127001924 Hybrid Technology AVL Capabilities

Electrification for CV AVL Services and References

Peter Ebner, Raimund Ellinger

Powertrain and Hybrid System

AVL-List

2

Introduction

AVL capability in Hybrid development

AVL capability in Hybrid / System engineering

AVL CV Hybrid experience / References

3

Introduction




4

0

50

100

150

200

250

300

350

400

450

500 1000 1500 2000 2500Vehicle Curb Weight [kg]

CO

2 E

mis

sio

n i

n N

ED

C [

g/k

m]

Gasoline NA

Diesel

Gasoline Turbo

Hybrid (gasoline)

CNG Turbo

China Stage 2 -CO2 [g/km]

China Stage 3 -CO2 [g/km]

EU-proposed CO2Limit

Source: AR 2010

Electrification Market - Overview Motivation

5

Serial Hybrid

Electric Coupling of

Engine & Wheels

Parallel Hybrid

Direct mech. Connection

Engine Wheels

Powersplit Hybrid

Electromechanic Coupling

eCVT Operation Mode

ICE

Inverter

Generator Motor

AC

DC

AC

DC

AC

DC

ICE

MT

/AT

Inverter

E-Motor

ClutchMotor A Motor B

AC

DC

AC

DC

ICE

S 400 Hybrid Citaro Hybrid ML 450 Hybrid

Hybrid Solutions Degree of Electrification & Hybrid Topologies

6

Micro Hybrid Mild Hybrid Full Hybrid PlugIn Hybrid RangeExt EV

1...5 km 10...45 km 25...50 km > 75 km

SOLUTIONS DIVERSITY Electrified Powertrains Today Are Highly Diversified

with ICE

1 – 3 kW 5 – 15 kW 20 – 60 kW 40 – 80 kW 20 – 120 kW 20 – 120 kW

<<1 kWh 0.5 – 1.5 kWh 1 – 5 kWh 5 – 15 kWh 10 – 15 kWh 15 – 30 kWh

Rated power

electric drive

Rated capacity

battery

Grid Charging

without

7

Control Strategy

Battery

Transmission

Electric Motor

IC Engine

Introduction of Hybrid Understanding & Managing of System Complexity

System electrification adds complexity due to:

Multiple torque providers (engine, motors)

Highly integrated systems (ex. powertrain to chassis)

Complex safety requirements (ex. high voltage devices)

Interactive controls requirements

Lack of field history

Managing the complexity requires a refined methodology and

disciplined systems engineering approach that balances and

optimizes system requirements.

8

Introduction of Hybrid Manage Complexity Define Configuration & Optimize Components

IC Engine

Transmission

Electric Motor

Control Strategy

Battery

9

IC Engine

Transmission

Electric Motor

Control Strategy


Battery

10

Powertrain • Performance

• Drivability

• Torque control

• Motor controls

• Motor noise

• Thermal Management

• Energy management

HVAC • Cabin Comfort

• Heated seats

• Defog/defrost

• NVH

Displays/HMI • Range indication

• Power limitations

• Charger status

• Efficiency aids

• Fault conditions

• Customer interaction

Safety/Reliability • DFMEA

• Hazard analysis

• Reliability targets

• Controls

• Crashworthiness

• HV mechanization, cabling, connectors

• Verification and validation

Chassis • Blended braking

• ABS

• Stability controls

• Steering

• Ride and handling

• Mounts

• Fuel system

HV Distribution • Battery performance

• Battery thermal

• Charging System

• Power management

• Power electronics

• Cabling & Fusing

• DC to DC

Electrification impacts many sub- systems

Requirements development and system design must

take all into account.

System Interactions

Wheel

Drive

Device

Propulsion system

Electric machine

Motor Control / Power Electronics

DC / DC Converter

HV Distribution

HV Battery

LV Battery

Vehicle Ambient Air /

Environment


Environment Vehicle

Ambient Air /

Environment

Vehicle

Ambient Air /

Environment

3 phase

3 p

h a

s e

3 phase

3 p

h a

s e

3 phase

3 p

h a

s e

Vehicle

Ambient Air /

Environment

Vehicle

Ambient Air /

Environment

HV Charger

Vehicle

Ambient Air /

Environment


Environment

Charge Coupler


Environment

H V I L

HVIL

H V

I L

H V I L

H V

I L

H V

I L

HVIL HVIL

BMS

MCU

Battery Module

MCU

Battery Module

MCU

Battery Module

Hybrid Controller


11

Transmission

Electric Motor

Control Strategy

IC Engine

Manage Electrification Optimize Interactions

More than 1000

engine development

project in the past 60

years!

Battery

12

AVL – Transmission Service Overview

Benchmark:

•AVL – DRIVE

•Testing

Concept&Design:

Analysis:

Calibration:

•AVL – GSP

•ACT

Simulation:

SW & Controls:

Testing: Maneuver &

event based testing

Hydraulic:

Specific design, analysis and

application know-how for

transmissions.

D:/AVL-Data/Documents and Settings/marquart/Local Settings/Documents and Settings/kokaljg/Local Settings/Temporary Internet Files/Documents and Settings/gallache/Local Settings/Temporary Internet Files/Documents and Settings/gallache/Local Settings/Temporary Internet Files/OLK17/approach2.wmv

13

Transmission

Electric Motor

Control Strategy

IC Engine


Battery

14

Testing & Benchmarking

Thermal simulation

Design Engineering

Prototype built-up BMS series development (SW & HW)

Validation target:

300.000 km cycle life

12 years calendar life

EMC targets fulfilled

System interaction ok

System validation

Cell/Pack Production

Process Assurance

Test equipment development

Battery

Battery Development at AVL

15

Transmission

Electric Motor

Control Strategy

IC Engine


Battery

16

Power Electronic

E-Motor Development

EMC

Electrical Machines

Power Electronics

Emissions

AVL E-Drive Development Elements

17

Power Electronic

E-Motor Development

EMC

AVL E-Drive Development Elements

Development of customized electrical

machines and power electronics

Experience over large bandwidth of

technologies and machine sizes

Development process Know How

(concept, design, validation and

industrialization)

Strong experience ‘designing EMC

behavior into the product’

Process frontloading using experience

and simulation capabilities

Concept study, single prototype or

series production development

18

test on testbench

system concept

design & simulation

AVL Trimerics: E-Motor Development Motor/Generator for CV Applications (PEPS)

~=

~=

~=

~=

~=

~=

E

E

E

E

E E

mechanical design

E-Machines: - High power density due to efficient liquid cooling - Integrated power electronics - 70% saving of space vs. standard systems - 40% saving of weight vs. standard systems - Completely electrical insulated

PEPS: Protected Electrical Power System

19

Transmission

Electric Motor

Control Strategy

IC Engine


Battery

20

Customer specific

Powertrain Control

Software and Function

solutions

CONCEPT &

PROTOTYPE

DEVELOPMENT

SERIES

SOFTWARE

DEVELOPMENT

SERIES

FUNCTION

DEVELOPMENT

SOFTWARE

VERIFICATION &

VALIDATION

SOFTWARE &

FUNCTION

DEVELOPMENT

CONSULTING

AVL Powertrain Control Services

Production Level SW available for:

Parallel Hybrid

EV with RE

21

Full or Mild HEV

ICE DC

Motor

Inverter

Motor

Generator

Battery

Control

Unit

EMS

Hybrid

Control

Unit

ABS

ESP

Resistor

HV MainRelay-P

Pre-chargeRelay

HV Main

Battery Modules-P

Battery Modules-NResistor

HV MainRelay-P

Pre-chargeRelay

HV Main

Battery Modules-P

Battery Modules-N

Battery Pack

Cluster HMI

OBD

CAN

AVL Powertrain Control Services Increase of Control Complexity

22

Transmission

Electric Motor

Control Strategy

IC Engine


Battery

23

Introduction




24

System Design Key Tasks Systematic Engineering & Development Approach

POWERTRAIN SUB-SYSTEM

Vehicle Attribute Targets

and Boundaries

Topology and System Integration

Sub-System Sepcification

Top Down Approach

The Vehicle Targets define the optimal system

topology & component requirements.

VEHICLE

25


VEHICLE POWERTRAIN SUB-SYSTEM

Vehicle Benchmark

System Simulation

Requirement Engineering

System Safety

System Integration

System Software

System Engineering

System Validation

System Calibration

Vehicle Attributes / Targets

Environmental Cond.

Use Cases / Regulations

26

Realisation / Implementation

Component Test Component Design

Time

System

Details

Powertrain Test

In Vehicle Test

Fleet Tests

Powertrain Design

Concept

Target Definition

Sys

tem

C

om

po

nen

t

Component Specification Component Integration

Phase 3: System Validation Phase 1:

System Design

Phase 2: Component Development


27

Realisation / Implementation

Component Test Component Design

Time

System

Details

Powertrain Test

In Vehicle Test

Fleet Tests

Powertrain Design

Concept

Target Definition

Sys

tem

C

om

po

nen

t

Component Specification Component Integration

Phase 3: System Validation Phase 1: System

Requirements and

Design

Phase 2: Component Development

Vehicle Benchmark

System Simulation

Requirement Engineering

System Safety

System Integration

System Software

System Test & Validation

System Calibration


28

Quality Gates

Development Generations (Operative & Coordinating)

Interface to Project Process

Interface to Element

Processes


29

Element Processes Direct

Support Documents

Support Documents

RASI

Generic Timeline

Skill Areas

Level 1 Level 2

Level 3

System & Element Quality Gates

Coordinating

System Engineering

Operative


30


Vehicle Benchmarking

Objective Measurement &

Quantification of Vehicle Attributes

(Reference Vehicle, hybrid or non-

hybrid)

Vehicle Level Attribute

Engineering: Definition &

Quantification of the Target

Attributes, the related Use- & Test

Case and the Acceptance Criteria

Analysis of vehicle and powertrain

functionalities

Analysis of powertrain and

component‘s attributes

(performance, efficiency)

Significant Measurement DataSignificant Measurement Data

-> Measures Driver input and Vehicles reaction!

130,0 131,5 133,0 134,5 136,0 137,5 139,0 140,5 142,0 143,5 145,0time [s]

Acc_

Ch

assis

X_

sm

o [m

/s²]

-2

0

2

4

6

8

En

gin

e_

Sp

ee

d [rp

m]

0

1000

2000

3000

4000

5000

Ve

hic

le_

Sp

ee

d [km

/h]

0

50

100

DC

DC

_S

tate

0

2

TC

C_

Sta

te

0

10

20

To

rqu

e [N

m]

-300

0

300

600

Acc_ChassisX_smo

Engine_Speed

TCC_Speed

EM2_Speed

Vehicle_Speed

DCDC_State

TCC_State

EM2_Torque

Engine_Torque

31


System Simulation - Concept

Extended and detailed simulation

of entire system

Assessment of Topology (Optimize

Configuration)

Assessment of Component

Performance

Assessment of System Functionality

Assessment of Fuel Efficiency,

Emissions and Performance

Assessment of Driveability aspects

Trade-off Analysis

Sensitivity Analysis

Benchmarking & Comparison of

Hybrid Concepts

Rating of Concepts according

application specific rating criteria

Powersplit

Double Clutch

32


Cycle 3 Cycle 2

Cycle 1

Cycle n

Real World Usage Profiles

Cycle 3 Cycle 2

Cycle 1

Cycle n

Cycle 3 Cycle 2

Cycle 1

Cycle n

20

40

60

80

10

0

12

0

14

0

16

0

18

0

20

0

22

0

24

0

12

34

56

78

910

1112

0%

1%

2%

3%

4%

5%

6%

7%

8%

9%

Events

Energy [kJ]Power [kW]

Recuperation Event Distribution - Rated with Road Distribution from RWUP

Component load profiles Load distribution =

collective load

Vehicle Simulation

System Simulation - Support

Detailing of Component

Specification:

Performance Requirements at appl.

spec. Performance Tasks

Lifecycle loads – load distribution

(input for reliability & lifecycle)

Detailing of System Function

Specification

system control functionality

Communication demands

torque & energy management

Target Achievement Tracking

Introduction of Supplier Information

Continuous Monitoring of Target

Achievement (virtual target tracking)

Generation of SIL, MIL & HIL

Model Development for

Integration- & Testing- Support

33

Requirement Engineering I

Systematic Description of

Vehicle (Application, Usage &

Boundary Conditions)

Powertrain Topology

Components & Sub- Components

Powertrain Functions (partly

functional Architecture)

Operations condition (Driving &

Non-driving)

Systematic specification of

components and Control SW

function requirements

Definition of Test Cases for

Component & System/Vehicle

Testing

Calibration Targets

Acceptance Criteria for Validation


Use Cases

Functions

Requirement

Functions

Product

Functions

Powertrain System

Vehicle

Requirements (technical & functional)

Powertrain Elements &

Components

Cu

sto

me

r o

rie

nte

d, tr

ace

able

, co

nsis

tent,…

34

System

Feature(s)

Driving

Feature

Non Driving

Feature

Torque

Distribution

Energy

Management

Engine

Start Stop

Drivetrain

Configuration

Auxiliary

Control

Development

Production

EOL

Safety

Diagnosis

Maintenance

Drive

Brake

Charge

Discharge

Comfort

Stability

Vehicle

Operation

Immobilizer


Requirement Engineering II

Systematic Development &

Description of System

Functionality

Driving Functions (e.g. el. Drive,

Recuperation, …)

Non- Driving Functions (e.g.

Charging from Grid, …)

Auxiliary Control Functions (e.g.

Board Net Supply, Cooling, …)

Calibration Guidelines

Acceptance Criteria

Generation of System related

Requirements for SW

Development

Generation Software related Use-

& Testcases for SW Development

& SW Testing

35


Software Development (System Level Functionality)

Development of SW Architecture

Interface Specification

System Interface

Base- & Application SW Interface

SW Component Specification

SW Component Requirement

Specification

Model Base Coding & Auto Code

Generation

SW Integration (into target Control

Unit)

SW Testing (component & system

level), incl. test documentation

SW Documentation

Calibration Guidelines

Application Lifecycle Management Integrity (MKS)

Label repository

ModelingCode generation

Verification &Validation

SW Build R

eq

uir

em

en

t e

ng

ine

eri

ng

Model Testing & Rapid Prototyping

AVL Plant model

HiL test

Naming convention

Modeling Guideline

MBFS-ASAM Blockset

Implementation Guideline

MBFS-ASAM Library

ADD (Visu-IT)Automotive Data Dictionary (in discussion)ADD (Visu-IT)Automotive Data Dictionary (in discussion)

Make,

Perl …

Compilers:

Altium…

Matlab / Simulink Matlab / Simulink

Ascet MD Ascet SE

TargetLink

Intecrio

ES910 ES1000

RTI

MicroAutoboxPT LabcarPT Labcar

Full Size

36

System Integration

Mechanical, thermal, electrical

and functional integration

Definition of Controller topology

and communication matrix

Definition of Changes for base

vehicle interfaces

Packaging

Powertrain

Control Units

Wiring Harness (LV, HV, CAN, …)

Cooling System

…

Supplier Management

Commissioning

Initial Testing


37

System Safety Development

Safety Assessment

Identification of Risks / Hazards

Functional, Mechanical, electrical

(HV) and chemical safety

Functional Safety Concept

Generation of Safety

Requirements

Methodology in place: Hazard

analysis, FMEAs

Safety Development according

Market & Application related

Standards & Regulations (e.g. ISO

26262 compliance for PC)

Technical Safety Concept

Compliant Technical Solution

Safety Process according

Standard

Safety Testing Verification of

Solution

Severity Exposure

Controllability


38


System Testing

Test planning (Component Test &

System Tests) = Generation of

DVP

Component Testing

Functional Testing

Integration Testing

Lifecycle & Reliability Testing

Definition of Acceptance Criteria

MIL / SIL / HIL Testing (Test

Execution)

Component Testing on related

Test- beds

Powertrain Testing (with battery

simulator)

Initial Calibration

Road Testing (introduction of in

vehicle test equipment)

Shutdown Positions

02

46

810

270

280290

300

310

320

330

340

350

0

10

20

30

40

50

60

7080

90

100110

120

130

140

150

160

170

180

190

200

210

220

230

240

250260

Valeo

All

Bosch

TDC Cylinder 1

Co

un

ts

39

Hybrid System Calibration

Deep understanding of overall

system and functional interactions

required

Robustness investigation (P-

diagram) for control functions in

order to define calibration targets

Calibration process with defined

quality gates

Coordinated, iterative approach

between component calibration &

system calibration

Introduction of specific tools &

equipment (battery simulator)

Simulation support for specific

criteria

Analysis of

Powertrain

Boundaries

Definition of

Functionality

Matrix

Definition of

Calibration

Requirements

and Priority

Detailed

Analysis

Field of

Calibration

Calibration

and Test

Planning


40


System Project Management

Continuous Customer

Communication

Continuous Project Target

Tracking & Monitoring

Ensure System Development

Process Compliance

Ensure Project Quality

Final Release of Project

Documents

Supplier Management

Change- & Concern Management

41

Integrated Toolchain for System Development

Chassis Dyno

Vehicle

Simulation

Vehicle

Development

Vehicle Validation

Prod. Signoff

System Testing /

HIL

Battery/Motor

Testing / HIL

Powertrain

Simulation

Cell/Module/Battery

Simulation

AVL Instrumentation & Test Systems

BATTERY

TESTBED

HIL DEVELOPMENT

POWERTRAIN

TESTBED

ICE

TESTBED

AVL-CRUISE

AVL-BOOST

AVL Software Tools for Powertrain System Development & Optimization

AVL-FIRE

AVL-CAMEO

AVL-DRIVE

AVL-EXCITE

42

AVL Offer Hybrid Development Services up to SOP

HEV Benchmarking

Simulation & Evaluation Target Definition

System Development & Requirements Engineering

Mechanical Integration

Functional and E/E Integration

Software Development

System Safety Development & Assessment

Component Development (e.g. Battery Systems)

Test, Verification & Validation planning and execution

Vehicle build and testing

Hybrid System Controls and Calibration

Consulting

43

Introduction



AVL Hybrid experience / References

44

BMW Efficient Dynamics Citroen C3 Stop&Start CPT Prototype (Audi A4)

Smart Starter Motor (SSM)

Belt Starter Generator (BSG)

AVL

AVL Hybrid Solutions & References Micro Hybrid Systems (Start / Stop)

45

AVL Mercedes-Benz S400 BlueHybrid AVL Turbohybrid P1 Diesel Mild Hybrid

AVL Hybrid Solutions & References Mild Hybrid Systems

46

AVL Peugeot 3008 HYbrid4 Porsche Cayenne S Hybrid JL&R V6D Hybrid

electrification

of auxiliaries

electrification

of auxiliaries

electrification

of auxiliaries

ICE

FE

AD

Automatized

Manual

Transmission

Differential

(front axle)

Battery

Differential

(rear axle)

Hybrid

Manager

Inverter

AVL Hybrid Solutions & References Parallel Full Hybrid Systems

47

AVL BMW Vision Efficient Dynamics Fisker Karma Plug-In Prototype

electrification

of auxiliaries

Battery

ICE

E-Motor /

Generator

Differential

DCT

Differential

(front axle)

E-Motor /

Generator

Inverter

Battery

Inverter

ICE

GeneratorDifferential (rear axle)

E-Motor /

Generator

AVL Hybrid Solutions & References Parallel Full Hybrid Plug- In Systems

48

AVL Jaguar C-X75 AVL EVARE Audi A1 e-tron

InverterBattery

GeneratorsMicro turbines

E-MotorsE-Motors

AVL Hybrid Solutions & References EV & EV with RE Systems (Series Configuration)

49

AVL VW Golf Twin Drive GM Volt GETRAG Boosted Range Extender

ICE

Differential

(front axle)

E-Motor /

Generator

Inverter Battery

ICE

Generator

Differential Inverter

Battery

Clutches

E-Motor /

Generator

AVL Hybrid Solutions & References EV with RE Systems (Series / Parallel Configuration)

50

Sta

rt S

top

Concept

Demo Car

Fleet

SOP

15

7

-

14

Mild

HE

V

Concept

Demo Car

Fleet

SOP

12

7

-

1

Fu

ll H

EV

Concept

Demo Car

Fleet

SOP

7

5

1

5

Plu

g I

n Concept

Demo Car

Fleet

SOP

1

4

-

-

Pu

re E

V

Concept

Demo Car

Fleet

SOP

4

20

-

-

RE

EV

Concept

Demo Car

Fleet

SOP

3

3

1

2

Electrification @ AVL Hybrid- & EV Production Program References

51

AVL’s Electrification Knowledge is NOT limited to Passenger Cars!

Peterbilt / Eaton

Amor Holdings

Agency for Defense Development

Fisher Coachworks

Likino Bus Plant (LIAZ)

Ford Otosan John Deere and Deutz

Mitsubishi Fuso / Freightliner

MAN

52

AVL ELECTRIC VEHICLE WITH RANGE

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127001924 Hybrid Technology AVL Capabilities

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