Search Results

Abstract Heat generation characteristics of lithium ion batteries are vital for both the optimization of the battery cells and thermal management system design of battery packs. Compared with other factors, internal resistance has great influence on the thermal behavior of Li-ion batteries. Focus on a 3 Ah pouch type battery cell with the NCM/C material system, this paper quantitatively evaluates the battery heat generation behavior using an Extended Volume-Accelerating Rate Calorimeter in combination with a battery cycler. Also, internal resistances of the battery cell are measured using both the hybrid pulse power characteristic (HPPC) and electro-chemical impedance spectroscopy (EIS) methods. Experimental results show that the overall internal resistance obtained by the EIS method is close to the ohmic resistance measured by the HPPC method. Heat generation power of the battery cell is small during discharge processes lower than 0.5 C-rate.

Abstract Battery Drain problems can occur in the vehicle due to improper network management between electronic control units (ECUs). Aim of this paper is to identify the factors that cause transmission and cease of transmission of a network management message of an ECU along with its application messages that controls the sleep/wake-up performance of other ECUs in the network. Strategy used here is, based on the root cause analysis of problems found in Display unit in vehicle environment, the functional CAN signals impacting sleep/wake-up behavior is re-mapped along with the state flow transition of AUTOSAR NM Algorithm. A re-defined test case design and simulation for vehicle model is created. Especially it focuses on validating the impact of functional CAN signals on DUT’s sleep/wake-up performance.

Abstract The high-frequency noise issue is one of the most significant noise, vibration, and harshness problems, particularly in battery electric vehicles (BEVs). The sound package treatment is one of the most important approaches toward solving this problem. Owing to the limitations imposed by manufacturing error, assembly error, and the operating conditions, there is often a big difference between the actual values and the design values of the sound package components. Therefore, the sound package parameters include greater uncertainties. In this article, an uncertainty analysis method for BEV interior noise was developed based on an interval model to investigate the effect of sound package uncertainty on the interior noise of a BEV. An interval perturbation method was formulated to compute the uncertainty of the BEV’s interior noise.

Abstract A key problem of the construction of fully electric aircraft is the limited energy density of battery packs. It is generally accepted that this can only be overcome via new, denser battery chemistry together with a further increase in the efficiency of power utilization. One appealing approach for achieving the latter is using laser-assisted filler-based joining technologies, which offers unprecedented flexibility for achieving battery cell connections with the least possible electrical loss. This contribution presents our results on the effect of various experimental and process parameters on the electrical and mechanical properties of the laser-formed bond.

Abstract Improving the energy performance of batteries can increase the reliability of electric aircraft. To achieve this goal, battery management systems (BMS) are required to keep the temperature within the battery pack and cells below the safety limits and make the temperature distribution as even as possible. Batteries have a limited service life as a result of unwanted chemical reactions, physical changes that cause the loss of active materials in the structure, and internal resistance increase during the charging and discharging cycle of the battery. These changes usually affect the electrical performance of batteries. Battery life can be increased only by reducing or preventing unwanted chemical reactions. Lithium-ion (Li-ion) batteries are a suitable option due to their high specific energy and energy density advantages. In this study, the necessity of heat management is emphasized. The discharge tests of the Li-ion battery provided 94.6 Wh under 10C and 90.9 Wh under 1C.

Abstract The range of an aircraft is determined by the amount of energy that its batteries can store. Today, larger batteries are used to increase the range of electric vehicles, although energy efficiency decreases as the weight of the vehicles increases. Among the elements, lithium (Li) is the lightest and has the highest electrochemical potential. Therefore, the use of Li-ion batteries is recommended for hybrid aircraft. In addition, Li-ion batteries are the most common type of battery that is used in portable electronic devices such as smartphones, tablets, and laptops. However, Li-ion batteries may explode due to temperature. Therefore, the thermal analysis of Li-ion batteries was investigated both experimentally and numerically. Li-ion batteries were connected in series (the number is 9). Noboru’s theory of heat generation was discussed in the estimation of energy data.

Abstract In this article, a unique design for Hydro-Pneumatic Energy Harvesting Suspension HPEHS system is introduced. The design includes a hydraulic rectifier to maintain one-way flow direction in order to obtain maximum power generation from the vertical oscillation of the suspension system and achieve handling and comfort car drive. A mathematical model is presented to study the system dynamics and non-linear effects for HPEHS system. A simulation model is created by using Advanced Modeling Environment Simulations software (AMEsim) to analyze system performance. Furthermore, a co-simulation platform model is developed using Matlab-Simulink and AMEsim to optimize the PID controller parameters of the external variable load resistor applied on the generator by using Particle Swarm Optimization (PSO).

Abstract Recently, electric heavy-duty tractor-trailers (EHDTTs) have assumed significance as they present an immediate solution to decarbonize the transportation sector. Hence, to illustrate the economic viability of electrifying the freight industry, a detailed numerical model to estimate the battery capacity for an EHDTT is proposed for a route between Washington, DC, to Knoxville, TN. This model incorporates the effects of the terrain, climate, vehicular forces, auxiliary loads, and payload in order to select the appropriate motor and optimize the battery capacity. Additionally, current and near-future battery chemistries are simulated in the model. Along with equations describing vehicular forces based on Newton’s second law of motion, the model utilizes the Hausmann and Depcik correlation to estimate the losses caused by the capacity offset of the batteries. Here, a Newton-Raphson iterative scheme determines the minimum battery capacity for the required state of charge.

Abstract Electric heavy-duty tractor-trailers (EHDTT) offer an important option to reduce greenhouse gases (GHG) for the transportation sector. However, to increase the range of the EHDTT, this effort investigates critical vehicle design features that demonstrate a gain in overall freight efficiency of the vehicle. Specifically, factors affecting aerodynamics, rolling resistance, and gross vehicle weight are essential to arrive at practical input parameters for a comprehensive numerical model of the EHDTT, developed by the authors in a subsequent paper. For example, drag reduction devices like skirts, deturbulators, vortex generators, covers, and other commercially available apparatuses result in an aggregated coefficient of drag of 0.367. Furthermore, a mixed utilization of single-wide tires and dual tires allows for an optimized trade-off between low rolling resistance tires, traction, and durability.

Abstract The present study aims to join the dissimilar materials such as Dual-Phase (DP) 600 Steel and AA6082-T6 Aluminum (Al) alloy via the friction stir welding (FSW) process with a reduced intermetallic compound (IMC) layer. The five different tool tilt angles of 0°, 0.5°, 1°, 1.5°, and 2° were selected to fabricate the joints. The weld characteristics such as tensile strength, hardness, macrostructure, and microstructure were analyzed. The weld interface was studied by employing an optical microscope and scanning electron microscope (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD) techniques. The joint produced with a 0.5° tilt angle has achieved the highest ultimate tensile strength (UTS) of 240 MPa. The IMCs were identified as Fe2Al8 and FeAl2 from the joint interface studies.

Abstract Direct welding of coated steels to aluminum alloys is challenging due to high energy requirements, decreased weldability, and unstable weld quality. The present study reports the application of a new design approach in vaporizing foil actuator welding (VFAW), where an asymmetric preform shape on the target sheet generated the requisite standoff, enabling direct spot welding of a typical automotive aluminum alloy (6022 T4) and two different zinc-coated steels, galvanized high-strength low-alloy 350 and galvannealed dual-phase 590. The use of the new approach enabled for the first time the ability to spot weld through coating without any preweld surface preparation. Characterization using lap-shear and peel testing revealed strong joints for both the weld pairs (AA 6022 T4-HSLA 350 and AA 6022 T4-DP 590). The weld interface characterized by scanning electron microscopy (SEM) revealed a hierarchical structure and the presence of a typical wavy region.

Abstract Reducing a vehicle’s weight is an efficient method to reduce energy consumption. Aluminum alloy is the best material for lightweight automobiles. However, the poor formability of aluminum means that it is difficult to develop stamping dies. This study designs a suitable forming tool for aluminum fenders. A simulation and an experiment are used to analyze the formability of aluminum fenders. A theoretical calculation, experimental testing, and sampling comparison are used to verify the design. The material properties of steel and aluminum are firstly studied and compared. The results show that a traditional S-type blank die face design is not suitable for aluminum because of its low tensile strength and the potential for elongation. A relatively flat trapezoid blank die face design is proposed to smooth the variation. However, a flat die face for a trapezoidal blank limits stretching, so another design is essential to improve the formability.

Abstract In the selection of automobile noise reduction schemes, the lack of comprehensive quantitative index system and objective evaluation method is a serious problem. In this article, the methods of analytic hierarchy process (AHP) and gray target decision were used to solve the problem. Firstly, AHP and gray target decision method were introduced respectively in detail. Secondly, three automobile noise reduction schemes were illustrated. Four types of data were selected as the decision indexes, and the weight coefficients of all the decision indexes were calculated using the AHP. Then multi-attribute mixed weighted gray target decision model was established. The optimum scheme was obtained by the calculation of the off-target distance and the sorting of the calculation results. The proposed method can quantify the evaluation process and overcome the disadvantages of the traditional analogy method. The example shows that the method is feasible.

Abstract The supersession of metallic alloys with lightweight, high-strength composites is popular in the aircraft industry. However, aviation electronic enclosures for large format batteries and high power conversion electronics are still primarily made of aluminum alloys. These aluminum enclosures have attractive properties regrading structural integrity for the heavy internal parts, electromagnetic interference (EMI) suppression, electrical bonding for the internal cells, and/or electronics and failure containment. This paper details a lightweight carbon fiber composite chassis developed at Meggitt Sensing Systems (MSS) Securaplane, with a copper metallic mesh co-cured onto the internal surfaces resulting in a 50% reduction in weight when compared to its aluminum counterpart. In addition to significant weight reduction, it provides equal or improved performance with respect to EMI, structural and flammability performance.

Abstract In this study, active-passive filling friction stir repairing (A-PFFSR) process was employed to repair the volume defects in friction stir welding (FSW) joints of Al-Cu alloy. The volume defects with varied geometries were first machined into taper holes, which are similar to keyhole defect by a rotational tool with a threaded pin. Then, the keyhole defect was effectively filled with the materials around the keyhole and an additional filler using a number of nonconsumable pinless tools with the shoulders having six spiral flutes. The macro/microstructures, microhardness, and tensile properties of the repaired joints were investigated. The influences of plunge speed on macro/microstructures and mechanical properties of the repaired joints have been analyzed too. It was noticed that decreasing plunge speed was effective to improve the frictional heat and material flow, which increased joint surface integrity avoiding interfacial drawbacks.

Abstract This article investigates the fuel savings potential of a series hybrid military truck using a simultaneous battery pack design and powertrain supervisory control optimization algorithm. The design optimization refers to the sizing of the lithium-ion battery pack in the hybrid configuration. The powertrain supervisory control optimization determines the most efficient way to split the power demand between the battery pack and the engine. Despite the available design and control optimization techniques, a generalized mathematical formulation and solution approach for combined design and control optimization is still missing in the literature. This article intends to fill that void by proposing a unified framework to simultaneously optimize both the battery pack size and power split control sequence. This is achieved through a combination of genetic algorithm (GA) and Pontryagin’s minimum principle (PMP) where the design parameters are integrated into the Hamiltonian function.

Abstract In the case of electric vehicles, due to the charging current limitation of lithium battery at low temperatures (below -20°C), it has been proposed to heat the battery pack up to a suitable temperature range before charging through a liquid-heating plate with PTC. However, at a low state of charge (SOC), there is a question which one could take the place of battery pack to supply power for PTC when heating. So that off-board charger (OFC) has been considered to supply power for PTC in this paper. In order to control the current charging into the battery pack as less as possible at low temperatures, three control schemes of battery management system (BMS) are proposed and compared. Scheme 1: BMS controls the value of charging current request close to the working current of PTC. Scheme 2: BMS controls the value of charging voltage request to reach a state of relative balance. Scheme 3: BMS disconnects the pack from the charger and keeps the connection between PTC and charger.

Abstract TOC

Abstract The principal issue in choosing an energy management strategy (EMS) for hybrid electric vehicles (HEVs) has been the way of determining the optimal share of electric energy in hybrid drive. In this article, a novel EMS is proposed that, along with maximum engine efficiency in the hybrid drive, can optimize the share of battery energy for the maximum efficiency of vehicle power train expanded with an imaginary power plant that, by delivering the electric energy to a grid, feeds the vehicle battery. It is proved that the expanded power train efficiency has the local maximum for a wide range of wheel power demand. The relation between the wheel power demand in hybrid drive, the share of battery energy, and the maximum efficiency of the expanded power train is conducted offline. Downloaded to the onboard control system, it enables the operation with the instantaneously optimal share of battery energy and the control system to operate with the low computational load.

Abstract The linear engine as compared with the traditional internal combustion engine has high efficiency and low emissions, so as a new type of hybrid power unit, it is very suitable for a hybrid electric vehicle to improve energy efficiency and environmental protection performances. In this article, a novel linear engine-based hybrid power system that is primarily selected for hybrid electric urban light commercial vehicles is introduced. Furthermore, the working efficiency of the proposed hybrid power system is briefly analyzed through a validation study example, and various inherent factors affecting the working efficiency of the hybrid power system are analyzed and discussed in detail. This work can provide a reference implementation for the research on the power unit for the hybrid electric urban light commercial vehicles.