An automotive battery pack for use in electric vehicles consists of a large number of individual battery cells that are structurally held and electrically connected. Making the required electrical and structural joints represents several challenges, including, joining of multiple and thin highly conductive/reflective materials of varying thicknesses, potential damage (thermal, mechanical, or vibrational) during joining, a high joint durability requirement, and so on. This paper reviews the applicability of major and emerging joining techniques to support the wide range of joining requirements that exist during battery pack manufacturing. It identifies the advantages, disadvantages, limitations, and concerns of the joining technologies. The maturity and application potential of current joining technologies are mapped with respect to manufacturing readiness levels (MRLs). Further, a Pugh matrix is used to evaluate suitable joining candidates for cylindrical, pouch, and prismatic cells by addressing the aforementioned challenges. Combining Pugh matrix scores, MRLs, and application domains, this paper identifies the potential direction of automotive battery pack joining.

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Although micro hybrid propulsion (MHP) systems are recognized as a feasible solution for off-highway construction machines (OHCMs), there is still a lack of understanding how existing MHP technologies can be transferred effectively from the automotive sector to the construction sector. To fill this gap, this paper is the first of a two-part study which focuses on micro hybrid construction machines paying attention to a novel idle-stop-start control (ISSC) strategy. Part A presents the system concepts and design procedure while Part B studies on a hardware-in-the-loop test platform for a comprehensive analysis on the potential fuel/emission saving of the proposed system in real-time. In this study-Part A-different types of OHCMs are briefly discussed to identify the target machine. The procedure to model the machine powertrain is also concisely introduced. Next, to minimize the fuel consumption and emissions without degrading the machine performance, a prediction-based idle-stop-start control (PISSC) approach is properly designed. The core of the PISSC is to estimate online the future engine working state changes in order to directly shut down the engine or shift it to low power regions during idle periods. Numerical simulations have been carried out to validate the potential of the proposed PISSC method.

Copyright and reuse:The Warwick Research Archive Portal (WRAP) makes this work by researchers of the University of Warwick available open access under the following conditions. Copyright © and all moral rights to the version of the paper presented here belong to the individual author(s) and/or other copyright owners. To the extent reasonable and practicable the material made available in WRAP has been checked for eligibility before being made available.Copies of full items can be used for personal research or study, educational, or not-for profit purposes without prior permission or charge. Provided that the authors, title and full bibliographic details are credited, a hyperlink and/or URL is given for the original metadata page and the content is not changed in any way. A note on versions:The version presented here may differ from the published version or, version of record, if you wish to cite this item you are advised to consult the publisher's version. Please see the 'permanent WRAP url' above for details on accessing the published version and note that access may require a subscription. AbstractEngine stop-start control is considered as the key technology for micro/mild hybridisation of vehicles and machines. To utilize this concept, especially for construction machines, the engine is desired to be started in such a way that the operator discomfort can be minimized. To address this issue, this paper aims to develop a simple powertrain modelling approach for engine stop-start dynamic analysis and an advanced engine start control scheme newly applicable for micro/mild hybrid construction machines. First, a powertrain model of a generic construction machine is mathematically developed in a general form which allows to investigate the transient responses of the system during the engine cranking process. Second, a simple parameterisation procedure with a minimum set of data required to characterise the dynamic model is presented. Third, a modelbased adaptive controller is designed for the starter to crank the engine quickly and smoothly without the need of fuel injection while the critical problems of machine noise, vibration and harshness can be eliminated. Finally, the advantages and effectiveness of the proposed modelling and control approaches have been validated through numerical simulations. The results imply that with the limited data set for training, the developed model works better than a high fidelity model built in AMESim while the adaptive controller can guarantee the desired cranking performance.