MINISTRY OF EDUCATION AND TRAINING HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION FINAL REPORT STUDENT'S SCIENTIFIC RESEARCH TOPIC RESEARCHING ON MANUFACTURING AND SIMULATING THE OPERATION OF THE TOYOTA PRIUS HYBRID'S MODEL S K C 0 0 3 9 5 9 TOPIC NUMBER: SV2022-153 PROJECT LEADER: NGUYEN QUOC VU SKC008096 Ho Chi Minh City, November, 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FALCUTY FOR HIGH QUALITY TRAINING SCIENTIFIC RESEARCH RESEARCHING ON MANUFACTURING AND SIMULATING THE OPERATION OF THE TOYOTA PRIUS HYBRID’S MODEL Project code: SV2022-153 Student: Nguyễn Phan Lương Bằng Student ID: 18145003 Student: Nguyễn Quốc Vũ Student ID: 18145079 Advisor: Master Vũ Đình Huấn Ho Chi Minh City, November 2022 TABLE OF CONTENTS CHAPTER1: INTRODUCTION .1 The reason for choosing the topic .3 Limit in the project .2 THE OVERVIEW OF THE HYBRID VEHICLES .1 Overview và The brief history of Hybrid vehicles.2 What is a Hybrid Electric Vehicle? .3 The working principle of Hybrid vehicles.3 Series-Parallel Hybrid .4 Rate of use of motors and electric motors in each system .6 Main components in Hybrid vehicles .7 Economics of Hybrid vehicle.8 Development trend of hybrid cars in developed countries. 11 CHAPTER 2: THEORETICAL BASIS OF HYBRID ENGINES.1 SERIES-PARALLEL HYBRID’S COMPENENTS .1 2ZR-FXE engine .3 MG1 và MG2 .4 POWER-SPLIT DEVICE (PSD) .5 High voltage source .3 Nickel-metal hydride high-voltage battery: .2 Method of controlling engine speed .3 Torque controlled method.4 Drivetrain controlled strategy .5 Engine speed controlled strategy .6 Traction moment controlled strategy .1 In the low speed zone: .2 In the medium vehicle speed zone .3 In the high vehicle speed zone .7 Controlled regenerative braking. 59 CHAPTER 3 CALCULATION,SIMULATION BY MATLAB/SIMULINK .1 MODEL CAR SPECIFICATIONS .2 SIMULATION OF MODEL IN MATLAB/SIMULINK .3 Power-Split Device .2 State of charge (SOC) .3 Moment and motor speed (MG2) .4 Moment and engine speed .5 Moment and generator speed (MG1). 85 LIST OF FIGURES Figure 1.1 The structure of Hybrid vehicle.2 Series hybrid drivetrain .3 Parallel hybrid drivetrain .4 Combinated powertrain diagram .6 Rate of use of motor and engine .7 Main components in hybrid vehicle .1 The diagram of Hybrid’s controlled unit .2 2ZR-FXE engine .4 Controller unit diagram MG1, MG2 .5 Power Split Device diagram .6 Power Split Device .8 Engine starts when car stops .10 Acceleration and Climbing .11 On the highway .12 Running by inertia .13 Simulate running on Creeping mode .14 Slow mode and EV mode .16 High voltage source structure .18 High-voltage battery .19 4th generation Prius battery ECU and later .20 Hybrid vehicle control method .22 Energy flow in motor-only mode .23 Energy flow in motor/traction generator only mode .24 Energy flow in Motor mode/generator working in conjunction with traction motor .25 Energy flow in Motor/generator mode works in conjunction with alternator motor .26 Energy flow in Speed coupling mode combined with traction motor .27 Energy flow in Speed Coupling mode combined with alternator motor .28 Energy flow in regenerative braking mode .29 Graph of torque and number of engine revolutions .30 The relationship between the moment-velocity .31 Controlled moment strategy.
1 Model overview on MATLAB/simulink.3 Driver Cycle block. 4 Components of Hybrid Systems block. 14 Simulation result of MG2. 15 Simulation of moment and engine speed.
16 Simulation result of MG1. 77 LIST OF TABLE Table 2.1 Technical speciffication of 2NZ-FXE .2 Technical specification of Hybrid gearbox .3 Technical specification of MG1 .4 Technical specification of MG2 .5 Relationship among components on PSD .6 The relationship between vehicle speed and power corresponding to engine and motor rotational speed.1 Model car specification. 60 LIST OF ACRONYMS AGM Absorbed Glass Mat CVT Continuously Variable Transmission ECM Electronic Control Module ECU Electronic Control Unit EVT Electric Variable Transmission GB Gear Box HEV Hybrid Electric Vehicle HV High Voltage ICE Internal Combustion Engine IGBT Insulated Gate Bipolar Transistor M/G Motor/ Generator MG1 Motor Generator 1 MG2 Motor Generator 2 PEHV Petroleum Electric Hybrid Vehicle PLG Planetary Gear PPS Peaking Power Source PSD Power Split Device RESS Rechargeable Energy Storage System SMR System Main Relay SOC State Of Charge SOCH State Of Charge Hight SOCL State Of Charge Low THS Toyota Hybrid System TM Traction Motor RPM Revolutions Per Minute HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY THE SOCIALIST REPUBLIC OF VIETNAM AND EDUCATION Independence - Freedom – Happiness FACULTY FOR HIGH QUALITY TRAINING Ho Chi Minh City, November 2022 SCIENTIFIC RESEARCH TASKS 1. General information - Project title: Researching on manufacturing and simulating the operation of the Toyota Prius hybrid’s model.
- Project manager: Nguyễn Quốc Vũ - Student ID:18145079 - Class:18145CLA3 - Falculty: Falculty for High Quality Training - Project member: No. Name Student ID Class Falculty 1 Nguyễn Phan Lương Bằng 18145003 18145CLA3 Falculty for high quality training - Advidor: Master Vũ Đình Huấn 2. Project mission - Reserching on hybrid theory of Toyota Prius. - Simulating and Controlling the model on MATLAB Simulink.
Project result - Simulating a hybrid vehicle model using MATLAB/Simulink software - Completing the theoretical basis of hybrid vehicles based on literature source - Run simulation on MATLAB/Simulink software based on experimental cycles Ho Chi Minh City, November 2022 Project manager (sign and write full name) Advisor's evaluation:. Ho Chi Minh City, November 2022 Advisor (sign and write full name) CHAPTER1: INTRODUCTION 1.1 The reason for choosing the topic In an era where industrialization and modernization are taking place in every corner of the globe like today, the demand for energy is enormous. Therefore, saving fuel, energy, and ensuring environmental safety are always the top requirements that are set for each country and each industry, especially the automotive industry, which always requires the technologies must change every day. The proposed solution is to flexibly combine gasoline engines, electric motors and structures to help conserve and convert energy efficiently.
Hybrid electric car was born as a way to solve that problem. Currently, plug-in hybrid vehicles (pure electric motor) have emerged as a phenomenon of fuel-saving vehicles that do not pollute the environment. However, in Vietnam, there is still not enough infrastructure to serve this car. Therefore, under the assignment of the Faculty of Mechanical Engineering - Ho Chi Minh City University of Technology and Education and the guidance of Master Vu Dinh Huan, our group researched the topic: Researching on manufacturing and simulating on Toyota Prius hybrid’s model- highly practical cars in Vietnam.2 Goals − Mastering the theoretical basis and operating principle of hybrid electric vehicles.
− Building a simulation model of a mixed-type hybrid vehicle on MATLAB/Simulink software. − Control and run the model suitable for the test cycle.3 Limit in the project − Only simulate on Matlab Simulink, have not built an experimental model yet.4 Reasearch methods − Using the theoretical basis of reference sources to build new models. 1 − Calculate the necessary parameters to the model or refer to the available vehicle parameters in reality to conduct simulation. − Using MATLAB/Simulink to build models according to empirical cycles.2 THE OVERVIEW OF THE HYBRID VEHICLES 1.1 Overview và The brief history of Hybrid vehicles.
Invented about 300 years ago by French inventor Nicolas - Joseph Cugnot (1725-1804), today's automobile has become one of the indispensable means of transportation in human society. That's why the low air pollution caused by exhaust gases from automobile engines is one of the burning problems of many countries today. In order to reduce environmental pollution from cars, there have long been many promising technical solutions such as electric cars, fuel cell cars, pneumatic engines, etc. , the above technologies have not yet been put into use because of many technological limitations.
For electric cars, it takes at least 4 hours to recharge the battery, which limits the range of electric cars. For fuel cell technology, liquid hydrogen must be stored at extremely low temperatures; Therefore, it is only suitable for countries with icy climates. Both technologies have a common problem that is to rebuild the entire fuel supply base system. The upper limits of these two futuristic technologies create a gap between the need for environmental protection and traditional automotive technology.
Recently, a new automobile manufacturing technique has been born to partly save non-renewable energy sources (fossil fuels) as well as protect the environment while fuel cell and electric battery technology is completed. Hybrid technology is a solution that is considered successful today and has been widely marketed in developed countries such as Europe, America and Japan, etc.1 The structure of Hybrid vehicle The automobile industry in the world is facing a big question: How to produce cars that do not pollute the environment and save energy? Hydrogen cars, electric cars, solar cell cars. are not easy to implement. But now Hybrid cars - cars using combined energy sources - have answered the above conundrum.
HYBRID cars completely reduce harmful emissions and reduce fuel consumption by up to half.2 What is a Hybrid Electric Vehicle? Hybrid car (Hybrid Electric Vehicle-HEV) is a car using a combination engine. In fact, the idea of “Hybrid” has been around for a very long time. According to Wikipedia, a hybrid vehicle is a means of transport that is driven by two or more sources of energy. For example, a combination of: Rechargeable Energy Storage System (RSS, or more specifically, Rechargeable Batteries) and Fuel Energy Source (Gasoline, diesel, etc.) A hybrid engine is a combination of a conventional internal combustion engine and an electric motor using battery power.
The electronic controller will decide when to use the electric motor, when to use the internal combustion engine, when to use synchronous operation and when to charge the battery for future use. In current practice, this term (Hybrid Vehicle) is often used to refer to a Hybrid Vehicle that combines power from electricity and gasoline (Petroleum Electric Hybrid Vehicle) and can also be abbreviated as PEHV or HEV (Hybrid Electric Vehicle) in short. According to 3 the common Vietnamese language, we can call it "Gasoline electric car", or in English it is Hybrid Car.3 The working principle of Hybrid vehicles. Hybrid cars work based on the following principle: The electric motor is used to start the vehicle, in which during normal operation it will operate synchronously.
The electric motor is also used to enhance the power supply for the vehicle to accelerate or climb slopes. When braking or going downhill, the electric motor is used as a generator to charge the battery. Unlike other electric vehicles, the hybrid engine does not need an external power source, the internal combustion engine will provide power to the battery. With the combination of internal combustion engine and electric motor, hybrid engine is extended working limit, reducing fuel consumption for internal combustion engine with high engine combination efficiency, large torque at rpm small rotation and reduce environmental pollution.4 Advantages Hybrid engine combination has the following advantages: − Make use of energy when braking: when you need to brake or when the vehicle slows down, the electric motor acts as a generator, braking energy is utilized to generate charging current for the battery.
− Reduced fuel consumption (Hybrid engines consume much less fuel than conventional internal combustion engines, only half) − The electric motor is used in the modes of acceleration or large load, so the internal combustion engine only needs to provide enough power, so the internal combustion engine has a compact size. − It is possible to use lightweight materials, optimal design to reduce the overall weight, wind resistance index of the car. Can run far and powerfully like normal gasoline cars. − Hybrid cars still use gasoline as fuel, so the driver does not have to worry about charging, which usually takes a lot of time.
4 − Hybrid cars are less polluting than conventional gasoline cars because electric motors are much more efficient than gasoline engines. Hybrid engines are often 100% more economical than traditional gasoline engines.5 Powertrain Methodology According to the powertrain method, Hybrid engines can be divided into 3 main types: series hybrid, parallel hybrid.