In electric vehicle applications, the majority of the traction motors can be categorized as Permanent Magnet (PM) motors due to their outstanding performance. As indicated in the name, there are strong permanent magnets used inside the rotor of the motor, which interacts with the stator and causes strong magnetic pulling force during the assembly process. How to estimate this magnetic pulling force can be critical for manufacturing safety and efficiency. In this paper, a full 3D magnetostatic model has been proposed to calculate the baseline force using a dummy non-slotted cylinder stator and a simplified rotor for less meshing elements. Then, the full 360 deg model is simplified to a 90deg quarter model based on motor symmetry to save the simulation time from 2 days to 4 hours. A rotor position sweep was conducted using the quarter model to find the max pulling force position. The result shows that the max pulling force happens when the rotor is 1mm overlapping with the stator core.
For the design optimization of the electric bus body frame orienting frontal crash, considering the uncertainties may impact the crashworthiness performance, a robust optimization scheme considering tolerance design is proposed, which maps the given acceptable objective and feasibility variations into the parameter space to analyze the robustness. Two contribution analysis methods those are the entropy weight and TOPSIS method and the grey correlation calculations method are adopted to screen all the design variables, and 15 shape design variables with relatively high effect are chosen for design optimization. A symmetric tolerance and interval model is used to describe the uncertainty of 15 shape design variables of the key components of the bus body skeleton to form an uncertainty optimization problem in the form of an interval, and a triple-objective robust optimization model is developed to optimize the shape design variables and tolerances simultaneously.
An experiment is carried out to measure creep groan of a drum brake located in a trailer axle of a truck. The noise nearby the drum brake and accelerations on brake shoes, axle and trailer frame are collected to analyze the occurring conditions and characteristics of the creep groan. A model with 1/4 trailer chassis structures is established using ADAMS for analyzing brake component vibrations that generates the creep groan. In the model, the contact force between involute cam and rollers of brake shoes, the contact friction and damping characteristics between brake linings and inner circular surface of brake drum, and the properties of chassis structure are included. Dynamic responses of brake shoes, axle and trailer frame during the braking process are estimated using the established model and the responses are compared with the measured results, which validate the model.
Catalytic converters have been considered as an integral part of the vehicle powertrain for over a decade now, their application along with the engines increased significantly with the constant evolution of emission standards. Recent regulations keep a strict control on the major four pollutants of engine exhaust gas, i.e., Carbon Monoxide (CO), Nitrogen Oxides (NOx), Hydrocarbons (HC) & Particulate Matter (PM), which demands a highly efficient aftertreatment system. Efforts are continuously being made to downsize the engine for better fuel economy and low emissions, this puts additional requirement of designing a compact aftertreatment system equipped with Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF) and Selective Catalytic Reduction (SCR). Compact catalytic converters experience larger vibration force transferred from the engine and hence the durability of the product is significantly impacted.
Wrap around distance (WAD) is an important indicator of the parameter to assess the position of the pedestrian's body in contact with the vehicle, and it is also one of the important parameters for accident reconstruction. In order to study the probability of pedestrian head WAD impact and injury risk in real accidents, a study of pedestrian head WAD impact rate and injury risk based on deep accident data is proposed. Firstly, a head WAD prediction model was established using a logistic regression algorithm around pedestrian height and vehicle collision speed. Second, pedestrian head impact probability distribution curves were constructed using the WAD prediction model for cars and SUVs, respectively. Finally, the pedestrian head injury risk curves were constructed by combining the pedestrian head WAD impact probability and the proportion of head injury distribution in real accidents in different areas of the vehicle.
In light of the current trend towards the electrification of commercial vehicles, the imperative for the development of a Beam eAxle solution has become apparent. The utilization of an electric drive unit in heavy-duty solid axle-based commercial vehicles presents unique and demanding challenges, including the necessity for elevated peak and continuous torque, while meeting spatial constraints, structural integrity requirements, additional functionalities, and extended service life. BorgWarner has developed a solution that addresses these challenges, meeting the rigorous demands of commercial vehicle electrification. This paper offers a comprehensive overview of the design and prototyping processes undertaken to develop the Beam eAxle, including an analysis of market demands, a comparative examination of eAxle solutions, and the methodologies and procedures employed in the design, prototyping, and evaluation phases of the Beam eAxle development.
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