Thermal Management Optimization of Hybrid Vehicles in GT-SUITE · Hybrid Mode Warm-Up Technologies...

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G. Fossaert, R. Corbishley, N. Gunter, T. Strauss Verification & Analysis MAHLE Powertrain

Thermal Management Optimization of

Hybrid Vehicles in GT-SUITE

European GT-User Conference

2019

1

MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019

Optimized Thermal Management For Hybrid Vehicles

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Motivation

MAHLE Powertrain is an Engineering Services Provider

Evolving customer needs

Customer Requests

Various request types

Performance evaluation

EV range estimation

Optimal HEV Layout

Drive cycle efficiency

Battery life estimations

Customer Applications

Combinations of

EV / HEV / ICE only

P0 / P1 / P2 / P3 / P4

FWD / RWD / AWD

Customer Demands

Project variability

Accurate results

Quick turn-around

Flexible



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New Full Vehicle Thermal Model

Our Solution

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Engine Friction

Engine Lubrication

Engine Cooling

Airside Cooling

HVAC

Electrical

Transmission Lubrication & Thermal

Transmission Friction

Engine Thermal Drive Cycle Model

3



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Presentation Overview

Modelling

– Generic Drive Cycle Model

– Engine Thermal Model

Case study

– DI3 Hybrid Electric Vehicle Thermal Management


Drive Cycle Model


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Engine Friction

Engine Lubrication

Engine Cooling

Airside Cooling

HVAC

Electrical



Engine Thermal Drive Cycle Model

5



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Generic HEV Model

Powertrain type

– ICE

– P0/P1/P2/P3/P4

Architecture options

– FWD

– RWD

– 4WD

Individual gearing options

– Transfer box

– Gearbox

– Final Drive

Specific powertrain selection for

– ICE only

– HEV

– EV

6

Available in single Generic HEV Model



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Generic HEV Model

Controllers

How to control the Generic HEV Model

Model User

– Powertrain layout selection

– Strategy definition

Driver and torque split controllers

– Driver calculates torque request

– Strategy

MGU / ICE operation

– Specific MGU and/or ICE torque passed onto component

7

Powertrain Layout

User

Driver Controller

Torque Request

Controller

Strategy Controller

MGU Selection

ICE Operation


Modes


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Generic HEV Model

Strategy Controller

Mode 2: EV only

Mode 3: HEV Series

Mode 4: HEV Parallel

Mode 1: Engine Only

Transition Conditions

Strategy

Mode 1

Mode 2 Mode 3 Mode 4

8

MGU(s) ICE Operation Clutch

USER INPUT

P3 12bar Locked

…

…


RDE facility is ideal test environment for Drive Cycle Model correlation

– Maximum altitude of 5km

– Climatic range: -40 to +60°C / 10 – 80% relative humidity

Cumulative fuel flow shows good correlation between simulation and vehicle test results

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Drive Cycle Model Correlation


9

WLTP Class 3 23°C AC Off

Veh

icle

Sp

eed

[k

m/h

]

020406080

100120140

En

gin

e S

peed

[rp

m]

0

1000

2000

3000

Fu

el

Flo

wR

ate

[g

/s]

0.0

1.0

2.0

3.0

4.0

Fu

el

Co

nsu

med

[g

]

0200400600800

1000

Time [s]

0 300 600 900 1200 1500 1800

Test Simulation


Drive Cycle Model


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Engine Friction

Engine Lubrication

Engine Cooling

Airside Cooling

HVAC

Electrical



Drive Cycle Model

10

Engine Thermal



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Engine Thermal Model

11

Engine Thermal Model Ease of implementation

within Full Vehicle Model Fast-running



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Thermal Model Correlation

The initial correlation results showed

model confidence

Heat flows predicted in the 1D

thermal model matched

– Indimaster / Dyno results

– CFD / Converge predictions

12

Metal temperatures showed a good correlation between the

CFD and the 1D FE Cylinder

– E.g. both sides of the cylinder head fire face


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Thermal Management Optimization of Hybrid Vehicle

Case Study

MAHLE DI3 Engine

P0 / P3 hybrid

WLTP Cycle B Segment Vehicle

Compact battery

13


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Optimized Thermomanagement

Considered Warm-Up Technologies

14

E-Pumps (Coolant/Oil)

Multi Flow Valve (MFV)

Split Cooling

Engine Oil Cooler (EOC)

Transmission Oil Cooler (TOC)


MAHLE DI3 1.2L ICE

LP EGR

Baseline

Mechanical water pump

Conventional thermostat

No warm-up prioritisation

Warm-up technologies

Electric water pump

– Flow on demand

Split cooling

– Stagnant block flow

Multi flow valve

– EOC or TOC flow prioritisation


Head C

oola

nt

Tem

pera

ture

[°C

]

20

40

60

80

100

120

Gearb

ox O

ilT

em

pera

ture

[°C

]

20

40

60

80

100

120

Lin

er

Tem

pera

ture

[°C

]20

40

60

80

100

120

140

160

Time [s]

0 300 600 900 1200 1500 1800

Engin

e O

ilT

em

pera

ture

[°C

]

20

40

60

80

100

120

Time [s]

0 300 600 900 1200 1500 1800

Baseline Warm-Up Technolgies

ICE Only

Warm-Up Improvements

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15

Head coolant shows slower warm-up

Faster engine oil warm-up

Faster gearbox oil warm-up

Elevated steady-state temperatures

2% fuel economy improvement achieved by thermal management optimisation


Transition Conditions

Modes HEV


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Hybrid Mode

Hybrid Strategy

EV P3 Load Shift P3 Load Assist P0/P3 Traction Engine Only

Strategy

EV

P3 Load Shift P3 Load Assist P0/P3 Traction

Engine Load: 12bar

16

Based on: • SOC • Power demand • Braking request

BM

EP

(B

ar)

0

5

10

15

20

25

30

Engine Speed (rpm)

1000 2000 3000 4000 5000 6000

BM

EP

(B

ar)

0

5

10

15

20

25

30

Engine Speed (rpm)

1000 2000 3000 4000 5000 6000


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Hybrid Mode

Warm-Up Technologies Included



17

Hybrid strategy optimisation to minimise warm-up time 10% fuel economy improvement achieved by hybrid strategy

Time [s]

0 300 600 900 1200 1500 1800

SO

C [

-]

0.0

0.2

0.4

0.6

0.8

1.0

1: EV2: Eng Only3: Load Shift4: Load Assist5: Traction

Mode [

-]

1.0

2.0

3.0

4.0

5.0

6.0

Head C

oola

nt

Tem

p.

[°C

]

20

40

60

80

100

120

ICE Only HEV

Engin

e O

ilT

em

p.

[°C

]

20

40

60

80

100

120

Gearb

ox O

ilT

em

p.

[°C

]

20

40

60

80

100

120

Time [s]

0 300 600 900 1200 1500 1800

Time [s]

0 300 600 900 1200 1500 1800

SO

C [

-]

0.0

0.2

0.4

0.6

0.8

1.0

1: EV2: Eng Only3: Load Shift4: Load Assist5: Traction

Mode [

-]

1.0

2.0

3.0

4.0

5.0

6.0

Head C

oola

nt

Tem

p.

[°C

]

20

40

60

80

100

120

ICE Only HEV

Engin

e O

ilT

em

p.

[°C

]

20

40

60

80

100

120

Gearb

ox O

ilT

em

p.

[°C

]

20

40

60

80

100

120

Time [s]

0 300 600 900 1200 1500 1800


Drive Cycle Model


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Results Summary

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Engine Friction

Engine Lubrication

Engine Cooling

Airside Cooling

HVAC

Electrical



Drive Cycle Model

Engine Thermal

18

10%

2%


Example of Toolset Deployment

MAHLE Modular Powertrain

High Voltage PHEV Powertrain

Engine <210g/kWh min BSFC

1/2/4 speed gearbox options

Scalable hybrid: B to J-Segment

Drive cycle CO2 below 2030 proposed target

19 Confidential

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Development supported with GT-SUITE

Performance targets

Vehicle capability targets

Hybrid mode

Hybrid strategy

Mechanical development

G. Fossaert, R. Corbishley, N. Gunter, T. Strauss Verification & Analysis MAHLE Powertrain

Confidential

© MAHLE

Thank you for your attention

20

Simon Duke

Chief Engineer

Verification & Analysis

[email protected]

+44 (0) 1604 738 148

Gery Fossaert

Senior 1D Analysis Engineer

Verification & Analysis

[email protected]

+44 (0) 1604 734 917

mailto:[email protected]

mailto:[email protected]

Thermal Management Optimization of Hybrid Vehicles in GT-SUITE · Hybrid Mode Warm-Up Technologies...

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