Beruflich Dokumente
Kultur Dokumente
Abstract
This paper examines the benefits of a drivetrain that is able to disengage its propulsion motor from the
driveline in an electric vehicle. The drivetrain was developed for an ultra-efficient eco vehicle competing in
the Shell 2013 Eco Marathon. Various clutch mechanisms were examined. In spite of the complexity and
losses associated with additional bearings and release surfaces, an actuated dog clutch was chosen as it
offers superior performance due to the dual capability of freewheeling and regenerative braking that results.
Track data from the event is presented along with experimental work that indicates that the clutch
mechanism reduces power consumption by more than 35% for a ferrous permanent magnet propulsion
motor. Savings were reduced to 5% for a coreless permanent magnet motor coupled to the driveline via an
11:1 straight cut spur gear arrangement. This reduced saving was due to the removal of hysteresis and eddy
current losses from the stator. The paper also demonstrates during a competition in which the driver was
aware of the energy consumption, the driving style changed when the technological option to free wheel
was available. Finally the study was inferred onto a real world application with further experimental and
simulation work on the Delta E4 Coupe, a high performance electric sports car. The vehicle uses a ferrous
permanent magnet direct drive arrangement, indicated a reduction in power consumption of 10 to 14%. It is
hoped that these insights are relevant when considering the development of electric vehicle drivetrains
where machine topology and drive cycle will determine the value of a clutch mechanism.
Nomenclature
m mass [kg]
Roman Symbols P power [W]
a, ! acceleration [m/s2] r radius [m]
A frontal area [m2] RR rolling resistance coefficient
C 1, C 2, C 3, constants t time [s]
Cd drag coefficient v, ! velocity [m/s]
Ek kinetic energy [J] x distance [m]
F force [N]
g acceleration due to gravity [m/s2] Greek Symbols
I moment of inertia [ ] θ angle of incline [o]
ρ density [kg/m3]
EVS27 International Battery, Hybrid and Fuel Cell Electric Vehicle Symposium 1
ω, Ω angular velocity [rad/s] drag by balancing form and skin drag
components. It has 2 wheels at the front and a
Roman Subscripts single steerable wheel at the back. In addition to
L losses steering, the rear wheel also delivers propulsion to
v vehicle the vehicle.
1 Introduction
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Maxon™ motor, a 11:1 spur gear (steel input pinion
and phosphor bronze output wheel) coupled to an
in section 2, was undertaken to determine whether there was a net benefit against the mass pen
18 inch wheel rim via a clutch integratedassociated
within the
with an actuated sprung dog hub clutching mechanism.
wheel hub as shown in Figure 3.
Wheel$rim
Hub$axle
200$Watt$Electric$ Figure 1 (Left) Photograph of PEGGIE Ultra low energy electric vehicle, (right) illustration of drive-train associat
Propulsion$Motor with rear wheel
50
Figure 3 Isometric CAD view of drive-train integrated into rear
Wheel speed
(rpm)
0
0 200 400 600 800 1000 1200 1400
Wheel Torque Power at Wheel
200
(W)
100
0
0 200 400 600 800 1000 1200 1400
3 Design of a clutch-able Drivetrain 5
(Nm)
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of the vehicle was within the speed constraint posed ShimanoTM ratchet clutch was also tested along
by the MaxonTM RE50 coreless propulsion motor. with a roller sprag clutch mechanism.
3.2 Specifying a clutch mechanism Table 1 Clutches and associated features [7, 8]
4 Experimental Work
4.1 Power Loss in Clutch Mechanisms
Figure 7 Section view of dog clutches within drivetrain developed
for PEGGIE with a) clutch disengaged, and b) clutch engaged In order to compare the performance of each of
the three candidate clutch mechanisms, the wheel
The arrangement comprises of a male dog hub was mounted with the drivetrain and clutch
which slides along the hub axle under a preloaded mechanism under test. A magnetic reed sensor
spring. An actuator (not shown) pulls the clutch was mounted to the wheel and connected to a Pico
draw chain to disengage the output gear from the Scope data logger as shown in Figure 8. With the
wheel hub and rim. A torsion spring was specified wheel off the ground, the motor was given a pulse
to reduce the torque transient associated with torque and the wheel was then left to coast down.
engagement at large relative mis-match speeds. Around a given time instant during the coast
Whilst the dog clutches facilitates regenerative down experiments, t, the power loss associated
braking, the mass penalty associated with the with the clutch under test, !(Ω), for a particular
actuator, torsion spring and dogs hubs provide a angular velocity, Ω, and reference inertia !!"# ,
motive for considering passive, unidirectional
was calculated using equation 2.
freewheeling alternatives. An integrated
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45"
PM#Ferrous#Motor#Engaged#
40"
Measured"Peggie"Drive"Losses"(Wa8s)"
PM#Coreless#Engaged#
35"
30"
25"
20"
15"
Figure 8 Test apparatus used to measure coast velocity/time profile
associated with each of the three candidate clutch mechanisms 10"
! 1 !
5"
! Ω = ! Ω ! (2)
!" 2 !"# 0"
0" 5" 10" 15" 20" 25"
4.5" PM#Coreless#Engaged#
4" Dog#Disengaged#
4.2 Coast down Vehicle Tests
Ratchet#Freewheeling#
3.5"
Sprag#Freewheeling# In order to determine the power loss over the
3" speed range of interest, a coast down test was
2.5" carried out. The test consisted of driving the
2"
vehicle in a straight line and then zeroing the
throttle to allow the vehicle to coast. The dog
1.5"
clutches were disengaged throughout the coast
1" down test so that the vehicle rolling losses, in
0.5" isolation of the drivetrain could be measured. The
speed and the time signals were logged using an
0"
0" 5" 10" 15" 20" 25" MBED NXPLPC1768.
Vehicle"Speed"(kph)"
The power loss curves as shown in Figure 10
Figure 9 Relationship between vehicle velocity and power loss were obtained by fitting a second order
derived from coast down angular velocity measurements. polynomial to the raw velocity/time data. The
It can be seen that having a clutch reduces the speed is hence obtained as a function of time.
overall drivetrain losses through comparison of the
PM Coreless Engaged curve (black) with each of ! = !! + !! ! + !! ! ! (3)
the declutched loss measurements (dashed). There
was relatively little difference between the 3 clutch The acceleration is then given by:
arrangements, however, the dog clutches facilitated
regenerative braking and were consequently !"
!= = !! + 2!! ! (4)
selected for integration into Peggie. !"
The coast down losses associated with the PM The fitted line is used to identify the vehicle
Coreless and PM in-hub ferrous machines is power loss as a function of vehicle speed. The
compared by Figure 9. The coreless motor had kinetic energy of the vehicle at any instant is the
significantly lower coast down losses, in spite of the sum of the translational energy of the entire
gear train due to the lack of hysteresis and eddy vehicle mass and the rotational energy of the three
current losses. wheels:
1 1
!! = !!"!!"#$ ! ! + !!!!!"# ! ! (5)
2 2
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where !!"!!"#$ is the total vehicle mass, including Table 2 Eco Marathon Test Results for 2012 and 2013
driver, shell and wheels, ! is the vehicle speed, ω is Race Year Energy Consumption
the angular velocity of the wheels and !!!!!"# were km/kWh
derived from measurement. 2012 271
2013 565
The power loss during coast could then be
computed by equation 6: Figure 12 and Figure 13 provides GPS track data
showing vehicle velocity against longitude and
!!!
!= latitude. In each figure, the vehicle completed 3
!" (6) attempts of the racetrack. Each attempt comprised
of ten laps. In Figure 12, the vehicle was fitted
The output of equation (6) for coast events is with the PM in-hub ferrous motor. Because of the
presented in Figure 11 (solid black). increased coast losses, due to a lack of clutch
mechanism, the vehicle decelerated more rapidly
Although these tests were both carried out on the during coast. Since a pulse and glide drive
same section of track and on the same day, strategy was adopted, this resulted in a larger
variations in conditions such as road surface and variation in vehicle speed which had to average
wind speed introduce an indeterminate error into 25kph over the course of the race for a valid
the results. However test results show a clear attempt to be registered (Figure 12). Where the
benefit for using the coreless motor over the ferrous coreless PM motor with gear stage and dog clutch
motor. It can be seen from Figure 11 that the was used, the coast losses were significantly
introduction of a clutch mechanism represents a lower resulting in reduced variation of vehicle
greater saving for the PM in-hub ferrous motor, speed.
where coast losses are reduced by 35 to 40% across
the speed range compared to 5% for the coreless
PM drivetrain.
60" 45"
Vehicle'Road'Losses'
Measured"Peggie"Total"Road"Loads"(WaDs)"
PM'Ferrous'Clutch'Savings'
40"
"Saving"Associated"With"Clutch""(%)"
PM'Coreless'Clutch'Savings'
50"
35"
40" 30"
25"
30"
20"
20" 15"
10"
10"
5"
0" 0" Figure 12: Visualisation of GPS track data showing the track
0" 5" 10" 15" 20" 25" profile (on the latitude-longitude axes) and the vehicle speed
Vehicle"Speed"(kph)" when fitted with the PM in-hub ferrous direct drive arrangement.
Figure 11 Plot of total road losses and % clutch savings for the ultra
low energy eco vehicle
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1400" 140"
Torque'(Nm)'
1200" 120"
Velocity'(rpm)'
Rotor"torque"(Nm)"
Rotor"speed"(rpm)"
1000" 100"
800" 80"
600" 60"
400" 40"
200" 20"
0" 0"
5" 7" 9" 11" 13" 15" 17" 19"
:me"(secs)"
Figure 15: Torque – speed monitor of the delta
Figure 13: Visualisation of GPS track data showing the track
profile (on the latitude-longitude axes) and the vehicle speed when
drive train
fitted with coreless-PM geared drivetrain
From the data presented in Figure 15 the
relationship between drivetrain losses and vehicle
speed could be derived by applying the analysis
5 Delta E4 Coupe Measurements shown in section 4.2.
and Simulation
To understand how the coast performance of an By adjusting the vehicle model, discussed in
electric vehicle with clutch would change with section 3, with parameters relevant to the Delta
vehicle size, experimental and numerical analysis of E4, the relationship between total road losses and
a high performance sports electric vehicle was straight line speed could be estimated. With the
undertaken. drivetrain loss measurements and vehicle coast
loss estimates, the value of a hypothetical clutch
mechanism was calculated over the vehicle’s
5.1 Coast Loss Analysis of a Delta E4 speed range (Figure 16).
The Delta E4 shown in Figure 14 is a prototype
coupe. The vehicle weighs 1000kg and makes use 18000" Road%Losses% 40"
of a carbon fibre chassis. The drivetrain comprises
An.cipated"Clutch"Savings"Based"on"
16000"
Simulated"Total"Road"Losses"(W)"
An+cipated%Clutch% 35"
two axial flux permanent magnet machines
Measured"Drive"Losses"(%)"
14000" Savings%(Delta)%
providing direct drive to the rear wheels. This 30"
2000" 5"
0" 0"
10" 30" 50" 70" 90" 110"
Vehicle"Speed"(kph)"
Figure 16: Plot of total road losses and % clutch savings for the
Figure 14: Delta E4, [22] Delta E4
In order to work out the coast down losses of the Figure 16 indicates that a clutch mechanism on
Delta E4 drive train, the vehicle wheels were lifted the Delta E4 would reduce coast losses by
off the ground and a controlled pulse torque was between 10 and 15% over the vehicle’s speed
demanded. The rotor velocity was recorded and is range. Depending on the vehicle drive cycle, this
shown in Figure 15.
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could lead to a significant energy saving over the continuous high speed driving is required where
course of a journey. total road losses dominate over unloaded
drivetrain losses.
6 Discussion
7 Conclusions
It has been demonstrated that the inclusion of a This paper explores the value of a clutch
clutch mechanism within an electric drive train can mechanism and how it relates to vehicle size and
realise significant savings during coast events. The motor topology. It was shown that:
savings depend on both the size of the vehicle and
the topology of the propulsion motor. The choice of • The inclusion of a clutch mechanism within
clutch mechanism had relatively little impact on a small single seat vehicle resulted in a
measured coast losses however an active dog 35+% reduction in coast losses.
arrangement facilitates freewheeling and • The machine topology choice influenced the
regenerative braking which may deliver higher fuel coast losses and hence value of the clutch
economy depending on the driving style. This mechanism. Where the drive train changed
comes at the expense of simplicity and reliability. from a PM in-hub ferrous direct arrangement
to a coreless PM geared drive, the reduction
As small vehicles for personal mobility become in coast losses via operation of the clutch
more prevalent, the losses associated with the was reduced to 5%. This was due to the
propulsion motor relative to the total road losses elimination of hysteresis and eddy current
increase due to the reduced efficiency of smaller losses.
drives. This was reflected by the fact that the • Testing and simulation of an equivalent
Peggie vehicle, which weighs 30kg un-laden, direct drive arrangement on the Delta E4
experienced a 40% reduction in coast losses when a coupe, indicated a 10% reduction in coast
direct drive, permanent magnet ferrous machine losses associated with operation of a
was declutched from the driveline. This was a hypothetical clutch.
significantly higher saving compared to the 1000kg • Experiments were conducted on a range of
Delta E4 coupe, where it is anticipated that a clutch clutch mechanisms. It was found that there
would result in a 10% drop in coast losses based on was little difference in performance between
measurement of the drive losses and simulation of the sprag, ratchet and dog arrangements
the total road losses. when freewheeling. However, since the dog
clutches can facilitate regenerative braking,
Another significant factor is the machine topology. they were incorporated into the 2013 Peggie
Where a coreless PM machine was operated within vehicle.
Peggie’s drivetrain, savings associated with the
clutch mechanism were reduced to 5% as a result of
the removal of hysteresis losses and eddy current Acknowledgments
joule heating which would otherwise occur in a The authors would like to thank the following
ferrous stator. It is anticipated that lower savings sponsors, without which our participation in the
will result when other machine topologies are used Shell Eco Marathon would not have been
where the rotor field is removed when the stator is possible: Oxford Martin School, Christ Church
de-energised. This may apply to vehicles such as College, Mansfield College, Pembroke College,
the Tesla Roadster, which is driven by an induction Baliol College, Maxon Motor, Future Energy,
machine along with vehicles using switched ARM, Accenture, Frazer-Nash, Shetland
reluctance drives. Composites, Goodrick Gears, Frankie’s
Paintshop.
Although it is outside the scope of this paper, the The contribution of Lucy Mahoney and Nicole
influence of drive cycle on the value of a clutch Miranda for driving PEGGIE during the Eco
mechanism would be an interesting topic to Marathon and during vehicle testing for this paper
explore. It is likely that driving strategies such as is also acknowledged.
pulse and glide, where coasting events occur often, The support of Nick Carpenter and Delta
will experience significant benefits from a clutch Motorsports is also acknowledged.
mechanism compared with scenarios where
regenerative braking events are frequent or
EVS27 International Battery, Hybrid and Fuel Cell Electric Vehicle Symposium 8
References [9] J. F. Gieras, R. J. Wang and M. J. Kamper,
Axial Flux Permanent Magnet Brushless
[1] M. S. Carmeli, F. Castelli Dezza, G. Machines. Springer Science, 2008.
Galmarini, M. Mauri and L. Piehari, A
vehicle with very low fuel consumption;
realization, analysis and optimization, in
XIX International Conference on Electrical
Machines, Rome, Italy, 2010, .
EVS27 International Battery, Hybrid and Fuel Cell Electric Vehicle Symposium 9
Robert Richardson graduated
Authors with a BEng (Hons) in
Mechanical Engineering from the
Robert Camilleri graduated with
National University of Ireland,
a BEng (Hons) in Mechanical Galway in 2012. His final year
Engineering from the University
thesis was focused on developing
of Malta in 2005, and from Computational Fluid Dynamics
Cranfield University with an (CFD) models to optimise the
MSc in Gas Turbine Technology
design of a Rapid Compression
in 2007. He is now reading for a Machine (RCM), a machine used
D.Phil. in Engineering Science at
to conduct combustion
the University of Oxford. His experiments at conditions
thesis title is Conjugate heat
relevant to internal combustion
transfer in high current density engines and gas turbines. In
Electric Machines, with the
October 2012, he joined the
research focusing on liquid Energy and Power Group as a
cooled high current density axial
DPhil student, where his research
flux electrical machines. is focused on thermal
management of lithium-ion
Pete Armstrong is a design batteries for electric vehicles.
engineer who graduated from
Edinburgh with a MEng in Dr David Howey is a University
Electrical and Mechanical
Lecturer in Engineering Science
Engineering prior to working as a and also holds a Tutorial
technical lead on a hybrid
Fellowship at St Hilda’s College.
transmission prototype for Within EPG, his research team's
QinetiQ. Currently undertaking a
interest is in the management of
PhD at Oxford in the application energy conversion and energy
of energy storage technologies to
storage components, primarily
power systems, Pete developed a for automotive applications such
phase-lock control strategy for
as electric and hybrid vehicles.
clutch mechanisms that earned He studied engineering and
the technical innovation award in
specialised in electrical and
the 2013 Shell Eco-Marathon. information sciences at Queens’
College, Cambridge University.
Nathan Ewin was an
He undertook a PhD at Imperial
undergraduate at Balliol College,
College London on the subject of
Oxford, where he received an
thermal design of electrical
MEng in Engineering Science.
machines. He subsequently
Upon graduating Nathan went on
worked as a post-doctoral
to work for Oxford YASA researcher there on automotive
Motors Ltd (OYM). Nathan
projects investigating electrically
joined EPG in April 2010 as a D. assisted turbocharging and
Phil. Student. Nathan's current advanced battery condition
research is looking at how to monitoring. He remains an
exploit the information that can Honorary Research Fellow at the
be extracted from the Energy Futures Lab at Imperial
measurements of the current and College.
the position signals from a
electric motor. The primary Dr Malcolm McCulloch heads
focus of this is to develop the Energy and Power Group.
traction control for electric Malcolm has active research
vehicles with independently programmes in the three sectors
driven wheels. of domestic, transport and
renewable generation. The
domestic sector is one of the
largest energy sectors in the UK.
A key research area is the
development of smart feedback
metering that provides useful
information to enable behaviour
EVS27 International Battery, Hybrid and Fuel Cell Electric Vehicle Symposium 10
change. This work lead the spin-
out Intelligent Sustainable
Energy, of which Malcolm is
both a founder and non-executive
director. This has merged to form
Navetas Energy Management. In
the transport sector, research is
ongoing in developing power
trains for electric and hydrogen
vehicles. A successful project
was that of the Morgan LifeCar –
the first ever Hydrogen sports
car. This project lead to the
development of high-efficiency
low-weight motors using new
materials- The yokeless and
segmented armature motor. This
has resulted in the Oxford spin-
out company Oxford Yasa
Motors, of which Malcolm is also
a founder and non-executive
director. He is also the director of
the Institute for Carbon and
Energy Reduction in Transport,
based at the Oxford Martin
School. In renewable generation,
novel lightweight low speed
direct coupled generators are
being developed along with a
transverse axis tidal turbine.
Malcolm has over 60
publications and 15 patent and
patent applications.
EVS27 International Battery, Hybrid and Fuel Cell Electric Vehicle Symposium 11