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Model-Based Powertrain Design and Control System Development for the Ideal All-Wheel Drive Electric Vehicle Haotian Wu Purdue University

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Model-Based Powertrain Design and Control System Development for the Ideal All-Wheel Drive Electric Vehicle Haotian Wu Purdue University Purdue University Purdue e-Pubs Open Access Dissertations Theses and Dissertations Fall 2014 Model-based powertrain design and control system development for the ideal all-wheel drive electric vehicle Haotian Wu Purdue University Follow this and additional works at: https://docs.lib.purdue.edu/open_access_dissertations Part of the Mechanical Engineering Commons Recommended Citation Wu, Haotian, "Model-based powertrain design and control system development for the ideal all-wheel drive electric vehicle" (2014). Open Access Dissertations. 392. https://docs.lib.purdue.edu/open_access_dissertations/392 This document has been made available through Purdue e-Pubs, a service of the Purdue University Libraries. Please contact [email protected] for additional information. *UDGXDWH6FKRRO)RUP30 5HYLVHG 0814 PURDUE UNIVERSITY GRADUATE SCHOOL Thesis/Dissertation Acceptance 7KLVLVWRFHUWLI\WKDWWKHWKHVLVGLVVHUWDWLRQSUHSDUHG %\ Haotian Wu (QWLWOHG MODEL-BASED POWERTRAIN DESIGN AND CONTROL SYSTEM DEVELOPMENT FOR THE IDEAL ALL-WHEEL DRIVE ELECTRIC VEHICLE Doctor of Philosophy )RUWKHGHJUHHRI ,VDSSURYHGE\WKHILQDOH[DPLQLQJFRPPLWWHH Richard M. French Haiyan H. Zhang Qingyou Han Ayhan Ince To the best of my knowledge and as understood by the student in the Thesis/Dissertation Agreement, Publication Delay, and Certification/Disclaimer (Graduate School Form 32), this thesis/dissertation adheres to the provisions of Purdue University’s “Policy on Integrity in Research” and the use of copyrighted material. Haiyan H. Zhang $SSURYHGE\0DMRU3URIHVVRU V BBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBB BBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBB $SSURYHGE\James L. Mohler 11/14/2014 +HDGRIWKHDepartment *UDGXDWH3URJUDP 'DWH MODEL-BASED POWERTRAIN DESIGN AND CONTROL SYSTEM DEVELOPMENT FOR THE IDEAL ALL-WHEEL DRIVE ELECTRIC VEHICLE A Dissertation Submitted to the Faculty of Purdue University by Haotian Wu In Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy December 2014 Purdue University West Lafayette, Indiana ii ACKNOWLEDGEMENTS I would like to express my deep gratitude to my advisor Haiyan H. Zhang. It has been an honor to be one of his Ph.D. students. I massively appreciate all his contributions of efforts, funding and ideas to make my Ph.D. experience joyful. He is my primary resource to get my research questions answered and obtain strong support during tough times in the Ph.D. pursuit. Haiyan is one of the most diligent and smartest people I know. I have been grateful for all the help from the members in his lab, Multidisciplinary Lab. I also deliver my sincere thanks to Siemens PLM Software that donated LMS Imagine.Lab Amesim for my research. In addition, I really want to thank the professors in my academic committee, Professors Qingyong Han, Richard M. French and Ayhan Ince for their helpful career advice and many insightful research discussions. I have also appreciated the professors in Purdue EcoCar2 Project, Professors Haiyan H. Zhang, Peter Meckl, Gregory M. Shaver, Oleg Wasynczuk, and Motevalli Vahid for helping me to cast my leadership and instructing me to see the research at different angles. Moreover, I massively appreciate that Prof. James L. Mohler provided valuable suggestions about the dissertation formatting and editing. I will forever be thankful to my former research advisor, Professor Xuexun Guo. iii He has been helpful in providing invaluable advice to pursue my Ph.D. degree at Purdue University. I still think fondly of my time as an undergraduate student and M.S. student in his lab. I also am very grateful to Yuanhai Ou, Professors Guofang Zhang and Yaohua He for their continuous support during my college and graduate school career. I also thank my friends for providing moral support and encouragement to the research. I would like to thank Cong Liao, Xiao Yuan and Xinyue Chang for their support in general. I am also thankful to Jiameng Wang for her tremendous help. It is too many friends to be listed here, but I believe you can feel my deep gratitude. I especially express my thanks from the underside of my affection to my mom, papa and sister. I would not have achieved this far without their unconditional love. My parents always sacrificed their lives to support my sister and myself when times are rough. iv TABLE OF CONTENTS Page ACKNOWLEDGEMENTS ........................................................................................................ii TABLE OF CONTENTS........................................................................................................... iv LIST OF TABLES .................................................................................................................. viii LIST OF FIGURES ................................................................................................................... x LIST OF ABBREVIATIONS ................................................................................................... xiv ABSTRACT ...................................................................................................................... xvi CHAPTER 1. INTRODUCTION .............................................................................................. 1 1.1 Overview .............................................................................................................. 1 1.2 Research Scope .................................................................................................... 3 1.3 Research Questions .............................................................................................. 4 1.4 Limitations ............................................................................................................ 4 1.5 Delimitations ........................................................................................................ 5 1.6 Organization ......................................................................................................... 6 1.7 Summary .............................................................................................................. 8 CHAPTER 2. LITERATURE REVIEW ...................................................................................... 9 2.1 Powertrain Architecture ....................................................................................... 9 2.2 Model-based Design ........................................................................................... 13 2.2.1 Vehicle and Tire Dynamics .......................................................................... 13 2.2.2 Steering Geometry ...................................................................................... 15 2.3 Motor and Powertrain Controls ......................................................................... 16 2.4 Summary ............................................................................................................ 19 CHAPTER 3. METHODOLOGY ........................................................................................... 20 3.1 Powertrain Architecture Design ......................................................................... 20 v Page 3.1.1 Architecture Overview ................................................................................ 21 3.1.2 Vehicle Technical Specifications ................................................................. 22 3.1.3 Component Selection and Sizing ................................................................ 24 3.1.3.1 Motor ...................................................................................................... 24 3.1.3.2 Reduction Gear ........................................................................................ 31 3.1.3.3 Battery ..................................................................................................... 34 3.2 Powertrain Modeling ......................................................................................... 38 3.2.1 Vehicle Dynamics Modeling ........................................................................ 38 3.2.1.1 Vehicle Coordinate Systems .................................................................... 38 3.2.1.2 Yaw Dynamics .......................................................................................... 40 3.2.1.3 Roll Dynamics .......................................................................................... 42 3.2.1.4 Weight Transfer ....................................................................................... 44 3.2.1.5 Longitudinal Dynamics ............................................................................ 46 3.2.1.6 Vehicle Slip Angle .................................................................................... 48 3.2.1.7 Tire Lateral and Longitudinal Slip Angle .................................................. 50 3.2.1.8 Tire and Vehicle Slip Angle Relationship ................................................. 52 3.2.1.9 Steering Angles ........................................................................................ 54 3.2.1.10 State Space .............................................................................................. 57 3.2.2 Electric Drive System................................................................................... 60 3.2.2.1 Motor Drive ............................................................................................. 61 3.2.2.2 Battery Modeling..................................................................................... 69 3.3 Control System Development ...........................................................................
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