Function Development With an Electric-Machine-in-the-Loop Setup: A Case Study

Etzold, Konstantin; Fahrbach, Timm; Klein, Serge; Scheer, R.; Guse, Daniel; Klawitter, Marc; Pischinger, Stefan; Andert, Jakob

doi:10.1109/tte.2019.2952288

Cited by 16 publications

(3 citation statements)

References 34 publications

(35 reference statements)

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“…Vehicle development is already supported by virtual test environments in many different phases and tasks. Especially in conceptual design and technology selection as well as for On-Board Diagnostics (OBD) verifications, simulation-based test scenarios are used [59,60]. Increasing virtualization is also taking place in the area of drivability [10,61,62] and emissions calibration [63][64][65] to increase the efficiency of the development processes.…”

Section: Virtual Test Benchesmentioning

confidence: 99%

Real Driving Emissions—Conception of a Data-Driven Calibration Methodology for Hybrid Powertrains Combining Statistical Analysis and Virtual Calibration Platforms

et al. 2021

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The combination of different propulsion and energy storage systems for hybrid vehicles is changing the focus in the field of powertrain calibration. Shorter time-to-market as well as stricter legal requirements regarding the validation of Real Driving Emissions (RDE) require the adaptation of current procedures and the implementation of new technologies in the powertrain development process. In order to achieve highest efficiencies and lowest pollutant emissions at the same time, the layout and calibration of the control strategies for the powertrain and the exhaust gas aftertreatment system must be precisely matched. An optimal operating strategy must take into account possible trade-offs in fuel consumption and emission levels, both under highly dynamic engine operation and under extended environmental operating conditions. To achieve this with a high degree of statistical certainty, the combination of advanced methods and the use of virtual test benches offers significant potential. An approach for such a combination is presented in this paper. Together with a Hardware-in-the-Loop (HiL) test bench, the novel methodology enables a targeted calibration process, specifically designed to address calibration challenges of hybridized powertrains. Virtual tests executed on a HiL test bench are used to efficiently generate data characterizing the behavior of the system under various conditions with a statistically based evaluation identifying white spots in measurement data, used for calibration and emission validation. In addition, critical sequences are identified in terms of emission intensity, fuel consumption or component conditions. Dedicated test scenarios are generated and applied on the HiL test bench, which take into account the state of the system and are adjusted depending on it. The example of one emission calibration use case is used to illustrate the benefits of using a HiL platform, which achieves approximately 20% reduction in calibration time by only showing differences of less than 2% for fuel consumption and emission levels compared to real vehicle tests.

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Section: Virtual Test Benchesmentioning

confidence: 99%

Real Driving Emissions—Conception of a Data-Driven Calibration Methodology for Hybrid Powertrains Combining Statistical Analysis and Virtual Calibration Platforms

et al. 2021

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“…The second method is to replace the real-time electric drive model with a physical testing bench. The vehicle model and electric drive controller are compiled and uploaded to real-time simulators, such as Opal-RT [14], Typhoon [15], and dSPACE [16]. During the real-time HIL testing, the vehicle model is solved with CPU.…”

Section: Introductionmentioning

confidence: 99%

Real-Time FPGA/CPU-Based Simulation of a Full-Electric Vehicle Integrated with a High-Fidelity Electric Drive Model

et al. 2022

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Real-time simulations refer to the simulations of a physical system where model equations for one time-step are solved within the same time period as in reality. An FPGA/CPU-based real-time simulation platform is presented in this paper, with a full-electric vehicle model implemented in a central processing unit (CPU) board and an electric drive model implemented in a field programmable gate arrays (FPGA) board. It has been a challenge to interface two models solved with two different processors. In this paper, one open-loop and three closed-loop interfaces are proposed. Real-time simulation results show that the best method is to transmit electric machine speed from the vehicle model to the electric derive model, with feedback electric machine torque calculated in FPGA. In addition, a virtual vehicle testing tool (CarMaker) is used when building the vehicle model, achieving more accurate modeling of vehicle subsystems. The presented platform can be used to verify advanced vehicle control functions during hardware-in-the-loop (HIL) testing. Vehicle anti-slip control is used as an example here. Finally, experiments were performed by connecting the real-time platform with a back-to-back electric machine test bench. Results of torque, rotor speed, and d&q axis currents are all in good agreement between simulations and experiments.

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“…Because of the opposing trend, we assume the best trade off at the middle of the entire process. In this phase, Hardware-in-the-Loop (HIL) tests in combination with model-based development are performed and a common approach in the automotive industry to test real prototypes such as control units, power electronics and electrical machines in a simulated environment [1]- [8]. The requirements for those tests are real-time capability and a parameterization by measurements or simulation tools such as finite element method (FEM).…”

Section: Introductionmentioning

confidence: 99%

An FPGA-Based Real-Time Spatial Harmonics Model of a PMSM Considering Iron Losses and the Thermal Impact

Scheer

Andert

Gries

et al. 2022

IEEE Trans. Transp. Electrific.

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Function Development With an Electric-Machine-in-the-Loop Setup: A Case Study

Cited by 16 publications

References 34 publications

Real Driving Emissions—Conception of a Data-Driven Calibration Methodology for Hybrid Powertrains Combining Statistical Analysis and Virtual Calibration Platforms

Real Driving Emissions—Conception of a Data-Driven Calibration Methodology for Hybrid Powertrains Combining Statistical Analysis and Virtual Calibration Platforms

Real-Time FPGA/CPU-Based Simulation of a Full-Electric Vehicle Integrated with a High-Fidelity Electric Drive Model

An FPGA-Based Real-Time Spatial Harmonics Model of a PMSM Considering Iron Losses and the Thermal Impact

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