Thermal Management of Electrified Vehicles—A Review

Vehicle electrification demands a deep analysis of the thermal problems in order to increase vehicle efficiency and battery life and performance. An efficient thermal management of an electrified vehicle has to involve every system of the vehicle. However, it is not sufficient to optimize the thermal behavior of each subsystem, but thermal management has to be considered at system level to optimize the global performance of the vehicle. The present paper provides an organic review of the current aspects of thermal management from a system engineering perspective. Starting from the definition of the requirements and targets of the thermal management system, each vehicle subsystem is analyzed and related to the whole system. In this framework, problems referring to modeling, simulation and optimization are considered and discussed. The current technological challenges and developments in thermal management are highlighted at vehicle and component levels

Research and Development on Noise, Vibration, and Harshness of Road Vehicles Using Driving Simulators - A Review

Noise, vibration, and harshness (NVH) is a key aspect in the vehicle development. Reducing noise and vibration to create a comfortable environment is one of the main objectives in vehicle design. In the literature, many theoretical and experimental methods have been presented for improving the NVH performances of vehicles. However, in the great majority of situations, physical prototypes are still required as NVH is highly dependent on subjective human perception and a pure computational approach often does not suffice. In this article, driving simulators are discussed as a tool to reduce the need of physical prototypes allowing a reduction in development time while providing a deep understanding of vehicle NVH characteristics. The present article provides a review of the current development of driving simulator focused on problems, challenges, and solutions for NVH applications. Starting from the definition of the human response to noise and vibration, this article describes the different driving simulator technologies to tackle all the involved perception aspects. The different available technologies are discussed and compared as to provide design engineers with a complete picture of the current possibilities and future trends

Multi-Disciplinary Optimisation of Road Vehicle Chassis Subsystems

Two vehicle chassis design tasks were solved by decomposition-based multi-disciplinary optimisation (MDO) methods, namely collaborative optimisation (CO) and analytical target cascading (ATC). A passive suspension system was optimised by applying both CO and ATC. Multiple parameters of the spring and damper were selected as design variables. The discomfort, road holding, and total mass of the spring–damper combination were the objective functions. An electric vehicle (EV) powertrain design problem was considered as the second test case. Energy consumption and gradeability were optimised by including the design of the electric motor and the battery pack layout. The standard single-level all-in-one (AiO) multi-objective optimisation method was compared with ATC and CO methods. AiO methods showed some limitations in terms of efficiency and accuracy. ATC proved to be the best choice for the design problems presented in this paper, since it provided solutions with good accuracy in a very efficient way. The proposed investigation on MDO methods can be useful for designers, to choose the proper optimisation approach, while solving complex vehicle design problems

Roundabouts: Traffic Simulations of Connected and Automated Vehicles—A State of the Art

The paper deals with traffic simulation within roundabouts when both “connected and automated vehicles” (CAVs) and human-driven cars are present. The aim is to present the past, current and future research on CAVs running into roundabouts within the Cooperative, Connected and Automated Mobility (CCAM) framework. Both microscopic traffic simulations and virtual reality simulations by dynamic driving simulators will be considered. The paper is divided into five parts. At first, the literature is analysed using the Systematic Literature Review (SLR) methodology based on Scopus database. Secondly, the influence of CAVs on roundabout-specific design features and configuration is analysed. Gap-acceptance models used to define the capacity of the roundabout, one of its most important key performance indicators, are also presented. Third, the most common simulation software are described and analysed in terms of traffic demand implementation. Then the communication approaches and path management algorithms are studied. An example is proposed on the integration of microscopic traffic simulations and dynamic driving simulators virtual reality simulations. Finally, car following models suitable for roundabout traffic are discussed. There is still a gap between simulations and actual experience. There are reasonable doubts on how modelling and optimizing CAVs’ behaviour into roundabouts in view of CCAM. It seems that Cooperative, Connected and Automated Vehicles (CCAVs), more than simply Connected and Automated Vehicles (CAVs), could optimise traffic flow, safety and driving comfort within the roundabout. A very promising technology for traffic simulation within the roundabout seems the one based on dynamic driving simulators

Eco-Driving Strategy Implementation for Ultra-Efficient Lightweight Electric Vehicles in Realistic Driving Scenarios

This paper aims to provide a quantitative assessment of the effect of driver action and road traffic conditions in the real implementation of eco-driving strategies. The study specifically refers to an ultra-efficient battery-powered electric vehicle designed for energy-efficiency competitions. The method is based on the definition of digital twins of vehicle and driving scenario. The models are used in a driving simulator to accurately evaluate the power demand. The vehicle digital twin is built in a co-simulation environment between VI-CarRealTime and Simulink. A digital twin of the Brooklands Circuit (UK) is created leveraging the software RoadRunner. After validation with actual telemetry acquisitions, the model is employed offline to find the optimal driving strategy, namely, the optimal input throttle profile, which minimizes the energy consumption over an entire lap. The obtained reference driving strategy is used during real-time driving sessions at the dynamic driving simulator installed at Politecnico di Milano (DriSMi) to include the effects of human driver and road traffic conditions. Results assess that, in a realistic driving scenario, the energy demand could increase more than 20% with respect to the theoretical value. Such a reduction in performance can be mitigated by adopting eco-driving assistance systems

Experimental characterization of a Polymer Metal Hybrid (PMH) automotive structure under quasi-static, creep, and impact loading

A feasibility study on a short fibre reinforced Polymer Metal Hybrid (PMH) solution of a car’s suspension control arm has been conducted through a simplified demonstrator, representative of the most critical portion of this component. It was injection moulded in two versions: an all composite one and a PMH version, in which the short fibre reinforced composite was over-moulded on to an aluminium insert. The demonstrator underwent quasi- static, creep and impact tests to simulate most of the loading conditions experienced by a suspension arm during its lifetime. The mechanical behaviours of the two demonstrator versions were compared to highlight the differences introduced by the proposed novel PMH solution. In particular, the ductile metal insert ensured the compliance of the PMH demonstrators with the automotive specific safety requirement of avoiding the complete separation at failure, which was successfully obtained in all testing conditions