Browse Topic: Electric vehicles

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Stochastic Gradient Pulse Adaptation for Onboard Pulse Charging in Grid-Friendly DC Fast Charging of Battery Electric Vehicles2026-01-0734To be published on 07/01/2026
The increasing deployment of battery electric vehicles (BEVs), particularly in commercial and heavy-duty applications, is driving demand for higher DC fast-charging power while placing growing pressure on battery lifetime and local grid capacity. In today’s multi-battery-pack vehicles, a common practical solution is the use of multi-step or multi-constant CC-CV charging, where charging current is reduced in stages to accommodate pack-to-pack differences in state of charge, state of health, and ageing behavior. While effective from a safety standpoint, this approach often leads to conservative charging profiles, longer charging times, and inefficient use of available grid power, especially at higher charging rates. This paper presents an onboard pulse-charging concept for electric powertrains that addresses these limitations through a combination of vehicle-side power electronics and an adaptive control strategy referred to as Stochastic Gradient Pulse Adaptation (SGPA). Instead of
Prakashkumar, Balagopal, Mannar, Vignesh
Passive Thermal Management of Battery Disconnect Units for Fast-Charging Electric Vehicles: A Comparative Study of Phase Change Material Heat Transfer Configurations2026-01-0759To be published on 07/01/2026
Reducing charging time remains a critical challenge for the widespread adoption of electric vehicles (EVs). Limited charging infrastructure availability, combined with the long duration required for battery recharging, significantly affects user acceptance. As a result, fast-charging technologies are increasingly being introduced in both newly designed EV platforms and existing vehicles through retrofitting solutions. Despite their benefits, fast-charging systems impose substantial thermal loads on vehicle components, charging stations, and associated power electronics. Excessive heat generation can compromise performance, reliability, and safety, making effective thermal management a key design concern. Within the high-voltage architecture, the Battery Disconnect Unit (BDU) plays a vital role by monitoring and controlling the connection of the battery to the powertrain and charging system. Traditionally, BDUs are designed for conventional charging power levels; however, higher
Salameh, Georges, Goumy, Guillaume, Frecinaux, Anthony, Ratajczack, Christelle, Palluel, Marlène, Noiseau, Pascal, Lardeux, Sébastien
Design and Prototyping of a winding reconfiguration system for electric traction applications2026-01-0730To be published on 07/01/2026
Battery electric vehicles (BEVs) place high demands on electric drives across a wide operating range: high efficiency in customer-related driving scenarios and maximum performance in dynamic driving modes. A promising solution to this challenge is the dynamic reconfiguration of the electric machine winding configuration between series and parallel mode, enabling optimal electromagnetic properties of the drive for different operating points. This paper presents the design and prototyping of an electronic winding reconfiguration system for high-performance traction applications. Unlike mechanical switching concepts, which have long transition times and cannot switch under load, the proposed system enables fast and safe load transitions between the winding configurations. The study describes the topology and hardware of the switching unit, including the integration of power semiconductors, the required connection assemblies, cooling concept and the control of the power electronics. A
Oestreicher, Raphael, Schneider, Jörg, von Ohlen, David, Fuchs, Patrick, Kulzer, André Casal
Enhancing Efficiency in Megawatt-Scale EV Charging via Adaptive Multi-Agent Control of DC/DC Converters2026-01-0769To be published on 07/01/2026
The rapid adoption of electric vehicles (EVs) demands high-power charging solutions that are efficient, scalable, and reliable. This work introduces a comprehensive simulation framework for megawatt-scale charging systems, focusing on the integration and control of multiple DC/DC converters. With the primary objective of maximizing overall system efficiency during megawatt-scale charging operations. The study addresses key challenges in multi-converter operation, including load distribution, synchronization, and system efficiency. A multi-agent adaptive control strategy was implemented to dynamically optimize operating points and allocate charging currents across converters in real time so that each participating converter operates at its optimal operating point where the maximum efficiency is delivered. This multi-agent adaptive control strategy allocates not only the individual optimal operating points of the multiple DC/DC converters but rather determines the optimal number of
Salah, Alia, Abu Mohareb, Omar
Identifying and mitigating resonance effects in HV Powernets2026-01-0742To be published on 07/01/2026
HV Power nets of electric vehicles consists of various HV components such as batteries, inverters, auxiliaries and cables. During in-vehicle testing, multiple failures of an auxiliary inverter were observed, caused by resonance issues within the component filter. Initial investigations revealed that these resonances, absent during manufacturer testbench evaluations, were influenced by the vehicle power net and its impedance characteristics. To better understand the underlying causes and identify preventative measures, extensive simulations were performed. The results demonstrate a diminishing influence of the power net capacitance when significantly larger than the component capacitance. Also they highlight the critical impact of cable inductance on the component resonance frequency when comparable to the component’s inductance. A simplified electrical equivalent circuit was used to derive an equation predicting the resonance frequency as a function of the component’s capacitance
Schmiel, Fabian, Aurand, Tobias, Koehnlechner, Benjamin, Zimmer, Markus
Dynamic Wireless Charging for Electric Vehicles2026-01-0748To be published on 07/01/2026
This paper investigates the electromagnetic and circuit-level performance of an inductive power transfer (IPT) system for dynamic wireless charging of electric vehicles (EVs). Key design parameters affecting power transfer efficiency (PTE) are explored. A simplified Series-Series (SS) compensated IPT model using Double-D coil geometry and shielded ferrite backing was developed using MATLAB software. The framework has been built around variations of air gap, lateral misalignment, load resistance, and operating frequency. The results show that PTE is highly sensitive to spatial alignment, with a significant efficiency loss at air gaps greater than 10 cm and misalignments beyond 15 cm. Both parameters can cause a compounded nonlinear effect on the PTE, thus a 3D surface plot was used to confirm the simultaneous effects of both parameters. Load resistance analysis revealed an optimal range around 10–15 Ω, while frequency analysis showed a peak efficiency near 85 kHz, in alignment with SAE
Abdelrahman, Marwan, Sodre, Jose Ricardo
Application of Deterministic and AI-Based Methods to Accelerate the Component-Level Development Process in Electric Vehicles2026-01-0766To be published on 07/01/2026
The global automotive landscape is undergoing a significant paradigm shift driven by the rapid development cycles of emerging competitors, leaving traditional European OEMs with a critical time-to-market gap. To bridge this gap, automotive engineering must pivot from traditional hardware-based processes toward agile, digital data-driven methodologies. This paper presents a comprehensive feasibility study on the implementation of data-centric approaches, using both Artificial Intelligence and deterministic methodologies, with focus on accelerating component development. It provides a detailed assessment of various AI-based and deterministic methodologies at specific stages of the product development process, targeting both: 1. Product design 2. Product development process The aim is to enhance component-level performance, quality, and functionality, while simultaneously optimizing workflows, increasing process and development efficiency, and facilitating knowledge reuse throughout the
Bode, Jana Pascal, Kröll, Sarah, Vohwinkel, Nikolaus, Paetzold-Byhain, Kristin
Methodology Development for EDM Vibro-acoustic Assessment using Simulation Measurement Comparison and RCA2026-01-0691To be published on 06/20/2026
The virtual development of Electric Drive Modules (EDM) for Battery Electric Vehicles (BEVs) requires proven and predictive methodologies. One part of the development investigates the vibro-acoustic assessment for low and high frequencies over the targeted operating range. The efficient usage of such a methodology requires the understanding of the accuracy and the validity of the achievable results as well as the derivation of suitable improvement measures for goals that have not been achieved. The usage of reference data from experimental investigations and a detailed root-cause analysis (RCA), to directly link a specific response and behavior to the excitations, modal content and transfer functions, is an essential and non-trivial part of the methodology development. This paper describes the development of such a methodology using the example of a new EDM virtual model for Noise, Vibration and Harshness (NVH) analysis, the simulation approach, validation, and evaluation procedure. It
Klarin, Borislav, Pevec, Denis, Resch, Thomas, Esposito, Sara, D'Alessandro, Vincenzo, Spanu, Giorgio
NVH Design and Refinement of Dedicated Hybrid Engine on Range Extender Electric Vehicle2026-01-0688To be published on 06/20/2026
Traditional NVH (Noise, Vibration, Harshness) refinement is reactive, addressing issues post-prototype. In contrast, this work establishes NVH as the primary driver in early engine development for range extender electric vehicles (REEVs). Customer demands for imperceptible engine operation [1] - intensified by absent masking noise in electrified powertrains [2] - necessitate a proactive methodology: Usage-Driven Operating Profile: Analysis of >500,000 km fleet driving data identified statistically dominant operating conditions. This enables precise NVH focus areas and proactive avoidance-zone definition in the engine operational map. Vehicle-Driven Target Setting: Subsystem-level NVH targets (e.g., <58 dB(A) idle noise → engine-level) were rigorously derived from vehicle imperceptibility requirements and the dominant usage profile. Preventive Design Optimization: Architectural choices (stiffness-enhanced bedplate block), component tuning (crankshaft/flywheel dynamics), and subsystem
Wang, Hao, Zhang, Guiqiang
An Experimental Setup for Vibroacoustic and Fluid-Borne Noise Characterization of Electric Refrigerant Compressors using R1234yf or R7442026-01-0724To be published on 06/20/2026
The increasing electrification of vehicles leads to a broader range of tasks for heating, ventila-tion and air conditioning systems and a shift in its priority assessment. Air conditioning systems in electric cars are no longer primarily responsible for cooling the passenger compartment, but also have to temperature-control the battery, especially during rapid charging, which repre-sents a high-load operating point. Additionally, the elimination of the combustion engine as a major noise source brings the NVH behaviour of the refrigerant compressor a higher priority in product selection. In order to investigate the vibration and acoustic behaviour, as well as fluid dynamic forces resulting from the cyclic compression principle of an electric refrigerant compressor, a test rig was previously developed, allowing compressors to be operated and measured isolated in an anechoic chamber under various defined operating points. This test rig has been expanded in two ways within the scope of
Beer, Gabriel, Saur, Lukas, Schwarz, Manuel, Zemsch, Stefan, Becker, Stefan
Vibroacoustic Analysis and Optimisation of an Electric Refrigerant Scroll Compressor2026-01-0722To be published on 06/20/2026
In electrified vehicles, auxiliary units can be a dominant source of noise, one of which is the refrigerant scroll compressor. Compared to vehicles with combustion engines, e-vehicles re-quire larger refrigerant compressors, as in addition to the interior, the battery and the electric motors must be cooled. Various types of excitation in the compressor cause vibrations on the compressor surface and the emission of airborne noise. Fluid dynamic forces resulting from the cyclic compression principle act on flow-conducting components, while alternating forces caused by the imbalance of the eccentrically running compressor scroll or by torque fluctua-tions on the drive shaft are transmitted to the housing via the bearings. In order to identify the sound generation mechanisms in the compressor, the vibrations of the compressor surface were measured using a laser scanning vibrometer and the sound radiation was characterised using a sound intensity probe. This paper illustrates the
Saur, Lukas, Beer, Gabriel, Fritzsche, Marco, Becker, Stefan
Validation of an adaptive order Finite Element model for transmission loss simulation of trimmed automotive structures2026-01-0707To be published on 06/20/2026
Vehicle electrification and increasing demands for driving comfort present significant challenges for designing effective noise control treatments in modern vehicles. Lightweight, low-emission designs often compromise acoustic efficiency. One way of compensating this is through the use of multi-layer ‘trim’ material configurations to mitigate noise across a wider frequency range. Traditional 3D finite element models, while accurate and even needed to capture the full dynamic behaviour, become computationally prohibitive for complex automotive structures like firewalls, which feature intricate shapes, high curvature, and material compression. This computational burden limits design exploration and timely noise performance predictions. This paper introduces the use of an innovative adaptive higher-order finite element method to address these challenges. The method utilizes a fixed finite element discretization of trim components and surrounding acoustic fluid, incorporating an automated
Van Genechten, Bert, Vansant, Koen, Purohit, Bimal, Effinger, Veronika
Spatial Noise Acquisition at the Driver's Position in an Electric Vehicle with Increased Accuracy2026-01-0723To be published on 06/20/2026
In vehicles with electrified powertrains, high-frequency tonal noise components have become increasingly prominent and can be perceived as particularly annoying by the driver. While recent advancements in international standardization—such as ECMA-74 and ECMA-418—have led to powerful new algorithms for tonal noise visualization and analysis, like our Tonality-Heatmaps, the measurement side still lacks sensor setups that adequately reflect the spatial sensitivity of noise, especially for tonal components. This challenge is amplified in enclosed vehicle cabins, where room modes create local minima and maxima that become increasingly dense at higher frequencies. As a result, even small head movements can lead to noticeable differences in perceived tonal noise. Current measurement approaches do not sufficiently account for this spatial variability. This contribution addresses the absence of tailored solutions for the driver’s position by introducing an improved microphone arrangement that
Schecker, Daniel, Rittenschober, Thomas
Regularized Inverse Methods for Tire Noise Source Identification and Pass-by Noise Estimation in Electric Vehicles2026-01-0709To be published on 06/20/2026
Tire exterior noise has become increasingly critical in vehicle acoustics due to two key developments: updated pass-by noise regulations, which amplify the relative contribution of tire noise, and the rise of Battery Electric Vehicles (BEVs), which lack traditional powertrain noise. Design trends in BEVs—such as increased vehicle mass from battery packs and the widespread use of large-diameter, wide, low-profile tires—further intensify tire noise due to stiffer constructions and altered contact dynamics. A common method for predicting tire noise is the source-transfer-receiver model, where the tire is represented by a set of monopoles with volume velocity Q derived from near-field measurements. Acoustic propagation is modeled via p/Q transfer functions. Despite its simplifications, this approach is practical for vehicle development, enabling clear separation between source and transfer mechanisms and facilitating targeted noise control strategies. In previous work, we proposed a
Morin, Benjamin, Di Marco, Federico, Horak, Jan, Lafont, Thibault, Kim, Minkyu, Kang, Min Kyoo, Yoo, Ji Woo
NVH Aspects of DC Charging2026-01-0703To be published on 06/20/2026
The deployment of high-power DC charging infrastructure for electric vehicles introduces new challenges in managing noise, particularly in public environments where acoustic comfort and regulatory compliance are essential. Noise emissions from both charging stations and vehicles during charging are a concern for operators of charging parks regarding customer experience and sound immission regulations. AVL employed a structured three-step approach to develop a non-expert tool for assessing the noise radiation of charging stations and vehicles during the charging phase. In a first step, AVL characterized the noise emissions with sound power measurements. Secondly, the measurement results were transferred to the virtual domain. To achieve this, the vehicles and charging station were characterized in the simulation with multiple monopole sources supported by transfer function measurements. This simulation model was validated against the sound power measurement results. After successful
Gojo, Josef, Polanz, Markus, Graf, Bernhard, Langjahr, Paco, Mehrgou, Mehdi
Optimizing recycled and recyclable PET felt lightweight formulations for best acoustic insulation as poroelastic springs with minimum weight2026-01-0702To be published on 06/20/2026
For sustainability reasons, the automotive market is requesting 100% mono-material noise treatments, particularly for the end-of-life recycling without any part separation operation. But also, the OEMs require super light, highly performance insulating noise treatments for electric vehicles in order to extend vehicle autonomy. PP meltblown fiber felts present good mono-material characteristics with very good absorption, but generally not so good insulation properties behind an airtight barrier due to lack of stiffness. Moreover, these PP meltblown fiber felts are relatively expensive and not thermoformable, thus obliging to use them as 2D die-cut parts behind existing hard or soft trims classically. The optimization approach proposes to return to 100% thermoformable recycled and recyclable PET formulations blending unusual coarse mechanical specific fibers, in order to optimize the viscothermal exchanges, while maintaining good mechanical properties, with microfibers for best
Duval, Arnaud, Lei, Lei, Wilkinson, Alexandre, Delinselle, Eric
Improving reliability of an automotive power electronic unit using Locally Resonant Metamaterials2026-01-0701To be published on 06/20/2026
The shift from internal combustion to electric vehicles necessitates addressing new challenges posed by novel components, materials, manufacturing processes and different operating regimes. This includes assessing new types of excitations and damages from a reliability perspective. This paper investigates a solution to enhance the reliability of the Printed Circuit Board (PCB) within a Power Electronic Unit (PEU). PCBs are critical electronic and mechanical supports for functional components (e.g. diodes, transistors, resistors) in numerous applications. Controlling critical vibration levels is crucial to prevent electronic component breakage and subsequent PEU functionality loss. Existing solutions often focus on improving sensor-PCB bonding, surface treatments, or stiffening components’ support structures. The proposed approach, instead, exploits Locally Resonant Metamaterials (LRMs) to reduce the vibrational load experienced by the PCB. LRMs are created by adding resonating elements
Tincani, Sara, Claeys, Claus, Deckers, Elke, Pandiya, Nimish, Dindorf, Christian
Field-Based Evaluation of Physiological Fatigue Reduction in Fuel Cell Refuse Collection Vehicle Using Heart Rate Variability2026-01-0690To be published on 06/20/2026
This study compared the physiological fatigue of drivers and accompanying workers operating diesel-powered (DI) and fuel cell-powered (FC) garbage compactor trucks under real-world working conditions. Reducing driver fatigue is critical for ensuring occupational safety and maintaining work efficiency, as fatigue in waste collection tasks is influenced by multiple factors such as vibration, noise, and vehicle operation characteristics. In this study, heart rate sensors and smartwatches were used to continuously monitor physiological responses during identical driving routes. Fatigue was evaluated using heart rate variability (HRV) indices—specifically, the root mean square of successive differences (RMSSD) and Lorenz plot (LP) area—calculated from RRI data. The results indicated that the RMSSD of drivers in FC trucks was approximately 60% higher and their LP area about 50% larger than those in diesel trucks. For accompanying workers, RMSSD was around 20% higher and LP area approximately
Utsumi, Atsuko, Yakoh, Takahiro
High-Fidelity NVH Analysis Model Development Process for EV Traction Motors Based on Experimental Correlation2026-01-0685To be published on 06/20/2026
This study presents a high-fidelity NVH (Noise, Vibration, Harshness) analysis model development process for EV traction motors. The proposed process consists of two main components: Path refinement through structural stiffness tuning, and Source refinement, focused on the motor’s excitation mechanisms. Model accuracy was validated through comparison of simulation results with dyno test data, with particular focus on the 24th-order electromagnetic vibration observed in an 8-pole, 48-slot motor. Path refinement was achieved through modal correlation between experimental results and finite element (FE) analysis. Nine modal test and simulation stages were conducted, ranging from individual components to the complete motor assembly. Mode shapes were compared using the Modal Assurance Criterion (MAC), and natural frequencies were matched within a 5% error margin by adjusting FE material properties. For the 24th-order electromagnetic vibration, simulation results agreed with test data within
Kim, Donghee, Kim, Dong-Jun, Lee, SangHan, Kim, Seon Hyeong, Hwang, Seung Gyu, Valente, Giorgio, Parisouz, Shahriar, Halse, Christopher
Electric drive unit housing ribbing for low noise radiation2026-01-0687To be published on 06/20/2026
Although propulsion noise often constitutes a minority of the overall noise in electric vehicles, it remains an important quality indicator due to its high-frequency tonal character, which is undesirable even at low levels. There are many factors that influence the interior car levels of propulsion noise, i.e. gear whine and electric motor whine. The primary ones to consider are the electric drive units (EDU) internal forces, but also secondary properties such as EDU housing design and encapsulation, vehicle sound pack and mount isolation play important roles. This work focuses on EDU housing design and more particularly on the housing ribbing that enables attachment point stiffness and housing strength, but which can also cause problems in terms of noise radiation. Numerical parameter studies on geometrical properties such as length dimensions, thickness and curvature were performed on single ribs of different types. For each design iteration, the key performance indicators radiated
Lennström, David, Malm, Oskar, wurzinger, Jakob, Cederlund, Johan
A High-Performance Computing Strategy for Acoustic Encapsulation Modeling of Electric Vehicle Subsystems Using Coupled BEM–PEM–FEM Methods2026-01-0694To be published on 06/20/2026
Electric vehicle subsystems, including powertrains, electric motors, and gearboxes, pose new challenges in achieving stringent acoustic performance targets for both interior and exterior noise. These challenges are intensified by increasingly demanding customer expectations regarding interior acoustic comfort, which encompasses the reduction of intrusive noise sources and the enhancement of overall sound quality across a broad frequency spectrum. A primary concern associated with electric vehicles subsystems is the generation of high-frequency tonal noise, commonly referred to as whine noise, which can significantly impact acoustic performance and passenger comfort. High-frequency whine noise propagates through multiple transmission paths and can be effectively attenuated at the source through encapsulation strategies, which also contribute to broadband noise reduction across a wide frequency spectrum. To predict the acoustic performance of encapsulation, a coupled simulation approach
Amichi, Kamel, Calloni, Massimiliano
The Influence of Interior Noise on Just-Noticeable Speed Differences in Conventional and Electric Vehicles2026-01-0671To be published on 06/20/2026
Electric vehicles (EVs) and internal-combustion-engine vehicles (ICEVs) differ fundamentally in their in-cabin acoustics, notably the attenuation or absence of engine-order content. Prior work reports associations between reduced engine sound, speed underestimation, and poorer speed maintenance; however, research on how EVs’ new sound affects speed perception and control is scarce, and most newer studies focus on comfort and subjective pleasantness rather than speed perception per se. Addressing this gap, the present study uses a two-interval, two-alternative forced-choice (2AFC) paradigm to directly measure just-noticeable differences (JNDs) in speed under ICEV, EV, and silent conditions. Thirty participants performed a 2AFC task in which, on each trial, they viewed two first-person highway clips (reference vs. comparison) and indicated which appeared faster. Results from ANOVA and post-hoc tests indicate that at the 40 km/h reference speed participants showed no clear differences
Li, Zhenxian, Parizet, Etienne, Colangeli, Claudio
Holistic sound package design for optimal NVH and carbon footprint of a BEV2026-01-0708To be published on 06/20/2026
Vehicle sound packages are usually designed to provide a given level of vehicle NVH comfort, under weight and cost constraints. Optimal comfort results can be obtained by considering the interaction of all the parts as a full physical system. So far, extensive research has already been performed and published on optimizing vehicle sound packages to achieve effective noise reduction at lowest cost and weight. Nowadays, due to the urgency of the transition to carbon neutrality, sound packages must also address the reduction of the full vehicle life cycle carbon emissions. Sound package components should use materials that have a low emission impact during production and that are suitable for recycling at the end of the vehicle’s life. This entails reconsidering the material solutions chosen for the sound package as a whole, rather than for each individual component. This article describes the design process of a sound package involving NVH, sustainability, and weight/cost requirements
Courtois, Theophane, Cardillo, Marco, Criscione, Mattia, Gerges, Youssef, Massocco, Andrea
Impact of door dynamics on vehicle interior low-frequency vibro-acoustics.2026-01-0679To be published on 06/20/2026
Interior acoustics represent an essential component of driving comfort in electric vehicles. Numerical simulation is an effective approach for assessing design concepts and enhancing acoustic performance. However, a fully coupled vibro-acoustic model for an entire vehicle remains computationally infeasible. Our approach couples mechanical and acoustic modal models on non-conforming interfaces in the low-frequency range, allowing independent mode combinations. Modal coupling reduces the computational effort significantly from full-order systems with millions of degrees of freedom to a selection of modes of the acoustic and mechanical systems. Modal models of the vehicle structure are derived from laser-vibrometer measurements while the interior acoustics are simulated numerically. Since laser measurements are restricted to the vehicle’s exterior surfaces and vibro-acoustic coupling occurs between the inner structural surface and the interior fluid, the structural behavior of the
Gutbrod, Manuel, Gabriel, Christoph, Müller, Gregor Johannes, Toth, Florian
Dynamic characterisation and modelling of Electric Cables under representative load conditions2026-01-0676To be published on 06/20/2026
Electric high voltage (HV) cables are commonly used in automotive applications and very prominently in electrified vehicles. These cables are potential flanking transmission paths for structure-borne sound in a broad frequency range and must therefore be included in the NVH design process. Electrical high voltage cables exhibit non-linear mechanical characteristics, when exposed to significant bending the internal geometry of the cable will change and a curvature dependent bending stiffness will result. The electrical cables envisaged in the current publication feature a helically wound stranded aluminium wire core. This conductive core is covered by, in sequence, a silicone rubber insulation, a braided aluminium wire shield with aluminium foil to minimize electromagnetic interference and a silicone rubber outer sheath. An extensive measurement campaign was carried out to dynamically characterize cable specimen of different lengths and cross sections in terms of multi-degree of freedom
Nijman, Eugene, Buchegger, Blasius, Böhler, Elmar, Zeller, Bernhard, Rejlek, Jan, Faksa, Lukáš, Lukavsky, David
Heavy-Duty Nonroad Material Handler Electrification Part 1: Real-World Drive Cycle Development02-19-03-00156/10/2026
Knowing a detailed operating cycle is critical for developing and testing equipment. Operating cycles can be separated by two clear distinctions: (1) regulatory or non-regulatory and (2) application at the engine-only or full machine level. The Environmental Protection Agency’s (EPA) Nonroad Transient Cycle (NRTC) may be a good representation of engine use in many types of equipment, but there is a gap in standardized and validated drive cycles specifically for nonroad material handlers. Lacking a standardized drive cycle makes it difficult to accurately benchmark machine performance and validate new powertrain technologies. The objective of this investigation is to illustrate the development of a custom drive cycle augmented with real-world customer use data that serves multiple purposes: (1) understand the range of operation and utilization that formulated inputs for electrified architecture analysis and (2) develop a repetitive and consistent maneuver to establish baseline energy
Czarnecki, Alexander, Goodenough, Bryant, Worm, Jeremy, Robinette, Darrell, LaTendresse, Phil, Westman, John
Development of a Load Responsive Mechanical Shifting Mechanism and its Benefits for Battery Electric Vehicles2026-37-00266/9/2026
Many high-end electric vehicles use an automatic two-speed transmission. The ability of the drivetrain to switch between two gear ratios improves vehicle performance and increases driving range. The aim of the presented research work is to transfer these advantages to small and lightweight battery-electric vehicles, which face significant cost and weight constraints and therefore cannot rely on highly sophisticated electric motors. Direct-drive systems are widely used in this vehicle class due to their simplicity and high baseline efficiency. However, they offer limited flexibility in adapting the operating point of the electric motor under varying load conditions. A two-speed transmission can overcome this limitation by enabling load point shifting, allowing the motor to operate closer to its optimal efficiency region during both urban and extra-urban driving. This results in improved energy consumption without adding substantial system complexity. Currently, only actuated
Napetschnig, Christof, Tromayer, Juergen, Stückler, David
Optimal Charging Planning with Energy Consumption Simulation for Battery Electric Long-Haul Trucks2026-37-00196/9/2026
Vehicle fleet decarbonization is a key objective for the coming years, with electrification representing the primary pathway to achieving the targets set by the European Union. The share of battery electric trucks in new registrations has been gradually increasing especially in light and medium size trucks. The replacement rate of diesel long-haul trucks with zero emission trucks is still low due to challenges posed by added complexity and limitations of battery charging. Depot overnight charging is not sufficient to cover the energy needs of a truck covering large distances and careful planning of the route using public charging infrastructure is crucial for an optimized route minimizing extra costs and range anxiety. The current work aims to develop a methodology to propose the optimal charging locations for a given route of a battery electric truck based on nearby stations along the route. Our study uses an open-source optimization algorithm for the fixed route vehicle charging
Perdikopoulos, Michail, Doulgeris, Stylianos, Livitsanos, Georgios, Kazakis, Thomas, Mellios, Giorgos, Ntziachristos, Leonidas
A Parametric Cradle-to-Grave Life Cycle Assessment Tool for Comparative Evaluation of Passenger Car CO₂ Emissions2026-37-00406/9/2026
This work presents the development of a user-oriented software tool for the cradle-to-grave Life Cycle Assessment (LCA) of passenger cars, enabling robust comparisons of greenhouse gas emissions across heterogeneous vehicle configurations. The tool supports informed decision-making by quantifying and visualizing environmental impacts associated with alternative mobility choices over the full vehicle life cycle, including production, use, maintenance, and end-of-life stages. The proposed framework allows key parameters describing both the vehicle and its usage to be explicitly defined, including powertrain type, dimensions and weight, ownership profile (new or second-hand vehicles, partial ownership periods, leasing scenarios), annual mileage, vehicle lifetime assumptions, and the carbon intensity of fuels or electricity sources. Country-specific energy mixes are incorporated, enabling the same vehicle to be assessed under different geographic contexts and highlighting the strong
Gastaldi, Chiara, Cibrario, Luca
Analysis of a Sorption Energy Storage System for Cabin Air Heating and Dehumidification in Electric Vehicles2026-37-00346/9/2026
This work investigates the integration of a Sorption Thermal Energy Storage (TES) into the Heating, Ventilation and Air Conditioning (HVAC) system of electric vehicles. The proposed device reduces the energy demand for cabin heating under winter conditions, leading to a driving range increase. The TES dehumidifies the cabin air through a desiccant bed (zeolite 4A), preventing window fogging, enabling higher air recirculation rates, and consequently reducing the required heating power. An experimentally validated numerical model was used to analyze the adsorption and regeneration processes and to identify suitable operating conditions. Regeneration was found to be effective at moderate temperatures (from 120°C), with a counter-current airflow configuration providing faster and more efficient desorption compared to parallel-flow one. A simplified model integrating TES, HVAC unit and cabin was developed and used to compare different configurations. Heating energy consumption with and
Verlingieri, Rebecca, Calabrese, Luigi, Freni, Angelo, Marocco, Luca, Scudeler, Gabriele, De Antonellis, Stefano
Hybridized Diesel Powertrains - An Important Enabler for Commercial Applications on the Long Journey towards Full Electrification2026-37-00226/9/2026
The ongoing efforts for reduction of the traffic-related greenhouse gas emissions and, at the same time, the mitigation of harmful pollutant emissions from vehicle exhaust emissions are important development tasks for the entire automotive industry worldwide according to demand to provide clean and efficient products. Further tightened fleet average FE standards and ultra-low limits for exhaust emissions require the continuous development of new propulsion system types. Due to the given reluctance of the end customer and corresponding low acceptance of fully electrified vehicles, especially in the commercial vehicle segment, new and innovative topologies are needed to meet regulatory requirements and maintain the high versatility of today’s dominating solutions. For further optimization of operating conditions with enhanced fuel efficiency, the technical strategy is also determined by uplifting the attractiveness of electric driving incl. the avoidance of areas with poor ICE efficiency
Koerfer, Thomas
Passenger Car Powertrain for Voltages above 800V2026-37-00206/9/2026
The EU funded innovation project High-Voltage fast-charging Efficient electric vehicle Powertrains (HiVEP) develops innovative technologies for mass-market electric vehicles (EVs) by advancing architectures operating above 800 V. These architectures integrate silicon carbide (SiC)-based power electronics, rare-earth-free electric machines with active winding reconfiguration, high C-rate batteries, and optimized thermal management systems. HiVEP aims to enable fast charging in less than ten minutes, reduce energy consumption by at least 25%, extend the driving range by 20%, and cut system costs by up to 20% in volume production. This article deals in detail with the project objectives, the methodological approach, and the expected key innovations, as well as the technical, environmental, and social impacts. The discussion situates HiVEP within the European research and innovation landscape, emphasizing its role in accelerating adoption of sustainable mobility solutions.
Schernus, Christof, Nada, Shady, Neuhaus, Christoph, Ewald, Jens, Swierc, Daniel, Kallur-Krishnamoorthy, Rajesh, Vasiliadis, Harilaos
Low-Voltage Electric Vehicle with a Reconfigurable Powertrain Architecture for Urban and Extra-Urban Mobility2026-37-00256/9/2026
This paper presents a novel concept for battery electric vehicles (BEVs), referred to as the low-voltage reconfigurable electric vehicle (LVREV). The LVREV is designed to bridge the gap between L- and M-class vehicles by adopting a <60 V multi-phase powertrain combined with a swappable battery system, maintaining the overall vehicle mass below one ton. This configuration enables adaptable driving range, optimized energy consumption in urban environments, and enhanced safety. The LVREV features two distinct operating modes. Frugal mode is intended for urban use and employs a smaller battery pack to maximize efficiency and reduce vehicle mass, while Dual mode is tailored for longer extra-urban trips through the use of a dual-battery configuration. The key innovations of the LVREV concept include a reconfigurable vehicle architecture capable of meeting both urban and extra-urban mobility requirements, thus providing a highly versatile transportation solution. In addition, the low-voltage
Tramacere, Eugenio, Favelli, Stefano, Galluzzi, Renato, Tonoli, Andrea
Enabling Flexibility Services through Interoperable V2X Infrastructures: Advanced Modeling and Operational Validation in the FLEXV2X Project2026-37-00246/9/2026
The integration of Electric Vehicles (EVs) as active grid resources represents a pivotal shift towards decarbonization. However, the implementation of effective Vehicle-to-Everything (V2X) services faces technical challenges regarding interoperability, predictive management, and battery health preservation. This work presents a comprehensive system design and research methodology developed within the framework of the FLEXV2X project, aimed at addressing interdependencies within a unified bidirectional charging ecosystem. The proposed scientific framework addresses two complementary timescales. At the device level, the study details the modelling and optimization of bidirectional converters, focusing on control algorithms designed to ensure robust dynamic response and efficiency. Building upon this hardware foundation, the paper describes a system-level optimization strategy. By employing open-source cyber-physical modelling, the architecture simulates complex EV-grid interactions. This
Lutzemberger, Giovanni, Barater, Davide, Ceraolo, Massimo, Fera, Cesare, Leaver, Ian, Pasini, Gianluca
Forecasting Electric Vehicle Fleet Growth and Energy Requirements in the UK2026-37-00436/9/2026
With the United Kingdom’s goal to achieve a fully decarbonised energy sector by 2035 and achieve net zero greenhouse gas emissions by 2050, the transition of the UK’s passenger car fleet to battery electric vehicles (BEVs) plays a crucial role in reaching this goal. This study evaluates the environmental and energy impact of large-scale BEV adoption by modelling future uptake scenarios using historical fleet data combined with assumed impact of future policy such as the 2030 ban on the sale of new petrol and diesel vehicles. Three predictive models have been developed: fast uptake, in which approximately 100% of the passenger car fleet is replaced by BEVs; moderate uptake, where a large majority of passenger cars are BEVs; and slow uptake, in which BEV adoption does not reach a majority. The results have shown that, if a medium- or large-scale adoption is possible by 2040 predicting nearly 37 million BEVs on the road, the associated electricity demand is predicted to rise close to 110
Burke, Bradley, Kateregga, Sunny, Sodre, Jose Ricardo
Thermal and Emission Characterization of Cylindrical Lithium-Ion Batteries under Thermal Abuse Using a Climate Chamber2026-37-00236/9/2026
Thermal safety in lithium-ion batteries is a critical aspect due to their increasing use in energy storage systems and electric vehicles. To investigate thermal abuse conditions, numerous studies employ specialized equipment to accurately measure physical variables during thermal runaway events. However, such tests typically require robust equipment which limit their availability in conventional laboratory environments. In this context, the present study proposes and evaluates an experimental methodology based on the use of a climate chamber combined with an instrumented reduced-volume container, to reproduce severe external heating conditions. The thermal behavior and gas emissions associated with thermal runaway events were characterized in six cylindrical lithium-ion batteries of two different chemistries. Six cylindrical cells with NMC and NCA cathode chemistries were subjected to thermal abuse tests. In addition, gaseous emissions and mass loss were quantified after the event
Penagos Vásquez, Diego Alejandro, Marco-Gimeno, Javier, Monsalve-Serrano, Javier, Garcia, Antonio, Perez Balastegui, Jose
SAE TOMORROW TODAY - Turning Streetlights Into EV Chargers135706/8/2026
What if the streetlights in your neighborhood could charge your EV overnight? Voltpost is making this vision a reality by transforming existing lampposts into modular, upgradeable EV charging stations managed by a mobile app. By partnering with utilities, the company is accelerating EV charging infrastructure deployment by retrofitting what's already in place. Listen in as we sit down with James Everley, Director of Business Development, to explore how Voltpost's streetlight EV charging solutions blend seamlessly into the urban landscape. From pricing that respects overnight charging habits to design choices that fit historic districts, you'll discover why low-power, on-street Level 2 charging is a critical piece of the broader EV ecosystem. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in mobility
Patterson, Lori
Automotive Engineering: June 202626AUTP066/4/2026
New York 2026: diversity on full display New powertrain choices keep popping up on new vehicles from OEMs that debuted at NYIAS this year. Sealing integrity in a Formula 1 limited-slip differential High-temperature hydraulic control in a Formula 1 drivetrain requires dimensional stability, controlled sealing force, and resistance to wear under sustained pressure cycling. Inside the limited-slip differential, the sealing architecture plays a defined mechanical role in maintaining consistent torque management under race conditions. From ADAS to autonomy How engineering thermoplastics can advance sensor-based technologies. Synthetic data and the future of ADAS validation Why ADAS validation can't be solved with more miles alone. Intelligent power distribution will change the way vehicles are designed Electronic fuse (eFuse) technology can create electronic power distribution modules (ePDMs) for architectural flexibility, higher reliability, greater safety, and proactive maintenance
Coordinated Path Tracking and Stability Strategy for Distributed Drive Electric Vehicles Using Model Predictive Control with Dual Feedback Adjustment10-10-04-00346/3/2026
Distributed drive electric vehicles (DDEVs) provide enhanced maneuverability through independent wheel torque control, but coordinating precise path tracking with lateral stability remains challenging under aggressive driving conditions. This paper presents a coordinated control strategy that integrates model predictive control (MPC) for path tracking with a proportional gain controller for stability regulation. The proposed framework adopts a hierarchical design. The path tracking control leverages MPC to compute front steering commands while accounting for vehicle dynamics and preview errors. The stability adjustment uses dual proportional gain controllers to generate an additional yaw moment, which is adaptively balanced through a phase plane coordination mechanism, enhancing yaw stability during path tracking. The generated yaw moment is subsequently distributed to individual in-wheel motors with an optimization torque allocation method, respecting tire force limitations. The
He, Yang, Zhu, Yuzheng, Guo, Ruixin, Zhu, Yueying, Xing, Chao, Liu, Shuangxi, Lin, Yier
Electrical and Copper Compatibility Studies of Transmission Lubricants for Advanced Electric Vehicles2026-01-50366/3/2026
Improved energy efficiency and lower CO2 emissions are the two major drivers for the emergence of E-mobility. Growth of electric vehicles (EVs) has sustained ever since their introduction till 2020 and has substantially increased thereafter. EVs require specialized lubricants, which are different from conventional lubricants mainly due to the addition of new hardware technology including e-motor, inverter, battery, and new materials (copper windings, elastomers, plastic, and other materials). Lubricant when used in an advanced powertrain electric vehicle specifically in E-powertrains may encounter the e-motor and must deliver unique performance attributes such as optimal electrical properties, thermal management, and material compatibility apart from the traditional features including extreme pressure, friction performance, oxidation, and wear control. In the current study, we have investigated conventional GL5, manual transmission fluid (MTF), automatic transmission fluid (ATF), and
Katta, Lakshmi, Seth, Sarita, Singh, Sandeep, Bhardwaj, Anil, Arora, Ajay Kumar
Heavy-Duty Nonroad Material Handler Electrification Part 2: Energy Efficiency and Performance Evaluation02-19-03-00166/2/2026
Decarbonization efforts achieved through electrification in nonroad mobile machinery can realize a reduction in fuel consumption of more than 20%, thanks to concepts familiar to light-duty passenger vehicles. This case study compares the results of a hybrid-electric material handler to its conventional counterpart, utilizing machine-specific drive cycles presented in part one of this paper series. The hybrid prototype features an extended-range electric vehicle (EREV) powertrain that demonstrated substantial energy efficiency improvements. Specifically, there was a reduction in equivalent fuel consumption of 75% when operating in electric-only mode, and 33% when maintaining the battery by charging with an on-board generator. Together, the efficiency improvements can be extrapolated over a low-intensity, 8-h shift characterized by significant idle time and highly dynamic engine load for a 47% reduction in net energy consumption. Key technologies that led to this improvement included
Czarnecki, Alexander, Goodenough, Bryant, Worm, Jeremy, Robinette, Darrell, LaTendresse, Phil, Westman, John, Subert, David, Heath, Matthew, Kiefer, Dylan, Black, Andrew
Top Speed Test Procedure for Electric MotorcyclesJ3007_202605 (Current)5/27/2026
This SAE Recommended Practice incorporates a track-based test procedure that produces a representative value for vehicle top speed when operating on a level paved road with a fully charged battery.
Motorcycle Technical Steering Committee
DDPG-Based Energy-Optimal Torque Split Strategy for Dual-Motor Electric Vehicles10-10-04-00335/22/2026
This study presents a torque distribution strategy for dual-motor electric vehicles utilizing a Deep Deterministic Policy Gradient reinforcement learning algorithm designed to optimize energy consumption. By using a simplified architecture and replicable reward functions, the proposed agents rely exclusively on standard CAN bus signals, commanded longitudinal force, and the motors’ velocities, eliminating the need for specialized sensors or complex plant models. Two reinforcement agents are trained using two different reward functions: power-based and State of Charge-based. These agents are validated through high-fidelity CarSim–Simulink co-simulations across soft, medium, and severe acceleration scenarios, in which they demonstrate superior performance to traditional adaptive methods. In the most demanding scenario, a typical adaptive strategy achieves an additional 7.8% of power consumption and 85% of optimal energy recovery, while the proposed reinforcement learning strategies reach
Meléndez-Useros, Miguel, Viadero-Monasterio, Fernando, López-Boada, María Jesús, López-Boada, Beatriz
Diffusion Framework with Cross-Modality Fusion Perception for Autonomous Driving in Urban Traffic2026-99-07495/15/2026
End-to-end autonomous driving in urban environments faces three core challenges. First, camera and LiDAR sensor heterogeneity causes cross-modal perception inconsistencies and sensor fusion instability. Second, diffusion models suffer from training instability due to scale variance and distribution changes, which limits generalization. Third, traditional trajectory decoders lack structured interaction with semantic elements, thereby undermining planning rationality. To address these issues, CMFPNet introduces an integrated framework with three key modules. The HGCF-Backbone integrates LiDAR and camera features using channel focus, deformable cross-focus, and state space modeling to enhance semantic alignment. The NST module maps physical trajectories to normalized space, employing truncated diffusion sampling for stable generation in just 2–4 steps. The NDA models trajectory generation as a semantic narrative, utilizing a six-stage semantic attention flow incorporating BEV context
Qu, Yanwei, Mo, Hangjie
Torque Coordination Control Strategy for Dual-Motor Electric Vehicles Considering Load Transfer and Slip Energy Dissipation2026-99-07095/15/2026
To address the issues of significant slip energy dissipation induced by severe tire slip, degradation of vehicle control stability, and insufficient accuracy of vehicle speed tracking under low-adhesion road conditions, a torque coordination control strategy for dual-motor electric vehicles (DM-EVs) considering load transfer and slip energy dissipation is proposed. First, a vehicle dynamics model integrating suspension system dynamics and tire slip characteristics is developed, fully accounting for the influence of front-rear axle load transfer on the tire slip ratio. Next, founded on the energy dissipation mechanism of tire slip, a quantitative model for energy dissipation during tire slip is developed. Finally, a longitudinal coordinated control system for vehicles according to nonlinear model predictive control (NMPC) is introduced. By comprehensively considering the tire slip ratio and vehicle load distribution, multi-objective coordinated optimization of wheel torque is achieved
Hou, Yingming, Li, Jie, Bai, Xianxu
Secondary Control Method for Parallel DC-DC Converters under FDI Attacks Based on Sliding Mode Observer2026-99-07085/15/2026
Currently, with the continuous development of electric vehicles, DC microgrids have attracted widespread attention due to their flexible access methods and high energy transmission efficiency. However, since the distributed secondary control of DC microgrids relies on information exchange through communication networks, false data injection (FDI) attacks on these networks may cause control algorithms to fail, leading to voltage deviations, output current imbalance, and in severe cases, system instability. This study focuses on DC microgrids based on parallel DC–DC buck converters and proposes a distributed secondary control strategy based on a sliding mode observer to address FDI attacks. By treating the system's FDI attack signals as an extended state, an extended sliding mode observer is designed to track the attack signals. Based on the observed attacks, a control algorithm is proposed that compensates the control inputs through the observer, ensuring proportional sharing of bus
Sun, Wei, Chen, Jing, Yu, Jinzhu, Yuan, Weibo, Peng, Bo, Lin, Fei
Automotive Engineering: May 202626AUTD055/14/2026
Forvia Hella ready with ADB, but NHTSA test stands in the way A demonstration ride shows the glare-free, game-changing power of adaptive driving beams, already available in Europe. An approval test from NHTSA is proving difficult for OEMs to pass. Sharper validation without brute force How CERTUS reshapes AV testing. Simulation-driven battery development From material selection to system-level performance. How simulation unlocks efficient and innovative motor design Engineers are still at the heart of the development process as simulation tools become great levelers. Engineering in the second quarter of the 21st Century Building a trusted digital twin and decision-centric simulation ecosystem. Engineering in the second quarter of the 21st Century Building a trusted digital twin and decision-centric simulation ecosystem. Independent materials testing for OEM validation How validated data provides the foundation for approved components. Editorial All the ways: Learning via print in a
SAE TOMORROW TODAY - Why Curing Motion Sickness Is Key to AV Success135675/11/2026
Did you know that motion sickness affects 1 in 3 people? As AVs gain traction and drivers become passengers, it may be the biggest barrier to the future of autonomous mobility. With a focus on addressing the root cause of motion sickness, Motion Sync offers breakthrough solution: a haptic pre-activation system that helps passengers anticipate vehicle movement with a personalized in-cabin experience that could redefine comfort and productivity. Listen in as we sit down with Dr. Daniel Sousa Schulman, CEO and Founder of Motion Sync, to unpack the science behind motion sickness and why it's a critical issue for EVs, robotaxis, and self-driving cars. You'll learn why passengers get sick, why drivers don't, and how EVs can actually make symptoms worse. As a topic critical to the success of autonomous vehicles, it's a conversation you don't want to miss. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take
Patterson, Lori
Optimal Heat Transfer and Coolant Flow Correlations in a Cylindrical Cell Format, Production-Based Battery Pack Model under Constant Discharge, Winter–Summer Driving14-15-02-00115/6/2026
A full lithium-ion battery (LIB) pack has hundreds to thousands of cells, coolant flow lines and channels, and channel bends to control cell temperature within its operating window and minimize cell internal resistance, aging, and fire risk. A 75 kWh LIB pack has four modules, and each has 23–25 bricks. Two challenges in battery state predictions for hot and subzero temperatures are battery temperature (Tbatt ) and coolant flow within the whole pack. In this work, a 1D 75 kWh full-pack model with its thermal management system is developed using a holistic reverse-engineering method, which can predict Tbatt at any bricks/modules and inlet/outlet coolant flow characteristics. A Tesla Model Y equipped with dual e-motors is tested on an in-house state-of-the-art chassis dynamometer. The test data at V = 60–80 km/h, 100–150 A constant discharge, and Tbatt = −10°C to 40°C are used to develop the model. The 75 kWh pack model features 4000+ cylindrical cells (96S46P, Panasonic 21700-format
Sok, Ratnak, Kusaka, Jin
A Comparative Assessment of Fuel Cell and Battery Powertrains for Formula Student Electric Applications2026-01-50324/27/2026
The organizers of the most prominent Formula Student competitions have recently initiated a preliminary feasibility study on the application of hydrogen-based propulsion technologies in future single-seater race vehicles. These include electric powertrains with electrochemically converted hydrogen in fuel cell–powered vehicles, competing within the electric championship league. Based on the initial set of regulations, this study presents a model-based comparison between battery-powered (BEVs) and fuel cell–powered electric vehicles (FCVs) for Formula Student. The analysis is conducted using energy, power, and efficiency metrics from four candidate models of propulsion systems, implemented in an open and publicly available MATLAB script: two BEVs with varying battery capacities, and two FCVs employing different hybridization strategies. The aim of this study is to pinpoint and quantify the advantages and disadvantages of each technology for the Formula Student use case, and to identify
Martoccia, Lorenzo, Breda, Sebastiano, Fontanesi, Stefano, d’Adamo, Alessandro
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