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SELECTION OF PROPULSION SYSTEMS FOR AUTOMOTIVE
APPLICATIONS
Pierre Duysinx
LTAS – Automotive Engineering Academic Year 2010-2011
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Bibliography
R. Bosch. « Automotive Handbook ». 5th edition. 2002. Society of Automotive Engineers (SAE)
M. Ehsani Y. Gao, S Gay & A. Emadi. Modern Electric, Hybrid Electric, and Fuel Cell vehicles. Fundamentals, Theory and Design. CRC press. 2005.
G. Genta. Motor Vehicle Dynamics – Modeling and Simulation.
World Scientific Publishing. 2003.
T. Gillespie. « Fundamentals of vehicle Dynamics », 1992, Society of Automotive Engineers (SAE)
W.H. Hucho. « Aerodynamics of Road Vehicles ». 4th edition.
SAE International. 1998
J.Y. Wong. « Theory of Ground Vehicles ». John Wiley & sons.
1993 (2nd edition) 2001 (3rd edition).
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Outline
Specification of propulsion systems for automobiles
Ideal motorization
Other characteristics
Alternative thermal motorizations
Steam engines
Stirling engines
Gas turbines
Piston engines
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Outline
Hybrid motorization
Definition
Layout
Architecture
Fuel cells
Definition
Fuel cell powered hybrid vehicles
Comparison
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Specification of propulsion systems
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Ideal characteristics of vehicle power plant
Remind first that the operating point of system is governed by the equilibrium between the power (forces) of the plant and the load.
The operating point is obtained by the intersection of the power (torque) curves of the plant and of the resistance loads
Resistance curves Plant curves
Equilibrium
Vitesse
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Ideal characteristics of vehicle power plant
Ideal characteristics of power plant for vehicle propulsion: power curve close to constant powerfor any regime and so torque curve proportional to inverse of speed
It is the curve that maximizes the power
transmitted to the vehicle for any velocity
power
Speed / rotation speed
Torque
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Ideal characteristics of vehicle power plant
For low speed operation, the friction between the wheel and the road is limiting the transmitted force
Intrinsic limitation to the maximum
Adhesive
speed Torque
C A
= ω
max
x z
F = µ F
max max
e x z e
C = R F = µ F R
max
e z
C = R µF
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Ideal characteristics of vehicle power plant
Sensitivity of drivers
At low speed: we are sensitive to the acceleration:
Large acceleration capability
Large drawbar pull
Large traction force
Large gradeability capability
At high speed we are sensitive to the power of the motor to be able to overcome the resistance forces (mainly aerodynamics)
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Ideal characteristics of vehicle power plant
Motorizations close to ideal specification
Electric machines (DC motor with separately induction supply)
Steam engines (Rankine cycles)
Piston engines have less favorable characteristics:
Stall rotation speed
Non constant torque and power
Transmission necessary
Why are they dominant? Because there are also other criteria to be considered!
Weight to power ratio
Reasonable energy consumption
Low production cost
Easy to start…
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Ideal characteristics of vehicle power plant
More over, piston engines take benefit of a long story of innovation and improvements
Improvement of fuel consumption
Electronic fuel injection,
Lean burn techniques
Turbocharged engine and direct injections
Control of emissions in reducing pollutant emission (CO, NOx, HC, PM, etc.)
3 ways catalytic reduction
DeNox and SCR
DFP
Etc.
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Ideal characteristics of vehicle power plant
Other criteria for vehicle power plants
Constant power
Weight to power ratio
Large speed operation range
Reasonable energy consumption
Control of pollutants emissions
Low production cost
Easy to start and operate
Serial production
Low maintenance
High reliability
Medium life time: 200.000 km about 2000 working hours
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Alternative power plants
Other internal combustion engine
Steam engines (Rankine cycle)
Gas turbines (Brayton cycle)
Stirling engine
Rotary piston engine (Wankel engine)
Other propulsion systems
Electric machines
Hydraulic and pneumatic motors
Hybrid propulsion systems
Fuel cells and electrochemical converters
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Alternative power plants
Vehicle propulsion
Combustion engines Electric motors
Internal combustion External combustion DC AC
Reciprocating engines Otto, Diesel,
Wankel, 2T / 4T
Stirling engine Steam engine (Rankine)
Continuous combustion Gas turbine Axial piston engines
Hybrids
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Steam engines
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Steam engines
Cugnot vehicle
Steam locomotive
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Steam engines
W
out= W
in+ Q
in- Q
out18
Steam engines
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Steam engines
Advantages:
Nearly ideal power / torque curves close to constant power
Is able to withstand temporary overcharge and high torque at low speed, so that there is no need for transmission
Large range of possible fuels
Emission of pollutants can be widely minimized because of external combustion
Drawbacks
Bad weight to power ratio
Bad volume to power ratio
Set up time is very long
Old solutions had a low efficiency (less than 20% in 180ies steam locomotive with exhaust of steam)
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Steam engines
1 – Piston 2 - Piston rod 3 - Crosshead bearing 4 - Connecting rod 5 – Crank 6 - Eccentric valve motion 7 – Flywheel 8 - Sliding valve 9 - Centrifugal governor.
http://en.wikipedia.org/wiki/Steam_engine
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Steam engines
Double piston stroke: uniflow steam engine
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Steam engines
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Stirling engine
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Stirling engine
Working principle of Stirling engine is based on a closed cycleand a working fluid (helium or hydrogen)that is heated and cooled alternatively
The Stirling engine is a external combustion engine
It is made of two iso thermal processes and two iso volume process.
The heat source calls for expansion a while cold source calls for compression
Both sources are separated by a regenerator.
The theoretical efficiency of Stirling cycle is equal to Carnot efficiency with the same difference of temperature.
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Stirling engine
Step I: the power piston (1) in lower position. The displacer piston (2) is moving in upper position. The working fluid is pushed in the cold chamber (3)
Step II: The power piston is compressing the cooled gas in isothermal process
Step III: The displacer piston moves downward and pushes the gas to the hot chamber (4) through regenerator and heater
Step IV: The Hot gas is expanding and is delivering some work to power piston. The displacer piston is moved downward
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Stirling engine
1. Power piston (dark grey) has compressed the gas, the displacer piston (light grey) has moved so that most of the gas is adjacent to the hot heat exchanger
2. The heated gas increases in pressure and pushes the power piston to the farthest limit of the power stroke
3. The displacer piston now moves, shunting the gas to the cold end of the cylinder.
4. The cooled gas is now compressed by the flywheel momentum. This takes less energy, since when it is cooled its pressure drops.
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Stirling engine
Advantages:
Very low specific pollutants emissions (external combustion)
Low noise generation
Several fuels can be used
Practical efficiency is equivalent to best Diesel engines
Drawbacks
In the state of the art: bad power to weight ratio
Mechanically complex
Low acceleration capabilities (better suited to stationary applications)
Too high manufacturing cost
Penalized by the large heat exchanger surface (air / air exchanger)
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Stirling engine
Practical layout of a Stirling engines with opposed pistons (Eshani et al. 2005)
Torque / speed curves of a Stirling engine (Eshani et al. 2005)
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Stirling engine
Performance and fuel consumption of a Stirling engine with 4 cylinder for vehicle traction (Eshani et al. 2005)
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Gas turbine
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Gas Turbine
Gas turbines are one the oldest type of internal combustion engines
Gas turbines are based on the Brayton cycle, which is an open cycle
They include an air compressor, a combustion chamber and a expansion turbine.
Turbines is actuated by the working fluid and convert the heat energy of the fluid into mechanical power. The shaft can be connected to a generator or connected to the wheels.
The combustion chamber of gas turbine can burn a wide variety of fuels: kerosene, gasoline, natural gas…
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Gas Turbine
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Gas Turbine
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Gas Turbine
Advantages:
High power to weight ratio
Ability to use a wide range of fuels
Low emissions of pollutants CO et HC
Good mechanical balancing because of rotary motion and low vibrations
Flat torque curves for double shaft solutions
Long periods between two maintenances
Disadvantages
Low efficiency outside design point
Bad fuel efficiency outside nominal design point
High cost (high temperature materials, heat exchangers)
Bad dynamic responses (rotation acceleration)
High rotation speed Îneed for a large reduction gear box (and so a weight penalty)
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Gas Turbine
Gas turbine with exchanger Eshani et al. 2005
Performance and fuel consumption of a gas turbine Konograd KKT. Eshani et al. 2005
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Gas Turbine
One repots several tentative applications of gas turbines to automobile
As soon as the WWII, Rover has been interested in gas turbines and has realized prototypes between 1950 and 1961.
In 1963, the Rover BRM 00 has participated to the La Mans 24 hours with Graham Hill et Richie Gunther and has finished in 8th position.
Later on gas turbines have been applied in heavy vehicles such as M1 Abraham armored vehicles.
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Gas Turbine
Turbine Car by Chrysler (1963)
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Piston engines
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History of ICE
1700: Steam engine
1860: Motor of Lenoir (efficiency η~5%)
1862 Beau de Rochas defines the working principles of internal combustion engines
1867: Motor of Otto & Langen: (η~11% and rotation <90 rpm)
1876: Otto invents the 4-stroke engine 4 temps with spark ignition (η~14% and rotation < 160 rpm)
1880: Two-stroke engine by Dugan
1892: Diesel invents the 4-stroke diesel engine with compression ignition
1957: Wankel invents the rotary piston engine
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Piston engines (Gasoline and Diesel)
One distinguishes several variants
Fuels:
Gasoline, diesel, LPG, Natural Gas, H2, bio-fuels…
Thermodynamic cycles:
Otto : spark ignition engine
Diesel : compression ignition engine
Fuel injection
direct or indirect
Turbocharged or atmospheric
Cycles
2 strokes
4 strokes
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Classification
The 4-stroke enginea performing the 4 steps in 4 strokes that is two
crankshafts rotation.
The 2-stroke engineis carrying out the four steps in two strokes, that is one crankshafts rotation.
The rotary engines: the rotating motion is replacing the alternating motion. The rotor rotation is realizing the four steps in one rotation
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Classification
SI engine
2 strokes 4 strokes
Carburetor Injection Carburetor Injection
CI engines
2 strokes 4 strokes
Indirect
injection Direct Injection Indirect
injection Direct Injection
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Classification
Atmospheric engine:
The air-fuel mixture or air is injected at atmospheric pressure during admission phase
The filling ratio is lower than 1
The power is limited by this coefficient
Supercharged / turbocharged engine
The air-fuel mixture / air is admitted with a overpressure
Compression increases the mass of admitted air so that one can inject more fuel and produce more power
Overpressure is realized by admitting the air through a compressor or a turbocharger
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4 stroke engines: gasoline
In 1862, Beau de Rochas developed a operation sequence that is still now the basis of any piston engine operations
The 4-stroke engine requires to 2 crankshaft revolutions to accomplish one thermodynamic cycles, which means 2 compression and expansion motions of the piston.
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4 stroke engines: gasoline
Stroke 1: Fuel-air mixture introduced into cylinder through intake valve
Stroke 2: Fuel-air mixture compressed
Stroke 3: Combustion (roughly constant volume) occurs and product gases expand doing work
Stroke 4: Product gases pushed out of the cylinder through the exhaust valve
Compression Stroke
Power
Stroke Exhaust
Stroke A
I R
Combustion Products Ignition
Intake Stroke FUEL
Fuel/Air Mixture
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4 stroke engines: gasoline
Advantages:
The spark ignition engine relies on a well-known principle, mature technology, and a well established technology
Good weight to power ratio
It is able to work while burning different fuels: gasoline, diesel, methanol, ethanol, natural gas, LPG, hydrogen…
It takes benefit of a large amount of technological developments to control the emissions of pollutants
Disadvantages:
Bad fuel economy and tedious emission control (HC, CO et NOx) when operated at part load and cold temperature conditions
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4 stroke engines: diesel
The Four stroke Compression Ignition (CI) Engine is generally denoted as the Diesel engine
The cycle is similar to Otto cycle albeit that it requires a high compression ratio and a low dilution (air fuel) ratio.
Air is admitted in the chamber and then compressed. The temperature rises the ignition point and then the fuel is injected at high pressure. It can inflame spontaneously.
There is no need for a spark and so stocheometric air fuel ration is not necessary.
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4 stroke engines: diesel
Stroke 1: Air is introduced into cylinder through intake valve
Stroke 2: Air is compressed
Stroke 3: Combustion (roughly constant pressure) occurs and product gases expand doing work
Stroke 4: Product gases pushed out of the cylinder through the exhaust valve
Compression Stroke
Power Stroke
Exhaust Stroke A
I R
Combustion Products
Intake Stroke
Air
Fuel Injector
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4 stroke engines: diesel
Advantages:
Higher efficiency because of higher compression ratio
Largely developed and technological availability
Low CO and HC emissions
Disadvantages:
Larger PM and NOx emissions ratios
Heavier and larger than gasoline engines, but still high compared to other technologies
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2-stroke engines
Dugald Clerk has invented the 2-stroke engine in 1878 in order to increase the power to weight ratio for a equal volume.
The 2-stroke engines is also simpler with regards to valve system
The 2-stroke principle is applicable to both spark ignition engine and compression ignition engine. It is however more usual with spark ignition engines.
The 2-stroke engine involves two strokes and the cycle is carried out during one single crankshaft revolution.
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2-stroke engines
Intake(“Scavenging”)
Compression Ignition Exhaust Expansion
Fuel-air-oil mixture Fuel-air-oil mixture compressed
Crank shaft Check valve
Exhaust port
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2-stroke engines
Stroke 1: Fuel-air mixture is introduced into the cylinder and is then compressed, combustion initiated at the end of the stroke
Stroke 2: Combustion products expand doing work and then exhausted
* Power delivered to the crankshaft on every revolution
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2-stroke engines
Compared to 4-stroke engines, 2-stroke engines have
Power to weight ratio is higher than the four stroke engine since there is one power stroke per crank shaft revolution.
Simple valve design
A lower fabrication cost
A lower weight
However several drawbacks:
Incomplete scavenging or to much scavenging
Higher emission rates: emission of HC, PM, CO is quite badly controlled (even though mitigated for CI 2-stroke engine)
Burns oil mixed in with the fuel
Exhaust gas treatment is less developed than 4-stroke engines
Most often used for small engine applications such as lawn mowers, marine outboard engines, motorcycles….
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Piston engines characteristics
Good combustion properties (and so the maximum torque) are obtained for a medium (design) rotation speed.
For increasing rotation speed, the admission pressure drop and the engine frictions are increasing and the brake mean effective (and the torque) pressure is dropping.
Power = torque * speed is still increasing till the torque drops is so high than power is falling as well.
A low regimes, the dilution is high and the combustion is deteriorated, while heat transfer to piston and walls is becoming more important. It comes that the mean effective pressure and the torque is also reduced.
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Piston engines characteristics
Gillespie, Fig. 2.1
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Piston engines characteristics: fuel consumption
Wong. Fig. 3.41 et 3.42
Gasoline engine
Diesel engine
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Piston engines characteristics: emission rates
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Wankel Rotary Engines
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Wankel rotary engines
In 1951, Felix Wankel began
development of the rotary piston engine at NSU.
The rotary engine uses a rotary design to convert pressure into a rotating motion instead of using reciprocating pistons.
Its four-stroke cycle takes place in a space between the inside of an oval-like epitrochoid-shaped housing and a rotor that is similar in shape to a Reuleaux triangle.
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Wankel rotary engines
E: Pinion – L:
Eccentric
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Wankel rotary engines
Combining a suitable layout of the inlet, outlet and ignition devices, the volume variation of the each chamber works out the 4 strokes of the Otto cycle in one revolution of rotor.
As the rotor makes 3 chambers, one sees a cycle every 1/3 of the rotor revolution
The gear ratio between the crankshaft pinion and interior gears of the eccentric provides a 1:3 reduction ratio so that one sees a cycle at each revolution of the crankshaft
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Wankel rotary engines
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Wankel rotary engines
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Wankel rotary engines
Advantages
Perfect balancing of rotating mass that allows high rotation speeds
Favorable (linear) torque curve
Compact and simple design
Lightweight
Can be operated with various fuels such as H2
Disadvantages
Lower efficiency than piston engines (lower compression ratio)
Slightly higher specific emissions (HC, NOx, CO)
The combustion chamber does not allow Compression ignition (Diesel) cycles
Manufacturing cost is more important
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Wankel rotary engines
Wankel rotary engines were used first in NSU vehicles
After the NSU collapse, Mazda has bought the rights for the patents of the rotary engines
Future applications of rotary engines is related to its ability to be operated with alternative gaseous fuels such as H2
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Electric traction
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Electric cars
Electric cars were very dominant at the turn of the 20th century but were substituted by ICE engine in the period from 105 to 1915
Revival interest for electric cars at every petrol or energy crisis
But up to now, electric cars have always been commercial failure
At the turn of the 21th century, electric propulsion systems are coming back at the front stage
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Electric propulsion
Advantages:
Zero direct emission
Low noise emissions
Regenerative braking
High torque at low speed
Good driving comfort Æurban application
Simple mechanical transmission (generally no gear box, no clutch), speed and torque regulation,
Perfect solution if external power supply (catenaries)
Disadvantages:
Batteries: cost, extra-weight, life time
Charging time (~6 hours)
Limitation of range (200 km)
Bolloré BlueCar
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Electric propulsion
Electric drivetrain are basically composed of four components:
1. The electrical power source: battery if energy is on board or catenaries system to connect to an external source as electric cables or rail
2. Power electronics to regulate the power, the speed, the torque
3. The electric machine that can operate as a motor or a generator
4. A simple mechanical transmission to communicate the mechanical power to the wheels
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Electric propulsion
Electric machines
DC shunt, series, or separately excited
AC asynchronous 1 or 3-phase, synchronous machine with PM
Switched reluctance motors
Power electronics
Chopper
DC / DC chopper
Inverter
Batteries:
Lead acid
Nickel-Cadmium
Ni – MH metal hydrides
Li ions / Li polymers
Supercaps, flywheels
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Families of electric motors
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DC electric motors
Working principal of a DC motor
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DC electric motors
Types of DC machines and torque curves
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Power electronics for DC machine
Working principle of a chopper
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AC asynchronous electric motors
Working principle of AC asynchronous motors
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3-phase AC asynchronous motors
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3-phase AC asynchronous motors
Torque-speed AC asynchronous motors
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Power electronics for 3-phase AC machines
Working principle of an inverter
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Traction electric machines
DC MOTORS
Serial or separated excitation
Price still high (-)
Reliability and control (+)
Maintenance (brush) (-),
Weight (-)
Max speed (-)
Efficiency ~80% (-)
Control by chopper with PWM command
AC MOTORS
Asynchronous machines
High maximum speed
Low maintenance, high reliability
Weight
Good efficiency (~95%)
Synchronous machines
Maintenance, efficiency , reliability (+)
Expensive (-),max speed lower than AC async(-)
Inverter with vector command (f,I,V)
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Batteries
Different kinds
Lead acid: known since 1900, industrial maturity
Ni-Cd : known from 19030ies, industrial maturity
Na Ni Cl (Zebra): since 1980ies. Small series
NiMH: Since 190ies. Industrial standard in automotive
Li-Ions: Known from mid 1990ies. Moving to mass production.
Performance criteria
Specific energy (W.h/kg)
Specific power (W/kg)
Charge – discharge efficiency
Life time
Specific cost
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Batteries performances
0,734 0,781
1,159 0,508
0,339 Specific cost [€/kW.h]
500 1200
1200 1200
600 Life cycles [cycles]
85 85
80 65
60 Charge – discharge
efficiency [%]
294 148
118 79
90 Specific power [W/kg]
105 74
62 38
17 Useful specific energy
[W.h/kg]
Li-Ions Zebra
Ni-MH Ni-Cd
Lead-Ac Batteries
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Batteries challenge
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Batteries challenge
84 2100
1420 Specific energy at wheel
[W.h/kg]
80 18
12 Average efficiency while
driving [%]
105 11.667
11.833 Specific energy [W.h/kg]
Li-Ions Diesel
Gasoline Fuel / energy systems
Gap 200!
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Supercapacitor
Supercapacitors:
Absord / release energy much faster: 100-1000 times: (Power density~ 10 kW/kg)
Lower energy density ( Energy density < 10 kWh/kg)
Higher charge / discharge current : 1000 A
Longer life time: > 100.000 charge discharge
Better recycling performances
Supercapacitors are distinguished from other class of devices for storing electrical energy such batteries.
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Hybrid propulsion systems
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Hybrid propulsion powertrains
The hybrid powertrains combines two kinds of propulsion systems and their related energy storages.
Generally the hybrid electric powertrains are the most famous.
They combines typically an ICE engine and an electric motor and a electric energy storage system
The goal of hybridization is to combine the advantages of the two basic systems (e.g. zero emission of EV and range of ICE) and to mitigate their drawbacks.
There are two major families of layout to assemble the two types of propulsion systems.
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Hybrid propulsion powertrains
Serial hybrid Parallel hybrid
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Parallel hybrid vehicles
The vehicle is equipped with a double propulsion system (electric + ICE) both connected to the wheels.
The vehicle is preserving its usual performances: range, acceleration, cruse speed….
The electric machines have a sufficient power to propel the car on a significant distance in pure electric modeor in combination with the ICE.
To deliver peak powers when needed, both propulsion systems can be operated simultaneously
There are several variant of the parallel layout
Hybridization index: Tp= Pel/(Pel+ Pth)
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Hybrid series vehicle
The electric machines is the single propulsion system to be connected to the wheels. The thermal engine is used in an optimized way to power the generator and supply the electric motor and / or the energy storage system.
In urban driving, the battery is able to supply the motors alone for short travels in pure electric mode with zero emissions
On highway travel and long distance driving cycles, the ICE is powering the generator to recharge the battery or supply the motor.
Hybridization index in series: Ts= Pth/Pel(generally between 40 and 80% Æ downsizing of ICE)
Extension possible to fuel cell vehiclesto substitute the ICE as prime mover
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The complex hybrid vehicles
Toyota Prius II
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Hybrid hydraulic vehicle
New reversible hydraulic motor /pump: Low drag, high efficiency, fluid=water ÎParker P2 or P3 series
Hydraulic accumulators (HP) / Reservoir (LP): high efficiency (95%)
En.: 0,63 Wh/kg Power ~ 90 kW/kg ÎHydac
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Fuel cells
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Fuel cell
H2Æ2H++ 2e-
Oxygen (air) Electrolyte
Anode Cathode
e-
2H++2e-+ ½ O2 ÆH2O H+
Water Hydrogen
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Fuel cell
Fuel Cell principle: direct electrochemical (oxydo- reduction) converter of Hydrogen fuel into electricity
Advantages:
No emission of pollutants
Using other fuels (ex methanol) is possible via reforming process
High conversion efficiency (theoretical 90% - practical 55%)
Drawbacks
Not mature technology
Thermal control is difficult to carry out
Lower power to weight compared to ICE
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Fuel cell powered vehicle layout
Control electronics H
2
F.C. Chopper
Electric motor
Chain transmission
H2
PAC Power electronics (chopper)
Electric motor
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Hybrid vehicle powered with a fuel cell
H2
DC
Fuel DC
Cell
Li-Ion Batter y
Chopper
Electric motor
Transmission (chain) Tension PAC
Tension batterie Tension moteur Tension Moteur
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Hybrid vehicle powered with a fuel cell
Toyota FCH4
Battery
M/G Fuel cells
Wheels Node
Tank
Chemical
Electrical
Mechanical
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Comparison of propulsion systems
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Comparison of propulsion systems
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Comparison of propulsion systems
Torque curve is favourable to electric motors and steam engines
Torque curve of gas turbines is completely is very bad with regards to the application