A Smart and Sustainable Solution for Automobiles

The hybrid solution developed by KPIT Cummins is a plug-in parallel hybrid solution that consists of the following key components:

• Electric motor
• Electronic motor controller
• Battery pack
• Mechanical assembly & coupling
• Proprietary software for control algorithms of the motor & batteries.
• Intelligent battery management system that enhances battery performance and battery life

Solution Details and Key Definitions

• Plug-in' – The batteries used in the solution can be charged from a standard external electricity source such as a domestic power outlet.
• Parallel hybrid' – The motor and engine work simultaneously at all times. At no point in time will the vehicle work like an electric vehicle only and hence will continue to operate as a conventional fuel vehicle if the batteries are fully discharged.
• The load sharing between the motor and engine is seamless and does not need any user intervention.
• The batteries are recharged through opportunity based regeneration and regenerative braking thereby enhancing the range per charge.
• The solution also includes an inbuilt Stop- Start feature, which improves the fuel efficiency in 'stop & go' traffic situations. ?The solution also has in-built intelligence which recognizes driving patterns and selfadjusts to provide optimum efficiency.
• Similarly the solution can also adjust performance based on user provided range selection.
• The solution is battery-agnostic, it can be adopted to work with various types of batteries such as lead acid batteries or lithium ion batteries. The test results being discussed were achieved using a lead acid battery based solution.
• The solution currently uses 'Valve Regulated Lead Acid' batteries. These batteries can withstand high ambient temperatures without compromising on safety or performance. Since they are gelbased they do not require top-ups with distilled water et al. Since they are sealed fumes are not emitted thus avoiding hazardous situations. Suitable mechanical safety has also been addressed.
• The solution works without any interaction or interference with the existing Engine Management System (EMS) of the vehicle. The system is thereby also adaptable to vehicles without EMS and without electronic engines.
• The solution requires low maintenance and has a reliable three phase AC induction motor.
• This solution can be made available as an Or iginal Equipment Manufacturer integrated solution or even retrofitted on vehicles as an aftermarket solution.
• 11 global patents have been filed in areas such as integrated system, motor design, motor mounting, and control system and battery management.

Benefits

• Fuel efficiency improvement of over 40% as observed during tests at ARAI. The solution however provides 60% to 80% improvement during city driving conditions & above 50% during highway driving.
• Solution is capable of reducing GHG emissions by over 30%.
• Solution provides more pep & additional power to the vehicle.
• Solution improves the ride handling and driving pleasure.
• Solution increases the life of the engine and reduces maintenance cost.
• For commercial applications when the vehicle is used for higher mileage (>55,000 kms), the breakeven is expected to be less than 1.5 years.
• Since the consumption of fuel will go down on account of the hybrid solution, the government would be able to save through the reduction in subsidy and foreign exchange outflow.
• The reduced GHG emissions will also significantly contribute to the voluntary target for emission reduction.
• Retro-fitment of this solution can be expeditiously done in 4 to 6 hours.
• Solution does not require additional infrastructure investments from the government.

Performance Results

The results of the pre-compliance test conducted at ARAI Pune

Product Note (*PDF)