Modeling of Electric Hybrid Vehicles based on Innovative Energy Storage Technologies for Super Sports Cars Applications

Today, the contribution of the transportation sector on greenhouse gases is evident. The fast consumption of fossil fuels and its impact on the environment has given a strong impetus to the development of vehicles with better fuel economy. Hybrid electric vehicles fit into this context with different targets, starting from the reduction of emissions and fuel consumption, but also for performance and comfort enhancement. Vehicles exist with various missions; super sport cars usually aim to reach peak performance and to guarantee a great driving experience to the driver, but great attention must also be paid to fuel consumption. According to the vehicle mission, hybrid vehicles can differ in the powertrain configuration and the choice of the energy storage system. Lamborghini has recently invested in the development of hybrid super sport cars, due to performance and comfort reasons, with the possibility to reduce fuel consumption. This research activity has been conducted as a joint collaboration between the University of Bologna and the sportscar manufacturer, to analyze the impact of innovative energy storage solutions on the hybrid vehicle performance. Capacitors have been studied and modeled to analyze the pros and cons of such solution with respect to batteries. To this aim, a full simulation environment has been developed and validated to provide a concept design tool capable of precise results and able to foresee the longitudinal performance on regulated emission cycles and real driving conditions, with a focus on fuel consumption. In addition, the target of the research activity is to deepen the study of hybrid electric super sports cars in the concept development phase, focusing on defining the control strategies and the energy storage system’s technology that best suits the needs of the vehicles. This dissertation covers the key steps that have been carried out in the research project.

Automotive Radars:towards smarter vehicles

Radars are expected to become the main sensors in various civilian applications, especially for autonomous driving. Their success is mainly due to the availability of low cost integrated devices, equipped with compact antenna arrays, and computationally efficient signal processing techniques. This thesis focuses on the study and the development of different deterministic and learning based techniques for colocated multiple-input multiple-output (MIMO) radars. In particular, after providing an overview on the architecture of these devices, the problem of detecting and estimating multiple targets in stepped frequency continuous wave (SFCW) MIMO radar systems is investigated and different deterministic techniques solving it are illustrated. Moreover, novel solutions, based on an approximate maximum likelihood approach, are developed. The accuracy achieved by all the considered algorithms is assessed on the basis of the raw data acquired from low power wideband radar devices. The results demonstrate that the developed algorithms achieve reasonable accuracies, but at the price of different computational efforts. Another important technical problem investigated in this thesis concerns the exploitation of machine learning and deep learning techniques in the field of colocated MIMO radars. In this thesis, after providing a comprehensive overview of the machine learning and deep learning techniques currently being considered for use in MIMO radar systems, their performance in two different applications is assessed on the basis of synthetically generated and experimental datasets acquired through a commercial frequency modulated continuous wave (FMCW) MIMO radar. Finally, the application of colocated MIMO radars to autonomous driving in smart agriculture is illustrated.

Investigation of innovative combustion systems for reduced fuel consumption and increased specific power production

This work resumes a wide variety of research activities carried out with the main objective of increasing the efficiency and reducing the fuel consumption of Gasoline Direct Injection engines, especially under high loads. For this purpose, two main innovative technologies have been studied, Water Injection and Low-Pressure Exhaust Gas Recirculation, which help to reduce the temperature of the gases inside the combustion chamber and thus mitigate knock, being this one of the main limiting factors for the efficiency of modern downsized engines that operate at high specific power. A prototypal Port Water Injection system was developed and extensive experimental work has been carried out, initially to identify the benefits and limitations of this technology. This led to the subsequent development and testing of a combustion controller, which has been implemented on a Rapid Control Prototyping environment, capable of managing water injection to achieve knock mitigation and a more efficient combustion phase. Regarding Low-Pressure Exhaust Gas Recirculation, a commercial engine that was already equipped with this technology was used to carry out experimental work in a similar fashion to that of water injection. Another prototypal water injection system has been mounted to this second engine, to be able to test both technologies, at first separately to compare them on equal conditions, and secondly together in the search of a possible synergy. Additionally, based on experimental data from several engines that have been tested during this study, including both GDI and GCI engines, a real-time model (or virtual sensor) for the estimation of the maximum in-cylinder pressure has been developed and validated. This parameter is of vital importance to determine the speed at which damage occurs on the engine components, and therefore to extract the maximum performance without inducing permanent damages.

Development of predictive energy management strategies for hybrid electric vehicles supported by connectivity

Nowadays, the spreading of the air pollution crisis enhanced by greenhouse gases emission is leading to the worsening of the global warming. In this context, the transportation sector plays a vital role, since it is responsible for a large part of carbon dioxide production. In order to address these issues, the present thesis deals with the development of advanced control strategies for the energy efficiency optimization of plug-in hybrid electric vehicles (PHEVs), supported by the prediction of future working conditions of the powertrain. In particular, a Dynamic Programming algorithm has been developed for the combined optimization of vehicle energy and battery thermal management. At this aim, the battery temperature and the battery cooling circuit control signal have been considered as an additional state and control variables, respectively. Moreover, an adaptive equivalent consumption minimization strategy (A-ECMS) has been modified to handle zero-emission zones, where engine propulsion is not allowed. Navigation data represent an essential element in the achievement of these tasks. With this aim, a novel simulation and testing environment has been developed during the PhD research activity, as an effective tool to retrieve routing information from map service providers via vehicle-to-everything connectivity. Comparisons between the developed and the reference strategies are made, as well, in order to assess their impact on the vehicle energy consumption. All the activities presented in this doctoral dissertation have been carried out at the Green Mobility Research Lab} (GMRL), a research center resulting from the partnership between the University of Bologna and FEV Italia s.r.l., which represents the industrial partner of the research project.

Automotive Antennas for V2X Communications

The main topic of this thesis is about the design and prototyping of automotive antennas that allows Vehicle to Everything (V2X) communications, that is the communication between the vehicle and all what else is relevant. In particular 5G will be an enabling technology for these communications. Vehicular connectivity is a mandatory feature in nowadays car. Typical applications are that one related to the infotainment, i.e. radio or mobile telephone, or security ones, i.e. radars. The antennas that support this type of communications can be divided in two frequency range: the sub-6GHz range and the millimeter wave (mmW) range. Also the 5G standard can be divided in this two frequency ranges. In this work different automotive antennas solutions are presented for both the frequency bands. For the sub-6GHz range two different antennas are presented: a tin sheet 5G-sub6 radiating element and a complete 5G-GNSS-V2X shark fin module. For the mmW frequency band, an automotive PCB planar solution is presented. Since these frequencies are a novelty for the automotive market, satellite communications (SatCom) field has been considered. In SatCom applications mmW solutions are a well-established technology. Thus, also mmW antennas solutions for SatCom applications are here presented.

Dry grinding technology for automotive gears manufacturing: process modeling and optimization

The following thesis focused on the dry grinding process modelling and optimization for automotive gears production. A FEM model was implemented with the aim at predicting process temperatures and preventing grinding thermal defects on the material surface. In particular, the model was conceived to facilitate the choice of the grinding parameters during the design and the execution of the dry-hard finishing process developed and patented by the company Samputensili Machine Tools (EMAG Group) on automotive gears. The proposed model allows to analyse the influence of the technological parameters, comprising the grinding wheel specifications. Automotive gears finished by dry-hard finishing process are supposed to reach the same quality target of the gears finished through the conventional wet grinding process with the advantage of reducing production costs and environmental pollution. But, the grinding process allows very high values of specific pressure and heat absorbed by the material, therefore, removing the lubricant increases the risk of thermal defects occurrence. An incorrect design of the process parameters set could cause grinding burns, which affect the mechanical performance of the ground component inevitably. Therefore, a modelling phase of the process could allow to enhance the mechanical characteristics of the components and avoid waste during production. A hierarchical FEM model was implemented to predict dry grinding temperatures and was represented by the interconnection of a microscopic and a macroscopic approach. A microscopic single grain grinding model was linked to a macroscopic thermal model to predict the dry grinding process temperatures and so to forecast the thermal cycle effect caused by the process parameters and the grinding wheel specification choice. Good agreement between the model and the experiments was achieved making the dry-hard finishing an efficient and reliable technology to implement in the gears automotive industry.

Study and experimental characterization of the laser welding process for the manufacturing of electric powertrain components in the automotive industry

The PhD project that will be presented in this thesis is focused on the study and optimization of the production process for the manufacturing of electrical powertrain components in the automotive field using the laser beam welding process (LBW). The objective is to define, through experimental activities, an optimized process condition for applications in the electrical field that can be generalized, that is, which guarantees its reproducibility as the types of connections vary and which represents the basis for extending the method to future applications in e-mobility sector. The work developed along two lines of research, the convergence of which made it possible to create prototypes of battery modules based on different types of lithium-ion cells and stator windings for electric motors. On the one hand, the different welding configurations involving the production of batteries based on pouch cells and therefore the welding of aluminum and copper in dissimilar configuration were studied, while for the prismatic cells only one configuration was analyzed. On the other hand, the welding of pure copper hairpins with rectangular shape in edge joint configuration was studied for the production of stator windings. The experimental tests carried out have demonstrated the feasibility of using the LBW process for the production of electric powertrain components entirely designed and developed internally as the types of materials and welding configurations vary; the methodologies required for the characterization methods, necessary for the end-of-line tests, for the evaluation of the properties of the different joint configurations and components (battery and electric motor) were also defined with the aim of obtaining the best performance. The entire doctorate program was conducted in collaboration with Ferrari Auto S.p.A. and the direct industrial application of the issues addressed has been faced.

Development of numerical methodologies to predict the liquid fuel sprays - wall interaction to optimize the mixing process of direct injection spark ignition engines

Nowadays the development of new Internal Combustion Engines is mainly driven by the need to reduce tailpipe emissions of pollutants, Green-House Gases and avoid the fossil fuels wasting. The design of dimension and shape of the combustion chamber together with the implementation of different injection strategies e.g., injection timing, spray targeting, higher injection pressure, play a key role in the accomplishment of the aforementioned targets. As far as the match between the fuel injection and evaporation and the combustion chamber shape is concerned, the assessment of the interaction between the liquid fuel spray and the engine walls in gasoline direct injection engines is crucial. The use of numerical simulations is an acknowledged technique to support the study of new technological solutions such as the design of new gasoline blends and of tailored injection strategies to pursue the target mixture formation. The current simulation framework lacks a well-defined best practice for the liquid fuel spray interaction simulation, which is a complex multi-physics problem. This thesis deals with the development of robust methodologies to approach the numerical simulation of the liquid fuel spray interaction with walls and lubricants. The accomplishment of this task was divided into three tasks: i) setup and validation of spray-wall impingement three-dimensional CFD spray simulations; ii) development of a one-dimensional model describing the liquid fuel – lubricant oil interaction; iii) development of a machine learning based algorithm aimed to define which mixture of known pure components mimics the physical behaviour of the real gasoline for the simulation of the liquid fuel spray interaction.

Colocated multiple-input multiple-output radars for smart mobility

In recent years, radars have been used in many applications such as precision agriculture and advanced driver assistant systems. Optimal techniques for the estimation of the number of targets and of their coordinates require solving multidimensional optimization problems entailing huge computational efforts. This has motivated the development of sub-optimal estimation techniques able to achieve good accuracy at a manageable computational cost. Another technical issue in advanced driver assistant systems is the tracking of multiple targets. Even if various filtering techniques have been developed, new efficient and robust algorithms for target tracking can be devised exploiting a probabilistic approach, based on the use of the factor graph and the sum-product algorithm. The two contributions provided by this dissertation are the investigation of the filtering and smoothing problems from a factor graph perspective and the development of efficient algorithms for two and three-dimensional radar imaging. Concerning the first contribution, a new factor graph for filtering is derived and the sum-product rule is applied to this graphical model; this allows to interpret known algorithms and to develop new filtering techniques. Then, a general method, based on graphical modelling, is proposed to derive filtering algorithms that involve a network of interconnected Bayesian filters. Finally, the proposed graphical approach is exploited to devise a new smoothing algorithm. Numerical results for dynamic systems evidence that our algorithms can achieve a better complexity-accuracy tradeoff and tracking capability than other techniques in the literature. Regarding radar imaging, various algorithms are developed for frequency modulated continuous wave radars; these algorithms rely on novel and efficient methods for the detection and estimation of multiple superimposed tones in noise. The accuracy achieved in the presence of multiple closely spaced targets is assessed on the basis of both synthetically generated data and of the measurements acquired through two commercial multiple-input multiple-output radars.

Modeling and optimization techniques for advanced vehicular networking

This thesis deals with optimization techniques and modeling of vehicular networks. Thanks to the models realized with the integer linear programming (ILP) and the heuristic ones, it was possible to study the performances in 5G networks for the vehicular. Thanks to Software-defined networking (SDN) and Network functions virtualization (NFV) paradigms it was possible to study the performances of different classes of service, such as the Ultra Reliable Low Latency Communications (URLLC) class and enhanced Mobile BroadBand (eMBB) class, and how the functional split can have positive effects on network resource management. Two different protection techniques have been studied: Shared Path Protection (SPP) and Dedicated Path Protection (DPP). Thanks to these different protections, it is possible to achieve different network reliability requirements, according to the needs of the end user. Finally, thanks to a simulator developed in Python, it was possible to study the dynamic allocation of resources in a 5G metro network. Through different provisioning algorithms and different dynamic resource management techniques, useful results have been obtained for understanding the needs in the vehicular networks that will exploit 5G. Finally, two models are shown for reconfiguring backup resources when using shared resource protection.

Joints and innovative components for automotive applications

The research activities described in this thesis were focused on two main topics: the study of shaft-hub joint performance, with particular regard to interference-fitted and adhesively bonded connection, and the fatigue characterization of additively processed metal alloys. The research on interference-fitted shaft-hub joints dealt with some studies in the field of fretting fatigue. Rotating bending fatigue tests were performed on different materials by not conventional specimens to determine the fatigue properties of interference-fitted joints and to investigate the fretting fatigue phenomenon, which led to novel and original results. In adhesively bonded and interference-fitted shaft-hub connections (called hybrid joints) the synergic effect of anaerobic adhesive and interference has the capability of improving the joint strength. However, the adhesive contribution depends on several factors. Therefore, its behavior was investigated for different coupling pressure, coupling procedure, operating temperature and joint design. The study on additively manufactured metal alloy deals with rotating banding fatigue tests. AlSi10Mg and Maraging Stainless Steel CX were involved in the campaign for their wide applicability in Automotive. Build direction, heat and surface treatments were considered as input parameters. Fatigue results were interpreted by statistical method and microscopy analyses in order to determine the effectiveness and the beneficial or detrimental effects of the considered factors. Fracture mode and microstructure were investigated by fractographic and micrographic analyses

Soluzioni per conferire robustezza a un broker di informazioni semantiche per l'Internet of Things basato su OSGi

Negli ultimi 50 anni Internet è passata da una piccola rete di ricerca, formata da pochi nodi, ad un’infrastruttura globale capace di connettere più di un milione di utenti. La progressiva miniaturizzazione e la riduzione di costi di produzione dei dispositivi elettronici, permette, tuttora, l’estensione della rete a una nuova dimensione: gli oggetti intelligenti. In questi scenari dove le risorse di rete sono spesso proibitive o la mobilità dei nodi è una caratteristica comune, è necessario che sia garantita forte robustezza a transitori di connessione. Lo dimostra uno studio precedente riguardo ad un applicativo d'agricoltura di precisione denominato Agri-Eagle. In esso vengono confrontate due diverse implementazioni utilizzando il framework SMART M3 e MQTT. Il lavoro di tesi in esame ne estende le considerazioni ed esplora vari metodi per conferire robustezza ad applicazioni sviluppati su SMART-M3. Verrà studiata la funzionalità di Lastwill e Testament proprie di MQTT e se ne tenterà una trasposizione nel mondo semantico. Infine verrà modificato il meccanismo di sottoscrizione in modo da renderlo più robusto a cadute di connessione.

Tracce, spazio, memoria. Progetto di riqualificazione dell'area del gasometro a Bologna.

Riqualificare un’area come quella delle ex officine del gas a Bologna significa confrontarsi inevitabilmente con tre sistemi antitetici che vivono in maniera isolata all’interno del tessuto urbano: il centro storico, la periferia, la ferrovia. La sfida principale del progetto è stata quella di mettere a sistema questi tre mondi attraverso pochi segni, molto chiari che nascono dalla lettura delle tracce urbane esistenti. Partendo da un’area specifica, ovvero l’attuale sede dell’Hera, il progetto ha poi subito un ampliamento planimetrico quasi naturale, andando ad inglobare altri brani di città. Al tema iniziale della riqualificazione urbana, molto vasto di per sè, si sono aggiunti quelli dell’inclusione della ferrovia all’interno di un sistema architettonico più ampio, il potenziamento del collegamento tra centro storico e periferia e la sistemazione di Porta Mascarella. Leggere l’area limitandola ai suoi confini precostituiti avrebbe portato ad un progetto isolato, e non avrebbe contribuito ad una vero cambiamento ma solo ad aggiungere nella città un altro episodio che sarebbe andato a sommarsi agli altri che costellano Bologna. Il progetto mostra il tentativo di ordinare il caos che caratterizza diversi isolati del XX secolo attraverso un impianto architettonico di inclusione della ferrovia. Il carattere di questo sistema viene delineato dalla composizione di due architetture urbane, pensate come quinte sceniche della città, due elementi fissi sui quali si attestano diverse situazioni di Bologna.

Il valore unitario dei portici nelle trasformazioni urbane di Bologna: "Avvertenze d'arte" per la loro valorizzazione e restauro.

La tesi si pone l’obiettivo di indagare il ruolo del portico nella città, non come singolo episodio architettonico, bensì come bene culturale diffuso in maniera capillare. Si vuole sottolineare l’importanza del binomio portici e tessuto urbano, poiché spesso ci si limita a studiarne solo l’evoluzione dei metodi costruttivi e del linguaggio. Il susseguirsi di episodi porticati, indistintamente dalla propria ricchezza architettonica, definisce la forma della città ed eleva il tessuto edilizio a monumento, pertanto una distinzione tra emergenze architettoniche ed edilizia minore, in termini di valore, non risulta soltanto superflua, ma bensì fuorviante. Il valore del portico è intrinseco alla sua presenza e si incorrerebbe in una serie di disguidi ad affermare che sono gli edifici monumentali a dare valore alla città: Portici monumentali e seriali dialogano nel continuum dando vita ad un unicum che assume valore in quanto intero, non totale, come più volte affermato da Cesare Brandi. La ricerca in parallelo sull’evoluzione urbanistica della città e sull’origine e lo sviluppo dei portici, intrecciata con i dati relativi ai rilievi diretti delle sezioni stradali e dei casi studio, ha permesso la ricostruzione dello sviluppo del portico in relazione all’evoluzione del tessuto urbano nel corso dei secoli, individuando tre momenti ritenuti fondamentali: la diffusione dell’elemento porticato nelle città medievali, la risposta politica di bologna e il portico come elemento determinante l’evoluzione del linguaggio della città. Si è così dimostrato come la città, in ogni epoca storica, abbia identificato nei portici un mezzo tramite il quale rinascere senza perdere la propria storicità e continuità architettonica. In conclusione, si è elaborata una “carta del restauro dei portici”, che possa indirizzare l’intervento di restauro verso un approccio culturale, al fine di garantire la salvaguardia dell’intero sistema porticato, a prescindere dal linguaggio del singolo manufatto.

Studio del processo di progettazione di una stampella sensorizzata

Lo studio presentato in questa tesi vuole riportare la ricerca e l’analisi di una nuova esperienza di utilizzo di una stampella, spinto dalla richiesta di migliorare la performance e l’interfaccia dello strumento con un paziente con rilevanti difficoltà motorie. Analizzando lo stato dell’arte e la ricerca in ambito ortopedico, la stampella risulta essere lo strumento più comunemente utilizzato in caso di riabilitazione o difficoltà motorie, ma, allo stesso tempo, comporta rischi e ulteriori danni al paziente, nel caso vi sia un uso scorretto dello strumento. Lo scopo principale del progetto è fornire un supporto, sia al paziente, sia alla terapia, tramite l’ottimizzazione e il miglioramento di alcuni elementi costituenti di una stampella e l’implementazione di un nuovo servizio. Durante lo studio sono stati sfruttati i metodi dell’ingegneria industriale, utili per le fasi di sviluppo del progetto, ma si è cercato anche di dare importanza alla user experience, riportando considerazioni e opinioni di diversi utilizzatori della stampella. Si spera che il risultato sia uno strumento funzionale, utile e soprattutto che vada incontro alle esigenze non solo dell’utente, ma anche delle figure che lo assistono, come il medico ortopedico o il fisioterapista.