Browse Topic: Tests and Testing

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Determination of Trace Elements in High Temperature AlloysARP1313E (Current)5/8/2026
This SAE Aerospace Recommended Practice (ARP) describes procedures for the determination of trace elements listed in AMS2280 for Nickel, Cobalt, and Iron-based high temperature alloys.
AMS F Corrosion Heat Resistant Alloys Committee
Requirements Extract for AS5127D Aerospace Standard Test Methods for Aerospace Sealants Methods for Preparing Aerospace Sealant Test SpecimensSA-DIG-000025/1/2026
This digital standard is a requirements extract of AS5127D Aerospace Standard Test Methods for Aerospace Sealants Methods for Preparing Aerospace Sealant Test Specimens. This file contains a general requirements extraction as well as files that are optimized for use with Doors Classic, Siemens Polarian, and PTC.
ALLOY WHEEL RIM LINEAR CRASH VALIDATION WITH BENCH LEVEL TEST PROCEDURE2026-26-05741/16/2026
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 solutions2026-26-03461/16/2026
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 Attributes2026-26-05701/16/2026
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 Wheels2026-26-05041/16/2026
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 Gaps2026-26-00911/16/2026
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 RWUP2026-26-05051/16/2026
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 Consumption2026-26-01751/16/2026
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 Charger2026-26-01771/16/2026
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 Vehicles2026-26-01861/16/2026
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 Testing2026-26-03631/16/2026
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 & AIS039/0402026-26-02441/16/2026
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 Vehicle2026-26-02151/16/2026
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 Simulations2026-26-04661/16/2026
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 Valve2026-26-05261/16/2026
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
A methodology to evaluate steering performance using Hardware in Loop Testing2026-26-05441/16/2026
In the present generation, steering system plays a major role in vehicle performance and factors like vehicle stability and control. This is because it is a direct interface to the driver. But to tune the steering system to the required standard, it takes several months for an OEM. This increases the lead time and development cost. Steering test benches have been increasingly popular in the recent automobile development process as they offering great advantages. They offer high level of control over system parameters which helps tune the performance of a steering system, especially for the perception of steering feel while driving. There are various steering test benches being developed to solve concerns that OEMs are facing while tuning and validating. A new methodology is defined involving the Steering Test Bench which can perform Hardware in Loop (HIL) and Driver in Loop (DIL) simulations. The objective of this paper is to establish correlation between Vehicle level & Virtual level
Agarwal, Gourav, Rajput, Srijan, Rasal, Shraddhesh, ahire, Manoj, Naidu, Kethireddi, Kumar, Deva, Prusty, B Rabi
Tractor Clutch wear simulation by Inhouse development2026-26-05721/16/2026
To develop an accelerated Clutch test simulation method at inhouse laboratory as System level of validation to replicate field phenomena in short time with controlled repeatability and increased test accuracy. Wet clutch is one of the M&M technology project for higher hp(75) tractors. Currently Mahindra having dry clutch system in higher hp tractors & presently Wet clutch development in progress for higher HP tractors for increasing clutch life & to reduce clutch pedal operation as per customer requirement, hence new test rig to be developed for validating new tractor wet clutch system as per RWUP. Previously tractor clutch system is completely evaluated through field testing on tractor level. Thus, there are several drawbacks in field testing like more waiting time to avail seasons, more testing time, evaluation of limited number of samples, non-availability of complete tractor on time, less accuracy, less repeatability of test results, unsafe conditions of rider, higher human fatigue
D, Yashwanth, Raja, R, Udayakumar, S, M, Jeevaharan, Vijayakumar, Narayanan
Ethanol Blended Diesel Fuel: Solution towards Carbon emission reduction and Sustainable Heavy Duty Transportation2026-26-01261/16/2026
Government of India has set up an ambitious net zero carbon emission target by 2070 in COP 26. To meet this target and to ensure energy security and energy sustainability, emphasis is being made to phase out petroleum derived fuels i.e. petrol, diesel etc. through sustainable alternatives. With all the environmental concern of diesel fuelled vehicles, it is a challenge to phase out them completely specifically from Heavy duty application due to their inherent attributes of high torque, efficiency and high range. Therefore, most pragmatic solution lies in reduction of carbon emission through fuel intervention and retain the characteristics of diesel fuelled vehicles. Efforts are under progress to explore the possibility of utilization of ethanol as blend in diesel fuels. This research work is focus on development and evaluation of ethanol blended diesel fuel in heavy duty engines. The ethanol and diesel are not miscible naturally so suitable agent was developed to make homogeneous
Mishra, Sumit Kumar
Development of a New Methodology for Measuring the Dimensions of Lighting Components in Construction Equipment Vehicles (CEVs) as per IS/ISO 12509:2004 using 3-Dimensional Planar Laser.2026-26-01451/16/2026
The light and light signalling devices installation test as per ISO 12509:2004 for Earth Moving Machinery / Construction Equipment Vehicles (CEV’s) is a mandatory test to ensure the safety of both road users and operators. Considering the shape and size of CEV’s, accurate measurement of lighting installation requirements is crucial for ensuring safety and regulatory compliance. The international standard ISO 12509:2004 specifies detailed criteria for these installations, including precise dimensional measurements of lighting components to guarantee optimal visibility and safety. Considering shape and Size of CEV’s, the accurate measurement of lighting installation requirements is crucial for regulatory compliance. ISO 12509:2004 outlines specific criteria for these installations requirements of lighting components, including the precise measurement of various dimensions to ensure optimal visibility and safety. Among these dimensional requirements, the dimension 'E' i.e., the “distance
Ghodke, Dhananjay Sunil, Belavadi Venkataramaiah, Shamsundara, Tambolkar, Sonali Ameya
Qualitative and Quantitative Correlation Study for Exterior Aerodynamics for Automotive Vehicle2026-26-04071/16/2026
The objective of the exterior aerodynamic performance assessment of automotive vehicles is to reduce the aerodynamic drag pressure and rear side wake zone, which improves overall energy consumption of the vehicle. Almost 30 to 40% of the energy is required to overcome the drag force and wake zone pressure offered by the air on the automotive vehicle. With the increase in high performance computing power (HPC) and its affordability, computational fluid dynamics (CFD) has become a popular and more effective tool for aerodynamic design and analysis in the automobile industry. In the real-world scenario, automotive vehicle is subjected to varying wind and operating conditions which affect its aerodynamic characteristics, and therefore it is difficult to reproduce such physical phenomenon in a conventional wind tunnel. Hence, the entire aerodynamic assessment was done in wind tunnel which is equipped with advanced aerodynamic assessment techniques like wheel rotations, boundary layer
Chalipat, Sujit, Biswas, Kundan, Tare, Kedar
Comprehensive Validation Methodologies for Hydrogen IC Engines: Combustion Analysis and Performance Metrics2026-26-02561/16/2026
The validation of hydrogen-fuelled internal combustion engine (H2 ICE) is critical to assess its feasibility as sustainable transportation with zero carbon emissions. Validation of H2 ICE necessitates a specialized testing & analysis methodologies to achieve reliable test results. This study shows the adverse effects on engine performance due to barometric pressure variation, turbo compressor out temperature variation due to increase in ambient temperature. The analysis also shows experimental results of engine performance variation based on hydrogen gas quality. Charge air quality reduces due to presence of nitrogen and moisture content in hydrogen gas and has direct impact on combustion. Engine Performance variation also observed due to engine components detoriation like valve seat wear & spark plug gap expansion. This study emphasizes the significance of precise instrumentation of thermocouples across engine on cylinder head, intake manifold & exhaust manifold, to detect performance
Vasudevan, Sindhuja, J, Narayana Reddy, Bolar, Yogesh Ganesh, Pandey, Sunil, N, Harish, N R, Varatharaj, Karthikeyan, K, Kumar D, Kishore
Virtual Powertrain Development and Calibration methodology: The Role of Model-in-the-Loop in Calibration and Testing of EV power Train integrated with real road simulation tools.2026-26-04721/16/2026
The automotive industry has witnessed significant advancements in powertrain development over recent years, with further evolution expected in the near future. Modern vehicle propulsion systems now encompass a broad spectrum, including fully electric vehicles, plug-in hybrid models, mild 48V hybrid powertrains, and traditional internal combustion engine vehicles. This growing variety demands extensive engineering efforts for development and testing across different powertrain configurations. To facilitate the simultaneous advancement of multiple powertrain technologies while keeping costs manageable, optimizing calibration and testing processes is crucial. A combination of cutting-edge simulation techniques and state-of-the-art testing equipment offers an effective solution, introducing innovative testing methodologies that streamline the development of sophisticated propulsion architectures. This paper explores the implementation of Model-in-the-Loop (MIL) testing as a key methodology
Elumalai, Elakkia, P, SahayaSurendiraBabu, S, Sivashankar, J, Frederick Royston, S, Gowtham
Automated evaluation of drive file simulation accuracy2026-26-05281/16/2026
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
Novel Approach on Material characterization Testing of various Wiring Harness2026-26-05481/16/2026
The automotive wiring harness (length of 4-5 km) is a very important and complex system in the development of a modern car due to a lot of new electric & electronic components and sensors. It is a very sensitive material unlike metals and is considered as a composite which is highly anisotropic in nature, as it consists of several different layers of copper/aluminum strands and insulation. Because of insulation, wiring harness exhibits viscous plastic behavior which is crucial in determining the durability and long-term performance of the cables. Material properties play an important role in determining the behavior of wiring harness after assembly into the car. Wiring harness may undergo Bending, Torsion and Tension loads, causing the stress and strain in the individual electrical wires. The lack of CAE validation of the wiring harness routing may lead to extra costs for the automotive OEMs over a period. This paper describes the novel method of Testing the Cables and Bundles used in
Beesetti, Siva, Kalkala Balakrishna, Prasad, James Aricatt, John, SHAH, Dipam, Tas, Onur, Krogmann, Stephan
Simulation-Driven Load Spectrum Prediction_ Virtual RLDA for Chassis and Suspension System2026-26-00951/16/2026
In the rapidly evolving and highly competitive automotive industry, manufacturers are under immense pressure to bring products to market quickly while meeting customer expectations. As a result, optimizing the product development timeline has become essential. Structural integrity analysis for chassis and suspension systems lies in the accurate acquisition of operational load spectra, conventionally executed through Road Load Data Acquisition (RLDA) on instrumented vehicles subjected to proving ground excitation. At this point, RLDA is mainly used for final validation and fine-tuning. If any performance shortfalls, such as premature component failure or durability issues, are discovered, they often trigger design revisions, prototype rework, and additional testing This study proposes a Virtual Road Load Data Acquisition (vRLDA) methodology employing a high-fidelity full-vehicle multibody dynamic (MBD) representation developed in Adams Car. The system is parameterized and uses high
Goli, Naga Aswani Kumar, PRASAD, TEJ PRATAP
Development of a Fuel Injector Driver for Accelerated Testing2026-26-05641/16/2026
This paper presents the design and development of a cost-effective fuel injector driver for accelerated testing of injectors. The driver accurately simulates injection patterns across various vehicle operating conditions. It can be programmed with injection maps for different engines, test cycles as per part drawings, predefined engine running cycles, and manual control where the frequency and duty cycle of PWM pulses are user-defined. The device can also be operated remotely via a Wi-Fi access point. This setup played a pivotal role for rapid comparative analyses among different suppliers, aiding in the final product selection. Accelerated testing was performed under various operating cycles, with performance evaluations done periodically. Conducting such tests at the vehicle level or on engine test benches would involve significant time and cost. However, the rapid development of the microcontroller-based test setup enabled quick initiation and completion of testing in a short span
Bhatt, Pancham, Agrawal, Adheesh, Kuchhal, Abhinav
A Deep Learning Approach for Dynamic Range Estimation in Electric Fleet Vehicles.2026-26-06751/16/2026
Keywords: Real-Time Range Prediction, Long Short-Term Memory (LSTM), Time Series Modelling, Deep Learning, Vehicular Telemetry, CAN Data, Range Anxiety Accurate and real-time range estimation is a critical enabler for efficient energy management and operational planning in Commercial Electric Vehicles (CVEVs). This project presents a robust deep learning-driven framework for vehicle range prediction, leveraging a Long Short-Term Memory (LSTM) network trained on high-frequency powertrain CAN data obtained from CVEVs operating across diverse driving environments. The dataset comprises key dynamic and environmental parameters—including State of Charge (SOC), vehicle speed, acceleration, and temperature—captured during real-world operations. Extensive data pre-processing techniques were applied to ensure signal integrity, including high-resolution timestamp synchronization, noise filtering, and imputation of missing values, thereby establishing a reliable foundation for time-series
surlekar, Samarth, Ghorpade, Swapnali, Kalghatgi, Bhakti
Measurement of Acoustic Sensitivity of Automotive Drum Brake to Multiple Faults2026-26-05551/16/2026
Multiple faults can occur over time in drum brakes, which are commonly used on the rear of heavy vehicles and two-wheelers, compromising passenger safety and ergonomics. Given the recent success of artificial intelligence in fault diagnosis, it can be applied effectively to automotive brakes during operation when combined with advanced measurement techniques. However, monitoring the brake health during operation is challenging due to the rotational motion of components and space constraints for sensors. Consequently, this study investigates the use of measured radiated noise from drum brakes (instead of vibrations) to detect faults. A test bench mimicking typical on-road braking dynamics has been developed to operate in a controlled environment with pre-determined fault levels. This setup measures acoustic signals during transient brake events. Acoustic responses from several experiments that imitate three common brake fault conditions are measured. The acoustic sensitivity to each
Shripad, Kumar Milind Rewanand, Yella, Akash, Sundar, Sriram
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
Evaluation of Methods used to Determine Vehicle Center of Gravity Height2026-26-05131/16/2026
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 Study2026-26-00771/16/2026
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 validation2026-26-05331/16/2026
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 perspective2026-26-01331/16/2026
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 performance2026-26-05021/16/2026
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 wheelers2026-26-05561/16/2026
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 Simulation2026-26-04051/16/2026
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 Prediction2026-26-03721/16/2026
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 Mechanisms2026-26-04251/16/2026
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 Management2026-26-04401/16/2026
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 Vehicle2026-26-03581/16/2026
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 Testing2026-26-02241/16/2026
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 guides2026-26-03641/16/2026
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 Vehicle2026-26-04101/16/2026
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 Tires2026-26-05801/16/2026
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 tool2026-26-04701/16/2026
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 Vehicles2026-26-04451/16/2026
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
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