Browse Topic: Test equipment and instrumentation

Items (2,528)
Find
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-disc 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 make statements about the friction behaviour and wear. Pairings for real brake systems with larger pad sizes can be tested on flywheel mass test benches 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-disc 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 stand 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
Heuser, Robert Michael, Rosenthal, Tobias Richard, Wiest, Daniel Christian, Meyer, Henning Jürgen
Technical Paper
Real-Time HIL Testing and Validation for Multi-ECU Smart Brake Systems: Design, Implementation, and System Optimization2025-01-0344To be published on 09/15/2025
This paper presents applied methodologies and results from real-time Hardware-in-the-Loop (HIL) testing of smart braking systems, based on experience gained during European Tier-1 supplier development programs. It outlines how HIL accelerated control software validation, enhanced fault coverage, and improved development cycles for emerging technologies like brake-by-wire and regenerative braking systems. As braking systems evolve to meet the demands of electrification and autonomy, their complexity has grown significantly requiring robust, scalable, and safety-focused validation techniques. Modern smart braking architectures often employ decentralized control, with individual ECUs managing each brake corner. To ensure safe and reliable operation of such systems, a real-time HIL test bench was developed to simulate a wide range of driving conditions and validate critical functionalities including Anti-lock Braking System (ABS), Vehicle Dynamics Control (VDC), and regenerative braking
Sathiyamoorthy, Pradeepraja
Technical Paper
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
Technical Paper
Modeling and Experimental Study on the Sealing Performance of Automobile Brake Fluid Reservoir2025-01-0354To be published on 09/15/2025
The brake fluid reservoir is an indispensable part of the hydraulic brake system. Due to the development of the electronic hydraulic brake system (EHB), the requirements for the sealing performance of the reservoir are also improved accordingly, and the traditional reservoir can no longer meet the current performance requirements. Based on a traditional brake fluid reservoir, this paper breaks through the traditional method of verifying the design through bench test, increases the evaluation standard of dynamic sealing performance test, supplements the problem of missing sealing simulation model, and adopts the method of combining modeling and simulation with bench testing to study the current sealing performance requirements. Through the establishment of high-precision static sealing performance simulation model and dynamic sealing performance simulation model under different working conditions, the simulation data of the current evaluation metrics are obtained. In order to further
Wang, Shiqi
Technical Paper
Method to Analyze Driving Dynamics During Faults in the Electric Drivetrain on a Vehicle-in-the-Loop Test Bench2025-24-0123To be published on 09/07/2025
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
Technical Paper
Numerical and Experimental Investigation of a Pre-chamber Igniter for Enhanced Low Load Stability in Internal Combustion Engines2025-24-0002To be published on 09/07/2025
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
Technical Paper
Integrated CFD-Experimental Methodology for Hydrogen-Fuelled Small Loop Scavenged Two-Stroke Engines2025-24-0014To be published on 09/07/2025
This paper presents an integrated methodology for the analysis of hydrogen-fuelled two-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 cc loop-scavenged engine with low-pressure direct hydrogen injection (LPDI), experimentally studied on a test bench. The performance of the hydrogen-fuelled engine was slightly lower compared to gasoline operation, achieving a maximum power output of 3.1 kW compared to 3.6 kW with gasoline, using a slightly lean air-fuel ratio (lambda = 1.3). The maximum engine speed for stable combustion without knocking was achieved at wide-open throttle (WOT) at 7000 RPM. The developed 1D CFD model, based on the layout at the test bench, was calibrated using average experimental data and specific full-load operating points. 3D CFD simulations were performed for two full-load operating points, focusing
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
Technical Paper
Experimental Study of the Lubricating Oil Impact on the Unsteady Performance of an Automotive Turbocharger2025-24-0078To be published on 09/07/2025
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
Technical Paper
Investigation of the Combustion Process of a Thermally Conditioned Active Prechamber in Monovalent Operation with Ammonia2025-24-0028To be published on 09/07/2025
The debate over synthetic fuels is intense especially in sectors with a high energy demand like maritime. Hydrogen production from renewable sources is growing, but immediate measures for decarbonization are needed. In this context, the project MethMag was funded, and a gas engine for methane combustion with an innovative cooling concept and a purged pre-chamber spark plug was virtually developed. Validation with data from the test bench demonstrates that the simulations accurately represent the operating conditions. This combustion process is adapted for ammonia, which is being considered as a climate-friendly fuel of the future, particularly in maritime transportation. This fuel faces significant combustion challenges and is therefore mostly considered in complex, bivalent systems. In particular, the pre-chamber is examined regarding the ignitability of ammonia. The transition to ammonia highlights the need for further adjustments. The geometry of the pre-chamber cap significantly
Rothe, Paul, Bikas, Georgios, Mauss, Fabian
Technical Paper
Optimum design and sizing approach for a series-hybrid vehicle2025-24-0099To be published on 09/07/2025
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
Technical Paper
Design of a pure synchro-reluctant machine with asymmetrical poles for high-speed applications2025-24-0129To be published on 09/07/2025
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 was carried out by identifying design levers and optimizing the magnetic circuit in order to remove 3 well know issues of this topology: maximizing the power factor to reduce the inverter rating and cost, minimizing sources of NVH and torque ripples in particular, and finally maximizing the efficiency in use to close the gap with magnet 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 (number of poles pairs, shape and number of barriers, etc.) are explained. The optimizations methods and the mechanical solutions used to reach the max speed are also detailed. A machine with symmetrical poles was
APPLAGNAT-TARTET, Antoine, Milosavljevic, Misa, Delpit, Pierre
Technical Paper
Model-based optimization of Diesel/OMEx fuelled CI engine under multiple blending conditions2025-24-0038To be published on 09/07/2025
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
Technical Paper
Experimental Analysis and Model-Based Characterization of the Toyota Mirai II's Electric Machine2025-24-0136To be published on 09/07/2025
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
Technical Paper
DLR Tire Road Wear Particle Emission Testing Methodology – Collection System Influence and Repeatability Assessments2025-24-0092To be published on 09/07/2025
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
Technical Paper
Visualization Analysis of Hydrogen Combustion Triggered by Non-Controlled Hotspots Using a Rapid Compression Expansion Machine2025-24-0047To be published on 09/07/2025
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 pre-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 pre-ignition occurrence. For each test bench configuration, ten successive tests were conducted to assess the probability of preignition occurrence. The presence of soot was ensured through a preliminary run with
Tempesti, Claretta, Yukitani, Takumi, Horibe, Naoto, Romani, Luca, Ferrara, Giovanni, Kawanabe, Hiroshi
Technical Paper
Innovative Full-GaN Inverter Development for 800V/100kW Automotive Applications2025-24-0133To be published on 09/07/2025
This abstract presents the development of an automotive traction inverter utilizing cutting-edge full-GaN technology, incorporating components from CGD for high-performance 800V applications. The inverter employs a three-level topology, which is a significant advancement over the conventional two-level designs predominantly used in the current state of the art. This design aims to enhance efficiency, reduce power losses, and improve thermal management compared to traditional IGBT and SiC-based inverters. In this article is detailed a scientific approach which focused on developing a mock-up to validate the power scaling of GaN components, to the complete design of a full-scale prototype representing an automotive traction inverter. Comparative analysis in the article demonstrates that the GaN-based three-level inverter not only surpasses traditional two-level IGBT and SiC inverters in terms of efficiency and thermal performance but also shows promising potential in improving signals
BATTISTON, Alexandre, Aghaei Hashjin, Saeid, FINDLAY, John, Haje Obeid, Najla, Siad, Ines
Technical Paper
Application of Sustainable Aviation Fuels in Compression Ignition Aviation Engines: In-Flight Investigations2025-01-031707/02/2025
To achieve a significant reduction in net CO₂ emissions in the aviation sector, sustainable aviation fuels (SAFs) are considered a key factor. Current research efforts are therefore focused on SAFs, which exhibit properties that differ from conventional kerosene, particularly in aspects critical to compression-ignition (CI) engines, such as cetane number, evaporation behavior or lubricity. These differences necessitate dedicated investigations to assess their suitability and performance in such engines. However, real operating conditions — such as intake air- and exhaust- pressure levels during flight — cannot be fully replicated on standard engine test benches. For this reason, real flight experiments were conducted to address these limitations. Notably, this work marks the first instance of in-flight testing of SAFs in CI aviation engines, constituting a significant milestone in this research area. In the course of these investigations, ASTM D7566 Annex A2-compliant HEFA
Kleissner, Florian, Reitmayr, Christian, Hofmann, Peter
Technical Paper
Improving Gearbox Acoustics through Elastomer-Based Bearing Damping2025-01-032307/02/2025
This study analyses the effect of external damping of roller bearings on the acoustic behaviour of gearboxes in electric powertrains. The growing use of electric vehicles has increased the importance of reducing gearbox noise, as the lack of noise masking from internal combustion engines and the higher operating speeds of electric motors exacerbate the acoustic challenges. Gearbox noise, which is primarily caused by tooth mesh excitation and its transmission through shafts and bearings, requires strategies to minimise its impact on vehicle comfort and performance. External damping is achieved through the integration of specific elements at the circumference of the outer bearing ring. These elements are utilised to modify the vibration transfer behaviour of the bearing assembly. This, in turn, can lead to a reduction in both structure-borne and airborne noise emissions at the gearbox housing. A test design was created to quantify the effects of different damping configurations. This
von Schulz, Kai, Linde, Tilmann, Jäger, Steffen
Technical Paper
Experimental Evaluation of Purge Strategies in the Recirculation Path of a PEM Fuel Cell System2025-01-031607/02/2025
PEM fuel cell technology plays a vital role in realizing an emission-free mobility and, depending on the considered use case, offers significant advantages over battery electric solutions as well as hydrogen combustion engines. When high performance over a longer period of time as well as short refueling times are key requirements, fuel cell powertrains show their core strengths. However, the adaption of fuel cells in the mobility sector strongly depends on their efficiency which directly relates to the vehicle’s fuel consumption, range and ultimately cost to operate. Therefore, the influence on efficiency and power of different purge strategies used to operate PEM fuel cells is experimentally investigated and compared. A concentration-dependent purge strategy is developed and examined in reference to a charge-dependent strategy. The measurements are carried out on a fuel cell system test bench which corresponds to a fully functional fuel cell system including all commonly used
Hauser, Tobias, Allmendinger, Frank
Technical Paper
Performance Specifications for Anthropomorphic Test Device TransducersJ2570_202506 (Current)06/30/2025
This SAE Recommended Practice defines the minimum performance specifications for sensors used within anthropomorphic test devices (ATDs) when performing impact tests per SAE J211. It is intended that any agency proposing to conduct tests in accordance with SAE J211 shall be able to demonstrate that the transducers they use would meet the performance requirements specified in this document.
Safety Test Instrumentation Standards Committee
Information Report
Ammonia-Diesel Engines Segmented Modeling Approach and Simplified Combustion model Research2025-01-023206/16/2025
Ammonia-diesel dual-fuel engines can effectively reduce greenhouse gas (GHG) emissions. Aiming at the real-time control requirements of ammonia/diesel dual-fuel engines, this study proposes a segmented real-time modeling method and a heat release rate model simplification strategy by linearized heat release rate curves. First, the engine working cycle is divided into three parts: intake and exhaust stage, compression and expansion stage, and combustion process. Different simulation steps and modeling strategies are designed to optimize computational efficiency while maintaining the necessary level of accuracy at each stage. Secondly, based on the calibrated heat release rate (HRR) curves, feature points are extracted to construct a simplified linear heat release model. In the absence of calibration data, the characteristic points of the HRR curves are obtained through interpolation. Compared with the commonly used combustion model, the Wiebe model, the proposed simplified model can
Li, Guangyuan, Chen, Run, Wang, Xinran, Li, Tie, Zheng, Kexiong, Liu, Shaoling, Liu, Yanzhao, Lyu, Xiaodong
Technical Paper
A Pitch Shift Synthesis Algorithm for Electric Vehicle Sound Based on Quadratic Interpolation and Continuous Sample Indexing2025-01-025406/16/2025
The electric vehicle driveline generates less vibration and noise compared to a conventional internal combustion engine vehicle, making it harder for the driver to perceive the vehicle’s operating status through driveline sounds, thereby diminishing driving engagement and experience. To compensate for the absence of engine sound in EV drivelines, Active Sound Design (ASD) technology has become a crucial method for drivetrain sound enhancement, with sound synthesis algorithms playing a key role in this process. Although pitch-shifting algorithms based on frequency shift principles can synthesize engine sounds, they suffer from spectral leakage and stuttering caused by sound splicing. To address these issues, a pitch-shifting synthesis algorithm (QCPS, Quadratic interpolation-based Continuous audio sample indexing Pitch Shifting algorithm) is proposed in this paper, which combines a quadratic interpolation method with a continuous audio sample indexing strategy. First, the frequency
Liu, Dezhu, Xie, Liping, Liu, Zhien, Lu, Chihua
Technical Paper
HFC-134a Refrigerant Electronic Leak Detectors, Minimum Performance CriteriaJ2791_202505 (Current)05/16/2025
This SAE Standard provides testing and functional requirements to meet specified minimum performance criteria for electronic probe-type leak detectors, so they will identify smaller refrigerant leaks when servicing all motor vehicle air conditioning systems, including those engineered with improved sealing and smaller refrigerant charges to address environmental concerns and increase system efficiency. This document does not address any safety issues concerning their design or use.
Interior Climate Control Service Committee
Technical Standard
A Comparative Analysis of Fault Diagnosis by Vibration Signals for Critical Gear Components in Electric Vehicle Motor Testing Machines Using Machine Learning Algorithms2025-01-004005/05/2025
Electric vehicles (EVs) are shaping the future of mobility, with drive motors serving as a cornerstone of their efficiency and performance. Motor testing machines are essential for verifying the functionality of EV motors; however, flaws in testing equipment, such as gear-related issues, frequently cause operational challenges. This study focuses on improving motor testing processes by leveraging machine learning and vibration signal analysis for early detection of gear faults. Through statistical feature extraction and the application of classifiers like Wide Naive Bayes and Coarse Tree, the collected vibration signals were categorized as normal or faulty under both loaded (0.275 kW) and no-load conditions. A performance comparison demonstrated the superior accuracy of the wide neural networks algorithm, achieving 95.3%. This methodology provides an intelligent, preventive maintenance solution, significantly enhancing the reliability of motor testing benches.
S, Ravikumar, Sharik, N, Syed, Shaul, V, Muralidharan, D, Pradeep Kumar
Technical Paper
Multi-Method Approach for Car Tailgate Electric Telescopic Rod Noise: Detection, Characterization, and Prediction2025-01-003805/05/2025
As the automotive industry moves towards greater intelligence, electric tailgate systems have seen widespread adoption, featuring remote control, obstacle detection, and intelligent opening functions that significantly enhance the user experience. The electric telescopic rod, as a key actuator, has drawn attention for its structural and transmission design. However, studies have shown that during actual operation, various noise issues arise with electric telescopic rods, affecting the sound quality and smoothness of the tailgate's opening and closing. This paper presents a noise detection and analysis study based on a dedicated testbench platform specifically developed for electric telescopic rods. The platform was designed to simulate the real-world opening and closing process of automotive tailgates, enabling a controlled environment for capturing and analyzing noise characteristics effectively. Using a microphone to capture noise signals, three main types of noise were identified
Fan, Sibei, Wang, Siling, Zhu, Zhehui, Li, Lei, Qin, Jiade, Meng, Dejian, Pei, Kaikun
Technical Paper
Characterize the Sound Field Generated from a Vehicle Horn by Pellicular Analysis2025-01-005805/05/2025
To predict the sound field produced by a vehicle horn requires a good source representation of it in the full vehicle model. This paper investigates the characterization of a physical vehicle horn by an inverse method called pellicular analysis. To implement this method, firstly an acoustic testing is performed to measure the sound pressure radiated from the horn at a certain number of microphone locations in a free field environment. Based on the geometry of a virtual horn, the locations of each microphone and measured sound pressure data, pellicular analysis is adopted to recover a set of vibration pattern of the virtual horn. The virtual horn and the recovered vibration information are then incorporated in a full vehicle numerical model to simulate its exterior sound field. The validity of this approach is confirmed by comparing the prediction for a horn in a production vehicle to the corresponding physical test which is required to meet the Brazilian regulation CONTRAN 764/2018.
Yang, Wenlong, Melo, Andre
Technical Paper
NVH Improvement of the BEV Transmission by Altering Bearing Mounting Arrangement2025-01-010405/05/2025
As per metaphor, “The squeaky wheel gets the grease,” and in the case of Battery Electric Vehicles (BEVs), the transmission system has become the focal point for NVH (Noise, Vibration, and Harshness) improvements. With the engine being replaced by the near-silent electric motor, the noise generated by the transmission has become more prominent, demanding greater attention to noise reduction. This shift has created a pressing need for innovations in both design and manufacturing processes to enhance the overall quietness of the vehicle. As a result, ongoing advancements are being made to address and improve the NVH characteristics of BEV transmissions. Following paper will discuss the improvement in NVH achieved through a design innovation in the way bearings are installed and demonstrated a significant amount of improvement. We have used SMT MASTA as a simulation tool to predict the expected results and a Transmission Dyno test bench in an anechoic chamber to test the NVH performance
Pingale, Abhijeet, Soni, Jaldeep
Technical Paper
Evaluation of Invariant Structural and Acoustic Loads Estimation Methods to be Used in Vehicle Platform Development Independent to the Boundary Conditions of Load Generation2025-01-005305/05/2025
Platform based vehicle development is standardized at John Deere. The challenges of frontloading the integration of individual components within different platforms using predictive methods is key to shortening the development cycle. Components are individually characterized on test benches and results cannot directly be used to evaluate system performance. Invariant characterization is needed instead, which is possible through techniques such as blocked loads estimation. To evaluate the applicability of such methods, the component-based loads and vehicle in-situ operational loads need to be compared. The confident use of these methods for obtaining structural and acoustic loads enables the use of hybrid system models, enhancing early NVH response predictions. The objective of this work was to enable the confident use of test stand measurements in predictive models across various vehicle platforms. This study compares a powertrain characterization in a vehicle against a test stand to
Vesikar, Prasad Balkrishna, Edgington, Jason, Drabison II, John
Technical Paper
Experimental Investigation on Genetic Algorithm Optimized Proportional Integral Derivative Based Active Suspension System2025-01-001405/05/2025
In this work, Genetic Algorithm (GA) optimized Proportional Integral Derivative (PID) controller is employed in the active suspension. The PID gain values are optimally tuned based on the objective function by the Integral Time Absolute Error (ITAE) criteria of various suspension measures like vehicle body displacement, suspension and tire deflections. The proposed GAPID controller is experimentally validated through the 3-DOF quarter-car (QC) test rig model. The fabricated model with passive suspension system (PASS) and active suspension system (ACSS) with an electrical actuator is presented. The schematic representation of the fabricated test set-up with and without ACSS is also illustrated. Further, simulation and experimental response of the fabricated model with and without ACSS are compared. It is identified that the proposed GAPID controller attenuates the sprung mass acceleration by about 41.64 % and 29.13 % compared with PASS for the theoretical as well as experimental cases
A, Arivazhagan, Kandavel, Arunachalam
Technical Paper
Active Control of Engine Order Noise for Heavy-Duty Trucks: Using the Genetic Algorithm for the Optimization of Error Microphone Arrangement2025-01-001305/05/2025
The arrangement of error microphones for a vehicle active noise control (ANC) system is no trivial work, especially for heavy-duty trucks, due to the dilemma resulted from the large volume of the cab and the limited number of microphones accepted by most manufacturers in the auto industry. Although some pioneering work has laid the foundation for the application of numerical methods exemplified by the genetic-algorithm (GA) to optimize the error sensor arrangement in an ANC system, most ANC developers still resort to trial and error in practice, which is not only a heavy workload given the amount of interested working conditions to be tested, but also does not guarantee to yield the optimum noise cancellation performance. In this paper, the authors designed and implemented an error microphone selection process using a genetic-algorithm (GA) -based mechanism. The target vehicle was a heavy-duty truck with a six-piston diesel engine, and two application scenarios were particularly
Wang, Jian, Ling, Zihong, Zhang, Zhe, Cai, DeHua, lv, Xiao, Zhang, Ming, Gao, GuoRan
Technical Paper
Test Methods and Equipment for Lighting Devices for Use on Vehicles Less than 2032 mm in Overall WidthJ575_202505 (Current)05/03/2025
This SAE Recommended Practice is intended as a guide toward standard practice and is subject to change to keep pace with experience and technical advances. This document provides standardized laboratory tests, test methods and equipment, and requirements for lighting devices covered by SAE Recommended Practices and Standards. It is intended for devices used on vehicles less than 2032 mm in width. Tests for vehicles larger than 2032 mm in overall width are covered in SAE J2139. Device-specific tests and requirements can be found in applicable SAE Technical Reports.
Test Methods and Equipment Stds Committee
Technical Standard
A New Test Rig for Electrically Actuated Landing Gear and Brake of a Small Transport Aircraft2025-01-016105/02/2025
Performing highly representative tests of aircraft equipment is a critical feature for gaining utmost confidence on their ability to perform flawlessly in flight under the entire spectrum of operating conditions. This can also contribute to accelerate the certification process of a new equipment. A research project (E-LISA) was performed in recent years, as part of the European funded Clean Sky 2 framework, with the objective of building an innovative facility for testing an electrically actuated landing gear and brake for a small air transport. The project eventually led to the development and construction of an Iron Bird able to reproduce in a realistic and comprehensive way a full variety of landing test cases consistent with certification specifications and landing histories available in the repository of the airframer. The Iron Bird that was eventually developed is a multi-functional intelligent and easy reconfigurable facility integrating hardware and software allowing to perform
De Martin, Andrea, Bertolino, Antonio, Jacazio, Giovanni
Technical Paper
Innovative High-Performance Active Dampers for Effective Mitigation of Helicopter Main Rotor Vibrations2025-01-016305/02/2025
Helicopter vibrations, primarily generated by the main rotor-gearbox assembly, are a major source of concern due to their impact on structural integrity, cockpit instrument durability, and crew comfort. These vibrations are mainly transmitted through the gearbox’s rigid support struts to the fuselage, leading to increased cabin noise and potential damage to critical components. This paper presents a solution for vibration mitigation which involves replacing traditional gearbox support struts with low-weight, high-performance active dampers. Developed by Elettronica Aster S.p.A., these active dampers are designed as electro-hydraulic actuators embedded within a compliant structure. The parallel nested configuration of the system enables high power densities and effective vibration control, significantly reducing the transmission of harmful vibrations to the fuselage. The comprehensive model-based design process is detailed, describing the development and use of a high-fidelity physics
Bertolino, Antonio Carlo, Sorli, Massimo, Porro, Paolo Giovanni, Galli, Claudio
Technical Paper
Eddy Current Inspection of Circular Holes in Nonferrous Metallic Aircraft Engine HardwareAS4787A (Current)05/02/2025
This SAE Aerospace Standard (AS) establishes minimum requirements for eddy current inspection of circular holes in nonferrous, metallic, low conductivity (less than 5% IACS) aircraft engine hardware with fasteners removed. The inspection is intended to be performed at maintenance and overhaul facilities on engine run hardware.
AMS K Non Destructive Methods and Processes Committee
Technical Standard
Verification Methods for AS5653 Network Controller, Network Terminal, and Switch Physical LayerAS6260 (Current)04/25/2025
This document was prepared by the SAE AS-1A2 Committee to establish techniques for verifying that Network Controllers (NCs), Network Terminals (NTs), switches, cables, and connectors comply with the physical layer requirements specified in AS5653B. Note that this verification document only verifies the specific requirements from AS5653B and does not verify all of the requirements invoked by documents that are referenced by AS5653B. The procuring authority may require further testing to verify the requirements not explicitly defined in AS5653B and in this verification document.
AS-1A Avionic Networks Committee
Technical Standard
Test Plan/Procedure for AS5643 IEEE-1394b Interface Requirements for Military and Aerospace Vehicle ApplicationsAS5657 (Current)04/25/2025
This document establishes test plans/procedures for the AS5643 Standard that by itself defines guidelines for the use of IEEE-1394b as a data bus network in military and aerospace vehicles. This test specification defines procedures and criteria for testing device compliance with the AS5643 Standard.
AS-1A Avionic Networks Committee
Technical Standard
Dynamic Analysis of Intake and Exhaust Valve Motion in a High-Performance 4-Stroke Engine. Part1 - Experimental Measurement of Valve Motion Using a High-Frequency Laser Sensor2024-32-008304/18/2025
The motion of the intake and exhaust valves plays a pivotal role in determining operational efficiency and performance, especially in high-specific power 4-stroke engines. At high rpm levels, the dynamic behavior of the valve may deviate from the kinematic model established during the design phase. This discrepancy arises due to the high accelerations and forces to which the valve and other components of the valvetrain system are subjected. Notably, under such conditions, the valve may detach from the cam profile at the conclusion of the opening stroke and can exhibit a bouncing behavior during the closing stroke. Moreover, the elasticity of all valvetrain system elements introduces additional complexities. Factors such as timing chain elongation, camshaft carrier deformation, and valve stem compression can contribute to a deviation in phase compared to the initially defined kinematics. Within this context, the direct measurement of the valves motion represents fundamental information
Grilli, Niccolò, Romani, Luca, Raspanti, Sandro, Bosi, Lorenzo, Ferrara, Giovanni, Trassi, Paolo, Fiaschi, Jacopo, Guarducci, Edoardo
Technical Paper
How Test Equipment Is Evolving to Keep Up with EV BatteriesTBMG-5279904/01/2025
Magazine Article
Research on the Thermal Performance of Thick Film Heater for Electric Vehicle Battery2025-01-815404/01/2025
A specific thick film heater (TFH) for electric vehicles is investigaed in this study, and its three dimensional heat tansfer analysis model is estab-lished. The heat transfer and fluid performance of the TFH is analyzed using a computational fluid dynamics soft-ware. The performance of TFH is measured on a test bench, and the measured data is used to validate the developed model. Using the established model, the heating efficiency of TFH is studied for different inlet temperatures and flow rates, and the influence of the fin spoiler structure on TFH heating efficiency and the heating board temperature is investigated. The result indicates that the spoiler structure has a large effect on the board heating temperature, but has little effect on the heating efficiency. An orthogonal experimental design method is used to optimize the design of the fins and water channels, and the purpose is to reduce the board heating temperature for preventing over burning. Under the 25°C inlet
Guan, Wenzhe, Guo, Yiming, Wu, Xiaoyong, Wang, Dongdong, Shangguan, Wen-Bin
Technical Paper
Aggressive Autonomous Control on Snow and Ice2025-01-804004/01/2025
In cold and snowy areas, low-friction and non-uniform road surfaces make vehicle control complex. Manually driving a car becomes a labor-intensive process with higher risks. To explore the upper limits of vehicle motion on snow and ice, we use an existing aggressive autonomous algorithm as a testing tool. We built our 1:5 scaled test platform and proposed an RGBA-based cost map generation method to generate cost maps from either recorded GPS waypoints or manually designed waypoints. From the test results, the AutoRally software can be used on our test platform, which has the same wheelbase but different weights and actuators. Due to the different platforms, the maximum speed that the vehicle can reach is reduced by 1.38% and 2.26% at 6.0 m/s and 8.5 m/s target speeds. When tested on snow and ice surfaces, compared to the max speed on dirt (7.51 m/s), the maximum speed decreased by 48% and 53.9%, respectively. In addition to the significant performance degradation on snow and ice, the
Yang, Yiming, Bos, Jeremy P.
Technical Paper
Integrated Nonlinear Observer and Prescribed Performance Control for a Four In-Wheel Motor-Driven Electric Vehicles Based on Stability Boundary and Road Information2025-01-829804/01/2025
To effectively improve the performance of chassis control of a four in-wheel motor (IWM)-driven electric vehicles (EVs), especially in combing nonlinear observer and chassis control for improving road handling and ride comfort, is a challenging task for the IWM-driven EVs. Simultaneously, inaccurate state-based control and uncertainty with system input, are always existing, e.g., variable control boundary, varying road input or control parameters. Due to the higher fatality rate caused by variable factors, how to precisely chose and enforce the reasonable chassis prescribed performance control strategy of IWM-driven EVs become a hot topic in both academia and industry. To issue the above mentioned, the paper proposes a novel observer-based prescribed performance control to improve IWM-driven EVs chassis performance under the double lane change steering. Firstly, a nonlinear nine degree-of-freedom of full-car model is developed to describe vehicle chassis dynamics, and the proposed
Wang, Zhenfeng, Long, Jiarong, Li, Shengchong, Zhang, Xiaoyang, Zhao, Binggen
Technical Paper
Performance Analysis of Cooling Plates for Battery Packages Based on Biomimetic Leaf-Vein Structures2025-01-817404/01/2025
The liquid-cooled plate is a critical component of the liquid-cooled system for battery packages.Battery overheating problem under charging and discharging can be solved effectively by a liquid-cooled plate with superior thermal performance.A liquid-cooled plate with a leaf-vein-like structure aiming to enhance the cooling performance was proposed and designed. A test bench of the battery pack cooling system was built,and an experimental for battery pack cooling system was carried. The maximum temperature,temperature difference of batteries inside a module and flow resistance the liquid-cooled plate were measured. A model for thermal analysis of the liquid-cooled plate was established,and the model was validated by the data obtained from the experiment.The effects of parameters such as the number of main and secondary flow channels,the inclination angle of the secondary flow channels and the inlet flow distribution on the fluid and temperature characteristics of the battery pack
Liao, Changsheng, Wang, Xihui, Zhou, Fupeng, Li, Kunyuan, Shangguan, Wen-Bin
Technical Paper
Advanced Driver Assistance Systems (ADAS): Assessing the Efficacy of Non-Impact Testing for Evaluating the Performance of Frontal Collision Mitigation Technology2025-01-805604/01/2025
As Automatic Emergency Braking (AEB) systems become standard equipment in more light duty vehicles, the ability to evaluate these systems efficiently is becoming critical to regulatory agencies and manufacturers. A key driver of the practicality of evaluating these systems’ performance is the potential collision between the subject vehicle and test target. AEB performance can depend on vehicle-to-vehicle closing speeds, crash scenarios, and nuanced differences between various situational and environmental factors. Consequently, high speed impacts that may occur while evaluating the performance of an AEB system, as a result of partial or incomplete mitigation by an AEB activation, can cause significant damage to both the test vehicle and equipment, which may be impractical. For tests in which impact with the test target is not acceptable, or as a means of increasing test count, an alternative test termination methodology may be used. One such method constitutes the application of a late
Kuykendal, Michelle, Easter, Casey, Koszegi, Giacomo, Alexander, Ross, Paradiso, Marc, Scally, Sean
Technical Paper
Investigation of Dimethyl Ether Injection Profiles in High-Pressure Direct Injection System2025-01-846404/01/2025
The majority of transportation systems continue to rely on internal combustion engines powered by fossil fuels. Heavy-duty applications, in particular, depend on diesel engines due to their high brake efficiency, power density, and robustness. Despite significant advancements in diesel engine technology that have reduced emissions and improved efficiency, complex and costly after-treatment systems remain necessary to meet the stringent emission regulations. Dimethyl ether (DME), which can be produced from various renewable feedstocks and possesses high chemical reactivity, is a promising alternative for heavy-duty applications, particularly in compression ignition direct injection engines. Its high reactivity, volatility, and oxygenated composition offer significant potential to address emission challenges while reducing reliance on after-treatment systems. However, DME’s lower energy density requires adjustments in injection parameters (such as injection pressure and duration) or
Cong, Binghao, Leblanc, Simon, Tjong, Jimi, Ting, David, Yu, Xiao, Zheng, Ming
Technical Paper
A Study of Tire Handling and Ride Performance Map According to Tire Tread Wear State2025-01-876004/01/2025
The electric vehicle market, vehicle ECU computing power, and connected electronic vehicle control systems continue to grow in the automotive industry. The results of these advanced and expanded vehicle technologies will provide customers with increased cost savings, safety, and ride quality benefits. One of these beneficial technologies is the tire wearing prediction. The improved prediction of tire wear will advise a customer the best time to change tires. It is expected that this prediction algorithms will be essential part for both the optimization of the chassis control systems and ADAS systems to respond to changed tire performance that varies with a tire’s wear condition. This trend is growing, with many automakers interested in developing advanced technologies to improve product quality and safety. This study is aimed at analyzing the handling and ride comfort characteristics of the tire according to the depth of tire pattern wear change. The handing and ride comfort
Kim, Changsu, Kwon, Seungmin, Sung, Dae-Un, Ryu, Yonghyun, Ko, Younghee
Technical Paper
Multi-Source Error Analysis for Loading Disk of Suspension Kinematics & Compliance Test Bench2025-01-829104/01/2025
The suspension Kinematics & compliance (K&C) characteristic test bench can simulate the excitation of the road to the wheels under various typical working conditions in a quasi-static manner on the bench, enabling the measurement of the K&C characteristics of the suspension system without knowing the specific suspension structure form, parameters, etc., assisting in the entire design process of the vehicle. In this paper, aiming at various geometric source errors existing in the processing and assembly process of the K&C characteristic test bench, an evaluation method based on the homogeneous transformation matrix is proposed to establish the position error of the center of the end loading disk in the series motion chain. Firstly, the mapping relationship between the position error of the end loading disk in the series mechanism kinematic chain and the assembly error is established by using the homogeneous transformation matrix. Then, the change matrix of the coordinate system from the
Sun, Haihua, Duan, Yupeng, Wu, Jinglai, Zhang, Yunqing
Technical Paper
Validation of SLA Control Arm Bushing Fatigue Life Under Multi-Channel Road Load Input2025-01-823504/01/2025
Continuing prior work, which established a simulation workflow for fatigue performance of elastomeric suspension bushings operating under a schedule of 6-channel (3 forces + 3 moments) road load histories, the present work validates Endurica-predicted fatigue performance against test bench results for a set of multi-channel, time-domain loading histories. The experimental fatigue testing program was conducted on a servo-hydraulic 3 axis test rig. The rig provided radial (cross-car), axial (for-aft), and torsional load inputs controlled via remote parameter control (rpc) playback of road load data acquisition signals from 11 different test track events. Bushings were tested and removed for inspection at intervals ranging from 1x to 5x of the test-equivalent vehicle life. Parts were sectioned and checked for cracks, for point of initiation and for crack length. No failure was observed for bushings operated to 1 nominal bushing lifetime. After 3 nominal bushing lifetimes, cracks were
Mars, Will, Barbash, Kevin, Wieczorek, Matthew, Pham, Liem, Braddock, Scott, Steiner, Ethan, Strumpfer, Scott
Technical Paper
Automotive fatigue Load Spectra: Modeling, Identification and Applications2025-01-824004/01/2025
Fatigue design is invariably of prior concern for the automotive industry, no matter of the evolution of the mobility market: at first because carmakers must stay compliant with general structural integrity requirements for reliability, notably applicable to the chassis system, then due to the endless competition for lightweighting in order to mitigate product costs and/or enhance vehicle efficiency. In the past, this key performance was often tackled by basic reference load cases, making use of the simplest signal content, e.g. sinus functions, to practice constant amplitude loads on test rigs and for computations, respectively. Nowadays, full time series coming from proving ground measurements, or any corresponding virtual road load data computations, may be applied to feed complex vehicle computations for virtual assessment and complex test facilities for final approval, under variable amplitude loads. In between, the concept of load spectra (i.e. distribution of amplitudes with
Facchinetti, Matteo Luca, Tjhung, Tana, Jaffre lng, Sébastien, Datta, Sandip, Hayat lng, Romain, Guo, Mingchao
Technical Paper
Characterisation and Variabilities of Sprays Produced by Tyres Rotating on Wet Surfaces2025-01-876304/01/2025
Understanding the formation and behaviour of sprays and aerosols generated by vehicles traveling on wet surfaces is crucial due to their impact on vehicle soiling, visibility, and autonomous driving. These sprays and aerosols can reduce visibility for other drivers, contribute to traffic accidents, and reduce the operational capabilities of sensors for driving assistance systems and future autonomous vehicles. Despite the critical importance of understanding the physical properties of these sprays and aerosols for the testing and validation of sensors used in environmental perception and recognition, field data on this subject remains limited. The formation and behaviour of these sprays and aerosols are complex. A fraction of the trailing droplets and ligaments originates directly from the tyres, while the remainder is generated upon the impact of the particles ejected from the tyres with the vehicle’s wheel houses and other surfaces, resulting in either coalescence or further
Otxoterena, Paul, Kallhammer, Jan-Erik, Eriksson, Peter, Ronelov, Erik
Technical Paper
A Zero-Emissions Braking System: Experimental Setup, System Characterization and Model Validation2025-01-825004/01/2025
Following the current need of the automotive sector on reducing secondary emissions coming from non-exhaust sources, this paper presents an innovative zero-emissions magneto-rheological braking system, specifically designed to reach future brake emission targets while maintaining safety brake performance. In particular, the article focusses on the experimental setup design to evaluate a full-sized brake prototype under real load conditions and it presents the first experimental results. The zero-emission braking prototype has been developed for reaching performance compatible with the automotive application, specifically a segment-A vehicle, being able to generate enough braking torque as to perform an emergency brake maneuver without any other traditional braking system. A central aspect to confirm the system’s performance is the development of a test bench engineered for assessing the magneto-rheological braking technology. Detailed insights into the comprehensive strategy
Tempone, Giuseppe Pio, De Carlo, Matteo, Carello, Massimiliana, de Carvalho Pinheiro, Henrique, Imberti, Giovanni
Technical Paper
Items per page:
1 – 50 of 2528