Green Energy and Technology
More information about this series at http://www.springer.com/series/8059
Bogdan Ovidiu Varga Florin Mariasiu
Dan Moldovanu Calin Iclodean
•
•
Electric and Plug-In Hybrid
Vehicles
Advanced Simulation Methodologies
123
Bogdan Ovidiu Varga
Automotive and Transport Department
Technical University of Cluj-Napoca
Cluj-Napoca, Cluj
Romania
Dan Moldovanu
Automotive and Transport Department
Technical University of Cluj-Napoca
Cluj-Napoca, Cluj
Romania
Florin Mariasiu
Automotive and Transport Department
Technical University of Cluj-Napoca
Cluj-Napoca, Cluj
Romania
Calin Iclodean
Automotive and Transport Department
Technical University of Cluj-Napoca
Cluj-Napoca, Cluj
Romania
ISSN 1865-3529
Green Energy and Technology
ISBN 978-3-319-18638-2
DOI 10.1007/978-3-319-18639-9
ISSN 1865-3537
(electronic)
ISBN 978-3-319-18639-9
(eBook)
Library of Congress Control Number: 2015940989
Springer Cham Heidelberg New York Dordrecht London
© Springer International Publishing Switzerland 2015
This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part
of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations,
recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission
or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar
methodology now known or hereafter developed.
The use of general descriptive names, registered names, trademarks, service marks, etc. in this
publication does not imply, even in the absence of a specific statement, that such names are exempt from
the relevant protective laws and regulations and therefore free for general use.
The publisher, the authors and the editors are safe to assume that the advice and information in this
book are believed to be true and accurate at the date of publication. Neither the publisher nor the
authors or the editors give a warranty, express or implied, with respect to the material contained herein or
for any errors or omissions that may have been made.
Printed on acid-free paper
Springer International Publishing AG Switzerland is part of Springer Science+Business Media
(www.springer.com)
Foreword
When Bogdan Varga asked me to write the Foreword to his book on “Electric and
Plug-In Hybrid Vehicles Advanced Simulation Methodologies” I was indeed
honored: Generally, people who are asked to write Forewords are those who matter
to the author.
I met Bogdan Varga in 2007 at a conference for automotive engineers organized
by the Technical University of Cluj. I had just taken over the job of Sales Manager
for Central and Eastern Europe for Instrumentation and Test Systems. I was
impressed by the determination and ardor Bogdan showed in his scientific work as
well as his professionalism and effectiveness in preparing big research projects.
In 2010, AVL together with Technical University of Cluj built a Laboratory for
Testing, Research, and Certification of Internal Combustion Engines, AVL delivering not only testing equipment but also research tools as well as software for data
processing and simulation.
Since then the Technical University of Cluj and AVL have been in close contact,
exchanging knowledge and experience in research, focusing mainly on methods to
deal with the increasing complexity of powertrains.
The complexity and diversity of future powertrain systems elevates dramatically.
One driving factor is given by enhanced legislative requirements, such as reduction
in CO2 fleet emissions and pollutant emissions under real-world driving conditions
(RDE).
Another factor is increased customer demands as positive driving experience,
safety, agility, comfort, and confidence in driver assistance systems. On top of this,
shorter model cycles and moderate cost of ownership are demanded.
One key to managing this complexity is to use and integrate virtual development
environments into the development process of powertrain systems.
In the past, for example, the functional integration of subsystems into a complete
vehicle system was done within a system integration using only real hardware.
Today this is combined with virtual environments, too. In future this integration
will be done in purely virtual environments in early stages of development.
v
vi
Foreword
With the book’s approach Bogdan provides an excellent tool for researchers
working on these challenges: he not only describes the simulation method of
complex powertrains, but also explains how to build a working virtual development
environment for classical, hybrid, and electrical powertrains.
I am convinced that Bogdan’s book will be a big help for any researcher to better
understand the process of modeling and simulation of complex powertrains and to
start out in creating a virtual laboratory.
Graz
April 2015
DI Stefan Kanya
Sales Manager Central and Eastern Europe
AVL List GmbH
Acknowledgments
The writing process of this book consumed a huge amount of work, research, and
documentation, but in the end, the effort is dedicated to those who are interested in
applicative use of advanced modeling and simulation technologies for the optimization of energy efficiency in automotive electric and hybrid powertrains.
First of all, we are deeply grateful to AVL LIST GmbH, A-8020 Graz,
Hans-List-Platz 1 (www.avl.com) for their essential logistic support, availability,
and also for provision of their high-level professional expertise and technical
support in the writing process of the book. Their advice definitely increased the
scientific and applicative quality of book.
Still, all of this would not have been possible if we did not have a strong and
permanent support of leadership (Prof. Nicolae Burnete, Ph.D.) and our colleagues
from Automotive Engineering and Transport Department of Technical University
of Cluj-Napoca, Romania. Therefore, we would like to extend our sincere thanks to
all of them.
Nevertheless, we express our gratitude toward our families for their support,
understanding, and encouragement, which helped us permanently throughout the
preparation of the book.
Bogdan Ovidiu Varga
Florin Mariasiu
Dan Moldovanu
Calin Iclodean
vii
Contents
1
Principles of Modeling and Simulation Processes . . . . . . . . . . . . .
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Mathematics Behind the Models . . . . . . . . . . . . . .
2.1 Vehicle (V) . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1
Properties. . . . . . . . . . . . . . . . . . . . .
2.1.2
User-Defined Variables . . . . . . . . . . .
2.1.3
Input and Output Variables . . . . . . . .
2.1.4
Computation of the Module Variables .
2.1.5
Equation System. . . . . . . . . . . . . . . .
2.2 Clutch (C) . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.1
Properties. . . . . . . . . . . . . . . . . . . . .
2.2.2
User-Defined Variables . . . . . . . . . . .
2.2.3
Input and Output Variables . . . . . . . .
2.2.4
Computation Variables . . . . . . . . . . .
2.2.5
Equation System. . . . . . . . . . . . . . . .
2.3 Torque Converter (T) . . . . . . . . . . . . . . . . . .
2.3.1
Properties. . . . . . . . . . . . . . . . . . . . .
2.3.2
User-Defined Variables . . . . . . . . . . .
2.3.3
Input and Output Variables . . . . . . . .
2.3.4
Computation Variables . . . . . . . . . . .
2.3.5
Equation System. . . . . . . . . . . . . . . .
2.4 Gearbox (G). . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1
Properties. . . . . . . . . . . . . . . . . . . . .
2.4.2
User-Defined Variables . . . . . . . . . . .
2.4.3
Input and Output Variables . . . . . . . .
2.4.4
Computation Variables . . . . . . . . . . .
2.4.5
Equation System. . . . . . . . . . . . . . . .
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1
7
9
9
9
12
20
20
21
28
29
30
31
32
32
33
34
35
37
38
39
40
41
44
46
47
47
ix
x
Contents
2.5
CVT—Continuously Variable Transmission (H) . . . . .
2.5.1
Properties. . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.2
User-Defined Variables . . . . . . . . . . . . . . . .
2.5.3
Input and Output Variables . . . . . . . . . . . . .
2.5.4
Computation Variables . . . . . . . . . . . . . . . .
2.5.5
Equation System. . . . . . . . . . . . . . . . . . . . .
2.6 Single Ratio Transmission (D) . . . . . . . . . . . . . . . . .
2.6.1
Properties. . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.2
User-Defined Variables . . . . . . . . . . . . . . . .
2.6.3
Input and Output Variables . . . . . . . . . . . . .
2.6.4
Computation Variables . . . . . . . . . . . . . . . .
2.6.5
Equation System. . . . . . . . . . . . . . . . . . . . .
2.7 Differential (N). . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1
Properties. . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.2
User-Defined Variables . . . . . . . . . . . . . . . .
2.7.3
Input and Output Variables . . . . . . . . . . . . .
2.7.4
Computation Variables . . . . . . . . . . . . . . . .
2.7.5
Equation System. . . . . . . . . . . . . . . . . . . . .
2.8 Planetary Gearbox (PG) . . . . . . . . . . . . . . . . . . . . . .
2.8.1
Properties. . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.2
User-Defined Variables . . . . . . . . . . . . . . . .
2.8.3
Input and Output Variables . . . . . . . . . . . . .
2.8.4
Equation System. . . . . . . . . . . . . . . . . . . . .
2.9 Internal Combustion Engine (E) . . . . . . . . . . . . . . . .
2.9.1
Properties. . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.2
User-Defined Variables . . . . . . . . . . . . . . . .
2.9.3
Input and Output Variables . . . . . . . . . . . . .
2.9.4
Computation Variables . . . . . . . . . . . . . . . .
2.9.5
Equation System. . . . . . . . . . . . . . . . . . . . .
2.9.6
Power Correction on Environment Conditions
2.9.7
Charger Response Behavior . . . . . . . . . . . . .
2.9.8
Temperature Models . . . . . . . . . . . . . . . . . .
2.9.9
Consumption Models . . . . . . . . . . . . . . . . .
2.9.10 Fuel Shut-Off . . . . . . . . . . . . . . . . . . . . . . .
2.10 Generator (L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.1 Properties. . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.2 User-Defined Variables . . . . . . . . . . . . . . . .
2.10.3 Input and Output Variables . . . . . . . . . . . . .
2.10.4 Computation Variables . . . . . . . . . . . . . . . .
2.10.5 Equation System. . . . . . . . . . . . . . . . . . . . .
2.11 Electrical Consumer (X) . . . . . . . . . . . . . . . . . . . . .
2.11.1 Properties. . . . . . . . . . . . . . . . . . . . . . . . . .
2.11.2 User-Defined Variables . . . . . . . . . . . . . . . .
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49
50
53
56
57
57
59
59
62
64
64
65
66
67
67
69
69
70
70
71
71
72
73
73
74
83
95
96
97
99
102
103
106
114
116
117
117
119
120
120
122
123
123
Contents
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
xi
2.11.3 Input and Output Variables
2.11.4 Computation Variables . . .
2.11.5 Equation System. . . . . . . .
Electric Motor (J) . . . . . . . . . . . . .
2.12.1 Properties. . . . . . . . . . . . .
2.12.2 User-Defined Variables . . .
2.12.3 Input and Output Variables
2.12.4 Computation Variables . . .
2.12.5 Equation System. . . . . . . .
Electric Machine (EM) . . . . . . . . .
2.13.1 Properties. . . . . . . . . . . . .
2.13.2 User-Defined Variables . . .
2.13.3 Input and Output Variables
2.13.4 Computation Variables . . .
2.13.5 Equation System. . . . . . . .
Battery H (QH) . . . . . . . . . . . . . .
2.14.1 Properties. . . . . . . . . . . . .
2.14.2 User-Defined Variables . . .
2.14.3 Input and Output Variables
2.14.4 Computation Variables . . .
2.14.5 Equation System. . . . . . . .
Gearbox Control (O) . . . . . . . . . . .
2.15.1 Properties. . . . . . . . . . . . .
2.15.2 User-Defined Variables . . .
2.15.3 Input and Output Variables
2.15.4 Computation Variables . . .
2.15.5 Equation System. . . . . . . .
Gearbox Program (P) . . . . . . . . . .
2.16.1 Properties. . . . . . . . . . . . .
2.16.2 User-Defined Variables . . .
2.16.3 Input and Output Variables
2.16.4 Computation Variables . . .
2.16.5 Equation System. . . . . . . .
CVT Control (H) . . . . . . . . . . . . .
2.17.1 Properties. . . . . . . . . . . . .
2.17.2 User-Defined Variables . . .
2.17.3 Input and Output Variables
Anti-Slip Control (ASC) . . . . . . . .
2.18.1 Properties. . . . . . . . . . . . .
2.18.2 User-Defined Variables . . .
2.18.3 Input and Output Variables
PID Control (PID) . . . . . . . . . . . .
2.19.1 Properties. . . . . . . . . . . . .
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124
125
125
125
126
126
128
129
129
131
132
133
135
136
137
140
140
141
145
146
147
148
148
150
151
151
151
153
153
154
161
162
162
162
162
163
164
165
165
165
166
167
167
xii
Contents
2.19.2 User-Defined Variables . . .
2.19.3 Input and Output Variables
2.19.4 Equation System. . . . . . . .
2.20 Brake (B) . . . . . . . . . . . . . . . . . .
2.20.1 Properties. . . . . . . . . . . . .
2.20.2 User-Defined Variables . . .
2.20.3 Input and Output Variables
2.21 Cockpit (CO) . . . . . . . . . . . . . . . .
2.21.1 Properties. . . . . . . . . . . . .
2.21.2 User-Defined Variables . . .
2.21.3 Input and Output Variables
2.22 Exhaust System (EX) . . . . . . . . . .
2.22.1 Properties. . . . . . . . . . . . .
2.22.2 User-Defined Variables . . .
2.22.3 Input and Output Variables
2.22.4 Computation Variables . . .
2.22.5 Equation System. . . . . . . .
2.23 MATLAB®/Simulink™ (ml) . . . . .
2.23.1 Properties. . . . . . . . . . . . .
2.23.2 User-Defined Variables . . .
2.23.3 Input and Output Variables
2.24 Function (FU) . . . . . . . . . . . . . . .
2.24.1 Properties. . . . . . . . . . . . .
2.24.2 User-Defined Variables . . .
2.24.3 Input and Output Variables
2.24.4 Equation System. . . . . . . .
2.25 Constants (CN). . . . . . . . . . . . . . .
2.25.1 Properties. . . . . . . . . . . . .
2.25.2 User-Defined Variables . . .
2.25.3 Input and Output Variables
2.26 Monitor . . . . . . . . . . . . . . . . . . . .
2.26.1 Properties. . . . . . . . . . . . .
2.26.2 Input and Output Variables
2.27 Wheel/Tire (W) . . . . . . . . . . . . . .
2.27.1 Properties. . . . . . . . . . . . .
2.27.2 User-Defined Variables . . .
2.27.3 Input and Output Variables
2.27.4 Computation Variables . . .
2.27.5 Equation System. . . . . . . .
References. . . . . . . . . . . . . . . . . . . . . . .
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168
169
169
170
170
171
172
173
173
174
175
176
176
177
178
179
179
179
179
180
180
180
181
181
183
183
185
185
185
185
186
186
186
186
187
189
194
194
195
200
Virtual Powertrain Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203
221
Contents
xiii
4
Classical Powertrain Configuration Model and Simulation
4.1 Classical Vehicle Model . . . . . . . . . . . . . . . . . . . . .
4.1.1
Classic CVT Model . . . . . . . . . . . . . . . . . .
4.1.2
Automatic FWD Model . . . . . . . . . . . . . . . .
4.2 Run Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1
Result Manager . . . . . . . . . . . . . . . . . . . . .
4.2.2
Standard Diagrams . . . . . . . . . . . . . . . . . . .
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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223
223
223
250
277
277
282
287
5
Hybrid Powertrain Configuration Model and Simulation
5.1 Hybrid Vehicle Model Creation . . . . . . . . . . . . . . .
5.1.1
Hybrid CVT Model. . . . . . . . . . . . . . . . . .
5.1.2
Hybrid Planetary Gearbox Model . . . . . . . .
5.2 Run Simulation . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1
Result Manager . . . . . . . . . . . . . . . . . . . .
5.2.2
Standard Diagrams . . . . . . . . . . . . . . . . . .
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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289
289
289
320
341
341
346
385
6
Electric Powertrain Configuration Model and Simulation .
6.1 Electric Vehicle Model Creation . . . . . . . . . . . . . . . .
6.1.1
Electric FWD Model . . . . . . . . . . . . . . . . . .
6.1.2
Electric FWD RE Model . . . . . . . . . . . . . . .
6.2 Run Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1
Result Manager . . . . . . . . . . . . . . . . . . . . .
6.2.2
Standard Diagrams . . . . . . . . . . . . . . . . . . .
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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387
387
387
397
424
424
430
462
7
Creating Virtual Road Infrastructure
7.1 AVL Road Importer . . . . . . . . .
7.1.1
Getting Started . . . . . . .
7.1.2
Data Submenu . . . . . . .
7.1.3
Road Submenu . . . . . . .
7.1.4
Plot Submenu. . . . . . . .
7.1.5
Export Submenu . . . . . .
7.1.6
Going Online . . . . . . . .
Reference . . . . . . . . . . . . . . . . . . . . .
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463
463
463
464
465
470
473
476
476
8
Loop Powertrain Simulation . . . . . . . . . .
8.1 IPG CarMaker . . . . . . . . . . . . . . . .
8.1.1
Virtual Vehicle Environment
8.1.2
CarMaker Main GUI . . . . . .
8.1.3
CarMaker Main Parameters .
8.1.4
Start Simulation . . . . . . . . .
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477
477
477
479
498
504
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xiv
Contents
8.2
CRUISE—CarMaker Co-Simulation . . . . .
8.2.1
General Settings . . . . . . . . . . . . .
8.2.2
CRUISE—CarMaker Interfaces . .
8.2.3
Model for Co-Simulation . . . . . . .
8.3 Running the Simulation for Electric Model
References. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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507
507
509
513
520
524
Abbreviations
4WD
ABS
ACC
ARB
ASC
AST
BMEP
CIT
CTF
CVT
DLL
DoE
DVA
EFG
EMS
EPS
ESP
EV
FCHEV
FWD
GHG
GIS
GPS
GUI
GXF
HEV
HPS
HTML
ICE
iFD
IFF
Four Wheel Drive
Anti-lock Braking System
Autonomous Cruise Control
Anti-Roll Bar
Anti-Slip Control
Advanced Simulation Technologies
Brake Mean Effective Pressure
CarMaker Interface Toolbox
Concerto Transport File
Continuously Variable Transmission
Dynamic Link Library
Design of Experiments
Direct Variable Access
Energy Flow Graphics
Engineering Measurement System
Electric Power Steering
Electronic Stability Program
Electric Vehicle
Fuel Cell Hybrid Electric Vehicle
Front Wheel Drive
GreenHouse Gas emissions
Geographic Information System
Global Positioning System
Graphic User Interface
GPS eXchange Format
Hybrid Electric Vehicle
Hydraulic Pneumatic Supplies
HyperText Markup Language
Internal Combustion Engine
Ratio of Final Drive
Input From File
xv
xvi
ISG
iTR
KML
NEDC
PHEB
PID
PNG
RE
RPN
SAM
SOC
SRT
VVE
XML
Abbreviations
Integrated Starter Generator
Ratio of Final Transmission
Keyhole Markup Language
New European Driving Cycle
Plug-in Hybrid Electric Bus
Proportional Integral Derivative
Portable Network Graphics
Range Extender
Reverse Polish Notation
System Analysis Mode
State Of Charge
Single Ratio Transmission
Virtual Vehicle Environment
eXtensible Markup Language