Browse Topic: Test facilities

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SAE TOMORROW TODAY - Smarter Automotive Testing with AI and Simulation1352207/03/2025
The new test track isn't asphalt--it's AI and simulation. From hardware-in-the-Loop (HIL) to real-time performance analytics, new innovations are reshaping how vehicles are designed, validated, and brought to market. At the forefront of this transformation is A&D Technology, a leader in integrated test automation and lab management solutions for the transportation and energy markets. By integrating AI-driven analytics with high-fidelity simulation environments, the company is empowering automotive engineers to streamline testing workflows, reduce physical prototypes, and accelerate innovation in everything from EV powertrains to autonomous systems. To learn more, we sat down with Mike Uhl, President & CEO, to discuss how A&D Technology's work in simulation and test automation is helping engineers bring the next generation of mobility technologies to life. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget
Hineman, Marcie
Quantitative Analysis of a Hybrid Electric HMMWV for Fuel Economy Improvement2024-01-335604/23/2025
ABSTRACT This paper presents a quantitative analysis and comparison of fuel economy and performance of a series hybrid electric HMMWV (High Mobility Multi-purpose Wheeled Vehicle) military vehicle with a conventional HMMWV of equivalent size. Hybrid vehicle powertrains show improved fuel economy gains due to optimized engine operation and regenerative braking. In this paper, a methodology is presented by which the fuel economy gains due to optimized engine are isolated from the fuel economy gains due to regenerative braking. Validated vehicle models as well as data collected on test tracks are used in the quantitative analysis. The regenerative braking of the hybrid HMMWV is analyzed in terms of efficiency from the kinetic energy at the wheels to the portion of regenerative power which is retrievable by the battery. The engine operation of both the series hybrid and conventional HMMWV are analyzed using a 2-D bin analysis methodology. Finally, the vehicle model is used to make
Nedungadi, Ashok, Masrur, Abul, Khalil, Gus
3D-Printed Reactor Core Makes Solar Fuel Production More EfficientTBMG-5219312/01/2024
In recent years, engineers at ETH Zurich have developed the technology to produce liquid fuels from sunlight and air. In 2019, they demonstrated the entire thermochemical process chain under real conditions for the first time, in the middle of Zurich, on the roof of ETH Machine Laboratory. These synthetic solar fuels are carbon neutral because they release only as much CO2 during their combustion as was drawn from the air for their production. Two ETH spin-offs, Climeworks and Synhelion, are further developing and commercializing the technologies.
Scientists Fuse Simulations and Machine Learning to Accelerate Novel Additively Manufactured MaterialsTBMG-5212712/01/2024
Researchers at the Johns Hopkins Applied Physics Laboratory (APL) in Laurel, Maryland, have demonstrated a novel approach for applying machine learning to predict microstructures produced by a widely used additive manufacturing technique. Their approach promises to dramatically reduce the time and cost of developing materials with tailored physical properties and will soon be implemented on a NASA-funded effort focused on creation of a digital twin.
ENGINE, BATTERY AND VEHICLE SIMULATION STRATEGIES FOR TRANSMISSION TESTING2024-01-311711/15/2024
WHY DO WE NEED SIMULATIONS? This paper is intended to provide a broad presentation of the simulation techniques focusing on transmission testing touching a bit on power train testing. Often, we do not have the engine or vehicle to run live proving ground tests on the transmission. By simulating the vehicle and engine, we reduce the overall development time of a new transmission design. For HEV transmissions, the battery may not be available. However, the customer may want to run durability tests on the HEV motor and/or the electronic control module for the HEV motor. What-if scenarios that were created using software simulators can be verified on the test stand using the real transmission. NVH applications may prefer to use an electric motor for engine simulation to reduce the engine noise level in the test cell so transmission noise is more easily discernable.
Johnson, Bryce
Quantitative Analysis of a Hybrid Electric HMMWV for Fuel Economy Improvement2024-01-3356-TEST-REC11/15/2024
ABSTRACT This paper presents a quantitative analysis and comparison of fuel economy and performance of a series hybrid electric HMMWV (High Mobility Multi-purpose Wheeled Vehicle) military vehicle with a conventional HMMWV of equivalent size. Hybrid vehicle powertrains show improved fuel economy gains due to optimized engine operation and regenerative braking. In this paper, a methodology is presented by which the fuel economy gains due to optimized engine are isolated from the fuel economy gains due to regenerative braking. Validated vehicle models as well as data collected on test tracks are used in the quantitative analysis. The regenerative braking of the hybrid HMMWV is analyzed in terms of efficiency from the kinetic energy at the wheels to the portion of regenerative power which is retrievable by the battery. The engine operation of both the series hybrid and conventional HMMWV are analyzed using a 2-D bin analysis methodology. Finally, the vehicle model is used to make
Nedungadi, Ashok, Masrur, Abul, Khalil, Gus
SAE TOMORROW TODAY: Solar Powered Boating on the Great Lakes1346707/23/2024
With 20 percent of the world's fresh water, Michigan plays a large role in the future of maritime mobility. Recreational boating, commercial shipping, ports, and harbors serve a crucial role in the economic vitality of Michigan's coastal communities and the Great Lakes. That's why the Michigan Economic Development Corporation recently launched the Fresh Coast Maritime Challenge to help decarbonize the state's waterways. As part of this grant, Lilypad Labs, a startup based in Holland, Mich., launched the Lilypad, a sharable, 100 percent solar powered boat that provides a quiet, sustainable, and pollution-free boating experience. To learn more about the importance of sustainable recreational and commercial boating, we sat down with Justine Johnson, Michigan's Chief Mobility Officer, Michigan Economic Development Corporation, and Dana Lowell, CEO, Lilypad Labs, to discuss how the public and private sectors are working together to decarbonize the Great Lakes waterways. If you'd like to get
Hineman, Marcie
Accelerated Lab Test facility for NRS Leaf Spring bracket for HCV Application2024-26-034401/16/2024
In the modern automotive sector, durability and reliability are the most common terms. Customers are expecting a highly reliable product but at low cost. Any product that fails within its useful life leads to customer dissatisfaction and affects the reputation of the OEM. To eradicate this, all automotive components undergo stringent validation protocol, either in proving ground or in lab. This paper tails on developing an accelerated lab test methodology for NRS leaf spring bracket by simulating field failure. Initially, potential failure causes for spring bracket were analyzed. Road load data was then acquired at proving ground and customer site to evaluate the damage on the spring bracket. To simulate the field failure, lab test facility was developed, reproducing similar boundary conditions as in vehicle. Field failure was simulated with the existing design samples and Improved design of spring bracket was validated in the same test conditions and compared with the life of existing
G, Manthiramoorthy
Acoustic characterization of AC motor using sound intensity in standard laboratory environments2025-01-001005/05/2023
Sound power is commonly used metric to quantify acoustic sources like AC motor in electrified powertrain. This testing is often performed in an anechoic environment to create free-field conditions around the unit. To eliminate the influence of extraneous noise sources, the anechoic facilities must be further isolated from driver and absorber dynamometers. These dynamometers are needed for running the AC motors in the desired speed and load conditions. For early detection of potential issues, it is advantageous to have the capability for engineers to conduct acoustic tests in standard laboratory environments. These may include non-acoustically treated rooms, presence of extraneous noise sources (e.g., driver and absorber dynos), etc. In such environments, sound intensity-based sound power determination methods could be utilized. The sound intensity-based approach is covered in ISO 9614 standard. The norm is to sweep an intensity probe on a sound source in constant speed condition to
Kumar, Aditya, Ippili, Rajani
Application of blocked force methodology to an electrified beam axle from a medium-duty truck in vehicle and in a dynamometer test cell2025-01-005405/05/2023
The recent shift in propulsion choice away from internal combustion engines has increased the relevance of sound and vibration from electric motors and gearboxes. Electrified beam axles require different metrics from conventional beam axles for noise and vibration because they have multiple sources of vibration energy, including an electric motor and sometimes multiple reduction gearsets. They also require different metrics from electric drive units because they have stiff suspension connections and lack significant isolation. Blocked force is a good candidate because it can completely characterize the vibration energy transmitted into a receiver and is especially useful because it is theoretically independent of the vehicle-side structure. While the blocked force methodology is not new, its application to beam axles is relatively unexplored in the literature. This paper demonstrates a case study of blocked force measurement of an electrified beam axle from a battery electric medium
Shaw, Matthew D, Grimmer, Michael J
Pass-by noise comparison of two test facilities with vehicles operating in electric mode2025-01-000505/05/2023
Outdoor test facilities for light vehicle exterior noise regulatory measurement need to have surfaces certified to meet ISO 10844. A recent study considered plug-in-hybrid vehicles operating purely in electric mode to compare results at two facilities, one in Japan and in the U.S. This emphasizes the pavement contribution. Overall results are generally similar, with a few differences which are discussed.
Sorenson, Steve, Shao, Guangxin
The DANA EV NVH Laboratory2025-01-000705/05/2023
A cutting-edge EV powertrain NVH laboratory has been established at DANA Incorporation’s world headquarters in Maumee, enhancing their capabilities in EV powertrain NVH development. This state-of-the-art and industry lead laboratory is designed to meet various NVH requirements for EV powertrain development and sign-off processes. This laboratory supports the use of a live motor for input and is equipped with an input module that allows for detailed examination of NVH characteristics of new powertrain configurations before prototype motors are available, significantly reducing development time for new drivetrain systems. Key features of the laboratory include a hemi-anechoic chamber, two AC asynchronous load motors, an acoustically isolated high-speed input motor, and two battery emulators that cover both low and high voltage requirements. The NVH laboratory enables engineers to assess system performance and correlate it with digital twin models. DANA engineers can develop and optimize
Cheng, Ming-Te, Zugo, Chris
SAE TOMORROW TODAY: Sustainable Rubber Hits the Road1337902/03/2023
When the rubber hits the road, one tire company stands out among the rest. From raw material traceability to supply chain transparency, Goodyear Tire & Rubber Company is not only helping to do what's good for business, but what's good for the planet, too. Driven by an ambitious sustainability strategy, Goodyear has set goals to develop a tire made of 100% sustainable materials by 2030 and using only renewable energy in its manufacturing facilities and operations by 2040. The company is even working to develop a domestic source of natural rubber from a specific species of dandelion in collaboration with the Department of Defense, the Air Force Research Lab, BioMADE and Farmed Materials. To learn more about Goodyear's impressive sustainability journey, we sat down with Ellis Jones, Vice President and Chief Sustainability Officer. He discusses the company's uniquely strong culture, the importance of working collaboratively with small farms, and the development of new sustainable tire
Hineman, Marcie
Faster Cool-Down of a Reefer Unit by Optimizing the System Losses through Experimental Investigation2022-28-044211/09/2022
Refrigerated shipping containers are one of the four segments of the cold chain; cooling and storage; refrigerated transport; distribution centre and refrigerated display in super markets. The term reefer has become an established term to refer refrigerated shipping containers. It is one of the emerging areas in transport segments. With the onset of ongoing pandemic this area has further drawn global attention recently and due focus is being given to the development and improvement of reefer unit Hence with the growing demand in this field the energy consumption is also leapfrogging day by day. Primary energy sources (fossil fuel) are depleting and their environmental impact is raising anxiety around the world. In order to minimize unnecessary energy waste in refrigerated shipping container system, it needs to be designed to be energy efficient and provide high cooling capacity to ensure rapid pull down to carriage temperature and to maintain product quality at idle. Improper operation
Sen, Somnath
Locking Side Pull Hoist RingTBMG-4691611/01/2022
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Q&A22AUTP10_1010/01/2022
In June 2022, Hyundai Motor America broke ground for its Safety Test and Investigation Laboratory (STIL), an industry-unique testing facility dedicated to root-cause crash investigations and electric vehicle/future-product analysis activities at its Michigan R&D campus west of Detroit. Not long after the $51.6-million STIL's inauguration, the company named Brian Latouf as its first-ever Global Chief Safety Officer to “integrate the engineering resources of Hyundai and HMNA by combining safety field investigations, safety data analysis and safety-engineering performance into a streamlined global technical function.” At the STIL groundbreaking, SAE Mobility Media editorial director Bill Visnic spoke with Latouf about Hyundai's crash-safety vision.
Allison's now open for hydrogen testing22TOFHP10_0510/01/2022
With the atomic number 1, hydrogen is the lightest element in the Periodic Table, but it's rapidly becoming a heavyweight for the mobility future. Development of hydrogen fuel cell vehicle (HFCV) and hydrogen-fueled combustion engines for commercial-vehicle use is driving demand for specialized testing and validation facilities. Allison Transmission is in the vanguard of this movement, recently launching a comprehensive hydrogen test capability at its 60,000-ft2 (5,575-m2) Vehicle Electrification + Environmental Test Center in Indianapolis. Prior to its official debut, SAE Media was provided an exclusive look at the new facility - which also includes compressed natural gas (CNG) testing - courtesy of David Proctor, the test center's general manager, and Tim Szilveszter, Allison's sales account manager.
Brooke, Lindsay
Design of a Laboratory Sampling System for Brake Wear Particle Measurements2022-01-117909/19/2022
Brake wear is one of the dominant sources of traffic-related particulate matter emissions and is associated with various adverse environmental and health hazards. To address this issue, the UNECE mandated the Particle Measurement Program to develop a harmonized methodology for sampling and measuring brake wear particles with a full-flow dilution tunnel on a brake dynamometer. Here we present the design of a novel, fully PMP compliant sampling tunnel. The dimensions and general layout of the tunnel are based on minimization of super-micron particle losses and consideration of space limitations in brake-dynamometer setups as well as the need for efficient utilization of the test facilities (reduced testing times). Numerical calculations suggested that the critical section of the system is the sampling train from the sample probes to the instrumentation inlet/filter holder. An optimal sampling train flow of ~10 l/min was identified and formed the basis for the design of a dedicated PM
Mamakos, Athanasios, Huber, Michael Peter, Arndt, Michael, Reingruber, Herbert, Steiner, Gerald, Weidinger, Christoph
Shaping Light Enables 2D Microscopes to Capture 4D DataTBMG-4598406/01/2022
Super temporal resolution microscopy allows imaging of fluorescent molecules 20 times faster than traditional lab cameras normally allow. A general method has been developed to let a microscope capture 3D spatial information along with the fourth dimension: molecular movement over time. This will help scientists who study dynamic processes view where molecules of interest are located and how fast they move; for example, within living cells.
Estimation of Advisory Vehicle Speed For Low Curvatures Assuming Ideal Steering Behaviour2022-01-111003/29/2022
In the current scenario, the vehicle is integrated with infotainment maps and a telematics module, which provide extensive information regarding the terrain, including the radii of curvature (R). The transportation authority had imposed stringent guidelines regarding the range of advisory vehicle speeds (AVS) (e.g. [15 25] MPH for R = 18.4m), but a unique value of AVS for a definite curvature is not recommended. The maximum allowable speeds for R = 8.34m (U-turn) is 6.7m/s (15mph), whereas for R = 42.57m (cloverleaf interchange) is 11.17m/s (25mph). Also, in the existing literature, the mathematical models developed to estimate the AVS does not include all the steering parameters [speed, RRC, yaw rate, lateral acceleration]. Therefore, in this article, the concept of Ideal Steering Behavior (ISB) was proposed, and driver behaviour vector (DBV) was utilised to adapt “human-like” driving to estimate a unique AVS for a definite R. The DBV was retrieved using the 2019 Cadillac Escalade
Jim, YaugerPresenter, Hay, Curtis L., Malik, Hafiz, Evans, Sally
Methodology and application on load monitoring using strain-gauged bolts in brake calipers2022-01-112103/29/2022
As technology evolves, the number of sensors and available data on vehicles grow exponentially. In this context, it is essential to use sensors for monitoring key components, increasing safety and reliability, and gathering data useful for mechanical dimensioning and control systems. This paper presents an application of strain-gauged bolts brake calipers fixation of two electric vehicles. With this approach it was possible to obtain the loads applied to the brake pads and correlate them with braking behavior, therefore gaining insights on braking conditions and system state. The goal of the study is analyzing the strengths and limitations of the method and proposing developments to deploy it in real applications. This topic is particularly important and novel for electric vehicles, where powertrains can create positive and negative torques and generate complex interactions with braking system. Strain-gauges are a long-known technology applied in many fields, and its usage in bolts and
de Carvalho Pinheiro, Henrique, Sisca, Lorenzo, Carello, Massimiliana, Ferraris, Alessandro, Airale, Andrea Giancarlo, Falossi, Marco, Carlevaris, Alberto
Proving Ground Durability Test Schedule Development for Electrified Vehicle Drivelines using Virtual Simulations2022-01-079003/29/2022
A new method is presented for developing proving ground durability tests for electrified vehicle (xEV) drivetrains. For xEVs, the durability tests must be able to capture the added driveline torques due to regenerative braking, customer battery charge/recharge usage, and battery power degradation over time. In terms of xEV duty cycle test schedule development, using actual vehicle data from specific proving ground test events might prove to be costly and time consuming. Furthermore, newer electrified prototype vehicles might not be available for trackside testing while still undergoing the design stage. The new method presented here aims to reduce the complexities of xEV proving ground duty cycle development with the use of a high-fidelity vehicle dynamics simulation model for electrified powertrains. The xEV model uses a mixture of forward (to predict speeds, given torque demands) and inverse dynamics (to predict torques, given constant speed requirements) to predict driveline
Mohamed, Richard, Salvatori, David, Ramakrishnan, Venkat, Magistrali, Stefano
Influence of Manufacturing Processes on the Structural behavior of Truck Frame Rail Sections2022-01-091403/29/2022
The sequence of manufacturing processes involved in the making of ladder shaped truck frame rail assembly leave certain amount of manufacturing and assembly imperfections in the form of plastic deformation and residual stresses in some areas of frame rail ‘C’ sections. The plastic deformation and the resulting residual stress should not be allowed to cross the safer limit as it would affect the structural behaviour of the frame rail while interacting with the externally induced loading stresses from extreme road operating conditions. If the combined stress level crosses the yield limit of the frame material, it may lead to premature failure of frame rail much before it gives the expected life. One such manufacturing induced premature failure in a truck frame rail assembly during proving ground trials was studied in detail using experimental analyses and presented in this paper. As part of this study, the local material crowding due to plastic deformation occurring at certain sections
K, Chinnaraj, KR, Balaji, Gopal, Gopi
Loading classification for fatigue design applied to automotive time-series2022-01-029903/29/2022
This study focuses on variable amplitude loadings applied to automotive chassis parts experiencing carmaker’s specific proving grounds. They are measured with respect to time at the wheel centres and composed of the six forces and torques at each wheel, within the standard vehicle reference frame. In the scope of high cycle fatigue, the loadings considered are supposedly acting under the structure yield stress. Among the loadings encountered during the vehicle lifetime, two classes stand out: • Driven Road: loads measured during the vehicle manoeuvre (cornering, braking). • Random Road: random loads mainly coming from the road asperity. To separate both effects, a frequency decomposition method is proposed before applying any lifetime assessment methods. The usual rainflow counting method is applied to the Driven Road signal. These loadings, depending on the vehicle dynamic, are time-correlated. Thus, the load spectra is set only thanks to the vehicle accelerations time-measurement
Bellec, Enora, Doudard, Cédric, Facchinetti, Matteo, Calloch, Sylvain, Moyne, Sylvain
US EPA NVFEL Repeatable-Vehicle Program – Emission Lab Testing System Performance Quality Monitoring2022-01-068903/29/2022
According to US FCR the vehicle emission testing system must be monitored and checked periodically, and NVFEL TATD has developed a quality control monitoring program named “Repeatable-Vehicle Program”, the current vehicle selected is a proper sized and featured sedan, so called RepCar. The vehicle emission lab cell test used a chassis dyno to simulate some road driving conditions, a CVS system to collect exhaust sample and analyzed by a group of chemical benches. The testing condition is satisfied the FCR requirement and controlled during the testing procedure. A specific driving cycle including two phases was designed to evaluate vehicle power system at different speed load performance and measurement instruments accuracy under different concentration range. The phase1 is modified FTP505, phase2 is the most aggressive part of US06, and at the end of phase2 driving trace had a 30-second constant 75 mph cruising followed by a coast down. The RepCar equipped a data logger recording few
Tang, Xiaoguo
SAE TOMORROW TODAY: Test Tracks of Reality: Applied Intuition and the Simulated Road, Warehouse and Port1318101/20/2022
What if you could test hundreds of thousands of traffic and road scenarios before your autonomous vehicles ever even touched asphalt? Imagine billions of miles and an untold number of road events encountered in the virtual world before your car or truck even left the factory floor. Talk about a head start when it comes to safety and efficiency. Using a comprehensive suite of products created from the best practices in software development, the minds at Applied Intuition work with clients to design virtual test environments that simulate everything the road can throw at them. They are creating a world where software-enabled vehicles are an integral part of society across all industries where there are vehicles - roads, yes, but also factories and ports as well. In this episode of SAE Tomorrow Today, Qasar Younis, Co-Founder and CEO, and Peter Ludwig, Co-Founder and CTO of Applied Intuition, discussed how they're combining Detroit engineering know-how with Silicon Valley digital
Hineman, Marcie
Inspection, Ultrasonic Product Over 0.5 Inch (12.7 mm) ThickAMS2630E (Current)11/09/2021
This specification covers procedures for ultrasonic inspection, by pulse-echo procedures, of flat, rectangular, round, cylindrical, and contoured products having a thickness or cross-sectional dimension greater than 0.5 inch (12.7 mm), using either contact or immersion methods, and using the longitudinal-wave or shear-wave modes or combinations of the two, as necessary. This specification may apply to testing finished machined parts provided the parts can meet the basic testability requirements, such as size, contour, metallurgical structure, and thickness.
AMS K Non Destructive Methods and Processes Committee
Inspection, Ultrasonic Product Over 0.5 Inch (12.7 mm) ThickAMS2630E-TEST-REC (Historical)11/09/2021
This specification covers procedures for ultrasonic inspection, by pulse-echo procedures, of flat, rectangular, round, cylindrical, and contoured products having a thickness or cross-sectional dimension greater than 0.5 inch (12.7 mm), using either contact or immersion methods, and using the longitudinal-wave or shear-wave modes or combinations of the two, as necessary. This specification may apply to testing finished machined parts provided the parts can meet the basic testability requirements, such as size, contour, metallurgical structure, and thickness.
AMS K Non Destructive Methods and Processes Committee
Component S/N Curve Testing Methodology for Exhaust System Validation2021-26-045109/22/2021
The exhaust system design and development needs to be more flexible and easily adaptable for the dynamic changes with the introduction of new emission and noise regulations. Conventionally, bending moment testing is used to validate significant components like inlet and outlet pipe/cone joints and bend pipes through Bi-Ax test rig. Road load re-production test is an improvement of the conventional approach to predict component durability. However, it is more time consuming and involves the sequential process of acquiring road load data such as sensor instrumentation, strain measurement at the test track, data processing and input to Bi-Ax testing. S/N Curve testing is introduced recently as an alternate method to minimize the use of RLDA. It can be done upfront during vehicle unavailability and other challenging conditions and also as a parallel activity along with RLDA. Our objective is to show the simulation and validation process of Component S/N Curve testing with a LNT+DPF system
Rajadurai, Sivanandi, Natarajan, Suresh, Srivatsan, Rajesh, Sivalingam, Ananth
Front Axle Kingpin Bush - Evaluation of Wear Rate in Operating Conditions2021-26-047309/22/2021
In automobiles, front axle assembly is a main load bearing member and houses steering linkages. Front axle assembly has two main parts viz. axle beam and axle arm, interconnected by a kingpin. This kingpin allows the rotation of axle arm during steering events. To avoid metal to metal contact between axle arm and kingpin, bushes are housed on the top and bottom half of the axle arm & in axle beam. Due to radial load and steering rotation, as a weak member, bushes will wear out faster. This affects the proper functioning of steering mechanism. Hence, the bushes need to be evaluated prior to its implementation in vehicle. In general, bushes are evaluated using Pin-On-Disc test as a comparative study, but it does not simulate exact boundary conditions as in vehicle. Next option is vehicle level validation but leads to more lead time and testing cost. Hence, as an optimized solution, the same vehicle operating conditions can be replicated in component level testing. Considering the
Bakthavachalam, Sathish Kumar, N, Gopi Kannan, Narasimman, Obuli Karthikeyan, R, Suresh
Coastdown Road Load Coefficients of Passenger Vehicles – Variation Analysis and its Correlation with Temperature2021-26-048709/22/2021
Road Load parameters (rolling resistance & aerodynamic drag) of a vehicle have strong impact on overall Vehicle Emissions & Fuel Economy. The road load coefficients are simulated on chassis dynamometer to carryout emission & fuel economy measurement and are hence required to be found beforehand. A realistic measure of road load parameters can be obtained by conducting a coastdown test. Coastdown test results are hugely impacted by various environmental parameters like ambient temperature, atmospheric pressure, wind speed etc. Though performed in standard boundary conditions, results of multiple tests performed on a vehicle vary from one another due to variations in the mentioned environmental parameters over & above standard test to test variation. This paper aims at studying the variation in test results due to ambient temperature as one of the parameters responsible. For this study, road load coefficients from more than 100 coastdown tests conducted on oval test track for almost 30
Kuhar, Saurabhh, Pattalwar, Ashutosh, Gupta, Parveen
Aerodynamic performance prediction using a novel approach of Ansys Mosaic mesh & revolutionary GEKO turbulence model, and application of Adjoint Solver for aerodynamic Optimisation of a car2021-26-035309/22/2021
In the present scenario, wherein the cost of transportation is continuously increasing, achieving optimum fuel efficiency is key area of focus for many Automotive OEMs. Aerodynamic drag is prominent form of resistance any vehicle encounters while it is in motion, and this particularly increases at higher speeds and overtakes all other forms of resistive forces acting on vehicle. Hence, predicting and improving aerodynamic performance of a car forms a very important aspect in overall product design cycle. Engineers and designers around the world try different methods for predicting and improving the aerodynamics of a car, including rigorous wind tunnel & test track testing. However, in our current paper, we will be discussing a novel approach to predict and improve the aerodynamics drag for an academic test vehicle (Ford-Ka) model. The paper will contain two sections, first section will showcase usage of a new meshing technology, Mosaic Mesh, and a revolutionary breakthrough turbulence
Patil, Tushar, Patil, Vivek
TEST METHODOLOGY DEVELOPMENT FOR MULTIPURPOSE BRACKET VALIDATION FOR HCV APPLICATION2021-26-046709/22/2021
In the modern automotive sector, durability and reliability are two terms of utmost importance and relevance. The ever improving standards and cut throat competition has led to customers expecting highly reliable products at low costs. Any product that fails within its useful life leads to customer dissatisfaction and affects the OEM’s reputation. To eradicate this, all automotive components undergo stringent validation protocol, either in proving ground or in lab. The multipurpose bracket is one of the most important and critical aggregate in the vehicle assembly. It encompasses various mounting components such as FUPD bracket, steering mounting bracket, front spring front bracket, cab mount bracket, cab tilt cylinder mounting bracket, front cross member, footstep bracket, FSM and bumper. All these components experience various degrees of vibration and fatigue during its running period. The multipurpose bracket has to be designed and tested to withstand these multi-dimensional forces
G, Manthiramoorthy, K, Karthick, N, Gopi Kannan, Narasimman, Obuli Karthikeyan, R, Suresh
Virtual simulation method to predict farm tractor durability load cycles for proving ground tests2021-26-009709/22/2021
Agriculture machinery industries have always relied on conventional product development process such as laboratory tests, accelerated durability track tests and field tests. Now a days the competitive nature seen in industry concerns need to enhance product quality, time to market and development cost. Utilization of computer aided engineering (CAE) methods not only provide solution but also could play key role in tractor development process. The objective is to assess the performance of virtual simulation model of mid segment farm tractor using Multibody System Model (MBS) for predicting the durability loads on virtual proving ground test tracks. Multibody simulation software MSC ADAMS is used to develop a virtual tractor model. Durability test tracks and simulation is carried out as per company testing standards. Data measurement is done using Wheel force Transducer (WFT) to study front and rear spindle forces and moments to evaluate the virtual model performance. Spindle vertical
Subbaiyan, Prasanna Balaji, N, Balaramakrishna, Londhe, Abhijit, Redkar, Dinesh, Arun, G
Autoliv’s Sound and Vibration Laboratory for Automotive Safety Component Development2021-01-109508/31/2021
The new sound and vibration laboratory at Autoliv’s Ogden Technical Center (OTC) was purpose-built with a focus on automotive safety restraint product development (air bags, seat belts, steering wheels, etc.). The laboratory requirements stem from the continued industry trend of quieter vehicles which drives the need for components with extremely low levels of rattle noise. The laboratory at OTC complements similar Autoliv testing facilities around the world. Test articles range from several cubic inches up to approximately one cubic foot and contain varying degrees of moving elements. With the new laboratory at OTC, Autoliv can test new product designs earlier in the development process and obtain test results and feedback faster. The function of the OTC test lab is vibration-induced rattle noise; shake components with a known input and measure the resulting noise. To provide an acceptable signal to noise ratio, the new laboratory was designed to have a 25 dBA re 20 μPa noise floor
Morgan, Christopher, Rozema, Randy, Knight, Timothy
Development Work for a New Damping Standard SAE J31302021-01-112208/31/2021
Standards organizations develop standards depending on the need in the market place. With the change in vehicle design, lightweighting structures, and body panels made out of aluminum and composites, SAE’s Acoustical Materials Committee is developing a new damping standard. This standard is also very suitable in determining the damping performance of materials used in the off-highway applications, where the thickness of the steel body panel is much greater than in the automotive application. The general methodology of this standard is based on the mechanical impedance measurement method and has been developed with the general consensus of automotive engineers, suppliers, and independent test laboratories. This method is essentially based on the fact that a bar is excited at the center by a shaker. The force exerted by the shaker and the corresponding vibration is measured at that point to determine the frequency response function of the mechanical impedance signal. This paper discusses
Saha, Pranab
Reliability Program StandardJA1000_202108 (Current)08/10/2021
This SAE standard establishes the requirement for suppliers to plan a reliability program that satisfies the following three requirements: a The supplier shall ascertain customer requirements b The supplier shall meet customer requirements c The supplier shall assure that customer requirements have been met
G-41 Reliability
Flexible Organic PhotovoltaicsTBMG-3960908/01/2021
Organic solar cells rely on carbon-based materials including polymers — as opposed to hard, inorganic materials like silicon — to capture sunlight and translate it into current. Organics are also thin, lightweight, semi-transparent, and inexpensive. While commercial silicon-based solar cells perform at about 22 percent efficiency, organics top out at around 15 percent.
Inspection, Ultrasonic, Wrought Metals, Process forAMSSTD2154E (Current)07/15/2021
The purpose of this standard is to provide uniform methods for the ultrasonic inspection of wrought metals and wrought metal products.
AMS K Non Destructive Methods and Processes Committee
Inspection, Ultrasonic, Wrought Metals, Process forAMSSTD2154E-TEST-REC (Historical)07/15/2021
The purpose of this standard is to provide uniform methods for the ultrasonic inspection of wrought metals and wrought metal products.
AMS K Non Destructive Methods and Processes Committee
Customized Co-Simulation Environment for Autonomous Driving Algorithm Development and Evaluation2021-01-011104/06/2021
Deployment of autonomous vehicles requires an extensive evaluation of developed control, perception, and localization algorithms. Therefore, increasing the implemented SAE level of autonomy in road vehicles requires extensive simulations and verifications in a realistic simulation environment before proving ground and public road testing. The level of detail in the simulation environment helps ensure the safety of a real-world implementation and reduces algorithm development cost by allowing developers to complete most of the validation in the simulation environment. Considering sensors like camera, LiDAR, radar, and V2X used in autonomous vehicles, it is essential to create a simulation environment that can provide these sensor simulations as realistically as possible. While sensor simulations are of crucial importance for perception algorithm development, the simulation environment will be incomplete for the simulation of holistic AV operation without being complemented by a
Cantas, Mustafa Ridvan, Guvenc, Levent
Assessment of In-Cylinder Thermal Barrier Coatings over a Full Vehicle Drive Cycle2021-01-045604/06/2021
In-cylinder thermal barrier coatings (TBCs) have the capability to reduce fuel consumption by reducing wall heat transfer and to increase exhaust enthalpy. Low thermal conductivity, low volumetric heat capacity thermal barrier coatings tend to reduce the gas-wall temperature difference, the driving potential for heat transfer from the gas to the combustion chamber surfaces. This paper presents a coupling between an analytical methodology for multi-layer coated wall surface temperature prediction with a fully calibrated production model in a commercial system-level simulation software package (GT-Power). The wall surface temperature at each time step was calculated efficiently by convolving the engine wall response function with the time-varying surface boundary condition, i. e., in-cylinder heat flux and coolant temperature. This tool allows the wall to be treated either as spatially uniform with one set of properties, or with independent head/piston/liner components. Steady state
Koutsakis, George, Miles, Scott, Ghandhi, Jaal
Analysis of Vehicle GPS and Derived Speed Data from BMW NBT Evo Systems Acquired with Berla iVe2021-01-090604/06/2021
Many late-model BMW vehicles are equipped with an NBT Evo infotainment system. This system is seen in BMW vehicles in all global markets. Like infotainment systems from other manufacturers, this system records data elements that can prove to be key evidence to investigators of vehicular incidents. This system records timestamped tracklogs that consist of GPS coordinates paired with date/time data. These tracklog points, however, are not recorded in regular intervals. Testing of an instrumented BMW 430i was conducted in and around the Bruntingthorpe Proving Grounds in the United Kingdom. The test vehicle was instrumented with a Racelogic Video VBOX Pro. Data from the instrumentation was compared to the data acquired from the BMW by the iVe Ecosystem from Berla Corporation. The accuracy of the GPS coordinates recorded in the BMW tracklogs was determined by computing the distance between the recorded BMW data and the reference instrumentation data. The derived speeds computed in iVe from
Vandiver, Wesley, Anderson, Robert
Sound Quality Evaluation Method for Engine Combustion Noise in an Engine Acoustic Test Cell2021-01-067404/06/2021
In order to efficiently enhance engine sound quality under acceleration, the authors have developed an evaluation method for primary judgment of the sound quality of engine combustion noise at the stage of advanced engine development before the prototype vehicle is built. This method is an application of an existing method for evaluating the sound quality of engine combustion noise in vehicle interiors to the evaluation of noise and vibration at an engine acoustic test bench. In this method, it is necessary to consider the air-borne and the structure-borne components separately. The analysis procedure for the air-borne component is as follows. First, the sound pressure at a point 1 m away from the engine and the in-cylinder pressure of each cylinder are measured simultaneously in a semi-anechoic engine dynamometer test chamber. Next, the signal correlated with engine combustion is extracted from the measured sound pressure using the time domain combustion noise separation method. Then
Torii, Kenji, Noumura, Kousuke, Miyazawa, Masaya, Kondo, Takashi
Experimental Fuel Consumption Results from a Heterogeneous Four-Truck Platoon2021-01-007104/06/2021
Platooning has the potential to reduce greenhouse gas emissions of heavy-duty vehicles. Prior platooning studies have chiefly focused on the fuel economy characteristics of two- and three-truck platoons, and most have investigated aerodynamically homogeneous platoons with trucks of the same trim. For real world application and accurate return on investment for potential adopters, non-uniform platoons and the impacts of grade and disturbances on a platoon’s fuel economy must also be characterized. This study investigates the fuel economy of a heterogeneous four-truck platoon on a closed test track. Tests were run for one hour at a speed of 45 mph. The trucks used for this study are two 2015 Peterbilt 579’s with a Cummins ISX15 and a Paccar MX-13, and two 2009 Freightliner M915A5’s, one armored and the other unarmored. Many analysis methodologies were leveraged to describe and compare the fuel data, including lap-wise and track-segment analysis. The methodology for dividing the data into
Stegner, Evan, Ward, Jacob, Siefert, Jan, Hoffman, Mark, Bevly, David M.
Comparison of Emissions Measurement Methods based on Chassis Dynamometer Testing2021-01-061104/06/2021
Engine and vehicle tailpipe emissions can be measured in laboratories equipped with engine dynamometers and chassis dynamometers, respectively. In addition to laboratory testing, there is an increase in interest to measure on-road vehicle emissions using portable emissions measurement systems in order to determine real-driving emissions. Current methods to quantify engine, vehicle tailpipe, and real-driving emissions include the raw continuous, dilute continuous, and dilute bag measurement methods. Although the dilute bag measurement method is robust, recent improvements to the raw and dilute continuous measurement methods can account for the time delay between the probe tip and analyzer in addition to gas transport dynamics in order to reliably recover the tailpipe concentration signals. These improvements significantly increase the reliability of results using the raw and dilute continuous measurement methods, making them possible alternatives to the bag method. This paper
Vais, Joseph, Iyer, Suresh
Horiba MIRA's Vision for World-Class AV Testing21AVEP03_0703/01/2021
A new autonomous vehicle development center called Assured CAV boasts a lengthy list of assets and capabilities. It is a bold company that uses the description “globally unique,” but that's the label engineering research and test provider Horiba MIRA has attached to its new AV development center. Called Assured CAV (connected/automated vehicle), it is scheduled to formally open in March 2021. The new complex is designed to cover multiple autonomous vehicle (AV) validation, verification and research, ranging from high-speed, at-the-limit controllability on its highway system, to automated valet parking in a multi-story facility. Its city section offers urban and suburban environments. There is a 5G mobile private network supported by Vodafone, an extensive digital replicas portfolio to help enable scaled technology, and robotic targets and junction layouts to meet ADAS protocols. The Assured CAV facility has been designed to incorporate the world's most advanced infrastructure and
Birch, Stuart
Reconfigurable Electronics Based on Multiferroics and Nanomagnetism21AERP02_0902/01/2021
Research could lead to the development of new materials with large magnetoelectric (ME) coupling for next-generation multifunctional devices, including, multi-state (neuromorphic-like) circuits and memories, and E-field tunable microwave resonators for secure communications. Air Force Research Laboratory, Arlington, Virginia Multifunctional magnetoelectric materials with high exchange represent a missing “holy grail” of materials physics. To combine polarization and magnetization in the same solid is nothing short of actually controlling the fundamental nature of electromagnetism in matter. Although magnetoelectricity (ME) is an intrinsic phenomenon in some natural materials at low temperature, such single-phase materials suffer from an extremely weak ME exchange. In contrast, composites consisting of magnetostrictive and piezoelectric phases can feature dramatically larger ME coefficients. This proposed program focuses on achieving the disruptive potential of emerging multifunctional
Reconfigurable Electronics Based on Multiferroics and NanomagnetismTBMG-3853902/01/2021
Multifunctional magnetoelectric materials with high exchange represent a missing “holy grail” of materials physics. To combine polarization and magnetization in the same solid is nothing short of actually controlling the fundamental nature of electromagnetism in matter. Although magneto-electricity (ME) is an intrinsic phenomenon in some natural materials at low temperature, such single-phase materials suffer from an extremely weak ME exchange.
Biocontainment Unit for Virus-Sized ParticlesTBMG-3833201/01/2021
Researchers have created an individual biocontainment unit (IBU) that uses negative pressure to suction the air from around a patient and filter out viral particles. This prevents environmental contamination and limits exposure to SARS-CoV-2. In addition to guarding against COVID-19, the IBU could be rapidly deployed to isolate patients with any respiratory illness such as influenza, MERS, or tuberculosis.
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