Two-phase evaporative battery thermal management technology for EVs/HEVs

Electric vehicle’s motor draws power from battery to meet its power demand in different road profiles. Battery high discharged currents are causes of warming battery’s cells. The temperature of 40 ºC and above reduces battery life span. The rationale of fuzzy controlled evaporative battery thermal management system (EC-BThMS) development from this study is to control the battery temperature in the range of 20 ~ 40 ºC both in charging/discharging modes. The proposed system has been developed with estimating the total cooling loads and thermal behavior of the battery cells. A fuzzy controlling system has been introduced with the EC-BThMS to control the electro-compressor and the expansion valve based on the response of battery temperature sensors.A battery pack of 8.6 kWh equipped EV has been operated with 60 km/h on 0 % gradient and 40 km/h on 5 % gradient in IIUM campus while 130 km/h on 0 % gradient and 50 km/h on 3.67 % gradient in Malaysia International Formula circuit to study the battery temperature profile and percentage of battery power saving. Comparison has been made on the performance of EC-BThMS with air cooling battery thermal management system (AC-BThMS) by using same vehicle. Result shows that EC-BThMS can save energy 17.69 % more than AC-BThM 1 and 23 % more than AC-BThM 2.     

Coupled thermo-mechanical analysis and shape optimization for reducing uneven wear of brake pads

In vehicle braking systems, the non-uniform contact pressure distribution on the brake pad is a major cause of uneven wear. The experimental approach of the wear phenomenon is the time consuming and costly. For this reason, a threedimensional finite element (FE) model of a brake system is presented for numerical simulation in this paper. A coupled thermo-mechanical analysis is carried out to confirm the non-uniform contact pressure distribution. A correlation between the non-uniform contact pressure and uneven wear is confirmed by measuring the amount of wear in the brake pad. The shape optimization of the brake pad is performed to reduce the uneven wear. In addition, the simulation results, such as natural frequency and temperature, are compared to experimental results.     

Aerodynamic study of a generic car model with wheels and underbody diffuser

Being a continuous subject of research, this study presents new aspects regarding the relevance of underbody diffusers in road vehicle aerodynamics. Using a generic car model on wheels as a reference, the effect of the wheels on the body fitted with an underbody diffuser was studied, where the diffuser length and angle were varied within ranges which are applicable for hatchback passenger cars. The results show that the vortices which originate from the rear wheelhouses have a major impact on the aerodynamics of the underbody diffuser, which results in increasing of drag and lift of the body. For cases studied, the average drag and lift increment due to the addition of wheels were (Δc_D)_mean = 0.058, respectively (Δc_L)_mean = 0.243. The lift of the body on wheels decreases with both diffuser length and diffuser angle, and there are situations when it may become negative as for a body without wheels. The results show also the possibility to reach a minimum drag according with normalised diffuser length.     

Energy management and design optimization for a series-parallel PHEV city bus

Series-parallel PHEV city buses combine the advantages of series and parallel configurations and have been used in China. However, the design and energy management of series-parallel PHEV city buses based on Chinese driving conditions still need to be investigated. In this paper, an equivalent consumption minimization strategy is provided to optimize energy management for series-parallel PHEV city buses, and the process of the equivalent consumption minimization strategy for series-parallel is presented in this paper. Compared with the validated rule-based energy control strategy, ECMS shows a fuel economy improvement of 8.2 % in the CBCD (Chinese Bus Driving Cycle). Based on the optimal energy management, a design for a generator motor in the series-parallel configuration has been processed. The fuel consumption has been shown to decrease, with an increase in generator power, because the system with the higher generator power can work at a higher efficiency in the series mode and operate the engine in the high efficiency area in the parallel mode. Besides, in terms of costof- ownership for a PHEV bus for lifetime of 8 years, although the high generator power will lead to high purchase cost for series-parallel PHEV bus, a series-parallel PHEV city bus with a generator of 100 kW maximum power will still show small advantage in cost-of-ownership, based on current motor price and natural gas price.     

Evaluation and Measurement the Recovered Energy from Automobile Suspension in the Operation Conditions

The purpose of this paper is to verify if it is possible to recover the energy from automobile suspensions, using a system who replace the shock absorber. The system consists of an electric generator, a mechanical system for transforming the translation of body car in rotational movement and an electronic control system. The tests were made on three road types, according to ISO 8608/1995 with four different driving speeds. The results showed that a significant quantity of energy was recovered during the test on inferior type of road, even at reduced speed. For the superior type of the road, the energy can be recovered only at high speed. The parameters that influences the system capacity of recovering energy are gross weight of the vehicle, road type and the vehicle speed.     

Gaussian Process Regression Feedforward Controller for Diesel Engine Airpath

Gaussian Process Regression (GPR) provides emerging modeling opportunities for diesel engine control. Recent serial production hardwares increase online calculation capabilities of the engine control units. This paper presents a GPR modeling for feedforward part of the diesel engine airpath controller. A variable geotmetry turbine (VGT) and an exhaust gas recirculation (EGR) valve outer loop controllers are developed. The GPR feedforward models are trained with a series of mapping data with physically related inputs instead of speed and torque utilized in conventional control schemes. A physical model-free and calibratable controller structure is proposed for hardware flexibility. Furthermore, a discrete time sliding mode controller (SMC) is utilized as a feedback controller. Feedforward modeling and the subsequent airpath controller (SMC+GPR) are implemented on the physical diesel engine model and the performance of the proposed controller is compared with a conventional PID controller with table based feedforward.     

Logical control approach to fuel efficiency optimization for commuting vehicles

A novel gearshift control approach for improving the fuel efficiency of the conventional commuting vehicles is addressed in this paper, where the optimization problem for gear control is formulated in the framework of stochastic logical dynamic system. By extracting the stochastic features of the driver acceleration intention in the specific route, the Markov process model is deduced and then applied for the optimization algorithm. Based on the logical system framework, the finite horizon optimization problem is solved by means of the algebraic expression of the dynamic programming algorithm with a lower computational complexity, thereby resulting in an optimal gearshift decision law in statistical sense. The software simulation and engine-in-the-loop based experiment results demonstrate the better fuel economy performance can be achieved by the proposed logic control scheme.     

Hierarchical Direct Yaw-Moment Control System Design for In-Wheel Motor Driven Electric Vehicle

In this study, a hierarchical structured direct yaw-moment control (DYC) system, which consists of a main-loop controller and a servo-loop controller, is designed to enhance the handling and stability of an in-wheel motor driven driven electric vehicle (IEV). In the main loop, a Fractional Order PID (FO-PID) controller is proposed to generate desired external yaw moment. A modified Differential Evolution (M-DE) algorithm is adopted to optimize the controller parameters. In the servo-loop controller, the desired external yaw moment is optimally distributed to individual wheel torques by using sequential quadratic programming (SQP) approach, with the tire force boundaries estimated by Unscented Kalman Filter (UKF) based on a fitted empirical tire model. The IEV prototype is virtually modelled by using Adams/Car collaborating with SolidWorks, validated by track tests, and serves as the control plant for simulation. The feasibility and effectiveness of the designed control system are examined by simulations in typical handling maneuver scenarios.     

Comparison of the Spray and the Spray/Wall Interaction of Two Gasoline Injectors

One important parameter influencing mixture formation and spray/wall interaction within engines is the geometry of the nozzle. In contrast to Diesel nozzles, the influence of the orifice geometry on spray formation has hardly be investigated for gasoline nozzles. In order to demonstrate the potential of adjusting the nozzle geometry of a modern GDI nozzle, we compare two six-hole, high-pressure nozzles with an identical structure, but different rounding radius of the orifice hole-inlet and different orifice hole-geometries: nozzle A with a rounded inlet and an orifice length to diameter ratio of 3/2 and nozzle B with a sharp inlet and an orifice length to diameter ratio of 1. In a first measurement campaign the spray formation is visualized using high-speed shadowgraphy imaging. The results show differences in spray angle and penetration depth. In a second measurement campaign we examine the spray/wall interaction and wall film formation by means of infrared thermography. The thermography measurements indicate that the geometry of nozzle B produces sprays with beneficial characteristics. This is very important for a clean combustion process and a decrease of soot emissions.     

Alterable-element method for vehicle-bridge interaction considering the transient jump of wheel

The so called "alterable-element method" (AEM) was introduced to deal with the coupling interac-tion of vehicle and sub-structure considering the actual transient jump of wheel, while the classical "contact allalong" assumption based on which wheels and lower structure are always contact was abandoned. The alterableelement used in this method is a conceptional element, which is used to calculate the coupling interaction ofupper and lower structures and has some typical characteristics: firstly it flows along with the moving of contactpoint; secondly whether it is used for calculation depends on the contact state; thirdly its sizes could changeaccording to specific problems and so on. VISUAL FORTRAN program was coded, and different moving vehiclemodels were presented taking into consideration the effects of random corrugation in the numerical study. Thenumerical solutions are favored comparing with the results obtained by alternative methods when there is nojump phenomenon existed. With abrupt irregularity, the transient jump of wheel was studied using the presentmethod.