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Electric Powertrain Topology Analysis and Design for Heavy-Duty Trucks

Author

Listed:
  • Frans J. R. Verbruggen

    (Department of Mechanical Engineering, Eindhoven University of Technology, P.O. Box 513, 5600 MB Eindhoven, The Netherlands)

  • Emilia Silvas

    (Department of Mechanical Engineering, Eindhoven University of Technology, P.O. Box 513, 5600 MB Eindhoven, The Netherlands)

  • Theo Hofman

    (Department of Mechanical Engineering, Eindhoven University of Technology, P.O. Box 513, 5600 MB Eindhoven, The Netherlands)

Abstract

Powertrain system design optimization is an unexplored territory for battery electric trucks, which only recently have been seen as a feasible solution for sustainable road transport. To investigate the potential of these vehicles, in this paper, a variety of new battery electric powertrain topologies for heavy-duty trucks is studied. Thereby, topological design considerations are analyzed related to having: (a) a central or distributed drive system (individually-driven wheels); (b) a single or a multi-speed gearbox; and finally, (c) a single or multiple electric machines. For reasons of comparison, each concurrent powertrain topology is optimized using a bilevel optimization framework, incorporating both powertrain components and control design. The results show that the combined choice of powertrain topology and number of gears in the gearbox can result in a 5.6% total-cost-of-ownership variation of the vehicle and can, significantly, influence the optimal sizing of the electric machine(s). The lowest total-cost-of-ownership is achieved by a distributed topology with two electric machines and two two-speed gearboxes. Furthermore, results show that the largest average reduction in total-cost-of-ownership is achieved by choosing a distributed drive over a central drive topology (−1.0%); followed by using a two-speed gearbox over a single speed (−0.6%); and lastly, by using two electric machines over using one for the central drive topologies (−0.3%).

Suggested Citation

  • Frans J. R. Verbruggen & Emilia Silvas & Theo Hofman, 2020. "Electric Powertrain Topology Analysis and Design for Heavy-Duty Trucks," Energies, MDPI, vol. 13(10), pages 1-30, May.
    • Handle: RePEc:gam:jeners:v:13:y:2020:i:10:p:2434-:d:357229
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    Citations

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    Cited by:

    1. Emad Roshandel & Amin Mahmoudi & Solmaz Kahourzade & Amirmehdi Yazdani & GM Shafiullah, 2021. "Losses in Efficiency Maps of Electric Vehicles: An Overview," Energies, MDPI, vol. 14(22), pages 1-27, November.
    2. Shantanu Pardhi & Sajib Chakraborty & Dai-Duong Tran & Mohamed El Baghdadi & Steven Wilkins & Omar Hegazy, 2022. "A Review of Fuel Cell Powertrains for Long-Haul Heavy-Duty Vehicles: Technology, Hydrogen, Energy and Thermal Management Solutions," Energies, MDPI, vol. 15(24), pages 1-55, December.
    3. Aroua, Ayoub & Lhomme, Walter & Redondo-Iglesias, Eduardo & Verbelen, Florian, 2022. "Fuel saving potential of a long haul heavy duty vehicle equipped with an electrical variable transmission," Applied Energy, Elsevier, vol. 307(C).
    4. Armin Norouzi & Hamed Heidarifar & Mahdi Shahbakhti & Charles Robert Koch & Hoseinali Borhan, 2021. "Model Predictive Control of Internal Combustion Engines: A Review and Future Directions," Energies, MDPI, vol. 14(19), pages 1-40, October.
    5. Anselma, Pier Giuseppe & Belingardi, Giovanni, 2022. "Fuel cell electrified propulsion systems for long-haul heavy-duty trucks: present and future cost-oriented sizing," Applied Energy, Elsevier, vol. 321(C).
    6. Shantanu Pardhi & Mohamed El Baghdadi & Oswin Hulsebos & Omar Hegazy, 2022. "Optimal Powertrain Sizing of Series Hybrid Coach Running on Diesel and HVO for Lifetime Carbon Footprint and Total Cost Minimisation," Energies, MDPI, vol. 15(19), pages 1-28, September.
    7. Sebastian Wolff & Svenja Kalt & Manuel Bstieler & Markus Lienkamp, 2021. "Influence of Powertrain Topology and Electric Machine Design on Efficiency of Battery Electric Trucks—A Simulative Case-Study," Energies, MDPI, vol. 14(2), pages 1-15, January.
    8. Konstantina Bitsi & Sjoerd G. Bosga & Oskar Wallmark, 2022. "Design Aspects and Performance Evaluation of Pole-Phase Changing Induction Machines," Energies, MDPI, vol. 15(19), pages 1-18, September.

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