To address the issue of insufficient estimation accuracy of the Hydraulic Control Unit (HCU) wheel cylinder pressure estimation algorithm for an integrated wire controlled hydraulic braking system with eight valve structure, this article proposed wheel cylinder hydraulic pressure estimation algorithm that can replace pressure sensors. The article first proposed a wheel cylinder hydraulic pressure estimation algorithm based on the Bernoulli principle, and then analyzed the basic characteristics of the hydraulic adjustment unit and the Pressure Volume (PV) characteristics of the brake fluid based on hardware in the loop experimental bench testing. Finally, it was verified through actual vehicle experiments. The experimental results show that under basic braking conditions, the root mean square error of the proposed wheel cylinder pressure estimation algorithm is within 0.259 MPa, the root mean square error under active braking conditions is within 0.374 MPa, which is equivalent to the accuracy of the scheme with added pressure sensors.

In order to improve the efficiency of reliability verification of the e-Axle under mechanical load and thermal load environment, this paper, taking the three-in-one e-Axle as the research object, analyzed the failure mechanism and influencing factors of each subsystem by comprehensively considering the actual operating environment and working conditions of the e-Axle, and studied the acceleration process and calculated equivalent test time according to the accelerated failure logic under different test conditions. The results show that the accelerated life endurance test method can support the reliability verification of the e-Axle.

To address the issue of low simulation accuracy, and large test resources investment in the development of acoustic package, this paper proposed a method based on ray tracing to calculate the external sound load of car body. Firstly, the hard wall panel on external surface of vehicle was extracted, and ray tracing solving model was established in VAOne. Secondly, the noise value of the key sound source of the vehicle was tested. Finally, the key noise sources were loaded into the ray tracing model to calculate the external acoustic load of the car body. With an SUV as the research object, the vehicle exterior acoustic load was calculated and compared with the test results. The result shows that the sound load calculated by the ray tracing model is in good agreement with the experimental value, which can improve the simulation accuracy of the acoustic package development.

Based on the experimental method and technical requirements of GB 15086—2013, a finite element analysis model was established to analyze inertial force resistance and optimize plastic tailgate structure. Firstly, the plastic tailgate structure failure motion mode and stress of inertial force resistance was predicted and analyzed based on the structural design feasibility of plastic tailgate by using finite element analysis model simulation; secondly, the issue of structural failure and cracking of plastic tailgate under inertial load were solved by adopting the method of structural optimization scheme through increasing the load transmission path of the tailgate inner plate and strengthening the local material thickness. Finally, the reliability of the optimization scheme of the plastic tailgate and the accuracy of the simulation analysis model were verified by the bench test.

In order to solve the problem of low accuracy in predicting the remaining service life of proton exchange membrane fuel cells, this paper proposed a dynamic fuel cell Remaining Useful Life (RUL) prediction model based on Northern Goshawk Optimization (NGO), Convolutional Neural Network (CNN) and Bi-directional Long Short-Term Memory (BiLSTM) neutral network. Firstly, NGO optimized the learning rate, hidden nodes and regularization coefficient of the CNN-BiLSTM model, and then the CNN-BiLSTM model extracted the features of the input data through the convolutional layer, and input it into the BiLSTM layer for timing modeling and prediction. In addition, wavelet threshold de-noising algorithm was used to smoothen the original data. Pearson correlation coefficient was used to extract model input variables, and NGO-CNN-BiLSTM network power prediction model was built. The simulation and verification results show that this method can effectively improve the prediction accuracy of the remaining service life of fuel cells up to 99.49%, which is higher than that of other comparative models.

With a light truck equipped with power-following fuel cell as the research object, a power-following energy management strategy of a fuel cell based on wavelet transformation has been constructed combining the frequency characteristics of the vehicle power demand under typical driving cycles using wavelet analysis method. The low frequency component of the vehicle power demand obtained after wavelet transform was allocated to the fuel cell, so as to improve the fluctuation of the fuel cell output power. In addition, the wavelet decomposition level was dynamically adjusted to regulate the power following degree automatically, to ensure the power supply of the vehicle under various power battery charge-discharge capacity and vehicle power requirement. The simulation result shows that the power-following allocation strategy based on wavelet transform can meet the vehicle power demand under typical driving conditions, and the SOC can be kept in the reasonable range, the power output fluctuation of the fuel cell has been decreased by 29.8%, in addition, the hydrogen consumption has been reduced by 1.5%.

To realize the coordinated control of the flow pressure of the air subsystem for Proton Exchange Membrane Fuel Cell (PEMFC), this paper applied the fuzzy control principle and the Mamdani inference method to reason the control rules of fuzzy decoupling control, to design the fuzzy decoupling composite controller with MAP feedforward control. Finally, the comparison test with the fuzzy PID controller and the supplementary environment adaptation test were carried out. The results show that the fuzzy decoupling controller can achieve better control effect and has good environmental adaptability with flow control error less than ±3 g/s, and pressure control error less than ±10 kPa.

This article analyzed the technical requirements of hydrogen sensors used in fuel cell vehicles, and studied the working principles, characteristics of various vehicular hydrogen sensors, compared the performance and parameters of mainstream hydrogen concentration sensors at present, summarized and analyzed the current development status of hydrogen concentration sensors. The technical development trend of hydrogen concentration sensors was predicted based on industry development needs.

In the state-of-charge estimation of power battery, the traditional Extended Kalman Filter (EKF) ignores high-order terms and Particle Filter (PF) suffers from particle degradation and loss of diversity during the resampling process. To address this issue, this paper proposed the improved Mixed Kalman Particle Filter (MKPF) algorithm. Firstly, the extended Kalman filter was used to generate the state estimate of the system, and then the unscented Kalman filter was used to repeat the process. The state estimates obtained by the extended Kalman filter and the unscented Kalman filter were used together as the particle filter proposal distribution, and value sorting was used to determine the survival of the fittest particles. Simulation and experimental results show that the maximum error of SOC estimate by the proposed algorithm is 1.2%, which is better than the estimation accuracy of the existing PF, EKF, and UKF algorithms on SOC.

Current Time Of Flight (TOF) camera products have problems such as small viewing angle, and inability to consider all passengers in the front row. To address this issue, this article proposed a design method for TOF cameras, which solved the heat dissipation problem through thermal design simulation, and effectively expanded the camera’s Field Of View (FOV) through optical design and simulation of the TOF camera lens. At the same time, a complete design verification test was conducted to verify the performance of the TOF camera product. The results show that the system fully realizes the functions of the TOF camera, cover the passengers in the front row with a large FOV, and meets the performance requirements of the automotive grade.