MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT AUTOMOTIVE ENGINEERING CALCULATION AND DESIGN METHODOLOGY FOR POWERTRAIN SYSTEM IN HYBRID VEHICLES ADVISOR: TRAN DINH QUY, ME. STUDENT: TRAN NGUYEN AN THINH DO HOANG MINH NGUYEN SKL 0 1 0 5 9 4 Ho Chi Minh City, December, 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AN EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS CALCULATION AND DESIGN METHODOLOGY FOR POWERTRAIN SYSTEM IN HYBRID VEHICLES Student: TRAN NGUYEN AN THINH Student ID: 18145064 Student: DO HOANG MINH NGUYEN Student ID: 18145042 Major: AUTOMOTIVE ENGINEERING Advisor: TRẦN ĐÌNH QUÝ, ME. Ho Chi Minh City, December 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AN EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS CALCULATION AND DESIGN METHODOLOGY FOR POWERTRAIN SYSTEM IN HYBRID VEHICLES Student: TRAN NGUYEN AN THINH Student ID: 18145064 Student: DO HOANG MINH NGUYEN Student ID: 18145042 Major: AUTOMOTIVE ENGINEERING Advisor: TRẦN ĐÌNH QUÝ, ME. Ho Chi Minh City, December 2022 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, December 15, 2022 GRADUATION PROJECT ASSIGNMENT Student name: Trần Nguyễn An Thịnh Student ID: 18145064 Student name: Đỗ Hoàng Minh Nguyên Student ID: 18145042 Major: Automotive Engineering Class: 18145CLA Advisor: Trần Đình Quý, ME Phone number: 0918069082 Date of assignment: 30/9/2022 Date of submission: 15/12/2022 1.
Project title: Calculation and design methodology for powertrain system in hybrid vehicles 2. Initial materials provided by the advisor: Textbook, previous file 3. Content of the project: Overview of hybrid electric vehicles, theoretical basis of ICE and electric motor in hybrid vehicles, calculation method for hybrid powertrain system, design principle in hybrid powertrain system. Final product: Final report file and presentation CHAIR OF THE PROGRAM ADVISOR (Sign with full name) (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, December 15, 2022 ADVISOR’S EVALUATION SHEET Student name: Trần Nguyễn An Thịnh Student ID:18145064 Student name: Đỗ Hoàng Minh Nguyên Student ID: 18145042 Major: Automotive Engineering Project title: Calculation and design methodology for powertrain system in hybrid vehicles Advisor: Trần Đình Quý.
Content of the project:. Approval for oral defense? (Approved or denied) .) Ho Chi Minh City, December 15, 2022 ADVISOR (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, December 15, 2022 PRE-DEFENSE EVALUATION SHEET Student name: Trần Nguyễn An Thịnh Student ID: 18145064 Student name: Đỗ Hoàng Minh Nguyên Student ID: 18145042 Major: Automotive Engineering Project title: Calculation and design methodology for powertrain system in hybrid vehicles Name of Reviewer:. Content and workload of the project. Approval for oral defense? (Approved or denied) .) Ho Chi Minh City, December 15, 2022 REVIEWER (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, December 15, 2022 EVALUATION SHEET OF DEFENSE COMMITTEE MEMBER Student name: Trần Nguyễn An Thịnh Student ID: 18145064 Student name: Đỗ Hoàng Minh Nguyên Student ID: 18145042 Major: Automotive Engineering Project title: Calculation and design methodology for powertrain system in hybrid vehicles Name of Defense Committee Member:.
Content and workload of the project .) Ho Chi Minh City, December 15, 2022 COMMITTEE MEMBER (Sign with full name DISCLAIMER We affirm that this thesis is an account of our work there. It has not been submitted elsewhere, and all other sources of information, papers, and documents consulted while creating this thesis have been properly acknowledged. i ACKNOWLEDGEMENTS We would like to express our heartfelt gratitude to Mr. Tran Dinh Quy for his enthusiastic assistance and support in the project "Calculation and design methodology for powertrain system in hybrid vehicles." My team would like to thank the professors who have passionately led and educated us during our time at Ho Chi Minh City University of Technology and Education, studying, practicing, researching, and training.
Due to limited experience and competence, as well as limited implementation time, faults are unavoidable while working on the issue, thus the team welcomes your comments and recommendations. ii TABLE OF CONTENTS DISCLAIMER. ii TABLE OF CONTENTS .iii LIST OF FIGURES. vi LIST OF TABLE.
ix Chapter 1: INTRUDUCTION. Goals and objectives of the project. Organization of chapters. 2 Chapter 2: OVERVIEW OF HYBRID ELECTRIC VEHICLES.
Definition of hybrid vehicles. About the hybrid technologies. Hybrid vehicle development trend. Classification of hybrid drivetrain architectures.
Series hybrid vehicle. Parallel hybrid vehicle. Series-Parallel hybrid vehicle. Pros and cons of each type of hybrid drivetrain.
Series hybrid vehicle. Parallel hybrid vehicle. Series-Parallel hybrid vehicle. Main components in a hybrid vehicle.
Internal combustion engine (ICE). 10 Chapter 3: BASIC THEORY FOR DESIGNING INTERNAL COMBUSTION ENGINE AND ELECTRIC MOTOR ON HYBRID ELECTRIC VEHICLES. Internal combustion engine. Internal combustion engine (ICE) operations and characteristics.
ICE characteristic curves. Power control strategy of internal combustion engines .1 Power control strategy of diesel engine (Compressed Ignition engine – CI engine). Power control strategy of gasoline engine (Spark Ignition engine – SI Engine) 13 3. Working principles of Brushless DC Motor.
Control principle of Brushless DC Motor. Speed control methods of Brushless DC Motor. Plan of building research model. Torque harmonization method.
Speed harmonization method…………………………………………. Series hybrid configuration. Parallel hybrid configuration. Series-Parallel hybrid configuration.
28 Chapter 4: CALCULATION AND CONTROL FOR POWERTRAIN SYSTEM ON HYBRID ELECTRIC VEHICLES. Theoretical basis of calculation and design hybrid powertrain system. Design principles for hybrid powertrain system. Calculation procedures for hybrid powertrain system.
Series hybrid powertrain parametric design. SOC-of-PPS Control Strategy. Engine on-off or thermostat control strategy. Case study for hybrid powertrain system calculation.
Total power requirement calculation. Motor power requirement calculation. Generator power requirement calculation. Battery requirement calculation.
Gearbox requirement calculation. Parallel hybrid powertrain parametric design. SOC-of-PPS control strategy. Engine on-off (thermostat) control strategy.
Constrained engine on-off control strategy. Case study for hybrid powertrain system calculation. Total power requirement calculation. Motor power requirement calculation.
Power ratio division. Internal combustion engine power requirement calculation. Generator power requirement calculation. Battery requirement calculation.
Speed-coupling device requirement calculation. Gearbox requirement calculation. Series-Parallel (power-split) hybrid powertrain parametric design. Engine speed control strategy.
Regenerative braking control. Case study for hybrid powertrain system calculation. Total power requirement calculation. Motor power requirement calculation.
Power ratio division. Internal combustion engine power requirement calculation. Generator power requirement calculation. Battery requirement calculation.
Speed-coupling device requirement calculation. Gearbox requirement calculation. 73 Chapter 5: CONCLUSION AND DEVELOPMENT RECOMMENDATIONS. 77 v LIST OF FIGURES Figure 2.
Predicting the development of hybrid market in the near future [6]. A rear-wheel drive series hybrid electric vehicle layout…………………. A rear-wheel-drive parallel hybrid electric vehicle layout……………………. A rear-wheel-drive series–parallel hybrid electric vehicle layout…….
Indicated and brake powers, torques, and specific fuel consumptions varying with engine speed [2]……………………………………………………………………. Fuel consumption contour of a gasoline engine [3]…………………. Typical variable-speed electric motor characteristics [2]……………. Wound-field DC motor [2]……………………………………………….
Speed characteristics of DC motors [2]………………………………………. Typical torque-coupling device [2]…………………………………. Commonly used mechanical torque-coupling devices [2]……………………20 Figure 3. Two-shaft configuration [2]……………………………………………….
Pre-transmission single-shaft torque combination in parallel hybrid electric……………………………………………………………………………………21 Figure 3. Post-transmission single-shaft torque combination in parallel hybrid electric drivetrain [2]………………………………………………………………………………21 Figure 3. Typical speed-coupling device [2] ……………………………………. Planetary gear unit [2] ………………………………………………….
Speed and torque relationship while one element is fixed [2] ………………23 Figure 3. Transmotor used as a speed coupler [2] …………………………………. Hybrid electric drivetrain with speed coupler device is a planetary gear unit [2] ………………………………………………………………………………………. Hybrid electric drivetrain with speed coupler device [2] ……………………24 Figure 3.
Series hybrid electric vehicle configuration [2] ……………………………. Parallel hybrid electric vehicle configuration [2] …………………. Series-Parallel hybrid electric vehicle configuration [2] ……………. Forces and moments exerted on a vehicle when moving uphill [4] ………….
Brushed DC motor……………………………………………………. Brushless DC motor (BLDC)…………………………………………. Permanent Magnet Synchronous Motor (PMSM)…………………………. Switched Reluctance Motor (SRM)…………………………………………36 Figure 4.
Synchronous Reluctance Motor (SyRM)……………………………………36 Figure 4. Axial Flux Ironless Permanent Magnet Motor………………………………37 Figure 4. Illustration of the maximum PPS SOC control strategy [3]…………………. Control flowchart of Max.
SOC-of-PPS control strategy [3]………………. Illustration of thermostat control [3]……………………………………. Flowchart of Max. SOC-of-PPS control strategy [3]……………………….
Illustration of engine on–off control strategy [3]……………………………51 Figure 4. Demonstration of various operating modes based on power demand [3]…. Engine torque control strategy with different demanded traction torque and PPS SOC [3]…………………………………………………………………………. Speed coupling of a planetary gear unit…………………….
Speed coupling of a planetary gear unit………………….18 Calculation strategy flowchart………………………………………………74 vii LIST OF TABLES Table 1. HF value of some commercial hybrid vehicles. Kia Morning engine specifications. Selected motor specifications.
Selected generator specifications. Engine torque control strategy with different demanded traction torque and PPS SOC. Selected motor specifications. Toyota Wigo engine specifications.
Selected generator specifications. Selected motor specifications. Ford 20kW gasoline engine specifications [5]. Selected generator specifications.
68 viii ABSTRACT Based on the instruction of lecturer Tran Dinh Quy, our team has conducted research thesis on the methodology of calculation and design powertrain system on hybrid electric vehicles (HEV). Though the subject selected can be familiar with teachers and students who are in major or studying automotive engineering industry, but with the developing country like Vietnam and upcoming trend of using environmentally friendly vehicle such as electric cars, natural gas vehicles… the subject selected can be useful for those concerning the effectiveness of hybrid vehicle concept and provide them a throughout look from the designer perspective. The research contains many chapters that describe the order of fulfilling objectives of the thesis and are arranged as most reasonable way as possible. ix Chapter 1: INTRUDUCTION First, we will introduce general information, goals and objectives of our research and the order of the conducted thesis.
Background information A number of unanticipated threats that could endanger the environment and human life have emerged in recent decades, in addition to the swift development of industrial sectors and categories. The issue of harmful emissions from transportation has not yet been fully resolved, particularly in the automotive sector. Furthermore, it is anticipated that fossil fuel, which is used to power the vehicle, would eventually run out. Since its introduction in the late 1800s, hybrid vehicles with a propulsion system combining an internal combustion engine and an electric motor have made a significant impression because to exceptional features when compared to traditional vehicles.
Internal combustion engines are becoming more and more popular, despite their lower cost due to mass manufacture and easier operation and repair. Prior to 1990, conventional cars dominated the market for hybrid vehicles. Since the early 1990s, hybrid vehicles have regained popularity and made impressive advancements under the mounting strain of requirements for conserving fossil fuels and more rigorous pollution rules. In addition to the hybrid option's inherent benefits, modern hybrid automobiles have been a huge success due to significant developments in manufacturing technologies, including mechanics, energy, electronics, information, etc.
Only when the operating modes of the energy sources are maximized through technological exploitation can the automotive hybridization solution be realized. This is an issue with the idea of improving the powertrain system's energy source control settings in hybrid automobiles. Documentary research reveals that there have been several studies on changing an automobile model that is often used in Vietnam or the application of research on device detail cluster design is highly regarded. There are still many research issues to be resolved because the majority of domestic research on hybrid vehicles still refers to basic ideas or highlights recent accomplishments of hybrid car manufacturers or a cluster of design and manufacturing equipment.
On the other hand, several of the world's top hybrid car manufacturers still keep their manufacturing techniques and efficient evaluation of hybrid power sources a secret.