Comprehensive and Cross-domain Vehicle Simulation for Electrification IPG apply & innovate 2014 2014 09-24 Powertrain Systems - Christian Appel, Ralf Kleemann Vehicle Systems - Benjamin Leidel Chassis & Driver Assistance - Stefan Zahariev 1
Agenda 1 2 3 4 5 Motivation Simulation working modes & tooling Aston Martin hybrid concept car Simulation validation Conclusion & outlook 2
Motivation for cross-domain simulation Use of simulation in the development process: Enable holistic evaluation of multiple vehicle topologies and functional concepts Cover the increasing number of OEM models, model variants and powertrain layouts Cover the increasing complexity and interconnectivity of systems Criteria categories T 1 T 2 T 3 LAP TIME PERFORMANCE 1,3 2,1... 11 5 STRAIGHT LINE PERFORMANCE 2,4 3,1... 6 12 1 POWER DENSITY 1,5 4,3... 10 7 4 2 PACKAGING FLEXIBILITY 2,9 2,7... TORQUE VECTORING 1,2 3,4... 13 9 8 3 FUEL ECONOMY 4,0 4,7... COST 3,3 1,2... THERMAL INTEGRATION 4,7 3,1... VEHICLE FUNCTIONAL SAFETY 2,3 2,3... NVH 1,5 4,6... CONTROLS COMPLEXITY 2,8 3,1... HIGH VOLTAGE INTEGRATION 5,2 1,8... Proposed concepts Score Balance performance and fuel economy/ legislation requirements Identification of optimal solution for given constraints Enable software development and virtual calibration with a common simulation platform NO T 1 T 5 T 7 T 10 Req. YES Final concepts Common simulation platform during all development phases 3
Working modes in simulation For single domain usage Vehicle Dynamics/ Driver Assistance Cross-domain usage Cross-Domain Vehicle Simulation DB (A) Assu mpti ons Defined interfaces Cross- Domain- DB Assu mpti ons Powertrain DB (B) Assu mpti ons Energy Management DB (C) Assu mpti ons Division individual simulation Separate databases Assumptions for other domains Weak interconnection Crossdomain simulation Strong interconnection Common database Considering V-Model Levels Common assumptions 4
Vehicle simulation tooling Modular vehicle simulation platform: Utilization of validated component libraries e.g. Simulink model libraries GT Suite model libraries ASCET/C ECU software code Integration platform: IPG CarMaker / Simulink Utilized tools in Co-Simulation: Vehicle dynamics: IPG CarMaker Controls: ASCET/C code (FMU / Simulink) Powertrain, thermal system: GTI GT-SUITE Low-voltage powernet: Simulink / Simscape Individual adaptation of simulation tool based on use cases and requirements 5
Shared simulation platform Joint development OEM and suppliers: OEM to provide base vehicle models (e.g. chassis dynamics, tires, combustion engine) Suppliers to deliver specific subsystems (e.g. third party supplier delivers active aero models) OEM: Vehicle Chassis Model OEM/BEG: Combustion Engine BEG: Hybrid Powertrain BEG: Hybrid/ Engine Control Cross-domain system development with multiple suppliers and OEM utilizing joint simulation model Increased use of more accurate simulation model in all development phases (e.g. base calibration tasks of hybrid operating strategy) OEM/BEG: Powertrain Cooling Sys. Supplier X: Aero Systems BEG: Driver Assist Systems BEG: Brake System Use existing know-how and models from all resources and increase accuracy 6
Aston Martin hybrid concept car Vehicle data and system topology: Vehicle data Aston Martin DB9 base vehicle Aston Martin DB9 hybrid concept vehicle Empty-weight 1689 kg 1983 kg ICE Transmission Maximum power (ICE) Maximum torque (ICE) V12 front engine, rear-wheel drive 6-speed manual transmission 410 kw / 557 PS 620 Nm Electric motors (EM) - - 2x SMG180/120 (2x 85 kw) 1x SMG138/80 (25 kw) Power electronics High-voltage lithium-ion battery 3x INVCON 2.3 8 kwh useable energy Source: MTZ 02/14, p.26-33, COMPREHENSIVE SIMULATION FOR POWERTRAIN ELECTRIFICATION, Appel, C., Freudenstein, S.; Temmen, C. 7
Aston Martin hybrid concept car Vehicle data and system topology: Vehicle data Aston Martin DB9 base vehicle Aston Martin DB9 hybrid concept vehicle Empty-weight 1689 kg 1983 kg ICE Transmission Maximum power (ICE) Maximum torque (ICE) V12 front engine, rear-wheel drive 6-speed manual transmission 410 kw / 557 PS 620 Nm Electric motors (EM) - - 2x SMG180/120 (2x 85 kw) 1x SMG138/80 (25 kw) Power electronics High-voltage lithium-ion battery 3x INVCON 2.3 8 kwh useable energy Source: MTZ 02/14, p.26-33, COMPREHENSIVE SIMULATION FOR POWERTRAIN ELECTRIFICATION, Appel, C., Freudenstein, S.; Temmen, C. 8
Simulink Co-simulation vehicle model Powertrain model (GT Suite) Integration Platform: Simulink SL Co-Sim Powernet (12V) model (Simscape) ECU models ESC SW model (SL) HCU SW model (SL) SL Model SL Model CarMaker 4 SL Vehicle dynamics Driver Maneuvers 9
GT-Suite powertrain model driving direction 10
FMU Co-simulation vehicle model Powertrain model (GT Suite) FMU Export Integration Platform: CarMaker (standalone) Vehicle dynamics Driver Maneuvers FMU s Powernet (12V) model (Simscape) FMU Export ECU models FMU Export ESC SW model (SL) HCU SW model (SL) 11
Integration of HCU * software (SL / FMU) Simulation and calibration of hybrid operating strategy: Approach: Selection of relevant hybrid control functions Generation of.dll file with ECCo Integration in simulation model Virtual base calibration Optimized application with ASCMO (ETAS GmbH) possible Benefits: Generation of realistic load profiles Simple replacement of functions (.dll s) Decrease in calibration time for prototypes and more efficient resource management Optimized calibration (e.g. for fuel economy) 12 * Hybrid control unit
Validation process of cross-domain simualtion Validation process: Maneuver catalogue for holistic validation (HW and SW models) Maneuver catalogue Vehicle and component measurements for defined maneuvers Validation on component/ subsystem level: Test framework for subsystems Validation of ECU SW models Validation of vehicle dynamics model TestRun #n TestRun #2 TestRun #1 Validation of complete simulation model, e.g. Vehicle lateral and longitudinal performance Overall energy consumption 13 Bosch Engineering
Validation - vehicle measurements Laptop 1 Laptop 2 Cronos Current sensors Temperature sensors HybridCAN Interface modules XCP from ESP HW ADMA (gyro system) via CAN VehicleCAN + HybridCAN Pressure sensors GPS antenna 14 Bosch Engineering
Conclusion and outlook Conclusion: Detailed and comprehensive model platform build-up in cooperation with OEM and other suppliers Integration of ECU functional software (e.g. hybrid controls, ESC) Cross-domain vehicle optimization Use of a common simulation platform for system development, software development and calibration Outlook: Holistic validation of vehicle, component and ECU SW models with measurements and in cooperation with IPG Integration of all control unit functions as FMUs to reduce Co-Simulation effort 15
Our vision of a hybrid sports car! Brake torque Control your car Feel your car Be your car Thank you for your attention! 16