Browse Topic: Commercial vehicles

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Backward Fuzzy Driving Control for 6×4 Off-Road Vehicles2026-01-0148To be published on 04/07/2026
Offroad autonomous vehicle systems must be able to operate across unstructured and variable terrain while avoiding obstacles. This presents significant challenges in vehicle and control system design, especially for less conventional platforms such as 6x4 vehicles. While forward driving autonomy has developed and matured in recent years, effective reverse navigation remains an under-explored area of vehicle co-design. Reversing 6x4 vehicles have limited rear steering authority, an extended wheelbase, and asymmetric traction, which introduce complex dynamics into any control system that is used. To address this need, a robust and experimentally validated fuzzy logic control architecture for 6x4 reverse navigation was developed during the course of this project. This architecture incorporates both near-field and long-range path data with adaptive outputs controlling steering and velocity based on a rule base that covers the whole vehicle state space. This method has low computational
Dekhterman, Sam, Patterson, Albert, Sreenivas PhD, Ramavarapu, Norris, William, Soylemezoglu PhD, Ahmet, Nottage PhD, Dustin
Research on Economy Mode Control Algorithm for Pure Electric Tractor with Powered Trailer2026-01-0425To be published on 04/07/2026
This research presents a comprehensive investigation into the electrification development pathway and energy-saving optimization methodologies for commercial tractor vehicles. Given the pivotal role that commercial vehicles play in modern logistics and transportation sectors, their propulsion systems are undergoing a fundamental transition from traditional internal combustion engines toward more sustainable hybrid and pure electric architectures. Simultaneously, the emerging trend of trailer electrification has gained considerable attention, where conventional trailers are retrofitted with motorized axles to form cooperative powertrain systems, demonstrating substantial energy-saving potential as confirmed by multiple research studies. Utilizing an integrated Trucksim and MATLAB/Simulink co-simulation platform, this study developed sophisticated vehicle dynamics models, detailed electric drive system models, and advanced battery models, which were subsequently integrated to establish a
tong, zi yu, Zheng, Hongyu, Li, Gang
Optimizing Custom Hybrid Solutions for Low-Volume Specialist Equipment2026-01-0479To be published on 04/07/2026
Off-road vehicles are typically powered by diesel engines, sized to cover the highest peak loads in their dutycycles. Such engines can be downsized, using hybridization to supplement engine power for short periods. However, many applications are low-volume and specialized, making it impractical to deploy heavy engineering resources to optimize every one. For this reason, manufacturers tend to produce maid-of-all-work vehicles to cover every situation. This paper demonstrates the benefits of custom hybridization for specialist applications. It also introduces a simulation tool to benefit OEMs who seek to provide custom low-volume vehicles based on common platforms. The simulation tool is a fast, low-cost, cloud-based software package under development at ZeBeyond, provisionally named "ePop Cloud". It allows many different architectures to be evaluated rapidly at the product planning stage, and can be quickly set up and used by engineers who are not specialists in simulation. An
De Salis, Rupert, Fons, Daniel
Multi-Physics Topology Optimization and Machine Learning Surrogates for Lightweight Cast Automotive Parts2026-01-0510To be published on 04/07/2026
This paper proposes an integrated optimization framework for lightweight cast vehicle structures by combining Multi-Physics Topology Optimization (MPTO) with machine learning (ML)-driven surrogate modeling. Conventional structural optimization approaches often rely on simplified load cases—such as 3 g inertial loading, frame torsion, or bending—rather than capturing the true complexity of performance-critical conditions like crashworthiness and fatigue durability. As a result, designs optimized for a single criterion frequently degrade in other performance areas, leading to costly redesigns or over-engineered solutions. The proposed methodology introduces MPTO through four structured steps that progressively build design fidelity. Step 1 establishes a baseline primitive topology optimization workflow using a standardized package checklist, ensuring that the design domain, boundary conditions, constraints, and key manufacturing rules are consistently defined as the foundation for
Kim, Hyosig, Senkowski, Andres, Gona, Kiran, Saroha, Lalit, Boraiah, Mahesh
Impact of Hydrogen on Methane and Pollutant Emissions over Three-Way Catalysts with Natural Gas–Hydrogen Blends2026-01-0357To be published on 04/07/2026
Natural gas (NG) is a domestically abundant, low-cost fuel with the potential to displace gasoline and diesel fuel in commercial and off-road vehicles. NG engines typically produce lower engine-out pollutant emissions, such as NOx, CO and particulate matter, which could simplify emission control systems. Blending NG with hydrogen (H₂) can improve engine performance and increase combustion efficiency to further reduce engine-out emissions. Additionally, the presence of H2 in the exhaust stream may also facilitate the catalytic conversion of methane and other pollutants, resulting in cleaner tailpipe emissions. This study evaluates the impact of H2 on the conversion of methane, CO, and NOx emissions on a commercial three-way catalyst (TWC) in a flow reactor using synthetic gas mixtures that simulate stoichiometric engine exhausts with NG or NG+H₂ combustion. The work examines whether, and how, the additional amount of H₂ in the exhaust stream affects the conversion efficiency of methane
Prikhodko, Vitaly, Wang, Min, Park, Yeonshil, Chen, Hai-Ying, Pihl, Josh
Protection of Megawatt-Scale DC Charging Infrastructure for Heavy Duty Vehicles: A Review of Current Technologies and Future Roadmap2026-01-0400To be published on 04/07/2026
Abstract Direct Current (DC) fast charging enables the direct delivery of megawatt (MW) scale power to the large battery systems of heavy-duty electric vehicles (EVs), such as trucks, buses, and construction machinery. This contrasts with Alternating Current (AC) charging, which is constrained by the limited capacity of onboard chargers. The feasibility of ultra-fast DC charging has been driven by advancements in semiconductor technology offering higher voltage and current handling capabilities as well as improvements in battery energy density. Ongoing research indicates continued growth in both semiconductor power handling and battery storage capacity, further strengthening the case for ultra-fast DC charging. Key benefits include significantly higher charging efficiency, drastically reduced charging times, and lower driver fatigue. However, unlike AC systems, DC charging infrastructure presents unique protection challenges. These challenges arise from the rapid rise of DC fault
Rahman, Md Rakib-Ur, Dobrzynski, Daniel
Survivability, Lethality, and Mobility Requirements of Military Vehicles Conducting Future Wet Gap Crossings2026-01-0264To be published on 04/07/2026
Wet gap crossings, which involve moving military forces across rivers and other water obstacles, are among the most difficult maneuvers that units can perform. These operations are complicated by choke points, fast-flowing water, and the exposure of forces to enemy fire. Despite these challenges, wet gap crossings remain critical to battlefield success, particularly during large-scale combat operations. Consequently, military vehicles must be designed with these operations in mind. This study examines doctrinal approaches to wet gap crossings and the trade-offs between mobility, survivability, and lethality in relation to fording, floating, rafting, and bridging. The analysis incorporates open-source data from the Institute for the Study of War, which provides daily updates on the Russia-Ukraine conflict, and Oryxspioenkop, which collates open-source images of Russian and Ukrainian battle-damaged equipment. This data is used to assess additional challenges encountered during wet gap
Lynch, Benjamin, Dosan, Logan, Mittal, Vikram
Energy Efficiency Analysis of U-Haul Truck and Trailer Systems: Impact of Tongue Weight and Load Variations2026-01-0466To be published on 04/07/2026
The demand for improved energy efficiency in real-world vehicle operations continues to grow with technology enhancement. When transporting large cargos 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
Wang, Gang, Yang, Allan, Chen, Yan
Energy Management Strategy for Hybrid Mining Trucks Based on Global SOC Planning and Neural Network Optimal Control2026-01-0446To be published on 04/07/2026
Hybrid mining trucks, as core equipment for mine transportation, face high energy consumption and significant fluctuations in power demand during cyclic operations due to prolonged exposure to demanding operating conditions characterized by heavy loads and variable working conditions. To address the issues of high energy consumption and significant fluctuations in power demand during the cyclic operation of mining trucks, this paper proposes a hybrid mining truck energy management strategy based on global SOC (State of Charge) planning and neural network optimization control. First, a powertrain model was developed for a typical operating cycle of a hybrid mining truck, and its accuracy was validated by comparing it with experimental data. Using dynamic programming algorithms to plan the SOC for single-cycle operations provides a rational reference for energy allocation across different operational phases of mining trucks during a single cycle. Next, using the powerful nonlinear
Yang, Jianyu, Zhao, Zhiguo, Chen, Huiyong, Li, Tao, ZHUANG, Wenyu, Shen, Peihong, Tang, Peng
Methodology for generating off-road tracks for powertrain simulation of off-road passenger vehicles2026-01-0275To be published on 04/07/2026
For off-road driving, particularly on steep grades and over barriers, the engine torque is a key design criterion of off-road vehicles. In conventional powertrains with combustion engines, mechanical all-wheel-drive systems combined with differential locks are used to distribute the torque demand between the front and the rear axle based on wheel-specific traction. With the growing market share of electric powertrains, off-road applications are becoming increasingly relevant for electric passenger cars. In comparison to conventional powertrains, electric all-wheel-drive configurations do not have a mechanical torque transfer between the two axles. If one axle experiences low traction, the second axle can rely on its own torque capability only. Transfer of unused torque of the slipping axle to the other one is not possible. The challenge, therefore, is to specify the right torque requirements for each axle for off-road driving while avoiding an over-dimensioning and high powertrain
Martin, Michael, Winkelheide, Jonas, Hartmann, Lukas, Sturm, Axel, Henze, Roman
Achieving 70% Urban Fuel Consumption Reduction: An Opposed-Piston Engine-Based Mild-Hybrid Powertrain Architecture for Light Commercial Vehicles (JLA-2/JLA-T)2026-01-0432To be published on 04/07/2026
This paper proposes a novel powertrain architecture for the urban Light Commercial Vehicle (LCV) segment, leveraging the compact JLA-2 opposed-piston (OP) engine paired with the reconfigurable JLA-T mild-hybrid architecture. Within SAE literature, OP engines are consistently associated with simplicity. As highlighted by Tom Ryan III (2008 SAE President) in the foreword of Opposed Piston Engines: Evolution, Use, and Future Applications, this architecture is characterized by its manufacturing simplicity” and described as a “relatively simple, robust, and cost effective” power unit solution. The present work builds on this established view. The JLA-2 engine solves traditional packaging constraints by reducing the block width by 30% for horizontal installation and is volumetrically self-sufficient, eliminating external compressors. Although the gear train required for crank synchronization introduces design challenges, explicitly accounted for in our model, the elimination of the cylinder
Nigro, Norberto, Aguerre, Horacio, Carignano, Mauro Guido, Alonso, José Luis, Juni, Carlos A.
Multiple-Parameter Joint Estimation for Unmanned Mining Trucks Based on Real-Time Cornering Stiffness Identification2026-01-0618To be published on 04/07/2026
High-precision estimation of key vehicle–road state parameters is essential for accurate and safe vehicle control, as well as for reliable trajectory tracking and path planning. However, the strong nonlinearity of tire forces makes real-time estimation of tire cornering stiffness challenging, and the uncertainty of this parameter significantly limits the performance of conventional estimation methods. To overcome this issue, this study proposes a novel joint estimation framework that integrates the Square-Root Cubature Kalman Filter (SCKF) with Moving Horizon Estimation (MHE). In the proposed approach, the SCKF provides high-accuracy estimation of the vehicle sideslip angle, while the MHE enables real-time identification and updating of tire cornering stiffness using vehicle state information over a short horizon. This establishes a closed-loop joint estimation mechanism between sideslip angle and cornering stiffness. Furthermore, the real-time updated cornering stiffness is
Xia, Xue, Shen, Peihong, Jiao, Leqi, Li, Tao, Chen, Huiyong, Zhao, Kun, Jiao, Leqi, Zhao, Zhiguo
Hybrid Prediction Model of Wheel-Traction Force on Soft Soil Based on High-Precision Contact Angle2026-01-0594To be published on 04/07/2026
Traction force plays a critical role in the design of off-road vehicles and the evaluation of terrain trafficability. The accuracy of the traditional Bekker-Wong semi-empirical formula for predicting wheel traction force depends on the precision of parameters such as the entry contact angle, departure contact angle, and maximum stress angle. However, the calculation of these angles is often influenced by multiple empirical factors, which significantly reduces the accuracy of traction force prediction.To improve prediction accuracy, this study proposes a hybrid traction force prediction method that integrates Abaqus simulation with a semi-empirical model. First, a wheel-soil interaction simulation model was established in Abaqus using the FEM-SPH coupling method. Then, computer vision-based image feature extraction techniques were applied to process the simulation result contours, obtaining accurate values for the entry contact angle, departure contact angle, and maximum stress angle
Cao, Ruibin, Wang, Kaidi, Shen, Yanhua, Liu, Zuyang
Speed Determination Using Audio of Dash Camera Video from Commercial Vehicle Tires Frequencies for Vehicle Accident Reconstruction2026-01-0536To be published on 04/07/2026
Prior research has validated a reliable method for determining vehicle speed using audio recorded by cameras mounted in vehicles, specifically for rolling passenger vehicle tires. Passenger vehicle tires produce a frequency component directly correlated to vehicle speed when traveling on concrete roadways. However, prior research has not been conducted on audio for rolling commercial vehicle tires, which differ in construction from passenger vehicle tires and therefore produce audio signals on roadway surfaces that passenger vehicles tires did not when tested in the prior study. The current research concluded that commercial vehicle tires rolling on various roadway surfaces also generated a frequency that varied with vehicle speed. The purpose of this study was to outline, test, and confirm the source of the speed-dependent frequency and to develop a validated method for use in forensic applications. A modified version of the passenger vehicle tire equation from prior research was
Vega, Henry V., Cornetto, Anthony, Ngo, Long Justin, Hatab, Ziad, Hunter, Eric
Performance Analysis and Optimization of a Drizzling-Based Evaporative Cooling for Enhanced Thermal Management of FCEV Stack2026-01-0115To be published on 04/07/2026
In response to increasingly stringent global emissions regulations, including Euro 7, the automotive industry is intensifying its focus on eco-friendly propulsion systems. Among them, hydrogen fuel cell electric vehicles (FCEVs) have emerged as a promising alternative in the commercial transport sector, offering high energy density, rapid refueling, long driving range, and minimal payload limitations. However, the operational efficiency and durability of fuel cell stacks heavily depend on effective thermal management, and insufficient cooling can lead to power degradation and reduced lifespan. This study proposes a novel thermal management strategy that enhances stack cooling performance by directly applying fuel cell discharge water onto the radiator surface, utilizing latent heat of evaporation. To overcome the structural complexity and control challenges of high-pressure spray systems, a gravity-driven low-pressure drizzling method was adopted, achieving both system simplification
LEE, DONGKEON, Seo, JUNGMIN, LEE, SEOGJUN, SON, DONGWOOK, Lee, HOSEONG, SHIN, YOONHYUK, KANG, HYUNSUNG
Clustering-Based Segmentation of Off-Road Vehicle Activity into Productive and Non-Productive States from GPS Data2026-01-0169To be published on 04/07/2026
Accurate identification of Productive and Non-Productive States or Off-Road vehicle duty cycles—comprising working, idle, and transport states—is critical for performance analysis, fuel optimization, and emissions modeling in agriculture machinery and fleet operations. This study explores the application of unsupervised machine learning techniques to classify duty cycles using GPS-derived parameters such as speed, location variance, and temporal patterns. Unlike supervised approaches, the proposed method does not rely on labeled datasets, making it scalable and adaptable across diverse operational contexts. Clustering algorithms, including K-means and DBSCAN, are employed to segment GPS data into distinct behavioral states. Feature engineering focuses on extracting motion signatures and spatial-temporal features that correlate with operational modes. Validation against manually annotated datasets demonstrates high accuracy in distinguishing idle, working, and transport phases. The
Maharana, Devi prasad, Gangsar, Purushottam, Dharmadhikari, Nitin, Pandey, Anand Kumar
Wind-Tunnel Study of the Traffic-Wake Impacts for Road-Vehicle Aerodynamics2026-01-0613To be published on 04/07/2026
When driving in traffic, the wakes of leading vehicles reduce the wind speed experienced by a following vehicle, lowering its drag relative to isolated driving. These wake effects can persist to large intervehicle distances, on the order of hundreds of meters, while lateral convection due to cross winds can influence vehicles in adjacent lanes. Wind tunnel testing was conducted at 30% scale for light- and heavy-duty-vehicle models in a large wind tunnel with a traffic-wake simulation system, expanding upon a previous study that examined only heavy vehicles. Three variants of the DrivAer model, four variants of the AeroSUV model, and three variants of a zero-emission heavy-duty-truck model were tested with a range of simulated wake conditions that varied the type, forward distance, and lane position of the wake-source vehicle(s), for a range of yaw angles up to 11deg. Results show drag reductions of up to about 10% for the heavy-truck model, and up to about 20% for the passenger-vehicle
McAuliffe, Brian, Ghorbanishohrat, Faegheh, Barber, Hali
Forensic Acquisition and Analysis of Unsupported Lexus Infotainment Modules via CMD42 Bypass and Data Carving2026-01-0540To be published on 04/07/2026
Crashes involving passenger vehicles increasingly include models equipped with infotainment modules that are unsupported by commercial vehicle system forensics hardware and software. Examiners facing these systems must overcome challenges in acquiring and analyzing user data, requiring an understanding of both digital forensics principles and the proprietary characteristics of the modules. This paper presents a novel methodology for acquiring data from previously unsupported Lexus infotainment modules, including techniques to bypass CMD42 security locks on SD cards and extract data in a forensically sound manner. Once acquired, the paper outlines methods for analyzing user data through data carving techniques, enabling recovery of information from binary images even when the full file system cannot be reconstructed. Emphasis is placed on maintaining the integrity of the evidence and validating findings through controlled testing. These validation procedures ensure that the recovered
Burgess, Shanon
A Proposed Methodology for Human Operator Modeling and Development of a Virtual Operator Model for Control of a Simulated Compact Track Loader2026-01-0146To be published on 04/07/2026
A methodology for performing Human Operator Modeling (HOM) using a Caterpillar Model 299D3 XE Compact Track Loader (CTL) is presented. The proposed method uses task analysis techniques to decompose a material excavation and moving task into smaller, individual tasks presented in a task list. A method for verifying and refining the task list is presented, along with a procedure for identifying relevant human operator sensory information and analyzing human decision making in the context of CTL operation. This methodology is then partially verified through the analysis of a non-expert human operator in Vortex Studio, a realistic construction equipment simulator. A modified test course is executed by a non-expert human operator in the simulation environment, and the recorded data is used to create a quantitative Human Operator Model. From this, a Virtual Operator Model (VOM) feedback controller simulating the performance of the human operator is developed. The VOM is implemented using a
Wang, Orson R., Norris, William R., Patterson, Albert E., Soylemezoglu, Ahmet, Nottage, Dustin S.
A Novel Power-Split Hybrid Electric Architecture for Off-Road Tracked Vehicles: Design and Performance Evaluation.2026-01-0258To be published on 04/07/2026
Tracked off-road vehicles operate at low speeds with high tractive effort and frequent skid-steer maneuvers, conditions that push torque and power demand to extremes and exacerbate powertrain efficiency losses. Electrification can improve energy conversion and mobility for such duty cycles. This paper introduces a novel power-split hybrid electric architecture for a tracked vehicle and benchmarks it against three designs: a conventional mechanical driveline, a series hybrid, and a P2 parallel hybrid. To enable fair, architecture-agnostic comparisons, a supervisory controller based on Stochastic Dynamic Programming (SDP) schedules engine operation and power flow across all layouts under representative off-road scenarios, including skid-steer events, with varying terrain and power-demand profiles. Results show higher energy conversion efficiency (lower fuel use) for the proposed power-split architecture, followed by the parallel, then series, and lastly conventional configuration across
Ghate, Atharva, Sundar, Anirudh, Zhu, Qilun, Prucka, Robert, Figueroa-Santos, Miriam, Barron, Morgan, Castanier, Matthew P.
Camera Monitor System Soiling Correlation for a Class-8 Truck Using Lattice Boltzmann Method2026-01-0596To be published on 04/07/2026
As Camera Monitoring Systems (CMS) become an integrated part of the driving experience for current automotive and heavy vehicles, keeping the CMS clean from water, dirt, sand, snow and ice is a main focus of the design process in order to avoid safety issues due to obscured visibility. On-road soiling prevention becomes an important feature when designing these camera and sensor systems. Computational Fluid Dynamics (CFD) analysis can be used to facilitate the design process, to provide important information of the cause of the problems and design mitigation mechanism to prevent the visibility issues. There are many published papers for soiling studies for the automotive application but very limited publication available for heavy trucks, this paper is targeted to fill this space. In these current studies during a design process, road tests were performed in Alaska by the testing department. Correlation was done between those road tests and the CFD analysis, performed in-house. This
He, Wei, Dasarathan, Devaraj, Linden, Tom, Park, Jeongbin
Hydrogen Propulsion for Heavy Commercial vehicle Applications in India : A Quality-Driven Approach from Tata Motors2026-01-0144To be published on 04/07/2026
As the global commercial vehicle sector searches for innovation in propulsion technologies that deliver sustainability and zero tail pipe emissions, hydrogen (H₂) mobility is gaining momentum—especially in heavy duty segments where battery electric drivetrains still face constraints. Tata Motors, recognized in India for its pioneering work in commercial vehicles, has launched an ambitious programme to engineer hydrogen powered solutions custom built for the nation’s heavy trucks and buses that underpin logistics and infrastructure. This paper outlines Tata Motors’ structured approach on ‘Failure mode avoidance’ for a safe and reliable H₂ propulsion, anchored in the ‘Quality by Design’ approach through Design Failure Mode and Effects Analysis (DFMEA) at a very early stage. Every critical vehicle system and sub-system—storage, fuel delivery, control and the propulsion unit itself—is subjected to DFMEA at the concept stage so that potential risks are detected and addressed before vehicle
Giri, Debabrata, Biswas, Kaushik, Saji, Amal
Machine Learning-Based Prediction of Wind-Induced Interior Noise in Ground Vehicles2026-01-0599To be published on 04/07/2026
In response to increasing customer demand for enhanced passenger comfort and perceived vehicle quality, OEMs in automotive and commercial vehicles are placing significant emphasis on reducing the interior cabin noise. At highway speeds, wind noise is a primary contributor to the overall noise within the vehicle cabin. Conventional approaches to predict vehicle wind noise rely on physical testing, which can only be conducted in the later stages of the design process once a physical prototype is available. Increased adoption of established computational fluid dynamics (CFD) methods has enabled earlier assessment. However, such simulations require several hours to complete, posing a challenge in the context of rapid design iteration cycles. With the growing adoption of artificial intelligence in engineering, machine learning (ML) approaches have been proposed to predict a vehicle’s aerodynamics performance. Nevertheless, development of ML techniques in the context of aeroacoustics
Higgins, John, Fougere, Nicolas, Sondak, David, Senthooran, Sivapalan, Moron, Philippe, Jantzen, Andreas, Bi, Jing, Oancea, Victor
Simulating Cryptographic Primitives in Model Based Systems Engineering Projects2026-01-0083To be published on 04/07/2026
Security has become an increasingly critical concern for large off-road vehicle manufacturers due to the growing threats posed by hackers, heightened awareness around data privacy, the implementation of anti-tamper technologies, and stringent emissions regulations. These pressures necessitate the development of robust security measures that can effectively safeguard vehicle systems while promoting responsible and sustainable innovation. To address these challenges, cybersecurity teams and engineers can leverage tools such as Model-Based Systems Engineering (MBSE), which facilitates the rapid and cost-effective development of comprehensive security mechanisms. This paper explores the application of systems engineering techniques to create a solution for ensuring integrity and authenticity in Controller Area Network (CAN) systems, which are commonly utilized in heavy-duty diesel engines. The deployment of solutions to secure the CAN bus will likely depend on cryptography. However
DiValentin, Maria, Daily, Jeremy
Simulink DevOps Evolution: Bridging Interactive Platforms for Accelerated Model-Based Workflows2026-01-0080To be published on 04/07/2026
This paper builds on last year’s paper presenting DevOps automation in the context of model-based development. Following that paper, we interviewed Simulink users in passenger automotive, motorsports, commercial vehicles, aviation, rocketry, and industrial automation. We discovered that much of the benefit of DevOps platforms to reduce product development cycle time relies on their interactive features. We prototyped new tools to bridge interactive DevOps Git-based platforms with model-based development workflows, and then gathered reactions from another round of interviews. Here we present these interactive DevOps workflows with the feedback from these interviews to contextualize how engineering teams could adopt them to accelerate their own model-based workflows.
Mathews, Jon, Ferrero, Sergio, Tamrawi, Ahmed, Sauceda, Jeremias
Research on Parameter Matching and Control Strategy of Electric Semi trailer Power System2026-01-0449To be published on 04/07/2026
Reducing carbon emissions is an important issue for environmental protection, while also saving fossil fuels for all mankind and preventing global warming. Therefore, reducing carbon emissions is of great significance. The carbon emissions in the transportation sector account for an important proportion of global carbon emissions, and the carbon emissions of heavy-duty commercial vehicles also account for an important proportion of the carbon emissions in the transportation sector. Therefore, the electrification of heavy-duty commercial vehicles is one of the important ways to save energy and reduce emissions for heavy-duty vehicles. Especially the research topic of this article: semi-trailer trains. Similar to passenger cars, semi-trailer trains also have two electrification ideas: hybrid and electric drive. Considering the high energy demand of heavy-duty commercial vehicles, the high cost of large capacity batteries, the current low level of development of electric heavy-duty
Zheng, Hongyu, Zhu, Kaixuan, Zhang, Yuzhou
Design and Development of a PWM Generator with Integrated Power Supply for BSVI / BSVII Dosing system2026-01-0365To be published on 04/07/2026
A Direct leap from BSIV to BSVI in 2020 necessitated rapid adaptation by automakers and fuel suppliers. New regulatory standards on engine pollutant emissions have expanded the engine operating conditions subjected to type approval tests, aiming to bridge the gap between regulated and real-driving emissions. The BSVI dosing system, comprising supply and dosing units, is integral to the aftertreatment systems for both on-highway and off-highway applications. This system is crucial for meeting BSVI norms by providing the necessary flow and pressure. Before market introduction, this system must undergo various validation processes. Traditionally, the system relies on a controlled modulated input signal and a closed-loop feedback system developed by manufacturer software. However, this setup was complex, bulky, and requires manual intervention during lab testing validation. To enhance this system, we developed an automated PWM generator with an integrated power supply that dynamically
Chavan, Amit, Rath, Jagannath Prasad, Magar, Vijay, JAHAGIRDAR, RADHIKA
Structural Redesign and Functional Integration of an Electrohydraulic Brake Valve for Enhanced Performance and Manufacturability2026-28-0002To be published on 02/12/2026
The Electrohydraulic Brake Valve (EBV) is a vital component in full-power brake systems for heavy-duty and off-highway vehicles, providing precise hydraulic pressure modulation through electrical control. Traditionally, EBV housings are manufactured using bar-machined components, which offer durability but contribute significantly to the overall weight and cost of the assembly. In response to increasing demands for lightweight and cost-effective solutions, this study presents a targeted design optimization of the EBV housing. The redesigned housing adopts a casting-based geometry, integrates sensor ports for pressure monitoring, and includes a nameplate mounting provision for customer identification. Material substitution and structural simplification were employed to enhance manufacturability and performance. Finite Element Analysis (FEA) was used to validate the mechanical integrity of the new design under operational conditions. The optimized EBV assembly achieved a weight reduction
R, Thangarajan
Intelligent Steering System to Improve Fuel Efficiency in Heavy Duty Vehicles2026-28-0103To be published on 02/12/2026
In commercial vehicles, conventional engine-driven hydraulic steering systems result in continuous energy consumption, contributing to parasitic losses and reduced overall powertrain efficiency. This study introduces an Electric Powered Hydraulic Steering (EPHS) system that decouples steering actuation from the engine and operates only on demand, thereby optimizing energy usage. Field trials conducted under loaded conditions demonstrated a 3–6% improvement in fuel economy, confirming the system’s effectiveness in real-world applications. A MATLAB-based simulation model was developed to replicate dynamic steering loads and vehicle operating conditions, with results closely aligning with field data, thereby validating the model’s predictive accuracy. The reduction in fuel consumption directly translates to lower CO₂ emissions, supporting regulatory compliance and sustainability goals, particularly in the context of tightening emission norms for commercial fleets. These findings position
T, Aravind Muthu Suthan, Mani, Kishore, Ayyappan, Rakshna, D, Senthil Kumar, S, Mathankumar
Genetic Algorithm Based Optimization of Chaboche Kinematic Hardening Parameters along with the Validation of FE Model through Characterized Crack Initiation2026-28-0086To be published on 02/12/2026
In the context of electro-mobility for commercial vehicles, the failure analysis of a connector panel in a DCDC converter is crucial, particularly regarding crack initiation at the interface of busbar and plastic component. This analysis requires a thorough understanding of thermo-mechanical behavior under thermal cyclic loads, necessitating kinematic hardening material modeling to account for the Bauschinger effect. As low cycle fatigue (LCF) test data is not available for glass fiber reinforced polyamide based thermoplastic composite (PA66GF), we have adopted a novel approach of determining non-linear Chaboche Non-Linear Kinematic Hardening (NLK) model parameters from monotonic uniaxial temperature dependent tensile test data of PA66GF. In this proposed work a detailed discussion has been presented on manual calibration and Genetic Algorithm (GA) based optimization of Chaboche parameters. Due to lack of fiber orientation dependent test data for PA66GF, here von Mises yield criteria
Basu, Parichay, Srinivasappa, Naveen
Optimized Design, Analysis, and Validation of a Tractor Muffler for Enhanced Back-Pressure Control and Cost Efficiency2026-28-0004To be published on 02/12/2026
Internal combustion engines generate intense acoustic pulses during combustion, necessitating the use of exhaust mufflers to suppress noise emissions. With evolving regulations on permissible noise levels and the automotive industry's drive toward lightweight, high-performance vehicles, muffler designs must balance effective sound attenuation, minimal back pressure, and reduced mass. This study presents a comparative analysis of three muffler configurations serpentine, rectangular, and zigzag designed using Solid Works for a light commercial vehicle (LCV) diesel engine. The models were evaluated using computational fluid dynamics (CFD) simulations to assess their acoustic and flow performance. Each design incorporated internal baffle arrangements to enhance sound absorption while aiming to minimize back pressure. The serpentine model featured a perforated baffle layout that promoted multiple reflections and dissipated acoustic energy more efficiently. Simulation results indicated that
Deepan Kumar, Sadhasivam, Palaniselvam, Senthil Kumar, D, Ashokkumar, R, Krishnamoorthy, Mahendran, M, Pasupuleti, Thejasree, G, Dhayanithi, L, Boopalan
Systematic Approach to Attenuate NVH Issues in Hydraulic Steering Gear2026-28-0065To be published on 02/12/2026
In commercial vehicles, Hydraulic Power Assisted Steering (HPAS) gear plays a crucial role in enhancing steering performance by providing hydraulic assistance. The HPAS gear comprises a Directional Control Valve (DCV) assembly, where the input shaft and recirculation units are integrated. The valve system which is known for the heart of the HPAS gear, operates under high-pressure conditions. In the DCV, the input shaft is equipped with bearings to support side loads exerted by the system, and a valve component is freely assembled to minimize friction caused by these side loads. The complexity of the floating valve design results in the less slot volume, leading to cavitation and vibrational noise. While this noise is typically suppressed in internal combustion (IC) engine-powered vehicles, its implementation in electric vehicles (EVs) has led to pronounced audible noise, dominating the system. Experimental vibration analysis of the steering gear reveals both low and high-frequency
Vijayenthran, Praveen, Ayyappan, Rakshna, D, Senthil Kumar, N, Prabhakar
Miner’s Safety Bot: An ESP32-Based Autonomous Mobile Mine Safety Monitoring System2026-28-0116To be published on 02/12/2026
Mining operations are important to industrial growth, but they expose the mining workers to risk including hazardous gases, elevated ambient temperatures, and dynamic structural instabilities within underground environments. Safety systems in the past, typically based on fixed sensor networks or manual patrols, fall short in accurate hazard detection amidst shifting mine conditions. The proposed project Miner's Safety Bot advanced this paradigm by leveraging an ESP 32 microcontroller as a mobile platform that integrates gas sensing, thermal monitoring, visual inspection and autonomous obstacle avoidance. The system incorporates MQ7 semiconductor gas sensor to monitor real time carbon monoxide (CO), offering detection range from 5 to 2000 ppm with accuracy of 5 ppm. Temperature and humidity are monitored through DHT11 digital sensor, calibrated to ensure reliability across the harsh microclimates in mines. Navigation and autonomous movement are enabled by Ultrasonic Sensor (HC-SR04
D, Suchitra, D, Anitha, Muthukumaran, Balasubramaniam, Mohanraj, Siddharth, Subash Chandra Bose, Rohan
Guidelines and Procedures for Horizontal Directional Drilling (HDD) Machine Tracking Equipment OperatorsJ2519_202601 (Current)2/1/2026
These general guidelines and precautions apply to personnel operating directional drilling tracking equipment when used with horizontal directional drilling (HDD) machines as defined in ISO 21467:2023.
MTC9, Trenching and Horizontal Earthboring Machines
Key Parameters for Turbocharger Selection & Experimental Validation for off-Highway Applications2026-26-01041/16/2026
Customers in off-highway industry are increasingly seeking high-performance capabilities for their tractors due to increasing penetration of mechanisation and labour scarcity. One effective solution to achieve enhanced performance is turbocharging of engines, while meeting emission and highly dynamic transient response of tractor field applications. The process of selecting and validating a suitable turbocharger for tractor field application suitability is significantly time and resources consuming activity due to extensive testbed and field trials. This study focuses on the selection of turbocharger for tractor engines through analytical calculations to freeze key parameters like lambda, boost pressure ratio & temperature within boundaries of exhaust temperature and turbo efficiency maps to deliver best field transient performance and fuel consumption. The selected parameters are further validated under real-world transient operating conditions, involving tractors and their implements
Kumar, Harish Kumar, Rawat, Saurabh, Dogra, DaljitSingh, Singh, Sachleen, Singh, Amarinder
Drive Cycle Based Energy Audit & Range Estimation for 4X2 Electric Truck2026-26-01631/16/2026
Transportation sector in India accounts for 12% of total energy consumption. Demand of energy consumption is being met by the imported crude oil, which makes transportation sector more vulnerable to fluctuating international crude oil prices. India is mindful of its commitment in 2016 Paris climate agreement to reduce GHG emissions intensity of its GDP by 40% by 2030 as compared to 2005 levels. To fast track the decarbonization of transportation sector, commercial vehicle manufacturers have been exploring other viable options such as battery electric vehicles (BEVs) as a part of their fleet. As on today, BEV has its own challenges such as range anxiety & high total cost of ownership. Range anxiety can be certainly addressed by optimum sizing of electric powertrain, reduction in specific energy consumption (SEC) & use of effective regeneration strategies. Higher SEC can be more effectively addressed by doing vehicle energy audit thereby estimating the energy losses occurring at each
Gijare, Sumant, Karthick, K., Juttu, Simhachalam, Thipse, Sukrut S., A, Jothikumar, J, Frederick Royston, SR, Subasree, G, Harini, M, Senthil Kumar
Legislative Framework and Emission Testing using PEMS for NRMM (Non-Road Mobile Machinery) in India: A Technological Perspective2026-26-01391/16/2026
Emission Regulations for NRMM in India have evolved significantly over past two decades. India has progressively adopted stricter standards to align with best practices carried out globally for curbing air pollution. The latest regulations have introduced stringent caps on nitrogen oxides (NOx), and other emission pollutants, ensuring compliance with environmental sustainability goals. Future legislative frameworks are expected to impose even more rigorous emission limits, while incorporating real-world emission monitoring. This will require powertrain manufacturers to integrate advanced after-treatment systems and adopt cleaner combustion technologies to meet compliance standards. To validate compliance with these stringent limits, rigorous testing methodologies are employed. Portable Emission Measurement Systems (PEMS) have become a crucial tool for real-world emission assessment. PEMS technology allows for on-road and field testing of NRMM under actual operating conditions
Rastogi, Aadhar, Garg, Varun, Ragot, Nicolas
Controls Solutions for Commercial Hydrogen Engines2026-26-01121/16/2026
India’s commitment to carbon neutrality is significantly shaping the future architecture of commercial vehicle powertrains. While the use of CO₂-free technologies such as battery-electric drivetrains has already been successfully demonstrated across various applications, challenges related to limited range and the lack of high-power charging infrastructure continue to hinder widespread adoption, particularly for productivity-critical commercial vehicles. This has shifted the spotlight toward sustainable fuels, which offer the advantage of fast refueling times. Among these, hydrogen internal combustion engines (H₂ ICE) have gained increasing attention in recent years. In regions such as the European Union, the primary motivation for hydrogen is CO₂ reduction. In contrast, for markets like India, hydrogen also presents a strategic opportunity for reducing dependency on fossil fuel imports. Over the past four years, multiple performance and emission development projects across various H
Arnberger, Anton, Danninger, Alois, Mannsberger, Stefan, Breitegger, Bernhard
A Practical Approach to Reduce Gear Whine Noise through Gear Tooth Contact Analysis in an Agricultural Tractor2026-26-03451/16/2026
Gear noise is a common challenge that all gear manufacturers must contend with. In tractors, while it is often sufficiently low in intensity to not pose a significant issue, there are instances where gear whine may occur which is noticeable. In such cases, identifying the source and effectively addressing the problem can prove to be particularly difficult. This paper addresses the root cause analysis carried out for the evaluation of factors influencing whine noise behavior of Spiral bevel gear pair (SO2) in a tractor transmission system. Numerous publications have been published on gear noise of spiral bevel gear pair, too many to list here. However, once the gearbox assembled into the transmission, such models are of limited practical value. The work explained in this paper is a typical example offers avenues in correcting the issue using more limited means.
P, Bharath, P, Priyadarshan, Janarthanan, Devakumara Raja, Chavan, Amit
Comprehensive Evaluation of Bolster Behaviour: Field Data Insights for Design Modifications2026-26-04971/16/2026
Bogie suspension systems are becoming increasingly popular in tipper vehicles to enhance their performance and durability, especially in demanding environments like construction and mining areas [1]. Bolsters contribute significantly to the overall performance and durability of the bogie suspension systems of tipper vehicles by evenly distributing the loads across the whole suspension system. They act as shock absorbers and negate the impact caused by the rough terrains and heavy loads, thereby reducing stress on individual components and maintaining the structural integrity of the vehicle. Bolsters also help in improving the ride comfort and to maintain the position of the suspension system [2]. This study focuses on the comprehensive testing and evaluation of bolsters to understand their modes and displacement data derived from field data. The primary objective is to analyse the performance and behaviour of bolsters under various operational conditions. Critical manners of
V Dhage, Yogesh, Kolage, Vikas
Performance Evaluation and Optimization of Engine Brake System using Chassis Dynamometer2026-26-05111/16/2026
Engine braking is a deceleration technique that leverages the internal friction and pumping losses within the engine. By closing the throttle and potentially selecting a lower gear, the engine creates a retarding force that slows the vehicle. This practice contributes to better fuel economy, decreased brake system load, and improved vehicle handling in specific driving scenarios, such as steep declines or slippery road surfaces. To alleviate stress on their primary braking systems and prevent overheating, heavy vehicles frequently incorporate engine-based braking. While older trucks relied on simple exhaust brakes with a butterfly valve to restrict exhaust flow, these had limited impact. Hence contemporary heavy vehicles almost exclusively use more advanced engine braking technologies. Traditionally, our heavy-duty vehicles use Exhaust brake system to elevate the braking performance on hilly terrains. Hence an improved sample of Engine brake was developed for enhanced braking
M, Vipin Prakash, Rajappan, Dinesh Kumar, R, Suresh, N, Gopi Kannan
Monitoring and Diagnosing Software-Defined Vehicle Architectures2026-26-06771/16/2026
Software-Defined Vehicles (SDV) are fostered through initiatives like SOAFEE and Eclipse SDV promoting the use of cloud-native approaches, distributed workloads and service-oriented architectures (SOA). This means that in these systems each vehicle is connected to the cloud and functions are executed both inside the vehicle and in the cloud. So far, there are no established solutions for monitoring and diagnosing SDVs. In designing these solutions, the cost-sensitive nature of every component inside a vehicle must be considered since it makes it unlikely that significant resources will be provided just for diagnostics. Therefore, conventional data centre monitoring approaches that usually rely on transferring large amounts of data to dedicated servers are not directly applicable in this scenario. To illustrate the challenges in providing new solutions for diagnosing and monitoring SDVs, a SOA that has been defined and studied in research projects is introduced. In this architecture
Böhlen, Boris, Fischer, Diana
Comprehensive Durability Assessment of Planet Carrier in Heavy-Duty Tipper Gearboxes Using RLDA Torque Data2026-26-04431/16/2026
In heavy-duty tippers, where challenging conditions demand high torque, planet carriers play a crucial role by enabling efficient load distribution and torque transmission while supporting gear ratio and speed variation in space-constrained systems such as automatic transmissions, hybrid drivetrains, and electric vehicles. This paper focuses on the comprehensive durability performance assessment of planet carrier housing (PCH) using duty cycles derived from road load data acquisition (RLDA) measurements for a heavy-duty tipper gearbox development program. The existing Design Validation Plan (DVP) for the planet carrier considers first gear utilization of 10-15% at 40% vehicle overload, in line with historical data. However, recent trends in mining applications revealed vehicle overloads of 55-65%, leading to an increase in first gear utilization (25-35%). This shift presents challenges for original equipment manufacturer (OEM) to enhance design durability while incorporating additional
Bagane, Shivraj, Pendse, Ameya
Clutch Thermal Adequacy Assessment in Repeat Restart Launch Conditions on Gradient2026-26-04341/16/2026
The clutch is a mechanical device that connects and disconnects engine power to the drivetrain through the clutch disc and cover assemblies. The disc, with friction material linings is mounted on the transmission shaft, transmits power when clamped between the flywheel and cover assembly. During operation, wear occurs due to speed differences and slippage between the engine and transmission. Clutch performance is evaluated under repeat restart conditions on steep gradients to assess thermal durability and reliability in commercial vehicles. The repeat restart test on a 12% gradient replicates truck launches under full load, where excessive slippage generates heat that may lead to friction material wear or failure if critical temperature limits are exceeded. To address the high cost and time of physical testing, a 1D thermal simulation was developed using GT Suite. The model replicates 90 repeat vehicle launches on a 12% gradient in first gear, integrating driver inputs and drive cycles
Munisamy, Sathishkumar, Chollangi, Damodar, Mane, Sudhir
First in the Industry 8.5 Ton GVW on Four Tyre Truck with 245/90R16 Tyre – A Global First2026-26-06021/16/2026
This project introduced a brand-new tire size 245/90R16 for the first time globally in the 16-inch tube-type category, designed specifically for commercial vehicles with Vehicles 8.5T -12T gross vehicle weight (GVW). The main goal was to create a compact vehicle that can carry more payload, reduce overall weight, and improve fuel efficiency with use of rear single tyre instead of twin tyre in 8.5T. This helps customers lower their operating costs and improve vehicle performance, especially on narrow roads. The new tire supports high load capacities: up to 2300 kg for single tire use and 2180 kg for dual tire fitment. It enables a new type of vehicle to be developed an 8.5-ton GVW vehicle with rear single tires offering better payload capacity without increasing the size of the vehicle. By using this new tire, the kerb weight of the vehicle is reduced, which increases the payload and helps improve fuel economy. This helps lower the cost of the vehicle by optimizing surrounding
Pawar, Dhondiram Dnyandeo, Shaikh, Matin, Ambekar, Prasad
A Procedure for Validation of a Full e-Vehicle CAE Model with Physical Tests for Passive Safety Applications2026-26-04111/16/2026
With the fast development of computational analysis tools and capacities during the past ten years, complex and substantial computer-aided engineering (CAE) simulations are now economically possible. While the cost of crash tests has risen steadily, the fidelity and complexity, which numerical simulations could address, has multiplied keeping the cost of computational analysis more stable. The fundamental goal of CAE is to achieve significant reduction in the number of physical tests conducted during the product development process. However, validating the CAE model with physical tests is essential to ensure accuracy and reliability. Simulations performed using a validated CAE model could be used to make decisions like airbag deployment or high voltage shutdown without an actual physical test being conducted. This paper discusses validating an electric commercial vehicle CAE model during a side impact thus emphasizing the safety of a high voltage battery system. The critical parameters
Upendran, Anoop, Knuth, Joseph, Krishnappa, Giri, Punnaiappan, Arunsankar
Optimization of Tactile Vibrations in Agricultural Tractor Using Design of Experiments2026-26-03441/16/2026
One of agricultural tractors most important aspects is operator comfort. In addition to working long hours, tractor operators may be at risk for health problems due to vibrations and mechanical shocks. The tactile vibrations of a tractor are a major consideration when choosing one for agricultural use. This project's mandate includes a study of tractor vibration control problems. It is essential to investigate the governing system in order to determine the cause of the problem. Evaluating the vibrations transmitted via the tractor and using the design of experiments (DOE) approach to lessen vibrations on particular tactile regions were the study's goals. There are several measures currently under investigation which can be used to reduce the vibrations caused by resonance in this paper, these include reducing the natural frequency so as to be able to avoid resonance with the second order engine frequency and the damping coefficient; this will ensure the amplitude of vibration at
Baviskar, Shreyas, dhobale, Vishwajeet, Bhangare, Amit, Kunde, Sagar, Wagh, Sachin
Migration from MIDC to WLTP in India: Challenges & Solutions for a Small Commercial Vehicle2026-26-02151/16/2026
In line with global peers (EU, Japan, etc.), the Automotive Industry Standard (AIS) Committee in India has decided to adopt “World harmonized Light vehicle Test Procedure (WLTP)” for M2 and N1 category vehicles not exceeding 3500 kg and for all M1 category vehicles. As a result, “World harmonized Light-duty vehicles Test Cycle (WLTC)” is set to replace currently applicable “Modified Indian Drive Cycle (MIDC)” in the next couple of years. The draft Corporate Average Fuel Economy (CAFE) III & CAFE IV norms for CO2 emission limits, which are set to be implemented in year 2027 and 2032 respectively refer to a shift to WLTP from MIDC. The latest draft of Central Motor Vehicle Rules (CMVR) for BS-VI emissions is also being revised to use WLTC as test cycle. This migration to WLTC is in sync with the demand for test procedures to replicate real driving conditions more appropriately. Further, the move to WLTC along with stricter emission norms is a major step towards realizing India’s COP26
Pawar, Bhushan, Ehrly, Markus, Sandhu, Rouble, Emran, Ashraf, Berry, Sushil
Pre-Crash Characteristics of Motorized Two-Wheeler Crashes on Indian Roads2026-26-00341/16/2026
India has emerged as the world’s largest market for motorized two-wheelers (M2Ws) in 2024, reflecting their deep integration into the country’s transportation fabric. However, M2Ws are also a highly vulnerable road user category as according to the Ministry of Road Transport and Highways (MoRTH), the fatality share of M2W riders rose alarmingly from 27% in 2011 to 44% in 2022, underlining the urgency of understanding the circumstances that lead to such crashes. This study aims to investigate the pre-crash behavior and crash-phase characteristics of M2Ws using data from the Road Accident Sampling System – India (RASSI), the country’s only in-depth crash investigation database. The analysis covers 3,632 M2Ws involved in 3,307 crash samples from 2011 to 2022, representing approximately 5 million M2Ws nationally. Key variables examined include crash configuration, collision partner, road type, pre-event movement, travel speed, and human contributing factors. The study finds that straight
Govardhan, Rohan, Padmanaban, Jeya, Jethwa, Vaishnav
Total Cost of Ownership Analysis of Fuel Cell and Hydrogen-Powered Commercial Vehicles for Cost Competitiveness with ICE and BEV2026-26-02541/16/2026
Worldwide, the automotive industry is pivoting towards electrification and zero-emission vehicles (ZEV) to address greenhouse gas emissions and to meet net-zero emission goals. Although pure electric vehicles with rechargeable high-voltage batteries seem to be the most popular choice to achieve climate goals, hydrogen-powered vehicles are also seen by many as a viable technology to clean up the transportation sector. Hydrogen fuel cells and fuel cell-powered vehicles have been in development for a long time, and hydrogen internal combustion engines (ICE) have seen rapid development in the past few years. While the technological feasibility of hydrogen fuel cells and H2 ICE is being proven, the mass adoption of these technologies depends, along with other factors such as hydrogen infrastructure, upon financial feasibility as well. This paper presents a systematic analysis of the total cost of ownership (TCO) of hydrogen-powered vehicles, especially fuel cell electric vehicles. Different
Jacob, Joe, Chougule, Abhijeet
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