GOVERNMENT POLYTECHNIC AMBAD

DEPARTMENT OF MECHANICAL ENGINEERING

AUTOMOBILE ENGINEERING - 22656

A MICRO PROJECT REPORT ON

Prepare report of electrical and hybrid vehicle

FOR THE AWARD OF

DIPLOMA IN MECHNICAL ENGINEERING

(Mechanical Engineering Third year Semester VI)

UNDER THE GUIDANCE OF

Prof. A.B.DESHPANDE SIR

SUBMITTED BY

Sr .No Roll .No Student Name Sign

1. 28 RUTIK VISHNU MULE

1
 CERTIFICATE
GOVERNMENT POLYTECHNIC AMBAD

DEPARTMENT of MECHANICAL ENGINEERING

(“Prepare report of electrical and hybrid vehicle”)

This is to certify that the micro-project entitled “Prepare report of electrical and
hybrid vehicle ” being submitted here with for the award of the Diploma in Mechanical
Engineering of Government Polytechnic, Ambad, Maharashtra State Board of Technical
education (MSBTE) sixth semester 2022-2023 is the result of micro-project work completed
by Mr. ………….To the best of my knowledge and belief, the work embodied in this Micro
Project has not formed earlier the basis for the award of any degree or diploma of this or any
other Board or examining body.

Place: Ambad Prof. A.B.DESHPANDE SIR

Date : Micro-project Guide
 DECLARATION

We, the undersigned, hereby declare that the project “Prepare report of electrical and
hybrid vehicle” is written and submitted by us to Government Polytechnic Ambad during Year
2022-23, Sixth Semester for partial fulfillment of the ‘Micro Project’ requirement of
AUTOMOBILE ENGINEERING subject under Maharashtra State Board of technical
Education, Mumbai curriculum, under the guidance of Prof:- A.B.DESHPANDE SIR is our
original work. The empirical finding in this project are based the data collected and are not
copied from any other sources.

Sr. No Roll .No Student Name Sign

1. 28 Rutik Vishnu mule

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I have great pleasure to express my immense gratitude towards a dynamic person and my
project guide Prof. A.B.DESHPANDE SIR Lecturer in MECHANICAL Engineering,
Government Polytechnic, Ambad for giving me an opportunity to work on an interesting topic
over one semester. The work presented here could not have been accomplished without her
most competent and inspiring guidance, incessant encouragement, constructive criticism and
constant motivation during all phases of our group Micro- project work. I am greatly indebted
to her.

I am very much thankful to Prof. P.T.KALE Head, Department of

MECHANICAL Engineering, all HODs of various departments and Prof. Dr. A.M.

JINTURKAR, Principal, Government Polytechnic, Ambad, for his encouragement and

providing me a motivating environment and project facilities in the Institute to carry out
experiments and complete this Micro-project work.

I would like to extend our thanks to all our professors, staff members and all our
friends who extended their co-operation to complete the project.

I am indeed indebted to my parents and other family members for their immense help
at all levels with moral, social & financial support, care and support throughout my studies
without which my work would not have seen light of the day.With warm regards,

Place: Ambad Yours Sincerely,

……………………………….

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 Report of electrical and hybrid vehicle

Introduction

In response to the environmental issues, an increasing demand of more efficient, sustainable and
less polluting vehicles, has been evident in the recent years.

Limited supply of fossil fuels and their destructive impacts on the environment has led us to
search for an alternative transportation propulsion system, which emits less pollutants and
consumes less fossil fuel.

The most popular solution appears to be electric hybrid vehicle. By definition, an electric vehicle
does not merely rely on an internal combustion engine as the propulsion system, moreover it
uses an electric drive system as a replacement or improves the ICE performance.

Electric Hybrid vehicle is one of the existing hybrid vehicles in the world which profits from
electrical machines and electrical storages beside the internal combustion engine. The other
hybrid vehicles can include a compressed air energy or flywheels in automotive powertrains.

In this article the fundamental concept, types, pros and cons of electric hybrid vehicles will be
discussed.

Types of power source

In general, 3 types of electric vehicles (EV), in terms of the power source can be distinguished as
below.

Full electric vehicle (FEV) is propelled solely by electric drive system. It benefits from a large
battery which can be recharged in charging stations or at home.Since these vehicles produce no
pollutants, they are suitable for population areas, like big cities, regarding that the whole emission
for electricity generation occurs inthe countries, out of population dense. Therefore, the FEVs are
not zero-emission vehicles, despite of what the manufacturers’ marketing claims.

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Hybrid electric vehicle (HEV) combines an ICE and electric motors within thedrivetrain. In
brief, the electric motor and the electric storage, contribute to higher fuel efficiency and better
performance of the engine. The vehicle can be driven by one of these or both at the same time.

Plug-in hybrid electric vehicle (PHEV) is equipped with a lager battery thanHVEs, which
allows the vehicle to be charged by charging stations.

In most cases the cars can be propelled by either a combustion engine or an electricmotor.
However, there are some vehicles in which the ICE is only used for chargingthe batteries. (fig1.1
free book)

Despite all the recent tremendous developments of hybrid and electric vehicles, stillthey have not
gain deserved popularity at a global scale. Some of the reasons are asfollows.

Limitations

Despite the enormous advantages of hybrid electric vehicles, there are many problems to be
tackled. In the following chapters, some limitations will be outlined.

Price: The major reason why EVs are much more expensive than the conventional vehicles is the
cost of batteries. Most EVs utilize lithium-ion batteries, which have high power to weight rate,
high energy efficiency, hightemperature performance and low self-discharge. Most
components of lithium-ion batteries can be recycled, but the cost of material recovery has
remained a challenge for industries. Research and development are going to reduce their
relative cost and some safety concerns regarding to overheating,in the few subsequent years.
Vehicle size: EVs are usually small to reduce energy consumption and to accommodate
batteries. So, this would be a challenge for some users who would like to transport heavy loads
using their vehicles.
Charging duration: Charging time for plug-in EVs are usually long. However,there are some
average fast charged vehicles for which charging time is about

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30 minutes that can be acceptable. Given that there are queues in charging stations, charging
time may take several hours.
Thus, fast charging and infrastructures in all points of the cities, will be a feasible solution to this
issue.
Limited range: in flat roads, the favorable range of distance driven by an EV could be 300 km and
this could be even lower when heating or air- conditioning is switched on.
The speed of EVs in an electric mode is limited, as well. Most manufacturerslimit the top speed
of EVs to preserve battery health.
Electromagnetic emissions: while there is no concrete evidence showing electromagnetic
radiation from EVs is dangerous, this issue has concerned manufacturers and authorities. It is still
under more investigation by many researchers.

Working principle of hybrid vehicles

Since there are two energy sources in HEVs, they can be combined in severalways and these
working phases can be found.

Fully electric mode: Batteries in this mode feed the electric motor through thepower electronics
(inverter) which controls the electric current and turn directcurrent into an alternative current. The
motor is completely detached from theICE when it is electrically driven.

The power produced by motor is finally transmitted by a transmission systemto the wheels. The
latter mechanism is quite similar to that of the conventionalcars, except that the transmission ratio
remains constant. This is rooted in the fact that electric cars do not require multi-speed
transmission, because the electric motor produces a consistent amount of torque at any given RPM
whilethe internal combustion engine requires multiple gears with definite ratios forpower output.
It is noteworthy that ICEs only generate efficient power at certain RPM ranges. However, EV
manufacturers calculate gear ratios to maximize effectively for the electric motor without having
to switch throughgears

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This is regarded as a limitation of ICEs, in which the rotational velocity is maximumly 6000-7000
RPM, while an electric motor can produce a consistent torque across beyond 10000 RPM with
ease. (Consequently, we only add complexity, inefficiency, weight and extra production costs in
ICE vehicles.)

Hybrid/electric assist: in the case of a closed clutch, the power is transmittedto the motor by both
ICE and batteries. This is often possible by planetary gears in parallel-series hybrid systems.

Battery charging: the ICE can drive a car by itself as well as charge the batteries, using the power
electronics and motors, in a reversed way (workingas a generator) while the car is coasting.

Regenerative braking: To enhance the fuel efficiency, one way is to recoverthe energy dissipated
while braking. The kinetic energy that was initially usedto propel the vehicle, makes the wheels
rotate the electric motors, turning intoa type of generator. This energy is stored in the batteries.

The regenerative braking system is usually accompanied by a hydraulic braking system. When
the car is traveling at high speed or the battery is fullycharged, too hot or too cold, the electric
motor cannot provide sufficient braking torque to stop the car. Thus, it will need the support of
the hydraulic braking system.

Architectures:

The main HEV powertrain configurations are parallel and series and theircombination and branches
which are to be discussed in this section.

Parallel hybrid powertrain: In this type of HVEs, both ICE and electricmotor can transmit
power to the wheels.

Parallel hybrid powertrain with two clutches: In a rear-wheel-drive vehicle,the structure of

hybridization is shown in figure1.

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 Figure 1.

There are two clutches, before and after the electric machine. The first one, between the engine
and motor, can connect or disconnect the powertrain of ICE. While it is open, the vehicle runs
with pure EV mode.

In addition, during the deceleration, in order to have the maximum recuperation of kinetic
energy, the ICE is disconnected from the motor to remove its braking effect.

The second clutch is used to disconnect the motor from the transmission and wheels. As a matter
of fact, this clutch is a component of the transmission, thus it is obviously open while the car is
coasting or decelerating.

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 Table 1. The states the clutches in a parallel HEV with two clutches

Parallel hybrid powertrain with double- clutch transmission: this type of mechanism is mostly
used in the vehicles with front engine front wheel due to lack of space. The architecture is shown
in fig2.

Figure 2

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In this case, the electric motor is a subdivision of the transmission. The torquetransmitted to the
wheels can directly come from the ICE or with assist of themotor thanks to the double-clutch
system. The torques are summed up at the shaft driving the transmission.

The states of the clutches during the phase of powertrain are shown in the table 2.

Table 2 The states of clutches in double clutch transmission

Axle-split parallel hybrid powertrain: In this type of HEVs, the ICE drives anaxle (usually front axle)
and second axle is driven by the electric machine. It must be pointed out again that the former
mechanism is done with contributionof a multi-speed gearbox, although the latter needs only
fixed ratio gears.

The iconic advantage of this structure is that the vehicle has all-wheel drive mode as long as the
battery has enough charge. The drawback differentiatingthis type is the lack of possibility of
charging the battery while the car is in stationary. To overcome this issue, another electric
machine can be permanently connected with the ICE, generating the power and store it in
batteries while the vehicle is at rest.

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Series hybrid powertrain: Obviously the powertrain path is comprised of thecomponents in a
series way. (Fig3)

Figure 3

In other words, the ICE is no longer able to drive the wheels independently and directly, but it is
connected to an electric motor which in turn can transmitthe torque needed for the propulsion.

Series hybrid vehicles: This kind of vehicles benefit from electric machines.

An electric generator connected to the engine.

An electric motor connected to a single ratio gearbox which in turn runs thewheels through
the differential.

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The most significant characteristic of series hybridization is that there is no need for a gearbox,
apart from the fact that ICE can operate almost in the mostefficient area of torque-speed map.
Also, there is no clutch between the motor and the wheels, therefor the vehicleis impossible to
coast, since the drive wheels are always connected to the electric motor.
Another deficiency of series hybrid is double energy conversion. In the case of running the motor
by the ICE, the mechanical energy is converted to the electrical energy, and then again it is turned
into the mechanical motion. Thisdefinitely reduces the overall efficiency of engine powertrain.
Series-parallel hybrid vehicle: It can transform to a series parallel one by adding a shaft and clutch
between two electric machines. Hence, the powertrain can behave as a series hybrid when the
clutch is open and acts likea parallel hybrid when the clutch is closed. The strength of series mode,
is that the engine can operate with high efficiency in low speeds.
Besides, in high speeds the engine transmits power to the wheels directly in parallel mode, and
it takes advantage of the motor assist, when the vehicle needs more power to accelerate or in
the rising slopes.

Figure 4

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This type is the combination of characteristics of both series and parallel hybrid. The advantage
is that the energy produced by the ICE is partly converted to the electric energy to actuate the
electric motor and charge the battery. The excessive energy, drives wheels mechanically.

This type has a better function in all driving states except coasting because a mechanical
connection exists between the drive wheels and the electrical motor.

The features, pros and cons of all the types above are summarized in the table3.
Table 3-1

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 Table 3-2

The most significant point encouraging manufacturers to produce and developHEVs is that it can
be constructed in smaller size and lower cost. This fact stems from sharing the workload of ICE
with the electric motor. Downsizingcan lead to weight reduction, which in turn contributes to
greater fuel economy.
Moreover, HEV engines are optimized to operate in a better efficiency and reduce most of the
pollutant emissions.
This is the superiority of HEV vehicles in comparison with conventional ICEvehicles to eliminate
the high emissions and poor fuel efficiency.

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 HEVs components and construction

Firstly, all hybrid electric vehicles require a hybrid power unit (HPU), which are employed to
produce the main power of the whole hybrid powertrain. Combustion engines are the most
common HPUs, such as compression ignition/direct injection engines, spark ignition/direct
injection engines, the Stirling engine and gas turbine engines.
Secondly, two most commonly used electric motors in HEV propulsion are permanent magnet
motor (PM) and induction motor (IM).
The most components of HEVs can be summarized in 3 groups.
1- Drivetrains: The ICE power source and electric drive integration.
2- Battery/Energy storage system (ESS): emphasizes energy storage andpower
capabilities.
3- Control system: Instructs electric system and ICE performance andmanages the
hybrid energy storage system (HESS).
4- Regenerative braking system.
In series HEVs, the generator actuated by the ICE, provides electrical energyin DC, which is then
converted to traction power by an electric motor.

In parallel HEVs, traction power can only be supplied by either an ICE or an EM, or by both
simultaneously. The EM is used to charge HESS by regenerative braking system.

The parallel Mild HEV can facilitate reaching to an ideal balance between thecost of the vehicle
and its performance, because it utilizes a smaller battery and the EM can only assist the torque
transmitted by the ICE.

The control system pointed out above, consists of an ECU, DC/AC convertors, Inventor,
Start/Stop, etc.

Regenerative braking system is a method for replacing the brake unwanted heat by electrical
energy. The principle is lied in electromagnetics induction.Briefly, when the torque produced by
the DC electric machine is in the same direction as the vehicle’s speed, the machine works as a
motor to thrust the vehicle. On the contrary, if the torque and speed are in different directions, it
means that the car is decelerating and the machine works as an alternator, thusthe energy used to
stop the car can be stored as the electric energy in batteries

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and recovered later. On the other hand, the heat produced in conventional braking systems is
fully dissipated in atmosphere.

In practice, to decelerate the car, instead of mechanical braking, an on-vehicleDC-DC converter is

activated which takes electrical energy from the vehicle’salternator to the batteries.

Having mentioned that, obviously the regenerative braking system operates on drive axles, either
it is front, rare or both.

Figure 5 Regenerative braking system

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Advantages of regenerative braking system are presented below.

 Improves Fuel Economy

 Emissions Reduction
 Improves performance of vehicle
 Reduce engine wear
 Reduce brake wear
 Accessories required are small
 Operational range is better than conventional braking
 The possible disadvantages of Regenerative Braking System:
 Extra weight added in vehicle
 Complex Arrangement of the system
 Available at reasonable cost if this has mass production
 Noise production depends on the system
 It adds extra maintenance requirement

Moreover, numerous new devices and mechanisms are overwhelmingly developed and applied
giving the HEVs a better performance and also high- tech features. Some of these new
technologies used in HVEs in the recent years will be mentioned here.

E-CVT: Electronic continuous variable transmission is more efficient than themechanical one (CVT)
and mostly applicable in HEVs. It selects the optimalspeed ratio, among infinite of ratios it has at
its disposal, by using a combination of planetary gears, real-time analyzing of vehicle’s speed,
road condition and drive power input. Needless to say, belts and chains are no longer in this
structure.

Advanced motors: As the electric motors play an key role in HEVs, they are more and more
becoming advanced in terms of the efficiency, power density and cost of the corresponding
drivetrain, easy controlled, torque-speed characteristics, compactness, thermal behavior, etc.

Some of the advanced motors tend to be installed particularly in HEVs, namely; Switched
reluctance motor, Brushless DC motor, permanent magnetsynchronous motor. The elaboration
of each is out of the scope of this study.

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VVT/VVL: Variable valve timing and variable valve lift are two relatively new technologies,
mounted on ICEs, to change the thermodynamic cycle it goes through, by altering the amount
and rate of air taking in the cylinders toameliorate the combustion condition. This could result in
the optimization of engine efficiency in both high-load and low-load periods. Theoretically,
Atkinson and Otto cycles are used for low-load and high-load states, respectively. It is usually
performed by overhead double camshaft system.

In addition, recently, electro-hydraulic and camless systems have emerged and taken into the
consideration as feasible alternative approaches.

PV technology: With the growing demand for switching over to renewable energy resources,
photovoltaic technology outstands other alternatives.

The various advantages like being noiseless, pollution-free, immunity to direct contamination,
simplicity in operation and its compatibility with hybridvehicles have attracted the attention of
engineering community.

The concept is assisting the hybrid electric vehicle by solar panels mounted on top of it. Although
the cost of solar panels is slightly dropping in recent years, still a trivial number of manufacturers
are willing to produce hybrid solar vehicles and it apparently needs more research and
investment.

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 References:
1- CRC Hybrid Vehicles Freebook, CRC PRESS
2- IA-HEV annual report- International energy agency
3- Hybrid solar vehicles by Gianfranco Rizzo, Ivan Arsie, Marco
Sorrentino
4- A comprehensive review on hybrid electric vehicles: architectures
and components by Krishna Veer Singh, Hari
Om Bansal,Dheerendra Singh
5- Hybrid Vehicles with DCT by Antonio Della Gatta – 2019
6- Hybrid vehicle by Karan C. Prajapati, Rachit Sagar, Ravi Patel – Pandit
Deendayal petroleum university
7- Regenerative braking system, by Mr. Shivam Sharma, Ashish Narayan
Singh, Rahul Yadav, Abhinav Jha, Kumar Vanshaj, Md. Fahim2

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