cross-domain systems engineering and vehicle simulation for … · 2015-01-30 · gt conference -...
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EVS28 KINTEX, Korea, May 3-6, 2015
Cross-domain Systems Engineering and Vehicle Simulation for Electrification
Christian Lingenfelser1, Christian Appel2, Christopher Irwin3, 1,2,3Bosch Engineering GmbH, Postfach 13 50, 74003 Heilbronn, Germany,
[email protected] [email protected] [email protected]
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GT Conference - Cross-domain Vehicle Simulation
Motivation
Simulation working modes & tooling
Aston Martin hybrid concept car
Conclusion
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2
3
5
4
Cross-domain Systems Engineering
Agenda
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GT Conference - Cross-domain Vehicle Simulation
Cross-domain Systems Engineering and vehicle simulation: • Enable holistic evaluation of multiple vehicle
topologies and functional concepts
• Cover the increasing complexity and inter- connectivity of systems
• Balance performance and fuel economy/ legislation requirements
• Cover the increasing number of OEM models, model variants and powertrain layouts
• Enable software development and virtual calibration with a common simulation platform
Motivation
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Identification of optimal solution for given constraints
Complexity of electrification systems
potential for CO2 saving
Inno
vatio
n lin
e
Mild HEV<60V
AStart
Stop24
6
x 1000 / min
4080
160
200km/h0
120
Strong HEV
AStart
Stop24
6
x 1000 / min
4080
160
200km/h0
120
Coasting
Stop/StartCoasting
AStart
Stop24
6
x 1000 / min
4080
160
200km/h0
PHEV
Recuperation
Boost
e-Drive
Coasting
AStart
Stop24
6
x 1000 / min
40
80
160
200km/h0
120
EVREX
Recuperation
e-Drive
AStart
Stop24
6
x 1000 / min
40
80
160
200km/h0
120
EV
Recuperation
e-Drive
AStart
Stop24
6
x 1000 / min
40
80
160
200km/h0
120
Recuperation
Boost
Coasting
e-Drive
Recuperation
Coasting
Boost
Variety of customer & legislation requirements
Cross-domain Systems Engineering and vehicle simulation
+
Cross-domain Systems Engineering
Functions CO2 reduction Boost Electric driving
Torque vectoring
All wheel drive
HEV Up to 25% + + +* +*
PHEV – Parallel > 25% ++ ++
PHEV – Axle Split > 25% +++ ++ +* +
EV Single EM Emission free ++ +++
EV Multi EM Emission free +++ +++ ++* +*
Conv. ICE HEV PHEV EV REX EV
* depends on topology and number of electric motors 4
Potential of powertrain electrification • Powertrain architecture – Increasing degree of electrification
• Powertrain functional features
Cross-domain Systems Engineering
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Performance Energy consumption Cost System complexity …
Power density Electric range Components Thermal …
Torque vectoring Cycle fuel economy Integration Controls …
Lap time Efficiency Software Functional safety … … … … … …
Powertrain concept evaluation • Derive potential concepts
− Definition of boundary conditions for synthesis − Base vehicle, constraints, degrees of freedom
• Identification of evaluation criteria
− System optimization targets − Relate all market and legal requirements − Quantify interdependence
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Cross-domain Systems Engineering
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Scale3 Row much more important than column1 Row more important than column0 Row as important as column
-1 Row less important than column-3 Row much less important than column
Criteria Weighting (%)
Performance 36
Energy consumption 14
Cost 27
System complexity 23
Powertrain concept evaluation • Weighting of evaluation criteria
− Pair-wise comparison is applied systematically to all criteria
− Relative importance for each pair − Calculation of overall weighting
• Methodology is applied to main and
sub-category levels
• Ranking derived by OEM and supplier experts
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Cross-domain Systems Engineering
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11 6 5 1
12 7
13
10
9 8
2
3
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Proposed Concepts
Final concept
C1 C4 C9 C12
Req.
YES
NO
Criteria Categories C1 C2 C3
POWER DENSITY 1.3 2.1 ...
TORQUE VECTORING 2.4 3.1 ...
LAP TIME 1.5 4.3 ...
ELECTRIC RANGE 2.9 2.7 ...
CYCLE FUEL ECONOMY 1.2 3.4 ...
EFFICIENCY 4.0 4.7 ...
COMPONENTS 3.3 1.2 ...
INTEGRATION 4.7 3.1 ...
SOFTWARE 2.3 2.3 ...
THERMAL 1.5 4.6 ...
CONTROLS 2.8 3.1 ...
… … … ...
Identification of optimal solution for given constraints using vehicle simulation
Powertrain concept evaluation • Pugh analysis performed on all concepts − Decision matrix
a. Column for each concept and row for each criteria
b. Each score represents concept‘s fulfillment of the weighted criteria
c. Score based on defined ranking scale − Scoring types
a. Analytical derivation b. Simulation results c. Peer evaluation
• Sensitivity analysis to validate robustness of analysis
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GT Conference - Cross-domain Vehicle Simulation
For single domain usage Cross-domain usage Vehicle Dynamics/ Driver Assistance
Powertrain
Energy Management
Cross-Domain Vehicle Simulation
DB (A)
DB (B)
DB (C)
Cross-Domain-
DB
Assumptions
Assumptions
Assumptions
Assumptions
Defined interfaces
Division individual simulation
Weak inter-connection
Separate databases
Assumptions for other domains
Cross-domain
simulation
Strong inter-
connection
Common database
Common assumptions
Considering V-Model Levels
Working modes in simulation
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GT Conference - Cross-domain Vehicle Simulation Vehicle simulation tooling
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Modular vehicle simulation platform: • Utilization of validated component libraries e.g.
− GT-SUITE model libraries − Simulink model libraries − ASCET/C ECU software code
• Integration platform: IPG CarMaker / Simulink • Utilized tools in Co-Simulation
− Powertrain, thermal system: GT-SUITE − Vehicle dynamics: IPG CarMaker − Controls: ASCET/C code (FMU / Simulink) − Low-voltage powernet: Simulink / Simscape
Individual adaptation of simulation tool based on use cases and requirements
GT Conference - Cross-domain Vehicle Simulation Shared simulation platform
OEM: Vehicle Chassis
Model
BEG: Hybrid
Powertrain
OEM/BEG: IC Engine
BEG: Brake System
Supplier X: Aero Systems
BEG: Hybrid/ Engine
Control
BEG: Driver Assist.
Systems
OEM/BEG: Powertrain Cooling Sys.
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Use existing know-how and models from all resources and increase accuracy
Joint development OEM and suppliers: • OEM to provide base vehicle models (e.g. chassis
dynamics, tires, combustion engine)
• Suppliers to deliver specific subsystems (e.g. third party supplier delivers active aero models)
• Cross-domain system development with multiple suppliers and OEM utilizing joint simulation model
• Increased use of more accurate simulation model in all development phases (e.g. base calibration tasks of hybrid operating strategy)
GT Conference - Cross-domain Vehicle Simulation Aston Martin hybrid concept car
Vehicle data Aston Martin
DB9 base vehicle
Aston Martin DB9 hybrid
concept vehicle
Empty-weight 1689 kg 1983 kg
ICE V12 front engine, rear-wheel drive
Transmission 6-speed manual transmission
Maximum power (ICE) 410 kW / 557 PS
Maximum torque (ICE) 620 Nm
Electric motors (EM)
- 2x SMG180/120 (2x 85 kW)
- 1x SMG138/80 (25 kW)
Power electronics 3x INVCON 2.3
High-voltage lithium-ion
battery
8 kWh useable energy
Source: MTZ 02/14, p.26-33, COMPREHENSIVE SIMULATION FOR POWERTRAIN ELECTRIFICATION, Appel, C., Freudenstein, S.; Temmen, C.
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Vehicle data and system topology:
Integration Platform: Simulink
CarMaker 4 SL Vehicle dynamics
Driver Maneuvers
GT Conference - Cross-domain Vehicle Simulation Simulink Co-simulation vehicle model
Powertrain model (GT-SUITE)
ESC SW model (SL) HCU SW model (SL)
SL Co-Sim
SL Model ECU models
Powernet (12V) model (Simscape) SL Model
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driving direction
GT Conference - Cross-domain Vehicle Simulation GT-SUITE powertrain model
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GT Conference - Cross-domain Vehicle Simulation Integration of HCU* software (SL)
Approach: • Selection of relevant hybrid control functions • Generation of .dll file with ECCo • Integration in simulation model • Virtual base calibration • Optimized application with ASCMO (ETAS GmbH) possible
Benefits: • Generation of realistic load profiles • Simple replacement of functions (.dlls) • Decrease in calibration time for proto-
types and more efficient resource management
• Optimized calibration (e.g. for fuel economy)
* Hybrid control unit
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Simulation and calibration of hybrid operating strategy:
GT Conference - Cross-domain Vehicle Simulation
Maneuver catalogue
TestRun #n
TestRun #2
TestRun #1
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Validation process cross-domain simulation
Joint development OEM and suppliers: • Maneuver catalogue for holistic validation (HW &
SW models)
• Vehicle and component measurements for defined maneuvers
• Validation on component/ subsystem level: − Test framework for subsystems − Validation of ECU SW models
• Validation of vehicle dynamics model
• Validation of complete simulation model, e.g.
− Vehicle lateral and longitudinal performance − Overall energy consumption
GT Conference - Cross-domain Vehicle Simulation
Pressure sensors
XCP from ESP HW
VehicleCAN + HybridCAN
ADMA (gyro system) via CAN
GPS antenna
HybridCAN Interface modules Cronos
Temperature sensors
Current sensors
Laptop 1
Laptop 2
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Validation - vehicle measurements
GT Conference - Cross-domain Vehicle Simulation Conclusion
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• Competing market and legal requirements are
resolved
• Systematic methodology for robust vehicle concept selection
• Validated cross-domain simulation environment with integrated HCU software handles increasing complexity
• Tooling and methodology significantly reduces development effort in systems projects
• Hybrid powertrain concepts without compromise
GT Conference - Cross-domain Vehicle Simulation Our vision of a hybrid sports car!
Control your car Feel your car
Be your car
Brake torque
Thank you for your attention!
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