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PEMP AEL2501
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Objectives
At the completion of this session, the delegates will understand and will be able to appreciateappreciate
The need for Hybrid automobiles The working principles of hybrid vehicles. Advantages and limitation and related issues
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Topics
Hybrid vehicles Introduction Hybrid system design Potential areas for efficiency improvement Types of Hybrid Vehicles Hybrid Vehicle Components Control Systems in Hybrids
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Hybrid Vehicles
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Background: In early days of automobiles competition between vehicles powered b IC engines and vehicles d by i d hi l powered by electricity. IC engine powered vehicles, electricity powered vehicles and steam cars were sold in the US (1890-1905) Work of the pioneers like Edison, Tesla and Westinghouse contributed to electric vehicle development. Limited range of EVs was not an issue for the small cities of that period 4
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Limitations of batteries - range and utility of EVs. Some developers went straight to IC engine powered vehicles. Some tried to marry the advantages of EVs and th internal combustion engine into d the i t l b ti i i t Hybrid vehicle First hybrid vehicle was built in 1898 and several vehicles were sold in 1900s Hybrid vehicles had significant problems:
Require two propulsion systems consumes
more space, add weight and greatly increases cost.
Careful coordination of the engine and motor was necessary for achieving much of the efficiency efficienc benefits and tackle drivability dri abilit problems (mechanical systems).
Thus, the EVs did not survive the continued development of IC engines. (early 1900s) What happened next?
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GM Hybrid System - Aura Green Lines hybrid powertrain is rated at 164 horsepower (122 kW) at 6400 rpm and 159 lb.-ft. (215 Nm) of peak torque at 5000 rpm.
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GM Hybrid system - Aura Green Lines hybrid powertrain is rated at 164 horsepower (122 kW) at 6400 rpm and 159 lb.-ft. (215 Nm) of peak torque at 5000 rpm. While maintaining the vehicle s sporty feel, the GM vehicles feel Hybrid system seamlessly reduces fuel consumption by:
Shutting off the engine when the vehicle is stopped, to minimize idling Restarting the engine promptly when the brake pedal is released Enabling early fuel shut-off during vehicle deceleration Capturing vehicle kinetic energy during deceleration through regenerative braking to charge the advanced nickel metal hydride battery Performing intelligent battery charging when it is most efficient
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Efficiency benefits:
The average efficiency of a gasoline IC engine driven automobile in a typical use:
Only about 15 % O h 85% i lost to Other is l
Engine heat Heated exhaust gases Aerodynamic drag Tire rolling resistance Driveline losses Braking
Combining electric motor and energy storage to the IC engine significantly improves efficiency in several ways depending upon the system design
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Idle-off
Average vehicle idles approximately 18-20% of the time in a city driving condition Stopping the engine at idle can reduce fuel consumption by about 5-8 pp g g p y %. [ time to restart] More fuel can be saved by cutting of the fuel during deceleration More powerful motor can restart the engine much more rapidly than a conventional starter motor and modern computers and fuel injection have solved the startup problems. A 3-5 kW motor can spin the engine up to normal idle speed in less than 500 ms F l control can eliminate un-burnt fuel and its hydrocarbon Fuel t l li i t b t f l d it h d b emissions. Idle-off systems need little energy storage and can be implemented with relatively small, low cost battery packs
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Regenerative Braking
When the vehicles slowdown or stops a large amount of kinetic stops, energy is lost mainly in the form of heat The energy is lost to friction
Primarily in the brakes To Mechanical friction losses in the engine
An electric motor can be used as a generator to capture some of this energy. This mode of operation of the motor is used to recharge the energy storage device. Most accelerations and decelerations are relatively mild and relatively of small duration duration. An electric motor of about 10 20 kW, depending on the size of the vehicle is sufficient for this purpose
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Large regenerative braking rates must be coordinated properly with friction brakes of the vehicle to avoid large deceleration or jerk in the forwards and backwards
Other issues:
Cost of the system and incremental efficiency benefits
[ motor and storage system].
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Engine Downsizing The power required for a vehicle is mainly dependent on:
Vehicle speed Load Operating condition
The peak power is required infrequently In hybrid systems, the electric motor can provide a power boost when appropriate, enabling the use of a smaller engine without degrading performance
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Usually a smaller engine is more efficient for a given load because it has Lower frictional losses L heat loss to engine block and cylinder Less h l i bl k d li d Lesser pumping losses [WOT operations]
Incremental efficiency benefit from the engine downsizing is roughly proportional to the incremental cost of the energy storage and electric motor (need for a trade off) But this does not translate into proportional costeffectiveness of the entire system. ff i f h i
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Engine Efficiency Engines are least efficient when operating at low loads or part loads A hybrid system can be designed to help keep the engine at higher loads and minimize engine operation during less efficient modes. Some examples:
Motor supplying power at low vehicle speeds and loads, engine shut-off. The high torque of the motor allows the engine to turn slower, and hence more efficiently, during the highway driving while maintaining adequate acceleration
Careful integration of the electric motor and transmission can allow the engine to operate at higher efficiency speed and load points. If additional charging of the battery pack is needed beyond that provided by regenerative braking, the engine could be controlled to id d b ti b ki th i ld b t ll d t supply the additional energy under higher engine efficiency modes. There are trade-offs with all of the potential efficiency benefits
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Electrical accessories The additional power in hybrid vehicles can be used to improve the efficiency of engine accessories, such as
Air conditioning compressor Power steering pump Water circulation pump and so on.
Currently all these are generally driven by engine (speed dependency) Using electric motors to power accessories allows them to be operated independently of the engine and only as needed The increase in overall vehicle efficiency could be in the range of 5 10 %
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IC Engine
Generator
Motor
Electric motor a single source of power for traction The engine drives a generator; never drives the vehicle The generator i turn generates electricity h in l i i The energy storage device may be charged by the generator output or by using the regenerative braking The configuration usually is set up with a small engine that provides a range-booster to a large battery pack
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Low on emissions and has excellent efficiency during stopand-go driving (minimizes inefficient engine operation and maximizes energy recaptured
from regenerative braking)
If the engine is used as primary source of power, double conversion increases the inefficiencies Many hybrids use combination of series and parallel hybrid
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Both engine and motor are connected directly to the drivetrain Highest efficiency range of each is selected and used, i h ffi i f hi l d d d depending upon the operating conditions
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Parallel hybrid system is more complicated as it poses more challenges in integration of two power sources The major advantage is that large efficiency gains can be derived with even a relatively small energy storage (weight
reduction)
Minimizes cost of energy storage and performance penalty from additional weight weight. There are two other variations of series and parallel configurations:
Th Through-the-road Hybrid h h d H b id Fuel Cell Hybrid
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Through-the-road Hybrid
An interesting configuration:
one set of wheels are powered by the engine Another set of wheels powered by electric motor
This system is called as Through-theroad Parallel Hybrid because the two power sources are run in parallel by independently driving different wheels The interaction between the IC engine and electric drive is completely done by wire and either of the systems can be turned off to drive the vehicle as an y electric or ICE system The main advantage - it adds part-time all-wheel-drive (AWD) capability. It also allows more flexibility in mounting locations of the motor But, it adds considerable complexity and cost
Motor
IC Engine
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BLDC Motor 100 kW, oil cooled BLDC motor for automotive application. Weight is 21 kg
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Honda Civic Motor The electric drive motors used in hybrids are hightorque heavy-duty permanent magnet motors. These compact, but powerful, dynamos operate on power raging up to about 650 volts. M.S Ramaiah School of Advanced Studies - Bangalore
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Energy Storage
Battery packs are the primary type of energy storage for hybrid vehicles Usually designed for hybrid vehiclesvehicles
With higher power density and Sized to deliver sufficient power without overheating.
Ultra Capacitors are high power versions of electrolytic capacitors - Store energy as an electrostatic charge. They have features like
Rapid transfer of power Potential for better durability Lower cooling requirement
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Example of an Ultra-capacitor
Honda uses an Ultra-capacitor in its Fuel Cell powered vehicle FCX. The ultra-capacitor serves as a supplementary power source to the main power source for more powerful performance under various driving conditions. It stores energy produced during deceleration and braking and provides powerful drive assist during startup, acceleration and at other times when an extra boost is required.
HONDA Ultra Capacitor Module
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Batteries
Various types of batteries are developed based on different technologies. Th lead acid battery is the most well known The l d id b i h ll k rechargeable type. Types of batteries include:
Lead acid Nickel metal hydride Nickel ion Nickel cadmium Lithium polymer Lithium ion Sodium sulfur Sodium metal chloride and so on.
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From the designers point of view the battery can be treated as a black box which has a range of performance criteria These criteria will include:
Specific energy (Wh.kg1) Energy density (Wh.m3) Specific power (W.kg1) Typical voltages Amp-hour efficiency (charging efficiency is less than 100%) Energy efficiency Commercial availability Cost Operating temperatures Self-discharge rates number of life cycles Recharge rates, and so on..
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Lithium-Ion batteries Higher power and energy level than NiMH battery Better low-temperature performance Toyota Li-Ion Battery Low self-discharge rate self discharge Need improvement in
Cycle life Durability Cost
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Regenerative Brakes
Regenerative braking allows a motor to act as a generator when coasting or braking Kinetic energy that normally would be wasted during braking is converted into electrical energy to recharge the battery The energy conversion is achieved within the integrated motor / generator units. While the brake pads and rotors stop the wheels at high speed or in emergency situations, the regenerative braking system slows the vehicle in normal driving
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Gasoline engines
The hybrid car has a IC engine much like the one found on conventional cars H However, th engine on a the i hybrid will be smaller and will use advanced technologies to reduce emissions and increase efficiency These are matched with efficient, electronically controlled transmissions
Epicyclic gear train CVT and so on
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Coil-on spark plug or waste spark ignition system ETC (drive-by-wire)- better control of engine operation Variable valve timing and lift mechanisms- improved performance at wide operating range Exhaust after treatment system for further reduction in emissions
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Throttle Body
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Stop-Start System
For a conventional vehicle, it is possible to implement to Stop-Start system (micro hybrid, Idle off) The system uses a redesigned conventional starter motor, and ECU, couple of sensor and CAN interface with the vehicle CAN bus. The ECU monitors various parameters like the battery condition, transmission status, clutch pedal travel sensor, Ignition key position and other safety interlock signals.
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ECU
Battery Sensor Indicator Lamp
Enable / Disable
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Power Electronics and Control DC motors generally use 3-phase motor windings. g 3 switching modules control the current flow to the proper windings as the motor turns. The switches must be able to rapidly and accurately turn large amounts of current on and off as well as the controlling the direction and phase of the current. P d Produces a l large amount of heat thus needs a t f h t th d cooling system. Size and cost is substantial
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Converters Converters (DC-to-DC) alter voltage up or down as needed for various components. This may require changing the battery voltage which may range from 144V to 488V to as low as 12V to power the lights, accessories and convenience systems, or step it up to as high as 650V to power drive motors. Inverters Inverters convert DC to AC for the purpose of driving AC motors Cooling Systems Battery pack and power electronics produces large amount of heat that needs to be cooled. g g g g y Charging and discharging a battery involves chemical reactions that generate heat as a byproduct. This heat degrades performance and shortens life. Efficient cooling system is required to cool both
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These controllers have to decide the most efficient mode of vehicle operation depending on the prevalent driving conditions and energy resources. This action has to be transparent to the driver
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EPA estimated M.S Ramaiahfuel economy rating of 49/51 mpg city / highway School of Advanced Studies - Bangalore
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Battery Module-(BM), Battery Condition Monitor-(BCM), Motor Control Module-(MCM), Power Control Module(PCU), Motor drive Module-(MDM), Voltage Converter Module, DC/DC Converter 48
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Summary
The historical background of Hybrid vehicles and need for hybrid vehicles have been studied Various configurations of hybrid vehicles have been explained Main components of hybrids, their use have been discussed with examples in a vehicle
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