1/15 Development of “Hino MELPHA Plug in Hybrid … · Head Office 3–1–1, Hinodai, Hino-shi,...

Copyright © 2016 Hino Motors, Ltd. All rights reserved.

1/15

Development of “Hino MELPHA Plug-in Hybrid bus“

with combination of Existing HIL and TruckMaker

To make the world a better

place to live by helping people

and goods get where they need

to go - safely, economically and

with environmental

responsibility - while focusing

on sustainable development.


2/15

Company Information

Company Name Hino Motors, Ltd.

Head Office 3–1–1, Hinodai, Hino-shi, Tokyo, Japan

Employees* 31,020

Products

Touring Coach Low-floor Bus

Heavy-Duty Trucks

HINO700 series

Medium-Duty Trucks

HINO500 series

Light-Duty Trucks

HINO300 series

Medium & Light-Duty Trucks

HINO600 series

Total lineup – Heavy / Medium / Light Duty Trucks and Buses

http://www.hino-global.com/products/trucks/500.html


3/15

Sales company

Manufacturing company

Parts Depot company

Sales / Manufacturing company

HINO Motors location

ThailandPhilippines

Malaysia

USA

Taiwan

Australia

Indonesia

Vietnam

Canada

Pakistan

ChinaBelgium

Colombia

Russia

Mexico

About 80 Countries / Areas of Sales (FY2015)

Venezuela

UAE

India

HQ, Hino Plant

Nitta

Plant

Koga Plant

Hokkaido

Memuro

Proving Ground

Ibaraki

Proving

Ground

Hamura

Plant


4/15

ＥＶ：Short

mileage

ＦＣＶ：middle

mileage

ＨＶ・pHV：Typical Low Emission VehicleLow Emission Diesel：long

mileage

We charge of this domain.

Range of low emission vehicle


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Length･Width・Height

8.9m･2.3m･3.0 m

Passengers 32+1(Driver)

GVW 10,765kg

Engine Max 169kW

Motor Max 175kW

Battery 40kWh(Li-ion)

Charging

Normal : AC200V

Rapid : CHAdeMO

Max Speed 70 km/h

Specification of Plug-in Hybrid Bus

Hino Motors started pre-production of the Plug-in Hybrid bus in 2016

External view


6/15

Power train system

Specification of Plug-in Hybrid Bus

Drive mode(Hybrid)

Charge

Discharge

Drive mode(EV)

Charge

Discharge

Engine

stopped

Clutch

Disconnect

Clutch

Connect


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System of Plug-in Hybrid Bus

CCU

TCU ECU

VCU PHV-ECU

AMTEngine

Clutch

plateMotor

inverterLi-ion

BatteryTransfer

Gear

Additional new devices for PHV-Bus Conventional system

First step : easy to build up HILS utilize already product devices.

To be realization above system is important to build up HILS.


8/15

How to build up effective the HILS

1st step: debug of software process

The 1st HILS have to debug huge algorithm of software.

2nd step: calibration of parameters process

The 2nd HILS is necessary to calibrate vehicle parameters.

Target system increases power efficiency and fuel efficiency.

Quicker performance of test maneuvers in

all possible conditions and repetition.

2nd HILS has been improved according to 1st HILS and the

added TruckMaker.


9/15

1st HILS for software debug process

CCU

VCUTCU

PHVDriver operation devices

ECUプラントモデル

TransmissionTransmissionTransmission

プラントモデルプラントモデル

Motor / Inverter



transfer batteryTransmission

Motor/

Inverter

Plant models

Control Desk

Target ECU

specification

coding

Verification on HILS

implementation

revise

･1st HILS description

･Work flow of create software

start

Product ECU

METER

CLUSTER


10/15

2nd HILS for calibration of parameters process

CCU

VCUTCU

PHV

ECUプラントモデル



Motor / Inverter




Motor/

Inverter

Plant models

Additional TruckMaker

Target ECU

･2nd HILS description

Driver

Condition

Road

Data

Target

Vehicle

Speed

input

Acceleration pedal signal

Brake pedal signal

Gear position signalVehicle

speed

Product ECU

METER

CLUSTER


11/15


CCUPHVTruckMaker

Target ECUTarget vehicle speed profile

For Japanese regulation

The field road data profile

Same driver condition

Setting parameters

Result of evaluate

power efficiency

Mo

to

r T

orq

ue

N

m

Motor Speed rpm

Motor T

orque#5 N

m

Motor T

orque#4 N

m

Motor T

orque#3 N

m

Motor T

orque#2 N

m

Motor T

orque#1 N

m

Fuel or electricity

efficiency


12/15



13/15

Exemplary results for simulation precision

Shopping plaza

Station A Station B

Route of bus service

Shopping plaza→station A→shopping plaza→station B→shopping plaza

4.5km 4.5km 4.7km 4.7km total 18.4km

Plug-in Hybrid bus stared run service on the field.

Results of comparison : fuel & electricity efficiency.

Field data HILS

Fuel efficiency(km/L)

Field data HILS

Electricity efficiency(kWh/km)

6% 14%


14/15

Running of Plug-in Hybrid Bus on the field


15/15

Development time efficiency

Develop

Term

1

Month

2

Month

3

Month

4

Month

5

Month

6

Month

7

Month

8

Month

9

Month

Location

of

validation

Validation in the laboratory Validation on the vehicle

Previous

ProcessConsider

system

Specific

ation

Design Debug calibration of parameters General validation

Current

process

Consider

system

Specification→design→HILS

Calibration

of

parameters

General

validation3 months reduction

Stage of create software Stage of Evaluation

Exemplary development schedule for the prototype

Include calibration

Succeeded in reduction of 3 months thanks to

removed calibration process with combination of

Existing HIL and TruckMaker.


16/15

Thank you for your attention


17/15

After sheets for reference


18/15

Shopping plaza

Station A Station B

３．走行データ解析

Route of bus service

Shopping plaza→station A→shopping plaza→station B→shopping plaza

4.5km 4.5km 4.7km 4.7km total 18.4km


19/15

2nd HILS for adaption of parameters process

CCU

METER

CLUSTERVCUTCU

PHVDriver operation devices

ECU

プラントモデル



Motor / Inverter




Motor/

Inverter

Plant models

Control Desk

Target ECU

specification

coding

Verification on HILS

implementation

revise

HILS description

Work flow for create software

start

1/15 Development of “Hino MELPHA Plug in Hybrid … · Head Office 3–1–1, Hinodai, Hino-shi,...

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