PSI - Issue 57

Marco Bonato et al. / Procedia Structural Integrity 57 (2024) 799–809 / Structural Integrity Procedia 00 (2019) 000 – 000

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The objective of the current paper is to show that vibration damage equivalent signals obtained with improper settings of the FDS (damping ratio and Basquin ’s coefficient) might result in unrealistic simulated fatigue life predictions. 1.4. FEA design validation The investigation considers two products developed by Valeo: the high voltage coolant heater and an alternator Both components are key players in the Valeo strategy to focus on the electrification of automotive mobility. 1.4.1. The Alternator The role of the alternator (Figure 2a) is to provide continual charge to the battery while the engine is running. Alternator is driven by the engine via pulleys and a belt drive to retrieve the appropriate energy level from the engine according to electrical energy needs. This supply of power prevents the battery from discharge, and provides the requested power to the car’s electrical devices. It finds current usage for 48 Volts technology initially developed for hybrid vehicles to all the new mobility applications such as light 2, 3 or 4 wheels. The alternator is typically mounted on the or near the vehicle engine (combustion or electric powertrain). The typical vibration loadings are mostly of harmonic type. 1.4.2. The high voltage coolant heater (HVCH) High Voltage Heaters are the future solution for plugin and e-powered buses and commercial vehicles that quickly, consistently and reliably heats the vehicle interior. The compact device ensures a constantly high heat output up to 12kW and allows for flexible use in a power range of 600 to 875 Volts. HVCH features infinitely variable heat output control by means of an integral control unit. This takes place either by regulating the water outlet temperature or by limiting the maximum heat output or power consumption. Thanks to its precise and stepless controllability: better performance and optimized power management. Furthermore, it is CAN-capable and transmits key operating data to the vehicle system using an intelligent diagnostic function. The HVCH (Figure 2b) is generally mounted on the body of the car. It therefore undergoes the typical vibration loadings resulting from driving on obstacles (potholes, etc) or harsh situations (rough roads, etc).

Fig. 2. (a) CAD model of the Alternator (b) CAD model of the High Voltage Coolant Heater Also this component can be described as a mechatronic system. The cylindrical structure of a heat exchanger (inlet and outlet hoses, coolant recirculating channels, holding brackets) is coupled with high power electronics that generates the heat (the heating elements, the control PCB and the (Local Interconnect Network) LIN communication system).