HODKINSON, R. (2001). Lightweight Electric Hybrid Vehicle Design.pdf

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Lightweight Electric/Hybrid Vehicle Design
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Lightweight Electric/
Hybrid Vehicle Design
Ron Hodkinson and John Fenton
OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHI
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iv Contents
Butterworth-Heinemann
Linacre House, Jordan Hill, Oxford OX2 8DP
225 Wildwood Avenue, Woburn, MA 01801-2041
A division of Reed Educational and Professional Publishing Ltd
A member of the Reed Elsevier plc group
First published 2001
© Reed Educational and Professional Publishing Ltd 2001
All rights reserved. No part of this publication may be reproduced in any
material form (including photocopying or storing in any medium by electronic
means and whether or not transiently or incidentally to some other use of this
publication) without the written permission of the copyright holder except in
accordance with the provisions of the Copyright, Designs and Patents Act
1988 or under the terms of a licence issued by the Copyright Licensing
Agency Ltd, 90 Tottenham Court Road, London, England W1P 9HE.
Applications for the copyright holder’s written permission to reproduce any
part of this publication should be addressed to the publishers
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloguing in Publication Data
A catalogue record for this book is available from the Library of Congress
ISBN 0 7506 5092 3
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Contents v
Contents
Preface
vii
About the authors
ix
Introduction
xi
Part 1 Electromotive Technology (Ron Hodkinson MSc MIEE)
1
3
1.1
Introduction
3
1.2
Case for electric vehicles
3
1.3
Selecting EV motor type for particular vehicle application
15
1.4
Inverter technology
21
1.5
Electric vehicle drives: optimum solutions for motors, drives and batteries
24
2 Viable energy storage systems
29
2.1
Electronic battery
29
2.2
Battery performance: existing systems
29
2.3
Status of the aluminium battery
35
2.4
Advanced fuel-cell control systems
39
2.5
Waste heat recovery, key element in supercar efficiency
50
56
3.1
Introduction
56
3.2
Electric truck motor considerations
56
3.3
Brushless DC motor design for a small car
58
3.4
Brushless motor design for a medium car
61
3.5
Brushless PM motor: design and FE analysis of a 150 kW machine
64
3.6
High frequency motor characteristics
68
3.7
Innovative drive scheme for DC series motors
73
80
4.1
Introduction
80
4.2
Reforming and other hydrogen feedstocks
82
4.3
Characteristics, advantages and status of fuel cells
83
4.4
Thermodynamics of fuel cells
84
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vi Contents
4.5
Process engineering of fuel cells
87
4.6
Steps towards the fuel-cell engine
89
4.7
Prospects for EV package design
93
4.8
Fuel-cell vehicles and infrastructure
96
4.9
The PNGV programme: impetus for change
98
103
(John Fenton MSc MIMechE)
105
5.1
Introduction
105
5.2
Electric batteries
105
5.3
Battery car conversion technology
115
5.4
EV development history
119
5.5
Contemporary electric car technology
122
5.6
Electric van and truck design
128
5.7
Fuel-cell powered vehicles
135
6 Hybrid vehicle design
141
6.1
Introduction
141
6.2
Hybrid drive prospects
143
6.3
Hybrid technology case studies
146
6.4
Production hybrid-drive cars
156
6.5
Hybrid passenger and goods vehicles
164
173
7.1
Introduction
173
7.2
The ‘composite’ approach
173
7.3
Plastic mouldings for open canopy shells
178
7.4
Materials for specialist EV structures
182
7.5
Ultra-lightweight construction case study
191
7.6
Weight reduction in metal structures
192
199
8.1
Introduction
199
8.2
Structural package and elements
200
8.3
‘Punt’-type structures
209
8.4
Optimizing substructures and individual elements
211
8.5
Designing against fatigue
217
8.6
Finite-element analysis (FEA)
218
8.7
Case study of FEA for EVs and structural analysis assemblies
223
8.8
Running gear design for optimum performance and lightweight
223
8.9
Lightweight vehicle suspension
231
8.10 Handling and steering
232
8.11 Traction and braking systems
235
8.12 Lightweight shafting, CV jointing and road wheels
241
8.13 Rolling resistance
243
Index
251
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