EMR’15LilleJune 2015
Summer School EMR’15“Energetic Macroscopic Representation”
HardwareHardware --InIn--thethe--Loop simulation : Loop simulation : HardwareHardware --InIn--thethe--Loop simulation : Loop simulation : hybrid locomotive Energy Storage hybrid locomotive Energy Storage
System behavior testsSystem behavior tests
Dr. Tony LETROUVE, Dr. Julien POUGETSNCF Innovation & Research Dep., MEGEVH network,
EMR’15, Lille, June 20152
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»- Outline -
1. HIL simulation interest and structuring problematic
2. Power HIL simulation of PLATHEE locomotive
3. Conclusion and outlooks
EMR’15LilleJune 2015
Summer School EMR’15“Energetic Macroscopic Representation”
HIL HIL simulation interest and structuring simulation interest and structuring problematicproblematic
EMR’15, Lille, June 20154
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
Customer needs
Sizing and power flow studies
Prototype elaboration
- Actual approach -
Feasability response
Prototype development
Prototype behavior validation
Direct validation of component behavior in real time on vehicle,
Components homologation (hardware),
All physics phenomenon are taken into account.
EMR’15, Lille, June 20155
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
Customer needs
Sizing and power flow studies
Prototype elaboration
Time to market
x2… x3 …
- Actual approach -
Feasability response
Prototype development
Prototype behavior validation
x2… x3 …
Cumulativedev. cost
Complex to develop, more than one prototype needed,
Time needed,
The development Cost is exponential with the time on prototype,
A lot of resources are needed (prototype, staffs and tracks availability),
unrepeatable tests,
Security and fault tolerance tests are made on-line.
Sizing Prototype
EMR’15, Lille, June 20156
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
Customer needs
Sizing and power flow studies
Time to market
Prototype elaboration
- Actual approach -
Feasability response
Prototype development
Prototype behavior validation Cumulative dev. cost
Sizing PrototypeAdding intermediary steps:
Reduce the time on prototype (reduce the cost and time of development),
Virtual homologation of some subsystems ahead of time.
Solution : simulation?
EMR’15, Lille, June 20157
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
Customer needs
Sizing and power flow studies
Time to market
Simulation
With SimulationActual approachWith SimulationActual approach
Component library
development using EMR
(common tool, formalism
unification, easy to share, …)
- Adding simulation -
Prototype elaboration
Feasability response
Mise au point du prototype
Prototype behavior validation
Cumulative dev. cost
Prototype development
Sizing ProtoSim.
Prototype debugging ahead of time (ex. control), Easy to use, Quick development, Availability, Repeatable tests.
EMR’15, Lille, June 20158
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
Customer needs
Sizing and power flow studies
Time to market
Simulation
Avec SimulationApproche initialeWith SimulationActual approach
- Adding simulation -
Prototype elaboration
Feasability response
Mise au point du prototype
Prototype behavior validation
Cumulative dev. cost
Prototype development
Sizing ProtoSim.
Models validity range,
virtual homologation complicated,
real time portability of the control?
EMR’15, Lille, June 20159
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
Customer needs
Sizing and power flow studies
Time to market
Simulation
Avec SimulationApproche initialeWith SimulationActual approach
- Adding simulation -
Prototype elaboration
Feasability response
Mise au point du prototype
Prototype behavior validation
Cumulative dev. cost
Prototype development
Sizing ProtoSim.
Solution: « SuperModel » development?
How many development time? All interaction are they taken into account?
EMR’15, Lille, June 201510
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
voltage
- Battery test example -
Control & Energy management
Battery + PE
Upstream system
current
Energy management
ageing? temperature? EMI? Etc.
Development time?Computation time?
EMR’15, Lille, June 201511
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
voltage
INTE
No more model dependency : real power part
+
- Battery test example -
Control & Energy management
Upstream system
current
ERFACE
-
Energy management
EMR’15, Lille, June 201512
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
Simulation Signal HIL Simulation
Power HIL Simulation
Prototype
- HIL simulation -
Power
Control
Power
Control Control
Power
Control
Power
EmulatedSoftware
Real componentsHardware
EMR’15, Lille, June 201513
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
Customer needs
Sizing and power flow studies
Control development
Time to market
Simulation
With simulationActual approach
With HIL
- HIL simulation benefits -
Prototype behavior validation
Feasability response
Cumul dev. cost
Simulation HIL RT control validation and
power subsystems validation
Siz. ProtoHILSim.
Reduce development time, Financial benefits (mobilization et component deterioration), Security et quality tests (fault tolerance tests), Repeatable tests, Virtual homologation available.
EMR’15, Lille, June 201514
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
Voltage
INTE
+
Power adaptations?(Signal) Measures
(Power) (Signal)
- Structuring needs problematic of a Power HILs -
Control & Energy management
Upstream system
Current
ERFACE
-
Studied system Energy management
Emulated models(signal)
Control (signal)
Studied system(Power)
Interface (Power and Signal)
Can EMR helps to structure the different parts of a HIL simulation?
EMR’15LilleJune 2015
Summer School EMR’15“Energetic Macroscopic Representation”
Power HIL simulation of PLATHEE locomotivePower HIL simulation of PLATHEE locomotive
EMR’15, Lille, June 201516
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
Traction
Wh.
DCM4*100 kW
DC Bus
- BB63500 – Diesel Electric locomotive hybridization -
Aux.
Generator
SMMth
600 kW
Drawbacks : - No energetic storage for traction or auxiliairies,
- Diesel engine is uninterrupted (Auxilairies, etc.),
- Diesel engine is not always in its maximal efficiency point.
EMR’15, Lille, June 201517
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
Traction
Wh.
DCM2*100 kW
DC Bus
Storage system
8x200 Scaps (6,94 kWh)SC
- PLATHEE - Power HIL simulation objective -
Aux.
Generator
SMMth
215 kW
Energy management
strategy
4x290 NiCd batt.(194 kWh)Bat
Objectifs : Defining a structured experiment for Energy storage tests,
Validation of the real time portability of the developed control and EMS,
Subsystem tests (nominal and fault tolerance) in a controlled environment before full prototype implementation.
EMR’15, Lille, June 201518
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
TractionDC Bus
Storage system
- PLATHEE - Power HIL simulation objective -
Generator
Energy management
strategy
Objectifs : Defining a structured experiment for Energy storage tests,
Validation of the real time portability of the developed control and EMS,
Subsystem tests (nominal and fault tolerance) in a controlled environment before full prototype implementation.
EMR’15, Lille, June 201519
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
- Power HIL simulation structure -
uc
uhach
iarmemach
mch
ihach
iarm
Fres
Ftot
2Croue
Ω roue
Froue
vtrainvtrain
Ftract
vtrain
vtrain
vtrain
Ffreins
Ffreins-ref
Cmcc
Ωred
uCuC2
mch.
vch
ich
is
usc tot
uc
is8
uc
isc DC
mch.
vch
ich
is
ubt tot
uc
is
4uc
ibt DC
Bat
C Ω
itot
ichuc
iaux
uc
SCs
Aux
Brak.
Env
imsCms
Cmth Ωarb
Ωarb
iarm_ref Cmcc_ref
Driving Strategy
uhach_ref Froue_ref Ftract_ref Ftot_refCroue_ref
kD
2
ICEuc
Cmth_ref
Ωarb_ref
Cms_ref
Generator Strategy
ich_refis_ref
vch_ref
ich_refis_ref
vch_ref
Cmth_ref Strategy
Pge_ref
EMS
ibt DC_ref
4
8isc DC_ref
Wh.
DCM2*100 kW
Aux.
DCBus
SM
ICE215 kW
Bat 1 160 NiCd batt. (194 kWh)
1 600 Scaps (6,94 kWh)SC
Energymanagment
strategy
EMR’15, Lille, June 201520
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
- Power HIL simulation structure -
System under test
uc
uhach
iarmemach
mch
ihach
iarm
Fres
Ftot
2Croue
Ω roue
Froue
vtrainvtrain
Ftract
vtrain
vtrain
vtrain
Ffreins
Ffreins-ref
Cmcc
Ωred
uCuC2
mch.
vch
ich
is
usc tot
uc
is8
uc
isc DC
mch.
vch
ich
is
ubt tot
uc
is
4uc
ibt DC
Bat
C Ω
itot
ichuc
iaux
uc
SCs
Aux
Brak.
Env
imsCms
Cmth Ωarb
Ωarb
iarm_ref Cmcc_ref
Driving Strategy
uhach_ref Froue_ref Ftract_ref Ftot_refCroue_ref
kD
2
ICEuc
Cmth_ref
Ωarb_ref
Cms_ref
Generator Strategy
ich_refis_ref
vch_ref
ich_refis_ref
vch_ref
Cmth_ref Strategy
Pge_ref
EMS
ibt DC_ref
4
8isc DC_ref
Wh.
DCM2*100 kW
Aux.
DCBus
SM
ICE215 kW
Bat 1 160 NiCd batt. (194 kWh)
1 600 Scaps (6,94 kWh)SC
Energy management
strategy
EMR’15, Lille, June 201521
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
- Power HIL simulation structure -
System under test
mch.
vch
ich
is
usc tot
uc
is8
uc
isc DC
mch.
vch
ich
is
ubt tot
uc
is
4uc
ibt DC
Bat
itot
uc
SCs
C Ω
uc
uhach
iarmemach
mch
ihach
iarm
Fres
Ftot
2Croue
Ω roue
Froue
vtrainvtrain
Ftract
vtrain
vtrain
vtrain
Ffreins
Ffreins-ref
Cmcc
Ωred
uCuC2
ich
iaux
uc
Aux
Brak.
Env
ims
iarm_ref Cmcc_ref
Driving Strategy
uhach_ref Froue_ref Ftract_ref Ftot_refCroue_ref
kD
2
Cms
Cmth Ωarb
Ωarb
ICEuc
Cmth_ref
Ωarb_ref
Cms_ref
Generator StrategyCmth_ref Strategy
Pge_ref
EMS
ibt DC_ref
4
8isc DC_ref
ich_refis_ref
vch_ref
ich_refis_ref
vch_ref
EMR’15, Lille, June 201522
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
- Power HIL simulation structure -
mch.
vch
ich
is
usc tot
uc
is
uc
isc DC
mch.
vch
ich
is
ubt tot
uc
is
8
4uc
ibt DC
Bat
itot
uc
SCs
uc
ich
uch
il
il
usource
uch-ref
mch
SE
PowertrainInterface System
Generator
System under test
iarm_ref Cmcc_ref
Driving Strategy
uhach_ref Froue_ref Ftract_ref Ftot_refCroue_ref
kD
2
uc
uhach
iarmemach
mch
ihach
iarm
Fres
Ftot
2Croue
Ω roue
Froue
vtrainvtrain
Ftract
vtrain
vtrain
vtrain
Ffreins
Ffreins-ref
Cmcc
Ωred
uCuC2
ich
iaux
uc
Aux
Brak.
Env
Cmth_ref
Ωarb_ref
Cms_ref
Generator Strategy
ich-ref il-ref
Cms
Cmth Ωarb
Ωarb
ICE
ims
ucuch
il
il
usource
ich-ref
il-ref
uch-ref
mch
SE
Generator Interface System
ich_refis_ref
vch_ref
ich_refis_ref
vch_ref
Cmth_ref Strategy
Pge_ref
EMS
ibt DC_ref
4
8isc DC_ref
EMR’15, Lille, June 201523
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
- Power HIL simulation structure -
mch.
vch
ich
is
usc tot
uc
is
uc
isc DC
mch.
vch
ich
is
ubt tot
uc
is
uc
ibt DC
Bat
itot
uc
SCs
uc
ich
uch
il
il
usource
uch-ref
mch
SE
8
4
Experimental test bed
System under test
iarm_ref Cmcc_ref
Driving Strategy
uhach_ref Froue_ref Ftract_ref Ftot_refCroue_ref
kD
2
uc
uhach
iarmemach
mch
ihach
iarm
Fres
Ftot
2Croue
Ω roue
Froue
vtrainvtrain
Ftract
vtrain
vtrain
vtrain
Ffreins
Ffreins-ref
Cmcc
Ωred
uCuC2
ich
iaux
uc
Aux
Brak.
Env
Cmth_ref
Ωarb_ref
Cms_ref
Generator Strategy
ich-ref il-ref
Cms
Cmth Ωarb
Ωarb
ICE
ims
ucuch
il
il
usource
ich-ref
il-ref
uch-ref
mch
SE
Real-time simulator
ich_refis_ref
vch_ref
ich_refis_ref
vch_ref
Cmth_ref Strategy
Pge_ref
EMS
ibt DC_ref
4
8isc DC_ref
Reduced-scale
Power adaptation element
EMR’15, Lille, June 201524
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
100
i
2 x OP5600
real-time simulator
Power ElectronicsSEMIKRON
1 – Same EMS than Prototype :
Models validation
- Experimental setup and results -
0 100 200 300 400 500 6000
20
40
60
80
100
0 100 200 300 400 500 600-250
-200
-150
-100
-50
0
-10
-5
0
t(s)
vloc [km/h]
Ptract
[kW]
(b)
(a)
80
40
500
-200
-100
0400 300 200
0
0
-10Paux
[kW]
100 600 0 100 200 300 400 500 600-10
-5
0
5
10
21
22
23
24
25
26
0
5
10
22
ibat
[A]
Ubat
[V]
isc
[A]
(f)
(g)
10
0
0
26
24
Reference Measure
t(s) 500 400 300 200 -10
100 600
10
48v Battery
pack
48v Maxwell
0 100 200 300 400 500 600-25
-20
-15
0 100 200 300 400 500 6000
50
100
150
200
250
0 100 200 300 400 500 6000
2
4
6
6
250
2
0
Pgs
[kW]
Cons [L]
(e)
(d)
50
150
4
-10
-20
(c)
0 100 200 300 400 500 600-10
-5
0
0 100 200 300 400 500 60021
22
23
24
25
26
0 100 200 300 400 500 60040
45
50
55
60
605550
Usc
[V]
(h)
(i)
(j)
-10
26
24
22
45Ubus
[V]
Reference Measure
Reference Measure 40
48v Maxwell
Supercaps
400W controllable
voltage source
EMR’15, Lille, June 201525
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
- Experimental setup and results -
i
100
OP5600
real-time simulator
Power ElectronicsSEMIKRON
2 – New EMS and studies outlooks :
Fair strategies comparison (maintenance, component behavior, fuel, …)
2 x OP5600
real-time simulator
0 100 200 300 400 500 600-10
-5
0
5
10
21
22
23
24
25
26
0
5
10
22
ibat
[A]
Ubat
[V]
isc
[A]
(f)
(g)
10
0
0
26
24
Reference Measure
t(s) 500 400 300 200 -10
100 600
10
0 100 200 300 400 500 6000
20
40
60
80
100
0 100 200 300 400 500 600-250
-200
-150
-100
-50
0
-10
-5
0
t(s)
vloc [km/h]
Ptract
[kW]
(b)
(a)
80
40
500
-200
-100
0400 300 200
0
0
-10Paux
[kW]
100 600
48v Battery
pack
0 1000 2000 30000.55
0.6
0.650.65
0.6
0.55
0 1000 2000 3000-100
0
100 ibat
[A]
SoCbat
[%]
48v Maxwell
0 100 200 300 400 500 600-10
-5
0
0 100 200 300 400 500 60021
22
23
24
25
26
0 100 200 300 400 500 60040
45
50
55
60
605550
Usc
[V]
(h)
(i)
(j)
-10
26
24
22
45Ubus
[V]
Reference Measure
Reference Measure 40
0 100 200 300 400 500 600-25
-20
-15
0 100 200 300 400 500 6000
50
100
150
200
250
0 100 200 300 400 500 6000
2
4
6
6
250
2
0
Pgs
[kW]
Cons [L]
(e)
(d)
50
150
4
-10
-20
(c)
400W controllable
voltage source
0 1000 2000 3000
Pgs
[kW]
Cons[L]
0 1000 2000 3000
1
0
0
0 1000 2000 3000
isc
[A]
SoCsc
[%]
48v Maxwell
Supercaps
EMR’15LilleJune 2015
Summer School EMR’15“Energetic Macroscopic Representation”
Conclusion and outlooksConclusion and outlooks
EMR’15, Lille, June 201527
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
EMR as a structuring tool :
- Such a complex system and experiment needs methodology : EMR,
- Integral causality allows to use description and control part in real time.
- Conclusion & outlooks -
Reduced-scale Power HIL simulation
- Reduce the cost and time to market of new developments,
- Do not required any prototype component,
- Quick development and adjustment possibility,
- Interface systems behavior validation,
- Prepare experiment for full-scale.PLATHEE Supercapacitors
Outlooks
- fault tolerance tests and control robustness,
- full-scale HIL simulation,
- implementation on prototype.
PLATHEE Supercapacitors
PLATHEE NiCd Batteries
EMR’15LilleJune 2015
Summer School EMR’15“Energetic Macroscopic Representation”
Thanks for your attention!Thanks for your attention!
Tony LETROUVE
Julien POUGET
EMR’15, Lille, June 201529
«« HIL simulation : hybrid locomotive ESS behavior t estsHIL simulation : hybrid locomotive ESS behavior tes ts»»
- Authors -
Dr. Julien POUGETSNCF, Innovation & Research Dept., MEGEVH, France
Dr. Tony LETROUVE
SNCF, Innovation & Research Dept., MEGEVH, FrancePhD in Electrical Engineering at University of Franche-Comte, BelfortResearch topics: optimal design, modeling, control and energy management applied in railway hybrid energy systems (electrical and diesel locomotive, electrical and thermal building and railway network)
Dr. Tony LETROUVESNCF, Innovation & Research Dept., MEGEVH, FrancePhD in Electrical Engineering at University of Lille & PSA (2013)Research topics: EMR, HIL simulation, Energy Management, Prototyping