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Model and Control System Development for a Plug-In Parallel Hybrid Electric Vehicle

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Model and Control System Development for a Plug-In Parallel Hybrid Electric Vehicle Model and Control System Development for a Plug-In Parallel Hybrid Electric Vehicle Eduardo De Jesus Marquez Brunal Thesis submitted to the faculty of the Virginia Polytechnic Institute and State University in partial fulfillment of the requirements for the degree of Master of Science in Mechanical Engineering Douglas J. Nelson, Chair John B. Ferris Steve Southward (May 3, 2015) (Blacksburg, VA) Keywords: Hybrid electric vehicle, model based design, vehicle model, control strategy, performance, fuel economy, energy consumption, bench testing, P3 parallel. Copyright 2016, Eduardo De Jesus Marquez Brunal Model and Control System Development for a Plug-In Parallel Hybrid Electric Vehicle Eduardo De Jesus Marquez Brunal Abstract The Hybrid Electric Vehicle Team (HEVT) of Virginia Tech is participating in the EcoCAR 3 Advanced Vehicle Technology Competition series organized by Argonne National Labs (ANL), and sponsored by General Motors (GM) and the U.S. Department of Energy (DOE). EcoCAR 3 is a 4-year collegiate competition that challenges student with redesigning a 2016 Chevrolet Camaro into a hybrid. The five main goals of EcoCAR 3 are to reduce petroleum energy use (PEU) and green house gas (GHG) emissions while maintaining safety, consumer acceptability, and performance, with an increased focus on cost and innovation. HEVT selected a P3 Plug-in Parallel hybrid electric vehicle (PHEV) to meet design goals and competition requirements. This study presents different stages of the vehicle development process (VDP) followed to integrate the HEVT Camaro. This work documents the control system development process up to Year 2 of EcoCAR 3. The modeling process to select a powertrain is the first stage in this research. Several viable powertrains and the respective vehicle technical specifications (VTS) are evaluated. The P3 parallel configuration with a V8 engine is chosen because it generated the set of VTS that best meet design goals and EcoCAR 3 requirements. The V8 engine also preserves the heritage of the Camaro, which is attractive to the established target market. In addition, E85 is chosen as the fuel for the powertrain because of the increased impact it has on GHG emissions compared to E10 and gasoline. The use of advanced methods and techniques like model based design (MBD), and rapid control prototyping (RCP) allow for faster development of engineering products in industry. Using advanced engineering techniques has a tremendous educational value, and these techniques can assist the development of a functional and safe hybrid control system. HEVT has developed models of the selected hybrid powertrain to test the control code developed in software. The strategy developed is a Fuzzy controller for torque management in charge depleting (CD) and charge sustaining (CS) modes. The developed strategy proves to be functional without having a negative impact of the energy consumption characteristics of the hybrid powertrain. Bench testing activities with the V8 engine, a low voltage (LV) motor, and high voltage (HV) battery facilitated learning about communication, safety, and functionality requirements for the three components. Finally, the process for parallel development of models and control code is presented as a way to implement more effective team dynamics. Model and Control System Development for a Plug-In Parallel Hybrid Electric Vehicle Eduardo De Jesus Marquez Brunal General Audience Abstract The Hybrid Electric Vehicle Team (HEVT) of Virginia Tech is participating in the EcoCAR 3 Advanced Vehicle Technology Competition series organized by Argonne National Labs (ANL), and sponsored by General Motors (GM) and the U.S. Department of Energy (DOE). EcoCAR 3 is a 4-year collegiate competition that challenges student with redesigning a 2016 Chevrolet Camaro into a hybrid. The five main goals of EcoCAR 3 are to reduce petroleum energy use (PEU) and green house gas (GHG) emissions while maintaining safety, consumer acceptability, and performance, with an increased focus on cost and innovation. HEVT selected a P3 Plug-in Parallel hybrid electric vehicle (PHEV) to meet design goals and competition requirements. This study presents different stages of the vehicle development process (VDP) followed to integrate the HEVT Camaro. This work documents the control system development process up to Year 2 of EcoCAR 3. Acknowledgements I would like to thank the Hybrid Electric Vehicle Team of Virginia Tech and all the team members that I had the honor to work with during Year 1 and Year 2 of EcoCAR 3. HEVT has given me the opportunity to further my technical, communication, and leadership skills while working with extremely smart, capable, and fun individuals. I would also like to thank General Motors, the U.S. Department of Energy, and Argonne National Lab for sponsoring and organizing EcoCAR 3. I want to thank all sponsors of EcoCAR 3, especially The MathWorks, where I will start my engineering career after completing my graduate studies. I would like to thank the creators of 5-Hour Energy drink for coming up with such a great product that enabled me to complete this work. Next I would like to thank Dr. Doug Nelson for being my faculty advisor and for teaching me valuable life and technical lessons. Dr. Nelson’s desire to share his automotive knowledge and experience, and his attention to detail are the elements that hold HEVT at such high excellence standards. I would like to thank my family for their support and love through the good and hard times. Their desire to see me succeed keeps me motivated through every challenge, no matter how difficult a situation may be. Finally and most importantly, I would like to thank God for his unconditional love. iv Table of Contents Academic Abstract ..................................................................................................................... ii Public Abstract .......................................................................................................................... iii Acknowledgements ................................................................................................................... iv Table of Contents ....................................................................................................................... v List of Multimedia Objects ....................................................................................................... vii Tables .......................................................................................................................................... vii Figures ......................................................................................................................................... vii List of Abbreviations ................................................................................................................. ix 1. Introduction .......................................................................................................................... 1 1.1. Hybridization in the Automotive Industry ............................................................................. 1 1.2. EcoCAR 3 ............................................................................................................................ 1 1.3. Vehicle Development Process ............................................................................................. 3 1.4. Model Based Design ........................................................................................................... 4 1.5. Rapid Control Prototyping ................................................................................................... 5 1.6. Objectives ............................................................................................................................ 5 2. Literature Review ................................................................................................................. 6 2.1. Control Strategies for Hybrid Electric Vehicles ...................................................................... 6 2.2. Design of Powertrains using Model-Based Design ................................................................ 7 2.3. Development of Energy Management Strategies for Hybrid Electric Vehicles ...................... 7 2.4. Energy Management Strategy Based on Fuzzy Logic ........................................................... 8 2.5. Structuring Models for Version Control and Work with Multiple Developers .......................... 9 2.6. Summary of Literature Review ............................................................................................... 9 3. Hybrid Powertrain Selection ............................................................................................. 11 3.1. Vehicle Technical Specifications .......................................................................................... 11 3.2. Feasibility Study ................................................................................................................... 12 3.2.1. Autonomie Modeling - Assumptions and Limitations ............................................ 13 3.2.2. PTW Energy Consumption Analysis for Stock Vehicle Model .............................. 14 3.2.3. Component Efficiency & Energy Losses in Stock Model ...................................... 15 3.2.4. Performance Characteristics of Stock Vehicle Model ........................................... 17 3.2.5. Study of Fuel Types .............................................................................................
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