In the evolving landscape of automotive engineering, commercial vehicles present a uniquely complex challenge. Unlike passenger cars, where usage patterns are relatively predictable, commercial vehicles serve a wide variety of applications—ranging from school buses to heavy-duty off-road tippers operating under unpredictable and often extreme conditions. This variability makes rigorous testing and validation not only more important but also far more complex, Dr N Saravanan, President & CTO, Ashok Leyland, has said.
Delivering the keynote on ‘Future Technologies’ at the SAE India Automotive Leadership Summit organised alongside Automotive Testing Expo 2025, he said customers purchasing commercial vehicles aren't swayed primarily by aesthetics—they are focused on purpose, reliability, and total cost of ownership (TCO). For OEMs, this means designing and validating vehicles to withstand diverse operating conditions, even when it's difficult to clearly define them. As India’s economy grows and freight movement increases, the demand for reliable commercial vehicles will continue to rise. At the same time, environmental concerns and safety regulations are intensifying, placing added pressure on manufacturers to deliver cleaner, safer, and more intelligent products, Saravanan pointed out.
Validation
In this context, validation plays a crucial role, he said. With increasing vehicle population, environmental impact is inevitable—even with stricter norms like BS-6 and upcoming advancements. Additionally, rising accident rates further amplify the urgency for enhanced safety features. Advanced Driver Assistance System (ADAS) is one such solution, gaining traction both from regulatory bodies and OEMs. However, implementing ADAS in India presents unique challenges. From erratic road conditions to unpredictable real-world scenarios, systems that work well in Europe often falter in Indian environments, he explained.
A New Era Unfolds
Another transformative shift is the evolution from a standalone vehicle approach to an ecosystem-based mindset. Fleet operators demand connectivity between vehicles for optimised logistics, turning software-defined vehicles (SDVs) into a critical requirement. Green energy is also reshaping the sector, with commercial vehicles embracing a broader energy mix—from diesel and CNG to hydrogen ICE and fuel cells. All of this demands a reimagining of testing and validation, he pointed out.
“OEMs must address increasing product complexity, tighter regulatory requirements, and shortened development cycles. Customers today want more features, more variants—and they want them sooner. That pushes OEMs to move faster without compromising on reliability,” Saravanan noted.
To meet this challenge, a shift towards virtual validation and intelligent testing is underway. While physical testing remains essential, “the goal is to bring real-world scenarios into labs and ultimately into simulation environments. This ‘left-shift’ in the V-cycle of product development emphasises early-stage simulations and digital twins, reducing the need for late-stage physical prototypes and accelerating time-to-market,” he said.
Yet, simulation comes with its own set of limitations. Current correlation levels between digital and physical testing—such as pedestrian protection or crash tests—hover around 90%, leaving room for improvement. “Bridging that final 10% is crucial, and intelligent testing will play a key role,” he said.
Automation, data analytics, and AI-driven models are helping engineers extract insights from vast datasets, pinpointing failure points and optimising test cycles. Data abundance is not the issue—it's the underutilisation of insights that hampers progress. Large Language Models (LLMs) and GenAI hold potential to revolutionise validation, turning raw data into actionable intelligence. They can assist in test case generation, automated reporting, requirements traceability, and knowledge management—helping teams identify edge conditions without excessive physical cycles, he observed.
Unified Action
“Commercial vehicle testing is now as much about collaboration as it is about technology. Validation is no longer the domain of OEMs alone; it requires coordinated effort across test agencies, suppliers, and digital solution providers. As complexity rises, partnerships and shared platforms will define how successfully the industry adapts,” he said.
The journey ahead demands not just robust engineering, but smarter, faster and more holistic approaches. In a market where reliability, regulation, and real-world conditions collide, the future of commercial vehicle validation will depend on intelligent testing ecosystems built on data, collaboration, and constant adaptation, he added.
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