Browse Topic: Electronic control systems
ABSTRACT AVL is developing a family of modular Auxiliary Power Units (APUs) based on the current gasoline range extender engine/generator developed by AVL for plug-in hybrid electric vehicles. These military specific variants will utilize the same basic architecture as the gasoline version while incorporating semi-direct fuel injection that is compatible with diesel fuel as well as kerosene based fuels such as F-44, JP-5, JP-8, Jet-A, etc. A systems engineering approach to the engine, generator, and power electronics modules enables a wide range of power outputs and packaging options to be easily developed from the base unit
ABSTRACT Curtiss-Wright has developed an advanced Smart Power Architecture for Intelligent Power Distribution, based on our Intelligent Power Distribution Demonstration (iPDD) and experience in providing power distribution components specifically for Heavy Brigade Combat Team (HBCT) vehicles. The challenges of power distribution and management in ground vehicles are presented, including issues of scalability, warfighter burden, and the complexity of distributing multiple vehicle power sources. The fundamental building blocks of Smart Power are described, including Power Distribution Units, Power Conditioning Units, and types of Power Conversion Units (AC/DC, DC/DC, DC/AC). A Smart Power Reference Architecture will be presented, showing how it enables scalable and modular power distribution systems. How modular Smart Power Architecture can enable commonality across vehicles and applications. How it can provide automatic and programmable load management, including startup and shutdown
ABSTRACT The mechanical behavior of a military vehicle during off-highway operation is complex and highly nonlinear. Some current vehicle concepts include added intelligence through the implementation of sensors and controllers to enable autonomous or semi-autonomous operations. Control systems have typically been developed with controls software where the mechanical plant and sensors are represented as simplified and often linearized blocks, resulting in a poor vehicle assessment. This paper describes the development of an integrated environment for a control system, mechanical system dynamics, and sensor simulation for an improved assessment of the vehicle system performance. The vehicle chosen is an autonomous robot that attempts to follow a prescribed path along an off-highway terrain. The effect of including a stability controller for vehicle mobility is assessed. The architecture of the integrated simulation environment is described and its potential to improve schedule and
ABSTRACT Military ground vehicles need greater electrical power generation to address continually increasing power demands due to various loads, e.g. advanced communications equipment, jamming equipment, electronic armor, and electronic weapons system. More electrical power is also required for electrification of auxiliary systems (steering, cooling fans, HVAC, and pumps) to improve system efficiency - currently driven mechanically. Electrical equipment can be powered from the 600 volt DC bus power supply or from the conventional 28 volt DC bus depending on size, cost, weight, cooling, performance, and cooling impact. Appropriate power electronics converters (dc to dc, ac to dc, dc to ac) are used to manipulate the DC source to drive equipment on the Stryker APOP electrical system. These devices are highly efficient and should lead to the reduction of parasitic losses. With the above in perspective, the US Army RDECOM-TARDEC, GVPM (Ground Vehicle Power and Mobility) has been pursuing
ABSTRACT This paper outlines the results from an ongoing collaborative development effort to apply a new powertrain controller in a real combat vehicle application. Specifically, TARDEC and L3T CPS have partnered to demonstrate a production viable electronically controlled fuel injected (EFI) version of the AVDS 1790 diesel engine, used in the M88 HERCULES vehicle. Highlights of the development project focus on coordinated engineering activity involving the following key enablers. The neXtECU jointly developed by ETAS and TARDEC, custom engineered to become a common powertrain controller for use on the Army’s future family of combat vehicles Engine control software jointly developed by TARDEC and L3T to perform EFI fuel system controls and auxiliary powertrain functions using the neXtECU AVDS 8CR 1050 hp engine with L3T design modifications to incorporate a derivative of a commercially available EFI fuel system
ABSTRACT In this paper, the authors present a line of newly developed high performance SiC power modules, HT-2000, for military systems and applications. The HT-2000 series of modules are rated to 1200V, are operational to greater than 100A, can perform at temperatures in excess of 250 °C, and can be constructed with SiC MOSFETs, JFETs, or BJTs. The newly developed module implements a novel ultra-low parasitic packaging approach that enables high switching frequencies in excess of 100 kHz, and weighs in at just over 100 grams (offering >4× mass reduction in comparison with industry standard power brick packaging technology). The paper discusses testing results of these modules in actual system applications, including: (a) complete static characterization vs. temperature, and (b) switching performance
ABSTRACT FEV North America will discuss application of advanced automotive cybersecurity to smart vehicle projects, - software safety - software architecture and how it applies to similar features and capabilities across the fleet of DoD combat and tactical vehicles. The analogous system architectures of automotive and military vehicles with advanced architectures, distributed electronic control units, connectivity to networks, user interfaces and maintenance networks and interface points clearly open an opportunity for DoD to leverage the technology techniques, hardware, software, management and human resources to drive implementation costs down while implementing fleet modifications, infrastructure methodology and many of the features of the automotive cyber security spectrum. Two of the primary automotive and DoD subsystems most relevant to Cyber Security threat and protection are the automotive connected vehicles analogous to the DoD Command, Control, Communications, Computers
ABSTRACT This paper discusses how programs can leverage VICTORY architecture and specifications in order to achieve interoperability between electronics systems integrated with ground vehicles. It explains the contents of the VICTORY architecture, and the concept of compliance with the VICTORY system and component type specifications. It suggests a model for Army ground vehicle programs to utilize the VICTORY architecture and specifications, and a process called guided self-verification to test components for compliance with VICTORY specifications
ABSTRACT Modern electronic control units (ECUs) typically contain many physically based models represented by a complex structure of maps, curves and scalar parameters. The purpose of these models is to monitor or predict engine values that are normally measured by actual sensors. If the model structure is a good representation of the physical system and the parameters are well fitted, such a model can replace the sensor and serve as a virtual sensor to reduce the cost and complexity of the overall system. Virtual sensors are commonly used in the ECU for predicting engine torque, air pressure and flow, emissions, catalyst temperature, and exhaust gas temperatures. To ensure an optimal prediction quality of these models, their parameters need to be calibrated using real measurement data collected, e.g., in the vehicle or in the test cell. Due to the models’ complexity and the high number of parameters, a manual calibration is very time consuming or even impossible. Instead, iterative
ABSTRACT Autonomous robots can maneuver into dangerous situations without endangering Soldiers. The Soldier tasked with the supervision of a route clearing robot vehicle must be located beyond the physical effect of an exploding IED but close enough to understand the environment in which the robot is operating. Additionally, mission duration requirements discourage the use of low level, fatigue inducing, teleoperation. Techniques are needed to reduce the Soldier’s mental stress in this demanding situation, as well as to blend the high level reasoning of a remote human supervisor with the local autonomous capability of a robot to provide effective, long term mission performance. GDRS has developed an advanced supervised autonomy version of its Robotics Kit (GDRK) under the Robotic Mounted Detection System (RMDS) program that provides a cost effective, high-utility automation solution that overcomes the limitations and burden of a purely teleoperated system. GDRK is a modular robotic
ABSTRACT Situations exist that require the ability to preposition a basic level of energy infrastructure. Exploring and developing the arctic’s oil potential, providing power to areas damaged by natural or man-made disasters, and deploying forward operating bases are some examples. This project will develop and create a proof-of-concept electric power prepositioning system using small autonomous swarm robots each containing a power electronic building block. Given a high-level power delivery requirement, the robots will self-organize and physically link with each other to connect power sources to storage and end loads. Each robot mobile agent will need to determine both its positioning and energy conversion strategy that will deliver energy generated at one voltage and frequency to an end load requiring a different voltage and frequency. Although small-scale robots will be used to develop the negotiation strategies, scalability to existing, large-scale robotic vehicles will be
ABSTRACT The paper presents the EMX Hybrid Electric Cross Drive transmission developed by Kinetics Drive Solutions to satisfy RCV as well as conventional tracked vehicle requirements. Key design characteristics are modularity to enable performance customization, scalability to suit various vehicle weight classes, and flexibility to adapt to latest advancements in electric motor/inverter technology and autonomous control. EMX1000 prototypes have been built and are currently undergoing testing on dyno as well as in vehicle. Future development includes refining the prototype design and scaling the design for a heavier weight class. Citation: Caldarella F., Johnson A., Wright G., Scheper R., “Development of a Modular and Scalable Hybrid Electric Cross Drive Transmission,” In Proceedings of the Ground Vehicle Systems Engineering and Technology Symposium (GVSETS), NDIA, Novi, MI, Aug. 16-18, 2022
ABSTRACT In this paper, I will describe what AUTOSAR is, and the benefits it can provide in the development of ECUs. AUTOSAR provides an industry standard framework for the development of modular software architectures, including multi-core, cyber-secure, safety critical applications in the automotive/ground vehicle systems
ABSTRACT The modern battlefield demands a high degree of electronic capability for both on board processing and off board command and control. The trend for additional electronic systems on board combat vehicles continues to increase at a geometric rate. Battlefield demands and operational scenarios have resulted in a greater need for, advanced sensor technology, increased processing power, greater connectivity and systems interoperability (VICTORY). The integration of these advanced sensors with communications place a large bandwidth and power demand on the vehicle infrastructure. This paper will identify an advanced vehicle electronic architecture enabled by the latest high density processing technologies. An architecture has been developed and is under continued investigation at GDLS. The architecture includes deterministic network technology for spatial and temporal coherence of the sensor data. It provides a mission capability that is crew centric for any function at any crew
ABSTRACT A method for the evaluation of military hybrid electric vehicle thermal management systems has been developed. The approach allows for the generation of a set of evaluation metrics for determination of the effectiveness of existing systems and the means to assess alternative concepts and advanced approaches. Further, through the use of a set of deterministic performance metrics the methodology allows for evaluation of performance margins for adverse boundary conditions and system operations. The thermal management systems of military hybrid electric vehicles can face challenging performance goals under the burden of unfavorable operating conditions. The cooling requirements of engines, motors, and power electronics impose specific requirements on thermal management system performance in terms of threshold temperatures and heat rejection capability. In addition, vehicle packaging concerns impose restrictions in terms of both volumetric occupancy and system weight
ABSTRACT Silicon carbide (SiC) semiconductor devices offer several advantages to power converter design when compared with silicon (Si). An increase in power density can be achieved with SiC thanks to the reduced conduction and switching losses and to the ability to withstand higher temperatures [1]. The main system level benefits of using SiC devices on mobile hybrid power systems include large reductions in the size, weight, and cooling of the power conditioning. In this paper, the authors describe the Wide-bandgap-enabled Advanced Versatile Energy System (WAVES) with a focus on the design and testing of a SiC prototype of a WAVES power inverter. The prototype is a 10 kW three-phase AC/DC inverter that is air-cooled, IP-67 rated, bi-directional, operates down to a power factor of 0.4, and designed to have overload capability up to 350% for up to 250µs of nominal rating. Because the inverter is bidirectional, it may be used as an AC input to DC output battery charger or as a DC input
ABSTRACT Problem: The traditional four (4) methods for improving reliability; 1) High design safety margin, 2) Reduction in component count or system architectural complexity, 3) Redundancy, and 4) Back-up capability, are often ignored or perceived as being excessively costly in weight, space claim as well as money. Solution 1: Discussed here are the practical and very cost effective methods for achieving improved reliability by Functional Interface Stress Hardening (FISHtm or FISHingtm). The Author has been able to apply FISH to eliminate 70-92% of unscheduled equipment downtime, within 30-60 days, for more than 30 of the Fortune 500 and many other large companies which utilize automation controls, computers, power electronics and hydraulic control systems. Solution 2: From Structured Innovation the 33 DFR Methods & R-TRIZ Tool can be used to grow or improve reliability, via rapid innovation. The R-TRIZ tool) is provided so that users can instantly select the best 2, 3 or 4 of these
ABSTRACT Future Military ground vehicle power trains can benefit from a hybrid-electric drive approach, particularly in packaging flexibility where drive train components can be modular and conveniently distributed. Small component size and operation with high-temperature liquid coolant are essential factors in the flexible packaging concept. This paper describes the development of one component, a 220 kW traction motor drive for a hybrid-electric power train. Challenging requirements for the motor-drive include power densities of at least 25 kW/liter and 15 kW/kg at 105°C coolant temperature. To achieve these densities, power modules capable of high-temperature operation were developed using SiC normally-off JFETs. This paper will discuss the unique custom packaging of the SiC JFET devices, as well as the arrangement of key components/packaging and thermal management issues
ABSTRACT Modern vehicular systems are comprised of numerous electronics control units (ECUs) that consist of thousands of microelectronics components. Individual ECU systems are reliant upon “trust” in the supply chain for defense. This paper describes an approach utilizing historically offensive-based cybersecurity technology, side-channels, to quantify and qualify malicious ECU states in a bus-agnostic, logically-decoupled method of assurance and verification. Providing a measure of supply chain assurance to end-users. Citation: Yale Empie, Matthew Bayer, “Assurance and Verification of Vehicular Microelectronic Systems (AV2MS): Supply Chain Assurance through Utilization of Side Channel Radio Frequency Emissions for Improved Ground Vehicle Cybersecurity,” In Proceedings of the Ground Vehicle Systems Engineering and Technology Symposium (GVSETS), NDIA, Novi, MI, Aug. 16-18, 2022
ABSTRACT Modern ground vehicles rely on Controller Area Network (CAN) bus for communication between Electronic Control Units (ECUs) as a vital component to connect sensors and actuators together in a mission-critical distributed real-time vehicle control system. CAN is well-suited to this task and over the more than three decades since its inception it has become a proven and ubiquitous technology. But its age means that it was not designed for modern security threats of local and remote attacks and special techniques must be deployed to protect CAN. This paper provides a simple taxonomy of attacks on CAN, including how an attack accesses a CAN bus, and discusses four techniques used to defend against these attacks. Citation: K Tindell, “Defending In-vehicle CAN Buses From Attacks,” In Proceedings of the Ground Vehicle Systems Engineering and Technology Symposium (GVSETS), NDIA, Novi, MI, Aug. 16-18, 2022
ABSTRACT Embedded systems are becoming increasingly complex and more distributed. Cost and quality requirements necessitate reuse of the functional software components for multiple deployment architectures. An important step is the allocation of software components to hardware. During this process the differences between the hardware and application software architectures must be reconciled. In this paper we discuss an architecture driven approach involving model-based techniques to resolve these differences and integrate hardware and software components. The system architecture serves as the underpinning based on which distributed real-time components can be generated. Generation of various embedded system architectures using the same functional architecture is discussed. The approach leverages the following technologies – IME (Integrated Modeling Environment), the SAE AADL (Architecture Analysis and Design Language), and Ocarina. The approach is illustrated using the electronic
ABSTRACT Due to the high complexity of modern internal combustion engines and powertrain systems, the proper calibration of the electronic control unit’s (ECU) parameters has a strong impact on project targets like fuel consumption, emissions and drivability, as well as development costs and project duration. Simulation methods representing the system behavior with a model can support the calibration process considerably. However, standard physics-based models are often not able to describe all effects with sufficient accuracy, or the effort to set up a detailed model is too high. Physics-based models can also have a high computational demand, so that their simulation is not real-time capable. More suited for ECU calibration are data-driven models, combined with Design of Experiment (DoE). The system to be calibrated is identified with few specific test bench or vehicle measurements. From these measurements, a mathematical regression model is built. This paper describes recently
ABSTRACT Future wheeled and tracked military vehicles will be equipped with multiple active chassis control systems, as systems currently in widespread use on passenger and commercial vehicles such as brake-based electronic stability control are implemented on military vehicles. It is essential that these systems work in an integrated fashion to avoid negative interactions between systems. The approach currently used to achieve integrated control in the passenger and commercial vehicle segments requires extensive tuning and development of the individual systems through cooperative efforts of the vehicle and active chassis system manufacturers, an approach that would generally not be feasible in the military vehicle segment. This paper presents a simple approach for achieving integrated control of multiple active chassis systems that is tailored to the unique commercial and developmental challenges faced by military vehicles
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