127001924 hybrid technology avl capabilities
DESCRIPTION
phevTRANSCRIPT
Electrification for CV AVL Services and References
Peter Ebner, Raimund Ellinger
Powertrain and Hybrid System
AVL-List
2
Introduction
AVL capability in Hybrid development
AVL capability in Hybrid / System engineering
AVL CV Hybrid experience / References
3
Introduction
AVL capability in Hybrid development
AVL capability in Hybrid / System engineering
AVL CV Hybrid experience / References
4
0
50
100
150
200
250
300
350
400
450
500 1000 1500 2000 2500Vehicle Curb Weight [kg]
CO
2 E
mis
sio
n i
n N
ED
C [
g/k
m]
Gasoline NA
Diesel
Gasoline Turbo
Hybrid (gasoline)
CNG Turbo
China Stage 2 -CO2 [g/km]
China Stage 3 -CO2 [g/km]
EU-proposed CO2Limit
Source: AR 2010
Electrification Market - Overview Motivation
5
Serial Hybrid
Electric Coupling of
Engine & Wheels
Parallel Hybrid
Direct mech. Connection
Engine Wheels
Powersplit Hybrid
Electromechanic Coupling
eCVT Operation Mode
ICE
Inverter
Generator Motor
AC
DC
AC
DC
AC
DC
ICE
MT
/AT
Inverter
E-Motor
ClutchMotor A Motor B
AC
DC
AC
DC
ICE
S 400 Hybrid Citaro Hybrid ML 450 Hybrid
Hybrid Solutions Degree of Electrification & Hybrid Topologies
6
Micro Hybrid Mild Hybrid Full Hybrid PlugIn Hybrid RangeExt EV
1...5 km 10...45 km 25...50 km > 75 km
SOLUTIONS DIVERSITY Electrified Powertrains Today Are Highly Diversified
with ICE
1 – 3 kW 5 – 15 kW 20 – 60 kW 40 – 80 kW 20 – 120 kW 20 – 120 kW
<<1 kWh 0.5 – 1.5 kWh 1 – 5 kWh 5 – 15 kWh 10 – 15 kWh 15 – 30 kWh
Rated power
electric drive
Rated capacity
battery
Grid Charging
without
7
Control Strategy
Battery
Transmission
Electric Motor
IC Engine
Introduction of Hybrid Understanding & Managing of System Complexity
System electrification adds complexity due to:
Multiple torque providers (engine, motors)
Highly integrated systems (ex. powertrain to chassis)
Complex safety requirements (ex. high voltage devices)
Interactive controls requirements
Lack of field history
Managing the complexity requires a refined methodology and
disciplined systems engineering approach that balances and
optimizes system requirements.
8
Introduction of Hybrid Manage Complexity Define Configuration & Optimize Components
IC Engine
Transmission
Electric Motor
Control Strategy
Battery
9
IC Engine
Transmission
Electric Motor
Control Strategy
Introduction of Hybrid Manage Complexity Define Configuration & Optimize Components
Battery
10
Powertrain • Performance
• Drivability
• Torque control
• Motor controls
• Motor noise
• Thermal Management
• Energy management
HVAC • Cabin Comfort
• Heated seats
• Defog/defrost
• NVH
Displays/HMI • Range indication
• Power limitations
• Charger status
• Efficiency aids
• Fault conditions
• Customer interaction
Safety/Reliability • DFMEA
• Hazard analysis
• Reliability targets
• Controls
• Crashworthiness
• HV mechanization, cabling, connectors
• Verification and validation
Chassis • Blended braking
• ABS
• Stability controls
• Steering
• Ride and handling
• Mounts
• Fuel system
HV Distribution • Battery performance
• Battery thermal
• Charging System
• Power management
• Power electronics
• Cabling & Fusing
• DC to DC
Electrification impacts many sub- systems
Requirements development and system design must
take all into account.
System Interactions
Wheel
Drive
Device
Propulsion system
Electric machine
Motor Control / Power Electronics
DC / DC Converter
HV Distribution
HV Battery
LV Battery
Vehicle Ambient Air /
Environment
Vehicle Ambient Air /
Environment Vehicle
Ambient Air /
Environment
Vehicle
Ambient Air /
Environment
3 phase
3 p
h a
s e
3 phase
3 p
h a
s e
3 phase
3 p
h a
s e
Vehicle
Ambient Air /
Environment
Vehicle
Ambient Air /
Environment
HV Charger
Vehicle
Ambient Air /
Environment
Vehicle Ambient Air /
Environment
Charge Coupler
Vehicle Ambient Air /
Environment
H V I L
HVIL
H V
I L
H V I L
H V
I L
H V
I L
HVIL HVIL
BMS
MCU
Battery Module
MCU
Battery Module
MCU
Battery Module
Hybrid Controller
Introduction of Hybrid Manage Complexity Define Configuration & Optimize Components
11
Transmission
Electric Motor
Control Strategy
IC Engine
Manage Electrification Optimize Interactions
More than 1000
engine development
project in the past 60
years!
Battery
12
AVL – Transmission Service Overview
Benchmark:
•AVL – DRIVE
•Testing
Concept&Design:
Analysis:
Calibration:
•AVL – GSP
•ACT
Simulation:
SW & Controls:
Testing: Maneuver &
event based testing
Hydraulic:
Specific design, analysis and
application know-how for
transmissions.
13
Transmission
Electric Motor
Control Strategy
IC Engine
Manage Electrification Optimize Interactions
Battery
14
Testing & Benchmarking
Thermal simulation
Design Engineering
Prototype built-up BMS series development (SW & HW)
Validation target:
300.000 km cycle life
12 years calendar life
EMC targets fulfilled
System interaction ok
System validation
Cell/Pack Production
Process Assurance
Test equipment development
Battery
Battery Development at AVL
15
Transmission
Electric Motor
Control Strategy
IC Engine
Manage Electrification Optimize Interactions
Battery
16
Power Electronic
E-Motor Development
EMC
Electrical Machines
Power Electronics
Emissions
AVL E-Drive Development Elements
17
Power Electronic
E-Motor Development
EMC
AVL E-Drive Development Elements
Development of customized electrical
machines and power electronics
Experience over large bandwidth of
technologies and machine sizes
Development process Know How
(concept, design, validation and
industrialization)
Strong experience ‘designing EMC
behavior into the product’
Process frontloading using experience
and simulation capabilities
Concept study, single prototype or
series production development
18
test on testbench
system concept
design & simulation
AVL Trimerics: E-Motor Development Motor/Generator for CV Applications (PEPS)
~=
~=
~=
~=
~=
~=
E
E
E
E
E E
mechanical design
E-Machines: - High power density due to efficient liquid cooling - Integrated power electronics - 70% saving of space vs. standard systems - 40% saving of weight vs. standard systems - Completely electrical insulated
PEPS: Protected Electrical Power System
19
Transmission
Electric Motor
Control Strategy
IC Engine
Manage Electrification Optimize Interactions
Battery
20
Customer specific
Powertrain Control
Software and Function
solutions
CONCEPT &
PROTOTYPE
DEVELOPMENT
SERIES
SOFTWARE
DEVELOPMENT
SERIES
FUNCTION
DEVELOPMENT
SOFTWARE
VERIFICATION &
VALIDATION
SOFTWARE &
FUNCTION
DEVELOPMENT
CONSULTING
AVL Powertrain Control Services
Production Level SW available for:
Parallel Hybrid
EV with RE
21
Full or Mild HEV
ICE DC
Motor
Inverter
Motor
Generator
Battery
Control
Unit
EMS
Hybrid
Control
Unit
ABS
ESP
Resistor
HV MainRelay-P
Pre-chargeRelay
HV Main
Battery Modules-P
Battery Modules-NResistor
HV MainRelay-P
Pre-chargeRelay
HV Main
Battery Modules-P
Battery Modules-N
Battery Pack
Cluster HMI
OBD
CAN
AVL Powertrain Control Services Increase of Control Complexity
22
Transmission
Electric Motor
Control Strategy
IC Engine
Manage Electrification Optimize Interactions
Battery
23
Introduction
AVL capability in Hybrid development
AVL capability in Hybrid / System engineering
AVL CV Hybrid experience / References
24
System Design Key Tasks Systematic Engineering & Development Approach
POWERTRAIN SUB-SYSTEM
Vehicle Attribute Targets
and Boundaries
Topology and System Integration
Sub-System Sepcification
Top Down Approach
The Vehicle Targets define the optimal system
topology & component requirements.
VEHICLE
25
System Design Key Tasks Systematic Engineering & Development Approach
VEHICLE POWERTRAIN SUB-SYSTEM
Vehicle Benchmark
System Simulation
Requirement Engineering
System Safety
System Integration
System Software
System Engineering
System Validation
System Calibration
Vehicle Attributes / Targets
Environmental Cond.
Use Cases / Regulations
26
Realisation / Implementation
Component Test Component Design
Time
System
Details
Powertrain Test
In Vehicle Test
Fleet Tests
Powertrain Design
Concept
Target Definition
Sys
tem
C
om
po
nen
t
Component Specification Component Integration
Phase 3: System Validation Phase 1:
System Design
Phase 2: Component Development
System Design Key Tasks Systematic Engineering & Development Approach
27
Realisation / Implementation
Component Test Component Design
Time
System
Details
Powertrain Test
In Vehicle Test
Fleet Tests
Powertrain Design
Concept
Target Definition
Sys
tem
C
om
po
nen
t
Component Specification Component Integration
Phase 3: System Validation Phase 1: System
Requirements and
Design
Phase 2: Component Development
Vehicle Benchmark
System Simulation
Requirement Engineering
System Safety
System Integration
System Software
System Test & Validation
System Calibration
System Design Key Tasks Systematic Engineering & Development Approach
28
Quality Gates
Development Generations (Operative & Coordinating)
Interface to Project Process
Interface to Element
Processes
System Design Key Tasks Systematic Engineering & Development Approach
29
Element Processes Direct
Support Documents
Support Documents
RASI
Generic Timeline
Skill Areas
Level 1 Level 2
Level 3
System & Element Quality Gates
Coordinating
System Engineering
Operative
System Design Key Tasks Systematic Engineering & Development Approach
30
System Design Key Tasks Systematic Engineering & Development Approach
Vehicle Benchmarking
Objective Measurement &
Quantification of Vehicle Attributes
(Reference Vehicle, hybrid or non-
hybrid)
Vehicle Level Attribute
Engineering: Definition &
Quantification of the Target
Attributes, the related Use- & Test
Case and the Acceptance Criteria
Analysis of vehicle and powertrain
functionalities
Analysis of powertrain and
component‘s attributes
(performance, efficiency)
Significant Measurement DataSignificant Measurement Data
-> Measures Driver input and Vehicles reaction!
130,0 131,5 133,0 134,5 136,0 137,5 139,0 140,5 142,0 143,5 145,0time [s]
Acc_
Ch
assis
X_
sm
o [m
/s²]
-2
0
2
4
6
8
En
gin
e_
Sp
ee
d [rp
m]
0
1000
2000
3000
4000
5000
Ve
hic
le_
Sp
ee
d [km
/h]
0
50
100
DC
DC
_S
tate
0
2
TC
C_
Sta
te
0
10
20
To
rqu
e [N
m]
-300
0
300
600
Acc_ChassisX_smo
Engine_Speed
TCC_Speed
EM2_Speed
Vehicle_Speed
DCDC_State
TCC_State
EM2_Torque
Engine_Torque
31
System Design Key Tasks Systematic Engineering & Development Approach
System Simulation - Concept
Extended and detailed simulation
of entire system
Assessment of Topology (Optimize
Configuration)
Assessment of Component
Performance
Assessment of System Functionality
Assessment of Fuel Efficiency,
Emissions and Performance
Assessment of Driveability aspects
Trade-off Analysis
Sensitivity Analysis
Benchmarking & Comparison of
Hybrid Concepts
Rating of Concepts according
application specific rating criteria
Powersplit
Double Clutch
32
System Design Key Tasks Systematic Engineering & Development Approach
Cycle 3 Cycle 2
Cycle 1
Cycle n
Real World Usage Profiles
Cycle 3 Cycle 2
Cycle 1
Cycle n
Cycle 3 Cycle 2
Cycle 1
Cycle n
20
40
60
80
10
0
12
0
14
0
16
0
18
0
20
0
22
0
24
0
12
34
56
78
910
1112
0%
1%
2%
3%
4%
5%
6%
7%
8%
9%
Events
Energy [kJ]Power [kW]
Recuperation Event Distribution - Rated with Road Distribution from RWUP
Component load profiles Load distribution =
collective load
Vehicle Simulation
System Simulation - Support
Detailing of Component
Specification:
Performance Requirements at appl.
spec. Performance Tasks
Lifecycle loads – load distribution
(input for reliability & lifecycle)
Detailing of System Function
Specification
system control functionality
Communication demands
torque & energy management
Target Achievement Tracking
Introduction of Supplier Information
Continuous Monitoring of Target
Achievement (virtual target tracking)
Generation of SIL, MIL & HIL
Model Development for
Integration- & Testing- Support
33
Requirement Engineering I
Systematic Description of
Vehicle (Application, Usage &
Boundary Conditions)
Powertrain Topology
Components & Sub- Components
Powertrain Functions (partly
functional Architecture)
Operations condition (Driving &
Non-driving)
Systematic specification of
components and Control SW
function requirements
Definition of Test Cases for
Component & System/Vehicle
Testing
Calibration Targets
Acceptance Criteria for Validation
System Design Key Tasks Systematic Engineering & Development Approach
Use Cases
Functions
Requirement
Functions
Product
Functions
Powertrain System
Vehicle
Requirements (technical & functional)
Powertrain Elements &
Components
Cu
sto
me
r o
rie
nte
d, tr
ace
able
, co
nsis
tent,…
34
System
Feature(s)
Driving
Feature
Non Driving
Feature
Torque
Distribution
Energy
Management
Engine
Start Stop
Drivetrain
Configuration
Auxiliary
Control
Development
Production
EOL
Safety
Diagnosis
Maintenance
Drive
Brake
Charge
Discharge
Comfort
Stability
Vehicle
Operation
Immobilizer
System Design Key Tasks Systematic Engineering & Development Approach
Requirement Engineering II
Systematic Development &
Description of System
Functionality
Driving Functions (e.g. el. Drive,
Recuperation, …)
Non- Driving Functions (e.g.
Charging from Grid, …)
Auxiliary Control Functions (e.g.
Board Net Supply, Cooling, …)
Calibration Guidelines
Acceptance Criteria
Generation of System related
Requirements for SW
Development
Generation Software related Use-
& Testcases for SW Development
& SW Testing
35
System Design Key Tasks Systematic Engineering & Development Approach
Software Development (System Level Functionality)
Development of SW Architecture
Interface Specification
System Interface
Base- & Application SW Interface
SW Component Specification
SW Component Requirement
Specification
Model Base Coding & Auto Code
Generation
SW Integration (into target Control
Unit)
SW Testing (component & system
level), incl. test documentation
SW Documentation
Calibration Guidelines
Application Lifecycle Management Integrity (MKS)
Label repository
ModelingCode generation
Verification &Validation
SW Build R
eq
uir
em
en
t e
ng
ine
eri
ng
Model Testing & Rapid Prototyping
AVL Plant model
HiL test
Naming convention
Modeling Guideline
MBFS-ASAM Blockset
Implementation Guideline
MBFS-ASAM Library
ADD (Visu-IT)Automotive Data Dictionary (in discussion)ADD (Visu-IT)Automotive Data Dictionary (in discussion)
Make,
Perl …
Compilers:
Altium…
Matlab / Simulink Matlab / Simulink
Ascet MD Ascet SE
TargetLink
Intecrio
ES910 ES1000
RTI
MicroAutoboxPT LabcarPT Labcar
Full Size
36
System Integration
Mechanical, thermal, electrical
and functional integration
Definition of Controller topology
and communication matrix
Definition of Changes for base
vehicle interfaces
Packaging
Powertrain
Control Units
Wiring Harness (LV, HV, CAN, …)
Cooling System
…
Supplier Management
Commissioning
Initial Testing
System Design Key Tasks Systematic Engineering & Development Approach
37
System Safety Development
Safety Assessment
Identification of Risks / Hazards
Functional, Mechanical, electrical
(HV) and chemical safety
Functional Safety Concept
Generation of Safety
Requirements
Methodology in place: Hazard
analysis, FMEAs
Safety Development according
Market & Application related
Standards & Regulations (e.g. ISO
26262 compliance for PC)
Technical Safety Concept
Compliant Technical Solution
Safety Process according
Standard
Safety Testing Verification of
Solution
Severity Exposure
Controllability
System Design Key Tasks Systematic Engineering & Development Approach
38
System Design Key Tasks Systematic Engineering & Development Approach
System Testing
Test planning (Component Test &
System Tests) = Generation of
DVP
Component Testing
Functional Testing
Integration Testing
Lifecycle & Reliability Testing
Definition of Acceptance Criteria
MIL / SIL / HIL Testing (Test
Execution)
Component Testing on related
Test- beds
Powertrain Testing (with battery
simulator)
Initial Calibration
Road Testing (introduction of in
vehicle test equipment)
Shutdown Positions
02
46
810
270
280290
300
310
320
330
340
350
0
10
20
30
40
50
60
7080
90
100110
120
130
140
150
160
170
180
190
200
210
220
230
240
250260
Valeo
All
Bosch
TDC Cylinder 1
Co
un
ts
39
Hybrid System Calibration
Deep understanding of overall
system and functional interactions
required
Robustness investigation (P-
diagram) for control functions in
order to define calibration targets
Calibration process with defined
quality gates
Coordinated, iterative approach
between component calibration &
system calibration
Introduction of specific tools &
equipment (battery simulator)
Simulation support for specific
criteria
Analysis of
Powertrain
Boundaries
Definition of
Functionality
Matrix
Definition of
Calibration
Requirements
and Priority
Detailed
Analysis
Field of
Calibration
Calibration
and Test
Planning
System Design Key Tasks Systematic Engineering & Development Approach
40
System Design Key Tasks Systematic Engineering & Development Approach
System Project Management
Continuous Customer
Communication
Continuous Project Target
Tracking & Monitoring
Ensure System Development
Process Compliance
Ensure Project Quality
Final Release of Project
Documents
Supplier Management
Change- & Concern Management
41
Integrated Toolchain for System Development
Chassis Dyno
Vehicle
Simulation
Vehicle
Development
Vehicle Validation
Prod. Signoff
System Testing /
HIL
Battery/Motor
Testing / HIL
Powertrain
Simulation
Cell/Module/Battery
Simulation
AVL Instrumentation & Test Systems
BATTERY
TESTBED
HIL DEVELOPMENT
POWERTRAIN
TESTBED
ICE
TESTBED
AVL-CRUISE
AVL-BOOST
AVL Software Tools for Powertrain System Development & Optimization
AVL-FIRE
AVL-CAMEO
AVL-DRIVE
AVL-EXCITE
42
AVL Offer Hybrid Development Services up to SOP
HEV Benchmarking
Simulation & Evaluation Target Definition
System Development & Requirements Engineering
Mechanical Integration
Functional and E/E Integration
Software Development
System Safety Development & Assessment
Component Development (e.g. Battery Systems)
Test, Verification & Validation planning and execution
Vehicle build and testing
Hybrid System Controls and Calibration
Consulting
43
Introduction
AVL capability in Hybrid development
AVL capability in Hybrid / System engineering
AVL Hybrid experience / References
44
BMW Efficient Dynamics Citroen C3 Stop&Start CPT Prototype (Audi A4)
Smart Starter Motor (SSM)
Belt Starter Generator (BSG)
AVL
AVL Hybrid Solutions & References Micro Hybrid Systems (Start / Stop)
45
AVL Mercedes-Benz S400 BlueHybrid AVL Turbohybrid P1 Diesel Mild Hybrid
AVL Hybrid Solutions & References Mild Hybrid Systems
46
AVL Peugeot 3008 HYbrid4 Porsche Cayenne S Hybrid JL&R V6D Hybrid
electrification
of auxiliaries
electrification
of auxiliaries
electrification
of auxiliaries
ICE
FE
AD
Automatized
Manual
Transmission
Differential
(front axle)
Battery
Differential
(rear axle)
Hybrid
Manager
Inverter
AVL Hybrid Solutions & References Parallel Full Hybrid Systems
47
AVL BMW Vision Efficient Dynamics Fisker Karma Plug-In Prototype
electrification
of auxiliaries
Battery
ICE
E-Motor /
Generator
Differential
DCT
Differential
(front axle)
E-Motor /
Generator
Inverter
Battery
Inverter
ICE
GeneratorDifferential (rear axle)
E-Motor /
Generator
AVL Hybrid Solutions & References Parallel Full Hybrid Plug- In Systems
48
AVL Jaguar C-X75 AVL EVARE Audi A1 e-tron
InverterBattery
GeneratorsMicro turbines
E-MotorsE-Motors
AVL Hybrid Solutions & References EV & EV with RE Systems (Series Configuration)
49
AVL VW Golf Twin Drive GM Volt GETRAG Boosted Range Extender
ICE
Differential
(front axle)
E-Motor /
Generator
Inverter Battery
ICE
Generator
Differential Inverter
Battery
Clutches
E-Motor /
Generator
AVL Hybrid Solutions & References EV with RE Systems (Series / Parallel Configuration)
50
Sta
rt S
top
Concept
Demo Car
Fleet
SOP
15
7
-
14
Mild
HE
V
Concept
Demo Car
Fleet
SOP
12
7
-
1
Fu
ll H
EV
Concept
Demo Car
Fleet
SOP
7
5
1
5
Plu
g I
n Concept
Demo Car
Fleet
SOP
1
4
-
-
Pu
re E
V
Concept
Demo Car
Fleet
SOP
4
20
-
-
RE
EV
Concept
Demo Car
Fleet
SOP
3
3
1
2
Electrification @ AVL Hybrid- & EV Production Program References
51
AVL’s Electrification Knowledge is NOT limited to Passenger Cars!
Peterbilt / Eaton
Amor Holdings
Agency for Defense Development
Fisher Coachworks
Likino Bus Plant (LIAZ)
Ford Otosan John Deere and Deutz
Mitsubishi Fuso / Freightliner
MAN
52
AVL ELECTRIC VEHICLE WITH RANGE
EXTENDER