Browse Topic: High voltage systems

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Hybrid Topology Selection & Optimization of a Compact SUV to Meet Future CO2 Norms - an Indian Case Study2026-26-0077To be published on 01/16/2026
Rising environmental concerns and stringent emissions norms are pushing automakers to adopt more sustainable technologies. There is no single perfect solution for any market and there are solutions ranging from biofuels, green hydrogen to electric vehicles. For Indian market, especially in the passenger car segment, hybrid vehicles are favoured when it comes to manufacturers as well as with consumer because of multiple reasons such as reliability, performance, fuel efficiency and lower long-term cost of ownership. For automakers planning to upgrade their fleets in the context of upcoming CAFE III (91.7 g CO2 / km) & CAFE IV (70 g CO2 / km) norms, hybridization emerges as the next natural step for passenger cars. Lately, various state governments have also promoted hybrid vehicle sales by offering certain targeted tax breaks which were previously reserved for EVs exclusively. Current study focuses on various parallel hybrid topologies for an Indian compact SUV, which is the highest
Emran, Ashraf, Sandhu, Rouble, Keizer, Ruben, Warkhede, Pawan
Validation of 0D-1D Co-Simulation Strategies in Cold Climate for ‘Full EV Digital Vehicle’2026-26-0448To be published on 01/16/2026
Electric Vehicles is embedded with increased software algorithms coupled with several physical systems. It demands the efficacy of components which are linked together to build a system. The digital models reviewed in this paper are at system-level and full vehicle-level, comprising several components and control design, analysis, and optimization. Systems pertaining to each functionality such as, AC loop, E-Powertrain, HEVC, Cooling system, Battery Management System, Vehicle control system etc. together make an 'Integrated Digital Vehicle'. Fidelity of Intersystem co-simulation [AMESIM + SIMULINK] is key to validate the thermal and energy management strategies. This paper elucidates the correlation of Digital Vehicle compared to Test for Thermal Strategy in different driving scenarios and Energy management. Validation of Digital vehicle with 52kWh, 40kWh High Voltage Battery for Intercity Travel of Customer usage and WLTP for Cold condition of -7degC). Also, to evaluate range
Sarapalli Ramachandran, Raghuveeran, Srinivasan, Rangarajan, Saravanan, Vivek, Dutta, Souham, Pichon, Martin, Leclerc, Cedric, Guemene, Alexis-Scott
Eliminating High-Voltage Pre-Charge Circuits in Electric Vehicles Using Bidirectional DC-DC Converters2026-26-0075To be published on 01/16/2026
Pre-charge circuit ensure the safety of the electric vehicle. During start up, the pre-charge circuits are critical for managing the initial connection between the high voltage battery and the power electronic system in all electric vehicles. Pre-charge circuits typically consist of resistors and contactors that gradually charge the input capacitors of inverters and DC-link systems to prevent sudden inrush currents that could damage components or trigger faults. However, traditional pre-charge solutions present several limitations like increased component count and system complexity, thermal losses due to resistor dissipation, mechanical wear of contactors over time, Slower start-up response, added cost and potential failure points. This paper introduces a novel method to eliminate conventional pre-charge circuits by utilizing bidirectional DC-DC converters to manage the pre-charge function. Through controlled ramp-up of voltage from the low-voltage system to the high-voltage bus, the
S, Aswathy, R O, Raghi
Thermal Management of High-Voltage Connectors using double-layered Phase-Change Materials (PCM)2026-26-0279To be published on 01/16/2026
Abstract: High Voltage cables and terminals are prone to high temperatures and rapid heat generation due to high current ratings, especially in electric vehicles (EVs). If the temperature exceeds a critical limit, danger may be posed to the components which are connected and the overall safety of the passengers. Traditionally, cooling methods are often energy-intensive and rely on active systems, which may not always be practical for high-power applications. Thus, a localized, fast, and reliable passive thermal management methodology that can be retrofitted into existing connector designs through modifications (e.g., enlargement and PCM integration) would provide significant safety enhancement. The material property of phase change materials, which possess high latent heat, has been used to maintain a steady temperature for a period of time. A dual PCM-layer has been incorporated into the design of the high-voltage connector to serve two purposes:1. The first PCM layer (PCM-1), with
Neogi, Angshuman, Shinde, Shardul
E-drive System Selection Criterion for Hybrid Electric Heavy Commercial Vehicles Segments2026-26-0467To be published on 01/16/2026
Automotive industry expediting progress toward electrification since climate change driven by global warming represents a significant environmental challenge with far-reaching implications. While electric vehicles offer considerable potential for mitigating CO₂ emissions, their elevated upfront costs pose a notable challenge to large-scale market penetration. Hybrid electric vehicles can serve as an effective intermediary solution, bridging the gap between conventional internal combustion engine vehicles and fully electric vehicles, owing to their comparatively lower initial costs. Hybrid electric vehicle component selection is a complex process which has to fulfil multiple requirements fuel economy, performance, drivability, packaging, total cost of ownership of vehicle and comfort. In addition, Hybrid configuration selection also plays a vital role in cost of hybrid electric vehicle. Hence, it is a great challenge to select right powertrain configuration including architecture
Shendge, Raman, Jadhav, Vaibhav, Wani, Kalpesh, Warule, Prasad
An Innovative Crash Sensing System Architecture for Robust functionality of Safety restraints in different Challenging Real World Accident scenarios2026-26-0017To be published on 01/16/2026
Title: An Innovative Crash Sensing System Architecture for Robust functionality of Safety restraints in different Challenging Real World Accident scenarios. Authors: Sunil Kovalam, Harihara Sudhan, Praveen Bansode and Sanjay Gaddamwar Mahindra & Mahindra Ltd Abstract: In the emerging markets especially like India and other similar countries, growing traffic density on the roads leading to different kind of accident types including head on collision, rear end collision, side impact collision and accidents involving with pedestrians or cyclists or two wheelers etc. These accidents could be due to over-speeding, distracted driving and inadequate road infrastructure. Providing necessary safety restraints system (Airbags and Seat belts) and its robust functionality in different real world accident scenarios will be a challenging to vehicle manufactures. It is a high time to redefine the traditional crash sensing architecture strategies with logical approach based on the thorough study of
KOVALAM, SUNIL KUMAR
A procedure for validation of full vehicle CAE models with physical tests for passive safety applications2026-26-0411To be published on 01/16/2026
With the fast development of computational analysis tools and capacities during the past ten years, complex and substantial computer-aided engineering (CAE) simulations are now economically possible. While the cost of crash tests has risen steadily, the fidelity and complexity, which numerical simulations could address, has multiplied keeping the cost of computational analysis more stable. The use of CAE simulations complements physical testing, accelerating the product development process, reducing cost, and ensuring safe and more optimized designs. The fundamental goal of CAE is a significant reduction in the number of physical tests conducted during the product development process. However, validating the CAE model with physical tests is essential to ensure accuracy and reliability. Simulations performed using a validated CAE model could be used to make decisions like airbag deployment or high voltage shutdown without an actual physical test. This paper discusses validating an
UPENDRAN, ANOOP
Evaluation of critical ignition coil parameters for an application On naturally aspirated gasoline engines2026-26-0589To be published on 01/16/2026
Today’s internal combustion engines require highly efficient combustion systems to meet stricter emission and fuel economy regulations. To fulfil to these requirements the ignition system of a gasoline engine plays a critical role. Along with ensuring that it meets the ignition characteristics across all engine operating conditions, it is also possess challenges like to comply with certain On-Board Diagnostics (OBD) norms .To meet these demands modern gasoline engines use inductive type ignition coils which are directly installed at the cylinder head above the spark plug. These ignition coils generate high voltage to produce a certain amount of spark energy and primary coil current which are necessary to meet the targets. However, it has been observed that in a traditional inductive type ignition coil system the ignition coil operating temperature can be a major limiting factor as it cannot exceed a maximum upper limit. The work described in this paper details the various systematic
Ghadge, Ganesh Narayan, Hosur, Viswanatha
Review on the flyback converter design for multi-output2026-26-0200To be published on 01/16/2026
With the increasing demand for DC loads, DC-DC converters have become indispensable in modern power electronic architectures. With high-voltage applications typical DC-DC converter topologies are required which include isolation for safety and voltage level conversion. Among various isolated converter topologies, the flyback converter is widely favored for low-power applications, typically under 100 W, due to its simplicity and cost-effectiveness. Like other DC-DC topologies, the flyback converter can operate in either continuous conduction mode or discontinuous conduction mode (DCM). The work have focused on the design and performance analysis of a flyback converter operating in DCM, with a specific emphasis on magnetic component design and loss evaluation. A 55 W multi-winding flyback converter employing a passive snubber circuit is studied and implemented. The loss analysis is done with switch losses around 3.4W and the coupled inductor core losses around 1.5W and copper losses
S, Denis, Deshpande, Prathamesh Pravin, Deshpande, Rohan
High Voltage Safety for Electric Vehicles from Standards Perspectives2026-26-0188To be published on 01/16/2026
With rise of EV adoption globally, electrical system of EV's are continuously moving towards higher voltage for enabling fast charging capabilities and addressing efficiency. High Voltage electrical safety is a crucial part of safety standards for Electric Vehicles. There are several challenges, when any electrical system operating in High voltage region. This is posing risk for user, it means from design stage these systems should be designed in such a way for safeguarding user. These electric safety concepts are already mapped through different safety standards. In this paper, this high voltage safety related test and functional & constructional requirements will be explored through different EV standards and finally a comparatively analysis carried out.
BHATESHVAR, YOGESH KRISHAN, Mulay, Abhijit B, Santosh Jambhale, Medha, Patil, Sanjay
A strategic approach to the selection of switchgear and busbars for EV battery packs2026-26-0165To be published on 01/16/2026
With the rising adoption of electric vehicles (EVs), the need for robust and efficient power distribution systems has become increasingly important. This paper outlines a strategic method for selecting switchgear and busbars in EV battery packs, emphasizing key factors such as safety, energy efficiency, thermal control, and future scalability. Proper optimization of these components can significantly improve performance, minimize power losses, and ensure durability under demanding operating conditions. The design and selection of battery conducting components, such as switchgears and busbars, are typically based on the maximum continuous and peak current capabilities of the EV battery pack. While this approach ensures that the components can withstand extreme conditions, it often leads to over-engineering, resulting in unnecessary costs and added weight. However, this method overlooks the dynamic power demands of the vehicle, which fluctuate based on driving conditions and usage. Real
Soman, Anu, satheesh, Goutham, K, Mathankumar
Design of the BIW structure for battery pack protection in case of side pole impact.2026-26-0025To be published on 01/16/2026
Electric vehicles (EVs) are becoming more popular than Internal Combustion Engine (ICE) powered vehicles, but their battery and motor components elevate their Gross Vehicle Weight (GVW), posing unique collision risks. Manufacturers strategically mount the high voltage (HV) battery packs under the passenger compartment to lower the Centre of Gravity and shield them from the front impacts. However, side impacts remain a concern, as the battery deformation in such instances could trigger fires or explosions, endangering occupants. To address this, crashworthiness designs adhere to New Car Assessment Program (NCAP) standards, particularly against side pole impact and side mobile barrier impact. Unlike the frontal section of BIW, which typically has larger crush space to absorb the crash energy, extensive design attention is required to the vehicle's side structure to absorb pole impacts without transmitting excessive force to the battery pack. Utilizing aluminium extrusions and sheet
Nivesh, Dharun, NAMANI, Prasad, Ramaraj, Rajasekar
Analysis of High voltage fuse failures due to reverse surge currents flow in the Power distribution unit of Electric vehicles2026-26-0182To be published on 01/16/2026
Commercial Electric vehicles are revolutionizing the transportation industries with zero emission, lower noise level and increased efficiency. But, High voltage (HV) fuse failures due to reverse surge currents in the Power distribution unit (PDU) hampers the field operation and raise the sensitive safety concerns. This paper embarks on an in-depth exploration of the Reverse surge current flows from the DC-DC converter and Auxiliary (AUX) inverters high voltage input side to Traction system high voltage input point. Failures of HV fuses can lead to the unintentional shutdown of the e-compressor system and steering motor system while operating the EV, which raises critical safety concerns. If the steering motor fails, the bus will lose power steering assistance, making the steering wheel much harder to turn. If the e-compressor fails, it could result in loss of braking assist. This could make it difficult to stop the vehicle, especially in an emergency situation or when driving at high
Bamania, Mihir, kinjalkar, Milind, Amancharla, Naga Chaithanya, Salunke, Pradeep
Aircraft Electrical Voltage Level DefinitionsAIR7502A (Current)12/09/2025
The scope of this report will document the various voltage levels and provide a rational for each level as discussed and agreed to in the AE-7 committee.
AE-7C Systems
Arc Damage Assessment of Arc Plume and Physical DamageAIR6982 (Current)11/26/2025
Describes the relative measurement of assessing the damage zone of arc plasma to determine appropriate separation/segregation requirements between a wire harness and nearby components
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Traction Voltage Level in Two-Wheelers: Considerations on Safety and Performance2024-32-006204/18/2025
Most electric 2-wheelers on the market today seek to replace combustion engine vehicles from 50cc to 150cc which equates to an electric motor power between 2 and 12 kW. The traction voltage level of these vehicles is mostly between 44V and 96V. However, the actual choice of voltage on a specific vehicle seems to be arbitrary and higher voltage does not necessarily correlate with higher motor power. This paper seeks to highlight considerations and tradeoffs which feed the choice of traction voltage levels. Important criteria are electrical safety standards and their impact on vehicle electrical architecture, the performance and availability of key electronics parts such as capacitors, MOSFETs, and gate drivers, while also highlighting functional safety aspects. This paper shows by a comprehensive analysis of the motor drive that for the vehicle class mentioned above the traction voltage level can be kept below 60V without any performance impact, while also ensuring electrical and
Schmitt, Stefan
Comparative Analysis of Electromagnetic Radiated Emission for electric powertrain and conventional Spark Ignition (SI) powertrain2024-26-013301/16/2024
Due to the transformation of the automotive industry from conventional vehicles to electric vehicles, new challenges have arrived concerning Electromagnetic Compatibility. Though the Radiated Emission limits are the same for both types of powertrains of vehicles, but due to the phenomena of conversion from high voltage to low voltage, rapid charging/discharging, and different components involved in electric powertrain, Radiated Emission from electric vehicles give a strikingly different trend which is challenging to combat. When comparing with the conventional Spark Ignition vehicle, many other electronic components of electric vehicle stay ON in the “Vehicle Ignition ON” state. Because of this, we observe a significant shift in the amplitude, and frequency throughout the frequency band of Radiated Emission measurement. This paper presents comparative analysis of the changing trends of Radiated Emission from Spark Ignition Engine to the electric powertrain in the “Vehicle Ignition ON
Pawar, Sneha Ravindra, Desai, Manoj Madhukar
Design and Development of a Green Mobile Air Conditioning System for Electric Vehicles2024-26-011501/16/2024
Electric Vehicles (EVs) have rapidly grown as a means for clean mobility, as they zero down tail pipe emission of greenhouse gases. Additionally, greenhouse gases such as Hydro-Fluoro-Carbon (HFCs) based refrigerants used in Mobile Air-Conditioning (MAC) are under global scrutiny for their high Global Warming Potential (GWP). To prevent earth environment to pass the climate tipping point that will be irreversible within human capacity, actions such as rapid phase down of HFCs under Kigali Amendment to Montreal Protocol are enacted. India being amongst signatory nations is now working to fast track phase-down use of high GWP refrigerant and transit to low GWP refrigerant options. Nearly half of national HFCs use and emissions are for manufacture and service MAC. Vehicle OEMs supplying to markets in developing countries (e.g. European nation and non-Article 5 Parties) have already phased out HFC-134a (GWP=1400) through alternate refrigerant solutions. The work presented here discusses a
Venu, Santosh, Mehta, Bhavik Haresh, Panchare, Datta, Maurya, Anurag, Kapoor, Sangeet
Acoustic characterization of AC motor using sound intensity in standard laboratory environments2025-01-001005/05/2023
Sound power is commonly used metric to quantify acoustic sources like AC motor in electrified powertrain. This testing is often performed in an anechoic environment to create free-field conditions around the unit. To eliminate the influence of extraneous noise sources, the anechoic facilities must be further isolated from driver and absorber dynamometers. These dynamometers are needed for running the AC motors in the desired speed and load conditions. For early detection of potential issues, it is advantageous to have the capability for engineers to conduct acoustic tests in standard laboratory environments. These may include non-acoustically treated rooms, presence of extraneous noise sources (e.g., driver and absorber dynos), etc. In such environments, sound intensity-based sound power determination methods could be utilized. The sound intensity-based approach is covered in ISO 9614 standard. The norm is to sweep an intensity probe on a sound source in constant speed condition to
Kumar, Aditya, Ippili, Rajani
The DANA EV NVH Laboratory2025-01-000705/05/2023
A cutting-edge EV powertrain NVH laboratory has been established at DANA Incorporation’s world headquarters in Maumee, enhancing their capabilities in EV powertrain NVH development. This state-of-the-art and industry lead laboratory is designed to meet various NVH requirements for EV powertrain development and sign-off processes. This laboratory supports the use of a live motor for input and is equipped with an input module that allows for detailed examination of NVH characteristics of new powertrain configurations before prototype motors are available, significantly reducing development time for new drivetrain systems. Key features of the laboratory include a hemi-anechoic chamber, two AC asynchronous load motors, an acoustically isolated high-speed input motor, and two battery emulators that cover both low and high voltage requirements. The NVH laboratory enables engineers to assess system performance and correlate it with digital twin models. DANA engineers can develop and optimize
Cheng, Ming-Te, Zugo, Chris
test 09/29/2022 2:00 pmSAE-PP-0773309/29/2022
test 09/29/2022 2:00 pm
Dongari, Madhukar
EXPERIMENTAL SETUP FOR VISUALIZATION OF PLASMA PROPELLED THRUSTERS2022-26-121805/26/2022
Plasma propelled propulsion thrusters(PPPT) is an advance propulsion system for deep space missions ,conventionally chemical propelled thrusters(CPT) are used to carry out space missions. High efficiency and high exhaust velocity will give a plasma propulsion a upper hand, in this project we are creating an visualization setup to visualize the flow of plasma under various electromagnetic fluctuation .plasma is created with the help of high voltage which is induced in a propellent gas (argon) in a ionization chamber . Thus the electron voltage required for argon to ionize is 15.76 Ev . The plasma created in the chamber will be propelled outward with the help of electromagnetic force even know as plasma fluttering technique. Different magnetic intensity will be applied to the vacuum chamber so as to observe the change in plasma because of the change in magnetic field intensity . The plasma will be captured using definition camera . The vacuum chamber is designed using design software's
bali, Rahuljeet singh, KALYAN, 1Lt REPUDI
Model-based thermal control strategy for electrified vehicles2022-01-022903/29/2022
Stringent requirements for high fuel economy and energy efficiency mandate using increasingly complex vehicle thermal systems in most types of electrified vehicles (xEVs). Enabling the maximum benefits of such complex thermal systems under the full envelope of their operating modes demands designing complex thermal control systems. This is becoming one of the most challenging problems for electrified vehicles. Typically, the thermal systems of such vehicles have several modes of operation, constituting nonlinear multiple-input/multiple-output (MIMO) dynamic systems that cannot be efficiently controlled using classical or rule based strategies. This paper covers the different steps towards the design of a model-based control (MBC) strategy that can improve the overall performance of xEV thermal control systems. To achieve the above objective, the latter MBC strategy is applied to control cooling of the cabin and high voltage battery. First, a plant model representative of a real vehicle
Hosseini, Mehrdad, Nahid, Mohammad, Talaei, Behzad, Shojaei, Sina, Ali, Syed Ashraf, Weslati, Feisel, Bouyoucef, Kamal
Novel Nanocrystalline Silver Alloy Coatings to Boost Performance of EV High Voltage Interconnects and Charging Interfaces2022-01-087403/29/2022
Electric vehicle performance needs challenge connector designers and powertrain engineers with new paradigms for performance under more rigorous operational conditions. Traditional connector design protocols direct the engineer to silver plating for the contact interface, but these coatings have a maximum interface temperature of 170 C (ambient temperature plus T-rise). To avoid thermal runaway, engineers have to derate the ampacity of powertrain connections, which reduces available energy delivery as the temperature increases. This is especially true during transient power events like regenerative braking and acceleration. The soft nature of silver coatings make them well suited for power delivery and low contact resistance, but requires an engineering trade-off for wear durability. This is especially problematic for charging connectors which require tens of thousands of mating cycles before failure. In this work, we demonstrate the performance enhancements that can be achieved using
Griffiths, Peteris, HILTY, Robert, Chan, Lisa, Cahalen, John
Eliminating the 12V battery with use of Sine Amplitude Converter modules to create 12V power from the high voltage vehicle battery2022-01-082303/29/2022
The 12V lead-acid car battery is dead. Europe has decreed that no new cars will have lead-acid batteries after 2030, creating a considerable challenge for OEMs to find alternative solutions. Power modules leveraging Sine Amplitude Converter (SAC™) topology enable replacement of the 12V battery by directly converting power from the high voltage (400V or 800V) main vehicle battery. The primary battery (800v/400v) can directly power 12V loads only with high density DC-DC converter with a transient response that meets or exceeds the performance of a 12V battery. Power modules leveraging proprietary SAC topology far exceeds the slew rate—the transient response—of 12V lead-acid batteries in a much smaller and lighter system. A modular approach leveraging SAC can process millions of amperes per second from the high voltage battery to the load eliminating any dips or loads falling out of regulation. Bench testing shows that modular power can deliver a response three times faster than a typical
Kowalyk, Patrick
Modelling of switching characteristics of hydrogen-nitrogen filled DC contactor under external magnetic field 2022-01-088503/29/2022
With an increasing demand for hybrid and battery electric vehicles, it has become imperative to make the electrical switching process safe. In electric vehicles, this process is carried out by compact DC contactors which are designed to withstand years of use over millions of cycles. The quick disconnection is often enabled by an external magnetic field and pressurized hydrogen-nitrogen environment in the contactor. The disconnection process of these contactors leads to the formation of an arc which results from the breakdown of the gas inside the contactor chamber. The breakdown occurs in the inter-connection gap; however, the arc starts to move across the gap between the connectors due to the self-induced magnetic field. The interaction of arcs to the connector's body could lead to undesired metal vapours which could further decrease the creepage distance. In order to contain the arc, an external magnetic field could be applied to move the arc in a fashion that allows for its quick
Ranjan, Rakesh, Thiruppathiraj, Sudharshanaraj, Karpatne, Anand, Breden, Douglas, Raja, Laxminarayan
Comparative Analysis of Protection Systems for DC Power Distribution in Electrified Vehicles2022-01-015303/29/2022
Electric transportation has the potential of mitigating CO2 emissions and reduce fuel needs. One of the challenges for the growth of this industry is limited range and efficiency of the vehicles associated with battery storage systems and electric drive technology. High voltage systems are expected to increase efficiency and then vehicle mileage, however this increases the severity of the fault conditions, especially in case of short circuit. Melting fuse is commonly used for the purpose of protection in electrified vehicles, while it is effective and reliable, there are several shortcomings such as lack of precision, effect of ambient temperature, bulky, interruption time depending on the fault condition etc. Additionally, the on-board DC power distribution system (PDS) is characterized by low impedance, in this environment fuses are not able to limit the fault current leading to damage of electronics and hazard for the battery pack. Thus, advanced protection systems such as pyro
Bavishi, Harsh, D'Arpino, Matilde, Ramesh, Prashanth, Guezennec, Yann, Colbert, Ian
Polyetherimide for magnet wire application 2022-01-040003/29/2022
Magnet wire is composed of conducting core and thin layer of electrical insulation. Cupper (Cu) is typically used as conducting core, and various polymers such as polyamideimide, polyimide, and polyesterimide are used for electrical insulation. The role of magnet wire is involved in interchanging between electrical energy and mechanical energy for energy transformation application such as transformer, motor, generator, and many other equipment. Currently, electric vehicles (EV) industry is rapidly growing and consequential demands on related components are increasing as well. Compared to combustion engine, EV needs more electrical power with higher voltages or higher currents, which can increase probability of electrical discharge. The degradation of insulation layer can happen with the polymer bond breakage under the partial discharge electric stresses. To keep high performance under higher voltage, insulating polymer should have high heat resistances, chemical resistance, and low
Kim, Sang Hoon, Lee, Dae Ho
Case Study on Optimized Cooling System Concept for Electric Compact-SUV with Indian Environmental Conditions2021-26-041009/22/2021
With the rising emission level in Indian cities, the focus on pure battery electric vehicle is increasing also in India. The Government of India his also focusing on preparing right policies like FAME-2 to promote the acceptability of EV's by providing subsidies as well as creating the required infrastructure. The environmental conditions in India is much different than other developed countries of Euro, China etc. The max. temperatures in India can go up to 55℃ in the hottest summer time, while during winters temperature can go up to <-25℃ in the northern Himalia region. In these conditions the cooling system of the electric-powertrain components like E-Machine Battery pack etc have to be protected for worst case scenarios specific to Indian conditions. Major cost driver of EV's lie in the HV battery packs and it is very important for acceptability of EV's that the Battery is maximized. With fast discharging and charging phenomena of battery pack required in automotive application can
Emran, M.Sc. Ashraf, Garg, Shivam, Manns, M.Sc. Patrick, Sharma, Vijay
Optimized Power Utilization of Air Conditioner in Electric City Bus Using Occupant Detection2021-26-014209/22/2021
Electric vehicles have a limitation of limited range and long charging time. Energy optimization plays a very crucial role in determining the range of an electric vehicle. The innovative system proposed here gives the opportunity to reduce energy wastage and efficiently direct the electrical energy to improve the driving range of a 9 meter AC electric bus. The high voltage air conditioner unit alone consumes more than 40% of the electrical energy stored in the traction battery which reduces the driving range of the electric bus drastically. The proposed system optimizes the air conditioner utilization to direct cool air only in areas where passengers are present. Buses do not always run on full capacity, when there are less number of people in the bus the system detects the locations of the passengers using sensors and occupant detection algorithm, this enables the controller to identify the areas where cooling has to be focused and where cooling can be reduced or stopped. Once the
Nesamani, Kevin, Pandey, Ramakant, Jain, Rajesh
A Comparative Study on the Ignition Mechanism of Multi-site Ignition and Continuous Discharge Strategy2021-01-116209/21/2021
Advanced combustion engines dominate all automotive applications. Future high efficiency clean combustion engines can contribute significantly to sustainable transportation. Effective ignition strategies are studied to enable lean and diluted combustion under considerably high-density mixture and strong turbulences, for improving the efficiency and emissions of future combustion engines. Continuous discharge and multi-site ignition strategies have been proved to be effective to stabilize the combustion process under lean and EGR diluted conditions. Continuous discharge strategy uses a traditional sparkplug with a single spark gap and multiple ignition coil packs. The ignition coil packs operate under a specific time offset to realize a continuous discharge process with a prolonged discharge duration. Multi-site ignition strategy also uses multiple ignition coil packs. The ignition coil packs are connected with a specially designed multi-core sparkplug, which has multiple high voltage
Sandhu, Navjot Singh, Yu, Xiao, Zhu, Hua, Chen, Guangyun, Liu, Mengzhu, Li, Liguang, Zheng, Ming
Assembly and Soldering Criteria for High Quality/High Reliability Soldering Wire and Cable Termination in Aerospace VehiclesAS4461D (Current)07/23/2021
This standard is applicable to manual soldering and machine soldering processes utilizing controlled soldering devices, for electrical connections for wiring and cabling used in aerospace vehicles. Description of a component or device herein is not to be construed as authorizing the use of the component or device.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Assembly and Soldering Criteria for High Quality/High Reliability Soldering Wire and Cable Termination in Aerospace VehiclesAS4461D-TEST-REC (Historical)07/23/2021
This standard is applicable to manual soldering and machine soldering processes utilizing controlled soldering devices, for electrical connections for wiring and cabling used in aerospace vehicles. Description of a component or device herein is not to be construed as authorizing the use of the component or device.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Unshielded High Voltage Primary CableJ1654_202107 (Current)07/15/2021
This SAE Standard covers unshielded cable, 22 gauge and larger, intended for use at a nominal system voltage up to 600 V or 1000 V (ACrms or DC). It is intended for use in surface vehicle electrical systems.
Cable Standards Committee
Unshielded High Voltage Primary CableJ1654_202107-TEST-REC (Historical)07/15/2021
This SAE Standard covers unshielded cable, 22 gauge and larger, intended for use at a nominal system voltage up to 600 V or 1000 V (ACrms or DC). It is intended for use in surface vehicle electrical systems.
Cable Standards Committee
Investigating the Effect of Water and Oxygen Distributions on Consistency of Current Density Using a Quasi-Three-Dimensional Model of a PEM Fuel Cell2021-01-073704/06/2021
Activation loss, mass transfer loss and ohmic loss are the three main voltage losses of the polymer electrolyte membrane fuel cell. While the former two types are relevant to concentration of oxygen in catalyst layer and the later one is associated with the water content in membrane. Distributions of water content and oxygen in a single cell are inconsistent which cause that current densities in each segment of the single cell are different. For the dry inlet gas, the water in the segments near the gas inlet channel will be carried to the segments near the gas outlet channel, which causes high ohmic loss of the segments near the gas inlet channel. In this work, a transfer non-isothermal quasi-three-dimensional model is developed to investigate inconsistency of current densities. Comprehensive physical and chemical phenomena inside the cell are included, especially the mass transfer of hydrogen, oxygen, vapor and liquid water in gas channels, gas diffusion layer and catalyst layer and
Wang, Xuhui, Lu, Yikang, Zhang, Baitao, Xu, Sichuan
Evaluation of 48V and High Voltage Parallel Hybrid Diesel Powertrain Architectures for Class 6-7 Medium Heavy-Duty Vehicles2021-01-072004/06/2021
Electrification of heavy-duty trucks has received significant attention in the past year as a result of future regulations in some states. For example, California will require a certain percentage of tractor trailers, delivery trucks and vans sold to be zero emission by 2035. However, the relatively low energy density of batteries in comparison to diesel fuel, as well as the operating profiles of heavy-duty trucks, make the application of electrified powertrain in these applications more challenging. Heavy-duty vehicles can be broadly classified into two main categories; long-haul tractors and vocational vehicles. Long-haul tractors offer limited benefit from electrification due to the majority of operation occurring at constant cruise speeds, long range requirements and the high efficiency provided by the diesel engine. However, vocational applications can realize a significant benefit from electrified powertrains due to their lower vehicle speeds, frequent start-stop driving and
Dahodwala, Mufaddel, Joshi, Satyum, Dhanraj, FNU, Ahuja, Nitisha, Koehler, Erik, Franke, Michael, Tomazic, Dean
Pyrofuse Modeling for eVTOL Aircraft DC Protection2021-01-004103/02/2021
Contemporary trends are leading towards the electrification of aircraft for urban mobility applications. Accordingly, there is a high demand for advancements in light-weight, high voltage technologies to realize these new aircraft types. Driven by recent developments in the automotive industry, hybrid Pyrofuse protection devices have emerged as one such new candidate technology. Pyrofuses offer rapid clearance of fault currents, reduced cost and weight when compared to conventional mechanical breakers. In addition, Pyrofuses have the ability to tune the time-current curve to fit the application’s fault response characteristics. However, Pyrofuses are non-resettable devices whose exclusive use for electrical protection could present potential operational hazards and certification challenges in aerospace applications. Model-based analysis will be critical in supporting this evaluation. Accordingly, this paper offers the first complete design methodology to transiently model Pyrofuse
Altouq, Shadan, Fong, Kenny, Norman, Patrick, Burt, Graeme
Aircraft Electrical Voltage Level DefinitionsAIR7502 (Historical)01/27/2021
The scope of this report will document the various voltage levels and provide a rational for each level as discussed and agreed to in the AE-7 committee.
AE-7C Systems
Cable Marking for Circuit Identification in Multi-Voltage Power Distribution SystemsJ3176_202101 (Current)01/13/2021
This SAE Standard establishes the minimum circuit identification and requirements for Multi-Voltage Power Distribution Systems (MVPDS) for use on trucks and buses. A Multi-Voltage Power Distribution System is one that distributes two or three voltages, up to 60 VDC, to power the controls, instruments, and devices.
Truck and Bus Electrical Systems Committee
Selecting the Best Power Supply for Your Stepper or Servo Motor ApplicationTBMG-3814212/01/2020
Motion control applications have some unique requirements compared to most applications; two are particularly unique: 1) they have a peak power demand that is typically very high relative to the average demand and 2) the motors often act as a generator rather than as a load, and pump current into the power supply rather than drawing from it (regenerated energy or “regen”).
Switch-Mode Power Supply (SMPS) Emissions Filtering: Attenuation vs. Leakage Trade-OffTBMG-3806111/01/2020
The AC/DC power converter is often the sole interface between a piece of equipment and a building’s electrical installation, which is in turn connected to any number of other off-line systems. It is also the element separating the hazardous high voltage mains from user-facing safety extra low voltage (SELV) networks. Accordingly, AC/DC power converters fall under a great deal of regulatory scrutiny, with mandates ranging from energy efficiency to safety to electromagnetic immunity and emissions. The requirements of each regulatory authority can often spawn contradictions in the resulting engineered solutions.
Long-life Batteries for the IIoTTBMG-3766509/01/2020
The remote wireless devices used throughout the Industrial Internet of Things (IIoT) should use long-life lithium batteries to deliver reliable performance that reduces the total cost of ownership. Using long-life lithium batteries can eliminate the need for hard-wiring devices to AC power, which can cost as much as $100/ft, or even more in remote locations.
Cellulose-Based Sensor Simultaneously Measures Pressure, Temperature, and HumidityTBMG-3748108/01/2020
Researchers have developed a single sensor that combines the ability to measure pressure, temperature, and humidity simultaneously. The sensor has applications such as monitoring patients at home, robotics, electronic skin, functional textiles, surveillance, and security.
Design of a Mild Hybrid Electric Vehicle with CAVs Capability for the MaaS Market2020-01-143704/14/2020
There is significant potential for connected and autonomous vehicles to impact vehicle efficiency, fuel economy, and emissions, especially for hybrid-electric vehicles. These improvements could have large-scale impact on oil consumption and air-quality if deployed in large Mobility-as-a-Service or ride-sharing fleets. As part of the US Department of Energy's current Advanced Vehicle Technology Competition (AVCT), EcoCAR: The Mobility Challenge, Mississippi State University’s EcoCAR Team is redesigning and doing the development work necessary to convert a conventional gasoline spark-ignited 2019 Chevy Blazer into a hybrid-electric vehicle with SAE Level 2 autonomy. The target consumer segments for this effort are the Mobility-as-a-Service fleet owners, operators and riders. To accomplish this conversion, the MSU team is implementing a P4 mild hybridization strategy that is expected to result in a 30% increase in fuel economy over the stock Blazer. MATLAB models of the vehicle system
Taoudi, Amine, Haque, Moinul Shahidul, Strzelec, Andrea, Follett, Randolph
Vehicle Design Considerations Enabling High-Performance Charging2020-01-144004/14/2020
Customer requirements such as range anxiety and charging time are the driver for increasing the charging power of battery-electric vehicles (BEV). High-performance charging (HPC) theoretically enables time targets of faster than 30 kilometers (19 miles) recharging per minute. Due to physical limitations (i.e., current limits of the components) a charging power of more than 200 kilowatt arises the question of the voltage level required to fulfill the power demand. One possible approach to achieve a high charging power is increasing the battery voltage, i.e., increase the voltage level from 400 V to 800 V. This publication discusses the main aspects of charging by incorporating all high-voltage components in the vehicle. An increase of the voltage level and charging power affect all high-voltage components. The thermal management of the battery has to be considered. High-voltage vehicle architecture design considerations are discussed including thermal-management and battery-design
Paar, Christian Josef, Waser, Helmut Martin, Kreimaier, Heimo, Cuenca-Jaen, Inés, Eibler, Florian
Choose Surface Treatments Early to Avoid Future ProblemsTBMG-3638504/01/2020
Too often, design engineers look at coating parts as an afterthought. Rather than being part of the discussion in the early stages of design, engineers sometimes try to solve problems with coatings during — or even after — manufacturing. While surface treatments such as anodizing, electroplating, and thermal spray provide their own unique set of properties and benefits, these processes also have limitations that demand attention early in the design process to ensure optimal performance.
GM underway with plan to build U.S. electric-vehicle charging infrastructure19AUTP09_1009/01/2019
Tesla has its coveted Supercharger network of high-voltage fast chargers, but despite a widely-discussed goal of contributing to a future with zero vehicle emissions, Mike Abelson, General Motors' vice president of EV infrastructure, admitted at the 2019 CAR Management Briefing Seminars conference that his company doesn't “wish to spend our capital to build (DC) fast chargers-we wish to spend our capital to build more electric vehicles.” Abelson said an extensive and robust public EV charging network-one presumably populated mostly with high-voltage, direct-current fast chargers-is “the key to convince people the EV really can be their primary vehicle.” The company's VP of EV infrastructure (a relatively new position at GM, incidentally) said the nation still doesn't have nearly enough so-called “enroute” charging, citing the conference's northern-Michigan locale as an example. Abelson showed a map of the state's uppermost region that indicated not a single DC fast-charger to
Visnic, Bill
Automotive Engineering: June 201919AUTP0606/06/2019
Rethinking aluminum for NVH abatement Engineers, abandon those mastics! New "quiet" materials solutions are at hand. Paradigm shift in NVH A new wave of vehicle technologies is changing the way Brüel & Kjaer attacks noise, vibration and harshness. How a Tier 2 tackles NVH Saint-Gobain invested in anechoic testing so small components can make a big NVH difference. Reducing NVH through refined powertrain measurement The C1000 vastly simplifies measuring the mass matrix of heavy, odd shaped engines and powertrains. Foam for NVH solutions New innovations for a wide variety of sound-deadening applications. Long time coming: 2020 Corvette After six decades of teasing enthusiasts with intriguing concepts, Chevrolet is launching an all-new Corvette with its engine located where Zora intended-behind the driver. Protecting high-voltage circuits Yazaki readies a new solution for arc suppression in circuits of 48V or more. Editorial The unforgettable pyramid on the hood Supplier Eye Enter the
Protecting high-voltage circuits19AUTP06_0706/01/2019
Yazaki readies a new solution for arc suppression in circuits of 48V or more. As OEMs develop their next-generation electrical architectures aimed at new hybrid, EV and autonomous vehicles, engineers are focused on delivering systems that are even more robust and “fail-safe” than those used today. Handling more power safely is a given, experts say, as more power-gobbling heated seats, electric turbos, active suspensions, lidars, on-board data processors and other safety sensors are added. “The industry is now undergoing a fundamental change in how much electrical power is being used,” observed Eric Varton, chief engineer of advance development for Yazaki North America Core Engineering. He noted that the typical 12V vehicle architecture launched in the early 1960s is only capable of deliveing around 2 kW power. In an autonomous vehicle, the autonomous Drive module alone could consume 2 kW.
Brooke, Lindsay
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