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Design of Mechanical Components for Hybrid Vehicle Application

11OutlineIntroductionLiterature ReviewProblem DefinitionObjectivesTheoretical BackgroundMethodologyResultsConclusionsWork Proposed For The Next TermReferences

22Introduction

Hybrid vehiclesare vehicles with two or more power sources in the drive train

Hybrids are classified by the division of power between sources both sources may operate in parallel to simultaneously provide acceleration

Or they may operate in series with one source exclusively providing the acceleration and the second being used to augment the first's power reserve. 33

Structure of a parallel hybrid electric vehicle[1]John.M.Miller, Propulsion Systerm for Hybrid vehicle, The Institution of Engineering and Technology, vol 1,2004Commonly produced at present, have both Internal Combustion engine (ICE) and an electric motor coupledParallel hybrids44Series hybridsIn a series-hybrid system, the combustion engine drives an electric generator instead of directly driving the wheels.[1]Structure of a series-hybrid vehicle

[1]John.M.Miller, Propulsion Systerm for Hybrid vehicle, The Institution of Engineering and Technology, vol 1,200455Depending upon the extent of hybridization any of the architecture can be chosen

Micro hybridMild hybridStrong Hybrid

66In conventional automobiles there is a separate starter motor for cranking and an alternator for generation.

Integrated Starter Generator (ISG) is a single machine which can be used to perform both the functions of starter motor and alternator. [3][3]. Amit Kumar Jain, Shashidhar Mathapati, V. T. Ranganathan, V. Narayanan, Integrated Starter Generator for 42-V Power-net Using Induction Machine and Direct Torque Control Technique, IEEE Transactions on Power electronics, vol. 21, no. 3, may 2006,701-71077ISG has four modes of operation they are [3] :-Mode 1:Engine cranking mode

Mode 2:Running power generation mode

Mode 3:Braking power generation mode

Mode 4:Power boost mode[3]. Amit Kumar Jain, Shashidhar Mathapati, V. T. Ranganathan, V. Narayanan, Integrated Starter Generator for 42-V Power-net Using Induction Machine and Direct Torque Control Technique, IEEE Transactions on Power electronics, vol. 21, no. 3, may 2006,701-71088In present Application 7.5kW, 95N-m ISG motorselected based on Engine operating conditions

ISG Motor satisfies requirement in Mode 2,3,4But does not satisfy starting torque requirement99Some alternatives which would be suggested for the current problem

High torque delivering capacity motor

Increasing the pulley ratio of Motor pulley to Engine pulley

To develop a Two speed pulley assembly to multiply the torque initially to 3:1 and then switch to 1:1 ratioIntroduction to Two Speed Pulley1010LITERATURE REVIEW

Yosuke enno Tokyo [5] has carried out a work on selective transmission using planetary gears an electro-magnetic clutch used for actuation[5]. Yosuke enno Tokyo, Planetary gear type electro-magnetic clutch, Mineba co.ltd, EP1426642A1, 9-06-2004.11Selective planetary gear train11The current running through the coil generates a magnetic field.

When magnetic flux overcomes the air gap between the armature and field, magnetic attraction pulls the armature which connects to the hub into contact with the rotor.

The rotor and armature slip past each other for the first 0.02 to 1.0 sec until the input and output speeds are the same[5].

[5]. Yosuke enno Tokyo, Planetary gear type electro-magnetic clutch, Mineba co.ltd, EP1426642A1, 9-06-2004.1212Coned annular-disk springs of uniform cross section may be proportioned to give a wide variety of load deflection curves[9]

[9]. J.O.Almen , and Laszlo, The American society of Mechanical Engineers, Newyork, RP-58-10, 1935.

Fig: Annular Disk spring1313

By the simply varying the free cone height and the working range of deflections, spring rates may be varied from positive, zero to negative [9][9]. J.O.Almen , and Laszlo, The American society of Mechanical Engineers, Newyork, RP-58-10, 1935.Fig8: shows load-deflection curve for a series of springs1414Literature Summary

Concept of Yosuke enno Tokyo work on selective transmission using planetary gears an electro-magnetic clutch can be used for actuation

Belleville washer can be used, a it is a conical shell which can be loaded along its axis either statically or dynamically

Consumes less space & by Varying the free cone height and the working range of deflections can be obtained1515THEORETICAL BACKGROUND

Procedure followed for designing components1616Kinematic analysis of planetary Gear trainSpur gears are used in the planetary gear arrangement. To avoid use of Thrust bearings

Fig 11: General representation of planetary gear 1717Kinematic analysis is done by tabular method [12]

[12]. S.S.Rathan, Theory of Machines, Tata McGraw-Hill publications, 3rd edition, 2009

1818

The graph [11] suggests the maximum no of planetary gears that can be selected is suggested 11. Peter ilynwander, gear drive systems. Design and application , Marcel Dekker, fourth edition,ISBN 0-8247-1896-81919

Fig :a and b showing the load sharing by three planet system and four planet system[11]11. Peter ilynwander, gear drive systems. Design and application , Marcel Dekker, fourth edition,ISBN 0-8247-1896-82020Planetary gear Assembly

When choosing the No of teeth in planetary gears, it must be understood that not every combination of gear teeth can be assembled [11]Where H= Whole no Integer NS=No of sun gear teeth Ni=No of Internal gear teeth K= No of Planets11. Peter ilynwander, gear drive systems. Design and application , Marcel Dekker, fourth edition,ISBN 0-8247-1896-82121Force analysis on gears [13]. Joseph.e shigley, Charles R.Mischikie, Mechanical Engineering Design, Tata McGraw-Hill publications9th edition, 2010,ISBN 978-007352928822

2223Load is assumed to be transmitted by a single teethPitch line velocity[13]

Ft= (P*103/dn)Planet gear experiences the reaction forces on the pin which will be = 2FCos .[13]. Joseph.e shigley, Charles R.Mischikie, Mechanical Engineering Design, Tata McGraw-Hill publications9th edition, 2010,ISBN 978-0073529288F= Ft/tan 23Design of gearsDesign of gears were done taking pair of spur gear at a time initially sun and planet gear were taken

Following steps are followed in designing of gears Lewis form factor for 20 Involute Identify the weaker MemberDesign based on weaker member Tangential load equation equated with tangential tooth load from Lewis equationVelocity factorSelecting standard moduleAllowable stress should be above Induced stress

2424Design of holding Pin for planetary gearsLoad Acting on the Pin is assumed to be acting at the end of a cantilever beam.

showing the loading condition of the pin

Combined bending and shear load equation 2525Design of friction diskDisk is designed for a maximum torque transmission of 100Nm [14]

Mt=Max torque to be transmitted Fa= axial force required for torque transmission

[14]. Mahadevan, balveer reddy, Design and Data Hand book for Mechanical Engineers2626Design of plate thickness required for pulleyLoad acting on to the pulley is due to pressure load acting on the peripheryConsidering Condition as supported at the centre over a circular area of radius b & udl of w[15]

15. Design data handbook, PSG College of Technology, Coimbatore.2727METHODOLOGY

Methodology for Two speed pulleyFrom the approach discussed in theoretical review dimensions of few components are derivedNo of Teeth of Sun Gear = 30No of Teeth of Planet Gear =15No of Teeth of Ring Gear= 60No of Planets selected = 3

Planetary gear assembly is possible

Forces coming on to the gear = 0.982kN

2828Planet gearSun gearInternal gearAddendum222Dedendum2.52.52.5Tooth thickness3.1463.1463.146Tooth space3.1463.1463.146Working depth444Whole depth4.54.54.5Clearance0.50.50.5Pitch diameter3060120Outside diameter3464116Root Diameter2555125Fillet radius0.80.80.82929Holding Pin dia for planetary gears =10mm

Axial load required on the friction disk =3.92kN

Plate thickness required for pulley = 10mm 3030Analysis of componentsThe components are designed analytically are modelled and subjected to static analysis to analyze whether the components satisfy strength requirement3131Sun gear static analysis

Sun gear model was modeled in Pro-E imported in hyper mesh for meshing. Here 63180 solid elements and 71552 nodes . Optistruct as the solverFig :showing the Meshed model of a sun gear3232Results of Sun gear

Fig 17 a: stress plot for load acting on a single teeth Fig 17 b: Displacement plot for sun gear 33Maximum Stress of 104 Mpa was developed. Which is below the allowable stress of 345Mpa.33Planet gear analysisPlanet gear model was modeled in Pro-E imported in hyper mesh for meshing. Here 45310 solid elements and 53328 nodes were generated. Optistuct as the solver.

Fig : showing the Meshed model of a Planet gear3434Planet gear results

Fig :stress plot for load acting on the planet gearFig : Displacement plot for Planet gear 35Maximum Stress of 167 Mpa was developed. Which is below the allowable stress of 345Mpa35Analysis on Pulley Pulley model was modeled in Pro-E imported in hypermesh for meshing. Here 262400 solid elements and 293200 nodes. Optistruct as the solver.

Fig : showing the Meshed model of a the pulley3636Pulley analysisFig19 a:stress plot for load acting on the pulleyFig19 b: Displacement plot for pulley

37Maximum Stress of 77 Mpa was developed. Which is below the allowable stress of 345Mpa37REFERENCES

John.M.Miller, Propulsion Systerm for Hybrid vehicle, The Institution of Engineering and Technology, vol 1,2004

Chris Mi, M. Abul Masrur , David Wenzhong Gao Hybrid electric Vehicles Principles and applications with practical perspectives A John Wiley & Sons, Ltd., Publication, ISBN 978-0-470-74773-5.

Amit Kumar Jain, Shashidhar Mathapati, V. T. Ranganathan, V. Narayanan, Integrated Starter Generator for 42-V Power-net Using Induction Machine and Direct Torque Control Technique, IEEE Transactions on Power electronics, vol. 21, no. 3, may 2006,701-710.

J.R Davis ,Gear Materials , properties & Manufacture, Davis & Associates, ASM International, 2005.

Yosuke enno Tokyo, Planetary gear type electro-magnetic clutch, Mineba co.ltd, EP1426642A1, 9-06-2004.

J. G. Kassakian, J. M. Miller, and N. Traub, Automotive power electronics up, IEEE Spectrum Mag., pp. 3439, May 2000.

Disc spring,www.schnorr.com/docs/Handbook.pdf, 20-Aug-2013

38388. S. Timoshenko d vas,Strength of materials Nostard company Newyork,Vol 2, 1934

9. J.O.Almen , and Laszlo, The American society of Mechanical Engineers, Newyork, RP-58-10, 1935.

10. P.Bhagavathiperumal et al, Elastic load-displacement Predictions for coned disc Springs subjected to axial Loading using the finite Element method, Journal of strain analysis, vol 26 ,1991.

11. Peter ilynwander, gear drive systems. Design and application , Marcel Dekker, fourth edition,ISBN 0-8247-1896-8

12. S.S.Rathan, Theory of Machines, Tata McGraw-Hill publications, 3rd edition, 2009

13. Joseph.e shigley, Charles R.Mischikie, Mechanical Engineering Design, Tata McGraw-Hill publications9th edition, 2010,ISBN 978-0073529288

14. Mahadevan, balveer reddy, Design and Data Hand book for Mechanical Engineers

15. Design data handbook, PSG College of Technology, Coimbatore.393940

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