Consistent developm ent of hybrid vehicles at the engine-in-the-loop - - PowerPoint PPT Presentation

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 1

Consistent developm ent of hybrid vehicles at the engine-in-the-loop testbed

Maxim ilian Bier, Matthias Kluin, Prof. Dr. Christian Beidl I nstitute for I nternal Com bustion Engines and Pow ertrain System s Technische Universität Darm stadt apply & innovate 2 0 1 2 I PG Technology Conference 1 8 and 1 9 Septem ber 2 0 1 2 | Ettlingen

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 2

Content Motivation Development process and tools for hybrid powertrains Consistent hybrid operating strategy Testing methodologies for hybrid powertrains Application examples at the engine-in-the-loop testbed Summary

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 3

Strong I ncrease of Param eters in Hybrid Pow ertrains

Operating strategy Vehicle size Cost of sales Component dimensions Cost of ownership Drivability/ fun-to-drive Powertrain architecture Usage scenario Vehicle param eters Custom er requirem ents

Hybrid Pow ertrains

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 4

Efficient and Coordinated Developm ent

• f Hybrid Vehicles

Efficiency in Developm ent

Efficient Operating

• Trade-Off:
• Lowest consumption

possible

• Emission limits
• Driveability
• Durability
• Sophisticated tuning in

harmonizing strategy and concept (usage rate of installed components)

Efficient Developm ent

• Few iteration steps
• Few prototypes
• Few test vehicles
• Determination and validation
• f optimal configurations

Consistent Tools, Models and Control Functions

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 5

Content Motivation Development process and tools for hybrid powertrains Consistent hybrid operating strategy Testing methodologies for hybrid powertrains Application examples at the engine-in-the-loop testbed Summary

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 6

Developm ent Tools in the Developm ent Process

System integration System tests System application Architecture Detailed function and component design Requirements Component test Component dimensioning Basic energy management

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 7

Architecture Definition and Com ponent Dim ensioning via Reverse Sim ulation

Virtual Vehicle Vehicle kinetics Driving resis- tance Operating strategy (HCU) + Powertrain ICE EM EG

dv(t)/ dt v(t) FWheel(t) nICE(t) TICE(t) nEM(t) TEM(t) nEG(t) TEG(t) PBat(t)

Battery Fuel tank

m Fuel(t)

Driving profiles

αIncl.(t) TGas(t) m Gas(t) XGas(t)

Exhaust system

• Reverse Simulation:
• Targets as inputs (velocity, torque, etc.)
• Highly comparative results by open loop control
• Simple models for fast simulation

 Need for basic operating strategy

Environm ent

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 8

Developm ent Tools in the Developm ent Process

System integration System tests System application Architecture Component dimensioning Detailed function and component design Requirements Component test Basic energy management

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 9

Detailed Forw ard Sim ulation

Driver Input Driver Model Environment vact Vehicle Model Operating Strategy

~ =

ICE Clutch Battery +

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 10

Developm ent Tools in the Developm ent Process

System integration System tests System application Architecture Component dimensioning Detailed function and component design Requirements Component test Basic energy management

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 11

Detailed Forw ard Sim ulation and Engine-in-the-Loop ( EiL)

TB Automation System

MG2

Dyno Converter

Tmeas.

Vehicle Model Driver Input Driver Model Environment Operating Strategy vact ICE

RT Simulation Platform

nset CAN Klemme 15, alpha nact

Speed Control

~ =

ICE Clutch Battery +

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 12

Developm ent Tools in the Developm ent Process

Architecture Component dimensioning Detailed function and component design Requirements Component test Basic energy management System integration System tests System application

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 13

X-in-the-Loop ( XiL)

TB Automation System

MG2

Dyno Converter

Tmeas.

Vehicle Model Driver Input Driver Model Environment Operating Strategy vact ICE

RT Simulation Platform

nset CAN Klemme 15, alpha nact

Speed Control Battery +

• ~

=

Battery Simulator.

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 14

in-the-Loop-Sim ulation

nist

TB Automation System

MG2

Dyno Converter Tmeas. Vehicle Model Driver Input Driver Model Environment Operating Strategy vact

RT Simulation Platform

nset CAN Klemme 15, alpha nact Speed Control

~ =

ICE Clutch Battery +

• Operating Strategy:
• Vehicle-realistic composition
• Depending on signals provided by real

components

• Depending on powertrain and vehicle

concept Vehicle m odels at VKM:

• Powersplit hybrid
• P1 parallel hybrid
• P2 parallel hybrid
• Boosted Range Extender

Focus of VKM

• Testbed set-up
• Application Methods for

Operating Strategies

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 15

Content Motivation Development process and tools for hybrid powertrains Consistent hybrid operating strategy Testing methodologies for hybrid powertrains Application examples at the engine-in-the-loop testbed Summary

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 16

Proposed Strategy Structure

Energy Managem ent

( OP-Determ ination, Therm o Managem ent)

Driving State

ECU

• Driver input
• Driver type
• Road state
• Track

information

• Trip

information

Power Electr.

Operating State

• SOC
• Power in

low voltage system

• ICE OP
• TCat
• …

Driver Feedback

TCU

Low Voltage System Control

Operating Strategy

BCU

+

• Auxilia-

ries Control of Dynam ics

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 17

Proposed Strategy Structure: State Analysis

Energy Managem ent

( OP-Determ ination, Therm o Managem ent)

Driving State

• Driver input
• Driver type
• Road state
• Track

information

• Trip

information Operating State

• SOC
• Power in

low voltage system

• ICE OP
• TCat
• …

Driver Feedback Low Voltage System Control

Operating Strategy

Control of Dynam ics

• Driver input interpretation
• Communication with

driver assistance systems

• Adaptation and prediction

functions

• Interpretation of sensor

signals

• Communication with

Control Units

• Virtual sensors
• High potential for reuse of

functions in different strategies

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 18

Proposed Strategy Structure: Operating Point Assignation

Energy Managem ent

( OP-Determ ination, Therm o Managem ent)

Driving State

• Driver input
• Driver type
• Road state
• Track

information

• Trip

information Operating State

• SOC
• Power in

low voltage system

• ICE OP
• TCat
• …

Driver Feedback Low Voltage System Control

Operating Strategy

Control of Dynam ics

• Quasi-stationary
• Basic operating point

Determination

• Conditioning functions
• Coordination in dynamic

manouvers:

• Engine start
• Mode switch
• Gear shifting
• Coordinate power

peaks

• Coordinate heat

provision with heat usage

• Facilitation of continuous evolution

and parallel developm ent

• Separation of test procedures

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 19

Proposed Strategy Structure: Driver Feedback

Energy Managem ent

( OP-Determ ination, Therm o Managem ent)

Driving State

• Driver input
• Driver type
• Road state
• Track

information

• Trip

information Operating State

• SOC
• Power in

low voltage system

• ICE OP
• TCat
• …

Driver Feedback Low Voltage System Control

Operating Strategy

Control of Dynam ics

• Advise for efficient

driving

• Range and Risk

information

• High potential for reuse of

functions in different strategies

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 20

Content Motivation Development process and tools for hybrid powertrains Consistent hybrid operating strategy Testing methodologies for hybrid powertrains Application examples at the engine-in-the-loop testbed Summary

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 21

Test Scenarios in the Developm ent of Hybrid Vehicles

Real World Cons. Durability Drivability Driver and Road Adaptation Cycle Consumpt. Emissions

Road Profile Traffic Driver

Trade-Off

Real W orld NEDC

Maneuvers

Durability Drivability Emissions Functionality

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 22

Strategy Developm ent and Application in Corresponding Test Scenarios

Energy Managem ent

( OP- Determ ination, Therm o Managem ent)

Driving State

• Driver input
• Driver type
• Road state
• Track

information

• Trip

information

Operating State

• SOC
• Power in

low voltage system

• ICE OP
• TCat
• …

Driver Feedback

Low Voltage System Control

Operating Strategy

Control of Dynam ics

Maneuver s

Real W orld

Functionality Driver and Road Adaptation

Maneuver s

XiL

Functionality

NEDC

Real W orld

Simulation, EiL

• Cyc. Consumpt.

Emissions RW Cons. Durability Drivability

Maneuver s

EiL, XiL

Durability Drivability Emissions Functionality

Maneuver s

Simulation, XiL

Durability Drivability Emissions Functionality

Simulation

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 23

Exam ple for Energy Managem ent Application

Driving Cycles Vehicle Parameters Simulation+ Test

Environm ent Virtual Vehicle

v MICE Pedals v

Driver Road+ Traffic/

• Vel. Profile

VM

α, Inj… SoC M F nWheels MEM Gear No. / i MSet nEM

Battery EM

U I nICE

I CE TB Vehicle Kinetics HCU

Environm ent Inf orm ation (Friction, Inclination, … )

Mech. System Wheels

Consumption/ CO2-Em. Emissions Durability Driveability

DoE Model Parameters

Targets (out of modelling)

Optimization

Validation

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 24

Content Motivation Development process and tools for hybrid powertrains Consistent hybrid operating strategy Testing methodologies for hybrid powertrains Application examples Summary

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 25

Exam ple for Energy Managem ent Application

Testrun:

• Forward simulation
• Powersplit hybrid
• TUD urban cycle (Real World)

Variation of 6 Param eters

• 2D-map for battery charging power

(3 Parameters)

• ICE state parameters (3 Parameters)

Targets

• Efficiency – fuel consumption with

SOC equivalent

• Durability – battery stress index

(depending on SOC and current) 50 100 150 200 250 300 4 5 6 7 8 9 Battery Stress [1/km] Fuel Consumption [l/100km]

Simulated Points (generated by DoE) Pareto Set Optima of Pareto Set used for Verification Verification

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 26

Exam ple for Advanced Energy Managem ent Application

Road Gradient Initial Speed Ego-Vehicle Traffic Speed Parameters Energy Management

Scenario and its param eters

Road Gradient [ m/ m] Traffic Speed [ m/ s]

• Cum. Battery Stress[ Wh]

Road Gradient [ m/ m] Traffic Speed[ m/ s] Energy Consumption [ Wh]

Sim ulation results Control functions and param eters

• ACC parameters
• Time gap
• Control constants
• HCU parameters
• SOC swing
• Max. el. Power

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 27

Driveability issues for clutch actuated ICE start in P2 hybrid

Exam ple for Control of Dynam ics Application

17.7 18.0 18.3 18.6 18.9 19.2 19.5 19.8 Time [s] Speed [rpm]

• 500

500 1000 1500 2000 2500 3000 Combined Torque [Nm]

• 240
• 160
• 80

80 160

I CE Speed EM Speed

Energy Managem ent

( OP-Determ ination, Therm o Managem ent)

Driving State

• Driver input
• Driver type
• Road state
• Track

information

• Trip

information

Operating State

• SOC
• Power in

low voltage system

• I CE OP
• TCat
• …

Driver Feedback

Low Voltage System Control

Operating Strategy

Control of Dynam ics

~ =

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 28

Content Motivation Development process and tools for hybrid powertrains Consistent hybrid operating strategy Testing methodologies for hybrid powertrains Application examples at the engine-in-the-loop testbed Summary

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 29

• Consistent simulation-based development methodologies help to

manage high complexity and number of variants in the development of hybrid powertrains

• In-the-loop simulation is key development methodology for a reliable

determination of relevant targets like fuel consumption or exhaust emissions in early development phases

• Necessary consistent use of hybrid operating strategy demands a

consequential structure of the hirarchy of the functions

• Testing methodologies like emission cycles, maeuvers or real-world

cycles have to be adopted to development targets

• Systematic optimization methodologies enable an efficient and reliable

determination of optimal parameter configurations for energy management functions Sum m ary

19 September 2012 | Ettlingen | Institute for Internal Combustion Engines | Matthias Kluin | 30

Thank you for your attention.