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Abstract Carbon fiber reinforced plastic (CFRP) has been used in automobiles as well as airplanes. Because of its light weight and high strength, CFRP is a good choice for making vehicle bodies lighter, which would improve fuel economy. Conventional metal bodies provide a convenient body return for electric wiring and offer good shielding against electromagnetic fields. Although CFRP is a conductor, its conductivity is much lower than that of metals. Therefore, CFRP bodies are usually not useful for electric wiring. In thunderstorms, an automotive body is considered to be a Faraday cage that protects the vehicle’s occupants from the potential harms of lightning. Before CFRP becomes widely applied to automotive bodies, its electric and electromagnetic properties need to be investigated in order to determine whether it also works as a Faraday cage against lightning. In this article, CFRP and metal body vehicles were tested under artificial lightning.

Abstract This article presents a fault diagnosis approach for roller bearing by applying the autocorrelation approach to filtered vibration measured signal. An optimal Morlet wavelet filter is applied to eliminate the frequency associated with interferential vibrations; the raw measured signal is filtered with a band-pass filter based on a Morlet wavelet function whose parameters are optimized based on maximum Kurtosis. Autocorrelation enhancement is applied to the filtered signal to further reduce the residual in-band noise and highlight the periodic impulsive feature. The proposed technique is used to analyze the experimental measured signal of investigated vehicle gearbox. An artificial fault is introduced in vehicle gearbox bearing an orthogonal placed groove on the inner race with the initial width of 0.6 mm approximately. The faulted bearing is a roller bearing located on the gearbox input shaft - on the clutch side.

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 ISO 26262 needs to be considered when developing safety-relevant E/E systems within the automotive industry. One part of the development process according to ISO 26262 is the derivation of the safety requirements for component functions. Here, one attribute of the safety requirements is the Automotive Safety Integrity Level (ASIL). The ASIL at a component level can be determined using ASIL allocation and decomposition. Considering complex systems such as vehicle electrical systems, countless possibilities can be identified for how the ASILs at a component level can be assigned in line with safety goals. In terms of efficiency, manual assignment is not expedient. Therefore, an algorithm for automated assignment of the ASILs will be introduced which considers constraints based on a fault tree analysis. The function of the approach will be demonstrated using the example of a vehicle electrical system from an automated vehicle.

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 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 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 Catalytic converters, a primary component in most automotive emissions control systems, do not function well until they are heated substantially above ambient temperature. As the primary energy for catalyst heating comes from engine exhaust gases, plug-in hybrid electric vehicles (PHEVs) that have the potential for short and infrequent use of their onboard engine may have limited energy available for catalytic converter heating. This article presents a comparison of multiple hybrid supervisory control strategies to determine the ability to avoid engine cold starts during a blended charge-depleting propulsion mode. Full vehicle and catalytic converter simulations are performed in parallel with engine dynamometer testing in order to examine catalyst temperature variations during the course of the US06 City drive cycle. Emissions and energy consumption (E&EC) calculations are also performed to determine the effective number of engine starts during the drive cycle.

Abstract The purpose of this article is to reduce the adverse effects of temperature rise on the electrical connector, reduce the failure risk of electrical connector due to the mismatch of current-carrying capacity selection, and improve the service life of the electrical connector. This article takes a certain type of vehicle electric connector as the research object. An accurate contact pair model of the electrical connector is established by SOLIDWORKS software. The force and thermoelectric coupling simulation analysis of the 3D solid model with reasonable load and boundary conditions was carried out by ABAQUS software. The results show that the insertion force and positive force of the electrical connector terminal are in line with the values specified in the standard.

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.

Abstract As electric vehicles (EVs) begin to increase their market share in the transport sector, the efficiency of battery packs becomes critical to their performance. Within large battery packs, cell variations occur due to manufacturing processes but can also become prominent during operation due to ineffective thermal management and accelerated degradation of some cells. A battery management system (BMS) will generally account for variations in state of charge (SOC) for cells in series through balancing, but conventional BMSs do not tend to consider the imbalances of cells in parallel as their SOCs should eventually converge themselves. This can, however, lead to cells experiencing higher currents and therefore increased degradation compared to other cells within the pack.