Browse Topic: Test procedures

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An analysis of material damping characteristics: A comparison of Oberst Bar Method and Center Impedance Method and their relationship to Component Level.2026-26-0317To be published on 01/16/2026
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 Height2026-26-0513To be published on 01/16/2026
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 Study2026-26-0077To be published on 01/16/2026
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.2026-26-0586To be published on 01/16/2026
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
Towards AI-Driven Automated Driving Systems: Homologation perspective2026-26-0133To be published on 01/16/2026
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
Facilitating Virtual Testing at an Industrial Level by Simulation Data Management2026-26-0440To be published on 01/16/2026
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
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 Testing2026-26-0224To be published on 01/16/2026
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
Study, design, electro-chemical testing and validation of fuel cell fixture of single cell assembly towards custom stationary application.2026-26-0265To be published on 01/16/2026
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 Tires2026-26-0580To be published on 01/16/2026
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
AI-Driven Digital Twin for Enhanced Suspension Assembly Testing in Automotive Vehicles2026-26-0445To be published on 01/16/2026
This paper presents the development and application of a digital twin for the suspension assembly of Automotive vehicle, a critical component in evaluating the performance and durability of automotive systems. The digital twin, a virtual replica of the physical suspension assembly, is created using advanced simulation techniques and physical test data integration. By leveraging machine learning algorithms, the digital twin provides a comprehensive and dynamic model that accurately reflects the behavior and performance of the physical system under various conditions. The primary objective of this study is to enhance the accuracy and efficiency of suspension assembly testing by enabling predictive maintenance, real-time monitoring, and optimization of test parameters. The digital twin allows for the identification of potential issues before they occur, reducing downtime and maintenance costs. Additionally, it facilitates the exploration of different test scenarios and conditions without
Sonavane, Pravinkumar, Patil, Amol
Assessment of emissions behaviour of Volatile compounds from polymeric materials used in automobile interiors2026-26-0222To be published on 01/16/2026
There is an increasing trend of using polymeric materials in the vehicle interior compartment. While the polymers provide benefits in terms of flexibility in profiling, lighter weight and aesthetics but one of the challenges with the polymers is emission of volatile organic compounds (VOCs) during their usage and particularly at a temperature prevailing in the vehicle cabin. VOCs adversely impact the vehicle interior air quality and can pose a risk to occupants’ health. However, there is a lack of information on volatile organic compound (VOC) emissions from automotive interior materials. There are two types of methods, a whole vehicle chamber method (ISO 12219-1) and a bag method (ISO 12219-2) for evaluation of VOCs emissions from materials used in vehicle interior parts. ISO 12219-2 method describes quantitative testing of VOCs and semi-VOCs. This test method is quick and cost effective for analysis of materials for quick emission checks and can prove to be very effective in
PAtil, Yamini Jitendra, Thipse, Sukrut, Bawase, Moqtik
Integration of virtual testing methods in automotive safety: Methodology validation for rollover protection system (ROPS)2026-26-0375To be published on 01/16/2026
During recent years, the integration of virtual testing methodologies has gained significant importance in vehicle development for the passive safety evaluation. The accuracy of simulation results depends basically on the correct replication of physical test into the virtual model, for example to assign the realistic material properties from the structural components and following the boundary conditions replicated from real conditions. In this study the safety standards ISO 3471_2008 and ANSI ROHVA/OPEI-2016 have been considered as references of the safety validation process of hollow section roll-over protective structure (ROPS) integrated into a vehicle. A key objective is to stablish a virtual test methodology that could be applicable across different standards considering various industry markets, as for example European, American and Asian. A sensitivity analysis is necessary to evaluate what are the main aspects that gives significant deviations in results and in which we can
Laso Rodríguez, Manuel, Hanumantha, Chandrashekhar, Singh, Amit Kumar, Lal, Kundan
Comparison of Bharat NCAP Crash test scenarios with real road accidents in India2026-26-0024To be published on 01/16/2026
This study is conducted to analyse the significance of BNCAP crash test protocol in the real road accidents in India. Accident data from on-the-spot investigation (Road Accident Sampling System India) and Government of India’s, Ministry of Road Transport and Highways official road accident statistics 2023 is used together to understand the real road accidents in India. The current BNCAP crash test protocol is compared against the real road accidents and the frequency of the same in discussed in this paper. A seven-step calculation method is developed to analyse real accidents together with existing crash tests by using similar crash-characteristics like impact area, overlap and direction of force. This method makes the real accident comparable with the corresponding crash test by calculating the impact energy during the collision between the real accident and a collision under crash test conditions. Relevant parameters in real accidents that significantly influence the test scenario
Moennich, Joerg, Lich, Thomas, Kumaresh, Girikumar
AI-Driven Predictive Methodology for Bolt Integrity in Vehicle Durability Testing2026-26-0648To be published on 01/16/2026
The application of AI/ML techniques to predict truck tailgate bolt loosening represents a major innovation for the automotive industry, aligning with the principles of Industry 4.0. Traditional physical testing methods are both expensive and time-consuming, often identifying issues late in the development process and necessitating costly design changes and prototype builds. By harnessing AI/ML, manufacturers can now analyze tailgate slam and bolt preload data to accurately forecast potential bolt loosening issues. This predictive capability not only enhances quality and safety standards but also significantly reduces the costs associated with tooling and builds. The AI/ML tool described in this paper can simulate a variety of load conditions and predict bolt loosening with over 90% accuracy, considering factors such as changes in loads, bolt diameters, washer sizes, and unexpected masses added to the tailgate. It provides valuable design insights, such as recommending optimal bolt
Sivakrishna, Masani, Das, Mahat, Singh, Abhinav, karra, Manasa, Shienh, Gurpreet, Luebke, Amy
Accelerating EV Thermal Controls Development: A Rapid controls prototyping framework using Speedgoat2026-26-0685To be published on 01/16/2026
In the era of software-defined vehicles, the complexity and requirements of automotive systems have increased significantly. Thermal management systems have become more complicated, incorporating multiple functions and strategies within software frameworks. This shift poses substantial challenges, increased development efforts and extending timelines in creating an efficient thermal management system for EVs. Fulfilling them in the early stages of design makes it more challenging due to the unavailability of key components such as fully developed ECU hardware, the battery pack, and the motor. To address this, a novel framework has been designed that combines virtual simulation with physical emulation, enabling the testing and validation of thermal control strategies without fully matured system and ECU hardware. The framework uses the Speedgoat platform as the central controller which hosts the control and thermal models developed in Simulink and Simscape. Speedgoat is physically
Chothave, Abhijeet, S, Bharathan, S, Ananth, Gangwar, Adarsh, Khan, Parvej, Gummadi, Gopakishore, Kumar, Dipesh
Optimization of Inverter Control Strategies for Improved Powertrain Efficiency Using E-Motor Emulation Platforms2026-26-0509To be published on 01/16/2026
The traction inverter is a critical component in electric vehicles (EVs), functioning as the heart and brain of the electric powertrain. It controls the power conversion between the high-voltage battery and the electric motor, enabling efficient propulsion and regenerative braking. As EV adoption grows, especially in emerging markets like India, the need for robust and scalable inverter testing solutions becomes paramount. Traditional testing methods involving real batteries and e-motors pose several challenges in the Indian context, including high safety risks, infrastructure limitations, high battery costs, and limited availability of prototype-grade components. This paper presents a comprehensive approach to inverter validation using the AVL Inverter TS™ system— an advanced Power Hardware-in-the-Loop (PHiL) test system based on e-motor emulation technology.. It enables safe, efficient, and reliable testing without the need for actual batteries or mechanical loads. The system
Mehrotra, Soumya, Chhabra, Rishabh
Crash Pulse Characterization for the Passenger Vehicle Fleet in India.2026-26-0029To be published on 01/16/2026
A crash pulse is the signature of the deceleration experienced by a vehicle and its occupants during a crash. The deceleration-time plot or crash pulse provides key insights into occupant kinematics, occupant restraints, occupant loading and efficiency of the structure in crash energy dissipation. Analysing crash pulse characteristics like shape, slope, maximum deceleration, and duration helps in understanding the impact of the crash on occupant safety and vehicle crashworthiness. This paper represents the crash pulse characterization study done for the vehicles tested at ARAI as per the ODB64 test protocol. Firstly, the classification and characterization of the crash pulses is done on the basis of the unladen masses of the vehicles. The same are further analysed for suitability of mathematical waveform models such as Equivalent Square Wave (ESW), Equivalent Triangular Wave (ETW), Equivalent Sine Wave (ESW), Equivalent Haversine Wave (EHSW) as well as EDTW (Equivalent dual trapezia
Jaju, Divyan, Mishra, Satish, Kulkarni, Dileep, Borse, Tanmay, Mahindrakar, Rahula Ashok, Mahajan, Rahul
Vision Driven Testing Framework for Human-Machine Interfaces: An Automated Approach Using Computer Vision / Machine Learning2026-26-0571To be published on 01/16/2026
Modern automotive infotainment systems and digital instrument clusters require rigorous testing to ensure reliability and compliance with industry standards. Traditional testing methods are labor-intensive and lack scalability. This research proposes a phased, vision-based approach using image processing, machine learning (ML), and computer vision (CV) to enhance testing automation and accuracy. Phase 1 employs open-loop testing using an NVIDIA Jetson Nano with camera modules to capture visual data from infotainment and instrument cluster displays. This phase focuses on the static analysis of visual elements, screen transitions, animations, and error messages. Feature extraction and pattern recognition techniques identify interface behaviors and detect anomalies without a feedback loop. This research will focus in depth on Phase 1, providing a detailed evaluation of its implementation and effectiveness. Phase 2 extends the testing environment with a hardware-in-the-loop (HIL) system
Lad, Rakesh Pramod, Mehrotra, Soumya, Mishra, Arvind
ALLOY WHEEL RIM LINEAR CRASH VALIDATION WITH BENCH LEVEL TEST PROCEDURE2026-26-0574To be published on 01/16/2026
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
Fuel Cell Electric Vehicles: Method for Characterization of Onboard Power Management System and Defining Vehicle Level Attributes2026-26-0570To be published on 01/16/2026
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 Wheels2026-26-0504To be published on 01/16/2026
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
Test method and set up development for electric parking brake performance and durability validation in vehicle level as per RWUP2026-26-0505To be published on 01/16/2026
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 Consumption2026-26-0175To be published on 01/16/2026
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
India WLTC vs MIDC: Comparative Analytical study on BEV Range & Energy Consumption as per AIS175 draft & AIS039/0402026-26-0244To be published on 01/16/2026
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 Vehicle2026-26-0215To be published on 01/16/2026
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
A methodology to evaluate steering performance using Hardware in Loop Testing2026-26-0544To be published on 01/16/2026
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
Comprehensive Validation Methodologies for Hydrogen IC Engines: Combustion Analysis and Performance Metrics2026-26-0256To be published on 01/16/2026
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
Novel Approach on Material characterization Testing of various Wiring Harness2026-26-0548To be published on 01/16/2026
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
Water Spray and High Humidity Endurance Test Methods for AMS1424 and AMS1428 Aircraft Deicing/Anti-Icing FluidsAS5901E (Current)11/26/2025
This document establishes the minimum requirements for an environmental test chamber, and test procedures to carry out anti-icing performance tests according to the current materials specification for aircraft deicing/anti-icing fluids. The primary purpose for such a test method is to determine the anti icing endurance under controlled laboratory conditions of AMS1424 Type I and AMS1428 Type II, III, and IV fluids.
G-12ADF Aircraft Deicing Fluids
Aluminum Alloy, Extrusions 4.5Cu - 0.85Si - 0.80Mn - 0.50Mg (2014-T6) Solution and Precipitation Heat TreatedAMS4153N (Current)11/13/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing up to 32 square inches (206 cm2) in area (see 8.5).
AMS D Nonferrous Alloys Committee
Landing Gear Component Heat DamageAIR5913B (Current)11/11/2025
The purpose of this report is to outline types of in-service heat damage that have been observed in high strength steel landing gear components, with an emphasis on a particular type that is referred to as “Ladder Cracking” which can develop in landing gear shock struts. The report discusses how ladder cracking can be detected visually and evaluated by non-destructive inspection methods, and how it can be repaired at overhaul with the prior approval of the Original Equipment Manufacturer. This report also describes the use of a bearing material that has resolved this problem without introducing other problems. Examples of other types of service induced heat damage are also discussed.
A-5B Gears, Struts and Couplings CommitteeNEW
Grease, Aircraft, General Purpose, Low Temperature Range, Lithium ThickenedAMS3052B (Current)09/30/2025
Committee AMS-M is establishing an Industry Managed Qualification Program through the remit of the Performance Review Institute which requires this specification to be revised to reference the qualification process and controlling documentation.
AMS M Aerospace Greases Committee
Impulse Testing of Hydraulic Tubing and Fittings, S-N CurveAS4265A (Current)09/29/2025
This aerospace test standard establishes the requirements and procedures for evaluating and comparing the impulse fatigue performance of high pressure hydraulic fittings and tubing. this test method may be used to test similar fluid system components, if desired.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Specification for Aero and Aero-Derived Gas Turbine Engine LubricantsAS5780E (Current)09/24/2025
This specification defines basic physical, chemical, and performance limits for 5 cSt grades of gas turbine engine lubricating oils used in aero and aero-derived marine and industrial applications, along with standard test methods and requirements for laboratories performing them. It also defines the quality control requirements to assure batch conformance and materials traceability, and the procedures to manage and communicate changes in oil formulation and brand. This specification invokes the Performance Review Institute (PRI) product qualification process. Requests for submittal information may be made to the PRI at the address in Appendix D Section D.2, referencing this specification. Products qualified to this specification are listed on a Qualified Products List (QPL) managed by the PRI. Additional tests and evaluations may be required by individual equipment builders before an oil is approved for use in their equipment. Approval and/or certification for use of a specific gas
E-34 Propulsion Lubricants Committee
non-SAE standard test - revision Standard for Safety Glazing Materials for Glazing Motor Vehicles and Motor Vehicle Equipment Operating on Land Highways - Safety Standardas-jms-1A (Current)09/23/2025
non-SAE standard test - revision Specifications, test methods, and usage provisions for safety glazing materials used for glazing of motor vehicles and motor vehicle equipment operating on land highways.
Automated Vehicle Safety Consortium
Testing Methods for Advanced Intelligent Driving Systems Based on Natural Driving Behavior Characteristics2025-01-714702/21/2025
The technology of advanced intelligent driving systems equipped in intelligent and connected vehicles evolves rapidly, while the corresponding testing and evaluation standards lag behind. To propose new testing methods for advanced intelligent driving systems, this study first identifies typical intelligent driving functions through extensive research. Based on the distribution characteristics of natural driving scenarios, a series of test cases for these typical functions are developed. By employing simulation methods and the "logical scenario-critical scenario-experimental scenario" mechanism, the generalized test cases are filtered, enabling the rapid extraction of high-value test cases for real-world field testing and validation. Finally, the typical intelligent driving functions of advanced driving systems are analyzed and evaluated from the perspectives of perception and decision-making, as well as control operations. The experimental results demonstrate that the proposed testing
Mo, Jingyue, Wu, Biao, Ma, Zhixiong, Ren, Hongze, He, Jiacan
Test Methodology Development For Rig Level Validation Of Light Weight Stabilizer Link Of EV Bus Suspension2024-26-035701/16/2024
In the modern and fast growing automotive sector, reliability & durability are two terms of utmost importance along with weight ad cost optimization. Therefore it is important to explore new technology which has less weight, low manufacturing cost and better strength. The new technology developed always seek for a quick, cost effective and reliable methodology for its design validation so that any modification can be made by identifying the failures. This paper presents the rig level test methodology to validate and to correlate the CAE derived strain levels, life cycle & failure mode of newly developed light weight stabilizer link for EV Bus suspension. Stabilizer link replaces the existing separate arrangement of anti-roll bar and parallel rods and light in weight by 30kg.This stabilizer link arrangement is having the short lever arms which are connected through torsion bar which goes under twisting moment and the short lever arms are intended to control wheel motion in longitudinal
Tangade, Atul Bandu, Babar, Sunil, Bankar, Milind Achyutrao, Mehendale, Ravindra, Dhumal, Kailas, Bhusari, Deepak
Front-loading: Virtual Validation and Calibration on LABCAR2024-26-024701/16/2024
The advent of BS6 coupled with RDE emission norms has increased the development efforts and costs due to the shear amount of testing and validation on real engines and vehicles which are necessitated by these stringed norms. Front-loading of tasks by moving actual vehicle and engine tasks on to virtual setup, will reduce the development efforts and costs significantly. This front-loading of tasks on to a LABCAR would need real time and highly accurate plant models, tools to parameterize these plant models and accurate data driven models to predict dynamic parameters like emissions. In this collaborative work between MSIL and ETAS India, ETAS VVTB + ICE plant models were parameterized with the data generated on engine test with ASCMO Global DoE test plan by using ASCMO MOCA. These plants models were optimized to an accuracy level of more than 95%. The ASCMO Global test plan also ensures the coverage of data points across the entire engine operating space. The optimized plant model
SAMADDAR, SOUMIK, Varsha, Anuroopa, Garg, Charu, Galgali, Abhishek, P R, Renjith
Adaptive EV range estimation and optimisation based on rider demand and terrain requirements2024-26-009501/16/2024
This paper presents a model-based algorithm designed for electric vehicles to estimate, control, and optimize their range. By utilizing both short-term and long-term energy consumption data, the algorithm accurately predicts the range based on the current riding pattern. To achieve the desired range, the algorithm incorporates Hamilton-Jacobi-Bellman (HJB) optimization, which optimizes a cost function. The algorithm leverages short-term energy consumption patterns to smoothen the real-time watt-hour consumption for accurate range estimation. Simultaneously, it monitors long-term energy consumption patterns to account for factors such as vehicle aging, wear, terrain dynamics, and initial wh/km calculation. A comprehensive cost function, considering parameters like wh/km, rider demand, and terrain requirements, ensures optimal range without compromising the overall ride experience. The algorithm employs HJB optimization to dynamically control the range using parameters such as battery DC
RAJAWAT, SHIV PRATAP, Gautam, Ashish, SJ, Janarthanan, Soni, Lokesh, Khandekar, Piyush
A research work to develop an e-Axle generic DVP for the Indian Market complying with Indian and International standards2024-26-011801/16/2024
The electric vehicle market of India has very high growth potential in the coming years, and several automotive manufacturers, including Tier-1 suppliers, are looking to take part in this growth phase. The electric powertrains used in e-cars on Indian roads comply with BIS and AIS standards, but these standards alone do not give much clarity on the complete list of tests required to develop an e-Axle through all stages of development. A major challenge for OEMs and Tier-1 suppliers is to develop the e-Axle in-house for the Indian market, which will play a significant role in overall profitability at high volumes in the long run. Compliance with BIS and AIS standards alone will not be enough to meet the development requirements of an e-axle because a comprehensive list of the Specific, Measurable, Achievable, Relevant, and Traceable requirements of any e-Axle are fulfilled through Performance, Functional, Durability, and Robustness categories of tests. This paper presents a study of
Ray, Rakesh Kumar, Vaither, G V N Selvavindhan
Corrosion Prediction Model for Electrical Components in Automobiles2024-26-030701/16/2024
Salt Spray Test is being used since 1930’s to accelerate the corrosion testing of materials and to understand the longevity of applied coating. The sample in this kind of test is exposed to a salt mist in a controlled environment and its corrosion resistance is evaluated by measuring the corrosion rate. The Wet-Dry cycle in Salt Spray Test has the ability to simulate the drying and wetting which occurs in real driving scenario, leading to formation of a film of corrosion products which is useful in analyzing the kinetics of electrochemical reaction. Despite the advancement in severity of these tests to understand the atmospheric corrosion phenomena, they still consume time and resources. Secondly, sometimes these kind of tests do not consider into account the effect of Temperature, Humidity and other chemicals in play. Thus, numerical simulation plays a pivotal role in digitalizing the corrosion analysis to a certain extent. It also helps to provide a timesaving, effective, accurate
Shukrey, Sarthak, Yenugu, Srinivasa, Shah, Srishty, Bernardi, Roman
Real time monitoring and control of engine reliability validation using IOT and AI2024-26-034701/16/2024
IoT and AI have revolutionized the way we live and work, providing significant benefits across industries. The application of these technologies in engine reliability testing has immense potential as they offer real-time monitoring and analysis of engine performance. Engine reliability testing plays a crucial role in ensuring the safety, efficiency, and longevity of engines. However, traditional engine reliability testing methods can be time-consuming, costly, and often rely on manual inspection and data analysis. This paper presents a series of case studies that demonstrate the potential of IoT and AI tools in engine reliability testing, highlighting their benefits and limitations. This paper offers a comprehensive solution proposal for each use case, outlining the challenges and limitations of current engine reliability testing techniques. After that, the study proposes and evaluates IoT- and AI-based solutions to address these challenges. The study compares the effectiveness of the
Mujtaba, Quadri Syed, Yadav, Sanjay Kumar, kumar, Prabhakar, Verma, Vivek, Srinu, Kuncha
Big Data Analytics (Telematics) for real time testing improvements and integration back to Development of Future Models/EVs2024-26-035201/16/2024
The Auto industry has relied upon traditional testing methodologies for product development and Quality testing since its inception. As technology changed, it brought a shift in customer demand for better vehicles with the highest quality standards. With the advent of EVs, OEMs are looking to reduce the going-to-market time for their products to win the EV race. Traditional testing methodologies have relied upon data received from various stakeholders and based on the same tests are planned. The data used is highly subjective and lacks variety. OEMs across the world are betting big on telematics solutions by pushing more and more vehicles with telematics devices as standard fitment. The data from such vehicles which gets generated in high levels of volume, variety and velocity can aid in the new age of vehicle testing. This live data cannot be simply simulated in test environments. The device generates hundreds of signals, frequently in a fraction of seconds. Multiple such signals can
Sahoo, Priyabrata, Singh, Saurabh, Prasad, Kakaraparti Agam
A Real-World Range Testing and Analysis Methodology Development for Battery Electric Vehicles2024-26-012401/16/2024
Range anxiety is one of the major factors to be dealt with for increasing penetration of EVs in current Automotive market. The major reasons for range anxiety for customers are sparse charging infrastructure availability, unreliable range prediction and uncertain real-world range values. The uncertainty in real world range is due to the variation between the testing condition during vehicle development and real-world customer usage condition. This paper illustrates a more accurate test methodology development to derive the real-world range in electric vehicles (LMV) with experimental validation and system level analysis. The test methodology developed will be replicating the real-world usage scenario and bridge the gap between testing and Indian customer usage condition. Test conditions are developed based on matrix consisting of different routes, drive modes, Regeneration levels, customer drive behavior, time of drive, locations, ambient conditions etc. Based on the real world
B, SAKTHIVEL, Shams, Tausif, Lalasure, Santosh, Karnure, Shabbir Lalaso, Rajakumar, K., Omprasad, Karthick
Design methodology for avoiding condensation in automotive head lamps2024-26-008301/16/2024
One of the important aspect to consider at the design stage is the condensation of water vapor inside the lighting system, under particular weather conditions of temperature and humidity, which may compromise the device functionality. Condensation of water vapor is an issue affecting functional and aesthetics of Head Lamp. The current paper analyses the process of water vapor condensation inside an automotive LED head lamp. This paper also discusses the design methodology to avoid condensation under particular conditions. Design methodology includes design considerations for better air movement for heat management, material selection, ease of moisture exchange, breather or vent selection, placement. Additionally, this paper would also discuss about effective use of simulations tools, test methods and assembly process guidelines to avoid impact due to condensation. This paper would consist of one example with application of above methodology, its test and field results.
RANE, SANDEEP BALU, Pawar, Nishant
New test methodology development for combined variable test conditions of potential failure cause to analyze and elimination of Radiator hose field failure2024-26-032601/16/2024
Testing is a part of design life cycle which is increases the design overhead as well as the lead time for release. Even though the virtual testing on a simulation software is a quicker solution to reduce testing time and cost, the results which we get will be the nearest approximation. But in some special cases, it is necessary to do physical validation since they will directly affect the performance of vehicle. when the physical validation comes into picture, recreation of field malfunction and elimination of the same is one fine elevation of engineering. This will increase reliability of product and brand value of organization. This paper describes about the study and analysis of field failure on Radiator hose. The modern problems do require modern way of approach to analyze and test. The objective of failure root cause has been analyzed using QC tools and listed down. This failure occurrence approached by combined test conditions of vibration and thermal pulsation belongs to
Langu, VenkataSatish
Understanding the Complexities and Validation of Exhaust System Components For New Emission Requirement with Thermal Load and Multi-Axis Vibration2024-26-033001/16/2024
The new emission requirement norms in India calls for a robust Exhaust and After Treatment System (EATS) in automobiles. Its main purpose is to reduce the emission of harmful pollutants into the environment. EATS have a series of components that cleans the diesel exhaust emitted by the engine prior to releasing it through the tailpipe to the outside air. All the EATS components must undergo stringent testing protocol prior to its implementation in vehicle. During the exhaust treatment process, a very high temperature of about 550°C is produced in the EATS system. Hence, the effect of this higher temperature needs to be considered for validation. Moreover, the components will undergo multi-axial vibration in real road conditions which also need to be simulated during validation. In addition, engine vibrations are directly transmitted through a flex bellow to EATS system. These vibrations need to be captured and simulated in component level testing. In this paper, we will discuss about
Sundarrajan, Manikandan
Physical Testing and Evaluation of methodology for Windscreen wiping zones and vision zones of vehicle category other than M1.2024-26-036601/16/2024
The windscreen wiping system is mandatory requirement for automotive vehicle as per Central motor vehicle rules. The main scope of the standard is to ensure vision zones to be wiped by wiping system to ensure maximum field of vision to the driver. The evaluation of vision zones as per IS 15802:2008 is generally determined by virtual simulation by OEMs. The Limitation of virtual simulation is actual tolerances in vehicle due to seat fitment, ergonomic dimensions and seat cushioning effect are not taken into consideration very well off. The testing methodology described in the paper is an in-house developed test method. 3D H-point machine( SAE J826) and a laser based machine Theodolite is used to develop various vision zones on an actual vehicle windscreen as per technical data. These zones are later compared with wiped area to evaluate field of vision. The standard is applicable to vehicle other than M1 category. Critical vehicle parameters such as SgRP( seating reference point) , seat
Joshi, Amol
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
A Detailed Study to Evaluate Sporty Sound Character of Passenger Cars2024-26-020701/16/2024
Sound design is becoming increasingly important for vehicle manufacturers. ‘Sportiness’ of a car is one of the important criteria to consider while designing a car for passionate customers and those who love aggressive driving. Automobile manufacturers are identifying a typical sound for their cars as a ‘key product specification’ to attract particular market. This study focused on identifying frequency ranges and order content through a detailed study of subjective feelings based on physiological acoustics. A benchmark study of various different sport vehicles has been done to measure and record sound samples; these samples were further analysed based on sound quality parameters. Subjective evaluations were carried out by NVH experts to determine their concept of sportiness. Frequency ranges and order noise quantity were confirmed by correlations between subjective and objective evaluations under various customer drive patterns. Relations of the dominant exhaust firing order and its
Sadekar, Umesh Audumbar, Titave, Uttam, ZALAKI, NITIN, Naidu, Sudhakara, Vardhanan K, Aravindha Vishnu
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