Configuration, Sizing and Control of Power-Split Hybrid Vehicles

Transcription

1 Configuration, izing and Control of Power-plit Hybrid Vehicles Huei PENG Professor, Department of Mechanical Engineering Executive Director, Interdisciplinary and Professional Engineering Programs University of Michigan Most of the work is based on the research of several Ph.D. students who worked with the author at the University of Michigan: C. Lin, D. Kim, and J. Liu. 8 ACC HEV workshop-

2 Power-plit Hybrid Powertrain ystem Engine Generator Transmission Vehicle Battery Motor Parallel HEV eries HEV Power-plit HEV 8 ACC HEV workshop-

3 HEV is ~3% of U Vehicle ales and Growing In April 8, hybrids sale up 46% in the U while overall car market down by 4% 8 ACC HEV workshop- 3

4 plit Hybrids Dominate Current Market split 8 ACC HEV workshop- 4

5 More plit Hybrids Are Coming Many GM-BMW-Daimler-Chrysler dual-mode models are or will be coming to the market. Chevrolet Tahoe, GMC Yukon, Chevy ilverado, aturn Vue, BMW X3 and X6, Dodge Durango(?) 8 ACC HEV workshop- 5

6 Popular plit Hybrid Vehicle Configurations Toyota Hybrid ystem Planetary Gear et Power Bus Battery Engine M/G M/G Vehicle Mechanical Linkage Electrical Linkage Allison Hybrid ystem Power Bus Battery Clutch M/G Clutch M/G Engine Vehicle Planetary Gear Holmes, A. G., Klemen, D., chmidt, M.., Electrically Variable Transmission with elective Input plit, Compound plit, Neutral and everse Modes, U.. Patent Number 6,57,658 B, issued Mar. 4, 3. Planetary Gear Mechanical Linkage Electrical Linkage 8 ACC HEV workshop- 6

7 Power-plit Hybrid Powertrain ystem Engine M/G Power plit CVT Vehicle U Patent 6,57,658 B U Patent 6,478,75 U Patent 5,93,757 Battery M/G Hermance,D. and Abe,., Hybrid Vehicles Lesson Learned and Future Prospects, AE # ACC HEV workshop- 7

8 Major Decisions for plit Hybrid Vehicle Design Configurations cattered in patents/few papers A systematic method to search through all possible configurations (and derive models quickly) has both academic and practical value Component sizing Given performance spec, find proper component sizes Control Dynamic Programming or implemented versions (suboptimal) 8 ACC HEV workshop- 8

9 Outline Introduction Dynamic Modeling of Power-plit Hybrid Vehicles Automated Modeling of Power-plit Hybrid Vehicles Configuration creening of Power-plit Hybrid Vehicles Combined Configuration Design, Component izing, and Control optimization of Power-plit Hybrid Vehicles Conclusion 8 ACC HEV workshop- 9

10 Modeling of a Power-plit Hybrid Vehicle Engine Driver upervisory Controller M/G Power plit CVT Vehicle Battery M/G 8 ACC HEV workshop-

11 Model Derivation of a Dual-Mode Power-plit Powertrain Mechanical Path Holmes, A. G., Klemen, D., chmidt, M.., Electrically Variable Transmission with elective Input plit, Compound plit, Neutral and everse Modes, U.. Patent Number 6,57,658 B, issued Mar. 4, 3.Gino T, ω F F T m/g ω ω ω ω ω e ω MG MG ( ) = e = ω ( ) MG out ( I I = T F F e ) c ω ( I I ) = T F e MG MG s MG ω ( I I I ) = T F F MG MG s r MG ω m I K F F K T mgf AC K K tire out 3 out ( c ) = ( ) fb r tire.5 ρ d ( ) tire T f M Ground K Clutch F F F F F Clutch F T e T m/g I m/g I e I m/g 8 ACC HEV workshop-

12 Model Derivation of a Dual-Mode Power-plit Powertrain Mechanical Path Holmes, A. G., Klemen, D., chmidt, M.., Electrically Variable Transmission with elective Input plit, Compound plit, Neutral and everse Modes, U.. Patent Number 6,57,658 B, issued Mar. 4, 3.Gino T, ω F F T m/g I m/g T f F F F F T e M K I e F F T m/g Ground Clutch Clutch I m/g Ie Ic Te ω e tire ω m I.5 ( ) c ω T mgf ρac K K K ωmg IMG Is = ωmg IMG Ir Is TMG T F MG F out 3 out fb r tire d tire 8 ACC HEV workshop-

13 Model Derivation of a Dual-Mode Power-plit Powertrain Mechanical Path Holmes, A. G., Klemen, D., chmidt, M.., Electrically Variable Transmission with elective Input plit, Compound plit, Neutral and everse Modes, U.. Patent Number 6,57,658 B, issued Mar. 4, 3.Gino T, ω F F T m/g I m/g T f F F F F T e M K I e F F T m/g Ground Clutch Clutch I m/g Ie Ic Te ω e tire ω m I.5 ( c ω out out Tfb mgfr tire ACd K ρ ) K ωmg K IMG Is Ir = ωmg IMG Ir Is TMG T F MG F 3 tire 8 ACC HEV workshop- 3

14 Outline Introduction Dynamic Modeling of Power-plit Hybrid Vehicles Automated Modeling of Power-plit Hybrid Vehicles Configuration creening of Power-plit Hybrid Vehicles Combined Configuration Design, Component izing, and Control optimization of Power-plit Hybrid Vehicles Conclusion 8 ACC HEV workshop- 4

15 Configuration earch Let s limit the scope to a split hybrid with planetary gears. Is there a universal model format which enables automatic modeling? 8 ACC HEV workshop- 5

16 Universal Format of the Power-plit Powertrain Mode I I e c e ω e tire out m I.5 ( ) c ω ω 3 out Tfb mgfr tire ρacd t ire K ω MG IMG Is = MG IMG Ir Is ω F F K T T T mg / mg / K J(4 4) D(4 ) Ω T T D( 4) = ( ) F 8 ACC HEV workshop- 6

17 7 8 ACC HEV workshop- Automated Generation of the Input Matrix D T T E E E E I A ) ( = J AJ T Ω= D J E = 3 3 3

18 ules to Generate the D and J matrix with a Power-plit Powertrain Design. Generate Kinematical Constraint Matrix D ule : The number of columns of D is equals to the number of planetary gears. ule : The number of rows of D is equals to the number of columns of D plus two, each representing a node on the lever diagram. ule 3: For the power source component(s) at each row, the node coefficient should be entered. The node coefficient is equals to: -i if connected to the sun gear; -i if connected to the ring gear; or ii if connected to the carrier gear. Here the subscript i presents the corresponding planetary gear set. ule 4: Fill all other entries in matrix D with zeros. ule 5: Matrix D can be further simplified to 4x using the information on the free-rolling node(s). Generate Inertia Matrix J Diagonal matrix with inertia of power source components. 8 ACC HEV workshop- 8

19 Example of Generating Powertrain Model (PG) PG PG Engine Vehicle M/G M/G PG PG PG PG Engine Vehicle M/G M/G 8 ACC HEV workshop- 9

20 8 ACC HEV workshop- GM Three Planetary Gears ECVT (chmidt, 999) Timken ystem (Ai and Mohr, 4) GM Two Planetary Gears ECVT (Holmes et al. 3) Toyota Hybrid ystem for Lexus G45 (Hermance and Abe, 6) Toyota Hybrid ystem for Highlander (Hermance and Abe, 6) Toyota Hybrid ystem for Prius (Hermance, 999) Design Matrices (Model) Design Low peed High peed

21 Model Corresponds To Configuration Given Configuration Engine Vehicle M/G M/G PG PG Engine Vehicle M/G M/G PG PG Given Model 8 ACC HEV workshop-

22 Outline Introduction Dynamic Modeling of Power-plit Hybrid Vehicles Automated Modeling of Power-plit Hybrid Vehicles Configuration creening of Power-plit Hybrid Vehicles Combined Configuration Design, Component izing, and Control optimization of Power-plit Hybrid Vehicles Conclusion 8 ACC HEV workshop-

23 Configuration creening Process Design Objective: Target Vehicle: HMMWV 54kg Engine: 8 KW MG MG = 6 KW PG ystem Design Automatically Generated All Possible Candidates: 4 4 / 4 36 = 5 Candidates: ACC HEV workshop- 3

24 Configuration creening Process _ tep Check Physical Feasibility MG Engine MG K Vehicle Ground The Feasibility corresponds to the DOF of the Powertrain ω ω D D D T T e T MG Ω= EV MG = ω out ω MG ω ω =D D MG T T e MG EV ω MG ω out Candidates: ACC HEV workshop- 4

25 Configuration creening Process _ tep TH configuration MG is limited to 3KW TH configuration MG is limited to 9KW T MG T MG_max T MG_max T MG_min T MG T MG_min PG AH configuration MG is limited to 3KW TMG = ( Pd Pe TMG ωmg)/ ωmg T MG T MG_max T MG_min Candidates: ACC HEV workshop- 5

26 Configuration creening Process _ tep Check Drivability ω ω ω e_min e_ k e_max ω ω ω e_min e_ k e_max ω ω ω MG_min MG_ k MG_max T T T MG_min MG_ k MG_max ω ω ω MG_min MG_ k MG_max T T T MG_min MG_ k MG_max T MG T MG_max T MG_min Candidates: ACC HEV workshop- 6

27 Configuration creening Process _ tep 3 Check Possible hifting Mode D mode = Engine MG CL CL Ground K Vehicle MG D = D mode = Engine MG CL MG K Vehicle Ground CL Candidates: ACC HEV workshop- 7

28 Configuration creening Process _ tep 3 Check Transmission Efficiency (Mechanical Point) Conlon, 5, Comparative Analysis of ingle and Combined Hybrid Electrically Variable Transmission Operating Modes Vehicle speed v Engine power P e Candidates: ACC HEV workshop- 8

29 Configuration creening Process _ tep 3 Check Transmission Efficiency (Mechanical Point) Conlon, 5, Comparative Analysis of ingle and Combined Hybrid Electrically Variable Transmission Operating Modes Vehicle speed v Engine power P e Candidates: ACC HEV workshop- 9

30 Configuration creening Process _ tep 3 Check Transmission Efficiency (Mechanical Point) Input-split: close to first gear Compound-split: close to overdrive gear ω ω =D D MG T T e MG EV ω MG ω out Conlon, 5, Comparative Analysis of ingle and Combined Hybrid Electrically Variable Transmission Operating Modes Candidates: ACC HEV workshop- 3

31 Outline Introduction Dynamic Modeling of Power-plit Hybrid Vehicles Automated Modeling of Power-plit Hybrid Vehicles Configuration creening of Power-plit Hybrid Vehicles Combined Configuration Design, Component izing, and Control optimization of Power-plit Hybrid Vehicles Conclusion 8 ACC HEV workshop- 3

32 Dynamic Programming to et Fuel Economy Benchmark 6 vehicle speed (mph) Inputs: T MG T e T MG tates: ω e (k) v(k) OC(k) Vehicle Dynamics ω e (k) v(k) OC(k) time (s) Cost Function N J = fuel αδ k= k OC Transitional cost Constraints ωe_min ωe_ k ω e_max ωe_min ωe_ k ωe_max ω ω ω T T T Fuel Consumption OC error MG_min MG_ k MG_max MG_min MG_ k MG_max ω ω ω T T T MG _ min MG _ k MG _ max MG _ min MG _ k MG _ max 8 ACC HEV workshop- 3

33 DP fuel economy results for different gear dimensions on the partial EPA urban cycle (Powertrain #) K K i = i i i (.5 < K < Fuel(mpg) K=.6.8 K= ) K ACC HEV workshop- 33

34 Effect of the Electric Machine izes Engine M/G Power plit ECVT Vehicle Battery M/G Everage Fuel Economy (mpg) t t t3 t4 t5 MG(kW) MG(kW) 8 ACC HEV workshop- 34

35 Comparison Between Different Configuration Designs Fuel efficiency Comparison esults PT # Target Vehicle: HMMWV 54kg Engine: 8 KW MG MG: 6 KW PT # K=.6 K=.8 MG= kw MG=4 kw K=.8 K=. MG= kw MG=4 kw 8 ACC HEV workshop- 35

36 Outline Introduction Dynamic Modeling of Power-plit Hybrid Vehicles Automated Modeling of Power-plit Hybrid Vehicles Configuration creening of Power-plit Hybrid Vehicles Combined Configuration Design, Component izing, and Control optimization of Power-plit Hybrid Vehicles Conclusion 8 ACC HEV workshop- 36

37 Conclusions A universal dynamic model for power-split HEVs, which can be used for exhaustive search of split hybrid configurations. A screening process systematically checks the configuration candidates based on optimal design and optimal control results. 8 ACC HEV workshop- 37