Labcar hybride réalisé par le groupement d entreprises

Transcription

1 Labcar hybride réalisé par le groupement d entreprises Le premier groupement de PME soutenu par Mov eo DAS CTGE, conférence "électrification des fonctions et des auxiliaires" 15 décembre 2016, Flins 0

2 Partnership & Complementarity Business Interest Group Mechanics & ICE Embedded Electronics Vibro-Acoustics Thermodynamics & Fluid Mechanics Turbo & Powertrain Testing Project Management Testing & validation 1

3 Everest Team Key Figures Everest Team Sales breakdown (M ) 1,45 Automotive Trucks Aerospace Misc 2,30 2,83 17,20 R&D M Everest Team Total Sales 29,0 100% In-house products 3,5 12% Public subsidies projects 3,5 12% Collective projects 5,0 17% Headcount Everest Team Total Total heads % Doctors / engineers 85 35% Technicians % 2 2

4 Multidisciplinary Project Team Organization Hybrid Labcar 3

5 Hybrid Labcar Objective: to test advanced energy supervision control algorithms System Architecture Powertrain: P2 parallel hybrid architecture ICE PSA EBO 1.0 l - 50 kw Electric motor 28 kw Gear box VW DSG7 Electric architecture: 2 Li-ion batteries 400 V, 2.2 kw.h, 4 kw Ultra caps 100 V, 100 W.h Embedded charger 400 V high voltage bus Propulsion modes Full Hybrid Electric Vehicle Plug-in Hybrid Electric Vehicle ICE only Electric power only 4

6 Hybrid Labcar Activities Design & creation of specific transmission between engine & gearbox Calculations (static & dynamic) Design Run-in on component test bench Mechanical integration study: Reverse engineering and CAD rebuild of EB0 engine, DSG7 gearbox, MGU-K in the Peugeot 208 under-the-hood and trunk environment Study of scenarii and integration design freeze Integration study of all components Vehicle integration and assembly of demo-car 5

7 Electric Motor & Gearbox Transmission (1) 6

8 Electric Motor & Gearbox Transmission (2) 7

9 Electric Motor & Gearbox Transmission (3) 8

10 Electric Motor & Gearbox Assembly on Engine (1) 9

11 Electric Motor & Gearbox Assembly on Engine (2) 10

12 Air Filter Assembly on Engine 11

13 Ultracapacitor & High Voltage Converter 12

14 13 Vehicle Integration

15 Hybrid Labcar Activities Study: E/E architecture definition & faisability Equipment and component selection Software Development: Service and on board safety controller (ifm): 12 V BUS management (equipment power supply and actuation, battery charging) Equipment liquid cooling Equipment control and security Engine management controller : ICE control Electric motor control Torque repartition between ICE and electric motor DSG7 gearbox control User interface display for dialog, supervision and integrated configuration (ifm) Communication CAN bus between equipment and vehicle Electrical & Electronic Development: Full vehicle electrical architecture (12 V, CAN, mid voltage, HVIL). Electrical wiring harness, vehicle integration 14

16 Hybrid Labcar Activities Test bench calibration: Tuning of the ORIANNE powertrain control system with the PSA EB0 engine on dyno Testing and tuning Unit and integration functional testing of all equipments Reverse engineering of EB0 EMS and DSG7 gearbox control Reverse engineering of Peugeot 208 intersystem CAN Chassis dyno tuning of powertrain system System calibration to optimize emissions, fuel economy, performances and driveability. 15

17 Hybrid Labcar Activities Definition & design of mecatronics chain cooling circuit Thermal management: numeric simulation & experimental validation Cooling circuit AMEsim model Fluid temperature variations for a user profile 16

18 Hybrid Labcar Activities Design of hydraulic test bench Testing Design of thermal exchangers Packaging and battery pack cooling Ultracapacitor external cooling system Cooling circuit validation test bench

19 Hybrid Labcar Result : the hybrid labcar runs in its various modes 18

20 Hybrid Labcar Conclusion Un groupement d entreprises tel qu Everest Team est : capable de réalisations multidisciplinaires complexes dans des délais courts à des couts raisonnables grâce à la réactivité des PME du GIE : performances d une grande société d ingénierie réactivité et compétitivité d une PME. L électrification des véhicules n a pas de secrets pour Everest Team Message de Jean de Lafontaine : «On a toujours besoin d un plus petit que soi» N hésitez pas à solliciter les groupements de PME français pour vos projets, même les plus fous! 19

21 Thank you for your attention ABOARD Engineering 10, rue de la Sausse F Saint Jean France Toulouse neighborhood Tel : +33 (0) dominique.loze@aboard-eng.com + 33 (0)

22 Back-up slides 21

23 Hybrid Labcar Activities Integration in the demo-car of an energy recovery brake system ABS adaptation Hybrid braking pedal Braking system testing and tuning

24 Powertrain Control Solutions Electronic system architecture Selection of sensors & actuators Powertrain control strategies Electric Vehicles Hybrid Vehicles Internal Combustion Engines System integration Calibration & validation 23