1. Mechatronics Research Labs Automotive Control and Mechatronics Research Center ICAT’08 İstanbul International Conference on Automotive Technologies November 13 - 14 th, 2008 FOHEV II - The Ford Otosan Hybrid Electric Research Prototype Vehicle İsmail M.C. Uygan, Ahu E. Hartavi, Levent Güvenç, Tankut Acarman Automotive Control and Mechatronics Research Center, Mechanical Engineering Department, İstanbul Technical University, İstanbul, Turkey Varlık Kılıç, İlker Özelgin, Murat Yıldırım Ford Otosan, Research and Development Department, Kocaeli, Turkey Volkan Sezer The Scientific and Technological Research Council of Turkey, Marmara Research Center, Energy Institute, Gebze, Turkey

2. mekar.itu.edu.tr autocom.itu.edu.tr 2/28 Automotive Control and Mechatronics Research Center ICAT 2008

3. mekar.itu.edu.tr autocom.itu.edu.tr 3/28 Overview Introduction oHybrid Electric Vehicle oMarket Trend of Hybrid Electric Vehicles Objective History: FOHEV I FOHEV-II Project Partners Series-Parallel Hybrid Configuration Components & Packaging Real-time Control System Control Strategy oStart-up & Shut-down Preocedure oMaximizing Overall Efficiency Strategy for Power Split Control oHybrid Brake Algorithm Experimental Results Conclusions

4. mekar.itu.edu.tr autocom.itu.edu.tr 4/28 What is Hybrid Electric Vehicle (HEV)? Internal Combustion Engine - The hybrid vehicle has an internal combustion engine much like the one found in most vehicles. However, the engine on a hybrid is smaller and uses advanced technologies to reduce emissions and increase efficiency Electric Motor - The electric motor on a hybrid car is very sophisticated. Advanced electronics allow it to act as a motor as well as a generator. Generator - The generator is similar to an electric motor, but it acts only to produce electrical power. It is used mostly on series hybrids. Controller: Manages the power flow and determines the mode of action. Batteries - The batteries in a hybrid car are the energy storage device for the electric motor. Unlike the fuel in the fuel tank, which can only power the internal combustion engine, the batteries on a hybrid car can put energy into the motor as well as draw energy from the motor. Hybrid Electric Vehicle(HEV) uses both electrical motor and internal combustion engine. HEV Main Components

5. mekar.itu.edu.tr autocom.itu.edu.tr 5/28 Why Hybrid Electric Vehicles? Effects of Global Warming Global Warming History and Future The chief causes of global warming are burning fossil fuels, releasing them into the atmosphere, and the emission of carbon dioxide and other greenhouse gases. Advances in Internal Combustion Engine (ICE) technology including advanced controls will not be enough to meet future emission reduction legislation. Hybrid Electric Vehicles (HEV) form an intermediate term solution for meeting these reduced emission level requirements.

6. mekar.itu.edu.tr autocom.itu.edu.tr 6/28 Hybrid Electric Vehicle Market Worldwide Hybrid ElectricVehicle Sales http://www.marklines.com/en/numproduct/index.jsp#hybrid

7. mekar.itu.edu.tr autocom.itu.edu.tr 7/28 Objective To design and build research prototypes of a hybrid electric light commercial vehicle based on the Ford Transit van, with internal combustion engine and electric motor(s) to reduce undesired emissions and to improve fuel economy while keeping the desired level of driving performance.

8. mekar.itu.edu.tr autocom.itu.edu.tr 8/28 History: FOHEV I Two prototype research vehicles were built. FOHEV I, the first prototype, is a parallel HEV with 2+2 driving capability. ICE powers the front drive while the EM powers the rear drive. A rule based HEV control strategy is used. FOHEV I was built for maintaining high performance along with the advantages achieved through hybridization. All electric driving and regenerative braking are possible.

9. mekar.itu.edu.tr autocom.itu.edu.tr 9/28 History: FOHEV I HEV Controller

10. mekar.itu.edu.tr autocom.itu.edu.tr 10/28 History: FOHEV I Acceleration Performance

11. mekar.itu.edu.tr autocom.itu.edu.tr 11/28 History: FOHEV II The current research prototype vehicle, FOHEV II, is a series-parallel HEV with 2+2 driving capability. ICE and/or EM1 power the front drive while EM2 powers the rear drive. HEV control strategy used maximized overall efficiency in selecting the power flow path. All electric driving, ICE shut-down, stop and go, regenerative braking and series charging are possible. EM1 EM2 Serial EM ICE

12. mekar.itu.edu.tr autocom.itu.edu.tr 12/28 * Overall project management and coordination * Supply of base vehicle * Design of modified vehicle * NVH studies * Determination of vehicle specs * Supplying the electrical machine, battery, control unit etc. * Supply/Manufacture of modified hardware * Integration of mechanical modifications * Performance / brake / fuel consumption and emission tests * Concept study and simulations * Integration of electrical interface * Vehicle control and implementation * Development of regenerative braking algorithm and implementation * Control of electromechanical clutch * Data capture * Engineering support * Selection of electric motors and battery * Electrical motors, battery, driver circuits * Concept study and simulations * Implementation of touch screen LCD * Engineering support * Concept study and simulations * Design and implementation of electromechanical clutch system * Road tests * Engineering support Project Partners FORD OTOSAN ITU-MEKAR ITU-OTAM TUBITAK MAM FOHEV-II Project Partners

13. mekar.itu.edu.tr autocom.itu.edu.tr 13/28 System Architecture 13 Modes of Operation  Pure ICE Mode  Pure EM Mode  Hybrid Mode  Cruise Charge  Assist  Serial Charge  Hybrid Braking Schematic of FOHEV-II Prototype Components and Interactions

14. mekar.itu.edu.tr autocom.itu.edu.tr 14/28 Electric Motor Assembly 14 Electric Motor Assembly Electrical Machines  Rated Power 25 kW  Brushless DC Machines

15. mekar.itu.edu.tr autocom.itu.edu.tr 15/28 Li-Ion Battery Pack 15 Energy Storage Unit The battery pack provides the maximum power required by the traction/braking motors at the same time.  Li-Ion 324 V  Max Power 50kW  Capacity 14.5 kWh Li-Ion Battery Pack

16. mekar.itu.edu.tr autocom.itu.edu.tr 16/28 Transmission 16 The new transmission enables:  Driving the front axle by ICE and/or EM1.  The use of regenerative braking and electric traction independent of the selected gear.  To shift the operating point of the diesel engine by loading or assisting it with EM1. New Transmission

17. mekar.itu.edu.tr autocom.itu.edu.tr 17/28 Clutch Control System 17 The hydraulic clutch control system was modified to add the capability of keeping the clutch disengaged independent of the driver. Configuration of modified electromechanical clutch  Conventional Mode: According to the driver’s request the power flow is cut by depressing the clutch pedal.  Hybrid Mode: The clutch is controlled according to the hybrid control algorithm.

18. mekar.itu.edu.tr autocom.itu.edu.tr 18/28 Retrofitted APM 18 To shift the operating point of the ICE to a more efficient region necessitates the modification of the Accelerator Pedal Module in a way that the hybrid controller can interfere in the gas signal sent from the APM to the ICE-ECU. Accelerator pedal module & interface circuit

19. mekar.itu.edu.tr autocom.itu.edu.tr 19/28 Hybrid Control System 19 Hybrid powertrain control system schematic

20. mekar.itu.edu.tr autocom.itu.edu.tr 20/28 Start Up - Shut Down Procedure Start up procedure:  Battery supply is provided with the engine start up  Battery KL-15 is shorted  EMs are shorted Shutdown procedure:  S tarts with the after-run state of engine  It is in the reverse order of the start-up procedure. Hybrid powertrain control module logical schematic

21. mekar.itu.edu.tr autocom.itu.edu.tr 21/28 21 Maximizing Overall Efficiency Strategy receives the gas pedal position and distributes the corresponding torque demand among the available paths to achieve the maximum overall efficiency. MOES Strategy Velocity Controller MOES CONTROLLER, Battery EM1 EM2 EM3 ICE Regenerative Braking Controller Autogear Parameter Update Simulation model of the hybrid powertrain with MOES controller

22. mekar.itu.edu.tr autocom.itu.edu.tr 22/28 Hybrid Brake System & Strategy 22 Hybrid brake system integrates regenerative braking into conventional hydraulic brake module to assist the brake torque production while recapturing brake energy. Hybrid brake strategy logical schematic

23. mekar.itu.edu.tr autocom.itu.edu.tr 23/28 Videos of FOHEV II

24. mekar.itu.edu.tr autocom.itu.edu.tr 24/28 Parallel ChargeRegenerative BrakingAssist Experimental Results

25. mekar.itu.edu.tr autocom.itu.edu.tr 25/28  The modification process of a front wheel drive Ford Transit vehicle into a four wheel drive series-parallel hybrid electric vehicle having the working modes listed below was presented. oPure ICE oPure EM oHybrid traction oEngine start/stop oHybrid braking  The mechanical modifications and packaging of the electrical systems, the electrical modifications such as signal interfacing studies, regenerative braking capability and the hybrid electric control algorithm were also presented.  An Optimal Power Management Strategy for a Hybrid Electric Vehicle (MOES), was developed, simulated and implemented in the FOHEV-II prototype. Other novel power management strategies are also being developed.  An Electric Power Assisted Brake algorithm was developed and implemented to the research prototype by considering brake force distribution, torque capacity of EMs, state of charge of battery and operating conditions of the vehicle. Conclusions

26. mekar.itu.edu.tr autocom.itu.edu.tr 26/28 FC@ECE Diesel [l/100km]10.88 Hybrid [l/100km]7.39 Reduction [%] 32.1 FC@NEDC Diesel [l/100km]8.82 Hybrid [l/100km]6.53 Reduction [%]25.9 Table 1. Fuel Consumption Estimations  Simulations and preliminary tests showed that the fuel consumption estimations presented in table below, can be achieved with this new type of hybrid powertrain. Conclusions  The hybrid electric Ford Transit was publicized with a press release with an accompanying test drive. Work on performance evaluation and enhancement is currently in progress.

27. mekar.itu.edu.tr autocom.itu.edu.tr 27/28 Acknowledgments 27 The authors would like to acknowledge Ford Otosan R&D Department for support through the FOHEV projects & the European Union Framework Programme 6 through project INCO-16426 for helping İTÜ-Mekar improve in its research thrust area of hybrid electric vehicle modeling, control and hardware-in-the-loop simulation Special thanks also go to the Project Partners for their technical support in making this project a success.

28. mekar.itu.edu.tr autocom.itu.edu.tr 28/28 Questions ? 28