Browse Topic: Production

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Post-EOL Cybersecurity Validation for Automotive Production ECUs2026-26-0608To be published on 01/16/2026
ISO/SAE 21434 emphasizes comprehensive cybersecurity risk management throughout the automotive lifecycle. However, specific guidance on validating cybersecurity measures at the production level remains limited. This paper addresses the gap in production-stage validation, particularly after End-of-Line (EOL) flashing, which includes configurations of security hardware and software protection (e.g., UCB confirmation, JTAG, and P-flash password settings). Problem articulation: Current automotive cybersecurity validation methods, despite adherence to ISO/SAE 21434, lack specific procedures for the production stage. The existing system-level validation using the ASPICE V-model (e.g., SWE.6, SYS.5) does not ensure the integrity and functionality of cybersecurity features in the final manufactured unit post-EOL flashing. This gap poses a risk of vulnerabilities being introduced during the EOL process, compromising critical security measures. Proposed solution: To mitigate the cybersecurity
Chakraborty, Sucheta, Kulanthaisamy, Nagarajan, Sankar, Ganesh
UNIQUE HYBRID PANORAMIC HEADLINER CLIP WITH HIGH TOLERANCE TO REPLACE DUAL LOCK FASTENERS2026-26-0299To be published on 01/16/2026
Mounting strategies for vehicles with panoramic sunroofs remains a challenge owing to its high complexity to balance cost, performance and assembly efficiency. Achieving efficient and reliable headliner mounting solutions is one of the conundrums where cost optimization must go together with uncompromised performance. Traditional methods like Dual Lock Fasteners (DLFs), have set high benchmarks for robustness but at the cost of increased manufacturing complexity and expense. In pursuit of a more economical and production-friendly alternative, various plastic clip designs were explored. However, these solutions posed significant challenges during validation due to the stringent requirements for mounting feasibility, tolerance management, and long-term durability This paper introduces a novel hybrid plastic-metal clip solution that addresses those challenges comprehensively. The new design achieves precise tolerance control, ensuring reliable headliner installation under varying Body-in
D, GOWTHAM, Kumarasamy, Raj Ganesh, Shoeb, Mohd, Chauhan, Aarti
Evaluating the Suitability of ADC12 for Sand Casting: Filling, Solidification, and Mechanical Properties2026-26-0296To be published on 01/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Jichkar, Pawan
Optimizing Suspension Joint Reliability: Overcoming Bolt Loosening and Torque Variability in Automotive Production2026-26-0492To be published on 01/16/2026
In modern automotive manufacturing, ensuring the integrity of suspension joints under real-world driving conditions is a critical aspect of vehicle safety and performance. These joints endure substantial transverse loads and large vibrations due to irregular road surfaces, dynamic manoeuvres, and varying environmental factors. As a result, bolt loosening becomes a significant concern, compromising joint integrity and overall vehicle reliability. This paper delves into the challenges associated with maintaining joint integrity, specifically focusing on pre-load determination, torque application, and production-related issues. The pre-load generated during torquing is the primary factor that ensures a suspension joint remains securely fastened under dynamic road conditions. This pre-load is derived using road load data acquisition (RLDA) inputs, which capture the forces acting on the joint during actual driving scenarios. RLDA inputs provide critical insights into the forces experienced
Kumar, Sabeesh, Vasant Kumar, Jesse Daniel, Mishra, Harshit, Senthil Raja, T, NAYAK, Bhargav, M, Sudhan, NAMANI, Prasad, Vibhute, Shekhar
Enhancing Factory Modelling: Integrating Drone Technology and Automated Post Processing Systems2026-26-0307To be published on 01/16/2026
The growing environmental, economic, and social challenges have spurred a demand for cleaner mobility solutions. In response to the transformative changes in the automotive sector, manufacturers must prioritize digital validation of products, manufacturing processes, and tools prior to mass production. This ensures efficiency, accuracy, and cost-effectiveness. By utilizing 3D modeling of factory layouts, factory planners can digitally validate production line changes, substantially reducing costs when introducing new products. One key innovation involves creating 3D models using point cloud data from factory scans. Traditional factory scanning processes face limitations like blind spots and periodic scanning intervals. This research proposes using drones equipped with LiDAR (Light Detection and Ranging) technology for 3D scanning, enabling real-time mapping, autonomous operation, and efficient data collection. Drones can navigate complex areas, access small spaces, and optimize factory
Narad, Akshay Maruti, C H, Ajheyasimha, Vijayasekaran, Vinothkumar, FASGE, ABHISHEK
Optimization of the Rodip CED Process Suitability through Strategic Fixture System for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing2026-26-0486To be published on 01/16/2026
The Ro-dip Cathodic Electrodeposition (CED) process is latest technology used by Automotive Manufacturers for higher quality corrosion protection in new generation Automobiles. This process involves multiple 360-degree rotation of automotive body in white (BIW) which exert higher hydrostatic forces on large surface panels like Hood. For maintaining consistent gaps & flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel Hood panel while undergoing through this CED process. This study investigates the enhancement of hood panel alignment through strategic optimization of support rod placement and quantity within the Ro-dip CED system. By conducting experimental trials and computational simulations, the research identifies critical deformation points and evaluates the impact of varying support rod configurations on dimensional stability. The outcome results demonstrate that positioning support rods at
Tile, Vikrant, Unadkat, Siddharth, ASKARI, HASAN, Jadhav, Devidas
Advanced Defect Detection Techniques Using AI, CAD Data, and Computer Vision2026-26-0644To be published on 01/16/2026
In area of modern manufacturing, ensuring product quality and minimizing defects are utmost important for maintaining competitive advantage and customer satisfaction. This paper presents an innovative approach to detect defect by leveraging Artificial Intelligence (AI) models trained using Computer-Aided Design (CAD) data. Traditional defect detection methods often rely on physical inspection, which can be time-consuming and prone to human error. The conventional method of developing an AI model requires a physical part data , By utilizing CAD data, the time to develop an AI model and implementing it to production line station can be saved drastically . This approach involves the use of AI algorithms trained on CAD models to detect and classify defects in real-time. The field trial results demonstrate the effectiveness of this approach in various industrial applications, highlighting its potential to revolutionize defect detection in manufacturing.
Kulkarni, Prasad Ramesh, Sahu, Dilip, Joshi, Chandrashekhar, Khatavkar, Akshay, Poddar, Shivani, Deep, Amar
A Machine Learning Approach to Early-Stage Failure Prediction in Traction Motor Manufacturing2026-26-0281To be published on 01/16/2026
Traction motors technology has, driving the EV industry forward with more efficient, lightweight, and durable solutions. However, despite these advancements, noise testing at the end of the production line remains a critical stage for identifying manufacturing defects in traction motors. Hence early fault detection in traction motors is crucial to ensure safety and reliability of EV. This research contributes a solution that predicts early-fault detection, supporting improved reliability, reduced material cost and minimizing process time in the series production line. To identify the root cause of this problem, historical quality data has been acquired from manufacturing plants to enable efficient analysis. Feature selection was then carried out using embedded and wrapper methods to identify the most important features. These selected features were subsequently used as input for ML models. The best accuracy was achieved using SVC model for early-stage motor failure prediction.
Gaikwad, Pooja, Nangare, Kapilraj, Suryawanshi, Chaitanya
The viability of Ammonia in the Automotive sector: Challenges and Opportunities2026-26-0128To be published on 01/16/2026
Ammonia has become an attractive alternative fuel for automotive use because of its high energy density, carbon-free combustion, and possibility of sustainable production. The work examines the viability of ammonia as a fuel for internal combustion engines (ICEs) and fuel cells in automotive applications. Ammonia presents a number of benefits, such as being capable of being produced from renewable energies and having the possibility to diminish reliance on fossil fuels. However, disadvantages such as ammonia's lower energy content per volume, NOx emission possibility, and need for engine adjustment remain significant challenges. The paper covers the combustion characteristics of ammonia and how it behaves in traditional ICEs and in emerging fuel cell technology. It also addresses the necessary infrastructure for the production, storage, and distribution of ammonia to be used in automotive applications. Through comparative testing and comparison with conventional fuels by experimental
Jadhav, Ajinkya, Bandyopadhyay, Debjyoti, Sutar, Prasanna S, Sonawane, Shailesh Balkrishna, Rairikar, Sandeep D, Thipse, Sukrut S
Transforming Gear Manufacturing_ A Deep Learning Approach to Quality Prediction2026-26-0646To be published on 01/16/2026
The automotive industry is rapidly transitioning towards Industry 4.0, transforming vehicle manufacturing. To achieve a lower carbon footprint, it is crucial to minimize raw material wastage and energy consumption. Reducing component wastage, lead time, and automating gear manufacturing are key areas. Gear micro-geometry inspection is vital, as variations affect service life and NVH (Noise, Vibration, Harshness). Despite standards for permissible errors, manual evaluation is often needed.This subjective evaluation approach will have a possibility that a gear with undesired variations gets assembled into the product. These issues can be detected during NVH testing, leading to replacement of part and re-assembly thus increasing lead time. This generates a need for an automated system which could reduce the human intervention and perform the activity. This paper discusses methodologies to meet these requirements and achieve desired results. The research aims to develop a deep learning
Ramakrishnan, Gowtham Raj, Baheti, Palash, PR, Vaidyanathan, Durgude, Ranjit, Bathla, Archana, R, Greeshmita, V, Rangarajan
Transforming Manufacturing: Increasing Throughput and Reducing production Complexity with Digital Twins2026-26-0449To be published on 01/16/2026
In traditional manufacturing, increasing production line capacity often involves physical trials, leading to downtime, high costs, and operational risks. This paper presents a bidirectional digital twin developed for the Fischertechnik Smart Factory Kit, enabling real-time simulation and validation of production line modifications before actual deployment. The digital twin integrates with a Siemens PLC to mirror real-world operations, capturing live production data and visualizing key parameters like cycle time and machine utilization in a 3D environment. Engineers can test various optimization scenarios adjusting conveyor speeds, optimizing robot paths, and modifying buffer sizes to enhance efficiency. The best-performing configurations are identified based on throughput, cycle time, and resource utilization, and validated changes are automatically deployed to the PLC, ensuring seamless implementation. Beyond capacity optimization, this solution improves overall production efficiency
Kumar, Rahul, Singh, Randhir
Balancing global and local formability properties through Nb microalloying2026-26-0303To be published on 01/16/2026
David Martin, CBMM Asia Bernardo Barile, CBMM Europe BV Caio Pisano, CBMM Europe BV Automotive high strength steels have specific microstructure-dependent forming characteristics. Global formability is generally associated with high uniform strain values which imply good drawability and stretch forming properties driven by pronounced work hardening. Local formability on the other hand is often measured by various fracture strain values—generally higher in single phase steels. In this respect, the so-called ‘local/global formability map’ concept has been established not only to provide a comprehensive methodology to characterize existing automotive steels but also to enable improvement strategies toward more balanced forming characteristics. Niobium (Nb) microalloying is a powerful tool to achieve both property improvement in general and property balance in particular. More than two decades of research has demonstrated that Nb-induced microstructural optimization is applicable to HSLA
Barile, Bernardo
A Novel Approach to Deep Drawing Using Hybrid System and Pneumatic-Assisted Forming2026-26-0301To be published on 01/16/2026
ABSTRACT: This paper presents a novel Plunger-Integrated Hybrid System aimed at enhancing the efficiency and performance of deep drawing operations in metal forming processes. The proposed hybrid system strategically combines the mechanical strength of metals with the elastic flexibility of polymers, specifically polyurethane rubber, to improve formability and reduce spring-back, two critical challenges in conventional sheet metal forming. A novel two-stage forming technique is employed, an initial drawing operation using a larger radius with polyurethane rubber, followed by final radius formation using the same rubber in conjunction with a pneumatic cylinder. This integrated approach ensures uniform force distribution via the embedded plunger, significantly minimizing forming defects and enhancing the dimensional accuracy of the final components. The solution has been validated using Finite Element (FE) simulation methods, confirming its capability to produce high-quality parts
Chava, Seshadri Reddy, Singh, Prakhar, DHANAJKAR, NARENDRA, Roy, Amlan, Raju, Gokul
Innovative Friction Locking Mechanism for High Voltage Busbar Connections in EV Batteries2026-26-0155To be published on 01/16/2026
In the development of high-voltage (HV) batteries, ensuring secure connections between HV conductors and maintaining the safety and performance of the battery pack is paramount. Therefore, In the pursuit of enhancing efficiency and reliability in electrical connections, this paper explores the innovative alternate for a traditional screwing method with a friction locking mechanism for connecting busbars. The novel design reimagines the busbar as a Friction clamp (Female part) that securely holds the male part of the Busbar, significantly increasing the contact surface area up to 50%. This enhanced surface area not only improves electrical conductivity but also reduces heat generation, addressing common issues associated with traditional screw-based connections. By eliminating the need for screws, the new design streamlines the assembly process, resulting in reduced cycle times and improved overall assembly line efficiency. This study presents the design methodology, performance
Venkatesh, Murali, Raghu, Arun, Bhramanna, Amol
Automated evaluation of drive file simulation accuracy2026-26-0528To be published on 01/16/2026
In the area of structural durability testing using servo-hydraulic actuators, developing drive files for the actuators is a major step. Testing outcomes depend on ensuring the simulation accuracy of each drive file. These drive files are developed in an iterative process for different test track surfaces at different road and load combinations till the time we achieve better correlation. Evaluation of simulation accuracy of the drive files is an extensive manual review process, making it time-consuming and resource-intensive. To address this challenge, an application has been developed to automate the comparison of actuator signals with predefined target signal files. This tool enables quick and accurate analysis of each drive file in a test run, facilitating a comprehensive review of signal deviations. Each test run has thousands of drive files based on road-load mix and actuator settings. This application helped us significantly optimize the simulation workflow by reducing the manual
SONI, YASH, Katake, Vrishali, Mullapudi, Dattatreyudu, Chaskar, Mithun
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-0501To be published on 01/16/2026
Manufacturing tolerances pose considerable challenges in the production of rubber-based components, often leading to dimensional variations that can compromise overall product reliability. These inconsistencies may result in a range of functional issues, including poor sealing, excessive wear, misfit during assembly, and premature failure. Among these components, grommets are especially sensitive due to the complex, non-linear behavior of rubber materials, making precise dimensional control critical to ensure consistent and dependable performance. Even minor deviations in grommet geometry can trigger substantial assembly difficulties. Issues such as misalignment, buckling, insertion challenges, and potential damage to neighboring parts are commonly encountered. These complications typically require multiple rounds of design revisions and physical testing, which extend development timelines and significantly increase production costs. Real-world observations from various automotive
Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, PATHAN, ERAM
Aluminum Alloy Castings, Permanent Mold, 5.0Si - 1.2Cu - 0.5Mg (355.0-T71), Solution Heat Treated and OveragedAMS4280K (Current)12/09/2025
This specification covers an aluminum alloy in the form of permanent mold castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Investment Castings, 7.0Si - 0.32Mg (356.0-T6), Solution and Precipitation Heat TreatedAMS4260H (Current)12/09/2025
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, 7.0Si - 0.55Mg - 0.12Ti (F357.0-T6), Solution and Precipitation Heat TreatedAMS4289A (Current)12/09/2025
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, Permanent Mold, 5.0Si - 1.2Cu - 0.50Mg (355.0-T6), Solution and Precipitation Heat TreatedAMS4281H (Current)12/09/2025
This specification covers an aluminum alloy in the form of permanent mold castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Castings 4.7Cu - 0.60Ag - 0.35Mn - 0.25Mg - 0.25Ti (B201.0-T7) Solution Heat Treated and Overaged AMS4242D (Current)12/09/2025
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Castings 4.5Cu - 0.70Ag - 0.30Mn - 0.25Mg - 0.25Ti (A201.0-T4) Solution Heat Treated and Naturally Aged AMS4223F (Current)12/09/2025
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, High Strength 4.5Cu - 0.70Ag - 0.30Mn - 0.25Mg - 0.25Ti (A201.0-T7) Solution Heat Treated and Overaged AMS4229H (Current)12/09/2025
This specification covers an aluminum alloy in the form of sand, permanent mold, and composite mold castings.
AMS D Nonferrous Alloys Committee
Nickel-Aluminum-Bronze, Martensitic, Sand, Centrifugal and Continuous Castings, 78Cu - 11Al - 5.1Ni - 4.8Fe, Quench Hardened and Temper AnnealedAMS4881E (Current)11/25/2025
This specification covers a nickel-aluminum bronze alloy in the form of sand, centrifugal or continuous castings.
AMS D Nonferrous Alloys Committee
Aluminum Bronze Alloy, Centrifugal and Continuous-Cast Castings, 81.5Cu - 10.3Al - 5.0Ni - 2.8Fe, Quench Hardened and Temper Annealed (TQ50)AMS4880E (Current)11/25/2025
This specification covers an aluminum bronze alloy in the form of centrifugal and continuous-cast castings.
AMS D Nonferrous Alloys Committee
Aluminum Bronze, Centrifugal and Chill Castings 85Cu - 11Al - 3.6Fe As CastAMS4870G (Current)11/25/2025
This specification covers an aluminum bronze alloy in the form of centrifugal and chill castings.
AMS D Nonferrous Alloys Committee
Castings, Leaded Bronze, Sand and Centrifugal 80Cu - 10Sn - 9.5Pb As CastAMS4842G (Current)11/25/2025
This specification covers a leaded bronze in the form of sand and centrifugal castings.
AMS D Nonferrous Alloys Committee
Verifying large alternate product code for an AMS document - AMS112425-1AMS112425XXXXXXXXXXXXXXXXXXXXXX-1 (Current)11/24/2025
Verifying large alternate product code for an AMS document - AMS112425-1
A-10 Aircraft Oxygen Equipment Committee
Aluminum Alloy, Die Castings 8.5Si - 3.5Cu (A380.0-F) As Cast AMS4291K (Current)11/21/2025
This specification covers an aluminum alloy in the form of die castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Die Castings 9.5Si - 0.50Mg (360.0-F) As Cast AMS4290N (Current)11/21/2025
This specification covers an aluminum alloy in the form of die castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, Centrifugal 7.0Si - 0.30Mg (356.0-T6) Solution and Precipitation Heat Treated AMS4285G (Current)11/21/2025
This specification covers an aluminum alloy in the form of centrifugal castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, Permanent Mold 7.0Si - 0.30Mg (356.0-T6) Solution and Precipitation Heat Treated AMS4284L (Current)11/21/2025
This specification covers an aluminum alloy in the form of permanent mold castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Castings, 5.0Si - 1.2Cu - 0.50Mg (C355.0-T6), Solution and Precipitation Heat TreatedAMS4215K (Current)11/13/2025
This specification covers an aluminum alloy in the form of sand, permanent mold, composite mold, and investment castings.
AMS D Nonferrous Alloys Committee
SAE TOMORROW TODAY - How Autonomy is Breathing New Life into Farming1351505/16/2025
Labor shortages are pushing many family farms to the brink. The solution? Autonomous technology which is emerging as a game-changer--boosting productivity, cutting risk, and giving family farms a fighting chance to thrive for generations to come. At the forefront of this transformation is Blue River Technology, a John Deere subsidiary leading the charge in precision agriculture. From AI-driven tools to autonomous machinery, the company is helping to build the future of farming the John Deere way, meeting farmers in the field and designing solutions grounded in real-world challenges. With safety and scalability built in, farmers can start small with retrofit kits that upgrade existing tractors, making automation more accessible than ever. To learn more, we caught up with Aaron Wells, Director of Engineering at Blue River, to explore how automation is transforming agriculture and giving farmers the tools they need to stay ahead--despite labor challenges. We'd love to hear from you. Share
Hineman, Marcie
Dependency of Gear Honing Machine Processing Accuracy on Machine Vibration and the Vibration Reduction Considering Contribution2024-32-002004/18/2025
In recent years, accurate gear processing is required for various products to improve efficient power transmission and small noise and vibration. On the other hand, the accuracy tends to be worse by high speed processing for increasing production efficiency. Therefore, we investigated relationship between gear honing machine vibration and the accuracy. The vibration acceleration of the honing machine was measured at various conditions, and the gear accuracy was measured after processing. As results, the accuracy was observed to be affected by both the original gear accuracy before honing processing and the gear secondary rotational vibration of the machine in operation. Subsequently, we applied transfer path analysis (TPA) to investigate which directional force in operation increased the vibration. As the results, the contribution from the input force at gear processing point along normal direction was the main contributor. Then, vibration transmission characteristics of the machine
Hanioka, Hiroaki, Ogawa, Yunosuke, Yoshida, Junji, Onishi, Yoichi, Kurokawa, Yasuhiro
SAE TOMORROW TODAY BRIEFS - Perfecting Solid-State Battery Production1350603/13/2025
When it comes to electrification, Honda has been focused on long-term strategy, emphasizing that the transition to EVs is a marathon, not a sprint. Recently, however, the company has been bullish on solid-state battery technology. By using a solid electrolyte instead of a liquid one, solid-state batteries offer advantages like higher energy density, reduced weight, and improved safety compared to liquid lithium-ion batteries. After perfecting the production of solid-state batteries in a lab environment, Honda is now focused on mass production. The company recently opened a test factory to produce battery packs for future EVs and to refine the production process. To learn more, Roberto Baldwin, Sustainability Editor, SAE Sustainable Mobility Solutions, sat down with Chris Martin, Technological Director of Communications, to discuss Honda's advancements in solid-state battery technology and the company's future plans for electrification. For more information on the evolution of
Hineman, Marcie
Revolutionizing Seafood Production with Adaptive RobotsTBMG-5217812/01/2024
Robotic automation technology is reshaping food manufacturing, packaging, and handling by driving significant improvements in efficiency, quality, and flexibility. By integrating advanced artificial intelligence, computer vision, and proprietary force-sensing technology, Flexiv has introduced cutting-edge automation to the food processing sector.
Contract Manufacturing: Accelerating Product DevelopmentTBMG-5217212/01/2024
Design and material choices can have a long-term impact on an original equipment manufacturer’s (OEM) production costs and product quality. When an OEM works together with an experienced contract design manufacturer (CDM) from the start of a project, many negative impacts to cost and quality can be avoided.
3D-Printed Reactor Core Makes Solar Fuel Production More EfficientTBMG-5219312/01/2024
In recent years, engineers at ETH Zurich have developed the technology to produce liquid fuels from sunlight and air. In 2019, they demonstrated the entire thermochemical process chain under real conditions for the first time, in the middle of Zurich, on the roof of ETH Machine Laboratory. These synthetic solar fuels are carbon neutral because they release only as much CO2 during their combustion as was drawn from the air for their production. Two ETH spin-offs, Climeworks and Synhelion, are further developing and commercializing the technologies.
Liv-in vehicle of the future2024-26-023701/16/2024
Liv-in vehicle of the future is a pioneer providing sustainable, highly customizable electric LCV solutions offering automated to autonomous driving, seamless connectivity to customers' ecosystems, peace-of-mind reliability and improved productivity and profitability. For flexibility, versatility, and economies of scale, modularity is essential. With a modular EV design, different vehicle models can share the same platform or components. This can accelerate development and provide manufacturing efficiencies, resulting in significant cost savings. With modular components parts sourcing is more efficient, and inventory management, processing, and storage are simplified. One plant can produce multiple vehicle variants far more easily and efficiently, with less complexity of retooling and physical layout changes. Advantages a) Reduced design and development costs. b) A flexible architecture that can be used for a variety of vehicle types. c) Economies of scale. d) Proven performance from
Dias, Francis Anton, Mane, Sushant
Effect Analysis of Form Factor on Thermo-Electric Generator Performance2024-26-038601/16/2024
One of the major contributor for the climate change and global warming is the residual thermal energy generated from automobiles as exhaust gases in IC engine powered vehicles and batteries and fuel cell heating in green vehicles. This waste heat or the thermal energy can be converted into useful electric energy using the thermos-electric generator (TEG). TEGs are devices that can generate electricity directly from temperature difference between two surfaces. They are manufactured using semiconductor materials that exhibit Seebeck effect, generating voltage due to temperature gradient across it terminals. These devices are compact, stable and more reliable electric power generators. The main setback of TEG is its low efficiency compared to other power generators. In this paper, form factor of TEG is studied in detail with its effect on figure of merit, for commercial vehicle applications. In addition, bottlenecks in implementing these TEGs in series production is discussed.
Bali, Gaurav, Mutagi, Megha Dharnendra, PONANGI, BABU RAO
Fixed High Ground Clearance Tractor2024-26-006301/16/2024
Row-crop intercultural activities are widely affected by unavailability of manpower & seasonal nature. Current tractors with lower ground clearance are unable to access field after certain crop stage, may damage crop after growth up to 1 foot. Some limited mechanization available (self-propelled boom sprayer) are of higher cost. Cropcare activities are intensive and consistently increasing cost. A retrofit height attachment is designed and developed to ensure the tractor to enter field of crops having height up to 3 ft and perform intercultural operations with lesser investment and operating cost to utilize the unmechanized gap for business benefit. The concept is converting 2WD base tractor to high ground clearance tractor having ground clearance of 3ft and rear track of 42&44'', with modular retrofit height attachment kit with lesser change on base tractor. The kit can be removed later after Cropcare and covert back the tractor to usual 2WD base tractor. The solution is suitable for
A, Gokila, Natarajan, Saravanan, T, Vimalraj, Subbaiyan, Prasanna Balaji, RS, Vijay, Redkar, Dinesh, Gupta Sr, Vishal
A Comparison of Wire Bonding vs. Spot Welding vs. Soldering in the Prevention of Thermal Runaway in a Battery Pack2024-26-010901/16/2024
EVs are a fast-growing market and appear as a promising option against the high emission of gasoline and diesel vehicles. The growth in the EV market has been decent and a regular buyer is still skeptical due to fire incidents occurring with EVs. Complex electronics, improper thermal management, mechanical abuse, improper cell grading activities and control in production, lack of testing in a production plant, and of course, uneven degradation of cells can be one of the reasons this promising technology is facing thermal runaway and in turn, the wrath of the government and public alike. One of the reasons thermal runaway can be triggered after a cell catches fire is because a part of heat travels via busbars to the neighboring cells, as the busbars can conduct heat faster than the air. For the heat that is conducted, it is easily understandable that we need to break the electrical, as well as thermal conduction connection to the neighboring cells. This paper presents a comparison of
Pawar, Aniruddha, Khan, Faiz, Shah, Harsh, Malani, Shekhar
Review on Laser welding of High Strength Aluminium alloy for Automotive Applications2024-26-019301/16/2024
High strength aluminium alloys are an ideal material in the automotive sector leading to a significant weight reduction and enhancement in product safety. In recent past extensive development in the field of high strength steel and aluminium was undertaken. This development has been propelled due to demand for light weight automotive parts. The high strength to weight ratio possessed by Al alloy helps in reducing the total weight of the vehicle without effecting the overall performance, thereby increasing the fuel economy and reducing the carbon emission level. Joining of high strength aluminium alloy is critical to develop durable automotive products. Joining of high strength aluminium alloy for mass production in automobile industry is a challenging task. Laser welding is recognized as an advanced process to join materials with a laser beam of high-power, high-energy density. In the present study efforts are made to summarise the influence of important process parameters of laser
Sahu, Hemant, Dave, Rajeev, Chauhan, Shiv, Dwivedi, Ravi
SAE TOMORROW TODAY: Avant-Garde EV Company to Build in the US1340106/22/2023
While you may not have heard of Polestar, its exceptional performance, unique buying experience, and commitment to sustainability enables this novel brand to "intercept" its customers. Headquartered in Sweden and built with Scandinavian minimalism in mind, Polestar offers a friction-free, primarily digital EV buying experience which includes boutique showrooms in areas with high foot traffic--a contrast to the traditional car lot. The company recently unveiled its first electric performance SUV, the Polestar 3, which is produced in United States. With a focus on supply chain traceability and sustainability labelling, Polestar assesses their vehicles' lifetime carbon footprint, covering emissions from materials production, manufacturing, and logistics, use phase, and end of life. As part of their commitment to an electrified future, Polestar also recently partnered with the SAE Foundation to spark STEM curiosity amongst students. To learn more about this burgeoning brand, we sat down
Hineman, Marcie
A Comparative Analysis of Fault Diagnosis by vibration signals for Critical Gear Components in Electric Vehicle Motor Testing Machines Using Machine Learning Algorithms2025-01-004005/05/2023
Electric vehicles (EVs) represent the future of the automobile industry, with the drive motor being a crucial component in modern EVs. To ensure optimal performance, a motor testing machine is used to verify the essential parameters of these electrical motors. This machine regularly evaluates electric motor characteristic curves and their electromagnetic behavior under different conditions. However, it has been observed that flaws in the testing machine's helical gear arrangement frequently cause malfunctions and suboptimal performance, affecting the efficiency of the electric vehicle production line. This research project aims to improve the motor test bench apparatus by modifying critical design parameters using machine learning and vibration signal analysis methods. Vibration signals are recorded at various gear settings, and statistical features are extracted from these signals. These signals are then classified using classifiers such as Naive Bayes and Decision Trees. Machine
S PhD, Ravikumar, V, Muralidharan, Syed, Shaul
Do EVs Snore?2025-01-007405/05/2023
As EV and PHEV adoption continues to increase more people will have direct experiences with these quieter vehicles in their daily lives. Topics such as 'propulsion sound' via Active Sound Design (ASD) and bystander safety through Acoustic Vehicle Alerting Systems (AVAS) have been discussed widely for many, many years...but who is talking about Charging Noise? Charging noise is a less spoken about topic because most EV / PHEV owners will charge their vehicles at their home, in their garage or their driveway, overnight when they are sleeping. Because of that people do not think much about charging noise. But anyone who has plugged in their car overnight will tell you a strange cacophony of sounds come from the car...and some can be downright concerning. In this paper data from several production EVs were measured during their normal charging cycle. Binaural recordings made inside and outside the vehicle are analyzed using psychoacoustics metrics to see what sounds would cause the most
Marroquin, Marc, Bray, Wade
Identification and Evaluation of Passthroughs That Affect the Acoustic Performance of a Dash System2025-01-012105/05/2023
This paper discusses a systematic process that was developed to evaluate the acoustic performance of a production electric vehicle dash system. The production dash panel was tested under different configurations to understand the importance of passthroughs in the acoustics of the dash system. Results show that often the performance of the passthroughs strongly affects the overall performance of the dash system and this may become the limiting factor to increase the system STL. The dash with passthroughs was then extensively tested to understand the acoustic strength of different passthroughs and to understand how these passthroughs affect the overall performance of the dash system. Subsequently a test procedure based on flat panel tests was developed so the OEM can develop target values and the suppliers can provide test results of their passthroughs that are meaningful and useful to the OEM to help build an acoustically competitive vehicle.
Saha, Pranab, Baack, Gregory, Geissler, Christian, Kaluvakota, Srikanth, Pilz, Fernando
Medical Device Machining: Precise and Reliable Parts for Critical ApplicationsTBMG-4695311/01/2022
SAE TOMORROW TODAY: Additive Manufacturing on Earth and Beyond1331409/23/2022
From industrial to medical to space, laser additive manufacturing and 3-D printing has the potential to transform production across nearly every sector. With almost one hundred years in business and nearly half a century in laser technology, TRUMPF has long been known as the gold-standard in advanced manufacturing solutions that now include additive manufacturing and 3-D printing. The company's advancements in production technology span space exploration, medical devices, and Smart Factory development. We sat down with Eliana Fu, Industry Manager for Aerospace & Medical at TRUMPF North America, to discuss how the company is transforming manufacturing processes for the better, both on earth and beyond. From assembling vehicles in space to manufacturing medical devices closer to the point of care to paving the way for the Smart Factory, TRUMPF is building the industrial world of tomorrow.
Hineman, Marcie
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