Browse Topic: Commercial vehicles

Items (6,047)

An Outer Waist Seal with Integrated Glass Wiping Mechanism for a Window Frame of a Vehicle

2026-26-0011To be published on 01/16/2026

This innovation addresses a major safety concern where drivers experience poor visibility of the Outside Rear View Mirror due to rain, fog, dust, or ice accumulation on the side door window glass. Existing solutions like hydrophobic coatings and heated door window glasses offer limited effectiveness, leading to the need for a more reliable and efficient system. To solve this issue, we have modified Outer Waist Seal by integrating Glass Wiping Mechanism in it. The Outer Waist Seal is a weatherproof strip located at the bottom edge of a vehicle’s side window, attached to the door panel. It prevents heavy water flow, dust, and debris from entering the door cavity while also supporting the window glass during its movement. This system features a stationary fixed arm and a rotating arm with an attached wiper blade, driven by a low-speed, high-torque motor and connected with the vehicle's Body Control Module. Upon activation, the rotating arm with blade wipes the Outside Rear View Mirror

Neelam, Rajat, Chowdhury, Ashok, Panchal, Girish, Kumar, Saurav

Systematic Study To Understand And Resolve Brake Pull In Commercial Vehicles Using Simulation And Proving Ground Tests

2026-26-0083To be published on 01/16/2026

In traditional commercial vehicles with leaf spring suspension and Recirculating Ball Joint (RCBT) steering systems often experience undesirable pulling due to unsymmetrical steering mechanism during braking, especially when the suspension and steering hardpoints are not properly tuned. This study investigates the causes behind such pulling behavior, specifically focusing on brake steer and bump steer, which occur due to misalignments in the suspension and steering geometries. Brake steer happens when the braking forces generate a torque, causing the vehicle to pull towards one side. On the other hand, bump steer refers to the unwanted changes in the wheel alignment when the suspension undergoes travel, leading to instability or unintended steering input. These two phenomena, if not controlled, can result in undesirable vehicle handling, especially under heavy braking conditions. The study aims to understand and quantify these mechanisms, providing insights into how they can be

Pandhare, Vinay Ramakant, M, Anantha Padmnabhan, NIZAMPATNAM, BALARAMAKRISHNA, Londhe, Abhijit, Doundkar, Vikas

Safety Locking and alert system for Container trailers with Geo fencing

2026-26-0273To be published on 01/16/2026

The Container trailer is used worldwide to transport goods & materials especially e-commerce applications with valuable materials. These container trailers are presently locked with a mechanical locking system and often broken and unlocked by unauthorized people. During transportation time, the driver stops for natural calls, food or any other breakdown, the attempt is made to steal the materials. Many cases were known only after damages are done. It has become a serious issue nowadays in the transportation industry. To avoid these problems, we have designed and developed a system that operates pneumatically with digital locking control. The system is designed to ensure proper safety by rigid mechanical locking. It is actuated by a pneumatic system consisting of Directional control valve & pneumatic cylinders. The lock and unlock inputs are given through digitally and the digital controller provides the appropriate input to solenoid operated direction control valve. Based on the

kumaran, Rajasekar

Agricultural tractor brake linkage efficiency prediction and correlation using Flexible Multibody Dynamics model

2026-26-0103To be published on 01/16/2026

In agricultural tractors, braking actuation is usually done through control linkages consisting of a series of connected four-bar linkages with multiple pivots from the pedal to the brake pads. The quality of force transmission is critical as it directly affects the braking performance of the tractor. Forces measured at the end of the control linkage or brake pull rod often show deviation with theoretically-based mechanical advantage calculations. This is due to various factors such as linkage transmission angle, elasticity, and friction in joints not considered, which contribute to loss in force transfer. A standardized simulation method needs to be developed and validated to predict the losses in the control linkage system. In this paper, the author proposes a simulation approach using multi-body dynamics, which includes contribution factors such as transmission angle, linkage elasticity, and friction in joints. MBS model for brake linkage system for three different tractors

Subbaiyan, Prasanna Balaji, Nizampatnam, Balaramakrishna, Redkar, Dinesh, Arun, G, K, Vinoth, R, Sengottu, Paulraj, Lemuel

Microcontroller-based modular mirror for Heavy and Mid commercial vehicles

2026-26-0018To be published on 01/16/2026

Existing ICE Mid and Heavy commercial vehicles in the Indian and international market are recording a large number of mishaps due to blind spots and non accessibility of the driver to the opposite side mirror in real-time driving. Non-driver side rear view mirror adjustment creates the need for the driver to get down and adjust the mirror manually/ get support from the co-passenger. The paper proposes a solution for a Microcontroller-based compact mirror adjustment system, which will run with minimal economy and highest efficiency. This will assist drivers in aesthetically and safely monitoring of mirror to check on specific blind spots in day conditions. Mirror will be actuated via a Modular control panel, a Dashboard with audio input or button-operated system based on vehicle type and customer need, along with a quick response mechanism to operate the mirror. This will reduce the prone accidents due to non-visibility by approximately 30%, ensuring enhanced road safety and driver

Jambagi, Vaibhavi Vyankatesh, Gangvekar, Onkar, Bhandari, Kiran Kamlakar

Early Prediction of CNG Filling Time using Artificial Intelligence for Design Optimization

2026-26-0662To be published on 01/16/2026

The CNG fuel system is a critical component in vehicle development and typically includes large-volume gas cylinders (up to 800 liters). As these vehicles often operate over long distances daily, frequent refueling is necessary, making a short gas filling time highly desirable. Currently, CNG filling time is evaluated after prototype development to determine the refueling duration. If the filling time is excessive, design changes to the fuel system are required, leading to significant cost and time penalties and causing delays in the vehicle product development cycle. By integrating AI/ML technology, a mathematical model has been developed based on various influencing parameters. This model will predict CNG gas filling time across all commercial vehicle platforms at the initial Zero design release gateway. This early prediction will enable further optimization to improve gas filling time. The goal of this research work to optimising the filling time for various platform before physical

Choudhary, Aditya Kant, Petale, Mahendra, Dutta, Surabhi, Bagul, Mithilesh

Evaluation of Methods used to Determine Vehicle Center of Gravity Height

2026-26-0513To 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

Comparative Study of EV Transmission Performance used in Various Vehicle Segments

2026-26-0584To be published on 01/16/2026

The transition to electric mobility has accelerated the evolution of drivetrain technologies, particularly in the design and performance of electric vehicle (EV) transmissions. Unlike traditional internal combustion engine (ICE) vehicles, EVs utilize simpler yet diverse transmission systems cater to specific performance, efficiency, and application requirements. The growing adoption of electric vehicles across diverse transportation sectors has intensified the need for optimized electric transmission systems as per vehicle requirements. This research presents a comparative study of electric transmission performance across various vehicle segments, including Passenger Cars, Small commercial Vehicle, Commercial three-wheelers and All-terrain vehicles. The study evaluates different transmission configurations namely single-speed and multi-speed, based on key performance metrics such as Drag loss and Efficiency. Through a combination of literature review, and performance benchmarking, the

Jain, Sankalp, P, EKHESH

Static Rollover Stability Analysis of Heavy Tipper vehicle

2026-26-0090To be published on 01/16/2026

Heavy tipper vehicles are primarily utilized for transporting ores and construction materials. These vehicles often operate in challenging locations, such as mining sites, riverbeds, and stone quarries, where the roads are unpaved and characterized by highly uneven elevations in both the longitudinal and lateral directions of vehicle travel. During the unloading process, the tipper bodies are raised to significant heights, which increases the vehicle's centre of gravity, particularly if the payload material does not discharge quickly. Such conditions can lead to tipper rollover accidents, causing severe damage to life and substantial vehicle breakdowns. To analyse this issue, a study is conducted on the vehicle design parameters affecting the rollover stability of a 35-ton GVW tipper using multi-body simulations in ADAMS software. The tilt table test was simulated to determine the table angle at which wheel lift occurs. Initially, simulations are performed with the rigid body model

Vichare, Chaitanya Ashok, Patil, Sudhir, Gupta, Amit

Development of Door Impact Loads Using Frugal use of Pedal Force Sensor

2026-26-0538To be published on 01/16/2026

The first step in designing or analyzing any structure is to understand “right” set of loads. Typically, off-road vehicles have many access doors for service/getting into cab etc. Design of these doors and their latches involve a knowledge of the closing loads when the door is shut mostly with an impact of varying magnitudes. In scenarios of these impact events, where there is sudden change of velocity within few milliseconds, produces high magnitude of loads on structures. One common way of estimating these loads using hand calculations involves evaluating the rate-of-change-of-momentum. However, this calculation needs “duration of impact”, and it is seldom known/difficult to estimate. Failing to capture duration of impact event will change load magnitudes drastically, e.g. load gets doubled if time-of-impact gets reduced from 0.2 to 0.1 seconds and subsequently fatigue life of the components in “Door-closing-event” gets reduce by ~7 times. For these problems, structures are usually

Valkunde, Sangram, Ghate, Amit, GAGARE, KIRAN

Adaptive Economy Drive Mode Algorithm Development for Fuel Efficient Operation in Light Commercial Vehicle

2026-26-0063To be published on 01/16/2026

In Commercial vehicles, during the transit of goods for delivery the vehicle is in laden condition and after delivery it returns in unladen condition. The engine is designed and calibrated to get good drivability in Gross Vehicle Weight (GVW) of the vehicle. When the vehicle is driven at unladen condition or partially laden condition, the vehicle is accelerated very high due to higher torque available from engine, leading to excessive fuel consumption. In some commercial vehicle models, Economy Drive mode option is available, in which the maximum torque delivered by engine is tapered to one level down to achieve better fuel economy. But in GVW condition with Economy Drive mode the driver may not feel the acceleration response and he tend to switch to Power mode. This technical paper describes Adaptive Economy Drive Mode algorithm development which operates with sufficient acceleration using optimum fuel. In Adaptive Economy Drive mode, there are 3 phases. The first phase is to sense or

U B, Gokulraj, S, Rajagopal, V, Sriram, M, James Arokiaraj

Decision-fatigue mitigation in Automotive HMI System

2026-26-0652To be published on 01/16/2026

Abstract - With advent of digital displays in driver cabins in commercial vehicles, the drivers are getting offered with many features. Due to availability of vast number of features, drivers face decision fatigue in choosing the appropriate features. Many are unaware of all available functionalities displayed in the HMI System, leading to a bare minimum usage or complete neglect of helpful features. This not only affects the driving efficiency but also increases cognitive load, especially in complex driving scenarios. Instead of manually choosing between multiple settings, the driver can simply activate a recommendation mode, allowing the system to optimize selections dynamically. Novelty of this proposal focuses on introducing Intelligence in HMI Systems in such a way that it will maximize the usage index and reduce decision fatigue in drivers. To achieve this, an AI-driven recommendation system is introduced, based on User Customization and Adaptive Learning Model along with ML

K, Sunil, Dhoot, Disha

State-of-the-Art Battery Thermal Management Technologies for SCV EV: An Integrated Approach to Enhance Energy Utilization, Boost Battery Efficiency, and Reduce Expenses

2026-26-0076To be published on 01/16/2026

The Effective battery thermal management is fundamental to ensuring both the performance and durability of small commercial electric vehicles. This study investigates advanced methods for maximizing energy efficiency, extending driving range, shortening charging durations, and lowering costs by employing insulation and thermoelectric cooling technologies. India's diverse and often extreme climatic conditions-ranging from intense summer heat to cold winters-significantly affect the thermal management of electric vehicle (EV) batteries. Also in small commercial vehicle segment uncontrolled operation condition (loading & off-road driving) of vehicle is common in India which leads to higher average C rate from battery implies need active battery cooling. Keeping batteries within their optimal temperature range is vital for maintaining their efficiency, safety, and service life. Advanced thermal insulating materials stabilize battery temperatures by minimizing heat gain and external

Chormule, Suhas Rangrao, Warule, Prasad, Nagpure, Rahul, Jadhav, Vaibhav

Noise Reduction of Construction Equipment Vehicle Through Structure-borne and air-borne Noise Reduction Strategy

2026-26-0318To be published on 01/16/2026

One can witness the constant development and redevelopment of cities throughout the world. Construction equipment vehicles (CEVs) are commonly used on the construction site. However, the noise pollution from construction sites due to the use of CEV has become a major problem for many cities. The construction equipment employed is one of the main causes of these elevated noise levels. The construction workers face a potential risk to their auditory health and well-being due to the noise levels they are exposed to. Different countries have imposed exterior and operator’s ear noise limits for construction equipment vehicles, enabling them to control noise pollution. In this study, three vehicles were selected and checked for NVH performance and found that the operator ear noise level of the identified vehicle is 6 dB(A) higher than the benchmark vehicle level in dynamic conditions, when tested as per ISO 6396. Similarly, there was another vehicle having exterior noise 2 dB(A) higher than

Shinde, Gaurav, Jawale, Pradeep, Jain, Sachinkumar, Harishchandra Walke, Nagesh

Adoptive safety solutions in Road Simulators for commercial vehicle structural validation

2026-26-0533To be published on 01/16/2026

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

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

Innovative Multi-Axial Testing approach for Enhanced Reliability of Cooling Modules in Commercial Vehicles

2026-26-0530To be published on 01/16/2026

This paper presents an innovative in-lab accelerated testing approach for chassis-mounted components, with a particular focus on the cooling module of commercial vehicles. The proposed method simulates real-time data acquired from field operations and replicates all critical chassis modes, including torsion. Additionally, real-time coolant circulation at specified pressure and temperature maintenance are feasible during durability testing, enhancing the realism of the test environment. The cooling modules, comprising the radiator, intercooler, and charge air cooler (CAC), often experience failures due to various multi-axial inputs and chassis modes. This paper introduces an innovative methodology for replicating field conditions in the lab, utilizing seven servo-hydraulic actuators to simulate multi-axial inputs. The accuracy of in-lab simulation for the acceleration levels at input and response locations of the cooling module exceeds 90%. This makes it a preferred choice for test

V Dhage, Yogesh, Satale, Sunil

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

2026-26-0502To be published on 01/16/2026

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

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

Thermal Management Control strategy for Primary & Secondary Drive Cooling Hybrid Electric Tractor

2026-26-0069To be published on 01/16/2026

Global emission norms are getting very strict due to combat the harmful pollutants from internal combustion engine. Hence internal combustion engine (ICE)-based agricultural tractors need to introduce complex after-treatment systems and fuel optimization to provide same or higher value to farmers as cost of these systems drive the overall cost of the product. Engineers around the world are building Electric vehicles to combat the problem and has range issues due to design constraints & Hybrid tractors have emerged as a promising intermittent solution. It helps in combining the advantages of respective ICE and electrification solutions while reducing overall vehicle emissions and enhances operational flexibility. This paper presents a modular thermal modes system developed for a hybrid electric tractor platform where a downsized diesel engine operates at optimal efficiency DC generator used to charge the battery & DC converter is used to charge the auxiliary battery. Battery which is

K, Sunil, Makana, Mohan, Natarajan, Saravanan, K, MALA

"Exploring the Effects of Oil Cooler Deletion on Tractor Engine Operation"

2026-26-0547To be published on 01/16/2026

Cost reduction remains a significant challenge for engine manufacturers, particularly for off-highway application vehicles. An optimal engine lubrication system, encompassing engine oil and an oil cooler, is critical for thermal management and minimizing frictional losses. This system ensures adequate lubrication and cooling of engine components, thereby maintaining optimal performance. This study investigates the implications of oil cooler removal in a 45HP inline engine tractor. Various validation trials were conducted, including high ambient temperature tests under worst-case conditions, high coolant temperature scenarios, and a rigorous tractor killer test. In the latter, the tractor underwent 100 hours of operation on a PTO bench at maximum engine RPMs. Despite an observable increase in lubricant oil temperature during these tests, the tractor did not exhibit any component seizure or failure. The findings aim to determine whether the inclusion of an oil cooler is essential for the

Gupta, Deepak, Kumar, Pankaj, Singh, Manjinder, Singh, Gagandeep, Kumar, Munish, SINGH, HARPREET, Singh, Maninder

Reverse Gear Duty Cycle Generation Using Virtual RLD Simulation

2026-26-0405To be published on 01/16/2026

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

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

The selection of a two-speed gearbox for small commercial electric vehicles aims to optimize powertrain efficiency

2026-26-0417To be published on 01/16/2026

In response to the significant environmental challenges posed by climate change driven by global warming, the automotive industry is accelerating the transition toward electrification. While electric vehicles offer considerable potential for mitigating CO₂ emissions, their elevated upfront costs pose a notable challenge to large-scale market penetration. Energy efficiency improvement of electric vehicles is emerging field of research to reduce total cost of ownership. Electric vehicle powertrain component selection in small commercial vehicles including three and four wheelers is a complex process which has to fulfil multiple requirements Range, performance, drivability, packaging, total cost of ownership of vehicle and comfort. In addition, powertrain configuration including battery, motor and transmission ratio selection plays a fundamental role in cost of electric vehicle. Hence, The task of selecting the right powertrain configuration, encompassing architecture, motor selection

Wani, Kalpesh, Jadhav, Vaibhav, Shendge, Raman, Warule, Prasad

Electroluminescent Coating Systems for Heavy-Duty Trucks: Advancing Safety and Sustainability through Smart Surface Technology

2026-26-0275To be published on 01/16/2026

As the transportation industry pivots towards safer and more sustainable mobility solutions, the role of advanced surface technologies is becoming increasingly critical. This paper presents a novel application of electroluminescent (EL) coating systems in heavy-duty trucks, exploring to enhance safety and environmental impact through lightweight, energy-efficient lighting integration. EL coatings, capable of emitting light uniformly across painted surfaces when electrically activated, offer a transformative alternative to conventional lighting systems and reflective materials. In the context of heavy-duty trucks, these systems can significantly improve visibility under low-light and adverse weather conditions, thereby reducing the risk of road accidents. Furthermore, illumination achieved without bulky fixtures and without interface gaps contributes to aerodynamic efficiency, fuel economy and reducing carbon emissions. use of this coating system, can optimize tooled up plastic part and

Harel, Samarth Dattatraya, Borse, Manoj

Utilization of an improved hardening model for finite element analysis and experimental correlation of a tractor ROPS Structure

2026-26-0404To be published on 01/16/2026

In recent years, virtual validation using finite element analysis (FEA) has become a key step in designing an agricultural tractor roll over-protective structure (ROPS). With the advancement of computation power and ability of finite element solver to handle bigger models; a higher fidelity model can be built to improve virtual validation accuracy. More & more advanced material model can be used to improve accuracy of the results. Along with ROPS, its mounting chassis and mounting bolts can also be validated. Virtual validation at the design phase not only saves time of new product development cycle; but also optimizes the weight & cost of the design. This study focusses on the application of advanced material models in simulating a real-life tractor ROPS system. For the ROPS structure, both conventional isotropic hardening models (employing bilinear and piecewise multilinear stress-strain curves) and advanced kinematic hardening models based on the multi-component Armstrong-Frederick

PANDEY, MANOJ KUMAR, Kumar, Arun, Redkar, Dinesh, THIRUGNANAM, Vivekanndan, Magendran, G, MANI, SURESH

Identification of productive and non-productive activities in agricultural machinery using ECU and GPS parameters through the application of machine learning techniques

2026-26-0102To be published on 01/16/2026

Any agricultural operation (such as cultivation, rotavation, ploughing, and harrowing) includes both effective work and non-productive activities (like transportation, stops, and idling) in the field. Non-productive work can distort the actual load profile, fuel consumption, and emissions. In this project, a machine learning-based methodology has been developed to differentiate between effective operations and non-productive activities, utilizing data collected in the field from data loggers installed on the machinery. Measurements were conducted on various machines across the country in all major applications to minimize the influence of any individual sample's deviation and to account for variability in customer operating practices. Nine critical parameters (Engine Speed, Exhaust Gas Temperature, THECU2, VPEXGAS, FULRAT, Actual Engine Percentage Torque, LBEGR, POIL & GPS Speed) were selected after screening & analyzing more than 100 CAN and GPS parameters. The critical parameters

Maharana, Devi prasad, Gangsar, Purushottam, gokhale, Varun, Pandey, Anand Kumar

Optimizing Heavy-Duty Mining Operations with LNG Powertrains: Boosting Efficiency and Minimizing Environmental Impact

2026-26-0438To be published on 01/16/2026

Heavy-duty mining is a demanding sector within the trucking industry. Mining companies are assigned coal mine sites, and fleet operators are tasked with efficiently extracting ore within the allotted timeframe. To accomplish this, companies deploy dumper trucks that operate in three shifts daily to transport payloads from the site. As a result, uptime is critical, requiring trucks with exceptionally robust powertrains. The profitability of mining operations depends on the efficient use of these dumper trucks. Fuel consumption in these mines represents a significant portion of total expenses. Using LNG as a fuel can help reduce operational fuel costs, thereby increasing customer profitability. Additionally, employing LNG has the potential to lower the CO2 footprint of mining operations. This paper details the development of a data-driven duty cycle for mining vehicles and the simulation methodology used to accurately size LNG powertrain components, focusing on maintaining uptime and

John, Ann Veena, Pendharkar, Koustubh

Thermal System design of Inter-City Fuel Cell Electric Bus

2026-26-0427To be published on 01/16/2026

In the current scenario, demand for alternate energy is increasing due to depletion of fossil fuels and countries commitment towards carbon neutrality by 2050. Hydrogen is considered as one of the cleaner fuels and many OEMs across the world started to work on various strategies like hydrogen combustion engine and fuel cell. Passenger vehicles like Buses are at the lookout for fuel cell technology at faster rate than other commercial vehicles. In fuel cell vehicles, cooling system design is critical & complex since it includes fuel cell cooling, Power electronics cooling & battery cooling. In this paper cooling system design of a Fuel cell electric bus for inter-city application is demonstrated. Radiators and Fans are selected based on the overall heat rejection and Coolant inlet temperature requirements of components. Cooling system circuit and pump is decided to meet the coolant flow rate targets. Flow simulation and thermal simulation done using simulation models using software KULI

M S, Vignesh, KIRAN, NALAVADATH

Intelligent Sequential Charging Control via Fleet-Managed Cloud System

2026-26-0207To be published on 01/16/2026

Electric Vehicles (EV) are increasingly becoming more and more popular in the markets, especially in the commercial vehicle segments. Amidst this, the need to find new elegant methods to perform charging of EV battery becomes extremely crucial. In areas with high demand and limited power capacity, performing charging for multiple vehicles necessitates efficient usage of charging infrastructure, which can’t be guaranteed by the traditional charging methods. Sequential charging is a new state of art technique for managing the charging of multiple EV’s simultaneously connected to a single charging station. Rather than dividing the available power equally among all connected vehicles or charging them one at a time, this technique dynamically allocates power based on various factors such as charging priority, vehicle needs and available infrastructure capacity. Currently, sequential Charging can only be implemented by a particular set of chargers that are interconnected via backend and

De, Abir, Bhattacharya, Ullash, Parihar, Aakash

Source Level Vibration Control of a Tractor Engine Through Inertial Force Balancing

2026-26-0323To be published on 01/16/2026

Controlling the source vibrations in internal combustion engines is a crucial approach to minimizing the vibration levels experienced by the driver. The driver's subjective perception of vibration is primarily dictated by the vehicle's low-frequency response (<100 Hz). In IC engines used in agricultural tractor applications, the primary sources of vibration include (a) first-order inertial force, (b) couples generated by rotating and reciprocating components such as the piston assembly, connecting rod, and crankshaft, and (c) in-cylinder combustion. In this study, an order ranking analysis was conducted on a single-cylinder, air-cooled, naturally aspirated tractor engine within the driver's operating range to identify the dominant contributors to source vibrations. The first-order inertial force was observed to be the dominant contributor to the engine's vibration levels. Subsequently, an attempt was made to mitigate the unbalanced forces by implementing counterweight-based balancing

Bhuntel, Ajay, Rajput, Surendra, Rawat, Ashish

Thermal Management and Engine Calibration Strategies for Enhanced Passive DPF Regeneration in CEV Stage V CI Engines

2026-26-0141To be published on 01/16/2026

Meeting the stringent emissions norms of CEV stage V for medium BMEP engines, CI engines present significant challenges. These stringent norms call for a highly efficient DPF. With the increasing demands for high-performance DPFs, the issue of soot accumulation and cleaning presents significant hurdles for DPF longevity. This paper explores the potential of passive DPF regeneration, which leverages naturally occurring exhaust gas conditions to oxidize accumulated soot, offering a promising approach to minimize fuel penalty and system complexity compared to active regeneration methods. The study investigates engine calibration techniques aimed at enhancing passive regeneration performance, emphasizing the optimization of thermal management strategies to sustain DPF temperatures within the passive regeneration range. Furthermore, the paper aims to expand the applicability of passive regeneration across diverse engine loads common in off-highway applications with effective passive

Saxena, Harshit, Gandhi, Naresh, Lokare, Prasad, Shinde, Prashant, Patil, Ajit, Raut, Ashish

Connected Traffic Warnings for Enhanced Commercial Trucking Safety

2026-26-0680To be published on 01/16/2026

Commercial trucking forms the backbone of global supply chains, but the consistently high number of truck-related fatalities emphasises the pressing need for enhanced safety systems. Connected safety systems present a significant opportunity to mitigate risks and prevent collisions by providing commercial vehicle operators with real-time hazard alerts. This paper delves into the operational mechanisms and potential benefits of such warning systems within the trucking industry. These systems function by establishing a network of connected vehicles capable of detecting and communicating hazardous situations through a centralised, cloud-based platform. By seamlessly integrating real-time telemetry data from individual trucks with information sourced from third-party providers, weather services, the system gains an understanding of prevailing road conditions. This allows for the identification of potential dangers such as traffic accidents, ongoing road construction or maintenance

Madarla, Manoj, George, Basil, Gangapuram, Siva, Hegde, Subrahmanya, Mukherjee, Shubhobroto, Dixith, Sampreetha, Hegde, Preetham

Path Planning and Control Strategies for a Semi-Autonomous Light Commercial Vehicle Navigating and Avoiding Static Obstacles in Urban Environments

2026-26-0134To be published on 01/16/2026

This paper presents the design and implementation of a Semi-Autonomous Light Commercial Vehicle (LCV) capable of following a person while performing obstacle avoidance in urban and controlled environments. The LCV leverages its onboard 360-degree view camera, RTK-GNSS, Ultrasonic sensors, and algorithms to independently navigate the environment, avoiding obstacles and maintaining a safe distance from the person it is following. The proposed system employs a path planning algorithm that generates a secondary lateral path originating from the primary driving path to navigate around static obstacles. A Behavior Planner is utilized to decide when to generate the path and avoid obstacles, ensuring timely and efficient navigation adjustments. The primary objective is to ensure seamless and safe navigation in environments where obstacles are present. The LCV's path tracking is achieved using a combination of Pure Pursuit and Proportional-Integral (PI) controllers. The Pure Pursuit controller

Ayyappan, Vimal Raj, Dhanopia, Rashmi, Ali, Ashpak, N, Ragesh, Sato, Hiromitsu

Auto Braking system for preventing commercial vehicle overloading.

2026-26-0032To be published on 01/16/2026

Overloading in commercial vehicles is a widespread issue that creates serious safety, operational, and regulatory concerns. Excessive loads can result in mechanical breakdowns, diminished braking performance, accelerated tire wear, and a higher likelihood of accidents, posing risks to drivers and other road users. Moreover, overloading accelerates road deterioration and increases infrastructure maintenance costs. To tackle this pressing problem, this study introduces a novel integrated system that merges advanced load-sensing technology with the vehicle's braking system. The system utilizes high-precision sensors placed at key locations, such as the suspension or axle, to monitor the vehicle's load in real time. These sensors send data to a central control unit, which triggers the braking mechanism if the load surpasses a predetermined safety limit. Importantly, the braking system activates only when the vehicle is stationary, ensuring it does not disrupt normal driving operations. The

RAJ, AMRITESH, Pujari, Sachin, Londhe, Mahesh, Shirke, Sumeet, Shinde, Akshay

Mobility Within Mines: Harmonization of Safety requirements for Underground Mining Trucks in India.

2026-26-0140To be published on 01/16/2026

The need for energy is ever increasing, though the dependency on renewable energy have increased, it is not sufficient to cater the demand. India is one of fastest developing country which depends on coal 55% for its total energy need. To achieve coal digging & transportation an underground mining vehicle has gained high importance. Underground mine environment is inherently dangerous due to various factors, including explosive and toxic gases, dust, and the potential for collapses. Thereby vehicles running in coal mines requires extreme safety features to safeguard its operator & coal mine workers. In India Directorate General of Mines Safety (DGMS) directing standards & safety provisions for Diesel equipment's working under ground mines. This Paper is providing complete guideline for required safety features for the latest available technology in underground mining trucks. This paper will take you through various standards available globally to insure safety of the operator. Further

Babar, Sagar, Akbar Badusha, A

EMC Regulations of Construction Equipment Vehicles in India : Challenges and Solutions

2026-26-0146To be published on 01/16/2026

Requirement for Construction Equipment Vehicles (CEVs) in India is continuously growing as India being fastest growing country in the world in terms of Infrastructure. The technology in the automotive industry is evolving rapidly in recent times. Thus, with the development of new technologies, the challenges are also ever-increasing from an Electromagnetic Interference, Susceptibility (EMI/EMC) and Safety perspective. CEVs include various types of machines including Compactor, Wheel Loader, Crane, Paver, Truck Crane, Cement Mixer etc. EMC requirements of all these types are internationally governed by ISO 13766-1, 2. This paper provides insights about various considerations to be taken during EMC Tests of each type of machines. It also includes guidelines related to antenna positioning, reference point calculations, Narrow Band and Broad band considerations. It will also provide general EMC guidelines and precautions related to component selection and placement along with typical EMC

Yeola, Mayur, Shinde, Avinash

Event-Driven Field-to-Lab Replication: A Scalable Framework for Evaluating Fuel Economy and Performance in Dual-Fuel Tractors

2026-26-0105To be published on 01/16/2026

The shift toward sustainable agricultural machinery has highlighted diesel and CNG/bio-CNG dual-fuel systems as promising solutions. Yet, standardized methods for assessing their fuel economy (FE) and performance under real-world operating conditions remain underdeveloped. This study introduces an event-based duty cycle synthesis to bridge this gap. Field data encompassing ploughing, rotavating, sowing, transportation, and idling were systematically acquired using CAN bus interfaces and dataloggers, capturing engine load, wheel torque, throttle dynamics, and fuel consumption. A high-fidelity duty cycle was subsequently devised, integrating the frequency, duration, and load intensity of field operations. This cycle was replicated in a controlled laboratory environment via a chassis dynamometer and engine-in-the-loop (EiL) platform, enabling precise, repeatable evaluation of dual-fuel (diesel-CNG) and pure diesel modes. Key metrics—including brake-specific fuel consumption (BSFC

Vishe, Prashant, Singh, Jitender, Saraswat, Shubham, Pawar, Abhijeet

NVH Refinement on the Agriculture Tractor using Coupled Test and Simulation Approach

2026-26-0316To be published on 01/16/2026

The Indian farmers choice of agriculture tractor brand is driven by the ease of operation and fuel efficiency. However, the customer preference for operator comfort is driving many tractor OEMs for improvement in noise and vibration at the operator location. Also, the compliance to CMVR regulation for noise at operator ear location and vibration at driver touch point location are mandatory for all the tractors in India. NVH refinement development of the tractor plays a critical role in achieving the regulated noise level and improved tactile vibration In presented work, Noise Source Identification (NSI) is carried out to identify and rank airborne and structure borne noise sources at tractor level through elimination method followed by engine level testing in hemi anechoic chamber to identify the major noise radiating components by using noise and vibration measurement, sound intensity mapping tools. The outcome of NSI has revealed silencer, timing gear cover and oil sump to be highest

Gaikwad, Atul Annasaheb, Bankar, Harshal, Yadav, Prasad S, Harishchandra Walke, Nagesh

Performance optimization of 2 Cylinder Flex Fuel Engine for Small Commercial vehicle – A STEP TOWARDS SUSTAINABILITY

2026-26-0119To be published on 01/16/2026

Increasing ethanol blending in gasoline is significant from sustainability point of view. Flex Fuel is an ethanol-gasoline blend containing ethanol ranging from 20% to 85%. Flex Fuel emerges as an exceptionally advantageous solution, adeptly addressing the shortcomings associated with both gasoline and ethanol. Performance optimization of flex fuel is major challenge as fuel properties varies with ethanol %, like knocking tendency, calorific value, vapour pressure, latent heat and stoichiometric Air Fuel Ratio etc. This paper elaborates the experimental results of trials conducted for optimization of engine performance with Flex Fuel for 2 cylinder engine used for Small Commercial Vehicle. In order to derive maximum benefit from the higher octane rating of ethanol fuel, compression ratio is increased. EMS calibration activities were conducted with E20 and E85 fuel and intermediate fuel performance was optimized using interpolation method. Fuel injection pressure is increased to address

Kulkarni, Deepak, Malekar, Hemant A, Kulkarni, Chaitanya, Katkar, Santosh, Undre, Shrikant, Upadhyay, Rajdip

Influence of Tipping Angles and Body Shapes on Payload Discharge Efficiency in Dump Trucks

2026-26-0493To be published on 01/16/2026

The payload retention and material outflow pattern during the unloading process of dump trucks are critical factors influencing the efficiency and effectiveness of operations in construction and mining industries. This paper investigates the impact of tipping angles and the shape of the dump truck body on payload retention and outflow characteristics. Using FEA methodology, we explore the material outflow pattern for different body geometries such as box body, scoop body etc. for comparative analysis in order to optimize the shape for better & effective unloading. The results demonstrate a comparative estimation for an optimal body shape configuration to effectively unload payload and correlation of payload retention at various tipping angles.

phukan, Prerna, Sahu, Hemant, Dave, Rajeev

Effect of E20 Fuel on Small Commercial Vehicle Powered of Twin Cylinder Gasoline engine

2026-26-0565To be published on 01/16/2026

In alignment with its carbon reduction commitments, India is transitioning towards higher ethanol-blended fuels, with E20 set for nationwide implementation by 2025. Ethanol is a renewable, domestically sourced biofuel produced through fermentation of biomass such as sugarcane, corn. It possesses a higher octane rating and oxygen content compared to conventional gasoline, making it a favorable additive for improving engine performance and reducing emissions. This study investigates the impact of E20 fuel on performance parameters of a twin-cylinder MPFI gasoline engine. For deriving maximum benefits of increased Octane rating of E20, compression ratio increased. Experimental analysis was conducted to assess the changes in combustion behavior, brake specific fuel consumption (BSFC), torque output, engine out emissions and thermal efficiency when operating on E20 compared to baseline gasoline-E10. Results indicate that E20 enables more efficient combustion due to its higher laminar flame

Kulkarni, Deepak, Malekar, Hemant A, Kulkarni, Chaitanya, Thonge, Ravindra, Kanchan, Shubham

Integrating Road Load Data Acquisition and Signal Processing Techniques to Generate Reliable Drive Files for Electrodynamic Shakers in Testing the Exhaust Systems of Off-Highway Applications

2026-26-0552To be published on 01/16/2026

Generating a reliable drive file for an electrodynamic (ED) shaker from Road Load Data Acquisition (RLDA) and validating its correlation with real-world conditions through damage and fatigue analysis is crucial for accurate component testing, particularly in complex systems like off-highway exhaust systems. This paper presents a methodology for creating such a drive file and establishing its validity, highlighting the necessity of ED shakers for simulating the intricate dynamic loads experienced by these systems. The process begins with acquiring comprehensive RLDA under representative operational conditions of the off-highway vehicle. Drive files are generated using this data, which records accelerations at important exhaust system mounting locations. Advanced signal processing techniques are employed to condense the raw RLDA into a format suitable for shaker control. To establish proper correlation, the generated drive file is used to excite the exhaust system on an ED shaker

Khaire, Santosh Ramdas, Khaire, Rushikesh, Yadav, Dnyaneshwar

E-drive System Selection Criterion for Hybrid Electric Heavy Commercial Vehicles Segments

2026-26-0467To be published on 01/16/2026

Automotive industry expediting progress toward electrification since climate change driven by global warming represents a significant environmental challenge with far-reaching implications. While electric vehicles offer considerable potential for mitigating CO₂ emissions, their elevated upfront costs pose a notable challenge to large-scale market penetration. Hybrid electric vehicles can serve as an effective intermediary solution, bridging the gap between conventional internal combustion engine vehicles and fully electric vehicles, owing to their comparatively lower initial costs. Hybrid electric vehicle component selection is a complex process which has to fulfil multiple requirements fuel economy, performance, drivability, packaging, total cost of ownership of vehicle and comfort. In addition, Hybrid configuration selection also plays a vital role in cost of hybrid electric vehicle. Hence, it is a great challenge to select right powertrain configuration including architecture

Shendge, Raman, Jadhav, Vaibhav, Wani, Kalpesh, Warule, Prasad

Measurement of Acoustic Sensitivity of Automotive Drum Brake to Multiple Faults

2026-26-0555To be published on 01/16/2026

Multiple faults can occur over time in drum brakes, which are commonly used on the rear of heavy vehicles and two-wheelers, compromising passenger safety and ergonomics. Given the recent success of artificial intelligence in fault diagnosis, it can be applied effectively to automotive brakes during operation when combined with advanced measurement techniques. However, monitoring the brake health during operation is challenging due to the rotational motion of components and space constraints for sensors. Consequently, this study investigates the use of measured radiated noise from drum brakes (instead of vibrations) to detect faults. A test bench mimicking typical on-road braking dynamics has been developed to operate in a controlled environment with pre-determined fault levels. This setup measures acoustic signals during transient brake events. Acoustic responses from several experiments that imitate three common brake fault conditions are measured. The acoustic sensitivity to each

Shripad, Kumar Milind Rewanand, Yella, Akash, Sundar, Sriram

Determining Optimal Suspension & Body in White Mountings to maximize Off-Road Capability of Passenger Vehicles

2026-26-0098To be published on 01/16/2026

The automotive market is shifting toward SUVs, with rising customer demand for off-road capability in passenger vehicles. While pure off-roaders offer advanced performance, the goal is to achieve similar functionality in passenger vehicles through minimal design changes. A key factor in off-road performance is wheel articulation, which ensures tire contact and stability on uneven terrain by allowing independent wheel movement. Wheel articulation plays a critical role in determining a vehicle's off-road capability. The vehicle is designed with key parameters like hard point configuration, strength and durability to meet performance targets. While Kinematic and Compliance setup suits standard ride and handling needs, adapting it for off-road capability exceeds its current design limits and requires further enhancements beyond conventional development. Relationship between wheel articulation and off-road performance, emphasizing the role of suspension design and geometry in enhancing

Siddiqui, Arshad, Iqbal, Shoaib, Dwivedi, Sushil

A study of Electric motor configuration for Multi Axle Electric Heavy Duty Commercial Truck Application to attain maximum potential of Torque vectoring

2026-26-0084To be published on 01/16/2026

As the air pollution level rises around the globe, the need for alternative sources of energy increases, and this need is applicable to automotive industry also. Commercial vehicles are one of the major sources of air pollution around the world as they have impactful applicability in our day to day life. With growing advancement in mobility solutions, commercial vehicles are undergoing transformation to improve efficiency, safety and performance. One of the emerging technologies is of torque vectoring which is a concept used to provide better traction and stability to the vehicle in different driving conditions and used in the vehicle having multi motor configuration. Advance torque vectoring concept coupled with electric motor can react to dynamic driving conditions by providing instant torque. The concept of torque vectoring can be useful for heavy commercial vehicles used in off-road applications such as mining because torque vectoring helps in better weight management, cornering

Agarwal, Pranjal, Chaudhari, Gitesh, Gangad, Vikas, Penta, Amar

A procedure for validation of full vehicle CAE models with physical tests for passive safety applications

2026-26-0411To be published on 01/16/2026

With the fast development of computational analysis tools and capacities during the past ten years, complex and substantial computer-aided engineering (CAE) simulations are now economically possible. While the cost of crash tests has risen steadily, the fidelity and complexity, which numerical simulations could address, has multiplied keeping the cost of computational analysis more stable. The use of CAE simulations complements physical testing, accelerating the product development process, reducing cost, and ensuring safe and more optimized designs. The fundamental goal of CAE is a significant reduction in the number of physical tests conducted during the product development process. However, validating the CAE model with physical tests is essential to ensure accuracy and reliability. Simulations performed using a validated CAE model could be used to make decisions like airbag deployment or high voltage shutdown without an actual physical test. This paper discusses validating an

UPENDRAN, ANOOP

Testing Methodology to Calculate the Fuel Economy in Km/Kg of Hydrogen Fuel Cell Electric Vehicle (FCEV) based on Current (Ampere) Method and Flow Method

2026-26-0248To be published on 01/16/2026

The globe is looking headlong to set up new benchmarks for the reduction of GHG (Green House Gases) considering short-term and long-term strategies. Efforts in the Internal Combustion Engines (ICE) domain have been accelerating to find an alternative way to reduce harmful emissions. Hydrogen is considered as a promising fuel to leapfrog this transition. Hydrogen fuel can be categorized into vast mobility areas viz. ICE and Fuel Cell Electric Vehicle (FCEV). Hydrogen fuel has attracted global attention from engine researchers due to the crude oil crisis and its rise in prices in recent years. This will serve the nation's goal towards carbon neutrality. Hydrogen has a few advantages such as less fueling time, higher heating value and more efficiency making it an eye-touching fuel for the automotive industry. In the contemporary FCEV segment, many fuel cell technologies have evolved, wherein the development of Proton Exchange Membrane (PEM) fuel cell technology has taken a new height for

JOSHI, ASHISH RAJENDRA, Kandalgaonkar, Siddhesh, Pawar, Yogesh

Dynamic Prime Mover Management for Enhanced Energy Efficiency in Electric Tractors

2026-26-0185To be published on 01/16/2026

Electric tractors present unique opportunities for efficient power management by decoupling traction and auxiliary loads. In the proposed system, two independent electric motors are employed: one dedicated to vehicle traction and the other to drive the power take-off (PTO) and hydraulic functions, including steering and auxiliary attachments like loaders. Hydraulic flow demand directly impacts operational productivity; traditionally, hydraulic flow is linked to engine speed, requiring frequent manual adjustments. This paper proposes an innovative dynamic control strategy that optimizes motor speed based on real-time application demands, introducing three distinct modes: Low Idle Mode, Loader Mode, and PTO Mode. The Vehicle Control Unit (VCU) at the heart in coordination with the Farm Machinery Control Unit (FMCU) and Motor Control Unit (MCU), dynamically selects the appropriate mode based on user inputs such as PTO activation and joystick controls Low Idle Mode minimizes energy usage

Natarajan, Saravanan, P, Shanmugavel, M, Rojer, Joshi, Priyanka, sundaram, Pavithra

Comprehensive Durability Assessment of Planet Carrier in Heavy-Duty Tipper Gearboxes Using RLDA Torque Data

2026-26-0443To be published on 01/16/2026

In heavy-duty tippers, where challenging conditions demand high torque, planet carriers play a crucial role by enabling efficient load distribution and torque transmission while supporting gear ratio and speed variation in space-constrained systems such as automatic transmissions, hybrid drivetrains, and electric vehicles. This paper focuses on the comprehensive durability performance assessment of planet carriers using duty cycles derived from RLDA measurements for a heavy-duty tipper gearbox development program. The existing Design Validation Plan (DVP) for the planet carrier considers first gear utilization of 10-15% at 40% vehicle overload, in line with historical data. However, recent trends in mining applications revealed vehicle overloads of 55-65%, leading to an increase in first gear utilization (25-35%). This shift presents challenges for OEMs to enhance design durability while incorporating additional safety margins to meet the demands of a competitive, cost-driven market

Bagane, Shivraj, Pendse, Ameya

Total cost of ownership analysis of fuel cell and hydrogen-powered commercial vehicles for cost competitiveness with ICE and BEV

2026-26-0254To be published on 01/16/2026

Worldwide, the automotive industry is pivoting towards electrification and zero-emission vehicles (ZEV) to address greenhouse gas emissions and to meet net-zero emission goals. Although pure electric vehicles with rechargeable high-voltage batteries seem to be the most popular choice to achieve climate goals, hydrogen-powered vehicles are also seen by many as a viable technology to clean up the transportation sector. Hydrogen fuel cells and fuel cell-powered vehicles have been in development for a long time, and hydrogen internal combustion engines (ICE) have seen rapid development in the past few years. While the technological feasibility of hydrogen fuel cells and H2 ICE is being proven, mass adoption of these technologies depends, along with other factors such as hydrogen infrastructure, upon financial feasibility as well. This paper presents a systematic analysis of the total cost of ownership (TCO) of hydrogen-powered vehicles, especially fuel cell electric vehicles. Different

Jacob, Joe, Chougule, Abhijeet

Development of a Passive Regeneration Diesel Particulate Filter System for an Agricultural tractor Engine

2026-26-0217To be published on 01/16/2026

This paper presents the development and evaluation of a passive regeneration Diesel Particulate Filter (DPF) system for a 4-cylinder, 3.18-liter naturally aspirated agricultural tractor engine based on the mDI engine family. The primary objective is to significantly reduce particulate matter (PM) emissions while maintaining optimal engine performance and fuel economy. The passive regeneration DPF system leverages the engine's operating conditions to generate sufficient heat for the oxidation of trapped particulate matter, eliminating the need for active regeneration techniques. The paper details the design process, including the selection of DPF material, filter geometry, and integration into the exhaust system. Rigorous experimental testing was conducted to assess the performance of the DPF system under various engine load and speed conditions. Results demonstrate substantial reductions in PM emissions without compromising engine power, torque, or specific fuel consumption. This

Maddali, Varun Suman, Jidigonti, Shashank, Kannan, S, Ramesh, Natrajan

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