Browse Topic: Test procedures

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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 Target
Yanaoka, Toshiyuki, Gunji, Yasuaki, Zulkipli, Zarir Hafiz, Matsushita, Tetsuya, Carroll, Jolyon, Puthan, Pradeep, Mohd Faudzi, Siti Atiqah, D-Wing, Kak, Miyazaki, Yusuke
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
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
Neural Surrogates and Reinforcement Learning for Heavy-Duty Diesel Torque Control2026-01-0199To be published on 04/07/2026
Accurate torque-trace reproduction on regulatory drive cycles is central to heavy-duty diesel certification and development testing. Conventional controllers such as Proportional Integral Derivative (PID or PI) can be enhanced with gain scheduling and feedforward (FF) maps to satisfy requirements but require extensive calibration and are sensitive to nonlinearities and delay. This paper evaluates a data-driven control framework comprising a recurrent neural surrogate of engine torque (specifically an LSTM – long short-term memory) trained on engine/dynamometer data and a reinforcement learning (RL) policy trained using this surrogate (“world model”) to track requested torque while regularizing control effort. The RL policy (specifically TD3 – twin delayed deep deterministic) is benchmarked against tuned PID and PID+FF baselines on the Environmental Protection Agency’s Heavy Duty Federal Test Procedure (HD-FTP) segments using EPA regression criteria (slope, |intercept|, R2) and tracking
Cook, James, Puzinauskas, Paulius, Bittle, Joshua, Hall, Spencer
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
A Cloud-Vehicle Integrated Closed-Loop Testing Framework for Intelligent Chassis2026-01-0051To be published on 04/07/2026
Vehicle system testing serves as a critical phase in obtaining road certification for prototype vehicles. While direct road testing with physical vehicles yields the most authentic data, this approach entails significant costs, challenges in reproducing extreme scenarios, and inherent safety risks. In contrast, virtual vehicle-based testing technologies represent advanced simulation methodologies for enhancing development efficiency and quality, effectively mitigating risks associated with complex real-world operating conditions and hazardous physical testing. However, virtual vehicle models often rely on idealized parameters, limiting their ability to reflect real-world dynamics and resulting in lower credibility of test outcomes. Furthermore, as evidenced in current mainstream virtual testing software, environmental simulations predominantly remain confined to the visual domain, with limited direct interaction between dynamic environmental changes and virtual vehicle responses. To
Liao, Yinsheng, Cheng, Qing Hua, Qu, Wenying, Wang, Zhenfeng, Wu, Yan, He, Chengkun, Zhang, Junzhi, Lu, Yukun
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 not interfere with measuring accurate fuel consumption results. SAE J1711-2010 required the NEC to 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 an imbalance of one unit of battery energy can translate into a likely fuel consumption error of roughly three units. A standard S-Factor, a dimensionless ratio of marginal fuel change to marginal NEC change, was introduced in J1711-2023 to improve SOC correction procedures. The method improves upon the previous J1711 (2010) 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 potentially achieve higher fuel economy in testing and real-world
Duoba, Michael
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
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 including a lubricant triple flush between tests, 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
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
SUNRISE - A Harmonised Safety Assurance Framework For Connected, Automated Mobility Systems2026-01-0060To be published on 04/07/2026
Safety assurance of Cooperative, Connected, and Automated Mobility (CCAM) systems is a crucial factor for their successful adoption in society, yet it remains a significant challenge. The SUNRISE project has consolidated previous and on-going efforts, and developed a harmonised Safety Assurance Framework (SAF) designed to operationalise the UNECE New Assessment/Test Method (NATM), targeting a wide range of stakeholders including (but not limited to) certifiers, regulators, manufacturers, suppliers, researchers, and assessors. It incorporates a scenario-based approach, underpinned by the system’s Operational Design Domain (ODD) and behaviour for safety assessment. In line with NATM, the SAF consists of multiple pillars: the Audit of manufacturer processes and Safety Management Systems, In-Service Monitoring and Reporting (ISMR) to ensure continued safety during deployment, and Performance Assurance to generate and evaluate safety evidence pre-deployment. While all pillars are integral
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
Development of an Advanced Tensile Testing Method for HDPE Composites in High Draw Molded Hollow Circular Regions: Effect of Sample Preparation, Asymmetry, Thermal Conditions, Pull Speeds and Fixture Parameters2026-01-0204To be published on 04/07/2026
High-Density Polyethylene (HDPE), Low-Density Polyethylene (LDPE) and Ethylene Vinyl Alcohol (EVOH) composite, particularly in high draw molded hollow circular configuration, present unique challenges in evaluating mechanical performance under tensile stress due to anisotropic deformation, geometric asymmetry, and localize thermal gradient. This study introduces an advanced tensile testing methodology designed specifically to assess such regions with greater precision and reproducibility. The method incorporates refines sample preparation protocols, tailored fixture geometry, and adjustable pull speed to accommodate varying thermal histories and draw ratios inherent to molded sections. Systematic variation of asymmetrical, temperature conditions, and clamping techniques revealed significant impact on tensile strength, elongation at break, and strain distribution. Findings emphasize the necessity of customized testing frameworks for molded composites geometries and demonstrate that
Bhalerao, Saurabh Shankar
Effects of Obstacle Height and Vehicle Roll Behavior on Electric Vehicle Side Impact Safety2026-01-0405To be published on 04/07/2026
Electric vehicles (EVs) face unique safety challenges under pole side impact conditions, largely due to the presence of floor-mounted battery packs. Existing regulatory test procedures, such as FMVSS 214, primarily address occupant injury using full-height cylindrical obstacles. These procedures were originally developed for internal combustion vehicles (ICVs). However, real-world roadside crashes frequently involve obstacles of varying heights, such as guardrails, curbs, and median bases. While these obstacles pose limited risk to the passenger compartment, they can intrude into the battery pack and trigger thermal runaway. This study investigates the influence of obstacle height on EV pole side impacts. Finite element simulations of a commercially available sedan were conducted against rigid obstacles of different heights. Results reveal a non-monotonic trend of battery intrusion governed by the interplay between rollover dynamics and structural stiffness. Theoretical analyses were
Ma, Chenghao, Xing, Bobin, Zhou, Qing, Xia, Yong
Challenges to Ranking Diesel Fuels for NO x Emissions Using a Constant-Volume Combustion Chamber2026-01-0348To be published on 04/07/2026
The market is witnessing an unprecedented proliferation of low-emission fuel components. To effectively evaluate the suitability of these novel fuels for engine applications, fuel blenders and original equipment manufacturers require rapid and reliable assessment methodologies. Traditionally, such evaluations rely on comprehensive engine testing, which, while thorough, is both time-intensive and costly. In response to the growing diversity of emerging fuel options, this work aims to establish a streamlined screening approach capable of effectively replicating the outcomes of full-scale engine testing. We 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 air at 650°C and 20 bar, where it ignited and burned. The chamber was sampled post-combustion using a chemiluminescence NOx analyzer
Luecke, Jon, Rahimi, Mohammad, Mohamed, Samah, Naser, Nimal, Chausalkar, Abhijeet, McCormick, Robert
Cantilevered Boom Crane Structures - Method of TestJ1063_202603 (Current)3/13/2026
This SAE Standard applies to mobile, construction-type lifting cranes utilizing cantilevered boom crane structures and associated jibs (see Figure 1).
Cranes and Lifting Devices Committee
Plain Bearing High Speed Oscillation TestARP5448/2 (Current)3/6/2026
This test method outlines a standard procedure for performing cyclic reversing load testing on oscillating sliding bearings. The wear data from these tests is to be used for qualification requirements and to establish bearing design criteria.
ACBG Plain Bearing Committee
Vehicle Level Validation Test Procedures for V2V Safety CommunicationsJ2945/1A_202603 (Current)3/3/2026
This document provides vehicle-level data collection, data analysis, and data verification procedures that may be used to verify that an instrument under test (IUT) satisfies the vehicle-level requirements specified in the SAE International (SAE) J2945/1 standard. For the purposes of this recommended practice, “vehicle-level requirements” primarily consist of those requirements which can be verified external to the vehicle. The IUT for these procedures is a configured dedicated short range communications (DSRC) vehicle-to-vehicle (V2V) device as defined in SAE J2945/1 and is installed on a light vehicle. While the IUT is conceptually separated from the vehicle it is installed on, the tests outlined in this document are primarily vehicle-level so the terms “vehicle” and “IUT” can generally be considered interchangeable. Additionally, non-vehicle-level complementary tests, not included in this document, are required to verify that the entire set of requirements specified in SAE J2945/1
V2X Core Technical Committee
Study on the Evolution of Precise Internal Short Circuit Damage in Li-Ion Batteries2026-01-70252/27/2026
One primary cause of NEV fires is thermal runaway initiated by internal short circuit in power batteries, leading to subsequent thermal diffusion throughout the battery system. Severe internal short circuit damage can precipitate thermal runaway phenomena in lithium-ion batteries, potentially culminating in fire incidents involving electric vehicles. Although mild internal short circuit may not immediately induce thermal runaway, continuous charge and discharge cycling can exacerbate such conditions, progressively elevating risks associated with thermal runaway and other pertinent safety hazards. Conventional safety testing methodologies, employing techniques such as crushing and nail penetration to simulate internal short circuit, often amplify the extent of these shorts and fail to accurately replicate less severe, deeper internal short circuit. Additionally, methods incorporating foreign objects like nickel pieces for simulating internal short circuit necessitate battery disassembly
Sun, Zhipeng, Ma, Tianyi, Han, Ce, Wang, Fang, Ren, Gaohui
An Integrated Model Approach for Predicting Vehicle Dynamics Performance in HiL Validation2026-28-00442/12/2026
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 Learning2026-28-01242/12/2026
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
Laboratory Testing of Vehicle and Industrial Heat Exchangers for Heat Transfer and Pressure Drop PerformanceJ1994_202602 (Current)2/12/2026
This SAE Recommended Practice is applicable to all heat exchangers used in vehicle and industrial cooling systems. This document outlines the tests to determine the heat transfer and pressure drop performance of heat exchangers under specified conditions. This document has been reviewed and revised by adding several clarifying statements to Section 4.
Cooling Systems Standards Committee
Corrosion Test Master EstablishmentJ2636_202602 (Current)2/10/2026
This SAE lab recommended practice may be applied to corrosion test methods such as salt spray, filiform, Corrosion creep back, etc. This procedure is intended to permit corrosion testing to be assessed between Laboratories for correlation purposes.
Wheel Standards Committee
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
Wheel Nut Seat StrengthJ2315_202601 (Current)1/27/2026
The purpose of this test is to evaluate the axial strength of the nut seat of wheels intended for use on passenger cars, light trucks, and multipurpose vehicles. In addition, a minimum contact area is recommended to ensure enough strength for the rotational force in tightening a nut against the nut seat. While this test ensures the minimum strength of the nut seat, the wheel must also have a degree of flexibility. This flexibility, as well as bolt tension, are important to maintain wheel retention.
Wheel Standards Committee
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
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
Robust Validation of Rotary Switch with TFT Display in Hardware in Loop Simulation2026-26-05401/16/2026
Modern automotive systems are increasingly integrating advanced human-machine interfaces, including TFT displays, to enhance driver experience and functionality. Ensuring the reliability of these systems under diverse operating conditions is critical, especially given their role in vehicle control. This paper presents a Hardware-in-the-Loop (HIL) testing methodology for validation of rotary switch with TFT display. The HIL setup simulates real-world vehicle conditions, including CAN communication, power fluctuations and user interactions, enabling early detection of potential failure modes such as display flickering or communication loss. The results demonstrate improved robustness and reliability of the gear selection switch, supporting its deployment across multiple vehicle platforms.
Bhuyan, Anurag, Jahagirdar, Shweta, Khandekar, Dhiraj
Hybrid Topology Selection & Optimization of a Compact SUV to Meet Future CO 2 Norms – an Indian Case Study2026-26-00771/16/2026
Rising environmental concerns and stringent emissions norms are pushing automakers to adopt more sustainable technologies. There is no single perfect solution for any market and there are solutions ranging from biofuels, green hydrogen to electric vehicles. For Indian market, especially in the passenger car segment, hybrid vehicles are favoured when it comes to manufacturers as well as with consumer because of multiple reasons such as reliability, performance, fuel efficiency and lower long-term cost of ownership. For automakers planning to upgrade their fleets in the context of upcoming CAFE III (91.7 g CO2 / km) & CAFE IV (70 g CO2/km) norms, hybridization emerges as the next natural step for passenger cars. Lately, various state governments have also promoted hybrid vehicle sales by offering certain targeted tax breaks which were previously reserved for EVs exclusively. Current study focuses on various parallel hybrid topologies for an Indian compact SUV, which is the highest
Warkhede, Pawan, Keizer, Ruben, Sandhu, Rouble, Emran, Ashraf
Assessment of Emissions Behaviour of Volatile Compounds from Polymeric Materials used in Automobile Interiors2026-26-02221/16/2026
There is an increasing trend of using polymeric materials in the vehicle interior compartment. While the polymers provide benefits in terms of flexibility in profiling, lighter weight and aesthetics but one of the challenges with the polymers is emission of volatile organic compounds (VOCs) during their usage and particularly at a temperature prevailing in the vehicle cabin. VOCs adversely impact the vehicle interior air quality and can pose a risk to occupants’ health. However, there is a lack of information on volatile organic compound (VOC) emissions from automotive interior materials. There are two types of methods, a whole vehicle chamber method (ISO 12219-1) and a bag method (ISO 12219-2) for evaluation of VOCs emissions from materials used in vehicle interior parts. ISO 12219-2 method describes quantitative testing of VOCs and semi-VOCs. This test method is quick and cost effective for analysis of materials for quick emission checks and can prove to be very effective in
PAtil, Yamini Jitendra, Thipse, Sukrut, Bawase, Moqtik
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
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
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
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
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
Transforming Headlamp Compliance Testing Through AI-Powered Predictive Modelling2026-26-06601/16/2026
As automotive headlamp serves Active Safety functions, it must comply the functional and performance requirements as per regulatory standards across various geographies like AIS (Automotive India Standards), FMVSS (Federal Motor Vehicle Safety Standards), ECE (Economic Commission of Europe) etc. The process of validating headlamp levelling compliance as per regulatory standards involves physical testing with various vehicle loading conditions. This traditional method is labor-intensive, time-consuming, and consumes significant resources. There is a need for a predictive solution that can simulate and validate headlamp levelling tests virtually, thereby reducing dependency on physical trials. Headlamp levelling compliance is a critical regulatory requirement to ensure optimal visibility and safety under varying vehicle loading conditions. This paper presents an Artificial Intelligence and machine learning-based (AI/ML) solution to simulate headlamp levelling tests virtually/digitally by
Mandloi, Prince, Joshi, Vivek S., GHANWAT, HEMANT, Ugale, Anand, Munda, Rohit, GHAN, PRAVIN
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
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
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
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
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
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