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Aalto UniversityFinlandMay 2011

« Energy Management of EVs & HEVs usingEnergetic Macroscopic Representation »

Aalto University

«« HHARDWAREARDWARE-- IINN--THETHE--LLOOP OOP ((HILHIL))SSIMULATION AND IMULATION AND EMREMR »»

Prof. A. Bouscayrol(University Lille1, L2EP, MEGEVH, France)

based on the tutorial“HIL simulation”, EVS’2009,

Stavanger (Norway)

HIL SHIL SIMULATION USING IMULATION USING EMREMR

Aalto University, May 20112- Outline -

1.1. WWHAT IS HAT IS HILHIL SSIMULATIONIMULATION??

22. . SSIGNALS AND IGNALS AND PPOWER OWER HILHIL SSIMULATION IMULATION

33. . FFULL AND ULL AND RREDUCEDEDUCED--SCALE SCALE HILHIL SSIMULATION IMULATION

44. . EEXAMPLES OF XAMPLES OF HILHIL SSIMULATIONIMULATION

1 example using EMR

presented at Aalto


Aalto University, May 20113- Classical approach of development of new product -

Example of an EV

simulation

Prototype I, II, III….

http://www.renault.com

real vehicle

Long development timeImportant costMaterial waste

Intermediarystep ?

HIL simulation ?

(towards a unique Prototype)


Aalto University, May 20114

processcontrol (blue)

Physical powersystem (orange)

- Graphical and colour Code -

powervariables

mathematicalmodel (purple)

signalvariables

SIMULATIONSOFTWARE

REAL-TIMECONTROLLER

SUBSYSTEM UNDER TEST



Aalto University

1. 1. WWHAT ISHAT IS

HHARDWAREARDWARE-- IINN--THETHE--LLOOP OOP SSIMULATIONIMULATION??

• Software simulation• HIL simulation• Models for HIL simulation



POWER SYSTEM

CONTROLLERBOARD (ECU)

measurements

processcontrol

control signals power

electronicselectricmachine

mechanicalpower train

- System & Control -

How to develop the control? Software simulation

Example of an electric drive for traction



SIMULATION ENVIRONMENT

powerelectronics

measurements

electricmachine


processcontrol

control signals

- Limitations of Software simulation -

How to check the control before real-time implementation?

HIL simulation?

model accuracy simulation solver

sensor effects (quantification, EMI..)ECU effects (discrete-time...)



SUBSYSTEM UNDER TEST


powerelectronics

electricmachine


processcontrol

control signals

Hardware-In-the-Loop (HIL) simulation: one simulation part is replaced by an actual part

- HIL simulation (1) -

Example: test of ECU and Power Electronics

electricmachine



Interface System Real-time simulation



Interface SystemCONTROLLERBOARD (ECU)

powerelectronics

processcontrol

HIL simulation: Includes a hardware part, a software part and a specific interface

- HIL simulation (2) -

electricmachine


HARDWARE SOFTWARE

HIL simulation = Real-time simulation (but including a hardware part)= Emulation


Aalto University, May 201110- Models for HIL simulation -

HIL simulation = Hardware (energy conversion) + Models computed in real-timein dynamic interactions

HARDWARE

REAL-TIME SIMULATION

energetic model

causal modeldynamic model

power

efficient results requires an accurate modeland a well-defined interface system!


Aalto University, May 201111- HIL simulation appraoch -

Example of an EV

simulation

prototype

http://www.renault.com

real vehicle

HIL platform



Aalto University

2. 2. SSIGNALS AND IGNALS AND PPOWER OWER

HILHIL SSIMULATIONSIMULATIONS

• Signal HIL simulation• Power HIL simulation




powerelectronics

measurements

electricmachine


processcontrol

control signals

The actual controller board containing theprocess control is tested.

- Signal HIL simulation (1) -

subsystem to test

Objectives:- control assessment- reliability of ECU- fault operation of ECU- …



SYSTEM UNDER TEST


powerelectronics

measurements

electricmachine


processcontrol

control signals

- Signal HIL simulation (3) -

Second controller board with its own interface

Fast dynamic: FPGA?

EMULATION CONTROLLER


Aalto University, May 201115- Example of signal HIL simulation -

ECU

subsystem to test


battery +chopper (1)

DC machine(2) (3)

mechanicaltrans. (4)-(6)

drivecontrol

sij

uuchop

idcmidcm_meas

Tdcm

gear

gear_meas

Vbat_meas

SYSTEM UNDER TEST


Remark: dynamic causal models

(2) eRiuidtdL dcmdcmchopdcm uuchop dtui chopdcm




powerelectronics

measurements

electricmachine


processcontrol

control signals

- Power HIL simulation (1) -

subsystem to test

Objectives:- control assessment- power device assessment- interactions (EMI…)- …

The actual controller board and a powersubsystem are tested.




SYSTEM UNDER TEST


powerelectronics

electricmachine


processcontrol

control signals


Interface System: • control and power signals• equivalent measurements• power action and reaction




SYSTEM UNDER TEST


powerelectronics

electricmachine


processcontrol

control signals


The same controller board can be used for:• control of the emulation system• real-time simulation of subsystems

emulationsystem

emulationcontrol




powerelectronics

measurements

electricmachine


processcontrol

control signals

- Power HIL simulation (extension) -

subsystem to test

Objectives:- drive assessment- test on static platform- …

Electrical power HILS

Mechanical power HILS


Aalto University, May 201120- Example of electrical power HIL simulation (1) -

ECU

subsystem to test

Luuchopidcm

idcm_refcurrent loop

example of emulation system

idcm

idcm

battery +chopper

DC machine(2) (3)

uuchop

battery +chopper

emulationsystem

uuchop

must imposethe same current




• fast current loop• small sampling period

- Example of electrical power HIL simulation (2) -

Luuchop

idcm

idcm_ref

current loop

emulation systemreal batteryand chopper

drivecontrol

ECU

DC machine(2) (3)

uuchop_est mechanicaltrans. (4)-(6)


Aalto University, May 201122- Example of mechanical power HIL simulation (1) -

ECU

subsystem to test

gear _refspeed / current loops

example of emulation system

Tdcm

gear

must imposethe same speed

gear

DCmachine

mechanicaltrans. (4)-(6)

Tdcm

?



emulation system

Tdcm

gear

realmachine

real bat.& chopper


- Example of mechanical power HIL simulation (2) -

drivecontrol

ECU

TTdcm_est mechanicaltrans. (4)-(6)

gear _ref

speed / current loops



Aalto University

4. E4. EXAMPLES OF XAMPLES OF HIL SHIL SIMULATIONSIMULATIONSa. Test of traction drive for an EVa. Test of traction drive for an EV

[Bouscayrol 2006b]

In collaboration with

FRANCE


Aalto University, May 201125- Objectives -

wh2 Tdiff2

Vbat

iinvgear

Tim

diff

Tgear

wh1 Tdiff1s11 s21 s31

Traction of the studied EV: VSI + Induction machine + differential + 2 driven wheels

Drive implementationfor an Electric Vehicle ?

1. Simulation of the EV (drive + vehicle dynamics)

2. Test of the actual traction drive

3. Test of the whole prototype

drive control

HIL simulation



Park’stransformation

Tim

gear

inductionmachine

udq idq

edqidq

d/s

rw

lw

Tdif

Tdif

Tgear

dif

gearbox differential

msteer

chassis environ.wheels

MSvevFtot

Flw

Frw

Fresvev

vlw

vrw

battery

ESubat

ivsi

VSI

svsi

uvsi

iim

rw Tdif

u bat

ivsigear

Tim

dif

Tgear

lw Tdifs11 s21 s31

- EMR of the studied vehicle -



control

- Maximum control structure -

msteer

battery VSI Park’stransformation


MSvevFtot

Flw

Frw

Fresvev

vlw

vrwrw

lw

Tdif

Tdif

TgearTim

dif

ESubat

ivsisvsi

gear

uvsi

inductionmachine

udq idq

iim edqidq

d/s


power

Ftot-ref vev-ref

vev-mes

Fres-mesFlw-ref

kRkP

Tdiff-ref1

Tgear-refTim-ref

Frw-refTdiff-ref2

PWM

m-ref

idq-refvdq-refuvsi-ref

FOC

d/s-est



control

- Estimation and strategy -

msteer



MSvevFtot

Flw

Frw

Fresvev

vlw

vrwrw

lw

Tdif

Tdif

TgearTim

dif

ESubat

ivsisvsi

gear

uvsi

inductionmachine

udq idq

iim edqidq

d/s


powerkRkP

Ftot-ref vve-ref

Flw-refTdiff-ref1

Tgear-refTim-ref

vev-mes

Fres-mes

Frw-refTdiff-ref2


FOC

m-refd/s-est

strategy

PWM

model

idq_est

edq m-est



control

- Synthetic EMR -

msteer



MSvevFtot

Flw

Frw

Fresvev

vlw

vrwrw

lw

Tdif

Tdif

TgearTim

dif

ESubat

ivsisvsi

gear

uvsi

inductionmachine

udq idq

iim edqidq

d/s


power

vev-mes

kRkP

Ftot-ref vve-ref

Flw-refTdiff-ref1

Tgear-refTim-ref

Fres-mes

Frw-refTdiff-ref2


FOC

m-refd/s-est

PWM

traction drive

drive control

mechanical power train

power traincontrol

vev-refTim-ref

Tim



mechanical power traintraction drive

drive control

control

- HIL simulation principle -

power

power traincontrol

vev-refTim-ref

Tim

Tim

model

mechanical power train

DC load drive

drive control

ref= mod



controllerboard

HIL simulator

- Overall HIL simulation -

MS

ES

vve-ref

PWM FOC

ES


Aalto University, May 201132- Experimental set-up -

IM DCM

inverterchopper

dSPACE 1103controller board


Aalto University, May 201133- Experimental set-up -

IM DCM

inverterchopper

dSPACE 1103controller board



Ngear-mes

Tim-ref

iim1-mes

idcm-mes

vlw-modNgear-ref

im-ref

ubat

vev-ref

vev-mod

vrw-mod

ma2-est

- ECE Drive Cycle -



Aalto University

CCONCLUSIONONCLUSION

HIL simulation interest: valuable intermediary step before the implementation of the control or a new subsystem in a real process

HIL simulation requirements: • respect of interactions between subsystems• respect of the physical causality for real-time implementation• development of an adapted interface system• use of a accurate causal dynamical model

EMR = valuable tool for organization ofthe numerous blocks of HIL simulation


Aalto University, May 201136- References -

A. L. Allègre, A. Bouscayrol, J. N. Verhille, P. Delarue, E. Chattot, S. El Fassi, “Reduced-scale power Hardware-In-the-Loop simulation of an innovative subway", IEEE transactions on Industrial Electronics, vol. 57, no. 4, April 2010, pp. 1175-1185 (common paper of L2EP Lille and Siemens Transportation Systems).

A. Bouscayrol, W. Lhomme, P. Delarue, B. Lemaire-Semail, S. Aksas, “Hardware-in-the-loop simulation of electric vehicle traction systems using Energetic Macroscopic Representation”, IEEE-IECON'06, Paris, November 2006, (common paper L2EP Lille and dSPACE France).

A. Bouscayrol, X. Guillaud, R. Teodorescu, P. Delarue, W. Lhomme, “Hardware-in-the-loop simulation of different wind turbines using Energetic Macroscopic Representation”, IEEE-IECON'06, Paris, November 2006, , (common paper L2EP Lille and Aalborg university, Denmark).

A. Bouscayrol, “Different types of Hardware-In-the-Loop simulation for electric drives”, IEEE-ISIE’08, Cambridge (UK), June 2008,

A. Bouscayrol, X. Guillaud, P. Delarue, B. Lemaire-Semail, “Energetic Macroscopic Representation and inversion-based control illustrated on a wind energy conversion systems using Hardware-in-the-loop simulation”, IEEE transaction on Industrial Electronics, vol. 56, no. 12, December 2009, pp. 4826-4835.

A. Bouscayrol, "Hardware-In-the-Loop simulation", Industrial Electronics Handbook, second edition, tome 3, Chapter M35, Editions Taylor & Francis, Chicago, March 2010, ISBN 9781848210967.

H. Hanselmann, "HIL simulation testing and its integration into a CACSD toolset", IEEE-CACSD’96, Dearborn, September 96.


Aalto University, May 201137- References (2) -

H. Li, M. Steurer, S. Woodruff, K. L. Shi, D. Zhang, "Development of a unified design, test, and research platform for wind energy systems based on hardware-in-the-loop real time simulation", IEEE trans. on Industrial Electronics, vol. 53, no. 4, June 2006, pp. 1144-1151.

W. Lhomme, R. Trigui, P. Delarue, A. Bouscayrol, B. jeanneret, F. Badin, “Validation of clutch modelingfor hybrid electric vehicle using Hardware-In-the-Loop simulation”, IEEE-VPPC’07, Arlington (USA), September 2007, (common paper L2EP Lille and LTE INRETS Bron according to MEGEVH project).

D. Maclay, "Simulation gets into the loop", IEE Review, May 1997, pp. 109-112.

J. N. Verhille, A. Bouscayrol, P. J. Barre, J. P. Hautier, “Validation of anti-slip control for a subway traction system using Hardware-In-the-Loop simulation”, IEEE-VPPC’07, Arlington (USA), September 2007, (common paper L2EP Lille and Siemens Transportation Systems).

C. A. Rabbath, M. Abdoune, J. Belanger, K. Butts, “Simulating hybrid dynamic systems”, IEEE Robotics & Automation Magazine, Vol. 9, no. 2, June 2002, pp. 39 – 47.

P. Terwiesch, T. Keller, E. Scheiben, "Rail vehicle control system integration testing using digitalhardware-in-the-loop simulation', IEEE trans. on Control System Technology, Vol. 7, no. 3, May 99, pp. 352-362.

R. Trigui, B. Jeanneret, B. Malaquin, F. Badin, "Hardware-In-the-Loop Simulation of a diesel parallel mild hybrid vehicle", IEEE-VPPC’07, Arlington (USA), September 2007.

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