ELECTRIFICATION TESTING SYSTEMS

Transcription

1 ELECTRIFICATION TESTING SYSTEMS AVL ITA - 5 Luglio - Circuito Tazio Nuvolari Luigi Giordano AVL List GmbH (Headquarters)

2 AVL DEVELOPMENT SYSTEMS FOR ELECTRIFICATION Dedicated application team since 2011 Passenger Cars 2-Wheelers Racing More than 500 installations worldwide Wide portfolio of solutions Construction Agriculture Commercial Vehicle Wide range of customer references Global presence Rail Marine Aviation Luigi Giordano ITS-NE 05 Juli

3 THE CHALLENGE: A WIDE RANGE OF NEW POWERTRAIN SOLUTIONS Increase Efficiency Replace Petroleum Mild Hybrid Full Hybrid PlugIn Hybrid BEV FCEV kw kwh 0,2 0,4 0,8 0, V 48V 450V 800V Electric Supercharging MT+ Belt e-axle MT + P2 Module + auto-clutch Dedicated Hybrid Transmissions Parallel Hybrid / e-axle AT, DCT, CVT Axle Split Two Gear One Gear PEM SOFC DCT, CVT, AT Luigi Giordano ITS-NE 05 Juli

4 AVL: CONSULTING THE DESIGN VALIDATION PROGRAM On the basis of the customer use cases, AVL can support in creating a tailored DVP: Collecting inputs from requirements, FMEA, component tests, Defining test overview & key specs, number of samples necessary Detailing of project timing Defining the generalized workflow Identifying the lab size and quantity of needed test systems Optimizing the efficiency of the test systems usage plan Luigi Giordano ITS-NE 05 Juli

5 EXAMPLE DVP: RESOURCES ESTIMATE FOR BATTERY PACK TESTING Luigi Giordano ITS-NE 05 Juli

6 AVL: FACILITY ENGINEERING On the basis of the customer Design Validation Program, AVL can design and realize complete facilities AVL CONSULTANCY (CONCEPT DESIGN) Feasibility and Financial studies Construction cost estimations Environmental impact studies Implementation Plans AVL ENGINEERING Preliminary Definitive Detail AVL MANAGEMENT Procurement and Construction Supervision / Project Management AVL FACILITY EQUIPMENT SUPPLY AND SYSTEMS INTEGRATION Luigi Giordano ITS-NE 05 Juli

7 EXAMPLE: FAW EV LABORATORY CHINA FAW, Changchun - China New EV Laboratory Advanced Engineering Services for: 12 E-Motor test beds 2 AWD Powertrain Test beds 2 inverter test beds Environmental test instruments area Battery Pack test area w/ 28 testers Battery cell & module test area w/ 72 testers 2 vehicle test beds Support areas Luigi Giordano ITS-NE 05 Juli

8 TESTING AND VALIDATION SOLUTIONS FOR ELECTRIFICATION AVL delivers systems to validate the complete electrified powertrain components and systems: Low Voltage or High Voltage upgrade packages for existing vehicle, powertrain and engine testbeds e-axle and e-powertrain testbeds E-motor testbeds Power electronic testbeds Battery testbeds Fuel Cell testbeds Solutions for NVH, EMC or EOL Combination of all the above in multi-configuration for integration validation Real Time Maneuver testing can be added to each of the above Luigi Giordano ITS-NE 05 Juli

9 EXAMPLE BATTERY EMULATION AND TESTING: RIMAC AUTOMOBILI Battery emulation on e-drive testbeds with 1kHz control interface Battery module and pack testing: Performance and life cycles testing with 0.01% FS accuracy Replication of dynamic load profiles with current rise time <0.4ms Luigi Giordano ITS-NE 05 Juli

10 BATTERY DEVELOPMENT AND TESTING CHALLENGES Insure full safety for UUT, TB and personal (toxic/explosive gas, fire!) Testing guidelines Validate energy Performances Optimise energy and cooling management Optimise battery model (SOC, SOH, etc ) and BMS Increase Reliability/Durability Luigi Giordano ITS-NE 05 Juli

11 EXAMPLE BATTERY TEST LABORATORY CHINA Inside Testing Room Drawing of complete Test Bed Climate Chamber with UUT Luigi Giordano ITS-NE 05 Juli

12 EXAMPLE BATTERY TEST LABORATORY CHINA Luigi Giordano ITS-NE 05 Juli

13 EXAMPLE BATTERY TESTING CENTER GRAZ control room battery test cell thermal conditioning Luigi Giordano ITS-NE 05 Juli

14 E-DRIVE DEVELOPMENT AND TESTING CHALLENGES Face big diversity of UUT s Insure Safety of UUT, TB and personal (high speed!) Testing guidelines Validate Performances in Motoring and Generating mode Validate Thermal model Optimise Efficiency Reduced torque ripples at very low speed Reduce Noise Increase Reliability/Durability Luigi Giordano ITS-NE 05 Juli

15 EXAMPLE: E-MOTOR TEST SYSTEMS TIER1 E-motor validation up to 400kW, rpm, with low inertia 0.075kgm² for high dynamic tests High quality simulation of start from rest/uphill (0 rpm and high torque) Very accurate speed control at low speed for UUT torque ripple optimization Modular and scalable design Can be easily upgraded to environment simulation (temperature, humidity, cold operation) Luigi Giordano ITS-NE 05 Juli

16 EXAMPLE: TESTING E-MOTOR SYSTEMS AT AVL Battery Emulator: with source/drain Function power: 320 KW voltage range: 8 to 800 V current range: +/- 600 A battery modeling can be statically and dynamically Dyno: AVL Dyno Spirit permanent magnet engine rotation direction: right / left four-quadrant operation controlled speed and torque max. power: 250 kw (momentary 312 kw) speed: U/min mass inertia: 0,15 kgm2 Luigi Giordano ITS-NE 05 Juli

17 AVL ACTIVE DYNAMOMETER FOR BSG TESTING Mec. Power nom/overload 30/60 kw Belt ratio Torque nom/overload Max. speed 1:1 150/300Nm 8000rpm 1:2 75/150Nm 16,000rpm 1:2.5 60/120Nm 20,000rpm 1:3 50/100Nm 24,000rpm Chamber Temp. range & gradient C ( C) 2K/min (5K/min) Luigi Giordano ITS-NE 05 Juli

18 USE CASE: EMC EMISSION MEASUREMENT Measurement of E-Motor and Inverter EMC emissions under different load and operating conditions. PUMA Open CISPR 25 ED 4 & ISO solution and Radar Pulse proposals E-Motor AVL Dyno Stable Dyno platform Luigi Giordano ITS-NE 05 Juli

19 EXAMPLE 2WD CONTAINER TESTBED CHINA Project execution time: 10 months Installation place Beijing China Modular container construction AVL Automation system 2WD test system for e-axle validation Dynamometers with 220kW / 3200Nm / 3000rpm with up to 50% overload Battery Emulation 320kW / 800V / 1200A UUT coolant conditioning system 20kw Luigi Giordano ITS-NE 05 Juli

20 EXAMPLE: E-POWERTRAIN NVH TESTING KOREA 2WD and 4WD configurations Test powertrain only or complete vehicle Extension to E-Integration testbed Luigi Giordano ITS-NE 05 Juli

21 INVERTER DEVELOPMENT AND TESTING CHALLENGES Integration with wide diversity of E- Motors types and production tolerances Reduce development time Testing guidelines Optimization of inverter switching frequency for drive efficiency / e- motor performance Radiated and conducted EMI testing for different drive cycles Reduced torque ripples Handling of fault conditions Increase Reliability/Durability Luigi Giordano ITS-NE 05 Juli

22 EXAMPLE: DAIMLER INVERTER TESTING LABORATORY Development of inverter control loop functions for the active damping of driveline torsional oscillations Inverter is tested in an office environment equipped with dynamic e-motor and battery emulators Vehicle and powertrain are fully simulated in real time Full power operation possible Luigi Giordano ITS-NE 05 Juli

23 FUEL CELL DEVELOPMENT AND TESTING CHALLENGES Automation System Connect Models from different sources Virtual Sensors XiL Testing Powertrain Integration Powertrain Architecture Design, Control Unit Development and Cooling System Strategy Stack level Cell level Fuel Cell Vehicle FCV Chassis Dyno Dyno Fuel Cell Powertrain FCPT Powertrain Dyno Dyno Fuel Cell System FCS FC System TB Fuel Cell Stack FC Stack FC Stack TB Single Fuel Cell FC TB PUMA Open for Fuel Cell Emerald + Fuel Cell specific measurement solutions Luigi Giordano ITS-NE 05 Juli

24 AVL AND GREENLIGHT TESTING SOLUTIONS Powertrain Test System Automation & Process Simulation Optimization & Calibration Measurement & Diagnostics FCEV R&D environment! Fuel Cell Test System Automation Measurement & Diagnostics Luigi Giordano ITS-NE 05 Juli

25 EXAMPLE: HYCENTA FUEL CELL SYSTEM TESTBED Up to 170 kw Fuel Cell Systems! 1 AVL E-Storage BTE 160 AVL ConsysAir 800 AVL E-Motor Cooling AVL ConsysCool 200 Dynamic operation With vehicle simulation Climatic Chamber T Range = C Size = 3 x 4 x 3 m 3 With environment simulation Virtual Testing Model.CONNECT ISAC InMotion VSM CRUISE (M) 2 PUMA Open 2, CAMEO, CONCERTO, FC H2/N2 Supply Module FC Exhaust Module FC Coolant Adaption Module Luigi Giordano ITS-NE 05 Juli

26 EXAMPLE: HYCENTA FUEL CELL SYSTEM TESTBED Develop your Fuel Cell System integrated into a virtual Vehicle -40 to 85 C Mimic ambient conditions 3x4x3 m Luigi Giordano ITS-NE 05 Juli

27 EXAMPLE: BMW E-BIKE TEST CENTER Testing laboratory for validation at component and system levels The user can rapidly test the combination of real components, like battery and e-motor, or partially emulate them Luigi Giordano ITS-NE 05 Juli

28 EXAMPLE PORSCHE HV INTEGRATION LABORATORY Testing laboratory for validation of single component and of their combinations Integration of all test equipment by use of the flexible AVL Puma automation Tests executed with real or simulated components Components protection by use of highly dynamic DC sources Real World Emulated World External controllers Gearbox, E-Motor, Battery controller, etc. Signal & Restbus Simulation Switch box Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.) UUT Battery UUT OBC BCU (BMS) 3xAC e-motor 3xAC Mains HV DC link UUT-Inverter E-Motor Configuration Switch Unit Battery Emulator/Tester Mains Emulator Universal Inverter e-motor Emulator Drive Shaft Load Unit Automation Simulation 14 different configurations possible, with automatic and rapid switching during the test procedure (5-6 times / day) Typical execution of more than 350 tests in two weeks time, with parallel testing of components to save 2-3 days on each session Time synchronised measurement and acquisition of all data sources, output in open file format Fast data analysis due to the highly automatized postprocessing Luigi Giordano ITS-NE 05 Juli

29 EXAMPLE: HV INTEGRATION TESTBED FOR COMPLETE VEHICLE Testing laboratory for validation of the electrified powertrain, the xev vehicle and its HV battery Usage of real or simulated components Multiple configurations possible, with automatic and rapid switching during the test procedure HV battery can be tested as integrated in the vehicle or in a separate climatic environment Simulation of driving maneuvers Time synchronized measurement and acquisition of all data sources Luigi Giordano ITS-NE 05 Juli

30 EXAMPLE MANEUVER TESTING: INTERACTION CHECK BETWEEN ELEMENTS Hybrid vehicle Automatic Reverse Parking + Curb Crossing Goal : Interaction check between all powertrain elements and controls Curb Wheel Torque Check of all Controlling Elements Results at early Stages in the Development Phase 100% Reproducibility... Luigi Giordano ITS-NE 05 Juli

31 EXAMPLE MANEUVER TESTING: US EPA BATTERY IN THE LOOP TESTING Automated testing of high voltage battery packs under realistic driving conditions Road, Driver, Vehicle and Powertrain are simulated in real time, inclusive of bus communication to battery pack High efficiency in the modification of the test cases, thanks to the modular parametrization concept Luigi Giordano ITS-NE 05 Juli