Design and Development of a Retrofit Solution for Converting a Conventional LCV into Parallel Hybrid Electric Vehicle

In today’s scenario, the emission norms are getting stringent day by day due to an increased level of pollution. The world is shifting towards low carbon footprint which made it necessary to adopt efficient technologies with fewer emissions. The hybridization of vehicles has resulted in improved efficiency with lower emissions which can fulfil the near future emission norms. Retrofitting of hybrid components into a conventional IC engine vehicle is so far the best way to achieve better performance both economically and technologically. This research is primarily focused on the design and development of a novel retrofit solution of P3x architecture for the light commercial vehicle. This retrofit solution is different from other hybrid solutions in terms of powertrain. It contains an innovative add-on powertrain along with the existing powertrain. This additional powertrain consists of a pair of helical gears followed by a chain and sprocket as a coupler for traction motor. The newly designed powertrain provides 5 different hybrid modes namely engine only mode, electric only mode, motor assist mode, battery charging mode and regenerative braking mode. The retrofit work also focuses on packaging design of hybrid components into chassis ensuring that it can sustain all load transferring from road along with additional weight without failure. To demonstrate the practical applicability of this indigenous powertrain with P3x hybrid configuration, a prototype has been developed and functionally tested on chassis dynamometer. The driving performance and fuel economy of the developed prototype were virtually tested for MIDC drive cycle. The results demonstrate a noticeable improvement in fuel economy and increase in payload compared to conventional ICE vehicle.