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1 Advanced Hybrid Powertrains for Commercial Vehicles By Haoran Hu Rudy Smaling Simon J. Baseley International Warrendale, Pennsylvania USA 400 Commonwealth Drive

2 Preface Acknowledgments ix xiii Chapter i Introduction of Hybrid Powertrains for Commercial Vehicles Introduction History of Commercial Vehicles Commercial Vehicle Classification Energy Consumption of Commercial Vehicles Drivers of the Efficient Powertrain for Commercial Vehicles Classification of Commercial Vehicle Hybrid Powertrains References 30 Chapter 2 Internal Combustion Engines for Commercial Vehicles Requirements of Internal Combustion Engines for Commercial Vehicles Basics of Internal Combustion Engines Major Engine Components and Subsystems Engine Operating Characteristics Advanced Engine Technologies References 70 Chapter 3 Introduction of Clutches and Transmissions for Commercial Vehicles Background of Transmissions Key Characteristics of Vehicle Transmissions Key Components of Commercial Vehicle Drivetrains Manual Transmission 88 V

3 Chapter 3 (continued) 3.5 Automated Manual Transmission Dual-clutch Transmission Fully Automatic Transmission Continuously Variable Transmissions for Commercial Vehicles Characteristics and Efficiency of Commercial Vehicle Transmissions References Appendix 107 Chapter 4 Energy Storage Systems: Battery, Ultracapacitor, Accumulator, and Flywheel Energy Storage Systems for Commercial Hybrid Applications Electrical Chemical Battery Battery Management Systems Hydraulic Energy Storage Flywheel Energy Storage (FES) References 145 Chapter 5 Hybrid-electric System Design and Optimization Characteristics of Hybrid-electric Powertrains Hybrid System Architectures Hybrid System Selection References 174 Chapter 6 Hybrid-electric Power Conversion Systems Basic Three-phase Motor Theory Basic Power Inverter Design and Operation Basic Motor/Generator Designs Stator Design Rotor Design Electric Motor Power Density 195 vi

4 Chapter 6 (continued) 6.7 Electric Motor Characteristics References 202 Chapter 7 Hydraulic Hybrid Powertrain System Design Introduction Hydraulic Hybrid System Architecture Design and Specification of Hydraulic Hybrid Systems Examples of Systems at or near Production Application References 226 Chapter 8 Hydraulic Hybrid Components and Controls Introduction Hydraulic Pumps and Motors Valves Pipes and Fittings Hydraulic Oils and Related Systems Control Units and Transducers References 255 Chapter 9 Fuel Cell Hybrid Powertrain Systems Fuel Cell Hybrid Powertrain Operating Principles of Fuel Cells Polymer Electrolyte Membrane (PEM) Fuel Cells for Commercial Vehicles Solid Oxide Fuel Cells Auxiliary Power Unit (APU) and Range Extender References Appendix: Comparison of Fuel Cell Technologies 281 Chapter 10 Commercial Vehicle Electrification Introduction Idle Reduction Technologies 284 vii

5 Chapter 10 {continued) 10.3 Electrically Driven Boost System and Other Components Electrification for Plug-in Hybrid Commercial Vehicles External Charging and Plug-in Hybrid Commercial Vehicles References 312 Chapter 11 Hybrid Powertrain System Modeling, Simulation, Validation, and Certification Modei-based Control System Development Models for Hybrid-electric Powertrains of Commercial Vehicles Dynamic Modeling of Hybrid-electric Powertrain System System Control and Optimization for Hydraulic Hybrid Vehicles Model-based Test and Validation Hybrid Vehicle Certification References Appendix: Drive Cycles 358 Chapter 12 Sustainable Transportation and Future Powertrain Technologies Introduction PHEV and Battery Charger Intelligent Transportation System, Smart Grid, and Multimodal Transportation Government Regulations and Incentives Future Powertrain Technologies and System Solutions for Sustainable Transportation References 389 Index 395 About the Authors 405 viii

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