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Calibration and Validation of a Hybrid Vehicle Model for Its Implementation in Optimization Routines for Model-Based Fuel Economy Optimization

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Calibration and Validation of a Hybrid Vehicle Model for Its Implementation in Optimization Routines for Model-Based Fuel Economy Optimization Calibration and Validation of a Hybrid Vehicle Model for its Implementation in Optimization Routines for Model-Based Fuel Economy Optimization THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Kshitij Shah, B.Tech. Graduate Program in Mechanical Engineering The Ohio State University 2017 Thesis Committee: Prof. Giorgio Rizzoni, Advisor Prof. Marcello Canova Copyrighted by Kshitij Shah 2017 Abstract The fuel economy prediction in an automobile is a significant and complex issue. There are numerous variables involved in a vehicle’s daily usage that influence its fuel economy. This problem is even more complex for a hybrid electric vehicle (HEV), due to the presence of the supervisory controller overseeing the energy management strategy. The control strategies implemented in production vehicles involve the use of hundreds of calibration parameters in the form of Lookup Tables (LUTs). The work described in this document aims to lay the ground-work in resolving this complex issue of fuel economy prediction in a HEV using a model based optimization approach. There are two distinct aspects of the approach utilized here: 1) Calibration and Validation of the Vehicle Models, 2) Optimization of the Supervisory Controller. An Open Loop Vehicle Model is utilized for the calibration and validation aspect. Experimental data corresponding to a driving distance of ~36,000 km collected over the span of 2 years is made available. The vehicle models used for the research represent the same vehicle on which this data was obtained. The calibration, validation and optimization tasks need to consider different weather patterns across the year to aid in accurately estimating the fuel economy. The primary reason for the use of an open loop model for the calibration and validation aspect is to eliminate the effects of the vehicle controller, so that an accurate representation of the ‘Vehicle Plant’ is available. This thesis details the methodology undertaken for validating the open loop model. A novel ii technique of converting a look-up table into a surface fit to calibrate the same is implemented and the results are discussed. Once validated, the model truly represents the actual vehicle behavior and the results obtained from the optimization performed on it are reliable. The optimization techniques used through the work described here and in further research, are termed as “Derivative-free Simulation based Optimization”. There is an absence of a definitive analytical function to describe the control variables as a function of the objective, and there is a vehicle simulator/model in this loop, that ultimately warrants the use of such methods. Finally, implementation of this validated plant in the closed loop model is illustrated using commonly available derivative-free optimization methods. iii Acknowledgments Foremost, I would like to thank my parents for supporting my decision for pursuing Masters study at the Ohio State University and keeping up with me during these two years. I am extremely grateful to my academic advisor and ‘skiing coach’, Prof. Giorgio Rizzoni for giving me this opportunity to work at the Center for Automotive Research and be a part of his team. His skiing lessons were a great introduction for me to this great sport. I would like to thank Adithya Jayakumar for being a great team member and the collaborative effort for the research work and helping me get through the strenuous times of graduate life. I am thankful to Dr. Jason Meyer and Dr. Jeff Doering from the Ford Motor Company for their support and guidance through the research work. Lastly, a special thanks to the entire community of the Center for Automotive Research for making my time at OSU a truly memorable and fun experience. iv Vita November 14, 1992 ........................................Born – Vadodara, India 2014................................................................B.Tech., Mechanical Engineering S.V. National Institute of Technology, India 2014 to 2015 ..................................................Graduate Engineer Trainee, Mahindra Trucks & Buses, R&D Division, Mahindra & Mahindra Ltd., Pune, India 2016 to 2017 .................................................Graduate Research Associate, Department of Mechanical Engineering, The Ohio State University Publications Shah, K., 2013. “Influence of Splitter Blade Position on the Performance of a Centrifugal Compressor of a Turbocharger”. In Proceedings of the 23rd National Conference on I.C Engines & Combustion, 2013, India. Fields of Study Major Field: Mechanical Engineering v Table of Contents Abstract ............................................................................................................................... ii Acknowledgments .............................................................................................................. iv Vita ...................................................................................................................................... v Publications ......................................................................................................................... v Fields of Study .................................................................................................................... v List of Tables ..................................................................................................................... ix List of Figures ..................................................................................................................... x CHAPTER 1: INTRODUCTION ...................................................................................... 1 1.1 Motivation ................................................................................................................. 1 1.2 Overview of Thesis ................................................................................................... 7 CHAPTER 2: LITERATURE REVIEW AND MOTIVATION ..................................... 10 2.1 Overview ................................................................................................................. 10 2.2 Background ............................................................................................................. 10 2.3 Optimization Techniques for Hybrid Electric Vehicle Design ............................... 13 vi 2.4 Energy Management Techniques in Hybrid Electric Vehicles ............................... 18 2.4.1 Rule based control strategies ............................................................................ 20 2.4.2 Optimization based control strategies ............................................................... 25 2.5 Conclusion ............................................................................................................... 30 CHAPTER 3: INTRODUCTION TO VEHICLE SIMULATORS AND POWERTRAIN ARCHITECTURE ............................................................................................................ 32 3.1 Overview ................................................................................................................. 32 3.2 Background ............................................................................................................. 32 3.3 Proposed framework to reduce fuel-consumption variability ................................. 33 3.4 Closed Loop Model ................................................................................................. 34 3.5 Open Loop Model ................................................................................................... 36 3.6 Powertrain Architecture of the Vehicle/Simulator .................................................. 37 3.7 Experimental Data for Calibration, Validation and Optimization .......................... 42 3.8 Conclusion ............................................................................................................... 46 CHAPTER 4: CALIBRATION AND VALIDATION OF THE OPEN LOOP MODEL 47 4.1 Overview ................................................................................................................. 47 4.2 Inverse Model Implementation ............................................................................... 47 4.3 Road Load Modification ......................................................................................... 52 4.4 Preliminary Results ................................................................................................. 54 vii 4.5 SOC Calibration ...................................................................................................... 58 4.5.1 Statistical analysis of SOC error percent .......................................................... 67 4.6 Fuel Map Calibration .............................................................................................. 69 4.6.1 Use of Surface Fitting to represent Lookup-Tables (LUTs) ............................. 69 4.6.2 Application of Optimization routines for calibration ....................................... 70 4.6.3 Statistical Analysis of fuel-consumption prediction ......................................... 75 4.7 Final Results ............................................................................................................ 77 4.7 Conclusion ............................................................................................................... 84 CHAPTER 5: CONCLUSION AND FUTURE WORK .................................................
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