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.

AGV Safety Areas Obstacle Detection and Interaction with Point Cloud Derived Map

This thesis project aims to the development of an algorithm for the obstacle detection and the interaction between the safety areas of an Automated Guided Vehicles (AGV) and a Point Cloud derived map inside the context of a CAD software. The first part of the project focuses on the implementation of an algorithm for the clipping of general polygons, with which has been possible to: construct the safety areas polygon, derive the sweep of this areas along the navigation path performing a union and detect the intersections with line or polygon representing the obstacles. The second part is about the construction of a map in terms of geometric entities (lines and polygons) starting from a point cloud given by the 3D scan of the environment. The point cloud is processed using: filters, clustering algorithms and concave/convex hull derived algorithms in order to extract line and polygon entities representing obstacles. Finally, the last part aims to use the a priori knowledge of possible obstacle detections on a given segment, to predict the behavior of the AGV and use this prediction to optimize the choice of the vehicle's assigned velocity in that segment, minimizing the travel time.