icat’08 İstanbul

Mechatronics Research Labs

Automotive Control and Mechatronics Research Center

ICAT’08 İstanbulInternational Conference on Automotive Technologies

November 13 - 14th, 2008

FOHEV II - The Ford Otosan Hybrid Electric Research Prototype Vehicle

İsmail M.C. Uygan, Ahu E. Hartavi, Levent Güvenç, Tankut Acarman

Automotive Control and Mechatronics Research Center , Mechanical Engineering Department,

İstanbul Technical University, İstanbul, Turkey

Varlık Kılıç, İlker Özelgin, Murat Yıldırım

Ford Otosan, Research and Development Department, Kocaeli, Turkey

Volkan Sezer

The Scientific and Technological Research Council of Turkey, Marmara Research Center, Energy Institute, Gebze, Turkey

mekar.itu.edu.tr

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Automotive Control and Mechatronics Research Center

ICAT 2008

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Overview

• Introductiono Hybrid Electric Vehicleo Market Trend of Hybrid Electric Vehicles

• Objective• History: FOHEV I• FOHEV-II Project Partners• Series-Parallel Hybrid Configuration• Components & Packaging• Real-time Control System• Control Strategy

o Start-up & Shut-down Preocedureo Maximizing Overall Efficiency Strategy for Power Split Controlo Hybrid Brake Algorithm

• Experimental Results• Conclusions

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What is Hybrid Electric Vehicle (HEV)?

• Internal Combustion Engine - The hybrid vehicle has an internal combustion engine much like the one found in most vehicles. However, the engine on a hybrid is smaller and uses advanced technologies to reduce emissions and increase efficiency

• Electric Motor - The electric motor on a hybrid car is very sophisticated. Advanced electronics allow it to act as a motor as well as a generator.

• Generator - The generator is similar to an electric motor, but it acts only to produce electrical power. It is used mostly on series hybrids.

• Controller: Manages the power flow and determines the mode of action.

• Batteries - The batteries in a hybrid car are the energy storage device for the electric motor. Unlike the fuel in the fuel tank, which can only power the internal combustion engine, the batteries on a hybrid car can put energy into the motor as well as draw energy from the motor.

Hybrid Electric Vehicle(HEV) uses both electrical motor and internal combustion engine.

HEV Main Components

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Why Hybrid Electric Vehicles?

Effects of Global Warming

Global Warming History and Future

The chief causes of global warming are burning fossil fuels, releasing them into the atmosphere, and the emission of carbon dioxide and other greenhouse gases.

Advances in Internal Combustion Engine (ICE) technology including advanced controls will not be enough to meet future emission reduction legislation. Hybrid Electric Vehicles (HEV) form an intermediate term solution for meeting these reduced emission level requirements.

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Hybrid Electric Vehicle Market

Worldwide Hybrid ElectricVehicle Saleshttp://www.marklines.com/en/numproduct/index.jsp#hybrid

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Objective

To design and build research prototypes of a hybrid electric light commercial vehicle based on the Ford Transit van, with internal combustion engine and electric motor(s) to reduce undesired emissions and to improve fuel economy while keeping the desired level of driving performance.

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History: FOHEV ITwo prototype research vehicles were built. FOHEV I, the first prototype, is a parallel HEV with 2+2 driving capability. ICE powers the front drive while the EM powers the rear drive. A rule based HEV control strategy is used. FOHEV I was built for maintaining high performance along with the advantages achieved through hybridization. All electric driving and regenerative braking are possible.

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History: FOHEV I HEV Controller

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History: FOHEV I Acceleration Performance

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History: FOHEV IIThe current research prototype vehicle, FOHEV II, is a series-parallel HEV with 2+2 driving capability. ICE and/or EM1 power the front drive while EM2 powers the rear drive. HEV control strategy used maximized overall efficiency in selecting the power flow path. All electric driving, ICE shut-down, stop and go, regenerative braking and series charging are possible.

EM1

EM2Serial EM

ICE

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* Overall project management and coordination* Supply of base vehicle* Design of modified vehicle* NVH studies* Determination of vehicle specs* Supplying the electrical machine, battery, control unit etc.* Supply/Manufacture of modified hardware* Integration of mechanical modifications* Performance / brake / fuel consumption and emission tests

* Concept study and simulations* Integration of electrical interface* Vehicle control and implementation* Development of regenerative braking algorithm and implementation* Control of electromechanical clutch* Data capture * Engineering support

* Selection of electric motors and battery* Electrical motors, battery, driver circuits* Concept study and simulations* Implementation of touch screen LCD* Engineering support

* Concept study and simulations* Design and implementation of electromechanical clutch system* Road tests* Engineering support

Project Partners

FORD OTOSAN

ITU-MEKAR

ITU-OTAMTUBITAK

MAM

FOHEV-II Project Partners

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System Architecture

13

Modes of Operation Pure ICE Mode Pure EM Mode Hybrid Mode Cruise Charge Assist Serial Charge

Hybrid Braking

Schematic of FOHEV-II Prototype Components and Interactions

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Electric Motor Assembly

14

Electric Motor Assembly

Electrical Machines Rated Power 25 kW Brushless DC Machines

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Li-Ion Battery Pack

15

Energy Storage Unit

The battery pack provides the maximum power required by the traction/braking motors at the same time.

Li-Ion 324 VMax Power 50kWCapacity 14.5 kWh

Li-Ion Battery Pack

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Transmission

16

The new transmission enables:

Driving the front axle by ICE and/or EM1.

The use of regenerative braking and electric traction independent of the selected gear.

To shift the operating point of the diesel engine by loading or assisting it with EM1.

New Transmission

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Clutch Control System

17

The hydraulic clutch control system was modified to add the capability of keeping the clutch disengaged independent of the driver.

Configuration of modified electromechanical clutch

Conventional Mode: According to the driver’s request the power flow is cut by depressing the clutch pedal.

Hybrid Mode: The clutch is controlled according to the hybrid control algorithm.

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Retrofitted APM

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To shift the operating point of the ICE to a more efficient region necessitates the modification of the Accelerator Pedal Module in a way that the hybrid controller can interfere in the gas signal sent from the APM to the ICE-ECU.

Accelerator pedal module & interface circuit

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Hybrid Control System

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Hybrid powertrain control system schematic

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Start Up - Shut Down Procedure

Start up procedure:Battery supply is provided with the engine start upBattery KL-15 is shorted EMs are shorted

Shutdown procedure: Starts with the after-run state of engine It is in the reverse order of the start-up procedure.

Hybrid powertrain control module logical schematic

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Maximizing Overall Efficiency Strategy receives the gas pedal position and distributes the corresponding torque demand among the available paths to achieve the maximum overall efficiency.

MOES Strategy

Velocity Controller

Vdes

vehV

MOES

CONTROLLER

,

Battery

brk

Vveh

SOC

Vbat

EM1

EM2

EM3

ICE

Regenerative Braking

Controller

thr

ICET

3EMT

2EMT

1EMT

3_refEMT

_refICET

2_refEMT

1_refEMT

1_refEMT

2_refEMT

vehV

Autogear

ICE

vehV

clt

clt

gn

gn

Parameter Update

KchKdch

Perpch

Ibat

Simulation model of the hybrid powertrain with MOES controller

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Hybrid Brake System & Strategy

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Hybrid brake system integrates regenerative braking into conventional hydraulic brake module to assist the brake torque production while recapturing brake energy.

Hybrid brake strategy logical schematic

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Videos of FOHEV II

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Parallel Charge Regenerative Braking Assist

Experimental Results

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The modification process of a front wheel drive Ford Transit vehicle into a four wheel drive series-parallel hybrid electric vehicle having the working modes listed below was presented.o Pure ICE o Pure EMo Hybrid tractiono Engine start/stopo Hybrid braking

The mechanical modifications and packaging of the electrical systems, the electrical modifications such as signal interfacing studies, regenerative braking capability and the hybrid electric control algorithm were also presented.

An Optimal Power Management Strategy for a Hybrid Electric Vehicle (MOES), was developed, simulated and implemented in the FOHEV-II prototype. Other novel power management strategies are also being developed.

An Electric Power Assisted Brake algorithm was developed and implemented to the research prototype by considering brake force distribution, torque capacity of EMs, state of charge of battery and operating conditions of the vehicle.

Conclusions

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FC@ECE

Diesel [l/100km] 10.88

Hybrid [l/100km] 7.39

Reduction [%] 32.1

FC@NEDC

Diesel [l/100km] 8.82

Hybrid [l/100km] 6.53

Reduction [%] 25.9

Table 1. Fuel Consumption Estimations

Simulations and preliminary tests showed that the fuel consumption estimations presented in table below, can be achieved with this new type of hybrid powertrain.

Conclusions

The hybrid electric Ford Transit was publicized with a press release with an accompanying test drive. Work on performance evaluation and enhancement is currently in progress.

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Acknowledgments

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The authors would like to acknowledge

Ford Otosan R&D Department for support through the FOHEV projects

&the European Union Framework Programme 6 through project INCO-16426 for helping İTÜ-Mekar improve in its research thrust area of hybrid electric vehicle modeling, control and hardware-in-the-loop simulation

Special thanks also go to the Project Partners for their technical support in making this project a success.

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Questions ?

28

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