configuration analysis of plug-in hybrid systems using global … audi a3 e-tron / vw golf phev phev...
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Configuration Analysis of Plug-in Hybrid
Systems using Global Optimization
Bill Insup Kim, Hyunsup Kim
Hyundai Motor Company
20 Nov 2013
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Agenda
1. Motivation & Purpose
2. Plug-in Hybrid Systems
3. Methodology
– Theoretical System Analysis
– Dynamic Programming
– Vehicle Modeling : Transmission element loss
4. Results
– Theoretical System Analysis Results
– Dynamic Programming Results
5. Conclusion
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1. Motivation & Purpose
• PHEV Models
Power Split
Series-Output split
Series-Parallel
Which system has Benefits in certain driving conditions?
• U.S PHEV Sales in 2013
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Series
Parallel
Combined Input split
Series-Output split
Series-Parallel
Prius PHEV C-Max/Fusion Energi
Chevrolet Volt
Accord PHEVOutlander PHEV
BMW i3 REx
Audi A3 E-tron / VW Golf PHEV (2014)PHEV
2. Plug-in Hybrid Systems
• PHEV Powertrains Topologies (Categorized by TM Mode)
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2. Plug-in Hybrid Systems
• PHEV Powertrains Topologies
Series Series + Parallel
Series + Output split Input split
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2. Plug-in Hybrid Systems
• Configuration of (Series + α) PHEVsPRIUS PHEV VoltAccord PHEV
EngEngine
Output
MG1
Battery
MG2
Charger
CLModes EV1 EV2 Series O/S
BK ON ON
CL1 ON ON
CL2 ON ON
Modes EV / Series Parallel
CL ON
Modes EV / Input split
BK ON
the Number of TM modes ↑
the Number of TM Elements ↑
=
System Efficiency ↑
Mechanical Losses ↑
Complexity of Control ↑
The Impact of Transmission Mechanical Losses is Considered
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• PHEV System Efficiency
2. Plug-in Hybrid Systems
Drive Driven
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3. Methodology- System Analysis
• Theoretical System Analysis
System Configuration
System Configuration
System EquationSystem
Equation
System Efficiency
- Elec. & Mech.
System Efficiency
- Elec. & Mech.
Systems
Comparison
Systems
Comparison
System Configuration
TMG2 =
Tout/R
System 1 System 2
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3. Methodology- Dynamic Programming
• Dynamic Programming
Known Drive CycleFinding Optimum
Operating Points
Minimizing
Fuel Consumption
Input Output Object
150 200 250 300 3500
50
100
150 200 250 300 350-1000
0
1000
Speed
Altitude
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• Vehicle Specification
Components Input split Series-output split Series-parallel
Engine 1.6L Gasoline, 82kW
MG1 / MG2 42kW / 60kW 55 kW / 111kW 100kW / 124kW
Battery LiPB, 342V, 20Ah
Gear Ratio 2.6 / 2.636 2.2432 0.882, 1.97, 0.575
FGR 3.5
Assuming Same Engine and Motor Efficiency and Final Gear ratio
3. Methodology- Vehicle Modeling
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• Transmission Component Loss Modeling
3. Methodology- Vehicle Modeling
- Assuming Constant Gear
Efficiency
- Considering Power split
ratio for PG
- Test Result - Test Result: Function of
(Speed, Number of Clutch)
Gear- Modeling
Clutch-Test Data
Oil Pump- Test Data
Gear Number PG SG
Efficiency 97% 99%
Prius 2 0
Volt 1 0
Accord 0 3
)( ,, ω∆= FrictionClutchLoss NfT),(, utchNumberofClfT OilPumpOilPumpLoss ωωωω=
CL 1 = Accord
CL 3 = Volt
CL 0 = Prius
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Split
- Parallel Path: Through Planetary gear 1 time
- Series Path: Through Planetary gear 2 times
Recirculation
- Parallel Path: Through Planetary gear 1 time
- Series Path: Through Planetary gear 3 times
Parallel Path
Series Path
Parallel Path
Series Path
Input split Output splitSplit
- Parallel Path: Through Planetary gear 1 time
- Series Path: Through Planetary gear 1 time
Recirculation
- Parallel Path: Through Planetary gear 1 time
- Series Path: Through Planetary gear 2 times
Parallel Path
Series Path
Parallel Path
Series Path
• Theoretical System Analysis – Gear Loss Modeling
3. Methodology- Vehicle Modeling
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70
75
80
85
90
95
100
speed ratio(input/output)
TM M
ech Efficiency (%)
Input split
Output split
Series-Parallel
• Theoretical System Analysis - Gear Loss
3. Methodology- Vehicle Modeling
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0 0.5 1 1.5 2 2.5 3 3.5 40
10
20
30
40
50
60
70
80
90
100
Speed ratio
Efficiency / Input split [%
]
Efficiency
Input split
4. Result
• Theoretical System Analysis – City Driving
0 0.5 1 1.5 2 2.5 3 3.5 40
10
20
30
40
50
60
70
80
90
100
Speed ratio
Efficiency / Series-O
utp
ut split [%
]
Efficiency - Output split
Efficiency - Series
Series
Output split
< Series - Output split >
High Speed
< Input split >
High Speed
0 0.5 1 1.5 2 2.5 3 3.5 40
10
20
30
40
50
60
70
80
90
100
Speed ratio
Efficiency / Series-Parallel [%
]
Efficiency
Series
Parallel
< Series - Parallel >
Parallel
High Speed
EVEVEV
• I/S : High efficiency in High speed ratio (City driving)
• S/O : High efficiency in Middle speed ratio (Suburban drving)
• S/P : High efficiency in Low speed ratio (Mild Highway driving)
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①①①① Disadvatage fo Split Compare to Parallel
4. Result
0.5 1 1.5 2 2.5 3 3.5 460
65
70
75
80
85
90
95
100
speed ratio(input/output)
TM M
ech Efficiency (%)
Input split
Output split
Series-Parallel
• Total System Analysis – (EM Loss ×××× Gear Loss)
②②②② As EM efficiency has improved, Series with Spur gear’s Efficiency will
improve more that Split with Planetary Gear
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4. Result
• Dynamic Programming – CD (Charging Depleting)
Input split
EngEngine
Output
MG1
Battery
MG2
Charger
Series-ParallelSeries-Output
Efficiency Input split Series-Output Series-Parallel
Mech.
Loss
Gear Loss 97% 97% 99%
MG drag 0~1% 0 0
Electrical Loss 90% (Assumption)
System Eff. 86~87% 87% 89%
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4. Result
• Dynamic Programming – CS (Charging Sustaining)
0 10 20 30 40 50 60 70 80 90 1000
200
400
600
800
1000
Wheel Torque (Nm)
EV
Input split
< DP result - Input split>
EV
Input Split
Wh
ee
l To
rqu
e (
Nm
)
0 10 20 30 40 50 60 70 80 90 1000
200
400
600
800
1000
Vehicle Speed (km/h)
Wheel Torque (Nm)
EV
Input split
< Test result – Prius PHEV >
EV
Input Split
Vehicle Speed (km/h)
Wh
ee
l To
rqu
e (
Nm
)
0 10 20 30 40 50 60 70 80 90 1000
200
400
600
800
1000
Wheel Torque (Nm)
EV
Series
Ouput split
< DP result- Series Output split>
Wh
ee
l To
rqu
e (
Nm
)
EV
Series
Output Split
0 10 20 30 40 50 60 70 80 90 1000
200
400
600
800
1000
Vehicle Speed (km/h)
EV
Series
Ouput split
< Test result – Volt>
Vehicle Speed (km/h)
Wh
ee
l To
rqu
e (
Nm
)
EV
Series
Output Split
0 10 20 30 40 50 60 70 80 90 1000
200
400
600
800
1000
Wheel Torque (Nm)
EV
Series
Parallel
< DP result – Series Parallel>
Wh
ee
lTo
rqu
e (
Nm
)
EV
Series
Parallel
0 10 20 30 40 50 60 70 80 90 1000
200
400
600
800
1000
1200
1400
Vehicle Speed (km/h)
Wheel Torque (Nm)
EV
Series
Parallel
< Test result – Accord PHEV >
Vehicle Speed (km/h)
Wh
ee
l To
rqu
e (
Nm
)
EV
Series
Parallel
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Efficiency Input split Series-Output Series-Parallel
CD(Mechanical)
City 96.0 96.1 96.9
HWY 96.0 97.0 97.5
CS
(System)
City 31.8 31.0 30.9
HWY 33.2 30.1 33.4
US06 34.1 32.2 33.9
4. Result
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5. Conclusion
• PRIUS = HEV Mode – City and Aggressive Driving
• Volt = EV Mode and Middle speed range
• Accord PHEV = EV Mode + Highway
City HighwayAggressive
Driving
EV Drive Volt / Accord
HEV Drive Prius Accord Prius
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5. Future Work
• In a certain area Which driving pattern is prevalent and
Which system has merits?
• How system type can affects the Component efficiency?
• Parallel PHEV’s Advantage?
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THANK YOU
Gracias
감사합니다
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4. Result
0.5 1 1.5 2 2.5 3 3.5 4-1
-0.8
-0.6
-0.4
-0.2
0
0.2
0.4
0.6
0.8
1
Speed ratio(input/output)
Power Ratio (Generator Power / Engine Power
Series
Input split
Output split
Parallel
0.5 1 1.5 2 2.5 3 3.5 450
55
60
65
70
75
80
85
90
95
100
Speed ratio(Input/Output)
Series P
ath E
fficiency (%)
Input split
Output split
Series
Parallel
High Speed Low Speed
Energy
Recirculation
Power
Split
• Theoretical System Analysis – Series-path
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3. Methodology- Dynamic Programming
• Dynamic Programming
Usage of Dynamic ProgrammingUsage of Dynamic Programming
1. Fuel Economy Potential
2. Optimum Control Strategy
3. Component Size Decision