Centre of Excellence of the Integrated Research and Exploitation of the Progressive Materials and Technologies in the Area of Automotive Electronics Basic Characteristics of the Project Operation Program Research end Development Co-financed by European Fund of the Regional Development and State Budget of Slovak Republic Priority Axis 2 Support of Research and Development Action 2.1 Support of Excellence Workplaces of Research and Development networks like pillars of regional development and support of over regional cooperation Assumed Costs 4 123 558,00.- € Number of Coworkers 57 Coordinator Prof. Dr.-Ing. Alena Pietriková Term of Solution Solution of activities and outputs: 09/2010 – 08/2013 Impacts of the project: 2018 Goals of the Project Goal of the Project Development of CEV Progressive Materials and Intelligent Technologies of Automotive Electronics for Complex Solution of Research Tasks Defined by the Strategic Demands. Specific Goal 1 of the Project Centre of Excellence of Integrated Research and Exploitation of Progressive Materials and Technologies in the Area of Automotive Electronics. Specific Goal 2 of the Project Support of Realization of Important Research and Development Projects Solved in the Frame of the Centre. Specific Goal 3 of the Project Slovak Network of Excellence Workplaces for Integrated Research of Progressive Materials and Technologies for Automotive Electronics. CEIR and Exploitation of Progressive Materials and Technologies in the Area of Automotive Electronics Laboratory of Sensor and Communication Networks of Safe Automobile of the Future LABO REC Laboratory of Automotive Electrotechnics LIVE TIME LISKA CEV Laboratory of EMC Electronic Devices and Biological Systems EM KOM Laboratory of Modeling and Measurement for Automotive Electronics LPM MOD MER Technological Laboratory for Research of Progressive Materials for Automotive Electronics Laboratory for Modification and Testing of Properties of Progressive Materials Laboratory of Intelligent Sensor and Communication technologies of an Automobile Guaranteeing Department: Department of Electronics and Multimedia Communications Head of Laboratory: doc. Ing. Ján Gamec, CSc. Fields of science problems solved in CENTRE Laboratory of Intelligent Sensor and Communication technologies of an Automobile new optoelectronic methods of signal processing and transmission in distributed optical sensor networks (DOSN) of future accident-proof vehicle, application of optical correlator in distributed traffic sensor systems (traffic control), optically powered industrial sensor system of future accident-proof vehicle, intelligent sensor systems for vehicle interior and exterior monitoring with emphasis on UWB radar sensors, monocular and binocular video sensors, new digital signal processing methods of an intelligent sensors, mobile communication of customer in an automobile with emphasis on mobile access network for digital television based on LTE, WiMAX, WiFi and other modern network technologies v mobile access networks, wireless MIMO technologies and reconfigurable wireless network technologies (Intelligent Vehicular Ad Hoc Networks – InVANET, V2V) . Picked results of research and development Development of digital signal processing methods for diagnostics of car engines and gearboxes (contract with Medav GmbH, Germany). Development of psychoacoustic methods for diagnostics of selected subsystems of cars and electrical drives (contract with Medav GmbH, Germany). Development of glasses quality monitoring system of welding robots (contract with Volkswagen Slovakia a.s.). Development of speech car corpus including phonetic and orthographic transcription for voice control systems (contract with Škoda Auto MB a.s. Czech Republic). Partnerships Centre of Excellence II, Hamburg University of Technology (TUHH), Prof. Hermann Rohling -UWB, Ilmenau University of Technology , Dr. Rudolf Zetík - UWB, 2J s.r.o. (Bardejov)– company oriented on development and manufacturing of of antennae for the use in GSM, GPRS, GPS, Galileo, Glonass and Telematic applications (automotive too)... Development of GPS Patch antenna Laboratory of Automotive Electrotechnics Responsible department: Department of Electrical Engineering and Mechatronics (KEM TUKE) Head of Laboratory: doc. Ing. Michal Girman, CSc. Main research fields solved in Centrum Laboratory of Automotive Electrotechnics Design and optimization of electrical motors with focus on efficiency by new methods and applying CAD technologies. Design of compact drive units for electrical vehicles: optimization of power converters and motors design in term of thermal endurance, efficiency and minimal weight. Design of control for compact drives and their supply systems for electrical vehicles applying new control and artificial intelligence methods and communication busses in vehicle. The renewable energy sources (fuel cells) will be applied also in vehicle supply system. Proposal for new testing methods of electrical vehicles drive systems and their supply components in laboratory by Hardware in the Loop technology. Design of autonomous driven vehicle. Fields of Industry Projects High frequency soft switching DC-DC converters for voltage and current sources Power converters for renewable energy sources Power converters for automotive technique Battery management systems Hardware in the Loop technologies for mechatronic dynamic systems and power converters. Testers of circuit breakers magnetic (left) and thermal release (right) made at KEM TUKE Fundamental research project solved during last 10 years in the field of Power Electronics High-Frequency Soft-Switching DC-DC Power Converters. Project VEGA 1/6110/99, 1999-2001, (prof. Dudrik). Voltage and Current Power Supplies with High Efficiency and Reduced Electromagnetic Interference. Project VEGA 1/9025/02, 2002–2004, (prof. Dudrik). Efficient utilisation of renewable energy sources using modern power electronics converters and special electrical machines. Project VEGA 1/2178/05, 2005–2007, (prof. Dudrik). Research of New Generation High Frequency Soft Switching Converters. Project APVV 0095-07 (2008-2010). (prof. Dudrik). Research of power semiconductor converters for industrial and electric utility applications. Project VEGA 1/0099/09 (2009-2011). (prof. Dudrik). Research of Power Semiconductor Converters with High Efficiency of Electric Power Conversion. Project APVV 0185-10 (2011-2014). (prof. Dudrik). Centre of excellence of power electronics systems and materials for their components. Code ITMS: 26220120003, (05/2009 - 04/2011). The project is funded by European Community, ERDF – European regional development fund. Project contractor: University of Žilina, co-operation FEI TU Košice, (prof. Dudrik). Applied research projects Test equipments for controlling and setting the circuit breaker thermal and magnetic releases. Project APVV-20-P03105, FEI-TU Košice, 2005 - 2007 (prof. Dudrik). Implementation of new technology into the production of residual current circuit breakers with overcurrent protection. Project APVV-99-P04705, SEZ Krompachy a.s., 2005 -2007 (co-operation FEI-TU Košice - prof. Dudrik ). Research and development of new generation electric linear drives with high resolution of position. Project APVV-99-031205, EVPÚ, Nová Dubnica, 2006 – 2008 (co-operation FEI-TU Košice - prof. Dudrik ). New Circuit Breaker up to 63 A and Equipments for Breaker Hourly Tests. Project APVV 0287-07 (2008-2010). SEZ Krompachy, (co-operation FEI-TU Košice - prof. Dudrik ). Patents Dudrik, J.: Circuits for Decreasing of the Switching Losses in Extreme Conditions of the Converter. Slovak patent No. 283721, 2003 Dudrik, J.: Auxiliary Circuit for Controlled Start of the Source. Slovak patent No. 287189, 2010. Dudrik, J., Lacko, M.: Non-Dissipative Turn-of Snubber for Converter. Slovak patent No. 287292 , 2010 Dudrik, J.: Auxiliary Circuits for Achievement of Zero-Current Switching in PWM DC-DC Converters. Slovak pending patent, No.0144-2007 Dudrik, J., Ruščin, V., Bodor, M.: Non-Dissipative Turn-of Snubber in DC-DC Converter with Controlled Output Rectifier. Slovak pending patent, No. 000332008 Activities in the field of automotive technology Laboratory of Automotive Electronics (LAE) founded in 2004. LAE is a joint project of TUKE and Volkswagen Slovakia with the main goals as follows: Education quality improving in the field of automotive electronics and electrotechnics Material and technical basis for orientation research in the field of automotive electronics Support for student projects and activities Laboratory of Automotive Electronics at FEI TUKE Basic equipment of LAE MasterBook VW Polo, Škoda Superb Bus analyzer for CAN, LIN, FlexRay CANoe (Vector) Diagnostic software for vehicles of VW group Car dynamics simulator CarSim including real-time version CarSim RT, equipped with sensors of vehicle environment (Mechanical Simulation) and interfaces for real car ECU Hardware in the Loop (HIL) simulator RT-Lab (Opal-RT) Škoda Octavia II, Škoda Superb, Kia ceed Laboratory measuring instruments, oscilloscopes Fuel cells Software tools for optimization of electrical motor design for electromobiles Support of student projects Self made electrical vehicles in Bosch Electromobile Race 2010 and 2011 (Miskolc, HU) Technological Laboratory for Integrated Research of Electro-physical Properties of Progressive Materials Certificatory Workplace: Department of Technologies in Electronics Head of the Laboratory: Prof. Dr.- Ing. Juraj Banský The scientific problems solved in the frame of the CENTRE Technological Laboratory for Integrated Research of Electro-physical Properties of Progressive Materials Micro and nanostructure analyses of electro-physical properties of materials applied in automotive electronics. Reliability and lifetime of materials, components and systems applied in automotive electronics. Technologies of screen printing for production of very soft thick film structures and their application in mount technologies for automotive electronics. CAD design techniques for production of PCB, HIO and multichip modules for automotive electronics. Integrated virtual technological laboratory for online education in the area of materials and technologies in automotive electronics. Technological Laboratory for Integrated Research of Electro-physical Properties of Progressive Materials Technological Laboratory for Integrated Research of Electro-physical Properties of Progressive Materials 1. Workplace of Technological Processes I. Development and production of thick films, design of basics and realization of screen printing processes for production of hybrid integrated circuits, including mounting of SMD components, multilayer integrated structures based on LTCC and polymer thick film structures. Contacting, trimming of resistors, substrates cutting and other necessary techniques, which depend on construction of the circuits. Deposition of layers – screen printing, various ways of stencil printing, dispensing, measurement of rheology of nonNewtonian liquids, lead-free solders and conductive adhesives. Technological Laboratory for Integrated Research of Electro-physical Properties of Progressive Materials 2. Workplace of Technological Processes II. Production of multichip modules, cutting of LTCC ceramic layers for multichip modules, 3D CNC milling and PCB drilling, PCB etching, immersion and reflow soldering. 3D shaped module with integrated pressure sensor Technological Laboratory for Integrated Research of Electro-physical Properties of Progressive Materials 3. Workplace of Virtual Technological Laboratory and CAD - Design Systems: CAD designs of all types of structures and elements with support of HIOCAD design software, (CAD – design system Altium Designer, CAD – design system HYDE). Technological Laboratory for Integrated Research of Electro-physical Properties of Progressive Materials 4. Workplace of Diagnostics and Thermal Processes. Thermal processing for firing of thick films samples realized in convection and programmable firing furnaces; solder paste reflow in reflow ovens for SMT. Reflow soldering in saturated vapors. Diagnostic tests and reliability tests – climatic chamber, shock chamber. Technological Laboratory for Integrated Research of Electro-physical Properties of Progressive Materials Intenzita [-] [-] Intensity β-Sn Ag3Sn Cu6Sn5 228ºC 230ºC Intenzita [-] Intensity [-] 5. Workplace of Optical Diagnostics and Inspection of Electronic Structures. Microscopic analyses, optical inspection of joints, preparation of metallographic cross-sections, testing of mechanical properties, testing of transition resistance, contacting. 232ºC 10 15 20 2θ [º] a) Heating 25 30 10 15 20 2θ [º] b) Cooling 25 Technological Laboratory for Integrated Research of Electro-physical Properties of Progressive Materials 6. Workplace of Measurement. The workplace is aimed at measurement of electrical and non-electrical parameters by using precise measuring devices for general applications with support of tools like LabWin software. Selected Results of Research and Development Advanced Solder Materials for High Temperature application-HISOLD Financing: COST MP0602, COST, Duration: 2008 – 2011, Coordinator: Prof. Dr.-Ing. Alena Pietriková Analysis and Design of Complex Methodology of Evaluation of Mount Components Joints and Systems Based on Lead-free Solders, Financing: VEGA Nr. 1/0108/09, Duration: 2009 – 2012, Coordinator: Prof. Dr.- Ing. Alena Pietriková Progressive Materials and Construction Solutions for Technology of Miniaturized Systems Integration, Financing: VEGA Nr. 1/0076/09 Duration: 2009 – 2011, Coordinator: Prof. Dr.- Ing. Stanislav Slosarčík Laboratory for modification and testing of advanced materials Guaranteeing department: Department of Physics Head of the Laboratory: doc. RNDr. Dušan Olčák, CSc. Laboratory for modification and testing of advanced materials The research areas focused to within the Centre Modification of magnetically soft ferromagnetic materials. Study of electric and magnetic properties of these materials aimed at their potential applications mainly in sensor technology. Modification of already known polymeric materials in order to obtain materials with new utilizable properties. Study of relationships between structure and properties of polymeric materials of interest. Development of non-commercial experimental techniques for modification and testing of materials under study. Relevant results of research and development Support for the completion of building of the nuclear magnetic resonance laboratory (FCHPT STU Bratislava) , funding: Project APVV No.: 2003SP200280203 Duration: 2010, Coordinator: doc. RNDr. Dušan Olčák, CSc. Anomalous effects in the rheology of polymeric liquids Funding: SGA Project No. 1/0646/09, Duration: 2009 – 2011, Coordinator: prof. RNDr. Vladimír Lisý, DrSc. Structure of amorphous ferromagnetic materials and their selected magnetic properties Funding: SGA Project No. 1/0136/10, Duration: 2010 - 2012 Coordinator: doc. RNDr. Ján Ziman, CSc. Potential cooperation with industrial companies: Chemosvit, a.s.,Svit Development of polymeric materials for automotive industry Laboratory for modification and testing of advanced materials Cooperation with research institutions in Slovakia and abroad Cooperation with research institutes and laboratories within the CE laboratory network Incorporation into activities at the TU of Kosice within building of Technicom. Laboratories: - - Laboratory of magnetic measurements (Aplications: Measurement of quasistatic and dynamic magnetization curves, measurement of the velocity of 180o domain walls in the samples with axial or circular easy axis of magnetization, measurement of longitudinal magnetoresistance and magnetoimpedance (at the frequencies up to 1MHz) Laboratory of nuclear magnetic resonance – Laboratory is equipped with the multinuclear NMR spectrometer for solids (Applications: Materials of organic and inorganic origin, biomaterials, amorphous and crystalline materials, materials in the form of powder, fibres, granules and bulk materials) Modelling and measurement laboratory for automobile electronics Responsible workplace: Department of theoretical electrical engineering and electrical measurement Head of laboratory: prof. Ing. Dobroslav Kováč, PhD. Fields of scientific problems solved by CENTRE: Modelling and measurement laboratory for automobile electronics computer simulation, analysis and mesurement of automobile electronic circuits, description, modelling, measurement and optimization of automobile parameters and its components from EMC point of view, expert and telemetric parameter measurement of automobile production and operation, proposal, implementation and maintenance of modern and effective diagnostic and measurement systems and methods. simulations of electrical power as well as non-power circuits simulations of electromagnetic fields in object´s vicinity multiphysics application problems simulation measurement and evaluation of operating parameters development of new measurement systems and methods automobile´s energy management using computer simulation for investigation of automobile´s EMC objects measurement of automobile´s EMC as well as its parts and manufacturing devices design of optimal technical and technological solutions development of new method for EMC disturbance elimination Modelling and measurement laboratory for automobile electronics - Cooperation with companies Telemetry field: Solving of automobile´s accumulator condition measurement problem, Maintenance, diagnostics and measurement field: Electronic FASE control tester developed for Volkswagen, a.s. Slovakia. ovládanie ventilov kanálu A signalizácia hradlových impulzov ventil pomocného zdvihu kanál B štart zvárania pre kanál A štart zvárania pre kanál B ovládanie ventilov kanálu B ventil pomocného zdvihu kanál A signalizácia uvoľnenia NBS signalizácia uvoľnenia NBS +24V je OK napätie pre riadenie servoventilu zapnutie/vypnutie testera voľba typu záťaže signalizácia konca zvárania bezpečnostný vypínač nulovanie signalizovaných chýb zoraďovanie zapnuté/vypnuté prítlak elektród je/nie je OK Patent submitted. zváranie s/bez prúdu teplota súčiastok je/nie je OK voľba a signalizácia programu Car´s bodywork degaussing equipment designed and developed for SAAB, Magna Styr, Graz, Austria. Measuring current transformer designed for ZPA Křižík, a.s.. 2 patents submitted. EMC Laboratory of Electronic Equipments and Biological Systems Guaranteeing department: Department of Electric Power Engineering Head of laboratory: prof. Ing. Roman Cimbala, PhD. Fields of scientific problems solved within the frame of CENTRE EMC Laboratory of Electronic Equipments and Biological Systems Research in the areas of diagnostics, testing and influence of electronic equipments in aspects of electromagnetic compatibility with focus on technical devices and biological systems. Transfer of EMC knowledge research and development, design and production of components, systems and electronic modules for utilization in the electrical engineer and other related scientific branches. Influence of external fields on controlling and communication systems Radiation of EM fields Sensitivity on EM fields Composite material Equipment Personal devices interferencies Printed circuits Radar Safety systems Components Hardware failures Software failures Loss of functionality Electromobiles and their interaction with electric power nets Automatic net controlling at the level of consumption and generation Smart grids, Smart metering EMC of biological systems It deals with overall „electromagnetic backgrounds" of living environment, permissible levels of disturbing and useful electromagnetic signals (natural and artificial) and their influence on living organisms. Research is oriented in this areas: dielectric properties of live substances, individual effects on molecular, tissue, organ and systemic levels, physiological, psycho - pathogenic and genetic effects, quantization in dosimetry and radiometry, therapeutic and diagnostic applications. Biological object replying manifests as active adaptation algorithm mechanisms, which have chances and abilities of compensation effects induced by external activity. This compensation is able to act in the range of permissible physiological change, or in pathological way . It not is easy to determine accurate boundary between them. EMC of biological systems Influence of non – ionising radiation on morphology changes red corpuscule has been monitored on the department. It has been determined bucking of red corpuspule (erythrocyte) after defined time it the front of CRT computer display as well as by the measurement at the high voltage distribution board. Examples are presented in the following figures: checking samples after 12 hours – erythrocytes – shape as rotating ellipsoid samples of blood after 12 hours exposure in the front of CRT computer display – bucking has been created on monitored samples – creation of acanthocytes EMC Laboratory of Electronic Equipments and Biological Systems 1. 2. 3. 4. Laboratory of electromagnetic compatibility Laboratory of high voltage technique Laboratory of discharge and ionizing activity Laboratory of diagnostics Industrial partners: East-Slovak Power Engineering, inc. Košice Research Institute of Nuclear Power Plants, inc. Trnava Enel, inc. Bratislava RWE Munich Institute of Experimental Physics, Slovak Academy of Science, Košice Parasitological Institute, Slovak Academy of Science, Košice Centre of excelences of living being and human ecology, Prešov