AUTOMOTIVE ELECTRIFICATION

Transcription

1 AUTOMOTIVE ELECTRIFICATION ELECTRIFICATION SOLUTIONS SYSTEM INTEGRATION Markus Maier AVL Europe ITS

2 ELECTRIFICATION TEST SYSTEMS AVL Electrification Test Systems First System sold by 2009 Business Unit Electrification & Racing Test Systems established in 2011 AVL Electrification Test System Expertise around the world # of qualified service personal Standard Level # of qualified service personal Expert Level More than 300 Systems in use since 2009 From System Concept to Service globally Markus Maier IST-N EU June

3 AGENDA 1. What What is an electrified car all about 2. How How do we develop an electrified car System Integration 3. Summary Markus Maier IST-N EU June

4 CONVENTIONAL, HYBRID AND ELECTRIC VEHICLES Conventional Vehicle Full Electric Vehicle 12V Battery ICE Gearbox Generator Hybrid Vehicles combine Combustion Engine and All Electric Propulsion Electric Motor Reduction Gearbox Charging Port Hybrid Vehicles Inverter U V W Starter DC/DC Converter + Charger Rechargeable Battery or Fuel Cell 12V Bordnet Micro-Hybrids use Starter and Battery for Stop-Start Functionality Markus Maier IST-N EU June

5 HYBRID POWERTRAIN LAYOUTS Parallel Hybrid Serial Hybrid Powersplit Hybrid Planetary Gearbox U V W U V W 2nd Battery Battery U V W Generator Electric driven rear-axles are also parellel Hybrids and so-called roadcoupled hybrids Benefit Fairly easy to realize Allows full-electric driving Allows electric boosting Benefit ICE is operated in steady state and has hence optimum efficiency Benefit Allows optimum combination of parallel and serial hybrid depending on driving situation Markus Maier IST-N EU June

6 Torque Torque TRACTION TORQUE WILL HAVE MANY SOURCES 100% 100% Electrical Power Mechanical Power 0% 0% Internal Combustion Engine Hybrid (HEV) Plugin Hybrid (PHEV) Extended Range Electric (RREV) Battery Electric (BEV) Fuel-Cell Electric (BEV) Mechanical Drive Mechanical Drive with electric Assist Electrical Drive with mechanical Assist Electrical Drive Markus Maier IST-N EU June

7 AGENDA 1. What What is an electrified car all about 2. How How do we develop an electrified car System Integration 3. Summary Markus Maier IST-N EU June

8 ELECTRIFIED POWERTRAINS TESTING The electrified Powertrain must be mastered and validated by the OEM Component Validation Energy Source: Battery or Fuel-Cell Battery Cells to validate electrifcal perfomance and life-time as well as to be able to judge new, upcoming technologies Batterypack and Module: to ensure the thermal and safety behavior of the whole system Fuel-Cell: from Cell to Stack to whole System Traction: E-Motor for driveability and longevity Power-Electronics: Inverter, Charging and DC Suppy as the back-bone and the brain System Validation Electrical Subsystem: Battery + E-Motor + Power-Electronics Powertrain: Comb. Engine + Gearbox + Battery + Power-Electronics Vehicle Driveability and optimisation of vehicle parameters (electrical distance, Power, Emission) Markus Maier IST-N EU June

9 ELECTRIFIED POWERTRAINS TESTING OEM must master the core technologies of the whole power train The Operating Strategy as co-operation of the electrical components defines the customers perceiption of the whole vehicle The Energy Source (Battery) is a core component and determines Power, Reach, Charging 60% Validation in the V-Cycle Validation of Vehicle ca. 60% 10% Validation of electr. Subsystem ca. 10% 30% Component Validation; ca. 30% Hauptteil der Absicherungszeit und Kosten heute sehr spät im Prozess investiert Markus Maier IST-N EU June

10 Clutch Gearbox Belt ELECTRIFIED POWERTRAINS TESTING Electrified Powertrains - Characteristics High number of operating modes (recuperation, boost, sailing, etc.) Integration of components from different Tier-1 New, partially unknown technology High number of interfaces to the vehicle (external loads) Today: Whole Powertrain Inverter Battery Generator Motor ICE System Integration Test - Today Integration with Combustion Engine and Gearbox to full Powertrain and Testing on Powertrain Testbench or in the Vehicle Challenges one Component can block the whole testing Debugging of faulty systems complex while in the car Battery Tomorrow: Subsystem Electrification Inverter AVL Solution Integration Testbench for Electrification Subsystem Motor Markus Maier IST-N EU June

11 INTEGRATION TESTBED - SUBSYSTEM U V W U V W Inv Inv Bat OBC Bat OBC HV Subsystem The HV-Subsystem is a complex system and has new challenges for the integration For the Validation, AVL has designed and delivered an Integration Testbench including new possibilities of emulation Markus Maier IST-N EU June

12 SYSTEM TESTBENCH OVERVIEW DVE motoric Loads / Sinks Ohmic Loads AVL inmotion Drive Shaft e-me Automation Load Unit OR OR universal Inverter OR universal electronic loads + Energy Storage Generator* Charger AVL PUMA + - OR Drive Shaft OR Restbus Load Unit OR * considered as DC source Grid Emulator Markus Maier IST-N EU June

13 ELECTRIFIED POWERTRAINS TESTING Objectives System Integration Testbench Functional Validation of the System incl. Validation of new SW / HW Validation of vehicle interfaces (e.g. electric loads) Robustness-testing by fault injection Pre-Calibration of the Subsystem Identification of Improvement Potential Concept Studies Field return analys Inverter Battery Engine, Gearbox and ECU Simulation Motor Vehicle & Load Simulation Markus Maier IST-N EU June

14 Real World Emulated World SYSTEM TESTBENCH OVERVIEW DVE* Battery Univ. Inv. e-me Grid Emu Load Emu AVL inmotion Automation Multipurpose Power Switch Box AVL PUMA + - DME, DGM HiL Restbus Battery Inverter Motor Charge Load Kl15,30, CAN,LIN,FlexRay *DVE = Driver, Vehicle, Environment Markus Maier IST-N EU June

15 Real World Emulated World REAL MOTOR AND POWERELECTRONICS DVE* Battery Univ. Inv. e-me Grid Emu Load Emu AVL inmotion Automation Multipurpose Power Switch Box All components real AVL PUMA + - DME, DGM HiL Restbus Battery Inverter Motor Charge Load Kl15,30, CAN,LIN,FlexRay *DVE = Markus Driver, Maier Vehicle, IST-N Environment EU June

16 Real World Emulated World EMULATED BATTERY DVE* Battery Univ. Inv. e-me Grid Emu Load Emu AVL inmotion Automation Multipurpose Power Switch Box Emulated Battery AVL PUMA + - DME, DGM HiL Restbus Batterie Inverter Motor Charge Load Kl15,30, CAN,LIN,FlexRay *DVE = Markus Driver, Maier Vehicle, IST-N Environment EU June

17 Real World Emulated World EMULATED PLUG-IN HYBRID DVE* Battery Grid Emu AVL inmotion Automation Multipurpose Power Switch Box AVL PUMA + - Restbus Battery Inverter Motor Charge Kl15,30, CAN,LIN,FlexRay *DVE = Markus Driver, Maier Vehicle, IST-N Environment EU June

18 AGENDA 1. Why Why do we look into Electrification 2. What What is an electrified car all about 3. How How do we develop an electrified car a. Components b. Systems 4. Summary Markus Maier IST-N EU June

19 HIGHLIGHTS AND POSSIBILITIES Realistic Simulation of Driving Cycles with different Start conditions NEFZ Cycle with different charging status of the battery Different Possibilities to inject Faults / Errors Network: Failure of single ECUs / Components E-Motor: cut single phase Grid Supply: Phase failure, asymmetric phases, Peaks Bordnet: Voltage Drops caused from dynamic loads HV-Bordnet: Isolation fault, cable breaks Excellent Comparison between Emulation and Vehicle Battery especially in dynamic load scenarios Dynamic switching between emulated and real component allows different use-cases to be tested e.g. driver selection switch for operating modes Markus Maier IST-N EU June

20 THE GOLDEN DEVICE Technical Experience A System Integration Testbench is the Golden Device Enables at every point in time the generation of reproducible Results Validate the progress of Systemintegration and Components Component Testing with a Reference Vehicle Enables to validate all components or just individual components in an emulated System Inverter Battery Engine, Gearbox and ECU Simulation Motor Vehicle & Load Simulation Markus Maier IST-N EU June

21 SUMMARY AND OUTLOOK U V W Inv Bat OBC For the validation of the complete vehicle, AVL has setup a new HV Integration Testbench at AVL Headquarters in Graz Validation whole Vehicle Validation whole Vehicle but emulate components Validation of Components Markus Maier IST-N EU June

22 THANK YOU Markus Maier Business Manager Electrification and Racing Test Systems European region Zettachring 4, Stuttgart