EXTENSION OF A POWERNET TESTBENCH · - Analyze and optimize every operation strategy and parameter...

Stefan Kurtz, BMW Group

Prof. Dr.-Ing. H.-G. Herzog, TUM

EXTENSION OF A POWERNET TESTBENCHWITH A VEHICLE SIMULATION INCLUDING ENVIRONMENT FOR A INTEGRATED DEVELOPMENT

AGENDA.

Extension of a power net test bench, Stefan Kurtz, 20.09.2016

Introduction

Approach

Architecture

Realization

Summary

Origin

General approach

Finalized work

Latest achievements

Status Quo

Requirements

HiL architecture overview

Hardware architecture

Software architecture

Implementation

Simple approach of a passenger

model

Results

Advantages

Outlook

ORIGIN.

Automotive power net designs grow more and more complex, they contain…

Energy storages (e.g. AGM battery, Li-Ion battery)

Power supplies (e.g. generator, DC/DC converter)

Consumer (e.g. ohmic sinks, electric motors and systems consuming constant

power)

In other words, there are…

Different voltage levels

100+ ECUs in highly equipped vehicles

100+ actuators in highly equipped vehicles

Massively connected functions that command several ECUs and actuators

Major question: How to coordinate energy and power aspects at it’s

best?


dummy

dummy

dummy dummydummy

dummy

GENERAL APPROACH.


Producer Storage Consumer

Generator Battery Actuator

Management Function

Energy & Power

Management [3,4]

Customer / System

function

Environment

Energy & Power

Prediction [6]

el. wiring information command

FINALIZED WORK.


The institute for Power Conversion Technology (EWT) at Technische UniversitätMünchen (TUM) builds up a reference power net test bench in cooperation with BMW Group.

The test bench consists of…

- An original BMW F01 (series 7) chassis

- An original wiring harness

- Numerous electronic sinks as replacement forreal components

- An original AGM battery

- An original generator carried by an electric motor

- A second voltage level (48V)

Additionally to a normal vehicle the test bench is equipped with…

- Numerous measuring points for voltage and current

- Simulated consumer behavior (decided to be independent of static ECU software versions)

TUM EWT reference power net test bench

A DETAILED VIEW TO THE TEST BENCH.


TUM EWT reference power net test bench

BMW F01

(series 7)

chassis

electronic sinks

wiring harness

AGM battery

measuring

points

generator

carried by an

electric motor

LATEST ACHIEVEMENTS.


Next generation Energy and Power Management [3, 4] analogue to an up-to-date

BMW series 7 (G11)

With complete access to the operation strategy and every parameter

(Optional) replacement of the AGM battery by a powerful battery simulation test

bench [5] containing

Electronic source (analogue to the performance of a battery)

Electronic sink

Different battery simulation models

STATUS QUO.

The test bench can…

- Rerun every situation logged in a real vehicle, with preparation of the logged data

- Run every artificial scenario

- Be configured as a customer can choose extra equipment

We can…

- Analyze and optimize every operation strategy and parameter

- Integrate any thinkable consumer or function for testing purposes


REQUIREMENTS.

For further work we need…

- The possibility to analyze and optimize in a massive dimension to identify the

global optimum

- For the operation strategy of the energy management system

- The classifiers of the prediction model for the power management

Which means to…

- Find the relevant situations

- Identify or even generate corresponding driving scenarios

- Parametrize the consumers and the battery simulation in the test bench

- Stimulate the whole test bench in a realistic way in real time

- Report the gain of the management system


HIL ARCHITECTURE OVERVIEW.


Simulation Models

Co-Simulation

A/D conversion

Impresscurrent

Measure

d d d

HARDWARE ARCHITECTURE (RUNNINGOPERATION).


NI PXI COTS

PC

PharLab

Generat

orBattery

COTS

PC

Host

COTS

PC

Measurin

g

El.

load

#1

El.

load

#1

El. Load

#1…n

NI PXImc

Analogue

input

Ethernet

Analogue

output

Simulatio

n models

Co-

Simulatio

n

A/D

conversi

on

Measure

Impress

current

Impress

current

NI Veristand (2)

FMIFMI

FMI FMI

SOFTWARE ARCHITECTURE.


A/D Hardware

NI Labview

Predictio

n

(Simulink /

C)

Power

Mgmt

(Dymola)

Consume

r model

#n

(Dymola )

IPG CarMaker

(custom device)

Passenge

r model

(Simulink )

Measure-

ment GUI

(LabView)

A/D

converter

measurement

(sensor) data

command

IMPLEMENTATION.


Integration of MATLAB/Simulink passenger model using CarMaker Plain

Template

Creation of a custom CarMaker kernel for LVRT

Integration of IPG custom device in NI VeriStand

Connection of all necessary inputs and outputs using aliases

Integration of Dymola customer / producer / management

models using FMI [1]

Integration of NI PXImc for communication to PC [2]

Connection of all necessary inputs and outputs using aliases

Deploy, wait, run, wait, have fun!

SIMPLE APPROACH OF A PASSENGER MODEL (PROTOTYPE).


Simple MATLAB/Simulink model

representing passenger behavior

Position specific behavior (driver, co-

driver, passenger) up to four (or

even more?) instances thinkable

Decisions linked to

Daytime and lightness

Driving time

Temperature (in- & outside)

Weather

Nearly all inputs were natively

generated by IPG CarMaker

Simulink passenger model snippet

IDEA AND DETAILS OF THE PASSENGER MODEL.LOW BEAM LIGHT DECISION.


Decision for low beam light (driver only)

Driver whishes low beam light between sunset and sunrise or

Otherwise when it’s dark like in a tunnel or a car park

Necessary inputs:

- Daytime

- Lightness

Possible optimization:

- Simple model of altitude of the sun


IDEA AND DETAILS OF THE PASSENGER MODEL.SEAT MASSAGE DECISION.


Decision for seat massage (possible for any passenger)

Passenger whishes seat massage “randomly” or

When he/she is sitting a long time

Necessary inputs:

- Driving time

- Pseudo random generator


RESULTS.


Extension of IPG CarMaker by customer inputs without an additional interface

Every synchronization is made by IPG CarMaker

Realistic real-time stimulation

of consumer models

of prediction models

Simple replay of test scenarios with much more details like traffic

Simple modification of test runs by changing the IPG CarMaker Simulation

ADVANTAGES.

Any test drive can be run on the test bench

Real

Simulated

Synthetic (also not real or not realistic)

Any parameter can be stressed

Individual

In combination (due to integration of IPG CarMaker simulation)

We now can…

- Run generated standard scenarios in great numbers and

- Rerun real test drives with the help of IPG CarMaker


OUTLOOK.


Import of real test drives with options or modifications

With or without velocity profile

With or without traffic

Build „fast-forward“ out of relevant situations to speed up simulation

THANKS FOR YOUR ATTENTION.


…further questions?

BACKUP.


REFERENCES.

[1] Michael Winter, Julian Taube, Joachim Froeschl und Hans-Georg Herzog,

„From Simulation to Testbench using the FMI-standard“ in Vehicle Power and

Propulsion Conference (VPPC), 2015

[2] Michael Winter, Julian Taube, Hans-Georg Herzog, „Skalierbare

Echtzeitemulation von Bordnetzkomponenten in einem Bordnetzprüfstand mit NI

VeriStand“ in Virtuelle Instrumente in der Praxis, VDE Verlag, 2015

[3] Joachim Fröschl, Christian Pichler, Veneta Dobreva, Hans-Georg Herzog, “A

new kind of an Energy Management System” in Electric & Electronic Systems in

Hybrid und Electric Vehicles and Electrical Energy Management, 2015

[4] Joachim Fröschl, Stefan Kurtz, Michael Winter, Julian Taube, Timur Nuritdinow,

Hans-Georg Herzog, „Concept od a decision system for an operation strategy in a

cybernetic energy and power management“ in Electric & Electronic Systems in

Hybrid und Electric Vehicles and Electrical Energy Management, 2016

[5] Michael Winter, Julian Taube, Andreas Stückl, Hans-Georg Herzog, "Emulation

of batteries and bidirectional components in the automotive power net“ in “Electric

& Electronic Systems in Hybrid and Electrical Vehicles and Electrical Energy

Management", 2016


REFERENCES.

[6] Stefan Kurtz, Niklas Willems und Hans-Georg Herzog, „Abstrakte Szenarien zur

Leistungs- und Energieprädiktion“ in Elektrik/Elektronik in Hybrid- und

Elektrofahrzeugen und elektrisches Energiemanagement, 2014


EXTENSION OF A POWERNET TESTBENCH · - Analyze and optimize every operation strategy and parameter...

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