Browse Topic: Quality management systems

Items (2,985)
The virtual development of Electric Drive Modules (EDMs) for Battery Electric Vehicles (BEVs) requires proven and predictive methodologies. One part of the development investigates the vibro-acoustic assessment for the low- and high-frequency ranges within the targeted operating range. The efficient use of such a methodology requires an understanding of the accuracy and validity of the achievable results, as well as the derivation of suitable improvement measures for goals that have not been achieved. The use of reference data from experimental investigations and a detailed root cause analysis (RCA), to directly link a specific response and behavior to the excitations, modal content, and transfer functions, is an essential and non-trivial part of the methodology development. This paper describes the development of such a methodology using the example of a new EDM virtual model for Noise, Vibration and Harshness (NVH) analysis, including the simulation approach, validation, and
Klarin, BorislavPevec, DenisResch, ThomasEsposito, SaraD'Alessandro, VincenzoSpanu, Giorgio
Achieving best-in-class Noise, Vibration, and Harshness (NVH) in electric powertrains demands a paradigm shift in development methodology. This paper presents a practice-oriented overview of simulation methods in NVH development methodology for electric drive units. This includes target cascading and multi-objective optimisation, and by attacking NVH at the source using KPIs early in the design cycle, significant reductions in development time and reliance on traditional testbed loops are realised. Machine learning (Neural Network) algorithms are utilized to find the best-in-class design, using multi-objective optimisation as well as refining simulation accuracy by adding tolerance effects while target cascading ensures alignment of system-level performance objectives down to subsystem contributions. Combined, these strategies enable rapid and robust NVH optimisation, using simulation for next-generation electric powertrain development. Several applications and real-life examples
Mehrgou, MehdiGarcia de Madinabeitia, InigoGraf, BernhardGojo, Josef
In recent years, the automotive industry has actively explored the application of various AI-based models such as Convolutional Neural Networks (CNN), Long Short-Term Memory (LSTM) networks, Autoencoders, and Transformers to improve defect detection rates at the End-of-Line (EOL) stage. However, implementing these approaches in the Noise, Vibration, and Harshness (NVH) area face several practical challenges: ① extended evaluation times compared to other data types, which limit the quantity of training data and lead to overfitting; ② label imbalance caused by the relatively small amount of defect data; ③ reduced labeling accuracy due to human error; ④ decreased robustness under domain shifts such as changes in jig fixtures, test environments, and signal-to-noise ratio (SNR); ⑤ diminished model reliability when new defect arise during development; and ⑥ constraints imposed by compatibility requirements with existing test equipment. This study proposes a Convolutional Autoencoder (CAE
Park, Jun-SeoJo, Hyeon-ChoelCho, In-JeSeo, Jae-YongYoo, Seong-Sik
Noise, Vibration, and Harshness (NVH) performance is critical in the automotive development process, yet identifying the true root causes of unwanted dynamic behavior remains a challenge in full vehicle or system-level finite element (FEM) models. This work demonstrates how Frequency Based Substructuring (FBS) provides an efficient framework for understanding NVH phenomena and facilitates new root cause analysis (RCA) types and processes. To begin, we prove the numerical accuracy of the FBS algorithm deployed in the presented investigation by comparing its results with those obtained with superelements and without substructuring. We point out that because the used FBS process starts with a modal representation of the components rather than their frequency response functions (FRF) a different class of RCA type becomes available. Then we introduce new RCA types starting with an analysis named Modal Influence (MI) that reveals the effect of the modes of any component on a certain response
Herbst, Markus
This AIR provides a general guideline on how to perform effective measurement systems analysis study (MSA) for rotor balancing tasks. The document also includes applicable data analysis methods and result interpretation.
EG-1A Balancing Committee
This digital standard is a digital model of AS9100D Quality Management Systems - Requirements for Aviation, Space, and Defense Organization. This file contains an MBSE model in a mdzip file for use in modeling applications.
This digital standard is a requirements extract of AS13001A Delegated Product Release Verification Training Requirements. This file contains a general requirements extraction as well as files that are optimized for use with Doors Classic, Siemens Polarian, and PTC.
This digital standard is a requirements extract of AS4159 Specification For An Automated Interchange Of Standards Data. This file contains a general requirements extraction as well as files that are optimized for use with Doors Classic, Siemens Polarian, and PTC.
This digital standard is a requirements extract of AS13100A Quality Management System Requirements for Aero Engine Design and Production Organizations. This file contains a general requirements extraction as well as files that are optimized for use with Doors Classic, Siemens Polarian, and PTC.
This digital standard is a requirements extract of AS9145 Requirements for Advanced Product Quality Planning and Production Part Approval Process. This file contains a general requirements extraction as well as files that are optimized for use with Doors Classic, Siemens Polarian, and PTC.
Aerospace manufacturing operates within an intricate ecosystem where quality, compliance and traceability are critical to success. Conventional digital thread frameworks provide connectivity but remain largely passive, lacking the intelligence to autonomously manage complex non-conformities across the product lifecycle. This paper introduces an Agentic Digital Thread powered by Agentic AI, designed to transform non-conformity management into an adaptive, self-orchestrating system that actively drives decision-making and corrective actions [1, 4]. The proposed architecture employs a Master Agent to coordinate workflows and maintain end-to-end data continuity, while specialized Agents autonomously manage domain-specific tasks. In the pre-manufacturing phase, these agents proactively validate requirements, material conformity and process planning through integration with PLM, MES, ERP, QMS and supplier systems. In the post-manufacturing phase, the framework extends to concession
Veluri, SastryGopala Krishnan, Kannan
This paper presents an automated framework for security compliance and quality assurance in DevSecOps CI/CD pipelines, specifically designed for safety-critical avionics software. The framework integrates regulatory compliance checks, security validation, and robust verification directly into the software development lifecycle, supporting continuous integration and delivery for aerospace applications. Automated processes such as code compilation, coding standards compliance, Cyclomatic Complexity Measurement, Sources Line of Code and CRC validation on target hardware are seamlessly orchestrated to maintain consistency and reliability. The system generates comprehensive compliance reports, highlights coding standard violations and security issues, and notifies relevant stakeholders to facilitate timely resolution and corrective actions. As new code is checked in, the framework automatically initiates all verification and compliance tasks, ensuring that every software update is
Bhagwat, Shashank RaviChangappa, Naveen KumarNath, Sunny
Aircraft lighting systems play a vital role in ensuring operational safety, visibility, and regulatory compliance. Exterior lighting systems are essential for aircraft identification, navigation, collision avoidance, and ground operations under varying environmental conditions. These systems typically include navigation lights, anti-collision lights, landing and taxi lights. An aircraft lighting system comprises light sources, optical elements, electronic control units, power interfaces, wiring harnesses, and mechanical mounting structures. Among these components, optics are critical as they control light distribution, intensity, color accuracy, and efficiency while withstanding harsh aerospace environments such as vibration, thermal cycling, and aerodynamic loads. Aircraft exterior lights are subjected to severe thermo-mechanical stresses due to aerodynamic loading, vibration, and thermal cycling. The use of high-performance optical polymers such as Cyclo Olefin Polymers (COP
Vialta, FredericoS, NikhilKatageri, PraveenSP, PradeepSingh, Abhimanyu Kumar
The importance of reliability in design engineering has significantly grown since the early 1960’s. Competition has been a primary driver in this growth. The three realities of competition today are: world class quality and reliability, cost-effectiveness, and fast time-to-market. Formerly, companies could effectively compete if they could achieve at least two of these features in their products and product development processes, often at the expense of the third. However, customers today, whether military, aerospace, or commercial, have been sensitized to a higher level of expectation and demand products that are highly reliable, yet affordable. Product development practices are shifting in response to this higher level of expectation. Today, there is seldom time, or necessary resources to extensively test, analyze, and fix to achieve high quality and reliability. It is also true that the rapid growth in technology prevents the accumulation of historical data on the field performance
G-41 Reliability
This document provides methods and techniques for implementing a reliability program throughout the full life cycle of a software product, whether the product is considered as standalone or part of a system. This document is the companion to the Software Reliability Program Standard [JA1002]. The Standard describes the requirements of a software reliability program to define, meet, and demonstrate assurance of software product reliability using a Plan-Case framework and implemented within the context of a system application. This document has general applicability to all sectors of industry and commerce and to all types of equipment whose functionality is to some degree implemented by software components. It is intended to be guidance for business purposes and should be applied when it provides a value-added basis for the business aspects of development, use, and sustainment of software whose reliability is an important performance parameter. Applicability of specific practices will
G-41 Reliability
The reliability of welded joints is a vital factor in modern manufacturing, directly affecting product performance and durability. This study investigates methods to enhance the mechanical and metallurgical quality of butt joints in AISI 304L stainless steel welded by the gas tungsten arc (GTA) process. A systematic experimental design was implemented using the Taguchi method with an L9 orthogonal array, considering welding current, gas flow rate, and travel speed as the main parameters. To determine overall weld performance, the joints were characterized by measuring ultimate tensile strength (UTS), yield strength, percentage elongation, and examining their microstructural morphology. An experimental strategy based on the Taguchi approach has been implemented. The welding performance of the material was investigated, and the process parameters were optimized using multiresponse optimization through principal component analysis (PCA), incorporating an orthogonal array design, signal-to
Ghosh, NabenduRoy, Angshuman
This standard establishes the common requirements for training of DPRV personnel for use at all levels of the aerospace engine supply chain. This standard shall apply when an organization elects to delegate product release verification by contractual flow down to its suppliers (reference 9100 and 9110 standards) and to perform product acceptance on its behalf. It is intended that organizations specify their DPRV requirements through the application of AS9117. While the delegating organization will use the AS13001 standard as the baseline for establishing DPRV process and product training, it may include additional contractual training requirements to meet its specific needs. The DPRV training material was primarily developed for aerospace engine supply chain requirements. However, this standard may also be used in other aerospace industry sectors where a DPRV process requiring specific training can be of benefit.
G-22 Aerospace Engine Supplier Quality (AESQ) Committee
This FMEA standard describes potential failure mode and effects analysis in design (DFMEA), supplemental FMEA-MSR, and potential failure mode and effects analysis in manufacturing and assembly processes (PFMEA). It assists users in the identification and mitigation of risk by providing appropriate terms, requirements, rating charts, and worksheets. As a standard, this document contains requirements—”must”—and recommendations—”should”—to guide the user through the FMEA process. The FMEA process and documentation must comply with this standard as well as any corporate policy concerning this standard. Documented rationale and agreement with the customer are necessary for deviations in order to justify new work or changed methods during customer or third-party audit reviews.
Automotive Quality and Process Improvement Committee
The study presented in this paper explores the potential of five open-source Large Language Models (LLMs) with parameter counts between 32 billion and 49 billion to automate enhancements in code quality and developer productivity. The evaluated models – CodeLlama [1], Command-R [2], Deepseek R1-32B [3], Nemotron [4], and QwQ [5] - 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 a larger code module. The evaluation also compared the impact of parameter count, hyperparameter tuning, model architecture, and fine-tuning. This comparison revealed that larger models showed superior overall performance, though with notable exceptions where smaller models performed better in specific rule categories. Additionally, hyperparameter tuning yielded modest improvements in performance. The study also highlighted
Struck, DanielKumaraswamy, Samanth
The intersection of Safety of Intended Functionality (SOTIF) and Functional Safety (FuSa) analysis of driving automation features has traditionally excluded Quality Management (QM) components from rigorous safety impact evaluations. While QM components are not typically classified as safety-relevant, recent developments in artificial intelligence (AI) integration reveal that such components can contribute to SOTIF-related hazardous risks. Compliance with emerging AI safety standards, such as ISO/PAS 8800, necessitates re-evaluating safety considerations for these components. This paper examines the necessity of conducting holistic safety analysis and risk assessment on AI components, emphasizing their potential to introduce hazards with the capacity to violate risk acceptance criteria when deployed in safety-critical driving systems, particularly in perception algorithms. Using case studies, we demonstrate how deficiencies in AI-driven perception systems can emerge even in QM
Abbaspour, Ali RezaMahadevan, ShabinZwirglmaier, KilianStafford, Jeff
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, MichaelGeier, BertramHofstetter, MartinHirz, Mario
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 vibration 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, AnastasiosJangid, Kuldeep
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 pack 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
Dixit, ManishRaja, VinayakGudiyella, Soumya
Non-uniform temperature distribution within lithium-ion battery cells is a critical challenge that accelerates degradation, compromises safety, and reduces pack-level performance in electric vehicles (EVs). This work focuses on modeling and minimizing these thermal gradients through the structured optimization of a liquid-based Battery Thermal Management System (BTMS). A one-dimensional transient thermal model is developed to capture the axial temperature differentials (ΔT) in a cylindrical cell under dynamic drive-cycle loading, incorporating detailed heat transfer from the cell interior through thermal interface materials (TIM) and an aluminum cooling plate to the coolant. Using a Design for Six Sigma (DFSS) approach with an L18 orthogonal array, key control factors—including coolant flow rate, inlet temperature, TIM properties, and plate geometry—are systematically analyzed to identify configurations that optimally balance low average temperature with minimal internal temperature
El-Sharkawy, AlaaAsar, MonaSerpento, StanSheta, Mai
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, AlaaAsar, MonaTaha, NahlaSheta, Mai
Safety isn’t just the absence of accidents - it’s the presence of trust, empowerment, and accountability at every level. The result is a high-trust culture where process becomes practice and safety is a shared achievement. When people closest to the work feel supported to act on what they see, safety becomes the standard. Thus, the deployment of autonomous driving systems (ADSs) requires not only technical rigor but also a resilient organizational safety culture that supports continuous learning, accountability, and transparent communication. This paper examines how safety culture can be operationalized in ADS development and operations by integrating guidance from standards such as UL 4600 and best practices from SAE AVSC. UL 4600’s requirements for systematic hazard analysis, safety case maintenance, and safety performance indicators (SPIs) are used as a foundation for quantifying organizational behavior within a Just Culture framework. This work draws on Human and Organizational
Wagner, MichaelGittleman, Michele
This specification covers quality assurance sampling and testing procedures used to determine conformance to applicable material specifications of corrosion- and heat-resistant steel and alloy forgings.
AMS F Corrosion and Heat Resistant Alloys Committee
Gasoline direct injection (GDI) engines are the most common technology on American roadways in 2025, and soon, an industrywide gasoline quality standard will better reflect their unique operational needs. Here's why that's important. It's no secret that fuel economy has been one of the greatest driving forces of automotive evolution over the past several decades. As corporate average fuel economy (CAFE) standards have grown increasingly lofty, OEMs eke out new efficiencies from every area of the vehicle. One of those areas, of course, is the engine, and many OEMs have deployed gasoline direct injection (GDI) technology, which is becoming the most common engine technology on American roadways. But while GDI engines proliferate, varying fuel additization throughout North America has not necessarily kept pace with their unique needs and can, in fact, hinder those engines from meeting and sustaining their full fuel economy potential.
Blackburn, Brett
In the rapidly evolving aerospace and defense landscape, simply keeping pace with trends isn't enough. Technology is advancing faster than ever, and in mission critical applications, failure is not an option. Systems must endure harsh environments while meeting uncompromising quality standards - an imperative that demands relentless innovation. Enter the Coyotes: WOLF's specialists in next generation rugged embedded systems, small form factor design, and bold, practical ideas. Whether on Earth or in orbit, they expand what high performance embedded computing can do across ground, orbital, lunar and deep space operations. Their work spans R&D, rapid prototyping and new product development for edge computing and artificial intelligence (AI) enabled imaging.
Lithium-ion batteries (LIBs) have become indispensable components in diverse energy applications driven by their high energy density, long cycle life, and low self-discharge. These excellent characteristics are directly influenced by their manufacturing processes, where variations in battery design and processing parameters will lead to significant differences in performance. Therefore, reliable and efficient evaluation of battery performance across manufacturing processes is essential for quality assurance and process improvement. Traditional methods rely on formation cycling and associated electrochemical tests, which are time and cost intensive. Different from them, a simulation-based approach for manufacturing performance evaluation is proposed in this study. The method employs the pseudo two dimensions (P2D) electrochemical model within the PyBaMM framework, where model parameters such as electrode type, electrode size, and particle size are derived from manufacturing data and
Yan, YifeiMeng, JinhaoSong, ZhengxiangZhang, ShiruiPan, YuhaoYang, PeihaoPeng, Jichang
Fuel adulteration affects operating costs, vehicle efficiency, and air pollution. Published estimates suggest it accounts for at least 10% of global sales. The Brazilian National Petroleum Agency (ANP) reported noncompliance in about 23% of inspections in 2023, including 4.3% confirmed adulteration. Quality verification requires laboratory equipment, and sensor-based approaches are often inaccessible to end consumers. This article proposes a sensorless (software-only) method that detects water adulteration in hydrated ethanol from standard Onboard Diagnostics (OBD) data using supervised machine learning, enabling on-vehicle fuel quality monitoring without additional hardware. The proposed approach is evaluated on real-world driving data from two production vehicles with three water adulteration levels in hydrated ethanol (0.0%, 2.5%, and 5.0%), achieving 84.85%–95.85% multiclass classification accuracy. These results indicate that software-only, OBD-based monitoring can provide a
Marchezan, Andre RicardoGiesbrecht, Mateus
This SAE Standard provides requirements and guidance to: Develop a Materiel authenticity plan. Procure Materiel from reliable sources. Assure authenticity and conformance of procured Materiel, including methods such as certification, traceability, testing, and inspection appropriate to the Commodity/item in question. Control Materiel identified as counterfeit. Report Suspect or Counterfeit Materiel to other potential users and Authorities Having Jurisdiction.
G-21 Counterfeit Materiel Committee
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, ArunachalamDhanraj, SudharsunGovindaraju, KarthikLokaiah, Srinivasan
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, AshishPathak, IshaKothari, Bhushan
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, AkhilSenthil Raja, TGhumare, DheerajChilakala, RaghavendraKundan, LalMohapatra, Durga Prasad
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, RahulSingh, Randhir
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, RakeshPatel, HiralNavale, Pradeep
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, ShwethaV, Sushmitha
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 SrinivasSrivastava, Anuj
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 RameshSahu, DilipJoshi, ChandrashekharKhatavkar, AkshayPoddar, ShivaniDeep, Amar
Gear noise is a common challenge that all gear manufacturers must contend with. In tractors, while it is often sufficiently low in intensity to not pose a significant issue, there are instances where gear whine may occur which is noticeable. In such cases, identifying the source and effectively addressing the problem can prove to be particularly difficult. This paper addresses the root cause analysis carried out for the evaluation of factors influencing whine noise behavior of Spiral bevel gear pair (SO2) in a tractor transmission system. Numerous publications have been published on gear noise of spiral bevel gear pair, too many to list here. However, once the gearbox assembled into the transmission, such models are of limited practical value. The work explained in this paper is a typical example offers avenues in correcting the issue using more limited means.
P, BharathP, PriyadarshanJanarthanan, Devakumara RajaChavan, Amit
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, SmitThambala, PrashanthSutar, SureshTodtermuschke, KarstenPatel, Hiral
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, AmrutaBagade, Aniket
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
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, IqbalKumar, Praveen
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, HafizAhuja, MuskanKalita, MrinmoyKumar, PrashantSithananthan, MArora, Ajay
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, SuchitJoshi, PawanKondhare, ManishCH, Sri RamGajbhiye, AbhishekS, Adm Akhinlal
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, AshokChoubisa, ManasKumar, RaviPathak, Mehul
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