Comparison of Powertrain Configuration Options for - Autonomie
Autonomie Training Part 1 Overvie - Training/training_part1.pdf · PSAT Used to Support R&D and...
Transcript of Autonomie Training Part 1 Overvie - Training/training_part1.pdf · PSAT Used to Support R&D and...
Training Part 1 Overview
Sponsored by Lee SlezakSponsored by Lee Slezak
“This presentation does not contain any proprietary or confidential information”
PSAT Used to Support R&D and Management Decisions After a thorough assessment, PSAT was selected in 2004 as the primary
vehicle model for all FreedomCAR and 21 CTP activities by the U.S.DOE, stating that “All future code development and enhancements for OFCVT
Management Decisions
stating that All future code development and enhancements for OFCVT shall focus on PSAT and PSAT‐PRO”
PSAT was awarded a R&D100 Award in 2004 and a Technology Transfer Award in 2007Award in 2007
PSAT is currently used by more than 130 companies and 700 users worldwide, including GM, Ford, Chrysler, Hyundai, Toyota
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Reliance on Modeling & Simulation is Continuously Increasing Reduce cost and time to production
Provides math‐based environment for more thorough multidisciplinary
Continuously Increasing
integration and testing in the virtual environment before hardware builds
Sorts technologies quickly to reduce hardware build iterations
Promotes parallel and integrated virtual development of control systems p g p yand hardware
Reduces/eliminates duplicate modeling and analysis work and activities
Enables fast to market with new technologies and real fuel Enables fast to market with new technologies and real fuel economy Delivers better‐integrated, initial designs that balance
( )Fuel Economy, Emissions and Drivability (FEED) requirements.
Provides common methods and tools for comparing/evaluating technologies.
Facilitates efficient, seamless link from research to production to maximize reuse of work products and eliminate waste.
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AUTONOMIE –
Taking it to the Next Level
The objective is to accelerate the development and j pintroduction of advanced technologies through a Plug&Play architecture that will be adopted by the
entire industry and research community.
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Accelerating the Development and I t d ti f Ad d T h l iIntroduction of Advanced Technologies
Why is Autonomie Unique?Why is Autonomie Unique?
Develop/Evaluate Component/Control Technologies
Develop/Evaluate Vehicle ArchitecturesDevelop/Evaluate Vehicle Architectures
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AUTONOMIE/PSAT Comparison p
Capability PSAT PSAT‐PRO AutonomieArchitecture
Plug & Play Architecture
Hierarchical Architecture Standards (Vehicle, syst…)
Model Reusability through System Experts (Concept to Production)Establish Standard Interfaces (Industry‐wide)
FeaturesCapability PSAT PSAT‐PRO Autonomie
Model/data Customization
Features
Powertrain Configuration Customization
Select Appropriate Level of Modeling
GUI Customization (process, post‐processing…)
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(p , p p g )
Database Management
AUTONOMIE/PSAT Comparison p
Capability PSAT PSAT‐PRO AutonomieUsage*
Capability PSAT PSAT PRO AutonomieEvaluate Fuel Consumption Benefits(technology, size, powertrain configuration…) Evaluate and Balance FEED in Simulation(Fuel Economy, Emissions & Drivability)Develop Component Requirements
Simulate Single Component
Develop System/Subsystem Requirements
Develop Vehicle Level Control
Develop System/Subsystem/Component ControlDevelop System/Subsystem/Component Control
Component‐in‐the‐Loop
Software‐in‐the‐Loop, Hardware‐in‐the‐Loop…
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*Final usage depends on the level of details of the models available
Develop a Software Architecture & Environment to Plug-and-Play Math-Based Models of Hardware & Control System Software Early or Up Front in the Design & Analysis ProcessSoftware Early or Up-Front in the Design & Analysis Process
Maximum User AccessDatabase
Maximum Flexibility
Reusability
EnterpriseWid S l ti
ControlDatabase
Flexibility
Selectable Complexity
Wide Solution
VersionControl
Interface
Complexity
CodeNeutrality
Control
DatabaseSearch
Models, Data
DatabaseModels, Data
y Search
Graphical User Interface
Linkage withOther Tools
ResultsVisualization
GenericProcesses
SetupSimulation
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Other ToolsVisualizationProcessesSimulation
Model & Data Requirements
■ Automated integration of existing models / controls / data ■ All models for a specific area of expertise in a single location■ Systems duplicated using Matlab API
MaximumReusability
Maximum■ Any system can be built automatically■ User can add their own configurations
Flexibility ■ Single components or entire vehicles can be simulated
■ Common nomenclature (i e naming I/O )Selectable Complexity
■ Common nomenclature (i.e., naming, I/O…)■ Common model organization (i.e, CAPS)■Model compatibility checked
CodeNeutrality
■Matlab / Simulink main environment■ Use S‐functions■ Co‐simulation (i.e., CoSimate*)
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( , )
* Not yet implemented
Graphical User Interface Requirements
SetupSimulation
■ Select architecture, model and data ■ Check compatibilities ■ Select simulation outputs to Workspace■ Select simulation type (i e fuel efficiency performance )
Generic
■ Select simulation type (i.e., fuel efficiency, performance…)
■ Calibration, Validation, Tuning■ Parametric study, including Monte Carlo analysis
Processes ■ Optimization algorithms■ Predefined set of simulations & report (i.e., Drive Quality)
■ Predefined calculations (i e fuel economy efficiency power )Results
Visualization
■ Predefined calculations (i.e., fuel economy, efficiency, power…)■ Predefined plots, both time based and lookup tables■ Energy balance■ Specific plots available for different models (users defined)
Linkage withOther Tools
■ Co‐simulation (i.e., CoSimate*)■ Specialty Tools (i.e, GT‐Power, CarSim, AMESIM, AVL Drive*…)■ Database Management (i.e., SourceSafe…)
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g■Well‐to‐Wheel (i.e., GREET*)
* Not yet implemented
Database Requirements
User AccessControl
■ Prevent unauthorized users from accessing restricted or proprietary data■ Allow authorized users to download all necessary files■ Ensure model is documented before integration into database
Enterprise
■ Ensure model is documented before integration into database
■ Allow users to collaborate (i.e. share models)■Main database accessible anywhere
Wide Solution ■ Consistent process for interacting with files
■Maintain traceability of all changesVersion Control
■Maintain traceability of all changes■ Keep linked files together through entire vehicle process (i.e. design, simulation and test)
DatabaseSearch
■ Use keywords to search data, models, controls related to specific projects■ Quickly find the correct model with the correct fidelity of
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Q y ymodeling and all related files
Key Benefits
Plug&Play
■ Flexibility & Reusability■ Customizable architectures■ Common Nomenclature■ Code Neutral
R d■ Common Methods to sort technologies quickly t d h d b ild it tiReduces
Cost & Time to
Production
to reduce hardware build iterations■ Reduces/eliminates duplicate modeling and analysis work■ Delivers designs that balance Fuel Economy, E i i d D i bilit (FEED) i t
Enterprise
Emissions and Drivability (FEED) requirements
Enterprise Wide
Solution
■ Database Management■ Provides common methods and tools for comparing/evaluating technologies
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No other tool currently allows the linkage with any legacy code!
Unique Feature – Plug & PlayImplement any language
Legacy Code
Implement any languageAutomated process to import legacy code (data, model, control, process)…
Calibration CarSim*
, p )
Plug & Play
Specialty Software (COTS)
Legacy
Processes
CalibrationValidationTuningDrive Quality…
CarSimGTPower*Amesim*AVL Drive…Drive Quality…
Database Management
Version ControlDatabase Search
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No other tool currently builds the model automatically!
Key New Feature – Software CustomizationModel organizationModel organizationSingle or multiple plantsController location
Model Configuration
Fuel economyModelsDataControls…
Fuel economyValidationDrive qualityControl…
Customization ProcessesProprietary Information
CalculationsPlotsR t
Post‐processing
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Reports…
Integrate Legacy Code
Example: Integrate Legacy Simulink ModelsLegacy Code
GUI Automatically Renames Variables, Creates Necessary Support FilesCreates Necessary Support Files
Ready for use in
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Model Plug&Play Capability Provided by “W ” “Wrapper”
Legacy Plant
First block automatically built to select the required input parameters change
Last block automatically built to change units (SI) and data type before sending
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the required input parameters, change units and data type
units (SI) and data type before sending the information to a bus to make them available to other systems
Experts Develop Systems1 Wh t i S t i A t i T i l ?1- What is a System in Autonomie Terminology?
Expert System
Initialization
DocumentationExpert System
Model
File
Pre‐processingFile
Test Data
File
Post‐processingFile
ReportFile (HTML)
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Experts Develop Systems2 E h S t C fi ti C B C t i d2- Each System Configuration Can Be Customized
Each System is OptionalEach System is Optional
ActuatorController Plant Sensor
Example: GM 2 Mode HEVTransmission Plant
Electric Machine #1
Any System can have Subsystems To Accurately Represent
Transmission Plant
Electric Machine #2
Gearbox
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y pHardware
Experts Systems Can Be Reused3 H C W R it?3- How Can We Reuse it?
Expert #9
Vehicle
Expert #1
Expert #3
BatteryExpert #7
Expert #2
Controller
Expert #7
ChassisPlant
Expert #8
Expert #4 Expert #5
Expert #6
EngineDriveline
Expert #4
Controller
Expert #5
Plant
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Autonomie Designed to Be Used For All Steps in the Development ProcessDevelopment Process
Easy selection & implementation of data, models, control or cycles
Run batch mode +Distributed
Build and compare large number of of data, models, control or cycles Distributed
computinglarge number of technology, powertrain, options
Ensure simulation t bilit
Analyze and compare test and
traceability, model compatibilities
psimulation data
Database M t
Enables MIL, SIL,
Generic ProcessesManagement RCP, HIL, CIL
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Accelerating the Development and I t d ti f Ad d T h l iIntroduction of Advanced Technologies
Why is Autonomie Unique?Why is Autonomie Unique?
Develop/Evaluate Component/Control Technologies
Develop/Evaluate Vehicle ArchitecturesDevelop/Evaluate Vehicle Architectures
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Develop Plant Models with Different Level of C l itComplexity
Steady State Model
Physical Model
Mean Efficiency Model
Highly Dynamic Model with Production Code
Different models are necessary to study different phenomena
Detailed models are required when technology
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Detailed models are required when technology cannot be tested or does not exist!
Link with Commercial Off the Shelf Tools (COTS)#1 – Develop Model in Native Environment
#2 – Integrate Model in Simulinkin Simulink
#3 – Use Model in Autonomie
COTS (1) can be used to generate maps(2) can be run in the Simulink environment(3) can be run in their own environment (co‐simulation)
23GT Power, CarSim have already been linked
(3) can be run in their own environment (co simulation)
Select the Appropriate Level of Modelingllers
Control or ororor
ts
oror
Plan
oror
oror
or
or
EngineExperts
TransmissionExperts
ChassisExperts
Battery, MotorExperts
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Experts Experts Experts
Vehicle Experts
Experts
Main Steps of Model Based Design
Hardware‐in‐the‐LoopSoftware‐in‐the‐Loop
Rapid Control Prototyping Component‐in‐the‐LoopRapid Control Prototyping Component in the Loop
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Develop Control Algorithm Software in the LoopSoftware-in-the-Loop
Specific configuration defined to develop and test new control algorithmsnew control algorithms
New algorithm(s) to be testedProduction Code
Real Time Operating System (RTOS) ensures call of functions at specific
intervals (such as CAN)intervals (such as CAN)
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Hardware input/outputSends and receives CAN signals
Test Low Level Control AlgorithmHardware in the Loop and Software in the Loop
Automatic building save days of development
Hardware-in-the-Loop and Software-in-the-LoopHardware‐in‐the‐Loop
(Control Hardware / Emulated Plant)Automatic building save days of development
All the lines connecting the blocks are built automatically
Block built automatically‐Change unitsChange data type‐Change data type‐Extract all the proper sensors
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Evaluate Fuel Consumption BenefitsModel in the LoopModel-in-the-Loop
Example “Evaluation of HCCI Engine Fuel Savings for Various Powertrain”E i f U fMEngine maps from UofM
Vehicle & ControlDevelopment
1.000
Ratio Fuel Consumption of HCCI vs Regular Engine
Fuel Consumption Analysis
p
0.850
0.900
0.950
Unad
justed
Fuel Con
sumption Ra
tio
Conventional
Micro_HEV
Mild_HEV
Split_HEV
Split_PHEV10
Split_PHEV20
Series_PHEV30
Series PHEV40
Detailed Analysis of Reasons Behind Benefits
0 950
1.000
HCCI Fuel Savings vs PI According to Hybridization Degree
0.750
0.800
1
U Series_PHEV40
0.800
0.850
0.900
0.950
Una
djusted Fuel Con
sumption Ra
tio
UDDS
HWFET
Combined
0.900
0.950
1.000
1.050
on Ratio
Fuel Consumption Ratio (High Case) of HCCI vs PI
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0.750
0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00%
Hybridization Degree (%)
0.600
0.650
0.700
0.750
0.800
0.850
0.900
0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00%
Una
djusted Fu
el Con
sumptio
Percent of Time Engine is ON
Evaluate Non Modeled Phenomena With HardwareComponent-in-the-LoopComponent-in-the-Loop
Example#1: Impact of battery cold start on PHEVs Fuel Consumption
Sensors Battery behaves as if in vehicle
Example #3: Engine and Battery are Coupled
Example #2: Impact of emission and engine
Rest of the Vehicle Modeled
y p
emission and engine cold start on PHEVs Fuel Consumption
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Engine behaves as if in vehicle
Evaluate Non Modeled Phenomena With HardwareComponent-in-the-Loop - ExamplesComponent-in-the-Loop - Examples
Impact of Vehicle Level Control on Battery Life
vehicle speedl l t d CO2 /
Impact of Vehicle Level Control on Engine Emissions
10
15
20
25
O2
gram
s/se
cond
calculated CO2 g/secengine torque/10 measured
200 250 300 350 400
0
5
Time in seconds
CO
Impact of Charger Rating on Battery Roundtrip Efficiency
2, 95.151.4, 95.56, 21.5
94
95
96
cien
cy
20
25
rent
-
Impact of Temperature on All Electric Range
8 0
9 0
1 0 0
eed
I n itia l te m p e rature 2 0 d e g re e s C ve hic le s p e e d in m e te rs p e r s e c o ndInitia l te m p e rature 0 d e g re e s CInitia l te m p e rarture -7 d e g re e s C
6 89 11
2, 71.4, 5
89
90
91
92
93
94te
ry ro
undt
rip e
ffic
(%)
5
10
15
tter
y ch
argi
ng c
urR
MS
(A)
4 0
5 0
6 0
7 0
Sta
te o
f Cha
rge,
Veh
icle
spe
30
6, 89.11
88
89
0 2 4 6 8
Charger Power (kW)
Bat
t
0
Ba
0 5 0 0 1 0 0 0 1 5 0 0 2 0 0 0 2 5 0 0 3 0 0 0 3 5 0 02 0
3 0
T im e in s e c o nd s
S
Define Component Requirementsen
t Data
D Teams
Testing
Battery AccessoriesCamry A/C Power
Prius A/C Power
Electric Machine2004 Prius
Compo
nefrom
R&D
IL Ro
Rp1 Rp2
OCVVLModel
Prius A/C Power
hicle
ations
Ip1 Ip2
Vehicle Classes
Vehicle DOE / USABC
Sizing & Simulation
Veh
Simula
Requirements DOE / USABC Requirements
Validation Battery RCP Vehicle Testing
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V
JCS VL41M
Accelerating the Development and I t d ti f Ad d T h l iIntroduction of Advanced Technologies
Why is Autonomie Unique?Why is Autonomie Unique?
Develop/Evaluate Component/Control Technologies
Develop/Evaluate Vehicle ArchitecturesDevelop/Evaluate Vehicle Architectures
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Validate Vehicle Models to Ensure Studies I t itIntegrity
Analyze Data Develop Control
Collect Test Data
Engine Torque
Validate Model
d d b d l b
APRF
Understand Gearbox Model Gearbox
Source : GM
33Example of GM 2 Mode Tahoe
Develop Vehicle Control to Maximize Fuel DisplacementGl b l O ti i ti
tSOCtP
tJtSOCtP '0,000 ,1',1
tU 0 Optimal Control
Teng Tmc
ωmc
Global Optimization
tSOCtP nm ,
tJtSOCtP MMMM ',' ,1,1
0
tU M
TX 0X.
.
.
.
.
.
Optimal Control, Minimal Fuel Cons.
Backward model Bellman Principle
ωeng
Backward model p
Various Control St t iVarious
Control Design
StrategiesControl Principles Rule‐Based Control Design
Heuristic Optimizationp
Optimally tunedParameters
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Existing Control Logic DIRECT Algorithm
Develop Vehicle Control Taking into Account N M d l d P tNon Modeled ParametersExample: Impact of Vehicle Level Control on Engine Emissions for PHEVs(collaboration with ORNL)(collaboration with ORNL)Step #1 – Evaluate Different Controls in Simulation
Vehicle Model Detailed After‐Treatment ModelEvaluation ofEvaluation of Different Vehicle Control Logic and Tuning
Step #2 – Verify the Trends with Engine‐in‐the‐LoopAnalyze Results
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Rest of the Vehicle Modeled Engine behaves
as if in vehicle
Match Technologies, Configurations to S ifi A li tiSpecific Applications
15Comparison of Aerodynamic Fuel Savings for Drive Cycles vs Steady States
Impact of Aerodynamics for Different Line Haul Applications
30.0
Impact of Mild and Full HEV for Line Haul Applications
5
10
15
mpr
ovem
ent f
rom
hig
h to
low C
d
Drive CyclesSteady States
16.0
13.716.3
24.022.4
15.513.1
15.6
21.319.2
15.112.5
15.0 14.015.5
10.0
15.0
20.0
25.0
sumption (gal/100
mi) CONV MILD‐HEV FULL‐HEV
50% load
0
5
Per
cent
age
Im
HTUF Class 6/
21 mph SSUDDS Truck/26 mph SS
HHDDT Cruise/42 mph SS
HHDDT High Speed/53 mph SS
0.0
5.0
10.0
HHDDT65 HHDDT Cruise HHDDT High Speed
HHDDT Transient
udds_truck
Fuel Con
s
h S f h C bi d h l i h S f h h l
16.0%
18.0%
20.0%
d
Impact of All Technologies on Fuel Consumption
Engine
Transmission
The Sum of the Combined Technologies < The Sum of Each Technology
Class 2B Pickup
14.9% 15.9%
1.2%1.6%1.7%1.4%
8.6%8.9%
4 0%
6.0%
8.0%
10.0%
12.0%
14.0%
Percen
t Fue
l Saved Transmission
RR
Cd
Weight
Hybrid
36
1.4% 1.4%
3.0% 3.8%
0.0%
2.0%
4.0%
Each technology (Conv)
Combination(Conv)
Each technology(Hybrid)
Combination(Hybrid)
Hybrid improvementsBaseline improvements
Evaluate Uncertainties Through Monte Carlo A l iAnalysis■ Uncertainty is modeled by a probability density function (pdf)■ How is the uncertainty propagated?
■ PHEV 10 miles All Electric Range (AER) midsize used as reference case■ PHEV 10 miles All Electric Range (AER) midsize used as reference case
Inputs Sampling Results
CdMonte Carlo (MC), Latin hypercube (LHS),Median Latin hypercube (MLHS)Quasi Monte‐Carlo
FA
Crr
Weight
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A f i d d d f k
SummaryA software environment and standard framework
Unifies the entire engineering organization for efficient operation
Focuses analysis on total system engineering and integration
Provides complete user customization by an open architecture
Simulates from single components, subsystems to entire vehicles
Manages models, data, processes, results and control code from research to production by configuration and database management
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