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Electrical-Loss Analysis of Power-Split Hybrid Electric Vehicles

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Electrical-Loss Analysis of Power-Split Hybrid Electric Vehicles energies Article Electrical-Loss Analysis of Power-Split Hybrid Electric Vehicles Andrea Bonfiglio 1 ID , Damiano Lanzarotto 1, Mario Marchesoni 1, Massimiliano Passalacqua 1, Renato Procopio 1,* and Matteo Repetto 2 1 Department of Electrical, Electronic, Tlc Engineering and Naval Architecture (DITEN), University of Genoa, via all’Opera Pia 11a, 16145 Genova, Italy; a.bonfi[email protected] (A.B.); [email protected] (D.L.); [email protected] (M.M.); [email protected] (M.P.) 2 Department of Mechanical, Energy, Management and Transportation Engineering (DIME), University of Genova, via all’Opera Pia 15, 16145 Genova, Italy; [email protected] * Correspondence: [email protected]; Tel.: +39-010-353-2730 Received: 28 September 2017; Accepted: 12 December 2017; Published: 15 December 2017 Abstract: The growing development of hybrid electric vehicles (HEVs) has seen the spread of architectures with transmission based on planetary gear train, realized thanks to two electric machines. This architecture, by continuously regulating the transmission ratio, allows the internal combustion engine (ICE) to work in optimal conditions. On the one hand, the average ICE efficiency is increased thanks to better loading situations, while, on the other hand, electrical losses are introduced due to the power circulation between the two electrical machines mentioned above. The aim of this study is then to accurately evaluate electrical losses and the average ICE efficiency in various operating conditions and over different road missions. The models used in this study are presented for both the Continuously Variable Transmission (CVT) architecture and the Discontinuously Variable Transmission (DVT) architecture. In addition, efficiency maps of the main components are shown. Finally, the simulation results are presented to point out strengths and weaknesses of the CVT architecture. Keywords: hybrid electric vehicle; power-split device; electric machine; energy efficiency; continuously variable transmission; hybrid synergy drive 1. Introduction The increasing spread of medium size HEVs in the market has been led by CVT architectures equipped with a power-split device (PSD) able to continuously vary the transmission ratio thanks to the synergy with two motor-generators. This architecture is sketched in Figure1, the main components are: internal combustion engine (ICE), two motor-generators (MG1 and MG2), planetary gear train, i.e., Sun gear (S), Ring gear (R), Carrier gear (C), and the battery (B). In HEVs, the alternative to this structure is given by a discontinuously variable transmission (DVT) equal to that used in conventional vehicles, typically with six different values of transmission ratio. This architecture is sketched in Figure2 (note that only one motor-generator is used). The optimal energy management of the two transmission is fundamental to provide drive comfort and reduce fuel consumption. In scientific literature, one can find various studies on the implementation of optimal control logics, regarding the two architectures described. In [1], an optimized control logic for the power split device (PSD) based architecture is proposed. In [2], a particular energy management system (EMS) is studied for the DVT architecture. Both the CVT structure and the DVT structure are considered for the optimization logic described in [3]. Many variables affect the optimization of the entire hybrid powertrain; in particular, the driving style can Energies 2017, 10, 2142; doi:10.3390/en10122142 www.mdpi.com/journal/energies Energies 2017, 10, 2142 2 of 16 EnergiesEnergies 2017 2017, 10, 10, 2142, 2142 2 2of of 17 17 play a crucial role, as analyzed in [4]. In [5,6], more sophisticated methods based on neural networks playplay a a crucial crucial role, role, as as analyzed analyzed in in [4]. [4]. In In [5,6], [5,6], more more sophisticated sophisticated methods methods based based on on neural neural networks networks and fuzzy logic are proposed. andand fuzzy fuzzy logic logic are are proposed. proposed. MMecchanicalecchanical link link S MG S MG11 ElectricalElectrical link link BB ICEICE CC MG MG22 RR DifferentialDifferential Motor speed Motor speed geargear reductionreduction gear gear FigureFigureFigure 1. 1. 1. CVTCVT CVT architecture. architecture. MMecchanicalecchanical link link BB EElectricallectrical link link ICEICE DVTDVT MMGG DifferentialDifferential gear gear Figure 2. DVT architecture. FigureFigure 2. 2. DVT DVT architecture. architecture. Thus,Thus,Thus, it is thenit it is is importantthen then important important to study to to study optimalstudy optimal optimal control co co techniques,ntrolntrol techniques, techniques, but to but but evaluate to to evaluate evaluate the energy the the energy energy virtuosity virtuosity of CVT based vehicles, analyzing electrical losses is essential. In [7–9], experimental tests of CVTvirtuositybased of vehicles, CVT based analyzing vehicles, analyzing electrical electrical losses is losses essential. is essential. In [7 In–9 ],[7–9], experimental experimental tests tests were were conducted with the aim of determining the efficiency of electric drives used in the HEVs conductedwere conducted with the aimwith of the determining aim of determining the efficiency the ef officiency electric of drives electric used drives in theused HEVs in the available HEVs on available on the market today. Knowing this parameter is a key step in designing control logic aiming the marketavailable today. on the Knowing market today. this parameter Knowing this is a parameter key step inis a designing key step in control designing logic control aiming logic at aiming optimizing atat optimizingoptimizing thesethese compcomponentsonents [10].[10]. Indeed,Indeed, thethe CVTCVT architecturearchitecture allowsallows anan optimaloptimal energyenergy these components [10]. Indeed, the CVT architecture allows an optimal energy management of the managementmanagement of of the the ICE ICE, ,but but at at the the cost cost of of certain certain of of electrical electrical losses losses which which are are absent absent in in the the DVT DVT ICE, butarchitecture.architecture. at the cost Thus, Thus, of certain one one can can of find electricalfind various various losses works works which on on the the are PSD PSD absent based based in vehicles thevehiclesDVT in in architecture.scientific scientific literature, literature, Thus, one can findhowever,however, various theythey works dodo not onnot dealthedeal PSD withwithbased aa combincombin vehicleseded evaluationevaluation in scientific ofof electrical literature,electrical losseslosses however, andand ICEICE they efficiencyefficiency do not deal withimprovement aimprovement combined evaluationderiving deriving from from of the electricalthe CVT CVT system. system. losses and ICE efficiency improvement deriving from the CVT system.TheThe main main aim aim of of this this paper paper is is to to quantify quantify these these losses losses in in every every possible possible operating operating condition condition and and Thecomparecompare main them them aim with ofwith this the the paper ICE ICE energy energy is to quantifysavings savings obtainable obtainable these losses by by continuously incontinuously every possible regulating regulating operating the the transmission transmission condition and ratio. Firstly, the PSD model is presented; secondly, the electrical losses model is shown; and, finally, compareratio. them Firstly, with the PSD the ICE modelenergy is presented; savings secondly, obtainable the electrical by continuously losses model regulating is shown; the and, transmission finally, the EMS is described. In addition, a brief description is reported of the MATLAB/Simulink (2017b, ratio.the Firstly, EMS theis described.PSD model In addition, is presented; a brief secondly, description the is electricalreported of losses the MATLAB/Simulink model is shown; and,(2017b, finally, Mathworks,Mathworks, Natick, Natick, MA, MA, USA) USA) DVT DVT and and CVT CVT powertrain powertrain models. models. the EMS is described. In addition, a brief description is reported of the MATLAB/Simulink (2017b, ParticularParticular attentionattention isis paidpaid duringduring thethe resultsresults analysisanalysis notnot onlyonly toto thethe electrical-losselectrical-loss Mathworks, Natick, MA, USA) DVT and CVT powertrain models. quantificationquantification but but also also to to the the ICE ICE management management in in both both architectures. architectures. Particular attention is paid during the results analysis not only to the electrical-loss quantification but also to the ICE management in both architectures. In fact, to compare the energy efficiency of the two architectures a combined evaluation of electrical losses and ICE efficiency is of primary importance. Energies 2017, 10, 2142 3 of 17 In fact, to compare the energy efficiency of the two architectures a combined evaluation of Energieselectrical2017, 10, losses 2142 and ICE efficiency is of primary importance. 3 of 16 2. Model 2. Model 2.1. Power Split Device Energy Model 2.1. Power Split Device Energy Model To mathematically describe the PSD, the energy convention depicted in Figure 3 has been Tochosen. mathematically describe the PSD, the energy convention depicted in Figure3 has been chosen. PSm Mecchanical link S MG1 Electrical link PICE Pe ICE C PMG,m2 MG2 P'w Pw R Differential P Rm Motor speed gear reduction gear FigureFigure 3. 3.CVT CVT energy convention. convention. In FigureIn Figure3,
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