avl electrification testing solutions - part 02

AVL Europe ITS

Markus Maier

AUTOMOTIVE ELECTRIFICATION

ELECTRIFICATION SOLUTIONSSYSTEM INTEGRATION

Markus Maier | IST-N EU | June 2016 | 2AVL UK Expo 2016

ELECTRIFICATION TEST SYSTEMS

# of qualified service personal Standard Level

# of qualified service personal Expert Level

• First System sold by 2009

• Business Unit

Electrification & Racing

Test Systems

established in 2011

• AVL Electrification Test

System Expertise around

the world

• More than 300 Systems

in use since 2009

• From System Concept to

Service globally

AVL Electrification

Test Systems


AGENDA

1. What

What is an electrified car all about

2. How

How do we develop an electrified car

System Integration

3. Summary


Micro-Hybrids use Starter and Battery for

Stop-Start Functionality

Conventional Vehicle Full Electric Vehicle

CONVENTIONAL, HYBRID ANDELECTRIC VEHICLES

Generator12V Battery

ICEGearbox

Starter

Hybrid

Vehicles

Hybrid Vehicles combineCombustion Engine and

All Electric Propulsion Charging Port

RechargeableBattery

orFuel Cell

Electric Motor

U V W

ReductionGearbox

Inverter

DC/DC Converter

+Charger

12V Bordnet


Powersplit Hybrid

Electric driven rear-axles are also parellel Hybrids and so-called road-

coupled hybrids

Parallel Hybrid Serial Hybrid

U V W

2nd BatteryBattery

U V W

U V W

Planetary Gearbox

Generator

HYBRID POWERTRAIN LAYOUTS

Benefit

• ICE is operated in steady state

and has hence optimum

efficiency

Benefit

• Fairly easy to realize

• Allows full-electric driving

• Allows electric boosting

Benefit

• Allows optimum combination of

parallel and serial hybrid

depending on driving situation


TRACTION TORQUE WILL HAVE MANY SOURCES

MechanicalPower

ElectricalPower

0% 0%

100%100%

InternalCombustion

Engine

Hybrid(HEV)

PluginHybrid(PHEV)

Extended Range Electric(RREV)

Battery Electric(BEV)

Fuel-CellElectric(BEV)

MechanicalDrive

Mechanical Drive with electric Assist Electrical Drive withmechanical Assist

Electrical Drive

To

rq

ue

To

rq

ue


AGENDA

1. What


2. How


System Integration

3. Summary


ELECTRIFIED POWERTRAINS TESTING

The electrified Powertrain must be mastered and validated by the OEM

Component Validation

Energy Source: Battery or Fuel-Cell

Battery Cells to validate electrifcal perfomance and life-time as well as to be able to judgenew, upcoming technologies

Batterypack and Module: to ensure the thermal and safety behavior of the whole system

Fuel-Cell: from Cell to Stack to whole System

Traction: E-Motor for driveability and longevity

Power-Electronics: Inverter, Charging and DC Suppy as the back-bone and the brain

System Validation

Electrical Subsystem: Battery + E-Motor + Power-Electronics

Powertrain: Comb. Engine + Gearbox + Battery + Power-Electronics

Vehicle

Driveability and optimisation of vehicle parameters (electrical distance, Power, Emission)



OEM must master the core technologies of the whole power train

The Operating Strategy as co-operation of the electrical components defines the customersperceiption of the whole vehicle

The Energy Source (Battery) is a core component and determines Power, Reach, Charging

Hauptteil der Absicherungszeit und Kosten heute sehr spät im Prozess investiert

Validation in the V-Cycle

• Validation of Vehicle

ca. 60%

• Validation of electr. Subsystem

ca. 10%

• Component Validation;

ca. 30%

60%

10%

30%



Electrified Powertrains - Characteristics

High number of operating modes (recuperation, boost, sailing, etc.)

Integration of components from different Tier-1

New, partially unknown technology High number of interfaces to the vehicle (external

loads)

System Integration Test - Today

Integration with Combustion Engine and Gearbox to full Powertrain and Testing on Powertrain Testbench or in the Vehicle

Challenges

one Component can block the whole testing

Debugging of faulty systems complex while in the car

AVL Solution

Integration Testbench for Electrification Subsystem

+ -

Be

lt

Clu

tch

ICEMotor G

ea

rbo

x

Battery

Inverter

Generator

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+ -

Motor

Battery

Inverter

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1011

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1011

Today: Whole Powertrain

Tomorrow:

Subsystem Electrification


INTEGRATION TESTBED - SUBSYSTEM

The HV-Subsystem is a complex system and has new challenges for the integration

For the Validation, AVL has designed and delivered an Integration Testbench includingnew possibilities of emulation

Inv

U V W

Bat

OBC

Inv

U V W

Bat

OBC

HV Subsystem


Drive Shaft

Load Unit

ORDrive Shaft

Load Unit

+

+ -

Energy Storage

OR

Generator*

SYSTEM TESTBENCH OVERVIEW

* considered as DC source

motoric Loads / Sinks

OR OR

Ohmic Loads

OR

Charger

OR

e-ME

universal

Inverter

universal

electronic

loads

Grid

Emulator

Automation

AVL

PUMA

Restbus

AVL

inMotion

DVE

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Objectives System Integration Testbench

Functional Validation of the System incl. Validation of new SW / HW

Validation of vehicle interfaces (e.g. electric loads)

Robustness-testing by fault injection

Pre-Calibration of the Subsystem

Identification of Improvement Potential

Concept Studies

Field return analys

+ -

Motor

Battery

Inverter

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Engine, Gearbox

and ECU

Simulation

Vehicle & Load

Simulation


SYSTEM TESTBENCH OVERVIEW

Em

ula

ted

Wo

rld

+ -

Battery Inverter LoadCharge

Battery Univ. Inv. e-ME Grid Emu Load Emu

Multipurpose Power Switch Box

Motor

AVL

inMotion

DVE*

Restbus

Automation

AVL

PUMA

Kl15,30, CAN,LIN,FlexRay

HiL

DME, DGM

*DVE = Driver, Vehicle, Environment

Re

al W

orl

d




REAL MOTOR AND POWERELECTRONICS

Em

ula

ted

Wo

rld

+ -

Battery Inverter LoadCharge



All components real

Motor

AVL

inMotion

DVE*

Automation

AVL

PUMA


RestbusHiL

DME, DGM


Re

al W

orl

d




EMULATED BATTERY

Em

ula

ted

Wo

rld

+ -

Batterie Inverter LoadCharge



Emulated Battery

Motor

AVL

inMotion

DVE*

Automation

AVL

PUMA


RestbusHiL

DME, DGM


Re

al W

orl

d




EMULATED PLUG-IN HYBRID

Em

ula

ted

Wo

rld

Re

al W

orl

d

+ -

Battery Inverter Charge

Battery Grid Emu


Motor

AVL

inMotion

DVE*

Restbus

Automation

AVL

PUMA






AGENDA

1. Why

Why do we look into Electrification

2. What


3. How


a. Components

b. Systems

4. Summary


HIGHLIGHTS AND POSSIBILITIES

• Realistic Simulation of Driving Cycles with different Start conditions

• NEFZ Cycle with different charging status of the battery

• Different Possibilities to inject Faults / Errors

• Network: Failure of single ECUs / Components

• E-Motor: cut single phase

• Grid Supply: Phase failure, asymmetric phases, Peaks

• Bordnet: Voltage Drops caused from dynamic loads

• HV-Bordnet: Isolation fault, cable breaks

• Excellent Comparison between Emulation and Vehicle Battery especially in dynamic load scenarios

• Dynamic switching between emulated and real component allows different use-cases to be tested

• e.g. driver selection switch for operating modes


THE GOLDEN DEVICE

Technical Experience

A System Integration Testbench is the „Golden Device“

Enables at every point in time the generation of reproducible Results

Validate the progress of Systemintegration and Components

Component Testing with a „Reference Vehicle“

Enables to validate all components or just individual components in an emulatedSystem

+ -

Motor

Battery

Inverter

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Engine, Gearbox

and ECU

Simulation

Vehicle & Load

Simulation


SUMMARY AND OUTLOOK

For the validation of the complete vehicle, AVL has setup a new HV Integration Testbench at AVL Headquarters in Graz

Validation whole Vehicle

Validation whole Vehicle but emulate components

Validation of Components

Inv

U V W

Bat

OBC

www.avl.com

THANK YOU

Markus MaierBusiness Manager Electrification and Racing Test SystemsEuropean region

Zettachring 4, 70565 Stuttgart+49-711-45041-22+49-171-6925831

[email protected]

avl electrification testing solutions - part 02

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