U.S. Army Combat Capabilities Development Command (DEVCOM), Aviation & Missile Center (AvMC) developed a Digital Backbone for the Rotorcraft Applied Systems Concepts Airborne Lab (RASCAL-X) UH-60M for rapid Modular Open Systems Approach (MOSA) mission system integrations. The RASCAL-X Digital Backbone is the cornerstone of a unique experimental flight test capability connecting the experimental research flight control system with the Mission Systems Flying Testbed (MSFTB) and other mission system components. The Digital Backbone with MSFTB provides a suite of capabilities to integrate, assess, and flight test Mission Systems Under Test. The RASCAL-X Digital Backbone supports many of the physical aspects of mission system integration by providing Nodal Points with provisioning for power, data, and connectivity. Numerous challenges in Digital Backbone design, fabrication and installation were successfully addressed and solved during the development effort. The RASCAL-X Digital Backbone

Padilla, Marcell, Wigginton, Scott, Nelson, Jeff

How to Enhance System Integration Test Rigs with Open-Source Real-Time Control and Data Acquisition

F-0081-2025-0277

5/20/2025

This paper will present the use of a licensed open-source software application based on commercially available off-the-shelf hardware for the control and data acquisition of aerospace system integration test rigs. System integration test rigs are complex systems requiring real-time deterministic control and high-speed data acquisition. Various aircraft flight systems and subsystems can be tested to see if they interact as they would on the aircraft without an airframe. These systems are critical to ensure interoperability during the development phase and facilitate the interchangeability of actual flight hardware, prototypes, and simulation models throughout the development cycle. Deploying open, flexible, and highly configurable real-time control and data acquisition systems ensures that development milestones will be achieved cost-effectively, whether using actual flight hardware or working with a simulation. This is because, as the prototype hardware is developed, the remaining

La Zar, Darryn

A Haptic Patch Can Transmit Complex Information to a Wearer’s Skin

TBMG-5224812/12/2024

Development and Demonstration of a Critical Rotorcraft Safety System: Advanced Helicopter Seating System

F-0080-2024-1195

5/7/2024

The Advanced Helicopter Seating System (AHSS) was started as an effort to evaluate and improve the current state of military rotorcraft seating. The overall goal of the program has been to improve pilot ergonomics and safety through the integration of advanced energy absorption and vibration reduction mechanisms as well as a broad approach to system integration based around updated occupant anthropometrics. An entirely new seating solution has been developed, with intent to integrate with the AH-64 Apache platform for demonstration purposes. The AH-64 development culminated with a series of static tests and dynamic test events to measure the effectiveness of the safety systems integrated on the seat as compared to the legacy AH-64 seating system. While lumbar load data and seat stroke data was obtained, issues with the anthropomorphic test device (ATD) configuration at the 95th male configuration caused some data to be suspect, and premature failure of several components also caused

Minton, Tyrone, Crocco, John, Richards, Marvin

Predictive Underhood Thermal Management Model

2024-26-02721/16/2024

In the automotive industry, thermal management is a very important way to solve the problems of energy saving and emission. The underhood thermal management is one of the critical aspects in vehicle thermal management since it caters to critical aspects of engine cooling, charge air cooling, air conditioning and turbocharger cooling. The appropriate thermal management of these critical components is necessary for ensuring the appropriate performance by the vehicle. Hence, under-hood thermal management is the core of the integrated vehicle thermal management. In the thermal management analysis approaches, the numerical simulation is widely adopted as an important approach. Hence, in this paper a model is developed in MATLAB to handle 1D parametric analysis of the cooling system, while reducing the testing time and resources taken for the product development. The developed model can be used to evaluate multiple aggregate options for CAC, Radiator, Engine, Fan etc. The model predicts the

P V, NAVANEETH, Prasad, Suryanarayana A N, ML, SANKAR

DEVELOPMENT OF A C-SHAPED EXHAUST AFTER-TREATMENT SYSTEM WITH AN AURICLE MIXER

2024-26-01431/16/2024

Internal combustion engines have been there for nearly a century and half and will continue to remain and play a major role in the mobility industry. Exhaust aftertreatment system is like a sibling to the internal combustion engine, since both work in tandem, complementing each other's functions and contributing to the overall goal of reducing emissions and improving environmental sustainability. The faster adoption of Euro VI emission norms globally and announcement of Euro VII norms, emphasizes the need to continually improve our exhaust aftertreatment systems. This paper presents a breakthrough in the development of a C-shaped compact, modular and cost-effective exhaust aftertreatment system (EATS) with an auricle mixer, designed at Ashok Leyland. This system is specifically engineered to meet the stringent requirements of BS VI OBD-II emission norms for diesel engine applications and can be upgraded for H2 ICE. A typical BS VI EATS has catalysts, sensors and urea nozzle integrated

Giridharan, Jyothivel, Chandrasekar, Vasu, L, suresh

Real time monitoring and control of engine reliability validation using IOT and AI

2024-26-03471/16/2024

IoT and AI have revolutionized the way we live and work, providing significant benefits across industries. The application of these technologies in engine reliability testing has immense potential as they offer real-time monitoring and analysis of engine performance. Engine reliability testing plays a crucial role in ensuring the safety, efficiency, and longevity of engines. However, traditional engine reliability testing methods can be time-consuming, costly, and often rely on manual inspection and data analysis. This paper presents a series of case studies that demonstrate the potential of IoT and AI tools in engine reliability testing, highlighting their benefits and limitations. This paper offers a comprehensive solution proposal for each use case, outlining the challenges and limitations of current engine reliability testing techniques. After that, the study proposes and evaluates IoT- and AI-based solutions to address these challenges. The study compares the effectiveness of the

Mujtaba, Quadri Syed, Yadav, Sanjay Kumar, kumar, Prabhakar, Verma, Vivek, Srinu, Kuncha

System Validation with Battery-in-the-Loop Configuration using a Virtual Testing Toolchain

2024-26-01161/16/2024

Challenge Today, the battery development process for automotive applications is relatively decoupled from the vehicle integration and system design validation phase. Battery module design targets are very much linked to vehicle-level requirements, such as performance, lifetime and cost but are often disregarded at very early design phases. Converging these requirements to more specific battery pack criteria is not straightforward and often based on previous vehicle generation data or cell testing measurements usually performed after prototyping and via artificial charge and discharge patterns Solution To reduce time to market, AVL proposes here a methodology guided by virtual testing techniques to consider vehicle-level validation steps at the very early phase of battery testing. In a first step, AVL utilises a vehicle system simulation supported with real-world test scenarios and high-fidelity battery models. To generate such realistic scenarios, AVL uses an online digital map and

Kolar, Ales, Santiago, Prabhu, Kural, Emre

Helicopter In-Flight Eye Tracking: System Integration Aspects and First Results

F-0079-2023-18025

5/16/2023

ABSTRACT

Maibach, Malte-Jörn, Greiwe, Daniel, Müllhäuser, Mario

Ensuring No Child Left Inside

22AVEP04_054/1/2022

Up-armed with new key technologies, Gentex is making ‘holistic’ driver and cabin monitoring a core-brand hallmark. A step-change in sensing precision is underway for vehicle interior applications, with increased capabilities spurred by new technology, customer interest in occupant safety and entertainment, and global regulations. Gentex is among those setting the pace in this fast-moving and hyper-competitive field, as it integrates its long experience in mirror-based opto-electronic systems and sensor fusion with the 2021 acquisition of Tel Aviv-based Guardian Optical Technologies and the 2020 purchase of Vaporsens. The Holland, Mich.-based Tier 1 uses the term “holistic driver and cabin monitoring” to describe the interconnection of the two main development thrusts. There is discrete driver monitoring, vital for SAE Levels 2 and 3 of driving automation, with a subset of features aimed at driver distraction, drowsiness, weariness, sudden sickness, etc. And there's the ‘holistic

Brooke, Lindsay

AI-based Signal Integrity Monitoring for Integrated Vehicle Health Management

2022-01-02563/29/2022

The increasing complexity of vehicle electronics and software is bringing an abundance of vehicle health related challenges, including quality issues and increasing costs of warranty claims, recalls, maintenance, and downtime. This negatively impacts both OEM and fleet profitability, user experience, and end customer costs. In order to reduce OEM costs and the total cost of ownership for consumers and fleets, new methods are needed to detect, predict, and diagnose vehicle health issues. Existing vehicle health management solutions rely on diagnostics trouble codes (DTC) and limited amounts of telematics data. These solutions can detect known failure modes using hard-coded signal behavior validation rules that are frequently based on thresholds. They also provide alerts based on pre-defined error codes. However, they are unable to detect and diagnose unforeseen failure modes that do not have hard-coded rules, nor can they prognose future vehicle health issues. By using deep learning

Apartsin, Sasha, Stein, Hilik, Reiter, Gil, Williams, Kyle W.

Influence of Motor and Controller Integration in Electric vehicle performance

2022-01-07803/29/2022

Electric vehicle performance is depending on many of the system level performance of the vehicle. Motor and controller are designed individually but booth are dependent and these systems affect directly to the vehicle performance by right integration approach. This approach is explained in this paper clearly and well defined and processed for the Motor design and controller design. The integration system process plotted by using Motor design indent and controller design indent. Motor and controller losses are considered for the effective vehicle performance which deals the efficiency of the Motor and control system. The improved version of Motor control integration gives 10% improvements in overall vehicle performance. This approach is shown and evaluated the Vehicle performance by efficient integration approach of Motor and controller. Key words – Electric Vehicle, Motors, Controller integration and Vehicle integration.

Neelakandan, Varatharaj, B, Prabakaran

An Integrated System to reduce Emissions from Industrial Naturally Aspirated Reciprocating Engine — Performance assessment of an Amperometric NOx/O2 Sensor.

2022-01-06973/29/2022

Emission reduction from Industrial naturally aspirated reciprocating engines (INARE) is of high priority to regulatory agencies due to their significant contribution to overall pollutant emissions. INAREs are well-known for their simplicity and are originally designed to work at some specific Air-to-Fuel ratios (AFRs). The AFR has been used as an effective parameter to control emissions in modern engines. However, such AFR control systems are not present in many INAREs. To solve this challenge, a novel, cost-effective retrofit kit is proposed in this paper that can be integrated with typical INAREs to control AFR and improve their performance and emissions at wide-ranging operating conditions. The retrofit kit comprises an air bypass mechanism integrated with a control unit and amperometric sensors adapted from the automobile industry. The amperometric sensors operate in the limiting current region, which enables the measurement of a wide range of NOx/O2 concentrations. This paper

Hassan, Hafiz Ahmad, Hartless, Matthew, Jha, Prabhat, Kazempoor, Pejman

A Simulation And Optimization Design Case for Heavy Truck Thermal Management

2022-01-02103/29/2022

In order to meet CHINA VI Emission Standard and high-horsepower engine system integration for fourth-stage fuel consumption standards, which will put higher heat load to the entire cooling system, Faw Jiefang is conducting development on vehicle thermal management technology system. This requires redesign of front grill and the underhood cooling system components such as, cooling airflow duct, and fan shroud. Simply increasing the cooling air mass flow rate could improve the overall cooling airflow system performance; however, it will also increase the fan power consumption and aerodynamic drag of the vehicle, which will lead to an increased fuel consumption and escalate emission. Hence, a multi-objective optimization towards engine cooling system is necessary to achieve desired cooling performance while maintaining or lowering aerodynamic drag. An accurate simulation methodology is a key component for this iterative design and optimization process, as it will expedite the development

Guo, Ping, Chen, Tao, Liao, Genghua, Yang, Yang, Li, Han, Friz, Heinz, Mukutmoni, Devadatta, Kandasamy, Satheesh

Design and Development Methodology of Automatic Electric Start System for Power Tiller

2021-26-00939/22/2021

This paper deals with designing and development methodology of Automatic Electric Start (AES) system for power tiller which has horizontal diesel engine as prime mover. Designing of AES system constitutes of designing of Starter Motor, Starter Motor Bracket, Flywheel Ring Gear, Battery, Electrical Circuit, Fan Alternator and then development these components as integrated system prototype. Unlikely tractor market, AES system are not so common in Indian power tiller market therefore, unprecedented design approach towards design of AES system on power tiller engine has been presented in this paper. An engine without AES system requires of huge amount of engine starting effort by farmer whereby farmers fatigue levels are always on higher side. AES system on power tiller has made 0 N force requirement to start engine which was approximately 92 N earlier. Design of AES system depends on analysis engine cranking torque, which is a complex process and involves calculation of moments, such as

singh, sahildeep, sakthiendran, s, kanase, kedar

Techniques to evaluate Energy Efficiency and Performance of an Electric Vehicle by leveraging Co-simulation

2021-26-03679/22/2021

After designing any Powertrain component/subsystem for a conventional or an Electric vehicle, System Energy efficiency and Performance improvement Simulations are an very important step to prove the worthiness of the product before we can go for Prototypes, Vehicle level Integration, Testing and benefit’s evaluation phases. This work describes how two simulation tools have been leveraged effectively for Energy efficiency and Performance simulations for an Electric vehicle. Schaeffler has an internal Physical modeling tool for building vehicle level models. This tool has readymade physical component blocks for various Mechanical and Electrical components. These blocks can be parameterized as per required specifications. The powertrain subsystems like the Battery, BLDC Motor, Vehicle Inertias and the Multi-speed transmission consisting of various mechanical elements have been modeled and parameterized using this tool. This tool is the front end of the Co-simulation. The Physical model is

Iyer, Ramkumar, Chen, Zhichao, SATYANARAYANA, PS, BHATTACHARJEE, ANTARA, JHA, NAVNEET, Ramalingam, Gomathi

Standard Practice for Habitability

SAE1007 (Historical)

9/14/2021

This Standard specifies the Habitability processes throughout planning, design, development, test, production, use and disposal of a system. Depending on contract phase and/or complexity of the program, tailoring of this standard may be applied. The primary goals of a contractor Habitability program include: Ensuring that the system design complies with the customer Habitability requirements and that discrepancies are reported to management and the customer. Identifying, coordinating, tracking, prioritizing, and resolving Habitability risks and issues and ensuring that they are: ○ Reflected in the contractor proposal, budgets, and plans ○ Raised at design, management, and program reviews ○ Debated in Working Group meetings ○ Coordinated with Training, Logistics, and the other HSI disciplines ○ Included appropriately in documentation and deliverable data items Ensuring that Habitability requirements are applied to all personnel environments, including operators, maintainers, trainers

G-45 Human Systems Integration

Standard Practice for Habitability

SAE1007-TEST-REC (Historical)9/14/2021

G-45 Human Systems Integration

EW: New Challenges, Technologies, and Requirements

21AERP08_058/1/2021

Now a critical part of worldwide defense strategy, Electronic Warfare (EW) must continually adapt in order to meet new threats. To do so, new technology together with emerging standards must be incorporated into EW system designs. Key elements of EW systems are now often combined within a single component, such as the RF System-on-Chip (RFSoC), including signal acquisition, processing, and generation. Hardware, firm-ware, and software have become more complex, increasing risk and expense, and thereby increasing the need for effective, high-level development tools.

Reimagining Automated Test During a Pandemic

21AERP08_048/1/2021

As we learned during the COVID-19 pandemic, aerospace and defense companies must continue to move forward and find workarounds to design, develop and test their products or systems. Engineers hit the challenge of how to build and test integrated hardware and software systems under pandemic-induced travel limitations. This challenge has also helped many test system suppliers question and reevaluate their own procedures and processes and look for smart improvements they can make to help drive key deliverables, such as quality, satisfaction, security and their own green credentials, creating a new, diverse and more inclusive normality when supplying solutions to their customers. How to make these changes remotely has meant ReEmagineering each area of test system design, build, validation and test.

Air Launched Effects Payload and Air Vehicle Integration

F-0077-2021-16823

5/10/2021

ABSTRACT

Lengyel, J., Sosa, Patrick

Human Engineering - Principles and Practices

HEB1D (Current)

4/14/2021

This Engineering Bulletin and its annexes provide guidance on the application of Human Engineering principles and practices to the analysis, design, development, testing, fielding, support, accident investigation, and training for military and commercial products throughout their intended life cycles.

G-45 Human Systems Integration

Development of High-Pressure Hydrogen Storage System for New FCV

2021-01-07414/6/2021

This paper describes the high-pressure hydrogen storage system developed for new FCV. With the aim of further popularizing FCVs, this development succeeded in improving the performance of the system and reducing costs. This new storage system consists of multiple tanks of different sizes, which were optimized to store the necessary amount of hydrogen without sacrificing the interior space of the vehicle. The new tanks achieved one of the highest volume efficiencies in the world by adopting high-strength carbon fiber, developed in conjunction with the carbon fiber manufacturer, and by optimizing the layered construction design which allowed the amount of carbon fiber to be reduced. To increase the amount of available hydrogen, the longer high pressure tanks were mounted under the vehicle floor unlike the previous model. This was accomplished by the following two measures: First, individual design and manufacturing measures for the tanks were adopted. The liner shape was optimized to

Yahashi, Hiroki, Yamashita, Akira, Shigemitsu, Nozomu, Goto, Sogo, Kida, Koji, Inou, Takashi

Systems Engineering Capability Model

EIA731_1A (Current)

3/16/2021

The purpose of this Standard is to support the development and improvement of systems engineering capability.

G-47 Systems Engineering

Mathematical Programming for Optimization of Integrated Modular Avionics

2021-01-00093/2/2021

Every state-of-art aircraft has a complex distributed systems of avionics Line Replaceable Units/Modules (LRUs/LRMs), networked by several Data buses. These LRUs are becoming more complex because of an increasing number of new functions need to be integrated into avionics architecture. Moreover, the complexity of the overall avionics architecture and its impact on cable length, weight, power consumption, reliability and maintainability of avionics systems encouraged manufacturers to incorporate efficient avionics architectures in their aircraft design process. The evolution of avionics data buses and architectures have moved from distributed analog and federated architecture to digital integrated modular avionics (IMA). IMA architecture allows suppliers to develop their own LRUs/LRMs capable of specific features that can then be offered to Original Equipment Manufacturers (OEMs) as Commercial-Off-The-Shelf (COTS) products. In the meantime, the aerospace industry has been investigating

Radaei, Mohammad

Single-Use Applications Maximize Biomanufacturing Agility

TBMG-3806611/1/2020

Biopharmaceutical manufacturing is changing. With the rise of biologics and personalized medicine, the industry is appreciating the single-use manufacturing style. Instead of large-scale production processes, manufacturers are finding it pays to be agile — which is why many are increasingly adopting single-use technologies to turn over new products and batches quickly and efficiently. Single-use technologies utilize disposable bioprocessing equipment in place of traditional stainless steel. By eliminating the time-consuming clean-in-place (CIP) and steam-in-place (SIP) processes between batches, single-use technologies cut down on the costs of labor, materials, and utilities — all while shortening time to market.

Bell V-280 System Identification and Model Validation with Flight Test Data using the Joint Input-Output Method

F-0076-2020-16393

10/5/2020

With modern aerospace vehicle configurations, highly-coupled redundant flight control surfaces are becoming standard practice. For such vehicles, traditional System Identification (SID) methods may not accurately capture the individual contributions of effectors to the vehicle bare-airframe response. A Joint Input-Output (JIO) methodology was used to estimate the control power for each highly-correlated roll effector of the Bell V-280 hover configuration. The methodology was demonstrated using flight test data, where the identification results were compared to a high-fidelity hardware-in-the-loop simulation in the V-280 System Integration Lab.

Berrigan, Caitlin, J., Mark, Prasad, J.V.R., Ruckel, Paul

Laser Wire Additive Manufacturing System

TBMG-3789110/1/2020

ADDere Additive Manufacturing Waukesha, WI 414-327-0000

Integrated Microchips for Electronic Skin

TBMG-3780110/1/2020

Human skin allows for interfacing with external physical environments through numerous receptors interconnected with the nervous system. Scientists have been trying to transfer these features to artificial skin, aiming at robotic applications. Operation of robotic systems heavily relies on electronic and magnetic field sensing functionalities required for positioning and orientation in space.

Standard Practice for Manpower and Personnel

SAE1010 (Historical)

9/18/2020

This Standard covers Manpower and Personnel (M&P) processes throughout planning, design, development, test, production, use, and disposal of a system. Depending on contract phase and/or complexity of the program, tailoring can be applied. The scope of this standard includes Prime and Sub-contractor M&P activities; it does not include Government M&P activities. The primary goals of a contractor M&P program typically include: Ensuring that the system design complies with the latest customer manpower estimates (numbers and mix of personnel, plus availability) and that discrepancies are reported to management and the customer. Ensuring that the system design is regularly compared to the latest customer Personnel estimates (capabilities and limitations) and that discrepancies are reported to management and the customer. Identifying, coordinating, tracking, and resolving M&P risks and issues and ensuring that they are: ○ Reflected in the contractor proposal, budgets, and plans. ○ Raised at

G-45 Human Systems Integration