Browse Topic: Quality assurance

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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
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.
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
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
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
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
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
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
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
Design Solutions for Ice-Induced CNG Filling Failures- Field Issue Resolution through Filter Geometry and Seal Material Reengineering2026-26-05151/16/2026
This study investigates the phenomenon of receptacle icing during Compressed Natural Gas (CNG) refueling at filling stations, attributing the issue to excessive moisture content in the gas. The research examines the underlying causes, including the Joule-Thomson effect, filter geometries, and their collective impact on flow interruptions. A comprehensive test methodology is proposed to simulate real-world conditions, evaluating various filter types, seal materials and moisture levels to understand their influence on icing and flow cessation. The findings aim to offer ideas for reducing icing problems. This will improve the reliability and safety of CNG refueling systems.
Virmani, Nishant, Sawant, Shivraj Madhukar, C R, Abhijith
EV Powertrain Systems Diagnostics & Prognostics Utilizing AI & ML (LLM) Based Approach2026-26-06641/16/2026
This study introduces a novel Large Language Model (LLM)-driven approach for comprehensive diagnosis and prognostics of vehicle faults, leveraging Diagnostic Trouble Codes (DTCs) in line with industry-standard automation protocols. The proposed model asks for significant advancement in automotive diagnostics by reasoning through the root causes behind the fault codes given by DTC document to enhance fault interpretability and maintenance efficiency, primarily for the technician and in few cases, the vehicle owner. Here LLM is trained on vehicle specific service manuals, sensor datasets, historical fault logs, and Original Equipment Manufacturer (OEM)-specific DTC definitions, which leads to context-aware understanding of the vehicle situation and correlation of incoming faults. Approach validation has been done using field level real-world vehicle dataset for different running scenarios, demonstrating model’s ability to detect complex fault chains and successfully predicting the associated root cause. By utilizing time series based future projection of the vehicle pattern, this approach could also predict the probable future faults as well as the requisite steps needed to prevent them. Overall, key contributions of this work include: (1) a modular diagnostic framework that seamlessly integrates different electronic control unit (ECU) architectures for sequential root cause analysis of vehicle faults, (2) cross-platform compatibility allowing utility across varied vehicle models and platforms, and (3) a user-friendly interface that eliminates the need for technical expertise by generating output data into simple, actionable insights. This work was benchmarked against traditional rule-based diagnostic tools and showed 50-70% reduction in the troubleshooting time for Root cause analysis (RCA). In the prognosis front, model could predict upcoming possible faults in the Battery behavior with significant accuracy. The framework also supports continuous learning by integrating new fault patterns, ensuring adaptability over time. This paper establishes the potential of integrating advanced language models into the automotive diagnostics pipeline and provides a scalable, intelligent, and intuitive solution for next-generation vehicle fault management.
Pandey, Suchit, Joshi, Pawan, Kondhare, Manish, CH, Sri Ram, Gajbhiye, Abhishek, S, Adm Akhinlal
Engine Oil Fluctuation Study in HLA Gallery and Impact of VVT Cam Phasing on Oil Fluctuation2026-26-05591/16/2026
Oil pressure, the most fundamental to engine's performance and longevity, is not only critical to ensure that the engine components are properly lubricated, cooled, and protected against wear and contamination, but also ultimately contributing to reliable engine performance. Due to several factors of engine such as, rotational fluctuation, aeration, functioning of hydraulic components there are fluctuations in oil pressure. In engines, with a crank-mounted fixed displacement oil pump (FDOP), these inherited pressure fluctuations cannot be eliminated completely. However, it is very necessary to control the abnormal oil pressure fluctuation because abnormal pressure fluctuation may lead to malfunction of hydraulic component functioning like variable valve timing (VVT), hydraulic lash adjuster (HLA) and dynamic chain tensioner which can further cause serious issues like excessive or sudden load drops, unstable engine performance, valve train noise, improper valve lift operation etc. In this paper, engine oil pressure fluctuation in HLA gallery is studied, and its impact was assessed on valve train system. Root cause analysis (RCA) was conducted using high frequency oil pressure measurement to understand the various reasons impacting high oil pressure fluctuations inside HLA galleries. Time domain analysis was performed to understand oil pressure fluctuations with respect to VVT cam phasing. Angle domain analysis was performed to assess the impact of oil pressure fluctuations on valve train behavior. Further findings from this study aim to enhance the understanding of impact of VVT cam phasing in oil pressure fluctuations.
Kumar, Ashok, Choubisa, Manas, Kumar, Ravi, Pathak, Mehul
Multispeed EV Transmission – Gear Shift Simulation and Validation2026-26-01571/16/2026
The advancement of electric vehicle (EV) transmission systems is currently a prominent trend aimed at decreasing carbon emissions and providing eco-friendly transportation alternatives. Most of the EV transmissions are single speed, but research conducted on multi speed EV transmissions show higher efficiency, good performance, high speed and torque demand when compared with single speed counterparts. Most of the multi speed EV transmissions that are developed are of non-synchromesh type, which have direct effect on NVH, driving dynamics and durability of drivetrain components. Due to aforementioned factors, gearshift analysis becomes critical for development. Simulation model is developed at early development phase for initial feedback. Using the feedback, drivetrain can be optimized furthermore and test on physical parts can be conducted for final verification. This paper provides a simulation based approach for modelling non-synchromesh two speed EV transmission using Simulation X. The model consists complete vehicle from prime mover, gear box to wheels. Non-synchromesh gearboxes lack synchronizers, which are essential for matching the speeds of the input and output shafts during a gear change, the model is capable of 3D visualization of gear synchro ring and shifter sleeve teeth during gear shift event, which is vital to observe any gear crashing phenomenon during gear shift event and will compute parameters such as forces acting on synchro pack, synchronization time and jerk on vehicle during engagement. Additionally, this paper gives details of bench test setup for gearshift quality tuning and system level validation with vehicle controller. Simulation results show good correlation with bench level data and serve as vital feedback for initial gearshift quality assessment. Multiple iterations can be carried out on simulation model by changing design parameters of synchro pack and speed difference between input and output shafts to observe the effect on gear shift quality and validated on final prototypes.
Kansagara, Smit, Thambala, Prashanth, Sutar, Suresh, Todtermuschke, Karsten, Patel, Hiral
Thermal Shock Test Rig for CNG Shut-Off Valve2026-26-05261/16/2026
In Automobile, Gasoline Engines are being used along with electrically operated shut-off valve installed at the roof of bus in case of higher capacity of CNG systems. In order to start/ stop CNG supply from cylinder for running of engine/ safety/ servicing an electrical operated ignition switch/ key controlled CNG Shut-Off Valve is placed just after the cylinders. There have been few failures of these CNG shut-off valves in field application. On investigation, it was observed that the CNG shut-off valve gets failed due to water ingress in coils from the cracks on surface generated due to spray of water (due to daily washing of bus and rain) on heated shut-off valves. In order to validate this field failure and subsequent validation of modified design, a need was felt to use a test rig which can exactly simulate the water spray based thermal shocks. However, there was no low cost facility available to simulate the field service condition for validation. Therefore, a low cost test set-up was designed and developed to simulate the failure in test lab to analyze the failure and root cause analysis and further durability validation of improved design. The designed and developed test rig was very useful to investigate the root cause of failures and validation of improved samples. The test rig has been in operation for 2 years without any failures and has validated more than 30 samples of existing and improved samples. The test rig was designed and developed completely in-house and is a low cost in price as well as low running cost.
Srivastava, Pravin Kumar, Vivekanand, Vivekanand, Kumar, Satish
An Investigation into the Structural Impacts of Off-Road Maneuvers on Rear Axle Upper Link Mounting Bracket2026-26-04901/16/2026
Multi-link rigid axle suspension is widely used as a rear suspension system for body-on-frame SUVs. The upper link in a multi link rear suspension plays a critical role in managing the vertical and longitudinal positioning of the axle, while the lower link ensures stability by regulating the axle's movement in the horizontal plane. This coordinated functionality of upper and lower link allows for controlled axle dynamics during compression and rebound, significantly enhancing ride comfort and improving vehicle handling characteristics. This study examines the failure of an upper link mounting bracket on the rear axle of an SUV during off-road events, despite no failures observed in other durability tests. Root cause analysis is conducted on failed samples to determine the specific reasons for failure only in off-road conditions. Additionally, the investigation focuses on understanding the dynamic loads experienced by the upper link during vehicle operation across various durability tracks, identifying their contribution to the observed failure. Using Road Load Data Acquisition (RLDA) techniques, loads at the mounting bracket location are measured while running the vehicle on different terrains. The acquired data enables to understand maximum stress acting on the bracket and which terrain is worst case for the bracket failure. The study further employs the finite element method (FEM) to develop a detailed FE model of the rear axle and upper link mounting bracket. The model is subjected to measured dynamic loads to analyze stress distribution and evaluate its impact on durability. Various design proposals are explored to enhance durability and mitigate stress concentrations, aiming to prevent structural failure. Based on the analysis, the study provides design improvement recommendations to ensure reliability and robustness. These insights are vital for manufacturers striving to produce high-performance SUVs capable of enduring demanding off-road maneuvers and conditions.
J, Akhil, Senthil Raja, T, Ghumare, Dheeraj, Chilakala, Raghavendra, Kundan, Lal, Mohapatra, Durga Prasad
Resolution of Automotive Air Compressor Noise in Low Powered ICE Vehicles2026-26-03141/16/2026
The interior noise and thermal performance of the passenger compartment are critical criteria for ensuring driving comfort [1]. This paper presents the optimization of air conditioning (AC) compressor noise, specifically for the low-powered 1.0 L - ICE engine paired with a 120 cc IVDC compressor. This combination is quite challenging due to the high operational load & higher operating pressure. To enhance better in-cabin cooling efficiency, compressor’s operating efficiency must be improved, which necessitates a higher displacement of the compressor. However, increased displacement results in greater internal forces which leads to more structure-borne induced noise inside the cabin. For this specific configuration, the compressor operating pressure reached up to 25 bars under most driving conditions. During dynamic driving scenario, a metallic tonal noise from the compressor was reported in a compact vehicle segment. It is reported as very annoying to passengers inside. A comprehensive root cause analysis was conducted, including Transfer Path Analysis (TPA), evaluation of compressor fixation points stiffness, and dynamic noise signature analysis. The investigation revealed that the metallic noise was a combination of moaning and whining sounds, primarily caused by internal excitation forces within the compressor. These forces generated dominant excitations at high operating pressures, resulting in the observed tonal noise. Several countermeasures were explored, including changes to the compressor pulley ratio to decouple engine firing frequency excitations, modifications to the AC pipe bends to reduce excitation forces, and optimization of acoustic mass and compressor mounting stiffness. Collaboration work has been done with the supplier focused on fine-tuning the Mass Flow Control Valve (MFCV) settings [6] and adjusting compressor shaft tolerance. The most effective solutions were the compressor pulley ratio change and the modification of the compressor’s planetary plate angle, which together achieved an improvement of approximately 6 dB(A) in compressor order noise, significantly reducing customer-perceived annoyance. As a result, key NVH (Noise, Vibration, and Harshness) design rules have been established and implemented
John Britto, Vijay Antony, Maluganahalli-Dharmappa Madhusoodan Sr, Madhusoodan, Natarajasundaram, Balasubramanian
Quality Assurance Sampling and Testing, Carbon and Low-Alloy Steel ForgingsAMS2372J (Current)1/1/2026
This specification covers quality assurance sampling and testing procedures used to determine conformance to applicable specification requirements of carbon and low-alloy steel forgings.
AMS E Carbon and Low Alloy Steels Committee
Application of Lean Manufacturing Tools to Reduce Defect Incidence in Tire Production2025-36-002112/18/2025
The continuous pursuit of operational excellence in the tire manufacturing industry necessitates structured approaches to minimize production defects, improve resource utilization, and enhance product reliability. This study presents a comprehensive case study focused on the implementation of Lean Manufacturing tools within a high-volume production facility specialized in truck and bus radial (TBR) tires. The production line under investigation exhibited recurring defects on the sidewall region of the cured tires, referred to as defect F1, stemming primarily from condensation phenomena and steam management inefficiencies during the curing process. A detailed root cause analysis was conducted through structured brainstorming sessions, Ishikawa diagrams, and the 5 Whys method, revealing multiple converging causes including excessive internal pressure, improper drainage angles, degraded sealing interfaces, and inadequate vapor shielding. In response, a corrective action plan was deployed, integrating the installation of pneumatic OR-valves, realignment of machinery to induce gravitational drainage, application of protective skirts, and the adoption of preventive maintenance protocols. The interventions yielded a defect reduction from an average of 3.0% to 1.4%, representing a 39% improvement, well above the initial target of 20%. Additionally, a 30-second cycle time reduction was achieved, enabling an incremental output of 1,358 tires over a 23-day observation window and translating into more than 390 hours of direct labor saved. These results underscore the effectiveness of integrating Lean principles such as Kaizen, Single Minute Exchange of Die (SMED), and 5S within the framework of industrial tire manufacturing. The study not only validates the technical efficacy of the proposed interventions but also highlights the strategic value of Lean-based quality engineering for driving competitiveness in automotive component production.
Filho, William Manjud Maluf, Yoshimura, Sofia Lucas, Marques, Ana Sung, Sousa, Julia Zanardo, Siqueira, Gonçalo, Alves, Marcelo Augusto Leal, Ferreira, Wallace Gusmão
Quality Assurance Sampling and Testing, Corrosion- and Heat-Resistant Steels and Alloys, Wrought Products and Forging StockAMS2371M (Current)11/12/2025
This specification covers quality assurance sampling and testing procedures used to determine conformance to applicable material specification requirements of wrought corrosion- and heat-resistant steel and alloy products and of forging stock.
AMS F Corrosion and Heat Resistant Alloys Committee
Multi-Objective Design Optimization and Pugh Matrix Analysis to Develop Exhaust Tail Pipe Mounting for EU6 Heavy Trucks2025-28-029311/6/2025
The key performance evaluation criteria for any automotive exhaust system are pass-by noise (PBN), exhaust backpressure, durability and reliability, exhaust brake performance, aesthetics (if visible from outside the chassis), cost, weight and safety. Also, with changes in emission norms, emission from Exhaust Aftertreatment Systems (EATS) is one of the crucial parameters while designing the exhaust system. This paper covers a critical problem faced during the Beta Proto Build and Testing phase of exhaust tail pipe assembly. The exhaust tail pipe assembly had loose fitting issues, which can cause problems during the functioning of the truck. Parameters like material of the pipe, length of strap, tightening torque and tolerance of the pipe diameter were considered to resolve the fitment issue. The resolution is done with the help of Design of Experiments (DoE) and Pugh Matrix Analysis based on QDCFSS (Quality, Design, Cost, Feature, Safety and Sustainability). Design for Assembly (DFA) is a critical event, especially at Beta Proto Build and the pre-launch production phase. It has the dependency with design, parts (piece to piece variations- like dimension, material property), method shop floor facilities / resources (workstation – tools / machines), method/practices (variations – plant to plant / location to location) and workforces (training and physical states - like height). In the subject case, torque loosening / variations and difficulty in assembly have been reported from different plants / proto shops globally for the mounting of the exhaust tail pipe of EU6 heavy Trucks. In this context, Multi-Objective Optimization (MOO) is done with reference to DoE and Pugh Matrix evaluation to resolve the validation phase (testing) blocker problem of EU6 global trucks. Also, Quality Tools are used to do Root Cause Analysis (RCA), find Interim Corrective Action (ICA), and come up with different inputs for DoE. The primary objective of this research is to investigate and optimize the factors involved in tail pipe mounting schemes, which consist of tail pipe (GD&T and material), mounting clamp, torquing, and orientation preference. In material selection, Sustainability which is focused on SOC (substance of concern), CO2 reduction and R-Cycle framework, is equally important in decision making. This work indicates that the DoE technique, along with QDCFSS assessment, is very effective in optimizing multiple factors and resolving the problem identified by the proto build and testing team and ensuring follow the project milestone and business continuity.
P, Balu Mukesh, Rokade, Aditya, Biswas, Sanjoy
Design Strategies for “Front Stabilizer Link Assembly” for Maximized Wheel Articulation in All Terrain for Passenger Car Application2025-28-030911/6/2025
The stabilizer link, also commonly referred to as the sway bar link or anti-roll bar link, plays a crucial role in the suspension system. It connects the sway bar to suspension components such as the knuckle, control arm, or strut. The primary function of the stabilizer link is to reduce body roll during cornering or when driving over uneven terrain. It helps stabilize the wheels during extreme articulation events and ensures smoother operation in terms of ride comfort and handling. Additionally, it is designed to assist in distributing forces across the suspension system, particularly in off-road or rugged terrain applications. This case study presents the failure of a stabilizer link assembly during extreme articulation events. The front stabilizer link failed during vehicle-level durability and functional testing across multiple terrains. Based on the root cause analysis, design strategies were developed to prevent such failures and to ensure reliable operation during demanding off-road and extreme articulation conditions. These strategies aim to develop a robust stabilizer link assembly that maintains the kinematic performance of passenger vehicles during extreme articulation events.
S, Praveen Kumar, Chilakala, Raghavendra, Senthil Raja, T, Jadhav, Prashant, Kundan, Lal, J, Akhil, Pawar, Sandip
Valve Wagging Prediction Methodology for Engine Brake Application2025-28-040210/30/2025
Eaton's decompression engine braking technology for medium and heavy-duty diesel engines delivers high braking power and provides several advantages to the commercial truck owner. Eaton offers rocker arm-based 1 stroke, 1.5 stroke, and 2 stroke systems for overhead cam and cam in block engine architectures. The Compression Release (CR) engine brake avoids overheating and fading of primary friction brake. It reduces or eliminates the need for a driveline retarder. One of the failure modes for Engine Brake (EB) system is excessive lateral displacement of the exhaust valve, caused by non-uniform pressure distribution across the valve during Brake Gas Recirculation (BGR) and Compression Release modes. This excessive deformation is referred to as Valve Wagging. Valve wagging significantly affects the structural stability of the engine brake mechanism. Analyzing its behavior is essential to minimize excessive wear on valve guide and Valve Seat Insert in new designs. Since evaluating the valve wagging phenomenon through prototype testing is both costly and time-consuming, a validated analytical approach was developed. A coupled CFD and structural dynamics analysis approach was developed to predict valve wagging phenomena. This approach includes simulating transient valve motion using a dynamic mesh technique, capturing the influence of valve motion on surrounding flow-field, and assessing the impact of flow field on valve structural displacement. The developed methodology was validated by comparing simulated valve lateral displacement with experimental results, showing good agreement between the two.
Soni, Lalitkumar R., Joshi, Himanshu, J, Gokulakrishnan, De Giovanni, Pierfrancesco
Advancing Vehicle-Level AC Thermal Management System Performance2025-28-043410/30/2025
Modern mobility solutions increasingly rely on HVAC systems due to growing transport demands, traffic congestion, and harsh environmental conditions. These systems, comprising a compressor, evaporator, condenser, and thermal expansion valve, require adequate airflow for optimal performance. Insufficient airflow, caused by factors like undersized ducts, improper fan settings, clogged filters, or high static pressures from duct restrictions, significantly hinders cooling capacity. The objective of this study is to develop a predictive model for passenger vehicle AC system performance under controlled environmental conditions. Discrepancies between predicted and desired performance will trigger a structured problem-solving process involving iterative testing, root cause analysis, and the development of corrective measures. The improvements will be focused on the vehicle-level HVAC design, adhering to customer specifications. This research will also establish an experimental validation protocol and offer recommendations for process optimization to reduce prototype/tooling costs in future projects.
Meena, Avadhesh Kumar, Agarwal, Roopak, Sharma, Kamal, Kishore, Kamal
A Re-Certification Guideline for Aerospace Platform Fiber Optic Training and Awareness Education Aerospace Fiber Optics Fabricator Hands-on CompetenciesARP5602/14 (Current)10/23/2025
This document establishes re-certification guidelines applicable to fiber optic fabricator technical training for individuals involved in the manufacturing, installation, support, integration and testing of fiber optic systems. Applicable personnel include: Managers Engineers Technicians Trainers/Instructors Third Party Maintenance Agencies Quality Assurance Production
AS-3 Fiber Optics and Applied Photonics Committee
A Guideline for Aerospace Platform Fiber Optic Training and Awareness Education Aerospace Fiber Optics Fabricator Hands-on CompetenciesARP5602/4 (Current)10/23/2025
This document establishes training guidelines applicable to fiber optic fabricator technical training for individuals involved in the manufacturing, installation, support, integration and testing of fiber optic systems. Applicable personnel include: Managers Engineers Technicians Trainers/Instructors Third Party Maintenance Agencies Quality Assurance Production
AS-3 Fiber Optics and Applied Photonics Committee
A Guideline for Aerospace Platform Fiber Optic Training and Awareness Education Introduction to Aerospace Fiber Optics Hands-on CompetenciesARP5602/2 (Current)10/23/2025
This document establishes training guidelines applicable to fiber optic safety training, technical training and fiber awareness for individuals involved in the manufacturing, installation, support, integration and testing of fiber optic systems. Applicable personnel include: Managers Engineers Technicians Logisticians Trainers/Instructors Third Party Maintenance Agencies Quality Assurance Shipping Receiving Production Purchasing
AS-3 Fiber Optics and Applied Photonics Committee
Nadcap at 35: Still Defining Excellence in Aviation, Defense and Space Manufacturing25AERP10_0110/1/2025
Celebrating its 35th year, the National Aerospace Defense Contractors Accreditation Program (Nadcap) continues to advance quality assurance and regulatory compliance for aviation, defense, and space OEMs and suppliers. This article summarizes how Nadcap accreditation works, its benefits for manufacturers, and its role in expanding additive manufacturing through industry-wide consensus. The Nadcap program was first established in 1990 by a small group of aerospace and defense OEMs. Their goal was to create an accreditation initiative that provides a common approach to auditing the manufacturing and production processes used by companies supplying parts, components, structures, and services to major aerospace and defense OEMs. This foundation set the stage for Nadcap's continued focus on quality assurance and regulatory compliance in the industry.
Aluminum Alloy, Plate (7255-T7751) 8.0Zn - 2.3Cu - 2.0Mg - 0.12Zr Solution Heat Treated, Stress Relieved, and OveragedAMS4463B (Current)7/1/2025
This specification covers an aluminum alloy in the form of plate 0.750 to 1.500 inches, incl (19.05 to 38.10 mm, incl) in thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Eddy Current Inspection of Circular Holes in Nonferrous Metallic Aircraft Engine HardwareAS4787A (Current)5/2/2025
This SAE Aerospace Standard (AS) establishes minimum requirements for eddy current inspection of circular holes in nonferrous, metallic, low conductivity (less than 5% IACS) aircraft engine hardware with fasteners removed. The inspection is intended to be performed at maintenance and overhaul facilities on engine run hardware.
AMS K Non Destructive Methods and Processes Committee
Empirical Analysis on Machine Vision Recognition of Green Bike Lanes for Vulnerable Road Users Safety2025-01-80174/1/2025
Deliberate modifications to infrastructure can significantly enhance machine vision recognition of road sections designed for Vulnerable Road Users, such as green bike lanes. This study evaluates how green bike lanes, compared to unpainted lanes, enhance machine vision recognition and vulnerable road users safety by keeping vehicles at a safe distance and preventing encroachment into designated bike lanes. Conducted at the American Center for Mobility, this study utilizes a vehicle equipped with a front-facing camera to assess green bike lane recognition capabilities across various environmental conditions including dry daytime, dry nighttime, rain, fog, and snow. Data collection involved gathering a comprehensive dataset under diverse conditions and generating masks for lane markings to perform comparative analysis for training Advanced Driver Assistance Systems. Quality measurement and statistical analysis are used to evaluate the effectiveness of machine vision recognition using metrics, such as Blind/Reference-less Image Spatial Quality Evaluator, Naturalness Image Quality Evaluator, and Entropy-based Image Quality Assessment. The results indicate that green bike lanes are more likely to be recognized by machine vision systems across a wide range of environmental conditions, demonstrating enhanced recognition capabilities. Green lane markings exhibit enhanced visibility and stability, with BRISQUE scores below 82, a median contrast ratio of 17.6, and improved resilience to motion blur and NIQE variations under diverse conditions.
Ponnuru, Venkata Naga Rithika, Das, Sushanta, Grant, Joseph, Naber, Jeffrey, Bahramgiri, Mojtaba
Aspects for the Optimization of Car Production Regarding Efficiency, Availability and Sustainability2025-01-86094/1/2025
Nowadays, more than in the recent decades, the design process for the body in white for passenger cars is driven by efficiency. This results in the enhanced usage of large-scale cast components made of aluminum, for the battery compartment, the front or rear body and other components. While the automotive industry is striving towards even larger structures made with so-called “Giga-Casting”, challenges in the casting and supply chain processes, but also maintenance and repair processes of these large structures, arise. Other tasks to solve might follow from controlling local microstructures, and thus the strength of the parts, when the flow length of the molten metal increases with component size, especially in relation to an increased fraction of recycled aluminum. Within the Fraunhofer-internal project “FutureCarProduction”, focus is directed towards understanding what drives efficiency, availability and sustainability of modern processes for the production of a car body. Moreover, the project addresses questions along the complete product chain of a car body, in terms of optimization of casting and joining, and quality assurance processes and seeks to give solutions for the efficiency and quality of different manufacturing processes. In the present paper, an overview of the project scope itself and the recent findings of “FutureCarProduction” are presented with a focus on the influences of higher fractions of secondary/recycled aluminum on the casting process, the occurring microstructure and defect situation in body in white components. This forms the basis for further investigations on the performance of different manufacturing and design opportunities for automotive components.
Bleicher, Christoph, Qaralleh, Ahmad, Lehmhus, Dirk, Haesche, Marco, Fernandes Gomes, Leonardo, Pintore, Manuel, Kleinhans, Robert, Sommer, Silke, Tlatlik, Johannes
Development of a New Concept Structure for 4-Way Electric Headrest Adjustment2025-01-86204/1/2025
At present, electric head restraints have been developed locally, so overseas mechanisms are used. In this study, two concept mechanisms were developed, and in addition, one patent for a wing-out head restraint mechanism was additionally applied. The new mechanism has had an excellent effect on cost reduction and improvement of operating noise compared to the current one.
Yu, Sanguk
Monitoring Compaction Of cement Stabilized Macadam Using Smart Aggregate Sensor2025-01-71513/19/2025
Monitoring changes in pavement material compaction degree and analyzing the interaction mechanism between particles are essential for improving compaction quality. In this paper, an on-site intelligent compaction test was carried out using intelligent sensor, the correlation between the in-situ test results and the intelligent compaction measurement value (ICMV) was written, and the influences of moisture content on the correlations were discussed. Further, the gyratory compaction tests were carried out using smart aggregate (SA) sensors to investigate the characteristics of the sensing results during the gyratory compaction of mixtures with different moisture contents, revealing the interaction mechanism between particles. Finally, the compaction characteristic indexes CEI, CDI and CSI were proposed using the SA sensing results, which were used to characterize the flow, compaction degree and stability characteristics of the mixtures, respectively. The conclusions of the study are of great significance for optimizing the compaction process and improving the compaction efficiency; meanwhile, it is helpful for revealing the interaction mechanism between particles under the compaction load.
Wang, Ning, Li, Qiang, Wang, Jiaqing
Experimental Case Study of Sonic Perception of a First-Generation Electric Truck14-14-02-00082/24/2025
The sound generated by electric propulsion systems differs compared to the prevalent sound generated by combustion engines. By exposing listeners to various sound situations, the manufacturer can start understanding which direction to take to achieve compelling battery electric vehicle trucks from a sound perspective. The main objective of this study is to understand what underlying aspects decide the experience and perception of heavy vehicle–related sounds in the context of electrified propulsion. Using a thematic analysis of data collected at a listening experiment conducted in 2020, factors affecting the perception of novel sounds generated by a first-generation electric truck are investigated. A hypothesis is that the experience of driving or being a passenger in electric trucks will affect the rating and response differently compared to listeners not yet experienced with this sound. The results show that the combination of individual preference and experience, hearing function, acoustic content, time variation, signal stability, load-dependent feedback, and situation-equivalent sounds affect the outcome. The assessment and rating of quality and acceptance did not differ between battery electric truck experienced listeners and first-time listeners in general. The only driving condition clearly breaking this pattern was the auxiliary brake condition, which, besides being significantly higher rated by novel listeners, also stood out as the highest-rated and most positively commented driving operation overall. In conclusion, several combined factors affect the assessment of electric truck sounds. Three identified aspects are removing disturbing sounds, making the sound environment smooth and silent, and providing clear functional feedback. Memory of the contextual experience is a key factor when assessing sounds from driving operations. The expected difference between listeners with and without experience with electric truck sounds will be minor unless there is exceptionally high sound quality.
Nyman, Birgitta, Fagerlönn, Johan, Nykänen, Arne
Inline Optical Power Monitoring, Network End-to-End Data Link Evaluation SystemAIR6552/1 (Current)10/7/2024
This document establishes methods to obtain, store, and access data about the health of a fiber optic network using commercially available inline optical power monitoring sensors. This document is intended for: Managers Engineers Technicians Contracting officers Third party maintenance agencies Quality assurance
AS-3 Fiber Optics and Applied Photonics Committee
Spacers and Washers, Procurement Specification for, MetricMA1784A (Historical)10/3/2024
This specification covers metric aircraft quality spacers for use as positioners for tubes, flat washers for use as load spreaders, galling protection of adjacent surfaces and or material compatibility, and key or tab washers for use as locks for bolts, nuts, and screws.
E-25 General Standards for Aerospace and Propulsion Systems
Age Controls for Hose Containing Age-Sensitive Elastomeric MaterialAS1933B (Current)9/17/2024
This document establishes age limit and guidance for acceptance of hose and hose assemblies containing elastomeric materials for use in aircraft, space vehicles, missiles and component assemblies thereof at time of delivery to the contractor, procuring activity, or contracting officer. This document does not establish limitations on storage times for military/civil activities nor operating life.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Testing Military-Grade Adhesive in Extreme Loading Conditions24AERP08_088/1/2024
Military performance requirements for adhesives have been traditionally derived to fulfill niche defense needs in harsh operational environments with little consideration for dual-use commercial potential. U.S. Army Research Laboratory, Aberdeen, MD The term “military-grade” can have a variety of meanings that are perspective dependent. In 2014, Ford Motor Company emphasized the term heavily in advertising campaigns to garner consumer acceptance for the transition from steel to aluminum in the body of their flagship F150 model. As cited by Ford, “Engineers selected these high-strength, military-grade aluminum alloys because of the metals' unique ability to withstand tough customer demands.” From this point-of-view, military-grade implies superior performance. However, the bureaucratic and logistical barriers required for certification to military-grade acceptance levels per DoD performance requirements can also be perceived as impediments to innovation and the transition of fundamental science into tangible product. This is in-part due to the legacy age of many DoD performance standards dating to the 1950s and 1960s when the US military peaked in technology market share and was responsible for approximately two-thirds of domestic research and development (R&D) and one-third of global R&D. In 2023 the commercial private sector provides the overriding funding stream for technology development for primarily non-military applications. Since the “golden age” of DoD-derived performance specifications the interactive roles between requirements and innovation are now understood to be dependent on their timings to product life cycle, which is typically ignored universally across the materials domain. Traditional DoD adhesive specifications are measures of late life cycle quality assurance for low-risk bonding applications with long-term historical usage and well-understood design allowables.
Fitting Automotive Quality and Safety Expectations to Free and Open Source Software2024-01-29847/2/2024
Due to manifold benefits compared to proprietary software solutions, free and open source software (FOSS) in general, and Linux especially becomes more and more relevant for embedded solutions in the automotive domain, especially in High Performance Computing Platforms (HPC). However, taking over liability and warranty for a FOSS-based problem raises the problem of software quality assurance, and thus risk control. In order to control and minimize the residual risk of a product or service, the traditional and well-accepted measure in the automotive domain is to assess the engineering processes and resulting work products via a process assessment model given by the ASPICE maturity model, as well as requirements from functional safety standards for safety related functions. The underlying process reference model of ASPICE covers software development performed and controlled by an organization. However, this situation is not given by and even contrary to the nature of FOSS development, where high quality is achieved based on feedback and contributions of an open community. While typical software quality assurance measures are widespread in community-based software development, a single entity cannot control these. This, along with the huge code base in Linux makes applying the low-level software related processes ASPICE Process Reference Model (PRM) both meaningless and economically infeasible. In this paper, we propose a selection and tailoring of standard ASPICE accompanied with compensation measures, which accounts for the FOSS specifics. This allows to achieve the quality assurance and risk mitigation goals of ASPICE, and consequently an assessment via the ASPICE Process Assessment Model (PAM) as well as functional safety standards. We further provide details on our solutions and strategies to fulfill the key elements of our solution. The solution presented here is one key factor for our EB corbos Linux – built on Ubuntu to provide a production grade Linux distribution suited to the automotive embedded needs, including liability, warranty, and long-term maintenance.
Schlosser, Joachim, Kirchmaier, Ulrich, Armbruster, Michael, Lindner, Wolfgang
Steel and Aluminum Molds: The Effect of Thickness on Productivity and Part Quality05-17-04-00246/28/2024
The use of aluminum to manufacture injection molds aims to maximize the productivity of plastic parts, as its alloys present higher heat conductivity than tool steel alloys. However, it is essential to accurately control the injection molding parameters to assure that the design tolerances are achieved in the final molded plastic part. The purpose of this research is to evaluate the use of aluminum alloys in high-volume production processes. It delves into the correlation between the type of material used for mold production (steel or aluminum) and the thickness of the injected part, and how these variables affect the efficiency of the process in terms of the quantity and quality of the produced parts. The findings suggest that replacing steel molds with aluminum alloys significantly reduces injection molding cycle time, the difference ranging from 57.1% to 72.5%. Additionally, the dimensional accuracy and less distortion provided by aluminum have improved product quality. In case of thinner geometries, the results indicated that higher pressures were needed to completely fill the cavity. In addition, an increase in the warping of the parts was observed due to the solidification of the flow front, resulting in more pronounced pressure gradients along the part. Therefore, due to their lower stiffness and high thermal conductivity, aluminum molds would not be recommended for this type of geometry in high-production processes. For the cases associated with lower pressures (greater thicknesses), aluminum molds showed better dimensional quality compared to steel. This result indicates that these tools could be an interesting alternative for manufacturing large volumes of parts in aluminum molds.
Marconi, Pedro, Amarante, Evandro, Ferreira, Cristiano, Beal, Valter, Ribeiro Júnior, Armando
Aerospace - General Requirements for Hydraulic Fuse - Quantity MeasuringAS5466 (Current)6/24/2024
This specification establishes the design, performance, and test requirements for hydraulic quantity measuring fuses intended to be used for hydraulic circuit protection.
A-6C5 Components Committee
Carbon Steel, Wire Spring Quality Music Wire 0.70 - 1.00C Cold DrawnAMS5112N (Current)6/24/2024
This specification covers a carbon steel in the form of wire supplied as coils, spools, or cut lengths (see 8.2).
AMS E Carbon and Low Alloy Steels Committee
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