This thesis is focused on lead-acid batteries used in hybrid electric vehicles. These cells work in specific conditions, particularly under partial charge referred to as PSOC. This fact is responsible for the premature loss of capacity cell lead-acid batteries and their short lifetime. The task of this thesis is to examine the effect of conductive ceramics as possible additives to the negative electrode active materials of lead-acid battery cells operating in a PSOC, in order to prolong their life.

The work deals with relatively new components allowing electric energy accumulation – ultracapacitors. It focuses on their application in traffic systems – in independent electric vehicles. Design and verification of a system with ultracapacitor and DC/DC adaptive converter was done. Control of the adaptive converter modifies very positively the time wafeform of the traction accumulator current during the drive cycle. The designed connection of ultracapacitor and DC/DC converter implemented in the drive structure of experimental electric vehicle with induction machine contributes to increment the action radius of the vehicle by 16% (determined by experimental verification). This result was achived particularly by limitation of traction accumulator current peaks, And by more effective storage of energy gained by recuperative braking of the vehicle as well. The core of the system is a control of the adaptive converter in order to provide an active filtration of the accumulator’s current to its long-period mean value, i.e. elimination of current (power) peaks. These are caused by acceleration from non-zero initial vehicle speed or by recuperative braking. This is done by a subsidiary current loop. The converter has a superior voltage regulation loop, which sets in long-time period the voltage of ultracapacitors to the proper value – indirectly dependent on the speed of the vehicle. This ensures the appropriate energy management of the ultracapacitor. In the following, properties of test set of ultracapacitors were verified. Finally, methods of suppression of capacity variability influence in series connection of these components were compiled and critically reviewed.

L’objectif de ce travail est d’élaborer un modèle performant/précis de la machine électrique permettant de proposer une technique de pronostic. Dans cette thèse, nous commençons par un état de l’art sur les véhicules électriques hybrides (VHE), les différents types de machines électriques utilisées dans les VHE ainsi que les différents types de défauts pouvant survenir dans ces machines électriques. Nous identifions également les indicateurs de défauts appropriés aux différents défauts considérés. Ensuite, une synthèse de techniques de pronostic pouvant être appliquées est proposée. Le modèle à éléments finis électromagnétiques, thermiques et vibratoires (FEM) de la machine à aimants permanents est présenté. Le modèle est élaboré en fonctionnement normal et défaillant. Les types de défauts considérés sont : démagnétisation, court-circuit et excentricité. Une comparaison entre les deux approches analytique et FEM (méthode numérique) pour la modélisation de machines électromagnétiques est effectuée. Les indicateurs de défauts analysés pour l’extraction les plus pertinents utilisent les différents signaux mesurées suivants : le couple, la température ainsi que les signaux vibratoires en états sains et défectueux. L’approche de pronostic adoptée qui est le modèle de Markov caché (HMM) est développée. L'aspect technique de la méthode est présenté et le module du pronostic est formulé. La méthode de HMM est utilisée pour détecter et localiser les défauts à petites amplitudes. Une stratégie systématique a été développée. Le vieillissement de l’équipement de la machine, en particulier des éléments sensibles comme la bobine de stator et l’aimant permanent, est une question très importante pour le calcul du RUL (Remaining Useful Life). Une stratégie d’estimation pour le calcul RUL est présentée et discutée. La configuration en boucle fermée est très importante. Elle est adoptée par tous les systèmes de véhicules disponibles. Par conséquent, les mêmes étapes mentionnées précédemment s'appliquent également à une configuration en boucle fermée. Un modèle global où l’entrée du FEM de la machine provient de l’onduleur modélisé est élaboré. / The core of the work is to build an accurate model of the electrical machine where the prognostic technique is applied. In this thesis we started by a literature review on hybrid electric vehicles (HEV), the different types of electrical machine used in HEV’s and the different types of faults that may occur in those electrical machine. We also identify the useful monitoring parameters that are beneficial for those different types of faults. Then, a survey is presented where all the prognostic techniques that can be applied on this application are enumerated. The electromagnetic, thermal and vibration finite element model (FEM) of the permanent magnet machine is presented. The model is built at healthy operation and when a fault is integrated. The considered types of faults are:demagnetization, turn to turn short circuit and eccentricity. A confrontation between analytical and FEM (numerical method) for electromagnetic machine modeling is illustrated. Fault indicators where useful measured parameters forfault identification are recognized and useful features from the measured parameters are extracted; torque, temperature and vibration signal are elaborated for healthy and faulty states. The strategy of the adopted prognostic approach which is Hidden Markov Model (HMM) is explained. The technical aspect of the method is presented and the prognostic model is formulated. HMM is applied to detect and localize small scale fault small scale faults were where a systematic strategy is developed. The aging of the machine’s equipment,specially the sensitive ones that are the stator coil’s and the permanent magnet, is a very important matter for RUL calculation. An estimation strategy for RUL calculation is presented and discussed for those mentioned machine’s components. Closed loop configuration is very important; it is adopted by all available vehicle systems. Hence, the same previously mentioned steps are applied for a closed loop configuration too. A global model where the input of the machine’s FEM comes from the modeled inverter is built.

Eine kompakte Integration der Leistungselektronik in einem Fahrzeuggetriebe des Hybridfahrzeugs stellt hohe Anforderungen an die Lastwechselfestigkeit der Halbleiter-Leistungsmodule. Gefordert wird die Auslegung für die Kühlmitteltemperatur von 125°C und für die Sperrschichttemperatur von 200°C. Für die Untersuchung der Lastwechselfestigkeit bei geforderten hohen Temperaturen werden neue Prüfstandskonzepte und Messmethoden vorgestellt. Mit realisierten Testständen wird die Lastwechselfestigkeit der neuen Aufbau- und Verbindungstechnologien „gehärtete Aluminiumbonddrähte”, „Diffusionslöten”, „Lötung mit vertikalen Strukturen” und „Niedertemperatur-Verbindungstechnik” untersucht. / High power density of the power electronics in a hybrid electric vehicle demands a high power cycling capability of the semiconductor power module. Requirements are: 125°C coolant and 200°C junction temperature. For the investigation of the power cycling capability at high temperatures new test benches and measurement methods are introduces. With realized methods the reliability of following new interconnection technologies is investigated: doped aluminium bond wires, diffusion soldering, solder layer with vertical microstructures, low temperature sinter technology.

[ES] La necesidad de mejorar el consumo de combustible y las emisiones de los sistemas propulsivos de automoción en condiciones reales de conducción es la base de esta tesis. Para ello, se exploran dos ejes: En primer lugar, el control de los sistemas de propulsión. El estado del arte de control en los sistemas propulsivos de automoción se basa en gran medida en el uso de técnicas de optimización que buscan las leyes de control que minimizan una función de coste en un conjunto de condiciones de operación denidas a priori. Estas leyes se almacenan en las ECUs de producción en forma de mapas de calibración de los diferentes actuadores del motor. Las incertidumbres asociadas al conjunto limitado de condiciones en el proceso de calibración dan lugar a un funcionamiento subóptimo del sistema de propulsión en condiciones de conducción real. Por lo tanto, en este trabajo se proponen métodos de control adaptativo que optimicen la gestión de la planta propulsiva a las condiciones esperadas de funcionamiento para un usuario y un caso determinado en lugar de a un conjunto genérico de condiciones. El segundo eje se reere a optimizar, en lugar de los parámetros de control del sistema propulsivo, la demanda de potencia de este, introduciendo al propio conductor en el bucle de control, sugiriéndole las acciones a tomar. En particular, este segundo eje se reere al control de la velocidad del vehículo (conocido popularmente como Eco-Driving en la literatura) en condiciones reales de conducción. Se proponen sistemas de aviso en tiempo real al conductor acerca de la velocidad óptima para minimizar el consumo del vehículo. Los métodos de control desarrollados para cada aplicación se describen en detalle en la tesis y se muestran ensayos experimentales de validación en los casos de estudio diseñados. Ambos ejes representan un problema de control óptimo, denido por un sistema dinámico, unas restricciones a cumplir y un coste a minimizar, en este sentido las herramientas desarrolladas en la tesis son comunes a los dos ejes: Un modelo de vehículo, una herramienta de predicción del ciclo de conducción y métodos de control óptimo (Programación Dinámica, Principio Mínimo de Pontryagin y Estrategia de Consumo Equivalente Mínimo). Dependiendo de la aplicación, los métodos desarrollados se implementaron en varios entornos experimentales: un motor térmico en sala de ensayos simulando el resto del vehículo, incluyendo el resto del sistema de propulsión híbrido y en un vehículo real. Los resultados muestran mejoras signicativas en el rendimiento del sistema de propulsión en términos de ahorro de combustible y emisiones en comparación con los métodos empleados en el estado del arte actual. / [CA] La necessitat de millorar el consum de combustible i les emissions dels sistemes propulsius d'automoció en condicions reals de conducció és la base d'aquesta tesi. Per a això, s'exploren dos eixos: En primer lloc, el control dels sistemes de propulsió. L'estat de l'art de control en els sistemes propulsius d'automoció es basa en gran manera en l'ús de tècniques d'optimització que busquen les lleis de control que minimitzen una funció de cost en un conjunt de condicions d'operació denides a priori. Aquestes lleis s'emmagatzemen en les Ecus de producció en forma de mapes de calibratge dels diferents actuadors del motor. Les incerteses associades al conjunt limitat de condicions en el procés de calibratge donen lloc a un funcionament subòptim del sistema de propulsió en condicions de conducció real. Per tant, en aquest treball es proposen mètodes de control adaptatiu que optimitzen la gestió de la planta propulsiva a les condicions esperades de funcionament per a un usuari i un cas determinat en lloc d'un conjunt genèric de condicions. El segon eix es refereix a optimitzar, en lloc dels paràmetres de control del sistema propulsiu, la demanda de potència d'aquest, introduint al propi conductor en el bucle de control, suggerint-li les accions a prendre. En particular, aquest segon eix es refereix al control de la velocitat del vehicle (conegut popularment com Eco-*Driving en la literatura) en condicions reals de conducció. Es proposen sistemes d'avís en temps real al conductor sobre la velocitat òptima per a minimitzar el consum del vehicle. Els mètodes de control desenvolupats per a cada aplicació es descriuen detalladament en la tesi i es mostren assajos experimentals de validació en els casos d'estudi dissenyats. Tots dos eixos representen un problema de control òptim, denit per un sistema dinàmic, unes restriccions a complir i un cost a minimitzar, en aquest sentit les eines desenvolupades en la tesi són comunes als dos eixos: Un model de vehicle, una eina de predicció del cicle de conducció i mètodes de control òptim (Programació Dinàmica, Principi Mínim de *Pontryagin i Estratègia de Consum Equivalent Mínim). Depenent de l'aplicació, els mètodes desenvolupats es van implementar en diversos entorns experimentals: un motor tèrmic en sala d'assajos simulant la resta del vehicle, incloent la resta del sistema de propulsió híbrid i en un vehicle real. Els resultats mostren millores signicatives en el rendiment del sistema de propulsió en termes d'estalvi de combustible i emissions en comparació amb els mètodes emprats en l'estat de l'art actual. / [EN] The need of improving the real-world fuel consumption and emission of automotive applications is the basis of this thesis. To this end, two verticals are explored: First is the online control of the powertrain systems. In state-of-the-art Optimal Control techniques (such as Dyanmic Programming, Pontryagins Minimum Principle, etc...) are extensively used to formulate the optimal control laws. These laws are stored in the production ECUs in the form of feedforward calibration maps. The unaccounted uncertainities related to the real-world during the powertrain calibration result in suboptimal operations of the powertrain in actual driving. Therefore, adaptive control methods are proposed in this work which, optimise the energy management of the conventional and the HEV powertrain control on real driving mission. The second vertical is regarding the vehicle speed control (popularly known as Eco-Driving in the literature) methods in real driving condition. In particular, speed advisory systems are proposed for real time application on a vehicle. The control methods developed for each application are described in details with their verication and validation on the designed case studies. Apart from the developed control methods, there are three tools that were developed and used at various stages of this thesis: A vehicle model, A driving cycle prediction tool and optimal control methods (dynamic programming, PMP and ECMS). Depending on the application, the developed methods were implemented on the Hardware-In-Loop Internal Combustion Engine testing setup or on a real vehicle. The results show signicant improvements in the performance of the powertrain in terms of fuel economy and emissions in comparison to the state-of-the-art methods. / Pandey, V. (2021). Online Control of Automotive systems for improved Real-World Performance [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/173716

The marine industry has increased its adoption of pure-electric, diesel-electric, and other non-traditional propulsion architectures to reduce ship emissions and fuel consumption. While these technologies can improve performance, the design of a propulsion system becomes challenging, given that no single technology is superior across all vessel types. Furthermore, even identical ships with different operating patterns may be better suited to different propulsion technologies. Addressing this problem, previous research has shown that if key elements of a vessel's operational pro file are known, simulation and optimization techniques can be employed to evaluate multiple propulsion architectures and result in a better propulsion system design and energy management strategy for a given vessel. While these studies have demonstrated the performance improvements that can be achieved from optimizing clean marine propulsion systems, they rely on vessel operational profiles obtained through physical measurement from existing ships. From a practical point of view, the optimization of a vessel's propulsion system needs to occur prior to a vessel's construction and thus precludes physical measurement. To this end, this thesis introduces a marine simulation platform for producing vessel operational profiles which enable propulsion system optimization during the ship design process. Core subsystem modules are constructed for simulating ship motions in 3 degrees of freedom and result in operational profile time-series, including propulsion power. Data is acquired from a benchmark vessel to validate the simulation. Results show the proposed approach strikes a balance between speed, accuracy, and complexity compared with other available tools. / Graduate

Indiana University-Purdue University Indianapolis (IUPUI) / There is a strong urge for advanced diagnosis method, especially in high power battery packs and high energy density cell design applications, such as electric vehicle (EV) and hybrid electric vehicle segment, due to safety concerns. Accurate and robust diagnosis methods are required in order to optimize battery charge utilization and improve EV range. Battery faults cause significant model parameter variation affecting battery internal states and output. This work is focused on developing diagnosis method to reliably detect various faults inside lithium-ion cell using electrochemical model based observer and fuzzy logic algorithm, which is implementable in real-time. The internal states and outputs from battery plant model were compared against those from the electrochemical model based observer to generate the residuals. These residuals and states were further used in a fuzzy logic based residual evaluation algorithm in order to detect the battery faults. Simulation results show that the proposed methodology is able to detect various fault types including overcharge, over-discharge and aged battery quickly and reliably, thus providing an effective and accurate way of diagnosing li-ion battery faults.

Premature loss of capacity, mode of partial charge, additives, negative electrode, lead acid battery, lead-acid battery cycling, hybrid electric vehicle, traction battery, ebonex, titanium dioxide