articles+ search results

Vehicle design, components selection, vehicle assembling, costs analysis, sustainability, and Technology

Hybrid vehicles currently represent a compromise between the maturity of conventional vehicles and the low consumption and attention to environmental issues of electric vehicles. This article analyzes the feasibility of a hybrid series vehicle where the heat engine is replaced by a micro gas turbine. In the continuous generation of electric current, it has numerous advantages compared to an internal combustion engine and the purpose of the article is to verify whether these advantages also apply to traction in a hybrid vehicle. The model will be a city car as problems in urban environments of pollution and optimization of consumption are more revealing. After defining performance requirements, the main components are sized and then selected from the catalog, paying attention in the search for a compromise between performance, space constraints, and costs. The Advisor software will then be used to simulate the configuration in both urban and suburban cycles, paying attention to performance, the state of charge of the battery, the operating points of the microturbine, the input and output energy for each element, and fuel consumption. Then, we analyze the level of pollutant emissions to verify that they are lower than the values set by European legislation, specifically the EURO 6 standard. Finally, the total life cycle costs of the car are analyzed as the sum of the purchase cost, operating costs, and maintenance costs to verify the competitiveness of the configuration in the current market. The car was then compared with the Toyota Yaris Hybrid in terms of performance, fuel consumption, emissions, and costs to highlight advantages and disadvantages.

fluid power, numerical model, lubrication, virtual prototyping, axial piston machine, and Technology

This article presents a novel methodology to design swash plate type axial piston machines based on computationally based approach. The methodology focuses on the design of the main lubricating interfaces present in a swash plate type unit: the cylinder block/valve plate, the piston/cylinder, and the slipper/swash plate interface. These interfaces determine the behavior of the machine in term of energy efficiency and durability. The proposed method couples for the first time the numerical models developed at the authors’ research center for each separated tribological interface in a single optimization framework. The paper details the optimization procedure, the geometry, and material considered for each part. A physical prototype was also built and tested from the optimal results found from the numerical model. Tests were performed at the authors’ lab, confirming the validity of the proposed method.

electromagnetic modeling, multi-objective optimization, permanent magnet, synchronous motor., and Technology

A high-performance 20 kW, 20 Nm, 8000 rpm, spoke-type interior permanent magnet motor to be integrated into a FormulaStudent electric car’s powertrain has been designed to meet demanding performance requirements for its driving cycle. This paper describes key steps in the design optimization, analysis, fabrication, and testing of this machine. Design optimization used the non-dominated sorting genetic algorithm II (NSGA-II) coupled with a hybrid analytical/finite element model to reduce the computational time, achieving a torque and efficiency of 20Nm and 98.6%, respectively. A prototype has been constructed. The final motor design has been tested, where experimental nominal torque and efficiency have reached 18.2 Nm and 90%, respectively. Design challenges regarding the manufacturing are presented, justified, and discussed in detail. Test results were conducted to evaluate reliability and motor temperatures with and without water refrigeration at nominal current. Despite those adjustments in the optimized design, one shows that the impact on the car's lap time was low, going from 77.3 s for the ideal optimized motor to 78.9 s for the prototyped motor.

field-programmable gate array (fpga), field-programmable system-on-chip (fpsoc), finite control set (fcs), model predictive control (mpc), voltage source inverter (vsi), and Technology

This work describes an efficient implementation in terms of computation time and resource usage in a Field-Programmable System-On-Chip (FPSoC) of a Finite Control Set Model Predictive Control (FCS-MPC) algorithm. As an example, the FCS-MPC implementation is used for the current reference tracking of a two-level three-phase power converter. The proposed solution is an enabler for using both complex control algorithms and digital controllers for high switching frequency semiconductor technologies. An original HW/SW (hardware and software) system architecture for an FPSoC is designed to take advantage of a modern operating system, while removing time uncertainty in real-time software tasks, and exploiting dedicated FPGA fabric for the most complex computations. In addition, two different architectures for the FPGA-implemented functionality are proposed and compared in order to study the area-speed trade-off. Experimental results show the feasibility of the proposed implementation, which achieves a speed hundreds of times faster than the conventional Digital Signal Processor (DSP)-based control platform.

light emitting diodes, power LEDs, multi-domain modelling, LED luminaire design, and Technology

This paper presents our approaches to chip level multi-domain LED (light emitting diode) modelling, targeting luminaire design in the Industry 4.0 era, to support virtual prototyping of LED luminaires through luminaire level multi-domain simulations. The primary goal of such virtual prototypes is to predict the light output characteristics of LED luminaires under different operating conditions. The key component in such digital twins of a luminaire is an appropriate multi-domain model for packaged LED devices that captures the electrical, thermal, and light output characteristics and their mutual dependence simultaneously and consistently. We developed two such models with this goal in mind that are presented in detail in this paper. The first model is a semi analytical, quasi black-box model that can be implemented on the basis of the built-in diode models of spice-like circuit simulators and a few added controlled sources. Our second presented model is derived from the physics of the operation of today’s power LEDs realized with multiple quantum well heterojunction structures. Both models have been implemented in the form of visual basic macros as well as circuit models suitable for usual spice circuit simulators. The primary test bench for the two circuit models was an LTspice simulation environment. Then, to support the design of different demonstrator luminaires of the Delphi4LED project, a spreadsheet application was developed, which ensured seamless integration of the two models with additional models representing the LED chips’ thermal environment in a luminaire. The usability of our proposed models is demonstrated by real design case studies during which simulated light output characteristics (such as hot lumens) were confirmed by luminaire level physical tests.

rapid prototyping, design methodology, DC-DC converters, user centered design, user interface, design optimization, and Technology

In this paper, power loss and cost models of power electronic converters based on converter ratings and datasheet information are presented. These models aid in creating rapid prototypes which facilitate the component selection process. Through rapid prototyping, users can estimate power loss and cost which are essential in design decisions. The proposed approach treats main power electronic components of a converter as building blocks that can be arranged to obtain multiple topologies to facilitate rapid prototyping. In order to get system-level power loss and cost models, two processes are implemented. The first process automatically provides minimum power loss or cost estimates and identifies components for specific applications and ratings; the second process estimates power losses and costs of each component of interest as well as the whole system. Two examples are used to illustrate the proposed approaches—boost and buck converters in continuous conduction mode. Achieved cost and loss estimates are over 93% accurate when compared to measured losses and real cost data. This research presents derivations of the proposed models, experimental validation of the models and demonstration of a user friendly interface that integrates all the models. Tools presented in this paper are expected to be very useful for practicing engineers, designers, and researchers, and are flexible and adaptable with changing or new technologies and varying component prices.

medium frequency transformer, design methodology, nanocrystalline core, DAB, and Technology

Medium frequency transformers (MFTs) are a key component of DC–DC dual active bridge (DAB)-type converters. These technologies are becoming a quintessential part of renewable energy solutions, such as photovoltaic systems and wind energy power plants, as well as in modern power grid interfaces functioning as solid-state transformers in smart-grid environments. The weight and physical dimensions of an MFT are key data for the design of these devices. The size of an MFT is reduced by increasing its operating frequency. This reduction implicates higher power density through the transformer windings, as well as other design requirements distinct to those used for conventional 60/50 Hz transformers; therefore, new MFT design procedures are needed. This paper introduces a novel methodology for designing MFTs, using nanocrystalline cores, and tests it using an MFT–DAB lab prototype. Different to other MFT design procedures, this new design approach uses a modified version of the area-product technique, which consists of smartly modifying the core losses computation, and includes nanocrystalline cores. The core losses computation is supported by a full analysis of the dispersion inductance. For purposes of validation, a model MFT connected to a DAB converter is simulated in Matlab-Simulink (The MathWorks, v2014a, Mexico City, Mexico). In addition, a MFT–DAB lab prototype (1 kVA at 5 kHz) is implemented to experimentally probe further the validity of the methodology just proposed. These results demonstrate that the analytic calculations results match those obtained from simulations and lab experiments. In all cases, the efficiency of the MFT is greater than 99%.

Axial flux machine, finite element analysis, permanent-magnet generator, wind power generator, and Technology

This paper contributes to the research and development of Axial Flux Permanent Magnet Synchronous Machines (AFPMSM); and in particular the design, the construction stages and measurements of a double rotor single internal non-ferromagnetic stator with a trapezoidal-concentrated winding machine for wind power generation applications. The initial dimensions of the machine were calculated using analytical formulas and a model was created and analyzed using the 3D Finite Element Method (FEM). The shape of the magnets of the machine was optimized and presented in a previous paper and a prototype was constructed and tested in the laboratory. In addition, a temperature test of the stator was performed experimentally. Finally, the effect of the different axial widths of the two air gaps on the electrical magnitudes and the field of the machine were investigated using both FEM analysis and experiments.

simulation and monitoring, energy analysis, solar decathlon, simulation-based control, and Technology

This paper presents a comparative analysis between an energy simulation model and an actual solar home. The case study used was the Team Missouri’s 2009 Solar Decathlon entry. The home was evaluated using the predicted data developed with the use of Energy-10 Version 1.8. The software simulates the energy use performance of building strategies ranging from building envelope and system efficiency options. The performance data used was collected during the 2009 Solar Decathlon competition. Results comparing energy efficient strategies, consumption and generation are explored with future implications discussed.

small wind turbine (SWT), blade design, BEM, wind tunnel test, rapid prototyping, and Technology

Small wind turbines (SWTs) can be significantly sensitive to variances in the blade geometry shape when their operation in relatively low ranges of Reynolds numbers is considered. An SWT case study, where an existing wind turbine prototype was equipped with a redesigned blade set, to increase its aerodynamic efficiency, is presented. The geometry modification process was targeted at maximizing the turbine power coefficient in the presumed point of low Reynolds operation. The applied design and analysis methods included practical implementation of previously established “Fast Track” procedure for wind turbine development. A newly prepared blade geometry and a reference blade set were examined numerically and experimentally. Selected design and assessment processes were supposed to be low resource demanding, making them possibly highly applicable in renewable energy industry. Therefore, the numerical analysis of both geometries was based on BEM (blade element momentum theory) equations. The research was expanded by model validation in small-scale wind tunnel tests to provide detailed information on BEM data reliability in comparison to the results of the experiment. The small-scale analysis, performed in Reynolds numbers below 100,000, provided information sufficient for evaluation of the redesigned blade. Implementation of the geometry obtained throughout the proposed procedure increased the rotor’s maximum power coefficient by 10%.

small wind turbine (SWT), rapid prototyping, wind tunnel, numerical flow analysis, and Technology

In general, standard aerodynamic design is divided into two paths—numerical analysis and empirical tests. It is crucial to efficiently combine both approaches in order to entirely fulfill the requirements of the design process as well as the final product. An effective use of computational analysis is a challenge, however it can significantly improve understanding, exploring and confining the search for optimal product solutions. The article focuses on a rapid prototyping and testing procedure proposed and employed at the Institute of Turbomachinery, Lodz University of Technology (IMP TUL). This so called Fast Track approach combines preparation of numerical models of a wind turbine rotor, manufacturing of its geometry by means of a 3D printing method and testing it in an in-house wind tunnel. The idea is to perform the entire procedure in 24 h. The proposed process allows one to determine the most auspicious sets of rotor blades within a short time. Owing to this, it significantly reduces the amount of individual subsequent examinations. Having fixed the initial procedure, it is possible to expand research on the singled-out geometries. The abovementioned observations and the presented overview of the literature on uses of 3D printing in aerodynamic testing prove rapid prototyping as an innovative and widely-applicable method, significantly changing our approach to experimental aerodynamics.

doubly fed induction generator, wind energy conversion system, field oriented control, rapid control prototyping, hardware-in-the-loop, and Technology

This paper presents the modeling, rapid control prototyping, and hardware-in-the-loop testing for real-time simulation and control of a grid-connected doubly fed induction generator (DFIG) in a laboratory-size wind turbine emulator for wind energy conversation systems. The generator is modeled using the direct-quadrature rotating reference frame circuit along with the aligned stator flux, and the field-oriented control approach is applied for independent control of the active and reactive power and the DC-link voltage at the grid side. The control of the active, reactive power and the DC-link voltage are performed using a back-to-back converter at sub- and super-synchronous as well as at variable speeds. The control strategy is experimentally validated on an emulated wind turbine driven by the Opal-RT real-time simulator (OP5600) for simultaneous control of the DC-link voltage, active and reactive power.

energy storage systems, energy management system, engineering support, smart grid architecture model, model-driven engineering, rapid prototyping, ontology, semantic web technologies, description logic, conflicts resolution, and Technology

Energy storage systems will play a major role in the decarbonization of future sustainable electric power systems, allowing a high penetration of distributed renewable energy sources and contributing to the distribution network stability and reliability. To accomplish this, a storage system is required to provide multiple services such as self-consumption, grid support, peak-shaving, etc. The simultaneous activation of controllers operation may lead to conflicts, as a consequence the execution of committed services is not guaranteed. This paper presents and discusses a solution to the exposed issue by developing an engineering support approach to semi-automatically detect and handle conflicts for multi-usage storage systems applications. To accomplish that an ontology is developed and exploited by model-driven engineering mechanisms. The proposed approach is evaluated by implementing a use case example, where detection of conflicts is automatically done at an early design stage. Besides this, exploitable source code for conflicts resolution is generated and used during the design and prototype stages of controllers development. Thus, the proposed engineering support enhances the design and development of storage system controllers, especially for multi-usage applications.

water hydraulics, axial piston pump, surface shaping, and Technology

A novel virtual prototyping algorithm has been developed to design one of the most critical lubricating interfaces in axial piston machines of the swash plate type—the piston–cylinder interface—for operation with water as the working fluid. Due to its low viscosity, the use of water as a lubricant can cause solid friction and wear in these machines at challenging operating conditions. The prototyping algorithm compensates for this by tailoring the shape of the bore surface that guides the motion of each piston in this type of positive displacement machine to conform with the piston surface, taking into account both the piston’s tilt and its deformation. Shaping these surfaces in this manner can render the interface more conducive to generating hydrodynamic pressure buildup that raises its load-carrying capacity. The present work first outlines the structure of the proposed algorithm, then presents a case study in which it is employed to design a bore surface shape for use with two prototypes, one virtual and one physical—both modified versions of a 444 cc commercial axial piston pump. Experimental testing of the physical prototype shows it to achieve a significantly higher maximum total efficiency than the stock unit.

LED digital twin, design flow, multi-domain compact model, tool agnostic, multi-LED, and Technology

At present, when designing a Light Emitting Diode (LED) luminaire, different strategies of development are followed depending on the size of the company. Since on LED datasheets there is only limited information provided, companies designing LED luminaires spend a lot of effort gathering the required input of LED details to be able to design reliable products. Small and medium size enterprises (SMEs) do not have the bandwidth to gather such input and solely rely on empirical approaches leading to approximated luminaire designs, while larger companies use advanced hardware and software tools to characterize parts, design versions, and finally optimize all design steps. In both cases, considerable time and money is spent on prototyping, sampling, and laboratory testing. Digitalization of the complete product development (also known as Industry 4.0 approach) at all integration levels of the solid state lighting (SSL) supply chain would provide the remedy for these pains. The Delphi4LED European project aimed at developing multi-domain compact models of LED (for a consistent, combined description of electronic, thermal, and optical properties of LEDs) as digital twins of the physical products to support virtual prototyping during the design of luminaires. This paper provides an overview of the Delphi4LED approach aimed at supporting new, completely digital workflows both for SMEs and larger companies (Majors) along with some comparison with the traditional luminaire design. Two demonstration experiments are described: One to show the achievable benefits of the approach and another one to demonstrate the ease of use and ability to be accommodated in a larger scale product design for assessing design choices like e.g., number and type of LEDs versus electrical/thermal conditions and constraints, in a tool agnostic manner.

additive manufacturing, three-dimensional printing, topology optimization, magnetic materials, soft magnetic materials, permanent magnets, and Technology

Additive manufacturing has many advantages over traditional manufacturing methods and has been increasingly used in medical, aerospace, and automotive applications. The flexibility of additive manufacturing technologies to fabricate complex geometries from copper, polymer, and ferrous materials presents unique opportunities for new design concepts and improved machine power density without significantly increasing production and prototyping cost. Topology optimization investigates the optimal distribution of single or multiple materials within a defined design space, and can lead to unique geometries not realizable with conventional optimization techniques. As an enabling technology, additive manufacturing provides an opportunity for machine designers to overcome the current manufacturing limitation that inhibit adoption of topology optimization. Successful integration of additive manufacturing and topology optimization for fabricating magnetic components for electrical machines can enable new tools for electrical machine designers. This article presents a comprehensive review of the latest achievements in the application of additive manufacturing, topology optimization, and their integration for electrical machines and their magnetic components.

Ion current, cylinder pressure, cooperative combustion diagnosis and control, field-programmable gate array, artificial neural network, and Technology

The application of advanced technologies for engine efficiency improvement and emissions reduction also increase the occurrence possibility of abnormal combustions such as incomplete combustion, misfire, knock or pre-ignition. Novel promising combustion modes, which are basically dominated by chemical reaction kinetics show a major difficulty in combustion control. The challenge in precise combustion control is hard to overcome by the traditional engine map-based control method because it cannot monitor the combustion state of each cycle, hence, real-time cycle-resolved in-cylinder combustion diagnosis and control are required. In the past, cylinder pressure and ion current sensors, as the two most commonly used sensors for in-cylinder combustion diagnosis and control, have enjoyed a seemingly competitive relationship, so all related researches only use one of the sensors. However, these two sensors have their own unique features. In this study, the idea is to combine the information obtained from both sensors. At first, two kinds of ion current detection system are comprehensively introduced and compared at the hardware level and signal level. The most promising variant (the DC-Power ion current detection system) is selected for the subsequent experiments. Then, the concept of ion current/cylinder pressure cooperative combustion diagnosis and control system is illustrated and implemented on the engine prototyping control unit. One application case of employing this system for homogenous charge compression ignition abnormal combustion control and its stability improvement is introduced. The results show that a combination of ion current and cylinder pressure signals can provide richer and also necessary information for combustion control. Finally, ion current and cylinder pressure signals are employed as inputs of artificial neural network (ANN) models for combustion prediction. The results show that the combustion prediction performance is better when the inputs are a combination of both signals, instead of using only one of them. This offline analysis proves the feasibility of using an ANN-based model whose inputs are a combination of ion current and pressure signals for better prediction accuracy.

positive energy districts labs, testing facilities, factsheets, statistical studies, and Technology

The development of city-driven urban laboratories was considered a priority by the European Commission through Action 3.2 of the Strategic Energy Technology Plan. In this context, positive-energy districts laboratories could take the role of urban drivers toward innovation and sustainability in cities. These urban labs can provide real-life facilities with innovative co-creation processes and, at the same time, provide testing, experimenting, and prototyping of innovative technologies. In this scope, the authors of this work want to share the very first results of an empirical study using the testing facilities provided by the members of the Joint Program on Smart Cities of the European Energy Research Alliance as positive-energy districts laboratories. Six climatic regions are studied as boundary conditions, covering temperate and continental climates. Four scales of action are analyzed: Building, campus, urban, and virtual, with building and campus scales being the most frequent. Most of these laboratories focus on energy applications followed by networks, storage systems, and energy loads characterization. Many of these laboratories are regulated by ICT technologies but few of them consider social aspects, lighting, waste, and water systems. A SWOT analysis is performed to highlight the critical points of the testing facilities in order to replicate optimized configurations under other conditions. This statistical study provides guidelines on integration, localization, functionality, and technology modularity aspects. The use of these guidelines will ensure optimal replications, as well as identify possibilities and opportunities to share testing facilities of/between the positive-energy district laboratories.

life cycle assessment, parametric, optimization, artificial intelligence, AI, algorithms, and Technology

The analyzed research issue provides a model for Carbon Footprint estimation at an early design stage. In the context of climate neutrality, it is important to introduce regenerative design practices in the architect’s design process, especially in early design phases when the possibility of modifying the design is usually high. The research method was based on separate consecutive research works–partial tasks: Developing regenerative design guidelines for simulation purposes and for parametric modeling; generating a training set and a testing set of building designs with calculated total Carbon Footprint; using the pre-generated set to train a Machine Learning Model;applying the Machine Learning Model to predict optimal building features; prototyping an application for a quick estimation of the Total Carbon Footprint in the case of other projects in early design phases; updating the prototyped application with additional features; urban layout analysis; preparing a new approach based on Convolutional Neural Networks and training the new algorithm; and developing the final version of the application that can predict the Total Carbon Footprint of a building design based on basic building features and on the urban layout. The results of multi-criteria analyses showed relationships between the parameters of buildings and the possibility of introducing Carbon Footprint estimation and implementing building optimization at the initial design stage.

torrefaction, pyrolysis, gasification, fixed bed, thermally thick particle, modelling., and Technology

Gasification of biomass in fixed bed gasifiers is a well-known technology, with its origins dating back to the beginning of 20th century. It is a technology with good prospects, in terms of small scale, decentralized power co-generation. However, the understanding of the process is still not fully developed. Therefore, assessment of the changes in the design of a gasifier is typically performed with extensive prototyping stage, thus introducing significant cost. This study presents experimental results of gasification of a single pellet and bed of particles of raw and torrefied wood. The procedure can be used for obtaining design parameters of a fixed bed gasifier. Results of two suits of experiments, namely pyrolysis and CO2 gasification are presented. Moreover, results of pyrolysis of pellets are compared against a numerical model, developed for thermally thick particles. Pyrolysis time, predicted by model, was in good agreement with experimental results, despite some differences in the time when half of the initial mass was converted. Conversion times for CO2 gasification were much longer, despite higher temperature of the process, indicating importance of the reduction reactions. Overall, the obtained results could be helpful in developing a complete model of gasification of thermally thick particles in a fixed bed.