Design and Analysis of a Low Production Cost Hybrid Electric High Mobility Multi-Purpose Wheeled Vehicle for Military Use
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University of Tennessee, Knoxville TRACE: Tennessee Research and Creative Exchange Masters Theses Graduate School 8-2004 Design and Analysis of a Low Production Cost Hybrid Electric High Mobility Multi-Purpose Wheeled Vehicle for Military Use Craig Blake Rutherford University of Tennessee - Knoxville Follow this and additional works at: https://trace.tennessee.edu/utk_gradthes Part of the Mechanical Engineering Commons Recommended Citation Rutherford, Craig Blake, "Design and Analysis of a Low Production Cost Hybrid Electric High Mobility Multi-Purpose Wheeled Vehicle for Military Use. " Master's Thesis, University of Tennessee, 2004. https://trace.tennessee.edu/utk_gradthes/2180 This Thesis is brought to you for free and open access by the Graduate School at TRACE: Tennessee Research and Creative Exchange. It has been accepted for inclusion in Masters Theses by an authorized administrator of TRACE: Tennessee Research and Creative Exchange. For more information, please contact [email protected]. To the Graduate Council: I am submitting herewith a thesis written by Craig Blake Rutherford entitled "Design and Analysis of a Low Production Cost Hybrid Electric High Mobility Multi-Purpose Wheeled Vehicle for Military Use." I have examined the final electronic copy of this thesis for form and content and recommend that it be accepted in partial fulfillment of the equirr ements for the degree of Master of Science, with a major in Mechanical Engineering. William R. Hamel, Major Professor We have read this thesis and recommend its acceptance: Jeffrey W. Hodgson, David K. Irick Accepted for the Council: Carolyn R. Hodges Vice Provost and Dean of the Graduate School (Original signatures are on file with official studentecor r ds.) To the Graduate Council: I am submitting herewith a thesis written by Craig Blake Rutherford entitled “Design and Analysis of a Low Production Cost Hybrid Electric High Mobility Multi-Purpose Wheeled Vehicle for Military Use.” I have examined the final electronic copy of this dissertation for form and content and recommend that it be accepted in partial fulfillment of the requirements for the degree of Master of Science, with a major in Mechanical Engineering. William R. Hamel_______ Major Professor We have read this thesis and recommend its acceptance: Jeffrey W. Hodgson________ David K. Irick_____________ Acceptance for the Council: Anne Mayhew_____________ Vice Chancellor and Dean of Graduate Studies (Original signatures are on file with official student records) DESIGN AND ANALYSIS OF A LOW PRODUCTION COST HYBRID ELECTRIC HIGH MOBILITY MULTI-PURPOSE WHEELED VEHICLE FOR MILITARY USE A Thesis Presented for the Master of Science Degree The University of Tennessee, Knoxville Craig Blake Rutherford August 2004 Copyright © 2004 by Craig Rutherford All rights reserved ii Dedication This thesis is dedicated to Drs. Jeffrey Hodgson and William Hamel without whom I would never have embarked on this endeavor, and my loving wife Kristy without whom I would never have finished. iii Acknowledgements I wish to thank all those who assisted me in the completion of this thesis and my Master of Science degree in Mechanical Engineering. I would like to thank Drs. Hodgson, Hamel, Irick, and Boulet for their patient input to the completion of my requirements and service on my advising committee. I would also like to thank the staff of the Mechanical Engineering department office and machine shop for their assistance with all of the paperwork, and machine work over the years. For sponsorship in this research I would like to thank the US Army Tank and Automotive Command (TACOM), Oak Ridge National Laboratories, and the University of Tennessee, Knoxville. For input into the technical information contained in this thesis and permission to use various data and software, I would like to thank Fiat America, Saft Battery Company, Hawker Energy Products, General Motors, Ford Motor Company, Unique Mobility, Lynx Motion Technology, University of Wisconsin, Madison’s Powertrain Control Research Lab, Oak Ridge National Laboratories, Argonne National Laboratories, and the National Renewable Energy Lab. Lastly I would like to thank all of my family and friends whose, patience and encouragement made this and all other work not only possible, but bearable. iv Abstract The conceptual design of a low production cost hybrid electric High Mobility Multi- purpose Wheeled Vehicle (HMMWV) is described. The design uses a parallel hybrid configuration incorporating a reduced displacement diesel engine, a permanent magnet electric motor, and lead-acid batteries. The design is termed “low production cost” because it uses commercial off the shelf (COTS) hardware where possible and does not require major alterations to either the chassis or drivetrain of the base vehicle. Computer modeling and simulation of the proposed design indicates that it can meet or exceed Army provided hybrid electric HMMWV performance criteria. The proposed design offers improved fuel efficiency, extended “silent watch” capability, pure electric “stealth” operation, and “limp home” capability in the event of failure of the electrical propulsion system. The design also permits the vehicle to be used as a mobile field generator for mobile headquarters, field hospital, and mobile communication applications. This thesis will include discussions of design trade-offs associated with the conversion of a HMMWV to hybrid electric operation. v Table of Contents CHAPTER PAGE 1. Introduction......................................................................................................................1 1.1. Research Objectives..................................................................................................1 1.2. Background of Hybrid and Electric Vehicles...........................................................2 1.2.1. History................................................................................................................2 1.2.2. Current and Future Research .............................................................................6 1.3. Hybrid Electric Vehicle Configurations ...................................................................7 1.3.1. Series Configuration ..........................................................................................8 1.3.2. Parallel Configuration........................................................................................9 1.3.3. Split-Mode Configuration................................................................................10 1.3.4. Other Configurations .......................................................................................11 1.4. Military Requirements ............................................................................................12 1.4.1. Stock Vehicle Performance..............................................................................12 1.4.2. Electric/Hybrid Vehicle Required/Target Performance...................................13 2. Description of Typical Hybrid System Components.....................................................14 2.1. Energy Storage System...........................................................................................14 2.1.1. Pb-Acid Battery ...............................................................................................14 2.1.2. Ni-MH Battery .................................................................................................15 2.1.3. Ni-Cd Battery...................................................................................................17 2.1.4. Ni-Zn Battery...................................................................................................17 2.1.5. Air Electrode Batteries.....................................................................................18 2.1.6. Na Batteries......................................................................................................19 2.1.7. Li Batteries.......................................................................................................20 2.1.8. Ultracapacitors .................................................................................................20 2.1.9. Flywheel Energy Storage.................................................................................21 2.1.10. Hydraulic Accumulator Energy Storage........................................................22 2.2. Auxiliary Power Unit..............................................................................................23 2.2.1. Spark Ignition Engine ......................................................................................24 2.2.2. Compression Ignition Engine ..........................................................................24 vi 2.2.3. Stirling Cycle Engine.......................................................................................25 2.2.4. Rankine Cycle Engine......................................................................................26 2.2.5. Gas Turbine Engine .........................................................................................28 2.2.6. Proton Exchange Membrane Fuel Cell ............................................................28 2.3. Electric Motor and Controller.................................................................................29 2.3.1. Brushed DC Motor and Controller ..................................................................30 2.3.2. Permanent Magnet Brushless Motor and Controller .......................................31 2.3.3. AC-Induction