Browse Topic: Electrical systems

Items (15,762)
Find
Experimental Investigation of Factors Influencing Thermal Runaway in Lithium-Ion Battery Cells2025-01-0306To be published on 07/02/2025
In the fast-paced automotive development environment, experimental testing is often constrained by time and budget limitations. Consequently, tests are frequently conducted to meet regulatory requirements, industry standards, or internal guidelines. This leads to minimalistic testing approaches such as "One Factor at a Time" (OFAT) or "Trial and Error", which fail to capture parameter interactions and system complexities. This study investigates the critical factors influencing the thermal runaway behavior of lithium-ion battery cells under controlled experimental conditions. A statistical full-factorial experimental design was implemented to evaluate the impact of state of charge (SoC), heating trigger power, and cell capacity. The experiments, conducted using an autoclave setup, allowed for precise control of external conditions and detailed measurement of thermal and mechanical responses. The cells investigated are automotive-grade lithium-ion cells from development projects
Ceylan, Deniz, Kulzer, André Casal, Winterholler, Nina, Weinmann, Johannes, Schiek, Werner
Technical Paper
Simulation-Based Investigation and its Experimental Validation of the Thermal Behaviour of a Battery Electric City Bus2025-01-0266To be published on 07/02/2025
Electrification of city busses is an important factor for decarbonisation of the public transport sector. Due to its strictly scheduled routes and regular idle times, the public transport sector is an ideal use case for battery electric vehicles (BEV). In this context, the thermal management has a high potential to decrease the energy demand or to increase the vehicles range. The thermal management of an electric city bus controls the thermal behaviour of the components of the powertrain, such as motor and inverters, as well as the conditioning of the battery system and the heating, ventilation, and air conditioning (HVAC) of the drivers’ front box and the passenger room. The focus of the research is the modelling of the thermal behaviour of the important components of an electric city bus in MATLAB/Simscape including real-world driving cycles and the thermal management. The heating of the components, geometry and behaviour of the cooling circuits as well as the different mechanisms of
Schäfer, Henrik, Meywerk, Martin, Hellberg, Tobias
Technical Paper
Modular Thermal Management Framework for Electric Drive System Development2025-01-0262To be published on 07/02/2025
The automotive industry is undergoing a major shift from internal combustion engines (ICE) to hybrid (HEV) and battery-electric vehicles (BEV), which has led to significant advancements and increased complexity in drivetrain design and thermal management systems. This complexity reflects the growing need to optimize energy efficiency, extend vehicle range, and ensure system reliability in modern electric vehicles. At the Institute of Automotive Engineering, a specialized synthesis tool for drivetrain optimization is used to identify the best drivetrain configurations based on specific boundaries and requirements. Building up on this toolchain a modular and adaptable thermal management framework has been developed, addressing another critical aspect of vehicle and drive development: efficient thermal circuit layout and its impact on energy consumption and overall system reliability. The thermal framework emphasizes the dynamic interactions between key components, such as electric
Notz, Fabian, Sturm, Axel, Sander, Marcel, Kässens, Christoph, Henze, Roman
Technical Paper
Thermal Simulation of CCS Charging Inlet at High Charging Currents with various Optimisation Approaches2025-01-0278To be published on 07/02/2025
Current status: In Europe, the CCS charging standard for electric vehicles is the most widely used charging system. In order to reduce the inconveniences caused by long charging times, the CCS charging standard has been gradually adapted to the need for higher charging capacities. Currently, charging currents of up to 500A are supported at a charging power of up to 500kW. In order to decarbonise road transport, commercial vehicles are also increasingly being electrified. Problem definition: Battery-electric commercial vehicles in particular have large battery capacities with several hundred kilowatt hours, some of which do not have enough energy for an entire working day, which is why they need to be recharged if necessary. High charging power with correspondingly high charging currents is required to recharge the electrical energy storage units of commercial vehicles in an acceptable time. Due to the electrical losses, waste heat is generated, which places a thermal load on the
Krings, Jochen, Reuss, Hans-Christian, Ziegler, Peter, Steinmetz, Paul
Technical Paper
Prediction of hazardous gaseous emissions from a gasoline engine during cold starts using machine learning methods2025-01-0321To be published on 07/02/2025
Internal combustion engines generate higher exhaust emissions of hazardous gases during the initial minutes after engine start. Experimental data from a state-of-the-art turbo-charged 3-cylinder, 999 cc gasoline engine are used to predict cold start emissions using two Machine Learning (ML) models: a Multilayer Perceptron (MLP) which is a fully connected neural network and an Encoder-Decoder Recurrent Neural Network (ED-RNN). Engine parameters and various temperatures are used as input for the models and NOx (Nitrogen Oxides), CO (Carbon monoxide) and unburned hydrocarbon (UHC) emissions are predicted. The dataset includes time series recordings from the Worldwide harmonized Light-duty vehicles Test Cycle (WLTC) and four Real Diving Emissions (RDE) cycles at ambient and initial engine temperatures ranging from -20 °C to +23 °C. In total, 21 cases are considered, consisting of eight different ambient temperatures and five distinct driving cycles. Each case consists of a sequence of 2500
Mangipudi, Manoj, Denev, Jordan A., Bockhorn, Henning, Trimis, Dimosthenis, Koch, Thomas, Debus, Charlotte, Götz, Markus, Zirwes, Thorsten, Hagen, Fabian P., Tofighian, Hesam, Wagner, Uwe, Braun, Samuel, Lanzer, Theodor, Knapp, Sebastian M.
Technical Paper
Design and Analysis of a Battery Thermal Management System for Fast Charging in Extreme Hot Condition2025-01-0322To be published on 07/02/2025
Fast charging of lithium-ion batteries presents significant thermal management challenges, due to the high demanding conditions of high C-rates, particularly at extreme ambient temperatures. This study explores the thermal behavior of a cylindrical lithium-ion cell during fast-charging scenarios designed to achieve a full charge in 15 minutes or less (SOC: 0%–100%), across a wide range of ambient temperatures. The analysis covers a broad spectrum of ambient temperatures, from 303 K to 333 K, addressing real-world operational challenges faced by electric vehicles and energy storage systems. A validated thermal model, calibrated with experimental data on the open circuit voltage (OCV) and internal resistance of the cell across varying conditions, is employed to accurately predict the temperature distribution of the cell at different states of charge (SOC). The model also includes scenarios involving high initial cell temperatures to assess their effect on thermal performance during fast
Jahanpanah, Jalal, Mahmoudzadeh Andwari, Amin, Babaie, Meisam, Konno, Juho, Akbarzadeh, Mohsen
Technical Paper
Optimization of Metallic Substrate by 1D simulations to fulfill High Power Cold Start Conditions2025-01-0308To be published on 07/02/2025
The future of the internal combustion engine is strictly related to his capability to have Life Cycle Emission comparable to the pure Battery Electric Vehicles. To achieve this goal, it will be necessary not only to have carbon free fuels but also to increase the hybridization of the powertrain in order to have lower fuel consumption. On the other hand, it will be necessary to reduce to almost zero any further emissions of pollutants. For this reason, highly sophisticated exhaust aftertreatment must be developed. One particular use case is the so-called High-Power Cold Start. This can occur for the Plug-In Hybrid Electric Vehicles when the transition from pure electric drive to ICE assisted drive happens during high load request, for example an acceleration on the freeway ramp. This use case has been evaluated by CARB and in many other works. Nevertheless, in this particular paper, the Authors would like to investigate which Metallic Substrate Technology fits better during a HPCS. This
Montenegro, Gianluca, Onorati, Angelo, Della Torre, Augusto, Marinoni, Andrea, Pace, Lorenzo, Konieczny, Katrin, Laurell, Mats, Klövmark, Henrik
Technical Paper
Automated Test Process for Highly Configurable Software-Defined Mobility Systems in CI/CD2025-01-0297To be published on 07/02/2025
In the pursuit of customizability and evolvability of vehicle functions, manufacturers shift towards software-defined vehicles (SDV) to enable flexible customization and over-the-air updates. This results in multiple variants and versions of a vehicle model. While shifting to SDVs adds value and flexibility for customers, manufacturers struggle with homologating new and updated functionality because existing testing processes do not scale for high-frequency release cycles that limit available testing resources. Overcoming this challenge by using a coherent test process designed for testing variant-rich systems in continuous evolution will be one of the key enablers for the future development of SDVs. This paper presents an innovative end-to-end pipeline for efficient and comprehensive testing of variant-rich vehicle functionality tailored to an application in continuous development. Our transferable test pipeline employs sample-based variant selection, a software-in-the-loop
Hettich, Lennard, Pett, Tobias, Nägele, Ann-Therese, Schindewolf, Marc, Eris, Halit, Wagner, Stefan, Sax, Eric, Schaefer, Ina, Weyrich, Michael
Technical Paper
Upgradable Mechatronic Systems – Integration of Upgrade Planning and Design for Sustainable Vehicle Development2025-01-0290To be published on 07/02/2025
The automotive industry faces the challenge of developing vehicles that meet current customer requirements while being future-proof. Surveys show that customers fear financial risks associated with essential subsystems like batteries due to aging and performance degradation, which significantly affects the service life of vehicles. Therefore, the rapid technological progress in electrified powertrain systems requires innovative approaches for high adaptability to changing demands. This paper presents an approach combining foresight-based planning of system-level upgrades with product architecture design to create adaptable and sustainable vehicles through modularity. Potential battery and energy storage technologies are identified, their market introduction is forecasted, and they are analyzed technically-functional and geometrically to create flexible design spaces within the product architecture. This enables the future integration of new, more efficient, or higher-performance
Fehrenbacher, Rüdiger, Kuebler, Maximilian, Zeng, Yunying, Bause, Katharina, Albers, Albert, Nootny, Fabio, Kolbe, Lucia, Jung, Luca
Technical Paper
Effect of ignition condition and fuel octane number on knock intensity in a small 2-stroke engine2025-01-0211To be published on 06/16/2025
The internal combustion engines are widely used on automotive transportation for its high energy storage system efficiency and the economic benefits. The 4-stroke engine has dominated all other forms to date, because the Otto cycle is much simpler to comprehend. However, the significant benefits such as, less pumping work and friction, lighter construction of 2-stroke engine, helped with applications which appreciate the simplicity and power density as well as meet the emission regulations. The disadvantages of the 2-stroke engine mainly caused by the lack of sufficient scavenging process, which limited its trapping efficiency. Also, the overlap of the intake and exhaust phases results in charge short-circuiting, more fuel consumption and high unburned hydrocarbon emissions. For the reason above, it is difficult for 2-stroke engines to realize stoichiometric combustion and unable to use three-way catalyst to control emissions. The residual exhaust gas in the cylinder makes the spark
Liu, Jinru, Iijima, Akira, Yamazaki, Yoshiaki, Yokota, Takumi, Kato, Hayato, Otaki, Yusuke
Technical Paper
Research on NVH Performance of Pulse Heating System of One Vehicle2025-01-0078To be published on 05/05/2025
When the ambient temperature is too low, the performance of the lithium-ion battery will deteriorate, and the car will have the problems of difficult charging, fast power consumption, and even difficult to start, so the battery needs to be heated before use to provide a comfortable working environment for the lithium-ion. The high-frequency pulse heating system can quickly and evenly raise the temperature of the battery, but there is noise during operation, which affects the NVH performance of the vehicle itself, and its noise comfort needs to be further optimized. Firstly, the high-frequency pulse heating system is discussed in detail, and the parameters affecting the NVH performance are explored. Secondly, NVH tests and subjective and objective evaluations were carried out based on different system parameters, relevant data were collected to establish a model, the influence degree of each parameter was demonstrated, and the best parameter combination was determined. Finally, the
Yun, Zhao, Shouhui, Huang, Hu, Zhongxun, Hui, Hui, Zhou, Changshui, Teng, Charlie
Technical Paper
Improving the Sound Transmission Loss of Wire Harness Pass Throughs2025-01-0118To be published on 05/05/2025
Abstract Improving the Sound Transmission Loss of Wire Harness Pass Throughs For years the NVH community has known that openings in the dash sheet metal, such as holes to pass wire harnesses through, create an acoustical weak point that limits the potential noise reduction of the dash insulation system. These pass throughs can also be a source of water leaks into the vehicle’s interior. With the combustible engine and now electric inverter power plants, the need to seal this area is vital. By molding a lightweight barrier that draws through the fiber/absorber interior decoupler and dash sheet metal which mates to a secondary seal molded into an outer engine dash decoupler, the two opposing molded barriers meet in the engine compartment and compress together forming a seal around the wire harness. This male/female molded seal replaces the conventional snap in grommet and eliminates noise/water leaks. The system Sound Transmission Loss (STL) is equivalent to similarly insulated sheet
Check, James, Moritz, Charles
Technical Paper
The DANA EV NVH Laboratory2025-01-0007To be published on 05/05/2025
A cutting-edge EV powertrain NVH laboratory has been established at DANA Incorporation’s world headquarters in Maumee, enhancing their capabilities in EV powertrain NVH development. This state-of-the-art and industry lead laboratory is designed to meet various NVH requirements for EV powertrain development and sign-off processes. This laboratory supports the use of a live motor for input and is equipped with an input module that allows for detailed examination of NVH characteristics of new powertrain configurations before prototype motors are available, significantly reducing development time for new drivetrain systems. Key features of the laboratory include a hemi-anechoic chamber, two AC asynchronous load motors, an acoustically isolated high-speed input motor, and two battery emulators that cover both low and high voltage requirements. The NVH laboratory enables engineers to assess system performance and correlate it with digital twin models. DANA engineers can develop and optimize
Cheng, Ming-Te, Zugo, Chris
Technical Paper
Evaluating Vibration Test Profiles for Battery Electric and Hybrid Vehicles2025-01-0009To be published on 05/05/2025
As the automotive industry transitions to electrification, understanding the differences in ambient operating vibration environments between conventional internal combustion engine (ICE) propulsion systems, battery electric vehicles (BEVs), and hybrid electric vehicles (HEVs) becomes increasingly important. Many automotive vibration testing standards provide frequency and amplitude test levels based on historical ICE vehicle data. Some standards note the potential inaccuracies of using this data source to test BEVs/HEVs and recommend using field-recorded data, if possible, while others make no note. Preliminary comparisons of BEV, HEV, and ICE vehicle ambient operating vibration environments show variations due to battery cell pack weight and engine vibration, among other factors. As accurate testing is tantamount to vehicle safety and longevity, the automotive testing industry must confirm the suitability of current test standards for BEVs and HEVs or create new ones. This paper
Achatz, Tom, Stoll, Cherie
Technical Paper
Plug-in hybrid and range extender NVH – Challenges and Solutions2025-01-0101To be published on 05/05/2025
The automotive industry continues to develop new powertrain and vehicle technologies aimed at reducing overall vehicle-level fuel consumption. While the use of electrified propulsion systems is expected to play an increasingly important role in helping OEM’s meet fleet CO2 reduction targets, hybridized propulsion solutions can play a vital role in the electrification strategy of vehicle manufacturers. Plug-in hybrid and range extender vehicles show unique NVH challenges due to their different possible operation modes. First, the paper outlines different driveline architectures for PHEV and range extenders. Given the multiple general architectures, as well as operation modes which typically occur for these vehicles, characterizations and source-path analysis of these vehicles can be more complicated than conventional vehicles. In the following steps, typical NVH related challenges are highlighted and potential solutions for NVH optimization are discussed. While the overall noise levels
Wellmann, Thomas, Ford, Alex, Pruetz, Jeffrey
Technical Paper
A Comparative Analysis of Fault Diagnosis by vibration signals for Critical Gear Components in Electric Vehicle Motor Testing Machines Using Machine Learning Algorithms2025-01-0040To be published on 05/05/2025
Electric vehicles (EVs) represent the future of the automobile industry, with the drive motor being a crucial component in modern EVs. To ensure optimal performance, a motor testing machine is used to verify the essential parameters of these electrical motors. This machine regularly evaluates electric motor characteristic curves and their electromagnetic behavior under different conditions. However, it has been observed that flaws in the testing machine's helical gear arrangement frequently cause malfunctions and suboptimal performance, affecting the efficiency of the electric vehicle production line. This research project aims to improve the motor test bench apparatus by modifying critical design parameters using machine learning and vibration signal analysis methods. Vibration signals are recorded at various gear settings, and statistical features are extracted from these signals. These signals are then classified using classifiers such as Naive Bayes and Decision Trees. Machine
S, Ravikumar, Sharik, N, Syed, Shaul, V, Muralidharan, D, Pradeep Kumar
Technical Paper
Integrating for Safety – A Proposed Approach to the Integration of Propulsion Battery Systems in Hybrid Electric Aviation2025-01-0148To be published on 05/02/2025
In the last year we have witnessed a notable surge in the designs and in the guidance material for electric and hybrid aircraft. FAA and EASA have continued to evaluate the safety of Propulsion Battery Systems (PBS), with a focus on thermal runaway containment testing. As a result, a harmonization white paper was issued to provide a certification path for Thermal Runaway (TR) Hazards, followed by an EASA certification memorandum on the acceptable approaches for the certification of Electric/Hybrid Propulsion Systems (EHPS). And just recently, an FAA Advisory Circular (draft) was issued for the “powered-lift” aircraft that feature these propulsion battery systems. In spite of the advances made by electric/hybrid aircraft manufacturers and the aviation authorities, there is still a missing piece of the puzzle. Mainly, we are still not confident in our ability to properly integrate the PBS into the EHPS architecture, in such a way where safety is never compromised, no matter the hazard
Hanna, Michael, Walker, Cherizar
Technical Paper
Enhancing Efficiency in Aerospace Manufacturing through AI Agent Based Bearing Diagnostics System2025-01-0158To be published on 05/02/2025
Industrial bearings are critical components in aerospace manufacturing, where their failures can result in costly downtime. Traditional fault diagnosis typically depends on time-consuming on-site inspections conducted by specialized engineers. This research introduces an innovative Artificial Intelligence application that functions as a virtual maintenance technician, empowering on-site personnel to perform preliminary diagnoses. By reducing the dependence on specialized engineers, this technology aims to minimize downtime. The AI system leverages large language models to guide the inspection process, answer queries from a comprehensive knowledge base, analyze defect images, and generate detailed reports with actionable recommendations. Multiple deep learning algorithms operate as backend APIs to support this functionality. This study details the architectural design of the expert system and provides a real-time simulation of its workflow, demonstrating its potential to enhance
Chandrasekaran, Balaji
Technical Paper
Model-Based Design and Energy Management of an Aeronautical Proton Exchange Membrane Fuel Cell System2025-01-0150To be published on 05/02/2025
The growing demand for air transport requires efficient and sustainable power systems to meet the pressing need for decarbonizing the sector. A hybrid unit, consisting of a proton exchange membrane fuel cell system and a lithium-ion battery, is a suitable option due to the benefits of reduced gravimetric and volumetric impacts, along with the flexibility of energy management strategies. This work addresses, using a model-based approach, the issue of integrating these electrochemical devices into the aircraft’s electrical architecture, considering both design and energy management aspects. Two scenarios are explored to match the DC bus line voltage requirements. In the first, the fuel cell system nominal power is kept constant, while the number of DC/DC converters operating in parallel is assessed by constructing bi-dimensional maps derived from literature. These maps relate the converter’s maximum deliverable power to the input and desired output voltage. The second scenario introduces
Aliberti, Paolo, Sorrentino, Marco, Cuomo, Fabrizio, Napolitano, Ciro
Technical Paper
Short-Time Current Rating of Aircraft Wire2025-01-0145To be published on 05/02/2025
This paper presents a comparative analysis of various short-time current rating formulas, focusing on applications in aircraft wiring. Examining historical formulas developed by pioneers such as W.H. Preece and I.M. Onderdonk alongside modern experimental data provide a comprehensive understanding of short-time current rating formulas. Also, exploring key challenges, such as environmental conditions and material variability in aviation with particular attention to adiabatic methods for current-carrying calculations. The findings of this paper offer practical insights into improving the safety and reliability of an aircraft electrical system with improving the accuracy of short-time current rating predictions.
Fifield, Jon
Technical Paper
Conceptual Design of a Superconducting Aero Electric Engine System2025-01-0146To be published on 05/02/2025
The goal of the development of an electric aircraft engine is to create an aircraft system that achieves ultimate efficiency using hydrogen fuel instead of fossil fuels. Therefore, it is necessary to focus on reducing weight as much as possible, and this paper describes the approach to such fuel cell-powered aircraft. The authors have adopted a superconducting coreless rotating electric machine with an integrated hydrogen tank and are pursuing a target of 70kg or less for the main components of a 2MW rotating electric machine. High-temperature superconducting wires have zero electrical resistance and can carry a very high current density, but the alternating current (AC) loss generated when used in AC has been an issue in their application to rotating electric machines. In 2023, The SCSC cable was developed to be a low-AC-loss, robust, and high current cable concept, in which copper-plated multifilament coated conductors are wound spirally on a core. In addition to using this
Oyori, Hitoshi, Sakurai, Sho, Kusase, Shin, Yoshida, Yukihiro, Yoshinaga, Seiichiro, Nose, Hiroyuki, Amemiya, Naoyuki
Technical Paper
Traction Voltage Level in Two-Wheelers: Considerations on Safety and Performance2024-32-006204/18/2025
Most electric 2-wheelers on the market today seek to replace combustion engine vehicles from 50cc to 150cc which equates to an electric motor power between 2 and 12 kW. The traction voltage level of these vehicles is mostly between 44V and 96V. However, the actual choice of voltage on a specific vehicle seems to be arbitrary and higher voltage does not necessarily correlate with higher motor power. This paper seeks to highlight considerations and tradeoffs which feed the choice of traction voltage levels. Important criteria are electrical safety standards and their impact on vehicle electrical architecture, the performance and availability of key electronics parts such as capacitors, MOSFETs, and gate drivers, while also highlighting functional safety aspects. This paper shows by a comprehensive analysis of the motor drive that for the vehicle class mentioned above the traction voltage level can be kept below 60V without any performance impact, while also ensuring electrical and
Schmitt, Stefan
Technical Paper
Assessing Lithium-ion Battery Functionality Post-Thermal Management with Water Mist2024-32-012204/18/2025
The danger of lithium-ion batteries in electric vehicles (EVs) is intensified when they are used at inappropriate temperatures, leading to self-heating and eventually contributing to thermal runaway. Nevertheless, there is uncertainty through the safety of reusing batteries after they have been exposed to heat damage and water mist from fire extinguishers. To address these concerns, this study aimed to experimentally investigate the impact of temperature on batteries and introduce a thermal management using a water mist. Subjecting a battery to a temperature of 100°C for a duration of 39 minutes can immediately detect inoperability from a sudden drop in voltage. The use of water mist was proposed to rapidly mitigate the heat production inside the battery. The state of health (SOH) and the impedance were employed to confirm the battery’s functionality after exposure to thermal abuse and water spraying. The SOH of fresh cells was measured as a reference line for comparison to tested
Trinuruk, Piyatida, Patthathum, Pathomporn, Jumnongjit, Apiwit
Technical Paper
Local and Global Entropy Generation of Topographically Optimized Porous Reactors in Reaction-Diffusion Systems Considering Coupling Effects between Heat and Mass Transfer2024-32-006904/18/2025
As the automotive sector shifts towards cleaner and more sustainable technologies, fuel cells and batteries have emerged as promising technologies with revolutionary potential. Hydrogen fuel cell vehicles offer faster refueling times, extended driving ranges, and reduced weight and space requirements compared to battery electric vehicles, making them highly appealing for future transportation applications. Despite these advantages, optimizing electrode structures and balancing various transport mechanisms are crucial for improving PEFCs’ performance for widespread commercial viability. Previous research has utilized topology optimization (TO) to identify optimal electrode structures and attempted to establish a connection between entropy generation and topographically optimized structures, aiming to strengthen TO numerical findings with a robust theoretical basis. However, existing studies have often neglected the coupling of transport phenomena. Typically, it is assumed that a single
Tep, Rotanak Visal Sok, Long, Mengly, Alizadeh, Mehrzad, Charoen-amornkitt, Patcharawat, Suzuki, Takahiro, Tsushima, Shohji
Technical Paper
Dynamic Modeling of an off-Road Vehicle with Whoops Behavior2024-32-008004/18/2025
Off-road vehicle demand is on the rise, particularly in North America. In connection with this trend, there is a demand for dynamic modeling to describe the behavior of off-road vehicles when driving terrains surfaces with successive bumps. However, conventional dynamic models has been insufficient in representing the situation where the tire-ground contact and detachment states switch successively during whoops behavior. Therefore, in this study, rigid-body multibody dynamics methodology was employed to model the vehicle and conduct numerical simulations. Numerical simulations were conducted using the constructed vehicle model, demonstrating that the behavior of off-road vehicles in whoops closely resembles the actual phenomenon.
Inoue, Tsuyoshi, Ejiri, Haruto, Heya, Akira, Yoshida, Masahiro
Technical Paper
Accelerating Battery Thermal Analysis by Integrating CFD Simulation and Machine Learning Techniques2024-32-012104/18/2025
The growing demand for sustainable transportation solutions and renewable energy storage systems has heightened the necessity for precise and effective prediction of battery thermal performance. However, achieving both precision and efficiency poses a challenge, necessitating exploration into diverse methodologies. The conventional use of Computational Fluid Dynamics (CFD) offers a comprehensive insight into thermal dynamics but prioritizes precision over efficiency. To enhance the efficiency of this traditional approach, numerous reduced-order modeling techniques have emerged, and the concept of Machine Learning (ML) presents a distinct avenue for enhancing simulation capabilities, particularly in the context of mobility solutions. This paper presents a novel approach to accelerate battery thermal analysis by integrating CFD and ML. The CFD simulations provide an intricate understanding of the thermal dynamics within batteries, encompassing fluid flow and temperature distributions
Devarajan, Gurudevan, Vaidyanathan, Ganesh, Bhave, Ajinkya, Ji, Lichao, Wang, Jiao, Zhou, Wei, He, Jiguang, Shi, Pengfei
Technical Paper
Optimal Porous Electrode Structures in All-Vanadium Redox Flow Batteries2024-32-008504/18/2025
To address the pressing issue of electrical fluctuations from renewable energy technologies, an energy storage system (ESS) is proposed. The vanadium redox flow battery (VRFB) is gaining significant attention due to its extended lifespan, durability, thermal safety, and independent power capacity, despite its high cost. Key components of the VRFB include a membrane, carbon electrode, bipolar plate, gasket, current collector, electrolyte, and pump. Among these, the carbon electrode and bipolar plate are the most expensive. Reducing capital costs in VRFB systems is crucial for advancing clean energy solutions. Conventional flow field designs like interdigitated flow field (IFF), serpentine flow field (SFF), and parallel flow field (PFF) are used to feed the electrolyte into the VRFB cell, necessitating thicker bipolar plates to avoid cracking during the machining process. This study focuses on optimizing the flow-through (FT) design, which eliminates the need for machining on bipolar
Aiemsathit, Poramet, Sun, Pengfei, Alizadeh, Mehrzad, Laoonual, Yossapong, Charoen-amornkitt, Patcharawat, Suzuki, Takahiro, Tsushima, Shohji
Technical Paper
3D-CFD Simulations of H2 ICEs: A Preliminary Evaluation of a Laminar Flame Speed Correction for Thermo-Diffusive Instability2024-32-007404/18/2025
In recent years, climate change and geopolitical instability have intensified the focus on sustainable power generation. This shift seeks alternatives that balance environmental impact, cost-effectiveness, and practicality. Specifically, in transportation and power generation, electric motors face challenges against internal combustion engines due to the high cost and mass of batteries required for energy storage. This makes electric solutions less favorable for these sectors. Conversely, internal combustion engines, when properly fueled, offer cost-effectiveness and a quasi-environmentally-neutral option. To address these challenges, researchers have explored e-fuels derived from renewable sources as a carbon-neutral supply for internal combustion engines. Among these, hydrogen is particularly promising. In hydrogen-powered internal combustion engines, 3D-CFD (Computational Fluid Dynamics) in-cylinder models are crucial. Once validated, these models can speed up the design process. A
Sfriso, Stefano, Berni, Fabio, Breda, Sebastiano, Fontanesi, Stefano, Cordisco, Ilario, Leite, Caio Ramalho, Brequigny, Pierre, Foucher, Fabrice
Technical Paper
Fuel Film Measurement in a SI Gasoline Engine Using a Newly Developed MEMS Sensor2024-32-007104/18/2025
The previously developed capacitance sensor for detecting a liquid fuel film was modified to apply to the in-cylinder measurement. On the developed sensor surface, comb-shaped electrodes were circularly aligned. The capacitance between the electrodes varies with the liquid fuel film adhering. The capacitance variation between the electrodes on the sensor surface was converted to the frequency variation of the oscillation circuit. In the previous study, it was revealed that the frequency of the oscillation circuit varies with the variation of the liquid fuel coverage area on the sensor surface. The developed sensor was installed in the combustion chamber of the rapid compression and expansion machine, and the performance of the developed sensor was examined. Iso-octane was used as a test fuel to explore the sensor that had been developed. As a result, the adherence of the liquid fuel directly injected into the cylinder was successfully detected under the quiescent and motoring
Kuboyama, Tatsuya, Moriyoshi, Yasuo, Takayama, Satoshi, Nakabeppu, Osamu
Technical Paper
Numerical Investigation of Electrolyte Feed System Designs at the Stack Level of Vanadium Redox Flow Batteries2024-32-006804/18/2025
The rise of electric vehicles (EVs) highlights the need to transition to a renewable energy society, where power is generated from sustainable sources. This shift is driven by environmental, economic, and energy security concerns. However, renewable energy sources like wind and solar are intermittent, necessitating extensive energy storage systems. Vanadium redox flow batteries (VRFBs) are promising for large-scale energy storage due to their long cycle life, scalability, and safety. In VRFBs, cells are typically connected in series to increase voltage, with electrolytes introduced through parallel flow channels using a single manifold. This design, while simple and low in pressure drop, often leads to imbalanced flow rates among cells, affecting performance. Balancing flow rates is crucial to minimize uneven overpotential and enhance durability, presenting an optimization challenge between achieving uniform flow and minimizing pressure drop. This study developed numerical models to
Suwanpakdee, Nut, Aiemsathit, Poramet, Charoen-amornkitt, Patcharawat, Suzuki, Takahiro, Tsushima, Shohji
Technical Paper
Effect of Mesopore Structure of Carbon Gel on Improving the Capacity of Electric Double-Layer Capacitors2024-32-002604/18/2025
Electric double-layer capacitors (EDLCs) store charge by adsorbing ions at the electrode-electrolyte interface, offering fast charge/discharge rates, high power density, minimal heat generation, and long cycle life. These characteristics make EDLCs ideal for memory backup in electronic devices and power assistance in electric and hybrid vehicles. However, their energy density is lower than that of batteries, necessitating improvements in electrical capacity and potential. Traditionally, activated carbon with a high specific surface area has been used, but recent research focuses on mesoporous carbon materials for better ion diffusion. This study uses resorcinol-formaldehyde-carbon cryogel (RFCC) with mesopores and organic electrolytes with a wider electrochemical window. Various RFCCs with different pore sizes were synthesized and evaluated. Comprehensive investigations into the pore structures and surface properties of both synthesized carbon gels and commercial mesoporous materials
Cheng, Zairan, Okamura, Tsubasa, Ohnishi, Yuto, Nakagawa, Kiyoharu
Technical Paper
Sustainable Design of Automotive Batteries2025-01-000104/18/2025
A consequence of the automotive industry's shift to electrification is that a significantly higher percentage of a vehicle's lifecycle CO₂ emissions occur during the production phase. As a result, vehicle manufacturers and suppliers must shift the focus of product development from the 'in-use phase only' to optimizing the complete product lifecycle. The proper design of a battery has the highest impact to all other phases following in the life-cycle. It influences the selection of materials, the manufacturing, in-use and end of life, respectively the recycling and recycling yield for a circular economy. Using real-life examples the paper will explain what are the main parameters necessary for designing a sustainable battery. What are the low hanging fruits to be considered? In addition, it will elaborate on the relation as well as the impacts to other KPIs like safety, costs and life-time of the battery. Finally it will round up in an outlook on how batteries will evolve in the future
Braun, Andreas, Rothbart, Martin
Technical Paper
Single Conductor Cable for Heavy-Duty Applications - Truck and BusJ2549_202504 (Current)04/16/2025
This SAE Standard establishes the minimum construction and performance requirements for single conductor cable for use on trucks, trailers, and converter dollies.
Truck and Bus Electrical Systems Committee
Technical Standard
Experiment Characterization and Simulation Analysis of a Lithium-Ion Battery in Different Ambient Conditions2025-01-502804/15/2025
A great number of performances of an electric vehicle such as driving range, powering performance, and the like are affected by its configured batteries. Having a good grasp of the electrical and thermal behavior of the battery before the detailed design stage is indispensable. This paper introduces an experiment characterization method of a lithium-ion battery with a coolant system from cell level to pack level in different ambient conditions. Corresponding cell and pack simulation models established in AMESim that aimed to capture the electrical and thermal features of the battery were also illustrated, respectively. First, the capacity test and hybrid pulse power characterization (HPPC) test were conducted in a thermotank to acquire basic data about the battery cell. Next, based on acquired data, first-order equivalent circuit model (1C-ECM) was built for the battery cell and further combined with environmental boundary conditions to check the simulation accuracy. Then, hybrid
Zhou, Shuai, Liu, Huaiju, Yu, Huili, Yan, Xu, Yan, Junjie
Technical Paper
Wire and Cable Splices: Preferred Methods for Use with Automated Wire Processing SystemsARP6673 (Current)04/14/2025
The purpose of this ARP is to provide information on splices, and the definition of the preferred methods of splicing single core wires and multi-conductor cables supplied on reels by vendors, to facilitate their processing on automated wire processing systems to allow continued uninterrupted machine operation without requiring operator intervention.
AE-8D Wire and Cable Committee
Recommended Practice
INDIVIDUAL SHIELD TERMINATION, CONNECTOR, ELECTRICAL (CATEGORY 9)AS85049/148A (Current)04/14/2025
AE-8C1 Connectors Committee
Technical Standard
SAE Truck & Off-Highway Engineering: April 202525TOFHP0404/10/2025
Designs on a diverse powertrain future Perkins details range of development efforts to power future off-highway machines, from clean-sheet diesel to hybrid-electric and hydrogen combustion. Autonomous trucking tech hits high gear While some developers of autonomous technology for commercial trucks have stalled out, there's renewed energy to deliver augmented ADAS and automated driving systems to mass production. Autonomous quarry haulage in high demand Komatsu works with Pronto to upfit a growing fleet of haul trucks operating at Komatsu's Arizona Proving Grounds and customer sites. Editorial Hydrogen is hitting some headwinds Cummins unveils new B7.2 diesel engine Artificial intelligence being schooled for mining applications FPT's 37-kWh battery pack dives into marine market Mitsubishi Fuso repurposes EV batteries for energy storage systems First drive: REE Automotive's electrifying P7 delivery chassis Kalmar launches 3rd-gen electric terminal tractor Product Briefs SPOTLIGHTS
Magazine Issue
Adapting Basic On-Road Data to the Heavy Heavy-Duty Diesel Truck Schedule for Guiding the Electrification of Long-Haul Truck Transport14-14-02-001104/10/2025
Heavy heavy-duty diesel truck (HHDDT) drive cycles for long-haul transport trucks were developed over 20 years ago and have a renewed relevance for performance assessment and technical forecasting for transport electrification. In this study, a model was constructed from sparse data recorded from the real-life on-road activity of a small fleet of class 8 trucks by fitting them into separate driving-type segments constituting the complete HHDDT drive cycle. Detailed 1-s resolution truck fleet raw data were also available for assessing the drive cycle model. Numerical simulations were conducted to assess the model for trucks powered by both 1.0 MW charging and 300 kW-level e-Highway, accounting for elevation and seasonally varying climate conditions along the Windsor–Quebec City corridor in Canada. The modeling approach was able to estimate highway cruising speeds, energy efficiencies, and battery pack lifetimes normally within 2% of values determined using the detailed high-resolution
Darcovich, Ken, Ribberink, Hajo, Soufflet, Emilie, Lauras, Gaspard
Journal Article
A Low-Entry Bus Body Structure Performance under the Conditions of the New Car Assessment Program Frontal Crash Tests09-13-02-000704/09/2025
The New Car Assessment Program (e.g., US NCAP and EuroNCAP) frontal crash tests are an essential part of vehicle safety evaluations, which are mandatory for the certification of civil means of transport prior to normal road exploitation. The presented research is focused on the behavior of a tubular low-entry bus frame during a frontal impact test at speeds of 32 and 56 km/h, perpendicular to a rigid wall surface. The deformation zones in the bus front and roof parts were estimated using Ansys LS-DYNA and considered such factors as the additional mass (1630 kg) of electric batteries following the replacement of a diesel engine with an electric one. This caused stabilization of the electric bus body along the transverse axis, with deviations decreased by 19.9%. Speed drop from 56 to 32 km/h showed a reduction of the front window sill deformations from 172 to 132 mm, and provided a twofold margin (159.4 m/s2) according to the 30g ThAC criterion of R80. This leads to the conclusion about
Holenko, Kostyantyn, Dykha, Aleksandr, Koda, Eugeniusz, Kernytskyy, Ivan, Royko, Yuriy, Horbay, Orest, Berezovetska, Oksana, Rys, Vasyl, Humeniuk, Ruslan, Berezovetskyi, Serhii, Chalecki, Marek
Journal Article
Predictive Battery Thermal Management System Control Strategy and Simulation in Electric Vehicle2025-01-502704/03/2025
With the global issue of fossil fuel scarcity and the greenhouse effect, interest in electric vehicles (EVs) has surged recently. At that stage, because of the constraints of the energy density and battery performance degradation in low-temperature conditions, the mileage of EVs has been criticized. To guarantee battery performance, a battery thermal management system (BTMS) is applied to ensure battery operates in a suitable temperature range. Currently, in the industry, a settled temperature interval is set as criteria of positive thermal management activation, which is robust but leads to energy waste. BTMS has a kilowatt-level power usage under high- and low-temperature environments. Optimizing the BTMS control strategy becomes a potential solution to reduce energy consumption and overcome mileage issues. An appropriate system simulation model provides an effective tool to evaluate different BTMS control strategies. In this study, a predictive BTMS control strategy, which adjusts
Huang, Zhipei, Chen, Jiangbo, Tang, Hai
Technical Paper
Connectors and Inlets for the North American Charging System (NACS) for Electric VehiclesJ3400/2_202504 (Current)04/03/2025
This document covers the dimensional definition of the SAE J3400 (NACS) electric vehicle coupler, which includes the connector and inlet.
Hybrid - EV Committee
Technical Standard
Learning-Based Energy Management Strategy of Fuel Cell City Buses Considering Power Source Degradation02-18-02-001204/02/2025
Fuel cell vehicles (FCVs) offer a promising solution for achieving environmentally friendly transportation and improving fuel economy. The energy management strategy (EMS), as a critical technology for FCVs, faces significant challenges of achieving a balanced coordination among the fuel economy, power battery life, and durability of fuel cell across diverse environments. To address these challenges, a learning-based EMS for fuel cell city buses considering power source degradation is proposed. First, a fuel cell degradation model and a power battery aging model from the literature are presented. Then, based on the deep Q-network (DQN), four factors are incorporated into the reward function, including comprehensive hydrogen consumption, fuel cell performance degradation, power battery life degradation, and battery state of charge deviation. The simulation results show that compared to the dynamic programming–based EMS (DP-EMS), the proposed EMS improves the fuel cell durability while
Song, Dafeng, Yan, Jinxing, Zeng, Xiaohua, Zhang, Yunhe
Journal Article
CRIMPING TOOL AND ACCESSORIES, REMOTE CRIMP HEAD, HYDRAULIC, WIRE SIZE 8 TO 0000 FOR INSULATED AND UN-INSULATED CRIMP BARRELSAS5259/1B (Current)04/02/2025
AE-8C2 Terminating Devices and Tooling Committee
Technical Standard
INSTALLING AND REMOVAL TOOLS, CONNECTOR ELECTRICAL CONTACT, TYPE I, CLASS 1, COMPOSITION CAS81969/17A (Current)04/02/2025
AE-8C2 Terminating Devices and Tooling Committee
Technical Standard
Use of Methanol in a High-Power Density Generator13-06-03-002104/02/2025
Increasing global pressure to reduce anthropogenic carbon emissions has inspired a transition from conventional petroleum-fueled internal combustion engines to alternative powertrains, including battery electric vehicles (EVs) and hybrids. Hybrids offer a promising solution for emissions reduction by addressing the limitations of pure EVs such as slow recharge and range anxiety. In a previous research endeavor, a prototype high-power density generator was meticulously designed, fabricated, and subjected to testing. This generator incorporated a compact permanent magnet brushless dynamo and a diminutive single-cylinder two-stroke engine with low-technology constructions. This prototype generated 8.5 kW of electrical power while maintaining a lightweight profile at 21 kg. This study investigates the performance and emissions reduction potential by adapting the prototype to operate on methanol fuel. Performance and emissions were experimentally evaluated under varying operating conditions
Gore, Matt, Nonavinakere Vinod, Kaushik, Fang, Tiegang
Journal Article
Modelling and Simulation of a Fuel Cell Powertrain for Extreme H Applications2025-01-800804/01/2025
This paper aims to model and simulate a design specification for a fuel cell electric powertrain tailored for Extreme H motorsport applications. A comprehensive numerical model of the powertrain was constructed using GT-SUITE v2024, integrating the 2025 Extreme H regulations, which include specifications for the fuel cell stack, electric motors, hydrogen storage, and battery systems. A detailed drive cycle representing the real-world driving patterns of Extreme E vehicles was developed, utilizing kinematic parameters derived from literature and real-world data. The performance of the Extreme H powertrain was benchmarked against the Toyota Mirai fuel cell vehicle to validate the simulation accuracy under the same racing conditions. The proposed design delivers a maximum power output of 400 kW, with 75 kW supplied by the fuel cell and 325 kW by the battery, ensuring optimal performance within the constraints set by the Extreme H 2025 regulations. Additionally, the design maintains an
Moreno Medina, Javier, Samuel, Stephen
Technical Paper
Optimal Usage of Engine Torque for a Disconnect Device in Situations Where Battery Power is Constrained2025-01-857804/01/2025
This paper introduces a novel approach to optimize battery power usage and optimal engine torque for Axle disconnect device engagement under power constrained scenarios for range extended hybrid vehicles. Range extended hybrid architecture provides benefits of BEV architecture and relief the range anxiety that BEV drivers often have. The Axle disconnect device helps improve the efficiency of the battery power usage when it is disconnected and provides better drivability and performance to fulfill driver demand when it is connected [1]. Under power constraint scenario, the disconnect device engagement could take too long or eventually fail to engage and result in degradation for drivability and vehicle level performance. This novel approach is utilizing the engine to either generate more power to spin up the disconnect motor faster under discharge limited case or generate less power to allow the disconnect motor to spin down under charge limited case. The effectiveness of this approach
Sha, Hangxing, Madireddy, Krishna Chaitanya, Banuso, Abdulquadri, Khanal, Shishir, Rock, Joe, Patel, Nadirsh
Technical Paper
Energy Price Sensitivity and Cost Analysis of Battery Electric and Fuel Cell Powertrains for Class 8 Heavy-Duty Trucks in Real-World Scenarios: A 2024, 2035, and 2050 Perspective2025-01-859204/01/2025
This study evaluates the performance of alternative powertrains for Class 8 heavy-duty trucks under various real-world driving conditions, cargo loads, and operating ranges. Energy consumption, greenhouse gas emissions, and the Levelized Cost of Driving (LCOD) were assessed for different powertrain technologies in 2024, 2035, and 2050, considering anticipated technological advancements. The analysis employed simulation models that accurately reflect vehicle dynamics, powertrain components, and energy storage systems, leveraging real-world driving data. An integrated simulation workflow was implemented using Argonne National Laboratory's POLARIS, SVTrip, Autonomie, and TechScape software. Additionally, a sensitivity analysis was performed to assess how fluctuations in energy and fuel costs impact the cost-effectiveness of various powertrain options. By 2035, battery electric trucks (BEVs) demonstrate strong cost competitiveness in the 0-250 mile and 250-500 mile ranges, especially when
Mansour, Charbel, Bou Gebrael, Julien, Kancharla, Amarendra, Freyermuth, Vincent, Islam, Ehsan Sabri, Vijayagopal, Ram, Sahin, Olcay, Zuniga, Natalia, Nieto Prada, Daniela, Alhajjar, Michel, Rousseau, Aymeric, Borhan, Hoseinali, El Ganaoui-Mourlan, Ouafae
Technical Paper
Barrier Weight Prediction for Vehicle Compatibility in North America Market Using Finite Element Analysis2025-01-862104/01/2025
The proliferation of the electric vehicle (EVs) in the US market led to an increase in the average vehicle weight due to the assembly of the larger high-voltage (HV) batteries. To comply with this weight increase and to meet stringent US regulations and Consumer Ratings requirements, Vehicle front-end rigidity (stiffness) has increased substantially. This increased stiffness in the larger vehicles (Large EV pickups/SUVs) may have a significant impact during collision with smaller vehicles. To address this issue, it is necessary to consider adopting a vehicle compatibility test like Euro NCAP MPDB (European New Car Assessment Program Moving Progressive Deformable Barrier) for the North American market as well. This study examines the influence of mass across vehicle classes and compares the structural variations for each impact class. The Euro NCAP MPDB (European New Car Assessment Program Moving Progressive Deformable Barrier) protocol referenced for this analysis. Our evaluation
Kusnoorkar, Harsha, Koraddi, Basavaraj, Guerrero, Michael, Sripada, Venu Vinod, Tangirala, Ravi
Technical Paper
Development of Ceramic Humidity Regulator (CHR) Using Honeycomb Type PTC Heater to Improve Electric Vehicle Driving Range in Winter2025-01-817704/01/2025
With Rapid growth of Electric Vehicles (EVs) in the market challenges such as driving range, charging infrastructure, and reducing charging time needs to be addressed. Unlike traditional Internal combustion vehicles, EVs have limited heating sources and primarily uses electricity from the running battery, which reduces driving range. Additionally, during winter operation, it is necessary to prevent window fogging to ensure better visibility, which requires introducing cold outside air into the cabin. This significantly increases the energy consumption for heating and the driving range can be reduced to half of the normal range. This study introduces the Ceramic Humidity Regulator (CHR), a compact and energy-efficient device developed to address driving range improvement. The CHR uses a desiccant system to dehumidify the cabin, which can prevent window fogging without introducing cold outside air, thereby reducing heating energy consumption. A desiccant system typically consists of two
Hamada, Takafumi, Shinoda, Narimasa, Konno, Yoshiki, Ihara, Yukio, Ito, Masaki
Technical Paper
Items per page:
1 – 50 of 15762