Design and Development of Series-Hybrid Automotive Powertrains

The new global pandemic determines people to change their ordinary habits, so personal transportation will play a very important role for a long period of time from now on. However, even though conventional vehicles offer enough range for replacing some trips that normally would be covered by planes, they have a harmful impact on the environment. By comparison, Electric Vehicles (EVs) suffer from this shortcoming (insufficient range), being more expensive, as well. Therefore, this article presents a very simple, unique and inexpensive methodology for designing the powertrain of a plug-in series-hybrid vehicle, based on measurements (regarding the engine torque requirements, but not limited to) performed on a compact passenger car, during real driving conditions, as well as based on mathematical calculations and computer-aided simulations (using MATLAB Simulink). The parameters of the proposed series-hybrid driving system which have been determined refer to the specifications of the Internal Combustion Engine (ICE) which is used to drive a generator, the rated output power of the electric generator, the required capabilities of the electric motor which is used to drive the wheels, the capacity of the high voltage battery pack (which supplies the electric motor), together with its other attributes, taking into consideration the vehicle's overall performance and characteristics. Besides this, it has been developed a very simple algorithm that manages the power generated by the engine and which can reduce the fossil fuel consumption with almost 38%, on average, compared to a conventional drivetrain.