Hybrid and Electric Vehicle Engineering Academy

Transcription

1 New! Hybrid and Electric Vehicle Engineering Academy November 15-19, 2010 SAE Automotive Headquarters Troy, Michigan, USA

2 Dear Colleague: We are pleased to announce SAE s first Hybrid and Electric Vehicle Engineering Academy. With an abundance of companies ramping up development plans related to hybrid, plug-in hybrid and battery electric vehicles, many newly hired or transferred engineers have asked for a comprehensive crash course that will extend their understanding of this rapidly developing and dynamic sector. With those needs in mind, we have developed the Hybrid and Electric Vehicle Engineering Academy to quickly bring your organization s key staff up-to-speed on the theory, analysis, design, and validation of hybrid vehicle powertrains. Participation in the Academy will enable the automotive professional to quickly survey the field, master core concepts, and shape his or her future learning path within the field. The Academy will be held November 15 19, 2010 at SAE Automotive Headquarters in Troy, Michigan. You will enjoy five days of structured, immersive training incorporating lectures, demonstrations, student participation, and case studies from the field. Many of the subjects included in this Academy also apply to battery electric vehicles, as well. Please take time to review the enclosed information and curriculum. We are confident that you will find this Academy to be one of the most timely, up-to-date, and relevant advanced technology courses available to the automotive industry today. If you have any questions or would like additional information regarding the Academy, please contact SAE Customer Service at or We look forward to your participation in this year s premier Hybrid and Electric Vehicle Engineering Academy. Sincerely, Jack Rosebro, Thomas Prucha, and Theodore Bohn Instructors

3 About the Hybrid and Electric Vehicle Engineering Academy SAE International is pleased to offer the first Hybrid and Electric Vehicle Engineering Academy. This Academy covers hybrid and electric vehicle engineering concepts, theory, principles, and practices necessary to understand electrified vehicle powertrains, and will focus on gasoline-electric and diesel-electric hybrids. The course will provide a collaborative, immersive learning experience comprised of lectures as well as structured practical sessions, including case studies. Some key hardware examples will also be on-hand. Attendees will gain useful insights into the design and development of hybrid and electrical vehicles taught by a team of instructors with extensive practical industry experience. Learning Objectives By attending this Academy, you will be able to: Describe the different hybrid architectures, their attributes, and appropriate implementation Explain the operation, attributes, and behavior of battery packs, inverters, motor-generators, on-board and off-board charging systems, and DC-DC converters across all ranges of performance Identify the different design configurations and requirements of electric drives in conventional hybrids as well as plug-in hybrids and all-electric vehicles Classify different types of battery packs, inverters, motors, and DC-DC converters Describe the functions and capabilities of an Energy Storage System (ESS) Describe the functions and capabilities of a Battery Management System (BMS) Specify the ESS influences in acceleration and range Apply the concepts of balancing an ESS (automatically and manually) Analyze the design and construction of a given electric powertrain, and evaluate its particular attributes and drawbacks Assess fault detection and protection strategies and circuits as well as on-board diagnostic requirements Appraise technical limitations of electric drive components, as well as design and technological trends that may address such limitations Evaluate internal-combustion engine technologies appropriate to specific hybrid vehicle powertrains List various advanced ancillary devices that can be integrated into hybrid powertrains to help improve overall powertrain efficiency Create a diagram of the power flow within a hybrid vehicle system Demonstrate a working knowledge of hybrid component sizing tools Utilize a greenhouse gas assessment tool (Greenhouse gases, regulated emissions, and energy use in transportation (GREET model) Who Should Attend Individuals who already have a basic understanding of hybrid and/or electric vehicles who are seeking to increase their knowledge and understanding of hybrid vehicle system applications including mechanical and electrical application engineers, design engineers, project managers, and other individuals who are working with or transitioning to hybrid-electric powertrain development for the following vehicle sectors, will find it particularly helpful: Light-duty passenger cars and trucks Medium and heavy-duty trucks and commercial vehicles (non-hydraulic hybrids) Some off-highway applications Prerequisites An engineering degree is highly recommended but not required. This Academy does not cover basic electrical concepts and assumes the attendee already understands such concepts (voltage, current, resistance, capacitance, inductance, etc). In order to understand concepts discussed, all participants are required to have driven an HEV prior to attending the academy. It may be helpful for participants to review the book Propulsion Systems for Hybrid Vehicles by John Miller prior to taking this academy.

4 Topical Outline Monday Basics of Hybrid Powertrains Series, parallel, and series-parallel powertrains HEV, PHEV, and E-REV - operational differences Generic electric drive components and operation Operation of series parallel and two-mode transmissions Plug-In Hybrids (PHEVs), Vehicle-To-Home (V2H), Vehicle-To-Grid (V2G) Advantages and disadvantages of PHEVs AER, charge-depleting and blended modes V2H and V2G integration Overview of Energy Storage Systems (ESS) Electrochemical cell operation Physical cell construction Performance terms (energy density, power density, etc.) Different chemistries (PbA, NiMH, Li-Ion, others) ELDCs, hybrid battery/capacitor systems Generic BMS, sensors, ventilation Relays, service plugs, ground fault detection Series and series-parallel arrangements Packaging issues On-board diagnostics Recycling, recovery, and resource issues Inverter and DC-DC Converter Operation Switching devices Basic DC to AC switching cell Pulse-width modulation (PWM) Space-vector modulation and field weakening Thermal management Packaging issues Boost converters DC-DC converters for 12V/24V bus Bi-directional DC-DC converters for battery charging PMSM and AC Induction Motors Vehicle propulsion needs Motor terms Single-phase motor operation Multiphase motor operation Winding construction PM and IM advantages and disadvantages Reluctance motor-generators Thermal management Fail-safe strategies Tuesday & Wednesday Vehicle Development Energy Storage System (ESS) Design Cell types Cell chemistries Cell configurations (cylindrical, pouch, prismatic etc.) Parallel and series cells Modules Bus bars and power distribution Connectors High voltage power distribution Locations for crashworthiness Structural batteries Liability Battery Management Systems (BMS): Design Considerations State of Charge (SOC) State of Health (SOH) Charge/discharge limits Temperature monitoring Balancing passive and active Safety systems: service disconnects, HV insulation, smoke, fusing, PTCs CAN bus topology and noise immunity Energy Storage System Servicing Better place swap model Installation and removal Manual cell/module balancing Racing applications Upgrades and enhancements Charging Systems Regenerative charging modes: pedal off, blended REGEN with electronic braking controllers On-board and off-board chargers Grid tied charging rates with respect to on-board/offboard Solar charging Auxiliary Power Units The series PHEV, aka E-REV, aka ReEV Operational strategies Charge depletion and charge sustaining modes Internal combustion engine types (Piston, Wankel rotary, microturbine, etc.) APU trailers Motors and Transmissions Centralized motors Per-wheel motors In-wheel motors Powered axles Single-speed transmissions Multi-speed transmissions CVT and ecvt Thursday & Friday Review of previous lessons, requirements and validation of hybrid powertrain design/development to meet those requirements Energy storage systems Motor-generators ICE integration Power electronics Attributes of each hybrid powertrain topology Hybrid Vehicle Testing Vehicle modeling for test plan development Instrumentation associated with vehicle benchmarking Dynamometer and on-track testing for performance, emissions, energy consumption Review of SAE J1711 (hybrid vehicle test procedures) Review of SAE J1634 (EV test procedures) SAE J2841 (utility factor definitions for plug-in hybrid vehicles)

5 Topical Outline (continued) Ratings and Limitations of Electric Drive Systems SAE J2907/J2908 (draft - motor ratings standards: component and vehicle system level) Definitions of load profiles; impulse, transient, peak, steady state Motor and electronics cooling systems Circuit protection and fault detection diagnostics Ancillary drive systems loading impacts AC and DC Off-board Charging Systems/Standards Public charging stations Charge Coupler requirements National Electrical Code (NEC) requirements SAE J1772 (charge coupler standards AC Level 1, 2, and 3) CHAdeMO (Japanese DC Standard) SAE J2847 (charger communication standardsmart grid) Tools to Assess Vehicle Performance and Fuel Consumption Vehicle Miles Traveled (VMT) Sankey power flow diagrams Overview of ADVISOR backward looking vehicle modeling tool Case study: evaluating hypothetical vehicle with constrained mass (e.g. <500kg vehicle) Case study: utilizing a greenhouse gas assessment tool-greet, for fuels/powertrains Advanced Energy Storage System Solutions Battery/capacitor hybrids On-road battery exchange Non-contact power transfer systems Flow batteries Future Trends in Advanced Power Electronics/Drive Systems Multilevel inverters Silicon carbide power devices Advanced component cooling methods Integrated drive systems Wrap-up/Questions and Answers Pre-Academy Activity Prior to attending the Academy, you will be asked to complete a pre-assessment. Results will be shared with the instructors to help establish the baseline of participants knowledge. Based on the results, participants may be asked to review additional material prior to attending the academy. Faculty Jack Rosebro Jack Rosebro is the Principal of Perfect Sky, Inc, an education provider for the automotive industry where he teaches hybrid, plug-in hybrid, and electric vehicle technology to a wide variety of industry professionals throughout North America. He has taught for or consulted to a wide variety of institutions and corporations, and is a frequent lecturer at industry conferences. He also writes articles on sustainable mobility for Green Car Congress. Mr. Rosebro received his Master of Science in Engineering from Blekinge Institute of Technology in Karlskrona, Sweden. Thomas Prucha Thomas Prucha is Principal Applications Engineer at Protean Electric, Inc., a manufacturer of in-wheel electric motor propulsion systems for vehicles. Mr. Prucha is responsible for the continuing development, demonstration, and maintenance of Protean s vehicle fleet in North America. Prior to his current position, he was a Sr. Technical Specialist at FEV, Inc., a world-renowned vehicle integrator for hybrid and electric vehicle applications. Mr. Prucha has more than 30 years of engineering experience in automotive powertrain, mechanics, and electronics. He has specialties in model-based design, rapid controller prototyping, high voltage power distribution systems, energy storage systems, and all aspects of hybrid and electric vehicle control systems. Theodore Bohn Theodore Bohn is the principal investigator of plug-in hybrid electric vehicle (PHEV) prototype vehicle development in the Vehicle Systems Group at the Center for Transportation Research at Argonne National Laboratory. The primary focus of his efforts includes in-vehicle traction battery subsystem benchmarking and validation, as well as power electronics and embedded systems control optimization of the electric powertrain in PHEVs. Recent research includes energy storage system cost, safety, performance and reliability studies, performed as part of the Battery Hardware-in-The-Loop experiments, as well as smart charging and standards related to adaptive charging controls. Mr. Bohn has worked for each of the U.S. based automobile manufacturers as well as various Tier I automotive suppliers and has also held an adjunct faculty position at the University of Wisconsin-Madison. He is the current Advanced Battery Technology Chair for SAE Congress, actively serves on battery and PHEV related SAE technical standards committees, and is the chair of the SAE Electric Machine Rating Standards task force. Mr. Bohn received his B.S. and M.S. in Electrical Engineering from the University of Wisconsin-Madison.

6 Related Education & Training Fundamentals of Shielding Design for EMC Compliance Seminar I.D.# C0835 November 8, 2010 Troy, Michigan This seminar introduces practical shielding theory, design fundamentals, and configurations, including shielding products, common and differential modes, electromagnetic fields, and enclosure shielding. A segment on enclosure testing is presented in conjunction with an aperture attenuation modeling program. Honeycomb vent panels, plating attenuation comparisons, and galvanic compatibility per MIL-STD 1250 will also be discussed. Fees: $725; Classic Members: $653; Premium Members: $616; Elite Members: $580 For complete seminar content, instructor bio and to register visit New! Safe Handling of High Voltage Battery Systems Seminar I.D.# C1019 December 8, 2010, 2010 Troy, Michigan This seminar will introduce participants to the risks encountered in handling high voltage battery systems and their component parts. The seminar will then address how to raise risk awareness and then methods of dealing with those risks. The outcome of this seminar should be improved avoidance of personal injury, reduced risk of reputation loss and product liability actions and reduced risk of loss of property and time. Fees: $725; Classic Members: $653; Premium Members: $616; Elite Members: $580 For complete seminar content, instructor bio and to register visit New! Embedded Control Systems Design Workshop I.D.# C0922 October 4-5, 2010 Troy, Michigan This highly interactive and entertaining seminar will help you learn fundamental concepts needed to design, implement, and calibrate a control function using a microcontroller model car. Overviews of engine, transmission, hybrid control functions and related sensors and actuators including electronic control signals will be presented, as well as microcontroller functions, control algorithms and software, and calibration of the system. Fees: $1,195; Classic Members: $1,076; Premium Members: $1,016; Elite Members: $956 For complete seminar content, instructor bio and to register visit Introduction to Hybrid and Electric Vehicle Battery Systems Seminar I.D.# C0626 December 9-10, 2010 Troy, Michigan This seminar will introduce participants to the concepts of hybrid vehicles, their missions and the role of batteries in fulfilling those requirements. Battery topics including limitations, trends in hybrid development, customer wants and needs, battery system development timelines, comparison of electrochemistries and safety will be examined. Current offerings, cost factors, pack design considerations and testing will also be reviewed. Fees: $1,195; Classic Members: $1,076; Premium Members: $1,016; Elite Members: $956 For complete seminar content, instructor bio and to register visit SAE 2011 Hybrid Vehicle Technology Symposium: Focusing on Technology Advancements and Platform Strategies in HEV, PHEV and BEV February 9-11, 2011 Anaheim, California

7 Registration Information Registration and Fees: Fees: $3,345 SAE Members - Classic: $3,010 Premium: $2,843 Elite: $2,676 Three Easy Ways to Register: Call SAE Customer Service at Or to CustomerService@sae.org Visit the Web site at pdevent/acad05 When registering refer to Product Code ACAD05 The fee for this program includes handout materials, continental breakfast and lunch each day. Telephone registrations must be guaranteed with a credit card. Registration for this Engineering Academy is limited to 30 participants. Cancellations If you cannot attend, you may send a substitute or transfer to a future offering. A full refund is issued if you notify SAE at least 14 days prior to academy start date. If canceled less than 14 days prior, the full fee is charged. For $50, you may process a one time transfer to a future offering within one year of canceled academy. Canceling may reduce group discounts. To cancel, transfer or send a substitute, call SAE Customer Service (numbers listed above). Continuing Education Units Upon completion of the Academy, students will receive a Certificate of Achievement awarding 3.8 Continuing Education Units. CEUs are a nationally recognized unit of measurement based on one CEU for every ten hours of classroom contact. This Academy is approved for IACET CEUs. Academy Site The HEV Academy will be conducted at the SAE Automotive Headquarters, PNC Center, Suite 1600, 755 West Big Beaver Road Troy, Michigan USA Hotel Accommodations Hotel reservations and ground transportation to and from the Academy site are the responsibility of the attendee. For hotel and travel information visit click on Hybrid Academy, then Hotel & Travel Information or contact SAE Customer Service. SAE will do what is feasible to make its events reasonably accessible to attendees. If you have special accommodation needs, please let us know in advance of how we can serve you better. Accommodations requested on-site will be provided only if possible for us to do so on short notice. Do you order standards frequently? Consider JPaks, a cost-effective, customized, and convenient way to purchase SAE standards. P100977

8 New! Hybrid and Electric Vehicle Engineering Academy November 15-19, 2010 SAE Automotive Headquarters Troy, Michigan, USA P100911