arXiv subjects

Theo Hofman

Publications and source records attributed to Theo Hofman.

At least 19 recordsLinked to original sources

arXiv2026

Geometric Scaling of Battery Cells and Its Effect on Key Performance Indicators

This paper presents a computationally lightweight scaling model for cylindrical lithium-ion battery cells, intended for early-stage battery design-space exploration. The model maps selected geometric and electrode-level design variables, including cell height, cell diameter, cathode active loading, and cathode porosity, to cell-level performance indicators such as capacity, DC internal resistance, mass, volume, and winding length. The scaling model is validated against available cylindrical cell data by comparing predicted capacity, internal resistance, and winding length. The validated model is subsequently used in a single-cell design-space exploration and global sensitivity analysis to evaluate capacity, internal resistance, gravimetric energy density, and volumetric energy density. The results identify the dominant design variables, favourable parameter directions, and key trade-offs between cell geometry, electrode loading, resistance, and energy density. The proposed model provides a basis for future integration into higher-level battery system and vehicle optimization frameworks.

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arXiv2026

Auto-DSM Under the Lens: A Black-Box Evaluation Framework for LLM-Based DSM Generation

This paper presents a black-box evaluation framework to systematically assess the ability of Large Language Models (LLMs) to generate Design Structure Matrices (DSMs) from structured technical documentation. Motivated by the closed-source nature of current Auto-DSM pipelines, the framework introduces a reproducible methodology that benchmarks generated DSMs (GEN-DSMs) against manually validated ground-truth matrices (GT-DSMs). The evaluation integrates both single-run and multi-run perspectives, combining structural metrics (Completeness, Correctness, Coupling Density), classification metrics (Selective Accuracy, Abstention Coverage), and stability measures (Entropy, Fleiss' $\kappa$). To synthesize these aspects, a Composite Quality Score (Q) is proposed. Controlled experiments are conducted on two datasets: a fictive abstract system and a real-world refrigerator decomposition, covering variations in phrasing, parameter-dataset alignment, and system complexity. Results show that LLMs can produce structurally plausible DSMs and achieve high reproducibility under well-structured inputs, but remain sensitive to ambiguity, inconsistent dependency definitions, and prompt formulation. The findings highlight systematic sources of hallucination and abstention failure, demonstrating both the potential and current limitations of LLM-driven DSM automation. The proposed framework provides a transparent benchmark for auditing Auto-DSM pipelines and establishes foundations for integrating LLM-based decomposition methods into model-based systems engineering (MBSE) workflows.

cs.AI↗

arXiv2026

A Decomposition-Based Framework for Joint Optimization and Spatial Packaging of Interconnected Systems with Physical Interactions

This paper presents an approach and application of optimization of spatial packaging of interconnected systems with physical interactions (SPI2) in three-dimensional component placement problems. To enable its application for an automotive use case, SPI2 must support both initial design generation, including component alignment, and robust system-level coordination, requiring improved solution reliability and tractable computational cost. To address these requirements, the proposed methodology improves convergence rate and solution quality by enhancing numerical robustness in gradient-based optimization while reducing computational load. Existing SPI2 approaches are extended through the addition of alignment capabilities, enabling the representation of port-to-port alignments between components. Furthermore, the applicability of SPI2 is expanded by treating component placement locations as design variables, allowing for penalty-based coordination to ensure design feasibility and enabling integration within system-level optimization. The approach is validated using a multi-objective optimization framework based on Nondominated Sorting Genetic Algorithm II (NSGA-II), applied to a combined powertrain optimization and battery chassis integration problem. This demonstrates the effectiveness of the SPI2 in a system-level design context. The results show a twofold application of SPI2 in an automotive use case: first, as a tool for initial design generation, and second, as part of a system-level design coordinator that outperforms a discretized exhaustive search while requiring lower computational cost.

cs.CE↗

arXiv2026

AI-Driven Synthesis for High-Tech System Design: Automating Innovation

This article addresses the combinatorial complexity inherent in modern high-tech system design by presenting automation-in-design (AiD) as a transformative paradigm. We propose computational design synthesis (CDS), a framework utilising deep learning and generative AI to automate the creation of novel systems. Two case studies (e-drive system design and spatial dimensioning problem) serve as proof-points for this approach. The AI-driven methods used in the case studies represent a fundamental shift in engineering, advancing from simulation-based optimisation towards autonomous design with minimal human supervision.

cs.AI↗

arXiv2026

An Optimal Power Management Policy for Hydrogen-based Hybrid Aero Engines

This paper presents a power management policy for a hydrogen-based hybrid aero engine combining a gas turbine and a solid oxide fuel cell (SOFC). Specifically, we first identify a quadratic quasi-steady-state model of the propulsion system and formulate the minimum-fuel optimal control problem as a function of the power split between gas turbine and SOFC that captures the interconnections between the components and accounts for their operational limits. Second, leveraging the Karush-Kuhn-Tucker optimality conditions and partial convexity and monotonicity model properties, we compute the globally optimal steady-state power split for the different phases of the flight in closed form. Finally, we verify this power management policy with a high-fidelity integrated static model %simulator across different flight phases, revealing in less than 1.5 % normalized root mean square error in power allocation and less than 0.7 % in predicted fuel consumption. Our results show that the optimal power management policy can be translated into a heuristic control law requesting the highest SOFC power that does not exceed its maximum operating temperature, ultimately paving the way for minimal-effort on-board implementations.

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arXiv2026

Optimization Models and Steady-State Minimum-Fuel Operating Strategies for Hydrogen-based Hybrid Electric Aerospace Propulsion Systems

This paper presents an optimization framework for the operation of hydrogen-based hybrid electric aerospace propulsion systems consisting of a hydrogen gas turbine and an electric motor powered by a solid oxide fuel cell, connected to the gas turbine via multiple gas channels and heat exchangers. Our framework computes the minimum-fuel optimal operating strategies over a flight mission accounting for the complex propulsion system with strong thermodynamic and mechanical coupling between components. First, we identify surrogate optimization models of the components employing high-fidelity model simulations. Second, we frame the minimum-fuel optimal control problem over a given flight mission and parse it into a static nonlinear optimization problem that can be efficiently solved with off-the-shelf nonlinear programming algorithms. Finally, we apply our optimization framework to a typical flight mission of an advanced, commuter aircraft (Beechcraft 1900D market segment), considering a parallel propulsion system architecture with four different configurations that share a common baseline but differ in the inclusion of an additional battery and by-pass valves around the two heat exchangers. The resulting optimal trajectories are validated against high-fidelity simulation results, demonstrating the accuracy of our framework. Results show that adding by-pass valves around the air and hydrogen heat exchangers can reduce fuel consumption by 19.11 % without the battery, and by 19.56% with the battery. We show that adding a battery yields a slight increase in fuel consumption (below 1%) for future projected energy densities under steady-state conditions. Conversely, when considering state-of-the art energy densities, the additional battery weight outweighs the benefits, limiting its potential applicability to only assisting transients, which are not considered in the present work.

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arXiv2026

Battery Electric Truck Infrastructure Co-design via Joint Optimization and Agent-based Simulation

As zero-emission zones emerge in European cities, fleet operators are shifting to electric vehicles. To maintain their current operations, a clear understanding of the charging infrastructure required and its relationship to existing power grid limitations is needed. This study presents an optimization frame-work for jointly designing charging infrastructure and schedules within a logistics distribution network, validated through agent-based simulations. We formulate the problem as a mixed-integer linear program and develop an agent-based model to evaluate various designs and operations under stochastic conditions. Our experiments compare rule-based and optimized strategies in a case study of the Netherlands. Results show that current commercial solutions suffice for middle-mile logistics, with central co-design yielding average cost reductions of 5.2% to 6.4% and an average 20.1% decrease in total installed power. While rule-based control effectively manages charging operations and mitigates delays, optimizing charge scheduling significantly reduces queuing times (99%), charging costs (13.5%), and time spent near capacity (10.9%). Our optimization-simulation framework paves the way for combining optimized infrastructure planning and realistic fleet operations in digital-twin environments.

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arXiv2026

Simultaneous Optimization of Electric Ferry Operations and Charging Infrastructure

Electrification of marine transport is a promising solution to reduce sector greenhouse gas emissions and operational costs. However, the large upfront cost of electric vessels and the required charging infrastructure can be a barrier to the development of this technology. Optimization algorithms that jointly design the charging infrastructure and the operation of electric vessels can help to reduce these costs and make these projects viable. In this paper, we present a mixed-integer linear programming optimization framework that jointly schedules ferry operations, charging infrastructure and ship battery size. We analyze our algorithms with the case of the China Zorrilla, the largest electric ferry in the world, which will operate between Buenos Aires and Colonia del Sacramento in 2025. We find that the joint system and operations design can reduce the total costs by 7.8\% compared to a scenario with fixed power limits and no port energy management system.

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arXiv2025

Meta-analysis of Life Cycle Assessments for Li-Ion Batteries Production Emissions

This paper investigates the environmental impact of Li-Ion batteries by quantifying manufacturing-related emissions and analyzing how electricity mix and production scale affect emission intensity. To this end, we conduct a meta-analysis of life cycle assessments on lithium-ion batteries published over the past two decades, categorizing them by year, battery chemistry, functional unit, system boundaries, and electricity mix. We then carry out a cradle-to-gate assessment for a nickel manganese cobalt 811 battery with a silicon-coated graphite anode, analyzing how variations in the carbon intensity of the electricity mix affect emissions, with case studies for China, South Korea, and Sweden. Finally, we develop a set of regression models that link annual battery production and the carbon intensity of China's electricity mix to the average mass-specific emissions observed each year. The meta-analysis shows a median global warming potential of 17.63 kg CO2-eq./kg of battery, with a standard deviation of 7.34. Differences in electricity mix mainly influence emissions from the energy-intensive cell production, particularly from cathode material processing. We found that a multivariate linear regression using production volume and the carbon intensity of the Chinese electricity mix as predictors explains emissions with moderate accuracy. The environmental impact of battery manufacturing can be reduced by using clean energy sources in production processes. However, achieving substantial reductions requires clean energy throughout the entire supply chain, as importing materials from regions with carbon-intensive electricity mixes can undermine these efforts. Our findings also highlight the emission-reducing effect of learning associated with increased production scale, supporting the integration of learning effects in future life cycle assessment models.

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arXiv2025

Optimal Co-Design of a Hybrid Energy Storage System for Truck Charging

The major challenges to battery electric truck adoption are their high cost and grid congestion.In this context, stationary energy storage systems can help mitigate both issues. Since their design and operation are strongly coupled, to make the best out of them, they should be jointly optimized. This paper presents a co-design framework for hybrid energy storage systems where their technology and sizing are optimized jointly with their operational strategies. Specifically, we consider a microgrid supporting truck chargers that consists of utility grid, solar panels, and energy storage systems including batteries, supercapacitors and flywheels. We frame the co-design problem as a mixed-integer linear program that can be solved with global optimality guarantees. We showcase our framework in a case-study of a distribution center in the Netherlands. Our results show that although the battery-only configuration is already competitive, adding supercapacitors or flywheel storage decrease total cost and increase energy sold back to the grid. Overall, the fully hybrid solution (Battery+Supercapacitors+Flywheel) offers the best outcomes, achieving the lowest overall cost (1.96\% lower compared to battery-only) and reduced grid dependency, but at a higher (2.6\%) initial investment.

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arXiv2025

Stochastic Model Predictive Control of Charging Energy Hubs with Conformal Prediction

This paper presents an online energy management system for an energy hub where electric vehicles are charged combining on-site photovoltaic generation and battery energy storage with the power grid, with the objective to decide on the battery (dis)charging to minimize the costs of operation. To this end, we devise a scenario-based stochastic model predictive control (MPC) scheme that leverages probabilistic 24-hour-ahead forecasts of charging load, solar generation and day-ahead electricity prices to achieve a cost-optimal operation of the energy hub. The probabilistic forecasts leverage conformal prediction providing calibrated distribution-free confidence intervals starting from a machine learning model that generates no uncertainty quantification. We showcase our controller by running it over a 280-day evaluation in a closed-loop simulated environment to compare the observed cost of two scenario-based MPCs with two deterministic alternatives: a version with point forecast and a version with perfect forecast. Our results indicate that, compared to the perfect forecast implementation, our proposed scenario-based MPCs are 13% more expensive, and 1% better than their deterministic point-forecast counterpart

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arXiv2025

Two-wheel-driven Electric Superbike Powertrain Optimization

In this paper, we propose an optimization framework for the powertrain design of a two-wheel-driven electric superbike, minimizing energy consumption. Specifically, we jointly optimize the force distribution between the wheels with the gear ratio, and rear motor and battery sizing while explicitly considering vehicle dynamics and performance constraints. First, we present an energy consumption model of the vehicle, including a scalable model of the electric machine based on data from the industry, accounting for iron, copper, and mechanical losses. Then, we analyze the propulsive blending strategy to distribute the required power to the wheels while considering adherence limits. Finally, we demonstrate the effectiveness of our approach by analyzing the design of a superbike, based on regulatory driving cycles and a custom high-performance circuit by comparing the force distribution approaches. The results underline the significance of joint optimization of powertrain components and propulsive bias, achieving a reduction of up to 22.36% in energy consumption for the Sport high-performance driving cycle.

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arXiv2024

A Framework to Estimate Life Cycle Emissions for Vehicle-Integrated Photovoltaic Systems

This paper presents a framework to estimate the environmental impact of solar electric vehicles, accounting for the emissions caused by photovoltaic system production as well as vehicle use. We leverage a cradle-to-gate life cycle assessment to estimate the greenhouse gas emissions of the vehicle-integrated photovoltaic system, from the raw material extraction to the final panel assembly, including the effect of the electricity mix both at the factory location and in the country of use. %the vehicle's life cycle, considering both Furthermore, we modify an existing optimization framework for battery electric vehicles to optimally design a solar electric vehicle and estimate its energy consumption. We showcase our framework by analyzing a case study where the mono-crystalline silicon extraction and refinement processes occur in China, while the final assembly of the panel is in The Netherlands, generating 118 kg of CO2 equivalents per square meter of solar panel. The results suggest that it is generally beneficial to operate solar electric vehicles in countries with a high irradiation index. However, when the local electricity mix already displays a low carbon intensity, the additional emissions introduced by the panel are unnecessary, requiring a longer vehicle lifetime to reach an advantageous emission balance.

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arXiv2024

Geometric Scaling Laws for Axial Flux Permanent Magnet Motors in In-Wheel Powertrain Topologies

In this paper, we present geometric scaling models for axial flux motors (AFMs) to be used for in-wheel powertrain design optimization purposes. We first present a vehicle and powertrain model, with emphasis on the electric motor model. We construct the latter by formulating the analytical scaling laws for AFMs, based on the scaling concept of RFMs from the literature, specifically deriving the model of the main loss component in electric motors: the copper losses. We further present separate scaling models of motor parameters, losses and thermal models, as well as the torque limits and cost, as a function of the design variables. Second, we validate these scaling laws with several experiments leveraging high-fidelity finite-element simulations. Finally, we define an optimization problem that minimizes the energy consumption over a drive cycle, optimizing the motor size and transmission ratio for a wide range of electric vehicle powertrain topologies. In our study, we observe that the all-wheel drive topology equipped with in-wheel AFMs is the most efficient, but also generates the highest material cost.

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arXiv2024

System-level thermal and electrical modeling of battery systems for electric aircraft design

This work introduces a framework for simulating the electrical power consumption of an 8-seater electric aircraft equipped with high-energy-density NMC Lithium-ion cells. We propose an equivalent circuit model (ECM) to capture the thermal and electrical battery behavior. Furthermore, we assess the need for a battery thermal management system (BTMS) by determining heat generation at the cell level and optimize BTMS design to minimize energy consumption over a predefined flight regime. The proposed baseline battery design includes a 304-kWh battery system with BTMS, ensuring failure redundancy through two parallel switched battery banks. Simulation results explore the theoretical flight range without BTMS and reveal advantages in increasing battery capacity under specific conditions. Optimization efforts focus on BTMS design, highlighting the superior performance of water cooling over air cooling. However, the addition of a 9.9 kW water-cooled BTMS results in a 16.5% weight increase (387 kg) compared to no BTMS, reducing the simulated range of the aircraft from 480 km to 410 km. Lastly, we address a heating-induced thermal runaway scenario, demonstrating the robustness of the proposed battery design in preventing thermal runaway.

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arXiv2024

Multi-layer optimisation of hybrid energy storage systems for electric vehicles

This research presents a multi-layer optimization framework for hybrid energy storage systems (HESS) for passenger electric vehicles to increase the battery system's performance by combining multiple cell chemistries. Specifically, we devise a battery model capturing voltage dynamics, temperature and lifetime degradation solely using data from manufacturer datasheets, and jointly optimize the capacity distribution between the two batteries and the power split, for a given drive cycle and HESS topology. The results show that the lowest energy consumption is obtained with a hybrid solution consisting of a NCA-NMC combination, since this provides the best trade-off between efficiency and added weight.

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arXiv2024

Multi-objective Optimal Trade-off Between V2G Activities and Battery Degradation in Electric Mobility-as-a-Service Systems

This paper presents optimization models for electric Mobility-as-a-Service systems, whereby electric vehicles not only provide on-demand mobility, but also perform charging and Vehicle-to-Grid (V2G) operations to enhance the fleet operator profitability. Specifically, we formulate the optimal fleet operation problem as a mixed-integer linear program, with the objective combining of operational costs and revenues generated from servicing requests and grid electricity sales. Our cost function explicitly captures battery price and degradation, reflecting their impact on the fleet total cost of ownership due to additional charging and discharging activities. Simulation results for Eindhoven, The Netherlands, show that integrating V2G activities does not compromise the number of travel requests being served. Moreover, we emphasize the significance of accounting for battery degradation, as the costs associated with it can potentially outweigh the revenues stemming from V2G operations.

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arXiv2024

Ride-pooling Electric Autonomous Mobility-on-Demand: Joint Optimization of Operations and Fleet and Infrastructure Design

This paper presents a modeling and design optimization framework for an Electric Autonomous Mobility-on-Demand system that allows for ride-pooling, i.e., multiple users can be transported at the same time towards a similar direction to decrease vehicle hours traveled by the fleet at the cost of additional waiting time and delays caused by detours. In particular, we first devise a multi-layer time-invariant network flow model that jointly captures the position and state of charge of the vehicles. Second, we frame the time-optimal operational problem of the fleet, including charging and ride-pooling decisions as a mixed-integer linear program, whereby we jointly optimize the placement of the charging infrastructure. Finally, we perform a case-study using Manhattan taxi-data. Our results indicate that jointly optimizing the charging infrastructure placement allows to decrease overall energy consumption of the fleet and vehicle hours traveled by approximately 1% compared to an heuristic placement. Most significantly, ride-pooling can decrease such costs considerably more, and up to 45%. Finally, we investigate the impact of the vehicle choice on the energy consumption of the fleet, comparing a lightweight two-seater with a heavier four-seater, whereby our results show that the former and latter designs are most convenient for low- and high-demand areas, respectively.

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