Browse Topic: High voltage systems

Items (325)

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

2024-32-006204/18/2025

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

Acoustic characterization of AC motor using sound intensity in standard laboratory environments

2025-01-001005/05/2023

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 Laboratory

2025-01-000705/05/2023

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

EXPERIMENTAL SETUP FOR VISUALIZATION OF PLASMA PROPELLED THRUSTERS

2022-26-121805/26/2022

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

Novel Nanocrystalline Silver Alloy Coatings to Boost Performance of EV High Voltage Interconnects and Charging Interfaces

2022-01-087403/29/2022

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

Comparative Analysis of Protection Systems for DC Power Distribution in Electrified Vehicles

2022-01-015303/29/2022

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

Model-based thermal control strategy for electrified vehicles

2022-01-022903/29/2022

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

Eliminating the 12V battery with use of Sine Amplitude Converter modules to create 12V power from the high voltage vehicle battery

2022-01-082303/29/2022

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

Case Study on Optimized Cooling System Concept for Electric Compact-SUV with Indian Environmental Conditions

2021-26-041009/22/2021

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 Detection

2021-26-014209/22/2021

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 Strategy

2021-01-116209/21/2021

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 Vehicles

AS4461D-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

Assembly and Soldering Criteria for High Quality/High Reliability Soldering Wire and Cable Termination in Aerospace Vehicles

AS4461D (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

Unshielded High Voltage Primary Cable

J1654_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

Unshielded High Voltage Primary Cable

J1654_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

Pyrofuse Modeling for eVTOL Aircraft DC Protection

2021-01-004103/02/2021

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 Definitions

AIR7502 (Current)

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 Systems

J3176_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 Application

TBMG-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”).

Cellulose-Based Sensor Simultaneously Measures Pressure, Temperature, and Humidity

TBMG-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.

Choose Surface Treatments Early to Avoid Future Problems

TBMG-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 infrastructure

19AUTP09_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

Automotive Engineering: June 2019

19AUTP0606/06/2019

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 circuits

19AUTP06_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

Consideration of Corrosion Behavior of Aluminum Wire at Crimped Terminal and Effective Anti-Corrosion Treatment

2019-01-048604/02/2019

The demand for weight reduction of vehicles is growing in compliance with CO2 emission control requirements. Also, demand for copper is on the rise with an increase in the number of electric vehicles because their motors and wiring require a lot of copper. This has raised concerns about higher copper prices and vehicle weight. Recently, attempts to reduce vehicle weight have been actively made by partially replacing copper with aluminum, which is lighter and less expensive. Although the use of aluminum wires on limited areas of some vehicles has already been reported, that on all areas has not been reported yet. The authors focus on reducing weight of wiring harnesses, which is about 20 kg per vehicle, and consider using aluminum instead of copper as the conductor of the electrical wires. One of the factors impeding the use of aluminum wires in wider areas is galvanic corrosion occurring at crimped terminals. Since aluminum causes galvanic corrosion when the metal is in electrical

Kawaguchi, Takuya, Fukaura, Keiji, Nakamura, Yuki, Mochizuki, Makoto, Otani, Satoshi

X-Ray Study of Low-Density Materials

TBMG-3390303/01/2019

It's hard to get an X-ray image of low-density material like tissue between bones because X-rays just pass right through like sunlight through a window. Sandia studies myriads of low-density materials, from laminate layers in airplane wings to foams and epoxies that cushion parts. So they borrowed and refined a technique from the medical field, X-ray phase contrast imaging, to look inside the softer side of things. The technique measures not just the number of X-ray photons that get through the sample, as in conventional X-ray imaging, but also the phase of the X-rays after they pass through, offering a complete look at interfaces inside a structure.

Manufacturing Technique Helps Inkjet Printers Deliver Ink More Evenly

TBMG-3370802/01/2019

When a coffee mug leaves a ring, the outer edges of that ring are darker than the inside of the ring. That's because the solute is separated from the liquid during the evaporation process — the coffee ring effect. This same effect can happen with printers. When printing a text document, the text itself consists of an outline of the letters and the inside of the letters. While it may not be visible to the untrained eye, the outlines are actually darker than the inside. This happens during the drying process, just like the coffee ring effect. Efforts have been made to find a way to remove this difference in pigmentation.

SAE Truck & Off-Highway Engineering: October 2018

18TOFHP1010/01/2018

Are higher voltage architectures imminent? As the limitations of current 12V architectures become more apparent, the commercial vehicle industry could be on the verge of adopting 48V. The only question is, will improvements in other technologies offer something better? Sensing changes in autonomous trucks Requirements for sensors and controls for commercial vehicles differ significantly from those used for cars. Many paths lead to reduced emissions A wide range of ICE technologies are needed to meet increasingly stringent emissions regulations. Quotes from COMVEC 2018 Industry leaders spoke extensively about all things autonomous-ADAS, big data, connectivity, cybersecurity, machine learning-at the annual SAE event. Here's some of what they had to say. Fuel-cell Class 8-take 2.0 With a longer-range and more-refined fuel cell-powered heavy-duty truck, Toyota aims to eventually eliminate emissions from trucks serving increasingly congested California ports. Editorial Bring innovation

Direct-Current Detector for Emergency Responder Safety

TBMG-3286309/01/2018

The Department of Energy's Oak Ridge National Laboratory has developed a direct-current detector technology to help emergency responders safely detect high voltages, which they have licensed to North Carolina-based Hotstick USA.

Auxiliary Power Solutions for 1500 VDC Photovoltaic Systems

TBMG-3250608/01/2018

Photovoltaic systems are continually evolving to improve their efficiency and financial viability. One trend is to move to larger strings of cells giving higher dc voltages to be converted to ac voltage for the grid. Cost savings result, but auxiliary power supplies for monitoring and control need to accept these higher voltages as inputs.

Design Requirements for Automotive Ethernet PoDL Compatible Connectors

2018-01-075404/03/2018

Ethernet technology has a promising future in the automotive industry. Data rates ranging from 10Mbps to 10Gbps are being, or already have been, standardized. To reduce the amount of cabling, a technology known as Power over Data Line (PoDL) has been developed that enables the data and power to share the same pair of wires. This paper will discuss the connector requirements needed to ensure safe power transmission for these PoDL voltages, and demonstrate a design that meets these requirements.

DiBiaso, Eric A., Chalas, Guadalupe

Demolition Probe Gives Construction Workers a Break

TBMG-2870304/01/2018

Initially designed for use on the Moon, the Electro-Hydraulic Fracturing system — developed at Auburn University with NASA funding — relies upon short, high-pulse power created by ultra-high capacitors. Two electrodes featuring a high voltage difference are placed in a small amount of non-toxic liquid — an ounce of water, for example. After the proprietary probe is placed in a drilled hole within concrete or rock, a very rapid release of high-voltage electrical energy, stored in the capacitors, is discharged. The liquid provides the spark between electrodes, resulting in a high-temperature containable “plasma ball.” The ping-pong-ball-sized bead creates a shock wave with pressures that exceed the material’s compressive strength, causing a fracture.

Silicon Carbide High-Voltage Switch

TBMG-2818001/01/2018

High-voltage wide bandgap (WBG) semiconductor devices like 15-kV silicon carbide (SiC) MOSFETs have attracted attention because of potential applications in high-voltage and high-frequency power converters. These devices, however, are not commercially available, and their high cost due to expensive material growth and fabrication may limit their widespread adoption in the future.

EDITORIAL: EVs lack a robust charging grid

17AUTP10_0410/01/2017

The flames lit up the sky when the electric-power substation in my town blew up one night last August. TV news had it covered: A transformer at the DTE Energy site had exploded, immediately knocking out power for over 4,000 homes and businesses. More than 9,000 residents dug out flashlights, lit candles and sweated the summer heat. The utility acted quickly, bringing in a convoy of five flatbed trailers-DTE Energy's mobile emergency units-each carrying a large diesel-electric generator rig. Humming away behind a makeshift fence and “DANGER: High Voltage” signs, the generator trailers formed the nucleus of a temporary grid while an army of helmeted technicians worked to get the juice flowing. Two days after the fire, the town's lights were back on and my beer was cold again. But as I write this seven weeks later, the emergency generators are still powering the town. And the utility still doesn't know for certain the cause of the explosion.

Brooke, Lindsay

Active Implants: How Gold Binds to Silicone Rubber

TBMG-2732308/01/2017

Flexible electronic parts could significantly improve medical implants. However, electroconductive gold atoms usually hardly bind to silicones. Researchers from the University of Basel have now been able to modify short-chain silicones in a way, that they build strong bonds to gold atoms. The results have been published in the journal Advanced Electronic Materials.

Products of Tomorrow: July 2017

TBMG-2722107/01/2017

This column presents technologies that have applications in commercial areas, possibly creating the products of tomorrow. To learn more about each technology, see the contact information provided for that innovation.

Thermoplastic Enclosure for a High Voltage Battery System

2017-01-119003/28/2017

As electrified powertrains proliferate through original equipment manufacturer vehicle offerings, the focus on system cost and weight reduction intensifies. This paper describes the development and evaluation of a High Voltage (HV) battery system enclosure molded from High Density Polyethylene (HDPE) to deliver substantial cost and weight opportunities. While previous HV battery system enclosure alternatives to steel and aluminum focus on thermoset composites and glass filled polypropylene, this solution leverages select HDPE design techniques established for fuel tanks and applies them to an HV battery system. The result is a tough, energy absorbing structure, capable of hermetic sealing, which simplifies manufacturing by eliminating nearly all fasteners. The authors evaluate performance with respect to crashworthiness, fire resistance, electro-magnetic compatibility and other challenges; using comparative research, computer analysis, and physical testing to demonstrate the system

Maguire, Patrick, Baek, Hyung, Liptak, Stephen, Lomax, Olivia, Palma, Rodolfo, Zhang, Yi

Self-Excited Wound-Field Synchronous Motors for xEV

2017-01-124903/28/2017

Compact, high efficiency and high reliability are required for an xEV motor generator. IPM rotors with neodymium magnets are widely applied for xEV motors to achieve these requirements. However, neodymium magnet material has a big impact on motor cost and there is supply chain risk due to increased usage of these rare earth materials for future automotive xEV’s. On the other hand, a wound-field rotor does not need magnets and can achieve equivalent performance to an IPM rotor. However, brushes are required in order to supply current to the winding coil of the rotor. This may cause insulation issues on xEV motors which utilize high voltage and high currents. Therefore, it is suggested to develop a system which supplies electric energy to the rotor field winding coil from the stator without brushes by applying a transformer between stator coil and rotor field winding. Specifically, add auxiliary magnetic poles between each field winding pole and wind sub-coils to these poles. The

Seguchi, Masahiro

Power MOSFET Technologies and Design Considerations for Automotive Electronic Systems *CSP Meta QA Testing*

2017-01-001603/28/2017

For over thirty years, the silicon power MOSFET’s role has expanded from a few key components in electronic engine control to a key component in nearly every automotive electronics system. New and emerging automotive applications such as 48 V micro hybrids and autonomous vehicle operation require improved power MOSFET performance. This paper reviews mature and state of the art power MOSFET technologies, from planar to shield gate trench, with emphasis on applicability to automotive electronic systems. The automotive application environment presents unique challenges for electronic systems and associated components such as potential for direct short to high capacity battery, high voltage battery transients, high ambient temperature, electromagnetic interference (EMI) limitations, and large delta temperature power cycling. Moreover, high reliability performance of semiconductor components is mandatory; sub 1 ppm overall failure rate is now a fundamental requirement. Autonomous vehicle

Zaremba, Don, Linehan, Emily, Ramirez Ramos, Carlos

xEV Labels to Assist First and Second Responders, and Others

J3108_201703 (Current)03/02/2017

This recommended practice prescribes clear and consistent labeling methodology for communicating important xEV high voltage safety information. Examples of such information include identifying key high voltage system component locations and high voltage disabling points. These recommendations are based on current industry best practices identified by the responder community. Although this recommended practice is written for xEVs with high voltage systems, these recommendations can be applied to any vehicle type.

Hybrid - EV Committee

Development of High Quality 4H-SiC Thick Epitaxy for Reliable High Power Electronics Using Halogenated Precursors

17AERP02_0602/01/2017

New approaches to synthesizing SiC epitaxial layers could improve electronics performance. Office of Naval Research, Arlington, Virginia Development of robust semiconductor devices with high energy efficiency and reliability is a key objective towards ‘Energy Conversion and Power Management’ for naval system applications. The goal of this research is to create the fundamental knowledge needed for the development of novel approaches to synthesize high-quality, thick SiC epitaxial layers (> 100μm) for reliable high voltage (≥10kV) / high power (>100 kW) electronics for navy ship applications. This program focuses on (a) developing innovative solutions to the current main limitation in SiC homoepitaxy - reduction/elimination of device-killing defects; (b) gaining understanding of the chemical vapor deposition processes in SiC epitaxy, specifically related to precursor gas decomposition dynamics and subsequent parasitic deposition of Si, C and SiC on the gas injector tube walls; and (c

Development of High Quality 4H-SiC Thick Epitaxy for Reliable High Power Electronics Using Halogenated Precursors

TBMG-2638602/01/2017

Development of robust semiconductor devices with high energy efficiency and reliability is a key objective towards 'Energy Conversion and Power Management ' for naval system applications. The goal of this research is to create the fundamental knowledge needed for the development of novel approaches to synthesize high-quality, thick SiC epitaxial layers (> 100μm) for reliable high voltage (≥10kV) / high power (>100 kW) electronics for navy ship applications.

3D Graphene Shows Promise for Bone Implants

TBMG-2573011/01/2016

Flakes of graphene welded together into solid materials may be suitable for bone implants, according to a study led by Rice University scientists. The Rice lab of materials scientist Pulickel Ajayan and colleagues in Texas, Brazil, and India used spark plasma sintering to weld flakes of graphene oxide into porous solids that compare favorably with the mechanical properties and biocompatibility of titanium, a standard bone-replacement material.

Design and Testing of a High Temperature Inverter

2016-01-206409/20/2016

The emergence of wide band gap devices has pushed the boundaries of power converter operations and high power density applications. The wide band gap devices in conjunction with silicon on insulator electronic components enable the realization of power converters that can operate at high ambient temperatures that are typically found in aerospace engine environments. This paper describes the design and test of a power electronic inverter that converts a fixed input DC voltage to a variable voltage variable frequency three phase output. The design of the key functional components such as the gate drive, power module, controller and communication will be discussed in this paper. Test results for the inverter at high temperature are also presented.

Krishnamurthy, Shashank, Savulak, Stephen, Wang, Yang

Designing VME Power Systems With Standard Modules

TBMG-2491006/01/2016

Military electronics continue to push the performance envelope in all directions. Each new system design faces the same challenges: the need for more processing power, tighter specs, and shorter development time. Continual advances in system performance often require similar advances in the power system. VME architecture is common in many military applications, as systems can readily be built around standard or custom circuit cards. Off-the-shelf VME power supplies are available, but often don’t meet the necessary requirements or haven’t kept up with recent performance advances. Usually, neither schedule nor budget allow for a full custom power supply development effort.

Designing VME Power Systems With Standard Modules

TBMG-2491106/01/2016

Military electronics continue to push the performance envelope in all directions. Each new system design faces the same challenges: the need for more processing power, tighter specs, and shorter development time. Continual advances in system performance often require similar advances in the power system. VME architecture is common in many military applications, as systems can readily be built around standard or custom circuit cards. Off-the-shelf VME power supplies are available, but often don’t meet the necessary requirements or haven’t kept up with recent performance advances. Usually, neither schedule nor budget allow for a full custom power supply development effort.

DESIGNING VME POWER SYSTEMS WITH STANDARD MODULES

16AERP06_0206/01/2016

Off-the-shelf DC-DC converter and EMI filter modules enable rapid development of custom power solutions. Military electronics continue to push the performance envelope in all directions. Each new system design faces the same challenges: the need for more processing power, tighter specs, and shorter development time. Continual advances in system performance often require similar advances in the power system. VME architecture is common in many military applications, as systems can readily be built around standard or custom circuit cards. Off-the-shelf VME power supplies are available, but often don't meet the necessary requirements or haven't kept up with recent performance advances. Usually, neither schedule nor budget allow for a full custom power supply development effort. Fortunately, an optimized VME power supply solution can be built from standard off-the-shelf high-reliability or COTS DC-DC converter modules. This solution can be rapidly developed at minimal cost since most of the

Development of a Novel Electrospinning System with Automated Positioning and Control Software

TBMG-2485006/01/2016

Electrospinning is a nanofiber fabrication technique that has grown in popularity due to its potential in numerous biomedical applications. The process uses an electrical charge to draw ultrafine fibers from liquid polymer solution to form a non-woven fiber scaffold. The polymer fiber diameters can range from millimeters to as small as nanometers in scale.

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