Browse Topic: Voltage regulators

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Communication Transceivers Qualification Requirements - EthernetJ2962-3_202109 (Historical)9/21/2021
This SAE Recommended Practice covers the requirements for ethernet physical layer (PHY) qualification. Requirements stated in this document provide a minimum standard level of performance for the PHY in the IC to which all compatible ethernet communications PHY shall be designed. When the communications chipset is an ethernet switch with an integrated automotive PHY (xBASE-T1), then the testing shall include performance for all switch PHY ports as well as each controller interface. No other features in the IC are tested or qualified as part of this SAE Recommended Practice. This assures robust serial data communication among all connected devices regardless of supplier. The goal of SAE J2962-3 is to commonize approval processes of ethernet PHYs across OEMs. The intended audience includes, but is not limited to, ethernet PHY suppliers, component release engineers, and vehicle system engineers.
Vehicle Architecture For Data Communications Standards
Aircraft Cargo ConveyorARP1836C (Current)4/8/2021
This SAE Aerospace Recommended Practice (ARP) outlines the functional and design requirements for a b self-propelled belt conveyor for handling baggage and cargo at aircraft bulk cargo holds. Additional considerations and requirements may legally apply in other countries. As an example, for operation in Europe (E.U. and E.F.T.A.), the applicable EN standards shall be complied with.
AGE-3 Aircraft Ground Support Equipment Committee
Supercapacitor Hybrid VehicleSAE-PP-002392/3/2021
Electric vehicles (EVs) has been in the rise in popularity, and as a result, opportunities for alternative power systems research have expanded. Traditional EVs consist of lithium-ion battery for the power source as they can provide long vehicle range at a relatively low cost. [1] Supercapacitors (SCs) are energy storage devices with the high-power density and low energy density, which means it can deliver and handle a high amount of energy in a short period, but energy deliverance is significantly shorter compared to batteries. As a result, supercapacitors cannot be the primary power source in electric vehicles as a long vehicle driving range is essential. However, supercapacitors are currently being studied for a hybrid electric vehicle powertrain. Compare to lithium-ion batteries, supercapacitors have higher charge/discharge efficiency, charge acceptance, and cycle life [2]. Using a supercapacitor as an ancillary device has been shown to reduce power loads on batteries.
Anthony, Lindsay
1.1.203 - Development and Control of Evasive Steer Assist Using Rear Wheel SteeringSAE-PP-002182/2/2021
A first step towards autonomous rear-end collision avoidance is to start providing natural support to driver in avoiding collision by steering and braking intervention. The proposed system detects slower-moving and stationary vehicles ahead and classifies the risk of having a rear-end-collision. If the risk is high and there is insufficient space to avoid a collision by braking only, the system helps the driver to steer around the obstacle by steering rear toe angle of the wheels individually. A lot of research already exist in the rear wheel steering but the role of rear wheel steering in collision avoidance is not researched yet in great details. Rear wheel steering is used to increase agility and manoeuvrability of vehicle at lower vehicle speed and stability of vehicle at higher vehicle speed. In the situation of the high speed rear end collision where steering is more effective than braking the strategy of control design of rear wheel steering needs to be dynamically updated. Linear threat assessment and path planning followed by optimal control of the trajectory in combination with driver steering shows a significant improvement in collision avoidance by steering. A test vehicle Mondeo is equipped with rear wheel steering is tested at different vehicle speed for collision avoidance against stationary and moving obstacles. A set of metrics are created to show the performance improvement against the base design of the vehicle.
Mutagaana, Festo
LEAD-FREE SOLDER VALIDATION TEST PLANUSCAR40-2 (Current)11/19/2020
This guideline is applicable to existing lead solder production products that will change to lead-free solder processes to meet the ELV Directive 2000/53/EC Annex II, exemption 8B requirements. This guideline is applicable to similar products used by multiple OEM's that have the same manufacturing processes / equipment. The intent is to streamline the supplier’s environmental testing via common qualification to reduce timing, quantities, and costs.
USCAR
Hybrid and Electric Vehicle Safety Systems Information ReportJ2990/2_202011 (Current)11/4/2020
This information report provides an overview of a typical high voltage electric propulsion vehicle (xEV) and the associated on-board safety systems typically employed by OEM’s to protect these high voltage systems. The report aims to improve public confidence in xEV safety systems and dispel public misconceptions about the likelihood of being shocked by the high voltage system, even when the vehicle has been damaged. The report will document select high voltage systems used for xEV’s and describe safety systems employed to prevent exposure to the high voltage systems.
Hybrid - EV Committee
Eddy Current Inspection of Open Fastener Holes in Aluminum Aircraft StructureARP4402A (Current)9/22/2020
This SAE Aerospace Recommended Practice establishes the requirements and procedures for eddy current inspection of open fastener holes in aluminum aircraft structures.
AMS K Non Destructive Methods and Processes Committee
Auxiliary Power Unit Electrical Interface Requirements for Class Eight TrucksJ2891_202004 (Current)4/29/2020
This SAE Recommended Practice covers the design and application of a 120 VAC single phase engine based auxiliary power unit or GENSET. This document is intended to provide design direction for the single phase nominal 120 VAC as it interfaces within the truck 12 VDC battery and electrical architecture providing power to truck sleeper cab hotel loads so that they may operate with the main propulsion engine turned off.
Truck and Bus Electrical Systems Committee
Energy Management of Dual Energy Source of Hydrogen Fuel Cell Hybrid Electric Vehicles2020-01-05954/14/2020
With the growing shortage of oil resources and the increasingly strict environmental regulations, countries are vigorously developing new energy vehicles, and as a truly zero-emission vehicle in the application, fuel cell electric vehicles can not only completely replace gasoline cars in term of fuel, but also have the advantages of high energy conversion efficiency, short hydrogenation time and long driving range. For Fuel Cell Hybrid Electric Vehicle (FCEV), and the Energy Management Control Strategy is the "core" of the whole vehicle control system, which has a direct and significant effect on the power and economy of the vehicle. In this paper, the "dual energy source system" composed of fuel cell and power battery is taken as the research object. Based on the proposed power system structure, a fuel cell hybrid power management control strategy is designed, and the simulation model based on Matlab/Simulink and real vehicle are adopted to perform performance verification on standard operating conditions. The strategy aims at optimizing the power and economy, sets the target control value of the SOC, coordinates the power output of the "dual energy source system" of the vehicle, reduces the load power fluctuation of Fuel Cell System(FCS), optimize the working range of fuel engine and improve the energy recovery efficiency according to the vehicle energy demand, the real-time status of the assembly and the vehicle operating conditions, so that the fuel cell and the power battery work as much as possible in the optimal efficiency range. The test results in vehicle show that the energy management control method is effective in engineering application, and the performance has reached the vehicle design goal.
Zhao, Yongqiang, Song, Haoyuan, Liu, Yuanzhi, Yu, Zhao
Sensorless Individual Cell Temperature Measurement by Means of Impedance Spectroscopy Using Standard Battery Management Systems of Electric Vehicles2020-01-08634/14/2020
Lithium ion technology is state of the art for actual hybrid and electrical vehicles. It is well known that lithium ion performance and safety characteristics strongly depend on temperature. Thus, reliable temperature measurement and control concepts for lithium ion cells are mandatory for applications in electrical cars. Temperature sensors for all individual cells increase the battery complexity and cost of a battery management system. Normally, temperature is measured on module level in current battery packs, without observation of the individual cell temperature. Sensorless cell impedance-based temperature measurement concepts have been published and are validated in laboratory studies. Dedicated test equipment is usually applied, which is not useful for automotive series application. This work describes a practical approach to enable impedance-based sensorless internal temperature measurement for all individual cells using state-of-the art battery management system components. Excitation is generated by DC to DC converters of a standard commercial active balancing systems. For data acquisition, also an established commercial battery monitoring circuit unit is used. To overcome bandwidth limitations, a sub-sampling scheme is presented, which allows to determine the impedance at higher frequencies than the sampling rate. Impedance calculation is performed by means of efficient digital signal processing concepts with low demand on memory and processing power. Thus, the method can be integrated into existing battery management systems with low implementation effort. The concept is demonstrated on a 4-cell submodule of 26 Ah automotive Li-ion cells. It can also be applied in low-cost battery management systems without active balancing capability.
Haussmann, Peter, Melbert, Joachim
Step by Step Conversion of ICE Motorcycle to a BEV Configuration2020-01-14364/14/2020
With the mass movement toward electrification and renewable technologies, the scope of innovation of electrification has gone beyond the automotive industry into areas such as electric motorcycle applications. This paper provides a discussion of the methodology and complexities of converting an internal combustion motorcycle to an electric motorcycle. In developing this methodology, performance goals including, speed limits, range, weight, charge times, as well as riding styles will be examined and discussed. Based on the goals of this paper, parts capable of reaching the performance targets are selected accordingly. Documentation of the build process will be presented along with the constraints, pitfalls, and difficulties associated with the process of the project. The step-by-step process that is developed can be used as a guideline for future build and should be used as necessary. During the development and conversion process, the model of the electric motorcycle was developed in Simulink to size the battery pack and the electric motor. This model was also the focus of different design experiments to choose the proper components and subsystems to minimize the development cycle time. The goal of this paper is also to provide guidelines of the conversion process for the future industry as well as the academic arena.
Lawrence, Matthew D., Siavoshani, Saeed
Hardware-in-the-Loop Testing of Electric Traction Drives with an Efficiency Optimized DC-DC Converter Control2020-01-04624/14/2020
In order to reduce development cost and time, frontloading is an established methodology for automotive development programs. With this approach, particular development tasks are shifted to earlier program phases. One prerequisite for this approach is the application of Hardware-in-the-Loop test setups. Hardware-in-the-Loop methodologies have already successfully been applied to conventional as well as electrified powertrains considering various driving scenarios. Regarding driving performance and energy demand, electrified powertrains are highly dependent on the dc-link voltage. However, there is a particular shortage of studies focusing on the verification of variable dc-link voltage controls by Hardware-in-the-Loop setups. This article is intended to be a first step towards closing this gap. Thereto, a Hardware-in-the-Loop setup of a battery electric vehicle is developed. The electric powertrain consists of an interior permanent magnet synchronous machine and an inverter, which are set up as real components at a laboratory test bench. The test bench is connected to a real-time vehicle simulation including a battery model and the dc-dc converter model. The entire Hardware-in-the-Loop setup is successfully validated by vehicle measurements performed on a chassis dynamometer. Thereafter, the battery electric vehicle is tested at this Hardware-in-the-Loop setup for the worldwide harmonized light vehicle test cycle class 3. The tests are performed for electric powertrain configurations with and without dc-dc converter. For the application with dc-dc converter, reductions in energy losses of the traction machine by 5.4% and of the traction inverter by 37.6% are determined. This leads to an efficiency improvement of the entire electric powertrain by 1.5 percentage points, which results in a total energy reduction by 0.28 kWh/100km for the investigated test cycle. This use case demonstrates the efficiency improvements of a variable dc-link voltage and how Hardware-in-the-Loop tests can support the verification of dc-dc converter controls during frontloading phases of automotive development programs.
Etzold, Konstantin, Scheer, René, Fahrbach, Timm, Zhou, Shuang, Goldbeck, Rafael, Guse, Daniel, Frie, Fabian, Sauer, Dirk Uwe, De Doncker, Rik W., Andert, Jakob
Powertrain Thermal System Development for Small BEV2020-01-13834/14/2020
The dynamic performance of battery electric vehicles (BEV) is affected by battery output power, which depends on state of charge (SOC) and the temperature of battery cells. The temperature of the batteries varies in particular with the environment, in which the user stores the vehicle, and the battery output power. It is therefore necessary to employ thermal management systems that can control the battery temperature within the optimal range under severely hot and cold conditions in BEVs. A highly sophisticated thermal management system and its operation strategy were developed to fulfill the above requirements. The powertrain components to be thermo-controlled were located into two coolant circuits having different temperature range. The compact and efficient front-end heat exchangers were designed to optimally balance the cooling performance of powertrain, cabin comfort, vehicle aerodynamics and the vehicle design. The battery pack was optimally thermo-controlled by precisely controlling two 3-way valves in all driving and environmental conditions. To reduce the temperature variation between battery cells, the coolant passage including cooling plates in the battery pack were designed so that the coolant was homogeneously distributed into all battery modules. The pre-conditioning system of the battery, which controlled its temperature before driving by using telematics, were added to the thermal management system. It was clarified that this system significantly enhanced the driving range at low ambient temperature conditions. The developed system including control strategy realized that Honda’s small BEV demonstrated high dynamic and energy-efficient performance under all environmental conditions.
Ohnuma, Yoshikazu, Yamagishi, Yosuke, Minami, Katsuya
Design of a Flexible Hybrid Powertrain Using a 48 V-Battery and a Supercapacitor for Ultra-Light Urban Vehicles2020-01-04454/14/2020
Global warming has put the transport sector, a major contributor of CO2 emissions, under high pressure to improve efficiency. In this context, ultra-light vehicles weighting less than 500 kg, as well as hybrid powertrains, are nowadays seen as promising development trends. The design process of the powertrain of a vehicle combining the advantages of the two concepts is presented in this paper. Through a performance study based on a simple MATLAB model, and mathematical simulation, a proposal is made. A powertrain using a battery and supercapacitor 48V dual power source network, two electric motors and clutches to switch between conventional, parallel, series and full electric modes proves to be an interesting system in terms of performance and costs. A simulation study conducted on a scenario with different outcome possibilities showed that high modularity of the system allows to achieve fuel efficiencies equivalent to approximately 3 l/100 km on the Artemis cycle. Finally, integration, packaging and cost are considered and some hints for further powertrain efficiency improvements are presented.
El Ganaoui-Mourlan, Ouafae, Miliani, El Hadj, Carlos Da Silva, Daniel, Couillandeau, Matthieu, Gonod, Charlie, Miller, Guillaume
Development of New Power Control Unit with Small Size and Low Cost for Small Hybrid Vehicle with Two-motor Hybrid System2020-01-04584/14/2020
A new power control unit (PCU) has been developed for a Honda small hybrid vehicle with a two-motor hybrid system launched in 2020. For small hybrid vehicles, downsizing and reducing costs of hybrid systems are major challenges. As such, there were emphatic requirements for the newly developed PCU to be small and affordable. To satisfy these requirements for the PCU, new technologies and components have been introduced such as an all-in-one type intelligent power module (IPM) with integrated functions and reverse conducting IGBT (RC-IGBT), a new control sequence for voltage control unit (VCU), and revised PCU packaging to improve cooling performance. The new IPM has a printed-circuit board (PCB) equipped with an electric control unit (ECU) and gate drive circuits, 7 current sensors, and a power module with RC-IGBTs. This functional integration led to a reduction in the number of main electrical PCU assembly components from 9 in the previous PCU to 2 in the new PCU. In addition, the number of mounted parts on the PCBs was reduced from 2,200 to 1,300 by means of various methods such as the integration of the ECU and gate drive circuits. Moreover, the size of the power module, the area of the RC-IGBTs, and the number of parts in the power module were reduced owing to the introduction of RC-IGBTs instead of conventional IGBTs and a diode pair, reduction of loss in the RC-IGBTs, and increased operating temperature of the RC-IGBTs. A new VCU control sequence suppresses the fluctuation in high DC line voltage, while a cooling structure that covers the surrounding of a high voltage capacitor reduces the capacitor temperature. These measures reduce capacitance of the capacitor almost by a half compared to that of the previous model. The newly developed technologies and components dramatically decreased the number and volume of parts in the PCU. Thus, a new PCU with small size and low cost was realized.
Nonaka, Kenichi, Takebayashi, Kenichi, Kashimura, Yukiya, Ueno, Yuichiro, Kondo, Yasuhiko
Development of Hydrogen Powered Fuel Cell e-Snowmobiles2019-32-05551/24/2020
In the highly innovative and holistic flagship project HySnow (Decarbonisation of Winter Tourism by Hydrogen Powered Fuel Cell Snowmobiles), funded by the Austrian Climate and Energy Fund, the decarbonization of winter tourism is being demonstrated. Within this project, two prototype e-snowmobiles have been developed including the adaption of a Polymer Electrolyte Membrane Fuel Cell (PEM-FC) system for the low temperature and high-performance targets and the integration of the drivetrain into the vehicle. In this paper the drivetrain development process of the prototype e-snowmobiles will be presented with the aim to derive specifications for the drivetrain components as PEM-FC system, hydrogen storage system, electric drive, battery and power electronics. Based on typical use cases for snowmobiles overall vehicle specifications and requirements are defined. Associated driving cycles are investigated and used as input for the development process. Subsequently, analyses regarding possible drivetrain topologies based on technical and economical vehicle requirements are carried out. In parallel, vehicle implementation concepts based on standardized development processes are performed. The development and the design process are verified by verification and optimization loops. The results define technical specifications of the PEM-FC, the battery along with the required hydrogen tank; to give an optimum concerning required drivetrain efficiency, and hence driving range as well as vehicle space and weight. It is expected that the hydrogen powered e-snowmobiles with high power, drivability, driving fun, and the lack of noise emission, pollutants, and GHG will convince the users of the concept benefits.
Pertl, Patrick, Aggarwal, Martin, Trattner, Alexander, Hinterberger, Walter, Foxhall, Nigel
How to Protect Patients from Potential Electrical FailureTBMG-357771/1/2020
People and power don’t mix well, and this is particularly true when people are medical patients. Aside from the more usual environment of a medical facility, patients are also increasingly using medical devices at home. Medical equipment is therefore heavily regulated by standards-based requirements and subsequent product testing to ensure the safety of patients and healthcare professionals alike.
System Level Vehicle Model Development of Light Heavy Duty Battery Electric Vehicle in GT-Suite2019-01-236912/19/2019
Model based development is an approach pursued to obtain an advanced insight into powertrain & vehicle development. This approach enables the ability to trace errors early on, thereby reducing the dependence on field testing and saving cost & time involved in the development process. The purpose of this study is to develop a system level battery electric vehicle model using GT-Suite as modeling platform, for Light Heavy Duty applications. The outcome of this study is electric range estimation, performance analysis, component sizing and optimization for inverter-motor and battery components. The model has been developed using a map-based approach. Hence, the simulation time is faster than real-time, requires less input data and can be used for preliminary range & performance estimation. The model fidelity has been validated against performance, acceleration, deceleration and coast-down data obtained from field testing. Apart from field data, standard EPA drive cycles and customer usage based drive cycles have been used as target to the model. Energy efficiency (Wh/mile) and MPGe calculations have been performed as part of model validation. The applications of this study are to observe and study the effect of parameters such as motor power, air conditioning, battery capacity etc. on range and performance.
Pasupathi, Santhosh, Shetty, Aishwarya, Rathod, Smruti, Bergsieker, Gerald
Development of Electric 4WD System For Compact Hybrid Car2019-01-221612/19/2019
In 2016, NISSAN launched a new electric power train for compact cars that shares the traction system for electric vehicle. NISSAN had utilized this high potential electric powertrain to combine the simple 4WD system, driven by electric motor. In 2002, NISSAN released a simple electric motor driven 4WD system for compact car that converts the engine output to electricity and drives the rear wheels with a direct current (DC) electric motor. This paper describes the system configuration and the value of new driving by combination of electric 4WD and new electric powertrain.
Konishi, Yasuhiro, Taira, Masahito, Ito, Hideaki Ootsuka Tomohiro, Yoshimoto, Kantaro
Cetrax Lite - Implementation on a Light Duty truck2019-01-237112/19/2019
Electric mobility becomes more and more important for commercial vehicle applications. Hybrid or electric vehicles help to reduce CO2 and other emissions, but also have additional benefits like reduced noise. The driveline design plays a crucial role for the operation of such vehicles but for an effective design, costs and on-weight also have to be considered. ZF Electric strategy provides tailored driveline solutions for Light Commercial Vehicles. This presentation resumes the implementation of such a driveline concept into a Japanese made LCV, where the differences between European and Asian application cases have been evaluated. The project shows a proof of concept where mechanics, HV system and functions have been tested in order to implement a series production design.
de la Cruz, Rafel Pascual, Speck, Frank-Detlef
Development Strategy for 4th Generation PCU2019-01-230912/19/2019
Toyota Motor Corporation has developed new Hybrid Vehicle (HV) and Plug in Hybrid Vehicles (PHV) from Compact class to Medium class. These vehicles incorporate newly developed hybrid systems for the improvement of fuel efficiency. The feature of these new generation power control unit is smaller, lighter, and higher efficiency than the previous generation. To adapt to various output systems, a development strategy of new generation Power Control Unit (PCU) was established. Based on the strategy, the development efficiency was improved. In this Paper, the strategy is described.
Jojima, Yuki
Design and Analysis of Sigma Z-Source Inverter for PV Applications2019-28-012310/11/2019
Traditional Voltage Source Inverter (VSI) produces lesser output voltage than the input and causes shoot-through due to the gating of the semiconductor device connected in same leg. The ZSI is used to overcome the inadequacies of VSI. The ZSI has been extensively used in electric drives, PV system and UPS. The conventional ZSI suffers some disadvantages like restricted boost capability, discontinuity in input current and large inrush current. These limitations are overcome by using a transformer which replaces the inductor in the impedance source network. In high-voltage gain applications, the single transformer-based ZSI topologies requires more turns ratio which requires large size transformer. For improving the boost capability, the TZSI is used. The Z-source network of the TZSI constitutes two transformers with low turns ratio. TZSI has certain demerits such as restricted boost capability, high inrush current and discontinuity in the input current. However, TZSI requires high turns ratio to increase the boost capability. Thus, the modified ZSI, i.e. sigma ZSI is investigated in this paper. The sigma ZSI has the advantage of having reduced turns ratio with enhanced boost capability.
Nallathambi, Kalaiarasi, Rangarajan, Uthra, Daniel, Anitha
A Fuzzy Logic Based Energy Management of Grid Connected Hybrid Energy System2019-28-007610/11/2019
On account of boundless presence and eco-friendly nature of Sustainable Energy Sources (SES) like Wind system, PV etc. power generation using SES became more captivating. This work concentrates on Energy Management (EM) of grid synchronized Hybrid Renewable Energy System (HRES) along with fuzzy logic control. Where the HRES system is a combination of solar panel and wind turbine as sources. Along with an electrical battery for energy storage via an interface using a DC-DC fused CUK-SEPIC converter with multiple input is adopted. This convertor is employed to incorporate the HRES to the main grid. In addition to grid integration a Fuzzy Logic Based (FLB) controller is employed to increase the efficiency of the system. The converter topology used is a crossbreed of wind and solar power system, which is used to eliminate the inclusion of MPPT. A two level framework is imposed, which includes a logic controller to ensure efficient EM when HRESs are interconnected with the grid. Simulation of the FLB energy management system is performed along with the implementation of hardware setup.
Dayalan, Suchitra, Rathinam, Rajarajeswari, Pandey, Pranav, Adap, Mrutyunjay
Fuel Cell-Based Powertrain Analysis for Tramway Systems2019-24-024810/7/2019
In this paper, a comparison of three different hybrid powertrains is analysed. The numerical model is used to simulate powertrain behaviour in rail application, on a pre-set drive cycle, composed of many acceleration and decelerations, in order to test the components features. The numerical model is dynamic and it is implemented in Matlab-Simulink environmental. A proton exchange membrane fuel cell (FC) is used; it is the most used in transport applications, thanks to its lower temperature compared to the other fuel cell types, which allows fast start up operation and rapid demand changes. A standard supercapacitor (SC), given by higher power density, is utilized as the energy storage system (ESS), Regarding the battery (B), two types are considered, because the battery is used both as prime mover and main component of the ESS; Li-ion batteries are chosen, owing to their good trade-off between specific power and energy. Therefore, three configurations, FC-SC, FC-B and B-SC, are analysed. The vehicle model takes into account other components. The regenerative brake system is used to recover energy during the deceleration phases, and the auxiliary system is modelled in order to consider the consumption due to lighting, air conditioning, etc. The DC/DC converter is used to connect energy sources and load; it is unidirectional for the FC and bidirectional for the other sources. This is because the ESS provides power for the drive cycle and it stores energy provided by the FC (when the power demand is low) and recovered by the regenerative brake (in deceleration operation). In addition, a control system is implemented, able to manage the entire system and set the power output of each source at each instant of time. It works in order to achieve good performance for each energy source, in terms of high efficiency and long lifetime. This means low power variations for the FC and a pre-set interval for the ESS state of charge. At the end, the results achieved by the simulations (such as efficiency, state of charge, and hydrogen consumption) are discussed and analysed for the different configurations.
Fragiacomo, Petronilla, Piraino, Francesco
Aircraft Electrical InstallationsARP4404C (Current)9/19/2019
It is the purpose of this document to present design recommendations that will provide a basis for satisfactory and safe electrical installations in transport aircraft. This document is not intended to be a complete electrical installation design handbook. However, the requirements for safety extend so thoroughly throughout the electric systems that few areas of the installation are untouched by the document. It is recognized that individual circumstances may alter the details of any design. It is, therefore, important that this document not be considered mandatory but be used as a guide to good electrical application and installation design. Transport aircraft electric systems have rapidly increased in importance over a number of years until they are now used for many functions necessary to the successful operation of the aircraft. An ever increasing number of these functions are critical to the safety of the aircraft and its occupants. The greatly increased power available in electric systems is another factor in aircraft safety. These considerations make it essential that aircraft electrical design practices be carefully considered from the standpoint of safety and reliability. It is believed that this document will be of value in pointing out potential difficulties and in solving many of the problems.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Inductive Power Transfer for Spaceflight SystemsTBMG-349138/1/2019
NASA Goddard Space Flight Center has developed technology that uses inductive power transfer (IPT) for wireless power interfaces between spaceflight elements (such as the payload, vehicle, and pad). Current spaceflight systems require traditional hardwire connections for power interfaces. This introduces risk of failure due to such factors as bent pins and contact contamination, as well as other disadvantages.
Hybrid and EV First and Second Responder Recommended PracticeJ2990_201907 (Current)7/29/2019
xEVs involved in incidents present unique hazards associated with the high voltage system (including the battery system). These hazards can be grouped into three categories: chemical, electrical, and thermal. The potential consequences can vary depending on the size, configuration, and specific battery chemistry. Other incidents may arise from secondary events such as garage fires and floods. These types of incidents are also considered in the recommended practice (RP). This RP aims to describe the potential consequences associated with hazards from xEVs and suggest common procedures to help protect emergency responders, tow and/or recovery, storage, repair, and salvage personnel after an incident has occurred with an electrified vehicle. Industry design standards and tools were studied and where appropriate, suggested for responsible organizations to implement. Lithium ion (Li-ion) batteries used for vehicle propulsion power are the assumed battery system of this RP. This chemistry is the prevailing technology associated with high voltage vehicle electrification today and the foreseeable future. The hazards associated with Li-ion battery chemistries are addressed in this RP. Other chemistries and alternative propulsion systems including hydrogen fuel cells are not considered in this version of SAE J2990. Recommendations for hazards associated with hydrogen vehicles can be found in SAE J2990/1.
Hybrid - EV Committee
Communication Transceivers Qualification Requirements - CANJ2962/2_201907 (Current)7/18/2019
This document covers the requirements for transceiver qualification. Requirements stated in this document will provide a minimum standard level of performance for the CAN transceiver in the IC to which all compatible transceivers shall be designed. No other features in the IC are tested or qualified as part of this recommended practice. This will assure robust serial data communication among all connected devices, regardless of supplier. The goal of SAE J2962-2 is to commonize approval processes of CAN transceivers across OEMs. The intended audience includes, but is not limited to, CAN transceiver suppliers, component release engineers, and vehicle system engineers.
Vehicle Architecture For Data Communications Standards
Communication Transceivers Qualification Requirements - LINJ2962/1_201907 (Current)7/18/2019
This document covers the requirements for transceiver qualification. Requirements stated in this document will provide a minimum standard level of performance for the LIN transceiver block in the IC to which all compatible transceivers shall be designed. No other features in the IC are tested or qualified as part of this recommended practice. This will assure robust serial data communication among all connected devices regardless of supplier. The goal of SAE J2962-1 is to commonize approval processes of LIN transceivers across OEMs. The intended audience includes, but is not limited to, LIN transceiver suppliers, component release engineers, and vehicle system engineers.
Vehicle Architecture For Data Communications Standards
Hydrogen Fuel Cell and Battery Hybrid Architecture for Range Extension of Electric VTOL (eVTOL) AircraftF-0075-2019-144905/13/2019
The objective of this paper is to study the impact of combining hydrogen fuel cells with lithium-ion batteries through an ideal power sharing architecture to mitigate the poor range and endurance of battery powered electric vertical take- off and landing (eVTOL) aircraft. The benefits of combining the two sources is first demonstrated by a conceptual sizing of an electric tiltrotor for an urban air taxi mission of 75 mi cruise and 5 min hover. It is shown that an aircraft of 5000-6000 lb gross weight can carry a practical payload of 500 lb (2-3 seat) with present levels of battery specific energy (150 Wh/kg) if only a battery-fuel cell hybrid powerplant is used, combined in an ideal power sharing manner, as long as high burst C-rate batteries are available (4-10 C) for a limited duration (2.5 min). A powerplant using batteries alone can carry less than half the payload; fuel cells alone can not lift off the ground. The operation of such a parallel system is explained using systematic hardware testing and modeling and simulation. The concepts of un- regulated and regulated power sharing architectures are described. A regulated architecture that can implement ideal power sharing is built-up in a step-by-step manner. It is found only two switches and three DC-to-DC converters are necessary, and if placed appropriately, are sufficient to achieve the desired power flow. The power system model is validated with test data and used to gain fundamental understanding of the power sharing architecture.
Ng, Wanyi, Patil, Mrinalgouda, Datta, Anubhav
Electrical Charging Systems for Off-Road Work MachinesJ180_201905 (Current)5/10/2019
This SAE standard describes alternator physical, performance, and application requirements for heavy-duty electrical charging systems for off-road work machines, including those defined in SAE J1116.
CTTC C2, Electrical Components and Systems
High Frequency Impedance and Electromagnetic Interference Suppression of Lithium-Ion Power Battery Pack2019-01-10604/2/2019
When electric vehicle speeds up or slows down, rapidly changing current and voltage (di/dt and du/dt) would occurs in its lithium-ion power battery. In this way, the impedance of power battery would changes with parasitic parameters because that the ion transport in electrolytes would influence diffusion effect and polarization effect of battery. Thus, the lithium-ion battery cannot be regarded as ideal component in high frequency, which could cause unpredictable problem in electromagnetic interference (EMI). However, most previous studies took lithium-ion power batteries as disturbed objects or transmission routes, which ignore the electromagnetic interference of battery itself. Based on it, this paper analyses the internal mechanism of EMI in lithium-ion power battery, and simulates the distribution of electromagnetic field as well as it corresponding interference suppression measures. Firstly, the test platform for parameter extraction of battery cell is built. The parasitic parameters are extracted through testing. The high-frequency equivalent circuit of power battery is consequently established. Secondly, peripheral circuit of lithium-ion battery (DC/AC system) is established to obtain the current at DC bus, which would be imported to an electromagnetic simulation tool as excitation source to conduct co-simulation of field and circuit for distribution of electromagnetic field in battery. Thirdly, the lithium-ion battery pack is optimally designed in EMI. The structure and parameters of the filter are selected according to energy distribution frequency band of EMI signal. Results of simulation and testing turn out that the designed filter could decrease EMI effectively.
Zhang, Ji, Lv, Yu
Design of a Grid-Friendly DC Fast Charge Station with Second Life Batteries2019-01-08674/2/2019
DC-fast charge (DCFC) may be amenable for widespread EV adoption. However, there are potential challenges associated with implementation and operation of the DCFC infrastructures. The integration of energy storage systems can limit the scale of grid installation required for DCFC and enable more efficient grid energy usage. In addition, second-life batteries (SLBs) can find application in DCFC, significantly reducing installation cost when compared to solutions based on new battery packs. However, both system architecture and control strategy require optimization to ensure an optimal use of SLBs, including degradation and thermal aspects. This study proposes an application of automotive SLBs for DCFC stations where high power grid connection is not available or feasible. Several SLBs are connected to the grid by means of low power chargers (e.g. L2 charging station), and a DC/DC converter controls the power to the EV power dispenser. The architecture of the DC bus, the size and state of health of the battery system determine efficiency, cost, and reliability of the station. A technical and economic comparison is proposed, evaluating solutions with different battery pack sizes and control strategies. An accurate numerical model is used to evaluate the performance of the different architectures. A realistic usage profile of the charging station is defined and real-world scenarios are considered for the SLB parameters.
D'Arpino, Matilde, Cancian, Massimo
EMI Coupling Mechanisms and Mitigations in a DC-DC Converter2019-01-06094/2/2019
The EMI coupling mechanisms of a DC-DC converter in electrified vehicles are investigated for both conducted and radiated EMI. The noise sources and propagation paths are identified and quantified. The results show that the magnetic coupling between noise sources to some sensitive locations, including HV/LV terminals and CAN connector, can cause excessive emissions. The coupling between different components of the EMI filters may also lead to the degradation of the filter performances. Strategies are proposed to reduce the coupling, improve the filter performance and mitigate the emissions. The performances are verified in experiment.
Xu, Zhuxian, Chen, Chingchi
Optimization and Evaluation of 12V/48V Architectures Based on EDS Simulation and Real Drive Cycles2019-01-04824/2/2019
Both the rising number of electrical systems and the electrical part of the powertrain are considerably increasing the electrical power requirements of vehicles. As a consequence, multiple voltage supply levels have been introduced. However, even if only the 12V/48V configuration is considered, as in this paper, the number of possible electrical distribution system (EDS) architectures is greatly enlarged. Additional degrees of freedom are the allocation of the loads to the voltage levels, the dimensioning of new components, and the control strategy. Hence, the optimization of such architectures must be based on simulation, which allows the evaluation of a multitude of variants and test scenarios within an acceptable time frame. While strict cost, weight, and quality constraints must be upheld, the stability of the voltage supply is a major focus because a significant part of future electrical systems is highly safety-critical. In this paper, quantitative quality criteria for the evaluation of the voltage stability are applied which enable a systematic assessment of the performance of an EDS. The presented approach is based on a modular simulation environment which allows the configuration and dimensioning of various EDS architectures and the use of hetero-geneous component models. Furthermore, a particular emphasis is placed on the definition of test scenarios, where drive-dependent loads can be activated by stored real drive-cycle data, while the other electrical devices are controlled via a predefined Gantt chart. Thus, realistic test conditions can be simulated and evaluated using the quality criteria mentioned above. The results enable comparative investigations into the impact of the operating strategy, the configuration, and the dimensioning of the 12V/48V components. Thus, the precondition for a systematic optimization is established. The paper presents the implemented simulation environment, the stability criteria, the applied test scenarios, results and a comparative evaluation for a set of EDS architectures, and a conclusion.
Brabetz, Ludwig, Ayeb, Mohamed, Sebastiao, Daniel
Electric Vehicle Fast Chargers Present Some Overlooked Circuit Protection ChallengesTBMG-341534/1/2019
The first mass-produced electric vehicles (EVs) hit the road late in 2010 with the introduction of the Nissan Leaf, which remains the world’s top-selling, highway-capable, all-electric car. In the United States, sales of EVs are gaining momentum, with 2017 sales up by 25% over 20161. EVs, however, are still outnumbered by roughly 300 to 1 by vehicles powered by internal combustion engines. EVs are unlikely to become fully mainstream until there is a nationwide network of charging stations that can charge a vehicle quickly enough to get travelers back on the road in a matter of minutes rather than hours.
Power Architectures for Patient-Connected Medical DevicesTBMG-3325611/1/2018
Meeting the requirements for patient-connected medical devices can present challenges for power system designers. There are several key elements to consider, including isolation, leakage/touch currents, electromagnetic compatibility (EMC), number of power outputs required, and the environment for use. This article discusses approaches for power architectures within medical devices for patient-connected applications.
Ground Support Equipment Electrical SystemsAIR1336B (Current)9/27/2018
This SAE Aerospace Information Report (AIR) considers the following major areas: 1 major components and their ratings; 2 selection criteria for optimum design balance for electrical systems; 3 effects of operating conditions and environment on both maintenance and life of components; 4 trouble signals - their diagnosis and cure.
AGE-3 Aircraft Ground Support Equipment Committee
Space Power StandardAS5698A (Current)9/13/2018
This standard defines the requirements and characteristics of electrical power for spacecraft. This standard also defines analysis, verification, and testing methodologies to be used to ensure that the loads operate when connected to the specified power quality and performance as defined by this standard.
AE-7C Systems
Aircraft electric propulsion technology review – A shift from turbofan to the ethrust era2018-36-00969/3/2018
Following the electrification trend observed in the automotive industry, the idea of an electric propulsion aircraft has also drawn attention and investments from a range of aviation industry stakeholders (including the world's largest aerospace companies) focused on both fuel burning reduction and environmental performance improvement (greenhouse gases (GHG), pollutants and noise emissions) potential of electric propulsion technology. Electric propulsion has the potential to provide more efficient, cleaner, quieter and more profitable aviation services, with potential benefits to both airlines and passengers. Furthermore, with its inherent quiet feature, it has also the potential to lead to a reassessment of the role of airports along the world cities, as well as revitalize regional short-haul flights and helps the launch of air service into underserved regions around the world. From a technical perspective , the aviation propulsion electrification strategy might involves the integration of electric powetrains into aircrafts into the i) all electric; ii) hybrid and iii) turboelectric approach. The former might rely solely on batteries as energy sources and requires engines up to 300 times more powerful than current available electric aviation motors (currently used for two-seater prototypes). The hybrid configuration uses gas turbines, for turbofan propulsion, and to charge batteries (with turbogenerators), which also provides energy for electric propulsion for one or more phases of flight. Finally, turboelectric configurations do not rely on batteries to supply propulsion energy. Rather, they use gas turbines to drive electric generators to feed distributed electric driven fans, with their inherent aerodynamic benefits associated with distributed propulsion. Hybrid architectures might provide a more realistic near-term pathway, while key enabling technologies - batteries, high power electric motors and superconducting electric power - reach the required improvement, into an expected 10 to 20 year timeframe. The most likely niche of the industry to first commercially launch this groundbreaking technology is the commuter and regional jet category, with a 50 to 70 passenger capacity and a short to mid range. This work is supposed to present an overview of aircraft electric propulsion technology, followed by an assessment of its potential operational, environmental and economic benefits, as well as the required technological breakthrough to reach the electric thrust era.
Barbosa, Fábio Coelho
Aircraft Flashtube Anticollision Lighting SystemsAIR1276B (Current)8/28/2018
This document covers red and white anticollision lights using flashtubes as the light source.
A-20B Exterior Lighting Committee
Auxiliary Power Solutions for 1500 VDC Photovoltaic SystemsTBMG-325068/1/2018
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.
Model Analysis of Efficiency and Energy Distribution in the Powertrain of an Electric Vehicle Equipped with a Solar Cell Battery2018-01-50267/23/2018
This article presents an analysis of implementation of a solar cell system within an electric vehicle (EV), putting emphasis on the energy efficiency and control of energy flows. In the considered system topology, interaction between the low-voltage (LV) photovoltaic system (PV system) and the high-voltage (HV) traction system is organized through the energy medium in the form of a buffer battery. Both system structure and control algorithm were designed taking into account actual efficiency characteristics of involved components in order to attain maximum energy performance of the entire system. Efficiency analysis of the PV system components allowed substantiating an idea of using a LV buffer battery, as well as proposing PV array configuration preferable from the energy point of view. Analysis also allowed to draw the essential principles for elaboration of the control algorithm, which provides maximum efficiency of energy distribution in the PV system. The article gives a description of the mathematical model developed for analyzing system operation and dynamics of its key parameters. The model calculates vehicle dynamics and essential variables of the powertrain components (batteries, traction electric drive, voltage converters, and solar cells). Control algorithm regulating energy flows within the PV system was implemented as a part of said model. To simulate actual operating conditions of PV cells, a model of the solar irradiance (SI) was employed considering specified location, season, daytime, and weather (i.e., clouds). Simulations were performed taking into account typical operating regimes of the vehicle including different levels of the auxiliary power that feeds LV onboard consumers.
Kulikov, Ilya, Karpukhin, Kirill
Characterization, Conducted ImmunityJ2628_201806 (Current)6/12/2018
The methods included in this document are: a Voltage-Temperature Design Margins. b Voltage Interruptions and Transients. c Voltage Dropouts and Dips. d Current Draw Under a Number of Conditions. e Switch Input Noise These methods are best applied during the Development stage but can be used at all stages (e.g., Pre-Qualification, Qualification or Conformity).
Electromagnetic Compatibility (EMC) Standards
Cost Effective Automotive Platform for ADAS and Autonomous Development2018-01-05884/3/2018
This paper presents a cost effective development platform, named FEV-Driver, for Advanced Driver Assistance Systems (ADAS) and autonomous driving (AD). The FEV-Driver platform is an electric go-kart that was converted into an x-by-wire vehicle which represents the behavior of a full-scale electric vehicle. FEV-Driver has the advantage of being a small-scale vehicle that can be used with a significant lower safety risk compared to full-sized vehicles. The ADAS/AD algorithms for this platform were developed in both Simulink and C++ software and implemented within the Robot Operating System (ROS) middleware. Besides the description of the platform, Lane Keep Assist (LKA) and Automatic Emergency Braking (AEB) algorithms are discussed, followed by a path planning algorithm which enables the vehicle to drive autonomously after a manually controlled training lap. The modular system architecture allows for complete controller exchange or adaptation to different vehicles. The adaptation and implementation of the platform into a full-scale passenger vehicle is described in the last section of this paper. The presented platform has proven to be a low-cost scalable platform for development and verification of ADAS and AD functions.
Alzu'bi, Hamzeh, Dwyer, Brian, Nagaraj, Sarika, Pischinger, Martin, Quail, Alanna
Model Prediction Based Boost Converter Control Method for HEV Applications2018-01-04524/3/2018
Boost converter is widely applied to hybrid electric vehicles (HEV). Typical control methods employ two proportional-integral (PI) regulators to fulfill DC bus voltage closed-loop control and inductor current closed-loop control, respectively. They have intrinsic performance limitations: 1) slow dynamic response of DC bus voltage regulation; 2) high overshoot voltage during transient state; 3) it is difficult to design four gains best fit all operational conditions. This paper proposes a model prediction based boost converter control method for HEV applications. The proposed control method employs model based instantaneous power prediction and dynamic optimization in real time by minimizing a defined cost function to overcome above issues. First of all, the issues of typical control methods are analyzed. Then, the proposed control method is presented in detail, followed by simulation verification and comparison with PI based control method. Simulation results show that the proposed control method provides much better performance to boost converter system than the PI-based control.
Ge, Baoming, Chen, Lihua, Zarei, Shahram
Transmission-Mounted Power Control Unit Including 12-Volt DC-DC Converter for Two-Motor Hybrid System2018-01-04574/3/2018
This research proposes a third-generation power control unit (PCU) for a two-motor hybrid system. To make a more compact intelligent power unit (IPU) to be located under the second seat, a PCU with a 12-volt DC-DC converter (DCDC) that mounts directly on the transmission was developed, whereas the DCDC was previously mounted within the IPU. Since this has a considerable impact on the engine room layout, the technology described below was used to make the PCU even more compact than the second-generation unit. The power module, a key component of the PCU, now uses Ag nanoparticles sintering bonding rather than conventional solder bonding. This helps lower thermal resistance and enables smaller power semiconductors. The voltage control unit (VCU) has a new circuit that uses a multi-stage switching circuit and electric power transfer capacitor instead of the conventional chopper circuit. This makes it possible to shrink the reactor to less than 65% of its usual volume without raising the carrier frequency, and enables a layout that efficiently uses both sides of the water jacket (W/J), so that no specially designed W/J needs to be added just for the DCDC. As for the W/J seal, friction stir welding (FSW) to increase rigidity was used to reduce seal width and to make the W/J itself more compact. The use of these compactness technologies enabled the PCU to maintain all the efficiency of a second-generation PCU and made it possible to build the DCDC in the PCU with its volume less than a second-generation one. Development of this PCU makes the IPU much more compact and provides a similar amount of trunk space as in a gasoline-powered vehicle.
Ozuchi, Yasuhiro, Tomokage, Ryoji
Development of High-Power-Density DC-DC Converter Using Coupled Inductors for Clarity Plug-In Hybrid2018-01-04584/3/2018
Honda has developed an electric powertrain for a 2017 plug-in hybrid vehicle using its second-generation SPORT HYBRID i-MMD powertrain system as a base. The application of the newly developed powertrain system realizes a long all-electric range (AER), allowing operation as an EV for almost all everyday driving scenarios, with dynamic performance making it possible for the vehicle to operate as an EV across the entire speed range, up to a maximum speed of 100 mph. The amount of assist provided by power from the batteries during acceleration has been increased, helping to downsize the engine while also balancing powerful acceleration with quietness achieved by controlling racing of the engine. In order to realize this EV performance with the second-generation SPORT HYBRID i-MMD system as the base, it was necessary to increase the power output of the DC-DC converter, taking restrictions on space into consideration. An interleaved circuit design using coupled inductors was employed as the method of increasing the power density of the DC-DC converter. This circuit design reduced magnetic flux generated in the inductor cores by direct current, making it possible to reduce the size of the inductors. However, it was not possible to position electric devices such as current sensors close to the coupled inductors due to magnetic flux leakage to the exterior, making it challenging to increase the integration density of the components. In order to address this issue, a configuration of coupled inductors that reduces magnetic flux leakage was developed, making it possible to increase the integration density of the peripheral layout of the DC-DC converter. The application of the proposed coupled inductors has increased the continuous power density of the DC-DC converter approximately 2-fold in comparison with the conventional unit employed in previous Honda hybrids.
Komatsuzaki, Akitomo, Hashino, Satoshi
Development of a 48 V P0 Demonstration Vehicle with eBooster® Air Charging2018-01-04184/3/2018
The design of a demonstration vehicle is presented where improvements to the electrical and air induction systems are made which provide increased performance with improved fuel economy. This is made possible by a 48 V architecture which enables the deployment of new components, specifically a belted motor generator unit (MGU) and electrically-driven compressor (eBooster®). The synergy between these components enables energy efficient means to collect regenerated energy and provide added torque, faster engine response, and extended engine off operation among a list of added features. Control features and strategy are highlighted along with simulation and vehicle test data. Resultant performance and fuel economy benefits are reviewed which support the contention of 48 V being a cost effective architecture to enable CO2 reduction relative to a higher voltage hybrid.
Mohon, Sara, Van Maanen, Keith, Liu, Xiaobing, Keller, Philip, Griffen, Matthew, Negandhi, Varun
Circuit Protection Challenges for Battery Management SystemsTBMG-287014/1/2018
The market for higher-voltage automotive systems is expanding. The number of electric vehicles that use battery-powered drive systems having voltage equal to or higher than 48V is expected to grow by double digits in the coming years. As both consumers and governments press toward less reliance on fossil fuels and demand improved air quality via lower or zero emissions, electric vehicles are moving to the forefront. At the same time, electric systems comprise a greater percentage of overall automotive function. Components that used to be driven mechanically or hydraulically now require higher voltage and more powerful batteries. Onboard entertainment, safety, and convenience features add to the electric draw.
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