Browse Topic: Tests and Testing

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Identifying and mitigating resonance effects in HV Powernets2026-01-0742To be published on 07/01/2026
HV Power nets of electric vehicles consists of various HV components such as batteries, inverters, auxiliaries and cables. During in-vehicle testing, multiple failures of an auxiliary inverter were observed, caused by resonance issues within the component filter. Initial investigations revealed that these resonances, absent during manufacturer testbench evaluations, were influenced by the vehicle power net and its impedance characteristics. To better understand the underlying causes and identify preventative measures, extensive simulations were performed. The results demonstrate a diminishing influence of the power net capacitance when significantly larger than the component capacitance. Also they highlight the critical impact of cable inductance on the component resonance frequency when comparable to the component’s inductance. A simplified electrical equivalent circuit was used to derive an equation predicting the resonance frequency as a function of the component’s capacitance
Schmiel, Fabian, Aurand PhD, Tobias, Koehnlechner, Benjamin, Zimmer PhD, Markus
Interpretable Tire Force Modeling for Formula Student Vehicle Dynamics and Lap Time Applications2026-01-0762To be published on 07/01/2026
Accurate tire models are a key enabler for vehicle dynamics simulation, control design, and lap time optimization, particularly in the context of Formula Student race cars, where vehicle setups and tire characteristics differ significantly from production vehicles. State-of-the-art tire models, such as Pacejka’s Magic Formula, provide high accuracy but rely on predefined functional structures and a large number of parameters, which limits interpretability and adaptability to new tire compounds. This paper presents a data-driven approach for deriving compact and physically interpretable tire force models using symbolic regression. The proposed method employs an intelligent tree search to systematically explore the space of mathematical expressions and identify models that optimally balance prediction accuracy and structural simplicity. In contrast to black-box machine learning approaches, the resulting models consist of explicit mathematical expressions that enable physical
Anselment, Marcel, Borowski, Julian, Rudolph, Stephan
Generating Machine-Processable Specifications from Natural Language Using Large Language Models in Automotive Commissioning and Testing2026-01-0768To be published on 07/01/2026
The commissioning of electric and electronic components contributes significantly to adding value in vehicle production. Moreover, testing these components and digital vehicle functions secures this value and ensures high-quality products. The emergence of software-defined vehicles, however, leads to an increased scope and complexity of commissioning and testing processes as software functions depend on electric and electronic components that take on perception, execution, and processing tasks. Nevertheless, assembly planning must still meet the requirement of providing thorough, error-free, yet cost-effective processes. In this context, this paper tackles a common challenge: Software that is deployed in vehicle production to implement commissioning and testing processes is developed upon specifications that define prerequisites, procedures, and target end results in unstructured natural language. Therefore, extensive manual translation into executable code is needed, being susceptible
Köhler, Katja, El Asad, Aiman, Hahn, Michael, Reuss, Hans-Christian
Context-Dependent Assessment of Driving Dynamics and User Perception in Automated Driving2026-01-0757To be published on 07/01/2026
Automated driving systems are increasingly operating in complex urban environments, where driving behavior is shaped not only by technical requirements but also by how users perceive the vehicle’s motion. While many studies evaluate automated driving performance in isolated maneuvers or specific traffic situations, little empirical evidence exists on whether similar driving dynamics are perceived consistently across different urban contexts. This work investigates whether comparable motion patterns, such as acceleration profiles or steering behavior, are evaluated similarly or differently when occurring in roundabouts and intersections using data from real-world driving studies. The empirical basis consists of two user studies. In the first study, 24 participants experienced automated driving in roundabout scenarios in public traffic. In the second study, 20 participants experienced automated driving through intersections on a test track under defined boundary conditions. In both
Panzer, Anna, Strenge, Emma, Iatropoulos, Jannes, Henze, Roman
From Wind Tunnels to an AI-Supported Data-Driven Development Ecosystem How Software Transforms Aerodynamic Testing into a Strategic Asset2026-01-0767To be published on 07/01/2026
Despite advances in CFD, wind tunnel testing remains indispensable for aerodynamic validation, correlation, and homologation. Increasing configuration complexity, shortened development cycles, and stringent result robustness and documentation requirements demand a shift from isolated facilities to integrated, data-driven ecosystems within the overall development and company-wide test processes. We present a software-centric approach integrating wind tunnel operations into a strategic element of the Digital Thread. By orchestrating test planning, execution, data acquisition, and documentation within a unified framework, experimental data becomes reusable across projects and traceable for compliance and homologation. The interaction between CFD and physical testing is important. Such systematically improves simulation models with wind tunnel tests. And CFD results guide efficient test matrix definition. Extended measurement methodologies include automated actuation of active aerodynamic
Jacob, Jan D.
Feasibility study on the mechanical adjustment of the vibration behaviour of a powertrain test rig for validating longitudinal vehicle shuffle2026-01-0735To be published on 07/01/2026
Vehicle manufacturers use Hardware-in-the-loop (HiL) approaches to validate overall vehicle characteristics, including those dependent on the powertrain, at an early stage of vehicle development. A powertrain test rig is a typical example. In the specific setup, the vehicle engine and side shafts are mechanically coupled to the load machines of the test rig, eliminating the physical influence of the rims, tires and vehicle body. Adapting a specimen to the test rig changes some characteristics. This affects the specimen's vibration behaviour, making it more challenging to validate comfort-related characteristics. A particular example is longitudinal vehicle shuffle; the powertrain's first torsional natural frequency causes it. The natural frequencies of the real vehicle and device under test differ significantly, so a road-matching approach is not directly feasible. To account not only for tire-road contact but also for the missing vehicle mass, some scientific studies propose a purely
Hübner, Carl, Prokop, Günther
Automating Component NVH Characterization: A Systematic Approach for Component Test Bench Testing2026-01-0704To be published on 06/20/2026
The automotive industry faces increasing pressure as electrification introduces new components and accelerated development cycles shorten time-to-market, leaving limited opportunity to resolve Noise, Vibration, and Harshness (NVH) issues. This environment demands virtual development tools that are fast, precise, and efficient, and that can be seamlessly interchanged between development sites, suppliers, and OEMs; capabilities that are critical for effective target setting. Component-based Transfer Path Analysis (C-TPA), standardized in ISO 20270:2019, enables independent component characterization and integration with virtual models to predict sound and vibration in new assemblies, referred to as Virtual Prototype Assemblies (VPA). However, conventional measurements are labor-intensive and therefore typically restricted to a small number of samples, overlooking production variability. This paper introduces a system for fully automated, ISO 20270 compliant C-TPA on non-rigid test
Sturm, Michael, Wienen, Kevin, Brandstetter, Markus, Sorber, Eric, Corbeels, Patrick, Verrecas, Bart, Gonçalves, Vinícius
Standardized Equivalent Tire Load measurements delivered by suppliers to an OEM enabling consistent and comparable simulation input.2026-01-0699To be published on 06/20/2026
Part- or component-level tests are commonly performed by Tiers and OEMs to investigate the NVH behavior and loading mechanisms. However, because test bench dynamics differ from those of the actual vehicle environment, correlating measured sound, acceleration, and forces between bench and vehicle often proves challenging. Blocked forces offer a way to address this issue, as they provide test bench– and vehicle–independent load representations, effectively enabling different Tiers to deliver consistent load data, which OEMs can then to better tune excitation and noise transmission on their vehicles. This paper focuses on 2 test bench compensation techniques, involving pure test and a simulation models of the tire, to obtain accurate blocked-forces. The compensation techniques are validated on four testbenches of different companies.
Reichart, Ron, de Klerk, Dennis
Towards Realistic Stick-Slip Testing: Efficiently Mapping Material Behaviour across a wide Range of Loading Conditions2026-01-0713To be published on 06/20/2026
To minimise noise caused by interior components rubbing against each other, automotive materials are usually tested in advance with the established stick-slip method according to VDA standard 230-206. This procedure is widely used for soft materials, upholstery and plastics. However, it is limited to constant climatic and selected loading conditions. Contrary, in real application, changing climates and dynamic excitations can nevertheless trigger noise issues even in materials rated as suitable in the prior tests. To address this gap, a new test method has been developed that evaluates the stick-slip behaviour of material combinations for a wide range of loading and climatic conditions. Conducted in a climate chamber with a standard stick-slip bench, the procedure applies sinusoidal excitations, dynamic climatic shifts and advanced data analysis. In addition to the usual results the new method also evaluates realistic scenarios such as starting a vehicle in different seasons or sudden
Fritz, Susanne, Strangfeld, Martin
An Experimental Setup for Vibroacoustic and Fluid-Borne Noise Characterization of Electric Refrigerant Compressors using R1234yf or R7442026-01-0724To be published on 06/20/2026
The increasing electrification of vehicles leads to a broader range of tasks for heating, ventila-tion and air conditioning systems and a shift in its priority assessment. Air conditioning systems in electric cars are no longer primarily responsible for cooling the passenger compartment, but also have to temperature-control the battery, especially during rapid charging, which repre-sents a high-load operating point. Additionally, the elimination of the combustion engine as a major noise source brings the NVH behaviour of the refrigerant compressor a higher priority in product selection. In order to investigate the vibration and acoustic behaviour, as well as fluid dynamic forces resulting from the cyclic compression principle of an electric refrigerant compressor, a test rig was previously developed, allowing compressors to be operated and measured isolated in an anechoic chamber under various defined operating points. This test rig has been expanded in two ways within the scope of
Beer, Gabriel, Saur, Lukas, Schwarz, Manuel, Zemsch, Stefan, Becker, Stefan
A Modular Method for Certified Virtual Validation of NVH Performance in Automotive Platforms2026-01-0684To be published on 06/20/2026
This work presents a modular engineering methodology (DigPhBalance - Digital Physical Balance) for the virtual validation of Noise, Vibration, and Harshness (NVH) performance in automotive development. The approach addresses the inefficiency of repeated physical testing across vehicle variants by introducing a structured two-phase process—Launcher and Reskin—centered on quantitative performance indicators with formal acceptance thresholds. In the Launcher phase, a digital replica of the base vehicle is built and iteratively correlated with physical test data. Validation is governed by objective indicators of confidence, conformity, and correlation, each evaluated against predefined thresholds. Once validated, the model becomes a certified reference, enabling its reuse across derivative configurations in the Reskin phase. Physical testing is only required if indicators fall below threshold, with a final gate test on pre-series vehicles ensuring industrial robustness. DigPhBalance
Celiberti, Lucia, Camia, Andrea
Development and Standardization of a Compensation Method for Measurement Equipment Effects to Improve Blocked Force Accuracy in Physical Tires2026-01-0698To be published on 06/20/2026
Although the tire system is not developed in-house but supplied by tire manufacturers, it is a critical component that significantly affects overall vehicle performance, including NVH. To ensure the supplied tires meet vehicle performance targets, our company provides detailed development guidelines, defining block force—closely related to road noise—as a key NVH performance index. As virtual tire development is introduced, manufacturers will submit block force data from virtual models with initial tire designs, enabling early prediction of tire and vehicle-level performance. However, this approach is still under evaluation, with unresolved challenges such as the absence of clear block force target-setting methods and limited accuracy in current virtual evaluations. To address this, we propose using block force measurements from mass-produced or prototype tires as a basis for data-driven target setting and as a reference to enhance virtual model accuracy. Since block force data is
Ahn, Youngeun, Kang, Min Kyoo, Kim, Yong Dae, Reichart, Ron, Kim, Yonghun, Han, Inhyuk, Ji, Unjin, Lee, JeongHwan
Simulation and Analysis of Flow and Acoustic Induced Structural Vibration2026-01-0696To be published on 06/20/2026
For analysing flow and acoustic induced structural vibration, a run time fully coupled framework combining a hybrid CFD-CAA approach with a modal response simulation was validated and presented at the ISVNH 2022 (SAE Technical Paper 2022-01-0938). In this contribution we show the application of this method on a production vehicle, simulating the flow and acoustic induced vibration of the bonnet. The simulation setup of this study resolves the geometry of the vehicle including the complex details of the bonnet structure, the frunk and the engine compartment. The FEM model for the modal analysis of the bonnet takes into account the complex boundary conditions at the bearings and provides the eigenmodes relevant for the low frequency range. Simulations are conducted in an undisturbed wind tunnel setup and the resulting vibrations are compared to acceleration measurements under wind tunnel and road conditions. Due to the employed hydrodynamic acoustic split approach, the relevance of the
Schwertfirm, Florian, Ocker, Joerg, Hartmann, Michael
Performance and Combustion Characteristics of Coryton SUSTAIN Classic Super 80 Carbon-Neutral Fuel Versus E95 in a 1980s Fiat 500 Engine2026-37-0033To be published on 06/09/2026
The energy transition requires a rapid reduction in the use of fossil fuels, whose combustion generates substantial greenhouse-gas emissions. In Europe, transport alone accounts for roughly a quarter of total greenhouse-gas emissions, with road transport being the predominant component. In this context, the use of biofuels has emerged as a potential solution for limiting further increases in CO₂ emissions. However, most studies available in the literature evaluate the performance of these fuels on modern engines, while their effects on historic carburetted engines remain largely unexplored. This is particularly significant given the large fleet of historic vehicles across Europe, supported by a long-standing tradition of vehicle preservation, associations, and classic car collectors. The main historic-vehicle federations advise caution and the use of low-ethanol formulations so as not to damage elastomers, fuel tanks, and carburettor float bowls. For this reason, a few suppliers have
Tarchiani, Marco, Fossati, Federico, Raspanti, Sandro, Baroni, Alberto, Ferrara, Giovanni, Romani, Luca
A predictive methodology for 3D-CFD simulation of piston thermal field in sustainable high-performance engines2026-37-0002To be published on 06/09/2026
In recent years, especially in high performance engines, the thermal stress of pistons has gradually increased due to the implementation of various technologies, aimed at meeting emission reduction and specific power increase requirements. If the heat is not properly dissipated, cracking and plastic deformation of the material as well as formation of hot spots triggering self-ignition can occur. To overcome these problems, one or more jets of oil are directed towards the piston undercrown region, impacting at high speed. This technique ensures immediate cooling and allows the engine performance to be increased without compromising the useful life. In order to optimize the oil jet effectiveness, 3D-CFD can be proficiently adopted. In this regard, the aim of this work is to define a robust numerical methodology able to simulate oil jet impingement and piston thermal field. In particular, a 3D-CFD Volume-of-Fluid (VoF) simulation is used to numerically assess the oil jet impact and
Duni, Andrea, Berni, Fabio, Breda, Sebastiano, Fontanesi, Stefano, Gilioli, Filippo
System and Method of Strain Emulation using a Beam Load Cell Test Setup2026-26-0743To be published on 06/01/2026
This novel method deals with emulation of Strain of a Structural Measurement System which includes software validation, acceptance tests and training. Current methods for simulating strain and force data for developing and verifying data acquisition (DAQ) software typically rely on costly electronic simulators or specialized hardware, making it challenging and expensive for developers, researchers, and small organizations to test their solutions under realistic conditions. To verify DAQ software, multiple specialized hardware solutions are deployed, that include Electronic Simulators, Commercial DAQ Modules and Hydraulic/Pneumatic test rigs. These technologies pose a challenge with limited flexibility and scalability options for small-scale prototyping, especially in budget-constrained scenarios. The sensors on these equipment may or may not be company approved inducing acceptance challenges. Our invention is an inexpensive, scalable, and mechanically simple alternative. Using a 3D
Murthy, Harsha, Bhat Venkatesh, Aditi, K Padmanabhan, Rahul, Madhu, Sheetal, Garag, Naveen
Automated Flight Maneuver Recognition for Intelligent Flight Simulator2026-26-0713To be published on 06/01/2026
The rapid growth in the number of aircrafts and pilots emphasizes the need for an AI-enabled training framework that can offer precise, automated examination of flight maneuvers, thereby optimizing the pilot’s training efficiency and minimizing iterations of the conduct of flight maneuvers thereby reducing the training time of the pilot for a flight. This paper introduces a novel hybrid methodology to intelligently detect manoeuvres performed during a flight using signal processing and machine learning techniques. A general framework is developed that can be used for all kinds of flight phases and aircraft types. The framework is implemented in a two-step approach. Firstly, Continuous Wavelet Transform (CWT) of the signals of interest for different manoeuvres are generated, to find the time at which a manoeuvre happens during a sortie. CWT looks at the energy levels in the transformed signal and uses smart thresholding technique to pick out only the parts with high energy, to extract
Sahu, Akash, C, Poornima, C, Aravindh, Kaliyari, Dushyant, TK, Khadeeja Nusrath
Leveraging True Altitude Data to Improve Static Pressure Calibration from Dynamic Manoeuvres2026-26-0729To be published on 06/01/2026
Accurate calibration of aircraft air data systems is essential for reliable measurement of flow angles, altitude, and airspeed, particularly during dynamic flight manoeuvres where errors can become significant. Externally mounted vanes and probes are used to measure flow angles, local pressures and temperature, respectively. However, because these sensors are positioned close to the aircraft fuselage, they operate within disturbed local flow fields that differ notably from the free-stream conditions. As a result, their outputs require Position Error Corrections (PEC) to accurately estimate free-stream parameters such as pressure, temperature, and flow angles. The pre-flight PEC data or calibration tables for these sensors are generated based on the CFD predictions/wind tunnel experiments. All the flight-measured local variables from air data sensors need to pass through the air data computers, which contain these lookup tables, to obtain the free stream information. Despite the pre
TK, Khadeeja Nusrath, Patel, Dr. Ambalal V, J, Prabhavathi Bhai
windpuls simonaero: validation of unsteady aerodynamic effects for single vehicles and vehicle platoons under real-world apparent flow conditions.2026-01-0764To be published on 06/01/2026
Validation of CFD methods against real-world measurements is particularly challenging under unsteady and disturbed flow conditions. In on-road and proving ground scenarios, vehicles are exposed to time-varying apparent wind fields resulting from environmental influences and vehicle interactions. This effect is amplified in vehicle platoons, where the aerodynamic coupling between multiple vehicles leads to complex, unsteady flow regimes. This paper presents an integrated test and validation toolchain designed to correlate steady-state CFD simulations with real-world measurements for single vehicles and vehicle platoons under unsteady apparent flow conditions. The presented use case focuses on proving ground measurements capturing time-resolved apparent flow conditions acting on both vehicles within a platoon. The apparent wind profiles include wind magnitude, incident flow angle, gust index (GI), turbulence intensity (TI), and side wind exposure (SE), derived from synchronized high
Feichtinger, Christoph Simon, Hörschinger, Rene
Effect of strap-on geometry on the aerodynamics of multibody launch vehicle2026-26-0727To be published on 06/01/2026
Strap-on boosters play a crucial role in heavy launch vehicles by providing additional liftoff thrust without major changes to the baseline design, enabling launch with existing propulsion systems. However, strap-on boosters introduce additional pressure drag and alters the overall aerodynamics of the vehicle. While efforts have been previously made to derive empirical relationships to predict the aerodynamics of different strap-on configurations, most are case-specific and primarily limited to estimating drag coefficients (CD) [1]. Strap-on geometry has a vital role in flow field interference effects. The present study focuses on primary non-dimensional geometric parameters such as (1) strap-on core diameter ratio (Ds/Dc), (2) strap-on core length ratio (Ls/Lc), and (3) strap-on-core radial gap (Xg/Dc). The results are used to derive an empirical relationship which can be applied during preliminary design stage of a launch vehicle to predict axial force coefficient (CA), normal force
Muraleedharan, Archana P., G, Ramana Bharathi, S, Gnanasekar
Neural Network-Enabled Synthetic Air Data System: Development and Validation2026-26-0720To be published on 06/01/2026
Synthetic Air Data System (SADS) provides a smart solution that can be used to predict critical air data parameters in the absence of conventional air data sensors. Traditional air data sensors, such as pitot-static tubes and vanes, are generally expensive, require regular maintenance, and can fail in harsh weather conditions. In addition, these sensors, along with their processor and computers, add weight to the aircraft. To address these issues, a synthetic air data system is proposed using a Recurrent Neural Network (RNN). Several flight variables were checked for Pearson correlation coefficient with respect to the angle-of-attack and angle-of-sideslip, and thereafter, input features were selected based on the thresholding technique. The proposed neural network has two hidden layers and regularization technique was implemented by adding two dropout layers to each hidden layer to prevent overfitting of the model. The neural network was trained using actual flight test data
Sahu, Sanju, C, Poornima, Kaliyari, Dushyant, TK, Khadeeja Nusrath, Hebbar, Archana
Accelerating aircraft verification and certification through an integrated virtual and physical testing approach2026-26-0710To be published on 06/01/2026
Aircraft verification and certification entails a variety of testing tasks and requires coordination among numerous stakeholders across different disciplines to ensure alignment on requirements. Historically, certification strategies have relied on both physical testing and high-fidelity simulation. The integration of these complementary approaches is essential to address their respective blind spots and to support credible certification evidence. A key challenge lies in the rigorous correlation of simulation models with physical test data. Flutter verification, for instance, is a critical component in defining the aircraft’s flight envelope and plays a foundational role in certifying safe operational boundaries. In this work, the process of freedom from flutter verification starting from the pre-test analysis is demonstrated. This work introduces a novel approach to combining simulation and test data with the aim to accelerate and streamline the verification process leading to more
Hallez, Raphael, Yadabettu, Dayanand Kumar, de Boer, Jens, Aspasiou, Vicky
Design of Acoustical Features for a quitter Aero-engine Test Facility2026-26-0787To be published on 06/01/2026
Indoor aero-engine test facilities (AETF) are generally used to evaluate the performance of both the newly manufactured and repaired/overhauled engines. Aero Engine Research & Design Center (AERDC) has already commissioned several facilities for testing of turbofan engines of around 40 kN thrust class which powers fighter aircrafts. A request has been received from a customer for installation and commissioning of a new test facility for testing of a similar class engine, with a challenge to make it acoustically better than the existing test facilities. The target was set to reduce the sound pressure level (SPL) in the control room and around the test facility as compared to the existing ones. To meet this requirement, a modified layout with a U-type (vertical intake and exhaust) configuration was planned along with specially designed high and low frequency silencers at the intake, exhaust system with an exhaust basket, splitters in the vertical exhaust chamber, and sound absorbing
Gouda, Bansidhar
Design of a Novel Intelligent Monitoring Platform for Low and Medium Altitudes2026-99-07395/15/2026
This paper presents the design of a novel intelligent monitoring platform for low and medium altitudes, aiming to offer a new solution for the development of intelligent equipment operating in this airspace. Current monitoring tasks are primarily performed by fixed-wing and multi-rotor UAVs, but these platforms face significant technical bottlenecks in flight endurance and monitoring precision. This research aims to address these deficiencies. The platform is based on a small-scale unmanned airship featuring a semi-rigid, hybrid lift-body structure. Improvements were made upon the traditional ellipsoidal hull; the hull profile was optimized using a geometric superposition method, introducing an aerodynamic camber line with a maximum camber (m) of 4% to enhance aerodynamic performance at small angles of attack. In terms of its energy system, the platform is powered by a purely electric energy system composed of solar panels and batteries; solar energy is used during the day, while
Song, Ziang, Gao, Wenxuan, Cao, Xiaochuan, Zheng, Xing, Zhao, Chong
Cabbage Cleaning Device Based on Fischertechnik Model2026-99-07345/15/2026
This article focuses on the problem of high labor cost, low processing efficiency and poor automation of the existing equipment in the postharvest processing of Chinese cabbage. It will design and produce an automated Chinese cabbage processing method called Smart Fresh Pack. Root removal, leaf removal, washing, loading, weighing, packaging and labeling functions were integrated, and smart dexterous intelligence was applied to core concepts and this can be used in the bulk production scenario of supermarkets in the city and countryside Compared with traditional assembly line equipment, obvious advantages in terms of structure, function and processing capacity: Key innovations include: Low-pressure air jet cleaning replaces water washing, which prevents a second contamination and weighing error due to surface moisture; pneumatic gripper and multi-DOF robotic arms combine to package and dynamically weigh simultaneously, streamlining these tasks; machine vision relies on an SSD
Chen, Yuhui, Zhang, Yixuan, Ruan, Jia, Zhu, Huayun, He, Lianzheng, Zhao, Ping
Design and Implementation of an Intelligent Mobile Waste Classification and Collection Robot System2026-99-07025/15/2026
To address the growing demand for waste management, improve the efficiency and accuracy of waste classification, reduce costs, promote environmental protection and circular economy development, and solve environmental pollution and resource waste problems through technological innovation. This paper proposes an intelligent mobile waste classification and collection robot system. The system consists of a picking mechanical arm subsystem, a waste classification and collection subsystem, a self-moving chassis subsystem, and a solar tracking power generation subsystem. The picking mechanical arm subsystem actively collects waste through a mechanical arm combined with machine vision technology and deposits it into the waste classification device, while the waste classification and collection subsystem completes functions such as classification, compression, collection, and dumping, utilizing a navigation and positioning-driven chassis to achieve autonomous waste collection, simultaneously
Xia, Ying, Zhu, Huabing, Jia, Ruitong, He, Yifan, Hou, Wentao, Fu, Shaozao, Lin, Jiaoyang
Unidirectional Carbon Fiber Tape Epoxy Repair Prepreg, Vacuum Curing Part 5 - Material Specification for Unidirectional Carbon Fiber Tape Epoxy Prepreg for Repair and Film Adhesive for Repair, 120 to 145 °C (250 to 290 °F) CuringAMS6885/5 (Current)5/7/2026
AMS6885/5 is the Material Specification (MS) which defines the requirements of a unidirectional carbon fiber tape epoxy repair prepreg capable of curing under vacuum for repair of carbon fiber reinforced epoxy structures. It also defines the requirements of an epoxy film adhesive to be applied in a co-bonding process with the prepreg for solid laminate and sandwich bonding.
AMS CACRC Commercial Aircraft Composite Repair Committee
Test Method for Condition in Container of Liquid Organic Coating ComponentsAS7378 (Current)5/6/2026
This test method covers procedures to qualitatively determine the visual and physical condition of a liquid organic coating component (pigmented base, base without pigment, curing solution, or thinner) in a container. Also covered is evaluation of the component container to determine any degradation.
AMS G8 Aerospace Organic Coatings Committee
Understanding and Modeling Effectiveness of Predictive Risk Notifications for Early Assistance for Safe Driving: A Public Road Testing Study09-14-01-00265/4/2026
While an enlarged lead time from risk notifications to collisions is widely acknowledged to facilitate safe driving, it remains challenging to effectively notify drivers of invisible risks and non-apparent risks coming from uncertain behaviors on the part of road users. The current study examined whether verbal notifications are able to assist early awareness of predictive risks. We also attempted to identify human and environmental factors that could possibly improve the effectiveness of predictive risk information. Twenty-eight licensed drivers participated in a public road test conducted in two different urban areas on 3 days. They drove predefined courses on which potential risk locations were identified prior to the test, using a sport utility vehicle equipped with an automatic verbal notification system triggered based on the distance to the potential risk locations. After passing through the locations each time, the participants were instructed to verbally evaluate the shift in
Maruyama, Masaki, Koyama, Keiichiro, Ezaki, Toru, Sakamoto, Junichi, Sawada, Yuta, Matsuoka, Takahiro
How Machina Labs is Reshaping Defense Manufacturing with AI-Driven 7-Axis Robotics26AERP05_015/1/2026
Machina Labs recently closed its latest round of financing with $124 million, enough to develop a facility featuring up to 50 of its RoboCraftsman cells capable of producing thousands of complex structural assemblies for aerospace and defense customers - a list that already includes Lockheed Martin and the U.S. Air Force, among others. Founded in 2019, Machina Labs is a California-based company that seeks to reinvent metal manufacturing with a robot that uses artificial intelligence (AI) to rapidly form and assemble complex military grade structures directly from digital design files. RoboCraftsman is the company's manufacturing robot that leverages its proprietary “RoboForming” process to integrate multiple manufacturing processes - including metal forming, trimming, scanning, and heat treating - into a single containerized machine.
Army Researchers Design 3D-Printed Soldier Portable Autonomous Reconnaissance Transitioning Aircraft26AERP05_075/1/2026
Army researchers recently developed a 3D-printable, easy-to-assemble drone designed to enhance intelligence, surveillance and reconnaissance capabilities. Army Research Laboratory, Adelphi, MD Researchers at the U.S. Army Combat Capabilities Development Command, or DEVCOM, Army Research Laboratory (ARL) harnessed bottom-up Soldier innovation to develop an experimental 3D-printed small unmanned aerial system, or drone, that was demonstrated at the inaugural U.S. Army Best Drone Warfighter Competition in Huntsville, Alabama. Known as the Soldier Portable Autonomous Reconnaissance Transitioning Aircraft, or SPARTA, the drone was developed at DEVCOM ARL in collaboration with Soldiers. By incorporating Soldier feedback early in the design process and leveraging ARL's world-class research facilities, researchers developed a 3D-printable, easy-to-assemble drone designed to enhance intelligence, surveillance and reconnaissance capabilities. ARL is actively working to partner the technology
Truck and Bus Coastdown ProcedureJ2978_202604 (Current)4/28/2026
This document describes a rigorous engineering test procedure that utilizes industry-accepted data collection and statistical analysis methods to determine the road load and to estimate the aerodynamic drag area of trucks and buses weighing more than 10000 pounds. The test procedure may be conducted on a test track or on a public road under controlled conditions and supported by extensive data collection and data analysis constraints. The estimated aerodynamic-drag-area result represents a single-speed and single-yaw-angle condition. Test results that do not rigorously follow the method described herein shall not be represented as an SAE J2978 result.
Truck and Bus Aerodynamics and Fuel Economy Committee
Synthetic Rubber Hot Oil Resistant, High Swell 45 - 55AMS3222J (Current)4/28/2026
This specification covers a synthetic rubber in the form of sheet, strip, tubing, extrusions, and molded shapes. This specification should not be used for molded rings, compression seals, O-ring cords, and molded in place gaskets for aeronautical and aerospace applications without complete consideration of the end use prior to the selection this material.
AMS CE Elastomers Committee
Real Turbulent Flow in Vehicle Aerodynamics: Overview of On-Road Measurements and Turbulence Generation in Wind Tunnels2026-01-50294/22/2026
Flow conditions on the road are quite different from the conditions used to develop vehicle aerodynamics. However, a significant amount of statistical data now exists that describes realistic road conditions. Some of these on-road flow characteristics can be replicated in wind tunnels. This paper reviews technical facilities designed to simulate on-road flow characteristics, such as turbulence intensity, turbulent length scales, and flow angle distribution. Reconstruction of a flow field that matches real road conditions is made possible by using active or passive turbulence generators within the wind tunnel. This review provides a comprehensive overview of these facilities, offering readers key insights into the challenges involved in replicating real-world flow conditions in wind tunnels.
Vondruš, Jan, Vančura, Jan
Research on Trajectory Tracking of Test Target Vehicles Based on an Improved Model Predictive Control Algorithm13-07-01-00024/17/2026
To address the performance testing requirements of autonomous vehicles (AVs), this study proposes a model predictive control (MPC) algorithm specifically designed for low-ground-clearance test target vehicles (TTVs) to achieve trajectory tracking control. First, the kinematic model of the TTV is established, and its state-space equations are derived. An objective optimization function incorporating both error weighting and control weighting is designed. Simulation analysis reveals the influence of the control error weighting ratio (CEWR) on both straight-line and curved trajectory tracking performance: For straight-line tracking, increasing the CEWR from 10 to 25 reduces the overshoot, but increases the distance required to reach the target trajectory by 4.7%. A similar pattern is observed in curved trajectory tracking. To overcome the limitations of the fixed CEWR, an improved MPC algorithm integrating fuzzy control is proposed. This algorithm dynamically adjusts the CEWR in real time
Ji, Shaobo, Lu, Yueqi, Liao, Guoliang, Chen, Zhongyan, Li, Meng, Lyu, Chengju, Zhang, Zhipeng
Acceptance Criteria - Magnetic Particle, Fluorescent Penetrant, and Contrast Dye Penetrant InspectionAS3071C (Current)4/16/2026
To establish the acceptance criteria for discontinuities as revealed by magnetic particle or liquid penetrant examination of aircraft utility parts as in 1.2.
E-25 General Standards for Aerospace and Propulsion Systems
Extreme Scale Automotive Aerodynamic Simulations2026-01-05974/7/2026
Achieving an optimal balance between simulation accuracy and computational efficiency remains a central challenge in automotive aerodynamics. While the adoption of AI and machine learning (ML) methods in vehicle development is expected to grow significantly, the demand for highly scalable, computationally efficient, and accurate computational fluid dynamics (CFD) methods persists. The emergence of GPU (graphics processing unit) technology presents new opportunities to deliver cost-effective, high-fidelity, scale-resolving simulations to industrial users. A comprehensive evaluation of Simcenter STAR-CCM+’s parallel scalability and accuracy across extensive CPU and GPU resources was executed on the Frontier supercomputer at Oak Ridge National Laboratory (ORNL). Steady-state and transient aerodynamic scalability simulations were executed using the DrivAer notchback vehicle configuration. Simulation accuracy was evaluated through transient simulations employing the SST-DDES turbulence
Larsson, Torbjörn, Grover, Ronald O., Landi, Simone, Altmann, Peter, McManus, Liam, Dowding, Steven
Aerodynamic Proximity Effects between the DrivAer and AeroSUV Standard Models, Part 2 – Adjacent-Lane and Lateral-Offset Interactions2026-01-06064/7/2026
Aerodynamic interactions between two 30%-scale passenger vehicles in close proximity were examined experimentally in a large wind tunnel, with a focus on longitudinal separations up to two vehicle lengths, lateral separations up to one lane width, and combinations thereof. Part 1 of this paper described the longitudinal following (platooning) configurations of these results, while this paper concentrates on adjacent-lane influences and lateral-offset effects when platooning at a single separation distance. Test models were based on the DrivAer and Aero-SUV open-access geometries, each with slant-back (Notchback or Fastback) and square-back (Estateback) variants. This provided four distinct model pairings, not all of which were tested in each positional arrangement. Adjacent-lane results matched the trends from a smaller-scale study in a different wind tunnel using the same geometry pair, with small-but-distinct differences attributed to different blockage ratios in the two wind-tunnel
McAuliffe, Brian, Ghorbanishohrat, Faegheh
Characterization of a Low-Cost Insulator Substrate for Traction Power Modules2026-01-01194/7/2026
Demand for cost-effective automotive traction inverters requires improved power module packaging. This paper presents a packaging method using an epoxy composite insulator applied directly to the cold plate surface, replacing Direct Bonded Copper (DBC) and Active Metal Brazed (AMB) substrates. This integration removes the substrate-to-cold plate solder interface and eliminates two material layers from the thermal path. The epoxy composite demonstrates a dielectric strength greater than 60 kV/mm. Thermal resistance (junction-to-coolant) measured approximately 0.17 K∙cm2/W. Electrical characterization showed a relative permittivity of 3.9, which is lower than standard ceramics and results in reduced parasitic capacitance. Initial thermal cycling tests indicated no significant degradation in thermal or electrical performance. These results suggest the epoxy composite insulator could be a promising alternative for traction power modules.
Chen, Yu, Mena-Garcia, Javier, Chen, Hao, Xiao, Kewei, Gupta, Man Prakash, Degner, Michael
Transformer-Based Deep Learning Framework for Efficient Prediction of Automotive Wind Noise2026-01-02224/7/2026
Aerodynamic wind noise is a critical challenge in modern automotive development, particularly with the rise of vehicle electrification and intelligent mobility, where cabin acoustic comfort is a key quality metric. While reliable, traditional methods like wind tunnel experiments and computational fluid dynamics (CFD) simulations are both costly and time-consuming. To address these challenges, we propose a novel Transformer-based framework for rapid and accurate wind noise prediction. Several model improvements, including the physical attention, geometry wave number embedding, hybrid FPS-random downsampling method and frequency separation output heads are properly employed to reduce the GPU memory cost and improve the prediction accuracy. This framework is pre-trained on a large-scale acoustic dataset of nearly 1,000 diverse vehicles generated using Improved Delayed Detached Eddy Simulation (IDDES). From a vehicle's point cloud coordinates, the model directly predicts the surface
Tang, Weishao, Liu, Mengxin, Qin, Ling, Duan, Menghua, Wang, Chengjun, Zhang, Yufei, Wang, Qingyang
Kissing Bonds Inspection by Comparing Natural Frequencies Using Digital Holography2026-01-02074/7/2026
Accurate detection and evaluation of kissing bonds in composite materials is essential to ensure the integrity of the component structure, but traditional NDT (non-destructive testing) methods struggle to identify imperfect bonds and zero-volume debonds. In this study, a vibration analysis method based on holography was applied to detect kissing bonds by monitoring the changes in natural frequencies of the same sample before and after fatigue loading. Both pristine and kissing bond samples were tested under identical conditions, and their vibration characteristics (natural frequency, amplitude, and mode shape) were measured using holography. The experimental results show for the intact sample exhibited no changes in natural frequency amplitude or mode shape after fatigue loading, confirming that the applied fatigue test did not affect the integrity of its adhesive layer. In contrast, for the sample with a kissing bond, after fatigue loading, the natural frequency decreased by up to 22
Gao, Zhongfang, Fang, Siyuan, Gerini-Romagnoli, Marco, Yang, Lianxiang
A Vehicle-Integrated Validation Method for Weather-Strip Sealing Performance in Automotive Closure Systems2026-01-02004/7/2026
Weather-strip sealing systems are critical to automotive closure performance, influencing water- and dust-tightness, aerodynamic noise control, and overall NVH quality. Conventional validation often relies on flat or straight JIG-based tests that inadequately represent the curved, angled, and non-uniform geometries of real closures such as doors, tailgates, hoods, roofs, and fixed or movable glass. This disparity limits the predictive accuracy of sealing performance in actual vehicles. This study proposes a vehicle-integrated validation framework that mirrors true geometric and contact conditions. The methodology combines finite element analysis (FEA) of both flat JIG and full-vehicle CAD geometries with experimental JIG tests, establishing a baseline for pressure distribution, compression load, and sealing contact behavior. A comparative analysis highlights significant deviations between flat-section predictions and vehicle-specific closure profiles. Results demonstrate that the
Ganesan, Karthikeyan, Seok, Sang Ho
Embedded Real-Time Control of a Distributed Trailer Propulsion System with Regenerative Braking for Net Neutral Load Towing2026-01-00654/7/2026
Towing imposes substantial efficiency penalties on both battery-electric vehicles (BEVs) and internal combustion engine (ICE) vehicles, reducing range by 30-50%. This paper presents a proof-of-concept embedded control architecture for distributed trailer propulsion that actively regulates drawbar force to reduce towing loads. Unlike proprietary e-trailer systems requiring specialized hardware, the proposed implementation demonstrates feasibility using commercial off-the-shelf (COTS) components and open-source software. The distributed architecture employs dual Raspberry Pi 4B single-board computers communicating via ROS 2 at 20 Hz. The trailer-mounted controller executes a Simulink-generated control node coordinating load cell acquisition (HX711 ADC), motor CAN bus telemetry, and throttle commands to a 5 kW BLDC traction motor powered by a 5 kWh LiFePO4 battery pack. A vehicle-mounted controller logs OBD-II/CAN validation data. The control pipeline implements cascaded EWMA/Hampel
Joshi, Gaurav, Adelman, Ian, Liu, Jun, Donnaway, Ruthie
A Correction Method to Estimate Wake Effects for Aerodynamic Performance Metrics2026-01-06014/7/2026
Wake effects modify the aerodynamic performance of a road vehicle when driving in traffic. Analysis of wind-tunnel measurements conducted in flows with wake characteristics, using a traffic-wake-simulation system, suggests that conventional uniform-wind performance coefficients can be scaled, using wake-flow-field information, to predict the influence of wake effects. This paper presents a flow-field-averaging method that estimates a dynamic-pressure correction and yaw-angle correction for application to uniform-wind data, to account for changes in performance due to wake effects. This first-order method is shown to provide reasonably-good accuracy when reverse correcting the wind-tunnel wake-effects measurements. Drag-coefficient data for light-duty-vehicle models, which showed wake effects exceeding 20%, were corrected to within 5% of uniform-wind values, while data for heavy-duty-vehicle models, which showed wake effects exceeding 15%, were corrected to within 2% of uniform-wind
McAuliffe, Brian
Vehicle Deceleration Levels during Wet-to-Dry Transitions on an Asphalt Surface with a High Proportion of Aggregate2026-01-05424/7/2026
The braking performance of a vehicle at varying levels of road wetness is an important factor in collision reconstruction. Here we quantify the deceleration levels of two modern vehicles equipped with antilock brake systems (ABS) on a wetted asphalt surface with a high proportion of exposed, large-sized aggregates as the road naturally dried over time. We also compare our current results to prior tests on asphalt with a small proportion of small-sized aggregate. Two ABS-equipped vehicles were maximally braked on an asphalt road surface as the road naturally transitioned from a saturated wet state to a completely dry state. Road wetness was visually categorized from photographs taken during testing. Overall, we found that deceleration levels on wet asphalt were significantly less than deceleration levels on dry asphalt (average dry: 0.902g and 0.962g; average wet: 0.787g and 0.818g for the two vehicles). Within the wetness categories we used, there was either no significant difference
Ahrens, Matthew, Arnold, Nikolas, Miller, Ian, Siegmund, Gunter P.
Evaluation of PAEB Performance of a GM Vehicle Using EDR and Ground Truth Data2026-01-00544/7/2026
In order to determine the on-board EDR data recording characteristics of a GM vehicle, a 2023 GMC Sierra Denali was tested in several Pedestrian Automatic Emergency Braking (P-AEB) scenarios. Using a variety of test tools, including the STRIDE robotic platform and its onboard data systems, a GPS/IMU installed in the vehicle, and several camera units, the vehicle was put into collision imminent scenarios in which the crash avoidance systems were actuated. The flags in the EDR data, the order in which EDR events were written, and the correlation between the EDR and data recorded by the aforementioned external acquisition systems were examined for each test case. Testing was done in both forward and reverse scenarios and at low speeds only. These results provide a picture of the current state of the additional data available in current EDRs installed on GM vehicles equipped with P-AEB capability, as well as an insight into the accuracy and meaning of that data which should prove
Bartholomew, Meredith, Arnett, Michael, Guenther, Dennis
Collision Avoidance Testing of the Waymo Automated Driving System2026-01-05194/7/2026
This paper describes Waymo's Collision Avoidance Testing (CAT) methodology: a scenario-based testing method that evaluates the safety of the Waymo Driver Automated Driving Systems' (ADS) intended functionality in conflict situations initiated by other road users that require urgent evasive maneuvers. Because SAE Level 4 ADS are responsible for the dynamic driving task (DDT), when engaged, without immediate human intervention, evaluating a Level 4 ADS using scenario-based testing is difficult due to the potentially infinite number of operational scenarios in which hazardous situations may unfold. To that end, in this paper we first describe the safety test objectives for the CAT methodology, including the collision and serious injury metrics and the reference behavior model representing a non-impaired eyes on conflict human driver used to form an acceptance criterion. Afterward, we introduce the process for identifying potentially hazardous situations from a combination of human data
Kusano, Kristofer, Beatty, Kurt, Schnelle, Scott, Favaro, Francesca, Crary, Cam, Victor, Trent
Introduction to Catesby Aero Research Facility, CARF, the Coast-Down Tunnel Proving Ground2026-01-06114/7/2026
This paper reports on the Catesby Aero Research Facility (CARF), which began commercial operation in 2019, and summarizes facility characteristics and associated measurement technologies, with an emphasis on vehicle-mounted component-force measurement devices. CARF is a proving ground converted from a former railway tunnel approximately 2.74 km in length and surfaced with high-quality tarmac. The road-surface quality was specified to be comparable to that of SUBARU's proving ground and was achieved using established construction methods. The course is approximately straight with a small longitudinal grade. Key course specifications include an approximately 40 m2 blockage area, a 6 m road width (maximum 8.4 m), flatness σ < 0.5 mm, and a gradient of 0.57%. Relative to outdoor coast-down testing, the tunnel length enables continuous measurement to very low speeds, thereby improving repeatability. A six-component force sensor integrated into the hub unit enables on-road measurement of
Shimoyama, Hiroshi
Wind-Tunnel Study of the Traffic-Wake Impacts for Road-Vehicle Aerodynamics2026-01-06134/7/2026
When driving in traffic, the wakes of leading vehicles reduce the wind speed experienced by a following vehicle, lowering its drag relative to isolated driving. These wake effects can persist to large inter-vehicle distances, on the order of hundreds of meters, while lateral convection due to cross winds can influence vehicles in adjacent lanes. Wind tunnel testing was conducted at 30% scale for light- and heavy-duty-vehicle models in a large wind tunnel with a traffic-wake simulation system, expanding upon a previous study that examined only heavy vehicles. Three variants of the DrivAer model, four variants of the AeroSUV model, and three variants of a zero-emission heavy-duty-truck model were tested with a range of simulated wake conditions that varied the type, forward distance, and lane position of the wake-source vehicle(s), for a range of yaw angles up to 11°. Results show drag reductions of up to about 10% for the heavy-duty-truck model, and up to about 20% for the passenger
McAuliffe, Brian, Ghorbanishohrat, Faegheh, Barber, Hali
The Stellantis North America Aero-Acoustic Wind Tunnel Upgrade2026-01-06094/7/2026
The Stellantis North America Aero-Acoustic Wind Tunnel (AAWT) has been upgraded with a cutting-edge 5-belt Moving Ground Plane (MGP) system, featuring an 8.5-meter center belt and four Wheel Spinning Unit (WSU) belts with advanced coatings for durability and visibility. The expanded 9.4-meter turntable enables ±90° yaw and supports vehicles with wheelbases from 1800 mm to 4500 mm and weights up to 5000 kg, accommodating the full Stellantis North America product range. The original 2-stage boundary layer control system was retained, with new tertiary slots added for improved flow quality. A high-stiffness, six-component Horiba balance with integrated calibration weights and tractive force measurement ensures accurate and precise measurements. Facility enhancements include a 550 m2 building addition for equipment and vehicle prep, a dedicated compressor container for clean air supply, and a vehicle underbody wash booth for efficient cleaning. Commissioning confirmed that flow quality
Lounsberry, Todd, Ladouceur, Brent, Fadler, Gregory
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