DLR 16.7.2013

H. Nonn

AVL Durchgängige Antriebsstrangentwicklung vom Verbrennungsmotor bis zum Brennstoffzellenantrieb

H.Nonn 2 2013

OUR EXPERIENCE FOR YOUR SUCCESS

AVL is world's largest privately owned company

for development, simulation and testing of:

Hybrid electrical vehicles

Combustion engines

Transmissions

Electric drives

Batteries

xCU software

AVL – more than 60 years’ experience

Involved in more than 2000 engine development projects

More than 4000 engine, powertrain and battery test bed installations

Passenger cars,

Trucks

Large engines

Offroad engines

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AVL SERVES ALL AUTOMOTIVE SEGMENTS

passenger cars 2-wheelers racing

construction agriculture commercial vehicle

locomotive marine power plants

AVL

Advanced

Simulation

Technologies

AVL

Instrumentation &

Test Systems

AVL

Powertrain

Engineering

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Chassis Dyno

Driveline Test

Systems

Vehicle

Simulation

Powertrain

Simulation

Vehicle

Development

Vehicle Validation

Prod. Signoff

AVL PRODUCT PORTFOLIO FOR SUCCESSFUL

POWERTRAIN DEVLOPMENT

AVL-CRUISE

AVL-BOOST

AVL Software Tools for Powertrain Development

AVL-FIRE

AVL-DRIVE

AVL-EXCITE

Engine Test

Systems

Battery/Motor

Testing / HIL

Component

(Battery/ Engine)

Simulation

AVL

MicroSoot

AVL Instrumentation & Software for Systemvalidation & Optimimization

E-Storage

Tester

AVL PUMA,

LYNX AVL-INDICOM

AVL CAMEO

AVL iGEM

Instruments

(emissions,

consumption) AVL M.O.V.E.

2013 H.Nonn Public

Torque Vectoring Toyota

Hybrid Systems e CVT

TTR Hybrid (e4WD)

BUSINESS DRIVER

INCREASING POWERTRAIN DIVERSITY

1980 2000 2010

Pow

ert

rain

Co

mple

xity

Standard Configuration

20xx

Active 4WD Systems

Active Transmissions

Calendar Year

Electrical Driving

e-Motor for each Wheel

Inte

gra

tion &

Valid

ation E

ffort

Hybrid Systems

e-Motor on front Wheels

Porsche

Driver Assistant and

Vehicle Safety Systems

2013 H.Nonn

AVL STRATEGY

INTEGRATING THE 5 ELEMENTS OF THE POWERTRAIN

Electrical energy

storage

(batteries, fuel cells)

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Test process

Test methods

Calibration Data

Evaluations

Models

ONE AUTOMOTIVE TEST PLATFORM SUPPORTING „FRONT LOADING“ IN THE DEVELOPMENT PROCESS

Common Requirement Management

Powertrain Testbed

Chassis Dyno

TestBed

Road Testing

Office Simulation

MIL/SIL Testing

Battery/ eMotor

TestBed

Engine Testbed

HIL Testing

Fuel Cell Testbed

R

ea

l w

orl

d

Vir

tua

l w

orl

d

Consistent and comparable results

Common Dataware, Modelware, Testware

Architecture Components Systems

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MANEUVER LIBRARY: VIRTUAL PROVING GROUND

+ x Roads goes Rig

H.Nonn 9 2013

VEHICLE ELECTRICAL COMPONENTS

Mains supply

12V accessories

Mains supply

E-Motor

Inverter

Battery

DC/DC

converter On Board

Charger

Quick

charging unit

H.Nonn 10 2013

POWER ELECTRONICS: INVERTER TESTING

Automation / Simulation

Mains Supply

Mains Supply

Power Measurement

T / P / U

Measurement

PUMA Open

Options:

- Climatic Chamber

- Switch Rack

Coolant

Conditioning

Test System

Cabinet

UUT-Inverter

U, I

AVL

InMotion™

e-Storage

Emulator

e-Motor-Emulator

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COUP-E TECHNICAL BATTERY INFORMATION

Battery Pack Details

nominal cell voltage 3,75 V

cell capacity 41 Ah

configuration 180s1p

number of cells 180

nominal pack voltage 675 V

installed pack energy 27,6 kWh

pack weight 242 kg

gravimetric pack energy density 114 Wh/kg

cooling method liquid

H.Nonn 12 2013

SUPPLY CHAIN: INTERFACES DEFINES DEMAND FOR FC TESTBEDS

FC System

FC Powertrain

FCV

Fuel cell technology provider

OEM Car manufacturer

Chassis Dyno testbed

Powertrain testbed

FC system testbed

FC stack testbed

Fuel cell stack/module

Test S

yste

ms

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3D-CFD Simulation

3D-CFD FIRE calculation of

of current/voltage

polarization cruves for

different operating

conditions

FUEL CELL PERFORMANCE & THERMAL MODELING

Scalable Fuel Cell Modeling

Surrogate Cell /

Stack Model

Surrogate fuel cell

model based on 3D-

CFD FIRE results

FC System /

Vehicle Modeling FC system model with

embedded surrogate fuel cell

model

Fuel C

ell

Sim

ula

tion

2013 H.Nonn

AVL SOFC APU FOR HD TRUCKS

Objective

Mobile SOFC generator fuelled with conventional

diesel

RTD Programme

System development, packaging & design

Component development (blowers, fuel processing, catalysts, burners,…)

Control system

Durability and reliability development

Vehicle integration

Benefit

3 kW continuous electric power

High efficiency >35%

Zero-emissions (limited & NVH)

AVL has successfully developed SOFC systems close to start-of-production level

apu@avl.com

Fuel C

ell

Applic

ations

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THDA - ONLINE FUEL CELL MONITORING

Background for Stack Monitoring

Usually critical operating status is monitored by measuring the cell

voltages individually. Large stacks thus require costly

instrumentation and elaborated wiring layouts.

Cost efficient solutions with less complexity are required.

AVL Approach THDA

On-line detection of critical FC operating conditions w/o

measuring individual cell voltages

Analysis of the effects of voltage drops instead of measuring

voltage drops itself

THDA technology analysis change in the harmonic distortion

content of a superimposed signal

Customer Benefits

Instrumentation effort is relatively small and of low complexity

2 channel measurement cost effective (no cell voltage

measurement required)

New extended functions enables identification of different

causes for critical conditions e.g.

water flooding / membrane drying / cathode- or anode effect

Dia

gnostics

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THDA - ONLINE FUEL CELL MONITORING EXAMPLE OF MEASUREMENT

Dia

gnostics

A3-FALCON ADVANCED 3D FUEL CELL ANALYSIS AND CONDITION DIAGNOSTICS

PROJECT DESCRIPTION The goal of A3-FALCON is to identify optimal operating strategies for fuel cells in terms of efficiency and lifetime. The

proposed solution comprises the first-time introduction of degradation models in a 3D CFD simulation, spatially resolved

experimental acquisition of critical cell states, a real-time data acquisition and signal analysis (based on AVL THDA) and the

correlation of results from simulation and experiment.

FUNDING PROGRAM FFG IV2Splus

PARTNERS TU Graz, S++, Intelligent Energy (assoc. Partner)

PROJECT TIME FRAME 05/2012 – 04/2014