Design of alternative energy storage systems for hybrid vehicles based on statistical processing of driving cycles information

Hybrid vehicles represent the future for automakers, since they allow to improve the fuel economy and to reduce the pollutant emissions. A key component of the hybrid powertrain is the Energy Storage System, that determines the ability of the vehicle to store and reuse energy. Though electrified Energy Storage Systems (ESS), based on batteries and ultracapacitors, are a proven technology, Alternative Energy Storage Systems (AESS), based on mechanical, hydraulic and pneumatic devices, are gaining interest because they give the possibility of realizing low-cost mild-hybrid vehicles. Currently, most literature of design methodologies focuses on electric ESS, which are not suitable for AESS design. In this contest, The Ohio State University has developed an Alternative Energy Storage System design methodology. This work focuses on the development of driving cycle analysis methodology that is a key component of Alternative Energy Storage System design procedure. The proposed methodology is based on a statistical approach to analyzing driving schedules that represent the vehicle typical use. Driving data are broken up into power events sequence, namely traction and braking events, and for each of them, energy-related and dynamic metrics are calculated. By means of a clustering process and statistical synthesis methods, statistically-relevant metrics are determined. These metrics define cycle representative braking events. By using these events as inputs for the Alternative Energy Storage System design methodology, different system designs are obtained. Each of them is characterized by attributes, namely system volume and weight. In the last part the work, the designs are evaluated in simulation by introducing and calculating a metric related to the energy conversion efficiency. Finally, the designs are compared accounting for attributes and efficiency values. In order to automate the driving data extraction and synthesis process, a specific script Matlab based has been developed. Results show that the driving cycle analysis methodology, based on the statistical approach, allows to extract and synthesize cycle representative data. The designs based on cycle statistically-relevant metrics are properly sized and have satisfying efficiency values with respect to the expectations. An exception is the design based on the cycle worst-case scenario, corresponding to same approach adopted by the conventional electric ESS design methodologies. In this case, a heavy system with poor efficiency is produced. The proposed new methodology seems to be a valid and consistent support for Alternative Energy Storage System design.

Design for uncertainty of aerospace structures

The aim of this work is to present a general overview of state-of-the-art related to design for uncertainty with a focus on aerospace structures. In particular, a simulation on a FCCZ lattice cell and on the profile shape of a nozzle will be performed. Optimization under uncertainty is characterized by the need to make decisions without complete knowledge of the problem data. When dealing with a complex problem, non-linearity, or optimization, two main issues are raised: the uncertainty of the feasibility of the solution and the uncertainty of the objective value of the function. In the first part, the Design Of Experiments (DOE) methodologies, Uncertainty Quantification (UQ), and then Uncertainty optimization will be deepened. The second part will show an application of the previous theories on through a commercial software. Nowadays multiobjective optimization on high non-linear problem can be a powerful tool to approach new concept solutions or to develop cutting-edge design. In this thesis an effective improvement have been reached on a rocket nozzle. Future work could include the introduction of multi scale modelling, multiphysics approach and every strategy useful to simulate as much possible real operative condition of the studied design.

Methodologies for attitude determination from MEMS sensors in vehicles

The focus of the thesis is the application of different attitude’s determination algorithms on data evaluated with MEMS sensor using a board provided by University of Bologna. MEMS sensors are a very cheap options to obtain acceleration, and angular velocity. The use of magnetometers based on Hall effect can provide further data. The disadvantage is that they have a lot of noise and drift which can affects the results. The different algorithms that have been used are: pitch and roll from accelerometer, yaw from magnetometer, attitude from gyroscope, TRIAD, QUEST, Magdwick, Mahony, Extended Kalman filter, Kalman GPS aided INS. In this work the algorithms have been rewritten to fit perfectly with the data provided from the MEMS sensor. The data collected by the board are acceleration on the three axis, angular velocity on the three axis, magnetic fields on the three axis, and latitude, longitude, and altitude from the GPS. Several tests and comparisons have been carried out installing the electric board on different vehicles operating in the air and on ground. The conclusion that can be drawn from this study is that the Magdwich filter is the best trade-off between computational capabilities required and results obtained. If attitude angles are obtained from accelerometers, gyroscopes, and magnetometer, inconsistent data are obtained for cases where high vibrations levels are noticed. On the other hand, Kalman filter based algorithms requires a high computational burden. TRIAD and QUEST algorithms doesn’t perform as well as filters.

Model driven design for embedded systems

Questo lavoro di tesi si focalizza sulla modellazione di sistemi software in grado far interagire piattaforme elettroniche differenti tra loro.

Design of an innovative electric vehicle simulator for Charging Systems' End-of-Line Testing

The trend related to the turnover of internal combustion engine vehicles with EVs goes by the name of electrification. The push electrification experienced in the last decade is linked to the still ongoing evolution in power electronics technology for charging systems. This is the reason why an evolution in testing strategies and testing equipment is crucial too. The project this dissertation is based on concerns the investigation of a new EV simulator design. that optimizes the structure of the testing equipment used by the company who commissioned this work. Project requirements can be summarized in the following two points: space occupation reduction and parallel charging implementation. Some components were completely redesigned, and others were substituted with equivalent ones that could perform the same tasks. In this way it was possible to reduce the space occupation of the simulator, as well as to increase the efficiency of the testing device. Moreover, the possibility of conjugating different charging simulations could be investigated by parallelly launching two testing procedures on a unique machine, properly predisposed for supporting the two charging protocols used. On the back of the results achieved in the body of this dissertation, a new design for the EV simulator was proposed. In this way, space reduction was obtained, and space occupation efficiency was improved with the proposed new design. The testing device thus resulted to be way more compact, enabling to gain in safety and productivity, along with a 25% cost reduction. Furthermore, parallel charging was implemented in the proposed new design since the conducted tests clearly showed the feasibility of parallel charging sessions. The results presented in this work can thus be implemented to build the first prototype of the new EV simulator.

Analysis and development of interface components and procedures for the design and commissioning toolchains in automation systems

The objective of the thesis project, developed within the Line Control & Software Engineering team of G.D company, is to analyze and identify the appropriate tool to automate the HW configuration process using Beckhoff technologies by importing data from an ECAD tool. This would save a great deal of time, since the I/O topology created as part of the electrical planning is presently imported manually in the related SW project of the machine. Moreover, a manual import is more error-prone because of human mistake than an automatic configuration tool. First, an introduction about TwinCAT 3, EtherCAT and Automation Interface is provided; then, it is analyzed the official Beckhoff tool, XCAD Interface, and the requirements on the electrical planning to use it: the interface is realized by means of the AutomationML format. Finally, due to some limitations observed, the design and implementation of a company internal tool is performed. Tests and validation of the tool are performed on a sample production line of the company.

Design and Characterization of an Active Three-Phase EMI Noise Separator for Three-Phase Power Electronics Systems

One of the major issues for power converters that are connected to the electric grid are the measurement of three phase Conduced Emissions (CE), which are regulated by international and regional standards. CE are composed of two components which are Common Mode (CM) noise and Differential Mode (DM) noise. To achieve compliance with these regulations the Equipment Under Test (EUT) includes filtering and other electromagnetic emission control strategies. The separation of differential mode and common mode noise in Electromagnetic Interference (EMI) analysis is a well-known procedure which is useful especially for the optimization of the EMI filter, to improve the CM or DM attenuation depending on which component of the conducted emissions is predominant, and for the analysis and the understanding of interference phenomena of switched mode power converters. However, separating both components is rarely done during measurements. Therefore, in this thesis an active device for the separation of the CM and DM EMI noise in three phase power electronic systems has been designed and experimentally analysed.