SEMINAR REPORT

J S EPSILON PANDA
“MILD HYBRID VEHICLE SYSTEM, AND IT’S
NATIONAL INSTITUTE OF
IMPACT ON FUEL CONSUMPTION, AND
TECHNOLOGY, WARANGAL
ENVIRONMENT.”
Roll Number: 193706
Registration Number: ME19706
M Tech 1st Year

Specialization: Automobile
Engineering

Branch: Mechanical
Engineering

9668583839

11-Oct-19
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Abstract:
With the advancement in 21st Century, there has been increase in usage of Oil
and Gas leading to problems like Global Warming, climate change, shortage of
crude oil, etc. Due to these reasons Automobile Companies have started doing
Research, for making Hybrid Technology, usable into the daily life. The Paper
starts from brief history about Hybrid Technology and also some brief
introduction on it. Conventional vehicles use gasoline or diesel to power an
internal combustion engine. Hybrids also use an internal combustion engine and
can be fueled like normal cars but have an electric motor and battery, and can be
partially or wholly powered by electricity. Hybrid cars can be configured to obtain
different objectives, such as improved fuel economy, increased power, or
additional auxiliary power for electronic devices and power tools. Many
technologies like regenerative braking, electric motor drive, automatic start or
shutoff are being used in hybrid cars to make them as good as conventional
vehicles. It basically focuses on the usage, implementation, and result as “Smart
Hybrid Vehicle System” (SHVS), a mild hybridization of a conventional IC Engine,
more commonly known as “ Mild Hybrid Vehicle System”, in Maruti Suzuki cars,
such as:- ERTIGA, The New CIAZ, S-Cross , The new Baleno and XL 6. Paper
concludes on the advantages and dis-advantages of Hybrid Cars and how this
technology will take over the world in future and would become the alternative
for Petrol and Diesel Cars.
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Contents

Topics Pages
1. Introduction …………………………………………………………………………………………………………………………….………….3

2. Configuration, Main Issues and Controls of HEVs………………………………………………………………………………..5

2.1 Configuration of HEVs………………………………………………………………………………………………………………………..5

2.1.1 Configuration of Series HEVs…………………………………………………………………………………………………………..7

2.1.2 Configuration of Parallel HEVs…………………………………………………………………………………………………………7

2.1.3 Configuration of Combination HEVs…………………………………………………………………………………………….….7

2.2 Main Issues of HEVs…………………………………………………………………………………………………………………………..7

2.3 Controls of HEVs………………………………………………………………………………………………………………………………..8

3. Smart Hybrid Vehicle by Suzuki …………………………………………………………………………………………………………11

3.1 Advantage of SHVS ………………………………………………………………………………………………………………………….15

3.2 Use of SHVS in Maruti Suzuki Ciaz…………………………………………………………………………………………………. 16

4. Conclusion………………………………………………………………………………………………………………………………………. 17

5. References………………………………………………………………………………………………………………………………………. 17
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1. INTRODUCTION
In today’s fast developing world, air pollution is rapidly increasing and affecting most of the
major cities of the world. These increased is mainly due to the emission of carbon dioxide and
other toxic gases from the vehicles which leads to gradual increasing in global warming. And
also demand for utilization of fossil fuels is increasing at a greater rate as the use of vehicles is
fast growing. In order to overcome and minimize these criteria hybrid engines were introduced.
A hybrid vehicle is a vehicle that uses two or more distinct power sources to move the vehicle.
The term most commonly refers to hybrid electric vehicles (HEVs), which combine an internal
combustion engine and one or more electric motors. A hybrid vehicle uses multiple propulsion
systems to provide motive power. The most common type of hybrid vehicle is the gasoline-
electric hybrid vehicles, which use gasoline (petrol) and electric batteries for the energy used to
power internal combustion engines (ICEs) and electric motors. These motors are usually
relatively small and would be considered "underpowered" by themselves, but they can provide
a normal driving experience when used in combination during acceleration and other
maneuvers that require greater power. The presence of the electric power train is intended to
achieve either better fuel economy than a conventional vehicle or better performance.

In 1834, the first vehicle, actually a tricycle, powered by battery, was developed. But with the
improvement in the internal combustion engine (ICE), ICE vehicles (conventional vehicles) have
occupied an absolute share in the market; pure electric vehicles (PEVs) have almost
disappeared since 1930’s. If all vehicles are powered by internal combustion engines, the
gasoline and diesel oil will be depleted quickly, and the emission will result in green house
effect. So, the energy conservation and environmental protection are growing concerns around
the world.

It is reported that vehicles emission accounts for 39.2% of the total emission in 2007 ; there
must be a drastic reduction in emission if humans want to avoid catastrophic greenhouse
effect, thus the governments all over the world adapt strict emission regulations, for example,
Emission Standard of Automobile of Europe IV Standard has been put in practice in Europe
since 2005 . Meanwhile, fuel duty taxes were imposed by government; higher crude oil price
plus fuel duty taxes result in higher fuel prices. So, Automobile Company sis forced to develop
EV for low-emission and high-fuel economy under laws and market together.

EV is a road vehicle which involves with electric propulsion . EV can be classified into three
types: pure electric vehicles (PEVs), hybrid electric vehicles (HEVs), and fuel cell electric vehicles
(FCEVs). Today, they are in different stages of development due to existing technology. We can
see that electric motor drives technique, in which the field-oriented control (FOC) and variable-
voltage variable frequency (VVVF) are adapted widely, is the common technique in EV. The
battery initial cost and battery management create bottleneck in PEVs in spite of zero emission;
these two barriers cannot be solved in the near future, so the HEV is the interim solution before
the full commercialization of PEV when there is a breakthrough in battery initial cost and
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management. FCEV has long-term potential for future main stream vehicles, however the
technology of its cost and refueling system is still in early development stage, and thus this
paper mainly discusses HEV.

Key Words:

EV - Electric Vehicle

PEV – Pure Electric Vehicle

FCEV – Fuel Cell Electric Vehicles

Types of EVs PEV HEV FCEV

Energy Source Battery Battery + Internal Fuel cells

Combustion Engine

Propulsion Technique Electric Motor Drives Electric Motor Drives Electric Motor Drives
+ Internal Combustion
Engine

Characteristics and (i) Zero emission (i) Low emission (i) Zero emission
features (ii) Short driving range (ii) Longer range (ii) Highest initial
(iii) Higher initial costs (iii) Complex costs
(iii) Medium
driving range

Major Techniques (i) Electric motor i) Electric motor (i) Fuel processor
control control (ii) Fueling system
(ii) Battery (iii) Fuel cell cost
(ii) Battery management
management (iii) Managing
(iii) Charging device multiple energy
sources and optimal
system efficiency
(iv) Components
sizing

Regenerative Braking Yes Yes Yes

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2. Configuration, Main Issues and Control of HEVs

2.1 Configurations of HEVs:
According to technical Committee 69 (electric road vehicles) of the International Electro
technical Commission, an HEV is a vehicle in which propulsion energy is available from two or
more kinds or types of energy sources or converters, and at least one of them can deliver
electrical energy . Based on this definition, there are many kinds of HEVs, for example, battery
and ICE, battery and capacitor, and battery and flywheel. Traditionally, HEV can be classified
into three types:

 series HEV

 parallel HEV

 Combination HEV

{Figure of a Series Combination HEV}

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{Figure of a parallel HEV}

{Figure of a combination HEV }

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2.1.1 Configuration of series HEVs

The series HEV is composed of ICE, generator, power converter, motor, and battery. There is no
mechanical connection between ICE and transmission, thus ICE can operate at maximum
efficient point by regulating the output power of battery to satisfy the required power of
vehicle. But, the energy from the ICE transmits via generator and motor, so much more energy
will be lost. Since the motor is the final and sole drive device, the motor must be larger enough
to satisfy performance of vehicle, and thus the regenerative braking power almost can be
stored in battery by motor.

2.1.2 Configuration of parallel HEVs

The parallel HEV allows both the electric motor and ICE to deliver power in parallel to drive the
vehicle, that is, ICE and motor can drive, respectively, or together. Different from the series
HEV, there is mechanical connection between ICE and transmission, and thus the ICE’s
rotational speed depends on the driving cycle, so the ICE can operate based on optimal
operating line by regulating the output power of battery.

2.1.3 Configuration of combination HEVs

The combination HEV incorporates the features of both series and parallel HEV, an additional
mechanical connection between ICE and transmission is added compared with the series
hybrid, and also an additional generator between ICE and power converter is added compared
with the parallel hybrid. Although the complexity of structure leads to more costly
manufacturing technologies, it is more flexible in control. Some modern HEVs prefer to adopt
this system.

2.2 Main Issues of HEVs

Compared to the conventional vehicles, HEVs can save fuel for the following reasons.

(i) HEVs can store part of the vehicle’s kinetic energy in battery while braking or down-slope, in
which otherwise is burnt in the brake drums in the form of heat in conventional vehicle.

(ii) The ICE in an HEV can be designed with a smaller displacement without compromising the
performance of vehicle.
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(iii) HEVs can make Internal Combustion Engines (ICE), operate at maximum efficiency point or
optimal operating line by regulating the output power of battery to satisfy the required power
of vehicle.

(iv) HEV is a multiple energy system; the main issue of HEV is how to optimize the power flow to
obtain best fuel economy or low emission at lower cost, which is often referred to as the energy
management (EM) problem.

2.3 Controls in HEVs

The most critical aspect in designing HEV, is to get most effective results with controlling
conversion of energy on the powertrain. Therefore, the controller design of HEV is the key point
of the design process. The aim of this section is to explain powertrain control strategies for HEV
and review the latest methods of EM strategies in detail. The aim of the control strategies is to
satisfy the following number of goals for HEV:

(i) Minimization of fuel consumption or maximum of fuel economy.

(ii) Minimization of emissions.

(iii) Good drivability.

2.3.1 Vehicle Control in HEV

HEV’s control system is very complex. The multilevel hierarchical control is an important control
method for large-scale and complex system. Thus hierarchical control is adapted widely in HEV
control as shown in Figure (series HEV). HEV controller consists of driver command interpreter,
vehicle system controller, and electronic controller. Vehicle system controller is the decision
level to decide the torque demands of motor, generator, ICE, and mechanical brake according
to the driver’s torque demand, speed of vehicle, and battery’s state of charge (SOC), where the
SOC is estimated by battery management system (BMS), the speed of vehicle is feed by sensor.
Electronic controller is execution level to carry out the command from the vehicle system
controller to make corresponding parts work.
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 Driver Command Interpreter

The function of driver command interpreter is to compute the driver’s torque demand
according to desired speed of vehicle and actual speed of vehicle. Speed of vehicle is
controlled by accelerator pedal and brake pedal position. This is a feed control system
by adjusting the accelerator pedal and brake pedal position to make the vehicle follow
the desired vehicle speed.

 Vehicle System Controller

Compared to the conventional vehicles, HEV is a multiple energy source, then, how to
split the required power among energy sources is called EM. Vehicle system controller
performs powertrain control by using EM strategies according to command signals
received from driver command interpreter and parameters information feedback from
electronic controller. Vehicle system controller can be divided into three function
blocks.
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(i) Required power of vehicle interpreter.

(ii) Energy management strategies.

(iii) Torque interpreter.

Required power of vehicle interpreter is a function block to convert the driver’s torque
demand to power demand. HEV is a multiple energy system, different from
conventional vehicles which can only output power, battery not only can output power
but also absorb power. For a required power, how to split the power required between
two energy sources and mechanical brake in order to minimum the fuel consumption or
emission is the hot topic among technology developers.

 Electronic Controller

Electronic controller is the embedded system which carries out the commands from the
vehicle system controller to make corresponding parts work. Electronic
controller, includes engine control unit (ECU), motor control unit (MCU), generator
control unit (GCU), electronic braking system control (mechanical brake) unit, and
battery management system (BMS).
Engine control unit is an electronic control unit (ECU) for controlling ICE; it makes the
ICE output desired torque coming from vehicle system controller command signal by
injecting fuel into the combustion chambers of the ICE. ICE’s operating point can be
described by torque and speed. In series HEV, there is no mechanical connection
between ICE and transmission, then how to control the speed of ICE? There is a
mechanical connection between ICE and generator, so ICE’s speed is controlled by
generator’s torque demand. Motor is the final drive device and coupled by mechanical
connection to transmission, and so the motor’s speed depends on the driving cycle,
similarly, motor’s operating point can be described by torque and speed usually; the
torque demand of motor is computed by driver’s torque demand due to mechanical
connection to transmission. MCU makes the motor operate at desired torque using FOC
technology usually. Motors, used for traction usually, are also able to become generator
during braking or down slope. Hence, the vehicle kinetic energy, which otherwise is
burnt in the brake drums in the form of heat, can be converted into electrical energy
and sent back to the battery. If the battery is unreceptive, then electronic braking
system control unit can be work.
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3. Smart/Mild Hybrid Vehicle by Suzuki (SHVS)

Mild hybrid vehicles have propulsion via an engine and an electric motor; the vehicle cannot be
driven solely by the electric motor. The motor only assists the engine is certain driving
conditions thus lowering the load on the engine and consequently fuel consumption and
emissions.
In India, the Maruti Ciaz and Ertiga SHVS (Smart Hybrid Vehicle by Maruti Suzuki) are examples
of this.
Mild hybrids generally also include the start-stop functionality. Although regarded as hybrids
these vehicles do not offer a comparable level of fuel and emissions reduction as full hybrids.
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The Smart Hybrid Vehicle System (SHVS) involves a large starter motor. This starter Motor
functions as a normal starter motor while cranking the engine. During braking, the circuit is
altered to make the same starter motor to act as a generator. The power losses during the
braking are hence regenerated and stored in a battery. This power can later be used, either for
auxiliary systems or to generate extra torque while accelerating. The extra torque delivery is
through the same starter motor.

Smart Hybrid is an advanced technology that helps increase fuel efficiency and enhances driving
performance. The engine automatically stops when idle and silently starts when the optimal
conditions are met in manual and automatic transmissions. It comes with a dual battery setup
including a Lithium Ion Battery. These high capacity batteries store the energy generated during
braking to assist the engine's idle start-stop and the torque assist functions. The energy stored
in the Lithium-ion battery assists during acceleration which helps engine in providing optimal
acceleration and performance.
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if the driver demands a surplus power delivery through sudden and full throttle positioning,
then the energy stored in the battery is used delivered at the starter motor. The starter motor
now acts as a motor, raising the power delivery at the flywheel. This is the working principle of
SHVS. All of this happens without the intervention of the driver.

SHVS essentially stands for Smart Hybrid Vehicle by Suzuki. It is a mild hybrid system that
incorporates an integrated starter generator (ISG) that offers the engine power assistance using
the motor and is capable of achieving power regeneration.
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It is a small generator that uses electricity from the battery to pass through what is technically
known as stator windings (copper wire coils) and create a magnetic field that causes the rotor
to spin and start the engine. In reverse, the rotors spin when operating freely (the main engine
is not under any load – like going downhill or coasting) and the spinning magnets within the
stator windings create electricity which can then be stored in the battery and utilized later. It is
a small unit that is normally fixed between the engine and the transmission and on occasion it
can be fitted externally to an engine and connected to the crankshaft via a drive belt. In such a
case the ISG will also act as the engine’s starter motor

An ISG is a small component that can be added to an existing engine and doesn’t require too
much to be re-engineered making it a cost effective option to enhance the vehicle’s fuel
efficiency though a number of functions including engine start/stop, provide additional power
to the engine when required, and provide regenerative braking.
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3.1 Advantages of Smart hybrid Technology

 Performance
 Improved Fuel Efficiency
 Reductions in Emissions

3.1.1 Performance

The torque assist function supplements the engine’s power during acceleration which reduces
the load on engine and the brake energy regeneration function captures the energy lost during
braking, eventually improving the engine life & performance

3.1.2 Improved Fuel Efficiency

The start/stop function turns off the engine automatically in the idle state thereby contributing
to the improved fuel efficiency.

3.1.3 Reductions in Fuel Emissions

The Smart Hybrid Technology helps reduce emissions by saving fuel consumption and
improving efficiency thereby helping keep environment clean and green.
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3.2 Maruti Suzuki’s The new Ciaz with SHVS System

1. Regenerative braking

Suzuki’s new SHVS system works on the principle of regenerative braking where kinetic energy
while slowing down is converted to electricity and stored in the battery of the car. The Ciaz
comes with a bigger lead acid battery in the SHVS model.
2. Integrated Starter Generator

Also referred to as an ISG, this electric motor is powered by the high capacity battery of the car.
It is used supplement the engine’s power while the car accelerates. As we know, an engine
burns more fuel to gain momentum at higher RPMs as compared to sustaining momentum
which is done at lower revolutions per minute. And since the ISG motor aids the Ciaz mild hyrid
in acceleration with electricity, the engine does not have to rev as much when the car
accelerates thereby saving fuel.
3. Idle Start/Stop

The Maruti Ciaz mild hybrid also comes with idle start/stop technology that shuts off the engine
when the car comes to a halt in order to save fuel in stop/start traffic conditions.
4. India’s most fuel efficient car

The incorporation of Suzuki’s SHVS system in the Maruti Suzuki Ciaz has understandably made
the car more fuel efficient than the standard model. The Maruti Suzuki Ciaz SHVS is available
only in the diesel engined model of the car. The standard Maruti Ciaz diesel (which has been
discontinued with the introduction of the new mild hybrid model) had an ARAI rated fuel
efficiency figure of 26.21 km/l. The new Ciaz diesel mild hybrid has an ARAI rated figure of
28.09 km/l. This makes the Maruti Suzuki Ciaz diesel the most fuel efficient car in India.
5. Competitive price
The incorporation of the mild hybrid system in the Ciaz has allowed Maruti Suzuki to avail
economic benefits from the National Electric Mobility Mission Plan. Suzuki Ciaz mild hybrid
diesel continues to be more affordable than rival models despite incorporation of the new mild
hybrid technology.
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4. CONCLUSION
Hybrid-electric vehicles (HEVs) combine the benefits of gasoline engines and electric motors
and can be configured to obtain different objectives, such as improved fuel economy, increased
power, or additional auxiliary power for electronic devices and power tools The transmission of
power using freewheels and chain wheels are very cheap and reliable. One disadvantage is that
driving on electric power is not a good option for a long distance travel. Though this combined
power train system can become much useful in more stop and go traffic situations. With the
use of this powertrain system, the overall fuel consumption and fuel economy is improved.
Such vehicle would run on fuel but would use its electric motor to boost the power when
needed. The costs of HEVs are a little more than the conventional cars but they more efficient
and the exhaust emissions are less.

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