Browse Topic: Transmissions

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From Reactive to Proactive: Applying Data Analysis and Automation to Mitigate PLC Communication Disruption2026-01-0250To be published on 04/07/2026
PLCs (Programmable Logic Controllers) are critical devices in manufacturing, enabling the functioning of machinery and the transmission of build data to other systems in a production facility. Thus, maintaining uptime of these devices is crucial for ensuring that a facility can keep its line running, as even a few minutes of downtime can cost a company thousands in lost units and revenue. One particular pain point that causes downtime is broken communication between the devices and downstream applications, especially those that track orders and traceability. While advances in computing and digital technology have enabled the quick detection of lost signalling and the quick restoration of communication channels, there is much work left to be done in this realm. Besides causing downtime, an incident disrupts the flow of the line, leading to much effort in order to restore normalcy of production, even after resolution of the incident. In addition, the outage and the post-incident recovery
Jan, Jonathan, Preston, Joshua
Research on the control of magnetic weakening scheme for the voltage utilization rate of hybrid transmission2026-01-0447To be published on 04/07/2026
This paper proposes a weak magnetic control method for PMSM current regulators based on the ratio of pressure to frequency and voltage utilization rate when the motor speed exceeds the weak magnetic speed. That is, the direct-axis offset current id is generated through the action of weak magnetic feedforward and weak magnetic I regulator, and the control of weak magnetic speed can directly adjust the demagnetization effect of id to achieve weak magnetic control of PMSM. The weak magnetic control method of PMSM current regulators with the outer loop of voltage utilization rate is adopted. It is proposed to use the phase-locked loop control method to decode the motor position signal in a closed loop and calculate the motor speed. The fluctuation of the position signal is reduced and the signal is more stable. This paper realizes constant power speed regulation based on high voltage utilization rate and weak magnetic control method at high speed operation above the base speed, which
Jing, Junchao, Yan, Xiaoqian, Liu, Yiqiang, Sun, Fengjiao, Dai, Zhengxing
Multi-Body Dynamics Control Integration Tool Application in Hybrid Vehicle System Identification2026-01-0417To be published on 04/07/2026
The multi-body dynamics (MBD) model and the MATLAB Simulink model can be integrated to create a control-integration model. Using a high-fidelity MBD model to represent the vehicle as the plant, this integrated model can be used to analyze vehicle system physics and develop control strategies. For hybrid vehicles, this process is more complex because the powertrain and other vehicle systems are often built as separate MBD models. This paper describes a method for integrating a powertrain model developed in AMESIM, a vehicle model developed in SIMPACK, and a control model developed in MATLAB Simulink. The resulting integrated model was then used to perform frequency sweep analysis to identify driveline system properties. In particular, the driveline frequency and the amplitude of the transfer function between motor speed and motor torque are critical parameters. By applying active damping control to the driveline system, the peak amplitude and driveline vibrations can be reduced. The
Xing, Xing, Mathew, Vino
Numerical Framework for Predicting Power Loss and Oil Flow Dynamics in Dip-Lubricated Gear Systems2026-01-0411To be published on 04/07/2026
Oil churning and windage power losses in dip-lubricated gearboxes can significantly improve overall transmission efficiency, particularly at high rotational speeds. As modern gearbox systems are pushed toward higher efficiency and reliability, understanding and predicting these losses becomes increasingly important. In addition to energy dissipation, the associated multiphase flow phenomena—such as oil splashing, thin film formation along gear surfaces, and aeration of the sump—strongly influence lubrication effectiveness, heat transfer, and component durability. Capturing these effects requires a robust numerical strategy that can resolve both power loss mechanisms and multiphase flow dynamics with sufficient accuracy. In this study, a single spur gear is numerically analyzed under varying oil depths and rotational speeds to quantify total power loss and investigate oil flow patterns. The computational approach employs a volume-of-fluid multiphase framework, and the predictions are
Mahyawansi, Pratik J., Haria, Hiral, Pandey, Ashutosh, KHAJEH HOSSEINI D, NAVVAB
Study of Approaches for Enhanced Traction Control Response for Hybrid Powertrain Architectures2026-01-0415To be published on 04/07/2026
Traction Control functionality requires fast and accurate response by powertrain system for wheel slip control. Close loop control effort of wheel slip shall be greatly reduced with more accurate feedforward torque. This paper explores the method of achieving requested traction control torque with better accuracy for torque converter-based hybrid electric powertrain architectures using improved dynamic modeling of torque converter. This method uses input inertia compensation involving feedforward and closed loop control modeling of torque converter and includes conversion of traction control intervention request through appropriate domains. Commanded torques by hybrid controller at wheel with and without these approaches are compared in Model in the loop simulation environment to identify optimum approach.
Karogal, Indrasen, Ober, Mitchell, Banuso, Abdulquadri, Sharma, Ashay
Development of Tilt Test Facility2026-01-0265To be published on 04/07/2026
Mobility, fire power and protection are the three most important characteristics of an Armoured Fighting Vehicle (AFV). Transmission system facilitates mobility to the fighting vehicle. Combat Vehicles Research and Development Establishment (CVRDE) is developing Automatic Transmission for Armoured Fighting vehicles which includes gearbox, steering system, braking system and control system. In the battle field, AFVs have to operate at different gradients & side slopes. The Automatic Transmission system being developed by CVRDE is a hydro-mechanical automatic transmission in which hydraulic oil is used for lubrication & control of various systems of it. A Tilt Test Facility (TTF) has been designed, developed, and installed at CVRDE to simulate different angles of gradients from +35° to - 35° & side slopes from +20° to -20°. The TTF enables to evaluate the functional aspects of the transmission system at different angles. The TTF consists of two tiltable platforms, Rotary actuators
V, Uma, Naik, Sheshu
Research on Reliability Test Methods for Electric Drive Axle Differentials2026-01-0007To be published on 04/07/2026
With the rapid socio-economic development, global issues such as the energy crisis and environmental pollution have become increasingly severe. Electric vehicles have garnered growing attention due to their environmental friendliness, simple structure, and high energy efficiency. Electric drive technology is regarded as the most ideal universal driving solution for pure electric vehicles, hybrid electric vehicles, and fuel cell vehicles. The electric drive axle, as a new type of integrated mechatronic transmission system, is being increasingly adopted owing to its advantages such as high drive efficiency, flexible spatial arrangement, and facilitation of digital and automated chassis control. This study focuses on reliability testing methods for the differential in electric drive axles, mainly including the extraction of reliability test conditions and feasibility analysis of the test scheme. The main research contents are as follows: First, based on specific parameters of an electric
Zheng, Hongyu, Li, Ziyu, Wang, Dajiang, tian, kai
Optimization of Lightweight Gear Blanks to Improve NVH for an Electric Drive Unit2026-01-0001To be published on 04/07/2026
A single-speed electric drive unit (eDU) with multi-stage reduction can have high gear whine due to high pitch-line velocity in the absence of engine masking noise. A comprehensive investigation is conducted focusing on the optimization of the first-stage transfer gear blanks to improve NVH performance and reduce mass for EV applications. A multibody dynamic model of the eDU was constructed, incorporating asymmetric gear blank geometry, shaft elasticity, bearing stiffness, and housing flexibility, in order to characterize realistic operating conditions and simulate gear contact mechanics with high fidelity and computational efficiency. NVH excitation sources, including static transmission error and dynamic meshing force, were systematically evaluated for solid and slotted gear configurations. Based on a DOE optimization study, an 8-slot gear blank design is selected to balance mass reduction, stress, NVH, and manufacturing requirements. Micro-geometry optimization was conducted for the
He, Song, Du, Isaac, Li, Bo, Bahk, Cheonjae, Grguras, Zachary, Baladhandapani, Dhanasekar, Patruni, Pavan Kumar
Vehicle Health Monitoring and Failure Prognosis through Edge-Based Component Wear Tracking2026-01-0094To be published on 04/07/2026
Traditional vehicle maintenance has relied primarily on mileage-based schedules and periodic visual inspections, approaches that often fail to account for variations in driving conditions, component quality, and usage patterns. These conventional methods typically result in either unnecessary premature replacements or unexpected component failures, leading to increased operating costs and unplanned downtime. Reactive maintenance strategies prove particularly problematic for critical wear components like clutch assemblies, brake systems, and suspension parts where undetected degradation can cause secondary damage. This paper presents an advanced monitoring system that shifts from scheduled maintenance to actual condition-based servicing through real-time wear measurement. The solution implements a network of distributed sensors that directly track critical parameters: ultrasonic measurement of clutch plate thickness, resistive wear sensors for brake pads, linear potentiometers for
Saraswat, Shubham, Vishe, Prashant
Experimental Validation of a Multi-Row Tapered Roller Bearing Analytical Model for Relating Preload to Frequency Response Characteristics2026-01-0008To be published on 04/07/2026
Roller bearings are used in many rotating power transmission systems in the automotive industry. During the assembly process of the power transmission system, some types of roller bearings (e.g., tapered roller bearings) require a compressive preload force. Those bearings' rolling resistance and lifespan strongly depend on the preload set during the installation process. Therefore, accurate setting of the preload can improve bearing efficiency, increase bearing lifespan and reduce maintenance costs over the life of the vehicle. A new method for bearing preload measurement has shown potential for both high accuracy and fast cycle time using the frequency response characteristics of the power transmission system. An open problem is experimental validation of the multi-row tapered roller bearing analytical model. After validation, the analytical model can be used to predict the assembled system damped natural frequency for a desired bearing preload. This work presents the experimental
Gruzwalski, David, Mynderse, James
New Inverter Switching Control Method to Enhance Sound Quality for Electric Vehicles2026-01-0437To be published on 04/07/2026
Conventional inverter control uses a fixed switching frequency, which leads to a high-pitched switching noise in electric vehicles (EVs) that does not vary with vehicle speed. Although EVs are generally much quieter than traditional internal combustion engine (ICE) vehicles, some EV owners complain about the lack of dynamic driving sound feedback. A new patented technology has been developed to enhance EV sound quality by dynamically controlling the inverter switching frequencies. This technology generates dynamic propulsion sound with new "switching order" features at multiple harmonics, with the pitch proportional to vehicle speed. A fixed pulse ratio between the switching frequency and the electric motor RPM is implemented to control the switching order. This reduces switching losses during low-speed operation and provides boosted acoustic feedback to the driver during acceleration, which enhances driving experience during sports driving. Furthermore, a special "EV shifting" sound
He, Song, Gagas, Brent, Welchko, Brian, Ball, Kerrie, Gong, Cheng
Dog Clutch actuator Control to mitigate NVH2026-01-0003To be published on 04/07/2026
Dog clutches have long been employed in the automotive industry across various applications, including transmission systems, transfer cases, axle disconnects, and hybrid driveline architectures. Their ability to provide direct mechanical engagement makes them ideal for torque transmission with minimal energy loss. However, the transition between engaged and disengaged states can introduce noise, vibration, and harshness (NVH), which may be perceptible to vehicle occupants and affect overall driving comfort. A typical dog clutch relies on interlocking teeth for torque transfer, and its actuation can result in NVH due to factors such as friction between mating surfaces, backlash between engagement components, teeth-on-teeth contact during synchronization, and impact forces during clutch engagement. This paper presents Stellantis’s approach to controlling the actuator system to mitigate NVH effects during clutch engagement and disengagement, focusing on strategies that enhance drivability
Xu, Chengyi, Sagi, Rama Rohit Varma, Madireddy, Krishna Chaitanya, Verhun, Brandon
Study of suppression properties on traffic waves of periodic vehicular platoons with typical platoon configurations2026-01-0167To be published on 04/07/2026
To investigate the suppression characteristics on traffic waves in the periodic configurations vehicular platoons, this paper analyzes the bandgap properties and frequency transmission characteristics of three typical platoon configurations: predecessor-following (PF), bidirectional (BD), and predecessor-leader-following (PLF). First, dynamic models of periodically structured platoons are developed for each configuration. Then, taking the BD periodic platoon as an example, the spacing error transfer matrix is derived by the lumped mass method, and a bandgap computation approach is formulated based on Bloch’s theorem. Building on this, the frequency transmission characteristics of periodic platoons using PF, BD, and PLF configurations are numerically solved and analyzed. Finally, numerical simulations are conducted to assess the suppression effect of platoons on traffic waves, comparing the bandgap properties and frequency transmission characteristics across different configurations
Yang, Xiujian, Zhuang, Qingyuan, Wu, Ruiqiong, Wang, Shenyi
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
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
Experimental Evaluation of Metro Rail Bogie Frame through Bench Testing2026-26-05611/16/2026
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 an 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 initial design phase. This helps to verify and evaluate the design and validate the quality of metro rail frame as per the requirement specified in EN13749:2021 European standard in early design stages.
Tormal, Uday Bapurao, Sinnarkar, Nitin, Shinde, Vikram
Drive Cycle Type Identification Using Data Driven Methodologies2026-26-06491/16/2026
Identifying the type of drive cycle is crucial for analyzing customer usage, optimizing vehicle performance and emission control. Methods that rely on geographical location for drive cycle identification 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 hybrid) 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 experience. 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
Reddy, Mallangi Prashanth, Gorain, Raju, Ganguly, Gourav
Tractor Clutch Wear Simulation by Inhouse Development2026-26-05721/16/2026
To develop a Test Method & Procedure for validating the Tractor clutch system performance & Wear simulation endurance test. Tractor clutch wear simulation test conducted along with transmission by operating clutch in different modes as per RWUP operation. In this test we can validate clutch field failures in short time with improved test accuracy at lab. In one of M&M technology project, Transmission Wet clutch system for higher HP tractors where we don’t have any dedicated test rig/methodology for validating Clutch wear & related failure simulation at lab
D, Yashwanth, Raja, R, Udayakumar, S, M, Jeevaharan, Vijayakumar, Narayanan
Design & Analysis of Dual Mass Flywheel During Engine Startup Condition in 3 Cylinder Gasoline Application2026-26-03491/16/2026
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 excitation amplitudes and NVH (Noise, Vibration, and Harshness) refinement more challenging. With growing customer expectations for premium driving experiences conventional clutch is 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 greater advantage on torsional filtration in normal drive and idle condition. But the torsional 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
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 Tractor2026-26-03451/16/2026
Gear noise is a common challenge that all gear manufacturers must contend with. In tractors, while it is often sufficiently low in intensity to not pose a significant issue, there are instances where gear whine may occur which is noticeable. In such cases, identifying the source and effectively addressing the problem can prove to be particularly difficult. This paper addresses the root cause analysis carried out for the evaluation of factors influencing whine noise behavior of Spiral bevel gear pair (SO2) in a tractor transmission system. Numerous publications have been published on gear noise of spiral bevel gear pair, too many to list here. However, once the gearbox assembled into the transmission, such models are of limited practical value. The work explained in this paper is a typical example offers avenues in correcting the issue using more limited means.
P, Bharath, P, Priyadarshan, Janarthanan, Devakumara Raja, Chavan, Amit
Performance Evaluation and Optimization of Engine Brake System using Chassis Dynamometer2026-26-05111/16/2026
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
Analysis and Optimization of Noise and Vibrational Performance of an Electric Axle2026-26-03401/16/2026
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 analyze 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
Clutch Thermal Adequacy Assessment in Repeat Restart Launch Conditions on Gradient2026-26-04341/16/2026
The clutch is a mechanical device that connects and disconnects engine power to the drivetrain through the clutch disc and cover assemblies. The disc, with friction material linings is mounted on the transmission shaft, transmits power when clamped between the flywheel and cover assembly. During operation, wear occurs due to speed differences and slippage between the engine and transmission. Clutch performance is evaluated under repeat restart conditions on steep gradients to assess thermal durability and reliability in commercial vehicles. The repeat restart test on a 12% gradient replicates truck launches under full load, where excessive slippage generates heat that may lead to friction material wear or failure if critical temperature limits are exceeded. To address the high cost and time of physical testing, a 1D thermal simulation was developed using GT Suite. The model replicates 90 repeat vehicle launches on a 12% gradient in first gear, integrating driver inputs and drive cycles
Munisamy, Sathishkumar, Chollangi, Damodar, Mane, Sudhir
Comprehensive Durability Assessment of Planet Carrier in Heavy-Duty Tipper Gearboxes Using RLDA Torque Data2026-26-04431/16/2026
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 carrier housing (PCH) using duty cycles derived from road load data acquisition (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 original equipment manufacturer (OEM) to enhance design durability while incorporating additional
Bagane, Shivraj, Pendse, Ameya
Bearing Creep Prevention in EV Transmission2026-26-05981/16/2026
As the trend shifts from Internal Combustion Engine (ICE) vehicles to Electric Vehicles (EVs), the operating speeds of prime movers have significantly increased. Commercial EV manufacturers prefer high-speed, low-torque motors coupled with transmissions over low-speed, high-torque motors due to higher efficiency and power density. This combination of high-speed, low-torque motors coupled with transmission is essential for achieving the required gradeability and enhances operational efficiency. However, the increased operating speeds of these EV transmissions have inherently increased the risk of ‘bearing creep’ [8]. The “bearing creep” is the phenomenon where unintended relative motion occurs between bearing races and their mounting surfaces, leading to premature wear of mounting surfaces [3]. This issue can lead to a series of failure modes such as increased gear mesh misalignment, bearing damage, seal damage, etc. These problems result into elevated transmission vibrations eventually
Bagad, Sachin Sunil, Kanase, Ashish, Hiremath, Satalingayya, Nevarekar, Sandip
Agricultural Tractor Brake Linkage Efficiency Prediction and Correlation Using Flexible Multibody Dynamics Model2026-26-01031/16/2026
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 from theoretical values based on mechanical advantage calculations. This is due to various factors such as linkage transmission angle, elasticity, and friction losses in joints. 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 models for brake linkage systems for three different tractors were developed with flex bodies using ADAMS/View
Subbaiyan, Prasanna Balaji, Nizampatnam, Balaramakrishna, Redkar, Dinesh, Arun, G, K, Vinoth, R, Sengottu, Paulraj, Lemuel
Engine Management System Strategies for Mitigating Dual Mass Flywheel Resonance in Gasoline Powertrains2026-26-00521/16/2026
In today’s fast paced and competitive automotive market, meeting the customer’s expectation 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
Fatigue Failure Analysis for Automotive Transmission2026-26-05771/16/2026
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 generates 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
Comparative Study of EV Transmission Performance Used in Various Vehicle Segments2026-26-05841/16/2026
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
Multibody Dynamic Analysis of Belt-Type CVT Systems in Two-Wheelers: A Study on Slip, Misalignment, and Transmission Efficiency2026-26-00791/16/2026
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 The method makes early design validation easier, minimizes iterations of physical prototyping and helps to maximize
Shah, Swapnil, Mane, Prashant, Voncken, Antonius, Emran, Ashraf
Oil Channelization for EV Transmission2026-26-00641/16/2026
Leakage of oil through breathers can be a serious concern in electric vehicle (EV) gearbox or transaxle units, especially due to the complexities presented by the small housing space and rotational components, which are running at relatively high speeds compared to conventional transmission units. Predicting the oil leakage from the transmission unit is another concern. Traditional methods are mostly centered on developing individual breather compartments, resulting in excess material usage, additional weight, and increased cost of manufacturing. To eliminate oil leakage through the air breather, the oil channelization technique used involves integrated oil deflection baffles, low-friction return channels, an oil accumulation cavity with cover, and strategically optimized airflow paths/vents. This design provides a number of benefits, such as increased gearbox reliability, minimized risk of component failure, and reduced maintenance needs, with all of these and a compact, cost
Ekshinge, Mahesh Shivaji, Agrawal, Devesh, Pandey, Ankit Kumar, Bhandari, Kiran Kamlakar
Development and Validation of a 1D Model for Evaluating Transmission Efficiency in Vehicles2026-26-00661/16/2026
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
Gear Shift Validation of Multi Speed EV Transmission on Test Bench using Vehicle Control Unit2026-26-05321/16/2026
Electric vehicle (EV) transmissions play a vital role in powering EVs by channeling 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 electric 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
Hypoid Gear Performance Redefined: Addressing Scoring & Whine Noise Concerns2026-26-00781/16/2026
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, one of the common issues with hypoid gears is gear scoring and whine noise, both of which can seriously affect durability and reduce the overall performance of a vehicle. In this study, the focus is on design changes as well as process improvements to address these problems and at the same time improve gear reliability. On the design side, changes such as refining the macro geometry, upgrading materials, and modifying the heat treatment cycle were carried out. These helped in improving properties like contact stress resistance, bending and impact strength, and also reduced motion transmission error (MTE). From the process point of view, careful control over carburizing, hardening, and quenching temperatures, along with adjustments in
Praveen, Abhinav, Deshpande, Praveen, Jain, Saurabh Kumar, Parmar, Mayur, Karle, Nilesh, Kanagaraj, Pothiraj, Pagar, Pawan
Analysis of Engagement Probability for Dog Clutch Geometry Parameters in Heavy-Duty Automated Mechanical Transmissions2026-26-04371/16/2026
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
Design & Optimization of CV Shaft System to Address Powertrain Induced NVH Issues2026-26-03361/16/2026
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 CV Shaft stiffness and
M A, Abdul Azarrudin, Jayachandran, Suresh kumar, Kumar, Shivani, Bhardwaj, Kinshuk, M, Devamanalan, Kanagaraj, Pothiraj, Ahire, Manoj
Virtual Validation of ADAS Algorithms Using Driver-in-the-Loop Simulation2026-26-00501/16/2026
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. By examining the current landscape of DIL simulator use cases, this paper critically focuses on Virtual Validation of ADAS algorithms by testing of repeatable scenarios and effect on driver response time through virtual stimuli of acoustic and optical warnings generated during simulation. To receive appropriate feedback from the driver, industrial grade actuators were integrated with a real-time controller, a high-performance workstation and simulation software called Virtual Test
Sharma, Chinmaya, Bhagat, Ajinkya, Kale, Jyoti Ganesh, Karle, Ujjwala
EV Transmission Efficiency Estimation Using Simulation X2026-26-04531/16/2026
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
Structural and Micro-Geometry Optimization of an Electric Drive Unit for Whine Noise Reduction2026-26-03151/16/2026
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
Efficiency Improvement of an Electric Vehicle e-Transaxle through Gear, Bearing, and Lubricant Optimization Strategies2026-26-00531/16/2026
Improving transaxle efficiency is vital for enhancing the overall performance and energy economy of electric vehicles. This study presents a systematic approach to minimizing power losses in a single-speed, two-stage reduction e-transaxle (standalone) by implementing a series of component-level design optimizations. The investigation begins with the replacement of conventional transmission oil with a next-generation low-viscosity transmission fluid. By adopting a lower-viscosity lubricant, the internal fluid resistance is reduced, leading to lower churning losses and improved efficiency across a wide range of operating conditions. Following this, attention is directed toward refining the gear macro-geometry to create a gear set with reduced power losses. This involves adjustments to parameters such as module, helix angle, pressure angle, and tooth count, along with the introduction of a positive profile shift. These modifications improve the contact pattern, lower sliding friction, and
Agrawal, Devesh, Bhardwaj, Abhishek, Bhandari, Kiran Kamlakar
Model Based Design of Gear Shift Control for Twin Clutch AMT2026-26-00541/16/2026
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
Power Loss Evaluation in 4WD Axle & Correlation with Testing Results2026-26-01071/16/2026
In tractors, efficiency is predominantly influenced by the transmission system, with transmission elements being the major contributors to power losses. Enhancing efficiency necessitates monitoring these power loss areas. Transmission power loss refers to the reduction in power from the engine to the final drive elements. Various parameters and factors affect these losses, and analyzing these conditions helps identify and improve the components that contribute most to driveline efficiency. This study correlates analytically calculated power loss with losses measured during testing under different load conditions. Additionally, critical parameters contributing to power loss in gears, bearings & in seals have been identified, and theoretical relationships have been established.
Jayapal, Jayaraj, Mahapatra, Soumya Ranjan, Sethi, Suvendu Kumar, Joshi, Shrikant, Bange, Prashant
Powertrain Optimization of Indian City Electric Bus Using Active Learning Simulation Methodology2026-26-06571/16/2026
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), e-Bus 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 e-Buses 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
Electromagnetically Levitated Engine Mount2026-26-03421/16/2026
In the evolving landscape of the automotive industry, enhancing passenger comfort and ride quality has become a key differentiator for manufacturers. While suspension systems have traditionally received significant attention, powertrain isolation through engine mounts plays an equally critical role in controlling noise, vibration, and harshness (NVH). Engine mounts are not only responsible for supporting the powertrain’s weight but also for mitigating the transmission of unbalanced engine forces to the vehicle body. Modern engine mount designs aim to eliminate any metal-to-metal contact between the powertrain and chassis, thereby achieving optimal vibration isolation. This study proposes a refined approach to completely decouple the powertrain from the vehicle structure, ensuring minimal vibration transfer and thereby extending the operational life and performance of the engine mount system.
Hazra, Sandip, Naik, Sarang Pramod, More, Vishwas
Optimization of Propeller Shaft Design to Eliminate Launch Undulation (Lateral Shake) and Vibration Level2026-26-03341/16/2026
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
E-Drive System Selection Criterion for Hybrid Electric Heavy Commercial Vehicles Segments2026-26-04671/16/2026
The automotive industry has been expediting progress toward electrification since climate change driven by global warming represents a significant environmental challenge with far-reaching implications. While electric vehicles offer considerable potential for mitigating CO₂ emissions, their elevated upfront costs pose a notable challenge to large-scale market penetration. Hybrid electric vehicles can serve as an effective intermediary solution, bridging the gap between conventional internal combustion engine vehicles and fully electric vehicles, owing to their comparatively lower initial costs. Hybrid electric vehicle component selection is a complex process that must fulfill multiple requirements: fuel economy, performance, drivability, packaging, total cost of ownership and comfort. Additionally, the selection of hybrid configuration also plays a vital role in determining the cost of the hybrid electric vehicle. Hence, it is a great challenge to select the right powertrain
Shendge, Raman, Jadhav, Vaibhav, Wani, Kalpesh, Warule, Prasad
The Selection of a Two-Speed Gearbox for Small Commercial Electric Vehicles Aims to Optimize Powertrain Efficiency2026-26-04171/16/2026
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 which includes 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
Wani, Kalpesh, Jadhav, Vaibhav, Shendge, Raman, Warule, Prasad
Multispeed EV Transmission – Gear Shift Simulation and Validation2026-26-01571/16/2026
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
3D Transient CHT Simulation of Frictional Heating in Jet-Lubricated Automotive Gears2026-26-04681/16/2026
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
Evaluation of Driveline NVH Performance Using Linear Dynamic Finite Element Simulation2026-26-03221/16/2026
Automotive driveline design plays an important role in defining a vehicle’s Noise, Vibration and Harshness (NVH) characteristics. Driveline system, responsible for torque transfer from the engine/transmission to the wheels, is exposed to a wide spectrum of vibrational excitations. The industry’s shift toward turbocharged engines with fewer cylinders while maintaining the equivalent torque and power has led to increased low-frequency torsional vibrations. This paper presents some key design considerations to drive the NVH design of a driveline system using linear dynamic FE simulations. Using an E-W All-Wheel Drive driveline architecture with independent suspension as a case study, the influence of various subsystem modes on driveline NVH performance is examined. The paper further explores the strategies for vibration isolation, motion control, and mode management to identify the optimal bushing rates and its location. Furthermore, it examines the ideal bushing specifications for
Joshi, Atul Kamalakarrao, Subramanian, MANOJ
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