Browse Topic: Electric vehicles

Items (43,068)

Development of the Mild Hybrid System for Off-Road Machinery

2024-32-006704/18/2025

In recent years, the importance of achieving carbon neutrality has been highlighted in response to the escalating severity of climate change. In the leading automobile market, the share of electric vehicles is gradually expanding, especially in passenger car sector. However, it is not same in commercial vehicle sector. In the off-road machinery market, as with electrification in commercial vehicles, the factors such as the need to install charging infrastructure and the requirement for large batteries to expand operating duration are significant challenge to full electrification. As one of the realistic solutions toward carbon neutrality for off-road machines, methods to utilize both internal combustion engines (ICE) and their applied products are being reconsidered. Under the circumstances, we have developed a mild-hybrid (MH) system for small off-road machinery. This system adopts a 48V power supply in order to minimize size of the system offers as a “Drop-in” package solution. This

Koyama, Kazuaki, Kimura, Ryota, Nagamori, Yuko, Horita, Tatsuhiko, Nosaka, Kento

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.

Predictive Battery Thermal Management System Control Strategy and Simulation in Electric Vehicle

2025-01-502704/03/2025

With the global issue of fossil fuel scarcity and the greenhouse effect, interest in electric vehicles (EVs) has surged recently. At that stage, because of the constraints of the energy density and battery performance degradation in low-temperature conditions, the mileage of EVs has been criticized. To guarantee battery performance, a battery thermal management system (BTMS) is applied to ensure battery operates in a suitable temperature range. Currently, in the industry, a settled temperature interval is set as criteria of positive thermal management activation, which is robust but leads to energy waste. BTMS has a kilowatt-level power usage under high- and low-temperature environments. Optimizing the BTMS control strategy becomes a potential solution to reduce energy consumption and overcome mileage issues. An appropriate system simulation model provides an effective tool to evaluate different BTMS control strategies. In this study, a predictive BTMS control strategy, which adjusts

Huang, Zhipei, Chen, Jiangbo, Tang, Hai

A review of warm forming for steels: History, Methodology and Emerging trends

2025-01-881404/01/2025

Many manufacturing techniques and process modifications have been implemented over the years to improve the formability of sheet metals. Warm forming of sheet metals is one such established method. However, it is more commonly and successfully applied to aluminum grades. The reevaluation of less-used metal forming technologies, such as warm forming and sheet hydroforming for steel, is a response to the challenges posed by competitive processes like large castings and the geometry requirements of new BEV parts. By understanding the effects of elevated temperatures (below recrystallization temperatures) on different steel grades and the impact of various heating methodologies, the industry can adapt and optimize these proven techniques for modern applications. This paper is a comprehensive summary of the effect of elevated temperatures on various grades of steel. Different heating techniques, their cycle times and effects on final forming feasibility is contrasted. The effect of

Kella, Caroline, Wormald, Tom, Gatts, Joshua

Optimizing Cooling Circuit Lines in between Batteries and Its Thermal Management Unit

2025-01-501703/21/2025

Ensuring uniform coolant distribution in electric buses is crucial for battery performance, longevity, and thermal stability. This study optimizes the battery thermal management system (BTMS) for an 18-m electric bus, addressing uneven coolant flow to battery packs caused by pressure drop variations. One-dimensional (1D) simulations were chosen for their ability to quickly and efficiently analyze flow and pressure variations, providing a fast solution to optimize coolant distribution across the system. dP-Q curves for the BTMS pump and battery packs were integrated into the 1D model based on supplier data, while the flow resistances of other components (pipes, bends) were calculated using KULI software. To correct flow imbalances, pipe diameters were adjusted to increase resistance in over-cooled areas, redistributing coolant to under-cooled sections. This modification resulted in a balanced flow and improved thermal consistency, contributing to longer battery life. Validation showed

Birgül, Çağrı Emre, Meydan, Ömer

SAE TOMORROW TODAY - AI-Powered Solution for Seamless EV Charging

1350703/20/2025

It's no secret that the EV charging experience can be a frustrating one. But what if you could connect the various EV charging networks to apps and services, standardizing them into a single point of integration? One company is doing just that by harnessing data to create a seamless, secure, and reliable EV charging experience. Meet Emobi, the leader in critical digital infrastructure that delivers a single point of integration to a vast network of EV charging stations and e-mobility partners through advanced AI and data refinement models. As the largest roaming ecosystem in North America, the company also enables traditional and streamlined (JustPlug) Plug & Charge technology, facilitating automatic charging identification between EVs and chargers. The company is trusted by EV manufacturers, startups, utilities, and U.S. government agencies alike. To learn more, we sat down with Lin Sun Fa, CEO, Emobi, to discuss how his company's solutions are unifying the fragmented e-mobility

Hineman, Marcie

SAE TOMORROW TODAY BRIEFS - Power Grid Solutions for EV Charging

1349901/28/2025

How do we balance the demands of EV charging with the capabilities of the power grid? The answer lies in coordination between automakers, consumers and utilities. Enter ChargeScape, a software platform that harnesses data analytics and managed EV charging to reward drivers for their flexibility and reduce the total cost of EV ownership. The goal is sustainable, affordable energy from a reliable power grid. To learn more, Roberto Baldwin, Sustainability Editor, SAE Sustainable Mobility Solutions, sat down with Joseph Vellone, CEO of ChargeScape, to discuss the complexities of the power grid and how flexible EV charging can reward consumers and boost EV ownership. For more information on the evolution of sustainability, head on over to sustainablecareers.sae.org. There, you can check out the latest news from CES 2025 including the Honda 0 Series, Toyota's Woven City, and Sony's Afeela 1. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to

Hineman, Marcie

Internet of Things Enabled Automatic Battery Cooling System Using the Peltier Effect

2025-01-500401/23/2025

Electric vehicles (EVs) have developed rapidly and are popular due to their zero emissions and efficiency. However, several factors limit electric car development, including battery performance, cost, lifetime, and safety. Battery management is crucial for achieving maximum performance under various conditions. The battery thermal management system (BTMS) plays an important role in controlling the battery’s thermal behavior. A BTMS manages the battery’s operating temperature by either dissipating heat when it is too hot or providing heat when it is too cold. Various methods of cooling batteries include air cooling systems, liquid cooling systems, refrigerant cooling systems, and phase change material cooling systems. This study focuses on an innovative BTMS utilizing a Peltier module, regulated via the Internet of Things (IoT) platform for real-time temperature monitoring and control. The objective of this research is to design and develop a temperature-controlled cooling system for EV

Gunasekar, N., Abishek, H., Bharath, N. S., Gokul, G.

New Battery Cathode Material Could Revolutionize EV Market and Energy Storage

TBMG-5214212/01/2024

A multi-institutional research team led by Hailong Chen, an Associate Professor with appointments in the George W. Woodruff School of Mechanical Engineering and the School of Materials Science and Engineering, has developed a new, low-cost cathode that could radically improve lithium-ion batteries (LIBs) — potentially transforming the electric vehicle (EV) market and large-scale energy storage systems.

Dormant Capacity Reserve in Lithium-Ion Batteries Detected

TBMG-5214312/01/2024

Lithium iron phosphate is one of the most important materials for batteries in electric cars, stationary energy storage systems, and tools. It has a long service life, is comparatively inexpensive and does not tend to spontaneously combust. Energy density is also making progress. However, experts are still puzzled as to why lithium iron phosphate batteries undercut their theoretical electricity storage capacity by up to 25 percent in practice. To utilize this dormant capacity reserve, it would be crucial to know exactly where and how lithium ions are stored in and released from the battery material during the charging and discharging cycles. Researchers at Graz University of Technology (TU Graz) have now taken a significant step in this direction. Using transmission electron microscopes, they were able to systematically track the lithium ions as they traveled through the battery material, map their arrangement in the crystal lattice of an iron phosphate cathode with unprecedented

Where Do EV Batteries Go When They Die?

TBMG-5213812/01/2024

At Cox Automotive’s EV Battery Solutions center in Oklahoma City, the conglomerate most famous for its KBB, Autotrader, and Manheim auction brands, has become a go-to for EV battery research, repair, remanufacturing, and recycling.

SAE TOMORROW TODAY: Taking Fleet Electrification to the Next Level

1348210/14/2024

How can companies electrify their fleets without the high costs and challenges of owning EV infrastructure? One company has the answer. Founded in 2017, Zeem Solutions is the leading provider of contract-based EV charging and fleet management services, serving more than 15,000 qualified fleets. With charging, parking, leasing, and co-locating solutions at secure hubs in major transport locations, Zeem is on a mission to help companies make the transition from diesel to electric. To learn more, we sat down with Paul Gioupis, Founder and CEO, Zeem Solutions, to discuss the importance of lowering operational costs with an EV charging depot model and how the company plans to scale nationwide. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in mobility with the leaders, innovators and strategists making it

Hineman, Marcie

What Do Consumers Really Think About EVs?

1345806/05/2024

Consumers are complex -- and so is the EV market. From high expectations to sobering market realities, the EV landscape is hard to gauge without expert insight on consumer behavior. That's why we sat down with Jessica Caldwell, AVP and Head of Insights, Edmunds, to discuss consumer sentiment and the overall trends affecting EV adoption. By leveraging millions of vehicle transactions and web behavioral data, Edmunds helps make sense of the EV landscape for consumers, sellers, and the industry at large. Listen in as Jessica breaks down consumer perceptions and behavior, as well as the effect of interest rates, affordability, and inventory. It's an interesting conversation on what consumers really want -- and what it will take to turn the tide on EV adoption.

Hineman, Marcie

An Efficient and Cost-Effective Solution for Battery Recycling

TBMG-5084906/01/2024

Used lithium-ion batteries from cell phones, laptops, and a growing number of electric vehicles are piling up, but options for recycling them remain limited mostly to burning or chemically dissolving shredded batteries. The current state of the art methods can pose environmental challenges and be difficult to make economical at the industrial scale.

Commercial Vehicles: Vol. 1

EPRCOMPV142023

05/03/2024

ABSTRACT

Lehmann, Johannes, Moorehead, Stewart, Muelaner, Jody E.

Cost-effective techniques for SCEV to improve performance & life of battery and motor by using efficient thermal systems

2024-26-027501/16/2024

The automotive world is moving towards electric powertrain systems. The performance of an electric powertrain and its electric components majorly depends on the operating temperature of the components. In the small commercial vehicle segment overall vehicle cost is a very sensitive parameter while competing in the market. This paper presents advanced efficient cost-effective thermal techniques for small commercial electric vehicles (SCEV) to improve the performance & life of major electric components. It is observed that from the literature survey, this technology is a novel technology for small commercial electric vehicle applications. The one-dimensional (1D) simulation approach is employed to evaluate the performance of the battery and traction cooling system during battery charging and vehicle driving scenario for different ambient conditions. The proposed thermal management techniques consist of simple and cost-effective thermal architectures having 3-way & 4-way valves which help

Chormule, Suhas Rangrao, Warule, Prasad, Jadhav, Vaibhav, Nagpure, Rahul

Development of Duty Cycle for Transmission System Components in a Two-Wheeled Electric Vehicle

2024-26-031801/16/2024

A two-wheeler is exposed to various dynamic loads transferred from roads and input given by the vehicle prime mover, which leads to the occurrence of torque on the wheel and transmission. The torque generated depends on the terrain and riding pattern of users, so it becomes important to develop a duty cycle of transmission considering multiple events enabling us to understand the durability standard of the component designed. The tests performed were on an EV two-wheeler that uses a belt drive transmission. The paper will focus on the following aspects, which cover the customization of the torque cell for the pulley system in the transmission, followed by the testing on different selected terrain conditions and analysis methodology for generating the duty cycle for different systems in transmission of the vehicle. A customized torque cell using strain gauges was developed with locations identified from finite element analysis performed on the wheel pulley. Strain gauge locations are

Ganju, Shubham, R S, Mahenthran, Prasad, Sathish Kumar, Balakrishnan, Sivakumar

Challenges for Indian Road Traffic with Sound Alert Devices on Electric Vehicles

2024-26-021101/16/2024

Challenges for Indian Road Traffic with Sound Alert Devices on Electric Vehicles For safety towards pedestrians and other road-vehicles, sound alert systems (horns) have been in use since development of Automobiles. On the same line but with special purpose of preventing a Driver to sleep in a running vehicle, a Driver Monitoring System [DMS] is recently developed. For Electric Vehicles which are very quiet during starting and driving till 20 km/hr, Acoustic Vehicle Alert System (AVAS) is deployed in Europe and likely to be implemented in India soon. For all these Alert Devices, there are Standard Regulations across the world: ECE R-28 for Horns and ECE R-138 for AVAS. They, however, define only lower and upper dBA limits of the sound radiated by them. For DMS, no such regulation exists till today. With this, there has been a long time debate on what an optimal dBA level should be there, for all road-users as well as for vehicle- users inside the cabin. It would be adequate, on one

A, Milind Ambardekar

Design & Optimization for Vehicle Dynamic events of Electric 2-Wheeler using Genetic Algorithm Approach

2024-26-026001/16/2024

The drive of Electric vehicles gained lot of traction in two-wheeler market, customer preferences and affordability are major reasons leaning towards electric 2 wheelers. As the two-wheeler market is huge, product development timelines are very sensitive to capture the market. Simulation based approaches are gaining lot of traction among manufacturers helping them to optimize the performance and production cycle time. During the design phase, hard points of the vehicle need to be defined. A multi body dynamic simulation approach will be made to evaluate the vehicle’s performance with initial design of hard points. Based on the ride and handling results, hardpoints optimization will be set up using Design of Experiments (DOE) studies. Suspension characteristics and sensitivities are studied to improve the ride behavior of the vehicle. A two-wheeler vehicle is a highly unstable and heavily depend on the skill of rider model. To improve the safety and handling behavior a fall detection

Gopakumar, Sreekanth, Gumma, Muralidhar

Dual-Motor-BEV Controls Optimization

2024-26-024301/16/2024

In this paper we will discuss different techniques of controls optimization for a dual motor BEV model and look at the most optimal solution with an objective to minimize motor losses or maximize efficiency. In a dual motor model, torque split ratio plays a vital role in deciding the operating points for each motor and hence the losses or inefficiency in the system. It is important to find the optimal torque split ratio to improve range and performance. Four techniques covered in this paper includes ECMS (Equivalent Consumption Minimization Strategy, DP (Dynamic Programming), DOE (Design of Experiment) and Empirical relation-based approach. ECMS is a local optimization technique whereas DP is global optimization technique. DOE was used to perform a full factorial analysis with an eventual goal of creating a map which relates TSR (Torque Split Ratio) to the operating points in the form of vehicle acceleration and vehicle speed. A quadratic empirical relation between vehicle acceleration

Chopra, Ujjwal

Influence of Rear Suspension Local Stiffness on Full vehicle Ride & handling Performance

2024-26-006101/16/2024

One of the biggest challenges for automotive industry is with respect to material saving and to have control on cost of development and still meeting performance in each aspect. Stringent weight targets help industries to have good margin on component costs. In recent times we have seen vehicle underbody contribution to total vehicle is significant in range of 12% to 18%. Total weight directly impacts the range of electric vehicle which is a key metric for success from real-world usage point of view and customer appeal. Hence control on suspension and frame design for light weighting is prominent trend in industry, this leads to deterioration of suspension compliance as well as vehicle ride and handling performance. Sub-frame and knuckle play crucial role in definition of overall suspension stiffness. Present Study focusses on electric vehicle rear cradle design for weight saving with minimum reduction of stiffness. Understanding compliance which obtained from frame\cradle in vehicle

Asthana, Shivam, Rasal, Shraddhesh, Ganesh, Lingadalu, V, Jesse Daniel, Nidasosi, Basavraj, Ramkumar, J, NAYAK, Bhargav, M, Sudhan, Vellandi, Vikraman

Electric Vehicle charging Interruptions

2024-26-013701/16/2024

This paper presents, an analysis of different kind of technical issues encountered while charging electric vehicle using plug-in charger. The electric vehicles is charged periodically, based on charging system configuration and requirements set by the vehicle. However, in certain instances, vehicle charging was interrupted and does not charge the battery completely. Therefore, condition of the itineraries get affected due to interruption of charging. To deal with such situation it is required to upgrade the charging process. Using logged vehicle measurement data, we analyzed the problem and updated the software and hardware in vehicle. The root cause of analysis showed how charging is interrupted and vehicle remains idle while coupler is still engaged. In this method, we identified different reasons of interruptions - mistaken communication while charging, power supply(Charger) failure, short protection, component leakage, charging facilities. This analysis were very useful in deriving

Ambuskar, Mandar Maruti

A Comparison of Wire Bonding vs. Spot Welding vs. Soldering in the Prevention of Thermal Runaway in a Battery Pack

2024-26-010901/16/2024

EVs are a fast-growing market and appear as a promising option against the high emission of gasoline and diesel vehicles. The growth in the EV market has been decent and a regular buyer is still skeptical due to fire incidents occurring with EVs. Complex electronics, improper thermal management, mechanical abuse, improper cell grading activities and control in production, lack of testing in a production plant, and of course, uneven degradation of cells can be one of the reasons this promising technology is facing thermal runaway and in turn, the wrath of the government and public alike. One of the reasons thermal runaway can be triggered after a cell catches fire is because a part of heat travels via busbars to the neighboring cells, as the busbars can conduct heat faster than the air. For the heat that is conducted, it is easily understandable that we need to break the electrical, as well as thermal conduction connection to the neighboring cells. This paper presents a comparison of

Pawar, Aniruddha, Khan, Faiz, Shah, Harsh, Malani, Shekhar

A Traffic Microsimulation Based Study of an Electric Road System with Dynamic Wireless Power Transfer

2024-26-010201/16/2024

Electrification of road transport is a critical step towards establishment of a sustainable transport ecosystem. However, a major hindrance to electric mobility is the high cost and weight of the battery pack. Downsizing the battery pack will not only address these issues, but will also reduce embedded emissions due to battery manufacturing. One approach towards reducing battery pack size and still offering the user of electric vehicles similar mobility experiences as in case of conventional vehicles is to set up extensive network of charging or battery swapping stations. Another approach is to provide the vehicle with required energy while it is on the move. However, conventional systems such as overhead line or conducting rails have several disadvantages in the urban environment. One solution that has come up in this regard in recent times is the concept of Electric Roads System (ERS), which involves dynamic wireless power transfer (DWPT) to the vehicles from power transmitters

Sardar, Arghya, Prasad, Mukti

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

Advanced Thermal Management System for Electric Vehicles – An Indian Case study

2024-26-012601/16/2024

Climate change and global warming is one of the major challenges faced by the world today. A significant number of Indian cities rank among the most polluted globally, with vehicular emissions being a primary contributor. To address this issue, Government of India is actively advocating for the adoption of zero-emission vehicles, such as electric vehicles, through policies and initiatives like FAME II, PMP, and the National Mission for Transformative Mobility and Storage. The acceptance of electric vehicles is growing in the Indian market seeing more than 200 % increased sales with large shares of 2-wheelers, 3-wheelers & compact cars getting electrified. One of the major inhibitors to EV sales being the high overall electric vehicle cost compared to conventional vehicles with HV battery is the most costly system on the present day electric vehicles . An electric vehicle having high energy efficiency can meet it's driving range requirements with a relatively smaller battery size

Emran, Ashraf, Chavan, Sagar, Franke, Kai, Sharma, Vijay, Garg, Shivam, Pawar, Bhushan, Hemkemeyer, David

Optimization of Trim Clips Design for Performance Improvement

2024-26-036701/16/2024

As customers are inching towards adoption of electric vehicles as an alternative to internal combustion engines, automotive OEM's will have to embrace this change and equip with new product development process. When it comes to Electric Vehicle (EV) in comparison with Internal Combustion Engine (ICE), NVH plays a major differentiator for vehicle refinement. Squeak and rattles will account for 25% of overall in-cabin noise source in an electric vehicle, most of which is observed from interior trims. Trim is mounted using small plastic clips which act as mounts and play a significant role in part retention and part integrity during normal operation and in case of any transient events. The engineering specifications for selecting a clip is force and it is mostly driven by ease of assembly, serviceability, and durability. A single DOF system with a specimen mass is developed and stiffness and damping are calculated for different options based on transmissibility. In this work, an attempt

Deole, Sameer Shrikant, Mohammed, Riyazuddin

A Study on Traction Battery Mounting Arrangements in Different EV Buses

2024-26-012101/16/2024

This paper provides an overview of the different types of traction battery mounting arrangements available in electric buses globally. The paper describes a key comparison of all the types of traction battery mounting strategies used in EV buses along with their dominance and limitations. In EV buses, bigger sized batteries are used which directly affect vehicle architecture, assembly & serviceability. On the other hand, larger-sized batteries are used in buses which carries heavy mass, which influences vehicle dynamics & performance characteristics such as vehicle ride, handling, braking & NVH. The most important consideration in EV vehicles is safety, which comes in first place, so this paper gives some ideas to carefully design battery mounting arrangements for EV bus applications. There has been seen a very positive adaptation of EV buses in the last few years due to the rise in Co2 and global warming. Many EV bus manufacturers have entered the market with their innovative ideas of

Jain, Gaurav, Pathak, Rahul, Gore, Pandurang

Methodology development for E-Axle NVH performance evaluation through virtual simulation

2024-26-012001/16/2024

Demand for electrically driven vehicles has increased significantly in recent years, due to its subsidized rate, economical operation and environmentally friendly features. If discussed about India, the sales have increased by 174% in a single year. This drastic jump in sales has encouraged the current automobile manufacturers to come up with more and more electric-driven vehicle platforms in a crunch time frame. And to fulfill these requirements, manufacturers have to work a lot to introduce new technologies like E-axle, which can be space effective, less expensive and easy to assemble. But the introduction of such new technologies brings an even bigger requirement for new validation methodologies, and in the case of electric vehicles (EV) where the development time has been very less, as brought a bigger challenge of more dependency on virtual simulation. As the operational procedure of E-axles is completely different from the conventional axles, the loads that are coming will also

Jain, Tanmay, Desai, Ankit, Kurna, Srinivas

Detection of unintended vehicle behaviour for driver safety

2024-26-010601/16/2024

The functional safety of electric vehicles has attracted a great deal of attention among automobile industries globally. A tricky yet necessary dual gamut of operational ease along with operational safety is something that cannot be ignored while using electric vehicles. Safety paired with vehicle reliability will go a long way in the market. Therefore, abnormal vehicle behavior due to factors such as unintended acceleration should not be kept in hind sight. Unintended acceleration is a phenomenon where the vehicle accelerates involuntarily without the knowledge of the driver which leads to accidents and fatal injuries. Thus, prior detection of unintended acceleration becomes mandatory for driver’s safety. Unintended acceleration is a result of various uncontrolled conditions like road driving conditions and system malfunction. This paper aims to estimate the load torque of a vehicle by utilizing the vehicle drive train model thereby ensuring the timely detection of unwanted

Ghube, Aditya Purushottam, Chauhan, Abhisha, Nidubrolu, Kranthi kumar

Simulating V2G Concept for optimized EV fleet charging in India

2024-26-010101/16/2024

The transport sector is bound to play a huge role in the imminent transition to green energy. India has pledged to reach net-zero emissions by 2070 at COP26 and is committed to have 30% EV sales by 2030. The Indian government has been facilitating fleet electrification through initiatives like FAME–II. India’s EV market is expected to grow at an annual rate of 90% between 2022 and 2030. With this projection combined with climate targets, comes the anticipated exponential rise in renewable energy contribution to the national grid accompanied by a huge transport related demand for electricity. NITI Aayog – India’s public policy think tank along with Ministry of Power is already looking into expansion of EV charging infrastructure in India as part of smart grid implementation. Deployment of Vehicle-to-Grid (V2G) technology as extension of smart charging initiative is imperative in smooth transition to renewable energy. The possibility of bi-directional energy flow between EV battery and

Sandhu, Rouble, Cao, Xinyuan, Faßbender, Max, Schade, Thomas, Emran, Ashraf, Andert, Jakob, Xia, Feihong, Sharma, Vijay

Anti-Rollback Function for Electric Vehicles without ABS/HSA System.

2024-26-009601/16/2024

In high-end commercial vehicles, technologies like Electronic Braking Systems (EBS) help pull away the vehicle from a standstill on steep gradients with no risk of rolling back. Tata Motors has developed an indigenous Anti-Roll Back (ARB) system that effectively minimizes this risk but without the use of EBS/HSA. The ARB delivers identical functionality to the HSA feature in the EBS but autonomously, and by purely electric means. In the proposed system the electric traction motor develops a high positive torque when the vehicle tries to roll back upon minimal accelerator pedal press. The system is autonomous in the sense that the driver does not need to press any HSA switch on the dashboard and the system works on relatively flatter road also which otherwise is not the case with HSA as it negatively affects the operation on flatter road by locking wheels and vehicle launches with a very high torque when brakes are automatically released by EBS upon threshold torque build-up. The launch

Ganguly, Sutanu, Amancharla, Naga Chaithanya, Sharma, Santosh, Shukla, Amisha, Singh, Upendra, Abhirag, Abhirag

Geometry, Sizing and Optimization of honeycomb structures along with embedded metal inserts on the floor for Truck-Mounted Container Applications

2024-26-018601/16/2024

With the rise of worldwide trends towards light weighting and the move towards electric vehicles, it is now more important than ever for the automotive industry to develop and implement lightweight materials that will result in significant weight reduction and product improvements. A great deal of research has been done on how to best combine and configure honeycomb cores with the right face sheets for Truck-Mounted Container Applications. Honeycomb structures possess the ability to bring about superior structural rigidity when the core parameters are selected and optimized based on the automotive application requirements. Through a variety of experimental tests for various combinations of the core parameters, the selection of the critical honeycomb core parameters to efficiently increase the compressive strength and panel rigidity of the entire container assembly has been evaluated and compared in order to determine the most effective combination to produce superior results for

phukan, Prerna, Dave, Rajeev

Electrifying the Giants: Green mobility solution for M&HCVs in India.

2024-26-013101/16/2024

Diesel operated Medium and Heavy Commercial Vehicles (M&HCV) account for nearly 70% of all road transportation in India which is expected to quadruple, from 4 million in 2022 to roughly 17 million trucks by 2050. Despite comprising a mere 5% of total vehicle fleet, they consume nearly 57% of fossil fuel used by the transport sector and responsible for 71% ,74% and 55% of CO2 ,PM and NOx emissions respectively. This necessities the transition of M&HCV into green mobility solution. Furthermore, smaller vehicles like 2W, 3W, 4 wheeler like cars and buses are adopting EV technology at a faster pace coupled with incentivization through government policies like FAME-I, FAME-II etc., advocates an immediate intervention on electrification of M&HCVs to multifold the impact. This paper suggests a collaborative approach amongst M&HCV manufactures and government agencies to realize the transition while integrating the benefits of reduced emissions, lower operating costs, quieter operation

Saurabh, Piyush, Giri, Debabrata

Comparison between state of art performance parameter of GaN and SiC Converters for electric vehicle application.

2024-26-013401/16/2024

Various aspects of vehicle design, such as powertrain, infotainment, connectivity, and driving assistance systems, are undergoing significant advancements and innovations in the automotive industry. To enhance the performance and efficiency of electric vehicles, designers are exploring advanced technologies beyond the conventional silicon-based solutions. One such technology that is gaining popularity is the use of wide-bandgap materials like silicon carbide (SiC) and gallium nitride (GaN) for power-semiconductor devices in electric vehicles. Wide-bandgap-based hard-switching voltage source converters made of these materials are superior to their silicon counterparts in terms of efficiency, but their performance depends on their utilization at high switching frequencies. To determine the best technology for future electric vehicle applications, researchers compared the efficiency of SiC and GaN devices by analyzing factors such as blocking voltage, conduction loss, switching loss, and

Mehrotra, Soumya, Ray, Rakesh Kumar, Pandey, Devbrat, Naithani, Hardik

HVAC NVH Refinement in Electric Vehicle

2024-26-020601/16/2024

Customers expect much more advanced features and comfort in electric vehicles. It is challenging for NVH engineers to reduce the vibration levels to a great extent in the vehicle without adding cost and mass. This paper focuses on reducing the tactile vibration in electric vehicle when AC is switched on. Vibration levels were high and modulating in nature in test vehicle. Electric compressor is used for cabin cooling and battery cooling in the vehicle. Compressor is connected to body with the help of isolators. Depending upon cooling load, the compressor operates between 1000 rpm and 8000 rpm. The 1st order vibration of compressor was dominant on tactile locations at all the compressor speeds. Vibration levels were improved by reducing the dynamic stiffness of isolators . To reduce the transfer of compressor vibration further, isolators are provided on HVAC line connection on body and mufflers are provided in suction and discharge line to reduce the effect of pulsation. With the above

S, Nataraja moorthy, Rao, Manchi, Raghavendran, Prasath, Manivannan, Giridharan

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

Automation of PID Calibration for Close Loop Control System in an Electric Vehicle to Achieve Objective Driveability Performance

2024-26-033201/16/2024

This paper introduces a novel approach to automate PID calibration for closed-loop control systems and the creep control function in an electric vehicle. Through a comprehensive literature survey, it is found that this method is the first of its kind to be applied in the field of automated electric vehicle calibration for Creep function. The proposed approach utilizes a systematic methodology that automatically tunes the PID parameters based on predefined performance criteria, including energy consumption and jerk. To implement this methodology, the ETAS INCA FLOW software, which provides guided calibration methods for in-vehicle testing & calibration, is employed. The calibration process is performed on a real-time electric vehicle platform to validate the effectiveness of the proposed approach. The results of this study showcases the advantages of automated PID calibration for closed-loop control systems and creep control function in small commercial electric vehicle. The proposed

G, Ashwin, Jadhav, Vaibhav V., Warule, Prasad B.

Liv-in vehicle of the future

2024-26-023701/16/2024

Liv-in vehicle of the future is a pioneer providing sustainable, highly customizable electric LCV solutions offering automated to autonomous driving, seamless connectivity to customers' ecosystems, peace-of-mind reliability and improved productivity and profitability. For flexibility, versatility, and economies of scale, modularity is essential. With a modular EV design, different vehicle models can share the same platform or components. This can accelerate development and provide manufacturing efficiencies, resulting in significant cost savings. With modular components parts sourcing is more efficient, and inventory management, processing, and storage are simplified. One plant can produce multiple vehicle variants far more easily and efficiently, with less complexity of retooling and physical layout changes. Advantages a) Reduced design and development costs. b) A flexible architecture that can be used for a variety of vehicle types. c) Economies of scale. d) Proven performance from

Dias, Francis Anton, Mane, Sushant

A design Approach to Optimize Suspension Clanking Noise in Electric Cars

2024-26-022601/16/2024

Designing an electric car suspension system is a key challenge for all OEMs because balancing buzz, squeak, and rattle (BSR) acoustic performance at low-speed driving and improving ride quality at high-speed driving conditions is difficult. Suspension noise deteriorates in-cab acoustic quietness and overall vehicle performance. For this reason, optimizing these noises is becoming increasingly prioritized as a key design issue throughout the development process of suspension system. This paper studies the various components of suspension system and their noises in an electric car. Based on customer voice index and drive pattern, suspension anomalous clanking noise was identified in Electric Car. This noise phenomenon was cascaded from the vehicle level to BSR rig and eventually to the suspension rig for root cause analysis. At the vehicle level evaluation, clanking noise problematic frequency identification was done for both near suspension source and incab with the help of a sound

Titave, Uttam Vasant, Naidu, Sudhakara, kalsule cEng, Shrikant

Powertrain Mounting system NVH simulation methodology using transfer path analysis technique for Electric vehicles

2024-26-022501/16/2024

In comparison to traditional gasoline-powered vehicles, Electric vehicles (EVs) development and adoption is driven by several factors such as zero emissions, higher performance, cost effective in maintenance, smoother and quieter ride. Global OEMs are competing to provide a reduced in-cab noise for ensuring a smooth and quiet driving experience. Short project timelines for EV demands quick design and development. In initial stages of project, input data availability of EV is limited and a simplified approach is necessary to accelerate the development of vehicle. This paper focuses on simulation methodology for predicting structure borne noise from powertrain deploying Transfer Path Analysis approach. Current simulation methodology involves full vehicle model with multiple flexible bodies and full BIW flexible model which leads to complex modelling and longer simulation times. The proposed transfer path analysis technique utilises, a simplified Multibody Dynamics EV powertrain model

Duraikannu, Dinesh, Iqbal, Shoaib

Noise reduction on electric two wheeler by structural modification and gear design optimization

2024-26-021501/16/2024

The low running cost of electric two wheelers is resulting in high popularity and growing market share. The electric two wheelers are generally considered silent. However, the tonal nature of radiated noise is annoying for both driver and pedestrians in electric vehicles. This study focuses on electric two wheeler with annoyance issue. The customer complained about non-linear noise with respect to speed and also whining during loading and coasting. The detailed Noise Source Identification (NSI) revealed that the noise is due to motor whine and structural resonances of chassis excited by this motor excitation during runup and gear whine orders during coasting when excitation by motor is absent. The motor mounting and chassis are structurally modified with suitable vibration isolators based on the results of modal analysis. The transmission gear geometry and contact pattern are optimized for transmission error reduction. The modification resulted in 6-8 dB overall noise reduction with

Chivate, Shriniwas Dilip, Gaikwad, Atul Annasaheb, Taware, Ganesh Nanasaheb

Countermeasures for Low Frequency Boom noise Reduction in Electric Vehicle

2024-26-021401/16/2024

Electric vehicles are much quieter than IC engine powered vehicles due to less mechanical components and absence of combustion. The lower cabin noise in electric vehicles make customers sensitive to even small disturbance in vehicle. Road boom noise is one of the major concerns to which the customers are sensitive in electric vehicles. The test vehicle is a front wheel driven compact SUV powered by electric motor. In normal plain road, noise levels are acceptable but when the vehicle has been driven on coarse road, the boom noise is perceived, and the levels are objectionable. Multi reference Transfer path Analysis (MTPA) is conducted to identify the path through which maximum forces are entering the body. Based on MTPA, modifications are proposed on the suspension bushes and the noise levels were assessed. Operational deflection shape (ODS) analysis is conducted on entire vehicle components like suspension links, sub frame, floor, roof, and doors to identify the deflection pattern of

S, Nataraja moorthy, Rao, Manchi, Raghavendran, Prasath, Selvam, Ebinezer

Solving Drive Shaft Failure in Electric Vehicles

2024-26-033401/16/2024

Inherent capability of electric motors to induce high instantaneous torque & causes high load reversals in electric vehicle drive shafts when subjected to certain road conditions & driving maneuvers, which necessitates specific countermeasures for drive shaft design improvements to achieve optimal sizing of drive shaft joints. This paper discusses systematic approach undertaken for root cause analysis of catastrophic driveshaft failure under specific vehicle testing condition on road with multiple speed breakers, leading to multiple high torque reversals and achieve system robustness with shaft design & process change to increase strength together with software calibration technique to reduce the torque demand upon detection of such operating condition. Vehicle level torque measurement, replication of failure on rig & simulation correlation & process sensitivities are studied before finalizing design & process changes & improvement is confirmed on rig level testing first. New drive

Singh, Deepak Vikram, JACOB, ABIJITH, Paua, Ketan, Vellandi, Vikraman, Mane, Yogiraj

High Speed Driveline Power Loss & Influencing Factors

2024-26-033701/16/2024

Energy savings in automotive applications has always remain an important aspect of research. In addition, today's highspeed requirements in electric vehicles require high-efficiency drivelines to match overall vehicle mileage or range. This paper presents the validation of the overall efficiency & drag losses of the highspeed Driveline for an ATV with 4 Wheel Drive System. The efficiency & drag losses were measured in the powertrain testbed where the test units were placed between two Transient Dynamometers. The main aim of the test was to validate the overall efficiency as a function of input speed and torque. All these measured values of the gearbox efficiency are included in various graphs. The tests were performed for complete functional range of UUT at max. operating oil temperatures for Transmission and Front Differential testing. Drive shafts tests were performed at its complete range and various inclination angle up to max. failure point. The Wheel Hub was tested at various

Jain, Sankalp, Singh, Parminder

Effect of Ceramifiable Silicone Rubber Composite based Thermal Insulators in Battery Packs

2024-26-035101/16/2024

Silicone and rubber composite, often called Ceramifiable Silicone Rubber (CSR) has proven to show excellent mechanical and thermal properties. CSR materials have been mainly used in industrial applications like electrical insulating cables, decorations, and fire-proof materials. The mechanical and ceramifiable properties of CSR can be altered by changing the silicone rubber matrix and by adding the right additives or fillers. In this work, we prove the potential of CSR composites as thermal insulating materials in battery packs. Specifically, we explore the usage of CSR inside the battery pack to improve safety during thermal events. We also characterize the material properties before and after exposing the CSR composite to elevated temperatures and flame. Finally, we investigate the effectiveness of the CSR composite sheet in preventing or delaying cell-to-cell thermal propagation during a thermal runaway event inside the battery pack. Our experiments show that the CSR composite sheet

Nambisan T M, Praveen Kumar, H, Manjunatha, R, Pavan, P, Hari Prasad Reddy, G M, Bharath, Kulkarni, Mukund Aravind, Sundaram, Saravanan

Study on Range Improvement Controls and Method for Electric Vehicles

2024-26-013201/16/2024

Electric Vehicles are rapidly growing in the market yet various failure incidents were noted all along the globe. On the other hand, range anxiety has greatly inspired manufacturers to explore new practices to improve. One of the most important components of an EV is the battery, which converts chemical energy to electrical energy thereby liberating heat energy as the loss. This heat loss when high, capability of system to deliver required energy to wheels is reduced significantly. With a higher heat loss in the battery, system is prone to failure or reduced mileage. Therefore, controlling/maintaining system temperature under safe usable zone even during harsh conditions is ideal. Simple reduction in energy consumption of electrical cooling/heating devices used with regenerative energy techniques can greatly help in range improvement. The intention of this paper is to explore easy methods to improve electric vehicle range in different ambient conditions. Few of the key benefactors here

MR, Vikram, Pattalwar, Ashutosh, Verma, Mrinal, Bawa, Vikas

A Real-World Range Testing and Analysis Methodology Development for Battery Electric Vehicles

2024-26-012401/16/2024

Range anxiety is one of the major factors to be dealt with for increasing penetration of EVs in current Automotive market. The major reasons for range anxiety for customers are sparse charging infrastructure availability, unreliable range prediction and uncertain real-world range values. The uncertainty in real world range is due to the variation between the testing condition during vehicle development and real-world customer usage condition. This paper illustrates a more accurate test methodology development to derive the real-world range in electric vehicles (LMV) with experimental validation and system level analysis. The test methodology developed will be replicating the real-world usage scenario and bridge the gap between testing and Indian customer usage condition. Test conditions are developed based on matrix consisting of different routes, drive modes, Regeneration levels, customer drive behavior, time of drive, locations, ambient conditions etc. Based on the real world

B, SAKTHIVEL, Shams, Tausif, Lalasure, Santosh, Karnure, Shabbir Lalaso, Rajakumar, K., Omprasad, Karthick

Electric Vehicle Battery SOH and RUL prediction using Digital Twin Hybrid ML Model considering effect of Driving Behaviour

2024-26-012201/16/2024

The adoption of Electric Vehicles (EVs) is primarily limited by their dependence on batteries, which have lesser power density as compared to conventional fossil fuels as well as its ageing deterioration issues over time. Therefore, there is an urgent need to understand the modifications in battery performance characteristics with respect to changes in temperature, charging behaviour and usage pattern, low and high charge states, current variations etc. To resolve such issues, this work proposes the development of a battery digital twin model to accurately reflect battery dynamics during run time. A digital twin is a virtual model replicating a physical system's characteristics. The digital twin is developed using a physics and machine learning model trained with bench-level and vehicle level actual test data. It uses an equivalent circuit model (ECM) to predict the battery's internal resistance and polarization effect due to ionic diffusion process in the cell. ECM model generates

Dongaonkar, Saharsh, Sarkar, Prasanta, Patil, Gaurav, KONDHARE, MANISH, nath, Subhrajyoti

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