2011 HORIBA Europe GmbH. All rights reserved. · 2011-05-12 · © 2011 HORIBA Europe GmbH. All...
Transcript of 2011 HORIBA Europe GmbH. All rights reserved. · 2011-05-12 · © 2011 HORIBA Europe GmbH. All...
© 2011 HORIBA Europe GmbH. All rights reserved.© 2011 HORIBA Europe GmbH. All rights reserved.
© 2011 HORIBA Europe GmbH. All rights reserved.
An Overview of HEV, E-motor, and Transmission Test Stands Using HIL Methods
Norm NewbergerHORIBA Automotive Test Systems
75 years of design refinement & technological improvement
© 2011 HORIBA Europe GmbH. All rights reserved.
Simulation Block Diagram
Virtual Battery: A HIL DC Power Simulation
E-motor Test Stands
Virtual Engine: A HIL Engine Torque Simulation
Wheel Slip: A HIL Tire to Road Surface Simulation
1
2
3
4
5
Discussion PointsAn Overview of HEV E-motor and Transmission Test Stands using Virtual Vehicle HIL Methods
© 2011 HORIBA Europe GmbH. All rights reserved.
Simulation Block Diagram
Virtual Battery: A HIL DC Power Simulation
E-motor Test Stands
Virtual Engine: A HIL Engine Torque Simulation
Wheel Slip: A HIL Tire to Road Surface Simulation
1
2
3
4
5
Discussion PointsAn Overview of HEV E-motor and Transmission Test Stands using Virtual Vehicle HIL Methods
© 2011 HORIBA Europe GmbH. All rights reserved.
Outside Temperature,Altitude, Humidity
Controller Commands
Pedal Position,
Brake Pedal, Vehicle Mode
Small (5.800H x 6.555D x 10.660W Rail Mount
2 Ethernet 100mb USB 2 serial portsProfibus or other PC104+ connectors
24V power Supply
Up to three IO Boards 2 are shown with digital (20) & analog I/O (8), Encoder (1), Frequency (2), & Bridge Type Transducers
6x CANbusPorts
Simulation Diagram:HEV Test Cell / Models
Vehicle Controller
Sub-system Controllers (ECU, BMS / EMU, PCU / TPIM, TCU, ABS, ESC…)
Bus Level commands
Power Flow
High Level commands
© 2011 HORIBA Europe GmbH. All rights reserved.
Controller Commands
Outside Temperature,Altitude, Humidity
Trans-missionsCoupling Tire ModelDrivetrain
Simulation Diagram:HEV Test Cell / Models
Vehicle Controller
MechanicalAccessories
Sub-system Controllers (ECU, BMS / EMU, PCU / TPIM, TCU, ABS, ESC…)
Pedal Position,
Brake Pedal, Vehicle Mode
HORIBA Calibration & DoE Software Tools
Bus Level commands
Power Flow
High Level commands
Small (5.800H x 6.555D x 10.660W Rail Mount
2 Ethernet 100mb USB 2 serial portsProfibus or other PC104+ connectors
24V power Supply
Up to three IO Boards 2 are shown with digital (20) & analog I/O (8), Encoder (1), Frequency (2), & Bridge Type Transducers
6x CANbusPorts
© 2011 HORIBA Europe GmbH. All rights reserved.
Outside Temperature,Altitude, Humidity
Controller Commands
Simulation Diagram:HEV Test Cell / Models
HORIBA Calibration & DoE Software Tools
Trans-missionsCoupling Tire ModelDrivetrain
MechanicalAccessories
Reduc-tion
Battery Pack
Sub-system Controllers (ECU, BMS / EMU, PCU / TPIM, TCU, ABS, ESC…)
Pedal Position,
Brake Pedal, Vehicle Mode
ElectricAccessories
E-Motor
Vehicle Controller
or
Bus Level commands
Power Flow
High Level commands
© 2011 HORIBA Europe GmbH. All rights reserved.
Controller Commands
Outside Temperature,Altitude, Humidity
or
Simulation Diagram:HEV Test Cell / Models
Vehicle ControllerHORIBA Calibration & DoE Software Tools
Bus Level commands
Power Flow
High Level commands
Trans-missionsCoupling Tire Model
Reduc-tion
Drivetrain
Battery PackE-Motor
MechanicalAccessories
Battery Pack
Virtual Battery
or
Virtual Engine
Engine
Sub-system Controllers (ECU, BMS / EMU, PCU / TPIM, TCU, ABS, ESC…)
Pedal Position,
Brake Pedal, Vehicle Mode
ElectricAccessories
or
© 2011 HORIBA Europe GmbH. All rights reserved.
Replicates terminal characteristics of an HEV, EV battery
Voltage
Charge/Discharge rate
Capacity, Ohms, etc
Flexible and adaptableChemistries
Configuration
Calibration to MFG specific cells
Retrofits into any DC-DC Power supply
Replaces both the batteryand the Battery Management System!
Temperature Management
SOC, DOD, Power limits, etc…
Predictive Capacity (short, long)
HORIBA Virtual BatteryMakes DC Power Supply act as if it were an actual battery
© 2011 HORIBA Europe GmbH. All rights reserved.
Virtual Battery System Benefits No battery maintenance
Perfectly repeatable
Parallel development of battery and powertrain
Avoids test cell down time for facility improvements for battery pack “events”
Eliminates lost or void testing because of prototype battery packs
Battery pack state (SOC, Life, Temperature) set instantly (no pre-condition test)
© 2011 HORIBA Europe GmbH. All rights reserved.
Tran
sfor
mer
Converter & Motor Inverters
480 VAC Bus
Test Cell
Bedplate
Headstock
STARS or TAS
Ethernet Real Time
3 phase AC Power
TP 260 AC DynoSystemM
otor
AM
otor
A
Mot
or B
Mot
or B
TPIM /PCU
PPPP
VFD Drive System
VirtualVehicle
-
Use
r Con
tact
40-500 VDC
Electric OutputDynamometer
Virtual Engine orICE Input
SPARC I/O interface or Canbus
Hybrid Transmission
3 phase AC Power
Use of Virtual BatteryTypical HEV Test Cell Diagram
© 2011 HORIBA Europe GmbH. All rights reserved.
Tran
sfor
mer
Converter & Motor Inverters
480 VAC Bus
Test Cell
Bedplate
Headstock
STARS or TAS
Ethernet Real Time
3 phase AC Power
TP 260 AC DynoSystemM
otor
AM
otor
A
Mot
or B
Mot
or B
TPIM /PCU
PPPP
VFD Drive System
VirtualVehicle
-
Use
r Con
tact
40-500 VDC
Electric OutputDynamometer
Virtual Engine orICE Input
SPARC I/O interface or Canbus
Hybrid Transmission
3 phase AC Power
20-700V DC regulated• Current / Power to user request• Very low ripple • Symmetric voltage around earth grnd.• Voltage equalization on start up• Flexibility to convert to motor inverter• Standard 480V Variable frequency drive
DC Supply
UVTrip
HORIBA’s HEV DC InterfaceCircuit Breaker
(full load interrupt capability
Use of Virtual BatteryTypical HEV Test Cell Diagram
Connectors supplied by Horiba(Twist locked)
© 2011 HORIBA Europe GmbH. All rights reserved.
20-700V DC regulated• Current / Power to user request• Very low ripple • Symmetric voltage around earth grnd.• Voltage equalization on start up• Flexibility to convert to motor inverter• Standard 480V Variable frequency drive
DC Supply
UVTrip
HORIBA’s HEV DC InterfaceTran
sfor
mer
Converter & Motor Inverters
480 VAC Bus
Test Cell
Bedplate
Headstock
STARS or TAS
Ethernet Real Time
3 phase AC Power
TP 260 AC DynoSystemM
otor
AM
otor
A
Mot
or B
Mot
or B
TPIM /PCU
PPPP
VFD Drive System
VirtualVehicle
-
Use
r Con
tact
40-500 VDC
Electric OutputDynamometer
Virtual Engine orICE Input
SPARC I/O interface or Canbus
Hybrid Transmission
3 phase AC Power
Virtual Battery
+
Use of Virtual BatteryTypical HEV Test Cell Diagram
40 – 1200V DC regulatedwith standalone systems
Circuit Breaker(full load interrupt
capability
© 2011 HORIBA Europe GmbH. All rights reserved.
Tran
sfor
mer
Converter & Motor Inverters
480 VAC Bus
Test Cell
STARS or TAS
Ethernet Real Time
TPIM /PCU
VFD Drive System
Use
r Con
tact
SPARC I/O interface or Canbus
20-700V DC regulated• Current / Power to user request• Very low ripple • Symmetric voltage around earth grnd.• Voltage equalization on start up• Flexibility to convert to motor inverter• Standard 480V Variable frequency drive
DC Supply
UVTrip
HORIBA’s HEV DC Interface
Virtual Battery
Circuit Breaker(full load interrupt
capability
40 – 1200V DC regulatedwith standalone systems
E-Motor Component Test Stand
Use of Virtual BatteryHEV Test Stand Examples
© 2011 HORIBA Europe GmbH. All rights reserved.
Tran
sfor
mer
Converter & Motor Inverters
480 VAC Bus
Test Cell
STARS or TAS
Ethernet Real Time
TPIM /PCU
VFD Drive System
Use
r Con
tact
SPARC I/O interface or Canbus
20-700V DC regulated• Current / Power to user request• Very low ripple • Symmetric voltage around earth grnd.• Voltage equalization on start up• Flexibility to convert to motor inverter• Standard 480V Variable frequency drive
DC Supply
UVTrip
HORIBA’s HEV DC InterfaceCircuit Breaker
(full load interrupt capability
40 – 1200V DC regulatedwith standalone systems
E-motor Assist Axle Test Stand
Virtual Battery +VirtualEngine
Virtual Battery
With 4 Wheel Dynos
Use of Virtual BatteryHEV Test Stand Examples
© 2011 HORIBA Europe GmbH. All rights reserved.
Tran
sfor
mer
Converter & Motor Inverters
480 VAC Bus
Test Cell
STARS or TAS
Ethernet Real Time
TPIM /PCU
VFD Drive System
Use
r Con
tact
SPARC I/O interface or Canbus
20-700V DC regulated• Current / Power to user request• Very low ripple • Symmetric voltage around earth grnd.• Voltage equalization on start up• Flexibility to convert to motor inverter• Standard 480V Variable frequency drive
DC Supply
UVTrip
HORIBA’s HEV DC InterfaceCircuit Breaker
(full load interrupt capability
40 – 1200V DC regulatedwith standalone systems
Virtual Battery +VirtualEngine
HEV Dual-Mode Transmission Stand
Use of Virtual BatteryHEV Test Stand Examples
© 2011 HORIBA Europe GmbH. All rights reserved.
Tran
sfor
mer
Converter & Motor Inverters
480 VAC Bus
Test Cell
STARS or TAS
Ethernet Real Time
TPIM /PCU
VFD Drive System
Use
r Con
tact
SPARC I/O interface or Canbus
20-700V DC regulated• Current / Power to user request• Very low ripple • Symmetric voltage around earth grnd.• Voltage equalization on start up• Flexibility to convert to motor inverter• Standard 480V Variable frequency drive
DC Supply
UVTrip
HORIBA’s HEV DC Interface
Virtual Battery
Circuit Breaker(full load interrupt
capability
40 – 1200V DC regulatedwith standalone systems
Use of Virtual BatteryHEV Test Stand Examples
HEV Fuel Economy and Range Calibration Chassis
Dyno
© 2011 HORIBA Europe GmbH. All rights reserved.
Tran
sfor
mer
Converter & Motor Inverters
480 VAC Bus
Test Cell
STARS or TAS
Ethernet Real Time
TPIM /PCU
VFD Drive System
Use
r Con
tact
SPARC I/O interface or Canbus
20-700V DC regulated• Current / Power to user request• Very low ripple • Symmetric voltage around earth grnd.• Voltage equalization on start up• Flexibility to convert to motor inverter• Standard 480V Variable frequency drive
DC Supply
UVTrip
HORIBA’s HEV DC InterfaceCircuit Breaker
(full load interrupt capability
40 – 1200V DC regulatedwith standalone systems
Virtual Battery +VirtualEngine
Virtual Battery
Use of Virtual BatteryHEV Test Stand Examples
HEV Powertrain Test StandWith 2 Wheel Dynos
© 2011 HORIBA Europe GmbH. All rights reserved.
Simulation Block Diagram
Virtual Battery: HIL DC Power Simulation
E-Motor Test Stands
Virtual Engine: HIL Engine Torque Simulation
Wheel Slip: HIL Tire to Road Surface Simulation
1
2
3
4
5
Discussion Points
© 2011 HORIBA Europe GmbH. All rights reserved.
E-Motor Component Test stands
Ergonomic MechanicsHeadstock – robust, universal (with adapters), ease of useBase Plate – robust vibration isolation, lab retrofits w/o inertia mass, minimizes installation costOne or Two devices under test
a
© 2011 HORIBA Europe GmbH. All rights reserved.
E-Motor Component Test stands
Comprehsive Test CapabilitiesVoltage, current, RMS measurements.Power Analyzer interface, DAC(temp, vibration)2000V isolaton, safe connections, up to 5Khz s/sRemote DAC (CanBus, Ethercat, Profibus)Automation, simulation/control, process control
© 2011 HORIBA Europe GmbH. All rights reserved.
E-Motor Component Test stands
Complete Test SolutionsDUT Support - (inverter / DC Power 40–700Vdc).DUT Support - Cooling / Ambient TemperatureDUT Support - Lock Rotor TestingTorsional Modeling & Analysis
© 2011 HORIBA Europe GmbH. All rights reserved.
Dynas TR150M260 (16kRPM)
Dynas TR 260M450 (18KRPM)
Dynas TR 230M550 (16KRPM)
Dynas TR 380M1200 (12KRPM)
Flexible & Diverse Dynos for E-motor
Powertrain Testing with a virtual engine FWD
Powertrain Testing with a virtual engine RWD.
AC Dyno xxx kW M= xxxx Rated Torque (N-m)
2 DUT for torque extension of dyno
Multi-Sample reduces total test time for Statistical significant results
Double/Single Ended Ratings Durability Test Stand Reuse as VE-PT* Input Dyno*VE-PT: Virtual Engine PowerTrain
© 2011 HORIBA Europe GmbH. All rights reserved.
Simulation Block Diagram
Virtual Battery: HIL DC Power Simulation
E-Motor Test Stands
Virtual Engine: HIL Engine Torque Simulation
Wheel Slip: HIL Tire to Road Surface Simulation
1
2
3
4
5
Agenda / Table of Contents
© 2011 HORIBA Europe GmbH. All rights reserved.
HEV/PHEV/RE-EV Have common APU The ICE is a prefered Auxilary Power Unit because of energy density of fuel
Combustion will have increasing efficiencies (~33% ~50%)Electified Powertrains offer opportunites for Fuel Economy optimization
Comparison of Energy Storage Densities & Power Densities
© 2011 HORIBA Europe GmbH. All rights reserved.
HEV/PHEV/RE-EV Have common APU The ICE is a prefered Auxilary Power Unit because of energy density of fuel
Production HEVs uses ICE as secondary energy source
Hybrid Electric Vehicle Structures
ICE development will continue and must be in parallel with remainder of powertrain
Torque / power production and related harmonics are crucial to verification, proper validaiton, & calibration of the powertrain
HORIBA’s Virtual Engine solves parallel development issues
© 2011 HORIBA Europe GmbH. All rights reserved.
Inertia = 0.084kg-m2
450N-m rated, 180% OL
269mm Dia, ½ shaft clearence
Development, Durability, NVH)
Flexible & Diverse Dynos for E-motor
Inertia = 0.75kg-m2
1200N-m rated 200%OL
Logitudinal ICE orientation
Development, Durability, NVH
Inertia = 0.13kg-m2
650N-m rated, 180%OL
269mm Dia, ½ shaft clearence
Development, Durability, NVH
DynasTP260M450 DynasTP460M650 DynasPT380M1200
© 2011 HORIBA Europe GmbH. All rights reserved.
Engine Map Simulation, with closed throttle & engine friction
Engine Inertia Simulation, with or with out flywheel mass,
Altitude, humidity, air temperature affects on map
Extensible for fuel consumption map as FE approximation
Full Featured Simulation with Validated Results
© 2011 HORIBA Europe GmbH. All rights reserved.
Full Featured Simulation with Validated Results
Engine Torque Pulse Simulation based on combustion cycle and mechanical configuration (1 to 16 cylinder, fuel type, boost, etc)
Variable Cylinder activation
Pedal Map Simulation: ECU intervention of throttle based on vehicle speed, and gas pedal demandFuel Cut: ECU intervention for fuel economy when gas pedal tips out to maintain constant vehicle velocity
© 2011 HORIBA Europe GmbH. All rights reserved.
Engine Start Simulation (Typical)
Engine Start Simulation for HEV (1 rev.)
Engine Idle Simulation (not shown)
Engine Accessory Load Simulation
Full Featured Simulation with Validated Results
= Crank Angle) = Torque Demand Signal
= Pumping & friction pulses = Speed (RPM
© 2011 HORIBA Europe GmbH. All rights reserved.
Torque Intervention during shift or clutch of transmission, coupling, or differential
Full Featured Simulation with Validated Results
© 2011 HORIBA Europe GmbH. All rights reserved.
Engine Crank & Timing Pulse Simulation
Cam, injector, other timing pulse simulation
Full Featured Simulation with Validated Results
© 2011 HORIBA Europe GmbH. All rights reserved.
Engine Speed deviation at WOT Same
Engine Speed deviation at IDLE same
Engine Speeds are the Same During a Road Load Simulation of transient durability Cycle
Getting it right…. Comparison in Durability Tests
SAE 2010-01-0919
Virtual Engine vs. Real Engine
© 2011 HORIBA Europe GmbH. All rights reserved.
Transmission Output Torque are the Same During a Road Load Simulation of transient durability Cycle
Getting it right…. Comparison in Durability Tests
SAE 2010-01-0919
Virtual Engine vs. Real Engine
© 2011 HORIBA Europe GmbH. All rights reserved.
Simulation Block Diagram
Virtual Battery: HIL DC Power Simulation
E-Motor Test Stands
Virtual Engine: HIL Engine Torque Simulation
Wheel Slip: HIL Tire to Road Surface Simulation
1
2
3
4
5
Discussion Points
© 2011 HORIBA Europe GmbH. All rights reserved.
Performance / NVH / Calibration
Electrical Inertia Simulation of Wheel + Tire ± Brake RotorCorrect damping of driveline natural frequencyOpen Tire Model including “simplified model”
Correct wheel speed dynamics (and all upstream driveline shafts)Correct dynamic tire force for torque limits on performance events and energy recoveryReproduces driveline natural frequency and characteristics
Connecting to the Road with Virtual WheelPatent Pending wheel slip controls:
Drivability
Efficiency
© 2011 HORIBA Europe GmbH. All rights reserved.
HORIBA Wheel Slip SimulationExtending dynamic capabilities to Road Load Simulation
Functional Split between TAS & Dyno Control
STARS calculates weight transfer per wheel and YAW based on the road segment
STARS performs “vehicle driver” functions of pedal, brake, turning, gear select, powertrain mode, etc
calculates max. transferable force (tire model) and acts as torque controller for wheel dynamometer to simulate road load and wheel slip
controls simulated wheel speed for stick / slip, tire dynamics, and wheel-tire inertia
© 2011 HORIBA Europe GmbH. All rights reserved.
High performance pernament magnet: >40,000RPM/sec.4000N-m, 1.05kg-m2 inertia105% OL.Most capable
State of the Art, AC induction : > 8,500RPM/sec..4000N-m, 8.5kg-m2 inertia200% OLCapable of abuse and special events (split mu, clutch dump, etc….)
HORIBA’s unique upgrade to very high inertia legacy dynamometersAvoids disruption of changing motor & driveCapable of abuse and special events (split mu, clutch dump, etc….)
Dynamometers for Wheel SlipWheel Spin events limited only by dynamometer acceleration rates
© 2011 HORIBA Europe GmbH. All rights reserved.
Vehicle Speed (kph) vs TimeLeft Wheel Torque (N-m) vs TimeLeft Wheel Speed (kph) vs Time (track & lab)
Validation in Contract Test ServicesVirtual Wheel using upgrade approach:
Clutch Dump at Max. Acceleration
Simple model or PacejcaSimple model for passenger care used
© 2011 HORIBA Europe GmbH. All rights reserved.
Thank you