1. Introduction to Hybrid Vehicles

2. HYBRID VEHICLE – DEFINITION
THE TERM HYBRID MEANS A BLEND OR MIX OF TWO DISSIMILAR TYPES
INTERNAL COMBUSTION ENGINE…….. [ ICE ]
ELECTRIC TRACTION MOTOR

3. Definitions HEV = Hybrid Electric Vehicle
Incorporates an electric motor / generator and an ICE engine
BEV = Battery Electric Vehicle
Has an electric motor / generator and batteries . Does not have an ICE engine
H2EV = Hydrogen Fuel Cell Vehicle
Has an electric motor and a hydrogen fuel cell to generate electricity from electro-chemical reaction between hydrogen and oxygen

4. Definitions H2ICE = Hydrogen Powered Internal Combustion Engine
A conventional ICE vehicle [diesel or spark ignition] that is fueled by hydrogen
PHEV = Plug in Hybrid Vehicle
A hybrid electric vehicle with additional batteries that are used to extend range and increase speed under electric operation and use energy from the electric power grid instead of gasoline.

5. ADVANTAGES OF HYBRID VEHICLES
INCREASED FUEL ECONOMY
Typically 20% to 30% better
PERFORMANCE IS IMPROVED
Especially at low speeds
RANGE & REFUELING TIME
Same as a conventional vehicle
DRIVEABILITY
Nearly identical to conventional vehicle

6. DISADVANTAGES OF HYBRID SYSTEMS
HIGHER COST
CURRENTLY HYBRID VEHICLES ARE PRICED TYPICALLY $3000 TO $6000 MORE THAN COMPARABLE CONVENTIONAL VEHICLES
SAFETY ISSUES
IN AN ACCIDENT RESCUE PERSONAL MUST BE AWARE OF THE PROPER PROCEDURES NEEDED TO EXTRACT ACCIDENT VICTIMS FROM THE VEHICLE
THE ENERGY POTENTIAL OF MOST HYBRID BATTERY SYSTEMS CAN ELECTROCUTE YOU IF YOUR BODY COMES INTO CONTACT WITH THE WIRING

7. Safety training
Rescue personnel need to be trained in the potential electrical hazards when extracting vehicle occupants after a crash

8. Parallel Hybrid Drive System
A Parallel Hybrid has a direct mechanical connection between the ICE engine and the wheels.
ICE Engine
PCM
Battery Array
Motor /
Generator
Inverter
Parallel Hybrids use a conventional transmission or an electro-mechanical torque splitting transmission that combines the power of the ice engine and electric motor[s]
Transmission

9. Series Hybrid Drive System
ICE
Engine
Electric
Motor
PCM
Battery
Array
Inverter
Generator
A Series Hybrid is essentially a battery powered electric vehicle that has an auxiliary power unit to provide additional range
In a series Hybrid there is no mechanical connection between the ICE engine and the wheels

10. Series Hybrid Drive System
A generator is bolted to the back of the engine to provide electric power to the motor after the battery SOC drops below minimum
The battery array is large enough to provide 40 miles of electric power – after 40 miles the ICE engine can provide power as long as there is gasoline in the tank
This type of vehicle is normally called an electric powered vehicle with a range extending gas engine
Generator
Electric Motor

11. Series Hybrid Chassis with Electric Motor and Generator Generator
Charging
Socket
Battery
Array
Traction
Motor
Chassis with Electric Motor and Generator
Image courtesy of General Motors Corp

12. 3 Cylinder turbocharged ICE engine
Series Hybrid
3 Cylinder turbocharged ICE engine
Inverter
Fuel
Tanks
With ICE engine and fuel tanks
Image courtesy of General Motors Corp

13. Series Hybrid With Cooling system, Steering and Brakes Electric
Power Assist
Brake Booster
Radiator
For ICE
Engine
Electric
Power Steering
With Cooling system, Steering and Brakes
Image courtesy of General Motors Corp

14. Hybrid efficiency Autostop Regenerative Braking
Two technologies that make hybrids more efficient than conventional vehicles
Autostop
Regenerative Braking

15. Electric Torque Assist
Most hybrids also have electric torque assist.
When power is required both the ICE engine and the electric motor provide torque.
Electric torque assist allows the ICE engine to be smaller and still have adequate performance

16. Autostop The ICE engine is shut down while vehicle is stationary
On some hybrids the system can shut off the ICE engine during coast, deceleration or driving at slower speeds under electric power
The ICE engine is restarted when the brake pedal is released or the gas pedal is depressed

17. Auto Stop Mode
The ICE Engine is turned off as long as the driver holds pressure on the brake pedal and the vehicle not moving.
Autostop
When the driver releases the pedal the engine will restart. Some hybrids restart when the accelerator pedal is depressed.

18. Regenerative Braking
During normal braking the hybrid drive system slows the vehicle by converting the electric motor into a generator – recharging the batteries
Instead of loosing all the kinetic energy to heat in conventional brakes the kinetic energy is converted into electricity which can be stored and used again to accelerate and climb hills

19. Hybrid Types
Light - Auto Stop and Regenerative Braking only Mild - Electric Traction assist – vehicle cannot run solely on electric power Full - Electric only operation at up to 30 MPH – engine shuts down on coast Plug In - batteries can be charged overnight by 110 or 220 volt household current. Vehicle can be driven 10 to 40 miles solely by electric power. Currently in the Prius Plug-in and Chevy Volt

20. Types of Hybrid Vehicles
LIGHT
MILD
FULL
PLUG IN
DOES NOT HAVE A TRACTION MOTOR – ELECTRIC MOTOR IS ONLY USED FOR STARTING THE ENGINE
TRACTION MOTOR ASSISTS ICE MOTOR WHEN EXTRA TORQUE IS NEEDED
VEHICLE CAN BE DRIVEN AT SPEEDS UP TO 30 MPH SOLELY ON ELECTRIC TRACTION MOTOR – FOR 1 TO 2 MILES
VEHICLE CAN BE DRIVEN SOLELY ON ELECTRICITY AT SPEEDS UP TO 100 MPH FOR A DISTANCE OF 40 MILES
VEHICLE IS NEVER DRIVEN BY ELECTRIC POWER
ICE MOTOR RUNS AS A GENERATOR WHENEVER THE VEHICLE IS IN MOTION
IN NORMAL DRIVING VEHICLE RUNS UNDER ELECTRIC POWER AT SPEEDS UP TO 30 MPH
ICE ENGINE RUNS WHEN MORE TORQUE IS REQUIRED, WHEN SPEED EXCEEDS 30 MPH OR BATTERY SOC IS LOW
ICE MOTOR ONLY RUNS WHEN BATTERIES ARE DEPLETED [BELOW 30% SOC] OR EXTRA TORQUE IS NEEDED
TRACTION MOTOR PROVIDES ALL THE TORQUE NEEDED
UTILIZES 42 VOLT BATTERY ARRAY
UTILIZES A HIGH VOLTAGE BATTERY ARRAY > 144 Volts
UTILIZES A HIGH VOLTAGE BATTERY ARRAY > 190+ Volts
UTILIZES A HIGH VOLTAGE BATTERY ARRAY > 225 +Volts
LEAD ACID BATTERIES
NICKEL METAL HYDRIDE BATTERIES
LITHIUM ION BATTERIES
BATTERIES RECHARGED BY ICE MOTOR + REGENERATIVE BRAKING AND DURING ICE OPERATION
VEHICLE IS RECHARGED AT NIGHT VIA ON BOARD 110 VOLT PLUG IN CHARGER AND DURING REGENERATIVE BRAKING

21. Types of Hybrid Vehicles
LIGHT
MILD
FULL
PLUG IN
HAS NO TRACTION MOTOR –
MOTOR / GENERATOR SERVES AS A STARTER
A 12 VOLT DC GEAR REDUCTION TYPE STARTER IS USED AS A BACKUP STARTER
TRACTION MOTOR IS CONNECTED TO THE ENGINE CRANKSHAFT – STARTS THE ICE ENGINE, GENERATES ELECTRICITY TO RECHARGE THE BATTERIES.
TRACTION MOTORS ARE LOCATED INSIDE THE TRANSMISSION, ALLOWING ICE ENGINE TO BE SHUT DOWN DURING COAST AND SLOW SPEED OPERATION
TRACTION MOTORS ARE LOCATED INSIDE THE TRANSMISSION – SINCE THE SYSTEM RUNS AT HIGHER SPEEDS THE MOTORS ARE LARGER AND MORE POWERFUL
SERIES PLUG IN HAS SEPARATE GENERATOR AND TRACTION MOTOR
ICE MOTOR IS TURNED OFF WHEN VEHICLE IS STATIONARY
THE ICE MOTOR IS TURNED OFF AT LOW SPEEDS < 20 MPH
THE ICE MOTOR RUNS ONLY WHEN BATTERY SOC IS LOW [BELOW 30% SOC]
CONVENTIONAL PLANETARY GEARSET TRANSMISSION + TORQUE CONVERTER
CVT RANSMISSION WITHOUT A TORQUE CONVERTER OR PLANETARY GEARSET TRANSMISSION WITH A TORQUE CONVERTER
ELECTROMECHANICAL TORQUE SPLITTER PLANETARY TRANSMISSION OR DUAL MODE TRANSMISSION – NO TORQUE CONVERTER -HAS NO REVERSE GEAR
PARALLEL - ELECTROMECHANICAL TORQUE SPLITTER
SERIES HAS NO TRANSMISSION ONLY A DIFERENTIAL
2004 GM PHT Silverado
Honda Civic & Accord
Saturn VUE
Toyota Prius
Ford Escape
Nissan Altima
2008 Chevy Tahoe
2012 Chevy Volt
2012 Prius Plug-in Hybrid

22. Stator Coils attached to Bell Housing
Light Hybrid – Type 1
Stator Coils attached to Bell Housing
Permanent magnets
attached to flex plate
Electrically driven
transmission pump
Motor/Generator built into bell housing.
Motor/Generator does not provide torque for power assist.
Conventional planetary gearset automatic transmission delivers torque to drive axels.
Electrically driven pump maintains pressure on transmission clutches and bands during auto stop.
Torque converter clutch is modified for 2 way torque transfer.
Transmission is calibrated to lock out freewheeling when brakes are applied.

23. Light Hybrid – Type 1 42 Volt hybrid system – Lead Acid Batteries
Motor/Generator serves as starter and generator
Electrical current produced by motor/generator is used for restarting the engine after auto stop and operating electric power steering pump for PS and Hydro-boost brake assist
Auto stop mode will not activate when A/C is set to MAX or defroster is selected
Motor/Generator can provide 24 Kw at 110 volts to outlets in the truck bed
Used on GM PHT trucks
Saturn Vue Greenline is similar

24. Mild Hybrid – Type 2
Stator coils attached to rear of engine block
Permanent magnets
embedded in flywheel
Starting Clutch
Motor/Generator provides extra torque for acceleration
Motor/Generator sandwiched between engine and bell housing
CVT [Continuously Variable] automatic transmission delivers torque to drive axel[s]
Starting clutch eliminates the need for a torque converter

25. Porsche Cayenne Hybrid Motor/Generator
Stator coils attached to rear of engine block
Permanent magnets
embedded in flywheel
Coolant
Image courtesy of Robert Bosch GMBH

26. Mild Hybrid – Type 2 Cannot run in electric only mode
High voltage hybrid system – 144 to 190 volts
Ni MH battery type
Motor / Generator develops 10 to 15 Kw [13 to 20 hp]
Motor / Generator is cooled by contact with engine block
Uses V-TEC technology for variable displacement and to reduce engine drag during regenerative braking

27. Full Hybrid – Type 3
Motor / Generator # 2
Motor / Generator # 1
Runs in electric only mode at speeds below 25 mph depending on battery state of charge
High voltage hybrid system – 190 to 400+ volts
Uses a torque splitter planetary gearset type transmission.

28. Full Hybrid – Type 3 Ni MH battery type
Motor / Generator develops 50 to 125 Kw [67 to 167 hp]
Motor / Generator must be liquid cooled. Antifreeze coolant or transmission fluid circulating through the transaxle removes excess heat
Atkinson cycle engine may be used for improved fuel economy
Uses VTT technology for Atkinson cycle operation and cylinder canceling to improve fuel economy at highway cruise speeds.
Since the vehicle can run on electric power alone, electric power steering and power brake assist are required
Air conditioning compressor will also be powered electrically

29. Full Hybrid transaxle
The motor/generators of a full hybrid are located inside the transaxle case
A full hybrid transaxle will normally have 2 large motor/generators inside the transaxle
A planetary gearset is used to combine the torque of the electric motor with that of the ICE engine

30. Plug in Hybrid – Type 4
Batteries are charged overnight by 110 volt household current
Li – ion battery type
Battery capacity is 4 times greater than Full Hybrid
Increased Battery
Capacity
Can be driven solely by electric power at speeds up to 100 mph
Has an electric only range of 10 to 40 miles
When battery SOC drops below 30% ICE engine automatically starts

31. Plug-in Series Hybrid
The 2014 Chevy Volt has an electric range of over 40 miles
A series hybrid is essentially an electric car that has a backup gasoline engine to extend the range.
Image courtesy of General Motors Corp

32. Plug-in Series Hybrid 40 mile range under electric power
Range Extender Engine
Charging
Receptacle
Battery Pack
40 mile range under electric power
The engine will start when the batteries are depleted, allowing the vehicle to be driven another 360 miles before refueling
Electric Motor

33. Full Hybrid vs. Plug In Hybrid
A full hybrid vehicle is primarily powered by an ICE engine. It’s electric vehicle technology enables it to recover energy normally wasted.
A plug In hybrid is primarily powered by electricity from the power grid, but has the extended range and refueling convenience of a conventional ICE vehicle when driven longer distances.
A plug in hybrid can run on any type of energy that can be used to generate electricity.

34. Hybrid Technology Smaller – yet more powerful engine systems
Both motors; electric and ICE combine to produce the power needed for acceleration and climbing hills
A small displacement 75 Hp ICE motor combined with a 67 HP electric motor[s] will have the same power as a conventional vehicle with a larger 140 Hp motor.

35. Accessories
Since the ICE engine is shut down during autostop and at low speeds power accessories that are normally driven by belt and engine vacuum must be powered by electricity:
Power Brakes
Power Steering
Air Conditioning

36. Electric Power Brake Assist
An electrically driven pump mounted on the ABS brake actuator assembly produces the high hydraulic pressure needed to bring the vehicle to a stop without excessive brake pedal force
In normal braking the Hybrid Control Module turns on solenoids in the ABS actuator that block the flow of hydraulic pressure to the front brakes. This allows the regenerative braking system to recover the maximum available energy.
Accumulator
Pump

37. Electric Power Steering
Control
Module
Electric
Motor
Steering
Torque
Sensor
Conventional hydraulic power steering uses up to 5 hp of engine power even when the need for steering assist is low.

38. Electric Power Steering
Steering input
torque sensor
The electric motor can be mounted on the rack or steering column.
Image courtesy of Robert Bosch GMBH

39. Electric A/C CompressorD
200+ volt
3 phase AC
Electric Motor
To maintain comfortable cabin temperatures during Auto-stop mode an electrically driven A/C compressor is used.

40. Electric A/C Compressor
200+ volt
single phase AC
Electric Motor S D
This GM electric compressor uses high voltage single phase AC current to drive the compressor motor.

41. Electric Heat
Heater core
Electric heating strips are attached to the fins of the heater core. During Auto-stop or electric drive mode electric current is applied to the heating strips.
Ribbon
Fin
Heating
Strips
Electrode

42. Low Drag Tires and Wheel Bearings
Tires used on high efficiency hybrid vehicles are designed for lower rolling resistance.
Rolling resistance is reduced by:
- Stiffer belts to reduce standing waves
- More flexible sidewalls
- Narrower tread width
Wheel bearings can be made of high silicon steel
The higher silicon content can tolerate bearing lubricants with lower viscosity
Improved seals are needed to retain this low viscosity lubricant

43. Improved Aerodynamics
Extending the slope of the front and rear ends of the body reduces turbulence and drag.

44. Improved Fuel Efficiency
Each of these technologies help improve vehicle fuel efficiency.
Combined in one vehicle they can add up to 40% increase in fuel efficiency.
No hybrid vehicle in production today has all of these technologies but some hybrids have most of them.

45. End of Presentation