Renewable Energy Series 7 Propulsion Systems for Hybrid Vehicles 2nd Edition Worldwide, the automotive industry is being challenged to make Dr John M. Miller PE is vice president 2nd Edition for Hybrid Vehicles Propulsion Systems dramatic improvements in vehicle fuel economy. In Europe there of systems and applications at Maxwell are CO2 emissions penalties prorated by the degree to which Technologies. He is also founder and principal vehicles exceed mandated CO2 levels.
In the United States, vehicle engineer of J-N-J Miller Design Services, PLC. fuel economy targets set by Congress in 2007 for 20 per cent fuel Dr Miller worked for 20 years in the automotive economy improvement by 2020 are now being accelerated by industry, leading several hybrid vehicle the Obama administration to 35.5 mpg by 2016 for a passenger technology programmes including 42 V Integrated Starter Alternator (ISG) for car. Taking effect in 2012, the new rules set more aggressive fuel application into a SUV. He has been active economy measures that will require significant gains in engine in collaborations at industry and government and driveline efficiency, better performance cabin climate control levels, including the NSF-funded systems and the introduction of electric hybridization.
This 2nd Edition of center for Future Renewable Electric Energy Propulsion Systems for Hybrid Vehicles addresses the electrification Delivery and Management (FREEDM). He innovations that will be required, ranging from low end brake was actively engaged in MIT’s Consortium on energy recuperators, idle-stop systems and mild hybrids on to Advanced Automotive Electrical and Electronic strong hybrids of the power split architecture in both single mode Components and Systems and has served as and two mode and introducing new topics in plug-in hybrid and Adjunct Professor of Electrical Engineering at battery electrics. Michigan State University and at Texas A&M University. Dr Miller has authored over 160 Propulsion Systems Important topics of the 1st Edition are retained and expanded technical publications, holds 53 US patents, and and some outdated material has been replaced with new has authored or co-authored five books.
He is a information. Fellow of the IEEE, Member of SAE, and 2009 recipient of the IEEE Kliman Innovator award. for Hybrid Vehicles Miller 2nd Edition The Institution of Engineering and Technology www. Miller IET RENEWABLE ENERGY SERIES 7 Propulsion Systems for Hybrid Vehicles 00_Miller_Prelims_pi-xiv 25 October 2010; 17:50:52 Other volumes in this series: Volume 1 Distributed generation N.
Strbac Volume 6 Microgrids and active distribution networks S. Crossley Volume 7 Propulsion systems for hybrid vehicles, 2nd edition J. Miller Volume 8 Energy: resources, technologies and the environment C. Ngo Volume 9 Solar photovoltaic energy A.
Villoz Volume 11 Cogeneration: a user’s guide D. Flin 00_Miller_Prelims_pi-xiv 25 October 2010; 17:50:52 Propulsion Systems for Hybrid Vehicles 2nd Edition John M. Miller The Institution of Engineering and Technology 00_Miller_Prelims_pi-xiv 25 October 2010; 17:50:52 Published by The Institution of Engineering and Technology, London, United Kingdom The Institution of Engineering and Technology is registered as a Charity in England & Wales (no. 211014) and Scotland (no.
† 2004 The Institution of Electrical Engineers † 2008, 2010 The Institution of Engineering and Technology First published 2004 (978-0-86341-336-0) Paperback edition 2008 (978-0-86341-915-7) Second edition 2010 This publication is copyright under the Berne Convention and the Universal Copyright Convention. All rights reserved. Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this publication may be reproduced, stored or transmitted, in any form or by any means, only with the prior permission in writing of the publishers, or in the case of reprographic reproduction in accordance with the terms of licences issued by the Copyright Licensing Agency. Enquiries concerning reproduction outside those terms should be sent to the publisher at the undermentioned address: The Institution of Engineering and Technology Michael Faraday House Six Hills Way, Stevenage Herts, SG1 2AY, United Kingdom www.org While the author and publisher believe that the information and guidance given in this work are correct, all parties must rely upon their own skill and judgement when making use of them.
Neither the author nor publisher assumes any liability to anyone for any loss or damage caused by any error or omission in the work, whether such an error or omission is the result of negligence or any other cause. Any and all such liability is disclaimed. The moral rights of the author to be identified as author of this work have been asserted by him in accordance with the Copyright, Designs and Patents Act 1988. British Library Cataloguing in Publication Data A catalogue record for this product is available from the British Library ISBN 978-1-84919-147-0 (paperback) ISBN 978-1-84919-148-7 (PDF) Typeset in India by MPS Ltd, a Macmillan Company Printed in the UK by CPI Antony Rowe, Chippenham 00_Miller_Prelims_pi-xiv 27 November 2010; 11:43:53 For Quentin Patrick Miller† 1983–2005 You will always be missed 00_Miller_Prelims_pi-xiv 25 October 2010; 17:50:52 00_Miller_Prelims_pi-xiv 25 October 2010; 17:50:52 Contents Preface xiii 1 Hybrid vehicles 1 1.1 Electric engine hybrids 2010 11 1.2 Limits of engine-only actions 12 1.3 Vehicle electrification and more electric vehicle 15 1.4 Performance characteristics of road vehicles 18 1.1 Partnership for new generation of vehicle goals 18 1.3 Drive cycle characteristics 22 1.4 Hybrid vehicle performance targets 26 1.5 Basic vehicle dynamics 27 1.5 Calculation of road load 32 1.1 Components of road load 32 1.2 Friction and wheel slip 38 1.6 Predicting fuel economy 41 1.2 Brake specific fuel consumption 42 1.3 Fuel economy and consumption conversions 43 1.7 Internal combustion engines: A primer 45 1.1 What is brake mean effective pressure (BMEP)? 47 1.2 BSFC sensitivity to BMEP 49 1.3 ICE basics: Fuel consumption mapping 51 1.8 Grid connected hybrids 56 1.1 The connected car, V2G 56 1.2 Grid connected HEV20 and HEV60 59 1.3 Charge sustaining and charge depleting 62 1.9 Exercises 64 References 65 2 Hybrid architectures 67 2.2 Series–parallel switching 74 2.3 Load tracking architecture 76 2.2 Pre-transmission parallel configurations 77 2.1 Energy recuperator systems 79 2.3 Mild hybrid 81 00_Miller_Prelims_pi-xiv 25 October 2010; 17:50:52 viii Propulsion systems for hybrid vehicles 2.3 Pre-transmission combined configurations 86 2.2 Power split with shift 93 2.3 Continuously variable transmission derived 96 2.4 Integrated hybrid assist transmission 97 2.4 Post-transmission parallel configurations 100 2.1 Post-transmission hybrid 101 2.2 Wheel motor hybrid 102 2.5 Hydraulic post-transmission hybrid 104 2.2 Hydraulic–electric post-transmission 105 2.3 Very high voltage electric drives 106 2.1 Texas A&M University transmotor 107 2.2 Petrol electric drivetrain 108 2.3 Swiss Federal Institute flywheel concept 109 2.7 Ultra-capacitor-only vehicles 110 2.1 Catenary powered vehicles with ultra-capacitors 110 2.2 Catenary powered vehicles with wayside ultra-capacitors 111 2.3 Ultra-capacitor trolley bus vehicles 113 2.8 Electric four wheel drive 113 2.2 Production ‘Estima Van’ example 115 2.9 Exercises 115 References 117 3 Hybrid power plant specifications 119 3.1 Grade and cruise targets 124 3.2 Wide open throttle 127 3.2 Launch and boosting 128 3.1 First two seconds 128 3.3 Braking and energy recuperation 129 3.3 RBS interaction with ABS 133 3.4 RBS interaction with IVD/VSC/ESP 134 3.4 Drive cycle implications 135 3.1 Types of drive cycles 135 3.2 Electric vehicle and regenerative electric vehicle cycles for PHEVs 136 3.3 Average speed and impact on fuel economy 138 3.4 Dynamics of acceleration/deceleration 139 3.5 Wide open throttle launch 139 3.2 Range and performance 140 00_Miller_Prelims_pi-xiv 25 October 2010; 17:50:52 Contents ix 3.3 Grade holding and creep 142 3.7 Exercises 143 References 143 4 Sizing the drive system 145 4.1 Matching the electric drive and ice 147 4.2 Gear step selection 149 4.3 Automatic transmission architectures 151 4.4 Summary of transmission types 155 4.2 Sizing the propulsion motor 155 4.4 Torque and power 164 4.5 Constant power speed ratio (CPSR) 168 4.3 Sizing the power electronics 173 4.1 Switch technology selection 175 4.2 kVA/kW and power factor 176 4.3 Ripple capacitor design 180 4.4 Switching frequency and PWM 183 4.4 Selecting the energy storage technology 184 4.1 Lead–acid technology 194 4.2 Nickel-metal hydride 196 4.4 Metal–air batteries 198 4.5 Electrical overlay harness 208 4.2 Inverter bus bars 212 4.3 High voltage disconnect 215 4.4 Power distribution centres 215 4.1 Communication protocol: CAN 219 4.2 Power and data networks 220 4.3 Future communications: TTCAN 222 4.4 Future communications: FlexRay 223 4.5 Competing future communications protocols 226 4.6 Diagnostic test codes (DTC) 227 4.2 Braking systems 229 00_Miller_Prelims_pi-xiv 25 October 2010; 17:50:52 x Propulsion systems for hybrid vehicles 4.3 Cabin climate control 230 4.5 Human–machine interface 233 4.8 Cost and weight budgeting 234 4.9 Exercises 237 References 238 5 Electric drive system technologies 243 5.1 Permanent magnets: A primer 244 5.2 What happened to Alnico? 247 5.3 Rare earth permanent magnets 248 5.3 Design essentials of the SPM 265 5.4 Dual mode inverter 274 5.3 Interior permanent magnet 277 5.3 Mechanical field weakening 287 5.2 Electronic pole change 296 5.3 Pole–phase modulation 298 5.4 Pole changing PM 304 5.5 Variable reluctance machine 306 5.3 Radial laminated structures 313 5.6 Relative merits of electric machine technologies 313 5.1 Dynamic performance comparisons 313 5.2 Comparisons for electric vehicles 315 5.3 Comparisons for hybrid vehicles 316 5.7 Exercises 319 References 320 6 Power electronics for ac drives 325 6.1 Semiconductor device technologies 326 6.1 Trends in power semiconductors 327 6.2 Wide bandgap devices 328 6.2 Essentials of pulse width modulation 330 6.3 Resonant pulse modulation 335 6.4 Space vector PWM 337 00_Miller_Prelims_pi-xiv 25 October 2010; 17:50:52 Contents xi 6.6 Comparison of PWM techniques 348 6.7 dc/dc converters 349 6.10 Sensors for current regulators 359 6.11 Interleaved PWM for minimum ripple 361 6.12 Exercises 363 References 365 7 Drive system control 367 7.1 Essentials of field oriented control 368 7.2 Dynamics of field oriented control 373 7.5 Direct torque control 388 7.6 Exercises 391 References 391 8 Drive system efficiency 395 8.2 Copper losses and skin effects 403 8.4 Energy storage system 412 8.6 Exercises 416 References 417 9 Hybrid vehicle characterization 419 9.6 Regulated cycle for hybrids 433 9.7 Exercises 435 References 438 10 Energy storage technologies 439 10.1 Lead–acid 447 00_Miller_Prelims_pi-xiv 25 October 2010; 17:50:52 xii Propulsion systems for hybrid vehicles 10.2 Nickel-metal hydride 449 10.1 Symmetrical ultra-capacitors 466 10.2 Asymmetrical ultra-capacitors 470 10.3 Ultra-capacitors combined with batteries 473 10.4 Hybridized battery example 481 10.5 Ultra-capacitor cell balancing 482 10.1 Dissipative cell equalization 484 10.2 Non-dissipative cell equalization 485 10.3 Electrochemical double layer capacitor specification and test 488 10.2 High pressure gas 496 10.6 Storage system modelling 499 10.2 Fuel cell model 504 10.3 Ultra-capacitor model 507 10.7 Exercises 516 References 519 11 Hybrid vehicle test and validation 523 11.1 Vehicle coast down procedure 525 11.2 Sports utility vehicle test 527 11.3 Sports utility vehicle plus trailer test 529 11.4 Class-8 tractor test 532 11.5 Class-8 tractor plus trailer test 535 11.6 Exercises 539 References 541 12 Automated electrified transportation 543 12.1 Personal rapid transit 546 12.2 Automated highway system 547 12.3 Non-contacting power transfer 549 12.1 Inductive coupling technology 550 12.2 Radiated near-field power transfer 552 12.5 Exercises 561 References 561 Appendix A 563 Index 567 00_Miller_Prelims_pi-xiv 25 October 2010; 17:50:53 Preface This second edition of Propulsion Systems for Hybrid Vehicles represents a major revision to the earlier book first published in 2004.
A lot has changed over the past seven years and a good deal of that progress has been captured in this work. There is also significant structure change to the chapters with the inclusion of worked examples in all the chapters to further clarify and expand on the material presented. Exercise problems are provided at the end of each chapter that are intended to solidify the materials covered. Answers are provided to these exercises so that the approach taken can be validated.
In this book attention is focused on hybrid technologies that are combined with gasoline internal combustion engines, or spark ignited, SI, engines as they are known. When an SI engine is direct injected it is more appropriate to refer to it as spark ignited direct injected, SIDI.