Table Of ContentRenewable Energy Series 7
Propulsion Systems
for Hybrid Vehicles
2nd Edition
Worldwide, the automotive industry is being challenged to make Dr John M. Miller PE is vice president 2 fP
dramatic improvements in vehicle fuel economy. In Europe there of systems and applications at Maxwell n or
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the Obama administration to 35.5 mpg by 2016 for a passenger technology programmes including 42 V n riio
Integrated Starter Alternator (ISG) for d
car. Taking effect in 2012, the new rules set more aggressive fuel n
application into a SUV. He has been active
eancodn dormivey limnee aesfuficreiesn tchya, tb wetiltle rre pqeurifroer msigannicfiec acnatb gina inclsim ina teen cgoinnetr ol in collaborations at industry and government Ve S
levels, including the NSF-funded systems y
and the introduction of electric hybridization. This 2nd Edition of h
center for Future Renewable Electric Energy s
Propulsion Systems for Hybrid Vehicles addresses the electrification Delivery and Management (FREEDM). He icte
innovations that will be required, ranging from low end brake was actively engaged in MIT’s Consortium on l
em
energy recuperators, idle-stop systems and mild hybrids on to Advanced Automotive Electrical and Electronic
s
strong hybrids of the power split architecture in both single mode Components and Systems and has served as s
and two mode and introducing new topics in plug-in hybrid and Adjunct Professor of Electrical Engineering at
battery electrics. Michigan State University and at Texas A&M
University. Dr Miller has authored over 160
Important topics of the 1st Edition are retained and expanded technical publications, holds 53 US patents, and
Propulsion Systems
and some outdated material has been replaced with new has authored or co-authored five books. He is a
information. Fellow of the IEEE, Member of SAE, and 2009
recipient of the IEEE Kliman Innovator award.
M for Hybrid Vehicles
ille
r
2nd Edition
The Institution of Engineering and Technology
www.theiet.org
John M. Miller
978-1-84919-147-0
IET RENEWABLEENERGYSERIES 7
Propulsion Systems
for Hybrid Vehicles
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Othervolumesinthisseries:
Volume1 DistributedgenerationN.Jenkins,J.B.EkanayakeandG.Strbac
Volume6 MicrogridsandactivedistributionnetworksS.Chowdhury,S.P.Chowdhury
andP.Crossley
Volume7 Propulsionsystemsforhybridvehicles,2ndeditionJ.M.Miller
Volume8 Energy:resources,technologiesandtheenvironmentC.Ngo
Volume9 SolarphotovoltaicenergyA.LabouretandM.Villoz
Volume11 Cogeneration:auser’sguideD.Flin
00_Miller_Prelims_pi-xiv 25October2010;17:50:52
Propulsion Systems
for Hybrid Vehicles
2nd Edition
John M. Miller
The Institution ofEngineeringand Technology
00_Miller_Prelims_pi-xiv 25October2010;17:50:52
PublishedbyTheInstitutionofEngineeringandTechnology,London,UnitedKingdom
TheInstitutionofEngineeringandTechnologyisregisteredasaCharityinEngland&
Wales(no.211014)andScotland(no.SC038698).
†2004TheInstitutionofElectricalEngineers
†2008,2010TheInstitutionofEngineeringandTechnology
Firstpublished2004(978-0-86341-336-0)
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Secondedition2010
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For Quentin Patrick Miller†
1983–2005
You will always be missed
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Contents
Preface xiii
1 Hybridvehicles 1
1.1 Electric engine hybrids2010 11
1.2 Limits of engine-only actions 12
1.3 Vehicle electrification and more electric vehicle 15
1.4 Performance characteristics of road vehicles 18
1.4.1 Partnershipfornewgenerationofvehicle goals 18
1.4.2 Enginedownsizing 19
1.4.3 Drivecycle characteristics 22
1.4.4 Hybridvehicle performancetargets 26
1.4.5 Basicvehicledynamics 27
1.5 Calculation of road load 32
1.5.1 Componentsofroadload 32
1.5.2 Frictionandwheelslip 38
1.6 Predicting fuel economy 41
1.6.1 Emissions 42
1.6.2 Brakespecificfuelconsumption 42
1.6.3 Fueleconomy andconsumptionconversions 43
1.7 Internal combustion engines: Aprimer 45
1.7.1 What isbrakemean effective pressure(BMEP)? 47
1.7.2 BSFCsensitivitytoBMEP 49
1.7.3 ICEbasics:Fuelconsumptionmapping 51
1.7.4 Emissionsregulations 52
1.8 Grid connected hybrids 56
1.8.1 Theconnectedcar,V2G 56
1.8.2 GridconnectedHEV20andHEV60 59
1.8.3 Chargesustainingandchargedepleting 62
1.9 Exercises 64
References 65
2 Hybridarchitectures 67
2.1 Series configurations 71
2.1.1 Locomotivedrives 71
2.1.2 Series–parallel switching 74
2.1.3 Loadtrackingarchitecture 76
2.2 Pre-transmissionparallel configurations 77
2.2.1 Energyrecuperatorsystems 79
2.2.2 Microhybrid 80
2.2.3 Mildhybrid 81
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viii Propulsion systems for hybrid vehicles
2.2.4 Powerassist 84
2.2.5 Dualmode 85
2.3 Pre-transmission combined configurations 86
2.3.1 Powersplit 88
2.3.2 Powersplitwithshift 93
2.3.3 Continuouslyvariabletransmissionderived 96
2.3.4 Integratedhybridassisttransmission 97
2.4 Post-transmission parallel configurations 100
2.4.1 Post-transmissionhybrid 101
2.4.2 Wheelmotorhybrid 102
2.5 Hydraulic post-transmission hybrid 104
2.5.1 Launch assist 104
2.5.2 Hydraulic–electric post-transmission 105
2.5.3 Veryhighvoltageelectric drives 106
2.6 Flywheel systems 107
2.6.1 TexasA&MUniversitytransmotor 107
2.6.2 Petrolelectric drivetrain 108
2.6.3 SwissFederal Instituteflywheelconcept 109
2.7 Ultra-capacitor-only vehicles 110
2.7.1 Catenarypoweredvehicleswithultra-capacitors 110
2.7.2 Catenarypoweredvehicleswithwaysideultra-capacitors 111
2.7.3 Ultra-capacitortrolleybusvehicles 113
2.8 Electric four wheel drive 113
2.8.1 TheE4system 114
2.8.2 Production‘Estima Van’example 115
2.9 Exercises 115
References 117
3 Hybrid power plantspecifications 119
3.1 Grade and cruise targets 124
3.1.1 Gradeability 127
3.1.2 Wide openthrottle 127
3.2 Launch and boosting 128
3.2.1 Firsttwoseconds 128
3.2.2 Lane change 128
3.3 Braking and energy recuperation 129
3.3.1 SeriesRBS 129
3.3.2 ParallelRBS 133
3.3.3 RBSinteraction withABS 133
3.3.4 RBSinteraction withIVD/VSC/ESP 134
3.4 Drive cycle implications 135
3.4.1 Typesofdrivecycles 135
3.4.2 Electric vehicle andregenerativeelectric vehicle cycles
forPHEVs 136
3.4.3 Averagespeedandimpact onfueleconomy 138
3.4.4 Dynamicsofacceleration/deceleration 139
3.4.5 Wide openthrottlelaunch 139
3.5 Electric fraction 140
3.5.1 Engine downsizing 140
3.5.2 Rangeandperformance 140
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Contents ix
3.6 Usage requirements 141
3.6.1 Customerusage 141
3.6.2 Electrical burden 141
3.6.3 Gradeholdingandcreep 142
3.6.4 Neutralidle 142
3.7 Exercises 143
References 143
4 Sizingthedrive system 145
4.1 Matching the electric drive and ice 147
4.1.1 Transmissionselection 149
4.1.2 Gearstepselection 149
4.1.3 Automatic transmissionarchitectures 151
4.1.3.1 Simpsontype 152
4.1.3.2 Wilsontype 154
4.1.3.3 Lepelletiertype 154
4.1.3.4 Summaryoftransmissiontypes 155
4.2 Sizing the propulsion motor 155
4.2.1 Step1 158
4.2.2 Step2 159
4.2.3 Step3 162
4.2.4 Torqueandpower 164
4.2.5 Constantpowerspeedratio(CPSR) 168
4.2.6 Machinesizing 170
4.3 Sizing the power electronics 173
4.3.1 Switchtechnology selection 175
4.3.2 kVA/kWandpowerfactor 176
4.3.3 Ripple capacitor design 180
4.3.4 Switchingfrequency andPWM 183
4.4 Selecting the energy storage technology 184
4.4.1 Lead–acidtechnology 194
4.4.2 Nickel-metalhydride 196
4.4.3 Lithiumion 196
4.4.4 Metal–airbatteries 198
4.4.5 Fuelcell 199
4.4.6 Ultra-capacitor 204
4.4.7 Flywheels 208
4.5 Electrical overlay harness 208
4.5.1 Cable requirements 209
4.5.2 Inverterbusbars 212
4.5.3 Highvoltage disconnect 215
4.5.4 Powerdistribution centres 215
4.6 Communications 216
4.6.1 Communication protocol:CAN 219
4.6.2 Poweranddatanetworks 220
4.6.3 Futurecommunications:TTCAN 222
4.6.4 Futurecommunications:FlexRay 223
4.6.5 Competing futurecommunicationsprotocols 226
4.6.6 Diagnostictestcodes(DTC) 227
4.7 Supporting subsystems 228
4.7.1 Steeringsystems 228
4.7.2 Brakingsystems 229
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