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Mode and Implementation of a Hybrid Control System for a 2-Mode Hybrid Electric Vehicle Zhenhua Zhu West Virginia University

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Mode and Implementation of a Hybrid Control System for a 2-Mode Hybrid Electric Vehicle Zhenhua Zhu West Virginia University Graduate Theses, Dissertations, and Problem Reports 2013 Mode and implementation of a hybrid control system for a 2-mode hybrid electric vehicle zhenhua Zhu West Virginia University Follow this and additional works at: https://researchrepository.wvu.edu/etd Part of the Electro-Mechanical Systems Commons, and the Navigation, Guidance, Control, and Dynamics Commons Recommended Citation Zhu, zhenhua, "Mode and implementation of a hybrid control system for a 2-mode hybrid electric vehicle" (2013). Graduate Theses, Dissertations, and Problem Reports. 8162. https://researchrepository.wvu.edu/etd/8162 This Dissertation is protected by copyright and/or related rights. It has been brought to you by the The Research Repository @ WVU with permission from the rights-holder(s). You are free to use this Dissertation in any way that is permitted by the copyright and related rights legislation that applies to your use. For other uses you must obtain permission from the rights-holder(s) directly, unless additional rights are indicated by a Creative Commons license in the record and/ or on the work itself. This Dissertation has been accepted for inclusion in WVU Graduate Theses, Dissertations, and Problem Reports collection by an authorized administrator of The Research Repository @ WVU. For more information, please contact [email protected]. MODE AND IMPLEMENTATION OF A HYBRID CONTROL SYSTEM FOR A 2-MODE HYBRID ELECTRIC VEHICLE Zhenhua Zhu Dissertation submitted To the Benjamin M. Statler College of Engineering and Mineral Resources at West Virginia University in partial fulfillment of the requirements for the degree of Doctor of Philosophy in Department of Mechanical Engineering Scott Wayne, Ph.D., Chair Nigel Clark, Ph.D. Hailin Li, Ph.D. Chris Atkinson, Ph.D. Natalia Schmid, Ph.D. Department of Mechanical Engineering Morgantown, West Virginia November 2013 Keywords: 2-Mode, hybrid electric vehicle, hybrid control, hybrid vehicle modeling Copyright 2013 [Zhenhua Zhu] ABSTRACT Modeling and Implementation of a Hybrid Control System for a 2-Mode Hybrid Electric Vehicle Zhenhua Zhu Automotive transportation consumes more than 71% of the world's total petroleum energy. The vehicle will have to use less because it will take less than 30 years to consume the rest of the proven conventional oil reservoir if the fuel consumption keeps the current trend. One of the methods to improve the vehicle efficiency is to develop Hybrid Electric Vehicle (HEV). An HEV combines an internal combustion engine (ICE) and electric motor(s) powered by batteries or capacitors to achieve better fuel economy. Among the HEVs, 2-Mode HEV combines an ICE and two electric motors with two planetary gear sets and allows the vehicle to operate in two Electrically Variable Transmission (EVT) modes with better fuel economy in both low speed range and high speed range. A prototype 2-Mode HEV powertrain was developed and included a 1.3 liter 4- cylinder turbocharger diesel engine, a 2-Mode front wheel drive transmission and a 330 V 12.9 kWh high voltage battery. A forward-looking quasi-static model of the 2-Mode HEV was developed and parameterized with bench test data to evaluate the vehicle performance and fuel economy. A rule-based hybrid control algorithm was implemented to achieve engine stop-start, transmission shifting, high voltage battery charge sustaining, optimal engine speed and torque control, vehicle propulsion and regenerative braking. The prototype 2-Mode HEV was tested on road to verify vehicle safety features, acceleration and braking capability, autocross time, towing capacity and combined city and highway drive capability. Local city and highway drive schedules comparable to the UDDS and HWFET drive schedules were developed to test the vehicle's fuel economy. The vehicle on-road test reached 24.5/31.5 MPG fuel economy, which was 23.8% higher than the mule vehicle, 19.0/26.0 MPG. The vehicle was tested on road to evaluate the loss of the performance. The vehicle achieved 16 s during the 0-60 mph acceleration and 10 s during the 50-70 mph acceleration, both of which were 1.4 s longer than the mule vehicle. The braking distance from 60-0 mph was 148.5 ft, which was the same as the mule vehicle. The vehicle demonstrated the same towing ability at constant 45 mph speed with a 3.5% grade for 15 miles. The 2-Mode hybrid powertrain with a turbocharger diesel engine demonstrated an alternative to sustain petroleum energy and reduce the petroleum oil dependence in automotive transportation with fuel economy improvement of 23.8%, but a small acceleration capability loss. The 2-Mode hybrid electric vehicle combined the strength iii iv and load capacity of conventional automatic transmission with the increased fuel economy provided by the hybrid electric vehicle architecture. v ACRONYM LIST A/C Air Conditioning ABS Antilock Brake System AC Alternating Current ACIM AC Inductance Motor ACU Auxiliary Control Unit ADC Analogue Digital Converter ADVISOR ADvanced VehIcle SimulatOR AMESim Advanced Modeling Environment for performing Simulations of engineering systems APP Accelerator Pedal Position ASM Automotive Simulation Model ASME American Society of Mechanical Engineers AVL Anstalt für Verbrennungskraftmaschinen List BAS Belt Alternator Starter BEV Battery Electric Vehicle BMS Battery Management System BPP Brake Pedal Position CAFE Corporate Average Fuel Economy CAN Controller Area Network CD Charge Depleting CHGA_AUX charger auxiliary voltage signal CHGA_WK charger wake signal CI Compression Ignition CO Carbon Monoxide CO2 Carbon Dioxide CS Charge Sustaining CVT Continuously Variable Transmission DBC Damping Bypass Clutch DC Direct Current DCA Dynamic Consumer Acceptance DECM Diesel Engine Control Module DFMEA Design Fault Mode and Effect Analysis DOE Department of Energy DPF Diesel Particulate Filter EDS Electric Distribution System EGR Exhaust Gas Recirculation EM Electric Motor EPA Environmental Protection Agency vi EPO Emergency Power Off E-REV Extended-Range Electric Vehicle ESS Energy Storage System EV Electric Vehicle EVT Electrically Variable Transmission FBD Free Body Diagram FE Fuel Economy FTA Fault Tree Analysis FWD Front Wheel Drive GHG Greenhouse Gas GM General Motors GMLAN GM High Speed CAN GPS Global Positioning System GREET Greenhouse Gas, Regulated Emissions, and Energy Use in Transportation Model HC Hydrocarbon HCP Hybrid Control Processor HEV Hybrid Electric Vehicle HIL Hardware-In-the-Loop HV High Voltage HVIL High Voltage Inter-Lock HWFET Highway Fuel Economy Driving Schedule IC Internal Combustion ICE Internal Combustion Engine ID Identification IEEE Institute of Electrical and Electronics Engineers IGN Ignition LSO Low Side Out LUT Lookup Table MCPA Motor Control Processor A MCPB Motor Control Processor B MHV Mild Hybrid Vehicle MIMO Multiple Input and Multiple Output MPG Mile per Gallon MPGge Mile per Gallon gasoline equivalent MUDS Morgantown Urban Drive Schedule MVM Mean Value Model NHTSA National Highway Traffic Safety Administration NOx Oxides of Nitrogen NREL National Renewable Energy Laboratory OCV Open Circuit Voltage ODE Ordinary Differential Equation vii OEM Original Equipment Manufacturer ORSE On Road Safety Evaluation PDE Partial Differential Equations PEU Petroleum Energy Use PHEV Plug-in Hybrid Electric Vehicle PI Proportional-Integral PM Particulate Matter PMSM Permanent Magnet Synchronous Motor PSAT Power System Analysis Toolbox PTEB Powertrain Extension Bus PWM Pulse Width Modulation PWR Power Line R19HW Route 19 Highway RTA Rear Traction Assistance RWD Rear Wheel Drive SAE Society of Automotive Engineers SCR Selective Catalytic Reduction SCU Supervisory Control Unit SFTP US06 Supplemental Federal Test Procedure SI Spark Ignition SIL Software-In-the-Loop SOC State of Charge SoftACU Software Simulation of the ACU SoftBMS Software Simulation of the BMS SUV Sport Utility Vehicle TCM Transmission Control Module THS Toyota Hybrid System THS-II Toyota Hybrid System II TPIM Transmission Powertrain Inverter Module TTW Tank-To-Wheel UDDS Urban Dynamometer Driving Schedule UF Utility Factor US United States Veh_WAKE Vehicle Wake Signal vs. versus VTS Vehicle Technical Specification VVT Variable Valve Timing WTP Well-To-Pump WTW Well-To-Wheel WVLAN West Virginia High Speed CAN WVU West Virginia University CONTENTS ABSTRACT ....................................................................................................................... iii ACRONYM LIST ............................................................................................................... v CONTENTS ..................................................................................................................... viii LIST OF FIGURES .......................................................................................................... xv LIST OF TABLES ........................................................................................................... xxi CHAPTER 1 Introduction................................................................................................. 22 1.1 Statement of the Problem .................................................................................. 22 1.1.1 Petroleum Oil Usage in Transportation ........................................................ 22 1.1.2 Automotive Tailpipe Emissions .................................................................... 25 1.2 Objective of the Research ................................................................................. 26 1.3 Research Methodology ....................................................................................
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