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Search Results (335)

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Keywords = two-speed electric vehicles

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16 pages, 2773 KiB  
Article
Enhancing Fuel Cell Hybrid Electric Vehicle Energy Management with Real-Time LSTM Speed Prediction
by Matthieu Matignon, Mehdi Mcharek, Toufik Azib and Ahmed Chaibet
Energies 2025, 18(16), 4340; https://doi.org/10.3390/en18164340 - 14 Aug 2025
Viewed by 171
Abstract
This paper presents an innovative approach to optimize real-time energy management in fuel cell electric vehicles (FCEVs) through an integrated EMS (iEMS) framework based on a nested concept. Central to our method are two LSTM-based speed prediction models, trained and validated on open-source [...] Read more.
This paper presents an innovative approach to optimize real-time energy management in fuel cell electric vehicles (FCEVs) through an integrated EMS (iEMS) framework based on a nested concept. Central to our method are two LSTM-based speed prediction models, trained and validated on open-source datasets to enhance adaptability and efficiency. The first model, trained on a 27 h real-time database, is embedded within the iEMS for dynamic real-time operation. The second model assesses the impact of incorporating external traffic data on the prediction accuracy, offering a systematic approach to refining speed prediction models. The results demonstrate significant improvements in fuel efficiency and overall performance compared to existing models. This study highlights the promise of data-driven AI models in next-generation FCEV energy management, contributing to smarter and more sustainable mobility solutions. Full article
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35 pages, 5873 KiB  
Article
Analysis of Vertical Vibrations of a Child Seat Using the ISOFIX System in the Context of Obtaining Electricity to Power a SMART Child Seat
by Damian Frej
Energies 2025, 18(16), 4332; https://doi.org/10.3390/en18164332 - 14 Aug 2025
Viewed by 132
Abstract
This article presents the results of an experimental study focused on evaluating the potential to harvest electrical energy from vertical vibrations affecting a child car seat installed on an ISOFIX base with a support leg during real driving conditions. The objective was to [...] Read more.
This article presents the results of an experimental study focused on evaluating the potential to harvest electrical energy from vertical vibrations affecting a child car seat installed on an ISOFIX base with a support leg during real driving conditions. The objective was to measure vibration levels in the seat structure and assess the feasibility of converting this mechanical energy into electrical power. The study involved two child seat models, each tested under loads of 9 kg and 15 kg, while driving over smooth asphalt, damaged asphalt, and speed bumps. Acceleration data were collected at three key structural locations: the seat surface, the ISOFIX base, and the support leg. These measurements served as the basis for estimating the mechanical energy available and the resulting electrical output. Findings show that in poor road conditions, the system can generate enough energy to power a 10 µW sensor for more than 42 days. The results confirm the feasibility of using vibration energy harvesting to supply smart safety features such as presence detection, temperature monitoring, or posture sensing in child seats, without the need for batteries or a connection to the vehicle’s electrical system. Full article
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20 pages, 5097 KiB  
Article
Performance Enhancement of an Electric–Wind–Vehicle with Smart Switching Circuit and Modified Sliding Mode Control
by Mohamed A. Shamseldin, Ramy S. Soliman and Samah El-khatib
Automation 2025, 6(3), 39; https://doi.org/10.3390/automation6030039 - 14 Aug 2025
Viewed by 165
Abstract
This paper presents a new strategy for wind energy harvesting to enhance the performance of the electric-wind vehicle (EWV). A wind turbine is mounted on the front of an electric-wind vehicle model to capture wind that blows in the opposite direction of the [...] Read more.
This paper presents a new strategy for wind energy harvesting to enhance the performance of the electric-wind vehicle (EWV). A wind turbine is mounted on the front of an electric-wind vehicle model to capture wind that blows in the opposite direction of the moving vehicle. When the primary battery runs low, the generator switches on, converting wind energy into electricity and storing it in a backup battery. The switching circuit is developed to alternate between the main battery and the backup battery based on the battery capacity level. During the movement of the EWV, the backup battery charges using the wind turbine while the main battery discharges. A modified sliding mode control is used to track the reference speed of the EWV and to regulate the speed by switching between the two batteries. Several scenarios are applied to investigate the proposed strategy. The results show that the proposed strategy can save power by 30% compared to the conventional strategy. Moreover, the modified sliding mode control enhances the EWV’s dynamic performance in contrast to PID control, which shows poor performance (low rise time and low overshoot). Full article
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26 pages, 16020 KiB  
Article
Energy Management of Hybrid Electric Commercial Vehicles Based on Neural Network-Optimized Model Predictive Control
by Jinlong Hong, Fan Yang, Xi Luo, Xiaoxiang Na, Hongqing Chu and Mengjian Tian
Electronics 2025, 14(16), 3176; https://doi.org/10.3390/electronics14163176 - 9 Aug 2025
Viewed by 425
Abstract
Energy management for hybrid electric commercial vehicles, involving continuous power output and discrete gear shifting, constitutes a typical mixed-integer programming (MIP) problem, presenting significant challenges for real-time performance and computational efficiency. To address this, this paper proposes a physics-informed neural network-optimized model predictive [...] Read more.
Energy management for hybrid electric commercial vehicles, involving continuous power output and discrete gear shifting, constitutes a typical mixed-integer programming (MIP) problem, presenting significant challenges for real-time performance and computational efficiency. To address this, this paper proposes a physics-informed neural network-optimized model predictive control (PINN-MPC) strategy. On one hand, this strategy simultaneously optimizes continuous and discrete states within the MPC framework to achieve the integrated objectives of minimizing fuel consumption, tracking speed, and managing battery state-of-charge (SOC). On the other hand, to overcome the prohibitively long solving time of the MIP-MPC, a physics-informed neural network (PINN) optimizer is designed. This optimizer employs the soft-argmax function to handle discrete gear variables and embeds system dynamics constraints using an augmented Lagrangian approach. Validated via hardware-in-the-loop (HIL) testing under two distinct real-world driving cycles, the results demonstrate that, compared to the open-source solver BONMIN, PINN-MPC significantly reduces computation time—dramatically decreasing the average solving time from approximately 10 s to about 5 ms—without sacrificing the combined vehicle dynamic and economic performance. Full article
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19 pages, 5965 KiB  
Article
Design of Electrical Control System for Precision Rice Hill Direct-Seeding Device and Seeding Performance Comparison Test
by Hanqing Li, Ke Yang, Lin Ling, Bingxin Yan, Guangwei Wu, Xiaojun Gao and Shengnan Liu
Agriculture 2025, 15(16), 1716; https://doi.org/10.3390/agriculture15161716 - 8 Aug 2025
Viewed by 274
Abstract
This study develops a novel electric-driven metering device to address the mismatch between the seeder rotation speed and vehicle speed in traditional mechanical precision hill direct-seeding metering devices for rice, which is caused by wheel slippage. The device integrates a Global Navigation Satellite [...] Read more.
This study develops a novel electric-driven metering device to address the mismatch between the seeder rotation speed and vehicle speed in traditional mechanical precision hill direct-seeding metering devices for rice, which is caused by wheel slippage. The device integrates a Global Navigation Satellite System (GNSS) speed measurement module and an optimised incremental Proportional-Integral-Derivative (PID) control algorithm, enabling precise seeding through electric drive. A multidisciplinary collaborative design approach is employed, and field experiments are conducted to evaluate the performance of the novel device under conditions of vehicle speeds ranging from 3 to 5 km/h, theoretical hill spacings of 0.15–0.25 m, and seeding rate adjustment positions of 1/3–1. The experiments use two rice varieties, “Longken 2021” from the northern rice growing region and “Jingliangyou Huazhan” from the southern rice growing region. The results demonstrate that the novel electric-driven metering device significantly outperformed the traditional mechanical device in terms of seeding precision, hill formation performance, and seeding rate accuracy. The novel device achieves a qualified rate of seeds per hill of 90.54%, with seedling omission and seed damage rates reduced to 4.98% and 0.69%, respectively. The hill diameter qualification rate increases to 95.21%, with no empty hills observed. The coefficient of variation of seeds per hill is maintained at 21.98%, meeting the agronomic requirement of 2–12 seeds per hill for conventional rice. However, for seeds with high moisture content and poor flowability (soaked seeds), the seed damage rate increases slightly by 0.47 percentage points. This study provided an efficient and reliable technical solution for the intelligent upgrading of precision rice direct-seeding equipment. Full article
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22 pages, 6150 KiB  
Article
Minimizing Power Losses in BLDC Motor Drives Through Adaptive Flux Control: A Real-Time Experimental Study
by Mohamed Fadi Kethiri, Omar Charrouf, Achour Betka, Muhammad Salman and Chiara Boccaletti
Actuators 2025, 14(8), 395; https://doi.org/10.3390/act14080395 - 8 Aug 2025
Viewed by 226
Abstract
This paper presents a novel methodology for minimizing power losses in brushless DC (BLDC) motors through the implementation of adaptive flux control techniques. Conventional motor control strategies, such as direct torque control (DTC), typically employ fixed flux values, which often result in suboptimal [...] Read more.
This paper presents a novel methodology for minimizing power losses in brushless DC (BLDC) motors through the implementation of adaptive flux control techniques. Conventional motor control strategies, such as direct torque control (DTC), typically employ fixed flux values, which often result in suboptimal performance, particularly under dynamic load and speed variations. To mitigate this inherent limitation, two adaptive flux control methods are introduced: incremental conductance (IncCond) and fuzzy logic. These proposed strategies facilitate real-time dynamic adjustment of the stator flux, thereby optimizing motor performance and significantly enhancing system efficiency. Experimental validation confirms the efficacy of these adaptive techniques, demonstrating substantial improvements in power loss reduction and overall efficiency when compared to traditional fixed flux control strategies. Notably, the fuzzy logic control strategy achieves the highest efficiency, registering a system efficiency of 66.59%, which surpasses both the incremental conductance method and conventional fixed flux control. These findings underscore the considerable potential of adaptive flux control in applications where energy efficiency is paramount, including electric vehicles and renewable energy-driven systems. Full article
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29 pages, 28606 KiB  
Article
The Speed of Shared Autonomous Vehicles Is Critical to Their Demand Potential
by Tilmann Schlenther and Kai Nagel
World Electr. Veh. J. 2025, 16(8), 447; https://doi.org/10.3390/wevj16080447 - 7 Aug 2025
Viewed by 371
Abstract
Under a 2021 amendment to German law, the KelRide project became the first public on-demand service operating electric autonomous vehicles (AVs) without fixed routes on public roads. This paper addresses two notable gaps in the literature by (1) conducting an ex post evaluation [...] Read more.
Under a 2021 amendment to German law, the KelRide project became the first public on-demand service operating electric autonomous vehicles (AVs) without fixed routes on public roads. This paper addresses two notable gaps in the literature by (1) conducting an ex post evaluation of demand predictions for a non-infrastructure (Mobility-on-Demand (MoD)) project and (2) using real-world data to analyze how demand responds to key Autonomous Mobility-on-Demand (AMoD) system parameters in a rural context. Earlier simulation-based demand forecasts are compared to observed booking data, and the recalibrated model is used to investigate the sensitivity of passenger numbers to vehicle speed, fleet size, service area, operating hours, and idle vehicle positioning. Results show that increasing vehicle speed leads to a superlinear rise in passenger numbers—especially at small fleet sizes—while demand saturates at large fleet sizes. A linear increase in demand is observed with expanding service areas, provided fleet size is sufficient. Extending operating hours from 9 a.m.–4 p.m. to full-day service increases demand by a factor of two to four. Passengers numbers also vary notably depending on the positioning of idle vehicles. Consistent with empirical findings, the analysis underscores that raising AV speed is essential for ensuring the long-term viability of autonomous mobility services. Full article
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18 pages, 3493 KiB  
Article
Red-Billed Blue Magpie Optimizer for Modeling and Estimating the State of Charge of Lithium-Ion Battery
by Ahmed Fathy and Ahmed M. Agwa
Electrochem 2025, 6(3), 27; https://doi.org/10.3390/electrochem6030027 - 31 Jul 2025
Viewed by 289
Abstract
The energy generated from renewable sources has an intermittent nature since solar irradiation and wind speed vary continuously. Hence, their energy should be stored to be utilized throughout their shortage. There are various forms of energy storage systems while the most widespread technique [...] Read more.
The energy generated from renewable sources has an intermittent nature since solar irradiation and wind speed vary continuously. Hence, their energy should be stored to be utilized throughout their shortage. There are various forms of energy storage systems while the most widespread technique is the battery storage system since its cost is low compared to other techniques. Therefore, batteries are employed in several applications like power systems, electric vehicles, and smart grids. Due to the merits of the lithium-ion (Li-ion) battery, it is preferred over other kinds of batteries. However, the accuracy of the Li-ion battery model is essential for estimating the state of charge (SOC). Additionally, it is essential for consistent simulation and operation throughout various loading and charging conditions. Consequently, the determination of real battery model parameters is vital. An innovative application of the red-billed blue magpie optimizer (RBMO) for determining the model parameters and the SOC of the Li-ion battery is presented in this article. The Shepherd model parameters are determined using the suggested optimization algorithm. The RBMO-based modeling approach offers excellent execution in determining the parameters of the battery model. The suggested approach is compared to other programmed algorithms, namely dandelion optimizer, spider wasp optimizer, barnacles mating optimizer, and interior search algorithm. Moreover, the suggested RBMO is statistically evaluated using Kruskal–Wallis, ANOVA tables, Friedman rank, and Wilcoxon rank tests. Additionally, the Li-ion battery model estimated via the RBMO is validated under variable loading conditions. The fetched results revealed that the suggested approach achieved the least errors between the measured and estimated voltages compared to other approaches in two studied cases with values of 1.4951 × 10−4 and 2.66176 × 10−4. Full article
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15 pages, 2070 KiB  
Article
Synthesis of Vibration Environment Spectra and Fatigue Assessment for Underfloor Equipment in High-Speed EMU Trains
by Can Chen, Lirong Guo, Guoshun Li, Yongheng Li, Yichao Zhang, Hongwei Zhang and Dao Gong
Machines 2025, 13(7), 628; https://doi.org/10.3390/machines13070628 - 21 Jul 2025
Viewed by 212
Abstract
With the continuous development of high-speed electric multiple units (EMUs), vibration issues of vehicles have become increasingly prominent. During operation, the underfloor equipment installed on the carbody is subjected to random multi-point vibrations transmitted from the carbody, inducing significant fatigue damage. This paper [...] Read more.
With the continuous development of high-speed electric multiple units (EMUs), vibration issues of vehicles have become increasingly prominent. During operation, the underfloor equipment installed on the carbody is subjected to random multi-point vibrations transmitted from the carbody, inducing significant fatigue damage. This paper presents a comprehensive analysis of multi-channel vibration environment data for various underfloor equipment across different operating speeds obtained through on-site measurements. A spectral synthetic method grounded in statistical principles is then proposed to generate vibration environment spectra for diverse underfloor equipment. Finally, utilizing fatigue analysis in the frequency domain, the fatigue damage to underfloor equipment is assessed under different operational environments. The research results show that the vibration environment spectrum of the underfloor equipment in high-speed EMU trains differs significantly from the vibration spectrum specified in the IEC 61373 standard, especially at high frequencies. Despite this difference in spectral characteristics, the overall vibration energy values of the two spectra are comparable. Additionally, the vibration spectra of different underfloor equipment exhibit variations that can be attributed to their installation positions. As operational speed increases, the fatigue damage to the underfloor equipment exhibits exponential growth. However, the total accumulated fatigue damage remains relatively low, consistently staying below a value of 1. Full article
(This article belongs to the Special Issue Research and Application of Rail Vehicle Technology)
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15 pages, 5296 KiB  
Article
Study on Multiple-Inverter-Drive Method for IPMSM to Improve the Motor Efficiency
by Koki Takeuchi and Kan Akatsu
World Electr. Veh. J. 2025, 16(7), 398; https://doi.org/10.3390/wevj16070398 - 15 Jul 2025
Viewed by 322
Abstract
In recent years, the rapid spread of electric vehicles (EVs) has intensified the competition to develop power units for EVs. In particular, improving the driving range of EVs has become a major topic, and in order to achieve this, many studies have been [...] Read more.
In recent years, the rapid spread of electric vehicles (EVs) has intensified the competition to develop power units for EVs. In particular, improving the driving range of EVs has become a major topic, and in order to achieve this, many studies have been conducted on improving the efficiency of EV power units. In this study, we propose a multiple-inverter-drive permanent magnet synchronous motor based on an 8-pole, 48-slot structure, which is commonly used as an EV motor. The proposed motor is composed of two completely independent parallel inverters and windings, and intermittent operation is possible; that is, only one inverter and one parallel winding is used depending on the situation. In the proposed motor, we compare losses including stator iron loss, rotor iron loss, and magnet eddy current loss by PWM voltage inputs for some stator winding topologies, we show that the one-side winding arrangement is the most efficient during intermittent operation, and that it is more efficient than normal operation especially in the low-speed, low-torque range. Finally, through a vehicle-driving simulation considering the efficiency map including motor loss and inverter loss, we show that the intentional use of intermittent operation can improve electrical energy consumption. Full article
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21 pages, 4275 KiB  
Article
Novel Hybrid Aquatic–Aerial Vehicle to Survey in High Sea States: Initial Flow Dynamics on Dive and Breach
by Matthew J. Ericksen, Keith F. Joiner, Nicholas J. Lawson, Andrew Truslove, Georgia Warren, Jisheng Zhao and Ahmed Swidan
J. Mar. Sci. Eng. 2025, 13(7), 1283; https://doi.org/10.3390/jmse13071283 - 30 Jun 2025
Viewed by 423
Abstract
Few studies have examined Hybrid Aquatic–Aerial Vehicles (HAAVs), autonomous vehicles designed to operate in both air and water, especially those that are aircraft-launched and recovered, with a variable-sweep design to free dive into a body of water and breach under buoyant and propulsive [...] Read more.
Few studies have examined Hybrid Aquatic–Aerial Vehicles (HAAVs), autonomous vehicles designed to operate in both air and water, especially those that are aircraft-launched and recovered, with a variable-sweep design to free dive into a body of water and breach under buoyant and propulsive force to re-achieve flight. The novel design research examines the viability of a recoverable sonar-search child aircraft for maritime patrol, one which can overcome the prohibitive sea state limitations of all current HAAV designs in the research literature. This paper reports on the analysis from computational fluid dynamic (CFD) simulations of such an HAAV diving into static seawater at low speeds due to the reverse thrust of two retractable electric-ducted fans (EDFs) and its subsequent breach back into flight initially using a fast buoyancy engine developed for deep-sea research vessels. The HAAV model entered the water column at speeds around 10 ms−1 and exited at 5 ms−1 under various buoyancy cases, normal to the surface. Results revealed that impact force magnitudes varied with entry speed and were more acute according to vehicle mass, while a sufficient portion of the fuselage was able to clear typical wave heights during its breach for its EDF propulsors and wings to protract unhindered. Examining the medium transition dynamics of such a novel HAAV has provided insight into the structural, propulsive, buoyancy, and control requirements for future conceptual design iterations. Research is now focused on validating these unperturbed CFD dive and breach cases with pool experiments before then parametrically and numerically examining the effects of realistic ocean sea states. Full article
(This article belongs to the Section Ocean Engineering)
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28 pages, 7946 KiB  
Article
U-Net Inspired Transformer Architecture for Multivariate Time Series Synthesis
by Shyr-Long Jeng
Sensors 2025, 25(13), 4073; https://doi.org/10.3390/s25134073 - 30 Jun 2025
Viewed by 494
Abstract
This study introduces a Multiscale Dual-Attention U-Net (TS-MSDA U-Net) model for long-term time series synthesis. By integrating multiscale temporal feature extraction and dual-attention mechanisms into the U-Net backbone, the model captures complex temporal dependencies more effectively. The model was evaluated in two distinct [...] Read more.
This study introduces a Multiscale Dual-Attention U-Net (TS-MSDA U-Net) model for long-term time series synthesis. By integrating multiscale temporal feature extraction and dual-attention mechanisms into the U-Net backbone, the model captures complex temporal dependencies more effectively. The model was evaluated in two distinct applications. In the first, using multivariate datasets from 70 real-world electric vehicle (EV) trips, TS-MSDA U-Net achieved a mean absolute error below 1% across key parameters, including battery state of charge, voltage, acceleration, and torque—representing a two-fold improvement over the baseline TS-p2pGAN. While dual-attention modules provided only modest gains over the basic U-Net, the multiscale design enhanced overall performance. In the second application, the model was used to reconstruct high-resolution signals from low-speed analog-to-digital converter data in a prototype resonant CLLC half-bridge converter. TS-MSDA U-Net successfully learned nonlinear mappings and improved signal resolution by a factor of 36, outperforming the basic U-Net, which failed to recover essential waveform details. These results underscore the effectiveness of transformer-inspired U-Net architectures for high-fidelity multivariate time series modeling in both EV analytics and power electronics. Full article
(This article belongs to the Section Intelligent Sensors)
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23 pages, 10488 KiB  
Article
An Enhanced Cascaded Deep Learning Framework for Multi-Cell Voltage Forecasting and State of Charge Estimation in Electric Vehicle Batteries Using LSTM Networks
by Supavee Pourbunthidkul, Narawit Pahaisuk, Popphon Laon, Nongluck Houngkamhang and Pattarapong Phasukkit
Sensors 2025, 25(12), 3788; https://doi.org/10.3390/s25123788 - 17 Jun 2025
Viewed by 465
Abstract
Enhanced Battery Management Systems (BMS) are essential for improving operational efficacy and safety within Electric Vehicles (EVs), especially in tropical climates where traditional systems encounter considerable performance constraints. This research introduces a novel two-tiered deep learning framework that utilizes a two-stage Long Short-Term [...] Read more.
Enhanced Battery Management Systems (BMS) are essential for improving operational efficacy and safety within Electric Vehicles (EVs), especially in tropical climates where traditional systems encounter considerable performance constraints. This research introduces a novel two-tiered deep learning framework that utilizes a two-stage Long Short-Term Memory (LSTM) framework for precise prediction of battery voltage and SoC. The first tier employs LSTM-1 forecasts individual cell voltages across a full-scale 120-cell Lithium Iron Phosphate (LFP) battery pack using multivariate time-series data, including voltage history, vehicle speed, current, temperature, and load metrics, derived from dynamometer testing. Experiments simulate real-world urban driving, with speeds from 6 km/h to 40 km/h and load variations of 0, 10, and 20%. The second tier uses LSTM-2 for SoC estimation, designed to handle temperature-dependent voltage fluctuations in high-temperature environments. This cascade design allows the system to capture complex temporal and inter-cell dependencies, making it especially effective under high-temperature and variable-load environments. Empirical validation demonstrates a 15% improvement in SoC estimation accuracy over traditional methods under real-world driving conditions. This study marks the first deep learning-based BMS optimization validated in tropical climates, setting a new benchmark for EV battery management in similar regions. The framework’s performance enhances EV reliability, supporting the growing electric mobility sector. Full article
(This article belongs to the Special Issue Applications of Machine Learning in Automotive Engineering)
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19 pages, 19877 KiB  
Article
Costless Improvement of Converter Efficiency in a Regenerative Braking System with a Brushless DC Machine
by Paweł Stawczyk
Electronics 2025, 14(12), 2390; https://doi.org/10.3390/electronics14122390 - 11 Jun 2025
Viewed by 376
Abstract
This paper focuses on the analysis of a new modulation method based on the reverse conduction of metal–oxide–semiconductor field-effect transistors (MOSFETs) for a three-phase voltage-feed full-bridge converter with two-switched transistors. The implementation of the proposed method allows efficient converter performance during regenerative braking [...] Read more.
This paper focuses on the analysis of a new modulation method based on the reverse conduction of metal–oxide–semiconductor field-effect transistors (MOSFETs) for a three-phase voltage-feed full-bridge converter with two-switched transistors. The implementation of the proposed method allows efficient converter performance during regenerative braking of a brushless DC machine. It does not require any additional components such as power switches, sensors, and high-performance microcontrollers. Previously known classical modulation methods were characterised by significantly lower efficiency of the converter due to diode conduction. The operating principle of the modified modulation method is clearly explained in detail with mathematical and simulation analyses presented. The theoretical results obtained were verified experimentally, demonstrating that the maximum efficiency of the converter increased from 88% (for classical modulation) to 95% with the new modulation strategy. The developed solution is dedicated to electric vehicles and enables effective regenerative braking even at low speeds. Full article
(This article belongs to the Special Issue Power Electronics and Renewable Energy System)
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25 pages, 13125 KiB  
Article
A Novel Double-Sided Electromagnetic Dog Clutch with an Integrated Synchronizer Function
by Bogdan Miroschnitschenko, Florian Poltschak and Wolfgang Amrhein
Actuators 2025, 14(6), 286; https://doi.org/10.3390/act14060286 - 10 Jun 2025
Cited by 1 | Viewed by 1522
Abstract
Dog clutches are superior to synchromesh units due to much less wear caused by friction but require an external torque source to synchronize the rotation speeds. The current trend in e-mobility to use the driving motor of an electric vehicle as this source [...] Read more.
Dog clutches are superior to synchromesh units due to much less wear caused by friction but require an external torque source to synchronize the rotation speeds. The current trend in e-mobility to use the driving motor of an electric vehicle as this source just creates another problem, which is known as torque holes. In this work, we propose a novel double-sided dog clutch that synchronizes the speeds electromagnetically by itself avoiding mechanical contact between the parts. A shift sleeve, two coils placed coaxially in their stators, and two complementary rings form an electromagnetic reluctance actuator, which is integrated inside the gearbox between two gearwheels and represents the double-sided clutch. Thus, intermediate parts between the shift sleeve and the actuator are not required. Both actuator sides can produce axial force and electromagnetic torque. However, torques and forces are generated simultaneously on both sides. Therefore, a special control algorithm is developed to keep the resulting axial force approximately equal to zero while the torque is generated in the neutral gear position. After the synchronization, the axial force is applied on the corresponding side to shift the required gear engaging the shift sleeve teeth directly with the slots of the complementary ring mounted on the gearwheel. So, an axial contact of the teeth at an unaligned state, which can lead to unsuccessful shifting, is avoided. A testrig, which includes a clutch prototype and a testing two-speed gearbox, has been designed and built. The developed theoretical ideas have been verified during the experiments under different conditions. The experiments confirm that the actuator can reduce positive and negative speed differences on both sides and subsequently shift the gear without a shift sleeve collision at misaligned angular positions. Full article
(This article belongs to the Section High Torque/Power Density Actuators)
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