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A Comparison Study Between Power-Split Cvts and a Push-Belt CVT

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A Comparison Study Between Power-Split Cvts and a Push-Belt CVT A comparison study between power-split CVTs and a push-belt CVT Pablo Noben DCT 2007.100 Master’s thesis Coaches: ir. T. Hofman dr. P.A. Veenhuizen Supervisor: prof. dr. ir. M. Steinbuch Technische Universiteit Eindhoven Department Mechanical Engineering Dynamics and Control Technology Group Automotive Engineering Science Group Eindhoven, August, 2007 Abstract Since the ongoing discussion about the global warming of the earth, this is mainly attributed to the greenhouse gasses. Which on their part are produced by vehicles, by internal combustion engines to be more accurate. More and more car manufacturers and research institutes are investigating alterna- tives for internal combustion engines. However changing the fuel for vehicles is very difficult because this is a complex collaboration of governments, oil companies and car manufacturers. On top of this years and years of development has resulted in the current infrastructure of the gas stations. A first solution to decrease the fuel consumption of vehicles is to develop hybrid power trains. With a hybrid power train, a power train consisting of two power sources is meant here. Normally this is an internal combustion engine combined with one or more electric machines. The fuel consumption of a hybrid vehicle is lower compared to a conventional vehicle because electric machines can recover brake energy which can be stored in a battery or a similar electrical storage system. Later this electric energy can be used to power the electric machines and assist the internal combustion engine to power the vehicle and herewith decreasing the fuel consumption. To realize a hybrid power train the most commercially successful hybrid vehicle makes use of a power split transmission. This power split transmission contains of a kinematic chain and an electric variator. The electric variator controls the overall transmission ratio and herewith the working point of the internal combustion engine. In literature different methods can be found to investigate power split transmissions. In this thesis some methods are treated. Schulz and Villeneuve investigate both a specific power split transmission. Mattsson on the other hand investigates several power split transmissions. Eventually the method by Mattsson is used to investigate the Toyota Hybrid System and the Renault IVT concept power train. Both transmissions are alike, however the Toyota hybrid system is a single mode transmission and the Renault IVT is a dual mode transmission. To compare these transmission considering efficiencies, a simplified loss model is used. Finally the Toyota hybrid system, as hybrid power train, is compared to a push-belt CVT, as conven- tional power train. Hereto three cases are studied, first the working point efficiency of the ICE is considered only. Followed by the implementation of constant efficiencies for the power train compo- nents. At the end working point dependent efficiencies are implemented for the electric machines in case of the Toyota hybrid system and for the push-belt CVT in case of the push-belt CVT. Herewith the overall efficiency of both power trains are compared. iii iv Samenvatting Door de voortdurende discussie over de opwarming van de aarde, die voor het merendeel aan de broei- kasgassen wordt toegeschreven. Die op hun beurt worden veroorzaakt door voertuigen, meer precies door verbrandingsmotoren. Steeds meer automobielfabrikanten en onderzoeksinstellingen zoeken naar alternatieven voor verbrandingsmotoren. Hoewel het erg moeilijk is om de brandstof van voer- tuigen te veranderen omdat dit wordt beïnvloed door de complexe samenwerking van regeringen, olie maatschappijen en automobielfabrikanten. Daarnaast is de huidige infrastructuur van tankstations door de jaren heen uitgegroeid tot een goed georganiseerd netwerk. Een eerste oplossing om het verbruik van voertuigen te verlagen is om een hybride aandrijflijn te ontwikkelen. Met een hybride aandrijflijn wordt hier een aandrijflijn bedoeld die door twee vermo- gensbronnen aangedreven wordt. Normaal gesproken is dit een verbrandingsmotor, gecombineerd met een of meerdere elektrische machines. Het brandstofverbruik van een hybride voertuig is lager ten opzichte van een conventioneel voertuig doordat de elektrische machines remenergie kunnen te- rugwinnen, wat opgeslagen kan worden in batterijen of een soortgelijk elektrisch opslag systeem. Na- derhand kan deze elektrische energie gebruikt worden om de elektrische machines aan te drijven en de verbrandingsmotor assisteren, hierdoor daalt het brandstofverbruik. Het meest commercieel suc- cesvolle hybride voertuig maakt gebruik van een vermogenssplit transmissie. Deze vermogenssplit transmissie bestaat uit een mechanisch gekoppelde keten van tandwielen en een elektrische variator. De elektrische variator regelt de transmissie ratio en hiermee ook het werkpunt van de verbrandings- motor. In de literatuur kunnen verschillende onderzoeken gevonden worden met betrekking tot vermogens- split transmissies. In dit verslag worden verschillende methodes behandeld. Schulz en Villeneuve onderzoeken allebei een specifieke vermogenssplit transmissie. Mattsson echter onderzoekt verschil- lende vermogenssplit transmissies. Uiteindelijk is de benadering van Mattsson gebruikt om het hybri- de systeem van Toyota en de Renault IVT te onderzoeken. Beide transmissies lijken op elkaar hoewel het hybride systeem van Toyota maar een mode heeft terwijl de Renault IVT twee modes heeft. Met een simpel rendementsmodel worden deze transmissies vergeleken met elkaar. Uiteindelijk is het hybride system van Toyota vergeleken met een duwband CVT. Hiervoor worden drie situaties bestudeerd, allereerst worden alleen de werkpunts afhankelijke rendementen van de verbran- dingsmotor beschouwd. Gevolgd door de toevoeging van constante rendementen voor de transmissie componenten. En uiteindelijk worden de werkpunts afhankelijke rendementen van elektrische ma- chines voor het hybride systeem van Toyota en van de duwband CVT voor de transmissie met duwband CVT. Hiermee wordt het totale rendement van beide transmissies met elkaar vergeleken. v vi Contents Abstract iii Samenvatting v Nomenclature ix 1 Introduction 1 2 Methodologies 7 2.1 Method by Schulz ...................................... 8 2.2 Method by Villeneuve .................................... 10 2.3 Method by Mattsson ..................................... 13 2.4 Discussion methodologies .................................. 14 3 Analyzing IVTs 15 3.1 Kinematics .......................................... 15 3.1.1 Toyota hybrid system ................................ 15 3.1.2 Renault IVT ..................................... 20 3.1.3 Comparison THS & Renault IVT .......................... 22 3.2 Mattsson ........................................... 23 3.2.1 Toyota hybrid system ................................ 23 3.2.2 Renault IVT ..................................... 23 3.2.3 Efficiencies ...................................... 24 4 Detailed efficiency analysis 27 4.1 Internal combustion engine ................................. 28 4.2 Toyota hybrid system ..................................... 29 4.2.1 Case A - ICE efficiency ............................... 30 4.2.2 Case B - Constant transmission component efficiencies ............. 31 4.2.3 Case C - EM working point efficiencies ...................... 32 4.3 Push-belt CVT ........................................ 33 4.3.1 Case A - ICE efficiency ............................... 34 4.3.2 Case B - Constant transmission component efficiencies ............. 36 4.3.3 Case C - CVT working point efficiencies ...................... 37 4.4 Discussion .......................................... 39 4.4.1 ICE strategy ..................................... 39 4.4.2 Comparison case A, B & C ............................. 41 4.4.3 Comparison THS & push-belt CVT ......................... 42 5 Conclusion & recommendations 45 5.1 Conclusion .......................................... 45 5.2 Recommendations ...................................... 46 vii viii CONTENTS Bibliography 47 A Kinematics planetary gear 49 B Clarification of the method by Schulz 51 B.1 M-file for the method by Schulz ............................... 52 C Clarification of the method by Villeneuve 55 C.1 M-file for the method by Villeneuve ............................. 56 D Clarification of the method by Mattsson 59 E Kinematics THS 61 F Kinematics push-belt CVT 65 G Toyota Prius specifications 67 Nomenclature Abbreviations 2WD / 4WD 2 / 4 Wheel Drive AMT Automated Manual Transmission AT automatic transmission BER Brake Energy Recovery CO2 Carbon dioxide CVT Continu Variable Transmission DNR Drive-Neutral-Reverse ECU Engine Control Unit EM Electrical Machine EMPAct CVT Electro-Mechanical Pulley Actuation CVT GNR Geared Neutral Ratio HEV Hybrid Electric Vehicle ICE Internal Combustion Engine IMA Integrated Motor Assist IVT Infinitely Variable Transmission OD Overdrive SOC State Of Charge SOOL System Optimal Operation Line SUV Sport Utility Vehicle THS Toyota Hybrid System e-line economy line rpm revolutions per minute Symbols Symbol Definition Unit P power [kW ] T torque [Nm] loh level of hybridization [−] r radius [m] r ratio [−] v velocity [m/s] z number of teeth [−] Φ power split ratio [−] ix x NOMENCLATURE η efficiency [−] λE power ratio [−] ω rotational velocity [rad/s] Subscripts Subscript Definition A1 planetary gear A1 A2 planetary gear A2 B planetary gear B C planetary gear C C1 clutch 1 C2 clutch 2 CVT push-belt CVT EM Electrical Machine F 1 brake 1 F 2 brake 2 H higher shaft ICE Internal Combustion Engine L lower shaft
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