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 Damage

AIR6982 (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

Multirotor UAS Wind Disturbances Rejection Using Dedicated Lateral Thrusters with Frequency-Split Control

F-0081-2025-0143

5/20/2025

Precision flight in windy conditions is a common challenge for multirotor UAS. It is especially challenging for in contact tasks that require high-precision positioning and good disturbance rejection capabilities. Such tasks include landing on high-voltage powerlines for in-contact inspections. This paper presents the implementation of small lateral thrusters to improve the lateral position hold ability of a large power line inspection UAS in windy conditions. Arranged in antagonistic pairs on each side, the lateral thrusters handle the high-frequency but smaller-amplitude wind turbulence components with a frequency split control. Using an identified model of the UAS flight dynamics alongside flight data in high-wind conditions, a control architecture with a frequency split in the lateral axis was optimized to increase the disturbance rejection. Experimental tests showed a 67% reduction in lateral position error with the proposed approach in high-wind conditions.

Leclerc, Marc-Antoine, Rancourt, David, Lussier Desbiens, Alexis

Traction Voltage Level in Two-Wheelers: Considerations on Safety and Performance

2024-32-00624/18/2025

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) powertrain

2024-26-01331/16/2024

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 Vehicles

2024-26-01151/16/2024

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 environments

2025-01-00105/5/2023

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 Laboratory

2025-01-00075/5/2023

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 pm

SAE-PP-077339/29/2022

test 09/29/2022 2:00 pm

Dongari, Madhukar

EXPERIMENTAL SETUP FOR VISUALIZATION OF PLASMA PROPELLED THRUSTERS

2022-26-12185/26/2022

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 vehicles

2022-01-02293/29/2022

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 Interfaces

2022-01-08743/29/2022

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 battery

2022-01-08233/29/2022

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

2022-01-08853/29/2022

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 Vehicles

2022-01-01533/29/2022

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

2022-01-04003/29/2022

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 Conditions

2021-26-04109/22/2021

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 Detection

2021-26-01429/22/2021

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 Strategy

2021-01-11629/21/2021

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 Vehicles

AS4461D (Current)

7/23/2021

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 Vehicles

AS4461D-TEST-REC (Historical)7/23/2021

AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install

Unshielded High Voltage Primary Cable

J1654_202107 (Current)

7/15/2021

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 Cable

J1654_202107-TEST-REC (Historical)7/15/2021

Cable Standards Committee

Evaluation of 48V and High Voltage Parallel Hybrid Diesel Powertrain Architectures for Class 6-7 Medium Heavy-Duty Vehicles

2021-01-07204/6/2021

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

Investigating the Effect of Water and Oxygen Distributions on Consistency of Current Density Using a Quasi-Three-Dimensional Model of a PEM Fuel Cell

2021-01-07374/6/2021

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

Pyrofuse Modeling for eVTOL Aircraft DC Protection

2021-01-00413/2/2021

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 Definitions

AIR7502 (Historical)

1/27/2021

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 Systems

J3176_202101 (Current)

1/13/2021

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