This paper describes the development of a liquid cooling system of battery module with lithium-ion prismatic metal can battery cells that can be used in hybrid electric vehicles (HEV). Initially, a design concept of a liquid cooled battery module is selected based on the functional requirements associated with maximum battery cell temperature rise, temperature uniformity across the battery module, temperature uniformity within each individual lithium-ion prismatic battery cell, and total pressure loss of the liquid cooling system. A three-dimensional battery module thermal model and an analytical optimization approach are developed for selected design concept of the liquid cooled battery module. Finally, by performing analytical optimization study to examine the effects of geometries of the inlet duct, manifold, and the outlet duct on battery module thermal behavior and total pressure loss of cooling system, the optimal design concept of liquid-cooled battery module is identified to maximize its durability and driving range.
Brake rotor thickness variation causes brake torque variation which can lead to brake judder and pulsation, steering wheel oscillations and chassis vibration. In this paper, we have proposed a prognostics methodology to predict the degradation level of brake rotor due to disc thickness variation. Leveraging the time and frequency domain analysis, this model creates health indicators to assess the health of the rotor and predict the rotor thickness variations of 36 micrometers or more. These health indicators that are calculated during braking events include: (i) envelope or variance of the brake master cylinder pressure (MCP); (ii) envelope or variance of the longitudinal acceleration (AX); (iii) the root mean square amplitude of the average order spectrum of the MCP at order one; and (iv) the root mean square amplitude of the average order spectrum of the AX at order one. This paper demonstrates that the above health indicators are significantly larger for a degraded brake rotor due to thickness variation compared to a healthy rotor.
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