Browse Topic: Electric drives

Items (290)

A Power Split eCVT Hybrid for Sustainable Urban Mobility

2024-32-002904/18/2025

The main drivers for powertrain electrification of two-wheelers, motorcycles and ATVs are increasingly stringent emission and noise limitations as well as the upcoming demand for carbon neutrality. Two-wheeler applications face significantly different constraints, such as packaging and mass targets, limited charging infrastructure in urban areas and demanding cost targets. Battery electric two wheelers are the optimal choice for transient city driving with limited range requirements. Hybridization provides considerable advantages and extended operation limits. Beside efficiency improvement, silent and zero emission modes with solutions allowing fully electric driving, combined boosting enhances performance and transient response. In general, there are two different two-wheeler base categories for hybrid powertrains: motorcycles featuring frame-integrated internal combustion engine (ICE) and transmission units, coupled with secondary drives via chain or belt; and scooters equipped with

Schoeffmann, W., Fuckar, G., Hubmann, C., Gruber, M.

A review and modelling of PMSM drive technology for Electric vehicle application

2024-26-012701/16/2024

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

Challenges in NVH refinement of electric vehicle built on ICE platform

2024-26-021601/16/2024

In recent years electric vehicles have seen rapid sales growth globally. Also, there is a massive push from global institutions for transition to electric mobility in the interest of reducing greenhouse gases and adhering to climate change agreements. In India, union government has set the target of 30% EV penetration in private cars, 70% in commercial vehicles & 80% in 2 wheelers by 2030. To meet such ambitious targets in a developing country like India, low-cost solutions are needed to democratize the electric mobility. In the case of electric cars, conversion of ICE platform to electric is the most cost feasible solution but at the same time it comes with various challenges. An electric car is being developed carrying over the top hat from the ICE version. Underbody is being redesigned to accommodate battery module under the floor. Except for BEV architecture, most of the parts are carried over from ICE platform to reduce development time and leverage cost advantage. NVH challenges

Channamaneni, Rajesh Babu, MR, Vikram

E-drive System Selection Criterion for EV Commercial and Passenger Vehicles Segments

2024-26-025301/16/2024

Electric Vehicles are one of the promising technologies to curb the climate change by reducing CO2 emissions significantly. Electric vehicle component selection is a complex process which has to fulfil multiple requirements with trade-off between Performance & Efficiency, Efficiency & cost, Performance & NVH, etc. Hence, it's a challenge to select right E-Drive comprising Motor and overall gear ratio to meet EV program targets. This study focuses on criterion used for selecting an E-Drive system comprising Motor, MCU and overall gear ratio for Electric Vehicles in Commercial and Passenger segments. The automotive market in India is analysed and the most popular vehicles in CV and PV segments with comparable Kerb Weights have been identified; Small Commercial Vehicle (SCV), and Compact SUV. The criterion is based on vehicle performance, design, cost, and NVH and efficiency requirements. The simulations are done to estimate motor torque/power requirements & overall gear ratio meeting the

Shendge, Raman Suresh, Jadhav, Vaibhav V., Warule, Prasad, Wani, Kalpesh

Design and Development of E-axle as a retro and OE fitment solution for Light Commercial Vehicles ranging from 1.5 to 5 Ton GVW

2024-26-011901/16/2024

The Light commercial vehicle (LCV) is primarily used for the last mile delivery and it holds the volume share of around 61% in the commercial vehicle segment. The last mile delivery services have seen a massive surge after the CoVID-19 pandemic resulting is the increase sale of LCV in last few years and is expected to grow further by 8-11% in the coming years. However, city logistic is also responsible for most pollution and noise in the city. Hence, policymakers are aiming to reduce carbon footprint by promoting the use of Electric vehicle by providing incentive to automakers though schemes like FAME-I and FAME-II. In order to effectively reduce the carbon footprint within city it is important to increase the use of new electric vehicle and convert the old polluting vehicles to electric. Hence, a retro fitment solution for converting used LCV to electric can help in reducing emission as well as noise pollution. Later the same solution can be offered as OE fitment solution. Though

VAIBHAV, KUMAR, Mulik, Rakesh Vilasrao, Shrikrishna Ramdasi, Sushil

Measurement uncertainty and its influence on e-Drive optimization applications

2024-26-009701/16/2024

This paper gives insights in the theoretical measurement uncertainty of E-Drive rotor position dependent results, like Id and Iq calculations, done by a modern propulsion power analyzer (PA). The calculation of Id and Iq is fundamental to perform control optimization and application tasks for an E-Drive system. In order to optimize the E-Drive system application towards e.g. best efficiency, best performance, or improved NVH the importance of the testing toolchain is described: a power analyzer delivering the required results, an automation system, and a Design of Experiment tool to set improved target values. Consequently, inverters applications featuring field-oriented control (FOC) with permanent magnet synchronous machines (PMSM) are updated with a chosen control strategy. For achieving a certain behavior of an E-Drive, different degrees of freedom in the Inverter Control Unit are available; Lookup tables Id and Iq represent two fundamental application labels to be considered

Platzer, Thomas, Fechter, Michael, Kammerstetter, Heribert, Kolb, Philipp

Electromagnetic compatibility (EMC) analysis for e-motors and controllers of electric two-wheelers.

2024-26-009801/16/2024

The Indian government has been promoting electric vehicles through various policy initiatives, such as offering incentives and subsidies to EV manufacturers and consumers, establishing charging infrastructure across the country, and setting ambitious targets for EV adoption. These measures aim to reduce the dependence on imported fossil fuels, mitigate air pollution, and promote sustainable mobility. As a result, the demand for electric vehicles across India is steadily increasing, and the country is emerging as a lucrative market for EVs globally. An electronically commuted brushless DC (BLDC) motor usually functions for traction in electric 2-wheelers. Electric vehicles need to comply with electromagnetic compatibility (EMC) requirements. During the EMC compliance of electric two-wheelers, it is certain that the BLDC motor and its controller play an important role. This paper presents the BLDC motor and controller’s Radiated Immunity (RI) and Radiated Emission (RE) performance at

Pawar, Sneha Ravindra, Desai, Manoj Madhukar

Analysis of Dynamic Characteristics and Load Sharing Performance of Electric Driven Planetary Gear System Based on Electromechanical Coupling Model

2023-01-701110/30/2023

Due to the multi-gear configuration and high integration of electric drive systems in electric vehicles, it is necessary to investigate the influence of drive motor torque fluctuation on the dynamic characteristics and load sharing performance of planetary gear transmission systems. Considering both motor torque fluctuation and internal excitations of the transmission system, a dynamic model of the electromechanical coupled system is established by combining the Maxwell motor electromagnetic model with the planetary gear dynamics model. Based on the proposed model, the dynamic characteristics, dynamic load performance and load sharing performance of the system considering motor torque fluctuation are analyzed, and the improvement of system load sharing performance due to sun gear floating is discussed. The results show that motor torque fluctuation leads to more complex dynamic response and causes the vibration displacement amplitude to more than doubled. Furthermore, the system

Guo, Fang, Li, Chen, Su, Jinzhan, Liu, Chao

Analysis and Control of Gear Rattle Noise for E-Axle

2023-01-701910/30/2023

As the main power form of new energy vehicles, e-axle systems are has been widely used in passenger vehicles and commercial vehicles. A passenger car equipped with an e-axle, in constant speed and low torque conditions, there is a noticeable rattle noise, through experimental investigation and comparative analysis, it is confirmed that the connection spline of motor and reducer is the main influencing factor. Then, Through the qualitative analysis of simulation, it is found that both spline clearance and misalignment have an amplification effect on the motor speed, thereby stimulating the gear pair of the reducer to produce rattle. The amplification effect of spline clearance is stronger than that of spline misalignment. Therefore, improving the stiffness and application amount of lubricating grease while controlling the spline sample to meet the design requirements can effectively solve the problem of rattle, improve the accuracy of spline alignment, and significantly reduce the

Wang, Dong, Zhang, Wei, Yang, Zhengrui

Gear Fault Diagnosis for Vehicle Electric Drive Systems Based on Stator Currents

2023-01-703010/30/2023

With the popularization of electric vehicles, the safety performance of electric vehicles has drawn much attention. However, the gears of electric vehicles are more prone to failure at high speeds, which can affect the safety performance of the vehicle. This topic proposes a electromechanical coupling model, which is composed of a permanent magnet synchronous motor model, a vehicle longitudinal dynamics model and a transmission system model, and will be applied to gear fault diagnosis. First, the sensitivity of the gear fault to the stator current signal, the electromagnetic torque signal and the q-axis current signal is investigated based on the time-varying meshing stiffness obtained by the potential energy method. The discrete wavelet algorithm is used to decompose the stator current signal, and the d1 component with obvious fault information is obtained. Then, the singular spectral entropy is selected to realize the feature extraction of the stator current signal by comparing the

Gong, Hao, Wang, Feng, Zhu, Xiaoyuan

Characterization and Prediction of Interior Noise Quality in Electric Vehicles through Drive Unit End-of-Line Testing (EOLT)

2025-01-003905/05/2023

This paper addresses the critical aspect of interior noise quality in electric vehicles (EVs), focusing on the characterization and prediction methodologies employed during drive unit end-of-line testing. The electric drive unit plays a pivotal role in determining the overall Noise, Vibration, and Harshness (NVH) quality of the final product. This study explores the impact of drive unit assembly process variation and individual component tolerance on the NVH characteristics of electric drive units, emphasizing their direct effect on overall vehicle acoustic quality and customer comfort. The research delves into the intricate relationship between drive unit vibrational response, vehicle interior noise, and customer subjective perception, providing valuable insights into their correlation and how they collectively influence user experience and satisfaction. It aims to enhance the understanding of how electric drive unit characteristics contribute significantly to the interior noise

Arvanitis, Anastasios, Parbat, Aniket, Jadhav, Prashant, Raphael, Andrew

Application of blocked force methodology to an electrified beam axle from a medium-duty truck in vehicle and in a dynamometer test cell

2025-01-005405/05/2023

The recent shift in propulsion choice away from internal combustion engines has increased the relevance of sound and vibration from electric motors and gearboxes. Electrified beam axles require different metrics from conventional beam axles for noise and vibration because they have multiple sources of vibration energy, including an electric motor and sometimes multiple reduction gearsets. They also require different metrics from electric drive units because they have stiff suspension connections and lack significant isolation. Blocked force is a good candidate because it can completely characterize the vibration energy transmitted into a receiver and is especially useful because it is theoretically independent of the vehicle-side structure. While the blocked force methodology is not new, its application to beam axles is relatively unexplored in the literature. This paper demonstrates a case study of blocked force measurement of an electrified beam axle from a battery electric medium

Shaw, Matthew D, Grimmer, Michael J

A Theoretical and Experimental Investigation of NVH of In-Wheel Reduced Motor System

2025-01-000605/05/2023

To enhance the power density of the system and reduce production costs, the in-wheel reduced motor system (IWRMS), characterized by its integrated design and control, is poised to become the future development trend. However, the high speeds of motors and gear reducers can lead to challenges such as system stability and issues related to NVH (Noise, Vibration, and Harshness). This paper specifically addresses the NVH concerns associated with the IWRMS. Firstly, a bench test scheme was established, and vibration and noise tests were conducted under a range of conventional operating conditions. The results indicated that at the torque of 200 Nm and the speed of 5500 rpm, the noise sound pressure level reached 86.2 dB, highlighting significant vibration and noise issues within the system. Subsequently, operating deflection shapes (ODS) testing and analysis were performed on the IWRMS. Vibration responses of 48th order show that breathing mode of the motor housing bring resonance

Huang, Chao, Xiong, Lu, Meng, Dejian, gong, Yu, Guo, Han, Zhang, Mengyuan

High-Fidelity NVH Model Development for Electric Motors using Deep learning and Machine Learning Algorithms

2025-01-012305/05/2023

Electric motor whine is a significant source of noise in electric vehicles (EVs). To improve the noise, vibration, and harshness (NVH) performance of electric propulsion systems, it is essential to develop a physics-based, high-fidelity stator model. In this study, a machine learning (ML) model is developed using an artificial neural network (ANN) method to accurately characterize the material properties of the copper winding, varnish, and orthotropic stator laminate structure. A design of experiments (DOE) approach using Latin hypercube sampling of parameters is implemented after evaluating alternative surrogate models. A finite element (FE) model is constructed using the nominal stator design parameters to train the ANN model using 121 DOE variables and 72,000 data points. The ML-trained ANN model is then verified to predict the driving point frequency response function (FRF) spectrum with reasonable accuracy. Subsequently, modal tests are conducted on the electric stator, and the

Rao, Bhyri Rajeswara, GSJ, Gautam, He, Song

NVH Analysis and Optimization of Electric Drive System in Over Modulation and Six-Step Regions

2025-01-008205/05/2023

Pulse width modulation (PWM) and the corresponding modulation index (MI) value are of critical importance to the performance of electric drive systems for electric vehicle applications. For interior permanent magnet (IPM) machines, operating in overmodulation (OVM) and six-step modes increases the voltage output beyond the linear region, allowing the motor to achieve higher torque and power with reduced inverter loss. However, the resulting distorted current waveforms and higher current ripple harmonics lead to a notable increase in the motor noise. A multi-disciplinary approach has been developed to analyze the NVH performance of a three-phase 8-pole IPM motor when it operates in the OVM and six-step regions at high speed. The PWM current ripple harmonics induced by voltage-source inverters are predicted using different MIs and subsequently validated through experiments. The current ripple data are used for the prediction of electric motor efficiency, including an analysis of copper

He, Song, Chang, Le, Gong, Cheng, Zhang, Peng, GSJ, Gautam

Asymmetric Gear Blank Optimization to Reduce Gear Noise for Electric Drive Units

2025-01-007905/05/2023

Gear whine has emerged as a significant challenge for electric vehicles (EVs) in the absence of engine masking noise. The demand from customers for premium EVs with high speed and high torque density introduces additional NVH risks. Conventional gear design strategies to reduce the pitch-line velocity and increase contact ratio may impact EV torque capacitor or its efficiency. Furthermore, microgeometry optimization has limited design space to reduce gear noise over a wide range of torque loads. This paper presents a comprehensive investigation into the optimization of transfer gear blanks in a single-speed two-stage FDW electric drive unit (EDU) with the objective of reducing both mass and noise. A detailed multi-body dynamics (MBD) model is constructed for the entire EDU system using a finite-element-based time-domain solver. This investigation focuses on the analysis and optimization of asymmetric gear blank design features with three-slot patterns. A DOE methodology is employed to

He, Song, Bahk, Cheonjae, Li, Bo, Du, Isaac, Patruni, Pavan Kumar, Baladhandapani, Dhanasekar

Methodology for Radiated Noise Refinement of Electrified Drivetrain Systems

2025-01-009805/05/2023

Electric drive units (EDU) of battery electric vehicles and electric drivetrain components of hybrid vehicles require significant development effort and planning to ensure that a refined NVH sound quality is achieved. New tools and methods are required to understand the NVH performance throughout the development process and to ensure that NVH risks can be quickly identified and mitigated within the correct EDU subsystems. This paper discusses the development of a methodology (EDSL – Electric Drive Sound Level) aimed at addressing this need. It also outlines how the EDSL tool can be used to address radiated noise issues and understand the NVH performance of the various subsystems within an electrified drivetrain component. The first use of the EDSL methodology is to characterize component-level radiated noise test results and compare the different mechanical and electrical noise sources to targets. The results from this are used to guide EDU development in the appropriate areas

Pruetz, Jeffrey E., Steffens, Christoph, Fu, Tongfang, Govindswamy, Kiran

Electric compressor integration noise influence in Battery Electric Vehicles

2025-01-007505/05/2023

Within the automotive industry’s shift to Battery Electric Vehicles, in order to meet the global zero emission target, thermal management systems are key aspects to address. For instance, vehicle cooling requirements are reinforced to take into account the cabin comfort as well as battery management performances. Consequently to the increased cooling requirements, the critical component that is the Electric Drive Compressor, must operate at higher speeds and refrigerant pressures to achieve these targets. This trend results in increased noise levels which might occur inside the car cabin and outside. In this paper, noise investigations were performed on different Battery Electric Vehicles to assess the behavior of the electric compressor within a temperature controlled environment. Then, the electric compressors alone were investigated on specific test benches with compressor load units. The vehicle level assessment highlighted significant noise differences between vehicles. Further

Bennouna, Saad, Yamayoshi, Itsukyo, Del Valle, Edward

Crash Performance Improvement: The Impact of Engine Mount Crash Plates on Achieving a 5-Star Safety Rating

2025-01-008505/05/2023

Electric vehicles (EVs) differ from internal combustion engine (ICE) vehicles in that they lack a conventional engine and feature an electric drive unit, leading to distinct dynamic behaviours in the powertrain. Additionally, the arrangement of auxiliary components in EVs often differs from that in traditional ICE vehicles, which can sometimes significantly impact safety ratings. This paper examines a case study of a critical failure during a crash test, where displacement of an engine mount arm caused substantial structural intrusion and reduced the vehicle's safety rating. To address this issue and enhance crashworthiness, a "crash plate" was designed and integrated into the mount system. This solution effectively constrained the mount arm's movement during impact, preventing the intrusion observed in previous tests. The paper provides a detailed analysis of the crash plate's dimensions and its relationship to the engine mount, demonstrating its potential for broader application in

Hazra, Sandip, Khan, Arkadip, Mohare, Gourishkumar

Immersion Cooling for Power Electronics

2022-28-044611/09/2022

The ability to precisely control electrical voltages on a large scale has made possible many efficient, powerful innovations, from high-speed electric trains to wind turbines to electric drive motors for everything from heavy earthmoving equipment to personal electric vehicles (EVs). But the equipment that manages this process — including power inverters, thyristors and variable-speed drives — requires high-performance power electronics cooling. As temperatures rise, the efficiency, reliability, and life spans of these devices drop, and the power electronics inside HEVs and EVs are no exception. Advancements in power electronic thermal management technologies will enable next generation automotive to fulfill increasingly demanding mission objectives. DC-DC converter and inverter systems slated for higher performances, reliable and sustainable applications. Even with very high efficiencies, the components of these systems produce kilowatts of power loss in the form of heat. The current

Study and Application of Gear Micro Modification of Electric Drive System

09/15/2022

Abstract The gear whine in the electric drive system of an electric vehicle is important and remains a challenge in developing novel electric vehicles. A gearbox dynamic model is established, and the effects of modification parameters on the sound pressure level, transmission error, and contact stress of the gear pair are introduced to reduce the gear whine. A multi-objective optimization study of four modification variables under multiple torque conditions is carried out by using transmission error and maximum contact stress as the objective functions. The eclectic programming method is imported to solve the convergence problem of multi-objective optimization. The influence of modification variables on objective functions is studied by establishing an approximate model of the optimal Latin hypercube design. Results show that the application of the multi-objective optimization method combined with the eclectic planning method for the micro modification of the gear can reduce the

Chen, Chen, Zhu, Linpei, Liu, Jing, Wei, Dan, Yu, Hao

Study and Application of Gear Micro Modification of Electric Drive System

15-16-01-0001-TEST-REC09/15/2022

Abstract The gear whine in the electric drive system of an electric vehicle is important and remains a challenge in developing novel electric vehicles. A gearbox dynamic model is established, and the effects of modification parameters on the sound pressure level, transmission error, and contact stress of the gear pair are introduced to reduce the gear whine. A multi-objective optimization study of four modification variables under multiple torque conditions is carried out by using transmission error and maximum contact stress as the objective functions. The eclectic programming method is imported to solve the convergence problem of multi-objective optimization. The influence of modification variables on objective functions is studied by establishing an approximate model of the optimal Latin hypercube design. Results show that the application of the multi-objective optimization method combined with the eclectic planning method for the micro modification of the gear can reduce the

Chen, Chen, Zhu, Linpei, Liu, Jing, Wei, Dan, Yu, Hao

Method and Apparatus for Data Processing and Acquiring High Speed Data of Electric Drive System using RS485 and MATLAB Functionality Based Developed Serial Reader Graphical User Interface Tool

2022-26-117605/26/2022

The Electric Drive System implemented in more electric aircraft architecture cover one of the applications like engine start up driving the starter generator machine in motoring mode for engine startup and voltage regulation from the starter generator in power generation mode. Electric Drive System undergoing the mode transitions through operating mode change requirements to perform all the operation defined by application either motor or generator operation. In the development of these controls, the conventional modeling and tuning will become tedious and time consuming. Multiple software updates and model updates are required. Our proposed method ties the models and allows temporary controls parameters update loads to the Electric Drive System for the real time testing. Electric Drive System software modifications are required to investigate field issues while integrating Starter Generator machine with the end application. The investigation requires high speed data acquisition of the

SAKINALA, KUMAR, Kashireddy, Davendar, Mani, Sivaraman, Cheng, Louis

Electric Vehicle Corner Architecture: Driving Comfort Evaluation Using Objective Metrics

2022-01-111903/29/2022

The transportation sector now faces several technological and societal challenges; the most urgent one is a shift to carbon-neutral mobility. One of the most efficient ways to reach this goal is car electrification. Vehicle corner architecture with an in-wheel motor is a promising stage of technological development for a new generation of electric vehicles. The state of art analysis indicates that a higher degree of integration between powertrain and chassis and the shift towards corner solution promises improved performances regarding new vehicle architecture design, energy efficiency, vehicle stability, reducing the overall system's weight. However, in-wheel mounted electric motor significantly increases unsprung vehicle mass; therefore, some undesirable impact on chassis loads and driving comfort occur. A possible solution lies in implementing cooperating active corner systems, which are not limited by traditional active suspension and brake-by-wire but can also include an advanced

Žuraulis, Vidas, Kojis, Paulius, Marotta, Raffaele, Šukevičius, Šarūnas, Šabanovič, Eldar, Ivanov, Valentin, Skrickij, Viktor

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

2022-01-015303/29/2022

Electric transportation has the potential of mitigating CO2 emissions and reduce fuel needs. One of the challenges for the growth of this industry is limited range and efficiency of the vehicles associated with battery storage systems and electric drive technology. High voltage systems are expected to increase efficiency and then vehicle mileage, however this increases the severity of the fault conditions, especially in case of short circuit. Melting fuse is commonly used for the purpose of protection in electrified vehicles, while it is effective and reliable, there are several shortcomings such as lack of precision, effect of ambient temperature, bulky, interruption time depending on the fault condition etc. Additionally, the on-board DC power distribution system (PDS) is characterized by low impedance, in this environment fuses are not able to limit the fault current leading to damage of electronics and hazard for the battery pack. Thus, advanced protection systems such as pyro

Bavishi, Harsh, D'Arpino, Matilde, Ramesh, Prashanth, Guezennec, Yann, Colbert, Ian

Structural Damping in the Isolation Path of Electric Drive Units in Electric Vehicles

2022-01-073103/29/2022

Electric Vehicles (EV) pose special challenges for isolating structure borne noise and vibration originating from the electric drive unit. The characteristics of the tonal noise and the frequency range of the source vibration make conventional isolation devices not adequate or appropriate for EV applications. For example, internal combustion engine powertrains have a primary frequency of concern up to 800 Hz., while electric drive unit frequency of concern can be up to 3000 Hz. In addition to the elastomer-based components in the isolation system, structural components have become even more critical for vibration transmissibility given the tonal nature and the high frequency range of the source energy. A novel approach to mitigating high frequency vibration isolation by utilizing new grade of PA66 glass-filled nylon resin with high structural damping will be discussed. The new grade resin was specifically developed for the all-new Cadillac LYRIQ EV drive unit mount structural support

Jomaa, Sam, Balaceanu, Andrei, quaggiotto, Michael

Optimized Semi-Solid Slurry Aluminum Die Casting for HPDC Structural Components

2022-01-028303/29/2022

Electric Vehicles (EV) are transforming the automobile industry by creating a renewed approach to propulsion through battery powered electric drive unit (EDU). Key to the success of the EV industry is vehicle drive range on a fully charged battery. That limit state is dependent on many factors, but one critical one is vehicle mass. Vehicle mass is a parasitic loss in energy consumption; and therefore, the mass of EV has been valued at much higher levels than for internal combustion engine vehicles. Therefore, finding opportunities for light weight options is crucial. In this paper, optimization method for aluminum semi-solid slurry die cast (SSD) for high pressure die casting (HPDC) will be discussed. A novel approach to slurry preparation, transfer, die operation, and post cast process was developed and was proven on structural components of EDU mounting system. 40% part mass saving was achieved in a study case compared to baseline conventional HPDC design. On average, it is

Jomaa, Sam, Risko, Frank, Xu, Yiwu, Liang, Xiaokang, Suchta, Wojciech, Quaggiotto, Michael

Concept Study of a 48V-Hybrid-Powertrain for L-Category Vehicles with Longitudinal Dynamic Simulation and Design of Experiments

2022-01-081203/29/2022

The demand for high efficiency powertrains in automotive engineering is further increasing, with hybrid powertrains being a feasible option to cope with new legislations. So far hybridization has only played a minor role for L-category vehicles. Focusing on an exemplary high power 3-wheel on-road vehicle, this research shows a new development approach of a hybrid electric powertrain, which combines longitudinal dynamic simulation (LDS) with “Design of Experiments” (DoE). Furthermore, addressing the technological aspect, this paper points out how such a vehicle can benefit from 48V-hybridization of its already existing internal combustion powertrain. A fully parametric LDS model is built in Matlab/Simulink, with exchangeable powertrain components and an adaptable hybrid operation strategy. Beforehand, characterizing decisions as to focus on 48V and on parallel hybrid architecture are made. Simulative investigations in this paper focus on pure electric driving. First acceleration

Hagenberger, Alexander, Schacht, Hans-Juergen, Schmidt, Stephan, Kirchberger, Roland, Lang, Michael, Friedl, Hubert, Hinterberger, Walter

Observer-Based Torque Vector Control of a Four In-wheel Motor-driven Electric Vehicles Considering with Unbalanced Electric Magnetic Field

2022-01-110703/29/2022

The accuracy and range of chassis control for a four in-wheel motor (IWM)-driven electric vehicles (EVs), especially in observer-based EVs control for improving road handling and ride comfort, is a challenging task for the IWM-driven vehicle system. Due to the high fatality rate caused by inaccurate state-based control algorithm, how to precisely acquire movement state and chose the reasonable observer-based control algorithm for IWM-driven EVs become a hot topic in both academia and industry. Simultaneously, uncertainty is always existing, e.g., varying road excitation, variable system parameters or nonlinear structure. Meanwhile, the coupling effects between the non-ideal IWM actuator and vehicle are ignored under the assumption of an ideal actuator. To deal with the above mentioned, the paper presents an observer-based control approach, which combines Takagi-Sugeno (T-S) fuzzy observer and torque vector control algorithm, to further improve the chassis performance for IWM-driven EVs

Wang, Zhenfeng, li, xin, Zhu, Yugang, Evans, Sally

Electric hybrid system Architecture & Functional component selection criteria for application based Off-Highway segment

2022-01-081503/29/2022

Hybridization continues to be growing trend in vehicular applications. Current study shows a holistic system approach for the design & integration of the powertrain in Off-Highway tractor applications. It includes study & benchmarking of system architecture of an all-electric and diesel-electric drive systems as per application requirement. Further comprehensive study was done on functional components for an electric powertrain, which includes electric drives, batteries & controllers. Selection & design of these components was studied & component selection approach was developed for typical Off-Highway tractor application. Current study was divided into three parts. 1. Study of different Off-Highway tractor applications & selection of all-electric, series & parallel hybrid architectures as per application requirement. For Parallel hybrid configuration, Comprehensive approach was developed for selection & optimization. 2. An optimum hybrid configuration selected for off-highway

NVH Comparative Analysis of 3in1 and 2in1 Electric Drive System Based on Experimental Research

2022-01-073003/29/2022

As the key assembly of new energy vehicles, the noise and vibration, and harshness (NVH) performance of integrated electric drive system directly affects the driving quality of new energy vehicles. In this paper, the vibration noise characteristic test of 3in1 electric drive system is carried out in the semi-muffler chamber. In order to compare and analyze the difference between 2in1 and 3in1 electric drive system NVH performance, the PEU in the 3in1 system was removed and placed on the ground away from the platform, and vibration noise test was carried out. In order to analyze the difference of NVH performance between 2in1 status and 3in1 status, the PEU in the 3in1 system was removed and placed on the ground far away from the bench, and the NVH test was carried out. The microphone signal at 1m position and the vibration acceleration signal of the key structural surface of the system are measured experimentally. The research results show that the addition of PEU enables the 3in1

Su, Hui, Zhang, Lijun, Meng, Dejian

Towards brand-independent architectures, components and systems for next generation electrified vehicles optimised for the infrastructure

2022-01-111703/29/2022

The virtual E-VOLVE (Electric Vehicle Optimized for Life, Value and Efficiency) Cluster is realizing and monitoring synergies between eight projects from the GV-01 Horizon 2020 call to execute joint dissemination, exploitation and standardization activities. The Projects ACHILES, CEVOLVER, SYS2WHEEL, EVC1000, and Multi-Moby are the members of the E-VOLVE Cluster that will present their achievements in this paper. Achiles, SYS2Wheel, EVC1000: The integration of the BEV demonstrators with the modeling, design and prototyping of the powertrain and chassis components has been successfully achieved with a new wheel concept and out-of-phase control for the brake system and a new torque vectoring algorithm for enhanced vehicle motion control. Performance and safety-related benefits of integrated corner solutions with in-wheel motors will be reported in the full paper. Optimized concepts for energy and thermal management will be outlined involving trip itinerary, range prediction, smart fast

Armengaud, Eric, Brandstätter, Bernhard, Biček, Matej, Buh, Joze, Sorniotti, Aldo, Hartavi, Ahu Ece, Schernus, Christof, Geury, Thomas, Arapoglou, Stella, Heydrich, Marius, Ivanov, Valentin

Stabilization Power of a Synchronous Machine During the Discharge of Autonomous Energy Sources

2022-01-087803/29/2022

The paper considers an automobile traction electric motor drive with a synchronous motor connected to a battery pack through a voltage inverter. Maintaining the power of the electric drive with fluctuations in the voltage of an autonomous energy source in discharge and changing the load is solved. The nominal (maximum permissible) power of the electric traction drive decreases in proportion to the voltage drop of the source. This factor can significantly degrade the performance of electric vehicles. The problem of stabilizing the electric traction of synchronous machines solves by algorithmic means that do not require voltage stabilizers (converters). The strategy assumes control of an electric traction drive according to the criterion of the maximum power factor of the three-phase voltage of a synchronous machine. The effect of power stabilization with a voltage drop achieves by increasing the active stator current. The development of control algorithms is based on the energy model of

Smolin, Viktor, Gladyshev, Sergey

Control strategy for ISD suspension considering dynamic vibration absorber of wheel motor

2022-01-033203/29/2022

Vehicles driven by in-wheel motors have the advantages of compact structure and high transmission efficiency, which is one of the most ideal energy-saving, environmentally friendly and safe driving forms in the future. However, the addition of the in-wheel motor significantly increases the unsprung mass of the vehicle, resulting in a decrease in the mass ratio of the vehicle body to the wheel, which will deteriorate the ride comfort and safety of the vehicle. To improve the vibration performance of in-wheel motor vehicles, a semi-active inerter-spring-damping(ISD) suspension based on in-wheel motor vibration absorption is proposed in this paper. Firstly, mounting elements are applied to the wheel to provide elastic isolation between the in-wheel motors and the tyre, which converts the in-wheel motor mass into a vibration absorber to suppress the high-frequency vibration of the unsprung mass. Secondly, an ISD suspension is used to improve the low and mid-frequency characteristics of the

Zhang, Kaidi, Wu, Jinglai, Zhang, Yunqing

Medium- and heavy-duty value of technology improvement

2022-01-064303/29/2022

Improvements in vehicle technology have an impact on the purchase price of the vehicle and its operating cost. In this study, we assume the monetary benefit of a technology improvement includes the potential reduction in vehicle price from using cheaper or smaller components, as well as the discounted value of the fuel cost savings. As technology progresses over time, the value and benefit of improving technology varies as well. For example, when a battery is heavy and expensive, a percentage increase in energy density and percentage reduction in cost are worth more than when the battery is already lighter and cheaper. In this study, we look at the value of a few technologies (battery energy density, electric drive efficiency, tire rolling resistance, aerodynamics, light weighting) and assign a dollar value to its associated savings. We show how the dollar value changes with the level of technology achievement, the powertrain selection and the vehicle type. We highlight for instance

Freyermuth, Vincent, Vijayagopal, Ram, Rousseau, Aymeric

Analytical Methodology to Derive a Rule-Based Energy Management System Enabling Fuel-Optimal Operation for a P24-Hybrid

2021-01-125409/21/2021

The variety of different hybrid vehicles developed by car manufacturers has steadily increased in the last couple of years. One predominant hybrid configuration has been the parallel hybrid in P2-configuration. Due to the demand for further electrification to reach future fuel efficiency targets and improve pure electric driving performance, concepts of hybrid vehicles with at least two electrical machines come into focus. Herein, the concept of adding an individual electrical axle to a P2-hybrid is gaining interest. However, the system complexity of a so called P24-hybird increases significantly because the number of possible system states rises. This leads to an increased development and calibration effort for an energy management. Especially the transfer from an optimized operating strategy to a rule-based energy management is challenging. Thus a development framework for the calibration of an online energy management system (EMS) is needed. Within this paper the applicability of a

Jungen, Mario, Goerke, Daniel, Langwiesner, Morris, Schmiedler, Stefan, Hofmann, Peter

Magna execs warns on impending EV complexities

21AUTP02_1002/01/2021

The industry's transition to electrified - and ultimately, fully electric vehicles (EVs) is bringing far greater overall complexity in product development and technology-management, according to Magna Powertrain executives speaking in an online media session during mid-January's CES 2021 virtual trade show. Magna's traditional strengths in lightweight structures, driver-assistance sensor technologies, active aerodynamic systems, powertrain/drivelines and full-vehicle assembly serve as the foundation for the company as it moves further into vehicle electrification and automated-driving solutions, noted Sherif Marakby, the company's recently hired executive VP. Markaby is a veteran leader of Ford's hybrid and EV programs and headed the automaker's Team Edison autonomous R&D group before joining Magna.

Brooke, Lindsay

CES 2021: GM creates BrightDrop electrified delivery and logistics company

21AUTP02_0902/01/2021

During her CES 2021 keynote in January, GM Chairman and CEO Mary Barra announced the creation of a new logistics company called BrightDrop. The new business will create an ecosystem of electrified products, software and services for first-to-last-mile delivery. This includes EPI, a new electric pallet to shuttle packages, as well as a new commercial delivery truck based on GM's Ultium battery platform, the EV600. The first customer of the new business will be FedEx Express. According to GM, BrightDrop's electrified solutions were created to help businesses reduce costs, maximize productivity, improve employee and freight security and support sustainability efforts. The EP1 pallet will be available in early 2021 and the EV600 light commercial vehicle (LCV) is expected to be on the road by late 2021. The EV600 is GM's first commercial application of its Ultium battery platform and the truck will feature both Level-2 and DC fast-charging capabilities.

Seredynski, Paul

Electric-Powered Warship

TBMG-3823912/01/2020

GE's Power Conversion Business Warwickshire, UK +44 (0) 1788 563386

Braking Systems for High Performance Electric Vehicles - A Design Study

2020-01-161210/05/2020

Any young person who has taken delight in playing with toy slot cars knows that the world of racing and the world of electric cars has been intertwined for a long time. And anyone who has driven a modern performance electric vehicle knows that the instant acceleration, exhilarating speeds, and joy of driving of slot cars is reflected in these full sized “toys”, with the many more practical benefits that come from being full-sized and steerable. There is strong foreshadowing of a vibrant future for performance cars in some of the EV’s on the market now and in the near future, some offering “ludicrous” acceleration, and others storied nameplates with performance to match. The ease at which powerful electric drives can capably hurtle a massive vehicle around the track at high speeds, combined with the potential for the same electric drives to exert powerful regenerative braking, creates a very interesting situation for brake engineers. What wins out in the end - raw power or regenerative

Antanaitis, David, Robere, Matthew

FEV and the Art of EV Testing

20AUTP10_0110/01/2020

The legendary powertrain-engineering group has expanded its global footprint into EV testing and development to keep pace with changing technologies and customer demand. Before the impending flood of electric vehicles (EV) expected for the 2025 timeframe enters the market, every one of them - and their subsystems - must be fully tested, validated and calibrated. Companies specializing in engineering, design and testing services are making significant investments to meet industry demand in this already-booming field. One of them, the Aachen, Germany-based FEV Group, has expanded its global footprint into the electrification-testing realm in a big way. Famous for its powertrain-development competency, FEV recently added a 12,000-m2 (∼130,000 ft2) facility dedicated to testing batteries, electric drives and related components. Dubbed eDLP, the complex is among the largest test facilities in FEV's global network and claims to be the largest independent battery-test facility in the world

Brooke, Lindsay

Hybrid Electric Drive

TBMG-3788910/01/2020

BAE Systems Sterling Heights, MI 586-795-2220

Airport Electrical Power System Harmonics

AIR5387 (Current)09/23/2020

This SAE Aerospace Information Report (AIR) is intended to cover all airport 50 or 60 Hz electrical systems as well as all electrical utilization equipment that is attached to those systems.

AGE-3 Aircraft Ground Support Equipment Committee

BIG FUTURE for e-axles, advanced motors

20TOFHP08_0108/01/2020

Top transmission engineers claim driveline electrification will transform everything from all-wheel drive to Class 8 tractor-trailers. A panel of high-ranking transmission and driveline engineers projected outsized adoption for electric-axle (e-axle) technology, as well as significant expansion of other driveline-electrification strategies now being adopted for new or near-future production vehicles. The engineering executives participated in a recent webinar in SAE's Leadership Roundtable series, a virtual event replacing the in-person program planned for April's SAE WCX 2020 conference that was cancelled because of the COVID-19 outbreak. Most of the panel agreed that hybrid and other electrification strategies such as e-axles are the transition from internal combustion-based drivetrains to volume production and sales of battery-electric vehicles (BEVs).

Top transmission engineers project big future for e-axles, advanced motors

20AUTP08_0907/01/2020

A panel of high-ranking transmission and driveline engineers projected outsized adoption for electric-axle (e-axle) technology, as well as significant expansion of other driveline-electrification strategies now being adopted for new or near-future production vehicles. The engineering executives participated in a recent webinar in SAE's Leadership Roundtable series, a virtual event replacing the in-person program planned for April's SAE WCX 2020 conference that was cancelled because of the COVID-19 outbreak. Most of the panel agreed that hybrid and other electrification strategies such as e-axles are the transition from internal combustion-based drivetrains to volume production and sales of battery electric vehicles (BEVs). “Long-term, BEV is going to be the better answer,” conceded Michael Solt, global head, transmission, driveline and axle at FCA USA LLC. But the EV solution - and when volume adoption happens - “depends on which market you're in,” he added.

Improved Customer Experience through Electric Vehicle Sound Enhancement

2020-01-136104/14/2020

Electric Vehicles are typically thought of as being quiet and refined, but they do come with some unique N&V challenges. Some of these challenges include a natural sound that can be undesirable due to its tonal nature, presence of high frequency, discontinuities in sound, and characteristics and levels that do not always naturally increase with motor torque and vehicle speed. One approach to address those challenges is Electric Vehicle Sound Enhancement (EVSE) which is a software feature embedded within the infotainment system. EVSE can be used to improve the perception of the vehicle by enhancing the preferred natural sounds of the vehicle, masking unusual and annoying components of the sound and aurally conveying information related to the vehicle performance. A jury study was conducted to better understand how EVSE can be used to accomplish this. This paper will summarize a typical EVSE system and highlight some of the tools and methods that can be used to develop an EVSE tuning

Valeri, Frank, Pietila, Glenn

Minimization of Electric Heating of the Traction Induction Machine Rotor

2020-01-056204/14/2020

The article solves the problem of reducing electric power losses of the traction induction machine rotor to prevent its overheating in nominal and high-load modes. Electric losses of the rotor power are optimized by the stabilization of the main magnetic flow of the electric machine at a nominal level with the amplitude-frequency control in a wide range of speeds and increased loads. The quasi-independent excitation of the induction machine allows us to increase the rigidity of mechanical characteristics, decrease the rotor slip at nominal loads and overloads and significantly decrease electrical losses in the rotor as compared to other control methods. The article considers the technology of converting the power of individual phases into a single energy flow using a three-phase electric machine equivalent circuit and obtaining an energy model in the form of equations of instantaneous active and reactive power balance. The quasi-independent excitation of the induction machine is

Nikiforova, Elena, Smolin, Victor, Gladyshev, Sergey

Research on Control Strategy Optimization for Shifting Process of Pure Electric Vehicle Based on Multi-Objective Genetic Algorithm

2020-01-097104/14/2020

With more and more countries proposing timetables for stopping selling of fuel vehicles, China has also issued a “dual-slope” policy. As electric vehicles are the most promising new energy vehicle, which is worth researching. The integration and control of the motor and gearbox have gradually become a hot research topic due to low cost with better performance. This paper takes an electric vehicle equipped with permanent magnet synchronous motor and two-gear automatic transmission without synchronizer and clutch as the research object. Through the action of the motor, gearbox and shift actuator in the shifting process, the whole vehicle dynamics is modeled in each stage of shifting, a method for determining a short-term driving style intensity factor for decision shifting is proposed, three evaluation indexes of the shift quality of electric vehicle are put forward, the control parameters affecting the shift quality are analyzed, and the mathematical relationship between the shift

Lei, Yulong, Zhang, Jingxu, Fu, Yao, Jia, Fuchun, Wang, Binyu

Iterative Dynamic Programming Based Model Predictive Control of Energy Efficient Cruising for Electric Vehicle with Terrain Preview

2020-01-013204/14/2020

As a global optimization method, dynamic programming (DP) can be employed to seek the optimal velocity with minimum energy consumption for EV on given driving cycles. Due to its terrible computational burden, conventional DP is not suitable for real-time implementation especially with higher dimensions. In this paper, we propose an iterative dynamic programming (IDP) approach to reduce computing time firstly. The IDP can obtain the optimal control laws alike the conventional DP by converging the optimal control strategy iteratively and save considerable computing time. Second, the developed IDP and model predictive control (MPC) are combined to establish a real-time cruising controller called IDP-MPC for an EV with terrain preview. In the predictive controller, we use the IDP to solve a constrained finite horizon nonlinear optimization problem. Finally, to assess the performance of the proposed cruising controller, simulation on a realistic urban expressway road terrain is implemented

Ju, Fei, Zhuang, Weichao, Wang, Liangmo, Wang, Qun

Low-Inductance DC Power Bus

TBMG-3616003/01/2020

Anew generation of power electronic conversion systems is being enabled by wide-bandgap (WBG) devices. Applications in civilian and defense sectors are already realizing improved power density and efficiency in power converters that utilize silicon carbide (SiC) and/or gallium nitride (GaN) switches; however, as semiconductor switches become capable of greater hold-off voltage, higher switching frequency, and higher junction temperature, limits on converter performance will depend on the remainder of the system: device packaging, filter components, and thermal management, as examples.

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