New model Optima (TF HEV) Technical Service Training book (Link tải bản full ở file đính kèm)

The concept vehicle development project began in 1995, and by 2008, Kia Motor Company launched pilot production of hybrid vehicles for the Gets and Rio models. In 2009, the TD Spectra model with LPI technology and lithium polymer battery was launched as the world’s first LPI hybrid vehicle. Following the TD Spectra, the Optima Hybrid Electric Vehicle is going to be launched. The Optima HEV is a fulltype hybrid with electric drive mode. It boasts excellent fuel efficiency and power that stands shouldertoshoulder with the world’s leading hybrid vehicles.

Copyright ⓒ 2009~2010 All rights reserved No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.

HEV(Hybrid Electric Vehicle)

Preface

1 Hybrid Electric Vehicle

2 Optima Hybrid System Overview

3 Optima Hybrid Control Mode

Preface

Learning Objectives

1 Describes overall summary about Hybrid Electric Vehicle (HEV)

2 Details the definition of Hybrid.

3 Describes the Hybrid System categories.

The concept vehicle development project began in 1995, and by 2008, Kia Motor Company

launched pilot production of hybrid vehicles for the Gets and Rio models In 2009, the TD

Spectra model with LPI technology and lithium polymer battery was launched as the world’s

first LPI hybrid vehicle Following the TD Spectra, the Optima Hybrid Electric Vehicle is going

to be launched The Optima HEV is a full-type hybrid with electric drive mode It boasts

excellent fuel efficiency and power that stands shoulder-to-shoulder with the world’s leading

hybrid vehicles

1 Hybrid Electric Vehicle

1.1 Why HEV?

Global automotive companies are making significant investments in developing new conceptautomobiles that deliver high efficiency output with low emission This trend is in line with worldwideefforts to develop alternative energy in preparation for depleting petroleum resources, as well as toreduce CO2 emission with strict environmental pollution regulations that call for reduced NOx andmeasures against global warming The world faces depletion of fossil fuel energy resources in the 21st

Century, and with increasing concern about global warming, there is an urgent need to develop vehiclesthat have reduced carbon dioxide emission and conform to the emission control regulations pertaining

to nitrogen oxide and hydrocarbon

The state of California has forced major automobile manufacturers to produce a minimum of 2% of allvehicles as pollution-free automobiles Such strict regulation is anticipated to spread throughoutAmerica And the gasoline-powered vehicles is anticipated to fade into the history by 2030.Encouragingly, the market for hybrid vehicles is increasing and is forecast to account for 24% of theentire automobile market by 2010, a figure increasing to almost 50% by 2030

Such reality is causing the global automotive industry to focus on hybrid vehicles with dual powersources as the next generation of automobiles

Developing hybrid vehicles is not an option but a necessity for automobile manufacturers to ensure asustainable future with ever strengthening environmental regulations worldwide

Environmentally Friendly Vehicles

Strict Emission Gas Regulation

CARB

EURO

Low Pollution Vehicle Ratio Regulation

Hybrid Electric Vehicle / Electric Vehicle / Fuel Cell Vehicle

New Concept Power-train

- Electricity: Electric Vehicle, Fuel Cell Vehicle

- Hybrid: HEV, Fuel Cell HEV High Efficiency Power-train / Development of alternative energy

- 2 Power sources are used (Combustion engine + Electric motor)

- Increased fuel economy

- Reduced emission

+

Memo

1.3 Types of HEV (by structure)

HEV

System

Parallel type

Power split FMED

(Flywheel Mounted Electric Device)

TMED (Transmission Mounted Electric Device)

: Mild (Soft) type

Available : Full (Hard) type

Available : Full (Hard) type

Power Split Type

The power split type, which is also known as the Toyota Hybrid System (THS) (because it was firstdeveloped by Toyota), connects the engine and 2 motors via planetary gear sets It uses planetarygears and motor control instead of transmission to control the vehicle speed As the power split type

Wheel

Wheel

Battery

Engine Motor TM FD Clutch

R1 C1 S1

R2 C2 S2 FD MG2

CL1 CL2 BK1

Wheel

Wheel Wheel

Wheel

allows electric drive mode, it is a full type hybrid Although it has the drawback of requiring a capacity motor, it boasts efficiency and outstanding driving stability Toyota, Ford, GM, BMW, andMercedes utilize the power split type in their hybrid vehicles.

high-1.4 Comparison of Mild Type and Full Type

The differentiating criteria of the mild type and the full type are whether the hybrid vehicle can drive withonly electric motor power and without the need for the engine

In the case of the mild type, which does not support electric drive mode, both the motor and the enginepower are used during startup However the vehicle runs by the engine without motor assist when lessloaded such as coasting driving In cases of acceleration or highly engine loaded such as in uphilldriving, the motor supports the engine power When the vehicles brakes, the generated heat energy istransformed into electricity by the motor and stored in the battery This process is also known asregenerative braking When the vehicle comes to a stop, the engine is also stopped to conserve fuel.This is known as idle stop

In the case of the full type, the vehicle is driven only by the electric motor during startup and low speed

[Full(Hard) type]

[Mild(Soft) type]

Motor+Engine

Inertia Energy Battery Charge

Engine Auto Stop Motor

Coasting (high speed)

1.5 Plug-In Hybrid Electric Vehicle (PHEV) System

Hybrid vehicles are more widely used for their environmentally friendliness However, the engine onhybrid vehicles are not being used efficiently and a large amount of electric energy is lost during theconversion and storing process

The PHEV, which many automobile manufacturers are recently turning to, eliminates energy loss duringthe energy conversion process and utilizes existing efficient engines The Plug-in Hybrid Vehicle is ahybrid vehicle with an added electric plug to charge the battery using general household electricity Thisrepresents a midpoint before complete migration to electric vehicles Compared to general hybridvehicles, the Plug-in Hybrid has a longer battery and motor driving distance It is therefore highlyefficient in terms of fuel consumption and emission gas This vehicle can travel approximately 30 miles

on a single charge, and it uses regular diesel or gasoline fuel for farther distances

Many major automobile makers forecast that the global hybrid vehicle market will grow to over 40 millionvehicles annually by 2020, and most believe that the majority of these hybrids will be Plug-in HybridVehicles

Gas Engine

Gas

Engine

Gas Electric

Gas

Battery Motor

Battery

Gas Engine

Electric

Electric Motor

2 Optima Hybrid System Overview

2.1 Hybrid System Components

The main components of the Optima hybrid system are,

· Theta-II 2.4 HEV

· 6 Speed Automatic Transaxle

· Electric motor & HSG (Hybrid Starter Generator)

· High voltage battery

· MCU (Motor Control Unit, or Inverter)

AHB (Active Hydraulic Booster)

- Increased regenerative energy Electric A/C compressor

Hybrid cluster

HSG (Hybrid Starter Generator)

- 8.5kW Electric oil pump

6 Speed AT

- Without torque converter

- Engine clutch + Electric motor

AAF (Active Air Flap)

2.2 Hybrid Engine (Theta-II 2.4 MPI with Atkinson Cycle)

Theta- Atkinson cycle hybrid engine basically uses Theta II 2.4L MPI engine, but it is modified tomaximize the engine efficiency and not the engine power for fuel economy In addition to the application

of the Atkinson Cycle to reduce engine pumping loss, more items are utilized as below

Compression ratio is increased and piston shape is changed to reduce the combustion chambervolume The thermostat opening temperature is increased to 88°C (190.4°F) resulting in bettercombustion Also, a lighter valve spring and a piston ring coated with low-friction material are used

0.0

5.0

10.0

Lower valve spring force

Piston ring coating

2.3 Hybrid Automatic Transaxle (A6MF2H)

Instead of CVT which is widely used in other competitors, the hybrid vehicle’s exclusive 6-speedautomatic transaxle is installed to transfer power from the engine or motor

The torque converter in existing automatic transaxle is removed Instead, the motor, engine clutch andtorsional damper are installed in its place

The electric oil pump is mounted on the side of the automatic transaxle It generates required hydraulicpressure for transaxle and engine clutch during low speed driving or Electric Vehicle mode in which thevehicle operates only on the motor with the engine stopped

Case

TCU (PCU Type)

Mechanical Oil Pump

Electric Oil Pump

Engine Clutch

Torsion Damper

OPU

Valve Body Gear Train

2.4 Electric Motor & HSG (Hybrid Starter Generator)

Electric Motor

The drive motor installed in the Optima Hybrid has achieved the highest performance in its class with amaximum power output of 30 kilo watt from the electric motor that produces a maximum torque of 205Newton meter

The hybrid electric motor is an important component that receives power from the battery and supportsthe engine power during acceleration It recharges the battery with the electric energy generated duringdeceleration

In Electric Vehicle mode, the electric motor provides traction power necessary to move the vehiclewithout support from the engine In hybrid mode, the electric motor supports engine power and storesoutput energy during braking using the generator

Hybrid Starter Generator (HSG)

Electric motor

HSG (Hybrid Starter Generator)

AT assembly

The Hybrid Starter Generator or HSG assembly allows the Optima Hybrid to switch between ElectricVehicle and Hybrid modes It cranks the engine for starting and can acts as a generator whennecessary if the hybrid battery state of charge is below a specified threshold.

2.5 High Voltage Battery & BMS

The high-voltage battery has four major components contained in the assembly

The 270 volt battery assembly is developed using the lithium-ion polymer battery technology Toenhance safety, the assembly uses a battery current check circuit which shuts off electric current incase of over-charge

A 12 volt blower air cooling system is used to maintain optimal battery temperature by passing cool airthrough the battery case

The Battery Management System module is contained inside the battery case and maintains the optimalperformance of the high voltage battery The BMS measures the current, voltage and temperature of thebattery and estimates the high voltage battery stage of charge It controls the battery cooling fan tomaintain optimal battery operation temperature and performs the cell balancing control which minimizesvoltage deviation of each cell during battery charging and discharging In addition, if a system faultoccurs, the BMS turns off the high-voltage relay to protect hybrid system from the high voltage

In addition, active protection devices such as the power relay assembly and fuse are used to improve

Lithium-ion polymer battery

270V / 5.3Ah, 72Cells in series

High voltage battery Maintain proper temperature

Equipped with BLDC* cooling pan

- Increase air flow & Reduce noise Cooling system

Voltage, Current, Temperature sensing

SOC* estimation, Power-cut, Cooling control,

Relay control, Cell balancing, Diagnosis

2.6 Motor Control Unit (MCU) or Inverter

The MCU has an inverter feature that transforms direct current to alternating current, and at the sametime a converter feature that does the reverse

The MCU’s inverter circuits generates alternating current to operate the electric motor from the directcurrent of the high voltage battery The MCU’s converter circuits transforms the alternating current ofthe motor to Direct current to charge the high voltage battery

- Inverter: Transforming the DC of High Voltage Battery to AC for Motor operation

- Converter: Converting the generated AC to DC for High Voltage Battery Charging

MCU = Inverter + Converter

DC Motor

2.7 Low voltage DC-DC converter (LDC)

In conventional vehicles, an alternator is used to supply 12-volt power to electric devices and charge thebattery while the engine is running But in Hybrid Electric Vehicle, the LDC transforms the electricpower from the high-voltage battery to 12 V and supplies power to electric devices and the auxiliarybattery

Because the LDC is used, there is no alternator on the HEV and not additional engine load

- Converting 270 DC voltage to 12V DC voltage

- Charging the 12V auxiliary battery (Alternator is removed)

Electric load

Aux

Battery(12V) Alternator

High voltage battery (270V)

Inverter (MCU)

2.8 Active Air Flap (AAF)

An active air flap is mounted between the front bumper grille and the radiator It is controlled according

to the driving conditions

The flap is closed while driving to reduce air resistance When the engine temperature increases to thethreshold, the flap is opened to reduce the engine room temperature

The engine coolant temperature, A/C pressure, and the vehicle speed are transmitted via CANcommunication and the smart actuator opens and closes the flap

Memo

Flap open

Smart Actuator Flap close

· Engine coolant temperature

- Reduced air resistance according to the driving condition

- Better fuel economy

2.9 Hybrid Brake System

The brake vacuum booster which uses the engine vacuum cannot be used in an electric-motor-drivenhybrid vehicle Therefore, an active hydraulic booster is used A pedal simulator and pedal travel sensorare also added and provide a pedal feeling for those drivers who are used to the vacuum booster.During braking, the hydraulic brake and regenerative brake by the electric motor are engagedsimultaneously

Hydraulic flow Electronic flow

ESC

(HEV)

Master cylinder + Pedal simulator

AHB (Active Hydraulic Booster) Pedal travel sensor

Total Braking Amount (Cooperative Control)

Regenerative Braking Amount (by Motor) Hydraulic Braking Amount

2.10 Electric A/C Compressor

2 Operating permission & Max power signal

3 Permission & Allowable power

An electric compressor is used to ensure continued operation of the A/C, even when the engine stops

If the A/C switch is pressed, the FATC sends an operation authorization request to the HCU The HCUtransmits the operation allowance signal with an allowable electric power amount to the FATC TheFATC controls the electric compressor within the allowable electric power range

Electric A/C Compressor FATC

2.11 Technology for Fuel Economy

EV , ist Ass

Stand by

Engine

T /M

Improve driving efficiency

EV, Assist

Better engine efficiency

The main goal of developing the hybrid vehicle is to reduce emission gas and increase fuel efficiency Inparticular, technology that recycles or reduces energy loss during combustion is utilized to improve fuelefficiency

Approximately 80% of energy is known to be lost in a gasoline engine Even when assuming completecombustion, most of the energy generated from the fuel in the combustion chamber undergoesnumerous loss-incurring processes, and only a portion of the energy is used to drive the vehicle Thereare various types of energy loss Some of the major areas of loss include exhaust, cooling, enginepumping, operation of various engine support components, drive resistance, and brake loss

In the case of hybrid vehicles, various technologies that either reduce or recycle such energy losses andtheir applications are listed as follows:

- Engine torque and RPM control activate the engine in fuel-efficient conditions

- Engine turn off when the vehicle comes to a stop (idle stop) to improve fuel efficiency

- Power loss reduction caused by removing the generator due to the LDC

- Atkinson Cycle application to reduce engine pumping loss

- Brake loss conversion to electric energy to charge the high voltage battery

- Torque converter elimination in automatic transmission to reduce power loss

- Vehicle’s air resistance reduction to improve fuel efficiency