Digital twin-driven intelligent design and fabrication of the energy-efficient wiper prototype for electrical vehicle

Abstract Electric vehicles (EVs) have gained popularity due to its efficiency, low emissions, and reduced noise. However, limited driving range, or range anxiety, remains a challenge, as all EV accessories rely on battery power. This study proposes a digital twin-driven methodology to design energy-efficient wipers, addressing this issue. Five driving modes are proposed, the authors analyzed wiper motor energy consumption through both experimental test and digital modeling, and compared with the traditional wiper drive mode, the results show potential efficiency improvements of up to 33%, demonstrating significant energy-saving opportunities. This study also examines wiper vibration properties and develop contact models to create quieter prototypes. This research guides the design of energy-efficient EV accessories, potentially easing range anxiety and improving overall performance. The approach could be applied to other EV components to further enhance efficiency and driving range.