technical presentation - hugo provencher · 09/09/2013 technical presentation 2 agenda 1.background...

Technical Presentation

Presented By: Hugo Provencher

09/09/2013 Technical Presentation 2

Agenda

1.Background2.Solar Car Overview3.EcoCAR

• Overview• Model-based design• HV System• Results

4.Other Projects• Matlab GUI• Work at GM

5.Q & A


Background

Bachelor degree in

focus on Power Systems

Bachelor degree inElectrical Eng.

focus on Power Systems

2005 2010 2012 End of 2013

Master’s degree in

High Voltage

Master’s degree inAutomotive Eng.

focus EV Controls & High Voltage

Solar Car #1

Solar Car #2

EcoCAR Y2

EcoCAR Y3

Controls Eng. at GM

GM /Hybrid Vehicle

ControlsGM /

Advanced Chassis

Ctrl & HV Lead

AssistantCtrl & HV

Lead

Ctrl Lead

Ctrl & HV Lead Calibrator

Ctrl Lead for 1 ATW

project

Montreal Toronto

2009 2011


Background

System Eng. In

Transportation

System Eng. InPower Electronics at

Bombardier Transportation

End of 2013 Today

High Voltage and Controls Eng. inElectric Vehicle at

Lion Bus

Auxiliary Power Supply

BART Project

Auxiliary Power Supply Equipment for the

BART Project

eLion Electric School Bus

System Eng.

Electric Vehicle Technical Lead

Montreal

Mid 2015


Solar Car Overview

The Technology• 84 Li-ion cells in 6 modules• 5 kWh total capacity (LTC, now Gaia)• Air-cooled• 1.5 kW wheel motor (BionX)• 25 kW motor controler (Tritium)

Skills Acquired• EV knowledge• High voltage systems• Hands-on• CAN• C code• Circuit and PCB design• Presentation

Darwin

Adelaide

World Solar Challenge 2007 and 2009


C code / PCB

Vehicle Integration Module• C code• Circuit design• PCB design• Integrated into carbon fiber

steering wheel


Solar Car Overview


EcoCAR

Vehicle Integration Module

HV distribution box

Front ESS Thermoelectric unit

12V distribution box

Underside ESS Thermoelectric unit

Dc/Dc


ESS Refinement

Year 2 Design• 84 Cells in 6 modules• 75 kWh total capacity• Air-cooled• Located in rear

passenger compartment

Final Design• 94 Cells in 2 modules• 84 kWh total capacity• Liquid-cooled• Located in engine compartment &

underside of vehicle


Motor / Motor Controller

Motor• Located in the engine bay• S10-EV :

102 kW 3-phase electric motor

Motor Controller• Located in the engine bay• Input:

80-400 Vdc• Output:

160 kW max 266 Arms 0-500 Hz


HV System

Year 2 Design• Located throughout vehicle• Majority of functions performed with

hardware• Location of hardware caused wiring to

run throughout vehicle

Final Design• Located within front ESS• Finite State Machine within MATLAB

used to control HV system• All HV components located within front

cradle. All HV contactors, fuses, and GFI integrated into front ESS enclosure.


HV Schematic


Veh. Integration Module / Chargers

Vehicle Integration Module• All Mototron code written in

MATLAB Simulink due to it’s simplicity.

• Woodward Mototron ECM5554 used as ECU

Chargers• Two more BRUSA chargers were

added to increase charging capacity to 16.5 kWh (previously 9.9 kWh)

2 additional chargers

3 chargers


MotoTron / Veh. Integration Module


GM / MicroAutoBox / Simulink

Confidential


Extrapolated Test Results - With Regenerative Braking

• Total Range: 268 miles (430 km)• Average Energy Consumption: 3 288 Wh/mi (179 Wh/km)• Average City MPGGE: 117.2 (2.0L/100km)• Regenerative braking improved city MPPGE by 30% based on UDDS

test cycle

EPA Testing Results


Matlab Data Import/Sim. Tool


GM / Research Project

Confidential


Thank you for your attention

Q & A


Backup


Detailed DesignDetailed Design

4


HIL / CAN / Simulink / Controler


Vehicle Architecture

Lithium Polymer (Li-Poly) CellsDrive Unit: 110 kW, GM S10-EV motor

Type: Full Function Electric Vehicle (FFEV)

90 kWh of Batteries: Dow Kokam, 240 AHElectric Motor: Delphi S10-EV, 110 kW (150 hp)Traction Inverter Drive: MES-DEA, TIM 600


ESS Refinement-Cont’d

Temperature SensorCoolant Block

Voltage Sensor

Positive Terminal

Negative Terminal

• BMS Control using REAP System• Each cell has voltage sensor• Every 2 cells has temperature sensor• BMS units actively balance the pack as it charges and discharges

Liquid Cooling System

• Each frame has cooling tube • Coolant plate every second frame• 50% water 50% glycol mixture• Thermoelectric units used for heating/cooling liquid

Battery Monitoring

technical presentation - hugo provencher · 09/09/2013 technical presentation 2 agenda 1.background...

Documents