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As technology evolves, the number of sensors and available data on vehicles grow exponentially. In this context, it is essential to use sensors for monitoring key components, increasing safety and reliability, and gathering data useful for mechanical dimensioning and control systems. This paper presents an application of strain-gauged bolts on brake calipers fixation of two electric vehicles. With this approach it was possible to evaluate the loads applied to the brake pads fixation zone and correlate them with braking behavior, therefore gaining insights on braking conditions and system state for an improved braking function control. The goal of the study is analyzing the strengths and limitations of the method and proposing developments to deploy it in real applications. This is particularly important and novel for electric vehicles, where powertrains can create positive/negative torques and generate complex interactions with braking system.

In recent years, there is an increasing global interesting in alternative sources of energy. For this reason, Shell Company creates Shell Eco Marathon, a competition for fuel-efficient vehicles designed by student around the world. IDRAkronos is a fuel cell hydrogen prototype developed at the Politecnico of Turin. The vehicle races in prototype category with the task to complete ten laps of an urban circuit driving a total distance of 15 km in a maximum time of 39 min, then with an average speed of approximately 25 km/h, obtaining the less consumption. The vehicle is a three wheels vehicle based on a carbon fibre monocoque pushed by a hydrogen fuel cell with a high efficiency DC electric motor. The paper describes modelling and optimization of the powertrain design applicable to the development of fuel cell electric vehicles.

Vehicle dynamics is a fundamental part of vehicle performance. It combines functional requirements (i.e. road safety) with emotional content (“fun to drive”, “comfort”): this balance is what characterizes the car manufacturer (OEM) driving DNA. To reach the customer requirements on Ride & Handling, integration of CAE and testing is mandatory. Beside of cutting costs and time, simulation helps to break down vehicle requirements to component level. On chassis, the damper is the most important component, contributing to define the character of the vehicle, and it is defined late, during tuning, mainly by experienced drivers. Usually 1D lookup tables Force vs. Velocity, generated from tests like the standard VDA, are not able to describe the full behavior of the damper: different dampers display the same Force vs. Velocity curve but they can give different feeling to the driver.