Browse Topic: Test procedures

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Collaborative Cybersecurity in a Shifting Automotive Supply Chain2026-01-0084To be published on 04/07/2026
The evolution toward software-defined vehicles (SDVs) is causing disruption to the traditional automotive supply chain and breaking down the common hierarchical OEM, tier 1 supplier, and tier 2 supplier relationships. With demands for faster software release cycles, more advanced software projects involving multi-party development, and considerations for end-to-end embedded and cloud integrations, new cybersecurity challenges are introduced that no single organization can address alone. Thus, this disruption creates new trust dependencies and requires new models for collaboration, transparency, and joint responsibility in cybersecurity. This paper presents a collaborative cybersecurity model, emphasizing shared responsibility during multi-party development between OEMs, tier 1 and 2 suppliers, engineering services organizations, and technology and services providers. As such, we explore collaborative approaches for each stage in the development lifecycle including design, development
Oka, Dennis Kengo, Vinzenz, Nico
Simulate, Validate, Repeat: Streamlining Testing with Record, Replay, & Simulation2026-01-0082To be published on 04/07/2026
As autonomous systems mature, the ability to test, validate, and debug them efficiently has become as critical as the underlying software and algorithms. This paper outlines an approach to enabling simulation, record and replay, and time control native to the development and validation process. The underlying application brings deterministic control, scalable recording, and simulator integration into one cohesive development workflow, enabling faster iteration, smarter testing and deployment. This approach uses a unified testing pipeline, across MiL, SiL, and HiL, supporting flexible testing and integration through interchangeable data feeds, recordings, or simulation inputs. The same application used to test in simulation can run unchanged on a vehicle, greatly accelerating iteration and de-risking deployment. Virtual time support systems allow for executing faster or slower than real time, while preserving correct behavior and deterministic timing. Built on ROS 2’s rosbag2 framework
Phillips, Chris
Development and Comparison of Benchmarking Methods for Electric Vehicle Drive Units2026-01-0198To be published on 04/07/2026
At the U.S. Environmental Protection Agency’s National Vehicle and Fuel Emissions Laboratory, a development project was implemented to compare various test methods for benchmarking the operation of vehicle electric drive units (EDUs). In earlier research, several test methods were identified, of which two were used to test a Chevrolet Bolt EDU: (a) in-vehicle testing of the complete EDU on a chassis hub dynamometer and (b) stand-alone testing of the EDU’s electric motor and inverter in a dedicated test cell after removal from the vehicle. The resulting data sets were compared with each other and with similar data previously published by GM. In this paper, additional EDU test methods are explored. First, the stand-alone testing of the EDU and its subcomponents is expanded to include testing both with and without the EDU gearing. This testing allows the electric motor, inverter, and gearbox to be characterized separately and the EDU to be characterized as a complete unit. Second, in
Moskalik, Andrew, Schauer, Ethan, Barba, Daniel
On-Road Vehicle Testing and Characterization2026-01-0195To be published on 04/07/2026
Vehicle testing for fuel economy and emissions is typically performed indoors over standard dynamometer drive schedules to minimize variability and maximize repeatability of the results. In contrast, during on-road operation, operational parameters such as vehicle speed and acceleration and environmental factors such as temperature and wind will change unpredictably. These factors influence vehicle fuel economy and emissions, making on-road operation much more variable than dynamometer results. However, even though on-road conditions may be unpredictable, the on-road operational data can still be used to characterize vehicle performance. This paper describes the development of an on-road vehicle test methodology, with a focus on accounting for on-road factors with a high degree of accuracy while requiring only an achievable and reasonable amount of data. To develop this methodology, a 2016 Honda Civic was instrumented and driven multiple times over a route covering urban, rural, and
Moskalik, Andrew, Barba, Daniel
Energy Management Strategy for Hybrid Mining Trucks Based on Global SOC Planning and Neural Network Optimal Control2026-01-0446To be published on 04/07/2026
Hybrid mining trucks, as core equipment for mine transportation, face high energy consumption and significant fluctuations in power demand during cyclic operations due to prolonged exposure to demanding operating conditions characterized by heavy loads and variable working conditions. To address the issues of high energy consumption and significant fluctuations in power demand during the cyclic operation of mining trucks, this paper proposes a hybrid mining truck energy management strategy based on global SOC (State of Charge) planning and neural network optimization control. First, a powertrain model was developed for a typical operating cycle of a hybrid mining truck, and its accuracy was validated by comparing it with experimental data. Using dynamic programming algorithms to plan the SOC for single-cycle operations provides a rational reference for energy allocation across different operational phases of mining trucks during a single cycle. Next, using the powerful nonlinear
Yang, Jianyu, Zhao, Zhiguo, Chen, Huiyong, Li, Tao, ZHUANG, Wenyu, Shen, Peihong, Tang, Peng
Experimental Research on Rapid Test Method for NOX and PN Emissions of Heavy Duty Vehicles2026-01-0375To be published on 04/07/2026
This article investigates the rapid testing equipment for NOX and PN, starting from the testing principle, discusses the development history of rapid testing for NOX and PN at home and abroad, and introduces the relevant equipment currently used for NOX and PN emission testing. By running the PEMS verification test conditions specified in Annex DC of GB 18352.6-2016 on a light-duty vehicle chassis dynamometer, and collecting emission data from portable emission devices, rapid PN testing devices, and CVS emission analyzers, the correlation and deviation between portable emission devices, rapid PN testing devices, and CVS emission analyzers are analyzed; By simulating vehicle idle and C-WTVC operating conditions on a heavy-duty vehicle chassis dynamometer, analyze the correlation between emission data at idle and C-WTVC operating conditions when the accelerator pedal is fully depressed; By running the WHTC and WHSC cycles specified in GB 17691-2018 on the engine bench, and collecting
Li, Lan, Ni, Jiacheng, Liu, Yiming, Zhuo, Yuanhong, Bai, Qi, Fu, Chunyun, Kang, Zhe
Machine Learning-Based Gear Defect Detection in Electric Vehicle Drive Units Using End-of-Line Vibration Analysis2026-01-0637To be published on 04/07/2026
The final assembly of electric vehicle (EV) drive units includes an essential End-of-Line (EOL) test to ensure both component integrity and Noise, Vibration, and Harshness (NVH) quality. This screening process, which uses dynamometers to measure vibration signals, is critical for identifying defects before a drive unit is installed in a vehicle. A significant source of failure during this test is gear defects, which can arise from manufacturing or handling issues. Traditional EOL testing methods rely on time-domain analysis and the impulsiveness of vibration signatures to detect these defects, a technique with inherent limitations in accuracy. This paper introduces and evaluates a novel approach using Machine Learning (ML) to analyze vibration signals for improved gear defect detection. We discuss the methodologies of both the traditional time-domain and the proposed ML-based techniques. Finally, we provide a comprehensive comparison of their respective efficiency and accuracy
Arvanitis, Anastasios, Michaloliakos, Anargyros
A Study on the Relationship between Impact Conditions and Head Injury Criterion (HIC) in Powered-Two-Wheeler to Car Crashes2026-01-0571To be published on 04/07/2026
Road Traffic crash statistics highlight the importance of reducing fatalities among Powered-Two-Wheeler (PTW) riders, and suggest the necessity of a robust method to evaluate PTW crashworthiness performance. The objective of this study is to clarify the relationship between impact conditions and the Head Injury Criterion (HIC) to establish a fundamental basis for determining representative crash configurations for safety. A total of 1,272 PTW-front to car-side impact simulations were conducted by using production car and PTW models. HIC was used as a metric indicating likelihood of head injury. Velocities, impact angle, and impact locations were varied to create response surfaces. The surfaces were evaluated in terms of their accuracy in identifying the representative impact conditions. In addition, head trajectories were analyzed to clarify the kinematics until head impact. The Finite Element (FE) simulations produced the following findings. - The HIC distribution by Head Impact
Yanaoka, Toshiyuki, GUNJI, Yasuaki, Zulkipli, Zarir Hafiz, Matsushita, Tetsuya, Carroll, Jolyon, Puthan, Pradeep, Mohd Faudzi, Siti Atiqah, D-Wing, Kak, Miyazaki, Yusuke
Typical cloud-vehicle-integration-based functional safety testing technology for intelligent chassis2026-01-0051To be published on 04/07/2026
Model-based virtual vehicle testing technology is an advanced simulation technique that significantly improves the efficiency and quality of vehicle development. It effectively addresses challenges such as complex operating conditions and experimental hazards in physical road testing. However, due to limitations in modeling accuracy, virtual vehicle parameters often remain overly idealized, resulting in limited credibility of test results. In response to the above issues, this article proposes a testing method based on vehicle-cloud fusion technology that combines the advantages of physical and virtual vehicle testing to avoid the disadvantages of both parties. Experimental validation demonstrates that the synchronization rate between virtual car and physical car data can reach 92.02%, which can safety and efficiently complete the initial vehicle testing, provide data support for subsequent physical car testing, and shorten the real car testing cycle.
Cheng, Qing Hua, Qu, Wenying, Liao, Yinsheng, Wu, Yan
Collision Avoidance Testing of the Waymo Automated Driving System2026-01-0519To be published on 04/07/2026
This paper describes Waymo's Collision Avoidance Testing (CAT) methodology: a scenario-based testing method that evaluates the safety of the Waymo Driver Automated Driving Systems' (ADS) intended functionality in conflict situations initiated by other road users that require urgent evasive maneuvers. Because SAE Level 4 ADS are responsible for the dynamic driving task (DDT), when engaged, without immediate human intervention, evaluating a Level 4 ADS using scenario-based testing is difficult due to the potentially infinite number of operational scenarios in which hazardous situations may unfold. To that end, in this paper we first describe the safety test objectives for the CAT methodology, including the collision and serious injury metrics and the reference behavior model representing a non-impaired eyes on conflict human driver used to form an acceptance criterion. Afterward, we introduce the process for identifying potentially hazardous situations from a combination of human data
Kusano, Kristofer, Beatty, Kurt, Schnelle, Scott, Favaro, Francesca, Crary, Cam, Victor, Trent
Design and validation of modern hydrogen and natural gas containers for on board vehicle storage2026-01-0188To be published on 04/07/2026
Ensuring the operational safety of gaseous fuel containers for hydrogen and natural gas vehicles requires robust and validated protective devices capable of responding reliably under diverse operating and accident scenarios. This paper presents the design considerations, test methodology, and validation outcomes for safety subsystems integrated into modern compressed gas storage vessels, with emphasis on pressure relief devices (PRDs), thermal protection systems, and valve assemblies. Drawing on experimental insights from previous studies of hydrogen and natural gas fueling systems and fire-resistance assessments, the work defines safety-critical conditions such as rapid temperature rise during bonfire exposure, localized flame impingement, over-pressurization from fast filling, and mixed-gas operation. A comprehensive validation protocol was established, combining standardized regulatory tests with additional stress profiles replicating service-realistic environments. These included
Flekiewicz, Marek, Flekiewicz, Wojciech
SUNRISE - a harmonised Safety assUraNce fRamework for connected, automated mobIlity SystEms2026-01-0060To be published on 04/07/2026
The SUNRISE project develops and demonstrates a harmonised Safety Assurance Framework (SAF) for Connected, Cooperative and Automated Mobility (CCAM) systems. The framework has been created in close alignment with the UNECE New Assessment/Test Method (NATM), and past and on-going international projects and initiatives. It also aligns with standardisation efforts in various standardisation bodies such as ISO, ASAM, SAE, and BSI. At the core of the SAF lies the Performance Assurance flow, which structures how safety evidence is generated and assessed. This flow is organised into three interconnected blocks: Scenario, Environment, and Safety Argument. The Scenario block encompasses the creation, formatting, and storage of scenarios that can be retrived to cover the system’s Operational Design Domain (ODD) and behaviour. The Environment block addresses the concretisation of test cases, their allocation across virtual, proving-ground, and real-world environments, and their execution. The
Zhang, Xizhe, Khastgir, Siddartha, de Vries, Stefan, Hillbrand, Bernhard, Op den Camp, Olaf, Bolovinou, Anastasia, Bourauel, Bryan, Ehrenhofer Gronvall, John Fredrik, Menzel, Thaddäus, Nieto, Marcos, Stettinger, Georg, Jennings, Paul
Challenges to Ranking Diesel Fuels for NOx Emissions Using a Constant-Volume Combustion Chamber2026-01-0348To be published on 04/07/2026
This study examined the use of a constant volume combustion chamber for the measurement of fuel effects on NOx emissions, with the goal of developing a method to rapidly screen or rank fuels in a small - volume experiment. A small amount of fuel was injected into the air at 650°C and 20 bars, where it ignited and burned. The chamber was sampled post-combustion using a chemiluminescence NOx analyzer. Extensive sampling method development was required to obtain repeatable results. Seven hydrocarbon fuels and two biodiesel fuels were tested, all of which have shown difference in NOx emissions in past engine studies. When using a single injection event to deliver the same amount of fuel energy, the test method could not clearly demonstrate the difference in NOx emissions between the hydrocarbon fuels as reported in engine combustion studies. To improve this, a dual-injection strategy was used. It included a small “pilot” injection followed by a main injection, timed based on each fuel’s
Luecke, Jon, Rahimi, Mohammad, Mohamed, Samah, Naser, Nimal, Chausalkar, Abhijeet, McCormick, Robert
Development of an Advanced Tensile Testing Method for HDPE Composites in High Draw Molded Hollow Circular Regions: Effects of Sample Preparation, Asymmetry, Thermal Conditions, Pull Speed, and Fixture Parameters.2026-01-0204To be published on 04/07/2026
High-density polyethylene (HDPE) composites, particularly in high draw molded hollow circular configurations, present unique challenges in evaluating mechanical performance under tensile stress due to anisotropic deformation, geometric asymmetry, and localized thermal gradients. This study introduces an advanced tensile testing methodology designed specifically to assess such regions with greater precision and reproducibility. The method incorporates refined sample preparation protocols, tailored fixture geometry, and adjustable pull speeds to accommodate varying thermal histories and draw ratios inherent to molded sections. Systematic variation of asymmetrical, temperature conditions, and clamping techniques revealed significant impacts on tensile strength, elongation at break, and strain distribution. Findings emphasize the necessity of customized testing frameworks for molded composite geometries and demonstrate that fixture alignment and thermal conditioning are critical to
BHALERAO, SAURABH SHANKAR
Establishing a Standard S-Factor: Improving Accuracy and Flexibility in SOC Corrections for HEV Testing2026-01-0422To be published on 04/07/2026
Hybrid-electric vehicle (HEV) fuel economy test procedures require that the net energy change (NEC) of the battery remain small enough to ensure accurate fuel usage results. SAE J1711-2010 required the NEC stay within 1% of fuel energy consumption, assuming that residual changes in state of charge (SOC) would have negligible impact. In practice, however, the asymmetry between fuel and electricity conversion efficiencies means that a 1% SOC imbalance can translate into a fuel consumption error approaching 3%. A standard S-Factor—a dimensionless ratio of marginal fuel change to marginal NEC change—was introduced in J1711-2023 to improve SOC corrections. The method improves accuracy by correcting all results for NEC changes and expands the NEC-to-fuel ratio (NECFR) window, enabling HEVs to use electric propulsion more aggressively and achieve higher fuel economy in testing and real-world usage. Using a standardized value (instead of requiring additional testing to determine the vehicle
Duoba, Michael
Experimental Validation of a Multi-Row Tapered Roller Bearing Analytical Model for Relating Preload to Frequency Response Characteristics2026-01-0008To be published on 04/07/2026
Roller bearings are used in many rotating power transmission systems in the automotive industry. During the assembly process of the power transmission system, some types of roller bearings (e.g., tapered roller bearings) require a compressive preload force. Those bearings' rolling resistance and lifespan strongly depend on the preload set during the installation process. Therefore, accurate setting of the preload can improve bearing efficiency, increase bearing lifespan and reduce maintenance costs over the life of the vehicle. A new method for bearing preload measurement has shown potential for both high accuracy and fast cycle time using the frequency response characteristics of the power transmission system. An open problem is experimental validation of the multi-row tapered roller bearing analytical model. After validation, the analytical model can be used to predict the assembled system damped natural frequency for a desired bearing preload. This work presents the experimental
Gruzwalski, David, Mynderse, James
Research on Reliability Test Methods for Electric Drive Axle Differentials2026-01-0007To be published on 04/07/2026
With the rapid socio-economic development, global issues such as the energy crisis and environmental pollution have become increasingly severe. Electric vehicles have garnered growing attention due to their environmental friendliness, simple structure, and high energy efficiency. Electric drive technology is regarded as the most ideal universal driving solution for pure electric vehicles, hybrid electric vehicles, and fuel cell vehicles. The electric drive axle, as a new type of integrated mechatronic transmission system, is being increasingly adopted owing to its advantages such as high drive efficiency, flexible spatial arrangement, and facilitation of digital and automated chassis control. This study focuses on reliability testing methods for the differential in electric drive axles, mainly including the extraction of reliability test conditions and feasibility analysis of the test scheme. The main research contents are as follows: First, based on specific parameters of an electric
Zheng, Hongyu, Li, Ziyu, Wang, Dajiang, tian, kai
Persistent Elevated Soot Emissions Induced by Clustered Stochastic Preignition Events2026-01-0314To be published on 04/07/2026
Stochastic Preignition (SPI) is an abnormal combustion phenomenon that can occur in spark-ignition engines particularly under high-load operation. SPI is characterized by uncontrolled initiation of combustion prior to spark discharge, an abnormal combustion process that can lead to severe knock events and significant engine damage. SPI has been associated with fuel properties, lubricant composition, and engine design and operation. In this work, a single-cylinder test engine with a dry-sump oil system was utilized to study the SPI response of E10 and E25 fuels with a range of Reid Vapor Pressure (RVP). An automated test procedure was employed, consisting of ten square-waved load profile segments, with each segment composed of 5 min of low-load operation followed by 25 min of sustained high-load operation. These tests were replicated across multiple days of testing with a triple flush of lubricant between each test, and an online Fuel in Oil diagnostic measurement. Exhaust particulate
Splitter, Derek, Jatana, Gurneesh, DelVescovo, Dan, Douvry-Rabjeau, Julien, Fioroni, Gina, Chapman, Elana, Salyers, John
An Integrated Model Approach for Predicting Vehicle Dynamics Performance in HiL Validation2026-28-0044To be published on 02/12/2026
In the automotive industry, increasing noise regulations are influencing product sales and passenger comfort, creating a need for more effective noise testing methods. Hardware-in-Loop (HiL) based virtual acoustic testing serves as a critical step before Driver-in-Loop testing, allowing for the assessment of vehicle performance and noise levels inside and outside the vehicle under various conditions before physical prototype testing is performed. The Hardware-in-the-Loop (HiL) simulator setup is equipped with joystick control that requires a physical representation of the vehicle dynamics model provided as a Functional Mock-up Unit (FMU) in real-time format. In contrast, the vehicle control logic is implemented in C++ code. The simulator incorporates both lateral and longitudinal dynamics. Additional interfaces are integrated to support joystick input and virtual road visualization enabling realistic vehicle maneuvering and dynamic performance evaluation. However, performing all test
Visuvamithiran, Rishikesan, Chougule, Sourabh, Srinivasan, Rangarajan, Laurent, Nicolas
Real time Implementation of Predictive Maintenance for Service Center Automation Using Automobile Life Extender (ALE) Based on Machine Learning2026-28-0124To be published on 02/12/2026
The Automobile Life Extender (ALE) comprises an on-board function, a machine learning model operating via cloud computing and a smartphone app. The on-board function receives signals such as engine RPM, throttle position, brake pedal position, and hydraulic pressure from the vehicle's ECUs. Based on this data, the on-board ALE module calculates the engine load, brake circuit load, etc., and sends it to the predictive maintenance model via the on-board IoT system. The predictive maintenance model contains recorded data about the type of engine, brake system, and their performance curves acquired from tests conducted by its OEM. Machine learning models holds a crucial role in dynamically analyzing vehicle data, identifying drive patterns, and predicting the need for maintenance of a part or system. A hybrid approach of training models based on supervised and unsupervised learning is incorporated, creating an active learning strategy to maximize the use of available data. Amazon SageMaker
Sundaram, Rameshselvakumar, Kumar, Lokesh, Saint Peter Thomas, Edwin, Sureshkumar, Srihari, Muthukumaran, Chockalingam, Menon, Abhijith
Wheels - Passenger Car and Light Truck Performance Requirements and Test ProceduresJ328_202601 (Current)2/4/2026
This SAE Recommended Practice provides minimum performance requirements and uniform procedures for fatigue testing of wheels intended for normal highway use and temporary use on passenger cars, light trucks, and multipurpose vehicles. For heavy truck wheels and wheels intended to be used as duals, refer to SAE J267. For wheels used on trailers drawn by passenger cars, light trucks, or multipurpose vehicles, refer to SAE J1204. These minimum performance requirements apply only to wheels made of materials included in Tables 1 to 4. The minimum cycles noted in Tables 1 through 4 are to be used on individual test and a sample of tests conducted, with Weibull Statistics using two parameter, median ranks, 50% confidence level, and 90% reliability, typically noted as B10C50.
Wheel Standards Committee
Wheel and Wheel Trim Weathering Testing for Paint CoatingsJ2633_202601 (Current)2/3/2026
This SAE lab test procedure should be used when performing the following specialized weathering tests for wheels; Florida Exposure, QUV, Xenon and Carbon Weatherometer. In addition to these procedures, some additional post-weathering tests may be specified. Please refer to customer specifications for these requirements.
Wheel Standards Committee
Structural Design and Construction Considerations for Enclosed Turbofan/Turbojet Engine Test CellsARP5305B (Current)1/31/2026
This SAE Aerospace Recommended Practice (ARP) is written for individuals associated with the ground-level testing of large and small gas turbine engines and particularly for those who might be interested in constructing new or adding to existing engine test cell facilities.
EG-1E Gas Turbine Test Facilities and Equipment
Filter Patch Testing Procedures for Aerospace Hydraulic Non-Rotating EquipmentARP1302A (Current)1/26/2026
This SAE Aerospace Recommended Practice (ARP) provides a procedure for obtaining filter patch test samples from the following types of aerospace non-rotating hydraulic equipment: Mechanical/Hydraulic Units Electro/Hydraulic Units Pneumatic/Hydraulic Units
A-6C1 Fluids and Contamination Control Committee
Ice Penetration Test Method for AMS1431 and AMS1435 Runway Deicing/Anti-Icing ProductsAS6211A (Current)1/23/2026
This document establishes a standardized test method designed to provide stakeholders—including runway deicing/anti-icing product manufacturers, users, regulators, and airport authorities—with a means of evaluating the relative ice penetration capacity of runway deicing and anti-icing products over time. The method measures ice penetration as a function of time, thereby enabling comparative assessments under controlled conditions. While commonly applied to runway treatments, these products may also be used on taxiways and other paved surfaces. The test is not intended to provide a direct measurement of the theoretical or extended ice penetration time of liquid or solid deicing/anti-icing products. Instead, it offers a practical and reproducible basis for performance evaluation, supporting operational decision-making and regulatory compliance.
G-12RDP Runway Deicing Product Committee
Tractor Clutch Wear Simulation by Inhouse Development2026-26-05721/16/2026
To develop a Test Method & Procedure for validating the Tractor clutch system performance & Wear simulation endurance test. Tractor clutch wear simulation test conducted along with transmission by operating clutch in different modes as per RWUP operation. In this test we can validate clutch field failures in short time with improved test accuracy at lab. In one of M&M technology project, Transmission Wet clutch system for higher HP tractors where we don’t have any dedicated test rig/methodology for validating Clutch wear & related failure simulation at lab
D, Yashwanth, Raja, R, Udayakumar, S, M, Jeevaharan, Vijayakumar, Narayanan
India WLTP Vs MIDC: Comparative Analytical Study on BEV Range & Energy Consumption for Proposing iWLTP 4-Phase2026-26-02441/16/2026
In India, Currently Continuous FULL MIDC (Modified Indian Driving Cycle) is used to declare the Range & Energy consumption of BEV (Battery Electric Vehicle). AISC (Automotive Industry Standards Committee) is looking to implement Worldwide Harmonized Light-Duty Test Procedure (WLTP) in India. AISC released AIS 175 for WLTP implementation from Apr 2027. The objective of WLTP is to standardize the test procedure globally for evaluating Emission/FE/Range of Light Duty Vehicles. But the effect of AIS 175 regulation on Battery Electric Vehicles Range Declaration is very less. The Range is almost same as Full MIDC declared Range. The On-road Range BEV is always lesser than the Declared Range of vehicles because of ambient conditions. Usually, the Full MIDC declared Range will be 20% ~26% higher than actual On Road Range. The Range of BEV as per India WLTP 3-Phase was observed 18% ~ 24% higher than actual On-road range of vehicles. There is only 2% difference observed between Full MIDC Range
Shiva Kumar, Mucharla, Tentu, Kavya
Migration from MIDC to WLTP in India: Challenges & Solutions for a Small Commercial Vehicle2026-26-02151/16/2026
In line with global peers (EU, Japan, etc.), the Automotive Industry Standard (AIS) Committee in India has decided to adopt “World harmonized Light vehicle Test Procedure (WLTP)” for M2 and N1 category vehicles not exceeding 3500 kg and for all M1 category vehicles. As a result, “World harmonized Light-duty vehicles Test Cycle (WLTC)” is set to replace currently applicable “Modified Indian Drive Cycle (MIDC)” in the next couple of years. The draft Corporate Average Fuel Economy (CAFE) III & CAFE IV norms for CO2 emission limits, which are set to be implemented in year 2027 and 2032 respectively refer to a shift to WLTP from MIDC. The latest draft of Central Motor Vehicle Rules (CMVR) for BS-VI emissions is also being revised to use WLTC as test cycle. This migration to WLTC is in sync with the demand for test procedures to replicate real driving conditions more appropriately. Further, the move to WLTC along with stricter emission norms is a major step towards realizing India’s COP26
Pawar, Bhushan, Ehrly, Markus, Sandhu, Rouble, Emran, Ashraf, Berry, Sushil
SEooC- Based Design Framework Integrated EV Power Conversion Systems under ISO-26262 Compliance2026-26-01921/16/2026
The work completed on “System level concepts to test and design integrated EV system involving power conversion to satisfy ISO26262 functional safety requirement” is included in the paper. Integrating power conversion and traction inverter subsystems in EVs is currently popular since it increases dependability and improves efficiency and cost-effectiveness. Maintaining safety standards is at danger due to the growing safety requirements, which also raise manufacturing costs and time. The three primary components of integrated EV systems are the PDU, DC-DC converter, and onboard charger. Every part and piece of software is always changing and needs to be tested and validated in an economical way. Since the failure of any one of these components could lead to a disaster, the article outlines the economical approaches and testing techniques to verify and guarantee that the system meets the functional safety criterion.
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
Comprehensive Engine Testing Methodologies for Hydrogen Internal Combustion Engine Validation with Combustion & Performance Evaluation Techniques2026-26-02561/16/2026
Validation of hydrogen-fuelled internal combustion engine (H2 ICE) is critical to assess its feasibility as sustainable transportation with zero carbon emissions. This experimental analysis conducted on Ashok Leyland’s 6cylinder 2V engine to evaluate the engine performance & durability with hydrogen fuel. Combustion behaviour of hydrogen ICE needs to be closely monitored during continuous operation of validation testing, due to its unique properties compared to other conventional fuels. During engine run, a pre-ignition source can cause knock event leading to instant failure of critical parts like piston assembly, spark plug, liner, valves & cylinder head. Also, hotspots inside IMF leads to backfire affecting the air intake & fuel injection assembly. This study emphasizes the significance of precise instrumentation of thermocouples across engine on cylinder head, intake manifold & exhaust manifold, to detect performance detoriation and combustion abnormalities causing knocking
Vasudevan, Sindhuja, J, Narayana Reddy, Bolar, Yogesh Ganesh, Pandey, Sunil, N, Harish, N R, Varatharaj, Karthikeyan, K, Kumar D, Kishore
Novel Approach on Material Characterization Testing of Various Wiring Harness2026-26-05481/16/2026
The automotive wiring harness (length of 4-5 km) is a very important and complex system in the development of a modern car due to lot of new electric & electronic components and sensors. It is a very sensitive material unlike metals and is considered as a composite which is highly anisotropic in nature, as it consists of several different layers of copper/aluminum strands and insulation. Because of insulation, wiring harness exhibits viscous plastic behavior which is crucial in determining the durability and long-term performance of the cables. Material property has a crucial role in determining the behavior of wiring harness after assembly into the car. Wiring harness may undergo Bending, Torsion and Tension loads, causing the stress and strain in the individual electrical wires. The lack of CAE validation of the wiring harness routing may lead to extra costs for the automotive OEMs during product development. This study explains the novel method of Testing the Cables and Bundles
Beesetti, Siva, Kalkala Balakrishna, Prasad, James Aricatt, John, Shah, Dipam, Tas, Onur, Krogmann, Stephan
Comparison of Bharat NCAP Crash Test Scenarios with Real Road Accidents in India2026-26-00241/16/2026
This study is conducted to analyse the significance of the Bharat NCAP crash test protocol in real road crashes in India. Accident data from on-the-spot investigation (Road Accident Sampling System India) and Government of India’s, Ministry of Road Transport and Highways official road accident statistics 2023 is used together to understand the real road accidents in India. The current Bharat NCAP crash test protocol is compared against the real road accidents and the frequency of the same in discussed in this paper. A seven-step calculation method is developed to analyse real accidents together with existing crash tests by using similar crash characteristics like impact area, overlap and direction of force. This method makes the real accident comparable with the corresponding crash test by calculating the impact energy during the collision between the real accident and a collision under crash test conditions. Relevant parameters in real accidents that significantly influence the test
Moennich, Joerg, Lich, Thomas, Kumaresh, Girikumar
An Analysis of Material Damping Characteristics: A Comparison of Oberst Bar Method and Center Impedance Method and their Relationship to Component Level for EV Application2026-26-03171/16/2026
Damping materials exhibit advantageous mechanical and acoustic characteristics that enhance the structural integrity of systems. These materials find extensive applications across various industries, including automotive, aerospace, and building acoustics, and are widely employed in the development of soundproofing materials. The damping characteristics of materials primarily pertain to the dissipation of vibrational energy, the reduction of oscillations, and the controlling and subsequent attenuation of vibration-induced noise emanating from structures. To improve both structural integrity and acoustic performance, it is crucial to accurately assess the damping properties of these materials. The Oberst bar test method is a standard method used in the automotive, railway and building industry for initial optimization of damping material However, questions have arisen about the degree to which the outcomes of the Oberst test truly reflect real-world applications. Numerous experimental
Kamble, Prashant Prakash, Joshi, Manasi, Jain, Sachinkumar, Harishchandra Walke, Nagesh
AI-Driven Predictive Methodology for Bolt Integrity in Vehicle Durability Testing2026-26-06481/16/2026
The application of AI/ML techniques to predict truck endgate bolt loosening represents a major innovation for the automotive industry, aligning with the principles of Industry 4.0. Traditional physical testing methods are both expensive and time-consuming, often identifying issues late in the development process and necessitating costly design changes and prototype builds. By harnessing AI/ML, manufacturers can now analyze endgate slam and bolt preload data to accurately forecast potential bolt loosening issues. This predictive capability not only enhances quality and safety standards but also significantly reduces the costs associated with tooling and builds. The AI/ML tool described in this paper can simulate a variety of load conditions and predict bolt loosening with over 90% accuracy, considering factors such as changes in loads, bolt diameters, washer sizes, and unexpected masses added to the endgate. It provides valuable design insights, such as recommending optimal bolt
Sivakrishna, Masani, Das, Mahat, Singh, Abhinav, Karra, Manasa, Shienh, Gurpreet, Luebke, Amy
Evaluating Passenger Car Tyre Performance: Lateral and Longitudinal Dynamics in Varied Testing Conditions2026-26-05781/16/2026
The lateral and longitudinal dynamics of passenger car tyres are critical to overall vehicle safety, handling, and stability. These characteristics directly influence braking, acceleration, and cornering performance. This study investigates the impact of key input parameters, namely inflation pressure, vertical load, and inclination angle, on tyre behaviour using a dual approach: Indoor testing with a Flat-Trac CT+ (FTCT+) and Outdoor evaluation using a skid trailer. Lateral dynamics are evaluated at slip angles to analyze lateral force and aligning moment characteristics. The influence of inclination angle, pressure, and load is quantified through cornering stiffness and aligning stiffness. The tests are conducted in both sweep and steady-state modes. To maintain data consistency, all tests use tyres of a single specification sourced from the same production batch. Longitudinal behaviour of a tyre is characterized by various parameters such as peak friction coefficient, sliding
Sethumadhavan, Arjun, Duryodhana, Dasari, Tomer, Avinash, Ghosh, Prasenjit, Mukhopadhyay, Rabindra
Crash Pulse Characterization for the Passenger Vehicle Fleet in India2026-26-00291/16/2026
A crash pulse is the signature of the deceleration experienced by a vehicle and its occupants during a crash. The deceleration-time plot or crash pulse provides key insights into occupant kinematics, occupant restraints, occupant loading and efficiency of the structure in crash energy dissipation. Analysing crash pulse characteristics like shape, slope, maximum deceleration, and duration helps in understanding the impact of the crash on occupant safety and vehicle crashworthiness. This paper represents the crash pulse characterization study done for the vehicles tested at ARAI as per the ODB64 test protocol. Firstly, the classification and characterization of the crash pulses is done on the basis of the unladen masses of the vehicles. The same are further analysed for suitability of mathematical waveform models such as Equivalent Square Wave (ESW), Equivalent Triangular Wave (ETW), Equivalent Sine Wave (ESW), Equivalent Haversine Wave (EHSW) as well as EDTW (Equivalent dual trapezia
Mishra, Satish, Kulkarni, Dileep, Borse, Tanmay, Mahindrakar, Rahula Ashok, Mahajan, Rahul, Jaju, Divyan
Facilitating Virtual Testing at an Industrial Level by Simulation Data Management2026-26-04401/16/2026
Automotive OEMs can derive significant cost savings by reducing the quantity of physical crash tests and thereby accelerate product development, when they follow the Euro NCAP Virtual Testing procedure. It helps in optimizing the overall vehicle development process via more efficient simulations, as well as facilitates in early adoption of new safety regulations. In this pursuit, companies must comply with strict Euro NCAP requirements, which includes transparency and traceability of virtual tests. A major challenge therein is model validation – which requires highly precise detailing and extensive use of data for accurately replicating real physics of the problem. Deploying these workflows into an existing simulation process can be a complicated and time-consuming task, particularly when integrating various simulation and testing methods. A powerful simulation process and data management system (SPDM) can thereby assist companies to automate their entire simulation process, ensures
Thiele, Marko, Sharma, Harsh
AI-Driven Digital Twin for Enhanced Suspension Assembly Testing in Automotive Vehicles2026-26-04451/16/2026
This paper presents the development and implementation of a digital twin (DT) for the suspension assembly of automotive vehicles—an essential subsystem for assessing vehicle performance, durability, ride comfort, and safety. The digital twin, a high-fidelity virtual replica of the physical suspension system, is constructed using advanced simulation methodologies, including Finite Element Analysis (FEA), and enriched through continuous integration of empirical test data. Leveraging machine learning techniques, particularly Artificial Neural Networks (ANNs), the DT evolves into a dynamic and predictive model capable of accurately simulating the behaviour of the physical system under diverse operational conditions. The primary aim of this study is to enhance the precision and efficiency of suspension testing by enabling predictive maintenance, real-time system monitoring, and intelligent optimization of test parameters. The digital twin facilitates early detection of potential failures
Sonavane, Pravinkumar, Patil, Amol
Design Solutions for Ice-Induced CNG Filling Failures- Field Issue Resolution through Filter Geometry and Seal Material Reengineering2026-26-05151/16/2026
This study investigates the phenomenon of receptacle icing during Compressed Natural Gas (CNG) refueling at filling stations, attributing the issue to excessive moisture content in the gas. The research examines the underlying causes, including the Joule-Thomson effect, filter geometries, and their collective impact on flow interruptions. A comprehensive test methodology is proposed to simulate real-world conditions, evaluating various filter types, seal materials and moisture levels to understand their influence on icing and flow cessation. The findings aim to offer ideas for reducing icing problems. This will improve the reliability and safety of CNG refueling systems.
Virmani, Nishant, Sawant, Shivraj Madhukar, C R, Abhijith
Accelerating EV Thermal Controller Development Using Rapid Control Prototyping on Speedgoat2026-26-06851/16/2026
In the era of Software Defined Vehicles, the complexity and requirements of automotive systems have increased knowingly. EV Thermal management systems have become more complicated while having multiple functions and control strategies within software frameworks. This shift creates new challenges like increased development efforts and long lead time in creating an efficient thermal management system for Electric Vehicles (EV’s) due to battery charging and discharging cycles. For solving these challenges in the early stages of development makes it even more challenging due to the unavailability of key components such as fully developed ECU hardware, High voltage battery pack and the motor. To address this, a novel framework has been designed that combines virtual simulation with physical emulation at the same time, enabling the testing and validation of thermal control strategies without fully matured system and the ECU hardware. The framework uses the Speedgoat QNX machine as the
Chothave, Abhijeet, S, Bharathan, S, Ananth, Gangwar, Adarsh, Khan, Parvej, Gummadi, Gopakishore, Kumar, Dipesh
Towards AI-Driven Automated Driving Systems_Homologations Perspective2026-26-01331/16/2026
This paper examines the challenges and opportunities in homologating AI-driven Automated Driving Systems (ADS). As AI introduces dynamic learning and adaptability to vehicles, traditional static homologation frameworks are becoming inadequate. The study analyzes existing methodologies, such as the New Assessment/Test Methodology (NATM), and how various institutions address AI incorporation into ADS certification. Key challenges identified include managing continuous learning, addressing the "black-box" nature of AI models, and ensuring robust data management. The paper proposes a harmonized roadmap for AI in ADS homologation, integrating safety standards like ISO/TR 4804 and ISO 21448 with AI-specific considerations. It emphasizes the need for explainability, robustness, transparency, and enhanced data management in certification processes. The study concludes that a unified, global approach to AI homologation is crucial, balancing innovation with safety while addressing ethical
Lujan Tutusaus, Carlos, Hidalgo, Justin
Vision-Based Framework for Automated Testing of Automotive HMI Systems Using Deep Learning Techniques2026-26-05711/16/2026
Nowadays, digital instrument clusters and modern infotainment systems are crucial parts of cars that improve the user experience and offer vital information. It is essential to guarantee the quality and dependability of these systems, particularly in light of safety regulations such as ISO 26262. Nevertheless, current testing approaches frequently depend on manual labor, which is laborious, prone to mistakes, and challenging to scale, particularly in agile development settings. This study presents a two-phase framework that uses machine learning (ML), computer vision (CV), and image processing techniques to automate the testing of infotainment and digital cluster systems. The NVIDIA Jetson Orin Nano Developer Kit and high-resolution cameras are used in Phase 1's open loop testing setup to record visual data from infotainment and instrument cluster displays. Without requiring input from the system being tested, this phase concentrates on both static and dynamic user interface analysis
Lad, Rakesh Pramod, Mehrotra, Soumya, Mishra, Arvind
Experimental Evaluation of High Energy Impact Test of Wheel Rim2026-26-05041/16/2026
High energy impact testing using free fall mass is a crucial method for evaluating the structural integrity, and safety performance of automotive components subjected to sudden impact forces. This study focuses on assessing critical parts such as wheel rims, suspension knuckles, commonly exposed to unintentional impacts during vehicle operation, maintenance, or collisions. The test involves dropping a standardized mass from predetermined heights onto the component to simulate real-world impact scenarios. Key performance indicators include deformation, crack propagation, fracture resistance, and energy absorption capacity. Wheel rims and knuckles are evaluated for their ability to maintain structural integrity under localized impact without compromising vehicle handling or safety. Seats and related interior structures are tested to ensure occupant protection during crash-like events. Other components, such as brackets, mounts, or housings, are included based on functional criticality
Roham, Prasad, Bagade, Mohan, Sinnarkar, Nitin, Pawar, Prashant R, Shinde, Vikram
A Novel Approach to Efficient System Level Validation of Vehicle Interior Systems2026-26-05341/16/2026
Mechatronic systems, which are integral to various automotive applications, enhance both functional criticality and user experience. As the complexity and number of features in automotive systems increase, the volume of test cases for system-level features and their interactions grows exponentially. This necessitates rigorous regression testing with each software update to ensure system reliability and performance. The systems engineering V-model is a crucial framework for the design and development of complex systems, emphasizing the importance of testing at every level, including system, subsystem, and software. Effective validation at the system level involves numerous subsystems and their software interacting, making the testing process resource-intensive and time-consuming. During system-level testing, issues often arise that require fixes within various subsystems. After addressing these issues, retesting is necessary to ensure that the changes do not negatively impact overall
Sureka, Sumit, Rawat, Gautam, Ghosh, Soumik, Vidhu, Nandagopal
Streamlined Methodology for E-Motor Performance Evaluation Using a Configurable Universal Inverter2026-26-05101/16/2026
Electric motor benchmarking is often constrained by limited availability of motor-specific data, particularly when dealing with commercially available or third-party electric motors. This paper presents a streamlined and scalable methodology for characterizing unknown E-Motors using a configurable universal inverter platform. The proposed approach is specifically designed for OEMs and Tier 1 suppliers seeking to evaluate performance metrics such as torque accuracy, peak and continuous capability, efficiency, and control behavior—without prior access to key motor parameters or simulation data. A central challenge in this context is the stepwise electromagnetic characterization required to determine the phase current needed for accurate speed and torque control, especially under a Maximum Torque per Ampere (MTPA) or Maximum Torque per Watt (MTPW) strategy. As this requirement is highly dependent on the motor’s topology and electromagnetic properties, most conventional approaches rely on
Kanya, Benjamin, Duchi, Francesco, Ravi, Abhishek
Alloy Wheel Rim Linear Crash Validation with Bench Level Test Procedure2026-26-05741/16/2026
Crash test plays a very crucial role in determining the passenger safety along with driver safety in most modern vehicles. This has become a prominent factor for many buyers to choose a safe car. During crash test, many components tend to fail. Amongst them, the major safety critical component which hampers the drivability of a vehicle is Wheel and Tyre Assembly. With the introduction of low aspect tyres, the failure rate of these assemblies has increased. A very high importance is given to ensure these parts withstand the subject load as it is directly related to function of vehicle. Many methods are available to test the Wheel and Tyre assembly to ensure they pass the crash criteria. We have developed a novel test method which can simulate the crash pattern in the rig/bench level. The method employs a mechanical actuator which can be operated at designated load application to ensure the assembly undergoes the anticipated failure. The process is repeated with different types of
Medaboyina, HarshaVardhan, Singh, Ram Krishnan, Sundaram, Raghupathi, Jithendhar, Ashokan
Test Method and Set Up Development for Electric Parking Brake Performance and Durability Validation in Vehicle Level as Per RWUP2026-26-05051/16/2026
The Objective is to develop a testing load case which can assess vehicle electric parking brake (EPB) performance and durability at vehicle level in different project development phases. In current scenario the EPB become one of a primary feature available in many passenger vehicles helps customers to apply this secondary braking system to hold the vehicle when parked. So, it is particularly important to evaluate this feature close to RWUP for the vehicle service life and studying the result before vehicle launch. The test method should be capable of capturing failures related to physical concerns, electrical characteristics, actuation time, gradient vehicle hold, effectiveness during vehicle running and durability. The most important challenge in this test method development is it should simulate the actual sequence followed by user in field on vehicle. A completely automated test set up integrating PLC and COBOT with closed loop feedback developed and discussed in this paper. During
Dhanapal, M R, Vijayakumar, Narayanan, Mahesh, B, B, Venkatasubramanian, Arthanathan, Sankaranarayanan
Optimization of Inverter Control Strategies for Improved Powertrain Efficiency Using E-Motor Emulation Platforms2026-26-05091/16/2026
As the brain and the core of the electric powertrain, the traction inverter is an essential part of electric vehicles (EVs). It controls the power conversion from DC to AC between the electric motor and the high-voltage battery to enable effective propulsion and regenerative braking. Strong and scalable inverter testing solutions are becoming more essential as EV adoption rises, particularly in developing nations like India. In India, traditional testing techniques that use actual batteries and e-motors present several difficulties, such as significant safety hazards, inadequate infrastructure, expensive battery prices, and a shortage of prototype-grade parts. This paper presents a comprehensive approach for traction inverter validation using the AVL Inverter TS™ system incorporating an advanced Power Hardware-in-the-Loop (PHiL) test system based on e-motor emulation technology. It enables safe, efficient, and reliable testing eradicating the need for actual batteries or mechanical
Mehrotra, Soumya, Chhabra, Rishabh
Shaping the Future of Mobility with Innovative Tailgate Testing Solutions2026-26-04731/16/2026
As vehicles evolve toward increased automation and comfort, Power Operated Tailgate (POT) have become a common feature, especially in premium and mid-segment vehicles. These systems, although user-friendly on the surface, involve complex interactions between electronic control units (ECUs), sensors, actuators, and mechanical systems. Ensuring the reliability, safety, and robustness of these features under diverse operating conditions presents a significant validation challenge. Traditional testing methods, which rely heavily on physical prototypes and manual interaction, are often time-consuming, expensive, and prone to human error. Moreover, testing certain safety [3] features, such as anti-pinch or stall protection, under real physical conditions poses inherent risks and limitations. This paper presents a Hardware-in-Loop (HiL)[1] based testing approach for POT [2] systems, offering a safer, faster, and more comprehensive alternative to conventional validation methods. The HiL
More, Shweta, Ghanwat, Hemant, Shetti, Suraj, Jape, Akshay, Kulkarni, Shraddha, Jagdale, Nitin
Cabin Heat-Up Thermal Assessment for Human Comfort in Passenger Car2026-26-04081/16/2026
The HVAC (Heating, Ventilation, and Air conditioning) system is designed to fulfil the thermal comfort requirement inside a vehicle cabin. Human thermal comfort primarily depends upon an occupant’s physiological and environmental condition. Vehicle AC performance is evaluated by mapping air velocity and local air temperature at various places inside the cabin. There is a need to have simulation methodology for cabin heating applications for cold climate to assess ventilation system effectiveness considering thermal comfort. Thermal comfort modelling involves human manikin modeling, cabin thermal model considering material details and environmental conditions using transient CAE simulation. Present study employed with LBM (Lattice-Boltzmann Method) based PowerFLOW solver coupled with finite element based PowerTHERM solver to simulate the cabin heat up. Human thermal comfort needs physiological modelling; thus, the in-built Berkeley human comfort library is used in simulation. Human
Baghel, Devesh Kumar, Kandekar, Ambadas, Kumar, Ravi, Dimble, Nilesh
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