Fuzzy Logic Controlled Two Speed Electromagnetic Gearbox for Electric Vehicle
Published at : 01 Apr 2022
Volume : IJtech
Vol 13, No 2 (2022)
DOI : https://doi.org/10.14716/ijtech.v13i2.3913
Rahman, A., Hassan, N., Ihsan, S.I., 2022. Fuzzy Logic Controlled Two Speed Electromagnetic Gearbox for Electric Vehicle . International Journal of Technology. Volume 13(2), pp. 297-309
| Ataur Rahman | Department of Mechanical Engineering, International Islamic University Malaysia, 50728 Kuala Lumpur, Malaysia |
| Nurul Hassan | Department of Mechanical Engineering, International Islamic University Malaysia, 50728 Kuala Lumpur, Malaysia |
| Sany Izan Ihsan | Department of Mechanical Engineering, International Islamic University Malaysia, 50728 Kuala Lumpur, Malaysia |
Epicyclic transmission (ET), five-speed manual
gearbox (5-SMT), automatic transmission (AT), and continuously variable
transmission (CVT) are all possible transmission options for electric vehicles
(EVs). The ET is so complex that motorists may be unaware that they are in
gear. As the 5-SMT, AT, and CVT transistors are heavier, they consume more
energy. Although a single-speed gearbox is lighter, it is not capable of
developing enough torque for acceleration. Therefore, this study presents a
fuzzy-logic-controlled electromagnetic two-speed gearbox (AEM-2SGB) model for
EVs. The electromagnetic actuator is modelled in terms of electromagnet size,
number of coil turns, supply current, and electromagnetic force needed to shift
gears. The parametric analysis of AEM-2SGB is conducted using Matlab Simulink
and a fuzzy simulation model. According to the results, the AEM-2SGB has a
first-gear shift time of 110 ms at 300 Nm motor torque and a second-gear shift
time of 116 ms at 110 km/h vehicle speed, with a maximum current supply of 16 A
using a 24 V lithium ion battery. The AEM-2SGB reduces weight by 37%-66%,
transmission losses by 40%–90%, and battery life by 5%.
AI-embedded IoT controller; Compact and low-cost transmission; Electromagnetic gearbox; Energy efficient; Fuzzy logic controller
The market share of electric vehicles (EVs) will be boosted by
their ability to reach higher ranges and their target to increase design
efficiency and reduce manufacturing costs to become affordable to more customer
segments (Bottiglione et al., 2014). In one
study, the adoption of two-speed transmission over single-speed transmission
gave rise to a reduction in energy consumption over numerous driving cycles of
up to 4% for the case study vehicles (Jose et al., 2021). The power
transmission of Evs mostly a single-speed transmission system, while MT, AT,
and CVT are the transmission options for hybrid electric vehicles (Miller, 2006; Jaafar et al., 2020). A novel
two-speed inverse automated manual transmission was examined, and the gear
ratios were optimized using dynamic programming. Gear shift control was
addressed, and a smooth shift process without a torque hole was achieved
through feed-forward and feed-back control of the clutch and the motor. The
performance of a two-speed transmission EV
was compared with that of
The power requirement of EVs
depends on the traction power, which mostly depends on the weight of the EVs.
The power loss of EVs is 5%–15% for manual transmission due to gear shifting
from the first to the fifth gear, 15%–20% for automatic transmission (AT) due
to slow pressure development in the torque converter, and 15%–25% for CVT (Rahman
et al., 2012). Sorniotti et al. (2011) examined
the performance of EVs using single-speed transmission and two-speed
transmission and found a significant advantage in adopting a two-speed
transmission system over a single-speed transmission system.
The power of EVs is limited
compared to that of an internal combustion engine, as it requires much time to
refuel energy. Therefore, it is important to save the power of EVs by
decreasing transmission weight and reducing transmission loss by eliminating
the number of gear shifts. Moreover, manual transmission, AT, and CVT are bulky
and unsuitable in the available space of EVs because their power train space is
limited in order to maintain vehicle performance (Sorniotti et al., 2011;
McKeegan, 2020).
According to a report, it could benefit EVs and make them 5% energy
efficient, but it caused much transmission power loss due to the slower motor
response (Porsche, 2019). Tesla
originally planned to put a two-speed gearbox in the original Roadster
manufactured by the gear manufacturing company ZF (Germany).
According to a review of EV
powertrains on the road, EVs can be equipped with epicyclic transmission, a
five-speed manual gearbox (5-SMT), AT, or CVT. Energy usage and gear shifting
are issues with the aforementioned transmission methods for EVs. Although a
single-speed gearbox is lighter, it is not capable of developing enough torque
for acceleration. As a result of transmission problems, a technological
innovation to solve them should emerge (Berawi, 2021, Rahman et
al., 2019).
This study aimed to present a two-speed
fuzzy-controlled electromagnetic gearbox (EMA2SGB). This aim was achieved by
(i) examining the vehicle’s dynamic torque requirement in traction and speed
while cruising and (ii) analyzing the electromagnetic force equivalent to the
gear shifting axial force. The gearbox was designed based on the outcome of the
first sub-objective outcome, and the second sub-objective outcome was used to
design the electromagnetic actuator (EMA) as the gear shifter.
The potential of AEM2-SGB is obvious in changing from the first to the second gear and from the second to the first gear because of the efficacy of the fuzzy controlling mechanism using sensors and magnets. The AEM-2SGB is a prospective gearbox for EVs owing to its weight reduction of 37%–66%, transmission loss reduction of 40%–90%, and battery life enhancement of 5%.
- For traction, AEM-2SGB’s autonomous fuzzy intelligence system allows it to shift gears from the second to the first in 110 ms and from the first to the second in 116 ms. As a result, it eliminates the issue of vehicle traction control interruption and reduces transmission loss by 42%–93%.
- In terms of energy savings, compared to other potential gearboxes, an EV will save 743 Wh, 1,245 Wh, and 1,500 Wh of battery power if the 5SMT, 7SDCT, and 4SAT are replaced with 2-SAEMT, respectively. As a result, the EV will gain an additional 6–8 km of mileage and a 15% boost in battery life due to a 10% reduction in battery charge frequency.
The
authors are grateful to the Finance Division of the International Islamic
University Malaysia for financing this project as a Flagship Project entitled
“Electric Coaster Innovation” (Ref. IRF19-032-0032).
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