2011 horiba europe gmbh. all rights reserved. · 2011-05-12 · © 2011 horiba europe gmbh. all...

© 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


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

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2

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Discussion PointsAn Overview of HEV E-motor and Transmission Test Stands using Virtual Vehicle HIL Methods


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


Controller Commands


Trans-missionsCoupling Tire ModelDrivetrain


Vehicle Controller

MechanicalAccessories


Pedal Position,


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



Controller Commands


HORIBA Calibration & DoE Software Tools

Trans-missionsCoupling Tire ModelDrivetrain


Reduc-tion

Battery Pack


Pedal Position,


ElectricAccessories

E-Motor

Vehicle Controller

or

Bus Level commands

Power Flow

High Level commands


Controller Commands


or


Vehicle ControllerHORIBA Calibration & DoE Software Tools

Bus Level commands

Power Flow

High Level commands

Trans-missionsCoupling Tire Model

Reduc-tion

Drivetrain

Battery PackE-Motor


Battery Pack

Virtual Battery

or

Virtual Engine

Engine


Pedal Position,


ElectricAccessories

or


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


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)


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


Tran

sfor

mer


480 VAC Bus

Test Cell

Bedplate

Headstock

STARS or TAS

Ethernet Real Time

3 phase AC Power


otor

AM

otor

A

Mot

or B

Mot

or B

TPIM /PCU

PPPP

VFD Drive System

VirtualVehicle

-

Use

r Con

tact

40-500 VDC




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


Connectors supplied by Horiba(Twist locked)



DC Supply

UVTrip

HORIBA’s HEV DC InterfaceTran

sfor

mer


480 VAC Bus

Test Cell

Bedplate

Headstock

STARS or TAS

Ethernet Real Time

3 phase AC Power


otor

AM

otor

A

Mot

or B

Mot

or B

TPIM /PCU

PPPP

VFD Drive System

VirtualVehicle

-

Use

r Con

tact

40-500 VDC




Hybrid Transmission

3 phase AC Power

Virtual Battery

+


40 – 1200V DC regulatedwith standalone systems

Circuit Breaker(full load interrupt

capability


Tran

sfor

mer


480 VAC Bus

Test Cell

STARS or TAS

Ethernet Real Time

TPIM /PCU

VFD Drive System

Use

r Con

tact



DC Supply

UVTrip

HORIBA’s HEV DC Interface

Virtual Battery


capability


E-Motor Component Test Stand

Use of Virtual BatteryHEV Test Stand Examples


Tran

sfor

mer


480 VAC Bus

Test Cell

STARS or TAS

Ethernet Real Time

TPIM /PCU

VFD Drive System

Use

r Con

tact



DC Supply

UVTrip




E-motor Assist Axle Test Stand

Virtual Battery +VirtualEngine

Virtual Battery

With 4 Wheel Dynos



Tran

sfor

mer


480 VAC Bus

Test Cell

STARS or TAS

Ethernet Real Time

TPIM /PCU

VFD Drive System

Use

r Con

tact



DC Supply

UVTrip





HEV Dual-Mode Transmission Stand



Tran

sfor

mer


480 VAC Bus

Test Cell

STARS or TAS

Ethernet Real Time

TPIM /PCU

VFD Drive System

Use

r Con

tact



DC Supply

UVTrip

HORIBA’s HEV DC Interface

Virtual Battery


capability



HEV Fuel Economy and Range Calibration Chassis

Dyno


Tran

sfor

mer


480 VAC Bus

Test Cell

STARS or TAS

Ethernet Real Time

TPIM /PCU

VFD Drive System

Use

r Con

tact



DC Supply

UVTrip





Virtual Battery


HEV Powertrain Test StandWith 2 Wheel Dynos



Virtual Battery: HIL DC Power Simulation

E-Motor Test Stands

Virtual Engine: HIL Engine Torque Simulation

Wheel Slip: HIL Tire to Road Surface Simulation

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Discussion Points


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



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



Complete Test SolutionsDUT Support - (inverter / DC Power 40–700Vdc).DUT Support - Cooling / Ambient TemperatureDUT Support - Lock Rotor TestingTorsional Modeling & Analysis


Dynas TR150M260 (16kRPM)

Dynas TR 260M450 (18KRPM)



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




E-Motor Test Stands



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2

3

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Agenda / Table of Contents


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


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


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


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



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


Engine Start Simulation (Typical)

Engine Start Simulation for HEV (1 rev.)

Engine Idle Simulation (not shown)

Engine Accessory Load Simulation


= Crank Angle) = Torque Demand Signal

= Pumping & friction pulses = Speed (RPM


Torque Intervention during shift or clutch of transmission, coupling, or differential



Engine Crank & Timing Pulse Simulation

Cam, injector, other timing pulse simulation



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


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




E-Motor Test Stands



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Discussion Points


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


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


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


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


Thank you

2011 horiba europe gmbh. all rights reserved. · 2011-05-12 · © 2011 horiba europe gmbh. all...

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