Final Presentation                 Group 5: The Wolf Pack                      Anthony Tawaf     S3194049                ...
   To minimise Mercedes Benz E-Class CO2 Emissions    2016 target = 137 g/km to ensure adherence to    Euro-6 legislative...
◦ Top Speed ≈ 250 km/hr◦ Acceleration (from 0-100 km/hr) ≈ 6.3s◦ Driving Range ≈ 500km◦ Maintain the signature E-Class “lo...
   Series Architecture    ◦ Zero emission driving range    ◦ Engine operates @ maximum operating efficiency    ◦ Packagin...
◦ x2 Electric Motors = AWD                                            Electric Motor Performance              350         ...
Ach Nein…Thank God it’s AWD!     Samuel Sainty – S3345524   14nd of May, 2012   6
       Gear Reduction = 5.91                                                                    Total Wheel Torque       ...
       Gear Reduction = 5.91                                                                    Total Wheel Torque       ...
   Based off Mahle Range Extender ICE /    Generator Package    ◦ Fuel Consumption = 280 g/kWh    ◦ 40 kW @ 4000rpm    ◦ ...
   Li-Ion Battery chosen is from SAFT VL 34 P.   The VL 34 P Li-Ion Battery offers advantages in    terms of charging/di...
   To achieve the requirement of the electric motors    the batteries are arranged in a way to achieve    voltage and cur...
   It is required to buck/boost the voltage for the    battery and the electric motor. The converter has    the ability t...
OPTIONAL                                       GENERATOR                                REGENERATIVE                      ...
Figure 2: Control Flowchart Engine On–Off or Thermostat Control Strategy                                                  ...
1000                                   European Drive Cycle @ 26.53%                                                      ...
State Of Charge for 55 NEDC.                     20000                                                                    ...
Original Mass = 1689 kg               Anthony Tawaf– S3194049   14nd of May, 2012   17
Hybrid Mass = 1990 kgdifferences of 299 kg               Anthony Tawaf– S3194049   14nd of May, 2012   18
Original                                                 HYBRID                   Cost €   Mass (kg)                      ...
Design Aim                            Value                     AccomplishedEmissions                          54.4 CO2g/k...
Design Aim                            Value                     AccomplishedEmissions                          54.4 CO2g/k...
Design Aim                            Value                     AccomplishedEmissions                          54.4 CO2g/k...
Design Aim                            Value                     AccomplishedEmissions                          54.4 CO2g/k...
Design Aim                            Value                     AccomplishedEmissions                          54.4 CO2g/k...
Design Aim                            Value                     AccomplishedEmissions                          54.4 CO2g/k...
Design Aim                            Value                     AccomplishedEmissions                          54.4 CO2g/k...
Design Aim                            Value                     AccomplishedEmissions                          54.4 CO2g/k...
Design Aim                            Value                     AccomplishedEmissions                          54.4 CO2g/k...
Design Aim                            Value                     AccomplishedEmissions                          54.4 CO2g/k...
◦ http://www.hybridcarblog.com/2009/11/nimh-hybrids-long-way-from-dead.html◦ http://about-auto-and-trucks.blogspot.com.au/...
Anthony Tawaf– S3194049   14nd of May, 2012   31
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Final Presentation[Final]

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Postgraduate Project 1 done by me and my research group at School of Aerospace, Mechanical, and Manufacturing Engineering.

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Final Presentation[Final]

  1. 1. Final Presentation Group 5: The Wolf Pack  Anthony Tawaf S3194049  Abdul Alidin s3313307  Nicholas Reisis S3336270  Samuel Sainty S3345524Auto 1027 – Automotive Project 1
  2. 2.  To minimise Mercedes Benz E-Class CO2 Emissions 2016 target = 137 g/km to ensure adherence to Euro-6 legislative standards. To upgrade the Mercedes Benz E-Class Powertrain system utilising current technologies implementing a Hybrid system. The design must comply with Mercedes Benz E-Class “Einspritzmotor”, core values. The design must comply with Mercedes Benz E-Class customer values. Samuel Sainty – S3345524 14nd of May, 2012 2
  3. 3. ◦ Top Speed ≈ 250 km/hr◦ Acceleration (from 0-100 km/hr) ≈ 6.3s◦ Driving Range ≈ 500km◦ Maintain the signature E-Class “look”;◦ High level of safety, reliability, build and ride quality;◦ Maintain rear wheel drive; and,◦ Minimise NVH. Samuel Sainty – S3345524 14nd of May, 2012 3
  4. 4.  Series Architecture ◦ Zero emission driving range ◦ Engine operates @ maximum operating efficiency ◦ Packaging versatility Samuel Sainty – S3345524 14nd of May, 2012 4
  5. 5. ◦ x2 Electric Motors = AWD Electric Motor Performance 350 200 300 250 150Torque (Nm) Power (kW) 200 100 150 100 50 50 Power to Accelerate Power for Top Speed 0 0 0 2000 4000 6000 8000 10000 12000 14000 Engine RPM Torque Power Power to Accelerate Power for Top Speed Samuel Sainty – S3345524 14nd of May, 2012 5
  6. 6. Ach Nein…Thank God it’s AWD! Samuel Sainty – S3345524 14nd of May, 2012 6
  7. 7.  Gear Reduction = 5.91 Total Wheel Torque 4000 Maximum Wheel Torque = 3570 Nm 3500 → Acceleration = 6 m/s2 3000Wheel Torque (Nm) 2500 2000 1500 1000 500 0 0 500 1000 1500 2000 2500 Wheel RPM 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear 7th Gear Electric Powertrain Samuel Sainty – S3345524 14nd of May, 2012 7
  8. 8.  Gear Reduction = 5.91 Total Wheel Torque 4000 Maximum Wheel Torque = 3570 Nm 3500 → Acceleration = 6 m/s2 3000Wheel Torque (Nm) 2500 2000 1500 1000 500 0 0 500 1000 1500 2000 2500 Wheel RPM 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear 7th Gear Electric Powertrain Samuel Sainty – S3345524 14nd of May, 2012 8
  9. 9.  Based off Mahle Range Extender ICE / Generator Package ◦ Fuel Consumption = 280 g/kWh ◦ 40 kW @ 4000rpm ◦ Inline Triple ◦ 1000 cc ◦ 95 Octane Fuel Samuel Sainty – S3345524 14nd of May, 2012 9
  10. 10.  Li-Ion Battery chosen is from SAFT VL 34 P. The VL 34 P Li-Ion Battery offers advantages in terms of charging/discharge times. This enables the E-class to achieve 0-100km in 6s and a top speed of 250km/h. Nicholas Reisis– S3336270 14nd of May, 2012 10
  11. 11.  To achieve the requirement of the electric motors the batteries are arranged in a way to achieve voltage and current requirements. The generator regulated output is 400V and 60A therefore there are 2 batteries in parallel and 8 units in series to supply power to the motors. Nicholas Reisis– S3336270 14nd of May, 2012 11
  12. 12.  It is required to buck/boost the voltage for the battery and the electric motor. The converter has the ability to buck/boost 300V to 500V. The Mercedes E-class control system will control the direction of converter depending on the SOC. Nicholas Reisis– S3336270 14nd of May, 2012 12
  13. 13. OPTIONAL GENERATOR REGENERATIVE BRAKING CONTROL CIRCUIT ALREADY INCLUDEDFigure 1: AC Propulsion electrical system / components[4] 13 Abdul Qaiyum– S3313307 14nd of May, 2012
  14. 14. Figure 2: Control Flowchart Engine On–Off or Thermostat Control Strategy Table 2: Generator Performances Table 1: Generator Operating Voltage Operating VoltagePerformance NominalPeak power 100 hp 75 kW battery input 270 to 336 VDCContinuous power 60 hp 45 kW rangePeak torque 176 lbf·ft 240 N·m OperatingContinuous torque 110 lbf·ft 150 N·m voltage input 250 to 400 VDCMaximum speed 8000 RPM rangeMaximum efficiency 94% Minimum 180 VDC (with deratedPower density (based on 75 kW) 1.11 hp/lb 1.83 kW/kg voltage limit power output) Input current limitation RMIT University©2011 A 400 14
  15. 15. 1000 European Drive Cycle @ 26.53% Regen Without Regen 800 With RegenEnergy (Whr) 600 NEDC No Regen = 996.88 Wh 400 NEDC With Regen = 732.25 Wh 200 0 0.0 23.3 53.3 86.7 120.0 133.3 160.0 206.7 236.7 263.3 303.3 330.0 350.0 383.3 423.3 460.0 470.0 526.7 540.0 566.7 596.7 636.7 666.7 700.0 733.3 746.7 773.3 820.0 920.0 1046.7 1130.0 Time (s) Anthony Tawaf– S3194049 14nd of May, 2012 15
  16. 16. State Of Charge for 55 NEDC. 20000 90% 18000 33.3 km 168 km 16000 Charge DischargeBattery Power KWhr 14000 12000 10000 8000 6000 4000 20% 2000 0 Range Max = 605 km 0 100 200 300 400 500 600 Km Worst Case @ 40% Reduction = 363 km Approx. Ave = 484 km Anthony Tawaf– S3194049 14nd of May, 2012 16
  17. 17. Original Mass = 1689 kg Anthony Tawaf– S3194049 14nd of May, 2012 17
  18. 18. Hybrid Mass = 1990 kgdifferences of 299 kg Anthony Tawaf– S3194049 14nd of May, 2012 18
  19. 19. Original HYBRID Cost € Mass (kg) Cost € Mass (kg) ICE 21000 165 ICE + Gen 3500 77 Trans 7000 80 Electric Motor x 2 4200 130 Tail shaft 1400 20 Diff x 2 3000 80Driveshafts x 2 2800 40 Driveshafts x 4 4000 80 Diff 2100 40 Exhaust 1500 50 Exhaust 3500 60 DC/DC Convertors x 2 150 20 Fuel + 70lt 2100 80 Fuel + 18lt 1000 25 Wiring 1400 25 Invertor 0 39 Reduction 20650 510 Battery Pack include Packaging 30240 270 Total 66000 1540 Wiring 5000 50Power train Bare 45350 1030 Total 52590 821 Percent 31% New Hybrid Cost 97940 1851 Anthony Tawaf– S3194049 14nd of May, 2012 19
  20. 20. Design Aim Value AccomplishedEmissions 54.4 CO2g/kmFuel Consumption 2.45 L/100kmTop Speed > 250 km/hrAcceleration (0 - 100 km/hr) < 6.3 sDriving Range 484 kmVehicle Mass 1854 kg - Einspritzmotor - SafetyMaintain Customer Values - Reliability - NVHPackaging More RoomVehicle Life > 15 years Anthony Tawaf– S3194049 14nd of May, 2012 20
  21. 21. Design Aim Value AccomplishedEmissions 54.4 CO2g/kmFuel Consumption 2.45 L/100kmTop Speed > 250 km/hrAcceleration (0 - 100 km/hr) < 6.3 sDriving Range 484 kmVehicle Mass 1854 kg - Einspritzmotor - SafetyMaintain Customer Values - Reliability - NVHPackaging More RoomVehicle Life > 15 years Anthony Tawaf– S3194049 14nd of May, 2012 21
  22. 22. Design Aim Value AccomplishedEmissions 54.4 CO2g/kmFuel Consumption 2.45 L/100kmTop Speed > 250 km/hrAcceleration (0 - 100 km/hr) < 6.3 sDriving Range 484 kmVehicle Mass 1854 kg - Einspritzmotor - SafetyMaintain Customer Values - Reliability - NVHPackaging More RoomVehicle Life > 15 years Anthony Tawaf– S3194049 14nd of May, 2012 22
  23. 23. Design Aim Value AccomplishedEmissions 54.4 CO2g/kmFuel Consumption 2.45 L/100kmTop Speed > 250 km/hrAcceleration (0 - 100 km/hr) < 6.3 sDriving Range 484 kmVehicle Mass 1854 kg - Einspritzmotor - SafetyMaintain Customer Values - Reliability - NVHPackaging More RoomVehicle Life > 15 years Anthony Tawaf– S3194049 14nd of May, 2012 23
  24. 24. Design Aim Value AccomplishedEmissions 54.4 CO2g/kmFuel Consumption 2.45 L/100kmTop Speed > 250 km/hrAcceleration (0 - 100 km/hr) < 6.3 sDriving Range 484 kmVehicle Mass 1854 kg - Einspritzmotor - SafetyMaintain Customer Values - Reliability - NVHPackaging More RoomVehicle Life > 15 years Anthony Tawaf– S3194049 14nd of May, 2012 24
  25. 25. Design Aim Value AccomplishedEmissions 54.4 CO2g/kmFuel Consumption 2.45 L/100kmTop Speed > 250 km/hrAcceleration (0 - 100 km/hr) < 6.3 sDriving Range 484 kmVehicle Mass 1854 kg - Einspritzmotor - SafetyMaintain Customer Values - Reliability - NVHPackaging More RoomVehicle Life > 15 years Anthony Tawaf– S3194049 14nd of May, 2012 25
  26. 26. Design Aim Value AccomplishedEmissions 54.4 CO2g/kmFuel Consumption 2.45 L/100kmTop Speed > 250 km/hrAcceleration (0 - 100 km/hr) < 6.3 sDriving Range 484 kmVehicle Mass 1854 kg - Einspritzmotor - SafetyMaintain Customer Values - Reliability - NVHPackaging More RoomVehicle Life > 15 years Anthony Tawaf– S3194049 14nd of May, 2012 26
  27. 27. Design Aim Value AccomplishedEmissions 54.4 CO2g/kmFuel Consumption 2.45 L/100kmTop Speed > 250 km/hrAcceleration (0 - 100 km/hr) < 6.3 sDriving Range 484 kmVehicle Mass 1854 kg - Einspritzmotor - SafetyMaintain Customer Values - Reliability - NVHPackaging More RoomVehicle Life > 15 years Anthony Tawaf– S3194049 14nd of May, 2012 27
  28. 28. Design Aim Value AccomplishedEmissions 54.4 CO2g/kmFuel Consumption 2.45 L/100kmTop Speed > 250 km/hrAcceleration (0 - 100 km/hr) < 6.3 sDriving Range 484 kmVehicle Mass 1854 kg - Einspritzmotor - SafetyMaintain Customer Values - Reliability - NVHPackaging More RoomVehicle Life > 15 years Anthony Tawaf– S3194049 14nd of May, 2012 28
  29. 29. Design Aim Value AccomplishedEmissions 54.4 CO2g/kmFuel Consumption 2.45 L/100kmTop Speed > 250 km/hrAcceleration (0 - 100 km/hr) < 6.3 sDriving Range 484 kmVehicle Mass 1854 kg - Einspritzmotor - SafetyMaintain Customer Values - Reliability - NVHPackaging More RoomVehicle Life > 15 years Anthony Tawaf– S3194049 14nd of May, 2012 29
  30. 30. ◦ http://www.hybridcarblog.com/2009/11/nimh-hybrids-long-way-from-dead.html◦ http://about-auto-and-trucks.blogspot.com.au/2011/04/electric-car-batteries-how-well-do- they.html◦ http://www.ecofriend.com/entry/eco-tech-li-ion-batteries-to-get-safe-and-cheap-with-a- change-in-their-chemistry/◦ http://astrobotic.net/2010/12/01/new-dcdc-converters-for-the-red-rover-successfully- integrated/◦ http://www.evassemble.com/index.php?main_page=product_info&cPath=17_18&products_id=1 30◦ Wikipedia, “File: Hybrid Peak.png”, http://en.wikipedia.org/wiki/File:Hybridpeak.png, March 2012◦ Koopmans, L. “AUTO1027 – Automotive Project: Lecture Slides, Weeks 1-5”, RMIT University◦ http://www.ecofriend.com/mercedes-unveils-electric-drivetrain-sls-amg-cell.html◦ http://www.sim-drive.com/english/technology/index.html◦ Lino Guzzela, Antonio Sciarretta, “Vehicle Propulsion Systems, Introduction to modelling and optimization”, Springer, Verlag Berlin Heidelberg Germany, ISBN-13 978-3-540-25195-8, 2005◦ http://www.google.com.au/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&ved=0CCYQFjAA&u rl=http%3A%2F%2Fwww.midmichigansae.org%2Fdocuments%2FDrGoverPresentationSAEApril20.p df&ei=Uw14T6CJF4ePiAfp4Y2FBQ&usg=AFQjCNFpo5iowEyRZqa_fjTZ6K5NhUD9Dg Anthony Tawaf– S3194049 14nd of May, 2012 30
  31. 31. Anthony Tawaf– S3194049 14nd of May, 2012 31

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