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

Transcription

1 System Simulation Tools for Electrified Vehicles Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin Dr. Stephen Jones stephen.jones@avl.com AVL List GmbH 30th June 2011

2 POWERTRAIN DEVELOPMENT PROCESS Generic OEM / System integrator SYSTEM Target Definition Concept Fleet Tests In Vehicle Test Powertrain Design Powertrain Test OEM / System integrator / Tier 1 COMPONENT Details Specification Specification Design Battery e-drive Transmission Engine Realization / Implementation Test Integration Integration Time 2

3 POWERTRAIN DEVELOPMENT PROCESS Generic OEM / System integrator SYSTEM Target Definition Phase Phase 1: 1: System System Design Design Concept Fleet Tests Phase In Vehicle 3: System Test Validation Phase 3: System Validation Powertrain Design Powertrain Test OEM / System integrator / Tier 1 COMPONENT Details Specification Specification Engine Design Battery e-drive Transmission Phase 2: Development Phase 2: Realization / Implementation Development Test Integration Integration Time 3

4 SYSTEM DESIGN Powertrain & Vehicle System Simulation Tool Driving Cycle Simulation with CRUISE: Vehicle and Powertrain Simulation Optimize Vehicle & s for Efficiency/CO2, Performance, Range, Comfort, Driveability, Safety Mechanics, Electrical Engineering & Signal Processing in One Tool Evaluation of Vehicle Powertrain Concepts (FEV, RE, Hybrid, Plug-in Hybrid, Fuel Cell, Conventional) Assessment of Control Strategies (e.g. Energy Management, Transmission) Collective Loads for Stress/Strain Calculations 4

5 SYSTEM SIMULATION - EXAMPLE TOYOTA PRIUS CRUISE MODEL Powertrain components Powertrain characteristics Driver signal interpretation Hybrid controller Calibration parameters 5

6 SYSTEM SIMULATION - EXAMPLE TOYOTA PRIUS CRUISE MODEL - VALIDATION CO2 EMISSION 105 g g 104 g PERFORMANCE 11,6 sec 11,8 sec Simulation Measurement Certification BATTERY SOC (STATE OF CHARGE) CRUISE Meas. 1 Meas. 2 Meas. 3 6

7 PURE EV SIMULATION Powerflow Simulation for BMW Mini Based EV 7

8 PURE EV SIMULATION PURE EV SIMULATION Mini EV Simulation Results: Maximum Battery Power Maximum Battery Power Power (kw) BMW E-Mini Hybrid Technologies E-Mini AVL E-Mini NEDC UDC FTP75' Artemis Urban Cycles Artemis Road 0 8

9 AVL EVARE ELECTRIC VEHICLE AND RANGE EXTENDER Extra Performance / Efficiency / Range with 2 Speed Transmission 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 At CTI conference Dec (Transmission Colloquium) 8x speeches (simulation & design) on 2 speed EV transmissions 9

10 EVARE EXTRA PERFORMANCE WITH 2 GEAR RATIOS Simulated Distance Travelled in 5.4 Seconds: Full Load Acceleration 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? 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**) Distance (m) *) 1-Speed = Transmission exclusively operated in 3rd Gear (Total Ratio of 3rd Gear 5.41) 10 **) 2-Speed = Transmission additionally operated in 2nd Gear (Total Ratio of 2nd Gear 8.73) 50 m w.o. shifting in next Gear

11 AVL SIMULATION FOR OpEneR CRUISE 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 m 300m 250m 400m 500m 250m 750m Velocity [km/h] 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 Velocity [km/h] Distance [m] 11

12 AVL SIMULATION FOR OpEneR CRUISE 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 m C2I information 30s before traffic light switch Red light phase 60 s 750m Velocity [km/h] C2I Scenario: (driver receives information that traffic light will switch, driver slows down to avoid stopping) Typical Driving Scenario: (stopping at traffic light) Standstill time 30 s + 6% AER Velocity [km/h] Distance [m] 12

13 MBD OF HCU SOFTWARE Cruise Plant Model & HCU Controller in Matlab Simulink Detailed Vehicle & Powertrain Model of HEV HCU Controller in Matlab/Simulink/Stateflow HEVC _M1b/CALCULATION/EMM_PMU/VE H_ON VEH_ON en : Entry_VEH _ON(); du : Durin g_veh_on() du : F_Trac tion _D river(); function en = Entry_VEH_ON function du = During_VEH_ON function du = F_Traction_D river 2 E NG_OFF [ ENG _OffC() ] [ ENG_StartC() ] 1 ENG_S TAR T E NG_S TOP [ ENG _R un C() ] [ ENG_StopC () ] [ ENG_Run C() ] E NG_R UN function startc = ENG_StartC func tion runc = ENG_RunC func tion OffC = ENG_ StopC func tion OffC = ENG_ OffC Parameters for the HEV System are optimised, for each cycle; the parameters and m aps are inputvalues depending on the Course signal. The internal structure of the Statemachine is not changed / varied. Pri nted 20-Dec :04:34 13

14 Vehicle, Track, Driver Model in IPG CarMaker, Powertrain Model in AVL CRUISE AVL CRUISE Powertrain model integrated into CarMaker environment via co-simulation. CarMaker 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 14

15 RT Simulation Maneuver Based Testing with AVL InMotion AVL InMotion Virtual Test Driving Real-Time Simulation AVL InMotion TM Simulation Powered by CarMaker 15

16 RT Simulation Maneuver Based Testing with AVL InMotion AVL InMotion Virtual Test Driving Real-Time Simulation AVL InMotion TM Simulation Powered by CarMaker ViL-, PiL - Configuration Vehicle REAL Powertrain REAL Hardware on Testbed Real: Stiffness of all s Inertia of all s Switching delay of all s 16

17 RT Simulation Maneuver Based Testing with AVL InMotion AVL InMotion Virtual Test Driving Real-Time Simulation AVL InMotion TM Simulation Powered by CarMaker ViL-, PiL - Configuration ViL Vehicle-in-the-Loop Testbed Vehicle REAL Powertrain REAL Hardware on Testbed Real: Stiffness of all s Inertia of all s Switching delay of all s 17

18 RT Simulation Maneuver Based Testing with AVL InMotion AVL InMotion Virtual Test Driving Real-Time Simulation AVL InMotion TM Simulation Powered by CarMaker ViL-, PiL - Configuration ViL PiL Vehicle-in-the-Loop Powertrain-in-the-Loop Testbed Testbed Vehicle REAL Powertrain REAL Hardware on Testbed Real: Stiffness of all s Inertia of all s Switching delay of all s 18

19 MANEUVER BASED SIMULATION FOR ENERGY EFFICIENT & SAFE EV BEHAVIOR Vehicle Stability (e.g. ESP) Engine Generator Transmission + - Converter Battery Gearbox E-Motor Differential 19

20 MANEUVER BASED SIMULATION FOR ENERGY EFFICIENT & SAFE EV BEHAVIOR Brake Blending Regeneration / Brake Strategy & Control? 20

21 SIMULATION TOOLCHAIN IN V CYCLE OEM / System integrator Target Definition Phase Phase 1: 1: System System Design Design Concept Powertrain Design Fleet Tests Phase In Vehicle 3: System Test Validation Phase 3: System Validation POWERTRAIN TESTBED Powertrain Test OEM / System integrator / Tier 1 Specification Specification System Details Engine Design e-motor Transmission Phase 2: Development Phase 2: Realization / Implementation Development AVL InMotion RT Test RT HIL DEVELOPMENT Integration Integration BATTERY TESTBED Generation Loops Generation Loops Time 21

22 Thank you for your Attention! 22