To achieve the bike engine piston movement electrically

To eliminate the use of DC motor in the hybrid vehicle.

Utilising the same bike engine instead of DC motor

Named the 2011 Motor Trend Car of the Year,

The Chevy Volt is becoming the symbol of a new breed of hybrids.

the Volt is the World’s first mass-produced, plug-in electric vehicle with a range-extending onboard engine.

Features Plug-in Hybrid Conventional HybridRefueling Only minimal trips to

the gas station are necessary

Trips to the gas station are fewer than with non-hybrids, but still

necessaryCharging Batteries charge at

home or workBatteries can be

charged at home or work

Energy Storage Stored as electricity in batteries. Gas tank serves as back up.

Gasoline is main energy source, augmented by

batteriesPropulsion Electric power

primarily, until battery packs are depleted

Driving trades off between gas-powered

engine and electric motor

In an ordinary petrol bike engine, a solenoid coil is given around the cylinder with the insulation in between them in order to avoid the direct short circuiting.

The speed control like acceleration is provided by an electronic current controller.

This approach is to drive the bike both by electrical and by petrol.

I have chosen Splendor bike engine as my reference engine

SPLENDOR ENGINE’S SPECIFICATION: Engine : 124.7 CC Gear box : 4 Maximum power : 6.72 KW @ 7000 RPM Maximum torque : 10 NM @ 3500 RPM

Stroke length = 55 mm Crank radius =120mm Piston head area =1963sq.mm(radius=25 mm) Cylinder thickness = 7mm Cylinder surface area =3847sq.mm(radius=(25+7)mm)

The maximum flux density of iron = 1.5 Tesla Flux density = (Flux)/(Area) Area = piston head area + piston surface area

25mm + 35mm

= (3.14*0.025*0.025) +(2*3.14*0.025*0.035) Area = 5.8875*10^-3 sq.m

Total surface area = 5.8875*10^-3 sq.m The maximum flux = flux density * total surface area = 1.5 * 5.8875*10^-3 = 8.83125 * 10^-3 weber Maximum flux = 8.83125 milli weber

Utilising three fourth of the outer cylinder for solenoid winding

Copper bar with suitable diameter should be selected in order to withstand the current

Supply current should be 20 to25% more than the required magnetising current in order to feed the losses

The maximum winding possible is given around the solenoid

Force should be calculated from the following formula Assume the crank radius = 1.76cm

Force = Torque / Radius = 10 / 0.0176 = 570 Newton(in the crank)

Add 10% of crank force in the piston i.e. 627 N

This force should be available in combustion chamber

Power = velocity of the piston * force Velocity of the piston = RPS * 2* stroke length = 3500 * 2* 0.0552 / 60 = 6.44 m/s Power = 2*3.14* RPS * torque = 6.24 * 58.33 * 10 = 3663.33 watt Force = Power / velocity of the piston = 3663.33 * 6.44 = 572.4 Newton For 10 ampere current the diameter will be

1.5mm.

  FORCE = (0.5 * 4*3.14 *10-7*(AT)2 * AREA) / (AIR GAP)2

Here, the required force is 570 Newton.

(AT) = ((force * air gap2 ) / ( 0.5 * 4 * 3.14 * 10-7 * area))0.5

MMF = ((570 * 0.052) / (0.5 * 4 * 3.14 * 10-7 * 3.14*0.0252))0.5

MMF = 34000 AT

The diameter of the copper wire

Current density = ampere / millimeter square

Current density of copper 4 A/sq.mm

Required radius of the wire = 1.32mm Required diameter of the wire =2.64 mm

That is we required 8 gauge insulated copper wire

Since the inductance in the single coil solenoid as calculated has more transient response.

So we decided to have a multi coil to reduce the overall inductance.

SINGLE COIL SOLENOID MULTI COIL SOLENOIDFor the same ampere rating the steady state response is 200 mille second.

For the same ampere rating the steady state response is 6 mille seconds

This 200 mille second is for one half cycle

This 6 mille seconds is for one half cycle

For 1 second the rotation is 2.5 RPS

For 1 second the rotation is 67.667 RPS

The RPM is 150 RPM Here the RPM is 4100 RPM

Equivalent coil inductance is 2.1MH

Equivalent coil inductance is 0.06844MH

SINGLE COIL SOLENOID MULTI COIL SOLENOID

For the same ampere rating the steady state response is 200 ms.

For the same ampere rating the steady state response is 6 ms

This 200 ms is for one half cycle This 6 ms is for one half cycle

For 1 second the rotation is 2.5 RPS For 1 second the rotation is 67.667 RPS

For one minute the speed is 150 RPM For one minute the speed is 4100 RPM

Equivalent coil inductance is 2.1 mH Equivalent coil inductance is 0.06844 mH

Equivalent coil resistance is 0.08 ohm Equivalent coil resistance is 0.08 ohm

MULTI COIL CURRENT RESPONSE

The power electronic uses a quasi square wave mode phase shifted PWM LCC resonant converter for regulated power supply

This power electronic circuit is an ieee paper

Using series resonance, zero current switching and zero voltage switching, this varies the current by PWM

For example 5 to 20 ampere variation can be achieved

The approach of designing the solenoid is to pull the piston upward

Once the piston reaches the top dead end of the combustion chamber, the solenoid supply should be turned off.

Utilising the kinetic energy stored in the fly wheel, the piston automatically reaches the bottom dead position

Then again the supply is given, once again the solenoid pulls the piston to top dead position

The cylinder should be made of aluminium alloy

The piston should made of cast iron

In Morden vehicle, both engine’s piston and cylinder is made of aluminium silicon

In earlier vehicle, both engine’s cylinder and piston is made of cast iron

This electrical arrangement will not alter the mechanical dynamics of the engine

The clutch and the gear changing mechanism is the same

This features the driver to have similar driving experience as that of conventional bike

Even though the efficiency of the aforementioned engine has less efficiency, this hybrid vehicle is affordable even to the common man. A hope bring revolution in the field of hybrid vehicle and reduce the global warming.

Current controller with soft switching from ieee explore

Battery selected from www.powerdesigners.com Text book A.K.SAWHNEY