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.

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.

Airport Security: Passenger's Perception and Design Issues

The main goal of this thesis is to report patterns of perceived safety in the context of airport infrastructure, taking the airport of Bologna as reference. Many personal and environmental attributes are investigated to paint the profile of the sensitive passenger and to understand why precise factors of the transit environment are so impactful on the individual. The main analyses are based on a 2014-2015 passengers’ survey, involving almost six thousand of incoming and outgoing passengers. Other reports are used to implement and support the resource. The analysis is carried out by using a combination of Chi-square tests and binary logistic regressions. Findings shows that passengers result to be particularly affected by the perception of airport’s environment (e.g., state and maintenance of facilities, clarity and efficacy of information system, functionality of elevators and escalators), but also by the way how the passenger reaches the airport and the quality of security checks. In relation to such results, several suggestions are provided for the improvement of passenger satisfaction with safety. The attention is then focused on security checkpoints and related operations, described on a theoretical and technical ground. We present an example of how to realize a proper model of the security checks area of Bologna’s airport, with the aim to assess present performances of the system and consequences of potential variations. After a brief introduction to Arena, a widespread simulation software, the existing model is described, pointing out flaws and limitations. Such model is finally updated and changed in order to make it more reliable and more representative of the reality. Different scenarios are tested and results are compared using graphs and tables.

GUI design for in-car message diagnosis

Electronics needs communication to serve the vehicular world, to let all ECUs to com- municate with each other are needed buses, each bus serves different stuffs and is able to communicate. In the evolution of automotive architecture, integration of multiple func- tionalities in a single ECU will be one of the key aspects. The analysis of in-vehicle data, both for diagnosis and study-case of a particular behaviour, is the basis for future’s technologies and applications. Starting from these ideas, the need of creating a correlation between the Vehicle state and the anomaly. In order to create a link among them, has been created an interface able to simplify the in-car diagnosis and creating a link among vehicle stateand anomaly, looking also to the study-case of the driver's behaviour.

Modeling and Design of Phase Shifted Full Bridge Isolated DC-DC ZVS Converter with Peak Current Mode Control

Nowadays, there is a boom in the use of electrification. Electric vehicles are gaining interest worldwide due to various factors, including climate and environmental awareness. In this thesis, a step-down isolated power supply for electric tractors is investigated, specifically the phase-shifted full-bridge (PSFB) DC-DC with synchronous rectification and zero-voltage switching (ZVS). This converter was selected for its high-power capacity with high efficiency. A 3500 W PSFB converter with peak current control (PCCM) is designed and modeled in MATLAB. The input voltage range is from 550 V to 820 V and the output voltage range is limited to 9 V to 16 V with a maximum output current of 250 A. All components were commercially designed and selected, including magnetics for the high-frequency transformer and inductors, taking into account loss calculations. Zero voltage switching for the lagging leg is achieved at 13% to 100% load. The proven efficiency of the converter is around 90

Design and implementation of an optimal motion cueing algorithm for the Stuttgart Driving Simulator

Driving simulators emulate a real vehicle drive in a virtual environment. One of the most challenging problems in this field is to create a simulated drive as real as possible to deceive the driver's senses and cause the believing to be in a real vehicle. This thesis first provides an overview of the Stuttgart driving simulator with a description of the overall system, followed by a theoretical presentation of the commonly used motion cueing algorithms. The second and predominant part of the work presents the implementation of the classical and optimal washout algorithms in a Simulink environment. The project aims to create a new optimal washout algorithm and compare the obtained results with the results of the classical washout. The classical washout algorithm, already implemented in the Stuttgart driving simulator, is the most used in the motion control of the simulator. This classical algorithm is based on a sequence of filters in which each parameter has a clear physical meaning and a unique assignment to a single degree of freedom. However, the effects on human perception are not exploited, and each parameter must be tuned online by an engineer in the control room, depending on the driver's feeling. To overcome this problem and also consider the driver's sensations, the optimal washout motion cueing algorithm was implemented. This optimal control-base algorithm treats motion cueing as a tracking problem, forcing the accelerations perceived in the simulator to track the accelerations that would have been perceived in a real vehicle, by minimizing the perception error within the constraints of the motion platform. The last chapter presents a comparison between the two algorithms, based on the driver's feelings after the test drive. Firstly it was implemented an off-line test with a step signal as an input acceleration to verify the behaviour of the simulator. Secondly, the algorithms were executed in the simulator during a test drive on several tracks.

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.

Design and specification of a modular automatic testing solution

Electric vehicles and electronic components inside the vehicle are becoming increasingly important. The software as well starts to have a significant impact on modern high-end cars therefore a careful validation process needs to be implemented with the aim of having a bug free product when it is released. The software complexity increases and thus also the testing phases is more demanding. Test can be troublesome and, in some cases, boring and easy. The intelligence can be moved in test definition and writing rather than on test execution. The aim of this document is to start the definition of an automatic modular testing system capable to execute test cycles on systems that interacts with the CAN networks and with DUT that can be touched with a robotic arm. The document defines a first version of the system, in particular the hardware interface part with the aim of taking logs and execute test in an automated fashion with the test engineer can have a higher focus on the test definition and analysis rather than execution.

A new concept for a Sport-Coupè car developed with the Industrial Design Structure method (IDeS)

The aim of this study, conducted in collaboration with Lawrence Technological University in Detroit, is to create, through the method of the Industrial Design Structure (IDeS), a new concept for a sport-coupe car, based on a restyling of a retro model (Ford Mustang 1967). To date, vintage models of cars always arouse great interest both for the history behind them and for the classic and elegant style. Designing a model of a vehicle that can combine the charm of retro style with the innovation and comfort of modern cars would allow to meet the needs and desires of a large segment of the market that today is forced to choose between past and future. Thanks to a well-conceived concept car an automaker company is able to express its future policy, to make a statement of intent as, such a prototype, ticks all the boxes, from glamour and visual wow-factor to technical intrigue and design fascination. IDeS is an approach that makes use of many engineering tools to realize a study developed on several steps that must be meticulously organized and timed. With a deep analysis of the trends dominating the automotive industry it is possible to identify a series of product requirements using quality function deployment (QFD). The considerations from this first evaluation led to the definition of the technical specifications via benchmarking (BM) and top-flop analysis (TFA). Then, the structured methodology of stylistic design engineering (SDE) is applied through six phases: (1) stylistic trends analysis; (2) sketches; (3) 2D CAD drawings; (4) 3D CAD models; (5) virtual prototyping; (6) solid stylistic model. Finally, Developing the IDeS method up to the final stages of Prototypes and Testing you get a product as close as possible to the ideal vehicle conceptualized in the initial analysis.