Browse Topic: Tests and Testing

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Adaptive Torque Vector Control for Distributed Drive Intelligent Electric Vehicles Using Model and Data Driven Approaches2026-01-0628To be published on 04/07/2026
To effectively improve the performance of chassis control of distributed drive intelligent electric vehicles (EVs) under difference road conditions, especially in combing road information and chassis control for improving road handling and ride comfort, is a challenging task for the distributed drive intelligent EVs. Simultaneously, inaccurate chassis control and uncertainty with system input, are always existing, e.g., varying road input or control parameters. Due to the higher fatality rate caused by variable factors, how to precisely chose and enforce the reasonable chassis control strategy of distributed drive intelligent EVs become a hot topic in both academia and industry. To issue the above mentioned, an adaptive torque vector hierarchical controller based on road level and adhesion is proposed, which optimizes the comprehensive. First, combined with the characteristic of the unbalance dynamic force caused by the air gap between the stator and the rotor of the in-wheel motor, a
Wang, Zhenfeng, Zhao, Gaoming, Zhang, Zhijie, Zhou, Zitao, Huang, Taishuo, Ma, Changye
Navigation Integrated End-to-end Path Planning Development and Vehicle Testing2026-01-0032To be published on 04/07/2026
In order to achieve fully autonomous driving, point to point autonomous navigation is the most important task. Most existing end-to-end models output a short-horizon path which makes the decision process hard to interpret and unreliable at intersections and complex driving scenarios. In this research, we build a navigation-integrated end-to-end path planner on top of an openpilot open source model. We created a navigation branch that encodes route polyline geometry, distance-to-next-maneuver, and high-level instructions and combines with path plan branch using residual blocks and feed-forward layers. By adding minimal parameters, new model keeps the original openpilot tasks unchanged and have the path output based on the navigation information. The model is trained on diverse urban scenes and lighting conditions, and it shows improved route adherence in vehicle testing. The proposed model is validated in a comma 3x device installed on a 2025 Nissan Leaf test vehicle. The road test
Wang, Hanchen, Li, Taozhe, Hajnorouzali, Yasaman, Burch, Collin, li, Victoria, Tan, Lin, Arjmanzdadeh, Ziba, Xu, Bin
Evaluating the Impact of Drag Coefficient Changes on Driving Energy Using a Probability Distribution Model of Yaw Angle Based on Empirical Data from North American Highways2026-01-0615To be published on 04/07/2026
This study estimates the impact on driving energy of differences in aerodynamic characteristics for yaw angle from natural wind during North American Highway mode driving. A previous study[1] clarified the potential to estimate the fuel consumption impact of natural wind by integrating the CD yaw characteristics and yaw angle occurrence frequency. The natural wind was measured on a vehicle while driving a representative North American Highway test course[2]. The driving energy is predicted from the obtained yaw frequency and CD yaw sweep data in a wind tunnel. Measurements were conducted every weekday for 8 hours in 2023, covering 70% of the traffic volume. The validity of the measurement period was evaluated by the deviation from the annual average of wind direction and speed. Since yaw frequency varies depending on the road environment, it is necessary to weight the road environment type frequency when calculating the driving energy. The frequency was calculated using machine
Onishi, Yasuyuki, Nucera, Fortunato, Nichols, Larry, Metka, Matt
BEV incremental CO2 emissions in a ranked order electric grid2026-01-0424To be published on 04/07/2026
Battery Electric Vehicles (BEV) have been promoted and required by many governments towards the need to reduce transportations CO2 emissions. BEV are not “Zero Emissions Vehicles” because they run on grid electricity, but could be ‘effectively ZEV’ if the incremental CO2 is ‘very small’. To answer this question at the national level, three metrics are needed and estimated: (1) ICEV fuel consumption, approximated by the total US gasoline consumption divided by the total fleet miles driven, 25 mpg or 350 g CO2/mi. For strong HEV it is about one third less, 240 g CO2/mi. (2) BEV energy consumption, using data from systematic on-road testing of a wide range of vehicles, estimated at 40 kWh/100 mi for a US sales mix. (3) Electric grid marginal CO2, with ranked order sourcing: zero-CO2 sources are prioritized and supplemented by fossil sources. IEA hourly data show that the US 48 contiguous states are nearly self-contained, with zero-CO2 sources providing about a third of total demand. The
Phlips, Patrick
Aerodynamic Proximity Effects Between the DrivAer and AeroSUV Standard Models, Part 1 – Same-Lane Interactions2026-01-0605To be published on 04/07/2026
Road-vehicle platooning is traditionally defined as close-distance longitudinal following in laterally-aligned formation. In this paper, the effects of aerodynamic interactions on the drag of a two-vehicle system are examined by considering the influence of separation distance, cross winds, vehicle size and shape. Testing was undertaken at 30% scale in a large wind tunnel with road-representative freestream turbulence. Separation distances of 0.5, 1.0, and 2.0 vehicle lengths were examined over a range of yaw angles between ±15deg. A highlight of the current study is the characterization of platoon drag-reduction benefits for different sizes and shapes of the lead and follower models, by using a DrivAer model and an AeroSUV model, each with slant-back (Notchback or Fastback) and square-back (Estateback) variants, providing four distinct model pairings. Drag reduction for the lead model appears to be affected mainly by the size of the follower vehicle, while the follower model shows a
McAuliffe, Brian, Ghorbanishohrat, Faegheh
A Correction Method to Estimate Wake Effects for Aerodynamic Performance Metrics2026-01-0601To be published on 04/07/2026
Wake effects modify the aerodynamic performance of a road vehicle when driving in traffic. Analysis of wind-tunnel measurements conducted in flows with wake characteristics, using a traffic-wake-simulation system, suggests that conventional uniform-wind performance coefficients can be scaled, using wake-flow-field information, to predict the influence of wake effects. This paper presents a flow-field-averaging method that estimates a dynamic-pressure correction and yaw-angle correction for application to uniform-wind data, to account for changes in performance due to wake effects. This first-order method is shown to provide reasonably-good accuracy when reverse correcting the wind-tunnel wake-effects measurements. Drag-coefficient data for light-duty-vehicle models, which showed wake effects exceeding 20%, were corrected to within 5% of uniform-wind values, while data for heavy-duty-vehicle models, which showed wake effects exceeding 15%, were corrected to within 2% of uniform-wind
McAuliffe, Brian
Challenges to Ranking Diesel Fuels for NOx Emissions Using a Constant-Volume Combustion Chamber2026-01-0348To be published on 04/07/2026
This study examined the use of a constant volume combustion chamber for the measurement of fuel effects on NOx emissions, with the goal of developing a method to rapidly screen or rank fuels in a small - volume experiment. A small amount of fuel was injected into the air at 650°C and 20 bars, where it ignited and burned. The chamber was sampled post-combustion using a chemiluminescence NOx analyzer. Extensive sampling method development was required to obtain repeatable results. Seven hydrocarbon fuels and two biodiesel fuels were tested, all of which have shown difference in NOx emissions in past engine studies. When using a single injection event to deliver the same amount of fuel energy, the test method could not clearly demonstrate the difference in NOx emissions between the hydrocarbon fuels as reported in engine combustion studies. To improve this, a dual-injection strategy was used. It included a small “pilot” injection followed by a main injection, timed based on each fuel’s
Luecke, Jon, Rahimi, Mohammad, Mohamed, Samah, Naser, Nimal, Chausalkar, Abhijeet, McCormick, Robert
Persistent Elevated Soot Emissions Induced by Clustered Stochastic Preignition Events2026-01-0314To be published on 04/07/2026
Stochastic Preignition (SPI) is an abnormal combustion phenomenon that can occur in spark-ignition engines particularly under high-load operation. SPI is characterized by uncontrolled initiation of combustion prior to spark discharge, an abnormal combustion process that can lead to severe knock events and significant engine damage. SPI has been associated with fuel properties, lubricant composition, and engine design and operation. In this work, a single-cylinder test engine with a dry-sump oil system was utilized to study the SPI response of E10 and E25 fuels with a range of Reid Vapor Pressure (RVP). An automated test procedure was employed, consisting of ten square-waved load profile segments, with each segment composed of 5 min of low-load operation followed by 25 min of sustained high-load operation. These tests were replicated across multiple days of testing with a triple flush of lubricant between each test, and an online Fuel in Oil diagnostic measurement. Exhaust particulate
Splitter, Derek, Jatana, Gurneesh, DelVescovo, Dan, Douvry-Rabjeau, Julien, Fioroni, Gina, Chapman, Elana, Salyers, John
Experimental Validation of a Multi-Row Tapered Roller Bearing Analytical Model for Relating Preload to Frequency Response Characteristics2026-01-0008To be published on 04/07/2026
Roller bearings are used in many rotating power transmission systems in the automotive industry. During the assembly process of the power transmission system, some types of roller bearings (e.g., tapered roller bearings) require a compressive preload force. Those bearings' rolling resistance and lifespan strongly depend on the preload set during the installation process. Therefore, accurate setting of the preload can improve bearing efficiency, increase bearing lifespan and reduce maintenance costs over the life of the vehicle. A new method for bearing preload measurement has shown potential for both high accuracy and fast cycle time using the frequency response characteristics of the power transmission system. An open problem is experimental validation of the multi-row tapered roller bearing analytical model. After validation, the analytical model can be used to predict the assembled system damped natural frequency for a desired bearing preload. This work presents the experimental
Gruzwalski, David, Mynderse, James
Implementation and evaluation of a method to defend in-vehicle networks using SAE J1939-91C to authenticate network messages between multiple ECUs.2026-01-0092To be published on 04/07/2026
The objective of this paper is to understand the effort required to integrate the hardware and software of in-vehicle cybersecurity systems. The in-vehicle cybersecurity method discussed is the SAE J1939-91C, which involves Network formation, Rekeying, and secure Message Exchange between Electronic Control Units (ECUs). The SAE J1939-91C network security protocol operates over a CAN-FD network to perform necessary cryptographic operations and key generation. To evaluate the method, test vectors were created to validate SAE J1939-91C key generations and cryptographic operations on the simulated ECU in-vehicle network system hardware. The evaluation results provide a benchmark for network system performance that can be used in a system test bench to assess compliance with the SAE J1939-91C standard and to test the standard's effectiveness in ambiguous edge cases. In the future, this benchmark could be utilized in "Plugtests" to assign test scores to non-uniform SAE J1939-91C
Zachos, Mark, Medam, Krishna Teja
SUNRISE - A Harmonised Safety Assurance Framework for Connected, Automated MobIlity Systems2026-01-0060To be published on 04/07/2026
The SUNRISE project develops and demonstrates a harmonised Safety Assurance Framework (SAF) for Connected, Cooperative and Automated Mobility (CCAM) systems. The framework has been created in close alignment with the UNECE New Assessment/Test Method (NATM), and past and on-going international projects and initiatives. It also aligns with standardisation efforts in various standardisation bodies such as ISO, ASAM, SAE, and BSI. At the core of the SAF lies the Performance Assurance flow, which structures how safety evidence is generated and assessed. This flow is organised into three interconnected blocks: Scenario, Environment, and Safety Argument. The Scenario block encompasses the creation, formatting, and storage of scenarios that can be retrived to cover the system’s Operational Design Domain (ODD) and behaviour. The Environment block addresses the concretisation of test cases, their allocation across virtual, proving-ground, and real-world environments, and their execution. The
Zhang, Xizhe, Khastgir, Siddartha, de Vries, Stefan, Hillbrand, Bernhard, Op den Camp, Olaf, Bolovinou, Anastasia, Bourauel, Bryan, Ehrenhofer Gronvall, John Fredrik, Menzel, Thaddäus, Nieto, Marcos, Stettinger, Georg, Jennings, Paul
Defect Depth Characterization via Thermally and Pneumatically Induced Shearography for Nondestructive Component Inspection in the Automotive Sector2026-01-0205To be published on 04/07/2026
The following approach introduces a novel method for defect depth characterization using digital Shearography, which is a non-contact, full-field, and material-independent optical interferometric method that enables fast and nondestructive testing (NDT) of components, especially in industrial environments such as the automotive sector. While traditional techniques like computed-tomography, ultrasonic-testing, or thermography can offer depth approximations but they often involve high costs, longer testing times, or limited accessibility. In contrast, the method introduced utilizes various excitation methods in combination with shearographic evaluation to derive procedures for depth estimation of subsurface defects. Recent developments in Shearography have enhanced the method’s robustness and industrial applicability. By detecting the surface deformation behavior in the nanometer range under defined loading, depth-related characteristics of hidden defects can be extracted. Loading can be
Bastgen, Valentin, Plaßmann, Jessica, Petry, Christopher, von Freymann, Georg, Schuth, Michael
Transformer-Based Deep Learning Framework for Efficient Prediction of Automotive Wind Noise2026-01-0222To be published on 04/07/2026
Aerodynamic wind noise is a critical challenge in modern automotive development, particularly with the rise of vehicle electrification and intelligent mobility, where cabin acoustic comfort is a key quality metric. While reliable, traditional methods like wind tunnel experiment and CFD simulations are both costly and time-consuming. To address this, we propose a novel transformer-based framework for rapid and accurate wind noise prediction. Several model improvements, including the physical attention, geometry wave number embedding, hybrid FPS-random down sampling method and frequency separation output heads are properly employed to reduce the GPU mermory cost and improve the prediction accuracy. This framework is pre-trained on a large-scale transient flow field dataset of 1,000 diverse vehicles generated using Delayed Detached Eddy Simulation (DES). From a vehicle's point-cloud coordinates, the model directly predicts the surface pressure spectrum on the driver-side window and the
TANG, Weishao, Liu, Mengxin, QIN, Ling, Duan, Menghua, wang, chengjun
NVH characterization of new PWM strategies2026-01-0224To be published on 04/07/2026
Pulse Width Modulation (PWM) technique is widely used to drive AC machines at variable speed, however it generates high frequency harmonics which degrade sound quality. In the last decades, different PWM strategies have been designed to limit switching loss, and/or harmonic generation. Among them, discontinuous strategies are based on the injection of a zero-sequence signal, that strongly impacts the resulting voltage spectrum. An analytic formulation of the zero-sequence signal is proposed by the authors. It allows the creation of new PWM strategies, that can be easily experimented. In this paper, a preliminary study is performed with six new PWM strategies based on this analytic formulation. They are implemented on a basic test bench to perform a NVH characterization. Sound quality metrics are used to qualify the sound signature they produce. The resulting SPL is comparable with that of existing strategies, however their timbre is different in terms of low-frequency content and
Wanty, Salomé, Delpoux, Romain, Glesser, Martin, Totaro, Nicolas, Parizet, Etienne, Degrendele, Karine
The Stellantis North America Aero-Acoustic Wind Tunnel Upgrade2026-01-0609To be published on 04/07/2026
The Stellantis North America Aero-Acoustic Wind Tunnel (AAWT), which came into operation in June of 2002, has undergone the significant upgrade of installing a state-of-the-art moving ground plane system. A 5-belt Moving Ground Plane (MGP) has been installed. The center belt measures 8.5m long by 1.1m wide. The new balance is capable of testing all of the Stellantis North America’s vehicles, from small cars to large pickup trucks. Flow quality and other wind tunnel performance parameters were unchanged and remain at previously published specifications, which are on par with the latest industry standards. The new 5-belt rolling road system brings the AAWT to world class capability and it became operational in October 2024.
Lounsberry, Todd, Ladouceur, Brent, Fadler, Gregory
Swept Collector Design for the Honda Automotive Laboratories of Ohio Wind Tunnel2026-01-0608To be published on 04/07/2026
Modern aeroacoustic wind tunnels are required to have flat axial static pressure distribution, very low background noise levels, and minimal low frequency pressure fluctuations. These characteristics enable accurate measurement of aerodynamic forces acting on a vehicle as well as identification of noise sources. The collector of an open-jet or ¾ open jet wind tunnel plays a critical role in achieving these goals. Collector self-generated noise contributes to the overall background noise level in the test section, and this contribution has become more significant as other noise sources, such as the main fan, have been addressed through improvements to acoustic treatment. Ever-increasing attention to detail is required to manage noise signatures as the overall facility noise floor is lowered. Furthermore, aspects of collector design that may be beneficial to aerodynamics or pressure fluctuation tend to be some of the worst offenders for noise generation. A new collector configuration was
Best, Scott, Nagle, Paul
Machine Learning-Based Gear Defect Detection in Electric Vehicle Drive Units Using End-of-Line Vibration Analysis2026-01-0637To be published on 04/07/2026
The final assembly of electric vehicle (EV) drive units includes an essential End-of-Line (EOL) test to ensure both component integrity and Noise, Vibration, and Harshness (NVH) quality. This screening process, which uses dynamometers to measure vibration signals, is critical for identifying defects before a drive unit is installed in a vehicle. A significant source of failure during this test is gear defects, which can arise from manufacturing or handling issues. Traditional EOL testing methods rely on time-domain analysis and the impulsiveness of vibration signatures to detect these defects, a technique with inherent limitations in accuracy. This paper introduces and evaluates a novel approach using Machine Learning (ML) to analyze vibration signals for improved gear defect detection. We discuss the methodologies of both the traditional time-domain and the proposed ML-based techniques. Finally, we provide a comprehensive comparison of their respective efficiency and accuracy
Arvanitis, Anastasios, Michaloliakos, Anargyros
Collaborative Cybersecurity in a Shifting Automotive Supply Chain2026-01-0084To be published on 04/07/2026
The evolution toward software-defined vehicles (SDVs) is causing disruption to the traditional automotive supply chain and breaking down the common hierarchical OEM, tier 1 supplier, and tier 2 supplier relationships. With demands for faster software release cycles, more advanced software projects involving multi-party development, and considerations for end-to-end embedded and cloud integrations, new cybersecurity challenges are introduced that no single organization can address alone. Thus, this disruption creates new trust dependencies and requires new models for collaboration, transparency, and joint responsibility in cybersecurity. This paper presents a collaborative cybersecurity model, emphasizing shared responsibility during multi-party development between OEMs, tier 1 and 2 suppliers, engineering services organizations, and technology and services providers. As such, we explore collaborative approaches for each stage in the development lifecycle including design, development
Oka, Dennis Kengo, Vinzenz, Nico
ProGuard: A Real-time Preemptive Artificial Intelligence-Based Anti-Pinch System for Bus Entryways on Low-Power Edge Devices2026-01-0100To be published on 04/07/2026
This paper proposes ProGuard, a novel approach to preemptive pinch detection systems for buses. ProGuard utilizes state-of-the-art AI object detection algorithms to identify potential pinching events in bus entryways before pinching occurs. Modern conventional anti-pinch systems, such as pressure sensors or hall effect sensors, often rely on mechanical contact before triggering. While these systems are established safety mechanisms, they are reactive and therefore require some level of pinching before triggering. This reactive approach presents numerous safety concerns for passengers, especially when considering children on school buses. Existing preemptive detection methods, such as infrared or ultrasonic sensors, solve the problems presented by these reactive detection systems. However, these systems either lack the range or environmental resilience needed for reliable operation in buses. The critical nature of anti-pinch systems requires a robust and reliable solution that can adapt
Bradley, Hudson, Zadeh, Mehrdad, TAN, Teik-Khoon
Correlating CFD and experimental vehicle aerodynamics using multi-fidelity simulation approaches2026-01-0595To be published on 04/07/2026
The automotive industry faces several challenges requiring faster product development, where numerical simulations and digitalization are key enablers to reduce time to market and development costs. Numerical methods require both short turnaround times and high-fidelity results. Capturing small differences across vehicle designs, by accurately predicting complex flow phenomena is crucial for aerodynamics optimization. The disruptive and fast development of GPGPU computing hardware, promising accelerated turnaround times at lower costs, found its natural position in this landscape. This paper describes simulation approaches with increasing fidelity applied to a set of variants of a Stellantis estate production car: these include geometrical, yaw angle and ride height changes, and all were tested in wind tunnel test facilities. Correlation between aerodynamics CFD simulations using Simcenter STAR-CCM+ and wind tunnel measurements is verified by comparing drag trends, pressure probes and
Landi, Simone, Altmann, Peter, Cannavacciuolo, Ciro, Johannesson, Mani, Borowiec, Grzegorz, RIBES, Charles, Guzman, Arturo, Miretti, Luca
Typical cloud-vehicle-integration-based functional safety testing technology for intelligent chassis2026-01-0051To be published on 04/07/2026
Model-based virtual vehicle testing technology is an advanced simulation technique that significantly improves the efficiency and quality of vehicle development. It effectively addresses challenges such as complex operating conditions and experimental hazards in physical road testing. However, due to limitations in modeling accuracy, virtual vehicle parameters often remain overly idealized, resulting in limited credibility of test results. In response to the above issues, this article proposes a testing method based on vehicle-cloud fusion technology that combines the advantages of physical and virtual vehicle testing to avoid the disadvantages of both parties. Experimental validation demonstrates that the synchronization rate between virtual car and physical car data can reach 92.02%, which can safety and efficiently complete the initial vehicle testing, provide data support for subsequent physical car testing, and shorten the real car testing cycle.
Cheng, Qing Hua, Qu, Wenying, Liao, Yinsheng, Wu, Yan
A Study on the Relationship between Impact Conditions and Head Injury Criterion (HIC) in Powered-Two-Wheeler to Car Crashes2026-01-0571To be published on 04/07/2026
Road Traffic crash statistics highlight the importance of reducing fatalities among Powered-Two-Wheeler (PTW) riders, and suggest the necessity of a robust method to evaluate PTW crashworthiness performance. The objective of this study is to clarify the relationship between impact conditions and the Head Injury Criterion (HIC) to establish a fundamental basis for determining representative crash configurations for safety. A total of 1,272 PTW-front to car-side impact simulations were conducted by using production car and PTW models. HIC was used as a metric indicating likelihood of head injury. Velocities, impact angle, and impact locations were varied to create response surfaces. The surfaces were evaluated in terms of their accuracy in identifying the representative impact conditions. In addition, head trajectories were analyzed to clarify the kinematics until head impact. The Finite Element (FE) simulations produced the following findings. - The HIC distribution by Head Impact
Yanaoka, Toshiyuki, GUNJI, Yasuaki, Zulkipli, Zarir Hafiz, Matsushita, Tetsuya, Carroll, Jolyon, Puthan, Pradeep, Mohd Faudzi, Siti Atiqah, D-Wing, Kak, Miyazaki, Yusuke
Investigation of the Blockage Phenomenon in Closed Wall Wind Tunnels During the Testing of Bluff Automotive Bodies with Small Wakes in Yawed Configurations2026-01-0607To be published on 04/07/2026
The difficulties of testing a bluff automotive body of sufficient scale to match the on-road vehicle Reynolds number in a closed wall wind tunnel has led to many approaches being taken to adjust the resulting data for the inherent interference effects. But it has been very difficult to experimentally analyze the effects that are occurring on and around the vehicle when these blockage interferences are taking place. The present study is an extension of earlier works by the author and similarly to those studies uses the computational fluid dynamics analysis of five bodies that generate relatively small wakes to examine the interference phenomena in solid wall wind tunnels and the effects that they have on the pressures, and forces experienced by the vehicle model when it is in yawed conditions up to 20 degrees. This is accomplished by executing a series of CFD configurations with varying sized cross sections from 0.4% to 14% blockage enabling an approximation of free air conditions as a
Gleason, Mark, Riegel, Eugen
Impact of C-rates on Electrical Behavior of Li-ion Batteries under Coupled Temperature-load Conditions2026-01-0383To be published on 04/07/2026
The utilization of lithium-ion batteries in electric vehicles becomes increasingly common. Battery performance degradation is influenced by both temperature and boundary constraints. Monitoring the usable cell capacity (UCC) under real-world operating conditions is essential for ensuring accurate state-of-health estimation. Capacity tests in laboratory settings are typically conducted at low C-rates to approximate equilibrium conditions, whereas in real vehicle applications, charging currents are often much higher. This discrepancy in charge/discharge rates frequently results in deviations between laboratory characterization and on-board BMS capacity estimation. To investigate the impact of C-rates under coupled temperature-load conditions, we conducted long-term cycling tests on LFP/graphite pouch cells at 25 °C and 45 °C under different constrained conditions. The UCC was evaluated at different test rates (1/20C, 1/3C, and 1C) as an indicator of aging. The results show that
ZHANG, Shan, Niu, Zhice, Xia, Yong
On-Road Vehicle Testing and Characterization2026-01-0195To be published on 04/07/2026
Vehicle testing for fuel economy and emissions is typically performed indoors over standard dynamometer drive schedules to minimize variability and maximize repeatability of the results. In contrast, during on-road operation, operational parameters such as vehicle speed and acceleration and environmental factors such as temperature and wind will change unpredictably. These factors influence vehicle fuel economy and emissions, making on-road operation much more variable than dynamometer results. However, even though on-road conditions may be unpredictable, the on-road operational data can still be used to characterize vehicle performance. This paper describes the development of an on-road vehicle test methodology, with a focus on accounting for on-road factors with a high degree of accuracy while requiring only an achievable and reasonable amount of data. To develop this methodology, a 2016 Honda Civic was instrumented and driven multiple times over a route covering urban, rural, and
Moskalik, Andrew, Barba, Daniel
Energy Management Strategy for Hybrid Mining Trucks Based on Global SOC Planning and Neural Network Optimal Control2026-01-0446To be published on 04/07/2026
Hybrid mining trucks, as core equipment for mine transportation, face high energy consumption and significant fluctuations in power demand during cyclic operations due to prolonged exposure to demanding operating conditions characterized by heavy loads and variable working conditions. To address the issues of high energy consumption and significant fluctuations in power demand during the cyclic operation of mining trucks, this paper proposes a hybrid mining truck energy management strategy based on global SOC (State of Charge) planning and neural network optimization control. First, a powertrain model was developed for a typical operating cycle of a hybrid mining truck, and its accuracy was validated by comparing it with experimental data. Using dynamic programming algorithms to plan the SOC for single-cycle operations provides a rational reference for energy allocation across different operational phases of mining trucks during a single cycle. Next, using the powerful nonlinear
Yang, Jianyu, Zhao, Zhiguo, Chen, Huiyong, Li, Tao, ZHUANG, Wenyu, Shen, Peihong, Tang, Peng
MBSE-Driven XIL Workflow for Energy Evaluation of Automated Vehicles: From Simulation to VIL Testing2026-01-0289To be published on 04/07/2026
This paper presents a Model-Based Systems Engineering (MBSE)-driven X-in-the-Loop (XiL) methodology for quantifying the energy impacts of automated vehicles in realistic road scenarios while preserving high-fidelity powertrain behavior. We developed Argonne’s multi-vehicle simulation tool, RoadRunner, which automatically builds closed-loop road scenarios (road geometry, vehicle sensors, other vehicles, and traffic controls) and connects them to Argonne’s validated, high-fidelity vehicle and powertrain models in Autonomie. The MBSE backbone in AMBER organizes requirements, interfaces, plant and controller models, and test scenarios into a single set of models that carries through pure simulation, Software-in-the-Loop (SiL), Processor-in-the-Loop (PiL), and Vehicle-in-the-Loop (ViL) stages. Each stage has a clear role: simulation enables rapid development and validation of advanced models or controls across a large number of scenarios; SiL supports standalone algorithm verification and
JEONG, Jongryeol, Sharer, Phillip, Di Russo, Miriam, Das, DEBASHIS, Zhang, Yaozhong, Karbowski, Dominik
Development and Comparison of Benchmarking Methods for Electric Vehicle Drive Units2026-01-0198To be published on 04/07/2026
At the U.S. Environmental Protection Agency’s National Vehicle and Fuel Emissions Laboratory, a development project was implemented to compare various test methods for benchmarking the operation of vehicle electric drive units (EDUs). In earlier research, several test methods were identified, of which two were used to test a Chevrolet Bolt EDU: (a) in-vehicle testing of the complete EDU on a chassis hub dynamometer and (b) stand-alone testing of the EDU’s electric motor and inverter in a dedicated test cell after removal from the vehicle. The resulting data sets were compared with each other and with similar data previously published by GM. In this paper, additional EDU test methods are explored. First, the stand-alone testing of the EDU and its subcomponents is expanded to include testing both with and without the EDU gearing. This testing allows the electric motor, inverter, and gearbox to be characterized separately and the EDU to be characterized as a complete unit. Second, in
Moskalik, Andrew, Schauer, Ethan, Barba, Daniel
Neural Surrogates and Reinforcement Learning for Heavy-Duty Diesel Torque Control: A Data-Driven Alternative to PID2026-01-0199To be published on 04/07/2026
Accurately reproducing the torque trace of regulatory drive cycles is central to heavy-duty diesel emissions certification and repeatable development testing. Conventional controllers—PI/PID with gain scheduling and feedforward mapping—can meet requirements but demand extensive hand-tuning and struggle with strong nonlinearities and time-varying delay. Building on prior work that quantified the limits and benefits of gain-scheduled and feedforward strategies under the FTP transient cycle, this work investigates a fully data-driven control framework. First, a recurrent neural network (LSTM) torque surrogate is trained on dynamometer data to capture engine dynamics from readily available signals (e.g., engine speed, commanded pedal/torque, recent torque history) and actuator constraints. Second, this learned “world model” is used to train a reinforcement learning (RL) policy that outputs pedal commands to minimize torque-tracking error while regularizing control effort and respecting
Cook, James, Puzinauskas, Paulius, Bittle, Joshua, Hall, Spencer
Research on Reliability Test Methods for Electric Drive Axle Differentials2026-01-0007To be published on 04/07/2026
With the rapid socio-economic development, global issues such as the energy crisis and environmental pollution have become increasingly severe. Electric vehicles have garnered growing attention due to their environmental friendliness, simple structure, and high energy efficiency. Electric drive technology is regarded as the most ideal universal driving solution for pure electric vehicles, hybrid electric vehicles, and fuel cell vehicles. The electric drive axle, as a new type of integrated mechatronic transmission system, is being increasingly adopted owing to its advantages such as high drive efficiency, flexible spatial arrangement, and facilitation of digital and automated chassis control. This study focuses on reliability testing methods for the differential in electric drive axles, mainly including the extraction of reliability test conditions and feasibility analysis of the test scheme. The main research contents are as follows: First, based on specific parameters of an electric
Zheng, Hongyu, Li, Ziyu, Wang, Dajiang, tian, kai
Evaluation of PAEB Performance of a GM vehicle using EDR and Ground Truth Data2026-01-0054To be published on 04/07/2026
In order to determine the on-board EDR data recording characteristics of a GM vehicle, a 2023 GMC Sierra Denali was tested in several pedestrian Automatic Emergency Braking (P-AEB) scenarios. Using a variety of test tools, including the STRIDE robotic platform and its onboard data systems, a GPS/IMU installed in the vehicle, and several camera units, the vehicle was put into collision imminent scenarios in which the crash avoidance systems were actuated. The flags in the EDR data, the order in which EDR events were written, and the correlation between the EDR and data recorded by the aforementioned external acquisition systems were examined for each test case. Testing was done in both forward and reverse scenarios and at low speeds only. These results provide a picture of the current state of the additional data available in current EDRs installed on GM vehicles equipped with P-AEB capability, as well as an insight into the accuracy and meaning of that data which should prove
Bartholomew, Meredith, Arnett, Michael, Guenther, Dennis
Leveraging Machine Learning for Occupant Body Size Estimation via B-Pillar Seatbelt Systems2026-01-0559To be published on 04/07/2026
Occupant body size in vehicles varies significantly, encompassing differences in height, weight, and overall body composition. Adaptive restraint systems, featuring adjustable parameters such as belt load limiters, steering column load limiters and stroke, seat pan stiffness, and airbag pressure, can offer more equitable protection tailored to individual body sizes. In this study, a test rig modeled after the Volvo XC90 was used to collect data from 47 seated participants. Key seatbelt-related parameters, including D-ring angle, belt payout length, lap belt length, and buckle tension, were measured. These measurements were used to train machine learning models to predict occupant characteristics: height, weight, sitting height. The results demonstrate that low-cost sensors embedded in the seatbelt system can provide sufficiently accurate occupant body size estimations to inform adaptive restraint systems. The prediction errors across both training and test datasets were as follows
Wang, Da, Ahmed, Jawwad, Rowe, Mike, Brase, Dan
Data-Driven Objective Road-Driving Classification For Durable Design Of Vehicles2026-01-0181To be published on 04/07/2026
Durability development in the automotive industry depends on a clear understanding of how road surfaces and driving characteristics affect structural road loads and fatigue. Traditionally, road surface classification has been subjective (e.g., city, highway, rural), and done through driving instrumented vehicles over a small selection of roads. The variations in driving characteristics that are often consequent to the road surface quality is rarely accounted for in designing vehicle level durability tests. This makes it difficult to establish targets for the durability testing that accurately match the wide variations in real-world roads and driving across the market of vehicles. This paper presents a data-driven approach to objectively classify road surface and driving characteristics using metrics derived from existing vehicle and road response metrics like Vibration Dose Value (VDV), International Roughness Index (IRI) and statistical estimates of vehicle speed and acceleration
Shaurya, Shubham, Ramakrishnan, Sankaran, Demiri, Albion, Khapane, Prashant
Collision Avoidance Testing of the Waymo Automated Driving System2026-01-0519To be published on 04/07/2026
This paper describes Waymo's Collision Avoidance Testing (CAT) methodology: a scenario-based testing method that evaluates the safety of the Waymo Driver Automated Driving Systems' (ADS) intended functionality in conflict situations initiated by other road users that require urgent evasive maneuvers. Because SAE Level 4 ADS are responsible for the dynamic driving task (DDT), when engaged, without immediate human intervention, evaluating a Level 4 ADS using scenario-based testing is difficult due to the potentially infinite number of operational scenarios in which hazardous situations may unfold. To that end, in this paper we first describe the safety test objectives for the CAT methodology, including the collision and serious injury metrics and the reference behavior model representing a non-impaired eyes on conflict human driver used to form an acceptance criterion. Afterward, we introduce the process for identifying potentially hazardous situations from a combination of human data
Kusano, Kristofer, Beatty, Kurt, Schnelle, Scott, Favaro, Francesca, Crary, Cam, Victor, Trent
Introduction to Catesby Aero Research Facility, CARF, the coast-down tunnel proving ground.2026-01-0611To be published on 04/07/2026
This paper reports on the Catesby Aero Research Facility (CARF), which began commercial use in 2019, and provides an overview of the facility and related technologies, particularly details on the vehicle-mounted component force measurement devices. CARF is a proving ground that was renovated from a former railway tunnel approximately 2.74km long and is now covered with high-quality tarmac. The road surface quality was designed to be at least as good as that of SUBARU's proving ground, and the standards were achieved using British construction technology. The course is almost straight, but there is a slight incline. The course specifications are: blockage 40m2, road width 6m (maximum 8.4m), flatness σ<0.5mm, and gradient 0.57%.In particular, compared to outdoor coastdown trucks, its overall length allows for continuous measurement right up to the stop, giving it a significant advantage in repeatability.At the same time, Subaru's newly developed six-component force sensor built into the
Shimoyama, Hiroshi
Simulation of Conjugate Heat Transfer using the Lattice Boltzmann Method2026-01-0135To be published on 04/07/2026
Flow simulation with conjugate heat transfer, which involves fluid flow, conduction, and radiation in solid components, is a critical capability that helps engineers design and evaluate cooling systems for heat-generating components such as brakes, powertrains, batteries, and power electronics for both gasoline and electric vehicles. For this study, we utilize PowerFLOW™, featuring its novel native thermal solver, which models both fluid and solid domains within a single model. For the flow domain, we use the Lattice Boltzmann Method with VLES turbulence modeling based on the RNG k-epsilon method. And for the solid domain, the finite volume method with second-order accuracy for thermal conduction and a surface-to-surface radiation for the surfaces. This approach not only leads to a more integrated and streamlined workflow but also enables an accurate modeling of conduction and radiation. In this study, we demonstrate the accuracy of the conjugate heat transfer simulation methodology
Mukutmoni, Devadatta, Shock, Richard, Li, Han, Wanderer, John
Minimal Binary Patching for Safety-Critical Systems2026-01-0088To be published on 04/07/2026
Patching vulnerabilities in safety-critical domains such as automotive and aerospace is costly and complex. A small code modification can trigger a complete rebuild, producing a binary with widespread changes. This inflates patch size, complicates regression testing, and makes over-the-air (OTA) updates inefficient, as traditional binary diffs often replace large portions of the executable. We present a binary rewriting–based experiment that shows the feasibility of a patch that updates only the affected bytes by computing the impact of a code change at the binary level. This produces minimal, localized patches rather than regenerated executables. The preliminary experiment shows that a single source change, which leads to thousands of modified bytes after recompilation, can be captured with only a few bytes using our method. For automotive and aerospace systems, this technique reduces patch size, conserves bandwidth, and minimizes disruption to certified software, offering a promising
Awadhutkar, Payas, Tamrawi, Ahmed, Sauceda, Jeremias
Camera Monitor System Soiling Correlation for a Class-8 Truck Using Lattice Boltzmann Method2026-01-0596To be published on 04/07/2026
As Camera Monitoring Systems (CMS) become an integrated part of the driving experience for current automotive and heavy vehicles, keeping the CMS clean from water, dirt, sand, snow and ice is a main focus of the design process in order to avoid safety issues due to obscured visibility. On-road soiling prevention becomes an important feature when designing these camera and sensor systems. Computational Fluid Dynamics (CFD) analysis can be used to facilitate the design process, to provide important information of the cause of the problems and design mitigation mechanism to prevent the visibility issues. There are many published papers for soiling studies for the automotive application but very limited publication available for heavy trucks, this paper is targeted to fill this space. In these current studies during a design process, road tests were performed in Alaska by the testing department. Correlation was done between those road tests and the CFD analysis, performed in-house. This
He, Wei, Dasarathan, Devaraj, Linden, Tom, Park, Jeongbin
Digital Twin Aerodynamics Model Validation for HALO Wind Tunnel2026-01-0610To be published on 04/07/2026
A simulation-based aerodynamics model of the Honda Automotive Laboratories of Ohio (HALO) Wind Tunnel, a three-quarter open-jet (ground plane) configuration opened in 2022 for full-scale automotive testing, is under development to support data fusion for more accurate surrogate models in vehicle engineering programs. The objective is to demonstrate that a matched set of boundary values between the physical wind tunnel and the three-dimensional numerical model yield correct responses for several key flow field quantities, starting with the baseline empty tunnel case: (1) streamwise static pressure distribution, (2) evolution of the free shear layers downstream of the nozzle exit plane, and (3) ground-plane boundary layer development. Pressure-based measurement probes were deployed in these regions using a four-axis overhead traverse to acquire validation data in the large facility, including instrument verification between a 14-hole probe and Pitot-static rake. Detached eddy simulation
Patel, Sajan, Disotell, Kevin, Eagles, Naethan
An Updated Correlation Study between the Full Size Wind Tunnels of General Motors, Ford Motor Company, and FCA US LLC2026-01-0612To be published on 04/07/2026
As automotive aerodynamic testing facilities evolve to capture more real-world behavior, updating the correlation between old and new technologies is essential. Recently, the three-member consortium of the United States Council for Automotive Research (USCAR) - FCA US LLC, Ford Motor Company, and General Motors - transitioned from full-size static ground plane facilities to 5-belt moving ground plane wind tunnel facilities. The primary objective of this study was to update the correlation data sets to maintain consistent and robust data sharing among companies, which is the cornerstone of USCAR efforts. To achieve this, a set of updated correlation data sets were calculated to replace the original correlation study results from 2008. Additionally, the methodology for applying correlation equations was revised from using averaged wind tunnel data to employing direct wind tunnel-to-wind tunnel correlation equations. In a two-phase correlation effort conducted in 2022 and 2025, the three
Nastov, Alexander, Lounsberry, Todd, Madin, Trevor, Langmeyer, Gregory, Fadler, Gregory, Skinner, Shaun, Horton, Damien
Wind-Tunnel Study of the Traffic-Wake Impacts for Road-Vehicle Aerodynamics2026-01-0613To be published on 04/07/2026
When driving in traffic, the wakes of leading vehicles reduce the wind speed experienced by a following vehicle, lowering its drag relative to isolated driving. These wake effects can persist to large intervehicle distances, on the order of hundreds of meters, while lateral convection due to cross winds can influence vehicles in adjacent lanes. Wind tunnel testing was conducted at 30% scale for light- and heavy-duty-vehicle models in a large wind tunnel with a traffic-wake simulation system, expanding upon a previous study that examined only heavy vehicles. Three variants of the DrivAer model, four variants of the AeroSUV model, and three variants of a zero-emission heavy-duty-truck model were tested with a range of simulated wake conditions that varied the type, forward distance, and lane position of the wake-source vehicle(s), for a range of yaw angles up to 11deg. Results show drag reductions of up to about 10% for the heavy-truck model, and up to about 20% for the passenger-vehicle
McAuliffe, Brian, Ghorbanishohrat, Faegheh, Barber, Hali
Aerodynamic Development of Maruti Suzuki VICTORIS2026-01-0602To be published on 04/07/2026
MSIL (Maruti Suzuki India Limited), India's leader in automotive sector, has various SUVs (Sports Utility Vehicle) in its model lineup. Conventionally, SUVs are considered to have an aggressive stance with a bold on-road presence, and this bold design language often deteriorates aerodynamic drag performance. In the past decade, the demand for this segment has significantly grown, whereas the CAFE (Corporate Average Fuel Economy) norms have become more stringent. To cater to this growing market demand, MSIL planned for a new compact SUV - VICTORIS with targeted best-in-class aerodynamic performance. This paper illustrates the aerodynamic development process for the vehicle using CFD (Computational Fluid Dynamics) and full scale WTT (Wind Tunnel Test). During the initial stages, the bolder design of the VICTORIS deteriorated the aerodynamic drag of the vehicle. Styling exterior surface modifications and addition of new aero parts facilitated the recovery of aerodynamic drag performance
Dey, Sukanta, Singh, Shekhar, Kumar, Chandan, Alphonse, Felix Regin
Design and validation of modern hydrogen and natural gas containers for on board vehicle storage2026-01-0188To be published on 04/07/2026
Ensuring the operational safety of gaseous fuel containers for hydrogen and natural gas vehicles requires robust and validated protective devices capable of responding reliably under diverse operating and accident scenarios. This paper presents the design considerations, test methodology, and validation outcomes for safety subsystems integrated into modern compressed gas storage vessels, with emphasis on pressure relief devices (PRDs), thermal protection systems, and valve assemblies. Drawing on experimental insights from previous studies of hydrogen and natural gas fueling systems and fire-resistance assessments, the work defines safety-critical conditions such as rapid temperature rise during bonfire exposure, localized flame impingement, over-pressurization from fast filling, and mixed-gas operation. A comprehensive validation protocol was established, combining standardized regulatory tests with additional stress profiles replicating service-realistic environments. These included
Flekiewicz, Marek, Flekiewicz, Wojciech
Development of an Advanced Tensile Testing Method for HDPE Composites in High Draw Molded Hollow Circular Regions: Effects of Sample Preparation, Asymmetry, Thermal Conditions, Pull Speed, and Fixture Parameters.2026-01-0204To be published on 04/07/2026
High-density polyethylene (HDPE) composites, particularly in high draw molded hollow circular configurations, present unique challenges in evaluating mechanical performance under tensile stress due to anisotropic deformation, geometric asymmetry, and localized thermal gradients. This study introduces an advanced tensile testing methodology designed specifically to assess such regions with greater precision and reproducibility. The method incorporates refined sample preparation protocols, tailored fixture geometry, and adjustable pull speeds to accommodate varying thermal histories and draw ratios inherent to molded sections. Systematic variation of asymmetrical, temperature conditions, and clamping techniques revealed significant impacts on tensile strength, elongation at break, and strain distribution. Findings emphasize the necessity of customized testing frameworks for molded composite geometries and demonstrate that fixture alignment and thermal conditioning are critical to
BHALERAO, SAURABH SHANKAR
Development of A Tire Blowout Experimental Platform for Dynamics and Control Validation2026-01-0202To be published on 04/07/2026
Tires are critical to vehicle dynamics, transmitting traction, braking, and cornering forces to the road. A tire blowout, the sudden and rapid loss of inflation pressure due to puncture or structural failure, can cause severe instability, rollover, or collisions. Understanding vehicle response during blowout events is essential for developing robust safety systems and control strategies. Earlier developed simulation models are used to study and understand vehicle behavior during blowouts, but there is a lack of on-road testing platforms to validate these models experimentally. A custom-built blowout device integrated with a data acquisition system has been developed to address this gap. It consists of multiple solenoid valves mounted on the wheel surface and powered by a 12V supply. All valves are triggered at the same time using an RF remote, producing rapid and synchronized deflation. An Arduino-based actuation system is being developed for individual valve actuation and custom
KANTHALA, Maha Vishnu Vardhan Reddy, Krishnakumar, Ashwin, Lin, Wen-Chiao, Chen, Yan
From Static Ground to Moving Ground Wind Tunnels: Feature Selection for Reliable Estimation of Drag Coefficient Discrepancies2026-01-0203To be published on 04/07/2026
Moving ground wind tunnels offer a more accurate test environment for ground vehicle drag coefficient measurement due to their highly realistic representation of the boundary layer phenomenon. However, historically most vehicles have been tested on static ground wind tunnels. As a result, the measured drag coefficient of these vehicles may not be sufficiently realistic for certification purposes. Therefore, it is valuable to build statistical models to estimate moving-ground wind tunnel drag coefficient by using information from a static-ground wind tunnel and other relevant vehicle characteristics such as presence of aerodynamic devices (spoilers, air dams, etc.). However, to build accurate statistical models, appropriate predictive features must be identified as a first step. In this paper, an aerodynamic feature selection study has been conducted to identify vehicle characteristics that contribute to drag coefficient estimation discrepancies between a static- and a moving-ground
Singh, Yuvraj, Jayakumar, Adithya, Rizzoni, Giorgio
Development of a virtual test rig to evaluate thermal management of a battery-electric vehicle under battery heating-cooling modes2026-01-0416To be published on 04/07/2026
A battery-electric vehicle (BEV) has multiple powertrain components (battery, inverter, e-motor), a thermal management system (compressor, heat exchanger, cabin heating, ventilation, and air-conditioning), and a vehicle body, among others. Vehicle testing is time-consuming, and also changing powertrain components during the testing and design process is costly. Simulation models (aka virtual or simulation test rig) have been widely used for efficient vehicle design. This work presents a systematic approach to developing a virtual test rig to evaluate the thermal performance of battery-electric vehicles. A Tesla Model Y is tested in a chassis dynamometer, and the measured vehicle performance data are used as boundary conditions for the complete vehicle model. The detailed lithium-ion battery (LIB) pack model, including its cooling system, was developed and calibrated using various transient driving cycle data. The HVAC model uses a simplified controller to maintain the cabin temperature
Sok, Ratnak, Kusaka, Jin
Establishing a Standard S-Factor: Improving Accuracy and Flexibility in SOC Corrections for HEV Testing2026-01-0422To be published on 04/07/2026
Hybrid-electric vehicle (HEV) fuel economy test procedures require that the net energy change (NEC) of the battery remain small enough to ensure accurate fuel usage results. SAE J1711-2010 required the NEC stay within 1% of fuel energy consumption, assuming that residual changes in state of charge (SOC) would have negligible impact. In practice, however, the asymmetry between fuel and electricity conversion efficiencies means that a 1% SOC imbalance can translate into a fuel consumption error approaching 3%. A standard S-Factor—a dimensionless ratio of marginal fuel change to marginal NEC change—was introduced in J1711-2023 to improve SOC corrections. The method improves accuracy by correcting all results for NEC changes and expands the NEC-to-fuel ratio (NECFR) window, enabling HEVs to use electric propulsion more aggressively and achieve higher fuel economy in testing and real-world usage. Using a standardized value (instead of requiring additional testing to determine the vehicle
Duoba, Michael
Cantilevered Boom Crane Structures - Method of TestJ1063_202603 (Current)3/13/2026
This SAE Standard applies to mobile, construction-type lifting cranes utilizing cantilevered boom crane structures and associated jibs (see Figure 1).
Cranes and Lifting Devices Committee
Time-Step Analysis of Sliding Mesh Rotation Modeling15-19-01-00043/13/2026
The current work analyzes the effect of time-step size on the predictive capability and computational cost of the Sliding Mesh (SM) method for modeling flows around the rotating wheels of a mass-production luxury sport utility vehicle (SUV). Two unsteady turbulence models [Unsteady Reynolds-Averaged Navier–Stokes (URANS) and Delayed Detached Eddy Simulations (DDES)] were tested using time-step sizes ranging from the current recommended time-step size of 1 degree of rotation per time-step (1 D/TS) up to 50 degrees of rotation per time-step (50 D/TS). The flow field predictions compare favorably to the 1 D/TS case for a time-step size as large as 5 D/TS. Using this time-step size leads to a reduction in computational cost of approximately 80% for both unsteady methods. At a time-step of 5 D/TS, the computational cost of the SM method is comparable to the more commonly used Moving Reference Frame (MRF) method. However, drag and flow field predictions by the SM method at this larger time
Struk, Michael, Aultman, Matthew, Disotell, Kevin, Duan, Lian, Bianco, Antonello, Metka, Matthew, Khasdeo, Nitin
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