Vehicle Validation using PSAT/Autonomie. Antoine Delorme, Aymeric Rousseau, Sylvain Pagerit, Phil Sharer Argonne National Laboratory
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1 Vehicle Validation using PSAT/Autonomie Antoine Delorme, Aymeric Rousseau, Sylvain Pagerit, Phil Sharer Argonne National Laboratory
2 Outline Validation Process Light Duty Conventional Vehicles Mild Hybrids Full Hybrids Plug in Hybrids Heavy Duty Line Haul Class 8 Additional Classes 2
3 Generic Methodology: From Test to Validation 1- Import Test Data into PSAT 2- Individual Sensor Evaluation 4- Calculate Effort/Flow From Sensors Quality Analysis (QA) 3- Sensor Comparison 5- Sensor & Calculation at Comparison Analysis & Validation 6- Control Strategy 7- Model Validation 3
4 Test Data are Renamed, Rescaled and Imported into the same environment as simulation
5 Individual Sensor are Evaluated to Find Major Issues (Range, Sign ) Electric Motor Temperatures 2004 Prius APRF Data 5
6 Redundant Sensors are Compared Direct Fuel Measurement vs. Bench 2004 Prius APRF Data 6
7 Summary Table Highlights the Main Results of the Comparison 7
8 Additional Efforts/Flows are Calculated
9 Calculated and Measured Signals are Compared Battery SO OC Time (sec) 2004 Prius APRF Data 9
10 Using Sensors from Different Sources may Lead to Added Uncertainties Engine Speed Sensor * (Nr+Ns) Generator Speed * Ns onal Speed (rpm) Rotati Engine Speed OBD * (Nr+Ns) Generator Speed * Ns Planetary Gear Equation Reveals Problem during Transients (different sampling rate, delay ) 2004 Prius APRF Data 10
11 Web Document is Automatically Generated to Accelerate the Process
12 Parameters are Selected Based on Detailed QA Signals with low correlation coefficients or that appeared suspicious from the visual check are scrutinized. Sensors installed by test engineers are preferred to OBD or dynamometer signals. Ensure consistency in the mathematical relationships. Signals from the OBD were not recognized (issue with units or with meaning). 12
13 Outline Validation Process Light Duty Conventional Vehicles Mild Hybrids Full Hybrids Plug in Hybrids Heavy Duty Line Haul Class 8 Additional Classes 13
14 Correlated Conventional Vehicles Vehicle Source UDDS PSAT (mpg) HWFET PSAT (mpg) UDDS Adjusted (mpg) HWFET Adjusted (mpg) Civic DX EPA UDDS Delta EPA (%) HWFET Delta EPA (%) (%) (%) Adjusted Values Focus ZTW auto EPA Adjusted Values Accord DX EPA Adjusted Values Taurus EPA Adjusted Values Equinox EPA Adjusted Values F150 EPA Adjusted Values Vehicle test data was not available except for the Equinox 14
15 Outline Validation Process Light Duty Conventional Vehicles Mild Hybrids Full Hybrids Plug in Hybrids Heavy Duty Line Haul Class 8 Additional Classes 15
16 Ford P2000 Validation Results Cycle Cons test Cons simul Diff in % SOC init SOCf test SOCf simul Diff in % mpg mpg Japan NEDC Fuel Rate Comparison on NEDC 16 16
17 Honda Insight Validation 80 vehicle speed (m/s) engine torque (N.m) 70 motor torque (N.m) 60 Motor Assist at high SOC Time (s) vehicle speed x10 m otor electrical power 12V power in Motor used to compensate 12V load
18 Honda Insight Validation 30 Measured Simulated Motor torque (N.m m) Time (s) 60 Measured Simulated Japan rque (N.m) Motor tor ZOOM Time (s) 18
19 Honda Insight Validation Japan SOC Comparison 62 Measured Simulated 61 SOC (%) Tim e (s) 19
20 Honda Insight Validation Results Cycle Cons test Cons simul Diff in % SOC init SOCf test SOCf simul Diff in % mpg mpg Japan NEDC HWFET UDDS
21 Outline Validation Process Light Duty Conventional Vehicles Mild Hybrids Full Hybrids Plug in Hybrids Heavy Duty Line Haul Class 8 Additional Classes 21
22 GM Precept Correlation Combined Test/Simulated Consumptions: 796/76mpg Small SOC difference in Simulation 22
23 Japan Prius Validation Engine Speed measured simulated Rd/s Engine Torque 700 Sec Nm simulated measured Sec Argonne National Laboratory 23
24 Japan Prius Validation Results Cycle Cons test t Cons simul Diff in % SOC initit SOCf testt SOCf simul Diff in % mpg mpg Japan Japan EUDC HWFET
25 2004 Prius - Boost Converter Output Voltage Follows Test Trends 500 Boost Converter Output 450 Volts Simu Meas UDDS Cycle time 25
26 2004 Prius - Example of SOC Comparison with Final Model Battery SOC Simu Meas 0.7 soc UDDS Cycle time (sec) 26
27 2004 Prius Fuel Economy Comparison Drive Cycle APRF Test (1) PSAT UDDS HWFET US Japan NEDC (1) Several averaged test results 27
28 Outline Validation Process Light Duty Conventional Vehicles Mild Hybrids Full Hybrids Plug in Hybrids Heavy Duty Line Haul Class 8 Additional Classes 28
29 Plug-in Prius Hymotion Vehicle Configuration and Specification Vehicle Mass 1586 kg High Capacity Battery 5 kwh, Li-ion A, B, C (SI Unit) 88.6, 0.14, 0.36 Test of date 10/30/2006 Low Capacity Battery Prius 1.3 kwh NiMH 230 VDC Battery Pack High CapacityBattery Hymotion 5kWh System Power Converter to 230VDC 115 VDC Li Ion 29
30 Engine Torque Comparison UDDS 30
31 High Capacity Battery Power 31
32 Charge Depleting Mode Comparison UDDS Absolute Relative Unit Test Simulation Difference Difference Fuel Economy mile/gallon % Elec. Consumption Wh/km % SOC Init % SOC Final % % System Efficiency % % Test t
33 Charge Sustaining Mode Comparison UDDS Unit Test Simulation Absolute Difference Relative Difference Fuel Economy mile/gallon % SOC Init % SOC Final % % System Efficiency % % Test
34 Outline Validation Process Light Duty Conventional Vehicles Mild Hybrids Full Hybrids Plug in Hybrids Heavy Duty Line Haul Class 8 Peterbuilt Truck w/ West Virginia Navistar Truck w/epa Additional Classes 34
35 PSAT Validation: Details of Tractor Truck Data from Chassis Dynamometer Tests and On-Road Tests Vehicle Model Year 1996 Test weight (lb.) Odometer Reading Transmission Type Manual Transmission Model RTLO 20918, 18 speed 20 Engine Type Engine Model Year 1996 Engine Disp. (Liter) 14.6 Number of Cylinders 6 Caterpillar 3406E Sp peed (mph) Time (s) UDDS Used for Chassis Dynamometer Testing 35
36 Modeling and Validation of Peterbilt Truck Component data development Engine map Auxiliary loads, including fan load. Vehicle losses developed to match chassis dynamometer. The transmission ratios and efficiencies were documented. ncy (%) 1 Transmis ssion Efficie UDDS Time (s) This vehicle was also simulated on a road route, PA43, as well as chassis dynamometer cycles. 36
37 Comparison of Actual and Predicted Results On-road result variability can be attributed in part to lack of knowledge of real rolling resistance and aerodynamic factors. For the chassis UDDS these factors were known. PSAT Validation With Chassis (Test weight lb) PSAT On road Test Results (Test weight lb) Parameters Measured PSAT Relative Parameters Measured PSAT Relative Simu. % Error Simu. % Error UDDS Cycle (mile) P 43 Route (mile) Fuel Econ. (MPG) Fuel Econ. (MPG) Fuel Mass (kg) Fuel Mass (kg) Eng. Fuel Rate (g/s) Eng. Fuel Rate (g/s) CO 2 (g/mile) CO 2 (g/mile) * Note: Engine fuel rate, engine torque, engine speed, engine power and vehicle speed are all average values Engine Fuel Rate (g/s) UDDS Time (s) Measured 30 PSAT R 2 = mulated e (g/s) PSAT Sim Fuel Rate Measured Fuel Rate (g/s) 37
38 Outline Validation Process Light Duty Conventional Vehicles Mild Hybrids Full Hybrids Plug in Hybrids Heavy Duty Line Haul Class 8 Peterbuilt Truck w/ West Virginia Navistar Truck w/epa Additional Classes 38
39 Truck Specifications A Navistar Prostar line haul class 8 truck was tested at SWRI by EPA Year model 2008 Mass Gearbox Engine kg 10 Speed Eaton Fuller FRM 15210B Cummins ISX ST Final Drive Arvin Meritor RT (ratio 2.64) 3 Drive Cycle traces corresponding to the CARB cycles were used HHDDT Transient ( 5D ) (5D) Time HHDDT Cruise ( 7D ) Cycle Speed [mile/h] 0 Cycle Speed [mile/h] Time HHDDT High ihspeed ( 8D ) 39 Cycle Speed [mile/h] Time
40 HHDDT Transient (Cycle 5D) Trace and Gear Vehicle Spe eed (mph) Simulation Test Cycle 5D Trace and gear number are very close for all cycles Test overshoots the Target Main differences come from the test truck which does not follow the trace very closely l Gear Number Simulation truck is able to start in 2 nd or 3 rd gear Cycle 5D Simulation Test Neutral requested early for Test Truck 40
41 HHDDT Cruise (Cycle 7D) Engine Speed & Fuel Rate En ngine Spee ed (rad/s) Cycle 7D Simulation Test Cycle 7D Simulation Test Fuel Ra ate
42 Fuel Consumption Comparison Using One Test Iteration Cycle 5D Cycle 7D Cycle 8D Test Simu Test Simu Test Simu Distance (miles) Fuel Economy (mpg) Fuel lconsumption (gal/100mi) Delta Fuel Consumption (Simu vs Test) 4.91% +0.91% +2.92% Delta Distance (Simu vs Test) 1.99% +1.88% +1.92% A positive delta fuel consumption value means the Simulation consumes more than the Test A positive Delta distance value means the Simulation travels further than the Test 42
43 Comparison with All Test Data 8 Vo lume of fuel in Gallons Cycle 5D Cycle 7D Cycle 8D Test variability Simulation The histograms show the volume of fuel consumed for the iteration of test recordings selected by EPA (used for fuel consumption calculations in slide 18) The black error bar shows the range of fuel volumes for all the test iterations. The red cross shows the volume of fuel consumed in simulation. 2 Cycle 5D Cycle 7D Cycle 8D For the three cycles, the Simulation is within 5% of the Test fuel consumption which is within the test to test repeatability. The discrepancy is greater for the low speed transient cycle than for high speed highway cycles. During each cycle, the simulation and test trucks did NOT drive the exact same distances and at the same average speed, which h most likely l explain li part of the fuel consumption discrepancies. 43
44 Outline Validation Process Light Duty Conventional Vehicles Mild Hybrids Full Hybrids Plug in Hybrids Heavy Duty Line Haul Class 8 Additional Classes 44
45 PSAT Has Been Correlated for Several Additional Vehicle Classes NABI 60LFW* New Flyer DE60LF, BRT* Other correlated vehicle classes include, but not limited to * Data provided by Herbert Fox (NYIT) 45
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