Browse Topic: High voltage systems

Items (977)
As part of the global effort to combat climate change, electric vehicles (EVs) are gaining popularity, even for long-haul commercial transportation. A battery pack is a critical component of an EV, and it contains several modules with many series- and parallel-connected electrochemical cells. Strict safety and operational limits are enforced on the cell-level to ensure safe operation of the battery pack. However, variations in the electrochemical properties among the cells in the pack causes some cells to reach the safety and operational limits faster than others. This limits the total power, and over time, the energy delivered and the lifetime of the battery pack. Maximizing the energy delivered by the battery pack (potentially also improving the battery pack’s lifetime) can be achieved by increasing cell-level control, and battery-integrated modular multilevel converters (BI-MMC) is presented as a solution. A BI-MMC has several series-connected DC-to-AC converters, commonly called
Balachandran, ArvindJonsson, TomasEriksson, Lars
A method for performance calculation and experimental method of a high voltage heater system in electric vehicles is proposed. Firstly, heater outlet temperature and pressure drop of the heater are used as metrics to compare simulation results with experimental data, thereby validating the established model. Then, simulations are performed on two heater flow channel configurations: a cavity flow channel and a cooling fin flow channel. It is observed that the latter significantly reduces the heating plate temperature. This reduction enhances the protection of heating elements and extends their operational lifespan, demonstrating the advantages of incorporating cooling fins into the flow channel structure. The optimization variables for multi-objective optimization include the fin unit length, fin height, fin thickness, fin width, and spacing between two adjacent rows of fins. The optimization objectives include pressure drop, heat transfer efficiency, and heating plate temperature
Gong, MingWang, XihuiWang, DongdongShangguan, Wen-Bin
In hybrid electric vehicles (HEVs), optimizing energy management and reducing system losses are critical for enhancing overall efficiency and performance. This paper presents a novel control strategy for the boost converter in hybrid electric vehicles (HEVs), aimed at minimizing energy losses and optimizing performance by modulating to a higher boost converter voltage only when necessary. Traditional approaches to boost converter control often lead to unnecessary energy consumption by maintaining higher voltage levels even when not required. In contrast, the proposed strategy dynamically adjusts the converter's operation based on real-time vehicle demands, such as driver input, Engine Start-Stop (ESS) events, Active Electric Motor Damping (AEMD), entry and exit transitions for Engine Fuel Cut-Off (DFCO), Noise-Vibration-Harshness (NVH) events like lash-zone crossing and other specific operational conditions. The control strategy leverages predictive algorithms and real-time monitoring
Basutkar, AmeyaHuo, ShichaoSullivan, ClaireBerger, DanielTischendorf, Christoph
As the complexity of electrified powertrains and their architectures continue to grow and thrive, it becomes increasingly important and challenging for the supervisory torque controller to optimize the torque commands of the electric machines. The hybrid architecture considered in this paper consists of an internal combustion engine paired with at least one electric motor and a DC-DC switching converter that steps-up the input voltage, in this case the high voltage battery, to a higher output voltage level allowing the electric machines to operate at a greater torque range and increased torque responsiveness for efficient power delivery. This paper describes a strategy for computing and applying the losses of the converter during voltage transformation to determine the optimal engine and electric motor torque commands. The control method uses a quadratic fit of the losses at the power limits of the torque control system and on optimal motor torque commands, within the constraints of
Venkataramu, AchyutWalsh, McKenzieTischendorf, ChristophSullivan, MaryPatel, NadirshHuo, ShichaoSharma, Ashay
The rapid adoption of electric vehicles (EVs), driven by stricter emissions norms, is transforming both urban and rural mobility. However, significant challenges remain, particularly concerning the charging infrastructure and battery technology. The limited availability of charging stations and the reliance on current high-energy-density cells restrict the overall effectiveness of the e-mobility ecosystem. These constraints lead to shorter vehicle ranges and longer charging times, contributing to range anxiety—one of the most critical barriers to widespread EV adoption. Adding to these challenges, auxiliary systems, especially air-conditioning (AC) systems, significantly impact energy consumption. Among all auxiliary systems, the AC system is the most energy-intensive, often exacerbating range anxiety by reducing the distance an EV can travel on a single charge. Hence, it is essential to focus on enhancing the efficiency of AC systems. This involves redefining and optimizing system
Sen, SomnathJadhav, YashSingh, KaramjeetSorte, SwapnilAnwar, Md Tahir
The driving capability and charging performance of electric vehicles (EVs) are continuously improving, with high-performance EVs increasing the voltage platform from below 500V to 800V or even 900V. To accommodate existing low-voltage public charging stations, vehicles with high-voltage platforms typically incorporate boost chargers. However, these boost chargers incur additional costs, weight, and spatial requirements. Most mature solutions add a DC-DC boost converter, which results in lower charging power and higher costs. Some new methods leverage the power switching devices and motor inductance within the electric drive motor to form a boost circuit using a three-phase current in-phase control strategy for charging. This approach requires an external inductor to reduce charging current ripple. Another method avoids the use of an external inductor by employing a two-parallel-one-series topology to minimize current ripple; however, this reduces charging power and increases the risk
Yuan, BaochengMa, YongXie, XiLiu, ShaoweiGuan, TianyuGe, KaiZheng, LifuXu, Xu
To promote the electric performance and safety of development for EV mobility, optimization methodology and design guide of high voltage bolted joint should be newly developed. This paper describes the development process of multi-physics (electrical, mechanical, thermal) FEA methodology, various experimental tests and establishment of optimization methodology of busbar bolted joint design in terms of bolt preload validation and joint temperature rise. The various key factors on high voltage joint tightening are quantitatively studied by utilizing this optimized methodology.
Lee, Joon HaWu, ZhijunGerini-Romagnoli, MarcoNassar, Sayed
This SAE Aerospace Standard (AS) establishes the minimum performance standards for equipment used as secondary alternating current (AC) electrical power sources in aerospace electric power systems.
AE-7B Power Management, Distribution and Storage
This document specifies dimensional, functional and visual requirements for Automotive grade coaxial cable. This material will be designated AG for general-purpose automotive applications or AG LL for low loss applications. It is the responsibility of the user of this cable to verify the suitability of the selected product (based on dimensional, mechanical, electrical and environmental requirements) for its intended application. It is the responsibility of the supplier to retain and maintain records as evidence of compliance to the requirements detailed in this standard.
USCAR
The advent of electric vehicles has increased the complexity of air conditioning systems in vehicles which now must maintain the safety and comfort of occupants while ensuring that the high voltage battery temperature is kept within safe limits. This new task is critical due to the influence of the cell and battery pack temperature on the efficiency. Moreover, high temperatures within the battery pack can lead to undesirable effects such as degradation and thermal runaway. Classical solutions to this problem include larger air conditioning components to support worst case scenario conditions where the cooling request from the battery and the cabin happen at the same time. In such conditions, for the safety of the battery, the cooling request is assigned to battery system which may cause discomfort to the passengers due the significant temperature increase in the cabin during such events. The probability of such events happening is certainly dependent on the weather conditions but in
Palacio Torralba, JavierKulkarni, Shridhar DilipraoShah, GeetJaybhay, SambhajiKapoor, SangeetLocks, Olaf
This study meticulously examines the ignition coil (IG), a pivotal component in engine operation, which transforms the low voltage from the battery into the high voltage necessary for spark plug electrode flashover, initiating the combustion cycle. Considering the importance of IG coils in engine operation which has a direct impact on the engine performance. Any failure in the IG coils is judged as a critical failure and encompasses severe repercussions. The paper details an investigation into the issue of ‘White Deposition’ on IG coils. White deposit was observed in IG Coils during new model development in bench level durability test. A comprehensive failure analysis was conducted, employing vibration analysis, thermal analysis, and chemical analysis of the white deposits to ascertain the root cause. Subsequent to identifying the root cause, the study elaborated on hardware design enhancements as a solution. These design changes were rigorously tested on engine benches, confirmed for
Patel, Hardik ManubhaiGupta, VineetChand, SubhashKumar, Nitish
The automotive industry relies heavily on software to enhance safety, performance, and user experience. The increasing complexity of automotive software demands rigorous testing methodologies. Ensuring the quality and reliability of this software is critical. In this paper, an innovative approach to software validation and verification using a Hybrid Hardware-In-the-Loop (HIL) test system has been proposed. This methodology integrates diverse hardware and software tools to establish a flexible and efficient testing environment. HIL environment can evaluate Device Under Test (DUT) with minimal alterations. This comprehensive solution includes the development of test strategies, plant model simulation, and compliance assurance, all in accordance with automotive standards such as ASPICE, ISO26262. Introduction of a Personality module for Automotive ECU (DUT), enables testing of multiple products using the same HIL setup. This is achieved by loading a DUT-specific signal mapping
Yadav, VikaskumarBhade, Nilesh
Heavy-duty vehicles, particularly those towing higher weights, require a continuous/secondary braking system. While conventional vehicles employ Retarder or Engine brake systems, electric vehicles utilize recuperation for continuous braking. In a state where HV Battery is at 100% of SOC, recuperated energy from vehicle operation is passed on to HPR and it converts electrical energy into waste heat energy. This study focuses on identification of routes which are critical for High Power Brake Resistors (HPRs), by analyzing the elevation data of existing charging stations, the route’s slope distribution, and the vehicle’s battery SOC. This research ultimately suggests a method to identify HPR critical vehicle operational routes which can be useful for energy efficient route planning algorithms, leading to significant cost savings for customers and contributing to environmental sustainability.
Thakur, ShivamSalunke, OmkarAmbuskar, MandarPandey, Lokesh
The traction for zero emission vehicles in the transportation industry is creating a focus on Battery Electric vehicles (BEV) as one of the potential alternate powertrain sources. To operate BEV safely and efficiently battery operating conditions and health is of utmost importance. Battery management system (BMS) controller is needed for optimized and safe operation of high voltage (HV) battery. For correct behavior of BMS, accuracy of state of charge (SoC) estimation is important. SoC is an important and decisive factor for deciding operating limits such as current limits, voltage limits and battery operational range (charge-discharge interval). Inaccurate SoC estimation can accelerate battery aging and cause damage to it. The current state of art deploys coulomb counting technique for SoC calculation, this approach encounters challenges like sensor noises and initial SoC error (carried from the previous charge-discharge cycle). This paper mainly focuses on exploring various
Kumar, RamanAHMAD, MD SAIFChalla, KrishnaRanjan, AshishBayya, Madhuri
The Battery Management System (BMS) plays a vital role in managing the energy present in the high voltage battery pack of electric vehicles. The wired battery management system is commonly used in automotive applications. The known difficulties with the wired battery management system includes the intricate wiring harness, wiring failures, system scalability and high implementation costs. To mitigate the above challenges, the wireless battery management system is proposed. Several wireless protocols, including BLE, Zigbee, and 2.4GHz proprietary protocol, are being examined for wireless BMS. However, there are technical difficulties with these protocols to be applied in the battery pack environment. This research paper looks at the Ultra-Wide Band (UWB) communication protocol for wireless BMS, considering UWB’s efficiency low latency and robust Radio Frequency (RF) performance. The UWB protocol is used to communicate between the Cell Supervisory Circuit (CSC) and the Battery Management
Dannana, Arun KumarSubbiah Subbulakshmi, NallaperumalChandirasekaran, RamachandranBeemarajan, Mutharasu
A device was developed that uses composite-based nonlinear transmission lines (NLTLs) for a complete high-power microwave system, eliminating the need for multiple auxiliary systems. The interest in NLTLs has increased in the past few decades because they offer an effective solid-state alternative to conventional vacuum-based, high-power microwave generators that require large and expensive external systems such as cryogenic electromagnets and high-voltage nanosecond pulse generators.
As the U.S. military embraces vehicle electrification, high-reliability components are rising to the occasion to support their advanced electrical power systems. In recent years, electronic device designers have started using wide band-gap (WBG) materials like silicon carbide (SiC) and gallium nitride (GaN) to develop the semiconductors required for military device power supplies. These materials can operate at much higher voltages, perform switching at higher frequencies, and feature better thermal characteristics. Compared to silicon, SiC-based semiconductors provide superior performance. The growing availability of these materials, in terms of access and cost, continues to encourage electrification. With the ever-present pressure of size, weight, and power (SWaP) optimization in military applications, and a desire to keep up with the pace of innovation, there's a need for capacitors that can deliver higher power efficiency, switching frequency, and temperature resistance under harsh
The proposed smart, efficient eco-cooling strategy leverages the AC system's efficiency sensitivity to the vehicle speed and the thermal storage of the cabin to coordinate the AC operation with the vehicle speed profile by actively shifting the AC thermal load toward the more efficient region at higher vehicle speeds. An investigation is now being conducted on vehicle cabin climate control systems to lower energy consumption and enhance battery electric vehicle range when in pure electric mode. OEMs of electric vehicles are always searching for novel concepts that will extend the driving range of their vehicles. Basically, an air conditioning system needs high-voltage power from high-voltage battery packs to keep the interior of the cabin in a comfortable temperature range during the summer. In order to meet these demands, the AC system in electric vehicles becomes an additional power consumer. This smart ECO AC system consists of the importance and impact of the various components of
Agalawe, KIRAN R.Nagarhalli, Prasanna VHAJGUDE, NIKHIL
Electric Vehicles (EVs) have rapidly grown as a means for clean mobility, as they zero down tail pipe emission of greenhouse gases. Additionally, greenhouse gases such as Hydro-Fluoro-Carbon (HFCs) based refrigerants used in Mobile Air-Conditioning (MAC) are under global scrutiny for their high Global Warming Potential (GWP). To prevent earth environment to pass the climate tipping point that will be irreversible within human capacity, actions such as rapid phase down of high GWP rated HFCs under Kigali Amendment to Montreal Protocol are enacted. India being amongst signatory nations is now working to fast track phase-down use of high GWP refrigerant and transit to low GWP refrigerant options. Nearly half of national HFCs use and emissions are for manufacture and service MAC. Vehicle OEMs supplying to markets in developing countries (e.g. European nation and non-Article 5 Parties) have already phased out HFC-134a (GWP=1400) through alternate refrigerant solutions. The work presented
Maurya, AnuragVenu, SantoshKapoor, SangeetKhan, Farhan
Pulsed field ablation (PFA) is a nonthermal method of tissue ablation technology that uses high amplitude pulsed electrical fields (PEF) to create irreversible electroporation (IRE) in tissues. Unlike traditional thermal ablation technologies, PFA does not rely on heating to damage and destroy tissue. Instead, PFA creates nanopores in cell membranes due to transient, high-voltage exposure that disrupts cell wall integrity, which leads to cell death.1
Reducing dust accumulation on any surface is key for lunar missions as dust can damage or impair the performance of everything from deployable systems to solar cells on the Moon’s surface. Electrodynamic dust shields (EDSs) are a key method to actively clean surfaces by running high voltages (but low currents) through electrodes on the surface. The forces generated by the voltage efficiently remove built up, electrically charged dust particles. Innovators at the NASA Kennedy Space Center have developed a new transparent EDS for removing dust from space and lunar solar cells among other transparent surfaces.
As the market for electric vehicles grows, so does the demand for appropriate charging infrastructure. The availability of sufficient charging points is essential to increase public acceptance of electric vehicles and to avoid the so-called “charging anxiety”. However, the charging stations currently installed may not be able to meet the full charging demand, especially in areas where there is a general lack of grid infrastructure, or where the fluctuating nature of charging demand requires flexible, high-power charging solutions that do not require expensive grid extensions. In such cases, the use of mobile charging stations provides a good opportunity to complement the existing charging network. This paper presents a prototype of a mobile charging solution that is being developed as part of an ongoing research project, and discusses different use cases. The solution presented consists of a semi-autonomous robotic platform equipped with a high voltage battery and multiple charging
Wessel, PatriciaFaßbender, MaxGerz, JonathanAndert, Jakob
In the dynamic landscape of battery development, the quest for improved energy storage and efficiency has become paramount. The contemporary energy transition, coupled with growing demands for electric vehicles, renewable energy sources, and portable electronic devices, has underscored the critical role that batteries play in our modern world. To navigate this challenging terrain and harness the full potential of battery technology, a well-defined and comprehensive data strategy resp. knowledge management strategy are indispensable. Conversely, the imminent and rapid progression of artificial intelligence (AI) is poised to have a substantial impact on the forthcoming landscape of work and the methodologies organizations employ for the management of their knowledge management (KM) procedures. Conventional KM endeavors encompass a spectrum of activities such as the creation, transmission, retention, and evaluation of an enterprise’s knowledge over the entire knowledge lifecycle. However
Badi, IbtihalBraun, AndreasKallis, Lena
Focused on the permanent magnet synchronous motor (PMSM) used in electric, this paper proposes an online insulation testing method based on voltage injection under high-temperature and high-humidity conditions. The effect of constant humidity and temperature on the insulation performance has been also studied. Firstly, the high-voltage insulation structure and principle of PMSM are analyzed, while an electrical insulation testing method considered constant humidity and temperature is proposed. Finally, a temperature and humidity experimental cycling test is carried out on a certain prototype PMSM, taking heat conduction and radiation models, water vapor, and partial discharge into account. The results show that the electrical insulation performance of the motor under constant humidity and temperature operation environment exhibits a decreasing trend. This study can provide theoretical and practical references for the reliable durability design of PMSM.
Zhang, WeiQiu, ZizhenKong, ZhiguoHuang, XinWang, Fang
General Motors (GM) is working towards a future world of zero crashes, zero emissions and zero congestion. It’s “Ultium” platform has revolutionized electric vehicle drive units to provide versatile yet thrilling driving experience to the customers. Three variants of traction power inverter modules (TPIMs) including a dual channel inverter configuration are designed in collaboration with LG Magna e-Powertrain (LGM). These TPIMs are integrated with other power electronics components inside Integrated power electronics (IPE) to eliminate redundant high voltage connections and increase power density. The developed power module from LGM has used state-of-the art sintering technology and double-sided cooled structure to achieve industry leading performance and reliability. All the components are engineered with high level of integration skills to utilize across TPIM variants. Each component in the design is rigorously analyzed and tested from component to system levels to ensure high
Nassiri Bavili, ArashBasher, KorobiChung, SungAlam, KhorshedLee, Jung-GiChoi, Hong GooKo, Jin-youngAnwar, Mohammad
Energy management of battery electric vehicle (BEV) is a very important and complex multi-system optimisation problem. The thermal energy management of a BEV plays a crucial role in consistent efficiency and performance of vehicle in all weather conditions. But in order to manage the thermal management, it requires a significant number of temperature sensors throughout the car including high voltage batteries, thus increasing the cost, complexity and weight of the car. Virtual sensors can replace physical sensors with a data-driven, physical relation-driven or machine learning-based prediction approach. This paper presents a framework for the development of a neural network virtual sensor using a thermal system hardware-in-the-loop test rig as the target system. The various neural network topologies, including RNN, LSTM, GRU, and CNN, are evaluated to determine the most effective approach. The solution proposed intends to use a combination of the states determined in other sensors and
Wray, AlexPipes, HarryDutta, NilabzaEbrahimi, Kambiz
An analytic first-order fuel consumption model is developed for FWD 2-motor HEV vehicles which on average achieve 36% EPA Combined efficiency. The premise of this paper is that this is primarily the result of new functionality specific to HEV. Detailed benchmarking data show that in such an HEV the engine not only provides traction power but simultaneously charges the battery. This combined operation of engine and electric powertrain is unique to HEV and is studied using their linear transfer functions. Charging by the engine enables extended electric driving at low traction power, which reduces engine running time and the associated overhead. The analysis predicts an engine duty cycle proportional to the traction power and inversely proportional to the engine output power: the electric driving is limited by the engine’s ability to deliver the required traction work. The model equations in terms of the major functional parameters predict engine running time fractions of 15% for the EPA
Phlips, Patrick
The hybrid system's thermal strategy is centered around controlling the cooling of the motor, inverter, DCDC and evaporator. In this electric drive circuit system, the water temperature sensor is positioned at the radiator outlet rather than within it. Consequently, when determining the required air volume for radiator cooling and water demand for sub-components of the electric drive circuit, an estimation of the inlet water temperature becomes necessary. This estimation relies on a heat transfer formula that converts heat released by circuit sub-components into their contribution to temperature rise within the circuit plus the outlet temperature from the previous round through the radiator to determine inlet water temperature. The inverter's heat transfer power depends on voltage and current levels. Adjusting motor torque leads to rapid changes in current flow while maintaining a low speed for optimal flow rate through the electric drive pump. As a result, there should be a
Jing, JunchaoWang, ZhentaoLiu, YiqiangHuang, WeishanDai, Zhengxing
The paper introduces two methods for controlling motor voltage. One method requires the implementation of boost hardware, while the other allows for voltage control in battery failure mode without any additional hardware requirements. The boost voltage strategy for the hybrid system is based on managing boost modes, determining target voltages, and implementing PI control. The boost mode control includes different modes such as initial mode, normal mode, shutdown mode, and fault mode. Determining the boost target voltage involves regulating the boost converter with variable voltages depending on the operating states of the motor and generator. The second voltage control method without boost hardware is proposed in order to ensure that the vehicle can still function like a traditional car even under abnormal conditions of high-voltage battery failure in micro-mixing systems. In this mode, instead of conventional torque control, the generator operates in a voltage control mode where
Jing, JunchaoSun, XudongLiu, YiqiangHuang, Weishan
In order to achieve seamless mode switching control for hybrid electric vehicles (HEVs) in the event of battery failure, we propose a motor voltage-controlled mode switching method that eliminates power interruptions. This approach is based on an analysis of the dual-motor hybrid configuration's mode switching. We analyze the overall vehicle operation when the high-voltage battery occurs in different hybrid modes. To ensure that the vehicle can still function like a conventional car under such circumstances, we introduce a novel "voltage control" mode. In this mode, instead of operating in its traditional torque control manner, the P1 motor adopts a voltage control strategy. The P1 controller's variable becomes "voltage," and VCU sends the motor's working mode switching request and PCM finishes the mode transition. During system operation, the P1 motor promptly responds to these target voltages to maintain bus voltage within a normal range. The P1 motor voltage is monitored and managed
Jing, JunchaoZhang, JunzhiHuang, WeishanLiu, YiqiangDai, Zhengxing
A multiple output dynamically adjustable capacity system (MODACS) is developed to provide multiple voltage output levels while supporting varying power loads by switching multiple battery strings between serial and parallel connections. Each module of the system can service either a low voltage bus by placing its strings in parallel or a high voltage bus with its strings in series. Since MODACS contains several such modules, it can produce multiple voltages simultaneously. By switching which strings and modules service the different output rails and by varying the connection strategy over time, the system can balance the states of charge (SOC) of the strings and modules. A model predictive control (MPC) algorithm is formulated to accomplish this balancing. MODACS operates in various power modes, each of which imposes unique constraints on switching between configurations. Those constraints are mathematically formalized so that MPC can be applied to minimize predicted SOC differences
Kang, Jun-MoRich, Dave
The objective of this report is to serve as an introductory (educational) document to cover the potential failure mechanisms related to EIS in high voltage electrical component or HV electrical equipment in aircraft power systems. It has the following contents: (1) an overview of the current understandings of potential failure mechanisms related to EIS for high voltage and high-power application in aircraft; (2) main aging stressors and aging processes of EIS in electrical components used in the aircraft power systems and their common failure modes, and (3) the key indicators to assess the status of electrical insulation degradation and related testing needs. This document aims to assist HV power system designers in understanding the key considerations for EIS design and testing of HV components in aircraft, as well as the requirements for predicting their designed service life. Detailed testing guideline including testing methods will be provided in ARP7375, and life modeling in
AE-11 Aging Models for Electrical Insulation in Hi-Enrgy Sys
Due to the transformation of the automotive industry from conventional vehicles to electric vehicles, new challenges have emerged concerning Electromagnetic Compatibility. Though the Radiated Emission limits in global regulation are the same for both types of powertrains of vehicles, however, due to the phenomena of conversion of high voltage to low voltage, rapid charging/discharging, and different components involved in electric powertrain, the Radiated Emission from electric vehicles give a strikingly different trend which is challenging to combat. When compared with the conventional Spark Ignition vehicle, many other electronic components of the electric vehicle stay in the mode of Power ON while in the “Ignition ON” steady state. This resulted in us observing a significant shift in the amplitude and frequency throughout the frequency band of Radiated Emission measurement. This paper presents a comparative analysis of the changing trends of Radiated Emission from Spark Ignition
Pawar, Sneha RavindraDesai, Manoj Madhukar
This paper aims at analysing the effect of regeneration braking on the amount of energy harnessed during vehicle braking, coasting and its effect on the drive train components like gear, crown wheel pinion, spider gear & bearing etc. Regenerative braking systems (RBS) is an effective method of recovering the kinetic energy of the vehicle during braking condition and using this to recharge the batteries. In Battery Electric Vehicles (BEV), this harnessed energy is used for controlled charging of the high voltage batteries which will help in increasing the vehicle range eventually. Depending on the type of the powertrain architecture, components between motor output to the wheels will vary, i.e., in an e-axle, motor is coupled with a gear box which will be connected with differential and the wheels. Whereas in case of a central drive architecture, motor is coupled with gearbox which is connected with a propeller shaft and then the differential and to the wheels. All the components
S, SrivatsaPethkar, ShivanandGhosh, Sandeep
This paper discusses automotive electrical harnesses, emphasizing their applicability and considering crucial aspects such as reliability, safety, innovation, simulation, and manufacturing. This text proposes to explore an introduction and addresses the importance of ensuring the reliability of harnesses. Highlighting the Electrified vehicle development importance and the harness applicability in both high-voltage and low-voltage systems, as well as the need for safe practices during design. Featuring innovation in the area, mentioning the evolution of materials and technologies used in modern wiring harnesses. Simulation is presented as an essential tool in the development process, allowing performance analysis prior to physical production. Finally, manufacturing is discussed, highlighting the importance of efficient processes and quality control.
Reis, B.Cella, H. DellaFerreira, M.Vaz, S.Cossolino, G.Montes, R.Ferreira, F.F.V.M.
Taking into account the high rotor speed of the generator and the trend of high voltage in direct current microgrids in high-power aviation hybrid propulsion systems, a hybrid power system with a power of 200 kilowatts (kW), a voltage of 540 volts (V), and a rated generator speed of 10500 r/min was established. Anticipating the demands of future high-power system tests, a matching simulation model was developed. The paper discusses various aspects including model construction, test design, and result validation, proposing an overall control strategy for series hybrid aviation propulsion systems – utilizing lithium-ion batteries to stabilize grid voltage and using the turboshaft-generator unit as the primary power source to meet the main power demands of the electric propulsion system. The established model consists of four modules: turboshaft engine, power generator, voltage-stabilizing battery, and electric motor/propeller. These modules are independently controlled and are unified
Diao, BoLi, PoZhu, JianfengHuang, GuochenShe, YunfengXing, Yaoren
Electric vehicles (EV) require an electric motor with a better power density, greater efficiency, a wide constant power area, ease of control, and low costs. A real time control adapted electric motor design is necessary to meet these criteria. In this work, interior permanent magnet synchronous motor (IPMSM) design was created from Ansys rotating machine expert and 2D model was developed in Ansys Maxwell based on various design parameters for the rotor and stator configuration, and the electromagnetic (EM) simulations are carried out in accordance with the essential required EV characteristics. Using Ansys Twin Builder, a model was made for the drive circuit, proportional integral (PI) speed controller, speed references, rotor position detection, and space vector pulse width modulation (SVPWM) / sinusoidal pulse width modulation (SPWM) are used. This method demonstrates the investigation of the torque ripple and total hormonic distortion (THD) and shows the influence of SVPWM and SPWM
Sannasi, SabarinathanGovvala, Venkata DhanababuDeutel, Markus
Electrification of off-road vehicle powertrains can increase mobility, improve energy efficiency, and enable new utility by providing high amounts of electrical power for auxiliary devices. These vehicles often operate in extreme temperature conditions at low ground speeds and high power levels while also having significant cooling airpath restrictions. The restrictions are a consequence of having grilles and/or louvers in the airpath to prevent damage from the operating environment. Moreover, the maximum operating temperatures for high voltage electrical components, like batteries, motors, and power-electronics, can be significantly lower than those of the internal combustion engine. Rejecting heat at a lower temperature gradient requires higher flow rates of air for effective heat exchange to the operating environment at extreme temperature conditions. High airflow rates, coupled with significant airpath restrictions, result in significant cooling power requirements and increased
Sundar, AnirudhVannarath, AshwinPrucka, RobertZhu, QilunKorivi, VamshiRuan, Yeefeng
The development of electric vehicles has been progressed, rapidly, to achieve Carbon neutrality by 2050. There have been increasing concerns about Electromagnetic Compatibility (EMC) performance due to increasing power for power trains of vehicles. Because same power train system expands to some vehicles, we have developed numerical simulations in order to predict the vehicle EMC performances. We modeled a vehicle which has inverter noises by numerical simulation to calculate electric fields based on GB/T18387. We simulated the common mode noise which flows through the shielding braid of the high voltage wire harnesses. As a result, it is confirmed a correlation between the electric fields calculated by numerical simulation and the measured one.
Miwa, KeishiWatari, ToshioNishimura, HiroyukiOgawa, Hiroki
Battery Electric Vehicles (BEVs) are becoming more competitive day by day to achieve maximum peak power and energy requirement. This poses challenges to the design of Thermal Interface Material (TIM) which maintains the cell temperature and ensure retention of cell and prevent electrolyte leak under different crash loads. TIM can be in the form of adhesives, gels, gap fillers. In this paper, TIM is considered as structural, and requires design balance with respect to thermal and mechanical requirements. Improving structural strength of TIM will have negative impact on its thermal conductivity; hence due care needs to be taken to determine optimal strength that meets both structural and thermal performance. During various crash conditions, due to large inertial force of cell and module assembly, TIM is undertaking significant loads on tensile and shear directions. LS-DYNA® is used as simulation solver for performing crash loading conditions and evaluate structural integrity of TIM
Seshadri, Srirambhavsar, TejasR, NarayanaGH, Shivaprakash
Designing power electronics to operate in harsh vehicle environments while meeting packaging requirements such as mass, volume, and power density, creates several challenges for their mechanical design. In this work, we concentrate on the power inverter module (PIM) which converts high voltage (HV) DC voltage power from the HV battery to AC power to drive the motor. The PIM main components are the power module, gate drive and the bulk capacitor. The sizing and selection of the bulk capacitor and power module depend on performance criteria and drive profiles in addition to operating temperatures. In this work, we share the main challenges of packaging components within the inverter. We then discuss best practices to ensure a robust mechanical design which meets inverter durability and reliability targets for an electric vehicle application. The main challenges discussed are bulk capacitor thermals, sealing, and Silicon Carbide (SiC) packaging. The bulk capacitor offers a low impedance
Abu-Zama, DawudBadawi, RanyaTeimor, MehrdadSuciu, Ioan
The recent introduction of high power Silicon Carbide (SiC) switching devices has enabled electric vehicle (EV) traction inverters to achieve >99% efficiency. The consequentially low heat loss is horrific to vehicle heating-systems designers, since ~200W of power is available, at highway speeds, to heat a liquid coolant -- an order of magnitude less than that necessary to thermally condition High Voltage (HV) battery packs, and is ~40x lower than the peak heating levels needed to warm a passenger cabin. Rather than resort to convention by adding expensive and unreliable immersion heaters, including their inherently leak-prone plumbing and high power electronics; or adding exotic heat pumps to scavenge heat, this paper discusses the benefits and implementation of a traction inverter, that eliminates resistive heaters altogether, through novel modalities of either maintaining SiC’s high efficiency or, using a logic signal, to turn on a heating mechanism inherent in switching devices
Turudic, Andy
This SAE Aerospace Information Report (AIR) considers the issue of proper design guidance for high voltage electrical systems used in aerospace applications. This document is focused on electrical discharge mechanisms including partial discharge and does not address personnel safety. Key areas of concern when using high voltage in aerospace applications are power conversion devices, electrical machines, connectors and cabling/wiring. The interaction between components and subsystems will be discussed. The AIR is intended for application to high voltage systems used in aerospace vehicles operating to a maximum altitude of 30000 m (approximately 100000 feet), and maximum operating voltages of below 1500 VRMS (AC)/1500 V peak (DC). These upper voltage limits have been incorporated because this report focuses on extending the operating voltage of non-propulsive electrical systems beyond that of existing aerospace systems. It is noted that electrical systems for electrical propulsion may
AE-10 High Voltage Committee
Electrostatic actuators are simple and lightweight devices that emulate human muscles. However, their usage has primarily been restricted to moving small devices since they need high voltages to generate significant forces. Now, however, it may be possible to use electrostatic actuators in artificial muscles thanks to research from Tokyo Institute of Technology (Tokyo Tech) that made use of ferroelectric materials to create an electrostatic actuator that can generate a strong force at a low driving voltage.
The technology below the smooth skin of BMW's i Vision Dee concept car, unveiled at CES 2023, marks a major step forward in the company's electric-vehicle competitiveness. Models based on the automaker's Neue Klasse EV architecture will ditch today's rectangular prismatic batteries for the type of large, cylindrical-form-factor cells that Tesla is pioneering with its “4680” cells, so named for their 46 mm × 80 mm dimensions. For its sixth-generation EV batteries, BMW and its battery partners - including China's CATL and EVE Energy - will adopt even-larger cells of “4595” and “46120” sizes. At a pre-CES media backgrounder held in Munich in December 2022, Martin Schuster, BMW Group VP for high-voltage batteries, said the new cells pack at least 10% more active battery material relative to their metal cases and are 20% more energy-dense.
Ulrich, Lawrence
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