Modern Electric, Hybrid Electric, and Fuel Cell Vehicles Third Edition Modern Electric, Hybrid Electric, and Fuel Cell Vehicles Third Edition Mehrdad Ehsani Yimin Gao Stefano Longo Kambiz M. Ebrahimi MATLAB®andSimulink®aretrademarkofTheMathWorks,Inc.andareusedwithpermission.TheMathWorksdoesnot warranttheaccuracyofthetextorexercisesinthisbook.Thisbook'suseordiscussionofMATLAB®softwareorrelated productsdoesnotconstituteendorsementorsponsorshipbyTheMathWorksofaparticularpedagogicalapproachor particularuseoftheMATLAB®andSimulink®software. CRCPress Taylor&FrancisGroup 6000BrokenSoundParkwayNW,Suite300 BocaRaton,FL33487-2742 ©2018byTaylor&FrancisGroup,LLC CRCPressisanimprintofTaylor&FrancisGroup,anInformabusiness NoclaimtooriginalU.S.Governmentworks Printedonacid-freepaper InternationalStandardBookNumber-13:978-1-4987-6177-2(Hardback) Thisbookcontainsinformationobtainedfromauthenticandhighlyregardedsources.Reasonableeffortshavebeenmade topublishreliabledataandinformation,buttheauthorandpublishercannotassumeresponsibilityforthevalidityofall materialsortheconsequencesoftheiruse.Theauthorsandpublishershaveattemptedtotracethecopyrightholdersofall materialreproducedinthispublicationandapologizetocopyrightholdersifpermissiontopublishinthisformhasnot beenobtained.Ifanycopyrightmaterialhasnotbeenacknowledged,pleasewriteandletusknowsowemayrectifyinany futurereprint. ExceptaspermittedunderU.S.CopyrightLaw,nopartofthisbookmaybereprinted,reproduced,transmitted,orutilized inanyformbyanyelectronic,mechanical,orothermeans,nowknownorhereafterinvented,includingphotocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. Forpermissiontophotocopyorusematerialelectronicallyfromthiswork,pleaseaccesswww.copyright.com(http:// www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923,978-750-8400.CCCisanot-for-profitorganizationthatprovideslicensesandregistrationforavarietyofusers. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. TrademarkNotice:Productorcorporatenamesmaybetrademarksorregisteredtrademarks,andareusedonlyfor identificationandexplanationwithoutintenttoinfringe. VisittheTaylor&FrancisWebsiteat http://www.taylorandfrancis.com andtheCRCPressWebsiteat http://www.crcpress.com To my Wonderful Wife, Zohreh Mehrdad Ehsani To my Wife Anni, and my Daughter, Yuan Yimin Gao To my Mum, Dad and Little Brother Stefano Longo To my Wife and Daughter Kambiz Ebrahimi Contents Preface...................................................................................xvii Acknowledgments....................................................................... xxi Authors................................................................................. xxiii 1. EnvironmentalImpactandHistoryofModernTransportation..................... 1 1.1 AirPollution.................................................................... 1 1.1.1 NitrogenOxides....................................................... 2 1.1.2 CarbonMonoxide ..................................................... 2 1.1.3 UnburnedHCs ........................................................ 2 1.1.4 OtherPollutants ....................................................... 2 1.2 GlobalWarming................................................................ 3 1.3 PetroleumResources............................................................ 5 1.4 InducedCosts................................................................... 7 1.5 ImportanceofDifferentTransportationDevelopmentStrategies toFutureOilSupply............................................................ 8 1.6 HistoryofEVs ................................................................. 11 1.7 HistoryofHEVs ............................................................... 12 1.8 HistoryofFuelCellVehicles................................................... 14 Bibliography.......................................................................... 15 2. FundamentalsofVehiclePropulsionandBraking ................................. 17 2.1 GeneralDescriptionofVehicleMovement .................................... 17 2.2 VehicleResistance ............................................................. 17 2.2.1 RollingResistance .................................................... 18 2.2.2 AerodynamicDrag ................................................... 21 2.2.3 GradingResistance ................................................... 21 2.3 DynamicEquation............................................................. 23 2.4 Tire–GroundAdhesionandMaximumTractiveEffort........................ 25 2.5 PowerTrainTractiveEffortandVehicleSpeed................................ 27 2.6 VehiclePerformance........................................................... 29 2.6.1 MaximumSpeedofaVehicle......................................... 30 2.6.2 Gradeability .......................................................... 31 2.6.3 AccelerationPerformance............................................. 31 2.7 OperatingFuelEconomy ...................................................... 34 2.7.1 FuelEconomyCharacteristicsofICEngines ......................... 34 2.7.2 ComputationofVehicleFuelEconomy............................... 35 2.7.3 BasicTechniquestoImproveVehicleFuelEconomy................. 37 2.8 BrakePerformance............................................................. 38 2.8.1 BrakingForce......................................................... 39 2.8.2 BrakingDistributiononFrontandRearAxles ....................... 41 2.8.3 BrakingRegulationandBrakingPerformanceAnalysis.............. 45 2.8.3.1 BrakingRegulation........................................ 45 vii viii Contents 2.8.3.2 BrakingPerformanceAnalysis............................. 47 Bibliography.......................................................................... 49 3. InternalCombustionEngines ....................................................... 51 3.1 SparkIgnitionEngine.......................................................... 51 3.1.1 BasicStructureandOperationPrinciplewithOttoCycle ............ 51 3.1.2 OperationParameters ................................................ 53 3.1.2.1 RatingValues.............................................. 53 3.1.2.2 IndicatedTorqueandIndicatedMeanEffectivePressure.. 53 3.1.2.3 BrakeMeanEffectivePressure(bmep)and BrakeTorque .............................................. 56 3.1.2.4 EmissionMeasurement.................................... 57 3.1.2.5 EngineOperationCharacteristics.......................... 58 3.1.3 BasicTechniquesforImprovingEnginePerformance,Efficiency,and Emissions............................................................. 59 3.1.3.1 ForcedInduction........................................... 59 3.1.3.2 GasolineDirectInjectionandLean-BurnEngines......... 61 3.1.3.3 MultivalveandVariableValveTiming.................... 61 3.1.3.4 VariableCompressionRatio............................... 61 3.1.3.5 ExhaustGasRecirculation................................. 62 3.1.3.6 IntelligentIgnition......................................... 62 3.1.3.7 NewEngineMaterials..................................... 62 3.1.4 BriefReviewofSIEngineControlSystem............................ 62 3.1.5 OperationPrinciplewithAtkinsonCycle............................. 64 3.1.5.1 OriginalEnginewithAtkinsonCycle ..................... 64 3.1.5.2 ModernEnginewithAtkinsonCycle...................... 65 3.2 CompressionIgnitionEngine.................................................. 68 3.3 AlternativeFuelsandAlternativeFuelEngines ............................... 69 3.3.1 AlternativeFuels...................................................... 69 3.3.1.1 EthanolandEthanolEngine............................... 69 3.3.1.2 CompressedNaturalGasandNaturalGasEngine........ 70 3.3.1.3 EnhancedHydrogen(H2Combustion).................... 72 Bibliography.......................................................................... 72 4. VehicleTransmission................................................................ 73 4.1 PowerPlantCharacteristics.................................................... 73 4.2 TransmissionCharacteristics................................................... 76 4.3 ManualGearTransmission(MT) .............................................. 78 4.4 AutomaticTransmission....................................................... 81 4.4.1 ConventionalAutomaticTransmission............................... 82 4.4.1.1 TorqueConverterOperation .............................. 82 4.4.1.2 PlanetaryorEpicyclicGearTrain.......................... 86 4.4.1.3 CompoundEpicyclicGear................................. 88 4.4.2 AutomatedManualandDual-ClutchTransmission.................. 89 4.5 ContinuouslyVariableTransmission.......................................... 91 4.6 InfinitelyVariableTransmissions.............................................. 91 4.7 DedicatedHybridTransmission(DHT) ....................................... 92 Bibliography.......................................................................... 93 Contents ix 5. ElectricVehicles ..................................................................... 95 5.1 ConfigurationsofElectricVehicles ............................................ 95 5.2 PerformanceofElectricVehicles............................................... 98 5.2.1 TractionMotorCharacteristics........................................ 98 5.2.2 TractiveEffortandTransmissionRequirement....................... 99 5.2.3 VehiclePerformance................................................. 101 5.3 TractiveEffortinNormalDriving............................................103 5.4 EnergyConsumption.........................................................105 Bibliography......................................................................... 110 6. HybridElectricVehicles............................................................ 113 6.1 ConceptofHybridElectricDrivetrains.......................................113 6.2 ArchitecturesofHybridElectricDrivetrains..................................116 6.2.1 SeriesHybridElectricDrivetrains(ElectricalCoupling)............. 117 6.2.2 ParallelHybridElectricDrivetrains(MechanicalCoupling)......... 119 6.2.2.1 ParallelHybridDrivetrainwithTorqueCoupling........ 120 6.2.2.2 ParallelHybridDrivetrainwithSpeedCoupling......... 126 6.2.2.3 HybridDrivetrainswithBothTorqueand SpeedCoupling........................................... 132 Bibliography......................................................................... 136 7. ElectricPropulsionSystems........................................................ 139 7.1 DCMotorDrives .............................................................141 7.1.1 PrincipleofOperationandPerformance ............................ 141 7.1.2 CombinedArmatureVoltageandFieldControl .................... 145 7.1.3 ChopperControlofDCMotors ..................................... 146 7.1.4 MultiquadrantControlofChopper-FedDCMotorDrives.......... 149 7.1.4.1 Two-QuadrantControlofForwardMotoringand RegenerativeBraking..................................... 150 7.1.4.2 Four-QuadrantOperation ................................ 153 7.2 InductionMotorDrives.......................................................153 7.2.1 BasicOperationPrinciplesofInductionMotors..................... 154 7.2.2 Steady-StatePerformance............................................ 157 7.2.3 ConstantVolt/HertzControl........................................ 159 7.2.4 PowerElectronicControl............................................ 160 7.2.5 FieldOrientationControl............................................ 163 7.2.5.1 FieldOrientationPrinciples............................... 163 7.2.5.2 Control.................................................... 170 7.2.5.3 DirectRotorFluxOrientationScheme.................... 172 7.2.5.4 IndirectRotorFluxOrientationScheme.................. 175 7.2.6 VoltageSourceInverterforFOC .................................... 177 7.2.6.1 VoltageControlinVoltageSourceInverter .............. 179 7.2.6.2 CurrentControlinVoltageSourceInverter .............. 181 7.3 PermanentMagneticBLDCMotorDrives....................................184 7.3.1 BasicPrinciplesofBLDCMotorDrives.............................. 185 7.3.2 BLDCMachineConstructionandClassification..................... 185 7.3.3 PropertiesofPMMaterials .......................................... 189