ELECTRIFICATION AVL e-Power Measurement and Analysis W.Giczi AVL - - PowerPoint PPT Presentation

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ELECTRIFICATION AVL e-Power Measurement and Analysis W.Giczi AVL List GmbH Public CONTENT AVL E-POWER MEASUREMENT SYSTEM A A INTRODUCTION, SYSTEM PORTFOLIO B B PROPERTIES, BENEFITS, USPs C C USE CASES, SYSTEM CONFIGURATIONS D SUMMARY

SLIDE 1

Public

AVL List GmbH W.Giczi

ELECTRIFICATION

AVL e-Power Measurement and Analysis

SLIDE 2

W.Giczi | MIP | 11 November 2015 | 2 Public

CONTENT

INTRODUCTION, SYSTEM PORTFOLIO PROPERTIES, BENEFITS, USPs USE CASES, SYSTEM CONFIGURATIONS SUMMARY

A B C A B C D

AVL E-POWER MEASUREMENT SYSTEM

SLIDE 3

W.Giczi | MIP | 11 November 2015 | 3 Public

CONTENT

INTRODUCTION, SYSTEM PORTFOLIO PROPERTIES, BENEFITS, USPs USE CASES, SYSTEM CONFIGURATIONS SUMMARY

A B C A B C D

AVL E-POWER MEASUREMENT SYSTEM

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W.Giczi | MIP | 11 November 2015 | 4 Public

ELECTRIFICATION OF THE POWERTRAIN 4 STEPS

Stop-Start Systems largely introduced. 48V Based systems promise best ratio between cost, features and safety Plug-In Hybrids (PHEV) very attractive for CO2 Super-Credits Battery Technology is key for pure electric driving (Battery Electric, BEV) market for pure electric vehicles to develop along new mobility concepts

Micro Micro / Mild Mild Full / Plug-In BEV / FC Hybrid Technology

12V 0,5..3 kW 0 km 12V / 48V 3..8 kW 0 km 48V .. 130V 10 .. 20 kW ~2 km 130V .. 400V > 20 kW > 20 km 400V .. 800V > 75 kW > 150 km Higher CO2 Benefit vs. increasing System-Complexity and System-Cost

Voltage

el. Power
el. Distance

1

4

2

3

2 4 Low (< 60V) Voltage High Voltage Safety!

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W.Giczi | MIP | 11 November 2015 | 5 Public

Advanced Simulation Tools (AST) Instrumentation & Test Systems (ITS) AVL ELECTRIFICATION INTEGRATED TOOL CHAIN

AVL-CRUISE HIL TB Battery TB AVL-BOOST AVL-EXCITE AVL-FIRE Inverter TB E-Motor TB Powertrain TB Vehicle TB

AVL-M.O.V.E./DRIVE

e-Power Measurement

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W.Giczi | MIP | 11 November 2015 | 6 Public

AVL E-POWER MEASUREMENT ACTUAL PORTFOLIO

Signal conditioning units: High Voltage Probe box HVP-Box Data acquisition unit: IndiModul.xEV Current Sensor interface and Supply box CSS-Box ü Split design to place the signal conditioning as close as possible to the UUT

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W.Giczi | MIP | 11 November 2015 | 7 Public

AVL E-POWER MEASUREMENT SPLIT MODULE DESIGN

E-Motor TB

Test chamber

Signal conditioning close to UUT Data acquisition unit inside test room (noisy, dangerous area)

Test room Control room

Gigabit Ethernet PC with control software, keyboard and screen.

Safe area!

High voltage, magn. fields!

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W.Giczi | MIP | 11 November 2015 | 8 Public

PURPOSE OF POWER ANALYZER FOR POWERTRAIN ELECTRIFICATION MEASUREMENT

BATTERY INVERTER E-MOTOR

POWER FLOW ELECTRICAL EFFICIENCY MECHANICAL EFFICIENCY

DC AC, 3~

AC + DC VOLTAGE AC + DC CURRENT

speed + torque 3x AC high voltage AC current DC high voltage Battery current

e-motor inverter battery

E-motor current

±10 V ±10 V ±1 A

Measurement of basic values: § AC + DC currents § AC + DC voltages § Engine speed and torque Calculation (IEEE 1459-2000) § Power from battery § Power into e-motor § Inverter efficiency § E-motor efficiency § Fundamental & Harmonics Display of: § Power / efficiency over time § Graphs of power, current and voltage traces

AVL e-Power Measurement System UUT

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W.Giczi | MIP | 11 November 2015 | 9 Public

AVL E-POWER MEASUREMENT ACTUAL PORTFOLIO

Electrical measurement equipment consists of: Current sensor signal conditioning (CSS-Box) § 4 channels for LEM current sensors § Current sensor supply and conditioning box transforms sensor output current to voltage Voltage signal conditioning (HVP-Box) § 4 channels High Voltage Probe box § 3ph ACV(e-motor) + 1 DCV(battery) Data acquisition (IndiModul.xEV) § 8 channels fast (800kHz) analogue data acquisition based on well proven IndiModul 622 § Torque and speed sensor channels and: PC with Data acquisition Software (IndiCom.xEV) based on well proven AVL IndiCom

LEM current transducer

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W.Giczi | MIP | 11 November 2015 | 10 Public

AVL INDICOM.XEV OPERATING SOFTWARE FLEXIBLE “LIVE-” RESULT DISPLAY EXAMPLE

Example of IndiCom.xEV Result windows: e-Power trend (results) + scope (raw data) + numeric + harmonics

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W.Giczi | MIP | 11 November 2015 | 11 Public

AVL INDICOM.XEV, DATA POST PROCESSING HYBRID POWERTRAIN DYNAMIC TEST

Transient e-motor investigation IndiCom.xEV Result windows: e-Power trend with cursor (full test time result graph) + zoomed trend window tracking the cursor above + scope raw data window tracking the trend cursor (time stamp synchronized)

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W.Giczi | MIP | 11 November 2015 | 12 Public

CONTENT

SYSTEM PORTFOLIO PROPERTIES, BENEFITS, USPs USE CASES, SYSTEM CONFIGURATIONS SUMMARY

A B C A B C D

AVL E-POWER MEASUREMENT SYSTEM

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W.Giczi | MIP | 11 November 2015 | 13 Public

AVL ELECTRIFICATION TEST INSTRUMENTATION PROPERTIES

ü Plug and Play

ü Identification of signal conditioning units for current and voltage measurement ü Current sensor type recognition ü Self reading of calibration data

Benefit:

Automatically self setup and parameterization, no manual input necessary No error due to fault data input Easy to start and run, test bed time saving

SLIDE 14

W.Giczi | MIP | 11 November 2015 | 14 Public

AVL ELECTRIFICATION TEST INSTRUMENTATION PROPERTIES

ü Easy operation:

v Device development focused and optimized for electric powertrain testing, no needless functionality like common universal power analyzer have v Calculations are preconfigured → Ready to run immediately after power on v Easy adaption of result calculations by customer due to graphic formula editor AVL CALCGRAPHTM or Calculator tool v Different numerical and graphical displays are available, GUI can be customized

Goals: High usability, powerful and quick & easy to use!

AVL CALCGRAPHTM

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W.Giczi | MIP | 11 November 2015 | 15 Public

AVL ELECTRIFICATION TEST INSTRUMENTATION PROPERTIES

ü Smart data recording:

v Storage of data together with results on PC hard disk with compressed format (AVL IFile or ASAM standard format MDF4 ), synchronized data packages, easy handling of long drive cycle test data v Post processing with powerful Software AVL CONCERTOTM

ü Online result display and raw data recording:

q Most common power analyzers: focused on online monitoring of results q Pure recording systems: focused on recording of raw data and post processing à AVL measurement system can do both!

ü High dynamic speed performance

due special adaptive detection algorithm:

60 120 180 240 300 360 Crank Angle [deg] Cylinder Pressures [bar] 10 20 30 40 [1/min] N_ENG N_EMOT 1100 1150 1200 1250 1300 [Nm] EMotTorque IndicatedTorque 100 200 300 400 AC Currents [A]

250 [deg] AngDev_b

5 Inner Torque E-Motor Angle Deviation - E-Motor

E-Motor providing 150Nm torque pulses - Ideal pulse position

ETorqueMax Nm 152.3 ETorqueMaxAngle deg 46.48 EMotTorqueAvg Nm 67.29 pmi bar 8.72 SPEED rpm 1176.7 2 4 6 MaxDevAng [deg] MaxDevAng deg 1.11 Indicated Torque Cylinder Pressures Speed - IC Engine Speed - E-Motor AC Currents

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W.Giczi | MIP | 11 November 2015 | 16 Public

CONTENT

SYSTEM PORTFOLIO PROPERTIES, BENEFITS, USPs USE CASES, SYSTEM CONFIGURATIONS SUMMARY

A B C A B C D

AVL E-POWER MEASUREMENT SYSTEM

SLIDE 17

W.Giczi | MIP | 11 November 2015 | 17 Public

USE CASE UUT: E-POWERTRAIN WITH 2 AND 4 E-MOTORS

Ø or two e-motor/inverter all-wheel drive systems design: Ø Hybrids with power split drive design (Motor + generator) Ø or combination of Integrated Starter Generators (ISG) and axle e-motor

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W.Giczi | MIP | 11 November 2015 | 18 Public

USE CASE UUT: HYBRID POWERTRAIN

HYBRID UPGRADES FOR ENGINE & POWERTRAIN TESTBEDS

Rapid rise of complexity at system and component level.
Calibration of all powertrain components to fulfill the various customer

demands (drivability) and to achieve the objective of future CO2 emission limits and optimal fuel efficiency APPLICATIONS The application spectrum for different kinds of hybrids up to pure electric vehicles ranges from:

engine start/stop
regenerative braking as well as
acceleration support relating to

vehicle stability, load shifting

durability testing and the
controller adjustment of the

electrified powertrains.

SLIDE 19

W.Giczi | MIP | 11 November 2015 | 19 Public

CONTENT

SYSTEM PORTFOLIO PROPERTIES, BENEFITS, USPs USE CASES, SYSTEM CONFIGURATIONS SUMMARY

A B C A B C D

AVL E-POWER MEASUREMENT SYSTEM

SLIDE 20

W.Giczi | MIP | 11 November 2015 | 20 Public

Ø

Designed for automotive test bed environments - modular and flexible

Ø

Online results display and raw data recording

Ø

Suitable for static and dynamic operation

Ø

Test bed integration (PUMA, CAN)

ü Very easy setup, plug & play ü Expandability up to 4 DAQ- units (32 Channels) ü Powerful calculations Unique software basis (IndiCom & CONCERTO) covering all aspects for data acquisition and traceability. Easy data handling, synchronized result and raw data files (time stamps)

SUMMARY: MAIN BENEFITS AND KEY FEATURES

SLIDE 21

www.avl.com

ELECTRIFICATION

AVL e-Power Measurement and Analysis

CONTENT

INTRODUCTION, SYSTEM PORTFOLIO PROPERTIES, BENEFITS, USPs USE CASES, SYSTEM CONFIGURATIONS SUMMARY

A B C A B C D

AVL E-POWER MEASUREMENT SYSTEM

CONTENT

INTRODUCTION, SYSTEM PORTFOLIO PROPERTIES, BENEFITS, USPs USE CASES, SYSTEM CONFIGURATIONS SUMMARY

A B C A B C D

AVL E-POWER MEASUREMENT SYSTEM

ELECTRIFICATION OF THE POWERTRAIN 4 STEPS

1

1

4

2

3

3

2

4 Low (< 60V) Voltage High Voltage Safety!

Advanced Simulation Tools (AST) Instrumentation & Test Systems (ITS) AVL ELECTRIFICATION INTEGRATED TOOL CHAIN

AVL E-POWER MEASUREMENT ACTUAL PORTFOLIO

Signal conditioning units: High Voltage Probe box HVP-Box Data acquisition unit: IndiModul.xEV Current Sensor interface and Supply box CSS-Box ü Split design to place the signal conditioning as close as possible to the UUT

AVL E-POWER MEASUREMENT SPLIT MODULE DESIGN

Test chamber

Test room Control room

PURPOSE OF POWER ANALYZER FOR POWERTRAIN ELECTRIFICATION MEASUREMENT

AVL e-Power Measurement System UUT

AVL E-POWER MEASUREMENT ACTUAL PORTFOLIO

AVL INDICOM.XEV OPERATING SOFTWARE FLEXIBLE “LIVE-” RESULT DISPLAY EXAMPLE

Example of IndiCom.xEV Result windows: e-Power trend (results) + scope (raw data) + numeric + harmonics

AVL INDICOM.XEV, DATA POST PROCESSING HYBRID POWERTRAIN DYNAMIC TEST

Transient e-motor investigation IndiCom.xEV Result windows: e-Power trend with cursor (full test time result graph) + zoomed trend window tracking the cursor above + scope raw data window tracking the trend cursor (time stamp synchronized)

CONTENT

SYSTEM PORTFOLIO PROPERTIES, BENEFITS, USPs USE CASES, SYSTEM CONFIGURATIONS SUMMARY

A B C A B C D

AVL E-POWER MEASUREMENT SYSTEM

AVL ELECTRIFICATION TEST INSTRUMENTATION PROPERTIES

ü Plug and Play

ü Identification of signal conditioning units for current and voltage measurement ü Current sensor type recognition ü Self reading of calibration data

Benefit:

Automatically self setup and parameterization, no manual input necessary No error due to fault data input Easy to start and run, test bed time saving

AVL ELECTRIFICATION TEST INSTRUMENTATION PROPERTIES

ü Easy operation:

Goals: High usability, powerful and quick & easy to use!

AVL ELECTRIFICATION TEST INSTRUMENTATION PROPERTIES

ü Smart data recording:

v Storage of data together with results on PC hard disk with compressed format (AVL IFile or ASAM standard format MDF4 ), synchronized data packages, easy handling of long drive cycle test data v Post processing with powerful Software AVL CONCERTOTM

ü Online result display and raw data recording:

q Most common power analyzers: focused on online monitoring of results q Pure recording systems: focused on recording of raw data and post processing à AVL measurement system can do both!

ü High dynamic speed performance

due special adaptive detection algorithm:

CONTENT

SYSTEM PORTFOLIO PROPERTIES, BENEFITS, USPs USE CASES, SYSTEM CONFIGURATIONS SUMMARY

A B C A B C D

AVL E-POWER MEASUREMENT SYSTEM

USE CASE UUT: E-POWERTRAIN WITH 2 AND 4 E-MOTORS

Ø or two e-motor/inverter all-wheel drive systems design: Ø Hybrids with power split drive design (Motor + generator) Ø or combination of Integrated Starter Generators (ISG) and axle e-motor

USE CASE UUT: HYBRID POWERTRAIN

HYBRID UPGRADES FOR ENGINE & POWERTRAIN TESTBEDS

demands (drivability) and to achieve the objective of future CO2 emission limits and optimal fuel efficiency APPLICATIONS The application spectrum for different kinds of hybrids up to pure electric vehicles ranges from:

vehicle stability, load shifting

electrified powertrains.

CONTENT

SYSTEM PORTFOLIO PROPERTIES, BENEFITS, USPs USE CASES, SYSTEM CONFIGURATIONS SUMMARY

A B C A B C D

AVL E-POWER MEASUREMENT SYSTEM

Ø

Designed for automotive test bed environments - modular and flexible

Ø

Online results display and raw data recording

Ø

Suitable for static and dynamic operation

Ø

Test bed integration (PUMA, CAN)

ü Very easy setup, plug & play ü Expandability up to 4 DAQ- units (32 Channels) ü Powerful calculations Unique software basis (IndiCom & CONCERTO) covering all aspects for data acquisition and traceability. Easy data handling, synchronized result and raw data files (time stamps)

SUMMARY: MAIN BENEFITS AND KEY FEATURES

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