Page i ELECTRIC and HYBRID VEHICLES Design Fundamentals Page ii This page intentionally left blank. Page iii ELECTRIC and HYBRID VEHICLES Design Fundamentals Iqbal Husain CRC PRESS Boca Raton London New York Washington, D. Page iv This edition published in the Taylor & Francis e-Library, 2005. To purchase your own copy of this or any of Taylor & Francis or Routledge’s collection of thousands of eBooks please go to www.
Library of Congress Cataloging-in-Publication Data Husain, Iqbal, 1964-Electric and hybrid vehicles: design fundamentals/by Iqbal Husain. Includes bibliographical references and index. Hybrid electric vehicles.22'93–dc21 2002041120 CIP This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated.
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Government works ISBN 0-203-00939-8 Master e-book ISBN International Standard Book Number 0-8493-1466-6 (Print Edition) Library of Congress Card Number 2002041120 Page v Preface The book presents a comprehensive systems-level perspective of electric and hybrid electric vehicles, with emphasis on technical details, mathematical relationships, and basic design guidelines. The electric vehicle is an excellent example of an electro-mechanical and electrochemical system that is technically challenging as well as highly intriguing to engineering students. With a good balance between technical details, design equations, numerical examples, and case studies, the subject matter presents an ideal platform for educating today’s engineers with a systems-level perspective—a concept that served as the primary motivation to develop this textbook on electric and hybrid vehicles. Automobiles are an integral part of our everyday lives.
Yet, conventional auto-mobiles are the major cause of urban pollution in the 21st century. The world will eventually encounter an acute energy crisis if we do not focus on alternative energy sources and transportation modes. Current environmental concerns are driving the international community toward developing low-emission (hybrid electric) and zero-emission (electric) vehicles to replace conventional internal combustion engine vehicles. The subject of electric and hybrid vehicles is becoming increasingly important, with intense drive from the government, environmental activists, and associated industries to advance the technology.
Several auto industries have already started marketing electric and hybrid electric vehicles. Furthermore, the next generation of conventional automobiles will experience a gradual replacement of the hydraulically driven actuators by electrically driven actuators. The trend clearly suggests that there is a need to adequately educate the engineers of today and tomorrow with the technical details of electric and hybrid vehicles and the electrical units used within an automobile. While there are ample books on electric and hybrid vehicles available, providing narrative descriptions of the components of vehicles, and numerous technical papers published with research results, none covers the technical aspects and mathematical relationships in a comprehensive way to educate a junior-or senior-level or a beginning graduate-level engineering student.
This book will serve to educate students on aspects of electric vehicles, which will generate interest to support the development and use of electric vehicles. The book will also serve as a reference for a working engineer dealing with design and improvement of electric and hybrid vehicles. Discussion on most topics has been limited to fundamentals only in the book, considering the wide spectrum of technical aspects related to an electric and hybrid vehicle system. Appropriate references are given to direct the readers toward details on topics for further reading.
The intent of the book is not to present the wide spectrum of the state of the art in electric and hybrid electric vehicles, but rather to prepare the student with the necessary background to evaluate the technology. Page vi The book, starting with a historical background on electric vehicles, will describe the system components, the laws of physics that govern vehicle motion, the mathematical relationships within a component and between components, the energy sources, and the design of components to meet the specifications for the complete vehicle system. After the introduction of the systems concept in Chapter 1, Chapter 2 focuses on the laws of physics to define the force characteristics of ground vehicles. The design guidelines for the power and energy requirements based on design specifications are established in this chapter.
The flow of the book shifts from mechanical to chemical concepts, when energy sources are introduced in Chapter 3, and the topic is continued in Chapter 4, with alternatives to battery power. The two major contenders for energy sources in road vehicles are batteries and fuel cells, which are described in detail, while other types of energy sources are mentioned briefly. Chapters 5 through 8 are mostly electrical, where electric motors for propulsion and power electronic drives for the motors are presented. The DC machines and AC induction machines suitable for propulsion are discussed in Chapter 5, while the permanent magnet and switched reluctance machines are presented in Chapter 6.
Chapters 7 and 8 are dedicated to the power-electronics-based motor drives for electric propulsion units. Vehicle system control fundamentals are also addressed in these two chapters. Mechanical and electrical concepts merge in Chapters 9 and 10. Drivetrain components, including the transmission for electric vehicles, are presented in Chapter 9, while Chapter 10 discusses the drivetrain and the design basics of hybrid electric vehicles.
This book is intended to be used as a textbook for an undergraduate or beginning graduate-level course on electric and hybrid electric vehicles. The ten chapters of the book can be comfortably covered in a three-credit, one-semester or a four-credit, one-quarter course. Although the materials in this book are biased toward the electrical units, it is still multidisciplinary enough to teach electrical, mechanical, and chemical engineers all in one course, utilizing the systems approach. In that case, parts of the electrical details appearing in Chapters 5 though 8 should be skipped.
This type of course will certainly mimic the real situation existing in many industries, where multidisciplinary engineers work together to devise a system and develop a product. The equations developed can be utilized to develop a system- level modeling and simulation tool for electric and hybrid electric vehicles on a suitable platform, such as MATLAB/SIMULINK. The book has several worked-out problems and many exercises that are suitable to convey the concept to students through numerical examples. Page vii Author Dr.
Iqbal Husain is an Associate Professor in the Department of Electrical and Computer Engineering at the University of Akron, Akron, Ohio, where he is engaged in teaching and research. After earning his Ph. degree in Electrical Engineering from Texas A&M University, College Station, in 1993, Dr. Husain worked as a lecturer at Texas A&M University and as a consulting engineer for Delco Chassis at Dayton, Ohio, prior to joining the University of Akron in 1994.
He worked as a summer researcher for Wright Patterson AFB Laboratories in 1996 and 1997. More recently, he taught at Oregon State University as a short-term visiting faculty member. His research interests are in the areas of control and modeling of electrical drives, design of electric machines, and development of power conditioning circuits. He has worked extensively in the development of switched reluctance motor drives, including sensorless controllers.
He also worked as a consultant for Delphi Automotive Systems, Goodyear Tire and Rubber Industry, ITT Automotive, Delphi Chassis, Graphic Enterprises, and Hy-Tech Inc. Husain received the 2000 IEEE Third Millenium Medal, the 1998 IEEE-IAS Outstanding Young Member award, and the NSF CAREER Award in 1997. He is also the recipient of three IEEE Industry Applications Society prize paper awards. Page viii This page intentionally left blank.
Page ix Acknowledgments I would like to express my sincere gratitude to all those who helped me devotedly to complete the work. I would like to thank my former and current graduate students, John Bates, Liu Tong, Nazmul Anwar, Shahidul Islam, Afjal Hossain, Faizul Momen, Virginie Raulin, Mihaela Radu, Ahmed Khalil, and Jin Wang, who helped me tremendously with problems, figures, and materials. I offer my gratitude to Dr. Don Zinger, who first offered a course on electric vehicles at the University of Akron, Akron, Ohio, and created an opportunity for me to prepare textbook materials on the topic.
I am extremely thankful to Dr. Robert Pasch of Oregon State University and Dr. Richard Gross of the University of Akron, both from Mechanical Engineering Departments, who educated and helped me in writing about the mechanical-related topics. I would also like to thank the reviewers who provided extremely useful suggestions that helped enhance the quality of the book.
The reviewers included Prof.Wallace and Prof. Annette von Jouanne, Department of Electrical and Computer Engineering, Oregon State University; Prof. Ehsani, Department of Electrical Engineering, Texas A&M University; Prof. Longya Xu, Department of Electrical and Computer Engineering, Ohio State University; Prof.
Pragassen Pillay, Department of Electrical and Computer Engineering, Clarkson University; Dr.Rahman, General Motors ATV; and Dr. Alexander Yokochi, Department of Chemistry, Oregon State University. I thank the staff of CRC Press LLC, especially Nora Konopka and Helena Redshaw, whose guidance was invaluable in preparing my first textbook manuscript. Finally, my sincere apologies and heartfelt gratitude to my wife, Salina, and my children Inan and Imon, who patiently stood by me with grave understanding and continuous support while I was preoccupied with the project.
Iqbal Husain Akron, Ohio Page x This page intentionally left blank. Page xi Table of Contents Chapter 1 Introduction to Electric Vehicles 1 1.1 Components of an EV 2 1.1 The Early Years 4 1.5 Recent EVs and HEVs 8 1.3 Capital and Operating Cost Comparison 11 1. Dependence on Foreign Oil 13 1.4 EV Market 13 References 14 Assignment 15 Chapter 2 Vehicle Mechanics 17 2.2 Laws of Motion 20 2.4 Dynamics of Vehicle Motion 25 2.1 Force-Velocity Characteristics 27 2.6 Velocity and Acceleration 29 2.1 Constant FTR, Level Road 29 2.2 Nonconstant FTR, General Acceleration 35 2.7 Propulsion System Design 38 Problems 39 Page xii Chapter Energy Source: Battery 43 3 3.2 Lead-Acid Battery 46 3.1 Cell Discharge Operation 47 3.2 Cell Charge Operation 48 3.1 Nickel-Cadmium Battery 50 3.2 Nickel-Metal-Hydride (NiMH) 51 Battery 3.3 Li-Ion Battery 52 3.4 Li-Polymer Battery 53 3.5 Zinc-Air Battery 54 3.6 Sodium-Sulfur Battery 54 3.7 Sodium-Metal-Chloride Battery 55 3.3 State of Charge 57 3.4 State of Discharge 58 3.5 Depth of Discharge 59 3.3 Constant Current Discharge 62 3.2 Battery Pack Design 65 3.6 Targets and Properties of Batteries 66 3.1 Constant Current Discharge 69 Approach 3.1 Fractional Depletion Model 70 3.2 Standard Driving Cycles 72 3.3 Power Density Approach 75 References 76 Problems 77 Chapter Alternative Energy Sources 81 4 4.1 Fuel Cell Characteristics 82 4.2 Fuel Cell Types 84 4.1 Alkaline Fuel Cell (AFC) 84 Page xiii 4.2 Proton Exchange Membrane (PEM) 84 4.3 Direct Methanol Fuel Cell (DMFC) 84 4.4 Phosphoric Acid Fuel Cell (PAFC) 84 4.5 Molten Carbonate Fuel Cell (MCFC) 85 4.6 Solid Oxide Fuel Cell (SOFC, ITSOFC) 85 4.3 Hydrogen Storage Systems 85 4.5 Fuel Cell EV 88 4.2 Supercapacitors and Ultracapacitors 91 4.3 Flywheels 92 References 93 Problem 94 Chapter DC and AC Electric Machines 95 5 5.1 Motor and Engine Ratings 96 5.2 EV and HEV Motor Requirements 97 5.4 Three-Phase AC Machines 103 5.