Browse Topic: Vehicle performance

Items (1,490)
Aiming at the problems of traditional physical model methods in aircraft endurance prediction, an end-to-end prediction model based on depth deterministic policy gradient (DDPG) is proposed. The model realizes continuous mapping from flight parameters to range index through Actor-Critic dual network architecture, and combines experience playback mechanism and soft update strategy of target network to effectively suppress training oscillation and improve convergence stability. UAV Delivery Aircraft Versus hybrid dataset was used to verify model performance in test samples. The results show that the MAE of the model is 9.2 km, which is 42.1% lower than that of DQN; the prediction accuracy of the model is the best (MAE 7.3 km) in cruise phase, which is due to the dynamic compensation of time series difference error to wind speed disturbance; in environmental disturbance test, the error increment (50.0%) is significantly lower than that of DQN (78.0%) at low temperature (-5 ° C), which highlights its robustness to battery voltage sag. The model provides real-time and reliable decision support for aircraft endurance management in high-dynamic airspace.
Bai, RongqiangChen, Li
The climb gradient along the takeoff trajectory at each point during takeoff reflects the aircraft’s ability to clear obstacles and reach a safe altitude, ensuring the safety of civil flights. Airworthiness regulations specify certain requirements for the single-engine-out climb gradient. Given that the data used in conventional calculation methods are significantly influenced by the flight status during the process, this paper explores two new climb performance calculation methods based on the existing ones. A set of data was calculated, and the resulting errors were all no more than 10%, indicating that both new calculation methods are effective and reliable. Therefore, they provide a certain reference value for the climb gradient calculation of transport category aircraft.
Jiang, TianjunLiu, Tao
The widespread adoption of electric vehicles is currently hindered by long charging durations and limited infrastructure. While fast-charging technologies address these issues, they impose significant thermal loads on high-voltage components. Within this architecture, the Battery Disconnect Unit plays a critical role as it monitors and controls the connection between the battery, powertrain, and charging system. However, the high currents required for fast-charging often drive these units' temperatures beyond safe operating limits, necessitating advanced thermal solutions that do not require extensive redesigns of the vehicle's electrical layout. To address this challenge, this study proposes a passive thermal management solution using Phase Change Material heat transfer devices to enhance the thermal robustness of the component. The methodology employs a dual approach involving initial experimental testing to pinpoint specific thermal hotspots under high-power conditions, followed by detailed numerical simulations using GT-Power software to predict system behavior. Furthermore, the paper provides a comparative analysis of various configurations, assessing their impact on temperature reduction, response time, and thermal uniformity. The results demonstrate that appropriately designed passive solutions significantly improve thermal performance, effectively enabling higher charging power capabilities while minimizing system complexity and integration effort. This innovation provides a scalable and efficient path for improving overall vehicle performance and safety during rapid energy transfer events.
Salameh, GeorgesGoumy, GuillaumeFrecinaux, AnthonyRatajczack, ChristellePalluel, MarlèneNoiseau, PascalLardeux, Sébastien
Hybrid electric vehicles rely heavily on battery pack power capability, which is often compromised by non-uniform aging and thermal gradients. Conventional battery models typically use bulk state-of-health metrics, failing to capture localized degradation that leads to current imbalances and reduced pack utility. This paper presents a multi-scale modelling framework that integrates Electrochemical Impedance Spectroscopy data into a fractional-order equivalent circuit model to simulate localized degradation in Lithium Iron Phosphate cells. Results show that the terminal voltage of LFP cells can be accurately modelled using the proposed fractional-order equivalent circuit with a discrete transfer-function implementation, maintaining root-mean-square errors below 20 mV across most state-of-health and state-of-charge conditions. The validated cell model is then extended to a degradation-aware battery pack representation. The battery pack in this work utilizes a 200-kWh, 800 V architecture consisting of five modules connected in parallel, each module composed of 13 parallel strings of 250 series cells, evaluated under multiple degradation scenarios. By integrating this pack model into a Class-8 series hybrid powertrain simulation, this study quantifies how cell-to-cell heterogeneity impacts vehicle performance under the VECTO regional delivery drive cycle. At the vehicle level, these battery constraints influence engine duty cycles and battery pack stress metrics. When localized degradation reaches up to 40% in one module while the remaining modules degrade up to 20% to 30%, such inhomogeneous degradation reduces the minimum pack terminal voltage by approximately 27% and increases peak discharge current by more than 30%, resulting in more rapid degradation. These battery-level limitations translate into higher fuel consumption by up to 6% in a charge-sustaining scenario.
Safavi, Seyed RezaHomayouni, HoomanShoa, TinaWang, JasonMcTaggart-Cowan, Gordon
Many high-end electric vehicles use an automatic two-speed transmission. The ability of the drivetrain to switch between two gear ratios improves vehicle performance and increases driving range. The aim of the presented research work is to transfer these advantages to small and lightweight battery-electric vehicles, which face significant cost and weight constraints and therefore cannot rely on highly sophisticated electric motors. Direct-drive systems are widely used in this vehicle class due to their simplicity and high baseline efficiency. However, they offer limited flexibility in adapting the operating point of the electric motor under varying load conditions. A two-speed transmission can overcome this limitation by enabling load point shifting, allowing the motor to operate closer to its optimal efficiency region during both urban and extra-urban driving. This results in improved energy consumption without adding substantial system complexity. Currently, only actuated transmissions are offered on the market, with automation adding a high degree of complexity and representing a major cost driver. Therefore, the focus during the concept development phase was on designing a fully mechanical, self-shifting system to meet the cost pressures of the targeted vehicle classes. Hence, the team at ITnA developed and patented a solution that enables automatic gear changes solely based on output torque, which reflects the motor load and the current driving situation. In the present work, both the operating principle of the technology and the advantages regarding the performance and efficiency of electric vehicles are described. Owing to its simple architecture and the absence of electronics, the transmission is inherently robust and durable, making it a significant contribution to the development of sustainable and affordable e-mobility for the mass market.
Napetschnig, ChristofTromayer, JuergenStückler, David
This SAE Recommended Practice incorporates a track-based test procedure that produces a representative value for vehicle top speed when operating on a level paved road with a fully charged battery.
Motorcycle Technical Steering Committee
The effects of hover operations near a partial boundary structure were assessed for a free-flying quadrotor platform under both wind-off and wind-on conditions. The partial boundary structure was selected to replicate a building facade or urban vertiport environment, providing a realistic operational context for these free-flight tests. Test points were chosen to investigate operations near the partial boundary wall and edge, and across a range of partial ground effect conditions to capture the progressive onset of ground effect characteristics. Regions of degraded vehicle performance, quantified primarily by rotor thrust coefficient (CT ) and power requirements, emerged near the partial boundary edge. These performance trends were attributed to localized changes in rotor inflow profile, characterized by near-field rotor pressure measurements. Partial ground effect was found to not resemble full ground effect until much of the vehicle had traversed over the partial boundary, with the vehicle airframe and fuselage serving as the primary factor driving the onset and development of ground effect characteristics. Under wind-on conditions, the interaction between the wind freestream and the partial boundary structure significantly shaped vehicle performance and handling qualities. The most adverse handling qualities coincided with regions of peak flow vorticity, highly unsteady flow, and large velocity gradients at the shear layer above the partial boundary.
Herz, SageTaylor, JuliaClar, LaurenMcCrink, Matthew
TOC
Tobolski, Sue
This study investigates the gradeability performance of an L7e-class electric micro truck from both vehicle dynamics and thermal perspectives. A 1D simulation model (Amesim) was developed and validated with multiple test results. Using inputs such as motor characteristics, drivetrain configuration, and vehicle mass, the model analyzed vehicle performance on a 20% gradient, calculating the required torque, achievable motor speed, and corresponding vehicle speed. Furthermore, gradeability limits were evaluated, and the effects of gear ratio and airflow rate around the air-cooled motor on both gradeability and thermal behavior were examined. The findings provide practical insights for improving the powertrain and cooling system design of lightweight electric vehicles. The results showed that selecting an appropriate gear ratio can enable the motor to operate more efficiently under demanding driving conditions. A 20% increase in the gear ratio was found to delay motor heating by up to 10%. However, its effect was observed to be negative under driving conditions such as WLTP, which require variable RPM demand.
Turan, AzimKantaroğlu, Hasan HüseyinAkbaba, MahirKasım, Recep FarukYarar, Göktuğ
The multi-body dynamics (MBD) model and the MATLAB Simulink model can be integrated to create a control-integration model. Using a high-fidelity MBD model to represent the vehicle as the plant, this integrated model can be used to analyze vehicle system physics and develop control strategies. For hybrid vehicles, this process is more complex because the powertrain and other vehicle systems are often built as separate MBD models. This paper describes a method for integrating a powertrain model developed in AMESIM, a vehicle model developed in SIMPACK, and a control model developed in MATLAB Simulink. The resulting integrated model was then used to perform frequency sweep analysis to identify driveline system properties. In particular, the driveline frequency and the amplitude of the transfer function between motor speed and motor torque are critical parameters. By applying active damping control to the driveline system, the peak amplitude and driveline vibrations can be reduced. The hybrid vehicle studied includes a transmission system with ten different gears. When the vehicle operates at different gear level, the system behaves differently. The analysis results can assist the driveline control team in developing appropriate strategies to improve overall vehicle performance.
Xing, XingMathew, Vino
Electric vehicle (EV) battery packs have undergone substantial advancements in recent years, driven by engineering design improvements, material innovations, and increasingly stringent regulatory enforcement. These developments have enabled battery packs to become more energy-dense, which is essential for extending driving range and improving overall vehicle performance. However, with increased energy density comes a higher severity of thermal events, such as thermal runaway, which continues to raise concerns regarding vehicle safety, reliability, and long-term durability. This review highlights the critical role that thermal insulation materials play in mitigating the impact of such thermal events within EV battery systems. It presents an overview of commonly used thermal insulation materials, emphasizing their chemical composition, thermal resistance, and mechanical integrity under extreme conditions such as high temperatures and physical stress. The ability of these materials to maintain performance during thermal abuse is essential for protecting both the battery and surrounding vehicle components. In addition to material properties, the review compares the methodology and performance metrics of common methods for evaluating flammability, including flame retardance test such as UL 94 and torch and grit flammability tests such as one described in UL 2596. These comparisons are crucial for identifying insulation materials that can withstand severe thermal conditions without compromising safety. Beyond flammability, high temperature, smoke, and other important considerations such as thermal properties, environmental durability, corrosion resistance, and dielectric strength will be discussed with examples. These factors contribute to the overall effectiveness and reliability of insulation materials in EV applications. By understanding and optimizing these properties, engineers can better design battery packs that are not only high-performing but also safe and durable under demanding operating conditions.
Ng, Sze-SzeDhyani, AbhishekGorin, CraigJeon, JunhoNuguri, SravyaRepollet Pedrosa, MiltonRylski, AdrianShete, AbhishekSteinbrecher, JacobThomas, Ryan
To effectively improve the performance of chassis control of distributed drive intelligent electric vehicles (EVs) under difference road conditions, especially in combing road information and chassis control for improving road handling and ride comfort, is a challenging task for the distributed drive intelligent EVs. Simultaneously, inaccurate chassis control and uncertainty with system input, are always existing, e.g., varying road input or control parameters. Due to the higher fatality rate caused by variable factors, how to precisely chose and enforce the reasonable chassis control strategy of distributed drive intelligent EVs become a hot topic in both academia and industry. To issue the above mentioned, an adaptive torque vector hierarchical controller based on road level and adhesion is proposed, which optimizes the comprehensive. First, combined with the characteristic of the unbalance dynamic force caused by the air gap between the stator and the rotor of the in-wheel motor, a nonlinear vehicle model based on motor unbalanced electromagnetic force is developed. Then, using the deep neural network, an algorithm for road level and adhesion recognition based on system response data is designed. Meanwhile, an adaptive torque vector controller based on road information is designed to improve the driving safety and handling stability of chassis. Finally, the proposed algorithm is validated on the full-car test rig platform, results show that the proposed algorithm can improve chassis performance under double lane-change test. The research achievements develop a reasonable algorithm to apply to the improving road handling and ride comfort performance for distributed drive intelligent EVs.
Wang, ZhenfengZhao, GaomingZhang, ZhijieZhou, ZitaoHuang, TaishuoMa, Changye
Heavy-duty electric trucks represent a growing innovation in the transport and logistics sector, aiming to reduce emissions and reliance on fossil fuels. A major challenge with battery electric trucks is the long recharging time which takes significantly longer than refueling conventional diesel trucks. This limitation highlights the importance of optimizing powertrain operations to reduce energy losses and maximize efficiency. One effective approach is implementing optimal speed control through a predictive cruise controller. By anticipating road conditions, traffic, and elevation changes, the predictive cruise controller can adjust the truck’s speed in real time to minimize energy consumption, enhancing the range and reducing the need for frequent charging. Many problem formulations for electric trucks focus primarily on minimizing the energy required at the wheels, often overlooking the impact of powertrain efficiencies. This simplification neglects critical factors such as the efficiency of the traction electric machine (EM), gear losses, and battery dynamics, which are essential for optimizing overall energy consumption and improving vehicle performance. This research paper shows the impact of powertrain efficiencies on the optimal speed profile generation with a predictive cruise controller (PCC). The PCC optimizes electric truck operation by focusing on three primary factors in its cost function: 1) battery energy consumption, 2) total trip time, and 3) battery state of charge (SOC). To achieve the optimal speed profile, Sequential Quadratic Programming (SQP) is used. A comparison was made with a conventional cruise controller, which simplifies the vehicle model by minimizing the required energy at wheels and ignores powertrain losses in its energy calculations. The results show that the proposed PCC offers a 12.85% improvement in battery SOC and 10.83 % improvement in energy consumption as compared to baseline.
Safder, Ahmad HussainVillani, ManfrediKhuntia, SatvikNelson, JamesMeijer, MaartenAhmed, Qadeer
The electrification of drayage fleets offers potential economic and operational benefits, but the financial viability of electrified vehicles remains sensitive to battery cost, energy price, and fleet usage patterns. While total cost of ownership (TCO) is a useful benchmark, fleet operators and investors are equally concerned with investment performance metrics such as payback period (PB) and Internal Rate of Return (IRR), which better reflect financial risks and investment return timelines. This study develops a unified techno-economic framework that jointly evaluates TCO, PB, and IRR to determine when electrified trucks become cost-effective alternatives to diesel trucks. Building on a previously developed cost modeling tool and using real-world telematics data from a Class 8 drayage fleet at the Port of Savannah, the analysis incorporates projected battery cost trajectories, electricity and diesel price trends, vehicle efficiency improvements, and multiple battery capacities. Parameter ranges reflect widely cited projections and observed drayage-duty-cycle variability. A surrogate-modeling method approximates economic performance across thousands of battery cost–electricity price combinations, enabling high-resolution identification of conditions that achieve TCO parity, acceptable PB thresholds, and target IRR levels. Additionally, the study estimates the evolving share of the fleet that can feasibly electrify over time under multiple economic metrics. This integrated framework offers a novel, data-driven approach to inform risk-aware decision-making for fleet electrification and supports investment planning under evolving cost and operational conditions.
Sun, RuixiaoSujan, VivekGoulet, NathanWang, Qixing
This work investigates the impact of the forthcoming 2026 FIA Formula 1 power unit regulations on vehicle track performance. This new regulation introduces a rebalanced power distribution between the internal combustion engine and the Motor Generator Unit-Kinetic (MGU-K), with each unit contributing up to 350 kW. This transition nearly triples the previous 120 kW output of the MGU-K while constraining the internal combustion engine through newly imposed fuel energy limits. A full vehicle powertrain model was developed in GT-Suite following the 2026 FIA technical directives. Particular attention was given to Articles 5.4.7 to 5.4.10, which define key constraints on hybrid operation: a maximum variation of 4 MJ in battery state of charge, up to 9 MJ of recoverable energy per lap, and a peak MGU-K electrical power output of 350 kW. The model includes updated architecture specifications, active aerodynamic modules, energy deployment logic, and component-level constraints. Telemetry data from the 2024-2025 qualifying sessions was employed for model development, validation, and benchmarking, enabling performance comparisons under realistic track conditions. Analysis results reveal notable deviations in powertrain response and vehicle performance across a range of circuits, establishing a correlation between the powertrain performance and track layouts. The model enables the decomposition of overall system effects into discrete contributions from specific regulatory requirements and individual component limitations. This paper will propose a justification and scheme for developing circuit-specific strategies based on maximum energy constraint and vehicle performance.
Giaquinta Aitala, LucioSamuel, Stephen
In high-end motorsport engineering, aerodynamic devices such as front and rear wings are prone to aeroelastic deformations under certain conditions, which can be exploited for vehicle performance gains. Considering the complex interactions between the aerodynamics and structures, experimental evaluation can prove to be a time-effective approach for design, optimisation, research and development regarding aeroelastic bodies. This study presents the development and experimental validation of a deformation tracking system using depth-sensing LiDAR (Light Detection and Ranging) camera technology. The system is based on the use of reflective markers mounted on a given model of interest; this project, a front wing model with a flexible, 3D printed flap element was used as a benchmark. Surface deformation is captured by post-processing point cloud data to extract three-dimensional displacement vectors. A series of controlled measurement tests were first conducted to assess accuracy and repeatability under known displacements. A full wind tunnel test campaign was then carried out to record surface deformation under aerodynamic loading, with flow speeds ranging from 10 to 35 m/s. Accuracy tests using a rigid marker setup showed a root mean square error (RMSE) range of 1 to 2 mm across a two-camera configuration with a combined error of sub-mm accuracy. The system was able to resolve consistent displacement trends as flow speed increased, with larger deformations observed near the centre-span of the flap element. Measured displacements exceeded 30 mm in the most flexible regions, and results were repeatable across test runs. The method demonstrated stable tracking performance and provided a practical alternative to more complex setups for characterising flexible aerodynamic components in controlled environments.
Altinbas, KoraySoares, Renan F.
A battery-electric vehicle (BEV) has multiple powertrain components (battery, inverter, e-motor), a thermal management system (compressor, heat exchanger, cabin heating, ventilation, and air-conditioning), and a vehicle body, among others. Vehicle testing is time-consuming, and changing powertrain components during the testing and design process is costly. Simulation models (aka virtual or simulation test rig) have been widely used for efficient vehicle design. This work presents a systematic approach to developing a virtual test rig to evaluate the thermal performance of battery-electric vehicles. A Tesla Model Y is tested in a chassis dynamometer, and the measured vehicle performance data are used as boundary conditions for the complete vehicle model. The detailed lithium-ion battery (LIB) pack model, including its cooling system, was developed and calibrated using various transient driving cycle data. The HVAC model uses a simplified controller to maintain the cabin temperature at 25 °C in both battery heating and cooling modes. The predicted thermal and electrical performance of the BEV is well validated by test data. Then, the complete vehicle model is used to compare the thermal performances of the BEV under cabin heating and cooling modes for various transient driving cycles. The simulated results show that using an external cabin air circulation model can reduce the battery energy consumption and dissipated heat by 9.9% and 2.4%, respectively. This calibrated virtual test rig can be used to evaluate a new HVAC system.
Sok, RatnakKusaka, Jin
The push for vehicle development through virtual prototyping and testing in motorsports highlights the critical challenge of tire model selection and calibration, especially when vehicle dynamics must be accurately captured. The calibration process for tire models such as the Pacejka Magic Formula (MF) relies on parameter identification and experimental data fitting. While optimization algorithms have been implemented to calibrate tire models, few studies explore the effects of parameter selection on overall vehicle performance, complicating prioritization for the vehicle’s modeling and simulation strategy. To bridge this gap, this paper leverages optimal control methods to quantify how the variability of MF tire model parameters propagates to the overall vehicle model and impacts lap time prediction accuracy. To achieve this, a subset of parameters critical to combined slip of the MF tire model are varied through a Design of Experiments (DOE). These variations are executed on a flat oval track to simplify the dynamics yet exhibit combined slip characteristics using a fixed vehicle configuration. The minimum lap time problem is solved using collocation methods via Dymos, an optimal control library for multidisciplinary systems. A neural network surrogate model enables an interactive profiler to visualize lap time sensitivity to tire model parameters. The primary contribution of this work is a framework that parametrically connects high-level, vehicle-wide metrics such as lap time to the calibration process and selection of tire models. The parametric and interactive nature of the framework allows high-level insights across the whole design space of tire model parameters. Insights derived from this framework provide a basis to develop a strategy for prioritizing testing and calibration efforts driven by vehicle level impacts of model parameter uncertainties.
Zarate Villazon, Angel M.Brown, IanBalchanos, MichaelMavris, Dimitri
Ensuring the safety of Vulnerable Road Users (VRUs) is a critical challenge in the development of advanced autonomous driving systems in smart cities. Among vulnerable road users, bicyclists present unique characteristics that make their safety both critical and also manageable. Vehicles often travel at significantly higher relative speeds when interacting with bicyclists as compared to their interactions with pedestrians which makes collision avoidance system design for bicyclist safety more challenging. Yet, bicyclist movements are generally more predictable and governed by clear traffic rules as compared to the sudden and sometimes erratic pedestrian motion, offering opportunities for model-based control strategies. To address bicyclist safety in complex traffic environments, this study proposes and develops a High-Order Control Lyapunov Function–High-Order Control Barrier Function–Quadratic Programming (HOCLF-HOCBF-QP) control framework. Through this framework, CLFs constraints guarantee system stability so that the vehicle can track its reference trajectory, whereas CBFs constraints ensure system safety by letting vehicle avoiding potential collisions region with surrounding obstacles. Then by solving a QP problem, an optimal control command that simultaneously satisfies stability and safety requirements can be calculated. Three key bicyclist crash scenarios recorded in the Fatality Analysis Reporting System (FARS) are recreated and used to comprehensively evaluate the proposed autonomous driving bicyclist safety control strategy in a simulation study. Simulation results demonstrate that the HOCLF-HOCBF-QP controller can help the vehicle perform robust, and collision-free maneuvers, highlighting its potential for improving bicyclist safety in complex traffic environments.
Chen, HaochongCao, XinchengGuvenc, LeventAksun Guvenc, Bilin
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 freeway segments. Vehicle operational data, environmental conditions, fuel consumption, and emissions were recorded. The route was divided into segments and drive cycle parameters were calculated for each segment. Simple empirical equations were developed for this vehicle correlating fuel consumption with drive cycle parameters and the environmental conditions. The empirical models were compared to fuel consumption data from dynamometer tests with good results. Criteria pollutants (CO, NOx, and THC) were also measured and compared to dynamometer data. Finally, the amount of testing and data required to adequately characterize vehicle performance is discussed.
Moskalik, AndrewBarba, Daniel
Aerodynamic simulations are crucial in vehicle design and performance evaluation. Traditionally, these simulations utilize Computational Fluid Dynamics (CFD) techniques to compute flow quantities such as velocity, pressure, and wall-shear stresses. Accurate prediction of these quantities is vital for estimating drag and lift forces, which directly impact fuel efficiency, stability, and acoustics. This study focuses on developing an AI surrogate for aerodynamic design of production mideo-size SUVs using NVIDIA’s PhysicsNeMo framework. Firstly, high-fidelity 3D CFD data are generated using first-principles solvers on 102 different geometry variants at a uniform inlet velocity of 38.89 m/s and a fixed set of boundary conditions. The DoMINO (Decomposable Multiscale Iterative Neural Operator) AI model, part of the PhysicsNeMo framework, is then used to train on this dataset, accurately predicting surface pressure and flow fields around vehicles for rapid estimation of critical aerodynamic metrics such as drag and lift. DoMINO is a neural operator that learns local geometry representations from point cloud data and predicts PDE solutions on discrete points using dynamically constructed computational stencils in local regions. By leveraging both short- and long-range geometric features, the DoMINO model predicts solution fields on the vehicle’s surface and in the surrounding flow domain—capabilities essential for informed design and engineering decisions in industrial applications. In this study, the DoMINO model is evaluated on a realistic production mid-size SUV vehicle designed by General Motors. Comprehensive hyperparameter tuning is conducted to optimize model performance, along with an analysis of input grid sensitivity. The findings highlight DoMINO's effectiveness as a robust and accurate tool for aerodynamic analysis in the automotive sector, enabling accelerated design cycles and enhanced vehicle performance.
Keum, SeunghwanRaul, VishalGrover, RonaldParrish, ScottRanade, RishikeshGhasemi, AbouzarKamenev, AlexeyTadepalli, Srinivas
When a vehicle performs planar motion, the tire side force induces a jacking-up effect determined by the suspension roll center height governed by suspension geometry. These jacking forces also excite pitching motion. In this study, the pitching degree of freedom, along with roll degree of freedom, was incorporated in the bicycle model of the vehicle motion, hence it becomes four-degree-of-freedom model, and a new analytical method that applies modal analysis method to the model decomposes the motion of the sprung mass of the vehicle into mutually independent vibration modes. Since the superposition of these vibration modes can reproduce vehicle motion, these vibration modes are the fundamental factors governing sprung-mass behavior. Therefore, understanding how these vibration modes respond to design parameters provides a theoretical foundation to design desired vehicle dynamics from the early stage of car development. This report presents, by conducting modal analysis of the four-degree-of-freedom model, that the pitching dominant mode and the mode associated with planar motion and roll, which constitute a three-degree-of-freedom system, are mutually independent dynamically. Furthermore, the suspension design method that controls the pitch-dominant mode can ameliorate the initial turn-in response of the sprung mass in the desirable direction. The insight presented in this report can offer a systematic understanding of the essential characteristics of sprung mass dynamics and can provide new theoretical framework for vehicle dynamics performance design.
Kusaka, KaoruYuhara, TakahiroKoakutsu, Shingo
In recent years, premium vehicles have increasingly incorporated suspension systems capable of adjusting ride height. The primary function of these systems is to enable the vehicle to traverse uneven terrain by elevating the chassis, thereby preventing contact between the underbody and the road surface. Notably, air spring-based mechanisms enhance ride comfort by modulating the wheel rate. The system proposed in this study achieves ride height adjustment through vertical displacement of the spring’s lower seat. By constructing a detailed mechanical topology model using a dynamic simulation tool, this research aims to evaluate the feasibility of improving driving performance not only through height regulation but also by actively controlling the vehicle’s posture during motion.
Park, JaeyongSang Hoon, LeeJong Min, KimChoi, Jang Han
The performance of chassis suspension mechanisms critically affects vehicle handling, ride comfort, and safety. Implementing real-time health monitoring for chassis systems contributes to preventing severe consequences such as increased body roll or loss of handling stability caused by shock absorber softening or spring stiffness degradation under deteriorating operating conditions, while circumventing the substantial costs associated with professional facility-based chassis inspections. With the rapid development of sensing and data analytics technologies, data-driven approaches are increasingly used in health monitoring. This study aims to achieve online monitoring of chassis suspension performance degradation using a deep neural network (DNN). First, a half-car model incorporating both vertical and pitch motions was established to simulate bumpy road conditions, with the aim of constructing a dataset that includes key vehicle suspension parameters and vehicle states related to their degradation characteristics. Subsequently, a DNN model comprising three hidden layers is developed to assess suspension performance degradation. To optimize model performance, the effects of different numbers of neurons and hidden layers on model accuracy are explored. Experimental results show that the maximum absolute percentage errors of the DNN model in predicting suspension stiffness and damping coefficients are less than 0.13% and 0.17%, respectively, with average absolute percentage errors below 0.046% and 0.06%. The coefficients of determination (R2) exceed 0.999. The proposed method accurately predicts the trend of key suspension parameters, providing robust data support for health management and maintenance decision-making. This is expected to reduce safety risks and maintenance costs while enhancing overall vehicle performance and reliability.
Liao, YinshengLei, YisongSu, AilinWang, ZhenfengShi, ShuaiZhang, LeiZhang, JunzhiMa, Changye
The demand for improved energy efficiency in real-world vehicle operations continues to grow with technology enhancement. When transporting large cargo loads with passenger pickup trucks and rental trailers, the interaction between vehicle payload, towing configuration, and fuel consumption becomes a key factor in overall system efficiency. Understanding how towing configurations and trailer loading influence fuel consumption and vehicle performance is critical for both consumer guidance and vehicle system design. This study investigates the energy efficiency of U-Haul truck and trailer systems, with a particular focus on the influence of trailer tongue weight. U-Haul truck and trailer simulation models were developed using AVL Vehicle Simulation Model (VSM) software, with an F-350 engine brake-specific fuel consumption (BSFC) map integrated to represent realistic engine performance. Two configurations with equal payload were evaluated: (1) a U-Haul truck alone, and (2) a U-Haul truck towing a trailer. Within these configurations, multiple scenarios were analyzed, including variations in payload levels and tongue weight distributions. Driving cycles were selected to capture common moving conditions such as urban stop-and-go traffic and extended highway operation. Simulation outputs quantified the interactions among vehicle dynamics, powertrain load, and fuel consumption. Results show clear differences in energy consumption between standalone and towing configurations, with tongue weight distribution exerting a significant influence on both efficiency and stability. The findings provide practical insights into the energy trade-offs between independent vehicle operation and towing scenarios. Moreover, the study highlights the importance of load distribution and driving cycle considerations in optimizing fuel consumption, offering a framework that can be extended to rental, commercial, and consumer towing applications where energy efficiency and vehicle performance are important.
Wang, GangKathadi, MohammadYang, WilliamChen, Yan
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 protocols directly on the HiL setup can be time-consuming and costly. To address this limitation of full HiL testing, in this study, an offline Software-in-the-Loop (SiL) Co-simulation framework was developed as an alternative. This method replicates the HiL environment within MATLAB/Simulink, where joystick actions are simulated according to predefined driving protocols. The dynamic behavior of the vehicle during a reverse driving protocol, involving a 540° constant steering angle and 0–100% acceleration pedal input, was analyzed and compared between Offline SiL and HiL environments. Results demonstrated that 85% of key parameters exhibited strong correlation (R2 > 0.9), confirming that the offline SiL-based approach effectively replicates HiL performance. The remaining parameters also showed acceptable consistency. These findings indicate that the proposed Offline Co-simulation method is a promising, cost-effective, and scalable alternative for accurately predicting vehicle dynamic behavior, aligning well with current automotive industry needs for early-stage validation and optimization.
Visuvamithiran, RishikesanChougule, SourabhSrinivasan, RangarajanLaurent, Nicolas
As internal combustion engines are replaced by quieter electric motors in ground vehicles, noise and vibration sources aside from the powertrain have become relatively more important. This is especially true of tires. Measurement of the dynamic vibratory characteristics of tires is critical to understanding their influence on the noise and vibration performance of vehicles, both outside the vehicle body and inside of it. In this work, the normal modes and operating deflection shapes of a Yokohama Geolander A/T light truck tire are measured using traditional modal analysis techniques as well as a non-contact Scanning Laser Doppler Vibrometry (SLDV) approach. Boundary conditions including free, fixed, loaded, and rotating are implemented to the tire and investigated. Rotating conditions are accomplished in a physical chassis dynamometer environment, with the measured tire mounted on the front axle of a Chevrolet Silverado 1500 pickup truck. Modes of vibration and associated natural frequencies that are measured in all four boundary conditions, including steady-state rotation, are reported and illustrated. Results of the study show that operating deflection shapes of a rotating light truck tire can be measured on a chassis dynamometer using SLDV, assuming the tire is undergoing steady-state rotation, but certain disadvantages in the dynamometer environment make the measurement procedure challenging. Specific concerns such as tire rotating speed consistency and sufficient spatial and frequency resolution of the measurements are delineated in this work. Moreover, practical recommendations for measurement of rotating tire operating deflection shapes using a SLDV are included, and a comparison with the Digital Image Correlation (DIC) method of measurement is presented.
Bastiaan, Jennifer M.Chauda, GauravBaqersad, JavadGupta, ArjunDhami, Kevalya
The recently increasing global concern about sustainability and greenhouse gas emission reduction has boosted the diffusion of electric vehicles. Research on this topic mainly focuses on either re-designing or adapting most conventional vehicle subsystems, especially the propulsion motor and the braking components. In this context, the present work aims to model, analyze, and compare three-braking system layouts design alternatives focusing on their contribution to vehicle performance and efficiency: a commercial vacuum-boosted hydraulic braking system, a commercial integrated electrohydraulic braking system, and a concept distributed electrohydraulic brake system. Braking systems performance are evaluated by simulating key maneuvers adopting a full model of a battery electric vehicle (BEV), which includes all relevant components like tires, and powertrain dynamics, which is validated against real-world data. Implementation and integration of the first two systems are discussed, followed by the design and detailed modeling of the third, which includes a control strategy for pressure modulation, including antilock braking system (ABS) and electronic stability control (ESC) functionalities. Once the simulation environment is set, simulations are performed and KPIs are defined to compare the three braking systems from both the performance and the energy consumption point of view. The results show that the distributed electrohydraulic system reduces the time to lock by 30.8%, the stopping distance by 5.89%, and the energy consumption by more than 50% in specific test cases compared to the analyzed vacuum-boosted system due to its distributed hardware and control architecture and power-on-demand operation.
Savi, LorenzoGarosio, DamianoFloros, DimosthenisVignati, MicheleTravagliati, AlessandroBraghin, Francesco
The Nissan Sentra has provided straightforward behavior and performance for sedan shoppers in the U.S. for over forty years. For 2026, Nissan took the solid 2025 model and made enough mechanical tweaks and visual changes to call it an all-new vehicle. This might sound like a bit of a stretch, but given how the advancements add up to an improved drive experience in a better-looking vehicle, we'll let it slide. Available in four grades - S, SV, SR and SL that range from $22,400 to $27,990, before destination fees and packages - the 2026 Sentra puts on airs like it's a simple vehicle, hiding some of its advanced technology to keep the interior clean and clear, from the driver's screen to the steering wheel buttons. Wireless device charging and wireless Apple CarPlay/Android Auto minimize wire clutter. The standard 12.3-in NissanConnect infotainment touchscreen hides its options in a selection of tiles, and it has a single round volume button that makes it easy to turn down quickly.
Blanco, Sebastian
This study investigates the performance and vibration characteristics of representative lift rotors for a notional lift+cruise electric vertical takeoff and landing (eVTOL) configuration. As new eVTOL concepts continue to be developed and others progress towards FAA certification, it is crucial to understand the performance and vibratory considerations associated with different lift rotor design choices, including the number of blades and the method of thrust control (e.g., variable blade pitch/fixed RPM vs. fixed blade pitch/variable RPM). The NASA Revolutionary Vertical Lift Technology (RVLT) Lift+Cruise configuration was chosen as the baseline vehicle for this analysis (Ref 1). The investigation includes the evaluation of multiple lift rotors with 2-, 3-, and 4-bladed configurations as well as variable- vs. fixed-pitch designs. Both isolated rotor and full vehicle simulations were assessed to demonstrate some of the design variables applicable to the full vehicle performance and vibratory content. Industry-standard rotorcraft comprehensive analysis software, the Rotorcraft Comprehensive Analysis System (RCAS) (Ref 3), was used to evaluate and compare each configuration for performance and vibratory loads at key points in the rotors and in the fuselage
Saberi, SaynaHasbun, MatthewSaberi, Hossein
The US trucking industry heavily relies on the diesel powertrain, and the transition towards zero-emission vehicles, such as battery electric vehicles (BEV) and fuel cell electric vehicles (FCEV), is happening at a slow pace. This makes it difficult for truck manufacturers to meet the Phase 3 Greenhouse Gas standards, which mandate substantial emissions reductions across commercial vehicle classes beginning of 2027. This challenging situation compels manufacturers to further optimize the powertrain to meet stringent emissions requirements, which might not account for customer application specifics may not translate to a better total cost of ownership (TCO) for the customer. This study uses a simulation-based approach to connect customer applications and regulatory categories across various sectors. The goal is to develop a methodology that helps identify the overlap between optimizing for customer applications vs optimizing to meet regulations. To use a data-driven approach, a real-world customer usage pattern analysis was conducted to identify key performance metrics required to optimize driveline components. Additionally, the impact of certification requirements on vehicle performance is examined to ensure compliance while maximizing the benefits of the proposed optimization strategies. The findings of this research will provide valuable insights for manufacturers, enabling the development of trucks that are not only efficient and high-performing but also compliant with environmental standards, ultimately leading to a more sustainable future in the trucking industry.
Mohan, VigneshDarzi, Mahdi
Electric Vehicles and Plug-in Hybrids alleviate the energy crisis but pose a unique challenge for vehicle dynamics. Though significant developments in motor control strategy and energy density management are evolving, we face significant challenges in torque management, with several ADAS features being an integral part of the EVs/xHEVs. It demands high-fidelity physical and control model exchanges between electric chassis, ride-handling, tire modelling, steering assist, powertrain, and validation using a 0D–1D platform. This paper explicates a unified strategy for improving overall vehicle performance by intelligently distributing and coordinating drive torque to enhance traction, stability, and drivability across diverse operating conditions through co-simulation. The co-simulation platform includes physical models in AMESIM, and control strategies integrated in MATLAB/Simulink. The platform features comprehensive representations of digital vehicles that require detailed modelling of the electric motor, transmission, differential, suspension, wheel dynamics, resistive forces (aerodynamic drag, rolling resistance), and road gradient effects, enabling accurate emulation of real-world vehicle behavior. Correlation of test vs. simulation validates the functionality and robustness of the interaction between physical, basic, and application software control strategy. Digital vehicle validation includes traction-based torque limitation (Correlation: >90%), distributing proportionate hydraulic and regenerative braking to improve braking performance, one-pedal driving and stoppage (Correlation: > 85%), SOC influence on regenerative braking, and smooth torque vectoring during dynamic behavior. Evaluation of diverse driving scenarios like, Gradient profiles (Uphill/Downhill/Curvilinear banking), Gradient-μ surfaces for real-world road profiles extracted from GPX/OSM data. Outcome of correlation details reduction of torque fluctuation, vehicle jerk during mode switching & stoppage, Anti-rollback, Aggressive Acceleration, Failure mode mimicking inverter failure in E-powertrain to construct a dynamic target to avoid lateral deviation.
Eruva, PatrickxavierSarapalli Ramachandran, RaghuveeranChougule, SourabhNatanamani-Pillai, Siva SubramanianScheider, ClementLeclerc, CedricNatarajasundaram, Balasubramanian
Public transport electrification is going to play a massive role in India’s COP26 pledge to achieve net zero emissions by 2070. India plans to electrify 800,000 buses in a push towards 30% EV penetration by 2030. Further encouraged by government incentives under National Electric Bus Program (NEBP), e-Bus market is expected to grow at a CAGR of ~86% annually over the next 5 years. With most OEMs going for fleet electrification for reducing CO2 emissions and to cater to growing demand in Indian cities for cleaner public transport, improving powertrain efficiency and performance of state-of-the-art e-Buses is a natural progression of e-mobility sector development in India. The first step in designing powertrain for an electric city bus is to determine the motor(s) size and transmission specifications (number of gears, gear ratios etc.). Complications arise due to a wider and non-linear operation range of eBus. This study focuses on powertrain optimization for a medium duty electric city bus for an Indian city. FEV’s in-house Vehicle Powertrain System Design & Controls (VPSC) tool is deployed for a structured approach. It uses backwards simulation approach to estimate energy consumption and performance of vehicle. An initial (reference) electric drive unit (EDU) is selected via local pre-simulation for detailed flux linked loss maps. This is followed by an iterative AI based Global Optimizer which uses Bayesian algorithm to arrive at subsequent designs until the objective is met within the stated constraints. Performance parameters considered include acceleration and gradeability. The simulation is performed on a high traffic Indian city duty cycle as well as a reference urban VECTO cycle. In both cycles, results show a significant improvement in energy consumption while at the same time improving upon performance with respect to initial pre-simulation selected design of motor and transmission.
Sandhu, RoubleChen, BichengEmran, AshrafXia, FeihongLin, XiaoBerry, Sushil
Accurate range estimation in battery electric vehicles (BEVs) is essential for optimizing performance, energy efficiency, and customer expectations. This study investigates the discrepancies between physical test data and simulation predictions for the BEV model. A detailed range delta analysis identifies key contributors to the observed deviations, including regenerative braking inefficiencies, increased propulsion demand, auxiliary loads, and estimated drivetrain losses within the Electric Drive Module (EDM) during traction and regen. Results indicate that the test vehicle exhibits lower regenerative braking efficiency, higher traction forces and lower regen energy than predicted by simulations, primarily due to EDM inefficiencies and friction brake usage during regeneration. The study underscores the importance of refining simulation methodologies by integrating real-world, test based EDM loss maps to improve accuracy and better align predictive models with actual vehicle performance. Future work will focus on enhancing simulation fidelity and minimizing range estimation deviations to support BEV development and validation.
Mahajan, PrasadKesarkar, SidheshAli, Shoaib
The customer perception of ride comfort with vehicle performance is the most important aspect in a vehicle design. The ride comfort and vehicle performance are influenced by driveline components i.e. propeller shaft phase angle, inclination angle and critical frequency of the driveline system. The optimization of the driveline system is essential to ensure the efficient and smooth power transfer. Propeller shaft is one of the critical components in the driveline to influence the vehicle performance. Propeller shaft characteristics influenced by several factors like vehicle max torque, propeller shaft joint type, materials properties, UJ phase and inclination angle and shaft unbalance value. The optimization of the above parameter within the tolerance limit enables to meet the required performance standard. Various methodologies are available to optimize these parameters to enhance the vehicle performance and comfort leads to customer satisfactions. This study focuses on the analytical optimization of the propeller shaft’s universal joint (UJ) phase and inclination angle and validated at vehicle level. An analytical model was employed to evaluate the velocity fluctuations across the full rotation of the propeller shaft by considering the different UJ phase angles (0° − 360°) and inclination angles (1° − 5°). It was observed from the study that optimization of these parameter improves the vibration performance and decreases the velocity fluctuations. The results shows that the well optimized propeller shaft will enhance smoothness in the driveline systems, reduction in NVH levels, vehicle performance and ride comfort. This study suggests the importance of the precise geometry alignment in driveline design and provide the further refinement methodology.
Kumar, SarveshSanjay, LS, ManickarajaKanagaraj, Pothiraj
Identifying the type of drive cycle is crucial for analyzing customer usage, optimizing vehicle performance and emission control. Methods that rely on geographical location for drive cycle identification are limited by varying driving conditions at the same location (e.g. heavy traffic during peak hours vs. free-flowing traffic at night). This paper proposes a methodology to identify the type of drive cycle (city, interurban, highway or hybrid) using drive characteristics derived from vehicle data rather than geographical location. Real-world vehicle data from testing trucks is taken, whose drive profiles are already known. Initially, multiple characteristic features of the drive cycle are identified from literature surveys and domain experience. These features, which can be extracted from basic signal data, include gear shifts, time spent in different driving modes (acceleration, cruise, standstill), velocity distributions, and an 'aggressiveness factor' representing overall driving style. Using ML based feature selection techniques, the most important features are selected for this cause. With these finalized parameters, a data-driven classification model is developed. This model is trained, validated, and tested using the identified real-world vehicle data. It classifies drive cycles into four major types: city, interurban, highway, and hybrid with a high degree of accuracy. This classification enables accurate identification of drive cycles, addressing the limitations of location-based methods. The developed model is employed to determine the type of drive cycle driven by customers, thereby aiding in the analysis of the influence of drive cycles on vehicle performance and emissions.
Reddy, Mallangi PrashanthGorain, RajuGanguly, Gourav
During vehicle launches in 1st gear, a lateral shake (undulation) and a pronounced metallic hitting noise were observed in the underbody. The noise was identified as the propeller shaft's second universal joint (UJ) yoke striking the fuel tank mounting bracket. Sensitivity to these issues varied with acceleration inputs: light pedal input during a normal 1st gear launch on a flat road resulted in minimal undulation, whereas wide open throttle (WOT) conditions in 1st gear produced significant lateral shake and intensified hitting noise. Further investigation revealed that the problem persists across all gears and occurs consistently during normal driving conditions, with continuous impact between the propeller shaft yoke and the fuel tank mounting bracket. Extensive experimental measurements at the vehicle level indicated that these issues were primarily caused by the center-mounted propeller shaft joint deviating from its central position and rotating eccentrically under torque. This eccentric movement was linked to the improper propeller shaft split ratio and shorter fitting length. A detailed design study combined with vehicle-level experiments (Design of Experiments, DOE) confirmed that these factors significantly contribute to the positional shift of the second UJ connection and its resulting eccentric behavior. This study provides a comprehensive approach to addressing the issue, focusing on reducing vibrations transmitted to the floor and seats and give NVH refinement through the propeller design optimization. By doing so, it ensures improved vehicle performance without compromising other critical parameters.
Sanjay, LS, ManickarajaKumar, SarveshKanagaraj, PothirajSenthil Raja, TB, Prem PrabhakarM, Kiran
Fatigue analysis is a vital aspect of suspension design, especially for load bearing components such as the Rear Twist Beam, where durability under cyclic loading is essential for long-term vehicle performance. Among the various durability tests, the roll fatigue test is a key procedure for validating suspension strength and reliability. However, conducting physical roll fatigue tests can be both expensive and time consuming, particularly when multiple design iterations are required. This not only increases cost but also extends the development timeline. This study presents a virtual simulation methodology that replicates roll fatigue test conditions within a finite element analysis environment, enabling early fatigue assessment and design optimization. Developed to support the early design phase, the roll fatigue test simulation process ensures robust designs that meet targeted fatigue life requirements. The approach begins with a detailed understanding of the physical roll fatigue test setup, which is then reproduced through Finite Element Analysis to closely match real test conditions. Enforced displacement applied at wheel center according to duty cycles, and boundary conditions are defined to match those of the physical test. Cumulative damage is then calculated in fatigue solvers to predict the fatigue strength of the components. The methodology is validated by correlating results with physical test data. This approach enables early detection of potential fatigue-critical areas, supports design optimization, and reduces both development cycle time and cost by minimizing physical testing. As a result, development cycles are shortened, costs are lowered, and durable, manufacturable designs can be achieved earlier in the product development process.
Kokare, SanjayNagapurkar, TejasIqbal, Shoaib
Nowadays, vehicle enthusiasts often vary the driving patterns, from high-speed driving to off-roading. This leads to a continuous increase in demand for four-wheel drive (4WD) vehicles. A 4WD vehicle have better traction control with enhanced stability. The performance and reliability of 4WD vehicles at high speeds are significantly influenced by driveline stiffness and natural frequency, which are largely affected by the propeller shaft and transfer case. This study focuses on the design optimization of the transfer case and the propeller shafts to enhance the vehicle performance at high speeds. The analysis begins with a comprehensive study of factors affecting the power transfer path, transfer case stiffness, and critical frequency, including material properties, propeller shaft geometry, and different boundary conditions. Advanced computational methods are employed to model the dynamic behavior of the powertrain, identifying the natural frequency of the transfer case and propeller shaft. Design parameters are modified by using optimization methods to ensure the critical frequency is outside the vehicle's operating speed. The modification involves to power transfer path of the transfer case, as well as the material and diameter of the propeller shaft. The optimized design is validated with a 4WD vehicle to ensure safe operating frequency and minimize resonant vibrations in the driveline systems at high speeds. The results indicate that the significant improvements in the performance of the transfer case and propeller shaft, reducing driveline vibrations and enhancing system reliability.
Kumar, SarveshYadav, SahdevS, ManickarajaSanjay, LKanagaraj, PothirajJain, Saurabh KumarDeole, Subodh M
This paper explores the requirement of multi speed – multi motor torque vectoring in a battery electric commercial truck. The area of focus was to compare the vehicle performance and range of a BEV truck with conventional central drive single motor configuration with the same vehicle consisting of a multi speed – multi motor torque vectoring control strategy. Through this exercise, we have analysed the motor power and torque requirements to meet the vehicle performance along with the required reduction ratios. A MATLAB based vehicle model is used to simulate the effect of multi motor operation on the vehicle range. Also simulated the effect of torque vectoring control algorithm on the vehicle performance like steady state cornering(SSC), Double Lane change (DLC), Off road dive Cycle, vehicle stability and turning circle diameter(TCD).
Pethkar, ShivanandS, SrivatsaGhosh, SandeepLondhe, Santkumar
Internal Combustion engines exhibit multi-order vibrations caused by the inertial forces of reciprocating masses. These vibrations induce drivetrain resonance, negatively impacting occupant comfort and the durability of drivetrain components. Torsional vibrations, a critical subset of these oscillations, demand efficient damping mechanisms. Torsional Vibration Dampers are instrumental in minimizing such vibrations by tuning mass and frequency characteristics to prevent resonance. By splitting resonant frequencies into avoidable zones within the engine's operational range, TVD enhance vehicle performance and refinement by dampening the vibrations. Structurally, TVD comprise an inertia ring integrated with a damping medium, such as vulcanized rubber, which attenuates torsional oscillations by permitting controlled oscillation of the inertia ring. This study focuses on the failure investigation and the geometric optimization of oscillating masses of TVD for performance and durability improvements as a design correction. Three different shapes (Spreaded, Rectangular, and I-shaped) of oscillating masses were analyzed. Analytical and experimental validations were conducted to evaluate the efficiency and durability. The deterioration of vehicle level noise studied at various intervals during test cycle. The recommended geometry demonstrated superior performance in terms of durability life and stress tolerance, attributed to its lower radius of gyration and enhanced load distribution. Additionally, the recommended shape showed minimal geometric package requirements for adapting the design, further contributing to its operational advantages. Results from this investigation underline the significant role of outer mass geometry in enhancing the functional reliability of TVD. The findings provide actionable insights for designing TVD with optimized performance, offering practical benefits for automotive drivetrain systems and improved overall vehicle noise level.
Wani, Sujit AshokS, ManickarajaKanagaraj, PothirajSenthil Raja, TVellandi, VikramanPatil, Dilip
Balance towards various Vehicle attributes often faces design contradictions, particularly in Noise, Vibration, and Harshness (NVH) optimization. Traditional approaches rely on trade-offs, but TRIZ (Theory of Inventive Problem Solving) offers a structured methodology to resolve contradictions innovatively. This paper presents TRIZ-based solutions for 2 key NVH challenges: (1) exhaust systems requiring noise reduction while maintaining low engine back-pressure, (2) engine mounts requiring both softness for vibration isolation and hardness for durability & vehicle stability, By applying TRIZ principles such as separation, mechanics change, etc. and using Thinking Tools such as thinking in time & scale, novel solutions are proposed to achieve superior performance without traditional compromises. These case studies demonstrate how TRIZ enhances automotive NVH refinements by enabling systematic innovations. This also explores benefits of Frugal Engineering for profitable launch of new vehicles in the market without sacrifice of customer satisfaction. At the same time, new innovative solutions are generated using past-present-future prediction models.
A, Milind Ambardekar
In automotive engineering, understanding driving behavior is crucial for decision on specifications of future system designs. This study introduces an innovative approach to modeling driving behavior using Graph Attention Networks (GATs). By leveraging spatial relationships encoded in H3 indices, a graph-based model constructed, which captures dependencies between various vehicle operational parameters and their operational regions using H3 indices. The model utilizes CAN signal features such as speed, fuel efficiency, engine temperature, and categorical identifiers of vehicle type and sub-type. Additionally, regional indices are incorporated to enrich the contextual information. The GAT model processes these heterogeneous features, learning to identify patterns indicative of driving behavior. This approach offers several significant advantages. Firstly, it enhances the accuracy of driving behavior modeling by effectively capturing the complex spatial and operational dependencies inherent in vehicle data. The use of GATs allows for the dynamic weighting of different features, ensuring that the most relevant information is prioritized in the analysis. Secondly, the integration of regional indices provides a deeper contextual understanding, enabling the model to discern region-specific driving patterns that might otherwise be overlooked. Furthermore, this method facilitates the identification of abnormal behavioral trends, offering valuable insights for design engineers. By understanding region-based driving behavior, engineers can modify vehicle systems to better meet the needs of specific areas, leading to improved performance and user satisfaction. The combination of graph-based methods with attention mechanisms represents a significant advancement in vehicle performance monitoring, paving the way for a more comprehensive understanding of driving behavior across different regions.
Salunke, Omkar
Steering I-shaft with rubber coupling (or hardy disc) is an important part of complete steering system mainly in body on frame (BOF) vehicles. Hardy discs are used to dampen the vibrations that transmit to steering wheel through frame, steering gear and I-shaft. They also support to accommodate the variation between frame and BIW (Body in white) of body on frame vehicles. They are made up of rubber or other polymer composites, which have less torsional stiffness as compared to metals. The overall torsional stiffness of steering system reduces since the hardy disc is used in series in steering system, that impacts on the overall performance of steering system. So, during development of I shafts with different design, stiffness of hardy discs are used to optimize the steering and NVH performance of vehicle. Considering the development time and cost, each design of I-shaft cannot be validated at vehicle level. The torsional and axial force or displacement of hardy disc is measured at vehicle level on different test tracks and block cycles are made that consists of different displacement / force along with frequencies. These block cycles are then used at bench level testing of I-shafts. This paper summarizes the methodologies to measure the force or displacement of I- shaft, converting raw data to useful block cycles and test set up for bench testing of steering I-shaft.
Kabdal, Amit
The automotive industry has been expediting progress toward electrification since climate change driven by global warming represents a significant environmental challenge with far-reaching implications. While electric vehicles offer considerable potential for mitigating CO₂ emissions, their elevated upfront costs pose a notable challenge to large-scale market penetration. Hybrid electric vehicles can serve as an effective intermediary solution, bridging the gap between conventional internal combustion engine vehicles and fully electric vehicles, owing to their comparatively lower initial costs. Hybrid electric vehicle component selection is a complex process that must fulfill multiple requirements: fuel economy, performance, drivability, packaging, total cost of ownership and comfort. Additionally, the selection of hybrid configuration also plays a vital role in determining the cost of the hybrid electric vehicle. Hence, it is a great challenge to select the right powertrain configuration, including architecture selection (P1, P2, P3 and P4), motor and overall gear ratio to achieve better overall performance compared to conventional vehicle constraints and targets. The present study investigates the principles guiding the selection of an electric drive system for hybrid electric vehicles in the heavy commercial vehicle segment. The analysis encompasses motor sizing, transmission configuration, and overall gear ratio optimization to meet defined vehicle-level performance targets. The automotive market in India is analyzed and the Heavy commercial vehicle segment selected to specify hybrid powertrain configuration. The principle is based on vehicle performance, design, cost and efficiency requirements. The simulation is done to estimate motor torque/power requirements & overall gear ratio meeting the vehicle target and constraints. Based on the analysis, a comparative matrix consisting of various parameters for heavy commercial vehicle (HCV) application is established. The analyzed results and comparative assessment indicate that
Shendge, RamanJadhav, VaibhavWani, KalpeshWarule, Prasad
The rapid evolution of electric vehicles (EVs) has amplified the demand for highly integrated, efficient, and intelligent powertrain architectures. In the current automotive landscape, EV powertrain systems are often composed of discrete ECUs such as the OBC, MCU, DC-DC Converter, PDU, and VCU, each operating in isolation. This fragmented approach adds wiring harness complexity, control latency, system inefficiency, and inflates costs making it harder for OEMs to scale operations, lower expenses, and accelerate time-to-market. The technical gap lies in the absence of a centralized intelligence capable of seamlessly managing and synchronizing the five key powertrain aggregates: OBC, MCU, DC-DC, PDU, and VCU under a unified software and hardware platform. This fragmentation leads to redundancy in computation, increased BOM cost, and challenges in system diagnostics, leading to sub-optimal vehicle performance. This paper addresses the core issue of fragmented control architectures in EV powertrains by proposing a domain controller based integrated solution for EV powertrain referred as Integrated Powertrain Domain Controller (IPDC).
Kumar, MayankDeosarkar, PankajInamdar, SumerTayade, Nikhil
This paper delivers a forward-looking data-driven assessment of the transformative innovation in electric vehicle motor systems with targeting breakthroughs in the power density, energy efficiency, thermal robustness, manufacturability & better intelligent control. A rigorous Multi Criteria Decision Making (MCDM) framework is done to systematically evaluate and defining the rank of emerging motor technologies across eight weighted performance indicators. The findings reveal that which design strategies & material advancements offering the greatest potential for redefine propulsion performance that enabling lighter more compact & more efficient drivetrain capable of sustained high power operation. High ranking solution exhibit strong alignment with the industry's push toward scalable, low cost & rare earth-independent systems while other are identified as high risk/high reward pathway requiring targeted research to overcome critical problems. By integrating engineering performance metric with manufacturability and system integration insights this study not only ranks innovations readiness but also providing a strategic roadmap for accelerating the development and deployment of next-generation EV motor. The outcome serving as a high value guide for OEMs, supplier & R&D leader seeking to prioritize the investment, streamline development & lead the transition to ultra-efficient, intelligent electric mobility platform.
Jain, GauravPremlal, PPathak, RahulGore, Pandurang
In the quest for enhancing electric vehicle performance and safety, this paper presents a comprehensive investigation into the design and performance of high-voltage (HV) battery cooling plates featuring dedicated cooling channels, integrated with structural bottom protection members. The study aims to address the dual challenges of thermal management and crash protection in electric vehicles during bottom impacts. The research evaluates the cooling efficiency and structural resilience of the proposed design through a combination of design iterations, thermal performance evaluation, and crash simulations. Findings reveal that the integrated cooling plates not only maintain optimal battery temperatures under various operating conditions but also significantly improve the vehicle's crashworthiness. It was found that the cooling efficiency of the HV battery plates improved compared to competitor’s design, resulting in a more stable thermal environment for the battery cells. Moreover, dedicated cooling channels result in a lower maximum battery temperature, with the temperature difference within the heated surface being less than 5 °C under peak load conditions. This leads to a more uniform temperature distribution and significant reductions in hot spots. Additionally, integrating structural crash members increased the energy absorption capacity by 33%, enhancing the vehicle's crashworthiness during bottom impacts when compared to no integrated structural crash members. The combined design led to around 14% reduction in the overall weight of the battery module, contributing to better vehicle performance and efficiency.
Dusad, SagarKummuru, SrikanthJoshi, Amarja
With the increasing tonnage of electric heavy commercial vehicles, there is a growing demand for higher power and torque-rated traction motors. As motor ratings increase, efficient cooling of the EV powertrain system becomes critical to maintaining optimal performance. Higher heat loads from traction motors and inverters pose significant challenges, necessitating an innovative cooling strategy to enhance system efficiency, sustainability, and reliability. Battery-electric heavy commercial vehicles face substantial cooling challenges due to the high-pressure drop characteristics of conventional traction system cooling architectures. These limitations restrict coolant flow through key powertrain components and the radiator, reducing heat dissipation efficiency and constraining the operating ambient temperature range. Inefficient cooling also leads to increased energy consumption, impacting the overall sustainability of electric mobility solutions. This paper presents a novel approach of optimizing coolant flow by reconfiguring the traction system layout and redesigning the coolant flow paths. These enhancements increase coolant flow by 100–200% compared to conventional systems, allowing the coolant pump to operate within its peak efficiency range. As a result, pumping power consumption is reduced by at least 33%, minimizing parasitic losses, improving vehicle range, and supporting green mobility initiatives by reducing energy waste. The increased coolant flow through the radiator enhances the tube-side heat transfer coefficient, significantly improving radiator heat dissipation and allowing for higher ambient temperature operation. Additionally, the optimized cooling system enables lower fan speeds, reducing both power consumption and cooling fan noise. This verified thermal management strategy, successfully implemented in production-ready heavy-duty electric vehicles, has effectively prevented traction propulsion motor power de-rating, leading to improved vehicle performance, energy efficiency, and long-term sustainability. Furthermore, a unique control strategy has been developed to dynamically regulate coolant pump and radiator fan operation by continues monitoring of each aggregate device temperatures. This optimized thermal management system ensures robust and efficient cooling.
Dixit, SameerPatil, BhushanGhosh, Sandeep
Fleet owners often encounter significant logistical and financial problems when dealing with battery packs of different ages and conditions. The standard industry practice is to replace old batteries with identical new ones. This process is inefficient because it costs a lot, creates too much inventory, and eliminates battery packs that are still useful too soon. The problem worsens when manufacturers stop making older battery models, which can force a vehicle to retire early. This paper puts forward a framework for mixing different types of battery packs to deliver the performance needed for a vehicle’s mission. We show how this works in three everyday service situations: 1) Repair, when a single damaged pack needs replacing; 2) Life Extension, where aged packs are combined with newer ones to meet mission range; and 3) Performance Restoration, which uses next-gen packs when the original parts are obsolete. The study shows that a vehicle can complete its required missions by strategically mixing new and old battery packs, holding up key performance metrics. This can also lower the total cost of ownership by about a third. The framework produces a Battery Replacement Matrix, which sets a specific minimum State of Health (SoH) threshold for the remaining packs.
Nair, Sandeep R.Ravichandran, Balu PrashanthHallberg, Linus
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