Electric Motor Simulations - ETAS · · 2018-03-19Electric Motor Simulations −Electric...

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Electric Motor Simulations




A Global and Growing Company




Leading Provider of Solutions and Services for Embedded Systems

Numbers

apply for

ETAS and

ESCRYPT

− ETAS with over 850 associates is part of the Bosch Group

− Revenue: 149 million EUR in 2013

− ETAS subsidiary ESCRYPT is a specialist for embedded systems security

ETAS Customers and Domains ESCRYPT Customers and Domains

Trusted by OEMs, tier one and ECU suppliers, as well as engineering service providers:

The ESCRYPT customer base includes:

Commercial Vehicles

Automotive Heavy Duty Engines Railway Powertrain Construction Machines

Consumer Electronics Off-Highway

Automotive

Mobile Machines & Transportation Energy Consumer Electronics Mobile Devices Industrial Automation

Financial & Government Logistics Health Care





Truly International – ETAS is present in 13 countries

Russian

Federation

Moscow

Togliatti

P.R. China

Beijing

Changchun

Chongqing

Guangzhou

Shanghai

Wuhan

India

Bangalore

Pune

Japan

Nagoya

Utsunomiya

Yokohama

Korea

Seoul

Thailand

Bangkok

Headquarters

of the region

Germany Headquarters)

Stuttgart

USA

Ann Arbor

Brazil

São Paulo

France

Saint-Ouen

Italy

Turin

Sweden

Göteborg

United Kingdom

Derby

York




Our Solution Portfolio

Software Engineering

Test and Validation

Measurement, Calibration, Diagnostic

Embedded Security

Real Time Application

ETAS Portfolio

ETAS Product

Consulting with Engineering Services

Virtualization Technology




ETAS Products within the V-Model

Release

Calibration

Validation

Vehicle Integration

Vehicle and System Environment

System Test

ECU- Integration

ECU electronic control unit

Software Integration

Software Implementation

Software Architecture

Software Functions

ISOLAR-A

ASCET-MD

INTECRIO

EHOOKS

ASCET-SE

LABCAR HiL

Virtual Validation Platform

INCA FLOW

INCA

ASCMO

ISOLAR CODER

RTA-OS, -RTE, COMASO




LABCAR HiL within the V-Model

Release

Calibration

Validation

Vehicle Integration

Vehicle and System Environment

System Test

ECU- Integration

ECU electronic control unit

Software Integration

Software Implementation

Software Architecture

Software Functions

ISOLAR-A

ASCET-MD

INTECRIO

EHOOKS

ASCET-SE

LABCAR HiL

Virtual Validation Platform

INCA FLOW

INCA

ASCMO

ISOLAR CODER

RTA-OS, -RTE, COMASO

LABCAR HiL




Agenda

Content

1 Electric Drivetrain

2 E-Motor Control

3 Simulation of E-Motor in LAB

4 ES5340 FPGA based Motor drive simulation

5 Motor simulation models from ETAS

6 Benefits of ETAS solution




Electric System

Electric Drivetrain


2

Electric Motor/Generator

Power Electronics

1

5

4

High Voltage Battery and

Battery Management

System

3

Low Voltage Battery

Electric

Accessories

like HVAC*,

power-steering, …



Agenda

Content


2 E-Motor Control








E-Motor/Generator

E-Motor Control

Is necessary for following technical

solutions

● Torque Assist

● E-Drive

● Recuperation

● (Start/Stop)

Realized as three-phase Motor/Generator

● Maintenance-free in comparison to

direct current motors




Types of E-Motor/Generator

Two relevant motor types -

Permanent-Magnet synchronous

machine (PMSM)

Induction machine (IM)

Stator generates rotating field for both

types

PSM

Permanent-magnet rotator follows

rotating field synchronously

IM

Stator rotating field induced current

creates rotating field in rotator

Rotator follows stator rotating field

asynchronously Stator rotating field speed

= Rotator speed Stator rotating field speed > Rotator speed


E-Motor Control



• The Motor Control ECU is integrated in

the Inverter

• It controls Motor as torque actuator

• It monitors the operating conditions of

the motor like temperature.

E-Motor Control ECU

E-Motor Control




I/O configuration of a Motor Control ECU


E-Motor Control



Agenda

Content


2 E-Motor Control

3 Simulation of E-motor in LAB







Challenges with HiL-testing of E-motor control in the lab

Simulation of E-motor in LAB


− Electric propulsion of passenger cars requires

control of power electronics in the range of 50 to

>100 kW

− Typically, integrated housing of control unit

and inverter (high electric power interfaces)

− Hence, HiL-testing needs handling of electric power, that is significantly higher than in traditional ECU-HiL-applications (power-level HiL)



Challenges with HiL-testing of E-motor control in the lab



− Highly dynamic electro-magnetic inverter/E-motor

system for electric propulsion of passenger cars

requires to compute update-frequency for control

signals in the range of 10-25 kHz

− This is significantly higher update frequency

compared to traditional ECU-HiL-applications in

power-train or chassis control domain



FPGA for E-Motor simulation

Ascet

Simulink

…

Vehicle

Electrical Domain

E-Machine (FPGA based)

Combustion Engine

Cylinder Pressure (FPGA Based)

Brake System

10ms

100µs-2 ms

< 1 µs





Agenda

Content


2 E-Motor Control


4 ES5340 FPGA based E-Motor drive simulation






More computation power for models


ES5340 FPGA based E-Motor drive simulation

● FPGA-based Simulation for highest timing requirements: 850 ns step size

● Optimized Models from ETAS:

− PMSM, three-phase model at 850ns step size

− IM, three-phase model at 850ns step size

● Direct link to I/O from FPGA

− Analog, Digital, PWM

● Integration of customer specific models:

− Simulink-to-VHDL Coder

● Applications:

− Hybrid: E-Machine Simulation

− Complex sensor models

− Highly dynamic plant models



Technical Details – HW/SW topology

ES5340 with FPGA

RTPC

SW In

(via PCIe)

HW In 2

SW Out (via

PCIe)

M1

M2

Config M2 on FPGA In 1 = SW In (register) In 2 = HW In 2 (digital) Out 1 = HW Out 1 (analog) Out 2 = HW Out 2 (digital)

In 1

In 2

Out 1

Out 2

HW In 1

HW Out 2

HW Out 1


ES5340 FPGA based E-Motor drive simulation



Agenda

Content


2 E-Motor Control


4 ES5340 FPGA based E-Motor drive simulation

5 E-Motor simulation models from ETAS





Induction Machine Model: Build-Up


E-Motor simulation models from ETAS

The model includes

− Power stage: Inverter stage model

− E-Motor: Induction machine (IM) model

− Vehicle: Rotating mass connected by elastic shaft



− ETAS provides FPGA models for both PMSM and IM E-motors.

The FPGA model consists of three parts:


E-Motor simulation models from ETAS

Inverter

• Simulation of phase voltages

• Simulation of DC voltage link

• Simulation of ohmic losses in switches and diodes

IM/PMSM

• Simulate the phase currents and the torque of the electric motor

• Other values like resistances, inductances and temperature are changeable during runtime

Mechanical load

• For the mechanical connection to the drive train, the spring-damper system is simulated inside the model



LABCAR Operator

− Integration of Models (ASCET, Matlab,

C-Code)

− Connection of Signals

− Configuration of Real-Time OS

− Configuration of CAN/LIN/FlexRay Bus

Simulation

− Code generation for LABCAR-RTPC

− User interface for test execution

− Parameter management

− Real-time signal generation and data

recording

− Furnishes test automation interface to

LABCAR Automation, INCA

Integration Platform Experiment Environment


E-Motor simulation models from ETAS: LABCAR Software



− The User

Interface in the

EE provides

possibilities to

configure the

speed controller

in the demo

setup.

− Green: Speed

Controller on

RTPC

− Yellow: PWM

Generator on

Flex-FPGA board

User Interface in EE


E-Motor simulation models from ETAS: IM model



− Measurements done at a desired

speed of 600 rpm and a load

torque of 10 Nm in engine mode

− The Duty cycle signals are the

outputs of the speed controller

− The currents show how the

machine is running. These signals

can be compared to the Duty

cycle signals.

− The rotor angle and the velocity

are the final mechanical outputs

of the machine

E-Motor simulation models from ETAS: IM model: Measurements




Agenda

Content


2 E-Motor Control








Key benefits


Benefits of ETAS solution

Simulation time as low as 850 ns

Models integrated with

the hardware for easy simulation

Compact and cost-effective

desktop system

Flexibility to download user defined model

Electric Motor Simulations - ETAS · · 2018-03-19Electric Motor Simulations −Electric...

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Transcript of Electric Motor Simulations - ETAS · · 2018-03-19Electric Motor Simulations −Electric...