simulation tools for the ev powertrain

04.07.2011

System Simulation Tools for Electrified VehiclesJoint EC / EPoSS / ERTRAC Expert Workshop in Berlin

Dr. Stephen [email protected]

+43 316 787 4484

AVL List GmbH

30th June 2011

2Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin

Realization / Implementation

Component TestComponent Design

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Powertrain Test

In Vehicle Test

Fleet Tests

Powertrain Design

Concept

Target Definition

Component SpecificationComponent Specification

Component IntegrationComponent IntegrationE

ngineTransm

ission

e-Drive

Battery

SY

ST

EM

CO

MP

ON

EN

TPOWERTRAIN DEVELOPMENT PROCESSGeneric




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POWERTRAIN DEVELOPMENT PROCESSGeneric

Powertrain Test

In Vehicle Test

Fleet Tests

Powertrain Design

Concept

Target Definition



ngineTransm

ission

e-Drive

Battery

SY

ST

EM

CO

MP

ON

EN

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Phase 3: System ValidationPhase 3: System ValidationPhase 1: System DesignPhase 1: System Design

Phase 2: Component DevelopmentPhase 2: Component Development


Driving Cycle Simulation with CRUISE:Driving Cycle Simulation with CRUISE:

nn Vehicle and Powertrain SimulationVehicle and Powertrain Simulation

nn Optimize Vehicle & Components for Optimize Vehicle & Components for

Efficiency/CO2, Performance, Range, Efficiency/CO2, Performance, Range,

Comfort, Driveability, SafetyComfort, Driveability, Safety

nn Mechanics, Electrical Engineering & Mechanics, Electrical Engineering &

Signal Processing in Signal Processing in OneOne ToolTool

nn Evaluation of Vehicle Powertrain Evaluation of Vehicle Powertrain

Concepts (FEV, RE, Hybrid, PlugConcepts (FEV, RE, Hybrid, Plug--in in

Hybrid, Fuel Cell, Conventional)Hybrid, Fuel Cell, Conventional)

nn Assessment of Control Strategies (e.g. Assessment of Control Strategies (e.g.

Energy Management, Transmission)Energy Management, Transmission)

nn Collective Loads for Stress/Strain Collective Loads for Stress/Strain

CalculationsCalculations

nn ……

SYSTEM DESIGNPowertrain & Vehicle System Simulation Tool


• Powertrain components

• Powertrain characteristics

• Driver signal interpretation

• Hybrid controller

• Calibration parameters

SYSTEM SIMULATION - EXAMPLE TOYOTA PRIUS CRUISE MODEL


CO

2 E

MIS

SIO

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PE

RF

OR

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NC

E

10

6-1

08

g

10

5 g

11

,6 s

ec

11

,8 s

ec

SimulationMeasurement

10

4 g

Certification

BA

TT

ER

Y S

OC

(ST

AT

E O

F C

HA

RG

E)

CRUISE Meas. 1 Meas. 2 Meas. 3

SYSTEM SIMULATION - EXAMPLE TOYOTA PRIUS CRUISE MODEL - VALIDATION


PURE EV SIMULATIONPURE EV SIMULATIONPowerflow Simulation for BMW Mini Based EVPowerflow Simulation for BMW Mini Based EV


BMW E-Mini

Hybrid Technologies E-Mini

AVL E-Mini

NEDCUDC

FTP75'Artemis

Urban

Artemis

Road

55

49.9

47.9

35.1

30.7

30.7

42.2

35.936.7

18.1

16

16.6

45.7

41.9

42.4

0

10

20

30

40

50

60

Power (kW)

Cycles

Maximum Battery Power

PURE EV SIMULATIONPURE EV SIMULATIONMini EV – Simulation Results: Maximum Battery Power


� Actual EVARE has 75 kW peak E-Machine

& one fixed gear ratio

� Actual single fixed speed EVARE ratio

selected for efficiency, reducing performance

vs. conventional Mini Cooper MT

� To improve EVARE performance & maintain

efficiency 2 speed transmission required

� One Gear Performance/Speed/Gradeability,

Other Gear for Efficiency & Electric Range

AVL EVARE – ELECTRIC VEHICLE AND RANGE EXTENDERExtra Performance / Efficiency / Range with 2 Speed Transmission

At CTI conference Dec. 2010 (Transmission Colloquium)

8x speeches (simulation & design) on 2 speed EV transmissions


________________________________________________________________________________________________________

*) 1-Speed = Transmission exclusively operated in 3rd Gear (Total Ratio of 3rd Gear 5.41)

**) 2-Speed = Transmission additionally operated in 2nd Gear (Total Ratio of 2nd Gear 8.73) – 50 m w.o. shifting in next Gear

Explanation: The Conventional Mini Cooper 1.6 (MT, 88 kW) is the Reference. For the Acceleration from 0 to 50 m it needs 5.4 Seconds (reaching the 50m in 2nd Gear) � How far do the various EVARE vehicles travel in the same time of 5.4s?

20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66

Distance (m)

Conventional Mini Cooper 1.6 MT (88kW)

EVARE

(75 kW - peak, 1-Speed*)

EVARE

(75 kW - peak, 2-Speed**)

EVARE

(88 kW - peak, 1-Speed*)

EVARE (88 kW - peak, 2-Speed**)

EVARE – EXTRA PERFORMANCE WITH 2 GEAR RATIOSSimulated Distance Travelled in 5.4 Seconds: Full Load Acceleration


AVL SIMULATION FOR OpEneRCRUISE Simulation – Potential Evaluation

Simulated course describes an urban road, with short sequenced traffic lights.

Legal maximum velocity allowed is 50 km/h. Segment repeats continuously.

0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250Distance [m]

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[km

/h]

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30

40

50

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loc

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[k

m/h

]

0

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20

30

40

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1000m 300m 250m 400m 500m 250m 750m

5050

Constant Speed Scenario:(moderate acceleration, then constant speed, only vehicle stop at 3450 m

journey segment end, gentle braking to maximise recuperation energy)

Typical Driving Scenario:

(high acceleration and deceleration, stops at every traffic light)+ 70% AER


0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250Distance [m]

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[k

m/h

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30

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[k

m/h

]

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40

50

2700m 750m

5050

C2I Scenario:

(driver receives information that traffic light

will switch, driver slows down to avoid

stopping)

Typical Driving Scenario:(stopping at traffic light)

Red light phase 60 sC2I information 30s

before traffic light switch

Standstill time 30 s

AVL SIMULATION FOR OpEneRCRUISE Simulation - C2I Potential “Traffic Light”

Simulated course describes a typical urban road with traffic light activated by walker. The

maximum allowed velocity is defined as 50 km/h.

+ 6% AER


MBD OF HCU SOFTWARECruise Plant Model & HCU Controller in Matlab Simulink

HEVC _M1 b/CALCUL ATION/EMM_PMU/VE H_ON

P ri nted 20-Dec- 2006 18: 04:34

VEH_ON

en : Ent ry_ VEH _ON();

du : Durin g_VEH_ON()

du : F_ Trac tion _D river();

en = Entry_VE H_ON func tion

du = Dur ing_VEH_ON function

du = F_Traction_D river function

E NG_OFF

E NG_S TOPENG_S TAR T

E NG_R UN

OffC = ENG_ StopC func tion

OffC = ENG_ OffC func tion

run C = EN G_RunC func tion

s tartC = ENG_StartC function

Param eters for the HEV System are optim ised, for each cycle; the param eters and m apsare inputvalues depending on the Course signal. The internal structure of the Statemachine

is not changed / var ied.

[ ENG _OffC() ]

[ ENG_StartC() ]

2

[ ENG _R un C() ]

1

[ ENG_StopC () ]

[ ENG_Run C() ]

Detailed Vehicle & Powertrain Model of HEV

HCU Controller in Matlab/Simulink/Stateflow


CarMakerCarMaker

� Body

� Masses & Inertias

� Body Flex

� Suspension

� Tires & Wheels

� Steering

� Brakes & Hydraulics

� Chassis control / ADAS

� Aerodynamics

� Trailer

� …

� Body

� Masses & Inertias

� Body Flex

� Suspension

� Tires & Wheels

� Steering

� Brakes & Hydraulics

� Chassis control / ADAS

� Aerodynamics

� Trailer

� …

� Combustion engine

� Torsional vibration damper

� Clutch

� Transmission

� Differential

� Electric motor / Inverter

� Battery / Voltage Converter

� Power train control

� Auxiliary devices

� …

� Combustion engine

� Torsional vibration damper

� Clutch

� Transmission

� Differential

� Electric motor / Inverter

� Battery / Voltage Converter

� Power train control

� Auxiliary devices

� …

AVL CRUISE Powertrain model integrated into CarMaker environment via co-simulation.

Vehicle, Track, Driver Model in IPG CarMaker, Powertrain Model in AVL CRUISE


Powered by CarMaker

Real-Time Simulation AVL InMotionTM

AVL InMotion“Virtual Test Driving”

Simulation

RT Simulation – Maneuver Based Testing with AVL InMotion


Hardware on Testbed

Powered by CarMaker


Vehicle REALPowertrain REAL

ViL-, PiL - Configuration


Real:

� Stiffness of all Components

� Inertia of all Components

� Switching delay of all Components

Simulation



Hardware on Testbed

Powered by CarMaker





Real:




Simulation

ViL – Vehicle-in-the-Loop Testbed



Hardware on Testbed

Powered by CarMaker





Real:




Simulation

ViL – Vehicle-in-the-Loop TestbedPiL – Powertrain-in-the-Loop Testbed



Engine

Generator

Transmission

Vehicle Stability (e.g. ESP)

Battery

Converter

+ -

E-Motor

Gearbox

Differential

MANEUVER BASED SIMULATION FOR ENERGY EFFICIENT & SAFE EV BEHAVIOR


MANEUVER BASED SIMULATION FOR ENERGY EFFICIENT & SAFE EV BEHAVIOR

?

Regeneration / Brake Strategy & ControlBrake Blending




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System

Details

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Powertrain Test

In Vehicle Test

Fleet Tests

Powertrain Design

Concept

Target Definition

Generation LoopsGeneration Loops



ngineTransm

ission

e-Motor

Phase 3: System ValidationPhase 3: System ValidationPhase 1: System DesignPhase 1: System Design

Phase 2: Component DevelopmentPhase 2: Component Development

RT

AVL InMotion RTBATTERY TESTBED

HIL DEVELOPMENT

SIMULATION TOOLCHAIN IN V CYCLE

POWERTRAIN TESTBED


Thank

you for

your

Attention!

simulation tools for the ev powertrain

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