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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
HIL SHIL SIMULATION USING IMULATION USING EMREMR
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)
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 20114
processcontrol (blue)
Physical powersystem (orange)
- Graphical and colour Code -
powervariables
mathematicalmodel (purple)
signalvariables
SIMULATIONSOFTWARE
REAL-TIMECONTROLLER
SUBSYSTEM UNDER TEST
Aalto UniversityFinlandMay 2011
« Energy Management of EVs & HEVs usingEnergetic Macroscopic Representation »
Aalto University
1. 1. WWHAT ISHAT IS
HHARDWAREARDWARE-- IINN--THETHE--LLOOP OOP SSIMULATIONIMULATION??
• Software simulation• HIL simulation• Models for HIL simulation
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 20116
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
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 20117
SIMULATION ENVIRONMENT
powerelectronics
measurements
electricmachine
mechanicalpower train
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...)
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 20118
SUBSYSTEM UNDER TEST
CONTROLLERBOARD (ECU)
powerelectronics
electricmachine
mechanicalpower train
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
mechanicalpower train
SIMULATION ENVIRONMENT
Interface System Real-time simulation
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 20119
Interface SystemCONTROLLERBOARD (ECU)
powerelectronics
processcontrol
HIL simulation: Includes a hardware part, a software part and a specific interface
- HIL simulation (2) -
electricmachine
mechanicalpower train
HARDWARE SOFTWARE
HIL simulation = Real-time simulation (but including a hardware part)= Emulation
HIL SHIL SIMULATION USING IMULATION USING EMREMR
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!
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201111- HIL simulation appraoch -
Example of an EV
simulation
prototype
http://www.renault.com
real vehicle
HIL platform
Aalto UniversityFinlandMay 2011
« Energy Management of EVs & HEVs usingEnergetic Macroscopic Representation »
Aalto University
2. 2. SSIGNALS AND IGNALS AND PPOWER OWER
HILHIL SSIMULATIONSIMULATIONS
• Signal HIL simulation• Power HIL simulation
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201113
CONTROLLERBOARD (ECU)
powerelectronics
measurements
electricmachine
mechanicalpower train
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- …
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201114
SYSTEM UNDER TEST
CONTROLLERBOARD (ECU)
powerelectronics
measurements
electricmachine
mechanicalpower train
processcontrol
control signals
- Signal HIL simulation (3) -
Second controller board with its own interface
Fast dynamic: FPGA?
EMULATION CONTROLLER
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201115- Example of signal HIL simulation -
ECU
subsystem to test
EMULATION CONTROLLER
battery +chopper (1)
DC machine(2) (3)
mechanicaltrans. (4)-(6)
drivecontrol
sij
uuchop
idcmidcm_meas
Tdcm
gear
gear_meas
Vbat_meas
SYSTEM UNDER TEST
CONTROLLERBOARD (ECU)
Remark: dynamic causal models
(2) eRiuidtdL dcmdcmchopdcm uuchop dtui chopdcm
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201116
CONTROLLERBOARD (ECU)
powerelectronics
measurements
electricmachine
mechanicalpower train
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.
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201117
SIMULATION ENVIRONMENT
SYSTEM UNDER TEST
CONTROLLERBOARD (ECU)
powerelectronics
electricmachine
mechanicalpower train
processcontrol
control signals
- Power HIL simulation (2) -
Interface System: • control and power signals• equivalent measurements• power action and reaction
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201118
EMULATION CONTROLLER
SYSTEM UNDER TEST
CONTROLLERBOARD (ECU)
powerelectronics
electricmachine
mechanicalpower train
processcontrol
control signals
- Power HIL simulation (4) -
The same controller board can be used for:• control of the emulation system• real-time simulation of subsystems
emulationsystem
emulationcontrol
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201119
CONTROLLERBOARD (ECU)
powerelectronics
measurements
electricmachine
mechanicalpower train
processcontrol
control signals
- Power HIL simulation (extension) -
subsystem to test
Objectives:- drive assessment- test on static platform- …
Electrical power HILS
Mechanical power HILS
HIL SHIL SIMULATION USING IMULATION USING EMREMR
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
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201121
EMULATION CONTROLLER
• 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)
HIL SHIL SIMULATION USING IMULATION USING EMREMR
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
?
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201123
emulation system
Tdcm
gear
realmachine
real bat.& chopper
EMULATION CONTROLLER
- Example of mechanical power HIL simulation (2) -
drivecontrol
ECU
TTdcm_est mechanicaltrans. (4)-(6)
gear _ref
speed / current loops
Aalto UniversityFinlandMay 2011
« Energy Management of EVs & HEVs usingEnergetic Macroscopic Representation »
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
HIL SHIL SIMULATION USING IMULATION USING EMREMR
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
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201126
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 -
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201127
control
- Maximum control structure -
msteer
battery VSI Park’stransformation
chassis environ.wheels
MSvevFtot
Flw
Frw
Fresvev
vlw
vrwrw
lw
Tdif
Tdif
TgearTim
dif
ESubat
ivsisvsi
gear
uvsi
inductionmachine
udq idq
iim edqidq
d/s
gearbox differential
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
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201128
control
- Estimation and strategy -
msteer
battery VSI Park’stransformation
chassis environ.wheels
MSvevFtot
Flw
Frw
Fresvev
vlw
vrwrw
lw
Tdif
Tdif
TgearTim
dif
ESubat
ivsisvsi
gear
uvsi
inductionmachine
udq idq
iim edqidq
d/s
gearbox differential
powerkRkP
Ftot-ref vve-ref
Flw-refTdiff-ref1
Tgear-refTim-ref
vev-mes
Fres-mes
Frw-refTdiff-ref2
idq-refvdq-refuvsi-ref
FOC
m-refd/s-est
strategy
PWM
model
idq_est
edq m-est
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201129
control
- Synthetic EMR -
msteer
battery VSI Park’stransformation
chassis environ.wheels
MSvevFtot
Flw
Frw
Fresvev
vlw
vrwrw
lw
Tdif
Tdif
TgearTim
dif
ESubat
ivsisvsi
gear
uvsi
inductionmachine
udq idq
iim edqidq
d/s
gearbox differential
power
vev-mes
kRkP
Ftot-ref vve-ref
Flw-refTdiff-ref1
Tgear-refTim-ref
Fres-mes
Frw-refTdiff-ref2
idq-refvdq-refuvsi-ref
FOC
m-refd/s-est
PWM
traction drive
drive control
mechanical power train
power traincontrol
vev-refTim-ref
Tim
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201130
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
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201131
controllerboard
HIL simulator
- Overall HIL simulation -
MS
ES
vve-ref
PWM FOC
ES
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201132- Experimental set-up -
IM DCM
inverterchopper
dSPACE 1103controller board
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201133- Experimental set-up -
IM DCM
inverterchopper
dSPACE 1103controller board
HIL SHIL SIMULATION USING IMULATION USING EMREMR
Aalto University, May 201134
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 UniversityFinlandMay 2011
« Energy Management of EVs & HEVs usingEnergetic Macroscopic Representation »
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
HIL SHIL SIMULATION USING IMULATION USING EMREMR
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.
HIL SHIL SIMULATION USING IMULATION USING EMREMR
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.