Electric Powertrain :Energy Systems, Power Electronics & Drives for Hybrid, Electric & Fuel Cell Vehicles

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Chapter

1.1.2 Part II – The Resurgent Electric Powertrain

1.1.3 Part III – Success at Last for the Electric Powertrain

1.2 Energy Sources for Propulsion and Emissions

1.2.1 Carbon Emissions from Fuels

1.2.1.1 Example: Carbon Dioxide Emissions from the Combustion of Gasoline

1.2.2 Greenhouse Gases and Pollutants

1.2.2.1 The Impact of NOx

1.3 The Advent of Regulations

1.3.1 Regulatory Considerations and Emissions Trends

1.3.2 Heavy-Duty Vehicle Regulations

1.4 Drive Cycles

1.4.1 EPA Drive Cycles

1.5 BEV Fuel Consumption, Range, and mpge

1.6 Carbon Emissions for Conventional and Electric Powertrains

1.6.1 Well-to-Wheel and Cradle-to-Grave Emissions

1.6.2 Emissions due to the Electrical Grid

1.6.2.1 Example: Determining Electrical Grid Emissions

1.7 An Overview of Conventional, Battery, Hybrid, and Fuel Cell Electric Systems

1.7.1 Conventional IC engine Vehicle

1.7.2 BEVs

1.7.3 HEVs

1.7.3.1 Series HEV

1.7.3.2 Parallel HEV

1.7.3.3 Series-Parallel HEV

1.7.4 FCEV

1.7.5 A Comparison by Efficiency of Conventional, Hybrid, Battery, and Fuel Cell Vehicles

1.7.6 A Case Study Comparison of Conventional, Hybrid, Battery, and Fuel Cell Vehicles

1.8 A Comparison of Automotive and Other Transportation Technologies

References

Further Reading

Problems

Assignments

Chapter 2 Vehicle Dynamics

2.1 Vehicle Load Forces

2.1.1 Basic Power, Energy, and Speed Relationships

2.1.2 Aerodynamic Drag

2.1.2.1 Example: Aerodynamic Drag

2.1.2.2 Example: Aerodynamic Drag and Fuel Consumption

2.1.3 Rolling Resistance

2.1.3.1 The Ford Explorer Recall

2.1.3.2 The A-Class Mercedes in the 1990s

2.1.3.3 The Tesla Model S in 2013

2.1.3.4 Example: Rolling Resistance

2.1.4 Vehicle Road-Load Coefficients from EPA Coast-Down Testing

2.1.5 Battery Electric Vehicle Range at Constant Speed

2.1.5.1 Example: Plot of BEV Range Versus Speed

2.1.5.2 Example: Estimate of BEV Range

2.1.5.3 Example: Effect of Auxiliary Loads on Range

2.1.6 Gradability

2.1.6.1 Example: Downgrade Force and Regeneration

2.2 Vehicle Acceleration

2.2.1 Regenerative Braking of the Vehicle

2.2.2 Traction Motor Characteristics

2.2.2.1 Example: 2015 Nissan Leaf Rated Speed

2.2.3 Acceleration of the Vehicle

2.2.3.1 Time-Step Estimation of Vehicle Speed

2.2.3.2 A Simplified Equation Set for Characterizing Acceleration by Ignoring Load Forces

2.3 Simple Drive Cycle for Vehicle Comparisons

References

Further Reading

Problems

Sample MATLAB Code

Assignment: Modeling of a BEV

Chapter 3 Batteries

3.1 Introduction to Batteries

3.1.1 Batteries Types and Battery Packs

3.1.1.1 Recent EVs and Battery Chemistries

3.1.2 Basic Battery Operation

3.1.3 Basic Electrochemistry

3.1.3.1 Lead-Acid Battery

3.1.3.2 Nickel-Metal Hydride

3.1.3.3 Lithium-Ion

3.1.4 Units of Battery Energy Storage

3.1.5 Capacity Rate

3.1.5.1 Example of the 2011 Nissan Leaf Battery Pack

3.1.6 Battery Parameters and Comparisons

3.1.6.1 Cell Voltage

3.1.6.2 Specific Energy

3.1.6.3 Cycle Life

3.1.6.4 Specific Power

3.1.6.5 Self-Discharge

3.2 Lifetime and Sizing Considerations

3.2.1 Examples of Battery Sizing

3.2.1.1 Example: BEV Battery Sizing

3.2.1.2 Example: PHEV Battery Sizing

3.2.2 Battery Pack Discharge Curves and Aging

3.3 Battery Charging, Protection, and Management Systems

3.3.1 Battery Charging

3.3.2 Battery Failure and Protection

3.3.3 Battery Management System

3.4 Battery Models

3.4.1 A Simple Novel Curve Fit Model for BEV Batteries

3.4.2 Voltage, Current, Resistance, and Efficiency of Battery Pack

3.4.2.1 Example: Determining the Pack Voltage Range for a BEV

3.4.3 A Simple Curve-Fit Model for HEV Batteries

3.4.3.1 Example: Determining the Pack Voltage Range for a HEV

3.4.4 Charging

3.4.4.1 Example: Fast Charging a Battery Pack

3.4.5 Determining the Cell/Pack Voltage for a Given Output\Input Power

3.4.5.1 Example: Battery Discharge

3.4.5.2 Example: Battery Charge

3.4.6 Cell Energy and Discharge Rate

3.4.6.1 Example: Cell Capacity

3.5 Example: The Fuel Economy of a BEV Vehicle with a Fixed Gear Ratio

References

Further Reading

Problems

Appendix: A Simplified Curve-Fit Model for BEV Batteries

Chapter 4 Fuel Cells

4.1 Introduction to Fuel Cells

4.1.1 Fuel Cell Vehicle Emissions and Upstream Emissions

4.1.2 Hydrogen Safety Factors

4.2 Basic Operation

4.2.1 Fuel Cell Model and Cell Voltage

4.2.1.1 Example: No-Load and Load Voltages of a PEM Fuel Cell

4.2.2 Power and Efficiency of Fuel Cell and Fuel Cell Power Plant System

4.2.2.1 Example: Full-Load Power and Efficiency of PEM Fuel Cell Stack

4.2.3 Fuel Cell Characteristic Curves

4.3 Sizing the Fuel Cell Plant

4.3.1 Example: Sizing a Fuel Cell

4.3.2 Toyota Mirai

4.3.3 Balance of Plant

4.3.4 Boost DC-DC Converter

4.4 Fuel Cell Aging

4.5 Example: Sizing Fuel Cell System for Heavy Goods Tractor–Trailer Combination

4.6 Example: Fuel Economy of Fuel Cell Electric Vehicle

References

Problems

Assignments

Chapter 5 Conventional and Hybrid Powertrains

5.1 Introduction to HEVs

5.2 Brake Specific Fuel Consumption

5.2.1 Example: Energy Consumption, Power Output, Efficiency, and BSFC

5.3 Comparative Examples of Conventional, Series, and Series-Parallel Hybrid Systems

5.3.1 Example: Fuel Economy of IC Engine Vehicle with Gasoline or Diesel Engine

5.3.2 Example: Fuel Economy of Series HEV

5.3.3 Example: Fuel Economy of Series-Parallel HEV

5.3.4 Summary of Comparisons

5.4 The Planetary Gears as a Power-Split Device

5.4.1 Powertrain of 2004 Toyota Prius

5.4.2 Example: CVT Operating in Electric Drive Mode (Vehicle Launch and Low Speeds)

5.4.3 Example: CVT Operating in Full-Power Mode

5.4.4 Example: CVT Operating in Cruising and Generating Mode

References

Problems

Assignments

Part 2 Electrical Machines

Chapter 6 Introduction to Traction Machines

6.1 Propulsion Machine Overview

6.1.1 DC Machines

6.1.2 AC Machines

6.1.3 Comparison of Traction Machines

6.1.4 Case Study – Mars Rover Traction Motor

6.2 Machine Specifications

6.2.1 Four-Quadrant Operation

6.2.2 Rated Parameters

6.2.3 Rated Torque

6.2.4 Rated and Base Speeds

6.2.5 Rated Power

6.2.6 Peak Operation

6.2.7 Starting Torque

6.3 Characteristic Curves of a Machine

6.3.1 Constant-Torque Mode

6.3.2 Constant-Power Mode

6.3.3 Maximum-Speed Mode

6.3.4 Efficiency Maps

6.4 Conversion Factors of Machine Units

References

Chapter 7 The Brushed DC Machine

7.1 DC Machine Structure

7.2 DC Machine Electrical Equivalent Circuit

7.3 DC Machine Circuit Equations

7.3.1 No-Load Spinning Loss

7.3.2 No-Load Speed

7.3.3 Maximum Power

7.3.4 Rated Conditions

7.4 Power, Losses, and Efficiency in the PM DC Machine

7.5 Machine Control using Power Electronics

7.5.1 Example: Motoring using a PM DC Machine

7.6 Machine Operating as a Motor or Generator in Forward or Reverse Modes

7.6.1 Example: Generating/Braking using a PM DC Machine

7.6.2 Example: Motoring in Reverse

7.7 Saturation and Armature Reaction

7.7.1 Example: Motoring using PM DC Machine and Machine Saturation

7.8 Using PM DC Machine for EV Powertrain

7.8.1 Example: Maximum Speeds using PM DC Machine

7.9 Using WF DC Machine for EV Powertrain

7.9.1 Example: Motoring using WF DC Machine

7.10 Case Study – Mars Rover Traction Machine

7.11 Thermal Characteristics of Machine

7.11.1 Example of Steady-State Temperature Rise

7.11.2 Transient Temperature Rise

7.11.3 Example of Transient Temperature Rise

References

Problems

Chapter 8 Induction Machines

8.1 Stator Windings and the Spinning Magnetic Field

8.1.1 Stator Magnetic Flux Density

8.1.2 Space-Vector Current and the Rotating Magnetic Field

8.2 Induction Machine Rotor Voltage, Current, and Torque

8.2.1 Rotor Construction

8.2.2 Induction Machine Theory of Operation

8.3 Machine Model and Steady-State Operation

8.3.1 Power in Three-Phase Induction Machine

8.3.2 Torque in Three-Phase Induction Machine

8.3.3 Phasor Analysis of Induction Motor

8.3.4 Machine Operation When Supplied by Current Source

8.3.4.1 Example: Motoring at Rated Speed using Induction Machine

8.3.4.2 Example: Motoring at Rated Speed using Induction Machine – Ignoring Leakage

8.3.4.3 Example: Generating at Rated Speed using Induction Machine

8.4 Variable-Speed Operation of Induction Machine

8.4.1 Constant Volts per hertz Operation

8.4.1.1 Example: Maintaining a Constant Volts per Hertz

8.4.2 Variable-Speed Operation

8.4.2.1 Example: Field-Weakened Motoring at Twice the Rated Speed using Induction Machine

8.4.2.2 Example: Stall/Start-Up using Induction Machine

8.4.2.3 Effects of Rotor Heating

8.5 Machine Test

8.5.1 DC Resistance Test

8.5.2 Locked-Rotor Test

8.5.3 No-Load Test

References

Further Reading

Problems

Sample MATLAB Code

Chapter 9 Surface-Permanent-Magnet AC Machines

9.1 Basic Operation of SPM Machines

9.1.1 Back EMF of a Single Coil

9.1.2 Back EMF of Single Phase

9.1.2.1 The Experimental Back EMF

9.1.2.2 Distributed Winding

9.1.3 SPM Machine Equations

9.1.3.1 Example: Phase Voltage of SPM Machine

9.2 Per-Phase Analysis of SPM Machine

9.2.1 Per-Phase Equivalent Circuit Model for SPM Machine

9.2.2 Phasor Analysis of SPM Machine

9.2.2.1 Example: Motoring using SPM Machine

9.2.3 Machine Saturation

9.2.3.1 Example: Motoring using SPM Machine

9.2.4 SPM Torque–Speed Characteristics

9.2.4.1 Example: Determining No-Load Speed

9.2.5 High-Speed Operation of SPM Machine above Rated Speed

9.2.6 Machine Characteristics for Field-Weakened Operation

References

Further Reading

Problems

MATLAB Code

Chapter 10 Interior-Permanent-Magnet AC Machine

10.1 Machine Structure and Torque Equations

10.2 d- and q-Axis Inductances

10.2.1 Example: Estimating the d-axis and q-axis Inductances for 2004 Toyota Prius Motor

10.3 IPM Machine Test

10.3.1 No-Load Spin Test

10.3.2 DC Torque Test

10.4 Basic Theory and Low-Speed Operation

10.4.1 Example: Motoring at Rated Condition

10.4.2 Maximum Torque per Ampere (MTPA)

10.4.3 Maximum Torque per Volt (MTPV) or Maximum Torque per Flux (MTPF)

10.5 High-Speed Operation of IPM Machine

10.5.1 Example: Motoring at High Speed using IPM Machine

10.6 dq Modeling of Machines

10.6.1 Constant Current Transformation

10.6.2 Constant Power Transformation

References

Further Reading

Problems

Assignments

Part 3 Power Electronics

Chapter 11 DC-DC Converters

11.1 Introduction

11.2 Power Conversion – Common and Basic Principles

11.2.1 The Basic Topologies

11.2.2 The Half-Bridge Buck-Boost Bidirectional Converter

11.3 The Buck or Step-Down Converter

11.3.1 Analysis of Voltage Gain of Buck Converter in CCM

11.3.1.1 Analysis of Buck Converter in CCM

11.3.1.2 Determining Low-Voltage Capacitor RMS Current

11.3.1.3 Capacitor Voltages

11.3.1.4 Example: Designing Buck Converter for CCM Operation

11.3.2 BCM Operation of Buck Converter

11.3.2.1 Example of Buck in BCM

11.3.3 DCM Operation of Buck Converter

11.3.3.1 Example: Buck Converter in DCM Operation

11.4 The Boost or Step-up Converter

11.4.1 Analysis of Voltage Gain of Boost Converter in CCM

11.4.1.1 Analysis of Boost Converter in CCM

11.4.1.2 Example: Analyzing Boost for CCM Operation

11.4.2 BCM Operation of Boost Converter

11.4.2.1 Example: Boost Converter in BCM

11.4.3 DCM Operation of Boost Converter

11.4.3.1 Example: Boost Converter in DCM Operation

11.5 Power Semiconductors

11.5.1 Power Semiconductor Power Loss

11.5.1.1 Conduction Losses of IGBT and Diode

11.5.1.2 Example: Boost IGBT Conduction Losses

11.5.1.3 Switching Losses of IGBT and Diode

11.5.1.4 Example: Switching Losses of IGBT Module

11.5.2 Total Semiconductor Power Loss and Junction Temperature

11.5.2.1 Example: Total IGBT Module Loss and Die Temperatures

11.6 Passive Components for Power Converters

11.6.1 Example: Inductor Sizing

11.6.2 Capacitor Sizing

11.6.2.1 Example: Capacitor Sizing

11.7 Interleaving

11.7.1 Example: Two-Phase Interleaved Boost Converter

References

Further Reading

Problems

Assignments

Appendix I

Appendix II: Buck-Boost Converter

Chapter 12 Isolated DC-DC Converters

12.1 Introduction

12.1.1 Advantages of Isolated Power Converters

12.1.2 Power Converter Families

12.2 The Forward Converter

12.2.1 CCM Currents in Forward Converter

12.2.1.1 Example: Current Ratings in Medium-Power Forward Converter

12.2.2 CCM Voltages in Forward Converter

12.2.2.1 Example: Voltage Ratings in a Medium-Power Forward Converter

12.2.3 Sizing the Transformer

12.2.3.1 Example: AP of a Forward Converter Transformer

12.3 The Full-Bridge Converter

12.3.1 Operation of Hard-Switched Full-Bridge Converter

12.3.2 CCM Currents in Full-Bridge Converter

12.3.2.1 Example: Current Ratings in a Medium-Power Full-Bridge Converter

12.3.3 CCM Voltages in the Full-Bridge Converter

12.3.3.1 Example: Voltage Ratings in a Full-Bridge Converter

12.4 Resonant Power Conversion

12.4.1 LCLC Series-Parallel Resonant Converter

12.4.2 Desirable Converter Characteristics for Inductive Charging

12.4.2.1 Basic Converter Operation

12.4.2.2 Design Considerations

12.4.3 Fundamental-Mode Analysis and Current-Source Operation

12.4.3.1 Example

12.4.4 Simulation

References

Further Reading

Problems

Assignments

Appendix I: RMS and Average Values of Ramp and Step Waveforms

Appendix II: Flyback Converter

Chapter 13 Traction Drives and Three-Phase Inverters

13.1 Three-Phase Inverters

13.2 Modulation Schemes

13.2.1 Sinusoidal Modulation

13.2.2 Sinusoidal Modulation with Third Harmonic Addition

13.2.3 Overmodulation and Square Wave

13.2.3.1 Example: AC Voltages Available from DC Link

13.3 Sinusoidal Modulation

13.3.1 Modulation Index m

13.3.2 Inverter Currents

13.3.3 Switch, Diode, and Input Average Currents

13.3.4 Switch, Diode, DC Link, and Input Capacitor RMS Currents

13.3.5 Example: Inverter Currents

13.4 Inverter Power Loss

13.4.1 Conduction Loss of IGBT and Diode

13.4.2 Switching Loss of IGBT Module

13.4.2.1 Example: Power Losses of Power Semiconductor Module

13.4.3 Total Semiconductor Power Loss and Junction Temperature

13.4.4 Example: Regenerative Currents

References

Further Reading

Problems

Assignments

Chapter 14 Battery Charging

14.1 Basic Requirements for Charging System

14.2 Charger Architectures

14.3 Grid Voltages, Frequencies, and Wiring

14.4 Charger Functions

14.4.1 Real Power, Apparent Power, and Power Factor

14.5 Charging Standards and Technologies

14.5.1 SAE J1772

14.5.2 VDE-AR-E 2623-2-2

14.5.3 CHAdeMo

14.5.4 Tesla

14.5.5 Wireless Charging

14.5.5.1 Inductive

14.5.5.2 Wireless

14.6 The Boost Converter for Power Factor Correction

14.6.1 The Boost PFC Power Stage

14.6.2 Sizing the Boost Inductor

14.6.2.1 Example: Sizing the Inductor

14.6.3 Average Currents in the Rectifier

14.6.3.1 Example: Input Rectifier Power Loss

14.6.4 Switch and Diode Average Currents

14.6.5 Switch, Diode, and Capacitor RMS Currents

14.6.6 Power Semiconductors for Charging

14.6.6.1 Example: Silicon MOSFET and SiC Diode Power Losses

14.6.6.2 Example: PFC Stage Losses

References

Further Reading

Problems

Assignments

Chapter 15 Control of the Electric Drive

15.1 Introduction to Control

15.1.1 Feedback Controller Design Approach

15.2 Modeling the Electromechanical System

15.2.1 The Mechanical System

15.2.2 The PM DC Machine

15.2.3 The DC-DC Power Converter

15.2.4 The PI Controller

15.3 Designing Torque Loop Compensation

15.3.1 Example: Determining Compensator Gain Coefficients for Torque Loop

15.4 Designing Speed Control Loop Compensation

15.4.1 Example: Determining Compensator Gain Coefficients for Speed Loop

15.5 Acceleration of Battery Electric Vehicle (BEV) using PM DC Machine

15.6 Acceleration of BEV using WF DC Machine

References

Problems

Assignment and Sample MATLAB Codes

Part 4 Electromagnetism

Chapter 16 Introduction to Electromagnetism, Ferromagnetism, and Electromechanical Energy Conversion

16.1 Electromagnetism

16.1.1 Maxwell´s Equations

16.1.1.1 Ampere´s Circuital Law (Based on Ampere–Maxwell Law)

16.1.1.2 Right Hand Screw Rule: Direction of Magnetic Flux

16.1.1.3 Magnetic Flux Density Vector (B)

16.1.1.4 Magnetic Flux

16.1.1.5 Gauss´ Law for Magnetism

16.2 Ferromagnetism

16.2.1 Magnetism and Hysteresis

16.2.2 Hard and Soft Ferromagnetic Materials

16.2.2.1 Soft Ferromagnetic Materials

16.2.2.2 A Review of Commonly Used Soft Ferromagnetic Materials

16.3 Self-Inductance

16.3.1 Basic Inductor Operation

16.3.2 Inductor Equations

16.3.2.1 Example: A Gapped Inductor

16.3.2.2 Inductance Variation with Magnetization Curve

16.3.3 Reluctance

16.3.3.1 Example: A Gapless Inductor

16.3.3.2 Reluctance of Gapped Magnetic Structures

16.3.3.3 Example: Reluctances of Gapped Inductor

16.3.4 Energy Stored in Magnetic Field

16.3.4.1 Example: Inductor Energy Storage

16.3.5 Core Loss

16.3.5.1 Hysteresis Loss

16.3.5.2 Eddy Current Loss

16.3.5.3 Core Loss

16.3.5.4 Example: Core Loss

16.3.5.5 Core Loss Equivalent Parallel Resistance

16.3.6 Copper Loss

16.3.6.1 Copper Loss of Wire

16.3.6.2 Example: Copper Loss

16.3.6.3 Copper Loss of CC Core with Helical Winding

16.3.6.4 Example: MLT of Winding

16.3.7 Inductor Sizing using Area Product

16.3.8 High-Frequency Operation and Skin Depth

16.4 Hard Ferromagnetic Materials and Permanent Magnets

16.4.1 Example: Remanent Flux Density

16.4.2 Example: The Recoil Line

16.4.3 Example: Air Gap Flux Density due to a Permanent Magnet

16.4.4 Maximum Energy Product

16.4.5 Force due to Permanent Magnet

16.4.5.1 Example: Lifting Force of Magnet with no Gap

16.4.5.2 Example: Lifting Force of Magnet with Gap

16.4.6 Electromagnet

16.4.6.1 Example: Air Gap Flux Density due to Field Winding

16.5 The Transformer

16.5.1 Theory of Operation

16.5.2 Transformer Equivalent Circuit

16.5.3 Transformer Voltages and Currents

16.5.3.1 Exciting the Transformer with Sinusoidal Wave

16.5.3.2 Example: Induction Machine Magnetizing Current

16.5.3.3 Exciting the Transformer with a Square Wave Voltage

16.5.3.4 Example: High-Frequency Transformer

16.5.4 Sizing the Transformer using the Area-Product (AP) Method

16.6 The Capacitor

16.6.1 Sizing Polypropylene High-Voltage Capacitor

16.7 Electromechanical Energy Conversion

16.7.1 Ampere´s Force Law

16.7.1.1 Fleming´s Left Hand Rule

16.7.2 General Expression for Torque on Current-Carrying Coil

16.7.3 Torque, Flux Linkage, and Current

16.7.4 Faraday´s Law of Electromagnetic Induction

16.7.5 Lenz´s Law and Fleming´s Right Hand Rule

References

Further Reading

Further Viewing

Problems

Assignments

Reference Conversion Table

Index

EULA

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