Browse Topic: Commercial vehicles

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Determining Optimal Suspension & Body in White Mountings to maximize Off-Road Capability of Passenger Vehicles2026-26-00981/16/2026
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 vectoring2026-26-00841/16/2026
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 applications2026-26-04111/16/2026
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 Method2026-26-02481/16/2026
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 Tractors2026-26-01851/16/2026
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 Data2026-26-04431/16/2026
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 BEV2026-26-02541/16/2026
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 Engine2026-26-02171/16/2026
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
Migration from MIDC to WLTP in India: Challenges & Solutions for a Small Commercial Vehicle2026-26-02151/16/2026
In line with global peers (EU, Japan etc.), the Automotive Industry Standard (AIS) Committee in India has decided to adopt "World harmonized Light vehicle Test Procedure (WLTP)" for M and N category vehicles with GVW not exceeding 3500 kg. As a result, "World harmonized Light-duty vehicles Test Cycle (WLTC )" is set to replace currently applicable "Modified Indian Drive Cycle (MIDC)" in the next couple of years. The draft CAFE III & CAFE IV norms for CO2 emission limits, which are set to be implemented in 2027 and 2032 respectively refer to a shift to WLTP from MIDC. This migration to WLTP is in sync with the demand for test procedures to replicate real driving conditions more appropriately. Further, with the Indian automotive sector growing at a robust CAGR of ~9%, the move to WLTP along with stricter emission norms is going to help the government take a major step towards India's COP26 pledge to achieve net zero emissions by 2070. WLTC cycle being much more dynamic with higher
Emran, Ashraf, Sandhu, Rouble, Pawar, Bhushan, Berry, Sushil
Sustainable, Innovative, Cost-Effective, Lightweight Roof Design for Automotive Commercial Vehicle2026-26-02931/16/2026
The automotive industry is progressively concentrating on sustainability, cost-efficiency, and safety, prompting the necessity for innovative design solutions. This paper presents the development of a groundbreaking lightweight Roof assembly for commercial vehicles, focusing on the essential aspects of roof strength and crash compliance. The proposed design notably reduces weight while enhancing structural integrity, strength and overall safety, addressing the growing demand for eco-friendly and efficient automotive components. Our research employs comprehensive finite element analysis (FEA) alongside rigorous real-world testing to validate the design's performance. These evaluations demonstrate the roof assembly's ability to withstand significant impact and deformation, ensuring robust safety standards. In addition to performance assessments, we conduct a thorough cost-benefit analysis to evaluate the economic viability of the design. The analysis underscores the potential for
Pandey, Sudheer, Navsariwala, Prashant, Ganesan, Balaji
Smart Multilink Cabin Suspension with Detachable Stabilizer Mechanism for Improved Ride Comfort and Maintenance Efficiency in Vehicle Cabins.2026-26-00881/16/2026
This paper presents the design and development of a novel suspension system for vehicle cabins, specifically aimed at improving ride comfort and reducing maintenance time and costs. The system features a detachable stabilizer bar pivotally coupled to a pair of brackets connected to the vehicle chassis. The stabilizer bar is removably connected to a pair of connecting links, which in turn are oupled to a second pair of brackets attached to the cabin. This configuration allows for easy access to the engine bay during maintenance without disassembling the entire suspension system. Additionally, the system includes damper units and pivot arms that enhance ride comfort by isolating vibrations from the chassis. The proposed design is particularly beneficial for commercial vehicles with fixed cabins, as it reduces idle time during engine overhaul and improves overall ride quality for occupants.
K, Akilan, Pardeshi, Mahesh, Mistri, Pratikkumar, Navsariwala, Prashant
Controls Solutions for Commercial Hydrogen Engines2026-26-01121/16/2026
India’s commitment to carbon neutrality is significantly shaping the future architecture of commercial vehicle powertrains. While the use of CO₂-free technologies such as battery-electric drivetrains has already been successfully demonstrated across various applications, challenges related to limited range and the lack of high-power charging infrastructure continue to hinder widespread adoption, particularly for productivity-critical commercial vehicles. This has shifted the spotlight toward sustainable fuels, which offer the advantage of fast refueling times. Among these, hydrogen internal combustion engines (H₂ ICE) have gained increasing attention in recent years. In regions such as the European Union, the primary motivation for hydrogen is CO₂ reduction. In contrast, for markets like India, hydrogen also presents a strategic opportunity for reducing dependency on fossil fuel imports. Over the past four years, AVL has carried out multiple performance and emission development
Arnberger, Anton, Danninger, Alois, Mannsberger, Stefan, Breitegger, Bernhard
A comprehensive strategy for Diesel Particulate Filter calibration to address the diverse applications of Stage V Construction Equipment Vehicles.2026-26-01431/16/2026
The legislation of CEV Stage V emission norms has necessitated advanced Diesel Particulate Filter calibration strategies to ensure optimal performance across diverse construction equipment applications in the Indian market. Considering the various duty cycles of cranes, backhoe loaders, forklifts, compactors, graders, and other equipment, different load conditions and operational environments require a comprehensive strategy to enhance DPF efficiency, minimize regeneration frequency, and maintain compliance with emission standards. The DPF, as an after-treatment system in the exhaust layout, is essential for meeting emission standards, as it effectively traps particulate matter. Regeneration occurs periodically to burn the soot particles trapped inside the DPF through ECU management. Therefore, understanding soot loading and in-brick DPF temperature behavior across various applications is the key. This paper explores the challenges in DPF calibration for CEV Stage V and provides a
Mohanty, Subham, Patil, Lalit, Chaudhari, Kuldeepak Arun, Mahajan, Atish, Madhukar, Prahlad
Evaluation of Vibration Reduction Techniques in Agricultural Tractors: A Design of Experiments Approach2026-26-03441/16/2026
Operator comfort is among the most crucial features of agricultural tractors. Tractor operators work long hours and are subjected to vibrations and mechanical shocks, which are potentially harmful to their health. When selecting a tractor for agricultural use, one of the main factors to consider is tactile vibrations. The mandate for this project includes an investigation of tractor vibration control issues. For identifying the source of the issue, study of the controlling system is crucial. The objective of the study was to evaluate the vibrations transmitted through the tractor and to reduce vibrations on specific tactile locations through the design of experiments (DOE) method. In this paper, testing is performed on the specified tactile locations; to reduce resonance-induced vibrations, a range of approaches are being explored, including lowering the natural frequency away from the second-order engine frequency and improving the damping coefficient to lower the vibration amplitude
Baviskar, Shreyas, dhobale, Vishwajeet, Bhangare, Amit, Kunde, Sagar, Wagh, Sachin
Key Parameters for Turbocharger selection & experimental validation for Off-Highway Applications2026-26-01041/16/2026
Customers in off-highway industry are increasingly seeking high-performance capabilities for their tractors due to increasing penetration of mechanisation and labour scarcity. One effective solution to achieve enhanced performance is turbocharging of engines, while meeting emission and highly dynamic transient response of tractor field applications. The process of selecting and validating a suitable turbocharger for tractor field application suitability is significantly time and resources consuming activity due to extensive testbed and field trials. This study focuses on the selection of turbocharger for tractor engines through analytical calculations to freeze key parameters like lambda, boost pressure ratio & temperature within boundaries of exhaust temperature and turbo efficiency maps to deliver best field transient performance and fuel consumption. The selected parameters are further validated under real-world transient operating conditions, involving tractors and their implements
RAWAT, SAURABH, KUMAR, HARISH KUMAR, Singh, Amarinder, Singh, Sachleen, Dogra, DaljitSingh
Combustion noise quality improvement in a common rail Diesel Engine at Low idle for Agriculture Tractor2026-26-03291/16/2026
Vehicle level NVH performance plays major role in customer comfort criteria. Tractor low idle rpm Sound Quality can be one of the parameter which influences customer purchasing decision based on comfort criteria. Modern diesel engines with stringent emission norms together with fuel economy requirements pose challenges to noise control. Common rail engine technology has advantage of precise fuel delivery and combustion control which needs optimization to achieve the conflicting requirements of noise, emission and fuel efficiency. Engine noise at low idle condition is dominated by combustion noise which depends on rate of pressure rise inside the cylinder during combustion. The important parameters which influence cylinder pressure rise are fuel injection timing, pilot injection quantity and its separation, rail pressure and EGR valve position. The study is carried out to understand which combustion parameter is most influencing to achieve better sound quality of engine. Taguchi design
p, Priyadarshan, Chavan, Amit, A, Kannanswamy, Patil, Sandeep, Chaudhari, Vishal V
Monitoring and Diagnosing Software-Defined Vehicle Architectures2026-26-06771/16/2026
Software-Defined Vehicles (SDV) are fostered through initiatives like SOAFEE and Eclipse SDV promoting the use of cloud-native approaches, distributed workloads and service-oriented architectures (SOA). Vehicles are connected to the cloud and functions are partially executed in the cloud and the vehicle. However, these approaches do not provide solutions for monitoring and diagnosing SDVs neither on-board nor off-board. Given the cost-sensitive nature of vehicles, OEMs are unlikely to allocate significant resources to diagnostics. Consequently, conventional data centre monitoring strategies, which rely on transferring large datasets to dedicated servers, are not directly applicable to vehicles. The paper describes a SOA used in research for several years where each vehicle functionality is implemented by independent services with an orchestrator for managing them. ASAM SOVD (ISO 17978) specifically supports diagnosing SDVs by providing functionality beyond UDS, such as access to log
Böhlen, Boris, Fischer, Diana
Design and evaluation of Integrated Engine-Mounted Exhaust Aftertreatment and Air Intake Filtration System with CEV/TREM Stage-5 IC engine for off-highway applications2026-26-01441/16/2026
Conventional exhaust aftertreatment systems (ATS) and air intake filters are typically mounted separately on the vehicle chassis, leading to complex routing, significant packaging volume, thermal management challenges for the ATS, and increased assembly complexity. This paper presents a novel system integrating the air intake filter and the complete exhaust aftertreatment system (including DOC, DPF, SCR components as applicable) into a single unit mounted directly onto the engine. This engine-mounted integrated architecture significantly reduces system footprint, minimizes exhaust and intake piping lengths, potentially improves ATS thermal efficiency through close coupling, and simplifies vehicle assembly. Design considerations, including vibration isolation, serviceability, and potential performance benefits such as reduced pressure drop and faster catalyst light-off, are discussed. This integrated approach offers a compelling solution for optimizing packaging space and system
P U, Balaji, sivasankaran, Siva, Arputharaj, Jeba, Kumar, Lingesh, Pandian, Teja, Patil, Shankar
Enhancing Pedestrian Safety: LIDAR-Based Deployment of Front LID/Bonnet and Airbag Systems in Heavy Commercial Vehicles During Low-Speed collisions.2026-26-00061/16/2026
As urban populations continue to grow, the safety of Vulnerable Road Users (VRUs) particularly in the presence of Heavy Good Vehicles (HGVs) has emerged as a critical concern. Research indicates that VRUs are at a 50% higher risk of fatal injury in collisions involving HGVs compared to passenger cars [1] [2]. To address this issue, this study proposes a novel pedestrian protection system that integrates LiDAR (Light Detection and Ranging) technology with a reusable airbag system to mitigate the severity of collisions. The proposed solution adopts a twofold approach for enhancing VRU protection in scenarios involving HGVs. In both approaches, LiDAR sensors are used to generate a real-time 3D model of the vehicle’s surroundings, enabling accurate VRU detection and predictive collision analysis. • Scenario 1: When vehicle speed exceeds the first threshold and a collision is unavoidable, the onboard ECU activates front lid actuators, extending the vehicle's front lid which can be retracted
Patil, Uday, Sriharsha, Viswanath, Pillai, Rajiv
Safer Trucks for India-Smart Tech Fusion2026-26-00311/16/2026
Commercial vehicle sector (especially trucks) has major role in economic growth of a nation. With improving infrastructure, increasing number of trucks on roads, accidents are also increasing. As per RASSI (Road Accident Sampling System India) FY2016-21 database, commercial vehicles are involved in 43% of total accidents on Indian roads. Involvement of trucks (N2 & N3) is 25% over total accidents. Amongst all accident scenarios of N2 &N3, frontal impacts are the most frequent (26%) and causing severe occupant injuries. Today, truck safety development for frontal impact is based on passive safety regulations (viz. front pendulum - AIS029) and basic safety features like seatbelts. In any truck accident, it is challenging rather impossible to manage comprehensive safety only with passive safety systems due to size and weight. Accident prevention becomes imperative in truck safety development due to extremely high energy involved in front impact scenarios. The paper presents unique safety
Joshi, Kedar Shrikant, GADEKAR, GANESH, Date, Atul, Koralla, Sivaprasad
Engine and After-treatment optimization using Simulation tools2026-26-00571/16/2026
To achieve world-class engineering quality and reduce the effort and cost associated with conventional techniques, it is essential to incorporate digital validation during the development and validation phases. This research paper explores the methodologies and applications of advanced simulation tools for creating models of engines and their sub-components using MATLAB/Simulink, parameterizing these systems with AVL CruiseM, and operating them using ETAS Labcar-Operator. The paper provides an in-depth analysis of optimizing engine and after-treatment parameters, demonstrating their impact on performance and environmental compliance. It presents a series of simulation case studies that illustrate the effects of different parameter settings on the efficiency and emission levels of diesel passenger and commercial vehicle engines. These case studies highlight the overall workflow of model-based system development, emphasize various development milestones, and correlate these with actual
Shukla, Saurabh, Shilledar, Aneesh
Development of a New Methodology for Measuring the Dimensions of Lighting Components in Construction Equipment Vehicles (CEVs) as per IS/ISO 12509:2004 using 3-Dimensional Planar Laser.2026-26-01451/16/2026
The light and light signalling devices installation test as per ISO 12509:2004 for Earth Moving Machinery / Construction Equipment Vehicles (CEV’s) is a mandatory test to ensure the safety of both road users and operators. Considering the shape and size of CEV’s, accurate measurement of lighting installation requirements is crucial for ensuring safety and regulatory compliance. The international standard ISO 12509:2004 specifies detailed criteria for these installations, including precise dimensional measurements of lighting components to guarantee optimal visibility and safety. Considering shape and Size of CEV’s, the accurate measurement of lighting installation requirements is crucial for regulatory compliance. ISO 12509:2004 outlines specific criteria for these installations requirements of lighting components, including the precise measurement of various dimensions to ensure optimal visibility and safety. Among these dimensional requirements, the dimension 'E' i.e., the “distance
Ghodke, Dhananjay Sunil, Belavadi Venkataramaiah, Shamsundara, Tambolkar, Sonali Ameya
Advanced Thermal Management for High-Tonnage EVs: Increasing Coolant Flow and Reducing Energy Losses2026-26-01961/16/2026
With the increasing tonnage of electric heavy commercial vehicles, there is a growing demand for higher power and torque-rated traction motors. As motor ratings increase, efficient cooling of the EV powertrain system becomes critical to maintaining optimal performance. Higher heat loads from traction motors and inverters pose significant challenges, necessitating an innovative cooling strategy to enhance system efficiency, sustainability, and reliability. Battery-electric heavy commercial vehicles face substantial cooling challenges due to the high-pressure drop characteristics of conventional traction system cooling architectures. These limitations restrict coolant flow through key powertrain components and the radiator, reducing heat dissipation efficiency and constraining the operating ambient temperature range. Inefficient cooling also leads to increased energy consumption, impacting the overall sustainability of electric mobility solutions. This paper presents a novel approach to
DIXIT, SAMEER, Patil, Bhushan, Ghosh, Sandeep
Clutch Thermal Adequacy Assessment in Repeat Restart Launch Condition on Gradient2026-26-04341/16/2026
The clutch is a mechanical device that engages and disengages power transmission from the engine to the wheels. It consists of the clutch disc assembly and cover assembly. The clutch disc, with friction material linings, is mounted on the transmission shaft and gets clamped between the flywheel and cover assembly to transmit power as required. However, wear and tear occur due to the differential speeds and slippage between the engine and transmission during operation. Clutch performance is assessed for its thermal behavior under repeat restart conditions on steep gradients, which is essential for the reliability and durability of commercial vehicle clutches. Repeat restart test is a key test to assess clutch performance on a 12% gradient. This test replicates real world scenarios, such as truck launches on hilly terrains under full load, where the clutch experiences significant slippage due to speed differences. This generates heat, and repeated engagements can cause the temperature to
Munisamy, Sathishkumar, Chollangi, Damodar, Mane, Sudhir
AI-powered intelligent cognitive lens for driver monitoring for safe transportation and increased fleet efficiency2026-26-06341/16/2026
The rapid evolution of intelligent transportation systems has made drivers’ attentiveness and adherence to safety protocols more critical than ever. Traditional monitoring solutions often lack the adaptability to detect subtle behavioral changes in real time. This paper presents an advanced AI-powered Driver Monitoring System designed to continuously assess driver behavior, fatigue, distractions, and emotional state across various driving conditions. By providing real-time alerts and insights to vehicle owners, fleet operators, and safety personnel, the system significantly enhances road safety. The system integrates lightweight AI/ML algorithms, image processing techniques, perception models, and rule-based engines to deliver a comprehensive monitoring solution for multiple transportation modes, including automotive, rail, aerospace, and off-highway vehicles. Optimized for edge devices, the models ensure real-time processing with minimal computational overhead. Alerts are communicated
Mardhekar, Amogh, Sing, Sandip, Chikhale, Shraddha, Hivarkar, Umesh
An In-Depth Exploration of the Evolution and Global Adoption of Electric Motors in New Energy Vehicles2026-26-01611/16/2026
In recent years, the global automotive sector has undergone a transformation at an unprecedented pace, driven by rapid technological advancements and evolving consumer expectations. Central to this shift has been the accelerated adoption of electric motors as the primary propulsion mechanism in New Energy Vehicles (NEVs). This research paper explores the technological trajectory of electric motor development across four vehicle segments: two-wheelers, three-wheelers, passenger vehicles, and heavy-duty commercial vehicles. It identifies the leading electric motor technologies utilized in each of these segments, along with their prevalence across key regulated global markets. Drawing upon historical data and existing academic literature, the paper provides a comprehensive overview of current e-motor technologies and their market distribution. A regional analysis is conducted to examine variations in manufacturer preferences and deployment strategies, supported by visual representations
SINGH, ASHISH, Ray, Rakesh Kumar
A practical approach to reduce Gear Whine noise through gear Tooth contact analysis in an Agricultural Tractor2026-26-03451/16/2026
Customer demand for comfortable tractors has gone multi-fold in last decade. Transmission gear whine noise as one of the major sources of noise, is an important factor influencing the perceived quality of a vehicle and customer comfort. Investigations were carried out on 57HP tractor reported with high whine noise during deceleration from high speeds to low speeds. The source of whine noise is identified through order analysis as spiral bevel gear. Mitigating spiral bevel gear whine noise is always a challenge because of geometry, tooling and assembly requirements. Tooth contact analysis was performed on the spiral bevel gear for simulating the meshing of gear teeth to determine factors like contact patterns, transmission errors, and load distribution. From tooth contact analysis the root cause for high deceleration noise was identified as the motion transmission was not smooth in entry and exit for both forward and reverse. A practical approach of microgeometry optimization was
P, Bharath, p, Priyadarshan, Janarthanan, Devakumara Raja, Chavan, Amit
Drive Cycle Based Energy Audit & Range Estimation for 4X2 Electric Truck2026-26-01631/16/2026
Transportation sector in India accounts for 18% of total energy consumption. Demand of energy consumption is being met by the imported crude oil, which makes transportation sector more vulnerable to fluctuating international crude oil prices. India is mindful of its commitment in 2016 Paris climate agreement to reduce GHG emissions by 35% by 2030 as compared to 2005 levels. To fast track the decarbonization of transportation sector, commercial vehicle manufacturers have been exploring other viable options such as battery electric vehicles (BEVs) as a part of their fleet. As on today, BEV has its own challenges such as range anxiety & high total cost of ownership. Range anxiety can be certainly addressed by optimum sizing of electric powertrain, reduction in specific energy consumption (SEC) & use of effective regeneration strategies. Higher SEC can be more effectively addressed by doing vehicle energy audit thereby estimating the energy losses occurring at each powertrain component of
Gijare, Sumant, Karthick, K., Juttu, Simhachalam, Thipse, Sukrut S., A, Jothikumar, J, Frederick Royston, SR, Subasree, G, Harini, M, Senthil Kumar
The Creation of the 245/90R16 Tire Size for Commercial Vehicles 8.5T -12T in the 16-Inch Tube-Type Category – A Global First2026-26-06021/16/2026
This project introduced a brand-new tire size—245/90R16—for the first time globally in the 16-inch tube-type category, designed specifically for commercial vehicles with Vehicles 8.5T -12T gross vehicle weight (GVW). The main goal was to create a compact vehicle that can carry more payload, reduce overall weight, and improve fuel efficiency with use of rear single tyre instead of twin tyre in 8.5T. This helps customers lower their operating costs and improve vehicle performance, especially on narrow roads. The new tire supports high load capacities: up to 2300 kg for single tire use and 2180 kg for dual tire fitment. It enables a new type of vehicle to be developed—an 8.5-ton GVW vehicle with rear single tires—offering better payload capacity without increasing the size of the vehicle. By using this new tire, the kerb weight of the vehicle is reduced, which increases the payload and helps improve fuel economy. It also helps lower the cost of the vehicle by allowing the use of lighter
Pawar, Dhondiram Dnyandeo, Shaikh, Matin, ambekar, Prasad
Performance Evaluation and Optimization of Engine Brake System using Chassis Dynamometer2026-26-05111/16/2026
Engine braking is a deceleration technique that leverages the internal friction and pumping losses within the engine. By closing the throttle and potentially selecting a lower gear, the engine creates a retarding force that slows the vehicle. This practice contributes to better fuel economy, decreased brake system load, and improved vehicle handling in specific driving scenarios, such as steep declines or slippery road surfaces. To alleviate stress on their primary braking systems and prevent overheating, heavy vehicles frequently incorporate engine-based braking. While older trucks relied on simple exhaust brakes with a butterfly valve to restrict exhaust flow, these had limited impact. Hence contemporary heavy vehicles almost exclusively use more advanced engine braking technologies. Traditionally, our heavy-duty vehicles use Exhaust brake system to elevate the braking performance on hilly terrains. Hence an improved sample of Engine brake was developed for enhanced braking
M, Vipin Prakash, Rajappan, Dinesh Kumar, R, Suresh, N, Gopi Kannan
Measurement of Acoustic Sensitivity of Automotive Drum Brake to Multiple Faults2026-26-05551/16/2026
Multiple faults can occur over time in drum brakes, which are commonly used on the rear of heavy vehicles and two-wheelers, compromising passenger safety and ergonomics. Given the recent success of artificial intelligence in fault diagnosis, it can be applied effectively to automotive brakes during operation when combined with advanced measurement techniques. However, monitoring the brake health during operation is challenging due to the rotational motion of components and space constraints for sensors. Consequently, this study investigates the use of measured radiated noise from drum brakes (instead of vibrations) to detect faults. A test bench mimicking typical on-road braking dynamics has been developed to operate in a controlled environment with pre-determined fault levels. This setup measures acoustic signals during transient brake events. Acoustic responses from several experiments that imitate three common brake fault conditions are measured. The acoustic sensitivity to each
Shripad, Kumar Milind Rewanand, Yella, Akash, Sundar, Sriram
An Outer Waist Seal with Integrated Glass Wiping Mechanism for a Window Frame of a Vehicle2026-26-00111/16/2026
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 Tests2026-26-00831/16/2026
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 fencing2026-26-02731/16/2026
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 model2026-26-01031/16/2026
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 vehicles2026-26-00181/16/2026
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 Optimization2026-26-06621/16/2026
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 Height2026-26-05131/16/2026
This paper contains a study of the measurement accuracies of two methods commonly used by vehicle industries and other stakeholders to determine vehicle center of gravity (CG) height. The two methods, which both appear in international standards, are the Axle Lift method and the Stable Pendulum method. The Stable Pendulum method requires a dedicated swinging platform mechanism, but it is generally considered to be more accurate than the Axle Lift method. Both methods rely on equations for computing CG height that are based on static balance models of a vehicle tested at various pitch angles. For each method, the accuracy of the resulting CG height computations is a function of the individual measurements needed in the model equations. The individual measurements needed depend on the method used, but they include weights, angles, and distance measurements. A theoretical error analysis study is presented that provides insight into the accuracy of both methods given the uncertainty in the
Heydinger, Gary, Zagorski, Scott, Bartholomew, Meredith, Andreatta, Dale
Comparative Study of EV Transmission Performance used in Various Vehicle Segments2026-26-05841/16/2026
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 vehicle2026-26-00901/16/2026
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 Sensor2026-26-05381/16/2026
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 Vehicle2026-26-00631/16/2026
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 System2026-26-06521/16/2026
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 Expenses2026-26-00761/16/2026
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 Strategy2026-26-03181/16/2026
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 validation2026-26-05331/16/2026
Road Simulators used to carry out accelerated structural durability validation of a vehicle. As a commercial vehicle manufacturer, for our commercial vehicles structural validation, we are using 8 poster road simulators. We use road load data, torture track data, synthetic profiles or events as the input test data. From a mini 4 wheeler trucks to high capacity 8 wheeler truck, and any bus variant is being tested at road simulator. All the vehicle variants are tested with prescribed road and load conditions for the pre-determined life. Each wheel of the vehicle is positioned on the wheel pan of the hydraulic actuators so that each actuator excites the corresponding vibration data. The vehicle is being restrained as per the manufacturers recommendation. Manufacturer recommendations widely addresses the risks associated with the test rigs. In addition to that there are risks associated with the vehicle running, vehicle handling, vehicle positioning. For example, when durability test
Arumugam, Paramasivam, N, Gopi Kannan, N, Mahendra, Muthu kumar, Pandurangan, Singh, laxman, Tiwari, Manish, V, Subash
Innovative Multi-Axial Testing approach for Enhanced Reliability of Cooling Modules in Commercial Vehicles2026-26-05301/16/2026
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 performance2026-26-05021/16/2026
The Electronic Locking Differential (ELD) is a critical component for enhancing off-road vehicle performance by ensuring optimal traction in challenging terrains. This paper addresses intermittent engagement issues observed in the ELD system during off-road trials, which impacted its reliability and functionality. It presents a comprehensive study of design robustness improvements implemented to resolve these concerns and optimize the ELD’s performance, ensuring enhanced customer satisfaction in demanding off-road environments. The analysis begins with identifying factors contributing to the intermittent engagement and disengagement of the ELD system upon actuation. These factors include residual magnetism, material properties, temperature effects, and the stack-up characteristics of transfer path components under various boundary conditions. To address these challenges, three key design modifications were introduced: (1) reduction of residual magnetism through an increased air gap
S, Mohd Imtiaz, AP, Baaheedharan, Ghumare, Dheeraj, Kanagaraj, Pothiraj, Jain, Saurabh Kumar
Thermal Management Control strategy for Primary & Secondary Drive Cooling Hybrid Electric Tractor2026-26-00691/16/2026
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"2026-26-05471/16/2026
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
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