University of Windsor Scholarship at UWindsor Electronic Theses and Dissertations Theses, Dissertations, and Major Papers 2013 Design of battery pack and internal combustion engine thermal models for hybrid electric vehicles Gabriele Catacchio University of Windsor Follow this and additional works at: https://scholar.uwindsor.ca/etd Recommended Citation Catacchio, Gabriele, "Design of battery pack and internal combustion engine thermal models for hybrid electric vehicles" (2013). Electronic Theses and Dissertations. 4964. https://scholar.uwindsor.ca/etd/4964 This online database contains the full-text of PhD dissertations and Masters’ theses of University of Windsor students from 1954 forward. These documents are made available for personal study and research purposes only, in accordance with the Canadian Copyright Act and the Creative Commons license—CC BY-NC-ND (Attribution, Non-Commercial, No Derivative Works). Under this license, works must always be attributed to the copyright holder (original author), cannot be used for any commercial purposes, and may not be altered. Any other use would require the permission of the copyright holder. Students may inquire about withdrawing their dissertation and/or thesis from this database. For additional inquiries, please contact the repository administrator via email ([email protected]) or by telephone at 519-253-3000ext. 3208. Design of battery pack and internal combustion engine thermal models for hybrid electric vehicles By Gabriele Catacchio A Thesis Submitted to the Faculty of Graduate Studies through the Department of Mechanical, Automotive and Materials Engineering in Partial Fulfillment of the Requirements for the Degree of Master of Applied Science at the University of Windsor Windsor, Ontario, Canada 2013 © 2013 Gabriele Catacchio Design of battery pack and internal combustion engine thermal models for hybrid electric vehicles By Gabriele Catacchio Approved by: ______________________________________________ Dr. Peter Frise, Co-Advisor Department of Mechanical, Automotive and Materials Engineering ______________________________________________ Dr. Narayan Kar, Co-Advisor Department of Electrical and Computer Engineering ______________________________________________ Dr. Jennifer Johrendt, Program Reader Department of Mechanical, Automotive and Materials Engineering ______________________________________________ Dr. Chris Lee, Outside Program Reader Department of Civil and Environmental Engineering August 12th, 2013 DECLARATION OF ORIGINALITY I hereby certify that I am the sole author of this thesis and that no part of this thesis has been published or submitted for publication. I certify that, to the best of my knowledge, my thesis does not infringe upon anyone’s copyright nor violate any proprietary rights and that any ideas, techniques, quotations, or any other material from the work of other people included in my thesis, published or otherwise, are fully acknowledged in accordance with the standard referencing practices. Furthermore, to the extent that I have included copyrighted material that surpasses the bounds of fair dealing within the meaning of the Canada Copyright Act, I certify that I have obtained a written permission from the copyright owner(s) to include such material(s) in my thesis and have included copies of such copyright clearances to my appendix. I declare that this is a true copy of my thesis, including any final revisions, as approved by my thesis committee and the Graduate Studies office, and that this thesis has not been submitted for a higher degree to any other University or Institution. iii ABSTRACT This thesis focuses on the design of computational models, capable of simulating the thermal behaviour of a battery pack and internal combustion engine equipping a hybrid electric vehicle tested over a given driving cycle. Both the models manage a lot of input variables and take into account all the thermophysical aspects regulating the heat exchange phenomena between the battery and engine devices and the cooling medium used to maintain their thermal control. The main objective of the research is to design the two models and integrate them in the simulation tool used by Chrysler to predict the performance of hybrid vehicles in the early design stages. After that, using the battery cooling system model, a sensitivity study is performed to understand which are the most important factor affecting the thermal behaviour of the battery cells. Finally, a validation phase is conducted for both the software to guarantee the validity of their results. iv DEDICATION To my grandma, who always believed in me. v ACKNOWLEDGEMENTS This work is the result of the cooperation of two universities, the Politecnico di Torino and the University of Windsor, and two companies, FIAT and Chrysler, and it is thanks to the precious guidance of many people from all these institutions that this thesis has been developed. Firstly, I would like to express my deepest gratitude to my FIAT tutor Dr. Vittorio Ravello, who always gave me professional and moral support during the whole project. I am also profoundly grateful to Prof. Andrea Tonoli and Prof. Alberto Tenconi, from the Politecnico di Torino, for all their help and suggestions. Then, I would like to thank my advisors Dr. Peter Frise and Dr. Narayan Kar from the University of Windsor, for their important assistance both during the academic year and during the writing of the thesis. Moreover, I am particularly grateful to Jan Stewart and Mike Houston, for their patience and their continuous support. Furthermore, I would like to express my deepest gratitude to all the people who assisted me in Chrysler, starting from my tutors Oliver Gross and Mengyang Zhang, who always helped me during the internship period and allowed me to live a fantastic professional experience in Auburn Hills. Special thanks go also to my Chrysler supervisor Mohammed Malik and to all the colleagues I worked with, for their guidance and suggestions: Craig, Sachin, Joydip, Carrie, Tony, Witt, Joel, Rene, Julie and Lucille. Last but not least, I am profoundly grateful to Prof. Giovanni Belingardi from Politecnico di Torino and Dr. Edoardo Rabino from FIAT, for their precious advices. The most important thanks are reserved to my fantastic parents and brother, to my adorable girlfriend Martina and to my friends Andrea, Maurizio, Gianmarco, Carlo and Yupeng, who made this experience wonderful and unforgettable. vi LIST OF CONTENTS DECLARATION OF ORIGINALITY .............................................................................. iii ABSTRACT ....................................................................................................................... iv DEDICATION ..................................................................................................................... v ACKNOWLEDGEMENTS ............................................................................................... vi LIST OF TABLES ............................................................................................................. xv LIST OF FIGURES ........................................................................................................ xvii NOMENCLATURE ...................................................................................................... xxiii ABBREVIATIONS ....................................................................................................... xxix 1 INTRODUCTION ........................................................................................................... 1 1.1 Objectives ................................................................................................................... 2 1.2 Thesis organization .................................................................................................... 3 2 LITERATURE REVIEW .............................................................................................. 5 2.1 Latest developments in the worldwide automotive scenario...................................... 5 2.1.1 Environmental effects of fossil fuels ................................................................... 5 2.1.2 Sustainable transportation solutions .................................................................... 7 2.2 Innovative features introduced by vehicle hybridization ........................................... 9 2.2.1 Fuel consumption and emission levels reductions ............................................ 10 2.2.2 Environmental impact of hybrid car batteries ................................................... 10 2.3 Hybrid drivetrains .................................................................................................... 11 2.3.1 General concepts about hybrid vehicle drivetrains ............................................ 11 2.3.2 Parallel configuration......................................................................................... 12 2.3.2.1 Parallel hybrid strengths ............................................................................. 14 2.3.2.2 Description of the integrated starter generator ............................................ 14 vii 2.3.3 Series configuration ........................................................................................... 16 2.3.3.1 Series hybrid strengths ................................................................................ 18 2.3.4 Series-parallel configuration .............................................................................. 19 2.3.4.1 The Toyota