PROJECT REPORT ON

“Development of hybrid electric vehicle powertrain test system

based on virtue instrument
Submitted in the partial fulfilment of the requirements for the award of degree of

BACHELOR OF TECHNOLOGY
IN
ELECTRICAL AND ELECTRONICS ENGINEERING
By

A.HEMANTH SAI KUMAR (183J1A0201)

R.ANIL(183J1A0202)
S.KARTHIK(183J1A0217)
D.HARIKA(193J1A0208)
MANIKANTA NAIDU(193J5A0208)

UNDER THE GUIDANCE OF

MR. SHIVA SIR
Associate Professor

Department of Electrical and Electronics Engineering

Raghu Institute of Technology

(Approved by AICTE, Affiliated to JNTUK , KAKINADA ) Dakamarri ,

Visakhapatnam-531162.
 RAGHU INSTITUTE OF TECHNOLOGY
DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

CERTIFICATE
This is to certify that this is a bonafied record of the seminar on “Development of hybrid

electric vehicle powertrain test system based on virtue instrument carried out by BATCH

2 Of Third year B. TECH during the year 20202021 in partial fulfilment of the requirement for the award

of the degree in Bachelor of Technology in Electrical and Electronics Engineering.

Project guide Head of Department

 ACKNOWLEDGEMENT

We are very much grateful to our seminar guide Mr.SHIVA sir,

Associate Professor, Department of Electrical and Communication Engineering

for assigning us a Multi-Disciplinary Real Time project and for his guidance. He

has been the continuous source of inspiration for us throughout the work. We

would extend our thanks for his constructive criticism without which the project

would not have taken shape.

We are also thankful to Mr G. JOGA RAO Sir, Associate Professor and Head
of

the EEE-Department for supporting in accomplishment of project work.

We are extremely thankful to Sri Raghu Garu, Chairman of Raghu Educational

Institutions for encouragement and support.

We are thankful to “Prof. S. SATYA NARAYANA Garu” Principal of Raghu

Engineering College for supporting us in all technical dimensions.

We are also thankful to our parents for their everlasting support and

encouragement in all walks of our lives.

 ABSTRACT

Hybrid powertrain has become the standard configuration of some

automobile
models. The test system of hybrid vehicle powertrain was developed
based on
virtual instrument, using electric dynamometer to simulate the work of
engines, to test the motor and control unit of the powertrain. The test
conditions include starting, acceleration, and deceleration. The results
show that the test system can simulate the working conditions of the
hybrid electric vehicle powertrain under various
conditions. `Gasoline-Electric Hybrid Engine Vehicle' is a vehicle
which works on electrical poweras well as fuel like petrol. It has many
benefits over its predecessors, which developed power using only fuel.
The thought is to design and construct a Hybrid Electric Vehicle
(HEV) powered by battery as well as petrol. The vehicle is made
dynamic in nature by making use of electrical power from battery and
fuel power. It consumes less fuel and creates comparatively less
pollution as compared to conventional vehicles. Hybrid electric
vehicles consists of a battery, to drive the electric motor and power
system with an IC engine to increase fuel economy reduce harmful
emissions from the exhaust. Also there is a provision for recharging
the battery using a generator which is run using a turbine, which runs
on the exhaust of the IC engine. In HEV, the battery single handedly
provides power for driving at low speeds where the efficiency of IC
engine is least. In cruising and high load conditions like moving up
the hill, the electric power assists the engine by providing additional
power. Thus the HEV is the best alternative in areas with high traffic
like urban metropolitan cities.
CONTENTS:

1.INTRODUCTION
2.SYSTEM HARDWARE DESIGN
3.SYSTEM SOFTWARE DESIGN

4.WORKING
5. ADVANTAGES
7.DISADVANTAGES
8.CONCLUSION
9.REFERENCES
INTRODUCTION
Hybrid electric vehicles, which combine the advantages of traditional
fuel vehicles and electric vehicles, can meet the requirements of low
emission, low fuel consumption and low cost, and so on [1]. Based on
the degree of mixing, hybrid electric vehicles can be divided into three
categories such as weak mixing (Micro Hybrid), light mixing (Mild
Hybrid) and the whole mixture (Full Hybrid) [2]. In consideration of
low investment and relatively high economy and power, hybrid vehicles
have obvious advantages comparing to the traditional internal
combustion engine vehicles. The key assemblies of hybrid vehicle
powertrain consist of power supply module, motor and motor
controller, engine and engine control unit. The verification test of key
assemblies’ performance and function is conducive to enhance the
design goal of hybrid vehicles. The team of author developed a hybrid
powertrain test system which can verify the function of integrated
starter-generator (ISG), power supply module, motor and motor
controller, engine and engine control unit based on virtual instrument.
A hybrid vehicle combines any two power (energy) sources. Possible
combinations include diesel/electric, gasoline/fly wheel, and fuel cell
(FC)/battery. Typically, one energy source is storage, and the other is
conversion of a fuel to energy. The combination of two power sources
may support two separate propulsion systems. Thus to be a True hybrid,
the vehicle must have at least two modes of propulsion.

For example, a truck that uses a diesel to drive a generator, which in

turn drives several electrical motors for all-wheel drive, is not a hybrid .
But if the truck has electrical energy storage to provide a second mode,
which is electrical assists, then it is a hybrid Vehicle.

These two power sources may be paired in series, meaning that the gas
engine charges the batteries of an electric motor that powers the car, or
in parallel, with both mechanisms driving the car directly.

SYSTEM HARDWARE DESIGN

The test system is composed of ISG motor module, dynamometer

module, power supply module, auxiliary electric system load
simulation module and host computer module, as shown in figure 1.
The ISG motor module contains ISG motor and motor controller. The
dynamometer module includes power dynamometer, converter /
inverter, measuring and controlling instrument, the speed and torque
sensor. The power supply module includes a power battery, battery
management system, programmable power source. The electric
system load simulation module includes DC/DC converter, electric
air conditioning compressor and other affiliated electrical system.
The host PC module includes data acquisition card, data processing
unit, display output unit. BSG motor module, International
Symposium on Resource
The dynamometer module adopts the AC electric dynamometer which
has the characteristics of low inertia moment, good regeneration
performance, high precision to control and fast response [3]. The
dynamometer can be used as the load of the engine to test the
performance of the engine, or used as load of the ISG motor to test the
performance of the motor. The dynamometer can work in driving
mode, taking electric energy from the power grid by the converter, or
work in load mode, generating electric energy and feeding to the
power grid by the inverter. The control of different working modes is
realized by the measuring and controlling instrument. Speed and
torque sensor was installed on the output shaft of dynamometer for
real-time monitoring. The ISG motor or engine is connected with the
dynamometer as the object to be measured. Power supply module is
used to supply power for test system. The power battery is connected
with the programmable power source through the common DC bus;
the controller of programmable power source is used to control the
output voltage and the current of the programmable power source,
simulating all kinds of power battery with different specifications.
During the test, the programmable power source and the power battery
can be used as the power supply of the test system respectively.
Programmable power source is integrated with programmable electric
load, which consists of discharge modules. The host computer module
obtains the working state, voltage and current of the programmable
power source. The host computer obtains the working state of the
power battery through the battery management system, and sets the
terminate condition of charging and discharging, the limit conditions
of voltage, current and temperature of the battery.

SYSTEM SOFTWARE DESIGN:-

Virtual instrument technology is a program development environment, it
can give full play to the computer's ability to create a stronger function of
the instrument, and users can define and develop a variety of instruments
according to their own needs [4]. The test system software of hybrid vehicle
powertrain was developed based on virtual instrument, using electric
dynamometer to simulate the work of engines, to test the motor and control
unit of the powertrain. The test conditions include starting, acceleration, and
deceleration. Take ISG motor starting engine condition as an example, the
test flow chart and human-computer interaction interface design as follows.

Test flow chart design :

 The test flow chart of starting condition design is shown in Figure 2. The
initialization parameters can be set in the host computer, and transmit to the
controller of programmable power source, measuring and controlling
instrument, the battery management system by CAN bus. Simulate torque
of the engine using dynamometer; electrify the motor to drive
dynamometer. The host computer sends out the control command to
measuring and controlling instrument to control the dynamometer
according to the feedback of test results and data processing to adjust the
power dynamometer through the inverter. If the measured resistance torque
is consistent with the set resistance torque, sent the speed feedback to host
computer, then the engine is start successfully.

✓ Human-computer interaction:
interface design Human-computer interaction interface of
the system was developed based on virtual instrument, which adopted
the form of the tab to realize the intuitive and friendly man-machine
interactive function. It contains the user login interface, the initial setup
interface, the main control program interface, etc.. The initial setup
interface, as shown in figure 3, can be used to set and adjust the test
parameters of the test system. The set of objects mainly include engine
parameters, starting and stopping motor parameters, communication
system parameters, cycle test times, power supply parameters, report
output path, etc.

The main control program interface of the test system is mainly

composed of the working status indicator, the running parameter output
display area and the system control command input area, as shown in
figure 4.

WORKING:
Hybrid electric vehicles (HEVs) combine the benefits of gasoline
engines and electric motors. They can be designed to meet different
goals, such as better fuel economy or more power.
Most hybrids use several advanced technologies:
Regenerate braking
A hybrid electric vehicle cannot be plugged in for the battery to
charge. The battery is charged with the help of regenerative braking
and by the internal combustion engine. It helps to transform kinetic
energy produced by the moving car into electrical energy stored back
into the batteries.

The electric motor powers the vehicle as well as resists its motion.
When you apply brakes to slow down, this resistance slows down the
wheel and simultaneously recharges the batteries.

Dual power
Depending on driving circumstances, power can come from either the
engine, motor or both. The electric motor is in use at low speeds.
When you pick up the speed, your combustion engine kicks in.
Afterward, the electric battery recharges itself using the combustion
engine. The electric motor also provides additional power to assist the
engine in accelerating or climbing.

Automatic start/shutoff

When the vehicle comes to a stop, it automatically shuts off the engine
and restarts it when the accelerator is pressed down. This automation
is much simpler with an electric motor. The additional power provided
by the electric motor can potentially allow for a smaller engine. The
battery not only power auxiliary loads, but it also reduces engine
idling when it stops. These features altogether result in better fuel
economy without hampering performance.

ADVANTAGES

1. Environmentally Friendly

One of the biggest advantages of a hybrid car over a gasoline-powered car is

that it runs cleaner and has better gas mileage, which makes it environmentally
friendly. A hybrid vehicle runs on twin powered engine (gasoline engine and
electric motor) that cuts fuel consumption and conserves energy.
2. Financial Benefits

Hybrid cars are supported by many credits and incentives that help to make
them affordable. Lower annual tax bills and exemption from congestion
charges come in the form of less amount of money spent on the fuel.

3. Less Dependence on Fossil Fuels

A Hybrid car is much cleaner and requires less fuel to run, which means fewer
emissions and less dependence on fossil fuels. This, in turn, also helps to
reduce the price of gasoline in the domestic market.

4. Regenerative Braking System

Each time you apply the brake while driving a hybrid vehicle, it helps you to
recharge your battery a little. An internal mechanism kicks in that captures the
energy released and uses it to charge the battery, which in turn eliminates the
amount of time and need for stopping to recharge the battery periodically.

5. Built From Light Materials

Hybrid vehicles are made up of lighter materials, which means less energy is
required to run. The engine is also smaller and lighter, which also saves much
energy.

6. Assistance From Electric Motor

The electric motor assists the internal combustion engine in case of

accelerating, passing or climbing a hill.

7. Smaller Engines

The gasoline engines used in hybrid cars are usually small, light, and highly
efficient as they don’t have to power the car alone

8. Automatic Start and Stop

In hybrid cars, the engine is automatically shut off when the vehicle is idle and
starts when the accelerator is pressed. In comparison to traditional hybrid
vehicles, PHEVs can drive longer distances at higher speeds. Hydrogen fuel
cell vehicles have lower energy emissions because they emit only water vapor
and warm air.

9. Electric-Only Drive

Hybrid vehicles can be driven entirely with electricity. This usually happens
while moving at low speeds, when the engine is idling at a stoplight or when
the engine starts up. Normally, the internal combustion engine starts operating
only at higher speeds, where it has more efficiency. This helps increase the
overall fuel efficiency of the vehicle.

10. Higher Resale Value

With a continuous increase in the price of gasoline, more and more people are
turning towards hybrid cars. The result is that these green vehicles have started
commanding higher than average resale values. So, in case you are not satisfied
with your vehicle, you can always sell it at a premium price to buyers looking
for it.

DISADVANTAGES

1. Less Power
Hybrid cars are twin powered engine. The gasoline engine, which is
the primary source of power, is much smaller as compared to what
you get in single-engine powered cars while the electric motor is of
low power. The combined power of both is often less than that of a
gas-powered engine. It is therefore suited for city driving and not for
speed and acceleration.

2. Can be Expensive
The biggest drawback of having a hybrid car is that it can burn a hole
in your pocket. Hybrid cars are comparatively expensive than a
regular petrol car and can cost $5000 to $10000 more than a standard
version. However, that extra amount can be offset with lower running
costs and tax exemptions.

3. Poorer Handling
A hybrid car houses a gasoline-powered engine, a lighter electric
engine and a pack of powerful batteries. This adds weight and eats up
the extra space in the car. Extra weight results in fuel inefficiency and
manufacturers cut down weight, which has resulted in motor and
battery downsizing and less support in the suspension and body.

4. Higher Maintenance Costs

The presence of a dual engine and continuous improvement in
technology make it difficult for mechanics to repair the car and
maintenance cost is also much higher. It is also difficult to find a
mechanic with such expertise.

5. Accident from High Voltage in Batteries

In case of an accident, the high voltage present inside the batteries can
prove lethal for you. There is a high chance of you getting
electrocuted in such cases, which can also make the task difficult for
rescuers to get other passengers and driver out of the car.

6. Battery Replacement is Pricey

According to Green Car Reports, battery replacement of hybrid
vehicles is currently rare. However, if a battery needs to be replaced, it
can get pricey.
7. Battery Disposal and Recycling
The batteries that are at the end of their useful life cycle can be
recycled to harvest usable materials for repurposing. This removes
waste from the environment. But, the main issue with recycling lies in
the collection rate of vehicle batteries.

The same problem lies in recycling lithium batteries in mobile

electronics. Although lithium is 100% recyclable, extracting it costs
too much to make it of high economic value. It is only done because
of federal mandates and/or ecological purposes.

8. Hydrogen Fuel Cell Issues

The source of hydrogen can be both “clean” sources such as solar or
wind power or dirty sources like coal and natural gas. Sourcing from
coal and natural gas undermines the ecological motive for the use of
hydrogen fuel cell vehicles.

Production of hydrogen is also expensive, and the fuel cells require to

be refueled at a hydrogen station. At present, these stations are only
located in California and near Toronto.

Applications :

• Consumer Electronics.
• Public Transportation.
• Aviation.
• Electricity Grid.
• Renewable Energy Storage.
• Military.
• Spaceflight.
• Wearable Technology.
CONCLUSION
Hybrid powertrain as the key to improve the automobile's economy,
it is necessary to carry out the relevant operation test. After repeated
testing and debugging, the developed system has been able to run
stably, and achieve the design goal of hybrid powertrain test. Login
the test system to verify the system. First set the relevant parameters
in the initial settings tab. The result of working condition test of 5
cycles is shown in Figure 5. Figure 5. The test result of 5 cycles
working condition. The test system developed in this paper realizes
the test function of hybrid powertrain, which can not only test
according to the specified conditions, but also be used in cycle
testing.

The test system developed in this paper realizes the test function of
hybrid powertrain, which can not only test according to the specified
conditions, but also be used in cycle testing.

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REFERENCES:

[1] Wang Liping, Li Shoucheng, Wu Haixiao, Yue Hongchao.

Study on Start/Stop Control of ISG Hybrid Vehicle, J.
Agricultural Equipment & Vehicle Engineering. 9(2011) 38-41.
(in Chinese)
[2] Eckhard Karden, Daniel Kok, etc.. Energy Management
and Storage Technologies in MicroHybrid Vehicles, J.
AutoTechnology.5(2005) 56-59.
[3] Tian Ying,Jin Zhenhua,etc..A Study on the Control System
of AC Dynamometer, J. Automotive Engineering. 36(2014)
125-128. (in Chinese)
[4] Liang Zhao-hua, Li Zhi.Development of field dynamic
balance testing system based on LabVIEW.Modern Electronic
Technique, 6 (2014) 110-113. (in Chinese).

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