Hybrid electric vehicles significantly reduce exhaust emissions and increase fuel economy. Power packs are the most fundamental components in a series powertrain configuration of a hybrid vehicle, which produce the necessary power to run the vehicle. The aim of this project is to design a compact power pack for a series hybrid vehicle, using virtual prototyping. The hybrid electric vehicle characteristics and configurations are analysed, followed by an explanation of the principles of induction machines. A new type of rotary induction machine with an outer rotor construction is designed to be coupled with the novel rotary internal combustion engine with rotating crankcase in order to form the compact power unit for the hybrid vehicle. The starting and generation performance of the designed machine is analysed by an electric machine simulator, called JMAG. ADVISOR software is studied and utilised to simulate the overall vehicle performance, employing different categories of power packs in the powertrain. Results show that the proposed compact power pack has the best performance in terms of fuel economy, emissions and battery charging compared to the existing power unit options. Over the city cycle, fuel economy is increased by up to 47 % with emission reduced by up to 36 % and over the highway cycle, fuel economy is increased by up to 69 % with emission reduced by up to 42 %.

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As the industry is being reshaped concentrically around sustainability, the consumption of fossil fuels is targeted to decrease day by day. As a consequence of that, a righteous rise of electricity as energy source prevails in different branches of industry. It results for electric vehicle components to increase in size and weight which in fact were relatively smaller on conventional fossil fuel driven vehicles e.g. trucks. Every component weighing more than two kilograms is classified as a large component by Scania and these large electric components uncovers the need of evaluation of established testing methods in terms of their validity. This thesis project was carried out at Scania, Södertälje, and deals with the investigation on vibration testing methods that are currently used in different fields of engineering and identification of potentially applicable ones at Scania in testing large components. A case study on the stiffness of an individual component is performed to assess its impact on alteration of eigenfrequencies. Few case studies based on empirical tests as well as finite element method simulations on certain large components, i.e. high voltage junction box and battery packs, are performed with respect to their vibration behaviours while undergoing Scania’s established vibration testing spectra. Investigation into the vibration behaviour on dependence on measurement locations were performed. Additionally, rudimentary case studies are conducted on thermal loads during vibration testing, thermal dwell time, and required energy to oscillate large components at certain levels. How thermal features of the component are affected due to its size is noted. / Den senaste tekniska paradigmen inom fordonsindustrin är fokus på minskning av beroende på fossila bränslen, högre energisnålhet och en ökad hållbarhet och effektivitet i produktionsprocessens alla delar. Detta och de stora genombrotten i batteritekniken hade som påföljd att utvecklingen av fordon riktades mot elektrifiering av alla fordon. Elmotorer har sedan tidigare funnit sin tillämpning på mindre maskiner i inomhusmiljöer som t.ex. palldragare och lasttruckar. För tyngre applikationer som t.ex. personbilar och lastbilar ställs det helt nya krav på komponenternas storlek och prestanda, vilket leder till de elektriska komponenternas högre vikt. Scania, som vill vara ledande inom denna omställning, klassificerar alla komponenter med större vikt än 2 kg som stora komponenter. De stora elektriska komponenterna skapar ett behov att utvärdera de aktuella testmetoderna och verifiera deras validitet. Det här magisterexamensarbetet har genomförts på Scania i Södertälje och handlar om undersökning av vibrationstestningsmetoderna som nuförtiden används i olika teknikområden samt identifiering av de eventuellt applicerbara metoderna för provning av stora elektriska komponenter. En fallstudie genomfördes gällande en individuell komponent och påverkan på dess egenfrekvenser med varierande styvhetskonstanter. Dessutom genomfördes några andra fallstudier utgående från empiriska tester samt simuleringar med hjälp av finita elementmetoden på vissa stora komponenter såsom högspänningsförgreningsdosa och batteripacken. Vibrationsprov genomfördes genom att utsätta komponenterna för Scanias nuvarande vibrationstestningsspektrum. Även vibrationsbeteendet beroende på positionen av mättningspunkterna har undersökts. Utöver det utfördes fallstudier angående termiska belastningar under vibrationstestning, tid för värmeöverföring samt energibehovet för att oscillera stora komponenter på förbestämda accelerationsnivåer. Inverkan av komponenternas storlek på deras värmeöverföringsegenskaper noterades.

Hybrid electric vehicles significantly reduce exhaust emissions and increase fuel economy. Power packs are the most fundamental components in a series powertrain configuration of a hybrid vehicle, which produce the necessary power to run the vehicle. The aim of this project is to design a compact power pack for a series hybrid vehicle, using virtual prototyping. The hybrid electric vehicle characteristics and configurations are analysed, followed by an explanation of the principles of induction machines. A new type of rotary induction machine with an outer rotor construction is designed to be coupled with the novel rotary internal combustion engine with rotating crankcase in order to form the compact power unit for the hybrid vehicle. The starting and generation performance of the designed machine is analysed by an electric machine simulator, called JMAG. ADVISOR software is studied and utilised to simulate the overall vehicle performance, employing different categories of power packs in the powertrain. Results show that the proposed compact power pack has the best performance in terms of fuel economy, emissions and battery charging compared to the existing power unit options. Over the city cycle, fuel economy is increased by up to 47 % with emission reduced by up to 36 % and over the highway cycle, fuel economy is increased by up to 69 % with emission reduced by up to 42 %.

Various potential methods and techniques for modifying surfaces to make themless sensitive to contamination have been researched for various applicationsbefore, to varying degrees of success. These are discussed in detail to potentiallyapply them in the automotive sector, to face the increasing technical cleanlinessrequirements, that are linked to more complexity in design and electrification. TheTheoretical background in dust adhesion and contact mechanics is discussed, withdevelopments in analytical and numerical methods highlighted. Then, someexamples of the surfaces in question are presented, and their topographiesmeasured. Potential techniques are identified from previous experimental research in otherfields, and their applicability and feasibility are discussed within the limits ofavailable data, then an attempt at a structured approach for choosing candidatesfor further experimental testing on a case by case basis is laid out, and suggestionsfor more comprehensive research into effective parameters and analytical methodsare made.

MSCAGR / Department of Agricultural Economics and Agribusiness / See the attached abstract below