Design of Planetary Plug-in Hybrid Powertrain and Its Control Strategy

Transcription

1 Wold Electic Vehicle Jounal Vol. 4 - ISSN WEVA Page EVS25 Shenzhen, China, Nov 5-9, 2010 Design of Planetay Plug-in Hybid Powetain and Its Contol Stategy Antoni Szumanowski 1, Zhiyin Liu 1, Yuhua Chang 1 1 The Faculty of Automotive and Constuction Machiney Engineeing, Wasaw Univesity of Technology, ul. Nabutta 84, Wasaw, , Poland Antoni.Szumanowski@sim.pw.edu.pl, zliu@sim.pw.edu.pl, yuhua.chang@sim.pw.edu.pl Abstact This pape pesents the new compact hybid planetay tansmission dive (CHPTD) as a solution of plug-in hybid electic vehicle (PHEV). The pesented CHPTD is moe compact and lowe costs than othe seiespaallel hybid dives equipped with planetay tansmission and two motos. Pope achitectue and elements wee designed to achieve functions of PHEV. The powetain and its components wee optimized and detemined by nonlinea dynamic modeling and simulations. Paametes of powetain wee adjusted and optimized by obsevation of simulation esults. Two basic contol stategies wee analyzed to achieve minimum enegy consumption and suitable opeation ange of battey state of chage. The vey effective opeation of the woked out powetain was poved by tests in diffeent diving conditions egading city taffic and subub aea. The advantages of planetay tansmission which is powe summing mechanical unit, was obtained by pope design and contol of innovative high enegy saving electomagnetic clutch/bake device based on classic dual-diaphagm sping system. Keywods plug-in hybid, planetay tansmission, design, simulation, enegy consumption minimizing 1 Configuation design of plug-in hybid powetain with planetay tansmission 1.1 Configuation design Diffeent topologies of hybid powetain system have been developed in the past decades. Geneally, plug-in hybids ae based on the same powetain achitectues as conventional electic hybids. The Compact Hybid Planetay Tansmission Dive (CHPTD) is a complex hybid powetain achitectue which was oiginal invented and developed by Pof. Szumanowski [1]. In this pape, CHPTD is applied as basic achitectue in configuation design of plug-in hybid powetain. Figue 1 shows the new CHPTD with pope adjustment fo plug-in hybid. M 4Q ICE CHPTD with 2-step geabox and C/B system Bake I Clutch/Bake II Planetay geabox 2-step geabox Clutch III Diffeential Fig. 1: Configuation of new CHPTD with pope adjustment fo plug-in hybid EVS25 Wold Battey, Hybid and Fuel Cell Electic Vehicle Symposium 1

2 Wold Electic Vehicle Jounal Vol. 4 - ISSN WEVA Page CHPTD uses only one electic moto fo all opeating modes such as pue electic dive, hybid dive and egeneative baking. A small intenal combustion engine is employed as an altenative powe souce. As a powe summing unit, the planetay geabox combines two powe souces. Clutch/bake system is equipped in powetain to achieve diffeent opeating modes of plug-in hybid powetain. When eithe Bake I o Clutch/Bake II woks in baking status, the feedom degee of planetay geabox deceases fom 2 to 1. It gives moe possibility and flexibility fo advanced contol stategies of plugin hybid powetain. Additionally, a 2-step geabox is equipped to obtain bette pefomance of enegy consumption in diffeent woking conditions. It also extends the diving ange of hybid vehicle. 1.2 Clutch/bake system design The clutch/bake system employed in the plug-in hybid powetain influences the pefomance of whole system. Howeve, the existent electomagnetic clutch/bake system consumes electic powe continuously. To minimize the enegy consumption, the innovative zeo steadystates electical enegy consumption clutch/bake system is selected [2]. Figue 2 pesents the clutch/bake system fo diffeent applications, which consists of bake, clutch/bake and clutch fo thee shafts. Fig. 2: Constuction of zeo steady-states electical enegy consumption clutch/bake systems 1- Electomagnetic actuato; 2 - Clutch elease plate; 3 - Fiction plate; 4 - diaphagm sping By pofiting fom the nonlinea chaacteistic of dual-diaphagm sping, the clutch/bake system can keep steady-states without consuming any electic enegy. 2 Modeling In ode to evaluate the feasibility of designed planetay plug-in hybid powetain and to optimize the paametes of system, dynamic model was built in MATLAB SIMULINK envionment by using the oiginal mathematical o digital models of each components. Fig. 3: The simulation flow of planetay plug-in hybid powetain dynamic model 2.1 Vehicle model The mathematical equations used fo vehicle model ae as following. The gadient esistance Fg was ignoed to simplify the model. M ( F F F F ) (1) wheel f aeo acc g dyn F mgcos f (2) f ca F dv Js j m Jk Facc mb ( b 1 ) dt m x 2 aeo v (3) dyn (4) 2.2 Planetay tansmission model Planetay geabox combines powe, toque and angula velocities of ICE, electic moto and output shaft. In this application, the ICE, electic moto and output shaft connect to sun wheel, cown and yoke of planetay gea sepaately. The following equations descibe the elation of toque and angula velocity. In these equations, kp is basic atio of planetay gea which makes big influence on powe summing and diffeencing of hybid powetain. k 1 k ) 0 (5) 1 p 2 ( p 3 1 J M M (6) k p k 1 J M M (7) p k p 2.3 ICE model ICE model is based on engine map (Figue 4). By inputting toque and otay speed of engine, fuel EVS25 Wold Battey, Hybid and Fuel Cell Electic Vehicle Symposium 2

3 Wold Electic Vehicle Jounal Vol. 4 - ISSN WEVA Page consumption ate is obtained as output of engine map. Table 1 shows the factos in equation (8) and (9) fo 30Ah/43V Li-ion module fom SAFT company which is used in simulation. The appoximated equation and factos ae based on battey dischaging chaacteistics obtained by expeiments. Fig. 6: The battey model in MATLAB SIMULINK Fig. 4: Engine map 2.4 Electic moto model The electic moto model is based on efficiency map of electic moto and invete (Figue 5). Powe efficiency is obtained by inputting the toque and moto otay speed. Fig. 5: Efficiency map of electic moto with invete Table 1: Factos of equation (8) and (9) fo 30Ah Liion battey module fom SAFT: Factos Intenal esistance duing dischaging R(k) Electomotive foce E(k) A B C D E F G Simulation esults 3.1 Simulation paametes In ode to analyze the influence of diffeent contol stategies and paametes, seveal compaison simulations wee done unde NEDC (New Euopean Diving Cycle). An ulta-light basket-tube fame vehicle is consideed as the vehicle model (Figue 7). The dimension of the ca is 3m in length and 1.5m in width. Table 2 shows the paametes of planetay plug-in hybid powetain. 2.5 Battey model A nonlinea dynamic battey model is used in battey modeling [4]. In this method, the electomotive foce E and intenal esistance ae esolved in 6-ode algebaic expession of battey SOC k E k Ak Bk Ck Dk Ek Fk G () e e e e e e e R k Ak Bk Ck Dk Ek Fk G (8) () (9) EVS25 Wold Battey, Hybid and Fuel Cell Electic Vehicle Symposium 3

4 Wold Electic Vehicle Jounal Vol. 4 - ISSN WEVA Page Fig. 7: The ulta-light basket-tube fame vehicle designed and pototyped by Pof. Szumanowski goup Table 2: Paametes of planetay plug-in hybid powetain and its components Vehicle Vehicle mass [kg] 750 Rolling esistance coefficient Aeodynamic dag coefficient Font suface squae [ m ] 1.6 Dynamic adius of wheel [m] Basic atio of planetay gea 1.99 Diving cycle NEDC Main educe atio 3.62 Reduce atio between moto and planetay tansmission 1.35 Battey Battey type Li-ion Battey pack numbe 3 Nominal voltage [V] 43*3 Nominal capacity [Ah] 30 PM moto Peak powe [kw] 75 Continuous powe [kw] 30 Maximal otay speed [pm] 5000 Nominal toque [Nm] 60 Maximal toque [Nm] 240 Themal engine (Gasoline) 3 Volume [ cm ] 1200 Maximal powe [kw] 35 Maximal toque [Nm] 78 Rotay speed ang [pm] 1000~ Basic contol stategy The contol of whole powetain is connected with clutch/bake opeations. Table 3 shows the elation between contol signal of clutch/bake system and opeating modes of powetain. In contol stategy, vehicle speed, toque on tansmission shaft and battey SOC ae used as feedback signals fo changing the opeating mode of powetain. The basic contol method is listed as below. Fo stating, pue electic mode is enabled to educe emission. Fo low speed and middle speed, contol system detemines the opeation mode accoding to toque on tansmission shaft and battey SOC. When toque is too low, pue electic mode is selected to avoid ICE woking in a poo condition. Fo high speed mode, hybid mode is selected when SOC is ove theshold. If SOC is lowe than theshold, pue engine mode is enabled to potect battey. Table 3: Contol signal of clutch/bake systems fo diffeent opeating modes of plug-in hybid powetain Opeation mode of plug-in hybid powetain Pue electic dive and egeneative bake Contol signal of clutch/bake systems Clutch/Bake Bake I* II** Pue engine dive on on Hybid dive on Engine chage battey (when vehicle stop) * on indicates bake engaged; ** on indicates clutch engaged and bake disengaged. 3.3 Compaison simulation fo diffeent contol stategies To investigate the influence of diffeent contol stategies, this pape sets up two contol stategies fo demonstation which ae Stategy I and Stategy II. In Stategy I, it uses vehicle speed coopeated with toque on tansmission shaft as feedback signal fo changing opeation mode. In Stategy II, it uses toque on tansmission shaft coopeated with demand powe as feedback signal fo changing opeation mode. EVS25 Wold Battey, Hybid and Fuel Cell Electic Vehicle Symposium 4

5 Wold Electic Vehicle Jounal Vol. 4 - ISSN WEVA Page Fig. 8: Compaison of aveage fuel consumption in diffeent contol stategy Fig. 9: Compaison of battey SOC in diffeent contol stategy Figue 8 and 9 show the simulation esults fo Stategy I and Stategy II. Fo the same diving ange (540km), fuel consumption of Stategy I is less than that of Stategy II by 2%. By the end of simulation, battey SOC is limited to the pope set value in Stategy II. While in Stategy I, battey SOC is out of contol and deceases to It means that the powetain could wok in hybid mode fo long distance diving to achieve bette fuel economy without damaging the battey. Consideing equiements of plug-in hybid and simila fuel economy pefomance, Stategy II is bette than Stategy I. 3.4 Simulation fo pue electic dive Battey capacity influences diving ange fo pue electic dive of plug-in hybid powetain. To fulfill the functionality of plug-in hybid, battey capacity is adjusted to 3.9kWh. Accoding to simulation esults, the hybid powetain could dive ove 50km fo pue electic dive with full chaged battey. 3.5 Optimization of 2-step geabox The 2-step geabox is an impotant element fo the plug-in hybid powetain. With pope adjusted gea atio and gea changing stategy, it could incease the enegy efficiency fo diffeent diving conditions egading to city taffic and sububan aea. Table 4 shows simulation esults fo diffeent gea atios. In these simulation expeiments, diving ange and battey conditions ae the same. Accoding to simulation esults, smalle 2ed-gea atio could achieve bette fuel efficiency fo high speed dive. Howeve, by changing gea atio, it also changes the opeating points of ICE on engine map. With limitation of opeating ange, the adjustment of gea atio should coopeate with obseving the opeating points to keep ICE woking in efficient aea. Table 4: Compaison of simulation esults fo diffeent gea atios 1 st - gea 2edgea Speed theshold fo changing gea (km/h) Aveage fuel consumption (L/100km) The simulation esults in Table 5 pove that the speed theshold fo changing gea also has influence on fuel consumption. Futhemoe, the main educe atio and additional gea atio between engine and planetay tansmission ae pope adjusted to coopeate with 2-step geabox fo minimizing fuel consumption. Table 5: Compaison of simulation esults fo diffeent speed theshold with the same gea atio 1/0.8 Speed theshold fo changing gea (km/h) Aveage fuel consumption (L/100km) Conclusions This pape pesents the method of designing plugin hybid powetain with planetay tansmission based on CHPTD. CHPTD is moe compact and lowe costs than othe seies-paallel hybid dives equipped with planetay tansmission and two motos. Dynamic model of the powetain has been established in MATLAB SIMULINK envionment. The simulation esults show: EVS25 Wold Battey, Hybid and Fuel Cell Electic Vehicle Symposium 5

6 Wold Electic Vehicle Jounal Vol. 4 - ISSN WEVA Page CHPTD is a suitable configuation fo plug-in hybid application. The advantage of planetay tansmission is obtained by pope design and contol of new electomagnetic clutch/bake device based on classic dual-diaphagm sping system. Contol stategy influences the pefomance of hybid powetain a lot. With pope designed contol stategy, the plug-in hybid powetain could achieve good pefomance on fuel consumption and battey SOC management. With optimized gea atio and contol stategy, the implementation of 2-step geabox inceases the fuel efficiency in diffeent diving conditions. Accoding to compaison simulation esults, the fuel consumption of hybid powetain with 2-step geabox is deceased by 9% than that without 2- step geabox. Refeences [1] Antoni Szumanowski, Yuhua Chang and Piot Piókowski, Analysis of Diffeent Contol Stategies and Opeating Modes of Compact Hybid Planetay Tansmission Dive, Vehicle Powe and Populsion, 2005 IEEE Confeence, Sep [2] Antoni Szumanowski, Zhiyin Liu and Hajduga Akadiusz, Zeo Steady-states Electical Enegy Consumption Clutch System, High Technology Lettes, Vol.16 No.1, Ma. 2010, pp: [3] Keyu Chen, Alain Bouscayol, Alain Bethon, Philippe Delaue, Daniel Hissel and Rochdi Tigui, Global Modeling of Diffeent Vehicles, Vehicula Technology Magazine, IEEE, Volume 4 Issue 2, Jun. 2009, pp: [4] Antoni Szumanowski, Yuhua Chang, Battey Management System Based on Battey Nonlinea Dynamics Modeling, IEEE Tansactions on Vehicula Technology, Volume 57 Issue 3, May 2008, pp: [5] T. Hofman, D. Hoeksta, R.M. van Duten and M. Steinbuch, Optimal Design of Enegy Stoage Systems fo Hybid Vehicle Divetains, Vehicle Powe and Populsion, 2005 IEEE Confeence, Sep [6] Mak S. Duvall, Battey Evaluation fo Plug-in Hybid Electic Vehicles, Vehicle Powe and Populsion, 2005 IEEE Confeence, Sep [7] A. Kleimaie, D. Schode, An Appoach fo the Online Optimized Contol of a Hybid Powetain, 7 th Intenational Wokshop on Advanced Motion Contol Poceedings, 2002, pp: Authos Pof. Antoni Szumanowski Antoni Szumanowski is the pofesso of Wasaw Univesity of Technology. He has been involved in hybid electic vehicles eseach since He eaned both Ph.D. and D.Sc. degees fom Wasaw Univesity of Technology, whee he is the leade of the Scientific Division which activity is suppoted by govenment and univesity gants. He is the membe of AVERE. Msc. Zhiyin Liu Zhiyin Liu obtained Msc degee fom the Automobiles and Constuction Machiney Engineeing Faculty of Wasaw Univesity of Technology (WUT) in He has been the eseach assistant of Pof. A. Szumanowski since 2009 in the field of HEVs populsion system simulation and components design. D. Yuhua Chang Yuhua Chang eceived the M.Sc. and Ph.D. degees fom Wasaw Univesity of Technology (WUT), Wasaw, Poland, in 2005 and 2007, espectively. Since 2003, she has been a Reseach Assistant of Pof. A. Szumanowski in the field of battey modeling and management in HEVs and the configuation design of a populsion system fo HEVs by simulation. EVS25 Wold Battey, Hybid and Fuel Cell Electic Vehicle Symposium 6