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Copper laser powder bed fusion (Cu-LPBF) is known as a challenging manufacturing process. Since copper is an excellent thermal and electrical conductor, low to medium laser power is insufficient to provide good wettability and fusion between either adjacent tracks or deposited layers due to heat dissipation and high reflectivity. Particle surface modification has therefore been proposed to improve optical absorptivity. A simple method to enhance optical absorptivity is to create a thin oxide film by heating copper powder in an air furnace. The first phase of the current work emphasizes that this technique is detrimental to the part quality if a medium laser power range is used. The second phase presents a novel technique of two stages of in-situ copper oxide reduction during LPBF. It provides an innovative approach for combining laser cleaning and melting in LPBF. The newly suggested technique uses recycled and surface oxidized Cu powders to develop a simple and chemical-free method to recover the contaminated powder. A significant improvement is achieved by applying laser surface cleaning to the powder and solidified layers. The oxygen content is reduced by 70% in the LPBF samples compared to the initial state of the oxidized powder. [ABSTRACT FROM AUTHOR]

Battery electric vehicles (BEVs) face challenges like their limited all-electric range, the discrepancy between promised and actual energy efficiency, and battery health degradation, despite their environmental benefits. This article proposes an optimal adaptive cruise control (OACC) framework by leveraging ideal vehicle-to-vehicle communication to address these challenges. In a connected vehicle environment, where it is assumed that the Ego vehicle's vehicle control unit (VCU) accurately knows the speed and position of the Leading vehicle, the VCU can optimally plan the acceleration trajectory for a short-term future time window through a model predictive control (MPC) framework tailored to BEVs. The primary objective of the OACC is to reduce the energy consumption and battery state-of-health degradation of a BEV. The Chevrolet Spark 2015 is chosen as the BEV platform used to validate the effectiveness of the proposed OACC. Simulations conducted under urban and highway driving conditions, as well as under communication delay and infused noise, resulted in up to a 3.7% reduction in energy consumption and a 9.7% reduction in battery state-of-health (SOH) degradation, demonstrating the effectiveness and robustness of the proposed OACC. [ABSTRACT FROM AUTHOR]

Simple Summary: Cells continually sense and receive signals from the environment and respond accordingly. Due to biological noise, however, the response is not always as expected. Such a response can induce a different cell fate and may disrupt some cellular functions. In the presence of noise, cells may either mistakenly perceive non-existent signals and act accordingly, or may ignore the actual signals and do nothing. We label these two as false alarm and signal miss events, respectively. In this paper, we consider an important signaling system with one input and two outputs to show how the likelihood of false alarm and signal miss events can be computed, using the experimentally measured joint response of the two outputs of the signaling system. The two system outputs are the nuclear factor κB (NFκB) and the activating transcription factor-2 (ATF-2), whereas the system input is the tumor necrosis factor (TNF). These molecules are highly involved in essential processes such as cell survival, cell death, and viral replication. The introduced methodology and the measured false alarm and miss probabilities using experimental data can model complex cellular decision-making processes and provide insight into how they may contribute to the development of some pathological conditions. A cell constantly receives signals and takes different fates accordingly. Given the uncertainty rendered by signal transduction noise, a cell may incorrectly perceive these signals. It may mistakenly behave as if there is a signal, although there is none, or may miss the presence of a signal that actually exists. In this paper, we consider a signaling system with two outputs, and introduce and develop methods to model and compute key cell decision-making parameters based on the two outputs and in response to the input signal. In the considered system, the tumor necrosis factor (TNF) regulates the two transcription factors, the nuclear factor κB (NFκB) and the activating transcription factor-2 (ATF-2). These two system outputs are involved in important physiological functions such as cell death and survival, viral replication, and pathological conditions, such as autoimmune diseases and different types of cancer. Using the introduced methods, we compute and show what the decision thresholds are, based on the single-cell measured concentration levels of NFκB and ATF-2. We also define and compute the decision error probabilities, i.e., false alarm and miss probabilities, based on the concentration levels of the two outputs. By considering the joint response of the two outputs of the signaling system, one can learn more about complex cellular decision-making processes, the corresponding decision error rates, and their possible involvement in the development of some pathological conditions. [ABSTRACT FROM AUTHOR]

Due to its exceptional electrical and thermal conductivity, pure copper is frequently employed in industry as the base metal for thermal management and electromagnetic applications. The growing need for complicated and efficient motor designs has recently accelerated the development of copper additive manufacturing (AM). The present work aims to improve the power density of the copper laser powder bed fusion (Cu-LPBF) coil by increasing the slot-filling factor (SFF) and the electrical conductivity. Firstly, the dimensional limitation of Cu-LPBF fabricated parts was identified. Sample contouring and adjusting beam offset associated with optimum scan track morphology upgraded the minimum feature spacing to 80 μm. Accordingly, the printed winding's slot-filling factor increased to 79% for square wire and 63% for round wire. A maximum electrical conductivity of 87% (IACS) was achieved by heat treatment (HT). The electrical impedance of full-size Cu-LPBF coils, newly reported in this study, was measured and compared with solid wire. It can reflect the performance of Cu-LPBF coils (power factor) in high-frequency applications. Furthermore, surface quality benefited from either sample contouring and HT, where the side surface roughness was lowered by 45% and an additional reduction of 25% after HT. [ABSTRACT FROM AUTHOR]

Double modulation wave carrier-based pulse width modulation (CBPWM) is a solution for eliminating the deviations of the neutral-point voltage (NPV) in three-level neutral-point clamped inverters. In this paper, a new hybrid CBPWM strategy is proposed that not only eliminates the neutral-point voltage oscillations but also reduces the common-mode voltage (CMV) by half. Furthermore, the harmonic content is also reduced compared with the available reduced CMV modulation by adjusting the modulation waves based on the location of the reference vector in the space vector diagram. An active neutral-point voltage controller is also realized in order to maintain the performance of the modulation strategy under the NPV perturbations. The performance of the proposed algorithm is compared to the available CBPWM-based techniques in the literature. The effectiveness of the proposed method is also verified by experimental results. [ABSTRACT FROM AUTHOR]

Multiphase drives (MPD) in general and six-phase in particular have been gaining popularity in many industries, which calls for a proper multiphase inverter (MPI) design. For voltage source inverter (VSI)-fed drives, the knowledge of voltage and current stresses on the dc-link are imperative for input capacitor sizing. To this end, the voltage and current stresses on the dc-link capacitor in two-level six-phase VSIs are examined thoroughly in this article for two configurations of load/winding spatial distribution: symmetric and asymmetric. First, the harmonic spectrum of the input dc current of each inverter is analyzed in detail by benchmarking them against the conventional three-phase VSI, to precisely establish the dc-capacitor requirement reduction in six-phase counterparts. Second, analytical formulae for the dc-link capacitor voltage ripples are derived for both configurations. Third, simple formulae for dc-capacitor sizing for six-phase VSIs with different load configurations are provided. The accuracy of the derived formulae is verified by simulation and experimental testing at various power factors and modulation depth. It is found that six-phase VSI supplying symmetric and asymmetric loads reaps 10% and 7% lower dc-link current ripples, respectively. Hence, six-phase symmetric loads yield the smallest capacitor size. [ABSTRACT FROM AUTHOR]

In this article, a low-ripple continuous control set (CCS) model predictive torque control (MPTC) method for switched reluctance machines (SRMs) is proposed. The inherent high nonlinearity of the SRMs makes it difficult to solve the optimization problem in the CCS MPTC algorithm analytically. To address this issue, an equivalent linear SRM model is adopted, and the cost function is also properly modified. Then, with the torque boundary values provided by executing the voltage vectors of an improved switching table, the optimization problem in the CCS MPTC method becomes simple and analytically solvable. The Lagrange multiplier method is employed to solve this optimization problem analytically and generate the optimum torque reference values for the active phases. Based on the estimated torque variation rates, the duty cycles for each phase are calculated. Extensive simulation and experimental tests are carried out in a four-phase 8/6 SRM setup. These testing results reveal that the proposed CCS MPTC method shows much lower torque ripples and current ripples in a wide speed range with a low computational burden than the existing finite control set MPTC methods. [ABSTRACT FROM AUTHOR]

This article presents a digital sliding mode based robust model-free pulsewidth mode current control method for switched reluctance machine (SRM) drives. The model-free nature of the proposed controller allows complete elimination of the phase inductance or flux-linkage identification process. From the controller point of view, this exclusion yields excellent computational efficiency and low memory usage. In the proposed control method, the model information required to achieve a consistent closed-loop dynamic response is treated as an extended state and it is estimated online via unit time-step delayed approximation. The effect of this delay becomes significant as the operating speed increases. The estimation accuracy of the extended state is also affected by the noise in the current measurement. The effect of these factors on the control performance is compensated by using an auxiliary control action derived from a Lyapunov energy function analysis in the discrete-time domain. The resultant controller achieves accurate tracking of the reference phase current profile at fixed switching frequency modulation. It demonstrates a robust tracking performance throughout the controllable operating range of the SRM drive amid low signal-to-noise ratio. [ABSTRACT FROM AUTHOR]

Stability of multi-converter power systems, which exist in advanced more electric vehicles, is of great importance. The stability issue is investigated in this paper, and design considerations and limitations of the methods that stabilize the open-loop converters are presented. By stabilizing the open-loop converter, it is shown that the feedback loop design is usually translated into a conventional feedback design task. The behavior of the unstable converter is also discussed, and a method for decreasing the amplitude of the output voltage oscillations is proposed. The model of a tightly regulated practical converter is presented. This model is used to decide how much damping should be added to make the feeder converter stable. Furthermore, because we have this information about the load converter, the feeder converter can be redesigned so that it does not see the load converter as a constant power load. Index Terms--Constant power loads (CPLs), continuous-conduction mode (CCM), damping methods, DC/DC converters, feedback, loop gain and bandwidth, multi-converter power systems, stability, vehicular power systems.

A highly efficient and novel control strategy for improving the transients in the output voltage of a dc-dc positive buck--boost converter, required for low-power portable electronic applications, is presented in this paper. The proposed control technique can regulate the output voltage for variable input voltage, which is higher, lower, or equal to the output voltage. There are several existing solutions to these problems, and selecting the best approach involves a tradeoff among cost, efficiency, and output noise or ripple. In the proposed method, instead of instantaneous transition from buck to boost mode, intermediate combination modes consisting of several buck modes followed by several boost modes are utilized to distribute the voltage transients. This is unique of its kind from the point of view of improving the efficiency and ripple content in the output voltage. Theoretical considerations are presented. Simulation and experimental results are shown to prove the proposed theory. Index Terms--Control, efficiency, Li-ion battery, positive buck--boost converter, transients.

Multi-converter power electronic systems exist in land, sea, air, and space vehicles. In these systems, load converters exhibit constant power load (CPL) behavior for the feeder converters and tend to destabilize the system. In this paper, the implementation of novel active-damping techniques on dc/dc converters has been shown. Moreover, the proposed active-damping method is used to overcome the negative impedance instability problem caused by the CPLs. The effectiveness of the new proposed approach has been verified by PSpice simulations and experimental results. Index Terms--Active damping, constant power loads (CPLs), continuous conduction mode (CCM), dc/dc converters, feedback control, multi-converter power systems, negative impedance, stability.

With the advent of battery-powered portable devices and mandatory adoption of power factor correction, noninverting buck-boost converters are garnering lots of attention. Conventional two-switch or four-switch noninverting buck-boost converters choose their operation modes by measuring input and output voltage magnitude. The criterion for the selection of the operation mode can cause higher output voltage transients in the neighborhood, where input and output are close to each other. For the mode selection, due to the voltage drops raised by the parasitic components, it is not enough just to compare the magnitude of input and output voltages. In addition, the difference in the minimum and maximum effective duty cycles between controller output and switching device yields discontinuity at the instant of mode change. Moreover, the different properties of output voltage versus a given duty cycle of buck and boost operating modes contribute to the output voltage transients. In this paper, the effect of the discontinuity due to the effective duty cycle derived from the device switching time at the mode change is analyzed. A technique to compensate the output voltage transient due to this discontinuity is proposed. In order to attain additional mitigation of output transients and a linear input/output voltage characteristic in buck and boost modes, the linearization of dc gain of the large-signal model in boost operation is analyzed as well. Analytical, simulation, and experimental results are presented to validate the proposed theory. Index Terms--Discontinuity, duty cycle, noninverting buck-boost converter, nonlinearity, transition.

In this article, a novel model predictive torque control (MPTC) method for switched reluctance machines (SRMs) is proposed based on the equivalent linear SRM model and the improved switching table. First, an improved switching table with only six switching states is developed based on the inductance characteristics. The adoption of this improved switching table not only reduces the computational burden by 25% but also improves the torque control performance and system efficiency at high-speed region. However, the look-up-table (LUT) based MPTC methods suffer from occupying numerous storage space. To ease this issue, the simple linear SRM model is utilized. The flux-linkage and torque equivalent transformations are introduced to address the difference between the linear and nonlinear SRM models. With these transformations, the MPTC realized on the linear SRM model is proposed. Compared to 1530 storage units consumption to store three two-dimensional (2-D) LUTs in the LUT-based MPTC methods, the proposed method only occupies 228 storage units. Experimental results on an 8/6 SRM setup verify that the proposed method effectively eliminates the commutation torque ripple with lower execution time, less storage space, and improves the torque control performance at a high-speed range compared with the conventional LUT-based method. [ABSTRACT FROM AUTHOR]

This article presents a simple and practical method to estimate the lumped radial force characteristics for the switched reluctance machines (SRMs). First, the relationship between the square root of the lumped radial force and the flux linkage is discussed and analyzed. With the geometry data of the studied SRM, the abovementioned relationship under nominal air-gap length and nominal material magnetic property conditions can be obtained through the finite-element analysis (FEA) software. As the radial flux density dominates the magnitude of the radial force and it concentrates on the overlapping area, the abovementioned relationship is analyzed to be roughly held when the air-gap length and/or material magnetic property vary. Based on this relationship obtained from the FEA and the actual measured flux-linkage characteristics, the lumped radial force can be easily reconstructed for the actual SRMs regardless of the possible air-gap length variation and material magnetic property deviation during the manufacturing process. Simulation results on the 8/6 SRM and 12/8 SRM verify that the proposed method provides good radial force estimation results when the air-gap length is reduced or increased up to 50%. Superior estimation results are also observed on the condition that the magnetic ${B}$ – ${H}$ curve is linearly varied by ±25%. The accurate and simple radial force estimation method proposed in this article provides a solid basis for the radial-force-shaping-based advanced control methods to suppress the acoustic noise. [ABSTRACT FROM AUTHOR]

The fuel efficiency and performance of novel vehicles with electric propulsion capability arc largely limited by the performance of the energy storage system (ESS). This paper reviews state-of-the-art ESSs in automotive applications. Battery technology options are considered in detail, with emphasis on methods of battery monitoring, managing, protecting, and balancing. Furthermore, other ESS candidates such as ultracapacitors, flywheels and fuel cells are also discussed. Finally, hybrid power sources are considered as a method of combining two or more energy storage devices to create a superior power source. Index Terms--Capacitors, energy storage, flywheels, fuel cells (FC), land vehicle, transportation.

With the requirements for reducing emissions and improving fuel economy, automotive companies are developing electric, hybrid electric, and plug-in hybrid electric vehicles. Power electronics is an enabling technology for the development of these environmentally friendlier vehicles and implementing the advanced electrical architectures to meet the demands for increased electric loads. In this paper, a brief review of the current trends and future vehicle strategies and the function of power electronic subsystems are described. The requirements of power electronic components and electric motor drives for the successful development of these vehicles are also presented. Index Terms--Electric machines, electric vehicles, fuel-cell vehicles, hybrid vehicles, motor drive, plug-in hybrid vehicles, power electronics, propulsion systems, vehicle strategy.

Efficiency, fuel economy, federal mandates, and global socio-political scenarios are the issues that are forcing the vehicular industry to seek more electrification. As land, sea/undersea, air, and space vehicles become more electric and less mechanical, vehicular industry is emerging as a leading application area for power electronics. Electrical architectures of power electronic based vehicular systems are in the form of multi-converter configurations. In multi-converter vehicular systems power electronic converters are mostly utilized in generating, distributing, and utilizing electrical energy in the vehicle. Power electronic converters, when tightly regulated, act as constant power loads. Constant power loads have a destabilizing effect on multi-converter systems. In order to mitigate this instability problem, which is also known as negative impedance instability, this paper introduces pulse adjustment, a novel digital control technique, to control dc/dc converters. This method applies predefined duty cycles, instead of conventional pulsewidth modulation (PWM) techniques, to regulate the output voltage. It is simple, cost-effective, and needs few logic gates and comparators to implement, thus, making it extremely simple and easy to develop using a low-cost application-specific integrated circuit (ASIC). Experimental results as well as simulation results are presented to describe and verify the proposed technique.

Multiconverter-distributed dc architectures have been utilized for power distribution in many applications such as telecommunication systems, sea and undersea vehicles, an international space station, aircraft, electric vehicles, hybridelectric vehicles, and fuel-cell vehicles, where reliability is of prime concern. The number of power-electronic converters (ac/dc, dc/dc, dc/ac, and ac/ac) in these multiconverter electrical power systems varies from a few converters in a conventional land vehicle, to tens of converters in an advanced aircraft, and to hundreds of converters in the international space station. In these advanced applications, power-electronic converters might need to have a tight output-voltage regulation. From the output perspective, this property is highly desirable. However, since power-electronic converters are efficient, tight regulation of the output makes the converter appear as a constant-power load (CPL) at its input side. Dynamic behavior of CPLs is equivalent to negative impedance and, therefore, can result in instability of the interconnected power system. In order to mitigate the instability of the power converters loaded by CPLs, this paper presents the pulse-adjustment digital control technique. It is simple and easy to implement in application-specific integrated circuits, digital-signal processors, or field-programmable gate arrays. Moreover, its dynamic response is fast and robust. Line and load regulations are simply achievable using this technique. Analytical, as well as simulation and experimental results of applying the proposed method to a dc/dc buck-boost converter confirm the validity of the presented technique. Index Terms--Automotive, buck-boost converter, constantpower loads (CPLs), control, electric vehicles, line regulation, modeling and analysis, multiconverter, negative-impedance instability, power converters.