Browse Topic: Electric power

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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
Opposed-piston free-piston engine generators (OFPEGs) are emerging as a promising technology for next-generation hybrid and electrified transportation systems due to their high efficiency, reduced mechanical complexity, and improved noise, vibration, and harshness (NVH) characteristics. However, due to eliminating the conventional crankshaft mechanism and directly coupling a free-piston engine with linear generators, performance of OFPEG systems is governed by a strong coupling between piston dynamics, in-cylinder combustion processes, and electrical loading conditions. This coupling presents substantial challenges for system design, control, and optimization, limiting the further development and application of OFPEGs. Existing researches lack a comprehensive numerical model that integrates detailed in-cylinder thermodynamic process with control system of linear generator, and quantitative analysis of the effect of piston motion trajectory on system performance remains insufficiently explored. In this study, a novel one-dimensional OFPEG model is developed in Gasdyn and coupled with a linear motor model and a control strategy in MATLAB/Simulink, thus forming a complete numerical model for OFPEG. The model is validated against experimental measurements, demonstrating effective prediction of thermodynamic and dynamic performance with acceptable errors. Based on the validated model, the effects of varying piston motion trajectory on system performance are analyzed. Lower Rt and higher Ωcom and Ωexp are recommended for higher performance. When Rt is reduced to 2.5:1, thermal efficiency and indicated power improve to 36.3% and 3.4 kW, respectively. When Ωcom is increased to 0.6, thermal efficiency and indicated power improve to 35.5% and 3.22 kW, respectively. When Ωexp is increased to 0.6, thermal efficiency and indicated power improve to 36.0% and 3.41 kW, respectively. These improvements are primarily attributed to reduced heat transfer losses and enhanced scavenging efficiency under the modified trajectories. The results provide valuable insights into the optimization of piston motion trajectory to achieve higher performance. Furthermore, the proposed numerical model provides an effective tool for OFPEG design, optimization, and control strategy development, supporting the advancement of high-efficiency, low-carbon OFPEG systems for future transportation applications.
Wang, JiayuMorandi, NicolaLucchini, TommasoFENG, HUIHUAJia, BoruRen, Peirong
SAE JA6097 (“Using a System Reliability Model to Optimize Maintenance”) shows how to determine which maintenance to perform on a system when that system requires corrective maintenance to achieve the lowest long-term operating cost. While this document may focus on applications to Jet Engines and Aircraft, this methodology could be applied to nearly any type of system. However, it would be most effective for systems that are tightly integrated, where a failure in any part of the system causes the entire system to go off-line, and the process of accessing a failed component can require additional maintenance on other unrelated components.
HM-1 Integrated Vehicle Health Management Committee
The present work focuses on the sizing and analysis of a parallel hybrid propulsion architecture for a conventional rotary light Unmanned Aerial Vehicle (UAV) in the 200kg class. First, the design methodology is outlined, with an emphasis on the optimization of the battery pack, which is one of the most crucial component of the whole powertrain. The sizing approach is applied to a wide range of thermal and electric power ratios, as well as two distinct hybridization strategies, to investigate the broad design space and discover possible sweet spots. For this aim, the various design points are then evaluated in terms of impact on aircraft capabilities, considering both extensive and intensive performance. Hence, the results provide the main advantages and disadvantages, performance wise, of the hybrid propulsion in comparison to a conventional full thermal solution.
Rovera, EugenioCorno, MatteoTrivella, AndreaBonini, ValerioNesci, Andrea
Hydrogen fuel cell powered vehicles for heavy duty trucking are a promising path for reducing future vehicle emissions due to their reduced mass for storage and faster refueling compared to battery electric trucks. These benefits come at the cost of increased system complexity stemming from the fact that fuel cells generate electricity through a chemical reaction which must be tightly controlled. The air handling system delivers the proper amount of air (oxygen) to react with fuel (hydrogen) in the fuel cell to produce power. Air delivery requires significant power and is the largest parasitic loss for a 300 kW fuel cell. Today’s systems use an electric motor driving an air compressor to supply pressurized air to the fuel cell stack. By operating at elevated pressure levels, fuel cells can achieve higher power density, which is important for vehicle powertrains. In addition to parasitic power loss, hydrogen fuel cell systems often have reliability issues associated with the air handling system. Reliability is of significant concern for heavy duty applications (especially long-haul applications). This project aims to improve both the electrical power consumption and reliability of hydrogen fuel cell air handling systems to meet the needs of heavy duty on-highway vehicle applications. The air handling is provided by a twin vortices series (TVS) compressor in addition to adding a TVS expander to recover waste heat energy back into the compressor. The final configuration includes a 600 V, 39 kW motor connected with a single shaft to the compressor and expander. This configuration reduced the total electrical power consumption from 48.6 kW to 37 kW at full load, 13.1 kW to 9 kW at half load and 0.44 kW to 0.22 kW at idle. The response time requirement was to be less than 2 sec while the final demonstration yielded 0.62 sec. Additional design changes, including water dosing into the compressor, addition of a recuperator, and elimination of the intercooler, were made to increase the energy efficiency of the air system.
Reich, EvanSwartzlander, MatthewWine, JonathanMcCarthy, Jr., JamesMiller, EricAkhtar, SaadReddy, SharanLawy, TJ
As the demand for electrical power has surged over recent years due to the increasing popularity of data centers for Artificial Intelligence (AI) and Electric Vehicles (EVs), it is becoming evident that the aging electrical grid infrastructure is struggling to keep up. Some of the problems this aging infrastructure has resulted in include frequent blackouts due to weather related events, reduced efficiency resulting in higher maintenance costs and outdated communication systems causing poor monitoring and response times. Modernization of the grid in conjunction with integration of the transportation sector with the grid is essential to ensure the reliability and resiliency of the grid. Electric vehicles have dramatically increased in popularity, with most vehicle manufacturers offering at least one electric option in their lineups. Looking at recent developments in vehicle-to-grid (V2G) technology, a new possibility becomes evident; instead of straining the power grid, the electric vehicle can synergize with it. This becomes possible when EVs can facilitate charging during off-peak (low demand) hours and supplying power back to the grid during on-peak (high demand) hours. There are quite a few challenges associated with this approach, lack of standardized charging infrastructure and higher install costs, regulatory and policy hurdles, gaps in technological know-how particularly in relation to impact of power supplied by EVs on grid and effect of V2G on EV battery degradation in the long run, to name a few. This paper reviews the current power demand and supply along with existing and projected power consumption metrics. We also discuss the V2G strategy to effectively manage load requirements, incentives that can be provided to facilitate the execution, and the challenges associated with its widespread implementation. Finally, we discuss case studies of vehicles that incorporate V2G capability and their implications.
Dahlmann, Alexander DrakeLele, Sneha
This work investigates the impact of the forthcoming 2026 FIA Formula 1 power unit regulations on vehicle track performance. This new regulation introduces a rebalanced power distribution between the internal combustion engine and the Motor Generator Unit-Kinetic (MGU-K), with each unit contributing up to 350 kW. This transition nearly triples the previous 120 kW output of the MGU-K while constraining the internal combustion engine through newly imposed fuel energy limits. A full vehicle powertrain model was developed in GT-Suite following the 2026 FIA technical directives. Particular attention was given to Articles 5.4.7 to 5.4.10, which define key constraints on hybrid operation: a maximum variation of 4 MJ in battery state of charge, up to 9 MJ of recoverable energy per lap, and a peak MGU-K electrical power output of 350 kW. The model includes updated architecture specifications, active aerodynamic modules, energy deployment logic, and component-level constraints. Telemetry data from the 2024-2025 qualifying sessions was employed for model development, validation, and benchmarking, enabling performance comparisons under realistic track conditions. Analysis results reveal notable deviations in powertrain response and vehicle performance across a range of circuits, establishing a correlation between the powertrain performance and track layouts. The model enables the decomposition of overall system effects into discrete contributions from specific regulatory requirements and individual component limitations. This paper will propose a justification and scheme for developing circuit-specific strategies based on maximum energy constraint and vehicle performance.
Giaquinta Aitala, LucioSamuel, Stephen
Off-road vehicles are typically powered by diesel engines, sized to cover the highest peak loads in their dutycycles. Such applications can be designed with downsized engines, using hybridization to supplement engine power with electrical power for short periods. However, many applications are low-volume and specialized, making it impractical to deploy heavy engineering resources to optimize each one. For this reason, manufacturers tend to produce maid-of-all-work vehicles to cover every situation. This paper demonstrates the benefits of custom hybridization for specialist applications, and addresses the lack of accessible software tools for evaluating such opportunities. Analysis is applied with a fast, low-cost, Concept-based software tool named “ePOP Concept”, suited to original equipment manufacturers (OEMs) who seek to provide custom low-volume vehicles. It allows many different powertrain architectures to be evaluated rapidly at the product planning stage, and can be quickly set up and used by non-specialists in simulation. Agricultural load cases are analyzed, showing the benefits of adding hybridization through electric motors and stored energy, supplementing engine power for demand peaks to enable engine downsizing. Use cases for four Fendt diesel tractors were taken from a dataset generated by Götz et al, at the agricultural facilities of the Technical University of Munich, which has been made publicly available by the authors to address the absence of standard load cycle data for the analysis of tractor electrification. The results show benefits for a customizable hybridization architecture to accommodate specific use cases, and the benefits of quick, accessible analysis methods for small engineering teams, to support early product decisions and what-if analyses.
De Salis, RupertFons, Daniel
The lifetime and aging of the high voltage battery is one of the major discussion points for the end-customer to decide between buying a car with an electric powertrain or still using a conventional powertrain. Therefore, the provision of adequate vehicles to the end-customer, the aging of the high voltage battery become an important topic for the complete vehicle development. In addition, also legal regulations (e.g. EU7) will preset minimum requirements for the warranty of the high voltage battery. These circumstances define the lifetime / aging of the HV battery to be a complete vehicle development target, which needs to be developed. The paper will present a method for the development process of a lifetime target from complete vehicle perspective. The method is based on the generation of a representative monthly power profile and temperature profile. Depending on a monthly user routine, ambient temperature profile and charging behavior, the vehicle specific battery power profile will be generated using energy flow simulation. In addition, the simulation of the HV battery SoC and temperature is included, too. Second, using a generic battery cell aging model, the impact on the state of health will be estimated using the power and temperature profile for the lifetime of the battery. The aging behavior over lifetime of the HV battery can be estimated. Using the tools, several sensitivity studies have been performed (e.g. impact on charging behavior, ambient temperature, vehicle operating strategy) to understand the main impacts on battery aging. The simulation tool as well as the results of the sensitivity analysis will be presented in the paper.
Martin, Michael
This SAE Aerospace Information Report (AIR) is intended to cover all airport 50 or 60 Hz electrical systems as well as all electrical utilization equipment that is attached to those systems.
AGE-3 Aircraft Ground Support Equipment Committee
Propeller driven rotors utilize propellers on the main rotor blade to spin the rotor. Past research efforts have highlighted dynamic issues that arise from the rotor-propeller Coriolis interaction. For this paper, a comprehensive multi-body analysis methodology, called Elastic Rotorcraft Analysis (ERA), was applied to various propeller driven rotor datasets. The focus of the modeling effort was on propeller driven rotor twirl phenomenon, which arises from rotor-propeller inertial couplings interacting with rotor blade modes. After describing the phenomenon, the paper is split into two parts: validations and predictions. In Part I of the paper, the ERA propeller driven rotor model was validated using three datasets: (i) a propeller flapping vacuum chamber experiment, (ii) a propeller/rotor loads vacuum chamber experiment, and (iii) a propeller driven rotor hover experiment. The ERA model showed good agreement with the data, and captured the important rotor-propeller Coriolis interaction. In Part II of the paper, predictions for several propeller driven rotor configurations were generated and analyzed. Loads were computed for an isolated propeller and are compared to propeller loads during propeller driven rotor operation. The analysis showed that operating the propeller on the rotor blade introduces significant inertial loads on the propeller. Finally, propeller placement along the main rotor blade span was investigated. The results of the present study agree with earlier research, which showed placing the propeller at the midspan location reduced the electrical power coefficient by nearly half compared to a tip mounted propeller.
Brown, RobertGul, SeyhanChopra, Inderjit
In response to the significant environmental challenges posed by climate change driven by global warming, the automotive industry is accelerating the transition toward electrification. While electric vehicles offer considerable potential for mitigating CO₂ emissions, their elevated upfront costs pose a notable challenge to large-scale market penetration. Energy efficiency improvement of electric vehicles is emerging field of research to reduce total cost of ownership. Electric vehicle powertrain component selection in small commercial vehicles including three and four wheelers is a complex process which has to fulfil multiple requirements which includes range, performance, drivability, packaging, total cost of ownership of vehicle and comfort. In addition, powertrain configuration including battery, motor and transmission ratio selection plays a fundamental role in cost of electric vehicle. Hence, The task of selecting the right powertrain configuration, encompassing architecture, motor selection, and gear ratio, is a critical challenge in optimizing overall vehicle performance while addressing the constraints and objectives of conventional vehicles. This study focuses on benefits of two speed transmission ratio for small commercial electric vehicle segment. The automotive market in India is analysed and the small commercial vehicle segment selected to define powertrain configuration. "The principle is grounded in the requirements for vehicle performance, design, cost, and efficiency, each of which must be carefully balanced to achieve optimal outcomes. The simulation are done to estimate motor torque/power requirements & overall gear ratios meeting the vehicle target and constraints. Based on the analysis, a comparative matrix consisting of various parameters for small commercial vehicle (SCV) application is established. The analysed results and established comparative matrix conclude that: 1 Small commercial vehicles necessitate an E-Drive system with high torque capability at low speeds, requiring deeper gear ratios, a lower maximum system speed, and overall reduced costs. For equivalent power ratings, motors with higher peak torque tend to be more expensive than those used in passenger vehicles, which typically employ motors with lower peak torque. 2 Two speed transmission, first gear increases gradeability performance by more than 40% with same motor and second gear allows motor to work in higher efficiency zone results up to 5% EV Range improvement 3 This approach allows to reduce the peak motor power/torque by 20-30% due to 2 speed gearbox, this is huge cost reduction solution with modularity. 4 The two-speed gearbox helps the motor operate more efficiently, which slightly reduces the electrical power needed from the battery. This leads to lower average battery current and less heating, which can improve battery life and reliability. As a result, it may reduce the need for extra warranty coverage on the battery, which is one of the most expensive parts of an electric vehicle. Considering the significant volume of the electric three-wheeler (e3W) market, it would be prudent for OEMs to explore the adoption of a two-speed automatic gearbox as a standard offering for light commercial vehicles (LCVs), especially if they have previously overlooked this rapidly growing sector.
Wani, KalpeshJadhav, VaibhavShendge, RamanWarule, Prasad
Requirement for Construction Equipment Vehicles (CEVs) in India is continuously growing as India being fastest growing country in the world in terms of Infrastructure. The technology in the automotive industry is evolving rapidly in recent times. Thus, with the development of new technologies, the challenges are also ever-increasing from an Electromagnetic Interference, Susceptibility (EMI/EMC) and Safety perspective. Recently CEVs include various types of machines including Compactor, Wheel Loader, Crane, Paver, Truck Crane, Cement Mixer etc. EMC requirements of all these types are internationally governed by ISO 13766-1, 2. This paper provides insights about various considerations to be taken during EMC Tests of each type of machines. It also includes guidelines related to antenna positioning, reference point calculations, Narrow Band and Broad band considerations. It will also provide general EMC guidelines and precautions related to component selection and placement along with typical EMC Failures and its remedies. Considering CMVR requirement in India, AIS 160 (for Diesel Engine CEVs) & AIS 174 (for Electric Power Train CEVs) is already notified and above research will certainly help OEMs to mitigate their EMC problems at early stage and will smoothen their development cycle.
Yeola, MayurShinde, Avinash
Toyota's big claim for its new sixth-generation 2026 RAV4 is that the SUV is now“ 100% electrified.” That's true, as Obi-wan once said, from a certain point of view. As it recently did with the Camry, the automaker has eliminated an ICE-only powertrain from the list of options, giving drivers the choice between a gas-electric hybrid or a plug-in hybrid (PHEV). The hybrids use Toyota's fifth-generation hybrid system, which uses a 2.5-L 4-cylinder aluminum Atkinson cycle engine that produces 163 lb-ft and up to 226 hp (169 kW) in FWD configuration, 236 hp (176 kW) in AWD. Seven trim levels - LE, XLE Premium (which Toyota expects to be the volume trim), Limited, SE, XSE and Woodland - can be had with the hybrid powertrain, while the driving-focused GR Sport version can only be had as a PHEV. The plug-in option is available on the SE, XSE and Woodland. These new RAV4s use Toyota's sixth-generation PHEV system, which produces 324 hp (242 kW) and up to 172 lb-ft So, yes, the entire line-up is electric, but most are also gas-powered.
Blanco, Sebastian
Leonardo DRS Arlington, VA mmount@drs.com
The growing demand for improved fuel efficiency and reduced emissions in diesel engines has led to significant advancements in power management technologies. This paper presents a dual-mode functional strategy that integrates electrified turbochargers to enhance engine performance, provide boost and generate electrical power. This helps in optimizing the overall engine efficiency. The engine performance is enhanced with boosting mode where the electric motor accelerates the turbocharger independent of exhaust flow, effectively reducing turbo lag and provides immediate boost at low engine speeds. This feature also improves high altitude performance of the engine. Conversely, in generating mode, the electric turbocharger recovers or harvest energy from exhaust gases depending on engine operating conditions, converting it into electrical energy for battery recharging purpose. Advanced control systems enable real-time adjustments to boost pressure and airflow in response to dynamic driving conditions, maximizing engine efficiency. Simulation studies and engine testing validate the expected benefits, demonstrating that the electrified turbocharger can significantly facilitate engine downsizing, reduce fuel consumption, and lower emissions through precise power management. These advancements align with global sustainability goals, presenting a viable solution to meet stringent environmental regulations while maintaining robust engine performance. The integration of electrified turbochargers represents a critical step towards the next generation of eco-friendly diesel engines, supporting both environmental sustainability and economic efficiency.
Borle, ShraddhaPrasad, LakshmiCouvret, SebastienFournier, HugoChenuet, Laurent
Requirement for Construction Equipment Vehicles (CEVs) in India is continuously growing due to India’s focus on infrastructure development. Technology in the automotive industry has evolved rapidly in recent times and it is also adding new dimensions to the compliance to Electromagnetic Interference, Susceptibility (EMI/EMC) and Safety. EMC and Safety requirements of CEVs are internationally governed by ISO 13766, Part 1 & Part 2. This paper discusses the significance of each aspect specified in these standards and its applicability. Due to nature of work carried out by construction equipment, there is absolutely no scope for compromise on safety for the same. Although Construction equipment standards are based on automotive standards, there are few additional tests which are part of ISO 13766, Part 1 and 2. This paper explains each aspect with practical case study. It also provides general EMC guidelines and precautions to be followed during design validation and product validation. It also provides information on basic “thumb-rules” related to component selection, placement, shielding, grounding, etc. Considering current CMVR requirement in India, AIS 160 (for ICE CEVs) & AIS 174 (for Electric Power Train CEVs) are already published and this paper can help OEMs to mitigate their EMC problems at early stage and to shorten their development cycle.
Yeola, MayurNigade, MaheshMulay, Abhijit B
The electric power of most electric two-wheelers on the market ranges between 2 and 12 kW. For this power range, the traction voltage level is mostly between 48V and 96V. There appears to be no strong correlation between electric power and traction voltage, suggesting that the current voltage choice is rather arbitrary. This paper briefly describes the e-motor model used in this study and introduces variations of four design parameters: DC voltage, maximum phase current, e-motor active length, and the number of turns in the e-motor winding. The consequences of these variations on peak performance, continuous performance, and efficiency maps are presented. Specific cases of parameter combinations are also studied. Two e-motors designed for 48V and 96V systems will be compared, showing that size, cost, and performance (power and losses) are equivalent. Additionally, the paper discusses how increasing the maximum phase current rating of the inverter can improve e-motor power in a 48V system. Downsizing the e-motor by using more phase current is also explored, with its impact on continuous performance and efficiency. The paper concludes that for most electric two-wheelers below 12 kW, a traction voltage higher than 48V does not offer significant advantages.
Albert, Laurent
A new bioimaging device can operate with significantly lower power and in an entirely non-mechanical way. It could one day improve detecting eye and even heart conditions. The device uses a process called electrowetting to change the surface shape of a liquid to perform optical functions. By creating a device that doesn’t use scanning mirrors, the technique requires less electrical power than other devices used for OCT and bioimaging. To test the device’s ability to perform biomedical imaging, the researchers turned to zebrafish. The researchers focused on identifying where the cornea, iris, and retina was from the zebrafish. The two benchmarks that the group hoped to achieve were 10 μm in axial resolution and then around 5 μm in lateral resolution.
The publishing of MIL-STD-3072 is critical to the Army’s introduction of electrified vehicles. It is the first of three documents to replace MIL-PRF-GCS600A, a performance specification that is loosely referenced by engineers but lacks necessary details. MIL-STD-3072 defines the characteristics of 600 VDC electric power that will be supplied to utilization equipment. Following this release, MIL-HDBK-3072 will provide suggested test methods for compliance with the standard, and MIL-PRF-3072 will provide generic device specifications for interfaces, control, and safety. Together, these three documents define a set of requirements that vehicles and equipment with 600 VDC electrical systems must operate within.
Haynes, AricSpina, JasonBest, Melissa
In recent years, the powertrains of agricultural tractors have been transitioning toward hybrid electric configurations, paving the way for a greener future agricultural machinery. However, stability challenges arise in hybrid electric tractors due to the relative small capacity to perform power-intensive tasks, such as plowing and harvesting. These operations demand significant power, which are supplied by the electric power take-off system. The substantial disturbances introduced by the electric power take-off system during these tasks render conventional small-signal analysis methods inadequate for ensuring system stability. In this article, we first develop a large-signal model of the onboard power electronic systems, which includes components such as the diesel engine–generator set, batteries, in-wheel motors, and electric power take-off system. By employing mixed potential theory, we conduct a thorough analysis of this model and derive a stability criterion for the onboard power electronic systems under large disturbance conditions. Using this criterion, we estimate the stability boundaries of the onboard power electronic systems and evaluate the influence of various circuit parameters on its performance under large load fluctuations. Finally, case studies are presented to validate the proposed stability criterion and to demonstrate the impact of key circuit parameters on system stability.
Li, FangyuanLi, ChenhuiGao, LefeiMa, QichaoLiu, Yanhong
Large-bore spark-ignited engines equipped with individual cylinder injection systems require advanced balancing strategies to achieve optimal combustion performance and mitigate risks associated with abnormal combustion phenomena. The integration of highly reactive fuels, such as hydrogen, introduces additional challenges for high-power-density, low-speed engines. This study investigates closed-loop cylinder balancing strategies utilizing real-time cylinder pressure feedback to optimize engine operation. Key performance metrics were evaluated on a 20-cylinder medium speed stationary gas engine (8.5 MW electrical power) under eight different control strategies. The results indicate that the tested balancing methods reduce average knock intensity and variation of combustion peak pressure across all cylinders compared with original manufacturer control strategy. Furthermore, the study demonstrates that a well-balanced engine offers significant advantages, including enhanced power output, a 0.5% improvement in thermal efficiency, and a 20% reduction in NOx emissions. These findings highlight the critical role of cylinder pressure-based balancing algorithms in improving the performance, efficiency, and environmental sustainability of engines operating on natural gas and hydrogen blends. This research provides a unique experimental campaign with valuable insights into the development of next-generation combustion control systems in large-scale industrial and power generation applications.
Martelli, AndréPenaranda, AlexanderMartinez, SantiagoZabeu, ClaytonSalvador, Roberto
While electric powertrains are driving 48V adoption, OEMs are realizing that xEV and ICE vehicles can benefit from a shift away from 12-volt architectures. In every corner of the automotive power engineering world, there are discussions and debates over the merits of 48V power networks vs. legacy 12V power networks. The dialogue started over 20 years ago, but now the tone is more serious. It's not a case of everything old is new again, but the result of a growing appetite for more electrical power in vehicles. Today's vehicles - and the coming generations - require more power for their ADAS and other safety systems, infotainment systems and overall passenger comfort systems. To satisfy the growing demand for low-voltage power, it is necessary to boost the capacity of the low-voltage power network by two or three times that of the late 20th century. Delivering power is more efficient at a higher voltage, and today, 48V is the consensus voltage for that higher level.
Green, Greg
PEM fuel cell technology plays a vital role in realizing an emission-free mobility and, depending on the considered use case, offers significant advantages over battery electric solutions as well as hydrogen combustion engines. When high performance over a longer period of time as well as short refueling times are key requirements, fuel cell powertrains show their core strengths. However, the adaption of fuel cells in the mobility sector strongly depends on their efficiency which directly relates to the vehicle’s fuel consumption, range and ultimately cost to operate. Therefore, the influence on efficiency and power of different purge strategies used to operate PEM fuel cells is experimentally investigated and compared. A concentration-dependent purge strategy is developed and examined in reference to a charge-dependent strategy. The measurements are carried out on a fuel cell system test bench which corresponds to a fully functional fuel cell system including all commonly used peripheral components. In the range investigated, both purge strategies show similar values regarding the analyzed utilization coefficients and power. However, for the maximum fuel cell current examined, the concentration-dependent purge strategy achieved slightly higher utilization coefficients while showing a minimally lower power output. Taking this into account, further research regarding the optimization of concentration-dependent purge strategies appears promising. For the time being, the decision between using a charge-dependent or a concentration-dependent purge strategy foremost relies on the presence of a suitable hydrogen concentration sensor.
Hauser, TobiasAllmendinger, Frank
Researchers at the National Aeronautics and Space Administration (NASA) have conducted a series of module-level tests on electric Vertical Take-off and Landing (eVTOL) Energy Storage Systems (ESS) for the generation of dynamic impact data to support standards developments. The tests were conducted on zero-state-of-charge Electric Power Systems (EPS) Electric Propulsion Ion Core (EPIC) modules at the National Institute for Aviation Research (NIAR), utilizing the NIAR outdoor drop test setup and personnel. Four total tests were conducted. For each test, the module was dropped at a specific orientation from a height of 50 feet while connected to a guided trolley in order to assess the effects of a 50-foot drop test on the ESS. The test velocities ranged between 46.9 and 52.8 ft/s with impact angles ranging between a flat, zero-degree impact and 18 degrees. Data were recorded in the form of temperatures, cell-level voltage, module level acceleration and digital image correlation from the tests. Accelerations were in the range of 1,500 g for a few millisecond duration, which were indicative of a shock type loading condition. No modules entered thermal runaway, and post-test inspections revealed a variety of internal deformations and damage present in the various modules tested, with specific damage occurring for specific orientations. The modules were ranked according to a custom developed scoring rubric developed by utilizing the test and post-test inspection results. The results were compiled, reported, and will be used to guide future ESS testing. Part 1 discusses the loading environments in the modules, while Part 2 will discuss the deformation and damage in the modules.
Littell, JustinGardner, NathanielEllafrits, Shay
Researchers at the National Aeronautics and Space Administration (NASA) have conducted a series of module-level 50-ft dynamic drop tests on electric Vertical Take-off and Landing (eVTOL) Energy Storage Systems (ESS) for the generation of dynamic impact data to support standards developments. The tests were conducted on zero-state-of-charge Electric Power Systems (EPS) Electric Propulsion Ion Core (EPIC) modules at the National Institute for Aviation Research (NIAR), utilizing the NIAR outdoor drop test setup and conducted by NIAR test personnel. Four total tests were conducted on modules oriented in four different orientations. During initial post-test inspections at the drop facility, it was observed that the modules experienced varying amounts of damage in various locations and forms. The damage was quantified to the maximum extent possible via photogrammetric methods such as digital image correlation and marker tracking. Post-test modules were then disassembled, and forensics were conducted, which involved inspections into various containment structures and the cells themselves. A scoring rubric was developed in order to utilize a common methodology to quantitatively assess the damage incurred into each module as way of determining the least and most amount of damage present. Results in the form of post-test inspections, digital image correlation deformations, and scoring rubric values will be all presented, along with proposed paths forward for future work.
Ellafrits, ShayGardner, NathanielLittell, Justin
Aircraft Certification is a mature and complex bureaucracy that has successfully ensured a very high degree of safety of aircraft design, construction, operation and maintenance. Outside of a very few doing the work, there is a general lack of knowledge of certification details. For novel technologies such as electric power, and innovative configurations such as multi-rotors, the rules are far less mature and still emerging and so also poorly understood. Within the Advanced Air Mobility (AAM) initiative, many new aircraft developments are underway using novel configurations, and the public announcements of regulatory progress toward FAA or EASA Type Certification capitalize on this ignorance by being vague or even misleading. Honeywell conceived the Regulatory Readiness Level (RRL) indicator as an objective measure of certification status to serve the AAM industry and ecosystem, with applicability across aviation. The released RRL Version 1 now enables credible, objective assessment of new aircraft progress toward FAA Type Certification, and Operational Approval for Part 135 operations, to allow consistent apples-to-apples comparisons with other aircraft in development. An emerging complementary version of the rubric for EASA Type Certification is ready for publication to enable RRL determination against the European Union criteria. Future releases will consider other Nation's regulatory authorities, supplemental types certifications (STCs), and risk-based airworthiness assessments such as the Specific Operations Risk Assessments (SORA).
Agrawal, PulkitNewman, Daniel
In addition to providing safety advantages, sound and vibration are being utilized to enhance the driver experience in Battery Electric Vehicles (BEVs). There's growing interest and investment in using both interior and exterior sounds for pedestrian safety, driver awareness, and unique brand recognition. Several automakers are also using audio to simulate virtual gear shifting of automatic and manual transmissions in BEVs. According to several automotive industry articles and market research, the audio enhancements alone, without the vibration that drivers are accustomed to when operating combustion engine vehicles, are not sufficient to meet the engagement, excitement, and emotion that driving enthusiasts expect. In this paper, we introduce the use of new automotive, high-force, compact, light-weight circular force generators for providing the vibration element that is lacking in BEVs. The technology was developed originally for vibration reduction/control in aerospace applications, has been recently tested in various vehicles, and demonstrates the effectiveness for providing a real haptic feel across the entire vehicle. Shaking the vehicle globally provides a unique capability for BEVs, including Hybrid Electric Vehicles and for helping to create a smooth transition between Gas and Electric power, for example. The technology can be used to generate and emulate high-performance, high power, combustion engine feel, including idle, engine run-up/acceleration, simulated gear shifts, and Advanced Driving Assistance and Systems (ADAS) haptic indicators. The optional and customizable vibration can also mask road vibration which becomes very noticeable in otherwise smooth BEVs and can provide the perfect supplement to existing audio enhancements and gear shifting features. Additionally, the paper describes how the force generating device can be packaged in a light weight, compact, low-power manner. The technology will be compared to other force generating methods, and discuss its pros and cons.
Norris, Mark A.Orzechowski, JeffreySanderson, BradSwanson, DouglasVantimmeren, Andrew
Battery Electric Vehicles (BEVs) are extremely sensitive in terms of NVH requirements. While the engine is being replaced with an almost silent electric motor, the transmission noise appears persistent and demands more silent transmission. This has raised demand for improvement in design as well as manufacturing quality. Various innovations are being made to drive an improvement in the NVH. The following paper will discuss the improvement in NVH achieved through a design optimization of the housing using modal analysis. Firstly, the NVH results were co-related with the modal analysis and the cause for the dominant peak in amplitude of the NVH graph associated with the housing modes were mapped. A simple Excel based correlation matrix is used to map the list of all Eigenfrequencies of housing and its corresponding gear tooth frequency. Further optimization is done in housing design to defer the modal frequencies and another NVH test was run. It was proven that housing design optimization using modal analysis can solve NVH issues and improve the overall performance of the transmission. It was demonstrated that the electric vehicle NVH is not only critically dependent upon gear geometry and accuracy but also equally impacted by housing design. The best engineered housing design can enhance overall NVH performance of vehicles as well as customer satisfaction. Background Regulatory pressures on Internal Combustion Engines (ICEs), combined with technological advancements in electric power trains and batteries, lead to an increase in demand for electric vehicles. Both the traditional carmakers as well as new entrants without ICE legacies are developing and putting new EV models on the market. The dynamics and performance of vehicles have changed significantly because of the switch from ICE vehicles to BEVs. The change in NVH characteristics is among the most noticeable differences. Unlike ICEVs, which generate engine noise that can mask other sounds, BEVs are inherently quieter due to their electric powertrain. This stillness, however, creates special difficulties for NVH since previously muffled sounds- like sounds from the road, wind, and electric motor- become more prominent and may interfere with the driving experience.
Pingale, Abhijeet SatishDeshpande, Prasannakumar
In this study, vibration characteristics inside an electric power unit at gravity center where direct measurement is impossible were estimated by using virtual point transformation to consider guideline for effective countermeasures to the structure or generated force characteristics inside the power source. Vibration acceleration, transfer function and the generated force in operation at the gravity center of the electrical power source were obtained by vibration characteristics at around the power source which can be measured directly. In addition, the transfer functions from the gravity center to the power source attachment points on the product were also estimated. And then, the contribution from the gravity center to the power unit attachment point was obtained by multiplying generated force with the transfer function. As results, the obtained total contribution was almost same with the actual measured vibration at the attachment point. Furthermore, the rotational contribution from the gravity center was found to be larger than translational contribution at the attachment point vibration along front-back direction.
Kubo, RyomaHara, KentaYoshida, Junji
Increasing global pressure to reduce anthropogenic carbon emissions has inspired a transition from conventional petroleum-fueled internal combustion engines to alternative powertrains, including battery electric vehicles (EVs) and hybrids. Hybrids offer a promising solution for emissions reduction by addressing the limitations of pure EVs such as slow recharge and range anxiety. In a previous research endeavor, a prototype high-power density generator was meticulously designed, fabricated, and subjected to testing. This generator incorporated a compact permanent magnet brushless dynamo and a diminutive single-cylinder two-stroke engine with low-technology constructions. This prototype generated 8.5 kW of electrical power while maintaining a lightweight profile at 21 kg. This study investigates the performance and emissions reduction potential by adapting the prototype to operate on methanol fuel. Performance and emissions were experimentally evaluated under varying operating conditions. In addition, a comparative analysis between methanol fuel and conventional gasoline was performed. It was found that the generator operable on methanol achieved an overall increase in performance with a peak power output of 10 kW when compared to gasoline. In addition, the generator demonstrated significant reductions in carbon emissions. The goal of this research is to adapt and demonstrate the high-power density, low-emission electric power generator from previous work, which was suitable for applications such as, for example, range extenders and UAV propulsion, to use renewable fuel. This research showcases a potential direction for an electrical generator that offers reduced emissions in applications where specific power is critical.
Gore, MattNonavinakere Vinod, KaushikFang, Tiegang
Based on the harmonic current injection method used to suppress the torsional vibration of the electric drive system, the selection of the phase and amplitude of the harmonic current based on vibration and noise has been explored in this paper. Through the adoption of the active harmonic current injection method, additional torque fluctuations are generated by actively injecting harmonic currents of specific amplitudes and phases, and closed-loop control is carried out to counteract the torque fluctuations of the motor body. The selection of the magnitude of the injected harmonic current is crucial and plays a vital role in the reduction of torque ripple. Incorrect harmonic currents may not achieve the optimal torque ripple suppression effect or even increase the motor torque ripple. Since the actively injected harmonic current is used to counteract the torque ripple caused by the magnetic flux linkage harmonics of the motor body, the target harmonic current command is very important, and the phase and amplitude of the harmonic current are set according to the following method. The phase and amplitude of the 5th harmonic current need to be selected. The amplitude of the 5th harmonic current involved in this paper is all based on the amplitude of the fundamental current as the reference object, and the phase of the 5th harmonic current is all based on the phase of the fundamental current as the reference object. After incorporating the harmonic suppression control loop into the operational prototype, the harmonic content is conspicuously reduced, and the amplitude of the torque ripple is decreased by 50% while the average torque remains essentially unaltered. The improvement spans from 5 to 10 dB within the range from 1400 rpm to 1900 rpm, and from 1 to 5 dB within the range from 1000 rpm to 1250 rpm.
Jing, JunchaoZhang, JunzhiLiu, YiqiangHuang, WeishanDai, Zhengxing
Reducing emissions in individual transport requires electrification and hybridization. Emission reduction depends on the degree of electrification, the specific powertrain design and optimized components. This is especially true for hybrids with the highest number of components, consisting of combustion engine, transmission, electric motors and batteries. The integration of the electric motor in the transmission for dedicated hybrid transmissions leads to many possible concepts. Computer-aided powertrain synthesis is therefore needed to develop new powertrain architectures. In a publicly funded project, we have developed a powertrain synthesis that includes a combustion engine synthesis and a transmission synthesis. In this paper we focus on the impact of the engine concept on the powertrain dimensioning, fuel consumption, performance and operating behavior in a parallel hybrid configuration. In addition to different engine concepts, the electrical power is also varied to discuss the relationship between the electrical and engine power in the vehicle and its implications. Furthermore, the impact on the operating behavior to achieve the best fuel economy is discussed for the different powertrain systems, as well as the resulting most promising concept.
Sturm, AxelHenze, RomanKüçükay, FeritWolgast, CarstenEilts, Peter
Polymer Electrolyte Membrane Fuel Cells (PEMFCs) recently received a relevant interest as an electric power generation technology in Fuel Cells Electric Vehicles (FCEVs) to decarbonize hard-to-abate sectors as a complement to Battery Electric Vehicles (BEVs). However, the massive requirements of power and durability indicate the urgent need to develop higher-than-ever power density designs with minimum internal gradients to mitigate degradation, discarding sub-optimal designs since the early design stage. Starting from the outcomes of a first study, confirming that for industry-relevant PEMFCs the parallel channel flow field was the only archetype able to minimize jointly pressure losses and limiting super-saturation at high current density, still several degrees of freedom exist for the cell designer. In this study, the research of the optimal PEMFC design is fine-tuned using a CAE-guided design process. Candidate solutions are explored using an optimization software and solving for the coupled mass/heat/charges transport processes in PEMFCs. The study aims at identifying the designs maximizing the current density and/or the membrane water content. The investigated input variables are the width of the bipolar plate ribs and the thickness of the gas diffusion layers, evaluated independently at cathodic and anodic side. The methodology shown in this paper leverages the versatility of parametrized 3D-CAD models and of multi-dimensional 3D-CFD simulation and it is applied to an elementary cell unit, albeit being easily scalable to more complex geometries. Starting from a conventional baseline design, two optimized configurations are identified that maximize the current density under the same voltage (+10%) and the uniformity of the membrane water content (+13%), respectively, showing the entity of performance gain made possible by the wise use of optimization methods in the field of PEMFC engineering.
Rossi, EdoardoCroci, FedericoMartoccia, LorenzoCicalese, GiuseppeD'Adamo, Alessandro
Electrifying truck fleets has the potential to improve energy efficiency and reduce carbon emissions from the freight transportation sector. However, the range limitations and substantial capital costs with current battery technologies imposes constraints that challenge the overall cost feasibility of electrifying fleets for logistics companies. In this paper, we investigate the coupled routing and charge scheduling optimization of a delivery fleet serving a large urban area as one approach to discovering feasible pathways. To this end, we first build an improved energy consumption model for a Class 7-8 electric and diesel truck using a data-driven approach of generating energy consumption data from detailed powertrain simulations on numerous drive cycles. We then conduct several analyses on the impact of battery pack capacity, cost, and electricity prices on the amortized daily total cost of fleet electrification at different penetration levels, considering availability of fast charging at the depot. Findings indicate that at typical energy density of current battery technology, there is an optimal battery pack capacity that results from the contradicting effects of increasing pack capacity on cost, life span, weight and energy consumption. It is also observed that with currently improving trends in battery pack costs and availability of reduced electricity prices at the depot, such as with renewable microgrids, fleet electrification can become viable even at low levels of penetration.
Wendimagegnehu, Yared TadesseAyalew, BeshahIvanco, AndrejHailemichael, Habtamu
Sustainable aviation fuels are becoming more widely available for current and future engine powered propulsion systems. However, the diversity of ignition behavior in these fuels poses a challenge to achieving robust, efficient operation. Specifically, low cetane fuels with poor ignitability exhibit highly variable torque production unless fuel is injected earlier during compression. The tradeoff is that earlier injection may cause dangerously high in-cylinder pressure rise rates. Novel models that can simulate these competing behaviors are needed so that appropriate strategies may be developed for controlling combustion at low cetane fueling conditions. This work builds upon a previously developed model that simulates asymmetric combustion phasing (CA50) distributions as a function of fuel cetane, fuel injection timing, and electrical power supplied to an in-cylinder thermal ignition assist device. An extension of the model is presented in which the phasing output is used to reconstruct in-cylinder pressure traces, by which indicated mean effective pressure (IMEP) can then be simulated. Additionally, a functional form is parametrized for modeling maximum in-cylinder pressure rise rate (MPRR). The model’s parameters are regressed using a total 121,237 engine cycles of experimental data from a commercial CI engine operating with four fuel blends with cetane number ranging from 25 to 48. Relative to the data, the model simulates mean CA50 within a root mean square error (RMSE) of approximately 3 CAD over a range of 64 CAD, mean IMEP within an RMSE of 0.85 bar over a range of 5.8 bar, and mean MPRR within an RMSE of 6.1 bar/CAD over a range of 88 bar/CAD. Along with the mean-value trends, it accurately emulates the variability of all three combustion metrics. Ultimately, this work marks the first time a low-order, control-oriented model simulates statistical distributions of CA50, IMEP, and MPRR.
Ahmed, OmarMiddleton, RobertStefanopoulou, AnnaKim, KennethKweon, Chol-Bum
In the United States (US), the off-road sector (i.e., agriculture, construction, etc.) contributes to approximately 10% of the country’s transportation greenhouse gas (GHG) emissions, similar to the aviation sector. The off-road sector is extremely diverse; as the EPA MOVES model classifies it into 11 sub-sectors, which include 85 different types of equipment. These equipment types have horsepower ranging from 1 to greater than 3000 and have very different utilization, which makes decarbonization a complex endeavor. To address this, Argonne’s on-road vehicle fleet model, VISION, has been expanded to the off-road sector. The GHG emission factors for several energy carriers (biofuels, electricity, and hydrogen) have been incorporated from Argonne’s GREET model for a sector-wide well-to-wheel (WTW) GHG emissions analysis of the present and future fleet. Several technology adoption and energy decarbonization scenarios were modeled to better understand the appropriate actions required to drive towards net-zero emissions of the off-road sector. Results show that WTW decarbonization up to 67% can be achieved from 2023 to 2050 in a business-as-usual scenario. But with aggressive sales increases of electric and hydrogen powertrains, WTW decarbonization up to 77% can be achieved, which can further increase to 85% if electricity production is aggressively decarbonized by 2035.
Tripathi, ShashwatKolodziej, ChristopherGohlke, DavidBurnham, AndrewZhou, YanLongman, Douglas
As the first pure electric flagship sedan under the Geely Galaxy brand, a challenging aerodynamic target was set at the early stage of Geely Galaxy E8 for reducing electric power consumption and improving vehicle range. In response, the aerodynamic team formulated a detailed development plan and an overall drag reduction strategy. After conducting numerous loops of simulations and wind tunnel tests, along with continuous cross-disciplinary communication and collaboration, a product with outstanding aerodynamic performance was successfully developed. During the aerodynamic development of the E8, the primarily utilized steady-state simulations sometimes revealed significant discrepancies when compared to wind tunnel test results, particularly in schemes such as the air curtain, aerodynamic rims, and rear light feature optimizations. Some trends were even contradictory. Further investigations demonstrated that unsteady simulation methods captured different flow field information, indicating variations in flow separation regions and locations compared with steady method, which aligned more closely with the trends observed in wind tunnel tests. Therefore, employing transient analysis is recommended to enhance the accuracy of simulations and provide more reliable guidance for design optimization, especially in areas affected by flow separation, wheel rotation, and vehicle wake.
Li, QiangLiu, HuanYang, TianjunLiang, ChangqiuZhu, ZhenyingLiao, Huihong
This SAE Aerospace Standard (AS) establishes the minimum performance standards for equipment used as secondary alternating current (AC) electrical power sources in aerospace electric power systems.
AE-7B Power Management, Distribution and Storage
Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in materials that conduct electricity, irrespective of their level of hardness. With the rising demand for superior products and the necessity for quick design modifications, decision-making in the industrial sector becomes increasingly complex. This study specifically examines Titanium Grade 7 and suggests creating prediction models through regression analysis to estimate performance measurements in ECM. The experiments are formulated based on Taguchi's ideas, utilizing a multiple regression approach to deduce mathematical equations. The Taguchi method is utilized for single-objective optimization in order to determine the ideal combination of process parameters that will maximize the material removal rate. ANOVA is a statistical method used to determine the relevance of process factors that affect performance measures. The suggested prediction technique for Titanium Grade 7 exhibits superior flexibility, efficiency, and accuracy in comparison to current models, providing expanded monitoring capabilities. The validated models demonstrate a robust link between empirical data and projected results. This study investigates the potential uses of Titanium Grade 7 in the automotive industry, highlighting its importance in sectors that need strong materials for challenging conditions.
Natarajan, ManikandanPasupuleti, ThejasreeKumar, VKrishnamachary, PCSomsole, Lakshmi NarayanaSilambarasan, R
Electrochemical machining (ECM) is a remarkably effective technique for producing detailed designs in materials that can conduct electricity, regardless of their level of hardness. As the desire for high-quality products and the necessity for rapid design changes grow, decision-making in the industrial sector becomes increasingly intricate. This work focuses on Titanium Grade 19 and proposes the development of prediction models using regression analysis to estimate performance measurements in ECM. The experiments are designed using Taguchi's methodology, employing a multiple regression approach to produce mathematical equations. The Taguchi technique is utilized for the purpose of single-objective optimization in order to determine the optimal combination of process parameters that will optimize the rate at which material is removed. ANOVA is a statistical method used to assess the relevance of process factors that impact performance indicators. The suggested prediction technique for Titanium Grade 19 exhibits higher flexibility, efficiency, and accuracy in comparison to existing models, providing improved monitoring capabilities. The validated models demonstrate a robust link between empirical data and expected outcomes. This study investigates the possible uses of Titanium Grade 19 in the automotive sector, with a focus on its significance in industries that demand robust materials for demanding environments.
Pasupuleti, ThejasreeNatarajan, ManikandanRamesh Naik, MudeSilambarasan, RD, Palanisamy
The process of electrochemical machining, often known as ECM, is capable of effectively shaping complicated structures in materials that conduct electricity, independent of the materials' level of hardness hence especially used for automobile and aerospace applications. As a result of the demand for high-quality products and the desire for rapid design changes, the manner in which decisions are made in the manufacturing industry has become increasingly contentious. With the assistance of regression analysis, this study proposes the development of predictive models for the purpose of forecasting the performance measures in electrochemical machining of Nimonic alloy. The trials are designed in accordance with Taguchi's principles, and a multiple regression model is utilized in order to derive the mathematical equations. Taguchi's method can be applied as a methodology for single objective optimization in order to attain the most optimal combination of process parameters for the purpose of optimizing the rate at which material is removed. For the purpose of determining the importance of process factors that have an effect on the performance measures, analysis of variance (ANOVA) is utilized. When compared to the models that are now in use, the technique that has been provided for predicting the intended performance measures is not only more flexible, proficient, and exact, but it also provides enhanced monitoring capabilities. In the end, the revised models are then checked for accuracy. There is a good correlation between the experimental data and the expected outcomes, which are formed from the models that have been formulated.
Natarajan, ManikandanPasupuleti, ThejasreeSagaya Raj, GnanaSilambarasan, RKiruthika, Jothi
Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in materials that conduct electricity, independent of their level of hardness. With the growing demand for superior products and the increasing necessity for quick design modifications, decision-making in the manufacturing industry becomes increasingly complex. The primary objective of this work is to concentrate on Cupronickel and suggest the creation of predictive models through the utilization of a Taguchi-grey technique for the purpose of multi-objective optimization in ECM. The trials follow Taguchi’s principles and utilize a Taguchi-grey relational analysis (GRA) technique to maximize numerous performance indicators concurrently. This involves optimizing the pace at which material is removed while decreasing the roughness of the surface and obtaining precise geometric tolerances. ANOVA is a statistical method used to determine the importance of process factors that influence these measurements. The suggested predictive technique for Cupronickel is superior to existing models in terms of flexibility, efficiency, and accuracy, providing improved capabilities for monitoring and control. Furthermore, the study investigates the potential uses of Cupronickel in the automotive industry, highlighting its importance in sectors that demand durable materials in corrosive settings. The experimental validation confirms a robust association between the anticipated results and the actual performance, thereby confirming the efficacy of the suggested approach.
Natarajan, ManikandanPasupuleti, ThejasreeC, NavyaSomsole, Lakshmi NarayanaSilambarasan, R
Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in materials that conduct electricity, irrespective of their hardness. Due to the increasing demand for superior products and the necessity for quick design modifications, decision-making in the manufacturing sector has become progressively more difficult. This study focuses on Cupronickel and suggests creating predictive models to anticipate performance metrics in ECM through regression analysis. The experiments are formulated based on Taguchi's principles, and a multiple regression model is utilized to deduce the mathematical equations. The Taguchi approach is employed for single-objective optimization to ascertain the ideal combination of process parameters for optimizing the material removal rate. The proposed prediction technique for Cupronickel is more adaptable, efficient, and accurate in comparison to current models, providing enhanced monitoring capabilities. The updated models have been verified, demonstrating a robust link between empirical data and projected results.
Pasupuleti, ThejasreeNatarajan, ManikandanSagaya Raj, GnanaSilambarasan, RSomsole, Lakshmi Narayana
Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in materials that conduct electricity, independent of their level of hardness. Due to the increasing demand for superior products and the necessity for quick design modifications, decision-making in the manufacturing sector has become progressively more difficult. This study primarily examines the use of Haste alloy in vehicle applications and suggests creating regression models to predict performance parameters in ECM. The experiments are formulated based on Taguchi's ideas, and mathematical equations are derived using multiple regression models. The Taguchi approach is employed for single-objective optimization to ascertain the ideal combination of process parameters for optimizing the material removal rate. ANOVA is employed to evaluate the statistical significance of process parameters that impact performance indicators. The proposed regression models for Haste alloy are more versatile, efficient, and accurate in comparison to the current models, providing enhanced monitoring capabilities. The updated models have been verified, demonstrating a robust link between empirical data and projected results.
Natarajan, ManikandanPasupuleti, ThejasreeD, PalanisamySilambarasan, RKrishnamachary, PC
Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in materials that conduct electricity, regardless of their level of hardness. Due to the growing demand for superior products and the necessity for quick design adjustments, decision-making in the manufacturing industry has grown increasingly intricate. This study specifically examines Titanium Grade 7 and suggests the creation of an Adaptive Neuro-Fuzzy Inference System (ANFIS) model for predictive modelling in ECM. The study employs a Taguchi-grey relational analysis (GRA) methodology to attain multi-objective optimization, with the goal of concurrently maximizing material removal rate, minimizing surface roughness, and achieving precise geometric tolerances. Analysis of variance (ANOVA) is used to assess the relevance of process characteristics that impact these performance measures. The ANFIS model presented for Titanium Grade 7 provides more flexibility, efficiency, and accuracy in comparison to conventional approaches, allowing for greater monitoring and control in ECM operations. Moreover, the study investigates the potential uses of Titanium Grade 7 in the automotive industry, emphasizing its crucial function in sectors that demand resilient materials in corrosive surroundings. The experimental validation demonstrates a strong correlation between the projected results and the actual performance, so confirming the effectiveness of the ANFIS-based strategy.
Natarajan, ManikandanPasupuleti, ThejasreeD, PalanisamyKiruthika, JothiSilambarasan, R
Aircraft Certification is a mature and complex bureaucracy that has successfully ensured a very high degree of safety of aircraft design, construction, operation and maintenance. Outside of a very few professionals doing the work, there is a general lack of knowledge of certification details. For novel technologies such as electric power, and for innovative configurations such as distributed lift and lift-plus-lift-cruise, the rules are far less mature and still emerging and so also poorly understood. Within the Advanced Air Mobility (AAM) initiative, many new aircraft developments are underway using novel configurations, and the public announcements of regulatory progress toward FAA or EASA Type Certification capitalize on this unfamiliarity by being vague or even misleading. Honeywell conceived the Regulatory Readiness Level (RRL) indicator as an objective measure of certification status to serve the AAM industry and ecosystem, with applicability across all of aviation. RRL Version 1 enables a credible, objective assessment of new aircraft progress toward FAA Type Certification, and Operational Approval for Part 135 operations, to allow consistent apples-to-apples comparisons with other aircraft in development. Future RRL releases with allow determination of progress against criteria from EASA and other regulatory authorities, for supplemental types certifications STCs), and for risk-based airworthiness assessments such as EASA Specific Operations Risk Assessments (SORA).
Newman, DanielAgrawal, Pulkit
A novel method of swashplateless rotor control is presented for a propeller driven rotor. A propeller driven rotor consists of small electric motors and propellers attached to the rotor blade to spin the main rotor. The control methodology involves varying the propeller RPM around one rotor revolution to generate rolling and pitching moments for the main rotor. A small test stand was fabricated using 2.7 ft diameter 3D printed rotor blades to investigate this concept with various tip propeller geometries. The test stand was utilized to characterize changes in motor commands to rotor rolling and pitching moments. Next, in an effort to reduce the required power for the propeller driven rotor, the propeller placement along the rotor blade span was varied. Placing the propeller at the mid span location on the main rotor blade resulted in a significant reduction of 50% in the electrical power loading coefficient CPe/σ compared to a tip propeller placement. Finally, the propeller driven rotor control strategy was experimentally compared with a 6 ft diameter, shaft driven rotor that used a conventional swashplate system. A comparison of the control authority derivatives for the different configurations showed that the propeller driven rotor control strategy resulted in a similar amount of control authority as a conventional swashplate system.
Brown, RobertChopra, Inderjit
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