Browsing by Author "Reuss, Hans-Christian"

Now showing 1 - 7 of 7

Open Access
Approach to design of piezoelectric energy harvester for sensors on electric machine rotors
(2024) Brandl, Lukas; Reuss, Hans-Christian; Heidle, Daniel
The reliability and efficiency of components are key aspects in the automotive industry. Electric machines become the focus of development. Thus, improvements in efficiency and reliability have gained significance. While it is established to attach sensors to the fixed parts of machines, such as stators, moving parts like rotors pose a major challenge due to the power supply. Piezoelectric generators can operate as energy harvesters on rotors and thus enable the rotor-based integration of sensors. The research in this article proposes the first approach to the design of a piezoelectric energy harvester (PEH) for an electric machine rotor dedicated to powering a wireless sensor system. After introducing the field of PEHs, the integration of the proposed device on a rotor shaft is presented. Further, a gap between the provided and needed data for the design of a PEH is identified. To overcome this gap, a method is presented, starting with the definition of the rotor shaft dimensions and the applied mechanical loads, including a method for the calculation of the imbalance of the rotor. With the first set of dimensions of the shaft and PEH, a co-simulation is performed to calculate the power output of this rotor and PEH set. The results of the simulation indicate the feasible implementation of the PEH on the rotor, providing enough energy to power a temperature sensor.
Open Access
Automated and virtual optimization of race-track simulation parameters on the power-train test bench
(2023) Schilling, Jannes; Wilmsen, Jan-Michael; Reuss, Hans-Christian; Schmidt, Henrik; Prokop, Günther
This paper focuses on powertrain test benches (PTB) in motorsports applications. In this case, a real powertrain is coupled with a virtual environment on the PTB to emulate mechanical loads experienced during racetrack driving. We utilize a Digital Twin of the PTB (a combination of the PTBs’ virtual environment, a powertrain model and a testbed model) to reduce setup time and allow offline virtual environment parameterization. The simulation models of the virtual environment may not always provide accurate representations due to unknown parameters or simplifications made to meet real-time requirements. Consequently, there are discrepancies between PTB and vehicle measurements. This paper aims to minimize such differences with a novel parame-ter optimization method.
Open Access
Comparison of driver models for powertrain test benches using a digital twin
(2023) Schilling, Jannes; Wilmsen, Jan-Michael; Nitschke, Paul; Reuss, Hans-Christian
Open Access
Design of zonal E/E architectures in vehicles using a coupled approach of k-means clustering and Dijkstra’s algorithm
(2023) Maier, Jonas; Reuss, Hans-Christian
Electromobility and autonomous driving has started a transformation in the automotive industry, resulting in new requirements for vehicle systems. Due to its functions, the electrical/electronic (E/E) architecture is one of the essential systems. Zonal E/E architecture is a promising approach to tackle this issue. The research presented in this paper describes a methodology for determining the optimal number of zones, the position of the zone control units (ZCU), and the assignment of electric components to these zones and ZCUs. Therefore, the design of the power supply and the wiring harness is essential. This approach aims to identify the most suitable system architecture for a given vehicle geometry and a set of electric components. For this purpose, the assignment of electric components is accomplished by k-means clustering, and Dijkstra’s algorithm is used to optimize the cable routing. As ZCUs will be the hubs for the in-vehicle data and information transport in zonal architectures, their position and their number are crucial for the architecture and wiring harness development. Simulations show a suitable zonal architecture reduces wiring harness length as well as weight and brings functional benefits. However, the number of zones must be chosen with care, as there may also be functional limitations.
Open Access
Development of a low-expansion and low-shrinkage thermoset injection moulding compound tailored to laminated electrical sheets
(2024) Braunbeck, Florian; Schönl, Florian; Preußler, Timo; Reuss, Hans-Christian; Demleitner, Martin; Ruckdäschel, Holger; Berendes, Philipp
This study presents a thermoset moulding compound designed for electrical machines with high power densities. The compound reduces residual stresses induced by the difference in thermal expansion during use and by shrinkage in the compound during the manufacturing process. To reduce the internal stresses in the compound, in the electrical sheet lamination and at their interface, first the moulding’s coefficient of thermal expansion (CTE) must match that of the lamination because the CTE of the electrical sheets cannot be altered. Second, the shrinkage of the compound needs to be minimized because the moulding compound is injected around a prefabricated electrical sheet lamination. This provides greater freedom in the design of an electric motor or generator, especially if the thermoset needs to be directly bonded to the electrical sheet. The basic suitability of the material for the injection moulding process was iteratively optimised and confirmed by spiral flow tests. Due to the reduction of the residual stresses, the compound enables efficient cooling solutions for electrical machines with high power densities. This innovative compound can have a significant impact on electric propulsion systems across industries that use laminated electrical sheets.
Open Access
EVIAN - Electric Vehicle Intelligent Charging Technology R&D combined with Electricity Network Adaptation and Battery Lifetime Factors : technical report
(Stuttgart : University of Stuttgart, Institute of Automotive Engineering, 2021) Auer, Chris; Brosi, Frank; Abu Mohareb, Omar; Reuss, Hans-Christian
This technical report is an outcome of the EVIAN-Project funded by the German Federal Ministry of Education and Research (Bundesministerium für Bildung und Forschung - BMBF). The aim of project EVIAN (Electric Vehicle Intelligent Charging Technology R&D Combined with Electricity Network Adaptation and Battery Lifetime Factors) is to intelligently integrate charging systems or electric vehicles with energy recovery into the power line. In order to be able to feed energy back into the grid, information must be exchanged and communicated between the vehicle, the charging station and the grid operator. This project identifies the parameters necessary to communicate such information between the participating systems. Therefore, a communication strategy is developed which takes into consideration the existing standards and protocols.
Open Access
Smart data preprocessing method for remote vehicle diagnostics to increase data compression efficiency
(2022) Görne, Lorenz; Reuss, Hans-Christian; Krätschmer, Andreas; Sauerwald, Ralf
The increasing number of functions in modern vehicle leads to an exponential increase in software complexity. The validity and reliability of all components must be ensured, making the use of appropriate vehicle diagnostics systems indispensable. The purpose of such systems is to collect and process data about the vehicle. To find issues during vehicle development, the OEMs will usually have a development fleet of thousands of vehicles. The challenge for diagnostic systems is to detect issues during these tests, as well as collecting as much data as possible about the circumstances that led to the fault. A single-vehicle produces hundreds of gigabytes of data per month. The required data bandwidth cannot be fulfilled by current mobile network subscriptions as well as WIFI or cable-based infrastructure. This limits the amount of data that can be collected during field tests and hinders big data analysis like AI training or validation. Hence a software solution for data reduction is necessary. The authors present a method for data handling that drastically reduces the amount of data consumption and optimizes the transfer delay between a remote-diagnostic systems and the cloud. Using a pipeline of data preprocessing as well as an established compression algorithm, the amount of transmitted data is reduced by a factor of nearly ten. This method will allow to collect more data in field testing and improve the understanding of issues during vehicle development.