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Technical Paper

Design Analysis of High Power Density Additively Manufactured Induction Motor

2016-09-20
2016-01-2061
Induction machines (IM) are considered work horse for industrial applications due to their rugged, reliable and inexpensive nature; however, their low power density restricts their use in volume and weight limited environments such as an aerospace, traction and propulsion applications. Given recent advancements in additive manufacturing technologies, this paper presents opportunity to improve power density of induction machines by taking advantage of higher slot fill factor (SFF) (defined as ratio of bare copper area to slot area) is explored. Increase in SFF is achieved by deposition of copper in much more compact way than conventional manufacturing methods of winding in electrical machines. Thus a design tradeoff study for an induction motor with improved SFF is essential to identify and highlight the potentials of IM for high power density applications and is elaborated in this paper.
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Technical Breakthroughs in Development of a Single Motor Full Hybrid System

2011-11-18
The energy crisis and rising gas price in the 2000s led to a growing popularity of hybrid vehicles. Hyundai-Kia Motors has been challenging to develop the new efficient eco-technology since introducing the mild type compact hybrid electric vehicle for domestic fleet in 2004 to meet the needs of the increasing automotive-related environmental issues. Now Hyundai has recently debuted a full HEV for global market, Sonata Hybrid. This system is cost effective solution and developed with the main purpose of improving fuel consumption and providing fun to drive. Presenter Seok Joon Kim, Hyundai Motor Company
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Achieving a Lightweight and Steel-Intensive Body Structure for Alternative Powertrains

2012-02-14
FutureSteelVehicle's (FSV) objective is to develop detailed design concepts for a radically different steel body structure for a compact Battery Electric Vehicle (BEV). It also will identify structure changes to accommodate larger Plug-In Hybrid (PHEV) and Fuel Cell (FCEV) vehicle variants. The presentation will demonstrate seven optimized structural sub-systems that contribute to the program's 35 percent mass reduction goals and meet its safety and life cycle emissions targets. It will explain the advanced design optimization process used and the resulting aggressive steel concepts. Presenter Jody R. Shaw, US Steel
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Neural Network-based Optimal Control for Advanced Vehicular Thermal Management Systems

2011-12-05
Advanced vehicular thermal management system can improve engine performance, minimize fuel consumption, and reduce emissions by harmoniously operating computer-controlled servomotor components. In this paper, a neural network-based optimal control strategy is proposed to regulate the engine temperature through the advanced cooling system. Presenter Asma Al Tamimi, Hashemite University
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Cooling Airflow System Modeling in CFD Using Assumption of Stationary Flow

2011-11-29
Battery Electric Vehicles and Extended Range Electric Vehicles, like the Chevrolet Volt, can use electrical energy from the Grid to meet the majority of a driver�s transportation needs. This has the positive societal effects of displace petroleum consumption and associated pollutants from combustion on a well to wheels basis, as well as reduced energy costs for the driver. CO2 may also be lower, but this depends upon the nature of the grid energy generation. There is a mix of sources � coal-fired, gas -fired, nuclear or renewables, like hydro, solar, wind or biomass for grid electrical energy. This mix changes by region, and also on the weather and time of day. By monitoring the grid mix and communicating it to drivers (or to their vehicles) in real-time, electrically driven vehicles may be recharged to take advantage of the lowest CO2, and potentially lower cost charging opportunities.
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Transesterification of Waste Cooking Oil in Presence of Crushed Seashell as a Support for Solid Heterogeneous Catalyst

2011-12-05
Developing relatively cheap and widely available resources for heterogeneous solid catalyst synthesis is a promising approach for biodiesel fuel industry. Seashell which is essentially calcium carbonate can be used as a basic support for transesterification heterogeneous catalysts. In the present investigation, the alcoholysis of waste frying oil has been carried out using seashell-supported K3 PO4 as solid catalyst. Presenter Essam Oun Al-Zaini, PhD student, UNSW
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Supplier Discussions - 2012

2012-03-29
Trans Tech recently debuted the all-electric eTrans school bus providing a total zero emission school bus. The presentation will demonstrate Smith Electric Vehicles and their history with electric vehicles. The presentation will help ensure that everybody has an idea of what the electric school bus will do and to dispel any rumors about the vehicle. Presenter Brian S. Barrington, Trans Tech. Bus
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Enabling New Optical Fiber Applications in Avionics Networks

2012-03-21
Optical fiber has begun replacing copper in avionic networks. So far, however, it has been mainly restricted to non-critical applications (video transmission to the flight deck, IFE?). In order to take advantage of the high-bandwidth, low weight, no EMI properties of optical fibers in all data transmission networks, it will be necessary to improve the testing. One part of the puzzle, which is still missing, is the self-test button: the possibility to check the network and detect potential failures before they occur. The typical testing tool of a technician involved in optical fiber cables is the ?light source ? optical power meter? pair. With this tool, one can measure the insertion loss of the fiber link. A second important parameter, the return loss at each optical connector, is not analysed. In addition, this is only a global measurement, which does not allow the detection of possible weak points.
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Ice Phobic Coatings for Control and Covered Surfaces

2012-03-14
Silicones have been utilized in multiple industries in the last 50 years and their applications are still expanding as technology grows. Ice phobic coatings, as an example, have been utilized on lock walls, navigation channels, wind turbines, hydropower intakes, and aircraft. Without protection these applications have a high risk of failure in the functions they perform. For example, ice build up on an aircraft?s aerodynamic surfaces increases drag which reduces lift during flight operations. Utilizing a silicone ice phobic coating significantly reduces the adhesion of ice to aerodynamic surfaces. Compared to other polymeric materials, silicones are known for their broad operating temperature range and lend themselves to excellent performance in a variety of harsh environments. Especially in low temperatures where ice adhesion is a concern, silicones retain their elastomeric physical properties and low modulus.
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High Speed Machining of CFRP Parts

2012-03-16
High Speed Machining of CFRP Parts Investigation of the influence of new geometries, cutting datas and coolant capabilities on the surface finish of CFRP parts. State of the art: Different CFRP grades and machining conditions make geometry adjustments to the tool necessary. Mechanical failures through machining operations can be avoided in most of the cases. New unidirectional CFRP grades and dry machining processes again lead to machining problems. This study investigates new geometries to avoid heat damage with dry maching and air coolant in case of unidirectional CFRP. With help of a thermo camera and the surface investigation with a scanning electron microscope, heat damage can be analysed and therefore new geometries can be developed and tested. Target is to develop a new multi purpose CFRP geometry to meet the requirements of the future. The reduction of different geometries used leads to major cost savings. Presenter Ingo von Puttkamer, Guhring oHG
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Tailored Conversion Coatings for Enhanced Adhesion to Metal

2012-03-21
As a result of recommendation from the Augustine Panel, the direction for Human Space Flight has been altered from the original plan referred to as Constellation. NASA's Human Exploration Framework Team (HEFT) proposes the use of a Shuttle Derived Heavy Lift Launch Vehicle (SDLV) and an Orion derived spacecraft (salvaged from Constellation) to support a new flexible direction for space exploration. The SDLV must be developed within an environment of a constrained budget and a preferred fast development schedule. Thus, it has been proposed to utilize existing assets from the Shuttle Program to speed development at a lower cost. These existing assets should not only include structures such as external tanks or solid rockets, but also the Flight Software which has traditionally been a ?long pole? in new development efforts. The avionics and software for the Space Shuttle was primarily developed in the 70's and considered state of the art for that time.
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Copper-Rotor Induction- Motors: One Alternative to Rare Earths in Traction Motors

2012-05-16
The copper-rotor induction-motor made its debut in automotive electric traction in 1990 in GM's Impact EV. Since then, this motor architecture has covered millions of miles on other vehicle platforms which will soon include Toyota's RAV4-EV. With the industry's attention focused on cost-effective alternatives to permanent-magnet traction motors, the induction motor has returned to the spotlight. This talk will overview where the copper-rotor induction-motor is today, how the technology has evolved since the days of the GM Impact, the state-of-play in its mass-manufacturing processes and today's major supply-chain players. Presenter Malcolm Burwell, International Copper Association Inc.
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Monitoring the Progression of Micro-Pitting in Spur Geared Transmission Systems Using Online Health Monitoring Techniques

2012-03-16
Micro-pitting is a fatigue effect that occurs in geared transmission systems due to high contact stress, and monitoring its progression is vital to prevent the eventual failure of the tooth flank. Parameter signature analysis has been successfully used to monitor bending fatigue failure and advanced phases of gear surface fatigue failure such as macro-pitting and scuffing. However, due to modern improvements in steel production the main cause of gear contact fatigue failure can be attributed to surface micro-pitting rather than sub-surface phenomena. Responding to the consequent demand to detect and monitor the progression of micro-pitting, this study experimentally evaluated the development of micro-pitting in spur gears using vibration and oil debris analysis. The paper presents the development of an online health monitoring system for use with back-to-back gear test rigs.
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Orbital Drilling Machine for One Way Assembly in Hard Materials

2012-03-23
In Aeronautic industry, when we launch a new industrialization for an aircraft sub assembly we always have the same questions in mind for drilling operations, especially when focusing on lean manufacturing. How can we avoid dismantling and deburring parts after drilling operation? Can a drilling centre perform all the tasks needed to deliver a hole ready to install final fastener? How can we decrease down-time of the drilling centre? Can a drilling centre be integrated in a pulse assembly line? How can we improve environmental efficiency of a drilling centre? It is based on these main drivers that AIRBUS has developed, with SPIE and SOS, a new generation of drilling centre dedicated for hard materials such as titanium, and high thicknesses. The first application was for the assembly of the primary structure of A350 engine pylons. The main solution that was implemented meeting several objectives was the development of orbital drilling technology in hard metal stacks.
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Study of Exit Burr Formation and Exit Burr Reduction in Automated Drilling of Titanium Stacked With Carbon Fiber Composite

2012-03-16
A series of flight tests were conducted to design and evaluate a Combined Vision System (CVS) that integrates a forward looking infrared video image with synthetic vision on a primary flight display. System features included colorizing the video image to mesh with the synthetic terrain background, decluttering the approach symbology to facilitate the detection of the approach lights and runway markings, creating a semi-transparent IR sky to ensure continuous situational awareness of the surrounding terrain, and annunciating the decision height to facilitate the transition to the actual runway environment. Over 100 approaches were flown during three flight test sessions. For the first flight test session pilots reviewed early CVS proofs of concept on Honeywell's Citation Sovereign.
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NHTSA Lightweighting and Safety Studies

2012-05-29
This paper presents a new concept for a 100% plastic prototype automotive door panel. This concept has the potential of providing a weight reduction of up to 40% compared to conventional steel door panels, but with equivalent performance (static strength). This innovative technology can be used for a variety of exterior automotive parts. The concept includes a composite sandwich panel combination of GFRP (glass fiber reinforced polymer), and LACTIF®, which is expanded beads foam made from PLA (polylactic acid) and developed by JSP Corporation. This GFRP+LACTIF® composite design offers the following characteristics: Excellent environmental resistance Strong adhesion Equivalent static strength (vs. conventional door panels) Design flexibility This concept also offers an alternative to conventional steel door panel systems by using unsaturated polyester material of plant origin as part of the GFRP composite.
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Lightweight Door Panel Made with Bio-Based Composite Material

2012-05-23
TERBAN® hydrogenated nitrile rubber (HNBR) is a specialty elastomer used in demanding engineering applications such as the automotive, heavy duty, and industrial markets. It has excellent combination of heat, oil and abrasion resistance in addition to its high mechanical strength, very good dynamic and sealing properties. This paper will present data on aging HNBR for five thousand hours in an aggressive and un-stabilized B30A biodiesel fuel blend (70% ULSD, 30% SME, and an aggressive additive package) and explore the effect of HNBR polymer properties and vulcanizate composition on the performance in such fuel blends. Presenter Victor Nasreddine
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Development of High Strength Polymer Based Bearing for Automotive Parts under Boundary Lubrication

2012-05-23
Composite bearings of PTFE as the base material have been widely used for automotive parts. However, in recent years, due to downsizing, faster sliding speeds, and tendency to increase the bearing load with high performance, particularly for boundary lubrication conditions, the PTFE-based composite bearing is often worn, making it difficult to apply to some applications. A high strength polymer was selected as an alternative to PTFE base material, and the mechanical properties and performance in a start-stop test, reciprocating sliding test and seizure test were evaluated. Focusing on the characteristics of high strength, by applying a PEEK resin, in each evaluation, it was confirmed that superior performance was achieved compared with a conventional PTFE based composite bearing. Presenter Yohei Takada, Daido Metal Co., Ltd.
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