Heavy-Duty Electric Vehicles: From Concept to Reality

EVs.

Preface

Abstract

This book presents and discusses a step-by-step guide for designing heavy-duty electric vehicle powertrain; from defining the subsystems and component selection to final integration and vehicle supervisory control system design. This book not only discusses technical aspects of motors, power electronics, batteries and vehicle dynamics; it also explains various aspects of integrating all these systems in a real application.

The book is divided into three main sections: 1. EV Drivetrain; 2. HV Energy Storage and Charging; and 3. EV Control Systems. It is believed the book will be of particular interest to system designers and application engineers active in this field. It would also help the decision-makers in making an informed choice about the most suitable powertrain for their niche application.

Keywords

Heavy-duty vehicles, Electric buses, Electric trucks, Powertrain, Standards and regulations, Electric vehicle policy, High voltage systems, Drivetrain topology, Electric motors, Battery pack manufacturing, Wireless charging, Battery management system

A battery electric city bus can be classified as the first on-road application of an electric powertrain technology that is both profitable and sustainable owing to fixed operating routes and schedules for a city bus, which results in a high utilization rate of the available battery capacity of an electric bus. Regarding freight transportation, trucks accounted for only 2% of the on-road vehicles in the European Union in the year 2020 yet were responsible for more than 22% of the total greenhouse gas emissions in the same year. Electrification of heavy-duty vehicles is crucial for containing the emissions from the road transport sector and for meeting the climate action goals.

Challenges to the electrification of heavy-duty road vehicles come from a lack of clear understanding of the government policies, R&D direction, and uncertainty around the performance of various subsystems in an electric powertrain, for example, durability of the battery pack under a range of conditions or the cost of charging infrastructure and its effect on the electric grid. Finding the right technological solution is the key to the successful integration of electric buses and electric trucks in existing public transportation networks, that is, without any negative impact on their daily performance. To that end, this book presents and discusses a detailed methodology for designing heavy-duty electric vehicle (EV) powertrain, from defining the subsystems and component selection to final integration and vehicle supervisory control system design. This book not only discusses technical aspects of motors, power electronics, batteries, and vehicle dynamics; it also explains various aspects of integrating all these systems in a real application.

The book provides a step-by-step heavy-duty EV concept design and development guide, suitable for engineers and people who are interested in the fast-growing EV industry. To begin with, Chapter 1 provides an overview of various standards and regulations established by different governing bodies to direct the research, design, and development process of EVs. Furthermore, a variety of subsidies announced by different countries and agencies to accelerate the introduction and adoption rate of heavy-duty EVs around the world are also comprehensively discussed in Chapter 1. The remainder of the book is divided into three main sections: (1) EV Drivetrain; (2) HV (high-voltage) Energy Storage and Charging; and (3) EV Control Systems. Chapter 2 describes various EV drivetrain (electric motor and its inverter drive) configurations and discusses their advantages and disadvantages for heavy-duty EV applications. This is followed by Chapter 3, which offers an explanation on the design process and selection of electric motor and drivetrain components parameters. Key discussed topics in this chapter are EV drivetrain topologies, suitable motor types, and motor-generator specification using load cycle data.

Battery technologies are the core of EV technology. Therefore the energy storage section focuses on aspects that are central to engineering of reliable battery packs such as material selection, manufacturing method, and packaging design. Chapter 4 shares insights on advancements made in materials domain, with an aim to develop next generation Li-ion batteries. It also introduces various advanced manufacturing methods, for example, 3D-printing, the dry electrode method, and cell-to-pack technology, which have the potential to push the development boundaries further. On the other hand, Chapter 5 discusses the creation of a robust electrical connection network and designing of appropriate battery packaging and support systems. Correspondingly, various design rules and elements of high-voltage systems needed to contain electric shock hazards are also described. In line with this, the chapter also presents possible means of limiting vibration transmission to battery packs and increasing their thermal stability. The standard procedure for testing propensity of battery packaging designs to thermal runaway propagation is briefly explained. Last, battery swapping mechanisms are covered. Chapter 6 aims to provide readers with an understanding of the charging and discharging processes and state-of-the-art charging technologies. Conductive charging is introduced as the most common and technically feasible technology for charging of the heavy-duty EVs. Nevertheless, the potential of emerging static and dynamic wireless charging technologies is also discussed. Then, charging levels and standards applied in different countries are introduced. The section closes with an analysis of impacts of EV charging system on the electric grid.

Proper functioning of EV control systems is essential to guarantee a smooth and successful operation of EVs on the road. They provide a fail-safe mode that limits damage to critical systems of the vehicle during a failure event. In view of this, Chapter 7 discusses various EV drivetrain operation modes, and explains their respective torque control strategies. Also, heavy-duty EV drivetrain torque mapping strategies in drive mode and brake mode are presented, and zero torque conditions are explained. Ultimately, specific control parameterizations required in inverter drive for optimal performance of the motor are briefly explained, and the methods to set them are introduced in this chapter. Chapter 8 describes the architecture of the battery management system and provides a comprehensive discussion on its essential functionalities, which include charge balance, temperature regulation, and data storage. Basics of heat generation estimation in batteries are also explained along with the temperature regulation methods. Chapter 9 describes the vehicle control structure for an EV application. It explains the concept of EV supervisory controller internal control layers in detail. After that, it discusses supervisory controller power management strategies for optimal performance of the heavy-duty EVs.

The book finishes by taking a close look at various technical, financial, and institutional challenges that impede the large-scale deployment of heavy-duty EVs in Chapter 10. Some technological changes are being planned to overcome these barriers. A brief introduction about some advancements that are in the pipeline is offered in the end.

Authors have extensive academic and industrial research and development experience in various EV design and development projects and have tried to share their knowledge within the context of heavy-duty vehicles. That being said, they anticipate that shared knowledge is directly transferable to nonroad mobile machinery. It is believed the book will be of particular interest to system designers and application engineers active in this field. It would also help the decision-makers in making an informed choice about the most suitable powertrain for their niche application. Last, it is hoped that the book will inspire the young graduates and engineers to make long-term commitments to the EV technology to build a greener future for humankind.

If your tree gains the fruit of knowledge,

You will bring down the lotus sky.

Naser Khosrow (1004–1088 CE)

Chapter 1: Heavy-duty Electric Vehicles and Society

Abstract

Electrification of public and freight transport systems is crucial for meeting the climate action goals. This chapter provides an overview of various standards and regulations established by different governing bodies to guide the design and development process of electric vehicles (EVs). They are also used to measure the delivered performance and to assess their safety ratings. In addition, a comprehensive discussion on a variety of subsidies announced by different countries and agencies to accelerate introduction and adoption rate of heavy-duty EVs around the world is offered. Noteworthy is that these subsidies and different regulations are connected to vehicle classification according to weight. To that end, the foremost challenge while deploying heavy-duty EVs is to maintain the same level of service as an equivalent diesel bus or truck. A practical example of this challenge is the passenger cabin design in e-buses, that is, with a fixed gross vehicle weight rating despite the additional weight of the battery packs, how can we maintain equivalent passenger capacity and comfort in e-buses?

Finding the right technology and solution for the targeted application is the key to successful integration of e-buses and e-trucks in existing public transportation networks, that is, without any negative impact on their daily performance. The remainder of this book provides information that serves this purpose.

Keywords

Heavy-duty vehicles; Electric trucks; Public transportation system; Freight transportation system; International regulations and design standards; Government policies and subsidies; China and United States; Europe; India; FAME scheme

1.1: Introduction

Electromobility is the concept of using electric powertrain for transporting people and goods with a view to support sustainable development. According to the United Nations Global Technical Regulations No. 20, electric powertrain refers to electric circuits comprising traction motors, rechargeable energy storage system (RESS), power electronic converters, associated connectors and wiring harness, and the coupling system for charging the RESS [1]. The European Union (EU) aims to lower their greenhouse gas (GHG) emissions from the transport sector by 60% by the year 2050 in comparison to the 1990 levels [2]. Electromobility enables improving air quality and reducing dependency on fossil fuels, which in turn allows addressing climate change concerns.

In the United States (US), travel by bus contributes 48% toward the public transportation usage. Average transit bus emits only 0.29 kg of carbon dioxide (CO2) per passenger mile in comparison to an average single-occupancy private vehicle that emits 0.44 kg of CO2 per passenger mile. CO2 emissions from the transit bus drop further down to 0.08 kg per passenger mile when the number of passengers in the bus is such that all the seats are taken [3]. The mass transit system is undoubtedly a cleaner alternative when compared with private vehicles. US federal law defines the mass transit system, also known as public transit, or mass transportation or public transportation system, as regular, continuing shared-ride surface transportation services that are open to the general public defined by age, disability, or low income [4]. To realize its complete benefits though, it is essential that the full capacity of the public transit system is utilized. However, public transportation system providers have struggled with decreasing ridership in the past few years owing to factors such as employment and residential decentralization, growing automobile availability, coupled with rising incomes. Therefore, investment in zero-emission or electric buses (e-buses) should be encouraged to isolate the effect of vehicle occupancy on its emission level.

All logistics and supply chain systems depend on goods or freight transportation. Ability to move goods from one site to another allows consumption to occur at a different location from production. Demand is generated by people and businesses that need finished products, supplies, or raw materials; this group is called shippers. Freight transportation service is provided by another group called carriers. Carriers are owners or operators of transport machines, such as trains, trucks, airplanes, and ships. Cargo characteristics and length of haul influences the transportation mode choice made by the shippers. Generally, air freight is used for transporting high-value goods that need to be delivered within a few hours. It is the costliest of all the modes. Railroads and marine transport carry slow-moving, low-value bulk cargo over long distances. In contrast, trucks provide a flexible and rapid transport service for high-value commodities, predominantly in short-haul movements at a slightly higher cost than railways. Trucks also provide the last-mile transport, that is, connect shippers to other modes of freight transport. Since the year 2000, emissions from trucks have risen at a rate of 2.2% annually. In the year 2020, trucks accounted for only 2% of the vehicles on-road yet emitted 22% of the total GHG emissions from the road transportation sector in the EU [5]. The strong economy has created a surge in demand for freight transportation causing an increase in trucking activity. The trend is expected to increase, which means that we will struggle to meet the commitments made in Paris Agreement until we decarbonize the road freight or trucks [6]. This chapter provides an overview of various standards and regulations developed to guide the design of electric vehicles (EVs). It also outlines various government policies implemented so far to support the introduction of heavy-duty EVs in some of the major EV markets globally.

1.2: Vehicle classification

Heavy-duty vehicles (HDV) used for road-based transportation can be classified into different streams, as shown in Fig. 1. They are briefly explained in the following text:

1.Length: The easiest way to differentiate between different buses is based on their chassis length. The commonly used categories are as follows:

•minibuses are buses with a length between 6 and 8 m

•midibuses have a length between 8 and 10 m

•standard buses include all buses longer than 10 m

Some buses with chassis length smaller than 6 m are also available; for example, Volkswagen Microbus.

2.Weight: Gross vehicle weight rating (GVWR) is a safety criterion and represents the maximum weight that a vehicle can operate without overloading. This manufacturer specified limit includes payload capacity in addition to its curb weight.

Fig. 1 Classification of electric vehicles.

According to the European Commission’s memo—dated May 21, 2014, Category M vehicles, that is, passenger transport vehicles, having more than eight seats are considered HDV. For freight transport or Category N vehicles, heavy-duty classification refers to vehicles weighing more than 3.5 tonnes. Comparatively, there is more granularity in the vehicle classification system defined by the US Environmental Protection Agency (EPA) [7]. Table 1 presents definitions of each of the categories listed by the EPA. However, industrial practice regards vehicles with GVWR up to 6.35 tonnes as light-duty vehicles (LDV), and medium-duty vehicles (MDV) are those with GVWR between 6.351 and 11.793 tonnes. Last, HDV include all vehicles with a GVWR equal to or more than 11.794 tonnes [8].

3.Charging capability: Depending on the battery chemistry employed, e-buses can either allow charging at normal rates, or they can be fast-charged. The former typically employs lithium iron phosphate (LFP), lithium manganese oxide (LMO), nickel cobalt aluminum oxide (NCA), and nickel manganese cobalt oxide (NMC) chemistries, whereas the latter uses lithium titanate oxide (LTO) batteries. Supercapacitors (SCs) can also be used in fast-charging e-buses. The maximum charging rate for normal charging is 1C. In contrast, rates greater than 3C are relatively standard in fast charging [9]. C-rate is a measure of applied or drawn current relative to the rated capacity of the battery. 1C-rate signifies a current that will charge or discharge the battery in 1 h. Fast-charging e-buses use relatively smaller battery packs because they can be charged quickly at any opportune moment. Others may allow swapping of their battery packs. Furthermore, induction coils can be integrated into the charging infrastructure to charge the battery packs wirelessly. Trolleybuses, that is, e-buses that derive power from overhead cables, are also available in the market. At the end of the year 2017, more than 40% of e-buses in China had a fast-charging option, and only 33% of the e-buses belonged to the normal charging category [10].

Table 1

Please note that the original classification is based on GVWR in pounds. Weight (in pounds) is divided by 2000 to convert it to weight in tonnes. LVW (loaded vehicle weight) = vehicle’s curb weight + 150 kg; ALVW (adjusted loaded vehicle weight) = average of vehicle’s curb weight and GVWR [7].

1.3: Standards and regulations

A standard is a document that defines a specific procedure or method in detail and sets out requirements for a component, material, item, system, or service. There are national standards and those of international relevance. The international standards for EVs are developed and issued mainly by the ISO (International Organization for Standardization), the IEC (International Electrotechnical Commission), and the SAE (Society of Automotive Engineers). In these organizations, technical committees are charged with the responsibility of preparing different standards. They establish working groups to develop specific portions within a target