Browse Topic: Materials handling

Items (3,764)
On-board diagnosis (OBD) of gasoline vehicle emissions is detected by measuring the fluctuations of the rear oxygen sensor due to the time-dependent deterioration of the oxygen storage capacity (OSC) contained in the automotive catalyst materials. To detect OBD in various driving modes of automobiles with an order of magnitude higher accuracy than before, it is essential to understand the OSC mechanism based on fundamental science. In this study, time-resolved dispersive X-ray absorption fine structure (DXAFS) using synchrotron radiation was used to carry out a detailed analysis not only of the OSC of ceria-based complex oxides, which had previously been roughly understood, but also of how differences in design parameters such as the type of precious metals, reducing gases (CO and H2), detection temperatures, and mileages (degree of deteriorations) affect the OSC rate in a fluctuating redox atmosphere. A fundamental characteristic was clearly demonstrated in ceria-based complex oxides
Tanaka, HirohisaMatsumura, DaijuUegaki, ShinyaHamada, ShotaAotani, TakuroKamezawa, SaekaNakamoto, MasamiAsai, ShingoMizuno, TomohisaTakamura, RikuGoto, Takashi
In order to comply with the tightening of global regulations on automobile exhaust gas, further improvements to exhaust gas control catalysts and upgrades to on-board diagnostics (OBD) systems must be made. Currently, oxygen storage capacity (OSC) is monitored by front and rear sensors before and after the catalyst, and deterioration is judged by a decrease in OSC, but it is possible that catalyst deterioration may cause the rear sensor to detect gas that has not been sufficiently purified. It is important to observe the activity changes when the catalyst deteriorates in more detail and to gain a deeper understanding of the catalyst mechanism in order to create guidelines for future catalyst development. In this study, we used a μ-TG (micro thermogravimetric balance) to analyze in detail how differences in design parameters such as the type of precious metal, detection temperature, and mileage (degree of deterioration) affect the OSC rate in addition to the OSC of the ceria-based
Hamada, ShotaUegaki, ShinyaTanabe, HidetakaNakayama, TomohitoJinjo, ItsukiKurono, SeitaOishi, ShunsukeNarita, KeiichiOnishi, TetsuroYasuda, KazuyaMatsumura, DaijuTanaka, Hirohisa
The paper presents novel studies on the electrical-to-thermal energy deposition to gas at different phases of a spark. The experiments utilized a 10.9 milliliter custom-built spark calorimeter. The energy transfer efficiencies across spark phases—breakdown+arc, and glow are quantified, emphasizing their importances in ensuring robust ignition. An AC capacitive ignition system was considered in the experiments. The spark plugs used in the experiments were of dual-nickel standard J-gap design of a fixed electrode gap. Test results show the breakdown+arc phases are highly efficient in converting electrical to thermal energy, crucial for ignition. The glow phase, offering control flexibility, is found to be less effective in energy transfer from spark to gas. In addition, a maximum threshold for both glow current and duration is found. Exceeding the threshold reduces the net energy deposition to the gas, indicating an increase in thermal energy losses, primarily to the spark plug
Saha, AnupamTunestal, PerAengeby, JakobAndersson, Oivind
Door sunshade in a vehicle has proven to be very comfortable and luxurious feature to the customers. Luxury vehicles provide power sunshade which is electrically operated with the activation of a switch, whereas cost conscious vehicles provide manual sunshade which requires manual coiling and uncoiling. This study is to develop a door panel structure that can accommodate both the manual sunshade and power sunshade, thereby serving both cost conscious as well as luxury seeking customers. Manual sunshade consists only of cassette, pull bar, spindle mechanism and hooks whereas the power sunshade consists of cassette, pull bar, spindle mechanism, flap mechanism, bowden cable mechanism, actuator and motor. Due to this difference in package, it becomes difficult to accommodate both variants of sunshade into the same body system. However, this study helps in developing a common body structure by ways of effective packaging, modifying the cable and actuator mechanism and critical packaging of
S M, Rahuld, AnanthaKakani, Phani Kumar
Modern military operations prove that increased terrain mobility is critical for heavy tracked vehicles’ (HTVs) survivability and lethality. HTV major system packaging as a component of preliminary design with many physical constraints and assumptions poses great challenges for mobility. This paper develops an approach and a method that accounts for such constraints/assumptions and optimizes the packaging of the HTV system assembly, including vehicle armor, armament and munition, powertrain, and fuel tanks. The optimization purpose is to accommodate the center of gravity for improving ground pressure distribution and then reducing the sinkage. This work is based on a literature review and combines numerous techniques rooted in Western literature and Eastern Soviet- and post-Soviet-era literature. The optimization process is developed using a genetic algorithm. The Mean Relative Design (MRD) parameter is proposed to study the average system rearrangement (i.e., re-packing) that is
Vardi, HaggayVantsevich, VladimirGorsich, David
Since the rapid development of the shipping and port industries in the second half of the twentieth century, the introduction of container technology has transformed cargo management systems, while simultaneously increasing the vulnerability of global shipping networks to natural disasters and international conflicts. To address this challenge, the study leverages AIS data sourced from the Vessel Traffic Data website to extract ship stop trajectories and construct a shipping network. The constructed network exhibits small-world characteristics, with most port nodes having low degree values, while a few ports possess extremely high degree values. Furthermore, the study improved the PageRank algorithm to assess the importance of port nodes and introduced reliability theory and risk assessment theory to analyze the failure risks of port nodes, providing new methods and perspectives for analyzing the reliability of the shipping network.
Li, DingCheng, ChengZhao, XingxiLi, Zengshuang
There are various steering technologies are available in market nowadays. Hydraulic Power Steering (HPS) is one of them. As hydraulic name is linked to it the temperature role comes to play. While doing hard cornering the hydraulic oil used to assist the working in steering system get over heated, due to which oil loses its viscosity became one of the major causes of hard steer in trucks. Also, due to limited space the large heat exchanger cannot be used there. So, objective of this Thesis is to examine an effective solution which can be compact in design and at the same time should be effective to solve this problem. After going through literature analysis, we finalize that the Principal of Pulsating Heat Pipe could be a possible solution. So, for that we design different model based on previous research work in Creo and simulate them in Star CCM+ to finalize the optimality.
Saikrishna, VNLP, RudreshaYadav, SatyendraB, RuthvikaVishwasa, Viditha
A workable shorter curing cycle is required for the manufacturing of carbon/epoxy towpreg and is crucial for attaining defect-free component consolidation. A rational "processing methodology" based approach is established in this paper, and a cure cycle design protocol is proposed. For thick component, autoclave processing with conventional and shorter curing cycles was used. This has been validated through experimental studies. For thick composites, an uncontrolled exotherm could lead to a cure of the component from the inside out, with high process-postulated residual stresses. To determine and regulate the exotherm cross-linking reaction’s maximal heat generation, thermal tests were conducted. These tests revealed isothermal holds and ramp rates were most effective in lowering the exothermic peak. Based on these findings, a shortened cure cycle was developed and applied to the material system. During the curing process, embedded thermocouples were utilized to track heat production
K, TejasviSingh, P. Sundar
It is emerging the need to take action to reduce the greenhouse effect, which is one of the major causes of climate change and environmental disasters that has been occurring frequently in recent decades throughout the planet. The burning of fossil fuels for electricity and energy generation are the main concerns and those that have greater incentives for its reduction, as its by-product of the reaction of burning CO2, which among the greenhouse gases is primarily responsible for its aggravation. The transport sector excels in CO2 emissions, emits about 20% of gas, according to the Intergovernmental Panel on Climate Change (IPCC), a scientific organization linked to the United Nations (UN). A promising solution to reduce the impact of this sector would be the use of hydrogen fuel cell, which if carried out through renewable energies, the electrolysis of hydrogen has zero CO2 emission throughout the cycle. However, one of the biggest challenges to make viable the use of hydrogen as fuel
Alves, JoyceSilva, AntônioPaterlini, BrunoSantos, FelipePedroso, HenriqueHenrique, PedroMilani, Pedro
This research investigates the impact of friction stir welding (FSW) used to join micro-alloyed steel, on the material and its mechanical characteristics. FSW increases the metallurgical and mechanical qualities of joints made from micro-alloyed steel. However, Friction Stir Welding has produced only modest improvements in connecting steels. Automobile chassis, offshore platforms, oil and gas pipelines, mining, shipbuilding and railroad carriages, pressure vessels, bridges, and storage tanks are just some of the many places and find micro-alloyed steels employed. Frictional heat and tool movement over the joint cause micro defects occurred. Tungsten carbide tools are used in this investigation. Welding shares the same process characteristics, such as the tool's rotating speed (900 rpm) and axial force (10 kN). The table's traverse speed options are available, including 50 mm/min, 60 mm/min, and 70 mm/min. Vickers microhardness testing machines and tensile testing machines are used to
Rajan, C. SakthiKumar, N. MathanKumar, K. VetrivelKannan, S.Soundararajan, S.
The fusion of virtualized base software with simulation technologies has transformed the methods used for development and system testing. This paper examines the architecture, implementation, and advantages of employing virtualization to improve simulation environments. Virtualized base software enables the creation of isolated, scalable, and replicable settings, essential for executing complex simulations that replicate real-world situations. Utilizing virtualization enhances simulations by making them more efficient, flexible, and cost-effective. The study covers the essential elements of virtualized simulation platforms, such as containerization, network abstraction and virtual drivers. It also analyzes how these components collaborate to create a strong framework for simulating diverse applications, ranging from software testing to hardware emulation. This approach offers several benefits, including better resource utilization, quicker deployment times, and the flexibility to
Shenoy, GaneshMalchow, Florian
This paper presents a work undertaken to simulate the logistics processes in the digital environment using a discrete event simulation software which involves the movements of the Material Handling Equipment [MHE]. MHE movements to the line side involves traffic, where the parts are transported from the supermarket area to the line side based on the part requirement list ordered from the line side. The intersections are the bottleneck in the system due to the traffic and if the vehicle scheduling is not streamlined, then during any failure/stoppage of the vehicle, would result in the blocking of the preceding vehicles causing line stoppage. This work outlines to develop a junction block in the digital environment using a discrete event driven approach where an optimal flow of the vehicles is maintained at the intersections. The Junction block is created based on the succeeding track occupancy level, thus the preceding MHE’s can overtake in case of any blockages based on the priority
Surendranath, SujithAmasa, SanjayKotegar, Shravan RajVenkataramana, SurendharSathiyamoorthi, Gokul
Shipbuilders didn’t have the option of fiberglass when the nonprofit American Bureau of Shipping (ABS) was established 160 years ago to help safeguard life and property on the seas. Fortunately, technology to help better ensure the safety of ocean vessels has also come a long way in that time, in part because people have become a spacefaring species.
Robotic automation technology is reshaping food manufacturing, packaging, and handling by driving significant improvements in efficiency, quality, and flexibility. By integrating advanced artificial intelligence, computer vision, and proprietary force-sensing technology, Flexiv has introduced cutting-edge automation to the food processing sector.
Lithium iron phosphate is one of the most important materials for batteries in electric cars, stationary energy storage systems, and tools. It has a long service life, is comparatively inexpensive and does not tend to spontaneously combust. Energy density is also making progress. However, experts are still puzzled as to why lithium iron phosphate batteries undercut their theoretical electricity storage capacity by up to 25 percent in practice. To utilize this dormant capacity reserve, it would be crucial to know exactly where and how lithium ions are stored in and released from the battery material during the charging and discharging cycles. Researchers at Graz University of Technology (TU Graz) have now taken a significant step in this direction. Using transmission electron microscopes, they were able to systematically track the lithium ions as they traveled through the battery material, map their arrangement in the crystal lattice of an iron phosphate cathode with unprecedented
This paper evaluates electric machine and reducer specifications along-side vehicle dynamics and drivability for an axial flux machine (AFM). The baseline is a conventional central drive unit with a single electric machine, reducer, and differential. It compares powertrain architectures with two in-wheel AFMs (IWD) and one AFM mounted perpendicular to the chassis against the E-Axle design. The study starts by determining wheel-level traction force and power requirements for a mid-sized vehicle, then derives necessary machine and reducer specifications. It also considers packaging and efficiency constraints. The E-Axle uses a single-stage planetary gearbox, while the perpendicular AFM connects to a bevel gear reducer, and the IWD requires no reducer. These architectures are analysed in a vehicle dynamics simulation with six degrees of freedom, suspension, tire, and road models. Efficiency is assessed using the Worldwide Harmonized Light Vehicles Test Cycle (WLTC). Besides acceleration
Wipfler, FelixYildirim, MetinNegrila, Andrei-RaduGerling, DieterBruell, MartinSabzewari, Kiarash
Researchers have developed better rechargeable batteries by applying silicon to the batteries’ cathodes. A previously unknown mechanism by which lithium gets trapped in batteries limits the number of times it can be charged and discharged at full power. By not maxing out their storage capacity, a new approach could provide steady and stable cycling for applications that need it.
Leak Before Break (LBB) is now widely applied in pressure vessels and other pressurized components to detect the failure by unstable crack initiation and propagation. This concept is also applied in pneumatic brake system components to validate the structural rigidity of the devices. Pneumatic brake system component plays a vital role in the commercial vehicle platform. It consists of four major systems such as charging systems, actuating systems, control systems and actuators. Charging System includes compressor, reservoir, air dryer, and system protection valves. Compressor acts as an energy source for pneumatic air brake systems, reservoir is used to store the compressed air generated by the compressor, and system protection valves are used to divide and distribute the air flow to the brake system. Air dryers are used to absorb moisture, oil particles and tiny foreign contaminants, regulate the system pressure, and blow off the excess pressure from the system. It contains a
Govindarasu, AnbarasuT, SukumarSubramanian, Vivek
Mi Rancho has been delighting customers with authentic and fresh tortillas, chips, and salsas since its establishment in 1939. Originally founded as a grocery store in Oakland, CA, the business has evolved and grown into a food provider for large nation-wide retail partners. To enable their continued growth, Mi Rancho recently partnered with Formic to introduce robotic automation to their food processing and packaging production operations.
Moisture adsorption and compression deformation behaviors of Semimet and Non-Asbestos Organic brake pads were studied and compared for the pads cured at 120, 180 and 240 0C. The 2 types of pads were very similar in moisture adsorption behavior despite significant differences in composition. After being subjected to humidity and repeated compression to 160 bars, they all deform via the poroviscoelastoplastic mechanism, become harder to compress, and do not fully recover the original thickness after the pressure is released for 24 hours. In the case of the Semimet pads, the highest deformation occurs with the 240 °C-cure pads. In the case of the NAO pads, the highest deformation occurs with the 120 0C-cure pads. In addition, the effect of pad cure temperatures and moisture adsorption on low-speed friction was investigated. As pad properties change all the time in storage and in service because of continuously changing humidity, brake temperature and pressure, one must question any
Rhee, Seong KwanRathee, AmanSingh, ShivrajSharma, Devendra
Getting 800 robots in a warehouse to and from their destinations efficiently while keeping them from crashing into each other is no easy task. In a sense, these robots are like cars trying to navigate a crowded city center.
In the medical device production environment, device packaging and sterilization is vital. The same level of rigorous quality controls and regulations that affect the devices themselves are also extended to their packaging. The mechanical and container closure integrity [CCI] evaluations of medical device packaging requires significant testing performed at multiple points throughout the commercialization and production processes.
Contract design and manufacturing organizations (CDMOs) play an increasingly crucial role in the pharmaceutical supply chain, providing the necessary capabilities and capacity to meet growing patient demand. The recent emergence of GLP-1 class drugs only emphasizes the importance of CDMOs, which con- tribute significant expertise related to fill-finish operations, secondary packaging, and distribution.
Sustainability remains a dominant trend in packaging and processing, continuing to attract the attention of the life sciences industry and inspire its new initiatives. Although pharmaceutical and medical device manufacturers must prioritize patient safety and product protection, concerns about climate change, greenhouse gas (GHG) emissions, plastic waste, and pressure to move toward a circular economy are prompting a greater focus on improving the sustainability of their products and packaging.
Manufacturing and servicing facilities in space are (finally) moving from the pages of science fiction to reality. For decades, we've seen movies with scenes of spacecraft being created and serviced in beautifully rendered factories with Earth in the background. And many more ideas have come from authors imagining bold futures where humanity does everything from creating giant nets of satellites to massive, spinning space stations. Some might lament that, back in reality, we’ve come so far with our achievements in space yet fallen short of the brightest visions. How can we have landed on the Moon 50 years ago and still be scrapping billion-dollar satellites when they run out of fuel? However, there’s good reason to believe that the space industry is almost done laying the foundations that will let us move from science fiction to engineering reality.
In response to global climate change, there is a widespread push to reduce carbon emissions in the transportation sector. For the difficult to decarbonize heavy-duty (HD) vehicle sector, hybridization and lower carbon-intensity fuels can offer a low-cost, near-term solution for CO2 reduction. The use of natural gas can provide such an alternative for HD vehicles while the increasing availability of renewable natural gas affords the opportunity for much deeper reductions in net-CO2 emissions. With this in consideration, the US National Renewable Energy Laboratory launched the Natural Gas Vehicle Research and Development Project to stimulate advancements in technology and availability of natural gas vehicles. As part of this program, Southwest Research Institute developed a hybrid-electric medium-HD vehicle (class 6) to demonstrate a substantial CO2 reduction over the baseline diesel vehicle and ultra-low NOx emissions. The development included the conversion of a 5.2 L diesel engine to
Wallace, JulianMitchell, RobertRao, SandeshJones, KevinKramer, DustinWang, YanyuChambon, PaulSjovall, ScottWilliams, D. Ryan
In recent years, the automotive industry has dedicated significant attention to the evolution of electric vehicles (EVs). The Electric-machine (as motor and generator, here and onward called E-machine as more general term) as the heart of the EDU (Electric Drive Unit) is very important component of powertrain and is the one of the main focuses of development. Traditionally, E-machine design has primarily focused on factors like efficiency, packaging, and cost, often neglecting the critical aspects of Noise, Vibration, and Harshness (NVH) specially at the early decision-making stages. This disconnect between E-machine design teams and NVH teams has consistently posed a challenge, which is the experience seen in many OEMs. This paper introduces an innovative workflow that unifies these previously separate domains, facilitating comprehensive optimization by integrating NVH considerations with other E-machine objectives, efficiency, weight, packaging and cost. This paper highlights AVL's
Mehrgou, MehdiGarcia de Madinabeitia, InigoAhmed, Mohamed Essam
As vibration and noise regulations become more stringent, numerical models need to incorporate more detailed damping treatments. Commercial frameworks, such as Nastran and Actran, allow the representation of trim components as frequency-dependent reduced impedance matrices (RIM) in direct frequency response (DFR) analysis of fully trimmed models. The RIM is versatile enough to couple the trims to modal-based or physical components. If physical, the trim components are reduced on the physical coupling degrees of freedom (DOFs) for each connected interface. If modal, the RIMs are projected on the eigenmodes of the connected component. While a model size reduction is achieved compared to the original model, most numerical models possess an extensive number of interfaces DOFs, either modal or physical, resulting in large, dense RIMs that demand substantial memory and disk storage. Thus, the approach faces challenges related to storage capacities and efficiency, because of the demanding
Paiva, AndreVerhaegen, JulienLielens, GregoryVan den Nieuwenhof, Benoit
Aitiip is a leading Spanish research and development institute and serves companies in the aeronautics, automation, industrial, and packaging sectors. The institute possesses strong platforms for the characterization of materials and processes and is known as a powerful integrator of technologies, which is constantly on the lookout for the next transformative technology. A year ago, Aitiip implemented an NXE 400 industrial resin 3D printer platform from Nexa3D to explore integrations of additive manufacturing and injection molding. Nexa3D is the Ventura, California-based provider of high-speed industrial printing technologies whose portfolio continues to grow, reflected in its acquisition of Essentium, one of the world's most well-known providers of extrusion 3D printing, earlier this year. Liebherr is one of the world's largest providers of a variety of industrial goods, services and products. Aerospace and transportation systems is one of 13 different product segments supplied by the
Rooftop solar panels will soon power about 90% of PFG's Gilroy, California, operations, the starting point for cold food deliveries. The vehicles getting the various edibles and food-related products from the warehouse to restaurants, schools, hotels and other customers include new battery-electric Class 8 trucks that mate to trailers fitted with zero-emission transport refrigeration units (TRUs). “Our Gilroy, California, location is the pilot for how we intend to develop sustainable distribution centers,” said Jeff Williamson, senior vice president of operations for Richmond, Virginia-headquartered Performance Food Group (PFG). Williamson and others were recently interviewed by Truck & Off-Highway Engineering following an Earth Day open house at the Gilroy site.
Buchholz, Kami
Most heavy trucks should be fully electric, using a combination of batteries and catenary electrification, but heavy trucks requiring very long unsupported range will need chemical fuels. Hydrogen is the key to storing renewably generated electricity chemically. At the scale of heavy trucks, compressed hydrogen can match the specific energy of diesel, but its energy density is five times lower, limiting the range to around 2,000 km. Scaling green hydrogen production and addressing leakage must be priorities. Hydrogen-derived electrofuels—or “e-fuels”—have the potential to scale, and while the economic comparison currently has unknowns, clean air considerations have gained new importance. The limited supply of bioenergy should be reserved for critical applications, such as bioenergy with carbon capture and storage (BECCS), aviation, shipping, and road freight in the most remote locations. Additionally, there are some reasons to prefer ethanol or methanol to diesel-type fuels as they are
Muelaner, Jody E.
The strategy for emission reduction in the P2.5 hybrid system involves the optimization of engine torque, engine speed, catalyst heat duration, and motor torque regulation in a coordinated manner. In addition to employing traditional engine control methods used in HEV models, unique approaches can be utilized to effectively manage emissions. The primary principle is to ensure that the engine operates predominantly under steady-state conditions or limits its load to regulate emissions levels. The main contributions of this paper are as follows: The first is the optimization of catalyst heating stage. During the catalyst heating stage, the system divides it into one or two stages. In the first stage, the vehicle is driven by the motor while keeping the engine idle. This approach stabilizes catalyst heating and prevents fluctuations in air-fuel ratio caused by speed and load changes that could potentially worsen emissions performance. The second stage corresponds to when the engine-driven
Jing, JunchaoLiu, YiqiangSun, JiazhenWang, ZhentaoZhang, Junzhi
Testing of ducted fuel injection (DFI) in a single-cylinder engine with production-like hardware previously showed that adding a duct structure increased soot emissions at the full load, rated speed operating point [1]. The authors hypothesized that the DFI flame, which travels faster than a conventional diesel combustion (CDC) flame, and has a shorter distance to travel, was being re-entrained into the on-going fuel injection around the lift-off length (LOL), thus reducing air entrainment into the on-going injection. The engine operating condition and the engine combustion chamber geometry were duplicated in a constant pressure vessel. The experimental setup used a 3D piston section combined with a glass fire deck allowing for a comparison between a CDC flame and a DFI flame via high-speed imaging. CH* imaging of the 3D piston profile view clearly confirmed the re-entrainment hypothesis presented in the previous engine work. This finding suggests that a DFI retrofit for this
Svensson, KenthFitzgerald, RussellMartin, Glen
The steam reforming of CH4 plays a crucial role in the high-temperature activity of natural gas three-way catalysts. Despite existing reports on sulfur inhibition in CH4 steam reforming, there is a limited understanding of sulfur storage and removal dynamics under various lambda conditions. In this study, we utilize a 4-Mode sulfur testing approach to elucidate the dynamics of sulfur storage and removal and their impact on three-way catalyst performance. We also investigate the influence of sulfur on CH4 steam reforming by analyzing CH4 conversions under dithering, rich, and lean reactor conditions. In the 4-Mode sulfur test, saturating the TWC with sulfur at low temperatures emerges as the primary cause of significant three-way catalyst performance degradation. After undergoing a deSOx treatment at 600 °C, NOx conversions were fully restored, while CH4 conversions did not fully recover. Experimental data under fixed lambda conditions reveal that sulfur stored on the catalyst leads to
Kim, Mi-YoungDadi, Karthik VenkataGong, JianKamasamudram, Krishna
Electrified vehicles represent mobility’s future, but they impose challenging and diverse requirements like range and performance. To meet these requirements, various components, such as battery cells, electric drives, fuel cells, and hydrogen vessels need to be integrated into a drive and storage system that optimizes the key performance indicators (KPI). However, finding the best combination of components is a multifaceted problem in the early phases of development. Therefore, advanced simulation tools and processes are essential for satisfying the customer´s expectation. EDAG Engineering GmbH has developed a flat storage platform, which is suitable for both, BEV and FCEV. The platform allows for the flexible and modular integration of batteries and hydrogen vessels. However, package space is limited and the impact of the design choices regarding the vehicle’s KPI need to be considered. Therefore, EDAG has developed a simulation model that combines automated 3D design and packaging
Viehmann, AndreasNauck, NiklasEsser, ArvedSchramm, Michael
Considering the current trend towards the electrification of commercial vehicles, the development of Beam eAxle solutions has become necessary. The utilization of an electric drive unit in heavy-duty solid axle-based commercial vehicles presents unique and demanding challenges. These include the necessity for elevated peak and continuous torque while meeting packaging constraints, structural integrity requirements, and extended service life. One such solution was developed by BorgWarner to address these challenges. This paper offers a comprehensive overview of the design and development process undertaken for this Dual Motor Beam eAxle system. This includes the initial comparison of various eAxle solutions, the specifications of components selected for this design, and the initial results from dyno and vehicle development.
Guo, ChengyunVan Maanen, KeithLiu, Xiaobing
Plastic design is one of the upcoming fields of interest when it comes to weight optimization, sustainability, strength, and overall aesthetics of an automobile. What is often ignored is the amount of flexibility a plastic designer has, of integrating and packaging various components of an automobile into a single part and still make it an integral part of its complex aesthetics. This paper highlights upon one such part that is being developed: An integrated bracket which packages ADAS camera, Rain Light Sensor, and an Auto-dimming IRVM. Apart from packaging the mentioned components, this bracket also has mounting provisions for an aesthetic cover (also referred to as beauty cover). The objective of this paper is to highlight the importance of integration of several parts into a single part for packaging multiple components that need to be placed in a close proximity with each other. This paper includes the demonstration of old design which consisted of multiple parts along with how we
Chandravanshi, PriyanshParthiban, MohanBable, ShubhamDharmatti, Girish
With the advent of this new era of electric-driven automobiles, the simulation and virtual digital twin modeling world is now embarking on new sets of challenges. Getting key insights into electric motor behavior has a significant impact on the net output and range of electric vehicles. In this paper, a complete 3D CFD model of an Electric Motor is developed to understand its churning losses at different operating speeds. The simulation study details how the flow field develops inside this electric motor at different operating speeds and oil temperatures. The contributions of the crown and weld endrings, crown and weld end-windings, and airgap to the net churning loss are also analyzed. The oil distribution patterns on the end-windings show the effect of the centrifugal effect in scrapping oil from the inner structures at higher speeds. Also, the effect of the sump height with higher operating speeds are also analyzed. The net churning losses obtained from the simulations are compared
Ballani, AbhishekSchlautman, JeffSrinivasan, ChiranthAhmed, RayhanSchroeder, Debera
The need for eco-friendly vehicle powertrains has increased drastically in recent years. The most critical component of an electric vehicle is the battery pack/cell. The choice of the appropriate cell directly determines the size, performance, range, life, and cost of the vehicle. Lithium-ion batteries with high energy density and higher cycle life play a crucial role in the progress of the electric vehicle. However, the packaging of lithium-ion cells is expected to meet lots of assembly demands to increase their life and improve their functional safety. Due to their low mechanical stability, the lithium-ion cell modules must have external pressure on the cell surface for improved performance. The cells must be stacked in a compressed condition to exert the desired pressure on the cell surface using compression foam/pads. The compression pads can be either packaged between each cell or once in every set of cells based on the cell assembly requirements. This paper describes the need for
Sithick Basha, AbubakkerChalumuru, MadhuSasikumar, K
The handling of flexible components creates a unique problem set for pick and place automation within automotive production processes. Fabrics and woven textiles are examples of flexible components used in car interiors, for air bags, as liners and in carbon-fiber layups. These textiles differ greatly in geometry, featuring complex shapes and internal slits with varying material properties such as drape characteristics, crimp resistance, friction, and fiber weave. Being inherently flexible and deformable makes these materials difficult to handle with traditional rigid grippers. Current solutions employ adhesive, needle-based, and suction strategies, yet these systems prove a higher risk of leaving residue on the material, damaging the weave, or requiring complex assemblies. Pincer-style grippers are suitable for rigid components and offer strong gripping forces, yet inadvertently may damage the fabric, and introduce wrinkles / folded-over edges during the release process. Non-planar
Strelkova, DoraUrbanic, Ruth Jill
Getting warehouse robots to and from their destinations efficiently while keeping them from crashing into each other is no easy task. It is such a complex problem that even the best path-finding algorithms struggle to keep up with the breakneck pace of e-commerce or manufacturing. In a sense, these robots are like cars trying to navigate a crowded city center. So, a group of MIT researchers who use AI to mitigate traffic congestion applied ideas from that domain to tackle this problem.
As manufacturers push for increased productivity, low-value tasks such as material transport have become clear targets for improvement. In efforts to reduce material transport in large facilities, companies have explored the use of intermediate warehouse areas throughout the production floor. However, this takes up valuable space, requires additional material processing and handling, and creates opportunities for errors and lost or misplaced materials.
Much has been written about the extraordinary vehicle production and market environment of the past four years in North America and beyond. The plethora of negative impacts from COVID, chip availability, scarcity of labor, inflation, shipping disruptions and union/OEM disputes can all be boiled down to what's best described as an “operational hell.” Everyone is happy to put this all behind us. The dawn of 2024, at least for North America, has enabled some stability from a volume perspective as the industry slowly rebuilds inventory and adjustments are made to the pace of BEV volume buildout over the next couple of years. This should offer some familiarity and a welcome breather from the highly unpredictable environments we've seen since late 2019. That being noted, there's a question in the air about the new, inexperienced challenges that might lurk around the corner.
This specification covers a corrosion- and heat-resistant steel in the form of welding wire.
AMS F Corrosion and Heat Resistant Alloys Committee
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