Browse Topic: Quality, Reliability, and Durability

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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, 1Lt 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
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
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
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, Rajaur, Deepak, Kumar, Shubham, Joshi, Rishi, Kumar, Mukesh
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
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
Patel, Hiral, Thambala, Prashanth, Sutar, Suresh, Todtermuschke, Karsten
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
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
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
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
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
Overview of Indian Government Policies, Evolution of Indian Automotive Regulations and Striking balance approach for adoption2026-26-0242To 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
Installation Quality Audit (IQA) To-Go with Augmented Reality (AR)2026-26-0420To be published on 01/16/2026
This paper presents a digital methodology that integrates the Installation Quality Assurance (IQA) process through augmented reality (AR) technology to rectify the part accessibility issues for assembly and service at the early design stage of the product. This technology enable engineers to overlay digital data on physical vehicle and verify the installation requirements on vehicle assembly which will meet the installation quality design (IQD) requirements done between OEM & supplier. For example: wire and tube, other aggregates etc. fitted on vehicle. AR will help to enhance visualization and better feel for vehicle integration and packaging aspects while performing fire path analysis, DMU review, DFA, DFS, signoff, etc. a live case study conducted for better understanding of the AR process. This technology will enhance quality DMU by ensuring sufficient gap/flash with each other as per design guidelines. Keywords: AR, IQA, IQD, DFA, DFS, DMU, OEM, etc.
Singh, Vinay Kumar, Kumar, Rahul, PANDARKAR, PRASHANT, Deep, Shivani Poddar
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
Analysis of High voltage fuse failures due to reverse surge currents flow in the Power distribution unit of Electric vehicles2026-26-0182To be published on 01/16/2026
Commercial Electric vehicles are revolutionizing the transportation industries with zero emission, lower noise level and increased efficiency. But, High voltage (HV) fuse failures due to reverse surge currents in the Power distribution unit (PDU) hampers the field operation and raise the sensitive safety concerns. This paper embarks on an in-depth exploration of the Reverse surge current flows from the DC-DC converter and Auxiliary (AUX) inverters high voltage input side to Traction system high voltage input point. Failures of HV fuses can lead to the unintentional shutdown of the e-compressor system and steering motor system while operating the EV, which raises critical safety concerns. If the steering motor fails, the bus will lose power steering assistance, making the steering wheel much harder to turn. If the e-compressor fails, it could result in loss of braking assist. This could make it difficult to stop the vehicle, especially in an emergency situation or when driving at high
Bamania, Mihir, kinjalkar, Milind, Amancharla, Naga Chaithanya, Salunke, Pradeep
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
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
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
Abstract: - 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
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
Navale, Pradeep, Kushwaha, Rakesh, Patel, Hiral
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
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
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
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
AI-Powered Innovation: Harnessing Data Analytics and AI in Modern Powertrain Development2026-26-0641To be published on 01/16/2026
The proposed presentation will delve into the transformative role of artificial intelligence (AI) in the automotive industry, specifically focusing on product development from concept to series support. The presented effort is driven by the need to enhance development efficiency, reduce time to market, improve product quality, and lower production costs. AI was explored as a solution to address challenges such as late availability of hardware components, issues during software integration, and high warranty costs. The AI applications discussed are primarily in the automotive industry, covering areas such as vehicle concept development, usage space analysis, root cause analysis, battery health monitoring, and failure prediction and health monitoring. The methodologies used include advanced AI methods to shorten the time from customer expectations to target agreements, statistical driving data analysis to understand user behaviour, machine learning (ML) surrogate models to identify key
Mayr, Christian, Keuth, Nikolaus
Achieving full ASIL-B level functional safety (FuSa) for Automotive Clusters2026-26-0008To be published on 01/16/2026
Traditionally, automotive cluster modules have not placed strong emphasis on functional safety (FuSa) measures for capturing and displaying data. Most cluster components are developed with a focus on Quality Management (QM) levels, and proprietary implementations are often used without adhering to standardized safety approaches. This paper highlights the need to bring certain cluster components under an Automotive Safety Integrity Level B (ASIL-B) context, proposing a standardized and structured methodology for their development — particularly by adopting Classic AUTOSAR frameworks. Several critical components within the cluster demand FuSa mechanisms to ensure reliable and safe operation. These components should be designed to comply with key safety principles, including freedom from interference, execution under privileged levels, and integrity verification. The FuSa goals for these components also extend to their configuration management and update strategies within the cluster
Singh, Iqbal, Kumar, Praveen
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
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
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
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
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
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
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 GC-PID technology alongside targeted forecourt measurements with handheld PID instrument. Benzene emissions during peak and off-peak hours, vehicle throughput, fuel sales volume, and
Mayeen, Hafiz, Ahuja, Muskan, Kalita, Mrinmoy, Kumar, Prashant, Sithananthan, M, Arora, Ajay
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 goal of Automotive cybersecurity is safety, reliability, confidentiality and authenticity. As the automotive industry grows smarter, so too do the cybersecurity protocols used to protect vehicles from malicious actors. Automotive cybersecurity secures communication networks, electronic systems, software and data collected by the new wave of intelligent cars The paper describes the cyber security threats its analysis ion wireless charging
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
Development of an Accelerated Stress Test for Fuel Cell Freeze Start Durability Using Real-World Driving Data of Light-Duty FCEVs2025-01-0526To be published on 11/25/2025
The reliability and durability of vehicles are crucial for the acceptance of new technologies by customers. Realistic test methods are necessary to ensure the lifespan of vehicles and their components, particularly regarding freeze start. This article provides an overview of the current state of research on the effects of freeze starts on the degradation of fuel cells. With this knowledge, relevant operating and boundary conditions for potential damage of the fuel cell are identified (e.g., start temperature, duration in subzero operation, dehydration). Based on these findings, the field data from the BMW demonstrator fleet of iX5 Hydrogen Next were analyzed to gain insights into realistic freeze start related stress to the fuel cells. It was found that the dynamics of heating rates and the influence of the operating strategy are best represented on a FCS. An experimental setup for a stack centered test on a fuel cell system was developed including a climatic chamber and a subzero
Schwarz, Markus, Albert, Albert, Eichel, Rüdiger-A.
Optimization System of E-commerce Logistics Distribution Path Based on Data Analysis2025-99-0108To be published on 11/11/2025
With the rapid development of e-commerce, the logistics industry also presents new features such as multi-level, integrated upstream-downstream operations, increasingly perfect service quality and low logistics costs. The exponential growth in online transactions and consumer expectations for faster, more reliable deliveries intensifies the pressure on logistics systems. The last-mile service network refers to the logistics nodes that have direct contact with consumers, and its geographical location and quantity will directly affect the service level, cost and customer service mode of the distribution network. However, with the rapid growth in the number of online shoppers and their imbalance on the Internet, these factors have gradually become an important basis for influencing the layout of terminal outlets. This imbalance, coupled with dynamic urban traffic conditions, renders traditional distribution planning methods inadequate. Therefore, in the e-commerce environment, how to
Tong, Tong, Gu, Xuefei, Li, Lingxiao
Customer Support – Failure and Warranty Analysis in Off-Highway Vehicles2025-28-030011/06/2025
The reliability and durability of off-highway vehicles are crucial for industries like construction, mining, and agriculture. Failures in such machines not only disrupt operations but can also lead to significant economic losses and safety concerns. Effective failure and warranty analysis processes are essential to improve customer support, minimize downtime, and enhance equipment life cycle. This paper outlines a comprehensive 7-step failure analysis methodology tailored for off-highway vehicles, accompanied by warranty analysis using Weibull, 6MIS, and 12MIS IPTV. It details the process from problem identification through permanent solution implementation, emphasizing tools and techniques necessary for sustainable improvements. The structured approach provides an actionable blueprint for OEMs and service teams to enhance customer satisfaction, support sustainable development goals, and maintain regulatory compliance.
Mulla, Tosif, Thakur, Anil, Tripathi, Ashish
Design Strategies for “Front Stabilizer Link Assembly” for Maximized Wheel Articulation in All Terrain for Passenger Car Application2025-28-030911/06/2025
The stabilizer link, also commonly referred to as the sway bar link or anti-roll bar link, plays a crucial role in the suspension system. It connects the sway bar to suspension components such as the knuckle, control arm, or strut. The primary function of the stabilizer link is to reduce body roll during cornering or when driving over uneven terrain. It helps stabilize the wheels during extreme articulation events and ensures smoother operation in terms of ride comfort and handling. Additionally, it is designed to assist in distributing forces across the suspension system, particularly in off-road or rugged terrain applications. This case study presents the failure of a stabilizer link assembly during extreme articulation events. The front stabilizer link failed during vehicle-level durability and functional testing across multiple terrains. Based on the root cause analysis, design strategies were developed to prevent such failures and to ensure reliable operation during demanding off
S, Praveen Kumar, Chilakala, Raghavendra, Senthil Raja, T, Jadhav, Prashant, Kundan, Lal, J, Akhil, Pawar, Sandip
Transformative Deep Learning for Image Colorization with Machine Learning-Based Classification2025-28-031711/06/2025
Imagine a user opening a technical manual, eager to troubleshoot an issue, only to find a mix of stark black-and-white illustrations alongside a few color images. This inconsistency not only detracts from the user experience but also complicates understanding. For technicians relying on these documents, grayscale graphics hinder quick interpretation of diagrams, extending diagnostics time and impacting overall productivity. Producing high-quality color graphics typically requires significant investment in time and resources, often necessitating a dedicated graphics team. Our innovative pipeline addresses this challenge by automating the colorization and classification of colored graphics. This approach delivers consistent, visually engaging content without the extensive investment in specialized teams, enhancing the visual appeal of materials and streamlining the diagnostic process for technicians. With clearer, more vibrant graphics, technicians can complete tasks more efficiently
Khalid, Maaz, Akarte, Anurag, Kale, Aniket, Rajmane, Gayatri, Nalawade, Komal
Ensuring The Reliability of Hydraulic Powered Steering System Through Life Data Analysis2025-28-029711/06/2025
The reliability of vehicle steering systems is extremely important to ensure safety, vehicle performance and gain customer satisfaction. Life data analysis conducted to analyze how the steering systems are performing in the field and assess whether the steering systems can meet the reliability target when deployed in the field. This article discusses about the systematic process to conduct the field data analysis of Hydraulic Powered Steering System (HPS) from the warranty claim data, usage of Weibull distribution to derive the life characteristic parameters. Based on the process described in this article, the statistical analysis of the warranty claim data performed and identified that, “the Hydraulic Power Steering Gears demonstrated more than 99% reliability in the field with statistical confidence of 90% and able meet the ZF’s Internal target for the HPS Systems”.
Ravindran, Mohan, Sugumar, Ganesh
Comprehensive Warranty Data Analytics: A Blend of Conventional & Advanced Methods2025-28-029911/06/2025
In today’s competitive landscape, industries are relying heavily on the use of warranty data analytics techniques to manage and improve warranty performance. Warranty analytics is important since it provides valuable insights into product quality and reliability. It must be noted here that by systematically looking into warranty claims and related information, industries can identify patterns and trends that indicate potential issues with the products. This analysis helps in early detection of defects, enabling timely corrective actions that improve product performance and customer satisfaction. This paper introduces a comprehensive framework that combines conventional methods with advanced machine learning techniques to provide a multifaceted perspective on warranty data. The methodology leverages historical warranty claims and product usage data to predict failure patterns & identify root causes. By integrating these diverse methods, the framework offers a more accurate and holistic
Quadri, Danishuddin S.F., Soma, Nagaraju
Multi-Objective Design Optimization and Pugh Matrix Analysis to Develop Exhaust Tail Pipe Mounting for EU6 Heavy Trucks2025-28-029311/06/2025
The key performance evaluation criteria for any automotive exhaust system are pass-by noise (PBN), exhaust backpressure, durability and reliability, exhaust brake performance, aesthetics (if visible from outside the chassis), cost, weight and safety. Also, with changes in emission norms, emission from Exhaust Aftertreatment Systems (EATS) is one of the crucial parameters while designing the exhaust system. This paper covers a critical problem faced during the Beta Proto Build and Testing phase of exhaust tail pipe assembly. The exhaust tail pipe assembly had loose fitting issues, which can cause problems during the functioning of the truck. Parameters like material of the pipe, length of strap, tightening torque and tolerance of the pipe diameter were considered to resolve the fitment issue. The resolution is done with the help of Design of Experiments (DoE) and Pugh Matrix Analysis based on QDCFSS (Quality, Design, Cost, Feature, Safety and Sustainability). Design for Assembly (DFA
P, Balu Mukesh, Rokade, Aditya, Biswas, Sanjoy
Technology Driven Solutions for Effective Tool Management2025-28-024911/06/2025
Tool management remains a persistent challenge in manufacturing, where misplaced or poorly calibrated tools such as torque guns and screwdrivers cause downtime, quality defects, and compliance risks. The Internet of Things (IoT) is transforming tool management from manual entries in spreadsheets and logs to real-time, data-driven solutions that enhance operational efficiency. With ongoing advancements in IoT architecture, a range of cost-effective tracking approaches is now available, including Ultra-Wideband (UWB), Bluetooth Low Energy (BLE), Wi-Fi, RFID, and LoRaWAN. This paper evaluates these technologies, comparing their trade-offs in accuracy, scalability, and cost for tool-management scenarios such as high-precision station tracking, zonal monitoring, and wide-area yard visibility. Unlike prior work that focuses on asset tracking in general, this study provides an ROI-driven, scenario-based comparison and offers recommendations for selecting appropriate technologies based on
Patel, Shravani Prashant
Advancing Vehicle-Level AC Thermal Management System Performance2025-28-043410/30/2025
Modern mobility solutions increasingly rely on HVAC systems due to growing transport demands, traffic congestion, and harsh environmental conditions. These systems, comprising a compressor, evaporator, condenser, and thermal expansion valve, require adequate airflow for optimal performance. Insufficient airflow, caused by factors like undersized ducts, improper fan settings, clogged filters, or high static pressures from duct restrictions, significantly hinders cooling capacity. The objective of this study is to develop a predictive model for passenger vehicle AC system performance under controlled environmental conditions. Discrepancies between predicted and desired performance will trigger a structured problem-solving process involving iterative testing, root cause analysis, and the development of corrective measures. The improvements will be focused on the vehicle-level HVAC design, adhering to customer specifications. This research will also establish an experimental validation
Meena, Avadhesh Kumar, Agarwal, Roopak, Sharma, Kamal, Kishore, Kamal
A Strategic TQM Approach to Enhance Passenger Cabin Comfort Using T-Matrix2025-28-042310/30/2025
This study demonstrates the application of the T-Matrix, a Total Quality Management (TQM) tool to improve thermal comfort in automotive climate control systems. Focusing on the commonly reported customer issue of insufficient cabin cooling, particularly relevant in hot and congested Indian driving conditions, the research systematically investigates 36 failure modes identified across the product lifecycle, from early design through production and post-sale customer usage. Root causes are first categorized using an Ishikawa diagram and then mapped using the T-Matrix across three critical stages: problem creation, expected detection, and actual detection. This integrated approach reveals process blind spots where existing validation and inspection systems fail to catch known risks, particularly in rear-seat airflow performance and component variability from suppliers. By applying this TQM methodology, the study identifies targeted improvement actions such as improved thermal targets
Jaiswara, Prashant, Kulkarni, Shridhar, Deshmukh, Ganesh, Nayakawadi, Uttam, Joshi, Gaurav, Shah, Geet, Jaybhay, Sambhaji
Valve Wagging Prediction Methodology for Engine Brake Application2025-28-040210/30/2025
Eaton's decompression engine braking technology for medium and heavy-duty diesel engines delivers high braking power and provides several advantages to the commercial truck owner. Eaton offers rocker arm-based 1 stroke, 1.5 stroke, and 2 stroke systems for overhead cam and cam in block engine architectures. The Compression Release (CR) engine brake avoids overheating and fading of primary friction brake. It reduces or eliminates the need for a driveline retarder. One of the failure modes for Engine Brake (EB) system is excessive lateral displacement of the exhaust valve, caused by non-uniform pressure distribution across the valve during Brake Gas Recirculation (BGR) and Compression Release modes. This excessive deformation is referred to as Valve Wagging. Valve wagging significantly affects the structural stability of the engine brake mechanism. Analyzing its behavior is essential to minimize excessive wear on valve guide and Valve Seat Insert in new designs. Since evaluating the
Soni, Lalitkumar R., Joshi, Himanshu, J, Gokulakrishnan, De Giovanni, Pierfrancesco
A Guideline for Aerospace Platform Fiber Optic Training and Awareness Education Introduction to Aerospace Fiber Optics Hands-on CompetenciesARP5602/2 (Current)10/23/2025
This document establishes training guidelines applicable to fiber optic safety training, technical training and fiber awareness for individuals involved in the manufacturing, installation, support, integration and testing of fiber optic systems. Applicable personnel include: Managers Engineers Technicians Logisticians Trainers/Instructors Third Party Maintenance Agencies Quality Assurance Shipping Receiving Production Purchasing
AS-3 Fiber Optics and Applied Photonics Committee
A Guideline for Aerospace Platform Fiber Optic Training and Awareness Education Aerospace Fiber Optics Fabricator Hands-on CompetenciesARP5602/4 (Current)10/23/2025
This document establishes training guidelines applicable to fiber optic fabricator technical training for individuals involved in the manufacturing, installation, support, integration and testing of fiber optic systems. Applicable personnel include: Managers Engineers Technicians Trainers/Instructors Third Party Maintenance Agencies Quality Assurance Production
AS-3 Fiber Optics and Applied Photonics Committee
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