LABORATORY OF APPLIED THERMODYNAMICS

ARISTOTLE UNIVERSITY THESSALONIKI

SCHOOL OF ENGINEERING

DEPT. OF MECHANICAL ENGINEERING

1

Zissis Samaras and Leonidas Ntziachristos

Outline of the Correlation Exercise

Input to the meeting of September 18, 2013

Main Work Packages

2

Inception phase – Set-up of the measurement and simulation schedule

Vehicle simulations

New testing to cover missing segments

Focus on future technology vehicles - PHEVs and/or range extenders

Management, reporting and participation to meetings

WP 100 Inception Phase

� In the inception phase of the project we need to

� to take decisions on the exact vehicles that will form the final sample and how they will be sourced

� clarify the main processes and the extend of the simulation approach.

� 20 vehicles to be included in the development of the correlation methodology

� At least 40% of the vehicle models should meet the acceptance criteria

3

Summary of vehicles to be tested

4

� Categorised in the following groups:

� Group 1: 6 vehicle models (calibrated and validated) available at LAT

� Group 2: 6 vehicle models provided by AVL

� Group 3: 3 vehicle models provided by JRC

� Group 4: 5 vehicles to be tested and simulated by LAT

Vehicles already available at LAT

# VehicleSegment

Fuel/Ele

c

Trans-mission

Hybrid-ization

Curb weight

[kg]

Displa-cement

[cc]

Max Power [PS@rpm]

Max torque [Nm@rpm]

Type approval FC [l/100 km]

1Alfa Romeo Mito 1.4 Turbo S&S (manual

transmission)C G MT (5) - 1135 1368

135 @ 5000

206 @ 1750

5.6

2Alfa Romeo Mito 1.4

Turbo S&S (TCT)C G DCT - 1170 1368

135 @ 5000

230 @ 1750 5.5

3BMW X1 sDrive20d efficient dynamics

J D MT (6)Micro HEV

1465 1995163 @ 4000

380 @ 1750

4.5

4Peugeot 308 1.6e-

HDi FAP 112C D MT (6) - 1318 1560

112 @ 3600

270 @ 1750

4.2

5 Toyota Auris HSD C G e-CVT Full HEV 1380 1798136 @ 5200

142 @ 4000

3.8

6 Toyota Avensis 1.6 C G MT (5) - 1423 1598128 @ 6400

160 @ 4400 6.6

7VW Golf 1.4 TSi 90

kWC G MT (6) - 1416 1390

120 @ 5000

200 @ 1500

6.5

8Toyota Prius PHEV

(2010)C G/E e-CVT PHEV 1390 1800

99 @ 5200

142 @ 2800

2.1

5

Vehicles for which simulation models are already available at AVL

# Vehicle Segment FuelTrans-

missionHybrid-ization

Hybrid Topology

Curb weight [kg]

9 Nissan Pathfinder 3.0L CVT J G m-CVT - - 2185

10 Mitsubishi i MiEV A E - EV - 1080

11 Audi A1 etron B G - REX - 1190

12 Volvo S60 D5 D D AMT - - 1490

13 AUDI A6 3.0 TFSI quattro E G DCT - - 1715

14Mercedes Benz S 400

HYBRIDF G AT Mild hybrid - 2100

15 Toyota Prius III C G e-CVT Full HEV Power Split 1380

16SMART Fortwo coupe 52

kW mhdA G AMT - - 750

17 Honda Civic Hybrid C G m-CVT Full HEV Parallel 1260

18 Fisker Karma E G - REX Serial 2400

19 BMW 116i C G MT - - 1385

20 Volvo C30 T5 C G AT - - 1450

21 Audi A3 1.4 TFSi C G MT - - 1175

6

Vehicles already available at JRC

# Vehicle

23Fiat Punto Evo

24Fiat Punto Evo

25Audi A4

7

Vehicle sample composition

Source Vehicles Status Sample Category

Number of vehicles

Group 1

Provided by LAT

Table 1: #1, #4, #5, #7

Artemis Urban, Road, NEDC, simulation models under

developmentN 4

Table 1: #3, #8*Artemis Urban, Road, NEDC,

WLTC. Simulation models completed

N 2

Group 2

Provided by AVL

Table 2: #12, #13, #14, #16, #20,

#21

No driving cycles, simulation models completed N 6

Group 4

New vehicle tests by LAT

To be decided in the inception

phase

NEDC, WLTC, Artemis Urban, Artemis Road, other cycles

decided in the inception phaseS 5

Group 3

Provided by OEMs or the JRC

To be decided in the inception

phase

NEDC, WLTC, Calibration and Validation cycles as a

minimumS 3

Total 20

8

* More options on the selection of a PHEV

Vehicles for group 4

9

� They should cover the following categories

� MPV Diesel MT engine cluster 3 (1685-1994cc) turbo

� SUV Diesel AT engine cluster 3 (1685-1994cc) turbo

� City car Gasoline MT engine cluster 1 (<=1198cc) turbo

� City car Gasoline MT engine cluster 1 (<=1198cc) non-turbo

� SW Diesel AT engine cluster 2 (1560-1685cc) turbo

� One car of each category needs to be sourced and tested by LAT

� Specific models for the vehicles of Group 4 are being defined and located in Greece

WP 200 Vehicle Simulations

10

� AVL Cruise

�Prediction of fuel consumption, performance and emissions

�Capable to model any kind of vehicle powertrain

�Driver model for closed loop control of the vehicle

�Coupled with AVL BOOST engine and aftertreatment models

� Includes cold start correction –NEDC and WLTC are cold started

Necessary components for the modelling of a vehicle in CRUISE

11

VehicleWheel BaseWeightResistances (Frontal Area, Drag or Coast Down)

Engine

InertiaDisplacementCyl NrMaximum SpeedIdle SpeedICE Full Load CurveMotoring CurveFuel TypeFuel Consumption Map

TransmissionTransmission Ratios Efficiency or Torque Loss

Final DriveTransmission Ratio Efficiency or Torque Loss

Wheels

InertiaDynamic RadiusRolling Resistance Function (when no coast down in Vehicle is used)

Additional components for the modelling of a vehicle in CRUISE

Vehicle Gravity Center

EngineEmissions MapsFuel Shut Off StrategyTurbo Charger

Dry Clutch

Torque CapacityRadii inner and outerFriction SurfacesFriction CharacteristicRelease vs Pressure Characteristic

TransmissionBasic Gearbox Inertias (In and Out)Advanced Gearbox with Whole Components Modelled (Planetary Gears, Clutches, Shafts...)

Propeller Elastic ShaftDifferential Torque Split FactorAxle Elastic Shaft

BrakesPiston SurfaceEffective Friction RadiusEfficiency

WheelsStatic Radius Traction MapSlip

Electric MachineType of MachineInertiaCharacteristics for the 4 quadrants (speed vs power/torque over voltage)

BatteryNominal values (Charge, Voltage, Cells)Basic Characteristics (Idle Voltage, Ohmic Resistance, Coulombic Resistance ...)

DriverStandard Cruise DriverShift Procedure (Acceleration and Clutch Pedal and Shifting Time)Pedal Map

Hybrid Strategy ControlBasic control strategy architectureBlack Box DLL built in Matlab & Simulink 12

Input data

� Details for the specifications will be requested from the individual manufacturers.

� Several of these data comprise proprietary information and will not become public. For example, transmission losses maps are pieces of information generally not provided.

� For the missing information, we will start from generally accepted values (or matrices in the case of engine efficiency) that will be properly scaled based on the measured data. The parameters used in the vehicle models will be available for review from the TWG.

13

Driving Cycles

15

Driving Cycles

ERMES Cycle

JC08 Cycle

Calibration and Validation

� We will present with a couple of exemplary cases what are the possibilities when using alternative approaches for the calibration and the validation driving cycles.

� We consider that some mix of a cold-start and a hot-start cycle is required for calibrating the model.

� For example, the Artemis Urban and cold start NEDC could be used for calibration and then the Artemis Road could be used for the validation.

16

Calibration and Validation

� We will test the criteria 1 – 4 of the ToR

� accuracy of the comparison,

� accuracy of the end results,

� consistency throughout the test, and

� correlation of the simulated and measured signals)

� for a couple of examples and investigate whether the particular criteria on one hand guarantee the quality of the simulation and on the other, when superimposed, do not provide redundant limitations.

17

Calibration and Validation

� We will make the final proposal to the TWG on which the three signals proposed for correlation should be and may suggest modification to the other quality criteria – that will offer improved versatility without sacrificing the quality of the simulation itself – for approval.

� For example, the criterion for consistency may offer better quality and more versatility if one would state it as follows: “the instantaneous simulated fuel consumption will remain within ±3.5% of the measured one up to the 90th percentile when instantaneous fuel consumption values are put in a descending order”.

� This leaves out these cases around idle, where large deviations may occur on a relative scale but which are negligible on an absolute scale.

18

WP 300 and 400 – Vehicle Testing

19

� Chassis dynamometer adjustable to both legislative (e.g. NEDC) and real world driving cycles (e.g. Artemis)

� Complete emissions analysis according to legislation requirements:

� bag analysis

� instantaneous results

� PM mass and number

� PM sampling according to PMP requirements

� Complete CVS installation for regulated emissions measurement (diesel, gasoline, hybrid)

Cycles to be used

� In order to make sure that alternative approaches can be followed and that the cold start will be modelled, the following driving cycles will be tested:

� NEDC Cold

� NEDC Hot

� WLTC Cold

� WLTC Hot

� ERMES

� Artemis Urban

� Artemis Road

� Some steady state modes

20

Vehicle Test Protocol

21

Several driving cycles

Example here: the OBD (Lot 5) test

protocol

Timetable for the tests to be performed

� 1st car 1 to 15 October 2013

� 2nd car 16 to 31 October 2013

� 3rd car 1 to 15 November 2013

� 4th car 16 to 30 November 2013

� 5th car 1 to 15 December 2013

� We have foreseen a contingency for the PHEV or Range extender

22

Estimated Time Schedule

23

9 10 11 12 1 2 3 4 5 6 7WP TASKWP 100: Inception phase - Set-up of the measurement and simulation schedule110 WP 200: Simulations210WP 300: Testing to cover missing segments and particular areas/questions310WP 400: Focus on future technology vehicles: PHEVs and/or range extenders410WP 500 510 Data Analysis, Reporting, project meetings

ad-hoc support 520 Project Management 530 Framework Contract Management

DELIVERABLESinception reportfirst provisional databasedraft final report and the final databasefinal report

20142013

Back-up slides

24

Tentative list for Group 4 vehicles

Kia Carens diesel VAN Manual transm.Fiat Multipla diesel VAN Manual transm.Ford Galaxy diesel VAN Manual transm.Opel Zafira diesel VAN Manual transm.VW Sharan diesel VAN Manual transm.VW Crafter diesel VAN Manual transm.VW Transporter diesel VAN Manual transm.

Opel Mokka diesel SUV Automatic transm.

Nissan Qashqay diesel SUV Automatic transm.

VW Polo gasoline Small car Manual transm.Peugeot 107 gasoline Small car Manual transm.Peugeot 208 gasoline Small car Manual transm.

Chevrolet Matiz/Kalos gasoline Small car Manual transm.Hyunday I10 gasoline Small car Manual transm.Dahiatsu Cuore gasoline Small car Manual transm.Toyota Aygo gasoline Small car Manual transm.Citroen C1 gasoline Small car Manual transm.Renault Clio/Twingo gasoline Small car Manual transm.

Seat Ibiza diesel SW Automatic transm.

VW Caddy diesel SW Automatic transm.

Skoda superb diesel SW Automatic transm.

Citroen Berlingo diesel SW Automatic transm. 25

Chassis dyno setting issues

26

List of test parameters and range of variation

Variable Dimension Set point Range of

variation

Notes

Test parameters – Representing the variables H and part of Z from the ToR

Test mass kg Kerb mass +

100

Set point ÷ TMH

Test

Temperature

°C 23 20 ÷ 30

Oil and coolant

Temperatures

°C 23 20 ÷ Tmax Oil,

Tmax Coolant

This will be

achieved by

carrying out

cold-start and

hot-start tests.

Road Load

Parameters

F0 [N]

F1 [N/kph]

F2[N/kph^2]

NEDC

manufacturer’s

data

Set point ÷

+25%

27

List of technologies and range of variation

Variable Dimension Set point Range of variation Notes

Technology (*) – Representing the variables K1 and part of Z from the ToR

Engine start-stop Off Off - On

MT/AT Manual T MT ÷ AT

MT/AT Automatic AT ÷ MT

Manual transmission Original vehicle

Gearbox

Set point ÷ 2 (additional

gears)

Transmission ratio Original vehicle

Gearbox

Set point ÷ one alternative

Automatic

transmission

Original AT 3 types

Downspeeding Original Setting Set point ÷ one alternative

Leanburn Stoichiometric Set Point ÷ Leanburn

VVT Original setting Set point ÷ one alternative

EGR Original setting Set point ÷ one alternative

Engine downsizing Original engine size Set point + one alternative

28

List of technologies and range of variation

Variable Dimension Set point Range of

variation

Notes

Technology (*) – Representing the variables K2 and part of Z from the ToR

Cylinder

managment

Original setting Set point + one

alternative

Energy

recuperation

Original setting Set point + one

alternative

Heat recovery Original setting Set point + one

alternative

HCCI/CAI Original setting Set point + one

alternative

Pollution

reduction

technologies/strat

egies

Original setting Set point + one

alternative

29