hil testing of hybrid & e-motor ecus

Users Conference South Korea 2010 &

HIL Testing of Hybrid & E-Motor ECUs

Kidong Yang

8. June 2010

Introduction on HEV-HIL & E-Drive

Introduction - Electric Motors in Automotive

An increasing number of electric motors is being used for automotive applications …

… but this is nothing new !!!What is new?

Recently…

Electric motors in automotive application became more and more powerful.

Conventional DC motors were replaced by BLDC, PSM, or induction motors.

Electric motors were increasingly incorporated into complex, basic, and safety-relevant vehicle functions such as vehicle dynamics control or powertrain.

Reasons:

Energy saving due to power on demand

Improved packaging of components (e.g., electric power steering)

If Engine is not running auxiliaries have to work independently from the engine

Easier and less maintenance

Introduction - Components of HEV

Conventional Powertrain:Hybrid Powertrain (Example: Parallel HEV):

Components:

Combustion Engine

Transmission

Drive Train

Electric Motor

Power Converter

High Voltage Battery

DC-DC Converter (auxiliary power)

Introduction - Components of HEV

Additional or Auxiliary Systems (examples):

Intermediate Clutch for HEV

Special Brake Management for HEV

Special Fuel Tank Management for HEV

Electric Power Steering

Electric Climate Compressor

Differs Auxiliary Electric Pumps (for water, hydraulic)

…

Intermediate Clutch

ClimateCompressor

Special Brake Management

EPS

Auxiliary Electric Pump

Special Fuel Tank Management

HEV HIL-Simulation – Electric Vehicle

HIL for Electric Vehicle :

Parts of Electric Vehicle System:

E-Motor ECU.

Battery Management

(Transmission ECU)

Electric Power Steering

Electric Climate Compressor

…

Subset of components which belongs to HEV

Introduction - Structure of HEV-System

ECU network for HEV (example structure):

Distributed functionsand ECU network

HEV HIL-Simulation

Testing Purpose of HEV HIL Simulator:

Function tests in early development stages

Tests are possible under any desired conditions

Tests in the laboratory reduce time and cost

Tests in failure and other dangerous situations are no-risk

Reproducible and automated tests also reduce time and costs

..... much more

Basically, we have the same familiar advantages as with HIL in general!

HEV HIL-Simulation - Structure of HEV HIL-Simulator

HIL topology for conventional Powertain:HIL topology for HEV-HIL (example structure):

HEV HIL-Simulation - Structure of HEV HIL-Simulator

HIL Topology for HEV-HIL (with Rest bus Simulation):

Engine Soft-ECU

Restbus Simulation for Transmission ECU

Simulated Systems

Restbus Simulation for Engine ECU

Parts of the HEV System can be simulated by CAN Restbus Simulation:

Engine ECU or

Transmission ECU or

Battery Management or

E-Motor ECU.

Soft-ECUs are available for supporting the Restbus Simulation:

Engine Soft-ECU,

E-Motor ECU.

ASM – Automotive Simulation Model

Engine Gasoline

Basic

Engine Diesel

In-Cylinder

Engine Diesel

Vehicle Dynamics

Engine Gasoline

Engine Gasoline

In-Cylinder

BrakeHydraulics

ASMPara

DieselExhaust

DrivetrainBasic

TurboCharger Traffic

Trailer

Truck

Electric Components

ModelDesk MotionDesk

TrafficSimulation

Real-time capable

“open” Simulink models, product-level

integrated into the tool chain

Centralized parameter administration

HEV HIL-Simulation - ASM-Packages for HEV Simulation

1

3Hybrid Electric Powertrain

Extension to Virtuall Vehicle

Engine Gasoline

Engine Diesel

Drivetrain

VehicleDynamics(incl. BH, MD)

ElectricComponents

Traffic Simulation

Diesel Exhaust

TurboCharger

Electric Motor Simulation


Electric power levelMechanical level

Controller Power stage E-Motor Mechanics

Signal level


Signal Level Electric Power Level Mechanical Level

Use

Ca s

eP r

ope r

t ies

Very flexible (e.g. parameters)Full scalableIndependent of power level Full access to the model Cost-efficientNo safety restrictions

• Power > 2 kW (especially HEV)• Components supplier• Simulators where the focus is not

on electric testing, e. g. CAN integration testing

Flexible (e.g. motor parameter)Full access to the model No knowledge of ECU internals requiredECU as it is, must not be crackedTesting of power stage is possibleTesting of diagnostics on electric level is possible

• Power < 2kW • Testing by OEM• Integration testing of dynamic

systems e.g., vehicle dynamics incorporating steering system and ESP

No knowledge about ECU and electric motor requiredECU as it is, must not be crackedTesting of mechanical parts is possibleTesting of power stage is possibleTesting of diagnostics on electric level is possible

• Testing by OEM without good knowledge of the system

• Integration testing of dynamic systems e.g., vehicle dynamics incorporating steering system and ESP

high power details about the system are not avalaible

Solutions/Signal Level

DS5202-PWM

PWM-Measurement

Position Sensor Simulation

DS5202-PSS

ASM-EC-Lib

Simulation on Signal Level

Solutions/Electric Power Level

DS5202-EMS

FPGA based Electric Motor Simulation

Position Sensor Simulation

DS5202-PSS

Simulation on Electric

Power Level

Electronic Loads

Electronic Load Simulation Module

by engineering only

Mitsubishi – Driving with no emissions (1)

Technical Details

Max. power 64 HP/47 kW

Max. torque 180 Nm

Max. speed 130 km/h

Battery Lithium ion

Total voltage 330 V

Total energy 16 kWh

Range 160 kilometers

Curb weight 1080 kg

Battery recharge Approx. 7 hours

Fast battery recharge Approx. 30 minutes (80% charged)


Mitsubishi's new electric vehicle, i-MiEV, lives and breathes by its complex electronics. Mitsubishi ran rigorous tests to ensure the quality of the software, yet still managed to cut the time-to-market.

The i-MiEV’s electronic platform is characterized by a distributed control format that uses five dedicated ECUs. Four ECUs (one for each function) are for a special battery unit, an individual cell monitoring unit, an electric motor control unit, and an onboard recharging unit. These four ECUs are connected to the fifth ECU, the electric vehicle ECU (EV ECU) to offer the various controls an electric vehicle needs.

In executing the testing, it was necessary to adapt the test design content for the test patterns quickly and accurately. For the sake of analysis, a high level of replication was needed when software bugs were detected. Therefore, a dSPACE Simulator Mid-Size was used to simulate user operation and the inputs to the ECUs accompanying it during the design process. An actual vehicle was used for the real load on the HIL simulator. The test automation software AutomationDesk was used as a means of creating test patterns quickly.


The cell pack and electric motor of the i-MiEV enable emission-free driving.

“In accordance with design content, dSPACE Simulator offers a very high level of general versatility and can be used for almost any vehicle and ECU.”

Dr. Kazuya Hayafune, Mitsubishi Motors Cooperation

“A dSPACE HIL Simulator consists of visually easy-to-understand components like AutomationDesk. We found that this test automation software is extremely easy to use.”

Masahiro Kaneda, Mitsubishi Motors Cooperation

ChangAn: Jiexun - A Hybrid Hero (1)

The ChangAn Jiexun mild hybrid car successfully rolled off the production line in December 2008

~ 80% of the hybrid controller strategy's code was generated with dSPACE TargetLink

ChangAn used dSPACE MicroAutoBoxes and dSPACE Simulator for successful controller development and testing

Lower emissions and more fuel economy: the Jiexun mild hybrid.


Features of the Jiexun Mild-Hybrid:

Electric engine based parking (while the gasoline engine is in idling mode)

Power assistance

Regenerative braking

During the 2008 Beijing Olympic Games, ChangAn already provided several pre-production hybrid Jiexuns as taxis and a press fleet.

Jiexun (杰勋) = hero + glorious deed; pronounced: jié xūn [d̥ʑ ̥i̯ɛ ɕyn]


The hybrid powertrain system of ChangAn’s hybrid car contains three newly developed control units: the hybrid control unit (HCU), the battery control unit (BCU), and an intelligent power unit (IPU).


“To develop the controllers of the new Jiexun hybrid vehicle, we relied on a dSPACE tool chain during the whole development process, and we will continue to use the dSPACE tools for further demanding projects.”

Dr. Ling Su, ChangAn Automotive

Hardware-in-the-loop testing at ChangAn Automotive.

“Compared to competitors’ code generators, ChangAn found the TargetLink-generated code to be of higher quality and efficiency.”

Dr. Ling Su, ChangAn Automotive

Battery Simulation

BMW Group: Virtual Energy Cells

Testing lithium ion battery management systems (BMS)

Challenges

High voltages

High precision

Single cell emulation

Cell temperature emulation

Requirements according to ISO 26262

Solution: precise simulation of a Li-Ion battery in real-time with dSPACESimulator


Excerpt of the tested BMS functions

Cell Balancing

Temperature Management

Charge control

Safety Functions

Isolation Monitoring

On-Board Diagnostics

Tested by automated, reproducible test cases


Battery management is performed by the BMS in conjunction with the cell ECUs(CEs), which are directly connected to, and monitor, the battery modules.


The BMS, some cell module emulators, and further real parts are integrated into the HIL simulator. dSPACE components round off the test environment.


Conclusion

Electrified drivetrain poses new challenges in developing and testing battery management ECUs

Test system to virtually represent the electrical and thermic properties of a lithium ion battery down to cell level

Comprehensive function tests with electric failure simulation for a battery management system

Ricardo: Battery Development Facility

Battery development facility for hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs) and electric vehicles (EVs)

Virtual vehicle with dSPACE Simulator, which simulates a vehicle, or portion thereof


The setup for testing battery packs. The dSPACE HIL Simulator is the heart of the virtual vehicle, and simulates all vehicle components necessary for the tests.


The test chambers are equipped with robust safety and filtration systems –ideal for working with cells and packs using unvalidated support systems.

Integration of a battery pack into the car.

Hyundai – Virtual Engine Test Bench

Test bench of the future: Real-time-capable thermodynamic engine models at Hyundai Motor Europe Technical Center GmbH

Development of Continuously Variable Valve Lift (CVVL)

Function design with RCP system and Bypassing

HIL-Simulator running thermodynamicmodel serves as controlled system(replaces engine)

ASM Gasoline Engine InCylinder Model

The in-cylinder pressure model calculatesthe pressure and mass flow values withsufficient precision, and the ECU can beoperated without errors


Design of the HIL system with a production ECU, a rapid prototyping system for thenew CVVL functions, and a real load for determining the actual valve train value.


The development ECU, consisting of a production ECU and the AutoBox, is connected to an HIL simulator.


Precalibration by simulator

Reducing expensive engine test bench hours

Easy variant studing by modified models

Frontloading by Linking RCP und HIL

Reuse of testcases

Seamless development process

Easy to extend open model

“By using the HIL simulator and the new in-cylinder pressure-based engine models, we were able to develop and validate new algorithms for the charge control of a gasoline engine with continuously variable valve lift very quickly and very efficiently, and then to use them successfully in a prototype vehicle.”

Patrizio Agostinelli, Hyundai Motor Europe Technical Center GmbH

Users Conference South Korea 2010 &

Thanks for listening!

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hil testing of hybrid & e-motor ecus

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