Browse Topic: Test facilities

Items (3,744)
For regions with cold climate, the range of an electric bus becomes a serious restriction to expanding the use of this type of transport. Increased energy consumption affects not only the autonomous driving range, but also the service life of the batteries, the schedule delays and the load on the charging infrastructure. The aim of the presented research is to experimentally and computationally determine the energy consumption for heating the driver's cabin and passenger compartment of an electric bus during the autumn-winter operation period, as well as to identify and analyze ways to reduce this energy consumption. To determine the air temperature in the passenger compartment, a mathematical model based on heat balance equations was used. This model was validated using data from real-world tests. The research was conducted at a proving ground under two conditions: driving at a constant speed and simulating urban bus operation with stops and door openings. The causes of heat loss in
Kozlov, AndreyTerenchenko, AlexeyStryapunin, Alexander
Highway Pilot (HWP) systems, classified as SAE Level 3 Automated Driving Systems (ADS), represent a potential advancement for safer and more efficient highway drives. In this work, the development of a connected HWP prototype is presented. The HWP system is deployed in a real test vehicle and designed to operate autonomously in highway environments. The implementation presented in this paper covers the complete setup of the vehicle platform, including sensor selection and placement, hardware integration and communication interfaces for both autonomous functionality and Vehicle-to-Everything (V2X) connectivity. The software architecture follows a modular design, composed of modules for perception, decision-making and motion control to operate in real-time. The prototype integrates Vehicle-to-Vehicle (V2V) communication, such as Cooperative Awareness Messages (CAM), to enhance situational awareness and improve the overall system behaviour. The modular structure allows new functionalities
Domingo Mateu, BernatLeiva Ricart, GiselaFacerias Pelegri, MarcPerez, Marc
Real-world usage subjects two-wheelers to complex and varying dynamic loads, necessitating early-stage durability validation to ensure robust product development. Conducting a full life-cycle durability testing on proving grounds is time-consuming, extremely difficult for the riders involved, and costly, which is why accelerated testing using rigs such as the road simulator system have become a preferred approach. The use of road simulators necessitates, accurately measured inputs and precise simulation to ensure proper actuation of the rig, thereby enabling realistic representation of road undulations. This paper covers two important aspects essential for achieving an accurate and clear representation of road simulation in a 4-DOF road simulator, encompassing both longitudinal and vertical simulations at the front and rear of the vehicle. The first aspect involves the development of an instrumentation strategy for the two-wheeler, with careful identification of directionally sensitive
Ganju, ShubhamV, VijayamirtharajPrasad, SathishR S, Mahenthran
Higher road noise is perceived in the cabin when the test vehicle encounters road irregularities like bump or pothole in the public roads. The transfer of transient road inputs inside the body caused objectionable cabin noise. Measurements are conducted at different road surfaces to identify the patch where the objective data well correlated with the noise measured at the public road. Wavelet analysis is carried out to identify the frequency zones since the events are transient in nature. TPA is carried out in time domain to identify the nature of the noise and the dominant path through which the transient road forces are transferring inside the body. Based on the outcome of TPA, various countermeasures like reduction of dynamic stiffness of suspension bushes, TMDs on the path are proposed to reduce the structure borne noise. Criteria which need to be considered for reduction of cabin noise due to transient road inputs is also discussed.
S, Nataraja MoorthyRao, ManchiSelvam, EbinezerRaghavendran, Prasath
The automotive industry is rapidly extending the capabilities of automated systems by incorporating connectivity and cooperation features that enable real-time information exchange between vehicles and road infrastructure. Within the Connected, Cooperative, and Automated Mobility (CCAM) framework, Vehicle-to-Vehicle (V2V) communication is expected to play a key role in improving road safety, traffic efficiency, and driving comfort. This work addresses a practical implementation of the standardized Manoeuvre Coordination Messages (MCMs), as defined in the ongoing ETSI standard (ETSI TS 103 561). The proposed approach is demonstrated through a cooperative cut-in use case in which two vehicles negotiate a lane change manoeuvre. In the considered scenario, the ego vehicle, driven by a Highway Pilot (HWP) system, receives the intention to cut-in from a neighbouring cooperative vehicle through an MCM. In response, the ego vehicle adapts its behaviour by decelerating to generate a safe
Leiva Ricart, GiselaDomingo Mateu, Bernat
In the area of structural durability testing using servo hydraulic actuators, developing drive files for the actuators is a major step. Testing outcomes depend on ensuring the simulation accuracy of each drive file. These drive files are developed in an iterative process for different test track surfaces at different road and load combinations till the time we achieved better correlation. Evaluation of simulation accuracy of the drive files is an extensive manual review process making it time-consuming and resource-intensive. To address this challenge, an application has been develop to automate the comparison of actuator signals with predefined target signal files. This tool enables quick and accurate analysis of each drive file in a test run facilitating a comprehensive review of signal deviations. Each test run is having thousands of drive files based on road-load mix and actuator settings. This application helped us in significantly optimizing the simulation workflow by reducing
Soni, YashKatake, VrishaliMullapudi, DattatreyuduChaskar, Mithun
The paper aimed to improve the accurate quantification of driver drowsiness and to provide comprehensive, evidence-based validation for a Vision-Based Driver Drowsiness and Alertness Warning System. Advanced quantification of driver drowsiness is designed to enhance distinction of true positive events from False Positive and False Negative events. Methodology to pursue this included assessing inputs such as facial features, driver visibility, dynamic driving tasks, driving patterns, driving course time and vehicle speed. The system is programmed to actively learn Eye Aspect Ratio (EAR) reference and adapt personalised EAR threshold value to process EAR frames against the learnt threshold value. This method optimized the data frames to enhance the evaluation and processing of essential frames, thereby reducing delays in the processor and the Human-Machine Interface (HMI) warning module. Comprehensive validation is systematically conducted within a controlled test track environment to
Balasubrahmanyan, ChappagaddaAkbar Badusha, A
In its conventional form, dynamometers typically provide a fixed architecture for measuring torque, speed, and power, with their scope primarily centered on these parameters and only limited emphasis on capturing aggregated real-time performance factors such as battery load and energy flow across the diverse range of emerging electric vehicle (EV) powertrain architectures. The objective of this work is to develop a valid, appropriate, scalable modular test framework that combines a real-time virtual twin of a compact physical dynamometer with world leading real-time mechanical and energy parameters/attributes useful for its virtual validation, as well as the evaluation of other unknown parameters that respectively span iterations of hybrid and electric vehicle configurations, ultimately allowing the assessment of multiple chassis without having to modify the physical testing facility's test bench. This integration enables a blended approach, using a live data source for now, providing
Kumar, AkhileshV, Yashvati
In the rapidly evolving and highly competitive automotive industry, manufacturers are under immense pressure to bring products to market quickly while meeting customer expectations. As a result, optimizing the product development timeline has become essential. Structural integrity analysis for chassis and suspension systems lies in the accurate acquisition of operational load spectra, conventionally executed through Road Load Data Acquisition (RLDA) on instrumented vehicles subjected to proving ground excitation. At this point, RLDA is mainly used for final validation and fine-tuning. If any performance shortfalls, such as premature component failure or durability issues, are discovered, they often trigger design revisions, prototype rework, and additional testing. This study proposes a Virtual Road Load Data Acquisition (vRLDA) methodology employing a high-fidelity full-vehicle multibody dynamic (MBD) representation developed in Adams Car. The system is parameterized and uses high
Goli, Naga Aswani KumarPrasad, Tej Pratap
O-rings play a critical role in ensuring leak-proof seals in a wide range of engineering systems. Accurate prediction of their compression and relaxation behavior under various material and geometric configurations is essential for optimal design and reliability. This study presents an analysis of machine learning techniques to predict two key performance outputs, compression force and relaxation force (after 10 minutes) trained on computer-aided engineering (CAE) simulation data. The experimental setup was represented in CAE simulation and the results were compared with experimental data conducted at ZF test facilities. Simulation results correlated well with the experimental data (deviation was less than the 5%). To create a dataset for training machine learning (ML) models, realistic ranges for the input parameters such as hardness and geometrical parameters were determined, and simulation data were generated using design of experiments (DOE). Multiple ML models were developed and
Kosgi, DurgaprasadAlva, P PanchamDangeti, VenkataKrishna Pavan
The Exhaust Emission Control is a vital part of automotive development aimed at ensuring effective control of pollutants such as NOx, CO, and HC. The traditional method of calibrating emission control strategies is a highly time-consuming process, which requires extensive vehicle testing under a variety of operating conditions. The frequent updates in emission legislation requires a high-efficiency process to achieve a faster time-to-market. The use of Machine Learning (ML) in the domain of emission calibration is the need of the hour to proactively improve the process efficiency and achieve a faster time-to-market. This paper attempts to explores emerging trend of Machine Learning (ML) based data analysis that have improved the overall process efficiency of emission control calibration. The data generated by automated programs could be used directly in data analysis with minimal or no need for data cleaning. The Machine Learning (ML) models could be trained by historical data from
Dhayanidhi, HukumdeenBalasubramanian, KarthickA, Akash
The transition toward zero-carbon propulsion technologies has highlighted the urgent need for specialized test infrastructure to support hydrogen and alternative fuel research. This paper presents the conceptualization, design, and operation of a High-Pressure Direct Injection (HPDI) Hydrogen Internal Combustion Engine (H2 ICE) test facility with integrated ammonia fuel testing capability, marking a significant advancement in India’s sustainable automotive research efforts. Drawing from practical experience, it outlines crucial technical specifications, safety protocols, and best practices for establishing robust, adaptable, and secure testing environments. Addressing the industry’s need for dedicated infrastructure, it is engineered for adaptability across various engine types including heavy-duty, light-duty, and multi-utility vehicles while aligning with global technical standards. Key technical considerations include a transient dynamometer with an advanced automation system for
Dhyani, VipinKurien, CaneonSubramanian, BalajiKhandai, ChinmayanandaMuralidharan, M
The precise validation of radar sensor is necessary due to surging demand for reliable Advanced Driver-Assistance Systems (ADAS) and autonomous driving technologies. Over-the-Air (OTA) Hardware-in-the-Loop approach is the optimal solution for the current challenges facing with traditional on road testing. This approach supports productive, controllable and repetitive environment because of its lab-based setup which will eliminates the drawbacks such as high costs, limited repeatability, safety related issues. Key parameters of radar such as accurate detection of objects, analysis of doppler velocity, range estimation, angle of arrival measurement, can be tested dynamically. And this test setup offers wide range of testing scenarios, including varying distance of target, relative speeds, simulation of objects and environmental effects also supported.OTA provides the flexibility to eliminate the physical test tracks or targets so that developers can simulate the errors, by introducing
Jadhav, TejasKarle, UjjwalaPaul, HarshitSNV, Karthik
This paper contains theoretical and experimental studies of the measurement accuracies of two methods commonly used by vehicle industries and other stakeholders to determine vehicle center of gravity (CG) height. The two methods, which both appear in international standards, are the Axle Lift method and the Stable Pendulum method. The Stable Pendulum method requires a dedicated swinging platform mechanism*, but it is generally considered to be more accurate than the Axle Lift method. Both methods rely on equations for computing CG height that are based on static balance models of a vehicle tested at various pitch angles. For each method, the accuracy of the resulting CG height computations is a function of the individual measurements needed in the model equations. The individual measurements needed depend on the method used, but they include weights, angles, and distance measurements. A theoretical error analysis study is presented that provides insight into the accuracy of both
Heydinger, GaryZagorski, ScottBartholomew, MeredithAndreatta, Dale
A significant contributor to particle mass (PM) emissions originating from road transport are particles emitted from brakes, which in Europe are considered in the upcoming Euro 7 emission legislation. UN-GTR (United Nations Global Technical Regulation) no. 24 describes the methodology for measuring brake particle emissions in a test cell setting with a dynamometer, both in terms of PM and PN (particle number). A regulation-compliant test fulfills various quality criteria for different control parameters, which can often be met by applying different control strategies. In this study, we evaluate the effects of implementing different control strategies for torque applied to the brake by the dynamometer, as well as for sampling flow. Additionally, we discuss the cost-saving potential of increasing the automation degree of testing, as well as modifying existing testbeds to accommodate brake emission testing. The torque control strategies applied in this study did not influence PN or PM
Martikainen, SampsaWeidinger, ChristophHuber, Michael Peter
The deployment of autonomous trucks in off-road environments poses significant engineering challenges due to terrain variability and dynamic operating conditions. While recent advancements in perception, planning, and control architectures have improved vehicle autonomy, experimental validations comparing autonomous and manual control particularly regarding propulsion efficiency remain limited. This study addresses this gap by conducting structured field experiments to evaluate the performance of a heavy-duty truck operating in autonomous and manual modes. Tests were performed on a dedicated proving ground using a multi-sensor autonomous system. Key performance indicators included vehicle speed stability, engine speed regulation, and fuel consumption. The results show that autonomous driving achieved a 4.5% reduction in fuel consumption compared to manual operation. This gain is attributed to the system’s ability to maintain lower speed variance and more consistent engine behavior
Paula Silva, CiriloYoshioka, Leopoldo RidekiKitani, Edson CaoruAndré, Fatec SantoSilva, Nouriandres Liborio
The U.S. Space Force (USSF) Space Systems Command (SSC) achieved a major milestone during a demonstration event in August, showcasing the Joint Antenna Marketplace (JAM) and successfully transferring the U.S. Naval Research Laboratory’s (NRL) Transmit/Receive Enterprise (TREx) Service from a research and development project into an SSC operational prototype.
Oak Ridge National Laboratory (ORNL) researchers have overcome a barrier to using a more affordable, dry process for manufacturing the Li-ion batteries used in vehicles and electronic devices. The resulting batteries provide greater electricity flow and reduced risk of overheating.
The U.S. Space Force (USSF) Space Systems Command (SSC) achieved a major milestone during a demonstration event in August, showcasing the Joint Antenna Marketplace (JAM) and successfully transferring the U.S. Naval Research Laboratory's (NRL) Transmit/Receive Enterprise (TREx) Service from a research and development project into an SSC operational prototype. During the demonstration, the team demonstrated the use of commercial antennas for real-time contacts between a Space Development Agency's (SDA) satellite operations center and their Tranche 0 satellites using JAM which leveraged the newly integrated TREx system.
NASA Johnson Space Center has developed the Micro-Organ Device (MOD) platform technology that serves as a drug screening system with human or animal cell micro-organs to supplement and reduce animal studies while potentially increasing the success of clinical trials. The technology was originally developed to evaluate pharmaceuticals in zero gravity to accelerate development and validation of countermeasures for humans in space as well as evaluate space and planetary stressors on a biological level.
The European Space Agency (ESA) has added a micro-vibration test instrument, developed by the National Physical Laboratory (NPL), to its satellite testing facilities. NPL is the United Kingdom’s National Measurement Institute, developing and maintaining the national primary measurement standards. The instrument measures vibrations generated by satellite subsystems, to quantify their effects on images and measurements made from space. This facility is the result of five years of collaboration between NPL and ESA.
Engine is the prime mover of an automobile. Tractor is also equipped with engine of higher capacity to meet the power requirement. Apart from powering the wheels, engine also runs different accessories such as water pump, alternator, AC pump, Oil pump and so on. The power from the engine is transferred to accessories via chain drive or belt drive through the crankshaft pulley. During field testing, in one of the tractors, engine pulley mounting bolt failure was reported. The failure resulted in immediate seizure of the engine making the tractor standstill in the field. The root cause of the failure was unknown. Hence, there was a need to develop a component or subsystem level test methodology to address the issue quickly. In the current scope, an attempt was made to develop a subsystem level laboratory test methodology to simulate the failure mode and to validate the design modifications in an accelerated manner. The failure mode was simulated in lab and different design iterations
Chakraborty, Abhirup
The new Stage 5 emission regulation requires several changes on engines as well as design and development of new auxiliary systems. These changes affected the engine dynamics and NVH characteristics. These changes are validated for various operating conditions on engine test cell in a controlled environment where engine is mounted on test cell with dyno. Further, this engine will be used by other machine forms, hence NVH performance needs to be evaluated for all the applications. Isolation of three-cylinder engines is challenging since it has to deal with inherent imbalance forces while providing the isolation to meet the durability requirements of heavy applications from off highway machines. This paper covers the methods used for verification of engine isolation performance. NVH tests are conducted for integration of three-cylinder engine with roadbuilding machine. An analytical model is developed to identify rigid body modes and mount transmissibility. Results from this analytical
Pawar, Sachin M.Mandke, Devendra LaxmikantKASABE, SANDEEPJadhav, Vijay
Researchers at the U.S. Department of Energy (DOE)’s Oak Ridge National Laboratory (ORNL) have developed an innovative new technique using carbon nanofibers to enhance binding in carbon fiber and other fiber-reinforced polymer composites — an advance likely to improve structural materials for automobiles, airplanes and other applications that require lightweight and strong materials.
Recent experimental work from the authors’ laboratory demonstrated that applying a boosted current ignition strategy under intensified flow conditions can significantly reduce combustion duration in a rapid compression machine (RCM). However, that study relied on spark anemometry, which provided only localized flow speed estimates and lacked full spatial resolution of velocity and turbulence near the spark gap. Additionally, the influence of turbulence on combustion behavior and performance across varying flow speeds and excess air ratios using a conventional transistor-controlled ignition (TCI) system was not thoroughly analyzed. In this study, non-reactive CFD simulations were used to estimate local flow and turbulent velocities near the spark gap for piston speeds ranging from 1.2 to 9.7 m/s. Simulated local velocities ranged from 0.7 to 96 m/s and were used to interpret experimentally observed combustion behavior under three excess air ratios (λ = 1.0, 1.4, and 1.6). Combustion was
Haider, Muhammad.ShaheerJin, LongYu, XiaoReader, GrahamZheng, Ming
Researchers have developed a portable device capable of detecting rare genetic mutations from a single drop of blood. The instrument was shown in lab experiments to quickly and accurately test for a genetic condition called hereditary transthyretin amyloidosis, which can cause heart problems. The disease is caused by a genetic mutation in the transthyretin gene. This mutation can lead to heart failure, especially in people of West African ancestry. The device, which amplifies nucleic acid segments and detects mutations using a microchip aims to bring a device equal to the performance and accuracy of a polymerase chain reaction (PCR) test, typically confined to laboratories, into doctors’ offices, homes, and community centers.
At UC Berkeley, researchers in Sergey Levine’s Robotic AI and Learning Lab eyed a table where a tower of 39 Jenga blocks stood perfectly stacked. Then a white-and-black robot, its single limb doubled over like a hunched-over giraffe, zoomed toward the tower, brandishing a black leather whip. Through what might have seemed to a casual viewer like a miracle of physics, the whip struck in precisely the right spot to send a single block flying out from the stack while the rest of the tower remained structurally sound.
As part of technology maturation efforts, the COAT Lab evaluated the impact of external audio on driving performance in simulated under amor environments. To do so, we conducted an Engineering Evaluation Test (EET) wherein participants were asked to drive a simulated military vehicle through a Slalom course (primary task) while monitoring for aerial threats (secondary task). Using a combination of objective and subjective metrics, this evaluation quantified participants’ ability to maneuver and detect threats while using external audio as an enabling technology. Evaluation results indicated external audio positively benefited driving performance and situation awareness. However, evaluation results also indicated that external audio was not sufficient in and of itself for detecting time-sensitive aerial threats. Together, these results suggest a development path forward in which external audio is combined with visual information to enhance crew situation awareness under armor.
Grant, LaurenShrestha, SumitHoffing, Russell Cohen
The ongoing shift toward electrification, particularly in the transport and energy sectors, has intensified the deployment of lithium-ion batteries (LIBs). While LIBs offer high energy density and efficiency, their increasing use also brings significant safety challenges—most critically, the risk of thermal runaway (TR) in confined environments. This study presents a fast and structured zero-dimensional/one-dimensional (0D/1D) methodology for estimating key parameters associated with TR events in sealed volumes. The model integrates empirical correlations, energy-based mass estimation approaches, and simplified combustion simulations to assess pressure and temperature rise during TR. Experimental vented mass and gas composition data—obtained through sealed canister testing—serve as the basis for the simulation inputs. A numerical procedure combining mixing dynamics and adiabatic combustion is used to predict critical outcomes such as maximum overpressure and peak temperature
Garcia, AntonioMicó, CarlosMarco-Gimeno, JavierGómez-Soriano, Alejandro
This paper deals with the hydrogen-to-helium jets comparison within the framework of the assessment of helium as a potential hydrogen surrogate. The comparison is centred on the assessment of the combined action of pressure ratio with gas properties on the dynamics of the jet exiting an outward-opening injector. The shots are performed at injection pressures and backpressures ranging from 21 to 36 bar and from 1.2 to 5 bar, respectively. The Schlieren technique is deployed to capture the jets images. The study demonstrates that at certain pressure ratios helium is an appealing solution bridging the lab safety with fidelity to hydrogen-like jet behaviour. Decreasing pressure ratio minimizes the hydrogen-to-helium difference in axial penetration and area, enabling helium to yield a hydrogen-like development. The findings underscore the impact of the pressure ratio on how the gas properties, such as density and diffusivity, dictate the evolution of the axial propagation and area
Coratella, CarloTinchon, AlexisHespel, CamilleDober, GavinFoucher, Fabrice
Naval Research Laboratory Washington D.C. nrlpao@nrl.navy.mil
High-altitude uncrewed aircraft can remain in the lower stratosphere for extended periods, performing a wide range of Earth observation and communications tasks – from monitoring shipping lanes and supporting disaster response to providing internet access. The German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt; DLR) has now taken an important step in the development of its own high-flying solar aircraft by successfully completing a Ground Vibration Test (GVT) on its innovative HAP-alpha high-altitude platform. Extensive ground trials took place at DLR’s National Experimental Test Center for Unmanned Aircraft Systems in Cochstedt, Germany. Further tests will follow and the first low-altitude flight trial is planned for 2026, subject to ideal weather conditions.
Air Force Research Laboratory Wright Patterson Air Force Base, OH 937-522-3252
The German Aerospace Center's (DLR) solar-powered high altitude platform (HAP) has completed ground vibration testing, in preparation for low altitude flight testing planned for 2026. German Aerospace Center (DLR), Cologne, Germany High-altitude uncrewed aircraft can remain in the lower stratosphere for extended periods, performing a wide range of Earth observation and communications tasks - from monitoring shipping lanes and supporting disaster response to providing internet access. The German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt; DLR) has now taken an important step in the development of its own high-flying solar aircraft by successfully completing a Ground Vibration Test (GVT) on its innovative HAP-alpha high-altitude platform. Extensive ground trials took place at DLR's National Experimental Test Center for Unmanned Aircraft Systems in Cochstedt, Germany. Further tests will follow and the first low-altitude flight trial is planned for 2026, subject to ideal
For years researchers at the Department of Energy’s (DOE’s) Pacific Northwest National Laboratory (PNNL) have been developing tools to accelerate the materials discovery and development of new energy storage technologies, including those that can predict the performance of the batteries systems for long-term grid services.
Researchers at the Department of Energy’s Oak Ridge National Laboratory are using advanced manufacturing techniques to revitalize the domestic production of very large metal parts that weigh at least 10,000 pounds each and are necessary for a variety of industries, including clean energy.
A research team led by scientists at Lawrence Berkeley National Laboratory (Berkeley Lab) has developed a new fabrication technique that could improve noise robustness in superconducting qubits, a key technology for enabling large-scale quantum computers.
U.S. Army researchers, in collaboration with academic partners, invented a stronger copper that could help advance defense, energy and aerospace industries thanks to its ability to endure unprecedented temperature and pressure extremes. Extreme materials experts at the U.S. Army Combat Capabilities Development Command (DEVCOM) Army Research Laboratory built on a decade of scientific success to develop a new way to create alloys that enable Army-relevant properties that were previously unachievable. An alloy is a combination of a metal with other metals or nonmetals.
Researchers at the U.S. Department of Energy (DOE)’s Oak Ridge National Laboratory (ORNL) have developed an innovative new technique using carbon nanofibers to enhance binding in carbon fiber and other fiber-reinforced polymer composites — an advance likely to improve structural materials for automobiles, airplanes and other applications that require lightweight and strong materials.
Not a traditional university lab, Harvard University’s Move Lab employs professional engineers, product developers, and academics who work across disciplines to bring research innovations to market. The lab is focused on human performance enhancement to protect people’s physical ability to guard against injury, extend their abilities beyond the limits of advancing age, and restore them to people who have lost them. They have developed wearable solutions that support functional movements and allow impaired individuals to more easily interact with their environment.
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