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


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


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


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


• PHEV Powertrains Topologies (Categorized by TM Mode)



• PHEV Powertrains Topologies

Series Series + Parallel

Series + Output split Input split



• 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


• PHEV System Efficiency


Drive Driven


3. Methodology- System Analysis

• Theoretical System Analysis

System Configuration


System EquationSystem

Equation

System Efficiency

- Elec. & Mech.

System Efficiency

- Elec. & Mech.

Systems

Comparison

Systems

Comparison


TMG2 =

Tout/R

System 1 System 2


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


• 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


• Transmission Component Loss 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


Split

- Parallel Path: Through Planetary gear 1 time

- Series Path: Through Planetary gear 2 times

Recirculation



Parallel Path

Series Path

Parallel Path

Series Path

Input split Output splitSplit


- Series Path: Through Planetary gear 1 time

Recirculation



Parallel Path

Series Path

Parallel Path

Series Path

• Theoretical System Analysis – Gear Loss Modeling


Organized by Hosted by In collaboration with Supported by0.5 1 1.5 2 2.5 3 3.5 4

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



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)


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


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%


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


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


EV

Series

Ouput split

< Test result – Volt>


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


Wheel Torque (Nm)

EV

Series

Parallel

< Test result – Accord PHEV >


Wh

ee

l To

rqu

e (

Nm

)

EV

Series

Parallel


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


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


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?


THANK YOU

Gracias

감사합니다


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


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

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