PROCEEDINGS OF THE INSTITUTE OF VEHICLES 5(91)/2012

49

Ireneusz Krakowiak

1

THE RESEARCH ACTIVITIES OF THE DEPARTMENT OF THE

MULTISOURCE PROPULSION SYSTEMS IN FIELDS OF HEV AND

ALTERNATIVE ENERGY SOURCES

1. The partnerships in the fields of HEV

The Department of Multisource Propulsion Systems works in partnership with many

organizations and universities in the world and has conducted the research and education

in the field of hybrid & electric drives and alternative energy sources for some years.

Fig. 1. The partnerships of the department

Fig. 2. The main of goals of the department

1 dr inż. Ireneusz Krakowiak, Warsaw University of Technology

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2. Overview of research activities

2.1. The Battery electrochemical

The modelling of drive and its components are specially emphasized. The equations

describing the rule of operation were written in the Simulink. The main feature of hybrid

drive is the balance of battery, it’s very important. It means state-of-charge (SOC) of

battery should be the same level at the beginning and in the end of driving cycle for “

full hybrid” power trains. The electric energy consumption also should be as low as

possible [1], [2], [3], [4], [15], [19].

Substitute circuit of electrochemical battery

)()()(

1,0( )()(

)()(

kRikukE

kk

kl

i

kEkbkR

wa

a

w

Re Rel ia

Ua

E

Generic battery mathematic model

),,,()(),(),,(

/,,,,,

QtiRtiQtuQiE

iQibEQRQRQiR

awaa

aaeelaw

k is SOC of battery, which is the function of current, temperature and time. Temperature

is not considered because the experimental data are tested at constant temperature.

Transferred battery mathematic modeling

Substitute circuit of electrochemical battery

)()()(

1,0( )()(

)()(

kRikukE

kk

kl

i

kEkbkR

wa

a

w

Re Rel ia

Ua

E

Generic battery mathematic model

),,,()(),(),,(

/,,,,,

QtiRtiQtuQiE

iQibEQRQRQiR

awaa

aaeelaw

k is SOC of battery, which is the function of current, temperature and time. Temperature

is not considered because the experimental data are tested at constant temperature.

Transferred battery mathematic modeling

Fig. 3. Substitute scheme of electrochemical battery: Rel – resistance of electrolyte, Re –

resistance of electrodes, Ua – battery voltage, ia – battery current load

The usable capacity of an accumulator is not related to temperature exclusively, it is

also influenced by current of its load and the duration of the current flow. Temporary

usable capacity Qu – being a function of temperature, current and time, for a case when ia

= f(t) can be described by a monotonic, non-decreasing function which can be derived

from the equation:

dttiiQtiQ

t

aaau 0

)(),(,, (2.1.1)

where:

dtti

t

a0

)( - usable which has been draw from the accumulator sine the instant

t=0 till the time t,

),( aiQ - accumulator’s capacity as a function of temperature and load

current.

These mathematical models were tested and verified on laboratory bench stands.

These works were presented in the grant “The NiMH traction battery construction,

diagnostic requirements and the monitoring system study for the hybrid drives”.

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Fig. 4. The laboratory stand for battery research

2.2. The Fuel cell

Problems with fossil fuels caused development of many alternative vehicle drive

systems. One of newly developed solution is a drive with hydrogen fuel cell. The fuel

cell is clean, silent and environmental-friendly solution, but this technology requires

high technology to obtain stable and safe fuel cell operation. In the project mechatronic

system was developed consisting of hydrogen line, air line, cooling and humidification

line, exhaust line. The control system was developed on the base of dSpace and

LabView hardware and software. It is expected to obtain stable and safe fuel cell

system’s operation and to keep expected parameters levels during operation in variable

conditions. Bench tests allow to verify control and monitoring algorithms and to adapt it

to hybrid vehicle requirements. The final results of work were presented in the research

grant „ Mechatronic system for testing drive with PEM fuel cell, electrochemical battery

and traction motor”.

Fig. 5. The laboratory stand for fuel cell

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2.3. The Clutch

It is originally invented by Prof. Szumanowski. This design is fresh new and it is not

developed, this figure only shows the concept of this design. The status of this clutch is

controlled by the current in electromagnet coil [5], [6].

Fig. 6. The configuration of the new clutch and its model designed in Catia

The results of work were presented on the International Symposium on Electric

Vehicle & 1st Annual Conference of National Engineering Laboratory for Electric

Vehicle in Beijing [10], [16].

electromagnetic clutch/brakeelectromagnetic clutch/brake

Fig. 7. The laboratory stand for hybrid drive

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2.4. The Structure of drive

The department of multisource propulsion systems is designing the structure and

adjustment of the proper energetic parameters of hybrid drives. The results of work were

presented in the two monographs by A. Szumanowski: “Fundamentals of hybrid vehicles

drives”, “Hybrid electric vehicles drives design” and the national research grant: “The

methodology of hybrid bus designing based on the structures with energy accumulation

modeling”. There are presented design the structure and adjustment of the proper

energetic parameters of hybrid drives. Minimizing of the consumption of fuel and

electricity by the proper adjustment of hybrid drive architecture and its control strategy

causes the minimum drive loss or maximum drive efficiency. The background is

parametric optimization based on comparable driving cycles for different power trains

architectures [10], [12], [13], [15], [16], [18], [19].

CU CUBattery

PM

GeneratorPM Motor/

Generator

Battery

monitoring unit

ICE Control

Unit

Throttle

valve

ICEE

Global

Control Unit

CAN bus

AC

DC AC

DC

Driving speed

CU CUBattery

PM

GeneratorPM Motor/

Generator

Battery

monitoring unit

ICE Control

Unit

Throttle

valve

ICEE

Global

Control Unit

CAN bus

AC

DC AC

DC

Driving speed

Fig. 8. The Structure for hybrid drive

where:

ICE – internal combustion engine,

PM Motor/Generator - permanent magnet motor/ generator,

CU – control unit,

AC/DC – converter,

DC/AC – converter.

The control strategy for hybrid electric vehicle (HEV) is difficult and depends on

operation modes, for example: constant speed and constant torque, variable speed and

constant torque, constant speed and variable torque. The results of work were presented

in the national research grants: “The multisource and electric vehicle drives”, and “The

heavy machineries and vehicles hybrid drives components and its control strategies

designing”.

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Fig. 9. The Laboratory stand for hybrid drive

2.5. The electrical differential

ME1J1 ME2 J2ME3 EE

SME1 SME2SME3

dSPACE

enviroment

ME4

SME4

BATBATBAT

I/ O ( dSpace)

ST_BAT

Matlab/ Simulink

ME1, ME2 – electric machines represents the vehicle traction motors

ME3, ME4 – electric machines represents the vehicle torque of resistance

SME1, SME2, SME3, SME4 – electric machines controlers

J1, J2 – inetial loading

E - speedometer

BAT - battery

ST_BAT – battery circuit controler

ME1J1 ME2 J2ME3 EE

SME1 SME2SME3

dSPACE

enviroment

ME4

SME4

BATBATBAT

I/ O ( dSpace)

ST_BAT

Matlab/ Simulink

ME1, ME2 – electric machines represents the vehicle traction motors

ME3, ME4 – electric machines represents the vehicle torque of resistance

SME1, SME2, SME3, SME4 – electric machines controlers

J1, J2 – inetial loading

E - speedometer

BAT - battery

ST_BAT – battery circuit controler

ME1J1 ME2 J2ME3 EE

SME1 SME2SME3

dSPACE

enviroment

ME4

SME4

BATBATBAT

I/ O ( dSpace)

ST_BAT

Matlab/ Simulink

ME1, ME2 – electric machines represents the vehicle traction motors

ME3, ME4 – electric machines represents the vehicle torque of resistance

SME1, SME2, SME3, SME4 – electric machines controlers

J1, J2 – inetial loading

E - speedometer

BAT - battery

ST_BAT – battery circuit controler

ME1J1 ME2 J2ME3 EE

SME1 SME2SME3

dSPACE

enviroment

ME4

SME4

BATBATBAT

I/ O ( dSpace)

ST_BAT

Matlab/ Simulink

ME1, ME2 – electric machines represents the vehicle traction motors

ME3, ME4 – electric machines represents the vehicle torque of resistance

SME1, SME2, SME3, SME4 – electric machines controlers

J1, J2 – inetial loading

E - speedometer

BAT - battery

ST_BAT – battery circuit controler

Fig. 10. The structure of electrical differential and laboratory stand

The picture shows a drawing up model and laboratory stand for research

electromechanical differential wheels. The Hybrid drive has two structural solutions, in

which the vehicle wheels can be driven directly by two or more electric motors for

performing the function of the drive axle differential. The electrical differential is a pair

of motors driving a common axis, another aspect of the application of differential

electrical motors (placed in the wheels) is to lower the vehicle floor. The results of work

were presented in the national grant “The electromechanic differential designing and its

controlling methodology” [14], [15], [19].

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2.6. Prototypes

The prototyped ultra light city vehicle was designed in Catia. The Department of the

Multisource Propulsion Systems in Warsaw University of Technology made prototype

hybrid electric vehicle in collaboration with company MESA. The obtained results look

very optimistic - especially in case of fuel and electricity consumption. The developed

hybrid power train for ultra light city vehicle characterizes low cost and sufficient

performances. The results of work were presented in the national grant “The designing

of lightweight vehicles with hybrid drives” [11], [17], [18], [20].

Fig. 11. The prototypes of city vehicle (project designed in Catia)

3. Conclusions

The modelling of drive and its components are specially emphasized. Nonlinear

dynamics modelling of city vehicle components as well as the entire power trains

including vehicle are backgrounds of city vehicle power trains. Our works are presented

in many conferences for example: EVS (Electric Vehicle Symposium) and The

International Symposium on Electric Vehicles with main organizers: Beijing Institute of

Technology and the Polish Society of Ecological Vehicles. The first symposium started

in 2009 in Beijng and next takes place in Poland (Warsaw) and in China (Beijng)

alternately. The Department of the Multisource Propulsion Systems in Warsaw

University of Technology participated in one EU 6FP HyHEELs, which its finished and

now we are started three in 7FP, and two are in negotiation phase. These projects are

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dedicated to the development, design and implementation of hybrid electric vehicle

technology in Europe.

References:

[1] Antoni Szumanowski, Yuhua Chang, “Battery Management System Based on

Battery Nonlinear Dynamics Modeling” IEEE Transactions on Vehicular

Technology, 2008,

[2] Antoni Szumanowski, Chang Yuhua, Piotr Piórkowski, “Battery parameters

adjustment for series hybrid bus by simulation”, Przegląd Elektrotechniczny”

2006 no. 2,

[3] Antoni Szumanowski, Piotr Piórkowski, "The Ultracapacitors Adjustment for

Urban Hybrid Bus”, European Ele-Drive Conference, International Advanced

Mobility Forum, Geneva, Switzerland, 2008,

[4] Antoni Szumanowski, Piotr Piórkowski „Batteries and Ultracapacitors Set in

Hybrid Propulsion System” 1st Annual Conference of National Engineering

Laboratory for Electric Vehicle, Beijing 2009,

[5] Antoni Szumanowski, Zhiyin Liu, A. Hajduga “New Clutch Solution for Hybrid

Powertrain System”, Beijing 2009,

[6] Antoni Szumanowski, Arkadiusz Hajduga „Optimization Series HEV Drive

Using Modelling and Simulation Methods” IEEE Vehicle Power and Propulsion

Conference, Windsor 2006,

[7] Antoni Szumanowski, Yuhua Chang, Arkadiusz Hajduga, Piotr Piórkowski

"Hybrid drive for ultralight city cars" European Ele-Drive Conference Brussels,

Belgium, 2007,

[8] ChangYuhua, Szumanowski Antoni, „The opportunity of plug-in hybrid vehicle

for market”, Polioptymalizacja i Komputerowe Wspomaganie Projektowania

2008, Koszalin – Sarbinowo,

[9] Antoni Szumanowski, Yuhua Chang, Piotr Piórkowski, “The Development and

The Future of Hybrid Electric Vehicles” Polioptymalizacja i Komputerowe

Wspomaganie Projektowania 2008, Koszalin – Sarbinowo,

[10] Antoni Szumanowski, A. Hajduga “Optimization Series HEV Drive Using

Modelling and Simulation Methods” 1st Annual Conference of National

Engineering Laboratory for Electric Vehicle, Beijing 2009,

[11] Yuhua Chang, Antoni Szumanowski, “Hybrid drive design for minibus by

simulation”, EVS-24, Stavanger Norway, 2009,

[12] Antoni Szumanowski, Yuhua Chang,“The design of hybrid drive system design

by simulation”, International Symposium on Electric Vehicle, Beijing, 2009,

[13] Roszczyk P.: “Engine – Generator Set Operating with Electrochemical Battery in

Hybrid Drive”, International Symposium on Electric Vehicle, Beijing 2009,

[14] Szumanowski Antoni, Nowicki Piotr, Hajduga Arkadiusz „Napęd elektryczny

pary kół pojazdu”, Polioptymalizacja i Komputerowe Wspomaganie

Projektowania, Mielno 2006,

[15] Antoni Szumanowski, Hybrid Electric Vehicle Drives Design - Edition Based On

Urban Buses, MonographBook, ITE Warsaw 2006,

[16] Antoni Szumanowski, Chang Yuhua, Piotr Piórkowski, Analysis of Different

Control Strategies and Operating Modes of Compact Hybrid Planetary

Transmission Drive, IEEE Vehicle Power and Propulsion Conference, Chicago,

Illinois, USA 2005,

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[17] Antoni Szumanowski, Piotr Piórkowski, Ultralight Small Hybrid Vehicles – Why

Not?, EET, Lisboa, Portugal 2004,

[18] Antoni Szumanowski, Piotr Piórkowski, Arkadiusz Hajduga, The hybrid drive for

city bus – the new concept of drive architecture and control strategy, EVS20 Long

Beach, California, USA 2003,

[19] Antoni Szumanowski, Fundamentals of Hybrid Vehicle Drives, Monograph book,

ITE Warsaw 2000,

[20] Antoni Szumanowski, Viet Khoa Nguyen, Arkadiusz Hajduga, Piotr Piórkowski,

Profit Range of the Hybrid Drive Application, Global Powertrain Congress GPC

Detroit, Michigan, USA 2001.

Abstract

This paper is dedicated to people, who are interested in hybrid electric vehicle

propulsion systems. The paper presents the research and activity of the Department of

the Multisource Propulsion Systems in Warsaw University of Technology and show how

we use research tools to design propulsion systems. The Department of the Multisource

Propulsion Systems promotes civilization progress especially in the field of ecological

transport, today called Sustainable Mobility.

The academic goals are scoped on limitation of energy use in road transport owed to

high efficient vehicles and preservation of environment through energy saving,

limitation of pollution, CO2, undoubtedly influencing global climate alterations. It has to

emphasized that road transport is responsible for one fourth of CO2 industrial emission.

We can offer R&D activity - designing and optimizing drive systems for city vehicle

and its structure by modeling and simulation in the laboratory stand, for example: control

strategy, controller, regenerative braking, battery management system, etc.

Keywords: powertrain, vehicle performance, simulation

DZIAŁALNOŚĆ BADAWCZA ZAKŁADU NAPĘDÓW WIELOŹRÓDŁOWYCH

W DZIEDZINACH POJAZDÓW HYBRYDOWYCH

I ALTERNATYWNYCH ŹRÓDEŁ ENERGII

Streszczenie

Kierownikiem Zakładu Napędów Wieloźródłowych umiejscowionego w strukturach

Instytutu Maszyn Roboczych Ciężkich Politechniki Warszawskiej jest prof. Antoni

Szumanowski. Pod Jego kierunkiem prowadzone są badania naukowe oraz prace

rozwojowe dotyczące doboru struktur układu napędowego, projektowania, wykonania

komponentów napędów pojazdów i maszyn roboczych w tym m.in. hybrydowego,

elektrycznego oraz możliwości akumulacji różnych źródeł energii.

Główne kierunki działalności Zakładu Napędów Wieloźródłowych, dotyczą

tematyki naukowo-dydaktycznej z dziedziny napędów elektromechanicznych maszyn

i pojazdów, możliwości odzysku energii kinetycznej podczas hamowania maszyn

i pojazdów oraz sterowania tymi procesami. Prowadzone badania mają na celu

ograniczenia szkodliwości oddziaływania współczesnych środków transportu na

środowisko naturalne oraz zmniejszenie kosztów istniejących rozwiązań oraz

opracowanie praktycznych zasad ekologii transportu, wykorzystując energetykę

alternatywną jako sposób przetworzenia energii dla niekonwencjonalnych pojazdów.

Słowa kluczowe: układ napędowy, badania, sterowanie