Comprehensive and Cross-domain Vehicle Simulation for ... · PDF fileComprehensive and Cross-domain Vehicle ... Electric motors (EM) - 2x SMG180/120 ... rear-wheel drive Transmission

BEG-PT/ESY1 - Appel | Oct/20/2014 | © Bosch Engineering GmbH 2014. All rights reserved, also regarding any disposal, exploitation,

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Bosch Engineering GmbH

Comprehensive and Cross-domain Vehicle

Simulation for Electrification

GT Conference 2014 2014 – 10 - 20


Powertrain Systems - Christian Appel, Ralf Kleemann

Vehicle Systems - Benjamin Leidel

Chassis & Driver Assistance - Stefan Zahariev

1



GT Conference - Cross-domain Vehicle Simulation


Motivation

Aston Martin hybrid concept car

Simulation validation

Conclusion & outlook

1

2

3

5

Agenda

4

Simulation working modes & tooling

2





Motivation for cross-domain simulation

Use of simulation in the development process:

Enable holistic evaluation of multiple vehicle

topologies and functional concepts

Cover the increasing number of OEM models, model

variants and powertrain layouts

Cover the increasing complexity and interconnectivity

of systems

Balance performance and fuel economy/ legislation

requirements

Identification of optimal solution for given constraints

Enable software development and virtual calibration

with a common simulation platform

11

6

5

1 12

7

13

10

9 8

2

3

4

Criteria categories T 1 T 2 T 3

LAP TIME PERFORMANCE 1,3 2,1 ...

STRAIGHT LINE PERFORMANCE 2,4 3,1 ...

POWER DENSITY 1,5 4,3 ...

PACKAGING FLEXIBILITY 2,9 2,7 ...

TORQUE VECTORING 1,2 3,4 ...

FUEL ECONOMY 4,0 4,7 ...

COST 3,3 1,2 ...

THERMAL INTEGRATION 4,7 3,1 ...

VEHICLE FUNCTIONAL SAFETY 2,3 2,3 ...

NVH 1,5 4,6 ...

CONTROLS COMPLEXITY 2,8 3,1 ...

HIGH VOLTAGE INTEGRATION 5,2 1,8 ...

T 1 T 5 T 7 T 10

Proposed concepts

Score

Req.

Final concepts

YES

NO

Common simulation platform during all development phases

3





Working modes in 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

Assu

mpti

ons

Assu

mpti

ons

Assu

mpti

ons

Assu

mpti

ons

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

4





Vehicle simulation tooling

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

5





Shared simulation platform

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)

OEM:

Vehicle

Chassis Model

BEG:

Hybrid

Powertrain

OEM/BEG:

Combustion

Engine

BEG:

Brake System

Supplier X:

Aero Systems

BEG:

Hybrid/ Engine

Control

BEG:

Driver Assist

Systems

OEM/BEG:

Powertrain

Cooling Sys.

Use existing know-how and models from all resources and increase accuracy

6






Vehicle data and system topology:

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.

7






Vehicle data and system topology:

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.

8

Integration Platform: Simulink

CarMaker 4 SL Vehicle dynamics

Driver

Maneuvers





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

9




GT-SUITE powertrain model

driving direction


10

Integration Platform:

CarMaker (standalone) Vehicle dynamics

Driver

Maneuvers

FMU’s





FMU Co-simulation vehicle model Powertrain model (GT-SUITE)

ESC SW model (SL) HCU SW model (SL)

FMU Export

FMU Export ECU models

Powernet (12V) model (Simscape) FMU Export

11





Integration of HCU* software (SL / FMU)

Simulation and calibration of hybrid operating strategy:

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 (.dll´s)

Decrease in calibration time for

prototypes and more efficient resource

management

Optimized calibration (e.g. for fuel

economy)

* Hybrid control unit

12

Validation process:

Maneuver catalogue for holistic validation (HW and

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




Bosch Engineering

Validation process of cross-domain simulation

Maneuver catalogue

TestRun #n

TestRun #2

TestRun #1

13




Bosch Engineering

Validation - vehicle measurements

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

14





Conclusion and outlook

Conclusion:

Detailed and comprehensive model platform build-up

in cooperation with OEM and other suppliers

Integration of ECU functional software (e.g. hybrid

controls, ESC)

Cross-domain vehicle optimization

Use of a common simulation platform for system

development, software development and calibration

Outlook:

Holistic validation of vehicle, component and ECU

SW models with measurements and in cooperation

with IPG

Integration of all control unit functions as FMUs to

reduce Co-Simulation effort

15





Our vision of a hybrid sports car!

Control your car

Feel your car

Be your car

Brake

torque

Thank you for your attention!

16

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Comprehensive and Cross-domain Vehicle Simulation for ... · PDF fileComprehensive and Cross-domain Vehicle ... Electric motors (EM) - 2x SMG180/120 ... rear-wheel drive Transmission