ICAT

1
FOHEV II - The Ford Otosan Hybrid Electric
Research Prototype Vehicle
Ismail M.C. Uygan, Ahu E. Hartavi, Levent Güvenç,
Tankut Acarman Automotive Control and
Mechatronics Research Center , Mechanical
Engineering Department, Istanbul Technical
University, Istanbul, Turkey Varlik Kiliç, Ilker
Özelgin, Murat Yildirim 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
ICAT08 Istanbul
International Conference on Automotive
Technologies
November 13 - 14th, 2008
2
Automotive Control and Mechatronics Research
Center
ICAT 2008
3
Overview

• Introduction
• Hybrid Electric Vehicle
• Market 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
• Start-up Shut-down Preocedure
• Maximizing Overall Efficiency Strategy for Power
  Split Control
• Hybrid Brake Algorithm
• Experimental Results
• Conclusions

4
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.

HEV Main Components
Hybrid Electric Vehicle(HEV) uses both
electrical motor and internal combustion engine.
5
Why Hybrid Electric Vehicles?
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.
Effects of Global Warming
6
Hybrid Electric Vehicle Market
Worldwide Hybrid ElectricVehicle
Sales http//www.marklines.com/en/numproduct/index
.jsphybrid
7
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
History FOHEV I
Two prototype research vehicles were built. FOHEV
I, the first prototype, is a parallel HEV with
22 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
History FOHEV I HEV Controller
10
History FOHEV I Acceleration Performance
11
History FOHEV II
The current research prototype vehicle, FOHEV II,
is a series-parallel HEV with 22 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
Serial EM
EM2
ICE
12
Project Partners

• 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

ITU-MEKAR
FORD OTOSAN

• Concept study and simulations
• Design and implementation of
• electromechanical clutch system
• Road tests
• Engineering support

TUBITAK MAM
ITU-OTAM

• Selection of electric motors and battery
• Electrical motors, battery, driver circuits
• Concept study and simulations
• Implementation of touch screen LCD
• Engineering support

FOHEV-II Project Partners
13
System Architecture

• 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
13
14
Electric Motor Assembly

• Electrical Machines
• Rated Power 25 kW
• Brushless DC Machines

Electric Motor Assembly
14
15
Li-Ion Battery Pack

• 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
15
16
Transmission

• 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
16
17
Clutch Control System
The hydraulic clutch control system was modified
to add the capability of keeping the clutch
disengaged independent of the driver.

• Conventional Mode According to the drivers
  request the power flow is cut by depressing the
  clutch pedal.
• Hybrid Mode The clutch is controlled according
  to the hybrid control algorithm.

Configuration of modified electromechanical
clutch
17
18
Retrofitted APM
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
18
19
Hybrid Control System
Hybrid powertrain control system schematic
19
20
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
• Starts 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
MOES Strategy
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.
Simulation model of the hybrid powertrain with
MOES controller
21
22
Hybrid Brake System Strategy
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
22
23
Videos of FOHEV II
24
Experimental Results
Parallel Charge
Regenerative Braking
Assist
25
Conclusions

• 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.
• Pure ICE
• Pure EM
• Hybrid traction
• Engine start/stop
• Hybrid 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.

26
Conclusions
Table 1. Fuel Consumption Estimations
FC_at_ECE Diesel l/100km 10.88
FC_at_ECE Hybrid l/100km 7.39
FC_at_ECE Reduction 32.1
FC_at_NEDC Diesel l/100km 8.82
FC_at_NEDC Hybrid l/100km 6.53
FC_at_NEDC Reduction 25.9

• Simulations and preliminary tests showed that the
  fuel consumption estimations presented in table
  below, can be achieved with this new type of
  hybrid powertrain.

• 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
Acknowledgments
The authors would like to acknowledge Ford
Otosan RD Department for support through the
FOHEV projects the European Union
Framework Programme 6 through project INCO-16426
for helping ITÜ-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.
27
28
Questions ?
28