Preliminary Hybridization Design of a Mid-Size Pickup Truck in the Brazilian Market with an Electric Motor Coupled to the Mechanical Differential on the Rear Axle

Aldo Silva Gonçalves; Alexandre da Silva Scari

doi:10.18540/jcecvl11iss1pp21725

Authors

Aldo Silva Gonçalves UFPE https://orcid.org/0009-0000-0582-1113
Alexandre da Silva Scari UFMG

DOI:

https://doi.org/10.18540/jcecvl11iss1pp21725

Keywords:

Hybrid vehicles. Mid-size pickup trucks. Mechanical differential. Vehicle dynamics. off-road vehicles.

Abstract

This work consists of the preliminary hybridization design of a mid-size pickup truck in the Brazilian market. In this sense, it is studied the technical feasibility of implementing an electric motor on the vehicle’s rear axle coupled to a mechanical differential. To this end, performance calculations for the vehicle, including climbing and overtaking are carried out, in addition to selecting a suitable electric motor, battery pack and designing the differential.

Subsequently, preliminary design conditions were analyzed. Regarding packaging, it was observed that the system's dimensions are compatible with the vehicle's size and do not encroach upon the cabin. A mass estimate indicated that the proposed hybrid pickup truck is approximately 90 kilograms lighter than a similar 4x4 Diesel pickup. Finally, by analyzing a hill climbing scenario on wet dirt terrain, it was concluded that the proposed vehicle possesses off-road capabilities.

Downloads

Download data is not yet available.

References

Ministério do Meio Ambiente. Resolução N. 490, de 16 de novembro de 2018. Governo Federal do Brasil, 2018. Available at: https://conama.mma.gov.br/?option=com_sisconama&task=arquivo.download&id=767. Accessed on: 22 out. 2024.

Gupta, Ajay Kumar, Kartik, V, and Ramanarayanan, C P. "Design, development and performance evaluation of a light diesel hybrid electric pickup vehicle using a new parallel hybrid transmission system." In 2015 IEEE International Transportation Electrification Conference (ITEC), 1-10, 2015. DOI: 10.1109/ITEC-India.2015.7386933.

Kumaran, Ajith, et al. "Affordable hybrid topology for PV and LDV's in prospering India: Case study of 48 V (P)HEV system benefits." In 2017 IEEE Transportation Electrification Conference (ITEC-India), 1-6, 2017. DOI: 10.1109/ITEC-India.2017.8333824.

Gao, David Wenzhong, Mi, Chris, and Emadi, Ali. "Modeling and Simulation of Electric and Hybrid Vehicles." Proceedings of the IEEE, 95(4): 729-745, 2007. DOI: 10.1109/JPROC.2006.890127.

Zhao, Hui, Li, Cheng, and Zhang, Guojiang. "Design of a versatile test bench for hybrid electric vehicles." In 2008 IEEE Vehicle Power and Propulsion Conference, 1-4, 2008. DOI: 10.1109/VPPC.2008.4677463.

Coelho, Margarida C., and Luiza, Marco B. "Evaluating the energy performance of a SUV hybrid electric vehicle." Transportation Research Part D, 2010, 443-450. DOI: 10.1016/j.trd.2010.04.003.

Verdonck, N., Chasse, A., Pognant-Gros, P., and Sciarretta, A. "Automated Model Generation for Hybrid Vehicles Optimization and Control." Oil and Gas Science and Technology, 65(1): 115-132, 2010. DOI: 10.2516/ogst/2009064.

Sittig, Andy, Mumelter, Georg, and Rabenstein, Friedrich. "Development and calibration of hybrid electric vehicle operating strategies using simulations and a hybrid power train test bench." In 2011 IEEE Vehicle Power and Propulsion Conference, 1-5, 2011. DOI: 10.1109/VPPC.2011.6043058.

Biswas, Prateek. "Adapting SUV AWD powertrain to P0/P2/P4 hybrid EV architecture: Integrative packaging and capability study." In 2017 IEEE Transportation Electrification Conference (ITEC-India), 1-5, 2017. DOI: 10.1109/ITEC-India.2017.8333842.

Werra, M., Sturm, A., and Küçükay, F. "Optimal and prototype dimensioning of 48V P0+P4 hybrid drivetrains." Automotive Engine Technology, 5: 173-186, 2020. DOI: 10.1007/s41104-020-00071-0.

He, Yu, et al. "Real-Time Torque-Split Strategy for P0+P4 Mild Hybrid Vehicles With eAWD Capability." IEEE Transactions on Transportation Electrification, 8(1): 1401-1413, 2022. DOI: 10.1109/TTE.2021.3103149.

Gillespie, Thomas. Fundamentals of Vehicle Dynamics. Warrendale: Society of Automotive Engineers International, 2021.

FENABRAVE. Informativo FENABRAVE Emplacamentos Dezembro 2023. 2024. Available at: https://www.fenabrave.org.br/portalv2/Conteudo/emplacamentos. Accessed on: 22 out. 2024.

Fiat. Toro - Manual de uso e manutenção. Brasil, 2023. Available at: https://servicos.fiat.com.br/content/dam/fiat/products/handbooks/226/2023/handbook-toro-2023_2023.pdf. Accessed on: 26 mar. 2024.

Lang, Fernando. "Inclinações das ruas e das estradas." Revista Física na Escola, V, 2007. Instituto de Física da UFRGS.

Szente, Márk. "Slip Calculation and Analysis for Four-wheel Drive Tractors." Járm?vek és Mobilgépek, V: 404-424, 2009. DOI: 10.1556/Progress.1.2005.1.2.

Ehsani, Mehrdad, Gao, Yimin, and Longo, Stefano. Modern Electric, Hybrid Electric & Fuel Cell Vehicles. New York: CRC Press, 2018.

Bilgin, Berker, and Emadi, Ali. "Electric Motors in Electrified Transportation: A step toward achieving a sustainable and highly efficient transportation system." IEEE Power Electronics Magazine, 1(2): 10-17, 2014. DOI: 10.1109/MPEL.2014.2312275.

Parreiras, Thiago M., et al. "Field Weakening Strategies to Suppress Intermediate DC-DC Conversion Stages in Hybrid Construction Machinery." In 2022 IEEE Transportation Electrification Conference and Expo, Asia-Pacific (ITEC Asia-Pacific), 1-6, 2022. DOI: 10.1109/ITECAsia-Pacific56316.2022.9942183.

EMRAX. 228 Datasheet. Eslovênia, 2020. Available at: https://emrax.com/wp-content/uploads/2024/02/EMRAX_228_datasheet_v1.5.pdf. Accessed on: 26 mar. 2024.

EMRAX. 268 Datasheet. Eslovênia, 2020. Available at: https://emrax.com/wp-content/uploads/2024/02/EMRAX_268_datasheet_v1.5.pdf. Accessed on: 26 mar. 2024.

WEG. Soluções em mobilidade elétrica. Brasil, 2019. Available at: https://www.weg.net/institutional/BR/pt/solutions/e-pwt. Accessed on: 20 mar. 2024.

Parker. GVM Global Vehicle Motor. EUA, 2022. Available at: https://www.parker.com/content/dam/Parker-com/Literature/Electromechanical-Europe/Literature/192_300108_GVM_catalogue.pdf. Accessed on: 22 out. 2024.

BorgWarner. iM-225 (Integrated module). EUA, 2024. Available at: https://cascadiamotion.com/images/catalog/DataSheets/im225.pdf. Accessed on: 22 out. 2024.

A123Systems. Nanophosphate® Lithium Ion Prismatic Pouch Cell. EUA, 2011. Available at: [https://www.buya123products.com/uploads/vipcase/468623916e3ecc5b

ANSI/AGMA-2001-D04. Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth. Alexandria, Virginia: AGMA STANDARD, 2004.

Jusbrasil. Pneu reserva é obrigatório? Conheça a lei e entenda as exceções. 2018. Available at: https://www.jusbrasil.com.br/artigos/pneu-reserva-e-obrigatorio-conheca-a-lei-e-entenda-as-excecoes/. Accessed on: 21 abr. 2024.

Canal da Peça. Novo motor 1.3 turbo da Fiat gera 185 cv!. 2021. Available at: https://www.canaldapeca.com.br/blog/novo-motor-1-3-turbo-da-fiat-gera-185-cv/. Accessed on: 21 abr. 2024.

Kyocera. SCC LE Series Low ESR Cylindrical SuperCapacitors. 2023. Available at: https://datasheets.kyocera-avx.com/AVX-SCC-LE.pdf. Accessed on: 22 out. 2024.