A Tutorial on Hybrid Electric Vehicles: EV, HEV, PHEV and FCEV

Dr. James Gover, IEEE Fellow Professor of Electrical Engineering Kettering University

Gasoline Prices Are Driving Commercial HEV Development

Gerhard Metschies, Pain at the Pump, Foreign Policy, July/August, 2007, p.28.

Nations Fuel Standards Are Driving HEV Development

IEEE Spectrum, September, 2006.

Power Electronics in Hybrid Vehicles

ELECTRIC DRIVE MODE BATTERY DISCHARGE ELECTRIC DRIVE MODE BUCK-BOOST CONVERTER ELECTRIC DRIVE MODE THREE PHASE INVERTER

HIGH VOLTAGE BATTERY

REGENERATIVE BRAKING MODE BATTERY CHARGE

DC-DC CONVERTER

INVERTER/ RECTIFIER

MOTOR

REGENERATIVE BRAKING MODE BUCK-BOOST CONVERTER

REGENERATIVE BRAKING MODE 3 PHASE DIODE RECTIFIER

Energy Flow Diagram for Series PHEV

ICE
Electric Generator Rectifier Battery DC to DC Converter Three Phase, Frequency Dependent Inverter

Wheel

120 Volts AC or 240 Volts AC External Power Source

Electric Motor

Systems Architectures of HEVs

C.C. Chan, The State of the Art of Electric Hybrid, and Fuel Cell Vehicles, Proceedings of the IEEE, April, 2007.

Types of EVs
Internal Combustion Engine
Belt Driven Integrated Starter Generator (ISG): 3-5kW With Idle Stop and Regenerative Braking Integrated Starter Generator: 7-12kW With Idle Stop, Regenerative Braking & Downsized ICE 30-50 kW, 200-500 Volts With Electric Launch, Idle Stop, Regenerative Braking & Downsized ICE

Battery Powered Electric Vehicles

75-100 kW Fuel Cell Electric Vehicles

K. T. Chau and C.C. Chan, Emerging Energy-Efficient Technologies for Hybrid Electric Vehicles, Proceedings of the IEEE, April, 2007.

Toyota Hybrid Roadmap

C.C. Chan, The State of the Art of Electric Hybrid, and Fuel Cell Vehicles, Proceedings of the IEEE, April, 2007.

Characteristics of EVs, HEVs, PHEVs and FCEVs

C.C. Chan, The State of the Art of Electric Hybrid, and Fuel Cell Vehicles, Proceedings of the IEEE, April, 2007.

Integrated Starter-Generator Based 42 Volt System

Ali Emadi, Kauskik Rajashekara, Sheldon Wiliamson and Srdjan Lukic,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

Series Hybrid System

Ali Emadi, Kauskik Rajashekara, Sheldon Wiliamson and Srdjan Lukic,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

Parallel HEV Drive Train

Ali Emadi, Kauskik Rajashekara, Sheldon Wiliamson and Srdjan Lukic,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

Series/Parallel HEV Hybrid

Ali Emadi, Kauskik Rajashekara, Sheldon Wiliamson and Srdjan Lukic,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

Planetary Gear Set

Mehrdad Ehsani, Yimin Gao, and John M. Miller, Hybrid Electric Vehicles: Architecture and Motor Drives, Proceedings of the IEEE, April, 2007.

FCEV & PHEV Volt Concepts

Fuel Cell Hydrogen Tanks
Fuel Tanks

Small Battery

Large Battery

FCEV Option

ICE

PHEV Option

Escape Hybrid Transaxle Cut-Away

High Voltage Connector

Transaxle Control Module

Planetary Gearset

Stefan Pototschnik, Overview of the Ford Escape Hybrid, Sept. 12, 2006, Kettering University.

Integration of PHEVs On Grid

POWER LINE TRANSIENTS

Mehdi Ferdowski, Plug-in Hybrid Vehicles A vision for the Future, 2007 IEEE VPPPC

Night Electricity Is the Fuel for PHEV

Source: EPRI

Thomas Schneider, Transportation Efficiency Through Electric Drives and the Power Grid, Capitol Hill Forum, Plug-in Hybrid Electric Vehicles: Towards Energy Independence , July 10, 2007.

PHEV Energy Storage Used for Power Peaking

PHEV USE

Harold Adams, Planning Considerations for a Carbon Constrained Grid, 10/2007

EPRI Assumptions for New Car US Sales

Two Battery Types Are Preferred for Hybrid-Electric Vehicles

Nickel Metal Hydride (NiMH)
Introduced near end of 20th century Similar performance to NiCad battery but its energy and power densities are higher and it charges faster The metals into which hydrogen is adsorbed are proprietary The battery cell must be sealed in order to keep air from reacting with the hydride Battery can require cooling if charged fast

Lithium Ion
Introduced in early 1990s. Precise voltage control is needed when charging battery because if too high, battery can be damaged and if too low, battery will be undercharged Because of its considerable weight advantage over other battery types, it is highly attractive for future hybrid electric vehicles Large batteries are prohibitively expensive

NiMH Battery Discharge Reactions

Metal alloy sponge that absorbs and then gives back hydrogen H2 + M H2 + 2OH
-

MH2 2H2O + 2e
-

K + H2O 2NiO(OH)+2H2O +2e

-

OH

2Ni(OH)2 + 2OH

Load

Charge Flow in Li-Ion Battery

Steven Vance, Parallel-Cell Connection in Lithium-Ion Battery, Kettering University Senior Thesis, 12/08

Hysteresis Effect in NiMH Battery Cell

Steven Vance, Parallel-Cell Connection in Lithium-Ion Battery, Kettering University Senior Thesis, 12/08

Comparison of Performance of Battery Types Used in HEV

Andrew F. Burke, Batteries and Ultracapacitors for Electric, Hybrid, and Fuel Cell Vehicles, Proceedings of the IEEE, April, 2007.

Battery Power as Function of Temperature

Steven Vance, Parallel-Cell Connection in Lithium-Ion Battery, Kettering UniversitySenior Thesis, 12/08

Effect of Temperature on NiMH Battery Performance

L. Serraro, Z. Chehab, Y. Guezennec and G. Rizzoni, An Aging Model fo NI-MH Batteries for Hybrid Electric Vehicles, IEEE VTS Vehicle Power and Propulsion Conference, July, 2005.

Dependence of NiMH Cycle Life on Depth of Discharge

L. Serraro, Z. Chehab, Y. Guezennec and G. Rizzoni, An Aging Model fo NI-MH Batteries for Hybrid Electric Vehicles, IEEE VTS Vehicle Power and Propulsion Conference, July, 2005.

Ultracapacitors Reduce Battery Surge Currents and Increase Battery Life

Andrew F. Burke, Batteries and Ultracapacitors for Electric, Hybrid, and Fuel Cell Vehicles, Proceedings of the IEEE, April, 2007.

Packaging of Prius Power Electronics

Staunton, Ayers, Marlino, Chiasson,& Burress, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System, ORNL/TM-2006/423, May, 2006.

Buck-Boost DC-DC ConverterContinuous Mode

Vo Vs Vo Vo Lmin D 1 D D RCf (1 D)2 R 2f
Note Ripple Voltage

Switch Closed

Switch Open
Hart, p. 201

Inverter Schematic

Low Voltage Battery, High Voltage Fuel Cell

Sih-sheng Lai and Douglas J. Nelson, Energy Management in Hybrid Electric and Fuel Cell Vehicles, Proceedings of the IEEE, April, 2007.

Low Voltage Fuel Cell, High Voltage Battery

Sih-sheng Lai and Douglas J. Nelson, Energy Management in Hybrid Electric and Fuel Cell Vehicles, Proceedings of the IEEE, April, 2007.

Prius Inverter IGBT/Diode Package

Staunton, Ayers, Marlino, Chiasson,& Burress, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System, ORNL/TM-2006/423, May, 2006.

Time Dependence of IGBT Switch Turn-Off

Switching Losses

Heat Removal Mechanisms from Chip Without Special Cooling

In ICs with conventional packaging, the heat generation is at the top surface of the chip.

CHIP
SUBSTRATE HEAT SINK

PRINTED WIRING BOARD

CONVECTION
CONDUCTION

RADIATION

Prius Inverter IGBT/Diode Package

Staunton, Ayers, Marlino, Chiasson,& Burress, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System, ORNL/TM-2006/423, May, 2006.

IGBT-Diode Pair

Staunton, Ayers, Marlino, Chiasson,& Burress, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System, ORNL/TM-2006/423, May, 2006.

Overview of Packaging in Prius Inverter/Converter

Staunton, Ayers, Marlino, Chiasson,& Burress, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System, ORNL/TM-2006/423, May, 2006.

Toyota Camry Hybrid Integrated Power Module

Camry HEV Inverters with Top Circuit Board and Side Housing Removed

Toyota HEV Packaging Innovation: Comparison of Prius and Camry Inverters and Converters
Parameter Motor inverter peak specific power (without converter), kW/kg Camry 105/~7.5=~14 Prius 50/8.8= 5.7

Motor inverter peak power density (without converter), kW/L

Buck/boost converter specific power, kW/kg Buck/boost converter power density, kW/L

105/~6 =~17.5

50/8.7=5.7

30/~7.6=~3.9

20/4.8=4.2

30/2.9=10

20/5.9=3.41

1 This low converter power density is largely the result of the non-optimal packaging of the converter filter capacitor in the Prius inverter/converter housing

Toyota Electric Drive Innovation: Prius Combined Inverter/Motor Efficiency Map

Staunton, Ayers, Marlino, Chiasson,& Burress, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System, ORNL/TM-2006/423, May, 2006.

Three Dimensions of Power Electronics Design

Steady Innovation Stream for IGBTs

Z. John Chen and Ichiro Omura, Power Semiconductor Devices for Hybrid, Electric and Fuel Cell Vehicles, Proceedings of the IEEE, April, 2007.

Evolution of Power Packaging Technology

Z. John Chen and Ichiro Omura, Power Semiconductor Devices for Hybrid, Electric and Fuel Cell Vehicles, Proceedings of the IEEE, April, 2007.

Cross-Section of Normally-On IonImplanted SiC VJFET.

0.19 Square Cm VJFETs Fabricated on a 3-Inch 4H-SiC Wafer

Power Electronics Noise in Hybrid Vehicles

NOISE SOURCES
ELECTRIC DRIVE MODE BATTERY DISCHARGE ELECTRIC DRIVE MODE BUCK-BOOST CONVERTER ELECTRIC DRIVE MODE THREE PHASE INVERTER

HIGH VOLTAGE BATTERY

REGENERATIVE BRAKING MODE BATTERY CHARGE

DC-DC CONVERTER

INVERTER/ RECTIFIER

MOTOR

REGENERATIVE BRAKING MODE BUCK-BOOST CONVERTER

REGENERATIVE BRAKING MODE 3 PHASE DIODE RECTIFIER

Inverter Common Mode Noise

Firuz Zare, EMC and Modern Power Electronics, Tutorial, 2007 IEEE International Symposium on EMC

Noise Spectrum Due to IGBT or MOSFET Switching in Power Electronics

A

'

'
T

Cn

n n ' Sin ( ) Sin 2A 2T ][ 2T ] [ n n ' T 2T 2T

Frequency Spectrum of an Ideal Trapezoid Signal

Trapezoid signal amplitude = 1, Frequency = 20kHz, Rise time = Fall time = 400ns = tau, full width at half max of current = 25 microseconds = t0.
F. Costa and D. Magnon, Graphical Analysis of the Spectra of EMI Sources in Power Electronics, IEEE Transactions on Power Electronics, Vol. 20, No. 6, Nov. 2005.

Electrical Behavior of Ball Bearings

Firuz Zare, EMC and Modern Power Electronics, Tutorial, 2007 IEEE International Symposium on EMC

Effects of Inverter Generated Common Mode Noise on Motors

Leakage Currents or Bearing Current Going to Ground Through Stray Capacitance Between Stator and Rotor Can Create Skin Currents on Auto Body. (Very low impedance at high frequency.)
Want CM return currents to flow on cable shield so no external electromagnetic field generated.

Shortened Insulation Lifetime of Stator Windings. Pitting of Bearings.