Hybrid Electric Vehicle System Modeling and Control

Revised edition of: Introduction to hybrid vehicle system modeling and control.

Preface xiv
List of Abbreviations xviii
Nomenclature xxii
1 Introduction 1
1. 1 Classification of Hybrid Electric Vehicles 2
1. 1. 1 Micro Hybrid Electric Vehicles 2
1. 1. 2 Mild Hybrid Electric Vehicles 2
1. 1. 3 Full Hybrid Electric Vehicles 3
1. 1. 4 Electric Vehicles 3
1. 1. 5 Plug-in Hybrid Electric Vehicles 4
1. 2 General Architectures of Hybrid Electric Vehicles 4
1. 2. 1 Series Hybrid 4
1. 2. 2 Parallel Hybrid 5
1. 2. 3 Series-Parallel Hybrid 6
1. 3 Typical Layouts of the Parallel Hybrid Electric Propulsion System 7
1. 4 Hybrid Electric Vehicle System Components 8
1. 5 Hybrid Electric Vehicle System Analysis 10
1. 5. 1 Power Flow of Hybrid Electric Vehicles 10
1. 5. 2 Fuel Economy Benefits of Hybrid Electric Vehicles 11
1. 5. 3 Typical Drive Cycles 11
1. 5. 4 Vehicle Drivability 11
1. 5. 5 Hybrid Electric Vehicle Fuel Economy and Emissions 13
1. 6 Controls of Hybrid Electric Vehicles 13
References 14
2 Basic Components of Hybrid Electric Vehicles 15
2. 1 The Prime Mover 15
2. 1. 1 Gasoline Engines 15
2. 1. 2 Diesel Engines 17
2. 1. 3 Fuel Cells 17
2. 2 Electric Motor with a DC-DC Converter and a DC-AC Inverter 20
2. 3 Energy Storage System 21
2. 3. 1 Energy Storage System Requirements for Hybrid Electric Vehicles 21
2. 3. 2 Basic Types of Battery for Hybrid Electric Vehicle System Applications 25
2. 3. 3 Ultracapacitors for Hybrid Electric Vehicle System Applications 34
2. 4 Transmission System in Hybrid Electric Vehicles 35
References 37
3 Hybrid Electric Vehicle System Modeling 38
3. 1 Modeling of an Internal Combustion Engine 38
3. 1. 1 Cranking (Key Start) 39
3. 1. 2 Engine Off 41
3. 1. 3 Idle 41
3. 1. 4 Engine On 41
3. 1. 5 Engine Fuel Economy and Emissions 44
3. 2 Modeling of an Electric Motor 48
3. 2. 1 Operation in the Propulsion Mode 48
3. 2. 2 Operation in the Regenerative Mode 49
3. 2. 3 Operation in Spinning Mode 49
3. 3 Modeling of the Battery System 53
3. 3. 1 Modeling Electrical Behavior 54
3. 3. 2 SOC Calculation 56
3. 3. 3 Modeling Thermal Behavior 56
3. 4 Modeling of the Transmission System 59
3. 4. 1 Modeling of the Clutch and Power Split Device 60
3. 4. 2 Modeling of the Torque Converter 67
3. 4. 3 Modeling of the Gearbox 69
3. 4. 4 Modeling of the Transmission Controller 70
3. 5 Modeling of a Multi-mode Electrically Variable Transmission 73
3. 5. 1 Basics of One-mode ECVT 73
3. 5. 2 Basics of Two-mode ECVT 78
3. 6 Lever Analogy as a Tool for ECVT Kinematic Analysis 85
3. 6. 1 Lever System Diagram Set-up 85
3. 6. 2 Lever Analogy Diagram for ECVT Kinematic Analysis 87
3. 7 Modeling of the Vehicle Body 91
3. 8 Modeling of the Final Drive and Wheel 92
3. 8. 1 Final Drive Model 92
3. 8. 2 Wheel Model 92
3. 9 PID-based Driver Model 94
3. 9. 1 Principle of PID Control 95
3. 9. 2 Driver Model 96
References 96
4 Power Electronics and Electric Motor Drives in Hybrid Electric Vehicles 97
4. 1 Basic Power Electronic Devices 97
4. 1. 1 Diodes 98
4. 1. 2 Thyristors 99
4. 1. 3 Bipolar Junction Transistors (BJTs) 101
4. 1. 4 Metal Oxide Semiconductor Field Effect Transistors (MOSFETs) 103
4. 1. 5 Insulated Gate Bipolar Transistors (IGBTs) 105
4. 2 DC-DC Converters 107
4. 2. 1 Basic Principle of a DC-DC Converter 107
4. 2. 2 Step-down (Buck) Converter 109
4. 2. 3 Step-up (Boost) Converter 117
4. 2. 4 Step-down/up (Buck-boost) Converter 121
4. 2. 5 DC-DC Converters Applied in Hybrid Electric Vehicle Systems 125
4. 3 DC-AC Inverters 129
4. 3. 1 Basic Concepts of DC-AC Inverters 129
4. 3. 2 Single-phase DC-AC Inverters 134
4. 3. 3 Three-phase DC-AC Inverters 137
4. 4 Electric Motor Drives 141
4. 4. 1 BLDC Motor and Control 141
4. 4. 2 AC Induction Motor and Control 152
4. 5 Plug-in Battery Charger Design 162
4. 5. 1 Basic Configuration of a PHEV/BEV Battery Charger 162
4. 5. 2 Power Factor and Correcting Techniques 164
4. 5. 3 Controls of a Plug-in Charger 168
References 168
5 Energy Storage System Modeling and Control 169
5. 1 Introduction 169
5. 2 Methods of Determining the State of Charge 171
5. 2. 1 Current-based SOC Determination Method 172
5. 2. 2 Voltage-based SOC Determination Method 177
5. 2. 3 Extended Kalman-filter-based SOC Determination Method 183
5. 2. 4 SOC Determination Method Based on Transient Response Characteristics (TRCs) 186
5. 2. 5 Fuzzy-logic-based SOC Determination Method 189
5. 2. 6 Combination of SOCs Estimated Through Different Approaches 191
5. 2. 7 Further Discussion on SOC Calculations in Hybrid Electric Vehicle Applications 192
5. 3 Estimation of Battery Power Availability 196
5. 3. 1 PNGV HPPC Power Availability Estimation Method 198
5. 3. 2 Revised PNGV HPPC Power Availability Estimation Method 199
5. 3. 3 Power Availability Estimation Based on the Electrical Circuit Equivalent Model 200
5. 4 Battery Life Prediction 207
5. 4. 1 Aging Behavior and Mechanism 207
5. 4. 2 Definition of the State of Life 209
5. 4. 3 SOL Determination under Storage Conditions 210
5. 4. 4 SOL Determination under Cycling Conditions 214
5. 4. 5 Lithium Metal Plating Issue and Symptoms in Li-ion Batteries 223
5. 5 Cell Balancing 224
5. 5. 1 SOC Balancing 224
5. 5. 2 Hardware Implementation of Balancing 224
5. 5. 3 Cell-balancing Control Algorithms and Evaluation 227
5. 6 Estimation of Cell Core Temperature 236
5. 6. 1 Introduction 236
5. 6. 2 Core Temperature Estimation of an Air-cooled, Cylinder-type HEV Battery 237
5. 7 Battery System Efficiency 241
References 242
6 Energy Management Strategies for Hybrid Electric Vehicles 243
6. 1 Introduction 243
6. 2 Rule-based Energy Management Strategy 244
6. 3 Fuzzy-logic-based Energy Management Strategy 245
6. 3. 1 Fuzzy Logic Control 246
6. 3. 2 Fuzzy-logic-based HEV Energy Management Strategy 253
6. 4 Determination of the Optimal ICE Operational Points of Hybrid Electric Vehicles 261
6. 4. 1 Mathematical Description of the Problem 261
6. 4. 2 Procedures of Optimal Operational Point Determination 263
6. 4. 3 Golden Section Searching Method 264
6. 4. 4 Finding the Optimal Operational Points 265
6. 4. 5 Example of the Optimal Determination 265
6. 4. 6 Performance Evaluation 269
6. 5 Cost-function-based Optimal Energy Management Strategy 278
6. 5. 1 Mathematical Description of Cost-function-based Optimal Energy Management 279
6. 5. 2 An Example of Optimization Implementation 282
6. 6 Optimal Energy Management Strategy Incorporated with Cycle Pattern Recognition 282
6. 6. 1 Driving Cycle/Style Pattern Recognition Algorithm 282
6. 6. 2 Determination of the Optimal Energy Distribution 285
References 287
7 Other Hybrid Electric Vehicle Control Problems 288
7. 1 Basics of Internal Combustion Engine Control 288
7. 1. 1 SI Engine Control 288
7. 1. 2 Diesel Engine Control 289
7. 2 Engine Torque Fluctuation Dumping Control Through the Electric Motor 289
7. 2. 1 Sliding Mode Control 293
7. 2. 2 Engine Torque Fluctuation Dumping Control Based on the Sliding Mode Control Method 296
7. 3 High-voltage Bus Spike Control 298
7. 3. 1 Bang-Bang Control Strategy of Overvoltage Protection 300
7. 3. 2 PID-based ON/OFF Control Strategy for Overvoltage Protection 301
7. 3. 3 Fuzzy-logic-based ON/OFF Control Strategy for Overvoltage Protection 301
7. 4 Thermal Control of an HEV Battery System 304
7. 4. 1 Combined PID Feedback with Feedforward Battery Thermal System Control Strategy 306
7. 4. 2 Optimal Battery Thermal Control Strategy 308
7. 5 HEV/EV Traction Motor Control 311
7. 5. 1 Traction Torque Control 311
7. 5. 2 Anti-rollback Control 313
7. 6 Active Suspension Control in HEV/EV Systems 313
7. 6. 1 Suspension System Model of a Quarter Car 314
7. 6. 2 Active Suspension System Control 318
7. 7 Adaptive Charge-sustaining Setpoint and Adaptive Recharge SOC Determination for PHEVs 325
7. 7. 1 Scenarios of Battery Capacity Decay and Discharge Power Capability Degradation 326
7. 7. 2 Adaptive Recharge SOC Termination Setpoint Control Strategy 326
7. 8 Online Tuning Strategy of the SOC Lower Bound in CS Operational Mode 333
7. 8. 1 PHEV Charge-sustaining Operational Characteristics 333
7. 8. 2 PHEV Battery CS-operation SOC Lower Bound Online Tuning 335
7. 9 PHEV Battery CS-operation Nominal SOC Setpoint Online Tuning 343
7. 9. 1 PHEV CS-operation Nominal SOC Setpoint Determination at BOL 343
7. 9. 2 Online Tuning Strategy of PHEV CS-operation Nominal SOC Setpoint 345
References 347
8 Plug-in Charging Characteristics, Algorithm, and Impact on the Power Distribution System 348
8. 1 Introduction 348
8. 2 Plug-in Hybrid Vehicle Battery System and Charging Characteristics 349
8. 2. 1 AC-120 Plug-in Charging Characteristics 349
8. 2. 2 AC-240 Plug-in Charging Characteristics 350
8. 2. 3 DC Fast-charging Characteristics 353
8. 3 Battery Life and Safety Impacts of Plug-in Charging Current and Temperature 355
8. 4 Plug-in Charging Control 355
8. 4. 1 AC Plug-in Charge Control 355
8. 4. 2 DC Fast-charging Control 358
8. 5 Impacts of Plug-in Charging on the Electricity Network 360
8. 5. 1 Impact on the Distribution System 360
8. 5. 2 Impact on the Electric Grid 362
8. 6 Optimal Plug-in Charging Strategy 364
8. 6. 1 The Optimal Plug-in Charge Back Point Determination 364
8. 6. 2 Cost-based Optimal Plug-in Charging Strategy 366
References 372
9 Hybrid Electric Vehicle Vibration, Noise, and Control 373
9. 1 Basics of Noise and Vibration 373
9. 1. 1 Sound Spectra and Velocity 373
9. 1. 2 Basic Quantities Related to Sound 374
9. 1. 3 Frequency Analysis Bandwidths 380
9. 1. 4 Basics of Vibration 382
9. 1. 5 Basics of Noise and Vibration Control 389
9. 2 General Description of Noise, Vibration, and Control in Hybrid Electric Vehicles 391
9. 2. 1 Engine Start/Stop Vibration, Noise, and Control 392
9. 2. 2 Electric Motor Noise, Vibration, and Control 400
9. 2. 3 Power Electronics Noise and Control 405
9. 2. 4 Battery System Noise, Vibration, and Control 408
References 411
10 Hybrid Electric Vehicle Design and Performance Analysis 412
10. 1 Hybrid Electric Vehicle Simulation System 412
10. 2 Typical Test Driving Cycles 414
10. 2. 1 Typical EPA Fuel Economy Test Schedules 414
10. 2. 2 Typical Supplemental Fuel Economy Test Schedules 418
10. 2. 3 Other Typical Test Schedules 421
10. 3 Sizing Components and Vehicle Performance Analysis 430
10. 3. 1 Drivability Calculation 431
10. 3. 2 Preliminary Sizing of the Main Components of a Hybrid Electric Vehicle 433
10. 4 Fuel Economy, Emissions, and Electric Mileage Calculation 454
10. 4. 1 Basics of Fuel Economy and Emissions Calculation 454
10. 4. 2 EPA Fuel Economy Label Test and Calculation 457
10. 4. 3 Electrical Energy Consumption and Miles per Gallon Gasoline Equivalent Calculation 463
References 478
Appendix A 480
Appendix B 520
Index 553