Browse Topic: Tests and Testing

Items (7,116)

An analysis of material damping characteristics: A comparison of Oberst Bar Method and Center Impedance Method and their relationship to Component Level.

2026-26-03171/16/2026

Damping materials exhibit advantageous mechanical and acoustic characteristics that enhance the structural integrity of systems. These materials find extensive applications across various industries, including automotive, aerospace, and building acoustics, and are widely employed in the development of soundproofing materials. The damping characteristics of materials primarily pertain to the dissipation of vibrational energy, the reduction of oscillations, and the controlling and subsequent attenuation of vibration-induced noise emanating from structures. To improve both structural integrity and acoustic performance, it is crucial to accurately assess the damping properties of these materials. The Oberst bar test method is a standard method used in the automotive, railway and building industry for initial optimization of damping material However, questions have arisen about the degree to which the outcomes of the Oberst test truly reflect real-world applications. Numerous experimental

Kamble, Prashant Prakash, Joshi, Manasi, Jain, Sachinkumar

Post-EOL Cybersecurity Validation for Automotive Production ECUs

2026-26-06081/16/2026

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

Evaluation of Methods used to Determine Vehicle Center of Gravity Height

2026-26-05131/16/2026

This paper contains a study of the measurement accuracies of two methods commonly used by vehicle industries and other stakeholders to determine vehicle center of gravity (CG) height. The two methods, which both appear in international standards, are the Axle Lift method and the Stable Pendulum method. The Stable Pendulum method requires a dedicated swinging platform mechanism, but it is generally considered to be more accurate than the Axle Lift method. Both methods rely on equations for computing CG height that are based on static balance models of a vehicle tested at various pitch angles. For each method, the accuracy of the resulting CG height computations is a function of the individual measurements needed in the model equations. The individual measurements needed depend on the method used, but they include weights, angles, and distance measurements. A theoretical error analysis study is presented that provides insight into the accuracy of both methods given the uncertainty in the

Heydinger, Gary, Zagorski, Scott, Bartholomew, Meredith, Andreatta, Dale

Hybrid Topology Selection & Optimization of a Compact SUV to Meet Future CO2 Norms - an Indian Case Study

2026-26-00771/16/2026

Rising environmental concerns and stringent emissions norms are pushing automakers to adopt more sustainable technologies. There is no single perfect solution for any market and there are solutions ranging from biofuels, green hydrogen to electric vehicles. For Indian market, especially in the passenger car segment, hybrid vehicles are favoured when it comes to manufacturers as well as with consumer because of multiple reasons such as reliability, performance, fuel efficiency and lower long-term cost of ownership. For automakers planning to upgrade their fleets in the context of upcoming CAFE III (91.7 g CO2 / km) & CAFE IV (70 g CO2 / km) norms, hybridization emerges as the next natural step for passenger cars. Lately, various state governments have also promoted hybrid vehicle sales by offering certain targeted tax breaks which were previously reserved for EVs exclusively. Current study focuses on various parallel hybrid topologies for an Indian compact SUV, which is the highest

Emran, Ashraf, Sandhu, Rouble, Keizer, Ruben, Warkhede, Pawan

Application framework with multi-tiered approach in validating UI based animation in automotive product.

2026-26-05861/16/2026

As part of their market segmentation strategy, each OEM is using UX (user experience) as a crucial aspect for product differentiation. Though there are many parts to UX, the one which would have a profound effect on the user is through animation of real-world aspects on the instrument panel, like falling snowflakes when it’s snowing outside, real time traffic conditions as part of Advanced Driver Assistance Systems (ADAS) or even a unique welcome or farewell message. The unique and realistic nature of such implementations and customizing it to the needs of market segments introduces a lot of complexity in evaluating the correctness of implementation with respect to design. In this paper, we would extensively evaluate the current practices in analyzing the test basis, test environment needs, test data and test methods used in testing animation. However, the primary focus of this paper is to introduce a novel multi-tiered approach towards evaluating animations - where we would introduce

Kandrattha A, Mohammed Azharuddin, Kulkarni, Apoorva

Adoptive safety solutions in Road Simulators for commercial vehicle structural validation

2026-26-05331/16/2026

Road Simulators used to carry out accelerated structural durability validation of a vehicle. As a commercial vehicle manufacturer, for our commercial vehicles structural validation, we are using 8 poster road simulators. We use road load data, torture track data, synthetic profiles or events as the input test data. From a mini 4 wheeler trucks to high capacity 8 wheeler truck, and any bus variant is being tested at road simulator. All the vehicle variants are tested with prescribed road and load conditions for the pre-determined life. Each wheel of the vehicle is positioned on the wheel pan of the hydraulic actuators so that each actuator excites the corresponding vibration data. The vehicle is being restrained as per the manufacturers recommendation. Manufacturer recommendations widely addresses the risks associated with the test rigs. In addition to that there are risks associated with the vehicle running, vehicle handling, vehicle positioning. For example, when durability test

Arumugam, Paramasivam, N, Gopi Kannan, N, Mahendra, Muthu kumar, Pandurangan, Singh, laxman, Tiwari, Manish, V, Subash

Towards AI-Driven Automated Driving Systems: Homologation perspective

2026-26-01331/16/2026

This paper examines the challenges and opportunities in homologating AI-driven Automated Driving Systems (ADS). As AI introduces dynamic learning and adaptability to vehicles, traditional static homologation frameworks are becoming inadequate. The study analyzes existing methodologies, such as the New Assessment/Test Methodology (NATM), and how various institutions address AI incorporation into ADS certification. Key challenges identified include managing continuous learning, addressing the "black-box" nature of AI models, and ensuring robust data management. The paper proposes a harmonized roadmap for AI in ADS homologation, integrating safety standards like ISO/TR 4804 and ISO 21448 with AI-specific considerations. It emphasizes the need for explainability, robustness, transparency, and enhanced data management in certification processes. The study concludes that a unified, global approach to AI homologation is crucial, balancing innovation with safety while addressing ethical

Lujan Tutusaus, Carlos, Hidalgo, Justin

Design Robustness of Electronic Locking Differential for enhanced off-road performance

2026-26-05021/16/2026

The Electronic Locking Differential (ELD) is a critical component for enhancing off-road vehicle performance by ensuring optimal traction in challenging terrains. This paper addresses intermittent engagement issues observed in the ELD system during off-road trials, which impacted its reliability and functionality. It presents a comprehensive study of design robustness improvements implemented to resolve these concerns and optimize the ELD’s performance, ensuring enhanced customer satisfaction in demanding off-road environments. The analysis begins with identifying factors contributing to the intermittent engagement and disengagement of the ELD system upon actuation. These factors include residual magnetism, material properties, temperature effects, and the stack-up characteristics of transfer path components under various boundary conditions. To address these challenges, three key design modifications were introduced: (1) reduction of residual magnetism through an increased air gap

S, Mohd Imtiaz, AP, Baaheedharan, Ghumare, Dheeraj, Kanagaraj, Pothiraj, Jain, Saurabh Kumar

A Frequency-Based correlation adjustment method for translating Proving Ground Test Tracks to 4-DOF Road Simulator Rig Testing of Electric Two wheelers

2026-26-05561/16/2026

Real-world usage subjects two-wheelers to complex and varying dynamic loads, necessitating early-stage durability validation to ensure robust product development. Conducting a full life-cycle durability testing on proving grounds is time-consuming, extremely difficult for the riders involved, and costly, which is why accelerated testing using rigs such as the road simulator system have become a preferred approach. The use of road simulators necessitates, accurately measured inputs and precise simulation to ensure proper actuation of the rig, thereby enabling realistic representation of road undulations. Road Load Data Acquisition (RLDA) is used to measure various inputs such as displacement, acceleration, strain, and predicted forces from the road which are then used to simulate real-world conditions in a road simulator. This paper covers two important aspects essential for achieving an accurate and clear representation of road simulation in a 4-DOF road simulator, encompassing both

Ganju, Shubham, V, Vijayamirtharaj, Prasad, Sathish, R S, Mahenthran

Reverse Gear Duty Cycle Generation Using Virtual RLD Simulation

2026-26-04051/16/2026

Keywords: RLD (Road Load Data), AVL VSM, AVL Route Studio, Duty Cycle, Transmission, Reverse Gear, Durability The development of transmission systems involves creating duty cycles for bench-level durability evaluations for both forward and reverse gears. For forward gear, vehicles are driven under various real-world conditions over thousands of kilometers, equipped with numerous sensors and components tailored for data collection. In contrast, duty cycles for reverse gear are often based on prior experience or rough estimations due to the lack of clear definition of real world use case. Reverse gear RLD is particularly scarce, especially for heavy-duty vehicles operating in off-road or mining environments, where specific reverse driving paths are not typically followed. This paper presents a detailed methodology highlighting the importance of reverse gear duty cycles by leveraging virtual RLD simulations on various gradients using tools such as AVL Route Studio and AVL VSM. By

Kansagara, Smit, Patel, Hiral, kira, Lucas, Sutar, Suresh, Soor, Debasis

Use Of Digital Wind Tunnel For Improved Aerodynamic Prediction

2026-26-03721/16/2026

In the automotive industry, external aerodynamic evaluations in digital environments are commonly conducted using simplified, large box tunnels with vehicle being static. These approaches are computationally efficient and ensure faster turnaround times. To closely replicate physical wind tunnel testing or real-world conditions, these simulations are often augmented with moving ground and rolling tire configurations. While such setups provide valuable directional feedback for aerodynamic drag improvements, they frequently exhibit significant discrepancies when compared to physical wind tunnel test data. It is observed that key factors such as wind tunnel blockage effects, boundary layer suctions, when not properly accounted for, distort the local flow field dynamics and introduce errors in the simulations. With OEMs aiming to accelerate time-to-market for new vehicle launches, many aspire to minimize reliance on physical testing and maximize use of digital methods for design sign-off

sharma, Sandeep Kumar, Chalipat, Sujit, Maiyya, Sandeep

Vehicle Self-Soiling from Exterior Cleaning Mechanisms

2026-26-04251/16/2026

The automotive industry is rapidly advancing towards autonomous vehicles, making sensors such as cameras, LiDAR, and RADAR critical components for ensuring constant information exchange between the vehicle and its surrounding environment. However, these sensors are vulnerable to harsh environmental conditions like rain, dirt, snow, and bird droppings, which can impair their functionality and disrupt accurate vehicle maneuvers. To maintain sensor performance, cleaning systems are implemented in vehicles. Testing sensor cleaning mechanisms under various weather conditions and vehicle operating situations is essential. One crucial aspect of testing is tracking the trajectory of the cleaning fluid to ensure it does not cause self-soiling of vehicle or affect other field of view, such as the windshield. While wind tunnel tests are valuable, digitalizing this process is vital for making design decisions early in vehicle development. This work presents a digital methodology to test the self

Mane, Suvidya, Makam, Sri Lalith Madhav, Varghese, Rixson, Desu, Harsha

Facilitating Virtual Testing at an Industrial Level by Simulation Data Management

2026-26-04401/16/2026

Automotive OEMs can derive significant cost savings by reducing the quantity of physical crash tests and thereby accelerate product development, when they follow the Euro NCAP Virtual Testing guidelines. It helps in optimizing the overall vehicle development process via more efficient simulations, as well as facilitates in early adoption of new safety regulations. In this pursuit, companies must comply with strict Euro NCAP requirements, which includes transparency and traceability of virtual tests. A major challenge therein is model validation – which requires highly precise detailing and extensive use of data for accurately replicating real physics of the problem. Deploying these workflows into an existing simulation process can be a complicated and time-consuming task, particularly when integrating various simulation and testing methods. A powerful simulation and process data management system (SPDM) can thereby assist companies to automate their entire simulation process, ensures

Thiele, Marko, Sharma, Harsh

Investigation and Reduction of Road Noise due to transient road inputs in Electric Vehicle

2026-26-03581/16/2026

Higher road noise is perceived in the cabin when the test vehicle encounters road irregularities like bump or pothole in the public roads. The sudden transfer of transient road inputs inside the body caused objectionable cabin noise. Measurements are conducted on the test track at different road surfaces to identify the patch where the objective data well correlated with the noise measured at the public road. Wavelet analysis is carried out to identify the frequency zones since the events are transient in nature. Transfer Path Analysis (TPA) is conducted in both time domain and frequency domain to identify the nature of the noise and the limitation in each of the methodologies are explained. The dominant path through which the transient road forces are transferring inside the body are also identified. Based on the outcome of TPA, various countermeasures like reduction of dynamic stiffness of suspension and cradle bushes , structural modifications on the path are proposed to reduce the

S, Nataraja Moorthy

Exhaust Hot end system Transient Heat Transfer Analysis using Heat Transfer Coefficient (HTC) approach, Thermo-Mechanical Fatigue Analysis to evaluate thermal durability and physical validation through Thermo-Shock Testing

2026-26-02241/16/2026

Exhaust system suppliers are continuously enhancing their processes by adopting advanced simulation techniques and expedited testing procedures for optimizing exhaust systems. This aims to reduce time to market, accelerate vehicle launches, and ensure first-time right and consistent compliance with performance and durability standards. Traditionally, the CFD team conducts Conjugate Heat Transfer (CHT) analysis on the exhaust hot end system using input conditions such as engine-out gas temperature and maximum mass flow rate. The CAE team then performs steady-state heat transfer analysis by sharing the structural CAE model with CFD for CHT skin temperature mapping. Once steady state heat transfer analysis complete, skin temperature plots are to be compared with CFD to match CHT temperature results. These results are used for steady-state thermo-mechanical analysis across all heat-up cycles and assume system under ambient temperature for all cool-down cycles to evaluate system thermal

Natarajan, Suresh, J Y, Raja Shangara Vel

A fluid-structure- interaction based methodology to evaluate aero-thermal performance of deformable air guides

2026-26-03641/16/2026

An air guide in a car directs fresh air onto the Heat Exchangers (HXs) to facilitate efficient thermal management. It is of paramount importance that the air guide creates a proper sealing and prevents any leakage of the incoming fresh air. It is achieved in two ways – 1) In the design condition, the air guide is manufactured in a way so that it overlaps/intersects with the surrounding components 2) the air-guide is made flexible with a highly elastic rubber seal at the edge. When the air-guide is assembled, the rubber portion of the air-guide deforms to produce a proper fit leading to a sealed air-intake pathway. At high-speed condition as well as high airflow conditions by the radiator fan during idling/stationary, like DC charging – incase of BEV, etc., the air guide encounters high pressure. Being elastic and flexible, these conditions make the air guide susceptible to deformation with potential leakage of incoming air. Digital evaluation of the air guide deformation at different

GADASU, RAVISHASTRI, CHOUDHURY, SATYAJIT, Umesh, Acharya Vaibhav, Kumar, Saravanan, Yenugu, Srinivasa, Zander, Daniel, Beesetti, Siva, Hattarke, Mallikarjun

A High-Fidelity Transient Fluid-Structure-Interaction Methodology for Evaluation of Rear Bumper Flutter of a Vehicle

2026-26-04101/16/2026

The need for fuel efficient and pedestrian safe cars leads to the use of thinner and lighter car exteriors. Interaction of these exterior car components at high speed with an aerodynamic load can lead to undesirable aero-elastic vibration and flutter. Early identification and mitigation of such vibration can bring significant cost and time benefit, by reducing dependence on prototype testing and recalibration of prototype tooling at later stages. The present work demonstrates a transient Fluid-Structure-Interaction based numerical methodology for estimation of aerodynamic-induced flutter of the rear bumper of an SUV. The proposed method performs coupled-high fidelity transient full vehicle aerodynamic Finite Volume based and dynamic rear bumper structural Finite Element based simulations required for flutter estimation. The method has been put through a two-step validation against experimental wind tunnel test data of a prototype car with modified bumper for the specific test-case. The

CHOUDHURY, SATYAJIT, Yenugu, Srinivasa, Walia, Rajat, Zander, Daniel, Gullapalli, Atchyut, BALAN, ARUN, Astik, Pritesh

Methodology to Accelerate BEV Range Testing Using Shortened Cycle Maintaining High Testing Reliability and Accuracy.

2026-26-04441/16/2026

In the era of Electric Vehicles (EVs), range is a critical factor for market success. To mitigate range anxiety, Original Equipment Manufacturers (OEMs) are equipping vehicles with larger battery packs. Unlike internal combustion engine (ICE) vehicles, where fuel economy can be determined with a single legislative cycle run, EVs require a full battery discharge to calculate their range. These tests typically take around 10 hours, and this time increases as battery pack sizes grow. A shortened testing cycle has been developed that reduces the testing time to approximately 4-5 hours, leading to significant savings in time, effort, and cost. The shortened cycle consists of three phases: Dynamic Segment1, Constant Speed, and Dynamic Segment2. Despite variations in battery size and powertrain configurations, the testing duration remains consistent. A key challenge in actual testing is accurately determining the start and end points of Dynamic Segment 2 (DS2), which is an iterative process

T, LAKSHMI PRASAD BEKAL, Krishnan, Karthikeyan N., S, VIVEK

Study, design, electro-chemical testing and validation of fuel cell fixture of single cell assembly towards custom stationary application.

2026-26-02651/16/2026

Fuel cell - as name suggests, it generates energy from fuel (Hydrogen). A three-input system produces three different outputs: electrical energy, heat, and pure water. Fuel cell can produce decent power depending on design of active area and possible current density. Overall required power output which is generated by a series of cells stacked together. The design once meets all the required performance parameters at single cell level, can be extrapolated to stack level design. The present work elaborates successful testing and validation of a compact, light weigh single cell fuel cell fixture. Further the design will be scaled to a fuel cell stack design with a capacity of 5 kW to cater various stationary application such as back-up/ stand-alone power generator for remote location. The same design philosophy will also be implemented in fuel cell stack design for automobile applications. The membrane electrode assembly (MEA) is heart of the fuel cell which produces the output while

Pandit`, Abhishek Rajshekhar, Chougule, Abhijeet, Khot, Ranjit, chaudhari, Shirish

Testing and Validation of Future Mobility Vehicles using Realistic Digital Twin of Road Corridors and Tires

2026-26-05801/16/2026

Recent development in Real Time Modelling & Driving simulator technology has made it possible to real time evaluation of vehicle/ tire performance like NVH, Ride-comfort, HMI and ADAS etc. objectively and subjectively using driving simulator. Many OEMs worldwide are adapting this technology for speeding up their tire and vehicle development by reducing decision making time and optimization of the performance by suitable design changes in initial phase of conceptualization. In order to use this technology, there is requirement of good digital twin of the vehicle, tire, road surfaces Test tracks & realistic Road Corridors. Focus of the current paper is on Digital Twin of Road Corridors. Digital Twin of road corridor comprises of various elements viz. the digitized road profile 3D (X-Y-Z) and road infrastructure elements that includes basic elements like road, barricades, signal, signage etc. along with infrastructure furniture like building, bus stops, flyovers etc. Digital twin of road

Joshi, Omkar Prakash, Pawar, Prashant R

Analysis and identification of discrepancies between test data and simulation results using an automated EV range analysis tool

2026-26-04701/16/2026

With growing consumer interest in electric vehicles due to their advantages over traditional internal combustion engine cars, including instant torque and enhanced safety, comprehensive testing of these vehicles has become crucial. Engineers are faced with the challenge of managing the large amounts of data generated during testing. This work aims to develop an automated framework for data processing and simulation of on-road test data and generate reports to monitor inconsistencies. To achieve this, range tests were conducted across various regions and each test data was processed using the EV range analysis tool to check for inconsistencies if any. It was observed that there was a mismatch between the tested and simulated range at expressways. This was due to the unrealistic extrapolation of the vehicle’s coastdown forces above 120 kmph. Hence, tests were conducted to measure the coastdown forces of the vehicle above 120 kmph which was then used in simulation to estimate the range

S, VIVEK, T, LAKSHMI PRASAD BEKAL, Krishnan, Karthikeyan N.

AI-Driven Digital Twin for Enhanced Suspension Assembly Testing in Automotive Vehicles

2026-26-04451/16/2026

This paper presents the development and application of a digital twin for the suspension assembly of Automotive vehicle, a critical component in evaluating the performance and durability of automotive systems. The digital twin, a virtual replica of the physical suspension assembly, is created using advanced simulation techniques and physical test data integration. By leveraging machine learning algorithms, the digital twin provides a comprehensive and dynamic model that accurately reflects the behavior and performance of the physical system under various conditions. The primary objective of this study is to enhance the accuracy and efficiency of suspension assembly testing by enabling predictive maintenance, real-time monitoring, and optimization of test parameters. The digital twin allows for the identification of potential issues before they occur, reducing downtime and maintenance costs. Additionally, it facilitates the exploration of different test scenarios and conditions without

Sonavane, Pravinkumar, Patil, Amol

Assessment of emissions behaviour of Volatile compounds from polymeric materials used in automobile interiors

2026-26-02221/16/2026

There is an increasing trend of using polymeric materials in the vehicle interior compartment. While the polymers provide benefits in terms of flexibility in profiling, lighter weight and aesthetics but one of the challenges with the polymers is emission of volatile organic compounds (VOCs) during their usage and particularly at a temperature prevailing in the vehicle cabin. VOCs adversely impact the vehicle interior air quality and can pose a risk to occupants’ health. However, there is a lack of information on volatile organic compound (VOC) emissions from automotive interior materials. There are two types of methods, a whole vehicle chamber method (ISO 12219-1) and a bag method (ISO 12219-2) for evaluation of VOCs emissions from materials used in vehicle interior parts. ISO 12219-2 method describes quantitative testing of VOCs and semi-VOCs. This test method is quick and cost effective for analysis of materials for quick emission checks and can prove to be very effective in

PAtil, Yamini Jitendra, Thipse, Sukrut, Bawase, Moqtik

Enhancing Thermal Comfort and Vehicle Energy Efficiency: A Simulation Study Using GT ISE + TAITherm

2026-26-04581/16/2026

The automotive industry is encountering difficulties in balancing occupant thermal comfort with HVAC system energy efficiency, particularly under the hot Indian conditions, to meet user expectations and address range anxiety in electric vehicles. Front-loaded comfort-based approach simulations during the development stages have the potential to increase energy savings compared to the stages required at the end of product design. The focus of the current research targets HVAC energy consumers, such as blower flow rates, temperatures, and Cabin heaters, and investigates how these factors influence occupant overall comfort. Additionally, design elements like glass properties and the impact of solar radiation on human comfort are studied at the early concept stages to adopt an energy-based approach for comfort optimization. Simulations are conducted using GT-SUITE and GT-TAITherm software, integrated with CFD field maps platforms to obtain exact flow field predictions. The simulation

BAVIRISETTI, SAI SAMPATH KUMAR, Chothave, Abhijeet, Gummadi, Gopakishore, Khan, Parvej, Thiyagarajan, Rajesh

Integration of virtual testing methods in automotive safety: Methodology validation for rollover protection system (ROPS)

2026-26-03751/16/2026

During recent years, the integration of virtual testing methodologies has gained significant importance in vehicle development for the passive safety evaluation. The accuracy of simulation results depends basically on the correct replication of physical test into the virtual model, for example to assign the realistic material properties from the structural components and following the boundary conditions replicated from real conditions. In this study the safety standards ISO 3471_2008 and ANSI ROHVA/OPEI-2016 have been considered as references of the safety validation process of hollow section roll-over protective structure (ROPS) integrated into a vehicle. A key objective is to stablish a virtual test methodology that could be applicable across different standards considering various industry markets, as for example European, American and Asian. A sensitivity analysis is necessary to evaluate what are the main aspects that gives significant deviations in results and in which we can

Laso Rodríguez, Manuel, Hanumantha, Chandrashekhar, Singh, Amit Kumar, Lal, Kundan

Analysis of Energy Consumption for Heating City Electric Buses and Ways to Reduce It

2026-26-01561/16/2026

For regions with cold climates, the driving range of electric buses becomes a significant obstacle to the broader adoption of this type of transport. The increased energy consumption affects not only the range of autonomous operation but also the lifespan of battery packs, the scheduling of bus departures, and the load on the charging infrastructure. In this context, finding ways to reduce the energy consumption of the climate control system is an actual issue. The aim of the presented research is to experimentally and computationally determine the energy consumption for heating the driver's cabin and passenger compartment of an electric bus during the autumn-winter operation period, as well as to identify and analyze ways to reduce this energy consumption. To determine the air temperature in the passenger compartment, a mathematical model based on heat balance equations was used. This model was validated using data from real-world tests. The research was conducted at a proving ground

Kozlov, Andrey, Terenchenko, Alexey, Stryapunin, Alexander

Comparison of Bharat NCAP Crash test scenarios with real road accidents in India

2026-26-00241/16/2026

This study is conducted to analyse the significance of BNCAP crash test protocol in the real road accidents in India. Accident data from on-the-spot investigation (Road Accident Sampling System India) and Government of India’s, Ministry of Road Transport and Highways official road accident statistics 2023 is used together to understand the real road accidents in India. The current BNCAP crash test protocol is compared against the real road accidents and the frequency of the same in discussed in this paper. A seven-step calculation method is developed to analyse real accidents together with existing crash tests by using similar crash-characteristics like impact area, overlap and direction of force. This method makes the real accident comparable with the corresponding crash test by calculating the impact energy during the collision between the real accident and a collision under crash test conditions. Relevant parameters in real accidents that significantly influence the test scenario

Moennich, Joerg, Lich, Thomas, Kumaresh, Girikumar

AI-Driven Predictive Methodology for Bolt Integrity in Vehicle Durability Testing

2026-26-06481/16/2026

The application of AI/ML techniques to predict truck tailgate bolt loosening represents a major innovation for the automotive industry, aligning with the principles of Industry 4.0. Traditional physical testing methods are both expensive and time-consuming, often identifying issues late in the development process and necessitating costly design changes and prototype builds. By harnessing AI/ML, manufacturers can now analyze tailgate slam and bolt preload data to accurately forecast potential bolt loosening issues. This predictive capability not only enhances quality and safety standards but also significantly reduces the costs associated with tooling and builds. The AI/ML tool described in this paper can simulate a variety of load conditions and predict bolt loosening with over 90% accuracy, considering factors such as changes in loads, bolt diameters, washer sizes, and unexpected masses added to the tailgate. It provides valuable design insights, such as recommending optimal bolt

Sivakrishna, Masani, Das, Mahat, Singh, Abhinav, karra, Manasa, Shienh, Gurpreet, Luebke, Amy

Accelerating EV Thermal Controls Development: A Rapid controls prototyping framework using Speedgoat

2026-26-06851/16/2026

In the era of software-defined vehicles, the complexity and requirements of automotive systems have increased significantly. Thermal management systems have become more complicated, incorporating multiple functions and strategies within software frameworks. This shift poses substantial challenges, increased development efforts and extending timelines in creating an efficient thermal management system for EVs. Fulfilling them in the early stages of design makes it more challenging due to the unavailability of key components such as fully developed ECU hardware, the battery pack, and the motor. To address this, a novel framework has been designed that combines virtual simulation with physical emulation, enabling the testing and validation of thermal control strategies without fully matured system and ECU hardware. The framework uses the Speedgoat platform as the central controller which hosts the control and thermal models developed in Simulink and Simscape. Speedgoat is physically

Chothave, Abhijeet, S, Bharathan, S, Ananth, Gangwar, Adarsh, Khan, Parvej, Gummadi, Gopakishore, Kumar, Dipesh

Optimization of Inverter Control Strategies for Improved Powertrain Efficiency Using E-Motor Emulation Platforms

2026-26-05091/16/2026

The traction inverter is a critical component in electric vehicles (EVs), functioning as the heart and brain of the electric powertrain. It controls the power conversion between the high-voltage battery and the electric motor, enabling efficient propulsion and regenerative braking. As EV adoption grows, especially in emerging markets like India, the need for robust and scalable inverter testing solutions becomes paramount. Traditional testing methods involving real batteries and e-motors pose several challenges in the Indian context, including high safety risks, infrastructure limitations, high battery costs, and limited availability of prototype-grade components. This paper presents a comprehensive approach to inverter validation using the AVL Inverter TS™ system— an advanced Power Hardware-in-the-Loop (PHiL) test system based on e-motor emulation technology.. It enables safe, efficient, and reliable testing without the need for actual batteries or mechanical loads. The system

Mehrotra, Soumya, Chhabra, Rishabh

Crash Pulse Characterization for the Passenger Vehicle Fleet in India.

2026-26-00291/16/2026

A crash pulse is the signature of the deceleration experienced by a vehicle and its occupants during a crash. The deceleration-time plot or crash pulse provides key insights into occupant kinematics, occupant restraints, occupant loading and efficiency of the structure in crash energy dissipation. Analysing crash pulse characteristics like shape, slope, maximum deceleration, and duration helps in understanding the impact of the crash on occupant safety and vehicle crashworthiness. This paper represents the crash pulse characterization study done for the vehicles tested at ARAI as per the ODB64 test protocol. Firstly, the classification and characterization of the crash pulses is done on the basis of the unladen masses of the vehicles. The same are further analysed for suitability of mathematical waveform models such as Equivalent Square Wave (ESW), Equivalent Triangular Wave (ETW), Equivalent Sine Wave (ESW), Equivalent Haversine Wave (EHSW) as well as EDTW (Equivalent dual trapezia

Jaju, Divyan, Mishra, Satish, Kulkarni, Dileep, Borse, Tanmay, Mahindrakar, Rahula Ashok, Mahajan, Rahul

Integration and Proving Ground Evaluation of a Connected Highway Pilot System

2026-26-01361/16/2026

Highway Pilot (HWP) systems, classified as SAE Level 3 Automated Driving Systems (ADS), represent a potential advancement for safer and more efficient highway drives. In this work, the development of a connected HWP prototype is presented. The HWP system is deployed in a real test vehicle and designed to operate autonomously in highway environments. The implementation presented in this paper covers the complete setup of the vehicle platform, including sensor selection and placement, hardware integration and communication interfaces for both autonomous functionality and Vehicle-to-Everything (V2X) connectivity. The software architecture follows a modular design, composed of modules for perception, decision-making and motion control to operate in real-time. The prototype integrates Vehicle-to-Vehicle (V2V) communication, such as Cooperative Awareness Messages (CAM), to enhance situational awareness and improve the overall system behaviour. The modular structure allows new functionalities

Domingo Mateu, Bernat, Leiva Ricart, Gisela, Facerias Pelegri, Marc, Perez, Marc

High-Frequency Dynamic Stiffness Measurements of Automotive Elastomers for Electric Vehicles

2026-26-03121/16/2026

The increasing adoption of electric vehicles (EVs) has intensified the demand for advanced elastomeric materials capable of meeting stringent noise, vibration and harshness (NVH) requirements. Unlike internal combustion engine (ICE) vehicles, EVs lack traditional powertrain-induced masking noise. In the automotive industry the dynamic stiffness of elastomers for internal combustion engines are determined traditionally using hydraulic test rigs up to test frequencies of max. 1000 Hz. Measurements in excess of these frequencies were not possible and are only carried out using computerized FE or CAE calculation models. Electric drive systems generate distinct tonal noise components in the high-frequency range up to 10 kHz , which are well perceptible even at low sound pressure levels. Consequently, the dynamic stiffness characteristics of elastomers up to 3000 Hz are critical for optimizing NVH performance. This study focuses on the high-frequency dynamic stiffness testing of automotive

Bohne, Christian, Gröne, Michael

Advancing Automotive Radar Characterization: OTA HIL Testing for Enhanced ADAS Safety

2026-26-00431/16/2026

The increasing demand for reliable Advanced Driver-Assistance Systems (ADAS) and autonomous driving technologies necessitates the precise validation of automotive radar sensors. Traditional on-road testing, while effective, presents challenges such as limited repeatability, high costs, and safety concerns. To address these limitations, this paper introduces an Over-the-Air (OTA) Hardware-in-the-Loop (HIL) methodology for radar characterization, providing a controlled and repeatable lab-based validation approach. This methodology enables dynamic testing of key radar parameters, including range estimation, angle of arrival measurement, Doppler velocity analysis, and object detection accuracy. The proposed setup supports diverse testing scenarios, such as variable target distances, relative speeds, multiple object simulation, and environmental effects, ensuring a comprehensive evaluation of radar behaviour under complex and safety-critical conditions. Through OTA testing, developers can

Jadhav, Tejas, Karle, Ujjwala, Paul, Harshit, SNV, Karthik

Vision Driven Testing Framework for Human-Machine Interfaces: An Automated Approach Using Computer Vision / Machine Learning

2026-26-05711/16/2026

Modern automotive infotainment systems and digital instrument clusters require rigorous testing to ensure reliability and compliance with industry standards. Traditional testing methods are labor-intensive and lack scalability. This research proposes a phased, vision-based approach using image processing, machine learning (ML), and computer vision (CV) to enhance testing automation and accuracy. Phase 1 employs open-loop testing using an NVIDIA Jetson Nano with camera modules to capture visual data from infotainment and instrument cluster displays. This phase focuses on the static analysis of visual elements, screen transitions, animations, and error messages. Feature extraction and pattern recognition techniques identify interface behaviors and detect anomalies without a feedback loop. This research will focus in depth on Phase 1, providing a detailed evaluation of its implementation and effectiveness. Phase 2 extends the testing environment with a hardware-in-the-loop (HIL) system

Lad, Rakesh Pramod, Mehrotra, Soumya, Mishra, Arvind

Power loss evaluation in 4WD axle and correlation with Testing results

2026-26-01071/16/2026

In the tractor, the efficiency depends on the transmission system, of all the losses major contribution is given by the transmission elements. To improve the efficiency, it became crucial to monitor the areas of power losses. Power loss in transmission refers the reduction in amount of power which being generated from the engine source to the final drive elements. There are various parameters and factors influence this condition, analyzing those conditions helps in identifying & improving the higher contributing components for driveline power loss. This study presents a comparative analysis of theoretical and experimental data regarding power loss in the gear train of a 70HP 4WD front axle. The investigation incorporates theoretical power loss calculations for individual components, including the bevel gear, bearings, thrust washer and seal arrangements. To evaluate and validate the power losses in the 4WD axle, a Gear Train Endurance test was conducted in a controlled laboratory

Jayapal, Jayaraj, Mahapatra, Soumya Ranjan, Sethi, Suvendu Kumar, JOSHI, SHRIKANT, BANGE, PRASHANT

ALLOY WHEEL RIM LINEAR CRASH VALIDATION WITH BENCH LEVEL TEST PROCEDURE

2026-26-05741/16/2026

Crash test plays a very crucial role in determining the passenger safety along with driver safety in most modern vehicles. This has become a prominent factor for many buyers to choose a safe car. During crash test, many components tend to fail. Amongst them, the major safety critical component which hampers the drivability of a vehicle is Wheel and Tyre Assembly. With the introduction of low aspect tyres, the failure rate of these assemblies has increased. A very high importance is given to ensure these parts withstand the subjection load as it is directly related to function of vehicle. Many methods are available to test the Wheel and Tyre assembly to ensure they pass the crash criteria. We have developed a novel test method which can simulate the crash pattern in the rig/bench level. The method employs a mechanical actuator which can be operated at designated load application to ensure the assembly undergoes the anticipated failure. The process is repeated with different types of

Medaboyina, HarshaVardhan, Singh, Ram Krishnan, SUNDARAM, RAGHUPATHI, Jithendhar, Ashokan

A Scientific approach to identify the source of intermittent steering rattle noise and implementing the design solutions

2026-26-03461/16/2026

Body-on-frame vehicles are well-regarded for their durability and off-road capabilities, but their structural design often makes them more vulnerable to noise, vibration, and harshness (NVH) issues. Vibrations originating from uneven roads are transmitted through the suspension and steering assemblies, sometimes resulting in rattles or other disturbances. These vibrations can be amplified by the inherent flexibility in the body-to-frame mounting system. In such vehicles, the steering system plays a critical role in driver comfort and is highly sensitive to vibrational inputs from the road surface, especially on coarse or uneven terrain. Occasionally, these inputs result in subtle rattle noises that are perceptible only to the driver and may not be detected under controlled testing environments. This poses a challenge for engineers trying to isolate and resolve such intermittent NVH phenomena. Identifying the source requires a combination of real-world driving evaluations, structural

Ramesh Chand, Karan Kumar, Gopinathan, Haridoss, Kabdal, Amit

Fuel Cell Electric Vehicles: Method for Characterization of Onboard Power Management System and Defining Vehicle Level Attributes

2026-26-05701/16/2026

Fuel Cell and Battery Pack/Capacitors are two power sources on-board a Fuel Cell Electric Vehicle. Each having it's own set of boundary conditions and ideal operating conditions in order to deliver expected performance over the intended useful life. Such a dual power source architecture poses a challenge of optimally balancing power delivery from Fuel Cell and Battery Pack/Capacitor in order to ensure health of both these important aggregates of vehicle over it's intended useful life. Therefore, a method and tool for characterizing the Power Management System of Fuel Cell Electric Vehicle is required during development and validation. "Aggregate Sizing" and "Calibration of Power Control Strategy" are significant factors for optimum life of Fuel Cell powered vehicle without compromising performance. Although the former is mainly a design decision, the latter is crucial during testing and validation to achieve the design objective and avoid unwanted failures. Distribution of load catered

Deshmukh, Naval, Ganguly, Sutanu, Sindgikar, Pavan, Jain, Sarika

Development of Component Level Testing Method for Passenger Car Wheels

2026-26-05041/16/2026

In the design of automotive wheels, safety is a crucial factor. Wheels contribute to a vehicle handling, braking and overall driving performance. Wheel are designed to withstand the weight of the vehicle and force generated during driving. It is the medium which isolates the obstacles coming from roads. Impact tests are usually performed after the wheel has been already designed and first prototypes have been produced. The test involves 90-degree free fall dynamic impact to determine the wheel resistance to deformation, cracking and overall structural failure. Its best method to captured the exact results during and post impact. These results are contributes the major role in development of automotive wheel rims. Most of the OEM’s are validating the wheels in virtual environment as FEA analysis software and LS Dyna. In this paper detailed procedure of testing of wheels at component level is presented. This work determines the development of test procedure for passenger car wheels in

Tormal, Uday Bapurao

Optimizing Vehicle Dynamics: A Methodology for Reducing Correlation Gaps

2026-26-00911/16/2026

In the highly competitive automotive industry, final design decisions are often made early in the product development cycle. However, physical prototypes may exhibit deviations from nominal specifications due to design tolerances, manufacturing tolerances, stiffness element fitment, and other noise factors. These deviations can lead to significant performance discrepancies (correlation gaps) between real-world performance and the digital twin representation created during the design phase. Repeatedly measuring all system parameters to account for these differences can be both costly and impractical. This research aims to bridge the gap between digital and physical models by identifying key system parameters from system characteristic data generated through controlled dynamic testing. Specifically, dynamic load cases are conducted using a 4-poster test rig, where vehicle responses are recorded at various suspension locations under controlled conditions. By analyzing these target

Verma, Rahul Ranjan, Goli, Naga Aswani Kumar, PRASAD, TEJ PRATAP

Test method and set up development for electric parking brake performance and durability validation in vehicle level as per RWUP

2026-26-05051/16/2026

The Objective is to develop a testing load case which can assess vehicle electric parking brake (EPB) performance and durability at vehicle level in different project development phases. In current scenario the EPB become one of a primary feature available in many passenger vehicles helps customers to apply this secondary braking system to hold the vehicle when parked. So, it is particularly important to evaluate this feature close to RWUP for the vehicle service life and studying the result before vehicle launch. The test method should be capable of capturing failures related to physical concerns, electrical characteristics, actuation time, gradient vehicle hold, effectiveness during vehicle running and durability. The most important challenge in this test method development is it should simulate the actual sequence followed by user in field on vehicle. A completely automated test set up integrating PLC and COBOT with closed loop feedback developed and discussed in this paper. During

DHANAPAL, M R, Vijayakumar, Narayanan, MAHESH, B, B, VENKATASUBRAMANIAN, Arthanathan, Sankaranarayanan

Parameterizing External Factors Influencing E-motor Consumption

2026-26-01751/16/2026

In recent times, a standard drive cycle is an excellent way to measure the electric range of EVs. This process is standardized and repeatable; however, it has the drawback of testing in a controlled environment with a low content of active functions. This can cause a significant variation in predicted range between drive cycles and actual on-road tests. This problem can be addressed via on-road testing and by using customer-based velocity cycles which involve more active functions. While on-road tests provide a more accurate idea of real-world consumption, the repeatability of these tests is low due to excessive randomness. External factors such as ambient temperature, driver behavior, traffic, terrain, altitude, and load conditions affect the vehicle during on-road testing, making repeatability difficult. No two measurements can have the same consumption even if done on the same road with the same vehicle due to these factors. This paper presents a machine learning-based method to

Kelkar, Kshitij, Kanakannavar, Rohit

Performance Analysis of Filter Resistance, Louver Airflow, and Fan Heat Dissipation to protect Swapping station Charger

2026-26-01771/16/2026

Efficient thermal management in electric vehicle (EV) charging stations is critical for ensuring the reliability, safety, and longevity of power electronics. This study presents a comprehensive bench test analysis of three key parameters influencing charger cooling efficiency: filter resistance, louver airflow, and fan heat dissipation. A test bench was developed to measure pressure drop, temperature gradients, and air velocity variations across multiple filter types, louver orientations, and fan configurations. The results show that higher-efficiency filters (e.g., HEPA, MERV13) significantly reduce airflow, increasing thermal stress on electronic components, while optimized louver angles improve directional airflow, reduce turbulence, and enhance cooling performance. High-performance axial and centrifugal fans with adaptive control mechanisms further contribute to effective heat dissipation, maintaining stable operating temperatures under varying load conditions. This study provides

S, Sri Saran, chinnanna, Manjunath, Ajith, Arjun, B, Viswanathan, Kulkarni, Mukund, R, Vigneshwaran, Dhachinamoorthi, Sivanantham

Steel-based Laminates for Lithium-ion Pouch Cell of Electric Vehicles

2026-26-01861/16/2026

Aluminium foils have gained traction with EV battery manufacturers for their pouch cell format. Over the years it has evolved as a material of choice, but it is still plagued by issues of stress concentration, swelling due to lower strength and stiffness of base aluminium layer. Preliminary investigation revealed that laminates using steel foil material (thickness <0.1mm) could be a potential candidate for EV pouch cell casing. Thus, steel-based laminate was developed meeting key functional requirements (e.g. barrier performance, insulation resistance, peel strength, electrolyte resistance, formable without cracking at edges, and heat sealing compliant). This innovative patented steel-based laminate was further used to manufacture pouch cell prototypes (maximum capacity 2.5Ah) for key performance tests (e.g. cell cycling, nail penetration and thermal runaway). The study paves the way for a low cost, sustainable and flexible yet strong steel-based laminate packaging material solution

Singh, Pundan Kumar, Raj, Abhishek, Kumar, Ankit, Chatterjee, Sourabh, Verma, Rahul Kumar, Samantaray, Bikash, Gautam, Vikas, Pandey, Ashwani

Digital Twin-Enhanced Chassis Dynamometer for EV Drivetrain Testing

2026-26-03631/16/2026

Accurate prediction of drivetrain performance and energy efficiency in electric vehicles (EVs) remains a challenge due to the limitations of conventional chassis dynamometer testing, which often overlooks dynamic vehicle-roller interactions, suspension responses, and regenerative braking effects. This paper presents a novel digital twin-enabled testing framework using a compact, two-roller chassis dynamometer integrated with real-time multibody dynamics and electromechanical co-simulation. The physical test bench is coupled with a virtual model of the EV, including suspension geometry, rear-to-front axle load distribution, tire–roller contact mechanics, and motor-inverter dynamics. By enabling bi-directional data exchange between the physical and virtual domains, the system emulates real-world load shifts, torque demand variations, and energy recovery under standardized drive cycles. This integrated approach enhances simulation fidelity, supports certification-compliant testing, and

Kumar, Akhilesh, V, Yashvati

India WLTC vs MIDC: Comparative Analytical study on BEV Range & Energy Consumption as per AIS175 draft & AIS039/040

2026-26-02441/16/2026

The Main Objective of WLTP (Worldwide Harmonized Light Vehicles Test Procedure) was to standardize the Globally Harmonized Test Procedure for evaluating Emission/ FE/ Range of Light Duty Vehicles. Europe has already adopted the WLTP from 2018. WLTC is a global harmonized test cycle that provides realistic emissions/ Range estimation based on its aggressive driving patterns. In India, currently Continuous Full MIDC (Modified Indian Driving Cycle) used to declare the Range of BEV's. Automotive Industry Standard (AIS) released a AIS 175 draft report for development of WLTP regulation in India (iWLTC : India WLTC). The real road Range of Battery Electric Vehicle (BEV) is observed 25% ~ 35% lower than declared Range of Full MIDC AER (All Electric Range). In Europe, real road range of BEV is 10% ~ 15% lower than declared range of WLTP AER. Analytical study performed on BEV Range/ EC as per AIS 175 draft & AIS 039/040 regulation to compare the impact of iWLTC vs MIDC cycle. The Range & Energy

Shiva Kumar, Mucharla, Tentu, Kavya

Migration from MIDC to WLTP in India: Challenges & Solutions for a Small Commercial Vehicle

2026-26-02151/16/2026

In line with global peers (EU, Japan etc.), the Automotive Industry Standard (AIS) Committee in India has decided to adopt "World harmonized Light vehicle Test Procedure (WLTP)" for M and N category vehicles with GVW not exceeding 3500 kg. As a result, "World harmonized Light-duty vehicles Test Cycle (WLTC )" is set to replace currently applicable "Modified Indian Drive Cycle (MIDC)" in the next couple of years. The draft CAFE III & CAFE IV norms for CO2 emission limits, which are set to be implemented in 2027 and 2032 respectively refer to a shift to WLTP from MIDC. This migration to WLTP is in sync with the demand for test procedures to replicate real driving conditions more appropriately. Further, with the Indian automotive sector growing at a robust CAGR of ~9%, the move to WLTP along with stricter emission norms is going to help the government take a major step towards India's COP26 pledge to achieve net zero emissions by 2070. WLTC cycle being much more dynamic with higher

Emran, Ashraf, Sandhu, Rouble, Pawar, Bhushan, Berry, Sushil

Multi-Model Analysis of O-Ring Compression and Relaxation Force Predictions Using Machine Learning and CAE Simulations

2026-26-04661/16/2026

O-rings play a critical role in ensuring leak-proof seals in a wide range of engineering systems. Accurate prediction of their compression and relaxation behavior under various material and geometric configurations is essential for optimal design and reliability. This study presents an analysis of machine learning techniques to predict two key performance outputs, compression force and relaxation force (after 10 minutes) trained on computer-aided engineering (CAE) simulation data. The experimental setup was represented in CAE simulation and the results were compared with experimental data conducted at ZF test facilities. Simulation results correlated well with the experimental data (deviation was less than the 5%). To create a dataset for training machine learning (ML) models, realistic ranges for the input parameters such as hardness and geometrical parameters were determined, and simulation data were generated using design of experiments (DOE). Multiple ML models were developed and

Kosgi, Durgaprasad, Alva, P Pancham, Dangeti, VenkataKrishna Pavan

Thermal Shock Test Rig for CNG Shut-off Valve

2026-26-05261/16/2026

In Automobile, Gasoline Engines are being used along with electrically operated shut-off valve installed at the roof of bus in case of higher capacity of CNG systems. In order to start/ stop CNG supply from cylinder for running of engine/ safety/ servicing an electrical operated ignition switch/ key controlled CNG Shut-Off Valve is placed just after the cylinders. There have been few failures of these CNG shut-off valves in field application. On investigation, it was observed that the CNG shut-off valve gets failed due to water ingress in coils from the cracks on surface generated due to spray of water (due to daily washing of bus and rain) on heated shut-off valves. In order to validate this field failure and subsequent validation of modified design, a need was felt to use a test rig which can exactly simulate the water spray based thermal shocks. However, there was no low cost facility available to simulate the field service condition for validation. Therefore, a low cost test set-up

Srivastava, Pravin Kumar, Vivekanand, Vivekanand, Kumar, Satish

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