Lifetime Modeling of SiC Power Modules in Automotive Traction Inverters

This thesis presents a model-based software implementation for the estimation of the damage of a power module inside and automotive traction inverter with few hardware test setup performed to support the simulation with real-life data.

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.

Development and Characterization of Biopolymers

Development and characterization of biopolymers was done in AIJU’s laboratories. AIJU, Technological Institute for children’s products and leisure is based in Spain. The work has the aim to study qualities and characteristics of bioplastics’ blends, in order to design where improvements can be executed. Biopolymers represent a sector with great development possibilities because they combine high technical potential and eco-sustainability. Nowadays, plastic pollution has becoming increasingly concerning, particularly in terms of management of waste. Bioplastics provide an alternative for the disposal of products, reducing the volume of waste and enhancing the end of life recovery. Despite the growing interest in biopolymers there is some gaps that need be filled. The main objective on this work, is the optimization of bioplastics mechanical properties, to find suitable substitutes, as similar as possible to conventional plastics. Firstly, investigations on processability of biomaterials has been deepen since the project deals with toy manufacturing’s sector. Thus, starting from laboratory scale the work aspires to expand industrially. By working with traditional machines, it was notable that, with some limited modifications, the equipment can perform the same functions. Therefore, operational processes do not emerge as an obstacle to the production chain. Secondly, after processing bio-blends, they are characterized by thermal tests (melt flow index, differential scanning calorimetry-DSC, thermogravimetry-TGA) and mechanical tests (traction and flexural tests, Charpy impact, SHORE D hardness and density). While the compatibility does not show relevant results, mechanical improvements has been visualized with addition of more ductile materials. The study was developed by inclusion of sustainable additive VINNEX® to blends. The thesis has highlighted that integration of more flexible materials provides elasticity without compromising bioplastics’ properties.

Analysis of the impact of stationary energy storage systems in trolleybus grids using Simulink-based modelling

The voltage profile of the catenary between traction substations (TSSs) is affected by the trolleybus current intake and by its position with respect to the TSSs: the higher the current requested by the bus and the further the bus from the TSSs, the deeper the voltage drop. When the voltage drops below 500V, the trolleybus is forced to decrease its consumption by reducing its input current. This thesis deals with the analysis of the improvements that the installation of an BESS produces in the operation of a particularly loaded FS of the DC trolleybus network of the city of Bologna. The stationary BESS is charged by the TSSs during off-peak times and delivers the stored energy when the catenary is overloaded alleviating the load on the TSSs and reducing the voltage drops. Only IMC buses are considered in the prospect of a future disposal of all internal combustion engine vehicles. These trolleybuses cause deeper voltage drops because they absorb enough current to power their traction motor and recharge the on board battery. The control of the BESS aims to keep the catenary voltage within the admissible voltage range and makes sure that all physical limitations are met. A model of FS Marconi Trento Trieste is implemented in Simulink environment to simulate its daily operation and compare the behavior of the trolleybus network with and without BESS. From the simulation without BESS, the best location of the energy storage system is deduced, and the battery control is tuned. Furthermore, from the knowledge of the load curve and the battery control trans-characteristic, it is formulated a prediction of the voltage distribution at BESS connection point. The prediction is then compared with the simulation results to validate the Simulink model. The BESS allows to decrease the voltage drops along the catenary, the Joule losses and the current delivered by the TSSs, indicating that the BESS can be a solution to improve the operation of the trolleybus network.

Motion Control of an Advanced Electric Implement for Agricultural Autonomous Vehicles

Nowadays, the development of intelligent and autonomous vehicles used to perform agricultural activities is essential to improve quantity and quality of agricultural productions. Moreover, with automation techniques it is possible to reduce the usage of agrochemicals and minimize the pollution. The University of Bologna is developing an innovative system for orchard management called ORTO (Orchard Rapid Transportation System). This system involves an autonomous electric vehicle capable to perform agricultural activities inside an orchard structure. The vehicle is equipped with an implement capable to perform different tasks. The purpose of this thesis project is to control the vehicle and the implement to perform an inter-row grass mowing. This kind of task requires a synchronized motion between the traction motors and the implement motors. A motion control system has been developed to generate trajectories and manage their synchronization. Two main trajectories type have been used: a five order polynomial trajectory and a trapezoidal trajectory. These two kinds of trajectories have been chosen in order to perform a uniform grass mowing, paying a particular attention to the constrains of the system. To synchronize the motions, the electronic cams approach has been adopted. A master profile has been generated and all the trajectories have been linked to the master motion. Moreover, a safety system has been developed. The aim of this system is firstly to improve the safety during the motion, furthermore it allows to manage obstacle detection and avoidance. Using some particular techniques obstacles can be detected and recovery action can be performed to overcome the problem. Once the measured force reaches the predefined force threshold, then the vehicle stops immediately its motion. The whole project has been developed by employing Matlab and Simulink. Eventually, the software has been translated into C code and executed on the TI Lauchpad XL board.