gkn hybrid power - mathworks · gkn hybrid power - background ... gyrodrive enabled bus. engine...
TRANSCRIPT
2
[MATLAB EXPO 2014]
GKN Hybrid Power - Background
We drive the wheels
of hundreds of
millions of cars…
EMPLOYEES MILESTONES
2007 3 Automotive Hybrid Power Ltd Incorporated; Contract with
WF1 for initial flywheel dev.
2008 5 WF1 invests in AHP, renamed WHP Ltd;
F1 system rig tested;
2009 10 Porsche GT3R Hybrid developed
2010 15 Porsche GT3R Hybrid raced
2011 25 Audi eTron Quattro developed; Productionisation
investment (tech, facility)
2012 35 Bus & Tram demonstrator contracts;
TSB Gyrodrive grant awarded;
Audi eTron Quattro wins Le Mans
2013 50 Bus demo trial in London (+20% fuel save); Audi eTron
Quattro wins Le Mans again
2014 50+ GKN acquisition;
Green Bus Certificate achieved;
APC grant awarded: £5.3m, 2 year project
Prototype Proving
Development for
Production
Volume Production
2009 - 2010 2011 - 2014 2015 onwards
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[MATLAB EXPO 2014]
Flywheel in Le Mans 24 Hr
A Simulated Lap
Flywheel helped power the
AUDI e-tron quattro to win
the Le Mans 24 hr race
three years running (2012 -
2014)
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[MATLAB EXPO 2014]
Model Development History
Vehicle fuel simulation model of generic SUV
Developed in association with JLR
Evaluation of fuel savings of a flywheel hybrid vehicle.
Gear
box ICE
Flywheel
Motor
Straight-line speed & torque simulation
Components
Differential, Gearbox, Engine,
Drive Motor, Flywheel
Losses
Vehicle level, Mechanical, Electrical
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[MATLAB EXPO 2014]
Model Development History
“Backward-looking” simulation, from
drive cycle to fuel burn and electrical
energy flow
Predicted NEDC fuel consumption of
base vehicle correlated
Analysis of NEDC and Artemis cycles
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[MATLAB EXPO 2014]
GUI development
GUI developed to aid quick changing of
simulation parameters, components and
drive cycle
Parameter files can be saved and loaded.
Separate tabs for different components.
Complete parameter file can be manually
used without GUI
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[MATLAB EXPO 2014]
Strategy Comparisons
Different Hybrid Control Strategies were Investigated
Yellow – Basic Strategy
Purple – Low Torque Strategy
Blue – Pre Spun Basic Strategy
e.g. Basic,
Low Torque,
Engine Loading,
Flywheel Pre-Spin
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[MATLAB EXPO 2014]
Performance Simulation
Assess hybrid capability for vehicle acceleration enhancement
Non-hybrid Range-Rover acceleration correlated to JLR supplied data
Engine Downsizing
0 – 100 kph
times
Baseline Diesel Non-Hybrid 9.4s
Downsized Engine Non-
Hybrid12.5s
Downsized Hybrid (35kW
motor)10.3s
Downsized Hybrid (70kW
motor)8.7s
3.0L Diesel non-hybrid vs
2.2L Diesel hybrid
35kW & 70kW motor with a
downsized engine &
Flywheel
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[MATLAB EXPO 2014]
CO2 NEDC HIL Simulation
-20000
-15000
-10000
-5000
0
5000
10000
15000
20000
25000
30000
35000
0 200 400 600 800 1000 1200
Power
Real Data Model Data
0
2500
5000
7500
10000
12500
15000
17500
20000
0 200 400 600 800 1000 1200
Flywheel Speed
Real Data Model Data
0
20
40
60
80
100
120
0 200 400 600 800 1000 1200
NEDC Speed ProfileHardware in the Loop NEDC Simulation
Power input provided by Simulation
Model
Mk III Flywheel run on test dyno
Good correlation achieved
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[MATLAB EXPO 2014]
Bus Simulation
Car fuel simulation model adapted for bus.
Data logged from CAN on non-hybrid bus.
Analysed to obtain, vehicle specific
parameters; gearbox ratios, driveline
ratios, ancillary loads and engine fuel map
Gear
box ICE
Flywheel
Motor Gearbox
MGU
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[MATLAB EXPO 2014]
0
10
20
30
40
50
60
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Spe
ed
[kp
h]
Time[s]
Marylebone to Putney - light traffic
0
10
20
30
40
50
60
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Spe
ed
[kp
h]
Time[s]
Putney to Marylebone - heavy traffic
Bus Correlation
Model calibrated against data logged
from real vehicle and fuel economy
taken from operator’s Telematics.
Correlation work key to gaining
confidence in analysis of hybridisation
schemes
Predicted fuel saving: 19%
Results fed into the design and
specification of the Gyrodrive system.
Av = 9.1 kph
Many different hybridisation schemes and electrical
strategies tested
Not all results were as expected,
Underlined importance of simulation first.
Model predicted fuel savings were key
to Go Ahead partnering for
development of first prototype hybrid
bus.
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[MATLAB EXPO 2014]
Performance of Gyrodrive System
Initial Gyrodrive Correlation:
Hybrid enabled model simulation
compared against CAN data from
Gyrodrive enabled bus.
Engine Torque (top chart),
Engine Speed (2nd chart)
Flywheel Speed (middle chart)
Fuel Burn (bottom chart).
All show reasonably good correlation
Av = 17.7 kph
Av = 9.1 kph
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[MATLAB EXPO 2014]
London Bus Fuel Trials
Work is continuing on model
correlation.
Further analysis of bus data to
understand impact of
gradients and passenger load.
Current state of hybrid model
correlation (left), including
gradients.
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[MATLAB EXPO 2014]
Multi-Flywheel Control
Large applications requiring more than one flywheel gives us scope to control the
charge/discharge cycles of each flywheel in unison and/or independently.
We simulated different methods of sharing the powers between different groupings of flywheels
to see if we could:
Lower losses
Improved availability of requested power
Improved life benefits
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[MATLAB EXPO 2014]
Flywheel Cycling History
Matlab script was used to scan the data
files and record the cycling history of the
flywheel in a 2-d array and produce
cycling “heat map” plots.
This cycling history is used in flywheel
fatigue life estimations.
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[MATLAB EXPO 2014]
Flywheel Efficiency Maps
Simulink model used to produce a 3D
map of Flywheel/Inverter efficiency, as a
function of flywheel speed and power.
Calibrated against test rig data
Used to aid understanding of Flywheel
behaviour and influence electrical
machine development trade-offs
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[MATLAB EXPO 2014]
Mathworks Tool Usage
Matlab : General data analysis
Simulink : System-level models, Vehicle-level models
Future development will use simDriveline,
simPowerSystems & Stateflow
Simulink/Stateflow/Embedded Coder : Gyrodrive
Hybrid Controller, Multi-Flywheel System Controller