Design of a Hybrid Electric Vehicle Powertrain for Performance Optimization Considering Various Powertrain Components and Configurations

A Review of Lithium-Ion Battery Thermal Runaway Modeling and Diagnosis Approaches

Lithium-ion (Li-ion) batteries have been utilized increasingly in recent years in various applications, such as electric vehicles (EVs), electronics, and large energy storage systems due to their long lifespan, high energy density, and high-power density, among other qualities. However, there can be faults that occur internally or externally that affect battery performance which can potentially lead to serious safety concerns, such as thermal runaway. Thermal runaway is a major challenge in the Li-ion battery field due to its uncontrollable and irreversible nature, which can lead to fires and explosions, threatening the safety of the public. Therefore, thermal runaway prognosis and diagnosis are significant topics of research. To efficiently study and develop thermal runaway prognosis and diagnosis algorithms, thermal runaway modeling is also important. Li-ion battery thermal runaway modeling, prediction, and detection can help in the development of prevention and mitigation approaches to ensure the safety of the battery system. This paper provides a comprehensive review of Li-ion battery thermal runaway modeling. Various prognostic and diagnostic approaches for thermal runaway are also discussed.

A Review of Equivalent Circuit Model Based Online State of Power Estimation for Lithium-Ion Batteries in Electric Vehicles

With rapid transportation electrification worldwide, lithium-ion batteries have gained much attention for energy storage in electric vehicles (EVs). State of power (SOP) is one of the key states of lithium-ion batteries for EVs to optimise power flow, thereby requiring accurate online estimation. Equivalent circuit model (ECM)-based methods are considered as the mainstream technique for online SOP estimation. They primarily vary in their basic principle, technical contribution, and validation approach, which have not been systematically reviewed. This paper provides an overview of the improvements on ECM-based online SOP estimation methods in the past decade. Firstly, online SOP estimation methods are briefed, in terms of different operation modes, and their main pros and cons are also analysed accordingly. Secondly, technical contributions are reviewed from three aspects: battery modelling, online parameters identification, and SOP estimation. Thirdly, SOP testing methods are discussed, according to their accuracy and efficiency. Finally, the challenges and outlooks are presented to inspire researchers in this field for further developments in the future.

Investigation of Individual Cells Replacement Concept in Lithium-Ion Battery Packs with Analysis on Economic Feasibility and Pack Design Requirements

The optimization of lithium-ion (Li-ion) battery pack usage has become essential due to the increasing demand for Li-ion batteries. Since degradation in Li-ion batteries is inevitable, there has been some effort recently on research to maximize the utilization of Li-ion battery cells in the pack. Some promising concepts include reconfigurable battery packs and cell replacement to limit the negative impact of early-degraded cells on the entire pack. This paper used a simulation framework, based on a cell voltage model and a degradation model, to study the feasibility and benefits of the cell replacement concept. The simulation conducted in MATLAB involves generating and varying Li-ion cells in the packs stochastically and simulating the life of the cells as well as the packs until they reach their end-of-life stage. It was found that the cell replacement method can increase the total number of cycles of the battery packs, effectively prolonging the lifespan of the packs. It is also determined that this approach can be more economically beneficial than the current approach of simple pack replacement. For the cell replacement concept to be practical, two main design criteria should be satisfied including individual cell monitoring and easy accessibility to cells at failure stage.

Retrospection of the Optimization Model for Designing the Power Train of a Formula Student Race Car

This article describes the power train design specifics in Formula student race vehicles used in the famed SAE India championship. To facilitate the physical validation of the design of the power train system of a formula student race car category vehicle engine of 610 cc displacement bike engine (KTM 390 model), a detailed design has been proposed with an approach of easing manufacturing and assembly along with full-scale prototype manufacturing. Many procedures must be followed while selecting a power train, such as engine displacement, fuel type, cooling type, throttle actuation, and creating the gear system to obtain the needed power and torque under various loading situations. Keeping the rules in mind, a well-suited engine was selected for the race track and transmission train was selected which gives the maximum performance. Based on the requirement, a power train was designed with all considerations we need to follow. Aside from torque and power, we designed an air intake with fuel efficiency in mind. Wireless sensors and cloud computing were used to monitor transmission characteristics such as transmission temperature management and vibration. The current study describes the design of an air intake manifold with a maximum restrictor diameter of 20 mm.

Soft Sensors for State of Charge, State of Energy, and Power Loss in Formula Student Electric Vehicle

The proliferation of electric vehicle (EV) technology is an important step towards a more sustainable future. In the current work, two-layer feed-forward artificial neural-network-based machine learning is applied to design soft sensors to estimate the state of charge (SOC), state of energy (SOE), and power loss (PL) of a formula student electric vehicle (FSEV) battery-pack system. The proposed soft sensors were designed to predict the SOC, SOE, and PL of the EV battery pack on the basis of the input current profile. The input current profile was derived on the basis of the designed vehicle parameters, and formula Bharat track features and guidelines. All developed soft sensors were tested for mean squared error (MSE) and R-squared metrics of the dataset partitions; equations relating the derived and predicted outputs; error histograms of the training, validation, and testing datasets; training state indicators such as gradient, mu, and validation fails; validation performance over successive epochs; and predicted versus derived plots over one lap time. Moreover, the prediction accuracy of the proposed soft sensors was compared against linear or nonlinear regression models and parametric structure models used for system identification such as autoregressive with exogenous variables (ARX), autoregressive moving average with exogenous variables (ARMAX), output error (OE) and Box Jenkins (BJ). The testing dataset accuracy of the proposed FSEV SOC, SOE, PL soft sensors was 99.96%, 99.96%, and 99.99%, respectively. The proposed soft sensors attained higher prediction accuracy than that of the modelling structures mentioned above. FSEV results also indicated that the SOC and SOE dropped from 97% to 93.5% and 93.8%, respectively, during the running time of 118 s (one lap time). Thus, two-layer feed-forward neural-network-based soft sensors can be applied for the effective monitoring and prediction of SOC, SOE, and PL during the operation of EVs.

Battery High Temperature Sensitive Optimization-Based Calibration of Energy and Thermal Management for a Parallel-through-the-Road Plug-in Hybrid Electric Vehicle

Preserving high-voltage battery pack lifetime represents a key issue in hybrid electric vehicles (HEVs). Temperature has remarkably major impacts on battery lifetime and implementing HEV thermal and energy management approaches to enhance fuel economy while preserving battery lifetime at various temperatures still represents an open challenge. This paper introduces an optimization driven methodology to tune the parameters of thermal and energy on-board rule-based control approaches of a parallel through-the-road plug-in HEV. Particle swarm optimization is implemented to this end and the calibration objective involves minimizing HEV operative costs concerning energy consumption and battery degradation over the entire vehicle lifetime for various ambient temperatures, driving conditions, payload conditions, and cabin conditioning system states. Numerical models are implemented that can estimate the evolution over time of the state of charge, state of health, and temperature of HEV high-voltage battery packs. Obtained results suggest that the calibrated thermal and energy management strategy tends to reduce pure electric operation as the ambient temperature progressively increases beyond 30 °C. The consequent longer internal combustion engine operation entails a gradual increase in the overall vehicle energy demand. At a 36 °C ambient temperature, the HEV consumes 2.3 times more energy compared with the 15 °C reference value. Moreover, activating the cabin conditioning system seems beneficial for overall plug-in HEV energy consumption at high ambient temperatures. The presented methodology can contribute to easing and accelerating the development process for energy and thermal management systems of HEVs.

Health Cost Estimation of Traffic-Related Air Pollution and Assessing the Pollution Reduction Potential of Zero-Emission Vehicles in Toronto, Canada

Fossil fuel vehicles, emitting air toxics into the atmosphere, impose a heavy burden on the economy through additional health care expenses and ecological degradation. Air pollution is responsible for millions of deaths and chronic and acute health problems every year, such as asthma and chronic obstructive pulmonary disease. The fossil-fuel-based transportation system releases tons of toxic gases into the atmosphere putting human health at risk, especially in urban areas. This analysis aims to determine the economic burden of environmental and health impacts caused by Highway 401 traffic. Due to the high volume of vehicles driving on the Toronto Highway 401 corridor, there is an annual release of 3771 tonnes of carbon dioxide equivalent (CO2e). These emissions are mainly emitted onsite through the combustion of gasoline and diesel fuel. The integration of electric and hydrogen vehicles shows maximum reductions of 405–476 g CO2e per vehicle-kilometer. Besides these carbon dioxide emissions, there is also a large amount of hazardous air pollutants. To examine the impact of air pollution on human health, the mass and concentrations of criteria pollutants of PM2.5 and NOx emitted by passenger vehicles and commercial trucks on Highway 401 were determined using the MOVES2014b software. Then, an air dispersion model (AERMOD) was used to find the concentration of different pollutants at the receptor’s location. The increased risk of health issues was calculated using hazard ratios from literature. Finally, the health cost of air pollution from Highway 401 traffic was estimated to be CAD 416 million per year using the value of statistical life, which is significantly higher than the climate change costs of CAD 55 million per year due to air pollution.

Physics-Based and Data-Enhanced Model for Electric Drive Sizing during System Design of Electrified Powertrains

In multi-drive electrified powertrains, the control strategy strongly influences the component load collectives. Due to this interdependency, the component sizing becomes a difficult task. This paper comprehensively analyses different electric drive system sizing methods for multi-drive systems in the literature. Based on this analysis, a new data-enhanced sizing approach is proposed. While the characteristic is depicted with a physics-based polynomial model, a data-enhanced limiting function ensures the parameter variation stays within a physically feasible range. Its beneficial value is demonstrated by applying the new model to a powertrain system optimization. The new approach enables a detailed investigation of the correlations between the characteristic of electric drive systems and the overall vehicle energy consumption for varying topologies. The application results demonstrate the accuracy and benefit of the proposed model.

Comparative Study of Equivalent Circuit Models Performance in Four Common Lithium-Ion Batteries: LFP, NMC, LMO, NCA

Lithium-ion (Li-ion) batteries are an important component of energy storage systems used in various applications such as electric vehicles and portable electronics. There are many chemistries of Li-ion battery, but LFP, NMC, LMO, and NCA are four commonly used types. In order for the battery applications to operate safely and effectively, battery modeling is very important. The equivalent circuit model (ECM) is a battery model often used in the battery management system (BMS) to monitor and control Li-ion batteries. In this study, experiments were performed to investigate the performance of three different ECMs (1RC, 2RC, and 1RC with hysteresis) on four Li-ion battery chemistries (LFP, NMC, LMO, and NCA). The results indicated that all three models are usable for the four types of Li-ion chemistries, with low errors. It was also found that the ECMs tend to perform better in dynamic current profiles compared to non-dynamic ones. Overall, the best-performed model for LFP and NCA was the 1RC with hysteresis ECM, while the most suited model for NMC and LMO was the 1RC ECM. The results from this study showed that different ECMs would be suited for different Li-ion battery chemistries, which should be an important factor to be considered in real-world battery and BMS applications.

A Review of Heavy-Duty Vehicle Powertrain Technologies: Diesel Engine Vehicles, Battery Electric Vehicles, and Hydrogen Fuel Cell Electric Vehicles

Greenhouse gas emissions from the freight transportation sector are a significant contributor to climate change, pollution, and negative health impacts because of the common use of heavy-duty diesel vehicles (HDVs). Governments around the world are working to transition away from diesel HDVs and to electric HDVs, to reduce emissions. Battery electric HDVs and hydrogen fuel cell HDVs are two available alternatives to diesel engines. Each diesel engine HDV, battery-electric HDV, and hydrogen fuel cell HDV powertrain has its own advantages and disadvantages. This work provides a comprehensive review to examine the working mechanism, performance metrics, and recent developments of the aforementioned HDV powertrain technologies. A detailed comparison between the three powertrain technologies, highlighting the advantages and disadvantages of each, is also presented, along with future perspectives of the HDV sector. Overall, diesel engine in HDVs will remain an important technology in the short-term future due to the existing infrastructure and lower costs, despite their high emissions, while battery-electric HDV technology and hydrogen fuel cell HDV technology will be slowly developed to eliminate their barriers, including costs, infrastructure, and performance limitations, to penetrate the HDV market.