Browse Topic: Tests and Testing

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Road Test Emulation: A Data-Driven Calibration Approach2025-01-0521To be published on 11/25/2025
The resource-intensive process of road testing constitutes an elementary part of the development of vehicle software. A significant proportion of explorative tests and adjustments for use in service are conducted during the vehicle test phase. However, the observed trends of decreasing development cycles and increasing system complexity generate a field of conflicts. In order to address this issue, this paper proposes road test emulation as a data-driven approach for continuously adapting vehicle software to the evolving overall system. Therefore, test scenarios equivalent to in-service conditions are determined based on customer data and test drives. These test scenarios enable an emulation of road testing and the analysis of the system in a real-world operational context from the early stages of the product development process. Sensitivity analyses are utilised to generate system-specific data for the vehicle under development, which is then employed to define initial parameter
Martini, Tim, Kempf, André, Winke, Florian, Auerbach, Michael, Kulzer, André Casal
Simulative temperature determination of an electric machine from test bench tests2025-01-0520To be published on 11/25/2025
One of the most important components of an electric vehicle is the drive motor. Induction motors are often used for this purpose. Power losses occur during the operation of these motors, particularly at high speeds. Among other things, this power loss corresponds to the sum of winding losses, iron core losses and mechanical losses. The power losses generate heat, causing the temperature in the rotor and stator to rise. The increase in temperature of the components inside the motor can lead to premature wear and fatigue failure. To prevent overheating, the motors are air or water cooled. Water cooling can be achieved by jacket cooling, for example. In this case, the heat generated is dissipated directly by forced convection. However, the cooling jacket makes it difficult to determine the temperature inside the motor. Determining these temperatures is necessary to prevent the motor from fatiguing prematurely. The temperatures that occur inside the motor during operation are of particular
Schamberger, Stephanie, Reuss, Hans-Christian
In-Flight Evaluation of Sustainable Hydrocarbon Fuels in Compression Ignition Aircraft Engines2025-01-0533To be published on 11/25/2025
With global air traffic projected to increase significantly in the coming decades, reducing the associated climate impact requires scalable solutions. While alternative propulsion technologies such as electric and hybrid-electric systems might offer long-term potential, their current applicability remains limited due to low energy density, limited range and scalability, and system complexity. Consequently, thermodynamic propulsion systems—such as gas turbines and piston engines—are expected to remain dominant in the medium term. In this context, sustainable hydrocarbon-based aviation fuels represent a practical and necessary solution. Certified sustainable aviation fuel (SAF) pathways are currently approved exclusively for use in gas turbines, with certification standards tailored to turbine-specific requirements. Consequently, fuel properties such as cetane number and evaporation behavior are not included in existing specifications. However, when SAF-kerosene blends are used in
Kleissner, Florian, Hofmann, Peter, Vogd, Philipp, Vauhkonen, Ville, Käkölä, Jaana, Greve, Alina
Fuel Differentiation for the Energy Efficiency in Heavy Duty Diesel Applications - A case study for the determination of exhaust emissions and fuel economy2025-28-0231To be published on 11/06/2025
For the achievement of Net Zero Emission goals, various corporates have started with the planning towards the achievement of short-term goals which are well defined with the implementation of energy conservation and efficiency. In this direction, differentiated diesel (Xtragreen) is an optimized combination of diesel fuel with higher Cetane Number fortified with Novel & Optimized multi-functional additives (MFAs) formulation for improved performance and specially designed by Indian Oil Corporation Limited for heavy duty diesel engines & off-highway applications. IndianOil innovative concept is based on enhancement of fuel economics by enhancement in fuel combustion, injector cleaning characteristics and reduction of frictional losses. The benefits associated with differentiated diesel are with High cetane fuel (55 against 51) with Superior cleanliness to keep high pressure diesel Injectors clean, better lubricity provides longer injector life, Superior Combustion leads to lower noise
Kumar, Prashant, Mayeen, Hafiz, Saroj, Shyamsher
Test methodology development for validating engine pulley bolt for accelerated durability2025-28-0234To be published on 11/06/2025
Engine is the prime mover of an automobile. Tractor is also equipped with an engine of higher capacity to meet the power requirement. Apart from powering the wheels, the engine also runs different accessories, such as a water pump, alternator, AC pump, oil pump, and so on. The power from the engine is transferred to accessories via chain drive or belt drive through the crankshaft pulley. During field testing, in one of the tractors, engine pulley mounting bolt failure was reported. The failure resulted in an immediate seizure of the engine, making the tractor standstill in the field. The root cause of the failure was unknown. There was a need to develop a component- or subsystem-level test methodology to address the issue quickly. In the current scope, an attempt was made to develop a subsystem-level laboratory test methodology to simulate the failure mode and to validate the design modifications in an accelerated manner. The failure mode was simulated in the lab, and different design
Chakraborty, Abhirup
Automating Fault Detection Time Intervals in Automotive Functional Safety Using HIL Simulation2025-28-0274To be published on 11/06/2025
Functional safety is driven by number of standards like in automotive its driven by ISO26262, in Aerospace its driven by DO-178C, and in Medical its driven by IEC 60601. Automotive electronic controllers must adhere to state-of-the-art functional safety standard provided by ISO26262. A critical functional safety requirement is the Fault Handling Time Interval (FHTI), which includes the Fault Detection Time Interval (FDTI) and Fault Reaction Time Interval (FRTI). The requirements for FHTI are derived from Failure Mode Effect Analysis (FMEA) conducted at the system level. Various fault categories are analyzed, including electrical faults (e.g., short to battery, short to ground, open circuits), systemic faults (e.g., sensor value stuck, sensor value beyond range), and communication faults (e.g., incorrect CAN message signal values). Controllers employ strategies such as debouncing and fault time maturity to detect these faults. Numerous FDTI requirements must be verified to ensure
Lengare, Sunil, Yadav, Vikaskumar, Shiraskar, Pallavi
Design IQ2025-28-0327To be published on 11/06/2025
Weight and cost are critical parameters in any new product development program, influencing aspects such as homologation and efficiency. Traditionally, tracking these parameters at the machine, subsystem, and module levels involves a manual, time-consuming process. This reactive approach often delays the program and hampers the productivity of design engineers. These challenges can be managed with an automation and simulation. WCOSAP automates the extraction of weight details, identifies outliers, calculates module-level impacts, and predicts future weight changes. This proactive tool eliminates repetitive manual work, enhances data accuracy, and supports dynamic updates. By integrating real-time data and predictive models, WCOSAP enables sound decision-making and proactive weight control during the design phase, ultimately improving efficiency and reducing the need for part revisions. This paper discusses the development, implementation, and benefits of the WCOSAP tool, highlighting
Patil, Vivek, Sahoo, Abhilash, Ballewar, Sachin, Chidanandappa, Basavaraj, Chundru, Satyanarayana
Isolation of Engine Vibrations from 3 Cylinder Engines on Off-Highway Machines2025-28-0292To be published on 11/06/2025
The BS4 regulation for emission required several changes on engines as well as design and development of new auxiliary systems. These changes affected the engine dynamic behavior and ultimately noise and vibration in engine. These changes are validated for various operating conditions on engine test cell in a controlled environment where engine is mounted on test cell with dyno. Further, this engine is used in various equipment application and needs to be validated for noise and vibration performance. Three-cylinder engines have inherent imbalance forces, hence it is extremely critical to select the proper engine isolators to reduce the vibrations and noise. This paper covers the methods used for verification of engine isolation performance. NVH tests are conducted for integration of three-cylinder engine with roadbuilding machine. An analytical model is developed to identify rigid body modes and mount transmissibility. Results from this analytical model were verified with a physical
Pawar, Sachin M., Mandke, Devendra Laxmikant, KASABE, SANDEEP, Jadhav, Vijay
Reduction in Product Development Time by Field-to-Lab Simulation2025-28-0282To be published on 11/06/2025
KEYWORDS: Flywheel Inertia, Clutch system, Gear Box, Tractor application, Instrumentation, data analysis, Design and develop new test methodology. ABSTRACT: Puddling is a crucial process in rice cultivation, involving the preparation of the soil in a flooded field to create a soft, muddy seedbed. There are two classifications for puddling: full cage and half cage. Full cage puddling involves replacing the rear wheels of the tractor with steel paddle wheels, which are used to till the rice paddies directly without any additional implement. In the half cage puddling, the rear wheels remain on the tractor, and a smaller cage or paddle wheel is attached to the outside. Considering the field size, the operator often releases the clutch very quickly after a speed or direction change. This generates torque spikes, which are harmful to Transmission Gears and Clutches. This can lead to gear teeth bending fatigue failure due to repeated higher bending stresses. In this paper, a study related to
Pathan, Irfan Hamidulla, Bardia, Prashant
Fatigue in Plastic Field of AISI 304L on an Engine Component: An Interesting Case on a Pulley for Automotive Application2025-32-0080To be published on 11/03/2025
This study investigates the failure mechanisms of a press-fitted AISI 304L pulley, which is used to drive an engine coolant variable water pump in automotive applications. The analysis focuses on the peculiar loading scheme of the pulley resulting from the innovative water pump design which combines high mean stress from press fitting with cyclic stress from rotating bending loads that exceed the material's yield point. This is coupled with the cyclic material behavior of AISI 304L which exhibit a strong cyclic hardening. This combination significantly influences the stress distribution and fatigue life of the component under cyclic loads combined with material plasticity, ultimately leading to fatigue failure at the pulley-shaft mating surface. Assembly endurance tests were conducted on a specialized test bench, allowing control of pulley bending load. A comprehensive failure analysis, including visual inspection, metallurgical examination, and finite element analysis (FEA) was
Franceschini, Alessandro, Squarcini, Raffaele, Rybicki, Gilles
Development of an Artificial Calibrator for Shift Program Optimization to Enhance Fuel Efficiency2025-32-0082To be published on 11/03/2025
The calibration of automotive electronic control units is a critical and resource-intensive task in modern powertrain development. Optimizing parameters such as transmission shift schedules for minimum fuel consumption traditionally requires extensive prototype testing by expert calibrators. This process is costly, time-consuming, and subject to variability in environmental conditions and human judgment. In this paper, we introduce an artificial calibrator – a software agent that autonomously tunes transmission shift maps using reinforcement learning (RL) in a Software-in-the-Loop (SiL) simulation environment. The RL-based calibrator explores shift schedule parameters and learns from fuel consumption feedback, thereby achieving objective and reproducible optimizations within the controlled SiL environment. Applied to a 7-speed dual-clutch transmission (DCT) model of a 1.5 L Mild Hybrid Electric Vehicle (MHEV), the approach yielded significant fuel efficiency improvements. In a case
Kengne Dzegou, Thierry Junior, Schober, Florian, Rebesberger, Ron, Henze, Roman
An SVM-based approach to develop a new control module for H2-powered engine using driver behaviour classification2025-32-0042To be published on 11/03/2025
In the next years, the global hydrogen vehicle market is expected to grow at a very high rate. Consequently, it is necessary for scholars and professionals to study and test specific components in order to rise motor efficiency leveraging the new features of connectivity available in smart roads. In particular, our research is focused on the developement of an engine control module driven by evaluation of usage characteristics (e.g., driving style) and "connected-to-x" scenarios using the standard engine control approach. Moreover, the module proposed enables the implementation of "fast running" models to improve the response of vehicle and make the best possible use of H2-powered engine characteristics. That said, in this paper is proposed a new approach to implement the control module, using Support Vector Machine (SVM) as the machine learning algorithm to detect driving style, and consequently modify the parameters of the engine. We choose SVM because i) it is less prone to
Mastroianni, Michele, Merola, Simona, Irimescu, Adrian, De Santis, Marco, Esposito, Christian, Aversano, Lerina
RDE testing of small Motorcycle in Indian Road Conditions and study the impact of instrumentation on emission and fuel economy2025-32-0075To be published on 11/03/2025
This paper presents the results of real-world driving emissions and fuel economy measurements for two-wheelers in India using a state-of-the-art FTIR PEMS technology. The study aimed to characterize the emissions profiles of a small motorcycle under typical Indian driving conditions, including congested urban traffic and highway driving. This is the continuation of the study conducted previously on bigger motorcycle using gas analyzer [ JSAE 20179041 / SAE 2017-32-0041][1], with necessary adaptations to suit the specific conditions of Indian roads and traffic. Key parameters such as NOx, CO, CO2 and Fuel consumption were measured during real-world driving cycles and comparison is done with standard WMTC emission testing cycle. The findings of this study provide valuable insights into the actual on-road emissions of two-wheelers in India, which can be used to inform regulatory policies, develop more accurate emission models, and guide the development of cleaner and more efficient two
AGRAWAL, RAHUL, Jaswal, Rahul, Yadav, Sachin
Experimental analysis of wheel bearing friction losses under realistic driving cycles on a component and roller test bench2025-32-0100To be published on 11/03/2025
The ongoing electrification of vehicle powertrains brings attention to components with a minor contribution to overall friction losses in research and development. To optimize the overall energy efficiency, it is essential to analyze and reduce the losses in these components. Wheel bearings are of particular interest in this context, as their friction losses affect both the driving and recuperation phases. These losses are dependent on temperature, mechanical loads and the bearing mounting situation into the vehicle. The analysis of friction losses and their dependency on the factors mentioned above is usually conducted by measurements on component test benches to allow an isolated evaluation. In contrast, the friction losses of the complete drive system are measured on powertrain or roller test benches. In this context, the factors affecting the losses in wheel bearings may deviate from the measurements obtained on component test benches. The purpose of this paper is to analyses the
Hartmann, Lukas, Erxleben, Lars, Rebesberger, Ron, Henze, Roman, Sturm, Axel
Emission Performance of Motorcycles: Regulated and Non-Regulated Pollutants under Harmonized and Extended Testing Conditions2025-32-0069To be published on 11/03/2025
This study investigates emissions from motorcycles, focusing on both regulated gaseous pollutants (e.g., CO, NOx, HC) and particulate number (PN) emissions, which are non-regulated for this vehicle category in the actual EU emission regulation. Using a state-of-the-art testbench setup equipped with advanced exhaust gas analysis and PMP system, emissions were analyzed under both standardized homologation cycles and more dynamic Real Driving Cycles (RDCs). Besides the measurement results the technological differences between different motorcycle categories are described. This is followed by a discussion of the influences of engine and exhaust gas aftertreatment systems on emission. The findings reveal that, there are two different subcategories of two-wheeler, which show different emission characteristics. L1e vehicles showed increased emissions compared to passenger cars, caused by the absence of advanced exhaust aftertreatment and on-board diagnosis systems which is driven by less
Schurl, Sebastian, Schmidt, Stephan, Bretterklieber, Niko, Kupper, Martin, Kirchberger, Roland
Development of Electric Vehicle Motor Test Rig for Performance Analysis2025-28-038010/30/2025
Electric two-wheeler testing before they are introduced in the market is one of the essential features needed by the certification agencies. Different types of test bench are available for measuring the torque and power from the electric two-wheeler that includes eddy current based motor test bench and mechanical based loading benches. In the present work an electric motor bench is designed and developed that takes care all features of electric two wheelers. The power supply to the motor is done through convertors and controller while mechanical loading is applied through belt. The other features that are kept in the rig includes lighting system and speed controller for the motor. The design is developed for variable outer diameter of electric two-wheeler testing. Tests were conducted on the developed rig. Test results were compared with electric motor specifications and were found to be in good agreement
Vashist, Devendra, Verma, Kartik, Chamok, Fahim, Tewatia, Bharat, Rajput, Neeraj
Research on Efficiency Optimization and Accuracy Benchmarking of Transient Simulation of Automotive Wind Noise2025-01-507210/30/2025
The current automotive development cycle is becoming shorter and shorter, therefore research is needed to improve the efficiency of wind noise transient calculation. This article summarizes 14 internal and external factors that affect the efficiency and accuracy of transient analysis of wind noise, and uses the ULH algorithm to design DOE for these 14 factors. A total of 200 efficiency improvement schemes are generated, and transient analysis is conducted on each of the 200 schemes. The simulation results and calculation time of wind noise inside the vehicle are statistically analyzed. And aerodynamic acoustic wind tunnel tests were conducted to verify this, with the optimization objectives of simulation values approaching 86.1 AI% (experimental values) and shortened calculation time. NSGA-II algorithm was used to optimize and obtain five sets of efficiency combination schemes that meet the requirements. Develop five appearance feature schemes for areas such as A-pillar and rearview
Li, Xiangliang, Zhang, Xiangdong, Liu, Xuelong, Wang, Haiyang, Huang, Zhongyuan
Optimizing Electric Vehicle Motor Testing with Fine Gaussian SVM and Bilayered Neural Network2025-28-039710/30/2025
Electric vehicles are shaping the future of the automotive industry, with the drive motor being a crucial component in their operation. Ensuring motor reliability requires rigorous testing using specialized test benches to validate key performance parameters. However, inefficiencies in the helical gear configuration within these test systems have led to frequent malfunctions, affecting production flow. This study focuses on optimizing the motor test bench by refining critical design parameters through vibration signal analysis and machine learning techniques. Vibrational data is collected under different gear configurations, utilizing an accelerometer integrated with a Data Acquisition (DAQ) system and MATLAB-based directives for seamless data collection. Machine learning classifiers, including Fine Gaussian SVM and Bilayered Neural Network, are applied to categorize signals into normal and faulty conditions, both with and without a 0.25 KW load. The analysis reveals that SVM achieves
S, Ravikumar, Sharik, N, Syed, Shaul, V, Muralidharan, D, Pradeep Kumar
A Guideline for Aerospace Platform Fiber Optic Training and Awareness EducationARP5602 (Current)10/23/2025
This document establishes training guidelines applicable to fiber optic safety training, technical training and fiber awareness for individuals involved in the manufacturing, installation, support, integration and testing of fiber optic systems. Applicable personnel include: Managers Engineers Technicians Logisticians Trainers/Instructors Third Party Maintenance Agencies Quality Assurance Shipping Receiving Production Purchasing
AS-3 Fiber Optics and Applied Photonics Committee
A Guideline for Aerospace Platform Fiber Optic Training and Awareness Education Introduction to Aerospace Fiber Optics Knowledge CompetenciesARP5602/1 (Current)10/23/2025
This document establishes training guidelines applicable to fiber optic safety training, technical training and fiber awareness for individuals involved in the manufacturing, installation, support, integration and testing of fiber optic systems. Applicable personnel include: Managers Engineers Technicians Logisticians Trainers/Instructors Third Party Maintenance Agencies Quality Assurance Shipping Receiving Production Purchasing
AS-3 Fiber Optics and Applied Photonics Committee
In-Service Fiber Optic Inspection, Evaluation, and Cleaning, Best Practices, Expanded Beam TerminiARP6283/1 (Current)10/23/2025
This document provides user information on best practice methods and processes for the in-service inspection, evaluation, and cleaning of expanded beam (EB) fiber optic interconnect components (termini, alignment sleeves, and connectors), test equipment, and test leads based on the information provided in AIR6031 and ARP6283. This document provides the user with a decision-making tool to determine if the fiber optic components are acceptable for operation with EB fiber optic termini.
AS-3 Fiber Optics and Applied Photonics Committee
A Guideline for Aerospace Platform Fiber Optic Training and Awareness Education Aerospace Fiber Optics Fabricator Knowledge CompetenciesARP5602/3 (Current)10/23/2025
This document establishes training guidelines applicable to fiber optic fabricator technical training for individuals involved in the manufacturing, installation, support, integration and testing of fiber optic systems. Applicable personnel include: Managers Engineers Technicians Trainers/Instructors Third Party Maintenance Agencies Quality Assurance Production
AS-3 Fiber Optics and Applied Photonics Committee
Rubber: Acrylonitrile-Butadiene Rubber (NBR) Fuel and Low Temperature Resistant 60 - 70 Type “A” Hardness For Seals in Fuel SystemsAMS7271K (Historical)10/22/2025
This specification covers an acrylonitrile-butadiene rubber in the form of molded rings, compression seals, O-ring cord, and molded-in-place gaskets for aeronautical and aerospace applications.
AMS CE Elastomers Committee
Research on Network Control System for Heavy Duty Trains Based on Laser + Ethernet2025-99-005110/17/2025
Trains traditionally transmit braking and mitigation commands through the air tube filling and exhausting method, which is easy to cause local large longitudinal impact. In order to meet the high-precision requirements of synchronous transmission of commands for heavy-duty trains with large groupings, this paper proposes a laser+industrial Ethernet network control system, which can meet the requirements of flexible train grouping and virtual connecting under the premise of ensuring synchronous transmission of commands for trains with large groupings. The system consists of central control unit, locomotive laser communication module, locomotive switch, mobile wireless communication terminal, security gateway, vehicle control unit, vehicle laser communication module, vehicle switch, etc. It is designed according to the three-layer architecture of vehicle-level network, train-level network and line-level network, which can realise the issuance of internal control commands and status
Meng, Xiangzhen, Li, Chuanhu, Zhu, Youlong
SAE TOMORROW TODAY - Introducing "TeleHealth" Video Chats For Car Repair1353810/10/2025
Have you every wished you could call up an experienced auto tech to diagnosis your car trouble? One company is doing just that by transforming the DIY auto repair experience. With nearly 1 million app downloads, Tinker DIY is the only platform that offers live video support with ASE-certified mechanics for auto repairs, rideshare inspections, and used car evaluations. Akin to "telehealth for your car," Tinker eliminates the need for YouTube guesswork or costly auto shop visits by guiding users through step-by-step auto repairs in real-time. Listen in as we sit down with authors Megan Han, Head of Operations, to discuss how Tinker helps connects users with expert guidance to help them diagnose and repair their vehicles on their own. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in mobility with the
Patterson, Lori
Effect of Flow Speed and Turbulence on Methane Combustion in a Rapid Compression Machine2025-01-039310/07/2025
Recent experimental work from the authors’ laboratory demonstrated that applying a boosted current ignition strategy under intensified flow conditions can significantly reduce combustion duration in a rapid compression machine (RCM). However, that study relied on spark anemometry, which provided only localized flow speed estimates and lacked full spatial resolution of velocity and turbulence near the spark gap. Additionally, the influence of turbulence on combustion behavior and performance across varying flow speeds and excess air ratios using a conventional transistor-controlled ignition (TCI) system was not thoroughly analyzed. In this study, non-reactive CFD simulations were used to estimate local flow and turbulent velocities near the spark gap for piston speeds ranging from 1.2 to 9.7 m/s. Simulated local velocities ranged from 0.7 to 96 m/s and were used to interpret experimentally observed combustion behavior under three excess air ratios (λ = 1.0, 1.4, and 1.6). Combustion was
Haider, Muhammad.Shaheer, Jin, Long, Yu, Xiao, Reader, Graham, Zheng, Ming
Influence on Electric Vehicle Performance by Reproduced Real-World Driving Wind on a Chassis Dynamometer2025-01-041010/07/2025
The latest electric vehicles (EVs) have advanced thermal management systems to regulate heat distribution across the vehicle, thereby improving the driving range. the author thinks that a key factor, which is influencing thermal performance during driving, is the effect of the driving-wind. However, EVs performance is evaluated by using a chassis dynamometer (CHDY), where it remains unclear whether the driving-wind specifications, which defined in the Worldwide Harmonized Light Vehicles Test Procedure (WLTP), adequately replicate real-world conditions. This study investigates both internal combustion engine vehicles and several electrical vehicles to estimate the potential discrepancies in WLTP’s driving wind requirements. Specifically, the author modified the CHDY vehicle-cooling fan to more accurately simulate wind speed at the front and underside of the vehicle under real-world driving conditions, which drove at outside road. The author analyzed the impact of these modifications
Okui, Nobunori
Simulation Study of Wheel Bearing Friction Losses at Vehicle Level2025-01-039910/07/2025
With the ongoing electrification of vehicles, components contributing a minor share of overall drivetrain losses are coming into focus. Analyzing these losses is crucial for enhancing the energy efficiency of modern vehicles and meeting the increasing demands for sustainability and extended driving range. These components include wheel bearings, whose friction losses are influenced by parameters such as temperature, mechanical loads, and mounting situation. Therefore, it is essential to analyze the resulting friction losses and their dependence on the mentioned influencing parameters at an early stage of development, both through test bench measurements and with the help of simulation models. To achieve these objectives, this submission presents a methodology that combines test bench measurements with a measurement-based simulation of the friction losses of wheel bearings occurring in the vehicle as a complete system under varying driving cycles and parameters. For this purpose, an
Hartmann, Lukas, Sturm, Axel, Henze, Roman, Notz, Fabian
Remaining Useful Life prediction of Engine Fuel System Using Machine Learning2025-01-037710/07/2025
Reliability and uptime are critical priorities in the automotive industry, prompting a shift toward predictive maintenance (PdM) to minimize unexpected failures and associated costs. This study presents a machine learning-based framework for early prediction of engine fuel system failures using embedded field performance data. This study introduces a machine learning-based framework for predicting failures and estimating the remaining useful life (RUL) of mid-range diesel engines with high-pressure common rail fuel systems in vehicles using classification and regression models applied to embedded field performance analysis data, aiming to enhance reliability and reduce unplanned downtime. Two classification models --- Random Forest and XGBoost top our model metrics chart. They were further tuned and evaluated, with XGBoost achieving superior performance, including 94% accuracy and 87% precision, and a low false positive rate of 0.01, enabling an 8-day lead time for proactive
Wang, Tingting, Goswami, Anil, Akinola, Michael, Yang, Tina, An, Qi
Bridging Fundamental Combustion Analysis and Engine Knock Behavior -1st Report, CFR Engine Test for Various RON Fuels2025-01-039110/07/2025
A collaborative study was conducted to bridge the gap between fundamental combustion research and engine-scale observations of knock in spark-ignition (SI) engines. Using Primary Reference Fuels (PRFs) with Research Octane Numbers (RON) of 80, 90, and 100, experiments were carried out with a Cooperative Fuel Research (CFR) engine at air-fuel ratio, λ = 1.0, focusing on knock onset conditions in terms of unburned gas pressure and temperature. In the engine tests, pressure traces under knocking conditions were analyzed to identify knock onset and to estimate the corresponding unburned gas temperature history. Results showed that the pressure at knock onset varies clearly with PRF value: higher RON fuels exhibited knock onset at higher pressures, likely due to changes in compression ratio applied to match standard RON test procedures. In contrast, the unburned gas temperature conditions showed partial overlap across different PRFs, but with a tendency for higher RON fuels to experience
Yasutake, Yuki, Misono, Katsuhiro, Suzuki, Yoshikatu, Naiki, Taketora, Watanabe, Manabu, Moriyama, Hinata, Morii, Youhi, Tsunoda, Akira, Maruta, Kaoru
Comparative Evaluation of Energy Efficiency and Performance of Electric and Counterpart Diesel Tractors2025-01-041710/07/2025
The objective of this trial was to compare the energy efficiency and performance of battery electric and conventional diesel tractors. Controlled road tests replicating normal operations were conducted using two electric and two diesel day-cab tractors. The test protocol was based on the TMC - Type III RP 1103A and SAE J1526 test procedures. The tests were conducted on a 110 km long route that included a 59 km hilly portion with a maximum altitude difference of 307 m. The tractors were divided into test groups of two vehicles. Trailers and drivers were switched throughout the trial between the tractors in a test group. The tests found that the two electric trucks consumed 60% and 63% less energy than their counterpart diesel trucks, respectively. Considering the average emission factor for production of electricity in Canada, the electric trucks emitted on average 82% less GHG emissions than the conventional diesel-powered tractors. The two diesel trucks showed similar fuel consumption
Surcel, Marius-Dorin, Partington, Mark, Tanguay-Laflèche, Maxime, Schumacher, Richard
Development of an SSP-180 Synchronizer Durability Test2025-01-040810/07/2025
Synchronizers are designed to provide smooth, efficient and safe transfer of torque between mechanical gears. Friction level, durability, and consistency of the fluid / friction lining system are crucial to ensuring crisp gear engagements without clashing and noise, vibration and/or harshness (NVH) for the life of the transmission. Excellent wear control of gears, synchronizer ring and cone surfaces is also critical to protecting the life of moving mechanical parts. The SSP-180 synchronizer rig measures friction durability and wear up to 100,000 engagements, using a variety of fluids and friction materials. Methodology for the development of a synchronizer durability procedure using the SSP-180 rig is presented for qualifying fluids for dry dual clutch (DCT) and manual transmission (MT) applications for General Motors. It will be shown that the new DEXRON® SSP-180 Synchronizer Durability Test in Appendix C of the GMW 16612 fluid specification [1] satisfies four key conditions for new
Glasgow, Michael B., Zreik, Khaled, Ezanno, Philippe Nicolas, Shelton, Robert W.
Derating as Thermal Protection for LED-Based Lighting Applications2025-01-506610/03/2025
This paper investigates the concept of derating in light-emitting diode (LED)–based automotive lighting systems, emphasizing its role in enhancing LED longevity, performance, and reliability under varying operating conditions. Derating is introduced from a general perspective and is modeled as an approximately linear function of the driving current with respect to the temperature measured by a negative temperature coefficient thermistor (NTC). The NTC serves as a temperature probe in this context. We demonstrate that poorly designed derating strategies can negatively impact luminous flux, lifespan, and overall system reliability. These theoretical insights are applied to a simplified lighting system, which is analyzed using both steady-state and transient computational fluid dynamics (CFD) simulations to illustrate the practical effects. It is shown that the distance between the NTC and the temperature-critical region primarily determines the slope of the derating curve, while having
Stahlbaum, Ruben
Nadcap at 35: Still Defining Excellence in Aviation, Defense and Space Manufacturing25AERP10_0110/01/2025
Celebrating its 35th year, the National Aerospace Defense Contractors Accreditation Program (Nadcap) continues to advance quality assurance and regulatory compliance for aviation, defense, and space OEMs and suppliers. This article summarizes how Nadcap accreditation works, its benefits for manufacturers, and its role in expanding additive manufacturing through industry-wide consensus. The Nadcap program was first established in 1990 by a small group of aerospace and defense OEMs. Their goal was to create an accreditation initiative that provides a common approach to auditing the manufacturing and production processes used by companies supplying parts, components, structures, and services to major aerospace and defense OEMs. This foundation set the stage for Nadcap's continued focus on quality assurance and regulatory compliance in the industry.
Improving the Performance of Asphalt Paver Machine Based on the Experiment Analysis and Control of Excitation Forces02-19-02-000809/30/2025
The excitation forces of the tamper pairs in the vibrational screed system not only affect the road density but also affect the road surface quality. Thus, to enhance the performance of the asphalt paver machine, an experimental study of an asphalt paver machine is carried out to evaluate in detail the effect of the excitation frequencies of the tamper pairs and vibrator screed on the density and quality of the road surface. From the actual structure of the vibrational screed system of the asphalt paver machine used in the experiment, its mathematical model is then built to calculate the vibration equations. The fuzzy controller is then applied to control the deflection angles between the tamper pairs to enhance the working performance of the vibrational screed system. The study result shows that both the excitation frequencies of the tamper pairs (ftp ) and vibrator screed (fvs ) greatly affect the density and quality of the road surface. To increase the compression density of the
Song, Fengxiang, Ren, Shage, Nguyen, Vanliem
Analyzing and Simulating Energy Consumption of Battery Electric Transit Buses in Real-Driving Conditions02-19-02-000709/29/2025
Analyzing and accurately estimating the energy consumption of battery electric buses (BEBs) is essential as it directly impacts battery aging. As fleet electrification of transit agencies (TAs) is on the rise, they must take into account battery aging, since the battery accounts for nearly a quarter of the total bus cost. Understanding the strain placed on batteries during day-to-day operations will allow TAs to implement best-use practices, continue successful fleet electrification, and prolong battery life. The main objective of this research is to estimate and analyze the energy consumption of BEBs based on ambient conditions, geographical location, and driver behavior. This article presents a model for estimating the battery energy consumption of BEBs, which is validated using the data on federal transit bus performance tests performed by Penn State University and experimental aggregated trip data provided by the Central Ohio Transit Authority (COTA). The developed simulator aims
Shiledar, Ankur, Shanker, Anirudh, Pulvirenti, Luca, Di Luca, Giuseppe, Akintade, Rebeccah, Rizzoni, Giorgio
Tungsten Carbide-Cobalt PowderAMS7879G (Current)09/18/2025
This specification covers tungsten carbide-cobalt in the form of powder.
AMS F Corrosion and Heat Resistant Alloys Committee
MIL-STD-3072: High Voltage for Army Ground Vehicles2025-01-050309/16/2025
The publishing of MIL-STD-3072 is critical to the Army’s introduction of electrified vehicles. It is the first of three documents to replace MIL-PRF-GCS600A, a performance specification that is loosely referenced by engineers but lacks necessary details. MIL-STD-3072 defines the characteristics of 600 VDC electric power that will be supplied to utilization equipment. Following this release, MIL-HDBK-3072 will provide suggested test methods for compliance with the standard, and MIL-PRF-3072 will provide generic device specifications for interfaces, control, and safety. Together, these three documents define a set of requirements that vehicles and equipment with 600 VDC electrical systems must operate within.
Haynes, Aric, Spina, Jason, Best, Melissa
Impact of External Audio on Driving Task Performance in Simulated under Armor Environments2025-01-047109/16/2025
As part of technology maturation efforts, the COAT Lab evaluated the impact of external audio on driving performance in simulated under amor environments. To do so, we conducted an Engineering Evaluation Test (EET) wherein participants were asked to drive a simulated military vehicle through a Slalom course (primary task) while monitoring for aerial threats (secondary task). Using a combination of objective and subjective metrics, this evaluation quantified participants’ ability to maneuver and detect threats while using external audio as an enabling technology. Evaluation results indicated external audio positively benefited driving performance and situation awareness. However, evaluation results also indicated that external audio was not sufficient in and of itself for detecting time-sensitive aerial threats. Together, these results suggest a development path forward in which external audio is combined with visual information to enhance crew situation awareness under armor.
Grant, Lauren, Shrestha, Sumit, Hoffing, Russell Cohen
Validating Modular Applications in the FACE and GCIA Architectures2025-01-047609/16/2025
Ground vehicle software continues to increase in cost and complexity, in part driven by tightly integrated systems and vendor lock-in. One method of reducing costs is reuse and portability, encouraged by the Modular Open Systems Approach and the Future Airborne Capability Environment (FACE) architecture. While FACE provides a Conformance Testing Suite to ensure portability between compliant systems, it does not verify that components correctly implement standard interfaces and desired functionality. This paper presents a layered test methodology designed to ensure that a FACE component correctly implements working communication interfaces, correctly handles the full range of data the component is expected to manage, and correctly performs all of the functionality the component is required to perform. This testing methodology includes unit testing of individual components, integration testing across multiple units, and full hardware in the loop system integration testing, offering a
Lingg, Michael, Paul, Howard, Sullivan, Kyle, VanSolkema, William
Revolutionizing Government Efficiency: Harnessing Commercial Off-the-Shelf Generative Artificial Intelligence Solutions for Enhanced Services and Decision-Making2025-01-048709/16/2025
This paper introduces a secure and cost-effective framework for integrating Commercial Off-the-Shelf (COTS) Generative Artificial Intelligence (GenAI) technology into government enterprise solutions. It explores key aspects of GenAI, emphasizing its transformative role in enhancing efficiency and decision-making within government operations. Central to the discussion is a GenAI Feasibility Study [1] conducted by Booz Allen for the Director, Operational Test & Evaluation (DOT&E), which outlines the development of the AI-Enabled Test & Evaluation Module (ATEM) GenAI Knowledge Assistant. The paper also examines critical factors for successful implementation, including use case definition, model selection, data quality, and prompt engineering.
Vandrovec, Bryan, Kruger, John, Birr, Calvin, Mazzara, Mark, Mossy, Glenn, Himmel, Max, Barnhart, James, Senger, Jeff
Foggy Windows: Predicting and Avoiding the Fleet’s Most Frustrating Failure2025-01-048909/16/2025
Delamination of transparent armor (TA) is one of the costliest and most frustrating failures facing the tactical vehicle community. When purchased, all TA appears equally pristine and has identical protective abilities, but some parts delaminate after only a few years while other parts last over a decade. Recent high delamination rates have resulted in large costs – a Warstopper study showed that transparent armor accounted for 20% of the maintenance cost for the HMMWV. One major advance in the last few years has been the Army-led development of an ‘Accelerated Life Test’ which consistently causes field relevant delamination in transparent armor parts. We present the development of a method to correlate test results with field life, thus allowing for life prediction and life cycle cost analysis. We demonstrate how the life prediction tool can be used to drive purchasing strategies, field use decisions, and vehicle design.
Merrill, Marriner H., Magner, Matthew J., Key, Christopher T., Humphrey, Barry A.
Military Battery Tester Development Using MBSE and Digital Twins2025-01-044409/16/2025
This paper presents a model-based systems engineering (MBSE) and digital twin approach for a military 6T battery tester. A digital twin architecture (encompassing product, process, and equipment twins) is integrated with AI-driven analytics to enhance battery defect detection, provide predictive diagnostics, and improve testing efficiency. The 6T battery tester’s MBSE design employs comprehensive SysML models to ensure traceability and robust system integration. Initial key contributions include early identification of battery faults via impedance-based sensing and machine learning, real-time state-of-health tracking through a synchronized virtual battery model, and streamlined test automation. Results indicate the proposed MBSE/digital twin solution can detect degradation indicators (e.g. capacity fade, rising internal impedance) earlier than traditional methods, enabling proactive maintenance and improved operational readiness. This approach offers a reliable, efficient testing
Sandoval, Roman
Enhanced Object Matching and Identification for Multi-Robot Systems in Complex Environments2025-01-043809/16/2025
Our research focuses on developing a novel loss function that significantly improves object matching accuracy in multi-robot systems, a critical capability for Safety, Security, and Rescue Robotics (SSRR) applications. By enhancing the consistency and reliability of object identification across multiple viewpoints, our approach ensures a comprehensive understanding of environments with complex layouts and interlinked infrastructure components. We utilize ZED 2i cameras to capture diverse scenarios, demonstrating that our proposed loss function, inspired by the DETR framework, outperforms traditional methods in both accuracy and efficiency. The function’s ability to adapt to dynamic and high-risk environments, such as disaster response and critical infrastructure inspection, is further validated through extensive experiments, showing superior performance in real-time decision-making and operational effectiveness. This work not only advances the state of the art in SSRR but also
Brown, Taylor J., Vincent, Grace, Nakamoto, Kyle, Bhattacharya, Sambit
Enhancing Robustness of Electro-Hydraulic Brake-by-Wire Actuators via Linear Active Disturbance Rejection Control2025-01-034109/15/2025
In recent years, motorsport has increasingly focused on environmental concerns, leading to the rise of hybrid and fully electric competitions. In this scenario, electric motors and batteries take a crucial role in reducing the environmental impact by recovering energy during braking. However, due to inherent limitations, motors and battery cannot fully capture all braking power, necessitating the use of standard friction brakes. To achieve an efficient balance between electric motors and friction brakes, the brake pressure can no longer be directly controlled by the driver. Instead, it must be computed by the Vehicle Control Unit (VCU) and sent to a smart actuator, i.e. the Brake-By-Wire (BBW), which ensures that the required pressure is applied. The standard approach to achieve precise pressure control is to design a nested Proportional-Integral-Derivative (PID) control architecture, which requires an accurate nominal model of the system dynamics to meet the desired tracking
Gimondi, Alex, Dubbini, Alberto, Riva, Giorgio, Cantoni, Carlo
A Novel Simulation Method for Vehicle Brake Wear Emissions2025-01-036109/15/2025
The effective reduction of particulate emissions from modern vehicles has shifted the focus toward emissions from tire wear, brake wear, road surface wear, and re-suspended particulate emissions. To meet future EU air quality standards and even stricter WHO targets for PM2.5, a reduction in non-exhaust particulate (NEP) emissions seems to be essential. For this reason, the EURO 7 emissions regulation contains limits for PM and PN emissions from brakes and tire abrasion. Graz University of Technology develops test methods, simulation tools and evaluates technologies for the reduction of brake wear particles and is involved in and leads several international research projects on this topic. The results are applied in emission models such as HBEFA (Handbook on Emission Factors). In this paper, we present our brake emission simulation approach, which calculates the power at the wheels and mechanical brakes, as well as corresponding rotational speeds for vehicles using longitudinal dynamics
Landl, Lukas, Ketan, Enis, Hausberger, Stefan, Dippold, Martin
A Study on the Prediction Method of Durability Characteristics of Brake Judder Using Simulation2025-01-034609/15/2025
In order to predict the durability characteristics of the brake judder, it is determined by analyzing the brake DTV (Disc Thickness Variation) and BTV(Brake Torque Variation) through the durability evaluation of the brake system or the vehicle. However, this method requires the real products and takes a long time to derive the result. When judder problems occur due to durability, there are many difficulties in deriving improvement plans through test methods. Therefore, in this study, CAE was used to derive the initial wear amount of the disc, and a method of predicting DTV after durability was developed using the results.
Hwang, Jaekeun, Kim, Sungho, Kim, Jeongkyu, Kang, Donghoon
Brake System Homologation: A Holistic, Simulation-Based Approach2025-01-035109/15/2025
With the introduction of the Euro 7 regulation, non-exhaust emissions – particularly those arising from brake and tire abrasion – will be regulated and subject to emission limits for the first time. This presents significant challenges not only for OEMs striving to meet these targets within the given timeframe, but also for suppliers, who must develop innovative solutions for the precise measurement, analysis, and mitigation of these emissions. To address this, it is essential to establish and industrialize new testing methodologies as structured, scalable, and cost-efficient processes. Beyond pure measurement capability, service providers in this domain are increasingly expected to serve as feedback mechanisms – identifying process limitations, proposing targeted improvements, and thereby enabling continuous development in line with evolving technical and regulatory requirements. In this context, AVL is pursuing a holistic development strategy that integrates brake emission
Grojer, Bernd
Analysis of Front Axle Wheel End Temperature Measurements in Heavy-Duty Trucks2025-01-036409/15/2025
The Front Axle wheel end assembly is a critical component of Vehicle functionality, comprising a wheel hub positioned to rotate smoothly on an Axle spindle. This rotational movement is enabled by bearings positioned between the hub and the spindle, allowing for frictionless rotation. The Front Axle wheel ends’ temperature typically depends on several factors such as type of Vehicle, Load & driving conditions and health of the components involved. In general, the wheel ends can become warm during normal operation owing to friction generated by the rotation of the wheels and the interaction of various mechanical components such as Bearings and Brakes. However, if the temperature of the wheel ends becomes excessively hot, it could indicate potential issues such as Overheating brakes, Wheel bearing problems, improperly inflated tyres, and faulty components. As temperature rise, materials tend to expand. This expansion can affect the dimensions of critical components in the Front Axle wheel
Pandiyan, Mahendran, Jayaraman, Karthik, R, Sabari, B, Ellavarasan, Bhanja, Subrat Kumar
Development of a Laboratory Brake for a Flywheel Mass Test Rig for Variable Pad Sizes and Shapes with a Force Distribution Unit for Ideal Contact Pressure and a Topography Measurement System for In-Situ Recording of Surface Changes and Wear2025-01-033109/15/2025
Pin-on-disk tribometers are used to determine the frictional behaviour and boundary layer dynamics of material pairings. Material pairings are examined under defined conditions in order to reason about the friction behaviour and wear. Pairings for real brake systems with larger pad sizes can be tested on flywheel mass test rigs in order to provide proof of suitability. This is mainly due to a lack of knowledge about the scaling behaviour of friction linings. The Department of Machinery System Design at TU Berlin has combined the classic approach of a pin-on-disk tribometer with a flywheel mass test rig (up to 12.78 kgm2) and thus set up a laboratory brake on which material pairings with different pad shapes and sizes (up to 48 cm2) can be examined. The flywheel mass test rig consists of an adjustable DC-motor that drives a shaft on which variable flywheel masses and brake disks can be installed. The variability allows for different kinetic energies at different friction speeds. The
Heuser, Robert Michael, Rosenthal, Tobias Richard, Wiest, Daniel Christian, Meyer, Henning Jürgen
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