Download Manual Drivetrains and Axles Fourth Edition

Hybrid and Alternative Fuel Vehicles
By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
Pearson Prentice Hall
Upper Saddle River, NJ 07458
OBJECTIVES
After studying Chapter 6, the reader should be able to:
1. Describe the operation of DC and AC electric motors.
2. Explain how a brushless DC motor works.
3. Discuss the advantages and disadvantages of using electric motors in hybrid electric
vehicles.
4. Explain how electric power steering works.
5. Describe how a DC-to-DC converter works.
6. Discuss how a DC-to-AC inverter works.
Hybrid and Alternative Fuel Vehicles
By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
Pearson Prentice Hall
Upper Saddle River, NJ 07458
FUNDAMENTALS OF MAGNETISM
Magnetism is a form of energy that is generated by the motion of electrons and
alignment of atoms in some materials. A type of iron ore, called lodestone, exists
as a magnet in nature.
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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A Cracked Magnet Becomes Two Magnets
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© 2009 Pearson Education, Inc.
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Lines of Force
In a bar magnet, the lines are concentrated at both ends of the bar and form closed,
parallel loops in three dimensions around the magnet. They come out of one end,
or pole, of the magnet and enter at the other end; they NEVER intersect.
Hybrid and Alternative Fuel Vehicles
By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
Pearson Prentice Hall
Upper Saddle River, NJ 07458
The opposite ends of a magnet are called its north and south poles. In reality, they should be
called the "north seeking" and "south seeking" poles, because they seek the earth's North Pole
and South Pole, respectively.
The stronger the magnet, the more magnetic lines that are formed. The magnetic
lines of force, also called magnetic flux or flux lines, form a magnetic field. The terms
magnetic field, lines of force, flux, and flux lines are used interchangeably.
Flux density refers to the number of flux lines per unit of area.
Hybrid and Alternative Fuel Vehicles
By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
Pearson Prentice Hall
Upper Saddle River, NJ 07458
A magnetic field can also be observed by using a compass. A compass is simply a
thin magnet or magnetized iron needle balanced on a pivot. The needle will rotate
to point toward the opposite pole of a magnet. It can be very sensitive to small
magnetic fields. Since it is a small magnet, a compass usually has one end marked
N and the other marked S.
Hybrid and Alternative Fuel Vehicles
By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
Pearson Prentice Hall
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If like poles are placed close together, the curving flux lines meet head-on, forcing
the magnets apart. Therefore, like poles of a magnet repel and the unlike poles
attract.
Hybrid and Alternative Fuel Vehicles
By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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Permeability
Magnetic flux lines cannot be insulated. There is no known material through which magnetic
force does not pass, if the force is strong enough. However, some materials allow the force
to pass though more easily than others. This degree of passage is called permeability.
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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Reluctance
While there is no absolute insulation for magnetism, certain materials resist the passage of
magnetic force. Air does not allow easy passage, so air has a high reluctance.
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© 2009 Pearson Education, Inc.
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ELECTROMAGNETISM
Scientists discovered that current-carrying conductors are also surrounded by a magnetic
field about 1820. The creation of a magnetic field by the use of an electrical current is called
electromagnetism. As current increases, more flux lines are created and the magnetic field
expands. As current decreases, the magnetic field contracts, or collapses.
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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The magnetic field surrounding a straight, current-carrying conductor exists along
the entire length of the wire. The strength of the current determines how many
flux lines there will be and how far out they extend from the surface of the wire.
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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Right-Hand Rule
Magnetic flux cylinders have direction, just as the flux lines surrounding a bar
magnet have direction.
Most automotive circuits use the conventional theory of current flow (+ to -), and
therefore the right-hand rule is used to determine the direction of the magnetic
flux lines.
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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Current-carrying conductors tend to move out of a strong field into a weak field,
so the conductors move away from each other.
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© 2009 Pearson Education, Inc.
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Electric motors, such as automobile starter motors, use this field interaction to
change electrical energy into mechanical energy. These forces cause the center of
the motor, where the conductors are mounted, to turn clockwise.
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Coil Conductor
If several loops of wire are made into a coil, the magnetic flux density is
strengthened. Flux lines around a coil are the same as the flux lines around a bar
magnet.
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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Electromagnets
The magnetic field surrounding a current-carrying conductor can be strengthened
by using a soft iron core. The concentration of force greatly increases the strength
of the magnetic field inside the coil. Coils with an iron core are called
electromagnets.
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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ELECTROMAGNETIC INDUCTION
Magnetic flux lines can create an electromotive force, or voltage, in a conductor if either the
flux lines or the conductor is moving. This creation of a voltage in a conductor by a moving
magnetic field is called electromagnetic induction.
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The highest voltage is generated when the motion is at right angles.
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© 2009 Pearson Education, Inc.
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Voltage Strength
There are four ways to increase induced voltage:
Increase the strength of the magnetic field, so there are more flux lines.
Increase the number of conductors that are breaking the flux lines.
Increase the speed of the relative motion.
Increase the angle between the flux lines and the conductor to a maximum of 90 degrees.
Hybrid and Alternative Fuel Vehicles
By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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Hybrid and Alternative Fuel Vehicles
By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
Pearson Prentice Hall
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Maximum voltage is induced if the conductors break flux lines at 90 degrees and
the voltage decreases when the flux lines are cut at angles between 0 and 90
degrees.
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An induced current moves so that its magnetic field opposes the motion that induced the
current. This principle is called Lenz’s law.
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ELECTRIC MOTORS
Electric motor power is expressed in kilowatts (kW).
A kilowatt is equal to 1,000 watts.
One hp is equal to 746 watts.
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Electric Motor Operation
The torque of a starter is determined by the strength of the magnetic fields.
Magnetic field strength is measured in ampere-turns. If the current or the
number of turns of wire is increased, the magnetic field strength is increased.
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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A typical DC motor today uses four poles.
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The following are the basic principles of a typical DC motor:
The speed of the motor is proportional to the applied voltage.
The torque is proportional to the applied current.
The speed is typically controlled by altering the voltage or current flow by using taps in the
motor windings or by using a variable voltage supply.
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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The use of brushes in an electric motor has many disadvantges including:
1. Any arcing of the brushes also causes electrical noise.
2. The brushes eventually wear out and require replacement.
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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What Is a “Traction Motor” and an “Electric Machine”?
A traction motor is a motor used to propel a vehicle. The term traction comes from the
engineering term that describes what must occur for a drive wheel to rotate and to transfer
torque from the propulsion unit to the drive wheels.
The term machine is commonly used to describe an electric motor because it is often more
than a simple motor and requires controllers and other components to function.
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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BRUSHLESS MOTORS
There are two types of electric brushless motors: the AC induction motor and the AC
synchronous motor.
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AC Induction Motor
An AC induction motor, as is used in the General Motors parallel hybrid truck (PHT).
An AC induction motor is also known as an AC asynchronous motor, or AC induction
motor (ACIM).
The term asynchronous means that the speed of the motor is not necessarily related to the
frequency of the current flowing through the stator windings. ACIMs include squirrel-cage
and wound-rotor induction designs.
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A squirrel-cage rotor.
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An alternate design is called the wound rotor.
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AC Synchronous Motor
The AC synchronous motor rotates exactly at the supply frequency or a submultiple of the
supply frequency. The speed is controlled by varying the frequency of the AC supply and the
number of poles in the stator winding, according to the relation:
RPM = 120F ÷ p
where
RPM = Synchronous speed
F = AC power frequency
p = Number of poles, usually an even number but always a multiple of the
number of phases
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Permanent magnet rotors.
Brushless permanent magnet motors use two designs of rotors:
The permanent magnets are part of the rotor in the core of the rotor. These are
called a surface permanent magnets (SPMs).
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In the other type, the permanent magnets are housed inside the outer shell of the rotor and are
called interior permanent magnets (IPMs). The Honda Accord, Ford hybrids, and Toyota
hybrids use an IPM-type rotor assembly.
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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In both types of motors, the stator coils are stationary and the permanent magnet
assembly rotates. Alternating current (AC) is fed to the varous phases in the stator
in order to get the permanent magnets in the rotor to “chase” the changing
magnetic field.
Hybrid and Alternative Fuel Vehicles
By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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Hybrid and Alternative Fuel Vehicles
By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
Pearson Prentice Hall
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There are ten electric motors, sometimes more, in most hybrid vehicles. These include:
1. One or two drive motor(s)
2. Motor to circulate the coolant during idle stop to keep the passengers warm
(Toyotas/Honda Accord/Honda Civic)
3. Motor for electric power steering (EPS) (all)
4. Motor for A/C compressor (New Prius and Accord)
5. Motor for cooling CVT (Ford/Toyota/Lexus)
6. Motor for AT trans (hybrid Accord, GM PHT, and Saturn VUE)
7. Motor(s) for air cooling the HV batteries (all)
8. Motor for hydroelectric power steering (GM 42/36v)
9. Motor in CVT to engage park (2004+ Prius)
10. Rear differential (Lexus RX400h/Highlander 4WD)
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By James D Halderman and Tony Martin
© 2009 Pearson Education, Inc.
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Electric Motors Are Perfect for Vehicles
An electric motor produces maximum torque at low speeds, making it the perfect power
source to get a vehicle moving from a stop. Then, when the torque of an electric motor starts
to drop off, the torque multiplied by the speed (RPM) results in power. Therefore, a typical
electric motor used on a hybrid vehicle has the following characteristics:
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© 2009 Pearson Education, Inc.
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Delivers constant torque at low speed, typically from zero to 1,500 RPM
Delivers constant power above 1,500 RPM
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MOTOR CONTROL
An example of traction motor control is the motor control module (MCM) used on Honda
hybrid electric vehicles. The MCM has three inputs from three rotor position sensors, A, B,
and C.
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The MCM has three outputs: U, V, and W. Each winding sends control
information (digital high-low) to the power drive unit (PDU).
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A typical Honda PDU schematic is shown.
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The current flow through the PDU is controlled by six insulated gate bipolar
transistors (IGBTs). The IGBTs are current drivers that send current from the
battery pack through the stator windings to energize the stator coils and move the
rotor to power the drive wheels. Most motor controllers include Hall-effect
current sensors.
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The IGBTs process drive current to the electric drive motor. The diodes form a
rectifier bridge to change the AC generated in the electric drive motor to pulsating
DC to charge the battery pack.
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Toyota and Lexus use a speed sensor called a resolver to detect the rotor position.
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Cooling the Electronics
The current flow and the electronic devices in hybrid electric control units
generate a lot of heat. Toyota, Ford, and GM hybrids use a liquid cooling method
to control the temperature of the electronics.
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CAPACITORS IN HYBRID CONTROLLERS
A capacitor consists of two conductive plates with an insulating material between them. The
insulating material is commonly called a dielectric. It may be air, mica, ceramic, glass,
paper, plastic, or any similar nonconductive material. The higher the dielectric constant
number of a material, the better it is as an insulator.
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When a capacitor is placed in a closed circuit, the voltage source, such as a
battery, forces electrons around the circuit. Because electrons cannot flow through
the dielectric of the capacitor, excess electrons collect on what becomes the
negatively charged plate. At the same time the other plate loses electrons, and
therefore becomes positively charged.
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Current continues until the voltage charge across the capacitor plates becomes the
same as the source voltage. At that time, the negative plate of the capacitor and
the negative terminal of the battery are at the same negative potential.
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An electrostatic field now exists between the capacitor plates because of their
opposite charges. It is this field that stores energy.
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If the circuit is opened, the capacitor will hold its charge until it is connected into
an external circuit through which it can discharge. When the charged capacitor is
connected to an external circuit, it discharges. After discharging, both plates of the
capacitor are neutral because all the energy from a circuit stored in a capacitor is
returned when it is discharged.
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When the ignition of an HEV is turned off, vehicle manufacturers warn that you
must wait 5 to 10 minutes for the capacitors to discharge before servicing the
high-voltage system. While these capacitors often discharge in less than five
minutes, it is wise to wait the amount of time specified by the vehicle
manufacturer.
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To avoid an electrical shock, any capacitor should be treated as if it were charged until it is
proven to be discharged.
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Capacitors are also called condensers. This term developed because electric charges collect,
or condense, on the plates of a capacitor much like water vapor collects and condenses on a
cold bottle or glass.
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Capacitance is measured in farads, which is named after Michael Faraday (1791-1867). The
symbol for farads is F. If a charge of 1 coulomb is placed on the plates of a capacitor and the
potential difference between them is 1 volt, the capacitance is then defined to be 1 farad.
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Snubbers
Snubbers are capacitors and resistors arranged in a circuit to control the highvoltages surges that can occur when circuits containing coils are switched on and
off.
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CONVERTERS AND INVERTERS
Converters
DC-to-DC converters (usually written DC-DC converter) are electronic devices used to
transform DC voltage from one level of DC voltage to another higher or lower level.
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One example of a DC-DC converter circuit is the circuit the PCM uses to convert
14 V to 5 V. The 5 volts is called the reference voltage, abbreviated V-ref, and is
used to power many sensors in a computer-controlled engine management system.
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Hybrid electric vehicles use DC-DC converters to provide higher or lower DC
voltage levels and current requirements.
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DC-DC Converter Circuit Testing
1. Always follow the manufacturer’s safety precautions when working with high-voltage
circuits. These circuits are usually indicated by orange wiring.
2. Never tap into wires in a DC-DC converter circuit to access power for another circuit.
3. Never tap into wires in a DC-DC converter circuit to access a ground for another circuit.
4. Never block airflow to a DC-DC converter heat sink.
5. Never use a heat sink for a ground connection for a meter, scope, or accessory connection.
6. Never connect or disconnect a DC-to-DC converter while the converter is powered up.
7. Never connect a DC-to-DC converter to a larger-voltage source than specified.
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Inverters
An inverter is an electronic circuit that changes direct current (DC) into
alternating current (AC). In most DC-AC inverters, the switching transistors usually metal oxide semiconductor field-effect transistors (MOSFETs) are
turned on alternately for short pulses.
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The waveform produced by an inverter is not the perfect sine wave of household
AC current, but is rather more like a pulsing DC current that reacts similar to sine
wave AC in transformers and in induction motors.
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AC motors are powered by inverters. An inverter converts DC power to AC power at the
required frequency and amplitude. The inverter consists of three half-bridge units and the
output voltage is mostly created by a pulse width modulation (PWM) technique. The threephase voltage waves are shifted 120° to each other to power each of the three phases.
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ELECTRIC POWER STEERING
The electric power steering (EPS), also called electric power-assisted steering
(EPAS), system includes the following components and inputs/outputs:
A DC motor
Reduction gear
Torque sensor
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The electric power steering (EPS) is controlled by the EPS ECU, which calculates the
amount of needed assist based on the input from the steering torque sensor. The steering
torque sensor is a noncontact sensor that detects the movement and torque applied to the
torsion bar. The torsion bar twists when the driver exerts torque to the steering wheel, and the
more torque applied causes the bar to twist further. This generates a higher-voltage signal to
the EPS ECU.
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The Toyota Highlander and Lexus RX 400h use a different electric power steering
unit due to the larger size of the vehicles. This unit uses a concentric brushless
DC motor on the steering rack.
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The Honda electric power steering uses an electric motor to provide steering assist and
replaces the need for a hydraulic pump, hoses, and gear. A torque sensor is used to measure
road resistance and the direction that the driver is turning the steering wheel. The torque
sensor input and the vehicle speed is used by the EPS controller to supply the EPS motor
with the specified current to help assist the steering effort.
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SUMMARY
1. Magnetic lines of force leave the north pole and enter the south pole of a magnet.
2. Magnetic lines of force are called flux lines.
3. Any conductor carrying an electrical current generates a magnetic field around the
conductor, and a moving magnetic field across a conductor creates electricity.
4. Like poles repel and unlike poles attract.
5. A brushless DC motor is also known as an AC synchronous motor.
6. Powerful permanent magnets are used in the rotors of both DC and AC brushless motors.
7. The operation of motors is performed by the controller, which is capable of switching the
voltage and/or the frequency of the current flowing through the stationary windings of the
motor.
8. DC-DC converters are used in hybrid electric vehicles to convert the high-voltage battery
current into a lower voltage used by the accessories and lighting systems.
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REVIEW QUESTIONS
1. How is an electrical current induced in a wire?
2. How does an AC synchronous motor work?
3. How does an AC induction motor work?
4. How is the operation of a brushless DC motor controlled?
5. What is a DC-DC converter, and why is it needed in a hybrid electric vehicle?
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