bluuebunny/crossref_metadata_2025 huggingface dataset:
A Multi-Disciplinary Optimization Approach for Lightweighting and Performance Improvement of Electric Light Commercial Vehicle
Authors: Kukkillaya U Saketh , Gumma Muralidhar , Potarlanka Srinivasarao , Durgam Padmaja
Published: January 2024

Rapid Urbanisation, in recent times, has created an exponential demand for light commercial vehicles. Electric vehicles are seen as a way to reduce the impact of emissions due to transportation in urban areas. Due to the growth of e-commerce, commercial transportation, and particularly last-mile delivery, is anticipated to increase. In this context, electric light commercial vehicles (eLCVs) have the potential to be a promising solution by tackling the emission impacts, ensuring faster delivery along with ideal running costs and payload capacity. To increase the range of electric vehicles, it has to be designed for lighter weight with optimal performance in order to meet the user requirements. Cargo capacity and payload have to be taken into account while design & validating the vehicle structure under static and dynamic conditions. Simulation driven product development will help the design team to account for the possible design failure cases at system and vehicle level. However, all these cases are multi-disciplinary and require validating the individual design verification plans (DVPs) of each discipline. Optimizing the performance of all these cases individually and provide design solutions will result in the increase of product development timelines. Structural Design verification plans for three disciplines a) Crash / Safety, b) Durability / Reliability, c) NVH / Comfort will be discussed in this work to meet the system and vehicle objectives. A Multi-Disciplinary Optimization (MDO) approach is explained which will provide upfront feasible design routes considering various disciplines performance targets and weight targets at systems level, based on the severity and importance of the system.
Coupled FEM-DEM for Determination of Payload Distribution on Tipper Load Body
Authors: Sadasivam Sivasankaran , Loganathan Ekambaram , Mahalingam Manikandan
Published: January 2024

Tippers used for transporting blue metal, construction and mining material is designed with different types of load body to suit the material being carried, capacity and its application. These load bodies are constructed with high strength material to withstand forces under various operating conditions. Structural strength verification of load body using FEM is conducted, by modelling forces due to payload as a pressure function on the panels of the load body. The spatial variation of pressure is typically assumed.

In discrete element method (DEM) granular payload material such as gravel, wet or dry sand, coal etc., can be modelled by accounting its flow and interaction with structure of load body for prediction of force/pressure distribution. In this paper, coupled FE-DEM is used for determining pressure distribution on loading surfaces of a tipper body structure of a heavy commercial vehicle during loading, unloading and transportation. This pressure is mapped onto the load body panels for structural verification. Also, the model is used for computing the CG of the granular bulk material which is then used for full vehicle analysis to estimate wheel reaction forces.
On- Board Diagnosis of Improper Reductant Detection in BS6 SCR System Using Virtual Sensor Modelling
Authors: M Jayashree , K Sabareeswaran , YS Ananth Kumar
Published: January 2024

Selective Catalytic Reduction (SCR) is an optimized technology developed to encounter current BS6 Emission Regulations. AdBlue is the reductant used in the SCR Dosing system to eliminate NOx in the Exhaust gas. In order to ensure engine emissions compliance, insufficient or improper reductant in tank required to be detected. The right AdBlue concentration of 32.5% is highly necessary to attain the higher NOX conversion efficiency. Low concentration of the reductant will drastically reduce the NOx conversion in the system. Hence monitoring the AdBlue concentration in the tank itself is more important as per the OBD legislation. This implies on a physical quality sensor in the tank for detecting the reductant concentration. The functionalities of the quality sensor can also be instituted via a virtual software modelling called Improper Reductant Detection (IRD). IRD logic is highly robust and work competently to meet the BS6 stage 2 legislation’s NOx target. The reductant is suspected after each tank refill event, automatically IRD logic runs in the software in general, but the routine is started only if the NOx conversion efficiency is getting worse as well. The approach is to increase the AdBlue dosing rate if there is a suspicion of an improper reductant. The comparison of the NOx conversion efficiency before and after increasing dosing determines whether the reductant is good or not. Henceforth, the component failure of high-cost Quality sensor can be prevented and improvised through a software model that promises a low-cost solution to the product which in turn benefits the customer.
Estimation of Gear Utilization and Durability Test Specifications through Virtual Road Torque Data Collection for Light Commercial Vehicles
Authors: Purohit Suryakant , Mullapudi Dattatreyudu , Shevate Hemant , Chaskar Mithun
Published: January 2024

The automotive world is rapidly moving towards achieving shorter lead time using high-end technological solutions by keeping up with day-to-day advancements in virtual testing domain. With increasing fidelity requirements in test cases and shorter project lead time, the virtual testing is an inevitable solution. This paper illustrates method adopted to achieve best approximation to emulate driver behavior with 1-D (one dimensional) simulation based modeling approach. On one hand, the physical testing needs huge data collection of various parameters using sensors mounted on the vehicle. The vehicle running on road provides the real time data to derive durability test specifications. One such example includes developing duty cycle for powertrain durability testing using Road Torque Data Collection (RTDC) technique. This involves intense physical efforts, higher set-up cost, frequent iterations, vulnerability to manual errors and causing longer test lead-time. Whereas, on the other hand, this entire process can be simulated in virtual environment. This approach involves 1-D simulation of longitudinal vehicle dynamics thus availing to understand intra-system component interactions resulting in simulating overall vehicle behavior.

Conventionally, in physical RTDC, the collected data is analyzed in the software like n-Code alongside the vehicle parameters for finding out percent gear utilization and Joint Probability Distribution (JPD) between speed and torque for each gear. This JPD can be further used in developing durability test specifications and the acceleration factors introduced using S-N curve of different gear materials. This paper envisions to study and establish the replication of entire RTDC process into 1-D simulation environment (called “VRTDC”) using Amesim software in such a way that it provides required driver behavior in a closed loop control in response to demand torque estimated at driver wheels, yielding better correlation with real test cases, simple modeling yet higher flexibility to change parameters, zero set up cost and shorter test time.
Numerical Analyses of AdBlue® Thawing Performance According to EU Norms
Authors: Govindarajan Vaishali , Varughese Shibu , Banik Soumendu , R Vineeth
Published: January 2024

Controlling NOx emission demand is getting more severe with Euro 7 legislation. In turn, this brings more focus on SCR (Selective Catalytic Reduction) technology, which uses a eutectic mixture of Urea (32.5%)– Water (67.5%) solution, more popularly known as Diesel Exhaust Fluid (DEF/ AdBlue®). Under extreme winter conditions, AdBlue® freezes as the ambient reaches below the freezing point (-11°C). Due to Legislation requirements (EU), estimating the time required to thaw a desired volume of frozen AdBlue® using forced heating is a matter of interest, leading to the concept of overall Melting/Thawing performance. So far, testing has been the primary method for arriving at a suitable melting mechanism and for designing electrical coils or hot coolant lines, which is expensive. This paper proposes a novel digital method using the 3D CFD tool STAR CCM+ to study the melting behavior of AdBlue®. The method is characterized by capturing phase change using the popular multiphase (VOF) approach and different modes of heat transfer involved in the process. The numerical analyses aided in understanding the influence of ambient (external airflow) conditions around the tank. Estimated AdBlue® temperature distribution inside the tank at various locations was benchmarked with two different test scenarios, viz., Climatic chamber test with external airflow around the tank & without any external airflow. The benchmarked simulation method showed good agreement with the test data. The effect of a completely insulated tank is also explored by modeling the AdBlue® tank under adiabatic condition. Additionally, one of the possible ways to reduce the computation time to estimate the melting performances is also explored. The computation domain was restricted to the region of interest around the sensors and benchmarked with test data. Using this digital method, clear design directions can be arrived at during the initial development stage, eliminating the need for multiple proto builds and validation.
Method and System for Creating Digital Twin of a Sensor for a Vehicle in Real Time
Authors: Ramesh Prashanth Mysore , Velichappattil Anvar Hussain
Published: January 2024

Modern Vehicles have many sensors equipped with them to give an idea to the control system of the vehicle as to what is happening in and around the vehicle. These sensors are very costly and they are critical in controlling the vehicle. If certain sensors fail, it can lead to the vehicle being stopped mid operation. Hence, it is imperative that the sensors have a reliable fail-safe mechanism so that above mentioned problems can be prevented, this will provide a better customer experience. For some of the sensors the mechanism for diagnosing and handling the failure is a legislative requirement itself.

However, the current failsafe mechanisms for sensors such as limp home, empirical maps, mathematical models etc. have their own drawbacks. This paper explains how a Deep Learning model trained in real time within a vehicle control unit provides a solution which overcomes all of the existing drawbacks. It also describes in detail what is the behavior of the Deep Learning model when it is getting trained in real time, what are the limitations of such a method and describes how to overcome those limitations. These tests are performed on a custom-built Deep Learning model in MATLAB Simulink and tested for 338 hrs of vehicle drive time simulations.
Simulation Techniques for Liquid Gasket Sealing Performance Prediction
Authors: Kumbhar Dipak Madhukar , Babar Ranjit , Patil Sanjay , Bagane Shivraj
Published: January 2024

In the automotive industry, silicon adhesive has become increasingly popular due to its benefits in ease of assembly and cost savings associated with material and manufacturing processes. To meet the imperative of minimizing both time and expenses during the project's development phase, it becomes essential to select the appropriate gasket material and an optimal flange design at the outset of the design process. In order to achieve stringent emission standards such as Real Driving Emission (RDE) and Corporate Average Fuel Economy (CAFE) norms, a better sealing performance is an essential parameter. Various types of liquid gaskets such as silicon rubber based Room Temperature Vulcanizing (RTV) sealants and thermoset plastic based Anaerobic sealants are widely used in an Internal Combustion engine. They are commonly used for the components such as oil sump, bedplate, and gearbox housings, etc. Traditional simulation methods could not capture the exact failure modes of the liquid sealants. Hence there is a need for a better understanding of the factors controlling a joint's sealing performance under realistic service conditions.

This paper describes a methodology to predict the sealing performance of liquid sealants at a very detailed level. An innovative 2 Dimensional (2D) and 3 Dimensional (3D) simulation approach is used for micro level modelling of the joint. In the first phase of the simulation, a 2D simulation approach is employed for predicting micro level joint behaviours under various initial conditions. In the second phase, a 3D approach is applied to find the assembly level joining surface behavior. Final sealing performance is evaluated by combining the 2D and 3D simulation results. Experimental validation for the most commonly used liquid gaskets were carried out to establish the correlation of this process. It has been observed that the anticipated sealing outcomes align closely with the results obtained through experimentation.
Numerical Modelling of Stone Lofting by a Treaded Tyre
Authors: Kumar Sourav , Babbar Ritvik , Pattankar Rohan , Venkatarama Nithin , Yenugu Srinivasa , Duggirala Ravi
Published: January 2024

In passenger cars, exterior damage due to external objects is a common and repetitive problem for the costumer. A vehicle running over an unpaved or granular road undergoes such damages where the tyre picks up stones (Figure 1) [1] and ejects them towards the vehicle exterior surfaces. These stones cause mechanical damage to the vehicle: affecting aesthetics, accelerating corrosion, and reducing safety. This mechanical damage is more severe in case of electrical vehicles as batteries are placed at the underside of the vehicle. Figure 2 [2] shows an example damaged caused by stone chipping. Induced erosion due to chipping cause corrosion propagation on the peeled surface, Figure 2 shows an example of such corrosion. So far, physical testing and analytical mathematical methods are the most common ways to evaluate damages. However, there is a need of computationally inexpensive, repeatable, and accurate method, which can account for the complex system. This paper describes a validated Multiphysics numerical model for stone lofting, using a stand- alone all-weather tyre. The presented Multiphysics model couples Discrete Element Method (DEM), Finite Element Method (FEM), Multi-body Dynamics (MBD). Results of this work correlate well with experimental findings from Andreas Schönberger [3]. These experiments were performed in a controlled environment with a standalone treaded tyre and for three different velocities of 30kmph, 50kmph and 80kmph which accounts for tyre rotation. The results presented in this work show that method used is capable to capture relevant physics and predict stone lofting numerically. This method is anticipated as a starting point for the development of more sophisticated numeric models for stone chipping prediction.
Cost Effective Techniques for SCEV to Improve Performance & Life of Battery and Motor by Using Efficient Thermal Systems
Authors: Chormule Suhas Rangrao
Published: January 2024

The automotive world is moving towards electric powertrain systems. The electric powertrain systems have emerged as a promising alternative to the conventional powertrain system. The performance of electric vehicle is highly dependent on operating temperature of electric and electronic components of the vehicle. All power electronics and electric components in EV generate heat during operation and it must be removed to prevent overheating of components. Higher temperatures raise safety concerns whereas lower temperatures deteriorate the performance of power electronics & electric components. These power electronics & electrical components perform efficiently and safely if operated within certain temperature range.

This paper presents an advanced efficient cost-effective thermal technique for small commercial electric vehicle (SCEV) to improve the performance & life of major electric components. It is observed from literature survey that this is a novel technology for small commercial electric vehicles. The one-dimensional (1D) simulation approach is employed to evaluate the performance of the existing thermal management systems for battery, motor, cabin and power electronics cooling & heating during various charging and discharge modes at different ambient temperature conditions. Further, advanced efficient cost-effective thermal management techniques are proposed and analysed by 1D simulation approach. The proposed thermal management techniques consist of simple and cost-effective thermal architectures having 3-way & 4-way valves which helps to recover waste heat, reduces compressor duty cycle and improve the overall vehicle performance in terms of range improvement or battery downsizing to achieve the same range. Simulations performed for new technique show that the combination of these techniques can significantly improve the thermal behaviour of the battery & electric motor as well as the range of the vehicle by 4 - 5 km. Also, it will improve the life of battery and motor. The additional cost of 3-way & 4-way valve at vehicle level will get recover within short duration of time compared to vehicle life.

Furthermore, the cost-effectiveness of the proposed thermal management system is demonstrated, making it a viable solution for all electric small commercial vehicles. This study provides valuable insights for the design and development of efficient and cost-effective thermal management systems for small commercial electric vehicles.
Data-Driven Toe Misalignment Detection in Single-Unit Twin-Axle Trucks
Authors: Burande Kalyani , Grandhe Roshan , Mukhopadhyay Arko , Sharma Mitanshu , Shankar Ram C S
Published: January 2024

Toe misalignment detection and its correction are important periodic tasks recommended by Original Equipment Manufacturers (OEMs) for Heavy Commercial Road Vehicles (HCRVs) to prevent premature tyre wear and improve fuel economy. Existing misalignment detection methods need skilled professionals to operate sophisticated equipment, while automated methods require additional sensors, which are not readily available in most trucks, making their implementation challenging. This study explores the effectiveness of a data-driven method to detect toe misalignment in single-unit twin-axle trucks with symmetric and asymmetric toe configurations. This method involves continuous monitoring of lateral dynamics variables measurable using sensors present in most trucks making it practically tractable. Ramp steer manoeuvres with a 45° steering angle and a rise time of 3 seconds in two directions (clockwise and anticlockwise) for two toe configurations (symmetric and asymmetric) constituted the four test manoeuvres. For each manoeuvre, a dataset of 192 number of feature vectors with different values of toe at the front axle wheels, containing an equal number of aligned and misaligned cases, was synthesised using IPG TruckMaker®. Support Vector Classifier (SVC) models were trained on 63.00% and 67.50% of the datasets for symmetric and asymmetric toe configurations, respectively. The symmetric toe misalignment detection precision was 96.77%, 100.00%, with false negatives (FN) of 8.33%, 6.94% and false positives (FP) of 1.39%, 0.00% for the anticlockwise and clockwise steer manoeuvres, respectively. While the asymmetric toe misalignment detection precision was 92.31%, 78.95%, with FN of 30.65%, 25.81% and FP of 1.61%, 6.45% for the anticlockwise and clockwise steer manoeuvres, respectively. This approach indicated better effectiveness in detecting symmetric toe misalignment with lesser FN and FP percentages for both ramp manoeuvres when compared with asymmetric toe misalignment. This study’s outcomes are expected to contribute towards an onboard automated misalignment detection method, including thrust misalignment, to alert drivers in real-time.
Comparative Analysis of P2 and P3 HEV Architectures for Different Vehicle Segments
Authors: Jadhav Vaibhav V. , Warule Prasad B.
Published: January 2024

Climate change due to global warming calls for more fuel-efficient technologies. Parallel Full hybrids are one of the promising technologies to curb the climate change by reducing CO2 emissions significantly. Different parallel hybrid electric vehicle (HEV) architectures such as P0, P1, P2, P3 and P4 are adopted based on different parameters like fuel economy, drivability, performance, packaging, comfort and total cost of ownership of the vehicle. It is a great challenge to select right hybrid architecture for different vehicle segments.

This paper compares P2 and P3 HEV with AMT transmission to evaluate most optimized architecture based on vehicle segment. Vehicles selected for study are from popular vehicle segments in India with AMT transmission i.e. Entry segment hatch and Compact SUV. HEV P2 and P3 architectures are simulated and studied with different vehicle segments for fuel economy, performance, drivability and TCO. The analyzed simulation results reveal similar fuel economy benefits for P2 and P3 HEV architectures. P3 hybrid offers better performance compared to P2 hybrid due to torque fill during gearshift and less power loss from motor to wheel. In addition, additional benefits in P3 like torque fill during gearshift enhances drivability of the vehicle. P2 hybrid has advantage of low cost over P3 hybrid. P3 hybrid requires mandatory extra P0 machine for engine auto start that makes it costly compared to P2 hybrid. In addition, P3 hybrid motor size is bigger compared to P2 hybrid motor due to lack of gear advantage that makes P3 hybrid more costly.

Finally, after analyzing the simulation results and considering the cost impact of HEV architectures, the paper concludes that P2 hybrids are most suitable for entry segment hatch due to low cost benefits and P3 hybrids are preferred for compact SUV segment where customer demands performance and drivability.
Integration and Optimization of Geneva Mechanism in the Car Door Handle
Authors: Kumar Vinayak
Published: January 2024

The car door handle is an essential component of any vehicle, as it plays a crucial role in providing access to the cabin and ensuring safety of the passenger. The primary function of the car door handle is to allow entry and exit from the vehicle while preventing unauthorized access. In addition to this, car door handles also play a critical role in ensuring passenger safety by keeping the door closed during accidents or when there is a significant amount of G-force acting on the vehicle. A typical car door handle comprises several components including the structure, cover, bowden lever, bracket, pins and other child parts. The structure provides the ergonomics and rigidity for grabbing the handle, while the cover gives the handle an aesthetic appearance. The Bowden lever facilitates the unlatching of the door and the intermediate parts ensure that the handle operates smoothly. The position of the Bowden lever is crucial for the unlatching process and for keeping the door closed during the accidents and unauthorized entry. Therefore, design of the car door handle must work under optimize force to ensure that the handle performs it’s function effectively. The proposed design focuses on integrating the new mechanism that includes the Geneva drive concept. The mechanism aims to optimize the working of the car door handle while unlatching the door, thereby providing a safer and more efficient means of accessing the vehicle cabin. The proposed design with the Geneva wheel concept offers an innovative approach to optimize the force on the handle.
Static Seat Comfort CAE DOE Variation Study to Understand the Impact of Seating Adjustment and Occupant Posture on Seat Pressure Distribution
Authors: H S Rakesh , Lal G M Sherin , Rahmani Reza
Published: January 2024

The automotive seat has undergone significant advancements in technology due to changing customer demands, levels of autonomy and vehicle regulations. These advancements have presented both opportunities and challenges in creating a pleasant experience for customers by ensuring optimal seat comfort and a joyful human experience. Seats are always being built to accommodate different percentiles of occupant comfort requirements; original equipment manufacturers come up with various seating adjustment features. However, there is considerable variation among each percentile of occupants in how they utilize these features to achieve a comfortable seating position based on their unique preferences and circumstances. Additionally, there are variations in occupant postures due to the ways people have adapted their driving habits or styles when it comes to the way they sit. The objective of this paper is to understand the sensitivity of seat adjustments and occupant postures on static seat comfort pressure distribution. This study was conducted by replicating the physical occupant seating posture in the CAE environment.
The Impact of Uncertainty Quantification and Sensitivity Analysis in CAE Simulation based Regulatory Compliance
Authors: Deshpande Saurabh , Mahajan Rahul , Jones Gavin
Published: January 2024

Computer-aided engineering (CAE) is a routinely used technology for the design and testing of road vehicles, including the simulation of their response to an impact. To increase automotive industry competitiveness by reducing physical test-based type approval and to improve road safety, recent initiatives have been taken by both industry and public authorities to promote the use of virtual testing through numerical simulation as an alternative way to check regulatory compliance. [1]

To ensure acceptance of this alternative method, the accuracy of the simulation models and procedures needs to be assured and rated independently of the modelling process, software tools, and computing platform. Similarly, it is also imperative to understand the uncertainties emerging out of different component design parameters and analyze their sensitivity towards producing deviations in the reported results as per the requirements of the regulatory standard. Simulations are however deterministic in nature and do not in general consider the uncertainty in areas such as design, manufacturing, and use of the product. Using machine learning and uncertainty quantification, engineers can predict the range of possible outcomes for a given design by accounting for such uncertainties. Training emulators (aka machine learning models, predictive model, etc.) of simulations can allow for the efficient performance of the advanced analytics required.

Design parameters of a front under-run protection device (FUPD) were evaluated using computer simulation as per Automotive Indian Standard (AIS) 069 loading conditions [2]. The process involved the use of Design of Experiments (DOEs) to collect emulator training data and uses the trained emulator to perform uncertainty propagation of manufacturer part tolerances. A sensitivity analysis study was carried out to understand the dependence of output results on crucial parameters.

The results obtained from this study lend benefit towards understanding the uncertainties involved in CAE simulation-based product assessments. It will also be useful as a benchmark to quantify uncertainties involved in other load cases wherein the regulatory standard allows the use of virtual testing as an alternative method to physical type approval.
One Dimensional (1-D) Simulation Model for Ride and Comfort Evaluation of a Two Axle Truck
Authors: Soni Yash , Bagal Vikram , Ghanwat Hemant , Mullapudi Dattatreyudu , Chaskar Mithun
Published: January 2024

In automotive industry, testing and validation teams are highly dependent on availability of prototype vehicles for testing and evaluation of ride & comfort behavior of vehicles. Special test tracks surfaces are also used (namely Tar road, Express way and driving over a Cleat) to evaluate the ride & comfort through subjective evaluation. Ride is largely affected by transmissibility of road excitations to the driver and other occupant’s seats, influence of suspension, bushes and tire are the major contributors in the transfer path of vibrations. A configurable 1–D simulation model of a Two Axle Truck is developed for quick evaluation of the ride & comfort behavior which is need of the hour for the testing team in optimizing the number of iterations in physical testing. These simulations will help in understanding the ride & comfort behavior and its sensitivity to changes in the component’s characteristics in absence of physical test vehicles. The developed model is then correlated with the physical measurements at identified locations over the vehicle and a correlation of acceleration in Z direction of about 85–90% is achieved with respect to the measured accelerations. More than 90% of correlation is achieved in permissible allowable value of ride index calculated from the simulations w.r.t to the ride index determined from the physical tests. The model developed is a configurable two axle truck model which can be deployed horizontally for any other configuration with minor tweaking which in turn can save resources with increase in productivity.
Method of Improving Slam Durability Fatigue of Vehicle Liftgate Subsystem for Fast-Track Vehicle Development Cycle
Authors: Subramanian Vijayasarathy , Evans Jon , Schoenow James , Arikatti Karegowda
Published: January 2024

With reference to present literature, most OEMs are working on reducing product development time by around ~20%, through seamless integration of digital ecosystem and focusing on dynamic customer needs. The Systems Engineering approach focuses on functions & systems rather than components. In this approach, designers (Computer Aided Design) / analysts (Computer Aided Engineering) need to understand program requirements early to enable seamless integration. This approach also reduces the number of iterative loops between cross functions thereby reducing the development cycle time. In this paper, we have attempted to tackle a common challenge faced by Closures (Liftgate) engineering: meeting slam durability fatigue life while replicating customer normal and abusive closing behavior. For modern vehicles with faster vehicle development processes, major challenges are balancing mass with improved structural and durability performance, while also considering frequent design changes due to styling considerations. The designer needs to successfully execute these changes without major impact to timing and cost. This brings a need for Agile methodology to solve fatigue problems in fast-track vehicle programs. The proposed method can be adapted to improve closures structural design for any vehicle door to improve fatigue life durability.
Identification and Correction of Fuel Level Indication in Automotives Using HIL System and Camera-Based Measuring System
Authors: K Vishali , Patil Pratik
Published: January 2024

Automotives are provided with a lot of intelligence that monitors, controls, actuates, and diagnose the various aspects of vehicle functionalities. One of the critical parameters required to monitor is Vehicle fuel level. Fuel level in the vehicle is a key input for engine performance, drivability, and fuel level indication in Instrumentation cluster for customer. Most economic and reliable fuel level sensor is resistive sensor with float. The purpose of this paper is to address the wrong fuel level indication in Vehicle level. Wrong fuel level indication may be due to malfunction of Instrumentation cluster signal input or Fuel level sensor function. To verify this, Instrumentation cluster is tested with HIL system instead of real time Fuel level sensor. By configuring the HIL module to analogue resistance channel, cluster is tested for fuel level bar indication. Fuel level sensor is tested by Vehicle level fuel calibration and exact issue is simulated. The failed fuel level sensor is stripped open for analysis and found resistance track length is not adequate, and it leans on the edge of the track due to vibrations. To address this issue, length of the resistance track is increased. When length is increased, the angle of the track changes and it implicates wrong fuel indication. Using this simulation, actions are taken in such a way that length and angle of the track modified to give correct resistance and indication. To rely on this actions, Camera enabled measuring systems is used to measure the length and angle of the resistance track. Corrected samples are taken for accelerated endurance test with the help of pressure cylinders setup and examined for action effectiveness. The details on failure simulation, action taken and validation for corrective samples are discussed in this paper.
Comparative Analysis of RocksDB, LMDB, and MongoDB: A Performance Evaluation
Authors: Agrawal Apurva , Mamajiwala Yusuf
Published: January 2024

This abstract provides a comprehensive comparison between RocksDB, LMDB, and MongoDB, three popular database systems, highlighting their differences in terms of architecture, performance, scalability, and use cases.

RocksDB, an embedded key-value store developed by Facebook, and LMDB (Lightning Memory-Mapped Database), a memory-mapped key-value store, are both optimized for high-performance and low-latency workloads. These databases excel in scenarios where efficiency and speed are critical factors, such as caching, session stores, and other applications that require fast data access. RocksDB is known for its persistent storage on disk and seamless integration with various programming languages, while LMDB leverages memory-mapped files for exceptional performance but lacks distributed capabilities. On the other hand, MongoDB, a document-oriented NoSQL database, offers a flexible schema and a rich set of features for handling complex data structures. MongoDB is highly scalable and suitable for applications requiring dynamic and evolving data models. It provides robust support for sharding and replication, allowing horizontal scaling across multiple nodes, making it ideal for large-scale distributed environments and cloud-native applications. In terms of data consistency, RocksDB and LMDB prioritize strong consistency, ensuring data integrity even in the face of failures. In contrast, MongoDB offers eventual consistency by default, providing improved scalability but potentially sacrificing immediate data consistency.Each database system has its strengths and weaknesses, and choosing the appropriate one depends on specific application requirements. RocksDB and LMDB are preferred for their superior performance and low latency, while MongoDB excels in scalability, flexibility, and handling complex data structures.
Automation of PID Calibration for Close Loop Control System in an Electric Vehicle to Achieve Objective Driveability Performance
Authors: G Ashwin , Jadhav Vaibhav V. , Warule Prasad B.
Published: January 2024

This paper introduces a novel approach to automate PID calibration for closed-loop control systems and the creep control function in an electric vehicle. Through a comprehensive literature survey, it is found that this method is the first of its kind to be applied in the field of automated electric vehicle calibration for Creep function. The proposed approach utilizes a systematic methodology that automatically tunes the PID parameters based on predefined performance criteria, including energy consumption and jerk. To implement this methodology, the ETAS INCA FLOW software, which provides guided calibration methods for in-vehicle testing & calibration, is employed. The calibration process is performed on a real-time electric vehicle platform to validate the effectiveness of the proposed approach. The results of this study showcases the advantages of automated PID calibration for closed-loop control systems and creep control function in small commercial electric vehicle. The proposed calibration methodology shows 45% reduction in calibration time and effort compared to traditional methods, all while ensuring the desired objective driveability performance irrespective of engineer’s expertise in calibration domain. Also it provides consistent results and automated test report with increased test accuracy. Engineers of varying calibration experience levels can benefit from this approach. Experienced engineers can save up to 25% of their time in testing and calibration, while new engineers can enjoy an impressive 45% reduction, giving them an advantage in their work. Overall, the proposed approach presents a unique and innovative solution for improving the calibration process in Small Commercial Electric Vehicles. This methodology enable more precise PID calibration for close loop control systems with objective vehicle performance, significant time reduction, consistent results irrespective of calibration expertise.
Determination of the Structural Member Life Cycle without Undergoing Complete Testing Using CAE Input for an Improved Design after Failure Correlation
Authors: Venkatesh Srinivasa
Published: January 2024

This case study involves the failure analysis of the wheel arch structure for a commercial truck. The wheel arch is an important vehicle trim aggregate from both the regulatory perspective (spray suppression) as well as from the aesthetics of the truck. But, the durability of this part is affected by the vehicle architecture, vehicle load capacity as well as the operating conditions. This is more critical due to the nature of the overhang experienced by the mounting bracket assemblies that hold these wheel arches/mud flaps. This generally consist of tubular and sheet metal welded structures bolted on to the main chassis long members. These failures were observed in a legacy vehicle, where very little details of the complete vehicle digital simulation and testing performance were readily available.

This paper deals with the

identification of the root cause of the failure

simulation of the root cause in CAE

improvement in design

CAE evaluation of improved design

Correlation of the failure and improvement in design using physical testing and

durability and life cycle evaluation of the improved design without undergoing the complete cycle of durability testing within a short time to facilitate implementation of the improved design and arrest the field failure.

This paper will deal with specific focus on the correlation of the failure as well as improvement of the design in physical testing and conclusion within a very limited period short duration using the CAE and physical evaluation input.
An Investigation on High Impact Torque of BEV and Driveshaft Robustness Improvements
Authors: Singh Deepak Vikram , Jacob Abijith , Paua Ketan , Vellandi Vikraman , Mane Yogiraj
Published: January 2024

The inherent capacity of electric motors to generate substantial instant torque can lead to significant load reversals in electric vehicle driveshafts under specific road conditions and driving maneuvers, highlighting the need for targeted improvements in driveshaft design, particularly in optimizing joint sizing. This paper presents a systematic approach to investigate the root causes of a catastrophic driveshaft failure that occurred during specific vehicle tests on a road with multiple speed bumps, resulting in numerous high torque reversals. The objective was to enhance system robustness through changes in driveshaft design and the manufacturing process, coupled with a software calibration technique to reduce torque demands under such operating conditions. The process encompassed torque measurements at the vehicle level, failure replication on a test rig, and correlation with simulations. Sensitivity analyses of the manufacturing process preceded the finalization of design and process modifications, initially validated through rig-level testing. The new driveshaft design exhibited an impressive 9% increase in ultimate torsional strength during rig-level testing, resulting in a substantial sixfold lifespan increase during vehicle-level testing. Furthermore, an additional fourfold increase in lifespan was attained through software calibration, effectively minimizing actual torque demands on the vehicle.
Development of Transmission Adaptor for Diesel Engine Application
Authors: Karale Pranjali
Published: January 2024

Transmission adapter is solid, located on cylinder block, on which sits the transmission housing. The function of a flexplate is to provide a mounting point for a torque converter which is used to couple the engine and transmission together when an automatic transmission is used. Transmission adapter provide access for torque convertor and flexplate assembly and protect the flexplate from external environment. Transmission adapter is also support and locate the starter.

This study deals with different alloy grade material use, improvement in process to reduce porosity. Porosity observed in first samples of the proposed grade material. The study represents investigation of Transmission adaptor porosity root cause. This also included visual observation, radiography -X ray testing, analysis, 3D scans, dimensional inspection, chemical analysis and comparison, tensile testing, truck testing validation tasks. Make sure critical parameter of the clearance meet between flexplate and transmission adapter. Result of the material alloy change is passed and field validation on truck application ran more than 150,000 miles without any issue.
Design and Development of EGR Valve Controller
Authors: Bhatt Pancham , Kumar Krishan , Kumar Sahil
Published: January 2024

Various emission and fuel economy norms for passenger cars have been introduced by the government worldwide. In India, meeting each revision of the Bharat Stage (BS) emission standards and Corporate Average Fuel Economy (CAFE) norms is challenging, and requires the incorporation of new technologies into IC engines. One such technology used in gasoline engines is Exhaust gas recirculation (EGR).

The entry of dust particles into the EGR system makes it vulnerable to failure. One such market failure case of EGR valve malfunctioning in passenger vehicles has been addressed in this study, where the EGR valve became stuck due to dust entry, leading to engine hunting and stalling.

The approach followed for the issue resolution demonstrates a method of developing an EGR valve controller for simulating the failure on a bench setup. The controller setup was built around a microcontroller chip that accurately operated the valve with similar logic to that of the vehicle ECU. In addition to operating the valve as per the set test cycle, the setup monitored the valve travel in real time, logged the test data on an SD card, and alerted the user if anomalies were detected.

Accelerated tests were designed and the proposed countermeasure was successfully validated using the controller setup. The versatility of the system enables it to be customized for various engines and test cycles, with minor changes in programming.
Bluetooth Profile Testing Using Packet Tracing in Automotive Domain
Authors: Selokar Ashish Kishor , Iqbal MD Farhan , Anilkumar Sandhya , Tavhare Sarika
Published: January 2024

With the advancement of automotive industries, the need for wireless connectivity between vehicle and smartphone is increasing. To meet the demand for wireless connectivity, Bluetooth plays a vital role. Testing Bluetooth systems is challenging and complex when development cycles of the system involve multiple partners. The system under test must fulfil consumers expectation of Bluetooth functionality paired with their personal devices. Despite many advances and existence of a few reliable systems, hardware limitation, and lack of standardization in Bluetooth test system are some of the prolonged issues. Throughout the course, various capabilities and existing traditional Bluetooth testing system practice were researched, which majorly at a system level (Black box). The gap of such testing is the escape of defect which involves the interoperability of multiple profiles like AVRCP, HFP, and A2DP. This paper focuses on a reliable testing approach which is based on packet level testing common to BLE and Bluetooth Classic. Research shows there is no common approach for BLE and Bluetooth Classic, some research provides BLE based solution for packet level tracing but lacks to bring it in Bluetooth Classic. The work here will help us in packet sniffing, processing, logging for both BT Classic and BLE profiles. Hence the need to test Bluetooth system to detect and deliver defect-free products would save development cost in terms of time involved in iterative development and testing cycle, and gain customer’s trust. This paper intends to introduce a humble solution to the testing community a step before the functional testing of Bluetooth system through validation of transmitted Bluetooth profile packet-id between the devices.
Effect of Ceramifiable Silicone Rubber Composite Based Thermal Insulators in Battery Packs
Authors: Nambisan T M Praveen Kumar , H Manjunatha , R Pavan , P Hari Prasad Reddy , G M Bharath , Kulkarni Mukund Aravind , Sundaram Saravanan
Published: January 2024

Silicone and rubber composite, often called Ceramifiable Silicone Rubber Composites(CSRCs), has proven to show excellent mechanical and thermal properties. CSRC materials have been mainly used in industrial applications like electrical insulating cables, decorations, and fire-proof materials. The mechanical and ceramifiable properties of CSRC can be altered by changing the silicone rubber matrix and by adding the right additives or fillers. In this work, we prove the potential of CSRCs as thermal insulating materials in battery packs. Specifically, we explore the usage of CSRC inside the battery pack to improve safety during thermal events. We also characterize the material properties before and after exposing the CSRC to elevated temperatures and flame. Finally, we investigate the effectiveness of the CSRC sheet in preventing or delaying cell-to-cell thermal propagation during a thermal runaway event inside the battery pack. Our experiments show that the CSRC sheet significantly reduces the propagation of thermal runaway between cells, improving the safety of the battery pack used in electric vehicles and energy storage applications.
Study and Analysis of Dynamic Seat Pressure Distribution by Human Subjects during Vehicle Running State on Test Tracks
Authors: Arthanathan Sankaranarayanan
Published: January 2024

The purpose of this study is to conduct dynamic seat pressure mapping on vehicle seats during its operation on different test tracks under ambient environmental conditions for a defined speed. The test track comprises of pave roads, high frequency track, low frequency track and twist track. The variations in pressure distribution on seat during diverse road load inputs help to understand the seat cushion and back comfort for unique percentiles of human subjects ranging from 50th to 95th percentile population. For conducting the study, a sport utility vehicle (SUV) loaded with leatherette seats has chosen. Totally six participants (human subjects), five male and one female selected for the study based on their BMI (Body mass index) and body morphology.

Pressure mats suitable for taking dynamic load inputs and able to log the data at a defined sampling rate mounted on seats and secured properly. The pressure mats should cover the seat cushion, bolster areas and back seat completely. The obtained data analyzed for the load variations from the normal 1g cushion and back load given by the participant in vehicle static condition. The outcome of this study and data analysis provides the inputs to seat design on dynamic load factors to be considered and seat ingress and egress durability test load case improvement, mainly in settle load case of human subject. Because in static seat pressure mapping, apart from ingress and egress, the human subject settle load have no significant variations since the vehicle in static condition.
WITHDRAWN: Powertrain and Cabin Cooling Performance Improvement by Optimization of Its Components
Authors: Mirajkar Nilesh Shridhar , Khairnar Rohit
Published: January 2024

This paper has been withdrawn by the publisher.