74 Electric and Hybrid Vehicles TABLE 3.4 Mass Analysis of ICEV and HEV Engine and transmission Exhaust system Fuel system (tank and lines) Fuel mass Component ICE Vehicle Mass, kg Hybrid Vehicle Mass, kg 147 125 9 15 Electric drive motor 108 40 13 38 50 Starter/generator Starter/generator controller 6 22 26 Electrical thermal management 15 Traction battery 75 12 V battery Alternator Battery hardware, cooling 28 14 6 5 Total powertrain Climate control and accessory Glider with chassis subsystems Total curb mass 26 1,445 1,734 263 30 1,449 1,954 479 FIGURE 3.18 Component packaging in a hybrid vehicle. motor-driven compressor pump.
The example analysis in Table 3.4 shows an increase of 82% in the powertrain mass for the Akron hybrid vehicle. The mass budget could have been restricted sig- nificantly had a downsized gasoline engine been used, although that would have adversely affected fuel economy. Packaging of components also has to be carefully evaluated during the design of a hybrid vehicle. A component packaging diagram must be developed to ensure that all the system components fit in the vehicle without compromise to safety and customer amenities. A simplified layout diagram based on the Akron hybrid is shown in Figure 3.18; the fuel lines and exhaust piping are not shown here for keeping the figure simple.
The packaging of the fuel and exhaust components can become cumbersome, especially when an IC engine vehicle is being re-engineered into a hybrid vehicle.