Browse Topic: Electric vehicles

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Securing the Future of Electric Vehicle Charging: Identifying and Mitigating Cybersecurity Vulnerabilities2026-26-06141/16/2026
This paper examines the key security vulnerabilities present in modern EV charging infrastructure, with a focus on the potential threats to payment systems, communication protocols, physical security, and data privacy. In particular, it looks at the vulnerabilities associated with unencrypted communication, the risks of unauthorized access to charging stations, and the potential for denial-of-service (DoS) attacks. As the global adoption of electric vehicles (EVs) accelerates, the importance of a secure and reliable EV charging infrastructure becomes paramount. However, the expansion of charging stations and the growing integration of smart technologies introduce significant cybersecurity risks that must be addressed to ensure the safety, privacy, and reliability of the network. In addition to discussing emerging risks in relation to new technologies, such as Vehicle-to-Grid (V2G) systems, and outlining the necessity of industry-wide collaboration and the development of standardized
Aggarwal, Akshit, Gupta, Saurabh, Sirohi, Kapil, Arisetty, Venkatesh, Chatterjee lng, Avik
Artificial Intelligence in Passenger Cars: Unlocking Intelligent Mobility and Human-Centric Vehicle Innovation2026-26-06721/16/2026
Artificial Intelligence (AI) is fundamentally reshaping the landscape of automotive engineering, particularly in passenger vehicles where comfort, safety, and customization are paramount. This paper presents a comprehensive review of current and emerging AI-driven applications in passenger cars, including intelligent vehicle insurance, real-time traffic optimization, personalized driving experiences, emotion recognition, and advanced EV battery management. The integration of AI technologies—ranging from machine learning and computer vision to natural language processing and deep neural networks—enables predictive maintenance, adaptive driver-assist systems, and next-generation human-machine interfaces. AI’s role in vehicle insurance is also explored through behaviour-based risk scoring and claims automation. Furthermore, emotion-aware cabin systems are discussed, which aim to detect driver fatigue, stress, or distraction to improve road safety and mental wellness. The paper also
Hazra, Sandip, Tangadpalliwar, Sonali, Khan, Arkadip
Cybersecurity threats for connected passenger EV Buses of state transport units in India.2026-26-06101/16/2026
There are several chances to enhance fleet management, passenger safety, and operational efficiency by integrating connected technology into electric passenger buses, especially in Indian state transport agencies. But this connectivity also brings with it a fresh set of cybersecurity threats that might jeopardize these cars' dependability and security. With an emphasis on India's state-run bus fleets, this study examines the cybersecurity risks unique to connected electric vehicles (EVs) utilized for public transportation. Vehicle-to-vehicle (V2V), vehicle-to-infrastructure (V2I), and fleet management communication systems are examined for key vulnerabilities. Potential attack vectors are highlighted, including data interception, GPS spoofing, unauthorized access, and cyberattacks on charging stations. We also look at how these cybersecurity threats affect public safety, operational disruptions, and passenger privacy. This paper also assesses the difficulties Indian state transport
Mokhare, Devendra Ashok
Analysis and Optimization of Stick-Slip Behaviour in Metal-Plastic Interfaces for Connected Tail Lamp Assemblies in Electric Vehicles2026-26-03321/16/2026
The seamless and sleek design of connected tail lamps adds a visually striking element to the car's exterior. It aligns with contemporary automotive trends and gives the vehicle a premium and futuristic appearance. Automakers use these lamps as a design signature to establish brand identity. Connected tail lamps improve visibility for drivers behind the vehicle. The assembly of connected tail lamps can pose several challenges, especially due to their complex design and integration requirements. Metal-plastic creak is a common concern in electric vehicles (EVs), often noticeable when driving on uneven roads. This primarily results from stick-slip behaviour at the interface of metal and plastic components, intensified by improper alignment. When the designed geometric dimensioning and tolerancing (GD&T) is not met in real manufacturing conditions, misalignment introduces unintended contact forces, leading to intermittent micro-sliding and frictional energy release, which manifests as an
MICHAEL STEPHAN, NAVIN ESTAC RAJA, C M, MITHUN, Mohammed, Riyazuddin
A Comprehensive Analysis of Sealing Methods for EV Battery Packs: Trends and Insights.2026-26-01801/16/2026
The widespread adoption of electric vehicles (EVs) has brought about unique engineering challenges, particularly in the design of battery packs, which are central to vehicle performance, safety, and longevity. One critical requirement is maintaining ingress protection (IP) ratings of IP67 or higher to safeguard against water and dust exposure. These ratings are essential to ensure compliance with homologation standards and to meet the demands of diverse terrains and operating conditions. Achieving effective sealing of EV battery packs is thus a key aspect of their design and engineering. This study presents an in-depth analysis of sealing technologies employed in EV battery packs, focusing on four primary types: Adhesive-based sealants, Cure-In-Place Gaskets (CIPG), Foam Cut seals, and Rubber Gaskets. Benchmarking data gathered from more than 90 vehicle models across 20+ brands provide insights into adoption trends, historical shifts, evolution and interface requirements of different
Varambally, Vishakha, Sithick basha, Abubakker, Chalumuru, Madhu, Yaser, K U Syed, Sasikumar, K
Reverse Engineering of CAN (Controller Area network) of an Electric vehicle2026-26-01501/16/2026
The communication between different vehicle electronic controller units (ECU) for various applications (I.e. To propel the vehicle or for In-vehicle Infotainment) CAN (Controller Area Network) is most frequently used for In-Vehicle communication. Given the proprietary nature and lack of standardization in CAN (Controller Area Network) configurations, which are often not disclosed by manufacturers, the process of CAN reverse engineering becomes highly complex and cumbersome. Additionally, the scarcity of publicly accessible data on electric vehicles, coupled with the rapid technological advancements in this domain, has resulted in the absence of a standardized and automated methodology for reverse engineering the Controller Area Network (CAN). This process is further complicated by the diverse CAN configurations implemented by various Original Equipment Manufacturers (OEMs), which are often not disclosed to the public. In this paper the manual approach is taken for reverse engineering
KUMAR, ROHIT, Sahu, Hemant, Penta, Amar, Bhatt, Purvish
Refinement of Road Induced Steering Wheel Vibration in Electric Vehicle2026-26-03371/16/2026
Nowadays, customers expect excellent cabin insulation and superior ride comfort in electric vehicle. OEMs focuses on fine tuning the suspension system in electric vehicle to isolate the road shocks which finally offers superior ride quality. This paper focuses on the enhancing the ride comfort by reducing the steering wheel vibration which mainly originates due to road inputs. Higher steering wheel vibrations are perceived on the test vehicle when driven on rough road at the speed of 50 kmph. To determine the predominant force transfer path, Multi reference Transfer Path Analysis (MTPA) is performed on the front and rear suspension. Based on the finding from MTPA, various recommendations are explored and the effect of each modification is discussed. Apart from this, Operational Deflection Shape (ODS) analysis is carried out on the entire steering system to identify the deflection shape at the operating condition. Based on ODS findings, recommendations like dynamic stiffness
S, Nataraja Moorthy
Assessment of Structure-borne Road Noise for Battery Electric Vehicle: Prediction and Improvement2026-26-03201/16/2026
In the absence of engine noise, road-induced noise has become a major concern specifically for Battery Electric Vehicles (BEVs), impacting Sound Pressure Level (SPL) for both drivers and passengers. Under the influence of random road load inputs, structural vibrations which transfer from road and tire to suspension to vehicle body, the cabin interior noise, particularly at lower frequencies, is significantly affected. To improve the road-induced low-frequency structure-borne noise behaviour, which frequently perceptible as ‘booming noises’, a study was carried out to assess predominant noise sources present in vehicle and to suggest refinements in reducing noise levels. By considering random excitations of road profile through tyre patch using CD-Tire model, vehicle interior noise was computed. Subsequently, to get insight of dynamic behaviour of vehicle, various diagnostic assessments to understand the influence from structure and paths were deployed. Major contributors from body
Paik, Dr. Suman, Raghuvanshi, Jayeshkumar, Chaudhari, Vishal Vasantrao, V, Radhika
Multispeed EV Transmission – Gear Shift Simulation and Validation2026-26-01571/16/2026
The advancement of electric vehicle (EV) transmission systems is currently a prominent trend aimed at decreasing carbon emissions and providing eco-friendly transportation alternatives. Most of the EV transmissions are single speed, but research conducted on multi speed EV transmissions show higher efficiency, good performance, high speed and torque demand when compared with single speed counterparts. Most of the multi speed EV transmissions that are developed are of non-synchromesh type, which have direct effect on NVH, driving dynamics and durability of drivetrain components. Due to aforementioned factors, gearshift analysis becomes critical for development. Simulation model is developed at early development phase for initial feedback. Using the feedback, drivetrain can be optimized furthermore and test on physical parts can be conducted for final verification. This paper provides a simulation based approach for modelling non-synchromesh two speed EV transmission using Simulation X
Patel, Hiral, Thambala, Prashanth, Sutar, Suresh, Todtermuschke, Karsten
Experimental and Numerical Investigation of Modal Behaviour in Electric Two-Wheeler Frames2026-26-03101/16/2026
This research investigates the dynamic characteristics of an electric two-wheeler chassis through a combined experimental and numerical approach. The study commences with the development of a detailed CAD model, which serves as the basis for Finite Element Analysis (FEA) to predict the chassis's natural frequencies and mode shapes. These numerical simulations offer initial insights into the structural vibration behaviour crucial for ensuring vehicle stability and rider comfort. To validate the FEA predictions, experimental modal analysis is performed on a physical prototype of the electric two-wheeler chassis using impact hammer excitation. Multiple response measurements are acquired via accelerometers, and the resulting data is processed to extract experimental modal parameters. The correlation between the simulated and experimental mode shapes is quantitatively assessed using the Modal Assurance Criterion (MAC). This matrix provides a measure of the consistency and similarity between
Das Sharma, Aritrya, Iyer, Siddharth, Prasad, Sathish, Anandh, Sudheep
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
Reverse Engineering and Digital Twins in Powertrain Design: Enhancing Performance and Sustainability2026-26-00651/16/2026
This study explores the application of reverse engineering (RE) and digital twin (DT) technology in the design and optimization of advanced powertrain systems. Traditional approaches to powertrain development often rely on legacy designs with limited adaptability to modern efficiency and emission standards. In this work, we present a methodology combining 3D scanning, computational modeling, and machine learning to reconstruct, analyze, and enhance internal combustion engines (ICEs) and electric vehicle (EV) drivetrains. By digitizing physical components through RE, we generate high-fidelity DT models that enable virtual testing, performance prediction, and iterative improvement without costly physical prototyping. Key innovations include a novel mesh refinement technique for scanned geometries and a hybrid simulation framework integrating finite element analysis (FEA) and multi-body dynamics (MBD). Our case study demonstrates a 12% increase in thermal efficiency for a retrofitted ICE
Bernikov, Mark Alexandrovich, Kurmaev, Rinat
Remaining Charging Time Accuracy Improvement through Preconditioning Prediction in Electric Vehicles2026-26-06781/16/2026
Remaining Charging Time (RCT) is an essential metric that is displayed to the customer/driver while charging the vehicle. It tells the driver how much time is remaining for the vehicle to be charged to 100% Display State of Charge (SOC) or the target SOC set by the driver. This metric helps drivers plan their time and decide when to unplug their device. For large battery systems like electric vehicles, the understanding of how much longer the battery needs to charge can help optimize energy use and avoid overcharging. The avoidance of un-necessary prolonged charging affects the long-term health of the battery. The RCT is calculated using a basic formula as the ratio of total energy needed to charge the battery to target SOC and the power pushed into the battery for charging. In this RCT formula numerator for a battery to be charged to a specific target SOC is fixed, but the denominator depends on lot of factors during charging and Battery Preconditioning is one of those factors that
Jawed, Shahid, Srikantaiah, Sudarshan
Advancing Sustainable Mobility: Transitioning to Zero-Emission Electric Vehicles with BEVs and FCVs2026-26-01641/16/2026
The transportation and mobility sector is undergoing a profound transformation, with a growing emphasis on sustainability and minimizing the environmental impact of transportation. Among the most significant trends is the transition to electric vehicles (EVs) in the form of Battery and Fuel cell, which produce zero emissions without any harmful gases release in nature. This review highlights several infrastructure-related issues and critical factors that could drive India's transportation sector toward adopting electric vehicles. It also delves into the fundamental understanding of e-mobility, shedding light on the daily challenges and barriers it faces. Furthermore, the study explores research aspects, including the strategies, methods, and tools used for electric vehicles to complete the research on Battery electric vehicles (BEV) and also comparative analysis with Fuel cell vehicles (FCVs). The shift BEVs has been driven by decreasing battery costs and advancements in charging
Kumar, Dr. Vijay Bhooshan
Dynamic Voltage EV System (DVEVS): Achieving Enhanced Electric Vehicle Efficiency and Performance through switchable Series-Parallel Battery Configuration2026-26-02031/16/2026
The study here investigates on the Electric vehicles (EVs), which are often segmented by range or performance, typically offered as distinct entities. Powertrain design also tends to be either settled or performance focused. A significant challenge in the automotive world is the charging time of EVs, a key performance indicator impacting customer convenience. Battery technology is evolving, allowing for potential architectural changes in battery modules over time. Issues such as cell balancing lead to energy wastage in batteries, and thermal management is critical as increased current causes higher I2R power losses and heat generation. Battery weight negatively affects EV efficiency and range. Adapting to new battery cell technologies and architectures can be costly. Addressing these challenges, this paper presents on Dynamic Voltage EV System (DVEVS) as a solution to enhance EV efficiency by dynamically adjusting battery voltage based on driving conditions. Such as Utilizing a smart
Amberkar S, Sunil, Raool, Anuj Rajesh, M G, Shivanag, RAJAPURAM, BHEEMA REDDY
Integrated Side Fairing and Crash Protection System for High Voltage EV Battery Safety2026-26-00281/16/2026
The paper presents a well-engineered and novel structural solution for side impact protection of high-voltage battery packs in electric trucks. While electric vehicles offer benefits like zero emissions and independence from fossil fuels, in turn present challenges in meeting crashworthiness standards and safety regulations. The device addresses the critical need for effective battery protection & styling of battery electric vehicles. The integration of a hybrid corrugated panel system with plastic side fairings is innovative, combining crashworthiness with aerodynamic and aesthetic benefits. The crash protection features two hat-section steel channels at the top and bottom and corrugated steel sheet with alternating ridges is attached to these channels. Corrugated panels are enforced with help of backing strips. This assembly is mounted on shear plates at both ends, secured to the vehicle's frame rail. During a side impact event, the plastic side fairings absorb the initial impact
Badgujar, Prathamesh, Devendra, Awachare, Hansen, Benjamin
Enhancing EV Battery Safety: Progressive Crushing and Energy Absorption Techniques2026-26-01891/16/2026
• The paper presents and provides a crash energy absorption assembly and method for enhancing the safety and structural integrity of battery packs in electric vehicles during collision events adhering to global regulations. • One of our novel analyses is described here, in which the assembly comprises a battery housing designed to mount one or more battery cells, at least one crash member coupled to the side surface of the battery housing, flexural members coupled to the crash member. The flexural members are designed to absorb impact forces, deform, and store potential energy during sudden impacts. This innovative approach ensures that the energy is stored within the flexural elements rather than being transferred to the battery cells, thereby reducing almost cell intrusion for example by 50% under a 100kN which is EC100R requirement. The design effectively delays intrusion, enhances battery safety and minimizes cell-level damage. • Also, the strategic placement of flexural members
Amberkar S, Sunil, Lakshman singh, Meenakumari, Bodaindala, Anil
Impact of density in simulation model for extreme cold ambient conditions2026-26-03881/16/2026
Battery Electric Vehicles (BEVs) necessitate highly efficient thermal management strategies, as cabin heating directly consumes energy from the finite traction battery, potentially reducing driving range significantly. Early-stage design evaluations of warmup performance commonly rely on one-dimensional (1D) simulations due to their computational speed and efficiency. The accuracy and predictive capability of these models are critically dependent on how well they represent blower operation and account for temperature-induced variations in air density. This fidelity is essential because engineers depend on warmup simulations to set HVAC targets that will deliver real‑world comfort and defrost performance within stringent range constraints. Earlier, warmup simulations employed a Constant Mass Flow (CMF) approach, which simplifies computations by assuming a fixed air density at a standard reference temperature. However, this approach contrasts with real-world blower behavior, where
Subramanian, Karthik, Mishra, Abhishek
Analysis of Second-Life electric vehicle batteries value maximizing through repurposing and resale, ways to achieve optimal performance and standardization challenges for testing and certification2026-26-01931/16/2026
As electric vehicle (EV) adoption accelerates globally, a growing volume of lithium-ion batteries are reaching end-of-life in their primary automotive application—despite retaining 60 to 80% of their original capacity. This presents a significant opportunity to extend battery utility through second-life applications such as stationary energy storage, microgrid support, and commercial backup systems. This paper analyzes the strategies for maximizing the residual value of second-life EV batteries through repurposing and resale, while also addressing the challenges associated with performance optimization and standardization of testing and certification procedures. The study evaluates the techno-economic viability of second-life batteries compared to new systems, emphasizing cost savings, environmental impact, and emerging market demand. Techniques for enhancing second-life performance are examined, including advanced state-of-health (SoH) diagnostics, machine learning models for usage
Agarwal, Pranjal, Penta, Amar
Comparative Analysis of Charger Identification Methods in Electric Truck Routing Algorithms2026-26-02061/16/2026
Optimizing Vehicle Routing is a key application for determining the most effective sequence of locations in electric trucks. This optimization not only enhances operational efficiency but also minimizes energy consumption and reduces overall costs. A critical aspect of Optimal Vehicle Routing is identifying charging stations along the route, particularly for electric vehicles with specific range requirements. The availability of these charging stations are crucial for maintaining the continuity of operations and preventing delays. This paper explores multiple methods for charger identification, simulating and comparing their effectiveness. The primary parameter for comparison is the execution time of the algorithm, which directly impacts the feasibility of real-time applications in logistics. The results of this study provide insights into the efficiency of different charger identification methods within the Optimal Vehicle Routing framework. By analysing execution times, the paper
Bhat, Adithya, Prasad P, Shilpa, Kolakar, Rakshita, Myers, Michael, Klein, Fischer, Shrivastava, Himanshu
Parameterizing External Factors Influencing E-motor Consumption2026-26-01751/16/2026
In recent times, a standard drive cycle is an excellent way to measure the electric range of EVs. This process is standardized and repeatable; however, it has the drawback of testing in a controlled environment with a low content of active functions. This can cause a significant variation in predicted range between drive cycles and actual on-road tests. This problem can be addressed via on-road testing and by using customer-based velocity cycles which involve more active functions. While on-road tests provide a more accurate idea of real-world consumption, the repeatability of these tests is low due to excessive randomness. External factors such as ambient temperature, driver behavior, traffic, terrain, altitude, and load conditions affect the vehicle during on-road testing, making repeatability difficult. No two measurements can have the same consumption even if done on the same road with the same vehicle due to these factors. This paper presents a machine learning-based method to
Kelkar, Kshitij, Kanakannavar, Rohit
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
Steel-based Laminates for Lithium-ion Pouch Cell of Electric Vehicles2026-26-01861/16/2026
Aluminium foils have gained traction with EV battery manufacturers for their pouch cell format. Over the years it has evolved as a material of choice, but it is still plagued by issues of stress concentration, swelling due to lower strength and stiffness of base aluminium layer. Preliminary investigation revealed that laminates using steel foil material (thickness <0.1mm) could be a potential candidate for EV pouch cell casing. Thus, steel-based laminate was developed meeting key functional requirements (e.g. barrier performance, insulation resistance, peel strength, electrolyte resistance, formable without cracking at edges, and heat sealing compliant). This innovative patented steel-based laminate was further used to manufacture pouch cell prototypes (maximum capacity 2.5Ah) for key performance tests (e.g. cell cycling, nail penetration and thermal runaway). The study paves the way for a low cost, sustainable and flexible yet strong steel-based laminate packaging material solution
Singh, Pundan Kumar, Raj, Abhishek, Kumar, Ankit, Chatterjee, Sourabh, Verma, Rahul Kumar, Samantaray, Bikash, Gautam, Vikas, Pandey, Ashwani
Overview of Indian Government Policies, Evolution of Indian Automotive Regulations and Striking balance approach for adoption2026-26-02421/16/2026
A well-regulated vehicle design and manufacturing instils driver and passengers' safety and comfort, and lays the foundation for safe and clean mobility. Evolution of Automotive regulation has a long legacy across the globe. India has been closely following the Automotive regulatory progress in the Europe as a cornerstone for technical harmonization, cross learning, gauge benefits and economic implications. Even though India being a developing country, it has not only shown its willingness to harmonize world's best practices but also been making right preparations towards safe and clean mobility. Adoption of BS-VI directly from BS-IV is a testament to India's commitment. While doing so, Government of India (GOI) has always been striking a balanced approach between harmonization of regulations and business implications (ground reality, TCO, business sustenance and growth). Given the above context, the paper explores about: i)Trajectory of evolution of Automotive regulations in India
Patil, Dharmarayagouda
Digital Twin-Enhanced Chassis Dynamometer for EV Drivetrain Testing2026-26-03631/16/2026
Accurate prediction of drivetrain performance and energy efficiency in electric vehicles (EVs) remains a challenge due to the limitations of conventional chassis dynamometer testing, which often overlooks dynamic vehicle-roller interactions, suspension responses, and regenerative braking effects. This paper presents a novel digital twin-enabled testing framework using a compact, two-roller chassis dynamometer integrated with real-time multibody dynamics and electromechanical co-simulation. The physical test bench is coupled with a virtual model of the EV, including suspension geometry, rear-to-front axle load distribution, tire–roller contact mechanics, and motor-inverter dynamics. By enabling bi-directional data exchange between the physical and virtual domains, the system emulates real-world load shifts, torque demand variations, and energy recovery under standardized drive cycles. This integrated approach enhances simulation fidelity, supports certification-compliant testing, and
Kumar, Akhilesh, V, Yashvati
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
India WLTC vs MIDC: Comparative Analytical study on BEV Range & Energy Consumption as per AIS175 draft & AIS039/0402026-26-02441/16/2026
The Main Objective of WLTP (Worldwide Harmonized Light Vehicles Test Procedure) was to standardize the Globally Harmonized Test Procedure for evaluating Emission/ FE/ Range of Light Duty Vehicles. Europe has already adopted the WLTP from 2018. WLTC is a global harmonized test cycle that provides realistic emissions/ Range estimation based on its aggressive driving patterns. In India, currently Continuous Full MIDC (Modified Indian Driving Cycle) used to declare the Range of BEV's. Automotive Industry Standard (AIS) released a AIS 175 draft report for development of WLTP regulation in India (iWLTC : India WLTC). The real road Range of Battery Electric Vehicle (BEV) is observed 25% ~ 35% lower than declared Range of Full MIDC AER (All Electric Range). In Europe, real road range of BEV is 10% ~ 15% lower than declared range of WLTP AER. Analytical study performed on BEV Range/ EC as per AIS 175 draft & AIS 039/040 regulation to compare the impact of iWLTC vs MIDC cycle. The Range & Energy
Shiva Kumar, Mucharla, Tentu, Kavya
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
Boosting the development of a BEV Rear Twist Beam suspension through a pioneering approach: ADAMS Real Time on Driving simulator2026-26-03971/16/2026
Twist beam suspensions are widely utilised in passenger vehicles because of their simplicity and cost-efficiency, yet they provide engineers with a complex challenge as their performance depends entirely upon the structural properties of the beam itself. Traditional methodologies rely on the generation of Modal Neutral Files (MNF) based upon vehicle dynamics requirements and packaging constraints, which is a highly time-consuming process that starts failing to fulfil the demands of a market where development times are being exponentially reduced. Besides this, part of flexible body’s real behaviour might be lost in the process of converting multibody models into parametric ones, which, in turn, presents difficulties in modifying compliant-related items. Thanks to a novel approach followed jointly by Mahindra and IDIADA, quick identification and optimisation of key tuneable items is achieved by employing a hybrid solution that combines full flexible and FE elements in ADAMS Car
Osorio, Alejandro García, Prabhakara Rao, Vageesh, Asthana, Shivam, Rasal, Shraddhesh
Simulation Based Approach to Optimize Electric Vehicle Battery Thermal System2026-26-03761/16/2026
The performance and longevity of Li-ion batteries in electric vehicles are significantly influenced by the cell temperature. Hence, efficient thermal management techniques are essential for battery packs. Simulation based optimization approaches can enhance these techniques during early product development and life cycle. In this work, a method to optimize the battery thermal system comprising of cooling plate and external insulation is described. The first part is to optimize the cell heat extraction by the cooling plate. The heat transfer coefficient of the coolant is a parameter which can indicate the thermal efficiency of a cooling plate. At the same time, it's important to keep the coolant pressure drop within a reasonable limit. A 1D simulation methodology is described to optimize the cooling channel height based on pressure drop and heat transfer coefficient targets. This methodology is based on empirical correlations and multi-objective pareto optimization. The advantage of
U, Reghunath, P S, Shebin
Testing Framework and Safety Evaluation for Vehicle-to-Vehicle (V2V) Charging Systems in Electric Mobility2026-26-01761/16/2026
As the adoption of electric vehicles (EVs) accelerates, innovative charging strategies like Vehicle-to-Vehicle (V2V) charging are gaining attention for their potential to offer emergency energy support and decentralized charging options. Particularly in countries like India, where the charging infrastructure is still maturing, V2V charging can play a vital role in extending operational range and enhancing user convenience in fleet and remote applications. This paper proposes a structured testing framework to evaluate the functionality, safety, communication protocols, and energy transfer efficiency of V2V systems. Emphasis is placed on real-time testing using HIL simulations, thermal behavior under load transfer, fault detection, and protection mechanisms. The framework supports OEMs and integrators in validating reliable, scalable V2V solutions aligned with future EV interoperability standards.
Uthaman, Sreekumar, Mulay, Abhijit B
Circularity and LCA: Enhancing Sustainability in the Indian Electric Vehicle Sector2026-26-02391/16/2026
The global shift to electric vehicles (EVs) is vital for reducing greenhouse gas emissions, but their sustainability hinges on effective battery lifecycle management. This review examines the interplay between Life Cycle Assessment (LCA) and circular economy (CE) principles in EVs, with a focus on both international trends and India-specific challenges. We analyze CE strategies such as extending battery lifespan, second-life applications, and recycling integrated with LCA to evaluate environmental impacts from raw material extraction to disposal. Key areas include battery chemistry, LCA methodologies, policy frameworks, and industrial practices, informed by a synthesis of over 50 peer-reviewed articles, technical papers, and sustainability reports. Challenges include inconsistent LCA baselines, low material recovery in informal recycling, and regulatory gaps, particularly in India. Despite these, innovations like solid-state batteries and advanced recycling techniques offer promise
Haregaonkar, Rushikesh Sambhaji, Kumar, Om, Sankar M, Gopi, Kumar, Rajiv
Modeling and Analysis of Transient Behavior of Surge Protective Devices in Electric Vehicle Charging Systems2026-26-01781/16/2026
This paper introduces a modeling and experimentation methodology for transient analysis of surge protective devices (SPDs) for electric vehicle (EV) application. The suggested SPD topology is to shield the EV power electronics from surge events generated by the grid during charging, with implementation on the grid-EV interface. A new surge protection circuit is designed to suppress transient over voltages and allow real-time monitoring of surge conditions. The SPD is evaluated in SPICE simulator in the time domain, including its nonlinear spark over characteristics as well as resistive, inductive, and capacitive effects. The equivalent circuit is developed and evaluated by simulation under typical surge conditions. The outcomes prove the topology to be effective in clamping voltage, reducing energy transfer to the EV side, and achieving surge event detection. The contribution of this work lies in the establishment of dependable and smart surge protection systems for secure and
CHANCHAL, KUMAR PREM CHANDRA, kulkarni, Swanand, Rajaram Joshi, Sanjay, Patil, Sagar
Assessment and Auralization of Cabin Noise from AVAS Operation in an Electric Vehicle Using a Hybrid BEM–SEA Methodology2026-26-03571/16/2026
In electric and hybrid vehicles, sound package optimization can follow a classical, proven, and structured approach for real-world loads, while also considering new transmission paths that might differ from those in traditional internal combustion engine vehicles. However, AVAS-induced interior noise is sometimes underestimated and therefore not taken into account during the optimization process. Nevertheless, especially at very low speeds, the presence of the AVAS can be perceived as an unwanted noise inside the vehicle, potentially compromising interior comfort. In this study, a hybrid boundary element–statistical energy analysis (BEM – SEA) approach is applied to an SEA dual-motor electric vehicle demonstrator model equipped with a baseline, standard sound package to assess AVAS-induced interior noise. A standard AVAS actuator is modeled, and a BEM model is used to compute the sound pressure levels on the exterior subsystems of the vehicle. These results are then transferred to the
Fiedler, Robert, Calloni, Massimiliano, Martin, Simon
High-Efficiency SiC-Based PSFB DC-DC Converter Using Peak Current Control with Digital Slope Compensation for LV Battery Charging In EV Applications2026-26-04221/16/2026
This paper presents the design, implementation, and evaluation of a high-efficiency Phase-Shifted Full-Bridge (PSFB) DC-DC converter utilizing Silicon Carbide (SiC) MOSFETs for low-voltage (LV) battery charging in electric vehicle (EV) applications. The converter operates with Peak Current Mode Control (PCMC), enhanced by a digitally implemented slope compensation technique to ensure control loop stability, counter subharmonic oscillations and accurate current regulation across a wide load range. The use of SiC devices enables high switching frequencies operation with reduced conduction losses, contributing to improved efficiency and power density of converter. The hardware design utilizes a planar transformer with shim inductance to enable Zero Voltage Switching (ZVS) of the primary switches, thereby reducing switching losses and mitigating transformer flux imbalance. The secondary stage employs diode rectification, while the overall PCB layout is optimized to minimize parasitics and
Kumar, Mayank, Deosarkar, Pankaj, Tayade, Nikhil, Inamdar, Sumer
Optimizing Busbar Design by Investigating Critical Parameters and Their Influence on Electrical and Thermal Behaviors for Reliable Electric Vehicle Battery Packs.2026-26-04741/16/2026
With the rise of EVs, researchers are focusing on optimizing busbar design to meet the demands of high energy density, fast charging, and compact battery packs. The busbar design starts with selecting the cross-sectional area based on current-carrying capacity and material type. The width matches or exceeds the battery cell terminal size, while the length is optimized based on space constraints. The research also highlights the risk of busbars to oxidation and corrosion, which increases resistance and decreases thermal conductivity for which Plating and coating techniques are applied to improve surface hardness, durability, and thermal conductivity while minimizing heat loss. Using simulations and experimental validation, the study examines three key design parameters: weld diameter, electrical resistance, and contact resistance. A detailed analysis investigates how weld diameter influences electrical resistance and temperature rise, as well as the impact of contact resistance between
Nogdhe, Yogesh, Singh, Shobit Kumar, Paul, Jibin, Mishra, Mukesh, MENON, Praveen
Enhancing Cybersecurity Protocols for secure communication between electric vehicles (EV) and the electric vehicle supply equipment (EVSE)2026-26-02021/16/2026
This paper discusses the cybersecurity precautions needed for EV and charger communication protocols to enable safe and reliable communication and charging. The Indian government's initiatives, such as the FAME program, aimed at accelerating electric vehicle (EV) adoption to combat pollution and global warming increased the establishment of DC fast charging infrastructure as well as the implementation of various communication protocols (GB/T, DC001, CHAdeMO, and CCS). The study describes the hazards encountered during EV charging, as well as the vulnerability and risk of hacking by cyber attackers. The paper exhibits the emulation of the charging setup, as well as the mitigation process required during it for a safe communication between EV and EV charger.
Uthaman, Sreekumar, Patil PhD, Urmila
High-Performance Computing for Software-Defined EV Powertrains: Design and Real-Time Validation with NXP S32E278 Domain Controller2026-26-06841/16/2026
Software-Defined Vehicles (SDVs) are redefining the automotive landscape by decoupling hardware from software and enabling dynamic, over-the-air updates, advanced control strategies, and real-time decision-making. To support this transformation, EV powertrain systems require high-performance computing (HPC) platforms capable of real-time control, data processing, and cross-domain communication. This paper introduces a fully SDV-compatible EV powertrain architecture built around the NXP S32E278 domain controller, which integrates a multi-core, lockstep-enabled processor specifically designed for zonal control and automotive functional safety. To meet the bandwidth and latency demands of modern SDV applications, the system replaces conventional CAN-based communication with automotive Ethernet, enabling gigabit data transfer, Time-Sensitive Networking (TSN), and low-latency coordination across software-defined control domains. The S32E executes critical functions such as field-oriented
Pawar, Ganesh, Inamdar, Sumer Deepak, Kumar, Mayank, Deosarkar, Pankaj, Tayade, Nikhil, Kanse, Dattatray, Chopade, Vipul
Totem-Pole PFC and LLC resonant converter based 6.6kW On-Board Charger for LEV Applications2026-26-01601/16/2026
As light electric vehicles (LEVs) gain popularity, the development of efficient and compact on-board chargers (OBCs) has become a critical area of focus in power electronics. Conventional AC-DC topologies often face challenges, including high inrush currents during startup, which can stress components and affect system reliability. Furthermore, DC-DC converters often have a limited soft-switching range under light load conditions, leading to increased switching losses and reduced efficiency. This paper proposes a novel 6.6 kW on-board charger architecture comprising a bridgeless totem-pole power factor correction (PFC) stage and an isolated LLC resonant DC-DC converter. The main contribution lies in the specific focus on enhancing startup behavior and switching performance. In PFC converters, limiting inrush current during startup is crucial, especially with fast-switching wide-bandgap devices like SiC or GaN. Conventional soft-start techniques fall short in of ensuring smooth voltage
Patil, Amruta, Bagade, Aniket
Challenges in Compliance Testing of off-Board Electric Vehicle Chargers: Analysis of Typical Failures and Remedial Measures2026-26-05821/16/2026
As India accelerates the adoption of electric vehicles (EVs) the development of a scalable, reliable, and efficient charging infrastructure becomes critical to ensuring the success of EV adoption. During type testing, the off board AC/DC EV chargers undergo a comprehensive assessment to ensure they meet safety and performance standards required by regulations. The tests examine crucial factors like electrical safety, EMC (electromagnetic compatibility), interoperability, environmental endurance, and mechanical strength. This paper provides information of the mandatory compliance requirements and highlights typical failure modes observed during the validation process of off-board chargers. Emphasis is placed on challenges associated with electrical safety, EMC performance, and interoperability. The objective is to support charger manufacturers to identify potential issues during design and development.
Murumkar, Aditya, Mulay, Abhijit B
Enhanced Integrated Cooling-Protection Plate for Battery pack Underbody Impact Resistance in Electric Vehicles2026-26-01691/16/2026
In the quest for enhancing electric vehicle performance and safety, this paper presents a comprehensive investigation into the design and performance of high-voltage (HV) battery cooling plates featuring dedicated cooling channels, integrated with structural bottom protection members positioned at the bottom. The study aims to address the dual challenges of effective thermal management and enhanced crash protection in electric vehicles. Through a combination of Design iterations, Thermal performance evaluation and Crash simulations, the research evaluates the cooling efficiency and structural resilience of the proposed design. Findings reveal that the integrated cooling plates not only maintain optimal battery temperatures under various operating conditions but also significantly improve the vehicle's crashworthiness. The paper concludes with the results of numerical simulations, rigorously validated against the robust design requirement globally accepted for series components to
DUSAD, SAGAR, Kummuru, Srikanth, Joshi, Amarja
Experimental Frequency-Based Substructuring for Full-Vehicle NVH Characterization in Electric Vehicles2026-26-03091/16/2026
Electric vehicles introduce new NVH challenges due to high-frequency excitations from e-motors and associated electronics. These excitations, often in the kilohertz range, are primarily transmitted as structure-borne noise and require advanced experimental methods for accurate characterization and mitigation. Traditional simulation approaches are insufficient to capture the true dynamic behavior of complex components under operational boundary conditions. This study presents a fully experimental Frequency-Based Substructuring (FBS) methodology applied to a complete electric vehicle. Frequency Response Functions (FRFs) of individual subsystems—such as the e-motor, mounting system, inverter housing, and body connection points—are measured and transformed using Virtual Point Transformation to obtain consistent six-degree-of-freedom representations. These Virtual Point models are assembled into a full-vehicle system to investigate the structure-borne transfer paths to the vehicle interior
Kohlhofer, Daniel, Pingle, Pawan Sharad, de Klerk PhD, Dennis
Multi Speed – Multi Motor Torque Vectoring Control for a Commercial Electric Truck to Enhance Drivability and Performance.2026-26-00581/16/2026
This paper explores the requirement of multi speed – multi motor torque vectoring in a battery electric commercial truck. The area of focus was to compare the vehicle performance and range of a BEV truck with conventional central drive single motor configuration with the same vehicle consisting of a multi speed – multi motor torque vectoring control strategy. Through this exercise, we have analyzed the motor power and torque requirements to meet the vehicle performance along with the required reduction ratios. A Matlab based vehicle model is used to simulate the effect of multi motor operation on the vehicle range. Also simulated the effect of torque vectoring control algorithm on the vehicle performance like steady state cornering, vehicle stability and turning circle diameter.
Pethkar, Shivanand, S, Srivatsa, Ghosh, Sandeep
Self-supervised diagnostics & prognostics framework for predictive maintenance in electric vehicles2026-26-06731/16/2026
Predictive maintenance is essential for enhancing the reliability, safety, and operational efficiency of connected vehicles. However, traditional supervised learning approaches for fault prediction depend heavily on large, labeled datasets of failure events, which are often scarce and expensive to obtain in real-world automotive environments. This paper proposes an original self-supervised anomaly detection framework that predicts emerging failures using only healthy operational data, eliminating the need for explicit failure labels. The approach employs self-supervised pretext tasks, such as masked signal reconstruction and future telemetry prediction, to learn robust representations of normal multi-sensor behavior (e.g., temperature, pressure, current, vibration). An unsupervised anomaly detection model then identifies deviations from these learned patterns. This integrated with data-informed predictive models enable early detection of faults across critical subsystems such as
Kumar, Pankaj, Deole, Kaushik, Hivarkar, Umesh
SEooC-Based Design Framework for Integrated EV Power Conversion Systems under ISO 26262 Compliance2026-26-01921/16/2026
The rapid integration of electric vehicle (EV) power conversion elements—such as traction inverters, onboard chargers, and DC-DC converters—into unified architectures poses new challenges for ensuring functional safety compliance as per ISO 26262. This paper presents a system-level framework that leverages the Safety Element out of Context (SEooC) approach to design and validate reusable safety-critical components independent of vehicle-specific applications. By defining clear assumptions of use and ASIL decomposition strategies, the proposed method facilitates early-stage fault analysis and verification. The framework integrates model-based development with Hardware-in-the-Loop (HIL) testing and formal verification techniques to validate both control logic and hardware behavior under diverse fault injection scenarios. The result is a scalable, standards-compliant methodology that reduces time-to-market and enhances reliability in integrated EV power electronics platforms. The work
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
Digital Twin for Motor & MCU incorporating Deep learning AI-ML algorithms for intelligent prognostics for Electric vehicles2026-26-04791/16/2026
As electric vehicles (EVs) become more advanced, so ensuring the reliability of critical components like the motor and Motor Control Unit (MCU) is essential. This paper presents a digital twin model designed to predict failures in motor and MCU components using machine learning. The approach focuses on detecting early signs of failure through real-world data and advanced analytics. We collected thermal and performance data from field vehicles, capturing both normal (healthy) and abnormal (faulty) operating conditions. Using this dataset, we developed and trained an Auto Encoder-based machine learning model that learns what “normal” looks like and flags deviations as potential issues. One key outcome of this study is the successful early prediction of Insulated Gate Bipolar Transistor (IGBT) degradation, where the system identified subtle behavioral changes long before any visible failure symptoms appeared. This digital twin acts as a virtual replica of the physical components
Joshi, Pawan, Pandey, Suchit, KONDHARE, Manish, UPADHYAY, ABHAY, JaganMoahanarao, Vana, Tank, Prabhu
Integrated Simulation of Electric Vehicle Model Using the ROM Approach2026-26-03691/16/2026
The growing demand for Electric Vehicles (EVs) has highlighted the importance of efficient and accurate simulation tools for design and performance optimization. The architecture of electric vehicles is distinct from that of internal combustion engine vehicles. It consists of on-board charger, DC-DC converter, Lithium ion battery pack, Inverter, electric motor, controllers and transmission. The battery pack supplies electric current to the traction motor, which then converts this electrical energy into mechanical energy, resulting in the rotational motion needed to drive the vehicle. Wide range of Multiphysics is involved in the simulation which involves Power electronics, Electromagnetics, Fluid Mechanics, Thermal engineering. This paper presents an integrated simulation and range prediction methodology for Electric Vehicles (EVs) using the Reduced Order Model (ROM) approach. The methodology includes simulation in both 3D and 1D domain. Computational fluid dynamics (CFD) simulation is
Shandilya, Anand, Kumar, Vivek
Evaluating Thermal Control Strategies to Improve Electric Vehicle Range Using GT Suite2026-26-03621/16/2026
This study focuses on enhancing energy efficiency in electric vehicle (EV) thermal management systems through the development and optimization of control logic. A full vehicle thermal management system (VTMS) was modeled using GT-Suite software, incorporating sub-systems such as the high-voltage battery (HVB), e-powertrain (EPT), and an 8-zone cabin. Thermal models were validated with experimental data to ensure accurate representation of key dynamics, including coolant-to-cell heat transfer, cell-to-ambient heat dissipation, and internal heat generation. Control strategies were devised for Active Grille Shutter (AGS) and radiator fan operations, targeting both cabin cooling and e-powertrain thermal regulation. Energy consumption was optimized by balancing aerodynamic drag, fan power, and compressor power across various driving conditions. A novel series cooling logic was also developed to improve HVB thermal management during mild ambient conditions. Simulation results demonstrate
Chothave, Abhijeet, Kumar, Dipesh, Gummadi, Gopakishore, Khan, Parvej, Thiyagarajan, Rajesh, Pandey, Rishabh, S, Ananth, Anugu, Anil, Mulamalla, Sarveshwar, Gangwar, Adarsh
Structural design and simulation of Composite Metal Hybrid based battery enclosure for an electric vehicle2026-26-03001/16/2026
Addressing the critical need for lightweight and safe energy storage solutions in electric vehicles, this paper presents the design and optimization of a novel Composite Metal Hybrid (CMH) battery pack structure. A computer aided simulation using Abaqus software was done to optimize the weight of battery pack. The structural integrity and crash worthiness of the optimized lightweight design were rigorously evaluated under various load cases like side impact (crush), shock loading and underfloor impact. Manufacturing aspects were discussed to ensure feasibility and integration. Modal analysis and load tests addressed demonstrate the CMH battery pack as a viable and promising lightweight solution for electric vehicle applications.
Shah, Bijay Kumar, Singh, Pundan Kumar, G., Manikandan
High Voltage Safety for Electric Vehicles from Standards Perspectives2026-26-01881/16/2026
With rise of EV adoption globally, electrical system of EV's are continuously moving towards higher voltage for enabling fast charging capabilities and addressing efficiency. High Voltage electrical safety is a crucial part of safety standards for Electric Vehicles. There are several challenges, when any electrical system operating in High voltage region. This is posing risk for user, it means from design stage these systems should be designed in such a way for safeguarding user. These electric safety concepts are already mapped through different safety standards. In this paper, this high voltage safety related test and functional & constructional requirements will be explored through different EV standards and finally a comparatively analysis carried out.
BHATESHVAR, YOGESH KRISHAN, Mulay, Abhijit B, Santosh Jambhale, Medha, Patil, Sanjay
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