World Electric Vehicle Journal

23 pages, 4194 KiB

Open AccessArticle

Load Analysis and Test Bench Load Spectrum Generation for Electric Drive Systems Based on Virtual Proving Ground Technology

by Xiangyu Wei, Xiaojie Sun, Chao Fang, Huiming Wang and Ze He

World Electr. Veh. J. 2025, 16(9), 481; https://doi.org/10.3390/wevj16090481 (registering DOI) - 23 Aug 2025

Abstract

The reliability of the EDS (Electric Drive System) in electric vehicles is crucial to overall vehicle performance. This study addresses the challenge of acquiring high-fidelity internal load data in the early development phase due to the absence of prototypes, overcoming the limitations of traditional road tests, which are costly, time-consuming, and unable to measure gear meshing forces. A method based on a VPG (Virtual Proving Ground) is proposed to acquire internal loads of a dual-motor EDS, analyze the impact of typical virtual fatigue durability road conditions on critical components, and generate load spectra for test bench experiments. Through point cloud data-based road modeling and rigid-flexible coupled simulation, dynamic loads are accurately extracted, with pseudo-damage contributions from eight intensified road conditions quantified using pseudo-damage calculations, and equivalent sinusoidal load spectra generated using the rainflow counting method and linear cumulative damage theory. Compared to the limitations of existing VPG methods that rely on simplified models, this study enhances the accuracy of internal load extraction, providing technical support for EDS durability testing. Building on existing research, it focuses on high-fidelity acquisition of EDS loads and load spectrum generation, improving applicability and addressing deficiencies in simulation accuracy. This study represents a novel application of VPG technology in electric drive system development, resolving the issue of insufficient early-stage load spectra. It provides data support for durability optimization and bench testing, with future validation planned using real vehicle data. Full article

(This article belongs to the Special Issue Electrical Motor Drives for Electric Vehicle)

18 pages, 6610 KiB

Open AccessArticle

Design and Implementation of a Teaching Model for EESM Using a Modified Automotive Starter-Generator

by Patrik Resutík, Matúš Danko and Michal Praženica

World Electr. Veh. J. 2025, 16(9), 480; https://doi.org/10.3390/wevj16090480 - 22 Aug 2025

Abstract

This project presents the development of an open-source educational platform based on an automotive Electrically Excited Synchronous Machine (EESM) repurposed from a KIA Sportage mild-hybrid vehicle. The introduction provides an overview of hybrid drive systems and the primary configurations employed in automotive applications, including classifications based on power flow and the placement of electric motors. The focus is placed on the parallel hybrid configuration, where a belt-driven starter-generator assists the internal combustion engine (ICE). Due to the proprietary nature of the original control system, the unit was disassembled, and a custom control board was designed using a Texas Instruments C2000 Digital Signal Processor (DSP). The motor features a six-phase dual three-phase stator, offering improved torque smoothness, fault tolerance, and reduced current per phase. A compact Anisotropic Magneto Resistive (AMR) position sensor was implemented for position and speed measurements. Current sensing was achieved using both direct and magnetic field-based methods. The control algorithm was verified on a modified six-phase inverter under simulated vehicle conditions utilizing a dynamometer. Results confirmed reliable operation and validated the control approach. Future work will involve complete hardware testing with the new control board to finalize the platform as a flexible, open-source tool for research and education in hybrid drive technologies. Full article

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16 pages, 13677 KiB

Open AccessArticle

Evolution of Characteristic Parameters in Fuel Cell Dynamic Response Under Durability Testing

by Zhexuan Qi, Xiangyang Chen, Ruidi Wang, Dong Hao, Wenlong Pan and Yongping Hou

World Electr. Veh. J. 2025, 16(9), 479; https://doi.org/10.3390/wevj16090479 - 22 Aug 2025

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Abstract

The evolution of two key dynamic response parameters—undershoot voltage and stabilization time—was investigated throughout a 1000-h durability test on four distinct PEMFCs. Results demonstrate that cells with superior mass transport exhibited higher undershoot voltages, an effect amplified at higher current densities due to a more pronounced gas supply-demand imbalance. Notably, the undershoot voltage decreased during the initial cell activation phase. Conversely, stabilization time showed no clear correlation with load magnitude but increased systematically with performance degradation. These findings reveal a strong connection between dynamic response characteristics and performance decay, providing meaningful insights for the design, application, and health assessment of high-performance fuel cells. Full article

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World Electr. Veh. J., Volume 16, Issue 9 (September 2025) – 3 articles

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