Comprehensive Thermal Modeling of Power Split Hybrid Drive System

Safety, performance and driving comforts are given high importance while developing modern day cars. All-Wheel Drive vehicles are exactly designed to fulfill such customer requirements. In modern times, human concern towards depleting fossil fuels and cognizance of ecological issues have led to new innovations in the field of Automotive engineering. One such outcome of the above process is the birth of electrical hybrid vehicles. The product under investigation is a combination of all wheel drive and hybrid system. A superior fuel economy can be achieved using hybrid system and optimized vehicle dynamic forces are accomplished by torque vectoring action which in turn provides All-Wheel Drive capabilities. The very basic definition of engineering is ‘to optimize phenomena of physics for the improvement of human lives’. Ideally, Engineers don’t like power losses. But heat generation is inevitable whenever there is a conversion of energy from one form into another. In this master thesis investigation, a thermal simulation model for the product is built using 1D simulation tool AMESim and validation is done against the vehicle driving test data. AMESim tool was chosen for its proven track record related to vehicle thermal management. The vehicle CAN data are handled in MATLAB. In a nutshell, Simulation model accounts for heat generation sources, oil flow paths, power loss modeling and heat transfer phenomena. The final simulation model should be able to predict the transient temperature evolution nin the rear drive when the speed and torque of motor is supplied as input. This simulation model can efficiently predict Temperature patterns at various locations such as casing, motor inner parts as well as coolant at different places. Various driving cases were tried as input including harsh (high torque, low speed) ones. Simulation models like this helps Engineers in trying out new cooling strategies. Flow path optimization, flow rate, convection area, coolant pump controlling etc. are the few variables worth mentioning in this regard.