Browse Topic: Safety testing and procedures

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Design and Development of Circular Crash Boxes: Evaluating Single and Dual Screw-Groove Configurations for Enhanced Crashworthiness2026-28-0013To be published on 02/01/2026
This study investigates the design and development of circular crash boxes aimed at enhancing crashworthiness through the analysis of screw-groove configurations. Two specific designs were evaluated: one featuring a single screw in two grooves and another incorporating two screws in four grooves. Finite Element Method (FEM) simulations were conducted using LS-DYNA, wherein a 700 kg impactor struck the crash boxes at varying velocities. The materials tested included Al5052 aluminium alloy and mild steel. In this study, we assessed and compared key crashworthiness performance metrics to evaluate the effectiveness of energy-absorbing structures. Results indicated that higher impact velocities led to increased energy absorption and peak forces but resulted in decreased crush force efficiency. Notably, the configuration with two screws in four grooves exhibited superior energy absorption and more favourable load distribution compared to the single screw design. These findings underscore the
R, Teddy Samuel, Mayakrishnan, Jaikumar
Microcontroller-based modular mirror for Heavy and Mid commercial vehicles2026-26-0018To be published on 01/16/2026
Existing ICE Mid and Heavy commercial vehicles in the Indian and international market are recording a large number of mishaps due to blind spots and non accessibility of the driver to the opposite side mirror in real-time driving. Non-driver side rear view mirror adjustment creates the need for the driver to get down and adjust the mirror manually/ get support from the co-passenger. The paper proposes a solution for a Microcontroller-based compact mirror adjustment system, which will run with minimal economy and highest efficiency. This will assist drivers in aesthetically and safely monitoring of mirror to check on specific blind spots in day conditions. Mirror will be actuated via a Modular control panel, a Dashboard with audio input or button-operated system based on vehicle type and customer need, along with a quick response mechanism to operate the mirror. This will reduce the prone accidents due to non-visibility by approximately 30%, ensuring enhanced road safety and driver
Jambagi, Vaibhavi Vyankatesh, Gangvekar, Onkar, Bhandari, Kiran Kamlakar
Facilitating Virtual Testing at an Industrial Level by Simulation Data Management2026-26-0440To be published on 01/16/2026
Automotive OEMs can derive significant cost savings by reducing the quantity of physical crash tests and thereby accelerate product development, when they follow the Euro NCAP Virtual Testing guidelines. It helps in optimizing the overall vehicle development process via more efficient simulations, as well as facilitates in early adoption of new safety regulations. In this pursuit, companies must comply with strict Euro NCAP requirements, which includes transparency and traceability of virtual tests. A major challenge therein is model validation – which requires highly precise detailing and extensive use of data for accurately replicating real physics of the problem. Deploying these workflows into an existing simulation process can be a complicated and time-consuming task, particularly when integrating various simulation and testing methods. A powerful simulation and process data management system (SPDM) can thereby assist companies to automate their entire simulation process, ensures
Thiele, Marko, Sharma, Harsh
The Impact of Color Correlated Temperature (CCT) on Automotive Headlights Performance and Driver Perception2026-26-0130To be published on 01/16/2026
Automotive lighting has been evolved from simple incandescent lamps to advanced LED based AFS and ADB functions. These lighting play crucial role in road traffic enhancing better visibility and safety to driver as well as other road users. Today’s Automotive Headlights use different light sources viz., Halogen, HID (Xenon), LED, and Laser each emitting light at different correlated color temperatures (CCT), measured in Kelvin (K). Color temperature not only influences visibility but also impacts the amount and perception of glare experienced by other drivers. The study was undertaken to evaluate the effect of correlated color temperature of automotive headlamps on driver visibility and comfort during night driving conditions. The experiment was conducted in a controlled laboratory environment using headlamps with different CCTs ranging from 3000K to 6500K. Participants from various age groups and genders were involved to capture diverse perceptions. Studies confirm that both CCT and
Patil, Mahendra G., Kirve, Jyoti, Parlikar, Padmakumar
Design Solutions for Ice-Induced CNG Filling Failures: Field Issue Resolution through Filter Geometry and Seal Material Reengineering2026-26-0515To be published on 01/16/2026
Compressed Natural Gas (CNG) systems in automotive applications are highly sensitive to fuel quality, especially with respect to moisture content. Field issues were observed where high moisture levels in the CNG led to the formation of ice inside the receptacle during refueling operations. This ice formation obstructed the CNG filling process and adversely impacted the sealing performance of the O-ring, particularly under low-temperature conditions induced by pressure differentials between the storage tank and the filling station. Investigation revealed that the existing tablet-type filter design contributed to moisture entrapment within its wire mesh, exacerbating ice formation within the receptacle. To address this, the filter design was modified from a tablet-type to a cup-type filter, significantly reducing the likelihood of moisture retention and subsequent ice formation. Additionally, the O-ring material was upgraded to a formulation with improved sealing properties at lower
Virmani, Nishant, Sawant, Shivraj Madhukar, C R, ABHIJITH
Chest Deflection mapping between HBM Connect® 50M and virtual ATD models2026-26-0010To be published on 01/16/2026
Objective Human Body Models (HBMs) are increasingly recognized by consumer protection agencies as essential tools for evaluating vehicle safety, complementing the use of traditional Anthropomorphic Test Devices (ATDs). However, HBMs are new for product development and pose challenges in connecting them with the ATDs. These challenges can be overcome if a link is established for the injury metrics between HBMs and ATDs. The study aims to develop a chest deflection mapping function between the HBM Connect® 50M (HBMC-50M) and two ATD models: THOR-50M and Hybrid III 50M for thoracic assessment in frontal impact. Method Several frontal chest loading scenarios were selected from the HBM4VT qualification catalogue (Euro NCAP technical bulletin CP 550), including hub impacts and table-top tests. Matched-pair LS-DYNA simulations were conducted with HBMC-50M and the ATD models recording peak chest deflections for developing the mapping function. In the HBMC-50M model, deflection outputs were
Velmurugan, Gopinath, Kumar PhD, Devendra, R, Udhaya Kumar, Kulavi, Pradeep, Soni, Anurag, Tejero de la Piedra, Ricardo, Fu, Stephen, Long, Teng, Arora, Tushar, Jagadish, Renuka, Shah, Chirag
Addressing Safety Belt Discomfort Among Female Driving Population Through Data Collection and Simulation2026-26-0016To be published on 01/16/2026
The rate of female drivers in India is increasing alongside the rapid growth of the Indian automotive industry. A driving comfort survey conducted among female drivers revealed that many experiences dis-comfort when wearing Safety belts-whether while driving or as front-seat passengers. This discomfort is primarily due to a phenomenon referred to as "neck cutting." The root cause of neck cutting is likely related to vehicle design, which is traditionally based on Anthropometric Test Devices (ATD's) representing the 5th, 50th & 95th percentile (%tile) of the global population. However, a literature review indicated that the anthropometric dimensions of the Indian populations are generally smaller than those of the global for the respective candidate. This highlighted the need to collect region-specific anthropometric data for India. To validate the neck-cutting issue, various female candidates were asked to sit in the Driver's seat for physical measurements trials. Accordingly
Kulkarni, Nachiket A, Chitodkar, Vivek V, Eknath Chopade, Santosh, Mahajan, Rahul, Yamgar, Babasaheb S
Development of Component Level Testing Method for Passenger Car Wheels2026-26-0504To be published on 01/16/2026
In the design of automotive wheels, safety is a crucial factor. Wheels contribute to a vehicle handling, braking and overall driving performance. Wheel are designed to withstand the weight of the vehicle and force generated during driving. It is the medium which isolates the obstacles coming from roads. Impact tests are usually performed after the wheel has been already designed and first prototypes have been produced. The test involves 90-degree free fall dynamic impact to determine the wheel resistance to deformation, cracking and overall structural failure. Its best method to captured the exact results during and post impact. These results are contributes the major role in development of automotive wheel rims. Most of the OEM’s are validating the wheels in virtual environment as FEA analysis software and LS Dyna. In this paper detailed procedure of testing of wheels at component level is presented. This work determines the development of test procedure for passenger car wheels in
Roham, Prasad, Bagade, Mohan, Sinnarkar, Nitin, Pawar, Prashant R, Shinde, Vikram
A procedure for validation of full vehicle CAE models with physical tests for passive safety applications2026-26-0411To be published on 01/16/2026
With the fast development of computational analysis tools and capacities during the past ten years, complex and substantial computer-aided engineering (CAE) simulations are now economically possible. While the cost of crash tests has risen steadily, the fidelity and complexity, which numerical simulations could address, has multiplied keeping the cost of computational analysis more stable. The use of CAE simulations complements physical testing, accelerating the product development process, reducing cost, and ensuring safe and more optimized designs. The fundamental goal of CAE is a significant reduction in the number of physical tests conducted during the product development process. However, validating the CAE model with physical tests is essential to ensure accuracy and reliability. Simulations performed using a validated CAE model could be used to make decisions like airbag deployment or high voltage shutdown without an actual physical test. This paper discusses validating an
UPENDRAN, ANOOP, Knuth, Joseph, krishnappa, Giri, Punnaiappan, Arunsankar
Development of a New Methodology for Measuring the Dimensions of Lighting Components in Construction Equipment Vehicles (CEVs) as per IS/ISO 12509:2004 using 3-Dimensional Planar Laser.2026-26-0145To be published on 01/16/2026
The light and light signalling devices installation test as per ISO 12509:2004 for Earth Moving Machinery / Construction Equipment Vehicles (CEV’s) is a mandatory test to ensure the safety of both road users and operators. Considering the shape and size of CEV’s, accurate measurement of lighting installation requirements is crucial for ensuring safety and regulatory compliance. The international standard ISO 12509:2004 specifies detailed criteria for these installations, including precise dimensional measurements of lighting components to guarantee optimal visibility and safety. Considering shape and Size of CEV’s, the accurate measurement of lighting installation requirements is crucial for regulatory compliance. ISO 12509:2004 outlines specific criteria for these installations requirements of lighting components, including the precise measurement of various dimensions to ensure optimal visibility and safety. Among these dimensional requirements, the dimension 'E' i.e., the “distance
Ghodke, Dhananjay Sunil, Belavadi Venkataramaiah, Shamsundara, Tambolkar, Sonali Ameya
Occupant Kinematics and injuries during high speed side impacts: An analysis of ARAI data 2016-20242026-26-0027To be published on 01/16/2026
The objective of the present study was to examine trends in occupant kinematics and injuries during side impact tests carried out on vehicle models over the period of time . Head, shoulder, torso, spine, and pelvis kinematic responses are analyzed for driver dummy in high speed side impacts for vehicle model years, MY2016-2024. Automotive Research Association of India side impact crash data is examined. The test procedure involved a 50.0 km/h moving deformable barrier (MDB) impacting the sides of stationary vehicles. Instrumented 50th-percentile male EURO SID-2 dummy was positioned in the driver seat. Occupant kinematics data, including head accelerations, Head Injury Criterion (HIC15), Torso deflections at thorax and abdominal ribs, spine accelerations at T12, and pelvis accelerations were evaluated and compared. The “peak” and “time to- peak” responses were compared across different vehicle model years. The effect of delta-V, vehicle MY, on occupant kinematics was examined. For
Mishra, Satish, Borse, Tanmay, Kulkarni, Dileep, Mahajan, Rahul
MOSAIC-TARA: A Comprehensive TARA Methodology for Automotive Cybersecurity2026-26-0609To be published on 01/16/2026
Threat Analysis and Risk Assessment (TARA) is a continuous activity, acting as a foundation of cybersecurity analysis for electrical and electronics automotive products. Existing TARA methodologies in the automotive domain exhibits challenges due to redundant and manual processes, particularly in handling recurring common assets across Electronic Control Units (ECUs) and functional domains. Two primary approaches observed for performing TARA are Manual-Asset-Centric TARA and Catalogue-Driven TARA. Manual-Asset Centric TARA is constructed from scratch by manually identifying the assets, calculating risks by likelihood, and impact determination. Catalogue-Driven TARA utilizes the precompiled likelihood and impact against identified assets. Both approaches lack standardized and modular mechanisms for abstraction and reuse. This results in poor scalability, increased efforts, and difficulty in maintaining consistency across vehicle platforms. The proposed method in this research overcomes
Goyal, Yogendra, Sinha, Swati, Sutar, Swapnil, Jaisingh, Sanjay
Accelerating engine auxiliaries’ development by deploying ML techniques in CFD virtual verification2026-26-0374To be published on 01/16/2026
The automotive and off-road industries are heavily investing in research and development (R&D) to improve both physical and virtual verification and validation techniques. Recent software and hardware advancements have extended these techniques from simple component evaluations to complex system assessments such as involving multi-physics scenarios. Despite the benefits of virtual validation tools like structural analysis and computational fluid dynamics (CFD), they often come with high development costs, particularly in CFD applications. Virtual verification methodology, especially when combined with data science, offer significant advantages over traditional physical methods by enhancing computer-aided engineering (CAE) efficiency and reducing resource consumption which can greatly improve product design and validation efficiency across many industries. The success of machine learning applications depends on effective data processing, adequate computational resources, and the right
Jadhav, Mitali, Kumbhar, Appaso, Tirumala, Bhaskar, Nisha, Kumari
Predictive Simulation Framework for Tyre Curb Impact Durability Assessment and Design Optimization2026-26-0396To be published on 01/16/2026
Tyre structural durability validation is a critical aspect of automotive design, considering the worsening road conditions. One of the key validation tests for assessing structural integrity is the curb impact test, which evaluates the tyre's ability to withstand sudden and concentrated impacts. Typically, this process involves physical testing of preliminary tyre samples, followed by iterative modifications to the tyre's construction to meet durability requirements. However, this approach often compromises ride performance, necessitating a more efficient and predictive methodology. To address this challenge, a frugal simulation-based prediction methodology has been developed to evaluate tyre curb impact durability before vehicle-level testing. This allows for the optimization of tyre design parameters early in the development process, ensuring structural performance while minimizing ride and handling (R&H) tuning iterations. By reducing the number of iterations, the methodology
Sundaramoorthy, Ragasruoban, LENKA., VISWESWARA
ALLOY WHEEL RIM LINEAR CRASH VALIDATION WITH BENCH LEVEL TEST PROCEDURE2026-26-0574To be published on 01/16/2026
Crash test plays a very crucial role in determining the passenger safety along with driver safety in most modern vehicles. This has become a prominent factor for many buyers to choose a safe car. During crash test, many components tend to fail. Amongst them, the major safety critical component which hampers the drivability of a vehicle is Wheel and Tyre Assembly. With the introduction of low aspect tyres, the failure rate of these assemblies has increased. A very high importance is given to ensure these parts withstand the subjection load as it is directly related to function of vehicle. Many methods are available to test the Wheel and Tyre assembly to ensure they pass the crash criteria. We have developed a novel test method which can simulate the crash pattern in the rig/bench level. The method employs a mechanical actuator which can be operated at designated load application to ensure the assembly undergoes the anticipated failure. The process is repeated with different types of
Medaboyina, HarshaVardhan, Singh, Ram Krishnan, SUNDARAM, RAGHUPATHI, Jithendhar, Ashokan
GEOMETRICAL ASSESSMENT OF THE CURTAIN AIRBAG COVERAGE IN INDIAN PASSENGER VEHICLES2026-26-0021To be published on 01/16/2026
Worldwide accident statistics for passenger vehicles indicate that the number of pole side impacts usually constitute a small percentage of total accident numbers. However, the rate of fatalities in narrow object side impacts is usually the highest due to direct exposure of head with the pole/narrow objects. Curtain airbags are the most effective protective systems to prevent severe/fatal head injuries in side collisions with narrow objects such as poles or trees. One of the important parameter of curtain airbags is the inflated zone of the airbag, which decides the possibility of head exposure for occupants with different anthropometries with narrow objects. To address this issue, EuroNCAP first introduced the concept of Head Protection Device Assessment (HPDA) in 2015, which in addition to the performance requirements in dynamic test, assesses the deployed curtain airbag for its area coverage and inflated zones for various anthropometries over occupant rows. With introduction of
Jaju, Divyan, Kulkarni, Dileep, Mahajan, Rahul
Investigating Pelvic Locking and Torso Kinematics using Human Body Models in Frontal Impact Scenarios2026-26-0002To be published on 01/16/2026
Occupant Safety systems are usually developed using anthropomorphic test devices (ATDs), such as the Hybrid III, THOR-50M, ES-2, and WorldSID. However, in compliance with NCAP and regulatory guidelines, these ATDs are designed for specific crash scenarios, typically frontal and side impacts involving upright occupants. As vehicles evolve (e.g., autonomous layouts, diverse occupant populations), ATDs are proving increasingly inadequate for capturing real-world injury mechanisms. This has led to the adoption of computational Human Body Models (HBMs), such as the Global Human Body Models Consortium (GHBMC) and Total Human Model for Safety (THUMS), which offer superior anatomical fidelity, variable anthropometry, active muscle behaviour modelling, and improved postural flexibility. HBMs can predict internal injuries that ATDs cannot, making them valuable tools for future vehicle safety development. This study uses a sled CAE simulation environment to analyze the kinematics of the HBMs
Raj, Pavan, Rao, Guruprakash, Pendurthi, Chaitanya Sagar, Nehe, Vaibhav, Chavan, Avinash
Characterization and material card calibration of PU foam under various strain rates for crash Simulation2026-26-0464To be published on 01/16/2026
Polyurethane (PU) foams are extensively utilized in automotive crash structures, seats, and interior components due to their exceptional capacity for energy absorption and dissipation during impact events. Specifically, PU foams in vehicle seats play a critical role in protecting occupants during crash scenarios by absorbing energy, distributing forces, and enhancing seatbelt performance, as well as providing countermeasures for head impact protection. The movement of the seat and the direction of the force during crash testing are inherently unpredictable. The material behavior of PU foam is captured using an isotropic, hyper-elasticity-based constitutive model available in LS-DYNA through *MAT_083. This model is designed to take into account the foam's compressibility, sensitivity to strain rates, low Poisson's ratio, and hysteresis. The characterization of a PU foam with a nominal density of 65 kg/m3 was performed using quasi-static compressive testing of 0.01/s and dynamic
Gaurav, Ashish Kumar, Krishnamoorthy, Kunju, Varatharajan, Senthilkumaran
Enhancing Factory Modelling: Integrating Drone Technology and Automated Post Processing Systems2026-26-0307To be published on 01/16/2026
The growing environmental, economic, and social challenges have spurred a demand for cleaner mobility solutions. In response to the transformative changes in the automotive sector, manufacturers must prioritize digital validation of products, manufacturing processes, and tools prior to mass production. This ensures efficiency, accuracy, and cost-effectiveness. By utilizing 3D modeling of factory layouts, factory planners can digitally validate production line changes, substantially reducing costs when introducing new products. One key innovation involves creating 3D models using point cloud data from factory scans. Traditional factory scanning processes face limitations like blind spots and periodic scanning intervals. This research proposes using drones equipped with LiDAR (Light Detection and Ranging) technology for 3D scanning, enabling real-time mapping, autonomous operation, and efficient data collection. Drones can navigate complex areas, access small spaces, and optimize factory
Narad, Akshay Maruti, C H, Ajheyasimha, Vijayasekaran, Vinothkumar, FASGE, ABHISHEK
A Model Based Framework for Safety Risk Assessment using Systems Theoretic Process Analysis for ASIL Justification According to ISO 262622026-26-0022To be published on 01/16/2026
With advancements in automotive systems, particularly in autonomous and electric vehicles, the increasing complexity of modern vehicular systems is challenging the traditional safety analysis methods prescribed by ISO 26262. Failure-based safety analysis techniques often struggle to identify systematic risks arising from software interactions, human factors, and emergent behaviors. This paper addresses this gap by providing a framework that utilizes Systems-Theoretic Process Analysis (STPA) to complement ISO 26262’s hazard analysis methods by considering emergent hazards during the justification of Automotive Safety Integrity Levels (ASIL). The aim of this paper is to present a model-driven hybrid methodology that combines traditional fault-based approaches with STPA for traceable ASIL justification, thereby enhancing ISO 26262’s Hazard Analysis and Risk Assessment (HARA) process. This approach allows for the integration of contemporary safety analysis techniques like STPA into
NAG, PRAMIT, Ali, Sam, Roy Choudhury, Diyanjan
Single Radar: A Robust and Cost-Effective Solution for ADAS and Parking functionality2026-26-0049To be published on 01/16/2026
With rapid advancements in Autonomous Driving (AD) & Advanced Driver Assistance Systems (ADAS), numerous sensors are integrated in vehicles to achieve higher and reliable level of autonomy. Due to the growing number of sensors and its fusion creates complex architecture which causes challenges in calibration, cost, and system reliability. Considering the need for further ADAS advancements and addressing the challenges, this paper evaluates a novel solution called One Radar - a single radar system with a wide field of view enabled by advanced antenna design. Placing the One Radar at the rear of the vehicle eliminates the need for corner radars and ultrasonic sensors used for parking assistance. With rigorous real-world testing in different urban and low-speed scenarios, the One Radar solution showed comparable accuracy in object detection with warning and parking assistance to the conventional combination of corner radars and ultrasonic sensors. The simple single sensor-based
Anandan, Ram, Sharma, Akash
Risk Based Security Monitoring Framework for CAN network2026-26-0616To be published on 01/16/2026
There is rapidly increasing advancement in Connectivity, Autonomous, Subscription and Electrification features in vehicles which are being developed. These trends have resulted in an increase in attack surface and security risks on vehicles. To handle these growing risks, it has become important to include passive security systems such as Intrusion detection systems (IDS) which can detect successful or possible attempts of intrusion into vehicle systems compromising their security. In vehicles based on Zonal Architecture, two types of IDS can be implemented, Network based IDS (NIDS) and Host Based IDS (HIDS). The NIDS is implemented in Gateway Electronic Control Unit (ECU) and can monitor multiple networks connected to Gateway, whereas the HIDS usually monitors one single host ECU. Extensive research material is available on NIDS for CAN Networks. For example, the CAN Network in a vehicle is monitored for various abnormal behaviours such as increased busload and invalid signal values
E L, Nanda Kumar, Mutagi, Megha, Sonnad, Preeti, Sharma, Dhiraj
Improvement study of Style steel wheel durability in Multiple pothole impacts2026-26-0539To be published on 01/16/2026
This study focuses on improving the durability of steel wheel rims subjected to Multiple Pothole which is commonly found in Indian village roads - a critical scenario affecting vehicle safety and wheel lifespan. Initial steel wheel designs often face significant deformation or failure under repeated strikes and resulting in tyre air loss due to wheel bend, prompting the need for enhanced performance standards. In this research, a combination of finite element modelling, experimental impact testing, and material optimization strategies were employed to assess and improve the structural integrity of steel rims. Key parameters such as rim profile geometry & material composition were systematically varied to evaluate their influence on impact resistance. Results demonstrate that strategic design modifications and material enhancements can significantly increase the rim's ability to absorb energy and resist bending without substantial weight penalties. The findings offer practical
DEsigan, Lakshmipathy, P, Praveen, K, CHANDRAMOHAN, C, Santhosh
Structural analysis and Design optimization of Cylinder Head of Cummins Light duty Engine for Medium Wheelbase (MWB) pick-up truck2026-26-0495To be published on 01/16/2026
This paper presents the design, structural analysis, and risk assessment done by Cummins to evaluate the structural integrity of Light Duty engine cylinder head for a Medium Wheelbase (MWB) pick-up truck. Initially, Cummins used F2.5L (4-cylinder) engine that has 154hp, but rising market demands for more power, fuel efficiency, lower cost and weight, and future emission compliance led to customer requirements for 177hp (Drive New F2.5L, 15% uprate) and 197hp+ (Drive New F3.0L, 22% uprate) from the same base engine. The increase in power requirement possesses challenges on critical components, especially cylinder heads in terms of thermal and structural limits. This paper addresses the challenges and risks in current cylinder head design driven by new power demands, specifically reduced fatigue margins in the water jacket area and increased temperatures on the combustion face under high thermomechanical loads. It explores the design modifications made to the cylinder head design to
Pathak, Arun Jyoti, Adiverekar, Vaidehi, Singh, Rahul, Biyani, Mayur
Risk assessment of cold side components using quick modal analysis correlation technique.2026-26-0441To be published on 01/16/2026
Abstract: Modal analysis is performed to determine the natural frequencies and mode shapes of a structure or system. It helps engineers understand how a system vibrates and how external forces, such as mechanical loads, might excite unwanted resonances. To check the stresses due to vibration inputs, certain G levels are assumed, and stresses are scaled to those vibration levels. This gives an understanding of the stresses of component with respect to its EFR limit and design margins are calculated. But, assumed acceleration levels in pre-prototype stage level can over predict or under predict the design margins. A quick modal analysis corelation technique can be used by using test measured accelerations conducted at prototype stage of the program. In this work, a modal analysis corelation technique is used to perform risk assessment of intake manifold. The intake manifold failed due to high vibration levels which were not captured from high cycle fatigue analysis with assumed G-level
Bale, Shrikant Bhaskar, Bawache, Krushna
Integration of virtual testing methods in automotive safety: Methodology validation for rollover protection system (ROPS)2026-26-0375To be published on 01/16/2026
During recent years, the integration of virtual testing methodologies has gained significant importance in vehicle development for the passive safety evaluation. The accuracy of simulation results depends basically on the correct replication of physical test into the virtual model, for example to assign the realistic material properties from the structural components and following the boundary conditions replicated from real conditions. In this study the safety standards ISO 3471_2008 and ANSI ROHVA/OPEI-2016 have been considered as references of the safety validation process of hollow section roll-over protective structure (ROPS) integrated into a vehicle. A key objective is to stablish a virtual test methodology that could be applicable across different standards considering various industry markets, as for example European, American and Asian. A sensitivity analysis is necessary to evaluate what are the main aspects that gives significant deviations in results and in which we can
Laso Rodríguez, Manuel, Hanumantha, Chandrashekhar, Singh, Amit Kumar, Lal, Kundan
Unique methodology to cluster and reuse the “Hazard Analysis and Risk Assessment” across different E/E systems and features2026-26-0004To be published on 01/16/2026
As software-defined vehicles advance in complexity, achieving robust functional safety in line with ISO 26262 becomes increasingly vital. This growing need has led to a significant increase in Hazard Analysis and Risk Assessment (HARA) activities across numerous electrical and electronic (E/E) systems and features. Traditionally, HARA is performed separately for each E/E system, feature, or component. This approach often results in redundant analyses of the same function in multiple places, which leads to inconsistent risk categorizations and even conflicting safety goals, such as assigning different Automotive Safety Integrity Levels (ASIL) to similar features. As a result, the overall engineering effort and risk of inconsistency increase. To address these challenges, this paper proposes a unique approach: performing consolidated HARA for a group of vehicle-level functions (termed “platform HARA”). Rather than deriving safety goals for each E/E system or feature individually, this
Somasundaram, Manickam, Vijayakumar, Melvin
Q-Series Child Dummy FE model development and validation for child occupant safety assessment in Automotive crashes2026-26-0390To be published on 01/16/2026
The Ministry of Road Transport and Highways (MoRTH), Government of India has established BHARAT NCAP to provide a fair, meaningful, and objective assessment of the crash safety performance of cars. This program evaluates vehicles across three key areas, including Child Occupant Protection (COP). A critical component of the COP assessment involves dynamic testing using Q-series child dummies representing a 1½-year-old (Q1.5) and a 3-year-old child (Q3). As per the BHARAT NCAP protocol these dummies are placed in the second-row outboard seating position within Child Restraint Systems (CRSs) and subjected to two primary dynamic impact tests: Offset Deformable Barrier (ODB) conducted at speed of 64 km/hr. and Mobile Deformable Barrier (MDB) Side Impact tests conducted at 50 km/hr. The dynamic assessment of these child dummies is primarily focused on the head, neck, and chest regions to evaluate the effectiveness of the CRSs and overall vehicle safety system in protecting young occupants
Khopekar, Maria, Lakshminarayana, Apoorva, Mohan, Pradeep, Kurkuri, Mahendra
Experimental Study to Investigate and Control Image Blurriness due to IRVM Vibration2026-26-0321To be published on 01/16/2026
Vibration is one of the prominent factors that determine the quality & comfort level of a vehicle. Moreover, if vibration occurs in areas that are almost entirely within customer touchpoints (during either city or highway driving conditions), it could become a critical factor behind the deterioration of brand image within the market. The interior rear-view mirror (IRVM) is one of the important components inside passenger cabin, providing drivers with a clear view of the rear traffic. However, vibrations induced by engine operation, road irregularities, and aerodynamic forces can cause the IRVM to oscillate, leading to image blurriness and compromised visibility and safety. This paper investigates the underlying causes of IRVM vibrations and their impact on image clarity. Through a combination of experimental analysis and computational modelling, we identify key factors contributing to mirror instability. The findings indicate the specific frequencies of vibration, particularly those
Khan, Aamir Naved, Saraswat, Vivek, Jha, Kartik, SINGH, HEMENDRA, Seenivasan, Gokulram, Khan, Nafees
Resilient Design Strategies for Wireless Charger ECUs: A Proactive Threat Analysis and Risk Assessment Framework for Ensuring Cybersecurity in EV Charging Ecosystems2026-26-0173To be published on 01/16/2026
The goal of Automotive cybersecurity is safety, reliability, confidentiality and authenticity. As the automotive industry grows smarter, so too do the cybersecurity protocols used to protect vehicles from malicious actors. Automotive cybersecurity secures communication networks, electronic systems, software and data collected by the new wave of intelligent cars The paper describes the cyber security threats its analysis ion wireless charging
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
Optimisation of frontal impact force scheme to accelerate the target setting process for development of front-end structures in vehicles.2026-26-0001To be published on 01/16/2026
A passenger vehicle's front-end structure's structural integrity and crashworthiness are crucial to ensure compliance with various frontal impact safety standards (such as those set by Euro NCAP & IIHS). For a new front-end architecture, design targets must be defined at a component level for crush cans, longitudinal, bumper beam, subframe, suspension tower and backup structure. The traditional process of defining these targets involves multiple sensitivity studies in CAE. This paper explores the implementation of Physics-Informed Neural Networks (PINNs) in component-level target setting. PINNs integrate the governing equations into neural network training, enabling data-driven models to adhere to fundamental mechanical principles. The underlying physics in our model is based upon a force scheme of a full frontal impact. A force scheme is a one-dimensional representation of the front-end structure components that simplifies a crash event's complex physics. It uses the dimensional and
Gupta, Ishan, Bhatnagar, Abhinav, Kumar, Ayush
Shaping the Future of Mobility with Innovative Power Tailgate Testing Solutions2026-26-0473To be published on 01/16/2026
Abstract With increasing demand for automation and user convenience in modern vehicles, Power Operated Tailgates (POT) have become standard in premium and mid-segment cars. However, validating such systems—comprising electronic control units (ECUs), sensors, actuators, and mechanical components poses significant challenges in safety, reliability, and cost. This paper introduces a Hardware-in-the-Loop (HiL) based validation framework that allows comprehensive, automated, and safe testing of POT systems without depending on full vehicle prototypes. The HiL platform integrates Real Time Hardware and Real Time software with dynamic models to simulate real-world behaviors. It enables automated validation of normal and fault scenarios—such as open/close commands, anti-pinch protection, voltage sensitivity, and communication errors—ensuring robust system performance. The proposed framework accelerates development, improves test coverage, and supports early fault detection, making it a
More, Shweta, GHANWAT, Hemant, Shetti, Suraj, Jape, Akshay, Kulkarni, Shraddha, Jagdale, Nitin
Comparison of Bharat NCAP Crash test scenarios with real road accidents in India2026-26-0024To be published on 01/16/2026
This study is conducted to analyse the significance of BNCAP crash test protocol in the real road accidents in India. Accident data from on-the-spot investigation (Road Accident Sampling System India) and Government of India’s, Ministry of Road Transport and Highways official road accident statistics 2023 is used together to understand the real road accidents in India. The current BNCAP crash test protocol is compared against the real road accidents and the frequency of the same in discussed in this paper. A seven-step calculation method is developed to analyse real accidents together with existing crash tests by using similar crash-characteristics like impact area, overlap and direction of force. This method makes the real accident comparable with the corresponding crash test by calculating the impact energy during the collision between the real accident and a collision under crash test conditions. Relevant parameters in real accidents that significantly influence the test scenario
Moennich, Joerg, Lich, Thomas, Kumaresh, Girikumar
Analysis of Road Accident Statistics for Females in India and Gaps in Safety Regulations2026-26-0020To be published on 01/16/2026
This paper investigates the current state of road safety for female occupants in India, with a particular focus on road accident statistics and the gaps in safety regulations. According to the Road Accident in India 2022 report by the Ministry of Road Transport and Highways (MoRTH), female occupants constitute 16% of passenger car fatalities. Leveraging a comprehensive dataset of 525 passenger car accidents involving at least one female occupant from the Road Accident Sampling System – India (RASSI), this study evaluates the severity and patterns of injuries sustained by female drivers and passengers. The analysis identifies critical shortcomings in existing safety measures, particularly in addressing anatomical disparities and male-centric safety designs. Gender-disaggregated injury trends reveal heightened vulnerabilities for women in crash scenarios, including disproportionate risks to the chest, neck, and pelvis. Current regulatory frameworks rely on crash test dummies developed on
Ayyagari, Chandrashekhar, G, Santhosh Kumar, Rao, Guruprakash
Integrated Evaluation of Pre-Crash Braking and Crash Injury Outcomes Using Human Body Models and ATDs2026-26-0019To be published on 01/16/2026
Traditionally, vehicle occupant safety research has focused on passive safety aspects like crashworthiness and occupant restraint systems. However, with the advent of Active Safety technologies such as Forward Collision Warning (FCW) and Autonomous Emergency Braking (AEB), research has expanded to include occupant kinematics during the pre-crash phase. AEB, by inducing occupant movement, often leads to out-of-position (OOP) behavior, compromising available space during the crash phase. Current Anthropometric Test Devices (ATDs) are limited in simulating occupant kinematics during the pre-crash phase, especially in the neck and torso regions. These devices are rigid and unable to replicate human body dynamics during low-acceleration events like AEB. To address this gap, Human Body Models (HBMs) such as THUMS, GHBMC, and SAFER are used to provide more biofidelic simulations. This study begins with physical vehicle trials conducted with human volunteers at various speeds to measure
Pendurthi, Chaitanya Sagar, THANIGAIVEL RAJA, T, Kondala, Hareesh, Sudarshan, B.Sudarshan, Nehe, Vaibhav, Rao, Guruprakash
Vehicle Self-Soiling from Exterior Cleaning Mechanisms2026-26-0425To be published on 01/16/2026
The automotive industry is rapidly advancing towards autonomous vehicles, making sensors such as cameras, LiDAR, and RADAR critical components for ensuring constant information exchange between the vehicle and its surrounding environment. However, these sensors are vulnerable to harsh environmental conditions like rain, dirt, snow, and bird droppings, which can impair their functionality and disrupt accurate vehicle maneuvers. To maintain sensor performance, cleaning systems are implemented in vehicles. Testing sensor cleaning mechanisms under various weather conditions and vehicle operating situations is essential. One crucial aspect of testing is tracking the trajectory of the cleaning fluid to ensure it does not cause self-soiling of vehicle or affect other field of view, such as the windshield. While wind tunnel tests are valuable, digitalizing this process is vital for making design decisions early in vehicle development. This work presents a digital methodology to test the self
Mane, Suvidya, Makam, Sri Lalith Madhav, Varghese, Rixson, Desu, Harsha
Rear-Facing Infant Seat Structural Integrity and Crashworthiness Under Front Seatback Loading in Rear-Impact Collisions2026-26-0554To be published on 01/16/2026
Rear-facing infant seats positioned behind front outboard vehicle seats are vulnerable to loading from rearward-yielding front seatbacks during rear-impact collisions in the presence of front occupants. This seatback loading can collapse and deform the infant seat’s plastic shell, increasing the risk of head injuries to the infant occupant. Shell deformation also introduces slack into the five-point harness system, exacerbating head excursions beyond the protective boundaries of the shell and increasing the likelihood of head contact with components such as the carry handle. Current rear-facing infant seat designs typically do not account for loading imposed by the front seatback during rear-impact scenarios, resulting in weak and collapsible shell structures. Furthermore, regulatory compliance tests, such as FMVSS 213, lack provisions for evaluating rear-facing infant seats under realistic rear-impact conditions. The standard test bench does not incorporate simulated vehicle interiors
Thorbole, Chandrashekhar
Thoracic Injury Mechanisms Due to Front Seatback–Rear Seat Pan Interaction in Severe Rear-Impact Collisions2026-26-0005To be published on 01/16/2026
Severe rear-impact collisions can cause significant intrusion into the occupant compartment when the structural integrity of the rear survival space is insufficient. Intrusion patterns are influenced by impact configuration—underride, in-line, or override—with underride collisions channeling forces below the beltline through the rear wheels as a primary load path. This force concentration rapidly propels the rear seat-pan forward, contacting the rearward-rotating front seatback. The resulting bottoming-out phenomenon produces a forward impulse that amplifies loading on the front occupant’s upper torso, increasing the risk of thoracic injury even when the head is properly supported by the head restraint. This study analyzes a real-world rear-impact collision that resulted in fatal thoracic injuries to the driver, attributed to the interaction between the driver’s seatback and the forward-moving rear seat pan. A vehicle-to-vehicle crash test was conducted to replicate similar intrusion
Thorbole, Chandrashekhar
Adaptive Restraints for Equitable protection.2026-26-0015To be published on 01/16/2026
Real-world crashes involve diverse occupants, but traditional restraint systems are designed for a limited range of body types considering the applicable regulations and protocols. While conventional restraints are effective for homogeneous occupant profiles, these systems often underperform in real-world scenarios with diverse demographics, including variations in age, gender, and body morphology. This study addresses this critical gap by evaluating adaptive restraint systems aligned with the forthcoming EURO NCAP 2026 protocols, which emphasize real-world crash diversity and occupant inclusivity. Through digital studies of frontal impact scenarios, we analyse biomechanical responses using adaptive restraints across varied occupant demographics, focusing on head and chest injury (e.g., Head Injury Criterion [HIC] and Chest Compression Criterion [CC]). This study used a Design of Experiments (DOE) approach to optimize occupant protection by timing the activation of these adaptive
satija, Anshul, Suryawanshi, Yuvraj, Chavan, Avinash, Rao, Guruprakash
Ambient Light Reflection Analysis using Dimensional Modelling Tools2026-26-0476To be published on 01/16/2026
The primary motivation is to improve driver safety and visual comfort. This is driven by the need to address the negative impact of ambient light reflecting off Head-Up Displays (HUDs), which can impair visibility through the windshield. There is a need for tools and methods to address this issue proactively during the vehicle design phase. Ambient light reflecting off internal components, specifically the Head-Up Display (HUD), creates unwanted reflections on the windshield. These reflections can obscure the driver's field of view, potentially compromising safety and reducing visual comfort. The extent of this obscuration is influenced by geometrical factors such as the angle of the HUD and the curvature of the windshield, which needs to be analyzed and managed. The study employs a tool-based modeling methodology to trace the pathways of ambient light from its source, reflecting off the HUD, and onto the windshield using a dimensional modeling tool. It focuses on geometrical factors
Muchchandi, Vinod, AKULA, SATYA JAYANTH, Mahindrakar, Pramod, G S, Sharath
Material Optimization in console armrest to comply occupant safety in crash test2026-26-0007To be published on 01/16/2026
Indian passenger vehicles sales touched an all-time high in FY25.Today’s customer expects high level of aesthetics, safety and connected features in the vehicle Interiors. This has created more diverse and demanding customer base that values interior design and quality. This has led OEMs to offer modern Indian mass car interiors with features like big infotainment system, Console Armrest…etc. The vehicle console armrest assembly is an integral part of a car's interior, designed to enhance comfort, ergonomics, and functionality for the driver and passengers. The console armrest is a complex assembly of many child parts like Armrest cushion/ sliding mechanism/ latch, locking mechanism/ hinge mechanism and storage compartment etc., Console hard plastic parts are the primary source of injuries when occupants interact with them in the event of an accident. Poorly designed armrests can contribute to flyoff of child parts in the event crash and can cause injuries to occupant. Therefore
A D, BALAMURUGA, BADDAM, SATHISH, MANGAL, GAUTAM, SINGH, DEEPAK, Shekhar, Ravi, Singh, Amit
Safer Trucks for India-Smart Tech Fusion2026-26-0031To be published on 01/16/2026
Commercial vehicle sector (especially trucks) has major role in economic growth of a nation. With improving infrastructure, increasing number of trucks on roads, accidents are also increasing. As per RASSI (Road Accident Sampling System India) FY2016-21 database, commercial vehicles are involved in 43% of total accidents on Indian roads. Involvement of trucks (N2 & N3) is 25% over total accidents. Amongst all accident scenarios of N2 &N3, frontal impacts are the most frequent (26%) and causing severe occupant injuries. Today, truck safety development for frontal impact is based on passive safety regulations (viz. front pendulum - AIS029) and basic safety features like seatbelts. In any truck accident, it is challenging rather impossible to manage comprehensive safety only with passive safety systems due to size and weight. Accident prevention becomes imperative in truck safety development due to extremely high energy involved in front impact scenarios. The paper presents unique safety
Joshi, Kedar Shrikant, GADEKAR, GANESH, Date, Atul, Koralla, Sivaprasad
"Automotive Cybersecurity: Regulatory Landscape, Type Approval, and the Road Ahead"2026-26-0246To be published on 01/16/2026
Effective communication is the key for bringing harmony - be it the communication between humans and humans, or communication between machine and machine. Today’s car is a sophisticated gadget, equipped with the best of technologies running using millions of lines of codes of software. The effective use of these technologies involve communication between car to car and car to infrastructure using Dedicated Short Range Communication (DSRC), C-V2X (Cellular Vehicle-to-Everything). It is pertinent that any communication using the internet needs to be digitally secure and that the systems are designed to mitigate the perceived threats. The methods used for ensuring cyber safety of automobiles need to be verified before the end product is put to use. Automotive Industry Standards AIS-189 and AIS-190 have been formulated to provide a harmonized verification framework. Both the vehicle manufacturer and the test agency need to equip themselves with necessary skills and tools to ensure
Nayak, Pratik, Tandon, Vikram, Badusha, Akbar, Desai, Manoj, Sathianesan, Rejin
Wetting prediction of power train components under the influence moving components using smooth particle hydrodynamics2026-26-0384To be published on 01/16/2026
Passenger cars are subjected to extensive conditions ranging from driving through wet roads, water puddles, icy roads, and rain. This can affect the performance of different parts over time, one such aspect is the vehicle corrosion, whose impact is felt on a wide spectrum from aesthetics to safety due to loss of material. The general condition for corrosion mainly requires electrolyte to be present on the metal surface, which is transported through self-soiling and foreign soiling. Vehicle soiling is an important aspect for vehicle design. Amongst the many aspects of vehicle soiling, one important aspect is the prediction of water accumulation that enables prediction of corrosion sensitive regions in the vehicle. Power train components like Engine, transmission and corresponding wiring harness are at highest risk of water-wetting, As the vehicle drives through the water pool the components are not just wet by the direct inflow of water but also by water being splashed by moving
Shukrey, Sarthak, Pattankar, Rohan, Yenugu, Srinivasa
Safety Model for Battery Resistance Monitoring and Lifecycle Optimization2025-01-051511/25/2025
This work proposes a novel framework for evaluating the second- and third-life viability of lithium-ion battery packs through the development of the RISE Index—a comprehensive metric based on Resistance growth, Integrity, Safety, and End-of-life usability. While previous research focuses on singular indicators such as residual capacity or State of Health (SoH), these approaches lack a unified, safety-informed structure for reuse qualification. This paper distinguishes itself by integrating multiple aging indicators, including resistance evolution, degradation theory, and thermal safety considerations, into a consolidated decision-making tool designed for practical deployment. The novelty lies in the formulation of the RISE Index, which fuses empirical data with electrochemical degradation mechanisms such as SEI formation, lithium plating, calendar aging, and cycling-induced impedance growth. The methodology includes a comparative analysis of Nickel Manganese Cobalt (NMC) and Lithium
Prakashkumar, Balagopal
Electrode-Level Modeling of Thermal Decomposition Reactions as a Foundation for Multiscale Thermal Runaway Analysis in Lithium-Ion Batteries2025-01-052311/25/2025
Thermal runaway in lithium-ion batteries represents a critical safety challenge, particularly in high-voltage battery systems used in electric vehicles and stationary energy storage. A comprehensive understanding of the multi-scale processes that initiate and propagate thermal runaway is essential for the development of effective safety measures and design strategies. This study provides a structured theoretical overview of the thermal runaway phenomenon across four hierarchical levels: electrode, single cell, module, and high-voltage battery system. At the electrode level, thermal runaway initiation is linked to electrochemical and chemical degradation mechanisms such as solid electrolyte interphase decomposition, separator breakdown, and internal short circuits. These processes lead to highly exothermic reactions that, at the cell scale, can result in rapid temperature increases, gas generation, and overpressure. On the module and system levels, thermal runaway can propagate through
Ceylan, Deniz, Kulzer, André Casal, Winterholler, Nina, Weinmann, Johannes, Schiek, Werner
Semiautomatic Headlamp Beam Switching DevicesJ565_202511 (Current)11/13/2025
This SAE Standard provides test procedures, performance requirements, and guidelines for semiautomatic headlamp beam switching (SHBSD) devices.
Road Illumination Devices Standards Committee
DriVE-Net: A Multi-Objective Framework for Generating Diverse, Realistic, and Hazard-Aware Driving Scenarios2025-99-013311/11/2025
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Xie, Dongxuan, Li, Dongyang, Zhang, Youkang, Zhao, Yingjie, Hong, Baofeng, Wang, Nan
Functional Safety of Electric or Hybrid Off-Highway Vehicles – An Embedded Software Viewpoint2025-28-021711/06/2025
To provide growing needs of food, clothing and infrastructure for growing population of the world, off-highway vehicles such as those in construction, agriculture and commercial landscaping are moving towards electrification for enhanced precision, productivity, efficiency and sustainability. It has also paved a way to adopt autonomy of these vehicles to address challenges like skilled labor shortage for timely and efficient execution. Despite the tremendous advantages of electrification, be it through completely replacing engines in vehicles or efficiency improvements using hybrid architecture for powertrain and auxiliary power demands, safety remains a significant challenge and critical requirement for off-highway electric vehicles. This paper explains the concept and importance of functional safety in electric off-highway vehicles, and shows how different standards like ISO 26262, ISO 25119, ISO 13849 can be utilized to achieve state of the art in functional safety for different off
Mujumdar, Chaitanya Gajanan, Bachhav, Kiran, Deshpande, Chinmay
Design and Implementation of a Portable Setup for Operator’s Field of Vision Testing on Construction Equipment Vehicles in accordance with IS/ISO 5006:20172025-28-027011/06/2025
The Operator’s Field of Vision (FOV) test, conducted in accordance with IS/ISO 5006:2017, is a vital assessment to ensure the safety and operational comfort of personnel operating Construction Equipment Vehicles (CEVs) / Earth-Moving Machinery. IS/ ISO 5006:2017 defines rigorous guidelines for evaluating the operator’s visibility from the driver's seat, with particular emphasis on the Filament Position Centre Point (FPCP), determined from the Seat Index Point (SIP) coordinates. The test includes assessment of masking areas, focusing on the Visibility Test Circle (a 24-meter diameter ground-level circle around the machine), and on the Rectangular Boundary on which a vertical test object is placed at a height specific to the machine type and its operating mass. These parameters are designed to simulate real-world operating conditions. This paper introduces a portable testing setup developed specifically for conducting the Operator’s FOV test as per IS/ISO 5006:2017. The setup facilitates
Ghodke, Dhananjay Sunil, Tambolkar, Sonali Ameya, Belavadi Venkataramaiah, Shamsundara
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