MEPCON 2019 Paper 188
MEPCON 2019 Paper 188
MEPCON 2019 Paper 188
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Abstract—The main purpose of this paper is to provide a wide performance of a complete EV powertrain was presented in
parametric design procedure for drivetrain system of electric [6] with experimental evaluation and assessment of each
vehicles (EVs). This method, for a given vehicle's specifications, plant. However, this work considered the possible
can determine both the ratings and maximum capabilities of the performance of the EV based on theoretical calculations
powertrain. The ratings include motor power, torque, speed, using its specifications. Moreover, it lacked to the battery
and battery capacity. In the proposed methodology, the ratings pack calculations. There exist only rare reports in the
consider the maximum velocity and maximum acceleration rate literature addressing the detail calculations of the power
of the vehicle to achieve the heaviest road conditions. The ratings of the drivetrain plants of the EVs/HEVs. The
validation of the proposed methodology is discussed with case
researchers in [7] covered various design aspects of EV
study: Nissan-Leaf2015 E-Car. The performance of the vehicles
development with main focus on powertrain system.
is simulated and assessed with two different driving cycles
(Urban Dynamometer Driving Schedule (UDDS) and high way Reference [8] proposed a methodology for pre-sizing the
ARTEMIS MW_130 and is validated through extensive electric motor propulsion power of an EV. However, the main
simulations at 100% ratings and up to 140% of power ratings. objective here was to find the minimum motor weight,
volume and cost that will meet the design constraints with
Keywords—Electric vehicle, tractive motor ratings, battery minimum power under the European ECE and EUDC driving
capacity, practical driving cycles. cycles. The vehicle level targets were used for developing a
novel approach to optimally size the traction motors using the
I. INTRODUCTION scalable electric machine model [9]. However, the approach
In recent years, more and more electric drives have been was demonstrated on the in-wheel motor electric powertrain.
involved in vehicle traction, such as electric vehicles (EVs), This paper develops a wide parametric design
hybrid electric vehicles (HEVs), and fuel cell powered methodology for the electric propulsion system and its energy
vehicles (FCVs). The drivetrain technologies are the most storage device of the EVs that addresses these challenges. It
promising vehicle solutions for the foreseeable future [1]. A adopts a methodology of assessment of vehicle's performance
modern electric drivetrain consists of three major with simulation results for maximum exploitation of the
subsystems: electric motor propulsion, energy source, and powertrain of EVs. The electric motor optimal power is
auxiliaries. The electric propulsion subsystem comprises the therefore calculated regarding the EV desired performances
vehicle controller, power electronic converter, electric motor, and given driving cycles. The power of the drive system can
mechanical transmission, and driving wheels. The energy be designed by two methods i.e. at maximum speed and at
source subsystem involves the energy source, the energy base speed. At base speed, the power depends on the selected
management unit, and the energy refueling unit. The auxiliary speed ratio which guarantees the designed acceleration rate;
subsystem consists of the power steering unit, the hotel whereas the other power is found to achieve the maximum
climate control unit, and the auxiliary supply unit [2]. A velocity at minimum acceleration rate. The chosen power
vehicle’s driving performance is usually evaluated by its rating has to satisfy the two requirements. The proposed
acceleration time, maximum velocity, and road gradeability. power sizing methodology is illustrated under modified
In EV's drivetrain design, proper motor power rating and Urban Dynamometer Driving Schedule (UDDS) and high way
transmission parameters are the primary considerations to ARTEMIS MW_130 driving cycles [10]. The proposed
meet the performance specification without oversized ratings. design methodology is applied to the commercial Nissan-leaf
The design of all these parameters depends mostly on the 2015 E-car.
speed-power (torque) characteristics of the traction motor and
predicted road circumstances. Some representative driving
cycles (driving schedules) have been developed to emulate
typical traffic environments. These driving cycles are
represented by the vehicle speeds versus the operating time
while driving on a flat road [1].
Some recent studies have reported progress towards the
parametric design of the drivetrain of the EVs [3].
Performance of two of the clean powertrain cars is evaluated
in Lab condition and on road in [4]. Description of a complete
EV system is introduced; and the performance of its
powertrain has been evaluated in [5], in which a test bench is Fig. 1 Forces acting on a vehicle moving up a grade
designed for modelling purposes of small EVs. The
Power
Force
force which is required from the electric powertrain of the
vehicle could be calculated by
= + + + (1)
= + + ( + ) +
(2)
where; , and are the vehicle mass, gravity coefficient Fig. 2. Motor power, traction force and road force versus vehicle's velocity
and the slop of the road, respectively. The vertical rise of the
road ∆ℎ represents the gradeability of the road when the A. Power Rating Design of the Traction Motor Based on
EV is traveled a horizontal distance of 100 . Then, the Maximum Vehicle's Velocity
slop could be found as [12] In this methodology, the rated power of the traction motor
= (3) is calculated when the EV runs at the maximum velocity
(point 1 in Fig. 2). At point 2 in Fig. 2, the total tractive force
Rolling force is the combination of all frictional load almost equals to the road force on gradeability as (4). At this
forces due to the deformation of the tire on the road surface condition, the acceleration force term in (2) could be canceled
and the friction within the drivetrain depend on the rolling i.e. = 0 and minimum road slop is considered.
coefficient . This coefficient is a function of the tire Then, the total tractive force of (2) becomes
material, tire structure, tire temperature and typical values of
rolling resistance coefficients could be found in [1]. The = ( + ) + ( cos + sin ).
resistance of air to the movement of the vehicle is called (5)
aerodynamic force . It depends on air density , frontal Then, the rated power of the traction motor depends on
area of the vehicle , air velocity , vehicle velocity the maximum velocity , the total tractive force and the
and drag coefficient . This coefficient depends on the shape efficiency of transmission gear box and it is expressed as
of the vehicle. The acceleration force due to the gross mass
and vehicle inertia is usually stated as the minimum time to = (6)
accelerate from 0 to 100 km/h on level ground. The effective
mass coefficient accounts for rotating parts and axle inertia B. Power Rating Design of the Traction Motor Based on
Maximum Acceleration Rate
in addition to vehicle mass = + , the
In the second methodology, the rated power is calculated
value of is around 1.08-1.1% [1]. The integration of the at the base velocity and the maximum acceleration rate
rolling, gravity, and aerodynamic forces are known as road
load force . of the vehicle (point 3 in Fig. 2). When the vehicle
is run with its maximum acceleration, it is sense to consider
= + + (4) a flat road ( = 0). Therefore, the total tractive force of (2)
III. PARAMETRIC DESIGN OF ELECTRIC DRIVETRAIN becomes
Power (kW)
100
Maximum velocity [km/h] 144 80 kW 3%
Maximum acceleration [km/h/sec] /dt 100/11.5 80
0%
Distance for one charging cycle [km] D 160 60
Wheel radius [m] 0.315
Transmission ratio 8.19 40 32 kW
Frontal area [m2] 2 20
Axle moment of inertia [kg/m2] J 3
Vehicle's coefficients 0
0 20 40 65 80 96 120 144 160 177 200
Rolling resistance 0.0083 Velocity (km/h)
Air density [kg/m2] 1.2 Fig. 3. Gradeability-based road load power at maximum velocity
Aerodynamic coefficient 0.28 8
X1 = 4
Transmission efficiency 0.96
7
Air velocity [km/h] 12 X2 = 3.3
76kW
-80
140%Rated power operating points
-150
0 50 (a) 100 150
400
Rated Torque
200
V. CONCLUSION
In this paper, the vehicle’s dynamics and the parametric
design of an electric drivetrain for EVs have been presented,
as well as battery capacity considering regenerative braking.
The objective was to assess typical vehicle usage on different
road types and implication on vehicle energy consumption
due to the drive cycles’ characteristics. For this evaluation
one reference vehicle (Nissan-leaf 2015 E-car) is designed
after set the performance requirements. For Nissan E-car,
when considering the maximum velocity for determining of
the power ratings, it was found that the vehicle can run at 144
km/h in a 7% grade road by 80 kW TM; while, when
considering maximum acceleration rate, it was found that the
same performance is got with speed factor of x=3.3.
Furthermore, the battery capacity considering regenerative
braking is found as 24 kWh and 32 kwh for the modified
UDDC and Artemis MW-130 drive cycles, respectively. The
vehicle performance dictates these vehicle capabilities, thus
dictating the power capacity of the powertrain. However, in
normal driving conditions these maximum capabilities are
rarely used. During most of the operation time, the powertrain
operates with partial load.
VI. REFERENCES
[1] Mehrdad Ehsani, Yimin Gao, Stefano Longo, Kambiz M. Ebrahimi,
Modern Electric, Hybrid Electric, and Fuel Cell Vehicles, 3rd Edition,
Taylor & Francis Group, LLC, 2018.
[2] C. C. Chan and K. T. Chau, Modern Electric Vehicle Technology,
Oxford University Press, New York, 2001.
[3] John G. Hayes, G. Abas Goodarzi, Electric Powertrain: Energy Systems,
Power Electronics and Drives for Hybrid, Electric and Fuel Cell
Vehicles. 1st ed., John Wiley & Sons Ltd, 2018.
[4] M. El-Baghdadi, L. De Vroey, T. Coosemans, J. V. Mierlo, W. Foubert,
R. Jahn, “Electric vehicle performance and consumption evaluation”,
World Electric Vehicle Journal Vol. 6, 2013.