development of hybrid electric vehicles
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1 IPG Technology Conference Karlsruhe 2012 A multi physical simulation architecture to support the development of hybrid electric vehicles James Chapman CAE Simulation Group Jaguar Land Rover Embedded Systems Group WMG University of Warwick
2 Contents Introduction > Objectives, Scope & Use Cases Simulation Platform Requirements Model Structure > Control/Plant tmodel larchitecture t > IPG CarMaker Integration > HIL (Hardware in the Loop) Environment Example Application: Regenerative Braking & Vehicle Dynamics Conclusions
3 Introduction LCVTP: Multi partner collaborative project with an aim to progress the development of low carbon vehicle technology within the WestMidlands Midlands. Systems Modelling Activities: Vehicle systems simulation platform developed to support integrated model based development activities across a range of different project workstreams. Objective to develop a single common simulation environment to promote collaborative development & dissemination of models among multiple project partners. Intended to accommodate a number of different use cases through the substitution of both plant & control subsystem components with varying degrees of functionality and fidelity.
4 Project Scope Example Use Cases: Model based development of control systems for low carbon vehicles. > VSC Vehicle Supervisory Control > HVAC & Cooling Advanced Thermal Energy Management Systems > BMS Battery Management System (High Voltage) > Regenerative Braking & Stability Control Study the impact of regenerative braking on vehicle dynamics. Performance & fuel economy predictionsfor competinghev architectures. > Incl. potential benefit from thermal energy recovery systems & minimisation of parasitic losses. Component sizing: e.g. drive motor, APU & energy storage units. Optimisation of powertrain cooling systems.
5 Platform Requirements Support a wide range of emerging hybrid electric vehicle architectures. > Requires capability for multi physical modelling of powertrain. Development of high/low voltage electrical networks. > Accommodate a range of different electrical architectures, subsystems & analysis. > Requires consideration of electrical dependency in model derivation & physical connections between HV/LV electrical subsystems. Development of thermal network. > Inclusion of thermal management system. > Requires inclusion of thermal dependency in subsystem models. > Support multiple interactions between thermally dependent subsystems.
6 Platform Requirements Required to support MATLAB/Simulink derived controllers. To include an appropriate realisation of the full vehicle model for real time simulation within a HIL (Hardware In Loop) environment. Framework required to extend into existing IPG CarMaker model environment to study vehicle dynamics. Vehicle level models to be derived from standard libraries of subsystem models to promote parallel development & maximise reuse of core assets. Appropriate SVN version control & standardised signal naming convention for project wide collaboration.
7 Model Structure
8 Model Structure Framework includes three top level implementations constructed from a single library of subsystem components. 1. Simulink Longitudinal Simulink based control models + embedded Dymola powertrain model. Example use cases fuel efficiency studies, controller development etc. 2. Dymola Standalone Basic control functionality + drive cycle implemented in standalone Dymola model. Example use cases HV electrical transients, vehicle dynamics etc. 3. CarMaker CarMaker extension of Simulink longitudinal inc. CarMaker suspension & tyre models. Example use cases vehicle dynamics, HIL simulation + failsafe tester etc.
9 Model Structure Control Architecture Control architecture based on JLR Vhil Vehicle Model Architecture (VMA). Subsystems modularised according to workstream activities & vehicle ECU deployment. Dymola powertrain integrated using standard Simulink s function interface. Plant subsystems lumped to maintain acausal interactions between components.
10 Model Structure Plant Architecture Dymola HEV vehicle model architecture. > High & low voltage electrical networks. > Thermal interactions between subsystems. Object orientated structure.
11 Model Structure IPG CarMaker Integration Complete powertrain model including plant & control integrated into CarMaker vehicle dynamics model via Simulink interface using DVA (Direct Variable Access).
12 Model Structure re HIL Real Time Environment Real time simulation of LCVTP full vehicle model implemented on CarMaker XPack4 HIL Platform HIL platform used to prove capability of control algorithms & diagnostics to run in real time on 32bit processor platform. Also used to study the impact of signal propagation delays over CAN & Flexray networks, & robustness to fault injection.
13 Model Structure HIL Real Time Environment Complete powertrain model, including plant & control, integrated into CarMaker HIL model. Executed on IPG XPack4 real time computer. Specific controllers split out onto independent ECUs.
14 Example UseCases Regenerative Braking Objective: To support the evaluation & development of integrated control systems associated with advanced regenerative braking. Competing electro hydraulic braking systems. Impact of brake system configuration on potential energy recovery & overall braking performance. Control strategy (interaction with ABS). Immediate vs. blended termination of regen in response to stability event. Control architecture. Impact of specific ECU deployment & latency signal propagation delays.
15 Example UseCases Regenerative Braking Vehicle level model based testing performed using medium fidelity powertrain subsystem models & CarMaker/Simulink kinterface. 1st order hydraulic brake models implemented in Dymola incl. Electro hydraulic regen brakes & ABS modulation. Neglection of 2nd order characteristics. Incompressible hydraulic fluid. Lumped compliance for pipes, pads & callipers. Linearisation of discontinuities. Suitable for real time application.
16 Example UseCases Regenerative Braking Control Architecture Case Study: BTAC Brake Torque Apportionment Controller responsible for arbitration of friction & e machine braking torques for a given driver demand. Design consideration: communication network & critical deployment of key functions onto vehicle ECUs.
17 Example UseCases Regenerative Braking Front axle regenerative braking with handover to friction braking at <35kph
18 Example UseCases Regenerative Braking Impact of signal propagation delays due to varying CAN message cycle times.
19 Example UseCases Regenerative Braking Standard foundation brake system response to high low grip event with & without ABS.
20 Example UseCases Regenerative Braking Impact of regenerative braking with varying control architecture & transit delays.
21 Conclusions Hybrid electric vehicle systems are inherently multi physical & require a more integrated systems approach to model based development. A vehicle systems simulation platform has been developed as part of the LCVTP to support integrated systems modelling activities across a range of different technology areas. Through the substitution of analogous library models with varying levels of functionality & fidelity, an array of diverse use cases may be addressed. IPG CarMaker & XPack4 have used in conjunction with MATLAB/Simulink & Dymola physical modelling package for HEV control development. For more information on the project see:
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