Browse Topic: Quality, Reliability, and Durability

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Optimizing Weld Placement in Automotive Structures Using Topology and Multi-Disciplinary Approaches2026-01-0514To be published on 04/07/2026
This work presents two approaches for weld optimization aimed at reducing manufacturing cost and process time, while meeting structural performance requirements in automotive structures. The first approach uses topology optimization to identify the most efficient weld layouts. A design space is generated along mating flanges, joints, and panel interfaces, where potential weld locations are defined. Welds are treated as discrete design variables, and the topology optimization systematically evaluates their contribution to global stiffness and load path integrity. Non-critical welds, those with minimal impact on stiffness, durability, or crashworthiness, are eliminated, resulting in a minimized weld pattern that maintains structural performance. The second approach applies Multi-Disciplinary Optimization (MDO) to balance weld reduction with performance targets across multiple domains, including linear and non-linear stiffness, crashworthiness, and fatigue. Using a preprocessing tool
Koppaka, Vinaya, Yoo, Dong Yeon, Chavare, Sudeep
Minimal Binary Patching for Safety-Critical Systems2026-01-0088To be published on 04/07/2026
Patching vulnerabilities in safety-critical domains such as automotive and aerospace is costly and complex. A small code modification can trigger a complete rebuild, producing a binary with widespread changes. This inflates patch size, complicates regression testing, and makes over-the-air (OTA) updates inefficient, as traditional binary diffs often replace large portions of the executable. We present a binary rewriting–based experiment that shows the feasibility of a patch that updates only the affected bytes by computing the impact of a code change at the binary level. This produces minimal, localized patches rather than regenerated executables. The preliminary experiment shows that a single source change, which leads to thousands of modified bytes after recompilation, can be captured with only a few bytes using our method. For automotive and aerospace systems, this technique reduces patch size, conserves bandwidth, and minimizes disruption to certified software, offering a promising
Awadhutkar, Payas, Tamrawi, Ahmed, Sauceda, Jeremias
An Updated Correlation Study between the Full Size Wind Tunnels of General Motors, Ford Motor Company, and FCA US LLC2026-01-0612To be published on 04/07/2026
As automotive aerodynamic testing facilities evolve to capture more real-world behavior, updating the correlation between old and new technologies is essential. Recently, the three-member consortium of the United States Council for Automotive Research (USCAR) - FCA US LLC, Ford Motor Company, and General Motors - transitioned from full-size static ground plane facilities to 5-belt moving ground plane wind tunnel facilities. The primary objective of this study was to update the correlation data sets to maintain consistent and robust data sharing among companies, which is the cornerstone of USCAR efforts. To achieve this, a set of updated correlation data sets were calculated to replace the original correlation study results from 2008. Additionally, the methodology for applying correlation equations was revised from using averaged wind tunnel data to employing direct wind tunnel-to-wind tunnel correlation equations. In a two-phase correlation effort conducted in 2022 and 2025, the three
Nastov, Alexander, Lounsberry, Todd, Madin, Trevor, Langmeyer, Gregory, Fadler, Gregory, Skinner, Shaun, Horton, Damien
The Necessity of a Holistic Safety Evaluation Framework for AI-Based Automation Features2026-01-0522To be published on 04/07/2026
The intersection of Safety of Intended Functionality (SOTIF) and Functional Safety (FuSa) analysis for driving automation features has traditionally excluded Quality Management (QM) components from rigorous safety impact evaluations. Historically, QM components have not been classified as safety-relevant, and therefore their potential influence on overall system safety has often been overlooked. However, recent advancements in artificial intelligence (AI) integration within automated driving systems have revealed that these components can, under certain conditions, contribute to SOTIF-related hazardous risks. This emerging reality challenges long-standing assumptions and underscores the need for a more inclusive approach to safety analysis. Furthermore, compliance with evolving AI safety standards, such as ISO/PAS 8800, necessitates a re-evaluation of safety considerations for components previously deemed outside the scope of FuSa and SOTIF frameworks. This paper examines the necessity
Abbaspour, Ali Reza, Mahadevan, Shabin, Zwirglmaier, Kilian, Stafford, Jeff
Active site characterization of CuSCR catalysts under H2-ICE exhaust gas conditions2026-01-0361To be published on 04/07/2026
Hydrogen engines (H2-ICEs) can be a bridge technology for reducing carbon emissions until fuel cells and battery systems reach full commercial readiness. Because they share similar components to diesel, allowing the use of existing components and infrastructure, making them easier to scale. At the same time, H2-ICEs can deliver diesel-like performance, durability, and reliability while maintaining the advantage of fast refueling. Lean-burn H2-ICE offers enhanced thermal efficiency while minimizing engine-out NOx emissions. One of the main challenges under lean-burn H2-ICE operation is the significant drop in turbo-out temperatures combined with higher water content and the possible presence of unburned hydrogen in the exhaust. This study examines the impact of excess water and residual hydrogen on Cu-SCR durability, active site chemistry, and stability for the case with and without an upstream oxidation catalyst, through aging tests at 450 °C and 550 °C. Changes in Cu redox cycles were
Kim, Mi-Young, Daya, Rohil, Kamasamudram, krishna
Predicting Electric Vehicle Interior Noise Quality from Drive Unit End-of-Line Vibration Testing2026-01-0223To be published on 04/07/2026
The Noise, Vibration, and Harshness (NVH) quality of electric vehicles (EVs) is heavily influenced by the performance of the electric drive unit. As a critical step in production, End-of-Line (EOL) testing of drive units is used to assess and control component-level NVH before vehicle assembly. However, the correlation between EOL test results and final vehicle interior noise quality, which directly impacts customer satisfaction, is not always fully understood. This paper presents a methodology for characterizing and predicting vehicle interior noise quality based on data from drive unit EOL vibration testing. Our study investigates the intricate relationship between drive unit assembly variations, component tolerances, and the resulting vibrational response. We establish a robust correlation between these drive unit characteristics and both objective vehicle interior noise levels and subjective customer perception. The findings provide a framework for using EOL data to proactively
Arvanitis, Anastasios, Jangid, Kuldeep
Data-Driven Objective Road-Driving Classification For Durable Design Of Vehicles2026-01-0181To be published on 04/07/2026
Durability development in the automotive industry depends on a clear understanding of how road surfaces and driving characteristics affect structural road loads and fatigue. Traditionally, road surface classification has been subjective (e.g., city, highway, rural), and done through driving instrumented vehicles over a small selection of roads. The variations in driving characteristics that are often consequent to the road surface quality is rarely accounted for in designing vehicle level durability tests. This makes it difficult to establish targets for the durability testing that accurately match the wide variations in real-world roads and driving across the market of vehicles. This paper presents a data-driven approach to objectively classify road surface and driving characteristics using metrics derived from existing vehicle and road response metrics like Vibration Dose Value (VDV), International Roughness Index (IRI) and statistical estimates of vehicle speed and acceleration
Shaurya, Shubham, Ramakrishnan, Sankaran, Demiri, Albion, Khapane, Prashant
Self-Supervised Gaussian-Based Framework for Robust Static-Dynamic Decomposition and Real-Time Urban Scene Reconstruction2026-01-0010To be published on 04/07/2026
We propose a self-supervised Gaussian-based framework that enhances the robustness and efficiency of static-dynamic decomposition and high-fidelity reconstruction in autonomous driving scenarios. Existing approaches demonstrate promising performance but remain prone to noisy motion segmentation, overfitting on sparse LiDAR observations, and degraded accuracy in low-texture or distant regions, resulting in unstable geometry. To address these challenges, our method introduces a feature fusion module that jointly exploits image semantics and geometric cues, enabling more reliable motion prior extraction under noise and illumination variations. A cross-sequence geometric consistency constraint is further designed to regularize reconstruction across temporal and viewpoint changes, ensuring physically coherent scene representations. In addition, we formulate an efficient Gaussian parameter optimization strategy that constrains scale and normal updates, preventing unrealistic ellipsoid growth
Feng, Runlei, Wang, Ning, Zhang, Zhihao
Maintaining a Healthy Safety Culture in Autonomous Vehicle Development and Operations2026-01-0528To be published on 04/07/2026
The deployment of autonomous vehicles (AVs) requires not only technical excellence but also the cultivation of a robust organizational safety culture. While safety engineering standards and assurance processes provide essential structure, a culture that prioritizes learning, accountability, and continuous improvement is critical to ensuring public trust and operational resilience. This paper explores how UL 4600, the comprehensive safety standard for the evaluation of autonomous systems, and Safety Performance Indicators (SPIs) can be leveraged to build and sustain a Just Culture within an AV company. UL 4600 emphasizes systematic hazard identification, safety case construction, and ongoing evidence generation. When applied beyond compliance, it provides a framework for embedding safety considerations into day-to-day engineering and operational decision making. By mapping UL 4600 clauses into organizational processes and linking them with measurable SPIs—such as rates of system
Wagner, Michael, Gittleman, Michele
Sensorless Estimation of In-Cabin CO2 Concentration for Model-Based Air Recirculation Control2026-01-0130To be published on 04/07/2026
This paper introduces a sensorless approach for data-driven modeling of in-cabin CO2 concentration to optimize air recirculation flap control without the need for a dedicated CO2 sensor. Elevated CO2 concentrations, resulting from passenger exhalation, can impair occupants’ cognitive function and comfort. Current state-of-the-art solutions rely either on time-based control strategies, which lack responsiveness to actual cabin conditions, or on direct CO2 measurements via sensors, which increase system complexity and costs. In contrast, the proposed approach aims to replicate the benefits of sensor-based control without requiring physical sensors. In this study, a model-based methodology is presented, utilizing empirical CO2 measurement data collected from real-world test drives at varying occupancies, fan stages, vehicle speeds, and flap positions. Data acquisition involves a multi-gas analyzer positioned within the passengers’ breathing zone under controlled operation of the vehicle’s
Stürmer, Michael, Geier, Bertram, Hofstetter, Martin, Hirz, Mario
Predictive Modeling and Sensitivity Analysis of Thermal Runaway in 800V Lithium-Ion Battery Pack Module Using DFSS Methodology2026-01-0124To be published on 04/07/2026
Thermal runaway in high-voltage lithium-ion battery modules should focus on critical safety and design challenges in electric vehicle applications, which need predictive methods that enhance passenger safety and support regulatory compliance. The primary purpose of a lithium-ion battery in an electric vehicle is to provide reliable energy storage while maintaining safe operation under different operating conditions. This study proposes a Design for Six Sigma (DFSS) methodology to virtually predict and correlate thermal runaway and its propagation in an 800V high-power lithium-ion battery module. Conventional propagation analysis relies heavily on physical testing, whereas the DFSS-based virtual framework enables cost-effective evaluation at early design stages. Input factors included are heat transfer pathways, which are sensitive to the temperature changes, as well as thermal propagation time. Control factors are the design or process parameters that engineers use to establish the
Dixit, Manish, Raja, Vinayak, Gudiyella, Soumya
АNALYSIS CURRENY SITUATION IN TESTING, RELIABILITY/DURABILITY AND SAFETY OF ENGINEERING PRODUCT2026-01-0138To be published on 04/07/2026
This paper reviews the current situation with testing, reliability/durability and safety of engineering product, that leads to recalls increasing and efficiency decreasing. Considers: inconsistent quality control, and manufacturing standards; historical decline in build quality; design priorities: style over substance; emphasis on power and size; slow adoption of technological advancements; competition American with Japanese and European manufacturers. Briefly describes the system, which the author developed for dramatically decreasing recall number as a result of successful prediction of product efficiency. Demonstrates common strategy of this prediction, five steps for improving engineering product, and step-by-step sequential strategy, which can help to increase the automotive product test level, reliability, quality, safety, durability, maintainability and decrease their life-cycle cost.
Klyatis, Lev
Application of DFSS for Optimizing Thermal Protection in Electric Vehicles During Battery Thermal Runaway Events2026-01-0142To be published on 04/07/2026
Battery thermal runaway is a major safety concern in electric vehicles because of the extreme heat and hazardous gases released during cell failure. These venting events can quickly raise the temperature of the battery enclosure and cabin floor, threatening occupant safety. To address this challenge, this study employs the Design for Six Sigma (DFSS) methodology to design and optimize a thermal protection system that delays and limits heat transfer to the cabin. A physics based transient heat transfer model was combined with DFSS principles to systematically evaluate insulation materials, shield layouts, surface emissivity, and layer geometry. An L 18 orthogonal array was used to identify key parameters and quantify their influence on thermal robustness. The optimized architecture reduced cabin floor temperature rise under severe runaway conditions (600–900 °C vent gas), meeting occupant egress safety requirements. Findings confirm DFSS as an effective framework for developing high
El-Sharkawy, Alaa, Asar, Mona, Taha, Nahla, Sheta, Mai
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 on the Regulation of the Three-Phase Microenvironment in Low-Platinum MEA2026-01-0443To be published on 04/07/2026
With the growth of energy demand, fuel cells as efficient and clean energy devices, have attracted increasing attention. However, the high cost of membrane electrode assembly (MEA) restricts their large-scale application. Therefore, reducing the platinum usage and improving performance have become key research point. In this work, MEA was prepared and excellent performance of 1.52 W·cm-2 was achieved at a low platinum loading. The influence of different ionomer/carbon (I/C) ratio on the performance of fuel cells was systematically investigated. It was found that the performance of the MEA was the highest when the I/C ratio is 0.6. Quantifying hydrophilic and hydrophobic characteristics of catalyst layers with varying ionomer contents revealed that the proton conduction efficiency is optimal when the I/C ratio is 0.6. This balance established efficient proton conduction pathways, from the results of proton conduction impedance testing. SEM analysis demonstrated that pore structure
Li, Xin, Cai, Xin, Lin, Rui
Open Source LLM Performance in Automating Embedded C Software Quality Improvements for Automotive2026-01-0103To be published on 04/07/2026
The study presented in this paper explored the potential of five open-source Large Language Models (LLMs) with parameter counts between 30 billion and 50 billion to automate enhancements in code quality and developer productivity. The evaluated models - CodeLlama, Command-R, Deepseek R1, Nemotron, and QwQ - were assessed on their ability to refactor a large and complex automotive mechatronic C language function. This assessment focused on adherence to provided code quality standards and successful compilation of the refactored function within its original code module. The evaluation also compared the impact of parameter count, hyperparameter tuning, model architecture, and fine-tuning. This comparison revealed that larger models generally outperformed smaller models against the provided quality standards. Additionally, hyperparameter tuning yielded a moderate improvement in performance. The study further highlighted that model architecture and fine-tuning had less predictable effects
Struck, Daniel, Kumaraswamy, Samanth
Development of Full Articulation Subsystem FEA Model for Validating Vehicle Suspension Durability2026-01-0190To be published on 04/07/2026
Vehicle durability is a cornerstone of automotive engineering, directly impacting customer satisfaction, brand reputation, and warranty costs. Traditionally durability validation of suspension systems often rely on virtual validation of individual components (an approach which can overlook complex non-linear system interactions) and followed by expensive full vehicle physical tests which happen very late in the vehicle development phase, which often results in correlation gap between virtual and physical realms, resulting in components redesigning and production delays. This paper presents a more efficient, high-fidelity, full-articulation suspension subsystem finite element (FE) model development specifically for durability assessments. This integrated model enables comprehensive block cycle durability assessments, providing a holistic understanding of system behavior and eliminating the inefficiencies of analyzing components in isolation. This methodology yields significant
Bavgi, Sai Kiran
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 an RTB design from an Internal Combustion Engine (ICE) vehicle platform presents several challenges, one of the challenges is accommodating increased rear vehicle load while minimizing cost, with maintaining existing rear hard points. To address this, we employed an experimental study for Computer-Aided Engineering (CAE) using the Taguchi DOE, which avoids costly physical durability tests. The key design parameters considered were the thickness and material grade of the RTB's components, specifically the cross beam, trailing arms, and reinforcements while preserving their original shapes. L8 Orthogonal array is constructed to design the experiment and identify the influence of the design parameters on durability performance, and the optimal combinations for maximizing durability are identified by using TOPSIS multi objective
Madaswamy, Arunachalam, Dhanraj, Sudharsun, Govindaraju, Karthik, Lokaiah, Srinivasan
Dual use Electric Vehicle Infrastructure for Enhancing Grid Resilience and Urban Sustainability2026-28-0114To be published on 02/12/2026
The growing global adoption of electric vehicles (EVs) has resulted in a spike in the number of EV charging stations. As EVs have become more and more popular worldwide, a large number of EV charging stations are opening up to accommodate their demands. During grid failures, an EV charging station can also serve as a flexible load connected to the grid to balance out voltage fluctuations. An EV charging station when powered using a separate source, such as solar or wind, can function as a powerhouse, bringing electricity to the grid when it's needed. Therefore, instead of installing more equipment to sustain voltage, the current EV charging station can be efficiently used to meet the grid's needs during failures. These stations have the potential to be dynamic, grid-connected assets for sustainable cities and communities in addition to their core function of vehicle charging (SDG 11). Because of their dual purpose, they can serve as adaptable loads that reduce voltage variations during
R, Uthra, Rangarajan, Ravi, D, Suchitra, D, Anitha
J1939 Digital AnnexJ1939DA_202601 (Current)2/1/2026
This document is intended to supplement the J1939 documents by offering the J1939 information in a form that can be sorted and searched for easier use.
Truck and Bus Control and Communications Network Committee
Quality Assurance Sampling and Testing, Carbon and Low-Alloy Steel ForgingsAMS2372J (Current)2/1/2026
This specification covers quality assurance sampling and testing procedures used to determine conformance to applicable specification requirements of carbon and low-alloy steel forgings.
AMS E Carbon and Low Alloy Steels Committee
Achieving Full ASIL-B Level Functional Safety (FuSa) for Automotive Clusters2026-26-00081/16/2026
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
New Generation Natural Rubber-Based Bump Stopper with Improved NVH Characteristics2026-26-02921/16/2026
In automotive suspension systems, components like bump stoppers and jounce bumpers play critical roles in controlling suspension travel and enhancing ride comfort. Material selection for these components is driven by functional demands and performance criteria. Traditionally, Natural rubber (NR) has traditionally been favored for bump stopper applications due to its excellent vibration absorption, tear resistance, cost-effectiveness, and biodegradability. However, in more demanding environments, it has been largely replaced by microcellular polyurethane (PU) elastomers, which offer superior durability, environmental resistance, and enhanced noise, vibration, and harshness (NVH) performance. This study revisits NR with the goal of re-establishing its viability by enhancing its performance to match or surpass that of PU. Through compound optimization and advanced material processing techniques, significant improvements have been achieved in NR’s mechanical strength, compression set
Murugesan, Annarajan, Hingalaje, Abhijeet, Perumal, Mathavan, Pawar, Rohit
A Machine Learning Approach to Early-Stage Failure Prediction in Traction Motor Manufacturing2026-26-02811/16/2026
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
Advanced Defect Detection Techniques Using AI, CAD Data, and Computer Vision2026-26-06441/16/2026
In area of modern manufacturing, ensuring product quality and minimizing defects are utmost important for maintaining competitive advantage and customer satisfaction. This paper presents an innovative approach to detect defect by leveraging Artificial Intelligence (AI) models trained using Computer-Aided Design (CAD) data. Traditional defect detection methods often rely on physical inspection, which can be time-consuming and prone to human error. The conventional method of developing an AI model requires a physical part data, By utilizing CAD data, the time to develop an AI model and implementing it to production line station can be saved drastically. This approach involves the use of AI algorithms trained on CAD models to detect and classify defects in real-time. The field trial results demonstrate the effectiveness of this approach in various industrial applications, highlighting its potential to revolutionize defect detection in manufacturing.
Kulkarni, Prasad Ramesh, Sahu, Dilip, Joshi, Chandrashekhar, Khatavkar, Akshay, Poddar, Shivani, Deep, Amar
Resilient Design Strategies for Wireless Charger ECUs: A Proactive Threat Analysis and Risk Assessment Framework for Ensuring Cybersecurity in EV Charging Ecosystems2026-26-01731/16/2026
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
Comparative Analysis and Implementation of Data Streaming Methodologies for Vehicle Navigation Mode for Electric Trucks2026-26-06921/16/2026
As electric trucks become more central to modern logistics, the need for smarter, more adaptive route planning is growing rapidly. This paper presents a key navigation feature for analyzing and recalibrating such optimized routes in real time. Integrating map features into the navigation mode improves user experience by offering real-time navigation and dynamic route adjustments based on traffic updates, road closures, vehicle coordinates and deviation in expected energy consumption. This study compares the performance of Server sent events (SSE), web sockets, and Application programming interface (API) polling methodologies, focusing on metrics such as data transmission efficiency, latency, resource utilization, scalability, and reliability. Our results 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
Bhandari, Mehul, Kaur, Prabhjot, Dadoo, Vishal, Mahendrakar, Shrinidhi, Ramanaiah, Rachala
Engine Oil Fluctuation Study in HLA Gallery and Impact of VVT Cam Phasing on Oil Fluctuation2026-26-05591/16/2026
Oil pressure, the most fundamental to engine's performance and longevity, is not only critical to ensure that the engine components are properly lubricated, cooled, and protected against wear and contamination, but also ultimately contributing to reliable engine performance. Due to several factors of engine such as, rotational fluctuation, aeration, functioning of hydraulic components there are fluctuations in oil pressure. In engines, with a crank-mounted fixed displacement oil pump (FDOP), these inherited pressure fluctuations cannot be eliminated completely. However, it is very necessary to control the abnormal oil pressure fluctuation because abnormal pressure fluctuation may lead to malfunction of hydraulic component functioning like variable valve timing (VVT), hydraulic lash adjuster (HLA) and dynamic chain tensioner which can further cause serious issues like excessive or sudden load drops, unstable engine performance, valve train noise, improper valve lift operation etc. In
Kumar, Ashok, Choubisa, Manas, Kumar, Ravi, Pathak, Mehul
Digital Control of Synchronous Rectification and Dead Time Configuration for Improving Efficiency and Longevity of DC Motors2026-26-00891/16/2026
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
Integrated Quality Assurance Frameworks for Testing Advanced Automotive Systems in the Era of ADAS and E-Mobility2026-26-05681/16/2026
Ensuring the safety and functionality of sophisticated vehicle technologies has grown more difficult as the automotive industry quickly shifts to intelligent, electric, and connected mobility. Software-defined architectures, electric powertrains, and advanced driver assistance systems (ADAS) all require strong quality assurance (QA) frameworks that can handle the multi domain nature of contemporary vehicle platforms. In order to thoroughly assess the functionality and dependability of next generation automotive systems, this paper proposes an integrated QA methodology that blends conventional testing procedures with model-based validation, digital twin environments, and real-time system monitoring. The suggested framework, which includes hardware-in-the-loop (HIL), software-in-the-loop (SIL), and over-the-air (OTA) testing techniques, concentrates on end-to-end traceability from specifications to validation. Simulating intricate situations for ADAS, electric vehicle battery temperature
Komanduri, Arun Srinivas, Srivastava, Anuj
Design Solutions for Ice-Induced CNG Filling Failures- Field Issue Resolution through Filter Geometry and Seal Material Reengineering2026-26-05151/16/2026
This study investigates the phenomenon of receptacle icing during Compressed Natural Gas (CNG) refueling at filling stations, attributing the issue to excessive moisture content in the gas. The research examines the underlying causes, including the Joule-Thomson effect, filter geometries, and their collective impact on flow interruptions. A comprehensive test methodology is proposed to simulate real-world conditions, evaluating various filter types, seal materials and moisture levels to understand their influence on icing and flow cessation. The findings aim to offer ideas for reducing icing problems. This will improve the reliability and safety of CNG refueling systems.
Virmani, Nishant, Sawant, Shivraj Madhukar, C R, Abhijith
Map-Less Yet Accurate: Trajectory Prediction for Traffic Agents Using Online HD Map Reconstruction for Autonomous Driving2026-26-00391/16/2026
Accurate trajectory prediction of traffic agents is critical for enabling safer and more reliable autonomous driving, particularly in urban driving scenarios where close-range interactions are most safety critical. High-definition (HD) and standard-definition (SD) maps play a vital role in this process by providing lane topology and directional cues for forecasting agent movements. However, HD maps are expensive and resource-intensive to create, often requiring specialized sensors, while SD maps lack the precision needed for reliable autonomous navigation. To address this, we propose a novel framework for trajectory prediction that leverages online reconstruction of HD maps using vehicle-mounted cameras, offering a scalable and cost-effective alternative. Our method achieves improvements in predicting accuracy, particularly in close-range scenarios, the most crucial for urban driving, while also performing robustly in settings without pre-built maps. Furthermore, we introduce a new
Upreti, Minali, Girijal, Rahul, B A, NaveenKumar, Thontepu, Phani, Ghosh, Shankhanil, Chakraborty, Bodhisattwa
Comprehensive Assessment of Volatile Organic Compounds and Efficacy of Vapor Recovery System at Fuel Stations2026-26-02331/16/2026
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
Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application2026-26-02861/16/2026
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
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
Effect of Pipe Bending by Rotary Tube Bending Process on Durability of Frame Structure2026-26-03701/16/2026
Automobile frames, particularly trellis frame structures, are engineered for superior dynamic performance, with stiffness being a paramount consideration1. These frames frequently utilize welded tubes, a manufacturing process made more complex by the necessity of bending tubes to precise angles to meet packaging and assembly requirements2. This bending, however, induces residual stresses that can substantially compromise the frame's durability3. This investigation employs a detailed finite element simulation to analyse the structural deformation and residual stresses that arise during the bending of Cold Electric Welded (CEW) annealed round pipes4. A comprehensive 3D mechanical model, incorporating realistic tooling and contact interactions, was developed to accurately simulate shape change, ovality, and wall thickness redistribution during the bending process5. CEW pipes, unlike their Electric Resistance Welded (ERW) counterparts, possess minimal initial forming stresses, and the
Rajwani, Ishwar, Khare, Saharash
EV Powertrain Systems Diagnostics & Prognostics Utilizing AI & ML (LLM) Based Approach2026-26-06641/16/2026
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 asks for significant advancement in automotive diagnostics by reasoning through the root causes behind the fault codes given by DTC document to enhance fault interpretability and maintenance efficiency, primarily for the technician and in few cases, the vehicle owner. Here LLM is trained on vehicle specific service manuals, sensor datasets, historical fault logs, and Original Equipment Manufacturer (OEM)-specific DTC definitions, which leads to context-aware understanding of the vehicle situation and correlation of incoming faults. Approach validation has been done using field level real-world vehicle dataset for different running scenarios, demonstrating model’s ability to detect complex fault chains and successfully predicting the
Pandey, Suchit, Joshi, Pawan, Kondhare, Manish, CH, Sri Ram, Gajbhiye, Abhishek, S, Adm Akhinlal
Ensuring Functional Safety in Electric Vehicle Inverters: A Case Study on ISO 26262 Implementation2026-26-01581/16/2026
The transition to electric vehicles (EVs) has brought about significant advancements in automotive technology, with inverters playing a crucial role in converting DC power from the battery to AC power for the electric motor. Ensuring the functional safety of these inverters is paramount, as any failure can have severe implications for vehicle performance and passenger safety. This case study explores the successful implementation of ISO 26262 standards in the development and validation of EV traction inverters. This paper begins by outlining the functional requirements and safety goals specific to EV inverters, followed by a detailed analysis of the potential hazards and risks associated with their operation. Using ISO 26262 as a framework, we describe the systematic approach taken to identify, assess, and mitigate these risks. Key methodologies such as Hazard Analysis and Risk Assessment (HARA), Failure Mode and Effects Analysis (FMEA), and Fault Tree Analysis (FTA) are employed to
Ramachandra, Shwetha, V, Sushmitha
A Quality-Driven Approach to Engineering Sign-Off for Software and Robust Product Development2026-26-05811/16/2026
Automotive Product Development is a very complex process involving many functions across the organization along with the application of numerous technologies. Generally, most original equipment manufacturers follow a stage-gate process for any new product development. The increasing application of electrical and electronic systems, software and enhanced regulations focusing on overall safety of the eco-system further increases the complexity during development. This paper details the development and implementation of a comprehensive framework designed to enhance the quality and governance of the product development in the automotive industry. As the sector undergoes significant transformation, 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 towards defect free design, robust engineering
Digikar, Ashish, Pathak, Isha, Kothari, Bhushan
Thermal Shock Test Rig for CNG Shut-Off Valve2026-26-05261/16/2026
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
Tailgate Stiffness Mitigation and Engineering Strategy for Full Width Tailgate-Mounted Tail Lamp Integration2026-26-04941/16/2026
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 Full width 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 lamp volume, thereby providing reduced design space, and intricate mounting schemes constrained by panel 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
Beryl, Joshua, Mohanty, Abhinab, Unadkat, Siddharth, Selvan, Veera
An Investigation into the Structural Impacts of Off-Road Maneuvers on Rear Axle Upper Link Mounting Bracket2026-26-04901/16/2026
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
Nexifi11D: A Comprehensive Multidimensional Framework for Futuristic Manufacturing Ecosystems2026-26-02821/16/2026
This paper presents Nexifi11D, a simulation-driven, real-time Digital Twin framework that models and demonstrates eleven critical dimensions of a futuristic manufacturing ecosystem. Developed using Unity for 3D simulation, Python for orchestration and AI inference, Prometheus for real-time metric capture, and Grafana for dynamic visualization, the system functions both as a live testbed and a scalable industrial prototype. To handle the complexity of real-world manufacturing data, the current model uses simulation to emulate dynamic shopfloor scenarios; however, it is architected for direct integration with physical assets via industry-standard edge protocols such as MQTT, OPC UA, and RESTful APIs. This enables seamless bi-directional data flow between the factory floor and the digital environment. Nexifi11D implements 3D spatial modeling of multi-type motor flow across machines and conveyors; 4D machine state transitions (idle, processing, waiting, downtime); 5D operational cost
Kumar, Rahul, Singh, Randhir
Durability Validation of Full Vehicle Structures Using Strain Correlation and RLDA-Based Simulations2026-26-05231/16/2026
Durability validation of full vehicle structures is crucial to ensure long-term performance and structural integrity under real-world loading conditions. Physical test strain and finite element (FE) strain correlation is vital for accurate fatigue damage predictions. During torture track testing of the prototype vehicle, wheel center loads were measured using wheel force transducers (WFTs). In same prototype strain time histories were recorded at critical structural locations using strain gauges. Preliminary FE analysis was carried out to find out critical stress locations, which provided the basis for placement of strain gauges. Measured loads at wheel centers were then used in Multi Body Dynamics (MBD) simulations to calculate the loads at all suspension mount points on BIW. Using the loads at hard points transient analyses were performed to find out structural stress response. Strain outputs from the FE model were compared with physical measurements. Insights gained from these
Jaju, Mayur, Dokhale, Sandeep, Gadre, Nilesh, Patil, Sanjay
Overview of Automotive Policies, Evolution of Automotive Regulations, and Striking a Balanced Approach for Harmonization2026-26-02421/16/2026
The automotive regulatory landscape in India is evolving rapidly, driven by a dynamic policy intervention by GOI, striking push for sustainable mobility, safety, technological advancements, dEnvironmentally soundeeper localization, energy self-reliance, product quality control and simplified registration process. Key regulations cover areas like vehicle safety norms, emission norms, fuel economy norms, BIS QCO, the promotion of EVs and alternative fuel vehicles, R & D roadmaps, ELVs, incentive policies and vehicle registration reforms. India has been keeping a close eye on the automotive regulatory progress in the Europe as well as other developed countries as a cornerstone for technical harmonization, cross learning, gauge benefits and economic implications. India is progressively aligning its automotive regulations with global standards, particularly with UN Regulations and GTRs, while also considering unique Indian driving and environmental conditions. This alignment is crucial for
Patil, Dharmarayagouda
Simulation-Driven Load Spectrum Prediction: Virtual RLDA for Chassis and Suspension System2026-26-00951/16/2026
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
Study of Real Time Impact on Automotive Cabin Air Quality due to the Various Usage Conditions in the Severely Polluted City2026-26-05311/16/2026
This study investigates the concentrations of PM2.5 and PM10 inside an automobile under real-world driving conditions, 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 New 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-world
Gupta, Rajat, Pimpalkar, Ankit, Patel, Abhishek, Kumar, Shubham, Joshi, Rishi, Kumar, Mukesh
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-05011/16/2026
Manufacturing tolerances play a critical role in the quality and functionality of components, particularly those made from rubber. Even slight deviations in dimensions can cause significant issues such as improper fit and reduced performance, leading to increased costs and project delays. This is especially true for rubber grommets, which are nonlinear elastic components commonly used as sealants, gaskets, and insulation covers in automotive and industrial applications. Typically manufactured from EPDM rubber with varying Shore hardness, grommets must maintain precise geometry to ensure sealing integrity and protect adjacent parts. Dimensional inaccuracies can result in failures such as buckling or misalignment, compromising both functionality and durability. This study proposes a digital simulation methodology for early-stage evaluation of grommet robustness, reducing reliance on physical prototypes. Using a stochastic design of experiments (DOE) approach, the influence of critical
Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, Pathan, Eram
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
Resolution of Automotive Air Compressor Noise in Low Powered ICE Vehicles2026-26-03141/16/2026
The interior noise and thermal performance of the passenger compartment are critical criteria for ensuring driving comfort [1]. This paper presents the optimization of air conditioning (AC) compressor noise, specifically for the low-powered 1.0 L - ICE engine paired with a 120 cc IVDC compressor. This combination is quite challenging due to the high operational load & higher operating pressure. To enhance better in-cabin cooling efficiency, compressor’s operating efficiency must be improved, which necessitates a higher displacement of the compressor. However, increased displacement results in greater internal forces which leads to more structure-borne induced noise inside the cabin. For this specific configuration, the compressor operating pressure reached up to 25 bars under most driving conditions. During dynamic driving scenario, a metallic tonal noise from the compressor was reported in a compact vehicle segment. It is reported as very annoying to passengers inside. A comprehensive
John Britto, Vijay Antony, Maluganahalli-Dharmappa Madhusoodan Sr, Madhusoodan, Natarajasundaram, Balasubramanian
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