Sunarto Kaleg

This systematic literature review investigates risk assessment methodologies for Battery Electric Vehicles (BEVs), highlighting their diversity and effectiveness in addressing emerging safety challenges. With the rapid global adoption of BEVs, there is an increasing need for robust methodologies to assess risks such as thermal runaway (TR), degradation, and operational failures. This review highlights techniques such as fuzzy failure mode and effect analysis (FMEA), hybrid neural networks, bayesian networks (BN), and entropy weight methods. These tools effectively identify and mitigate risks; however, they face challenges in providing holistic, system-level safety assessments and adapting to long-term, real-world conditions. Unlike previous works, this study integrates interdependent BEV subsystems into unified risk models and examines underexplored areas such as maritime transport safety. The transport of BEVs by vessels presents unique risks, including high humidity and confined cargo spaces, which intensify the battery safety challenges. Tools like FMEA and real-time monitoring systems are critical to mitigate these risks. The findings highlight the growing reliance on real-time diagnostics and advanced algorithms for enhancing BEV safety and reliability. By identifying gaps and proposing recommendations, this review aims to support the development of standardized frameworks to ensure BEV safety across various environments and operational scenarios, contributing to their continued global adoption.

Steer-by-wire (SbW) is the latest steering evolution, providing many benefits, such as reduced vehicle weight and enhanced steering capability. While reliability is one of the main concerns hindering its widespread application, the potential of this technology to revolutionize the automotive industry is huge. Control techniques play an important part in achieving the full potential of SbW by focusing on the development of its performance and safety aspects. This paper provides a review of the control techniques that are being used in SbW technology to achieve better performance and enhance safety. Various control techniques for SbW exist to serve different purposes when dealing with the non-linear nature of the SbW dynamics. Although there is no one-size-fits-all control technique for all the requirements of the SbW, this study highlights that the non-linear controllers based on the sliding mode control (SMC) are a popular option for enhancing the accuracy of SbW systems. However, these controllers often suffer from a downside known as chattering. In contrast, robust controllers like Model Predictive Controllers (MPCs) can effectively manage uncertain dynamics and eliminate chattering, although they pose challenges due to their high computational costs.

This study investigates the effects of Boric Acid (BA) , H3BO3, and Sodium Silicate (SS), Na2SiO3, as single fillers on the mechanical and fire-resistant properties of Glass Fiber Reinforced Polymer (GFRP) composites. Various compositions of BA and SS were incorporated into the GFRP matrix, and the resulting composites were analyzed using X-ray Diffraction (XRD), Fourier Transform Infrared Spectroscopy (FTIR), Scanning Electron Microscopy (SEM), Thermo-Gravimetric Analysis (TGA), and Differential Thermal Analysis (DTA). The results demonstrate that BA significantly enhances the amorphous structure and mechanical strength of GFRP composites, with optimal performance at 10% BA content. In contrast, SS improves thermal stability but reduces mechanical strength at higher concentrations due to agglomeration. Fire resistance testing revealed that both fillers increase the ignition time and decrease the burning rate, with BA exhibiting superior performance. These findings suggest that BA is a more effective filler for improving the mechanical and fire-resistant properties of GFRP composites, while SS can serve as a complementary additive to enhance thermal stability.

Lithium-ion batteries are fundamental to modern electric vehicles, offering high energy density, long cycle life, and low self-discharge rates. However, thermal runaway—a critical safety issue involving uncontrolled temperature increases—can lead to fire or explosion. Ensuring flame retardancy is crucial in accidents where battery packs are exposed to external fires. Additionally, battery packs are susceptible to mechanical stresses and potential damage from ground impacts like debris or uneven road surfaces. Effective thermal management significantly impacts capacity and longevity. This review emphasizes the importance of researching flame retardancy, ground impact resistance, and thermal management, especially in composite battery enclosures. Composites serve as a lightweight alternative to metals and help overcome one of the main constraints of EVs, which is weight. Ground impact refers to the physical force battery packs endure during collisions, hitting potholes, debris, or accidents. Therefore, understanding the effects of ground impact on battery enclosures is crucial for design considerations. Effective thermal management is also essential, as it directly affects the performance and safety of Lithium-ion battery packs in EVs.

The use of a polymer composite material in electric vehicles (EVs) has been extensively investigated, especially as a substitute for steel. The key objective of this manuscript is to provide an overview of the existing and emerging technologies related to the application of such a composite, especially for battery pack applications, in which its high strength-to-weight ratio, corrosion resistance, design flexibility, and durability are advantageous compared to any metal in general. This study explores the key considerations in the design and fabrication of composites, including base material selection, structural design optimization, reinforcement material, manufacturing processes, and integration with battery systems. The paper also discusses the performance characteristics of composite battery pack structures, such as mechanical properties, thermal management, safety aspects, and environmental sustainability. This study aims to contribute to sharpening the direction of future research and innovations in the area of composite battery pack technology.

This paper examines the power transfer efficiency of three-phase gate switches to drive BLDC motors. The three-phase gate switch has six gate switches with eight switch states, which are used to control voltage or current. The effect of voltage arising on connection lines between gate switches can be determined by taking into account the rise time, fall time, and propagation delay parameters. Switching causes a loss of power and lowers efficiency. This is because the switching speed increases and the switching frequency increases, so the power loss also increases but the efficiency actually decreases. In order to overcome the problem of power transfer efficiency, the programmed PWM method is applied to regulate the switching transition by eliminating low-harmonic signals. Thus, the power transfer efficiency can be increased by about 21.16% compared to the power transfer conditions in the benchmark.

In this paper, a monitoring system has been developed that can be accessed and managed remotely using IoT technology to continually monitor the state of the electro hydraulic power steering (EHPS) performance. EHPS as an item, IoT devices, data gathering, and sensors are all part of the monitoring system. The EHPS performance can be examined based on the characteristics of the EHPS parameters based on the measured data from the sensor. Furthermore, the level of accuracy of measurement is determined by analyzing the percentage of accuracy and precision. As for the data transmission speed, it can be calculated based on the propagation delay and transmission delay. This monitoring system can be applied because it has an accuracy rate of around 96.82 % and has a good transmission speed.

A battery box made of polymer material must consider mechanical strengthand flame retardancy. One solution to increase the flame retardancy of polymers is toadd a flame retardant filler. However, sometimes adding a flame retardant filler cancause degradation of mechanical strength compared to neat polymers. The combinationof more than one type of filler or hybrid fillers can produce the optimal combination offlame retardancy and mechanical strength. An experimental study was carried out tocharacterize several composite polymer samples of unsaturated polyester (UP) resincombined with fillers of aluminum tri-hydroxide (ATH) to increase flame retardancyand short glass fiber (G) to improve mechanical strength. The DSC results show thatthe maximum endothermic of all samples occurred at a temperature of around 70 ºC.The TGA results prove that ATH and G can maintain the thermal stability of UP so thatthe composite samples were degraded at higher temperatures by reducing the rate ofweight degradation due to a temperature of around 0.1%/ºC. The burning test alsoshows that samples with ATH and G have a lower burning rate value than neat UP. Formechanical characterization, the tensile strength of the samples with ATH and G waslower than that of neat UP. However, UP/ATH/G2 showed an optimal compositioncompared to other filler compositions with a tensile strength of 41.5 MPa. This samplealso produces an optimal bending strength of 68.9 MPa and even higher than neat UP.These results were confirmed by SEM observations, in which filler G was exfoliated inthe UP. The broken G particles on the fracture surface observation prove the goodinterlock bonding between UP and G, which contributes to increasing the mechanicalstrength of the UP composite.

A composite container for an electric vehicle (EV) battery module filled with a phase-change material (PCM) was experimentally tested at various discharge rates. The average cell temperatures at 1 C, 2 C, and 4 C discharge rates, respectively, might reach 38 °C, 50 °C, and 70 °C in the absence of any heat-absorbing material. The temperature was noticeably lower with PCM present than with a conventional battery module. For instance, at 4 C discharge rates, none of the battery cells inside the PCM-filled module were able to reach 70 °C. Unfortunately, the PCM addition also degraded the composite’s tensile qualities. Further investigations used Paraffin-20 and Caprylone since PCMs provide a notably different thermal performance due to their distinctive latent heat profiles. It was observed that a high melting temperature of the paraffin mixture, despite its slightly lower latent heat capacity compared to Caprylone, could lead to a more uniform temperature. Overall, both PCMs can be used as passive protection against any potential thermal abuses in EV battery modules, while in terms of mechanical strength, the use of a composite reinforcement material is strongly encouraged.

Glass fiber reinforced plastic (GFRP) composites have great potential to replace metal components in vehicles by maintaining their mechanical properties and improving fire resistance. Ease of form, anti-corrosion, lightweight, fast production cycle, durability and high strength-to-weight ratio are the advantages of GFRP compared to conventional materials. The transition to the use of plastic materials can be performed by increasing their mechanical, thermal and fire resistance properties. This research aims to improve the fire resistance of GFRP composite and maintain its strength by a combination of pumice-based active nano filler and commercial active filler. The nano active filler of pumice particle (nAFPP) was obtained by the sol–gel method. Aluminum trihydroxide (ATH), sodium silicate (SS) and boric acid (BA) were commercial active fillers that were used in this study. The GFRP composite was prepared by a combination of woven roving (WR) and chopped strand mat (CSM) glass fibers with an unsaturated polyester matrix. The composite specimens were produced using a press mold method for controlling the thickness of specimens. Composites were tested with a burning test apparatus, flexural bending machine and Izod impact tester. Composites were also analyzed by SEM, TGA, DSC, FT-IR spectroscopy and macro photographs. The addition of nAFPP and reducing the amount of ATH increased ignition time significantly and decreased the burning rate of specimens. The higher content of nAFPP significantly increased the flexural and impact strength. TGA analysis shows that higher ATH content had a good contribution to reducing specimen weight loss. It is also strengthened by the lower exothermic of the specimen with higher ATH content. The use of SS and BA inhibited combustion by forming charcoal or protective film; however, excessive use of them produced porosity and lowered mechanical properties.