Browse Topic: Tests and Testing

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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
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
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
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
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
Simulation of Grade Sensors for Truck Transmission Controllers (Off Highway Application)2025-28-0265To be published on 11/06/2025
The use of 3-axis industrial accelerometers in transmission controllers is prevalent in off-road vehicle applications. To evaluate the performance of heavy vehicles on various grades, simulation is essential prior to actual vehicle testing. This study proposes simulating the grade sensor integrated into the transmission controller using SPI communication and 3-axis industrial accelerometer models on an FPGA. The 3-axis industrial accelerometer, a sensor utilized in truck applications, identifies the x-y-z position and determines the gradient. This sensor is part of the vehicle's transmission controller, which is mounted on the transmission controller PCB. As the vehicle moves and tilts, the sensor calculates the vehicle's gradient. To test software functionality across multiple grades, the ECU typically needs to be physically moved to various grades on vehicle test tracks with different gradients. This proposal aims to replicate test track grades in a lab setting using a Hardware-in
Bhade, Nilesh, Kulkarni, Pallavi
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
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 Analysis2025-28-0380To be published on 10/30/2025
Electric two-wheeler testing before they are introduced in the market is one of the essential feature 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
Design & Validation of High-Altitude Test Rig for ATS & component level testing2025-28-0367To be published on 10/30/2025
New regulation standards on engine pollutant emissions are widening the engine operating conditions subjected to type approval tests to prevent from the gap between regulated and real-driving emissions. In this regard, ambient temperature and driving altitude are new boundaries to be considered. Although the basis of the impact of these variables has been studied concerning the engine performance, new challenges appear to meet the emission limits and the aftertreatment conversion efficiency. When operating at high altitude (up to 6000 ft) in a wide range of ambient temperature (range -5° C to 50°C), Particular focus is put on the modelling of the DEF Dosing. Starting from a sea-level calibration, the proposed methodology accounts for mechanical criteria as well as the impact on the engine raw emissions and exhaust flow properties to define new calibration setting for altitude operation. The paper focuses on developing an altitude rig to simulate the test conditions and helps enable
Rath, Jagannath Prasad, Varpe, Pradnya, Magar, Vijay, JAHAGIRDAR, RADHIKA
Optimizing Electric Vehicle Motor Testing with Fine Gaussian SVM and Bilayered Neural Network.2025-28-0397To be published on 10/30/2025
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 a 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
S, Ravikumar, Sharik, N, Syed, Shaul, V, Muralidharan, D, Pradeep Kumar
Influence on Electric Vehicle Performance by Reproduced Real-world Driving Wind on Chassis Dynamometer2025-01-0410To be published on 10/07/2025
The latest electric vehicles (EVs) incorporate advanced thermal management systems to regulate heat distribution throughout the vehicle, thereby improving driving range. A key factor influencing thermal performance is the effect of driving wind during motion. However, evaluations of EV performance are often conducted using a chassis dynamometer (CHDY), where it remains unclear whether the driving wind specifications defined in the current Worldwide Harmonized Light Vehicles Test Procedure (WLTP) framework adequately replicate real-world conditions. This study investigates the vehicle performance of both internal combustion engine vehicles and EVs to verify the wind requirements of the WLTP. Specifically, we simulated the wind speed at the front and underside of the vehicle under real-world driving conditions, and modified the vehicle-cooling fan of the CHDY. We analyzed the impact of these modifications, and we discussed the future considerations for refining the driving wind
Okui, Nobunori
Simulation study of wheel bearing friction losses at vehicle level2025-01-0399To be published on 10/07/2025
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
Comparative Evaluation of Energy Efficiency and Performance of Electric and Counterpart Diesel Tractors2025-01-0417To be published on 10/07/2025
The objective of this trial was to compare the energy efficiency and performance of battery electric against 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 61% and 64% less energy than their counterpart diesel trucks, respectively. Considering the production mode 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 virtually identical fuel consumption and
Surcel, Marius-Dorin, Partington, Mark, Tanguay-Laflèche, Maxime, Schumacher, Richard
Development of an SSP-180 Synchronizer Durability Test2025-01-0408To be published on 10/07/2025
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 SSP-180 Synchronizer Durability Test in Appendix C of the dDCT fluid specification [1] satisfies four key conditions for new mechanical
Glasgow, Michael B., Zreik, Khaled, Ezanno, Philippe Nicolas, Shelton, Robert W.
Analysis of Front Axle Wheel End Temperature Measurements in Heavy-Duty Trucks2025-01-0364To be published on 09/15/2025
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
Brake System Homologation: A Holistic, Simulation-Based Approach2025-01-0351To be published on 09/15/2025
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
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 Wear2025-01-0331To be published on 09/15/2025
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
A Novel Simulation Method for Vehicle Brake Wear Emissions2025-01-0361To be published on 09/15/2025
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 Simulation2025-01-0346To be published on 09/15/2025
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
Enhancing Robustness of Electro-Hydraulic Brake-by-Wire Actuators via Linear Active Disturbance Rejection Control2025-01-0341To be published on 09/15/2025
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
Impacts of Hydrotreated Vegetable Oil as Renewable Diesel Fuel on Engine Performance and Emissions in a Heavy-Duty Diesel Engine03-18-06-003509/08/2025
As the pressure increases to move to renewable carbon-neutral fuel sources, especially in heavy-duty diesel engine applications, hydrotreated vegetable oil (HVO) has shown to be an attractive alternative fuel to fossil diesel. Therefore, this study investigated the impacts of HVO used as a drop-in fuel on performance and emissions of a nonroad heavy-duty diesel engine by running back-to-back D2 ISO 8178 cycles with ultra-low sulfur diesel (ULSD) and HVO. The measurement results showed that brake specific fuel consumption with respect to mass reduced by 1.1%–3.6% switching from ULSD to HVO due to greater heating values of HVO, which is supported by 0.7%–3.5% lower CO2 emissions recorded with HVO. Conversely, brake specific fuel consumption with respect to volume increased by 0.3%–2.9% with HVO because of its smaller density. Combustion analysis revealed that combustion of both fuels is comparable at high loads while HVO ignites earlier at low power. Thus, lesser reductions in NOx
Duva, Berk Can, Abat, Bryan, Engelhardt, Jens
Numerical and Experimental Investigation of a Pre-Chamber Igniter for Enhanced Low Load Stability in Internal Combustion Engines2025-24-000209/07/2025
Developing innovative ignition technologies offers a crucial opportunity to improve the performance of internal combustion engines while significantly reducing harmful emissions, contributing to a more sustainable future. The replacement of the standard spark plug with a pre-chamber igniter is a well-known combustion accelerator for externally ignited engines for passenger vehicles. An increase in engine efficiency, especially at high loads, can be realized. However, pre-chamber ignition technology has not yet been widely adopted in the market, primarily due to the difficulty of achieving stable operation at lower engine loads. A better understanding of the flow and mixture conditions is needed to improve the combustion stability with the pre-chamber igniter in low-load operating conditions. The gas exchange in the passive pre-chamber was studied using a combination of numerical modelling and experimental methods. Accessing those parameters experimentally requires a high effort in test
Fellner, Felix, Härtl, Martin, Jaensch, Malte, D'Elia, Matteo, Burgo Beiro, Marcos, Nambully, Suresh Kumar, Rothbauer, Rainer
Design of a High-Speed Pure Synchro-Reluctant Machine with Asymmetrical Poles for Automotive Applications2025-24-012909/07/2025
In this article, the authors present the various choices made to design a magnet free and directly recyclable pure synchro-reluctant (Pure-SynRel) machine with asymmetrical poles operating at a maximum speed of ~21,000 rpm dedicated to automotive. This project focused on identifying design levers and optimizing the magnetic circuit to address three well-known challenges of this topology that limit its application as an automotive traction machine. These challenges include: maximizing the power factor to reduce inverter rating and cost, minimizing sources of NVH (noise, vibration, and harshness) and torque ripples, and ultimately maximizing efficiency to bridge the performance gap with magnet-based technologies (PMaSynRel). The sizing of stator components—such as the choice of winding (concentric or distributed, full or fractional pitch, round or hairpin wire)—and rotor components (e.g., the number of pole pairs, shape, and number of barriers) are explained. Additionally, the
Applagnat-Tartet, Antoine, Milosavljevic, Misa, Delpit, Pierre
Method to Analyze Driving Dynamics during Faults in the Electric Drivetrain on a Vehicle-in-the-Loop Test Bench2025-24-012309/07/2025
The mechanical components of drive systems for electric vehicles are less complex than those of conventional drives and are therefore generally less prone to faults. On the other hand, a challenge lies in the relatively limited experience in dealing with faults in the electric drivetrain and their effects on driving dynamics compared to conventional drives. To meet these challenges, this paper presents a method to simulate faults in the electric powertrain of a real demonstrator vehicle on a full vehicle test bench and to evaluate the influence on driving dynamics. For this purpose, the demonstrator vehicle was modeled in detail in a co-simulation between the driving dynamics simulation software CarMaker and the real-time solution for simulating and testing electrical components Typhoon HIL. This enabled the investigation of the vehicle’s behavior in the event of a fault. Subsequently, tests with the vehicle were performed on the Vehicle-in-the-Loop full vehicle test bench and the
Rautenberg, Philip, Konzept, Anja, Hitz, Arne, Frey, Michael, Reick, Benedikt
A Novel Nozzle Orifice Design of a Heavy-Duty Diesel Engine to Achieve Higher Thermal Efficiency with Significantly Reduced Heat Loss2025-24-003709/07/2025
This study investigated a novel nozzle orifice design to improve thermal efficiency. The offset orifice nozzle has holes drilled offset of less than 0.5 mm from the radial center of the nozzle. Engine performance test and in-cylinder combustion observation were carried out by means of a heavy-duty diesel engine. The experimental results demonstrated that the offset orifice nozzle achieved significant improvements in both heat loss and thermal efficiency, regardless of the compression ratio and operating load conditions. However, the underlying mechanisms have not been revealed yet. Therefore, investigation into the mechanisms behind heat loss reduction and thermal efficiency improvements with the offset orifice geometry is the purpose for establishing design guidelines for optimization. It was revealed by the combustion visualization that the flame tip length of the offset orifice nozzle was shortened with significantly wider flame cone angle from very close to the orifice exit even
Mukayama, Tomoyuki, Uchida, Noboru
Investigation of the Combustion Process of a Thermally Conditioned Active Prechamber in Monovalent Operation with Ammonia2025-24-002809/07/2025
The debate over synthetic fuels is intense especially in sectors with a high energy demand like maritime [1, 2]. Hydrogen production from renewable sources is growing, but immediate measures for decarbonization are needed [3, 4]. In this context, the project MethMag was funded, and a gas engine for methane combustion with an innovative cooling concept and a purged prechamber (PC) spark plug was virtually developed [5, 6]. Validation with data from the test bench demonstrates that the simulations accurately represent the operating conditions [7, 8]. This combustion process is adapted for ammonia, which is being considered as a climate-friendly fuel of the future, particularly in maritime transportation [4, 9]. This fuel faces significant combustion challenges and is therefore mostly considered in complex, bivalent systems [10]. In particular, the prechamber is examined regarding the ignitability of ammonia. The overarching objective is to eliminate the necessity for a secondary fuel
Rothe, Paul, Bikas, Georgios, Mauss, Fabian
DLR Tire and Road Wear Particle Emission Testing Methodology–Collection System Influence and Repeatability Assessments2025-24-009209/07/2025
Tire and road wear particles (TRWP) have emerged as air quality hazardous matters and significant sources of airborne microplastic pollution, contributing to environmental and human health concerns. Regulatory initiatives, such as the Euro 7 standards, emphasize the urgent need for standardized methodologies to quantify TRWP emissions accurately. Despite advancements in measuring tire abrasion rates, critical gaps persist in the characterization of airborne TRWP, particularly regarding the influence of collection system design and influencing parameters on measurement accuracy and repeatability. This study addresses these challenges by designing a controlled methodological framework that aims to minimize the influencing effects and ensure comparability in TRWP emission quantification results. At the German Aerospace Center (DLR) dynamometer testbench in Stuttgart, Germany, a methodical framework was established to ensure the repeatability and comparability of TRWP measurements
Celenlioglu, Melis Seren, Epple, Fabius, Reijrink, Nina, Löber, Manuel, Reiland, Sven, Vecchi, Roberta, Philipps, Franz
Simulation of Swirl and Discharge Coefficient Trade-off for Diesel Engine Intake Ports2025-24-000709/07/2025
In Diesel engines, charge motion usually consists of swirl and squish flow patterns. Traditionally, swirl generation is controlled through the design of the intake ports, presenting a trade-off between swirl and mass flow rate. An alternative approach to generate swirl is to use vortex-generating jets in the intake port. As a comparative basis for this approach a Pareto front was established between swirl and mass flow rate based solely on geometric variations. A new fully parametric geometry was deployed, with two intake ports per cylinder adhering to some constraints. Stationary flow-bench test setup was modeled, where a blower draws air through the intake ports at a constant pressure difference. The Pareto front was generated using semi-randomly selected geometries in combination with automated unsteady RANS (URANS) simulations, while scale adaptive simulations (SAS) were also employed on select geometries. These turbulence modeling approaches were explored using the OpenFOAM
Kahraman, Ali Berk, Ritter, Johann, Eilts, Peter, Scholz, Peter
Optimum Design and Sizing Approach for a Series-Hybrid Vehicle2025-24-009909/07/2025
The need to reduce pollutant emissions has pushed the automotive industry towards sustainable mobility promoting new technological solutions, among which the use of hybrid powertrains stands out. The development of a hybrid architecture is very complex and demands proper components sizing and the determination of optimized power-split strategies among different power sources, for example: Internal Combustion Engine (ICE), electric generator/motor and batteries. Moreover, the experimental analysis regarding performance and emissions requires that the whole propulsive system must be set up on the test bench, hence, negatively affecting the cost of the entire design phase. In this scenario, an optimum design and sizing approach for a series-hybrid electric vehicle (S-HEV) is proposed aiming at a design cost reduction. The presented procedure relies on numerical modelling of the hybrid powertrain and on the optimization of the fuel consumption and the driving range. The series-hybrid
Lisi, Leonardo, Saponaro, Gianmarco, Episcopo, Domenico, Torresi, Marco, Camporeale, Sergio Mario
Model-Based Optimization of Diesel/OMEx Fuelled CI Engine under Multiple Blending Conditions2025-24-003809/07/2025
The search for alternative solutions for vehicle electrification, while reducing the carbon footprint during the transition to green mobility, leads to the investigation of electro-fuels (e-fuels) in conventional internal combustion engines. Leveraging previous research, the present study focuses on the optimisation of a Compression Ignition (CI) engine combustion control in response to the use of the Oxymethylene Dimethyl Ethers (OMEx) blended with conventional diesel. The selected e-fuel is the OME3, which is expected to be used as a drop-in solution and to easily achieve a reduction in soot emissions due to both its high oxygen content and lack of direct carbon bonds in its molecular structure. To verify its potential, a 1D single-cylinder CI multi-zone engine model has been exploited to simulate various diesel/OME3 blends in a wide engine operating range. The first step deals with the evaluation of performance and emissions to demonstrate the differences, particularly in terms of
Foglia, Antonio, Cervone, Davide, Frasci, Emmanuele, Arsie, Ivan, Polverino, Pierpaolo, Pianese, Cesare
AeroSolfd: Advancing Air Quality through Retrofitted Gasoline Particulate Filters – Insights from Laboratory and Real-World Evaluations2025-24-008809/07/2025
This article details the experimental and testing activities of the EU project AeroSolfd, with a particular focus on the project's efforts to reduce combustion-based nanoparticle emissions in exhaust gases for the European fleet of vehicles by developing a GPF retrofit solution. The technical activities undertaken the process of developing such a retrofit are examined in this article. The findings illustrate the viability of reducing nanoparticle levels in gasoline-powered vehicles with the utilization of appropriate GPFs. For this purpose, in addition to a fleet, four vehicles were examined in great detail and underwent the process of obtaining component approval for the particulate filter. The vehicles were measured in a preliminary state, then following the installation of the GPF, and subsequently after several months of continuous field operation. A total of four vehicles were selected for evaluation as a representative subgroup of a larger test fleet of vehicles in the project
Engelmann, Danilo, Mayer, Andreas, Comte, Pierre, Rubino, Lauretta, Larsen, Lars
Visualization Analysis of Hydrogen Combustion Triggered by Non-Controlled Hotspots Using a Rapid Compression Expansion Machine2025-24-004709/07/2025
Research on hydrogen-fueled internal combustion engines has gained growing attention as a carbon-neutral solution to reducing emissions in the transport sector. However, challenges remain, with the risk of abnormal combustion being one of the major criticalities. This paper aims to clarify the ignition process of a hydrogen-air mixture caused by lubricant oil droplets and soot deposition. To achieve this, high-speed imaging methods were applied with a Rapid Compression Expansion Machine under engine-like conditions. Direct imaging and OH* chemiluminescence were captured simultaneously on the engine head to visualize the ignition point and flame propagation. Different operating conditions were tested to evaluate the influence of lambda, intake pressure, and soot quantity on ignition occurrence. For each test bench configuration, ten successive tests were conducted to assess the probability of ignition. The presence of soot was ensured through a preliminary run with diesel injection. The
Tempesti, Claretta, Yukitani, Takumi, Horibe, Naoto, Romani, Luca, Ferrara, Giovanni, Kawanabe, Hiroshi
Experimental Analysis and Model-Based Characterization of the Toyota Mirai II’s Electric Machine2025-24-013609/07/2025
The electrification of the transportation sector relies on extensive research and data availability to accelerate technological advancements. However, for certain key components such as electric machines, detailed operational information remains scarce, which in turn limits the development of accurate system-level models for electrified powertrains. As a contribution to addressing this challenge, this study presents an experimental benchmark of the electric machine in the second-generation Toyota Mirai, a fuel cell hybrid electric vehicle (FCHEV) featuring a variable DC voltage bus, which was tested on a roller test bench. The proposed methodology aims to characterize the electric machine with minimal instrumentation and prior knowledge of the machine’s configuration, by identifying electrical and geometric parameters that are relevant for a steady-state model of the machine, applicable to system-level studies, with the objective of providing a methodology that can be used in future
Carlos Da Silva, Daniel, Kefsi, Laid, Sciarretta, Antonio
Innovative Full-GaN Inverter Development for 800V/100kW Automotive Applications2025-24-013309/07/2025
In the rapidly advancing field of EV applications, the design of high-efficient inverters is one of the key factors in improving overall vehicle performance. This paper presents the design of a three-level (3-L) automotive inverter based on GaN technology, aimed at enhancing the performance and efficiency of electric vehicles (EVs). GaN components, sourced from Cambridge GaN Devices (CGD), are utilized to leverage their superior switching characteristics and efficiency. The work is supported by both simulation and experimental results, which confirm the advantages of integrating GaN components and the 3-L inverter topology. The findings demonstrate improved performance, lower losses, and enhanced overall efficiency, making this design a promising solution for the future of EV power electronics.
Battiston, Alexandre, Aghaei Hashjin, Saeid, Findlay, John, Haje Obeid, Najla, Siad, Ines
Experimental Simulation of a Real Mission for Identifying a Telematics-Based Diagnostic Model in Connected Light Commercial Vehicles2025-24-012409/07/2025
Remote monitoring of commercial vehicles is taking an increasingly central position in automotive companies, driven by the growth of the on-road freight transportation sector. Specifically, telematics devices are increasingly gaining importance in monitoring powertrain operability, performance, reliability, sustainability, and maintainability. These systems enable real-time data collection and analysis, offering valuable support in resolving issues that may occur on the road. Moreover, the fault codes, called Diagnostic Trouble Codes (DTCs), that arise during actual road driving constitute fundamental information when combined with several engine parameters updated every second. This integration provides a more accurate assessment of vehicle conditions, allowing proactive maintenance strategies. The principal goal is to deliver an even faster response for resolving sudden issues, thus minimizing vehicle downtime. High-resolution data transmission and failure event information
D'Agostino, Valerio, Cardone, Massimo, Mancaruso, Ezio, Rossetti, Salvatore, Marialto, Renato
A 0D/1D Methodology for Estimating Critical Parameters in Thermal Runaway Tests of Lithium-Ion Batteries in Closed Volumes2025-24-015009/07/2025
The ongoing shift toward electrification, particularly in the transport and energy sectors, has intensified the deployment of lithium-ion batteries (LIBs). While LIBs offer high energy density and efficiency, their increasing use also brings significant safety challenges—most critically, the risk of thermal runaway (TR) in confined environments. This study presents a fast and structured zero-dimensional/one-dimensional (0D/1D) methodology for estimating key parameters associated with TR events in sealed volumes. The model integrates empirical correlations, energy-based mass estimation approaches, and simplified combustion simulations to assess pressure and temperature rise during TR. Experimental vented mass and gas composition data—obtained through sealed canister testing—serve as the basis for the simulation inputs. A numerical procedure combining mixing dynamics and adiabatic combustion is used to predict critical outcomes such as maximum overpressure and peak temperature
Garcia, Antonio, Micó, Carlos, Marco-Gimeno, Javier, Gómez-Soriano, Alejandro
Integrated CFD-Experimental Methodology for Hydrogen-Fuelled Small Loop Scavenged Two-Stroke Engines2025-24-001409/07/2025
This paper presents an integrated methodology for the analysis of hydrogen-fueled 2-Stroke engines, combining experimental data, 1D-CFD simulations, and 3D-CFD combustion calculations. The proposed approach aims to enhance the understanding of scavenging, injection, and combustion processes in a 50 cm3 loop-scavenged engine with low-pressure direct hydrogen injection, experimentally studied on a test bench. The hydrogen-fueled engine was capable of achieving a maximum power output of 3.1 kW, using a slightly lean air-to-fuel ratio (lambda = 1.3). The maximum engine speed for stable combustion without knocking was achieved at wide open throttle at 7119 RPM. The developed 1D-CFD model, based on the engine layout at the test bench, was calibrated using average experimental data and specific full load operating points. 3D-CFD simulations were performed for one full load operating point, focusing on combustion dynamics and fuel distribution within the chamber, with combustion model
Caprioli, Stefano, Ferretti, Luca, Scrignoli, Francesco, Fiaschi, Matteo, D'Elia, Matteo, Oswald, Roland, Schoegl, Oliver, Nambully, Suresh Kumar, Rothbauer, Rainer, Mattarelli, Enrico, Kirchberger, Roland, Rinaldini, Carlo
Experimental Study of the Lubricating Oil Impact on the Unsteady Performance of an Automotive Turbocharger2025-24-007809/07/2025
Turbocharging technique is a key technology for the development of hydrogen engines, allowing high lambda values to reach low NOx emissions. In ultra-lean mixture conditions, the thermal management of the lubricating oil and its cold condition becomes a crucial aspect that cannot be neglected. Accordingly, the impact of different lubricating oils and different lubricant thermal conditions is highlighted referring to the performance of a turbocharging system for automotive application. To this aim, an experimental campaign is conducted at the test bench for components of propulsion systems of the University of Genoa. Tests are performed on a turbocharger equipped with a variable geometry turbine under both steady and unsteady flow conditions, considering different positions of the turbine regulating device. A 4-cylinder engine head was coupled to the turbocharger in order to reproduce the pulsating flow related to the opening and closing of the engine valves. The influence of the
Marelli, Silvia, Usai, Vittorio, Cordalonga, Carla
LES and RANS Modeling of a Hydrogen Low-Pressure Direct-Injection Injector2025-24-006609/07/2025
Hydrogen direct injection is a promising strategy for enabling high-efficiency, low-emission powertrains. However, challenges related to mixture stratification and jet modeling persist, particularly under engine representative conditions. This study numerically investigates a simplified injector model, focusing on the downstream hydrogen jet behavior from of a hydrogen low-pressure direct-injection jet-forming cap under both constant-volume chamber (CVC) and engine conditions. The primary objective is to evaluate numerical methodologies and explore model simplification strategies that remain computationally feasible while preserving physical fidelity—particularly relevant for early-stage hydrogen injector development. Experimental data serve as validation benchmarks across operating regimes. In the CVC platform, large eddy simulations (LES) provide turbulence-resolving insights that inform the refinement of Reynolds-averaged Navier–Stokes (RANS) models. RANS simulations are then
Menaca, Rafael, Liu, Xinlei, Silva, Mickael, Wu, Hao, Ben Houidi, Moez, Mohan, Balaji, Cenker, Emre, AlRamadan, Abdullah, Syed, Iltesham, Pei, Yuanjiang, Roberts, William, Im, Hong G.
Experimental Investigation of the Comparison between Helium and Hydrogen Jets Exiting a DI Outward-Opening Injector via Schlieren Technique2025-24-006809/07/2025
This paper deals with the hydrogen-to-helium jets comparison within the framework of the assessment of helium as a potential hydrogen surrogate. The comparison is centred on the assessment of the combined action of pressure ratio with gas properties on the dynamics of the jet exiting an outward-opening injector. The shots are performed at injection pressures and backpressures ranging from 21 to 36 bar and from 1.2 to 5 bar, respectively. The Schlieren technique is deployed to capture the jets images. The study demonstrates that at certain pressure ratios helium is an appealing solution bridging the lab safety with fidelity to hydrogen-like jet behaviour. Decreasing pressure ratio minimizes the hydrogen-to-helium difference in axial penetration and area, enabling helium to yield a hydrogen-like development. The findings underscore the impact of the pressure ratio on how the gas properties, such as density and diffusivity, dictate the evolution of the axial propagation and area
Coratella, Carlo, Tinchon, Alexis, Hespel, Camille, Dober, Gavin, Foucher, Fabrice
A Novel Mechanical Model Simulating a Pavement Deflection Measuring System for Non-Invasive Pavement Monitoring Based on a Reliability-Based Optimization Algorithm02-18-03-002509/04/2025
This article presents a novel mechanical model for simulating the behavior of pavement deflection measuring systems (PDMS). The accuracy of the model was validated by comparing the acceleration of the new model with the data achieved through experimental tests fusing a deflection measurement system mounted on a Ford F-150 truck. The experimental test for the PDMS is carried out on a random road profile, generated by an inertial profiler, over a 7.4-mile (12 km) loop around a lake near Austin, Texas. Integrating a reliability-based optimization (RBO) algorithm in a PDMS aims to optimize system parameters and reduce vibrations effectively. The PDMS noises and uncertainties make it crucial to use a robust system to ensure the stability of the system. This article presents a robust algorithm for considering the uncertainties of PDMS parameters, including the damping coefficients and spring stiffness of the supporting brackets. Moreover, it considers the variation of system parameters, such
Yarmohammadisatri, Sadegh, Sandu, Corina, Claudel, Christian
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