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Hybrid Electric Vehicle powertrain development The impact on processes, methods and testing systems

Instrumentation and Testing Solutions

Stefan Kanya

AVL List GmbH

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2Hybrid & Battery Testing Technology

Definition of Hybrid Powertrain

A hybrid vehicle utilizes at least

! two energy-storage systems with

! two energy-converting systems

to propel the vehicle.

Source: UNO 2003

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Definitions

Micro Hybrid:

The e-motor is used for the start/stop function and backs up energy if the vehicle is retarded. It is not able todrive the vehicle and has a low power of about 2,7 to 4 kW/t.

Mild Hybrid:

The e-motor is used assisting the combustion engine for driving the vehicle and for the start/stop function. Itbacks up energy if the vehicle is retarded. It is not able to drive the vehicle and has a power of 6 to 14 kW/t.

Full Hybrid:

The e-motor is used assisting the combustion engine for driving the vehicle and for the start/stop function. Itbacks up energy if the vehicle is retarded. It is able to drive the vehicle at low speed (e.g. Toyota Prius up to70 km/h) and has a power above 20 kW/t.

Electric Vehicle:

The e-motor replaces the combustion engine for driving the vehicle. It backs up energy if the vehicle is

retarded. Solutions as a Plug in Hybrid are possible (The e-motor is used in the city for short distances, thecombustion engine is used on request)

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Parallel Hybrid System:

Both, the electrical motor and the combustion engine serve for driving the vehicle.

Serial Hybrid System:

The combustion engine provides the energy which is converted to the electrical motor which drives thevehicle.

Mixed Hybrid System (Power Split Systems):

The electrical motor and/or the combustion engine serve for driving the vehicle.

e.g. Hybrid Synergy Drive (Toyota, Ford):One part of the energy is provided directly to the vehicle, the other part is provided by the electrical motor.The gear ratio and the speed is controlled by the electrical motors

e.g. Two Mode Transmission (GM, Daimler, Ford):

One electrical motor works parallel, the second electrical motor work serial. The power distribution is doneby clutches. Besides the transmission has 4 fixed gears for the parallel driving mode.

Definitions

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The Electric Motor in the VehicleParallel Hybrid System

Honda IMA

K ... Clutch G ... Gear Box B ... BatteryE ... E-Motor

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The Electric Motor in the VehicleSerial Hybrid System

Volkswagen MEGA

G ... Gear Box B ... BatteryE ... E-Motor

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The Electrical Motor in the VehicleTwo-Mode Hybrid System

G ... Gear Box B ... BatteryE ... E-Motor

GM/DC/BMW Two-Mode Hybrid

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Combustion

EnginePlanetaryGear Box

PlanetaryGear Box

Generator

Generator

Motor

Motor

Differential

Differential

The Electrical Motor in the VehiclePower Split Hybrid System

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VW twinDRIVEAn Example of a Hybrid Powertrain

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Interaction

Environment

Driv

er

Sta

nd

ards

Vehicle

Performance

Interaction

Interaction

Measurement and analysisof parameters

Application ofcontrol unitsStress of physicalcomponents

FunctionalityDurability

Testing of Hybrid and Electric Vehicles

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! Mechanical Parameters

! Electrical Parameters

! Thermal Parameters

! Combustion

Engine

! E-Motor

! Battery

! Gear Box

! Vehicle

! Combustion

Engine CU

! Hybrid CU

! Battery CU

! Gear Box CU

! Vehicle CU

! Safety

! Emissions

! Sportive

! Economical

Testing of Hybrid and Electric Vehicles

Environment

Driv

er

Sta

ndard

s

Vehicle

Performance

FunctionalityDurability

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High End DC Power SupplyBattery Simulator

Battery Tester

Vehicle

Test Bed

Transm.

Test Bed

Powertrain

Test Bed

Engine

Test Bed

Fuel Cell

Test Bed

AVL Hybrid Testing SolutionsProduct and Solution Overview

E-MotorTest Bed

Battery

Test Bed

Virtual Vehicle & Environment Platform

AVL InMotionTM powered by CarMakerTM

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E-Motor

Test Bed

Powertrain

Test Bed

Vehicle

Test Bed

Electronics

Test Bed

Power-Up and Shut-Down

Function Development

Basic Calibration

Simulation models of vehicle, driver, road and traffic

Efficiency

Durability

Calibration

Powertrain Dynamics

Energy Management

Vehicle Stability Functions

Performance, Efficiency, Safety

Thermal Behavior

Acoustic Behavior

Safety Validation

Frontloading supported by a model-based development process

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Engine Test Bed

VCU

SimulationModels:

Brakes

Road

Driver

CAN

ECU

LoadUnit

IC-Engine

TCU

Tyre

Vehicle

HCU

BCU Battery

E-Motor

Transmission

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Powertrain Test Bed Configuration FWD - Hybrid

VCU

SimulationModels:

Brakes

Road

Driver

CAN

ECU

LoadUnit

LoadUnit

Trans.

IC-Engine

TCU

Tyre

Vehicle

HCU

BCU Battery

E-Motor

E-Motor

BatterySimulator

HV-DC

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Powertrain Test Bed Configuration RWD - Hybrid

VCU

SimulationModels:

Brakes

Road

Driver

CAN

ECU

TCU

Tyre

Vehicle

HCU

BCU Battery

BatterySimulator HV-DC

E-Motor

LoadUnit

LoadUnit

IC-Engine

Trans./E-Motor

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Powertrain Test Bed Configuration 4WD - Hybrid

VCU

SimulationModels:

Brakes

Road

Driver

CAN

ECU

LoadUnit

LoadUnit

T/M

IC-Engine

TCU

Tyre

Vehicle

HCU

BCU Battery

E-Motor

BatterySimulator

HV-DC

E-Motor

LoadUnit

LoadUnit

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xCU

Powertrain CAN

I/O

Automation System

Signal Conditioning

Testrun Control

Signal Monitoring

Real Prototype Load Unit

xCU

Fast Ethernet

AVL InMotion Workstation

AVL InMotion RT Node

CANTestbed

Interface

Remote

Control

Virtual

Prototypes

Graphical User InterfaceData Storage

Ethernet

Concept of X-in-the-Loop Test Bed

xCU(AUTOSAR)

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Highly dynamic engine test bed

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! Functional testing

! Durability testing

! Safety testing

! EMC testing

! Driving in electric mode

! Boost performance

! Regenerative braking

! Shift strategy! Gearshift torque compensation

! Vehicle stability

Testing of Hybrid and Electric Vehicles - Challenges

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Concept of X-in-the-Loop Test Bed

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AVL InMotion Expandable Simulation Platform

Mobile Systems Integration into Cabinet

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Integration of Customer Models from Development Projects

Model Selection

to select a standard orcustomer specific model

1

1

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Example: Battery Loading and Vehicle Range (AER)

Real test vehicle Virtual test vehicle

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Example: Inner City Driving with Driver Assistance

Real test vehicle Virtual test vehicle

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Maneuver Based Testing at the Test Bed

Mini Driving Maneuver

! HV Power On / Off

! AC with vehicle at rest

! Mode-Shift

! Hill-Holding / Creep

! Partial / Full Load Acceleration

! Constant driving! Braking / Cornering

! ...

Driving Maneuver

! City

! Overland

! Highway

! Mountain

! Race track

! Handling course

! Emission cycle

! ...

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Example: Fuel consumption in NEDC at the Test Bed

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0 10 20 30 40 50 60 70 80 90 1000

20

40

60

80

100

120

140

Distance [km]

Speed[km/h]

Actual

Limit

Example: Real world driving at the Test Bed

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+5 %+4 %+3 %Difference

8.9 l/100km7.2 l/100km6.9 l/100kmRoad x-y-z

8.5 l/100km6.9 l/100km6.7 l/100kmRoad s-z

Driver SportiveDriver NormalDriver Economy

Example: Real world driving at the Test Bed

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Example: Multi Configuration Test Bed for Electric Vehicles

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Configuration 1: Transmission Testing

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Configuration 2: Powertrain Testing 2WD

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Configuration 3: E-Motor Testing

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Configuration 4: Parallel Testing

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Battery Tester

Vehicle

Test Bed

Transm.

Test Bed

Powertrain

Test Bed

Engine

Test Bed

Fuel Cell

Test Bed


E-MotorTest Bed

Battery

Test Bed



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One Battery for all Applications ?

Source: www.eco-aesc.com, 03/2009

At System Level:

! Applications increase from HEV to EV

! Percentage of pure electric driving

increases! Usable SOC range increases

At Component Level:

! HEV: Power/Energy > 15

! EV: Power/Energy ~ 2

! Reduction of unused energy in thebattery to save costs

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Battery Technology Chemistry and Cell Design

HEV

EV

Plug-In HEV

Source: www.saftbatteries.com

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EnergySafety

Life time

Costs Power

Battery technology 5 major focus areas

Goals & Test procedures defined by

1. Public private partnershipse.g. FreedomCAR (USA), VDA (EU), JARI (JP)

2. OEM specific procedurese.g. Volvo standard procedures

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3. Self

discharge

3. x days @ 30!C, until capacity loss > 5% (x = f(chemistry))

5.Thermal

performance

5. Perform tests 1 to 4 at various temp. (range: -30 to +52!C)

2. Power 2. Discharge with constant power or with hybrid power pulses1. Discharge with constant current to cut-off voltage1)1. Static

capacity

1) Hybrid Pulse Power Characterization Current; IHPPC = PCDT / (Vavg *BSF)

IHPPC HPPC discharge current between pulses [A]

PCDT Power of const. discharge test [W]

Vavg Arithmetic average voltage between Vmax and Vmin

BSF Battery size factor (min. number of cells or modules that is necessary to meet all performance and life targets)

6. Energy

efficiency

6. Charge balanced pulse profile (33s, 3kW/3s,27kW/52s,-3.2kW/2s,-18kW) to calculate energyefficiency (100 times @ def. SOC & T)

4. Cold

cranking

4. 3 pulses (2s, 7kW) @ -30!C (10s break in between)7. Life

tests

7a. Charge sustaining cycle life test (flat cycles)

7b. Charge depleting cycle life test (deep cycles)

7c. Combined cycle life test

7d. Calendar life test

Battery technology Performance tests

Source: www.uscar.org, U.S. Department of Energy, Vehicle Technologies Program, Battery Test Manual For Plug-In Hybrid Electric Vehicles,

03/2008

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safe under any circumstances (use and abuse)

Battery technology End of Life (E.O.L) goals

EnergySafety

Life time

Costs Power

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Battery technology Safety tests Abuse conditions

Mechanical Thermal

Electrical

Shock (Module)

Drop (Pack)

Penetration (Cell)

Roll over (Module)

Immersion (Module)

Crush (Cell)

Vibration (Cell)

Radiant Heat (Cell)

Thermal Stability (Cell)

Thermal Insulation (Module)

Thermal Runaway (Module)

Thermal Shock (Cell)

Elevated Temperature

Storage (Cell)

Extreme cold temperature (Cell)

Short circuit (Cell)

Partial short circuit (Module)

Overcharge (Cell)

Over discharge (Cell)

AC exposure (Pack)

Source: www.uscar.org, United States Advanced Battery Consortium, Electrochemical Storage System, Abuse Test Procedure Manual, 1999

Note: Remarks in brackets mark thelowest level of assembly recommendedfor test

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costs: 200 to 300 ! / kWh (2015)


EnergySafety

Life time

Costs Power

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cycle life: > 10001),a) to 50002),b) (charge depleting cycles) > 3000003),b) (charge sustaining cycles)

overall lifetime: 101),a) to 154),b) yrs. operating temperature : -30 to +52!Cb)


1) cycled @ 80% depth of discharge (DOD)

2) charge depleting life at a discharge throughput of 17 MWh

3) charge sustaining HEV cycle life @ 50 Wh profile

4) calendar life @ 40!C

Source:

a) www.uscar.org, Long-term goals as stated in USABC Goals for Advanced Batteries for EVs.pdf

b) www.uscar.org, U.S. Department of Energy, Vehicle Technologies Program, Battery Test Manual For Plug-In Hybrid Electric Vehicles, 03/2008

EnergySafety

Life time

Costs Power

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Source:

a) www.uscar.org, U.S. Department of Energy, Vehicle Technologies Program, Battery Test Manual For Plug-In Hybrid Electric Vehicles, 03/2008

b) www.uscar.org, United States Advanced Battery Consortium, Electrochemical Storage System, Abuse Test Procedure Manual, 1999

Battery technology Battery life time

Battery life limits

Battery life tests

Thermal stress

Electrochemical stress

(cycling conditions,

charge turnaround)

Mechanical stress

Charge sustaining cycle life testa)

Charge depleting cycle life testa)

Combined cycle life testa)

Calendar life testa)

Vibration Testb)

Shock Testsb)

Battery abuse tests

No test covers all topics

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Flat Road

Uneven Road

Car: Honda Civic Hybrid

Drive cycle: Part of New European Drive Cycle

Acceleration to 0 to 32 kmh-1

Deceleration from 32.5 to 0 kmh-1

Road: Changes from flat to uneven1)

Result: Mechanical impactElectrical behavior of the E-Motor

1) ISO 8608 "Mechanical vibration - Road surface profiles

NEDC-drive cycle

Speed

[km/h]

Time [s]

used part

Battery Testing Realistic Usage Pattern

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Duration 25s

3.5 kW

30 Nm

Torque E-Motor [Nm]Power E-Motor [W]

Acceleration in z [m/s2]

Flat Road

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Duration 25s

3.5 kW

30 Nm

noise up to 0.5 kW

Torque E-Motor [Nm]Power E-Motor [W]

Acceleration in z [m/s2]

Uneven Road

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Battery Tester

Hardware

Climatic Chamber

Battery

AVL InMotion

Driving

Maneuvers

Powertrain

Model

Driver

Model

Virtual Electric

Conditions

Environmental

Conditions

Real Electric

Conditions

Shaker

Battery

AVL Battery TestbedVirtual Proving Ground

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BatteryTester

Climatic

Chamber Battery

Fail Safe-

PLC

TB213/214

Tempera

ture

Cont

rol

STOP

Voltage,Current

Inert

Gas

ALARM

Dilution

Inertization

Air

Exhaust

System

Flap

600V, 300A

90kW max.

Error

Error

Gas !

Smoke, Fire !

in Climatic Chamber

AVL Battery TestbedAVL Safety Concept

Safety Concept

for Lithium Ion

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AVL Battery TestbedPlug & Play Container Solution

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Battery Tester

VehicleTest Bed

Transm.Test Bed

PowertrainTest Bed

EngineTest Bed

Fuel CellTest Bed


E-MotorTest Bed

BatteryTest Bed



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Test

Characterization

Modelling

Simulation, HiL

f (T,SOC,.....)

40 60 80 100 120 140-20

-15

-10

-5

0

5

10

15

20

25

30

35

Re

Im

T=0

T=25

T=40

From Battery Testing to Battery Simulation

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cooling

control unit

power cabinet

AVL BTS-BS Battery SimulatorsHardware Overview

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Battery Test Bed and Simulator Performance Range

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Battery Tester

VehicleTest Bed

Transm.Test Bed

PowertrainTest Bed

EngineTest Bed

Fuel CellTest Bed


E-MotorTest Bed

BatteryTest Bed



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Electric Motor Technology Classes and Limits

Belt StrengthPackagingEnergy StorageLimitations due to

8.000 rpm * Ratio8.000 rpm>15.000 rpmMaximum Speed

30 kW60 kW160 kWMaximum Power

20 kW40 kW120 kWRated Power

Belt-Starter-

Generators (BSG)

Integrated

Systems (ISG)

Axle

Drives

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Characteristic curve measurement

Goal:

! Capturing attributes of the motor with characteristiccurves

! Recording of motor parameters:

! DC and AC currents

! DC and AC voltages

! Torque

! Speed

! Coil temperatureSpeed [rpm]

Field weakening rangeBasic speed range

Torq

ue

[Nm

]

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Measurement (e.g.: max. characteristic curve):

! Run the motor from 0 to nmax with maximum load

! Measure torque and speed

! Display the characteristic curve

! Compare it with the input characteristic curve and look for changes

! The characteristic curve has to be in defined specification range

! Measure the machine parameters (DC and AC currents, DC and AC voltages, torque, speed and coiltemperature)

VA

n, M

Converter PMSM Gearbox Work machine

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Needed:

! Galvanometer

! Voltmeter

! Torque measurement

! Speed measurement

! Temperature sensor

Power Analyzer

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Insulation resistance measurement

Measurements:Apply voltages:

1. UVW separately to ground

2. UVW separately to sensors

3. Sensors to ground

Read off insulation measurement device

PMSM

U

V

W

UDCUDC

Sensor

UDC

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Insulation resistance measurement

Needed:

! Insulation measurement device

Goal:

! Determination of insulation resistance

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Winding resistance measurement

Measurements:

! Apply voltages between U-V, U-W, V-W

! Measure the voltages and currents

! Calculate winding resistance

RU

RV

RW

U

A

V

E.g.: Measuring of U-W resistance

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Surge test

Goal:

! No flashover

! No damage on insulation and dielectric fluid

! Measuring of equalizing currents and comparingwith the value of end of line (EOL)

Needed:

! Surge tester

! Measuring device for leakage current

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Test flow chart

Axialpulsen

[-X1-] Konditionierung / [-X2-] Eingangsparameterbestimmung

Korrosionsprfung

Hochtemperatur-

Dauerlauf

(HTOE)

Berechnung

nach Arrhenius

[-X3-] Ausgangsparameterbestimmung

Datei:

Stand: 14.11.2008

Temperaturwechsel-

Dauerlauf

(PTCE)

Berechnung

nach Coffin-Manson

Feuchte Wrme

Dauerlauf

(HTHE)

Berechnung

nach Lawson

IP Schutzklassenprfung

Zustzliche Einzelprfungen

Chem. Bestndigkeit

Thermoschock in Luft

Schadgas

Biegeumlaufprfung fr

Rotor

Torsionswechselprfungfr Rotor

Schleuderprfung

Tieftemperaturlagerung

Thermoschock in Luft

Mechanischer Schock &

Vibrationsprfung

Salzsprhnebelprfung

Staubprfung

A B C D E F

6 6 6 6 6 x


Vibrationsprfung


Vibrationsprfung

Schleuderprfung

Steinschlag

Feuchte Wrme zyklisch

Kombiniert mit Frost

Tauchprfung Tauchprfung Tauchprfung

Tauchprfung


Vibrationsprfung

Kurzschlussfestigkeit

Berstdrehzahlermittlung

Bemerkung: - Im Anschluss an jede Prfung ist entweder der groe Parametertest ( ) bzw. der kleine Parametertest ( )durchzufhren.

- Eine Reinigung des Prflings ist zu keiner Zeit zulssig.

[-A1-]

[-A2-]

[-A3-]

[-B1-]

[-B2-]

[-B3-]

[-B4-]

[-B5-]

[-B6-]

[-B7-]

[-B8-]

[-B9-]

[-B10-]

[-C1-]

[-C2-]

[-C3-] [-D3-] [-E3-]

[-E2-]

[-E1-][-D1-]

[-D2-]

[-F1-]

[-F2-]

[-F3-]

[-F4-]

[-F5-]

[-F6-]

[-F7-]

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Electric Motor Test Bedfor ISG and BSG Motors

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Functional Test Beds

Durability Test Beds

Electric Motor Test BedTest Field Layout

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E-motor

E-motor

Inverter

DC/DC

E-motor inverterBattery simulator

Hybrid CU

Automation

System

Dynamo-

meter

Power measurement device

DC/AC dyno

inverter

AC/DC

converter

Mains

DC/AC E-motor

inverter

Electric Motor Test BedTypical Architecture of the Test Cell

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Air cushion system serves for an easymovement inside the climatic chamber

Fast aligning and media docking

Standard receiver for ISG and SSG pallets

Main components in stainless steel

Electric Motor Test BedUnique Pallet System

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! Torsion stiff design

! Evaluation of radial and axial Offsets

! Use of BSD couplings

! Special adapter for docking station

! Shaft Guard

! End position monitoring switch

Electric Motor Test BedShaft Layout and Design

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! Capacity 1200 l! Temperature -70 to +180C

! Temperature gradient >+/-5C/min

! Heat compensation at -55C > 4,5 kW

! Reinforced bottom plate in the climaticchamber (300kg)

! Inner walls made of stainless steel

! Interface to automation

Electric Motor Test BedClimatic Chamber with integrated Pallet System

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High speed Dynamometers Gear box solutions

! Air cooled motor with attached lowinertia planetary gear box

! Compact Orbital Gear design ofepicyclical gearbox with balancedtoothed loading tailored to beflange mounted and flexiblycoupled directly to the driving or

the driven machine! Co-axial arrangement allows

integral mounting, flangemounting and simplified bedplatedesign

! Standard AVL power cabinet withmulti drive design

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High speed Dynamometers Gear box Solutions

DynoDur 220/5.2-20:

! Continuous Power: 220kW

! Continuous torque: 400Nm

! Max. speed: 20,000rpm

! Overload: 50%

! Inertia: 0.06kgm"

DynoDur 350/5.6-15:



! Max. speed: 15,000rpm! Overload: 70%

! Inertia: 0.45kgm"

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High speed Dynamometers Dyno only solutions

DynoDur 150/4.6-15:




! Overload: 20%

! Inertia: 0.3kgm"

DynoRoad 202/12:




! Overload: 25%

! Inertia: 0.3kgm"

Shinko Denki HL-420




! Inertia: 0.2kgm"

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Auxiliary Equipment

Measurement Box:

Front-End Modules for Pressure and Temperaturemeasurement

Location of the Front-End Modules very close tothe unit under test

Connection Box:

Place for the inverter and the power analyzer

Voltage sensing close to the unit under test

Connection Box for the unit under test inverter

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E-Motor Test Bed Automation and Control

! Pallet system handling! Full integration of

! Battery Simulator

! Dynamometer System

! Cooling Unit

! Climatic Chamber

! Power-Analyzer

! Vibration Monitoring System

! CAN or Profibus Interface to UUT

! Speed / Torque / X-Control

! Dynamic limit monitoring

! Predefined test runs! Efficiency mapping

! Dynamic durability

! ...

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PUMA Open Hardware

DriverPower Analyzer

IntegrationDevice Handler

Device

Framework

PUMA Open Software

Device HandlerBSQ etc.

Power Analyzer

Yokogawa WT3000 / WT1600

Ethernet

Ethernet Card

Electric Motor Test BedIntegration of Power Analyzer

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Battery Simulator

Hardware

Climatic Chamber

E-Motor

AVL InMotion

Driving

Maneuvers

Powertrain

Model

Driver

Model

Virtual Electric

Conditions

Environmental

Conditions

Real Electric

Conditions

Mechanical

Conditions

Dyno

Electric Motor Test BedVirtual Proving Ground

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Your Benefits

! Compact design! No special requirement for the base plate

! Short UUT exchange time (in minutes)

! Test of different UUT on the same test cell

! Fast cooling and heating of the UUT

! Overload capabilities of the load units

! Complete commissioning before delivery

! Modular design allows future upgrades

! Integration of the specific measuring equipment in the automation system

! Slim interface of the conditioning devices for the connection in the conditioning system

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Why AVL?

! Worldwide one of the biggest supplier for test cells! Complete, customer oriented solutions for e-motor tests

! Big derived knowledge from high dynamic and high speed test cells

! Many References

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References for E-motor Testing Solutions

America

! GM

! Michigan University

! Magna Electrics

Japan

! Honda

Europe

! Arsenal Research Vienna

! Continental

! ZF Sachs

! Racing (Kers)

China

! Harbin University

! Harbin Institute of Technology

! Jing-Jin Electric

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Battery Tester

VehicleTest Bed

Transm.Test Bed

PowertrainTest Bed

EngineTest Bed

Fuel CellTest Bed


E-MotorTest BedBatteryTest Bed



Upgrade Packages for Hybrid Testing

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Upgrade Packages for Hybrid Testingat Engine and Powertrain Test Beds

Package 2: Battery simulation and electric

measurements

- AVL Battery Simulator

- Interface to Power Analyzer

Package 3: Fully hybrid vehicle simulation

and control units integration

- AVL InMotion

- AVL Electronics Pallet

Package 1: Start/Stop capability- Software application with PUMA Open

- Test bed clutch

- Test bed gearbox

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Package 1:Test Bed Modification on mechanical Assembly for Engine only

Existing situationEnginepallet

Loadunit

Movement of dyno and palletdocking station to increasethe intermediate distance

Insertion of a remotelyactuated clutch

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Package 2:Test Bed Configuration Hybrid Engine only

HV-DC

LoadUnit

IC-Engine

E-Motor

Powerdistribution

unit

HV-DC

Powerdistribution

unit

Clutch

LoadUnit

Clutch

E-Motor

IC-Engine

BatterySimulator

MILD HybridConfiguration

MICRO HybridConfiguration

BatterySimulator

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AVL InMotionTM

powered by CarMakerTMAVL Highly Dynamic Testbed

Vehicle Tire Trailer Digitalized Road Driver Traffic

Package 3: Virtual Vehicle Environment

Office

OfflineLab

HILTestbed

HILRoad

HIL

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References for Hybrid Testing Solutions (Excerpt)

Industrial:

! Magna Canada

! PSA France

! VPT France

! VTEC Sweden

! Tubitak Turkey

! FAW China

! Honda Japan

! Toyota Japan

! Continental Germany

! General Motors USA

Research:

! Arsenal Research Vienna Austria

!University Karlsruhe Germany

! University of Michigan - USA

Motor Sports:

! Formula 1 KERS (4 Teams - Confidential)

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REFERENCE INSTALLATIONS

HYBRID & BATTERY TESTING TECHNOLOGY

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ARSENAL RESEARCH, AUSTRIA

Configuration: 1 x E-Motor test bed

Application: realtime simulation of hybridvehicle for maneuver basedtesting of E-Motor with controlunits

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ARSENAL RESEARCH, AUSTRIA

MotorControl Unit

BatteryControl Unit

TransmissionControl Unit

EngineControl Unit

Engine

Transmission

DifferentialAxles

Tires

Chassis Driver

Road

Traffic

CAN-Bus

Realtime Simulation Models of:

Hybrid Development Platform

Power Module BatterySimulator

DynoElectricMotor

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UNIVERSITY OF MICHIGAN, USA

Configuration: 1 x Engine test bed

Application: realtime simulation ofconventional and hybridpowertrain

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BMW, GM

PUMA Open Interface to Yokogawa PowerAnalyzer WT3000 / WT1600

Power Analyzer

EthernetPUMA Open Hardware

Interface Card

Driver SoftwarePower Analyzer

Integration DeviceHandler

DeviceFramework

PUMA Open Software

Device HandlerBSQ etc.

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UNIVERSITY KARLSRUHE, GERMANY

Configuration: 1 x Powertrain test bed1 x Transmission test bed1 x Chassis dyno test bed

Application: realtime simulation of hybridvehicle for maneuver based testingof powertrain and transmission with

simulated traffic

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Chassis DynoControl

AVL InMotionSimulation Platform

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Chassis Dyno Control

Control and Monitoring

AVL InMotion RT Node

Model Execution, I/O Interface

Powertrain-CAN

TCP/IP

AVL InMotion WorkstationModel Editor, Data Logging,

Visualization, Simulation Test Runs

Analog

DynoDyno

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CONTINENTAL, GERMANY

Configuration: E-Motor test beds

Application: functional and durability testing ofelectric motors

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BOSCH, GERMANY

Configuration: Battery test beds

Application: R&D Testbed for development andverification of Lithium-Ion batterypacks

TV certified

Battery

Tester

Climatic

Chamber Battery

Fail Safe-

PLC

TB213/214

Temperature

Control

STOP

Voltage,Current

Inert

Gas

ALARM

Dilution

Inertization

Air

Exhaust

System

Flap

600V, 300A

90kW max.

Error

Error

Gas !

Smoke, Fire !

in Climatic Chamber

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TOYOTA, JAPAN

Configuration: Powertrain test beds

Application: realtime simulation of battery formaneuver based testing ofpowertrain and hybrid controlunit

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HONDA, JAPAN

Configuration: Powertrain test beds

Application: realtime simulation of battery formaneuver based testing ofpowertrain and hybrid controlunit

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AVL TECHCENTER, GRAZ


Application: realtime simulation ofconventional and hybridpowertrain for maneuverbased testing of engine andengine control unit

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UNIVERSITY DARMSTADT, GERMANY


Application: realtime simulation ofconventional and hybridpowertrain for maneuverbased testing of engine,electric motor and control units

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VOLVO TECHNOLOGY, SWEDEN

Configuration: 1 x Powertrain test bed

Application: realtime simulation of vehicleand battery for maneuver basedtesting of powertrain and vehiclecontrol units of trucks and

busses

Documents

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