Published

2016-09-01

Design of a 200kW electric powertrain for a high performance electric vehicle

Diseño de un tren de potencia eléctrico de 200kW para un vehículo eléctrico de alto desempeño

Keywords:

Electric vehicle, ultracapacitors, interleaved dc-dc converter, coupled inductor, efficiency, power density (en)
Vehículo eléctrico, supercondensadores, convertidor dc-dc intercalado, inductor acoplado, eficiencia, densidad de potencia (es)

Downloads

Authors

  • Wilmar Martinez Ph.D. Candidate, Shimane University, Japan. Universidad Nacional de Colombia, Bogotá, Colombia
  • Camilo A. Cortes Universidad Nacional de Colombia
  • Luis E. Munoz Universidad de Los Andes
  • Masayoshi Yamamoto Shimane University

With the purpose of designing the electric powertrain of a high performance electric vehicle capable of running a quarter mile in 10 seconds, firstly it is necessary to calculate the required energy, torque, and power in order to size and select the suitable storage components and electric motors. Secondly, an assessment of the powertrain arrangement is needed to choose the best internal configuration of the vehicle and guarantee the highest efficiency possible. Finally, a design of the power conversion stages, specifically the DC-DC converter that interfaces the storage unit with the electric motors, is required as well. This paper shows the energy calculation procedure based on a longitudinal dynamic model of the vehicle and the selection method of the storage components and motors needed for this application, as well as the design of two 100kW interleaved boost converters with coupled inductors. In addition, a novel operation of the interleaved boost converter is proposed in order to increase the efficiency of the converter. As a result, the designed converter achieved a power density of 24,2kW/kg with an efficiency of 98 %, which was validated by experimental tests of a low power prototype.

Para diseñar el tren de potencia de un vehículo eléctrico de alto desempeño capaz de correr un cuarto de milla en 10 segundos, primero es necesario calcular la potencia y energía necesarias para dimensionar y seleccionar los componentes de almacenamiento y los motores adecuados. Segundo, se requiere una evaluación de varios trenes de potencia para seleccionar la mejor configuración interna del vehículo con el propósito de garantizar la mayor eficiencia posible. Finalmente, se necesita un diseño del convertidor de potencia DC-DC que haga la interfaz entre la unidad de almacenamiento y los motores eléctricos con sus respectivos inversores. Este artículo presenta el procedimiento para el cálculo de la energía necesaria para correr el vehículo con base en un modelo dinámico longitudinal. Así mismo, se presenta el método de selección de los componentes de almacenamiento de energía necesarios. Finalmente, se presenta el diseño de dos convertidores intercalados con inductores acoplados de 100kW operando bajo una novedosa operación propuesta para incrementar la eficiencia del convertidor. Como resultado, el convertidor diseñado logró una densidad de potencia de 24,2kW/kg y una eficiencia de 98%, la cual es validada con pruebas experimentales de un prototipo de baja potencia.

References

Aharon. I., & Kuperman, A. (2011). Topological Overview of Powertrains for Battery-Powered Vehicles with Range Extend-ers. IEEE Transactions on Power Electronics, 26(3), 867-870.DOI: 10.1109/TPEL.2011.2107037

Bonfiglio, C., & Roessler, W. (2009). A Cost Optimized Battery Management System with Active Cell Balancing for Lithium Ion Battery Stacks. Vehicle Power and Propulsion Conference, VPPC’09, 304-309. DOI: 10.1109/vppc.2009.5289837

Castro, N., Lopez, O., & Munoz, L. (2013). Computational pre-diction of a vehicle aerodynamics using detached Eddy simu-lation. SAE International Journal of Passenger Cars - Mechani-cal Systems, 6(1), 414-423. DOI: 10.4271/2013-01-1254

Donglai, G., Yu, Z., & Zhongyang, Z. (2014). Input Current Ripple Cancellation Technique for Boost Converter Using Tapped Inductor. IEEE Transactions on Industrial Electronics, 61(10), 5323-5333. DOI: 10.1109/TIE.2014.2300045

Gillespie, T. (1992). Fundamentals of vehicle dynamics. 1st Ed., SAE International. DOI: 10.4271/r-114

Gu, B., Lai, J., Kees, N., & Zheng, C. (2013). Hybrid-Switching Full-Bridge DC–DC Converter with Minimal Voltage Stress of Bridge Rectifier, Reduced Circulating Losses, and Filter Requirement for Electric Vehicle Battery Chargers. IEEE Transactions on Power Electronics, 28 (3), 1132-1144. DOI: 10.1109/TPEL.2012.2210565

Hirakawa, M., Nagano, M., Watanabe, Y., Andoh, K., Nakatomi, S., & Hashino, S. (2009). High Power Density DC/DC Converter using the Close-Coupled Inductors. IEEE Energy Conversion Congress and Exposition, (ECCE), 1760-1767. DOI: 10.1109/ECCE.2009.5316389

Hucho, W.H. (1998). Aerodynamic Drag of Passenger Cars. Aerodynamic of road vehicles. SAE International, Warendale, PA.

Imaoka, J., Ishikura, Y., Kawashima, T., & Yamamoto, M. (2011). Optimal design method for interleaved single-phase PFC converter with coupled inductor. IEEE Energy Conversion Congress and Exposition (ECCE), 1807-1812.DOI: 10.1109/ECCE.2011.6064004

Luk, P., & Rosario, L. (2006). Power and Energy Management of a Dual-Energy Source Electric Vehicle - Policy Implementation Issues. 5th International Power Electronics and Motion Control Conference - IPEMC 2006, 1-6. DOI: 10.1109/IPEMC.2006.297407

Mantilla, J., Galeano, C., Acevedo, H., & Duque, C. (2008). Implementation of a bus with natural gas articulated motor in Colombia’s massive transportation system: A technical study. Rev. Fac. Ing. Univ. Antioquia, 43, 18-32.

Martinez, W., Cortes, C., & Munoz, L. (2012a). Sizing of Ultraca-pacitors and Batteries for a High-performance Electric Vehi-cle. IEEE International Electric Vehicle Conference – IEVC, 535-541.

Martinez, W., & Cortes, C. (2012b). Design a DC-DC Converter for a High-performance Electric Vehicle. IEEE International Conference on Connected Vehicles and Expo – ICCVE, 335-340. DOI: 10.1109/iccve.2012.73

Martinez, W., & Cortes, C. (2013). High Power Density Interleav-ed DC-DC Converter for a High-performance Electric Vehicle. IEEE Workshop on Power Electronics and Power Quality – PEPQA, 1-6.

Munoz, L.E., Blanco, J.C., Barreto, J.P., Rincon, N.A., & Roa, S.D. (2012). Conceptual Design of a Hybrid Electric Off-Road Ve-hicle. IEEE International Electric Vehicle Conference – IEVC, 576-584.

Nai-Man Ho, C., Breuninger, H., Pettersson, S., Escobar, G., Serpa, L., & Coccia, A. (2012). Practical Design and Imple-mentation Procedure of an Interleaved Boost Converter Us-ing SiC Diodes for PV Applications. IEEE Transactions on Power Electronics, 27(6), 2835–2845. DOI: 10.1109/TPEL.2011.2178269

Rosario, L.C., & Luk, P.C. (2006). Power and Energy Manage-ment Policy Implementation of a Dual Energy Source Electric Vehicle. 3rd IET International Conference on Power Electron-ics, Machines and Drives- PEMD, 464-468. DOI: 10.1049/cp:20060152

Yilmaz, M., & Krein, P. (2013). Review of Battery Charger Topol-ogies, Charging Power Levels, and Infrastructure for Plug-In Electric and Hybrid Vehicles. IEEE Transactions on Power Elec-tronics, 28(5), 2151-2169. DOI: 10.1109/TPEL.2012.2212917

License

Copyright (c) 2016 Wilmar Martinez, Camilo A. Cortes, Luis E. Munoz, Masayoshi Yamamoto

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

The authors or holders of the copyright for each article hereby confer exclusive, limited and free authorization on the Universidad Nacional de Colombia's journal Ingeniería e Investigación concerning the aforementioned article which, once it has been evaluated and approved, will be submitted for publication, in line with the following items:

1.    The version which has been corrected according to the evaluators' suggestions will be remitted and it will be made clear whether the aforementioned article is an unedited document regarding which the rights to be authorized are held and total responsibility will be assumed by the authors for the content of the work being submitted to Ingeniería e Investigación, the Universidad Nacional de Colombia and third-parties;

2.    The authorization conferred on the journal will come into force from the date on which it is included in the respective volume and issue of Ingeniería e Investigación in the Open Journal Systems and on the journal's main page (https://revistas.unal.edu.co/index.php/ingeinv), as well as in different databases and indices in which the publication is indexed;

3.    The authors authorize the Universidad Nacional de Colombia's journal Ingeniería e Investigación to publish the document in whatever required format (printed, digital, electronic or whatsoever known or yet to be discovered form) and authorize Ingeniería e Investigación to include the work in any indices and/or search engines deemed necessary for promoting its diffusion;

4.    The authors accept that such authorization is given free of charge and they, therefore, waive any right to receive remuneration from the publication, distribution, public communication and any use whatsoever referred to in the terms of this authorization.