Hardware-in-the-Loop Testing of Electric Traction Drives with an Efficiency Optimized DC-DC Converter Control

Etzold, Konstantin; Scheer, R.; Fahrbach, Timm; Zhou, Shuang; Goldbeck, Rafael; Guse, Daniel; Frie, Fabian; Sauer, Dirk Uwe; Doncker, Rik W. De; Andert, Jakob

doi:10.4271/2020-01-0462

Cited by 5 publications

(5 citation statements)

References 18 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…In BEV powertrain architecture, the addition of an HV DC/DC converter can have several benefits. First of all, booster mode allows higher and variable DC-link voltage operation, which offers 1.5% lower losses in the drivetrain components (i.e., improvement of losses in inverter by 37.6% and motor by 5.4%) and improves the battery pack ageing [26], [27]. Due to the HV DC/DC converter, system design dependency on the customer's battery pack voltage is reduced, which improves the design scalability [26].…”

Section: Role Of Hv Dc/dc Converter In E-drivetrainmentioning

confidence: 99%

See 1 more Smart Citation

Real-Life Mission Profile-Oriented Lifetime Estimation of a SiC Interleaved Bidirectional HV DC/DC Converter for Electric Vehicle Drivetrains

Chakraborty

Hasan

McGahan

et al. 2022

IEEE J. Emerg. Sel. Topics Power Electron.

View full text Add to dashboard Cite

The rapid growth of Battery Electric Vehicles (BEVs) in the automotive field has led to a need for improving their drivetrain performance, mainly focusing on the extension of the battery operating range. However, the majority of performed technical assessments only consider battery SoC and depth of discharge while neglecting the effects on lifetime and failure probability of power electronic components, more specifically the emerging wide-bandgap-based (WBG) technologies. Toward fulfilling this gap, the EV market demands lifetime estimation performed under real-life mission profile to confirm efficiency and reliable operation of EV power electronics for an extended range meeting the EVs lifetime requirements. In this regard, the present study proposes a versatile experimental device-under-test setup to investigate a novel stepwise holistic system-level lifetime estimation approach for BEV drivetrains equipped with SiC interleaved bidirectional HV DC/DC converter (IBC). To this end, three different real-life mission profile use-cases are investigated in this paper and provides systematic stress-based lifetime estimation, statistical analyses, and validations in comparison. The study outcome highlights realistic information related to significant impacts of operation range and battery SoC features on the IBC lifetime from all aspects.

show abstract

Section: Role Of Hv Dc/dc Converter In E-drivetrainmentioning

confidence: 99%

“…( −1) . −( ) for t ≥ 0 (27) Where β is the shape parameter, η is the scale parameter, and t is the time duration. The shape parameter describes which phase of the "bathtub" curve the failure mode is a part of, as illustrated in Fig.…”

Section: (A)mentioning

confidence: 99%

Real-Life Mission Profile-Oriented Lifetime Estimation of a SiC Interleaved Bidirectional HV DC/DC Converter for Electric Vehicle Drivetrains

Chakraborty

Hasan

McGahan

et al. 2022

IEEE J. Emerg. Sel. Topics Power Electron.

View full text Add to dashboard Cite

show abstract

“…The influences of the electrical components can be used with different degrees of precision in the selected model environment. As far as no real components are available, sub-models for electrical components of different complexities can be applied for calibration tasks of these [79]. Both simple map-based substitute models and highly complex physical models are possible.…”

Section: Outlook To Hybrid Strategy Calibrationmentioning

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

View full text Add to dashboard Cite

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.

show abstract

“…On the other hand, authors in [41], describe a 2-phase IBC with a detailed DSPbased controller and verified results with a 1 kW and 120 V hardware prototype. Additionally, a 6-phase interleaved FC is proposed in [42], it describes a detailed HiL setup for the HV DC/DC converter in Class 3 vehicle system and illustrated advantages of the inclusion the converter in the EVs. A 3phase DC multifunctional converter is presented in [36], considering the functionality of the topology, the control scheme and the average losses contribution of the semiconductor modules.…”

Section: E Automotive Hv Dc/dc Converter's Research Trendsmentioning

confidence: 99%

“…Standard modelling procedures are used by OEMs to reduce the time, cost, and risk associated with the full-scale testing of products. For that, model verification-based HiL has become a fundamental methodology used to make engineering predictions with confidence that can be quantified [42]. The HiL test consists of a type of RT simulation that verifies the modelling and the control system strategy of dedicated hardware that is often in the development stage [55].…”

Section: The Ibc Hil Testbench Developmentmentioning

confidence: 99%

Scalable Modeling Approach and Robust Hardware-in-the-Loop Testing of an Optimized Interleaved Bidirectional HV DC/DC Converter for Electric Vehicle Drivetrains

et al. 2020

View full text Add to dashboard Cite

Automotive Original Equipment Manufacturers (OEMs) require varying levels of functionalities and model details at different phases of the electric vehicles (EV) development process, with a trade-off between accuracy and execution time. This article proposes a scalable modelling approach depending on the multi-objective targets between model functionalities, accuracy and execution time. In this article, four different fidelity levels of modelling approaches are described based on the model functionalities, accuracy and execution time. The highest error observed between the low fidelity (LoFi) map-based model and the high fidelity (HiFi) physics-based model is 5.04%; while, the simulation time of the LoFi model is ~10 4 times faster than corresponding one of the HiFi model. A detailed comparison of all characteristics between multi-fidelity models is demonstrated in this paper. Furthermore, a dSPACE SCALEXIO Hardwarein-the-Loop (HiL) testbench, equipped with a minimal latency of 18μsec, is used for real-time (RT) model implementation of the EV's HV DC/DC converter. The performance of the entire HiL setup is compared with the Model-in-the-Loop (MiL) setup and the highest RMSE is limited to 0.54 among the HiL and MiL results. Moreover, the accuracy (95.7%) of the passive component loss estimation is verified through the Finite Element Method (FEM) software model. Finally, the experimental results of a full-scale 30-kW SiC DC/DC converter prototype are presented to validate the accuracy and correlation between multi-fidelity models. It has been observed that the efficiency deviation between the hardware prototype and multi-fidelity models is less than 1.25% at full load. Furthermore, the SiC Interleaved Bidirectional Converter (IBC) prototype achieves a high efficiency of 98.4% at rated load condition. INDEX TERMS DC/DC interleaved converter, EV, efficiency, electro-thermal modelling, multi-fidelity models, optimization, scalable modelling, Hardware-in-the-loop, and wide-bandgap technology.

show abstract

Hardware-in-the-Loop Testing of Electric Traction Drives with an Efficiency Optimized DC-DC Converter Control

Cited by 5 publications

References 18 publications

Real-Life Mission Profile-Oriented Lifetime Estimation of a SiC Interleaved Bidirectional HV DC/DC Converter for Electric Vehicle Drivetrains

Real-Life Mission Profile-Oriented Lifetime Estimation of a SiC Interleaved Bidirectional HV DC/DC Converter for Electric Vehicle Drivetrains

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

Scalable Modeling Approach and Robust Hardware-in-the-Loop Testing of an Optimized Interleaved Bidirectional HV DC/DC Converter for Electric Vehicle Drivetrains

Contact Info

Product

Resources

About