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Validation Process of a HEV System Analysis Model: PSAT
November 2004
Aymeric Rousseau,Phil Sharer and Maxime PasquierArgonne National Laboratory
Sponsored by Lee Slezak
This presentation does not contain any proprietary, confidential, or otherwise restricted information
Outline
PSAT Introduction
Vehicle testing
Component Validation
Control Strategy Understanding
Drivetrain Validation Drivetrain Validation
Conclusion
2
ANL System Analysis Program
Modeling, testing, and hardware control usedto investigate various technologies of advancedvehicles (diesel emissions, CVTs…)
1. Modeling software: PSAT2. Development/integration of new
models/data into PSAT
1. Control software: PSAT-PRO2. Rapid Prototyping (RP) 3. Hardware In the Loop (HIL)models/data into PSAT
3. Control strategy developmentp ( )
MODELING PROTOTYPING
EXPERIMENTALTESTING
3
1. Instrumentation2. Emissions equipment3. Data processing
What is PSAT? Developed by ANL under the direction and with the Developed by ANL under the direction and with the contribution of Ford, General Motors and DaimlerChrysler for contribution of Ford, General Motors and DaimlerChrysler for the Partnership for New Generation of Vehicle (PNGV)the Partnership for New Generation of Vehicle (PNGV)the Partnership for New Generation of Vehicle (PNGV)the Partnership for New Generation of Vehicle (PNGV)
Funded by USCAR and now by DOEFunded by USCAR and now by DOE
A powerful forwardA powerful forward--looking modeling tool that allows the looking modeling tool that allows the user to realistically simulate:user to realistically simulate:
F l ti d h t i i ( F d l T tF l ti d h t i i ( F d l T tFuel consumption and exhaust emissions (e.g. Federal Test Fuel consumption and exhaust emissions (e.g. Federal Test Procedure, highway, all other cycles)Procedure, highway, all other cycles)
Performance (e g 0Performance (e g 0 30mph 030mph 0 60 mph 4060 mph 40 60 mph60 mphPerformance (e.g. 0Performance (e.g. 0--30mph, 030mph, 0--60 mph, 4060 mph, 40--60 mph, 60 mph, distance in 5 sec., maximum launch grade, maximum distance in 5 sec., maximum launch grade, maximum continuous speed, 55mph at 6% grade)continuous speed, 55mph at 6% grade)
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Forward Looking ModelingForward looking models (PSAT) represent how systems respond in realityIn a vehicle, the driver input creates the vehicle response
Commands from a Powertrain Controller to obtain the desired vehicle speedCommands from a Powertrain Controller to obtain the desired vehicle speed
Forward looking modeling is consistent with industry practice for vehicle design Forward looking modeling is consistent with industry practice for vehicle designAccurate representation of a dynamic system (e.g. engine starting, shifting, clutch engagement / disengagement…) Possibility to implement advanced component models (e.g. 1D engine y p p ( g gmodel to characterize emissions…) Develop control strategies that can be later tested on a bench or in a vehicle Small time step
5
p
Extensive Data Collection With Torque Sensors
SpacerSpacer
THS
Engine
addedadded
~5”
THSTransaxle
Half‐shaft input
Damper
Torque Sensor Spacer
Prius engine torque sensor AxleAxle
Strain Gage CollarStrain Gage Collar
Insight axle torque sensor
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Strain Gage CollarStrain Gage Collar
Different Types of Tests Are Needed Steady‐state speeds
Vehicle Speed
Succession of accelerations and decelerations at different speedsTime
Succession of accelerations and decelerations at different speeds
Standard cycles (EUDC, Japan…)
Vehicle Speed
Time
Each 1mn
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Each 1mn
Control Strategy Understanding
500
600
Vehicle Speed (m/s) * 100
400
500 Vehicle Speed (m/s) 100Engine Speed (rad/s) Generator Speed (rad/s) SOC (ratio) * 1000 Motor Current*10 (amps)
200
300
0
100
0 50 100 150 200 250 300 350-200
-100
8
secSource: ANL data
Acceleration / Deceleration Tests
150 3
50
100
1
2
0
50
3 0 0 3 5 0 4 0 0 4 5 0 5 0 0 5 5 0 6 0 0 6 5 0
0
1
MPa
-50 -1
kph
-100 -2
kphCurrent [A]Front Brake [MPa]Rear Brake [MPa]
Regen
9
-150 -3Source: ANL data
What is the Uncertainty of Each Model?
Physical Vehicle Simulated Component
Measured Current SimulatedMeasured Current
d l Si l d l
Simulated SOC
Measured Voltage = Simulated Voltage
Valid Battery Model
Measured SOC = Simulated SOC
y
10
Battery and Engine Validation
0 6
0.62Battery SOC
Simulated (Amps integration) Measured (Amps integration)Measured (Scan Tool)
Battery ValidationSimulated (Amps integration) Measured (Amps integration)Measured (Scan Tool)
OC 0.56
0.58
0.6 Measured (Scan Tool)Measured (Scan Tool)
SO
0.52
0.54
2
x 10-3 Engine Fuel Rate Validation
simulatedmeasured
0 100 200 300 400 500 600 700 8000.5
sec
1
1.5
g/s
0.5
1
Engine Validation
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Source: ANL data 100 150 200 250 3000
sec
Control Strategy May Differ From One Cycle to Another One
Highway CycleEngine torque vs. Engine Speed
Japan 10-15
to Another One
g y yp
Simulated best efficiency curve
Test data
12
Source: ANL data
Specific Tools Are Necessary to Understand HEV Control Strategies
13
The Japanese Prius Does Not always Follow the Best Efficiency Curve
Prius Engine Map – Efficiency = f(Speed ,Torque)
Estimated Best Efficiency curve
the Best Efficiency Curve
Estimated Best Efficiency curve
Change of torque when a mediumVariation of the pedal demand occursVariation of the pedal demand occurs
Change of speed when a largeVariation of the pedal demand occurs
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PSAT Prius Validation is Within 5%Cycle Cons
test mpg
Cons simul mpg
Diff in % SOC init SOCf test
SOCfsimul
Diff in %
Japan 10-15
44.9 45.1 0.4 0.600 0.580 0.583 0.5
J 48 8 50 7 3 9 0 610 0 575 0 561 2 3Japan 10-15
48.8 50.7 3.9 0.610 0.575 0.561 2.3
EUDC 44.0 43.8 0.4 0.610 0.605 0.593 2.0
FHDS 48.2 46.7 3.2 0.550 0.571 0.573 0.3
UDDS 42.3 39.9 5.9 0.550 0.530 0.570 8.7
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Component Behavior is ValidatedEngine Speed
200
250measured simulated
Rd/s
50
100
150
Sec0 100 200 300 400 500 600-50
0
700
Engine Torque
40
60
80
100
Engine Torque
Nm
40
-20
0
20
40
16
Sec0 100 200 300 400 500 600 700
-60
-40 simulatedmeasured
Conclusions
HEVs require new approach for validation
A validation methodology has been developed for A validation methodology has been developed for HEV validationSpecific tests have been definedSpecific tools have been developed
The Japan Toyota Prius has been validated within 5% onThe Japan Toyota Prius has been validated within 5% on different cycles with different SOC using PSAT
The generic methodology and tools developed can be applied to any HEV validation process
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