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Technical Paper

Aerodynamics' Influence on Performance in Human-Powered Vehicles for Sustainable Transportation

2024-06-12
2024-37-0028
The issue of greenhouse gas (GHG) emissions from the transportation sector is widely acknowledged. Recent years have witnessed a push towards the electrification of cars, with many considering it the optimal solution to address this problem. However, the substantial battery packs utilized in electric vehicles contribute to a considerable embedded ecological footprint. Research has highlighted that, depending on the vehicle's size, tens or even hundreds of thousands of kilometers are required to offset this environmental burden. Human-powered vehicles (HPVs), thanks to their smaller size, are inherently much cleaner means of transportation, yet their limited speed impedes widespread adoption for mid-range and long-range trips, favoring cars, especially in rural areas. This paper addresses the challenge of HPV speed, limited by their low input power and non-optimal distribution of the resistive forces.
Technical Paper

Advanced squeak and rattle noise prediction for vehicle interior development – numerical simulation and experimental validation

2024-06-12
2024-01-2925
Squeak and rattle (SAR) noise audible inside a passenger car causes the product quality perceived by the customer to deteriorate. The consequences are high warranty costs and a loss in brand reputation for the vehicle manufacturer in the long run. Therefore, SAR noise must be prevented. This research shows the application and experimental validation of a novel method to predict SAR noise on an actual vehicle interior component. The novel method is based on non-linear theories in the frequency domain. It uses the harmonic balance method in combination with the alternating frequency/time domain method to solve the governing dynamic equations. The simulation approach is part of a process for SAR noise prediction in vehicle interior development presented herein. In the first step, a state-of-the-art linear frequency-domain simulation estimates an empirical risk index for SAR noise emission. Critical spots prone to SAR noise generation are located and ranked.
Technical Paper

Towards the Design-driven Carbon Footprint reduction of Composite Aerospace and Automotive components: An overview

2024-06-12
2024-37-0032
Composite materials, pioneered by aerospace engineering due to their lightweight, strength, and durability properties, are increasingly adopted in the high-performance automotive sector. Besides the acknowledged composite components’ performance, enabled lightweighting is becoming even more crucial for energy efficiency, and therefore emissions along vehicle use phase from a decarbonization perspective. However, their use entails energy-intensive and polluting processes involved in raw material production, in manufacturing processes, and, in particular, in end-of-life disposal. Carbon footprint is the established indicator to assess the environmental impact of climate-changing factors on products or services. Research on different carbon footprint sources reduction is increasing, and even the European Composites Industry Association is demanding the development of specific Design for Sustainability approaches.
Technical Paper

Analysis of the Mechanism by Which Spline Pitch Errors Affect Powertrain Vibration

2024-06-12
2024-01-2910
As environmental concerns have taken the spotlight, electrified powertrains are rapidly being integrated into vehicles across various brands, boosting their market share. With the increasing adoption of electric vehicles, market demands are growing, and competition is intensifying. This trend has led to stricter standards for noise and vibration as well. To meet these requirements, it is necessary to not only address the inherent noise and vibration sources in electric powertrains, primarily from motors and gearboxes, but also to analyze the impact of the spline power transmission structure on system vibration and noise. Especially crucial is the consideration of manufacturing discrepancies, such as pitch errors in splines, which various studies have highlighted as contributors to noise and vibration in electric powertrains. This paper focuses on comparing and analyzing the influence of spline pitch errors on two layout configurations of motor and gearbox spline coupling structures.
Technical Paper

Metrics based design of electromechanical coupled reduced order model of an electric powertrain for NVH assessment

2024-06-12
2024-01-2913
Electric vehicles offer cleaner transportation with lower emissions, thus their increased popularity. Although, electric powertrains contribute to quieter vehicles, the shift from internal combustion engines to electric powertrains presents new Noise, Vibration, and Harshness challenges. Unlike traditional engines, electric powertrains produce distinctive tonal noise, notably from motor whistles and gear whine. These tonal components have frequency content, sometimes above 10 kHz. Furthermore, the housing of the powertrain is the interface between the excitation from the driveline via the bearings and the radiated noise (NVH). Acoustic features of the radiated noise can be predicted by utilising the transmitted forces from the bearings. Due to tonal components at higher frequencies and dense modal content, full flexible multibody dynamics simulations are computationally expensive.
Technical Paper

Velocity Estimation of a Descending Spacecraft in Atmosphereless Environment using Deep Learning

2024-06-01
2024-26-0484
Landing of spacecraft on Lunar or Martian surfaces is the last and critical step in inter planetary space missions. The atmosphere on earth is thick enough to slow down the craft but Moon or Mars does not provide a similar atmosphere. Moreover, other factors such as lunar dust, availability of precise onboard navigational aids etc would impact decision making. Soft landing meaning controlling the velocity of the craft from over 6000km/h to zero. If the craft’s velocity is not controlled, it might crash. Various onboard sensors and onboard computing power play a critical role in estimating and hence controlling the velocity, in the absence of GPS-like navigational aids. In this paper, an attempt is made using visual onboard sensor to estimate the velocity of the object. The precise estimation of an object's velocity is a vital component in the trajectory planning of space vehicles, particularly those designed for descent onto lunar or Martian terrains, such as orbiters or landers.
Technical Paper

Study of Crew Seat Impact Attenuation System for Indian Manned Space Mission

2024-06-01
2024-26-0469
The descent phase of GAGANYAAN (Indian Manned Space Mission) culminates with a crew module impacting at a predetermined site in Indian waters. During water impact, huge amount of loads are experienced by the astronauts. This demands an impact attenuation system which can attenuate the impact loads and reduce the acceleration experienced by astronauts to safe levels. Current state of the art impact attenuation systems use honeycomb core, which is passive, expendable, can only be used once (at touchdown impact) during the entire mission and does not account off-nominal impact loads. Active and reusable attenuation systems for crew module is still an unexplored territory. Three configurations of impact attenuators were selected for this study for the current GAGANYAAN crew module configuration, namely, hydraulic damper, hydro-pneumatic damper and airbag systems.
Technical Paper

CFD Methodology Development to Predict Lubrication Effectiveness in Electromechanical Actuators

2024-06-01
2024-26-0466
Electromechanical actuators (EMAs) play a crucial role in aircraft electrification, offering advantages in terms of aircraft-level weight, rigging and reliability compared to hydraulic actuators. To prevent backdriving, skewed roller braking devices called "no-backs" are employed to provide braking torque. These technology components are continuing to be improved with analysis driven design innovations eg. U.S. Pat. No. 8,393,568. The no-back mechanism has the rollers skewed around their own transverse axis that allow for a combination of rolling and sliding against the stator surfaces. This friction provides the necessary braking torque that prevents the backdriving. By controlling the friction radius and analyzing the Hertzian contact stresses, the brake can be sized for the desired duty cycle. No-backs can be configured to provide braking torque for both tensile and compressive backdriving loads.
Technical Paper

Aerospace Vehicle Motion Simulation with Real-Time Telemetry Data

2024-06-01
2024-26-0483
In any aerospace mission, after the vehicle has taken off, the visual is lost and the information about its current state is only through the sensor data telemetered in real-time. Very often, this data is difficult to perceive and analyze. In such cases, a 3D, near to real representation of the data can immensely improve the understanding of the current state of mission and can aid in real-time decision making if possible. Generally, any aerospace vehicle carries onboard an inertial system along with other sensors, which measures the position and attitude of the vehicle. This data is communicated to ground station. The received telemetry data is encoded as bytes and sent as packets through the network using the Universal Datagram Protocol (UDP).  The transmitted data is often available in a very low frequency, which is not desirable for a smooth display. It is therefore necessary to interpolate the data between intervals based on the time elapsed since last rendered frame.
Technical Paper

Fault Detection in Machine Bearings using Deep Learning - LSTM

2024-06-01
2024-26-0473
In today's industrial sphere, machines are the key supporting various sectors and their operations. Over time, due to extensive usage, these machines undergo wear and tear, introducing subtle yet consequential faults that may go unnoticed. Given the pervasive dependence on machinery, the early and precise detection of these faults becomes a critical necessity. Detecting faults at an early stage not only prevents expensive downtimes but also significantly improves operational efficiency and safety standards. This research focuses on addressing this crucial need by proposing an effective system for condition monitoring and fault detection, leveraging the capabilities of advanced deep learning techniques. The study delves into the application of five diverse deep learning models—LSTM, Deep LSTM, Bi LSTM, GRU, and 1DCNN—in the context of fault detection in bearings using accelerometer data. Accelerometer data is instrumental in capturing vital vibrations within the machinery.
Technical Paper

INLS 3U Unipod Nano Satellite (CubeSat) Dispenser System for 3U Class Satellites

2024-06-01
2024-26-0458
With the present state of the art technology, size and mass of the satellites have come down. This necessitated the need for a low shock separation system that does not have mass attached to the separated satellite. Development of Nano satellites with mass of the order of 1 to 24 kg has become popular among scientific/ academic institutions for carrying out scientific experiments. INLS 3U Unipod System (Nano satellite dispenser system) is a satellite dispensing system designed by ISRO for accommodating four 3U class Nano satellites in a single structure where each satellite is deployed independently by separate actuation commands. INLS stands for ISRO's Nano satellite Launch System. The Unipod separation system successfully flown first time in PSLV C56 Mission for the deployment of three foreign satellites namely Nulion, Galassia-2 and SCOOB II.
Technical Paper

Synergized Mixed-Signal System-on-Chip (SoC) Design and Development using System-level Modeling and Simulation

2024-06-01
2024-26-0463
In recent decades, research based innovative system-on-chip (SoC) design has been a very important issue, due to the emerging trends and application challenges. The SoCs encompass digital, analog and mixed-signal hardware and software components and even sensors and actuators. Modelling and simulation constitute a powerful method for designing and evaluating complex systems and processes for many analysts and project managers as they engage in state of-the-art research and development. Modelling and simulations not only help them with the algorithm or concept realization and design feasibility, but it also allows experimentation, optimization, interpretation of results and validation of model.
Technical Paper

Deep Learning-Based Digital Twining Models for Inter System Behavior and Health Assessment of Combat Aircraft Systems

2024-06-01
2024-26-0478
Modern combat aircraft demands efficient maintenance strategies to ensure operational readiness while minimizing downtime and costs. Innovative approaches using Digital Twining models are being explored to capture inter system behaviours and assessing health of systems which will help maintenance aspects. This approach employs advanced deep learning protocols to analyze the intricate interactions among various systems using the data collected from various systems. The research involves extensive data collection from sensors within combat aircraft, followed by data preprocessing and feature selection, using domain knowledge and correlation analysis. Neural networks are designed for individual systems, and hyper parameter tuning is performed to optimize their performance. By combining the outputs of these during the model integration phase, an overall health assessment of the aircraft will be generated.
Technical Paper

Design of Mini-Hexapod Rover System for Future Lunar Exploration

2024-06-01
2024-26-0456
Lunar tubes, natural underground structures on the Moon formed by ancient volcanic activity, offer natural protection from extreme temperatures, radiation, and micro-meteorite impacts, making them prime candidates for future lunar bases. However, the exploration of lunar tubes requires a high degree of mobility. Given the Moon's gravity, which is approximately six times weaker than Earth's, efficient navigation across rugged terrains within these lava tubes is achievable through jumping. In this work, we present the design of subsystems for a miniature hexapod rover weighing 1 kg, which can walk, jump, and stow. The walking system consists of two subsystems: one for in-plane walking, employing four single-degree-of-freedom (DOF) legs utilizing the KLANN walking mechanism, and another for directional adjustments before jumping. The latter employs a novel three-DOF mechanism employing a cable pulley mechanism to optimize space utilization.
Technical Paper

Development of Deployment Mechanism for RAMBHA-LP Payload Onboard Chandrayaan-3 Lander

2024-06-01
2024-26-0455
RAMBHA-LP (Radio Anatomy of Moon Bound Hypersensitive Ionosphere and Atmosphere - Langmuir Probe) is one of the key scientific payloads onboard the Indian Space Research Organization’s (ISRO) Chandrayaan-3 mission. Its objectives were to estimate the plasma density and its variations on the near lunar surface. The probe was initially kept in a stowed condition attached to the lander. A mechanism was designed and realized to meet the functional requirement of deploying the probe at a distance of 1 meter, equivalent to the Debye length of the probe in the moon’s plasma environment. The probe deployment mechanism consists of the Titanium alloy spherical probe with a Titanium Nitride coating on its surface to achieve a constant work function, a long carbon-fiber-reinforced polymer boom, a double torsion spring, a dust-protection box, and a shape-memory alloy-based Frangibolt actuator for low-shock separation. The entire mechanism weighed less than 1.5 kilograms.
Technical Paper

Comparative Analysis of Axial Flux and Radial Flux Motors for UAV Propulsion: Design and Suitability Assessment

2024-06-01
2024-26-0467
In the architecture of an Unmanned Aerial Vehicle (UAV), a crucial component responsible for the propulsion system is the electric motor. Over the years, different types of electric motors, including Brushless Direct Current (BLDC), have supported the UAV’s propulsion system in diverse configurations. However, in the context of flux flow, the Radial Flux Permanent Magnet Motor (RFPMM) has been given more priority than the Axial Flux Permanent Magnet Motor (AFPMM) due to its sustainability in design and construction. Nevertheless, the AFPMM boasts higher speed, power density, lower weight, and greater efficiency than the RFPMM, because of its shorter flux path and the absence of end-turn winding. Therefore, this paper focuses on conducting a suitability analysis of an AFPMM as a shaft-connected propeller-mounted motor, with the intention of replacing the RFPMM in UAV applications.
Technical Paper

Automatic Maneuver Detection in Flight Data using Wavelet Transform and Deep Learning Algorithms

2024-06-01
2024-26-0462
The evaluation of aircraft characteristics through flight test maneuvers is fundamental to aviation safety and understanding flight attributes. This research project proposes a comprehensive methodology to detect and analyze aircraft maneuvers using full flight data, combining signal processing and machine learning techniques. Leveraging the Wavelet Transform, we unveil intricate temporal details within flight data, uncovering critical time-frequency insights essential for aviation safety. The integration of Long Short-Term Memory (LSTM) models enhances our ability to capture temporal dependencies, surpassing the capabilities of machine learning in isolation. These extracted maneuvers not only aid in safety but also find practical applications in system identification, air-data calibration, and performance analysis, significantly reducing pre-processing time for analysts.
Technical Paper

Assessing the Structural Feasibility and Recyclability of Flax/PLA Bio-Composites for Enhanced Sustainability

2024-06-01
2024-26-0407
Bio-composites have gained significant attention within the aerospace industry due to their potential as a sustainable solution that addresses the demand for lightweight materials with reduced environmental impact. These materials blend natural fibers sourced from renewable origins, such as plant-based fibers, with polymer matrices to fabricate composite materials that exhibit desirable mechanical properties and environmental friendliness. The aerospace sector's growing interest in bio-composites originates from those composites’ capacity to mitigate the industry's carbon footprint and decrease dependence on finite resources. This study aims to investigate the suitability of utilizing plant derived flax fabric/PLA (polylactic acid) matrix-based bio-composites in aerospace applications, as well as the recyclability potential of these composites in the circular manufacturing economy.
Technical Paper

Selective Laser Melting Based Additive Manufacturing Process Diagnostics using In-line Monitoring Technique and Laser-Material Interaction Model

2024-06-01
2024-26-0420
Selective Laser Melting (SLM) has gained widespread usage in aviation, aerospace, and die manufacturing due to its exceptional capacity for producing intricate metal components of highly complex geometries. Nevertheless, the instability inherent in the SLM process frequently results in irregularities in the quality of the fabricated components. As a result, this hinders the continuous progress and wider acceptance of SLM technology. Addressing these challenges, in-process quality control strategies during SLM operations have emerged as effective remedies for mitigating the quality inconsistencies found in the final components. This study focuses on utilizing optical emission spectroscopy and IR thermography to continuously monitor and analyze the SLM process within the powder bed, with the aim of strengthening process control and minimizing defects.
Technical Paper

Elastomeric Swaging Finite Element Analysis Methodology to Evaluate Structural Integrity of Internal Swaged Joints

2024-06-01
2024-26-0428
In applications demanding high performance under extreme conditions of pressure and temperature, a range of Mechanically Attached Fittings (MAFs) is offered by various Multinational Corporations (MNCs). These engineered fittings have been innovatively designed to meet the rigorous requirements of the aerospace industry, offering a cost-effective and lightweight alternative to traditional methods such as brazing, welding, or other mechanically attached tube joints. One prominent method employed for attaching these fittings to tubing is through Internal Swaging, a mechanical technique. This process involves the outward formation of rigid tubing into grooves within the fitting. One of the methods with which this intricate operation is achieved is by using a drawbolt - expander assembly within an elastomeric swaging machine.
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