Browse Topic: Electrical systems

Items (15,397)

Design and Computational Investigations on the Performance attainment and Structural Integrity of Advanced Horizontal Axis Wind Turbines for Unmanned Marine Vehicles

2025-28-0188To be published on 02/07/2025

The integration of advanced Horizontal Axis Wind Turbines (HAWTs) into Unmanned Marine Vehicles (UMVs) significantly enhances their operational efficiency by providing power source. These vehicles, designed for diverse applications, require efficient power systems to operate autonomously over extended periods. The major disadvantages are limited battery life and energy storage capabilities restrict their operational range and endurance of the UMVs. Utilizing HAWTs in UMVs provide a renewable energy source, reducing operational costs. This continuous power supply enhances mission capabilities and promote energy independence, making them ideal for long-term missions. Ansys Composite PrepPost (ACP) is employed for the pre-processing of HAWT blades, enabling the layering of different composites. The layering of various materials can significantly increase the strength and durability of the HAWT blades. These composites provide superior resistance to fatigue and environmental degradation

Gunasekaran, Durga Devi, KANNAN, HARIDHARAN, Sourirajan, Laxana, Vinayagam, Gopinath, Gnanasekaran, Raj Kumar, Kulandaiyappan, Naveen Kumar, Stanislaus Arputharaj, Beena, L, Natrayan, Raja, Vijayanandh

DEVELOPMENT OF COMPOSITE PCM TO ENHANCE HEAT TRANSFER RATE WITH THE ADDITION OF NANOPARTICLES IN THERMAL ENERGY STORAGE

2025-28-0023To be published on 02/07/2025

This paper explores the augmentation of thermal conductivity in paraffin wax through the incorporation of aluminum oxide (Al2O3) and copper oxide (CuO) nanoparticles, leading to the development of composite phase change materials (PCMs). The objective is to enhance heat transfer rates, crucial for various energy storage applications including industrial waste heat recovery and solar thermal energy storage. Differential Scanning Calorimetry (DSC) testing was employed to experimentally investigate the thermal properties of the resulting nanocomposite PCM.The experimental results reveal that the nanocomposite PCM, composed of 96.14% paraffin wax, 2% aluminum oxide, and 1.6% copper oxide, exhibits 1.35 times increase in heat transfer rate compared to conventional paraffin wax. The integration of nanoparticles into the PCM matrix, facilitated by a magnetic stirrer at 50°C for 4 hours, results in uniform distribution and improved grain morphology, as evidenced by SEM images. Moreover, the

Tarigonda, Hariprasad, Kumar, YB Kishore, Kala, Lakshmi K, R L, Krupakaran

Cloud-Based Monitoring of Lithium-Ion Battery Management Systems for Health Estimation in Manufacturing Industries

2025-28-0200To be published on 02/07/2025

The increasing reliance on lithium-ion batteries in manufacturing necessitates advanced monitoring techniques to ensure their longevity and reliability. Cloud technology offers a solution by enabling real-time data collection, analysis, and accessibility, facilitating thorough monitoring and predictive maintenance. Digital twin technology, creating a virtual replica of the physical battery system, provides a platform for simulating real-world conditions and predicting potential issues before they arise. By integrating sensor data and historical usage patterns, the digital twin model can accurately predict battery degradation, aiding in the implementation of timely maintenance strategies. This proactive approach not only enhances battery operational efficiency but also extends their lifespan, leading to cost savings and improved safety. The paper explores the use of cloud-based monitoring systems to enhance the health estimation and management of lithium-ion batteries. A comprehensive

ZEESHAN, MOHAMMAD, AKRE, VINEET

Deep Learning Approach for EV Battery Optimum Power Management Using IoT

2025-28-0206To be published on 02/07/2025

In the ever-evolving landscape of electric vehicles (EVs), optimizing energy consumption remains paramount, especially considering the growing global demand for electricity. This study delves into the potential of deep learning algorithms for anomaly detection in EV power usage. The proposed approach leverages a Long Short-Term Memory (LSTM) auto-encoder, a powerful deep learning architecture, to analyze real-time energy consumption data obtained from a smart meter integrated within the EV. The core functionality of the system lies in its ability to identify deviations from typical power consumption patterns. By continuously monitoring and analyzing the incoming data stream, the LSTM auto-encoder can effectively detect anomalies that deviate from the established baseline for specific timeframes. These anomalies might signal potential issues within the EV's battery or drivetrain, enabling proactive maintenance strategies. Early detection of such anomalies can not only prevent breakdowns

Deepan Kumar, Sadhasivam

Powering Precision: Ensemble Learning for Superior Battery Health Estimation

2025-28-0204To be published on 02/07/2025

In recent years, there has been a notable shift from fossil fuels to renewable energy sources due to energy challenges and the scarcity of oil resources. This transition has significantly increased the adoption of battery-powered electric vehicles (EVs) and hybrid electric vehicles (HEVs), replacing traditional internal combustion engine (ICE) vehicles. A crucial element of EVs and HEVs is the Battery Management System (BMS), which is essential for ensuring the battery pack operates safely, reliably, and efficiently. As batteries experience numerous charge and discharge cycles, their performance inevitably degrades, which can lead to failure and potentially catastrophic outcomes if the battery unexpectedly reaches the end of its life. This paper presents an innovative machine learning-based method to estimate battery health and mitigate related risks on real time battery data. The study employs proprietary data collected from Nickel Cobalt Aluminum (NCA) chemistry cells under dynamic

Joshi, Umita, Mandhana, Abhishek

Advancing Safety Measures: Exploring Lithium-Ion Battery Thermal Runaway and Battery Thermal Management Strategies

2025-28-0083To be published on 02/07/2025

In the era of EV adoption, lithium-ion batteries are extensively used in commercial and industrial applications. Under normal operating conditions, lithium-ion batteries are safe. However, they are highly sensitive to abnormal conditions, which can pose safety hazards. The primary safety concern with lithium-ion batteries is temperature management. Battery thermal runaway can lead to extended fires or explosions if left unattended. Nowadays, there is a wide range of lithium-ion battery technologies, with some considered comparatively safe, while others are more prone to thermal runaway due to battery mismanagement. This research emphasizes that thermal runaway can result from mechanical abuse, electrical abuse, or thermal abuse, heat generation phenomena, and critical thermal issues such as the solid electrolyte interface theory potentially leading to battery electrolyte leakage, fires, and explosions. Addressing these risks requires robust battery thermal management strategies and

Dhage, Sonam, K, Barathi Raja

Investigation on Heat Transfer Properties of Graphene Nanoplatelets Blended Distilled Water-Ethylene Glycol Mixtures in Battery thermal management system

2025-28-0089To be published on 02/07/2025

In this investigation, the performance of graphene nanoplatelets (GNP) during heat transmission has been examined. Compared to other nanoparticles, carbon nanostructures exhibit higher thermal conductivity due to their low density and integrated thermal conductivity. The experimental findings are relevant in that compared with the base fluid, nanofluid samples had heat transfer capability. The physicochemical characteristics of investigated GNP were characterized using X-ray diffraction analysis (XRD), a scanning electron microscope (SEM), and UV–Vis spectrophotometry. The thermal conductivity and physical properties in the base fluid of Distilled water- ethylene glycol (70:30) and 100 % vol. of glycol with 120 minutes of sonication time, based on graphene nanofluids were measured. Nanofluid concentrations of 0.025, 0.05, 0.075, and 0.1 wt% were obtained for graphene nanoplatelets in a specific surface area of 500 m2/g. After investigating dispersion properties, the stability of

S, Palanisamy, Selvan, Arul Mozhi

Crash performance study on high-speed electric two wheeler battery enclosure

2025-28-0203To be published on 02/07/2025

The growth rate of Electric Vehicles (EVs) industry and the annual production rate have increased significantly over the years. This is due to the development of rechargeable electrical energy storage system (battery pack), which is the main power source for EVs. Lithium-ion batteries (LIBs) pack is predominantly used across all major vehicle category such as 2 wheelers, 3 wheelers and light commercial vehicle. LIB is one of the high energy-dense sources of volume. However, LIBs have a challenge to poses a risk of short circuits and battery pack explosions, when expose to an external damage. Controlled crash analysis is performed for various velocities ranging from 40 kmph to 70 kmph against an obstruction directly and at an offset from the wheel, so as to mimic the real-world crash of high-speed two-wheelers. The behaviour of the battery enclosure is examined through evaluating the structural integrity of the battery enclosure used in a realistic two-wheeler after crash at various

Venkatesan Sr, Aiyappan, Nelson, N Rino, HARIHARAN NAIR, ADARSH

Improvement in Shift Quality in an Automated Multi-Speed Transmission of a Battery Electric Vehicle through Optimization of Required Shift Force

2025-28-0105To be published on 02/07/2025

In the context of heavy-duty applications for Battery Electric Commercial Vehicles, the development of multi-speed transmissions paired with smaller traction motors is increasingly pertinent. This combination is essential for achieving the necessary gradeability while enhancing operational efficiency. However, the primary challenge lies in comprehending the shifting methodology in electric vehicles, which do not employ physical clutches to disengage the transmission from the traction motor during gear shifts. This unique characteristic of electric vehicles renders traditional methods for estimating shift force inapplicable, presenting a novel challenge for the industry. The advent of electric vehicles has presented opportunities for optimizing various attributes of mechanical powertrains. A particularly promising approach involves the design of a compact shift system that employs smaller actuators for automated gear shifting. During gear shifts, the unlocking of the dog clutch

Sharma, Saurabhkumar

Investigation on the Effectiveness of Phase Change Materials in Battery Thermal Management System of Electric Vehicles

2025-28-0178To be published on 02/07/2025

Electric vehicles (EVs) are a clean, sustainable alternative to conventional internal combustion engines representing a paradigm shift in the transportation sector. Electric vehicles (EVs) have significantly improved in performance in battery technology. With the rapid proliferation of Electric Vehicles (EVs), effective Battery Thermal Management Systems (BTMS) are essential to ensure optimal performance and longevity of the battery packs. This study aims to investigating the effect of Phase Change Materials (PCM) in a hybrid cooling of liquid cold plate with battery pack. With the rapid proliferation of Electric Vehicles (EVs), effective Battery Thermal Management Systems (BTMS) are essential to ensure optimal performance and longevity of the battery packs. This study aims to investigating the effect of Phase Change Materials (PCM) in a hybrid cooling of a liquid cold plate with the battery pack. In models of battery cell arrangement of 5x13 arrays of aligned modules with the PCM and

S, Palanisamy, Selvan, Arul Mozhi

Machine Learning Based Variation Studies for Electric Vehicle Drive Unit Virtual System Models

2025-28-0171To be published on 02/07/2025

In electric vehicles development, manufacturing variations pose big challenge in designing various mechanical components as these variations directly impact various customer perceivable performance outputs. If the manufacturing variations can be included in design phase itself, overall robustness of the design can be enhanced. This paper delineates machine learning based methods to include manufacturing variations in designing drive units for electric vehicles. In an electric vehicle, the drive unit transfers power or torque from a battery through an inverter to wheels. The drive units are subjected to different types of loads under various vehicle maneuvers. To evaluate the drive unit system virtually, system level simulations are performed. Traditionally, nominal values of the several inputs such as bearing parameters, gear parameters and clearances etc. are used. However, the drive unit must be designed in such a way that outputs meet target considering all the variations of inputs

Penumatsa, Venkata Ramana Raju, Katha, Venkateswar, Black, Derrick, Jain, Sachin, Maddipati, Seshagiri

An Evaluation of Automotive Electric Vehicle Cell-to-Pack Battery Technology for Higher Power-to-Weight Ratio

2025-28-0078To be published on 02/07/2025

The world is moving towards a green transportation system. The governments also push for green mobility. Electric vehicles are becoming more popular in Europe, China, India, and developing countries. The energy density plays a crucial role in the battery pack architecture. The OEMs are moving towards a higher power-to-weight ratio. Higher capacity battery packs are needed to increase the range of the vehicle. The battery pack architecture is vital in defining the gravimetric and volumetric energy densities. The battery architecture depends on the battery cell, battery cell chemistry, and Government regulations. The cell-to-pack battery technique aims to achieve a higher power-to-weight ratio by eliminating unnecessary weight in the battery architecture. In this work, different battery pack architectures were analyzed to enhance the higher power-to-weight ratio and volumetric ratio. The different architectures were evaluated using statistical techniques to meet an optimum design

K, Barathi Raja

Enhancing Solar Still Productivity with Aluminium Oxide Nanoparticles and Phase Change Materials

2025-28-0026To be published on 02/07/2025

The present study is focused on the integration of phase change materials (PCMs) and Al2O3 nanoparticles into solar stills presents a promising approach to enhance their efficiency. This paper explores the design and performance analysis of a solar still system incorporating PCMs and Al2O3 nanoparticles with different concentration like 200ppm and 400ppm. The primary goal is to investigate the impact of these enhancements on the solar still's productivity and thermal efficiency.The Aluminium Oxide Nanoparticle were synthesized by Sol-Gel method. The Aluminium Oxide particles were characterized by XRD, SEM, EDS, and FTIR etc. In this experiment TN+30 was used as phase change materials and Aluminium Oxide Nanoparticles used for energy storage materials. The water is taken about 15(ltrs) and the optimal depth of water found to be 1cm. The energy materials TN+30 along with Al2O3 shown improvement in collection efficiency with 200ppm and 400ppm was 21.65% and 32.97% when compared with PCM

R L, Krupakaran, PETLA, RATNA KAMALA, Anchupogu, Praveen, Tharehallimata, Gurubasavaraju, Kala, Lakshmi K

A Comparative Study on fault diagnosis of Electrical vehicle motor testing machine Gear Components Using machine Learning algorithms

2025-28-0177To be published on 02/07/2025

Electric vehicles (EVs) are the way of the future for the automobile industry. The drive motor is a vital part of modern EVs. A motor testing machine is used to verify the critical parameters of the electrical motor, which is seen to be of the utmost importance. Electric motor characteristic curve points and their electromagnetic behaviour under different conditions are regularly found using the motor testing machine. But it has been noted that a flaw in the testing machine's helical gear arrangement causes frequent malfunctions and less-than-ideal performance, which impacts the assembly line's effectiveness in producing electric cars. The research project is to enhance the motor test bench apparatus by modifying crucial design parameters using machine learning and vibration signal analysis methods. Vibration signals are recorded at various gear settings before statistical features are extracted. Following that, these signals are classified using classifiers such Quadratic SVM and

S PhD, Ravikumar, V, Muralidharan, D, Pradeep Kumar

Exploring Trapezoidal Salt Gradient Solar Pond Performance A Combined Numerical and Experimental Analysis with and without Reflective Covered Surface

2025-28-0201To be published on 02/07/2025

This study investigates the thermal performance of trapezoidal salt gradient solar ponds through a combined approach of experimental analyses and MATLAB numerical simulations. Salt gradient solar ponds offer a promising solution for sustainable energy generation by harnessing solar radiation and storing it as thermal energy for various applications. However, optimizing their performance is essential to maximize energy efficiency and economic viability. Laboratory experiments were conducted to evaluate the thermal dynamics of trapezoidal salt gradient solar ponds under different conditions, including the presence or absence of a reflective covered surface. These experiments provided valuable empirical data on temperature distribution and heat storage capacity. Additionally, numerical simulations were performed using MATLAB to model the thermal behavior of the ponds and validate the experimental findings. The simulations allowed for a deeper understanding of the underlying mechanisms

J, VINOTH KUMAR

Review of Integrated Thermal Management system for electric vehicle

2024-28-0227To be published on 12/05/2024

Electric vehicles use Li-ion batteries due to their high energy and power densities. Working of Li-ion batteries is very sensitive to temperature thus thermal management system becomes very important to provide safety and performance under different working conditions. This paper review different integrated thermal management system developed for electric vehicles. integrated thermal management content Battery thermal management, cabin thermal management and Electric drive thermal management. These systems share some common objectives and common parts so integrating these systems will help to optimize the number of components in the electric vehicles thermal management system. The integrated thermal management system also helps to optimize the weight and use of waste heat to heat the cabin or battery which will also help in optimization of energy consumed by the thermal management system and range improvement. But integrating different systems which content refrigerant and coolant

Mhaske, Pramodkumar Chimaji

Drag Prediction of an Electric Cargo Scooter

2024-28-0173To be published on 12/05/2024

Drag prediction is a very important stage in the design of an electric cargo scooter. Early knowledge of the drag forces will enable designers to accurately estimate the motor power, size, battery pack size, vehicle range, and the maximum speed of the vehicle. In the present paper we present a simulation-based methodology to estimate the drag forces and drag coefficient accurately and to identify possible design changes to optimize and reduce them. The main advantage of simulation-based method is reducing the number of prototypes built during the initial design stages and reducing wind tunnel tests. Future variants also will not require any wind tunnel measurements as they can be accurately predicted using the established process. Reynolds Averaged Navier Stokes (RANS)-based steady state Computational method is utilized. The study includes mesh independence, inlet velocity independence, and Turbulence model independence

Balachandran, Karthik, Das, Alok, Shinde, Pranav

Characterization of Cut and Chip Damage in Ultra Low Rolling Resistance Tire for Electric Vehicles

2024-28-0175To be published on 12/05/2024

Since the inception of battery driven electric vehicles in the automotive world, there has been a constant challenge in maximizing the range of an electric vehicles through various means including battery technology, vehicle weight optimization, low drag coefficients etc. The tires being a viscoelastic composite material have now become a vital to the range performance of an EV. The rolling resistance of a tire is now become a hotter topic than ever. The rolling resistance coefficient (RRC) is the measure of energy loss during rolling due to viscoelastic dissipation in the tire. The viscous dissipation in tire arises due to hysteresis in the various components of a tire including tread, sidewall, inner liner, apex etc rubber compounds. The internal friction between layers of body ply, steel belts and tread crown ply also contribute to the internal heat generation. Therefore, the development of ultra-low RRC tires is a serious challenge for tire engineers. Nevertheless, the recent

Mishra, Nitish, Singh, Ram Krishnan

Precise and robust SoC estimation using adaptive filters-based techniques for Electric Trucks

2024-28-0152To be published on 12/05/2024

The traction for zero emission vehicles in the transportation industry is creating a focus on Battery Electric vehicles (BEV) as one of the potential alternate powertrain sources. To the relevance of electric trucks, the range estimation and optimum energy prediction & utilization brings utmost importance. Battery management system (BMS) controller is needed for optimized and safe operation of high voltage (HV) battery. For correct behavior of battery management system, it is important to accurately estimate the state of charge (SoC). SoC is an important and decisive factor for deciding operating limits such as current limits, voltage limits & battery operational range (charge-discharge interval). Inaccurate State of Charge (SoC) estimation can accelerate battery aging and cause damage to components, affecting energy throughput. Current state of art deploys coulomb counting technique for SoC calculation, this approach encounters the challenges like sensor noises and initial SoC error

Kumar, Raman, AHMAD, MD SAIF, Challa, Krishna, Ranjan, Ashish, Bayya, Madhuri

Evaluation of Dynamic Load Coming on E-Driveline Due to Bump and Study its Effect on Motor Mountings and Battery Position

2024-28-0171To be published on 12/05/2024

During the development of E-Driveline, it is observed that loading failure encountered with On-highway vehicle’s E-Drivelines has increased in comparison with traditional driveline. The major cause of these failures is motor and battery reaction loads acting on driveline in electric vehicles. The main source of load generation is acute dynamic reaction coming from road conditions i.e., bumps, potholes, ditch, uneven surfaces and get transferred to motor or batteries through the E-Driveline. The uneven distribution of motor and battery loads in vehicle will amplify the dynamic reactions which may lead to severe failures. It will be useful if we predict the dynamic loads in early design and simulation stage for accurate solution. This work is based on development of multi body dynamic modeling and simulation approach to predict loads coming on to E-Driveline due to road conditions and correlate it with test setup of actual vehicle running on these road conditions. After the correlation

Deshmukh, Shardul, Nikam, Vinod

A method on HPR critical route identification and evaluation in electric trucks

2024-28-0150To be published on 12/05/2024

Heavy-duty vehicles, particularly those towing higher weights, require a continuous/secondary braking system. While conventional vehicles employ Retarder or Engine brake systems, electric vehicles utilize recuperation for continuous braking. In a state where high voltage battery of electric vehicles is at 100% of its designed capacity, at such scenario if vehicle travels on a route which has brake requirement, all this recuperated energy generated from the vehicle operation is passed on to high performance brake resistors(HPR) and this energy gets converted from electrical energy into waste heat energy. This study focuses on a method for identification of such a routes, which are critical for Brake Resistors, by analyzing the elevation data of existing charging stations, the route’s slope distribution, and the vehicle’s battery SOC. In the results entire method is demonstrated with the example of all the charging stations of Switzerland. This method has a significant applications in

Thakur, Shivam, Salunke, Omkar, Ambuskar, Mandar, Pandey, Lokesh

Anomaly Detection in Fleet Vehicle Data and Statistical approach to develop Engine System OBD thresholds

2024-28-0195To be published on 12/05/2024

On-Board-Diagnostics are crucial for ensuring the proper functioning of Vehicle’s emission control system by continuously monitoring various sensors and components. When the failure is detected, the Check Engine Light (CEL) is triggered on Vehicle’s dashboard, alerting the driver to seek professional service to address the issue. However, the task of developing the Diagnostics strategies and perform robust calibration is a challenging and time consuming. Model in Loop Testing and Simulation is a technique used to understand and estimate the behavior of system or sub system. The diagnostics model can be tested and refined within the model-based environment allowing a complex system to be efficiently regulated. Model in loop framework could be used at various stages of development from very early in the design phase to later stages of series developments through vehicle fleet data. This framework allows an early identification and correction of errors and bugs. In this paper, the

Kumar, Amit, Hegde, Karthik, Challa, Krishna, H, YASHWANTH

A Multivariable Function Based Optimised Charging Algorithm for Electric Vehicle Battery Management Systems

2024-28-0228To be published on 12/05/2024

Conventional Constant Current- Constant voltage (CC-CV) based charging techniques initially consist of Constant Current (CC) phase for quick charging of the battery till it reaches the safety voltage limit wherein the Constant Voltage (CV) phase starts. Then the CV phase of the charging ensures safe charging of the battery till it is fully charged but it takes comparatively a long duration of time to the amount of charge pumped into the battery. Adoption of efficient charging algorithms are crucial for optimising the charging time, reducing the range anxiety and improving the long-term health of electric vehicle (EV) batteries. This paper proposes an innovative charging algorithm that optimises the transition from Constant Current (CC) to Constant Voltage (CV) charging stages utilising a multivariable function based on the real-time data of State-of-Charge (SoC), temperature, State-of-Health (SoH) and battery impedance parameters. By dynamically adjusting the charging parameters based

Rajawat, Shiv Pratap, Moorthi, Sathiya, Soni, Lokesh, Jain, Swati

A Review of Hydrogen Storage system (HSS) and Hydrogen Internal Combustion Engine (H2-ICE) for the Potential H2-ICE Vehicle

2024-28-0129To be published on 12/05/2024

The different energy policies and legislations across the globe, unions, or country wise are the key influencer for evaluation of Transport Industry in both advancement of Technologies and Ecosystem development. Accordingly, European Climate law is focusing on achieve net zero greenhouse (or carbon neutral) gas emissions for EU (European Union) countries by 2050. Similarly in India, National Green Hydrogen Mission (NGHM) by Ministry of New and Renewable Energy (MNRE) is aiming for significant decarbonization and to become market leader in Green Hydrogen Transition. The hydrogen is potential fuel for H2-FCEV (Hydrogen Fuel Cell Electric vehicle) and H2-ICE (Hydrogen -Internal combustion Engine) due to its carbon free molecule and other properties. This review paper is focusing on comprehensive study of different aspects of H2- ICE vehicle. Key study areas are mainly Hydrogen Storage System (HSS), H2-ICEs, Hydrogen storge pressure and H2-ICE vehicle architecture. The advantages

Biswas, Sanjoy, Naik, Amit Kumar, Kashyap, Krishna

Impact on FEAD Dynamic performance of Mild hybrid engine with increase in Engine torque

2024-28-0204To be published on 12/05/2024

Front End Accessory Drive (FEAD) systems are used in automobiles to transfer power from the engine-to-engine accessory components such as the alternator, water pump, etc. using a Belt and Tensioner. The emergence of Mild hybrid technologies has led to the replacement of alternator with Belt-driven Integrated Starter-generator (B-ISG) In conventional configuration of FEAD, the power transfer is in single direction but in mild hybrid engine power transfer is bidirectional: tight and slack side of the Belt changes as per Torque assist or Regeneration mode. The presence of an integrated starter-generator (ISG) in a belt transmission places excessive strain on the FEAD System and necessitates checking the dynamic performance of FEAD System thoroughly. Study of Increase in Engine Torque in existing Vehicle was done to understand its effect on various system. This vehicle is Mild Hybrid and consists of Belt-driven Integrated Starter generator system. Increase in Engine torque lead to increase

Kumar, Aditya, Gupta, Avinash, Bharti, Anil Kant

An approach to reduce noise generated by thermal management systems in electric vehicles

2024-28-0211To be published on 12/05/2024

Electric vehicles are transforming the future of transportation for the world while achieving the goal of sustainable development. While the concept and use of battery-powered vehicles has also penetrated the logistics and supply chain industry, it has also brought upon new challenges during its development. As OEMs strive to develop EVs with extended range, the components within the propulsion and drivetrain system tend to demand a higher power output from the energy storage systems. This results in EVs generating higher levels of thermal heat energy, which must be dissipated / rejected for optimal performance and safety. Eventually, to reject this heat, EVs must deploy thermal management systems with higher capacities. This increase in size is accompanied by the inclusion of many parts that generate noise and contribute to increased noise levels in EVs. In today’s EV market, optimization of noise levels is a significant factor when ensuring passenger comfort, while also showing

Shedge, Atharva Vikas, Shalgar, Sandeep, Srivastava, Sarvesh, Nagarhalli, Prasanna V

Writing and Effective Technical Safety Concept in accordance with ISO26262

2024-28-0207To be published on 12/05/2024

With the trend of increasing technological complexity, software content and mechatronic implementation, there are increasing risks from systematic failures and random hardware failures, which is to be considered within the scope of functional safety. ISO 26262 series of standards provides guidance to mitigate these risks by providing appropriate requirements and processes. To develop a safe product with respect to above mentioned complexities, it is very critical to develop a safe system and hence a thorough and robust “Technical Safety Concept” is very important to ensure absence of unreasonable risk due to hazards caused by malfunctions of E/E systems. ISO26262-Part 4 provides guidelines for “Product development at the system level”, to design safety-related systems that include one or more electrical and/or electronic (E/E) systems and that are installed in series production road vehicles. Defining requirements at system level for each individual technology and systematically

Cheni, Dileep Kumar, Desai, Priyanka Pradeep

Design improvement on cooling plates/tube of BTMS of Electric vehicles by changing internal structure and coolant mass flow rate

2024-28-0203To be published on 12/05/2024

The lithium-ion battery is most common types of batteries in modern electric vehicles. During operation of vehicle and charging of batteries, temperature of the battery cells increases. From any battery, its temperature needs to be controlled and maintained within a defined limit to achieve the maximum efficiency. Considering the overall thermal effect on the battery, a battery cooling system is of great importance in electric vehicles to maintain the temperature of the battery cells inside the battery pack. There are different types of systems for battery cooling but water cooled systems are very popular. It uses mixture of water and ethylene glycol to absorb heat from the battery cells. The coolant circulates through components that surround the cells, such as tubes and cold plates surrounded by cells. The paper involves the study of internal structure of tubes on the temperature variation of battery cell. It involves by changing the design of internal structure of the tube how the

Parayil, Paulson, Ahmad, Taufeeq, Dagar, Aakash, Goel, Arunkumar

Kalman-based estimation of remaining Battery discharge run-time and run-distance for electrified off-highway Vehicle using Battery parameters

2024-28-0230To be published on 12/05/2024

Kalman-based estimation of remaining Battery discharge run-time and run-distance for electrified off-highway Vehicle using Battery parameters Supriya Narwade, Tejal Sarda Abstract: Electrification in off-highway vehicles is facing several challenges due to the unique requirements and driving features of heavy-duty applications. A few key challenges are power demand, limited range, weight, size and cost of electrification. Lithium-based batteries have limited capacity and range, and heavy-duty operations can instantly drain the battery's power. Managing battery power for these operations requires careful planning and optimization of the vehicle's power consumption to ensure that the battery's capacity is utilized efficiently. In electric off-highway vehicles, remaining battery discharge run-time strongly relates to the management of driving the applications on the field. Here, utilization of battery power for heavy operations can be achieved by estimating battery run-time and run

Narwade, Supriya, Sarda, Tejal

Electrical-Thermal Modelling and Analysis of Battery Energy System in Electric vehicles

2024-28-0155To be published on 12/05/2024

The development and implementation of Lithium-ion (Li-ion) batteries, particularly in Automotive applications, requires substantial diagnostic and practical modelling efforts to fully understand the electrical and thermal characteristics in the batteries across various operating conditions. Electrical thermal modelling prompts the understanding of the battery electrical characteristics along with the thermal behavior beyond what is possible from experiments, and it provides a basis for exploring electrical and thermal management control strategies for batteries in electric vehicles (EVs). For the purpose of replicating the electrical behavior of Li-ion batteries under varied operating situations, an equivalent circuit model (ECM) must be created. This model aids in forecasting the transient distribution of electrical and thermal properties at various operating states as well as estimating heat generation within the battery pack. The research paper focus in the following application

Data learning based SoH estimation supported by modified charging algorithm for electric vehicle applications

2024-28-0222To be published on 12/05/2024

As the demand for electric vehicles continues to surge, ensuring the longevity and efficiency of EV batteries becomes critical. The state of health (SoH) of these batteries serves as a critical metric, influenced by various factors such as State of Energy (SoE) and State of Power (SoP). Understanding the dynamics of EV battery health is essential for optimising performance and extending lifespan. The impedance values of battery cells (R and C values) serve as few of the fundamental parameters influencing SoE and SoP, inevitably degrading over time due to factors such as usage at varying C-rates, temperature fluctuations, and the number of charge cycles. This paper introduces an innovative approach for estimating the State of Health (SoH) of a battery. The charging algorithm is tailored to support the SoH algorithm, with modifications enabling the estimation of R & C parameters periodically throughout charging cycles, across a range of State of Charge (SoC) levels and various

Rajawat, Shiv Pratap, Soni, Lokesh, Badiger, Kartik, Sankla, Karan

Effect of vibrational abuse on the electrodes of Nickel Manganese Cobalt (NMC) and Lithium Iron Phosphate (LFP) 18650 cells

2024-28-0156To be published on 12/05/2024

In light of the growing demand of Electric vehicles (EVs) as a sustainable mode of transportation, it becomes essential to understand the effect of various abuse conditions that batteries undergo. Vibrational abuse is a significant condition experienced by batteries in operation. Vibrations caused by road roughness, acceleration inertia, and other factors can affect key performance indicators such as cycle life, capacity retention, and safety. These cells undergo various chemical and mechanical reactions over time, leading to degradation of components like the anode, cathode, electrolyte, separator, and current collector, resulting in reduced performance. Therefore, understanding battery degradation is important for managing system performance. This study is focused on a detailed analysis of Lithium Iron Phosphate (LFP) and Nickel Manganese Cobalt (NMC) cells subjected to vibrational abuse. Vibration testing was carried as per International Electrotechnical Commission (IEC) standard

Manwatkar, Asmita Ashok, Pandit, Sachin Prabhakar, Santosh Jambhale, Medha, Mahagaonkar, Nitin

A Facile Synthesis and molecular characterization of Electroactive Polyaniline Nanocomposites materials based on Sliver Embedded Poly Aniline copolymers for application in automobile industries

2024-28-0158To be published on 12/05/2024

In-situ chemical oxidative polymerization was used to develop a new series of functional electroactive nanocomposites based on HCl doped and silver embedded poly (aniline-co-3-chloroaniline). In order to investigate these copolymer nanocomposites, FTIR, UV-visible spectroscopy, X-ray diffraction (XRD), scanning electron microscopy (SEM), and a conventional four probe conductivity approach were all used. The developed copolymer has excellent solubility in widely used organic solvents like DMF, THF, and NMP. The spectral value at 341nm is related to π-π* electronic transition of benzenoid ring and peak at 624 nm is attributed to n-π* electronic transition of quinoid ring. The band at 1300 cm-1 has been accredited to the combination of C-N in quinoid and benzenoid sequences. X-ray diffraction (XRD) reveals the crystalline nature of copolymer. Surface morphological studies exhibit nanoneedle like appearance with average particle size of 150-300 nm. Applications of Composites based on PANI

Pachanoor, Vijayanand, Moorthi, Bharathiraja

Synthesis and characterization of advanced multi nanoparticle based nanofluid stabilized by surfactants

2024-28-0139To be published on 12/05/2024

Recently, there has been a growing emphasis on Thermal Management Systems (TMS) for Lithium-ion battery packs due to safety concerns related to fire risks when temperatures exceed operating limits. Elevated temperatures accelerate electrochemical reactions, leading to cell degradation and reduced electronic system performance. These conditions can cause localized hotspots and hinder heat dissipation, increasing the risk of thermal runaway due to high temperatures, flammable gases, and heat-producing reactions. To tackle these issues, many automotive manufacturers employ indirect liquid cooling techniques to maintain battery pack and electronic system temperatures within safe limits. Engineered nanofluids, particularly those containing multi-nanoparticles dispersed in water and ethylene glycol, are being explored to enhance thermo-physical properties. This paper focuses on the experimental characterization of nanofluid containing Titanium Dioxide (TiO2), Copper Oxide (CuO), Aluminum

Nahalde, Sujay, Honrao, Gaurav, More, Hemant

A comprehensive review of advancement in anode material with modified architecture for lithium-ion batteries

2024-28-0142To be published on 12/05/2024

Anode material, responsible for the critical storage and release of lithium ions during charge and discharge cycles, holds paramount importance. By strategically altering the material design and composition of the current graphite, researchers aim to significantly improve fast charging capabilities, energy density, cycling stability and overall electrochemical kinetics within Lithium ion battery. Anode materials operate through three primary mechanisms: insertion/de-insertion that is allowing for reversible lithium ion accommodation within the host structure; alloying, where lithium ions form chemical bonds with the anode material; and conversion reactions, involving the creation of new phases during charge/discharge cycles. This review delves into a captivating array of advanced anode materials with the potential to surpass the limitations of traditional graphite. Carbon-based nanomaterials like graphene and its derivative, reduced graphene oxide, offer exceptional conductivity and

Borkar, Shweta, Nahalde, Sujay, Ruban J S, Alwin, More, Hemant

A predictive controller for battery cooling systems to tackle the comfort-safety-efficiency dilemma

2024-28-0147To be published on 12/05/2024

The advent of electric vehicles has increased the complexity of air conditioning systems in vehicles which now must maintain the safety and comfort of occupants while ensuring that the high voltage battery temperature is kept within safe limits. This new task is critical due to the influence of the cell and battery pack temperature on the efficiency. Moreover, high temperatures within the battery pack can lead to undesirable effects such as degradation and thermal runaway. Classical solutions to this problem include larger air conditioning components to support worst case scenario conditions where the cooling request from the battery and the cabin happen at the same time. In such conditions, for the safety of the battery, the cooling request is assigned to battery system which may cause discomfort to the passengers due the significant temperature increase in the cabin during such events. The probability of such events happening is certainly dependent on the weather conditions but in

Palacio Torralba, Javier, Kulkarni, Shridhar Diliprao, Shah, Geet, Jaybhay, Sambhaji, Kapoor, Sangeet, Locks, Olaf

Thermal Modeling of Large Format Prismatic Lithium-ion Cell – A Comparative Study

2024-28-0144To be published on 12/05/2024

Energy storage has become hugely important and necessary, as the world is moving towards greener and zero carbon footprints. Lithium-ion batteries are one such prominent energy storage device that can store electrical energy in the form of chemical energy and release it whenever required. During their operation, Lithium-ion batteries generate heat that needs to be removed to ensure their optimum performance and safety. A prior knowledge of heat generation rate can help design efficient thermal management systems. Numerical models are quite successful in estimating the heat generation inside Lithium-ion cells. In the present study a computational fluid dynamics (CFD) model is developed to estimate the heat generation and temperature distribution within a 30 Ah Prismatic Lithium-ion cell using two modeling approaches namely, the Newman, Tiedemann, Gu, and Kim (NTGK) model and the Pseudo 2-Dimensional (P2D) model. The NTGK model, known for its robust representation of electrochemical and

M, Abhishek, Napa, Nagaraju, Agrawal, Manish Kumar, Tamma, Bhaskar, Garg, Akhil

Development of new generation battery cooling hoses with TPV material

2024-28-0161To be published on 12/05/2024

The market for battery-fitted electric cars continues to experience robust growth globally as well as Indian market. During the charging process heat generation happen because of internal resistance of the battery cells and electrical connectors. Making an efficient battery cooling system is vital for all electric vehicles. One common cause of battery overheating is cooling efficiency, highlighting the importance of scientifically designing coolant circuits and selecting appropriate hose materials. Currently, EPDM (ethylene propylene diene monomer) material is widely used for battery cooling hoses due to its design flexibility, compatibility with a 50:50 glycol-water mixture, and resistance to thermal and ozone cracking. This study benchmarked EPDM's technical properties against leading EV battery cooling plastic hose materials, such as polyamide, TPEs (thermoplastic elastomers), and TPVs (thermoplastic vulcanizates). Comparative experiments, including burst pressure, vacuum collapse

Murugesan, Annarajan

Battery Digital Twin With Edge Deployment

2024-28-0120To be published on 12/05/2024

Today's battery management systems include cloud-based predictive analytics technologies. When the first data is sent to the cloud, battery digital twin models begin to run. This allows for the prediction of critical parameters such as state of charge (SoC), state of health (SoH), remaining useful life (RUL), and the possibility of thermal runaway events. The battery and the automobile are dynamic systems that must be monitored in real time. However, relying only on cloud-based computations adds significant latency to time-sensitive procedures such as thermal runaway monitoring. Because automobiles operate in various areas throughout the intended path of travel, internet connectivity varies, resulting in a delay in data delivery to the cloud. As a result, the inherent lag in data transfer between the cloud and cars challenges the present deployment of cloud-based real-time monitoring solutions. This study proposes applying a thermal runaway model on edge devices as a strategy to reduce

Sarkar, Prasanta, Pardeshi, Rutuja, Kharwandikar, Anand, Kondhare, Manish

Performance Evaluation of Battery Cooling System for Electric Bus Applications Using MATLAB

2024-28-0145To be published on 12/05/2024

As the electrification of transportation continues to gain momentum, the thermal management of onboard batteries remains a critical aspect to ensure optimal performance, efficiency, and longevity. To address this challenge, we developed a standalone cooling system with a cooling capacity specifically tailored for electric buses. This paper presents a comprehensive analysis of the performance comparison between simulation and testing data for a standalone battery cooling system designed for electric bus applications. The study encompasses two primary components: numerical simulation using MATLAB Simulink and experimental testing. In the experimental phase, rigorous tests were conducted in a laboratory environment to evaluate the system's cooling performance under various operating conditions. Key metrics such as cooling capacity, temperature profile, and power consumption were measured and recorded to assess the system's effectiveness. A detailed numerical simulation model was developed

Suman, Saurabh, Kushwah, Yogendra Singh, Shukla, Ankit

Detailed FE Modeling of battery pack to predict Thermal Runaway

2024-28-0154To be published on 12/05/2024

Electrified powertrain is the essential need to meet the C02 and NOX emissions compliance. Thereby focus of automotive industry is shifting towards to Electric Vehicle (EV). Thermal Runaway (TR) is still a big challenge to the safety of the EV. The major cause of TR is internal short-circuit of batteries under external mechanical abuse. When Anode and cathode of the battery comes in contact and short circuit happens. Internal short circuit is causing high amount of current flow and energy generation which leads to high increase in temperature. The approach that is used till date by OEMs is to protect the battery pack from structural damage during crash resulting into overdesigning of the vehicle. In this paper, detailed FE modeling of the battery system is considered for evaluating internal short circuit and TR. Solid Randle circuit is used for Multiphysics coupling simulation in Ls-dyna. Solid Randle circuits solves this Multiphysics and derives these electrical and thermal parameters

Jain, Tripti, Bonala, Sastry, Dangare, Anand

Battery Digital Twin for Electric Vehicle Deployed on cloud

2024-28-0153To be published on 12/05/2024

The recent few years have witnessed a rapid rise in the count of electric vehicles (EVs) plying on the roads, which is reflective of their widespread acceptance for reducing carbon footprint. This is a clarion call to the automotive fraternity to build energy-efficient vehicles with minimal issues, leveraging proactive monitoring & diagnostics to reduce vehicle downtime ultimately pushing up customer satisfaction. It is also imperative to understand the changes in how the battery performs when it undergoes variations in operating parameters like temperature, charging behaviour, current and other factors like usage patterns, charge patterns etc. This calls for the industry to adopt innovative technologies like Battery Digital Twins (BDTs). A digital twin presented here is a virtual representation of the physical battery system of a vehicle which runs basis a hybrid model - Electrochemical model plus Machine Learning model, thus providing valuable insights into key parameters of the

Sasi Kiran, Talabhaktula, Kondhare, Manish, Patil, Suyog, Nath, Subhrajyoti, CH, Sri Ram, Tank, Prabhu, Sarkar, Prasanta

Onboard State of Charge Estimation for LiFePO4 Battery Packs Using a Hybrid Extended Kalman – Particle Filter Algorithm

2024-28-0223To be published on 12/05/2024

In recent years, Lithium Iron Phosphate (LiFePO4) has emerged as a popular choice for Li-ion battery chemistry in electric vehicles and energy storage systems due to its inherent safety, long lifecycles, absence of cobalt and nickel, and reliance on common raw materials. State-of-Charge (SoC) is a derived parameter used for optimal and safe battery operation. The Kalman Filter-based SoC estimator is highly regarded for its accuracy and suitability in Battery Management systems. However, estimators within the Kalman Filter Family requires an accurate initial SoC to deliver precise estimates. Errors in this initial SoC can result in significant inaccuracies, prolonging the time required for the estimator to converge to the true value. The Open Circuit Voltage–SoC (OCV–SoC) method is commonly used to set the initial battery SoC during idle periods. This method proves ineffective in LiFePO4 chemistry due to its flat OCV-SOC profile. Given the critical nature of battery applications, where

Ns, Farhan Ahamed Hameed, Jha, Kaushal, Shankar Ram, C S

Investigation on Thermal Performance of Battery Cooling Plate for Lithium-ion Battery

2024-28-0259To be published on 12/05/2024

Electric Vehicles are regarded to be the most effective way to lower emissions of greenhouse gases from transportation industry. Lithium-ion batteries are rechargeable and ideally suited for vehicle electrification due to their high specific energy and energy density in comparison to others. Electric Vehicle performance greatly depends on efficient operation of Li-ion Battery. Battery thermal management plays a crucial role in ensuring the optimum vehicle operation. Heat dissipation from the battery should be dealt with, for safe operation and to prolong the battery life cycle. To achieve the battery’s optimal temperature, an efficient cooling system should be established. Battery cooling plate is an essential component which is necessary for heat transfer from battery pack to coolant. Four different battery cooling plates such as dimple, U shaped, Splitter, Serpentine with varying profiles are modeled for computational fluid dynamics simulation. Models are compared based on pressure

K, Muthukrishnan, S, Saikrishna, K, Keshavbalaje

Equivalent Circuit Modeling of Sodium-Ion Batteries Incorporating Temperature Effects: A Comprehensive Investigation

2024-28-0225To be published on 12/05/2024

The shift from internal combustion engine vehicles to electric vehicles has driven significant advancements in battery technology, aiming for safer and more reliable energy storage solutions. While Lithium Iron Phosphate (LFP) batteries are known for their safety, they are dependent on critical elements such as copper, lithium, and graphite. The safe transport of Li-ion batteries remains a concern. Addressing these challenges, Sodium Ion Batteries (SIBs) have emerged as sustainable alternatives suitable for lightweight electric vehicles (EVs). Ensuring their seamless integration into EV battery packs requires preparedness for the rapid evolution of SIB technology. Model-based approaches, including Equivalent Circuit Models (ECMs), play a pivotal role in developing advanced Battery Management Systems (BMS) and State of Charge (SoC) estimation algorithms for precise battery control. This study conducts a comprehensive evaluation using various order resistance-capacitance (RC) ECM

Ns, Farhan Ahamed Hameed, Gupta, Shubham, Jha, Kaushal

Safe Phase Current Measurement for Motor Controlled Traction-Inverter Application

2024-28-0141To be published on 12/05/2024

The Traction-Inverter is a key component of electric vehicles, as it connects the battery, the motor, and the vehicle control systems as automotive industry is moving towards electrification. Phase current measurement one of its functionalities ensures to achieve accurate motor control, efficient torque production and optimal performance in traction inverter application. This paper proposes method for phase current measurement of PMSM (Permanent magnet synchronous motor) with EVADC (Enhanced Versatile Analog-Digital-Converter) to measure current of three phases motor synchronously. To accomplish measurements free of current ripples, the EVADC module converts sensed data synchronously at the middle of the PWM (Pulse Width Modulation) trigger signal. Due to due to its high precision and flexibility, conversion speed, synchronization and parallel sampling, DMA (Direct Memory Access)- driven result handling, anti-aliasing filtering, system integration, arbitration and conversion sequences

Birari, Ashwini Anil

Evaluating the Thermal Behavior of Miniature Battery Packs Encapsulated with Diverse Potting Materials through Simulation and Experimentation

2024-28-0224To be published on 12/05/2024

Electric vehicles represent a pivotal shift in the automotive sector, offering a sustainable alternative to conventional gasoline-powered vehicles. Lithium-ion batteries are extensively chosen as the primary energy source for these vehicles due to their exceptional energy density and extended operational lifespan. Achieving thermal stability during normal battery pack operations is imperative for ensuring both safety and efficiency in electric vehicle technology. Various encapsulants are used to fill the gaps between the cells, providing not only structural rigidity on undulating roads but also enhancing heat transfer capabilities among the cells, thereby maintaining a uniform temperature gradient inside the battery pack. This study explores the effectiveness of three distinct commercially available potting materials—polyurethane (PU) foam, silicone, and silicone-based epoxy—as encapsulants for lithium-ion battery packs. A 3x3 cell configuration is modeled as a battery pack using 18650

Somarajupalli, Shanmukhadev, Vedantam, Srikanth, Gupta, Shubham, Jha, Kaushal Kumar

UWB based communication for Electric Vehicle Battery Management System

2024-28-0149To be published on 12/05/2024

The Battery Management System (BMS) plays a vital role in managing the energy present in the high voltage battery pack of electric vehicles. The wired battery management system is commonly used in automotive applications. The known difficulties with the wired battery management system includes the intricate wiring harness, wiring failures, system scalability and high implementation costs. To mitigate the above challenges, the wireless battery management system is proposed. Several wireless protocols, including BLE, Zigbee, and 2.4GHz proprietary protocol, are being examined for wireless BMS. However, there are technical difficulties with these protocols to be applied in the battery pack environment. This research paper looks at the Ultra Wide Band(UWB) communication protocol for wireless BMS, considering UWB’s efficiency low latency and robust Radio Frequency (RF) performance. The UWB protocol is used to communicate between the Cell Supervisory Circuit (CSC) and the Battery Management

Dannana, Arun Kumar, Subbiah Subbulakshmi, Nallaperumal, Chandirasekaran, Ramachandran, Beemarajan, Mutharasu

SAE TOMORROW TODAY BRIEFS - The Future of Solid-State Batteries

1348911/22/2024

Most EV batteries are heavy and provide limited range. But Factorial Energy is developing breakthrough solid-state solutions that offer longer range per charge and increased safety. With higher energy density--390 watt-hours per kilogram to be exact--Factorial's solid-state batteries allow for less weight and extended EV range. And the company's partnerships with major automakers like Stellantis and Mercedes are key in validating their proprietary technology and bringing it to market. To learn more, Roberto Baldwin, Sustainability Editor, SAE Sustainable Mobility Solutions, sat down with Dr. Raimund Koerver, Senior Director and Head of Commercial at Factorial, to discuss the EV battery landscape and the company's advancements in solid-state battery technology. For more information on the evolution of sustainability, head on over to sustainablecareers.sae.org. There, you can check out our video interview with Lucid CEO Peter Rawlinson as we chat about EV efficiency. We'd love to hear

Hineman, Marcie

Medium/Heavy-Duty E/E Systems Diagnosis Nomenclature

J2403_202411 (Current)

11/21/2024

This SAE Recommended Practice is applicable to all E/E systems on MD and HD vehicles. The terms defined are largely focused on compression-ignited and spark-ignited engines. Specific applications of this document include diagnostic, service and repair manuals, bulletins and updates, training manuals, repair data bases, under-hood emission labels, and emission certification applications. This document focuses on diagnostic terms, definitions, abbreviations, and acronyms applicable to E/E systems. It also covers mechanical systems which require definition. Nothing in this document should be construed as prohibiting the introduction of a term, abbreviation, or acronym not covered by this document. The use and appropriate updating of this document is strongly encouraged. Certain terms have already been in common use and are readily understood by manufacturers and technicians, but do not follow the methodology of this document. These terms fall into three categories: a Acronyms that do not

Truck and Bus Control and Communications Network Committee

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