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
3Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
Realization / Implementation
Component TestComponent Design
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TimeDetails
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POWERTRAIN DEVELOPMENT PROCESSGeneric
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
T
Phase 3: System ValidationPhase 3: System ValidationPhase 1: System DesignPhase 1: System Design
Phase 2: Component DevelopmentPhase 2: Component Development
4Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
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
5Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
• Powertrain components
• Powertrain characteristics
• Driver signal interpretation
• Hybrid controller
• Calibration parameters
SYSTEM SIMULATION - EXAMPLE TOYOTA PRIUS CRUISE MODEL
6Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
CO
2 E
MIS
SIO
N
PE
RF
OR
MA
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
7Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
PURE EV SIMULATIONPURE EV SIMULATIONPowerflow Simulation for BMW Mini Based EVPowerflow Simulation for BMW Mini Based EV
8Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
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
9Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
� 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
10Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
________________________________________________________________________________________________________
*) 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
11Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
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]
Ve
loc
ity
[km
/h]
0
10
20
30
40
50
Ve
loc
ity
[k
m/h
]
0
10
20
30
40
50
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
12Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250Distance [m]
Ve
loc
ity
[k
m/h
]
0
10
20
30
40
50
Ve
loc
ity
[k
m/h
]
0
10
20
30
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
13Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
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
14Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
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
15Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
Powered by CarMaker
Real-Time Simulation AVL InMotionTM
AVL InMotion“Virtual Test Driving”
Simulation
RT Simulation – Maneuver Based Testing with AVL InMotion
16Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
Hardware on Testbed
Powered by CarMaker
Real-Time Simulation AVL InMotionTM
Vehicle REALPowertrain REAL
ViL-, PiL - Configuration
AVL InMotion“Virtual Test Driving”
Real:
� Stiffness of all Components
� Inertia of all Components
� Switching delay of all Components
Simulation
RT Simulation – Maneuver Based Testing with AVL InMotion
17Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
Hardware on Testbed
Powered by CarMaker
Real-Time Simulation AVL InMotionTM
Vehicle REALPowertrain REAL
ViL-, PiL - Configuration
AVL InMotion“Virtual Test Driving”
Real:
� Stiffness of all Components
� Inertia of all Components
� Switching delay of all Components
Simulation
ViL – Vehicle-in-the-Loop Testbed
RT Simulation – Maneuver Based Testing with AVL InMotion
18Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
Hardware on Testbed
Powered by CarMaker
Real-Time Simulation AVL InMotionTM
Vehicle REALPowertrain REAL
ViL-, PiL - Configuration
AVL InMotion“Virtual Test Driving”
Real:
� Stiffness of all Components
� Inertia of all Components
� Switching delay of all Components
Simulation
ViL – Vehicle-in-the-Loop TestbedPiL – Powertrain-in-the-Loop Testbed
RT Simulation – Maneuver Based Testing with AVL InMotion
19Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
Engine
Generator
Transmission
Vehicle Stability (e.g. ESP)
Battery
Converter
+ -
E-Motor
Gearbox
Differential
MANEUVER BASED SIMULATION FOR ENERGY EFFICIENT & SAFE EV BEHAVIOR
20Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
MANEUVER BASED SIMULATION FOR ENERGY EFFICIENT & SAFE EV BEHAVIOR
?
Regeneration / Brake Strategy & ControlBrake Blending
21Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
Realization / Implementation
Component TestComponent Design
OE
M /
Sys
tem
inte
gra
tor
Time
System
Details
OE
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Sys
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inte
gra
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Powertrain Test
In Vehicle Test
Fleet Tests
Powertrain Design
Concept
Target Definition
Generation LoopsGeneration Loops
Component SpecificationComponent Specification
Component IntegrationComponent IntegrationE
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
22Stephen Jones, 30th June 2011, Joint EC / EPoSS / ERTRAC Expert Workshop in Berlin
Thank
you for
your
Attention!