Method for prediction of EMI Emissions from Automotive Ethernet to Vehicle Antennas

In automotive application new point-to-point (P2P) wideband communication systems e.g. Automotive Ethernet 100BASE-T1 imply an increasing effort in safeguarding its electromagnetic compatibility (EMC). The state-of-the-art EMC safeguarding process proposes a pre-compliant system level test before the vehicle level test, which may have significant variation in test results due to the different electromagnetic environment. This work presents an approach to calculate the emission signal at the vehicle antenna from the ECU output signal given by the power spectral density (PSD) of the Automotive Ethernet ECUs. The determination is performed via a transfer function which describes the coupling between the Ethernet wire harness and the antenna. This approach considers the modelling of the complex vehicle environment by the transfer function which promises the determination of an accurate emission signal before performing the vehicle level test. Further, the transfer function for a specifically EMC critical cable harness routing along the cockpit area is analyzed in more detail with a 3D simulation, which validates the chosen measurement technique of the transfer function.

Studies on Dry Sliding Wear and Solid Particle Erosive Wear Behaviours of Natural Fibre Composite Developed from Water Hyacinth Aquatic Plant for Automotive Application

In this research, an attempt is made to investigate the abrasive and erosion wear resistance of aquatic waste plant water hyacinth converted fibre-reinforced polymer composites. From a novel approach, the new fibre extraction machine is designed to extract the hyacinth fibre from the parent plant and reinforce it to the epoxy matrix material to produce a natural fibre composite for frictional applications. The extracted fibre is dried in the open sunlight area for 22 to 35 days to remove moisture and external dust particles. Then, different weight percentages (15, 20, 25, 30, and 35) of composite samples are produced with the help of the hot press compression moulding technique. Improved hyacinth composite tribology properties are tested by utilizing the pin on the disk machine. This setup included various processing parameters like load (10, 20, and 30 N), velocities (1, 2, and 3 m/s), speed (160, 320, and 479 rpm), and constant sliding distance condition, and the erosion setup also influences the essential parameters like impact angle (30, 45, and 60°), erodent velocity (1, 2.5, and 3.3 m/s), and discharge rate (28, 41, and 72 g/m). The factorial techniques are used to identify the important design factors. The final results represent the weight loss, volume loss, and erosion rate of hyacinth fibre composite. By utilizing the SEM (scanning electron microscope), the worn surface morphology of different weight percentages of hyacinth fibre samples are analysed. To upgrade the usage of hyacinth reinforced composites for different industrial applications, wear and erosion studies are conducted with different parameter conditions.

Modeling the Business Value of an Early Fault Detection System using Monte Carlo Simulation

The automotive industry is undergoing a period of rapid advancement, as OEMs race to develop the next generation of electric and autonomous vehicles. Many manufacturers are investing in prognostics technology, which has made advancements mainly in the aerospace industry over the past couple decades. Unlike aerospace applications, which have relatively more safety-critical systems, it can be more challenging to identify a business case for developing a prognostics or early fault detection system for an automotive application. In the retail setting, early fault detection systems may increase warranty costs, and the benefits to customer satisfaction may not be worth this additional cost. For fleet managers who own and operate many vehicles, however, a business case can be made based on the value of preventing unexpected downtime and unnecessary maintenance. Developing a reliable early fault detection algorithm for a complex system can be an expensive undertaking, requiring many parts, months of data collection, and possibly years of effort, so it is important to understand the possible return on investment for the effort. In this paper, we present a method to model the business value of an early fault detection system. The method is generic and may be applied to any system where the failure modes are purely fatigue based (i.e. abuse modes are excluded), and the failure rate of each part in the system can be independently modelled using a time-to-failure probability density function. The model is based on Monte Carlo simulation, and the assumptions and limitations are explored. The model can be used to estimate the expected savings from implementing an early fault detection system and derive requirements on the true positive and false positive rates required for the fault detection system to meet its business objectives. An example is presented with application to a two-stage gearbox, such as one that may be found in an electric vehicle powertrain. The example shows how to estimate the parameters for each component, how to estimate the costs associated with failure, and ultimately how to interpret the model outputs and drive business decisions.

Advanced Controller Development Based on eFMI with Applications to Automotive Vertical Dynamics Control

High-level modeling languages facilitate system modeling and the development of control systems. This is mainly achieved by the automated handling of differential algebraic equations which describe the dynamics of the modeled systems across different physical domains. A wide selection of model libraries provides additional support to the modeling process. Nevertheless, deployment on embedded targets poses a challenge and usually requires manual modification and reimplementation of the control system. The novel proposed eFMI Standard (Functional Mock-up Interface for embedded systems) introduces a workflow and an automated toolchain to simplify the deployment of model-based control systems on embedded targets. This contribution describes the application and verification of the eFMI workflow using a vertical dynamics control problem with an automotive application as an example. The workflow is exemplified by a control system design process which is supported by the a-causal, multi-physical, high-level modeling language Modelica. In this process, the eFMI toolchain is applied to a model-based controller for semi-active dampers and demonstrated using an eFMI-based nonlinear prediction model within a nonlinear Kalman filter. The generated code was successfully tested in different validation steps on the dedicated embedded system. Additionally, tests with a low-volume production electronic control unit (ECU) in a series-produced car demonstrated the correct execution of the controller code under real-world conditions. The novelty of our approach is that it automatically derives an embedded software solution from a high-level multi-physical model with standardized eFMI methodology and tooling. We present one of the first full application scenarios (covering all aspects ranging from multi-physical modeling up to embedded target deployment) of the new eFMI tooling.

Comparative Evaluation of Control Techniques of PMSM Drive in Automotive Application

This paper deal with comparative evaluation of control techniques of Permanent magnet synchronous motor (PMSM) drive in automotive application is investigated. The FOC, DTC and proposed SVM-DTC with LC-Snubber circuit are presented. In SVM-DTC, this reduces low torque ripple by using space vector modulated. The parameters of FOC, DTC and proposed SVM-DTC with LC-Snubber method are studied by simulation. The simulation analysis of control method is investigated in terms of speed, current and torque ripples It was observed that the proposed method upgrade the performance of PMSM drive in respect to speed, current ripples, and torque responses

Functional Safety BMS Design Methodology for Automotive Lithium-Based Batteries

The increasing use of lithium batteries and the necessary integration of battery management systems (BMS) has led international standards to demand functional safety in electromobility applications, with a special focus on electric vehicles. This work covers the complete design of an enhanced automotive BMS with functional safety from the concept phase to verification activities. Firstly, a detailed analysis of the intrinsic hazards of lithium-based batteries is performed. Secondly, a hazard and risk assessment of an automotive lithium-based battery is carried out to address the specific risks deriving from the automotive application and the safety goals to be fulfilled to keep it under control. Safety goals lead to the technical safety requirements for the next hardware design and prototyping of a BMS Slave. Finally, the failure rate of the BMS Slave is assessed to verify the compliance of the developed enhanced BMS Slave with the functional safety Automotive Safety Integrity Level (ASIL) C. This paper contributes the design methodology of a BMS complying with ISO 26262 functional safety standard requirements for automotive lithium-based batteries.

Design for Additive Manufacturing and for Machining in the Automotive Field

High cost, unpredictable defects and out-of-tolerance rejections in final parts are preventing the complete deployment of Laser-based Powder Bed Fusion (LPBF) on an industrial scale. Repeatability, speed and right-first-time manufacturing require synergistic design approaches. In addition, post-build finishing operations of LPBF parts are the object of increasing attention to avoid the risk of bottlenecks in the machining step. An aluminum component for automotive application was redesigned through topology optimization and Design for Additive Manufacturing. Simulation of the build process allowed to choose the orientation and the support location for potential lowest deformation and residual stresses. Design for Finishing was adopted in order to facilitate the machining operations after additive construction. The optical dimensional check proved a good correspondence with the tolerances predicted by process simulation and confirmed part acceptability. A cost and time comparison versus CNC alone attested to the convenience of LPBF unless single parts had to be produced.