Design of Environmental Friendly

Hybrid Electric Vehicle

B.Dinesh Kumar (2nd Year) S.Kiran Kumar(2nd Year)
Electrical and Electronics Engineering Electrical and Electronics Engineering
GRT Institute of Engineering and Techonology GRT Institute of Engineering and Techonology
Tiruttani. Tiruttani.

Abstract— Hybrid electric vehicles (HEVs) powered by The beauty of the HEV is that energy can be fed back
electric machines and an internal combustion engine into the battery for storage, e.g., during regenerative braking
(ICE) are a promising mean of reducing emissions and (which is otherwise wasted as heat in a conventional vehicle).
fuel consumption without compromising vehicle Leading car manufacturers like Toyota and Honda have
functionality and driving performances. This paper already started mass producing HEV cars, Prius and Insight
presents the design of an environmental friendly hybrid respectively, which are now becoming very popular among
car that feature the gasoline engine and batteries pack. the consumers for their incredible mileage and less emissions.
The fuel consumption benefited by hybridization are Aside from that, a number of automotive manufacturers are
benchmarked to conventional Gasoline and Diesel fueled marketing hybrid vehicles for the general population,
vehicles. The relationship between fuel consumption and examples are DaimlerChrysler, Mitsubishi, Nissan, Fiat,
vehicle weight is investigated for Gasoline as well as for Renault, Ford, GM, and Subaru [1]. Although the number for
Diesel fueled vehicles. Although the automobile alternative electric vehicles is not significantly higher when
manufacturers have reduced the greenhouse gases such efficiency is evaluated on the basis of conversion from crude
as hydro-carbons, carbon monoxide, carbon dioxide, etc., oil to traction effort at the wheels, it makes a difference.
from the vehicle, they cannot produce a zero-emission
In [2] electrical components and overall system design of
vehicle unless they produce an electric vehicle (EV). An
a conversion car-turned-to-hybrid are discussed. Battery
electric vehicle is an emission free, environmental
(lead-acid) and super-capacitors was used as electrical
friendly vehicle. The proposed design of HEV
intelligently gets around the individual problems storage unit. The battery and super-capacitor used made it
possible to transfer power bi-directionally between wheels,
associated with the gasoline engine and the electric
batteries, or super-capacitors in desired proposition. It also
vehicle. It diminishes the production of emissions and the
use of fuel. The problem of batteries for the electric features EMC (Energy Management Computer) installed in
vehicle is conquered. An HEV charges itself; it never has the vehicle that monitors entire system to determine what
to be plugged in. When it does not provide power, the each unit should do. Using capacitor bank instead of battery
motor can run as a generator to transfer energy from alone had significantly reduces the power and energy cycling
regenerative braking and from the gasoline engine to the requirement, thus increasing battery life. However,
batteries. efficiency is reduced as EMC performs most of the power
transfer between batteries and super-capacitors. The EMC
Keywords- Hybrid electric vehicles; gasoline engine; communicates with the capacitor and battery controllers, the
batteries; dc motor; greenhouse gases. IC engine, and the driver controls to decide the torque
required from the battery and capacitor motors. The
I. INTRODUCTION parameters that are measured by the information structure
developed are cell voltages and current, DC link voltage,
An electric vehicle is an emission free, environmental power, speed, phase current and temperatures. If the
friendly vehicle. However, the electric vehicles remain measured parameters increased to above 10% of limit level,
unpopular among the consumers due to their lack of system shutdown is initiated by hardware as self-protection
performance and their inability to travel long distances in battery and capacitor units.
without being recharged. So, vehicle that embraces both the
In [3] extensive investigation is done on how battery
performance characteristics of the conventional automobile
management system can be used to lengthen the lifetime of
and the zero-emission characteristics of the electric vehicles
the battery pack. The key to this approach is to monitor and
are greatly being anticipated by the general consumers and
charge the batteries individually. As batteries in HEVs have
the environmentalists alike.
very dynamic discharging and charging cycles, it needs
Technically, the quest for higher fuel economy is shaped intelligent system to maintain and prolong the batteries’ life
by two major factors: how efficiently a power train converts cycles. Due to manufacturing inconsistencies and operational
fuel energy into useful power, and how sleek a vehicle is in variations each cell of battery can have different performance
terms of mass, streamlining, tire resistance, and auxiliary characteristics. The suggestion by the author is to close
loads. On the other hand, vehicle functionality and comfort monitoring and to control the charging cycles. They also
are shaped by various other factors, many of which run described the many possible ways to recharge the batteries as
counter to higher fuel economy. Examples abound, from the such, constant voltage charging and constant current
way torque converter sacrifices efficiency to provide better charging.
shift smoothness and responsiveness to the wide variety of
features that add mass to a vehicle.
In most application of HEV, a single charger is used for entire Advantages:
battery pack. The intelligent system discussed is to provide Low emission drive is possible most of the time
individual chargers for each battery. This made possible due to a Engine can run more efficiently because it is not directly
number of advances that have allowed DC/DC converters that connected to the drive train.
are used as the battery chargers, to be considerably reduced in Flexibility of location of engine-motor set
size and weight. Each charger can be turned on independently Suitability for short trips.
and the voltage limits can be adjusted remotely. However, there
are still needs of more research attention to improve the HEV Disadvantages:
performance with lowest emission of carbon gasses which The vehicle needs a full-sized electric motor, an electric
severely affect the environment. generator and an IC engine, each of which can supply the
required power for the vehicle.
In this paper, a new prototype of low emission environment The vehicle is only driven by the electric motor, which
friendly HEV is developed. The proposed HEV prototype is places great constraints on the battery pack and in
constructed with simple design procedure and low cost available particular requires large battery capacities.
equipments compare to mentioned design. All three drive train components need to be sized for
maximum power for long distance, sustained, high speed
II. HEV CONFIGURATIONS driving. This is because the batteries will exhaust fairly
A brief description about various HEV configurations quickly, leaving ICE to supply all the power.
available in the market is presented. The three main B. Parallel HEV Configuration
configurations are the series, parallel and the dual-mode
In the parallel HEV configuration there are two power paths
configurations and the explanation of each one of them with
for the drive train, while one comes from the engine the other
their merits and demerits follows.
comes from the electric motor. During short trips the electric
A. Series HEV Configuration motor can power the vehicle, while during long drives the IC
engine can power the vehicle. The vehicle can thus have engine
In series HEV configuration, only the electric motor is only, motor only, or a combination of engine and motor mode of
connected to the drive train and thus the vehicle is entirely operation. The electric motor can also assist the engine during
driven by the electric motor. The Internal Combustion (IC) hill climbs and vehicle accelerations, thus the rating of the IC
engine drives an electric generator (commonly known as engine can be reduced. This configuration is illustrated in Figure
alternator), which then supplies the electric power to the motor 2.
and battery pack. The IC engine will turn off if the battery is
fully charged. In some cases, the electric power supply for the In parallel HEV configuration, the drive train is connected to
electric motor can come both from the battery and the engine- the electric motor and engine through a mechanical coupling or
generator set. As only the electric motor is connected to the an angle gear. These vehicles do not require a generator (as in
drive train, the IC engine can run at an optimum speed to run the the case of series HEV configuration) and they can be connected
generator thus greatly reducing the emissions. The batteries can to an electric grid (off-board) for recharging the batteries. The
either be charged off-board, by external DC power link from the electric motor can be made to act as generator via a mechanical
electric-grid, or on-board, with the help of an alternator and an clutch which can then be used for regenerative braking. Both the
IC engine. In this setup, it is possible to design the operation gas-powered engine and the electric motor can turn the
such that the IC engine never idles and thus the overall transmission simultaneously, and the transmission, of course,
emissions are reduced. The schematics of series HEV is shown turns the wheels. The fuel tank and gas engine and the batteries
in Figure 1. and electric motor connect independently to the transmission—
as a result, in a parallel hybrid; both the electric motor and the
gas engine can provide power.
Advantages:
In this configuration, the battery size can be small, as both
the engine and motor are connected to the drive train.
The performance is very much comparable to conventional
vehicles due to dual power sources.
The constraints on the battery pack and the electric motor
are relaxed in this configuration.
Disadvantages:
Figure 1. Series HEV drive train The vehicle cannot get full acceleration support from the
electric motor when the battery pack charge is low.
It can be seen that the IC engine is connected to the The control complexity increases significantly, because the
alternator (generator) which in turn is connected to the battery power flow has to be regulated and blended from two
pack and electric motor through an electronic control unit. This parallel sources.
scheme allows the electric motor to get its power from either The power blending from the ICE and the motor
battery pack or the alternator or both as per the battery state of necessitates a complex mechanical device.
charge and vehicle acceleration requirements [4-6].
 III. DESIGN AND IMPLEMENTATION

A. Mechanical Design
Mechanical design of the proposed HEV starts with the
functional block diagram, and design of the chassis, the major
components involved in prototyping and the parts constructed.
Functional block diagram: A simple and comprehensive
block diagram is presented to manage the workflow of this
study. In designing the prototype of the hybrid car,
Figure 2. Parallel HEV drive train
mechatronics design approach illustrated in Figure 4.

C. Dual Mode HEV Configuration

Dual mode hybrid vehicles are parallel hybrids, but differ
from them in the aspect that an alternator (generator) is coupled
to the IC engine that charges the battery. During normal
operation, the IC engine turns both the drive train and the
generator, which in turn feeds the battery pack through the
electronic control unit. During full-throttle acceleration, the
electric motor gets power from the battery and assists the IC
engine to attain the requested acceleration. Choosing a full size
electric motor, which uses the IC engine only for charging the
battery and occasionally for turning the wheels, can reduce tail
pipe emissions and this can be achieved with the help of a Figure 4. Functional block diagram of the proposed HEV
mechanical clutch. This configuration exhibits dual capability
and hence the name dual mode HEV configuration. The Chassis design: Chassis is the base part of the mechanical
schematic of the dual-mode HEV configuration is shown in design. The chassis took shape of only the rear part of the actual
Figure 3. vehicle, this is to consider the place where all the main
components will reside and thus reduce the manufacturing cost
of the prototype. The dimensions are calculated by considering
the general size of the components after research conducted.
The angle aluminum is considered as the main material for the
construction of the chassis. There are few reasons why this
angle aluminum is very suitable for the construction of the
prototype such as light weight, easy to connect, high strength etc.
Gasoline Engine: The selected engine is BG-328 brush
cutter, with peak power 0.81kW. Important advantages of this
engine include fuel efficiency and weight. A detailed
specification is provided in Table I.

TABLE I. SPECIFICATIONS OF GASOLINE ENGINE

Model BG-328
Engine type 2 cycle, single cylinder, gasoline engine
Displacement 30.5 cc
Maximum output 0.81kW
Fuel Mix fuel of gasoline and 2 cycle oil
Dimension (LxWxH) 345 X 280 X 401 mm
Dry weight 9.4kg
Supplier OTONANI Co. Ltd
Figure 3. Dual Model HEV drive train
DC motor: The type of motor used can vary depending on
Advantages: the power system of the vehicle and its size. Current internal
It has both the advantages of the series and parallel combustion hybrid cars tend to use AC induction motors due to
both the power requirements and the generally increased
configuration.
efficiency over commutated DC motors. However for smaller
Disadvantages: low-speed vehicles the desire would be to use some form of DC
It needs more components such as an electric motor, an motor to decrease the overall complexity of the vehicle. The use
electric generator, an IC engine and a battery pack, for its of a DC motor would reduce the power conditioning
operation which makes it more expensive.
requirements by eliminating the need for an inverter from DC to To reverse the direction of rotation of motor, it is necessary
AC power. Despite being slightly less efficient, the reduced to reverse the polarity of the voltage on the motor. This requires
expense and balance of plant obtained by using DC motors the use of an H-Bridge. An H-Bridge schematic diagram is
makes them more suitable for low speed hybrid vehicles. There shown in Figure 6. The application of H-Bridge will be
are some other mechanical parts included such as SLA battery, explained in later section of the chapter. Using this topology, it
alternator and wheels, transmission, belting, chain etc. is possible to provide variable speed control in both directions.

B. Electrical Design PIC 16F877A Microcontroller: It has 40 pins and 5 input-

Microcontroller is used to control the electrical part of the output (I/O) ports. Port A consists of 6 pins which can be set up
design. There are many types of microcontrollers of different as either digital I/O or analog inputs. Port B is an 8-pin port
platforms in the market with various features. These include which can be used for both digital I/O operations and in-circuit
Atmel’s AVR, Intel compatible 8051 from various debugger (ICD) operations. Port C, on the other hand, is a 5-pin
manufacturers, DS80C400 Networked microcontroller from multi-functional port, which can be used for digital I/O, as
Dallas Semiconductors, and the famous PIC series capture-compare (CCP) input, or pulse-width modulation
microcontrollers from Microchip [7-9]. In this study the (PWM) output. Moreover, it can be used as universal
microcontroller used is PIC 16F877A. asynchronous receiver/transmitter (UART) for serial
Electrical system functional block diagram: Every motor communications. Port D is an 8-pin port, which can be used for
control circuit can be divided into the drive electronics and the both digital I/O as well as parallel slave port (PSP) functions.
controlling software. These two pieces can be fairly simple or Finally, Port E is a 3-pin port, which is used for external
extremely complicated depending upon the motor type, the memory connections. The clock is provided by a crystal
system requirements and the hardware/software complexity oscillator. Supply voltage VDD = 5V is regulated DC Voltage.
trade-off. The drive electronics as well as the controlling The connections are as shown in Figure 6. VSS = 0V is the
software will be explained and discussed thoroughly. The ground. The crystal oscillator is connected to the ground with 30
functional block diagram of the electrical system connection of pF capacitors.
this study is shown in Figure 5. It is fairly simple in term of
linking as much of the controlling is done by software. The
main connection is between the motor and the battery, and the
battery to the alternator. The potentiometer is be used as means
of controlling the speed of the motor.

Figure 5. The functional block diagram of the electrical part of

the proposed HEV

Pulse-Width Modulation is critical to modern digital motor

controls. By adjusting the pulse width, the speed of a motor can
be efficiently controlled without larger linear power stages. PIC Figure 6. The clock and input connection
16F877A has hardware PWM modules on them. These modules
are built into the Capture/ Compare/PWM (CCP) peripheral. Battery voltage indicator: The circuit in Figure 7 below is a
CCP peripherals are intended for a single PWM output, while voltage analyzer that gives an audio-visual indication of the
the Enhanced CCP (ECCP) is designed to produce the complete battery voltage level and also warns about the critical voltage
H-Bridge output for bidirectional Brushed DC motor control. level at which the battery require charging. This circuit is
integrated just as an indication. It is separated from the main
controlling circuit as the main circuit that consists of
microcontroller can only take 5V power supply and the battery The program will start to recharge the battery at voltage
voltage indicator work with 12V power supply. It also feature value = 11.8V. The program is also set to be able to move
switch on-off to easily interface between the user and the circuit. forward and reverse by a button switch as a mean to do so.

V. CONCLUSIONS
An HEV intelligently gets around the individual problems
associated with the gasoline engine and the electric vehicle. It
diminishes the production of emissions and the use of fuel. The
problem of batteries for the electric vehicle is conquered. An
HEV charges itself – it never has to be plugged in. When not in
use providing power, the motor can run as a generator to
transfer energy from regenerative braking and from the gasoline
engine to the batteries.
The only recharging necessary is refueling by going to the
gas station. Also, there is not the same demand on the batteries
as there would be in an electric vehicle, where the batteries must
store all the energy the car needs. These batteries are smaller,
and only have to be able to provide for the high-power uses.
Similarly, the engine for a HEV is smaller than it would be in a
traditional car, as it doesn’t have to provide as much horsepower.
Figure 7. The battery voltage indicator circuit
ACKNOWLEDGMENT
This research work is supported by IIUM under endowment
IV. RESULTS AND DISCUSSION
project EDWB11-044-0522.
The design of HEVs permits great flexibility, allowing the
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