Browse Topic: Transmissions

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Computational study on dynamic handling performance of a retro-fitted Electric Two wheeler using 125cc powered ICE reference2026-28-0047To be published on 02/12/2026
With the development in motor technology and battery manufacturing technologies, the scope for a budget working EV has been increasing in India. There remains an after-mark potential for conversion of an ICE powered two-wheeler to an EV power train. Such a move reduces the carbon footprint from the vehicle drastically and is still being explored. This study investigates the effect of replacing the ICE with an electric motor in a 125cc motorcycle, with a particular focus on vehicle handling performance using Slalom test. The two wheelers were modelled using calculated mass properties and estimated / calculated moments of inertia using CAD for both ICE and electric powertrains. The electric propulsion system took into consideration the role of a battery pack in the mass and MI calculation. The framework with degrees of freedom is well established in BIKESIMTM simulation environment. A slalom test with automatic gear shift and throttle to maintain speed of the vehicle was set-up to
Sankarasubramanian, Hariharan, M, Shaghasra, V, Ramprathap
Design and Development of Integrated Brake and Bull Cage System for Enhanced Tractor Performance and Sustainability2026-28-0005To be published on 02/12/2026
Conventional tractor transmission systems feature separate Brake and Bull Cage housings, with brakes often being proprietary components and Bull Cage designed by the Original Equipment manufacturer (OE). To optimize design and performance, an innovative integrated system was developed, combining an in-house braking system with a unitized Bull Cage assembly. This robust design reduces part count, eliminates proprietary dependency (except for friction liners), and enhances performance. Virtual simulations performed under RWUP conditions demonstrated enhanced strength and stiffness in the integrated design. In this Integrated Brake & Bull Cage assembly (IBCA) , the braking layout was reconfigured from a 4+1 friction design to a 3+2 configuration which improved balancing, enhancing customer braking experience and increasing contact area by 11%. This adjustment extends friction liner life and boosts mechanical advantage by 7.5%, significantly improving tractor stability and performance
Dumpa, Mahendra Reddy, Dhanale, Swapnil, Perumal, Solairaj, Gomes, Maxson, Redkar, Dinesh, Savant, Kedarnath, V, SARAVANAN
Simulation Driven Virtual Road Load and Accelerated Duty Cycle Generation for 3-Speed eAxle Systems2026-26-0401To be published on 01/16/2026
The transition from Internal Combustion Engine (ICE) vehicles to Battery Electric Vehicles (BEVs) introduces significant challenges in drivetrain development, particularly when historical road load data (RLDA) is unavailable. This research proposes a methodology for virtually generating and processing RLDA to evaluate the durability of a novel 3-speed electric axle (eAxle) system before physical prototype construction. By employing AVL Route Studio, we simulated diverse global driving conditions across urban, highway, and mixed terrains to generate high-frequency torque and speed data. Since the resulting millions of data points are impractical for direct fatigue assessment, we utilised Romax software to condense the virtual RLDA into an accelerated duty cycle while maintaining the original fatigue damage characteristics. Unlike traditional binning techniques that often mischaracterise load severity, our damage-matching approach ensures the condensed cycle accurately replicates gear
Ligade, Pratik, Khan, Nuruzzama Mehadi, Koona, Rammohan Rao
The selection of a two-speed gearbox for small commercial electric vehicles aims to optimize powertrain efficiency2026-26-0417To be published on 01/16/2026
In response to the significant environmental challenges posed by climate change driven by global warming, the automotive industry is accelerating the transition toward electrification. While electric vehicles offer considerable potential for mitigating CO₂ emissions, their elevated upfront costs pose a notable challenge to large-scale market penetration. Energy efficiency improvement of electric vehicles is emerging field of research to reduce total cost of ownership. Electric vehicle powertrain component selection in small commercial vehicles including three and four wheelers is a complex process which has to fulfil multiple requirements Range, performance, drivability, packaging, total cost of ownership of vehicle and comfort. In addition, powertrain configuration including battery, motor and transmission ratio selection plays a fundamental role in cost of electric vehicle. Hence, The task of selecting the right powertrain configuration, encompassing architecture, motor selection
Wani, Kalpesh, Jadhav, Vaibhav, Shendge, Raman, Warule, Prasad
Indian City Electric Bus Powertrain Optimization Using Active Learning Simulation Methodology2026-26-0657To be published on 01/16/2026
Public transport electrification is going to play a massive role in India's COP26 pledge to achieve net zero emissions by 2070. India plans to electrify 800,000 buses in a push towards 30% EV penetration by 2030. Further encouraged by government incentives under National Electric Bus Program (NEBP), eBus market is expected to grow at a CAGR of ~86% annually over the next 5 years. With most OEMs going for fleet electrification for reducing CO2 emissions and to cater to growing demand in Indian cities for cleaner public transport, improving powertrain efficiency and performance of state-of-the-art eBuses is a natural progression of e-mobility sector development in India. The first step in designing powertrain for an electric city bus is to determine the motor(s) size and transmission specifications (number of gears, gear ratios etc.). Complications arise due to a wider and non-linear operation range of eBus. This study focuses on powertrain optimization for a medium duty electric city
Sandhu, Rouble, Chen, Bicheng, Emran, Ashraf, Xia, Feihong, Lin, Xiao, Berry, Sushil
EV Transmission efficiency estimation using Simulation X2026-26-0453To be published on 01/16/2026
Electric vehicle (EV) transmission efficiency is crucial for optimizing energy use and enhancing performance. It minimizes power losses during energy transfer from the motor to the wheels, directly impacting the vehicle's range and battery life. High efficiency ensures smoother acceleration and better driving dynamics, improving the overall user experience. Unlike internal combustion engine (ICE) transmissions, EV transmissions often employ simpler, single-speed systems, reducing complexity and energy loss. Efficient transmissions help reduce energy usage, lower costs, and minimize environmental impact. As a result, transmission efficiency plays a vital role in ensuring the sustainability and reliability of EV designs. This paper proposes a simulation model based methodology to estimate EV transmission efficiency based on modelica models developed on simulation X. A single speed EV model is developed which contains whole transmission layout discretized into simple components which
Sutar, Suresh, Thambala, Prashanth, Patel, Hiral
Analysis of Engagement Probability for Dog Clutch Geometry Parameters in Heavy-Duty Automated Mechanical Transmissions.2026-26-0437To be published on 01/16/2026
This study presents a simulation-based approach to estimate the dog clutch engagement probability maps under different vehicle operating conditions. The developed probability function incorporates multiple critical parameters including initial speed differential between engaging components, application of countershaft brake, number of tooth in dog clutch, friction coefficients at tooth interfaces, applied actuation force, dog tooth geometry, and component inertia. Using MATLAB and Simulink, comprehensive simulation models were developed to analyze engagement dynamics and produce detailed probability maps at different vehicle speeds. The present work effectively outlines optimal operational zones for successful engagement while identifying critical regions prone to tooth clash and engagement failure. The effect of tooth geometry on engagement probability has been investigated to study its effect on the optimal mismatch speeds. The resulting engagement maps serve as valuable diagnostic
Khan, Mohammad Adeeb, Khan, Nuruzzama Mehadi, Koona, Rammohan
Gear Shift Validation of Multi Speed EV transmission on Test Bench using Vehicle Control Unit2026-26-0532To be published on 01/16/2026
Electric vehicle (EV) transmissions play a vital role in powering EVs by channelling energy from the electric motor to the wheels. Recently, the focus has shifted to multi-speed transmissions in the EV sector due to their potential to improve efficiency and performance. By utilizing various gear ratios, these transmissions enable the motor to function within its most efficient range across different speeds. Most of these transmissions need electronic control unit (ECU) with software for optimal functionality and smoother gear shifting. These controllers incorporate controller area network (CAN) communication protocol to operate along with other ECUs. Thus validation of these transmissions is a challenge as they are clutch less, motor has to be controlled for speed matching and have electro mechanical systems replacing conventional systems for operation. This paper proposes a methodology to validate multispeed EV transmissions on a test bench. The validation setup consists of electric
Thambala, Prashanth, Patel, Hiral, Soor, Debasis
Comparative Study of EV Transmission Performance used in Various Vehicle Segments2026-26-0584To be published on 01/16/2026
The transition to electric mobility has accelerated the evolution of drivetrain technologies, particularly in the design and performance of electric vehicle (EV) transmissions. Unlike traditional internal combustion engine (ICE) vehicles, EVs utilize simpler yet diverse transmission systems cater to specific performance, efficiency, and application requirements. The growing adoption of electric vehicles across diverse transportation sectors has intensified the need for optimized electric transmission systems as per vehicle requirements. This research presents a comparative study of electric transmission performance across various vehicle segments, including Passenger Cars, Small commercial Vehicle, Commercial three-wheelers and All-terrain vehicles. The study evaluates different transmission configurations namely single-speed and multi-speed, based on key performance metrics such as Drag loss and Efficiency. Through a combination of literature review, and performance benchmarking, the
Jain, Sankalp, P, Ekhesh
FATIGUE FAILURE ANALYSIS FOR AUTOMOTIVE TRASNMISSION2026-26-0577To be published on 01/16/2026
A fatigue failure in the transmission input shaft was identified during a bench-level endurance test under 2nd gear loading conditions. The test transmission’s input shaft comprises fixed 1st, reverse, and 2nd gears, with the remaining gears mounted as floating. The shaft was subjected to cyclic torsional loads, and failure occurred after a defined number of cycles. Metallurgical analysis revealed a brittle fracture surface with crack initiation at the outer surface, propagating to core in a helical pattern, ultimately resulting in complete shaft fracture. To monitor and replicate the failure, the test setup was instrumented with a Reilhofer Delta Analyzer for early fault detection. TTL signals from accelerometers mounted on the transmission and a bench speed sensor were fed into the system, which generated FFT spectra and trend indices. A warning alarm triggered upon deviation in the trend index, indicating premature damage initiation. The test was subsequently halted for component
Kushwaha, Rakesh, Patel, Hiral, Navale, Pradeep
Structural and Micro-Geometry Optimization of an Electric drive unit for Whine Noise Reduction2026-26-0315To be published on 01/16/2026
The noise generated by pure electric vehicles (EVs) has become a significant area of research, particularly due to the increasing adoption of electrified propulsion systems aimed at meeting OEM fleet CO₂ reduction targets. Unlike internal combustion engines, which mask many drivetrain noises, EVs expose new challenges due to the quieter operation of electric motors. In this context, the transmission system and gear structures have emerged as primary contributors to noise, vibration, and harshness (NVH) in EVs. The present study provides an NVH study that focuses on the gear whine noise issue that is seen at the vehicle level and cascades to the powertrain level. Comprehensive root cause identification, focusing on the transmission system's structural and dynamic behavior. The research emphasizes modifications to both the gearbox housing and gear structures to reduce noise level, and model validation was all part of the study, which was accompanied by physical test results. Using MBS
Baviskar, Shreyas, Kamble, Pranit, Ghale, Guruprasad, Bendre, Parag, Prabhakar, Shantanu, Kunde, Sagar, Thakur, Sunil, Wagh, Sachin
Design & Optimization of CV shaft system to address powertrain induced NVH issues2026-26-0336To be published on 01/16/2026
The automotive industry is a crucial sector that plays a significant role globally. Government policies have a profound impact on this automotive industry in defining the regulatory standards and emission controls. Such regulations incentivized automakers to invest in research and development complying those standards towards reduction of vehicle emission which intern result in higher torsional vibrations and excitations amplitudes. To address the rising NVH related concerns in driveline system. Drive shafts (CV shafts) is an important component in power-train system in vehicle. Drive shaft’s main purpose to transfer torque from engines to wheels at multiple speeds with different articulation angles. The roughness generated by the engine follows a transfer path from engine to transaxle and transaxle to half shafts in monocoque vehicles which generates discomfort to the drivers whenever the vehicle is driven. The roughness can also be addressed by proper design of driveshaft stiffness
M A, Abdul Azarrudin, Jayachandran, Suresh kumar, Kumar, Shivani, Bhardwaj, Kinshuk, M, Devamanalan, Kanagaraj, Pothiraj, Ahire, Manoj
Optimization of Propeller shaft design to eliminate Launch Undulation (Lateral shake) and Vibration level2026-26-0334To be published on 01/16/2026
During vehicle launches in 1st gear, a lateral shake (undulation) and a pronounced metallic hitting noise were observed in the underbody. The noise was identified as the propeller shaft's second universal joint (UJ) yoke striking the fuel tank mounting bracket. Sensitivity to these issues varied with acceleration inputs: light pedal input during a normal 1st gear launch on a flat road resulted in minimal undulation, whereas wide open throttle (WOT) conditions in 1st gear produced significant lateral shake and intensified hitting noise. Further investigation revealed that the problem persists across all gears and occurs consistently during normal driving conditions, with continuous impact between the propeller shaft yoke and the fuel tank mounting bracket. Extensive experimental measurements at the vehicle level indicated that these issues were primarily caused by the center-mounted propeller shaft joint deviating from its central position and rotating eccentrically under torque. This
Sanjay, L, S, Manickaraja, Kumar, Sarvesh, Kanagaraj, Pothiraj, Senthil Raja, T, B, Prem Prabhakar, M, Kiran
Development and Validation of a 1D Model for Evaluating Transmission Efficiency in Vehicles2026-26-0066To be published on 01/16/2026
This study develops a one-dimensional (1D) model to enhance transmission efficiency by evaluating power losses within a transmission system. The model simulates power flow and identifies losses at various stages such as gear mesh, bearing, churning, and windage losses. Using ISO/TR 14179, which provides a method for calculating the thermal transmittable power of gear drives with an analytical heat balance model, the 1D model ensures accurate thermal capacity evaluation under standard conditions. A key advantage of this 1D model is its efficiency in saving time compared to more complex 3D modelling, making it particularly useful during the conceptual stage of transmission system development. This allows engineers to quickly assess and optimize transmission efficiency before committing to more detailed and time-consuming 3D simulations. To validate the model, experimental tests were conducted at various motor speeds (RPM) and torque values, using high-precision sensors and dynamometers
Bandi, Nagendra Reddy, Kolla, Kalyan, P, Selvandran, Pulugundla, Krishna Chaitanya, M A, Naveen Kumar
Power loss evaluation in 4WD axle and correlation with Testing results2026-26-0107To be published on 01/16/2026
In the tractor, the efficiency depends on the transmission system, of all the losses major contribution is given by the transmission elements. To improve the efficiency, it became crucial to monitor the areas of power losses. Power loss in transmission refers the reduction in amount of power which being generated from the engine source to the final drive elements. There are various parameters and factors influence this condition, analyzing those conditions helps in identifying & improving the higher contributing components for driveline power loss. This study presents a comparative analysis of theoretical and experimental data regarding power loss in the gear train of a 70HP 4WD front axle. The investigation incorporates theoretical power loss calculations for individual components, including the bevel gear, bearings, thrust washer and seal arrangements. To evaluate and validate the power losses in the 4WD axle, a Gear Train Endurance test was conducted in a controlled laboratory
Jayapal, Jayaraj, Mahapatra, Soumya Ranjan, Sethi, Suvendu Kumar, Joshi, Shrikant, Bange, Prashant
Oil channelization for EV transmission.2026-26-0064To be published on 01/16/2026
Leakage of oil through breathers can be a serious concern in electric vehicle (EV) transaxle units, especially due to the complexities presented by small housing space and rotational components, which are running at relatively high speed compared to conventional transmission unit. Traditional methods are mostly centred on developing individual breather compartments, resulting in excess material usage, additional weight, and increased cost of manufacturing. This paper presents a novel and compact way of oil channelization that has been created for the gearbox housing and seeks to counter oil leakage along with maximizing space and efficiency. The improved design incorporates a cover, deflector fins, and obstruction ribs together with a strategically placed oil catcher cavity that effectively keeps the breather isolated from direct exposure to oil. The larger cavity minimizes internal pressure build-up, the fins restrict oil velocity, and an exclusive return path guarantees uninterrupted
Ekshinge, Mahesh Shivaji, Agrawal, Devesh, Pandey, Ankit Kumar, Bhandari, Kiran Kamlakar
Agricultural tractor brake linkage efficiency prediction and correlation using Flexible Multibody Dynamics model2026-26-0103To be published on 01/16/2026
In agricultural tractors, braking actuation is usually done through control linkages consisting of a series of connected four-bar linkages with multiple pivots from the pedal to the brake pads. The quality of force transmission is critical as it directly affects the braking performance of the tractor. Forces measured at the end of the control linkage or brake pull rod often show deviation with theoretically-based mechanical advantage calculations. This is due to various factors such as linkage transmission angle, elasticity, and friction in joints not considered, which contribute to loss in force transfer. A standardized simulation method needs to be developed and validated to predict the losses in the control linkage system. In this paper, the author proposes a simulation approach using multi-body dynamics, which includes contribution factors such as transmission angle, linkage elasticity, and friction in joints. MBS model for brake linkage system for three different tractors
Subbaiyan, Prasanna Balaji, Nizampatnam, Balaramakrishna, Redkar, Dinesh, Arun, G, K, Vinoth, R, Sengottu, Paulraj, Lemuel
Model Based Design of Gear Shift Control for Twin Clutch AMT2026-26-0054To be published on 01/16/2026
Model Based Design (MBD) uses mathematical modelling to create, test and refine systems in simulated environment, primarily applied in control system development. This paper discusses an approach to control gear shifting using shift logic on vehicle level for twin clutch transmission using prototype controller. Twin clutch transmission is a concept with two clutches, one at input end of the transmission called primary clutch and the other at output end of the transmission called secondary clutch. This concept is proposed to counter the challenges with conventional transmission which include increased gear shift time and effort in lower gears, potential rollback of vehicle in uphill condition and chance of missed shifts. The advantages of this concept include reduced gear shift effort and improved synchronizer life with potential for reducing the size of the synchro pack. This paper proposes a methodology to develop shift logic, integrate hardware with software, flashing and calibration
Patel, Hiral, Thambala, Prashanth, Tongaonkar, Yogesh, Mosthaf, Joerg, Malpure, Khushal
Efficiency Enhancement of Electric Vehicle Drivetrains through Advanced Gearbox Strategies2026-26-0053To be published on 01/16/2026
In the pursuit of sustainable mobility solutions, optimizing drivetrain efficiency has emerged as a critical factor in enhancing the overall performance, reliability, and market acceptance of electric vehicles (EVs). This study specifically focuses on achieving efficiency improvements within the gearbox system of Electric Vehicles, a major contributor to mechanical losses in the drivetrain. Key technical strategies explored include the adoption of low-viscosity lubricants, utilization of low-friction bearings, incorporation of high-efficiency oil seals, and the application of low-loss gear designs. Collectively, these enhancements aim to reduce mechanical frictional losses, leading to tangible benefits such as increased vehicle driving range, reduced energy consumption, lower carbon emissions, and decreased long-term maintenance costs. In addition to component-level improvements, the study investigates the integration of a 2-speed gearbox within electric vehicles as a system-level
Agrawal, Devesh, Bhardwaj, Abhishek, Bhandari, Kiran Kamlakar
Engine Management System Strategies for Mitigating Dual Mass Flywheel Resonance in Gasoline Powertrains2026-26-0052To be published on 01/16/2026
In today's fast paced and competitive automotive market meeting the customers expectations is the key to any OEM. This has led to development of downsized high performance engines with refinement as an important deliverable. However developing such high output engines do come with challenges of refinement, especially higher torsional vibrations leading to transmission noise issues. Hence, it becomes important to isolate the transmission system from these high torsional vibration input. To address this, one of the most common method is to adopt Dual Mass flywheel (DMF) as this component dampens torsional vibrations and isolates the transmission unit from the same. While Dual Mass Flywheel assemblies do great job in protecting the transmission units by not allowing the oscillations to pass through them, they do have their own natural resonance frequency band close to the engine idle (low) engine speeds, which must be avoided for a continuous operation otherwise it may lead to Dual Mass
Raiker, Rajan, viswanatha, Hosur C, Jadhav, Aashish, Jain, Ojase, Jadhav, Marisha
Multibody Dynamic Analysis of Belt-Type CVT Systems in Two-Wheelers: A Study on Slip, Misalignment, and Transmission Efficiency2026-26-0079To be published on 01/16/2026
More efficient drivetrain technologies are in greater demand in the two-wheeler market as a result of the introduction of BS6.2 emission standards. In order to satisfy these performance and regulatory requirements, Continuously Variable Transmission (CVT) systems—which are renowned for their stepless gear shifting and increased fuel efficiency—are being given more and more consideration. However, because CVT is nonlinear and multibody dynamic, accurately predicting its behavior is still a difficult task. With an emphasis on variables like belt slip, pulley misalignment, and transmission efficiency, this study provides a thorough multibody dynamic analysis of a belt-type CVT system used in two-wheelers. High-fidelity analysis of the belt-pulley interaction under various load and speed conditions is now possible thanks to the development of a novel modeling methodology using advanced multibody dynamics simulation software – Virtual Dynamics. The method makes early design validation
Shah, Swapnil, Mane, Prashant, Voncken, Antonius, Emran, Ashraf
Hypoid Gear Performance Redefined: Addressing Scoring and Whine Noise Concerns2026-26-0078To be published on 01/16/2026
Rear drive vehicles transfer power to the rear wheels through the Gear Carrier Assembly, which is fit at the central section of the Rear Axle. The Gear Carrier Assembly includes hypoid ring and pinion gears, set at the heart of the system. However, gear scoring and whine noise frequently emerge as critical challenges, leading to reduced durability and compromised performance of the vehicle. This study focuses on the design and process improvements aimed at addressing these concerns while enhancing the overall performance and reliability of hypoid gears. Design enhancements include macro geometry refinements, material upgrades, and modifications in the heat treatment process. These changes improved key mechanical properties such as contact stress, bending strength, impact strength, and motion transmission error (MTE). Process optimizations involved precise control over carburizing, hardening, and quenching temperatures, as well as adjustments in quenching pressure. These measures
Praveen, Abhinav, Deshpande, Praveen, Jain, Saurabh Kumar, Parmar, Mayur, Karle, Nilesh, Kanagaraj, Pothiraj, Pagar, Pawan
Comprehensive Durability Assessment of Planet Carrier in Heavy-Duty Tipper Gearboxes Using RLDA Torque Data2026-26-0443To be published on 01/16/2026
In heavy-duty tippers, where challenging conditions demand high torque, planet carriers play a crucial role by enabling efficient load distribution and torque transmission while supporting gear ratio and speed variation in space-constrained systems such as automatic transmissions, hybrid drivetrains, and electric vehicles. This paper focuses on the comprehensive durability performance assessment of planet carriers using duty cycles derived from RLDA measurements for a heavy-duty tipper gearbox development program. The existing Design Validation Plan (DVP) for the planet carrier considers first gear utilization of 10-15% at 40% vehicle overload, in line with historical data. However, recent trends in mining applications revealed vehicle overloads of 55-65%, leading to an increase in first gear utilization (25-35%). This shift presents challenges for OEMs to enhance design durability while incorporating additional safety margins to meet the demands of a competitive, cost-driven market
Bagane, Shivraj, Pendse, Ameya
3D Transient CHT Simulation of Frictional Heating in Jet-Lubricated Automotive Gears2026-26-0468To be published on 01/16/2026
Gears play a critical role in automotive transmission systems. During operation, frictional heat is generated in the intermeshing region due to loading. Effective lubrication and cooling are essential to minimize heat generation and ensure smooth operation. Lubrication failure can lead to a significant local temperature rise, potentially causing gear scuffing—a phenomenon where intermeshed gear teeth weld together and tear apart during rotation—resulting in severe damage and compromised transmission performance. To prevent this, gears are typically lubricated using splash or jet lubrication techniques. This study presents a Conjugate Heat Transfer (CHT) simulation of a jet-lubricated gear pair in an automotive transmission system to predict the local temperature rise due to frictional heating in the intermeshing region of the gears. The paper focuses on implementation of the frictional heat generation on the gear teeth and resultant transient temperature rise in the gear contact region
Ballani, Abhishek, Vartanian, Aleksandr, Schlautman, Jeff, Raj, Gowtham, Srinivasan, Chiranth, Maiti, Dipak
Drive Cycle Type Identification Using Data Driven Methodologies2026-26-0649To be published on 01/16/2026
Identifying the type of drive cycle is crucial for analyzing customer usage and optimizing vehicle performance and emission control. Methods that rely on geographical location are limited by varying driving conditions at the same location (e.g., heavy traffic during peak hours vs. free-flowing traffic at night). This paper proposes a methodology to identify the type of drive cycle (city, interurban, highway or others) using drive characteristics derived from vehicle data rather than geographical location. Real-world vehicle data from testing trucks is taken, whose drive profiles are already known. Initially, multiple characteristic features of the drive cycle are identified from literature surveys and domain experiences. These features, which can be extracted from basic signal data, include gear shifts, time spent in different driving modes (acceleration, cruise, standstill), velocity distributions, and an 'aggressiveness factor' representing overall driving style. Using ML based
Reddy, Mallangi Prashanth, Gorain, Raju, Ganguly, Gourav
Performance Evaluation and Optimization of Engine Brake System using Chassis Dynamometer2026-26-0511To be published on 01/16/2026
Engine braking is a deceleration technique that leverages the internal friction and pumping losses within the engine. By closing the throttle and potentially selecting a lower gear, the engine creates a retarding force that slows the vehicle. This practice contributes to better fuel economy, decreased brake system load, and improved vehicle handling in specific driving scenarios, such as steep declines or slippery road surfaces. To alleviate stress on their primary braking systems and prevent overheating, heavy vehicles frequently incorporate engine-based braking. While older trucks relied on simple exhaust brakes with a butterfly valve to restrict exhaust flow, these had limited impact. Hence contemporary heavy vehicles almost exclusively use more advanced engine braking technologies. Traditionally, our heavy-duty vehicles use Exhaust brake system to elevate the braking performance on hilly terrains. Hence an improved sample of Engine brake was developed for enhanced braking
M, Vipin Prakash, Rajappan, Dinesh Kumar, R, Suresh, N, Gopi Kannan
Tractor Clutch wear simulation by Inhouse development2026-26-0572To be published on 01/16/2026
To develop an accelerated Clutch test simulation method at inhouse laboratory as System level of validation to replicate field phenomena in short time with controlled repeatability and increased test accuracy. Wet clutch is one of the M&M technology project for higher hp(75) tractors. Currently Mahindra having dry clutch system in higher hp tractors & presently Wet clutch development in progress for higher HP tractors for increasing clutch life & to reduce clutch pedal operation as per customer requirement, hence new test rig to be developed for validating new tractor wet clutch system as per RWUP. Previously tractor clutch system is completely evaluated through field testing on tractor level. Thus, there are several drawbacks in field testing like more waiting time to avail seasons, more testing time, evaluation of limited number of samples, non-availability of complete tractor on time, less accuracy, less repeatability of test results, unsafe conditions of rider, higher human fatigue
D, Yashwanth, Raja, R, Udayakumar, S, M, Jeevaharan, Vijayakumar, Narayanan
Clutch Thermal Adequacy Assessment in Repeat Restart Launch Condition on Gradient2026-26-0434To be published on 01/16/2026
The clutch is a mechanical device that engages and disengages power transmission from the engine to the wheels. It consists of the clutch disc assembly and cover assembly. The clutch disc, with friction material linings, is mounted on the transmission shaft and gets clamped between the flywheel and cover assembly to transmit power as required. However, wear and tear occur due to the differential speeds and slippage between the engine and transmission during operation. Clutch performance is assessed for its thermal behavior under repeat restart conditions on steep gradients, which is essential for the reliability and durability of commercial vehicle clutches. Repeat restart test is a key test to assess clutch performance on a 12% gradient. This test replicates real world scenarios, such as truck launches on hilly terrains under full load, where the clutch experiences significant slippage due to speed differences. This generates heat, and repeated engagements can cause the temperature to
Munisamy, Sathishkumar, Chollangi, Damodar, Mane, Sudhir
Analysis and optimization of noise and vibrational performance of an e-axle2026-26-0340To be published on 01/16/2026
As the electric mobility landscape evolves, there is a growing emphasis on addressing the Noise, Vibration, and Harshness (NVH) challenges associated with electric drivetrains. The absence of an IC engine in EVs shifts the focus to other noise contributors such as gear meshing, electric machine operation, and structural vibrations. Despite the known influence of micro-geometry on gear dynamics, current optimization practices often rely on empirical adjustments or standard guidelines without fully utilizing advanced computational methods to predict and optimize NVH performance. There exists a pressing need for a systematic approach to analyse and optimize gear micro-geometry to reduce noise and vibration in high-speed e-axle applications. This research aims to bridge that gap by investigating the relationship between micro-geometry optimization and NVH characteristics of an e-axle. Through detailed modelling and optimization techniques, this research aims to identify optimal gear micro
Ankit, Priyadarshi, Kulkarni, Krishna, Momin, Vaseem
Wetting prediction of power train components under the influence moving components using smooth particle hydrodynamics2026-26-0384To be published on 01/16/2026
Passenger cars are subjected to extensive conditions ranging from driving through wet roads, water puddles, icy roads, and rain. This can affect the performance of different parts over time, one such aspect is the vehicle corrosion, whose impact is felt on a wide spectrum from aesthetics to safety due to loss of material. The general condition for corrosion mainly requires electrolyte to be present on the metal surface, which is transported through self-soiling and foreign soiling. Vehicle soiling is an important aspect for vehicle design. Amongst the many aspects of vehicle soiling, one important aspect is the prediction of water accumulation that enables prediction of corrosion sensitive regions in the vehicle. Power train components like Engine, transmission and corresponding wiring harness are at highest risk of water-wetting, As the vehicle drives through the water pool the components are not just wet by the direct inflow of water but also by water being splashed by moving
Shukrey, Sarthak, Pattankar, Rohan, Yenugu, Srinivasa
EVALUATION OF DRIVELINE NVH PERFORMANCE USING LINEAR DYNAMIC FINITE ELEMENT SIMULATION2026-26-0322To be published on 01/16/2026
Automotive driveline design plays an important role in the NVH characteristics of the overall vehicle. Driveline systems are an integral part of delivering torque from the engine/transmission to the tires which propel the vehicle and drivelines often experience a wide frequency of excitation which poses unique NVH challenges. With the increasing trend in the automotive industry to introduce turbocharged engines with fewer cylinders while delivering the same torque / power, the driveline systems are excited with increased lower frequency torsional vibration in addition to other vibrations transmitted from powertrain and road. In this paper, we address the key design consideration for developing an optimal driveline system with consideration to NVH while keeping durability and other functional requirements in perspective. We consider the example of a front wheel drive-based vehicle architecture with independent suspension. The effect of fundamental prop shaft frequency to determine
Joshi, Atul Kamalakarrao, Subramanian, MANOJ
Multispeed EV Transmission – Gear Shift Simulation and Validation2026-26-0157To be published on 01/16/2026
The advancement of electric vehicle (EV) transmission systems is currently a prominent trend aimed at decreasing carbon emissions and providing eco-friendly transportation alternatives. Most of the EV transmissions are single speed, but research conducted on multi speed EV transmissions show higher efficiency, good performance, high speed and torque demand when compared with single speed counterparts. Most of the multi speed EV transmissions that are developed are of non-synchromesh type, which have direct effect on NVH, driving dynamics and durability of drivetrain components. Due to aforementioned factors, gearshift analysis becomes critical for development. Simulation model is developed at early development phase for initial feedback. Using the feedback, drivetrain can be optimized furthermore and test on physical parts can be conducted for final verification. This paper provides a simulation based approach for modelling non-synchromesh two speed EV transmission using Simulation X
Kansagara, Smit, Thambala, Prashanth, Sutar, Suresh, Todtermuschke, Karsten, Patel, Hiral
Design & analysis of Dual Mass flywheel during Engine startup condition in 3 Cylinder Gasoline application2026-26-0349To be published on 01/16/2026
Modern automotive powertrains are increasingly adopting engine downsizing and down speeding to meet stringent emission regulations and improving fuel efficiency However, these changes result in higher torsional vibrations and excitation amplitudes makes more challenge in NVH (Noise, Vibration, and Harshness) refinement. With growing customer expectations for premium driving experiences conventional clutch are no longer sufficient. To meet the NVH performance targets of the vehicle Dual Mass Flywheels (DMFs) are used In DMF due to lower stiffness and inertia separation there is a great advantage on torsional filtration in normal drive and idle condition. but the resonance frequency of the connected DMF is lower than the idle RPM. Engine startup is a key drawback with DMF equipped vehicles. The proper tuning of starter motor performance & DMF stiffness is required to cross the resonance zone faster otherwise it will lead to DMF to stay in the resonance zone for a longer time leading to
Jayachandran, Suresh Kumar, Vijayaragavan, Thirupathi, M, Devamanalan, Kanagaraj, Pothiraj, Ahire, Manoj, Vellandi, Vikraman
A practical approach to reduce Gear Whine noise through gear Tooth contact analysis in an Agricultural Tractor2026-26-0345To be published on 01/16/2026
Customer demand for comfortable tractors has gone multi-fold in last decade. Transmission gear whine noise as one of the major sources of noise, is an important factor influencing the perceived quality of a vehicle and customer comfort. Investigations were carried out on 57HP tractor reported with high whine noise during deceleration from high speeds to low speeds. The source of whine noise is identified through order analysis as spiral bevel gear. Mitigating spiral bevel gear whine noise is always a challenge because of geometry, tooling and assembly requirements. Tooth contact analysis was performed on the spiral bevel gear for simulating the meshing of gear teeth to determine factors like contact patterns, transmission errors, and load distribution. From tooth contact analysis the root cause for high deceleration noise was identified as the motion transmission was not smooth in entry and exit for both forward and reverse. A practical approach of microgeometry optimization was
P, Bharath, P, Priyadarshan, Janarthanan, Devakumara Raja, Chavan, Amit
Virtual Validation of ADAS Algorithms Using Driver-in-the-Loop Simulation2026-26-0050To be published on 01/16/2026
Driver-in-the-Loop (DIL) simulators have become crucial tools across automotive, aerospace, and maritime industries in enabling the evaluation of design concepts, testing of critical scenarios and provision of effective training in virtual environments. With the diverse applications of DIL simulators highlighting their significance in vehicle dynamics assessment, Advanced Driver Assistance Systems (ADAS) and autonomous vehicle development, testing of complex control systems is crucial for vehicle safety. A comprehensive review of current research trends reveals key areas of focus such as realism of simulated experiences through improved vehicle dynamics models and advanced sensory feedback. The integration of virtual and augmented reality technologies help to create more immersive and informative simulations to improve the cost-effectiveness and accessibility of DIL simulation platforms. By examining the current landscape of DIL simulator use cases, this paper critically focuses on
Sharma, Chinmaya, Bhagat, Ajinkya, Kale, Jyoti Ganesh, Karle, Ujjwala
Experimental Evaluation of Metro Rail Bogie Frame through Bench Testing2026-26-0561To be published on 01/16/2026
Bogie frame is a main skeleton and structural member in railway system which is carrying all the loads such as Suspensions,Axles,wheels, car body, Motor, Gear box etc. The frame is subjected the exceptional and service stresses in Vertical, Longitudinal, Lateral and twist directions throughout the service life which should be withstand for a life span of 30 years without failure. The purpose of this project is to determine the Structural integrity of the Metro rail bogie frame in consideration with EN13749 standard .This paper is the outcome of bench testing of metro rail bogie frame with the application of multiaxial loading in static and dynamic campaign through which stress data is collected with strain gauge sensors and correlated with the FEA results at design stage. This helps to verify and evaluate the design and validate the quality of metro rail frame as per the requirement specified in EN13749 European standard in early design stages.
Tormal, Uday Bapurao, Sinnarkar, Nitin, Shinde, Vikram
Optimization Design of Typical Vehicle Frame Structure Using Power Flow Transmissibility Objective Function Method — Taking SD160-3 Model as an Example2025-99-021312/23/2025
According to a problem of the vibration and noise suppression of an engineering vehicle cab, a dynamical model of the engine-frame-cab system was established to describe the vibration transmission path. The method of calculation of the vibratory power flow, which is transmitted from the vibration source engine to the cab through the frame and isolators, was deduced. And then an optimization strategy for the frame structure and the corresponding analysis algorithm process were proposed based on the objective function of power flow. The method proposed was validated through an application to a practical example, which would have practical value in the field of vehicle vibration reductions and optimization design of frame structures.
Wang, Qiang, Huo, Rui, Guan, Yanfeng, Zhang, Daokun
Development of a Data Acquisition System for an Electric Formula SAE Vehicle2025-36-015112/18/2025
The acquisition of sensor data is essential for the operation and validation of the SAE vehicle. This system must be capable of converting analog data into digital form and communicating with the sensors. To this end, printed circuit boards (PCBs) were designed and manufactured, incorporating electromagnetic interference mitigation solutions through various analog filters, in order to ensure the integrity of the acquired signals. Data conversion and communication were implemented using a microprocessor from the STM32 family, with efficient transmission of the processed data carried out via the CAN protocol.
David, Mateus Padilha, Andrade, Fernanda Matsumoto Lima, Sousa Oliveira, Ivan, Carvalho, Luis Pedro Feio, Guerreiro, Joel Filipe, Ribeiro, Rodrigo Eustaquio, Santos Neto, Pedro José
Dynamic Analysis of a Continuously Variable Transmission and Effects on Vehicle Performance2025-36-000212/18/2025
CVT is a transmission system widely applied in automobiles due to its better efficiency of the vehicle available power. That happens because of the continuously variation of the transmission since its pulleys mechanisms makes it possible for them to open or close according to engine speed and resistive forces. This paper presents a dynamical analysis of a CVT Transmission that utilizes a rubber belt. It is considered that the influence of the pulley’s mechanisms and the axial movement of the belt, and these effects in the vehicle longitudinal dynamics.
da Silva, Gustavo Procópio, Vieira Fernandes, Bernard Prata M., Lopes, Elias Dias Rossi, Rodrigues, Gustavo Simão
Impact of Hydrogen Electrification on Transmission Systems for Heavy-Duty Vehicles2025-36-017812/18/2025
Powertrain architecture is being reshaped by the electrification of heavy-duty military vehicles using hydrogen fuel cell technology, particularly in transmission systems. Unlike conventional internal combustion engines, hydrogen fuel cell electric vehicles (FCEVs) typically use single-speed or direct-drive configurations due to the high torque of electric motors. This paper examines the impact of hydrogen electrification on military vehicle transmissions, focusing on armored multi-role models such as the VBMT-LSR, Guarani, and Leopard 1A5 of the Brazilian Army. The study compares traditional gearboxes with alternative solutions optimized for fuel cells, analyzing the trade-offs in efficiency, durability, and operational adaptability. Additionally, it explores adaptations required for hydrogen internal combustion engines (H2-ICEs), considering their distinct characteristics and demands. The study employs a three-step validation methodology combining computational simulations, technical
Biêng, Ethan Lê Quang, Pontes, Guilherme Ayroso, Conrado, Guilherme Barreto Rollemberg, Lopes, Elias Dias Rossi, Rodrigues, Gustavo Simão
Evaluation of Surface Integrity Aspects Induced by Different Gear Manufacturing Paths for Electric Vehicle Transmission Systems2025-36-006212/18/2025
The mobility electrification process is currently of great interest due to its environmental appeal, but it is accompanied by new technical requirements for vehicle systems, the powertrain being one of those with the most significant trade-offs to be solved. Higher power densities, higher torque efficiency and lower noise and vibration generation are simultaneously required. The literature shows that the manufacturing chain can influence the final state of surface integrity of a part, which affects the operational behavior and service life of a component. Therefore, a customized transmission system design for electric propulsion requires several analyses, from the raw material to the gear manufacturing processes, so that surface integrity plays a significative role in the required performance. From the perspective of their capability to meet the e-mobility requirements in terms of surface integrity is essential to conduct a comparative analysis of gear manufacturing processes. So, the
Gomes, Caio F. S., Gomes, Gilberto M. O., Colombo, Tiago C. A., Rego, Ronnie R., Michelotti, Alvaro C., Berto, Lucas F.
Vehicle Gear Shifting Optimization for Fuel Consumption and Emissions Minimization2025-36-011112/18/2025
Vehicles powered by internal combustion engines play a crucial role in urban mobility and still represent the vast majority of vehicles produced. However, these vehicles significantly contribute to pollutant emissions and fossil fuel consumption. In response to this challenge, various technologies and strategies have been developed to reduce emissions and enhance vehicle efficiency. This paper presents the development of a solution based on optimized gear-shifting strategies aimed at minimizing fuel consumption and emissions in vehicles powered exclusively by internal combustion engines. To achieve this, a longitudinal vehicle dynamics model was developed using the MATLAB/Simulink platform. This model incorporates an engine combustion simulation based on the Advisor (Advanced Vehicle Simulator) tool, which estimates fuel consumption and emissions while considering catalyst efficiency under transient engine conditions. Based on these models, an optimization method was employed to
Da Silva, Vitor Henrique Gomes, Carvalho, Áquila Chagas, Lopez, Gustavo Adolfo Gonzales, Casarin, Felipe Eduardo Mayer, Dedini, Franco Giuseppe, Eckert, Jony Javorski
Design and Construction of a Bench Test System for Elastomers Suspension2025-36-004112/18/2025
This study presents the design, construction, and experimental validation of a test bench for characterizing elastomer-based torsion suspensions in light vehicle applications. The system replaces conventional spring-damper assemblies with viscoelastic elements that simultaneously absorb and dissipate road-induced vibrations. We developed a scaled prototype instrumented with an Arduino-based data acquisition system and analyzed results using Octave®. The experimental protocol comprised: (1) tribological tests to identify optimal friction pairs through coefficient of friction (μ) and wear rate measurements, and (2) dynamometric evaluations of torque transmission capacity, power output, and efficiency across gear ratios (2.03-6.34). Results indicate that a steel-steel friction pair under a normal force of 250-300 N achieves optimal performance, delivering an output power of 1706 W (84.8% efficiency) and a torque of 30.25 Nm. Comparative analysis shows this configuration reduces wear rates
Silva, Diego Bruno, Grandinetti, Francisco José, Castro, Thais Santos, Dias, Érica Ximenes, Souza Soares, de Álvaro Manoel, Martins, Marcelo Sampaio, Reis de Faria Neto, dos Antônio
Feasibility Analysis of a Hybrid CVT-Manual Transmission: A Comparative Performance Study2025-36-019712/18/2025
Transmission systems play a crucial role in vehicle performance, efficiency, and adaptability. Conventional transmissions, such as Continuously Variable Transmissions (CVTs) and Manual Transmissions (MTs), each offer distinct advantages—CVTs provide smooth gear transitions and optimized fuel efficiency, whereas MTs deliver superior driver control, mechanical simplicity, durability, and high torque efficiency. This study explores the feasibility of integrating a dual-mode CVT-MT transmission into passenger vehicles to enhance driving dynamics and fuel efficiency. The proposed system uses the first gear to improve initial acceleration, a critical factor in urban driving, stop-and-go traffic, and high-load scenarios where CVTs struggle with torque delivery. After launch, the drivetrain transitions into CVT mode, leveraging its continuously adjustable gear ratios for efficiency and smooth power delivery. A simulation model based on MATLAB / Simulink will analyze the performance of the
Baldi, Eduardo, Lopes, Matheus Carlos Sinobio Elias D, Rodrigues, Gustavo Simão
Gear Ratio Variation Concept Influence on Energy Efficiency Optimization of Light Vehicles2025-36-010412/18/2025
The growing concern regarding global warming pushes the contribution of all emitting sources to mitigate greenhouse gases. The significant light passenger vehicle fleet deserves continued attention, both in the implementation of more efficient new technologies and in the optimization of conventional technologies, which are still widely used. The vehicle’s energy efficiency is directly influenced by the coupling of the internal combustion engine to the transmission system. Engines have a restricted operation region of maximum efficiency that must be adequately explored by the transmission system in the different conditions of vehicle use. Thus, this paper analyzes and quantifies the sensitivity of the vehicle’s energy efficiency of two distinct engine technologies, naturally aspirated and turbocharged, coupled to an automatic transmission system with six discrete or continuously variable gears. Experimental data on the overall efficiency of the engines and the transmission concepts
Rovai, Fernando Fusco, Menezes Lourenço, Maria Augusta de, Rohrig, Marcelo
Automatic Transmissions - Schematic DiagramsJ647_202512 (Current)12/11/2025
The following schematic diagrams reflect various methods of illustrating automotive transmission arrangements. These have been developed to facilitate a clear understanding of the functional interrelations of the gearing, clutches, hydrodynamic drive unit, and other transmission components. Two variations of transmission diagrams are used: in neutral (clutches not applied) and in gear. For illustrative purposes, some typical transmissions are shown.
Automatic Transmission and Transaxle Committee
Dynamic Resource Allocation and Redundancy Optimization for AFDX Networks2025-99-043312/10/2025
With the continuous development of avionics systems towards greater integration and modularization, traditional aircraft buses such as ARINC 429 and MIL-STD-1553B are increasingly facing challenges in meeting the demanding requirements of next-generation avionics systems. These traditional buses struggle to provide sufficient bandwidth efficiency, real-time performance, and scalability for modern avionics applications. In response to these limitations, AFDX (Avionics Full-Duplex Switched Ethernet), a deterministic network architecture based on the ARINC 664 standard, has emerged as a critical solution for enabling high-speed data communication in avionics systems. The AFDX architecture offers several advantages, including a dual-redundant network topology, a Virtual Link (VL) isolation mechanism, and well-defined bandwidth allocation strategies, all of which contribute to its robustness and reliability. However, with the increasing complexity of onboard networks and multi-tasking
Yang, Lei, Yang, Youzhi, Wang, Zhaoyi, Chang, An, Zhang, Xin, Lin, Zi
Response Analysis and Optimization of a Lightweight Seat Ring under Airborne Landing Impact2025-99-041112/10/2025
In order to meet the high lightweight and transmission accuracy requirements of a certain airborne system, the seat ring bearing adopts a lightweight material 4-point contact ball slewing bearing. However, the non-linear contact of a large number of balls during the working process of the seat ring makes simulation difficult, and ball damage often occurs in previous experiments. Based on the bearing capacity of the shaft, the influence of uneven load transmission of the ball on the response was considered. The response of the bearing under shooting and airdrop landing impact loads was calculated and analyzed using multi rigid body and finite element methods, respectively. The results indicate that under the impact load, the stress on the ball has exceeded the yield limit of the material, resulting in irreversible plastic deformation. The plastic deformation morphology is basically consistent with the damage morphology of the test ball, which verifies the accuracy of the simulation
Zhang, Taiping, Ning, Bianfang, Wang, Huating, Fan, He
Research on Off-Road Performance Optimization Strategy for Agricultural Smart Vehicles Based on Traction Control System2025-99-011811/11/2025
(TC)The paper presents a designed and evaluated optimal traction control (TC) strategy for unmanned agriculture vehicle, where onboard sensors acquire various real-time information about wheel speed, load sharing, and terrain characteristics to achieve the precise control of the powertrain by establishing an optimal control command; moreover, the developed AMT-adaptive SMC combines the AMT adaptive control algorithm and the SMC to implement the dynamic gear shifting, torque output, and driving mode switching to obtain an optimal power distribution according to different speed demand and harvest load. Based on the establishment of models of the autonomous agriculture vehicle and corresponding tire model, a MATLAB/Simulink method based on dynamic simulation is adopted to simulate the unmanned agricultural vehicle traversing different terrains conditions. The results from comparison show that the energy saving reaches 19.0%, rising from 2. 1 kWh/km to 1. 7 kWh/km, an increase in
Feng, Zhenghao, Lu, Yunfan, Gao, Duan, An, Yi, Zhou, Chuanbo
PTO Clutch Hydraulic Performance Evaluation Methodology Development & Correlation2025-28-029511/06/2025
This paper presents an analysis methodology developed to comprehend the impact of pressure spikes in off-highway applications, particularly during PTO (Power Take-Off) clutch engagement. These pressure spikes can adversely affect hydraulic subsystem components such as seals, gaskets, and valve operations. Assessing hydraulic system performance through physical trials can be cumbersome, resulting in longer development times and increased costs. To address this, a methodology was developed in a virtual environment to evaluate hydraulic system performance. The virtual method outlined in this paper is created in a 1D environment using a simulation methodology to replicate the transient behavior of the dynamic system. The hydraulic system primarily includes a relief valve, solenoid valves, a pump, and a clutch. An analytical model was developed for the hydraulic system components with appropriate fidelity to accurately replicate the transient behavior and magnitudes of pressure spikes. This
Memane, Nilesh, Kumar, Suneel, Veerkar, Vikrant
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