Browse Topic: Vehicles, Equipment, and Performance

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Development of an Accelerated Stress Test for Fuel Cell Freeze Start Durability Using Real-World Driving Data of Light-Duty FCEVs2025-01-0526To be published on 11/25/2025
The reliability and durability of vehicles are crucial for the acceptance of new technologies by customers. Realistic test methods are necessary to ensure the lifespan of vehicles and their components, particularly regarding freeze start. This article provides an overview of the current state of research on the effects of freeze starts on the degradation of fuel cells. With this knowledge, relevant operating and boundary conditions for potential damage of the fuel cell are identified (e.g., start temperature, duration in subzero operation, dehydration). Based on these findings, the field data from the BMW demonstrator fleet of iX5 Hydrogen Next were analyzed to gain insights into realistic freeze start related stress to the fuel cells. It was found that the dynamics of heating rates and the influence of the operating strategy are best represented on a FCS. An experimental setup for a stack centered test on a fuel cell system was developed including a climatic chamber and a subzero
Schwarz, Markus, Albert, Albert, Eichel, Rüdiger-A.
Potential and Challenges of Next Generation Fuel Cell Powered Heavy-Duty Long Haul Trucks2025-01-0525To be published on 11/25/2025
Vehicle manufacturers are to reduce the CO₂ emissions of new trucks dramatically within the next decade. That requires to consider emission-free/neutral vehicles in the fleet mix. Especially for the application of heavy-duty (HD) long haul trucks, fuel cell powered trucks demand a holistic concept for the integration of the entire powertrain, its auxiliaries and the complete vehicle’s energy management. Key topics and takeaways: - Challenges of mechanical, thermal, EE and functional integration - Importance of predictive energy management for cost-efficient operation and lifetime optimization - Achievements in the latest fuel cell system developments and its impact on truck integration - Potential of further fuel cell stack improvements
Döbereiner, Rolf, Schörghuber, Christoph, Schenk, Alexander, Schubert, Thomas, Stöckl, Bernhard
Thermal Model of a Traction Inverter for an Automotive Application including DC-link capacitor, power modules and electrical connections2025-01-0519To be published on 11/25/2025
In automotive applications a traction inverter is used for energy conversion between battery and electrical machine. For high performance drives lightweight design is demanded. Additionally, higher efficiency of the inverter results in lower cooling requirements but is often achieved by increasing component weight. Hence, thermal modelling of the components and their interactions is essential to determine the best compromise between weight, efficiency and cooling requirements. In traction inverters the DC-link capacitors, power modules, high voltage electrical connections and low voltage devices dissipate power. In this paper the focus is on the thermal modelling of the DC-link capacitor, power modules and high voltage electrical connections and their system, as the performance of the inverter is defined by these components. The thermal models are derived based on geometries and physical properties. First, the DC-link capacitor thermal model is presented and considers the anisotropic
Blaschke, Wolfgang Maximilian, Mengoni, Leonard, Pflüger, Robin, Kulzer, André Casal
Energy and Mobility – The Illustrated Energy Primer for Modern Drivers2025-01-0517To be published on 11/25/2025
The path to carbon-neutral mobility is one of the greatest cultural transformations. Caught between industrial tradition, innovative mobility solutions, and energy providers are the drivers of 1.5 million motor vehicles. Conflicting publications on resource availability, energy efficiency, and the climate impact of different propulsion technologies add to their uncertainty. This led to the motivation to an energy guide for consumers, the „Illustrated Energy Primer for Modern Drivers“. The target audience focusses on technically interested individuals, whether as engaged citizens or as professionals. The guide presents the fundamentals of energy and power in a clear and accessible way. Typical energy demands of motor vehicles and households—both in personal use and scaled to a national level—complete this section of the guide. The guide then presents examples of energy generation systems. From coal-fired power plants to wind turbines, solar farms, and even balcony-mounted mini solar
Daberkow, Andreas
Development of a Comprehensive Predictive QD Knock Simulation Model for Hydrogen, Methanol, and an Ammonia–Hydrogen Blend2025-01-0528To be published on 11/25/2025
This work presents a comprehensive predictive 0D simulation model for the knock behavior of hydrogen, methanol, and an ammonia-hydrogen blend. With the increasing focus on carbon neutrality, synthetic fuels are gaining attention as viable alternatives to fossil fuels. Their potential applications include land and marine transport, construction machinery, and automotive powertrains, sectors with high carbon dioxide emissions. As their development requires extensive experimental validation, simulations offer a cost- and time-efficient alternative. In particular, 0D simulations offer a good balance between predictive capability and computational effort, making them well suited for concept evaluations and parametric studies. In spark-ignition engines, knock is a major limitation to achieving high thermal efficiency, emphasizing the need for accurate and fuel-specific knock prediction methods. The objective of this work is to enable a predictive and versatile 0D knock modeling framework for
Benzinger, Steffen, Yang, Qirui, Grill, Michael, Kulzer, Andre Casal, Plum, Lukas, Hermsen, Philipp, Günther, Marco, Pischinger, Stefan, Hurault, Florian, Foucher, Fabrice, Rousselle, Christine
Road Test Emulation: A Data-Driven Calibration Approach2025-01-0521To be published on 11/25/2025
The resource-intensive process of road testing constitutes an elementary part of the development of vehicle software. A significant proportion of explorative tests and adjustments for use in service are conducted during the vehicle test phase. However, the observed trends of decreasing development cycles and increasing system complexity generate a field of conflicts. In order to address this issue, this paper proposes road test emulation as a data-driven approach for continuously adapting vehicle software to the evolving overall system. Therefore, test scenarios equivalent to in-service conditions are determined based on customer data and test drives. These test scenarios enable an emulation of road testing and the analysis of the system in a real-world operational context from the early stages of the product development process. Sensitivity analyses are utilised to generate system-specific data for the vehicle under development, which is then employed to define initial parameter
Martini, Tim, Kempf, André, Winke, Florian, Auerbach, Michael, Kulzer, André Casal
Simulative temperature determination of an electric machine from test bench tests2025-01-0520To be published on 11/25/2025
One of the most important components of an electric vehicle is the drive motor. Induction motors are often used for this purpose. Power losses occur during the operation of these motors, particularly at high speeds. Among other things, this power loss corresponds to the sum of winding losses, iron core losses and mechanical losses. The power losses generate heat, causing the temperature in the rotor and stator to rise. The increase in temperature of the components inside the motor can lead to premature wear and fatigue failure. To prevent overheating, the motors are air or water cooled. Water cooling can be achieved by jacket cooling, for example. In this case, the heat generated is dissipated directly by forced convection. However, the cooling jacket makes it difficult to determine the temperature inside the motor. Determining these temperatures is necessary to prevent the motor from fatiguing prematurely. The temperatures that occur inside the motor during operation are of particular
Schamberger, Stephanie, Reuss, Hans-Christian
Electrode-Level Modeling of Thermal Decomposition Reactions as a Foundation for Multiscale Thermal Runaway Analysis in Lithium-Ion Batteries2025-01-0523To be published on 11/25/2025
Thermal runaway in lithium-ion batteries represents a critical safety challenge, particularly in high-voltage battery systems used in electric vehicles and stationary energy storage. A comprehensive understanding of the multi-scale processes that initiate and propagate thermal runaway is essential for the development of effective safety measures and design strategies. This study provides a structured theoretical overview of the thermal runaway phenomenon across four hierarchical levels: electrode, single cell, module, and high-voltage battery system. At the electrode level, thermal runaway initiation is linked to electrochemical and chemical degradation mechanisms such as solid electrolyte interphase decomposition, separator breakdown, and internal short circuits. These processes lead to highly exothermic reactions that, at the cell scale, can result in rapid temperature increases, gas generation, and overpressure. On the module and system levels, thermal runaway can propagate through
Ceylan, Deniz, Kulzer, André Casal, Winterholler, Nina, Weinmann, Johannes, Schiek, Werner
Safety Model for Battery Resistance Monitoring and Lifecycle Optimization2025-01-0515To be published on 11/25/2025
This paper presents a risk assessment framework to evaluate the safety implications of internal resistance growth in EV batteries, focusing on NMC and LFP chemistries. How the resistance growth affects performance, efficiency, and thermal stability, posing safety risks during the battery lifecycle. The framework integrates empirical and model-based estimation methods, including DCIR, EIS, historical regression, equivalent circuit models, and physics-based approaches. Simulations incorporate temperature, depth-of-discharge, and cycle count to predict resistance trends and their impact on power output and efficiency. A scoring system that evaluates safety risks based on state-of-resistance, state-of-health, and risk indicators, aiding battery pack selection for second and third life applications. Results show that NMC and LFP cells exhibit distinct resistance growth patterns, emphasizing the need for chemistry-specific safety strategies. The scoring system is a weightage based equation
Prakashkumar, Balagopal
ANALYSIS OF FACTORS INFLUENCING THE EFFICIENCY IMPROVEMENT POTENTIAL OF A WINDING CHANGEOVER IN AN ELECTRIC MACHINE2025-01-0518To be published on 11/25/2025
The winding configuration of an electric machine has a decisive influence on the properties of a traction drive. When designing the electric drive, the optimum compromise must be found between maximum torque, maximum power and high efficiency over a wide operating range. A decisive factor in this design conflict is the choice of the winding configuration. The concept of winding switching offers a way of solving the design conflict and improving the characteristics of the drive through the additional degree of freedom of the variable winding configuration. Switching the number of parallel winding branches in a serial and parallel configuration is a promising approach to overcome the challenge of a high spread between maximum power and high efficiency in customer related driving scenarios of an electric vehicle. The aim of this study is to identify factors influencing the efficiency improvement potential of the winding switching topology under consideration compared to a reference drive
Oestreicher, Raphael, Koenen, Christian, Kulzer, André Casal
Investigation of Active Pre-Chamber Ignition on an Optically Accessible Ultra-Lean DI Hydrogen Engine2025-01-0524To be published on 11/25/2025
Hydrogen is a promising alternative to conventional fuels for decarbonizing the commercial vehicle sector due to its carbon-free nature. This study investigates the ignition and flame propagation characteristics of hydrogen in a 2-liter single-cylinder optical research engine representative of the commercial vehicle sector. The main objective was to enable high power density operation while minimizing NOx emissions. For that, ultra-lean combustion was employed to lower in-cylinder temperatures, addressing the challenge of NOx formation. To counteract delayed and unstable combustion under lean conditions, an active pre-chamber ignition system was implemented. It uses a gas-purged pre-chamber with separate hydrogen injection and spark plug ignition. Turbulent hot gas jets from the pre-chamber ignite the fresh mixture in the main combustion chamber, enabling faster and more stable ignition compared to conventional spark plugs. Additionally, the low volumetric energy density of hydrogen
Borken, Philipp, Bill, Daniel, Link, Lukas, Dinkelacker, Friedrich, Hansen, Hauke
Data-Based Modeling of Power-Split Hybrids Using Cascaded Neural Networks2025-01-0522To be published on 11/25/2025
Power-split hybrid powertrains represent one of the most advanced and complex types of powertrain systems. The combination of multiple energy sources and power paths offers great potential but results in complex interactions that require improved strategies for optimal efficiency and emission control. The development and optimization of such operating strategies typically involve algorithms that demand fast computational environments. Traditional high-accuracy numerical simulations of such a complex system are computationally expensive, limiting their applicability for extensive iterative optimizations and real-time applications. This paper introduces a data-based approach designed specifically to address this challenge by efficiently modeling the dynamic behavior of power-split hybrid powertrains using cascaded neural networks. Cascaded neural networks consist of interconnected subnetworks, each specifically trained to represent individual drivetrain components or subsystems. This
Frey, Markus, Itzen, Dirk, Yang, Qirui, Grill, Michael, Kulzer, André Casal
Software Radio Based ASM Signal Ranging Delay Measurement System2025-99-0121To be published on 11/11/2025
In contemporary society, where Global Navigation Satellite Systems (GNSS) are utilised extensively, their inherent fragility gives rise to potential hazards with respect to the safety of ship navigation. In order to address this issue, the present study focuses on an ASM signal delay measurement system based on software defined radio peripherals. The system comprises two distinct components: a transmitting end and a receiving end. At the transmitting end, a signal generator, a first time-frequency synchronisation device, and a VHF transmitting antenna are employed to transmit ASM signals comprising dual Barker 13 code training sequences. At the receiving end, signals are received via software-defined radio equipment, a second time-frequency synchronisation device, a computing host, and a VHF receiving antenna. Utilising sliding correlation algorithms enables accurate time delay estimation. The present study leverages the high performance and low cost advantages of the universal
Li, Hao, Sun, Xiaowen, Wang, Tianqi, Zhou, Zeliang, Wang, Xiaoye
Intelligent Decision-Making and Trajectory Planning of Semi-Trailer Trains Under Multi-Vehicle Interference2025-99-0125To be published on 11/11/2025
Semi-trailer trains are the main force of highway freight. In a complex environment with multiple vehicles, accidents are easily caused by complex structures and driver operation problems. Intelligent technology is urgently needed to improve safety. In view of the shortcomings of existing research on its dedicated models and algorithms, this paper studies the intelligent decision-making and trajectory planning of semi-trailer trains under multiple vehicles. A local trajectory planning method based on global path planning and Frenet coordinate decoupling based on the improved A* algorithm is proposed. The smooth weight transition function and B-spline curve are introduced to optimize the global path. The polynomial function is combined with the acceleration rate to optimize the local trajectory. TruckSim, Prescan and Simulink are used to build a joint simulation platform for multi-condition verification. The simulation results show that the search efficiency of the improved A* algorithm
Song, Zeyuan, Geng, Shuai
Design and Application of UAV Disaster Reconnaissance System2025-99-0122To be published on 11/11/2025
The geological disasters along the Sichuan-Tibet Highway are frequent, and the traffic environment is complex. Traditional disaster reconnaissance methods struggle to meet the timeliness and accuracy requirements of emergency response. With the development of unmanned aerial vehicle (UAV) technology, it has significant advantages in rapid disaster information acquisition and complex terrain coverage. Considering the large elevation fluctuations, variable climate, and limited communication conditions in the study area, this paper focuses on UAV disaster reconnaissance in complex mountainous environments. By systematically summarizing and categorizing existing UAV disaster reconnaissance methods, this paper designs a UAV disaster reconnaissance system and applies it in practical engineering projects, providing technical support for disaster reconnaissance and emergency management along the Sichuan-Tibet Highway.
Wu, Guorong, Xu, Huayan, Chen, Yunjin, Tang, Luwei, Mo, Shiying, Luo, Shuzhao, Huang, Ziyang, Liu, Xianxin
A Rapid Carbon Verification System for Flight Emissions Based on Process Re-Engineering2025-99-0116To be published on 11/11/2025
Aviation carbon verification plays a crucial role in China’s achievement of its “dual carbon goals”. Traditional manual sampling methods are difficult to meet the timeliness requirements of the rapidly increasing volume of flight data. A rapid verification system for flight carbon emissions designed based on process reengineering relies on three spatio-temporal verification methods: weekly cycle verification, flight segment verification, and flight tail number verification. A comprehensive verification framework that can replace manual sampling has been constructed. The system adopts a modular architecture, integrating the functions of data management and rapid verification. Experimental results show that in scenarios with 100,000 flight data, the average verification time of the system is 0.12 hours. Compared with manual methods, the efficiency has been greatly improved, and the f1 score has remained stable at over 89.5%. These findings confirm that the system has advantages in both
Ding, Weichen, Chen, Jingjie
Multimodal Intelligent Transportation Data Fusion and Application Methods in Heavy-Duty Vehicles2025-99-0139To be published on 11/11/2025
Heavy-duty commercial vehicles (HDCVs) are the key mobile nodes in intelligent transportation systems (ITS). However, their complex operating conditions and the diversity of data sources (such as road conditions, driver behavior, traffic signals, and on-board sensors) present considerable difficulties for accurately estimating the state and perceiving the environment using a single modality of data. This requires effective multi-modal data fusion to enhance the control and decision-making capabilities of HDCVs. This paper addresses this need by proposing a customized multi-modal intelligent transportation data fusion framework for intelligent HDCVs. This paper presents a solution for establishing a multi-modal intelligent transportation data collection platform, including real-scene collection methods and simulation scene collection methods based on the SUMO-MATLAB joint simulation platform. Through three representative case studies, the application methods of multi-modal traffic data
Chen, Zhengxian, Wang, Shaoqi, Jiang, Huiming, Zhou, Fojin, Wang, Mingqiang, Li, Jun
Research on Low-Power Control of Offshore Wind Sail Stabilization Devices Based on Single Pendulum Control Simulation2025-99-0131To be published on 11/11/2025
To tackle persistent operational instability and excessive energy consumption in marine observation platforms under wave-induced disturbances, this paper introduces a novel ultra-low-power stabilization system based on pendulum dynamics. The system employs an innovative mechanical configuration to deliberately decouple the rotation axis from the center of mass, creating controlled dynamic asymmetry. In this behavior, the fixed axis serves as a virtual suspension pivot while the camera payload functions as a concentrated mass block. This configuration generates intrinsic gravitational restoring torque, enabling passive disturbance attenuation. And its passive foundation is synergistically integrated with an actively controlled brushless DC motor system. During platform oscillation, embedded algorithms detect angular motion reversals. In addition, their detection triggers an instantaneous transition from motor drive to regenerative braking mode, and transition facilitates bidirectional
Zhang, Tianlin, Liu, Shixuan, Xu, Yuzhe
Micro-Circulation Bus Route Area Identification under the TOD Concept2025-99-0136To be published on 11/11/2025
Based on the TOD (Transit-Oriented Development) concept, this paper addresses the “last mile” issue in urban public transportation. It proposes a multidimensional decision-making model for identifying micro-circulation bus route areas. By integrating indicators such as the TOD comprehensive index, short-distance demand intensity, and branch network density, relevant data is processed using FME linking ArcGIS. The model combines entropy-weighted TOPSIS and unsupervised consensus clustering analysis techniques, utilizing ArcGIS spatial analysis functions to accurately identify priority deployment areas for micro-circulation buses. Taking Jiangbei District in Chongqing as an example, the model divides the study area into four types of traffic zones: (1) Core high-density areas, which require an increase in micro-circulation bus routes due to extremely high short-distance travel demand; (2) Periphery active population areas, which require flexible shuttle services due to transit gaps and
Jiang, Tao, Jia, Xiaoyan, Li, Jie
AI-Empowered Lightweight In-Vehicle Network Security Mechanisms: From Cryptographic Algorithms to Collaborative Defense Architectures2025-99-0132To be published on 11/11/2025
With the rapid development of Internet of Vehicles (IoV) and cyber-physical systems (CPS), connected autonomous vehicles (CAVs) have also developed rapidly. However, at the same time, in-vehicle networks also face more security challenges, mainly in terms of resource constraints, dynamic attacks, protocol heterogeneity, and high real-time requirements. Firstly, the trade-offs between lightweight encryption primitives and their software and hardware collaborative design in terms of performance, resource overhead, and security strength are analyzed. Secondly, the resource efficiency of AI-based intrusion detection system (IDS) is evaluated at the edge. Finally, we propose a dynamic adaptive collaborative defense framework (DACDF), which integrates federated learning with dynamic weight distillation, blockchain authentication with lightweight verifiable delay function (Light-VDF) and cross-domain IDS with hierarchical attention feature fusion to deal with collaborative attacks in resource
Zhou, You, Zhang, Jigui, Ding, Kani, Yang, Guozhi
Research on Off-Road Performance Optimization Strategy for Agricultural Smart Vehicles Based on Traction Control System2025-99-0118To be published on 11/11/2025
(TC)The paper presents a designed and evaluated optimal traction control (TC) strategy for unmanned agriculture vehicle, where onboard sensors acquire various real-time information about wheel speed, load sharing, and terrain characteristics to achieve the precise control of the powertrain by establishing an optimal control command; moreover, the developed AMT-adaptive SMC combines the AMT adaptive control algorithm and the SMC to implement the dynamic gear shifting, torque output, and driving mode switching to obtain an optimal power distribution according to different speed demand and harvest load. Based on the establishment of models of the autonomous agriculture vehicle and corresponding tire model, a MATLAB/Simulink method based on dynamic simulation is adopted to simulate the unmanned agricultural vehicle traversing different terrains conditions. The results from comparison show that the energy saving reaches 19.0%, rising from 2. 1 kWh/km to 1. 7 kWh/km, an increase in
Feng, Zhenghao, Lu, Yunfan, Gao, Duan, An, Yi, Zhou, Chuanbo
Hydro-Pneumatic Suspension Optimization for Mining Explosion-Proof Vehicles in Underground Coal Mines2025-99-0106To be published on 11/11/2025
This study investigates the critical factors influencing the performance of hydro-pneumatic suspension systems (HPSS) in mining explosion-proof engineering vehicles operating in complex underground coal mine environments. To address challenges such as poor ride comfort and insufficient load-bearing capacity under harsh mining conditions, a two-stage pressure HPSS was analyzed through integrated numerical modeling and field validation. A mathematical model was established based on the structural principles of the suspension system, focusing on key parameters including cylinder bore (195–255 mm), piston area (170–210 mm), damping orifice diameter (7–8 mm), check valve flow area, and accumulator configurations (low-pressure: 1.2 MPa, high-pressure: 6 MPa). Experimental trials were conducted in active coal mines, simulating typical mining scenarios such as uneven road surfaces (120 mm obstacles), heavy-load gangue transportation, and confined-space operations in thin coal seams (<1.5 m
Song, Yan, Liang, Yufang
SAE TOMORROW TODAY - Your Order Has Landed: The Power of Drone Delivery1354211/07/2025
From crispy French fries to critical medical supplies, one company is transforming how goods move around the world with autonomous drone delivery technology. In 2016, Zipline, began with life-saving deliveries of blood and medical products in Rwanda and has since evolved into a global network expanding access to healthcare, consumer goods, and food. Operating across four continents and completing a delivery every 60 seconds, Zipline now serves more than 5,000 hospitals, retailers, and restaurants. Listen in as we sit down with Keenan Wyrobek, Co-Founder and CTO, to explore how Zipline's pioneering approach to drone logistics is saving lives, reducing emissions, and opening new doors for economic opportunity -- one autonomous flight at a time. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in mobility
Patterson, Lori
Design and Implementation of a Portable Setup for Operator’s Field of Vision Testing on Construction Equipment Vehicles in accordance with IS/ISO 5006:20172025-28-027011/06/2025
The Operator’s Field of Vision (FOV) test, conducted in accordance with IS/ISO 5006:2017, is a vital assessment to ensure the safety and operational comfort of personnel operating Construction Equipment Vehicles (CEVs) / Earth-Moving Machinery. IS/ ISO 5006:2017 defines rigorous guidelines for evaluating the operator’s visibility from the driver's seat, with particular emphasis on the Filament Position Centre Point (FPCP), determined from the Seat Index Point (SIP) coordinates. The test includes assessment of masking areas, focusing on the Visibility Test Circle (a 24-meter diameter ground-level circle around the machine), and on the Rectangular Boundary on which a vertical test object is placed at a height specific to the machine type and its operating mass. These parameters are designed to simulate real-world operating conditions. This paper introduces a portable testing setup developed specifically for conducting the Operator’s FOV test as per IS/ISO 5006:2017. The setup facilitates
Ghodke, Dhananjay Sunil, Tambolkar, Sonali Ameya, Belavadi Venkataramaiah, Shamsundara
Hybrid Safety Framework for Autonomous Off-Highway Vehicles2025-28-032511/06/2025
The evolution of Autonomous off-highway vehicles (OHVs) has transformed mining, construction, and agriculture industries by significantly improving efficiency and safety. These vehicles operate in high dust, uneven terrain, and potential communication failures, where safety is challenged. To guarantee vehicle safety in such situations, a robust architecture that combines AI-driven perception, fail-safe mechanisms, and conformance to many ISO standards is required. In unstructured environments, AI-driven perception, decision-making, and fail-safe mechanisms are not fully addressed by traditional safety standards like ISO26262 (road vehicles), ISO19014 (earth-moving machinery and it is replacing withdrawn ISO 15998), ISO12100 (Safety of machinery) and ISO25119 (agriculture), ISO 18497 (safety of highly automated agricultural machinery), and ISO/CD 24882 (cybersecurity for machinery).These standards mainly concentrate on the reliability of mechanical and electric/electronic systems
Muthusamy, Sugantha
Enhancing Tractor Operator Comfort and Safety Through Advanced Drive Assistance Features2025-28-021611/06/2025
Operating tractors on inclined & uneven terrains for prolonged operations presents safety and ergonomic challenges. Applications such as shuttle operations, loader use, or long-duration implement usage prove to be highly critical based on field observations across Mahindra tractor platforms and it requires skill & experience for maneuvering at ease across usage. We identified the need to offload these repeatable tasks from the operator to improve control & offer comfort. This paper explains the role of Advanced drive assistance features developed for Mahindra tractors suited for all prime mover types – ICE, Alternate Fuels including electric. These features include Hill Hold, Electronic parking brake, Cruise control & Creep mode. Each feature is designed to offload frequent manual tasks from the operator and ensure smoother, safer operation. Hill hold and electronic parking brake work in tandem to offer unparalleled safety by eliminating the fear of tractor roll back in uneven terrain
M, Rojer, Sundaram, Pavithra, Natarajan, Saravanan, Devakumar, Kiran, Muniappan, Balakrishnan
E-Motor Thermal Management Using 2D-3D Coupling2025-28-022511/06/2025
In the electrical machines, detrimental effects resulted often due to the overheating, such as insulation material degradation, demagnetization of the magnet and increased Joule losses which result in decreased lifetime, and reduced efficiency of the motor. Hence, by effective cooling methods, it is vital to optimize the reliability and performance of the electric motors and to reduce the maintenance and operating costs. This study brings the analysis capability of CFD for the air-cooling of an Electric-Motor (E-Motor) powering on Deere Equipment's. With the aggressive focus on electrification in agriculture domain and based on industry needs of tackling rising global warming, there is an increasing need of CFD modeling to perform virtual simulations of the E-Motors to determine the viability of the designs and their performance capabilities. The thermal predictions are extremely vital as they have tremendous impact on the design, spacing and sizes of these motors.
Singh, Bhuvaneshwar, Tirumala, Bhaskar, Badgujar, Swapnil, HK, Shashikiran
Enhancing Diagnostic Efficiency and Customer Support for Off-Highway Vehicles in India2025-28-030111/06/2025
Off-highway vehicles (OHVs) are vital for India’s construction, mining, agriculture, and infrastructure sectors. With growing demand for productivity and sustainability, the need for efficient customer support and precise diagnostic techniques has become paramount. This paper presents a comprehensive study of challenges faced in India, current and emerging diagnostic technologies, troubleshooting techniques, and strategies for effective customer support. Case studies, tables, and diagrams illustrate practical solutions.
Mulla, Tosif, Thakur, Anil, Tripathi, Ashish
Adaptive Terrain Morphing Chassis for Off-Highway Vehicles: Enhancing Fuel Efficiency through Dynamic Structural Adaptation2025-28-034211/06/2025
Off-highway vehicles (OHVs) routinely navigate unstable and varied terrains—mud, sand, loose gravel, or uneven rock beds—causing increased rolling resistance, reduced traction, and high energy expenditure. Traditional rigid chassis systems lack the flexibility to adapt dynamically to changing surface conditions, leading to inefficiencies in vehicle stability, maneuverability, and fuel economy. This paper proposes an adaptive terrain morphing chassis (ATMC) that can actively modify its structural geometry in real-time using embedded sensors, hydraulic actuators, and soft robotic elements. Drawing inspiration from nature and recent advances in adaptive materials, the ATMC adjusts vehicle ground clearance, track width, and load distribution in response to terrain profile data, thereby optimizing fuel efficiency and performance. Key contributions include: A multi-sensor fusion system for real-time terrain classification Hydraulic actuators and morphing polymers for variable chassis
Vashisht, Shruti
Development of Door Impact Loads Using Frugal use of “Pedal Force Sensor”2025-28-028311/06/2025
The first step in designing or analyzing any structure is to understand “right” set of loads. Typically, off-road vehicles have many access doors for service or getting into cab etc. Design of these doors and their latches involve a knowledge of the loads arising when the door is shut which usually involves an impact of varying magnitudes. In scenarios of these impact events, where there is sudden change of velocity within few milliseconds, produces high magnitude of loads on structures. One common way of estimating these loads using hand calculations involves evaluating the rate-of-change-of-momentum. However, this calculation needs “duration of impact”, and it is seldom known/difficult to estimate. Failing to capture duration of impact event will change load magnitudes drastically, e.g. load gets doubled if time-of-impact gets reduced from 0.2 to 0.1 seconds and subsequently fatigue life of the components in “Door-closing-event” gets reduce by ~7 times. For these problems, structures
Valkunde, Sangram, Ghate, Amit, Gagare, Kiran
Design IQ: An Integrated System for Smart Engineering Metrics2025-28-032711/06/2025
Weight and cost are pivotal factors in new product development, significantly impacting areas such as regulatory compliance and overall efficiency. Traditionally, monitoring these parameters across various stages involves manual processes that are often time-intensive and prone to delays, thereby affecting the productivity of design teams. In current workflows, designers must manually extract weight and center of gravity (CG) data for each component from disparate sources such as CAD models or supplier documents. This data is then consolidated into reports typically using spreadsheets before being analyzed at the module level. The process requires careful organization, unit consistency, and manual calculations to assess the impact of each component on overall system performance. These steps are not only laborious but also susceptible to human error, limiting agility in design iterations. To address these challenges, there is a conceptual opportunity to develop a system that could
Patil, Vivek, Sahoo, Abhilash, Ballewar, Sachin, Chidanandappa, Basavaraj, Chundru, Satyanarayana
Customer Support – Failure and Warranty Analysis in Off-Highway Vehicles2025-28-030011/06/2025
The reliability and durability of off-highway vehicles are crucial for industries like construction, mining, and agriculture. Failures in such machines not only disrupt operations but can also lead to significant economic losses and safety concerns. Effective failure and warranty analysis processes are essential to improve customer support, minimize downtime, and enhance equipment life cycle. This paper outlines a comprehensive 7-step failure analysis methodology tailored for off-highway vehicles, accompanied by warranty analysis using Weibull, 6MIS, and 12MIS IPTV. It details the process from problem identification through permanent solution implementation, emphasizing tools and techniques necessary for sustainable improvements. The structured approach provides an actionable blueprint for OEMs and service teams to enhance customer satisfaction, support sustainable development goals, and maintain regulatory compliance.
Mulla, Tosif, Thakur, Anil, Tripathi, Ashish
Bale Wrap Orientation Tracking for On-Field Storage2025-28-027911/06/2025
In the agricultural industry, the logistics of transporting and storing bales, used as cattle feed, pose significant challenges for large scale farms. Traditional storage of bales in barns is labor-intensive, high in capital expenditure and requires multiple trips of transport vehicle on and off the field. Improper handling during this transition can lead to substantial losses in time, resources and loss of hay. This development aims to eliminate the last-mile transportation step, by enabling year-round storage of bales directly in the field. A patented wrapping material, along with strategic orientation of wrapped bales, enhances their resistance to weather conditions. Field experiments demonstrated that this innovative material not only protects the bales from adverse environmental factors but also effectively retains their nutrient and moisture content. A critical aspect of this solution is ensuring the correct orientation of the wrap seams, as the bales are continuously rotated
Kadam, Pankaj
Design Strategies for “Front Stabilizer Link Assembly” for Maximized Wheel Articulation in All Terrain for Passenger Car Application2025-28-030911/06/2025
The stabilizer link, also commonly referred to as the sway bar link or anti-roll bar link, plays a crucial role in the suspension system. It connects the sway bar to suspension components such as the knuckle, control arm, or strut. The primary function of the stabilizer link is to reduce body roll during cornering or when driving over uneven terrain. It helps stabilize the wheels during extreme articulation events and ensures smoother operation in terms of ride comfort and handling. Additionally, it is designed to assist in distributing forces across the suspension system, particularly in off-road or rugged terrain applications. This case study presents the failure of a stabilizer link assembly during extreme articulation events. The front stabilizer link failed during vehicle-level durability and functional testing across multiple terrains. Based on the root cause analysis, design strategies were developed to prevent such failures and to ensure reliable operation during demanding off
S, Praveen Kumar, Chilakala, Raghavendra, Senthil Raja, T, Jadhav, Prashant, Kundan, Lal, J, Akhil, Pawar, Sandip
Mechanical Boom Vibration Mitigation Using Active Force Control2025-28-034511/06/2025
This paper studies an important industrial controls engineering problem statement on mitigating vibrations in a mechanical boom structure for an off-highway agricultural vehicle. The work discusses the implementation of an active force control concept to efficiently dampen out vibrations in a boom. Through rigorous simulation comparison with respect to an existing PID mechanism, the efficacy of the AFC is demonstrated. A notable reduction of 60 % to 70 % in the boom vibrations was observed.
Patil, Bhagyesh, Bawankar, Shubham
Optimization of Shuttle Shifting Process of Agricultural Tractor using Simulation Environment2025-28-028511/06/2025
Transmission tuning involves adjusting parameters within a vehicle's transmission control unit (TCU) or transmission control module (TCM) to optimize performance, efficiency, and driving experience. Transmission tuning is beneficial for optimizing performance, improving fuel efficiency, smoother shifting and enhancing drivability particularly when a vehicle's power output is increased or for specific driving conditions. Especially in offroad and agricultural machines, transmission tuning is vital to significantly improve vehicle performance during different operations. The process of transmission tuning is quite time consuming as multiple tuning iterations are required on the actual vehicle. A significant reduction in tuning time can be achieved using a simulation environment, which can mimic the actual vehicle dynamics and the real time vehicle behavior. In this paper, tuning during the forward and reverse motion of the tractor is described. A two-level PI control-based shift strategy
Varghese, Nithin
Impact of Cooling Airflow and Its Path on Underhood Cooling in Farm Tractors2025-28-028011/06/2025
To ensure the effective operation of engine cooling systems in agricultural tractors, several critical parameters must be considered, including grille opening area and location, grille resistance, front-end blockage, fan speed, and coolant flow rate. While grille design has been moderately explored for highway vehicles, research specific to grille configuration in agricultural tractors remains limited. This study investigates the influence of grille location, grille resistance (modeled using porous inertial and viscous resistance coefficients) front-end blockage, fan speed, and coolant flow rate on radiator top tank temperature (TTT) using Computational Fluid Dynamics (CFD). The analysis is conducted in two phases: first, the effects of grille opening area and location, grille resistance, and front-end blockage are evaluated under fixed fan speed and coolant flow rate; second, an orthogonal array design of experiments is employed to rank the influence of grille opening area, fan speed
Subramani, Sridharan, Baskar, Subramaniyan, Gopinathan, Nagarajan
Decarbonizing Off-Highway Vehicles: Fuel Alternatives and Implementation Strategies2025-28-023011/06/2025
Off-Highway Vehicles (OHVs) — including mining trucks, construction machinery, and agricultural equipment — contribute significantly to greenhouse gas (GHG) emissions and local air pollutants due to their dependence on fossil diesel. Achieving sustainable development goals in off-highway sectors requires transitioning toward alternate fuels that can reduce CO₂, NOₓ, and particulate matter (PM) emissions while maintaining performance and reliability. This paper comprehensively evaluates alternate fuels such as biodiesel, renewable diesel, compressed and liquefied natural gas (CNG/LNG), liquefied petroleum gas (LPG), hydrogen, and alcohol-based blends. Using insights from Service Bulletins, fuel standards, and the Worldwide Fuel Charter, it discusses fuel properties, engine compatibility, operational challenges, sustainability impacts, economic feasibility, safety considerations, and regulatory aspects. Case studies of alternate fuel deployment in OHVs illustrate practical challenges and
Mulla, Tosif, Thakur, Anil, Tripathi, Ashish
Virtual Load Sensor Methodology for Structural Verification2025-28-026911/06/2025
Large off-highway vehicles, such as combine harvesters, corn heads, and hinged drapers, are complex machines comprised of multiple interacting subsystems. Consequently, capturing the load path through full vehicle finite element modeling poses significant challenges and can be computationally intensive during the design development process. We primarily employ two structural analysis approaches based on the availability of load inputs: Full Frame Finite Element Model Setup Subsystem Finite Element Model Setup Just like virtual verification, physical verification can also be performed at both the full vehicle and subsystem levels. The most critical input for both physical and virtual structural verification is load data. Traditionally, we acquire structural loads induced by ground excitations using wheel force transducers. For subsystem finite element models, interface loads are essential, which often necessitate custom load transducers during data collection. However, instrumenting
Zalte, Swapnil Suresh, S Kulkarni, Prasad, Gupta, Shikha, Aundhe, Abhijeet, Darade, Shubham
Challenges in Transitioning from 400V to 800V Off-Highway Power Electronics2025-28-028111/06/2025
Electrification applications are increasingly moving towards higher voltage systems to enable greater power delivery and faster battery charging. This trend is particularly evident in the shift from 400V to 800V systems, which offers several benefits and poses unique technical challenges. Higher voltage systems reduce current flow, minimizing energy losses, and improving overall efficiency. This is crucial for applications like electric vehicles and off-highway machinery, where efficient power management is essential. One of the primary benefits of increasing the DC link voltage beyond the 400V is the ability to support higher power levels. Additionally, higher voltage systems can reduce the size and weight of power components, contributing to more compact and lightweight designs. However, transitioning to 800V systems introduces several technical challenges in power electronics design. Key components such as power components (IGBT, MOSFET etc.) must be optimized to handle higher
Hatkar, Chetan Manohar, Pipaliya, Akash
Significance of EMC Tests for Construction Equipment Vehicles2025-28-025611/06/2025
Requirement for Construction Equipment Vehicles (CEVs) in India is continuously growing due to India’s focus on infrastructure development. Technology in the automotive industry has evolved rapidly in recent times and it is also adding new dimensions to the compliance to Electromagnetic Interference, Susceptibility (EMI/EMC) and Safety. EMC and Safety requirements of CEVs are internationally governed by ISO 13766, Part 1 & Part 2. This paper discusses the significance of each aspect specified in these standards and its applicability. Due to nature of work carried out by construction equipment, there is absolutely no scope for compromise on safety for the same. Although Construction equipment standards are based on automotive standards, there are few additional tests which are part of ISO 13766, Part 1 and 2. This paper explains each aspect with practical case study. It also provides general EMC guidelines and precautions to be followed during design validation and product validation
Yeola, Mayur, Nigade, Mahesh, Mulay, Abhijit B
Advanced Manufacturing Processes – Construction Equipment’s2025-28-024311/06/2025
With the global increase in demand for construction equipment, companies face immense pressure to produce more products in a competitive and sustainable way by utilizing advanced manufacturing technologies. Additionally, the need for data analytics and Industry 4.0 is increasing to take better decisions early in the development cycles and during the production phase. Advanced manufacturing processes & adopting Industry 4.0 is the only viable solution to address these challenges. However, the implementation of advanced manufacturing processes in heavy fabrication and construction equipment factories has been slow. A significant challenge is that the products being produced were originally designed for conventional manufacturing processes. When factories are becoming smart and connected through Industry 4.0 solutions, companies must reconsider many established assumptions about advanced manufacturing processes and their benefits. To maximize efficiency gains, improve safety standards
Bhorge, Pankaj, Saseendran, Unnikrishnan, Rodge, Someshwar
Structural Evaluation and Improvement of Mobile Vehicle Battery Storage Architecture2025-28-025911/06/2025
Environmental concerns are prompting the global mobility sector to transition towards electrification. Increased research and development in the field of electric vehicles have made them an increasingly efficient and compelling option for reducing greenhouse gas emissions and improving the sustainability of freight transport. Electric vehicles require batteries that offer long range, shorter charging times and high energy efficiency. During long-distance travel, for customer convenience, mobile charging stations have become a trending and highly meaningful solution. For such mobile charging stations, it is essential to ensure the durability and safety parameters of the battery and its structure. For this to happen, it is mandatory that the system possess the strength and stiffness behavior to withstand the various dynamic loads arising from the environment and acting on the vehicle and system. Moreover, the system should maintain a weight that is as low as possible so that it is both
Sonare, Pushpesh, Ganeshan, Subramanian, Dattawade, Vishal
Digital Simulation of Rear Axle Brake Lines Articulation for Commercial Vehicles2025-28-025711/06/2025
This paper focuses on defining the optimal length of rear axle brake lines (flexible polyamide tubes) for commercial vehicles by simulating the lines digitally by considering tube behavior and various axle articulation conditions. Currently, the length of rear axle brake lines are predominantly defined with the help of a physical mockup by articulating axle conditions in a vehicle. This approach requires actual components such as frame, axle, suspension, etc., which consumes considerable time and cost. Through technological advancements, prototyping can be reduced and convergence on digital to build can be achieved through digital simulation. This paper explores tube properties, axle configurations and definitions, and various methods of digitally simulating line articulation. Boundary conditions, space reservations and design criteria for pneumatic routing are defined for the type of line designed. Digital simulation of rear axle brake lines articulation was performed and compared
Duraiswamy, Rupesh, Sankaran, Bhargav, Raj, Santhosh
Leveraging AI for Autonomous Vehicle Simulations in SIL and HIL Frameworks2025-28-027111/06/2025
This paper offers recent ideas and its implementation on leveraging AI for off highway Autonomous vehicle Simulations in SIL and HIL frameworks. Our objective is to enhance software quality and reliability while reducing costs and efforts through advanced simulation techniques. We employed multiple innovative solutions to build a System of Systems Simulation. Physics based models are a prerequisite for detailed and accurate representation of the real-world system, but it poses challenges due to its computational complexity and storage requirements. Machine learning algorithms were used to create surrogate/reduced order models to optimize by preserving the expected fidelity of models. It helped to speed up simulation and compile model code for SIL & HIL Targets. Built AI driven interfaces to bridge windows, Linux and Mobile Operating systems. Time synchronization was the key challenge as multiple environments were needed for end-to-end solutions. This was resolved by reinforcement
Karegaonkar, Rohit P., Aole, Sumit, Dasnurkar, Swapnil, Singh, Vishwajeet, Saha, Soumyadeep
Cooling System Design Approach for Off-Road Vehicles Using 3D CFD and 1D Tools2025-28-026011/06/2025
The average product development cycle spans 3-5 years, involving extensive virtual and physical testing of the machine. Advances in simulation tools have significantly enhanced our ability to identify product solutions early in the design phase. Tools like 1D KULI and Creo Flow Analysis (CFA) offer faster solutions in less time, thereby accelerating the product development cycle. Cooling systems are crucial components of off-highway tractor machines, directly affecting engine efficiency and overall machine functionality. An optimized cooling system ensures the engine operates within safe temperature ranges, preventing overheating and potential damage. Thus, designing an effective cooling system is a vital aspect of machine engineering. 3D Computational Fluid Dynamics (CFD) simulations are essential for evaluating cooling system performance. These high-fidelity simulations provide detailed insights into fluid flow and heat transfer, enabling engineers to predict and enhance cooling
Ukey, Snehal, Tirumala, Bhaskar, Nukala, Ramakrishna
Smart Fleet Management for Mechanical Tillage Implements2025-28-031211/06/2025
Tillage, a fundamental agricultural practice involving soil preparation for planting, has traditionally relied on mechanical implements with limited real-time data collection or adjustment capabilities. The lack of real-time data and implement statistics results in fleet managers struggling to track performance, driver behavior, and operational efficiency of the implements. Lack of data on vehicle performance can result in unexpected breakdowns and higher maintenance costs, ensuring compliance with regulations is challenging without proper data tracking, potentially leading to fines and legal issues. Bluetooth-enabled mechanical implements for tillage operations represent an emerging frontier in precision agriculture, combining traditional soil preparation techniques with modern wireless technology. Implement mounted battery powered BLE (Bluetooth Low Energy) modules operated by solar panel based rechargeable batteries to power microcontroller. When Implement is operational turns
Kaniche, Onkar, Rajurkar, Kartik, Gokhale, Sourabha, Vadnere, Mohan
A Measurement Method to Correlate CFD Prediction of Air Flow Velocities across Cooling Pack for Farm Tractor2025-28-027311/06/2025
An agricultural tractor comprises a tightly packed underhood compartment, which poses distinct challenges in managing airflow through its heat exchangers. The intricate design results in uneven airflow patterns, as the fan-driven system draws air from the front, top, and side openings. This work presents a methodology to measure the cooling airflow volume in the tractor and establishing a correlation between test airflow and CFD simulated airflow values. A handheld anemometer and 3x3 matrix type anemometer used for airflow measurement. Measurements were taken at front and back of heat exchanger. It was concluded that, measuring airflow through the heat exchanger with a matrix-type anemometer positioned behind it can enhance the correlation with CFD results to 84%.
A, Boopalshanmugam, Ganesan, Thanigaivel, Reddy, Lakku, Sateesh, Tadi, Gopinathan, Nagarajan
Environmental Factors and Off-Highway Vehicle Safety Abstract2025-28-032211/06/2025
Off Highway vehicles recreation has rapidly expanded across the globe hence it is important to consider the safety of off-highway vehicles which is significantly influenced by various environmental factors, which can pose unique challenges and risks. it is important to make sure that the entire vehicle operates safely and reliably even in the toughest conditions. This paper investigates the impact of environmental conditions on the safety and performance of off-highway vehicles, such as construction equipment, agricultural machinery, and mining vehicles. By examining factors such as terrain, weather conditions, visibility, and natural obstacles, the study aims to identify key hazards and propose strategies to mitigate them. The paper explores how advanced technologies, including digital twins and predictive analytics, can be leveraged to enhance safety measures and improve vehicle resilience in diverse environmental settings. Through comprehensive case studies and empirical data, we
Mogal, Masthanvali, Chennamalla, Chandra Shekar
Use of the Sound-intensity Method to Identify Acoustic Leakages from Off Highway Machine Cab2025-28-026711/06/2025
The operator station or “cab” in off Highway equipment plays a critical role to provide a comfortable workspace for the operator. The cab interfaces with several elements of the off-highway equipment which can create gaps and openings. These openings have the potential for acoustic energy leakage, ultimately increasing sound within the cab. During machine operation, noise generated around the cab conducts inside through these leakages resulting in increased sound levels. Acoustic leakages are among the key noise transfer paths responsible for noise inside the cab. Therefore, before considering noise control treatments it is best to first identify and minimize any leakages from joints, corners, and pass-throughs to achieve the required cab noise reduction. In this effort the sound intensity technique is used to detect the acoustic leakages in cab. The commercial test system is used for measuring the sound intensity field over objects. For the cab, an acoustic source is used inside the
Pawar, Sachin M., Mandke, Devendra, Fapal, Anand, Cone, Kerry
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