Energy Sources and Powertrain Electrification PDF

Energy Sources and Powertrain Electrification Course Introduction ©pManifold EV Academy 2 Course Introduction: Energy Sources and Powertrain Electrification Course Objectives ✓ Understand the various automotive powertrain layouts and architectures ✓ Analyze and evaluate...

Energy Sources and Powertrain Electrification Course Introduction ©pManifold EV Academy 2 Course Introduction: Energy Sources and Powertrain Electrification Course Objectives ✓ Understand the various automotive powertrain layouts and architectures ✓ Analyze and evaluate various automotive powertrain architectures against vehicle propulsion requirements ✓ Analyze and evaluate various energy sources and on-board energy storage along with their conversion devices ✓ Analyze the tank to wheel efficiency for various powertrain architectures and on-board energy storage mix Week 1 Week 2 Week 3 Week 4 Basics and Evolution of ICE Powertrains ICE Vs xElectric drive CNG & LNG - properties & infrastructure Sources of electricity in fixed generation ICE basic calculations On-board Energy Storage Devices Biofuels - properties & infrastructure Renewable electricity sources Hydrogen (PEM) Fuel Cells Hydrogen - properties & infrastructure Electrification of Automotive Powertrains Solar PV efficiency required for on-board Fuel Cell basic sizing calculations Comparing fuels for Well-to-tank Electrification Basics and Impact calc sheet Transmission & Distribution Fossil Fuels - properties & infrastructure Electricity on-board vehicle BEV energy consumption calc. sheet Hydrogen consumption calculations Tailpipe emission estimation tool Lifecycle Energy Analysis Energy consumption assessment of xEVs Calculating Tank-to-Wheel efficiency Grid emission facttor estimation tool Hybrid Energy Solutions Text/References: 1. M. Ehsani, Y. Gao and A. Emadi, “Modern Electric, Hybrid Electric and Fuel cell vehicles: Fundamentals, theory and design,” 2nd edition, CRC Press, Taylor and Francis, 2010. 2. Energy Studies (3rd Edition) by William Shepherd (Author), David William Shepherd, 2014. 3. Special issue, “State of Art Electric Vehicle Technologies,” Proceedings of IEEE, vol. 95, no. 4, Sept 2007. ©pManifold EV Academy 3  Course Faculties Vikrant Vaidya Bhushan Bissa Dr. Makarand Lokhande Co-founder & President, evACAD Trainer, evACAD Associate Professor, VNIT Nagpur Educational Qualifications Educational Qualifications Educational Qualifications Bachelor of Engineering (Mechanical) from Nagpur Bachelor of Engineering (Mechanical) from Nagpur Bachelor of Engineering (Electrical) from Nagpur University University 2001 University 2008 2001 Master of Engineering (Energy Systems Engineering) Master of Technology (Automotive Engineering) from Master of Engineering (Power System) from University of from University of Michigan Ann Arbor 2014 Vellore Institute of Technology 2010 Pune 2003 PhD in Energy Science and Engineering from IIT Bombay, Overall experience 22+ years 2010 Overall experience 13+ years pManifold EV Academy: 3+ Years Overall experience 14+ years pManifold Business Solutions: 3+ Years GuruNanak Institute of Engineering and Technology 1+ Years Pandit Deendayal Petroleum University Gandhinagar: 4+ Tata Consultancy Services (Jaguar-Land Rover & Shri Ramdeobaba College of Engineering and Years Citroen) – 5+ Years Management: 12 Years Sardar Vallabhbhai National Institute of Technology, Surat: 2 General Motors Powertrain – 10.5 Years Years Tata Motors – 3+ Years Visvesvaraya National Institute of Technology Nagpur: 8+ Other Certifications Other Certifications Years Six Sigma Green Belt – Product Engineering from Member SAE INDIA Other Certifications General Motors Life member of ISTE Senior IEEE Member 3 inventions (defensive publications) in hybrid 2 IPR, 3 Design Patent Life member of ISTE powertrain, battery controls & repurposing 1 Invention (Indian patent) for a unique design of solar cooker ©pManifold EV Academy 4 Tentative Course Delivery Mode Mon Tue Wed Thu Fri Sat Live Live Self Live Self Live Online Online Paced Online Paced Online Activity ©pManifold EV Academy 5 Course Pre-requisites – MS Excel or Similar Spreadsheet Calculator Formula Bar Fixed Inputs Initial Conditions Operating Conditions Calculations Activity-based learning and assignments will involve extensive use of MS Excel. MS Excel proficiency is a must in automotive product development! ©pManifold EV Academy 6 Discipline, Tips, Tricks & Hacks ⮚ Attend all live sessions as recordings are only for emergencies ⮚ Engage with the trainers answering questions in the live sessions and asking a few of your own ⮚ Take own notes to document trainer experiences which cannot be shared formally ⮚ Actively participate in activities on a proper computer instead of tab / mobile ⮚ Tutorial videos can be run on computer using dual screen, or on mobile while working on computer ⮚ Keep up with daily tasks, otherwise catching up can be challenging ⮚ Activities, quizzes, assignments, and mini projects have weightage in final score of the courses ⮚ Sequence of sessions, self-paced videos and activities can be critical – don’t mix it up ©pManifold EV Academy 7 Basics and Evolution of ICE Powertrains ©pManifold EV Academy 8 Basics of Internal Combustion Engine (ICE) 2 Stroke 1 – Scavenging & Compression Stroke 2 – Combustion & Exhaust Stroke 1 2 Diagram of a cylinder as found in an 4 Stroke overhead cam 4-stroke gasoline engine: C – crankshaft E – exhaust camshaft 1 – Intake Stroke I – inlet camshaft P – piston 2 – Compression Stroke R – connecting rod S – spark plug 3 – Combustion/Power Stroke V – valves. red: exhaust, blue: intake. W – cooling water jacket 4 – Exhaust Stroke Gray structure – engine block 1 2 3 4 ©pManifold EV Academy 9 Petrol (Spark Ignition – SI) v/s Diesel (Compression Ignition – CI) Spark Compression Ignition Ignition Low Less noise High More noise & efficiency & vibration efficiency vibration Petrol Diesel CR Light & CR Heavy & 6 to 12 Cheap 14 to 22 Costly The compression ratio (CR) is the ratio between the volume of the cylinder with the piston in the bottom position and in the top position. The higher this ratio, the greater will be the power output from a given engine. ©pManifold EV Academy 10 IC Engine Typical Applications High Speed Medium Speed Slow Speed Small 4-Stroke 4-Stroke 2-Stroke diesel 2-Stroke SI & CI for light Marine Marine Motorcycles vehicles Stationary Largest Stationary Outboards CI for heavy duty & Champions of Snow-blowers machinery efficiency (~60%) Source: https://gokartnerds.com/2-stroke-vs-4-stroke-engines/ ©pManifold EV Academy 11 IC Engine Based Powertrains Driveshaft Transmission Transmits power to next Provides various speed / torque ratios component of powertrain Engine Produces power Differential Allows power transfer with difference in wheel speeds Launch Device while cornering (Clutch / Torque Converter) Allows slippage during vehicle launch Powertrain Layouts Advantages Typical Applications Details Front Engine – Rear Wheel Drive Better traction & weight Utility & Commercial vehicles distribution Rear Engine – Rear Wheel Drive Performance Cars All Wheel Drive Off-road Vehicles Front Engine – Front Wheel Drive Compact & light Passenger cars ©pManifold EV Academy 12 Evolution of IC Engine Otto Engine, 1867 47L, CR = 4.8 3 HP, Brake Thermal Efficiency = 14% Emissions = many gm/miles (unknown) Source - https://en.wikipedia.org/wiki/Otto_engine Modern SI Engine, 2018 BMW B58 3.0-Liter Turbocharged Inline-Six, CR = 11 Power = 382 HP @ 5,800 – 6,500 rpm Torque = 500 N-m @ 1,800 – 5,000 rpm Emission – NOx ( 2.5 L 4. Turbochargers 5. DOC + DPF – 700 to 800 bar 4. Cooled EGR with Intercooler 6. LNT on engines 3. EGR Operation 5. DOC for PM with displacement reduction (Volatile volume > 2.0 L Fraction) Road Vehicle Technologies and Fuels (RSC Publishing) DOI:10.1039/9781788010221-00001 ©pManifold EV Academy 15