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1 a Simulation-Based Assessment of Plug-In Hybrid Electric Vehicle A Simulation-Based Assessment of Plug-in Hybrid Electric Vehicle Architectures by Daniel Sotingco B.S. Mechanical Engineering Franklin W. Olin College of Engineering, 2010 SUBMITTED TO THE DEPARTMENT OF MECHANICAL ENGINEERING IN PARTIAL FULLFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF MASTER OF SCIENCE IN MECHANICAL ENGINEERING AT THE MASSACHUSETTS INSTITUTE OF TECHNOLOGY June 2012 ©2012 Massachusetts Institute of Technology All rights reserved. Signature of author: ………………………………………………………………………………………………………………………………….. Department of Mechanical Engineering May 11, 2012 Certified by: ……………………………………………………………………………………………………………………………………………… Professor Jerome Milgram William I. Koch Professor of Ocean Engineering Thesis Advisor Accepted by: …………………………………………………………………………………………………………………………………………….. Professor David E. Hardt Ralph E. and Eloise F. Cross Professor of Mechanical Engineering Chair, Committee on Graduate Students 1 2 A Simulation-Based Assessment of Plug- in Hybrid Electric Vehicle Architectures By Daniel S. Sotingco Submitted to the Department of Mechanical Engineering on May 11, 2012 in Partial Fulfillment of the Requirements for the Degree of Master of Science in Mechanical Engineering Abstract Plug-in hybrid electric vehicles (PHEVs) are vehicles that utilize power from both an internal combustion engine and an electric battery that can be recharged from the grid. Simulations of series, parallel, and split-architecture PHEVs, as well as parallel and split PHEVs with ultracapacitors, were performed in Autonomie, the vehicle simulation package released by Argonne National Laboratory as the successor to the Powertrain System Analysis Toolkit (PSAT). The PHEV configurations were parameterized by battery capacity, motor peak power, engine peak power, and ultracapacitor capacity if applicable. Results were compared to EPA data for the Chevrolet Volt and Toyota Prius, showing close agreement on values for fuel consumption, charge-depleting range, and acceleration time. While most PHEVs today are of the series or split variety, analysis of the simulation results indicates that including features from a parallel architecture could improve performance without undue additional cost from components. In addition, ultracapacitors were found to have a significant positive effect on all-electric fuel consumption. Furthermore, pricing models were created to predict approximate MSRP and 5-year cost-to-own for future PHEVs. These models were incorporated into a graphical user interface built using MATLAB that allows access to the simulation results in a way that is accessible to the average consumer. Thesis Supervisor: Jerome Milgram Title: William I. Koch Professor of Ocean Engineering 3 Acknowledgements First, I would like to thank Professor Jerry Milgram for giving me the opportunity to work on this research project under his supervision. His insights and guidance were instrumental in completing this project. Many thanks to the members of the MIT Sloan Automotive Laboratory for hosting me in their facilities, especially my officemate, Dr. Emmannuel Kasseris, who led me to find the right resources to advance my project at times when I got stuck. Special thanks go to the Baja SAE team at Franklin W. Olin College of Engineering, which first sparked my interest in automotive technology. Last but not least, I would like to thank my parents, David and Rita Sotingco, for their love and support. 4 Table of Contents Abstract .................................................................................................................................................. 3 Acknowledgements ................................................................................................................................. 4 List of Figures .......................................................................................................................................... 8 List of Tables ........................................................................................................................................... 9 Abbreviations & Symbols ....................................................................................................................... 10 1. Introduction ...................................................................................................................................... 12 2. Background ....................................................................................................................................... 12 2.1 Motivation for Electrified Vehicles ............................................................................................... 12 2.2 Electrified Powertrains ................................................................................................................ 12 2.2.1 Hybrid Electric Vehicles (HEVs) ............................................................................................. 12 2.2.2 Plug-in Hybrid Electric Vehicles (PHEVs) ................................................................................ 13 2.2.3 Battery Electric Vehicles (BEVs) ............................................................................................ 14 2.2.4 Fuel Cell Vehicles (FCVs) ....................................................................................................... 15 2.3 Energy Storage ............................................................................................................................ 15 2.3.1 Batteries ............................................................................................................................... 15 2.3.2 Ultracapacitors ..................................................................................................................... 16 2.3.3 Battery and Ultracapacitor Performance and Pricing ............................................................ 16 2.4 HEV and PHEV Considerations ..................................................................................................... 17 2.4.1 Degree of Hybridization (DOH) ............................................................................................. 17 2.4.2 Equivalent Miles per Gallon (MPGe) ..................................................................................... 18 2.4.3 Charge-Sustaining (CS) and Charge-Depleting (CD) Modes .................................................... 20 2.4.4 Charge-Depleting Range ....................................................................................................... 20 2.4.5 Considerations for the Grid................................................................................................... 21 2.4.6 Utility Factor (UF) ................................................................................................................. 23 2.5 HEV and PHEV Vehicle Architectures ........................................................................................... 26 2.5.1 Series Architecture ............................................................................................................... 26 2.5.2 Parallel Architecture ............................................................................................................. 27 2.5.3 Split Architecture .................................................................................................................. 29 2.6 Hybrid Vehicle Technologies ........................................................................................................ 30 2.6.1 Toyota: Hybrid Synergy Drive ............................................................................................... 30 2.6.2 Honda: Integrated Motor Assist ............................................................................................ 32 5 2.6.3 GM: 2-Mode Hybrid.............................................................................................................. 32 2.6.4 GM: Voltec ........................................................................................................................... 33 2.6.5 Honda: Earth Dreams Two-Motor Hybrid System.................................................................. 34 2.6.6 AFS Trinity: Extreme Hybrid .................................................................................................. 35 2.7 Current and Upcoming PHEVs ...................................................................................................... 36 2.8 EPA Fuel Economy Labeling ......................................................................................................... 37 2.8.1 Drive Cycles .......................................................................................................................... 37 2.8.2 MPG-Based EPA Formulas .................................................................................................... 39 2.8.3 Vehicle-Specific City MPG Formula ....................................................................................... 39 2.8.4 Vehicle-Specific Highway MPG Formula ................................................................................ 40 2.9 Monroney Stickers....................................................................................................................... 41 2.10 SAE J1711 .................................................................................................................................. 44 3. Simulation Procedure .......................................................................................................................
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