. This study builds upon previous research investigating the impact of detailed injector tip geometry on parcel simulations of non-flash boiling condition. Flash boiling spray interaction with these boundary conditions were not considered previously. Four key parameters were varied individually on baseline spray simulation model which resulted in total five cases. The four key parameter variation against baseline model were the presence of detailed injector tip geometry versus simplified flat surface, parcel initialization at the nozzle exit versus the counterbore exit, the use of experimental rate of injection versus one-way coupling with internal nozzle Volume of
Kumar, Aman, Van Dam, Noah
Technical Paper
Intebrake 3-D CFD Transient Simulation Studies for Predicting Flow Performance2025-01-8362To be published on 04/01/2025
This paper presents transient, complex, moving mesh, three-dimensional CFD analysis of Intebrake lubrication oil circuit for predicting flow performance. Intebrake is a method of improving braking performance during overspeeding conditions by briefly opening the exhaust valve at the end of compression stroke with a small valve lift and releasing the compressed gases. There is no fueling and hence, no combustion during the Intebrake operation. During intebrake operation, opening of exhaust valve is achieved by using a complex lube oil circuit inside the exhaust rocker lever. The intebrake lube oil circuit consists of various spring-operated valves with micron sized clearances, high oil pressure generation up to ~ 250 bar, three-dimensional movement of the parts, and transient operation. The three-dimensional motion consists of simultaneous rotation and translatory motion with some dynamic motions due to net force balance between spring and fluid forces. All these factors make simulation
Tawar, Ranjit Ramchandra, Pasunurthi, Shyam Sundar, Bedekar, Sanjeev, Ranganathan, Raj
Technical Paper
Numerical investigation on behaviors of under-expanded hydrogen jets: Influence of straight nozzle structure2025-01-8459To be published on 04/01/2025
In internal combustion engines, the use of hydrogen is considered as one of the most promising alternatives to reduce CO2 emissions. In such a context, traditional injectors for hydrocarbon fuels are currently being tailored to be used with hydrogen or a single-hole/multi-hole cap mounted at the injector tip was used. Nevertheless, hydrogen injection has to be operated at high pressure due to the low density of the hydrogen, which leads to the formation of highly under-expanded fuel jets and have a significant influence on the downstream mixture formation. Therefore, in order to achieve better hydrogen-air mixture, this work aims to numerically analyze high-pressure hydrogen spray behaviors, focusing on the effect of nozzle structure on the formation and the structure of the shock waves. The nozzle diameter ranged from 0.1 mm to 2.0 mm, with the ratio of nozzle length to diameter from 0.5 to 5. The nozzle pressure ratio varied from 5 to 10 with different combination of injection
Jiahui, Lang, Li, Yanfei, Xu, Lubing, Xiao, Ma, Shuai, Shijin
Technical Paper
A hybrid algorithm for optimizing machining and spraying parameters in MQL-turning of Inconel 800H2025-28-0042To be published on 02/07/2025
Inconel 800H superalloy is a difficult-to-turn material. This study aims to achieve optimal machining results, including reduced cutting force, improved surface roughness, and minimized residual stress, by optimizing input machining parameters like cutting speed, feed rate, spraying angle, and nozzle distance on Inconel 800H. The Taguchi L27 method is utilized for experimentation, while the Harris hawks optimizer (HHO) is applied in a multi-objective optimization model. Additionally, the Technique for Order of Preference by Similarity to the Ideal Solution (TOPSIS) is used to identify the optimal input parameters. Five distinct weight schemes were employed, including the Analytic Hierarchy Process (AHP), the Entropy weight method, Criteria Importance through Inter-Criteria Correlation (CRITIC), Grey relational analysis (GRA), and Principal Component Analysis (PCA) to determine response weights. The analysis revealed that the primary factor affecting all measured weights is the feed
Kannan, Venkatesan, Mokshajna, Kotha
Technical Paper
Gear misalignment optimization for Electric Drive Unit using Machine learning based Prescriptive Analytics2025-28-0166To be published on 02/07/2025
Gear mesh misalignment in electric drive unit may result in shifts in the load distribution of a gear pair that can increase contact and bending stresses. It may move the peak bending and contact stresses to the edge of the face width, and also increase gear noise. Lower misalignment value is often required to reduce the peak bending and contact stresses and have a balanced load distribution along the gear flank. This paper delineates a method which is also called prescriptive analytics that combines virtual simulations, Machine learning (ML) and optimization techniques to minimize different gear misalignments for electric vehicle drive unit. The gear misalignments are dependent on stiffness of different components in the drive unit. So, a comprehensive approach that incorporates effect of individual components and their interactions is needed. Generally, an assembly level virtual simulation is performed to evaluate gear misalignments. In order to minimize the misalignments, manual
Penumatsa, Venkata Ramana Raju, Thomas, Benson, Black, Derrick, Jain, Sachin
Technical Paper
Numerical Analysis of Capillary Performance of Various Lattice Structures for Vapor Chamber Application2025-28-0062To be published on 02/07/2025
Additive manufacturing has made it possible for the design of increasingly complex structures that require precise manufacturing. This may be particularly beneficial for heat pipe and vapor chamber design – particularly for the wick structure, a very important component. This study uses numerical simulation to analyze three different types of lattice structures of increasing complexity, in terms of their capillary performance. This is one of the most important parameters which determine the wick efficacy. Simple cubic, Column and Octet lattice models are computationally designed and CFD is used to simulate capillary action in a pipe of 0.4 mm inner radius for 2 milliseconds, after validation of the numerical model with existing experimental results. It is found that the Octet lattice (with the most complex inner structure) has the greatest capillary rise in the same amount of time. The rate of rise is not uniform for any structure, but is highest for Octet. This study demonstrates the
Sundararaj, Senthilkumar, Hudge, Ajay, Basuroy, Suhashini, Kang, Shung-Wen
Technical Paper
Temperature Reduction of Servo Oil in Steering System Using Pulsating Heat Pipe2025-28-0104To be published on 02/07/2025
There are various steering technologies that are available in market nowadays. Electro- Hydraulic Power Steering (EHPS) is one of them. As hydraulic name is linked to it, the temperature role comes to play. While doing hard cornering the hydraulic oil used to assist the working in steering system gets over heated, due to which oil loses its viscosity and becomes one of the major causes for hard steering in trucks. Also, due to packaging constraints in the truck, a large heat exchanger cannot be used. So, objective of this Thesis is to examine a effective solution which can be compact in design and at the time should be effective to solve this problem. After going through literature analysis, we finalize that the Principal of Pulsating Heat Pipe could be a possible solution. So, for that we design different model based on previous research work in Creo and simulate them in Star CCM+ to finalize the optimality
Saikrishna, VNL, P, Rudresha, Yadav, Satyendra, B, Ruthvika, Vishwasa, Viditha
Technical Paper
INSERT, SCREW THREAD, HELICAL COIL, METRIC SERIES, FREE RUNNING, CRES, UNCOATEDMA3279D (Current)01/09/2025
E-25 General Standards for Aerospace and Propulsion Systems
Technical Standard
Numerical Simulation of Drive Cycles for Formula Electric Vehicle Comparative Powerflow Analysis2024-36-009712/20/2024
This paper proposes a theoretical drive cycle for the competition, considering the battery pack project under design. The vehicle has a non-reversible, double-stage gear train, created without a dynamic investigation. To evaluate the effect on performance, several ratios were analyzed. Dynamic model uses Eksergian’s Equation of Motion to evaluate car equivalent mass (generalized inertia), and external forces acting on the vehicle. The circuit is divided into key locations where the driver is likely to accelerate or brake, based on a predicted behavior. MATLAB ODE Solver executed the numerical integration, evaluating time forward coordinates, creating the drive cycle. Linear gear train results provided data as boundary conditions for a second round of simulations performed with epicyclic gear trains. Model is updated to include their nonlinearity by differential algebraic equation employment with Lagrange multipliers. All data undergoes evaluation to ascertain the mechanical and
Rodrigues, Patrícia Mainardi Tortorelli, Silveira, Henrique Leandro
Technical Paper
Management Model Applied in an Auto Parts Industry: Decision Pyramid2024-36-001612/20/2024
This work presents the elements that demonstrate the use of a new mental concept (mindset), a way of thinking and interacting with the most diverse corporate situations in an independent and mature way to act with the best decision for the business. Based on a decision model by a systemic logic that naturally seeks to become a habit, with applications in the most diverse situations, being applied in an auto parts industry in the Brazilian national market. By following a unique model of interaction, intervention and action in an organizational system, the interaction between decisions requires the sense of being the owner of the business, something that will be explored throughout the course of the application of the model, and demonstrating that this concept should be applied at all types of decision, including personal life
Júnior, Jairo José Modesto Gonçalves, Araujo, Edgar Junior Alves, Teixeira, Natália Siqueira
Technical Paper
Multi Criteria Analysis Selection of Cylindrical Spur Gears2024-36-011712/20/2024
Organizations need to maintain their processes at high levels of efficiency to be competitive, asset management and industrial maintenance are extremely important to obtain positive results in optimizing operating costs, saving energy resources, reduction of environmental impacts among other characteristics that are considered differential for organizations. In this scenario, methods are increasingly being sought to assist managers in decision-making processes that contain several alternatives and selection criteria involved. The AHP and TOPSIS methods have been widely associated with prioritization studies, cost evaluation, resource selection, suppliers, among others. Thus, the selection of equipment and industrial elements can be evaluated by means of multicriteria decision methods where the criteria considered important by specialists in the area are inserted into the model. The objective of this article was to present a selection process for spur gears based on stress analysis and
de Oliveira, Geraldo Cesar Rosario, de Oliveira, Vania Aparecida Rosario, Silva, Carlos Alexis Alvarado, Guidi, Erick Siqueira, Salomon, Valério Antonio Pamplona, Rosado, Victor Orlando Gamarra, de Azevedo Silva, Fernando
Technical Paper
Experimental Determination of the Residual Torque Range in a Plastic Connector of the Fuel Pump Module at End of Life2024-36-012912/20/2024
The study of residual torque is necessary in various fields to ensure the safety and reliability of bolted joints. The present study aims to determine, experimentally, the decrease in torque applied to a nut used in the assembly of two polymeric components (POM - Polyoxymethylene). These components are part of the fuel supply module, responsible for supplying fuel from the tank to the engine. This reduction in torque initially applied is mapped to the end-of-life of the components and is used as an approval criteria in the audit procedures of the Robert Bosch company. The first component features an overmolded metallic screw, injected into POM. The mating part is also injection molded from POM and is assembled onto the first part, secured by tightening a metal nut. Due to the plastic-to-metal interface, it’s expected that there will be a reduction in the initially applied torque required to fasten the pieces together. The study was based on 5 steps: 1 Theoretical study on residual
Spitaletti, Laís Scotelari, da Fonseca, Márcio Ghiraldelli
Technical Paper
Steel Bars, Forgings, Tubing, and Forging Stock 1.0Cr - 3.25Ni - 0.40Mo (0.17 - 0.22C) Electroslag Remelted or Consumable Electrode Vacuum Remelted Premium Aircraft QualityAMS6493C (Current)12/18/2024
This specification covers a premium aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock
AMS E Carbon and Low Alloy Steels Committee
Material Specification
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