Dr Charlie Gaylard

Charlie joined the AAPS CDT with a background in the motorsport industry. After graduating in Motorsport Technology in 2011, Charlie held operational roles including Production Controller and Design Coordinator within Formula 1 teams and composites specialists. In 2017, he returned to his studies in Automotive Engineering at the University of Brighton, where he played an integral role in the design and manufacture of a Formula Student chassis, with particular attention to ergonomics and regulatory compliance.

Following graduation, Charlie joined Mahindra Racing’s Formula E team as a Design Engineer, where he contributed to the development of the cooling system and inboard suspension components. His experience in Formula E inspired a deeper interest in the energy management of electrified propulsion systems which led him to AAPS where he saw an opportunity to deepen his expertise and contribute to improving efficiency and sustainability in automotive systems.

Outside of engineering and research, Charlie enjoys playing electric guitar, motorsport, occasionally surfing, and more recently has taken up in-door bouldering.

PhD Focus

Charlie’s PhD thesis, titled “Predictive Integrated Energy and Thermal Management for Advanced Propulsion Systems” investigates the use of predictive control strategies to improve energy efficiency and thermal safety in advanced vehicle propulsion systems. Sponsored by AVL and supervised by Dr Nic Zhang and Prof Chris Brace, the research relies on mathematical modelling and simulation.

The thesis examines two specific case studies: a hydrogen fuel cell hybrid bus and a battery electric vehicle with a multi-mode holistic thermal management system. Using deterministic Dynamic Programming, integrated cost functions are applied to identify optimal control strategies for managing propulsion power and thermal energy.

The work also investigates the potential for online predictive control and the effects of using shorter horizons vs full horizon-global optimisation to approximate the trade-offs with real-time implementation. The thesis provides insights into the potential application and the challenges for predictive optimisation to improve efficiency while maintaining system constraints such as temperature limits and passenger comfort in electrified vehicles.

Looking Forward

Charlie has continued his association with the University of Bath and has joined the IAAPS research institute as an engineer where he has been working on a range of projects in simulation and testing for both commercial and research purposes.

The Reflection on AAPS

Charlie reflects on his time with the AAPS CDT as transformative. Initially viewing automotive propulsion systems purely through an engineering lens, the CDT has helped him to appreciate the broader, multidisciplinary nature of the field including its intersections with business, policy, and social sciences. The CDT’s supportive structure helped ease his transition from industry to academia, and the collaborative community has been a highlight of his experience.

He’s particularly grateful for the regular seminars, guest lectures, and research incubators that foster learning and connection within the community. The PhD journey has also provided an exciting and thorough opportunity to test both resilience and perseverance, as well as understanding the importance of viewing problems from multiple disciplinary perspectives.