Browse Topic: Electrical systems

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CONNECTORS, ELECTRICAL, CIRCULAR, MINIATURE, COMPOSITE, HIGH DENSITY, QUICK COUPLING, THREADED, ENVIRONMENT RESISTANT, REMOVABLE CRIMP CONTACTS, NUT, HEXAGON, CONNECTOR MOUNTINGAS29600/7 (Current)To be published on 08/01/2990
AE-8C1 Connectors Committee
CONNECTOR RECEPTACLE, BAYONET COUPLING, IN LINEAS95234/1A (Current)To be published on 06/01/2103
AE-8C1 Connectors Committee
Identifying and mitigating resonance effects in HV Powernets2026-01-0742To be published on 07/01/2026
HV Power nets of electric vehicles consists of various HV components such as batteries, inverters, auxiliaries and cables. During in-vehicle testing, multiple failures of an auxiliary inverter were observed, caused by resonance issues within the component filter. Initial investigations revealed that these resonances, absent during manufacturer testbench evaluations, were influenced by the vehicle power net and its impedance characteristics. To better understand the underlying causes and identify preventative measures, extensive simulations were performed. The results demonstrate a diminishing influence of the power net capacitance when significantly larger than the component capacitance. Also they highlight the critical impact of cable inductance on the component resonance frequency when comparable to the component’s inductance. A simplified electrical equivalent circuit was used to derive an equation predicting the resonance frequency as a function of the component’s capacitance
Schmiel, Fabian, Aurand, Tobias, Koehnlechner, Benjamin, Zimmer, Markus
Methodology for Battery System Optimization and Evaluation Using Format Flexible Pouch Cells2026-01-0749To be published on 07/01/2026
Electrification using battery systems is one of the most relevant solutions regarding ecological challenges within multiple application cases such as mobility, tools or stationary power supply. Nonetheless besides recent achievements in some cases battery systems are still lacking behind operational requirements compared to conventional propulsion systems, therefore limiting the potential of electrification. Especially when purpose design possibilities are limited. Besides improving properties of cell materials, better usage of the available installation space offers potential for overall optimization of the battery system. The development of battery systems is complex, as it involves multiple system levels and domains, along with a wide range of design options and architectures. Battery cells that can be manufactured in flexible formats offer the potential to make more efficient use of available installation spaces. At the same time, these additional degrees of freedom increase design
Müller-Welt, Philip, Bause, Katharina, Spohn, Hannes, Albers, Albert
Multi-Scale Modelling of Localized Battery Degradation in Heavy-Duty Series Hybrids: From Electrochemical Impedance Spectroscopy to Powertrain and Battery Pack Performance2026-01-0747To be published on 07/01/2026
The operational efficiency of heavy-duty hybrid electric vehicles (HEVs) is intrinsically linked to the health and power capability of the battery pack. Traditional battery management systems often rely on bulk State-of-Health (SOH) metrics, failing to account for localized degradation and the resulting current imbalances within parallel-connected modules. Recent literature emphasizes that cell-to-cell variations and thermal gradients can lead to a 6% reduction in accessible energy and a 5.2% acceleration in degradation rates due to heterogeneous current distribution. This study addresses these gaps by presenting a multi-scale modelling framework that translates cell-level electrochemical degradation features into system-level powertrain optimization. Initially, a thorough experimental campaign was conducted on LFP cells, using accelerated cyclic and thermal aging at 25°C and 60°C. High-fidelity battery parameters were extracted from EIS data using fractional-order equivalent circuit
Safavi, Seyed Reza, Homayouni, Hooman, Shoa, Tina, Wang, Jason, McTaggart-Cowan, Gordon
Passive Thermal Management of Battery Disconnect Units for Fast-Charging Electric Vehicles: A Comparative Study of Phase Change Material Heat Transfer Configurations2026-01-0759To be published on 07/01/2026
Reducing charging time remains a critical challenge for the widespread adoption of electric vehicles (EVs). Limited charging infrastructure availability, combined with the long duration required for battery recharging, significantly affects user acceptance. As a result, fast-charging technologies are increasingly being introduced in both newly designed EV platforms and existing vehicles through retrofitting solutions. Despite their benefits, fast-charging systems impose substantial thermal loads on vehicle components, charging stations, and associated power electronics. Excessive heat generation can compromise performance, reliability, and safety, making effective thermal management a key design concern. Within the high-voltage architecture, the Battery Disconnect Unit (BDU) plays a vital role by monitoring and controlling the connection of the battery to the powertrain and charging system. Traditionally, BDUs are designed for conventional charging power levels; however, higher
Salameh, Georges, Goumy, Guillaume, Frecinaux, Anthony, Ratajczack, Christelle, Palluel, Marlène, Noiseau, Pascal, Lardeux, Sébastien
Design and Prototyping of a winding reconfiguration system for electric traction applications2026-01-0730To be published on 07/01/2026
Battery electric vehicles (BEVs) place high demands on electric drives across a wide operating range: high efficiency in customer-related driving scenarios and maximum performance in dynamic driving modes. A promising solution to this challenge is the dynamic reconfiguration of the electric machine winding configuration between series and parallel mode, enabling optimal electromagnetic properties of the drive for different operating points. This paper presents the design and prototyping of an electronic winding reconfiguration system for high-performance traction applications. Unlike mechanical switching concepts, which have long transition times and cannot switch under load, the proposed system enables fast and safe load transitions between the winding configurations. The study describes the topology and hardware of the switching unit, including the integration of power semiconductors, the required connection assemblies, cooling concept and the control of the power electronics. A
Oestreicher, Raphael, Schneider, Jörg, von Ohlen, David, Fuchs, Patrick, Kulzer, André Casal
Stochastic Gradient Pulse Adaptation for Onboard Pulse Charging in Grid-Friendly DC Fast Charging of Battery Electric Vehicles2026-01-0734To be published on 07/01/2026
The increasing deployment of battery electric vehicles (BEVs), particularly in commercial and heavy-duty applications, is driving demand for higher DC fast-charging power while placing growing pressure on battery lifetime and local grid capacity. In today’s multi-battery-pack vehicles, a common practical solution is the use of multi-step or multi-constant CC-CV charging, where charging current is reduced in stages to accommodate pack-to-pack differences in state of charge, state of health, and ageing behavior. While effective from a safety standpoint, this approach often leads to conservative charging profiles, longer charging times, and inefficient use of available grid power, especially at higher charging rates. This paper presents an onboard pulse-charging concept for electric powertrains that addresses these limitations through a combination of vehicle-side power electronics and an adaptive control strategy referred to as Stochastic Gradient Pulse Adaptation (SGPA). Instead of
Prakashkumar, Balagopal, Mannar, Vignesh
Enhancing Efficiency in Megawatt-Scale EV Charging via Adaptive Multi-Agent Control of DC/DC Converters2026-01-0769To be published on 07/01/2026
The rapid adoption of electric vehicles (EVs) demands high-power charging solutions that are efficient, scalable, and reliable. This work introduces a comprehensive simulation framework for megawatt-scale charging systems, focusing on the integration and control of multiple DC/DC converters. With the primary objective of maximizing overall system efficiency during megawatt-scale charging operations. The study addresses key challenges in multi-converter operation, including load distribution, synchronization, and system efficiency. A multi-agent adaptive control strategy was implemented to dynamically optimize operating points and allocate charging currents across converters in real time so that each participating converter operates at its optimal operating point where the maximum efficiency is delivered. This multi-agent adaptive control strategy allocates not only the individual optimal operating points of the multiple DC/DC converters but rather determines the optimal number of
Salah, Alia, Abu Mohareb, Omar
Low-Temperature Internal Heating of Lithium-Ion Cells by Zero-Mean Square-Wave Current Excitation: Thermal Response and Aging Effects2026-01-0753To be published on 07/01/2026
Lithium-ion batteries commonly used today may only be charged at temperatures above 0 °C. However, the heating elements currently used to warm the battery packs make the battery heavier and more complicated in design. In addition, heat is transferred from outside into the cell, causing the temperature inside the cell to rise slowly. The aim is to heat the cells without additional components by applying alternating current and without significantly accelerating aging. To this end, a series of measurements were carried out at temperatures between 0 °C and -20 °C and at frequencies between 50 Hz and 10 mHz. A square wave signal and an amplitude of 5 A were kept constant in all measurement series. The cells were heated for 30 minutes and then cooled for 60 minutes. After every 50 heating cycles, the state of health (SOH) of the cells was determined, and a total of 400 heating cycles were carried out. Aging due to heating is independent of temperature and frequency, with the SOH ending at
Raiber, Stefan, Allmendinger, Frank, Degler, David, Parschau, Anke
Harmonizing Generative AI and ISO 26262 for Safe and Intelligent ADAS Systems2026-01-0785To be published on 07/01/2026
The convergence of Generative AI (GenAI) and Functional Safety (FuSa) under ISO 26262 is reshaping Advanced Driver Assistance Systems (ADAS) by merging adaptive intelligence with stringent safety assurance. GenAI significantly improves perception, object classification, pedestrian intent prediction, and risk assessment, empowering vehicles to navigate highly dynamic, real-world environments. Furthermore, GenAI-driven synthetic data generation accelerates ADAS validation by enabling exhaustive testing of rare and safety-critical scenarios not covered by conventional datasets. However, the integration of GenAI into safety-critical automotive systems introduces major challenges. Its probabilistic nature, limited transparency, and vulnerability to adversarial inputs directly conflict with ISO 26262 principles that demand determinism, traceability, and fault isolation. This paper proposes a co-engineering framework that combines GenAI’s learning-based adaptability with deterministic safety
Jain, Yesha
A Comprehensive CFD‑Driven Approach to Battery Thermal Modeling and Cooling System Optimization2026-01-0752To be published on 07/01/2026
In recent years, the thermal management batteries for automotive applications has become a key factor to further improve their performance and ensure their efficiency, durability and safety. As a matter of the fact, an overheat of these devices can result in various issues, including degradation of insulation materials, decreased efficiency, shortened lifespan, and even failure and consequent thermal runaway. In this context, this work aims to improve the comprehension of heat dissipation in batteries and to model the cooling circuit through the integration of CFD, in order to provide guidelines for the optimization of the overall system. To this scope, a novel OpenFOAM solver is introduced, capable of computing electric quantities along with losses inside the battery cells, consequently assessing heat generation across various components. The combined thermodynamic and electric analysis of the battery, which predicts the heat sources and temperature distribution under the effective
Montenegro, Gianluca, Onorati, Angelo, Della Torre, Augusto, Tariq, Muhammad Hasnain, Bonetti, Elisa
Application of Deterministic and AI-Based Methods to Accelerate the Component-Level Development Process in Electric Vehicles2026-01-0766To be published on 07/01/2026
The global automotive landscape is undergoing a significant paradigm shift driven by the rapid development cycles of emerging competitors, leaving traditional European OEMs with a critical time-to-market gap. To bridge this gap, automotive engineering must pivot from traditional hardware-based processes toward agile, digital data-driven methodologies. This paper presents a comprehensive feasibility study on the implementation of data-centric approaches, using both Artificial Intelligence and deterministic methodologies, with focus on accelerating component development. It provides a detailed assessment of various AI-based and deterministic methodologies at specific stages of the product development process, targeting both: 1. Product design 2. Product development process The aim is to enhance component-level performance, quality, and functionality, while simultaneously optimizing workflows, increasing process and development efficiency, and facilitating knowledge reuse throughout the
Bode, Jana Pascal, Kröll, Sarah, Vohwinkel, Nikolaus, Paetzold-Byhain, Kristin
Towards a Smarter E-Bike: Enhancing Energy Efficiency through Adaptive Speed Control2026-01-0736To be published on 07/01/2026
This paper presents the development of a speed controller for e-bikes, designed as part of an energy-adaptive assistance system. The controller provides riders with appropriate support along planned routes, based on the available battery capacity. The control concept is intended for integration into existing commercial e-bikes without requiring extensive modifications to the drive system. Therefore, the rider remains part of the control loop, adjusting the support mode according to instructions from the controller. The speed controller is implemented as a rule-based state machine, enabling comprehensible design and parameterization Since the rider must manually switch between support modes while riding, the control logic incorporates hysteresis and dead times to ensure stability, prevent oscillations and avoid frequent mode switching. The user interface is a smartphone application that issues visual and audio instructions for switching support modes. An initial, system-independent
Rauch, Yannick, Simmann, Gabriel, Schneider, Manuel, Goss, Christian, Kriesten, Reiner
Model-Based Sensitivity Study of Thermal Runaway Onset and Severity in Lithium-Ion Cells: Effects of Geometry and Thermal Boundary Conditions2026-01-0755To be published on 07/01/2026
Thermal runaway assessment in automotive battery development is still largely driven by single-point abuse tests, while design decisions often require a quantitative understanding of how cell geometry, material thresholds, and thermal boundary conditions influence TR onset and severity. This paper presents a systematic parameter study using a coupled electrochemical–thermal model (SPMe combined with a lumped thermal model) augmented by Arrhenius-type decomposition reactions to represent the key exothermic pathways leading to Thermal Runaway. Two trigger modes are considered: (i) a nail-induced internal short circuit and (ii) an external heat-trigger scenario. Four parameter groups are investigated: cell length scaling, separator decomposition temperature, external trigger power, and convective heat transfer coefficient to the environment. For the nail-triggered internal short circuit, larger cells exhibit lower peak temperatures but longer times to reach the maximum, highlighting a
Ceylan, Deniz, Kulzer, André Casal, Winterholler, Nina, Giek, Michael, Weinmann, Johannes
Regularized Inverse Methods for Tire Noise Source Identification and Pass-by Noise Estimation in Electric Vehicles2026-01-0709To be published on 06/20/2026
Tire exterior noise has become increasingly critical in vehicle acoustics due to two key developments: updated pass-by noise regulations, which amplify the relative contribution of tire noise, and the rise of Battery Electric Vehicles (BEVs), which lack traditional powertrain noise. Design trends in BEVs—such as increased vehicle mass from battery packs and the widespread use of large-diameter, wide, low-profile tires—further intensify tire noise due to stiffer constructions and altered contact dynamics. A common method for predicting tire noise is the source-transfer-receiver model, where the tire is represented by a set of monopoles with volume velocity Q derived from near-field measurements. Acoustic propagation is modeled via p/Q transfer functions. Despite its simplifications, this approach is practical for vehicle development, enabling clear separation between source and transfer mechanisms and facilitating targeted noise control strategies. In previous work, we proposed a
Morin, Benjamin, Di Marco, Federico, Horak, Jan, Lafont, Thibault, Kim, Minkyu, Kang, Min Kyoo, Yoo, Ji Woo
Dynamic characterisation and modelling of Electric Cables under representative load conditions2026-01-0676To be published on 06/20/2026
Electric high voltage (HV) cables are commonly used in automotive applications and very prominently in electrified vehicles. These cables are potential flanking transmission paths for structure-borne sound in a broad frequency range and must therefore be included in the NVH design process. Electrical high voltage cables exhibit non-linear mechanical characteristics, when exposed to significant bending the internal geometry of the cable will change and a curvature dependent bending stiffness will result. The electrical cables envisaged in the current publication feature a helically wound stranded aluminium wire core. This conductive core is covered by, in sequence, a silicone rubber insulation, a braided aluminium wire shield with aluminium foil to minimize electromagnetic interference and a silicone rubber outer sheath. An extensive measurement campaign was carried out to dynamically characterize cable specimen of different lengths and cross sections in terms of multi-degree of freedom
Nijman, Eugene, Buchegger, Blasius, Böhler, Elmar, Zeller, Bernhard, Rejlek, Jan, Faksa, Lukáš, Lukavsky, David
Development of a Convolutional Autoencoder-Based Unsupervised Classification and Visualization Model for Extracting Feature Frequency in C-EPS Fault Diagnosis2026-01-0717To be published on 06/20/2026
In the automotive industry, deep learning models such as convolutional neural networks, autoencoders, and transformers have been actively studied to improve defect detection rates in End-of-Line (EOL) processes. However, applying these approaches to the field of Noise, Vibration, and Harshness (NVH) faces several practical challenges. ① Difficulty in securing sufficient training data and risk of overfitting due to longer evaluation times compared to other data types. ② Label imbalance caused by the relatively small amount of defective data. ③ Reduced labeling accuracy due to human error. ④ Decreased model robustness under domain shifts such as jig variations, evaluation environments, signal-to-noise ratio (SNR), and the occurrence of new abnormal noises. ⑤ Constraints in application due to compatibility issues with existing evaluation equipment. To address these issues, this study proposes an unsupervised learning-based method for classifying operating noise data of Column-type
Park, Jun-Seo, Jo, Hyeon-Choel, Cho, In-Je, Seo, Jae-Yong, Yoo, Seong-Sik
Forecasting Electric Vehicle Fleet Growth and Energy Requirements in the UK2026-37-0043To be published on 06/09/2026
With the United Kingdom (UK) goal to achieve a fully decarbonised energy sector by 2035 and achieve net zero greenhouse gas emissions by 2050, the transition of the UK’s passenger car fleet to battery electric vehicles (BEVs) plays a crucial role in reaching this goal. This study evaluates the environmental and energy impact of large-scale BEV adoption by modelling future uptake scenarios using historical fleet data combined with assumed impact of future policy such as the 2030 ban on the sale of new petrol and diesel vehicles. The results have shown a large-scale adoption is possible by 2040, predicting almost 37 million BEVs on the road. However, the associated electricity demand is predicted to rise to nearly 110 TWh annually, signifying the need for rapid development in renewable energy generation. Although BEVs significantly reduce transport sector emissions, the overall climate impact is dependent on a continued effort of grid decarbonisation.
Burke, Bradley, Kateregga, Sunny, Sodre, Jose Ricardo
Impact of Compression Ratio and Stroke on Hydrogen Requirement for Emission Optimized Operation of an Ammonia-Fuelled Spark-Ignition Engine2026-37-0030To be published on 06/09/2026
Ammonia-fuelled engines have emerged as a promising route toward net-zero emission targets due to ammonia’s carbon-free nature, ease of storage, and established handling infrastructure. However, the low burning speed and narrow flammability limits of ammonia pose a significant combustion challenge, which can be addressed through hydrogen co-fuelling. For practical implementation, on-board hydrogen production via thermal catalytic cracking of ammonia is an attractive solution, as it eliminates the need for external hydrogen storage and associated handling and capital costs. Previous studies by the present authors identified a lean operating strategy that achieves an equal molar ratio of NOx and unburned ammonia (NH3), enabling complete conversion to nitrogen and water vapour when coupled with a Selective Catalytic Reduction (SCR) system. This strategy was further validated using cracked ammonia-derived hydrogen in place of bottled H2 through an on-board cracker, thereby representing a
Yadav, Neeraj Kumar, Ambalakatte, Ajith, Geng, Sikai, Gopakumar Suja, Gagan, Birch, Alexander, Cairns, Alasdair, Harrington, Anthony, Hall, Jonathan
Passenger Car Powertrain for Voltages above 800V2026-37-0020To be published on 06/09/2026
The EU-funded innovation project High-Voltage fast-charging Efficient electric vehicle Powertrains (HiVEP) develops new technologies for mass-market electric vehicles (EVs) by advancing architectures operating above 800 V. These architectures integrate silicon carbide (SiC)-based power electronics, rare-earth-free electric machines with active winding reconfiguration, high C-rate batteries, and optimised thermal management systems. HiVEP aims to deliver sub-10-minute fast charging, reduce energy consumption by at least 25%, extend range by 20%, and cut system costs by up to 20% in volume production. This article expands on the project objectives, methodological approach and expected key innovations as well as technical, environmental, and societal impacts. The discussion situates HiVEP within the European research and innovation landscape, emphasising its role in accelerating adoption of sustainable mobility solutions.
Schernus, Christof, Nada, Shady, Neuhaus, Christoph, Ewald, Jens, Swierc, Daniel, Kallur-Krishnamoorthy, Rajesh, Vasiliadis, Harilaos
Low-Voltage Electric Vehicle with a Reconfigurable Powertrain Architecture for Urban and Extra-Urban Mobility2026-37-0025To be published on 06/09/2026
The growing penetration of electric mobility in urban environments calls for vehicle solutions that balance accessibility, safety, and operational flexibility. However, high upfront costs and the widespread oversizing of battery systems remain significant barriers to large-scale adoption, particularly for short-range use cases. To address these limitations, this paper presents the Low Voltage Reconfigurable Electric Vehicle (LVREV), a modular vehicle concept designed to bridge the gap between L7e and M1 categories. The proposed architecture integrates a low-voltage electrical system (<60 V), a reconfigurable powertrain, and a modular, swappable battery, enabling mission-adaptive performance while reducing cost, weight, and energy consumption. The vehicle architecture features a dual 52 V inverter system coupled with a six-phase permanent magnet synchronous motor, optimized through model-based design and genetic algorithms. Energy storage consists of two independent swappable battery
Tramacere, Eugenio, Favelli, Stefano, Galluzzi, Renato, Tonoli, Andrea
Thermal and Emission Characterization of Cylindrical Lithium-Ion Batteries under Thermal Abuse Using a Climate Chamber2026-37-0023To be published on 06/09/2026
Thermal safety in lithium-ion batteries is a critical aspect due to their increasing use in energy storage systems and electric vehicles. To investigate thermal abuse conditions, numerous studies on cylindrical cells employ specialized equipment to accurately measure temperature and pressure during thermal runaway events. However, such tests typically require robust, dedicated, and high-cost facilities, which limit their availability in conventional laboratory environments. In this context, the present study proposes and evaluates an experimental methodology based on the use of a climate chamber combined with an instrumented reduced-volume container, to reproduce severe external heating conditions. The thermal behavior and gas emissions associated with thermal runaway events were characterized in six cylindrical lithium-ion batteries of two different chemistries. Initially, the experimental setup was validated using a reference cell to verify the methodology and the measurement systems
Penagos Vásquez, Diego Alejandro, Marco-Gimeno, Javier, Monsalve-Serrano, Javier, Garcia, Antonio, Perez Balastegui, Jose
Analysis of a sorption energy storage system for cabin air heating and dehumidification in electric vehicles2026-37-0034To be published on 06/09/2026
This work investigates the integration of a Sorption Thermal Energy Storage (TES) into the Air Conditioning (AC) system of electric vehicles. The proposed device reduces the energy demand for cabin heating under winter conditions, leading to a driving range increase. The TES dehumidifies the cabin air through a desiccant bed (zeolite 4A), preventing window fogging, enabling higher air recirculation rates, and consequently reducing the required heating power. An experimentally validated numerical model was used to analyze the adsorption and regeneration processes and to identify suitable operating conditions. Regeneration was found to be effective at moderate temperatures (around 120°C), with a counter-current airflow configuration providing faster and more efficient desorption compared to parallel-flow operation. A simplified model integrating TES, AC unit and cabin was developed and used to compare different configurations. Heating energy consumption with and without TES under
Verlingieri, Rebecca, Calabrese, Luigi, Freni, Angelo, Marocco, Luca, Scudeler, Gabriele, De Antonellis, Stefano
Experimental investigation on cold start and warm-up phases for an ethanol fueled SI engine.2026-37-0031To be published on 06/09/2026
Engine operation during the initial warm-up period is characterized by pronounced thermal non-uniformities, which have a direct impact on fuel efficiency, combustion stability, tailpipe emissions and engine long-term reliability. For these reasons, accelerating the warm-up process represents an effective strategy to improve both environmental impact and overall engine performance. This paper presents an experimental study carried out on a 1.2 liter, naturally aspiered, four-cylinder SI engine equipped with a Port Fuel Injection (PFI) system. The engine is fueled with standard gasoline and an ethanol-gasoline blend containing 30% ethanol by volume (E30), with the aim of assessing the influence of fuel formulation on thermal evolution after a cold start. Each test begins with the engine at ambient temperature and is continued until thermal equilibrium is established. Experiments are carried out at a single steady operating point of 2000 rpm and 20 Nm, selected to reproduce representative
Falbo, Luigi, Falbo, Biagio, Perrone, Diego, Castiglione, Teresa
Integration of energy consumption simulation in optimal charging planning for battery electric long-haul trucks2026-37-0019To be published on 06/09/2026
Vehicle fleet decarbonization is a key objective for the coming years, with electrification representing the primary pathway to achieving the targets set by the European Union. The share of battery electric trucks in new registrations has been gradually increasing especially in light and medium size trucks. The replacement rate of diesel long-haul trucks with zero emission trucks is still low due to challenges posed by added complexity and limitations of battery charging. Depot overnight charging is not sufficient to cover the energy needs of a truck covering large distances and careful planning of the route using public charging infrastructure is crucial for an optimized route minimizing extra costs and range anxiety. The current work aims to develop a methodology to propose the optimal charging locations for a given route of a battery electric truck based on nearby stations along the route. Our study uses an open-source optimization algorithm for the fixed route vehicle charging
Perdikopoulos, Michail, Doulgeris, Stylianos, Livitsanos, Georgios, Kazakis, Thomas, Mellios, Giorgos, Ntziachristos, Leonidas
SAE TOMORROW TODAY - The Battery Isn't the Problem--Execution Is135716/4/2026
Batteries don't fail because of chemistry. They fail because of execution. Qnovo provides advanced software to optimize lithium-ion battery health and safety, proving that competitive advantage isn't just about the battery itself, but how intelligently you manage it. By leveraging sophisticated battery models enhanced with AI and machine learning, the company delivers real-time insights into battery performance and operation. Listen in as we sit down with Nadim Maluf, Co-founder and CEO, to discuss how software has become the soul of modern batteries. From extending smartphone battery warranties to enabling faster, safer EV charging, you'll discover why the future of electrification isn't about new materials ... it's about intelligence, scale, and trust. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends
Patterson, Lori
Electrical and Copper Compatibility Studies of Transmission Lubricants for Advanced Electric Vehicles2026-01-50366/3/2026
Improved energy efficiency and lower CO2 emissions are the two major drivers for the emergence of E-mobility. Growth of electric vehicles (EVs) has sustained ever since their introduction till 2020 and has substantially increased thereafter. EVs require specialized lubricants, which are different from conventional lubricants mainly due to the addition of new hardware technology including e-motor, inverter, battery, and new materials (copper windings, elastomers, plastic, and other materials). Lubricant when used in an advanced powertrain electric vehicle specifically in E-powertrains may encounter the e-motor and must deliver unique performance attributes such as optimal electrical properties, thermal management, and material compatibility apart from the traditional features including extreme pressure, friction performance, oxidation, and wear control. In the current study, we have investigated conventional GL5, manual transmission fluid (MTF), automatic transmission fluid (ATF), and
Katta, Lakshmi, Seth, Sarita, Singh, Sandeep, Bhardwaj, Anil, Arora, Ajay Kumar
Electric Health-Monitoring Wiring (E-Wiring) for Aircraft2026-26-07856/1/2026
Modern aircraft depend on extensive electrical wiring networks for power distribution, avionics, and control systems; however, these wiring systems are vulnerable to wear, insulation degradation, and arcing over time, leading to safety risks and costly unscheduled maintenance. This paper introduces an advanced Electric Health-Monitoring Wiring (E-Wiring) system that integrates temperature, current, insulation, vibration, and environmental sensors directly into aircraft wiring harnesses to enable continuous monitoring and intelligent fault detection. Data from these embedded sensors are processed through a distributed edge AI network, forming an Electrical Health Monitoring System (EHMS) capable of real-time diagnostics, predictive maintenance, and fault localization. The architecture comprises smart cable segments with sensor nodes, local harness gateways for edge processing, aircraft-level EHMS integration via AFDX/Ethernet, and cockpit or maintenance displays linked to ground-based
Tammana, Bala Sai Sri Rohit, Murthy, Harsha, Mendu, HarikaSivaniSunandha
Design Optimization of Aircraft Light Optics: Eliminating Fasteners by Flexure-Based Clamp to Mitigate the Crack Formation and Validation through HALT2026-26-07506/1/2026
Aircraft lighting systems play a vital role in ensuring operational safety, visibility, and regulatory compliance. Exterior lighting systems are essential for aircraft identification, navigation, collision avoidance, and ground operations under varying environmental conditions. These systems typically include navigation lights, anti-collision lights, landing and taxi lights. An aircraft lighting system comprises light sources, optical elements, electronic control units, power interfaces, wiring harnesses, and mechanical mounting structures. Among these components, optics are critical as they control light distribution, intensity, color accuracy, and efficiency while withstanding harsh aerospace environments such as vibration, thermal cycling, and aerodynamic loads. Aircraft exterior lights are subjected to severe thermo-mechanical stresses due to aerodynamic loading, vibration, and thermal cycling. The use of high-performance optical polymers such as Cyclo Olefin Polymers (COP
Vialta, Frederico, S, Nikhil, Katageri, Praveen, SP, Pradeep, Singh, Abhimanyu Kumar
Electrical Harnessing in Satellite Launch Vehicles of ISRO – Methods for Sustainable, Safe and Reliable Systems2026-26-07796/1/2026
The electrical harness system of satellite launch vehicles functions as the backbone of spacecraft avionics; inter connecting subsystems through complex networks of wires and connectors. An electrical harness is a group of wires bunched together and terminated in connectors. The common insulations used for launch vehicle applications include PTFE, Polyimide, ETFE and TKT. The connectors used are of aerospace grade and connectors tailored for space applications. With over 5000 connectors and 200 km of cables constituting nearly 20% of vehicle mass, the design, fabrication, and sustainability of these systems are critical. The insulations of connectors inserts or the wires are critical for the durability of harness elements. Nevertheless, these insulations are non-expendable and pose disposal challenges and some releases toxic gases when burned or due to vacuum outgassing phenomenon. Also, the cadmium plating which is often used for the environmental resistance of connector shells
K S, Nithish, TR, Binny, D S, Praveen Kumar
Impact Study of Terrestrial Jamming on GNSS Receiver On-Board Launch Vehicles and Mitigation Technique Using RF Switch2026-26-07666/1/2026
Global Navigation Satellite System (GNSS) receivers are widely being used in aerospace as well as automotive applications primarily for navigation applications. ISRO uses indigenously developed GNSS receivers in its Launch vehicles (LV) mainly for POD (Preliminary Orbit Determination) and for INS aiding in long duration missions. Advanced GNSS receivers are being developed and used in ISRO’s new generation launch vehicles for closed loop guidance (CLG) applications. Being used in CLG, continuous solution availability and robustness of GNSS solutions are of paramount importance. From April 2023 onwards, GNSS receivers on-board ISRO’s LV missions have shown degraded performance in terms of reduction in no. of satellites tracked and in some cases loss of GNSS solution as well. This was seen in multiple missions and was analyzed in detail. It was observed that there is nearly 3-4dB reduction in carrier to noise density (C/No) ratio and corresponding change in RF AGC gain is also observed
A, Mohammed Basim, O T, Anand Shankara, V S, Biju, V Gopal, Biju, V S, Vinoj, K, Balan, C, Radhakrishna Pillai
A Study on the Future of Battery Based Electric Aircraft Propulsion2026-26-07826/1/2026
Today the aviation industry is witnessing a paradigm shift in the propulsion technology which has been unseen since the 1930s, when the gas turbine took over from the more established piston engines. For the emerging electric propulsion to survive and flourish, it must demonstrate clear superiority over the mature baseline technology of the gas turbine. It is a fact that the current battery technology is a limiting factor as it is not competitive compared to a gas turbine that is 30-50 times more energy dense. Naturally, the present electric propulsion developments concentrate on smaller aircraft applications and use on a large aircraft is possibly decades away. Apart from the energy density, from a thermal perspective the architectures are vastly different from each other. A conventional aircraft fitted with a gas turbine has readily available heat sinks in fuel and air that aids in heat transfer. Compressed air bleeds from the engine manage the thermal demands of the engine itself
Arun, K P, Srinivas, Varsha, Joshi, Jayanth, Suresh, Chandini, Naskar, Proloy Jyoti
Research on the Statistical Method of Real Driving Emission Data of Commercial Vehicle under Low Load2026-99-17215/22/2026
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Tang, Gangzhi, Liu, Jiajun, Wang, Shuaibin, Du, Baocheng, Deng, Xuefei
Research on Automatic Installation of Flash-Type Bird Collision Warning Device on Drones2026-99-17195/22/2026
Bird accidental collision with overhead transmission lines poses a threat to the ecology of rare bird populations. This article analyzes the warning measures to prevent birds from accidental collisions at home and abroad. In response to the low efficiency of manual installation and the poor static warning effect in preventing birds from accidental collisions with overhead transmission lines, the visual characteristics of birds are analyzed. A drone-based automatic installation flash-type bird accidental collision warning device is proposed, which includes a fixture, a disc, and a luminous circuit. The fixture can be carried and installed on the overhead line by a drone and can be easily disassembled. The disc adopts eye-catching colors and has a hollow structure to reduce wind resistance load. The luminous circuit includes solar panels, charge and discharge control circuits, flicker control circuits, batteries, and luminous components. The drone suspension warning device test was
Wang, Jian, Wang, Xiulong, Liu, Bin, Li, Danyu, Xu, Xunjian
Continuous Active Balancing for Sodium-Ion Batteries: HiNA 50kW/100kWh Case Study2026-99-17235/22/2026
This paper presents an intelligent continuous active Battery Management System (BMS) implementation in sodium-ion battery (SIB) energy storage systems (ESS). The 50kWh/100kWh SIB-ESS demonstration project by HiNa Battery Technology Co., Ltd. (HiNa), demonstrates better discharge voltage differential consistency 102mV (vs. 240mV without continuous active BMS) and achieving 97.6% capacity retention after 1,500 cycles. The average round-trip efficiency of the 50 kW/100 kWh energy storage station is 93.9%. The demonstration application of full-time active balancing in sodium-ion battery energy storage power stations provides valuable support for the further promotion of large-scale energy storage.
Zhou, Yuanchao, Mao, Xuefei, Chen, Kai, Liu, Guangyu, Kang, Libin, Shi, Dongliang, Fang, Donglin, Zhu, Huayang, Xu, Fei, Wang, Yinglai
Study on Impact Resistance of Sandwich-Structured Battery Protection Panels2026-99-17285/22/2026
With new energy vehicles developing rapidly, battery safety, as an important part of the impact on the range of new energy vehicles and vehicle safety, has become the focus of attention. The battery pack protection plate is a core component to protect the battery, its performance needs not only impact resistance, but also lightweight, honeycomb sandwich structure with its excellent energy absorption characteristics and weight reduction performance by the battery pack protection plate performance research. At present, the core-to-face sheet interaction in conventional sandwich structures subjected to impact loads has not been fully elucidated, and the quantitative characterization of damage is insufficient, so this paper aims to optimize the lightweight impact-resistant structure by exploring the synergistic energy dissipation mechanism between the high-strength core material and the steel plate. The study combines theory and simulation, adopting ideal rigid-plastic film theory to
Zhang, Guanghao, Zhang, Mingming, Luo, Changjie, Zhou, Jun, Zhang, Fengqiang, Yu, Wenze, Li, Jiongfeng, Guo, Qingrong
Multi-Physics Modeling of Aircraft Hybrid Propulsion Systems Integrating Batteries, SOFC, and Jet Engine2026-99-17035/22/2026
This paper presents a multi-physics modeling approach for a hybrid propulsion system designed for High-Altitude Long-Endurance Unmanned Aerial Vehicles (HALE UAVs), integrating solid oxide fuel cells (SOFCs), lithium-ion batteries, and a jet engine. A dynamic model was developed to analyze the coupled characteristics of pressure, temperature, and power under steady-state conditions. Simulation results demonstrate that the internally integrated system achieves efficient fuel and waste heat recovery, delivering a net power output of 300–700 kW, sufficient to meet the operational demands of HALE UAVs. Key innovations include a heat exchanger maintaining SOFC stack inlet temperatures above 850 K for optimal performance and a compressor-fan subsystem enhancing gas compression efficiency. Experimental validation confirmed the accuracy of the SOFC model, with simulated electrical characteristics aligning closely with empirical data. The proposed hybrid system addresses limitations in specific
Zhang, Lin, Zhang, Di, Zhao, Lulu, Li, Xi
Assessment of Flexibility Adequacy in Power Systems and Flexibility Resource Allocation2026-99-17175/22/2026
With the introduction of China’s dual-carbon goals (carbon peak and carbon neutrality), renewable energy has experienced rapid development in the country, particularly wind energy, which has established a pivotal role within the new energy sector. However, the inherent fluctuations in wind power generation pose significant challenges to maintaining grid stability and operational reliability. In power systems where the proportion of installed wind power capacity has significantly increased, the allocation of flexible resources becomes crucial. These resources help the system adapt to fluctuations in wind power generation and load demand, avoid wind power curtailment, and reduce costs. In addition, energy storage enhances grid flexibility and stabilizes renewable energy, but is constrained by high costs. Therefore, optimizing energy storage allocation and improving its economic efficiency have become urgent issues. This study focuses on flexibility adequacy assessment and resource
Peng, Jian, Wei, Jinpeng, Zhu, Zhengyin, Hu, Jianmin, Li, Yuxiang, Miao, Gang, Zhang, Huaide
Research on Temperature Measurement Requirements for Seasonal Thermal Energy Storage Water Pits2026-99-17055/22/2026
Solar seasonal thermal energy storage technology is an important means to solve the problem of seasonal uneven distribution of solar resources, and as the core component, the thermal storage capacity of the water pit directly affects the performance of the whole system. Accurately mastering the water pit temperature is essential for scientifically evaluating its thermal storage capacity. Based on the thermal storage water pit simulation software developed in the laboratory, this study focuses on determining the optimal number of temperature measurement points required for seasonal thermal energy storage water pits under an accuracy requirement of ±0.1°C, and establishes the mathematical relationship between the number of measurement points and the height-diameter ratio (H/D) as well as the inlet position. The proposed method can cover the temperature measurement point design for cylindrical and frustum-shaped water pits, and can also be referenced for prism-shaped configurations
Niu, Pengbin, Ma, Jianfu, Wang, Fangxing, Qi, Shiyu
Study on the Hierarchical Control Algorithm of SMES-BESS Hybrid Energy Storage Based on VMD and Fuzzy Control2026-99-07105/15/2026
In China, the installed capacity of renewable energy sources such as wind and photovoltaic power has ranked first in the world for consecutive years, and new energy has become a core driver of energy structure transition. However, the strong volatility and intermittency of new energy output seriously affect the safe and stable operation of the power system, and high-efficiency energy storage technology is the key to solving this problem. Focusing on the short-term high-power charging and discharging characteristics of high-temperature superconducting magnets (SMES), this study proposes a Hybrid Energy Storage System (HESS) that combines SMES with Battery Energy Storage Systems (BESS) to enhance the short-term power support capability of electrochemical energy storage. Variational Mode Decomposition (VMD) is introduced to establish a multi-level power allocation method, which addressing issues such as mode mixing, end effects, and low decomposition efficiency that are prone to occur in
Liu, Haiyang, Wang, Pengfei, Zhou, Wen, Lu, Jing, Wu, Yanan, Yin, Yunkuo, Jiang, Liping
Research on Fault Diagnosis Agent of Monorail Crane Based on Knowledge Graph and Lightweight Large Model2026-99-07415/15/2026
The monorail crane is important in mining operations, and its operation affects both safety and efficiency. Currently, fault diagnosis for monorail cranes has several challenges, such as heterogeneous mixing of multimodal data, poor use of knowledge, low real-time requirements, and high deployment costs for large-scale models. To solve these problems, we present an agent framework using a multimodal knowledge graph and a lightweight large model. In particular, we construct a fault knowledge graph for monorail cranes, organizing professional knowledge about components, failure modes, symptoms, and maintenance. By employing retrieval-augmented generation (RAG) technology, the knowledge graph is merged with the Qwen lightweight large model (low-rank adaptation) for fine-tuning to develop a diagnostic agent with task planning, tool invocation and memory. The experimental results show that the agent framework reduces “machine hallucination” and outperforms conventional diagnostic accuracy
Zhang, Yixuan, Xue, Shun, Bi, Xiang, Wei, Xing, Kang, Ranyu, Jue, Jie, Cheng, Liruiran
Research on Hole Enlargement Process and Modeling Optimization for Type III Hydrogen Storage Tanks2026-99-07205/15/2026
The global automotive industry is accelerating its transition toward low-carbon solutions, with hydrogen fuel cell vehicles offering core advantages of zero emissions and extended range. Their critical component is the Type III fiber-wound hydrogen storage tank, whose performance directly impacts vehicle operational safety and driving range. This technology has now achieved widespread adoption. However, two significant challenges persist in the dome region of these tanks: first, modeling accuracy is difficult to control due to dynamic variations in thickness and winding angles; second, fiber thickness buildup frequently occurs near the pole holes. These issues compromise both the design reliability and manufacturing quality of hydrogen storage tanks. Therefore, this study adopted a combined approach of theoretical analysis and numerical simulation. First, based on composite mechanics theory and calibrated with experimental data (Tensile, Compression, and Shear Tests on NOL and
Wang, Jianguo, Zhang, Qian, Cao, Xuewen, Zheng, Xuanxuan, Li, Jiajie
Multi-Mode Control Strategy for Controllable Vehicle Suspension Systems2026-99-07125/15/2026
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Li, Zhiying, Li, Jei, Zhu, Anding, Bai, Xianxu, Li, Weihan, Li, Rui
Linear Trajectory Planning of Hydrogen Storage Tank with Unequal Polar Holes2026-99-07185/15/2026
In this paper, the design and process research of uniform filling linear trajectory for filament wound hydrogen storage tank with unequal polar holes are carried out. Firstly, by optimizing the slip coefficient, the winding angles of the left and right heads are smoothly and continuously transitioned to the cylindrical section. We study the necessary conditions for achieving the central angle of uniform filling, and calculate the tangent points of the trajectory line based on the continuous fraction principle. Meanwhile, the slip coefficients at the left and right ends that satisfy stable winding and uniform covering are determined. Based on the equal contour constraint conditions, we analyze the motion trajectory equation of the four-axis winding machine and convert it into the corresponding machine code for actual winding operations. Experimental results show that stable winding of fibers on the surface of the unequal-polar-hole mandrel is achieved, and uniform filling and winding
Chen, Baosen, Fu, Jianhui, Cao, Xuewen, Yu, Libin
Fatigue Resistance of High-Pressure Hydrogen Storage Vessels with Aluminum Liner2026-99-07315/15/2026
Although carbon fiber-reinforced aluminum-lined hydrogen storage vessels (Type III) exhibit outstanding specific strength and specific stiffness, the constraints imposed by their design parameters on fatigue performance and ultimate load-bearing capacity remain incompletely elucidated. We propose a fatigue life prediction method for high-pressure vessels that couples progressive damage in the fiber composite with cumulative damage in the metallic liner, aimed at forecasting the fatigue performance of Type III pressure vessels under cyclic loading. Furthermore, a finite element analysis systematically investigates the influence of key design parameters, for nominal pressure, liner diameter and liner thickness, on fatigue performance and ultimate load-bearing capacity. Results indicate that fatigue life significantly decreases with increasing nominal pressure and liner diameter, with nominal pressure exerting a more pronounced effect. Notably, altering the autoclave pressure alone cannot
Bi, Zhihai, Zhang, Qian
Secondary Control Method for Parallel DC-DC Converters under FDI Attacks Based on Sliding Mode Observer2026-99-07085/15/2026
Currently, with the continuous development of electric vehicles, DC microgrids have attracted widespread attention due to their flexible access methods and high energy transmission efficiency. However, since the distributed secondary control of DC microgrids relies on information exchange through communication networks, false data injection (FDI) attacks on these networks may cause control algorithms to fail, leading to voltage deviations, output current imbalance, and in severe cases, system instability. This study focuses on DC microgrids based on parallel DC–DC buck converters and proposes a distributed secondary control strategy based on a sliding mode observer to address FDI attacks. By treating the system's FDI attack signals as an extended state, an extended sliding mode observer is designed to track the attack signals. Based on the observed attacks, a control algorithm is proposed that compensates the control inputs through the observer, ensuring proportional sharing of bus
Sun, Wei, Chen, Jing, Yu, Jinzhu, Yuan, Weibo, Peng, Bo, Lin, Fei
Thermal Management Modeling, Simulation and Experimental Verification of Lithium-Ion Power Battery Packs2026-99-07425/15/2026
To enhance the safety and efficiency of power batteries for new energy vehicles, a high-fidelity thermal management simulation model for lithium-ion batteries was established using a multi-scale coupled approach encompassing "cell-module-pack" levels. Charge/discharge experiments within the 15–45°C temperature range and under various State of Charge (SOC) conditions were conducted to obtain cell characteristic parameters. A second-order RC equivalent circuit model was constructed and validated. A three-dimensional thermal model of the battery pack was developed using the NX and STAR-CCM+software platforms and validated through high/low-temperature humidity tests. Results indicate that simulation errors for battery pack temperature and cooling line pressure were both below 3%. The model accurately simulates thermal behavior from microscopic cell characteristics to macroscopic battery pack dynamics.
Luo, Zhaoyang, Song, Lan
A Hierarchical Distributed Architecture for Power Sharing and Average Voltage Regulation in AC/DC Microgrids2026-99-07065/15/2026
With the rapid growth of renewable energy sources such as photovoltaics, energy storage systems, and wind power, hybrid AC/DC microgrids (H-MGs) are gradually emerging as a key technology for achieving efficient interconnection between generation units and load demands. However, issues such as communication delays, unequal power sharing, and the restoration of voltage and frequency in hybrid microgrids have posed serious threats to the stable operation of microgrids. We also need to appropriately adjust the simulation parameters to ensure that the proposed control framework maintains sufficient flexibility under different load conditions and achieves high operating efficiency in simulation. To tackle these challenges, this paper proposes a distributed secondary control strategy grounded in coordinated consensus and combined with droop-based interlinking converters (ICs) to realize power coupling between the AC and DC subgrids. The proposed method enables precise active-power sharing
Yu, Peijie, Zhang, Fanghai, Sun, Wei, Yuan, Weibo, Peng, Bo
Research on Three-Stage Pre-Charging Control of Cascaded Energy Storage Converters Considering Battery Characteristics2026-99-07115/15/2026
To address the issues of battery overcharge damage caused by voltage imbalance and excessive grid-connected inrush current when high-rate charge-discharge energy storage batteries are connected to the DC side of cascaded energy storage converters, this paper proposes a three-stage pre-charging control strategy considering battery characteristics. This strategy achieves rapid charging and voltage balancing control of energy storage modules through the orderly connection of three stages: “uncontrolled rectification - sorting and voltage balancing - balancing maintenance”. In the first stage, an uncontrolled rectification method with series soft-start resistors is adopted to reduce the inrush current at power-on. In the second stage, based on the FPGA parallel full-comparison sorting algorithm, the DC-side voltage of each sub-module is quickly balanced by switching sub-modules. In the third stage, the number of fixed sub-modules to be cut off is maintained to continuously optimize the
Gu, Cong, Wu, Rui, Zhou, Wen, Cai, Wenjie, Tian, Yunxiang, Yang, Zhiqing
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