Browse Topic: Simulation and modeling

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Development and Validation of a Reduced Order Model Incorporating a Semi-Empirical Degradation Model for Pouch Type LiFePO 4 /Graphite Cells2017-01-121804/23/2025
We propose a reduced order model (ROM) for LFP/graphite cells derived from the electrochemical thermal principles that considers degradation effects and validated against experimental data obtained from a large format pouch type LFP/graphite cell whose nominal capacity is 20Ah. The characteristics of the two-phase transition and path dependence were taken into account in the ROM using a shrinking-core model with a moving interface that presents lithium rich and deficient phase. Different currents (0.1/1/3/4C) were applied to fresh cells at different ambient temperatures (25/35/45°C). Comparison between simulated results of the ROM and the collected experimental data shows a good match. The path dependence was also analyzed experimentally. For degradation model, side reaction is treated as the predominant cause of degradation of cells, which are affected by the operating conditions, such as temperature and SOC cycling range. At every 30 or 40 cycles, the capacity and impedance of five
ZHAO, XINCHEN, Bi, Yalan, Choe, Song-Yul
Journal Article
Virtual Calibration Approach to the Development of Control Systems and Strategies for Hybrid L-Category Vehicles2024-32-006604/18/2025
Hybrid powertrain for motorcycles has not been widely adopted to date but has recently shown significant increased interest and it is believed to have great potential for fuel economy containment in real driving conditions. Moreover, this technology is suitable for the expected new legislations, reduced emissions and enables riding in Zero Emissions Zones, so towards a more carbon neutral society while still guaranteeing “motorcycle passion” for the product [1, 2]. Several simulation tools and methods are available for the concept phase of the hybrid system design, allowing definition of the hybrid components and the basic hybrid strategies, but they are not able to properly represent the real on-road behaviour of the hybrid vehicle and its specific control system, making the fine tuning and validation work very difficult. Motorcycle riders are used to expect instant significant torque delivery on their demand, that is not properly represented in legislative cycles (e.g. WMTC); rider
Antoniutti, Christian, Sweet, David, Hounsham, Sandra
Technical Paper
3D-CFD Simulations of H2 ICEs: A Preliminary Evaluation of a Laminar Flame Speed Correction for Thermo-Diffusive Instability2024-32-007404/18/2025
In recent years, climate change and geopolitical instability have intensified the focus on sustainable power generation. This shift seeks alternatives that balance environmental impact, cost-effectiveness, and practicality. Specifically, in transportation and power generation, electric motors face challenges against internal combustion engines due to the high cost and mass of batteries required for energy storage. This makes electric solutions less favorable for these sectors. Conversely, internal combustion engines, when properly fueled, offer cost-effectiveness and a quasi-environmentally-neutral option. To address these challenges, researchers have explored e-fuels derived from renewable sources as a carbon-neutral supply for internal combustion engines. Among these, hydrogen is particularly promising. In hydrogen-powered internal combustion engines, 3D-CFD (Computational Fluid Dynamics) in-cylinder models are crucial. Once validated, these models can speed up the design process. A
Sfriso, Stefano, Berni, Fabio, Breda, Sebastiano, Fontanesi, Stefano, Cordisco, Ilario, Leite, Caio Ramalho, Brequigny, Pierre, Foucher, Fabrice
Technical Paper
Novel Statistical Modelling-Based Approach for Exhaust Mass Flow Calculation in Motorcycles2024-32-007204/18/2025
The exhaust mass flow measurement for motorcycles poses a unique challenge due to presence of pulsations arising from an unfavorable combination of the engine displacement-to-exhaust system volume ratio and the long or even unequal ignition intervals. This pulsation phenomenon significantly impacts the accuracy of the differential pressure-based measurement method commonly employed in on-board measurement systems for passenger cars. This paper introduces an alternative approach calculating exhaust mass flow in motorcycles, focusing on statistical modelling based on engine parameters. The problem at hand is rooted in the adverse effects of pulsations on the differential pressure-based measurement method used in the EFM. The unfavorable combination of engine characteristics specific to motorcycles necessitates a novel approach. Our proposed alternative involves utilizing readily available OBD parameters, namely engine speed and calculated engine load as there is mostly no data for intake
Schurl, Sebastian, Sturm, Stefan, Schmidt, Stephan, Kirchberger, Roland
Technical Paper
Representative Point of Measurement of Engine ECU and Effect of Vortices and Ambient Wall on Forced Air-Cooling2024-32-003604/18/2025
The Electric Control Unit (ECU) is a crucial computing unit responsible for engine regulating various functions. However, non-airflow thermal design due to the complexity of engine bay turbulent flow simulation is limiting ECU’s potential with the increasing demand of computation power consumption, thermal design faced additional challenges. Moreover, the lack of standardized ECU design guidelines forced substantial investments in customized thermal solutions for different engine bay packaging. Through this research, the method of finding representative points of ambient temperature efficiently and reliably is investigated, so that thermal design can be achieved by estimating flow properties during the ECU design stage efficiently. This research involves studying the effects of airflow on ECU cooling using experimental and numerical analysis in Computational Fluid Dynamics (CFD). Alongside the representative points of ambient temperature uncovered from the numerical result
Zhong, Jiajun, Inaba, Kazuaki, Yamaguchi, Ryota, Yasui, Ryuta, Umeno, Masafumi
Technical Paper
Enhancements in Hydrogen Low Pressure Injection on Small Two-Stroke Engines2024-32-004704/18/2025
The use of small 2-stroke crankcase scavenged engines running on hydrogen is very attractive for low power rates, when low cost and compact dimensions are the fundamental design constraints. However, achieving optimal performance with hydrogen fuel presents challenges, including uneven air-fuel mixtures, fuel losses, and crankcase backfiring. This research focuses on a small 50cc 2-stroke loop-scavenged engine equipped with a patented Low-Pressure Direct Injection (LPDI) system, modified for hydrogen use. Experimental results demonstrate performance comparable to the gasoline counterpart, but further optimizations are needed. Consequently, CFD-3D simulations are employed to analyses the injection process and guide engine development. The numerical analysis focuses on a fixed operating condition: 6000 rpm, Wide Open Throttle (WOT), with a slightly lean mixture and injection pressure fixed at 5 bar. A numerical model of the entire engine is set up with the primary objective of improving
Caprioli, Stefano, Schoegl, Oliver, Oswald, Roland, Kirchberger, Roland, Mattarelli, Enrico, Rinaldini, Carlo Alberto
Technical Paper
DoE-Based Numerical Optimization of Intake and Exhaust Port Geometry of a Small Opposed-Piston 2-Stroke (OP2S) Hydrogen Engine2024-32-005404/18/2025
The future potential of an opposed-piston two-stroke (OP2S) engine has attracted the attention of researchers worldwide as it offers a high thermal efficiency and power-to-weight ratio with a simple engine configuration. This engine can be used with low-carbon fuels and hydrogen to reduce greenhouse gas emissions. However, the two-stroke operation has always been limited by its low scavenging efficiency and short-circuit of fresh charge. The current work is focused on optimizing scavenging efficiency and short-circuit in a small 200 cc single-cylinder OP2S SI engine using 3-D computational fluid dynamic (CFD) simulations. The effect of four parameters, namely, area of intake ports, area of exhaust ports, and angular orientations of intake ports (swirl and tilt) on scavenging efficiency and short-circuit, has been assessed and optimized. A Latin-hypercube based Design of Experiments (DoE) methodology is used to sample the design space spanning over a range of four parameters. A response
Singh, Saurabh, Boggavarapu, Prasad, Himabindu, M., Ravikrishna, R.V.
Technical Paper
Predictive Battery Thermal Management System Control Strategy and Simulation in Electric Vehicle2025-01-502704/03/2025
With the global issue of fossil fuel scarcity and the greenhouse effect, interest in electric vehicles (EVs) has surged recently. At that stage, because of the constraints of the energy density and battery performance degradation in low-temperature conditions, the mileage of EVs has been criticized. To guarantee battery performance, a battery thermal management system (BTMS) is applied to ensure battery operates in a suitable temperature range. Currently, in the industry, a settled temperature interval is set as criteria of positive thermal management activation, which is robust but leads to energy waste. BTMS has a kilowatt-level power usage under high- and low-temperature environments. Optimizing the BTMS control strategy becomes a potential solution to reduce energy consumption and overcome mileage issues. An appropriate system simulation model provides an effective tool to evaluate different BTMS control strategies. In this study, a predictive BTMS control strategy, which adjusts
Huang, Zhipei, Chen, Jiangbo, Tang, Hai
Technical Paper
Optimization of the Numerical Spray Modeling for Polyoxymethylene Dimethyl Ethers for Combustion Prediction in CONVERGE2025-01-502604/03/2025
Different approaches are undertaken to mitigate the impact of the transport sector on climate change. Alongside electrifying powertrains, sustainable e-fuels such as polyoxymethylene dimethyl ethers (OME) are considered a promising bridging technology for different applications. However, this requires that the engines are optimized for the new fuels. Accordingly, this study aims to optimize the numerical spray modeling of OME in CONVERGE. Based on the KH–RT break-up model, the spray simulations of three different commercial injectors for heavy-duty applications are analyzed regarding the predictability of the liquid and gaseous penetration lengths and the total simulation time. A sensitivity analysis is conducted for the turbulence model, mesh size, and spray parameters prior to optimizing the spray model and validating it with experimental results. While each parameter individually influences the different phases of the injection event, the sensitivity analysis reveals that the break
Zepf, Andreas, Härtl, Martin, Jaensch, Malte
Technical Paper
System Configuration and Validation of Hybrid-Based Six Degrees of Freedom Motion Platform for Vehicle Dynamic Testing2025-01-502103/27/2025
Scenario-based testing has become one of the important elements to evaluate the performance of automated vehicle systems before deploying on actual road. There are several approaches that can be used to conduct scenario-based testing via simulation approach. One of the important aspects in scenario-based safety testing is the driver-in-the-loop (DiL) simulation where it involves integration of hardware and human interaction. Therefore, motion platform-based vehicle driving simulators are commonly used for the DiL simulation for scenario-based testing. Generally, a high degree of freedom driving simulator is used for scenario-based testing such as 6 degrees of freedom (DoF) to achieve high accuracy to represent an actual vehicle response. Moreover, most of the motion platforms are designed using hexapod configuration, which also contributes to 6-DoF. However, this type of design requires large space to conduct the testing because the field of motion (FoM) is high in three axes and high
Kleolee, KahOnn, Aparow, Vimal Rau, Cheok, Jun Hong, de Boer, Niels, Jamaluddin, Hishamuddin
Technical Paper
Analysis of Left-Turn Mixed Traffic Flow Dynamics at Y-Shaped Signalized Intersections Using Cellular Automata2025-01-720402/21/2025
Through the method of on-site video observation, this study divides the intersection area into three parts according to the road traffic characteristics of the Y-shaped signalized intersections, and at the same time obtains the relevant parameters. These parameters include the left-turn speed and traffic density of motor vehicles within both the internal and exit areas, the frequency of lane-changing and queuing behaviors of non-motorized vehicles in the internal area, and the left-turn speed and traffic density of non-motorized vehicles in both the internal and exit areas. The data extraction and analysis of the parameters provide strong data support for further analysis of the subsequent mixed traffic flow. A cellular automaton model is developed using the intersection’s exit area as the scenario. The exit area is divided into three lanes based on the queuing patterns of mixed traffic. Corresponding traffic rules are established according to the traffic density of motorized and non
Yuan, Li, Liu, Xiaowei
Technical Paper
Automatic Detection of Dead-End Roads in High-Resolution Satellite Image2025-01-716502/21/2025
There are dead-end roads in the road network, and many of them have the function of indicating specific target clues, which is of great significance in the fields of military, urban construction, and disaster relief and rescue. However, many of the important cut-offs are in mountainous or wilderness areas, and surveying them is difficult and costly. The research objective of this project is to extract the breakpoints in the road network using high-resolution Google satellite imagery, so as to provide clues and indications for the subsequent relevant work. Firstly, the image is corrected and pre-processed to highlight road edge information.Then the phase grouping method is improved by setting a double-angle threshold, filtering the edge operator to reduce the calculation error of the gradient angle, and the road network is extracted by the improved phase grouping method. And finally screens out the dead-end road points with the eight-neighbourhood method, and marks them on the
Liu, Ruohan, Haoping, Qi, Jingjie, Kang, Yanyan, Wu, Feifei, Li
Technical Paper
Nonlinear Joint Dynamic Estimator of Sideslip Angle and Tire-Road Peak Adhesion Coefficient Based on Improved Brush Tire Model2024-01-703312/13/2024
The sideslip angle and tire-road peak adhesion coefficient (TRPAC) are crucial parameters for intelligent active safety systems in automobiles. The accuracy and real-time estimation of these parameters significantly affect control effectiveness. And there is a strong coupling between the two parameters, which brings great challenges to the joint estimation. This paper proposes a nonlinear dynamic estimator that pre-estimates tire lateral force to achieve synchronous estimation of sideslip angle and TRPAC. Additionally, to cope with sudden changes in road adhesion condition, a TRPAC preliminary estimation optimization algorithm is introduced. Moreover, an adaptive gain adjustment algorithm for the sideslip angle estimator is implemented to address large lateral excitation conditions. Simulation results on various road surfaces and under various lateral excitation conditions demonstrate that the proposed joint estimator enables accurate and rapid estimation of sideslip angle and TRPAC.
Zhao, Wenrui, Leng, Bo, Han, Yinfeng, Yu, Zhuoping, Xiong, Lu
Technical Paper
Modeling and Analyzing Inter-Satellite Relative MotionTBMG-5219712/01/2024
From a mission operations perspective, swarms pose a planning challenge due to the limited scalability of ground operations. The capabilities needed to support swarm missions go beyond operator-specified geometry, alignment, or separation, but also crosslink communication with maintaining position in the formation. To address scalable control of orbital dynamics, NASA Ames Research Center has patented Swarm Orbital Dynamics Advisor (SODA) — a solution that accepts high-level configuration commands and provides the orbital maneuvers needed to achieve the desired type of swarm relative motion.
Magazine Article
Mastering Physical Contact with New Algorithm for RobotsTBMG-5218112/01/2024
Penn Engineers have developed a new algorithm that allows robots to react to complex physical contact in real time, making it possible for autonomous robots to succeed at previously impossible tasks, like controlling the motion of a sliding object.
Magazine Article
SCENE ADJUSTMENT TOOLS FOR AUTONOMY SIMULATION2024-01-400511/15/2024
ABSTRACT This paper introduces a set of Simulation Scene Adjustment Tools which allow users to adjust relevant geo-environmental parameters to create an unlimited number of new scenes that are based on, and share relevant characteristics with, the original. We also introduce a set of novel quantitative metrics that compare the simulation scenes from the perspective of an automated vehicle system. These tools are useful for automated vehicle development and testing to alleviate the problem of having only a few simulation scenes with which to prove out the system. Citation: J. Auchter, R. Brothers, D. Beer, “Scene Adjustment Tools for Autonomy Simulation,” In Proceedings of the Ground Vehicle Systems Engineering and Technology Symposium (GVSETS), NDIA, Novi, MI, Aug. 15-17, 2023.
Auchter, Joseph, Brothers, Robert, Beer, Daniel
Technical Paper
THE ARMY’S NEED FOR COGNITIVE ENGINEERING2024-01-310811/15/2024
ABSTRACT Imagine Soldiers reacting to an unpredictable, dynamic, stressful situation on the battlefield. How those Soldiers think about the information presented to them by the system or other Soldiers during this situation – and how well they translate that into thinking into effective behaviors – is critical to how well they perform. Importantly, those thought processes (i.e., cognition) interact with both external (e.g., the size of the enemy force, weather) and internal (e.g., ability to communicate, personality, fatigue level) factors. The complicated nature of these interactions can have dramatic and unexpected consequences, as is seen in the analysis of military and industrial disasters, such as the shooting down of Iran Air flight 655, or the partial core meltdown on Three Mile Island. In both cases, decision makers needed to interact with equipment and personnel in a stressful, dynamic, and uncertain environment. Similarly, the complex and dynamic nature of the contemporary
McDowell, Kaleb, Zywiol, Harry J.
Technical Paper
SIMULATION FOR VEHICLE-TO-VEHICLE AND VEHICLE-TO-GRID RESOURCE SHARING ANALYSIS2024-01-344411/15/2024
ABSTRACT A simulation capable of modeling grid-tied electrical systems, vehicle-to-grid (V2G) and vehicle-to-vehicle(V2V) resource sharing was developed within the MATLAB/Simulink environment. Using the steady state admittance matrix approach, the unknown currents and voltages within the network are determined at each time step. This eliminates the need for states associated with the distributed system. Each vehicle has two dynamic states: (1) stored energy and (2) fuel consumed while the generators have only a single fuel consumed state. One of its potential uses is to assess the sensitivity of fuel consumption with respect to the control system parameters used to maintain a vehicle-centric bus voltage under dynamic loading conditions.
Jane, Robert S., Parker, Gordon G., Weaver, Wayne W., Goldsmith, Steven Y.
Technical Paper
Vehicle-Level Control Systems Framework for Use in Create-GV Vehicle Dynamics Simulations2024-01-410709/16/2024
Abstract This paper presents a software framework developed for the simulation of vehicle-level control systems for modern (existing or conceptual) ground vehicles, targeted for high-performance platforms (Linux clusters). The framework augmented existing ground vehicle simulation environments (such as CREATE-GV MERCURY or other object-oriented software packages) making it possible to perform a comprehensive evaluation of a ground vehicle’s performance when equipped with vehicle level controllers to determine the effectiveness of the control systems on the vehicle. The framework, implemented as part of the PACE (Powertrain Analysis Computational Environment), was comprised of software components (a C++ objects library) simulating various vehicle-level controllers, an Application Programming Interface for the development of new components to be used within the framework, and C++ code for integrating these components into simulations of control systems within a ground vehicle simulation
Jelinek, Bohumir, Henley, Greg, Card, Angela, Hannis, Tyler, Gibson, Michael, Priddy, Jody, Boyle, Sara, Figueroa-Santos, Miriam, Mange, Jeremy
Technical Paper
EDITORIAL: It's not nothing, man24AUTP06_0406/01/2024
Mathematicians, hold your ire. There's a hidden message in this issue that there's no difference between zero and infinity. Let me explain. In mid-May, I attended VI-Grade's Zero Prototype Summit (ZPS). As the name suggests, the company - like so many others working in the test simulation space - is trying to provide OEMs and suppliers with the tools to reduce the number of physical prototypes that have to be developed and built before those vehicles or components reach production-ready status. We haven't yet entered the zero-prototype automotive world, but we're getting closer. You can find detailed ZPS coverage starting on page 22.
Blanco, Sebastian
Magazine Article
Machine-Learning-Accelerated Simulations for the Design of Airbag Constrained by Obstacles at Rest2023-22-000103/04/2024
Abstract Predicting airbag deployment geometries is an important task for airbag and vehicle designers to meet safety standards based on biomechanical injury risk functions. This prediction is also an extraordinarily complex problem given the number of disciplines and their interactions. State-of-the-art airbag deployment geometry simulations (including time history) entail large, computationally expensive numerical methods such as finite element analysis (FEA) and computational fluid dynamics (CFD), among others. This complexity results in exceptionally large simulation times, making thorough exploration of the design space prohibitive. This paper proposes new parametric simulation models which drastically accelerate airbag deployment geometry predictions while maintaining the accuracy of the airbag deployment geometry at reasonable levels; these models, called herein machine learning (ML)-accelerated models, blend physical system modes with data-driven techniques to accomplish fast
Valenzuela del Rio, Jose E., Lancashire, Richard, Chatrath, Karan, Ritmeijer, Peter, Arvanitis, Elena, Mirabella, Lucia
Journal Article
Machine-Learning-Accelerated Simulations for the Design of Airbag Constrained by Obstacles at Rest2023-22-0001-TEST-REC03/04/2024
Abstract Predicting airbag deployment geometries is an important task for airbag and vehicle designers to meet safety standards based on biomechanical injury risk functions. This prediction is also an extraordinarily complex problem given the number of disciplines and their interactions. State-of-the-art airbag deployment geometry simulations (including time history) entail large, computationally expensive numerical methods such as finite element analysis (FEA) and computational fluid dynamics (CFD), among others. This complexity results in exceptionally large simulation times, making thorough exploration of the design space prohibitive. This paper proposes new parametric simulation models which drastically accelerate airbag deployment geometry predictions while maintaining the accuracy of the airbag deployment geometry at reasonable levels; these models, called herein machine learning (ML)-accelerated models, blend physical system modes with data-driven techniques to accomplish fast
Valenzuela del Rio, Jose E., Lancashire, Richard, Chatrath, Karan, Ritmeijer, Peter, Arvanitis, Elena, Mirabella, Lucia
Journal Article
Longitudinal Air-Breathing Hypersonic Vehicle Nonlinear Dynamic Simulation with Different Control Inputs01-17-02-001503/04/2024
The air-breathing hypersonic vehicle (AHV) holds the potential to revolutionize global travel, enabling rapid transportation to low-Earth orbit and even space within the next few decades. This study focuses on investigating the nonlinear dynamic simulation, trim, and stability analysis of a three-degrees-of-freedom (3DOF) longitudinal model of a generic AHV for variable control surface deflection,and. A simulation is developed to analyze the burstiness of the AHV’s nonlinear longitudinal behavior, considering the complete flight envelope across a wide range of Mach numbers, from= 0 to 24, for selected stable. The presented simulation assesses trim analysis and explores the dynamic stability of the AHV through its flight envelope and bifurcation method analysis is carried out to gain insight and validate the dynamic stability using eigen value approach.
Singh, Ritesh, Prakash, Om, Joshi, Sudhir, Sharma, Rakesh Chandmal
Journal Article
Reduction of Gearbox noise by optimizing Gear micro geometry2024-26-023401/16/2024
Vehicle noise level has to be maintained within the limit specified by Pass By Noise (PBN) standards to meet the regulatory requirements. Gearboxes and engines are the main sources of noise in a vehicle, owing to the mechanical and physical processes involved. The noise problem in transmission system is characterized by high amplitude acoustic signals, and the gear mesh noise can be indirectly estimated using the Transmission error parameter. Transmission error is defined as the difference between the actual position of the output gear and the position it would occupy if the gear drive were perfect, which can be attributed to various factors such as tooth profile errors, misalignment, and tooth deflections. A six-speed manual transmission commercial vehicle is observed to exhibit higher noise levels during the vehicle PBN test. The gearbox is modelled in Romax gearbox simulation software and the transmission error value is identified to be high. The micro geometry parameters lead
G R, Santosh Kumar, Ks, Dhianeshwar, Basim, K Mohammed
Technical Paper
Study of Critical Vias Design Parameters for Power Electronics Thermal Management2024-26-031701/16/2024
With the advent of wide band gap semiconductor devices like SiC based MOSFETs/Diodes, there is a growing demand for utilizing electrical power instead of the conventional fuel-based power generation in both automotive and aerospace industry. In automotive/aerospace industry the focus on electrification has resulted in a need for sub-systems like inverters, power distribution units, motor controllers, DC-DC converters that actively utilize SiC based power electronics devices. To address the growing power density requirements for electronics in next generation product families, more efficient & reliable thermal management solution plays a critical role. The effective thermal management of the power electronics is also critical aspect to ensure overall system reliability. The conventional thermal management system (TMS) optimization targets heat sink/ cold plate design parameters like fin spacing, thickness, height etc. or sizing of the required cooling pump/fan. This paper focuses on
Bhardwaj, Divyanshu, Patil, Sachin, Datta, Sauradeep, Pawar, Sunny, Dougherty, Derek
Technical Paper
Soot sensor elimination with DPF substrate failure monitoring.2024-26-015301/16/2024
The automobile industry is going through one of the most challenging times, with increased competition in the market which is enforcing competitive prices of the products along with meeting the stringent emission norms. One such requirement for BS6 phase 2 emission norms is the inclusion of PM (Soot) sensor in diesel passenger cars. PM sensor detects soot leakage in case of DPF substrate failure. There is a cost factor along with extensive calibration efforts which are needed to ensure sensor works flawlessly. This paper deals with the development of an algorithm with which robust detection of DPF substrate failure is achieved. In order to achieve this, a thermodynamic model of DPF substrate was created using empirical relations between parameters like exhaust flow rate, exhaust gas temperature and soot mass content. The modeling was done in both empty (no soot) and filled (threshold soot content) substrate conditions. There were two methodologies, namely integration method and
Jain, Praveer Kirtimohan, Yadav, Omkar, Chendil, Chellapandi
Technical Paper
A New Holistic Approach for System-Level Development of Seat Features2024-26-038101/16/2024
System engineering-based approach is now ubiquitous in the automotive industry. It is a disciplined approach that ensures that targets are clearly defined and met through a structured and holistic approach. In this paper, we report an application of a systems engineering-based methodology for developing seating system features. It starts with a Business Requirement Document (BRD), which enlists the business requirements of a feature. We then developed a Logical Architecture Diagram (LAD) on a Simulink environment, which serves as an initial proposal for the design of the logic that would realize the desired functionality. As a next step, we perform Functional Failure Analysis (FFA) on the LAD to identify potential failure modes. We propose a few ways to mitigate the identified failures or modify the design so that these failures are rendered inconsequential to the end user. Based on the updated LAD, a System Requirement Document (SRD) is created, which contains all the requirements
Ghosh, Soumik, Vidhu, Nandagopal
Technical Paper
Detailed Tire-Wheel modelling for crash related development in LS-Dyna2024-26-037601/16/2024
Vehicle performances in Crash related events like Small offset rigid barrier tests are crucially dependent on Tire-Wheel modelling. The objective of this study is to develop a detailed tire-wheel model subjected to loading, performance and failure criteria. The modelling technique should be robust, replicable and stable across a wide spectrum of simulations cutting down on unnecessary delays. This project evaluates the options offered in LS-dyna (damping, loads, sensors, materials etc.) and current states of models being widely used. There is a focus on offering additional tools in the model for analyst to control the failure and model behaviour. This tire-wheel model is subjected to scrutiny at multiple levels namely standalone, sub-system and full vehicle. The results achieved on this new modelling technique shows confidence in this. This model checks all the right boxes in terms of robustness, efficiency and development. The correlation is better on subsystem level tests. Tire-wheel
Sirohi, Yograj
Technical Paper
3-D Multiphase Flow Simulation of Coolant Filling and Deaeration Processes in an Engine Coolant System2024-26-031001/16/2024
The thermal performance of an engine coolant system is efficient when the engine head temperature is maintained within its optimum working range. For this, it is desired that air should not be entrapped in the coolant system which can lead to localized hot spots at critical locations. However, it is difficult to eliminate the trapped air pockets completely. So, the target is to minimize the entrapped air as much as possible during the coolant filling and deaeration processes, especially in major components such as the radiator, engine head, pump, etc. The filling processes and duration are typically optimized in an engine test stand along with design changes for augmenting the coolant filling efficiency. However, it is expensive and time-consuming to identify air-entrapped locations in tests, decide on the filling strategy and make the design changes in the piping accordingly. In the current effort, a simulation-based testing method for coolant filling and deaeration processes is
Khandagale, Vitthal, Pasunurthi, Shyam Sundar, Maiti, Dipak, Bollu, Theja, Saha, Rohit
Technical Paper
Thermal Design & Multi-Objective Optimization of On-Board Chargers in Electric Vehicles2024-26-030401/16/2024
For the foreseeable future, On-Board Charging will be a critical feature for all EVs, as it allows greater flexibility when charging vehicles from common power points and dedicated EVSEs. The OBC (On-Board Charger) has no function while the vehicle is moving; at the same time, heavy or large OBC reduces range. So, designers must design OBCs that are both energy efficient and lightweight. In addition to surviving the rigors of the automotive environment, such as heat and vibrations, they must also be cost-competitive. Designing OBCs encapsulating multiple objectives thus becomes a necessity. However, current methods often use the "most important" objective and transform other objectives into constraints that do not truly reflect the tradeoffs among all possible designs. Simulating Multi-Objective Optimization methods allow for an in-depth exploration of the solution and tradeoffs. This current work proposes a comprehensive thermal design approach based on modeling and simulation to
Vadladi, Amrutha Lakshmi, Ravikrishna, K V S, Gangrade, Akashdeep, Tata, Srikanth, Jadhav, Shantaram
Technical Paper
Integrated Testing Platform for Complete ECU Software Validation2024-26-034001/16/2024
In today's scenario EE software validation phase in the automotive software development cycle uses three different testing environments (Verification uses Model In Loop (MIL), function validation uses Software In Loop (SIL), HW and system level tests uses Hardware In Loop (HIL), & system testing uses Vehicle). Each of these platforms are highly expensive to deploy & maintain and poses major constraints in directly comparing the test results across platforms due to the difference in test reporting structures. It is also noticed that there is high redundancy or overlapping of test cases and timely availability of these platforms for timely SW releases. The solution helps in combining MIL, SIL & HIL testing stages into one single "Integrated Testing Platform" which eventually saves testing time, effort & cost along with early bug detection during software development phase. With the reuse of relevant compatible test-cases, test-case redundancy is eliminated thus reducing total man-hours
Jain, Nayank, N T, Savitha, G, Sudip, BHOGENAHALLY LAKSHMINARAYANA, ANUROOPA, Manish, Kumar
Technical Paper
A Novel Method to Select Hyperparameters of The DBSCAN Algorithm for RADAR Applications2024-26-003001/16/2024
Abstract- As the automotive industry is coming up with various ADAS solutions, RADAR is playing an important role. There are many parameters concerning RADAR detections to acknowledge. Unsupervised Clustering methods are used for RADAR applications. DBSCAN clustering method which is widely used for RADAR applications. The existing clustering DBSCAN is not aligned very well with its hyperparameters such as epsilon (the radius within which each data point checks the density) and minimum points (minimum data points required within a circle to check for core point) for which a calibration is needed. In this paper, different methods to choose the hyperparameters of DBSCAN are compared and verified with different clustering evaluation criteria. A novel method to select hyperparameters of the DBSCAN algorithm is presented with the paper. For testing the given algorithm, ground truth data is collected, and the results are verified with MATLAB-Simulink. Keywords- (clustering, DBSCAN, DBSCAN
Payghan, Vaibhav Santosh, Prajapati, Miit, Chauhan, Abhisha
Technical Paper
Digital evaluation of mirror (IRVM & ORVM)2024-26-026401/16/2024
Abstract This paper provides the required projection, mirror locations, contours, and curvature area calculation in the design phase. Similarly, we can also do measurements of the driver's head and eye locations by looking into each mirror. This method can be applied to passenger cars, light & heavy trucks. The required projected area can be calculated by using simulation and modeling software (CATIA), and further projected area of ORVM and IRVM can be fulfilled by modifying the size and shape of the mirror as per the requirements. Rotation and position can be controlled by rays from the manikin's eye to the edge of the ORVM/IRVM and helps control the blind zone. ORVM & IRVM fitment in vehicle is carried out with the help of AIS standards (automotive industrial standards) in INDIA. According to the AIS standards, there are specific measurements as per the class of vehicle. For example: AIS-002 (Part 1) (Rev. 1):2011 Automotive Vehicles - Approval of Devices for Indirect Vision intended
Dias, Francis Anton
Technical Paper
Engine Warm-up Prediction using Machine Learning Methodology.2024-26-029501/16/2024
In the recent times, when emission & CO2 legislations are becoming more stringent, we need to adjust our simulation methods to the engine warm-up for better prediction. A typical fuel economy simulation for a WLTP drive cycle with and without considering warm-up effect differentiates up to 6-8%. Thus, there is a need to consider engine warm-up parameters for drive cycle simulations. The engine warm-up can be predicted in multiple ways but the most common way is detailed Physics based 1D modelling. These thermodynamic based models have a very good accuracy in temperature characteristics compared to actual test but take a lot of simulation time. The current requirement is to have models, which can do the same with 0.3 times real time so that these can be coupled with SiL simulation. The current paper will portrait a machine learning based methodology to predict Engine Oil & Coolant temperature based on driving profile and fuel consumption. ML model is trained by using data from one drive
Kelkar, Kshitij, Bensch, Simon, Gopalkrishnan, Suresh Kumar, Meissner, Ronny
Technical Paper
The Impact of Uncertainty Quantification and Sensitivity Analysis in CAE Simulation based Regulatory Compliance2024-26-029401/16/2024
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, 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
Deshpande, Saurabh, Mahajan, Rahul, Jones, Gavin
Technical Paper
Lubrication Effectiveness Determination for Wet-Sump Transmissions using Multiphase Computational Fluid Dynamics Modeling2024-26-029801/16/2024
Wet-sump transmissions are widely used in heavy duty and medium duty vehicles. As these transmissions do not have a dedicated forced lubrication system, it is important that the gear train, shafts, and enclosure are designed appropriately so that enough oil splashes to critical locations to ensure sufficient lubrication. The lubrication effectiveness of such transmissions can be studied through detailed tests or numerical simulations. Often, the vehicle, and therefore the transmission, encounters some severe operating conditions, such as climbing on an incline, driving downhill, etc. Studying these conditions through tests is an expensive process and this imposes the need for an analysis first approach. In this paper, 3D multiphase Volume of Fluid (VOF) method is used to examine two such extreme cases: an 8-degree tilted installation of transmission in a vehicle, and an inclined condition of transmission during 10-degree uphill climb. By studying the oil volume fraction on gears and
r, Shamini, Sachdeva, Aniket, Handa, Joji, Sena, Carlos, Marson, Luigi
Technical Paper
Generation of tire digital twin for virtual MBD simulation of vehicles for durability, NVH and handling evaluation2024-26-030101/16/2024
With the recent development in virtual modelling and vehicle simulation technology, many OEM's worldwide are using digital road profiles in virtual environment for vehicle durability load prediction and virtual design evaluation. For precise simulation results, it is important to have the tire digital twin which is the realistic representation of tire in the virtual environment. The study comprises of discussion about different types of tire models such as empirical, solid model, rigid ring model and flexural ring models such as Pacejka, MF Swift, CD tire, F tire etc. and also the complexity involved in development of these tire models. Generation of virtual tire model requires highly sophisticated test rigs as well as vehicle level testing with Wheel Force transducers and other vehicle dynamics sensors. The large number of data points generated with testing are converted in standard TYDEX format to be further processed in various software tool for virtual model generation. Thus, a
Bakal, Nikhil
Technical Paper
Electric Powertrain - Standardization of Adaptable Software in Loop System2024-26-011701/16/2024
Motivation With an increase in the complexity involved in modern-day ECUs (Electronic Control Unit), it is very important to verify and validate robustness, functionality, and reliability of ECUs. Till date, Hardware in Loop (HiL) based validation or vehicle level validation is generalized approach used for testing. However, this method requires physical setup, which can incur more cost and time during the development phase. Solution We believe in minimizing the software testing time using Software in Loop (SiL) validation. Creating virtual-ECUs and the plant models is an important step in SiL. We are presenting the modularized and scalable plant models in this paper. Adaptable SiL Solution for EV This paper focuses on the standardization of electric vehicle plant models, which can help users to reduce the software development and software testing time. We created the standardized plant models for following virtual ECUs, which can be used as modular units. • Battery Management System
Sajnani, Abhishek, Vernekar, Kiran, Gosavi, Rupesh, Naik, Venkatesh
Technical Paper
Qualitative and Quantitative Correlation Study for Exterior Aerodynamics for Automotive Vehicle2024-26-026201/16/2024
The main objective of the external aerodynamic performance assessment of automotive vehicles is to reduce the aerodynamic drag, which improves overall energy consumption of the vehicle. Almost 40% of the energy is required to overcome the drag force offered by the air on the automotive vehicle. With the increase in high performance computing power (HPC) and its affordability, computational fluid dynamics (CFD) has become a popular and more effective tool for aerodynamic design and analysis in the automobile industry. In the real-world scenario, automotive vehicle is subjected to varying wind and operating conditions which affect its aerodynamic characteristics, and therefore it is difficult to reproduce such physical phenomenon in a conventional wind tunnel. Hence, the entire aerodynamic assessment was done in S2A wind tunnel which is equipped with advanced aerodynamic assessment techniques like wheel rotations, boundary layer suction, moving ground etc. The current work mainly focuses
Biswas, Kundan, Tare, Kedar, Chalipat, Sujit
Technical Paper
Design Implementation through Computational fluid dynamics (CFD) analysis to reduce Fuel filling time in NGVs2024-26-030901/16/2024
In the past few decades CNG (Compressed Natural Gas) fuel growing as an alternate fuel due to its more economically as compared to Gasoline & Diesel fuels by vehicle running cost in both passenger as well as commercial vehicles, additionally it is more environment friendly & safer fuel with respect to gasoline & diesel. At standard temperature & pressure fuel density of Natural Gas (0.7-0.9 kg/m3) is lower than Gasoline (715-780 kg/m3), Diesel (849~959 kg/m3), therefore CNG fuel require higher storage space as compared to Gasoline & Diesel & also it stores at very high pressure (200-250 bar) to further increase the fuel density 180 kg/m³ (at 200 bar) and for 215 kg/m³ (at 250 bar) in CNG cylinders so that max fuel contains in the cylinders and increase the vehicle running capacity per fuel filling & reduces its fuel filling frequency at filling stations. Therefore to gain max vehicle running mileage in a single fuel filling, NGVs (Natural Gas powered vehicles) require more numbers CNG
Singh, Gaurav Kumar, Kumar, Satish, Patil, Praveen, Sharma, Mukesh
Technical Paper
Drivetrain pressure spike evaluation methodology & optimization: Simulation and Testing Correlation2024-26-027701/16/2024
This paper describes a simulation methodology developed for pressure spike evaluation and optimization of hydraulic system architecture for off-highway applications with hydraulically actuated clutch. This pressure spike leads to a very high torque spike in driveline components during clutch pop-up conditions in puddling operations. These torque spikes lead to potential failure of driveline components i.e. gear, shaft, bearing and torsional damper during sudden engagement events. To assess the hydraulic system performance during clutch pop-up cornering conditions is very challenging and leads to compromise on operator safety in the paddy field. It is essential to develop a simulation methodology in a virtual environment to understand the system behavior during clutch pop-up condition and impact of various hydraulic system parameters. This study adopts a model-based design approach for understanding hydraulic system pressure spike phenomenon and dynamic response. Pressure spike
Memane, Nilesh, Kumar, Suneel, Veerkar, Vikrant
Technical Paper
Thermal Management of An Automotive Headlamp2024-26-028601/16/2024
These days, the use of virtual simulations through Computation Fluid Dynamics (CFD) methodology is increasing exponentially during the development phase of an automotive headlamp. Thereupon, the automotive industries are becoming competent enough to build an ingenious and creative design with optimal performance within the coherent time. Considerable amount of heat is generated inside the headlamp when it is switched on for a longer time. Hence it becomes vital to reduce the risks if any during the development phase by providing an adequate thermal management strategy within the headlamp. The present study conducted an experimental analysis on an automotive headlamp to determine its thermal characteristics and behavior. Numerical analysis was also performed to determine the airflow and temperature distributions within a headlamp. This study also focuses on finding the main hotspot regions over the headlamp through virtual simulations. The methodology shows a consensus with the
Kolhe, Shailesh Madhukar
Technical Paper
New test methodology development for combined variable test conditions of potential failure cause to analyze and elimination of Radiator hose field failure2024-26-032601/16/2024
Testing is a part of design life cycle which is increases the design overhead as well as the lead time for release. Even though the virtual testing on a simulation software is a quicker solution to reduce testing time and cost, the results which we get will be the nearest approximation. But in some special cases, it is necessary to do physical validation since they will directly affect the performance of vehicle. when the physical validation comes into picture, recreation of field malfunction and elimination of the same is one fine elevation of engineering. This will increase reliability of product and brand value of organization. This paper describes about the study and analysis of field failure on Radiator hose. The modern problems do require modern way of approach to analyze and test. The objective of failure root cause has been analyzed using QC tools and listed down. This failure occurrence approached by combined test conditions of vibration and thermal pulsation belongs to
Langu, VenkataSatish
Technical Paper
Thermal system simulation and modelling for Alternative Fuels in a Heavy Duty Truck2024-26-029601/16/2024
In the current scenario, demand for Alternate energy source is increasing to reduce dependency on presently available fuels. Internal Combustion engines working on multiple fuels developed in which LNG/CNG is a close contender. Cooling system is one of the critical components of an automobile that influences the engine performance and efficiency. Higher heat demands efficient Cooling system. In this paper an approach is defined to arrive at a Cooling system architecture for CNG/LNG fuel. The aim is to finalise a Cooling system package which is simple and Energy efficient. Modelling is done in Thermal simulation software KULI. Detailed study is done on simulation results of air flow and temperatures and correlated with test results.
M S, Vignesh, KIRAN, NALAVADATH, M, VIGNESH
Technical Paper
Simulation of Crimping Process for Electrical Contacts to ensure Structural Integrity of Crimped Joint under Static Loads2024-26-029101/16/2024
The use of electrical contacts in aerospace applications is crucial, particularly in connectors that transmit signal and power. Crimping is a widely preferred method for joining electrical contacts, as it provides a durable connection and can be easily formed. This process involves applying mechanical load to the contact, inducing permanent deformation in the barrel and wire to create a reliable joint with sufficient wire retention force. This study utilizes commercially available Abaqus software to simulate the crimping process using an explicit solver. The methodology developed for this study correlates FEA and testing for critical quality parameters such as structural integrity, mechanical strength, and joint filling percentage. A four-indenter crimping tool CAD model is utilized to form the permanent joint at the barrel-wire contact interfaces, with displacement boundary conditions applied to the jaws of the tool in accordance with MIL-C-22520/1B standard. The study identifies the
Aher, Ravi, More, Sandip Raghunath, Demarthon, Simon
Technical Paper
Tire-Rim Impact failure prediction using mathematical model2024-26-031401/16/2024
Early design or concept phase involve decision of key Chassis & Suspension parameters finalization, in which tire size selection is one of the most important aspect. Tire size affects overall vehicle ride & handling, steering performance and styling. In addition, it will dictate the majority of suspension packaging in subsequent design phase. An improper tire size selection can lead to major design changes in later stages and cause delay in the project deliverables. Conventional method of tire size selection mainly based on load rating using Tire standards like ETRTO, JATMA etc. is sufficient for vehicle application & basic durability point of view but lacks the insight for typical tire-rim impact failure mode. Aim of the study is to develop the methodology of predicting durability failure especially kerb strike event using simplified suspension-tire mathematical model, which will help in selection of optimal tire size or its specifications in early design phase to mitigate the impact
Atal, Abhishek, Lakhera, Vivek
Technical Paper
Test Methodology Development For Rig Level Validation Of Light Weight Stabilizer Link Of EV Bus Suspension2024-26-035701/16/2024
In the modern and fast growing automotive sector, reliability & durability are two terms of utmost importance along with weight ad cost optimization. Therefore it is important to explore new technology which has less weight, low manufacturing cost and better strength. The new technology developed always seek for a quick, cost effective and reliable methodology for its design validation so that any modification can be made by identifying the failures. This paper presents the rig level test methodology to validate and to correlate the CAE derived strain levels, life cycle & failure mode of newly developed light weight stabilizer link for EV Bus suspension. Stabilizer link replaces the existing separate arrangement of anti-roll bar and parallel rods and light in weight by 30kg.This stabilizer link arrangement is having the short lever arms which are connected through torsion bar which goes under twisting moment and the short lever arms are intended to control wheel motion in longitudinal
Tangade, Atul Bandu, Babar, Sunil, Bankar, Milind Achyutrao, Mehendale, Ravindra, Dhumal, Kailas, Bhusari, Deepak
Technical Paper
A Machine Learning Approach for Hydrogen Internal Combustion (H2ICE) Mixture Preparation2024-26-025401/16/2024
The present work discusses the potential benefits of using computational fluid dynamics (CFD) simulation and artificial intelligence (AI) in the design and optimization of hydrogen internal combustion engines (H2ICEs). A Machine Learning (ML) model is developed and applied to the CFD simulation data to identify optimal injection system parameters on the Sandia H2ICE Engine to improve the mixing. This approach can aid in developing predictive ML models to guide the design of future H2ICEs. For the current engine configuration, it is observed that hydrogen (H2) gas injection contributes mixing of H2 with air. If the injector parameters are optimized, mixture preparation is better and eventually combustion. A base CFD model is validated from the Sandia H2ICE engine data against Particle Image Velocimetry (PIV) data for velocity and Planar Laser Induced Fluorescence (PLIF) data for H2 mass fraction. Design of Experiments (DoE) was derived for the injection system parameters to train the ML
Jose, Alen, Probst, Daniel, Biware, Mukul
Technical Paper
Estimation of gear utilization and durability test specifications through Virtual Road Torque Data Collection for Light Commercial Vehicles.2024-26-025701/16/2024
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
Purohit, Suryakant, Mullapudi, Dattatreyudu, Shevate, Hemant, Chaskar, Mithun
Technical Paper
Impact of Toe and Thrust Angle Misalignment on Roll Behaviour of a Heavy Commercial Road Vehicle2024-26-005601/16/2024
Heavy Commercial Road Vehicles (HCRVs) may be more susceptible to rollover incidents due to their higher centre of gravity position than passenger vehicles, and rollover is one of the significant causes of HCRV accidents. Therefore, variation in vehicle roll behaviour becomes crucial to the safety of an HCRV. Toe misalignment is a commonly observed phenomenon in HCRVs, and studying its impact on roll behaviour is important. In this work, the impact of the symmetric toe and thrust misalignment on the roll behaviour of an HCRV is analysed using IPG TruckMaker®, a vehicle dynamics simulation software. A ramp steer manoeuvre was used for the simulations, and the toe misalignment on a wheel was chosen from the range [−0.21°, 0.21°]. Variation in roll behaviour was quantified using the steering wheel angle at which one-wheel lift-off (OWL) occurred (SWA_L). Additionally, an analytical model was formulated to predict OWL and the model predictions were compared with the results from IPG
Chandran, Amarchand, Grandhe, Roshan, Mukhopadhyay, Arko, Sharma, Mitanshu, Shankar Ram, C S
Technical Paper
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