Browse Topic: Electrical systems

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BALL BEARINGS.060002To be published on 01/01/2099
HESS, HENRY
Technical Paper
Basic Science and Art of Aircraft Wreckage ReconstructionR-48004/23/2025
Basic Science and Art of Aircraft Wreckage Reconstruction is a unique title which addresses important aspects of investigating crashes, who does this kind of work, and how a healthy attitude and open mind are required to properly perform investigations. It also discusses what to expect from the on-scene part of the investigation, and the fundamental approaches to common types of wreckage reconstruction. Written by Don Knutson, a veteran of this industry, Basic Science and Art of Aircraft Wreckage Reconstruction is intended for the practitioner, student, or those who are simply curious about how aircraft wreckage is reconstructed. Full references are provided in the various chapters for additional reading and research. Many examples of aircraft crash scenarios and circumstances are presented in a "generic" form but relate to actual investigations, which should prove as a useful investigative resource whether you are an apprentice or an experience professional with a government aviation
Knutson, Donald F.
Reference
Fuel Film Measurement in a SI Gasoline Engine Using a Newly Developed MEMS Sensor2024-32-007104/18/2025
The previously developed capacitance sensor for detecting a liquid fuel film was modified to apply to the in-cylinder measurement. On the developed sensor surface, comb-shaped electrodes were circularly aligned. The capacitance between the electrodes varies with the liquid fuel film adhering. The capacitance variation between the electrodes on the sensor surface was converted to the frequency variation of the oscillation circuit. In the previous study, it was revealed that the frequency of the oscillation circuit varies with the variation of the liquid fuel coverage area on the sensor surface. The developed sensor was installed in the combustion chamber of the rapid compression and expansion machine, and the performance of the developed sensor was examined. Iso-octane was used as a test fuel to explore the sensor that had been developed. As a result, the adherence of the liquid fuel directly injected into the cylinder was successfully detected under the quiescent and motoring
Kuboyama, Tatsuya, Moriyoshi, Yasuo, Takayama, Satoshi, Nakabeppu, Osamu
Technical Paper
3D-CFD Simulations of H2 ICEs: A Preliminary Evaluation of a Laminar Flame Speed Correction for Thermo-Diffusive Instability2024-32-007404/18/2025
In recent years, climate change and geopolitical instability have intensified the focus on sustainable power generation. This shift seeks alternatives that balance environmental impact, cost-effectiveness, and practicality. Specifically, in transportation and power generation, electric motors face challenges against internal combustion engines due to the high cost and mass of batteries required for energy storage. This makes electric solutions less favorable for these sectors. Conversely, internal combustion engines, when properly fueled, offer cost-effectiveness and a quasi-environmentally-neutral option. To address these challenges, researchers have explored e-fuels derived from renewable sources as a carbon-neutral supply for internal combustion engines. Among these, hydrogen is particularly promising. In hydrogen-powered internal combustion engines, 3D-CFD (Computational Fluid Dynamics) in-cylinder models are crucial. Once validated, these models can speed up the design process. A
Sfriso, Stefano, Berni, Fabio, Breda, Sebastiano, Fontanesi, Stefano, Cordisco, Ilario, Leite, Caio Ramalho, Brequigny, Pierre, Foucher, Fabrice
Technical Paper
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
Technical Paper
Effect of Mesopore Structure of Carbon Gel on Improving the Capacity of Electric Double-Layer Capacitors2024-32-002604/18/2025
Electric double-layer capacitors (EDLCs) store charge by adsorbing ions at the electrode-electrolyte interface, offering fast charge/discharge rates, high power density, minimal heat generation, and long cycle life. These characteristics make EDLCs ideal for memory backup in electronic devices and power assistance in electric and hybrid vehicles. However, their energy density is lower than that of batteries, necessitating improvements in electrical capacity and potential. Traditionally, activated carbon with a high specific surface area has been used, but recent research focuses on mesoporous carbon materials for better ion diffusion. This study uses resorcinol-formaldehyde-carbon cryogel (RFCC) with mesopores and organic electrolytes with a wider electrochemical window. Various RFCCs with different pore sizes were synthesized and evaluated. Comprehensive investigations into the pore structures and surface properties of both synthesized carbon gels and commercial mesoporous materials
Cheng, Zairan, Okamura, Tsubasa, Ohnishi, Yuto, Nakagawa, Kiyoharu
Technical Paper
Predictive Battery Thermal Management System Control Strategy and Simulation in Electric Vehicle2025-01-502704/03/2025
With the global issue of fossil fuel scarcity and the greenhouse effect, interest in electric vehicles (EVs) has surged recently. At that stage, because of the constraints of the energy density and battery performance degradation in low-temperature conditions, the mileage of EVs has been criticized. To guarantee battery performance, a battery thermal management system (BTMS) is applied to ensure battery operates in a suitable temperature range. Currently, in the industry, a settled temperature interval is set as criteria of positive thermal management activation, which is robust but leads to energy waste. BTMS has a kilowatt-level power usage under high- and low-temperature environments. Optimizing the BTMS control strategy becomes a potential solution to reduce energy consumption and overcome mileage issues. An appropriate system simulation model provides an effective tool to evaluate different BTMS control strategies. In this study, a predictive BTMS control strategy, which adjusts
Huang, Zhipei, Chen, Jiangbo, Tang, Hai
Technical Paper
Optimizing Cooling Circuit Lines in between Batteries and Its Thermal Management Unit2025-01-501703/21/2025
Ensuring uniform coolant distribution in electric buses is crucial for battery performance, longevity, and thermal stability. This study optimizes the battery thermal management system (BTMS) for an 18-m electric bus, addressing uneven coolant flow to battery packs caused by pressure drop variations. One-dimensional (1D) simulations were chosen for their ability to quickly and efficiently analyze flow and pressure variations, providing a fast solution to optimize coolant distribution across the system. dP-Q curves for the BTMS pump and battery packs were integrated into the 1D model based on supplier data, while the flow resistances of other components (pipes, bends) were calculated using KULI software. To correct flow imbalances, pipe diameters were adjusted to increase resistance in over-cooled areas, redistributing coolant to under-cooled sections. This modification resulted in a balanced flow and improved thermal consistency, contributing to longer battery life. Validation showed
Birgül, Çağrı Emre, Meydan, Ömer
Technical Paper
Internet of Things Enabled Automatic Battery Cooling System Using the Peltier Effect2025-01-500401/23/2025
Electric vehicles (EVs) have developed rapidly and are popular due to their zero emissions and efficiency. However, several factors limit electric car development, including battery performance, cost, lifetime, and safety. Battery management is crucial for achieving maximum performance under various conditions. The battery thermal management system (BTMS) plays an important role in controlling the battery’s thermal behavior. A BTMS manages the battery’s operating temperature by either dissipating heat when it is too hot or providing heat when it is too cold. Various methods of cooling batteries include air cooling systems, liquid cooling systems, refrigerant cooling systems, and phase change material cooling systems. This study focuses on an innovative BTMS utilizing a Peltier module, regulated via the Internet of Things (IoT) platform for real-time temperature monitoring and control. The objective of this research is to design and develop a temperature-controlled cooling system for EV
Gunasekar, N., Abishek, H., Bharath, N. S., Gokul, G.
Technical Paper
Analyses of Cold Thermal Energy Storage Systems Using Eutectic Mixtures of Inorganic Hydrated Salts as Phase Change Materials2025-01-500301/23/2025
Cold thermal energy storage using phase changing materials is being researched to find freezing and thawing points. The use of inorganic hydrated salts, a type of phase changing material (PCM) used in cold energy storage systems without the use of existing renewable energy systems, allows for a longer cooling effect and saves energy. A high volumetric storage density and relatively high thermal conductivity make hydrated salts suitable materials for thermal energy storage. They can be used only as inorganic mixtures or else they can also be used as eutectic mixtures, which involve mixtures of inorganic–inorganic salts or simply a combination of two or more inorganic salts. This research deals with eutectic mixtures, which are 4% KNO3 + 96% H2O, 4% NaHCO3 + 96% H2O, and 2% KNO3 + 2% NaHCO3 + 96% H2O. Three different novel eutectic mixtures were examined and found a suitable mixture for a cold thermal energy system. An efficient phase change approach involving 2% KNO3 + 2% NaHCO3 + 96
Vasanthkumar, P., Santhoshkumar, A., Gopika, P., Murali, M., Meera, C.
Technical Paper
New Battery Cathode Material Could Revolutionize EV Market and Energy StorageTBMG-5214212/01/2024
A multi-institutional research team led by Hailong Chen, an Associate Professor with appointments in the George W. Woodruff School of Mechanical Engineering and the School of Materials Science and Engineering, has developed a new, low-cost cathode that could radically improve lithium-ion batteries (LIBs) — potentially transforming the electric vehicle (EV) market and large-scale energy storage systems.
Magazine Article
Researchers Discover a Surprising Way to Jump-Start Battery PerformanceTBMG-5214012/01/2024
A lithium-ion battery’s very first charge is more momentous than it sounds. It determines how well and how long the battery will work from then on — in particular, how many cycles of charging and discharging it can handle before deteriorating.
Magazine Article
Solving the Battery Recycling ChallengeTBMG-5214812/01/2024
Magazine Article
Dormant Capacity Reserve in Lithium-Ion Batteries DetectedTBMG-5214312/01/2024
Lithium iron phosphate is one of the most important materials for batteries in electric cars, stationary energy storage systems, and tools. It has a long service life, is comparatively inexpensive and does not tend to spontaneously combust. Energy density is also making progress. However, experts are still puzzled as to why lithium iron phosphate batteries undercut their theoretical electricity storage capacity by up to 25 percent in practice. To utilize this dormant capacity reserve, it would be crucial to know exactly where and how lithium ions are stored in and released from the battery material during the charging and discharging cycles. Researchers at Graz University of Technology (TU Graz) have now taken a significant step in this direction. Using transmission electron microscopes, they were able to systematically track the lithium ions as they traveled through the battery material, map their arrangement in the crystal lattice of an iron phosphate cathode with unprecedented
Magazine Article
DC-DC Converters for High Reliability eVTOL Auxiliary Power SystemsTBMG-5214712/01/2024
Magazine Article
Second Life of Lithium-Ion Batteries Could Take Us to SpaceTBMG-5214412/01/2024
The global use of lithium-ion batteries has doubled in just the past four years, generating alarming amounts of battery waste containing many hazardous substances. The need for effective recycling methods for spent lithium-ion batteries is becoming increasingly critical. In the journal ChemElectroChem, scientists from various Polish research institutions, including Bydgoszcz University of Science and Technology (PBS), the Institute of Fundamental Technological Research of the Polish Academy of Sciences, the Institute of Physical Chemistry of the PAS in Warsaw, and Wroclaw University of Science and Technology, presented a promising solution to this issue.
Magazine Article
Crafting Safe, Long-Cyclable Lithium Metal Batteries for High TemperaturesTBMG-5213912/01/2024
Existing commercial battery technologies, which use liquid electrolytes and carbonaceous anodes, have certain drawbacks such as safety concerns, limited lifespan, and inadequate power density particularly at high temperatures. This has prompted researchers to search for solid electrolytes that are safe and compatible with lithium metal anodes, which are known for their high theoretical specific power capacity.
Magazine Article
Where Do EV Batteries Go When They Die?TBMG-5213812/01/2024
At Cox Automotive’s EV Battery Solutions center in Oklahoma City, the conglomerate most famous for its KBB, Autotrader, and Manheim auction brands, has become a go-to for EV battery research, repair, remanufacturing, and recycling.
Magazine Article
SIMULATION FOR VEHICLE-TO-VEHICLE AND VEHICLE-TO-GRID RESOURCE SHARING ANALYSIS2024-01-344411/15/2024
ABSTRACT A simulation capable of modeling grid-tied electrical systems, vehicle-to-grid (V2G) and vehicle-to-vehicle(V2V) resource sharing was developed within the MATLAB/Simulink environment. Using the steady state admittance matrix approach, the unknown currents and voltages within the network are determined at each time step. This eliminates the need for states associated with the distributed system. Each vehicle has two dynamic states: (1) stored energy and (2) fuel consumed while the generators have only a single fuel consumed state. One of its potential uses is to assess the sensitivity of fuel consumption with respect to the control system parameters used to maintain a vehicle-centric bus voltage under dynamic loading conditions.
Jane, Robert S., Parker, Gordon G., Weaver, Wayne W., Goldsmith, Steven Y.
Technical Paper
400Hz High Speed Static Transfer Switch2008-01-287711/11/2024
The objective of this project was to replace electromechanical power line contactors with a Static Transfer Switch (STS) to improve the transfer of electrical power between aircraft generators and decrease required maintenance. The switch requirements include high reliability, lightweight, and high speed (less than 15mS) power transfer. An STS can shorten the bus transfer time to less than the “ride-through” of aircraft electronic loads and therefore have the ability to control and transfer electrical power while maintaining critical mission requirements. The content of this paper and presentation will discuss the initial problem, the research and development approach, design, and initial testing of the STS.
Cooper, Ronald C., Cooper, Evan C.
Journal Article
Clutch Torque Optimization for Heavy-Duty Vehicles Starting Based on Intelligent Identification of Driver’s Starting Intention, Vehicle Mass, and Road Grade02-17-03-001810/08/2024
For heavy-duty vehicles equipped with automated mechanical transmission (AMT), the control of automatic clutch torque is crucial during the start-up process. However, the difficulty of controlling clutch torque is exacerbated by differences in driver’s starting intentions, changes in vehicle mass, and road gradient. Therefore, this article proposes the clutch starting torque optimization strategy based on intelligent recognition of driver’s starting intention, vehicle mass, and road gradient. First, an intelligent recognition strategy is proposed based on the combination of data-driven and onboard transmission control unit (TCU) algorithms, which improves the accuracy of recognizing the driver’s intention to start as well as the vehicle mass and road gradient. Based on the vehicle’s historical state data information, the predictive model is trained offline using a long–short-term memory (LSTM) network to obtain predicted parameter identification results, which are then used to
Geng, Xiaohu, Liu, Weidong, Lei, Yulong, Fu, Yao, Xue, Maohan
Journal Article
CSP-7124 testTATSIANA07/17/2024
QA Test
Airlines Electronic Engineering Committee
Journal Article
CSP-7124 QA TestTATSIANAA07/15/2024
QA Testing
Aviation Maintenance Committee
Journal Article
PrePrint Testing - Tatsiana 0153PMSAE-PP-0944707/12/2024
QA Test
Mutagaana, Festo
Pre-Print Article
An Efficient and Cost-Effective Solution for Battery RecyclingTBMG-5084906/01/2024
Used lithium-ion batteries from cell phones, laptops, and a growing number of electric vehicles are piling up, but options for recycling them remain limited mostly to burning or chemically dissolving shredded batteries. The current state of the art methods can pose environmental challenges and be difficult to make economical at the industrial scale.
Magazine Article
Additive Manufacturing in the Mobility Industry: Vol. 1EPRCOMPV01202304/15/2024
Reference
Additive Manufacturing in the Mobility Industry: Vol. 1EPRCOMPV012023-TEST-REC04/15/2024
Reference
QA Test 032124SAE-PP-0921903/21/2024
Test
Mutagaana, Festo
Pre-Print Article
Liquid Runway Deicing/Anti-icing ProductAMS1435E (Current)03/12/2024
This specification covers runway deicing and anti-icing products in the form of a liquid. Unless otherwise stated, all specifications referenced herein are latest (current) revision.
G-12RDP Runway Deicing Product Committee
Material Specification
Liquid Runway Deicing/Anti-icing ProductAMS1435E-TEST-REC (Current)03/12/2024
This specification covers runway deicing and anti-icing products in the form of a liquid. Unless otherwise stated, all specifications referenced herein are latest (current) revision.
G-12RDP Runway Deicing Product Committee
Material Specification
Cost-effective techniques for SCEV to improve performance & life of battery and motor by using efficient thermal systems2024-26-027501/16/2024
The automotive world is moving towards electric powertrain systems. The performance of an electric powertrain and its electric components majorly depends on the operating temperature of the components. In the small commercial vehicle segment overall vehicle cost is a very sensitive parameter while competing in the market. This paper presents advanced efficient cost-effective thermal techniques for small commercial electric vehicles (SCEV) to improve the performance & life of major electric components. It is observed that from the literature survey, this technology is a novel technology for small commercial electric vehicle applications. The one-dimensional (1D) simulation approach is employed to evaluate the performance of the battery and traction cooling system during battery charging and vehicle driving scenario for different ambient conditions. The proposed thermal management techniques consist of simple and cost-effective thermal architectures having 3-way & 4-way valves which help
Chormule, Suhas Rangrao, Warule, Prasad, Jadhav, Vaibhav, Nagpure, Rahul
Technical Paper
An Experimental Approach towards Sustainable Solution for Material Recycling of ELV Plastic Bumpers and EV Batteries2024-26-016401/16/2024
The automotive industry in India generates a significant amount of waste and pollution through end-of-life vehicles (ELVs). This paper addresses the current state and challenges of ELV recycling in India and presents a sustainable solution for recycling waste bumpers and electric vehicle (EV) batteries. With the Indian domestic passenger vehicle sales reaching 3.9 million units in 2022-2023, the need for effective recycling measures is becoming increasingly critical. The study estimates that in FY 2023-24 alone, the Indian automotive passenger vehicle industry will produce approximately 2.9 million tons of scrap, with 0.1 million tons attributed to plastic materials. Considering the 15-year end-of-life period for vehicles and the historical sales figures, this scrap generation is expected to grow exponentially each year. To address this issue, the paper proposes a comprehensive recycling approach that focuses on two key aspects: plastic recycling and the recovery of precious metals
Baviskar, Ajay, Khera, Pankaj, Telgote, Ashish, Dhuria, Himanshu, Sharma, Amit
Technical Paper
Development of an efficient vehicle energy management system for fuel cell electric vehicles.2024-26-017301/16/2024
Fuel cell electric vehicles generally have two power sources – the fuel cell power system and a high voltage battery pack - to power the vehicle operations. The fuel cell power system is the main source of power for the vehicle and its operations are supported by the battery pack. The battery pack helps to tackle the dynamic power demands from the vehicle such as during acceleration, to which the response of the fuel cell might be slower. The battery is also used to recover the energy from regeneration during braking and can also be used to extend the range of the vehicle in case the storage tanks runs out of hydrogen. In order to maximize the fuel efficiency of the fuel cell power system it is critical that these two power sources are used in conjunction with each other in an optimal manner. The two power sources must operate such that the power demand from the vehicle is met at all times without over exerting either of these two sources as this can lead to drop in life and health of
Jacob, Joe, Brahmbhatt, Smitan, Adsul, Aniket, PRASAD, PULUGURTHA
Technical Paper
A Comparative Analysis and Novel Powertrain Topology for FCEVs, Integrating Ultracapacitor and Batteries.2024-26-016801/16/2024
This paper proposes a comparative analysis and novel topology for a fuel cell electric vehicle bus (FCEV-Bus) that combines the advantages of fuel cells, ultra-capacitors, and batteries. The integration of these three energy storage devices aims to enhance the overall performance, efficiency, and reliability of the FCEV while addressing the challenges associated with traditional fuel cell systems. The proposed topology utilizes a FC stack as the primary power source, which provides a steady and efficient supply of electricity. To overcome the limitations of fuel cells in responding to sudden power demands, ultra-capacitors are incorporated into the system. Ultra-capacitors can rapidly discharge and absorb high power, making them suitable for capturing regenerative braking energy and delivering power during acceleration or other high-power events. Moreover, to address the issue of slow-response and transient power variations, a battery-system is integrated into the topology. In which
Bhardwaj, Rohit, Saurabh, Saurabh, Gadve, Dhananjay, Amancharla, Naga Chaithanya
Technical Paper
Simulation Based Validation of Battery Structural Integrity for Mechanical Abuse as per AIS 1562024-26-024201/16/2024
Battery is one of the safety critical systems in EV. As the number of EVs increases, battery safety becomes an important task to avoid any mishap during its use, as even small accidents may slow down the adaptation of EVs. Automotive environment being one of the harshest operating environments, it is important to ensure both mechanical and electrical safety of the battery pack. Li-Ion batteries are most popular among traction batteries, due to their high energy density, long life, and fast charging capabilities. But mechanical damage, overtemperature, short-circuit, etc. may lead to battery thermal runaway, causing a major accident. Mechanical abuse of battery can be one of the reasons that may lead to the damages mentioned above, eventually causing thermal runaway in batteries. That’s why all major battery safety standards have requirements for vibration and mechanical shock tests. In this paper, we will be developing a methodology to evaluate the structural integrity of a battery
Dandge, Sunil, Mahamuni, Ameya, Sevda, Gaurav, H, Rajesh, Kumar, Ravindra, Mahajan, Rahul
Technical Paper
A Comparison of Wire Bonding vs. Spot Welding vs. Soldering in the Prevention of Thermal Runaway in a Battery Pack2024-26-010901/16/2024
EVs are a fast-growing market and appear as a promising option against the high emission of gasoline and diesel vehicles. The growth in the EV market has been decent and a regular buyer is still skeptical due to fire incidents occurring with EVs. Complex electronics, improper thermal management, mechanical abuse, improper cell grading activities and control in production, lack of testing in a production plant, and of course, uneven degradation of cells can be one of the reasons this promising technology is facing thermal runaway and in turn, the wrath of the government and public alike. One of the reasons thermal runaway can be triggered after a cell catches fire is because a part of heat travels via busbars to the neighboring cells, as the busbars can conduct heat faster than the air. For the heat that is conducted, it is easily understandable that we need to break the electrical, as well as thermal conduction connection to the neighboring cells. This paper presents a comparison of
Pawar, Aniruddha, Khan, Faiz, Shah, Harsh, Malani, Shekhar
Technical Paper
Adaptive derating algorithm for EV application based-Li-Ion battery for safe and healthy operation2024-26-010801/16/2024
Battery packs used in Electric Vehicles (EVs) pose significant safety risks and can incur additional costs and downtime when facing extreme conditions such as thermal and undervoltage hard cut-off. This article emphasizes the importance of implementing thermal and voltage based derating techniques to ensure the safe operation of battery packs. Thermal derating controls the maximum allowed battery current to prevent thermal runaway along with maintaining the health of the cells. While voltage derating prevents cut-off at low SOC regions by managing the cell voltage operating range through real time calculation of DCIR based voltage drop. By adopting these methods, battery packs can operate more safely and reliably in various environment conditions, which is essential in many applications. The article introduces the adaptive derating index, which utilizes State of Health (SoH) and real-time measurements of battery parameters such as temperature, voltage drop, and current to adjust the
Gautam, Ashish, SJ, Janarthanan, Badiger, Kartik, Soni, Lokesh
Technical Paper
A Traffic Microsimulation Based Study of an Electric Road System with Dynamic Wireless Power Transfer2024-26-010201/16/2024
Electrification of road transport is a critical step towards establishment of a sustainable transport ecosystem. However, a major hindrance to electric mobility is the high cost and weight of the battery pack. Downsizing the battery pack will not only address these issues, but will also reduce embedded emissions due to battery manufacturing. One approach towards reducing battery pack size and still offering the user of electric vehicles similar mobility experiences as in case of conventional vehicles is to set up extensive network of charging or battery swapping stations. Another approach is to provide the vehicle with required energy while it is on the move. However, conventional systems such as overhead line or conducting rails have several disadvantages in the urban environment. One solution that has come up in this regard in recent times is the concept of Electric Roads System (ERS), which involves dynamic wireless power transfer (DWPT) to the vehicles from power transmitters
Sardar, Arghya, Prasad, Mukti
Technical Paper
A Multistage adaptive charging algorithm for Li-Ion battery-based EV Applications2024-26-010301/16/2024
With the increase of electric vehicles and lack of standardization in charging infrastructure, the variance in the charger cable length, battery health, and battery capacity can result in unevenness in the charging of lithium-ion batteries (LIBs), which increases the charging time and can deteriorate the battery’s health. Enabling adaptive charging of LIBs can accelerate the commercial application of electric vehicles (EVs). Charging of LIBs is critical and can be optimized to curtail the effective charging time. In this paper, a multistage adaptive charging strategy is presented for LIB-based EV applications to boost the SOC of the battery system in the shortest time. In the proposed charging strategy, initially, multiple pre-charge CC stages are employed to bring the battery out of the deep discharge state and to simultaneously calculate the resistances of the harness (line resistance), and the battery. These resistance values are then used to estimate the charging currents as the
RAJAWAT, SHIV PRATAP, Moorthi, Sathiya, Soni, Lokesh
Technical Paper
Effect of Busbar Design on the Thermal Performance of Battery Packs2024-26-013501/16/2024
Li-ion batteries face challenges which is not usually present with other chemistries is cell balancing. If a high imbalance occurs within a parallel circuit, possibly because of the poor cell -grading or due to temperature localization, the other cells will charge the unbalanced cell and it may be possible that the imbalance never completely fades away and the other cells also end up unbalanced, One of the key solutions to maintaining cell balance is to ensure that all cells within a battery pack are kept at a uniform temperature. This requires careful thermal management, which can be achieved through a combination of conduction and convection circuits. In this paper, a 1D-3D simulation study has been performed on a 12 V 4s4p pack by varying the thickness of HV busbars and temperature localization effects and temperature uniformity has been observed. The holder has 16 cells with a 4*4 grid pattern, each cell has a diameter of 18 mm and a length of 65mm. The cells are connected in
Jagtap, Aditya, Khan, Faiz, Shah, Harsh, Malani, Shekhar
Technical Paper
A review and modelling of PMSM drive technology for Electric vehicle application2024-26-012701/16/2024
The increased pollution and environmental damage caused by rapid consumption of fossil fuel as the increased number of vehicles on road given a strong impetus to the growth and development of fuel-efficient vehicles. INDIA has already adopted the stringent CAFÉ II norms in 2022 which penalizes the CO2 levels above the corporate average target. This will give a push to automotive manufacturer to reduce their carbon footprint. Considering all the above-mentioned factors, Electric Vehicles are proving to be a promising solution to curb the Carbon footprint and limit the dependence on the fossil fuel which will dampen the effect of increased fuel prices on customers as well. The main advantage to EVs is that the motor and battery configuration allows the vehicle to operate more efficiently. The main components of Electric vehicles are HV battery, E-Drive (Motor), Inverter, On board charger, Power distribution Unit. The performance of EVs greatly depends on these components and its
Sharma, Prashant, V, Suryanarayanan, Redii, Ashok, Raut, Sandip, Hareesh, Sangaraju
Technical Paper
A Review on Fire Prevention and Suppression Solutions for EV Battery Packs2024-26-001201/16/2024
The lithium-ion batteries are susceptible to fires or explosions due to their extremely volatile nature. The energy-dense batteries, such as LiNi_0.8 Mn_0.1 Co_0.1 O_2/Graphite (NMC811) battery that meets the consumer range demands, are most vulnerable under thermal events. A wide number of solutions are being explored to suppress or prevent battery fires. The solutions range from integrating active cooling techniques, passive heat dissipation using heat carrier pads, thermal insulating materials to prevent thermal propagation, safety vents to remove ejecta, and protection circuitries with advanced battery management system. In this paper, we review various safety solutions employed in battery packs for preventing or suppressing potential fire during any thermal runaway event. The identified safety solutions also feature distinctive methods such as usage of hydrogel agents, aerosol fire suppressants and design features. Among the reviewed countermeasures, we provide a detailed analysis
H, Manjunatha, Nambisan T M, Praveen Kumar, R, Pavan, P, Hari Prasad Reddy, G M, Bharath, Kulkarni, Mukund Aravind, Sundaram, Saravanan
Technical Paper
A Study on Traction Battery Mounting Arrangements in Different EV Buses2024-26-012101/16/2024
This paper provides an overview of the different types of traction battery mounting arrangements available in electric buses globally. The paper describes a key comparison of all the types of traction battery mounting strategies used in EV buses along with their dominance and limitations. In EV buses, bigger sized batteries are used which directly affect vehicle architecture, assembly & serviceability. On the other hand, larger-sized batteries are used in buses which carries heavy mass, which influences vehicle dynamics & performance characteristics such as vehicle ride, handling, braking & NVH. The most important consideration in EV vehicles is safety, which comes in first place, so this paper gives some ideas to carefully design battery mounting arrangements for EV bus applications. There has been seen a very positive adaptation of EV buses in the last few years due to the rise in Co2 and global warming. Many EV bus manufacturers have entered the market with their innovative ideas of
Jain, Gaurav, Pathak, Rahul, Gore, Pandurang
Technical Paper
Electric Powertrain - Standardization of Adaptable Software in Loop System2024-26-011701/16/2024
Motivation With an increase in the complexity involved in modern-day ECUs (Electronic Control Unit), it is very important to verify and validate robustness, functionality, and reliability of ECUs. Till date, Hardware in Loop (HiL) based validation or vehicle level validation is generalized approach used for testing. However, this method requires physical setup, which can incur more cost and time during the development phase. Solution We believe in minimizing the software testing time using Software in Loop (SiL) validation. Creating virtual-ECUs and the plant models is an important step in SiL. We are presenting the modularized and scalable plant models in this paper. Adaptable SiL Solution for EV This paper focuses on the standardization of electric vehicle plant models, which can help users to reduce the software development and software testing time. We created the standardized plant models for following virtual ECUs, which can be used as modular units. • Battery Management System
Sajnani, Abhishek, Vernekar, Kiran, Gosavi, Rupesh, Naik, Venkatesh
Technical Paper
System Validation with Battery-in-the-Loop Configuration using a Virtual Testing Toolchain2024-26-011601/16/2024
Challenge Today, the battery development process for automotive applications is relatively decoupled from the vehicle integration and system design validation phase. Battery module design targets are very much linked to vehicle-level requirements, such as performance, lifetime and cost but are often disregarded at very early design phases. Converging these requirements to more specific battery pack criteria is not straightforward and often based on previous vehicle generation data or cell testing measurements usually performed after prototyping and via artificial charge and discharge patterns Solution To reduce time to market, AVL proposes here a methodology guided by virtual testing techniques to consider vehicle-level validation steps at the very early phase of battery testing. In a first step, AVL utilises a vehicle system simulation supported with real-world test scenarios and high-fidelity battery models. To generate such realistic scenarios, AVL uses an online digital map and
Kolar, Ales, Santiago, Prabhu, Kural, Emre
Technical Paper
Enhancing Electric Vehicle Performance and Battery Life through Flywheel Energy Storage System: Modelling, Simulation, and Analysis2024-26-013601/16/2024
This research paper focuses on the modelling and analysis of a flywheel energy storage system (FESS) specifically designed for electric vehicles (EVs) with particular emphasis on the flywheel rotor system associated with active magnetic bearings. The methodology used simulation approaches to investigate the dynamics of the flywheel system. The objective of this study is to explore the effects of implementing the flywheel energy storage system on the performance of the EV. The paper presents a comprehensive model of the flywheel energy storage system, considering the mechanical and electrical aspects. The mechanical model accounts for the dynamic behaviour of the flywheel, including parameters such as rotational speed, inertia, and friction. The electrical model describes the interaction between the flywheel and the power electronics, such as the converter and motor/generator. To evaluate the benefits of the flywheel energy storage system, simulations are conducted. Simulation studies
Akhtar, Juned
Technical Paper
Electrifying the Giants: Green mobility solution for M&HCVs in India.2024-26-013101/16/2024
Diesel operated Medium and Heavy Commercial Vehicles (M&HCV) account for nearly 70% of all road transportation in India which is expected to quadruple, from 4 million in 2022 to roughly 17 million trucks by 2050. Despite comprising a mere 5% of total vehicle fleet, they consume nearly 57% of fossil fuel used by the transport sector and responsible for 71% ,74% and 55% of CO2 ,PM and NOx emissions respectively. This necessities the transition of M&HCV into green mobility solution. Furthermore, smaller vehicles like 2W, 3W, 4 wheeler like cars and buses are adopting EV technology at a faster pace coupled with incentivization through government policies like FAME-I, FAME-II etc., advocates an immediate intervention on electrification of M&HCVs to multifold the impact. This paper suggests a collaborative approach amongst M&HCV manufactures and government agencies to realize the transition while integrating the benefits of reduced emissions, lower operating costs, quieter operation
Saurabh, Piyush, Giri, Debabrata
Technical Paper
Utilizing Computed Tomography for Cell Characterization, Quality Assessment, and Failure Analysis2024-26-018901/16/2024
This abstract presents an experimental study on using Computed Tomography (CT) scan technology for analyzing battery cell failures. Lithium-ion battery cells with known failure modes were subjected to cyclic test under different temperature and C-rates. CT scans provided high-resolution cross-sectional images of internal structures, revealing failure-related features. The advanced image processing techniques quantitatively assessed electrode morphology, active material distribution, and separator integrity. The study demonstrated CT scan's potential in non-destructive analysis, enabling a deeper understanding of failure mechanisms and informing improvements in cell design and manufacturing processes.
Singh, Sathya Prakash, Baidya, Kapil Krishna, ADHALE, Pratik
Technical Paper
Study Of Derived Battery Features for Real Time Estimation of SOH And RUL Of EV Battery Using Data Analysis2024-26-012301/16/2024
Lithium-ion batteries have been widely used in EV’s. It is desired to predict the SOH of batteries to achieve optimal operation and health management. The most significant obstacle to accurately predicting battery health is choosing battery features. In this study, numerous data analysis strategies are introduced to manage feature irrelevancy and help in determining which features can be selected and used in real time. The first step in manually crafting features is to analyses the evolution pattern of numerous essential characteristics of battery. Second, correlation between selected features and degraded capacity analyses. Then, selected features are fed into representative machine learning regression model to effectively predict remaining capacity of battery to find the SOH status. Finally, the remaining capacity of battery is selected as feature to predict the RUL in terms of remaining charge-discharge cycles.
Nangare, Kapilraj, Nidubrolu, Kranthi, Gaikwad, Pooja
Technical Paper
Simulation of Crimping Process for Electrical Contacts to ensure Structural Integrity of Crimped Joint under Static Loads2024-26-029101/16/2024
The use of electrical contacts in aerospace applications is crucial, particularly in connectors that transmit signal and power. Crimping is a widely preferred method for joining electrical contacts, as it provides a durable connection and can be easily formed. This process involves applying mechanical load to the contact, inducing permanent deformation in the barrel and wire to create a reliable joint with sufficient wire retention force. This study utilizes commercially available Abaqus software to simulate the crimping process using an explicit solver. The methodology developed for this study correlates FEA and testing for critical quality parameters such as structural integrity, mechanical strength, and joint filling percentage. A four-indenter crimping tool CAD model is utilized to form the permanent joint at the barrel-wire contact interfaces, with displacement boundary conditions applied to the jaws of the tool in accordance with MIL-C-22520/1B standard. The study identifies the
Aher, Ravi, More, Sandip Raghunath, Demarthon, Simon
Technical Paper
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