Electric Powertrain. Public presentation

Transcription

1 Electric Powertrain Public presentation Objective: Electric Powertrain Build technological knowledge on the integration of individual driven electric motors with switch reluctance techology and expand knowledge of the battery system. Integrate the knowledge of above goal by building a 2WD showcase vehicle Approach WP13 Functional safety WP1 System Architecture WP12 Project management WP2 Vehicle controller software WP11 Knowledge management WP3 Drivetrain integration WP4 EMC WP10 MMI WP9 NVH and comfort WP8 System Testing WP7 Packaging and integration WP5 Thermal Management WP6 Battery Pack 2

2 Electric Powertrain Development partners NVH testing & simulation Electric motor & Gear Battery pack & system integration Cooling concept & simulation & testing EMC testing g& advice GaN technology study for power electronics Functional Safety Supporting partners WP1 System architecture

3 WP1 System architecture WG1: Battery WP1 System architecture WG2: Integration

4 WP1 System architecture MGU : Software & Control WP1 System architecture TCU1 TCU2 TCU3 TCU4 MGU

5 WG1: Battery pack Development of modular battery pack, suitable for integration in complex geometries with advanced thermal management features. High quality simulation studies are being performed to support prototype design. Cell/Module design Fluid cooling media developed by Advanced simulation flow/temperature/material Battery pack design & integration leader Prediction towards thermal management pack design WG1: Battery pack Development of modular battery pack, suitable for integration in complex geometries with advanced thermal management features. High quality simulation studies are being performed to support prototype design. Cell/Module design Fluid cooling media developed by Advanced simulation flow/temperature/material Battery pack properties Cells per module 12 Modules per pack 30 Cells per pack 360 Pack nominal voltage (V) 800 Energy (kwh) 11,9 Overall performance Peak power out (kw) 316 Cont power out (kw) 158 Peak power regen (kw) 316 Cont power regen (kw) 158 Battery pack design & integration leader Prediction towards thermal management pack design

6 WG2: Integration Goal: Integration of SR motor & gear Integration of Batterypack, SR motor & gear into vehicle Step1: Designing lay out & housing of SR motor & gear COMPLETED Step 2: Make overall packaging gstudy COMPLETED. Step 3:Build test frame suitable for Motor/Gear/BP/Controller ONGOING Step 4: Make Motor/Gear/BP/Controller package suitable for car built in PLANNED JUNE : System architecture & functional safety Operating modes Hill descent control mode Agility control mode Traction Control mode Hazardous events Operational situatons Side collision with another vehicle City driving Pedestrian accident Snow and ice Front collision with an object (eg. Tree) Mountain pass Vehicle states Driving at constant speed Accelerating stand still Input from system and environment description document Generic Hazard list, experience, customer input Safety goal SG01 The ECU shall give the correct pedal position SG 02 Magnitude and sign of the torque transfer shall not destabilize the vehicle Result: Safety goals for system design/architecture

7 : System architecture & functional safety Result: HARA, safety integrity level and safety goals determination document Hazardous events Operational situatons Side collision with Risk another classification vehicle by team City driving Pedestrian accident evaluation of Severity, Front collision Exposure with an object &(eg. Control Tree) Operating modes Hill descent control mode Agility control mode Traction Control mode Snow and ice Mountain pass Input from system and environment description document Vehicle states Driving at constant speed Accelerating stand still Generic Hazard list, experience, customer input Safety goal SG01 The ECU shall give the correct pedal position SG 02 Magnitude and sign of the torque transfer shall not destabilize the vehicle Result: Safety goals for system design/architecture : System architecture & functional safety Result: HARA, safety integrity level and safety goals determination document Hazardous events Operational situatons Side collision with Risk another classification vehicle by team City driving Pedestrian accident evaluation of Severity, Front collision Exposure with an object &(eg. Control Tree) Operating modes Hill descent control mode Agility control mode Traction Control mode Snow and ice Mountain pass Number Safety Goal The magnitude and sign of the torque delivered to each front wheel shall not Vehicle states Driving at constant speed Accelerating stand still Safety Goal Description ASIL Safety State destabilize the vehicle in all driving situations. The sign shall be correct. The magnitude shall be within +/-5% of the required value. The time and phase lag of the torque transfer shall not destabilize the vehicle in all driving situations. Time lag shall be less tha 100 ms. Phase lag shall be less than 20 ms. Input from system and SG environment 01 description document SG 02 SG 03 D D Generic Hazard list, experience, customer input The system shall provide a level of control sufficient to allow the driver to bring the vehicle to a safe condition. The system shall provide a level of control sufficient i to allow the driver to bring the vehicle to a safe Safety goal SG01 The ECU shall give the correct pedal position SG 02 Magnitude and sign of the torque transfer shall not destabilize the vehicle condition. Result: Safety goals for system y g design/architecture No torque shall be delivered by the system when the vehicle is connected to a charging g B The system shall bring spot. the vehicle to standstill.

8 (Torque, energy and safety mechanisms) (Torque, energy and safety mechanisms) I2A,dem;..;2C,dem I4A,dem;..;4C,dem m3,c,dem m4,c,dem ' m 3,c,dem ' m4,c,dem m1,c,dem m2,c,dem ' m 1,c,dem ' m2,c,dem i1,c i3,c i2,c i4,c m1,c m3,c m2 m4 b,c b,c : System architecture & functional safety Result: HARA, safety integrity level and safety goals determination document Hazardous events Operational situatons Side collision with Risk another classification vehicle by team City driving Pedestrian accident evaluation of Severity, Front collision Exposure with an object &(eg. Control Tree) Operating modes Hill descent control mode Agility control mode Traction Control mode Snow and ice Mountain pass Number Safety Goal The magnitude and sign of the torque delivered to each front wheel shall not Vehicle states Driving at constant speed Accelerating stand still Safety Goal Description ASIL Safety State destabilize the vehicle in all driving situations. The sign shall be correct. The magnitude shall be within +/-5% of the required value. The time and phase lag of the torque transfer shall not destabilize the vehicle in all driving situations. Time lag shall be less tha 100 ms. Phase lag shall be less than 20 ms. Input from system and SG environment 01 description document SG 02 SG 03 D D Generic Hazard list, experience, customer input The system shall provide a level of control sufficient to allow the driver to bring the vehicle to a safe condition. The system shall provide a level of control sufficient i to allow the driver to bring the vehicle to a safe Safety goal SG01 The ECU shall give the correct pedal position SG 02 Magnitude and sign of the torque transfer shall not destabilize the vehicle condition. Result: Safety goals for system y g design/architecture No torque shall be delivered by the system when the vehicle is connected to a charging g B The system shall bring spot. the vehicle to standstill. : System architecture sub component level Vehicle software with high speed communication protocols (FlexRay) in safety critical functions Functional safety V- position φ, θ, ψ pbr Driver Motor Generator vcar, Unit, vcar, ω1,..,4, ωm1,..,m4, μx1,..x4, Fy1,..,y4, Fz1,..,z4 ψ FLEX XRAY I1A,dem;..;1C,dem; I1A,..,1C; I2A,..,2C Torque Control ; Q ; Q,c Unit + + Vehicle I3A,dem;..;3C,dem; I3A,..,3C; I4A,..,4C vcar ;,c Q ; Q vcar sensor Q Q Ib; Vs1,..,sn; Ks1,..,sn data Q b,h Battery management Q " b,c,dem ; " b,h, dem ' b,c, dem Qbc b,c,dem ; System ; ; ; Advanced software functions with electrical controlled ABS, torque vectoring & energy management.

9 Supporting Workpackages WP 4: EMC Our partner EIA investigated and listed all necessary requirements and standards regarding emission & immunity towards development of the powertrain & its components When selecting different possible sources of emission, care is taken that suitable products are chosen and they comply with the necessary regulations Within the Inductive Charging project, the Volvo C30 was tested on EMC which provided valuable information towards the Electric Powertrain project WP 9: NVH (Noise, vibration and harshness) Our partner LMS performed an extensive bench mark study on electrical vehicles that will be used as base reference for further powertrain development By advanced simulation models, NVH issues can be detected at design level and tackled in prototype products 17