Vehicle Components Research Articles

The effect of hardness on bending value in manufacturing brake pads from shell and palm fiber

Motorbikes are one of the primary needs for many people because they are more effectively used to carry out community activities than public transportation. Because motorbikes are used so frequently, the braking system is one of the parts that must be updated. Brake pads are motorbike equipment that function to slow and stop the vehicle comfortably. The research aims to determine the characteristics of brake linings and the optimal composition of brake linings that are good for use. Brake pads are a component of motorcycle vehicles that are useful for slowing down and stopping the speed of the vehicle comfortably. The purpose of this study is to find out how the characteristics of palm shells and fibers if used as material for making brake linings. The method used is direct experimentation with a qualitative approach. The results obtained are the characteristics of brake pads made from filler palm shell powder and palm fiber with polyurethane matrix have a hard texture, solid brown, if viewed from the surface of the brake lining is a little rough because the fiber is too long. The test results showed the best hardness value of 91 R and the best bending test with a value of 10.21 kgf/mm2

Exploring the Drive Motor of Electric Vehicles: Structure, Temperature Rises, and Operational Control of Permanent Magnet Motors

The drive motor is a critical component of electric vehicles. The design of its structure, along with the regulation of temperature rises and operational control, significantly impact the overall performance of electric vehicles, affecting aspects such as dynamic response, anti-interference capabilities, speed stability, and efficiency. This paper provides a review and comprehensive analysis of the Special Issue titled “Temperature Field, Electromagnetic Field, and Operation Control of Permanent Magnet Motor for Electric Vehicles”, and discusses the future development directions of permanent magnet motors in electric vehicles. The analysis reveals that the structural design is crucial for both the static and dynamic performance of permanent magnet motors. Additionally, it is imperative to identify an optimal trade-off among various performance parameters in these motors. The paper also verifies several future development directions for permanent magnet motors, including high-speed control, the use of advanced silicon steel sheets, power quality, battery charging efficiency, and energy feedback.

Advancing Vehicle Security: Deep Learning based Solution for Defending CAN Networks in the Internet of Vehicles

The Internet of Vehicle (IoV) is revolutionizing the automobile sector by allowing vehicles to interact with one another and with roadside infrastructure. The Controller Area Network (CAN) is a vital component of such smart vehicles, allowing communication between various Electronic Control Units (ECUs). However, the CAN protocol's intrinsic lack of security renders it open to a variety of cyber-attacks, posing substantial hazards to both safety and privacy.This research investigates the use of deep learning with multi-layer perceptron to improve the security of CAN networks inside the IoV framework. We discuss current threats to CAN networks, including spoofing, replay, and denial-of-service attacks, and how deep learning may be used to identify and mitigate these threats efficiently. We propose a unique deep learning-based defense mechanism for real-time threat detection. The suggested method is highly effective in identifying and mitigating potential risks, as evidenced by extensive testing on real-world CAN datasets. Based on our findings, the proposed solution has the potential to considerably enhance the security of CAN networks in the Internet of Vehicles, making car communication systems more secure and reliable.

Predicting the most economical option of managing electric vehicle battery at the end of its serviceable life

It is predicted that millions of electric vehicle batteries (EVBs) will retire in the next decade. With the global Electric Vehicles (EVs) market share increasing to over 40 million by 2030, the replacement of unwanted EVBs will become more abundant and may end up in landfills. These discarded EVBs can become a threat to the environment and to human health if they are not treated, disposed of, and recycled appropriately. Numerous end-of-life (EOL) cost estimation methods that have been developed are mainly for evaluating fossil fuel vehicle components. Research within the scope of EOL of EVBs however, is slow in progress, therefore, this work focuses on developing a cost estimation method for predicting EOL costs of EVBs by adopting a circular economy approach. This proposed method is validated through a case study using two Nissan's EV battery packs. The significance of this study may provide valuable information which could, indirectly lead to the redesign of EVBs for better business circular economy and less waste pollution for future EVs. The main results show that the potential economic benefit that generated by reusing/repurposing EOL EVBs is 92% more profitable than recycling and 52% more profitable than remanufacturing. This study concludes that reuse/repurpose becomes the most profitable process when EVBs reach the end of their serviceable life. Remanufacturing method can also be economically viable if it considers multi-cell replacement of an EVB.

Research on Electric Vehicle Powertrain Systems Based on Digital Twin Technology

As a critical component of electric vehicles, the powertrain has a significant impact on the overall performance of vehicles. In addressing the challenge of lengthy testing cycles, this study develops a para model of the powertrain, utilizing digital twin (DT) technology, thereby establishing a framework for simulation testing of multi-controller intermodulation. We establish functional definition coverage testing by designing specific functional requirement use cases, and we validate the failure mechanism via fault injection use cases. The results indicate that the DT testing platform can effectively simulate the operational interactions among various controllers within the powertrain system. In comparison to traditional field testing, the digital twin-based testing methodology offers enhanced operational efficiency and allows for the examination of testing conditions that are impractical to implement in real vehicles, particularly in the context of fault injection testing, thus facilitating the early detection of potential safety risks within the system. The advancement of this technical solution holds significant practical implications for the future mass production and development of electric vehicles.

Characterisation of surface morphology of high voltage DC relay contacts under arc erosion

Abstract High voltage DC relays are a crucial component in new energy vehicles. Due to the high failure rate caused by contact sticking (fusion welding), existing technologies can only analyze contact morphology after failure. There is an urgent need to determine the quantitative characterization value of contact surface morphology and the correlation between morphology, failure mechanisms, and working conditions. In this study, an Olympus DSX1000 microscope is used to extract surface topography data, and a quantitative topography characterization method based on a machine vision system is proposed to quantitatively analyze contact surface changes after arc erosion. Grey correlation analysis was applied to explore the relationship between electrical parameters such as voltage, current, and capacitance, and the contact morphology features. The results show that current and capacitance have the greatest influence on contact surface features after arc erosion, while voltage has a relatively smaller influence. This conclusion is consistent with the experimentally observed arc erosion features. Finally, an arc ion sputtering deposition model was developed to analyze the material transfer mode and its influence on the contact failure mechanism. The results provide a scientific basis for the analysis and design improvement of high voltage DC relays.

Autonomous Vehicle Diagnostics and Support: A Framework for API-Driven Microservices

The rapid evolution of autonomous vehicles (AVs) demands robust and scalable diagnostic and support systems to ensure seamless operations, safety, and performance. This paper presents a framework for API-driven microservices tailored to address the unique diagnostic and support requirements of AVs. Traditional monolithic systems are insufficient for managing the complex, real-time data generated by AVs, necessitating a shift toward microservices architecture. By leveraging API-driven microservices, the proposed framework ensures modularity, scalability, and real-time communication between various vehicle components and external support systems. The framework is designed to support continuous vehicle monitoring, predictive maintenance, fault detection, and real-time decision-making, all while minimizing latency. APIs play a critical role in enabling interaction between different microservices, allowing for seamless data exchange across diverse platforms. This interoperability facilitates integration with third-party services, such as cloud-based diagnostics, real-time traffic information, and software updates. Additionally, the microservices architecture ensures fault isolation, meaning that failures in one service do not compromise the entire system. The framework also emphasizes the importance of cybersecurity and data privacy. Given the sensitive nature of AV data, API security protocols such as OAuth2 and TLS encryption are incorporated to safeguard communication between microservices and external systems. Furthermore, the design is scalable, allowing for the integration of future AV technologies and third-party service enhancements without disrupting existing functionalities. In conclusion, API-driven microservices provide an efficient, flexible, and secure solution for autonomous vehicle diagnostics and support. This framework has the potential to improve AV reliability, reduce downtime, and enhance safety by enabling real-time, data-driven decision-making and proactive maintenance. Future work may explore the integration of machine learning algorithms to further optimize diagnostics and predictive maintenance capabilities. Keywords: Autonomous Vehicles, Microservices, API-Driven Architecture, Diagnostics, Predictive Maintenance, Real-Time Data, Cybersecurity, Vehicle Support Systems, Modularity, Scalability.

In‐use dissipation of technology‐critical elements from vehicles and renewable energy technologies in Vienna, Austria: A public health matter?

AbstractThe rollout of electric vehicles and photovoltaic panels is essential to mitigate climate change. However, they depend on technology‐critical elements (TCEs), which can be harmful to human health and whose use is rapidly expanding, while recycling is lacking. While mining has received substantial attention, in‐use dissipation in urban areas has so far not been assessed, for example, corrosion and abrasion of vehicle components and weather‐related effects affecting thin‐film photovoltaic panels. Therefore, the question arises to which extent TCEs dissipate during use and which potential non‐occupational human health impacts could occur. We assessed the available information on urban in‐use dissipation and human health concerns and conducted exploratory modeling of in‐use technology stocks, in‐ and outflows, and in‐use dissipation of neodymium, dysprosium, lanthanum, praseodymium, cerium, gallium, germanium, and tellurium contained in 21 vehicle and renewable energy technologies, for Vienna, Austria. In prospective scenarios, TCE dynamics in a trend‐continuation vis à vis official city policy plans and a more ambitious transition scenario were then assessed. We find that electrifying the vehicle fleet without demand‐reduction is the main driver of TCE consumption, effectively doubling cumulative end‐of‐life outflows to 3,073 [2,452–3,966] t and cumulative in‐use dissipation to 9.3 [5.2–15.7] t by the year 2060. Sufficiency‐based measures could reduce demand and in‐use dissipation well below levels with continued trends, thus highlighting the need to combine decarbonization with demand‐reducing measures. These results help assess potential future in‐use dissipation dynamics and inform discussions about potential public health hazards associated with exposure to TCEs accumulating in the urban environment.

Optimization of vehicle conceptual design problems using an enhanced hunger games search algorithm

Abstract Electric vehicles have become a standard means of transportation in the last 10 years. This paper aims to formalize design optimization problems for electric vehicle components. It presents a tool conceptual design technique with a hunger games search optimizer that incorporates dynamic adversary-based learning and diversity leader (referred to as HGS-DOL-DIL) to overcome the local optimum trap and low convergence rate limitations of the Hunger Games search algorithm to improve the convergence rate. The performance of the proposed algorithms is studied on six widely used engineering design problems, complex constraints, and discrete variables. For the HGS-DOL-DIL practical feasibility analysis, a case study of shape optimization of an electric car suspension arm from the industry is carried out. Overall, the inclusion of the OL strategy has proven its superiority in solving real-world problems, especially in solving real-world problems such as shape optimization of an electric vehicle automobile suspension arm, showing that the algorithm improves the search space improves the solution quality, and reflects its potential to find global optimum solutions in a well-balanced exploration and exploitation phase.

Improvement of bionic surface of thrust rod ball joint and finite element analysis

The thrust rod is an important component of heavy-duty vehicles. It can transmit force and torque during vehicle driving and play the role of flexible connection. This paper mainly applies the bionic friction-increasing principle of locust foot pads to the rubber surface of the thrust rod ball joint of commercial vehicles. A bionic ball crown-shaped flexible protrusion is constructed on the surface of the rubber ball joint to increase the stiffness of the ball joint. The height, radius and spacing of the bionic flexible protrusion are changed, and the finite element analysis is performed using Abaqus software to study the radial stiffness, deflection stiffness and torsional stiffness of the thrust rod ball joint. The results show that the best effect is achieved when the protrusion height is 1 mm, the radius is 4 mm and the spacing is 10 mm. Finally, the optimal solution is comprehensively analyzed, and the feasibility of the solution is verified through simulation and experiment.

PELATIHAN PERAWATAN KENDARAAN SEPEDA MOTOR BAGI MASYARAKAT DESA SIRNAJAYA

A motorcycle is an engine-driven two-wheeled vehicle composed of different parts that are subjected to different loads during operation, such as heat load, chemical load, impact, bump, twist, push-pull-bend force, friction, pressure. The precision of vehicle components will vary from their original and standard conditions over time such as becoming looser, weaker, or finer. To ensure it is always in top condition, cars require regular maintenance which can be done by a garage or by yourself. In improving the ability to maintain motorcycles and make an income through their own business, especially in the field of motorcycle maintenance services. Through this community service project, counseling on business management and training on motorcycle maintenance skills, including the correct adjustment and use of repair equipment, are provided. The service method applies socialization of motorcycle maintenance theory and direct assistance on how to perform motor vehicle maintenance for Sirnajaya Village youth. The results of this service activity are the increased knowledge, understanding, and abilities of the participants in the field of motorcycle maintenance and repair, besides that this service program supports the success of the community in establishing their own business.

The Effects of Adding TiO2 and CuO Nanoparticles to Fuel on Engine and Hand–Arm Driver Vibrations

Occupant comfort is a key consideration in automobile dynamics, with vibrations potentially causing long-term physical discomfort, especially for drivers. This study investigates the impact of adding TiO2 and CuO nanoparticles to fuel on engine-induced vibrations. Experiments were conducted at various nanoparticle concentrations (0, 50, 100, and 150 ppm) and engine speeds (1000, 2000, and 3000 rpm). Key performance metrics, including kinematic viscosity, density, heating value, thermal conductivity, and brake power (BP), were analyzed. The results indicated that increasing nanoparticle concentration led to a rise in BP. The highest reduction in root mean square (RMS) vibration accelerations occurred at 3000 rpm and 150 ppm, with vibration reductions of 30.33% for CuO and 28.61% for TiO2. Additionally, 8–10% of engine vibrations were transmitted to the steering wheel. The use of 150 ppm CuO nanoparticles resulted in reduced vibration transmission to the steering wheel at all tested speeds. These findings suggest that nanoparticle-enhanced fuels can significantly reduce engine vibrations, potentially improving driver comfort and reducing wear on vehicle components.

Impact of road noise components (rolling/propulsion) by vehicle categories (light-duty, heavy-duty and two-wheeled vehicles) on population's noise exposure and associated adverse health effects

Exposure to road traffic noise can lead to various adverse health effects, ranging from annoyance and night-time sleep disturbances to ischemic heart diseases. The aim of this paper is to identify the contribution of the road noise components (rolling/propulsion) for each vehicle category (light-duty, heavy-duty and two-wheeled vehicles) on population's noise exposure and the associated adverse health effects. This analysis focuses on the case study of Lyon, France. The input data align with the requirements of the 4th deadline of Directive 2002/49/CE and adhere to the CNOSSOS calculation standard. The results reveal that the rolling noise component of light-duty vehicles is predominant due to vehicle speed and traffic volume. It is the sole noise component (i) significantly exposing a portion of the population to Lden > 68 dBA, noise limit set by the French decree of April 4, 2006, and (ii) where over half of the population is exposed to Lden > 53 dBA, recommended threshold by the World Health Organization (2018). By using transfer functions established between noise components for each vehicle category, and population's noise exposure, noise source-abatement solutions can be quantified in terms of their impact on population's noise exposure, thus determining the reduction in health impacts.

Corked Microcapsules Enabling Controlled Ultrasound-Mediated Protein Delivery.

While ultrasound represents a facile, portable, and noninvasive trigger for drug delivery vehicles, most reported ultrasound-triggered drug delivery vehicles predominately present "burst" release profiles that are hard to control after the initial activation stimulus. Herein, we report a submerged electrospraying technique to fabricate protein-loaded microcapsules in which silica "corks" are embedded within the microcapsule shell. Upon the application of an ultrasound trigger, the corks can be perturbed within the shell, allowing for the release of the protein payload through a phantom tissue mimic to a degree proportional to the number/time of pulses applied. Specifically, multiple ultrasound pulses were shown to enable a 15- to 23-fold increase in the rate of release of the model bovine serum albumin protein payload relative to no ultrasound being applied, with release returning to a lower level when the ultrasound stimulus was removed. Coupled with the low cytotoxicity of the vehicle components, the corked microcapsules show promise for expanding the potential to use ultrasound to facilitate both on-demand and pulsatile release profiles.

An experimental analysis of mechanical properties for a dissimilar pattern structure in the 3-D printing of a PLA5F filament using the Taguchi method

Abstract Many automobile components and machine parts can be fabricated using the Fused Deposition Modeling (FDM) process with materials such as Polylactic Acid (PLA), Acrylonitrile Butadiene Styrene (ABS), Polyethylene Terephthalate Glycol (PET-G), and polymeric composite materials (e.g., PLA with carbon fiber, PLA with glass fiber). In this study, a new polymeric composite material was fabricated using Polylactic Acid and natural flax fiber was analysed for tensile stress, elongation, and impact load resistance using Taguchi Analysis. This analysis optimized the printing parameters, including layer thickness (0.15, 0.25, 0.35 mm), nozzle movement speed (80, 100, 120 mm s−1), filling structure (Lines - a, Triangular - b, and Octet - c), and occupancy rate (20%, 40%, 60%). The American Society for Testing and Materials (ASTM) standards for tensile strength (ASTM D638) and impact strength (ASTM D256) were used for evaluation. As a result, layer thickness was found to be the most effective variable for improving tensile characteristics, compared to extruder temperature, occupancy rate, or filling structure pattern. Mechanical properties including a layer thickness of 0.25 mm, an occupancy ratio of 20% for the bottom of the 2nd layer and 40% for the top of the 4th layer, triangular and octet filling structures, a nozzle speed of 100 mm s−1, and an extruder temperature of 200 °C are considered the most appropriate parameters for producing automotive parts in Three Dimensional (3D) Printing. Due to its tensile properties and impact strength resistance, these settings can be utilized in potential application in a wide variety of machine parts and vehicle components.

Mechanical simulation and electrical performance analysis of high current connectors

Abstract Automotive high-current connectors are one of the key components in new energy vehicles, used for transmitting high currents within the vehicle. However, vibration is unavoidable during the actual operation of connectors. This vibration directly affects the contact pressure between the connector’s contact points, thereby influencing the electrical contact performance of the connector. This paper simplifies the contact components of the electrical connector using a cantilever beam model and conducts theoretical calculations of the contact pressure. Utilizing Ansys Workbench simulation software, the study investigates the contact pressure of the electrical connector under static and various sinusoidal vibration conditions, followed by sinusoidal frequency sweep vibration experiments. The research findings indicate that under vibration conditions, the contact pressure is lower than that under static conditions, and the electrical resistance fluctuates during the vibration process.

INNOVATIVE APPROACH TO ENSURING THE QUALITY OF GAS TURBINE ENGINE PARTS PRODUCED BY SELECTIVE LASER SINTERING FOR UAV

The research objects are gas turbine engines parts, manufactured using an innovative method of additive manufacturing – selective laser sintering. The main problem solved in this work is the low quality of the surface layer and the residual porosity of the parts obtained by this method, which significantly limits their operational characteristics and durability. As a result of the experimental studies, rational operating parameters of diamond smoothing were established. This allowed to significantly improve the surface quality and increase the operational characteristics of parts made of heat-resistant alloys INCONEL 718 and an intermetallic alloy based on titanium aluminide OX45-3ODS. The effectiveness of diamond smoothing is explained by local plastic deformation and compaction of the surface layer of parts under the influence of high contact pressures and temperatures. This leads to a significant reduction in surface roughness, an increase in the surface hardness due to strain hardening and a significant reduction in the size and number of residual pores. A characteristic feature of the obtained results is the ability to control the quality parameters of the surface layer by varying the diamond smoothing operating parameters – smoothing force, feed, radius, and geometry of the smoother's working part. The established regularities of the smoothing operating parameters have an impact on the quality characteristics of the surface. This information can be utilized in the development of highly efficient technological processes for the production and restoration of gas turbine engines, critical components of unmanned aerial vehicles, obtained through selective laser sintering. Implementing the elaborated technological recommendations will permit broadening the range of goods produced by additive manufacturing and enhancing their capacity and dependability during operation under conditions of cyclical loads and extreme temperatures.

A Review on Tribological Considerations in the Transition from IC Engines to Electric Vehicles

The shift from internal combustion (IC) engines to electric vehicles (EVs) marks a significant transformation in the automotive industry, prompting a comprehensive reassessment of various engineering considerations. Among these, tribological factors play a critical role in ensuring the performance, reliability, and longevity of vehicle components. This review examines the tribological challenges and opportunities posed by the transition to EVs, focusing on key components such as bearings, gears, and braking systems, which face unique operating conditions in electric powertrains compared to their IC counterparts. The paper addresses how electric vehicles encounter distinct tribological scenarios, such as lower operating temperatures but higher torque loads, which demand new materials and lubrication strategies. It also explores how the near absence of internal combustion in EVs affects component wear and the mechanisms of friction reduction. Additionally, the tribological challenges in IC engines are revisited to provide a comparative understanding of how they differ from those in EVs, particularly regarding energy efficiency and frictional losses. This review emphasizes the importance of minimizing wear and friction to maximize energy efficiency, which is crucial for extending vehicle range and improving performance in EVs. By synthesizing the latest research findings and industry advancements, the review offers valuable insights for researchers and engineers involved in the design and optimization of tribological systems for the next generation of electric vehicles.

Enhancing lubrication of electrified interfaces by inert gas atmosphere

Abstract Considering the growing interest in increasing performance and efficiency of driveline components of modern electric vehicles, this work aims to analyze and report the wear mechanisms and notable enhancement of the lubrication of electrified contact interfaces by inert gas atmospheres. Systematic tribological studies were conducted on AISI 52100 steel test pairs using driveline lubricants under unelectrified and electrified conditions in ambient air and dry N2. Test results showed that in ambient air and electrification, the formation of iron oxides (in particular hematite) was most dominant and gave rise to severe abrasive wear regardless of the lubricant type being used. In dry N2, however, the tribo-oxidation was suppressed but the formation of a carbon-rich tribofilm was favored (especially under electrified conditions). Such a shift from surface oxidation to carbonaceous film formation resulted in dramatic reductions (by factors of 8 to 10) in the wear of test pairs.

Ablation resistance of C/C–Hf1-xZrxC composites under an oxyacetylene flame at above 2700 °C

To the better application of C/C composites in thermal components of vehicles above 2700 °C, C/C–Hf1-xZrxC composites were prepared by CLVD, and the ablation behavior of composites was investigated. The results show that C/C–Hf0.5Zr0.5C has excellent ablation properties with linear and mass ablation rates of −0.23 μm/s and −0.31 mg/(s·cm2), respectively. ZrO2 molten phase and HfxZr1-xO2 particles are generated on the surface of C/C–Hf1-xZrxC composites during ablation. During the ablation process, defects are healed by the ZrO2 molten phase due to its mobility, which inhibits the diffusion of oxygen into the substrate. The ZrO2 molten phase is stabilized by the pinning effect of the HfxZr1-xO2 particles, which makes the ZrO2 molten phase better resistant to the scouring of the air stream. A relatively complete oxide layer is generated on the C/C–Hf0.5Zr0.5C surface, with a moderate amount of HfxZr1-xO2 exerting a pinning effect to hold the ZrO2 molten phase.