Browse Topic: Quality management systems

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Research on Machining Deformation Simulation and Prediction of Low-Stiffness Structural Components under Cutting Force2026-99-02377/31/2026
During the cutting process of low-stiffness structural components, the coupling effect between dynamic deformation and cutting forces presents a significant challenge in accurately predicting machining-induced deformations, thereby complicating quality control in the manufacturing of such parts. To address this issue, a cutting force-structural coupling simulation method that combines experiment and finite element is proposed, which takes into account the low-stiffness characteristics of structural components. Focusing on thin-plate parts as the research object, an orthogonal experimental scheme is designed considering workpiece thickness that serves as an indicator of rigidity. A milling force prediction model correlated with workpiece thickness is established. Based on the predicted cutting forces, a multi-analysis-step simulation method is introduced to analyze the machining deformation of structural parts. Additionally, a theoretical analytical model for the machining deformation of thin-plate workpieces is developed. A comparison between the theoretical and simulation results shows a relative error of less than 1.03%, validating the accuracy of the proposed simulation method. Finally, the exponential regression model for the machining deformation is constructed using training data obtained from the simulations. The prediction error of the regression model is less than 15%. The findings of this study are also applicable to predicting machining deformations in other large and low-stiffness structural components.
Zhao, Yongsheng, Gao, Pengfei, Xu, Jingjing, Liu, Zhifeng
Discussion on Methods for Studying Material Fatigue Life: Taking Aluminum Alloy as An Example2026-99-01217/31/2026
Fatigue design is a key common quality technology for improving the quality control capability of China’s automotive products. The fatigue of materials is a multi-scale damage evolution process. Characterizing and processing the large number of three-dimensional defects inside the material, which have different shapes and distributions, and predicting the material’s lifespan based on the cross-scale damage evolution mechanism, is one of the key technologies for fatigue optimization design. This paper discusses the research methods for the fatigue life of aluminum alloy materials. Firstly, based on the staged fatigue damage experiments, the three-dimensional defect features are obtained through CT scanning and reconstruction, and a defect characterization and processing method based on k-d tree and multi-scale feature pyramid is established to accurately represent the topological and geometric relationships of non-uniformly distributed three-dimensional defects. Secondly, a mathematical model for the evolution of micro-damage and macro-cracks is constructed, and the cross-scale transformation of defects is achieved through hierarchical and recursive methods, revealing the cross-scale evolution mechanism of fatigue damage in aluminum alloy materials. Finally, a remaining life prediction model based on defect information and feature weights is established through the support vector regression algorithm (SVR). This research method can provide technical support for the fatigue life optimization design application of lightweight materials such as aluminum alloys.
Zhang, Liangxia, Niu, Zhijun, Cheng, Fangfang, Chen, Hao, Yang, Yali
Dynamic Assessment and Optimization of Bridge Resilience under Multi-Hazard Coupling2026-99-08297/30/2026
Traditional methods for assessing bridge resilience often focus on single hazards or static conditions. Yet bridges today face more complex multi-hazard threats. To address this, this research develops a dynamic model to evaluate bridge resilience under multi-hazard conditions, which is intended to provide scientific support for decision-making to improve resilience. The study first establishes an index system that measures a bridge’s ability to absorb impacts, adapt during an event, and recover afterward. We also propose a method to calculate the coupling degree, which quantifies the amplification effect of multiple hazards, such as an earthquake followed by a flood, on each other’s impacts. Next, we clarify the interrelationships among key resilience factors. Using this understanding, we construct a system dynamics model that simulates the variation of bridge resilience over a full disaster cycle. Finally, a numerical simulation is carried out for a concrete continuous girder bridge in China’s coastal areas as a case study. The results confirm the model is valid and clearly show the differences in bridge resilience between single-hazard and multi-hazard events. More importantly, they prove that combined hazards make the bridge system much more vulnerable. The model also identifies the best strategies for intervention: a strategy that coordinates actions across all disaster phases performs best, as it most effectively reduces the impact of compound hazards and keeps the resilience curve smoother. In short, this study presents a new method for assessing bridge resilience and provides engineers and managers with a practical tool to identify structural weaknesses and optimize resource allocation for resilience improvement.
Lin, Jiachen, Chai, Liang
Research on the Structural Performance of a New Modular Fireproof Wall for Converter Station Valve Hall in High-Altitude Areas2026-99-08327/30/2026
Aligned with the “3060 dual carbon” goal, the rapid growth of new energy installation capacity in China’s western high-altitude regions has caused an urgent demand for UHV converter station construction. This paper suggests a prefabricated structural system by using embedded ear-shaped tongue-and-groove UHPC wall-column connections to meet the challenges of traditional cast-in-place concrete firewalls, such as prolonged construction periods and difficulty in quality control in harsh environments. The seismic performance of the connection was investigated through pseudo-static tests and finite element analysis. The results show that failure mainly occurs on the wall–column interface, with cracks mainly appearing at the wall panel corners. The scaled model demonstrated full hysteresis loops, indicating stable energy dissipation. The ear-shaped tongue-and-groove connection showed superior initial stiffness and ultimate load-bearing capacity (404.3 kN) compared with the straight-type connection (177.5 kN). An increase in the semicircular diameter improved load capacity, while the axial compression ratio had little effect. This study proposes a theoretical reference for the design and application of prefabricated valve hall structures in high-altitude regions.
Wang, Fengyun, Yan, Yong, Zeng, Cheng, Zhou, Ting, Ren, Zhaoyang
Research on Early Warning Mechanisms for Fastener Substitution in Aircraft Production2026-99-16247/24/2026
This research overcomes the serious problem of unregulated fastener substitution in aviation manufacturing, which is due to supply chain disruption, design modification, improved production, and permanent installation of substitute fasteners other than temporary installation substitutes. It can introduce potential risks, including the differences between designed and as-built configurations, and problems with the structural strength of parts. Analysis of a 20XX aircraft model that has been documented with 9 types of fasteners reveals that shortages of 4CE5 and 1CD6 remain constant manufacturing nonconformities and a major element causing long term quality erosion. We have developed an early warning system centered on data with the introduction of the Tolerable Substitution Ratio (TSR) and the non-substitution ratio (NSR). Empirical results show that after implementation, the substituted materials can save as much as 25%, which is approximately $534,000 on domestic sourcing costs and permanently revised drawing costs. We should consider both users’ specifications and the production facility’s actual capabilities when designing the degree of substitution tolerances; substitution deviating from the original specification would not be tolerated. For an extended cycle longer than one year, phase adaptive tolerance adjustments are critical for achieving the acceptable quality limit (AQL). Real-time alignment of the key trigger point in the process stream with supply chain analytics takes away the historical trade-off between operational efficiency and the quality of the final deliverable. The result of this process is that there were more than 1,600 fewer ad-hoc deployments but higher levels of system stability, even as the processes had become more unstable. The payoff in terms of verified protocols for mitigating risk was much greater.
Feng, Yu
Calculation and Test on Ultimate Burst Strength of Tubing2026-99-16057/24/2026
Tubing Ultimate burst strength Full scale test
Cheng, Wenjia, Yang, Hongbin, Ge, Yuan, Zhong, Chongdi, Meng, Lingkun, Ji, Bingyin, Shi, Jiaoqi
Study on the Removal of Volatile Organic Compounds in Water by Ultracrosslinked Network Hydrogels2026-99-16427/24/2026
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Chen, Ruini, Lu, Bing
Generating Machine-Processable Specifications from Natural Language Using Large Language Models in Automotive Commissioning and Testing2026-01-07687/1/2026
In vehicle production, commissioning and testing processes of electric and electronic components are essential for value creation and quality assurance. The emergence of software-defined vehicles, however, leads to an increased scope and complexity of these processes as software functions depend on electric and electronic components for perception, execution, and processing tasks. In this context, this paper tackles a common challenge: Software that is deployed in vehicle production to implement commissioning and testing processes is developed upon specifications that define prerequisites, procedures, and target results in natural language. Therefore, extensive human interpretation and manual translation into executable code are needed being susceptible to errors as well as time-consuming. The large number of vehicle configurations and rapid changes in vehicle software further complicate the development of commissioning and testing software, particularly as verbose textual dependency descriptions risk impairing comprehensibility. Machine-processable specifications facilitating automated validation and code generation or direct execution could consequently ensure consistency, reduce manual effort, and accelerate the development process. For this purpose, we examine the processability of commissioning and testing specifications in natural language by proposing a pipeline designed to systematically transform these specifications into a machine-processable format. In particular, we introduce a unified schema that serves as an input format for the large language models tasked with the transformation. Subsequently, several large language models are evaluated in practical trials, based on their ability to translate commissioning and testing specifications into a machine-processable notation. In summary, this study aims to enable more efficient and data-driven software development based on textual requirements. This work offers valuable insights into the suitability and applicability of large language models within the planning of automotive commissioning and testing processes, targeting enhanced automation and efficiency.
Köhler, Katja, El Asad, Aiman, Hahn, Michael, Reuss, Hans-Christian
Evaluating the Impact of Fuel Additives on Stochastic Pre-ignition Using Center for Quality Assurance (CQA) Approved Methodology03-19-03-00166/22/2026
Stochastic preignition (SPI) or low-speed preignition (LSPI) is an abnormal combustion phenomenon observed in downsized turbocharged direct-injection spark-ignition engines at highly boosted conditions. SPI results from the ignition of the air-fuel mixture from a fuel or oil droplet or a detached deposit before the spark discharge, and its occurrence can lead to extremely high peak pressures and severe knock, which can cause physical damage to the engine. This phenomenon limits the downsizing and boosting potential of direct-injection spark-ignition engines, thereby constraining the efficiency benefits that can be achieved. The propensity for SPI to occur is impacted by engine operating conditions as well as the properties of the fuel, fuel additives, lubricant, and lubricant additives. To mitigate its occurrence, it is important to understand the factors that impact the frequency of SPI events. As this abnormal combustion phenomenon is relatively recent, there was a lack of a standard procedure to detect the impact of a parameter on SPI frequency. This study details the development and validation of an engine dynamometer test procedure—the TOP TIER™ Standardized Dynamometer Test Method to Evaluate Additized Detergent Gasoline for SPI—approved by the Center for Quality Assurance (CQA), to evaluate gasoline additives for their impact on SPI. In this project, the newly validated SPI test protocol was used to compare the relative SPI tendencies of four TOP TIER™ fuel additives at maximum retail concentration against unadditized SPI test fuel, which served as the baseline. All four fuel additives were tested three times in randomized order. The results revealed that none of the TOP TIER™ additives tested had a statistically significant impact on the SPI rate.
Gopujkar, Siddharth, Davis, Richard, Worm, Jeremy, Tuma, Nic, Shukla, Prajwal, Reilly, Veronica, Chapman, Elana, Ciaravino, Joseph, Seyfried, Philipp
Best-in-Class NVH Optimisation for Electric Powertrains, Holistic Front-Loading Approaches2026-01-06896/20/2026
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 demonstrate how simulation helped with NVH issue identification or improvement.
Mehrgou, Mehdi, Garcia de Madinabeitia, Inigo, Graf, Bernhard, Gojo, Josef
FBS as Key Enabler for Efficient Root Cause Analysis in NVH Simulations2026-01-07106/20/2026
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. Its key characteristic is that MI analysis is not restricted to the response component opposite to the well-known modal participation factors. Finally, a second novel analysis type is introduced, an advanced variant of Transfer Path Analysis (TPA). While standard TPA assesses the paths between only two system components, the new Expanding TPA is a multi-step process that identifies the most critical path across all components in a fully automated way.
Herbst, Markus
Methodology Development for Electric Drive Module Vibro-Acoustic Assessment Using Simulation Measurement Comparison and Root Cause Analysis2026-01-06916/20/2026
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 evaluation procedure. It discusses how RCA can be applied to different observed phenomena in EDM NVH behavior and detected deviations between the initial model and the measurements, the main influencing parameters, and the identified improvement potential for simulation models.
Klarin, Borislav, Pevec, Denis, Resch, Thomas, Esposito, Sara, D'Alessandro, Vincenzo, Spanu, Giorgio
Unsupervised Feature Frequency Map Extraction for Simple C-EPS Defect Detection2026-01-07176/20/2026
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) based framework trained on NVH datasets collected from normal and defective Column-type Electric Power Steering (C-EPS) systems. Latent variables at the bottleneck layer are used for dimension reduction, enabling visualization and unsupervised classification using a clustering algorithm. A classification model derived from the encoder is fine-tuned with clustered data, and Gradient-weighted Class Activation Mapping (Grad-CAM), an eXplainable AI (XAI) technique, is applied to extract Feature Frequency Maps (FFM) highlighting defect-related noise and vibration characteristics. The proposed approach does not rely on the deep learning model to directly classify defect. Instead, it utilizes extracted FFM as weights(mask) to detect defect. This method enables quantitative data representation and ensures high applicability with existing EOL equipment. Post-processing within the FFM enables root cause analysis, reducing issue resolution time and supporting integration with conventional signal analysis techniques.
Park, Jun-Seo, Jo, Hyeon-Choel, Cho, In-Je, Seo, Jae-Yong, Yoo, Seong-Sik
Direct Delivery Authorization Guidance for Aerospace CompaniesAS9107 (Current)6/12/2026
Limited to the commercial aerospace industry where a request is made for a PO to have Direct Delivery Authorization (DDA), which includes an Appropriate Arrangement (AA) between the PO and the Design Organization (DO). In this process, the DO is responsible for ensuring the continuous updating of approved design data to the PO, whilst the PO is responsible for assurance that the manufactured article conforms to approved design data. The PO is responsible to provide airworthiness release documentation.
SAE Committee
Delegated Product Release VerificationAS9117A (Current)6/12/2026
This standard specifies requirements for DPRV to establish common product/service requirements for use at all levels of the supply chain. This standard shall apply when an organization elects to delegate product release verification by contractual flow down to their supplier (reference 9100 and 9110 standards) to perform product acceptance on their behalf. The delegating organization shall use this standard as the baseline for establishing a DPRV process, although they may include additional contract requirements to meet their specific needs.
SAE Committee
Requirements Extract for AS9145 Requirements for Advanced Product Quality Planning and Production Part Approval Process SA-DIG-000096/9/2026
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.
Digital Model for AS9100D Quality Management Systems - Requirements for Aviation, Space, and Defense Organization SA-DIG-000086/9/2026
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.
Requirements Extract for AS13001A Delegated Product Release Verification Training Requirements SA-DIG-000066/9/2026
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.
Requirements Extract for AS4159 Specification For An Automated Interchange Of Standards Data SA-DIG-000046/9/2026
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.
Requirements Extract for AS13100A Quality Management System Requirements for Aero Engine Design and Production Organizations SA-DIG-000076/9/2026
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.
Design Optimization of Aircraft Light Optics: Eliminating Fasteners by Flexure-Based Clamp to Mitigate the Crack Formation and Validation through HALT2026-26-07506/1/2026
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) provides excellent light transmission and stability; however, their relatively lower mechanical toughness makes them susceptible to stress-induced cracking during assembly. In the baseline configuration, the Circuit Board Assembly (CBA) was fastened directly onto the optic using self-tapping screws. During assembly, frequent crack initiation was observed in the optic around the fastener locations, leading to concerns regarding reliability and maintainability. To address this issue, a redesigned mounting approach was developed that eliminated direct fastener penetration into the optic. Instead, the CBA is retained using a precision clamping mechanism, thereby distributing assembly loads uniformly and avoiding localized stress concentrations. COP material was retained due to its superior optical characteristics and compliance with photometric requirements for aircraft lighting applications. The redesigned optic-CBA interface was validated through Highly Accelerated Life Test (HALT), incorporating combined vibration, temperature, and thermal shock profiles. Test results confirmed that the new clamping design prevented crack formation, improved mechanical robustness, and ensured long-term optical performance. This paper presents the problem definition, root cause analysis of fastener-induced cracking, the design rationale for adopting a clamp-based mechanism, and detailed HALT validation results. The study highlights the importance of integrating material properties, fastening strategies, and environmental testing in the design of aerospace lighting systems. The proposed design methodology provides a pathway to enhance reliability and lifecycle performance of critical optical components in aircraft applications.
Vialta, Frederico, S, Nikhil, Katageri, Praveen, SP, Pradeep, Singh, Abhimanyu Kumar
Automating DO-178C Verification and Security Compliance in DevSecOps CI/CD Pipelines for Safety Critical Avionics Software2026-26-07176/1/2026
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 thoroughly validated without manual intervention. Daily automated testing and coding standards checks are performed to maintain ongoing software quality and compliance. By automating key verification and compliance activities, the framework minimizes human error and supports efficient regulatory compliance throughout the development process. Integration of these capabilities within DevSecOps pipelines enables rapid, repeatable, and auditable software releases, significantly reducing manual effort and accelerating delivery of high-quality builds to customers. The framework enhances digital verification, validation, and certification readiness by providing comprehensive evidence required for regulatory audits, ultimately improving overall project assurance and reducing technical debt for aerospace software teams. These automation techniques collectively help organizations achieve verification processes of DO-178C standards more effectively, ensuring that safety-critical software meets stringent industry requirements while streamlining the certification process, reducing time-to-market, and enabling faster deployment of reliable solutions to end users and stakeholders.
Bhagwat, Shashank Ravi, Changappa, Naveen Kumar, Nath, Sunny
Agentic Digital Thread for Managing the Non-Conformities in Manufacturing of Aerospace Products2026-26-07636/1/2026
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 management, enabling structured workflows for identifying, evaluating and approving deviations during inspection or final assembly. By embedding AI-driven anomaly detection, semantic search of historical concessions, and Generative AI-powered report authoring, the system accelerates resolution and predicts concession acceptance with high confidence. Continuous feedback loops between design, production and quality assurance transform the digital thread from a static data conduit into an intelligent ecosystem that ensures compliance, reduces delays and rework, and fosters continuous improvement. This approach delivers a resilient and adaptive aerospace manufacturing process aligned with the demands of next-generation aircraft production [9, 10].
Veluri, Sastry, Gopala Krishnan, Kannan
Software Reliability Program Implementation GuideJA1003_201205 (Current)5/26/2026
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 depend on the reliability-significance of the software, application domain, and life cycle stage of the software. Following guidelines in this document does not guarantee required reliability will be achieved, or that any certification authority will accept the results as sufficient evidence that requisite reliability has been achieved. Following guidelines in this document will provide insight into what level of reliability has been achieved. With proper customer, certification authority, and supplier negotiation and interaction in accordance with these guidelines, it is more likely that the achieved reliability will be acceptable.
G-41 Reliability
Evaluation of Mechanical Tensile Properties on TIG-Welded AISI 304L Austenitic Stainless Steel Using Principal Component Analysis05-19-04-00275/14/2026
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-noise (S/N) ratio, and analysis of variance (ANOVA). C1G1S3—the predicted optimal parameter combination—is the ideal factor configuration as determined by PCA (welding current = 100 A, gas flow rate = 10 L/min, travel speed = 2 mm/sec). Results demonstrate that precise control of process parameters significantly enhances weld quality. The methodology also provides a systematic framework that engineers and practitioners can apply to produce reliable stainless steel welds with improved accuracy and predictability.
Ghosh, Nabendu, Roy, Angshuman
Delegated Product Release Verification Training RequirementsAS13001A (Current)5/13/2026
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
Potential Failure Mode and Effects Analysis (FMEA) Including Design FMEA, Supplemental FMEA-MSR, and Process FMEAJ1739_202605 (Current)5/8/2026
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
Gear Coatings for Loss of Lubrication: System Level Transmission Experiment within VIPERF-0082-2026-00405/5/2026
The Army requires rotorcraft drive systems to operate for 30 minutes following a loss of lubrication event to make an emergency landing. Coatings research has shown great promise for loss of lubrication, but coating repeatability and quality control is a primary hurdle. The Army partnered with Acree Technologies via a Small Business Innovation Research (SBIR) effort to develop an optimized gear coating for loss of lubrication. The research culminated in a system level transmission experiment that maintained flight relevant torque and speed through a helicopter gearbox without oil for three hours. The authors decided to shutdown the experiment for inspection after three hours of operation without oil because the temperature and vibration signals maintained steady state conditions without signs of failure. Teardown analysis showed the transmission gear surfaces did not scuff, scanning electron microscope analysis showed coating remained on the gear teeth, and cross-sectional SEM analysis showed a measurable coating thickness remaining on the gear teeth after three-hours of operation without oil.
Riggs, Mark, Pomplon, William, Fetty, Jason, Milligan, Ryan, Woods, Ron, Wong, Kelvin, Matzke, Caleb, Jacques, Kelly, Hood, Adrian
Application of an Automated HUMS Data Chain for Rapid Engine Installation Diagnostics in New Generation Aircraft Production EnvironmentF-0082-2026-02335/5/2026
This paper presents the implementation of a fully automated Health and Usage Monitoring System (HUMS) data chain designed to accelerate installed engine performance diagnostics during the pre-delivery phase of new-generation helicopters. Ensuring that engine performance remains consistent with original engine manufacturer (OEM) baseline data is a critical step in the final assembly process, yet traditionally time-consuming. The developed system automates data offloading and integrates three distinct streams: OEM engine performance characteristics, in-flight Engine Power Checks (EPC), and high-frequency continuous recordings. The core innovation lies in a multi-source data fusion methodology combined with a physics-based model to differentiate between genuine installation discrepancies and sensor anomalies through temperature deviation analysis. Results from the production environment demonstrate that this automated approach significantly reduces troubleshooting lead times and ensures on-time aircraft delivery. By shifting advanced monitoring from in-service operations to manufacturing, this system establishes a new digital benchmark for quality control in helicopter production.
Esterle, Florent, Lecauchois, Claire, Maisonneuve, Pierre-Loïc, Calvet, Thomas
Predictive Modeling and Sensitivity Analysis of Thermal Runaway in 800V Lithium-Ion Battery Module Using DFSS Methodology2026-01-01244/7/2026
Thermal runaway in high-voltage lithium-ion battery modules should focus on critical safety and design challenges in electric vehicle applications, which need predictive methods that enhance passenger safety and support regulatory compliance. The primary purpose of a lithium-ion battery in an electric vehicle is to provide reliable energy storage while maintaining safe operation under different operating conditions. This study proposes a Design for Six Sigma (DFSS) methodology to virtually predict and correlate thermal runaway and its propagation in an 800V high-power lithium-ion battery 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 the functional performance of a system. The noise factors capture material variability and manufacturing tolerances affecting thermal properties. Output responses included the maximum cell temperature Versus time, thermal propagation time to adjacent cells, and total propagation duration across the module, measured in minutes. The validated 1D GT-SUITE model shows strong correlation with experimental data, confirming its reliability to predict thermal propagation time and supporting safer, thermally optimized battery pack designs. The validated model can be integrated into system (battery pack) level 1D thermal simulations, offering a calibrated model for future pack level propagation studies and supporting the development of safer, thermally optimized battery architectures.
Dixit, Manish, Raja, Vinayak, Gudiyella, Soumya
Predicting Electric Vehicle Interior Noise Quality from Drive Unit End-of-Line Vibration Testing2026-01-02234/7/2026
The Noise, Vibration, and Harshness (NVH) quality of electric vehicles (EVs) is heavily influenced by the performance of the electric drive unit. As a critical step in production, End-of-Line (EOL) testing of drive units is used to assess and control component-level NVH before vehicle assembly. However, the correlation between EOL test results and final vehicle interior noise quality, which directly impacts customer satisfaction, is not always fully understood. This paper presents a methodology for characterizing and predicting vehicle interior noise quality based on data from drive unit EOL vibration testing. Our study investigates the intricate relationship between drive unit assembly variations, component tolerances, and the resulting 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 identify critical manufacturing risks and optimize processes. This approach not only facilitates the delivery of a superior, noise-concern-free product but also contributes to reducing manufacturing costs by minimizing scrap and rework. This research advances NVH quality assessment for EVs and provides manufacturers with a vital tool to enhance customer experience and satisfaction in a competitive market.
Arvanitis, Anastasios, Jangid, Kuldeep
Modeling Non-Uniform Temperature Distribution in Lithium-Ion Batteries2026-01-01204/7/2026
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 variation. The results provide a data-driven framework for designing robust cooling systems that mitigate the risks of localized hotspots and thermal runaway, thereby enhancing the durability and safety of EV battery packs.
El-Sharkawy, Alaa, Asar, Mona, Serpento, Stan, Sheta, Mai
Application of DFSS for Optimizing Thermal Protection in Electric Vehicles during Battery Thermal Runaway Events2026-01-01424/7/2026
Battery thermal runaway is a major safety concern in electric vehicles because of the extreme heat and hazardous gases released during cell failure. These venting events can quickly raise the temperature of the battery enclosure and cabin floor, threatening occupant safety. To address this challenge, this study employs the Design for Six Sigma (DFSS) methodology to design and optimize a thermal protection system that delays and limits heat transfer to the cabin. A physics-based transient heat-transfer model was combined with DFSS principles to systematically evaluate insulation materials, shield layouts, surface emissivity, and layer geometry. An L-18 orthogonal array was used to identify key parameters and quantify their influence on thermal robustness. The optimized architecture reduced cabin-floor temperature rise under severe runaway conditions (600–900 °C vent gas), meeting occupant-egress safety requirements. Findings confirm DFSS as an effective framework for developing high-robustness EV thermal protection systems under uncertainty and extreme boundary conditions.
El-Sharkawy, Alaa, Asar, Mona, Taha, Nahla, Sheta, Mai
Open Source LLM Performance in Automating Embedded C Software Quality Improvements for Automotive2026-01-01034/7/2026
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 that model architecture and fine-tuning had less predictable effects, suggesting further exploration is required. Furthermore, some rules were more difficult to apply than others, and generated code often contained critical logical issues such as uninitialized variable use, excessive placeholders, and missing logic. This paper provides insights into patterns and behaviors observed in the study related to the strengths and weaknesses demonstrated by these open-source LLMs.
Struck, Daniel, Kumaraswamy, Samanth
Maintaining a Healthy Safety Culture in Autonomous Vehicle Development and Operations2026-01-05284/7/2026
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 Performance (HOP) research, including foundational contributions from Hollnagel, Reason, Dekker, Conklin, and Rasmussen, linking cultural dynamics to workforce involvement and effective safety controls. We propose a taxonomy of seven safety-culture SPIs that trace directly to UL 4600 § 16.2.5 and demonstrate how they can be deployed within an incident-handling process. Each SPI is defined mathematically and mapped to process steps, enabling both leading- and lagging-indicator assessment of safety culture maturity. This proposed framework, which requires formal research validation, transforms SPIs from compliance metrics into qualitative diagnostic tools for trust, empowerment, and system learning. The approach aligns organizational processes with Just Culture principles, distinguishing human error, at-risk behavior, and reckless conduct, while supporting continuous improvement and evidence-based conformance with UL 4600 and related ADS safety standards.
Wagner, Michael, Gittleman, Michele
Sensorless Estimation of In-Cabin CO 2 Concentration for Model-Based Air Recirculation Control2026-01-01304/7/2026
This paper introduces a sensorless approach for data-driven modeling of in-cabin CO2 concentration to optimize air recirculation flap control without the need for a dedicated CO2 sensor. Elevated CO2 concentrations, resulting from passenger exhalation, can impair occupants’ cognitive function and comfort. Current state-of-the-art solutions rely either on time-based control strategies, which lack responsiveness to actual cabin conditions, or on direct CO2 measurements via sensors, which increase system complexity and costs. In contrast, the proposed approach aims to replicate the benefits of sensor-based control without requiring physical sensors. In this study, a model-based methodology is presented, utilizing empirical CO2 measurement data collected from real-world test drives at varying occupancies, fan stages, vehicle speeds, and flap positions. Data acquisition involves a multi-gas analyzer positioned within the passengers’ breathing zone under controlled operation of the vehicle’s climate control unit. Based on these measurements, time-dependent CO2 concentration profiles are represented using exponential functions. These regression curves capture CO2 accumulation, depletion, and balancing behaviors, considering factors such as cabin leakage, pressure differentials at varying speeds, and ventilation conditions. These influences are inherently included in the calibration curves due to their empirical basis. The derived regression curves are implemented into a control model to simulate CO2 concentration throughout the drive, including situations where outside pollution is high and prolonged air recirculation is necessary – such as when driving through tunnels or behind trucks. On the baseline of this simulation, the sensorless control strategy adjusts flap positions accordingly, thereby minimizing both excessive CO2 buildup and unnecessary energy losses due to overventilation. By omitting CO2 sensors and relying solely on existing in-vehicle databus signals, this approach offers a cost-effective solution for cabin air quality management. Future work will focus on real-world validation of the control model and integration of exterior air quality monitoring as a complementary input.
Stürmer, Michael, Geier, Bertram, Hofstetter, Martin, Hirz, Mario
The Necessity of a Holistic Safety Evaluation Framework for AI-Based Automation Features2026-01-05224/7/2026
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-classified components, leading to unintended functional behaviors with critical safety implications. By bridging theoretical analysis with practical examples, this paper argues for the adoption of comprehensive FuSa, SOTIF, and AI standards-driven methodologies to identify and mitigate risks in AI components. The findings demonstrate the importance of revising existing safety frameworks to address the evolving challenges posed by AI, ensuring comprehensive safety assurance across all component classifications spanning multiple safety standards.
Abbaspour, Ali Reza, Mahadevan, Shabin, Zwirglmaier, Kilian, Stafford, Jeff
Quality Assurance Sampling and Testing, Corrosion- and Heat-Resistant Steel and Alloy ForgingsAMS2374G (Current)3/12/2026
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
Manufacturing Spotlight: Rugged Computing for Infinite Exploration26AERD03_043/1/2026
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.
How higher-quality gasoline keeps modern engines CLEAN AND EFFICIENT26AUTP03_033/1/2026
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
Simulation-Based Evaluation of Lithium-Ion Batteries Manufacturing Performance2026-01-70052/27/2026
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 built-in parameter data. The model predicts key performance indicators including capacity, resistance, and loss of lithium inventory (LLI) under specified tests conditions. A LGM50T cell was tested under varying operational scenarios, demonstrating the feasibility of the approach. Results indicate that low temperature condition significantly accelerates degradation and Lithium plating, with the capacity degradation at 5 °C reaching about three times that at 25 °C, while moderate variations in charge current rate induce only minor differences of about 0.5%. Simultaneously, depth of discharge (DOD) and average state of charge (SOC) have similar effects on capacity degradation and LLI. By replacing extensive reality tests with physics-based simulations, this method enables rapid evaluation of manufactured or unprocessed battery process formulas, substantially reducing time and material costs while providing mechanistic insights into process performance interactions.
Yan, Yifei, Meng, Jinhao, Song, Zhengxiang, Zhang, Shirui, Pan, Yuhao, Yang, Peihao, Peng, Jichang
Detecting Fuel Adulteration for Otto-Cycle Vehicle Using Onboard Diagnostics Data and Supervised Machine Learning04-19-02-00082/26/2026
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 practical solution for in-use fuel quality control.
Marchezan, Andre Ricardo, Giesbrecht, Mateus
Counterfeit Materiel; Assuring Acquisition of Authentic and Conforming MaterielAS6174B (Current)2/17/2026
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
Efficient Multi-Parameter Optimization of a Twist Beam Rear Axle for Electric Vehicles Using TOPSIS Method for Durability2026-28-00672/12/2026
This study investigates the parameter optimization of a Rear Twist Beam (RTB) for an electric vehicle (EV) during the early stages of product development. Adapting an RTB design from an Internal Combustion Engine (ICE) vehicle platform presents several challenges, one of the challenges is accommodating increased rear vehicle load while minimizing cost, with maintaining existing rear hard points. To address this, we employed an experimental study for Computer-Aided Engineering (CAE) using the Taguchi DOE, which avoids costly physical durability tests. The key design parameters considered were the thickness and material grade of the RTB's components, specifically the cross beam, trailing arms, and reinforcements while preserving their original shapes. L8 Orthogonal array is constructed to design the experiment and identify the influence of the design parameters on durability performance, and the optimal combinations for maximizing durability are identified by using TOPSIS multi objective method. This approach offers significant cost savings by avoiding different iterative physical testing during vehicle development stage. The study found that while changes in the thickness or material of components had mere effect on the rear axle's stiffness, the thickness of the cross beam and trailing arms significantly impacted its durability under various loads.
Madaswamy, Arunachalam, Dhanraj, Sudharsun, Govindaraju, Karthik, Lokaiah, Srinivasan
Ensuring Functional Safety in Electric Vehicle Inverters: A Case Study on ISO 26262 Implementation2026-26-01581/16/2026
The transition to electric vehicles (EVs) has brought about significant advancements in automotive technology, with inverters playing a crucial role in converting DC power from the battery to AC power for the electric motor. Ensuring the functional safety of these inverters is paramount, as any failure can have severe implications for vehicle performance and passenger safety. This case study explores the successful implementation of ISO 26262 standards in the development and validation of EV traction inverters. This paper begins by outlining the functional requirements and safety goals specific to EV inverters, followed by a detailed analysis of the potential hazards and risks associated with their operation. Using ISO 26262 as a framework, we describe the systematic approach taken to identify, assess, and mitigate these risks. Key methodologies such as Hazard Analysis and Risk Assessment (HARA), Failure Mode and Effects Analysis (FMEA), and Fault Tree Analysis (FTA) are employed to ensure comprehensive safety coverage. This case study showcases the integration of key safety mechanisms—such as redundancy, fault tolerance, and real-time monitoring—to significantly enhance the reliability and robustness of the inverter system. It also explores the challenges encountered during implementation, including the complexity of managing safety critical high-voltage systems and the need to stay aligned with evolving safety standards.
Ramachandra, Shwetha, V, Sushmitha
Integrated Quality Assurance Frameworks for Testing Advanced Automotive Systems in the Era of ADAS and E-Mobility2026-26-05681/16/2026
Ensuring the safety and functionality of sophisticated vehicle technologies has grown more difficult as the automotive industry quickly shifts to intelligent, electric, and connected mobility. Software-defined architectures, electric powertrains, and advanced driver assistance systems (ADAS) all require strong quality assurance (QA) frameworks that can handle the multi domain nature of contemporary vehicle platforms. In order to thoroughly assess the functionality and dependability of next generation automotive systems, this paper proposes an integrated QA methodology that blends conventional testing procedures with model-based validation, digital twin environments, and real-time system monitoring. The suggested framework, which includes hardware-in-the-loop (HIL), software-in-the-loop (SIL), and over-the-air (OTA) testing techniques, concentrates on end-to-end traceability from specifications to validation. Simulating intricate situations for ADAS, electric vehicle battery temperature management, and dynamic system updates in connected platforms are prioritized. This study also outlines the main obstacles to integrating QA methods with changing regulatory environments and draws attention to discrepancies between operational performance in real-world scenarios and compliance benchmarks. Early fault detection, lifecycle validation, and continuous improvement are made possible by the QA process's transition from reactive to proactive through the integration of digital twins and predictive analytics. A strategic roadmap for QA specialists and test engineers to adjust to changing industry demands is presented in the paper's conclusion. In addition to promoting safety and dependability, the suggested framework speeds up time to market, lowers development costs, and increases consumer confidence in cutting-edge automotive technologies.
Komanduri, Arun Srinivas, Srivastava, Anuj
Totem-Pole PFC and LLC Resonant Converter based 6.6kW On-Board Charger for LEV Applications2026-26-01601/16/2026
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 transitions. Moreover, maintaining stable operation across a universal input voltage range and achieving a high-power factor under light load conditions remain persistent challenges. Although resonant converters are widely used for their natural soft-switching ability, achieving zero voltage switching (ZVS) over a wide range of loads, especially at light load conditions, is still a technical challenge. Existing solutions rely on complex control strategies or hardware modifications, which increase cost and design complexity. The proposed architecture was modeled and simulated using MATLAB/Simscape to assess dynamic and steady-state behavior under a range of operating conditions. Results demonstrated high input power factor, line/load regulation, and switch-node waveforms to confirm ZVS operation. Additionally, the proposed charger exhibits low harmonic distortion, ensuring compliance with IEC 61000-3-2 power quality standards. These findings confirm the topology’s effectiveness for high-performance LEV charging and set a strong foundation for future experimental validation and hardware development.
Patil, Amruta, Bagade, Aniket
A Practical Approach to Reduce Gear Whine Noise through Gear Tooth Contact Analysis in an Agricultural Tractor2026-26-03451/16/2026
Gear noise is a common challenge that all gear manufacturers must contend with. In tractors, while it is often sufficiently low in intensity to not pose a significant issue, there are instances where gear whine may occur which is noticeable. In such cases, identifying the source and effectively addressing the problem can prove to be particularly difficult. This paper addresses the root cause analysis carried out for the evaluation of factors influencing whine noise behavior of Spiral bevel gear pair (SO2) in a tractor transmission system. Numerous publications have been published on gear noise of spiral bevel gear pair, too many to list here. However, once the gearbox assembled into the transmission, such models are of limited practical value. The work explained in this paper is a typical example offers avenues in correcting the issue using more limited means.
P, Bharath, P, Priyadarshan, Janarthanan, Devakumara Raja, Chavan, Amit
Nexifi11D: A Comprehensive Multidimensional Framework for Futuristic Manufacturing Ecosystems2026-26-02821/16/2026
This paper presents Nexifi11D, a simulation-driven, real-time Digital Twin framework that models and demonstrates eleven critical dimensions of a futuristic manufacturing ecosystem. Developed using Unity for 3D simulation, Python for orchestration and AI inference, Prometheus for real-time metric capture, and Grafana for dynamic visualization, the system functions both as a live testbed and a scalable industrial prototype. To handle the complexity of real-world manufacturing data, the current model uses simulation to emulate dynamic shopfloor scenarios; however, it is architected for direct integration with physical assets via industry-standard edge protocols such as MQTT, OPC UA, and RESTful APIs. This enables seamless bi-directional data flow between the factory floor and the digital environment. Nexifi11D implements 3D spatial modeling of multi-type motor flow across machines and conveyors; 4D machine state transitions (idle, processing, waiting, downtime); 5D operational cost breakdowns covering electricity, tooling, labour, coolant, and depreciation; 6D AI/ML-based failure prediction using temperature and pressure inputs; 7D predictive downtime triggers based on learned thresholds; 8D sustainability analytics measuring CO₂ emissions per motor; 9D workforce optimization via virtual shift scheduling and fatigue simulation; 10D supply chain resilience through simulated part delays and buffer modeling; and 11D risk and quality management using defect simulation and risk scoring. All data are generated live and visualized through Grafana dashboards, enabling real-time monitoring of OEE, energy use, defects, and AI-based alerts. Nexifi11D establishes a unified, cyber-physical platform for intelligent, sustainable, and predictive manufacturing, making multidimensional factory optimization practically demonstrable within one connected environment.
Kumar, Rahul, Singh, Randhir
Fatigue Failure Analysis for Automotive Transmission2026-26-05771/16/2026
A fatigue failure in the transmission input shaft was identified during a bench-level endurance test under 2nd gear loading conditions. The test transmission’s input shaft comprises fixed 1st, reverse, and 2nd gears, with the remaining gears mounted as floating. The shaft was subjected to cyclic torsional loads, and failure occurred after a defined number of cycles. Metallurgical analysis revealed a brittle fracture surface with crack initiation at the outer surface, propagating to core in a helical pattern, ultimately resulting in complete shaft fracture. To monitor and replicate the failure, the test setup was instrumented with a Reilhofer Delta Analyzer for early fault detection. TTL signals from accelerometers mounted on the transmission and a bench speed sensor were fed into the system, which generates FFT spectra and trend indices. A warning alarm triggered upon deviation in the trend index, indicating premature damage initiation. The test was subsequently halted for component inspection, revealing tool serration marks and initial hairline cracks near the 2nd gear location. Order analysis confirmed the dominance of the 2nd gear order and its harmonics. Additionally, the trend index energy was six times higher than baseline levels, indicating abnormal mechanical behavior. Finite element simulations were conducted on models with and without tool serration marks on the input shaft. The results showed significantly elevated stress concentration and shear stress in the failure zone for shafts with tool marks, whereas smooth shafts exhibited no severe stress concentrations. The input shaft was re-machined to eliminate tooling marks, and subsequent testing showed no abnormal trend index variation, confirming alignment with simulation predictions. This paper outlines the root cause analysis, simulation correlation, and mitigation strategy to prevent fatigue failure in rotating transmission components under cyclic loads. The methodology is scalable to similar components operating under dynamic loading environments.
Kushwaha, Rakesh, Patel, Hiral, Navale, Pradeep
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