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ASTERICS project presentation - EGVI · ASTERICS- Advanced energy Simulation & TEsting under Real...
Transcript of ASTERICS project presentation - EGVI · ASTERICS- Advanced energy Simulation & TEsting under Real...
ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
ASTERICS project presentation
Horst Pfluegl, AVL List Graz
Coordinator ASTERICS
EGVI Expert Workshop: “Research and Innovation needs in testing and evaluation procedures”, Brussels, 03.07.2014
ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
Content
Problem Statement
General project information - aim and objectives
Thematic challenge
Results so far
Further need for research activities - DRAFT
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
Main drivers for Fully Electric Vehicles (FEV)
Primary Energy Savings
Reduction of Greenhouse Gas Emissions and Climate Change
Reduction of noxious emissions (raising public health)
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Double performance of FEVs
Cut costs of technology into half
Cut development time into half
ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
Today´s shortcomings in design & development of FeVs
• Simulation models of Electrical components for EV lack simulation quality and accuracy
• Interactions between components are either not well known or not fully explored;
• EV specific driving and stress situations for full vehicles and components are not known
• Simulation models for batteries, especially ageing, are inaccurate and durability prediction is questionable
• Testing procedures are ICE-optimized and efforts to adapt to EV’s demands are unacceptable or even not known
• Testing equipment for FEV‘s needs to be identified, specifiedand developed
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
ASTERICS
Start date: 1/10/2012
End date: 30/09/2015
Total budget: 4.3 M€
Total EU funding: 2.7 M€
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Impact
Reduction of overall development time and testing efforts for FEV and components by 50%
Enable improvement and optimization of overall efficiency and performance of FEV by at least 20%
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
Thematic challenges
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Real world drivingcycles
Testingprocedures
Detailed models
Test bench integrationand validation
ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
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Subdivision of each trip into micro-trips
Analysis and grouping of micro-trips
Analysis of micro-trip sorting
Creation of synthetic cycle like succession of representative micro-trips and validation of cycle
Flow chart for Driving Cycles
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
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Driving cycle «builder» tool
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Real-world data used to build tailoredcycles
From representative cycle to multi-variated cycles System testing Control tuning
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
Verification & Validation & Frontloading
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
Use-cases able to describe demands to simulation models for EV-components in co-simulation environments
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
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WP2 – Battery Modelsmeasurement parameter fitting simulation
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
Battery Simulation on Pack-Level
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WORKFLOW
Analytic fit
Single cell simulation
Module simulation
ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
Battery Simulation on Pack-Level, with AVL FIRE ®
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Pack:
15 Modules
180 Cells
3x12cells
One of the 15 modules is simulated (1st step)
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
Battery Simulation on Pack-Level
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Battery Pack Details
nominal cell voltage 3,75 Vcell capacity 41 Ahconfiguration 180s1pnumber of cells 180nominal pack voltage 675 Vinstalled pack energy 27,6 kWhpack weight 242 kggravimetric pack energy density 114 Wh/kgcooling method liquid
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
Full vehicle Life Cycle Analysis (LCA)
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CO2for production
• Middle-class vehicle (Golf)
• Electric: +30% due to battery
Total emissions
• Electric: -50%
• Energy production: 590 gCO2/kWh
• USE: 150.000 km
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WP2 – Battery Models – further activities Execute measurement-procedures on test-bed
Evaluate the battery models with real data gathered fromtest-bed
Integrate Battery Models into WP5 – Full vehicle models
Exemplary exchange of battery models between different simulation environments
Co-simulation with battery models in the loop
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
WP3 – Inverter models and tests Stressors in accelerated reliability tests are typically temperature,
voltage, current, humidity or vibrations
Advanced inverters with high power ranges above 100kW in connection with high speed motor drives up to 22000rpm
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
WP3 – Inverter models and tests
Inverter models in AMEsimsimulation environment with detailed component modelling
Models are used for high frequencystudies and include thermal losses(switching and conducting losses)
Thermal and electrical behaviourneeds to be simulated at the same time
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
WP3 – further activities
Execute measurement-procedures on test-bed
Evaluate the inverter models with real data gathered fromtest-bed
Design a bi-directional galvanically isolated DC-DC converterfor test-bed configurations => enable high-frequency tests, low energy consumption
Integrate Inverter Models into WP5 – Full vehicle models
Exemplary exchange of inverter models between different simulation environments
Co-simulation with inverter models in the loop
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WP 4 - High accuracy & efficiency Electric motor models
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Integration step > 1/1000s, ideally 1/100s
INPUT OUTPUT
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Simulation models & virtual prototyping with SRM
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Simulation models and virtual prototyping, PMSM
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- Apply Genetic Algorithms to cycle representation
- Faster E-drive optimization (using GAs)
- Faster testing via condensed cycles
ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
Simulation models and virtual prototyping - PMSM
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- Investigations into E-machine ageing
ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
Simulation models and virtual prototyping - PMSM
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ASTERICS- Advanced energy Simulation & TEsting under Real world conditions forInnovative electric vehicle Components and Systems
WP5 Integration of models and components in different simulation environments – just started One dimensional longitudinal simulation (not including lateral
vehicle performance) Main focus is on powertrain models: simplified vehicle motion
resistance Due to the complexity of thermal modeling and the unique nature
of each powertrain, ageing effects of subsystems models are partly considered.
Exchange of models (e.g. electric machine with efficiency map and mechanical performances)
Subsystem model exchange with S-function or FMI approach (preferred approach)
In Matlab FMI creation requires special third party toolboxes (e.g. Modelon or DYMOLA)
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WP5 Integration of models and components in different simulation environments – Capabilities/start
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Future Research Topics for Testing andSimulation of EV‘s
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Instrume-ntation
TestingTechnologies
Testing Procedures
EV Testing
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0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8-600
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Summenströme (Phase mit Schirm), Versuch: 1
uu zu v
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uw zu u
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Research Topics for Instrumentation
Diagnosis and analysis technologies • Advanced electrochemical impedance spectroscopy • Correlation and effect models• Advanced hardware: signal processing, analysis, hardware
design• Instrumentation for analysis of state of health of
electrochemical systems, ageing effects - degradation• Instrumentation for analysis of state of charge of
electrochemical systems
Fast Electric Values Measurement and Phenomenon Analysis
• High frequency/voltage/current measurement devices: signal processing, analysis, hardware design
• Instrumentation for measurement and analysis of wireless vehicle charging
• Ageing, degradation effects of e-motors, e.g. for increased stress due to higher power density, higher switching frequencies of inverter
• Inter system electromagnetic interference (EMI), measurement and analysis of the coupling mechanism and influence of electromagnetic fields generated by the powertrain to the complex in-car data busses, control and communication systems
• Analysis of the exposure of electronic equipment (e.g. telecommunication) to the magnetic fields of the electric powertrain and inductive charging devices.
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Research Topics for Instrumentation, cont.
Instrumentation for on-board testing (in-vehicle usage)
• Integration of in-vehicle measurement technologies with the vehicle data bus system
• Interoperability: Integration/communication with environment and infrastructure (V2x)
• Optimization of measurement equipment for in-vehicle use: packaging, power consumption, robustness, shock and vibration, electromagnetic compatibility (EMC), etc
Advanced transducers and sensors • Micro-electromechanical systems (MEMS)
• Wireless sensors with autonomous energy harvesting from the environment
• Communication and data transmission considering EMI
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Resarch Topics for Testing Technologies
Advanced test beds • Energy efficient components
• Energy circulation strategies and management
• Test beds for EV system testing
Battery emulation• High frequency and peak testing
technologies
• Battery safety testing
• Performance and reliability testing technologies
• Ageing testing technologies
Inverter testbeds• Advanced testbed inverter technologies
(multi-level, high-frequency, …)
• Multiple Hardware-in-the-Loop (HIL) –technologies: HIL-systems for controller development, emulators for insulated-gate bipolar transistors (IGBT), e-motors
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Resarch Topics for Testing Technologies, cont.
E-motor• Testbed controllers and dynamometers for
very low and very high speed e-motors
• Transmission and e-motor optimisation
• E-motor testbed with virtual vehicle
Charging infrastructure testing• Inductive charging
• Conductive charging
• Fast charging testing technologies
• Safety and robustness investigation
• EMC testing
• Smart charging
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Resarch Topics to Testing Procedures
Automated test procedures• Testing procedures for hybrid-vehicles,
electrification-components and for manoeuvres
Testing methods & virtual testing for various aspects:
• Design of Experiments
• Semantic methods
• Battery prediction model testing
• Driveability testing
• Testing (driving) cycles
• Testing system architecture: combination of different tools and different components based on different use-cases => global optimization of testing procedures
• Procedures for optimisation of highly interacting components and individual strategies
• Load management: efficient grid integration
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Resarch Topics to Testing Procedures, cont.
Hybrid system testing methodologies (SIL, MIL, HIL, testbed)
• Component testing• Testing scenarios, use-cases & manoeuvres for
different test environments: start-stop, downhill, regenerative braking, etc.
• Controller strategies• Optimized driving strategies (based on GPS-data,
V2x communication, …)• Integrated component models
Data management• Calibration data• Simulation models• Testing result data• Testing parameters• Seamless access to data and data interfaces • Data processing and analysis for EV development• Charging data• Interoperability with charging operator (and/or
DSO)
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http://www.asterics-project.eu
Disclaimer
The FP7 project has been made possible by a financial contribution by the European Commission under Framework Programme 7.
This project – ASTERICS GA No 314157 - is co-funded by the 7th FP (Seventh Framework Programme) of the EC - European Commission DG Research
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Thank you for your attention