Indo German Winter Academy 2010

Hybrid Cars

Presented by : Ruprekha Brahmachari

3rd year,B.Tech (Electrical Engineering)
Indian Institute of Technology, Roorkee

Tutor : Prof. Heiner Ryssel

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 What are Hybrid Vehicles?
A hybrid vehicle is a vehicle that uses two or more distinct power
sources to move the vehicle

Power Power
source Hybrid
Source
1 Vehicle
2

Power Sources-> Gasoline, Hydrogen, Ethanol, Biomass, Electricity,

muscle power, etc
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Hybrid Cars
 Why Hybrid Vehicles?

• Declining fuel reserves

• Increasing Demand
• Environmental Degradation

An electric-powered car cannot go more than 100 miles (161 km)

between recharging, is difficult to re-charge and doesn't drive beyond
60 mpg, although it emits little pollution
Hence, Hybrid Vehicles
Hybrid Vehicles (increased drive train efficiency  30-40%)
• Reduce emission
• Increase fuel economy
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Hybrid Cars
 Why Hybrid Vehicles?

Conventional Car Hybrid Electrical Vehicle

Operating Characteristics of ICE

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Hybrid Cars
 Why Hybrid Electric Vehicles?

Goes Goes
Goes ½ as
1/44 as 1/3rd as
Fuel Biomass far as
Ethanol far as Cell far as
Electric
Electric Electric
Car
Car Car

• ICE only vehicle is inefficient at idle speeds - consumes fuel without providing the
propulsion power
• Conventional vehicle -- only 10%–15% of the energy contained in gasoline is
converted to traction
• ICE -- Perform exceedingly well at constant speeds
• Electric traction motors-> can provide quick acceleration
•Therefore, Hybrid Electric Vehicle -- the drive train efficiency can potentially be improved to
about 30%–40%

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Hybrid Cars
 Main Features and Working

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 Main Features and Working
HEV Efficiency Factors:
• Engine Stop/Start when vehicle at standstill
• Regenerative Braking to charge batteries
• Smaller engine size and reduced emissions
• Vehicle weight and aerodynamic design
• Using low rolling resistance tires

Important Features

• Atkinson Cycle Engine

• Permanent Magnet motor
• Micro-converter and micro-inverter
• Nickel-Metal Hydride/Lithium-Ion battery

Regenerative Braking

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Hybrid Cars
 Topologies

• Series
Advantages

• ICE running mostly at optimal speed

and torque
• ICE can be turned off in zero emission
zone No Mechanical Coupling between ICE and wheels
• Low floor possible
• Low fuel consumption
• High fuel efficiency
Disadvantages

• Many energy conversions -> energy loss

• More suitable for city driving

Chevrolet Volt
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Hybrid Cars
 Topologies

• Parallel
Advantages
Honda Civic hybrid
• ICE directly connected to wheels ->
fewer power conversions Disadvantages
• Electric machine and gearboxes
present -> ICE working pt. can be • ICE & electrical machines must be
chosen freely mounted together -> no low floor

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Hybrid Cars
 Topologies

• Power Split
Advantages

• ICE can be turned off

• ICE speed can be chosen by adjusting
generator speed

Disadvantages

• Power vicious cycle may occur leading

to low efficiency
• Relatively complex
• Expensive

Toyota Prius
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Hybrid Cars
 Topologies

• Power Split
Planetary Gear

• Distribution of the power produced

by the gas/petrol engine to the drive
train and to the generator

• Consisting of a ring gear, pinion

gears, a sun gear and a planetary
carrier.

Courtesy : www.hybridsynergydrive.com

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Hybrid Cars
 Hybrid Levels
Hybrid is defined in different levels: micro, mild, full, and plug in hybrid.
Micro and micro/mild hybrid Mild and full hybrid
650V DC
120/400V DC/DC DC/AC
DC/AC Micro Inverter Alternator High V Boost Micro E Motor
Battery Converter
DC/DC Boost DC/DC Inverter
Converter Converter
ICE ICE
14V battery 14V battery

Plug in hybrid and EV

650V DC AC Link
120/400V DC/DC DC/AC
High V Boost E Motor DC Link
Micro
Battery Converter Inverter
DC/DC
AC/DC Converter
Charger ICE
14V battery

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Hybrid Cars
 Hybrid Levels : Mild Hybrid
Key Features :
• a special starter, turns off engine when
the car brakes, coasts or stops, and
then seamlessly restarts -> saves fuel

• electric motor in a mild hybrid cannot

(and does not) actually propel the
vehicle on its own.

• Acts as a power booster

Advantage:
• More fuel efficient (10-15%)
compared to conventional gas
powered car

• less expensive than fully hybrid

Disadvantage:
Less fuel efficient than fully hybrid

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Hybrid Cars
 Hybrid Levels : Plug-in hybrid
Key Features:
• Rechargeable batteries
• Electric motor -> primary power source,
gasoline engine -> supplemental motivation

• Require deeper battery charging and

discharging cycles than conventional hybrids

• Charging topologies
―On-board chargers
―Off-board chargers
―Using electric motor's inverter and
inductance
• Modes of Operation
― Charge-depleting mode
― Charge-sustaining mode
― Mixed mode

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 Hybrid Levels : Plug-in hybrid
Advantages:
• Energy resilience and petroleum
displacement
• Fuel efficiency
• Lower greenhouse gas emissions
• Lower operating costs
• Range anxiety elimination
• Reduction of smog
• Vehicle-to-grid electricity

Disadvantages:
• Cost of batteries
• Recharging outside home garages
• Emissions shifted to electric plants in some countries
• Lithium availability and supply security

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 Hybrid Levels
Comparison between Electric vehicle, micro, mild, full and plug-in hybrid
Functions Micro & Micro- Mild Full Hybrid Plug in EV
Mild hybrid Hybrid hybrid
(PHEV)
Start/Stop
Regenerate braking
(micro-mild only)

Additional electric power for

few seconds (micro-mild only)

Electric power for mild

distance (city)
Electric power for long
distance & recharge on grid
Energy Savings 5-10% 10-25% 25-40% 50-100% 100%
(upto 25% in city
traffic)

Electric Power 1.5-10KW 5-20kW 30-75kW 70-100kW 30-100kW

Car Examples PSA C2 Honda Toyota GM Volt Nissan leaf

Civic Prius
Courtesy : http://www.powersystemsdesign.com/power-electronics-in-electric--hybrid-vehicles
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Hybrid Cars
 Hybrid Vehicle Battery
Key Features:
• Electrolyte ->
– liquid, gel, or solid material.
– acidic or alkaline, depending on the type of battery
• advanced batteries -> a gel, paste, or resin
• Pb-acid, NiMH, and Lithium (Li)-ion batteries

Salient points for traction batteries:

• one charge to provide a long range or mileage
• stable power with deep discharge characteristics to allow for acceleration and
ascending power capability of the EV
• Long cycle life with maintenance free and high safety mechanisms built into the
battery
• Wide acceptance as a recyclable battery from the environmental standpoint

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Hybrid Cars
 Hybrid Vehicle Battery
Nickel Metal Hydride Battery

Pros
• energy density of 30-80Wh/kg
• can have exceptionally long lives if
used properly
• Faster charging

Cons
• poor efficiency Courtesy: http://batterydata.com/
• high self-discharge
• very finicky charge cycles
• poor performance in cold weather

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Hybrid Cars
 Hybrid Vehicle Battery
Lithium Ion Battery
Pros
• High energy density
• Solid electrolyte
• typically 40% smaller and weigh half than
NiMH
• open circuit voltage (OCV) of approximately 3-
4V at full charge Courtesy: http://batterydata.com/
• Lesser charge discharge time
• More environment friendly

Cons
• Overcharging may cause damage to electrodes
• Dangerous if not handled carefully
• Safety features required for both cell and
battery pack

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Hybrid Cars
 Power Electronics Module (PEM)
• power inverter and charging system

72 insulated gate
bipolar
DC Power AC Power
transistors
(IGBTs).

• increase in power output compared to first-generation electric

cars (o/p ~ 200kW at peak accl.)
• Control charge and discharge rates
• Controls voltage levels, the motor's RPM, torque and
the regenerative braking system
• Aluminum heat dissipation fins and a rear-mounted ventilation
port -> overheating protection

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 Power Electronics Module (PEM)
Main Components
• Resistors used in:
o Inrush Current Limiting Resistors o Active Battery Cell Balancing
o Battery Charging Systems o Current Sense
o Inverters o Power Management on High Voltage
o Load Dump and Transient Resistors Buses
o Capacitor Discharge o Resistive Heaters
o Fuel Cell Load Dump and
Management

• High voltage capacitors to filter and maintain the charging

system voltage
• Position sensors -> inductive type

• Inverters and converters to provide power at voltage levels to

support the BAS from the vehicle charging system

• Inverters (DC -> AC) for electric motor

• Converter (AC/DC to different voltage value)

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 Power Electronics Module (PEM)
Main Electronic Components

Courtesy: www.ttelectronics.com
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Hybrid Cars
 Power Electronics Module (PEM)
Main Electronic Components

Courtesy: www.ttelectronics.com

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Hybrid Cars
 Inverters and Converters
Inverters and converters combined into one unit manage the power and recharging
circuits in hybrids and electric vehicles

• Direct current is supplied by the battery and must be

converted by power electronics to the alternating current
required by the motor

• Both hybrids and EVs use relatively low voltage DC batteries

(about 210-V) to keep the physical size (and cargo space
consumed) down

• Generally use highly efficient, and high voltage (about 650V)

AC motor/generators

• The inverter/converter unit choreographs how these

divergent voltages and current types work together
Courtesy : http://www.hybridsynergydrive.com/
• These may have their own dedicated cooling system
independent from engine’s cooling system

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Hybrid Cars
 Inverters and Converters
Inverter

High-Voltage DC from
Inverter 3-Phase AC for motor
HV battery

Inverters are roughly the same for full hybrid, plug in hybrid and EV cars with an average
power of 50kW.
Device/Material Choice

IGBT SiC GaN

• high power applications • better power density • better performance/
• High efficiency • less losses cost ratio compared to
• Fast switching • higher operating SiC
• Problem – dissipation temperature – low
of heat generated cooling costs
• Problem - Cost

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Hybrid Cars
 Inverters and Converters
Inverter
• Converts DC from battery to AC for running the motor
• The inverter assembly includes a separate inverter for the air conditioning system
• Converts 201.6V DC into 201.6AC (Toyota Prius) to power the AC system’s electric
inverter compressor

Inverter Assembly Diagram

AC Inverter

Courtesy : www.autoshop101.com
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Hybrid Cars
 Inverters and Converters
Converter
• Voltage-Boosting Converter
– steplessly increases the normal 201.6 V DC supply to feed the electric motors and
the generator as required
– more power can be generated from a small current to bring out high
performance from the high output motors
– enhancing overall system efficiency
– also means that the inverter could be made smaller and lighter

• DC/DC Converter
– steps down the 201.6
V supply voltage from
the battery to 14 V to
be used by ancillary
systems and electronic
devices like the ECU.

DC/DC Converter (Courtesy:www.autoshop101.com)

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Hybrid Cars
 Vehicle System Controller
• The brains of the vehicle

• built into the powertrain control module

• manages charging, drive assist and starting

• Regenerative Braking

•Controls operation of hybrid transaxle

•The electronically-controlled,
controlled, continuously variable transmission (eCVT) controls the
ICE and electric motors to drive the wheels and affords smooth accelerations,
upshifts and downshifts

•It
It oversees the operation of the inverter and converter as they balance the power
requirements of the vehicle’s many 14-volt
volt components and the high voltage
components of the hybrid system powertrain

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Hybrid Cars
 Vehicle System Controller
collects and communicates
processes the with the necessary
necessary data makes a decision system(s) which
from the other are responsible for
systems the final execution

• The choice of energy source(s) for a

particular HEV is governed by the HEV
strategy of the vehicle.

• One area which is monitored and

controlled by the HEV strategy is the
state of the batteries.

• Therefore, a well designed algorithm

could optimise the process, and help to
increase the benefits of the HEV
application.

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Hybrid Cars
 Available Hybrid Car Models

Toyota Prius Honda Civic Nissan Altima Ford Escape

Hybrid Hybrid Hybrid
Specifications
Engine size 1.5 1.3 2.5 2.5
Cylinder 4 4 4 4
Transm. Charact. VMODE VLKUP EMS EMS VLKUP
Fuel Economy Average of 25 cars Average of 14 cars Average of 5 cars Average of 5 cars
estimates 4.6 5.1 7.1 6.8
(from drivers) 2.9 (lo) 5.9(hi) 3.7(lo) 6.2(hi) 6.2(lo) 9.4(hi) 6.4(lo) 7.4(hi)

Annual 7.4 Barrels 8.2 Barrels 10.1 Barrels 10.7 Barrels

Petroleum
Consumption
Metric tonnes of 3.7 4.1 5.0 5.3
CO2
emitted(p.a.)
Courtesy : www.fueleconomy.gov
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 Indian Hybrid Car Models
REVA NXP
Speed : 104 km/h
Distance : 160 km
Weight(empty) : 700 kg
E-motor : 13kW (max.)
Battery : 72 V (14 kWh) Li-ion or 48 V Pb-acid
Energy recuperation

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Hybrid Cars
 Future of Hybrid Cars
Pros Cons
• Environment Friendly • Car can be expensive –high maintenance
• Fuel Efficient cost
• Reduced Noise • Different drive experience – heavier car
• Better Performance • Less Power
• Financial Benefits – Govt. aid • Low fuel mileage on highway
• Safety - risk of exposure to high voltage
wires in case of crash
• Disposal of Hybrid car battery

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Hybrid Cars
 References
•http://www.hybridcars.com/frontpage
•http://ezinearticles.com/?Hybrid-Cars---The-Vehicle-For-The-Future-For-The-People-On-Todays-
Roads&id=1031265
•http://www.authorstream.com/Presentation/aSGuest55594-443754-hybrid-vehicles/
•http://t3.gstatic.com/images?q=tbn:ANd9GcSdQjI-_DXAL7Ls5lgNdgwrmciae98l74Nj1kNxgIrnBWXVo2UJkA
•http://www.hybridcars.com/top-hybrid-cars-list
•http://www.forbes.com/2009/05/29/confusing-car-technology-lifestyle-vehicles-confusing-
technology_slide_6.html
•http://www.calcars.org/vehicles.html
•http://en.wikipedia.org/wiki/Plug-in_hybrid
•http://www.whyhybridcars.net/page/3/
•http://www.cartsand.com/articles/2008/06/coming-up-greener-auto-engines.html
•http://www.allabouthybridcars.com/ebook/how-hybrids-work3.htm
•http://www.teslamotorsclub.com/showthread.php/2126-Roadster-under-the-skin
•http://www.fueleconomy.gov/feg/hybrid_sbs.shtml
•http://www.hybridcars.com/hybrid-car-battery
•http://auto.howstuffworks.com/car-models/plug-in-hybrids/plug-in-hybrid-car.htm
•http://en.wikipedia.org/wiki/Electric_vehicle_conversion
•http://www.dolcera.com/wiki/index.php?title=Hybrid_Electric_Vehicle_Battery_System
•http://www.hybridcars.com/hybrid-car-battery
•http://www.powersystemsdesign.com/power-electronics-in-electric--hybrid-vehicles?a=1&c=1153
•http://www.scientificamerican.com/blog/post.cfm?id=hybrid-cars-which-is-most-fuel-effi-2008-10-21
•http://www.powerdesignindia.co.in/STATIC/PDF/201002/PDIOL_2010FEB16_PORTP_TA_01.pdf?SOURCES=DOWNLOA
D
•http://www.wired.com/autopia/2010/12/dual-battery-powers-electric-bus-of-tomorrow/

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 References
• K. Jonasson, “Analysing Hybrid Drive System Topologies”, 2002, Lund University
•A. Emadi, “Topological Overview of Hybrid Electric and Fuel Cell Vehicular Power
System Architectures and Configurations”, IEEE TRANSACTIONS ON VEHICULAR
TECHNOLOGY, VOL. 54, NO. 3, MAY 2005
•W. M. Arshad, E. Nordlund, P. Thelin, System ”New Drive Topologies for Hybrid-
Electric Vehicles”, Kungliga Tekniska Högskolan
• G. Berdichevsky, K.Kelty, JB Straubel and E.Toomre, “The Tesla Roadster Battery
System, Tesla Motors”, 2006
• M. Olszewski “Evaluation of 2004 Toyota Prius Hybrid Electric Drive”, Oak Ridge
National Laboratory, May 2005
• H. Wetzel, R. Bonert, F.P. Dawson, “Converter Configurations for a Serial Hybrid
Drive Assuming only Capacitive Energy Storage”
• Electric Vehicle Battery Systems
• B. Randall, “The Future of Cars is Electric”, Tesla Motors, 2008
• M. Golub, J. Zhang, ”Electric Cars in Arctic Regions”, University of Alaska
Fairbanks, Centre for Research Services, Flint Hills Resources
• Dr Geoff Walker, “Hybrid Electric Vehicles meet the Electricity Grid: Plug-in
Hybrids (PHEVs) & Vehicle to Grid (V2G)”, Sustainable Energy Research Lab, School
of Information Technology and Electrical Engineering, University of Queensland
• EV101: Owning and Operating an Electric Vehicle (Graunke)
• B. Bruninga, “Prius / Power / Energy”, Feb 2008
• Reviving the Electric Car
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 Hybrid Cars : Atkinson’s Cycle
Ideal Atkinson’s cycle :
1-2 Isentropic or reversible adiabatic compression
2-3 Isochoric heating ( Qp )
3-4 Isobaric heating ( Qp' )
4-5 Isentropic expansion
5-6 Isochoric cooling ( Qo )
6-1 Isobaric cooling ( Qo' )
Goal :
• to allow the pressure in the combustion chamber
at the end of the power stroke to be equal to
atmospheric pressure
• thus, all the available energy has been obtained
from the combustion process.
• the greater expansion ratio => more energy to be
converted from heat to useful mechanical energy
 the engine is more efficient.

Disadvantage :
Reduced power density

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 Hybrid Cars : An Example
“Two-mode" hybrid transmission :

Input-split mode —
• Low speeds – either electric
motor/generators, the internal combustion
engine, or both (full hybrid)
• All accessories still remain functioning on
electric power,
• the engine can restart instantly if needed
• one of the motor/generators (M/G 1) acts as
a generator, while the other operates as a
motor (M/G 2)
• operational for the two continuously variable
ranges (input split and compound split)) of the
transmission

Compound-split mode —
• Higher speeds or heavier loads – the internal
Jointly developed by General Motors, Daimler, and Chrysler LLC,
combustion engine always runs
with BMW joining in 2005
• the system uses advanced technologies
like Active Fuel Management and late intake
valve closing to optimize engine and fuel
efficiency
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Hybrid Cars
 Hybrid Cars : Topologies

Number of components included in the presented topologies. Figures in parenthesis

mark possibility for divergent number of components

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 Hybrid Cars : Components Detail
Internal Permanent Magnet Motor

• Internal permanent magnets embedded within the rotor to

create the superior flux density and distribution that gives
the improvement in torque density
• Typical applications will be those where high torque is
required such as lifts/elevators cranes/hoists and machine
tool axes and spindles. However the new IPM motors also
offer advantages where large amounts of energy are
consumed such as in continuous-duty fans, pumps and
compressors
• In direct-drive spindles for machine tools the heat-rise
characteristic of the motors is one-third that of a
conventional ac induction motor. Minimising heat losses
not only saves energy but also helps maintain the precision
of the machine tool
• IPM takes up lesser space and has simpler speed control
Courtesy : www.yaskawa.com
• Moreover the IPM motor is more efficient converting
97.5percent of the available electricity into motive energy
in assist mode which compares with 94.6 per cent
previously

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 Hybrid Cars : Regenerative braking
Regenerative Braking : Conventional Braking :
Slows vehicle by converting its Kinetic energy converted to heat
kinetic energy into another form by friction in brake linings and
wasted

Limitations :
• The regenerative braking effect drops off at lower speeds
• Friction Brake required as backup
• Friction based braking required in cases of adverse conditions in two-wheel
drive vehicles
• It is normal to also incorporate dynamic braking to absorb the excess energy
• Friction braking is required to absorb the surplus energy in order to allow an
acceptable emergency braking performance

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Hybrid Cars
 Hybrid Cars : Regenerative braking

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Hybrid Cars
 Hybrid Cars : Active battery cell balancing
Multi cell battery prevented from giving its maximum energy output due to cell imbalance.

Causes of cell imbalance: Methods:

• non-uniform thermal stress • Passive cell balancing – uses a straightforward
• impedance deltas cell discharge path that provides a current
• poor cell capacity matching bleed for higher voltage cells until all cell
• and chemical variations. voltages are equal
Solutions: • Active cell balancing – uses capacitive or
• cell choice inductive charge shuttling to transfer charge
• good pack design. between battery cells

Courtesy : http://www.powerdesignindia.co.in/STATIC/PDF/201002/PDIOL_2010FEB16_PORTP_TA_01.pdf?SOURCES=DOWNLOAD
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 Hybrid Cars : ‘Dual Battery’
GE Global Research Centre has come up with a new type of battery – ‘dual battery’
for hybrid vehicles

The system combines a high-energy density sodium battery with a high-power

lithium-ion battery. It’s betting the technology accelerates the electrification of buses,
delivery trucks and other large heavy-duty fleet vehicles.

Why?

Because the combination of high-energy and high-power storage capacity could

achieve optimal range and performance requirements for large vehicles in a battery
of reasonable size and price.

Lithium ion batteries provide lots of power for optimal acceleration at the expense of
storage capacity — aka range. Sodium batteries can store lots of energy but aren’t
optimized for power

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 Hybrid Cars : Plug-in Hybrid Vehicles
Charging Topologies

On-board chargers which are mounted inside the vehicle. The connector to the grid is
standardisized, so that the hybrid can be charged at home as well as at charging stations in
the cities. The on-board charger spends place and weight of the vehicle, and so the power
for charging via grid is limited to a few kilowatts.

Off-board chargers are much bigger and more heavier than on-board chargers, so they are
mounted stationary, for example in the garage. They have more power and can charge the
vehicle's battery more faster. Off-board chargers are adapted to the vehicle's battery
(voltage, charging method,...) and need special connectors to the vehicle.

Using electric motor's inverter and inductance has the advantage, that no much extra
space and weight is required. The charging method is on-board, grid flexible with standard
connector, cost efficient and with high power capacity. The electric machine must be
designed for this method, and the inverter needs some extensions. AC Propulsion for
example uses this charging method.

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 Hybrid Cars : Plug-in Hybrid Vehicles
Modes of Operation

Charge-depleting mode allows a fully charged PHEV to operate exclusively (or depending on
the vehicle, almost exclusively, except during hard acceleration) on electric power until its
battery state of charge is depleted to a predetermined level, at which time the vehicle's
internal combustion engine or fuel cell will be engaged. This period is the vehicle's all-
electric range. This is the only mode that a battery electric vehicle can operate in, hence
their limited range.
Charge-sustaining mode is used by production hybrid vehicles (HEVs) today, and combines
the operation of the vehicle's two power sources in such a manner that the vehicle is
operating as efficiently as possible without allowing the battery state of charge to move
outside a predetermined narrow band. Over the course of a trip in a HEV the state of charge
may fluctuate but will have no net change. The battery in a HEV can thus be thought of as an
energy accumulator rather than a fuel storage device. Once a plug-in hybrid has exhausted
its all-electric range in charge-depleting mode, it can switch into charge-sustaining mode
automatically.

Mixed mode describes a trip in which a combination of the above modes are utilized. This
contrasts with a charge-depleting trip which would be driven within the limits of a PHEV's
all-electric range. Conversely, the portion of a trip which extends beyond the all-electric
range of a PHEV would be driven primarily in charge-sustaining mode, as used by a
conventional hybrid.

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Hybrid Cars