• Title/Summary/Keyword: Vehicle Powertrain

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The Dynamics of Noise and Vibration Engineering Vibrant as ever, for years to come

  • Leuridan, Jan
    • Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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    • 2010.05a
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    • pp.47-47
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    • 2010
  • Over the past 20 years, constant progress in noise and vibration (NVH) engineering has enabled to constantly advance quality and comfort of operation and use of really any products - from automobiles to aircraft, to all kinds of industrial vehicles and machines - to the extend that for many products, supreme NVH performance has becomes part of its brand image in the market. At the same time, the product innovation agenda in the automotive, aircraft and really many other industries, has been extended very much in recent years by meeting ever more strict environmental regulations. Like in the automotive industry, the drive towards meeting emission and CO2 targets leads to very much accelerated adoption of new powertrain concepts (downsizing of ICE, hybrid-electrical...), and to new vehicle architectures and the application of new materials to reduce weight, which bring new challenges for not only maintaining but further improving NVH performance. This drives for innovation in NVH engineering, so as to succeed in meeting a product brand performance for NVH, while as the same time satisfying eco-constraints. Product innovation has also become increasingly dependent on the adoption of electronics and software, which drives for new solutions for NVH engineering that can be applied for NVH performance optimization of mechatronic products. Finally, relentless pressure to shorten time to market while maintaining overall product quality and reliability, mandates that the practice and solutions for NVH engineering can be optimally applied in all phases of product development. The presentation will first review the afore trends for product and process innovation, and discuss the challenges they represent for NVH engineering. Next, the presentation discusses new solutions for NVH engineering of products, so as to meet target brand values, while at the same time meeting ever more strict eco constraints, and this within a context of increasing adoption of electronics and controls to drive product innovation. NVH being very much defined by system level performance, these solutions implement the approach of "Model Based System Engineering" to increase the impact of system level analysis for NVH in all phases of product development: - At the Concept Phase, to be able to do business case analysis of new product concepts; to arrive at an optimized and robust product architecture (e.g. to hybrid powertrain lay-out, to optimize fuel economy); to enable target cascading, to subsystem and component level. - In Development Phase, to increase realism and productivity of simulation, so as to frontload virtual validation of components and subsystems and to further reduce reliance on physical testing. - During the final System Testing Phase, to enable subsystem testing by a combination of physical testing and simulation: using simulation models to simulate the final integration context when testing a subsystem, enabling to frontload subsystem testing before final system integration is possible. - To interconnect Mechanical, Electronical and Controls engineering, in all phases of development, by supporting model driven controls engineering (MIL, SIL, HIL). Finally, the presentation reviews examples of how LMS is implementing such new applications for NVH engineering with lead customers in Europe, Asia and US, with demonstrated benefits both in terms of shortening development cycles, and/or enabling a simulation based approach to reduce reliance on physical testing.

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Proposal of Potted Inductor with Enhanced Thermal Transfer for High Power Boost Converter in HEVs

  • You, Bong-Gi;Ko, Jeong-Min;Kim, Jun-Hyung;Lee, Byoung-Kuk
    • Journal of Electrical Engineering and Technology
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    • v.10 no.3
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    • pp.1075-1080
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    • 2015
  • A hybrid electric vehicle (HEV) powertrain has more than one energy source including a high-voltage electric battery. However, for a high voltage electric battery, the average current is relatively low for a given power level. Introduced to increase the voltage of a HEV battery, a compact, high-efficiency boost converter, sometimes called a step-up converter, is a dc-dc converter with an output voltage greater than its input voltage. The inductor occupies more than 30% of the total converter volume making it difficult to get high power density. The inductor should have the characteristics of good thermal stability, low weight, low losses and low EMI. In this paper, Mega Flux® was selected as the core material among potential core candidates. Different structured inductors with Mega Flux® were fabricated to compare the performance between the conventional air cooled and proposed potting structure. The proposed inductor has reduced the weight by 75% from 8.8kg to 2.18kg and the power density was increased from 15.6W/cc to 56.4W/cc compared with conventional inductor. To optimize the performance of proposed inductor, the potting materials with various thermal conductivities were investigated. Silicone with alumina was chosen as potting materials due to the high thermo-stable properties. The proposed inductors used potting material with thermal conductivities of 0.7W/m·K, 1.0W/m·K and 1.6W/m·K to analyze the thermal performance. Simulations of the proposed inductor were fulfilled in terms of magnetic flux saturation, leakage flux and temperature rise. The temperature rise and power efficiency were measured with the 40kW boost converter. Experimental results show that the proposed inductor reached the temperature saturation of 107℃ in 20 minutes. On the other hand, the temperature of conventional inductor rose by 138℃ without saturation. And the effect of thermal conductivity was verified as the highest thermal conductivity of potting materials leads to the lowest temperature saturations.

Components sizing of powertrain for a Parallel Hybridization of the Mid-size Low-Floor Buses (중형저상버스 병렬형 하이브리드화를 위한 동력전달계 용량매칭)

  • Kim, Gisu;Park, Yeong-il;Ro, Yun-sik;Jung, Jae-wook
    • Journal of the Korea Academia-Industrial cooperation Society
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    • v.17 no.8
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    • pp.582-594
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    • 2016
  • Most studies on hybrid buses are on large-sized buses and not mid-sized low-floor buses. This study uses MATLAB simulation to evaluate the fuel efficiency of such buses powered by diesel. Based on the results, a hybrid electric vehicle system is recommended for the best combination of power and gear ratio. A parallel hybrid system was selected for the hybridization, which transmits front and rear wheel power independently. The necessary power to satisfy the target performance was calculated, and the applicable capacity area was designed. Dynamic programing was used to create and optimize a component sizing algorithm, which was used to scale the capacity of each component of the power source to satisfy the design criteria. The fuel efficiency rate, optimum power source capacity, and gear ratio can be improved by converting a conventional bus into a parallel hybrid bus.

Study of laser welding for differential case & ring gear (레이저 용접에 관한 디퍼렌셜 케이스와 링기어 구조에 관한 고찰)

  • Chung, Taek-Min;Kim, Su-Lae;Rhee, Se-Hun
    • Proceedings of the KWS Conference
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    • 2009.11a
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    • pp.121-121
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    • 2009
  • 자동차는 코너 주행 시 In-corner와 Out-corner 의 바퀴 궤적이 달라지므로, 특별한 장치가 없이 좌우 구동 측의 바퀴가 같은 속도로 회전을 하게 되면 정상적인 주행이 불가능하다. 따라서 정상적인 코너 주행이 가능 하려면, 코너 안쪽 바퀴보다 바깥쪽 바퀴가 더 빨리 회전해야 하며 이러한 회전 차를 보상받지 못할 경우 바깥쪽 바퀴가 끌리는 현상이 발생하는데 이를 방지하기 위해 디퍼렌셜 기어가 필요하다. 현재 디퍼렌셜 기어는 디퍼렌셜 케이스와 링기어를 볼트로 체결하는 조립 공법을 통해 생산되고 있다. 하지만 볼트 체결 공법은 조립을 위한 볼트와 볼트 체결을 위한 플랜지와 볼팅을 위한 홀을 가공하는 공정이 필요하기 때문에 재료비 절감 및 생산 효율 향상에 매우 불리하고 볼트체결을 위한 부분 때문에 불필요한 무게가 증가하게 된다. 따라서 본 연구에서는 이러한 기계적 체결 방식을 레이저 용접 방식으로 대체하여 재료비를 절감하고 무게 저감을 통해 주행성능을 향상시키고자 하였다. 링기어의 소재는 침탄처리강(SCM420H)이며 디퍼렌셜 케이스의 소재는 주철(GCD500)을 사용하고 있다. 주철은 용접시 용접부와 열영향부에서 마르텐사이트 조직과 레데브라이트, 시멘타이트 조직이 생성되며 고탄소 모재의 탄소 확산으로 인한 부분 혼합영역에서 탄소 합금이 생성되어 균열이 발생하는 등 용접성이 매우 좋지 않은 것으로 알려져 있다. 이러한 주철의 난용접성을 해결하는 방법으로는 고탄소 모재 용접시 발생하는 탄소의 확산을 억제하거나 예열이나 후열 처리를 통한 냉각 속도의 제어하는 방법과 오스테나이트 안정화 원소를 첨가한 필러와이어를 사용하여 용접시 마르텐사이트와 시멘타이트의 성장을 방해하는 방법 등이 이용되고 있다. 본 연구에서는 예열처리나 후열처리를 통한 주철의 용접법은 대량 생산을 통한 원가절감을 노리는 자동차 업계의 특성에 비추어 볼 때 비용이나 프로세스 구성 면에서 적용하는 것이 어려울 것이라 판단하여 Ni-base filler metal을 통한 주철의 용접법을 선택하였고 그 결과 실차에 적용하기 위한 비틀림 강성 테스트나 내구 테스트는 통과하였으나 NVH 테스트 결과 볼팅 체결 방식에 비하여 소음이 커지는 문제가 발생하고 링기어의 HAZ부가 고경화 되는 문제가 발생하였다. 때문에 용입깊이를 초기 시제품인 5mm에서 4mm로 변경시켜 입열량 감소 및 용접변형을 줄여 소음 문제를 해결하고자 하였으며 링기어의 침탄층을 1mm 절삭하여 링기어 HAZ부의 고경화 문제를 해결하고자 하였다. 이러한 용접 구조 변경이 용접변형 및 강성과 피로에 미치는 영향력을 알아보고자 용접 및 열처리 상용 소프트웨어인 SYSWELD, 구조해석 상용소프트웨어인 NX_NASTRAN, 피로 해석 상용 소프트웨어인 FEMFAT을 이용하여 시뮬레이션 하였고 실제 구조 변경한 용접 시제품과 비교, 분석하였다.

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