Browse Topic: Test procedures

Items (12,717)
This SAE Recommended Practice establishes uniform test procedures and performance requirements for the defrosting system of enclosed cab trucks, buses, and multipurpose vehicles. It is limited to a test that can be conducted on uniform test equipment in commercially available laboratory facilities. For laboratory evaluation of defroster systems, current engineering practice prescribes that an ice coating of known thickness be applied to the windshield and left- and right-hand side windows to provide more uniform and repeatable test results, even though - under actual conditions - such a coating would necessarily be scraped off before driving. The test condition, therefore, represents a more severe condition than the actual condition, where the defroster system must merely be capable of maintaining a cleared viewing area. Because of the special nature of the operation of most of these vehicles (where vehicles are generally kept in a garage or warmed up before driving), and since
Truck and Bus Windshield Wipers and Climate Control Comm
This SAE Aerospace Standard (AS) establishes vibration and transmissibility test procedures which compare the relative strengths of various loop and saddle type support clamps. This procedure is intended for conducting fatigue testing which is standard throughout the aerospace industry thereby establishing a clamp strength comparison that can be used in an evaluation process. The testing required by this document ensures that clamps will meet adequate fatigue requirements only. It does not infer qualification of the clamp installation techniques or its ability to meet in-service environments or operating conditions. Separate qualification testing should be performed to ensure satisfactory service of the installed clamp.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Scenario-based testing has become a central approach of safety verification and validation (V&V) of automated driving. The standard ISO 21448: Safety of the intended functionality (SOTIF) [1] proposes triggering conditions (e.g., an occluded traffic sign) as a new aspect to be considered to organize scenario-based testing. In this contribution, we discuss the requirements and the strategy of testing triggering conditions in an iterative, SOTIF-oriented V&V process. Accordingly, we illustrate a method for generating test scenarios for evaluating potential triggering conditions. We apply the proposed method in a two-fold case study: We demonstrate how to derive test scenarios and test these with a virtual automated driving system in simulation. We provide an analysis of the testing result to show how triggering condition-based testing facilitates spotting the weakness of the system. Besides, we exhibit the applicability of the method based on multiple triggering conditions and nominal
Zhu, ZhijingPhilipp, RobinHowar, Falk
In some IC engines, fuel injection pump is driven by camshaft; thus, these camshafts are designed for bending and torsional loads. Conventionally, camshafts are built-to-specification. Typically, durability assessment of camshaft happens at engine level, this calls for proto or calibration engine to be made and available for testing. As there are limited number of engine level proto testing, the overall scatter in camshafts due to manufacturing/process variations is not possible to be covered. This poses a risk of camshaft failures in the final stages of product development. To mitigate this risk, a component level standard test method is needed for quickly validating design and manufacturing process of camshafts for second source suppliers. The current paper discusses the process followed for arriving at a standard test setup and overcoming the challenges in terms of capturing the appropriate physics for camshaft failure during the engine level testing. Camshaft rear end experiences
Chakraborty, AbhirupS, AravamuthanK, Karthikeyan
O-rings are essential components in engineering products as they ensure leak-proof sealing and hinders amalgamation of various fluids in the system. O-rings in general have lot of factors that go into deciding the right design for a system. With the help of FEA, O-ring design is varied to ensure optimal results. However, this process is time and resource consuming. Considering this situation, an alternative approach to predict the outcome with the help of DOE study is chosen in this paper. It leverages the Machine Learning models to predict the output parameters effectively with less resources. With the help of performance parameters, this paper proposes a comparison of various native ML models like Linear Regression, Random Forrest, SVM, KNN, Boosting, Artificial Neural Networks and Kriging [7]. The Goal is to systematically compare the prediction performance of various models based on bootstrapping and hypothesis testing techniques to identify the most effective approach. This
Mallu, Venkata ReddyPenumatsa, Venkata Ramana RajuChirravuri, BhaskaraDuddu, VaraprasadMiller, RonaldSahu, Abhishek
Lubricant oil in combustion engines undergoes thermal degradation under high temperatures and forms solid deposits. These deposits, called coke, are insidious, black, and carbonaceous solids. To mitigate the problems associated with oil coking, an effective testing methodology must be developed to characterize the coke formation qualitatively and quantitatively. Previously, testing methodologies have been developed to measure coking tendency however some of the international standards such as the SAE ARP 6166 use visual inspection methods to assess coke. Such methods are unsuitable for advanced research as they are prone to error in human judgment. This paper intends to bridge this gap and discusses test methodologies that can measure Coke quantitatively and qualitatively. Coke formation has been studied using different laboratory methods such as static immersion, thin film oxidation, and dynamic spray tests to replicate the various conditions. In a static immersion test, a metal
Jeyaseelan, ThangarajaS, ShanmugasundaramBansal, LalitNegi, AshishKoka, Tirumala RaoDas, Arnab
This paper discusses the design and analysis of the Three-point linkage of an agricultural tractor for uncommon abusive usage practices during haulage applications. Some operators use the Three-point linkage for generating additional traction to navigate gradient surfaces, which requires additional wheel torque to overcome road slope when the trailer is attached. These maneuvers induce higher loads on Three-point linkage components, such as the lower link, lift rod, and powertrain components, which may lead to structural failures. A virtual simulation and lab-level test methodology need to be established to simulate the usage pattern upfront and predict potential failures. Multi-body dynamics (MBD) simulation was deployed to simulate the physics and extract realistic loads for Computer Aided Engineering (CAE) analysis. Data acquisition was carried out to record the strain levels during the uncommon haulage usage practices, which will be used for further studies. CAE analysis has been
Kumar, YuvarajPerumal, SolairajV, Ashok KumarSavsani, SmitkumarSubbaiyan, Prasanna BalajiBhandwalkar, AnandV V H Krishna Prasad, Tadikamalla
In the Agricultural tractor- transmission system plays major role to transfer power from Engine to final drive through gear box enabling Forward/Reverse (F/R) movements during field operations and transportation conditions. The F/R retainer plate with idler gear, shaft is located between clutch housing and transmission gear box housing. If the retainer housing plate gets failure, then power will not be able to transfer from engine to transmission gear box main drive. In one of the tractor model retainer plate failures was observed during field testing. To simulate the failure mode from field to lab condition, the resultant forces and angle were calculated based on the drive line assembly. Resultant loads were applied on Idle gear shaft assembly through servo actuator in cyclic mode at lab. The failure was observed in the retainer plate and the location of failure was matching with field failure. CAE virtual simulation was carried out for measured load as per the laboratory boundary
V, SaravananMani, SureshKumar, SasiMore, AmitDumpa, Mahendra Reddy
This SAE Recommended Practice establishes a uniform, powered vehicle test procedure and minimum performance requirement for lane departure warning systems used in highway trucks and buses greater than 4546 kg (10000 pounds) gross vehicle weight (GVW). Systems similar in function but different in scope and complexity, including lane keeping/lane assist and merge assist, are not included in this document. This document does not apply to trailers, dollies, etc. This document does not intend to exclude any particular system or sensor technology. This document will test the functionality of the lane departure warning system (LDWS) (e.g., ability to detect lane presence and ability to detect an unintended lane departure), its ability to indicate LDWS engagement, its ability to indicate LDWS disengagement, and its ability to determine the point at which the LDWS notifies the human machine interface (HMI) or vehicle control system that a lane departure event is detected. Moreover, this
Truck and Bus Automation Safety Committee
The internal short circuit of a traction battery is one of the most typical failure mechanisms that can lead to thermal runaway, potentially triggering thermal propagation across the entire battery system. This phenomenon poses significant safety risks, especially in electric vehicles and large-scale energy storage systems. Therefore, it is essential to explore and understand the internal short circuit behavior to mitigate these risks. One of the most effective testing methods for reproducing an internal short circuit is the penetration test, where specific test conditions must be carefully designed based on the failure behavior. Among these conditions, the penetration step length plays a crucial role, as it directly influences the short circuit dynamics. Despite the importance of penetration step length, there is currently no standardized test procedure that dictates how to select the appropriate step size for different battery samples. This gap in standardization complicates the
Wang, FangSun, ZhipengMa, TianyiDai, XiaoqianDai, CeYan, PengfeiMa, XiaoleChen, LiduoMa, HaishuoShen, Shaopeng
Electrified powertrain configurations are critical to the fuel economy and performance of hybrid vehicles. While single planetary gear (PG) configurations - such as the Toyota Prius - have the advantage of simple control and excellent fuel economy, the generator1 is unable to participate in the drive, resulting in poor acceleration. To overcome these problems, we propose a new multi-gear electronically controlled continuously variable transmission (ECVT) due to its high efficiency and excellent acceleration performance. It requires only one PG and two synchronizers. For this type of multi-gear ECVT hybrid vehicle, this paper describes in detail the synchronizer-based shift logic of the new configuration. Furthermore, the power flow and dynamics modeling process in different operating modes are systematically analyzed. In addition, the global optimal Dynamic Programming (DP) algorithm is presented and a new near-optimal energy management strategy, Rapid-DP, is employed to evaluate the
Zou, YungeZhang, YuxinYang, YalianLiu, Changdong
The durability of fuel cell vehicle (FCV) has always been one of the key factors affecting its large-scale application. However, the durability test methods of FCV and its key components, fuel cell stack (FCS), are incomplete all over the world, especially the lack of vibration test method on FCV. Focused on the FCS, this paper collects the road load spectrum of different vehicle models in their typical working conditions, so as to obtain the power spectral density of FCS of different vehicle models, which is used as the input signal of durability test. Through the FCS testing and analysis of fuel cell passenger car, bus, tractor and cargo van, the results show that the vibration intensity in three directions of FCS of different models is basically less than that of power battery, and only the FCS of fuel cell bus is greater than that of power battery in the direction of vehicle travel.
Wang, GuozhuoWu, ZhenGuo, TingWu, ShiyuLiang, RongliangNie, Zhenyu
PEM electrolysis system has characteristic of excellent performance such as fast response, high electrolysis efficiency, compact design and wide adjustable power range. It provides a sustainable solution for the production of hydrogen, and is well suited to couple with renewable energy sources. In the development process of PEM electrolysis controller, this article originally applied the V-mode development process, including simulation modeling, RCP testing, and HIL testing, which can provide guidance in the practical application of electrolytic hydrogen production. In this paper, we present modeling and simulation study of PEM water electrolysis system. Model of electrolytic cell, hydrogen production subsystem and thermal management subsystem are constructed in Matlab/Simulink. Controller model was designed based on PI control strategy. A rapid prototyping controller with MPC5744 chip was used to develop the control system of electrolytic hydrogen production system. Hardware in the
Hua, YuweiJin, ZhenhuaTian, YingTao, Yuepeng
Currently, the application scope of fuel cell vehicles is gradually expanding. There is currently no durability testing method for the entire vehicle level in its research and development design process. In this article, a certain fuel cell passenger car is taken as the research object. The load spectrum data of its key components is collected. A ‘user goal test field’ multi-channel multi-dimensional load correlation optimization model is established. The goal is to minimize the difference in pseudo damage of special components such as the fuel cell vehicle stack structure under the user’s full life cycle target load and the test field test load. The characteristics of the multi-dimensional load of the fuel cell components corresponding to the optimized solution in the rainflow distribution and frequency domain distribution are calculated. And a durability reliability acceleration testing specification for fuel cell vehicle test fields for special components such as the stack structure
Wu, ShiyuGuo, TingWang, YupengWu, ZhenWang, Guozhuo
The development of hydrogen economy is an effective way to achieve peak carbon emission and carbon neutralization. Therein, the green production of hydrogen is a prerequisite to reach the goal of decarbonization. As an ideal route, water electrolysis has triggered intense responses under the strong support from policies, which further presenting a phenomenon of water electrolysis equipment manufactures competing to enter the market. However, the extensive growth mode is not conducive to a long term healthy development of the water electrolysis hydrogen production market where products can be sold without requiring compulsory inspection or quality inspection process due to the absence of laws and test & evaluation standards. Considering the market status and technology maturity, the main working principles and characteristics of alkaline water electrolysis (AWE) and proton exchange membrane (PEM) hydrogen production systems are summarized, and the test frameworks of the AWE and PEM
Jiao, DaokuanWang, XiaobingHao, Dong
This research aimed to explore the integration of Virtual reality technology in ergonomically testing automotive interior designs. This objective was aimed at ensuring that such technology could be used to ameliorate user comfort through controlled simulations. Existing ergonomic testing methods are often limited when it comes to recreating actual driving situations and quickly repeating design improvements. VR could be used as a solution because its ergonomically tested simulation can be used to provide users with the real experience of driving. The users can be observed while they experience it and asked for their feedback. For this research, an interactive VR environment imitating a 10-minute-long trip through traffic and changing road conditions was created. It was populated by ten users, concatenated equally in men and women, both aged 20-35, representing approximate demographics of workers in the automotive production industry. Participants of the research were asked to use
Natrayan, L.Kaliappan, SeeniappanSwamy Nadh, V.Maranan, RamyaBalaji, V.
This study presents a method for identifying the reliability state of diesel engines by utilizing artificial neural networks (ANNs). The Sulzer 6AL20/24 marine diesel engine was selected as the test subject for this research. Vibration signals were collected during tests conducted on a laboratory test stand under normal operating conditions and during simulations of six different engine faults. Next, the recorded signals were analyzed and transformed into labeled samples for supervised learning. In this phase, the time histories of the vibration signals were divided into segments and augmented, with several key features calculated for each segment. Highly correlated signals were excluded from further analysis based on the Pearson correlation coefficient. The processed samples were then used to train and fine-tune the ANN. The trained ANN was subsequently used to identify the engine’s reliability state and classify the present fault type. To evaluate the effectiveness of the proposed
Pająk, MichałKluczyk, MarcinMuślewski, ŁukaszLisjak, Dragutin
Fused deposition modeling (FDM) is a rapidly growing additive manufacturing method employed for printing fiber-reinforced polymer composites. Nonetheless, the performance of printed parts is often constrained by inherent defects. This study investigates how the varying annealing parameter affects the tribological properties of FDM-produced polypropylene carbon fiber composites. The composite pin specimens were created in a standard size of 35 mm height and 12 mm diameter, based on the specifications of the tribometer pin holder. The impact of high-temperature annealing process parameters are explored, specifically annealing temperature and duration, while maintaining a fixed cooling rate. Two set of printed samples were taken for post-annealing at temperature of 85°C for 60 and 90 min, respectively. The tribological properties were evaluated using a dry pin-on-disc setup and examined both pre- (as-built) and post-annealing at temperature of 85°C for 60 and 90 min printed samples
Nallasivam, J.D.Sundararaj, S.Kandavalli, Sumanth RatnaPradab, R.
Accurate and responsive trajectory tracking is a critical challenge in intelligent vehicle control system. To improve the adaptability and real-time performance of intelligent vehicle trajectory tracking controllers, we propose a genetic algorithm adaptive preview (GAAP) scheme that offline optimizes the preview distance based on vehicle speed and reference path curvature. The goal is to obtain the optimal preview distance that balances tracking accuracy, stability, and real-time performance. By establishing a relationship between optimal preview distance, speed, and curvature, we enhance real-time performance through online table checking during trajectory tracking. Our trajectory tracking error model takes into account not only position errors but also heading errors. A feedback–feedforward trajectory tracking controller is then designed to achieve rapid responses without compromising robustness. Simulation tests conducted under straight circular arc condition and double lane change
Cheng, KehanZhang, HuanhuanHu, ShengliNing, Qianjia
SBW(Steer-by-wire) is a steering system that transmits the driver’s request and gives feedback to the driver through electrical signals. This system eliminates the mechanical connection of the traditional steering system, and can realize the decoupling of the steering wheel and the road wheel. In addition, this system has a perfect torque feedback system, which can accurately and delicately feedback the road surface information to the driver. However, vehicle driving deviation is one of the most common failure modes affecting vehicle performance in the automotive aftermarket, this failure mode can exacerbates tire wear, reducing their life cycle, at the same time, the driver must apply a counter torque to the steering wheel for a long time to maintain straight-line travel during driving. This increases the driver’s operational burden and poses safety hazards to the vehicle’s operation. Based on the steer-by-wire system and vehicle driving deviation characteristics, this paper proposes
Xiangfei, XuQu, Yuan
The purpose of this study is to analyze different airfoils using various tools like X-Foil and Reynolds-averaged Navier–Stokes (RANS) computational fluid dynamic (CFD) analysis (ANSYS Fluent) and compare both the results with wind tunnel experimental data to choose an aerodynamically efficient airfoil, which is suitable for an unmanned aerial vehicle/micro aerial vehicle (UAV/MAV) and its operational domain of Reynolds number. The main objective of this analysis is to identify and give us an understanding of the airfoil that has a higher value of Cl max and minimum possible value of Cd. This article discusses various low Reynolds number airfoils, i.e., for the range of Reynolds number between 50,000 and 200,000, which is mostly used for MAVs. Also, between the range of 100,000 and 200,000 for UAVs, which have displayed considerable performance in the past. The article also presents an effort to understand the phenomenon of laminar separation bubbles.
Roy, IndranilRao, Sameera
Modern vehicles are increasingly integrating electronic control units (ECUs), enhancing their intelligence but also amplifying potential security threats. Vehicle network security testing is crucial for ensuring the safety of passengers and vehicles. ECUs communicate via the in-vehicle network, adhering to the Controller Area Network (CAN) bus protocol. Due to its exposed interfaces, lack of data encryption, and absence of identity authentication, the CAN network is susceptible to exploitation by attackers. Fuzz testing is a critical technique for uncovering vulnerabilities in CAN network. However, existing fuzz testing methods primarily generate message randomly, lacking learning from the data, which results in numerous ineffective test cases, affecting the efficiency of fuzz testing. To improve the effectiveness and specificity of testing, understanding of the CAN message format is essential. However, the communication matrix of CAN messages is proprietary to the Original Equipment
Shen, LinXiu, JiapengZhang, ZhuopengYang, Zhengqiu
This SAE Recommended Practice provides performance, sampling, certifying requirements, test procedures, and marking requirements for aftermarket wheels intended for normal highway use on passenger cars, light trucks, and multipurpose passenger vehicles. For aftermarket wheels on trailers drawn by passenger cars, light trucks, or multipurpose vehicles, refer to SAE J1204. These performance requirements apply only to wheels made of materials included in Tables 1 and 2. For wheels using composite material, refer to SAE J3204. New nomenclature and terms are added to clarify wheel constructions typically not used in OEM applications. The testing procedures and requirements are based on SAE standards listed in the references.
Wheel Standards Committee
The purpose of this SAE Recommended Practice is to establish uniform test procedures for measuring and rating air delivery and cooling capacity of truck and off-road self-propelled work machines used in earth moving, agriculture, and forestry air-conditioner evaporator assemblies. It is the intent to measure only the actual cooling capacity of the evaporator. It is not the intent of this document to rate and compare the performance of the total vehicle air-conditioning system.
Truck and Bus Windshield Wipers and Climate Control Comm
This SAE Recommended Practice establishes uniform cold weather test procedures and performance requirements for engine coolant type heating systems of bus that are all vehicles designed to transport 10 or more passengers. The intent is to provide a test that will ensure acceptable comfort for bus occupants. It is limited to a test that can be conducted on uniform test equipment in commercially available laboratory facilities. Required test equipment, facilities, and definitions are included. There are two options for producing hot coolant in this recommended practice. Testing using these two approaches on the same vehicle will not necessarily provide identical results. Many vehicle models are offered with optional engines, and each engine has varying coolant temperatures and flow rates. If the test is being conducted to compare the performance of one heater design to another heater design, then the external coolant source approach (Test A) will yield the most comparable results. If the
Truck and Bus Windshield Wipers and Climate Control Comm
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