J. Balic, 11/2016

josko.balic@avl.com

Daniel Baumann, IT

AVL List GmbH

VIRTUAL ELECTRIC VEHICLEHands-on Road Validation

Confidential for PDiM 2016 | System Simulation for Virtual Electric Vehicle| J. Balic| 11/2016 | 2

Josko BalicProduct Manager

System Simulation

josko.balic@avl.com

Confidential for PDiM 2016 | System Simulation for Virtual Electric Vehicle| J. Balic| 11/2016 | 3

Driver Assistance and

Vehicle Safety Systems

MANAGING POWERTRAIN COMPLEXITY

1990 2000 2010 2015Calendar Year

Torque Vectoring

Toyota

Hybrid Systems

e CVT

TTR Hybrid (e4WD)

Po

we

rtra

in C

om

ple

xity

Active 4WD Systems

Active

Transmissions

Electrical Driving

e-machine for each Wheel

Inte

gra

tio

n W

ork

Development time and costs

20xx

Standard Configuration

Porsche

Hybrid Systems

e-machine on front Wheels

FOCUS: ENTIRE SYSTEM

TOOLS: BETTER, FASTER, NEWER

APPLICATIONS: CROSS-DOMAIN (EV/HEV, VTMS, xCU, RDE, ADAS)

ENVIRONMENT: SW, HW, OFFICE, LAB, ROAD, MIX

Confidential for PDiM 2016 | System Simulation for Virtual Electric Vehicle| J. Balic| 11/2016 | 4

800V EV ENERGY EFFICIENCY OPTIMIZATION OBJECTIVES

• Improving detail level of coupled

mechanical-electric and thermal modeling

• Reducing development time of electric

vehicles and their components

• Efficiency and performance optimization

VALIDATION

• AVL Coup-E 800 Electric Vehicle

• Chassis: MB CLC 180 (CL203)

Po

wert

rain

op

tim

iza

tio

n

Thermal management optimization

E-MOTOR

BATTERY

INVERTER

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POWERTRAIN SYSTEM DESIGN…

Cycle Simulation:• Consumption

• Emissions

• Workload Distribution

• Torsional Vibration

• Energy Balance

Performance:• Max. Speed

• Acceleration

• Elasticity

• Hill climbing

• Traction force

• Coast down

… FOR LONGITUDINAL DYNAMICS

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FROM POWERTRAIN SYSTEM DESIGN…

… TO HARDWARE TESTING ENVIRONMENT

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HCU VALIDATION ON AVL PUMA OPENWITH AVL CRUISE HYBRID VEHICLE MODEL

Confidential for PDiM 2016 | System Simulation for Virtual Electric Vehicle| J. Balic| 11/2016 | 8

TOOLCHAIN FOR ELECTRIFICATION

3D electro-chemical

model or battery

measurements E-Motor

Testbed

Battery Wizard

Parameterization

Battery

Testbed

Confidential for PDiM 2016 | System Simulation for Virtual Electric Vehicle| J. Balic| 11/2016 | 9

48V MILD HYBRID VEHICLEBSG CONTROL VALIDATION ON HIL

• Start-Stop

• Regenerative Braking

• eDRIVE

• Torque Assist

BSG

TISG

Baseline Model

48V Mild Hybrid

Confidential for PDiM 2016 | System Simulation for Virtual Electric Vehicle| J. Balic| 11/2016 | 10

Fiat Punto EV, 800kg, 4 e-machines with 12.5kW each

Single e-machine (front left) fails with full positive torque while running in a

circle, speed=70km/h, radius=110m, wet asphalt road µ=0.4

Two vehicles in snapshots:

Grey colour car: Reference without EM failure

Blue colour car: With single EM failure

EV WITH MULTIPLE E-MACHINESE-MACHINE FAILURE & SAFETY

e-TVC = E-Torque Vectoring Control

Confidential for PDiM 2016 | System Simulation for Virtual Electric Vehicle| J. Balic| 11/2016 | 11

FROM POWERTRAIN SYSTEM DESIGN …

… TO MULTI-PHYSICS DEVELOPMENT TOOL

Oil

Cooling

Engine

Crankangle-

resolved

Aftertreatment

Applications:• VTMS

• xCU Development

& Calibration

• Real Driving Frontloading

Confidential for PDiM 2016 | System Simulation for Virtual Electric Vehicle| J. Balic| 11/2016 | 12

FROM POWERTRAIN SYSTEM DESIGN …

… TO MULTI-PHYSICS DEVELOPMENT TOOL

Oil

Cooling

Engine

Crankangle-

resolved

Aftertreatment

Applications:• VTMS

• xCU Development

& Calibration

• Real Driving Frontloading

Confidential for PDiM 2016 | System Simulation for Virtual Electric Vehicle| J. Balic| 11/2016 | 13

AVL L.ive I.n V.ehicle E.nergy balancing

MODELING, BENCHMARKING, OPTIMIZATION

Confidential for PDiM 2016 | System Simulation for Virtual Electric Vehicle| J. Balic| 11/2016 | 14

Ageing and efficiency Simulation & TEsting under Real world conditions for Innovative electric vehicle Components and Systems

Source: http://www.asterics-project.eu/

SYSTEM SIMULATIONEV Energy & Thermal Efficiency

&

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FROM POWERTRAIN SYSTEM DESIGN …

… TO RAPID PROTOTYPING PLATFORM

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FROM POWERTRAIN SYSTEM DESIGN …

EXAMPLE:RDE Frontloading• Remote Engine/AT Simulation

• Real Sensors and CUs

• Real or Automated Driving

• VSM Vehicle Dynamics

… TO AVL’S TOOL-FREE INTEGRATION PLATFORM

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FROM POWERTRAIN SYSTEM DESIGN …

… TO ADVANCED CONNECTED DRIVING CONTROLS

ADAS functions development

• ACC/PCC/FCC

• Eco-routing

• Lane keeping

• Overtaking

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