presentatie paul van oorschot, tu
TRANSCRIPT
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Software development in an electric vehicle:
the TU/e Lupo EL
ir. Paul van OorschotMechanical Engineering, Dynamics and Control
October 3, 2011, Eindhoven
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TU/e Lupo EL
• picture + specs
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Donor vehicle: VW Lupo 3LVehicle mass: 1060 kg Battery capacity: 27 kWhTop speed: 130 km/hRange: up to 200km, 170km@100km/h0 – 100 km/h: 12 sec.4 seats
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Carrying energy in batteries
energy density• batteries
weight: 273 kgvolume: 180 literscapacity: 27 kWh
• equivalent fossil fuel: 10 L petrol (8 kg), 7 L diesel (6 kg)
energy flow• normal fuel pump: 40 L/minute
• normal socket (Europe: 3.6 kW): approx. 1.5 L petrol/hour (1600x slower)
• DC fast charging (50 kW, CHAdeMO): approx. 20 L petrol/hour (120x slower)
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System overview
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Chassis 598 kg
ICE = 239 kgFocus points:
• Lightweight• Efficient• Flexible control• Extensive measurement abilities
Electric vehicle system diagram
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Packaging
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• No interior space lost
• Weight distribution improved
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Front compartment
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Aluminium mounting and battery box design
Charger
Inverter
DC-DC 12V
Controller
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IFM CR0232 PLC
80x IO ports
4x CAN bus
Electric system layout
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VW systems fully functional (CAN)
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Controller
IFM CR2032, Industrial PLC• Infineon TriCore 1796, 32 bit CPU, 150 Mhz• 32 Inputs (analog/digital)• 48 Outputs (PWM, high/low side, current controlled)• 4 CAN bus interfaces (2.0 A/B, up to 1Mbit/s)
Software• CoDeSys v2.3 software development platform• IEC 61131-3 based, following languages available
• Instruction list (IL)• Structured text (ST)• Ladder diagram (LD)• Function block diagram (FBD)• Sequential function chart (SFC)
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Control and safety features
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ABS active ? -> Disable regenerative braking
Airbags(crash) -> Disable systems and HV
Door opened ?• Initialize safety systems• Isolation monitoring• Brake booster vacuum
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Data Aquisition
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Real-time logging via CAN bus
Extensive data on:• Energy flows• Battery condition• Vehicle dynamics
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PLC cycle setup
Cycle time ≈ 7 ms
Inputs read, values determined> 50 CAN identifiers> 200 parameters stored in structs
Sequential function execution• Functions in order of priority• Higher priority overrides
Outputs temporarily stored• Outputs sent at end of cycle
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Traction
Enable traction (start the vehicle)
Traction control
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Regenerative braking
Brake pressure
Current limit
Regenerative braking control• Based on brake system pressure• Torque controlled (better brake blending)
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User interface
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Original VW console Touchscreen computer• Energy flows to components• Measured data per component• Errors and warnings• Charging control
Battery SOC
Power (-30 to +50 kW)
Energy consumption
Speed
Visual and audible indication• Ready to drive• Traction enabled while door open• System errors• HV disabled
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Thank you for your attention!
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