Progress in Engineering Technology IV

This book contains a collection of peer-reviewed papers from the 2020 Conference on Multidisciplinary Engineering and Technology (COMET 2020) held online on December 15–16, 2020. It contains twenty-five papers covering energy harvester, thermodynamics, vibration, dynamic of mechanics, manufacturing process, computer-aided manufacturing (CAM), CFD analysis, electronics, and microcontroller. Preface Contents About the Editors 1 Brake Squeal Analysis and Optimization Using the Finite Element Method and Taguchi Techniques 1.1 Introduction 1.2 Methodology 1.2.1 3D Design if the Brake Disc Model 1.2.2 Finite Element Analysis 1.2.3 Modal Analysis 1.3 Result and Discussion 1.3.1 Natural Frequency Using Mild Steel, Gray Cast Iron, and Carbon Ceramic 1.3.2 Comparison Natural Frequency Between All Three Design and Materials 1.3.3 Taguchi Method Using Minitab 1.4 Conclusion References 2 Potential Experimental Analysis of Electrical Discharge Machine Process Parameters on Stainless Steel ANSI 304 2.1 Introduction 2.2 Literature 2.2.1 Electrical Discharge Machining 2.2.2 Die-Sinking 2.2.3 Wire EDM Process 2.2.4 Dielectric Fluid 2.2.5 EDM Machine Components 2.2.6 Material Removal Rate 2.2.7 Surface Quality Analysis 2.2.8 Taguchi Method 2.3 Methodology 2.3.1 Research Structure 2.3.2 Experimental Setup 2.3.3 Selection of the Workpiece 2.3.4 Tool Design 2.3.5 Mechanism and Measurement of the MRR 2.3.6 Mechanism and Evaluation of Surface Roughness 2.3.7 Design of Experiments Analysis 2.4 Conclusions References 3 Embedded System Using a PIC Microcontroller for Series Motor Four Quadrants Drive DC Chopper Controllers for the Application in Electrical Vehicles 3.1 Introduction 3.2 Literature Review 3.3 Methodology 3.3.1 Embedded System of FQDC Controllers 3.3.2 Detailed Operation Function on Each of the Controllers 3.3.3 Simulation Software and Experimental Setup for Simulation and Experiment 3.4 Results 3.5 Conclusion References 4 Pre-weld Heating Temperature Effect on the Welding Quality of a 100 T Truck Crack Frame—Case Study 4.1 Introduction 4.2 Methodologies 4.2.1 Data Collection Method 4.2.2 Data Analysis 4.3 Discussion 4.3.1 Taguchi Analysis 4.4 Conclusions References 5 Features Extraction from a Second-Order Black Box Model Matched to the Veltink Model for a System Identification of Knee Extension for Control Law and Formulations of Close-Loop Controller Rehabilitation Using Functional Electrical Stimulation 5.1 Introduction 5.2 Literature 5.3 Methodology 5.3.1 Second-Order Black Box Model System 5.3.2 Second-Order System Features Extraction 5.3.3 Simulation Model Using Matlab/Simulink Function 5.4 Result and Discussion 5.5 Conclusions References 6 Analysis of an Adjustable Topside Mechanic’s Creeper for Automotive Repair and Maintenance Using Simulation Methods 6.1 Introduction 6.2 Literature 6.3 Methodology 6.3.1 Design Process 6.3.2 Design of Foldable Topside Mechanic’s Creeper 6.3.3 Simulation Analysis 6.4 Results and Discussion 6.4.1 Simulation Results and Discussion 6.5 Conclusions References 7 Potential Use of a Vibration Energy Harvester in Vehicles Using a Linear Motion Electromagnetic Suspension System 7.1 Introduction 7.2 Linear Electromagnetic Energy Harvesting in the Vehicle Suspension System 7.2.1 Electromagnetic Regenerative Shock Absorber 7.2.2 Tubular Linear Electromagnetic Transducers 7.2.3 Electromagnetic Linear Vibration Energy Harvester with Ferrofluid as a Lubricant 7.2.4 Hybrid Regenerative Shock Absorber 7.3 Discussion 7.4 Conclusion References 8 Performance Analysis of a Coated Porous Medium Burner for Cogeneration 8.1 Introduction 8.2 Literature 8.3 Methodology 8.4 Results and Discussion 8.5 Conclusions References 9 Child Safety in Car Crashes: A Modeling Approach for Safety System Improvements 9.1 Introduction 9.2 Literature 9.2.1 Application of Child Booster Seat to Prevent Child Injuries 9.2.2 Categorization of Child Car Seats 9.3 Methodology 9.4 Results and Discussion 9.5 Conclusion References 10 Modelling of Air-Gap Magnetic Flux Density Distribution for Surface-Mounted Permanent Magnet Synchronous Motor Using the Analytical Sub-Domain Method 10.1 Introduction 10.2 Literature Review 10.2.1 Sub-Domain Method 10.2.2 Airgap Flux Density for Slotless PMSM 10.3 Methodology 10.3.1 Motor Parameters and 2-D Design 10.3.2 Airgap Flux Density for Slotless PMSM 10.4 Results and Discussion 10.5 Conclusion References 11 Comparative Study on the Performance of Electrical Vehicles with DC Drive and Series Motor, DC Drive and Separately Excited DC Motor, and AC Drive and PMSM Motor. Part 1: Driving and Braking Operations 11.1 Introduction 11.1.1 Review Stage 11.1.2 DC Series Motor and Four Quadrants DC Chopper Four Series Motor 11.1.3 DC Drive EV Four Quadrants DC Chopper for Series Motor 11.1.4 DC Separately Excited DC Motor and Four Quadrants DC Chopper 11.1.5 DC Drive EV Four Quadrants DC Chopper for Separately Excited DC Motor 11.1.6 Four Quadrants Drive DC Chopper Operation Modes 11.1.7 AC Drive EV with PMSM Motor 11.1.8 Permanent Magnet Synchronous Motor Drive System 11.1.9 AC Drive EV Inverter 11.2 Methodology 11.2.1 Electric Car Motor 11.2.2 Vehicle Dynamics 11.3 Conclusion References 12 Overall Heat Transfer Coefficient of Different Coolants and Frontal Air Velocity in Automotive Radiators 12.1 Introduction 12.2 Literature 12.2.1 Coolants 12.2.2 Air Flow 12.3 Methodology 12.3.1 Experimental Setup 12.3.2 Data Analysis 12.4 Results 12.4.1 Effect of Coolant in Real Engine and Educational Test Rig 12.4.2 Effect of Frontal Air Velocity in Real Engine at Different RPM 12.5 Conclusions References 13 Magnetic Field Distribution for Single Coil Pulsed Linear Accelerator 13.1 Introduction 13.2 Literature Review 13.3 Methodology 13.4 Results and Discussion 13.5 Conclusion References 14 Formulations After Features Extraction of Veltink to Second-Order Critical Damped Black Box Model for Observer Formation Representing Knee Extension 14.1 Introduction 14.2 Methodology 14.3 Result and Analysis 14.4 Conclusion References 15 Optimization of Process Parameters in Electric Discharge Machining Wire-Cut of Magnesium Alloys Using the Taguchi’s Approach 15.1 Introduction 15.2 Literature 15.2.1 Magnesium Alloys 15.2.2 Electric Discharge Machine 15.2.3 Statistical Method 15.3 Methodology 15.4 Results and Discussion 15.5 Conclusions References 16 Design of Micro Turbocharger Runners for Automotive Application 16.1 Introduction 16.2 Literature Review 16.2.1 Design of a New Improved Intake Manifold for F-SAE Car 16.2.2 Simulation Analysis of Spark Ignition Engine Intake Manifold for Better Performance 16.2.3 Air Flow Behaviour on Different Intake Manifold Angles for Small 4-Stroke PFI Retrofit Kit System 16.3 Methodologies/Experimental Set-Up/Model Set-Up 16.3.1 Methodology Process 16.4 Results and Discussion 16.5 Conclusion References 17 Study on Ripple Current, Ripple Torque in Parallel Mode of Series Motor Four Quadrants DC Chopper for Electric Vehicles 17.1 Introduction 17.2 Review Stage 17.3 Methodology 17.4 Results 17.5 Conclusion References 18 Statistical Approach for Predictions of Motorcycle Engine Block Surface Roughness Property After CNC Machining 18.1 Introduction 18.2 Literature 18.2.1 Surface Roughness 18.2.2 CNC Milling 18.2.3 Cutting Speed 18.2.4 Feed 18.2.5 Depth of Cut 18.2.6 Cemented Carbide 18.2.7 Engine Cylinder Block 18.2.8 Response Surface Methodology 18.3 Methodology 18.3.1 Block Diagram of Surface Roughness 18.3.2 Block Diagram of CNC Milling Cutting 18.4 Results 18.5 Conclusion References 19 Contamination Control on Hydraulic Oil Excavator Using an Off-Board Filtering System—Case Study 19.1 Introduction 19.2 Methodologies 19.2.1 Data Collection Method 19.2.2 Data Analysis 19.3 Discussion 19.3.1 Taguchi Analysis of PC06 Response 19.3.2 Taguchi Analysis of PC14 Response 19.3.3 Taguchi Analysis of V100 Response 19.4 Conclusions References 20 Hardware Development for Zero Crossing of a Multilevel Single Phase Rectifier Chopper for Plug-In Electric Car Battery Charger Using a PIC Microcontroller 20.1 Introduction 20.2 Review Stage 20.2.1 Literature on Zero Crossing 20.3 Methodology 20.3.1 Hardware Application Circuit 20.3.2 Coding for Zero Crossing 20.3.3 Hardware Applications 20.3.4 Algorithm 2 20.3.5 Simulation Applications 20.3.6 Hardware Development 20.4 Conclusion References 21 Topology Optimization of an Engine Mounting Bracket Using Finite Elements 21.1 Introduction 21.1.1 Based on Application Aspects of Mounts 21.2 Methodology 21.2.1 Design Model 3D of Engine Mounting Bracket 21.2.2 Finite Element Analysis (FEA) 21.2.3 Modal Analysis 21.2.4 Topology Optimization 21.3 Result and Discussion 21.3.1 Comparison Result from FEA and EMA 21.3.2 Optimized Design Engine Mounting Bracket 21.4 Conclusions References 22 Air Conditioning System Comfort Level and Power Consumption Monitoring Device with RF-Based Wireless Sensor Modules and Android Mobile Application 22.1 Introduction 22.2 Literature 22.2.1 Thermal Comfort 22.2.2 Mobile Applications 22.3 Methodology 22.3.1 Project Planning 22.3.2 Fabrication 22.3.3 LCD Display Sample 22.3.4 Experimental Setup 22.4 Results and Discussion 22.5 Conclusions References 23 A Key Comparative Study Between a Self-Aspirated and an Air-Induced Porous Medium Burner 23.1 Introduction 23.2 Literature 23.3 Methodology 23.4 Results and Discussion 23.5 Conclusions References 24 Analysis of the Lower Control Arm in a Front Suspension System Using Finite Element Analysis and Analysis of Variance (ANOVA) Method 24.1 Introduction 24.2 Methodology 24.2.1 Three-Dimensional Design Model 24.2.2 Statics Structural Analysis of the Main Body Part 24.2.3 Load Impact Testing Experimental 24.2.4 Modal Analysis Simulation 24.2.5 Design Modifications 24.2.6 Determining Factor of Analysis by Using ANOVA Method 24.3 Result and Discussion 24.3.1 Modal Analysis with LMS Load Impact Testing Result 24.3.2 Statics Load Structural Analysis of Lower Control Arm 24.3.3 Statics Structural Analysis Result of the New Modified Result 24.3.4 Main Factor Analysis Result by using Analysis of Variance (ANOVA) 24.3.5 Comparison of Final Design and Existing Final Design Project 24.4 Conclusions References 25 Model of Effectiveness Earned Value Management in the Malaysian Manufacturing Sector 25.1 Introduction 25.2 Literature 25.2.1 Implementation EVM in a Project 25.2.2 Problem Using Earn Value Management 25.2.3 Benefit of Using EVM 25.3 Methodology 25.3.1 Design of Conceptual Model 25.3.2 Conceptual Model of Effectiveness in EVM 25.3.3 Conceptual Model of Effect of Benefit in EVM 25.3.4 The Complete Conceptual Model 25.4 Results and Discussion 25.4.1 Outer Loading Based on the Model 25.5 Conclusions References