To achieve the bike engine piston movement

electrically

To eliminate the use of DC motor in the hybrid vehicle.

Utilising the same bike engine instead of DC motor





Named the 2011 Motor Trend Car of the Year,

The Chevy Volt is becoming the symbol of a new breed
of hybrids.

the Volt is the Worlds first mass-produced, plug-in
electric vehicle with a range-extending onboard engine.

Features Plug-in Hybrid Conventional Hybrid
Refueling Only minimal trips to
the gas station are
necessary
Trips to the gas station
are fewer than with
non-hybrids, but still
necessary
Charging Batteries charge at
home or work
Batteries can be
charged at home or
work
Energy Storage Stored as electricity in
batteries. Gas tank
serves as back up.
Gasoline is main energy
source, augmented by
batteries
Propulsion Electric power primarily,
until battery packs are
depleted
Driving trades off
between gas-powered
engine and electric
motor
In an ordinary petrol bike engine, a solenoid coil is given
around the cylinder with the insulation in between them in
order to avoid the direct short circuiting.

The speed control like acceleration is provided by an
electronic current controller.

This approach is to drive the bike both by electrical and by
petrol.


I have chosen Splendor bike engine as my reference
engine

SPLENDOR ENGINES SPECIFICATION:
Engine : 124.7 CC
Gear box : 4
Maximum power : 6.72 KW @ 7000 RPM
Maximum torque : 10 NM @ 3500 RPM



Stroke length = 55 mm
Crank radius =120mm
Piston head area =1963sq.mm(radius=25 mm)
Cylinder thickness = 7mm
Cylinder surface area =3847sq.mm(radius=(25+7)mm)
The maximum flux density of iron = 1.5 Tesla
Flux density = (Flux)/(Area)
Area = piston head area + piston surface area
25mm + 35mm


= (3.14*0.025*0.025) +(2*3.14*0.025*0.035)
Area = 5.8875*10^-3 sq.m

Total surface area = 5.8875*10^-3 sq.m
The maximum flux = flux density * total surface area
= 1.5 * 5.8875*10^-3
= 8.83125 * 10^-3 weber
Maximum flux = 8.83125 milli weber
Utilising three fourth of the outer cylinder for solenoid
winding
Copper bar with suitable diameter should be selected in
order to withstand the current
Supply current should be 20 to25% more than the
required magnetising current in order to feed the losses
The maximum winding possible is given around the
solenoid


Force should be calculated from the following formula
Assume the crank radius = 1.76cm

Force = Torque / Radius
= 10 / 0.0176
= 570 Newton(in the crank)

Add 10% of crank force in the piston i.e. 627 N

This force should be available in combustion chamber
Power = velocity of the piston * force
Velocity of the piston = RPS * 2* stroke length
= 3500 * 2* 0.0552 / 60
= 6.44 m/s
Power = 2*3.14* RPS * torque
= 6.24 * 58.33 * 10
= 3663.33 watt
Force = Power / velocity of the piston
= 3663.33 * 6.44
= 572.4 Newton
For 10 ampere current the diameter will be
1.5mm.



FORCE = (0.5 * 4*3.14 *10
-7
*(AT)
2
* AREA) / (AIR GAP)
2

Here, the required force is 570 Newton.

(AT)

= ((force * air gap
2
) / ( 0.5 * 4 * 3.14 * 10
-7
* area))
0.5


MMF = ((570 * 0.05
2
) / (0.5 * 4 * 3.14 * 10
-7
* 3.14*0.025
2
))
0.5

MMF = 34000 AT

The diameter of the copper wire

Current density = ampere / millimeter square

Current density of copper 4 A/sq.mm

Required radius of the wire = 1.32mm

Required diameter of the wire =2.64 mm

That is we required 8 gauge insulated copper wire


Since the inductance in the single coil solenoid as
calculated has more transient response.

So we decided to have a multi coil to reduce the overall
inductance.
SINGLE COIL SOLENOID MULTI COIL SOLENOID
For the same ampere rating the
steady state response is 200 mille
second.
For the same ampere rating the
steady state response is 6 mille
seconds
This 200 mille second is for one
half cycle
This 6 mille seconds is for one
half cycle
For 1 second the rotation is 2.5
RPS
For 1 second the rotation is
67.667 RPS
The RPM is 150 RPM Here the RPM is 4100 RPM
Equivalent coil inductance is
2.1MH
Equivalent coil inductance is
0.06844MH
SINGLE COIL SOLENOID MULTI COIL SOLENOID
For the same ampere rating the steady
state response is 200 ms.
For the same ampere rating the steady
state response is 6 ms
This 200 ms is for one half cycle This 6 ms is for one half cycle
For 1 second the rotation is 2.5 RPS For 1 second the rotation is 67.667 RPS
For one minute the speed is 150 RPM For one minute the speed is 4100 RPM
Equivalent coil inductance is 2.1 mH Equivalent coil inductance is 0.06844 mH
Equivalent coil resistance is 0.08 ohm Equivalent coil resistance is 0.08 ohm
MULTI COIL CURRENT RESPONSE
The power electronic uses a quasi square wave mode
phase shifted PWM LCC resonant converter for
regulated power supply

This power electronic circuit is an ieee paper

Using series resonance, zero current switching and zero
voltage switching, this varies the current by PWM

For example 5 to 20 ampere variation can be achieved


The approach of designing the solenoid is to pull the piston
upward

Once the piston reaches the top dead end of the combustion
chamber, the solenoid supply should be turned off.

Utilising the kinetic energy stored in the fly wheel, the
piston automatically reaches the bottom dead position

Then again the supply is given, once again the solenoid
pulls the piston to top dead position
The cylinder should be
made of aluminium alloy
The piston should made of
cast iron
In Morden vehicle,
both engines piston and
cylinder is made of
aluminium silicon
In earlier vehicle, both
engines cylinder and piston
is made of cast iron


This electrical arrangement will not alter the
mechanical dynamics of the engine

The clutch and the gear changing mechanism is the
same

This features the driver to have similar driving
experience as that of conventional bike
Even though the efficiency of the
aforementioned engine has less efficiency,
this hybrid vehicle is affordable even to the
common man. A hope bring revolution in the
field of hybrid vehicle and reduce the global
warming.
Current controller with soft switching from ieee
explore
Battery selected from www.powerdesigners.com
Text book A.K.SAWHNEY