Hybrid Vehicles. Electric and. Design Fundamentals. Iqbal Husain SECOND EDITION. Taylor & Francis Group, an informa business

Transcription

1 Electric and Hybrid Vehicles Design Fundamentals SECOND EDITION Iqbal Husain CRC Press is an imprint of the Taylor & Francis Group, an informa business

2 Contents Preface Acknowledgments Author xv xix xxi 1. Introduction to Alternative Vehicles Electric Vehicles Hybrid Electric Vehicles Electric and Hybrid Vehicle Components Vehicle Mass and Performance Electric Motor and Engine Ratings Electric and Hybrid Vehicle History The Early Years s s s and 1990s Recent EVs and HEVs Well-to-Wheel Analysis EV/ICEV Comparison Efficiency Comparison Pollution Comparison Capital and Operating Cost Comparison U.S. Dependence on Foreign Oil Electric Vehicle Market 26 References 27 Assignment Vehicle Mechanics Roadway Fundamentals Laws of Motion Vehicle Kinetics Dynamics 2.5 Propulsion Force-Velocity of Vehicle Motion 37 Power 38 Characteristics Maximum Gradability Velocity and Acceleration Constant FTR, Level Road 41 Velocity Profile Distance Traversed Tractive Power Energy Required Nonconstant FTR, General Acceleration 46 v

3 vi Contents 2.7 Tire-Road Force Mechanics Slip Traction Force at Tire-Road Interface Force Transmission at Tire-Road Interface Quarter-Car Model Traction Limit and Control Propulsion System Design 57 Problems 58 References Alternative Vehicle Architectures Electric Vehicles Hybrid Electric Vehicles Hybrids Based on Architecture Series and Parallel Architectures Series-Parallel Architecture Series-Parallel 2x2 Architecture Hybrids Based on Transmission Assembly Hybrids Based on Degree of Hybridization Plug-In Hybrid Electric Vehicle Powertrain Component Sizing EV Powertrain Sizing Initial Acceleration Rated Vehicle Velocity Maximum Velocity Maximum Gradability HEV Powertrain Sizing Rated Vehicle Velocity Initial Acceleration Maximum Velocity Maximum Gradability HEV Powertrain Sizing Example Total Power Required: Initial Acceleration IC Engine Power: Cruising Speed Maximum Velocity Generator Sizing Battery Sizing Mass Analysis and Packaging Vehicle Simulation Simulation Model Standard Drive Cycles 93 Problems 97 References 98

4 Contents vii 4 Battery Energy Storage Batteries in Electric and Hybrid Vehicles Battery Basics Battery Cell Structure Chemical Reactions Battery Parameters Battery Capacity Open Circuit Voltage Ill Terminal Voltage Practical Capacity Discharge Rate State of Charge State of Discharge Depth of Discharge Battery Energy Specific Energy Battery Power 117 Power Specific Ragone Plots Electrochemical Cell Fundamentals Thermodynamic Voltage Electrolysis and Faradaic Current Electrode Kinetics Mass Transport Electrical Double Layer Ohmic Resistance Concentration Polarization Battery Modeling Electric Circuit Models Basic Battery Model Run-Time Battery Model Impedance-Based First Principle Model 138 Model Empirical Models Range Prediction with Constant Current 142 Discharge Range Prediction with Power Density Approach Traction Batteries Lead-Acid Battery Nickel-Cadmium Battery Nickel-Metal-Hydride Battery Li-Ion Battery Li-Polymer Battery 154

5 viii Contents Zinc-Air Battery Sodium-Sulfur Battery Sodium-Metal-Chloride Battery Goals for Advanced Batteries Battery Pack Management Battery Management System SoC Measurement Battery Cell Balancing Battery Charging 164 Problems 165 References Alternative Energy Storage Fuel Cells Fuel Cell Characteristics Fuel Cell Types Alkaline Fuel Cell Proton Exchange Membrane Fuel Cell Direct Methanol Fuel Cell Phosphoric Acid Fuel Cell Molten Carbonate Fuel Cell Solid Oxide Fuel Cell Fuel Cell Model Hydrogen Storage Systems Reformers Fuel Cell Electric Vehicle Ultracapacitors Symmetrical Ultracapacitors Asymmetrical Ultracapacitors Ultracapacitor Modeling Compressed Air Storage Flywheels 191 Problems 193 References Electric Machines Simple Electric Machines Fundamental Machine Phenomena Motional Voltage Electromagnetic Force DC Simple Machine Induced Voltage Force and Torque DC Machine Back-EMF and Torque 204

6 Contents ix Simple Reluctance Machine DC Machines Three-Phase AC Machines Sinusoidal Stator Windings Number of Poles Three-Phase Sinusoidal Windings Space Vector Representation Interpretation of Space Vectors Inverse Relations Resultant mmf in a Balanced System Mutual Inductance L, and Induced Stator Voltage Types of AC Machines Induction Machines Per-Phase Equivalent Circuit Simplified Torque Expression Speed Control Methods Regenerative Braking Permanent Magnet Machines Permanent Magnets Ferrites Samarium Cobalt Neodymium-Iron-Boron PM Synchronous Motors PMSM Models Voltage Equations Per-Phase Equivalent Circuit PM Brushless DC Motors PM BLDC Machine Modeling Switched Reluctance Machines Advantages and Disadvantages SRM Design/Basics Principle of Operation Voltage-Balance Equation Energy Conversion Torque Production 256 Characteristics Torque-Speed Problems 259 References Power Electronic Converters Power Electronic Switches Diode Power BJT Power MOSFET 266

7 X Contents 7.1A IGBT Bidirectional Switch DC/DC Converters Non-Isolated DC/DC Converters Buck Converter Boost Converter Buck-Boost Converter Fourth-Order DC/DC Converters Powertrain Boost Converter Isolated DC/DC Converters Cell Balancing Converters Passive Balancing Methods Active Balancing Methods Individual DC/DC Converter Centralized DC/DC Converter Current Diverter DC /DC Converter 285 References Electric Motor Drives Electric Drive Components DC Drives Two-Quadrant Chopper Open Loop Drive Steady-State Analysis of Quadrant Ripple Reduction in i Acceleration (CCM) Acceleration (DCM) Acceleration (Uncontrollable Mode) Braking Operation (CCM in Steady State) Regenerative Power Operating Point Analysis AC Drives Six-Step Operation Harmonic Analysis Pulse Width Modulation Sinusoidal PWM Harmonics in Sinusoidal PWM Space Vector PWM Generation of SV PWM Switching Signals Current Control Methods Hysteresis Current Controller Ramp Comparison Controller SRM Drives SRM Converters SRM Controls 327

8 Contents xi Control Parameters Advance Angle Calculation Voltage-Controlled Drive Current-Controlled Drive Advanced Control Strategies 330 Problems 331 References Control of AC Machines Vector Control of AC Motors cfy Modeling Rotating Reference Frame Induction Machine dq Model Power and Electromagnetic Torque Induction Machine Vector Control Rotor Flux-Oriented Vector Control Direct and Indirect Vector Control Direct Vector Control Indirect Vector Control Vector Control Implementation PM Machine Vector Control Voltage and Torque in Reference Frame Simulation Model Transformation Equations PM Synchronous Motor Drives Flux Weakening Current and Voltage Controllers 360 Problems 361 References Internal Combustion Engines Internal Combustion Engines Reciprocating Engines Practical and Air-Standard Cycles Air-Standard Otto Cycle Air-Standard Diesel Cycle Gas Turbine Engines BMEP and BSFC Vehicle Fuel Economy Fuel Economy in Hybrids Emission Control System Generation of Pollutants Effect of Air-Fuel Ratio on Emissions NOT Flow Rate Emission Control Components 388

9 xii Contents Exhaust Gas Recirculation Catalytic Converter Treatment of Diesel Exhaust Emissions Diesel Oxidation Catalysts Diesel Particulate Filters Methods of NO, Reduction 391 Problem 393 References Powertrain Components and Brakes Powertrain Components Electric Vehicle Powertrain Gears Gear Ratio Torque-Speed Characteristics Planetary Gear Set Cratches Differential Transmission Manual Transmission Automatic Transmission Torque Converter Automatic Transmission in Hybrids Continuously Variable Transmission ecvt/hev Transmission Vehicle Brakes Conventional Brake System Electromechanical Brake System 422 Problem 425 References Cooling Systems Climate Control System Vapor-Compression Refrigeration Cycle Vehicle Air-Conditioning System Powertrain Component-Cooling System 433 References Hybrid Vehicle Control Strategy Vehicle Supervisory Controller Mode Selection Strategy Mechanical Power-Split Hybrid Modes Electric Only (Low Speeds, Reverse, Battery Charging) Engine Starting (Low Speeds) 446

10 Contents xiii Parallel Mode (Heavy Acceleration) Power-Split Mode (Cruise, Light Acceleration) Engine-Brake Mode (Driver Selectable Mode) Regeneration Mode (Vehicle Braking) Series-Parallel 2x2 Hybrid Modes Electric-Only (Low Speeds, Reverse, Battery Charging) Series Mode (Low Speeds) Power-Split Mode (Cruise, Light Acceleration) Parallel Mode (Heavy Acceleration) Modal Control Strategies Series Control Parallel Control Series-Parallel Control Mechanical Power-Split IC Engine Control Series-Parallel 2x2 Control Energy Storage System Control Regeneration Control 461 Problems 465 References Vehicle Communications OSI Seven-Layer Model In-Vehicle Communications Controller Area Network CAN Transfer Protocol CAN Transfer Layer Bit Timing CAN Message Frames Message Arbitration Error Detection and Error Signaling CAN Physical Layer CAN Programming 483 References 486 Index 487