KPIT Cummins Infosystems Ltd. Capability Overview in HEV, EV and Motor Control Areas 2003-09 2005 KPIT KPIT Infosystems Cummins Infosystems Limited Limited We value our relationship We value our relationship Version : 1.0
KPIT Cummins Involvement in HEV and EV Domain Energy Storage Unit Functional validation of Production intent BMS Battery Management System Development Battery charger board prototype Battery Pack plant model development Battery Management System Consultancy Motor controls Pseudo ABS development thro Motor Control for EV Motor control IP for low power motors AC drives commisioning tool Using pocket PC Services Requirement Engineering Technical Consultancy Software development ECU HW development MIL / SIL testing ECU Virtualization Functional testing Hardware in Loop testing Integration and Testing System / Vehicle Testing Rear Wheel Hybridization Revolo -Hybrid Retrofit solution Hybridization solutions KPIT Initiative Customer Program KPIT Product 2 HEV/EV System Expertise
Overview of KPIT s Involvement in Battery Domain Application Chemistry Status Functional validation of Production intent BMS Battery Pack plant model development Complete development Of BMS Mild Hybrid Li-Ion Concept Prototype Full Hybrid Ni-MH In production Mild Hybrid Lead acid Production Prototype Smart JBs Lead Acid In production Services Requirement Engineering Partnership for Development of complete Battery Electronics & Electricals Battery charger board prototype Technical Consultancy Algorithm development Model-in Loop testing Software in Loop testing Joint IP in SOC and SOH Algorithms for Li-Ion Battery characterization Experiments and testing CAD/ CAM / CAE for battery systems ECU Virtualization & testing Hardware in Loop testing Unit Testing KPIT Initiative Integration and Testing Customer Program System Testing 3 Complete involvement in all Battery systems.
Product Development life Cycle @KPIT Product Conceptualization Requirement Analysis Hardware Engineering Hardware Architecture VLSI Design Board circuit Design / simulation Reliability Analysis PCB Design PCB Fabrication, Assembly Board V&V Software Engineering Software Architecture BSP development Device Drivers development RTOS Porting Application development Software V&V Mechanical Engineering Engineering Design Industrial Design Reliability Analysis CAD / CAM Prototyping Fabrication (Rapid Prototypes only) Mechanical QC In house capability Tie up with partners Future Plan Optional AUTOSAR flavor Product Integration System testing & Product Testing Product Certifications 4
Battery Test Setup 5
Battery Test setup 6
Testing Setup Battery Programmable load DAS D.A.S Model Validation Charger 7
Case Study 1: Hybrid Control Unit ( HCU ) development Our Role Production intent project for MY 2011 PHEV US Tier-1 customer responsible for entire powertrain development for PHEV : Hybrid Control Unit, DC-DC converter, Plug-in charger and Inverters DEVELOPMENT ENVIRONMENT Complete requirement engineering and generation of documents as per SPICE standards and development of following features Pedal input sensing and redundant path development PRNDL inputs processing using finite state machines Immobilizer feature development OBD-II for all electrical I/Os and CAN signals i. MATLAB / SIMULINK version R2009a ii. iii. iv. RTW Embedded coder for Motorola MPC5554 Woodward tool chains and OS Clearcase / Clearquest v. ATI Vision UDS implementation as per ISO 15765-3 specification for HCU Independent V & V arm for the entire right half of V cycle : MIL/ SIL / HIL and Vehicle testing, Low level Microcontroller core self tests Identification of various Hazards in PHEVs and working with customer to implement ISO 26262 functional safety compliance 8
Case Study 2: eawd System Overview KPIT Developed KPIT Developed KPIT Developed Vehicle Altenator Vehicle Signals - - <Functi + I Vehicle Battery 12 V Lead Acid + Battery Pack Charging System + - BMS Control Module Ioc[ VDc] PWM A PWM B PWM C PWM_FAN Ctrl T1~T5 IGNITION FUSE + - Battery Pack (3 Lead Acid Batteries) Battery Box Ambient 12 VTemp. Battery 12 V Battery 12 V Battery 12 V Battery 12 V Battery - E Con + + AND Co nta cto r + ACM Control Module Electro- Mechanical Load (for simulation substitute large resistor to provide loading on the Batteries ) FAN on/off Battery GND V Batt 12 VDc 36 ~ 42 VDc CAN 1 Communications between Modules Hardwired Signals I/O Signal 9
Case Study 3: BMS End to End solution Problem statement: Development of end to end generic Battery management system independent of various battery chemistries Challenges: SOC estimation based on various scenarios Achieve goal of maximizing the battery life Design of optimum battery charging algorithm Estimation of battery ageing Design of thermal management system for battery and charger Handholding the customer to complete the specifications and algorithms Program phases: Battery and charger requirement engineering Implementation using MBD and validating using rapid prototypes HIL setup and validation In-vehicle validation KPIT CUMMINS CONTRIBUTION: Coordination with Customer as well as Battery manufacturer Leverage on in depth HEV technology expertise Rapid prototyping to aid customer in selection of battery chemistry and rating 10 End to End Solution
Case Study 4: Plant Modeling of Battery Pack Problem statement: Development of generic high-fidelity battery plant models & validating the characteristics against manufacturer specification for future Analysis and V & V Challenges: In depth understanding of battery chemistries Synthesizing the battery chemistries and development of equivalent electrical circuit Building all the fidelity to model to validate against the Battery manufacturer provided characteristics. Parametric Model ( Exp. data + DoE) KPIT CUMMINS CONTRIBUTION: Providing expert consultancy to the customer in coming up with virtual validation of control strategies by suggesting MIL /SIL testing relevance. Leverage on in depth Model based development expertise Generation of plant model characteristics report in MATLAB User interface environment. Technologies: SimPowerSystems toolbox MATLAB scripts SIMULINK report generator 11 Analytical high-fidelity modeling
Case Study 5: HEV Software Validation Ni-MH Chemistry Problem statement: Functional validation of BMS legacy code in MATLAB environment Our Role: To generate unit and functional test plan To carryout unit testing for 16 sub features using RTRT To perform feature testing for 14 sub feature using Matlab environment. Challenges Faced: Changes in the source code during course of the activity Limited and outdated availability of requirement specifications Limitation using RTRT for long instructions and limitations in memory when large number of test cases are run Development of S-function wrapper function to accommodate various hand coding styles Tools Used: i. RTRT version 2003 ii. SDS single step Simulator for PowerPC iii. Matlab version 2006 KPIT CUMMINS VALUE ADDITION: Extensive experience in Testing projects, which helped recommend the unit testing tools and the decision to develop feature test tool in house 12 Verification and Validation
Case study 6: ABS Control System for Electric Vehicle Problem statement: Recover the maximum Regen braking energy while maintaining a good braking performance, under wheel locking scenario KPIT Role: Understanding of existing motor controller POC of the control algorithm using MATLAB simulation Implementation of the ABS algorithm on the Motor Controller Validation of the control algorithm by conducting in-vehicle testing Support for Vehicle Track testing Project Metrics 3 resources over 3 months of engineering effort Challenges faced Algorithm development from scratch Braking force algorithm tweaking In-Vehicle Validation of the algorithm Detecting wheel lock in absence of wheel speed sensors and acceleration sensor. Developing software in Curtis controller with limited programming feature like Fixed point Math, Arrays and Pointers Developing software with limited debugging features (capture and timing). Calibration of algorithm in different road conditions Ripple and noise issue in input variables RPM and Brake 13
Low Power Motor and Valve Control Related Experience 14
Motor Control Experience Summary EPAS
Product Design and Engineering Solutions 300+ vehicle programs Software Electronics 3000+ projects Mechanical Controls 2000+ Engineers 8/25/2010 16
PDES - Offerings Technical Expertise Hardware Design Software Development Mechanical Design Domain Automotive Industrial Automation Consumer Electronics Bio-Medical Offerings Prototype Building Value Engineering Reverse Engineering Product V&V Product Certification 8/25/2010 17
Electric Power Assisted Steering Design and Development Abstract: The goal of this project was to support the Electric Power Assisted Steering development for platform software and motor control. Challenges: q First time Tier-1 was giving the work to offshore q Templates from Tier-1 was in evolving stage q Mismatch between design and implementation q Frequent Change in Requirements q Multi location development Tools and Technologies: V850E/PHO3 controller GHS compiler, NEC MINICBE debugger Parasoft C++Test tool for unit test and static check CANape and CANalyzer DOORS requirement management tool MATLAB Our Role: q Platform software update and development (Review existing driver, Design, Unit testing and Integration testing) q Motor control software development support (MATLAB Model update and testing for Motor torque calculation and motor winding temperature calculation) q Integration of platform software and motor control with the application Motor Control Information: Permanent Magnet Synchronous Motor Control Peripheral was used PWM specifically designed for motor control - for faster outputs Feedback Current read was achieved using Input Capture Unit of V850 Customer Details: q European based Tier 1 for an European OEM Metrics: q Approx. effort: 80 man months q Duration: 12 Months q On site and Off-shore 18
Intelligent Wiper Control OBJECTIVE Complete Redesign with Automotive Certifications SOLUTION Redesign with low cost 16-Bit microcontroller PID implementation Complete product development LIN 2.1 communication protocol Automotive Certification Testing in ARAI Cost Reduction SYSTEM DIAGRAM DC motor Drive, Improved EMC PCB enclosure, Hall Effect position encoder CHALLENGES & ACHIEVEMENTS First engagement in Chinese market for product development Supplier negotiations to get best quotation Partnership with ARAI Onsite product testing in actual vehicle Manufacturability aspects Twin Wiper blades
Power Sunshade OBJECTIVE Complete Redesign with reduced BOM cost with Automotive Certifications SOLUTION SYSTEM DIAGRAM Redesign with Low Power AT tiny series Performance and Durability Testing Automotive Certification Testing in ARAI Cost Reduction Mass Production Nylon Curtain Improved EMC compliance, Low Cost CHALLENGES & ACHIEVEMENTS Maintaining existing mechanical constraints Supplier negotiations to get best quotation Partnership with ARAI Sustaining target BOM cost Product compliance to customer specified Performance & Durability tests Manufacturability aspects PCB and Enclosure Redesigning
Instrument Cluster (Dash Board) OBJECTIVE To showcase new MCU capabilities for cluster applications SOLUTION SYSTEM DIAGRAM Modular board design to drive digital dial gauges CAN Network interface Telltale and Chime simulation for automotive environment Segmented LCD drive for ODO and TRIP counts CHALLENGES & ACHIEVEMENTS Product compliance to Automotive EMI EMC standards: ISO 11452 & CISPR-25 (Level-5) Software Layered architecture Configuration GUI for system trimming to 2 or 4 wheeler with required features Demonstration GUI for effective demonstration
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