Sae Technical Paper Series: Saurabh Mahapatra, Tom Egel, Raahul Hassan, Rohit Shenoy and Michael Carone
Sae Technical Paper Series: Saurabh Mahapatra, Tom Egel, Raahul Hassan, Rohit Shenoy and Michael Carone
SAE TECHNICAL
PAPER SERIES 2008-01-0085
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DESIGN CONSIDERATIONS
Vehicle dynamics - The focus is on friction and Requirements - Equally challenging is defining the right
aerodynamic drag interactions with weight and set of requirements to meet the vehicle performance and
gradability factors accounted for in the equations. functionality goals. Requirements refinement proceeds
iteratively and depends on implementation costs and
Overall System Design - The first step in the design equipment availability.
process of the hybrid powertrain is to study the
maximum torque demand of the vehicle as a function of System-level realization – The systems engineer has to
the vehicle speed. A typical graph is shown in Figure 2. conceptualize the operation of the system’s various
Ratings of the motor and the engine are determined components and understand the complex interactions
iteratively to satisfy performance criteria and constraints. between them. This often requires experimentation with
The acceleration capabilities are determined by the peak various system topologies. For example, studies may
power output of the motor while the engine delivers the include comparing a series configuration with a parallel
power for cruising at rated velocity, assuming that the configuration. Because the goal is a better
battery energy is limited. Power sources are coupled to understanding of the overall system behavior, the
supply power by the power-splitter, and the gear ratio of models must include the appropriate level of detail.
the power-splitter is determined in tandem. The next
steps include developing efficient management System integration – As the design progresses from a
strategies for these power sources to optimize fuel system level to a more detailed implementation,
economy and designing the controllers. The final steps engineers elaborate the subsystem models to realize the
focus on optimizing the performance of this system complete detailed system model. This can be
under a variety of operating conditions. accomplished by replacing each initial model of a
component with the detailed model and observing the
effects on performance. Completing this process and
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realizing a detailed model of the system requires robust prototype. Figure 3 shows the key elements of Model-
algorithms for solving complex mathematics in a timely Based Design.
fashion.
The system model forms the “executable specification”
Multidomain complexity – The HEV system has electrical that is used to communicate the desired system
and mechanical components. Typically these performance. This model is handed over to the various
components are designed by domain specialists. To specialists who use simulation to design and further
speed development, these engineers need to effectively elaborate the subsystem models. These specialists
communicate and exchange design ideas with a refine the requirements further by adding details or
minimum of ambiguity. modifying them. The detailed models are then integrated
back into the system level realization piece by piece and
Power management strategy – A principal goal of a verified through simulation. This goes on iteratively until
typical HEV design is to increase the fuel efficiency of a convergence to an optimal design that best meets the
the vehicle while maintaining performance demands. requirements results. During Model-Based Design, C-
Intuitively, one can look at this problem as finding the code generation becomes an essential tool for verifying
optimal use of the power sources as a function of the the system model. The control algorithm model can be
vehicle internal states, inputs, and outputs satisfying automatically converted to code and quickly deployed to
various constraints. This translates to the requirement the target processor for immediate testing. Code can
for switching between various operational “power also be generated for the physical system to accelerate
modes” of the vehicle as a function of the states, inputs, the simulation and/or to test the controller with Hardware
and measured outputs [4]. In a true environment for in the Loop simulation.
Model-Based Design the power management algorithms
co-exist with the physical system models.
Requirements are refined when each of the component additional benefit. Because we are primarily interested in
models is delivered to component designers for the drive cycle performance, we will limit our vehicle
additional refinement. There are, however, certain model to longitudinal dynamics only. For example, the
requirements that the system architect understands fully, vehicle was initially modeled as a simple inertial load on
and can lock down. As the project moves from a rotating shaft connected to the drive train.
requirements gathering to specification, the concepts of
the system architects can be included in the model. ENGINE
Collaboration between architects and designers leads to
a much better and more complete specification. The A complete engine model with a full combustion cycle is
system can be expressed as a series of separate also too detailed for this application. Instead, we need a
models that are to be aggregated into an overall system simpler model that provides the torque output for a given
model for testing. Breaking down the model into throttle command. Using Simulink® and SimDriveLine™,
components facilitates component-based development we modeled a 57kW engine with maximum power
and allows several teams to work on individual delivery at 523 radians per second, as shown in Figure
components in parallel. 5.
VEHICLE DYNAMICS
POWER MANAGEMENT
MODE LOGIC
5. MODEL ELABORATION
REQUIREMENTS REFINEMENT
Figure 8: Mode logic modeled with Stateflow®.
The machine drive is an aggregated model of the
SYSTEM REALIZATION machine and the power electronics drive. In the system
level modeling phase, the key specification is the torque-
After the HEV components have been designed, they speed relationship and the power loss. This information
can be assembled to form the parallel hybrid system was sufficient to define an abstract model to meet the
shown in Figure 9. high-level conceptual requirements.
4. CONTROLLER DEPLOYMENT
Figure 15: Speed and L/100 km metric comparisons Figure 17: Comparison of Simulink® simulation
for averaged and detailed models for the HEV. modes for the detailed HEV model.
The authors would like to acknowledge the following Component Parameter SI Units
fellow MathWorks staff who contributed towards the
development of the HEV models used in this paper and Vehicle Mass 1325 kg
the writing of this paper. In alphabetical order—Bill Horizontal distance 1.35 m
Chou, Craig Buhr, Jason Ghidella, Jeff Wendlandt, Jon from CG to
Friedman, Rebecca Porter, Rick Hyde, and Steve Miller. front/rear axle
Frontal area 2.57 m2
REFERENCES
Drag coefficient 0.26
1. L. Brooke, “Cost remains the boss”, Automotive
Tire rolling radius 0.3 m
Engineering International, April 2007, SAE
International. Tire rated vertical 3000 N
2. Iqbal Husain, “Electric and Hybrid Vehicles—Design load
Fundamentals”, 1st Edition, © 2003 CRC Press. Tire slip at peak 0.1
3. S J. Chapman, “Electric Machinery Fundamentals”, force at rated load
4th Edition, © 2004 McGraw-Hill Inc. Tire inertia 0.5 kg-m2
4. Han, Zhang, Yuan, Zhu, Guangyu, Tian and
Quanshi, Chen, “Optimal energy management Planetary Ring-to-Sun gear 2.6
strategy for hybrid electric vehicles”, SAE Paper Gear ratio
2004-01-0576. Engine Maximum power 57 kW
5. P. F. Smith, S. Prabhu, and J. Friedman, “Best
Speed at maximum 523.33 rad/s
Practices for Establishing a Model-Based Design
power
Culture”, SAE Paper 2007-01-0777.
Maximum speed 628 rad/s
6. Sameer M. Prabhu, J. Wendlandt, J. Lass, T. Egel,
“Multi-Domain Modeling and Simulation of Electro- Shaft inertia 1 kg-m2
Hydraulic Implement System”, SAE Paper 2006-01-
3490. Battery Capacity 6.5 Ah
7. A.E. Fitzgerald, C. Kingsley, S. D. Umans, “Electrical Initial voltage 201.6 V
Machinery”, 6th Revised Edition, © 2005 McGraw-Hill
Inc. Initial state-of- 33.33 %
8. J. Ghidella, P. J. Mosterman, “Requirements-Based charge
Testing in Aircraft Control Design”, AIAA 2005-5886. Maximum power 21 kW
9. J. Ghidella, A. Wakefield, S. Grad-Freilich, J. output
Friedman, V. Cherian, “The Use of Computing Synchronous Shaft inertia 4 kg-m2
Clusters and Automatic Code Generation to Speed Generator
Up Simulation Tasks”, AIAA 2007-688. (Permanent
Magnet)
Maximum voltage 500 V
CONTACT
Synchronous Shaft inertia 1 kg-m2
Motor
Saurabh Mahapatra—Design Automation Technical
Marketing Group, The MathWorks Inc., (Permanent
[email protected] Magnet)
Maximum voltage 500 V
Tom Egel—Applications Engineering Group, The Maximum power 50 kW
MathWorks Inc., [email protected] output
Maximum torque 400 Nm
The MathWorks, Inc. retains all copyrights in the figures and excerpts of code
provided in this article. These figures and excerpts of code are used with
permission from The MathWorks, Inc. All rights reserved.