Hybrid-electric-and-fuel-cell-vehicle

HYBRID, ELECTRIC & FUEL-CELL VEHICLES Jack Erjavec Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States Copyright 2012 Cengage Learning All Rights Reserved May not be copied, scanned, or duplicated, in whole or in part Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s) Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it This is an electronic version of the print textbook Due to electronic rights restrictions, some third party content may be suppressed Editorial review has deemed that any suppressed content does not materially affect the overall learning experience The publisher reserves the right to remove content from this title at any time if subsequent rights restrictions require it For valuable information on pricing, previous editions, changes to current editions, and alternate formats, please visit www.cengage.com/highered to search by ISBN#, author, title, or keyword for materials in your areas of interest Copyright 2012 Cengage Learning All Rights Reserved May not be copied, scanned, or duplicated, in whole or in part Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s) Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Hybrid, Electric & Fuel-Cell Vehicles, Second Edition Jack Erjavec Vice President, Editorial: Dave Garza Director of Learning Solutions: Sandy Clark Executive Editor: Dave Boelio Managing Editor: Larry Main
c 2013, 2007, Delmar, Cengage Learning ALL RIGHTS RESERVED No part of this work covered by the copyright herein may be reproduced, transmitted, stored, or used in any form or by any means graphic, electronic, or mechanical, including but not limited to photocopying, recording, scanning, digitizing, taping, Web distribution, information networks, or information storage and retrieval systems, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without the prior written permission of the publisher Senior Product Manager: Matthew Thouin Editorial Assistant: Courtney Troeger Vice President, Marketing: Jennifer Baker Marketing Director: Deborah S Yarnell Marketing Manager: Erin Brennan Associate Marketing Manager: Jillian Borden For product information and technology assistance, contact us at Cengage Learning Customer & Sales Support, 1-800-354-9706 For permission to use material from this text or product, submit all requests online at www.cengage.com/permissions Further permissions questions can be e-mailed to permissionrequest@cengage.com Production Director: Wendy Troeger Production Manager: Mark Bernard Library of Congress Control Number: 2012931308 Senior Content Project Manager: Cheri Plasse ISBN-13: 978-0-8400-2395-7 ISBN-10: 0-8400-2395-2 Delmar Maxwell Drive Clifton Park, NY 12065-2919 USA Cengage Learning is a leading provider of customized learning solutions with office locations around the globe, including Singapore, the United Kingdom, Australia, Mexico, Brazil, and Japan Locate your local office at: international.cengage.com/region Cengage Learning products are represented in Canada by Nelson Education, Ltd To learn more about Delmar, visit www.cengage.com/delmar Purchase any of our products at your local college store or at our preferred online store www.cengagebrain.com Notice to the Reader Publisher does not warrant or guarantee any of the products described herein or perform any independent analysis in connection with any of the product information contained herein Publisher does not assume, and expressly disclaims, any obligation to obtain and include information other than that provided to it by the manufacturer The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities described herein and to avoid all potential hazards By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions The publisher makes no representations or warranties of any kind, including but not limited to, the warranties of fitness for particular purpose or merchantability, nor are any such representations implied with respect to the material set forth herein, and the publisher takes no responsibility with respect to such material The publisher shall not be liable for any special, consequential, or exemplary damages resulting, in whole or part, from the readers’ use of, or reliance upon, this material Dr Ing h.c F Porsche AG is the owner of numerous trademarks, both
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R R R R R R PORSCHE , CAYENNE , PANAMERA , 911 , GT3 , 918 SPYDER , and the permission of Porsche Cars North America, Inc and Dr Ing h.c F Porsche AG Printed in the United States of America 14 13 12 Copyright 2012 Cengage Learning All Rights Reserved May not be copied, scanned, or duplicated, in whole or in part Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s) Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it 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 practical ways to meet the new standards Much of the research has 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 engines 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 dependency 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 allelectric, battery-operated vehicles These will be discussed, 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, regardless 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 service electric drive vehicles unimpeded This is not true To prevent great personal injury and/or damage to the vehicle, you must 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 dangers, 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 understand 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 through provide the basics for the rest of the book Basic electricity, as it applies to these xi Copyright 2012 Cengage Learning All Rights Reserved May not be copied, scanned, or duplicated, in whole or in part Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s) Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it 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 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 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 That chapter does not go into extreme detail because the manufacturers 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 technologies 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 I sincerely hope the information in this book opens doors of thought and rewards for you The electric drive technology is different, rewarding, and exciting Jack Erjavec 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 I would also like to thank the following individuals who took the time to review the manuscript and to make sure this book had a minimum of errors and that it met its goals: Thomas Connors Spokane Community College Spokane, WA Lance David College of Lake County Grayslake, IL Curt Goodwin Northwest Kansas Technical College Goodland, KS David Hostert Morton College Cicero, IL Anthony K Rish Gateway Community College North Haven, CT xii Copyright 2012 Cengage Learning All Rights Reserved May not be copied, scanned, or duplicated, in whole or in part Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s) Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Contents Preface xi CHAPTER An Introduction to Electric Vehicles Introduction Why Electric Drive? Alternative Fuels Propane/LPG Vehicles Ethanol/Methanol Vehicles Natural Gas Vehicles Energy Density The Basics of Electric Vehicles Regenerative Braking Battery-Operated Electric Vehicles Hybrid Electric Vehicles Economics Fuel Cell Electric Vehicles A Look at History Precautions for Working on Electric Drive Vehicles Battery Precautions Review Questions CHAPTER 11 14 15 15 Electrical Basics 17 Introduction Electrical Terms Ohm’s Law Power Circuit Terminology Alternating Current Conductors and Insulators Circuits Circuit Components Resistors Circuit Protective Devices Switches Solenoids Capacitors Semiconductors Diodes Transistors 18 18 19 19 19 20 22 22 23 23 24 24 25 25 26 26 27 iii Copyright 2012 Cengage Learning All Rights Reserved May not be copied, scanned, or duplicated, in whole or in part Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s) Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Electromagnetism Basics Fundamentals of Magnetism Magnetic Circuits and Reluctance Induced Voltage Transformers Electrical Systems High-Voltage Systems Review Questions CHAPTER 29 29 30 30 31 31 31 32 Motor and Generator Basics 35 Introduction Simple Explanation of Basic Motor Types The Distant Past Basic Motor Operation Electromagnets Generators Faraday’s Law Self-Inductance Lenz’s Law Inductive Reactance DC Motors Motor Housing Field Windings Armatures Commutator Field Winding Designs Work Brushless DC Motors AC Motors Basic Construction Basic Operation Synchronous Motor Induction Motor Switched Reluctance Motors Generators DC Generators AC Generators Motor/Generators Controllers Inverters and Converters Review Questions CHAPTER 35 36 36 36 37 39 39 39 40 40 41 41 41 42 42 42 43 44 44 45 45 46 48 49 50 50 51 52 53 54 55 Battery Basics 57 Introduction 58 Basic Battery Theory 59 Effects of Temperature Battery Hardware Battery Arrangements Charging Recycling Batteries 59 59 60 61 62 iv Copyright 2012 Cengage Learning All Rights Reserved May not be copied, scanned, or duplicated, in whole or in part Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s) Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Battery Ratings Ampere-Hour Watt-Hour Rating Cold-Cranking Amps Cranking Amps Reserve Capacity Common Types of Batteries Battery Chemistry High-Voltage Batteries Applications Safety Issues Lead-Acid Batteries Basic Construction Discharging and Charging Service Testing Battery Safety Nickel-Based Batteries Nickel-Metal Hydride Cells Nickel-Cadmium Cells Lithium-Based Batteries Lithium-Ion Battery Lithium-Polymer Batteries Ultra-Capacitors Capacitors Ultra-Capacitors Review Questions CHAPTER 62 64 64 64 64 64 64 65 67 67 68 70 70 72 74 74 76 77 77 78 78 78 80 80 81 82 84 The Basics of a Battery-Operated Electric Vehicle 85 Introduction Advantages Cost BEV vs ICEV Torque Emissions Disadvantages Flywheel Energy Storage Monroney Label Major Parts Component Specifications Controller Inverter/Converter Regenerative Braking Battery Charging Charge Levels Inductive Charging Charge Times Charging Procedures Accessories HVAC 86 86 87 88 89 89 90 90 90 92 92 94 95 96 96 98 100 100 100 101 102 v Copyright 2012 Cengage Learning All Rights Reserved May not be copied, scanned, or duplicated, in whole or in part Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s) Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Power Brakes Power Steering Driving an EV Starting Driving and Braking Maximizing Range Nissan Leaf Battery Pack Charging Telematics Sound for Pedestrians Mitsubishi i MiEV Tesla Motor Battery Charging Model S Smart Fortwo Electric Drive (or Smart ED) Ford Focus Electric Basic Diagnosis Precautions Self-Diagnostics Review Questions CHAPTER 102 103 103 104 105 106 106 106 107 108 108 108 109 109 110 110 110 110 111 111 113 113 114 Hybrid Basics and Series-Type Hybrids 115 Introduction What is a Hybrid Vehicle? Types Benefits of a Hybrid Fuel Economy Air Pollution Cost Availability Technology Internal Combustion Engine Diesel Engines Stop-Start Feature Regenerative Brakes Accessories HVAC Power Brakes Power Steering Types of HEVs Series Hybrids Chevrolet Volt 115 116 116 117 118 118 118 119 119 121 122 122 122 124 124 125 125 125 127 127 Basic Operation Economics Battery Pack Charging Methods Programmable Charging 129 130 130 131 133 vi Copyright 2012 Cengage Learning All Rights Reserved May not be copied, scanned, or duplicated, in whole or in part Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s) Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Basic Operation Cooling System Engine Cooling System and Heater Loop Electric Drive Cooling System Power Electronics Cooling Loop High-Voltage Battery Cooling System Disabling a Volt First Responder Fisker Driver-Selected Operating Modes Battery Charging Plug-in Hybrids Mercedes-Benz Sprinter Hydraulic Hybrids Review Questions CHAPTER 134 138 139 139 140 140 140 140 141 141 142 142 142 143 145 Mild and Assist Hybrids 147 Introduction Stop-Start Flywheel/Alternator/Starter Hybrid System General Motors Belt Alternator/Starter Hybrid System General Motors Assist Hybrids DaimlerChrysler General Motors eAssist Honda’s Hybrids Honda Insight Honda Civic Assist Hybrid Honda Accord Hybrid Honda Hybrid Safety Issues Porsche GT3R Review Questions CHAPTER 148 148 148 148 150 151 152 152 153 154 154 163 167 172 174 174 175 Power-Split-Type Full Hybrids 177 Introduction Toyota’s Hybrids Toyota Prius Prius Plug-In Toyota’s Hybrid SUVs Ford Hybrids Operation Electronic Components 177 178 179 193 194 201 202 204 Engine Transaxle Four-Wheel Drive (4WD) Review Questions 205 206 207 207 vii Copyright 2012 Cengage Learning All Rights Reserved May not be copied, scanned, or duplicated, in whole or in part Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s) Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it