ASTERICS project presentation - EGVI · ASTERICS- Advanced energy Simulation & TEsting under Real...

ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems

ASTERICS project presentation

Horst Pfluegl, AVL List Graz

Coordinator ASTERICS

EGVI Expert Workshop: “Research and Innovation needs in testing and evaluation procedures”, Brussels, 03.07.2014


Content

Problem Statement

General project information - aim and objectives

Thematic challenge

Results so far

Further need for research activities - DRAFT

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Main drivers for Fully Electric Vehicles (FEV)

Primary Energy Savings

Reduction of Greenhouse Gas Emissions and Climate Change

Reduction of noxious emissions (raising public health)

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Double performance of FEVs

Cut costs of technology into half

Cut development time into half


Today´s shortcomings in design & development of FeVs

• Simulation models of Electrical components for EV lack simulation quality and accuracy

• Interactions between components are either not well known or not fully explored;

• EV specific driving and stress situations for full vehicles and components are not known

• Simulation models for batteries, especially ageing, are inaccurate and durability prediction is questionable

• Testing procedures are ICE-optimized and efforts to adapt to EV’s demands are unacceptable or even not known

• Testing equipment for FEV‘s needs to be identified, specifiedand developed

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ASTERICS

Start date: 1/10/2012

End date: 30/09/2015

Total budget: 4.3 M€

Total EU funding: 2.7 M€

5

Impact

Reduction of overall development time and testing efforts for FEV and components by 50%

Enable improvement and optimization of overall efficiency and performance of FEV by at least 20%

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Thematic challenges

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Real world drivingcycles

Testingprocedures

Detailed models

Test bench integrationand validation


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82013-07-03

Subdivision of each trip into micro-trips

Analysis and grouping of micro-trips

Analysis of micro-trip sorting

Creation of synthetic cycle like succession of representative micro-trips and validation of cycle

Flow chart for Driving Cycles

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Driving cycle «builder» tool

0 500 1000 1500 2000 2500 3000 35000

2

4

6

8

10

12

14

16

18

20

Time (s)

Spe

ed (

m/s

) 0

20

40

-5

0

5

0

0.02

0.04

Speed (s)

Original set

Acceleration (m/s2)D

ensi

ty

0

20

40

-5

0

5

0

0.02

0.04

Speed (s)

Synthetic set

Acceleration (m/s2)

Den

sity

Original set

Speed (s)

Acc

eler

atio

n (m

/s2 )

5 10 15 20 25

-2

-1

0

1

2

0.005

0.01

0.015

0.02

0.025

Synthetic set

Speed (s)

Acc

eler

atio

n (m

/s2 )

5 10 15 20 25

-2

-1

0

1

2

0.005

0.01

0.015

0.02

0.025

Real-world data used to build tailoredcycles

From representative cycle to multi-variated cycles System testing Control tuning

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Verification & Validation & Frontloading

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Use-cases able to describe demands to simulation models for EV-components in co-simulation environments

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WP2 – Battery Modelsmeasurement parameter fitting simulation

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Battery Simulation on Pack-Level

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WORKFLOW

Analytic fit

Single cell simulation

Module simulation


Battery Simulation on Pack-Level, with AVL FIRE ®

14

Pack:

15 Modules

180 Cells

3x12cells

One of the 15 modules is simulated (1st step)

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Battery Simulation on Pack-Level

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Battery Pack Details

nominal cell voltage 3,75 Vcell capacity 41 Ahconfiguration 180s1pnumber of cells 180nominal pack voltage 675 Vinstalled pack energy 27,6 kWhpack weight 242 kggravimetric pack energy density 114 Wh/kgcooling method liquid

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Full vehicle Life Cycle Analysis (LCA)

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CO2for production

• Middle-class vehicle (Golf)

• Electric: +30% due to battery

Total emissions

• Electric: -50%

• Energy production: 590 gCO2/kWh

• USE: 150.000 km

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WP2 – Battery Models – further activities Execute measurement-procedures on test-bed

Evaluate the battery models with real data gathered fromtest-bed

Integrate Battery Models into WP5 – Full vehicle models

Exemplary exchange of battery models between different simulation environments

Co-simulation with battery models in the loop

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WP3 – Inverter models and tests Stressors in accelerated reliability tests are typically temperature,

voltage, current, humidity or vibrations

Advanced inverters with high power ranges above 100kW in connection with high speed motor drives up to 22000rpm

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WP3 – Inverter models and tests

Inverter models in AMEsimsimulation environment with detailed component modelling

Models are used for high frequencystudies and include thermal losses(switching and conducting losses)

Thermal and electrical behaviourneeds to be simulated at the same time

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WP3 – further activities

Execute measurement-procedures on test-bed

Evaluate the inverter models with real data gathered fromtest-bed

Design a bi-directional galvanically isolated DC-DC converterfor test-bed configurations => enable high-frequency tests, low energy consumption

Integrate Inverter Models into WP5 – Full vehicle models

Exemplary exchange of inverter models between different simulation environments

Co-simulation with inverter models in the loop

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WP 4 - High accuracy & efficiency Electric motor models

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Integration step > 1/1000s, ideally 1/100s

INPUT OUTPUT

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Simulation models & virtual prototyping with SRM

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Simulation models and virtual prototyping, PMSM

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- Apply Genetic Algorithms to cycle representation

- Faster E-drive optimization (using GAs)

- Faster testing via condensed cycles


Simulation models and virtual prototyping - PMSM

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- Investigations into E-machine ageing


Simulation models and virtual prototyping - PMSM

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WP5 Integration of models and components in different simulation environments – just started One dimensional longitudinal simulation (not including lateral

vehicle performance) Main focus is on powertrain models: simplified vehicle motion

resistance Due to the complexity of thermal modeling and the unique nature

of each powertrain, ageing effects of subsystems models are partly considered.

Exchange of models (e.g. electric machine with efficiency map and mechanical performances)

Subsystem model exchange with S-function or FMI approach (preferred approach)

In Matlab FMI creation requires special third party toolboxes (e.g. Modelon or DYMOLA)

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WP5 Integration of models and components in different simulation environments – Capabilities/start

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Future Research Topics for Testing andSimulation of EV‘s

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Instrume-ntation

TestingTechnologies

Testing Procedures

EV Testing

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0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8-600

-400

-200

0

200

400

600

t in ms

u in

V

i in

10m

A

Summenströme (Phase mit Schirm), Versuch: 1

uu zu v

uv zu w

uw zu u

i - berechnet

i - gemessen

Research Topics for Instrumentation

Diagnosis and analysis technologies • Advanced electrochemical impedance spectroscopy • Correlation and effect models• Advanced hardware: signal processing, analysis, hardware

design• Instrumentation for analysis of state of health of

electrochemical systems, ageing effects - degradation• Instrumentation for analysis of state of charge of

electrochemical systems

Fast Electric Values Measurement and Phenomenon Analysis

• High frequency/voltage/current measurement devices: signal processing, analysis, hardware design

• Instrumentation for measurement and analysis of wireless vehicle charging

• Ageing, degradation effects of e-motors, e.g. for increased stress due to higher power density, higher switching frequencies of inverter

• Inter system electromagnetic interference (EMI), measurement and analysis of the coupling mechanism and influence of electromagnetic fields generated by the powertrain to the complex in-car data busses, control and communication systems

• Analysis of the exposure of electronic equipment (e.g. telecommunication) to the magnetic fields of the electric powertrain and inductive charging devices.

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Research Topics for Instrumentation, cont.

Instrumentation for on-board testing (in-vehicle usage)

• Integration of in-vehicle measurement technologies with the vehicle data bus system

• Interoperability: Integration/communication with environment and infrastructure (V2x)

• Optimization of measurement equipment for in-vehicle use: packaging, power consumption, robustness, shock and vibration, electromagnetic compatibility (EMC), etc

Advanced transducers and sensors • Micro-electromechanical systems (MEMS)

• Wireless sensors with autonomous energy harvesting from the environment

• Communication and data transmission considering EMI

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https://projects.avl.com/10/0223/Media Gallery/Move24.jpg





Resarch Topics for Testing Technologies

Advanced test beds • Energy efficient components

• Energy circulation strategies and management

• Test beds for EV system testing

Battery emulation• High frequency and peak testing

technologies

• Battery safety testing

• Performance and reliability testing technologies

• Ageing testing technologies

Inverter testbeds• Advanced testbed inverter technologies

(multi-level, high-frequency, …)

• Multiple Hardware-in-the-Loop (HIL) –technologies: HIL-systems for controller development, emulators for insulated-gate bipolar transistors (IGBT), e-motors

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Resarch Topics for Testing Technologies, cont.

E-motor• Testbed controllers and dynamometers for

very low and very high speed e-motors

• Transmission and e-motor optimisation

• E-motor testbed with virtual vehicle

Charging infrastructure testing• Inductive charging

• Conductive charging

• Fast charging testing technologies

• Safety and robustness investigation

• EMC testing

• Smart charging

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Resarch Topics to Testing Procedures

Automated test procedures• Testing procedures for hybrid-vehicles,

electrification-components and for manoeuvres

Testing methods & virtual testing for various aspects:

• Design of Experiments

• Semantic methods

• Battery prediction model testing

• Driveability testing

• Testing (driving) cycles

• Testing system architecture: combination of different tools and different components based on different use-cases => global optimization of testing procedures

• Procedures for optimisation of highly interacting components and individual strategies

• Load management: efficient grid integration

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Resarch Topics to Testing Procedures, cont.

Hybrid system testing methodologies (SIL, MIL, HIL, testbed)

• Component testing• Testing scenarios, use-cases & manoeuvres for

different test environments: start-stop, downhill, regenerative braking, etc.

• Controller strategies• Optimized driving strategies (based on GPS-data,

V2x communication, …)• Integrated component models

Data management• Calibration data• Simulation models• Testing result data• Testing parameters• Seamless access to data and data interfaces • Data processing and analysis for EV development• Charging data• Interoperability with charging operator (and/or

DSO)

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35

http://www.asterics-project.eu

[email protected]

Disclaimer

The FP7 project has been made possible by a financial contribution by the European Commission under Framework Programme 7.

This project – ASTERICS GA No 314157 - is co-funded by the 7th FP (Seventh Framework Programme) of the EC - European Commission DG Research

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Thank you for your attention

http://www.asterics-project.eu/

mailto:[email protected]

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