Vehicle design and control is an attractive area of research in that it embodies a convergence of societal need, technical limitation, and emerging capability. Environmental, political, and monetary concerns are driving the automotive industry towards sustainable transportation, manifested as increasing powertrain electrification in a gradual transition to fossil-free energy vectors. From an electrochemical degradation and control systems perspective, this transition introduces significant technical uncertainty. Initial indications are that the initial battery designs will have twice the required capacity due to degradation concerns. As the battery is a major contributor to the cost of these vehicles the over-sizing represents a significant threat to the ability of OEMs to produce cost-competitive vehicles. This potential barrier is further amplified when the combustion engine is removed and battery-electric or fuel-cell hybrid vehicles are considered. This thesis researches the application of model-based design for optimal design of fuel cell hybrid powertrains considering power source degradation. The intent is to develop and evaluate tools that can determine the optimal sizing and control of the powertrain; reducing the amount of over-sizing by numerically optimization rather than a sub-optimal heuristic design. A baseline hybrid fuel cell vehicle model is developed and validated to a hybrid fuel cell SUV designed and built at the University of Waterloo. Lithium-ion battery degradation models are developed and validated to data captured off a hybrid powertrain test stand built as part of this research. A fuel cell degradation model is developed and integrated into the vehicle model. Lifetime performance is modeled for four hybrid control strategies, demonstrating a significant impact of the hybrid control strategy on powertrain degradation. A plug-in variation of the architecture is developed. The capacity degradation of the battery is found to be more significant than the power degradation. Blended and All-electric charge-depleting hybrid control strategies are integrated and lifetime performance is simulated. The blended charge-depleting control strategy demonstrated significantly less degradation than the all-electric strategy. An oversized battery is integrated into the vehicle model and the benefit of oversizing on reducing the battery degradation rate is demonstrated.

Vehicle design and control is an attractive area of research in that it embodies a convergence of societal need, technical limitation, and emerging capability. Environmental, political, and monetary concerns are driving the automotive industry towards sustainable transportation, manifested as increasing powertrain electrification in a gradual transition to fossil-free energy vectors. From an electrochemical degradation and control systems perspective, this transition introduces significant technical uncertainty. Initial indications are that the initial battery designs will have twice the required capacity due to degradation concerns. As the battery is a major contributor to the cost of these vehicles the over-sizing represents a significant threat to the ability of OEMs to produce cost-competitive vehicles. This potential barrier is further amplified when the combustion engine is removed and battery-electric or fuel-cell hybrid vehicles are considered. This thesis researches the application of model-based design for optimal design of fuel cell hybrid powertrains considering power source degradation. The intent is to develop and evaluate tools that can determine the optimal sizing and control of the powertrain; reducing the amount of over-sizing by numerically optimization rather than a sub-optimal heuristic design. A baseline hybrid fuel cell vehicle model is developed and validated to a hybrid fuel cell SUV designed and built at the University of Waterloo. Lithium-ion battery degradation models are developed and validated to data captured off a hybrid powertrain test stand built as part of this research. A fuel cell degradation model is developed and integrated into the vehicle model. Lifetime performance is modeled for four hybrid control strategies, demonstrating a significant impact of the hybrid control strategy on powertrain degradation. A plug-in variation of the architecture is developed. The capacity degradation of the battery is found to be more significant than the power degradation. Blended and All-electric charge-depleting hybrid control strategies are integrated and lifetime performance is simulated. The blended charge-depleting control strategy demonstrated significantly less degradation than the all-electric strategy. An oversized battery is integrated into the vehicle model and the benefit of oversizing on reducing the battery degradation rate is demonstrated.

Advanced hybrid vehicle architectures can exploit multiple power sources and optimal control to achieve high efficiency operation. In this work, a method for generating the best-possible energy efficiency benchmark for a hybrid architecture is introduced. The benchmark program uses Dynamic Programming to analyse a reduced-fidelity MATLAB model over standard driving cycles, and bypasses vehicle controls to identify the optimal control actions and resulting fuel consumption of the Series-Parallel Multiple-Regime retrofitted PHEV of the UVic EcoCAR2 program. The simulation results indicate an optimal fuel consumption value of 4.74L/100km, in the parallel regime, compared to the stock Malibu's 8.83L/100km. The results are found to be sensitive to the allowed level of regenerative braking, with an optimal consumption value of 6.56L/100km obtained with restricted regen power limits. The parallel regime provided more efficient operation overall, especially during more aggressive driving conditions. However, the series regime provided more desirable operation during gentle driving conditions, where opportunities for regenerative braking are limited. The generated powertrain control profiles were then used to drive a higher-fidelity Simulink model. Due to the significant difference between the model structures of the MATLAB and Simulink models, comparison of results were not conclusive. A different simulation approach is required to make this proof-of-concept more useful for controls development. This research forms the foundation for further studies. / Graduate / 0540 / snkaban@gmail.com

The paper describes the design of a prototype vehicle used by Dana Holding Corporation as a mobile laboratory for the development of Spicer® PowerBoost® hydraulic-hybrid powertrain technology. A telehandler vehicle was selected due to its versatility. Starting from the high-level requirements, design choices from the powertrain layout to the control architecture are discussed. The hydraulic-hybrid powertrain system is described, and its performance is analyzed based on representative driving cycles.

Energy-efficient powertrain components and advanced vehicle control strategies are two effective methods to promote the potential of hybrid electric vehicles (HEVs). Aiming at hybrid system efficiency improvement, this thesis presents a comprehensive review of energy-efficient hybrid powertrain specific engines and proposes three improved energy management strategies (EMSs), from a basic non-adaptive real-time approach to a state-of-the-art learning-based intelligent approach. To evaluate the potential of energy-efficient powertrain components in HEV efficiency improvement, a detailed discussion of hybrid powertrain specific engines is presented. Four technological solutions, i.e., over-expansion cycle, low temperature combustion mode, alternative fuels, and waste heat recovery techniques, are reviewed thoroughly and explicitly. Benefits and challenges of each application are identified, followed by specific recommendations for future work. Opportunities to simplify hybrid-optimized engines based on cost-effective trade-offs are also investigated. To improve the practicality of HEV EMS, a real-time equivalent consumption minimization strategy (ECMS)-based HEV control scheme is proposed by incorporating powertrain inertial dynamics. Compared to the baseline ECMS without such considerations, the proposed control strategy improves the vehicle drivability and provides a more accurate prediction of fuel economy. As an improvement of the baseline ECMS, the proposed dynamic ECMS offers a more convincing and better optimal solution for practical HEV control. To address the online implementation difficulty faced by ECMS due to the equivalence factor (EF) tuning, a predictive adaptive ECMS (A-ECMS) with online EF calculation and instantaneous power distribution is proposed. With a real-time self-updating EF profile, control dependency on drive cycles is reduced, and the requirement for manual tuning is also eliminated. The proposed A-ECMS exhibits great charge sustaining capabilities on all studied drive cycles with only slight increases in fuel consumption compared to the basic non-adaptive ECMS, presenting great improvement in real-time applicability and adaptability. To take advantage of machine learning techniques for HEV EMS improvement, a deep reinforcement learning (DRL)-based intelligent EMS featuring the state-of-the-art asynchronous advantage actor-critic (A3C) algorithm is proposed. After introducing the fundamentals of reinforcement learning, formulation of the A3C-based EMS is explained in detail. The proposed algorithm is trained successfully with reasonable convergence. Training results indicate the great learning ability of the proposed strategy with excellent charge sustenance and good fuel optimality. A generalization test is also conducted to test its adaptability, and results are compared with an A-ECMS. By showing better charge sustaining performance and fuel economy, the proposed A3C-based EMS proves its potential in real-time HEV control. / Thesis / Doctor of Philosophy (PhD)

This dissertation addresses the challenges of scoping and sizing components and modeling the tank to wheel energy flows in new and rapidly evolving classes of automotive vehicles. It introduces a system of computer models, known as the Oxford Vehicle Model (OVEM), which provide for the novel simulation of the powertrains of electric (EV) and hybrid electric vehicles (HEV). OVEM has a three-level structure that makes a unique contribution to the field of vehicle analysis by enabling a user to proceed from performing scoping and sizing exercises through to accurately simulating the energy flows in powertrains of EVs and HEVs utilizing existing and emerging technologies based on real world data. Level 1 uses simplified models to support initial component scoping and sizing exercises in an analysis environment where uncertainty regarding component specifications is high. Level 2 builds on Level 1 by obtaining more refined component scoping and sizing estimates via the use of component models based on well-understood scientific principles that are product-independent – a crucial feature for obtaining unbiased scoping and sizing estimates. Level 3 employs a high degree of fidelity in that its models impose actual physical limits and are based on data from real technologies. This dissertation concludes with two chapters based on studies published as journal articles that used OVEM to address key issues facing the development of EVs and HEVs. The first study used OVEM to make the novel comparison between high-speed flywheels, batteries, and ultracapacitors on the bases of cost and fuel consumption while functioning as the energy storage systems in an HEV. The second study applied OVEM towards a novel examination of the CO2 emissions from plug-in HEVs (PHEVs) and compares their CO2 emissions to those from similar EVs and ICE-based vehicles.

For vehicles whose duty cycle is dominated by start-stop operation, fuel consumption may be significantly improved by better management of the start-stop process. Pneumatic hybrid technology represents one technology pathway to realise this goal. Vehicle kinetic energy is converted to pneumatic energy by compressing air into air tank(s) during the braking. The recovered air is reused to supply an air starter, or supply energy to the air path in order to reduce turbo-lag. This research aims to explore the concept and control of a novel pneumatic hybrid powertrain for a city bus application to identify the potential for improvements in fuel economy and drivability. In order to support the investigation of energy management, system architecture and control methodologies, two kinds of simulation models are created. Backward-facing simulation models have been built using Simulink. Forward-facing models have been developed in the GT-POWER and Simulink co-simulation. After comparison, the fully controllable hybrid braking system is chosen to realize the regenerative braking function. A number of architectures for managing a rapid energy transfer into the powertrain to reduce turbo-lag have been investigated. A city bus energy control strategy has been proposed to realize the Stop-Start Function, Boost Function, and Regenerative Braking Function as well as the normal operations. An optimisation study is conducted to identify the relationships between operating parameters and respectively fuel consumption, performance and energy usage. In conclusion, pneumatic hybrid technology can improve the city bus fuel economy by at least 6% in a typical bus driving cycle, and reduce the engine brake torque response and vehicle acceleration. Based on the findings, it can be learned that the pneumatic hybrid technology offers a clear and low-cost alternative to the electric hybrid technology in improving fuel economy and vehicle drivability.

A major cause of CO2 emissions today is fossil fuel vehicles, and lowering these emissions is of key importance, resulting in increasing electrification and hybridisation nowadays. Turbochargers have been used for a long time to recycle exhaust gas heat losses to improve engine performance by compressing the intake air. This thesis investigates a turbocharger with an added electric machine, to see if further energy can be recovered from these gasses, as well as how to control this machine for improved transients during acceleration and reduced turbo lag. A complete Simulink model is created of the system, comprised of a variable geometry turbine, compressor, cylinder, electric motor and battery model. This plant model is then evaluated on test cycles, which results in consistently lowered brake-specific fuel consumption and quicker responses at the cost of electric charge. The results show that an electrically assisted turbocharger poses as a feasible option for further improvements in fuel economy and performance during transients for spark ignited engines.

The master’s thesis deals with modelling of various architectures of hybrid powertrains for three vehicle sizes in GT-SUITE and compares them in daily commuting operating mode. On top of making of the hybrid vehicle simulation models, control algorithms had to be created to manage the energy split between the internal combustion engine and the electric motor for each of the architectures. Routes to work and back were logged using the GPS and postprocessed to obtain the speed and the road grade profiles. Resulting data was used as an input in simulations of daily commuting. To compare all hybrid powertrain architectures, fuel economy and electricity consumption were evaluated for WLTP and daily commuting operating modes. Finally, the environmental impact of each topology was assessed based on an estimation of corresponding well-to-wheel emissions.

<div>The commercial vehicle sector is an important enabler of the economy and is heavily dependent on fossil fuels. In the fight against climate change, reduction of emissions by improving fuel economy is a key step for the commercial vehicle sector. Improving fuel economy deals with reducing energy losses from fuel to the wheels. This study aims to analyze efficiency improvements for two systems that are important in reducing CO2 emissions - hybrid powertrains and natural gas engines. At first, a prototype series hybrid powertrain was analyzed based on on-highway data collected from its powertrain components. Work done per mile by the electrical components of the powertrain showed inefficient battery operation. The net energy delivery of the battery was close to zero at the end of the runs. This indicated battery was majorly used as an energy storage device. Roughly 15% of losses were observed in the power electronics to supply power from battery and generator to the motor. Ability of the hybrid system to capture regenerative energy and utilize it to propel the vehicle is a primary cause for fuel savings. The ability of this system to capture the regenerative energy was studied by modeling the system. The vehicle model demonstrated that the system was capturing most of the theoretically available regenerative energy. The thesis also demonstrates the possibility of reduction of vehicular level losses for the prototype truck. Drag and rolling resistance coefficients were estimated based on two coast down tests conducted. The ratio of captured regenerative to the drive energy energy for estimated drag and rolling resistant coefficients showed that the current system utilizes 4%-9% of its drive energy from the captured regenerative energy. Whereas a low mileage Peterbilt 579 truck could increase the energy capture ratio to 8%-18% for the same drive profile and route. Decrease in the truck’s aerodynamic drag and rolling resistance can potentially improve the fuel benefits.</div><div>The second study aimed to reduce the engine level pumping losses for a natural gas spark ignition engine by cylinder deactivation (CDA). Spark ignited stoichiometric engines with an intake throttle valve encounter pumping/throttling losses at low speed, low loads due to the restriction of intake air by the throttle body. A simulation study for CDA on a six cylinder natural gas engine model was performed in GT- Power. The simulations were ran for steady state operating points with a torque range 25-560 ftlbs and 1600 rpm. Two , three and four cylinders were deactivated in the simulation study. CDA showed significant fuel benefits with increase in brake thermal efficiency and reduction in brake specific fuel consumption depending on the number of deactivated cylinders. The fuel benefits tend to decrease with increase in torque. Engine cycle efficiencies were analyzed to investigate the efficiency improvements. The open cycle efficiency is the main contributor to the overall increase in the brake thermal efficiency. The work done by the engine to overcome the gas exchange during the intake and exhaust stroke is referred to the pumping losses. The reduction in pumping losses cause an improvement in the open cycle efficiency. By deactivating cylinders, the engine meets its low torque requirements by increase in the intake manifold pressure. Increased intake manifold pressure also resulted in reduction of the pumping loop indicating reduced pumping losses. A major limitation of the CDA strategy was ability to meet EGR fraction requirements. The increase in intake manifold pressure also caused a reduction in the delta pressure across the EGR valve. At higher torques with high EGR requirements CDA strategy was unable to meet the required EGR fraction targets. This limited the benefits of CDA to a specific torque range based on the number of deactivated cylinders. Some variable valve actuation strategies were suggested to overcome this challenge and extend the benefits of CDA for a greater torque range.</div><div><br></div>