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Aircraft Plenum Air Outlet Optimization Method

Embraer-Fernando Stancato
  • Technical Paper
  • 2020-01-0021
To be published on 2020-03-10 by SAE International in United States
It is possible to observe a growing interest by mobility industry toward a increased passenger comfort perception. This tendency is being characterized in the aviation sector by interior project that would guarantee the passenger comfort in entertainment, ergonomics, lightning, air quality, acoustics and thermal environment. Regarding this last three aspects, the air distribution through the plenum has a great impact on them. In this work it is presented a method to select the best outlet orifice configuration. The method was applied on seven different plenums. Acoustic evaluation was done using a rig experiment. Based on noise levels of each configuration, the dominant frequency range is identified. Objectives metrics, such as overall levels, speech interference level (SIL3) and loudness were applied. Subsequently, subjective analysis was conducted using the paired comparison method. Finally, an acoustic performance classification was established. Draft effect and air temperature distribution inside the cabin was done using CFD simulation. Besides that, a one-dimensional duct model was done for each configuration to evaluate plenum velocity and pressure distribution. Through these models, it was possible…
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Tools for the Conceptual Design of a Stratospheric Hybrid Platform

CIRA - Italian Aerospace Research Centre-Vincenzo Rosario Baraniello, Giuseppe Persechino, Roberto Borsa
  • Technical Paper
  • 2020-01-0025
To be published on 2020-03-10 by SAE International in United States
The Italian Aerospace Research Center is currently developing the design of a HAPS (High Altitude Pseudo Satellite). Different HAPS configurations have been proposed in recent years. Airbus Zephyr family and Aurora Odysseus are based on the flying wing configuration. Thales Stratobus is an airship, while Google Loon project is based on balloons. Our proposal concerns a hybrid configuration where the weight is balanced by both aerodynamic and aerostatic forces. In this paper we present the tools we have implemented to develop the conceptual design of our platform. The tools have been implemented in Mathworks Matlab® and Grasshopper® integrated with Rhino 3-D. In the Matlab environment, we have developed an optimization algorithm which can estimate some geometric and energetic global parameters of the platform (weight, surface, volume, required power, width, length and height) using as input the desired speed, altitude and period of the year in which the mission will be performed. In this algorithm, we have included a modelling of the principal subsystems affecting the overall platform weight and energy consumption and availability, the aerodynamic…
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Cable Impedance calculations employed in designing aerospace electrical power systems.

Astronics AES-Jon Fifield
  • Technical Paper
  • 2020-01-0037
To be published on 2020-03-10 by SAE International in United States
This paper presents design considerations in utilizing cable impedance calculations in the design of an aerospace electrical power system. (EPS) Past wiring design guidelines featured a tabular constructed single-point design reference. This results in a cable selection which adds unnecessary weight and under-utilized the wire’s performance ability when considering a vehicle’s design requirements. Present wiring design guidelines have lagged behind the growing movement to achieve an optimized wire selection. Understanding the shortfalls with past and present wiring design methods will improve future methods to comply with increasingly restrictive vehicle performance requirements. This paper will discuss two of the most important design requirements for future aerospace electrical power and distribution feeders, which are weight and thermal limits assigned to an EPS design.
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A Study on the development of Aerostructures Design for Assembly guidelines and their effective use to proactively identify opportunities for improvement in mitigating common defects of the Aerostructures Assembly.

GITAM School of Technology, Hyderabad-Mani Rathinam Rajamani, Eshwaraiah Punna
  • Technical Paper
  • 2020-01-0009
To be published on 2020-03-10 by SAE International in United States
An Aircraft’s assembly process plays a vital part in its design, development and production phases and contributes to about half of the Total cost spent in its entire product lifecycle. DFA principles have been one of the proven effective methodologies in Automotive and Process industries. Use of DFA principles have resulted in proactively simplifying and optimizing engineering designs with reduced product costs, and improved inefficiencies in product design and performance. Standardization of Assembly guidelines is vital for “Design and Build” and “Build-To-Print” manufacturing supplier organizations. However, Standardizing design methodologies, through use of proven tools like Advanced Product Quality Planning, (APQP) are still in the initial stages in Aerospace part and process design processes. Thus, there is a tremendous opportunity for research on the application of the existing DFA guidelines to optimize Engineering Aerospace Assembly processes aiming to simplify, standardize design methodologies by building on existing industry practices which have a common platform for design communication and are easy to adopt within the existing process/systems. This technical paper is to discuss the framework for application of…
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Optimal Sizing and Control of Battery Energy Storage Systems for Hybrid Turbo-Electric Aircraft

Georgia Institute of Technology-Christopher Perullo
Ohio State University-Aaronn Sergent, Michael Ramunno, Matilde D'Arpino, Marcello Canova
  • Technical Paper
  • 2020-01-0050
To be published on 2020-03-10 by SAE International in United States
Hybrid-electric gas turbine generators are considered a promising technology for more efficient and sustainable air transportation. The Ohio State University is leading the NASA University Leadership Initiative (ULI) Electric Propulsion: Challenges and Opportunities, focused on the design and demonstration of advanced components and systems to enable high-efficiency hybrid turboelectric powertrains in regional aircraft to be deployed in 2030. Within this large effort, the team is optimizing the design of the battery energy storage system (ESS) and, concurrently, developing a supervisory energy management strategy for the hybrid system to reduce fuel burn while mitigating the impact on the ESS life. In this paper, an energy-based model was developed to predict the performance of a battery-hybrid turboelectric distributed-propulsion (BHTeDP) regional jet. A study was conducted to elucidate the effects of ESS sizing and cell selection on the optimal power split between the turbogenerators (TGs) and ESS. To this extent, the supervisory energy management strategy is formulated into a discrete time optimal control problem and solved via dynamic programming. The performance of BHTeDP was compared to a turboelectric…
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Two-Speed Transmission Gear Shift Process Analysis and Optimization Using Genetic Algorithm

SAE International Journal of Alternative Powertrains

China-Zhan Cao
China Automotive Technology and Research Center Co., Ltd., China-Jiansen Yang, Xinyu Wang
  • Journal Article
  • 08-09-01-0001
Published 2020-01-16 by SAE International in United States
Electric Vehicle (EV) equipped with two-speed transmission has benefit in improving dynamic performance and saving battery consumption. However, during gear shift process, torque interruption and shift impact may lead to a bad shift quality. This work investigates gear shift process in an Automated Manual Transmission (AMT) configuration-based two-speed transmission. First of all, a typical gear shift process is analyzed. Parameters like motor speed, shift force, motor torque change rate, and speed difference between synchronizer and target engage gear are all included to find the relationships with shift duration. Then vehicle jerk is introduced as a criterion to evaluate shift impact. Besides, a comprehensive shift control strategy is developed. While keeping the output torque at wheels unchanged, the shift strategy also improved motor working efficiency after gear shift. Therefore, to determine an optimum shift strategy and achieve a balance among different parameters, Genetic Algorithm (GA) multi-objective optimization method is implemented. Through GA optimization, several solutions are presented and discussed. The final results can well satisfy the requirements of different objectives. This work provides a novel and…
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Hierarchical Predictive Control of a Combined Engine/SCR System with Limited Model Knowledge

SAE International Journal of Engines

Friedrich-Alexander University Erlangen Nuremberg, Germany-Knut Graichen
MTU Friedrichshafen, Germany-Jens Niemeyer, Jörg Remele
  • Journal Article
  • 03-13-02-0015
Published 2020-01-16 by SAE International in United States
In this article, the problem of minimizing the overall operational cost of a heavy-duty off-highway diesel engine combined with a selective catalytic reduction (SCR) catalyst is considered. Here, we propose a hierarchical model-based scheme described as an optimal control problem. The sequence of resulting optimal control values are setpoints for the underlying engine controller, applied in a model predictive control (MPC) fashion. The presented scheme meets several demands. While minimizing the overall costs, it handles box constraints for the control variables as well as a nonlinear NOx-conversion rate constraint ensuring that a given emission target is met. The approach makes use of Gaussian process models for the input-output behavior of the underlying components and a technique for online adaptation. Thus, the presented hierarchical scheme is able to compensate model uncertainties and aging effects of engine, air path, and SCR catalyst. Moreover, in comparison to the literature, our approach doesn’t require detailed models of the underlying components, and the hierarchical, modular design allows the applicability to different engines and SCR controllers. We illustrate the proposed approach…
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A Coupled Approach Using CFD and FEA Solution for Solving the Cooling of Automotive Disk Brake

Siemens Industry Software-Joel Sanvezzo Junior, Douglas Dutra
  • Technical Paper
  • 2019-36-0012
Published 2020-01-13 by SAE International in United States
The cooling efficiency of automotive disk brakes comprises an important area of development, since the system performance is directly related to the overheating level that is being achieved during the braking period. The heat generation occurs during the conversion of kinetic energy into heat. After this process, it is crucial an effective thermal dissipation in order to assure the decay of temperature levels. Such thermal dissipation results mainly from the interaction of the brake components with the external airflow in the wheel arch, where there are the occurrence of heat transfer mechanisms including conduction, convection and radiation. In this sense, through the application of simulation models, it is possible to predict the thermal- structural behavior by combining solutions in the fluid dynamics and structural areas. In this work, a one-way fluid-structure approach is proposed by combining conventional CFD (Computational Fluid Dynamics) and FEA (Finite Element Analysis) models. The CFD modeling aim to solve the disk brake cooling during the airflow passage in the wheel arch and its interaction with the brake components. The FEA modeling…
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Analysis of an automotive vibration issue through bond-graphs

Ford Motor Company – MSXi-Luis Guilherme, Mariano Viana Martins
  • Technical Paper
  • 2019-36-0280
Published 2020-01-13 by SAE International in United States
Modal coupling phenomena are one of the most sensitive issues to the vehicle occupant perception. Commonly understood as a vibrational transfer function (VTF) problem only, those events not rarely are the root cause of noise transfer function (NTF) issues too, increasing exponentially its potential to degrade the vehicle comfort performance. As result, when not solved through computer aided engineering (CAE) tools along initial project phases, the vehicle must use expensive masses and dampers to fix, with delay, a design issue that could have be solved earlier. The use of bond graph modeling technique makes possible to segregate and evaluate only a specific part of the vehicle structure, calibrating its mass and stiffness separately. The results of this analysis allows to design a modal decoupled system faster and accurately than using a complete finite element model (FEM), in order to feedback the design conception parameters with the optimized modal responses, improving its development time and cost besides the final product quality.
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Engine component development based on the application of non-parametric topology optimization

Robert Bosch Ltda.-Rafael de Souza Almeida, Andre Morais Ferreira, Marcos Gomes Bissolatti
  • Technical Paper
  • 2019-36-0097
Published 2020-01-13 by SAE International in United States
Topology optimization plays an important role to reach the goal of creating parts within the desired compromise of cost, time and quality. Its use reduces recursions and gives a better understanding of the product in order to design reliable and lightweight components that comply with validation criteria. This present paper explores a non-parametric topology optimization case study applied to the development of a plastic fuel rail, focusing on evaluating its dynamic response based on commercial optimization software. Results have shown that natural frequencies target could be achieved with less recursions in comparison to usual development methods without topology optimization.
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