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Function analysis provides the backbone of systems engineering design and underpins the use of Design for Six Sigma and Failure Mode Avoidance tools. Identification and management of interfaces is a key task in systems engineering design, in ensuring that the system achieves its functions in a robust and reliable way. The aim of the work presented in this paper was to develop and implement a structured approach for function analysis of a complex system, which focuses on the identification and characterization of interfaces. The proposed approach is based on the principle of separation of the functional and physical domains and development of function decomposition through iteration between functional and physical domains. This is achieved by integrating some existing / known engineering tools such as Boundary Diagram, State Flow Diagram, Function Tree and an enhanced interface analysis within a coherent flow of information.

Tata Motors Limited plan to launch a range of full electric vehicles (FEVs) to the European market. Regenerative braking is advantageous in maximising range between recharging, but presents challenges of acceptable performance, weight, cost and the ‘blending’ of regenerative braking with friction braking. Control systems for regenerative braking have been developed by manufacturers to enable recuperation of kinetic energy which would otherwise be converted to heat and wasted through the use of friction brakes. This paper presents the approach taken by Tata Motors Ltd. to optimise the design and operation of a regenerative braking system to maximise range and energy efficiency. The Tata Ace EV is a Class N1 light commercial FEV with drive to the rear wheels only. This presents the challenge of harvesting energy from the axle which contributes a varying amount of the vehicle braking effort depending upon load.