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FEA Beyond Basics Thermal Analysis

2019-12-16
Finite Element Analysis (FEA) is a powerful and well recognized tool used in the analysis of heat transfer problems. However, FEA can only analyze solid bodies and, by necessity thermal analysis with FEA is limited to conductive heat transfer. The other two types of heat transfer: convection and radiation must by approximated by boundary conditions. Modeling all three mechanisms of heat transfer without arbitrary assumption requires a combined use of FEA and Computational Fluid Dynamics (CFD).
Technical Paper

Powertrain topologies for 2 wheelers : From ICE to Electrification

2019-11-21
2019-28-2480
As Battery cost is expected to see a Downward trend, Electrification of Powertrain in general is expected to pick up and 2wheeler Market is foreseen to be the Flag bearer in this race towards Electrification. In this paper, we would like to emphasize on the Journey of 2wheelers from Conventional Internal combustion Engine to Electrified Powertrains which we foresee in the future. Methodology: EV - Analysis of OEM strategies and upcoming trends in connectivity and electrification. Estimation of current market size of 2Wheeler and segmentation based on different personas. Building survey data based personas around ownership patterns for electric 2Wheelers. Mapping consumer decision process for electric 2Wheelers. Analyse the decision influencers and role of influencers in decision making process. Hybrid - Analysis of different hybrid topologies. Feasibility study via simulation and focus group assessments to evaluate the design. PoC will also be tried to validate the concept.
Technical Paper

A novel approach on range prediction of a hydrogen fuel cell electric truck

2019-11-21
2019-28-2514
A novel approach on range prediction of a hydrogen fuel cell electric truck C.Venkatesh - Manager - Product Development, Sustainable Mobility & Advanced Technologies Abstract: A novel approach on range prediction of a hydrogen fuel cell electric vehicle Abstract: Today's growing commercial vehicle population creates a demand for fossil fuel surplus requirement and develops highly polluted urban cities in the world. Hence addressing both factors are very much essential. Battery electric vehicles are with limited vehicle range and higher charging time. So it is not suitable for the long-haul application. Hence the hydrogen fuel cell based electric vehicles are the future of the commercial electric vehicle to achieve long range, zero emission and alternate for reducing fossil fuels requirement. The hydrogen fuel-cell electric vehicle range, it means the total distance covered by the vehicle in a single filling of hydrogen into the onboard cylinders.
Technical Paper

SELF EXPRESSIVE & SELF HEALING CLOSURES HARDWARES FOR AUTONOMOUS AND SHARED MOBILITY

2019-11-21
2019-28-2525
Shared Mobility is changing the trends in Automotive Industry and its one of the Disruptions. The current vehicle customer usage and life of components are designed majorly for personal vehicle and with factors that comprehend usage of shared vehicles. The usage pattern for customer differ between personal vehicle, shared vehicle & Taxi. In the era of Autonomous and Shared mobility systems, the customer usage and expectation is high. The vehicle needs systems that will control customer interactions (Self-Expressive) & fix the issues on their own (Self-Healing). These two systems / methods will help in increasing customer satisfaction and life of the vehicle. We will be focusing on vehicle Closure hardware & mechanisms and look for opportunities to improve product life and customer experience in ride share and shared mobility vehicles by enabling integrated designs, which will Self-Express & Self-Heal.
Technical Paper

Finite Element Simulation and co-relation with automotive certification testing

2019-11-21
2019-28-2558
Automotive industry needs to exhibit compliance of their product with respect to the Automotive Industry Standards (AIS) at government approved test agencies. CAE (Computer Aided Engineering) plays a vital role in achieving the compliance for the same. With physical testing being more expensive for design iterations, CAE simulations are being considered as vital option. Considering the importance of time for approval, simulation tools are used to understand the physics of testing and failure.
Technical Paper

To establish the correlation in between Computer Aided Engineering & physical testing of automotive parts returnable case (Stacktainer).

2019-11-21
2019-28-2569
Automotive returnable cases (Stacktainers) are being used to transport the automotive parts through surface & seaways. No automotive manufacturer wants to spend money on woods, paper & cardboard again and again, it`s better to pay once for robust & reusable cases. these provide better protection to parts from its manufacturing to assembly line of vehicle. While transporting, any kind of crack or failure of returnable cases may lead to loss of money, human & time. To ensure the safety, these pallets have to be validated for vibrations coming from surface irregularities, sea waves & load due to stacking of cases one above other. The objective of this study is to establish a correlation in between the physical testing & simulation in Computer added Engineering (CAE) of automotive returnable case (Stacktainers). There are different types of tests considered to validate the returnable case, rough road evaluation, Multi-axial Vibration & strength evaluation.
Technical Paper

Steering and Handling Performance Optimization Through Correlation of Objective - Subjective Parameters and Multi-body Dynamics Simulation

2019-11-21
2019-28-2412
RESEARCH OBJECTIVE: Automobile Industry has driven through the ages with continuous development with innovative technologies and frugal engineering. Expectation of customer is also increasing through the generations. To meet the customer demand for performance and be best in market, OEM needs to deliver best performance of vehicle with cost effective and short development process. Steering and Handling of vehicle is one of major customer touchpoints and needs to be tuned to achieve various conflicting requirements. The objective of this research is to optimize the steering and handling using correlation between three major methods of evaluation. METHODOLOGY: Methodology for optimization of steering and handling performance using correlation between subjective evaluation, objective measurement and multi-body-dynamic simulation is presented.
Technical Paper

Realtime Tuning and optimization of EV traction motors with controllers on E-motor testbench

2019-11-21
2019-28-2478
The need for dedicated development of indigenous electric power-train is becoming much essential in the recent times with upcoming trends and policies. Hence, The validation and optimization of the newly developed electric power-train becomes much crucial in order to ensure smooth real world operation. This can be only possible in E-motor test benches with dedicated equipment for thorough evaluation. Also, there are no practical limitations to check the peak characteristics in a controlled laboratory environment. Initially, the motor is setup by mechanically coupling with the dynamo-meter and the controller in the open loop method with constant parameters to check steady state operability without load or external parameters that affect the torque production and speed of the drive. Then progresses to closed loop method incorporating the feedback control and external parameters including torque loading at the shaft from the dynamo-meter.
Technical Paper

Non-linear dynamic Modeling, Simulation and Control of Five-Phase 10/8 Switched Reluctance Motor for Electric Vehicle Application

2019-11-21
2019-28-2473
The SRM is gaining much interest for EVs due to its rare-earth-free characteristic and excellent performance. SRM possess several advantages such as low cost, high efficiency, high power density, fault-tolerant and it can produce extended constant power region, and this makes SRM as viable alternative over conventional PM drives. Objective: The objective of this paper is to establish proof of theoretical concepts related to SRM. The key to achieve an effective SRM modeling is to use a methodology that allow the nonlinearity of its magnetic characteristics to be represented while maximizing the simulation speed. This paper represents how magnetization data obtained from FEA in the form of look up tables is most appropriate way to represent SRM model. In this paper, performance analysis of SRM is done with the help of Open loop and Closed loop MATLAB simulations. These dynamic simulations of SRM will assist in understanding behavior of SRM in various loading and speed conditions.
Technical Paper

Rapid Prototyping and Implementation of traction motor drive for E- Mobility

2019-11-21
2019-28-2472
Objective / Question: Is it possible to extend the envelope of simulation driven design and its advantages to development of complex dynamic systems viz. traction motor drives? The objective that then follows is how to enable OEM/Tier-1s to reduce wastes in the process of traction motor controller design, development, optimization and implementation. Motor control design to validation process is time consuming and tricky! Additionally, the requirement of software knowledge to write code to implement drive engineer's control ideas. The challenges here are - to name a few - algorithm for real time, addressing memory constraints, debugging, comprehending mathematical overflows, portability & BOM cost. These introduces wastes in parameters like time, cost, performance, efficiency and reliability. Methodology: Developing a new traction motor controller for E Mobility takes 18 - 24 months typically. 2 distinct activities take place in a loop.
Technical Paper

Analysis Of GaN Based BLDC Motor Drive For Automotive Application

2019-11-21
2019-28-2471
Objective Automotive sector is rapidly moving towards electric vehicle. BLDC motor is gaining popularity in the field of electric vehicle due to its high torque to weight ratio and simple control. In this paper we will focus on Switching loss characterization of 3 kW GaN based BLDC drive for electric vehicle. To improve efficiency of drive gallium-nitride based power transistor is used instead of Si MOSFET. GaN devices enable the design of inverter at higher frequencies with improved power density and efficiency as compared to traditional Si MOSFETs. Methodology In this paper commercially available GaN devices compared with Si MOSFETs. The power devices, which are selected for the performance comparison, are EPC2022 GaN by EPC, GS61008P GaN by Gan System and SiDR668DP Si MOSFET by Vishay. The Switching losses analytically predicted in MATHCAD tool and then compared with SPICE simulation losses. Double pulse test circuit is used to find out power losses of power transistors.
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