Electric Commercial Vehicles - ECV 3. national seminar

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2 Electric Commercial Vehicles - ECV 3. national seminar ECV2-LUT / Tubridi project Tubridi virtual platform and Hardware-In-Loop Result highlights Lasse Laurila, Paula Immonen, Jarkko Nokka LUT School of Energy Systems Electricity Energy Environment Mechanics

3 Background: Non-Road Mobile Machinery Hybridization Methods by Virtual Design and Electric Drive Models Original loader Virtual model - Fuel consumption - Productivity - Maneuvrability Tubridi hybrid test platform 150 Virtual test platform - Fuel consumption - Productivity - Maneuvrability - Component sizing Simulink models MeVEA models Powers [kw] Driveline Generator Hydraulics Time [s] LUT School of Energy Systems Electricity Energy Environment Mechanics Liters Diesel Hybrid

4 Virtual model of EJC-90 load haul machine - Traditional diesel engine version of the machine

5 Simulated vs. measured results The virtual model of original loader EJC-90 The mechanics and hydraulics (+ working environment) of traditional dieselpowered load haul machine (EJC-90) is modeled with multibody dynamics software by Mevea. Work hydraulics model used in simulations Transmission model used in simulations

6 Simulated vs. measured results Working environment and work cycle 2300 kg rock load is taken from the bottom of the mine, brought back up and unloaded, once. This is virtual replica of the real working environment during measurements and measured work cycle. Measurements were done earlier by Aalto University. 1. Start / 4. End 3.Unloading 2. Loading

7 Simulated vs. measured results Work cycle analysis Work cycle: Vehicle speed Idling 0 50 s Drive to the bottom of the mine s Loading rocks 170 s 200 s Reverse back up to the start s Unloading rocks s Idling s Probable differences: - by the driver - by the model

8 Simulated vs. measured results Hydraulic motor power Simulated hydraulic motor powers correspond well to measured ones

9 Simulated vs. measured results Hydraulic pump power Simulated hydraulic pump powers correspond well to measured ones

10 Simulated vs. measured results Diesel engine rotational speed, torque and power Fuel consumption of the work cycle is evaluated by diesel engine fuel consumption chart. Simulated diesel engine values correspond well to measured ones.

11 Simulated vs. measured results - EJC-90 diesel engine model Fuel consumption Measured Simulated Difference Energy demand from diesel engine E D [MJ] % Fuel consumption of work cycle [l] % Average fuel consumption [l/h] % Simulated fuel consumption corresponds well to measured fuel consumption. The difference is only 5 %.

12 Simulated vs. measured results - EJC-90 diesel engine model Conclusions The models and methods, including real-time virtual model of the mobile working machine and the working environment were verified by measurement results in the case of a loud haul machine. One of the main targets, fuel consumption, was in the accuracy range of 95% between simulated and measured results. The result is better than expected. The verified methods form the basis on other cases to be modeled during the Tubridi-project and in the future. One of the other cases is hybrid version of the load haul machine (Tubridi test platform).

13 Virtual model of EJC-90 load haul machine - Hybrid version of the machine (Tubridi test platform)

14 EJC-90 virtual hybrid model Preliminary results - The model approaches step by step the Aalto Tubridi test platform: kwh battery, - 85 kw IM generator, kw PMSM for hydraulics, - Needs tuning - Load cycle similar, but needs exactly the same load of 2300 kg to be fully comparable Power [kw] Traction Genset Hydraulics Genset losses Time [s]

15 EJC-90 virtual hybrid model Preliminary results - Battery State of Charge, SoC SoC [%] Time [s]

16 EJC-90 virtual hybrid model Preliminary results - Fuel consumption steady Fuel consumption [l/h] Time [s]

17 Hardware-in-Loop test setup Original target: Full scale (1:1) Hardware-In-the-Loop - up to 300 kw - for component, system, control and software tests,

18 Hardware-In-Loop test setup Current stage of development Research PC Simulink Simulator Network Router Mevea Simulator PC1 EasyConnect Simulator laboratory Ethernet Load cycle from: Virtual simulator in real-time (Human-In-the-Loop) Tubridi load haul machine model (hybrid version) Power electronics laboratory AC500 CAN Inverter Induction motor, 100kW(Drive) Shaft Inverter Induction motor, 350kW (Load)

19 Hardware-In-Loop test setup - Remote operation

20 Results Publications: Nokka Jarkko, Montonen Jan-Henri, Bin Baharudin Ezral, Immonen Paula, Rouvinen Asko, Laurila Lasse, Lindh Tuomo, Mikkola Aki, Sopanen Jussi, Pyrhönen Juha. Multi-body Simulation based Development Environment for Hybrid Working Machines, International Review on Modelling and Simulations (IREMOS), (accepted). Bin Baharudin Ezral, Nokka Jarkko, Montonen Jan-Henri, Immonen Paula, Rouvinen Asko, Laurila Lasse, Lindh Tuomo, Mikkola Aki, Sopanen Jussi, Pyrhönen Juha. Simulation Environment for the Real-time Dynamic Analysis of Hybrid Mobile Machines, ASME 2015 International Design Engineering Technical Conferences & Computers and Information in Engineering Conference (IDETC/CIE 2015), Boston, Massachusetts, August 2 5, Nokka, J., Laurila, L., Pyrhönen, J. Virtual simulation in energy efficient hybrid powertrain design. The 16th European Conference on Power Electronics and Applications, EPE 14-ECCE Europe. Lappeenranta, Aug Aalto, LUT, VTT: Tubridi roadmap, published yearly Q1/ at FIMA seminar

21 Virtual simulation test bench gives answers to: What is the drive cycle like of this machine? What size of battery or electric motor should I choose? How much does the productivity increase by hybridisation? How many kg or m 3 is moved in an hour? How much fuel is saved by the hybridisation? How does it feel to drive the hybrid machine? that is not yet even manufactured as a prototype. Is the usability improved by hybridisation? Energy efficiency Productivity Usability Control systems

22 Virtual simulation test bench can be used for Customer validation Virtual validation First reference tests of prototypes Performance analysis Energy efficiency analysis Control software development Bug fixing Testing of individual components Testing of systems Virtual prototyping Combining digital twin and hardware Early and later stages of development

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