ITS-NE Introduction Electrification Testing - AVL ITA … Automation system 2WD test system for...

Luigi Giordano

AVL List GmbH (Headquarters)

Public

ELECTRIFICATION TESTING SYSTEMSAVL ITA - 5 Luglio - Circuito Tazio Nuvolari

Luigi Giordano | ITS-NE | 05 Juli 2017 | 2Public

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Dedicated application team since 2011

More than 500 installations worldwide

Wide portfolio of solutions

Wide range of customer references

Global presence

AVL DEVELOPMENT SYSTEMS FOR ELECTRIFICATION

Passenger Cars Racing2-Wheelers

Construction Commercial VehicleAgriculture

Rail AviationMarine


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THE CHALLENGE: A WIDE RANGE OF NEW POWERTRAIN SOLUTIONS

Dedicated HybridTransmissions

kWh

PlugIn Hybrid BEV FCEV

Replace Petroleum

Mild Hybrid Full Hybrid

Increase Efficiency

Electric Supercharging

0,4 – 0,8

48V

8-12

MT+ Belt

0,2

12V

1-4

MT + P2 Module + auto-clutch

0,8

15-18

8 - 16

450V

80-120kW

One Gear

35 - 100

Axle Split

75-270

Two Gear

800V

440

Parallel Hybrid / e-AxleAT, DCT, CVT

e-Axle

15 - 100

PEMSOFC

DCT, CVT, AT


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On the basis of the customer use cases, AVL can support in creating a tailored DVP: Collecting inputs from requirements,

FMEA, component tests,… Defining test overview & key specs,

number of samples necessary Detailing of project timing Defining the generalized workflow Identifying the lab size and quantity

of needed test systems Optimizing the efficiency of the test

systems usage plan

AVL: CONSULTING THE DESIGN VALIDATION PROGRAM


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EXAMPLE DVP: RESOURCES ESTIMATE FOR BATTERY PACK TESTING


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On the basis of the customer Design Validation Program, AVL can design and realize complete facilities

AVL CONSULTANCY (CONCEPT DESIGN) Feasibility and Financial studies

Construction cost estimations

Environmental impact studies

Implementation Plans

AVL ENGINEERING Preliminary

Definitive

Detail

AVL MANAGEMENT Procurement and Construction Supervision / Project Management

AVL FACILITY EQUIPMENT SUPPLY AND SYSTEMS INTEGRATION

AVL: FACILITY ENGINEERING


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EXAMPLE: FAW EV LABORATORY CHINAFAW, Changchun - ChinaNew EV Laboratory

Advanced Engineering Services for:▪ 12 E-Motor test beds▪ 2 AWD Powertrain Test beds▪ 2 inverter test beds▪ Environmental test instruments area▪ Battery Pack test area w/ 28 testers▪ Battery cell & module test area w/ 72 testers▪ 2 vehicle test beds▪ Support areas


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AVL delivers systems to validate the complete electrified powertrain components and systems:

Low Voltage or High Voltage upgrade packages for existing vehicle, powertrain and engine testbeds

e-axle and e-powertrain testbeds

E-motor testbeds

Power electronic testbeds

Battery testbeds

Fuel Cell testbeds

Solutions for NVH, EMC or EOL

Combination of all the above in multi-configuration forintegration validation

Real Time Maneuver testing can be added to each of the above

TESTING AND VALIDATION SOLUTIONS FOR ELECTRIFICATION


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EXAMPLE BATTERY EMULATION AND TESTING: RIMAC AUTOMOBILI

Battery emulation on e-drive testbeds with 1kHz control interface

Battery module and pack testing:

• Performance and life cycles testing with 0.01% FS accuracy

• Replication of dynamic load profiles with current rise time <0.4ms


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▪ Insure full safety for UUT, TB and

personal (toxic/explosive gas, fire!)

▪ Testing guidelines

▪ Validate energy Performances

▪ Optimise energy and cooling

management

▪ Optimise battery model (SOC,

SOH, etc…) and BMS

▪ Increase Reliability/Durability

BATTERY DEVELOPMENT AND TESTING CHALLENGES


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Inside Testing Room

Climate Chamber with UUT

Drawing of complete Test Bed

EXAMPLE BATTERY TEST LABORATORY CHINA


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EXAMPLE BATTERY TEST LABORATORY CHINA


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EXAMPLE – BATTERY TESTING CENTER GRAZcontrol room

thermal conditioning

battery test cell


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E-DRIVE DEVELOPMENT AND TESTING CHALLENGES

▪ Face big diversity of UUT’s

▪ Insure Safety of UUT, TB and personal (high speed!)


▪ Validate Performances in Motoring and Generating mode

▪ Validate Thermal model

▪ Optimise Efficiency

▪ Reduced torque ripples at very low speed

▪ Reduce Noise



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E-motor validation up to 400kW, 20.000rpm, with low inertia 0.075kgm² for high dynamic tests

High quality simulation of start from rest/uphill (0 rpm and high torque)

Very accurate speed control at low speed for UUT torque ripple optimization

Modular and scalable design

Can be easily upgraded to environment simulation (temperature, humidity, cold operation)

EXAMPLE: E-MOTOR TEST SYSTEMS TIER1


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Battery Emulator:

with source/drain Function

power: 320 KW

voltage range: 8 to 800 V

current range: +/- 600 A

battery modeling can be statically and dynamically

Dyno: AVL Dyno Spirit permanent magnet engine

rotation direction: right / left

four-quadrant operation

controlled speed and torque

max. power: 250 kW (momentary 312 kW)

speed: 0 – 20.000 U/min

mass inertia: 0,15 kgm2

EXAMPLE: TESTING E-MOTOR SYSTEMS AT AVL


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AVL ACTIVE DYNAMOMETER FOR BSGTESTING

Mec. Power nom/overload

Belt ratio

Torquenom/overload Max. speed Chamber Temp.

range & gradient

30/60 kW

1:1 150/300Nm 8000rpm -40+130°C(-70+180°C)2K/min(5K/min)

1:2 75/150Nm 16,000rpm1:2.5 60/120Nm 20,000rpm1:3 50/100Nm 24,000rpm


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USE CASE: EMC EMISSION MEASUREMENT

E-Motor

Stable Dyno platform

AVL Dyno

• Measurement of E-Motor and Inverter EMC emissions under different load and operating conditions.

• CISPR 25 ED 4 & ISO 11452 solution and Radar Pulse proposals

PUMA Open


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Project execution time: 10 months Installation place Beijing ChinaModular container constructionAVL Automation system2WD test system for e-axle validationDynamometers with 220kW /

3200Nm / 3000rpm with up to 50% overload

Battery Emulation 320kW / 800V / 1200A

UUT coolant conditioning system 20kw

EXAMPLE 2WD CONTAINER TESTBED CHINA


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EXAMPLE: E-POWERTRAIN NVH TESTINGKOREA

• 2WD and 4WD configurations

• Test powertrain only or complete vehicle

• Extension to E-Integration testbed


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▪ Integration with wide diversity of E-Motors types and production tolerances

▪ Reduce development time


▪ Optimization of inverter switching frequency for drive efficiency / e-motor performance

▪ Radiated and conducted EMI testing for different drive cycles

▪ Reduced torque ripples

▪ Handling of fault conditions


INVERTER DEVELOPMENT AND TESTING CHALLENGES


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Development of inverter control loop functions for the active damping of driveline torsional oscillations

Inverter is tested in an office environment equipped with dynamic e-motor and battery emulators

Vehicle and powertrain are fully simulated in real time

Full power operation possible

EXAMPLE: DAIMLER INVERTER TESTING LABORATORY


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FUEL CELL DEVELOPMENT AND TESTING CHALLENGES

Chassis Dyno

Powertrain Dyno

PUM

A O

pen

for F

uel C

ell

Stack level

Powertrain Integration

Powertrain Architecture Design, Control Unit Development and Cooling System Strategy

Cell level

Fuel Cell VehicleFCVChassis Dyno

Fuel Cell PowertrainFCPTPowertrain Dyno

Fuel Cell SystemFCSFC System TB

Fuel Cell StackFC StackFC Stack TB

Single Fuel CellFC TB

Emer

ald

AutomationSystem

Virtu

al S

enso

rsXiL

Tes

ting

ConnectModels fromdifferentsources

Fuel Cell specificmeasurement solutions

+


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Automation & Process

Simulation

Measurement & Diagnostics

Optimization & Calibration

Automation

Measurement & Diagnostics

Powertrain Test System Fuel Cell Test SystemFCEV R&D environment!

AVL AND GREENLIGHT TESTING SOLUTIONS


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Dynamic operation

With vehicle simulation

With environment simulation

EXAMPLE: HYCENTA FUEL CELL SYSTEM TESTBED

2

1

2

33

1

FC H2/N2 Supply ModuleFC Exhaust ModuleFC Coolant Adaption Module

AVL E-Storage BTE 160AVL ConsysAir 800AVL E-Motor CoolingAVL ConsysCool 200…

Climatic ChamberTRange = -40 .. +85°CSize = 3 x 4 x 3 m

Virtual TestingModel.CONNECTISACInMotionVSMCRUISE (M)

PUMA Open 2,CAMEO,CONCERTO,

…

Up to 170 kW Fuel Cell Systems!


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EXAMPLE: HYCENTA FUEL CELL SYSTEM TESTBED

3x4x3 m

-40 to 85 °C

Develop your

Fuel Cell Systemintegrated into a virtual

Develop your

Fuel Cell Systemintegrated into a virtual

VehicleVehicle

Mimic ambient conditions


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Testing laboratory for validation at component and system levels

The user can rapidly test the combination of real components, like battery and e-motor, or partially emulate them

EXAMPLE: BMW E-BIKE TEST CENTER


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Testing laboratory for validation of single component and of their combinations

Integration of all test equipment by use of the flexible AVL Puma automation

Tests executed with real or simulated components

Components protection by use of highly dynamic DC sources

14 different configurations possible, with automatic and rapid switching during the test procedure (5-6 times / day)

Typical execution of more than 350 tests in two weeks time, with parallel testing of components to save 2-3 days on each session

Time synchronised measurement and acquisition of all data sources, output in open file format

Fast data analysis due to the highly automatized post-processing

EXAMPLE PORSCHE HV INTEGRATION LABORATORY

UUT OBC

e-Motor Emulator Mains Emulator

Rea

l Wor

ld

Emul

ated

Wor

ld Signal& Restbus

Simulation Switch box

Universal Inverter

3xAC e-m

otor

3xAC M

ains

HV D

C link

Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.)

Gearbox, E-Motor, Battery controller, etc.

External controllers

Load Unit

Drive Shaft

UUT Battery

BCU (BMS)

UUT-Inverter E-Motor

BatteryEmulator/Tester

Automation

Simulation

Configuration Switch Unit


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Testing laboratory for validation of the electrified powertrain, the xEV vehicle and its HV battery

Usage of real or simulated components

Multiple configurations possible, with automatic and rapid switching during the test procedure

HV battery can be tested as integrated in the vehicle or in a separate climatic environment

Simulation of driving maneuvers

Time synchronized measurement and acquisition of all data sources

EXAMPLE: HV INTEGRATION TESTBED FOR COMPLETE VEHICLE


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Curb

❑ Hybrid vehicle❑ Automatic Reverse Parking + Curb Crossing❑ Goal : Interaction check between all powertrain elements and controls

❑ Check of all Controlling Elements❑ Results at early Stages in the Development

Phase❑ 100% Reproducibility❑ ...

Wheel Torque

EXAMPLE MANEUVER TESTING: INTERACTION CHECK BETWEEN ELEMENTS


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Automated testing of high voltage battery packs under realistic driving conditions

Road, Driver, Vehicle and Powertrain are simulated in real time, inclusive of bus communication to battery pack

High efficiency in the modification of the test cases, thanks to the modular parametrization concept

EXAMPLE MANEUVER TESTING: US EPA BATTERY IN THE LOOP TESTING

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ITS-NE Introduction Electrification Testing - AVL ITA … Automation system 2WD test system for...

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