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Articol Conversie Electrica
Articol Conversie Electrica
Danciu, Grigore*
University "Politehnica", Faculty of Transportation
313, Splaiul Independentei, Bucharest, Romania, mail: danciu@ieee.org, mobile:+40-723.389.045
ABSTRACT
This paper presents a design study for electrification of a Utility Task Vehicle (UTV). It starts with
the state-of-the-art and motivations for UTV. Then, it presents a design model for the vehicle
electrification, based on the dynamic model of the power-train. Many implementation solutions are
discussed. Based on this model, a practical selection is done, concerning the necessary equipment:
motor, controller, transmission, battery, and charger. Conclusions present a short analysis of this
design.
1 Introduction
Environmental protection by using renewable energy and mainly in its electrical form is a must of
our society, as presented in EU-Directive (2009), by International Energy Agency-IEA (2015) or
Romanian Ministry of Environment (2012). On the other hand, mobility is also a must with a very
fast growing. Combining these, the rational towards the move to electrical mobility is now well
described in a large number of documents and trends can be summarized by the following points:
Radical cut of green‐house gas (GHG) emissions all across Europe, independently from
where and how the electricity is produced. With respect to the internal combustion engine vehicles
(ICEV), comparable electric vehicles (EVs) would achieve on average up to 50% GHG reduction
per equal kilometers run. This reduction is very likely to remain stable all along the forthcoming
decade, which makes that by 2020 both the 95gCO2/km target per average fleets based on ICEVs
only and the EU-Directive (2009) on Renewable Energies will be met only with EV contribution;
Cancellation of noxious emissions in cities recognized to be the cause of a higher number of
deaths than those caused by road fatalities (in EU of the order of 35.000/Year);
Avoid the use of the most critical primary energy source (petroleum);
Rapid convergence of the technologies developed for renewable energy with those adopted
for electrical mobility (power electronics, energy storage, etc.);
Either first generation bio‐fuels or third generation ones (algae), have not been proved to
have a Life Cycle satisfactory positive energy balance and appear to be desperate solutions against
the challenges posed by oil. While technologies to low cost cellulosic bio-ethanol (second
generation bio‐fuels), although having a rather positive energy return, they still need to be further
developed before they could meet the cost parity with petroleum based fuels;
Further improvements of ICEs are possible, but another 5% improvement of the peak
efficiency will not change the challenge posed by liquid fuels whose world demand are supposed to
grow on average 1.3%/year until 2035, as presented by IEA(2015);
In the year 2000, Light Electrical Vehicles (LEVs) such as bicycles, scooters, tricycles,
mopeds, quad‐cycles, and UTVs accounted for a global production of the order of 100.000 per year
while in the 2015 they are expected to be produced in several tens of millions per year. To support
these developments there is an ongoing replacement of lead‐acid batteries with much more efficient
and cleaner technologies, like Li‐ion; China, Korea, and Japan are rolling out large scale
production, addressing manufacturing cost issues;
LEVs are now evolving to micro cars and conventional mid‐sized cars. European companies
will then be exposed to a novel vertically organized supply chain supported by large nations where
regulations are made by fast acting Governmental Institutions. This is having and will have an ever
increasing impact on the relations amongst Tier1‐2 suppliers and OEMs, which is likely to be
reflected on heavy industrial restructuring. European industries are then faced to manage the effects
caused by this radical change of the supply chain adopting quickly and properly sized competing
instruments that could avoid the move of the European productions to the new high tech countries;
The demand of new forms of mobility is spreading all over the world reflecting people
awareness on the ever increasing problems to provide primary energy and raw materials, on climate
change, and on the impact of noxious emissions on health. Rather than offering forms of mobility
based on ever increasing prices, the industry is now faced to satisfy a rationale demand of mobility.
Not only clean, low energy consume, and safe vehicles, but it needs vehicles requiring less energy
to be produced, using recyclable and eventually self disposable materials‐systems.
In this context, the present paper proposes a study of Utility Task Vehicle (UTV) electrification.
Detailed information and pictures for UTV may be found at dealers or producers as UTVGuide
(2015), Polaris (2015) or TITANUTV (2015). UTV is known also as Side by Side or Recreational
Off-road Vehicle (ROV) and is bigger than ATV (All-Terrain Vehicle), has a higher payload
capability (400 to 800kg) and a side-by-side seating arrangement, with roll-over protection. It has a
lot of applications but some are in urban locations such maintenance works in gardens and car
parks, streets and industrial locations, sport and recreational activities, etc. In such applications, a
dedicated EV is the best solution, but in some case an acceptable solution could be the
electrification or retrofitting of an existing ICEV.
2 Electrification design
B 2.1 Architecture
B
The power-train of a full electric vehicle (FEV) which is
the case of this study could have a very flexible
C architecture, as presented by Racicovschi, Danciu and
Chefneux (2007). The figure 2.1a presents the simplest
C S C
M solution, where power electrical link is with solid line,
low power coordination is with dash line, and
M M mechanical link is with double line. It is similar to the
R
ICEV propulsion. The driving axle has the usual
differential, D. It is mechanically coupled with the
D R R reduction gear, R. Usually it has a fix reduction ratio, but
the new trend is to use a two steps gear. The electric
a)With differential; b)Independent driving wheels
machine, M, is reversible and works both as motor and
B-battery; C-controller; M-motor;
R-reduction gear; D-differential generator. It was initially a DC machine, but the trend is
to replace it with an AC machine such:
Fig.2.1.EV architectures i) a permanent magnet (PM) synchronous
machine fed with sinus currents (vector controlled) or
with rectangular currents, known as Brushless DC. In the first case the control algorithm is more
complex and needs a high resolution position transducer, but has a higher efficiency and lower
torque ripple.
ii) an induction machine which is cheap and very robust, but has a complex control
algorithm(vector controlled) and position transducer.
iii) a switched reluctance machine which is the most robust and cheap but has some
disadvantages in specific torque and power, and torque ripple. It is not widely used.
Always, the electric machine is fed by a digital controller, C. It controls the torque by controlling
the currents and thus controls the position, speed and acceleration. It also monitors and controls the
machine status (temperature, maximum torque, etc.). Finally, the energy source or storage, B,
could usually be a rechargeable battery, a supercapacitor, or a fuel cell. This paper does not discuss
catenary solutions. The batteries are the main supply solution. Despite the lithium chemistry is
widely used on cars and buses, many electric UTVs still use lead batteries. In figure 2.1.b, the
mechanical differential is replaced by independent driving wheels. Each wheel has a gear, motor
and controller, supplied from the same storage. The axle’s wheels are coordinated by a supervisor,
S, which commands the two controllers. It can implement, also, advanced dynamic strategies such
ABS/ASR/ESP functions, thus increasing the axle effectiveness. Other solutions are possible, too.
One could present two driving axles, each having a differential, a gear and a motor with controller,
supplied from the same battery. The two controllers are coordinated by a supervisor. Other solution
could have four independent driving wheels, each having a gear and a motor with controller,
supplied from the same battery and coordinated by a single supervisor, etc.
2.2.4 Battery
Concerning batteries, different chemistries are available, but the majority of new UTV designs use
lead or lithium technologies. The lithium battery has a much higher specific energy and power, but
is very expensive and more delicate in exploitation, concerning vibration resistance, cooling,
balancing, etc. Battery selection has the following steps:
a) Selection of the battery technology;
b) Calculation of the units’ number (cells or modules), N. Usually the manufacturers offer two
solutions: individual cells or battery modules, composed of many cells internally connected. The
rated voltage of the cell depends of the technology. For instance, Li-NMC oxide cell (short from
nickel, manganese and cobalt) has 3.7V, LiFePO4 has 3.2V, and lead has 2V/cell. The rated module
voltage, VN1, could be 6V, 12V or higher. The total necessary battery voltage, VDC, is given by the
controller-motor producers as presented in paragraph 2.2.3. It results:
N = VDC / VN1 (2.15)
c) The battery capacity (or energy) is calculated considering that the necessary battery energy is
used for propulsion and for auxiliary services like lighting, heating, servo, etc.
Wnec = Wprop + Waux (2.16)
c1)The necessary propulsion energy, Wprop, is usually calculated based on the given range
on a horizontal road, at constant speed, close to the average traffic speed, vtraffic . Usually, this
speed is 50-60% of the maximum speed. For instance, for a car with vmax= 100km/h, vtraffic
=60km/h. A more complicated cycle model could be used, but this solution needs a computer model
and is not considered here. Consequently, the propulsion energy for the range, S, and constant
speed, vtraffic, measured respectively in [kWh], [km], [km/h], is:
Wtraffic = S * Tpvtraffic /3600 (2.17)
where Tpvtraffic is the traction force corresponding to the vehicle resistances at traffic speed,
vtraffic. It results by replacing vh-max with vtraffic in relation (2.6). Considering the efficiencies of the
motor, controller and transmission, respectively ηm, ηc and ηt, the propulsion energy is:
𝑊
𝑊𝑝𝑟𝑜𝑝 = 𝜂 𝑡𝑟𝑎𝑓𝑓𝑖𝑐 (2.18)
𝑚 𝑐 ∗𝜂 ∗𝜂
𝑡
c2)The auxiliary energy depends of the necessary average power, Paux and the travel
duration, ts for the range S, and speed vtraffic :
ts = S/vtraffic , Waux = Paux * ts (2.19a)
d)On the other hand, the working cycle of a battery does not involve all its capacity. A full charge
of the battery, especially at lithium could overheat the battery. A deep discharge can also damage
the battery. Consequently each battery has maximum and minimum acceptable values for the depth
of discharge (DOD) coefficients. Usually, for lithium DODmax is about ~0.8 (discharged) and
DODmin ~ 0.1(fully charged), but for lead the range is higher. It results:
𝑊
𝑊𝑡𝑜𝑡 = 𝐷𝑂𝐷 𝑛𝑒𝑐 (2.20)
−𝐷𝑂𝐷
𝑚𝑎𝑥 𝑚𝑖𝑛
e)The battery capacity measured in [Ah] can be obtained as:
Ctot = 1000*Wtot/VDC (2.21)
Special attention must be paid to the battery location to avoid safety problems (explosion or electric
shocks) especially in the event of an accident, and axles’ loading balance.
2.2.5 Charger and BMS
The new battery technologies, and especially lithium, need a special attention to control and
monitor the battery. This is made by an electronic device, known as Battery Management System
(BMS). It measures the current, voltages and temperatures for each cell or module and
communicates with the charger and controller in order to keep an appropriate battery state and to
extend battery life. It also does the
Dimensions (LxWxh) cm 297x147x185(108"x56.5"x73")
Engine power kW 21.6(29HP) 455cc-1 cylinder necessary periodic balance of the
Dry mass kg 476 (1050lbs) battery elements. Usually BMS is
Max. payload Kg 454 (1000lbs) recommended by the battery producer
Towing rating kg 567(1250lbs) or even is incorporated in the battery
Tires Front/Rear 25 x 8-12; 25 x 10-12 unit.
Ground clearance cm 25.4 (10”) The on-board charger is also
Top speed km/h 64 (40mph)
recommended by the controller
Transmission Automatic PVT
Table 3.1. Ranger 400 parameters from UTVGuide (2015) manufacturer or the battery producer.
Its principal parameters are: cooling
and charging methods, rated input voltage and current, rated output voltage and current and the
maximum and minimum values for these, battery technology, charging algorithm permitted, etc.
For this purpose of this exercise it was selected a very popular UTV, Polaris Ranger 400, model
2012, available on Romanian market, too. Its principal specifications are given in table 3.1, based
on UTVGuide (2015) information. For this exercise, a simple electrification solution was to replace
the conventional power-train with an electrical one, keeping the original architecture. That is to
replace the engine and gear box with a motor and reduction gear, and fuel supply system (tank,
pump, etc) with batteries and charger.
5 References
Gillespie, T.D. (1992) Fundamentals of Vehicle Dynamics”. Warrendale, PA: SAE
RACICOVSCHI, V. et al. (2007) Electric and Hybrid Vehicles (in Romanian). Bucharest: Electra
http://www.oerlikon.com/graziano/en/products/automotive/transfer-cases-for-full-electric-zero-
emission-vehicles-2/ consulted 10-Oct-2015
http://www.autoevolution.com/moto/polaris-ranger-400-2009.html#aeng_polaris-ranger-400-2009-455
consulted on 12-Oct-2015
http://www.renault.fr/gamme-renault/vehicules-electriques/twizy/twizy/caracteristiques-
techniques.jsp consulted on 12-Oct-2015