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HEV 595 Introduction to Electric Vehicle Systems

Course Introduction
Slides with are adapted from C. Mi

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Course Information
Instructors: Oleg Wasynczuk and Maryam Saeedifard Office: EE 144 and EE 146 (Electrical Engineering Building) Emails: wasynczu@ purdue.edu maryam@purdue.edu Office Hours: Saeedifard: MWF 2:30 -3:30 PM (or by appointment) Wasynczuk: MWF 3:30-4:30 PM (or by appointment) Course Website: Blackboard-Vista Textbook: C. Mi, A. Masrur, and D. W. Gao, Hybrid Electric Vehicles with Practical Perspectives, IEEE/Wiley, 2011 Reference: M. Ehsani, Y. Gao, and A. Emadi, Modern Electric, Hybrid Electric, And Fuel Cell Vehicles: Fundamentals, Theory, And Design, CRC Press
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Course Information
Prerequisite:Undergraduate ECE 321 and ECE 433 or graduate standing Description: The primary objective of the course is to introduce architectures and technologies associated with electric and hybrid electric vehicles including their constituent components. Specific topics include electric and hybrid electric drive trains, energy storage (batteries/ ultra-capacitors), electromechanical energy conversion (induction and permanent magnet motors and generators), power electronics, vehicle-level modeling and control, and optimization.
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Course Outline
(4) (5) (6) (8) (6) (3) (3) (3) (5) Introduction to architectures (series, parallel, split torque) Powertrain fundamentals Battery characteristics, limitations, and management Power train electronics Motor drives (induction, permanent magnet) Vehicular control and overall energy management Sizing and optimization Regenerative braking Advanced modeling and simulation tools

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Course Objectives
Understanding of the principal architectures of electric and hybrid electric vehicles Ability to analyze performance characteristics and understand limitations/advantages/disadvantages of each architecture Understanding of the principal components of an HEV including the power/energy storage, conversion, transmission, and control subsystems Ability to integrate disparate subsystem models to form end-to-end vehicle model
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Grading
Projects: There will be four projects. Information on the projects and instructions on how to submit them will be posted later. Each project contributes to 15% of the final grade. Exams: Exam I - (20% of the overall mark), Date: October 16, 2013 in the evening (8:009:30 p.m.). Exam II: (20% of the overall mark). Date: Final Exam period.
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Grading (cont.)
Course Grading Policy: Midterm Exam: 20% Final Exam: 20% Four Projects: 60% (15% each) Letter grades will be determined by the following approximate cutoffs: 85% A 70% B 55% C 40% D The instructors may adjust these cutoffs by no more than 2.5 points based upon overall class performance and extenuating circumstances.
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Academic Dishonesty
All project reports and exams are to be an individuals own work. You may discuss homework/projects with one another; however, the solution/report write-ups must be your own work. Copying on an exam or plagiarizing another students write-up will result in an F for the course. Late projects will results in a deduction of mark for that project.
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Emergencies
If you need to miss an exam because of an illness or family emergency, you should let the instructors know beforehand. If it is an illness, you will need a note from your doctor, with his/her name and contact number, saying that, based on the doctors best judgment, you need to miss the exam. A note simply saying that you have been to PUSH is not enough. The note does not need to say anything about the nature of the illness---thats private information between you and your doctor. In the event of a major campus emergency, course requirements, deadlines and grading percentages are subject to changes that may be necessitated by a revised semester calendar or other circumstances. In such an event, information will be provided through the course website.

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Why EV or HEV?
Oil Reserves

http://www.eia.gov/pub/international/iealf/crudeoilreserves.xls
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Why EV or HEV?
Oil Consumption
http://www.eia.gov/cfapps/ipdbproject/IEDIndex3.cfm?tid=5&pid=54&aid=2

1342 109 barrels 85,000 103 barrels/day 365days/year 43years

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Present Challenges
Based upon known reserves and present rate of usage, ~ = 40 Years of oil remaining Gasoline = 44.4 MJ/kg, Li-Ion = 0.46-0.72 MJ/kg Gasoline = 34.8 MJ/liter, Li-Ion = 0.83-3.6 MJ/liter 10 Gpm gasoline ~ = 2 MW ~ = 100 homepower ~ = 20,000 peoplepower Improvements drastically needed in storage density, charge-discharge efficiency, and charge rates

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EVs Not New !

1897 - French Krieger Co. EV: Weight 1000 kg., Top Speed 25 km/h, Range 84 mi/charge. 1900 - French B.G.S. Co. EV: Top Speed - 67mph, Range - 160 mi/charge. 1915 - Woods EV: Top Speed - 67 mph, Range - 160 mi/charge. 1915 - Lansden EV: Weight 1100 kg, 150 mi/charge, 1000 kg payload capacity. 1912 - 34,000 EVs registered; EVs outnumber gas powered vehicles 2-to-1. 1920s - EVs disappear and ICEVs become predominant.
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Then and Now An Analogy

1898 2010

First Hybrid Car (Munson Omnibus) built in La Porte, Indiana. It combined the best virtues of both gasoline and electricity. This car made two trips from La Porte to New York City and was the first to drive on the famous Riverside Drive. www.nusslihausbooks.com

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can travel 244 miles on a single charge of its lithium-ion battery pack, and can accelerate from 060 mph in 3.7 seconds. The Roadster's efficiency, as of September 2008 was reported as 120 mpgge (2.0 L/100 km). It uses 135 Wh/km battery-to-wheel, and has an efficiency of 92% on average. http://en.wikipedia.org/wiki/Tesla_Roadster

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Factors that Led to the Disappearance of EV

Invention of starter motor in 1911 made gas vehicles easier to start. Improvements in mass production of gaspowered vehicles which sold for $260 in 1925 compared to $850 in 1909. EVs were more expensive. Rural areas had very limited access to electricity to charge batteries, whereas, gasoline could be sold in those areas.
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Resurgence of EVs in 1960s

Resurgence of EV research and development in 1960s due to increased awareness of air quality. Congress introduces bills recommending the use of EVs as a means of reducing air pollution. Major ICEV manufacturers become involved in EV R&D (e.g., GM, Ford).
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1970s
Gasoline prices increase dramatically as energy crisis increases. This led to immense interest in EV. Oil embargo of 1973 increases demands for alternate energy sources. Less dependence on foreign oil becomes desirable. In 1975, 352 electric vans were delivered to US postal service for testing. In 1976, Congress enacts Public Law 94-413, the Electric and Hybrid Vehicle Research, Development and Demonstration Act of 1976. This act authorizes a federal program to promote electric and hybrid vehicle technologies and to demonstrate the commercial feasibility of electric vehicles.
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1980s and 1990s

Technological Developments Affecting EV Design
Development of magnetic bearings used in flywheel energy storage systems. Improvements of high-power high-frequency semiconductor switches, along with microprocessor revolution, led to improved power converter design.

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1980s and 1990s

Organizational Support
Legislation passed by the California Air Resources Board: By 1998, 2% of all vehicles (about 40,000) would be zero emission vehicle (ZEV). By 2003, 10% (about 500,000) would be EV. More than one dozen eastern states also adopted this law to comply with federal regulations on emission standards. SERA (Solar & Electric Racing Association) organizes electric car races around the country. This organization wants to do for electric vehicles what Racing does for ICEVs (Improvements and developments through racing).
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More on HEV
What is HEV Types of HEV Why HEV Key Advantage of HEV Environmental Impacts of HEV Interdisciplinary Nature of HEV

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What is HEV

HEV Stands for Hybrid Electric Vehicle An HEV is a vehicle that involves multiple sources of propulsions
An EV is an electric vehicle, battery (with or w/o ultra capacitor, fly wheels) operated only. Sole propulsion by electric motor A fuel cell vehicle is considered a series hybrid vehicle A traditional vehicle has sole propulsion by ICE or diesel engine Energy source can be gas, natural gas, battery, ultra capacitor, fly wheel, solar panel, etc.
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Types of HEV
According to the method the energy sources are arranged
Parallel HEV: multiple propulsion sources can be combined, or drive the vehicle alone with one of the energy sources Series HEV: sole propulsion by electric motor, but the electric energy comes from another on board energy source, such as ICE

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Types of HEV
Continued
Simple HEV, such as diesel electric locomotive, energy consumption is not optimized; are only designed to improve performance (acceleration etc.) Complex HEV: can possess more than two electric motors, energy consumption and performance are optimized, multimode operation capability Heavy hybrids trucks, locomotives, diesel hybrids, etc.

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Types of HEV
According to the onboard energy sources
ICE hybrids Diesel hybrids Fuel cell hybrids Solar hybrids (race cars, for example) Natural gas hybrids Hybrid locomotive Heavy hybrids
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Why HEV ?

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To Overcome the Disadvantage of Pure EV and Conventional Vehicles

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Key Drawbacks of Battery EVs

High Initial Cost
Many times that of conventional vehicles

Short Driving Range

Less miles during each recharge People need a vehicle not only for commuting (city driving), but also for pleasure (long distance highway driving)
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Key Drawbacks of Battery EVs

Recharging takes much longer time than refueling gasoline
unless infrastructure for instantly replaceable battery cartridges are available (something like home BBQ propane tank replacing)

Battery pack takes space and weight of the vehicle which otherwise is available to the customer
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Key Drawbacks of ICE Vehicles

High energy consumption: resources, independent of foreign oil High emissions, air pollution, climate change and global warming High maintenance cost Environmental impacts Noisy

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Key Advantages of HEVs

Optimize the fuel economy
Optimize the operating point of ICE Stop the ICE if not needed (ultra low speed and stops) Recover the kinetic energy at braking Reduce the size (hp and volume) of ICE

Reduce emissions
Minimize the emissions when ICE is optimized in operation Stop the ICE when its not needed Reduced size of ICE means less emissions Solve the emission problem of cold start of the engine
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Key Advantages of HEVs - continued

Quiet Operation
Ultra low noise at low speed because ICE is stopped Quiet motor, motor is stopped when vehicle comes to a stop, with engine already stopped

Increased functionality and controllability with onboard components. For example, ABS and traction control may be realized with onboard propulsion motor therefore eliminate hydraulic usage
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Key Advantages of HEVs - continued

Reduced maintenance because ICE operation is optimized, less hazardous material
fewer tune ups, longer life cycle of ICE fewer spark-plug changes fewer oil changes fewer fuel filters, antifreeze, radiator flushes or water pumps fewer exhaust repairs or muffler changes
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Key Concerns of HEVs

High initial cost
Increased components such as battery, electric machines, motor controller, etc.

Reliability concern
Increased components, especially power system, electronics, sensors

Warranty issues
Issues on major electric components Dealership and repair shop not familiar with new components

Safety: high voltage system employed in HEV EMC Vulnerability

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Current Status of HEV

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HEV Sales
2000: 9,367 2001: 20,287 2002: 35,961 2003: 47,525 2004: 83,153 2005: 209,711 2006: 246,642 2007: 324,318 2008: 315,688 2009: 290,237
0 450000 400000 350000 300000 250000 200000 150000 100000 50000

2010:

2000

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

Actual

Predicted

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Available HEV(2008)
Chevrolet Tahoe Hybrid Chevrolet Malibu Hybrid Chrysler Aspen Dodge Durango Hybrid Honda Accord Hybrid Honda Civic Hybrid Ford Escape Hybrid GMC Silverado Hybrid GMC Sierra Hybrid GMC Yukon Hybrid
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Toyota Prius Toyota Highlander Hybrid Lexus 400h Lexus GS 450h Lexus 600h Mazda Tribute Hybrid Mercury Mariner Hybrid Nissan Altima Hybrid Saturn Aura Green Line Saturn VUE Green Line

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Available HEV(2008-)
Cadillac Escalade Hybrid (available late 2008 as a 2009 model) Chevrolet Silverado Crew Cab (available late 2008 as a 2009 model) GMC Sierra Crew Cab (available late 2008 as a 2009 model) Ford Fusion Hybrid (2008) Mercury Milan Hybrid (2008) Fisker Karma (late 2009) Chevy Volt (2011) Saturn VUE Green Line 2-mode (2010)

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2008 Hybrid Electric Passenger Vehicles Sales

Chevy Tahoe/GMC Yukon: 3,683 (Jun/Jul/Aug/Oct/Dec only) Chevy Malibu Hybrid: 1,811(Jun/Jul/Aug/Oct/Dec only) Honda Accord Hybrid: 198 Honda Civic Hybrid: 31,297 Lexus 600h: 330 (through March only) Lexus 400h: 15,200 Nissan Altima Hybrid: 4,242 (through May only) Saturn Aura Hybrid: 141 (Jun/Jul/Aug/Oct/Dec only) Saturn Vue Hybrid: 1,748(Jun/Jul/Aug/Oct/Dec only) Toyota Camry Hybrid: 44,384 (through November only) Toyota Highlander Hybrid: 19,391 Toyota Prius: 158,884 Cadillac Escalade 2-Mode Hybrid:537 (Aug/Oct/Dec only) Year to Date Total for vehicles above: 281,846 General Motors YTD Hybrid Sales: 14,439 Toyota/Lexus YTD Hybrid Sales: 241,405
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2008 Hybrid Electric Passenger Vehicles Sales (through July 2008)

Chevy Tahoe/GMC Yukon: 898 (June/July only) Chevy Malibu Hybrid: 644 (June/July only) Honda Accord Hybrid: 194 Honda Civic Hybrid: 22,472 Lexus 600h: 330 (through March only) Lexus 400h: 10,477 Nissan Altima Hybrid: 4,242 (through May only) Saturn Aura Hybrid: 59 (June/July only) Saturn Vue Hybrid: 639 (June/July only) Toyota Camry Hybrid: 33,177 Toyota Highlander Hybrid: 14,424 Toyota Prius: 106,225

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2009 Hybrid Electric Passenger Vehicles Sales

Ford: 33,502
Includes: Ford Fusion, Ford Escape, Mercury Milan, Mercury Mariner

General Motors: 16,142

Includes: Cadillac Escalade, Chevy Tahoe, Chevy Malibu, Chevy Silverado, GMC Yukon, GMC Sierra, Saturn Aura, Saturn VUE

Honda: 35,691
Includes: Civic hybrid, Accord hybrid, and Insight hybrid

Lexus: 21,890
Includes: RX400h, 600h, 250h, and GS

Nissan: 9,357
Includes: Altima hybrid

Toyota: 173,655

Sales in North America

Includes: Camry hybrid, Highlander hybrid, and PriusToyota/Lexus YTD Hybrid Sales: 241,405

Total for the manufacturers above: 290,237 (2.78% of light duty vehicle sales)
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Hybrids as Percentage of Model Sales for July 2005

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Roads Towards Sustainable Transportation

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Current US Market Models

Toyota Highlander Hybrid 4x4, V6, $34,430: 31/27 mpg (conventional model: $27,840, 18/24 mpg) (Highlander Hybrid Limited $37,890) Toyota Prius, 1.5LDOCH 16-valve VVT-I 4-cylinder, $21,725, 60/51/55 mpg. Ford Escape, SUV, 2.3L, 33/29 mpg 4X4, 36/31 mpg 4X2 (Conventional model: 19/22mpg 4X4, 24/29 4X2). $27,515 front wheel drive, $29140 four wheel drive

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Current US Market Models

Honda Accord Sedan, 5-spd AT, $30,140, 29/37 mpg, Conventional: $25,100 25/29mpg Honda Civic Hybrid, 1.3L, MT: $19,900, 46/51 mpg, CVT: $20,900, 48/47 mpg (conventional model, AT, $18,310, 1.7L I4, 31/38) Honda Insight, 5-spd MT, $19,330, 1.0L, 60/66 mpg, CVT: $21530, 57/56 mpg

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Fuel Economy Improvements of Current Passenger Hybrid Vehicles

Model
Honda Civic Honda Accord Toyota Prius Ford Escape GM Silverado

City FE Gain
66% 43% 100% 80% 10~15%

Hwy FE Gain
24% 23% 34% 24% 10~15%

Note
EPA Cycle EPA MPG Compared w/ Corolla EPA MPG Cycle unknown

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Fuel Economy of Hybrid Trucks

Model
Hino Ranger FedEx W700 UPS P100 Coke 4400 HTUF Utility

FE Gain
20% 50% 36% 34% 35%

Emissions
PM 85%; NOX 50%; CO2 17% PM 93%; NOX 54%; CO 60%

Note
Japan Cycle, advertised FedEx Cycle, Dyno Field test Field test CILCC Cycle, simulation

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Environmental Impacts of HEVs

Reduced air pollution including Nitrogen oxides, Carbon monoxide, unburned hydrocarbons, and Sulfur oxides due to less fuel needed in HEVs Reduce global warming effect by burning less fuel and emitting less carbon oxides Reduce dependence on oil and leave room for the future
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Interdisciplinary Nature of HEV

Vehicle Dynamics Energy Storage Vehicle Design

Power Electronics & Electric Machines

Automotive Electronics

Vehicle Modeling Simulation

Emerging Technology

Control & Power Management

Regenerative Braking

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