Browse Topic: Vehicle drive systems

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Research on the Parameter Optimization Method for a Dual-Motor Coupled Integrated Single-Axle Drive System2025-01-8284To be published on 04/01/2025
This paper explores a parameter optimization calculation method for a dual-motor coupled integrated single-axle drive system, aiming to achieve the optimal balance between vehicle dynamics, fuel efficiency, and system efficiency under this configuration. By constructing a vehicle longitudinal dynamics model and referencing motor models, the effective operating range is calculated. Vehicle acceleration time, gradeability, and maximum speed are used as constraints, while the proportion of the high-efficiency operating area of the drive system is taken as the objective function for optimizing relevant system parameters. This method improves computational efficiency by dividing the contour lines, thus eliminating the need to traverse all points in the constraint area and converting them into an intuitive analysis of the operating range, which reduces the need for point-by-point calculations across the entire working area.
Gu, Zhuangzhuang, You, Jianhui, Wu, Jinglai, Zhang, Yunqing
Technical Paper
Vehicle Motion Management - A Model Predictive Control Approach to Realize Holistic Redundancy to Enable Actuator Fail Operational Autonomous Driving2025-01-8812To be published on 04/01/2025
Since the introduction of ABS (1978), TCS (1986) and ESC (1995) in series production, the number of modern vehicle dynamics control functions and advanced driver assistance systems (ADAS) has been continuously increasing. Meanwhile, many functions are available that influence vehicle motion (vehicle dynamics). Since these are only partially and not hierarchically coordinated, the control of vehicle motion is still suboptimal. Current megatrends (automated driving, electromobility, software-defined vehicles) and new key technologies (steer-by-wire, brake-by-wire, domain-based E/E architectures) lead to an increasing number of electrified, motion-relevant components being introduced into series production. These components enable the development of an integrated chassis control (ICC) that controls all motion-relevant components, networks them with each other and coordinates them holistically to optimally control the vehicle motion regarding an adjustable desired driving behavior. Vehicle
Wielitzka, Mark, Ahrenhold, Tim, Vocht, Moritz, Rawitzer, Jonas, Schrader, Jonas
Technical Paper
Digital Twin, A Multiphysics Numerical Tool Chain for Next Generation Electric Drive Design2025-01-8624To be published on 04/01/2025
Following an early adoption phase, the BEV market focus shift towards mass market strategy. This shift has placed greater emphasis on crucial attributes, such as system cost reduction and range extension. System efficiency has always been at the center of the BEV product development, where efficiency metric influenced greatly the range and cost of the vehicle. For example, higher efficiency of an iDM (Integrated Drive Module) reduces the need for bigger battery thus cost reduction, alternatively for a same battery size the end user will benefit with an extended range. BorgWarner adopted Digital Twin technology to optimize iDM within a vehicle ecosystem, Digital Twin is an assembly of high-fidelity physics based numerical tool suites which offer greater degree of freedom to engineers in designing, sizing, optimizing a component vs. system benefit tradeoff, thus enabling most efficient product design within constraints of economics. At BorgWarner we have adopted Analytical System
Bossi, Adrien, Bourniche, Eric, Leblay, Arnaud, David, Pascal, Nanjundaswamy, Harsha
Technical Paper
The development and real-time application of DP-based optimized A-ECMS algorithm for multi-mode series-parallel hybrid electric vehicles2025-01-8589To be published on 04/01/2025
The hybrid electric drive system shows its great potential in the energy sustainability of the automotive industry. This paper investigates the improved adaptive equivalent consumption minimization strategy (A-ECMS) for a multi-mode series-parallel hybrid electric vehicle. First, a basic ECMS algorithm for the series-parallel vehicle is established, which considers the instantaneous optimal torque matching in the electric, serial hybrid, and engine driving modes. Then, Genetic Algorithms (GA) are used for offline global optimization of the equivalent factor and penalty function exponent. Under the condition that the future traffic information scenario is known, it is desired to realize the global optimal planning based on the combination of dynamic programming (DP) and ECMS. Therefore, the SOC, engine speed, and torque results calculated by the DP strategy are used as benchmarks to develop the improved SOC-AECMS and S-AECMS strategies, which better incorporate the advantages of the
Zhu, Jingyu, Han, Mengwei, Liu, Chongfan, Yang, Chenfan, Nishida, Keiya
Technical Paper
European initiatives for User-Centric design of Electric Vehicle2025-01-8807To be published on 04/01/2025
E-mobility is revolutionizing the automotive industry by improving energy efficiency, lowering CO2 and non-exhaust emissions, innovating driving and propulsion technologies, redefining the hardware-software-ratio in the vehicle development, facilitating new business models, and transforming the market circumstances for electric vehicles (EVs) in passenger mobility and freight transportation. Ongoing R&D action is leading to an uptake of affordable and more energy efficient EVs for the public at large through the development of innovative and user-centric solutions, optimized system concepts and components sizing, and increased passenger safety. Moreover, technological EV optimizations and investigations on thermal and energy management systems as well as the modularization of multiple EV functionalities result in range maximization, driving comfort improvement, and greater user-centricity. This paper presents the latest advancements of multiple EU-funded research projects under the
Ratz, Florian, Bäuml, Thomas, Kompara, Tomaž, Kospach, Alexander, Simic, Dragan, Jan, Petra, Möller, Sebastian, Fuse, Hiroyuki, Parades Barros, Esteban, Armengaud, Eric, Amati, Nicola, Sorniotti, Aldo, Lukesch, Walter
Technical Paper
A 3-D CFD Performance Simulation of a Feedback Controlled Variable Displacement Vane Pump2025-01-8179To be published on 04/01/2025
Variable Displacement Vane Pumps (VDVP) find extensive use in the lubrication systems of engines, transmissions, and electric drive units. In this current CFD study, a rotational VDVP is coupled with an Oil Control Valve (OCV) to establish a feedback loop that regulates the eccentricity of the cam ring, thereby controlling the pump outlet flow rate. In previous studies, Simerics-MP+ has been successfully employed to model the VDVP pump without the effect of OCV. OCV consists of a solenoid valve coupled with a spring-loaded spool valve. Due to the absence of the actual valve geometry, in CFD the valve’s behavior is represented by a 2-D table correlating the control chamber flow rate with the supply pressure and control pressure. Finally, the eccentricity of cam ring is determined by the iterative balance between fluid torques from vane chamber pressures and control chamber pressure, and the spring torque. Simulation predictions for the solenoid valve at 0% and 100% PWM conditions align
Khatri, Rachit Rajesh, Liu, Yuchan, Pasunurthi, Shyam Sundar, Ahmed, Rayhan, Stallmann, John, Yang, Bo, Huang, Yuli, Sivaji, Rangarajan, Scheffler, David
Technical Paper
A Minimalist High-Power Boost Charging Solution Integrated Into Electric Drives2025-01-8560To be published on 04/01/2025
The drive power and charging performance of leading electric vehicles (EVs) continue to advance, with high-performance EVs elevating their high-voltage platform ranges from below 500V to 800V and even 900V. To be compatible with existing public charging stations of lower voltage, vehicles with high-voltage platforms often equip a boost charge device. However, this boost charge device incurs additional costs, weight, and space requirements. Most mature solutions employ an additional DC-DC boost converter, which, however, results in low charging power at a high cost. Some new approaches utilize the power switching devices and motor inductance of electric drives to form a boost converter circuit, using a three-phase current in-phase control strategy for charging. This method requires external inductors to reduce charging current ripples. Alternatively, to minimize current ripple without external inductors, a two-phase parallel and one-phase series topology is used, albeit at the expense
Yuan, Baocheng, Ma, Yong, Xie, Xi, Liu, Shaowei, Guan, Tianyu, Ge, Kai, Zheng, Lifu, Xu, Xu
Technical Paper
Propulsion System Design of Cadillac Lyriq Electric Vehicle2025-01-8566To be published on 04/01/2025
The design and development of EVs and HEVs has become a growing issue recently due to concerns about pollution and dependence on non-renewable fossil fuels. Accordingly, General Motors (GM) has an evolving vehicle electrification plan over the past several decades and into the future to deliver low-cost and efficient EVs. The propulsion system of GM-Cadillac's first electric vehicle, the Lyriq, is designed to deliver significant improvements in both range and peak performance. Its propulsion system uses an optimized drive unit consisting of interior permanent magnet (IPM) motors and silicon traction inverters. The main objective of the drive unit design was to minimize energy loss and cost while maximizing hardware consolidation, range, performance, power density and scalability. Two IPM motors are designed with different stack lengths and number of stator turns, while keeping the rotor design and stator conductor profiles the same. The larger motor is used in rear-wheel drive (RWD
Momen, Faizul, Jensen, William, He, Song, Chowdhury, Mazharul, Zahid, Ahsan, Forsyth, Alexander, Alam, Khorshed, Anwar, Mohammad, Kim, Young
Technical Paper
A Novel EV Inverter Drive System with Integrated Single Stage Buck-Boost and Sinusoidal Output Voltage2025-01-8571To be published on 04/01/2025
A battery electric vehicle (BEV) employs a traction inverter to control a traction motor. One popular configuration is to make a HV battery directly connected to the input of the motor inverter. As a result, the maximum motor voltage is limited by the state of charge (SOC) of the traction battery. When the battery voltage is low the maximum motor speed and power are limited. This voltage limitation can be solved by using a traditional boost converter-based inverter. However, this approach has several disadvantages. The motor winding terminals see a PWM voltage, which results in high frequency harmonics that lead to EMI, NVH and potential additional insulation stress. Also, there are PWM-induced common mode voltages that are known to produce bearing failures as well as EMI/EMC problems that are extremely difficult to eliminate. Finally, the topology is significantly more expensive due to the high number of active switching devices needed. To solve some of the limitations and issues
Ge, Baoming, Munoz, Alfredo R., Jiang, Hong
Technical Paper
Integrated Nonlinear Observer and Prescribed Performance Control for a Four In-wheel Motor-Driven Electric Vehicles Based on Stability Boundary and Road Information2025-01-8298To be published on 04/01/2025
To effectively improve the performance of chassis control of a four in-wheel motor (IWM)-driven electric vehicles (EVs), especially in combing nonlinear observer and chassis control for improving road handling and ride comfort, is a challenging task for the IWM-driven EVs. Simultaneously, inaccurate state-based control and uncertainty with system input, are always existing, e.g., variable control boundary, varying road input or control parameters. Due to the higher fatality rate caused by variable factors, how to precisely chose and enforce the reasonable chassis prescribed performance control strategy of IWM-driven EVs become a hot topic in both academia and industry. To issue the above mentioned, the paper proposes a novel observer-based prescribed performance control to improve IWM-driven EVs chassis performance under the double lane change steering and various road input. Firstly, a nonlinear nine degree-of-freedom of full-car model is developed to describe vehicle chassis dynamics
Wang, Zhenfeng, Long, Jiarong, Li, Shengchong, Zhang, Xiaoyang, Zhao, Binggen
Technical Paper
A zero-emission braking system: experimental setup, system characterization and model validation2025-01-8250To be published on 04/01/2025
Following the current need of the automotive sector on reducing secondary emissions coming from non-exhaust sources, this paper presents an innovative zero-emissions magneto-rheological braking system, specifically designed to meet future brake emission targets while maintaining state-of-the-art brake performance. In particular the article focusses on the experimental setup definition to evaluate the full-sized prototype under real load conditions and presents the preliminary results obtained from the experimental campaign. The zero-emission braking prototype has been developed for reaching performance compatible with the automotive application, specifically a segment-A vehicle, being able to generate enough braking torque as to perform an emergency brake maneuver without any other traditional braking system. A central aspect to confirm system’s performance is the development of a test bench engineered for assessing the magneto-rheological braking technology. Detailed insights into the
Tempone, Giuseppe Pio, De Carlo, Matteo, Carello, Massimiliana, de Carvalho Pinheiro, Henrique, Imberti, Giovanni
Technical Paper
Computational Fluid Dynamics Analysis of Gearbox Churning Loss and Oil Splash Characteristics in Electric Vehicle Drive Units2025-01-8182To be published on 04/01/2025
The efficient operation of electric vehicles (EVs) heavily relies on the proper lubrication of the E-drive unit components, particularly the transmission gears and bearings. Inadequate oil supply can lead to mechanical failures, while excessive oil can increase power loss due to churning. This study focuses on utilizing Computational Fluid Dynamics (CFD) simulations to analyze the impact of drive speed, oil level and temperature on gear churning loss in E-drive units. The research also investigates the influence of a baffle plate on power loss and oil splash characteristics. The simulations, conducted using the volume of fluid (VOF) method in Simerics-MP+, consistently illustrate a reduction in power loss with rising oil temperature and reveal decreased gear churning loss with a baffle plate, especially under high-speed conditions, highlighting its potential for enhancing energy efficiency in EVs. Additionally, post-processing analysis of oil splash patterns sheds light on the
Kumar, P. Madhan, Motin, Abdul, Pandey, Ashutosh, Ganamet, Alain, Maiti, Dipak, Gao, Haiyang, Ranganathan, Raj
Technical Paper
Flow and Heat Transfer Performance Analysis of Plate-Fin Heat Exchanger in Electric Vehicles2025-01-8157To be published on 04/01/2025
In driving condition, the electric drive system of electric vehicles generates significant heat, which increases temperature of the motor, leading to reduced performance and energy loss. To manage the motor temperature and recover energy, a plate-fin heat exchanger (PFHE) is used to facilitate heat exchange between the electric drive system and the vehicle's thermal management system. In this study, Computational Fluid Dynamics (CFD) method was used to investigate the fin structure on thermal flow performance within the PFHE. A CFD simulation model was developed for a local heat exchange unit, considering the generic boundary conditions and temperature-dependent properties of the coolant and oil in the PFHE. The pressure drop and heat transfer rate of the local heat exchange unit were calculated under different boundary conditions, and an empirical formula for the friction factor was derived. The Wilson plot method was applied to separate convective heat transfer resistance from the
Yin, Jintai, Yin, Zhihong, Lu, Xuan, Wang, Mengmeng, Liu, Qian
Technical Paper
Concept of on-board diagnostic system of vehicle electric drive2025-01-8095To be published on 04/01/2025
The problem of monitoring parametric failures of a traction electric drive unit consisting of an inverter, a traction machine and a gearbox when interacting with a battery management system has been solved. The strategy for solving the problem is considered for an electric drive with three-phase synchronous and induction machines. The drive power elements perform electromechanical energy conversion with additional losses. The losses are caused by deviations of the element parameters from the nominal values during operation. Monitoring gradual failures by additional losses is adopted as a key concept of on-board diagnostics. Deviation monitoring places increased demands on the information support and accuracy of mathematical models of power elements. The first harmonics of currents and voltages of a three-phase circuit, which are the dominant energy source, were taken into account. Higher harmonics of PWM appear as harmonic losses. Mechanical losses in the rotor and gearbox can be many
Smolin, Victor, Gladyshev, Sergey, Topolskaya, Irina
Technical Paper
Efficient Process for Multidisciplinary Optimization of Electric Drive Units: A Case Study on Enhancing Design Efficiency2025-01-8645To be published on 04/01/2025
The design of drive units in electric vehicles (EVs) presents challenges due to the need to pass multiple linear and non-linear load cases. This can result in inefficient design. Therefore, optimization plays a critical role in improving the design efficiency. However, setting up the optimization process itself can be challenging, especially when dealing with complex design variables and different load cases that require the use of various computer-aided engineering (CAE) solvers. The drive unit, being a casting component, presents additional challenges in setting up Multidisciplinary Design Optimization (MDO) process. This paper introduces an efficient process for addressing these challenges by presenting a sample Multidisciplinary Design Optimization (MDO) problem. The problem involves the manipulation of discrete design variables, such as the number of ribs, and incorporates five different load cases that require the utilization of different CAE solvers. The proposed process
Chavare, Sudeep, Bamane, Sachin, Chen, Chi, Kim, Jong-Eun, Li, Haiyan, Bandi, Punit
Technical Paper
HEV Fuel Consumption Analysis, including Transmission Losses2025-01-8535To be published on 04/01/2025
A first-order HEV fuel consumption model is developed by solving for the transition between electric drive at low and negative traction power and engine drive and charging at high traction power. Turning the engine on above the 'breakeven power' minimizes fuel consumption: indirect electric driving from engine charging is more efficient below it, and direct engine operation above it. This is derived analytically and observed in benchmarking data on different drive cycles. The engine breakeven bmep is a function of engine loss and electric round trip efficiency. The location of the breakeven power on the cumulative traction work vs. time distribution enables the estimation of the engine running time at high traction power levels and of the engine work needed for extended electric driving. The approach is generalized to HEVs with substantial transmission and driveline (T&D) losses, such as the 'P2' Rear Wheel Drive (RWD) hybrid vehicles, with a motor sandwiched between the engine and the
Phlips, Patrick
Technical Paper
Research on motor Harmonic injection control in Hybrid System to Suppress the Torsional Vibration2025-01-8515To be published on 04/01/2025
Based on the harmonic current injection method used to suppress the torsional vibration of the electric drive system in this paper, and the exploration of the selection of the phase and amplitude of the harmonic current based on vibration and noise. 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
Jing, Junchao, Zhang, Junzhi, Liu, Yiqiang, Huang, Weishan, Dai, Zhengxing
Technical Paper
Path planning and path following control of all-wheel steering vehicle with dual modular chassis2025-01-8793To be published on 04/01/2025
Abstract: A large-scale logistics transport vehicle composed of two four-wheel drive and four-wheel steering skateboard chassis is investigated in this paper. This unmanned vehicle with dual-modular chassis (VDUC) is suitable for transporting varying size of goods. The two chassis can be used jointly or driving separately as needed, which enhancing the reconfigurability of transport vehicle. Considering the road environment uncertainty and the rollover safety problem associated with large transport vehicle, this paper proposes the path planning of VDUC using the APF+MPC while incorporating the rollover stability index. Due to the independent operation of the two modular chassis, based on the hierarchical control approach, the path following controller of the two modular chassis are designed separately according to the vehicle’s planned path. Distributed model predictive control is applied to coordinate the front and rear modular chassis, thus it can realize the path following for the
Liu, Zuyang, Shen, Yanhua, Wang, Kaidi, wang, Haoshuai
Technical Paper
A design of electric drive system for all-wheel drive Formula Student racing car to improve racing performance2025-01-8005To be published on 04/01/2025
This paper introduces an innovative in-wheel electric drive system designed for all-wheel drive Formula Student Electric racing cars. The system utilized AMK's DD5-14-10-POW-18600-B5 model as the driving motor, with a gearbox transmission ratio of 13.2 determined through Optimum Lap simulation. A two-stage gear reducer was integrated into a unified hub-spoke assembly, which connected directly to the ten-inch carbon fiber rim. The planetary carriers were integrated with the wheel-edge suspension columns, and certain structural components were topologically optimized using Altair Inspire. This integration allowed the entire electric drive system to be housed within the wheel, resulting in a weight reduction of over 10% and an improvement in overall aerodynamic performance by approximately 5%, compared to conventional designs where the planetary gearboxes are integrated within the suspension columns. Meanwhile, a special floating brake disc mounting method was employed, which increased
Guo, Ruijie, Zeng, Junhao, Yang, Yuancai, Hou, Yijie, Zhu, Zhonghui, Xiong, Jiaming
Technical Paper
Development of deep reinforcement learning traction controllers for front and rear wheel drive electrified vehicles2025-01-8803To be published on 04/01/2025
Traction control plays a key role in improving vehicle safety, especially for driving scenarios involving low levels of tyre-road friction. Over the past 30 years, academic and industrial research in traction controllers has mainly favoured deterministic approaches. This paper introduces a traction control strategy based on a deep reinforcement learning agent tailored for straight-line acceleration manoeuvres from standstill in low-friction conditions. The proposed agent is trained on two different electric vehicles, a front-wheel drive city car (from EU vehicle segment A), and a rear-wheel drive sedan (from EU vehicle segment D). The paper presents a deep reinforcement learning agent formulation suitable for training on different vehicles, assesses the performance of the resulting controllers, and evaluates their response to changes in vehicle mass, powertrain parameters and tyre-road friction conditions. The assessment uses a high-fidelity co-simulation model, combining AVL VSM and
Caponio, Carmine, Mihalkov, Mario, Hankovszki, Zoltan, Fuse, Hiroyuki, Ivanov, Valentin, Sorniotti, Aldo, Gruber, Patrick, Montanaro, Umberto
Technical Paper
Research on Motor Safety Monitoring Control for Powertrain Control System2025-01-8511To be published on 04/01/2025
The motor controller, as one of the important controllers in the electric drive system, may cause unexpected acceleration or deceleration of the vehicle by the driver due to systematic failure and random hardware failure. Conducting research on the functional safety of drive motors for new energy vehicles is of great significance for reducing the systematic failure and random hardware failure of the electric drive. This paper has carried out designs including the allowable motor torque design for safety monitoring, the motor torque prediction design for safety monitoring, the rationality judgment design of the motor torque for safety monitoring, the rationality judgment design of the motor direction for safety monitoring, the functional safety motor degradation design, and the active discharge state monitoring of the motor, so that the system can transition to a safe state when an error occurs. Among them, the motor torque prediction design for safety monitoring includes predicting the
Jing, Junchao, Zuo, Botao, Liu, Yiqiang, Huang, Weishan, Dai, Zhengxing
Technical Paper
Design and Development of Range Extended-Hybrid Power Train for Two-Wheeler2025-28-019402/07/2025
Environmental awareness is being fostered in every sector, with particular emphasis on the automotive industry. Conventional internal combustion engines are responsible for greenhouse gas emissions and health issues. Researchers are looking for alternative technologies to reduce carbon footprint and for a green environment. In this study, electric drivetrain is designed for 20% range extension and retrofitted in conventional two-wheeler. An effective control technique has been developed, thoroughly tested, and effectively implemented on the two-wheeler. The hybrid drivetrain architecture is assessed for complexities such as the required space for the battery and the location for fitting the electric motor. During low-speed conditions, the electric motor reduced the emissions and minimized fuel consumption. Consequently, the overall utilization of internal combustion engines at low-speed conditions has decreased, leading to a decrease in the vehicle's fuel consumption and exhaust gases.
Banad, Chandrashekhar B, Devunuri, Suresh, Nair, Jayashri Narayanan, Hadagali, Balappa, Prasad, Gvl
Technical Paper
Analysis and Refinement of Road Boom Noise in Electric Vehicle2025-28-005702/07/2025
Customers are expecting higher level of refinement in electric vehicle. Since the background noise is less in electric vehicle in comparison with ICE, it is challenging for NVH engineers to address even minor noise concerns without cost and mass addition. Higher boom noise is perceived in the test vehicle when driven on the coarse road at a speed of 50 kmph. The test vehicle is rear wheel driven vehicle powered by electric motor. Multi reference Transfer Path Analysis (TPA) is conducted on the vehicle to identify the path through which maximum forces are entering the body. Based on the findings from TPA, solutions like reduction in the dynamic stiffness of the suspension bushes are optimized which resulted in reduction of noise. To reduce the noise further, Operational Deflection Shape (ODS) analysis is conducted on the entire vehicle to identify the deflection shapes of all the suspension components and all the body panels like floor, roof, tailgate, dash panel, quarter panel and
S, Nataraja Moorthy, Rao, Manchi Venkateswara, Raghavendran, Prasath, Selvam, Ebinezer
Technical Paper
Gear Misalignment Optimization for Electric Drive Unit Using Machine Learning Based Prescriptive Analytics2025-28-016602/07/2025
In Electric vehicle Drive Unit Gears, high mesh misalignments result in shift in load distribution of a gear pair that can increase contact and bending stresses. It can move the peak bending and contact stresses to the edge of the face width and increase gear noise as well. Lower misalignment value is often required to reduce the peak bending and contact stresses and have a balanced load distribution along the gear flank, which in turn helps in reducing noise and improving durability of drive unit. This paper delineates Prescriptive Analytics method that combines virtual simulations, Machine learning (ML) and optimization techniques to minimize different gear misalignments for the electric vehicle drive units. Generally, the manual optimization process is carried out by sequential modifications of stiffness of individual components. However, this process is time consuming and does not account for interactions between the components. In this study, firstly, Machine learning models are
Penumatsa, Venkata Ramana Raju, Thomas, Benson, Black, Derrick, Jain, Sachin
Technical Paper
Design and Development of Tractor Front Three Point Linkage System2025-28-000602/07/2025
Today’s agriculture demands increased productivity due to the higher cropping intensities. Agricultural field readiness for cultivation requires various operation in field resulting in delay in cultivation which lower down productivity. Therefore, field operation needs to be more efficient in terms of both input cost and time consumption. One way to achieve this is by performing multiple operations in a single tractor pass, utilizing the increased power available in modern Tractors. In some agricultural operations, implements need to be mounted on the front of the tractor. Therefore, designing a front three-point hitching system for the tractor is essential to meet various farming needs, allowing customers to perform multiple operations simultaneously. The use of a front three-point linkage better utilizes the potential of four-wheel drive, higher horsepower tractors. This paper focuses on the comprehensive design process for developing and validating a front hitch system for both
Kumar, Yuvaraj, V, Ashok Kumar, Perumal, Solairaj, Gaba, Rahul, Ramdebhai, Karavadara, Subbaiyan, Prasanna Balaji, M, Kalaiselvan
Technical Paper
Modeling and Simulation Analysis of Thermal Management System for Hydrogen Fuel Cell Vehicle2025-01-709101/31/2025
An effective vehicle integrated thermal management system (ITMS) is critical for the safe and efficient operation of proton exchange membrane fuel cell (PEMFC) vehicles. This paper takes a fuel cell vehicle (FCV) as the research object, comprehensively considers the vehicle layout environment and thermal management requirements, and designs a complete thermal management system for FCV. The key components are selected and designed to match the performance and the control strategy of ITMS of fuel cell vehicle is developed. To do that, the ITMS model is established based on the heating principle and heat transfer theory of each key component. Then, the ITMS under Worldwide Harmonized Light Vehicles Test Cycle (WLTC) operating conditions at different ambient temperatures are simulated and analyzed by selecting indicators such as coolant flow rate and temperature. Under the ambient temperature of 40°C, the temperature of PEMFC is basically stable between 78 °C and 83°C, the coolant outlet
Jiang, Qi, Xiong, Shusheng, Wang, Yupeng, Zhu, Shaopeng, Chen, Huipeng
Technical Paper
Inductance Characteristics of the Axial-Radial Hybrid Excitation Motor with Fractional Slot Centralized Winding2025-01-705601/31/2025
The inductance parameter is important for the flux regulation performance of the hybrid excitation motor, and the axial structure leads to the change in the inductance parameter of the axial-radial hybrid excitation motor (ARHEM). To clarify the inductance characteristic of the ARHEM with different winding construction and the mutual coupling effect between the axial excitation and permanent magnet excitation on the inductance. Firstly, the structure of the ARHEM is presented. Secondly, the self and mutual inductance characteristics of ARHEM are analyzed using the winding function method. Then, the influence of the axial excitation structure on the armature reaction field and saliency ratio of ARHEM. On this basis, the mechanism of the mutual coupling, between the axial excitation and permanent magnet field under different excitation currents on the main air gap magnetic field, and the inductance of ARHEM with fractional slot are revealed.
Fu, DongXue, Zhao, Hewei, Wu, Qimin, Yuan, Chunwei, Wang, Dong, Qiu, Hongbo
Technical Paper
Fusion Control Strategy Based on Rule and Dynamic Objective of Heat Pump Type Thermal Management System for Electric Vehicles2025-01-702301/31/2025
Thermal management system of electric vehicles (EVs) is critical for the vehicle's safety and stability. While maintaining the components within their optimal temperature ranges, it is also essential to reduce the energy consumption of thermal management system. Firstly, a kind of architecture for the integrated thermal management system (ITMS) is proposed, which can operate in multiple modes to meet various demands. Two typical operating modes for vehicle cooling in summer and heating in winter, which utilizes the residual heat from the electric drive system, are respectively introduced. The ITMS based on heat pump enables efficient heat transfer between different components. Subsequently, an ITMS model is developed, including subsystems such as the battery system, powertrain system, heat pump system and cabin system. The description of modeling process for each subsystem is provided in detail. The model is tested under world light vehicle test cycle (WLTC) condition of six different
Zhao, Luhao, Tan, Piqiang, Yang, Xiaomei, Yao, Chaojie, Liu, Xiang
Technical Paper
Model Predictive Torque Control of PMSM Without Weighting Factors Based on MRAS Parameter Identification2025-01-705701/31/2025
The design of weighting factors in the cost function of traditional model predictive torque control (MPTC) is relatively cumbersome, at the same time, the accuracy of the prediction model decreases obviously when the motor parameters are mismatched. Therefore, a model predictive control without weighting factors based on on-line identification of motor parameters is studied. Firstly, the control objectives transformed from torque and flux of traditional MPTC to active torque and reactive torque, since they are of the same dimension the design of weighting factors is unnecessary. Secondly, aiming at the problem of control performance degradation caused by the change of motor parameters in the prediction model, the online identification of motor parameters based on model reference adaptive system is studied, the identification results are applied to the prediction process to avoid the bad influence caused by the parameter variation. The findings from the simulation indicate that the
Zhang, Yanqing, Jia, Danyang, Yin, Zhonggang, Liu, Qi
Technical Paper
Direct Yaw Moment Control for Distributed Drive Electric Vehicles Based on Full-Order Terminal Sliding Mode2025-01-702401/31/2025
Distributed Drive Electric Vehicles (DDEVs), as a significant development form of electric vehicles, have garnered considerable focus owing to their excellent energy utilization efficiency and the capability for flexible torque distribution. However, DDEVs still face numerous challenges in practical applications, particularly in the coordinated control of hub motors and system stability. This paper focuses on the whole-vehicle control technology and distributed control theory of DDEVs and researches the active safety function of Direct Yaw-moment Control (DYC): acceleration and turning. A full-order terminal sliding mode controller is utilized to suppress the chattering of sliding mode control and to reduce torque fluctuations in the output. Results show that the proposed method can enhance the vehicle’s yaw stability and driving safety with the linear sliding mode.
Zhou, Minghao, Wu, Weiwei, Fei, Xueran, Chen, Zhenqiang, Jiang, Longbin, Cai, William
Technical Paper
Predictive Torque Control of Open End Winding PMSM Under Single Phase Fault with Torque Ripple Suppression2025-01-705301/31/2025
To enhance the operating performance of the common-bus open-winding permanent magnet synchronous motor under single-phase open-circuit faults, this paper proposes a model predictive torque control strategy with torque ripple suppression. First, the operating principles of the model predictive torque control system for both normal operation and single-phase fault conditions are analyzed. Based on this analysis, the electromagnetic torque controller in the model predictive torque control system is restructured. However, if the conventional space vector modulation strategy used during fault-free operation is continued, the required stator voltage cannot be achieved. Therefore, analyze the phase relationship of the current before and after the fault, derive a new Clark transformation matrix, and then based on the principle of torque invariance that can be generated by the fundamental magnetic flux, derive the coefficients of the Park transformation of the two-phase current. To simplify the
Zhang, Dongdong, Mo, Fushen, Lin, Xiaogang
Technical Paper
Advanced Design Validation Planning Techniques for Commercial Vehicle E-Axles02-17-04-002412/16/2024
Design validation plays a crucial role in the overall cost and time allocation for product development. This is especially evident in high-value manufacturing sectors like commercial vehicle electric drive systems or e-axles, where the expenses related to sample procurement, testing complexity, and diverse requirements are significant. Validation methodologies are continuously evolving to encompass new technologies, yet they must be rigorously evaluated to identify potential efficiencies and enhance the overall value of validation tests. Simulation tools have made substantial advancements and are now widely utilized in the development phase. The integration of simulation-based or simulation-supported validation processes can streamline testing timelines and sample quantities, all the while upholding quality standards and minimizing risks when compared to traditional methods. This study examines various scenarios where the implementation of advanced techniques has led to a reduction in
Leighton, Michael, Tuschkan, Alwin, Playfoot , Ben
Journal Article
AI-Based Smart Vehicle Parking System2024-01-524212/10/2024
This project presents the development of an advanced Autonomous Mobile Robot (AMR) designed to autonomously lift and maneuver four-wheel drive vehicles into parking spaces without human intervention. By leveraging cutting-edge camera and sensor technologies, the AMR integrates LIDAR for precise distance measurements and obstacle detection, high-resolution cameras for capturing detailed images of the parking environment, and object recognition algorithms for accurately identifying and selecting available parking spaces. These integrated technologies enable the AMR to navigate complex parking lots, optimize space utilization, and provide seamless automated parking. The AMR autonomously detects free parking spaces, lifts the vehicle, and parks it with high precision, making the entire parking process autonomous and highly efficient. This project pushes the boundaries of autonomous vehicle technology, aiming to contribute significantly to smarter and more efficient urban mobility systems.
Atheef, M. Syed, Sundar, K. Sham, Kumar, P. P. Prem, Karthika, J.
Technical Paper
Development and Analysis of Hybrid Electric Two-Wheeler for City Driving2024-01-521612/10/2024
In highly populated countries two-wheelers are the most convenient mode of transportation. But at the same time, these vehicles consume more fuel and produces emissions in urban driving. This work is aimed at developing a hybrid two-wheeler for reducing fuel consumption and emissions by incorporating electric vehicle technology in a conventional two-wheeler. The hybrid electric scooter (HES) made consisted of an electric hub motor in the front wheel as the prime mover for the electrical system. The powertrain of the HES was built using a parallel hybrid structure. The electric system is engaged during startup, low speeds, and idling, with a simple switch facilitating the transition between electric and fuel systems. The HES was fabricated and tested through trial runs in various operating modes. Before conversion to a hybrid system, the two-wheeler achieved a mileage of 34 km/liter. After conversion, the combined power sources resulted in an overall mileage of 55 km. It was observed
Rajesh, K., Chidambaranathan, Bibin, Raghavan, Sheeja, Ashok Kumar, R., Arunkumar, S., Soundararajan, Gopinath, Madhu, S.
Technical Paper
Review on Integrated Thermal Management Systems of Electric Vehicles2024-28-022712/05/2024
Electric Vehicles use Li-ion batteries due to their high energy and power densities. Performance of Li-ion cell is sensitive to temperature. Temperature control of these batteries becomes very important to provide safety and performance under different working conditions. This paper review different integrated thermal management system developed for Electric Vehicles. integrated thermal management content. Battery thermal management, Cabin thermal management and Electric drive thermal management. These systems share some common objectives and common parts. Integration of these systems will help to optimize the number of components in the Electric Vehicles thermal management system. The integrated thermal management system also helps to optimize the weight and use of waste heat to heat the cabin or battery. This will help in optimization of energy consumed by the thermal management system and range improvement. Integrating different systems which content refrigerant and coolant circuit
Mhaske, Pramodkumar Chimaji
Technical Paper
PRODUCT BRIEFS24AUTP12_1312/01/2024
Magazine Article
PRODUCT BRIEFS24TOFHP12_1312/01/2024
Magazine Article
A Novel Approach to the Design and Development of a C-Core Sandwich-Type Radial Field Switched Reluctance Motor with On-Shaft Implementation in EV Application14-14-01-000711/19/2024
A novel design for a radial field switching reluctance motor with a sandwich-type C-core architecture is proposed. This approach combines elements of both traditional axial and radial field distribution techniques. This motor, similar to an in-wheel construction, is mounted on a shared shaft and is simple to operate and maintain. The rotor is positioned between the two stators in this configuration. The cores and poles of the two stators are separated from one another both magnetically and electrically. Both stators can work together or separately to produce the necessary torque. This adds novelty and improves the design’s suitability for use with electrical vehicles (EVs). A good, broad, and adaptable torque profile is provided by this setup at a modest excitation current. This work presents the entire C-core radial field switched reluctance motor (SRM) design process, including the computation of motor parameters through computer-aided design (CAD). The CAD outputs are verified via
Patel, Nikunj R., Mokariya, Kashyap L., Chavda, Jiten K., Patil, Surekha
Journal Article
An Active Control Method Based on the Study of Dynamic Characteristics of Integrated Electric Drive Systems02-18-01-000211/13/2024
Integrated electric drive systems are characterized by high power density, reliability, and controllability, making them increasingly prevalent in the realm of electric commercial vehicles. However, the direct coupling between the motor shaft and the transmission system has introduced a series of undesirable torsional vibration phenomena. To investigate the dynamic characteristics of electric drive systems in operation for electric commercial vehicles, a comprehensive modeling approach is employed. This modeling framework takes into account key factors such as gear backlash, structural flexibility, and electromagnetic spatiotemporal excitations. Based on this model, the influence of the electrical system on time-varying gear mesh stiffness, gear transmission error, bearing forces, and other factors is investigated. Building upon this foundation, the article proposes an approach for active harmonic voltage injection. This method effectively reduces torque fluctuations, decreases the
Xi, Xin, Chen, Xiaoli, Zhao, Hongyang, Zhao, Xuan, Wei, Jing, Liu, Yonggang
Journal Article
Energy Efficiency Evaluation of a Hybrid Electric Tractor-Semi-Trailer Prototype2024-01-431911/05/2024
The objective of the project was to evaluate the energy efficiency of a hybrid electric tractor-semi-trailer combination prototype. The prototype was developed for log hauling application by integrating an existing tractor with an electric semi-trailer to improve fuel consumption and reduce greenhouse gas emissions. One of the conventional axles of the quad axle semi-trailer was replaced with a drive axle powered by an electric motor. Tests were conducted on a 105 km test route with a maximum difference in elevation of 355 m, including a hilly section with a length of 89 km. The results indicated fuel savings ranging from 10.5% to 14% per test run, with an average fuel savings of 12% when the electric drive axle was engaged. The hybrid electric tractor semi-trailer consumed 17.5% less fuel up-hill and 9.4% less down-hill. Throughout each test run, the battery’s state of charge fluctuated, averaging between 88% at the start and 52% at the end. Prior to each run, the batteries were
Surcel, Marius-Dorin, Mercier, Steve, Bonsi, Adime Kofi
Technical Paper
WITHDRAWN: Evaluating the Ratcheting Performance of Park Lock Mechanism for Electric Drive Unit Using Multibody Dynamics Approach2024-01-4315.0111/05/2024
This paper has been withdrawn at the request of Dana Inc., owner of proprietary information within the paper.
Deshmukh, Shardul, Kakade, Shriram Sopan
Technical Paper
Design and Development of a Micromobility Smart Electric Scooter to Revolutionize Urban Commuting2024-28-002110/17/2024
Urban areas around the world are facing an increasing number of issues, such as air pollution, parking shortages, traffic congestion and inadequate transit options, all of which necessitate innovative solutions. Lot of people are becoming interested in micromobility in urban areas as a replacement for quick excursions and round trips to get to or from transportation services (e.g., Offices, Institutions, Hospitals, Tourist spots, etc.). This research examines the critical role that micromobility plays, concentrating on the effectiveness of micromobility smart electric scooters in resolving urgent urban problems. Micromobility, which includes both human and electric-powered vehicles, presents a viable substitute for normal and short-distance urban commuting. This study presents a micromobility smart electric scooter that is portable and easy to operate, with the goal of transforming urban transportation. 3D model was designed using SOLIDWORKS and analyzed using ANSYS. For strength and
Tappa, Raju, Singh Chowhan, Sri Aanshu, Shaik, Amjad, Maroju, Abhinav, Talluri, Srinivasa Rao
Technical Paper
Enhancing Gear Performance: Discrete Response Optimization through OptiSLang2024-28-004010/17/2024
Original equipment manufacturers have already begun to transition their vehicles from traditional internal combustion engines (ICEs) to electric drives (EVs). As the industry continues to move towards electrification, the entire industry, and especially Valeo, is focusing on lean product development (LPD) with the help of numerical simulation. Optimization techniques help industry achieve the most accurate product at the lowest cost without sacrificing performance. Generally gears are mainly used for power transmission in the advanced technologies of electric vehicles. There are many factors that must be taken into account when designing a gear transmission system. Finding the most appropriate design parameters for a gear transmission system can be a challenge, and optimization parameters will help to find the best compromise between them. The main objective of this study is to increase the contact safety factor of the gear system by fulfilling 14 constraints, which are continuous (5
C, Lokesh, Lawrence, Leons, Drouet, Benjamin, G, Rajesh Kumar, Gopalakrishnan, Hemanth Kumar
Technical Paper
Design, Modeling and Analysis of Roll Cage for SAE BAJA Vehicle2024-28-001210/17/2024
This paper studies design parameters, selection of materials and structural analysis for an All-Terrain Vehicle (ATV) BAJA roll cage at the event site in any possible situation. SolidWorks 2022 was used for creating the prototype of the roll cage and then both static structural as well as dynamic crash analysis for the roll cage was done using Altair HyperWorks 2023 for various collisions like front, rear, side, rollover, torsional, front bump, rear bump, front roll over, side roll over and rear roll over. In addition to their corresponding deformation, Von Mises stresses were observed and a safety factor was calculated for these load cases which was found to be in the range of 1.5 to 3. Without reducing the roll cage’s strength, the roll cage designed for a four-wheel drive configuration is developed with driver comfort and safety in mind. Finding the optimal safety factor is the core objective of the analysis, as it ensures in any situation, the ATV’s roll cage will stay secure.
L, Ravi Kumar, Sanjay P, Chiranjeev, T J, Pravin Chander, Moses J, Jebish, D, Parthesun, G, Sureshmani
Technical Paper
A Comparative Study on Autonomous Vehicle Local Path Planning Through Model Predictive Control and Frenet Frame Method12-07-04-002910/07/2024
In recent years, autonomous vehicles (AVs) have been receiving increasing attention from investors, automakers, and academia due to the envisioned potentials of AVs in enhancing safety, reducing emissions, and improving comfort. The crucial task in AV development boils down to perception and navigation. The research is underway, in both academia and industry, to improve AV’s perception and navigation and reduce the underlying computation and costs. This article proposes a model predictive control (MPC)-based local path-planning method in the Cartesian framework to overcome the long computation time and lack of smoothness of the Frenet method. A new equation is proposed in the MPC cost function to improve the safety in path planning. In this regard, an AV is built based on a 2015 Nissan Leaf S by modifying the drive-by-wire function and installing environment perception sensors and computation units. The custom-made AV then collected data in Norman, Oklahoma, and assisted in the
Arjmandzadeh, Ziba, Abbasi, Mohammad Hossein, Wang, Hanchen, Zhang, Jiangfeng, Xu , Bin
Journal Article
Method and System for Efficient Thermal Management in Electric Vehicles2024-28-006009/19/2024
Electric Trucks offer one of the most promising alternatives to vehicles in the field of transport of goods. In battery electric trucks, heat is generated by components present in the electric truck such as battery of the electric vehicle, electric drive system, Endurance Brake System etc. which require cooling and Thermal management system to control and monitor the cooling system. The thermal management system considered here includes two coolant tanks. The first coolant tank performs thermal management for the battery and Electric-Drive(e-Drive) components which can heat up to 600C and the second coolant tank performs thermal management for HPR circuit, and it is used to break the charging circuit to protect the battery getting charged beyond 100% using regenerative braking concept. HPR (High performance resistor) is the component which can heat up to ~950C and make sure the battery is not getting charged beyond the safe limits. Since HPR is a critical component and operates at high
Pekala, Sagar Mohana, Zacharias, Nevin, Kulkarni, Krathika
Technical Paper
Modern Tools for Tribological Optimization of EV Transmissions and e-Axles2024-24-001309/18/2024
EV motors and transmissions operate at high speeds and handle high power densities, placing heavy demands on bearings, seals, and gears. TEHD and meshless CFD simulations open new ways to the design and optimization of lubrication and thermal management solutions for EV transmissions and e-axles. Properly parametrized CAE models can provide valuable insights into the effects of different lubricant properties on cooling and lubrication efficiencies, thereby helping in matching the lubricant and hardware characteristics for optimal performance. In the present communication, we demonstrate the effects of different lubricants and surface finishing technologies on the tribology of high-speed gears using tribological tests and simulations. Important roles of lubricity additives and surface finish optimization are highlighted in conjunction with a move towards ultralow viscosity fluids.
Zhmud, Boris, Merelli, Michele
Technical Paper
Towards an Analytical Method for a Combined Energy Management and Shift Strategy in Hybrid Electric Vehicles, and Its Rule-Based Implementation2024-24-000209/18/2024
In conventional vehicles the shift strategy has a well-known impact on the system’s efficiency. An appropriate gear choice allows the internal combustion engine (ICE) to operate in efficient operating points (OPs) and thus contributes significantly to a reduced fuel consumption. Further efficiency improvements can be achieved by the hybridization of the powertrain. Due to the two propulsion systems, an additional degree of freedom arises, that requires an energy management strategy (EMS). The EMS controls the split of the requested power between the electric machine (EM) and the ICE. Accordingly, the system’s overall efficiency in hybrid electric vehicles (HEVs) is highly influenced by the quality of the EMS. This paper proposes to adapt an existing method for deriving fuel-optimal rule-based EMS by including the shift strategy for parallel HEVs. It is shown that fuel-optimal control can be achieved. The analytically derived look-up tables can be used to automatically calibrate in
Ehrenberg, Bastian, Engbroks, Lukas, Schmiedler, Stefan, Hofmann, Peter
Technical Paper
Snowmobile Drive MechanismsJ1279_202408 (Current)08/12/2024
This SAE Standard is applicable to snowmobiles as defined in SAE J33.
Snowmobile Technical Committee
Recommended Practice
Toyota, Mazda, Subaru agree carbon is ‘the enemy’ with new internal combustion engine announcement24AUTP08_1008/01/2024
Toyota, Mazda and Subaru announced a new technological effort to create new internal combustion engines and ways to use them in the electrification era, specifically for hybrid and plug-in hybrid vehicles. The companies said at a joint press conference in Japan that they would encourage increased use of petroleum alternatives like biofuels and eFuels in their effort to create carbon-neutral vehicles. A joint statement from the three OEMs claims this push for new and better ICEs comes with a focus on “carbon as the enemy” as they develop engines that can better work with electric motors, batteries, and other electric drive units. Toyota, Mazda and Subaru made clear they are not getting rid of EV-only vehicle plans. Here's how each company will approach the new ICE+EV era (quotes provided in English by on-site interpreters).
Blanco, Sebastian
Magazine Article
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