thermal management optimization of hybrid vehicles in gt-suite · hybrid mode warm-up technologies...
TRANSCRIPT
Confidential
© MAHLE
G. Fossaert, R. Corbishley, N. Gunter, T. Strauss Verification & Analysis MAHLE Powertrain
Thermal Management Optimization of
Hybrid Vehicles in GT-SUITE
European GT-User Conference
2019
1
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Optimized Thermal Management For Hybrid Vehicles
Confidential
© MAHLE 2
Motivation
MAHLE Powertrain is an Engineering Services Provider
Evolving customer needs
Customer Requests
Various request types
Performance evaluation
EV range estimation
Optimal HEV Layout
Drive cycle efficiency
Battery life estimations
Customer Applications
Combinations of
EV / HEV / ICE only
P0 / P1 / P2 / P3 / P4
FWD / RWD / AWD
Customer Demands
Project variability
Accurate results
Quick turn-around
Flexible
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Optimized Thermal Management For Hybrid Vehicles
Confidential
New Full Vehicle Thermal Model
Our Solution
© MAHLE
Engine Friction
Engine Lubrication
Engine Cooling
Airside Cooling
HVAC
Electrical
Transmission Lubrication & Thermal
Transmission Friction
Engine Thermal Drive Cycle Model
3
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Optimized Thermal Management For Hybrid Vehicles
Confidential
© MAHLE 4
Presentation Overview
Modelling
– Generic Drive Cycle Model
– Engine Thermal Model
Case study
– DI3 Hybrid Electric Vehicle Thermal Management
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Drive Cycle Model
Optimized Thermal Management For Hybrid Vehicles
Confidential
New Full Vehicle Thermal Model
© MAHLE
Engine Friction
Engine Lubrication
Engine Cooling
Airside Cooling
HVAC
Electrical
Transmission Lubrication & Thermal
Transmission Friction
Engine Thermal Drive Cycle Model
5
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Optimized Thermal Management For Hybrid Vehicles
Confidential
© MAHLE
Generic HEV Model
Powertrain type
– ICE
– P0/P1/P2/P3/P4
Architecture options
– FWD
– RWD
– 4WD
Individual gearing options
– Transfer box
– Gearbox
– Final Drive
Specific powertrain selection for
– ICE only
– HEV
– EV
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Available in single Generic HEV Model
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Optimized Thermal Management For Hybrid Vehicles
Confidential
© MAHLE
Generic HEV Model
Controllers
How to control the Generic HEV Model
Model User
– Powertrain layout selection
– Strategy definition
Driver and torque split controllers
– Driver calculates torque request
– Strategy
MGU / ICE operation
– Specific MGU and/or ICE torque passed onto component
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Powertrain Layout
User
Driver Controller
Torque Request
Controller
Strategy Controller
MGU Selection
ICE Operation
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Modes
Optimized Thermal Management For Hybrid Vehicles
Confidential
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Generic HEV Model
Strategy Controller
Mode 2: EV only
Mode 3: HEV Series
Mode 4: HEV Parallel
Mode 1: Engine Only
Transition Conditions
Strategy
Mode 1
Mode 2 Mode 3 Mode 4
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MGU(s) ICE Operation Clutch
USER INPUT
P3 12bar Locked
…
…
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
RDE facility is ideal test environment for Drive Cycle Model correlation
– Maximum altitude of 5km
– Climatic range: -40 to +60°C / 10 – 80% relative humidity
Cumulative fuel flow shows good correlation between simulation and vehicle test results
Confidential
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New Full Vehicle Thermal Model
Drive Cycle Model Correlation
Optimized Thermal Management For Hybrid Vehicles
9
WLTP Class 3 23°C AC Off
Veh
icle
Sp
eed
[k
m/h
]
020406080
100120140
En
gin
e S
peed
[rp
m]
0
1000
2000
3000
Fu
el
Flo
wR
ate
[g
/s]
0.0
1.0
2.0
3.0
4.0
Fu
el
Co
nsu
med
[g
]
0200400600800
1000
Time [s]
0 300 600 900 1200 1500 1800
Test Simulation
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Drive Cycle Model
Optimized Thermal Management For Hybrid Vehicles
Confidential
New Full Vehicle Thermal Model
© MAHLE
Engine Friction
Engine Lubrication
Engine Cooling
Airside Cooling
HVAC
Electrical
Transmission Lubrication & Thermal
Transmission Friction
Drive Cycle Model
10
Engine Thermal
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Optimized Thermal Management For Hybrid Vehicles
Confidential
© MAHLE
New Full Vehicle Thermal Model
Engine Thermal Model
11
Engine Thermal Model Ease of implementation
within Full Vehicle Model Fast-running
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Optimized Thermal Management For Hybrid Vehicles
Confidential
© MAHLE
New Full Vehicle Thermal Model
Thermal Model Correlation
The initial correlation results showed
model confidence
Heat flows predicted in the 1D
thermal model matched
– Indimaster / Dyno results
– CFD / Converge predictions
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Metal temperatures showed a good correlation between the
CFD and the 1D FE Cylinder
– E.g. both sides of the cylinder head fire face
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Confidential
Optimized Thermal Management For Hybrid Vehicles
© MAHLE
Thermal Management Optimization of Hybrid Vehicle
Case Study
MAHLE DI3 Engine
P0 / P3 hybrid
WLTP Cycle B Segment Vehicle
Compact battery
13
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Confidential
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Optimized Thermomanagement
Considered Warm-Up Technologies
14
E-Pumps (Coolant/Oil)
Multi Flow Valve (MFV)
Split Cooling
Engine Oil Cooler (EOC)
Transmission Oil Cooler (TOC)
Optimized Thermal Management For Hybrid Vehicles
MAHLE DI3 1.2L ICE
LP EGR
Baseline
Mechanical water pump
Conventional thermostat
No warm-up prioritisation
Warm-up technologies
Electric water pump
– Flow on demand
Split cooling
– Stagnant block flow
Multi flow valve
– EOC or TOC flow prioritisation
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Head C
oola
nt
Tem
pera
ture
[°C
]
20
40
60
80
100
120
Gearb
ox O
ilT
em
pera
ture
[°C
]
20
40
60
80
100
120
Lin
er
Tem
pera
ture
[°C
]20
40
60
80
100
120
140
160
Time [s]
0 300 600 900 1200 1500 1800
Engin
e O
ilT
em
pera
ture
[°C
]
20
40
60
80
100
120
Time [s]
0 300 600 900 1200 1500 1800
Baseline Warm-Up Technolgies
ICE Only
Warm-Up Improvements
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Optimized Thermal Management For Hybrid Vehicles
WLTP Class 3 23°C AC Off
15
Head coolant shows slower warm-up
Faster engine oil warm-up
Faster gearbox oil warm-up
Elevated steady-state temperatures
2% fuel economy improvement achieved by thermal management optimisation
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Transition Conditions
Modes HEV
Optimized Thermal Management For Hybrid Vehicles
Confidential
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Hybrid Mode
Hybrid Strategy
EV P3 Load Shift P3 Load Assist P0/P3 Traction Engine Only
Strategy
EV
P3 Load Shift P3 Load Assist P0/P3 Traction
Engine Load: 12bar
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Based on: • SOC • Power demand • Braking request
BM
EP
(B
ar)
0
5
10
15
20
25
30
Engine Speed (rpm)
1000 2000 3000 4000 5000 6000
BM
EP
(B
ar)
0
5
10
15
20
25
30
Engine Speed (rpm)
1000 2000 3000 4000 5000 6000
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Confidential
© MAHLE
Hybrid Mode
Warm-Up Technologies Included
Optimized Thermal Management For Hybrid Vehicles
WLTP Class 3 23°C AC Off
17
Hybrid strategy optimisation to minimise warm-up time 10% fuel economy improvement achieved by hybrid strategy
Time [s]
0 300 600 900 1200 1500 1800
SO
C [
-]
0.0
0.2
0.4
0.6
0.8
1.0
1: EV2: Eng Only3: Load Shift4: Load Assist5: Traction
Mode [
-]
1.0
2.0
3.0
4.0
5.0
6.0
Head C
oola
nt
Tem
p.
[°C
]
20
40
60
80
100
120
ICE Only HEV
Engin
e O
ilT
em
p.
[°C
]
20
40
60
80
100
120
Gearb
ox O
ilT
em
p.
[°C
]
20
40
60
80
100
120
Time [s]
0 300 600 900 1200 1500 1800
Time [s]
0 300 600 900 1200 1500 1800
SO
C [
-]
0.0
0.2
0.4
0.6
0.8
1.0
1: EV2: Eng Only3: Load Shift4: Load Assist5: Traction
Mode [
-]
1.0
2.0
3.0
4.0
5.0
6.0
Head C
oola
nt
Tem
p.
[°C
]
20
40
60
80
100
120
ICE Only HEV
Engin
e O
ilT
em
p.
[°C
]
20
40
60
80
100
120
Gearb
ox O
ilT
em
p.
[°C
]
20
40
60
80
100
120
Time [s]
0 300 600 900 1200 1500 1800
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Drive Cycle Model
Optimized Thermal Management For Hybrid Vehicles
Confidential
Results Summary
© MAHLE
Engine Friction
Engine Lubrication
Engine Cooling
Airside Cooling
HVAC
Electrical
Transmission Lubrication & Thermal
Transmission Friction
Drive Cycle Model
Engine Thermal
18
10%
2%
MAHLE Behr GmbH & Co. KG, Verification & Analysis, G. Fossaert, 07-October-2019
Example of Toolset Deployment
MAHLE Modular Powertrain
High Voltage PHEV Powertrain
Engine <210g/kWh min BSFC
1/2/4 speed gearbox options
Scalable hybrid: B to J-Segment
Drive cycle CO2 below 2030 proposed target
19 Confidential
© MAHLE
Optimized Thermal Management For Hybrid Vehicles
Development supported with GT-SUITE
Performance targets
Vehicle capability targets
Hybrid mode
Hybrid strategy
Mechanical development
G. Fossaert, R. Corbishley, N. Gunter, T. Strauss Verification & Analysis MAHLE Powertrain
Confidential
© MAHLE
Thank you for your attention
20
Simon Duke
Chief Engineer
Verification & Analysis
+44 (0) 1604 738 148
Gery Fossaert
Senior 1D Analysis Engineer
Verification & Analysis
+44 (0) 1604 734 917