Smart Design: Application of an Automatic New Methodology for the Energy Assessment and Redesign of Hybrid Electric Vehicle Mechanical Components

Abstract

This work aimed to develop an automatic new methodology based on establishing if a mechanical component, designed for a conventional propulsion system, is also suitable for hybrid electric propulsion. Change in propulsion system leads to different power delivery and vehicle dynamics, which will be reflected in different load conditions acting on the mechanical components. It has been shown that a workflow based on numerical simulations and experimental tests represents a valid approach for the evaluation of the cumulative fatigue damage of a mechanical component. In this work, the front half-shaft of a road car was analyzed. Starting from the acquisition of a speed profile and the definition of a reference vehicle, in terms of geometry and transmission, a numerical model, based on longitudinal vehicle dynamics, was developed for both conventional and hybrid electric transmission. After the validation of the model, the cumulative fatigue damage of the front half-shaft was evaluated. The new design methodology is agile and light; it has been dubbed “Smart Design”. The results show that changing propulsion led to greater fatigue damage, reducing the fatigue life component by 90%. Hence, it is necessary to redesign the mechanical component to make it also suitable for hybrid electric propulsion.

Prediction of Electric Vehicle Driving Range and Performance Characteristics: A Review on Analytical Modeling Strategies With Its Influential Factors and Improvisation Techniques

“…Based on the sign of dV, the driver command for acceleration or deceleration and braking is generated to follow the Vdesired [93]. In most cases, the driver sub-model has two subsystems such as the driver controller and commands for acceleration and braking.…”

Fatigue life evaluation of automotive mechanical components by using smart design algorithm

“…Hence, the Goodman criteria, Gerber criteria, and Morrow criteria 17,23,24 have been applied to accomplish this. The three criteria are defined in ( 13), ( 14), and (15), respectively.…”

“…The innovative aspect of this work is the creation of an automated algorithm developed in MATLAB™ environment aimed at rapidly evaluating the cumulative fatigue damage of a mechanical component in the automotive industry and, in the present work, the front halfshafts of a sport utility car (SUV). The so called smart design algorithm has been already used by the authors in a previous work in order to compare the fatigue damage related to the change of propulsion, that is, from conventional to hybrid electric 15 of a Sedan car. In this work, apart from the different size of the reference vehicle, a comparison between three different mean stress fatigue criteria has been implemented in the algorithm.…”

Smart design of a high-performance seat frame for a luxury car

“…The design of mechanical components in recent years has been experiencing a series of innovative processes which, in addition to the classic methodologies, also support topological and structural optimization considering the product life cycle (LCA) [1] These innovative aspects make it possible to reduce the weight of the components and the impact on the environment, both during production and during operation [2] The purpose of this work is to create a tool for the "intelligent design" of automotive components through optimization automatic method called "Smart Design". Smart Design was presented for the first time in [3] by Previti et al This new way of design, verifying and re-designing mechanical components has been called "Smart Design". Indeed, in the modern era, it is impossible to think that structural design does not make use of virtual, digital, rapid and secure prototyping methods.…”