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Layered materials are one of the most commonly used acoustical treatments in the automotive industry, and have gained increased attention, especially owing to the popularity of electric vehicles. Here, a method to model and couple layered systems with various layer types (i.e., poro-elastic layers, solid-elastic layers, stiff panels, and fluid layers) is derived that makes it possible to stably predict their acoustical properties. In contrast with most existing methods, in which an equation system is constructed for the whole structure, the present method involves only the topmost layer and its boundary conditions at two interfaces at a time, which are further simplified into an equivalent interface. As a result, for a multi-layered system, the proposed method splits a complicated system into several smaller systems and so becomes computationally less expensive.

In the last years, lithium-ion batteries (LIBs) have become the most important energy storage system for consumer electronics, electric vehicles, and smart grids. A LIB is composed of several unit cells. Therefore, one of the most important factors that determine the performance of a LIB are the characteristics of the unit cell. The design of LIB cells is a challenging problem since it involves the evaluation of expensive black-box functions. These functions lack a closed-form expression and require long-running time simulations or expensive physical experiments for their evaluation. Recently, Bayesian optimization has emerged as a powerful gradient-free optimization methodology to solve optimization problems that involve the evaluation of expensive black-box functions. Bayesian optimization has two main components: a probabilistic surrogate model of the black-box function and an acquisition function that guides the optimization.

Tire/road noise has become a significant issue in the automotive industry, especially for electric vehicles. Among the various tire/road noise sources, the air-cavity mode can amplify the forces transmitted from the tire to the suspension system causing noticeable cabin noise near 200 Hz. Furthermore, when the tire is deformed by loading, the fundamental air-cavity mode separates into two acoustic modes, a fore-aft mode and vertical mode due to the break in geometrical symmetry. This is important because the two components of the split mode can increase force levels at the hub by interacting with neighboring structural modes, thus resulting in increased interior noise levels. In this research, finite element simulations of five commercial tires at rated load were performed with a view to identifying the frequency split and its interaction with structural resonances. These results have been compared with previously obtained empirical results.

This paper presents experimental results that validate eco-driving and eco-heating strategies developed for connected and automated vehicles (CAVs). By exploiting vehicle-to-infrastructure (V2I) communications, traffic signal timing, and queue length estimations, optimized and smoothed speed profiles for the ego-vehicle are generated to reduce energy consumption. Next, the planned eco-trajectories are incorporated into a real-time predictive optimization framework that coordinates the cabin thermal load (in cold weather) with the speed preview, i.e., eco-heating. To enable eco-heating, the engine coolant (as the only heat source for cabin heating) and the cabin air are leveraged as two thermal energy storages. Our eco-heating strategy stores thermal energy in the engine coolant and cabin air while the vehicle is driving at high speeds, and releases the stored energy slowly during the vehicle stops for cabin heating without forcing the engine to idle to provide the heating source.

Electrical connectors and terminals are widely used in the automotive industry. It is desirable to mate the electrical connections using materials or coatings with low friction force to improve the ergonomics of the assembly process while maintaining good electrical conduction over the lifetime of the vehicle. We have previously shown that plasma-enhanced chemical vapor deposition (PECVD) of graphene on gold (Au) and silver (Ag) terminals can significantly reduce the insertion force (friction force during the terminal insertion process). However, the cost of this deposition method is rather high, and its high temperature process (> 400 oC) makes it impractical for materials with low melting temperatures. For example, tin (Sn) coating with a melting temperature of 232 oC is commonly used in electrical connectors, which cannot sustain the high temperature process. In this study, reduced graphene oxide was prepared using a low-cost solution process and applied onto metallic terminals.

The design of better active materials for lithium-ion batteries (LIBs) is crucial to satisfy the increasing demand of high performance batteries for portable electronics and electric vehicles. Currently, the development of new active materials is driven by physical experimentation and the designer’s intuition and expertise. During the development process, the designer interprets the experimental data to decide the next composition of the active material to be tested. After several trial-and-error iterations of data analysis and testing, promising active materials are discovered but after long development times (months or even years) and the evaluation of a large number of experiments. Bayesian global optimization (BGO) is an appealing alternative for the design of active materials for LIBs. BGO is a gradient-free optimization methodology to solve design problems that involve expensive black-box functions. An example of a black-box function is the prediction of the cycle life of LIBs.

Inside an automobile, hundreds of connectors and electrical terminals in various locations experience different corrosive environments. These connectors and electrical terminals need to be corrosion-proof and provide a good electrical contact for a vehicle’s lifetime. Saltwater and sulfuric acid are some of the main corrosion concerns for these electrical terminals. Currently, various thin metallic layers such as gold (Au), silver (Ag), or tin (Sn) are plated with a nickel (Ni) layer on copper alloy (Cu) terminals to ensure reliable electrical conduction during service. Graphene due to its excellent chemical stability can serve as a corrosion protective layer and prevent electrochemical oxidation of metallic terminals. In this work, effects of thin graphene layers grown by plasma-enhanced chemical vapor deposition (PECVD) on Au and Ag terminals and thin-film devices were investigated. Various mechanical, thermal/humidity, and electrical tests were performed.

Nowadays, the increasing number of structural high pressure die casting (HPDC) aluminum parts need to be joined with high strength steel (HSS) parts in order to reduce the weight of vehicle for fuel-economy considerations. Self-Pierce Riveting (SPR) has become one of the strongest mechanical joining solutions used in automotive industry in the past several decades. Joining HPDC parts with HSS parts can potentially cause joint quality issues, such as joint button cracks, low corrosion resistance and low joint strength. The appropriate heat treatment will be suggested to improve SPR joint quality in terms of cracks reduction. But the heat treatment can also result in the blister issue and extra time and cost consumption for HPDC parts. The relationship between the microstructure of HPDC material before and after heat treatment with the joint quality is going to be investigated and discussed for interpretation of cracks initiation and propagation during riveting.

The transportation sector is facing three revolutions: shared mobility, electrification, and autonomous driving. To inform decision making and guide smart transportation system development at the city-level, it is critical to model and evaluate how travelers will behave in these systems. Two key components in such models are (1) individual travel demands with high spatial and temporal resolutions, and (2) travelers’ sociodemographic information and trip purposes. These components impact one’s acceptance of autonomous vehicles, adoption of electric vehicles, and participation in shared mobility. Existing methods of travel demand generation either lack travelers’ demographics and trip purposes, or only generate trips at a zonal level. Higher resolution demand and sociodemographic data can enable analysis of trips’ shareability for car sharing and ride pooling and evaluation of electric vehicles’ charging needs.

Fatigue damage prediction approaches in both time and frequency domains have been developed to simulate the operational life of mechanical structures under random loads. Fatigue assessment of mechanical structures and components subjected to those random loads is increasingly being addressed by frequency domain approaches because of time and cost savings. Current frequency-based fatigue prediction methods focus on stationary random loadings (stationary Power Spectral Density), but many machine components, such as jet engines, rotating machines, and tracked vehicles are subjected to non-stationary PSD conditions under real service loadings. This paper describes a new fatigue damage modeling approach capable of predicting fatigue damage for structures exposed to non-stationary (evolutionary) PSD loading conditions where the PSD frequency content is time-varying.

Driveline and suspension notched components of off-road ground vehicles often experience multiaxial fatigue failures along notch locations. Large nominal load histories may induce local elasto-plastic stress and strain responses at the critical notch locations. Fatigue life prediction of such notched components requires detailed knowledge of local stresses and strains at notch regions. The notched components that are often subject to multiaxial loadings in services, experience complex stress and strain responses. Fatigue life assessment of the components utilizing non-linear Finite Element Analysis (FEA) require unfeasibly inefficient computation times and large data. The lack of more efficient and effective methods of elasto-plastic stress-strain calculation may lead to the overdesign or earlier failures of the components or costly experiments and inefficient non-linear FEA.

In order to improve efficiency and increase the operation of electric vehicles, assistive energy regeneration systems can be used. A hydraulic energy recovery system is modeled to be used as a regenerative system for supplementing energy storage for a pure electric articulated passenger bus. In this study a pump/motor machine is modeled to transform kinetic energy into hydraulic energy during braking, to move the hydraulic fluid from the low pressure reservoir to the hydraulic accumulator. The simulation of the proposed system was used to estimate battery savings. It was found that on average, approximately 39% of the battery charge can be saved when using a real bus driving cycle.

A parallel-through-the-road (PTTR) plug-in hybrid electric vehicle is being created by modifying a 2013 Chevrolet Malibu. This is being accomplished by replacing the stock 2.4L gasoline engine which powers the front wheels of the vehicle with a 1.7L diesel engine and by placing a high voltage electric motor in the rear of the vehicle to power the rear wheels. In order to meet the high voltage needs of the vehicle created by the PTTR hybrid architecture, an energy storage system (ESS) will need to be created. This paper explains considerations, such as location, structure integrity, and cooling, which are needed in order to properly design an ESS.

Deep-hole drilling is among the most critical precision machining processes for production of high-performance discrete components. The effects of drilling with superimposed, controlled low-frequency modulation - Modulation-Assisted Machining (MAM) - on the surface textures created in deep-hole drilling (ie, gun-drilling) are discussed. In MAM, the oscillation of the drill tool creates unique surface textures by altering the burnishing action typical in conventional drilling. The effects of modulation frequency and amplitude are investigated using a modulation device for single-flute gun-drilling on a computer-controlled lathe. The experimental results for the gun-drilling of titanium alloy with modulation are compared and contrasted with conventional gun-drilling. The chip morphology and surface textures are characterized over a range of modulation conditions, and a model for predicting the surface texture is presented. Implications for production gun-drilling are discussed.

The Purdue University EcoMakers team has completed its first year of the EcoCAR 2 Competition, in which the team has designed a Parallel-Through-the-Road Plug-in Hybrid Electric Vehicle that meets the performance requirements of a mid-size sedan for the US market, maintaining capability, utility and consumer satisfaction while minimizing emissions, energy consumption and petroleum use. The team is utilizing a 1.7L 14 CI engine utilizing B20 (20% biodiesel, 80% diesel), a 16.2 kW-hr A123 battery pack, and a Magna E-Drive motor to power the front and rear wheels. This will allow the vehicle to have a charge-depleting range of 75 miles. The first year was focused on the simulation of the vehicle, in which the team completed the controls, packaging and integration, and electrical plans for the vehicle to be used and implemented in years two and three of the competition.

The new devices and missions to achieve the aims of NASA's Science Mission Directorate (SMD) are creating increasingly demanding thermal environments and applications. In particular, the low conductance of metal-to-metal interfaces used in the thermal switches lengthen the cool-down phase and resource usage for spacecraft instruments. During this work, we developed and tested a vacuum-compatible, durable, heat-conduction interface that employs carbon nanotube (CNT) arrays directly anchored on the mating metal surfaces via microwave plasma-enhanced, chemical vapor deposition (PECVD). We demonstrated that CNT-based thermal interface materials have the potential to exceed the performance of currently available options for thermal switches and other applications.

When high-intensity discharge (HID) electric lamps are used for plant growth, system inefficiencies occur due to an inability to effectively target light to all photosynthetic tissues of a growing crop stand, especially when it is closed with respect to light penetration. To maintain acceptable crop productivity, light levels typically are increased thus increasing heat loads on the plants. Evapotranspiration (ET) or transparent thermal barrier systems are subsequently required to maintain thermal balance, and power-intensive condensers are used to recover the evaporated water for reuse in closed systems. By accurately targeting light to plant tissues, electric lamps can be operated at lower power settings and produce less heat. With lower power and heat loads, less energy is used for plant growth, and possibly less water is evapotranspired. By combining these effects, a considerable energy savings is possible.

Bioregenerative systems for removal of gaseous contaminants are desired for long-term space missions to reduce the equivalent system mass of the air cleaning system. This paper describes an innovative design of a new biofiltration test lab for investigating the capability of biofiltration process for removal of ersatz multi-component gaseous streams representative of spacecraft contaminants released during long-term space travel. The lab setup allows a total of 24 bioreactors to receive identical inlet waste streams at stable contaminant concentrations via use of permeations ovens, needle valves, precision orifices, etc. A unique set of hardware including a Fourier Transform Infrared (FTIR) spectrometer, and a data acquisition and control system using LabVIEW™ software allows automatic, continuous, and real-time gas monitoring and data collection for the 24 bioreactors. This lab setup allows powerful factorial experimental design.

Complete reuse of graywater will be essential during long duration human space missions. The highest loaded and most important component to remove from graywater is surfactant, the active ingredient in soaps and detergents. When considering a biological treatment system for processing of graywater, surfactant biodegradability becomes a very important consideration. Surfactants should be chosen that are degraded at a fast rate and yield inconsequential degradation byproducts. Experiments conducted for this research examined the biodegradation of the surfactants in Pert Plus for Kids, disodium cocoamphodiacetate (DSCADA) and sodium laureth-3 sulfate (SLES), using respirometry. Rates of CO2 production, or ultimate degradation, are reported. DSCADA was found to be toxic to bacteria when present at 270 ppm whereas no toxicity was observed during experiments with SLES.

Electric machinery is typically based upon the interaction of magnetic fields and current to produce electromagnetic force or torque. However, force and torque can also be produced through the use of electric fields. The purpose of this investigation is to briefly analyze the use of a switched capacitance electric field based machine to see if it may have aerospace applications for use as either propulsion motor for unmanned aerospace vehicle (UAV) or lightweight flywheel applications for aerospace applications. It is shown that although its use as a hub propulsion motor is not feasible, it may be a candidate for use in a power flywheel energy storage system.