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Impact of Vehicle Electrification on Brake Design

Maruti Suzuki India, Ltd.-Vipul Gupta
  • Technical Paper
  • 2019-28-2499
To be published on 2019-11-21 by SAE International in United States
Electric vehicles have come full circle from being primary vehicle type in 19th century (much before IC powered vehicles) to 21st century where major stake holders in mobility have announced plans towards vehicle electrification. Apart from battery & powertrain system, braking system is area which will undergo major changes because of vehicle electrification. But Why? Major keywords are regenerative braking, increased vehicle weight, no or insufficient vacuum from engine and silent powertrains. This paper tries to outline potential impact on hydraulic brake system & its component design for M1 and N1 category of four wheelers with advent of vehicle electrification. Needless to say extent of change will vary depending upon extent of electrification and extent of recuperation during regenerative braking. Extent of electrification depends upon whether vehicle is range extender type hybrid vehicle, plug in hybrid vehicle, battery electric vehicle, fuel cell vehicle etc. Extent of electrification defines in turn extent of recuperation possible, extent of increase in vehicle weight, availability of vacuum and NVH of powertrains. Extent of recuperation is constrained by motor generator…

Review of architecture and control strategies of Hybrid Electric and Fuel Cell Technology for Automotive Application

ARAI-Rakesh Vilasrao Mulik
VIT Universtity-Senthil Kumar Senthilkumar
  • Technical Paper
  • 2019-28-2509
To be published on 2019-11-21 by SAE International in United States
Well-functioning and efficient transport sector is a requirement for economic and social development in the 21st century. Another side of this transport sector is responsible for a many negative social and environmental effects, like a significant contribution to global greenhouse gas emissions, air pollution and reduction in fossil fuels resources. It is need of time to shift to a greener and low carbon economy and for that it is necessary to improve the ways in which energy is produced and used. Other energy sources like battery, fuel cells (FC), supercapacitors (SC) and photovoltaic cells (PV) are the alternative solutions to the conventional internal combustion engines (ICE) for automobiles. Development of Hybrid electric vehicles (HEV) along with other cleaner vehicle technologies like Fuel cell electric vehicles (FCV), battery electric vehicles are continuously increasing in the list of green energy options. This paper presents a comprehensive review on various control strategies and Energy Management Systems (EMS) proposed and developed for HEVs. This paper revisits architecture of HEVs and different types of HEVs. An optimum control strategy for…

Environmental and Health Impact of Electric and Hydrogen Light Vehicles: The Case of an Italian Small City

University of Roma Tor Vergata-Luca Andreassi, Giacomo Falcucci
University of Tuscia-Andrea Luigi Facci, Stefano Ubertini
  • Technical Paper
  • 2019-24-0250
To be published on 2019-10-07 by SAE International in United States
As the emission regulations get more and more stringent, the electric and fuel cell electric vehicles have attracted growing attention by automakers, governments, and consumers. In fact, electric and fuel cell vehicles coupled with low-carbon electricity sources offer the potential for reducing greenhouse gas emissions and exposure to tailpipe emissions from personal transportation. In particular, Pedal Assisted Bicycles (PAB) popularity is rising in urban areas due to their low energy consumption and environmental impact. In fact, they are zero emission vehicles with low noise emissions, as well. These positive characteristics could be even improved by coupling a PAB with a fuel cell based power generation system, thus increasing the vehicle autonomy without influencing their emissions and consumption performances. In this paper, four types of vehicles are compared from an environmental and accessibility point of view: conventional car, bus, electric PAB, and hydrogen fuel cell PAB. For such vehicles, the respective utilization stages are considered, i.e. without considering the manufacturing process. The analysis has been carried out comparing different vehicles performance along different routes of an…

Effects of the Feature Extraction from Road Surface Image for Road Induced Noise Prediction Using Artificial Intelligence

Gifu University-Yuichi Matsumura, Kojiro Matsushita
Toyota Motor Corp.-Shunsuke Nakamura, Masashi Komada, Keisuke Ishizaki
Published 2019-06-05 by SAE International in United States
Next generation vehicles driven by motor such as electric vehicles and fuel cell vehicles have no engine noise. Therefore the balance of interior noise is different from the vehicles driven by conventional combustion engine. In particular, road induced noise tends to be conspicuous in the low to middle vehicle speed range, therefore, technological development to reduce it is important task. The purpose of this research is to predict the road induced noise from the signals of sensors adopted for automatic driving for utilizing the prediction result as a reference signal to reduce road induced noise by active noise control (ANC). Using the monocular camera which is one of the simplest image sensors, the road induced noise is predicted from the road surface image ahead of the vehicle by machine learning. The effects to extract features (Histograms of Oriented Gradients (HOG) feature, autoencoder feature, Convolutional Neural Network (CNN) feature) from road surface images are evaluated by visualization result of t-SNE. From the features acquired by the above method, the frequency characteristics of the road induced noise…
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Real-Time Testing Technology of Powertrain System in Proton Exchange Membrane Fuel Cell Electric Vehicles: A Review

Tongji University-Haiyu Gao, Tong Zhang, Ke Song, Wenxu Niu, Huicui Chen
Published 2019-04-02 by SAE International in United States
The proton exchange membrane fuel cell (PEMFC) vehicle is one kind of new energy vehicle with fuel cell as power source, which has environmental friendliness, high power density and quick refueling. However, the productlization testing in powertrain system, especially for subsystems and key parts, is one of the critical technical challenges, which restricts the industry development and large-scale commercialization of fuel cell electric vehicles (FCEVs). In this paper, comprehensive testing requirement and latest testing technologies were reviewed, the development status and directions of testing technologies in FCEV powertrain system were presented. Based on comprehensive analysis, X-in-the-Loop (XiL) testing technology was proposed, and it is quite helpful to improve Real-time testing performance and functions for FCEV powertrain system. Furthermore, real-time and reliability as the two key factors for the XiL application was deeply analyzed and discussed.
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Research on Control Algorithm of Air Supply System for High-Pressure PEMFC Engine

SAIC Motor-Jilong He
Tongji University-Fengxiang Chen, Zhicheng Lin, Jieran Jiao
Published 2019-04-02 by SAE International in United States
The Proton Exchange Membrane Fuel Cell (PEMFC) is the most widely used engine in fuel cell vehicles. For PEMFC, whether the supply of oxygen for cathode is adequate or not is a critical factor for its net output power and service life, and the proper control of air supply mass flow and pressure can effectively improve its system performance and efficiency. At present, fuel cells need to reduce the mass and volume and increase the power density. Therefore, it is necessary to increase the air supply pressure for PEMFC. But at the same time, many auxiliary devices are appended to the system to provide high-pressure air, such as air compressor, intercooler, and back pressure valve, which make the control of the entire air supply system very complicated. So an excellent control algorithm is needed. This paper mainly focuses on the air supply system of a 85kW high-pressure PEMFC stack, researches its control algorithms, and discusses and studies the control effects of the feedforward control and the feedback control. For the feedback control, the traditional PID…
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Lifetime Prediction Modeling of Automotive Proton Exchange Membrane Fuel Cells

Wuhan University of Technology-Zongsong Wang
Published 2019-04-02 by SAE International in United States
Knowledge about the health conditions and expected lifetime of an operating fuel cell stack is essential to system control and maintenance of a fuel cell vehicle. To quickly and accurately estimate a stack’s lifetime, a data-driven prediction model for proton exchange membrane fuel cells (PEMFCs) is proposed in this study. In this model, the voltage output of the fuel cell stack is taken as the lifetime evaluation index. Two methods are used to establish the lifetime decay evaluation criteria of the PEMFC stack, i.e., (1) Least Squares Fitting (LSF) method that establishes the standard for stack voltage degradation behavior, and (2) Back Propagation (BP) neural network that learns the stack’s voltage decay characteristics and establishes the standard for the stack’s voltage degradation behavior. The Autoregressive Moving Average (ARMA) time series model is then employed to learn part of the known decay behavior of stack voltage so as to predict future stack decay. To verify the accuracy of ARMA predictions, the predicted results are compared against two established voltage decay standards as well as the real…
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Development of Fuel Cell (FC) System for New Generation FC Bus

Toyota Motor Corp.-Tomohiro Ogawa, Kenji Umayahara, Yoshihiro Ikogi
Published 2019-04-02 by SAE International in United States
Toyota Motor Corporation has been actively pursuing the development of fuel cell vehicles (FCVs) to respond to global environmental concerns and demands for clean energy. Toyota developed the first fuel cell (FC) bus to receive vehicle type certification in Japan. Subsequently, a new FC bus has been developed, which adopts two FC systems and four high-voltage batteries to achieve the required high power performance and durability. For enhanced durability, the FC system is controlled to maximize usage of the high-voltage batteries and to reduce the number of electric potential changes of the fuel cell. To accomplish this, the voltage of the FC stack must be kept high and FC power must be kept low. The high-voltage batteries were used to actively minimize FC power during acceleration. When the high voltage battery cannot supply power because of a low battery state of charge (SOC), such as during a long hill climb, the lower limit voltage of the FC is temporarily reduced to increase the FC power. A lifetime durability test was carried out, including conditions under…
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Numerical Analysis and Optimization Design of a Centrifugal Compressor’s Volute for PEM Fuel Cell Vehicle

CATARC-Chunjing Lin
Tongji University-Yuemeng Zhang, Sichuan Xu, Qing Zhan
Published 2019-04-02 by SAE International in United States
Centrifugal compressors used in polymer electrolyte membrane fuel cell systems are different from turbochargers in internal combustion engines, because they are required to work at high speed, low mass flow rate, narrow range which nears surge boundaries. In order to meet these requirements, a centrifugal compressor’s volute is designed, analyzed and optimized on its cross-section area, shape of volute tongue and tapered angle of exit. The numerical results show that surge boundary of the compressor is influenced by spiral area significantly and that volute tongue has a major impact on aerodynamic performances at high mass flow rates.
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Powering back to the FUTURE

Automotive Engineering: April 2019

Lindsay Brooke, Erika Anden
  • Magazine Article
  • 19AUTP04_04
Published 2019-04-01 by SAE International in United States

Rotaries, gas turbines, hybrids-even nukes! Propulsion tech from the past, present, and beyond the horizon is revealed at the SAE Mobility History display at WCX'19.

Credit Leonardo DaVinci for creating what many historians believe was the first depiction of a self-powered vehicle. It was powered by springs. And in the centuries since then, engineers have found increasingly complex and interesting solutions for vehicle propulsion.

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