HYBRID ELECTRIC VEHICLE SYSTEM MODELING AND CONTROL

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1 HYBRID ELECTRIC VEHICLE SYSTEM MODELING AND CONTROL Second Edition Wei Liu General Motors, USA WlLEY

Contents Preface List of Abbreviations Nomenclature xiv xviii xxii 1 Introduction 1 1.1 Classification of Hybrid Electric Vehicles 2 1.1.1 Micro Hybrid Electric Vehicles 2 1.1.2 Mild Hybrid Electric Vehicles 2 1.

2 Contents Preface List of Abbreviations Nomenclature xiv xviii xxii 1 Introduction Classification of Hybrid Electric Vehicles Micro Hybrid Electric Vehicles Mild Hybrid Electric Vehicles Füll Hybrid Electric Vehicles Electric Vehicles Plug-in Hybrid Electric Vehicles General Architectures of Hybrid Electric Vehicles Series Hybrid Parallel Hybrid Series-Parallel Hybrid Typical Layouts of the Parallel Hybrid Electric Propulsion System Hybrid Electric Vehicle System Components Hybrid Electric Vehicle System Analysis Power Flow of Hybrid Electric Vehicles Fuel Economy Benefits of Hybrid Electric Vehicles Typical Drive Cycles Vehicle Drivability Hybrid Electric Vehicle Fuel Economy and Emissions Controls of Hybrid Electric Vehicles 13 References 14

viii Contents Basic Components of Hybrid Electric Vehicles 15 2.1 The Prime Mover 15 2.7.7 Gasoline Engines 15 2.7.2 Diesel Engines 17 2.1.3 Fuel Cells 17 2.

3 viii Contents Basic Components of Hybrid Electric Vehicles The Prime Mover Gasoline Engines Diesel Engines Fuel Cells Electric Motor with a DC-DC Converter and a DC-AC Inverter Energy Storage System Energy Storage System Requirements for Hybrid Electric Vehicles Basic Types ofbattery for Hybrid Electric Vehicle System Applications Ultracapacitors for Hybrid Electric Vehicle System Applications Transmission System in Hybrid Electric Vehicles 35 References 37 Hybrid Electric Vehicle System Modeling Modeling of an Internal Combustion Engine Cranking (Key Start) Engine Off Idle Engine On Engine Fuel Economy and Emissions Modeling of an Electric Motor Operation in the Propulsion Mode Operation in the Regenerative Mode Operation in Spinning Mode Modeling of the Battery System Modeling Electrica! Behavior SOC Calculation Modeling Thermal Behavior Modeling of the Transmission System Modeling ofthe Clutch and Power Split Device Modeling ofthe Torque Converter Modeling of the Gearbox Modeling of the Transmission Controller Modeling of a Multi-mode Electrically Variable Transmission Basics of One-mode ECVT Basics of Two-mode ECVT Lever Analogy as a Tool for ECVT Kinematic Analysis Lever System Diagram Set-up Lever Analogy Diagram for ECVT Kinematic Analysis Modeling of the Vehicle Body 91

Contents ix 3.8 Modeling of the Final Drive and Wheel 92 3.8.1 Final Drive Model 92 3.8.2 Wheel Model 92 3.9 PID-based Driver Model 94 3.9.1 Principle ofpid Control 95 3.9.2 Driver Model 96 References 96 Power Electronics and Electric Motor Drives in Hybrid Electric Vehicles 97 4.

4 Contents ix 3.8 Modeling of the Final Drive and Wheel Final Drive Model Wheel Model PID-based Driver Model Principle ofpid Control Driver Model 96 References 96 Power Electronics and Electric Motor Drives in Hybrid Electric Vehicles Basic Power Electronic Devices Diodes Thyristors Bipolar Junction Transistors (BJTs) Metal Oxide Semiconductor Field Effect Transistors (MOSFETs) Insulated Gate Bipolar Transistors (IGBTs) DC-DC Converters Basic Principle of a DC-DC Converter Step-down (Bück) Converter Step-up (Boost) Converter Step-down/up (Buck-boost) Converter DC-DC Converters Applied in Hybrid Electric Vehicle Systems DC-AC Inverters Basic Concepts of DC-AC Inverters Single-phase DC-AC Inverters Three-phase DC-AC Inverters Electric Motor Drives BLDC Motor and Control AC Induction Motor and Control Plug-in Battery Charger Design Basic Configuration of a PHEV/BEV Battery Charger Power Factor and Correcting Techniques Controls of a Plug-in Charger 168 References 168 Energy Storage System Modeling and Control Introduction Methods of Determining the State of Charge Current-based SOC Determination Method Voltage-based SOC Determination Method Extended Kalman-filter-based SOC Determination Method SOC Determination Method Based on Transient Response Characteristics (TRCs) 186

5.2.5 Fuzzy-logic-based SOC Determination Method 189 5.2.6 Combination ofsocs Estimated Through Dijferent Approaches 191 5.2.7 Further Discussion on SOC Calculations in Hybrid Electric Vehicle Applications 192 5.

5 5.2.5 Fuzzy-logic-based SOC Determination Method Combination ofsocs Estimated Through Dijferent Approaches Further Discussion on SOC Calculations in Hybrid Electric Vehicle Applications Estimation of Battery Power Availability PNGV HPPC Power Availability Estimation Method Revised PNGV HPPC Power Availability Estimation Method Power Availability Estimation Based on the Electrical Circuit Equivalent Model Battery Life Prediction Aging Behavior and Mechanism Definition ofthe State oflife SOL Determination under Storage Conditions SOL Determination under Cycling Conditions Lithium Metal Plating Issue and Symptoms in Li-ion Batteries Cell Balancing SOC Balancing Hardware Implementation of Balancing Cell-balancing Control Algorithms and Evaluation Estimation of Cell Core Temperature Introduction Core Temperature Estimation of an Air-cooled, Cylinder-type HEVBattery Battery System Efficiency 241 References 242 Energy Management Strategies for Hybrid Electric Vehicles Introduction Rule-based Energy Management Strategy Fuzzy-logic-based Energy Management Strategy Fuzzy Logic Control Fuzzy-logic-based HEV Energy Management Strategy Determination of the Optimal ICE Operational Points of Hybrid Electric Vehicles Mathematical Description of the Problem Procedures of Optimal Operational Point Determination Golden Section Searching Method Finding the Optimal Operational Points Example of the Optimal Determination Performance Evaluation Cost-function-based Optimal Energy Management Strategy Mathematical Description of Cost-function-based Optimal Energy Management An Example of Optimization Implementation 282

Contents xi 6.6 Optimal Energy Management Strategy Incorporated with Cycle Pattern Recognition 282 6.6.1 Driving Cycle/Style Pattern Recognition Algorithm 282 6.6.2 Determination of the Optimal Energy Distribution 285 References 287 Other Hybrid Electric Vehicle Control Problems 288 7.

6 Contents xi 6.6 Optimal Energy Management Strategy Incorporated with Cycle Pattern Recognition Driving Cycle/Style Pattern Recognition Algorithm Determination of the Optimal Energy Distribution 285 References 287 Other Hybrid Electric Vehicle Control Problems Basics of Internal Combustion Engine Control SI Engine Control Diesel Engine Control Engine Torque Fluctuation Dumping Control Through the Electric Motor Sliding Mode Control Engine Torque Fluctuation Dumping Control Based on the Sliding Mode Control Method High-voltage Bus Spike Control Bang-Bang Control Strategy of Overvoltage Protection PID-based ON/OFF Control Strategy for Overvoltage Protection Fuzzy-logic-based ON/OFF Control Strategy for Overvoltage Protection Thermal Control of an HEV Battery System Combined PID Feedback with Feedforward Battery Thermal System Control Strategy Optimal Battery Thermal Control Strategy HEV/EV Traction Motor Control Traction Torque Control Anti-rollback Control Active Suspension Control in HEV/EV Systems Suspension System Model of a Quarter Car Active Suspension System Control Adaptive Charge-sustaining Setpoint and Adaptive Recharge SOC Determination for PHEVs Scenarios of Battery Capacity Decay and Discharge Power Capability Degradation Adaptive Recharge SOC Termination Setpoint Control Strategy Online Tuning Strategy of the SOC Lower Bound in CS Operational Mode PHEV Charge-sustaining Operational Characteristics PHEV Battery CS-operation SOC Lower Bound Online Tuning PHEV Battery CS-operation Nominal SOC Setpoint Online Tuning PHEV CS-operation Nominal SOC Setpoint Determination at BOT Online Tuning Strategy ofphev CS-operation Nominal SOC Setpoint 345 References 347

XU Contents 8 Plug-in Charging Charactenstics, Algorithm, and Impact on the Power Distribution System 348 8.1 Introduction 348 8.

7 XU Contents 8 Plug-in Charging Charactenstics, Algorithm, and Impact on the Power Distribution System Introduction Plug-in Hybrid Vehicle Battery System and Charging Characteristics AC-120 Plug-in Charging Characteristics AC-240 Plug-in Charging Characteristics DC Fast-charging Characteristics Battery Life and Safety Impacts of Plug-in Charging Current and Temperature Plug-in Charging Control AC Plug-in Charge Control DC Fast-charging Control Impacts of Plug-in Charging on the Electricity Network Impact on the Distribution System Impact on the Electric Grid Optimal Plug-in Charging Strategy The Optimal Plug-in Charge Back Point Determination Cost-based Optimal Plug-in Charging Strategy 366 References Hybrid Electric Vehicle Vibration, Noise, and Control Basics of Noise and Vibration Sound Spectra and Velocity Basic Quantities Related to Sound 31A Frequency Analysis Bandwidths Basics of Vibration Basics of Noise and Vibration Control General Description of Noise, Vibration, and Control in Hybrid Electric Vehicles Engine Start/Stop Vibration, Noise, and Control Electric Motor Noise, Vibration, and Control Power Electronics Noise and Control Battery System Noise, Vibration, and Control 408 References Hybrid Electric Vehicle Design and Performance Analysis Hybrid Electric Vehicle Simulation System Typical Test Driving Cycles Typical EPA Fuel Economy Test Schedules Typical Supplemental Fuel Economy Test Schedules Other Typical Test Schedules All 10.3 Sizing Components and Vehicle Performance Analysis Drivability Calculation 431

8 Contents xiii Preliminary Sizing ofthe Main Components ofa Hybrid Electric Vehicle Fuel Economy, Emissions, and Electric Mileage Calculation Basics offuel Economy and Emissions Calculation EPA Fuel Economy Label Test and Calculation Electrical Energy Consumption and Miles per Gallon Gasoline Equivalent Calculation 463 References 478 Appendix A 480 Appendix B 520 Index 553

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