SAE R-396-2012 Advanced Hybrid Powertrains for Commercial Vehicles (To Purchase Call 1-800-854-7179 USA Canada or 303-397-7956 Worldwide).pdf

1、Haoran Hu Rudy Smaling and Simon J. Baseley Advanced Hybrid Powertrains for Commercial Vehicles Hu Smaling Baseley The term commercial vehicle applies to everything from light delivery vehicles to class 8 long haul trucks, buses, and coaches. These vehicles are used for a wide range of duties, inclu

2、ding transporting goods or people and infrastructure service. The recent development of hybrid powertrain components and system integration technologies can reduce fuel consumption by up to 50% compared to conventional IC engine-powered vehicles. However, energy consumption outpaces production, and

3、worsening air quality and traffic congestion demand that sustainable transportation solutions be explored. This book provides a broad and comprehensive look at hybrid powertrain technologies for commercial vehicles. It begins with the fundamentals of hybrid powertrain systems, government regulations

4、, and driving cycles, then provides design guidelines and key components of hybrid powertrains for commercial vehicles. It was written for vehicle and component engineers and developers, researchers, students, policymakers, and business executives in the commercial vehicle and transportation industr

5、ies to help them understand the fundamentals of hybrid powertrain technologies and market requirements for commercial vehicles. It is useful for anyone who designs or is interested in hybrid powertrains and their key components. About the AuthorsHaoran Hu is chief scientist at Eaton Corporation. He

6、has over 20 years of experience in R phone 877-606-7323 (U.S. and Canada only) or 724-776-4970 (outside U.S. and Canada); fax 724-776-0790; email CustomerServicesae.org; website http:/books.sae.org. R_396_book_CS5.indb 2 7/2/12 4:23 PM Advanced Hybrid Powertrains for Commercial Vehicles By Haoran Hu

7、 Rudy Smaling Simon J. Baseley Warrendale, Pennsylvania, USA R_396_book_CS5.indb 3 7/2/12 4:23 PM Copyright 2012 SAE International eISBN: 978-0-7680-7727-8 400 Commonwealth Drive Warrendale, PA 15096-0001 USAE-mail: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada)724-776-4970 (outs

8、ide USA) Fax: 724-776-0790 Copyright 2012 SAE International. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, distributed, or transmitted, in any form or by any means without the prior written permission of SAE. For permission and licensing requests,

9、contact SAE Permissions, 400 Commonwealth Drive, Warrendale, PA 15096-0001 USA; email: copyrightsae.org; phone: 724-772-4028; fax: 724-772-9765. ISBN 978-0-7680-3359-5 SAE Order Number R-396 DOI 10.4271/R-396 Library of Congress Cataloging-in-Publication Data Hu, Haoran.Advanced hybrid powertrains f

10、or commercial vehicles / by Haoran Hu, Rudy Smaling, Simon J. Baseley.p. cm.“SAE order number R-396.”Includes bibliographical references.ISBN 978-0-7680-3359-51. Hybrid electric vehiclesPower trainsDesign and construction. 2. Commercial vehiclesDesign and construction. I. Smaling, Rudy. II. Baseley,

11、 Simon J. III. Title. TL260.H825 2012629.2504-dc232012012047 Information contained in this work has been obtained by SAE International from sources believed to be reliable. However, neither SAE International nor its authors guarantee the accuracy or completeness of any information published herein a

12、nd neither SAE International nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SAE International and its authors are supplying information, but are not attempting to render engineering

13、 or other professional services. If such services are required, the assistance of an appropriate professional should be sought. To purchase bulk quantities, please contact: SAE Customer Service Email: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada) 724-776-4970 (outside USA) Fax:

14、724-776-0790 Visit the SAE International Bookstore at http:/books.sae.org R_396_book_CS5.indb 4 7/2/12 4:23 PMv Contents Preface ix Acknowledgments xiii Chapter 1 Introduction of Hybrid Powertrains for Commercial Vehicles 1 1.1 Introduction 1 1.2 History of Commercial Vehicles 2 1.3 Commercial Vehic

15、le Classification 5 1.4 Energy Consumption of Commercial Vehicles 7 1.5 Drivers of the Efficient Powertrain for Commercial Vehicles 10 1.6 Classification of Commercial Vehicle Hybrid Powertrains 18 1.7 References 30 Chapter 2 Internal Combustion Engines for Commercial Vehicles 33 2. 1 Requirements o

16、f Internal Combustion Engines for Commercial Vehicles 33 2.2 Basics of Internal Combustion Engines 34 2.3 Major Engine Components and Subsystems 43 2.4 Engine Operating Characteristics 57 2.5 Advanced Engine Technologies 60 2.6 References 70 Chapter 3 Introduction of Clutches and Transmissions for C

17、ommercial Vehicles 73 3. 1 Background of Transmissions 73 3.2 Key Characteristics of Vehicle Transmissions 77 3.3 Key Components of Commercial Vehicle Drivetrains 81 3.4 Manual Transmission 88 R_396_book_CS5.indb 5 7/2/12 4:23 PMvi Contents 3.5 Automated Manual Transmission 92 3.6 Dual-clutch Transm

18、ission 95 3.7 Fully Automatic Transmission 97 3.8 Continuously Variable Transmissions for Commercial Vehicles 98 3.9 Characteristics and Efficiency of Commercial Vehicle Transmissions 104 3.10 References 105 3.11 Appendix 10 7 Chapter 4 Energy Storage Systems: Battery, Ultracapacitor, Accumulator, a

19、nd Flywheel 109 4. 1 Energy Storage Systems for Commercial Hybrid Applications 109 4.2 Electrical Chemical Battery 11 2 4.3 Battery Management Systems 12 9 4.4 Hydraulic Energy Storage 13 7 4.5 Flywheel Energy Storage (FES) 14 3 4.6 References 14 5 Chapter 5 Hybrid-electric System Design and Optimiz

20、ation 149 5. 1 Characteristics of Hybrid-electric Powertrains 14 9 5.2 Hybrid System Architectures 15 4 5.3 Hybrid System Selection 16 1 5.4 References 17 4 Chapter 6 Hybrid-electric Power Conversion Systems 177 6. 1 Basic Three-phase Motor Theory 17 7 6.2 Basic Power Inverter Design and Operation 1

21、8 1 6.3 Basic Motor/Generator Designs 18 3 6.4 Stator Design 19 0 6.5 Rotor Design 19 2 6.6 Electric Motor Power Density 19 5 Chapter 3 ( continued) R_396_book_CS5.indb 6 7/2/12 4:23 PMvii Contents 6.7 Electric Motor Characteristics 19 7 6.8 References 20 2 Chapter 7 Hydraulic Hybrid Powertrain Syst

22、em Design 203 7.1 Introduction 20 3 7.2 Hydraulic Hybrid System Architecture 20 8 7.3 Design and Specification of Hydraulic Hybrid Systems 21 3 7.4 Examples of Systems at or near Production Application 22 0 7.5 References 22 6 Chapter 8 Hydraulic Hybrid Components and Controls 229 8.1 Introduction 2

23、2 9 8.2 Hydraulic Pumps and Motors 22 9 8.3 Valves 245 8.4 Pipes and Fittings 24 7 8.5 Hydraulic Oils and Related Systems 24 8 8.6 Control Units and Transducers 25 4 8.7 References 25 5 Chapter 9 Fuel Cell Hybrid Powertrain Systems 257 9. 1 Fuel Cell Hybrid Powertrain 25 7 9.2 Operating Principles o

24、f Fuel Cells 25 8 9.3 Polymer Electrolyte Membrane (PEM) Fuel Cells for Commercial Vehicles 26 2 9.4 Solid Oxide Fuel Cells Auxiliary Power Unit (APU) and Range Extender 26 7 9.5 References 27 9 9.6 Appendix: Comparison of Fuel Cell Technologies 28 1 Chapter 10 Commercial Vehicle Electrification 283

25、 10.1 Introduction 28 3 10.2 Idle Reduction Technologies 28 4 Chapter 6 ( continued) R_396_book_CS5.indb 7 7/2/12 4:23 PMviii Contents 10.3 Electrically Driven Boost System and Other Components 29 1 10.4 Electrification for Plug-in Hybrid Commercial Vehicles 29 6 10.5 External Charging and Plug-in H

26、ybrid Commercial Vehicles 299 10.6 References 31 2 Chapter 11 Hybrid Powertrain System Modeling, Simulation, Validation, and Certification 315 11. 1 Model-based Control System Development 31 5 11.2 Models for Hybrid-electric Powertrains of Commercial Vehicles 320 11.3 Dynamic Modeling of Hybrid-elec

27、tric Powertrain System 33 1 11.4 System Control and Optimization for Hydraulic Hybrid Vehicles 338 11.5 Model-based Test and Validation 34 4 11.6 Hybrid Vehicle Certification 34 8 11.7 References 35 5 11.8 Appendix: Drive Cycles 35 8 Chapter 12 Sustainable Transportation and Future Powertrain Techno

28、logies 363 12.1 Introduction 36 3 12.2 PHEV and Battery Charger 36 5 12.3 Intelligent Transportation System, Smart Grid, and Multimodal Transportation 37 1 12.4 Government Regulations and Incentives 38 0 12.5 Future Powertrain Technologies and System Solutions for Sustainable Transportation 38 3 12.

29、6 References 38 9 Index 395 About the Authors 40 5 Chapter 10 ( continued) R_396_book_CS5.indb 8 7/2/12 4:23 PMix Preface C ommercial vehicles cover a wide range of applications from light delivery vehicles and vocational trucks to Class 8 long-haul trucks, city buses, and intercity coaches. Commerc

30、ial vehicles are used for a wide range of duties, including transporting goods or people and infrastructure service. In 2010, the worldwide production of commercial vehicles exceeded 19 million units. Commercial vehicles transported over half of the value traded by the United States with Canada and

31、Mexico. Over the last 100 years, the powertrain of commercial vehicles has seen continued development since the late 19th Century invention of the gasoline- or diesel-fueled internal combustion engine. In 1904, Ferdinand Porsche built the first hybrid vehicle that housed electric motors in the front

32、 wheel hubs while a gasoline-engine-powered generator provided power. During the first decade of the 1900s, both General Electric in the United States and Siemens in Germany produced hybrids as commercial vehicles. In the 1920s, heavy- duty commercial vehicles were firmly established as a major mean

33、s of freight conveyance. Diesel engines, invented and first built by Dr. Rudolf Diesel in 1897, have been used in large trucks since the 1930s in the United States due to their larger torque and higher thermal efficiency compared to gasoline- powered engines. In the early 1970s, concerns emerged ove

34、r growing dependence on imported petroleum and deteriorating air quality due to emissions from fos- sil fuel combustion. In response, the U.S. Congress passed the Electric and Hybrid Vehicle Research, Development worsening pollution and traffic congestion in major cities demand that sustainable tran

35、sportation solutions be explored. In addition to the IC engine hybrid powertrain, further powertrain improvement technologies may include the utilization of various fuel sources with optimized energy conversion efficiency. This can include plug-in hybrid, range extender electric, and pure electric v

36、ehicles. Other options are mul- timodal transportation with intelligent transportation technologies, smart grid, advanced energy storage technologies, and intelligent electric charg- ing infrastructure. Sustainable transportation may also include renewable resources such as biofuels, or energy deriv

37、ed from solar, wind, or geothermal sources. Reduction of energy demand through government policy and incen- tives, advanced transportation planning, and public awareness and participa- tion is another option. This book, Advanced Hybrid Powertrains for Commercial Vehicles, pro- vides a broad and comp

38、rehensive insight into hybrid powertrain technologies for commercial vehicles. Based on the authors extensive experiences in devel- oping advanced powertrain technologies, this book explains the fundamentals of hybrid powertrain systems, government regulations, and driving cycles. It provides design

39、 guidelines and describes key components to prospective engineers and developers, powertrain researchers, engineering students, poli- cymakers, and business executives in the commercial vehicle and transporta- tion industries. Chapter 1 introduces the basics of commercial vehicles, including the dev

40、elopment history of commercial vehicles, classification, driving cycles, regulations, the fundamentals of powertrain hybridization, and various hybrid system technologies, including the hybrid-electric powertrain, hybrid hydrau- lic powertrain, and hybrid pneumatic powertrain. This chapter also anal

41、yzes the advantages and disadvantages of various hybrid technologies for different driving cycles and applications. Chapter 2 describes basic concepts and new developments of internal com- bustion engines for the commercial vehicle market, such as HCCI and low- temperature combustion, emission reduc

42、tion technologies, urea-based SCR and LNT NOx aftertreatment technologies, DPF systems for PM reduction, etc. Chapter 3 introduces the basics of clutches and transmissions for com- mercial vehicles. It discusses the basic design principles and characteristics of clutches and manual, automated manual, and automatic transmissions; double clutch transmissions (DCTs); and continuously variable transmissions (CVTs). R_396_book_CS5.indb 10 7/2/12 4:23 PM