103 sudhir

Experimental analysis of 1400 cc diesel engine car converted into Hybrid Electric Vehicle by using

BLDC hub motors

byProf. Sudhir Gupte

Automobile Engineering DepartmentA.D.Patel Institute of Technology

1IV th International Conference on

Advances in Energy Research 12 Dec' 2013

Introduction

Two reasons for the need of Conversion.

2IV th International Conference on Advances in Energy Research 12

Dec' 2013

Fossil fuel resources depleting

Environment PollutionGlobal Warming

Stringent Mandatory norms

Newer TechnologiesHike in Fuel pricesDemand and supply

To achieve mandatory pollution standards out of compulsion

Introduction: What is Automotive Industry doing ?

3IV th International Conference on Advances in Energy Research - 12

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Power to Weight Ratio

Reduction in Vehicular Weight

Improvement in Combustion

EV/HEV

Air/Fuel Ratio

Engine down sizing

Study of Driving cycle Aerodynamics

Mild, Micro etc. Hybrids. But all these comes at very high development cost and complicated & expensive installations on the vehicle.

BUTIf per capita consumption is not reduced drastically and if alternate energy vehicles are not developed, they will not be able to sustain the market conditions in the near future.


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Integrated holistic approach to improve Quality of air

Improvement in Roads and traffic conditions Fuel Quality standards Bio Fuels & Alternate energy sources. Electric vehicle mission plan declared by Govt. India 9th

Jan, 2012.


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HoweverThose Millions of old vehicles will be still guzzling unwanted, harmful pollutants in the atmosphere at an alarming rate, still contributing towards the menace of global warming, which will continue, if they are not converted into hybrid electric vehicles.


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Hence

1400 cc diesel engine car converted

into Hybrid Electric Vehicle by using

BLDC hub motors –

An Experimental analysis

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Following points were considered while attempting to contribute towards improving the quality of air or reduce further damage being created by the existing /old gasoline and /or diesel vehicles.

conversion should be economical and affordable. Conversion should be easy. An unskilled

worker/mechanic should be able to carry out the conversion within 4 to 5 hours, after receiving necessary one day training.

Minimum requirement of special tools. Return on investment should be measurable and

attractive for the user. Convenient to use by the customer. Hassel free service. Ease of maintenance. Ease of implementation even for vehicle manufacturer

on the similar new models. Satisfactory performance.


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Concept : Proposed Hybrid system

Using the existing IC engine as main source. Electric motors providing driving force as

Auxiliary power source. Can be used as four wheel drive as and when

necessary. All four wheels disc brake system. No/Minimum modifications in the existing drive

train.


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Concept : Proposed Hybrid system

… Cont. On board Energy flow: Separate Battery pack

for Existing engine and for electric motors. Plug-in type charging system for Electric motor

batteries and existing alternator charging system for the vehicular battery.

Regenerative braking system not adopted, because, under most ideal conditions, efficiency of loop, battery to kinetic and kinetic to battery charging is no greater than 50 %. Also, it adds to cost, which may prohibit customers for conversion.


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Models Applicable:

Maruti: M800, Alto, Zen Tata: Indica Hundai: Santro All “B segment” cars with Front Transverse

Engine.


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Kit comprising of Parts Permanent Magnet BLDC Hub Motors Controller Accelerator pedal control Battery Pack (options to choose type of

Battery: Pb/Acid, Lithium-Ion, Lithium polymer, etc.)

Wiring harness (inclusive of switches) Charging system Measuring Instruments (optional) Brakes system


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Performance Test Results

Parameters RouteConventional ICE Vehicle

PrototypeHEV

% Saving of Fuel

in EV mode V/s ICE

Fuel Consumption, Liters//100Km

State highway 4.65 2.29 50.8

State highway 4.83 2.62 45.8

NH 8 5.05 2.19 56.6

Express way 5.12 1.97 61.5Maximum Speed Achievable in HEV

62 km/hr


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ParametersConventional

ICE VehicleHEV after Conversion

Engine Peak Power 52 PS @ 5000 52PS

Engine Max. Torque, NM 85 @ 2500 rpm 85 @ 2500 rpm

Peak Power of Motor, PM BLDC

- 2.5+2.5 = 5 kw

HEV Battery Pack, 4x12 V, Lead Acid type

- 150 Ah

Passenger Weight 150 Kg 150 Kg

Curb weight of vehicle 1050 Kg 1250 Kg

Total 1200 Kg 1400 Kg


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Torque at WheelsDescription Unit rpm @ ICE HEV

Peak power Ps 5000 52 5

Peak toque Nm 2500 85

Final drive ratio 4.40

Gear Ratios 1st Nm 3.64

2nd Nm 1.95

3rd Nm 1.27

4th Nm 0.88

5th Nm 0.64

Reverse Nm 3.50Tyre Size 165X65R14

Rolling radius m 0.272 0.272

Max. Torque at wheels 1st Nm 1361.36

2nd Nm 729.30

3rd Nm 474.98

4th Nm 329.12

5th Nm 237.86 200

Reverse Nm 1309.00

Max. Speed Km/hr 92 61.5


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Why change EV driving cycle

Prius changes to EV during congested traffic conditions and runs on ICE on highways. OK for urban driving cycles in Metro cities.

In other cities car users are driving in cities for 10 % distances and remaining on highways.

High speed running on highway obviously fuel consumption is high.

With low powered, light weight PMBLDC hub motors, it is proposed to run vehicle on ICE in city traffic conditions and switching on to EV on highway.


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Results and Discussions

By using proposed lower power Hub Motors, up to 61 % saving is achievable on the existing cars.

Peak performance of the available drive line is retained / assured.

Veh. existing electrical system is not disturbed. Existing Hyd. Brakes with Disc brakes in rear. No additional Instrumentation required. Power Steering and A/c are driven by ICE, hence

ICE has to run on idling while running in EV mode.


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Results and Discussions …Cont.

Appropriate torque capacity of PM BLDC hub motors can be selected for the particular vehicle for conversion in to HEV, for deriving optimum results.

Advantage of hub motors is that the output is directly driving the wheels; hence the motors efficiency is the only loss. Geared hub motors add to varying torque reqyuirement.

Well to wheel energy efficiency for Prototype HEV is measures at 0.87 km/MJ as against 0.64 for Insight and 0.56 for Prius models but 1.14 for Tesla (pure EV).


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Conclusions Proposed method is expected to reduce the fuel

consumption by 45 % to 61 % (with A/c & P/S). Results can improve further, if the high Ah, light

weight batteries are utilized. Possible to convert majority of the old cars with

front engine front wheel drive vehicles in to Hybrid Electric car, without much of difficulty and at reasonable cost.

Easy to implement in new veh. models –Existing/introduced in future, by the vehicle manufacturers.


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Conclusions …Contd.

Serviceability and life of components is improved.

Increase Service life of ICE and driveline components.

Reduced maintenance cost of ICE and driveline assembly components.

ROI from 11 to 15 months @ 3000 km per month.


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THANK YOU


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103 sudhir

Technology

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