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Vehicle Plant Modeling and Simulation to Optimize Mild Hybrid 48V BAS (Belt- Driven Alternator Starter) System Controller Algorithm Design

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Vehicle Plant Modeling and Simulation to Optimize Mild Hybrid 48V BAS (Belt- Driven Alternator Starter) System Controller Algorithm Design 저작자표시-비영리-변경금지 2.0 대한민국 이용자는 아래의 조건을 따르는 경우에 한하여 자유롭게 l 이 저작물을 복제, 배포, 전송, 전시, 공연 및 방송할 수 있습니다. 다음과 같은 조건을 따라야 합니다: 저작자표시. 귀하는 원저작자를 표시하여야 합니다. 비영리. 귀하는 이 저작물을 영리 목적으로 이용할 수 없습니다. 변경금지. 귀하는 이 저작물을 개작, 변형 또는 가공할 수 없습니다. l 귀하는, 이 저작물의 재이용이나 배포의 경우, 이 저작물에 적용된 이용허락조건 을 명확하게 나타내어야 합니다. l 저작권자로부터 별도의 허가를 받으면 이러한 조건들은 적용되지 않습니다. 저작권법에 따른 이용자의 권리는 위의 내용에 의하여 영향을 받지 않습니다. 이것은 이용허락규약(Legal Code)을 이해하기 쉽게 요약한 것입니다. Disclaimer 공학전문석사학위연구보고서 Vehicle Plant Modeling and Simulation to Optimize Mild Hybrid 48V BAS (Belt- driven Alternator Starter) System Controller Algorithm Design 마일드 하이브리드 48V 바스 상위 제어기 최적 설계를 위한 차량 플랜트 모델링과 시뮬레이션 2018 년 02 월 서울대학교 공학전문대학원 응용공학과 이 헌 수 Vehicle Plant Modeling and Simulation to Optimize Mild Hybrid 48V BAS (Belt- driven Alternator Starter) System Controller Algorithm Design 마일드 하이브리드 48V 바스 상위 제어기 최적 설계를 위한 차량 플랜트 모델링과 시뮬레이션 지도교수 차 석 원 이 리포트를 공학전문석사학위 연구보고서로 제출함 2017 년 11월 서울대학교 공학전문대학원 응용공학과 이 헌 수 이헌수의 공학석사 학위논문을 인준함 2017 년 12월 위 원 장 : (인) 위 원 : (인) 위 원 : (인) Abstract Vehicle Plant Modeling and Simulation to Optimize Mild Hybrid 48V BAS (Belt-driven Alternator Starter) System Controller Algorithm Design Hunsoo Lee Graduate school of Engineering Practice Seoul National University It has already been 20 years since Toyota introduced a hybrid vehicle call “Prius”. Many Hybrid vehicles have been produced since then, but even so many years have passed.7 There is still a long way to the popularization of the hybrid vehicle. It is still very low compared to the total number of vehicles. Why? That is probably due to the cost of the Hybrid system being added.21 Even though Hybrid vehicles are eco-friendly and high fuel efficiency, the cost of producing the vehicle is too high compared to the benefits to the customer.18 The cost is about $5,000 which is too much. The very cost was a problem which is stumbling block to i popularization. To solve this problem, 48V BAS (Belt-driven alternator starter) hybrid system is proposed. This is the Mild Hybrid compared to the Toyota Prius. This system can design the entire hybrid system at about $800.20 The problem in research and development organization of our company is that it is difficult to understand the development contents because we outsourced the various modeling to universities and professional developers. In order to solve this problem, we set it as a GSEP project. The basic model was based on the EV (electric car) model that was previously performed in our company. And then the necessary parts from the 48V BAS have been added. The main point of this project is the vehicle modeling that is the target of the high level controller –EDU. Generation of the input variable (output variable) which required for high level controller was simulated. Keyword: Mild Hybrid, 48V, BAS, Modeling, Simulation. Student Number: 2016-22251 ii Contents Abstract.........................................................................................i Contents.......................................................................................iii List of Tables…………………………………...………………………v List of Figures………………………………….………………….…. vi Chapter 1. Introduction………………………...……………….…….1 1.1 Study Background…………………………………………………….1 1.1.1 Needs for EV…………………………………......…......…. `1 1.1.2 Why especially 48V Mild Hybrid EV…………….….….2 1.1.3 Mild Hybrid Technology trend…….………………………3 1.2 Purpose of This Project………………….…………….…….….….6 Chapter 2. System Configuration……………………………………7 2.1 Mild Hybrid 48V BAS Architecture……………………….……7 2.2 48V Power Network…………………………………………….…8 2.3 Vehicle and EDU Modeling………………………………….……9 2.4 Configuration of HILS and RCP17……………………….……….10 2.5 Configuration of the interface between the Controller…….11 Chapter 3. Vehicle System Modeling …………………………….13 3.1 Input & Output Variable…………………………………….…13 iii 3.2 Vehicle Modeling……………………………………………….18 3.2.1 Plant: EV (Electric vehicle) Model Analysis...........18 3.2.2 Plant_CAN: MEV Block……………………...………….20 3.2.3 Combination of MEV Block and Autonomie Model….21 3.2.4 Battery(ESS) function update………………………….24 3.2.5 Dynamics (Wheel + Chassis) function update…….26 3.2.6 CAN communication set up…………………………….28 3.3 EDU Logic Modeling……………………………………….….30 Chapter 4. The Result for Simulation……………………...…...32 4.1. Simulation based on driving cycle……………………………32 4.1.1. Analysis result of UDDS driving cycle…………………...32 4.1.2. Analysis result of NEDC driving cycle………….……….35 4.1.3. Analysis result of WLTC running cycle………………….38 4.2. Actual vehicle verification……………………………………….42 Chapter 5. Conclusion……………………………………………….44 Bibliography………….…………………………………………………45 국문 초록…..…………..………………………………………………..50 iv List of Tables Table 3.1 Input Variable from ECM…………………………………….......13 Table 3.2 Input Variable from BMS…………………………………….......14 Table 3.3 Input Variable from INVERTER……...………………….......15 Table 3.4 Input Variable from LDC……...……….………………….......16 Table 3.5 Output Variable from EDU……….…….………………….......17 Table 3.6 Wheel and Chassis Dynamic function update…….........27 Table 3.7 CAN Specification ………………....…….………………….......28 Table 3.8 CAN Definition for Engine state....….………………….......29 Table 4.1 Fuel Economy comparison of 48V BAS vs Conventional type at UDDS………………………………………………….……………….32 Table 4.2 Fuel Economy comparison of 48V BAS vs Conventional type at NEDC……………………………………………………,.…….….......35 Table 4.3 Fuel Economy comparison of 48V BAS vs Conventional type at WLTC ……………...............................................................................38 v List of Figures Figure 1.1 Global New Powertrain System requirement...................1 Figure 1.2 HEV Function & Classification........................................3 Figure 1.3 VCU (Vehicle Control Unit) and Vehicle Modeling..........5 Figure 2.1 Mild Hybrid BAS 48V Architecture7................................7 Figure 2.2 48V Power Network16……………………….........................8 Figure 2.3 Vehicle Modeling Concept ........………………....................9 Figure 2.4 Configuration of HLS and RCP tool........................................11 Figure 2.5 Interface between the controller...…………..........................12 Figure 3.1 Electric Vehicle Model Overview...…………..........................19 Figure 3.2 MEV Bock modification...…………...........................................20 Figure 3.3 Combination of MEV Block and Component Model.............22 Figure 3.4 Vehicle and subsystem structure............................................23 Figure 3.5 Battery(ESS) function update before and after.................25 Figure 3.6 48V BAS Key mode.....................................................................30 Figure 3.6 EDU logic function structure....................................................31 Figure 4.1 UDDS (Urban Dynamometer Driving Schedule……….......33 Figure 4.2 Engine and Motor Operating Point at UDDS…………........34 vi Figure 4.3 NEDC (New European Driving Cycle) ………………….......36 Figure 4.4 Engine and Motor Operating Point at NEDC………….......37 Figure 4.5 WLTC (Worldwide Light vehicle Test Cycle) ……….......39 Figure 4.6 Engine and Motor Operating Point at WLTC………….......40 Figure 4.7 48V BAS Vehicle (Front)…………………………………......41 Figure 4.8 HILS Installation…………………………………………...........42 Figure 4.9 DC/DC Converter Installation………………………...…........42 Figure 4.10 BAS (Belt driven alternator starter Installation…………43 Figure 4.11 48V Battery Installation……………………………………...43 vii Chapter 1. Introduction 1.1. Study Background 1.1.1 Needs for EV As the environment of the automobile industry changes rapidly, the demand for a new type of vehicle powertrain has been increased. Especially a solution for the exhaust gas regulation, global warming, and energy problem in each country was needed. To satisfy these demands, EV (Electric Vehicle), FCEV (Fuel Cell Electric Vehicle) and HEV (Hybrid Electric Vehicle) have emerged.3 Figure 1.1 Global New Powertrain System requirement21 １ 1.1.2 Why especially 48V Mild Hybrid EV? In the case of the Full HEV (Hybrid Electric Vehicle) which was launched with the Toyota Prius, the vehicle price was very high, since the system configuration cost was very high. This was a fatal weakness for the growth of EV vehicles. Since its debut in 1997, It has not been popularized for nearly 20 years due to its high price. On the other hand, for Micro HEVs the effect was insufficient compared to rising costs for the system due to low efficiency.6,18 However, the 48V Mild Hybrid BAS, which we are planning to develop, will cost about $800 for the system configuration.20 And fuel economy improvement can be expected up to 15%.1 It is the most cost-effective system available. ２ Figure 1.2 HEV Function & Classification21 1.1.3 Mild Hybrid Technology Trend As the safety and convenience specifications of vehicles have recently been expanded and the demand for high-power / high- efficiency systems for exhaust gas regulation has increased, existing systems have been replaced by electric motors and electronic control devices.2,4,16 The EU passed a regulation to reduce carbon dioxide emissions by 27% from 130g / km in 2015 to 95g / km in 2021 in February 2014.15 Currently, the generation capacity of general passenger cars is about 1.2 [KW] ~ 1.5 [KW]. ３ However, since 2015 the demand for power generation capacity required by automobiles increased from 3.0 [KW] ~ 7.0 [KW]. Research has been actively conducted on a 12 V and 48 V dual voltage power system that is capable of using a high voltage load and is highly compatible with a conventional 12 V power system.16 European automakers will be mass-produced in sooner or later by applying BAS (Belt-driven Alternator Starter) based on a 48 [V] power system through collaboration with related parts companies.21 In order to cope with exhaust gas and fuel efficiency regulations such as Euro6, demand for electric equipment based on 48 [V] 18 power supply is increasing. ４ 1.2 Purpose of This Project The purpose of this project is to integrate BAS E-Machine and Inverter, two-way DC-DC converter and 48-V lithium-ion battery, which are core components of an automotive 48 [V] power system to improve fuel efficiency and efficiency of the automobile.18,16 Figure 1.3 VCU (Vehicle Control Unit) and Vehicle Modeling Project Scope was Mild Hybrid 48V BAS System Development.
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