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The calibration of Engine Control Units (ECUs) for road vehicles is challenged by stringent legal and environmental regulations, coupled with short development cycles. The growing number of vehicle variants, although sharing similar engines and control algorithms, requires different calibrations. Additionally, modern engines feature increasingly number of adjustment variables, along with complex parallel and nested conditions within the software, demanding a significant amount of measurement data during development. The current state-of-the-art (White Box) model-based ECU calibration proves effective but involves considerable effort for model construction and validation. This is often hindered by limited function documentation, available measurements, and hardware representation capabilities. This article introduces a model-based calibration approach using Neural Networks (Black Box) for two distinct ECU functional structures with minimal software documentation.

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.

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.

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.

Metasurfaces, comprised of sub-wavelength structures, possess remarkable electromagnetic wave manipulation capabilities. Their application as radar absorbers has gained widespread recognition, particularly in modern stealth technology, where their role is to minimize the radar cross-section (RCS) of military assets. Conventional radar absorber design are tedious by their time-consuming, computationally intensive, iterative nature, and demand a high level of expertise. In contrast, the emergence of deep learning-based metasurface design for RCS reduction represents a rapidly evolving field. This approach offers automated and computationally efficient means to generate radar absorber designs. However, the practical implementation of radar-absorbing structures on complex aircraft bodies presents significant challenges.

In a typical Launch Vehicle (LV), dynamic responses due to various flight events are estimated through Coupled Load Analysis (CLA) where the launch vehicle is coupled with a spacecraft. A launch vehicle is subjected to various loads during its flight due to engine thrust depletion / shut-off, thrust oscillation, wind and gust, maneuvering loads. In aerospace industry a standard CLA is performed by generating the mathematical model of launch vehicle and coupling it with reduced mathematical model of satellite and applying the boundary conditions. A CLA is a time consuming process as several flight instances and load cases need to be considered along with generation of structural dynamic model at each time instants. For every new mission, the satellites are mission specific whereas the launch vehicle and the loads remain unchanged. To take advantage of this fact, a new method called “Fast CLA through Reanalysis technique” is proposed in the present paper.

Advanced Air Mobility (AAM) envisions heterogenous airborne entities like crewed and uncrewed passenger and cargo vehicles within, and between urban and rural environment. To achieve this, a paradigm shift to a cooperative operating environment similar to Extensible Traffic Management (xTM) is needed. This requires the blending of Traditional Air Traffic Services (ATS) with the new generation AAM vehicles having their unique flight dynamics and handling characteristics. A hybrid environment needs to be established with enhanced shared situational awareness for all stakeholders, enabling equitable airspace access, minimizing risk, optimized airspace use, and providing flexible and adaptable airspace rules. This paper introduces a novel concept of distributed airspace management which would be apt for all kinds of operational scenarios perceived for AAM. The proposal is centered around the efficiency and safety in air space management being achieved by self-discipline.

Hypersonic flight vehicles have potential applications in strategic defence, space missions, and future civilian high-speed transportation systems. However, structural integration has significant challenges due to extreme aero-thermo-mechanical coupled effects. Scramjet-powered air-breathing hypersonic vehicles experience extreme heat loads induced by combustion, shock waves and viscous heat dissipation. An active cooling thermal protection system for scramjet applications has the highest potential for thermal load management, especially for long-duration flights, considering the weight penalty associated with the heavier passive thermal insulation structures. We consider the case of active cooling of scramjet engine structural walls with endothermic hydrocarbon fuel. We have developed a semi-analytical quasi-2D heat transfer model considering a prismatic core single cooling channel segment as a representative volume element (RVE) to analyse larger-scale problems.

The Aerospace Industry's drive towards zero defects has seen a significant shift to prevent defects and improve product quality during the design phase, instead of waiting until post-production inspection to discover and troubleshoot problems. Trying to ensure zero defects during the post-production inspection phase is too late in the product life cycle because it can lead to substantial costs. Aerospace Engine Supplier Quality (AESQ) introduced the Advanced Product Quality Planning (APQP) process to realize zero defects. In APQP Phase 2, Product and Design Development, a key output is performing a Design Failure Modes and Effects Analysis (DFMEA). Moog has effectively implemented a DFMEA process that adeptly identifies and mitigates design risks. This paper showcases Moog's successful deployment of DFMEA, exemplifying the industry best practices. This paper also presents simplified and innovative interpretations of DFMEA definitions and approaches.

A typical high-pressure hose assembly consists of hose made with synthetic polymer braids and Teflon tube crimped with metallic fittings. These hose assemblies are mainly used for aircraft landing gear application considering its high-pressure sustenance and better flexibility. The proposed study investigates the effect of thermo-mechanical stress generated due to cyclic soaking and flexibility testing at thermostatic subzero (-65°F) and high temperature (+275°F) on performance of high-pressure hose assembly. This effect is further studied through hose tear-down which was envisioned to investigate the hose layer degradation and focused on changes in inner PTFE tube, which ultimately leads to product performance issues. Keywords: braids, tear down analysis, thermo-mechanical, inter-layer abrasion.

Launch vehicles are vulnerable to aeroelastic effects due to their lightweight, flexible, and higher aerodynamic loads. Aeroelasticity research has therefore become an inevitable concern in the development of the Reusable Launch Vehicle (RLV). RLV is the space analogy of an aircraft, a unanimous solution to achieve more affordable access to space. The lightweight control surface of the RLV signifies the relevance of the study on control effectiveness. It is the capability of a control surface such as an elevon or rudder to produce aerodynamic forces and moments to change the launch vehicle's orientation and maneuver it along the intended flight path. The static aeroelastic problem determines the efficiency of control, aircraft trim behaviour, static stability, and maneuvering quality in steady flight conditions. In this study, static aeroelastic analysis was performed on a typical RLV using MSC/NASTRAN inbuilt aerodynamics.

The aim of this paper is to present a numerical analysis of high-speed flows over a missile geometry. The N1G missile has been selected for our study, which is subjected to a high-speed flow at Mach 4 over a range of Angle of attack (AoA) from 0° to 6°. The analysis has been conducted for a 3-dimensional missile model using ANSYS environment. The study contemplates to provide new insights into the missile aerodynamic performance which includes the coefficient of lift (CL) , coefficient of drag (CD) and coefficient of moment (CM) using computational fluid dynamics (CFD). As there is a lack of availability of data for missile geometry, such as free stream conditions and/or the experimental data for a given Mach number, this paper intends to provide a detailed analysis at Mach 4. As the technology is advancing, there is a need for high-speed weapons (missiles) with a good aerodynamic performance, which intern will benefit in reduction of fuel consumption.

Design and Manufacturing of an Inclinometer sensing element for launch vehicle applications Tony M Shaju, Nirmal Krishna, G Nagamalleswara Rao, Pradeep K Scientist/Engineer, ISRO Inertial Systems Unit, Vattiyoorkavu, Trivandrum, India - 695013 Indian Space Research Organisation (ISRO) uses indigenously developed launch vehicles like PSLV, GSLV, LVM3 and SSLV for placing remote sensing and communication satellites along with spacecrafts for other important scientific applications into earth bound orbits. Navigation systems present in the launch vehicle play a pivotal role in achieving the intended orbits for these spacecrafts. During the assembly of these navigation packages on the launch vehicle, it is required to measure the initial tilt of the navigation sensors for any misalignment corrections, which is given as input to the navigation software. A high precision inclinometer is required to measure these tilts with a resolution of 1 arc-second.

Abstract : In any human space flight program, safety of the crew is of utmost priority. In case of exigency during atmospheric flight, the crew is safely and quickly rescued from the launch vehicle using Crew escape system. Crew escape system is a crucial part of the Human Space flight vehicle which carries the crew module away from the ascending launch vehicle by firing its rocket motors (Pitch Motor (PM), Low altitude Escape Motor (LEM) and High altitude Escape Motor (HEM)). The structural loads experienced by the crew escape system during the mission abort are severe as the propulsive forces, aerodynamic forces and inertial forces on the vehicle are significantly high. Since the mission abort can occur at anytime during the ascent phase of the launch vehicle, trajectory profiles are generated for abort at every one second interval of ascent flight time considering several combinations of dispersions on various propulsive parameters of abort motors and aero parameters.

A structural load estimating methodology was developed for the RLV-TD HEX-01 mission, the maiden winged body technology demonstrator vehicle of ISRO. The technique characterizes atmospheric regime of flight from vehicle loads perspective and ensures adequate structural margin considering atmospheric variations and system level perturbations. Primarily the method evaluates time history of station loads considering effects of vehicle dynamics and structural flexibility. Station loads in the primary structure are determined by superposition of quasi-static aerodynamic loads, dynamic inertia loads, control surface loads and propulsion system loads based on actual physics of the system. Spatial aerodynamic distributions at various Mach numbers along the trajectory have been used in the study. Argumentation in aerodynamic loads due to vehicle flexibility is assessed through the use of spatial aerodynamic distributions.

Dimensional optimization has always been a time consuming process, especially for aerodynamic bodies, requiring much tuning of dimensions and testing for each sample. Aerodynamic auxiliaries, especially wings, are design dependent on the primary model attached, as they influence the amount of lift or reduction in drag which is beneficial to the model. In this study CFD analysis is performed to obtain pressure counter of wings. For a wing, the angle of attack is essential in creating proper splits to incoming winds, even under high velocities with larger distances from the separation point. In the case of a group of wings, each wing is then mentioned as a wing element, and each wing is strategically positioned behind the previous wing in terms of its vertical height and its self-angle of attack to create maximum lift. At the same time, its drag remains variable to its shape ultimately maximizing the C L /C D ratio.

Effective contrail management while ensuring operational and economic efficiencies for flight services is essential for providing services with minimal adverse environmental impact. The paper explores various aspects of contrail management applicable to different platforms such as Unmanned vehicles, Commercial airliners and Business & regional jets. The aspects unique to each platform such as flight levels of operation, fuel types, flight endurance and radius of operation have been analyzed. Expanse of 5G network is resulting in increased flight activity at flight levels not envisaged hitherto. The paper also dwells on the ramifications of the increased proliferation of different platforms at newer flight levels from the perspective of contrail management.

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