Browse Topic: Electric drives
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
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
ABSTRACT Future Military ground vehicle power trains can benefit from a hybrid-electric drive approach, particularly in packaging flexibility where drive train components can be modular and conveniently distributed. Small component size and operation with high-temperature liquid coolant are essential factors in the flexible packaging concept. This paper describes the development of one component, a 220 kW traction motor drive for a hybrid-electric power train. Challenging requirements for the motor-drive include power densities of at least 25 kW/liter and 15 kW/kg at 105°C coolant temperature. To achieve these densities, power modules capable of high-temperature operation were developed using SiC normally-off JFETs. This paper will discuss the unique custom packaging of the SiC JFET devices, as well as the arrangement of key components/packaging and thermal management issues
ABSTRACT There is continued demand for military vehicles to provide increased fuel economy. Recent trends have appropriately turned to the development of duty cycles that better represent the real-life usage of vehicles. The advent of hybrid electric propulsion and power system architectures offer opportunities for reducing fuel consumption and greater power generation flexibility. The challenge is to effectively quantify the predicted performance for the architectures under consideration using tools that are applicable to shorter development schedules. This paper discusses the importance of using multidomain physics-based computer simulations to perform the fuel consumption analyses. The models used include mechanical, electrical, magnetic and thermal effects, and their intimate interaction in order to predict the fuel consumption for a tracked vehicle traversing courses at varying speed, up and down hills, and negotiating turns. This paper also compares the fuel consumption
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
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
Encapsulations of E-drive systems are gaining importance in electric mobility, since they are a simple measure to improve the noise behavior of the drive. Current experimental evaluation methods, however, pose substantial challenges for the test personnel and are associated with considerable effort in both time and cost. Evaluating the encapsulation on an e-drive test bed, for example, requires a functional e-drive and test bed resources. Evaluations in the vehicle on the other hand make objective assessments difficult and are subject to increasingly limited availability of prototype vehicles fit for NVH testing. To overcome these challenges, AVL has developed a new experimental evaluation method for the NVH efficiency of e-drive encapsulations. In this method, the e-drive is freely suspended in a semi-anechoic chamber and its structure is excited using shakers while the radiated noise with and without encapsulation is measured. The NVH efficiency of the encapsulation is evaluated by
Accelerated adoption of electric propulsion system in mobility industry has stressed the time and iterations of product development cycle which was traditionally known to go over multiple iterations and phases. Current market demands a timely introduction of compelling products that brings high value to end user. Further, a growing emphasis over reducing mineral content using sustainable options and process, adds further complexity to multi-objective-optimization of electric drive systems. At BorgWarner our engineers use Digital-Twins, physics-based models which closely represent BorgWarner products in greater dept (physics) thus allowing an improved assessment of product design (components and systems) to target application at very early stage in product development. The spring success with Digital-Twin, BorgWarner furthered enhanced the model through introducing Artificial Intelligent (AI) and Machine Learning (ML) technologies in both modelling and virtual sensing. This paper will
The paper solves the problem of increasing the accuracy of measuring torque and use of an electronic torque meter as a feedback sensor of synchronous and induction machines of an electric traction drive. Relevance of the problem and methods for its solving by indirect means using simulation models of electric machines are considered. The theoretical development of the meter is based on the energy model of electric machines in the form of differential equations for active and reactive power balance. This eliminates the direct influence of instability and nonlinearity of inductive elements and takes into account electrical, magnetic, mechanical, and harmonic losses using the simplest algorithms. Key variables of the model in the form of total active power and angular velocity are measured directly, and the high nominal efficiency of traction machines (95%) provides a wide tolerance range for calculating total losses. The information support of the meter is based on the traditional
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