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NYBRII,

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DELMAR CENGAGE Learning’ Hybrid, Electric & Fuel-Cell Vehicles, Second Edition Jack Erjavec

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“Copyigh ©2013 Cengage Learing In Retieved 'rom vawu/ krovel com Copyrighted Materials

Preface

The U.S government has set new standards that require new cars and light trucks to average the equivalent of 54.5 mpg in 2025 while reducing greenhouse gas emissions to 163 grams per mile To achieve this, auto manufacturers are investing great amounts of time and money looking for practi to meet the new standards Much of the res been focused on battery-operated electric vehicles, hybrid electric vehicles, and fuel cell electric vehicles These are the main subjects of this book

Although refinements to internal combustion en- gines have made them more efficient, they will never be developed to the point where they emit zero emissions Nor can an internal combustion engine ever be 100 percent energy efficient To meet the new government standards, the industry cannot rely on refinements to an engine Attention must also be spent on designing special-purpose all-electric vehicles and combinations of engine and electric Although the total elimination of the internal combustion engine would meet the new standards, this is not yet practical Many different alternative fuels have been tested and used in conventional engines to reduce our de- pendency on fossil fuels and to reduce emission levels All of these show promise and are briefly discussed in this book However, the only technology that promises to drastically reduce emissions and provide excellent fuel economy is the electric drive vehicle

A few manufacturers are currently offering all- electric, battery-operated vehicles These will be dis-

cussed, as will a brief history of electric vehicles

Much of what was discovered in the past about electric vehicles is being used today in hybrid vehicles and will also be used in fuel cell vehicles

Electric drive vehicles are powered by high-voltage systems With the high voltages also come serious safety issues The voltages of electric drive vehicles are high enough to kill anyone who does not respect them and does not carefully adhere to the precautions given by the manufacturers of these vehicles If this book has one dominant theme, it is “respect the voltage!”

Throughout this book, regardl of the topic,

CAUTIONS, NOTES, and WARNINGS are given to

remind everyone who reads this book to be very careful while doing anything on an electric drive vehicle

Many assume that because some of the vehicle’s systems are just like what has been used for years in conventional vehicles, they can just maintain and ser- vice electric drive vehicles unimpeded This is not true To prevent great personal injury and/or damage to the vehicle, you must do what you can to work safely on these vehicles

Too often, technicians and others take some risks to complete a job quickly On electric drive vehicles, moving too quickly or proceeding without checking a few things can end a career or a life quickly These messages are not meant to scare anyone away from working on electric vehicles; rather they are intended to make one aware of the dangers Knowing the dan- gers, I hope that everyone will enjoy the technology and the thrill of working with it

Electric drive technologies are advancing very quickly So much has changed between the time I started writing this and the time I thought I was finished In fact, when I thought it was completed, and I reviewed what I

had written, I saw some vehicles I did not write about that

were running on the roads Unfortunately, this will be the case for quite some time, so I decided to stop If I waited to stop until the technology cooled down a bit, this book would not have been available for another 10 years or so But I did try to cover the basics to allow you to under- stand those systems that cannot be covered in this book The topics are presented in a progression, from yesterday’s technology to tomorrow’s The first chapter focuses on the basics The various types of electric drive vehicles are defined and described There is also a discussion of various alternative fuels that can be used in an internal combustion engine This discussion may

seem out of place for a book about electric vehicles, but

these fuels can be used in hybrid vehicles and as sources of hydrogen for fuel cell vehicles There is also a quick look at the history of electric drive vehicles

Chapters 2 through 4 provide the basics for the rest

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vehicles, is covered from a theoretical and practical

standpoint The basics of electric motors and batteries are also covered, in separate chapters Regardless of the type of electric drive vehicle being considered, the two most important items are the motor and battery Many different designs of both are covered in these chapters because many designs have been and can be used in electric vehicles

Chapter 5 covers pure electric vehicles These battery-operated vehicles are currently available from

different manufacturers, and more will be available in

the future

Since hybrid vehicles are quite popular today, there are five chapters, Chapters 6 through 10, dedicated to

the subject All hybrid vehicles available at the time of this writing are described and discussed These are grouped by system and operational commonalities Chapter 10 addresses general service to these vehicles

ACKNOWLEDGMENTS

I would like to thank the following companies for their help in the preparation of this book:

Aisin AW Co., LTD

American Honda Motor Co., Inc Ballard Power Systems The Battery Council International Beta Research & Development Ltd The BMW Group Continental Automotive Systems Daimler Corporation Dana Corporation Fluke Corporation Ford Motor Company Grainger, Inc

Hyundai Motor Company Johnson Control Battery Group, Inc Moteur Development International

PowerCell, Se

The Southern Company

Toyota Motors Corporation

United Technologies Company The U.S Department of Energy

Visteon Corporation

That chapter does not go into extreme detail because the manufacturers do not want technicians going deeply into their systems without special training However, because of the high voltages found in these vehicles, many common nonhybrid service procedures need to be modified to work safely Many of these new procedures are presented in the chapter

Chapter 11 is a look into the future It contains a look at fuel cell vehicles and other potential tech- nologies that may affect the operation of an automobile in the future Manufacturers have built and tested many fuel cell vehicles, and this chapter looks at what worked and what did not in many of these vehicles

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CHAPTER 1 CHAPTER 2 Copyrighted Materials “Copyigh ©2013 Cengage Learing In Retieved 'rom vawu/ krovel com Contents

Preface ccc een eens xi

An Introduection to Electric Vehieles . 1

Introduction Why Electric Drive?

Alternative Fuels - eee eee 3 Propane/LPG Vehicles Ethanol/Methanol Vehicles Natural Gas Vehicles 2.00.00 00000 cee Energy Density The Basics of Electric Vehicles Regenerative Braking Battery-Operated Electric Vehicles Hybrid Electric Vehicles

Economics

Fuel Cell Electric Vehicle: A Look at History

Precautions for Working on Electric Drive Vehicles

Battery Pr€CdMfOHS ẶẶ eee

Review Questions 2.0.0 ec ett eee teen eee Electrical Basics Introduction

Electrical Terms sees cece eee sees + Ohm S LaW Ặ eee Ôn Circuit Terminology

Alternating Current

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Electromagnetism Basics

Fundamentals oƒ Magnetism Magnetic Circuits and Reluctance Induced Voltage Transformers Electrical Systems High-Voltage Systems Review Questions CHAPTER 3 Motor and Generator Basics - - 35 Introduction 35 Simple Explanation of Basic Motor Types 36 The Distant Past 36 Basic Motor Operation 36 Electromagnets 37 Generators - 39 Faraday’s Law 39 Self-Inductance 39 Lenz's Law 40 Inductive Reactance 40 DC Motors Motor Housing Field Windings Armatures Commutator Field Winding Designs Work AC Motors Basic Construction Basic Operation Synchronous Motor Induction Motor Switched Reluctance Motors

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CHAPTER 5 Battery Ratings Ampere-Hour Watt-Hour Rating Cold-Cranking Amps Cranking Amps Reserve Capacity

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