Designs

With the advancement of technology, the Single-Edge Nibble Transmission (SENT) protocol has become increasingly prevalent in automotive sensor applications, highlighting the need for a robust SENT signal simulation and acquisition system. This paper presents a real-time SENT signal acquisition system based on NI Field Programmable Gate Array (FPGA) technology. The system supports a range of message and data frame formats specified by the SAE J2716 SENT protocol, operates autonomously within a LabVIEW self-compiled environment, and is compatible with NI hardware-in-the-loop (HIL) systems for virtual electronic control units (ECU) calibration. This innovative, self-developed SENT system accommodates four message formats, seven data frame formats, and three pause pulse modes. Benchmarking tests were conducted by integrating this system with the dSPACE SCALEXIO HIL (located in Paderborn, Germany) system for SENT signal simulation and acquisition. The results confirm that the system effectively simulates and acquires SENT signals in accordance with SAE J2716 standards, establishing it as an invaluable asset in the electronification, intelligentization, informatization, and smart sensing of automotive and agricultural machinery. Full article

The transition from polylithic (composed of many parts) to monolithic (one part) design in automotive components presents an opportunity for a reduction in part count, weight, processing routes, and production time without compromising performance. The traditional design approaches for rooftop tents assemble various sheet metal and extrusions together using different joining processes such as welding, adhesive bonding, bolting, and riveting. This is often associated with disadvantages, such as increased weight, high production time, and leaking joints. This research, therefore, presents the development of a monolithic, lightweight, stiffened, non-rotational automotive rooftop tent that is manufactured via the deep-drawing process. An onsite company case study was conducted to analyze the polylithic product and its production process to determine its limitations. This was followed by the design of a lightweight, non-rotational monolithic product whose purpose is to eliminate the identified disadvantages. The stiffness geometries were developed to enhance the overall structural integrity without adding unnecessary weight. The Analytic Hierarchy Process (AHP) was used to analyze and evaluate alternative layouts against criteria such as complexity, tool design, symmetry, rigidity, and cost. Simulations conducted using NX 2024 software confirmed the effectiveness of this design. The results show that the monolithic rooftop tent has a comparable stiffness performance between the lightweight, monolithic rooftop tent and the heavy, polylithic rooftop tent. At the same time, the part count was reduced from twenty-three (23) single parts (polylithic) to a one (1) part (monolithic) rooftop tent, the weight was reduced by 15.6 kg, which translates to a 30% weight reduction without compromising the performance, processing routes were reduced from eight (8) to three (3), production time was reduced by 120 min, and leaking was eliminated. It can, therefore, be concluded that the design and manufacturing of monolithic rooftop tents leads to a lighter and stronger product. Full article

This study explores sustainable practices in energy resource management, with the aim of optimizing energy consumption while maintaining quality of life. It focuses on energy efficiency in the residential sector of the autonomous community of Extremadura. The methodology involved collecting data from 50 households, using a computer tool to assess and classify energy efficiency levels. The results showed that homes built before 1994 had low energy ratings, whereas those built afterward demonstrated improvement, reflecting a growing environmental awareness. It was found that small investments, such as the installation of control devices and the adoption of conscious consumption habits, can significantly improve energy efficiency. The study highlights the importance of raising community awareness about energy efficiency and notes that, despite limitations in the data, the findings provide valuable insights for future interventions. In conclusion, energy efficiency is key to a sustainable future, and we all share the responsibility of improving it. Full article

Commercial vehicles frequently experience lateral interferences, such as crosswinds or side slopes, during extreme maneuvers like emergency steering and high-speed driving due to their high centroid. These interferences reduce vehicle stability and increase the risk of rollover. Therefore, this study takes a bus as the carrier and designs an anti-rollover control strategy based on mixed-sensitivity and robust $H_{\infty }$ controller. Specifically, a 7-DOF vehicle dynamics model is introduced, and the factors influencing vehicle rollover are analyzed. Based on this, to minimize excessive intervention in the vehicle’s dynamic characteristics, the lateral velocity, roll angle, and roll rate are recorded at the vehicle’s rollover threshold as desired values. The lateral load transfer rate (LTR) is chosen as the evaluation index, and the required additional yaw moment is determined and distributed to the wheels for anti-rollover control. Furthermore, to verify the effectiveness of the proposed anti-rollover control strategy, a co-simulation platform based on MATLAB/Simulink and TruckSim is developed. Various dynamic lateral interferences (side winds with different changing trends and wind speeds) are introduced, and the fishhook and J-turn maneuvers are selected to analyze and compare the proposed control strategy with a fuzzy logic algorithm. The results indicate that the maximum LTR of the vehicle is reduced by 0.11. Additionally, the lateral acceleration and yaw rate in the steady state are reduced by more than 1.8 m/s² and 15°, respectively, enhancing the vehicle’s lateral stability. Full article

Identifying the parameters of a triple-diode electrical circuit structure in PV modules is a critical issue, and it has been regarded as an important research area. Accordingly, in this study, a differential evolution algorithm (DEA) is hybridized with an electromagnetism-like algorithm (EMA) in the mutation stage to enhance the reliability and efficiency of the DEA. A new formula is presented to adapt the control parameters (mutation factor and crossover rate) of the DEA. Seven different experimental data sets are used to improve the performance of the proposed differential evolution with an integrated mutation per iteration algorithm (DEIMA). The results of the proposed PV modeling method are evaluated with other state-of-the-art approaches. According to different statistical criteria, the DEIMA demonstrates superiority in terms of root mean square error and main bias error by at least 5.4% and 10%, respectively, as compared to other methods. Furthermore, the DEIMA has an average execution time of 27.69 s, which is less than that of the other methods. Full article

Novelty architecture buildings can be tiled with conventional rectangular solar photovoltaic (PV) modules with both close-packed cells or partially transparent modules, vastly increasing renewable energy, reducing carbon emissions, and allowing for positive energy buildings. To enable this potential, in this study, for the first time, two open-source programs were developed and integrated to provide a foundation for designing and coating real-life novelty architecture buildings and objects with solar PV modules. First, a tiling algorithm was proposed and integrated into Blender that can generate solar PV modules on the face of any 3D model, and an augmented Python version of SAM was developed to simulate the performance of the resultant irregularly shaped PV systems. The integrated open-source software was used to analyze the energy performance of seven different novelty BIPVs located across the globe. The buildings’ energy performance was compared to conventional ground-based PV systems, and the results showed that the conventional arrays generate more energy per unit power than the BIPVs. The analysis reveals that the more complex the building model geometry, the less energy the building generates; however, the novelty BIPV power and energy densities far surpass conventional ground-based PV. The real estate savings observed were substantial, reaching 170% in one case where the BIPV reached 750 m in height. The BIPVs’ energy production is optimized by orienting the building via rotation and only needs to be carried out a single time for replication anywhere globally. The results show that the energy yield of the BIPV increases as the building becomes more detailed while the total power and energy decrease, indicating the need for the careful balancing of priorities in building design. Finally, the energy simulations demonstrate the potential for net-positive energy buildings and contribute to net-zero-emission cities. The findings indicate that BIPVs are not only appropriate for conventional residential houses and commercial buildings, but also for historical building replicas or monuments in the future. Further studies are needed to investigate the structural, electrical, and socio-economic aspects of novelty-architecture BIPVs. Full article

Hydrogen energy is a promising alternative to traditional fossil fuels, offering a clean and sustainable solution to address the challenges of climate change and environmental degradation. Fuel cells provide direct and environmentally friendly conversion of chemical energy from a fuel source into electrical energy, emitting only water vapor when utilizing hydrogen from renewable sources. This study delves into the design of a portable proton-exchange membrane fuel cell (PEMFC) device tailored for household use in rural areas. The research focuses on achieving a minimum peak power of 1000 W and a voltage of 220 VAC at 50 Hz for the fuel cell. Employing theoretical calculations derived from existing formulas and literature reviews, various fuel cell components are meticulously assessed, including real power, voltage drop, performance under current load, and pressure drop on the bipolar plate. Additionally, the study encompasses the selection of auxiliary components like converters, inverters, fans, and others. The resultant fuel cell design showcases a device capable of generating a peak power of 1132.32 W with an efficiency rating of 48.66%. Identifying suitable auxiliary components further contributes to developing a practical and efficient portable power solution for rural households. Full article

The water diversion surge shaft is vital for a hydropower station. However, the complex geological properties of the surrounding rock make it challenging to obtain its mechanical parameters. A method combining particle swarm optimization (PSO) and support vector machine (SVM) algorithms is proposed for estimating these parameters. According to the engineering geological background and support scheme, a three-dimensional model of the water diversion surge shaft is established by FLAC3D. An orthogonal test is designed to verify the accuracy of the numerical model. Then, the surrounding rock mechanical parameter database is established. The PSO-SVM intelligent inversion algorithm is used to invert the optimal values of the mechanical parameters of the surrounding rock. The support for excavating the next layer depends on the mechanical parameters of the current rock layer. An optimized design scheme is then compared and analyzed with the original support scheme by considering deformation and plastic characteristics. The research results demonstrate that the PSO-SVM intelligent inversion algorithm can effectively improve the accuracy and efficiency of the inversion of rock mechanical parameters. Under the influence of excavation, the surrounding rock in the plastic zone mainly fails in shear, with maximum deformation occurring in the middle and lower parts of the excavation area. The maximum deformation of the surrounding rock under support with long anchor cables is 0.6 cm less than that of support without long anchor cables and 4.07 cm less than that of support without an anchor. In the direction of the maximum and minimum principal stress, the maximum depth of the plastic zone under the support with long anchor cables is 1.3 m to 2.6 m less than that of the support without long anchor cables and the support without an anchor. Compared with the support without long anchor cables and support without an anchor, the support with long anchor cables can effectively control the deformation of the surrounding rock and limit the development of the plastic zone. Full article

A comprehensive model for evaluating the functionality of a multi-gear pump has been developed. The integrated model for assessing the functionality of a multi-gear pump contains a computational fluid dynamics analysis (CFD) model combined with a finite element method (FEM)-based strength model. Two submodels were linked: a CFD submodel to evaluate the internal pressure distribution of the pump and a structural FEM submodel to calculate the stresses and structural displacements of the pump due to fluid pressure. Finite element analysis in SolidWorks 2016 was used to evaluate the strength of the gear joints of the pump gears. As the pressure of the working fluid increases from 6 to 20 MPa, a linear increase in Mises stresses is observed. At the shaft, these stresses increase to 226.2 MPa, and at the tooth mouths, they reach a maximum value of 205.5 MPa. With the increase in torque on the drive shaft from 100 to 500 N·m, there is a significant increase in Mises stresses localized in the contact zones of the shaft with the drive gear. Analysis of the data obtained showed that the displacements caused by the pressure of the working fluid are insignificant compared to the displacements arising under the action of torque. With increasing pressure and torque, there is a tendency to decrease the safety factor, which indicates a decrease in the safety factor of the design of the multi-gear pump. The safety factor is not provided at a torque of 400–500 N·m. The simulation results are confirmed by correlation analysis. The average approximation error is 5–7%. Full article

This study investigates the innovative design of a bicycle saddle by incorporating sustainable ergonomics, universal design principles, and systematic innovation methods. Initially, the literature related to bicycle saddle design and its impact on the human body during riding was analyzed. The TRIZ contradiction matrix was then used to identify relevant invention principles, which served as references for the innovative design of the bicycle saddle. Biomechanics and the human–machine system analysis within human factors engineering were applied to ensure the innovative design is ergonomic and user-friendly. The design features a horizontally expandable and foldable bicycle saddle, enhancing its adaptability and sustainability. Universal design principles were applied to make the innovative design more accessible to the general public, and the prototype was simulated using Inventor drawing software. The research results include: (1) An innovative bicycle saddle design with horizontal expansion and folding functions is proposed. This design divides the saddle into three components, enabling the left and right parts to expand or retract based on user preferences. (2) A bicycle backrest design featuring vertical adjustability is introduced. It incorporates a quick-release adjustment mechanism at the junction of the backrest and saddle, allowing users to freely adjust the backrest height. (3) A quick-operation bicycle saddle design is presented, utilizing quick-release screws to facilitate the swift operation of the horizontal expansion and folding mechanisms. This validation method confirmed that the innovative design meets both sustainable ergonomic standards and user expectations. The systematic innovation approach used in this study can serve as a valuable reference for future research and design applications. Full article

Recent research emphasizes the growing use of advanced composite materials in modern transportation, highlighting their superior weight-to-strength ratio. These materials are increasingly replacing steel and aluminium in housings to enhance sustainability, improve efficiency, and reduce emissions. Considering these advancements, this article reviews recent studies on composite materials, focusing on fatigue life assessment models. These models, which include performance degradation, progressive damage, and S–N curve models, are essential for ensuring the reliability of composite materials. It is noted that the fatigue damage process in composite materials is complex, as failure can occur in the matrix, reinforcement, or transitions such as interlaminar and intralaminar delamination. Additionally, the article critically examines the integration of artificial intelligence techniques for predicting the fatigue life of composite materials, offering a comprehensive analysis of methods used to indicate the mechanical properties of battery shell composites. Incorporating neural networks into fatigue life analysis significantly enhances prediction reliability. However, the model’s accuracy depends heavily on the comprehensive data it includes, including material properties, loading conditions, and manufacturing processes, which help to reduce variability and ensure the precision of the predictions. This research underscores the importance of continued advancements and their significant scientific contributions to transportation sustainability, especially in the context of emerging artificial intelligence technologies. Full article

The optimization of a contact-less magnetoelastic sensing setup designed to detect substances/agents accumulating in its environment is presented. The setup is intended as a custom-built, low-cost yet effective magnetoelastic sensor for pest/bug detection in constrained places (small museums, labs, etc.). It involves a short, thin, and flexible polymer slab in a cantilever arrangement, with a short Metglas^® 2826 MB magnetoelastic ribbon attached on part of its surface. A mobile phone both supports and supplies low-amplitude vibration to the slab’s free end. When vibrating, the magnetoelastic ribbon generates variable magnetic flux, thus inducing voltage in a contact-less manner into a pick-up coil suspended above the ribbon. This voltage carries specific characteristic frequencies of the slab’s vibration. If substances/agents accumulate on parts of the (suitably coated) slab surface, its mass distribution and, hence, characteristic frequencies change. Then, simply monitoring shifts of such frequencies in the recorded voltage enables the detection of accumulating substances/agents. The current work uses extensive testing via various vibration profiles and load positions on the slab, for statistically evaluating the sensitivity of the mass detection of the setup. It is shown that, although this custom-built substance/agent detector involves limited (low-cost) hardware and a simplified design, it achieves promising results with respect to its cost. Full article

The extensive industrial applications of aluminum (Al) metal matrix composites (MMCs) require optimal drilling conditions in the manufacturing industries. The effects of drilling variables, for instance, the point angle, spindle speed and feed rate on torque, thrust force, burr, surface quality, and dimensional errors were analysed while producing holes in MMC. The results showed that the torque and thrust force decreased with an increase in point angle and speed but increased with the rise in feed rate. Similar trends were also noticed for the chip thickness as these parameters vary. The burr height, circularity, and diameter error at the exit and entrance of the workpiece material were highly impacted by the point angle. In addition, the feed rate showed a strong influence on torque, burr height at the exit of the workpiece, and chip thickness. Thrust force and circularity as well as the diameter error at the exit of the workpieces were highly affected by the feed rate. The variation in surface roughness was not significant with the variations in the parameters considered in this investigation. Full article

Additive manufacturing (AM) has become a key topic in the manufacturing industry, challenging conventional techniques. However, AM has its limitations, and understanding its convenience despite established processes remains sometimes difficult, especially in preliminary design phases. This investigation provides a hybrid multi-criteria decision-making method (MCDM) for comparing AM and conventional processes. The MCDM method consists of the Best Worst Method (BWM) for the definition of criteria weights and the Proximity Index Value (PIV) method for the generation of the final ranking. The BWM reduces the number of pairwise comparisons required for the definition of criteria weights, whereas the PIV method minimizes the probability of rank reversal, thereby enhancing the robustness of the results. The methodology was validated through a case study, an aerospace bracket. The candidate processes for the bracket production were CNC machining, high-pressure die casting, and PBF-LB/M. The production of the bracket by AM was found to be the optimal choice for small to medium production batches. Additionally, the study emphasized the significance of material selection, process design guidelines, and production batch in the context of informed process selection, thereby enabling technical professionals without a strong AM background in pursuing conscious decisions. Full article

This paper examines the current generation of displays, as found primarily in smartphones, laptops and tablet computers, from an interaction design perspective. Today’s displays are multifunctional, versatile devices with a standardized, rectangular shape and a standardized interaction. We distinguish two pitfalls. First, they facilitate an interaction that is isolated and detached from the physical environment in which they are used. Second, their multi-touch interface provides users with few tangible clues and handles. From our background in embodied interaction, we establish an alternate, hypothetical vision of displays: the content-specific display. The content-specific display is defined as a display designed for one specific function and one type of on-screen content. We explore this concept in three student projects from the First Year Master’s program at Product Development, University of Antwerp, and present two key themes that emerge from it: causality and transformation. Both themes reside in the field of coupling, a concept well-known within the field of embodied interaction, and aim at a more seamless integration of on-screen content within the physical world. Finally, we discuss how the content-specific display influences the design process of digital products, and how it fosters collaboration between product designers and designers of graphical user interfaces. Full article

As individuals age, physiological changes can make it increasingly difficult to sit up unassisted. This study aimed to develop ergonomic self-help lifting pads to aid elderly individuals. The first phase involved constructing the pads and a needs assessment with elderly participants and caregivers to survey the physical dimensions and requirements for the design. The second phase focused on cost, engineering, and usage efficiency. Cost efficiency was analyzed using descriptive statistics, engineering efficiency was assessed through testing seat cushion, force reduction, and electrical safety, and usage efficiency was evaluated with participants aged 40 to 50 years. Results from the first phase indicated that the pads should be at least 53.15 cm wide and 153 cm long, with a need for relaxation and affordability. In the second phase, prototype pads were developed according to these specifications. A cost analysis showed that while the manual pad was more expensive than comparable products, the other variants were more cost-effective. Engineering tests confirmed that the cushions met ASTM D3574 standards and that the electrical components conformed to IEC 60335 standards. Usage efficiency ratings were the highest for the massage system pad. Participant feedback indicated longer pads, more convenient controls, and increased cushion comfort, guiding the development of the second version. Full article

Collaborative production is growing in its importance to the global economy, and along with it, so are other collaborative activities along the production chain, such as collaborative design. Nowadays, collaborative detail design can be implemented using Computer-Aided Design (CAD) through task sharing and Product Lifecyle Management (PLM) systems, but collaborative conceptual design is still poorly supported by CAD. Therefore, there is a need for a dedicated CAD platform that can support collaborative conceptual design as well. This paper contains the basic architecture for a CAD system used in collaborative conceptual–embodiment design, the proposed workflow for using the CAD system, and the design comparison method included in the system, that together comprise a CAD-based collaboration framework for conceptual–embodiment design. The framework is based on Coevolution Design Theory and developed such that it can be used to design complex products in an efficient, collaborative manner. A simple case study describing the use of the framework is included to illustrate how the framework can be used to design a product. In the future, this framework can be used to further develop and build a fully functional CAD system that will help designers to engage in a global collaborative setting. Full article

As an emerging technology in the field of additive manufacturing, 4D printing is highly disruptive to traditional manufacturing processes. Therefore, it is necessary to systematically summarize the research on 4D printing to promote the development of related industries and academic research. However, there is still an obvious gap in the visual connection between 4D printing theory and application research. We collected 2070 studies from 2013 on 4D printing from the core collection of Web of Science. We used VOSviewer 1.6.20 and CiteSpace software 6.3.3 to visualize the references and keywords to explore focuses and trends in 4D printing using scientometrics. In addition, real-world applications of 4D printing were analyzed based on the literature. The results showed that “tissue engineering applications” is the most prominent focus. In addition, “shape recovery”, “liquid crystal elastomer”, “future trends”, “bone tissue engineering”, “laser powder bed fusion”, “cervical spine”, “4D food printing”, “aesthetic planning” are also major focuses. From 2013 to 2015, focuses such as “shape memory polymers” and “composites” evolved into “fabrication”. From 2015 to 2018, the focus was on “technology” and “tissue engineering”. After 2018, “polylactic acid”, “cellulose”, and “regenerative medicine” became emerging focuses. Second, emerging focuses, such as polylactic acid and smart polymers, have begun to erupt and have become key research trends since 2022. “5D printing”, “stability” and “implants” may become emerging trends in the future. “4D + Food”, “4D + Cultural and Creative”, “4D + Life” and “4D + Clothing” may become future research trends. Third, 4D printing has been widely used in engineering manufacturing, biomedicine, food printing, cultural and creative life, and other fields. Strengthening basic research will greatly expand its applications in these fields and continuously increase the number of applicable fields. Full article