Task 1.6
Contents
1. Provide the interface system for real ECU s Depending on manufacturer input in task 1 4 the ECU model interface will be standardized If individual vehicles in validation phase 2 request additional signals they will be made available at the interface to run the HILS system How to handle multiple ECU s has to be discussed Manufacturer input on quantity and required signals is needed GF Ji N Be ENNA i 4 WA SIR Aa i fui i TNO dis ar I FA Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 49 or I e TU OR Institut f r Fahrzeugantriebe CHALMERS bi i 10th of October 2012 Task 3 3 Deliverables amp comments Adaptations and improvements on the methods for component testing test cycle definition and simulation method according to demands of industry and Commission gt For eventual adaptation and improvement of methods suggested by the HDH group two weeks of work is reserved Maybe transient model behaviour will get a topic gt Currently transfer functions and time constants are used e g for ICE torque buildup gt Not clear how they are specified in the component test methods Effort tuning the time constants can not be estimated today at earliest possible in validation phase 2 SEN i TNO nun Rane Ey FA Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 50 Graze Sn Institut f r Fahrzeugantrie be CHALMERS amp Automobiltechnik gi a e2. Gr Pore vy ANCES bY TNO oe EETU ee Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 1 i iebe bil i 10th of October 2012 O D Working Paper No HDH 11 04e 11th HDH meeting 10 to 12 October 2012 GRPE HDH Research Project 11 meeting of the GRPE informal group on heavy duty hybrids HDH Report of the Institutes on validation test program 1 ANa u Graze Institut f r Fahrzeugantriebe Jonas Fredriksson Gerard Silberholz Christoph Six TNO innovation TU Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 2 for life l Graze 10th of October 2012 Content Working tasks in current validation phase 1 until mid year 2013 Deliverables gt Current results Timetables and milestones gt Required manufacturer input Outlook on validation phase 2 A SER TNO for life i TU A l AD Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 3 Graze eri itut f Institut f r Fahrzeugantriebe CHALMERS amp Automobiltechnik 10th of October 2012 GH We Validation phase 1 overview Task 1 Adaptation of the Japanese HILS Simulator for serial hybrid 7 sub tasks where we are currently working on Task 2 Adaptation of the HILS Simulator for parallel hybrid 4 sub tasks officially starting this month Due to intersections with task 1 already began earlier Task 3 Report on test procedure and adap
3. Time dependence of current voltage behavior Measured voltage behavior due to a rectangular current pulse commercial 7OAh Kokam LiPoly cell gt Time dependence is required for a better estimation current A D of the power loss 0 5 1 1 5 2 2 5 l l Parameter estimation Almost the same measurements as described in Kokujikan No 281 but different data analysis needed cell voltage V 0 0 5 1 1 5 2 2 9 time minutes No time dependent model as shown in Kokujikan No 281 Time dependent model TNO innovation for life GG A Bm AGNES Br 3 Ay FA Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 33 anaes or j S Institut f r Fahrzeugantriebe GAZE cHa mers Anoob 10 of October 2012 Task 1 6 Extend the GIR HILS Simulator with thermal models Thermal model for electric motor gt From Kokujikan No 281 gt Model calculates torque electric power and current in dependence of revolution speed voltage and torque demand Required Extensions to calculate motor controller and fluid temperatures Separation of power losses for EM and controller leading also to individual power consumption maps for the motor and controller Adding thermal models of motor and controller Combining the calculated power losses and the thermal models calculation of the corresponding temperatures TNO innovation TU FA Developing a Methodology for Cert
4. plug amp play Manufacturers should be able to bring in their own submodels we can only provide a minimum of signals that are needed af A oN IE SAY a f Yi APRES N TNO 32 EETU ey Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 42 5 s iebe bil i 10th of October 2012 Op L MMM Task 2 3 Discussion point gt Adapt the Software to simulate a parallel HDH Would be good if we know which drivetrain topologies we will have in validation phase 2 to prepare parallel and serial HDH models Task 2 already starting In need of control strategy Depend on topology Idea of control strategy Is this acceptable for doing simulations g LIND TNO ation EETU y FA gt Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 43 Grazu CHALMERS A Er l amp Automobiltechn 10th of October 2012 Task 2 3 Deliverables gt Adapt the Software to simulate a parallel HDH In need of control strategy Depend on topology Idea of control strategy Is this acceptable for doing simulations The control strategy is to use the electric machine below a certain speed and the combustion engine above that If energy level stored in the accumulator is lower than a certain value the electric machine is used as generator and is then driven either by the engine or purely by the kinetic energy of the vehicle The electric machine is used for braking
5. Tq_limit_demand Ta_limit_rate EgDriveTq Nm q Jimit rate Fuel_cut EgLossTa_Nm Fuel_cut Idle_rpm_adjust idle rpm adjust ACC_switch ACC_switch 24 Tq_limit_switch Tq_limit_switch Eq_tpm Fuel_inst Ni_rpm Motor_assist_ta Motor_i_in Motor_ta_hm 20 Motor_CLin Rap Motor_Rev Motor_T Motor Fev accessory1_on accessory2_on p Product 1 os3_current_acessory ASR_ON_In Motor_Power TQ_Ret_In RESS_vol Reduction_ON Command_change Reduction_ Switch Motor_Power otor_Current Motor_Current Motor_ta_fb O Reduction _ON Reduction_SW MotorDriveTq Max_Nm MotorRegenTq Max Nm Motor RegTqMax MOTOR_UNIT RESS_Voltage CAPACITOR_MODEL RESS_SOC Batt Voltage_Out Motor_Current Batt Soc_out Batt Power w BATTERY_MODEL RESS_Power Current_add RESS_Current RESS_change TNO fle TNO ation WE y F A D Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 41 TU i ll Institut Fahrzeug antrie amp Automobiltechnik 10th of October 2012 T N a a aa Task 2 2 Discussion point Set up a data bus system in the model to allow various combinations of engines gear boxes and storage systems Bring up the question who is the owner of the model in the end Who is responsible for structure who for components Are these different persons authorities gt model will never be
6. heat capacities heattransfer coefficients componentmasses c d voltage c d current Thermal model Temperature battery soc battery Maps for open voltage internal resistance coolant massflow Model parameters spec heat capacities heat transfer coefficients component masses E A WA CNANCES Ae M TNO ation wpHTU nr Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 31 Fi i iebe bil i 10th of October 2012 Ge je a Task 1 6 Extend the GIR HILS Simulator with thermal models Thermal model for electric storage device From Kokujikan No 281 Actual state of charge coulomb counting SOC 50 ar 7 gg 100 C mina 3600 i Hoe min a f gt Calculation of the electrical power P V1 R 4 Required Extensions to calculate battery and fluid temperatures Adding a time dependence time constant for the current voltage behavior Adding a thermal model of the battery pack Calculation of the power loss and in combination with the thermal battery pack model calculation of the temperatures Bam innovati CD IFA TNO nun TU BIN I A Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 32 BEIDE Graze Batya Institut fiir Fahrzeugantrieb en amp Automobiltechnik 10th of October 2012 Task 1 6 Extend the GIR HILS Simulator with thermal models Thermal model for electric storage device
7. Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 36 Grazi CHALMERS amp Au catia Sak zu 10th of October 2012 a Validation phase 1 overview Task 1 Adaptation of the Japanese HILS Simulator for serial hybrid Timetable and milestones Task 1 1 and 1 2 serial hybrid model with different driver models are completed Task 1 3 modelling non electric components is finalized overall model implementation deferred with regard to validation phase 2 gt Task 1 5 and 1 6 modelling of components and thermal models is planned to end in November to have enough time for overall model validation which should start in December Task 1 report to ACEA at the end of February 1 SILS for serial hybrid T 118etupaseriaHDHassus To S To 0 T S 1 2lAdapt driver mode So T S T T oo o Library for non electric com Pot fF fy fy ft ft Se BE BE BEE BEE BE BE BEE EEE BEE BE DI 2 FT PP PT HE HE 11 6 Thermal models 1 7 Simulation runs and validation f 0 T 0 f f f E 2 x lt TNO 22 i Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 37 TNO life i ome bil i 10th of October 2012 Op nme ee Validation phase 1 overview gt Task 2 Adaptation of the HILS Simulator for parallel hybrid 4 sub tasks officially starting this month Due to intersections with task 1 already began earlier v R
8. gt Will most likely be used for parallel hybrids in task 2 Planetary gearbox models without inertias and losses already implemented in the library Models considering gear inertias and losses under development Manufacturer input is needed for component testing methods and available model input parameters e g how efficiencies are specified FAo gt Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 21 Institut f r Fahrzeugantriebe amp Automobiltechnik 10th of October 2012 TNO innovation for life Task 1 5 Extend the Simulator with a library for power pack components Planetary gearbox for power split 3 basic models are provided in the library Gearbox output at gt Sun gear Ring gear Planet gear carrier gt Models require Gear tooth numbers Component inertias gt Gear efficiencies S P P R Validation through other software gt GT Suite Dymola Ring gear Source ww csacom Planet gears PA amp N N WA ESS Aa f ifyi i TNO dis ar I FA Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 22 or I e TU OR Institut f r Fahrzeugantriebe CHALMERS biltechni 10th of October 2012 Task 1 6 Deliverables Extend the GTR HILS Simulator with thermal models for exhaust gas aftertreatment components coolant lube oil battery and electric motor In previous project phase it was decided that HDH will
9. GIR HILS Simulator with thermal models Thermal models for exhaust gas aftertreatment components one Pe maps for temperature exh out lambda massflow ji maps for emissions Calculations in MATLAB code a a a a a d g z a F a a a z z 2 s e s z 31 3 f r r ow m i B Y m _ N K N y N x Y w gt o te 3 maps for conversion rates of catalyst ei int FAo gt Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 28 Institut f r Fahrzeugantriebe amp Automobiltechnik 10th of October 2012 TNO innovation for life Task 1 6 Extend the GIR HILS Simulator with thermal models gt Thermal model for coolant and lube oil gt implemented in Simulink gt measurements on engine testbed for parameterization of model currently running needs to be adapted parameterized and validated with measurement data ICE torque Thermal model Temperature coolant and oil ICE rot speed coolant and lube oil Maps for engine waste heat coolant massflow oil massflow e Model parameters spec heat capacities heattransfer coefficients component masses fds TNO ation wpHTU Co I FAD Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 29 Graze Bhs ll Institut f r Fahrzeugantriebe biltechni 10th of October 2012 Task 1 6 Extend the GIR HILS Simulator w
10. RESS_change accesso accessory2_on ECU_Tq_ref_In Reduction_ON Command_change Reduction_switch 13 Koubai Drag_ Manipulator _GENERATOR MOTOR_DRIVE S 1 ENG_NE Gen_Power Gen_Tq_Nm 4 Fuel_Consumption Driver_demand_rate Current_ Eng_Tq_rate S ane GH ISC 12 Eng_Tq_rate2 EgDriveTq EqLossTq EqgMaxTq EgDriveTq_woLoss Eg_Tq_map_sirei Gen_speed RESS_Voltage CE ED RESS_SOC RESS_Power RESS_Current Current_ amp SPD_kmh RL_Nm Motor_rpm Motor_Tq_ Nm Motor_power_kW kasokudo_m s2 Motor DriveTqMax Motor RegenTqMax Motor _Tq_ref DIST_km Moment_WheelHub Rev_WheelHub Ori dermand_ini shift_p_out SPD_kmih DIST_km 3 o Het DIST_km g BRION TE dist_reset 1 DIST Sur EB RL_N 2 shift_p l SPD_km_P_h IG_In Motor_CLin No_rpm Motor_J_In 1 Eg_rpm Motor_Ta_In Ne_out Cluch_position KA SOKUDO KASOKUDO F_coup_Oh_in Ni rpm Cg Lock_Up_in Nttpm koubai_in Eng_T_ini 1G_In Fuel_Consumption fuka pei ST_In Eng_Tq_out ST In EXHE_In Ena_Ta_rate EXHB_In 14 Rev_demand Loss_Ta_rate 15 Hev demand Rev_control_demand Driver_demand_rate Rey_control_demand 16 Rev_limit_demand Rev limit demand wl ockaido DRU_demand_inj ACCkaido GED Sireikaido Loss_Tq_rate2 EED Sireikaido Ta_limit_demand Eng_Ta_rate2
11. Z i Sn AN E FAo gt Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 38 aman acess lt Page Institut f r Fahrzeugantriebe SS amp Automobiltechnik 10th of October 2012 TNO innovation for life Task 2 1 Deliverables gt Meetings with OEM s and stakeholders gt See Task 1 4 E A WA CNANCES Ae M TNO ation mtu ee Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 39 Fi i iebe bil i 10th of October 2012 Op A A T Task 2 2 Discussion point Set up a data bus system in the model to allow various combinations of engines gear boxes and storage systems gt Difficult in the current model to setup a data bus system Components are represented in different ways in the two vehicle models Components are lumped in different ways gt There might be a need to restructure the models innovation for life CHALMERS UNIVERSITY OF TECHNOLOGY IFAo gt Institut f r Fahrzeugantriebe amp Automobiltechnik Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 40 10th of October 2012 keyOn_In lt gt ST_In EXHB_In dB Rev_demand Rev_control_demand D Rev _limit_demand ACCkaido 0 Sireikaido Tq_limit_demand Tq_limit_rate Fuel_cut ED Idle_rpm_adiust ACC_switch Tq_limit_switch 16 ECU_ref_Tq ED ST_Tg Engine_Start_active Gen_ref_rev Eng_start_flag Eng_stop_flag
12. dation phase have to be specified hybrid stakeholders Adapt the Software to parallel HDH Simulation runs and validation Mn up a data bus system in the model TNO 4 TNO life Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 46 10th of October 2012 SS EEE Validation phase 1 overview gt Task 1 Adaptation of the Japanese HILS Simulator for serial hybrid sub tasks where we are currently working on Task 2 Adaptation of the HILS Simulator for parallel hybrid gt 4 sub tasks officially starting this month gt Due to intersections with task 1 already began earlier Task 3 Report on test procedure and adaptations 3 sub tasks ending on schedule in June 2013 Gr Pore vy ANCES bY TNO ation EETU ee Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS A7 i iebe een 10th of October 2012 Task 3 1 Deliverables gt Report on test procedure and user manual for software Component testing procedure Application of the HILS simulator Validation procedure of the HILS setup User manual for the software Reports can only be on schedule if we agree to keep working with the current HILS model structure E A WA CNANCES Ae M TNO ation EETU BEE Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 48 Fi i iebe bil i 10th of October 2012 Op N T DE Task 3 2 Deliverables
13. e Er E Validation phase 1 overview Task 3 Report on test procedure and adaptations gt Timetable and milestones Reporting to ACEA will start in January only Task 1 Total validation phase 1 report is planned to start on schedule Reports can only be on schedule if we agree to keep working with the current HILS model structure Changing the model structure will postpone the targeted end of validation phase 1 but may be advantageous for modelling future hybrid vehicles Reporting on test procedure and writing a user manual for software Report on test procedure user Adaptations and improvements of methods VE EA TNO ation EETU y FAD Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 51 Grazu CHALMERS ie ome amp Automo biltechnik 10th of October 2012 Outlook on validation phase 2 from spring 2013 Validation phase 2 influences current work Certain points have to be clarified at earliest see previous slides Still an open question is who will work on validation phase 2 and which vehicles will be tested gt We will not provide vehicle models which are not used in validation phase 2 We propose to leave the non electric components outside the model in the library and focus on modelling vehicle structures tested in validation phase 2 SS N I FAD Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 52 Institu
14. ed to current Task 1 2 gt The final worldwide HILS method should be as far as reasonable in agreement with the test procedure for conventional engines gt The review of vehicle related data resulted in power demand cycles at the power pack shaft which are similar to the test cycle for conventional engines WHTC This makes the type approval of a hybrid power pack generally more comparable to conventional combustion engines To allow for charging of a hybrid vehicle s RESS rechargeable energy storage system during phases of deceleration a corresponding negative power course for mechanical braking was added in the existing motoring phases of the WHTC a WA CNANCES Ae n TNO nun l J BIN I FAD Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 12 Graze chame peas Institut f r Fahrzeugantriebe CHALMERS amp Automobiltechnik 10th of October 2012 T S Du General preface concerning driving cycles from the previous project phase linked to current Task 1 2 There are three different options for the realisation of the developed World Heavy Duty Hybrid Cycle WHDHC gt B 1 power cycle at the wheel hubs with WHVC as speed signal B 2 power cycle at the power pack shaft with original engine speed signal acc to WHTC method WHVC as speed signal B 3 vehicle speed cycle WHVC ee ee ee eee eee ee Engine Engine Electric i motor Generator Electric moto
15. er Cycle reference tables Watchdog system 2 open closed Loop control Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 9 TNO innovation for life 10th of October 2012 nnn 7 ee Task 1 1 Set up a serial HDH in the simulator with the ECU as software in the loop gt Simulation results gt Input vehicle cycle permitted tolerances ICE operation strategy actual vehicle speed l desired vehicle speed J lower speed limit upper speed limit Speed km h Pedal position 25 30 35 40 45 FL time s GE 2 BIN I FA Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 10 t f r Fahrzeugantrieb t Institut f r amp Automobiltechnik 10th of October 2012 TNO innovation for life lt te Graze CHALMERS Task 1 1 Set up a serial HDH in the simulator with the ECU as software in the loop Simulation results Output ICE torque and speed cycle tolerance cycle violation 3500 S000 2500 2000 1500 1000 s Eng speed rpm 0 Eng Torque Nm time s g FLA ES J I F AD Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 11 Institut f r Fahrzeugantriebe CHALMERS Automobiltechnik 10th of October 2012 sr eee ea ee TNO ation TNO life General preface concerning driving cycles from the previous project phase link
16. h thermal models Thermal models for exhaust gas aftertreatment components 2 separate aftertreatment systems i e DOC POC and SCR modeled O dimensional heat capacities Heat transfer between exhaust gas and heat capacities convection turb lam gt Catalyst heat input through chemical reactions conversion rate maps gt Cooldown of stopped engine empiric cool down curve SHHCHCHCTCHCTCKSKESCKSECHSCHECRERC ZZ RT ZB ZB ZB ZI BED eee z a Vana aan a a Cokiak thermocouple before thermocouple after thermocouple thermocouple after r r Va a a a a aftertr system 1 aftertr system 1 after pipe 1 before aftertr system 2 aftertr system 2 ee FR n T oss OR i o o dhee OB oe es Oy hreat capacity waneansereesersnes manna aftertr system 2 rion 5 mn te nn GAFELEELELED t exh quaal stats pes thermocouple before thermocouple after thermocouple thermocouple after et 1 a aaae n pd ER i TNO innovation for life ie EELA nnalnnunna cote a a e 5 oe rn Ss I Ye tr m BEIEELEREEIERERIM EEEE t exh quasi stat E FAo gt Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 25 Institut f r Fahrzeugantrieb amp Automobiltechnik 10th of October 2012 Task 1 6 Extend the GIR HILS Simulator with thermal models Thermal models for exhaust gas aftertreatment components gt Heat transfer between heat capacities and envi
17. have to undergo a cold start test similar to the conventional ICEs HDH ECUs will need plausible information on the temperature levels of all relevant components to select the correct operation strategies gt Simple thermal models with generic input parameters are being developed adapted and integrated into the HILS simulator TNO innovation for life V Gor A ug Rag F AD Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 23 u Institut f r Fah trieb Ga ers oe 10th of October 2012 Task 1 6 Extend the GIR HILS Simulator with thermal models Thermal models for exhaust gas aftertreatment components gt implemented in Simulink validation with existing measurement data finished ready to be linked to the main Simulink model Thermal model ICE torque Temperature exhaust gas ICE rot speed aftertreatment components different locations in exhaust system Maps for exhaust temperature exhaustmassflow a emissions Model parameters a spec heat capacities componentmasses Bs 4 oy MW EXTANCEs bys wh GY 2 X SG SO Say Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 24 SN aE ee Dan Grazi cuaimers TNO innovation for life Institut f r Fahrzeugantriebe amp Automobiltechnik 10th of October 2012 Task 1 6 Extend the GIR HILS Simulator wit
18. hodology for Certifying Heavy Duty Hybrids based on HILS 17 Simulation models for non electric powertrain components Mathematical models are developed for gt Flywheel gt Accumulator gt Pump Motor CVT Accumulstor AcTempersture K Accumulstor 1 tempersture Accumulstor 1 mass_of_gss Accumulstor 1 gss_constant Constant2 n Accumulator_Q_m3ps flow fb in m3 s Accumulstor 1 volume_tank Accumulator 1 volume_fluid_max TNO innovation for life Task 1 3 Summary 10th of October 2012 TU U Riad 4 FAo gt Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 18 anges nstitut f r Fahrzeugantriebe race CHALMERS en Mathematical models for non electric components are available in MATLAB Simulink Simple models suitable for HILS gt Input and output signals are defined Mesel__ Input Output ___Symbol_ __Meaning of signa __ aaa EL egemuner ER Em es eal he __ oa E UUU input 1 JAccumulator ActPressure Pa Pressure in accumulator Pk linput 2___ Accumulator_ActTemperature_K Temperature in accumulator KT input 1 Pump _ActTorque Nm Actual pump motortorque Nm Inputa pump _Actvoitiow maps Actual pump motor volume fow dr linput 4 Pump ActAccPressure Pa Actual accumulator pressure Pa Pump Motor linput S Pump ActResPressure Pa Actualreservoirpressure Pa oe a H Output 3 Pump RefTorque_N
19. ifying Heavy Duty Hybrids based on HILS 34 for life Graze Institut f r Fahrzeugantriebe amp Automobiltechnik 10th of October 2012 Task 1 6 Extend the GIR HILS Simulator with thermal models gt Thermal model for one component battery motor controller Thermal mass is considered as a point mass Heat transfer is modeled by a constant heat transfer coefficient Pressure drop for fluid flow is stored in a lookup table Onuid in age a Pios Thermal F cooling N Heat Mass Transfer Dawica Druid out gt Parameter estimation Same measurements as described in Kokujikan No 281 but additional measurement between controller and motor is needed TNO RZ PREN 3 TNO ation Nr I FA D Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 35 TU ll Institut Fahrzeug antrie amp Automobiltechnik 10th of October 2012 G i Task 1 7 Deliverables gt Simulation runs and validation of basic functions gt Simple control strategy for model validation including vehicle driver thermal and non electric models With regard to validation phase 2 models of later on tested vehicles should be used for validation here Largely realistic control strategy would be favourable gt Different input data will be used gt Generic values Measurement data from institutes Measurement data from manufacturers if available TNO ation mtu Co y FA gt
20. ith thermal models gt Thermal model for coolant and lube oil exemplarily for coolant Cooling circuit divided into 2 cells O dimensional heat capacities for ICE amp cooler Qin 4 equations Tu dT I ice Mice 5 Q Ay Ay Tier T Point mass Tice Cice aT II cy my Oy Ay Ty Cy tit Ty Ty T const T Wall gt FICE dT IIT Cw My dt Cy tn Ty Ty gt ya Aya Te Ty2 Tin out aT IV Cc Mc On Ay T Tya Apr Ay r Tun T Point mass u T cooler Cooter T Open simulate engine test conditions with constant T poler Teg cans 2 Teor oT we ou Or vehicle conditions with variable a A aa n G sees 3 innovation LOAN wad 18239 gt ma for life J Ne MAQA Graze r Fahrzeugantriebe Soe a Institut f r Fahr CHALMERS amp Automobiltechnik Task 1 6 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 30 10th of October 2012 Extend the GIR HILS Simulator with thermal models gt Thermal models for battery and electric motor gt under preparation in cooperation with Institute of Electrical Measurement and Measurement Signal Processing at TUG OEM input and validation data needed EM torque Thermal model Temperature EM electric motor EM current Maps for electric motor losses coolant massflow Model parameters spec
21. m Referencetoraue 2 __LL nm Models not implemented in the Simulator yet Japanese open source model TNO ation TNO life Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 19 10th of October 2012 Task 1 4 Deliverables gt Meetings with OEM s and stakeholders to discuss relevant components to be included in a first version of the GTR HILS model as basis for tasks 1 5 and 1 6 gt Input of the Institutes gt List with already available components gt List with signals at the ECU Hardware interface of the model Dialogue and manufacturer input is needed Provided lists should be a basis for discussion Also component test methods have to be reviewed with manufacturers gt Meeting at the beginning of Nov in Stuttgart is aimed If we get no input we can only rely on the information from the Japanese model will not be sufficient TNO ation TNO life PA 3 N STR f YA NA Beis N H ar I FA Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 20 OR itut f r Fah iebe TU CHALMERS amp Automo ee 1 on of October 201 2 Task 1 5 Deliverables Extend the Simulator with a library for power pack components not yet included in the Japanese HILS model gt Components are modelled according to the manufacturers input in task 1 4 Currently a planetary gearbox is offered and already under development
22. r Generator I i E A WA CNANCES Ae M TNO ation mtu BEE Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 13 2 i iebe biltechni 10th of October 2012 Task 1 2 Deliverables gt Elaborate a driver model which allows to run the simulator with test cycles consisting on power and rpm at the wheel hub and at the power pack shaft 2 different driver models for power cycle input 2 PID Controllers per driver model needed Cycle reference tables Watchdog system Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 14 TNO innovation for life Institut f r Fahrzeugantriebe amp Automobiltechnik 10th of October 2012 Task 1 2 Elaborate a driver model for power cycles at the hub and at the power pack shaft Example power pack shaft driver gt Torque controller controlling driving torque Speed controller controlling load torque Load torque Driving torque f vehicle speed at constant inertia F A Dn amp PaA VA Nh Gapeeee Aa os TINO erie wae I F AD Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 15 W CHALMERS itut f r Fahrzeugantriebe amp Automo biltechnik 10th of October 2012 Task 1 1 1 2 Summary Driver models are able to run serial hybrid powertrains Monitoring system detects faulty or undesired system reactions Function check with diffe
23. rent input cycles and vehicles Differences between the 3 driving cycle inputs vehicle speed power at hub shaft are currently under investigation PID control parameter variation for different vehicle configuration gt Seems to be a moderate effort for accurate results within tolerances Too aggressive control parameters may lead to erratic engine operation gt To run parallel hybrid powertrains the driver models have to be adapted in the upcoming task 2 starting this month Functions for shifting gears and actuating the clutch have to be added VE EA TNO ation mtu y FAD Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 16 Grazu CHALMERS on om amp Automo biltechnik 10th of October 2012 Ee Task 1 3 Deliverables Extend the Simulator with a library for non electric components as defined in part one of the project The result is a set of simulation models of non electric powertrain components which are suitable to use in a HILS setup gt Non electric hybrid powertrain topologies concepts fits well into the same categories as for electric hybrid powertrains Interesting non electric powertrain concepts gt CVT and flywheel gt Motor generator and flywheel Hydraulic or pneumatic pump motor and accumulator innovation TNO for life EETU Grazi Task 1 3 CHALMERS Institut f r Fahrzeugantriebe amp Automobiltechnik Developing a Met
24. ronment convection radiation Heat conduction between masses neglected effect much smaller than O d model accuracy Thermal behavior of thermocouples included essential for comparison of model results with measurement data aftertr system 1 aftertr system 1 after pipe 1 before aftartr system 2 aftertr system 2 ot mms et ge ee sussusszsussewi zssz feat capacity enifoid turbooh ay FAD Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 26 Be Institut f r Fahrzeugantriebe eee amp Automobiltechnik 10th of October 2012 TNO innovation for life Task 1 6 Extend the GIR HILS Simulator with thermal models Thermal models for exhaust gas aftertreatment components Input signals engine speed power vehicle speed engine status Maps exhaust gas temp after turbocharger exhaust gas massflow lambda emissions conversion rates in catalyst Input parameters masses start temperatures heat capacities heat transfer coefficients lengths amp diameters of pipe sections Soope5 Out Scopet Dats Es Scope aes Signal From Workspace Scopes Constant Temperatures of exhaust system Scoped Scope Institut f r Fahrzeugantriebe amp Automobiltechnik 10th of October 2012 a Sy TNO for life maa EETU CANY FAo gt Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 27 AZE craimers Task 1 6 Extend the
25. t f r Fahrzeugantriebe CHALMERS amp Automobiltechnik 10th of October 2012 TNO innovation for life T THANK YOU FOR YOUR ATTENTION AE X AE AEN eh Pit es RA JANCE wy WW ANCES hy pe ty y u 7 Fa SE RS 1939S As aap aes 2 a a a N Graze Institut f r Fahrzeugantriebe CHALMERS 1 UNIVERSITY OF TECHNOLOGY amp Automobiltechnik Jonas Fredriksson Gerard Silberholz Christoph Six
26. tations 3 sub tasks ending on schedule in June 2013 Gore WA CNANCES Ae M TNO ation mtu ee Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 4 Fi i iebe biltechni 10th of October 2012 Task 1 1 Deliverables gt Set up a serial HDH in the simulator with the ECU as software in the loop as basis for further programming and software development Basic serial hybrid model was provided by JARI ECU control strategy with different ICE operation points was added Driver model running the model with a vehicle speed cycle as input Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 5 af A Sm iF SAGE Sh Y DER CHS W TNO 4 INS NSE aS en 7 Le TNO life en CHALMERS ut f r Fahrzeugantriebe re chnik 10th of October 2012 Task 1 1 Set up a serial HDH in the simulator with the ECU as software in the loop Basic serial hybrid model was provided by JARI ECU functions were added Hardware ECU msi FREE BUNERENE fe ECU Switch _ Serial hybrid u Hardware Software ri chicle model Tee cade co Eh et eae Po ene eu A cnc nt eR DEE AEA Cu cad cu Iti ad ech eu ta cack DIA nn Persist TE vehicle speed km h innovation for life 200 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 6 Graze Oe institut f r Fahr
27. the vehicle when possible if the brake torque is not enough then the mechanical brakes are used as well The electric machine is also used for power assist when the desired torque interpreted from the accelerator pedal position Is larger than the combustion engine can deliver E A WA CNANCES Ae M TNO ation mtu ee Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 44 Fi i iebe bil i 10th of October 2012 Op SSS ee ew EN Task 2 4 Deliverables Simulation runs and validation of basic functions including the functions from task 1 See Task 1 7 Generic data or measurement data of institutes or manufacturers will be used Depending on vehicles in validation phase 2 gt Provided simulation models have to be specified Models for all possible combinations of library components will not be provided FAD Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 45 ARE I i y ANCES Si innovation TI J CA m wh y N pe TNO for life mane oe Grazm cn E Sag Bes en I i r F e ALMERS amp Automobiltechnik 10th of October 2012 Validation phase 1 overview Task 2 Adaptation of the HILS Simulator for parallel hybrid Timetable and milestones Task 2 2 the model structure and the further proceeding has to be discussed at earliest Task 2 3 control strategy proposal has to be discussed gt Task 2 4 available vehicles in vali
28. zeugantriebe en amp Automobiltechnik 10th of October 2012 Task 1 1 Set up a serial HDH in the simulator with the ECU as software in the loop Driver model running the model with a vehicle speed cycle as input Vehicle cycle input is needed at the driver model Tolerances have to be specified gt Tolerance cycles are calculated automatically in MATLAB Kan XxX Si 400 600 800 1000 1200 1400 1600 1800 time s vehicle speed km h innovation for life Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 7 DE NA E ut f r Fahrzeugantriebe Graze CHALMERS gAutomobiltechnik 10th of October 2012 Task 1 1 Set up a serial HDH in the simulator with the ECU as software in the loop Driver model running the model with a vehicle speed cycle as input Vehicle cycle input is needed at the driver model Tolerances have to be specified gt Tolerance cycles are calculated automatically in MATLAB i WHVC a 770 775 780 785 790 795 800 805 810 200 400 600 800 1000 1200 1400 1600 1800 time s time s TNO ation eee fe a I FAD Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 8 rFa CHALMERS S re psa omobi a hn or ia 10th of October 2012 Re eee eee Task 1 1 Set up a serial HDH in the simulator with the ECU as software in the loop Driver model running the model with a vehicle speed cycle as input PID Controll
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