7 Centuries of Education, Research and Technology Transfer for Excellence
The automotive showcase
Marco Raugi, [email protected] Vice-rector for Reasearch & Technology Transfer, Director of CIRESS, Full Professor of Electrical Engineering
Massimo Ceraolo, [email protected] Full Professor of Electrical Engineering Sergio Saponara, [email protected] Full Professor of Electronic Engineering UNIVERSITY OF PISA
Past Glories • Galileo Galilei Piazza dei Miracoli • Antonio Pacinotti (Physics) • Ulisse Dini (Math)
Nobel Prizes & Fields Medals • Giosuè Carducci (Nobel Literature, 1906) • Enrico Fermi (Nobel Physics, 1938) Leaning Tower (1173) & • Carlo Rubbia (Nobel Physics, 1984) Cathedral (1063) • Enrico Bombieri (Fields Medal Math, 1974) • Alessio Figalli (Fields Medal Math, 2018) School of Engineering Presidents of Republic/Prime Ministers • Carlo Azeglio Ciampi, President of Republic, 1999-2006 • Giovanni Gronchi, President of Republic, 1955-1962 • Giuliano Amato, Prime Minister, 1992-1993 & 2000-2001 • Enrico Letta, Prime Minister, 2013-2014 UNIVERSITY - HUMAN RESOURCES
• Founded in 1343; • Number of students: ≃ 58000; • Study Programmes: • First level (3 years): 58 (≃ 31000 st.); • Second level (2 years): 67 (≃ 18000 st.); • 5 years degrees: 8 (≃ 2000 st.); • PhD, Master,...: 34 + 109 (≃ 9000 st.); • Enrolled st.: ≃ 10000 (1st lv 5300, 2nd lv 3500); • Graduates: ≃ 7000 (1st lv 4500, 2nd lv 2500); • PhD graduates: ≃ 280; • Academic institutions: • Departments: 20; • Schools: 2 (Eng. and Med.); • Research and teaching staff: 1270; • Technical-administrative staff: 1565; • 300 Laboratories • Academic Ranking World Universities 2019: • Top 150-200 Worldwide, Top 1-3 in Italy • QS Automotive related ranking, 5th in Italy QS RANKING 2019
Electrical & Electronic Engineering
Disciplines in : - Electric Machines, Power Converters & Control Units - Mechatronics & Industry 4.0 - Energy storage (battery, fuel cells) & energy management - Embedded Systems, IoT & Vehicular Networks - Robotics, AI & Autonomous Driving Systems - Safety & security for vehicles and automotive components UNIVERSITY – TECH. TRANSFER
The University of Pisa has a rich source of innovation within its over 200 labs and 20 departments, which span all areas of science and technology. Since the early 2000s, it Patenting started to manage the technology transfer & Licensing process through a dedicated team composed • 105 filed Italian patents, of which 81 granted; of experts in intellectual property • 117 filed international patents, of which: management and commercialization of • 10 US Patents, of which 7 granted; research. • 23 European patents, of which 14 granted;.
Spin-offs FINANCED PROJECTS (FP)
Technology • 21 spin-offs approved; AVERAGED YEARLY VALUES • 107 prizes awarded Best practices Transfer • 13 spin-offs;Spin-offs generated 1000 FP;& 11.2 MEur in PhD+ programme. networks 1/3 Competitive Calls 2/3 INDUSTRY GRANTS
2 FP each permanent staff member every 3 years UNIVERSITY – PATENTS PI PoliTO
PD
BO
RM
Università di Pisa ENGINEERING -HUMAN RESOURCES
DM School of Engineering DF Department of Mathematics (founded in 1913) Department of Physics 210 profs + 140 post-doc res.
DICI DII Department of Civil and Department of Industrial Engineering DESTEC Information Engineering Department of Energy and 85 profs + 46 post-doc researc. Systems Engineering 75 profs + 67 post-doc researc.
• Research area 50 profs + 27 post-doc researc. • Research area • Aerospace engineering • Biomedical engineering • Civil engineering • Research area • Computer engineering • Chemical engineering • Electrical engineering • Electronic engineering • Mechanical engineering • Energy engineering • Robotics and automat. eng. • Nuclear engineering • Building and structural eng. • Telecommunication eng. • Hydraulic, transp., terr. eng. • Management engineering ENGINEERING -EDUCATION
• 19 Master Degrees (2nd level): ≃ 6000 st. • Bionics Engineering*; • Computer Engineering; • Embedded Computing Systems*; • Aerospace engineering; • Biomedical engineering; • Chemical engineering; • Computer engineering; • 12+1 Bachelor Degrees: ≃ 3000 st. • Electrical engineering; • Aerospace engineering; • Electronic engineering; • Biomedical engineering;** max 220 st. • Energy engineering; • Chemical engineering; • Management engineering; • Civil, envir. and building eng.; • Mechanical engineering; • Energy engineering; • Nuclear engineering; • Electronic engineering; • Robotics and automation eng.; • Management engineering; • Telecommunication engineering; • Computer engineering;** max 220 st. • Vehicles engineering; • Mechanical engineering;** max 220 st. • Civil Infrastr. and Environ. eng.; • Telecommunication engineering; • Structural and Building eng.; • Industrial Design;** max 50 st. • Materials and Nanotechnology; • Architecture and Building eng. (5y) • 4 PhD Courses: ≃ 200 st. TEACHING ELECTRIC VEHICLES
Unipi has a Ms Course on Vehicle engineering • Vehicular electronics (6 CFU) • Signal processing and telemetry (6 CFU) • Electric and Hybrid Vehicles (12 CFU)
Teaching of electric and hybrid vehicles, for and half takes place in a laboratory
Higher Education Challenges Formula SAE Driverless Roborace Rexus student ESA challenge ENGINEERING -HIGHER EDUCATION
Short-Courses for Industry Training (@ industry premises) • Course on Mechatronics for MAGNA • Course on Digital Power Conversion for ABB-Powerone • Course on Power & Control Electronics for Pierburg-Rheinmetall RESEARCH & TECHNOLOGY TRANSFER
Projects at DII (MIUR Excellence Department) 25 EU Active Projects (49 in the last 3 years) 5 EU Projects lead by DII faculty members 2 ERC Grants 10 MIT-UNIPI seed funds Research Units hosted 23 EU-funded Regional Projects Magneti Marelli 130+ Projects Commissioned by Companies STMicroelectronics 630+ Collaborations with Companies SIIE (Sino-Italian Information Eng.) CNIT (National consortium for TLC) CNR (National Research Council) CINI (National consortium for computing) TECHNOLOGY TRANSFER IMPACT
International High-Tech Companies in Pisa Area attracted by High Skilled Engineers & UniPI Tech Transfer Capability: • Apple (exDialog) • Intel • Continental • Pierburg-Rheinmetall • Magna • Austria Micro Systems (AMS) • Piaggio • Aitronik • Pitom • P2C (PurePowerControl) • Hanking Electronics • Leonardo (Sistemi Dinamici) • Resiltech • Kayser • Kiunsys • Navionics UNIPI is part of MOVET PAST AND PRESENT PARTNERS PAST AND PRESENT PARTNERS EPI EUROPEAN PROCESSOR INITIATIVE
AI Servers accelerators & Cloud AeroSpace Automotive
Industry 4.0 Core Safety & Robotics HPC Drivers Critical
sovereignty
120M€ in 5 years, 26 partners from 10 countries EPI: the European Processor for the European Automotive Industry EPI ROADMAP & ARCHITECTURE
Secure channel
Embedded HPC V2X V2V
1st EPI chip in 7nm TSMC BSG FOR HYBRID VEHICLES
Wheel Clutches Differential gear
Internal Gearbox Combustion Engine (ICE)
Belt Motor Generator Beltless Motor Generator 12V - 48V 48V - 300V
<10kW >10kW
Collaboration with Valeo & AMS in FP7 Athenis3D 48 V Belt Starter Generator (up to 15 kW) with Integrated Control Electronics & Power Converters Tested on a Peugeot 308 Hybrid BATTERY MANAGEMENT SYSTEMS
• 10+ year experience in BMS design for mid to high power applications • Tuscany region funded projects: Progetto Idrogeno, Prot-One, SUMA • European funded projects: 3Ccar, AutoDrive, NewControl • Company funded projects • National and International collaborations • Tested on real vehicles: Enea Electric BuS, CarbonDream E-bike, GGP Gardening E-tools
AutoDrive SMART BATTERY & 48V DC/DC
Parameter Identification
[R0,R1,C1] iL R1 - vM R0 +
C1 VOC LUT VOC -SOC 1 SOC + - Qn ʃ v T + L - ELECTRIC BUS WITH FAST CHARGE
120 Nominal 110 Dynamometer 100 Route 1 Route 2 90 Route 3
80
70
60
50 Charging time per km (s/km) km per time Charging SOC=25% 40 SOC=70% SOC=0% 10% 30 16 17 18 19 20 21 22 23 24 25 26 Charging power (kW) ADVANCED CONTROL OF E-MOTORS
• Advanced Power Drive Control Algorithm (FLC) Extended Kalman Flter (EKF) Sensorless control
MIT-UNIPI Seed Fund Cogging Reduction
Desired Trajectory FLC Control PID Control ICSFORSMART SENSE&POWER
SENSIPLUS Sensor platform Temp, radiation, humidity, ChiplEss MultisEnsor Rfid for GrEen NeTworks gases + communication Low cost RFID Reliable and low cost RFID tags and antennas for WSN
48 V DC/DC switched-cap converter with 3D passives FP7 Athenis 3D
MEMS Smart sensors acoustic, thermal, flow MECHATRONIC CO-DESIGN/VERIFICATION
Integrated Environment for Co-design & Co-Verification of mechanics, control SW & Electronic/Electrical parts in automotive e-drives: The smart latch case study ROBOTICS WITH AI CAPABILITY
Robots with AI capability Designed to intervene, as a human, in industry 4.0 environments & extreme scenarios Soft-robots for people interaction MARELLI JOINT RESEARCH LAB
Joint Research Laboratory (JRL) started June 2019
• 3-year framework agreement, funded by Marelli year-by-year • Mixed DII – Marelli JRL steering committee • Activity: Cybersecurity Research & Technology Transfer • 2 themes funded for 2019/20 (100 k€ year budget): Penetration tests & Vulnerability analysis of connected cars AI-enabled Intrusion Detection Systems & ECUs Fingerprinting • Research Grant for objective: Patent, Innovative Product Development • DII people involved: 2 professors, 3 PhDs, 4 Master Thesis Students SIIE JOINT RESEARCH LAB
SIIE (Sino Italian Information Engineering) Joint Research Lab started Dec 2017 • Activity: Research & Higher Education • 1.2 M€ initial budget Main research themes • Electronics & Nanotechnology • AI & Robotics • Electromagnetic scattering and radiation, Antennas Chinese partners involved: • Beijing Institute of Space LM Vehicle (part of China Aerospace Science and Technology Corporation) • Beijing Institute of Technology (BIT) PhD double degree • Program 111 with Xidian University, Xi’an • DII lab hosting 10 Chinese PhDs in 2 years, funds by China Scholarship Council AUTOMOTIVE RELATED RESEARCH
Numerical and analytical methods: Electromagnetic compatibility:
● Advanced Transmission Lines Modelling; ● Integral and Hybrid FEM/MOM formulations; ● Crosstalk Evaluation; ● Equivalent Network formulations; ● Statistical analysis of systems with uncertain parameters ● FEM analysis of EM devices: Effe, Ansys, Magnet, Comsol and cable bundles; ● Fourier/Bessel analytical methods; ● High Speed Interconnects identification; ● GPU-accelerated formulations; ● Sensitivity analysis of complex interconnects. ● 6DoF electromechanical coupled formulations. AUTOMOTIVE RELATED RESEARCH
Macro-Topics: Innovative Machines Rotary-linear Brushless •Electric Machines •Power Electronics DC hybrid •Electrical Drives and Applications excitation Activities: •Theoretical modeling and analysis •Numerical modeling and Simulation Brushless Axial flux consequent •Design and Experimentation variable pole reluctance
Small Machines Large Machines Power Electronics Heaters regulators
Automotive actuators Magna Synchronous Ansaldo Energia Mains extender
Modulation techniques ~1 PM Alternators Axis-EU Induction and PM ASI-Nidec
vk 1 ik [pu] 0.5 Active Filters 0
-0.5 Uni Nottingham
-1
0.26 0.27 0.28 0.29 0.3 0.31 0.32 0.33 0.34 t [s] AUTOMOTIVE RELATED RESEARCH
DriveTraction for Hybridmotor: electricIPM Brushless vehicle Drive for Hybrid electric vehicle Hybrid working machines Traction motor: IPM Brushless
Pn = 40 kW
Direc drive brushless for mix concrete This IPM motor was designed from scratch to match requirements of a vehicle prototype (Piaggio Porter) ELECTRIFIED RAIL
• Hybrid electro-mechanical modelling of trains together with feeding systems • Evaluated effectiveness of stationary storage to enhance energy efficiency • Collaboration with Trasporti Elettrificati Bergamo (company that manages bergamo tramways)
• Electro-mechanical evaluation of 2x25 kV Railway feeding systems • Collaboration with Università di Roma and Italcertifer ELECTROCHEMICAL STORAGE
We test individual cells and modules, up to 60V - 500 A, within thermal changer operating between -40 and +180°C.
What we did: 1. We tested several types of cells and supercaps, in collaboration with ENEA 2. We used tests to develop reliable battery models 3. We use model to develop State-of-Charge evaluation algorithms. 4. During 2019 we tested cells on behalf of Cassioli Group, which is evaluating changing their batteries for in-storehouse vehicles as a consequence of our tests. 5. We are currently testing batteries for Toyota Material Handling Italia, which wants to enhance their electric and hybrid front-end loaders ELECTROCHEMICAL STORAGE
30-h, 45 NEDC tests, with automatic charge balancing (based on OCV-SOC correlation)
50 [A] Current (A) 25
0
-25
Temperature-rise based stress evaluation -50 0 200 400 600 800 1000 t (s) 1200 (file nedc.mat; x-var t) i 30 Battery We were able to test the equivalent of several temperatures (°C) case thousand kilometres; the result was that the 25 batteries were able to withstand much higher Room pulse-charging currents than the very 20 0 200 400 600 800 1000 t [s](s) 1200 manufacturer knew! (file 6C_symm_mult.mat; x-var x) T_batt T_amb ELECTROCHEMICAL STORAGE
According to our studies two installations were built: • A 1MWh battery and VSC to perform active and reactive power-based grid services in a location near Pisa (collaboration with EEI - Equipaggiamenti Elettronici Industriali) • A system installed in Bergamo railway to recover braking energy • Our series-hybrid fuel-cell based vehicle's battery HYBRID VEHICLES
Modeling and design of hybrid vehicles PEGS* ON/ * ? s* OFF SOC P T primary converterbus electric drive mechanical U ED power Fuel DC PEGS PU PED Driver input driver requests EGS EPC EPC EM Fuel (and emission) interpretation P P optimisation driver RESS AUX * High algorithm SOC long-term Normal AUX intention PEGS* ESS TED* Low ? s* Ppaf ON/OFF SOC other Load forecast signals driver Power Management Module (PMM) PMM requests
EGS = Electricity Generator System EPC = Electronic Power Conditioner EM = Electrical Machine ESS = Energy Storage System
30 The department owns a specific 20 10 capability of simulating hybrid vehicle 0 power trains, to define optimal control -10 powerpower (kW) (kW) -20 strategies. PEGS(t)RESS PESS(t) ED PUFCS(t) -30 600 700 800 900 1000 1100 1200 This capability has been exploited in time (s) several funded projects (next slide) 80
40 speed (km/h) speed
0 600 700 800 900 1000 1100 1200 tim e (s) HYBRID VEHICLES
The concept and architecture (UNIPI)
EP C
V, I, θ p* CVT R ω ICE CC r
EM BS GHP OM EMS driver (PMM) oo, ω i dashboard OO, TVA
OO: engine on-off signal Internal Combustion Engine ICE TVA: throttle valve aperture BS: braking signal Continuously-variable Transmission CVT GHP: gas handle position Centrifugal clutch CC OM: operating mode Electric Machine EM P*: controlled electrical power oo: on/off state of ICE Electronic Power Converter EPC ω ω i, r: angular speeds Reduction Gear R V, I, θ: battery voltage, current, temperature Energy Management System EMS
36 HYBRID VEHICLES
Physical realizations
The first working prototype of the hybrid power train
A study (By Piaggio) for the final realisation
The real thing! (Piaggio)
The whole project was a successful collaboration between Unipi and Piaggio. HYBRID VEHICLES
Physical realizations A study was carried out in the framework of Industria 2015 project in conjunction with BredaMenariniBus. The study, for its hybrid vehicle part, aimed at defining, through simulations, the vehicle architecture, control strategy, component size. The bus was then built and tested by BredaMenariniBus
A study was carried out around 2010 to create a hybrid fuel-cell vehicle. The main purpose was to locate all components below the vehicle floor, so that no space penalty was introduced in comparison with the existing commercial version. Funded by Regione Toscana The vehicle was successfully built and tested. FUEL-CELL VEHICLES FUEL-CELL VEHICLES
Everything is below the floor: mission complete! MULTI-PHYSICS
Simulation of vehicles requires simulating interaction among different engineering systems: electric, electronic, mechanic, thermal control, fluids. Conventional simulation tools have limitations in doing this. Multi-physics Cyber-physical simulation allows overcoming these limitations and difficulties.
Destec excels in using Modelica language for cyper-physical, multi engineering simulations
It also collaborates with Open-Source Modelica Consortium* to improve Here a hybrid vehicles is simulates in its three four simulation tools and libraries. layers: driver, Energy management system, power train, vehicular (longitudinal) mechanics. It involves *www.openmodelica.org control, mechanical and electrical parts WHAT'S NEXT
There is a tough discussion on the real environmental friendliness of electric vehicles. The best approach is a Life-Cycle Assessment, and, for the useful life-part, well-to- wheels analysis.
• Professional studies show a good edge for the battery electric vehicles • Fuel-cell vehicles are somewhat intermediate between battery electric and conventional ones, but they may be useful to diversify • More studies are needed: most approaches, for instance, consider the pollution induced by electricity consumption without considering the time of the day, which can distort things dramatically 7 Centuries of Education, Research and Technology Transfer for Excellence
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