ITS-NE Introduction Electrification Testing - AVL ITA … Automation system 2WD test system for...
Transcript of ITS-NE Introduction Electrification Testing - AVL ITA … Automation system 2WD test system for...
Luigi Giordano
AVL List GmbH (Headquarters)
Public
ELECTRIFICATION TESTING SYSTEMSAVL ITA - 5 Luglio - Circuito Tazio Nuvolari
Luigi Giordano | ITS-NE | 05 Juli 2017 | 2Public
2
Dedicated application team since 2011
More than 500 installations worldwide
Wide portfolio of solutions
Wide range of customer references
Global presence
AVL DEVELOPMENT SYSTEMS FOR ELECTRIFICATION
Passenger Cars Racing2-Wheelers
Construction Commercial VehicleAgriculture
Rail AviationMarine
Luigi Giordano | ITS-NE | 05 Juli 2017 | 3Public
3
THE CHALLENGE: A WIDE RANGE OF NEW POWERTRAIN SOLUTIONS
Dedicated HybridTransmissions
kWh
PlugIn Hybrid BEV FCEV
Replace Petroleum
Mild Hybrid Full Hybrid
Increase Efficiency
Electric Supercharging
0,4 – 0,8
48V
8-12
MT+ Belt
0,2
12V
1-4
MT + P2 Module + auto-clutch
0,8
15-18
8 - 16
450V
80-120kW
One Gear
35 - 100
Axle Split
75-270
Two Gear
800V
440
Parallel Hybrid / e-AxleAT, DCT, CVT
e-Axle
15 - 100
PEMSOFC
DCT, CVT, AT
Luigi Giordano | ITS-NE | 05 Juli 2017 | 4Public
4
On the basis of the customer use cases, AVL can support in creating a tailored DVP: Collecting inputs from requirements,
FMEA, component tests,… Defining test overview & key specs,
number of samples necessary Detailing of project timing Defining the generalized workflow Identifying the lab size and quantity
of needed test systems Optimizing the efficiency of the test
systems usage plan
AVL: CONSULTING THE DESIGN VALIDATION PROGRAM
Luigi Giordano | ITS-NE | 05 Juli 2017 | 5Public
5
EXAMPLE DVP: RESOURCES ESTIMATE FOR BATTERY PACK TESTING
Luigi Giordano | ITS-NE | 05 Juli 2017 | 6Public
6
On the basis of the customer Design Validation Program, AVL can design and realize complete facilities
AVL CONSULTANCY (CONCEPT DESIGN) Feasibility and Financial studies
Construction cost estimations
Environmental impact studies
Implementation Plans
AVL ENGINEERING Preliminary
Definitive
Detail
AVL MANAGEMENT Procurement and Construction Supervision / Project Management
AVL FACILITY EQUIPMENT SUPPLY AND SYSTEMS INTEGRATION
AVL: FACILITY ENGINEERING
Luigi Giordano | ITS-NE | 05 Juli 2017 | 7Public
7
EXAMPLE: FAW EV LABORATORY CHINAFAW, Changchun - ChinaNew EV Laboratory
Advanced Engineering Services for:▪ 12 E-Motor test beds▪ 2 AWD Powertrain Test beds▪ 2 inverter test beds▪ Environmental test instruments area▪ Battery Pack test area w/ 28 testers▪ Battery cell & module test area w/ 72 testers▪ 2 vehicle test beds▪ Support areas
Luigi Giordano | ITS-NE | 05 Juli 2017 | 8Public
8
AVL delivers systems to validate the complete electrified powertrain components and systems:
Low Voltage or High Voltage upgrade packages for existing vehicle, powertrain and engine testbeds
e-axle and e-powertrain testbeds
E-motor testbeds
Power electronic testbeds
Battery testbeds
Fuel Cell testbeds
Solutions for NVH, EMC or EOL
Combination of all the above in multi-configuration forintegration validation
Real Time Maneuver testing can be added to each of the above
TESTING AND VALIDATION SOLUTIONS FOR ELECTRIFICATION
Luigi Giordano | ITS-NE | 05 Juli 2017 | 9Public
9
EXAMPLE BATTERY EMULATION AND TESTING: RIMAC AUTOMOBILI
Battery emulation on e-drive testbeds with 1kHz control interface
Battery module and pack testing:
• Performance and life cycles testing with 0.01% FS accuracy
• Replication of dynamic load profiles with current rise time <0.4ms
Luigi Giordano | ITS-NE | 05 Juli 2017 | 10Public
1
▪ Insure full safety for UUT, TB and
personal (toxic/explosive gas, fire!)
▪ Testing guidelines
▪ Validate energy Performances
▪ Optimise energy and cooling
management
▪ Optimise battery model (SOC,
SOH, etc…) and BMS
▪ Increase Reliability/Durability
BATTERY DEVELOPMENT AND TESTING CHALLENGES
Luigi Giordano | ITS-NE | 05 Juli 2017 | 11Public
1
Inside Testing Room
Climate Chamber with UUT
Drawing of complete Test Bed
EXAMPLE BATTERY TEST LABORATORY CHINA
Luigi Giordano | ITS-NE | 05 Juli 2017 | 12Public
1
EXAMPLE BATTERY TEST LABORATORY CHINA
Luigi Giordano | ITS-NE | 05 Juli 2017 | 13Public
1
EXAMPLE – BATTERY TESTING CENTER GRAZcontrol room
thermal conditioning
battery test cell
Luigi Giordano | ITS-NE | 05 Juli 2017 | 14Public
1
E-DRIVE DEVELOPMENT AND TESTING CHALLENGES
▪ Face big diversity of UUT’s
▪ Insure Safety of UUT, TB and personal (high speed!)
▪ Testing guidelines
▪ Validate Performances in Motoring and Generating mode
▪ Validate Thermal model
▪ Optimise Efficiency
▪ Reduced torque ripples at very low speed
▪ Reduce Noise
▪ Increase Reliability/Durability
Luigi Giordano | ITS-NE | 05 Juli 2017 | 15Public
1
E-motor validation up to 400kW, 20.000rpm, with low inertia 0.075kgm² for high dynamic tests
High quality simulation of start from rest/uphill (0 rpm and high torque)
Very accurate speed control at low speed for UUT torque ripple optimization
Modular and scalable design
Can be easily upgraded to environment simulation (temperature, humidity, cold operation)
EXAMPLE: E-MOTOR TEST SYSTEMS TIER1
Luigi Giordano | ITS-NE | 05 Juli 2017 | 16Public
1
Battery Emulator:
with source/drain Function
power: 320 KW
voltage range: 8 to 800 V
current range: +/- 600 A
battery modeling can be statically and dynamically
Dyno: AVL Dyno Spirit permanent magnet engine
rotation direction: right / left
four-quadrant operation
controlled speed and torque
max. power: 250 kW (momentary 312 kW)
speed: 0 – 20.000 U/min
mass inertia: 0,15 kgm2
EXAMPLE: TESTING E-MOTOR SYSTEMS AT AVL
Luigi Giordano | ITS-NE | 05 Juli 2017 | 17Public
1
AVL ACTIVE DYNAMOMETER FOR BSGTESTING
Mec. Power nom/overload
Belt ratio
Torquenom/overload Max. speed Chamber Temp.
range & gradient
30/60 kW
1:1 150/300Nm 8000rpm -40+130°C(-70+180°C)2K/min(5K/min)
1:2 75/150Nm 16,000rpm1:2.5 60/120Nm 20,000rpm1:3 50/100Nm 24,000rpm
Luigi Giordano | ITS-NE | 05 Juli 2017 | 18Public
1
USE CASE: EMC EMISSION MEASUREMENT
E-Motor
Stable Dyno platform
AVL Dyno
• Measurement of E-Motor and Inverter EMC emissions under different load and operating conditions.
• CISPR 25 ED 4 & ISO 11452 solution and Radar Pulse proposals
PUMA Open
Luigi Giordano | ITS-NE | 05 Juli 2017 | 19Public
1
Project execution time: 10 months Installation place Beijing ChinaModular container constructionAVL Automation system2WD test system for e-axle validationDynamometers with 220kW /
3200Nm / 3000rpm with up to 50% overload
Battery Emulation 320kW / 800V / 1200A
UUT coolant conditioning system 20kw
EXAMPLE 2WD CONTAINER TESTBED CHINA
Luigi Giordano | ITS-NE | 05 Juli 2017 | 20Public
2
EXAMPLE: E-POWERTRAIN NVH TESTINGKOREA
• 2WD and 4WD configurations
• Test powertrain only or complete vehicle
• Extension to E-Integration testbed
Luigi Giordano | ITS-NE | 05 Juli 2017 | 21Public
2
▪ Integration with wide diversity of E-Motors types and production tolerances
▪ Reduce development time
▪ Testing guidelines
▪ Optimization of inverter switching frequency for drive efficiency / e-motor performance
▪ Radiated and conducted EMI testing for different drive cycles
▪ Reduced torque ripples
▪ Handling of fault conditions
▪ Increase Reliability/Durability
INVERTER DEVELOPMENT AND TESTING CHALLENGES
Luigi Giordano | ITS-NE | 05 Juli 2017 | 22Public
2
Development of inverter control loop functions for the active damping of driveline torsional oscillations
Inverter is tested in an office environment equipped with dynamic e-motor and battery emulators
Vehicle and powertrain are fully simulated in real time
Full power operation possible
EXAMPLE: DAIMLER INVERTER TESTING LABORATORY
Luigi Giordano | ITS-NE | 05 Juli 2017 | 23Public
2
FUEL CELL DEVELOPMENT AND TESTING CHALLENGES
Chassis Dyno
Powertrain Dyno
PUM
A O
pen
for F
uel C
ell
Stack level
Powertrain Integration
Powertrain Architecture Design, Control Unit Development and Cooling System Strategy
Cell level
Fuel Cell VehicleFCVChassis Dyno
Fuel Cell PowertrainFCPTPowertrain Dyno
Fuel Cell SystemFCSFC System TB
Fuel Cell StackFC StackFC Stack TB
Single Fuel CellFC TB
Emer
ald
AutomationSystem
Virtu
al S
enso
rsXiL
Tes
ting
ConnectModels fromdifferentsources
Fuel Cell specificmeasurement solutions
+
Luigi Giordano | ITS-NE | 05 Juli 2017 | 24Public
2
Automation & Process
Simulation
Measurement & Diagnostics
Optimization & Calibration
Automation
Measurement & Diagnostics
Powertrain Test System Fuel Cell Test SystemFCEV R&D environment!
AVL AND GREENLIGHT TESTING SOLUTIONS
Luigi Giordano | ITS-NE | 05 Juli 2017 | 25Public
2
Dynamic operation
With vehicle simulation
With environment simulation
EXAMPLE: HYCENTA FUEL CELL SYSTEM TESTBED
2
1
2
33
1
FC H2/N2 Supply ModuleFC Exhaust ModuleFC Coolant Adaption Module
AVL E-Storage BTE 160AVL ConsysAir 800AVL E-Motor CoolingAVL ConsysCool 200…
Climatic ChamberTRange = -40 .. +85°CSize = 3 x 4 x 3 m
Virtual TestingModel.CONNECTISACInMotionVSMCRUISE (M)
PUMA Open 2,CAMEO,CONCERTO,
…
Up to 170 kW Fuel Cell Systems!
Luigi Giordano | ITS-NE | 05 Juli 2017 | 26Public
2
EXAMPLE: HYCENTA FUEL CELL SYSTEM TESTBED
3x4x3 m
-40 to 85 °C
Develop your
Fuel Cell Systemintegrated into a virtual
Develop your
Fuel Cell Systemintegrated into a virtual
VehicleVehicle
Mimic ambient conditions
Luigi Giordano | ITS-NE | 05 Juli 2017 | 27Public
2
Testing laboratory for validation at component and system levels
The user can rapidly test the combination of real components, like battery and e-motor, or partially emulate them
EXAMPLE: BMW E-BIKE TEST CENTER
Luigi Giordano | ITS-NE | 05 Juli 2017 | 28Public
2
Testing laboratory for validation of single component and of their combinations
Integration of all test equipment by use of the flexible AVL Puma automation
Tests executed with real or simulated components
Components protection by use of highly dynamic DC sources
14 different configurations possible, with automatic and rapid switching during the test procedure (5-6 times / day)
Typical execution of more than 350 tests in two weeks time, with parallel testing of components to save 2-3 days on each session
Time synchronised measurement and acquisition of all data sources, output in open file format
Fast data analysis due to the highly automatized post-processing
EXAMPLE PORSCHE HV INTEGRATION LABORATORY
UUT OBC
e-Motor Emulator Mains Emulator
Rea
l Wor
ld
Emul
ated
Wor
ld Signal& Restbus
Simulation Switch box
Universal Inverter
3xAC e-m
otor
3xAC M
ains
HV D
C link
Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.)
Gearbox, E-Motor, Battery controller, etc.
External controllers
Load Unit
Drive Shaft
UUT Battery
BCU (BMS)
UUT-Inverter E-Motor
BatteryEmulator/Tester
Automation
Simulation
Configuration Switch Unit
Luigi Giordano | ITS-NE | 05 Juli 2017 | 29Public
2
Testing laboratory for validation of the electrified powertrain, the xEV vehicle and its HV battery
Usage of real or simulated components
Multiple configurations possible, with automatic and rapid switching during the test procedure
HV battery can be tested as integrated in the vehicle or in a separate climatic environment
Simulation of driving maneuvers
Time synchronized measurement and acquisition of all data sources
EXAMPLE: HV INTEGRATION TESTBED FOR COMPLETE VEHICLE
Luigi Giordano | ITS-NE | 05 Juli 2017 | 30Public
3
Curb
❑ Hybrid vehicle❑ Automatic Reverse Parking + Curb Crossing❑ Goal : Interaction check between all powertrain elements and controls
❑ Check of all Controlling Elements❑ Results at early Stages in the Development
Phase❑ 100% Reproducibility❑ ...
Wheel Torque
EXAMPLE MANEUVER TESTING: INTERACTION CHECK BETWEEN ELEMENTS
Luigi Giordano | ITS-NE | 05 Juli 2017 | 31Public
3
Automated testing of high voltage battery packs under realistic driving conditions
Road, Driver, Vehicle and Powertrain are simulated in real time, inclusive of bus communication to battery pack
High efficiency in the modification of the test cases, thanks to the modular parametrization concept
EXAMPLE MANEUVER TESTING: US EPA BATTERY IN THE LOOP TESTING