Component and system design of a mild hybrid 48 V powertrain for a light vehicle
Doctoral thesis, 2020
The first part comprises methodologies and extensive testing of lithium-ion battery cells in order to establish the electric and thermal performance using equivalent circuit models. Empirical, lumped-parameter models are used to ensure fast simulation execution using only linear circuit elements. Both electrochemical impedance spectroscopy and high-current pulse discharge testing is used to extract model parameters. Plenty of parameter results are published for various cells, temperatures and SOC levels. Further on, the model accuracy in voltage response is also evaluated. It is found that an R+2RC equivalent circuit offers the lowest error, 11 mV RMSE in a 1.5 h drive cycle, which is among the lowest numbers found in the literature for similar models.
In the second part, electric machines with tooth-coil windings are explored as a viable candidate for mild hybrids. First, a method of analytically calculating the high-level electro-magnetic properties for all possible combinations of three-phase, dual layer tooth-coil winding machines is established and presented in a graphically appealing manner. Then, a pair of pseudo-6-phase 50 kW PMSMs are designed, constructed and validated in a custom designed calorimetric dynamo test stand. These machines feature in-stator and in-slot forced oil cooling, enabling very high current densities of 25 A/mm² continuous and 35 A/mm² peak. A high net power density (19 kW/l) and a large area of high peak efficiency (95%) is shown numerically and validated by calorimetric measurements.
Finally, low-level design, construction and evaluation of 48 V inverter hardware is explored. By using high-performance, extra-low-voltage silicon-based MOSFETs with custom designed metal substrate printed circuit boards, custom made gate drivers, and water cooling, 3x220 A RMS is reached experimentally on a 154 cm² area and an efficiency of 95.6%.
MOSFET
48 V
Calorimetric measurement
Inverter
Li-ion battery
Permanent Magnet Synchronous Machine
Efficiency
Hybrid Electric Vehicle
Power Electronics
PWM
Multi-phase
Power density
Extra low voltage
Oil cooling
Author
Stefan Skoog
Chalmers, Electrical Engineering, Electric Power Engineering, Electrical Machines and Power Electronics
Parameterization of Equivalent Circuit Models for High Power Lithium-Ion Batteries in HEV Applications
18th European Conference on Power Electronics and Applications, EPE 2016 ECCE Europe, Karlsruhe, Germany, 5-9 September 2016,; (2016)
Paper in proceedings
Parameterization of linear equivalent circuit models over wide temperature and SOC spans for automotive lithium-ion cells using electrochemical impedance spectroscopy
Journal of Energy Storage,; Vol. 14(2017)p. 39-48
Journal article
Pole-Slot Selection Considerations for Double Layer Three-phase Tooth-Coil Wound Electrical Machines
2018 XIII International Conference on Electrical Machines (ICEM),; (2018)p. 934-940
Paper in proceedings
Experimental and model based evaluation of mile hybrid fuel consumption gains and electric machine utilization for personal vehicle application
2017 IEEE Transportation Electrification Conference and Expo, Asia-Pacific, ITEC Asia-Pacific 2017,; (2017)
Paper in proceedings
Electro-thermal modeling of high-performance lithium-ion energy storage systems including reversible entropy heat
Conference Proceedings - IEEE Applied Power Electronics Conference and Exposition - APEC,; (2017)p. 2369-2373
Paper in proceedings
Acquaviva, A. Stefan, S. Thiringer, T. Design and Verification of In-slot Oil-Cooled Tooth Coil Winding PM Machine for Traction Application
Acquaviva, A. Stefan, S. Grunditz, E. Thiringer, T. Electromagnetic and Calorimetric Validation of Direct Oil Cooled Tooth Coil Winding PM Machine for Traction Application
Acquaviva, A. Stefan, S. Thiringer, T. Manufacturing of in-slot cooled tooth coil winding PM machines
Utilize 48V system to gain CO2, safety & improved UX
VINNOVA, 2014-04-01 -- 2017-12-31.
Areas of Advance
Transport
Subject Categories
Aerospace Engineering
Other Materials Engineering
Other Electrical Engineering, Electronic Engineering, Information Engineering
ISBN
978-91-7905-323-9
Doktorsavhandlingar vid Chalmers tekniska högskola. Ny serie: 4790
Publisher
Chalmers University of Technology
Online - please e-mail PhdAdm.e2@chalmers.se in advance to get the password
Opponent: Thomas M. Jahns, University of Wisconsin-Madison