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Technical Paper

Validation of an Organic Rankine Cycle Simulation Tool against European Stationary Cycle Test Modes

The development of experimental ORC systems is an extremely complex, time consuming and costly task. Running a range of experiments on a number of different component configurations may be prohibitively expensive and subject to equipment issues and failures. Yet ORC systems offer significant potential for automotive manufacturers to improve vehicle efficiency, reduce fuel consumption and vehicle emissions; the technology is particularly relevant for those involved in the design and/or manufacture of heavy duty trucks. This paper is focused on the validation of a computational ORC system simulation tool against a number of SAE published test results based on the European Stationary Cycle. Such studies on industry standard systems are essential in order to help promote confidence in a virtual prototype approach.
Technical Paper

The Opportunity - Improving Aerospace Configuration Management

Meeting aerospace configuration control mandates involves a host of issues such as data access control, configuration context and release management, just to name a few factors. Currently, many companies rely on the existing product lifecycle management (PLM) environment to identify and sort out issues during data release. This has proven to be inadequate. In this paper, it is postulated that new design tools employing automation can save a great deal of time when meeting these mandates and eliminate errors as well. The tools are based on the model-based development (MBD) process, which puts much more emphasis on the actual data instead of simply drawings. This paper explores how leading aerospace original equipment manufacturers (OEMs) are adopting new capabilities for the designers during the development process in an effort to mitigate errors related to data inconsistencies.
Technical Paper

Systems Engineering Approach to Electrical Wire Interconnection System (EWIS) Development

The development of the Electrical Wire Interconnection System, or EWIS, for today's advanced aircraft is one of the most complicated engineering activities around. In addition to having to respond to very high rates of change during development, the aircraft are continually evolving in electronic and electrical content through their entire lifecycle. Relatively new mandates, such as the CFR Part 25 Subpart H EWIS, have put additional demands on aircraft OEMs and their key suppliers, forcing companies to reassess their design practices and methodologies. This paper investigates how a systems engineering approach to the development of the electrical wiring systems can enable and facilitate a more efficient EWIS development and maintenance methodology.
Technical Paper

Design Automation and its Challenges in AUTOSAR-Based Vehicle E/E Systems

AUTOSAR 4.x is being deployed by many of the world's top automotive OEMs. It has also seen increased adoption in regions outside of Europe. OEMs exert significant effort in the design, configuration, integration, and final build of AUTOSAR-based systems. This presentation gives an overview on the main advantages and critical gaps of adopting AUTOSAR to E/E design automation, including the digital interaction between Tier 1 suppliers and OEMs. This paper also discusses how the Electronics Architecture and Software Technology Architecture Description Language, or EAST-ADL, complements some of the weaknesses found in the current AUTOSAR release.
Technical Paper

Every Engineer can be a Quality Engineer

Correct-by-construction design processes can be dramatically enhanced using simulation techniques, especially early in the design process. But simulation is too often the preserve of specialist staff, who may work disconnected from day-to-day design updates. This paper highlights simulation and analysis tools that can be used by every electrical engineer, addressing topics ranging from functional verification to component sizing to failure modes and effects analysis. Furthermore, valuable results can be obtained with the simplest of models; and the models themselves can mature as the organization's use of simulation matures.
Technical Paper

Enhancing Automotive Wire Harness Manufacturing Through Digital Continuity

Manufacturing companies are benefiting from technology in most key areas of the flow from design through manufacture. This applies to the wire harness industry which is a key element of the modern automotive industry. Wire harness manufacturing engineering, however, is a critical path function that is under severe pressure and yet has been under-served by technology. In some respects it has become the weak link in the chain. Recent innovations in commercial off-the-shelf (COTS) technology are set to change this situation. Software applications are now available to deliver transformational manufacturing engineering automation as well as being able to integrate with technology in other areas of the process. This will enable a digitally continuous data flow that can remove excessive cost, time, and pressure - while helping manufacturers meet the increasing demands of the industry.
Technical Paper

Mixed Voltages and Aluminum Conductors: Assessing New Electrical Technologies

The architecture of vehicle electrical systems is changing rapidly. Electric and hybrid vehicles are driving mixed voltage systems, and cost pressures are making conductor materials like aluminum an increasingly viable competitor to copper. The challenge of assessing the impact of these technologies on vehicle safety and of understanding cost/weight trade-offs is a critical design activity. This session will discuss and demonstrate tradeoff studies at the vehicle level, show how to automatically generate an electrical Failure Mode Effects and Analysis (FMEA) report, and optimize wire sizes for both copper and aluminum at the platform level.
Journal Article

Platform Engineering Approach to the Electrical Systems Architecture Development Process

Until recently, the electrical systems architecture that connects hardware devices and their accompanying control components were not separately a part of formal certification mandates. This changed with the advent of the FAR Part25 Subpart H EWISi (Electrical Wire Interconnection Systems) mandate. Interestingly this mandate, like certain others, does not impose specific solution. Instead it provides a structure that outlines what must be accomplished from a variety of perspectives - safety, signal separation, part selection, etc. The designer has some flexibility on which decisions to make, but those decisions can have significant cross-domain impact, which in turn, have influence on the intended product performance. What is needed is a method to design, verify and build virtually the entire electrical architecture with confidence that the best architecture is defined within the program constraints.