Armament and Technics of Land Forces 2010

OPTIMIZED DESIGN OF HYBRID POWERTRAIN FOR UNMANNED

LIGHT FIGHTING VEHICLE

Martin BUGÁR1, Vladimír STAŇÁK2 Viktor FERENCEY3

Abstract

BUGÁR, Martin – STAŇÁK, Vladimír – FERENCEY, Viktor :

OPTIMIZED DESIGN OF HYBRID POWERTRAIN FOR UNMANNED LIGHT FIGHTING
VEHICLE
– Názov univerzity. Slovenská technická univerzita v Bratislave, Názov fakulty. Fakulta
elektrotechniky a informatiky, Názov katedry. Katedra mechaniky
– Liptovský Mikuláš: AOS LM, 2009. X s.

The paper presents conceptual model of powertrain system for UGV (Unmanned Ground
Vehicle).
Examined UGV or so called ULIFIV (Unmanned Light Fighting Vehicle) uses the
TATRAPAN chassis. Serial hybrid powertrain with ZEBRA batteries is the main power
source of ULIFIV. Engine is designed to perform across a wide range of operating conditions.
The vehicle is equipped with two electric motors and can operate on and off road, at speeds
up to 70 km/h. The vehicle can carry a payload of up to 500 kg. The UGV can carry a wide
variety of sensors, including video and thermal cameras. UGV can also be manually
controlled by remote control system.
The paper was prepared with support of scientific VEGA grant, registration number
1/0627/10.

Keywords:
UGV , Serial hybrid, Powertrain, Control system, Sensors

1
Ing. Martin Bugár, Slovak University of Technology, Bratislava, Faculty of Electrical engineering and
Information technologies, Department of Mechanics, Ilkovičova 3, 812 19 Bratislava e-mail:
martin.bugar@stuba.sk)

2
Ing. Vladimír Staňák., Slovak University of Technology, Bratislava, Faculty of Electrical engineering and
Information technologies, Department of Mechanics, Ilkovičova 3, 812 19 Bratislava e-mail:
vladimir.stanak@stuba.sk)

3
Prof. Ing. Viktor Ferencey, PhD., Slovak University of Technology, Bratislava, Faculty of Electrical engineering
and Information technologies, Department of Mechanics, Ilkovičova 3, 812 19 Bratislava e-mail:
viktor.ferencey@stuba.sk)
 16th International Scientific Conference, Liptovský Mikuláš 2010

Kľúčové slová:
UGV, Sériový hybrid,. Hnacia sústav, Riadiaci systém, Senzory

INTRODUCTION
Different sorts of the operations controlled in the course military and non - military
conflicts, its alternation and mutual intersect are throwed back and in the wide spectra
activities as large movements, wandering, or alternation tactical wholes, space outside battle,
management stacked against the diversionary activities, battle in the encircled, exploring
activity and management various form tactical activities limited power. Diversity form of
various tactical activities, its mutual intersection and alternation will be one of the major
characteristic in the future operations and battles.
With reason oneself will put assume, that in future operation oneself will increase
movement rail battles activities, which is conditional and raising mobility one and tactical
wholes. Factors, which are allowing the increase in mobility armies belongs its outfit mobile
centers. These mobile resources will be must be considered to be equipped effective
weapons the system, the system on protection ferried persons, assembly secure high capacity
in the terrain as well as equipped cap good conditions for activity service car.

1 CONCEPTUAL MODEL OF VEHICLE

ULFV – Unmanned Light Fighting Vehicle is unmanned wheeled vehicle, which
characteristic notes are absence humane crew, armor protection, firepower and good
maneuverability. These ground facilities must be considered to be in a certain mutual
harmony. Degree of harmony is divided in the every stage development cars and depend
primarily for the purpose and manner operational uses car and up to the mark technical
progress. Car has low silhouette, excellent terrain driving, which be given choices of chassis
conception . Other feature characteristic is advanced system drive and electronic outfits, for
viewing or direction and weapons the system.
Car is powered by series hybrid electric propulsion, who be formed by two of master
electric motor and joint with conjunctive speed-gearbox, small capacity internal combustion
engine , generator, accumulator and necessary electronics. In ascending shaft electric motor is
classic arrangement driving system with the clutch, speed-gearbox, final drive housing and
differentials. Electric motors are set in the vehicle axle side by side and its performance is
transferred over mechanical speed-gearbox on inter-axle ( central ) differential and further on
wheels. Internal combustion engine drives generator, who he adds electric current pro
accumulator and electric motors. Advantages of electric propulsion power train are
characteristics torsional moment electric motor and in posse relatively silent run through the
accumulators without having activities of internal combustion engine. Hybrid drive system
enables one cut - down fuel consumption, extension endurance distance, chances of the
energy recovery.
 Armament and Technics of Land Forces 2010

2 CONSTRUCTION OF CHASSIS AND DRIVE SYSTEM IN UNMANNED LIGHT

FIGHTING VEHICLE
Vehicle chassis is formed of three swinging axles with the six wheels. Swinging axles are
made from car Tatrapan. Priorities of this conception are : robustness, attested construction,
good movement in terrain , resistance stacked against the explosion mine. Disadvantage
stand weight, tread change by the compression travel and bigger tire wear. Conception spinal
chassis with carrying pipe transfers a part of powers functioning between wheels and
roadway, what enables one applying simple and easier supporting frame. Supporting frame is
three - dimensional composition and is made riveting from sectional steel. On the frame are
joined components of driving system, supporting systems car and armor.

Fig.1 Construction of vehicle chassis and drive system

1 – inter-axle differential, 2 – wheel hub, 3 – air axle suspension, 4 – central torque tube of backbone-
type frame, 5 – axle differential , 6 – axle , 7 – final drive housing, 8 – final wheel drive

Final drive gear consists of couple conic transfers with Oerlikon- Spiromatic gearing.
Axle is equipped with wheel reduction, with planetary gearing. Differential shipped with axle
has position with exploitations balance.
 16th International Scientific Conference, Liptovský Mikuláš 2010

3 DESIGN OF HYBRID POWERTRAIN FOR UNMANNED LIGHT FIGHTING VEHICLE

Wheels are powered through the two electromotor/generators type- Siemens 1PV5135-
4WS28, which are coupled through the connecting gearbox with single - shaft output.
Performance of one electromotor/generator is 67 kW in the continuous term / 120 kW for a
peak term. By the effectiveness 95 % be its input power about 126,3 kW. Rpm governing EM
is solved over invertor from same producer. Because of his effectiveness it needs inputs 155
kW.
Energy for continuous operation is obtained from electric generator powered by internal
combustion engine. Generator is one, it is Siemen 1FV5139- 6WS28 and it gives in the
continuous term 85 kW (for a peak term 100 kW) by the 2500 revolution per a minute. It is
concerned alternating synchronous machine, therefore it is advisable tension direct - in the for
remembered for invertors , whose effectiveness is 96 %. For performance peaks and for quiet
drive be intended accumulator. It is to size on voltage - 619 volts in the in the continuous
terms and 696 volts for a peak terms. . This configuration (accumulator is compound of
several smaller) will put performance about 35,5 kW, during peak term this is able to give
power too more, on the contrary in the continuous term less power.

Fig.2 Conceptual model design of powertrain for Unmanned ground vehicle

1 – electromotors/generators SIEMENS, 2 – hydraulic shock-absorber of vehicle suspension, 3 – inter-

axle differential , 4 – spaceframe of vehicle, 5 – air axle suspension,
 Armament and Technics of Land Forces 2010

6 – radiator of internal combustion engine, 7 – central torque tube of backbone-type frame, 8 –

radiator of electric power train components, 9 – fuel reservoir, 10 – automatic five gear transmission,
11 –drive line, 12- electronic control units of weapon components,
13 – wheels

Fig. 3 Powertrain wiring diagram with connectivity of components

1 – Diesel internal combustion engine VW 2,0 TDi with ECU, 2 – Generator 1FV5139 – 6WS28,
3 – Communication interface SAE-CAN, 4 – Invertor of electromotor/generators Siemens, 5 –
ZEBRA Battery Type Z37 - 620-ML3X-32, 6 – Invertor of powertrain Siemens , 7 –
electromotor/generator Siemens 1PV5135-4WS28, 8 – Electromotor/generator Siemens 1PV5135-
4WS28, 9 – Auxiliary electromotor

CONCLUSION
For unmanned ground vehicle is suitable to use serial hybrid powertrain system. For this
drive conditions, course torque and performance of power are basically convenient. In this
application internal combustion engine would be worked in persistent revolution, but
apparently by the various loaded. It will be over electro generator works in this modes:
1.) Power of the electromotor with permanent input power = charging battery = full
load
2.) Power of the electromotor with partial input power = light load
3.) Under braking trailing of electromotor plus charging battery = light load
4.) Under braking trailing of electromotor plus charging battery = zero load
5.) ( internal combustion engine would be switch off in the event that the vehicle will
ride over long drive down road)
6.) By the stop vehicle trailing of electromotor plus charging battery = light load
 16th International Scientific Conference, Liptovský Mikuláš 2010

Fig.4 Unmanned ground vehicle ( Unmanned light fighting vehicle )

Vehicle´s fuel tank of Unmanned ground vehicle have 100 liters, what would by the
consumption of 10 liters of diesel per hour of operation ability of internal combustion engine ,
had it go around 10 hours of vehicle operation drive.

The paper was prepared with support of scientific VEGA grant, registration number
1/0627/10.

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