Browse Topic: Power and Propulsion

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Predictive Modelling of NOx and Unburned Hydrogen Emissions in a Direct-Injection Hydrogen SI Engine2026-37-0007To be published on 06/09/2026
Hydrogen is emerging as a compelling energy carrier for future transportation due to its potential to enable fully decarbonised operation and near-zero tailpipe pollutant emissions. Realising this potential in reciprocating internal combustion engines requires a detailed understanding of the complex interactions governing hydrogen combustion and emissions formation. In this context, physics-based emission predictive modelling offers a powerful means to accelerate the development and optimisation of hydrogen-fuelled engines by enabling rapid evaluation of operating strategies without the need for extensive experimental campaigns. This study investigates the simulation of pollutant emissions from a 0.5L single-cylinder research engine equipped with side-mounted direct hydrogen injection and spark ignition. The work focuses on the development and assessment of predictive models for nitrogen oxides (NOx) and unburned hydrogen (uH₂) emissions within a 1D–0D simulation framework. For NOx
Malfi, Enrica, De Felice, Massimiliano, Esposito, Stefania, Ribnishki, Aleksandar, King, Aidan, Akehurst, Sam, Jones, Peter, Goyal, Harsh
Investigating the potential of two individually controlled injectors per rotor for a DI hydrogen Wankel engine2026-37-0008To be published on 06/09/2026
Hydrogen-fuelled rotary engines offer a promising alternative for zero-emission powertrains in commercial applications, particularly where compact packaging is required. This study presents experimental results of the further development of the naturally aspirated hydrogen rotary engine by HTM with direct injection, integrated with an electric machine into a hybrid or genset system. Despite the lower volumetric energy density of hydrogen compared to conventional fuels, the compact design of the rotary engine enables installation within the packaging of a conventional internal combustion engine with comparable power output. Initial applications, including an airport baggage tractor, have demonstrated the feasibility of the concept. However, engine calibration revealed pre-ignition phenomena that constrained the maximum achievable torque. To address this limitation, the influence of mixture formation is further investigated. An experimental engine setup is used where two individually
Endres, Jonas, Beidl, Christian, Herold, Tim, Lavall, Philipp, Schmidt, Marvin, Hofmann, Silas, Kahl, Jonas
Evaluation of Flamelet-Based Combustion Models for Hydrogen-Ammonia Spark-Ignition Engines2026-37-0027To be published on 06/09/2026
Besides the electrification of the transport sector, the growing interest in alternative fuels for internal combustion engines represents a promising pathway to effectively decarbonize transportation over the coming decades. Predictive combustion models implemented within CFD frameworks are a critical tool to guide the design of next-generation internal combustion engines fuelled with alternative fuels. Accurate prediction of the combustion heat release process is influenced by multiple interacting parameters, requiring combustion models that can reliably adapt to variations in fuel chemical properties and operating conditions. In this study, two well-established combustion models considered to model combustion development in Spark-Ignition engine, namely the Extended Coherent Flame Model (ECFM) and the G-equation model, are compared to assess their capability to adapt to changes in fuel chemical composition. Both models, based on the flamelet formulation are deliberately tested beyond
Sola, Riccardo, Baratta, Mirko, Misul, Daniela, Rousselle, Christine, BREQUIGNY, Pierre, Colin, Olivier
Rapid Fuel Distribution Prediction in RCCI Marine Engines Using CFD-Informed, Active Learning Framework2026-37-0017To be published on 06/09/2026
Accurate prediction of in-cylinder fuel distribution (FD) is fundamental to reduced-order combustion modeling and emissions prediction, yet remains computationally prohibitive with high-fidelity CFD alone. This work develops a CFD-informed machine-learning surrogate for spatial FD in a large-bore diesel engine, based on a Wärtsilä W20 injector and representative engine conditions. A fully coupled injector–spray–engine CFD framework under engine-like RCCI inert conditions determines the needle-lift profile and resolves the combined effects of injector geometry, needle dynamics, and operating conditions on in-cylinder flow, capturing physical phenomena not reproducible by isolated free-spray simulations. A high-fidelity database is generated using Latin Hypercube Sampling, from which FD is extracted at 15 CAD before top dead center within an annular multi-zone (MZ) representation consistent with reduced-order combustion models. A multi-output Random Forest (RF) surrogate, augmented with
Moradi, Jamshid, Salahi, Mahdi, Heidarabadi, Shadab, Andwari, Amin, Konno, Juho, Wik, Christer, Mikulski, Maciej
Low-Voltage Electric Vehicle with a Reconfigurable Powertrain Architecture for Urban and Extra-Urban Mobility2026-37-0025To be published on 06/09/2026
The growing penetration of electric mobility in urban environments calls for vehicle solutions that balance accessibility, safety, and operational flexibility. However, high upfront costs and the widespread oversizing of battery systems remain significant barriers to large-scale adoption, particularly for short-range use cases. To address these limitations, this paper presents the Low Voltage Reconfigurable Electric Vehicle (LVREV), a modular vehicle concept designed to bridge the gap between L7e and M1 categories. The proposed architecture integrates a low-voltage electrical system (<60 V), a reconfigurable powertrain, and a modular, swappable battery, enabling mission-adaptive performance while reducing cost, weight, and energy consumption. The vehicle architecture features a dual 52 V inverter system coupled with a six-phase permanent magnet synchronous motor, optimized through model-based design and genetic algorithms. Energy storage consists of two independent swappable battery
Tramacere, Eugenio, Favelli, Stefano, Galluzzi, Renato, Tonoli, Andrea
Numerical simulation of spark-ignited flame kernels towards prospective application to hydrogen SI engines2026-37-0015To be published on 06/09/2026
The ongoing energy transition demands the decarbonization of the transport sector, for which the use of premixed hydrogen in spark-ignition (SI) engines appears very promising. However, modeling the combustion of the lean hydrogen/air mixtures required for safe, efficient, and low-NOx engine operation involves multiple open issues. Correct prediction of flame kernel initiation and growth is a difficulty that hydrogen shares with hydrocarbon fuels, while properly accounting for the instabilities that characterize lean hydrogen flames is an additional demanding task. In this work, a 1D kernel expansion model of general validity recently proposed by the authors is implemented into OpenFOAM, an open-source 3D CFD software package, to enable numerical simulation of expanding spark-ignited flame kernels. Firstly, the OpenFOAM framework is presented focusing on XiFluid, its thermophysical combustion model based on a regress variable whose evolution depends on the laminar flame speed. Then
Dotteschini, Enrico, Pretto, Marco, Giannattasio, Pietro, Gadalla, Mahmoud
A Holistic CFD Methodology for Full- and Multi-Cycle Simulation of Hydrogen Direct-Injection Internal Combustion Engines2026-37-0016To be published on 06/09/2026
Hydrogen is emerging as a viable energy carrier for the decarbonization of internal combustion engines (ICEs), representing a necessary step toward the long-term sustainability of this technology. In particular, hydrogen direct injection (DI) operation is receiving increased attention due to its inherent advantages over port fuel injection (PFI), such as reduced risks of abnormal combustion, higher specific power, and improved thermal efficiency. However, the mixture preparation process in DI operation generally leads to a stratified charge, especially under intermediate-to-late injection strategies, which in turn strongly affects ignition, combustion performance, and engine-out emissions. Therefore, investigating mixture formation, its key influencing parameters, and the resulting effects on the combustion process is essential for the proper design and optimization of hydrogen-fuelled DI ICEs. In this context, computational fluid dynamics (CFD) emerges as a powerful tool to address
Capecci, Marcolucio, Lucchini, Tommaso, Sforza, Lorenzo, Pezza, Vincenzo, Tosi, Sergio
Potential of ORC-Based Waste Heat Recovery in Conventional and Hybrid Heavy-Duty Powertrains2026-37-0018To be published on 06/09/2026
Heavy-duty vehicles are major contributors to greenhouse gas emissions and urban air pollution, particularly under cold-start and transient operating conditions where engine efficiency and exhaust aftertreatment effectiveness are reduced. In this context, waste heat recovery (WHR) technologies represent a practical pathway for improving fuel efficiency and reducing CO₂ emissions in real-world heavy-duty applications. This study investigates the integration of an Organic Rankine Cycle (ORC)–based WHR system within conventional and hybrid electric powertrain architectures applied to a reference heavy-duty truck (ISUZU FTR850). A sensitivity analysis is performed on four WHR configurations, combining shell-and-tube and plate heat exchangers with simple and regenerative ORC layouts. For the parallel hybrid configuration, two engine sizes and two energy management strategies are compared: a fuel-minimizing fuzzy logic rule-based strategy and a constant-power strategy aimed at stabilizing
Donateo, Teresa, Morrone, Pietropaolo
Investigation into Cooling Loss Reduction Associated with Changes in In-Cylinder Flame Distribution by Offset Orifice Nozzle2026-37-0003To be published on 06/09/2026
Recently, an increase in compression ratio has been widely recognized as one of the essential technologies for improving the thermal efficiency of heavy-duty diesel engines. However, a higher compression ratio tends to result in increased cooling loss, which could diminish the thermal efficiency gains. Therefore, novel approaches which can reduce cooling loss while maintaining or improving thermal efficiency are required. In our previous studies, it was found that an offset orifice nozzle, in which the orifices are drilled with a small offset from the radial center of the nozzle, improves thermal efficiency and reduces cooling loss simultaneously. However, key factors contributing to the significant reduction in cooling loss have not been sufficiently clarified. This study aims to investigate the mechanism of cooling loss reduction associated with changes in flame distribution when using an offset orifice nozzle in heavy-duty diesel engines, based on in-cylinder combustion observations
Mukayama, Tomoyuki, Enomoto, Yoshiteru, Mikami, Naotaka, Nomoto, Shigeru, Uchida, Noboru
Development and validation of a one-dimensional model for an opposed-piston free-piston engine generator with parametric analysis2026-37-0021To be published on 06/09/2026
Opposed-piston free-piston engine generators (OFPEGs) have emerged as a promising technology for next-generation hybridized and electrified transportation systems, offering the potential for high efficiency, reduced mechanical complexity, and favorable noise, vibration, and harshness (NVH) characteristics. By eliminating the conventional crankshaft mechanism and directly coupling a free-piston engine with linear generators, OFPEGs enable the direct conversion of combustion energy into electrical power. This architecture is particularly attractive for hybrid and range-extender applications, where operational flexibility and high system efficiency are critical to achieving significant reductions in fuel consumption and CO₂ emissions. Despite these advantages, the performance of OFPEG systems is governed by a strong coupling between piston dynamics, in-cylinder combustion processes, and electrical loading conditions. This coupling presents substantial challenges for system design, control
Wang, Jiayu, Morandi, Nicola, Lucchini, Tommaso, FENG, HUIHUA, Jia, Boru, Ren, Peirong
Development of a Load Responsive Mechanical Shifting Mechanism and Its Benefits for Battery Electric Vehicles2026-37-0026To be published on 06/09/2026
Many high-end electric vehicles use an automatic two-speed transmission. The ability of the drivetrain to switch between two gear ratios improves vehicle performance and increases driving range. The aim of the presented research work is to transfer these advantages to small and lightweight battery-electric vehicles, which face significant cost and weight constraints and therefore cannot rely on highly sophisticated electric motors. Direct-drive systems are widely used in this vehicle class due to their simplicity and high baseline efficiency. However, they offer limited flexibility in adapting the operating point of the electric motor under varying load conditions. A two-speed transmission can overcome this limitation by enabling load point shifting, allowing the motor to operate closer to its optimal efficiency region during both urban and extra‑urban driving. This results in improved energy consumption without adding substantial system complexity. Currently, only actuated
Napetschnig, Christof, Tromayer, Juergen, Stückler, David
CFD Modelling of an Asymmetric Hydrogen Injector Cap for Direct Injection Applications: Design Impact on Jets Structure and Momentum Flux2026-37-0011To be published on 06/09/2026
The adoption of hydrogen as a carbon-neutral sustainable fuel for internal combustion is regarded as a promising solution to reduce greenhouse gases and pollutant emissions. In this framework, the injection system plays a crucial role, being responsible for delivering a large amount of fuel to the combustion chamber. Currently, low-pressure direct injection is considered one of the best solutions to ensure the appropriate fuel delivery. The use of caps has proven particularly effective, as they enable a potentially unlimited range of geometries while minimizing modifications to the injector hardware. Experimental campaigns and computational fluid dynamics (CFD) simulations can be used together as complementary tools to speed up the development process and explore multiple combinations of parameters, thereby optimizing the overall design of both the engine and the caps. In the present paper, a single-hole GDI-derived hydrogen prototype injector equipped with a two-hole asymmetric cap
Pavan, Nicolo, Breda, Sebastiano, Duni, Andrea, Martino, Manuel, Fontanesi, Stefano, Postrioti, Lucio
Comparison of Detailed Chemistry and Flamelet-Based Models for Hydrogen Combustion in a Heavy-Duty PFI Engine2026-37-0014To be published on 06/09/2026
Addressing climate change requires substantial reductions in emissions from the transportation sector, where alternative fuels for internal combustion engines play a crucial role. Among these options, hydrogen stands out as a compelling energy carrier capable of enabling low-carbon combustion while leveraging existing engine technologies. Its adoption can support a transition toward fuel-flexible powertrains and deliver rapid decreases in exhaust carbon emissions. This approach is particularly relevant for hard-to-abate segments such as heavy-duty transportation, where full electrification remains challenging. Building on this perspective, this numerical study investigates the modelling behaviour of a heavy-duty port fuel injection (PFI) internal combustion engine fuelled with hydrogen. Initially, the mixture was assumed to be fully premixed to avoid uncertainties related to injection and mixing processes and to significantly reduce computational cost; this assumption was subsequently
Scopelliti, Alex, Misul, Daniela Anna, Baratta, Mirko, Gallo, Alessandro, Rapetto, Nicola, Vargiu, Luca
On natural gas combustion split into diesel like architecture of a compression ignition engine retrofitted for spark ignition operation2026-37-0029To be published on 06/09/2026
In commercial areas that no longer favor diesel engine, such as Europe, it might be interesting to convert an existing compression ignition (CI) engine to the spark ignition (SI) operation and to use natural gas (NG) because of its advantages: availability of still abundant NG supplies worldwide and environmental benefits of NG compared to conventional liquid fossil fuels. This paper presents experimental results on NG combustion inside such a converted engine with diesel-like architecture dedicated to light-duty vehicles (LDV) and passenger cars (PC). Particularly, our study carried out at the engine test bed revealed that in certain operating points (low speed and load, stoichiometric mixture and rather high spark advance), the combustion is split into two distinct events, which is not specific to the standard SI engine. This is clearly illustrated by a rate of heat release (RoHR) profile with two peaks. This kind of RoHR profile appeared following a spark advance sweep carried out
Clenci, Adrian F., Popa PhD, Robert, Berquez, Julien, Iorga-Siman PhD, Victor, Magheru, Catalin, Punov PhD, Plamen, NICULESCU, Rodica
A predictive methodology for 3D-CFD simulation of piston thermal field in sustainable high-performance engines2026-37-0002To be published on 06/09/2026
In recent years, especially in high performance engines, the thermal stress of pistons has gradually increased due to the implementation of various technologies, aimed at meeting emission reduction and specific power increase requirements. If the heat is not properly dissipated, cracking and plastic deformation of the material as well as formation of hot spots triggering self-ignition can occur. To overcome these problems, one or more jets of oil are directed towards the piston undercrown region, impacting at high speed. This technique ensures immediate cooling and allows the engine performance to be increased without compromising the useful life. In order to optimize the oil jet effectiveness, 3D-CFD can be proficiently adopted. In this regard, the aim of this work is to define a robust numerical methodology able to simulate oil jet impingement and piston thermal field. In particular, a 3D-CFD Volume-of-Fluid (VoF) simulation is used to numerically assess the oil jet impact and
Duni, Andrea, Berni, Fabio, Breda, Sebastiano, Fontanesi, Stefano, Gilioli, Filippo
Dynamic Transient Control of Hydrogen Direct-Injection SI Engines: Effects of Ramp Timing on Engine Performance and Abnormal Combustion2026-37-0013To be published on 06/09/2026
Dynamic Transient Control of Hydrogen Direct-Injection SI Engines: Effects of Ramp Timing on Engine Performance and Abnormal Combustion The application of hydrogen combustion engines in real-world transportation offers significant potential for high efficiency with zero carbon emissions. However, the adoption of zero-carbon hydrogen as the primary fuel across a wide operational range will require optimising transient performance to ensure efficient and safe operation, thereby eliminating abnormal combustion. This study investigates the transient control of a 0.4 Litre single-cylinder, downsized direct injection spark ignition (DI-SI) hydrogen engine, focusing on the impact of ramp timing on in-cylinder pressure overshoot, abnormal combustion behaviour, and overall engine performance. Utilising a closed-loop control strategy at a target lambda of 2.75, the research evaluates engine behaviour across a spectrum of transient intensities by varying the ramp timing from 1.38s to 0.24s. A
Zaman, Zayne, Wang, Xinyan, Zhao, Hua, Mohamed, Mohamed
Hybridized Diesel Powertrains - an important enabler for commercial applications on the long journey towards full electrification2026-37-0022To be published on 06/09/2026
The ongoing efforts for reduction of the traffic-related greenhouse gas emissions and, at the same time, the mitigation of harmful pollutant emissions from vehicle exhaust emissions are important development tasks for the entire automotive industry worldwide according to demand to provide clean and efficient products. Further tightened fleet average FE standards and ultra-low limits for exhaust emissions require the continuous development of new propulsion system types. Due to the given reluctance of the end customer and corresponding low acceptance of fully electrified vehicles, especially in the commercial vehicle segment, new and innovative topologies are needed to meet regulatory requirements and maintain the high versatility of today’s dominating solutions. For further optimisation of operating conditions with enhanced fuel efficiency, the technical strategy is also determined by uplifting the attractiveness of electric driving incl. the avoidance of areas with poor ICE efficiency
Koerfer, Thomas
Investigation of Combustion Dilution Strategies on Performance and Emissions of a Single-Cylinder Spark-Ignition Direct-Injection Hydrogen Engine2026-37-0009To be published on 06/09/2026
Hydrogen internal combustion engines research is particularly relevant for propulsion systems requiring long range and fast refuelling while offering advantages in fuel purity requirements and operational efficiency. Leveraging the existing engine industry offers the potential for a fast response in the reduction of greenhouse gas emissions. However, abnormal combustion and high NOx emissions limit the feasibility of stoichiometric operation in hydrogen engines, making the evaluation and optimisation of dilution strategies essential. While lean combustion has been widely studied, the impact of exhaust gas recirculation (EGR), particularly in combination with lean mixtures, has yet to be comprehensively assessed. This study investigates the effectiveness of different dilution strategies, with a specific focus on the combined effects of air dilution and EGR on hydrogen combustion. Their joint influence on thermal efficiency, combustion stability, and emissions is evaluated across a range
King, Aidan, Islam, Reza, Pickering, Simon, Yuan, Hao, Mudge, Henry, Giles, Karl, Goyal, Harsh, Jones, Peter, Akehurst, Sam, Esposito, Stefania
Engine thermal management strategies for emissions reduction during real driving tests2026-37-0036To be published on 06/09/2026
Thermal management in internal combustion engines (ICEs) strongly affects fuel consumption and pollutant emissions, especially during engine warm-up. Particularly, the oil temperature is strictly related to the organic efficiency of the vehicle: in the early phase of a driving cycle, the low temperature produces a high-viscous oil, which increases friction losses and increases fuel consumption, with respect to full thermal regimated oil. Usually, the oil and coolant thermal behaviours are interconnected, thanks to a coolant/oil heat exchanger in the engine. In this study, a prototyped electrical coolant pump has been applied and integrated in a small SUV vehicle, replacing the original mechanical unit. An off-board experimental campaign allowed a complete hydraulic characterization of the cooling system, including thermostat operation, and led to a physically based correlation between flow rates and pressure drops in each branch. Based on these results, the pump was designed and
Di Battista, Davide, Di Bartolomeo, Marco, Cipollone, Roberto
Nitrogen-based emissions from Ammonia Combustion in a Heavy-Duty Spark Ignition Engine2026-37-0032To be published on 06/09/2026
Ammonia (NH3) is increasingly recognized as one of the paths toward decarbonizing power generation and transportation. Its carbon-free molecular structure and ease of storage compared to hydrogen put NH3 at the forefront of alternative fuels. However, transitioning from hydrocarbon fuels to NH3 in internal combustion engines significantly alters the profiles of nitrogen oxide (NOx) and nitrous oxide (N2O) emissions. In traditional hydrocarbon combustion, NOx is formed mainly via the thermal Zeldovich mechanism, where atmospheric nitrogen reacts with oxygen at high temperatures. In contrast, ammonia combustion introduces "fuel-NOx," where the nitrogen atom within the NH3 molecule itself is oxidized. This study used experiments and numerical simulations to evaluate the effect of engine geometry and operating condition on these differences. In addition, the study observed the differences in NOx and N2O formation and destruction with respect to the engine cycle timeline. While ammonia's
Trujillo Grisales, Juan, Saenz Prado, Stefany, Alvarez, Luis F., Akkerman, Vyacheslav, Dumitrescu, Cosmin E.
Experimental investigation on cold start and warm-up phases for an ethanol fueled SI engine.2026-37-0031To be published on 06/09/2026
Engine operation during the initial warm-up period is characterized by pronounced thermal non-uniformities, which have a direct impact on fuel efficiency, combustion stability, tailpipe emissions and engine long-term reliability. For these reasons, accelerating the warm-up process represents an effective strategy to improve both environmental impact and overall engine performance. This paper presents an experimental study carried out on a 1.2 liter, naturally aspiered, four-cylinder SI engine equipped with a Port Fuel Injection (PFI) system. The engine is fueled with standard gasoline and an ethanol-gasoline blend containing 30% ethanol by volume (E30), with the aim of assessing the influence of fuel formulation on thermal evolution after a cold start. Each test begins with the engine at ambient temperature and is continued until thermal equilibrium is established. Experiments are carried out at a single steady operating point of 2000 rpm and 20 Nm, selected to reproduce representative
Falbo, Luigi, Falbo, Biagio, Perrone, Diego, Castiglione, Teresa
Effect of Ar mass ratio and mixture equivalence ratio on the integrated hydrogen argon power cycle2026-37-0012To be published on 06/09/2026
This paper investigates hydrogen combustion in an argon–oxygen (Ar–O₂) environment for compression ignition engine applications using computational fluid dynamics (CFD). The numerical framework is validated through two independent datasets: experimental results from Sandia National Laboratories and hydrogen jet ignition experiments conducted in an Ar–O₂ atmosphere, establishing confidence in the predictive capability of the model. A parametric analysis is performed to evaluate the effects of excess air ratio (λ) and argon mass fraction on ignition characteristics, combustion efficiency, and engine performance. The results indicate that operating under lean conditions improves combustion efficiency but leads to a substantial reduction in engine load. Increasing the argon mass ratio enhances engine thermal efficiency, primarily due to the higher specific heat ratio of argon, which improves the thermodynamic efficiency of the cycle. However, elevated argon concentrations significantly
Chitsaz, Iman, Ahammed, Sajid, Kakoee PhD, Alireza, Salahi, Mohammad Mahdi, Andwari, Amin, Ahmad, Zeeshan, Hyvonen, Jari, Mikulski, Maciej
Comparative Toxicological Assessment of Exhaust Emissions from Modern Low-Emission Passenger Vehicles2026-37-0005To be published on 06/09/2026
The transition towards low-emission vehicle technologies, driven largely by efforts to reduce fleet-average CO2 emissions, has led to the widespread introduction of advanced powertrains, including hybridized gasoline vehicles, modern diesel vehicles, and compressed natural gas (CNG) vehicles [1]. While these technologies are primarily promoted for their reduced regulated emissions, their comparative toxicological impacts under realistic driving conditions remain insufficiently understood. This study presents a comparative toxicological assessment of exhaust emissions from five state-of-the-art passenger vehicles representing different propulsion technologies. The vehicles were tested on a chassis dynamometer under controlled laboratory conditions, following a common experimental protocol. The test matrix included gasoline vehicles with varying degrees of hybridization and particulate filtration (with and without gasoline particulate filters, GPF), a diesel vehicle equipped with a
Tsakonas, Georgios, Stamatiou, Rodopi, Lazou, Antigone, Samaras, Zissis, Elihn, Karine
Development and Experimental Validation of a 1D Model for Performance and Emissions Analysis of Oxygenated Fuel Blends in a CI Engine2026-37-0028To be published on 06/09/2026
Emissions reduction remains a major concern for internal combustion engines in view of increasingly stringent environmental regulations. To address these challenges while maintaining acceptable engine performance, a wide range of alternative fuels and fuel blends have been investigated to ensure the continued viability of CI engines. This study reports the effects of blending the oxygenated fuel diethylene glycol diethyl ether (DGDE) with hydrotreated vegetable oil biodiesel (HVO) on engine performance and emissions. The investigation is conducted on a 2.3-liter, four-cylinder, common-rail diesel engine equipped with variable geometry turbocharger and a high-pressure exhaust gas recirculation system. The objectives of this study are achieved by developing a one-dimensional predictive engine model using the commercial GT-Suite software. The engine model is developed and experimentally validated, at different operating conditions and HVO–DGDE fuel blends, to predict their effects on
Arain, M Wajahat Rasool, Foglia, Antonio, Frasci, Emmanuele, Vitek, Oldrich, Pianese, Cesare, Arsie, Ivan
Performance and Combustion Characteristics of Coryton SUSTAIN Classic Super 80 Carbon-Neutral Fuel Versus E95 in a 1980s Fiat 500 Engine2026-37-0033To be published on 06/09/2026
The energy transition requires a rapid reduction in the use of fossil fuels, whose combustion generates substantial greenhouse-gas emissions. In Europe, transport alone accounts for roughly a quarter of total greenhouse-gas emissions, with road transport being the predominant component. In this context, the use of biofuels has emerged as a potential solution for limiting further increases in CO₂ emissions. However, most studies available in the literature evaluate the performance of these fuels on modern engines, while their effects on historic carburetted engines remain largely unexplored. This is particularly significant given the large fleet of historic vehicles across Europe, supported by a long-standing tradition of vehicle preservation, associations, and classic car collectors. The main historic-vehicle federations advise caution and the use of low-ethanol formulations so as not to damage elastomers, fuel tanks, and carburettor float bowls. For this reason, a few suppliers have
Tarchiani, Marco, Fossati, Federico, Raspanti, Sandro, Baroni, Alberto, Ferrara, Giovanni, Romani, Luca
An open-source framework to Automate Virtual Optimization of Internal Combustion Engine Calibration Maps through shape-based strategy2026-37-0001To be published on 06/09/2026
The automotive industry is facing increasingly stringent regulatory constraints, driving the need for faster and more efficient powertrain development. This results in higher systems complexity, making internal combustion engine calibration progressively more challenging to meet performance and emissions targets. This, combined with the manual nature of traditional calibration workflows, leads to a time‑consuming process that heavily relies on human expertise. Although virtualization can reduce development time and costs, the overall workflow remains largely dependent on manual decision‑making and iterative refinement. In this context, this work presents a virtual calibration framework based on a genetic algorithm, aimed at the automated optimization of engine calibration maps to satisfy performance and emissions constraints, while reducing manual effort. Each calibration map is represented through a polynomial parameterization. Specifically, a generic three‑dimensional polynomial with
Romano, Gianvito, Aglietti, Filippo, Spedicato, Tonio, cozza, Ivan Flaminio, Capra, Andrea
Development of a Diesel Combustion System for Next‑Generation Heavy‑Duty Engines Using a Synergistic Analysis‑and‑Testing Approach2026-37-0004To be published on 06/09/2026
Regulators and policymakers have introduced increasingly stringent limits on tailpipe CO₂ and pollutant emissions to accelerate the decarbonization of heavy-duty vehicle applications. The development of innovative propulsion technologies — such as advanced combustion systems, low-friction reciprocating components, and improved aftertreatment solutions — combined with hybridization and the adoption of alternative fuels (e.g., biogas, HVO, green hydrogen), represents a key pathway for meeting future emission and GHG targets. In this study, advanced combustion systems were developed for a 13‑liter diesel engine for heavy-duty truck applications, with the objective of complying with forthcoming Euro VII regulations while maximizing thermal efficiency. The combustion system architecture—including open-bowl geometry with high aspect ratio, injector nozzle with wider spray opening angle, and reduced swirl ratio—was optimized using a Machine Learning–algorithm trained on high-fidelity 3D CFD
Belgiorno, Giacomo, Centini, Maria Pia, Pezza, Vincenzo, cozza, Ivan F., Pesce, Francesco C., Vassallo, Alberto, Colombo, Giovanni, Gallo, Alessandro, Mirzaeian, Mohsen, Borg, Jonathan
Alcohol-Based Energy Carriers in Transportation: Status, Standards, and Outlook2026-37-0042To be published on 06/09/2026
The global transport sector accounts for approximately 28% of total energy consumption and 15.8% of greenhouse gas emissions worldwide, with road transport alone responsible for 11.8%. As the world seeks pathways toward carbon neutrality, methanol and ethanol emerge as promising alternative energy carriers capable of leveraging existing logistics infrastructure while reducing dependence on fossil fuels. This review examines the production pathways, lifecycle considerations, and costs associated with both alcohols. Global methanol production reached 111 million metric tons in 2022, and global ethanol production totaled approximately 93.3 million metric tons in 2024. In comparison, the yearly production of gasoline and diesel amounts to over 2 billion metric tons per year. The review evaluates fuel requirements across multiple transport modes, including passenger vehicles, light- and heavy-duty vehicles, maritime shipping, aviation, and rail, and assesses regulatory frameworks governing
Fitz, Patrick, Fellner, Felix, Rößlhuemer, Raphael, Härtl, Martin, Jaensch, Malte
A Design-Oriented Experimental Method for Evaporative Cooling under Automotive Boundary Conditions2026-37-0035To be published on 06/09/2026
Minimizing cooling air mass in passenger cars substantially improves aerodynamic efficiency. In low-temperature circuits, the small temperature difference between ambient air and component limits increases cooling air demand. Peak cooling is often achieved with a closed refrigeration cycle, at the expense of power, complexity, and cost. Open-loop evaporative water injection can boost cooling capacity during short-term peaks, but automotive-relevant prediction and design methods are missing. Here, water is misted upstream of a low-temperature radiator using various hollow-cone spray nozzles. An holistic, experimentally validated test-bench methodology quantifies three superimposed mechanisms: air precooling by upstream evaporation, evaporation on the radiator surface, and sensible heat uptake by residual liquid water. Nozzles are first characterized in free-stream using a laser diffractometer to measure Mean Sauter Droplet (SMD) diameter and water mass flow rate. The influence on heat
Döbler, Philip, Henzler, Michael, Auerbach, Michael
Effect of Fluid Flow/Time Duration on Static Voltage Generation for Aerospace Hose Assembly2026-26-0757To be published on 06/01/2026
Static electricity is an electrical imbalance on the surface of a material that can interact with other components made of the same or different materials. Fluid (hydrocarbons) flow within the hose assembly generates static voltage due to the friction caused by fluid flow in pipes, which needs to be appropriately quantified and dissipated. Accumulation of such static charge may lead to sudden discharge, resulting in spark generation. Spark generation around fuel flow might lead to system failure and failure in aircraft engines. Experiments were conducted to analyze the static voltage generated in the hose assembly with a fixed hose assembly length due to fuel flow, with the objective of achieving acceptable voltage levels to avoid ESD (electrostatic discharge) failure. The procedure includes fuel flow rate monitoring and voltage measurement. The testing revealed that the curvature of the hose affects the readings, highlighting the importance of consistent meter alignment. Using a
Waghmare, Shashank
Evaluating Volume and Hardness change in Fluorocarbon and Ethylene Propylene Rubber Elastomers: Effects of Fluid Aging2026-26-0758To be published on 06/01/2026
Abstract: This research paper investigates the performance of FKM (Fluorocarbon) seal material when exposed to a 50:50 ethylene glycol-water mixture. The study aims to determine the volume change percentage and Hardness change of FKM elastomers under standardized testing conditions. The experimental approach follows ASTM D471 and ASTM 2240 guidelines, focusing on weight and hardness measurements of the test samples to establish a success criterion. The results provide critical insights into the chemical compatibility and durability of FKM elastomers in Aerospace and industrial applications where ethylene glycol-water mixtures are commonly used. The findings contribute to enhanced material selection and design considerations for sealing applications subjected to glycol-based fluids. Samples of FKM material were immersed in the fluid at controlled temperatures and durations, simulating real-world operational conditions. The primary metric of interest, volume change percentage and
Yarolkar, Makrand, Patil, Sandip, Singh, Tanul
Coupled Loads Analysis of a Single Stage Launch Vehicle for Vibration test Level Generation2026-26-0741To be published on 06/01/2026
Gaganyaan is an important mission for the Indian space program to put humans into space. The success of the mission depends on the development of required technology and systems. A test vehicle is developed for the technological demonstration for all envisioned abort flight scenarios of Gaganyaan mission. This is new configuration of launch vehicle with single liquid stage and a number of flights are planned. Coupled Loads analysis of launch vehicle system is a standard practice to estimate response and loads for design of structures and generating sine vibration test levels. Usually a vehicle rests on the launch pad through base shroud with horizontal support and no vertical restraint. Upon ignition of the engine, thrust builds up and upon overcoming gravity the vehicle takes off. In the current analysis the launch vehicle is held in position using a holding / retracting mechanism and at a predefined time the vehicle is released. The boundary condition required a novel method to
Kurudimath, Kottresh Maharudraiah, JALAN, SALIL, ROSE, JANCY
Conceptual Design of Hydrogen Fuel-Cell-Based Utility Aircraft2026-26-0783To be published on 06/01/2026
The aviation industry contributes to around 2% of global carbon dioxide emissions. As various sectors of the economy look to reduce their global carbon footprint, the aviation industry is positively acknowledging alternatives to jet fuel. Hydrogen proves to be one such alternative having a high energy density and producing zero carbon emissions on combustion. Hydrogen when used in a jet engine produces water vapour and NOx emissions. In order to reduce the effect of GHGs, the current study aims to develop aircraft concepts suitable with hydrogen propulsion through fuel cells for a short-haul commercial mission profile. Aircrafts such as Metro-23 and Dornier 228-212 were referenced for the requirements of a utility turboprop aircraft. The weight estimation was done to obtain the take off weight of 10,863 kg following the optimization of thrust to weight ratio and wing loading to calculate the initial dimensions. OpenVSP was used to model the initial structure of the aircraft. For the
Bhattacharya, Anisha, Seetha Ramu, Sree Valli, C N, Lakshmi Manasa, Rohit, Benjamin
Electric Air Mobility Using Fuel Cells2026-26-0774To be published on 06/01/2026
Electric air mobility (EAM) is redefining the future of aviation by presenting sustainable, efficient, and adaptable solutions for both urban and regional travel. Within this emerging field, aircraft powered by fuel cells are rapidly gaining recognition as a promising route toward cleaner skies. Hydrogen fuel cells, in particular, stand out due to their impressive energy density, quick refueling times, and the fact that they emit no pollutants during operation. This makes them an appealing replacement for traditional internal combustion engines, as well as an alternative to conventional battery-electric systems. This document delves into the core principles, benefits, challenges, and long-term prospects of adopting fuel cell technology for electric air mobility. It examines how these advancements could revolutionize aviation and significantly support the global push for decarbonization. Specifically, the study evaluates Proton Exchange Membrane (PEM) fuel cells operating at 60
Kari, Sreedhar, KOLIPAKA, PRADEEP
Weight Estimation of Novel Aircraft Configurations in Early Design Phase2026-26-0773To be published on 06/01/2026
Initial Weight estimation based on the Top Level Aircraft Requirements, hereon referred to as TLAR, is one of the key points to begin with the design of any aircraft. A quick and accurate estimation at the initial stages allows to achieve optimal design solution in fewer steps. This has more relevance in a setup like DOE, i.e., Design of Experiments, where the idea is to explore the complete design space and choose the best solution. At present, there are techniques available to estimate the weight from TLAR for conventional tube and wing configurations with JetA1 fuel. These techniques are primarily based on trends and empirical equations that have been derived from historical data of aircrafts previously built. A lot of new aircraft concepts have been (eg: VTOL) and are being (eg - BWB, H2 as fuel, OpenFan Propulsion etc.) considered for the commercial future. Currently, there are no standard methods established to estimate their weights due to the scarcity of historical data. The
Goyal, Tushar
Numerical Methodology For Aircraft Light Explosion Proofness Study2026-26-0790To be published on 06/01/2026
The increasing demand for safety and reliability in aerospace applications necessitates rigorous testing of aircraft components, including light units, for explosion proofness. Traditional explosion proofness tests are destructive, expensive, and time-consuming, requiring significant resources for test setups and prototypes. To address these challenges, this research presents a numerical methodology using Computational Fluid Dynamics (CFD) simulations to investigate the explosion proofness for aircraft light units. The primary motivation of this study is to develop a cost-effective and efficient alternative to physical testing that provides comprehensive insights into explosion dynamics and facilitates design optimization. This work contributes to advancing engineering practices in the aerospace industry by demonstrating the efficacy of CFD simulations in evaluating and enhancing the explosion proofness of light units. The proposed CFD model, implemented in ANSYS Fluent, adheres to the
Selvaraj, Sugumaran, Nataraja, Prabhu
AI Based Energy Sustained Series Hybrid Aircraft2026-26-0776To be published on 06/01/2026
This paper investigates the energy consumption characteristics of series hybrid aircraft with a focus on comparing conventional energy management approaches against an AI-powered optimization framework. The study comprehensively models the energy demands of a series hybrid aircraft across all major flight phases, including Idle & Ground Operations, Taxi, Takeoff, Climb, Cruise, Descent, Approach, Landing, and Rollout & Taxi. For each phase, detailed mathematical formulations are developed to capture power requirements and energy flow, incorporating real-time operational parameters to enhance the accuracy of the energy consumption estimations measured in kilowatt-hours (kWh). The AI-based optimization leverages advanced control strategies, specifically Model Predictive Control (MPC) and Reinforcement Learning (RL) algorithms, to dynamically manage the aircraft's energy systems. MPC is employed to predict and optimize future energy usage by solving constrained optimization problems over
Kanchagar, Amogha
Investigation of Aluminium Alloy Composites Reinforced with Zirconium oxide and Solid Lubricant Attributes for Brake and Clutch Components of Aircrafts2026-26-0752To be published on 06/01/2026
For brake and clutch components of aircraft, which require higher mechanical strength and wear resistance, lightweight aluminum composites were developed by infusing solid lubricant. In this study, hybrid composites were developed using the powder metallurgy route, using aluminum alloy AA356 and various amounts of zirconium oxide (ZrO₂) (0, 5, 10, 15, and 20 wt.%) as reinforcements. A solid lubricant, hexagonal boron nitride (hBN), at a fixed 5 wt.% is considered. Following the appropriate ASTM guidelines, the specimens were mechanically characterized by measuring their density, porosity, micro-hardness, compression strength, impact strength, and flexural strength, among other properties. The findings showed that the composites' physical and mechanical behaviour were greatly affected by the addition of ZrO₂.Porosity increased as a result of particle clustering and interfacial voids, while density increased gradually as ceramic content increased. Consistently increasing ZrO₂ addition
Senthilkumar, N.
Enabling Circularity in the Aerospace Maintenance Ecosystem through Generative-AI Driven Back-to-Birth Traceability of Life-Limited Engine Parts2026-26-0719To be published on 06/01/2026
Circular economy principles are increasingly central to aerospace sustainability strategies, aiming to extend asset life, improve asset valuations, and enhance benefits to stakeholders in the part ownership and maintenance lifecycle. In aircraft engines, achieving circularity hinges on the safe reuse, repair, and recirculation of high-value components. Life-Limited Parts (LLPs) are among the most critical in this context, but their reuse is strictly contingent on complete Back-to-Birth (BtB) traceability. Any gap in BtB records—often due to fragmented data across multiple airline operators, shop visits, document formats, and time expanse—renders otherwise serviceable LLPs unusable, leading to premature scrappage and lost circular value. This paper presents a Generative AI (GenAI)-driven methodology to reconstruct and validate complete LLP BtB histories from heterogeneous, unstructured, and legacy maintenance datasets. By combining aerospace domain-trained language models with embedded
Bhate, Ujwal, Jain, Dilip Kumar, Kulkarni, Ninad, Kalaiyarasan, Aravindh, Jha, Ashish, Shenoy, Karthik
Design and Development of a Morphing-Fin Hybrid Rocket-Powered Loitering Interceptor Drone for Surface-to-Air Missile Applications2026-26-0756To be published on 06/01/2026
This project aims to develop a novel loitering interceptor drone that combines the high-speed launch capabilities of a surface-to-air missile (SAM) with the maneuvering and persistence of a drone. The system will utilize a solid-propellant rocket booster to rapidly ascend and reach operational altitude. Upon reaching a designated threshold, the system will activate a morphing-fin mechanism, in which the missile’s stabilizing fins will dynamically reconfigure into a drone-like control surface system. This transformation is intended to enable the vehicle to switch from missile mode to a loitering drone mode, with the ability to hover, patrol, and track aerial threats over extended durations. The proposed interceptor will be equipped with autonomous navigation and decision-making modules, leveraging radar-based target detection, IFF (Identification Friend or Foe) logic, and path-prediction algorithms. Simulations will be developed using MATLAB/Simulink, where radar sweep behaviour
E, Rahul
Augmented Reality and Multimodal Interfaces for Astronaut Training and In-Orbit Operations2026-26-0796To be published on 06/01/2026
Augmented Reality (AR) and multimodal human–machine interfaces (HMI)—combining visual overlays, voice, gesture, eye-tracking, and biometric sensing—are now maturing into flight-relevant technologies capable of transforming astronaut training and in-orbit operations. These interfaces reduce task time, lower error rates, and mitigate cognitive load, thereby strengthening both crew autonomy and mission safety. For India, the timing is critical: Gaganyaan human spaceflight program is approaching decisive crewed missions in the late 2020s, and the Bharatiya Antariksh Station (BAS) is targeted for the 2030s. AR/MMI can be positioned not as an accessory but as a core enabling system for training throughput, real-time crew support, and resilient station operations. This paper provides (i) an overview of India’s current scenario, including Gaganyaan astronaut training ecosystems, IIT Madras collaborations on AR/VR, and Vyommitra humanoid readiness; (ii) synthesis of global case studies—NASA
Yadav, Anoop Singh
A Study on the Future of Battery Based Electric Aircraft Propulsion2026-26-0782To be published on 06/01/2026
Today the aircraft industry is witnessing a paradigm shift in the propulsion technology which has been unseen since the 1930s, when the gas turbine took over from the more established piston engines. For electric propulsion to survive and flourish, it must demonstrate clear superiority over the mature baseline technology of the gas turbine. It is a fact that the current battery technology is a limiting factor as it is not competitive compared to a gas turbine that is 30-50 times more energy dense. Naturally, the present electric propulsion developments concentrate on smaller aircraft designs and use on a large aircraft is possibly decades away. Apart from the energy density, from thermal perspective the architectures are vastly different from each other. A conventional aircraft fitted with a gas turbine has readily available heat sinks in fuel and air that aids in heat transfer. Compressed air bleeds from the engine manage the thermal demands of the engine itself plus the aircraft
Arun, K P, Srinivas, Varsha, Joshi, Jayanth, Suresh, Chandini, Naskar, Proloy Jyoti
THERMO-STRUCTURAL ANALYSIS OF GRID FINS FOR RE-ENTRY MODULES2026-26-0749To be published on 06/01/2026
Grid fins are lattice structures employed as aerodynamic control surfaces to achieve the required static stability of re-entry modules during atmospheric descent. Grid fins help to stabilize the re-entry modules by counteracting aerodynamic instabilities, especially when the module is moving through the atmosphere at high speeds. Each panel within the grid fin functions as an individual fin, generating lift and drag forces that enhances the overall stability of the re-entry module. In contrast to conventional fins, grid fins incorporate a distinctive waffle-like pattern or grid pattern configuration, offering superior aerodynamic performance in supersonic regimes and enabling compact storage through folding during launch followed by deployment at the time of exigency. The separation of re-entry modules from their launch vehicles is typically executed using high-thrust, fast-acting solid rocket motors (SRMs) which provide the impulsive force needed for clean detachment. The primary
Mali, Somanath Nandu, Sundar raj, R, Sundaresan, MK, R, Suresh
Design of Acoustical Features for a quitter Aero-engine Test Facility2026-26-0787To be published on 06/01/2026
Indoor aero-engine test facilities (AETF) are generally used to evaluate the performance of both the newly manufactured and repaired/overhauled engines. Aero Engine Research & Design Center (AERDC) has already commissioned several facilities for testing of turbofan engines of around 40 kN thrust class which powers fighter aircrafts. A request has been received from a customer for installation and commissioning of a new test facility for testing of a similar class engine, with a challenge to make it acoustically better than the existing test facilities. The target was set to reduce the sound pressure level (SPL) in the control room and around the test facility as compared to the existing ones. To meet this requirement, a modified layout with a U-type (vertical intake and exhaust) configuration was planned along with specially designed high and low frequency silencers at the intake, exhaust system with an exhaust basket, splitters in the vertical exhaust chamber, and sound absorbing
Gouda, Bansidhar
Thermal Management of Electric Microtruck Motors2026-01-50264/9/2026
This study investigates the gradeability performance of an L7e-class electric micro truck from both vehicle dynamics and thermal perspectives. A 1D simulation model (Amesim) was developed and validated with multiple test results. Using inputs such as motor characteristics, drivetrain configuration, and vehicle mass, the model analyzed vehicle performance on a 20% gradient, calculating the required torque, achievable motor speed, and corresponding vehicle speed. Furthermore, gradeability limits were evaluated, and the effects of gear ratio and airflow rate around the air-cooled motor on both gradeability and thermal behavior were examined. The findings provide practical insights for improving the powertrain and cooling system design of lightweight electric vehicles. The results showed that selecting an appropriate gear ratio can enable the motor to operate more efficiently under demanding driving conditions. A 20% increase in the gear ratio was found to delay motor heating by up to 10
Turan, Azim, Kantaroğlu, Hasan Hüseyin, Akbaba, Mahir, Kasım, Recep Faruk, Yarar, Göktuğ
STUD, LOCKED-IN RING, SERRATED, HIGH STRENGTHAS51992D (Current)4/8/2026
E-25 General Standards for Aerospace and Propulsion Systems
Electrified Propulsion System Balancing for Light Duty Full Size Truck and Sport Utility Vehicles: A 2026 North American Market Perspective2026-01-04124/7/2026
Achieving the stringent EPA CAFE 2032 standards for light-duty full-size trucks and sport-utility vehicles (SUVs) in North American poses significant challenges. While Battery Electric Vehicles (BEVs) offer a clear path to zero tailpipe emissions, their widespread adoption in this segment faces hurdles including range anxiety, payload/towing capabilities, and traditional truck/SUV use cases. This paper investigates a balanced approach, focusing on optimizing propulsion system design with appropriate hardware content, can effectively meet future fuel economy and emissions standards. This investigation examines advanced BEVs and hybrid electric vehicle architectures, including full hybrids (HEVs), and plug-in hybrids (PHEVs) tailored for full-size trucks and SUVs. Considerations include the optimal sizing of internal combustion engines, electric motors, and battery packs to deliver robust performance while maximizing energy efficiency. This paper analyzes the integration of technologies
Babcock, Dillon, Robinette, Darrell
The Influence of Split Injection Ratio on Efficiency and NO x Emissions in a Pilot Diesel-Ignited Hydrogen Direct Injection Engine2026-01-03294/7/2026
This study investigates the impact of the hydrogen split injection ratio on the combustion of pilot diesel-ignited hydrogen direct-injection engines, which is expected to affect hydrogen-air mixture conditions and thus flame propagation and diffusion flame developments. Experiments were conducted on a 1-litre single-cylinder diesel engine equipped with an additional hydrogen injector operating at 35 MPa. Hydrogen accounting for 95% of total input energy was injected at 150 and 60 °CA bTDC for the first and second pulses, which were selected as high-efficiency injection timings from previous equal-split injection tests. The 5% diesel energy was injected near TDC to control CA50 at 10 °CA aTDC. While varying the split ratio between the two hydrogen injections, in-cylinder pressure/aHRR profiles, engine efficiency/power output and engine-out emissions of NOx and CO2 were evaluated. Results showed that the hydrogen split ratio does not significantly affect IMEP/efficiency, which
Zhao, Yifan, Chan, Qing Nian, Kook, Sanghoon
Flame Velocity and Combustion Behaviour of Ammonia–Hydrogen Blends: A Combined Experimental and Numerical Study2026-01-03204/7/2026
Ammonia is emerging as a promising energy vector for decarbonising the maritime sector. However, its low flame speed can lead to incomplete combustion, reduced engine efficiency, and increased emissions of unburned ammonia (NH3). Blending hydrogen with ammonia helps to address these issues, but the fundamental combustion characteristics of such mixtures remain insufficiently understood. This study examines the combustion dynamics of an NH3–H2 blend containing 30% hydrogen at 3 bar initial pressure. Experiments were performed in a 1.2 L optically accessible constant-volume combustion chamber fitted with a wall-mounted surface spark plug. High-speed shadowgraph imaging with 6,000 fps captured the flame evolution throughout the combustion process. The pressure and temperature values were monitored using piezoresistive pressure transducers and K-type thermocouples. Combustion times and flame extensions were extracted via post-processing of flame images using custom MATLAB algorithms. The
Bodur, Tuna Murat, Bowling, William, La Rocca, Antonino, Cairns, Alasdair
Multi-Stage Packaging and Routing Optimization for Automotive Component Layout, Wire Harness and Duct Route Design2026-01-05074/7/2026
Modern vehicle design involves complex considerations and tradeoffs between system integration and layout which have a direct impact on performance, efficiency, and cost. The placement of equipment including control boards, motors, and fans as well as the routing of ducts and wire harnesses poses a time-consuming and intricate problem for design engineers. This paper presents an automated methodology to determine the optimal component packaging configuration, duct routing, and wire harnessing layout to maximize component packing density and minimize the total routing length. A two-stage optimization framework has been developed where the first stage packages the components within the design space with considerations for space utilization, component overlap, proximity relationships, point-to-point accessibility, and component mounting. The second stage implements a custom A* path-finding algorithm and gradient based optimization to determine the optimal route layout between port points
LeFrancois, Richard, Kim, Il Yong
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