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Intelligent Alternator Control Strategy Development for Hybrid Automotive Applications

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Intelligent Alternator Control Strategy Development for Hybrid Automotive Applications Mississippi State University Scholars Junction Theses and Dissertations Theses and Dissertations 1-1-2008 Intelligent Alternator Control Strategy Development For Hybrid Automotive Applications Stephen Gordon Phillips Follow this and additional works at: https://scholarsjunction.msstate.edu/td Recommended Citation Phillips, Stephen Gordon, "Intelligent Alternator Control Strategy Development For Hybrid Automotive Applications" (2008). Theses and Dissertations. 2770. https://scholarsjunction.msstate.edu/td/2770 This Graduate Thesis - Open Access is brought to you for free and open access by the Theses and Dissertations at Scholars Junction. It has been accepted for inclusion in Theses and Dissertations by an authorized administrator of Scholars Junction. For more information, please contact [email protected]. INTELLIGENT ALTERNATOR CONTROL STRATEGY DEVELOPMENT FOR HYBRID AUTOMOTIVE APPLICATIONS By Stephen Gordon Phillips A Thesis Submitted to the Faculty of Mississippi State University in Partial Fulfillment of the Requirements for the Degree of Master of Science in Electrical Engineering in the Department of Electrical and Computer Engineering Mississippi State, Mississippi December 2008 Copyright by Stephen Gordon Phillips 2008 INTELLIGENT ALTERNATOR CONTROL STRATEGY DEVELOPMENT FOR HYBRID AUTOMOTIVE APPLICATIONS By Stephen Gordon Phillips Approved: _________________________________ _________________________________ G. Marshall Molen Herbert L. Ginn, III Diversified Technology - Ergon Assistant Professor of Electrical and Distinguished Professor of Electrical and Computer Engineering Computer Engineering (Committee Member) (Major Advisor and Director of Thesis) _________________________________ _________________________________ Stanislaw Grzybowski James E. Fowler Mississippi Power Professor in Electrical Professor of Electrical and Computer and Computer Engineering Engineering (Committee Member) (Graduate Program Director) _________________________________ Sarah A. Rajala Dean of the Bagley College of Engineering Name: Stephen Gordon Phillips Date of Degree: December 12, 2008 Institution: Mississippi State University Major Field: Electrical Engineering Major Professor: Dr. G. Marshall Molen Title of Study: INTELLIGENT ALTERNATOR CONTROL STRATEGY DEVELOPMENT FOR HYBRID AUTOMOTIVE APPLICATIONS Pages in Study: 78 Candidate for Degree of Master of Science Stringent government mandates for the fuel economy and emissions of light-duty consumer vehicles have forced manufacturers to focus on improvements in these areas. Increased consumer pressure has also shifted the automobile market towards higher efficiency vehicles. This study investigates the use of intelligent engine peripheral control to improve fuel efficiency and reduce vehicle emissions. The conventional automotive alternator control strategy contributes to higher overall vehicle losses and increased fuel consumption through indiscriminate loading of the engine. The improved method focuses on the selective reduction of engine loading and the recapture of vehicle energy during braking using intelligent control of the alternator system. The concept was demonstrated on the Mississippi State University Challenge X hybrid vehicle. The fuel economy and NOx emissions of the vehicle were improved by 6.6% and 10.5%, respectively, over the drive cycle developed by the 2006 Mississippi State University Challenge X team to evaluate emissions. DEDICATION I would like to dedicate this work to my parents, Paul and Regina Phillips, and my siblings, Sarah and Matthew Phillips. Without their inspiration and occasional steering in my life, this thesis would never have come to pass. ii ACKNOWLEDGEMENTS This thesis would not have been possible without the contributions of many individuals and organizations. I need to thank Dr. Marshall Molen for his continued support, careful guidance, and tolerance of me thieving his books on occasion. I would also like to thank the all of the members of the Challenge X team, specifically David Oglesby, Christopher Whitt, Kyle Crawford, Kennebec Walp, Ron Lewis, Ryan Williams, Michael Barr, Matthew Doude, and Brian Christian. I have learned much from all of them and their work has inspired me in mine. Special thanks go to Matthew Young and Angela Card, who countless times have answered my controls questions, stayed up late in the high-bay, let me steal their Mototron hardware, and listened to me rant and rave. Countless thanks go to the organizers of the Challenge X program, Argonne National Labs, and General Motors for allowing me and many other students to participate in the best experience of my academic career. I’d like to also thank Bill Beggs, our GM mentor for Challenge X and a friend that has pushed me to be a better engineer in every way. Finally, I’d like to thank Jenna Grantham, with whom I’ve endured thick and thin, long nights working on the Challenge X vehicle, and many hours of testing. Through it all, I have rarely found her without a smile for me. iii TABLE OF CONTENTS DEDICATION..................................................................................................................... i ACKNOWLEDGEMENTS ................................................................................................ ii LIST OF TABLES............................................................................................................. vi LIST OF FIGURES .......................................................................................................... vii LIST OF SYMBOLS ...........................................................................................................x CHAPTER 1. INTRODUCTION .............................................................................................1 2. AUTOMOTIVE CHARGING SYSTEMS ........................................................4 2.1 Conventional Alternator Control and Operation....................................4 2.2 Historical Review...................................................................................5 2.3 Alternator Construction and Regulation ................................................6 2.4 Power Output of the Synchronous Machine ........................................12 2.5 Alternator Output Control using PWM Field Excitation .....................13 2.6 Diode Rectified 3-Phase Output ..........................................................18 3. INTELLIGENT ALTERNATOR CONTROL ................................................21 3.1 Problem Statement ...............................................................................21 3.2 Review of Current Efforts in Alternator Control.................................22 3.3 Proposed Solution for Hybrid Vehicles ...............................................23 4. INTELLIGENT ALTERNATOR CONTROL STRATEGY ..........................30 4.1 Requirements of an Intelligent Control System ...................................30 4.2 Control Strategy Development ............................................................33 iv 5. SOFTWARE, HARDWARE IMPLEMENTATION, AND TEST APPARATUS ......................................................................................44 5.1 Mototron and MATLAB Simulink ......................................................44 5.2 Test Fixture ..........................................................................................45 5.3 Alternator Modification, Driver Board, and Sensors ...........................47 5.4 Challenge X Hybrid Vehicle Testing Platform ....................................51 6. EXPERIMENTAL RESULTS AND EVALUATION ....................................53 6.1 Testing on Mototron Control Unit using Test Fixture .........................53 6.2 Implementation on MSU Challenge X Vehicle ...................................61 6.3 Control Effectiveness ...........................................................................65 7. CONCLUSIONS AND FUTURE WORK ......................................................66 7.1 Conclusions..........................................................................................66 7.2 Future Work .........................................................................................68 REFERENCES ..................................................................................................................71 APPENDIX A. DETAILED CURRENT REGULATOR DIAGRAM .....................................73 B. DERIVATION OF SYNCHRONOUS MOTOR STATOR VOLTAGE ........75 v LIST OF TABLES TABLE Page 3.1 Operating modes and their corresponding change in kinetic energy ...............26 5.1 Minimum motor specifications ........................................................................46 6.1 Before and after alternator control results .......................................................62 vi LIST OF FIGURES FIGURE Page 2.1 Voltage regulated alternator control ..................................................................5 2.2 Alternator claw pole rotor showing the field coil, south pole, and north pole halves [4] ........................................................................................7 2.3 Alternator cutaway, showing the housing, rotor, stator, and diode pack [5] ..................................................................................................8 2.4 Electromechanical alternator control schematic [2] ..........................................9 2.5 Electronic alternator control schematic [2] ......................................................10 2.6 Zener diode alternator over-voltage protection
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