Multi-disciplinary Design of Alternative Drivetrains an Integrated Approach for Simulation and Validation

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1 Multi-disciplinary Design of Alternative Drivetrains an Integrated Approach for Simulation and Validation Univ.-Doz. Dr. Daniel Watzenig, Divisional Director E/E Kompetenzzentrum Das Virtuelle Fahrzeug Forschungsgesellschaft mbh (ViF) 16. November ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 1

2 Outline Introduction New challenges and possibilities Safety, safety, safety! Vehicle simulation Multi-domain simulation by example Intelligent energy management Electrification of the drive train Summary ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 2

3 Potentials of vehicle electrification Reduction of CO2 emissions depending on type of electricity generation Securing energy supply (reducing dependency on fossil fuel) Reduction of local emissions of pollutants and noise Grid integration for better overall energy efficiency Providing basis for intelligent future mobility concepts ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 3

4 E-Mobility : Challenges and possibilities Ressources Components Vehicles Infrastructure Mobility provider Technological restrictions Safety Range Energy storage (battery) Capabilities of power electronics Comfort Fun to drive Challenges Seasonal performance (summer/winter) Vehicle safety in development New technical possibilities Innovative vehicle/drive concepts Lightweight technologies Advanced driver assistance Intelligent energy management ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 4

5 Road to E-Mobility Development plan for E-Mobility Phase 1 Further development of conventional vehicles, using highly advanced combustion engines Increasing the overall efficiency of vehicles by means of hybrid technologies Current focus Phase 2 Development of HEV with grid integration Phase 3 Development of pure EV (BEV) The development of (P)HEV will play an important role in the near future. BEV: battery electric vehicle PHEV: Plug-in hybrid electric vehicle ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 5

6 New challenges in development Managing complexity of alternative drive train concepts (thermal, electrical, NVH, dynamics) Integrated and functional safety, advanced driver assistance systems ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 6

7 Development of (hybrid) electric vehicles Technical challenges in the HEV-Development System change Challenges Restriction of battery technology Use of hybrid storage system Hybrid Electric Vehicle (HEV) Additional energy converter Electrification of mechanical systems Control of the energy flow Stabilizing the vehicle power net multi-domain system Interactions between subsystems Local vs. global optimum Introduction of thermal sensible systems Extended need for thermal management High complexity! Handling the complexity with Co-Simulation Simulation of energy flow Electrical / thermal analysis Control strategy development Integration of vehicle environment ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 7

8 Example 1: Integrated (active+passive) safety systems Environment Driving Dynamics Sensors Crash t0 Crash Safety Controller Driver Crash not avoidab ble time Active Safety Passive Safety Integrated Safety Accident avoidance Reduction of Accident Severity ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 8

9 Example 2: Drive train simulation and validation Conventional approach vs. multi-domain simulation Domain specific simulation approach System analysis Co-Simulation approach with ICOS thermal Battery thermal model Electric machine Cooling circuit of the RE Matlab/ Simulink electrical mechanical thermal Cruise Dymola Motor / Alternator Rectifier Vehicle dynamic Battery thermal model Vehicle model Range extender Converter SuperCaps Battery Range extender (RE) Electrical machine Cooling circuit of the RE KULI Motor / Alternator Rectifier Converter SuperCaps Battery Adams ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 9

10 Example: Plug-in hybrid electric vehicle (PHEV) with range extender ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 10

11 Parallel HEV with Li-ion battery and SuperCap Graphical User Extended energy storage system Energy Controller SuperCap Lithium-Ion Battery Co-Simulation Framework Vehicle Speed Profile Virtual Driver Cooling System Electric Motor Engine & Drivetrain Hybrid Controller ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 11

12 Intelligent energy management Plug-in-hybrid electric vehicle (PHEV) Electric motor and an ICE HEV characteristics Large battery and a plug to the electrical grid Pure EV characteristics Increasing overall efficiency by optimal utilization of the two energy sources ICE decoupled from the drive train Battery charged by ICE or recuperation Optimal operation strategy depending on: Driving route Environment information Tank (T) Battery (B) E-motor (E) ICE (V) Generator (G) Plug-in (S) Predictive approach ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 12

13 Intelligent energy management Predictive control based on topographical information Optimal charge / discharge of battery Model-predictive control using environmental data ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 13

14 Example: Electrified transmission A3+ project (AVL, ViF, TUG) ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 14

15 Example: Electrified transmission (A3+ TNT) Double clutch transmission with integrated electric motor No mechanical synchronisation dog clutches Integrated electric motor No synchronizers, coupled to shafts via planetary gearset just dog clutches Low cost Low weight Hybrid features Small package High efficiency Very small package Boost (even during shifting) Recuperation Engine Start/Stop Electric launching/driving High customer benefits with minimum system change! ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 15

16 Development of the software concept Graphical User Control functions (Software) Engine Controller Hybrid Controller Transmission Controller Co-Simulation Framework Modeling options Virtual Driver Vehicle Dynamics Drivetrain inclice, E-motor Drivetrain inclice, E-motor Drivetrain inclice, E-motor Drivetrain inclice, E-motor AVL Cruise Matlab /Simulink Dymola OpenModelica ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 16

17 Summary and conclusion Multi-domain competence is highly required for (H)EV development. Co-simulation is a reliable and reasonable approach for solving cross-domain design problems. The VIRTUAL VEHICLE solution ICOS has proven its value for various applications in different research and development projects, e.g.: Drive train simulation Integrated safety Multi-domain control of advanced driver assistance functions Vehicle dynamics control Thermal management on vehicle level HW and SW Co-simulation and Co-validation ECO-MOBILITY 2011 disclosure or duplication without consent prohibited 17

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