Power Train Of SAE Hybrid Formula, 2023

Islamic University
‫الجامعة اإلسالمية‬
Faculty of Engineering
Department of Mechanical
‫كليه الهندسة‬
Engineering ‫قسم الهندسة الميكانيكية‬

ME-3872

SENIOR DESIGN PROJECT I

2023/1445

Final Report

Project Title:

Power Train Of SAE Hybrid Formula

Submitted By:

Abdulrhman Mostafa…... 411012053

Advisor:

Dr. Faisal Omar Al-Mahrouqi

_____________________________________________________________________________________

A report submitted in part fulfilment of the degree of

Bachelors in mechanical engineering

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 Power Train Of SAE Hybrid Formula, 2023

Declaration

This report has been prepared on the basis of our own work. Where other published and unpublished
source materials have been used, these have been acknowledged.

Word Count:

Students Names and Signatures:

Student Name Signatures

Abdulrhman Mostafa Abdulhamid

Date of Submission: November 16, 2023

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 Power Train Of SAE Hybrid Formula, 2023

Table of Contents
Declaration..................................................................................................................................................1
List of Figure................................................................................................................................................3
Abstract.......................................................................................................................................................4
1. Introduction.........................................................................................................................................5
1.1 Study Background........................................................................................................................6
1.2 Problem Statement......................................................................................................................6
1.3 Objectives....................................................................................................................................7
1.4 Scope of work..............................................................................................................................7
1.5 Outline of the report....................................................................................................................7
2. Literature review.................................................................................................................................8
2.1 There are two different sources of power[2]:..............................................................................8
2.1.1 Engine..................................................................................................................................8
2.1.2 Electric machines (motor and generator).............................................................................8
2.2 The main types of hybrid [3]:.......................................................................................................8
2.2.1 The series hybrid system......................................................................................................8
2.2.2 The parallel hybrid system...................................................................................................9
2.2.3 Power-split hybrid system..................................................................................................10
2.3 Planetary Gear System:..............................................................................................................11
2.3.1 The sun gear, is connected to the generator.....................................................................11
2.3.2 The carrier gear, is connected to the engine ....................................................................11
2.3.3 The ring gear, is connected to the transmission.................................................................11
2.4 Powersplit Desine:.....................................................................................................................11
2.4.1 Electric-Only Drive Mode (EV Mode):.................................................................................11
2.4.2 Hybrid-Electric Drive Mode:...............................................................................................11
2.4.3 Parallel Mode:....................................................................................................................13
2.4.4 Deceleration:......................................................................................................................14
3. Methodology.....................................................................................................................................15
3.1 Components from the market...................................................................................................15
3.2 Bill of materials..........................................................................................................................18
4. Conclusion.........................................................................................................................................19
5. Bibliography.......................................................................................................................................20
6. Appendix............................................................................................................................................21

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List of Figure
Figure 1: Power-split-type HEV configuration [3].........................................................................................7
Figure 2: connecting the motors in series....................................................................................................9
Figure 3: The form of connecting the motors in series [4]...........................................................................9
Figure 4:The form of connecting the motors in parallel.............................................................................10
Figure 5: The pre-transmission architecture [5].........................................................................................10
Figure 6: Simple planetary gear set [8]......................................................................................................12
Figure 7: real planetary gear set [7]...........................................................................................................12
Figure 8: Planetary gear set [9]..................................................................................................................16
Figure 9: One-way cultch [10]....................................................................................................................16
Figure 10: Generator break [10].................................................................................................................17
Figure 11: Chain.........................................................................................................................................17
Figure 12: Generator..................................................................................................................................18
Figure 13: Motorcycle engine....................................................................................................................18

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Abstract
Power-split hybrid vehicles represent a paradigm shift in automotive technology, seamlessly
integrating internal combustion engines (ICE) with electric motors to achieve a harmonious
blend of efficiency and performance. This abstract explores the underlying principles and key
features of power-split hybrid systems, focusing on their ability to dynamically distribute power
between the ICE and electric motor. The power-split architecture employs a planetary gear set
that allows for flexible power distribution, enabling the vehicle to operate in multiple modes,
including electric-only, engine-only, and a combined hybrid mode. This versatility is leveraged to
optimize fuel efficiency, reduce emissions, and enhance the overall driving experience across a
range of conditions [1].

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1. Introduction
First of all there are two types of hevs, namely 1) the series hybrid system and 2) the
parallel hybrid system. The more recent type of complex HEV , i.e., the power-split hybrid
system , combines the benefits of both the parallel- and series-type hybrid systems Without
sacrificing the cost effectiveness of this hybrid system. This system consists of two types of
power sources, a gasoline engine, a motor, a generator, and a high-voltage battery. This The
system also has the ability to drive the vehicle on electric power as well (a full HEV) . Fig. 1
describes the power-split HEV configuration and its control system. This power train system
consists of four subsystems/components [2].

Namely 1) the engine subsystem, 2) the transaxle subsystem, 3) the brake subsystem, and 4)
the battery subsystem. They are connected to the driveline through a combination of engine
and generator subsystems using a planetary gear set to connect each other and the electric
drive system (motor, generator, and battery subsystems) to construct two power sources to
propel the vehicle. Each subsystem requires its own controller [2], It can be noted that the
transaxle subsystem controller module (TCM) is integrated with this transaxle subsystem where
both electric machines, i.e..

The motor and The generator, are housed to provide electrical functionality and are used for
different purposes, depending on the driving conditions. It can also be noted that the brake
subsystem is an electrohydraulic brake system, which provides the seamless integration of the
friction brakes and regenerative braking functionality. In order to ensure that all these
controllers work [2].

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Figure 1: Power-split-type HEV configuration [3].

1.1 Study Background

We searched in many scientific researches to find scientific ideas to solve these problems
and found many ideas and the best of them was 3, the first idea is to connect the motor with
the motor in parallel using a clutch, and the second is to connect the motor and the motor in
series using a clutch between the motor and the engine, and the third is the best to use a
planetary gear set. Researching it we found it to be the best way to connect.

And in this third idea, the solutions to all the problems that we encountered from the battery,
the generator was connected with the sun gear, which charges the battery, and the other
problem is the engine running during the operation of the vehicle, which will be solved by the
planetary gear set.

1.2 Problem Statement

Hybrid cars contain two engines, an electric motor and an internal combustion engine. We
had a problem in the beginning, how to connect the two engines. After researching, I found that
there is more than one type to connect the two engines to each other in order to synchronize
them, so I focused on the three most important types: the first type is parallel hybrid, and the
second type is series hybrid. . The third and most important type that I focused on is the
powersplit. After researching, I found that it is one of the best types because it works to divide
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the energy so that there is low energy loss like other systems, and it is highly efficient because it
contains a set of planetary gears that work to divide the energy between the generator, the
electric motor, and the internal combustion engine in several cases, so that there is no loss. As
in the previous cases or types, the clutch is used to remove excess energy. I found that this
system would be suitable for manufacturing in the racing car that we will manufacture to
participate in the SAE competition and conform to the specifications.

1.3 Objectives
The objectives of this project are as follows:

 Review specifications for the SEA competition.

 Collect information about available systems.
 Determine the best system to develop and use it.
 Start manufacturing the system.

1.4 Scope of work

In this project, we focused on identifying a highly efficient system to work on, develop and
manufacture to participate in the SIA competition.

1.5 Outline of the report

Design requirements are the requirements and criteria outlined in the Contract that
describe the minimum acceptable technical standards and provide the parameters for how the
Project's design must be developed and implemented. For instance, the team cannot utilize
random components since the automobile must pass the SAE challenge and every component
must adhere to SAE requirements. That complies with SAE requirements, The essential
components that our design has to have in order to succeed are known as our design
requirements.

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2. Literature review

2.1 There are two different sources of power[2]:

2.1.1 Engine
2.1.2 Electric machines (motor and generator)

2.2 The main types of hybrid [3]:

2.2.1 The series hybrid system
It is to connect the internal combustion engine with the electric motor in series, by
connecting the internal combustion engine with the motor by the clutch and connecting the
electric motor to the shaft connected with the transmission to the differential to the tires[4].

Figure 2: connecting the motors in series.

Figure 3: The form of connecting the motors in series [4].

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2.2.2 The parallel hybrid system

It is to connect the internal combustion engine with the electric motor in parallel, by
connecting the internal combustion engine with the clutch to operate the engine when it is
needed, and the electric motor is connected with the shaft that contains the clutch to the
transmission and from there to the differential to the tires[5].

Figure 4:The form of connecting the motors in parallel.

Figure 5: The pre-transmission architecture [5].

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2.2.3 Power-split hybrid system

This is the best way to synchronize, and it is the method that has been adopted. In this
method, a group of planetary gears was used to provide smoothness and improve efficiency.
The sun gear was connected to the electric generator to charge the battery, and the carrier was
connected to the internal combustion engine, and the ring was connected to the shaft
connected to the box. The gears are also connected with the electric motor to the gearbox, and
from there to the differential cores of the tires [3].

Figure 6: design planetary rear connections [6].

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Figure 7: real planetary gear set [7].

Figure 6: Simple planetary gear set [8].

2.3 Planetary Gear System:

The heart of the power-split system is a planetary gear set, which consists of a sun gear, a ring gear,
and planet gears. The arrangement allows for different power paths and combinations[3].

2.3.1 The sun gear, is connected to the generator.

2.3.2 The carrier gear, is connected to the engine .
2.3.3 The ring gear, is connected to the transmission.

2.4 Powersplit Desine:

2.4.1 Electric-Only Drive Mode (EV Mode):
In the Electric-Only Drive Mode (EV Mode) of the power-split hybrid electric vehicle (HEV) system, the
engine is turned off, and the electric motor draws power from the battery to provide propulsion to the
vehicle for both forward and reverse motions. In this mode, the generator can also function as a motor,
drawing power from the battery to assist the vehicle's forward launch. This functionality is enabled by a
one-way clutch at the carrier (engine) shaft [3].

 The electric motor draws power from the battery to propel the vehicle for forward and reverse
motions. The engine is off in this mode.
 The generator can also act as a motor due to a one-way clutch at the carrier (engine) shaft,
helping with the vehicle's forward launch.

2.4.2 Hybrid-Electric Drive Mode:

In the Hybrid-Electric Drive Mode of a power-split hybrid electric vehicle (HEV), the engine output
power is divided into two paths by controlling the generator [3].

2.4.2.1 The engine's output power is split into two paths by controlling the generator:
 Mechanical Path:
Power flows from the engine to the carrier to the ring gear to the counter shaft.

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The Mechanical Path in the Hybrid-Electric Drive Mode of a power-split hybrid electric
vehicle (HEV) refers to the route through which part of the engine's output power is transmitted
directly to the wheels. In this path, the power flows from the engine to the carrier, then to the
ring gear, and finally to the counter shaft. This mechanical transmission of power is one of the
key components that differentiates a power-split HEV from other types of hybrid vehicles, as it
allows for a direct mechanical connection between the engine and the wheels, enhancing
efficiency and performance.
 Electrical Path:
Power flows from the engine to the generator to the motor to the counter shaft.

The Electrical Path in the Hybrid-Electric Drive Mode of a power-split hybrid electric vehicle
(HEV) refers to the route through which a portion of the engine's output power is converted to
electrical energy and then used to power the electric motor. In this path:

1) The engine generates mechanical energy.

2) This mechanical energy is converted into electrical energy by the generator.
3) The electrical energy produced by the generator is then used to power the electric motor.
4) The electric motor then delivers mechanical power to the counter shaft.

This electrical path allows for the efficient use of energy, as it can be adjusted and controlled more
precisely than the mechanical path. It provides a way to optimize the engine's efficiency by using the
generated electrical energy for propulsion or for charging the battery, contributing to the overall
efficiency and flexibility of the power-split HEV system.

This division of engine power, made possible by the kinematics of the planetary gear set, allows for
the engine speed to be controlled independently of the vehicle speed. By varying the generator speed,
the engine speed can be decoupled from the vehicle speed, providing flexibility in the vehicle's
operation.

 The engine speed is controlled independently of vehicle speed, allowing for decoupling of the
engine speed from the vehicle speed by varying the generator speed.

 Positive Split Mode:

The generator acts as a generator if the engine speed that results from the desired engine
speed is in the opposite direction of its torque. This mode typically occurs when more power is
needed or the battery requires charging.

In the Positive Split Mode of a power-split hybrid electric vehicle (HEV), the generator rotates in
the positive direction, aligning with the defined sign convention. This mode of operation is
characterized by the motor torque varying based on driver demand and the response of the
engine and generator. In this mode, when the generator speed and torque are zero, indicating
that the generator brake is actuated, the vehicle operates in the parallel mode. Here, the motor
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torque is dependent on the engine's torque output. The Positive Split Mode is distinct from the
Negative Split Mode, where the generator provides a negative torque, similar to the Positive Split
Mode, but rotates in the opposite direction. In both modes, the motor torque adjusts to match
the required driver demand and engine/generator response
 Negative Split Mode:
The generator adds power to the drivetrain if it rotates in the same direction as its torque.
This mode is engaged, for example, when the driver reduces the demand for power.

In the Negative Split Mode of a power-split hybrid electric vehicle (HEV), the generator operates
in a manner that contrasts with the Positive Split Mode. Key characteristics of the Negative Split
Mode include:

1) Generator Rotation: The generator provides negative torque, but it rotates in the
negative direction, opposite to its rotation in the Positive Split Mode.
2) Motor Torque Variation: Similar to the Positive Split Mode, the motor torque in the
Negative Split Mode varies according to the driver's demand and the response of the
engine and generator. However, the direction of generator rotation is reversed.
3) Supplemental Tractive Force: The motor torque in this mode can also compensate for
the desired driver demand, helping to maintain the drive trace. This results in a
supplemental tractive force being provided.

Overall, the Negative Split Mode is a distinctive aspect of the power-split system in HEVs,
allowing for a versatile and efficient use of the powertrain by varying the direction and amount
of torque provided by the generator

2.4.3 Parallel Mode:

In the Parallel Mode of a power-split hybrid electric vehicle (HEV), all of the engine's output power
is transmitted to the drivetrain exclusively through the mechanical path, maintaining a fixed mechanical
ratio. This mode is characterized by:

1) Transmission of Engine Power: The engine's power is only delivered through its mechanical path
to the drivetrain, which is used for propulsion.
2) Generator's Role: When the vehicle decelerates, the operation of the system in this mode is
similar to the Positive Split Mode. The generator is controlled in response to the decrease in
vehicle speed, functioning as a generator to ensure that the engine operates within the desired
and allowable region.
3) Electric Motor Functionality: In Parallel Mode, the electric motor not only provides regenerative
braking torque to meet the driver's demand but also absorbs torque from the engine.
 When the generator brake is actuated, the sun gear is locked, and the generator braking torque
provides the reaction torque to the engine output torque.
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 All the engine output power is transmitted to the drivetrain only through the mechanical path
with a fixed mechanical ratio.

2.4.4 Deceleration:

The section on Deceleration in the research paper on power-split hybrid electric vehicles (HEVs) appears
to discuss the vehicle's performance during a specific driving scenario. This scenario includes
accelerating from 0 to 26.82 meters per second (approximately 0 to 60 miles per hour), maintaining a
constant speed of 26.82 meters per second, and then decelerating to 0 meters per second. This drive
cycle is chosen for its effectiveness in demonstrating the operation of the vehicle under all its hybrid
modes and for studying speed-related aspects of the vehicle's performance [3].

 Similar to the positive split mode, the generator is controlled according to the decrease of
vehicle speed to function as a generator.
 The electric motor provides regenerative braking torque and also absorbs torque from the
engine.

Generetor break

Electro-Mechanical Brake (EMB) is the brake system that is actuated by electrical energy and has a
similar design with the Electric Parking Brake (EPB). It uses motor power and gears to provide the
necessary torque and a screw & nut mechanism is used to convert the rotational movement into a
translational one. The main difference of EMB compared with EPB is that the functional requirements of
components are much higher to provide the necessary performance for service braking such as response
time. Such highly responsive and independent brake actuators at each wheel lead to enhanced
controllability which should result in not only better basic braking performance, but also improvements
in various active braking functions such as integrated chassis control, driver assistance systems, or
cooperative regenerative braking. Although the EMB system has the potential for numerous advantages
and innovations in braking, it has yet to be successfully introduced in series production mainly due to
safety and cost concerns. Recent studies have been made to investigate the functional safety aspects[1]
and additional mechanical backup measures[2] in this regard.

Although the EMB is conventionally thought of as a solution for oil-free braking system[3-4], the EMB
system introduced in the current paper includes a hydraulic piston to make several functions possible.
First, the hydraulic system allows for a mechanical back-up mechanism that leads to increased reliability.
Second, the clamping force for braking control can be measured with a pressure sensor. And finally, the
dual piston structure proposed in the current paper, which leads to amplification of the force
transmission, allows for the design of lower specification and higher cost effective motor and gear
components.

This new concept of EMB is termed the hEMB (hybrid EMB) in this paper. This study proposes to use a
combined system of front hEMB and rear hydraulic caliper. This type of system has the potential of
providing many advanced braking functions without the high cost associated with fully electric four
wheel brake by wire systems. Prototypes of hEMB actuators were made and attached in a test vehicle.
Results of bench and vehicle tests will be given to show the functionality of the system

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3. Methodology
It focuses on qualitative validation using computer simulation. The primary goal of this step
is to verify if the developed power-split HEV dynamics model, under simulation, behaves
similarly to the actual vehicle in all possible modes, including electric drive mode, positive split
mode, parallel mode, and negative split mode.

3.1 Components from the market

PLANETARY GEAR SET

A planetary gear set, also known as an epicyclic gear train, is a complex mechanical system used
in various applications such as automatic transmissions in vehicles, bicycles, and industrial
machinery.

Figure 8: Planetary gear set [9].

ONE-WAY CULTCH
A one-way clutch, also known as a freewheel clutch, is a mechanical device that allows a
rotating shaft to engage and drive in one direction, but freewheels (disengages and allows free
rotation) when the direction of rotation is reversed. It's a key component in various mechanical
and automotive applications.

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Figure 9: One-way cultch [10].
 Power Train Of SAE Hybrid Formula, 2023

GENERATOR BREAK
The generator brake system is used to stop the rotor blades from turning when wind speeds are
too high for safe operation, during maintenance, or in emergency situations.

Figure 10: Generator break [10].

CHAIN

A chain used to transfer force is an integral component in various mechanical systems, serving as a
simple yet efficient means of transmitting power.

Figure 11: Chain.

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 Power Train Of SAE Hybrid Formula, 2023

GENERATOR
A generator is often used to convert mechanical energy into electrical energy and vice versa, The
generator is a key component in regenerative braking and is responsible for converting the kinetic energy
of the vehicle into electrical energy to recharge the battery

Figure 12: Generator.

MOTORCYCLE ENGINE

Combination of an internal combustion engine (ICE) 250CC and an electric motor. The choice of the
internal combustion engine depends on the specific design and goals.

Figure 13: Motorcycle engine.

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 Power Train Of SAE Hybrid Formula, 2023

3.2 Bill of materials

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 Power Train Of SAE Hybrid Formula, 2023

4. Conclusion

The conclusion regarding power-split systems in hybrid electric vehicles (HEVs) highlights their
significant role in advancing vehicle efficiency and performance. Power-split systems uniquely combine
the features of both series and parallel hybrid architectures, enabling optimal energy utilization and
dynamic performance. These systems provide the flexibility to split engine power into mechanical and
electrical paths, allowing for more efficient energy management under various driving conditions, power-
split systems represent a significant technological advancement in HEVs, offering an effective solution for
achieving higher fuel economy and lower emissions while maintaining performance and driver comfort.
As environmental concerns and fuel economy standards continue to evolve, power-split HEVs will likely
play an increasingly important role in the automotive industry's transition towards more sustainable
transportation solutions.

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5. Bibliography
[1] “MODELING, CONFIGURATION AND CONTROL OPTIMIZATION OF POWER-SPLIT HYBRID VEHICLES”
https://deepblue.lib.umich.edu/bitstream/handle/2027.42/57675/jinmingl_1.pdf?
sequence=2isAllowed=y .

[2] “Hybrid Vehicles – a simple guide” https://www.aathornton.com/hybrid-vehicles-simple-guide/ .

[3] “Derivation and Experimental Validation of a Power-Split Hybrid Electric Vehicle Model”
https://citeseerx.ist.psu.edu/document?
repid=rep1&type=pdf&doi=bf9913fa95bea0d934a399d328b5208fd88f2e61 .

[4] “Electric, Hybrid Electric and Fuel Cell Vehicles, Architectures of”
https://link.springer.com/referenceworkentry/10.1007/978-1-4419-0851-3_797 .

[5] “Analysis of Energy Management for Hybrid Electric Vehicle”

https://iopscience.iop.org/article/10.1088/1742-6596/2386/1/012097/pdf .

[6] “Control and Powertrain Management for Mult Autonomous Hybrid Vehicles”
https://par.nsf.gov/servlets/purl/10126748 .

[7] “ lanetary Gearset-Based Torque-On-Demand Transfer Case”

https://www.theautotechnical.com/2023/06/torque-on-demand-transfer-case.html .

[8] “Simple planetary gear set” https://www.researchgate.net/figure/Simple-planetary-gear-

set_fig1_338641942 .

[9]"One way clutch purchase occurred Alibaba"https://www.alibaba.com/pla/Backstop-Cam-Clutch-

FXM38-17-Overrunning-Freewheel_62035198329.html?
mark=google_shopping&biz=pla&searchText=bearings&product_id=62035198329&pcy=US&src=sem_gg
l&field=UG&from=sem_ggl&cmpgn=19169251561&adgrp=&fditm=&tgt=&locintrst=&locphyscl=1028873
&mtchtyp=&ntwrk=x&device=c&dvcmdl=&creative=&plcmnt=&plcmntcat=&aceid=&position=&gad_sou
rce=1&gclid=CjwKCAiAmsurBhBvEiwA6e-
WPPcBtQ_KyKuzaHd9NLnDd4HujN5CbYfz837gaIQ8hMnvh264_7O_oxoCts0QAvD_BwE

[10] “Rojek Electro Mechanical Motor Brake - S100 180v brake Coil - 154 mm Diameter eBay”
https://www.ebay.com/itm/334076359473?chn=ps&norover=1&mkevt=1&mkrid=711-167022-198210-
5&mkcid=2&itemid=334076359473&targetid=293946777986&device=c&mktype=pla&googleloc=10288
73&poi=&campaignid=20710301935&mkgroupid=154555959069&rlsatarget=pla-
293946777986&abcId=&merchantid=427089677&gclid=CjwKCAiAmsurBhBvEiwA6e-WPJ-
YporX2nzLTyqAqT8pulV2vgodmN1NoF4RG4rLGUWx4l9UwGgVHhoCO2AQAvD_BwE

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6. Appendix

The assembly:

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