AVL Electrification Testing Solutions - Part 02 ...
Transcript of AVL Electrification Testing Solutions - Part 02 ...
AVL Europe ITS
Markus Maier
AUTOMOTIVE ELECTRIFICATION
ELECTRIFICATION SOLUTIONSSYSTEM INTEGRATION
Markus Maier | IST-N EU | June 2016 | 2AVL UK Expo 2016
ELECTRIFICATION TEST SYSTEMS
# of qualified service personal Standard Level
# of qualified service personal Expert Level
• First System sold by 2009
• Business Unit
Electrification & Racing
Test Systems
established in 2011
• AVL Electrification Test
System Expertise around
the world
• More than 300 Systems
in use since 2009
• From System Concept to
Service globally
AVL Electrification
Test Systems
Markus Maier | IST-N EU | June 2016 | 3AVL UK Expo 2016
AGENDA
1. What
What is an electrified car all about
2. How
How do we develop an electrified car
System Integration
3. Summary
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Micro-Hybrids use Starter and Battery for
Stop-Start Functionality
Conventional Vehicle Full Electric Vehicle
CONVENTIONAL, HYBRID ANDELECTRIC VEHICLES
Generator12V Battery
ICEGearbox
Starter
Hybrid
Vehicles
Hybrid Vehicles combineCombustion Engine and
All Electric Propulsion Charging Port
RechargeableBattery
orFuel Cell
Electric Motor
U V W
ReductionGearbox
Inverter
DC/DC Converter
+Charger
12V Bordnet
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Powersplit Hybrid
Electric driven rear-axles are also parellel Hybrids and so-called road-
coupled hybrids
Parallel Hybrid Serial Hybrid
U V W
2nd BatteryBattery
U V W
U V W
Planetary Gearbox
Generator
HYBRID POWERTRAIN LAYOUTS
Benefit
• ICE is operated in steady state
and has hence optimum
efficiency
Benefit
• Fairly easy to realize
• Allows full-electric driving
• Allows electric boosting
Benefit
• Allows optimum combination of
parallel and serial hybrid
depending on driving situation
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TRACTION TORQUE WILL HAVE MANY SOURCES
MechanicalPower
ElectricalPower
0% 0%
100%100%
InternalCombustion
Engine
Hybrid(HEV)
PluginHybrid(PHEV)
Extended Range Electric(RREV)
Battery Electric(BEV)
Fuel-CellElectric(BEV)
MechanicalDrive
Mechanical Drive with electric Assist Electrical Drive withmechanical Assist
Electrical Drive
To
rq
ue
To
rq
ue
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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 2016 | 8AVL UK Expo 2016
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 judgenew, 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)
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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 customersperceiption of the whole vehicle
The Energy Source (Battery) is a core component and determines Power, Reach, Charging
Hauptteil der Absicherungszeit und Kosten heute sehr spät im Prozess investiert
Validation in the V-Cycle
• Validation of Vehicle
ca. 60%
• Validation of electr. Subsystem
ca. 10%
• Component Validation;
ca. 30%
60%
10%
30%
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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)
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
AVL Solution
Integration Testbench for Electrification Subsystem
+ -
Be
lt
Clu
tch
ICEMotor G
ea
rbo
x
Battery
Inverter
Generator
010111001010001011
010111001010001011
+ -
Motor
Battery
Inverter
01011100101000
1011
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1011
Today: Whole Powertrain
Tomorrow:
Subsystem Electrification
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INTEGRATION TESTBED - 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 includingnew possibilities of emulation
Inv
U V W
Bat
OBC
Inv
U V W
Bat
OBC
HV Subsystem
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Drive Shaft
Load Unit
ORDrive Shaft
Load Unit
+
+ -
Energy Storage
OR
Generator*
SYSTEM TESTBENCH OVERVIEW
* considered as DC source
motoric Loads / Sinks
OR OR
Ohmic Loads
OR
Charger
OR
e-ME
universal
Inverter
universal
electronic
loads
Grid
Emulator
Automation
AVL
PUMA
Restbus
AVL
inMotion
DVE
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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
+ -
Motor
Battery
Inverter
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Engine, Gearbox
and ECU
Simulation
Vehicle & Load
Simulation
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SYSTEM TESTBENCH OVERVIEW
Em
ula
ted
Wo
rld
+ -
Battery Inverter LoadCharge
Battery Univ. Inv. e-ME Grid Emu Load Emu
Multipurpose Power Switch Box
Motor
AVL
inMotion
DVE*
Restbus
Automation
AVL
PUMA
Kl15,30, CAN,LIN,FlexRay
HiL
DME, DGM
*DVE = Driver, Vehicle, Environment
Re
al W
orl
d
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REAL MOTOR AND POWERELECTRONICS
Em
ula
ted
Wo
rld
+ -
Battery Inverter LoadCharge
Battery Univ. Inv. e-ME Grid Emu Load Emu
Multipurpose Power Switch Box
All components real
Motor
AVL
inMotion
DVE*
Automation
AVL
PUMA
Kl15,30, CAN,LIN,FlexRay
RestbusHiL
DME, DGM
*DVE = Driver, Vehicle, Environment
Re
al W
orl
d
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EMULATED BATTERY
Em
ula
ted
Wo
rld
+ -
Batterie Inverter LoadCharge
Battery Univ. Inv. e-ME Grid Emu Load Emu
Multipurpose Power Switch Box
Emulated Battery
Motor
AVL
inMotion
DVE*
Automation
AVL
PUMA
Kl15,30, CAN,LIN,FlexRay
RestbusHiL
DME, DGM
*DVE = Driver, Vehicle, Environment
Re
al W
orl
d
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EMULATED PLUG-IN HYBRID
Em
ula
ted
Wo
rld
Re
al W
orl
d
+ -
Battery Inverter Charge
Battery Grid Emu
Multipurpose Power Switch Box
Motor
AVL
inMotion
DVE*
Restbus
Automation
AVL
PUMA
Kl15,30, CAN,LIN,FlexRay
*DVE = Driver, Vehicle, Environment
Markus Maier | IST-N EU | June 2016 | 18AVL UK Expo 2016
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
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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
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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 emulatedSystem
+ -
Motor
Battery
Inverter
010111001010001011
010111001010001011
Engine, Gearbox
and ECU
Simulation
Vehicle & Load
Simulation
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SUMMARY AND OUTLOOK
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
Inv
U V W
Bat
OBC
www.avl.com
THANK YOU
Markus MaierBusiness Manager Electrification and Racing Test SystemsEuropean region
Zettachring 4, 70565 Stuttgart+49-711-45041-22+49-171-6925831