Design and Manufacturing of Hybrid Electric Vehicle Pride at University of Kashan

Nowadays, internal combustion vehicles are the main reason of air pollution in urban areas. Reducing the emissions, energy optimization, and fuel economy are the main goals of vehicle manufacturers. Design and development of clean vehicle including electric vehicles (EVs), hybrid electric vehicles (HEVs), and fuel cell vehicles (FCVs) are the mid and long term strategies to capture the above goals. Unfortunately, these technology in spite of development the clean vehicles in advanced countries, are not the objectives in our country. This paper in order to develop of hybrid electric vehicle technology and using the available resources in Iran, proposes the design and manufacturing steps of the first HEV based on Pride platform. Hybrid Prides that is named Shaheb2 has been manufactured by a joint group student of electrical and mechanical engineering at University of Kashan and prepared for third national competition for manufacturing of hybrid vehicles. Due to some cost and time limitations, Trough-To-Road (TTR) or separated-axle parallel hybrid electric vehicle topology has been chosen. Internal combustion engine of Shaheb2 is 1300CC engine of Pride vehicle that as well as mechanical transmission components such as gearbox, differential are implemented on the front axle. Electric propulsion including electric motor (EM) and drive, energy storage system are located on the rear axle. Employed EM is a 22 kW PMSM that is controlled via field oriented scheme based on space vector modulation inverter and works in two modes torque control and speed control. To store of electrical energy, a set of Li-Ion-Polymer batteries with 192 dc volt has been used. To have an optimum performance for the vehicle, Hybrid Control Unit (HCU) has been developed in which the vehicle can work in different modes only motor, only engine, hybrid and regenerative braking. Employed control method in HCU is based on On/Off strategy that has been implemented by using AVR microcontroller. Due to extra weight of electric propulsion system and so the change of center of mass and total weight of the vehicle, and to increase the stability of the vehicle, the vehicle’s chassis has been enforced and the results have been confirmed via finite element analysis in ANSYS. Suspension system and other auxiliary systems of the vehicle have been recalculated and verified. Aerodynamic performance of the vehicle’s body has been analyzed in Gambit and Fluent and some changes have been made on the body.