All-in-one Simulation and DoE Methodology for the Evaluation and Optimisation of HEV Configurations. W.-R. Landschoof, M. Kämpfner, Dr. M.

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1 All-in-one Simulation and DoE Methodology for the Evaluation and Optimisation of HEV Configurations W.-R. Landschoof, M. Kämpfner, Dr. M. Zillmer 1

2 Contents 1. Motivation 2. Hybrid concepts 3. Significance of the simulations 4. Structure of the universal hybrid-vehicle model 5. An example of results based on a parallel hybrid concept 6. Use of the integrated DoE approach 7. Summary 8. Outlook 2

3 1. Introduction Hybrid vehicles worldwide Vehicle volume [in thsds.] 2009 Growing hybrid-vehicle markets in all classes 3

4 1. Introduction Volkswagen will launch the Touareg Hybrid on the market in

5 2. Hybrid concepts C2 EM1 C1 TM Hochener gie- LiIon- Batterie FKLG- Rangeext ender Battery EM2 TM EM1 Battery TM EM2 EM1 Battery Parallel hybrid Serial hybrid Power split? Other concepts? 5

6 3. Significance of the simulations Optimisation of components Optimisation of strategies Simulations Functional analyses Reduction of tests 6

7 4. Model structure Concept; vehicle data; loss maps; driving curve; strategy Simulation Consumption, performance General aspects of the simulation model Comparability of concepts in respect of performance and consumption Speedy preparation and execution of the simulation Simple handling Use of power losses based on engine maps High degree of precision 7

8 4. Model structure Basic idea: One model for different concepts Control EM C C EM C TM C W EM TM Internal combustion engine E machine Transmission Bat Bat W Battery Wheel C Clutch Mechanical Electrical Control 8

9 4. Model structure Parallel hybrid Internal combustion engine Control EM E machine C EM C TM C W TM Transmission Bat Bat Battery W Wheel C Clutch C2 EM1 C1 TM Hochener gie- LiIon- Batterie FKLG- Rangeext ender Battery Mechanical Electrical Control 9

10 4. Model structure Serial hybrid Internal combustion engine Control EM C EM C TM W EM TM E machine Transmission Bat Bat W Battery Wheel C Clutch EM2 TM EM1 Battery Mechanical Electrical Control 10

11 4. Model structure Power split Internal combustion engine Control EM E machine EM Bat T M EM W TM Bat Transmission Battery W Wheel C Clutch TM EM2 Battery EM1 Mechanical Electrical Control 11

12 4. Model structure Solution: All-in-one model Fig.: GT Suite model without control system 12

13 4. Model structure Solution: All-in-one model with following characteristics One file for all models (3 files in the case of power split) Assignment of data via the user interface Integration of improvements by means of DoE Computing time faster than real time or the several hours needed for DoE 13

14 4. Model structure Modelling of the control system Fig.: Control system of the model 14

15 4. Model structure Model levels Level Definition Example Concept Operating mode Description of the power train Description of the closedloop control strategies Parallel hybrid Parallel operation Operating state Component Description of the energy flow Description of the status variables Recharging SOC of the battery 1. Parallel hybrid 2. Parallel operation C2 EM1 C1 TM Recharging Hochene rgie- LiIon- Batterie FKLG- Rangeext ender Battery 4. SOC 15

16 4. Model structure Strategy of the operating states Condition Logic State SOC < SOC min,bat Load demand > Limit or SOC < SOC target on SOC > SOC min,bo and and Recharging Boosting Dependency of the recharging, boosting and electric driving operating states ( off) on the battery's state of charge (SOC) and the load demand 16

17 5. Results Parallel hybrid example Compact Class vehicle Cycle: NEDC State of charge 17

18 5. Results Parallel hybrid example Compact Class vehicle Cycle: NEDC Engine Speed [1/min] 18

19 5. Results Parallel hybrid example Compact Class vehicle Cycle: NEDC Engine power [kw] 19

20 6. Design of Experiment Steps involved 1. Model making 2. Parameter optimisation 3. Variant for comparison 4. Parameter optimisation 20

21 6. Design of Experiment Target magnitudes Fuel consumption Minimum State of charge Initial value Compact Class vehicle Cycle: FTP 72 General condition: End SOC = Start SOC 21

22 7. Summary Inclusion of the GT Suite model in the Volkswagen simulation environment Model depth Low High Component simulation Component Coupled simulations GT Suite model Vehicle 22

23 7. Summary A universal vehicle model has been developed for vehicle simulations with the following main characteristics: Functionality Simulations of consumption and performance for hybrid and electric vehicles User-friendliness - Parameter list for inputs - Simple file handling - Clear model - Easy to change Postprocessing - Time curves - integral variables - DoE 23

24 7. Outlook Specifying the details of individual components Taking the thermal management into account Coupling in the context of component simulations 24

25 Thank you! 25

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