• Energy Research

Recent studies show that hybrid powertrains with dual clutch transmission are becoming more common. This is mainly influenced by the fact that they have higher efficiency, allow power-on shifting, and are more compact. However, the electric motor attached to the primary shaft of the transmission might represent some critical issues in statics and dynamics due to additional torque, inertia, and working irregularities. This paper aims to investigate the influence of the electric motor integration in the transmission on the reliability of the overall system. The focus is on the investigation of potential over stresses of the ICE bearings due to the bending of the gearbox primary shaft. To achieve the aim, the static and the rotor dynamic analysis of the inner and outer primary shafts is performed. The numerical analyses show the potential critical issues that can arise from the excessive manufacturing and assembling tolerances, the interaction of the e-machine torque irregularities and inertia with the bending dynamics of the primary shafts.

This work represents the development of a Fuel Cell Hybrid Electric Vehicle (FCHEV) model, its validation, and the comparison of different control strategies based on the Toyota Mirai (1st generation) vehicle and its subsystems. The main investigated parameters are hydrogen consumption, and the variation of the state of charge, current, and voltage of the battery. The FCHEV model, which is made up of multiple subsystems, is developed and simulated in MATLAB® Simulink environment using a rule-based control strategy derived from the real system. The results of the model were validated using the experimental data obtained from the open-source Argonne National Laboratory (ANL) database. In the second part, the equivalent consumption minimization strategy is implemented into the controller logic to optimize the existing control strategy and investigate the difference in hydrogen consumption. It was found that the ECMS control strategy outperforms the rule-based one in all drive cycles by 0.4–15.6%. On the other hand, when compared to the real controller, ECMS performs worse for certain considered driving cycles and outperforms others.

Hybrid electric vehicles have proven to be an effective solution for the auto industry to satisfy the increasingly stringent CO2 regulations for the short-medium term. Proper sizing of the different components is required to benefit from the hybrid architecture full potential. This paper proposes a unified method that can be applied in both cases. The method uses the energy flow, storage, and consumption during a cycle to perform the sizing. A 350 V P2 plug-in hybrid and a 48 V P2 mild hybrid are taken as a case study. The sizing is performed by adopting the WLTP cycle and subsequently analyzing the energy profile.

The primary objective of a hybrid electric vehicle (HEV) is to optimize the energy consumption of the automotive powertrain. This optimization has to be applied while respecting the operating conditions of the battery. Otherwise, there is a risk of compromising the battery life and thermal runaway that may result from excessive power transfer across the battery. Such considerations are critical if factoring in the low battery capacity and the passive battery cooling technology that is commonly associated with HEVs. The literature has proposed many solutions to HEV energy optimization. However, only a few of the solutions have addressed this optimization in the presence of thermal constraints. In this paper, a strategy for energy optimization in the presence of thermal constraints is developed for P2 HEVs based on battery sizing and the application of model predictive control (MPC) strategy. To analyse this approach, an electro-thermal battery pack model is integrated with an off-axis P2 HEV powertrain. The battery pack is properly sized to prevent thermal runaway while improving the energy consumption. The power splitting, thermal enhancement and energy optimization of the complex and nonlinear system are handled in this work with an adaptive MPC operated within a moving finite prediction horizon. The simulation results of the HEV SUV demonstrate that, by applying thermal constraints, energy consumption for a 0.9 kWh battery capacity can be reduced by 11.3% relative to the conventional vehicle. This corresponds to about a 1.5% energy increase when there is no thermal constraint. However, by increasing the battery capacity to 1.5 kWh (14s10p), it is possible to reduce the energy consumption by 15.7%. Additional benefits associated with the predictive capability of MPC are reported in terms of energy minimization and thermal improvement.

The energy management system (EMS) of a hybrid electric vehicle (HEV) is an algorithm that determines the power split between the electrical and thermal paths. It defines the operating state of the power sources, i.e., the electric motor (EM) and the internal combustion engine (ICE). It is therefore one of the main factors that can significantly influence the fuel consumption and performance of hybrid vehicles. In the transmission path, the power generated by the ICE is in part employed to accelerate the rotating components of the powertrain, such as the crankshaft, flywheel, gears, and shafts. The main inertial components are the crankshaft and the flywheel. This additional power is significant during high-intensity acceleration. Therefore, the actual engine operation is different from that required by the power split unit. This study focuses on exploring the influence of engine inertia on HEV fuel consumption by developing a controller based on an equivalent consumption minimisation strategy (ECMS) that considers crankshaft and flywheel inertia. The optimal solution obtained by the ECMS controller is refined by incorporating the inertia effect of the main rotating components of the engine into the cost function. This reduces the engine operation during high inertial torque transient phases, resulting in a decrease in vehicle CO2 emissions by 2.34, 2.22, and 1.13 g/km for the UDDS, US06, and WLTC driving cycles, respectively.

Small capacity and passively cooled battery packs are widely used in mild hybrid electric vehicles (MHEV). In this regard, continuous usage of electric traction could cause thermal runaway of the battery, reducing its life and increasing the risk of fire incidence. Hence, thermal limitations on the battery could be implemented in a supervisory controller to avoid such risks. A vast literature on the topic shows that the problem of battery thermal runaway is solved by applying active cooling or by implementing penalty factors on electric energy utilization for large capacity battery packs. However, they do not address the problem in the case of passive cooled, small capacity battery packs. In this paper, an experimentally validated electro-thermal model of the battery pack is integrated with the hybrid electric vehicle simulator. A supervisory controller using the equivalent consumption minimization strategy with, and without, consideration of thermal limitations are discussed. The results of a simulation of an MHEV with a 0.9 kWh battery pack showed that the thermal limitations of the battery pack caused a 2–3% fuel consumption increase compared to the case without such limitations; however, the limitations led to battery temperatures as high as 180 °C. The same simulation showed that the adoption of a 1.8 kWh battery pack led to a fuel consumption reduction of 8–13% without thermal implications.