HYBRID ENGINE CONTROL
SYSTEMS
HYBRID CONTROL SYSTEM
• It is a system in hybrid engine powered vehicle to control,
manage and coordinate with the internal combustion engine
and electric motor. Ensures the performance and efficiency
o the engine and electric motor.
• It monitors the state-of-charge of the battery pack, also
monitors the current, temperature, and flow of the system to
ensure the safeness of the vehicle
VEHICLE MODE CONTROL PROCESS
• Senses the position of key ignition, it couples
the engine and electric motor to work together
by electric clutch on the hybrid coupler.
• It tells when to run the engine depending on
the speed and throttle demand of the driver.
BATTERY MODE CONTROL PROCESS
• It is a subsystem that monitors the state of charge of the battery
pack, if it is in need of charge and how much power should be
demanded on the internal combustion engine to maintain its
state of charge.
• It monitors the power required to maintain the state of charge of
the battery pack, also gathers data to maintain the temperature
of the battery pack.
ENERGY MODE CONTROL PROCESS
• Communicates with the Vehicle control module to ensure the
performance that is demanded by the driver while
maintaining the efficiency of fuel and state of charge of the
battery pack. Communicates with VCMP & BMCP
• EMCP is a subsystem that serves a protection for the
subsystem components that contributes on the hybrid system
and especially the high-voltage through the battery pack.
REGENARATIVE BRAKING CONTROL PROCESS
• It monitors the brake pressure and speed of the
vehicle to implement regenerative braking to
charge the battery pack.
• Reduces the regenerative braking depending on
the vehicle’s speed.
BATTERY MANAGEMENT SYSTEMS (BMS)
• This system allows to observe, maintain, and control
power storage systems on the hybrid vehicle. It seeks
the battery health and delivery output on the hybrid
system.
• Main functions include cell balancing, cell health and
wear leveling, charge and discharge monitoring and
safety assurance. All of these functions require galvanic
isolation to separate lower voltage systems from high
BATTERY MANAGEMENT SYSTEMS (BMS)
• MS monitors the voltage, current, temperature, and wear leveling of battery cells.
Additional functions include monitoring faults, system health, available energy and
remaining useful lifetime. Individual lithium-ion battery cells are in the 3 – 4V
range. They are connected in series to deliver higher voltage, and in parallel to
increase capacity.
• The battery management system (BMS) is a critical component of electric and hybrid
electric vehicles. The purpose of the BMS is to guarantee safe and reliable battery
operation. To maintain the safety and reliability of the battery, state monitoring and
evaluation, charge control, and cell balancing are functionalities that have been
implemented in BMS. As an electrochemical product, a battery acts differently under
different operational and environmental conditions.
The oversight that a BMS provides usually includes:
Monitoring the battery
Providing battery protection
Estimating the battery’s operational state
Continually optimizing battery performance
Reporting operational status to external devices
How do battery management systems work?
• There are many BMS design features, with battery pack protection
management and capacity management being two essential features.
• Battery pack protection management has two key arenas:
-electrical protection, which implies not allowing the battery to be
damaged via usage outside its SOA,
- thermal protection, which involves passive and/or active
temperature control to maintain or bring the pack into its SOA.
Electrical Management Protection: Current
- Monitoring battery pack current and cell or module voltages is the road to electrical
protection. The electrical SOA of any battery cell is bound by current and voltage.
- Figure illustrates a typical lithium-ion cell SOA, and a well-designed BMS will protect the
pack by preventing operation outside the manufacturer’s cell ratings.
Electrical Management Protection: Current
• - Lithium-ion cells have different current limits for charging than for discharging, and both modes
can handle higher peak currents
• - Battery cell manufacturers usually specify maximum continuous charging and discharging
current limits, along with peak charging and discharging current limits.
• - A BMS providing current protection will certainly apply a maximum continuous current.
However, this may be preceded to account for a sudden change of load conditions; for example,
an electric vehicle’s abrupt acceleration. A BMS may incorporate peak current monitoring by
integrating the current and after delta time, deciding to either reduce the available current or to
interrupt the pack current altogether.
• - This allows the BMS to possess nearly instantaneous sensitivity to extreme current peaks,
such as a short-circuit condition that has not caught the attention of any resident fuses, but also
be forgiving to high peak demands, as long as they are not excessive for too long.
Electrical Management Protection: Voltage
- since any battery pack experiences a significant amount of current cycling, discharging due
to load demands and charging from a variety of energy sources, these SOA voltage limits are
usually further constrained to optimize battery lifespan. The BMS must know what these
limits are and will command decisions based upon the proximity to these thresholds.
- For example, when approaching the high voltage limit, a BMS may request a gradual
reduction of charging current, or may request the charging current be terminated altogether if
the limit is reached. On the other hand, when approaching the low voltage limit, a BMS will
request that key active offending loads reduce their current demands.
- He BMS must make safety considerations for the driver the highest priority while protecting
the battery pack to prevent permanent damage.
Thermal Management Protection: Temperature
- A BMS can control the temperature of the battery pack through heating and cooling.
Thermal Management Protection: Temperature
• Cooling is particularly vital to minimize the performance loss of a lithium-ion battery pack. For example,
perhaps a given battery operates optimally at 20°C; if the pack temperature increases to 30°C, its
performance efficiency could be reduced by as much as 20%. If the pack is continuously charged and
recharged at 45°C (113°F), the performance loss can rise to a hefty 50%.
• Battery life can also suffer from premature aging and degradation if continually exposed to excessive heat
generation, particularly during fast charging and discharging cycles.
• Cooling is usually achieved by two methods, passive or active, and both techniques may be employed.
- Passive cooling relies on movement of air flow to cool the battery. In the case of an electric vehicle,
this implies that it is simply moving down the road. air speed sensors could be integrated to strategically auto-
adjust deflective air dams to maximize air flow.
- Active temperature-controlled fan can help at low speeds or when the vehicle has stopped, but all
this can do is merely equalize the pack with the surrounding ambient temperature
Thermal Management Protection: Temperature
- In the event of a scorching hot day, this could increase the initial pack temperature. Thermal
hydraulic active cooling can be designed as a complementary system, and typically utilizes
ethylene-glycol coolant with a specified mixture ratio, circulated via an electric motor-driven
pump through pipes/hoses, distribution manifolds, a cross-flow heat exchanger (radiator),
and cooling plate resident against the battery pack assembly.
- A BMS monitors the temperatures across the pack, and open and closes various valves to
maintain the temperature of the overall battery within a narrow temperature range to ensure
optimal battery performance.
Capacity Management
- Maximizing a battery pack capacity is arguably one of the most vital battery performance features that a BMS
provides. If this maintenance is not performed, a battery pack may eventually render itself useless. The root of
the issue is that a battery pack “stack” (series array of cells) is not perfectly equal and intrinsically has slightly
different leakage or self-discharge rates.
- lithium-ion cells do not deal well with over-charging. Once fully charged, they cannot accept any more current,
and any additional energy pushed into it gets transmuted in heat, with voltage potentially rising quickly, possibly
to dangerous levels. It is not a healthy situation for the cell and can cause permanent damage and unsafe
operating conditions if it continues.
Capacity Management
- If one has a perfectly balanced set of cells, all is fine as each will charge up in equal fashion, and the charging
current can be cut off when the upper 4.0 voltage cut-off threshold is reached. However, in the unbalanced
scenario, the top cell will reach its charge limit early, and the charging current needs to be terminated for the
leg before other underlying cells have been charged to full capacity.
- Passive balancing is the easiest to implement, as well as to explain the general balancing concept. The
passive method allows every cell in the stack to have the same charged capacity as the weakest cell. Using a
relatively low current, it shuttles a small amount of energy from high SOC cells during the charging cycle so
that all cells charge to their maximum SOC.
Types of battery management systems
- Battery management systems range from simple to complex and
can embrace a wide range of different technologies to achieve
their prime directive to “take care of the battery.” However, these
systems can be categorized based upon their topology, which
relates to how they are installed and operate upon the cells or
modules across the battery pack.
Centralized BMS Architecture
- All the battery packages are connected to the central BMS directly. The structure of a centralized BMS is
shown in Figure . The centralized BMS has some advantages. It is more compact, and it tends to be the most
economical since there is only one BMS. However, there are disadvantages of a centralized BMS. Since all the
batteries are connected to the BMS directly, the BMS needs a lot of ports to connect with all the battery
packages. This translates to lots of wires, cabling, connectors, etc. in large battery packs, which complicates
both troubleshooting and maintenance.
Modular BMS Topology
- Similar to a centralized implementation, the BMS is divided into several duplicated modules, each with a
dedicated bundle of wires and connections to an adjacent assigned portion of a battery stack. See Figure 7. In
some cases, these BMS submodules may reside under a primary BMS module oversight whose function is to
monitor the status of the submodules and communicate with peripheral equipment. Thanks to the duplicated
modularity, troubleshooting and maintenance is easier, and extension to larger battery packs is straightforward.
The downside is overall costs are slightly higher, and there may be duplicated unused functionality depending
on the application.
Primary/Subordinate BMS
- Conceptually similar to the modular topology, however, in this case, the slaves are more restricted to just
relaying measurement information, and the master is dedicated to computation and control, as well as external
communication. So, while like the modular types, the costs may be lower since the functionality of the slaves
tends to be simpler, with likely less overhead and fewer unused features.
Distributed BMS Architecture
- Considerably different from the other topologies, where the electronic hardware and software are
encapsulated in modules that interface to the cells via bundles of attached wiring. A distributed BMS
incorporates all the electronic hardware on a control board placed directly on the cell or module that is being
monitored. This alleviates the bulk of the cabling to a few sensor wires and communication wires between
adjacent BMS modules. Consequently, each BMS is more self-contained, and handles computations and
communications as required. However, despite this apparent simplicity, this integrated form does make
troubleshooting and maintenance potentially problematic, as it resides deep inside a shield module assembly.
Costs also tend to be higher as there are more BMSs in the overall battery pack structure.
The Benefits of Battery Management Systems
Functional Safety. Hands down, for large format lithium-ion battery packs, this is particularly prudent
and essential. But even smaller formats used in, say, laptops, have been known to catch fire and
cause enormous damage. Personal safety of users of products that incorporate lithium-ion powered
systems leaves little room for battery management error.
Life Span and Reliability. Battery pack protection management, electrical and thermal, ensures that
all the cells are all used within declared SOA requirements. This delicate oversight ensures the cells
are taken care of against aggressive usage and fast charging and discharging cycling, and inevitably
results in a stable system that will potentially provide many years of reliable service.
Performance and Range. BMS battery pack capacity management, where cell-to-cell balancing is
employed to equalize the SOC of adjacent cells across the pack assembly, allows optimum battery
capacity to be realized. Without this BMS feature to account for variations in self-discharge,
charge/discharge cycling, temperature effects, and general aging, a battery pack could eventually
render itself useless.
The Benefits of Battery Management Systems
Diagnostics, Data Collection, and External Communication. Oversight tasks include continuous
monitoring of all battery cells, where data logging can be used by itself for diagnostics, but is often
purposed to the task for computation to estimate the SOC of all cells in the assembly. This
information is leveraged for balancing algorithms, but collectively can be relayed to external devices
and displays to indicate the resident energy available, estimate expected range or range/lifetime
based on current usage, and provide the state of health of the battery pack.
Cost and Warranty Reduction. The introduction of a BMS into a BESS adds costs, and battery
packs are expensive and potentially hazardous. The more complicated the system, the higher the
safety requirements, resulting in the need for more BMS oversight presence. But the protection and
preventive maintenance of a BMS regarding functional safety, lifespan and reliability, performance
and range, diagnostics, etc. guarantees that it will drive down overall costs, including those related to
the warranty.
REFERENCES
• https://trace.tennessee.edu/cgi/viewcontent.cgi?article=1756&co
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• https://www.skyworksinc.com/Application-Pages/Automotive-Batt
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QPaEFFC3vBXvUkY-G4gNhDo7CNhg
• https://www.synopsys.com/glossary/what-is-a-battery-management-system
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