GRPE-HDH Research Project

Transcription

1 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 1 Working Paper No. HDH-13-03e (13th HDH meeting, 21/22 March 2013) GRPE-HDH Research Project 13 th meeting of the GRPE informal group on heavy duty hybrids (HDH) Report of the Institutes on validation test program 1 Jonas Fredriksson Gérard Silberholz Christoph Six

2 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 2 Content Summary of working tasks 1 at validation test program 1 Summary of working tasks 2 at validation test program 1 Drive cycle investigations Test methodology investigations Offer for validation test program 2

3 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 3 Validation test program 1 overview Task 1) Adaptation of the Japanese HILS Simulator for serial hybrid Task 1) Adaptation of Japanese Serial Hybrid model is completed Serial Hybrid model available at HDH download area (based on Japanese model structure) Driver- and Thermal models implemented in vehicle model SILS model test runs were performed with different generic vehicles (battery, motor power, mass, tires, drivetrain gear ratios,..) New components have been identified at previous OEM meeting 1 SILS for serial hybrid 1.1 Set up a serial HDH as SILS 1.2 Adapt driver model Library for non electric 1.3 components Meetings with OEM s and 1.4 stakeholders Library for new power pack 1.5 components 1.6 Thermal models 1.7 Simulation runs and validation Jun Jul Aug Sept Oct Nov Dec Jan Feb Mar Apr May

4 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 4 Validation test program 1 overview Task 1.4) Meetings with OEM s and stakeholders Meetings with Volvo, Scania, Daimler and MAN took place drive cycle investigations with Daimler were intensified approval of drive cycle approach with MAN and Daimler is scheduled (see upcoming slides) current hybrid models will not match with proposed OEM vehicles for validation test program 2 e.g. 2 separate electric drive motors coupled via transmission hybrid models will have to be adapted to specific vehicle topology request by OEMs that WHTC remains as alternative type approval test for low-volume and niche vehicles HILS type approval would be very high effort

5 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 5 Validation test program 1 overview Task 1.5) Library for new power pack components Additionally required components were identified during last OEM meetings DC/DC - Converter (to run el. components on different voltage levels) Braking resistor (to dissipate energy and control energy flows) Automatic transmission gearbox with torque converter 3 weeks of modelling and validating new components was planned Remaining capacities will be used to start modeling DC/DC-converter and braking resistor ATM can not be covered within this work program (see upcoming slides)

6 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 6 Validation test program 1 overview Task 1.6) Thermal models model structure for engine cooling fluid and engine oil

7 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 7 Validation test program 1 overview Task 1.6) Thermal models model structure for exhaust system

8 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 8 Validation test program 1 overview Task 1.6) Thermal models model structure for RESS

9 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 9 Validation test program 1 overview Task 1.6) Thermal models model structure for RESS single cell model

10 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 10 Validation test program 1 overview Task 1.6) Thermal models model structure for component mass cooling (electric motor, RESS)

11 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 11 Validation test program 1 overview Task 1.7) Simulation runs and validation Japanese Serial Hybrid Model was adapted Thermal model for ICE oil and water Thermal model for ICE exhaust system Thermal model for electric motor/generator Driver models for vehicle speed and propulsion power demand Thermal model for energy storage Energy storage model

12 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 12 Validation test program 1 overview Task 1.7) Simulation runs and validation Outline of simulation test runs ICE torque/speed pattern as final result for emission test

13 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 13 Validation test program 1 overview Task 2) Adaptation of the Japanese HILS Simulator for parallel hybrid 2.1 Meetings with OEM s and stakeholders 2.2 Set up a data bus system in the model to allow various combinations of engines, gear boxes and storage systems 2.3 Adapt the Software to simulate a parallel HDH 2.4 Simulation runs and validation of basic functions, including the functions from task 1 Adaptation of SILS for parallel 2 HDH Meetings with OEMs and O 2.1 stakeholders Set up a data bus system in the O 2.2 model Adapt the Software to parallel 2.3 HDH O 2.4 Simulation runs and validation Procedure and Manual 3 writing/reporting Report on test procedure, user 3.1 manual Provide the interface system for 3.2 real ECUs Adaptations and improvements 3.3 of methods Sept Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug

14 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 14 Task 2.1) - Deliverables Meetings with OEM s and stakeholders See Task 1.4

15 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 15 Task 2.2) - Deliverables Set up a data bus system in the model to allow various combinations of engines, gear boxes and storage systems 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 There is a need to restructure the models

16 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 16 Task 2.2)* Restructuring of Models Two types of interfaces are needed: The physical interface is related to how different components are connected together physically The signal interface is related to control/sensor signals (needed for ECU) cmd in sensor cmd in sensor elec in [V] mech out [Nm] elec f b in [A] elec out [V] mech fb in [rad/s] elec fb out [A] RESS electricmotor

17 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 17 Task 2.2)* Restructuring of Models Signal interface Controller Physical Component Physical interface A port based approach: This structure is similar as the simulation models in for example Autonomi, Dymola (Powertrain library), CAPSim, VSIM, TruckSim

18 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 18 Task 2.2)* Restructuring of Models Test cycle / environment HILS ECU (hardware) ECU (software) SILS Interface model (simulink software) manufacturer specific HILS Model interface (Signal interface) HILS vehicle model (simulink software) Data Bus Signal interface Signal interface clutch Phys. interface Phys. interface ICE

19 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 19 Task 2.2)* Restructuring of Models [A] [A] From RESS [A] To Controller From Controller Ctrl RESS [A] From Elmotor Ctrl Elmotor From [A] [A] Goto [A] From1 [A] Goto1 cmd in sensor elec fb in [A] elec out [V] RESS cmd in elec in [V] mech fb in [rad/s] electricmotor sensor mech out [Nm] elec fb out [A]

20 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 20 Task 2.2)* Restructuring of Models Parameter and signal naming must be defined Proposal: Parameters dat.parameter.comment dat.parameter.unit dat.parameter.value Signals description [unit] Signals can be lumped together in a MATLAB/Simulink databus Flexible structure Easy to new add signals

21 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 21 Model and associated data file cmd in sensor elec f b in [A] elec out [V] RESS dat.comment = 'Open source model battery data'; dat.filename = 'para_battery_open.m'; dat.version = '1'; dat.lastmodified = ' '; dat.modifiedby = 'Jonas Fredriksson'; dat.capacity.comment = 'cell capacity'; dat.capacity.unit = 'Ah'; dat.capacity.value = 6; dat.initialsoc.comment = 'initial state of charge'; dat.initialsoc.unit = '%'; dat.initialsoc.value = 60;

22 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 22 Task 2.2)* Restructuring of Models In the GTR: the physical interface can be specified (fixed) a minimum set of control/sensor signal can be specified* *) If other signals are needed or more complex models are needed (no change of physical interface) it is possible for OEMs to include those without effecting the model structure

23 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 23 Task 2.3) - Deliverables Adapt the Software to simulate a parallel HDH Basic parallel hybrid model was provided by JARI ECU control strategy was added Driver model running the model, from Task 1.1 and 1.2

24 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 24 Task 2.3) Set up a serial HDH in the simulator with the ECU as software in the loop Basic parallel hybrid model was provided by JARI ECU functions were added Parallel HEV Model_with Ref_ECU Model JARI 1 koubai 2 3 IG Motor_CL 4 IG 5 Motor_cont_mode 7 BR_N_in 9 shift_p_in 11 Lock_Up 13 Clutch_position 6 RESS_change 8 CL_q_Percent 10 F_coup_ON 12 flg_engst IG_ECU Mortor_CL_ECU Clutch_position_ECU Motor_cont_mode_ECU RESS_change_ECU BR_TQ_[N]_ECU1 CL_q_[1]_ECU1 shif t_p_ecu F_coup_ON_ECU Lock_Up_ECU f lg_mortor_cl Clutch_psition Reduction_ON RESS_change BR_TQ_[N]1 koubai IG_In Mortor_CL Clutch_position Reduction_ON Ne_out SPD_km_P_h DIST_km RL_N Nc_rpm No_rpm Eg_Fuka_Nm 1 Ne_rpm_Out 2 Speed_Out 3 Distance 4 Road_Load 5 Nc_rpm_Out 6 No_rpm 7 Driver model flg_exhb 15 flg_egasr 17 Acc_ref 19 Tq_limit_demand 21 flg_fc0 23 ACC_switch Software ECU 25 MotorASRRef 27 Command_change 29 Accessory1_ON Vehicle_Speed Eng_Ne 14 EgASRRef 16 Rev_limit_demand 18 Sireikaido 20 Tq_limit_rate 22 Idle_rpm_adjust 24 Tq_limit_switch 26 MotorTqRef 28 Reduction_SW 30 Accessory2_ON IG Motor_CL Clutch_position Motor_cont_mode RESS_change Brake_Tq CL_q_out Shif t_position F_coup_ON Lock_Up f lg_engst Driv er_thp f lg_exhb Signal builder or Driv er model EgASRRef f lg_egasr Rev _limit_demand ACC Sireikaido Drv AccPdl Tq_limit_demand Tq_limit_rate f lg_fc0 Idle_rpm_adjust v ehicle_speed_km/h Driv er_brake ACC_switch Drv BrkPdl Tq_limit_switch MotorASRRef MotorTqRef Command_change f lg_engst_ecu CL_q_[1]1 f lg_exhb_ecu EgASRRef _ECU shif t_p f lg_egasr_ecu Rev _limit_demand_ecu ACC_ECU F_coup_ON Sireikaido_ECU Tq_limit_demand_ECU Lock_Up Tq_limit_rate_ECU f lg_fc0_ecu Idle_rpm_adjust_ECU Switch f lg_engst ACC_switch_ECU Tq_limit_switch_ECU f lg_exhb MotorASRRef MotroTqRef Rev _demand Command_change_ECU Hardware/Software Reduction_SW_ECU Rev _control_demand Accessory1_ON_ECU Accessory2_ON_ECU IG_model Rev _limitl_demand Mortor_CL_model Clutch_position_model ACCkaido Motor_cont_mode_model RESS_change_model Sireikaido BR_TQ_[N]_model1 CL_q_[1]_model1 shif t_p_model Tq_limit_demand F_coup_ON_model Lock_Up_model Tq_limit_rate f lg_engst_model f lg_exhb_model f lg_fuel_cut_0 EgASRRef _model f lg_egasr_model Rev _limit_demand_model Idle_rpm_adjust ACC_model Sireikaido_model ACC_switch Tq_limit_demand_model Tq_limit_rate_model Tq_limit_switch f lg_fc0_model Idle_rpm_adjust_model ACC_switch_model Ref _Rev Tq_limit_switch_model MotorASRRef _model Tq_Ref MotroTqRef _model Command_change_model Command_change Reduction_SW_model Accessory 1_ON_model Accessory 2_ON_model Reduction_SW ECU_SW Accessory 1_ON RESS_change KASOKUDO BR_TQ_N Ni_rpm CL_q_1 Nt_rpm Fuel_Consumption shif t_p Eng_Tq F_coup_ON Eng_Tq_rate Lock_Up Loss_Tq_rate ST_In Driv er_demand_rate EXHB_In lsc DRV_demand_inj Rev _demand Loss_Tq_rate2 Rev _control_demand Eng_Tq_rate2 Rev _limit_demand Motor_Tq ACCkaido Motor_Rev Sireikaido Motor_Power Motor_Current Tq_limit_demand Motor_tq_f b Tq_limit_rate MotorDriv etqmax Fuel_cut MotorRegTqMax Idle_rpm_adjust RESS_Voltage ACC_switch RESS_SOC RESS_Power Tq_limit_switch RESS_Current Ref _Rev EgDriv etq_[nm] Tq_Ref EgLossTq_[Nm] Command_change EgMaxTq_[Nm] Reduction_SW EgDriv etq_woloss Eg_Tq_map_sirei accessory 1_on shif t_p_out accessory 2_on Fuel_inst Standard_parallel_HEV_model1 EgFukaTq 8 Kasokudo 9 Ni_rpm 10 Nt_rpm 11 Fuel_Consumption 12 Eng_Tq 13 Eng_Tq_rate 14 Parallel hybrid Loss_Tq_rate 15 Driver_demand_rate 16 ISC 17 DRV_demand_Ing vehicle model 18 Loss_Tq_rate2 19 Eng_Tq_rate2 20 Motor_Tq 21 Motor_Rev 22 Motor_Power 23 Motor_Current 24 Motor_tq_fb 25 MotorDriveTqMax 26 MotorRegenTqMax 27 RESS_Voltage 28 RESS_SOC 29 RESS_Power 30 RESS_Current 31 EgDriveTq_[Nm] 32 EgLossTq_[Nm] 33 EgMaxTq_[Nm] 34 EgDriveTq_woLoss 35 Eg_Tq_map_sirei 36 shift_p RESS_SOC Reduction_SW Accessory 1_ON Accessory 2_ON Accessory 2_ON sub_ecu_sw Driv er_activ e Ref_ECU_model -C- Constant_ECU Scope1 1_Real_ECU_0_ECU_MODEL 9 Driver Scope Scope2

25 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 25 Task 2.4) - Deliverables Simulation runs and validation of basic functions, including the functions from task 1 The same simulation runs from task 1.7 can be performed for task 2.4 Additional slides will be added (simulation results)

26 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 26 System level verification Criteria First 120 s of a driving cycle: Complete driving cycle:

27 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 27 System level verification Example: Gearshift timing error First 140 s of WTVC: Complete WTVC:

28 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 28 Drive cycle investigations Motivation Comparison of engine load points for a conventional HD vehicle (14 ton / 240 kw) Test methodology for conv. engines (WHTC) and hybrids (HILS) should lead to comparable emission results HILS uses WHVC add road gradients to match WHTC power curve Huge changes of road gradient every second due to highly fluctuation WHTC power curve Statement after investigations: currently no prospect for a practical solution

29 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 29 Drive cycle investigations Promising HDH drive cycle approach Identified boundary conditions Developed drive cycle should - be drivable on chassis dyno - have WHTC cycle work and similar load/speed pattern (cover full load operation) - produce similar emission results than WHTC for a conventional vehicle WHTC (T,n) ICE Engine test bed Emissions ICE Conv. HDV Chassis dyno new test cycle (v)

30 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 30 Drive cycle investigations Promising HDH drive cycle approach Approach was simulated with a conventional HDV 13 ton delivery truck, 248HP EU5, 12 speed transmission At least 4 sec. remaining in one gear, pref. shifting speed, allow to skip one gear if low torque demand 1. Step: simulate vehicle at WHVC (plane road)

31 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 31 Drive cycle investigations Promising HDH drive cycle approach 2. Step: calculate positive WHTC cycle work for specific ICE and compare it to WHVC cycle work for tested vehicle Different work load for same IC engine due to different test methods (WHVC / WHTC)

32 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 32 Drive cycle investigations Promising HDH drive cycle approach 3. Step: divide WHVC in mini-cycle parts (from zero to zero speed) Calculate WHTC/WHVC work difference for each mini-cycle and transform it into average mini-cycle slopes #1 #2 #4 #7 #5 #3 #6 #8 #9 #10 #11 #12

33 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 33 Drive cycle investigations Promising HDH drive cycle approach 4. Step: simulate vehicle at WHVC with calculated slopes and again calculate cycle work After one iteration loop, cycle work matches within ~2% Adapt calculated slopes for better matching (e.g. at mini-cycle #12)

34 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 34 Drive cycle investigations Promising HDH drive cycle approach 5. Step: check if ICE load/speed distribution is similar to WHTC Enriched operational points at full load Similar operation pattern like WHTC

35 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 35 Drive cycle investigations Promising HDH drive cycle approach Step: compare emissions / WHVC with slopes vs. WHTC For this early investigations no measurement data was available Emissions were simulated using PHEM (TUG emission simulation tool) ETC-limits EURO V NB: RAW = engine out values w/o NOx after treatment system NB: EURO V engine w/o particulate filter WHTC results in higher PM emission than ETC 10 0 [kwh] [g/kwh] [g/kwh] [mg/kwh] [mg/kwh] cycle work NOx_RAW CO_TP HC_TP PM_TP WHVC with slopes WHTC

36 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 36 Drive cycle investigations Promising HDH drive cycle approach Conclusion Approach seems to deliver comparable results between engine and vehicle test cycle and is therefore feasible for HDH Calculation of mini-cycle slopes can be automated in HILS tool Robustness of method has to be proofed Simulation of several different con. vehicles, investigate influencing factors (gearshift strategy, extreme power/mass ratios, ) Validate with measurements of specific vehicles and engines (drivability on chassis dyno, compare emissions, ) Also test HILS and drive cycle approach with conv. EURO 6 vehicle Solve remaining questions (set slopes to zero for HDH deceleration,..) Further investigations in validation test program 2 proposed

37 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 37 Drive cycle investigations Possible test sequence Test object: 12 ton HDH delivery truck Define rated power of hybrid power pack just rated power - not shape of full load curve Denormalize WHTC with rated power and calculate reference work for WHVC test run Run WHVC and calculate slopes WHVC can be run with specific vehicle data or with generic vehicle data (avg. vehicle mass of class or depending of rated power,.) Only affects available recuperation energy Re-run WHVC with slopes Get ICE operation pattern from HILS model for emission test

38 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 38 Drive cycle investigations Summary HILS model can be run with vehicle speed referenced test cycle (compatible to Japanese test procedure) Due to added slopes emission results should be comparable to conventional vehicles New approach replaces power cycle (pre-, post-transmission) approaches Ability of running power cycles (e.g. WHDHC) in HILS remains for a later possible CO2 interface

39 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 39 Test methodology investigations Japanese test procedure build HDH vehicle simulation model according to vehicle topology determine input parameters and component maps for the HDH vehicle to be tested (according to standard values from regulation, specific vehicle data and component tests) actual vehicle test by means of system bench or chassis dynamometer run simulation with vehicle model using identical test cycle from system bench or chassis dynamometer compare measured values to simulated output values to check if vehicle model represents real vehicle operation ICE emission test

40 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 40 Test methodology investigations Modelling depth and handling Points to discuss for GTR / Open questions Simple standard vehicle models should be preferred Driver model and gear shifting affects ICE operation and emissions one standardized driver model with tunable parameters + defined gear shifting for MT is proposed (VECTO gear shift model) Also simple model must be able to depict shift events currently no interruption of traction force during gear shift event at parallel hybrid influence on ICE operation and emissions For hybrid power pack certification, gearbox model of VECTO could be used OEM specific models should also be allowed by using GTR model structure

41 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 41 Test methodology investigations Component tests Points to discuss for GTR / Open questions pre-conditioning / aging status of components for testing Mainly important for energy storage Boundary conditions for components to be tested have to be defined Pre-conditioning cycles have to be defined Component tests acc. to regulation vs. OEM component data Do component tests acc. to the regulation have to be proofed to the type approval authority? Use OEMs specific data >>> just pass verification criteria?

42 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 42 Test methodology investigations Vehicle measurements for model verification Points to discuss for GTR / Open questions Vehicle test (measurements) on chassis dyno/testbed required for model verification acc. to Japanese regulation complex, expensive infrastructure On-road tests could be an attractive alternative Verification of model with on-road data can be challenging manageable acc. to meetings with OEMs Vehicle model will be verified with data from one specific test (e.g. on-road test cycle) model still valid for different certification cycle (i.e. modified WHVC)? Further investigations in validation test program 2 proposed

43 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 43 Test methodology investigations OEM specific interface model Points to discuss for GTR / Open questions Interface model will be designed for vehicle at HILS verification test For testing other vehicles with validated HILS model changes in the interface model may become necessary e.g. tested vehicle without traction control new derivative with TC additional control bits are needed in interface model new HILS verification necessary? Which / how much changes are allowed before new model validation is needed Description of interface model indispensable in GTR

44 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 44 Test methodology investigations Multiple ECUs Points to discuss for GTR / Open questions High manpower and cost effort for multiple ECUs at HILS test rig Several ECU logics are supposed to be represented in OEM specific interface model Functions and modifications in interface model have to be defined Further investigations necessary Japanese regulation not sufficient at this point

45 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 45 Test methodology investigations Re-Verification of simulation model / Re-Certification of ICE emissions Points to discuss for GTR / Open questions What can be changed in the HILS system (i.e. parameters, maps, signal interface definition, OEM specific interface, hardware ECU) without having to verify the model again? avoid frequent real-vehicle measurements for verification prevent model inaccuracy and deviation from real-vehicle operation What can be changed in the HILS system without having to certify the ICE for emissions again? dependent on resulting engine operation points definition of limits possible? (What is new worst case scenario?)

46 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 46 Test methodology investigations Disclosure of models and parameters Points to discuss for GTR / Open questions Which items have to be disclosed to the type approval authority? Models (e.g. OEM specific component models)? Parameters / Maps for components? OEM specific interface model? CAN communication? Is data stored at the type approval authority? Data protection by type approval authority? NDAs with suppliers component parameters / software logics in interface model Influences on modeling depth / accuracy

47 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 47 Test methodology investigations Vehicle-independent emission certification Points to discuss for GTR / Open questions vehicle-independent emission certification of a hybrid-powerpack would be a desireable approach to reduce complexity and effort standardized vehicle parameters (e.g. depending on rated power or vehicle class) just one engine emission test per powerpack needed powerpack could be used in all similar vehicles ( family concept ) elaboration of alternative new test procedure necessary standardized vehicle parameters for HILS test need to be defined limits of vehicle specifications usage of powerpack need to be defined What is a similar vehicle?( family concept ) limits of vehicle specifications for model verification need to be defined Further investigations in validation test program 2 proposed

48 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 48 Test methodology investigations Emission test options / requests by OEMs Points to discuss for GTR / Open questions request by OEMs that WHTC remains as alternative type approval test for low-volume and niche vehicles HILS type approval procedure would be very high effort Viable solution? Output of test cycle for combustion engine from HILS model engine test cycle typically in 1Hz model simulation timesteps in 2000Hz conversion method of engine speed and torque from 2000Hz to 1Hz has to be defined (esp. loads changes at gearshifts should not be filtered)

49 Offer for Validation Test Program 2 Identified work packages - outline (1) Software 1.1) Finalization of new model structure for GTR 1.2) Implementation of new structure in HILS models Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 49 (2) OEM Support and adaptation of HILS model 2.1) Adapt HILS model to OEM specific needs 2.2) Supervise/support validation test of OEMs close cooperation 2.3) Support Matlab models and test methodology 2.4) Elaborate options for HILS model verification, discuss with OEMs (interaction with WP 3)

50 Offer for Validation Test Program 2 Identified work packages - outline Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 50 (3) Provide methodology to verify the HILS model in the GTR 3.1) Verification of HILS simulation model according to a) Japanese method b) test alternative methods (e.g. frequency distribution in engine map, ) (measurements from OEMs or JRC and from 3.2) and 3.3) to be analysed from 3 HDH, Basis is WHVC, test also one or two alternative cycles on the chassis dyno) Analyse the measurands to be recorded at the vehicle test Analyse relevant accuracy between HILS model and measurement for each measurand Elaborate tolerable margins for the relevant measurands Compare instantaneous versus integrated data demands Different options for measuring the vehicle are analysed in 3.2) to 3.4)

51 Offer for Validation Test Program 2 Identified work packages - outline Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 51 (3) Provide methodology to verify the HILS model in the GTR 3.2) On-road measurements on one HDH (On-road tests could be an attractive alternative to Japanese method) It is suggested to test the first validation HDH within the consortium to allow quick and flexible adaptation of test program Measurands to be recorded as identified in 3.1 Test track short cycle (SORT like cycles) On-road PEMS driving procedure Use measured wheel hub torque as input to the HILS model and compare simulation results with measured values. Methods like in 3.1

52 Offer for Validation Test Program 2 Identified work packages - outline Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 52 (3) Provide methodology to verify the HILS model in the GTR 3.3) Chassis dyno measurements by TUG on one HDH Test cycles are WHVC and a test cycle from 3.2. (on road test) 3.4) Analysis of transferability of on-road test to chassis dyno Compare results to analyse if chassis dyno provides representative results for HDH (e.g. only one axle braked on chassis dyno with effects on brake energy recuperation) 3.5) Elaborate new draft verification procedure for GTR on-road / dyno / both simulation rules for gear box and gear shift needed description of interface model and hybrid ECU needed

53 Offer for Validation Test Program 2 Identified work packages - outline Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 53 (4) Elaborate definitions for the validity of a verified simulation model Family Concept 4.1) vary power-pack & vehicle parameters to test limits of change without affecting the accuracy of the simulation model 4.2) Evaluation and analysis of measurements with different vehicle & power-pack set ups 4.3) Which vehicle set-up (combination of parameters) has to be used for HILSmodel verification? Evaluation and analysis of effects of: Battery, vehicle mass, final drive ratios,. 4.4) Sensitivity analysis of verification method for the HILS model HILS test stand assumed to be installed at OEM and results provided to consortium for results (engine test cycle) for variations in vehicle set up

54 Offer for Validation Test Program 2 Identified work packages - outline (5) Test and certification cycles Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS ) Improvement of WHVC modification method (as presented on ) Simulation of several different vehicles, investigate influencing factors (gearshift strategy, extreme power/mass ratios, ) 5.2) Drivability investigations on chassis dyno ( road slopes ) 5.3) Compare resulting engine torque and speed with WHTC 5.4) Compare resulting emissions Option a -> by simulation Option b -> by measurements (would need engine tests also) Investigations for 5.1 to 5.4 can be done with a conventional HDV A comparison of resulting engine test cycles can be done with any HDE, e.g. the results from HILS for HDH can be compared with WHTC for a conventional EU VI engine (6) Adapt HILS test description for GTR component test procedures, HILS test procedure, verification procedure

55 Developing a Methodology for Certifying Heavy Duty Hybrids based on HILS 55 THANK YOU FOR YOUR ATTENTION! Jonas Fredriksson Gérard Silberholz Christoph Six jonas.fredriksson@chalmers.se silberholz@ivt.tugraz.at christoph.six@tuwien.ac.at