ELECTRIFICATION AVL e-Power Measurement and Analysis W.Giczi AVL List GmbH Public
CONTENT AVL E-POWER MEASUREMENT SYSTEM A A INTRODUCTION, SYSTEM PORTFOLIO B B PROPERTIES, BENEFITS, USPs C C USE CASES, SYSTEM CONFIGURATIONS D SUMMARY Public W.Giczi | MIP | 11 November 2015 | 2
CONTENT AVL E-POWER MEASUREMENT SYSTEM A A INTRODUCTION, SYSTEM PORTFOLIO B B PROPERTIES, BENEFITS, USPs C C USE CASES, SYSTEM CONFIGURATIONS D SUMMARY Public W.Giczi | MIP | 11 November 2015 | 3
ELECTRIFICATION OF THE POWERTRAIN 4 STEPS Low (< 60V) Voltage High Voltage Safety! Hybrid Technology 1 2 3 4 Micro Micro / Mild Mild Full / Plug-In BEV / FC 12V 12V / 48V 48V .. 130V 130V .. 400V 400V .. 800V Voltage 0,5..3 kW 3..8 kW 10 .. 20 kW > 20 kW > 75 kW el. Power 0 km 0 km ~2 km > 20 km > 150 km el. Distance Higher CO 2 Benefit vs. increasing System-Complexity and System-Cost Stop-Start Systems largely introduced. 1 48V Based systems promise best ratio between cost, features and safety 2 3 Plug-In Hybrids (PHEV) very attractive for CO2 Super-Credits 4 Battery Technology is key for pure electric driving (Battery Electric, BEV) market for pure electric vehicles to develop along new mobility concepts Public W.Giczi | MIP | 11 November 2015 | 4
AVL ELECTRIFICATION INTEGRATED TOOL CHAIN Advanced Simulation Tools (AST) AVL-FIRE AVL-EXCITE AVL-BOOST AVL-CRUISE AVL-M.O.V.E./DRIVE Powertrain TB E-Motor TB Vehicle TB Inverter TB HIL TB Battery TB e-Power Measurement Instrumentation & Test Systems (ITS) Public W.Giczi | MIP | 11 November 2015 | 5
AVL E-POWER MEASUREMENT ACTUAL PORTFOLIO Signal conditioning units: H igh V oltage P robe box C urrent S ensor interface and S upply box HVP-Box CSS-Box Data acquisition unit: IndiModul.xEV ü Split design to place the signal conditioning as close as possible to the UUT Public W.Giczi | MIP | 11 November 2015 | 6
AVL E-POWER MEASUREMENT SPLIT MODULE DESIGN Control room Test room Test chamber E-Motor TB Gigabit Ethernet High voltage, magn. fields! PC with control software, Data acquisition unit Signal conditioning keyboard and screen. inside test room close to UUT Safe area! (noisy, dangerous area) Public W.Giczi | MIP | 11 November 2015 | 7
PURPOSE OF POWER ANALYZER FOR POWERTRAIN ELECTRIFICATION MEASUREMENT MECHANICAL ELECTRICAL E-MOTOR POWER FLOW BATTERY INVERTER EFFICIENCY EFFICIENCY UUT AVL e-Power Measurement System Measurement of basic values: e-motor § AC + DC currents speed + torque § AC + DC voltages § Engine speed and torque AC + DC VOLTAGE 3x AC high voltage Calculation (IEEE 1459-2000) AC, 3~ ±10 V PC § Power from battery inverter E-motor current § Power into e-motor § Inverter efficiency DC high voltage § E-motor efficiency AC current DC ±1 A ±10 V § Fundamental & Harmonics Battery current AC + DC CURRENT Display of: § Power / efficiency over time battery § Graphs of power, current and voltage traces Public W.Giczi | MIP | 11 November 2015 | 8
AVL E-POWER MEASUREMENT ACTUAL PORTFOLIO Electrical measurement equipment consists of: Current sensor signal conditioning ( CSS-Box ) § 4 channels for LEM current sensors § Current sensor supply and conditioning box LEM current transducer transforms sensor output current to voltage Voltage signal conditioning ( HVP-Box ) § 4 channels H igh V oltage P robe box § 3ph ACV(e-motor) + 1 DCV(battery) Data acquisition ( IndiModul.xEV ) § 8 channels fast (800kHz) analogue data acquisition based on well proven IndiModul 622 § Torque and speed sensor channels and: PC with Data acquisition Software ( IndiCom.xEV ) based on well proven AVL IndiCom Public W.Giczi | MIP | 11 November 2015 | 9
AVL INDICOM.XEV OPERATING SOFTWARE FLEXIBLE “LIVE-” RESULT DISPLAY EXAMPLE Example of IndiCom.xEV Result windows: e-Power trend (results) + scope (raw data) + numeric + harmonics Public W.Giczi | MIP | 11 November 2015 | 10
AVL INDICOM.XEV, DATA POST PROCESSING HYBRID POWERTRAIN DYNAMIC TEST Transient e-motor investigation IndiCom.xEV Result windows: e-Power trend with cursor (full test time result graph) + zoomed trend window tracking the cursor above + scope raw data window tracking the trend cursor (time stamp synchronized) Public W.Giczi | MIP | 11 November 2015 | 11
CONTENT AVL E-POWER MEASUREMENT SYSTEM A A SYSTEM PORTFOLIO B B PROPERTIES, BENEFITS, USPs C C USE CASES, SYSTEM CONFIGURATIONS D SUMMARY Public W.Giczi | MIP | 11 November 2015 | 12
AVL ELECTRIFICATION TEST INSTRUMENTATION PROPERTIES ü Plug and Play ü Identification of signal conditioning units for current and voltage measurement ü Current sensor type recognition ü Self reading of calibration data Benefit : Automatically self setup and parameterization, no manual input necessary No error due to fault data input Easy to start and run, test bed time saving Public W.Giczi | MIP | 11 November 2015 | 13
AVL ELECTRIFICATION TEST INSTRUMENTATION PROPERTIES ü Easy operation: v Device development focused and optimized for electric powertrain testing , no needless functionality like common universal power analyzer have v Calculations are preconfigured → Ready to run immediately after power on v Easy adaption of result calculations by customer due to graphic formula editor AVL CALCGRAPH TM or Calculator tool v Different numerical and graphical displays are available, GUI can be customized Goals: High usability, powerful and quick & easy to use! AVL CALCGRAPH TM Public W.Giczi | MIP | 11 November 2015 | 14
AVL ELECTRIFICATION TEST INSTRUMENTATION PROPERTIES ü Smart data recording: v Storage of data together with results on PC hard disk with compressed format (AVL IFile or ASAM standard format MDF4 ), synchronized data packages, easy handling of long drive cycle test data E-Motor providing 150Nm torque pulses - Ideal pulse position pmi Cylinder Pressures [bar] bar 40 8.72 30 Cylinder Pressures SPEED 20 rpm 10 1176.7 0 EMotTorqueAvg Nm 400 [Nm] 67.29 IndicatedTorque Indicated Torque v Post processing with powerful 300 ETorqueMax EMotTorque Nm 200 152.3 Inner Torque E-Motor 100 0 MaxDevAng [deg] Software AVL CONCERTO TM 6 1300 N_ENG 4 1250 2 [1/min] Speed - E-Motor Speed - IC Engine 1200 0 N_EMOT MaxDevAng 1150 deg 1100 5 1.11 AngDev_b Angle Deviation - E-Motor [deg] 0 AC Currents [A] 250 -5 AC Currents 0 ETorqueMaxAngle -250 deg -360 -300 -240 -180 -120 -60 0 60 120 180 240 300 360 ü Online result display and raw data recording: 46.48 Crank Angle [deg] q Most common power analyzers: focused on online monitoring of results q Pure recording systems: focused on recording of raw data and post processing à AVL measurement system can do both ! ü High dynamic speed performance due special adaptive detection algorithm: Public W.Giczi | MIP | 11 November 2015 | 15
CONTENT AVL E-POWER MEASUREMENT SYSTEM A A SYSTEM PORTFOLIO B B PROPERTIES, BENEFITS, USPs C C USE CASES, SYSTEM CONFIGURATIONS D SUMMARY Public W.Giczi | MIP | 11 November 2015 | 16
USE CASE UUT: E-POWERTRAIN WITH 2 AND 4 E-MOTORS Ø Hybrids with power split drive design (Motor + generator) Ø or combination of Integrated Starter Generators (ISG) and axle e-motor Ø or two e-motor/inverter all-wheel drive systems design: Public W.Giczi | MIP | 11 November 2015 | 17
USE CASE UUT: HYBRID POWERTRAIN HYBRID UPGRADES FOR ENGINE & POWERTRAIN TESTBEDS • Rapid rise of complexity at system and component level. • Calibration of all powertrain components to fulfill the various customer demands (drivability) and to achieve the objective of future CO2 emission limits and optimal fuel efficiency APPLICATIONS The application spectrum for different kinds of hybrids up to pure electric vehicles ranges from: • engine start/stop • regenerative braking as well as • acceleration support relating to vehicle stability , load shifting • durability testing and the • controller adjustment of the electrified powertrains. Public W.Giczi | MIP | 11 November 2015 | 18
CONTENT AVL E-POWER MEASUREMENT SYSTEM A A SYSTEM PORTFOLIO B B PROPERTIES, BENEFITS, USPs C C USE CASES, SYSTEM CONFIGURATIONS D SUMMARY Public W.Giczi | MIP | 11 November 2015 | 19
SUMMARY: MAIN BENEFITS AND KEY FEATURES Ø Designed for automotive test bed environments - modular and flexible Ø Online results display and raw data recording Ø Suitable for static and dynamic operation Ø Test bed integration (PUMA, CAN) ü Very easy setup, plug & play ü Expandability up to 4 DAQ- units (32 Channels) ü Powerful calculations Unique software basis (IndiCom & CONCERTO) covering all aspects for data acquisition and traceability. Easy data handling, synchronized result and raw data files (time stamps) Public W.Giczi | MIP | 11 November 2015 | 20
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