Electrification for CV

AVL Services and References

Peter Ebner, Raimund Ellinger Powertrain and Hybrid System AVL-List

Introduction
AVL capability in Hybrid development AVL capability in Hybrid / System engineering AVL CV Hybrid experience / References

Introduction
AVL capability in Hybrid development AVL capability in Hybrid / System engineering AVL CV Hybrid experience / References

Electrification Market - Overview

Motivation
450 400 Gasoline NA Diesel Gasoline Turbo Hybrid (gasoline) CNG Turbo China Stage 2 CO2 [g/km] China Stage 3 CO2 [g/km] EU-proposed CO2 Limit
Source: AR 2010

CO2 Emission in NEDC [g/km]

350 300 250 200 150 100 50 0 500

1000

1500 Vehicle Curb Weight [kg]

2000

2500
4

Hybrid Solutions
Degree of Electrification & Hybrid Topologies

Parallel Hybrid
E-Motor Clutch

Serial Hybrid
Generator Motor

Powersplit Hybrid
Motor A Motor B

ICE MT /AT
AC

ICE

ICE

Inverter
DC
AC AC
AC AC

Inverter
DC DC
DC DC

Direct mech. Connection Engine Wheels

Electric Coupling of Engine & Wheels

Electromechanic Coupling eCVT Operation Mode

S 400 Hybrid

Citaro Hybrid

ML 450 Hybrid

SOLUTIONS DIVERSITY
Electrified Powertrains Today Are Highly Diversified

Micro Hybrid
1 3 kW <<1 kWh

Mild Hybrid
5 15 kW 0.5 1.5 kWh

Full Hybrid
20 60 kW 1 5 kWh

PlugIn Hybrid
40 80 kW 5 15 kWh

RangeExt
20 120 kW 10 15 kWh

EV
20 120 kW 15 30 kWh
Rated power electric drive Rated capacity battery

25...50 km

> 75 km

1...5 km

10...45 km

with ICE

without

Grid Charging

Introduction of Hybrid
Understanding & Managing of System Complexity System electrification adds complexity due to:
Multiple torque providers (engine, motors) Highly integrated systems (ex. powertrain to chassis)

IC Engine

Complex safety requirements (ex. high voltage devices) Battery

Interactive controls requirements Lack of field history

Transmission Managing the complexity requires a refined methodology and disciplined systems engineering approach that balances and optimizes system requirements.

Electric Motor
Control Strategy
7

Introduction of Hybrid Manage Complexity

Define Configuration & Optimize Components

IC Engine Battery

Transmission

Electric Motor Control Strategy

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Introduction of Hybrid Manage Complexity

Define Configuration & Optimize Components

IC Engine Battery

Transmission

Electric Motor Control Strategy

9

Introduction of Hybrid Manage Complexity

Define Configuration & Optimize Components
Electrification impacts many sub- systems Requirements development and system design must take all into account.

Powertrain
Performance Drivability Torque control Motor controls Motor noise Thermal Management Energy management

HV Distribution
Battery performance Battery thermal Charging System Power management Power electronics Cabling & Fusing DC to DC

Chassis
Blended braking ABS Stability controls Steering Ride and handling Mounts Fuel system

Displays/HMI
Range indication Power limitations Charger status Efficiency aids Fault conditions Customer interaction

HVAC
Cabin Comfort Heated seats Defog/defrost NVH

System Interactions

Safety/Reliability
DFMEA Hazard analysis Reliability targets Controls Crashworthiness HV mechanization, cabling, connectors Verification and validation
Propulsion system Wheel Drive Device Ambient Air/ Environment Vehicle

Vehicle

Ambient Air/ Environment

Vehicle

Ambient Air/ Environment

HVIL

Electric machine
3 phase 3 phase 3 phase

Ambient Air / Environment HV Distribution HVIL HVIL

3 p h a se

Vehicle

3 p ha se

Motor Control/ Power Electronics HVIL HV Battery BMS Ambient Air / Environment

3 p ha se

HVL I

HVIL

DC/DC Converter Ambient Air/ Environment LV Battery

Vehicle MCU MCU MCU Battery Battery Battery Module Module Module

Hybrid Controller

Vehicle HVIL Charge Coupler HVIL HV Charger

Vehicle

Ambient Air / Environment

Vehicle

Ambient Air / Environment

Vehicle

Ambient Air / Environment

10

Manage Electrification
Optimize Interactions

IC Engine Battery

More than 1000 engine development project in the past 60 years!

Transmission

Electric Motor
Control Strategy
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AVL Transmission Service Overview

Calibration: AVL GSP ACT

Specific design, analysis and application know-how for transmissions.

Simulation:

Concept&Design: Benchmark: AVL DRIVE Testing

SW & Controls: Testing: Maneuver & event based testing Hydraulic:

Analysis:

12

Manage Electrification
Optimize Interactions

IC Engine Battery

Transmission

Electric Motor
Control Strategy
13

Battery Development at AVL

Test equipment development Cell/Pack Production Process Assurance

Testing & Benchmarking

Thermal simulation

Validation target:

Battery

System validation

300.000 km cycle life 12 years calendar life EMC targets fulfilled System interaction ok

Design Engineering

BMS series development (SW & HW)

Prototype built-up
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Manage Electrification
Optimize Interactions

IC Engine Battery

Transmission

Electric Motor
Control Strategy
15

AVL E-Drive Development

Elements
E-Motor Development

Electrical Machines

Power Electronics
Power Electronic

Emissions
EMC

16

AVL E-Drive Development

Elements
E-Motor Development

Development of customized electrical machines and power electronics Experience over large bandwidth of technologies and machine sizes

Power Electronic

Development process Know How (concept, design, validation and industrialization) Strong experience designing EMC behavior into the product

EMC

Process frontloading using experience and simulation capabilities Concept study, single prototype or series production development
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AVL Trimerics: E-Motor Development

Motor/Generator for CV Applications (PEPS)

E-Machines:
= ~ = ~ = ~ = ~

E
= ~

E
= ~

system concept

- High power density due to efficient liquid cooling - Integrated power electronics - 70% saving of space vs. standard systems - 40% saving of weight vs. standard systems - Completely electrical insulated

design & simulation

mechanical design
PEPS: Protected Electrical Power System

test on testbench
18

Manage Electrification
Optimize Interactions

IC Engine Battery

Transmission

Electric Motor
Control Strategy
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AVL Powertrain Control Services

CONCEPT & PROTOTYPE DEVELOPMENT

SERIES SOFTWARE DEVELOPMENT

Customer specific Powertrain Control Software and Function solutions

SERIES FUNCTION DEVELOPMENT

SOFTWARE VERIFICATION & VALIDATION SOFTWARE & FUNCTION DEVELOPMENT CONSULTING

Production Level SW available for: Parallel Hybrid EV with RE

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AVL Powertrain Control Services

Increase of Control Complexity
Full or Mild HEV
Hybrid Control Unit OBD

CAN

EMS

Inverter Motor Generator

Battery Control Unit

ABS ESP

Cluster

HMI

ICE

DC Motor

Battery Pack
HV Main Relay -P Battery Modules -P Pre Resistor -charge Relay HV Main Battery Modules -N

21

Manage Electrification
Optimize Interactions

IC Engine Battery

Transmission

Electric Motor
Control Strategy
22

Introduction
AVL capability in Hybrid development AVL capability in Hybrid / System engineering AVL CV Hybrid experience / References

23

System Design Key Tasks

Systematic Engineering & Development Approach

VEHICLE

POWERTRAIN

SUB-SYSTEM

Vehicle Attribute Targets and Boundaries

Topology and System Integration

Sub-System Sepcification

Top Down Approach The Vehicle Targets define the optimal system topology & component requirements.

24

System Design Key Tasks

Systematic Engineering & Development Approach

VEHICLE

POWERTRAIN

SUB-SYSTEM

Vehicle Attributes / Targets Environmental Cond. Use Cases / Regulations

System Engineering System Safety System Validation

Vehicle Benchmark System Simulation

System Integration System Calibration

Requirement Engineering System Software

25

System Design Key Tasks

Systematic Engineering & Development Approach

System

Target Definition

Fleet Tests

Phase 1: Concept System Design

Powertrain Design Component Specification

In 3: System Phase Vehicle Test Validation

Powertrain Test Component Integration

Component

Component Design

Component Test

System Details

Phase 2: Component Development Realisation / Implementation

Time
26

System Design Key Tasks

Systematic Engineering & Development Approach

Vehicle Benchmark
System
Target Definition Fleet Tests

System Simulation
Phase 1: System Concept Requirements and Requirement Engineering Design
Powertrain Design

System Calibration
In 3: System Phase Vehicle Test Validation

System Test & Validation

Powertrain Test

System Safety
Component Specification

System Software

Component Integration

Component

System Integration
Component Design Component Test

System Details

Phase 2: Component Development Realisation / Implementation

Time
27

System Design Key Tasks

Systematic Engineering & Development Approach

Interface to Project Process

Quality Gates Development Generations (Operative & Coordinating) Interface to Element Processes

28

System Design Key Tasks

Generic Timeline

Level 1

Systematic Engineering & Development Approach

Level 2

Level 3

Skill Areas

System Engineering RASI Operative Element Processes Direct System & Element Quality Gates Support Documents

Coordinating Support Documents

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System Design Key Tasks

Systematic Engineering & Development Approach
Significant Measurement Data

Vehicle Benchmarking
Objective Measurement & Quantification of Vehicle Attributes (Reference Vehicle, hybrid or nonhybrid) Vehicle Level Attribute Engineering: Definition & Quantification of the Target Attributes, the related Use- & Test Case and the Acceptance Criteria
Acc_ChassisX_smo [m/s]

-> Measures Driver input and Vehicles reaction!

4 2 0 -2

3000 2000 1000 0 2 0 600 300 0 -300

Vehicle_Speed [km/h]

100 50 0 20 10 0
130,0 131,5 133,0 134,5 136,0 137,5 time [s] 139,0 140,5 142,0 143,5 145,0

TCC_State

30

Torque [Nm]

DCDC_State

Analysis of powertrain and components attributes (performance, efficiency)

Engine_Speed [rpm]

Analysis of vehicle and powertrain functionalities

8 6

Acc_ChassisX_smo Engine_Speed TCC_Speed EM2_Speed Vehicle_Speed DCDC_State TCC_State EM2_Torque Engine_Torque

5000 4000

System Design Key Tasks

Systematic Engineering & Development Approach System Simulation - Concept
Extended and detailed simulation of entire system
Assessment of Topology (Optimize Configuration) Assessment of Component Performance Assessment of System Functionality Assessment of Fuel Efficiency, Emissions and Performance Assessment of Driveability aspects Trade-off Analysis Sensitivity Analysis

Powersplit

Benchmarking & Comparison of Hybrid Concepts

Rating of Concepts according application specific rating criteria

Double Clutch

31

System Design Key Tasks

Systematic Engineering & Development Approach System Simulation - Support
Detailing of Component Specification:
Performance Requirements at appl. spec. Performance Tasks Lifecycle loads load distribution (input for reliability & lifecycle)
Cycle 1 Cycle 2 Cycle 3

Real World Usage Profiles

Vehicle Simulation

Detailing of System Function Specification

system control functionality Communication demands torque & energy management

Cycle n

Component load profiles

Load distribution = collective load

Recuperation Event Distribution - Rated with Road Distribution from RWUP
9% 8% 7% 6% 5%

Target Achievement Tracking

Events
4%

1 2 3

Power [kW]

10

11

12

Continuous Monitoring of Target Achievement (virtual target tracking)

Generation of SIL, MIL & HIL Model Development for Integration- & Testing- Support

Cycle 1 Cycle 2 Cycle 3 Cycle n

Cycle 1 Cycle 2 Cycle 3 Cycle n

240 220 200 180 160 140 120 100 80 60 40 20

Introduction of Supplier Information

3% 2% 1% 0%

Energy [kJ]

32

System Design Key Tasks

Systematic Engineering & Development Approach Requirement Engineering I
Systematic Description of
Customer oriented, traceable, consistent, Vehicle (Application, Usage & Boundary Conditions)

Use Cases Requirements

(technical & functional)

Powertrain Topology
Components & Sub- Components Powertrain Functions (partly functional Architecture) Operations condition (Driving & Non-driving)

Requirement Functions

Functions

Product Functions

Systematic specification of components and Control SW function requirements

Powertrain Elements & Components

Definition of Test Cases for Component & System/Vehicle Testing

Calibration Targets Acceptance Criteria for Validation

Powertrain System
Vehicle

33

System Design Key Tasks

Systematic Engineering & Development Approach Requirement Engineering II
Systematic Development & Description of System Functionality
Driving Functions (e.g. el. Drive, Recuperation, )
Non- Driving Functions (e.g. Charging from Grid, ) Auxiliary Control Functions (e.g. Board Net Supply, Cooling, ) Calibration Guidelines Acceptance Criteria
System Feature(s) Driving Feature
Torque Distribution Energy Management Engine Start Stop Drivetrain Configuration Auxiliary Control Development Stability Comfort Drive Brake Charge Discharge

Generation of System related Requirements for SW Development Generation Software related Use& Testcases for SW Development & SW Testing

Non Driving Feature

Production EOL Safety Diagnosis Vehicle Operation Maintenance Immobilizer

34

System Design Key Tasks

Systematic Engineering & Development Approach Software Development
(System Level Functionality) Development of SW Architecture Interface Specification
System Interface Base- & Application SW Interface

SW Component Specification SW Component Requirement Specification Model Base Coding & Auto Code Generation SW Integration (into target Control Unit) SW Testing (component & system level), incl. test documentation SW Documentation Calibration Guidelines
Application Lifecycle Management Label repository
Integrity (MKS)
ADD (Visu-IT) Automotive Data Dictionary (in discussion)

Naming convention

Modeling

Requirement engineering

Modeling Guideline Code generation MBFS-ASAM Blockset

Implementation Guideline MBFS-ASAM Library SW Build

Matlab / Simulink

TargetLink Make, Perl

Ascet MD

Ascet SE Compilers: Altium

Verification &Validation
Model Testing & Rapid Prototyping HiL test
Full Size

AVL Plant model

Intecrio
ES910 ES1000

RTI
MicroAutobox

PT Labcar

35

System Design Key Tasks

Systematic Engineering & Development Approach System Integration
Mechanical, thermal, electrical and functional integration Definition of Controller topology and communication matrix Definition of Changes for base vehicle interfaces Packaging

Powertrain
Control Units Wiring Harness (LV, HV, CAN, ) Cooling System

Supplier Management Commissioning Initial Testing

36

System Design Key Tasks

Systematic Engineering & Development Approach System Safety Development
Safety Assessment Identification of Risks / Hazards
Functional, Mechanical, electrical (HV) and chemical safety

Functional Safety Concept Generation of Safety Requirements

Methodology in place: Hazard analysis, FMEAs Safety Development according Market & Application related Standards & Regulations (e.g. ISO 26262 compliance for PC)

Severity Exposure Controllability

Technical Safety Concept Compliant Technical Solution Safety Process according Standard Safety Testing Verification of Solution

37

System Design Key Tasks

Systematic Engineering & Development Approach
Counts
230

System Testing
Test planning (Component Test & System Tests) = Generation of DVP
Component Testing
Functional Testing Integration Testing Lifecycle & Reliability Testing
220 210 200 190 180 170

Shutdown Positions
270 250 240 260

10

280

290 300 310 320

330

340

Valeo All Bosch

350

TDC Cylinder 1

10

160

20

150 140 130 120 110 100 90 80 70 60 50 40

30

Definition of Acceptance Criteria

MIL / SIL / HIL Testing (Test Execution) Component Testing on related Test- beds Powertrain Testing (with battery simulator) Initial Calibration Road Testing (introduction of in vehicle test equipment)
38

System Design Key Tasks

Systematic Engineering & Development Approach Hybrid System Calibration
Deep understanding of overall system and functional interactions required
Analysis of Powertrain Boundaries Definition of Functionality Matrix Definition of Calibration Requirements and Priority

Robustness investigation (Pdiagram) for control functions in order to define calibration targets
Calibration process with defined quality gates Coordinated, iterative approach between component calibration & system calibration Introduction of specific tools & equipment (battery simulator) Simulation support for specific criteria

Detailed Analysis Field of Calibration

Calibration and Test Planning

39

System Design Key Tasks

Systematic Engineering & Development Approach System Project Management
Continuous Customer Communication Continuous Project Target Tracking & Monitoring Ensure System Development Process Compliance Ensure Project Quality

Final Release of Project Documents

Supplier Management Change- & Concern Management

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Integrated Toolchain for System Development

AVL Instrumentation & Test Systems
Cell/Module/Battery Simulation Powertrain Simulation Vehicle Simulation

ICE TESTBED

Battery/Motor Testing / HIL

BATTERY TESTBED HIL DEVELOPMENT System Testing / HIL Chassis Dyno

POWERTRAIN TESTBED

AVL-CRUISE AVL-BOOST AVL-EXCITE AVL-FIRE

Vehicle Development AVL-CAMEO AVL-DRIVE Vehicle Validation Prod. Signoff

AVL Software Tools for Powertrain System Development & Optimization

41

AVL Offer Hybrid Development Services

up to SOP
HEV Benchmarking Simulation & Evaluation Target Definition

System Development & Requirements Engineering

Mechanical Integration Functional and E/E Integration Software Development System Safety Development & Assessment Component Development (e.g. Battery Systems) Test, Verification & Validation planning and execution Vehicle build and testing Hybrid System Controls and Calibration Consulting
42

Introduction
AVL capability in Hybrid development AVL capability in Hybrid / System engineering AVL Hybrid experience / References

43

AVL Hybrid Solutions & References

Micro Hybrid Systems (Start / Stop)

AVL
BMW Efficient Dynamics Citroen C3 Stop&Start CPT Prototype (Audi A4)

Smart Starter Motor (SSM)

Belt Starter Generator (BSG)

44

AVL Hybrid Solutions & References

Mild Hybrid Systems

AVL
Mercedes-Benz S400 BlueHybrid AVL Turbohybrid P1 Diesel Mild Hybrid

45

AVL Hybrid Solutions & References

Parallel Full Hybrid Systems

AVL
Peugeot 3008 HYbrid4 Porsche Cayenne S Hybrid JL&R V6D Hybrid

Hybrid Manager

Differential (front axle) Battery

Automatized Manual Transmission

Inverter

FEAD

ICE Differential (rear axle)

electrification of auxiliaries

electrification of auxiliaries

electrification of auxiliaries

46

AVL Hybrid Solutions & References

Parallel Full Hybrid Plug- In Systems

AVL
BMW Vision Efficient Dynamics Fisker Karma Plug-In Prototype

E-Motor / Generator Battery

E-Motor / Generator

Generator

Differential (rear axle)

DCT Inverter

Inverter

ICE
Differential (front axle)

Differential

ICE
Battery

E-Motor / Generator

electrification of auxiliaries

47

AVL Hybrid Solutions & References

EV & EV with RE Systems (Series Configuration)

AVL
Jaguar C-X75 AVL EVARE Audi A1 e-tron

Micro turbines

Generators

E-Motors

Battery

Inverter

E-Motors

48

AVL Hybrid Solutions & References

EV with RE Systems (Series / Parallel Configuration)

AVL
VW Golf Twin Drive GM Volt GETRAG Boosted Range Extender

E-Motor / Generator

Clutches

Differential (front axle)

E-Motor / Generator

Generator

Battery

ICE
Inverter Battery Differential

ICE Inverter

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Electrification @ AVL
Hybrid- & EV Production Program References
Mild HEV Start Stop Concept Demo Car Fleet SOP Concept Demo Car Fleet SOP Concept Demo Car Fleet SOP Concept Demo Car Fleet SOP Concept Demo Car Fleet SOP Concept Demo Car Fleet SOP 15 7 14 12 7 1 7 5 1 5 1 4 4 20 3 3 1 2
50

RE EV

Pure EV

Plug In

Full HEV

AVLs Electrification Knowledge is NOT limited to Passenger Cars!

Peterbilt / Eaton

Agency for Defense Development

MAN

Fisher Coachworks

Ford Otosan

John Deere and Deutz

Mitsubishi Fuso / Freightliner

Likino Bus Plant (LIAZ)

Amor Holdings
51

AVL ELECTRIC VEHICLE WITH RANGE EXTENDER

52