Day 1 :
Keynote Forum
Francisco Trinidad
Exide Technologies, Spain
Keynote: SPECTRA 2.3-Carbon nano fiber additives to improve battery performance for electric vehicle recharge infrastructure
Time : 10:00-11:00
Biography:
Francisco Trinidad is working as a Doctor in Electrochemistry and received his MSc and PhD degree at the University of Madrid. He joined Tudor Group in 1977 and served as Research Laboratory Manager in Azuqueca, Spain and Development Director for the Industrial Division in Soest, Germany. After Exide acquisition of several battery groups in Europe (Tudor, Ceac, BIG, Hagen, Deta), he was nominated as Research Director in Paris, France and later Development Director Transportation Europe. In the actual position, he is responsible for basic research, including R&D labs and basic processes in Exide Europe. He is author of more than 60 papers and 20 patents, and has made numerous presentations on battery technology and related conferences. After more than 39 years of experience with several electrochemical systems, he is a worldwide recognized battery expert in the industry.
Abstract:
The main objectives of this research is to enhance charge acceptance, performance and durability of lead batteries by using new carbon nano fiber materials with high surface area and electrical conductivity as additives in the manufacture of positive and negative electrodes. In order to achieve these goals the following scientific and technological challenges are considered: Making optimum dispersion of small carbon particles in aqueous solutions; investigating the interaction of the high surface area carbon particles with organic polymers; understanding the influence of carbon on the electrochemical performance of PbC electrodes; developing new paste formulation to enhance charge acceptance of the negative electrodes without increasing the maintenance needs (negligible water loss along battery life); improving inter-particle conductivity allowing higher charge currents under partial state of charge conditions (or after rest periods) that usually produce heavy sulfation; and enhancing durability and cycle life of lead batteries by the incorporation of carbon nano particles into the active materials. This work package is integrated in the project SPECTRA (Smart Personal CO2-Free Transport), consortium recently created by 8 companies and 10 R&D centers and funded by the Spanish Center for Technological & Industrial Development (CDTI). The carbon nano fibers are being developed by Grupo Antolín (Burgos) and the research activities will be made in cooperation with two public institutions: GAIKER (Technology Center, Bilbao), that will perform the studies to achieve a good dispersion of the carbon particles in the active materials; and UAM (University of Madrid), that will conduct electrochemical studies to determine the effect on charge acceptance and hydrogen evolution (water consumption) of PbC cells. Once the optimum combination of additives is screened from the electrochemical studies, Exide will manufacture Enhanced Lead Carbon Batteries to be tested in EV recharge installations by Fagor Electronica (Mondragon).
Keynote Forum
Janus Juul Rasmussen
CEO and Founder of Valcon Design A/S, Denmark
Keynote: Six Theta(r) Design – Early-Stage Design Methodology for Achieving Predictable Product Performance
Time : 11:15-12:15
Biography:
Janus Juul Rasmussen is the Founder and CEO of the Danish Engineering Consulting firm Valcon Design A/S. He is a Mechanical Engineer and has worked with product design for more than 15 years as an expert within the field of kinematics and moving mechanics. He has developed the Six Theta(r) Design methodology and has a close co-operation with the Robust Design Academy at the Technical University of Denmark.
Abstract:
The six sigma methodology is widely accepted as a strong tool to minimize variation in manufacturing processes and to achieve the intended functionality of a given engineering design. Minimization of variation can also be achieved by using robust design methodologies where focus is on developing engineering designs that are insensitive to geometrical variations, changes in ambient conditions, etc. However, existing robust design methodologies are often not applicable for early-stage engineering design. In this contribution, the Six Theta® Design methodology, which has been developed by the author, will be presented. Six Theta® Design is a set of tools and methods that help engineers design products with a predictable performance, ensuring that the functional performance is as intended. Six Theta® Design can also be used to evaluate and compare design quality based on fully objective, quantifiable criteria. Impact of Six Theta® Design compliant solutions include improved development speed with fewer design iterations, higher innovation height, vastly reduced production costs due to simplified designs with non-strict tolerance demands, and predictable performance of products in the field.
Keynote Forum
Gareth Dafydd Owen Davies
University of South Wales, UK
Keynote: Cyber Forensics & Automobile Electronics
Time : 12:15-13:15
Biography:
Gareth Dafydd Owen Davies is a Senior Lecturer (Digital Forensics) and Researcher in the Faculty of Computing, Engineering and Science at the University of South Wales. The main focus of his research is the forensic analysis of physical data storage technologies, in particular data recovery of malfunctioning hardware such as hard disk drives and memory chip-based devices. Over the past 5 years, he has built a name for himself as a Consultant and Investigator on incident response, forensic and evidential recovery cases. His clients include Hi-Tech Crime Units, The National Crime Agency, the Ministry of Defense, Government and large commercial organizations. He is also registered as an expert in forensic data recovery on the National Crime Agency Database. He holds three Adjunct Lecturer positions; one with the Security Research Institute Centre at Edith Cowan University, Western Australia, the second with The Centre for Cyber Security, Longwood University, Virginia, USA, and in the UK, Cranfield University, The UK Defense Academy. He is also a Committee Member of the Association of Digital Forensics, Security and Law based in the USA with equal responsibilities. He has also been awarded the Welsh Livery Company (London City Company) Gold Award for 2015, for significant contribution in his area of technology.
Abstract:
Modern vehicles contain computer systems that enable navigation, communication and entertainment. These units have the potential to generate evidence for a criminal or civil investigation. Research work undertaken thus far looks at applying digital forensic data recovery techniques to a number of automobile systems, both original equipment manufacturer and aftermarket. A number of challenges are faced by the community and are presented along with case studies, data analysis and suggestions for future work.
- Automotive Design & Vehicle Electronics |Automotive Manufacturing |Automotive Safety | Electric and Hybrid Vehicles
Location: Valencia, Spain
Chair
Francisco Trinidad
Exide Technologies, Spain
Co-Chair
Derya Haroglu
Erciyes University, Turkey
Session Introduction
Dohee Kim
Hyundai Motor Company, Korea
Title: Realistic energy management strategy on parallel hybrid electric vehicles
Time : 14:00-14:30
Biography:
Dohee Kim has received his PhD Degree in 2011 from the Department of Mechanical and Aerospace Engineering, University of Florida. He has published more than 20 papers for nonlinear controls and applications in reputed journals and conferences.
Abstract:
For the realistic energy management of hybrid powertrains an approach which provides efï¬cient management of state of charge (SOC) and improvement of drivability by utilizing an adaptive torque control and an instantaneous minimization method known as equivalent consumption minimization strategy (ECMS) is presented. The main idea is to control the electric motor torque through SOC-based gain adaptation so as to obtain effective energy management within the prescribed SOC window while securing drivability by suppressing a sense of incompatibility caused by the power sources. To the best of authors’ knowledge, this is the ï¬rst result on the ECMS synthesis considering the improvement of drivability through direct torque control from a perspective of realistic implementation. To directly adapt the power sources which are a representative cause for interior noise, the adaptive torque control input is designed outside the ECMS framework. Within the prescribed SOC window an adaptive torque distribution makes the energy management effective while directly adjusting the source strength for improving interior noise, vibration and harshness (NVH). The proposed strategy has been applied to the prototype of Sonata Hybrid of Hyundai Motor Company (HMC) to practically assess driving performance. Test results show the performance about the SOC management and the noise attenuation comparing to adaptive ECMS methods.
Derya Haroglu
Erciyes University, Turkey
Title: Prioritizing sensor performance characteristics for automotive seat weight sensors in quality function deployment (QFD)
Time : 14:30-15:00
Biography:
Derya Haroglu has completed her PhD in December 2014 from North Carolina State University. She is an Assistant Professor in the Department of Industrial Design Engineering at Erciyes University, Turkey.
Abstract:
Quality function deployment (QFD), a key tool to convert the customer needs into product features, is generally integrated into the new product development (NPD) process at the design stage. Prioritizing customer needs in a QFD process leads to using the resources (time, money and staffing) effectively by eliminating the unimportant customer needs. The overall goal of the research was to develop a textile-based optical fiber sensor for automotive seat occupancy. The findings of this paper were focused on the design of experiments in our previous publication. In this paper, a research study was conducted to better understand market demands in terms of sensor performance characteristics for automotive seat weight sensors, as a part of the QFD House of Quality (HOQ) analysis. A survey was sent to more than 20 companies operating in the field of automotive seat weight sensors and original equipment manufacturers (OEM) via e-mail. Only 5 companies participated in this study due to competitive concerns and confidentiality reasons. However, the companies responded to the survey were of quality relevant to the research and could be perceived as representative of the group of experts. All 5 companies participated in the survey agreed on the first 5 most important sensor characteristics: Reproducibility, accuracy, selectivity, aging and resolution; where the Analytic Hierarchy Process (AHP) was applied to prioritize the sensor characteristics.
Dai Vo Quoc
RMIT University, Australia
Title: Variable caster steering in vehicle dynamics
Time : 15:00-15:30
Biography:
Dai Vo Quoc is currently working toward his PhD degree in Automotive Engineering at School of Engineering, RMIT University, Australia. His research interests include kinematics, dynamics of vehicle systems; dynamics, ride, handling and stability of vehicles. He has published and written 5 papers and book chapters.
Abstract:
When a vehicle is cornering, its wheels usually lean outwards from the center of rotation. This effect decreases lateral force and eventually limits tyre performance, especially when the tyre is working under a high side slip regime. This paper proposes a strategy for varying caster of the front steerable wheels to counter the effect. The homogeneous transformation is utilized to develop the kinematics of a road steering wheel which includes the dynamic camber during the cornering manoeuvre. A variable caster scheme is proposed based on the analysis of the dynamic camber. A roll vehicle model and a camber-included tyre force model are constructed; and MATLAB/Simulink is used to simulate the dynamic behavior of the vehicle with and without the variable caster. The results of step-steer, ramp-steer and swept-steer simulations show that the outwards leaning effect of the steering wheels is reduced significantly, leading to an improvement in lateral acceleration, and yaw rate capacities without compromising with other handling characteristics.
Marcin Korzeniowski
Wroclaw University of Science and Technology, Poland
Title: The criteria and methodology for evaluation the quality of Magnetic Impelled Arc But Welding joints in automotive industry
Time : 15:30-16:00
Biography:
Korzeniowski M is an Assistant Professor at Wroclaw University of Science and Technology. His scientific activities and research work cover the basic techniques in the field of welding, in particular welding and robotic welding, welding process automation and quality control of welded joints, non-destructive methods, mainly application of ultrasonic techniques in automotive industry.
Abstract:
Current trends in the automotive industry are forcing manufacturers of automotive components to improve the production process in terms of producing quality products at relatively low unit price. One way of achieving these assumptions is the radical change in manufacturing technology. Nowadays, manufacturers of drive shafts components noticeably follow the Magnetically Impelled Arc Butt (MIAB) welding technique, which has a number of advantages, especially important from an industrial point of view. The global automotive industry still has not solved the problem of quality assurance of MIAB welded joints, using random destructive testing of produced batch particular items. An alternative to the existing investigative methods are immersive systems of non-destructive testing based on modern ultrasound techniques. Information on engineering practice of destructive and non-destructive testing of Magnetically Impelled Arc Butt (MIAB) welded components were presented. Concept of the process was characterized and its advantages in comparison with alternative technologies were demonstrated. Status of documents, guidelines and instructions determining the correct performance of joints were described. Procedures of welds quality control were presented and were divided into two basic groups – in the process analysis and research of performed joints. Practical aspects were emphasized, taking as an application example the elements of drive transmission. Moreover, the concept of experiment set-up for utrasonic nondestructive testing and preliminary research, based on using lateral wave were presented.
Pawel Adamski
Technical University of Lodz, Poland
Title: Evaluation of possibility of a family car conversion into electric basing on traction characteristics
Time : 16:20-16:50
Biography:
Pawel Adamski has completed his graduation from Arts et Métiers Paristech and Technical University of Lodz in the field of Mechanical Engineering. He is the Commercial Director of PEVT s.c., an innovative company dedicated to e-mobility. He is now working on electric drives for vehicles along with his PhD studies at Technical University of Lodz.
Abstract:
Converting the cars being in use into electric cars without a major change in their construction seems to be very promising way of rapid adaptation of the automotive market to ongoing legislative restrictions. In this work, traction characteristics of Syrena 105 family car were elaborated for original S-31 engine and for asynchronous HPEVS AC-35 electric motor in order to compare the performance of the car with ICE and electric motor. It was concluded that there is a possibility of running the family car Syrena 105 with the electric motor through the original gearbox and original final drive, with satisfactory results. It was however noticed, that changing only the final drive ratio can enhance its performance outperforming the original vehicle specification.
Yasunori Ota
Value Engineering Trainer, Japan
Title: Benchmarking VE and drawing VE
Time : 16:50-17:20
Biography:
Yasunori Ota is a Value Engineering Trainer and has been in VE practice since 10 years. In relation to cost planning in particular, he took initiative in increasing profitability by coordinating target value in the procurement, design and production technology departments, providing a list of items for cost reduction and managing their progress.
Abstract:
This presentation introduces two specific approaches regarding the VE method- Benchmarking VE and Drawing VE. I have been concerned about how to come up with good ideas effectively. I have used various methods by trial and error in idea generation sessions. By doing so, I noticed that two methods proved to be effective; one was Benchmarking VE. It is used at the early development stage in order to coordinate the relationship between function and parts. Further, by applying this method to your competitors function and parts, you are able to ascertain the strengths and weaknesses of your company and you can think of good ideas from comparison contents. The other is Drawing VE. It can be used before, during and after production. Specifically, it reexamines the role of the instructions in the drawing (materials, dimensional tolerance, function of thickness, thickness of the board and post-processing). And you can think cost reduction idea from reexamines the role of the instructions in the drawing. Based on this, the method allows you to develop new solutions. I hope to share these methods with other VE practitioners around the world in order to contribute to the promotion of VE.
Subhash Rakheja
Concordia University, Canada
Title: Influence of operating factors on modal characteristics of a rolling truck tyre
Time : 17:20-17:50
Biography:
Subhash Rakheja is a professor of mechanical engineering at the CONCAVE Research Center, Concordia University, Montreal, Canada. He is a research chair in vehicular ergo-dynamics in Concordia University. Dr. Rakheja is a fellow of the CSME and of the ASME. He is the editor of the International Journal of Industrial Ergonomics and associate editor of the SAE Journal of Commercial Vehicles and International Journal of Heavy Vehicle Systems. He continues to serve in the Canadian Advisory Council on International Standards.
Abstract:
A structural 3D tyre model is developed for estimating modal characteristics of a rolling truck tyre using LS-DYNA finite element analysis platform. The model takes into account the complex construction of a pneumatic tyre such as the multi-layered composite designs of carcass and belts as well as hyper-elastic rubber materials forming the tread and bead fillers. The validity of the structural tyre model was thoroughly examined via comparisons with reported experimental data in view of vertical and lateral forces, and aligning moment characteristics. The verified tyre model is subsequently employed to study its modal characteristics in terms of variations in vibration modes and frequencies of the pre-loaded pneumatic tyre structure considering ranges of loading conditions such as inflation pressure, normal load and rolling speed. The influences of these loading conditions are incorporated in the eigenvalue calculations via applying the large-deformation finite element theory, where a new term, known as the geometric stiffness matrix, is introduced to the material stiffness matrix of the system. This new term accounts for nonlinear geometric effects due to rotations of stresses arising from the loading conditions. A number of prior explicit dynamic simulations are thus necessitated in order to determine the stress state throughout the tyre model at circumstances when the modal characteristics are desired. This is achieved using LS-DYNA via the intermittent eigenvalue extractions during an explicit dynamic simulation at three distinct instants including: (i) Following tyre inflation in response to the internal pressure under given loading condition; (ii) following steady-state tyre deflection due to applied normal load; and (iii) following a given steady rolling speed. These permitted the analyses of variations in modal frequencies and deflection modes under applied inflation pressure, loading and rolling speed. The validity of the simulation results are established through demonstrating correlations of predicted natural modes and frequencies with the reported data for similar tyres. Furthermore, a computationally efficient algorithm is formulated and applied to facilitate model reformulations for parametric studies. The results showed significant contributions of all the operating factors considered, namely, inflation pressure, vertical load and rolling speed. Several pairs of conjugate mode frequencies were further detected for the inflated tyre due to symmetry. For the deflected tyre, however, each pair diverged to two distinct frequencies with one lower and other higher than the corresponding frequency of the tyre under inflation alone.