Browse Topic: Quality, Reliability, and Durability

Items (10,073)
Find
Efficient Multi-Parameter Optimization of a Twist Beam Rear Axle for Electric Vehicles using TOPSIS method for Durability2026-28-0067To be published on 02/12/2026
This study investigates the parameter optimization of a Rear Twist Beam (RTB) for an electric vehicle (EV) during the early stages of product development. Adapting the RTB design from a current Internal Combustion Engine (ICE) vehicle platform presents a complex challenge: accommodating increased rear vehicle load while minimizing cost and maintaining existing rear hard points. To address this, a Computer-Aided Engineering (CAE)-driven optimization using the Taguchi method was employed, avoiding costly physical durability tests. The key design parameters considered were the thickness and material grade of the RTB's child parts: the cross beam, trailing arms, and reinforcements, while preserving their original shapes. An L8 orthogonal array was utilized to efficiently evaluate the influence of these parameters on durability performance, and the optimal combinations for maximizing durability were identified. Furthermore, an Analysis of Variance (ANOVA) was conducted to quantify the
Madaswamy, Arunachalam, Dhanraj, Sudharsun, Govindaraju, Karthik, Lokaiah, Srinivasan
Dual use of Electric Vehicle infrastructure for Enhancing Grid Resilience and Urban Sustainability2026-28-0114To be published on 02/12/2026
The rapid global adoption of Electric Vehicles (EVs) has led to a surge in the deployment of EV charging stations. Beyond their primary role of vehicle charging, these stations hold potential as dynamic, grid-connected assets for sustainable cities and communities (SDG 11). When integrated with renewable energy sources such as wind or solar, EV charging stations can function as decentralized power units, supplying energy to the grid during times of need. This dual functionality allows them to act as flexible loads that mitigate voltage fluctuations during grid faults, facilitating access to reliable energy (SDG 7). Utilizing existing EV infrastructure in this way reduces the need for additional grid-support devices and supports resource efficiency (SDG 13) promoting a low-carbon energy transition. However, their ability to support the grid is limited when fully committed to meeting charging demands, especially during grid faults. To address this challenge, a novel coordinated operation
R, Uthra, Rangarajan, Ravi, D, Suchitra, D, Anitha
Resilient Design Strategies for Wireless Charger ECUs: A Proactive Threat Analysis and Risk Assessment Framework for Ensuring Cybersecurity in EV Charging Ecosystems2026-26-0173To be published on 01/16/2026
The proliferation of wireless charging technology in electric vehicles (EVs) introduces novel cybersecurity challenges that require comprehensive threat analysis and resilient design strategies. This paper presents a proactive framework for assessing and mitigating cybersecurity risks in wireless charger Electronic Control Units (ECUs), addressing the unique vulnerabilities inherent in electromagnetic power transfer systems. Through systematic threat modeling, vulnerability assessment, and the development of defense-in-depth strategies, this research establishes design principles for creating robust wireless charging ecosystems resistant to cyber threats. The proposed framework integrates hardware security modules, encrypted communication protocols, and adaptive threat detection mechanisms to ensure operational integrity while maintaining charging efficiency. Experimental validation demonstrates the effectiveness of the proposed security measures in preventing unauthorized access, data
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
Digital Control of Synchronous Rectification and Dead Time Configuration for Improving Efficiency and Longevity of DC Motors2026-26-0089To be published on 01/16/2026
This paper elucidates the implementation of software-controlled synchronous rectification and dead time configuration for bi-directional controlled DC motors. These motors are extensively utilized in applications such as robotics and automotive systems to prolong their operational lifespan. Synchronous rectification mitigates large current spikes in the H-bridge, reducing conduction losses and improving efficiency [1]. Dead time configuration prevents shoot-through conditions, enhancing motor efficiency and longevity. Experimental results demonstrate significant improvements in motor performance, including reduced thermal stress, decreased power consumption, and increased reliability [2]. The reduction in power consumption helps to minimize thermal stress, thereby enhancing the overall efficiency and longevity of the motor.
Patil, Vinod, Kulkarni, Malhar, Soni, Asheesh Kumar
Achieving Full ASIL-B Level Functional Safety (FuSa) for Automotive Clusters2026-26-0008To be published on 01/16/2026
Integrating advanced technologies into modern vehicles has led to an increasing focus on Functional Safety (FuSa), especially for the Automotive Integrated Cluster Module (ICM) to ensure the safety of the driver and passengers. This paper highlights the need to bring certain ICM components under an Automotive Safety Integrity Level B (ASIL-B) context using Classic AUTOSAR. This paper discusses the challenges faced and the solutions implemented for achieving compliance with ISO 26262 standards along with the Classic AUTOSAR framework. We are proposing a standardized and structured methodology for the design of the components in compliance with the key safety principles, including Freedom from Interference (FFI), execution under privileged levels, and integrity verification, particularly by adopting Classic AUTOSAR frameworks. This paper also presents the Functional Safety (FuSa) goals for these components and also extend to their configuration management and updating strategies within
Singh, Iqbal, Kumar, Praveen
Comprehensive Assessment of Volatile Organic Compounds and Efficacy of Vapor Recovery System at Fuel Stations2026-26-0233To be published on 01/16/2026
In densely populated urban environments, fuel retail outlets represent sources of Volatile Organic Compounds (VOCs), particularly benzene, toluene, and xylene. These emissions occur during various operations including storage tank filling, underground storage, and vehicle refuelling at retail outlets. The contribution of VOC by fuel distribution infrastructure to urban VOC pollution has been adequately addressed by oil marketing companies (OMCs) by the installation of vapor recovery system which is deployed for the comprehensive capture of fugitive emissions. This study employed a novel approach at an OMC Retail Outlet in Delhi, to evaluate benzene concentrations with different operational case studies. The methodology integrated continuous ambient air monitoring system equipped with VOC analyser of Gas Chromatography – Photo Ionization Detector (GC-PID) technology alongside targeted forecourt measurements with handheld PID instrument. Benzene emissions during peak and off-peak hours
Mayeen, Hafiz, Ahuja, Muskan, Kalita, Mrinmoy, Kumar, Prashant, Sithananthan, M, Arora, Ajay
Totem-Pole PFC and LLC Resonant Converter based 6.6kW On-Board Charger for LEV Applications2026-26-0160To be published on 01/16/2026
As light electric vehicles (LEVs) gain popularity, the development of efficient and compact on-board chargers (OBCs) has become a critical area of focus in power electronics. Conventional AC-DC topologies often face challenges, including high inrush currents during startup, which can stress components and affect system reliability. Furthermore, DC-DC converters often have a limited soft-switching range under light load conditions, leading to increased switching losses and reduced efficiency. This paper proposes a novel 6.6 kW on-board charger architecture comprising a bridgeless totem-pole power factor correction (PFC) stage and an isolated LLC resonant DC-DC converter. The main contribution lies in the specific focus on enhancing startup behavior and switching performance. In PFC converters, limiting inrush current during startup is crucial, especially with fast-switching wide-bandgap devices like SiC or GaN. Conventional soft-start techniques fall short in of ensuring smooth voltage
Patil, Amruta, Bagade, Aniket
Simulation-Driven Load Spectrum Prediction: Virtual RLDA for Chassis and Suspension System2026-26-0095To be published on 01/16/2026
In the rapidly evolving and highly competitive automotive industry, manufacturers are under immense pressure to bring products to market quickly while meeting customer expectations. As a result, optimizing the product development timeline has become essential. Structural integrity analysis for chassis and suspension systems lies in the accurate acquisition of operational load spectra, conventionally executed through Road Load Data Acquisition (RLDA) on instrumented vehicles subjected to proving ground excitation. At this point, RLDA is mainly used for final validation and fine-tuning. If any performance shortfalls, such as premature component failure or durability issues, are discovered, they often trigger design revisions, prototype rework, and additional testing. This study proposes a Virtual Road Load Data Acquisition (vRLDA) methodology employing a high-fidelity full-vehicle multibody dynamic (MBD) representation developed in Adams Car. The system is parameterized and uses high
Goli, Naga Aswani Kumar, Prasad, Tej Pratap
Design Solutions for Ice-Induced CNG Filling Failures: Field Issue Resolution through Filter Geometry and Seal Material Reengineering2026-26-0515To be published on 01/16/2026
Compressed Natural Gas (CNG) systems in automotive applications are highly sensitive to fuel quality, especially with respect to moisture content. Field issues were observed where high moisture levels in the CNG led to the formation of ice inside the receptacle during refueling operations. This ice formation obstructed the CNG filling process and adversely impacted the sealing performance of the O-ring, particularly under low-temperature conditions induced by pressure differentials between the storage tank and the filling station. Investigation revealed that the existing tablet-type filter design contributed to moisture entrapment within its wire mesh, exacerbating ice formation within the receptacle. To address this, the filter design was modified from a tablet-type to a cup-type filter, significantly reducing the likelihood of moisture retention and subsequent ice formation. Additionally, the O-ring material was upgraded to a formulation with improved sealing properties at lower
Virmani, Nishant, Sawant, Shivraj Madhukar, C R, Abhijith
Engine oil fluctuation study in HLA gallery and impact of VVT cam phasing on oil fluctuation.2026-26-0559To be published on 01/16/2026
Oil pressure, the most fundamental to engine's performance and longevity, is critical as it ensures that the engine components are properly lubricated, cooled, and protected against wear and contamination, ultimately contributing to reliable engine performance. Due to several factors of engine, such as speed and load, there are fluctuations in oil pressure, which can be controllable and sometimes unpredictable. Controlled oil pressure fluctuations are essential for engine efficiency and adaptability, such as adaptive lubrication, temperature compensation, and hydraulic component functioning like variable valve timing, VVT, and hydraulic lash adjuster, HLA. But excessive or irregular fluctuations can indicate serious issues like excessive or sudden drops, unstable engine performance, valve train noise, improper lifter operation, VVT malfunctions, overheating, and increased wear. In this paper, HLA gallery pressure fluctuations are studied, and its impact was assessed on valve train
Kumar, Ashok, Choubisa, Manas, Kumar, Ravi, Pathak, Mehul
Integrated Quality Assurance Frameworks for Testing Advanced Automotive Systems in the Era of ADAS and E-Mobility2026-26-0568To be published on 01/16/2026
As the automotive industry rapidly transitions toward intelligent, electrified, and connected mobility, ensuring the safety and performance of advanced vehicle systems has become increasingly complex. Technologies such as Advanced Driver Assistance Systems (ADAS), electric powertrains, and software-defined architectures demand robust quality assurance (QA) frameworks capable of addressing the multi-domain nature of modern vehicle platforms. This paper presents an integrated QA methodology that combines traditional testing protocols with model-based validation, digital twin environments, and real-time system monitoring to comprehensively evaluate the reliability and functionality of next-generation automotive systems. The proposed framework focuses on end-to-end traceability from requirements to validation, encompassing hardware-in-the-loop (HIL), software-in-the-loop (SIL), and over-the-air (OTA) testing strategies. Emphasis is placed on simulating complex scenarios for ADAS, battery
Komanduri, Arun Srinivas, Srivastava, Anuj
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
Accelerating Product Development Life Cycle through Digitalization of Fatigue Life for Structural Components2026-26-0496To be published on 01/16/2026
In today’s competitive market, accelerating product development without compromising durability is critical. Durability is a key benchmark for assessing the quality and reliability of automotive products. To meet rising customer expectations and regulatory demands, the industry must develop vehicles that offer high performance and reduced weight while ensuring safety. A well-engineered vehicle must retain structural integrity and functionality under normal operating conditions and withstand extreme load events without critical failure. Achieving this requires effective Road Load Data Acquisition (RLDA), integrated with robust design practices and efficient validation processes. However, physical RLDA is time-consuming and costly, as it depends on prototype vehicles that are often available only in the later development stages. Failures identified during these late-stage tests can delay the product launch significantly. To address these challenges, this paper introduces a digital
Kokare, Sanjay, Dwivedi, Sushil, Siddiqui, Arshad, Iqbal, Shoaib
A Quality-Driven Approach to Engineering Sign-Off for Software and Robust Product Development2026-26-0581To be published on 01/16/2026
This abstract outline a paper detailing the development and implementation of a comprehensive framework designed to enhance the quality and governance of the product development process in the automotive industry. As the sector undergoes significant transformation—driven by electrification, autonomous systems, and increasing regulatory and customer expectations—the need for structured development approach and robust oversight has become critical to success. The paper introduces a newly developed framework for Final Data Judgment (FDJ) and Engineering Sign-Off (ESO), representing a next-generation strategy to defect free design, robust engineering quality management and product maturity assurance. This methodology emphasizes customer-centric deliverables, risk-based assessments, and technical rigor to minimize post-SOP issues and ensure alignment with end-user expectations. The approach prioritizes end-user impact by embedding rigorous quality checkpoints that align engineering outputs
Digikar, Ashish, Pathak, Isha, Kothari, Bhushan
Tailgate Stiffness Mitigation and Engineering Strategy for Y-to-Y Tailgate-Mounted Tail Lamp Integration2026-26-0494To be published on 01/16/2026
The tailgate, as the rearmost vehicle opening, plays a pivotal role in defining the rear aesthetic theme while ensuring structural durability and maximizing luggage space. Contemporary automotive design trends highlight an increasing demand for Y-to-Y tailgate-mounted tail lamp configurations, which deliver a bold and dynamic visual appeal. Enhanced by animated lighting features, these designs cater to the preferences of Gen Z customers, becoming a decisive factor in purchasing decisions. However, integrating these complex tail lamp structures introduces significant engineering challenges, including increased X-dimension volume, reduced design space, and intricate mounting schemes constrained by stamping limitations. These factors necessitate the development of innovative joinery strategies and structural definitions to maintain durability targets, including achieving 25,000–30,000 slam cycles without failure, while preserving luggage space. This paper explores a comprehensive approach
Beryl, Joshua, Mohanty, Abhinab, Unadkat, Siddharth, Selvan, Veera
An investigation into the Structural Impacts of Off-Road Manoeuvres on Rear Axle upper Link Mounting Bracket2026-26-0490To be published on 01/16/2026
Multi-link rigid axle suspension is widely used as a rear suspension system for body-on-frame SUVs. The upper link in a multi-link rear suspension plays a critical role in managing the vertical and longitudinal positioning of the axle, while the lower link ensures stability by regulating the axle's movement in the horizontal plane. This coordinated functionality of upper and lower link allows for controlled axle dynamics during compression and rebound, significantly enhancing ride comfort and improving vehicle handling characteristics. This study examines the failure of an upper link mounting bracket on the rear axle of an SUV during off-road events, despite no failures observed in other durability tests. Root cause analysis is conducted on failed samples to determine the specific reasons for failure only in off-road conditions. Additionally, the investigation focuses on understanding the dynamic loads experienced by the upper link during vehicle operation across various durability
J, Akhil, Senthil Raja, T, Ghumare, Dheeraj, Chilakala, Raghavendra, Kundan, Lal, Mohapatra, Durga Prasad
EV Powertrain Systems Diagnostics & Prognostics utilizing AI & ML (LLM) based approach2026-26-0664To be published on 01/16/2026
This study introduces a novel Large Language Model (LLM)-driven approach for comprehensive diagnosis and prognostics of vehicle faults, leveraging Diagnostic Trouble Codes (DTCs) in line with industry-standard automation protocols. The proposed model represents a significant advancement in automotive diagnostics by not only identifying fault codes but also reasoning through the root causes behind them, thereby enhancing fault interpretability and maintenance efficiency. The LLM is trained on extensive service manuals, sensor datasets, historical fault logs, and OEM-specific DTC definitions, enabling context-aware understanding and correlation of faults. Analytical validation has been performed using real-world vehicle datasets from multi-brand platforms, demonstrating the model’s ability to detect complex fault chains and accurately predict probable root causes. By utilizing time series based projection of vehicle pattern, model could also predict the potential future faults basis the
Pandey, Suchit, Joshi, Pawan, Kondhare, Manish, CH, Sri Ram, Gajbhiye, Abhishek, S, Adm Akhinlal
Comparative Analysis and Implementation of data streaming methodologies for Vehicle Navigation Mode for Electric Trucks2026-26-0692To be published on 01/16/2026
In the realm of electric truck logistics, optimizing route planning is essential. This paper presents a key navigation feature for analyzing such optimized routes. Integrating map features into the drive mode improves user experience by offering real-time navigation and dynamic route adjustments based on traffic updates, road closures, and vehicle coordinates. This study compares the performance of Server sent events(SSE), web sockets and API polling methodologies, focusing on metrics such as data transmission efficiency, latency, resource utilization, scalability, and reliability. Our findings demonstrate the advantages and limitations of each method, providing insights into their suitability for real-time route optimization in electric truck logistics. The results highlight the potential of SSE in achieving efficient and timely data updates, contributing to more effective route planning and resource management. Additionally, we discuss how API Polling, Web sockets, and SSE each make
Bhandari, Mehul, Kaur, Prabhjot, Dadoo, Vishal, Mahendrakar, Shrinidhi, Ramanaiah, Rachala
UNIQUE HYBRID PANORAMIC HEADLINER CLIP WITH HIGH TOLERANCE TO REPLACE DUAL LOCK FASTENERS2026-26-0299To be published on 01/16/2026
Mounting strategies for vehicles with panoramic sunroofs remains a challenge owing to its high complexity to balance cost, performance and assembly efficiency. Achieving efficient and reliable headliner mounting solutions is one of the conundrums where cost optimization must go together with uncompromised performance. Traditional methods like Dual Lock Fasteners (DLFs), have set high benchmarks for robustness but at the cost of increased manufacturing complexity and expense. In pursuit of a more economical and production-friendly alternative, various plastic clip designs were explored. However, these solutions posed significant challenges during validation due to the stringent requirements for mounting feasibility, tolerance management, and long-term durability This paper introduces a novel hybrid plastic-metal clip solution that addresses those challenges comprehensively. The new design achieves precise tolerance control, ensuring reliable headliner installation under varying Body-in
D, Gowtham, Kumarasamy, Raj Ganesh, Shoeb, Mohd, Chauhan, Aarti
Lightweight AI Deployment for Legacy Automotive ECUs: A Practical Optimization Approach2026-26-0663To be published on 01/16/2026
Automotive systems are increasing adopting data-driven and intelligent functionality in the areas of predictive maintenance, virtual sensors and diagnostics. This has led to a need for the AI models to be directly run on vehicle ECUs. However, most of these ECUs – especially those in cost-sensitive or legacy platforms lack the computational capacity and parallel processing support required for standard AI implementations. Given the stringent real-time and reliability requirements in automotive environments, deploying such models presents a unique challenge. This paper proposes a practical methodology to optimize both the training and deployment phases of AI models for low-computation ECUs that operate without parallelism. Designing lightweight model architectures, using pruning and quantization techniques to minimize resource utilization, and putting in place a strategy appropriate for single-threaded execution are the three main objectives of the developed approach. The goal is to
Sharma, Sahil, Mathew, Melvin John
Durability Validation of Full Vehicle Structures Using Strain Correlation and RLDA-Based Simulations2026-26-0523To be published on 01/16/2026
Durability validation of full vehicle structures is crucial to ensure long-term performance and structural integrity under real-world loading conditions. Accurate strain correlation between physical testing and finite element (FE) simulations plays a key role in the validation, ensuring reliable predictions of vehicle durability. In this paper, a comprehensive methodology for strain correlation on a full vehicle subjected to torture track testing is implemented. Strategic placement of strain gauges is determined through a combination of static analysis, modal analysis, and identification of critical stress regions in the FE model. Strain gauges were installed on key structural locations of a prototype to capture strain responses under severe loading environments. Simultaneously, vehicle wheel loads were recorded on the torture track to build a detailed Road Load Data Acquisition (RLDA) dataset at critical hard points, Loads measured in terms of wheel loads (WFT) are fed to MBD model to
Jaju, Mayur, Dokhale, Sandeep, Gadre, Nilesh, Patil, Sanjay
Thermal Shock Test Rig for CNG Shut-off Valve2026-26-0526To be published on 01/16/2026
In Automobile, Gasoline Engines are being used along with electrically operated shut-off valve installed at the roof of bus in case of higher capacity of CNG systems. In order to start/ stop CNG supply from cylinder for running of engine/ safety/ servicing an electrical operated ignition switch/ key controlled CNG Shut-Off Valve is placed just after the cylinders. There have been few failures of these CNG shut-off valves in field application. On investigation, it was observed that the CNG shut-off valve gets failed due to water ingress in coils from the cracks on surface generated due to spray of water (due to daily washing of bus and rain) on heated shut-off valves. In order to validate this field failure and subsequent validation of modified design, a need was felt to use a test rig which can exactly simulate the water spray based thermal shocks. However, there was no low cost facility available to simulate the field service condition for validation. Therefore, a low cost test set-up
Srivastava, Pravin Kumar, Vivekanand, Vivekanand, Kumar, Satish
Dimensional Management in Automotive Vehicle Design & Development for Perceived Quality Improvement in Buses2026-26-0447To be published on 01/16/2026
Perceived quality (PQ) is one of the most important factors in engineering signoff as well as customer delight and product improvement (feel, look & touch). The PQ is something related to feel of the product in terms of gap, flushness, fitment and appearance as per the costumer perceptions and expectations. Validate both design and engineering with the perceived quality review. In today's automotive bus industry this is equally applicable. In this paper we have explored the dimensional management scope in improving the PQ requirements and expectations by utilising the dimensional variation analysis (DVA) approach. We have explored & explained the fundamentals of vehicle aggregates fitment process and impact of fitment tolerances as used in DVA model to resolve vehicle packaging issues (critical gaps & clearance variation as per expected no. of vehicles to be manufactured in future at initial stage of the vehicle design). It is further extended into system level DFMEA to include DVA in
Singh, Vinay Kumar, Dewangan, Ved Prakash, Kumar, Rahul, Deep, Amar
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-0501To be published on 01/16/2026
Manufacturing tolerances pose considerable challenges in the production of rubber-based components, often leading to dimensional variations that can compromise overall product reliability. These inconsistencies may result in a range of functional issues, including poor sealing, excessive wear, misfit during assembly, and premature failure. Among these components, grommets are especially sensitive due to the complex, non-linear behavior of rubber materials, making precise dimensional control critical to ensure consistent and dependable performance. Even minor deviations in grommet geometry can trigger substantial assembly difficulties. Issues such as misalignment, buckling, insertion challenges, and potential damage to neighboring parts are commonly encountered. These complications typically require multiple rounds of design revisions and physical testing, which extend development timelines and significantly increase production costs. Real-world observations from various automotive
Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, Pathan, Eram
Automated evaluation of drive file simulation accuracy2026-26-0528To be published on 01/16/2026
In the area of structural durability testing using servo-hydraulic actuators, developing drive files for the actuators is a major step. Testing outcomes depend on ensuring the simulation accuracy of each drive file. These drive files are developed in an iterative process for different test track surfaces at different road and load combinations till the time we achieve better correlation. Evaluation of simulation accuracy of the drive files is an extensive manual review process, making it time-consuming and resource-intensive. To address this challenge, an application has been developed to automate the comparison of actuator signals with predefined target signal files. This tool enables quick and accurate analysis of each drive file in a test run, facilitating a comprehensive review of signal deviations. Each test run has thousands of drive files based on road-load mix and actuator settings. This application helped us significantly optimize the simulation workflow by reducing the manual
Soni, Yash, Katake, Vrishali, Mullapudi, Dattatreyudu, Chaskar, Mithun
Study of real time impact on automotive cabin Air Quality due to the ambient air pollution in the severely polluted city2026-26-0531To be published on 01/16/2026
This study investigates the concentrations of PM2.5 and PM10 inside an automobile under real-world driving conditions in Delhi, one of the most polluted cities globally. India faces severe air pollution challenges in many cities, including Delhi, which are consistently ranking among the most polluted cities in the world. Major contributors to this pollution include vehicular emissions, industrial activities, construction dust, and biomass burning. Exposure to PM2.5 and PM10 has been linked to numerous adverse health effects, including respiratory and cardiovascular diseases, aggravated asthma, decreased lung function, and premature mortality. PM2.5 particles, being smaller, can penetrate deeper into the lungs and even enter the bloodstream, causing more severe health issues. In big cities like Delhi, long driving times exacerbate exposure to these pollutants, as commuters spend extended periods in traffic. Measurements were taken both inside and outside the vehicle to assess the real
Gupta, Rajat, Pimpalkar, Ankit, Patel, Abhishek, Kumar, Shubham, Joshi, Rishi, Kumar, Mukesh
Enhanced Methodologies for predicting Automotive Wheel Bearing life and damage using RLDA2026-26-0482To be published on 01/16/2026
The durability of wheel bearings is assessed in terms of raceway life and flange life. Raceway life focuses on the performance and damage tolerance of rolling elements, while flange life evaluates the structural integrity of wheel flanges under operational stresses. Traditionally, durability predictions relied on conventional design methods and analytic formulas for raceway spalling, as well as static load assumptions for flange fatigue analysis. Recently, integrating design of experiments (DOE) with traditional approaches has enhanced these methods, enabling systematic evaluation of design variables and loading conditions. This paper introduces a methodology for analysing raceway life and damage in automotive wheel bearings using RLDA (Road Load Data Acquisition) data. The process involves acquiring raw deterministic load data, filtering it to preserve high-peaked signals, and transforming the filtered data into block cycles derived from load time histories. Each block cycle contains
Narendra, Vishwanath, Mane, Yogiraj, Paua, Ketan, Singh, Ram Krishnan, Vellandi, Vikraman
Resolution of Automotive Air Compressor Noise in Low Powered ICE vehicle2026-26-0314To be published on 01/16/2026
Passenger compartment's interior noise and thermal performance are one of the essential criteria for the driving comfort of vehicles. This paper explains that how the AC compressor noise is optimized in specific to low powered 1 L - ICE engine and 120 cc IVDC compressor combination. This combination is quite challenging due to high operational load & higher operating pressure. For better in-cabin cooling efficiency, compressor operating efficiency to be improved which in turn leads to higher displacement of the compressor. Higher displacement will lead to higher internal forces which leads to more structure borne induced noise in-side the cabin. For this specific combination, the compressor operating pressure reached to 25 bar at most of the driving condition. During dynamic driving condition, compressor metallic tonal noise was reported in one of the A segment vehicle developments. It was reported as very annoying to inside passenger. Transfer Path Analysis, Compressor fixation point
John Britto, Vijay Antony, Maluganahalli-Dharmappa Madhusoodan Sr, Madhusoodan, Natarajasundaram, Balasubramanian
Combustion noise quality improvement in a common rail Diesel Engine at Low idle for Agriculture Tractor2026-26-0329To be published on 01/16/2026
Vehicle level NVH performance plays major role in customer comfort criteria. Tractor low idle rpm Sound Quality can be one of the parameter which influences customer purchasing decision based on comfort criteria. Modern diesel engines with stringent emission norms together with fuel economy requirements pose challenges to noise control. Common rail engine technology has advantage of precise fuel delivery and combustion control which needs optimization to achieve the conflicting requirements of noise, emission and fuel efficiency. Engine noise at low idle condition is dominated by combustion noise which depends on rate of pressure rise inside the cylinder during combustion. The important parameters which influence cylinder pressure rise are fuel injection timing, pilot injection quantity and its separation, rail pressure and EGR valve position. The study is carried out to understand which combustion parameter is most influencing to achieve better sound quality of engine. Taguchi design
P, Priyadarshan, Chavan, Amit, A, Kannanswamy, Patil, Sandeep, Chaudhari, Vishal V
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
Overview of Automotive Policies, Evolution of Automotive Regulations, and Striking a Balanced Approach for Harmonization2026-26-0242To be published on 01/16/2026
A well-regulated vehicle design and manufacturing instils driver and passengers' safety and comfort, and lays the foundation for safe and clean mobility. Evolution of Automotive regulation has a long legacy across the globe. India has been closely following the Automotive regulatory progress in the Europe as a cornerstone for technical harmonization, cross learning, gauge benefits and economic implications. Even though India being a developing country, it has not only shown its willingness to harmonize world's best practices but also been making right preparations towards safe and clean mobility. Adoption of BS-VI directly from BS-IV is a testament to India's commitment. While doing so, Government of India (GOI) has always been striking a balanced approach between harmonization of regulations and business implications (ground reality, TCO, business sustenance and growth). Given the above context, the paper explores about: i)Trajectory of evolution of Automotive regulations in India
Patil, Dharmarayagouda
Predictive Simulation Framework for Tyre Curb Impact Durability Assessment and Design Optimization2026-26-0396To be published on 01/16/2026
Tyre structural durability validation is a critical aspect of automotive design, considering the worsening road conditions. One of the key validation tests for assessing structural integrity is the curb impact test, which evaluates the tyre's ability to withstand sudden and concentrated impacts. Typically, this process involves physical testing of preliminary tyre samples, followed by iterative modifications to the tyre's construction to meet durability requirements. However, this approach often compromises ride performance, necessitating a more efficient and predictive methodology. To address this challenge, a frugal simulation-based prediction methodology has been developed to evaluate tyre curb impact durability before vehicle-level testing. This allows for the optimization of tyre design parameters early in the development process, ensuring structural performance while minimizing ride and handling (R&H) tuning iterations. By reducing the number of iterations, the methodology
Sundaramoorthy, Ragasruoban, Lenka, Visweswara
Design Robustness of Electronic Locking Differential for enhanced off-road performance2026-26-0502To be published on 01/16/2026
The Electronic Locking Differential (ELD) is a critical component for enhancing off-road vehicle performance by ensuring optimal traction in challenging terrains. This paper addresses intermittent engagement issues observed in the ELD system during off-road trials, which impacted its reliability and functionality. It presents a comprehensive study of design robustness improvements implemented to resolve these concerns and optimize the ELD’s performance, ensuring enhanced customer satisfaction in demanding off-road environments. The analysis begins with identifying factors contributing to the intermittent engagement and disengagement of the ELD system upon actuation. These factors include residual magnetism, material properties, temperature effects, and the stack-up characteristics of transfer path components under various boundary conditions. To address these challenges, three key design modifications were introduced: (1) reduction of residual magnetism through an increased air gap
S, Mohd Imtiaz, AP, Baaheedharan, Ghumare, Dheeraj, Kanagaraj, Pothiraj, Jain, Saurabh Kumar
Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application2026-26-0286To be published on 01/16/2026
Quality of the Shear Trimmed edge of HSLA 550 steels is significantly affected by process variations such as Shear Trimming Clearance, trim tolerance, burr height and clamping force. All these parameters largely influence the characteristics of the Shear Affected Zone, a region on sheet metal where it undergoes deformation during the trimming process. The Shear Affected Zone is predominantly vulnerable to failure due to work hardening and the effects of strain rate, induced by the tonnage during the trimming operation. To assess the edge ductility of these materials, Tensile, Fatigue Strength, Die Punch Clearance, Roughness and Hardness Tests are carried out. These tests are crucial for applications that demand high formability and resistance to edge failure. Virtual simulation of edge trimming operation using elastoplastic material models in LS-Dyna have been performed to gain insights into burr formation and damage evolution during shearing. These simulations act as a precursor to
Thota, Badri Vishal, Kashyap, Amit, Bhuvangiri, Jaydev
A Machine Learning Approach to Early-Stage Failure Prediction in Traction Motor Manufacturing2026-26-0281To be published on 01/16/2026
Traction motors technology has, driving the EV industry forward with more efficient, lightweight, and durable solutions. However, despite these advancements, noise testing at the end of the production line remains a critical stage for identifying manufacturing defects in traction motors. Hence early fault detection in traction motors is crucial to ensure safety and reliability of EV. This research contributes a solution that predicts early-fault detection, supporting improved reliability, reduced material cost and minimizing process time in the series production line. To identify the root cause of this problem, historical quality data has been acquired from manufacturing plants to enable efficient analysis. Feature selection was then carried out using embedded and wrapper methods to identify the most important features. These selected features were subsequently used as input for ML models. The best accuracy was achieved using SVC model for early-stage motor failure prediction.
Gaikwad, Pooja, Nangare, Kapilraj, Suryawanshi, Chaitanya
Technical management: Focus Matrix Methodology Applied to the 2° GEN of Bosch Flex Fuel Pump2025-36-005212/18/2025
Reliability and performance are critical for product success in engineering. With this aim, the Focus Matrix is a strategic tool designed to enhance the development process by effectively managing technical requirements and prioritizing resources. This paper outlines the application of the Focus Matrix in product development to organize technical packages based on complexity and the technical expertise of the project team. The methodology will be illustrated through a case study on the second-generation Flex Fuel (EVO) fuel pump developed by Bosch. The Fuel pump is responsible for delivering fuel to the engine while maintaining optimal pressure and flow rate. Transitioning to a second generation of a fuel pump focuses on optimizing performance to keep the product relevant in the market, necessitating a thorough analysis of lessons learned and current technological trends. Throughout the development phase, the Focus Matrix provided a structured approach for identifying and mitigating
de Souza, Ana Laura Lima, de Oliveira Melo, Lazaro Benedito, Aguiar, Rayssa Moreno Silva, Azevedo Fernandes, Luiz Eduardo de, Boa, Nathan Barroso Fonte
Methodology for Characterization and Measurement of Pavement Potholes2025-36-000912/18/2025
Potholes pose significant challenges to road infrastructure and the automotive industry, leading to safety risks, vehicle damage, and increased maintenance costs. These road defects form due to water infiltration, freeze-thaw cycles, heavy traffic, and inadequate maintenance, creating localized depressions with well-defined edges that compromise pavement integrity. Their impact extends to vehicle durability, affecting tires, suspension systems, and chassis components. This study presents a standardized manual methodology for pothole characterization, focusing on geometry, depth, and distribution assessment. Unlike advanced techniques such as LiDAR and GPR, this cost-effective approach requires no specialized equipment, making it accessible and practical for real-world applications. The methodology involves profile measurements, lateral positioning analysis within the lane, and density calculation based on pothole concentration by square kilometers. To validate the methodology was
Arias, Caio Borges, Dedini, Franco Giuseppe, Eckert, Jony Javorski
Urban Mobility: A Technological Contribution to the Modeling of a Conceptual Framework in a Cyber-Physical Environment for Reducing Traffic Congestion in the Expanded Downtown Area of São Paulo2025-36-009512/18/2025
2
Mello Filho, Luiz Vicente Figueira de, Canteras, Felippe Benavente, Meyer, Yuri Alexandre, Emiliano, William Machado, Júnior, Vitor Eduardo Molina, Gabriel, João Carlos, Iano, Yuzo
Injection Molding Parameters Optimization to Enhance Mechanical Properties of Glass-Fiber Reinforced PA9T Polymer2025-36-012412/18/2025
4
Mendonça, Arthur S., Michelotti, Alvaro Canto, Berto, Lucas F., Salvaro, Diego B., Binder, Cristiano
Case Study: Nanocomposite-Based 3D Printing and the Implementation of Quality Management to Enhance the Production of Automotive Parts2025-36-020612/18/2025
Additive manufacturing is one of the pillars of technologies of the industry 4.0 and enables rapid prototyping, testing of new materials, and customized manufacturing of parts with personalized design. Poly(lactic acid) (PLA) is a bio-based and biodegradable polymer that is used in packaging, medical applications, and consumer goods. However, it presents low mechanical strength and thermal stability, which limits its use in automotive parts. The use of reinforcement materials such as cellulose nanofibers (CNF) aim to increase the mechanical strength and thermal stability of PLA without reducing its ecological appeal. However, the addition of nanofibers in the 3D printing process can lead to reproducibility problems and constant clogging of the extruder nozzle due to the material’s lower printability. These difficulties may restrict its application to industrial processes due to reduced productivity. To address the challenges in the production of automotive parts with PLA/CNF composites
Oliveira, Vinícius, Horiuchi, Lucas Nao, Gonçalves, Ana Paula, Souza, Mariana, Polkowski, Rodrigo
Application of Lean Manufacturing Tools to Reduce Defect Incidence in Tire Production2025-36-002112/18/2025
The continuous pursuit of operational excellence in the tire manufacturing industry necessitates structured approaches to minimize production defects, improve resource utilization, and enhance product reliability. This study presents a comprehensive case study focused on the implementation of Lean Manufacturing tools within a high-volume production facility specialized in truck and bus radial (TBR) tires. The production line under investigation exhibited recurring defects on the sidewall region of the cured tires, referred to as defect F1, stemming primarily from condensation phenomena and steam management inefficiencies during the curing process. A detailed root cause analysis was conducted through structured brainstorming sessions, Ishikawa diagrams, and the 5 Whys method, revealing multiple converging causes including excessive internal pressure, improper drainage angles, degraded sealing interfaces, and inadequate vapor shielding. In response, a corrective action plan was deployed
Filho, William Manjud Maluf, Yoshimura, Sofia Lucas, Marques, Ana Sung, Sousa, Julia Zanardo, Siqueira, Gonçalo, Alves, Marcelo Augusto Leal, Ferreira, Wallace Gusmão
Manufacturing Optimization of Automotive Coatings: Applying Lean Six Sigma to Improve Filling Line Performance2025-36-001112/18/2025
This study presents the results of applying a Lean Six Sigma-based analytical approach to optimize the manufacturing of automotive coatings, specifically in a PU primer filling process. Through production flow mapping and the Define, Measure, Analyze, Improve, and Control (DMAIC) methodology, unplanned stoppages in the filling line were significantly reduced, addressing critical inefficiencies in automotive coating production. The research was driven by the need to enhance manufacturing productivity and ensure process reliability in the production of coatings used in the automotive sector. To achieve this, Quality Management tools, such as Pareto Analysis and the Cause-and-Effect Diagram, along with Lean Manufacturing techniques, including Kaizen Blitz, were applied. These methods facilitated the identification and mitigation of key causes of unplanned downtime, improving process efficiency and reliability. The results demonstrated a significant reduction in downtime, enhanced
Filho, William Manjud Maluf, Rodrigues, Mateus Ferreira, Carriero, Emily Amaral, Yoshimura, Sofia Lucas, Marini, Vinicius Kaster, Siqueira, Gonçalo, Alves, Marcelo Augusto Leal
Analyzing the Operation of Road Cold Chain Transportation Using Big Data in the Context of Cost Reduction, Quality Improvement, and Efficiency Enhancement2025-99-030312/17/2025
In recent years, the market size of cold chain transportation in China has been expanding, but the industry has problems such as low cold chain circulation rate, low efficiency, high damage rate, and high cost. Under the background of reducing costs and improving quality and efficiency in transportation and logistics, an index set for operational analysis covering average freight rates, daily average number of over-temperature alarm incidents, daily average driving distance, and daily average driving time was established from the perspectives of economic efficiency, quality, and efficiency. Based on data from a third-party platform, including vehicle trajectories, temperatures, speeds, and freight rates, the running situation of road cold chain transportation industry was analyzed. The analysis results show that in 2023, the average freight rate of China’s highway cold chain will rebound, the fluctuation range will significantly narrow, the standardization level of temperature control
Li, Sicong, Ye, Jing, Cao, Mengfei
Advanced Geological Prediction and Monitoring Measurement for Tunnels in Water-Rich Sections Near Reservoir Areas2025-99-032912/17/2025
In order to ensure the construction safety of tunnels in water-rich sections near reservoir areas, it is very important to adopt comprehensive and reliable advanced geological prediction technology combined with on-site monitoring and measurement. Taking the Chenlingding tunnel as an example, through the comprehensive geological prediction of the broken rock section near the reservoir, the numerical model of the broken rock section was established, and compared with the field measurement data. The results show that the comprehensive advanced geological prediction system combining short, medium and long distances, such as geological radar, seismic wave reflection method and advanced horizontal drilling, has high accuracy in adverse geology, rock fragmentation and water rich conditions in the tunnel; The rich water condition, fault information and rock engineering geology provided by the advanced geological prediction can provide reliable guarantee for the tunnel excavation scheme, the
Dai, Yunfei, Feng, Meijie, Liu, Dacheng, Tang, Xianyuan
Study on the Effect of Frequency-Modulated Rail Damper on Rail Vibration2025-99-032212/17/2025
To delay the formation and development of local periodic fluctuations on the surface of rail structures and improve the durability of rail facilities, the dynamic response and wheel-rail interaction of rail structures were studied in depth based on frequency-modulated rail dampers (TRDs). A fully-coupled 3-D FE framework of the wheel–rail assembly, integrating frequency-modulated rail dampers (TRDs), was developed to quantify vibration energy dissipation. Simulated decay curves revealed a marked rise (> 50 %) in lateral damping efficiency within 600–1 000 Hz, confirming TRD’s targeted suppression of rail transverse motion. Then, the suppression effect of rail corrugation after TRD installation was tested, and the data collection was carried out in the test section to calculate the frequency of rail corrugation. It was found that the possibility of corrugation deterioration of the rail structure was greatly reduced after the installation of the rail damper, and the suppression effect of
Li, Chengshun, Lei, Zhenyu
Research on Optimization Method for Railway Route Schemes in the Western Mountainous Area Considering the “Dual-Carbon” Strategy2025-99-030412/17/2025
Building a green and ecological railway transportation system that incorporates the “Dual-Carbon” Strategy is a central focus and challenge in current industry research. In the western mountainous regions with complex engineering geological conditions and fragile ecosystems, it is particularly important to explore the optimal railway route under the framework of the “Dual-Carbon” strategy. By analyzing the characteristics of the geographic environment of the western mountainous areas and the trend of low-carbon railroad construction, and referring to the relevant principles of railroad line selection, the method of quantifying the carbon emissions during the construction phase of the railroad and the carbon sequestration capacity of the land lost as a result of the railroad project’s land occupation is proposed by selecting 23 indicators from the five aspects of engineering adaptability, low-carbon adaptability, economic adaptability, environmental adaptability, and social adaptability
Wang, Yibo
Research on Risk Analysis of Emergencies in Heavy-Haul Railway Operations Based on Knowledge Graph2025-99-034712/17/2025
Heavy-haul railways are a critical component of China’s dedicated freight rail network, serving as the primary land transport channel for energy and resource intermodal transportation. Their safe operation and transportation is essential for ensuring the reliable delivery of energy and raw materials. Taking the Shuohuang Heavy-haul Railway as a case study, based on the hazards identified across its entire operational chain, an ontology model structured as "professional module–task–process–hazard–risk attribute–management object" is constructed in this paper. Based on this model, a knowledge graph for heavy-haul railway operational emergencies is established. The study analyzes the connectivity between different nodes (e.g., work processes and hazards) in the knowledge graph and their potential relationships with risk values. Using directed graph-based degree centrality analysis, a risk assessment method incorporating node centrality is proposed. Risk values are computed at both the
Fu, Liqiang, Ren, Xiaolin, Rong, Lifan
Manufacturing Reliability Growth for Automotive Engineering Volume IIIR-55112/11/2025
As the third installment in SAE International's DOE for Product Reliability Growth series, this volume explores the critical intersection of manufacturing processes, reliability, and profitability in automotive engineering. With a sharp focus on innovation, cost-efficiency, and customer satisfaction, this book demonstrates how design of experiments (DOE) methodologies can transform product quality through smarter manufacturing decisions. From structural assemblies to additive manufacturing, Volume III offers hands-on, data-driven guidance for engineers and professionals. Key topics include: • Structural Joints: Analyze and optimize bonded and mechanical joints-bolts, rivets, welds, adhesives, and more-using real-world DOE case studies to ensure robust assembly. • Mechanical Fabrication: Improve precision and consistency in processes like injection molding, drilling, heat treatment, and surface finishing through targeted DOE applications. • Electronic Fabrication: Harness DOE to enhance
Chiang, Young J.
Dynamic Graph Convolutional Recurrent Networks Based on Progressive Learning2025-99-044112/10/2025
Traffic flow prediction is the core challenge of transportation, and its key lies in effectively capturing the spatio-temporal dynamic dependencies. Aiming at the deficiencies of existing methods in modeling global temporal relations and dynamic spatial heterogeneity, this paper proposes a dynamic graph convolutional recurrent network (DGCRN) based on interactive progressive learning. First, the interactive progressive learning module (IPL) is designed to segment the input sequences through a tree structure, synchronize the extraction of spatiotemporal features using the interactive learning of parity subsequences, and adaptively capture the dynamic associations among nodes by combining with the dynamic graph convolutional recursive module (DGCRM). Secondly, a spatio-temporal embedding generator (STEG) is constructed to fuse temporal and spatial embedding to generate dynamic graph structures. Experiments validate the effectiveness of DGCRN on the PEMS04 and PEMS08 datasets with MAE
Su, Jiangfeng, Xie, Zilong, Liu, Chunya, He, Lan, Kou, Yujiao, Xue, Xue
Research on EBOM Scheme for Aviation Mechanical and Electrical Products2025-99-040112/10/2025
With the continuous improvement of information technology in aerospace manufacturing enterprises, the need for the integration and connection of various links in the product development process is becoming increasingly urgent. This article mainly introduces the research on BOM product structure, BOM effectiveness management, and product dataset management solutions for electromechanical products, and elaborates on the key technical content involved in detail, providing a basic capability framework for the comprehensive implementation of XBOM construction in the future.
Zhang, Dong, Zhou, Wenzao, Zhou, Huachuang
Items per page:
1 – 50 of 10073