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Development and Implementation of Control System for an Advanced Multi-Regime Series-Parallel Plug-In Hybrid Electric Vehicle

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Development and Implementation of Control System for an Advanced Multi-Regime Series-Parallel Plug-In Hybrid Electric Vehicle Development and Implementation of Control System for an Advanced Multi-Regime Series-Parallel Plug-in Hybrid Electric Vehicle by Daniel Prescott B.Eng, University of Victoria, 2009 A Thesis Submitted in Partial Fulfillment of the Requirements for the Degree of Master of Applied Science in the Department of Mechanical Engineering Daniel Prescott, 2015 University of Victoria All rights reserved. This thesis may not be reproduced in whole or in part, by photocopy or other means, without the permission of the author. ii Supervisory Committee Development and Implementation of Control System for an Advanced Multi-Regime Series-Parallel Plug-in Hybrid Electric Vehicle by Daniel Prescott B.Eng, University of Victoria, 2009 Supervisory Committee Dr. Zuomin Dong, (Department of Mechanical Engineering) Supervisor Dr. Curran Crawford, (Department of Mechanical Engineering) Departmental Member Dr. Brad Buckham, (Department of Mechanical Engineering) Departmental Member iii Supervisory Committee Dr. Zuomin Dong, (Department of Mechanical Engineering) Supervisor Dr. Curran Crawford, (Department of Mechanical Engineering) Departmental Member Dr. Brad Buckham, (Department of Mechanical Engineering) Departmental Member Abstract Following the Model-Based-Design (MBD) development process used presently by the automotive industry, the control systems for a new Series- Parallel Multiple-Regime Plug-in Hybrid Electric Vehicle (PHEV), UVic EcoCAR2, have been developed, implemented and tested. Concurrent simulation platforms were used to achieve different developmental goals, with a simplified system power loss model serving as the low-overhead control strategy optimization platform, and a high fidelity Software-in-Loop (SIL) model serving as the vehicle control development and testing platform. These two platforms were used to develop a strategy-independent controls development tool which will allow deployment of new strategies for the vehicle irrespective of energy management strategy particulars. A rule-based energy management strategy was applied and calibrated using genetic algorithm (GA) optimization. The concurrent modeling approach was validated by comparing the vehicle equivalent fuel consumption between the simplified and SIL models. An equivalency factor (EF) of 1 was used in accounting for battery state of charge (SOC) discrepancies at cycle end. A recursively-defined subsystem efficiency-based EF was also iv applied to try to capture real-world equivalency impacts. Aggregate results between the two test platforms showed translation of the optimization benefits though absolute results varied for some cycles. Accuracy improvements to the simplified model to better capture dynamic effects are recommended to improve the utility of the newly introduced vehicle control system development method. Additional future work in redefining operation modes and mode transition threshold conditions to approximate optimal vehicle operation is recommended and readily supported by the control system platform developed. v Table of Contents Supervisory Committee ............................................................................................. ii Abstract ..................................................................................................................... iii Table of Contents ....................................................................................................... v List of Tables ............................................................................................................ ix List of Figures ........................................................................................................... xi List of Abbreviations ............................................................................................... xv Acknowledgments................................................................................................. xviii Dedication ............................................................................................................... xix Chapter 1: Introduction .............................................................................................. 1 1.1. EcoCAR2 Student Competition ...................................................................... 1 1.2. Overview of Vehicle Architecture .................................................................. 3 1.3. Considerations for Control Development for Selected Architecture .............. 4 1.3.1. Connection to Existing Research ............................................................. 4 1.3.2. Driveability Challenges of Controlling Selected Architecture ................ 6 1.4. Controls Implementation Platform and Development Process ....................... 7 Chapter 2: Introduction to Hybrid Powertrain Technology ....................................... 9 2.1. The Benefit of Hybrid Powertrain Technology .............................................. 9 2.1.1. A Brief History of Hybrid Electric Vehicles ......................................... 11 2.1.2. Powertrain Electrification ...................................................................... 13 2.1.3. Manipulating Engine Operating Point ................................................... 15 2.2. Major Enabling Technologies ....................................................................... 16 2.2.1. High Power Density Traction Motors .................................................... 16 2.2.2. Battery Energy Storage Systems ............................................................ 17 2.2.3. Optimization Design via Model-Based-Design ..................................... 19 2.3. Production Hybrid Vehicle Architecture Variations ..................................... 20 2.3.1. Mild Hybrid ........................................................................................... 21 2.3.2. Parallel Hybrid ....................................................................................... 22 2.3.3. Series Hybrid ......................................................................................... 23 2.3.4. Power-Split Hybrid ................................................................................ 24 vi 2.3.5. Series-Parallel Hybrid ............................................................................ 26 2.4. Hybridization Benefits and Applicability of Advanced Controls to Marine Vessel Powertrains .................................................................................. 27 2.4.1. Marine Vessel Power System Overview and Hybridization Potential ................................................................................................ 27 2.4.2. Current Marine Vessel Emissions .......................................................... 30 2.4.3. Availability of Hardware ....................................................................... 32 2.4.4. Challenges Associated with Optimal Design of Marine Hybrid Powertrains............................................................................................ 34 Chapter 3: Vehicle Control System Development ................................................... 37 3.1. Vehicle Component Details .......................................................................... 37 3.1.1. GM 2.4L EcoTEC Engine...................................................................... 38 3.1.2. GM 6T40 Transmission ......................................................................... 39 3.1.3. Magna E-Drive Rear Traction Motor .................................................... 42 3.1.4. TM4 Motive B Belted Alternator Starter Motor .................................... 44 3.1.5. A123 Lithium Ion Battery Pack ............................................................. 47 3.1.6. Driver Interface ...................................................................................... 49 3.2. Operational Performance Targets ................................................................. 50 3.2.1. Vehicle Technical Specifications ........................................................... 50 3.2.2. Operational Flexibility ........................................................................... 52 3.3. Model-Based-Design Process ....................................................................... 56 3.3.1. Development Process Flow.................................................................... 56 3.3.2. Design Failure Mode Effects Analysis and Test Case Feedback .......... 59 3.3.3. Automated Testing ................................................................................. 61 3.3.4. Process Documentation and Development Team Organization ............ 64 3.3.5. Multi-Platform Controls Development .................................................. 68 3.3.6. SIL to HIL to Vehicle Validation .......................................................... 76 3.3.7. Linear Vehicle Dynamics ...................................................................... 78 3.4. Control System Development Summary ...................................................... 79 Chapter 4: Vehicle Control System Logic and Strategy .......................................... 80 4.1. High Level Controller Logic Hierarchy ........................................................ 80 vii 4.2. Safety Critical System Design ...................................................................... 82 4.2.1. Subsystem Level Requirements Handling ............................................. 82 4.2.2. System Driver Torque Request Handling .............................................. 84 4.2.3. System Level Failure
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