Researching on manufacturing and simulating the operation of the toyota prius hybrid’s model

MINISTRY OF EDUCATION AND TRAINING HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION FINAL REPORT STUDENT'S SCIENTIFIC RESEARCH TOPIC RESEARCHING ON MANUFACTURING AND SIMULATING THE OPERATION OF THE TOYOTA PRIUS HYBRID'S MODEL S K C 0 9 TOPIC NUMBER: SV2022-153 PROJECT LEADER: NGUYEN QUOC VU SKC008096 Ho Chi Minh City, November, 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FALCUTY FOR HIGH QUALITY TRAINING SCIENTIFIC RESEARCH RESEARCHING ON MANUFACTURING AND SIMULATING THE OPERATION OF THE TOYOTA PRIUS HYBRID’S MODEL Project code: SV2022-153 Student: Nguyễn Phan Lương Bằng Student ID: 18145003 Student: Nguyễn Quốc Vũ Student ID: 18145079 Advisor: Master Vũ Đình Huấn Ho Chi Minh City, November 2022 TABLE OF CONTENTS CHAPTER1: INTRODUCTION 1.1 PROJECT OVERVIEW 1.1.1 The reason for choosing the topic 1.1.2 Goals 1.1.3 Limit in the project 1.1.4 Reasearch methods 1.2 THE OVERVIEW OF THE HYBRID VEHICLES 1.2.1 Overview The brief history of Hybrid vehicles 1.2.2 What is a Hybrid Electric Vehicle? 1.2.3 The working principle of Hybrid vehicles 1.2.4 Advantages 1.2.5 Powertrain Methodology 1.2.5.1 Series Hybrid 1.2.5.2 Parallel Hybrid 1.2.5.3 Series-Parallel Hybrid 1.2.5.4 Rate of use of motors and electric motors in each system 1.2.6 Main components in Hybrid vehicles 1.2.7 Economics of Hybrid vehicle 10 1.2.8 Development trend of hybrid cars in developed countries 11 CHAPTER 2: THEORETICAL BASIS OF HYBRID ENGINES 13 2.1 SERIES-PARALLEL HYBRID’S COMPENENTS 13 2.1.1 2ZR-FXE engine 14 2.1.2 Hybrid gearbox 16 2.1.3 MG1 MG2 17 2.1.4 POWER-SPLIT DEVICE (PSD) 19 2.1.5 High voltage source 38 2.1.5.1 Overview 38 2.1.5.2 Power cable 39 2.1.5.3 Nickel-metal hydride high-voltage battery: 40 2.1.5.4 ECU battery 41 2.2 Controlled mehod 43 2.2.1 Operation modes 43 2.2.2 Controlled stratery 51 2.2.2.1 Controlled system 51 2.2.2.2 Method of controlling engine speed 52 2.2.2.3 Torque controlled method 53 2.2.2.4 Drivetrain controlled strategy 55 2.2.2.5 Engine speed controlled strategy 55 2.2.2.6 Traction moment controlled strategy 56 2.2.2.6.1 In the low speed zone: 57 2.2.2.6.2 In the medium vehicle speed zone 58 2.2.2.6.3 In the high vehicle speed zone 58 2.2.2.7 Controlled regenerative braking 59 CHAPTER CALCULATION,SIMULATION BY MATLAB/SIMULINK 60 3.1 MODEL CAR SPECIFICATIONS 60 3.2 SIMULATION OF MODEL IN MATLAB/SIMULINK 60 3.2.1 Driver 61 3.2.2 Hybrid Systems 62 3.2.2.1 Controller 63 3.2.2.2 Electrical 66 1.2.8.1 Engine 69 3.2.2.3 Power-Split Device 70 3.2.3 3.3 Vehicle 71 SIMULATION RESULTS 73 3.3.1 Velocity 73 3.3.2 State of charge (SOC) 73 3.3.3 Moment and motor speed (MG2) 74 3.3.4 Moment and engine speed 75 3.3.5 Moment and generator speed (MG1) 76 3.3.6 Fuel consumption 77 CHAPTER CONCLUSION 85 LIST OF FIGURES Figure 1.1 The structure of Hybrid vehicle Figure 1.2 Series hybrid drivetrain Figure 1.3 Parallel hybrid drivetrain Figure 1.4 Combinated powertrain diagram Figure 1.5 2010 Toyota Prius Figure 1.6 Rate of use of motor and engine Figure 1.7 Main components in hybrid vehicle 10 Figure 2.1 The diagram of Hybrid’s controlled unit 13 Figure 2.2 2ZR-FXE engine 14 Figure 2.3 Hybrid gearbox 16 Figure 2.4 Controller unit diagram MG1, MG2 19 Figure 2.5 Power Split Device diagram 20 Figure 2.6 Power Split Device 21 Figure 2.7 Transmission Layouts 22 Figure 2.8 Engine starts when car stops 24 Figure 2.9 Engine started 26 Figure 2.10 Acceleration and Climbing 28 Figure 2.11 On the highway 30 Figure 2.12 Running by inertia 32 Figure 2.13 Simulate running on Creeping mode 34 Figure 2.14 Slow mode and EV mode 35 Figure 2.15 Reverse 38 Figure 2.16 High voltage source structure 39 Figure 2.17 Power cable 40 Figure 2.18 High-voltage battery 41 Figure 2.19 4th generation Prius battery ECU and later 41 Figure 2.20 Hybrid vehicle control method 42 Figure 2.21 Transmission layout 44 Figure 2.22 Energy flow in motor-only mode 45 Figure 2.23 Energy flow in motor/traction generator only mode 46 Figure 2.24 Energy flow in Motor mode/generator working in conjunction with traction motor 49 Figure 2.25 Energy flow in Motor/generator mode works in conjunction with alternator motor 49 Figure 2.26 Energy flow in Speed coupling mode combined with traction motor 50 Figure 2.27 Energy flow in Speed Coupling mode combined with alternator motor 51 Figure 2.28 Energy flow in regenerative braking mode 51 Figure 2.29 Graph of torque and number of engine revolutions 52 Figure 2.30 The relationship between the moment-velocity 54 Figure 2.31 Controlled moment strategy 56 Figure Model overview on MATLAB/simulink 61 Figure Driver block 61 Figure 3.3 Driver Cycle block 62 Figure Components of Hybrid Systems block 62 Figure Controller block 63 Figure Traction block 64 Figure 3.8 Electrical block 66 Figure Engine block 70 Figure 10 PSD block 71 Figure 11 Vehicle block 72 Figure 12 Velocity simulation 73 Figure 13 SOC 74 Figure 14 Simulation result of MG2 75 Figure 15 Simulation of moment and engine speed 76 Figure 16 Simulation result of MG1 77 LIST OF TABLE Table 2.1 Technical speciffication of 2NZ-FXE 16 Table 2.2 Technical specification of Hybrid gearbox 17 Table 2.3 Technical specification of MG1 18 Table 2.4 Technical specification of MG2 18 Table 2.5 Relationship among components on PSD 22 Table 2.6 The relationship between vehicle speed and power corresponding to engine and motor rotational speed 29 Table 3.1 Model car specification 60 LIST OF ACRONYMS AGM Absorbed Glass Mat CVT Continuously Variable Transmission ECM Electronic Control Module ECU Electronic Control Unit EVT Electric Variable Transmission GB Gear Box HEV Hybrid Electric Vehicle HV High Voltage ICE Internal Combustion Engine IGBT Insulated Gate Bipolar Transistor M/G Motor/ Generator MG1 Motor Generator MG2 Motor Generator PEHV Petroleum Electric Hybrid Vehicle PLG Planetary Gear PPS Peaking Power Source PSD Power Split Device RESS Rechargeable Energy Storage System SMR System Main Relay SOC State Of Charge SOCH State Of Charge Hight SOCL State Of Charge Low THS Toyota Hybrid System TM Traction Motor RPM Revolutions Per Minute HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION THE SOCIALIST REPUBLIC OF VIETNAM Independence - Freedom – Happiness FACULTY FOR HIGH QUALITY TRAINING Ho Chi Minh City, November 2022 SCIENTIFIC RESEARCH TASKS General information - Project title: Researching on manufacturing and simulating the operation of the Toyota Prius hybrid’s model - Project manager: Nguyễn Quốc Vũ - Student ID:18145079 - Class:18145CLA3 - Falculty: Falculty for High Quality Training - Project member: No Name Student ID Class Falculty Nguyễn Phan Lương Bằng 18145003 18145CLA3 Falculty for high quality training - Advidor: Master Vũ Đình Huấn Project mission - Reserching on hybrid theory of Toyota Prius - Simulating and Controlling the model on MATLAB Simulink Project result - Simulating a hybrid vehicle model using MATLAB/Simulink software - Completing the theoretical basis of hybrid vehicles based on literature source - Run simulation on MATLAB/Simulink software based on experimental cycles Ho Chi Minh City, November 2022 Project manager (sign and write full name) When the vehicle starts operating in the period from 0-30s, the vehicle speed Vx5 (m/s), due to the alternating operation of the engine pulling the generator, it contributes to the load on the PPS, causing the SOC to gradually increase to the upper limit (SOCH=0.7) After increasing to the upper limit, and the SOC active in a range between 0.35