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Abstract With increasing demands for higher performance along with lower vehicle emissions, lightweight vehicle system construction is key to meet such demands. Suspension and transmission assemblies being the key areas for weight-reduction, we have designed a revolutionary new type of suspension system which combines the suspension links with the powertrain assembly and thus completely eliminates one suspension member. Less weight means lower fuel-consumption with improved passenger-comfort and road-holding due to reduction in unsprung mass. Elimination of a suspension link reduces the overall cost of material, machining & fabrication making our design cost-effective than existing setups. This paper deals with the design and implementation of of our concept. A working prototype is also constructed and tested which completely validates our design.

Abstract The brake discs are subjected to thermal load due to sliding by the brake pad and fluctuating loads because of the braking load. This combined loading problem requires simulation using coupled thermo-mechanical analysis for design evaluation. This work presents a combined thermal and mechanical finite element analysis (FEA) and evolutionary optimization-based novel approach for estimating the optimal design parameters of the ventilated brake disc. Five parameters controlling the design: inboard plate thickness, outboard plate thickness, vane height, effective offset, and center hole radius were considered, and simulation runs were planned. A total of 27 brake disc designs with design parameters as recommended by the Taguchi method (L27) were modeled using SolidWorks, and the FEA simulation runs were carried out using the ANSYS thermal and structural analysis tool.

Abstract This article applies a new method for the evaluation and estimation of real-life energy consumption of two different thermal management systems based on driving behavior in the course of the day. Recent attempts to find energy-efficient thermal management systems for electric and plug-in hybrid electric vehicles have led to using secondary loop systems as an alternative approach for meeting dynamic heating and cooling demands and reducing refrigerant charge. However, the additional layer of thermal resistance, which influences the system’s transient behavior as well as passenger compartment comfort during cool-down or heat-up, makes it difficult to estimate the annual energy consumption. In this article, the overall energy consumption of a conventional and a secondary loop system is compared using a new method for describing actual customers’ driving behavior in the course of the day.

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 In this study, an attempt is made to deduce the number of teeth in the driven sprocket of a Formula SAE (FSAE) car using Optimum Lap software based on track run simulation of the car, which comes out to be 51 teeth. The sprocket material was selected as Aluminum Alloy AL-7075 T6 because of its strength-to-weight ratio. In addition to it, the generative design strategy by Fusion-360 was utilized to automatically engender the slotted sprocket design on the ground of stress induced on it during operation. Furthermore, the design was verified virtually carrying out static structural and fatigue analysis under the worst-case scenario in CAE software. The overall weight reduction achieved was around 45%. Furthermore, the center-to-center distance between the sprockets and the number of chain links required were also calculated on the basis of space constraints and the wrap angle of the sprocket.

Abstract This article presents the application of the Life Cycle Sustainability Assessment (LCSA) methodology for integrating environmental, economic, and social assessment results by the direct application of Fuzzy-Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS). The aim of this work is to test the applicability of LCSA methodology as a potential tool to support the design phase, providing solutions tailored to its application in the automotive sector. To validate the proposed procedure, two alternative design solutions for a car dashboard are used as case study. In response to the need of methods and tools for evaluating and comparing sustainability of alternative design solutions, LCSA is seen as one of the most promising method, but which needs further testing with real cases to solve some methodological challenges.

Abstract Maximum lifetime and minimum manufacturing cost for new products are the primary goals of companies for competitiveness. These two objectives are contradictory and the geometric dimensions of the products directly control them. In addition, the earlier design errors of new products are predicted, the easier and more inexpensive their rectification becomes. To achieve these objectives, we propose in this article a novel model that makes it possible to solve the problem of optimizing the lifespan and the manufacturing cost of new products during the phase of their design. The prediction of the life of the products is carried out by an energy damage method implemented on the finite element (FE) calculation by using the ABAQUS software. The manufacturing cost prediction is carried out by applying the ABC cost estimation analytical method. In addition, the optimization problem is solved by the method of genetic algorithms.

Abstract The proposed approach present the development of a computer tool that allows, in the first phase, the modeling of the electric vehicle power chain. This phase is based on a library developed under the Matlab-Simulink simulation environment. This library contains all the components of the power chain; it offers the selection of the desired configuration of each component. In the second phase, the tool solves the autonomy optimization problem. This problem is resolved by a program based on genetic algorithms. This program permits to optimize the configuration parameters maximizing the vehicle autonomy of the chosen chain. This tool is based on a graphical interface developed under the Matlab simulation environment.

Abstract Aerodynamic optimization of the exterior vehicle shape is a highly multidisciplinary task involving, among others, styling and aerodynamics. The often differing priorities of these two disciplines give rise to iterative loops between stylists and aerodynamicists. Reduced-order modeling (ROM) has the potential to shortcut these loops by enabling aerodynamic evaluations in real time. In this study, we aim to assess the performance of ROM via proper orthogonal decomposition (POD) for a real-life industrial test case, with focus on the achievable accuracy for the prediction of fields and aerodynamic coefficients. To that end, we create a training data set based on a six-dimensional parameterization of a Volkswagen passenger production car by computing 100 variants with Detached-Eddy simulations (DES).

Abstract Future SAE Level 4 and Level 5 autonomous vehicles (AV) will require novel applications of localization, perception, control, and artificial intelligence technology in order to offer innovative and disruptive solutions to current mobility problems. This article concentrates on low-speed autonomous shuttles that are transitioning from being tested in limited traffic, dedicated routes to being deployed as SAE Level 4 automated driving vehicles in urban environments like college campuses and outdoor shopping centers within smart cities. The Ohio State University has designated a small segment in an underserved area of the campus as an initial AV pilot test route for the deployment of low-speed autonomous shuttles. This article presents initial results of ongoing work on developing solutions to the localization and perception challenges of this planned pilot deployment.

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.

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Abstract Recent research has demonstrated that gasoline compression ignition (GCI) can improve the soot-oxides of nitrogen (NOx) trade-off of conventional diesel engines due to the beneficial properties of light distillate fuels. In addition to air handling and aftertreatment, fuel systems also require further development to realize the potential efficiency and emissions benefits of GCI. Injector one-dimensional (1-D) hydraulic modeling is an important design tool used for this purpose. The current study is a continuation of prior work that used computed physical fuel properties and hydraulic models to accurately simulate high-pressure injection behavior relevant to GCI. With respect to fuel characteristics for the model, physical properties were validated by direct comparison to measurements at temperatures and pressures reaching 150°C and 2500 bar, respectively.

Abstract As bicycle design continues to develop, consumers are not satisfied with just the convenience and power-saving features of bicycles, but they also demand a fancy appearance. To achieve dramatic deforming of bike frames, an extreme high-profile difference is required. Thus, this study used rotary swaging, which is the best forging method among shrink forming processes, as the preforming process. The tube diameter reduction rates of 0.28 and 0.31 were set as the main parameters, and the effects of feeding speed, feeding method, and friction factor on the formed tube were analyzed. The results indicated that a higher feeding speed results in a lower rate of tube thickness increase and a lower friction factor results in a lower rate of tube thickness increase. Regarding the effects of feeding methods, the automatic feeding method yielded better surface roughness than the manual method.

Abstract Currently, the governments are encouraging automotive vehicle manufacturers to produce electric vehicles (EVs) as these vehicles have a zero-emission footprint. Generally, the EVs are expected to be quieter compared to internal combustion engine (ICE) vehicles. But the absence of engine noise in EVs brings more challenges for noise, vibration, and harshness (NVH) as the other noise sources become more audible. Most of these noise sources are tonal in nature and, hence, cause discomfort to the passengers. The present work is related to the noise refinement in a pure EV. The dominant noise sources observed in this vehicle are the electric powertrain, cooling fan, and air compressor. The powertrain consists of a traction motor and a gearbox (GB) with a planetary gear system. The root cause identification of electric powertrain noise has been investigated with masking trials and with the acoustic camera.

Abstract Due to the advantages of hybrid vehicles in comparison with pure electric vehicles, Hybrid Electric Vehicle (HEV)/Plug-in HEV (PHEV) no undoubtedly becomes the reasonable and practical solution in the development of vehicle electrification at the moment. Meanwhile, Dedicated Hybrid Transmission (DHT), as the especially designed hybrid transmission for HEV/PHEV, represents the development direction of hybrid vehicles. But in the market, the well-known DHT concepts are all protected by patents by large Original Equipment Manufacturers (OEMs). How to break the patents and more importantly develop the innovative DHT concepts in the next generation is of vital importance in the development of HEV/PHEV. In this article, firstly, the features and comparisons of different well-known DHT concepts are discussed and analyzed. The mechanical and electrical complexity are introduced to essentially analyze the advantage and disadvantage of different kinds of DHT concepts.

Abstract Objectified analysis and evaluation tools offer cost- as well as time-saving potentials regarding the calibration process of vehicle control units. To reduce the time required for the calibration effort, standardized processes including the frontloading of development tasks enable swift calibration procedures and can be used to develop a basis for the comparison of different vehicles and also the calibration quality. In this environment, objectified evaluation methods are also being developed for the investigation of the drivability of electric vehicles. This article presents a methodology for assessing the longitudinal drive behavior of battery electric vehicles during deceleration maneuvers. The aim is to objectively evaluate the vehicle deceleration by means of reproducible driving maneuvers. In addition to further measurement signals, the longitudinal acceleration signal serves as the main evaluation basis.

Abstract This work puts presents an all-inclusive state of the art bibliographical review of all categories of electrified transportation (xEVs) standards, issued by the most important standardization organizations. Firstly, the current status for the standards by major organizations is presented followed by the graphical representation of the number of standards issued. The review then takes into consideration the interpretation of the xEVs standards developed by all the major standardization organizations across the globe. The standards are differentiated categorically to deliver a coherent view of the current status followed by the explanation of the core of these standards. The ISO, IEC, SAE, IEEE, UL, ESO, NTCAS, JARI, JIS and ARAI electrified transportation vehicles xEV Standards from USA, Europe, Japan, China and India were evaluated. A total approximated of 283 standards in the area have been issued.

Abstract Uncertainties in design represent a considerable industrial stake. Controlling the reliability and robustness of a mechanical system at the level of design has become necessary in order to control these uncertainties. Using the theory of probabilistic design optimization, the present work reports on the application of the concept of reliability-based robustness on minimizing the weight of a planetary gear train (PGT). The optimum combination of reliability and robustness for the minimum weight of the PGT was found using an optimization algorithm based on Particle Swarm Optimization (PSO) and Monte Carlo Simulation (MCS). The algorithm was developed by combining the propagation of uncertainties with the optimization of the function objective within a single probabilistic model. The results show that a reliability-based robust design offers a better alternative to the traditional deterministic design models.