SAE Engineering Academies provide comprehensive and immersive training experiences, helping new and re-assigned engineers become proficient and productive in a short period of time. The Hybrid and Electric Vehicle Engineering Academy covers hybrid and electric vehicle engineering concepts, theory, and applications relevant to HEV, PHEV, EREV, and BEV for the passenger car industry. While the theory and concepts readily apply to the commercial vehicle industry as well, the examples and applications used will apply primarily to the passenger car industry.
- Define and analyze fundamental electrochemistry of battery operation and performance requirements for HEV, PHEV, EREV and full electric vehicle applications
- Estimate the size of a cell to meet a specific requirement
- Create a cradle-to-grave, or cradle-to-use list of materials used in any type of automotive battery
- Compute the temperature response of battery cell and pack assemblies for a simple model
- Describe the functions performed by a Battery Management System (BMS)
- Explain different approaches to estimating state of charge, state of health, power and energy
- Apply the operation of brushless dc and induction motors to HEV and EV vehicles
- Define the torque speed curves for motors and the application to electric and hybrid electric vehicles
- Describe the features of buck, boost, and Transformer converters
- Compare and contrast the various industry and regulatory standards for hybrid vehicle components, batteries, and charging systems
- Describe the main hybrid and electric vehicle development considerations and performance requirements for various vehicle system
- Identify how to define key vehicle system requirements and select and size system components that best meet those requirements
An engineering degree is highly recommended, but not required. This Academy does not cover basic electrical concepts and assumes that the attendee already understands such concepts (voltage, current, resistance, capacitance, inductance, etc.) In order to understand concepts discussed, all participants are required to have driven an HEV prior to attending the academy.
Please be advised that this course may involve one or more of the following: driving and/or riding in a vehicle; participating in a vehicle demonstration; and/or taking part in an offsite tour using outside transportation. You will be required to sign a waiver on-site and produce a valid driver's license from your state/country of residence
Attendees are asked to bring a calculator for in-class exercises.
Systems Integration and Analytical Tools
- Vehicle Development Process Overview
- Requirements Development
- Hybrid Components and Architectures
- Major components in hybrid powertrain
- Controls integration
- Component sizing and integration tradeoffs
- Hybrid architecture overview
- System Design and Development Considerations
- Vehicle integration (ex. performance, drivability, NVH)
- Powertrain integration (ex. energy, power, efficiency, torque, thermal management)
- HV/LV electrical systems (ex. safety, DC/AC voltage, charging system, efficiency, cables, connectors, fuses,
- Chassis (ex. braking, vehicle dynamics, powertrain to chassis dynamics, ride and handling, steering, fuel system)
- Displays/information (ex. messages, information aids, usage efficiency aids)
- HVAC (ex. HV compressor, HV heater, cabin comfort, efficiency considerations)
- Verification and Validation Considerations
- Verification and validation test requirements and planning
- Component test considerations
- System test considerations
- Fleet testing
- Summary/Conclusions
- Standards Roadmap for Electric Vehicles
- - SAE; - UL; - IEC
- - Performance and Safety
- Applicable Battery Standards
- Battery Transportation
- Battery Safety
- Battery Pack: SAE J2464/J2929
- Compare and Contrast the various industry standards
- Vehicle and Charging Standards
- FMVSS
- Electric Vehicle Supply Equipment (EVSE) Descriptions
- Governing Bodies for Regulations
- Certification Requirements and Options
- Performance Standards
- Charging interfaces
- SAE J1772 charge protocol
- USABC/FREEDOMCAR
- Battery Characterization and life cycle testing
- Video Demonstrations
- Mechanical Shock
- Short Circuit
- Overcharge
- Fire Exposure
Thermal Management for Batteries and Power Electronics
- Introduction
- Thermal control in vehicular battery systems: battery performance degradation at low and high temperatures
- Passive, active, liquid, air thermal control system configurations for HEV and EV applications
- Brief Review of Thermodynamics, Fluid Mechanics, and Heat Transfer
- First Law of Thermodynamics for open and closed systems; internal energy, enthalpy, and specific heat
- Second Law of Thermodynamics for closed systems; Tds equations, Gibbs function
- Fluid mechanics: laminar vs. turbulent flow, internal flow relationships, Navier Stokes equations
- Heat transfer: simple conduction, convection, and radiation relationships; Nusselt number relationships for convective heat transfer; energy equation
- Battery Heat Transfer
- Introduction to battery modeling: tracking current demand, voltage, and State of Charge as functions of time for given drive cycles
- Development of thermodynamic relationships for cell heat generation
- Lumped cell and pack models for transient temperature response to drive cycles
- Model parametric study results
- Thermal Management Systems
- Overall energy balance to determine required flowrates
- Determination of convection and friction coefficients for air and liquid systems in various geometric configurations: flow around cylinders, flow between plates, flow through channels
- Development of a complete thermal system model and parametric study results
- Temperature control and heat transfer using phase change materials
- Thermal Management of Power Electronics
Battery Management Systems
- Block Diagram - Main Functions of a BMS
- Sensing Requirements
- Cell/module level: cell voltage, cell/module temperature, (humidity, smoke, air/fluid flow)
- Pack level: current, pre-charge temperature, bus voltage, pack voltage, isolation
- Control Requirements
- Contactor control, pre-charge circuitry
- Thermal system control
- Cell Balancing: Active versus passive, strategies
- Estimation Requirements
- Strategies: different approaches and benefits of model-based approach
- How to create a model via cell tests
- State of Charge estimation
- State of Health estimation
- Power estimation
- Energy estimation (range estimation)
- Electronics Topologies
- Monolithic versus master/slave versus daisy-chain
- Implications of battery pack topologies: parallel strings versus series modules
- Available chipsets for designing electronics
- Other Requirements: CAN communication, data logging, PH/EV charger control, failure modes/detection, thermal systems control
- Future Directions for Battery Management, Degradation Control
Wednesday
Electrochemistry and Battery Materials Design
Power Electronics
- Introduction - Why Power Electronics?
- Overview of Power Density
- Effects of air vs. liquid cooling
- Effects of efficiency
- Converter Topologies
- Buck, boost, transformer
- Inverter Topology
- 6-pack inverter
- Space Vector Control
- Sources of Loss in Power Electronics
- Conduction, switching, leakage, and control losses
- Power Semiconductors
- Insulated Gate Bi-polar Transistor (IGBT)
- Metal-Oxide-Silicon Field Effect Transistor (MOSFET)
- Emerging technologies: Moore¿s law, silicon carbide
Thursday
Electric Motors
- Magnetic Circuits
- The basic concepts of magnetic circuits
- Governing laws
- Magnetic material behavior
- Losses and minimization of losses
- DC Motors
- Basic concepts of DC motors
- Governing laws
- Construction
- Modeling
- Control
- Permanent magnet and separately excited motors
- PM AC Synchronous Motors
- Construction and generation of magnetic field
- 3-phase behavior
- Torque generation
- Modeling
- Control
- Miscellaneous issues
- Basic Battery Reactions
- Overcharge Reactions
- Consequences of Overcharge
- Design Considerations
- Thermal Considerations
- Charging Infrastructure/methods
- Basic Definitions
- Conductive Charging
- Method
- Standards
- Inductive Charging
- DC Charging
- Definition
- Issues: Infrastructure, Thermal, and Life
- Grid Infrastructure
- Basic infrastructure
- Grid interactions: bi-directional communication and power flow
- Aspects of Battery Pack Design
Friday
Lithium-Ion Battery Design
Friday session ends at 3:30.
Saeed Siavoshani Dr. Saeed J. Siavoshani is currently a Principal Research Scientist at the Dow Chemical Corporation and is also an adjunct professor at the University of Detroit Mercy where he teaches a comprehensive electric vehicle course. In addition Dr. Siavoshani is the Chief Industry Advisor for SAE Professional Development Department¿s hybrid vehicle technology curriculum. Over the past two decades, he has worked for General Motors Corporation and Ford Motor Company. During his career, Dr. Siavoshani has worked on composite projects related to offshore oil and gas, infrastructures, and pressure vessels and automotive systems including vehicle powertrain, body, exterior/interior vehicle, and exhaust/induction systems. He has been instrumental in the development of new technology, notably the integrated Front of Dashboard concept and Acoustomize, a unique method of analyzing and offering solutions to automotive noise problems. He has also worked in the area of thermoforming utilizing electro-magnetic field technology. Dr. Siavoshani has helped to build the infrastructure for the electric vehicle battery pack including thermal management as well as reducing the weight of the overall battery. He has been granted several patents and was presented the Forest R. McFarland Award in 2012 for distinction in professional development and education. Dr. Siavoshani has a M.S. in Mechanical Engineering from Wayne State University and a Ph.D. in Mechanical Engineering from Oakland University.
Bruce Blakemore
Mr. Blakemore is currently a Technical Expert in battery manufacturing and system integration at Ford Motor Company. Mr. Blakemore has been developing and manufacturing batteries for over 25 years. He began his career by designing Nickel Cadmium, Nickel Metal Hydride and Nickel Hydrogen batteries for aerospace usage. Bruce went on to be principal design engineer for the EV1 and then the principle manufacturing product engineer for the assigned manufacturing plant. Over the next two decades Mr. Blakemore has had many roles in battery design and manufacturing including plant chief manufacturing engineer, quality manager, and HV Battery controls engineer. Mr. Blakemore has played key design and integration roles in many EV programs including: GM EV1, Ford Ranger, Ford Escape Hybrid, and the Ford Electric Transit Connect. Over the course of his career Mr. Blakemore has been granted several patents including patents for State Of Charge Determination, Distance to Empty Calculation, and patents for fuel cells and oxygen batteries. Mr. Blakemore has a B.S. in Chemistry from the University of the State of New York.
Rich Byczek
Mr. Byczek is the Technical Lead for Electric Vehicle and Energy Storage at Intertek where he is responsible for the technical development of Intertek¿s EV and Battery testing labs across North America, Europe and Asia. For the past 5 years, Mr. Byczek was the Operations Manager of the Livonia site, directly responsible for all battery performance, safety and transportation testing, as well as reliability and certification testing of Electric Vehicle charging stations and support electronics. Mr. Byczek has significant experience in product validation, EMC testing, and automotive product development. He sits on several performance and safety standards committees related to batteries and electric vehicle systems. Mr. Byczek has a B.S.in Electrical Engineering from Lawrence Technological University.
Alexandra Cattelan
Ms. Cattelan is currently the Chief Engineer of New Energy Systems at AVL. She has extensive experience in hybrid and electric vehicle and powertrain system design, development, validation and production and has been in automotive engineering for 20 years. Prior to her current position, Ms. Cattelan was the Assistant Chief Engineer for the Chevrolet Volt and Vehicle Performance Manager for the Midsize Hybrids at General Motors. She also has extensive experience in natural gas and propane vehicle engineering including responsibilities in system development, software and controls engineering, calibration and validation, as well as experience in vehicle manufacturing and environmental consulting. Ms. Cattelan holds a B.S. in Industrial Engineering and a M.S. in Mechanical Engineering, both from the University of Toronto, Canada.
Shuvra Das
Dr. Shuvra Das is Professor of Mechanical Engineering and the Associate Dean for Research and Outreach for the College of Engineering and Science at University of Detroit Mercy. His research and teaching interests include engineering mechanics, computational mechanics using finite and boundary element methods, modeling and simulation, inverse problems, mechatronics, modeling and simulation of mechatronics systems, condition based health monitoring of engineering systems, etc. Dr. Das, author of the text entitled Mechatronic Modeling and Simulation Using Bond Graphs has over fifty conference and journal publications and has received several awards, including the Best Teacher award from the North Central section of ASEE and the Junior Achievement award at University of Detroit Mercy. Dr. Das received his Ph.D. and M.S. degrees in Engineering Mechanics from Iowa State University. In addition, he received his B.Tech (Hons.) in Mechanical Engineering from the Indian Institute of Technology in Kharagpur, India.
G. Abbas Nazri
Dr. Nazri is currently the technical director of new technologies at Frontier Applied Sciences and Technologies, LLC. and is also an adjunct professor of Physics and Chemistry at Wayne State University, Oakland University, and University of Windsor, Canada. Dr. Nazri began his career as a Research Scientist at General Motors Global Research and Development Center after two years of postdoctoral fellowships at the Lawrence Berkeley National Laboratory. He also served as a visiting Professor at the University of Pierre and Marie Curie, Paris France, Institute of Condense Matter Chemistry at Bordeaux France, and Institute of Materials at Nantes, France. He is an active organizer of Symposia on advanced batteries and is on the International Science Advisory Board of several Lithium Battery Meetings and Conferences. Dr. Nazri has published over 100 scientific papers, 12 proceedings volumes, two text books on science and technology of lithium batteries, and is the holder of 15 U.S. patents. His research interests are in the area of materials for advance batteries for transportation applications, supercapacitors, solid-state hydrogen storage materials, electrochemical catalysis, synthesis of novel materials, and advanced analytical techniques for real time study of electrochemical systems. Dr. Nazri received his Ph.D. in Physical Chemistry from the Center for Electrochemical Sciences, Case Western Reserve University.
Gregory Plett
Dr. Plett is currently an Associate Professor of Electrical and Computer Engineering at the University of Colorado at Colorado Springs (UCCS). Dr. Plett has taught courses at Stanford University, Universidad Nacional Autónoma de México, and UCCS; has published papers in IEEE, Electrochemical Society, Elsevier, and Wiley journals and multiple conferences; is presently managing research projects with overall budget exceeding $1M; and is a joint holder of a number of U.S. patents. He is a Senior Member of the IEEE. Dr. Plett's research areas include linear and nonlinear adaptive filtering, dynamic system modeling, state estimation and control. His focus is on the modeling and estimation requirements for proper battery management of advanced battery technologies (e.g., for hybrid and electric vehicle systems). Dr. Plett received a B.Eng. in Computer Systems-Engineering with high distinction from Carleton University, (Ottawa, Canada), and a M.S.E.E. and Ph.D. in Electrical Engineering from Stanford University (Stanford, CA).
Robert Spotnitz
Dr. Spotnitz leads Battery Design LLC, a company that provides consulting and software for battery developers and users. He founded Battery Design in 1999 and developed Battery Design Studio®, a virtual environment for battery design and simulation (see www.batdesign.com). Over the last decade he participated in the start-up of two battery developers: American Lithium Energy Corp. and Enovix. Prior to that, he was Director of Advanced Product Development at PolyStor Corp. where he led efforts to develop large lithium-ion batteries for hybrid electric vehicles. Before that he was a Staff Engineer for Hoechst's Celgard Division where he built from the ground-up the Battery Applications Development Center and helped commercialize the tri-layer battery separator and also worked at the R&D center of W.R. Grace & Co where he co-invented multi-layer battery separators, as well as a number of electrochemical processes. Dr. Spotnitz provides tutorials on batteries for the Advanced Automotive Battery Conference, the Battery Power conferences, the EIS Short Course, as well for the Electrochemical Society. He has18 patents and 34 publications (including 3 book chapters). He is a member of the International Society of Electrochemistry and the Electrochemical Society. He has a B.S. in Chemical Engineering from Arizona State University, a M.S. in Computer Science from Johns Hopkins, and a Ph.D. in Chemical Engineering from the Univ. WI-Madison.
Tom Stoltz
Mr. Stoltz is currently a Senior Engineering Specialist at Eaton Corporation¿s Innovation Center and is also an Adjunct Professor of Electrical Engineering at the University of Detroit Mercy. His core expertise is in embedded computing hardware for control of energy systems; however, he enjoys practicing and teaching a broad range of engineering topics. Mr. Stoltz has over a decade of industry experience at several companies, small and large. His range of industrial experience includes: manufacturing, product design, corporate research, and engineering management in automotive powertrain controls, distributed generation, high efficiency hydraulics, and automated transmissions for heavy trucks. Mr. Stoltz received a B.S in Electrical Engineering from Michigan State University, a M.S. in Electrical Engineering from the University of Detroit Mercy and is a registered Professional Engineer in the State of Michigan.