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Kaushik Rajashekara The University of Texas at Dallas Richardson, TX Transportation Electrification – Trends and Future Strategies 1 www.utdallas.edu/pedl November 7, 2015

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Page 1: Transportation Electrification – Trends and Future Strategiesconfadmin.cpss.org.cn/ueditor/net/upload/2015-11-16/9242a243-4a4f... · Transportation Electrification – Trends and

KaushikRajashekara

TheUniversityofTexasatDallasRichardson,TX

Transportation Electrification –Trends and Future Strategies

1www.utdallas.edu/pedl

November 7, 2015

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WhyElectrificationofTransportation

1. Reduce Emissions2. Reduce fuel consumption3. Meet the regulations and Standards4. To meet the increasing electrical power demand5. Higher efficiency of electrical systems compared to IC engines,

pneumatic, and hydraulic systems6. Ease of control and operation

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Emissions StandardsAutomotive- CAFE (Corporate Average Fuel Economy)

The U.S. government current rules for the Corporate Average Fuel Economy, or CAFE, program mandates an average of about 29 miles per gallon, with gradual increase to 35.5 mpg by 2016.

This will increase to 54.5 miles per gallon starting from 2025 model year Every state has set its own emission regulations

Aerospace - ACARE (Advisory Council for Aeronautics Research in Europe) goals to be achieved by 2020) 50% reduction of CO2 emissions through drastic reduction of fuel consumption 80% reduction of NOx emissions

International Civil Aviation Organization goals Improving fuel efficiency by an average two percent per year until 2050 Keeping the global net carbon emissions from international aviation from 2020 at the

same level

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2020 European ‘CAFE’ prospective

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Electrification of Vehicles

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The continuous increase of functionality for comfort, safety, driver assistance and infotainment systems as well as the insertion of innovations raise the power requirements.In combination with the electrification of powertrain functions and ancillary units for CO2 reductions, these requirements drive today´s vehicle power supply to its limits

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Electronically controlled systems in an Automobile

Heated windscreen Compartment warm-up

Engine water pump

Engine lubricant pump

Automated gearbox

Electric power steeringElectrically heated catalytic converter

Electrical air conditioning compressor

Electronic engine valve actuation

Entertainment

Electronically controlled suspension

Brake by wire

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GeneralMotorsEV1electricvehicle

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Powertrain:ModelSisarearwheeldriveelectricvehicle.Theliquid‐cooledpowertrainincludesthebattery,motor,driveinverter,andgearbox.Microprocessorcontrolled,60kWhlithium‐ionbattery(230milesrange.Itis300mileswith85kWh),

Charging:∗ 10kWcapableon‐

boardchargerwiththefollowinginputcompatibility:85‐265V,45‐65Hz (Optional20kWcapableTwinChargersincreasesinputcompatibilityto80A)

TeslaModel‐ S

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SuperchargerRated up to 135KWFor 85KWh Battery, 180 miles for 30mins of charging

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Hybrid Power train TopologyConventional

ElectricMotor

Engine

Battery

Electric Motor

Battery

Micro HybridMicro Hybrid

Full Hybrid

Electric Vehicle

Range extender

Series Hybrid

Parallel

Fuel Cell

Series

Mild HybridMild Hybrid

GeneratorEngineFuel Cell

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Toyota Crown

Chevy Volt withPlug-in capability

Honda FCX

Honda Insight

Toyota Prius

Nissan Leaf

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Hybrid Vehicles classification

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Functions of different types of hybrid vehicles

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Function Micro Hybrid

Mild Hybrid

Full Hybrid

Plug-in Hybrid

Fuel economy 5% to 10% 7% to 15% >30% >50%

Power levels 3kW to 5kW 10kW to 15kW

>20kW >20kW

Automatically stops/starts the engine in stop-and –go traffic

Uses regenerative braking and operates above 60V

Uses electric motor to assist a combustion engine

Can drive at times using only the electric motor

Recharges battery from an external supply

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48V Micro-Hybrid: Start/Stop system

• Start-stop technology is gaining momentum in last years due to stringent carbon emission norms enacted by European parliament and the need by vehicle manufacturers to meet these stringent norms.

• More than 50% of the newly registered vehicles will have start-stop as standard technology after 2013.

• Even though the technology is widely utilized for small / mid segment cars in Europe it also has high potential for compact and luxury car segments.

• It can be expected, that especially micro-mild hybrid technology will gain increasing relevance in the coming years as technological challenges are solved (high voltage electrical system, for e.g. 48V).

• Start-stop is a key technology to be used in conjunction with other fuel saving technologies to attain the stringent carbon norms of 2020

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2014 Insight Hybrid: Front Wheel DriveEngine: 1.3 liter, 4 cylinder; 98HP@5800rpmBattery: 100.8V DC (NiMH battery), 5.75 AhMotor/Generator: 13 HP @1500rpmPermanent Magnet Brushless DC

Fuel consumption (City/Highway): 41/44 MPG with CVT

Honda Integrated Motor Assist (IMA) Hybrid Architecture (Integrated starter/Generator)

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History of Toyota Hybrid Systems

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ChevroletVOLTConcept(PHEV)

∗ GlobalCompactVehicleBased∗ ElectricDriveMotor

• 120kWpeakpower• 320Nmpeaktorque(236lb‐ft)

∗ Li‐ionBatteryPack• 136kWpeakpower• 16kWhenergycontent• Homeplug‐incharging

∗ Generator• 53kW

∗ InternalCombustionEngine• 1.0L3‐cylinderturbo

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2015 Toyota Mirai

17http://www.toyota.com/mirai/fcv.html

Toyota hydrogen fuel cell car Mirai will arrive in USA at the end of 2015. Cost is $57,500Range: 650 km5 kg of hydrogen at 70 Mpa, normal operating pressure245V, 1.6kWh NiMH battery

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Name Toyota Fuel Cell System (TFCS)- 2015Toyota Mirai

Number of occupants 4

Max. Speed 111 mph

Curb Weight 1850kg

Time from (0 to 60mph) 9 seconds

Motor

Max. Output 113 KW (152hp)

Max. Drive (Torque) 335Nm

Type AC Synchronous Electric Motor (Permanent Magnet)

Fuel cell stack

Type Solid Polymer Electrolyte Fuel Cell

Output 114 KW (153hp)Output Density: 3.1KW/L

370 cells (single lining stack)

Fuel

Type Compressed Hydrogen Gas

Storage High Pressure Hydrogen Tank

Pressure 87.5MPa (maximum filling pressure)70 MPa (normal operating pressure)

Capacity 5kg approx. Refueling time: approx. 5 min

Battery 245V 1.6KWh (Nickel Metal Hydride)

Range 650 km (404 miles)

Exhaust 240ml of water for every 4km

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Honda’s Next Generation Advanced Powertrain Vehicles

• An all-new Honda plug-in hybrid model (PHEV) in 2018• An all-new Honda battery-electric vehicle (BEV) in 2018• Honda FCV Concept - next-generation Honda fuel-cell vehicle, launching in

2016• The Honda FCV CONCEPT is equipped with a 70 MPa high-pressure

hydrogen storage tank that provides a cruising range of more than 700 km. The tank can be refilled in approximately three minutes, making refueling as quick and easy as today’s gasoline vehicles.

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GridInterface

PluginFuelCellVehicle

SOFCAPU∗ providesback‐uporsustainedheatandpowertothehouse

Li‐IonBattery∗ consumessurplusoff‐peakelectricity– whenavailable∗ provideshighqualityback‐uppower(UPSfunction)∗ providesshort‐termbi‐directionalgridsupportfunction.

RangeextenderEV

LithiumIonBatteryand

SOFCrangeextenderFuel

ElectricPower

CommunityNetwork

Heat

Fuel

(PEMFuelcellcouldalsobeused)

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V2G and G2V Strategies Development of smart charging – Integration of energy flow and

information flow• Bidirectional communication with distribution infrastructure• Local wireless network architecture with connectivity between EVSE

home area network gateway• EVSE to EVSE communication networks and neighborhood area network

that do not require any direct connection to the utility company Integration of ac charging and ultra fast dc charging in a single system

that will have one charging inlet per vehicle, one integrated controller, and one charging communication

“Uber for Energy”

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Wireless Charging

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Connected and Automated Vehicles

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Connected Vehicles• Connected vehicles refer to the wireless connectivity enabled vehicles that can

communicate with their internal and external environments, i.e., supporting theinteractions of V2S (vehicle-to-sensor on-board), V2V (vehicle-to-vehicle), V2R(vehicle-to-road infrastructure), and V2I (vehicle-to-Internet).

• The connected vehicles are considered as the building blocks of the emergingInternet of Vehicles (IoV), a dynamic mobile communication system thatfeatures gathering, sharing, processing, computing, and secure release ofinformation and enables the evolution to next generation IntelligentTransportation Systems (ITS).

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Connected and Automated Vehicles• A connected vehicle system is based on wireless communication

among vehicles of all types and the infrastructure• Automated vehicles are those in which at least some aspect of a

safety-critical control function (e.g., steering, throttle, or braking) occurs without direct driver input.

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ProbeData

E-payment Transactions

Signal Phase and Timing Information Real Time Network Data

Situation Relevant Information

Infrastructure Communications

Opportunity for

Innovation

V2V Safety Messages

“The Network”

Connected Vehicles

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Mitsubishi eX Concept 

27http://www.mitsubishi‐motors.com/en/events/motorshow/2015/tms2015/technology/

• The MITSUBISHI eX Concept is the combination of several technologies• Uses the next‐generation EV system which brings together a longer cruising range as 

well as superior driving performance. • It has front and rear compact high‐output motors. • eX Concept has a cruising range of 400 km.• It delivers 70 kW to both front and rear wheels for a total output of 140 kW of power.• Advanced connected car technology integrates vehicles with information networks• Linked constantly to cloud

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Mitsubishi eX Concept 

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The MITSUBISHI eX Concept can be connected to a V2H device that allows the energy stored in the drive battery to supply enough electricity battery to power domestic appliances in an average household for four days. A 1500W 100V AC socket also allows the battery to power home electric appliances when enjoying outdoor pursuits.

If involved in an accident, it automatically transmits sensor information on the damage (the seriousness of the crash, whether airbags have deployed or not, etc.) as well as the location of the crash through a vehicle emergency communication system. 

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More Electric Aircraft/Electric Aircraft

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Electrical Power Generation Strategies in Airplanes

Ian Moir and Allan Seabridge, “Aircraft Systems: Mechanical, Electrical and Avionics Subsystems Integration,” 3rd Edition, Wiley, 2008

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Voltage and Generation Types The system is a hybrid AC and DC system of following voltage types:

• 115 Vac• 28 Vdc• 230 Vac• ±270 Vdc

230 Vac generating system• Variable frequency starter generators on engines • Variable frequency starter generators on APU

Traditional

Replacing the traditional pneumatic system Higher voltages to minimize the weight impact

Electrical System Voltages in More Electric Aircraft

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Airbus 330 Engine off take loads

Mechanical power- Engine Fuel Pump- Engine Oil Pump

- Engine start200kW (peak)

100kW (local)

Hydraulic power- Flight Controls- Landing gear- Braking- Reverse- Doors

240kW-206bars

Electrical power- Avionics- Commercial- Pumps- De-icing- Lights- …...

115VAC-230kVA

Pneumatic power- Air conditioning- Pressurisation- Ice Protection

- Engine start

From some barsup to 20bars-1200kW

Example: Power used on A330

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Thrust for Propulsion

Generator

Traditional Aircraft Electric Load

Environment Control System

Oil, Hydraulic and Fuel Pump Motors

Other Access Loads

Electric de-icing, galley loads

Generator can be mounted to the shaft (as embedded generator or on the gearbox)

Jet Fuel

More Electric Engine (MEE)

In a More Electric Aircraft (MEA) system, the jet engine is optimized to produce the thrust and the electric power.

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N3-X Concept Description

Superconducting-motor-driven fans in a continuous nacelle

Wing-tip mounted superconducting turbogenerators

• TeDP-HWB: Turboelectric Distributed Propulsion– Hybrid Wing Body• Decoupled propulsive producing device from power producing device• Two wingtip mounted turboshaft engines driving superconducting

generators• Superconducting electrical transmissions• Fifteen superconducting motor driven propulsors embedded in fuselage• Two cooling schemes, cryo-cooled and LH2-cooled

Turboelectric Distributed Propulsion Engine Cycle Analysis for Hybrid Wing Body Aircraft – (AIAA) 2009-1132

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N.O.

N.O.

SCFCL SCFCL

Generator

Converter Transmission Line

Converter and Propulsor Motor

Energy Storage

(if necessary)Protection Equipment

(throughout)

Power Generation and Distribution Technology

M. Armstrong, M.,C.Ross,M. Blackwelder, and K. Rajashekara,., Propulsion System Component Considerations forNASA N3-X Turboelectric Distributed Propulsion System, 2012 SAE Power Systems Conference, Phoenix,AZ, PaperNo. 2012-01-2165, October 2012

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Fuel Cell Aircraft - World's first zero-emission four-seater passenger aircraft.

German H2FLY Consortium is developing the World's first zero-emission four-seater passenger aircraft, to deploy as electric air taxis. The consortium’s vision is the advancement of emission-free electrified flight using hydrogen, and its aircraft, named HY4, is expected to make its maiden flight from Stuttgart Airport in the summer of 2016

The HY4 electric motor has an output of 80 kilowatts, a top speed of around 200 km/h and a cruising speed of 145 kilometers per hour. Depending on speed, altitude and load a range, 750 to 1500 kilometers are possible

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Why Flying Cars? Flying cars will significantly enhance the personal transportation Flying cars will revolutionize the whole transportation industry and improve the

standard of living in many parts of the world, particularly in underdeveloped countries.

The flying cars will enable to skip the whole infrastructure development, which is building roads and bridges and thus saving billions of dollars. It will also save a number of trees being cut, thus improving the air qulaity. It preserves the landscape.

This will enable building only fewer airports thus reducing the number of air traffic control problems.

Develops a new class of industry, thus creating millions of jobs in several disciplines. Flying car components industry- electrical, mechanical, electronics, etc. Power conversion and electric machines Microturbines Signals, controls, and communications Many other related areas

It could replace the helicopters and provide versatile operation with reduced emissions, fuel use, and capital cost.

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Flying Cars

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Terrafugia‐Transition

TF‐X

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Enabling Technologies

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Electric Drive System Components

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Typical propulsion System components of a EV Power-train

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WideBandGapSemiconductors∗ Wide band gap semiconductor - power electronic components have high current

density, faster, and more efficient than silicon (Si)-based devices.∗ They have lower on-resistances (Ron), so lower conduction losses [SiC

MOSFETS]∗ They operate efficiently at much higher temperatures, voltages, and switching

frequencies.∗ These materials are significantly more powerful and energy efficient than those

made from conventional semiconductor materials∗ Handles voltages 10 times higher than Silicon.∗ Operates at temperatures over 300°C.∗ Operates at frequencies 10 times higher than silicon.∗ Higher breakdown voltages.∗ Large band gap∗ High carrier mobility∗ High electrical conductivity∗ High thermal conductivity

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SiC based Toyota Camry Hybrid

50Toyota expects 10% improvement in efficiency using SiC devices

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Batterycharacteristics• ThemainconsiderationsintheselectionofEV/HEVbatteriesare

∗ Powerdensity∗ Energydensity∗ Weight∗ Volume∗ Cyclelife∗ Temperaturerange∗ Environmentalconditions∗ Cost

Power densityIn W/kg

Energy Density  in Wh/kg

Acceleration

Range

Battery type Lead acid NiMH Lithium‐ion

Energy Density(Wh/kg)

30‐40 50‐80 100‐160

Power density(W/kg)

120‐200 250‐1000 1000‐1500

Cycle life 200‐300 300‐500 500‐1000

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LithiumAirbatteries∗ Lithium Air batteries could significantly increase the range of electric vehicles

due to their high energy density, which could theoretically be equal to the energy density of gasoline.

∗ It is estimated that these batteries could hold 5-10 times the energy of lithium-ion batteries of the same weight, and twice the energy for the same volume.

∗ The lithium/air has a theoretical energy density that is close to the limit of what is possible for a battery (~10,000 Wh/kg). They have the potential of achieving the energy density in the range of 2000 to 3500 Wh/kg. P.ractically, it could be about 700Wh/kg

∗ One of the biggest challenges facing lithium-air batteries is their limited number of charge/discharge cycles

∗ In addition, the process of charging the lithium air battery is a relatively slow process as compared with the lithium ion battery.

∗ Several companies are working on to develop lithium–air battery that will be expected to be more powerful than the lithium-ion batteries used in many electric and hybrid vehicles

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Summary

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SummaryofTrends∗ Powertrain

• Plug‐in‐hybrid;48Vstart‐Stop;Plug‐infuelcellhybridvehicles(PFCVs),EVs∗ FuelCellVehicles

• DirectHydrogen(CompressedorliquidHydrogen)• Hydrogengenerationusingrenewableenergy• PEMfuelforpropulsion.SOFCforon‐boardpowergenerationinlargervehicles(Trucks,Train,

Ships,Airplanes,etc)∗ EnergyStorage

• Lithiumion,LithiumAir(longterm)• Highvoltage(withorwithoutboostconverter)

∗ ElectricMachine• PermanentMagnet,Induction,Synchronousreluctance/PM‐AssistSynchronousreluctance

∗ PowerConverter• Silicin basedInsulatedGateBipolarTransistors‐IGBT(MovingtowardsSiC devices– longterm

GaN)

• Charging– Integrationofenergyflowandinformationflow, Fastcharging,Wirelesscharging– V2GandG2V

• ConnectedVehicles• MoreElectricEnginesandMoreElectricAircrafts• AircraftwithHybridPropulsion• Flyingcars

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∗ There will be an exponential growth in electrical power demands in transportation systems

∗ Almost every auto manufacturer is working on the development of new generation of electric/hybrid vehicles

∗ “More Electric” is a technology enabler for power generation, energy storage, conversion systems, and other technologies

∗ Some of the technologies such as fuel cells require significant R&D to bring them to the level so that industry can make them commercially viable for transportation applications.

• Connected vehicles is important, innovative, and evolving. They are also thebuilding blocks of emerging Internet of Vehicles (IoV).

• It is no longer enough to sell personal transportation; people want a personalizeddriving experience that keeps them connected to everything that is important tothem—friends, information, music, maps, schedules, and more

• Future cars will augment our driving capabilities and make our travel experiencesafe

• Driverless Vehicles leading to Uber for “Energy”

Summary

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REFERENCES

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