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Experimental analysis of 1400 cc diesel engine car converted into Hybrid Electric Vehicle by using
BLDC hub motors
byProf. Sudhir Gupte
Automobile Engineering DepartmentA.D.Patel Institute of Technology
1IV th International Conference on
Advances in Energy Research 12 Dec' 2013
Introduction
Two reasons for the need of Conversion.
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Fossil fuel resources depleting
Environment PollutionGlobal Warming
Stringent Mandatory norms
Newer TechnologiesHike in Fuel pricesDemand and supply
To achieve mandatory pollution standards out of compulsion
Introduction: What is Automotive Industry doing ?
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Power to Weight Ratio
Reduction in Vehicular Weight
Improvement in Combustion
EV/HEV
Air/Fuel Ratio
Engine down sizing
Study of Driving cycle Aerodynamics
Mild, Micro etc. Hybrids. But all these comes at very high development cost and complicated & expensive installations on the vehicle.
BUTIf per capita consumption is not reduced drastically and if alternate energy vehicles are not developed, they will not be able to sustain the market conditions in the near future.
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Integrated holistic approach to improve Quality of air
Improvement in Roads and traffic conditions Fuel Quality standards Bio Fuels & Alternate energy sources. Electric vehicle mission plan declared by Govt. India 9th
Jan, 2012.
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HoweverThose Millions of old vehicles will be still guzzling unwanted, harmful pollutants in the atmosphere at an alarming rate, still contributing towards the menace of global warming, which will continue, if they are not converted into hybrid electric vehicles.
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Hence
1400 cc diesel engine car converted
into Hybrid Electric Vehicle by using
BLDC hub motors –
An Experimental analysis
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Following points were considered while attempting to contribute towards improving the quality of air or reduce further damage being created by the existing /old gasoline and /or diesel vehicles.
conversion should be economical and affordable. Conversion should be easy. An unskilled
worker/mechanic should be able to carry out the conversion within 4 to 5 hours, after receiving necessary one day training.
Minimum requirement of special tools. Return on investment should be measurable and
attractive for the user. Convenient to use by the customer. Hassel free service. Ease of maintenance. Ease of implementation even for vehicle manufacturer
on the similar new models. Satisfactory performance.
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Concept : Proposed Hybrid system
Using the existing IC engine as main source. Electric motors providing driving force as
Auxiliary power source. Can be used as four wheel drive as and when
necessary. All four wheels disc brake system. No/Minimum modifications in the existing drive
train.
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Concept : Proposed Hybrid system
… Cont. On board Energy flow: Separate Battery pack
for Existing engine and for electric motors. Plug-in type charging system for Electric motor
batteries and existing alternator charging system for the vehicular battery.
Regenerative braking system not adopted, because, under most ideal conditions, efficiency of loop, battery to kinetic and kinetic to battery charging is no greater than 50 %. Also, it adds to cost, which may prohibit customers for conversion.
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Models Applicable:
Maruti: M800, Alto, Zen Tata: Indica Hundai: Santro All “B segment” cars with Front Transverse
Engine.
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Kit comprising of Parts Permanent Magnet BLDC Hub Motors Controller Accelerator pedal control Battery Pack (options to choose type of
Battery: Pb/Acid, Lithium-Ion, Lithium polymer, etc.)
Wiring harness (inclusive of switches) Charging system Measuring Instruments (optional) Brakes system
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Performance Test Results
Parameters RouteConventional ICE Vehicle
PrototypeHEV
% Saving of Fuel
in EV mode V/s ICE
Fuel Consumption, Liters//100Km
State highway 4.65 2.29 50.8
State highway 4.83 2.62 45.8
NH 8 5.05 2.19 56.6
Express way 5.12 1.97 61.5Maximum Speed Achievable in HEV
62 km/hr
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ParametersConventional
ICE VehicleHEV after Conversion
Engine Peak Power 52 PS @ 5000 52PS
Engine Max. Torque, NM 85 @ 2500 rpm 85 @ 2500 rpm
Peak Power of Motor, PM BLDC
- 2.5+2.5 = 5 kw
HEV Battery Pack, 4x12 V, Lead Acid type
- 150 Ah
Passenger Weight 150 Kg 150 Kg
Curb weight of vehicle 1050 Kg 1250 Kg
Total 1200 Kg 1400 Kg
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Torque at WheelsDescription Unit rpm @ ICE HEV
Peak power Ps 5000 52 5
Peak toque Nm 2500 85
Final drive ratio 4.40
Gear Ratios 1st Nm 3.64
2nd Nm 1.95
3rd Nm 1.27
4th Nm 0.88
5th Nm 0.64
Reverse Nm 3.50Tyre Size 165X65R14
Rolling radius m 0.272 0.272
Max. Torque at wheels 1st Nm 1361.36
2nd Nm 729.30
3rd Nm 474.98
4th Nm 329.12
5th Nm 237.86 200
Reverse Nm 1309.00
Max. Speed Km/hr 92 61.5
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Why change EV driving cycle
Prius changes to EV during congested traffic conditions and runs on ICE on highways. OK for urban driving cycles in Metro cities.
In other cities car users are driving in cities for 10 % distances and remaining on highways.
High speed running on highway obviously fuel consumption is high.
With low powered, light weight PMBLDC hub motors, it is proposed to run vehicle on ICE in city traffic conditions and switching on to EV on highway.
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Results and Discussions
By using proposed lower power Hub Motors, up to 61 % saving is achievable on the existing cars.
Peak performance of the available drive line is retained / assured.
Veh. existing electrical system is not disturbed. Existing Hyd. Brakes with Disc brakes in rear. No additional Instrumentation required. Power Steering and A/c are driven by ICE, hence
ICE has to run on idling while running in EV mode.
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Results and Discussions …Cont.
Appropriate torque capacity of PM BLDC hub motors can be selected for the particular vehicle for conversion in to HEV, for deriving optimum results.
Advantage of hub motors is that the output is directly driving the wheels; hence the motors efficiency is the only loss. Geared hub motors add to varying torque reqyuirement.
Well to wheel energy efficiency for Prototype HEV is measures at 0.87 km/MJ as against 0.64 for Insight and 0.56 for Prius models but 1.14 for Tesla (pure EV).
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Conclusions Proposed method is expected to reduce the fuel
consumption by 45 % to 61 % (with A/c & P/S). Results can improve further, if the high Ah, light
weight batteries are utilized. Possible to convert majority of the old cars with
front engine front wheel drive vehicles in to Hybrid Electric car, without much of difficulty and at reasonable cost.
Easy to implement in new veh. models –Existing/introduced in future, by the vehicle manufacturers.
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Conclusions …Contd.
Serviceability and life of components is improved.
Increase Service life of ICE and driveline components.
Reduced maintenance cost of ICE and driveline assembly components.
ROI from 11 to 15 months @ 3000 km per month.
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THANK YOU
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