Browse Topic: Electrical systems

Items (16,666)
Due to the constraints of manufacturing costs and cycles, it is difficult to simulate the full-scale operating conditions of aircraft electrical power systems. Usually, scaled-down low-power systems are used for prototype development and experimental research. This paper puts forward a systematic framework for developing scaled physical models of aircraft electrical power systems by using similarity theory. In this paper, according to the general design principles of DC-DC converters, a 10-kW low-power DC-DC converter and a 250-kW high-power DC-DC converter are designed. Mathematical models for both systems are developed, and a time-domain performance index analysis is carried out using the per-unit dynamic equivalence principle. A metric conversion model is established and equivalently mapped to a high-power DC-DC converter simulation model. The waveform consistency between the converted model and the aforementioned 250-kW high-power model is verified, which shows the validity of the proposed conversion method.
Ma, HuanAi, FengmingBi, WenyanPei, XiaoningLiu, Liangliang
During the high-speed operation of packaging machines, if the abnormal components evolve into faults, the packaging machines often stop for inspection or even damage, causing production stagnation and huge economic losses. If key variables are predicted and faults are identified before the evolution of packaging machine failures, it is of great significance to ensure equipment safety and reduce maintenance costs and losses for enterprises. The purpose of fault prediction is to use the information modeling of equipment historical data to output the changes in key features before component failures in the future. Firstly, for the redundant data of multiple measurement points of the same variable in the packaging machine process variables, Pearson correlation analysis is used to obtain more accurate variable data. We reuse adaptive empirical mode decomposition (EEMD) for signal processing and feature extraction, reduce redundant information, use convolutional neural network (CNN) models for spatial feature learning, and then use bidirectional long short-term memory models to capture temporal dependencies of CNN information for capturing time series data. A model is established on the normal training set to fit the normal state of the packaging machine, identify different types and degrees of equipment fault characteristics through normal test set data, and send the predicted results of the equipment state to the fault classifier for judgment to determine whether to issue a fault warning. The results indicate that this article has validated the effectiveness of the model in fault feature extraction and high-precision fault classification through training on equipment status data.
Wu, AiminLiu, ShixianZhao, LihuiLiu, ZhaoWu, TaoLi, Lianbing
Hydrogen-powered aircraft primarily utilize the conversion of liquid hydrogen into gaseous hydrogen to replace aviation kerosene, where hydrogen is directly combusted to provide propulsion. This study applied Amesim software to establish a complicated model simulating the liquid hydrogen to gaseous hydrogen conversion and ignition combustion processes. The simulation contains converting liquid hydrogen into gaseous hydrogen through a heat exchanger and simulating the mixture of gaseous hydrogen and air in the engine combustion chamber, and then igniting the mixture. The pressure, temperature, and flow rate of gaseous hydrogen and air during the ignition and combustion process in the engine combustion chamber, as well as the outlet temperature of the combustion chamber, are simulated and analyzed. The results demonstrate that during the simulation process, the internal pressure of the liquid hydrogen storage tank, the outlet pressure and flow rate of the liquid hydrogen pump, and the pressure and flow rate of gaseous hydrogen meet the requirements of the ignition combustion test. In addition, varying gaseous hydrogen flow rates had significant impacts on the temperature of the combustion chamber during combustion.
Gao, PengfeiWang, Lijian
This study aims to solve the trajectory optimization problem of multi degree of freedom micro air vehicle (MAV) with the aim of improving its flight performance through technological innovation. A multi degree of freedom trajectory optimization (MDFTO) method with sideslip angle and angle of attack as the core control variables was proposed for multiple complex constraints in combat environment, such as terminal accuracy and overload limitation. This method can more accurately characterize and adapt the strong nonlinear, dynamic coupling and time varying characteristics of the MAV in high-speed maneuvering flight. In order to solve this MDFTO problem with multiple constraints and strong nonlinear characteristics efficiently, the hp adaptive pseudospectral method is used in this study, and is verified by simulations based on the GPOPS-II optimization platform. The algorithm has the advantages of highly accurate discrete state and control variables, efficient processing of path and terminal constraints, and adaptive adjustment of the distribution point density. GPOPS-II is able to efficiently adapt to the MDFTO method. The simulation results show that the GPOPS-II can accurately capture the MAV’s dynamic response. Its adaptive node adjustment mechanism effectively balances computational efficiency with solution accuracy, especially during flight phases where state changes drastically, ensuring the reliability of results. The MDFTO method successfully achieves the optimal solution, and the generated trajectory strictly follows the laws of vehicle dynamics and kinematics. This method provides an effective and engineering feasible technical approach for the trajectory optimization of the MAV under complex constraints, and has important theoretical and practical value for improving its strike accuracy, maneuverability and comprehensive combat effectiveness.
An, ZhichaoMing, ChaoWen, Guangbao
This article focuses on a wide range of high-precision storage and supply systems. Under the rated flow rate of 2.928 mg / s of the proportional flow controller, the instantaneous flow fluctuation range of the BangBang valve reaches 2.963 mg / s, exceeding the control accuracy requirement of 1% for the proportional flow controller. By establishing mathematical models of the BangBang valve, proportional valve, and proportional flow controller for simulation analysis, the trend of the simulation results is consistent with the experimental results. Furthermore, considering the spatial layout and weight of the storage and supply system, this paper proposes a method to improve the accuracy of flow output by adding 180 mL of air capacity between the proportional valve and the proportional flow controller. Ultimately, the maximum flow fluctuation of the proportional flow controller at the moment of the BangBang valve opening and closing is 2.941 mg / s, which meets the control accuracy of the proportional flow controller. Moreover, the error between the output flow rate of the proportional flow controller and the rated working flow rate is minor after increasing the air capacity.
Li, ZhongYan, ZelongHuang, Tiankun
Terminal guidance is critical for ensuring strike precision in the final phase of flight. However, traditional methods, such as proportional navigation and optimal guidance laws, face significant challenges regarding real-time performance and adaptability to dynamic targets. To address these issues, neural networks offer a promising solution by enabling adaptive adjustments to guidance parameters, thereby improving performance under various constraints.
Ma, HengweiWang, YongfengWen, HongLiu, DiWei, YuanhangDong, LonghaoLuo, Ying
In recent years, drone technology has seen widespread application in both civilian and military fields. By 2025, China will introduce supportive policies from multiple dimensions, including industrial development, technological innovation, and application promotion, to significantly increase the number of UAVs in use and their frequency. However, drones are prone to malfunctions due to factors such as bad weather and electromagnetic interference, which may result in serious consequences, including property damage and casualties. Therefore, improving the accuracy of fault detection and the response time of drones is of great significance. Although current research has made progress, there are still deficiencies: First, most of them rely on a single or limited data source, resulting in incomplete information and vulnerability to interference, which leads to low detection accuracy and reliability; Second, traditional methods are mostly based on fixed thresholds or simple rules, lacking real-time dynamic monitoring and adaptive analysis capabilities, making it difficult to issue timely warnings of potential faults. To this end, this study proposes a multi-scale time series prediction model based on multimodal and multi-branch, integrating multimodal data, constructing a dual-branch architecture, and combining deep learning and attention mechanisms to enhance the anomaly detection effect of unmanned aerial vehicles. A dual-branch anomaly detection model based on 1DCNN-BiLSTM and continuous wavelet transform is proposed, including a trajectory prediction difference branch and a full time series data branch. In the dual-branch output stage, the attention gating mechanism is utilized to fuse features and improve the detection performance. The experimental results show that this model performs excellently in both normal trajectory prediction and anomaly detection, providing an effective solution for drone anomaly detection.
Pu, ZhenglinZhang, Lin
Flexible cables are widely used in aircraft and are essential for ensuring the proper functioning of critical systems and flight safety. The design and validation of these cables represent a foundational technology in enabling the transmission of electrical power and signals throughout the entire aircraft. To achieve their intended service life, appropriate protective measures and experimental verification must be implemented. Drawing on the development experience of flexible cables for a specific domestic aircraft model, this paper proposes a combined protection method designed to extend the service life of flexible cables. Experimental analysis demonstrates the practicality and reference value of this approach.
Shi, LiqingHu, HuanghuaGe, Zengwen
To ensure the successful implementation of the separation, evacuation, and return processes of manned spacecraft after long-term docking at the space station, regular on-orbit health assessments must be conducted. Based on this requirement, a technical method for evaluation through autonomous on-orbit testing is proposed. First, the docking status and characteristics of the manned spacecraft’s systems, such as information management, crew environmental control, thermal control, power management, docking function, attitude, and orbit control function, are described. Then, the functional requirements for the separation, evacuation, and return of the manned spacecraft, such as the relative measurement, the relay communication, TT&C and data transmission, image and voice, instrument display and alarm, and the attitude measurement, are analyzed. Subsequently, the on-orbit testing system, test items, test procedures, and test methods for health assessment are detailed. It also provides the design of TT&C support, the design of energy support, and the main principle explanation for autonomous on-orbit testing of the system.
Cheng, WeiNan, HongtaoTian, YeZhao, Zheng
Requirements of Interface for Aircraft/Store Electrical Interconnection System (GJB 1188A-99) is the current standard followed by all types of carrier aircraft and stores. This paper designed a 1553B bus remote terminal mode code configuration method that met the requirements of GJB1188A standard, completing the interrupt initialization and data initialization of compulsory mode codes. These comprehensive test results confirm that the proposed mode code configuration method is both reliable and effective, and provides strong portability, which can be used as a reference for the GJB1188A interface software design of other components
Han, BinZhang, KunLiu, XuhanYe, JinhanLi, Zhengmao
This paper investigates the tracking of highly maneuverable targets during flight and the corresponding satellite scheduling problem in a space-based observation system. Based on dual-satellite measurements, a nonlinear observation equation was formulated. The J2 perturbation model and the current statistical model were utilized within an Interacting Multiple Model filtering framework to achieve adaptive estimation of the target states of the boost-glide vehicles. Building upon this framework, a greedy satellite scheduling algorithm based on IMM model probabilities is proposed. This method dynamically selects the optimal measurement set within a given prediction window to maximize observation performance. The proposed strategy is compared against rolling-horizon scheduling and fast-slow timescale scheduling approaches. Simulation results demonstrate that the proposed method effectively adjusts model weights in response to target maneuvers, enhancing adaptability during highly maneuverable phases. Meanwhile, it reduces the number of satellite switches while maintaining estimation accuracy, significantly improving scheduling efficiency and tracking continuity.
Deng, SiruiLiu, ChengzheWang, Yandong
Aiming at problems such as low efficiency and poor accuracy in fault identification for traditional small satellites, this paper proposes a multi-model fusion method based on machine learning. By constructing a telemetry data preprocessing module based on the Data Generation Adversarial Network, it effectively deals with outliers and fills missing values. Combining single model methods such as polynomial curve fitting, the grey model, and the ARMA model, and introducing the Long Short-Term Memory network and Gated Recurrent Unit to fuse with these models enhance the ability to process complex data features. The prediction results of each model are fused using machine learning methods, and finally, the fused value is taken as the final prediction result. The numerical simulation results show that this prediction method can predict the anomalies of different types of satellite telemetry parameters and has achieved good results.
Liu, BiyanChen, YeGuo, Qi
This document provides recommendations to identify battery group sizes and dimensions for 6 V, 8 V, 12 V, and 24 V lead acid batteries.
Starter Battery Standards Committee
This recommended practice (RP) presents a methodology to evaluate RESS Cells Closure Integrity (Leak Tightness) requirement. This RP applies to two types of RESS Cells, each containing liquid electrolyte: Lithium ion (Li-ion) Cells and Sodium ion (Na-ion) Cells. The Equivalent Channel Method is used as a suggested cell closure integrity requirement for a given RESS Cell design during its production and product validation phases. The Closure Integrity requirements intended to assure no electrolyte leakage and no excessive moisture ingress during the usage of these cells as part of the RESS (Battery Pack), which is crucial to assure the safety and performance of these RESS. This RP specifies non-destructive Integrity (leak) testing processes of the Cell Closure. It describes approved leak testing technologies, testing procedures, tooling requirements, and leak test systems validation/verification requirements. This document may be applied to RESS Cell Closure Integrity testing during their initial product validation and their in-line 100% of production integrity/leak testing. This RP applies to RESS Cells with rigid packaging (cylindrical or prismatic) or flexible packaging (pouch).
Battery Standards Testing Committee
As a key component of unmanned aerial vehicles (UAVs), the stable operation of motor bearings is of vital importance to the stability of UAVs. In view of the incomplete data set in the actual diagnosis process, samples not encountered during model training are highly likely to appear. This paper proposes an Adaptive Class-Incremental Learning(ACIL) intelligent fault diagnosis method. This method construct a ResNet framework embedded with Coordinate Attention as the base architecture for class-incremental learning. Furthermore, the Information Preservation Example Selection(IPES) method is utilized to alleviate catastrophic forgetting and update the model from the previous phase using knowledge distillation under coordinate attention. The effectiveness of this method is verified through experiments on the bearing test dataset. The results show that, both average incremental accuracy and average incremental forgetting rate achieve state-of-the-art performance, which means that the performance of the proposed method outperforms than those of other methods.
Song, ZiyangLu, JiantaoWu, WeiLi, Shunming
The gearbox is a key component of the mechanical transmission system, and its fault diagnosis is essential to the reliability of the equipment. However, obtaining fault samples under actual working conditions for gearbox fault diagnosis is challenging. In this paper, the rigid-flexible coupling dynamic simulation model of the gearbox is established, and the co-simulation of gear normal, crack, and breakage is carried out in the ADAMS and MATLAB environments. The comparison between the simulated and measured signals shows that the simulation method can accurately reflect the key characteristics, such as rotation frequency and meshing frequency, and verify its reliability and accuracy. The research results can provide effective data support for gearbox fault diagnosis and improve the operational safety of mechanical systems.
Li, DongxiaoZhang, QianqiZhang, ZhongzhengLi, Yongbo
To minimize energy input and preheating time, this study first analyzed the energy consumption of intake air, lubricating oil, and coolant preheating through simulations. Temperature rise data were collected under various heating parameters. Next, simulations evaluated the hybrid power system’s resistance characteristics immediately after startup and the combustion parameters during the first cycle post-ignition under different temperatures. The temperature thresholds for successful start-up were identified, defining the feasible domain for optimization. Optimization calculations aimed to minimize preheating time and energy input, constrained by maximum preheating power. Results show that intake air heating has the greatest impact on start-up success, followed by lubricating oil heating. It is recommended to increase energy allocation to intake air and lubricating oil heating. This optimized strategy reduces preheating time and energy input by approximately 26% without changing the preheating equipment.
Wei, ShengchenZhao, Zhenfeng
Batteries generate a large amount of heat during operation, and if it cannot be dissipated in a timely and effective manner, it will seriously affect the performance, lifespan, and even safety of the battery. Therefore, battery heat dissipation has become a key challenge in the development of new energy vehicles. The traditional liquid cooling system has problems such as complex design and control, and the need to improve heat dissipation efficiency. To address these issues, this study proposes an optimized design scheme for battery environment heat dissipation control system based on liquid cooling heat dissipation system. This study first conducted an in-depth analysis of the thermal generation mechanism of lithium-ion batteries and studied existing examples of thermal management schemes. On this basis, an innovative forward and reverse circulation device was designed, combined with a liquid cooling heat dissipation structure. The Keil uVision4 programming software was used to write the microcontroller control program, and the circuit was simulated and verified using Proteus simulation software. This study established an experimental platform and conducted physical testing and thermal imaging detection. By collecting temperature change data under different heat dissipation modes and analyzing the experimental data, the results show that the optimized liquid cooling heat dissipation system significantly improves the heat dissipation efficiency. The system exhibits good performance under different cooling modes.
Ding, XvqiangNi, YiweiGu, ChenZhang, JinChen, MingyangJiao, Yunxiao
Nowadays, the majority of intelligent fault diagnosis approaches are still centered on individual faulty components, while only a limited number of models are capable of performing integrated diagnosis for rotating systems that consist of shafts, bearings, and gears. Under variable-speed operating conditions, the large scale of vibration data further complicates the process of effective feature extraction. To improve these challenges, this study develops a comprehensive diagnostic framework for rotating components, termed WGAN-SAFC. The proposed architecture integrates a Wasserstein Generative Adversarial Network (WGAN) with a hybrid structure of stacked autoencoders and sparse filtering (SAFC). SAFC integrates the feature-learning capability of SAE and the sparsity-driven representation of SF, while incorporating adversarial data generation to address sample imbalance and enhance fault diagnosis performance. Experimental verification on collected vibration datasets demonstrates that WGAN-SAFC achieves superior diagnostic accuracy and robustness compared with existing methods.
Li, ShunmingFeng, Mengqi
As a special vehicle, motor caravans have high customer demand and expectations for product quality under current market conditions. At the same time, customers generally have strong demands for functional differentiation and modification. To meet the requirements, manufacturers need to redesign and construct the production process platform, including redesigning and transforming various functional unit modules on the vehicle. For example, the flexibility of production process platform systems, standardization of electrical interfaces, and modularization of functional units, etc. In the implementation process, by embedding flexible architecture into the existing universal process system, motor caravans modification can be flexibly organized according to customer orders and requirements while ensuring streamlined production. In the implementation process, the focus of the new installation process system is to match the electrical systems inside the vehicle, ensuring not only the matching between different unit systems, but also the compatibility between the new installation system and the original vehicle system. When formulating the modification process, it is necessary to meet the actual usage requirements and environmental conditions of the motor caravans, while also considering the speed of production organization. The beginning of in car modification often means rebuilding local systems, and whether the compatibility and compatibility of the overall system modules are complete is the ultimate goal pursued by modification production enterprises. In the research process, methods such as comparison, literature review, and examples were used to attempt to illustrate the role of flexible process system architecture in promoting motor caravans modification, especially personalized and differentiated modification, in the context of rapid development of the contemporary automotive industry. Especially in today's rapidly developing advanced control technology of artificial AI, breaking down the whole into smaller parts and standardizing them one by one is of great significance for improving production efficiency and enhancing the automation level of process systems.
Li, Sheng
This document defines the test procedures and performance limits of steady state and transient voltage characteristics for 12 V, 24 V, or 48 V electrical power generating systems used in commercial ground vehicles.
Truck and Bus Electrical Systems Committee
The Active Wheel-Corner (AWC) integrates driving, braking, steering, and suspension systems into the wheel end, forming a fully drive-by-wire, four-wheel independent steering and four-wheel independent driving (4WIS&4WID) vehicle platform. While improving vehicle control performance, the full by-wire architecture also places higher demands on system reliability and fault tolerance. The steer-by-wire system has electrical, communication, and software failure risks, which may cause the vehicle to lose steering capability and trigger severe traffic accidents. This article proposes a hierarchical active fault-tolerant control strategy based on fault information reconstruction (FAST-FTC), enabling fault diagnosis and active fault-tolerant control when the steer-by-wire system fails, effectively ensuring the steering maneuverability and lateral stability of the vehicle under fault conditions. First, the strategy designs an adaptive observer combined with the Dugoff tire model to estimate nonlinear tire forces, while introducing a fault factor to achieve quantitative grading of steering system faults. Second, a hierarchical controller is designed for steering system faults. The upper-level controller, based on Adaptive Super-Twisting Sliding Mode Control (AST-SMC), determines the generalized forces required to track the desired trajectory under different fault conditions. The lower-level controller, based on the Fault-Aware Model Predictive Control (FA-MPC) strategy, dynamically adjusts weight matrices according to the fault factor and tire reconstructed stiffness, coordinating the allocation of four-wheel driving and the steering of healthy wheels to ensure lateral stability. Finally, the effectiveness of the proposed active fault-tolerant control strategy is validated through Hardware-in-the-Loop (HIL) simulation and real-vehicle tests.
Xiao, FengJiang, YueyongCheng, RuiXu, ChangheTang, XiangjiaoGao, FenglingLi, Jianhua
Thermal runaway assessment in automotive battery development is still largely driven by isolated abuse tests, while design decisions require quantitative insight into how cell geometry, material thresholds, and thermal boundary conditions influence thermal runaway onset and severity. This paper presents a systematic sensitivity study using a coupled electrochemical and thermal model augmented with Arrhenius-based decomposition reactions to represent the dominant exothermic pathways. Thermal runaway onset is defined using a temperature rise-rate criterion to distinguish gradual heating from runaway acceleration. Two trigger modes are considered: an internal short circuit initiated by nail penetration and an external heating trigger. Four parameter groups are investigated: cell length scaling, separator decomposition temperature, external heating power, and the 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, indicating a geometry-driven shift from rapid escalation to a slower, more moderated evolution. In the external heating case, increasing cell size significantly delays onset, while peak temperature shows a nonlinear trend and approaches saturation rather than scaling inversely with size. Increasing the separator decomposition temperature also shows a saturation effect because alternative reactions can dominate the triggering sequence. External heating power exhibits a threshold: below a critical level, convective losses balance the input and prevent runaway. Even when external heating is stopped at an intermediate temperature, higher preheating power can still lead to higher peak temperatures due to a larger remaining reactive inventory when the internal short circuit occurs. Improved heat rejection consistently delays onset, reduces peak temperature, and accelerates cool-down. Overall, the study extends prior trigger-specific analyses by providing a unified reduced-order sensitivity view across two abuse pathways and by identifying threshold and saturation behaviors that translate directly into design-relevant robustness levers.
Ceylan, DenizKulzer, André CasalWinterholler, NinaGiek, MichaelWeinmann, Johannes
This paper investigates the integration of Artificial Intelligence (AI) within radar-based perception for Advanced Driver Assistance Systems (ADAS) under safety considerations aligned with ISO 26262 [1] for functional safety and ISO 21448 (SOTIF) [2] for performance-related safety of the intended functionality. The study evaluates a hybrid architecture in which AI-based perception modules are combined with deterministic supervisory mechanisms to maintain safety compliance. A simulation-based case study using CARLA with radar sensor modeling is presented to compare a deterministic radar perception pipeline with an AI-enhanced approach under nominal and degraded environmental conditions. Performance is evaluated using precision, recall, and F1 score metrics. Results indicate improved recall and F1 score under adverse scenarios for the AI-based perception module, accompanied by a moderate increase in false positives. The paper discusses architectural constraints required to limit non-deterministic behavior, including confidence gating, deterministic supervision, and scenario-based validation. The findings are limited to simulation and are intended to provide preliminary insights into the technical and safety implications of incorporating AI-based radar perception within ISO 26262-compliant ADAS architectures.
Jain, Yesha
The mitigation of Greenhouse Gas (GHG) emissions poses a major challenge for the transportation sector, driving the need for renewable fuels. Bioethanol represents a promising fuel for Spark-Ignition (SI) engines, combining a reduced life-cycle CO₂ impact with advantageous combustion properties. However, despite its proven performance under steady-state conditions, the widespread of fuels with high ethanol content is still constrained by significant difficulties during engine cold-start operation. This study aims to experimentally assess the effect of ethanol concentration on cold-start performance and warm-up transient behavior of a Naturally Aspirated (NA), Port Fuel Injected (PFI) SI engine. Warm-up tests were conducted at an operating condition of 2000 rpm engine speed and 20 Nm torque using three fuels with increasing ethanol content: commercial gasoline (E5), E30 and E60. In addition, dedicated startability tests were carried out for E60 and neat ethanol (E100) at different initial engine wall temperatures to evaluate fuel sensitivity to thermal conditions during engine start. The experimental results indicate that increasing ethanol concentration has a negligible effect on the overall duration of the warm-up process, while leading to a modest reduction in both engine wall and exhaust gas temperatures. At the same time, E100 displays severe startability limitations at low initial wall temperatures, requiring repeated cranking attempts before stable operation can be achieved. The same startability issues have been observed for E60 but with limited intensity. Two minimum engine wall temperature ranges were identified for reliable cold-start operation at 20-25 °C for E60 and 25-30°C for E100. Overall, these findings experimentally confirm the dominant influence of engine thermal conditions on the reliable startability of ethanol-fueled spark-ignition engines.
Falbo, LuigiFalbo, BiagioPerrone, DiegoCastiglione, Teresa
Electrification using battery systems is one of the most relevant solutions regarding ecological challenges within multiple application cases such as mobility, power 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 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 enable possibilities to make more efficient use of available installation spaces. At the same time, these additional degrees of freedom increase design complexity and significantly expand the solution space. For example, numerous options for sizing and positioning of the cells are available that are interacting with the cooling system and housing design. Also, additional challenges regarding electrical and thermal load distribution occur using format flexible cells. To support developers, new methods and tools are necessary to handle this complexity. Therefore, the authors present a methodology that includes an installation space optimization using format-flexibly produced pouch cells that generates different possible layouts of cells and modules, an approach for electrical and thermal modeling of the battery system that is applicable for varying cell arrangements as well as possibilities for a fast criteria-based evaluation of different cell and module arrangements that can be used for an overall optimization of the battery system. Finally, the authors are discussing benefits and disadvantages of the presented methodology as well as the usage of format flexibly produced pouch cells using an illustrative case study.
Müller-Welt, PhilipBause, KatharinaSpohn, HannesAlbers, Albert
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 feasibility study on the implementation of data-centric approaches in component development, evaluated using the high-voltage wiring harness (HVWH) as a representative example. The HVWH serves as a practical validation case for the presented methodologies, covering both Artificial Intelligence (AI) based and deterministic methods. The study provides a detailed assessment of various AI-based and deterministic methodologies at specific stages of the product development process, targeting both product design and the product development process itself. The objective is to reduce time-to-market at the component-level by optimizing workflows, increasing process and development efficiency, and enabling knowledge reuse throughout the development process. Beyond individual method evaluation, the study examines how deterministic and AI-based approaches can be integrated into development workflows. For this purpose, process mining is first applied to identify general challenges specific to the HVWH development workflow and to derive use cases in which AI can contribute to reducing development time. From these, three use cases are selected for detailed investigation. For each use case, the necessary prerequisites, the applied methodology, the results and the limitations of AI integration are described and discussed. By integrating structured knowledge with automated workflows, the proposed frameworks allow for autonomous application of historical insights to current design parameters, streamlining the decision-making process. This semantic structure prevents the loss of critical engineering knowledge and enables continuous AI-assisted improvement across different vehicle generations. The study concludes that the proposed use cases provide a technically viable pathway to shorten development timelines, enabling European OEMs to match the speed of competitors while maintaining high standards of quality, functionality and safety.
Bode, Jana PascalKröll, SarahVohwinkel, NikolausPaetzold-Byhain, Kristin
With the continued expansion of electric mobility, liquid-cooled thermal management systems have become indispensable for ensuring the performance, durability, and safety of automotive battery packs. This work presents a novel cooling-plate design that integrates offset strip-fin turbulators to enhance convective heat transfer between lithium-ion cells and the circulating coolant. A comprehensive multi-region CFD model of the full battery pack is developed, incorporating an implicit lumped-parameter representation of cell heat generation. The numerical predictions are validated against dedicated experimental measurements available in the literature. Subsequently, a parametric study is conducted in which the number of hydraulic sub-modules and the inlet/outlet configurations are systematically varied to generate all feasible design permutations. The resulting configurations are compared to assess thermal performance and to quantify the benefits—as well as the potential penalties—introduced by the turbulators relative to the experimentally validated baseline.
Montenegro, GianlucaOnorati, AngeloDella Torre, AugustoTariq, Muhammad HasnainBonetti, Elisa
This paper presents Stochastic Gradient Pulse Adaptation (SGPA), a real-time adaptive pulse-charging system for rechargeable electrochemical batteries that dynamically adjusts charging aggressiveness based on the battery's internal response, as opposed to predetermined CC–CV or fixed pulse profiles. SGPA is different from traditional charging methods that use static current de-rating and conservative voltage limits. Instead, SGPA uses gradient-based feedback from terminal voltage behaviour, temperature changes, internal resistance changes, and state of charge to continuously adapt pulse amplitude and duty cycle. This algorithm boosts the charging intensity when the electrochemical circumstances are good. It lowers the pulses slowly when signs of thermal or impedance-related stress show up. Simulation-based proof-of-concept experiments on a heavy-duty multi-battery system show that charging time is less than with multi-CCCV charging, while still keeping the current distribution across packs balanced. The suggested SGPA method adds an adaptive charging algorithm that is easy to understand and ready to use. It makes fast charging more efficient without lowering voltage and thermal safety limits.
Prakashkumar, BalagopalMannar, Vignesh
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. The hardware prototype has been designed and built, but has not yet been tested, which is why the results are based on simulations. Unlike mechanical winding reconfiguration 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 novel control strategy is presented that ensures continuous current paths during switching, prevents overvoltage in the windings and minimises torque interruptions. To this end, the active short-circuit operation of the electric drive is taken into account. Simulations show that the system achieves efficiency gains of up to two percentage points in the partial load range while maintaining its full performance. The additional losses caused by the switching unit remain low in the partial load range, ensuring a net efficiency gain. The proposed concept offers a practical approach to extending the range of BEV drives by dynamically reconfiguring the windings of the electric machine, thereby improving partial load efficiency without compromising performance.
Oestreicher, RaphaelSchneider, Jörgvon Ohlen, DavidFuchs, PatrickKulzer, André Casal
Current lithium-ion batteries should generally only be charged above 0 °C, as charging below this temperature can promote lithium plating and irreversible degradation. However, conventional pack-level heating elements increase system mass and design complexity. In addition, heat is transferred from outside into the cell, causing the temperature inside the cell to rise slowly. This study evaluates internal Joule heating of cylindrical Li-ion cells using a zero-mean square-wave current excitation and quantifies the associated aging impact. LG INR21700-M50L cells were tested at 0 °C, −10 °C, and −20 °C with three excitation frequencies (50 Hz, 1 Hz, 10 mHz) at 5 A amplitude. Each cycle consisted of 30 min heating followed by 60 min cooling; reference capacity-based state of health (SOH) was assessed every 50 cycles up to 400 cycles. A maximum surface temperature rise of 14.3 K was achieved, with larger temperature rise at lower ambient temperature and lower excitation frequency. Capacity fade remained below approximately 1% for most conditions; however, at −20 °C and 10 mHz a pronounced SOH decrease to 87% was observed, indicating a critical operating regime. The results provide practical guidance for pulse-heating parameter selection and highlight the need for safeguards and further diagnostics in extreme low-frequency excitation at very low temperatures. This heating approach is particularly suitable for simpler battery-electric applications without thermal management, such as e-bikes or power tools. However, it may also be relevant for applications with existing thermal management systems, as it simplifies battery pack design.
Raiber, StefanAllmendinger, FrankDegler, DavidParschau, Anke
HV Power nets of electric vehicles consist 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/inductance and the cable length to the main power net capacitances. Based on these findings, recommendations for component filter design and testing protocols were proposed to mitigate similar failures in future applications.
Schmiel, FabianAurand, TobiasKoehnlechner, BenjaminZimmer, Markus
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 version that relied on GPS-based speed measurement was found to be insufficiently accurate for the control task. Furthermore, it was found that detection of the pedaling state was essential for proper operation. To address these issues, a Bluetooth-based hardware adapter was developed to access relevant signals from the e-bike’s CAN bus communication system. These include pedal power, cadence and speed, which are made accessible through reverse engineering of the CAN bus. The proposed concept is evaluated in a chassis dynamometer study with 13 participants on two test profiles: a synthetic gradient profile for assessing control stability and a realistic elevation profile for dynamic evaluation. Additional measurements taken with one of the test riders at different speeds demonstrate the system’s reliability and its potential to improve the energy efficiency. The results show that, with approximately the same power brought in by the rider, only 27% more electrical energy is required to increase the average speed by 45%.
Rauch, YannickSimmann, GabrielSchneider, ManuelGoss, ChristianKriesten, Reiner
The widespread adoption of electric vehicles is currently hindered by long charging durations and limited infrastructure. While fast-charging technologies address these issues, they impose significant thermal loads on high-voltage components. Within this architecture, the Battery Disconnect Unit plays a critical role as it monitors and controls the connection between the battery, powertrain, and charging system. However, the high currents required for fast-charging often drive these units' temperatures beyond safe operating limits, necessitating advanced thermal solutions that do not require extensive redesigns of the vehicle's electrical layout. To address this challenge, this study proposes a passive thermal management solution using Phase Change Material heat transfer devices to enhance the thermal robustness of the component. The methodology employs a dual approach involving initial experimental testing to pinpoint specific thermal hotspots under high-power conditions, followed by detailed numerical simulations using GT-Power software to predict system behavior. Furthermore, the paper provides a comparative analysis of various configurations, assessing their impact on temperature reduction, response time, and thermal uniformity. The results demonstrate that appropriately designed passive solutions significantly improve thermal performance, effectively enabling higher charging power capabilities while minimizing system complexity and integration effort. This innovation provides a scalable and efficient path for improving overall vehicle performance and safety during rapid energy transfer events.
Salameh, GeorgesGoumy, GuillaumeFrecinaux, AnthonyRatajczack, ChristellePalluel, MarlèneNoiseau, PascalLardeux, Sébastien
Hybrid electric vehicles rely heavily on battery pack power capability, which is often compromised by non-uniform aging and thermal gradients. Conventional battery models typically use bulk state-of-health metrics, failing to capture localized degradation that leads to current imbalances and reduced pack utility. This paper presents a multi-scale modelling framework that integrates Electrochemical Impedance Spectroscopy data into a fractional-order equivalent circuit model to simulate localized degradation in Lithium Iron Phosphate cells. Results show that the terminal voltage of LFP cells can be accurately modelled using the proposed fractional-order equivalent circuit with a discrete transfer-function implementation, maintaining root-mean-square errors below 20 mV across most state-of-health and state-of-charge conditions. The validated cell model is then extended to a degradation-aware battery pack representation. The battery pack in this work utilizes a 200-kWh, 800 V architecture consisting of five modules connected in parallel, each module composed of 13 parallel strings of 250 series cells, evaluated under multiple degradation scenarios. By integrating this pack model into a Class-8 series hybrid powertrain simulation, this study quantifies how cell-to-cell heterogeneity impacts vehicle performance under the VECTO regional delivery drive cycle. At the vehicle level, these battery constraints influence engine duty cycles and battery pack stress metrics. When localized degradation reaches up to 40% in one module while the remaining modules degrade up to 20% to 30%, such inhomogeneous degradation reduces the minimum pack terminal voltage by approximately 27% and increases peak discharge current by more than 30%, resulting in more rapid degradation. These battery-level limitations translate into higher fuel consumption by up to 6% in a charge-sustaining scenario.
Safavi, Seyed RezaHomayouni, HoomanShoa, TinaWang, JasonMcTaggart-Cowan, Gordon
The rapid adoption of electric vehicles (EVs) with longer driving range 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. A multi-agent adaptive control strategy is 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 possible 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 participating DC/DC converters at each time instance during the charging session. In addition to that, the strategy provides the option of delivering the optimal charging current during each time instance, so that maximized system efficiency is guaranteed during the charging process. Simulation results demonstrate that even a small efficiency improvement of 0.5% can yield substantial environmental benefits at a scale, where a 10 MW charging park avoids nearly 0.9 GWh of energy use and more than 350 t of CO₂ emissions over 10 years. By fully passing these efficiency gains to customers, charging becomes more affordable without compromising service provider margins, while the resulting climate benefits scale directly with utilization, installed capacity, electricity prices, and system lifetime. The proposed approach enables intelligent supervisory control for next-generation high-power charging stations, combining efficiency, cost-effectiveness, and sustainability. These findings support the development of modular, resource-efficient infrastructure for future EV ecosystems.
Salah, AliaAbu Mohareb, Omar
This document provides recommendations involving BEV battery data retention and battery design that enhance the potential for BEV battery reuse and serviceability and that can improve recyclability. These recommendations have been developed by a group of professionals skilled in the secondary-use of batteries and in the research, development, and manufacture of BEV batteries and battery systems.
Secondary Battery Use Committee
This document establishes standardized dimensional cell geometry, performance-test procedures, and reporting requirements for secondary (i.e., rechargeable) pouch cells used in Group 1 sUAV. It defines reference geometries, test conditions, and uniform data formats to allow direct comparison of pouch-cell performance across manufacturers and to improve interoperability within the sUAV ecosystem.
Battery Cell Size Standardization Committee
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 rigorous framework to optimize both the spatial distribution and strength of the monopole sources. Positions were identified using an L1-norm regularization via the Lasso algorithm, promoting sparsity and physical interpretability. Strengths were estimated using an L2-norm Tikhonov regularization, which stabilizes the solution against measurement noise. While the Tikhonov regularization parameter was previously tuned manually through trial and error, we now enhance predictive accuracy by selecting it via a cross-validation technique, ensuring a more robust and data-driven optimization. Besides this, compared to the previous work the approach here is validated for the prediction of both indoor and outdoor pass-by noise, as well as for multiple tire types providing different noise levels. Results demonstrate the method’s robustness, accuracy, and applicability for acoustic development in modern vehicle platforms.
Morin, BenjaminDi Marco, FedericoHorak, JanLafont, ThibaultKim, MinkyuKang, Min KyooYoo, Ji Woo
In recent years, the automotive industry has actively explored the application of various AI-based models such as Convolutional Neural Networks (CNN), Long Short-Term Memory (LSTM) networks, Autoencoders, and Transformers to improve defect detection rates at the End-of-Line (EOL) stage. However, implementing these approaches in the Noise, Vibration, and Harshness (NVH) area face several practical challenges: ① extended evaluation times compared to other data types, which limit the quantity of training data and lead to overfitting; ② label imbalance caused by the relatively small amount of defect data; ③ reduced labeling accuracy due to human error; ④ decreased robustness under domain shifts such as changes in jig fixtures, test environments, and signal-to-noise ratio (SNR); ⑤ diminished model reliability when new defect arise during development; and ⑥ constraints imposed by compatibility requirements with existing test equipment. This study proposes a Convolutional Autoencoder (CAE) based framework trained on NVH datasets collected from normal and defective Column-type Electric Power Steering (C-EPS) systems. Latent variables at the bottleneck layer are used for dimension reduction, enabling visualization and unsupervised classification using a clustering algorithm. A classification model derived from the encoder is fine-tuned with clustered data, and Gradient-weighted Class Activation Mapping (Grad-CAM), an eXplainable AI (XAI) technique, is applied to extract Feature Frequency Maps (FFM) highlighting defect-related noise and vibration characteristics. The proposed approach does not rely on the deep learning model to directly classify defect. Instead, it utilizes extracted FFM as weights(mask) to detect defect. This method enables quantitative data representation and ensures high applicability with existing EOL equipment. Post-processing within the FFM enables root cause analysis, reducing issue resolution time and supporting integration with conventional signal analysis techniques.
Park, Jun-SeoJo, Hyeon-ChoelCho, In-JeSeo, Jae-YongYoo, Seong-Sik
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 transfer stiffnesses from 20 to 2000 Hz. In order to investigate possible temperature dependences this dynamic characterisation was carried out for temperatures ranging from -30 until +60 °C. Moreover, additional measurements on bent cable specimen allowed to assess the dependence of the bending stiffness on the cable curvature. It is shown that suitable results can be obtained by modelling the conductive core using an isotropic multi-layer continuum model and by using corrected material characteristics to account for curvature effects. Temperature effects are shown to be negligible within the tested range.
Nijman, EugeneBuchegger, BlasiusBöhler, ElmarZeller, BernhardRejlek, JanFaksa, LukášLukavsky, David
This SAE Recommended Practice describes the recommended methods for testing flexible harness coverings for use on ground vehicle electrical distribution systems. It shall apply to all tapes, extruded tube, and textile tube.
Harness Covering Standards Committee
This SAE Standard applies to lead-acid 12 V heavy-duty storage batteries as described in SAE J537 and SAE J930 for uses in starting, lighting, and ignition (SLI) applications on motor vehicles and/or off-road machines. These applications have some of the following characteristics: High levels of power are required to start the vehicle’s internal combustion engine. The need to supply this power limits the maximum depth of discharge to a fraction of the total capacity of the battery. The battery must be maintained at a charge level sufficient to perform this primary function by the vehicle’s voltage-regulated charging system. The vehicle’s engine powers a voltage-regulated charging system that limits the charging voltage when spinning at sufficient speed and when total loads do not exceed its output limits. The battery is subject to deeper discharging than a typical automotive application as a result of the following conditions: High daily hours of use High numbers of starts per day Electrical loads often exceeding charging system output (at idle) Batteries will be classified into two types for this life test. Type 1 applies to BCI group sizes typically with reserve capacity (RC) rating of 250 minutes or less. Type 2 applies to larger batteries typically with reserve capacity greater than 250 minutes.
Starter Battery Standards Committee
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