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Analysis and Design of the Powertrain and Development of an Energy 1 Analysis and Design of the Powertrain and Development of an Energy Management Strategy for InMotion IM01 Hybrid Race Car I.Papaliouras, P.Beviz, A.Pliatskas, E.Stamatopoulos, E.Papanikolaou, S.A.Krishna, S.Velayutham, C.Vichas, K.H.F.E.Emam, V.Sridhar, B.D.Cano and E.A.Ross PDEng Automotive Systems Design, Stan Ackermans Institute Eindhoven University of Technology, Eindhoven, The Netherlands. Email: [email protected] and J.J.H.Paulides Electromechanics and Power Electronics Group, Department of Electrical Engineering, Eindhoven University of Technology, Eindhoven, The Netherlands. Email: [email protected] Abstract—This paper describes the analysis and design of an achieve high performance, races such as Le Mans and com- energy efficient powertrain configuration for the InMotion IM01 panies such as Audi, Porsche and Nissan have silenced that race car. It is a Hybrid Electric Vehicle (HEV) with several scepticism. In that context, the InMotion racing team has an- novel technologies, aiming to participate in the 24-hour Le Mans nounced and started the production of a high-performance low- race, competing in the Garage 56 category. InMotion, the main consumption hybrid supercar (IM01) that is set to participate developer of the IM01, is a multidisciplinary project-oriented in the Le Mans race in 2017. group supported by Eindhoven University of Technology (TU/e). The main goal of the InMotion team is to achieve better fuel The InMotion student group consists of students from TU/e efficiency and performance than that of their competitors in the and Fontys University of Applied Sciences, as well as experts LMP1 category of the Le Mans race, namely, the Audi R18 e-tron in the field of automotive domain. They have a close collab- (2014) on Circuit de la Sarthe. The Automotive Systems Design oration with the two universities and automotive companies (ASD) generation 2014-2016 are involved in the development [1]. In this context, trainees of the Automotive System Design of the series powertrain architecture of IM01 super car. This (ASD) PDEng program in TU/e were assigned to develop paper presents an optimal HEV powertrain analysis, including a powertrain model and an energy management strategy for the description of different components, focused on using the series hybrid powertrain topology and taking into account the their race car. The findings of this research are presented in design restrictions from InMotion and the constraints of the this paper. There are certain safety regulations imposed on the Garage 56 category. We recommend improvements to the Internal contestants and the vehicle must comply with the performance Combustion Engine (ICE), the Energy Storage System (ESS) type and reliability criteria, but in general, it is an opportunity to selection and introduce a component sizing algorithm. Several test novel technological achievements. Energy Management Strategies (EMS) are investigated within this The work carried out by the ASD group focuses on configur- study; a rule-based controller and an Equivalent Consumption Minimization Strategy (ECMS) are implemented and validated ing a series hybrid powertrain for IM01, modelling and sizing using a Simulink forward model of the HEV. A scaled model of the components, and simulating the performance of the of the drive cycle is proposed using a test bench to observe the vehicle for different drive cycles using two energy management behavior of the electric motor on Circuit de la Sarthe. strategies. The proposed sized powertrain is simulated on a drive cycle that is based on the La Sarthe circuit track Keywords—Hybrid Electric Race Car, InMotion, Garage 56, properties. The speed and acceleration profiles, and the power Energy Management Strategy, Series Powertrain, ECMS, Le Mans demand profile have been modified to match the current pow- ertrain configuration, and different driving strategies have been developed to increase the efficiency. Furthermore, two Energy Management Strategies (EMS), Equivalent Consumption Min- I. INTRODUCTION imization Strategy (ECMS)[2][3]and a rule-based strategy, are YBRID vehicle technology is continuously evolving by implemented and compared. H introducing innovative technologies into the automotive During the development of the powertrain of IM01 race car, industry. The main goals of the ongoing research are to achieve several restrictions have been taken into consideration. These the best combination of performance and efficiency, reduce constraints are mainly Garage 56 safety regulations, as well the emissions and create an environment-friendly means of as performance requirements that must be met, based on the transportation. Despite skepticism that hybrid vehicles cannot main opponent’s performance, i.e. Audi R18. Figure1 shows 2 the preliminary performance results of IM01 compared to Audi II. HEV POWERTRAIN ANALYSIS R18. There are also restrictions imposed by InMotion, regard- By the term hybrid electric vehicle, this paper refers to the ing the selection of components. The main requirements that vehicle that features two or more different types of energy are derived from these restrictions and are initially considered sources [5]. The two main power sources are the prime mover as follows: and the energy storage system, which can consist of various • The curb weight of the vehicle, including the fuel, must components. In most cases, the prime mover is an Internal not exceed 900kg. Combustion Engine (ICE), or a Fuel Cell (FC) and the energy • The topology will be that of a series powertrain to ensure storage system consists either of batteries, or ultra-capacitors, easier assembly [4]. or a flywheel, or a combination. • Some of the components that are being used are the same as in the IM/e (Fully electric race car (2015) of A. Topologies and Advantages=Disadvantages InMotion) vehicle [1]. The powertrain is the sum of the components that are • The maximum voltage on the electric circuits of the generating and delivering energy to the road surface for the vehicle must not exceed that of 1kV . propulsion of the vehicle. These components mainly include • The fastest lap time of Audi R18 is 3min 22.57s. the prime mover, the transmission, the wheels, the generator, IM01 must achieve a lap time equal or less than the the electric motors, the power electronics for the power con- aforementioned. version and the energy storage system. There are three main • The number of laps Audi R18 completed in 2014 is types of HEV powertrain topologies: series, parallel and series- 379laps. That number is based on the total distance parallel. covered by Audi in 2014 in 24 hours. In order to achieve In the parallel configuration, there is a mechanical coupling over and above 379laps the average speed of the IM01 between the internal combustion engine and the wheels, as well should be at-least equal to 215.25km=h. as between the electric motors and the wheels. This translates • The average fuel consumption during the 24-hour race of into the wheels being propelled by these two sources either Audi R18 is 32l=100km. The average fuel consumption individually or simultaneously. The benefits of this layout are of IM01 must be at least equal or smaller. the low energy conversion losses, since the power from the prime mover is directly delivered to the driving wheels, the lower fuel consumption and the increased efficiency, and the fact that only two propulsion devices are needed, namely the prime mover and the electric motor [6][7]. On the other hand, the connection of the prime mover to the wheels requires the presence of a gear mechanism. This, in combination with the complex transmission results in mechanical losses as well as a complex control strategy [4]. A simplified architecture of the parallel configuration is shown in figure2. FUEL TANK ENGINE Mech WHEEL . Fig. 1: The initial performance results of IM01 Vs. Audi R18 Coupler 2014 DC/DC I/C MOTOR / ESS DC BUS CONVERTER UNIT GENERATOR A brief literature review of the existing powertrain topolo- gies and components used in HEVs is introduced in sectionII, AUXILLIARIES as well as the decision process followed to select the optimum type of each of the powertrain components. The mathematical modelling of these components is described in section III in Fig. 2: Parallel powertrain topology order to reach a complete forward model of the powertrain using the parameters of the selected components. Two EMS strategies are implemented, compared and tested using the In the series configuration (figure3), the mechanical power developed forward model to validate the race requirements in output of the internal combustion engine is converted to terms of fuel efficiency. A lab testing methodology is presented electrical energy through the generator. This energy either in sectionIV that describes a procedure for scaling and charges the Energy Storage System (ESS) or propels the testing the drive cycle using a lower power test bench. The wheels through the electric motors. The motors can also results of the model simulation and a comparison of different be used for regenerative braking. It is a simple powertrain control strategies are listed in sectionV. Finally, we present configuration, in terms of mechanical connection, control and a conclusion of what has been achieved and recommendations energy management, that is based upon the principle of using for future work. the engine (ICE or FC) as a range extender for the energy 3 storage system on board [7]. The independence of the engine engine and the generator are outside the scope of this speed from the vehicle load and speed allows the engine to be paper. operated under its most efficient conditions. Additionally, it 1) Engine – Generator Unit (EGU): In this study, different enables the use of a lightmass high speed internal combustion options for the engine are considered to define the best engine [6]. When developing a series powertrain, however, we selection for the IM01 race car.
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