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An ECMS-Based Controller for the Electrical System of a Passenger

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An ECMS-Based Controller for the Electrical System of a Passenger An ECMS-Based Controller for the Electrical System of a Passenger Vehicle THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Jeremy R. Couch B.S. (Case Western Reserve University) 2011 Graduate Program in Mechanical Engineering The Ohio State University 2013 Master's Examination Committee: Professor Marcello Canova, Advisor Professor Giorgio Rizzoni, Committee Member Dr. Lisa Fiorentini, Committee Member Copyright by Jeremy R. Couch 2013 Abstract A primary concern for automotive manufacturers is increasing the fuel economy of their vehicles. One way to accomplish this is by reducing the losses associated with operating the ancillary loads such as the loads of the vehicle’s electrical system. In the electrical system of a vehicle, the alternator provides current to the electrical loads. The difference between the load current demand and the current provided by the alternator is either accepted or supplied by the battery. Therefore, the current demand of the electrical loads can be met by the alternator, the battery or a combination thereof. While improving the efficiency of the actual components of the electrical system (alternator, battery and electrical loads) is beneficial, additional gains can be realized with a smart control strategy for the alternator. Conventional alternator control strategies make little use of the battery; the power demand from the electrical loads is almost solely met by the alternator. However, since the alternator is directly connected to the engine, this results in increased fuel consumption, particularly at idle speed conditions. To this extent, more advanced control strategies could be implemented to make use of the battery energy buffer to limit the use of the alternator at low engine efficiency conditions. ii The focus of this thesis is the design of an advanced alternator control strategy. First, a model of a vehicle’s electrical system is developed with control design in mind. The system is modeled starting from a lumped-parameter, energy-based characterization of the battery and alternator. This is followed by a thorough calibration using experimental data and, finally, validation on a vehicle chassis dynamometer considering a standard (production) alternator control strategy. Next, a novel alternator control algorithm is designed by applying the Equivalent Consumption Minimization Strategy (ECMS), a well known energy management approach often used to control the powertrain of hybrid electric vehicles. This strategy works by determining the optimal alternator current to minimize the instantaneous fuel consumption while complying with input and state of charge constraints. The ECMS algorithm was extensively calibrated for a variety of drive cycles and load current profiles. This proposed control strategy was then compared in simulation to the production alternator controller and fuel consumption reductions of up to 2.18% have been shown. An adaptive ECMS (A-ECMS) is then defined, using feedback from the battery’s state of charge to dynamically tune the ECMS calibration parameter in real- time. Simulation results for the A-ECMS show fuel savings compared to the baseline alternator control strategy that are on the same order of magnitude as the ECMS. Furthermore, a robustness study verifies the A-ECMS is insensitive to model inaccuracies, poor tuning of the parameters and variations in the load current profile. iii Acknowledgements I have had a great experience as a graduate student at The Ohio State University and, in particular, the Center for Automotive Research (CAR). I owe much thanks to those who have helped me in my time here. Thank you to my advisor, Professor Marcello Canova, for bringing me into CAR, guiding me into a rewarding project, and supporting me throughout these two years. Thank you to Dr. Lisa Fiorentini for her infinite patience and for making time for me when she had none for herself. Thank you to Dr. Fabio Chiara for sharing his knowledge and sense of humor when things got tough. Thank you to Professor Giorgio Rizzoni for his insight on the ECMS and Dr. Shawn Midlam-Mohler for his expertise on hardware instrumentation. Thank you to Yann Guezennec for his valuable input on battery modeling and John Neal for helping conduct the battery testing. Thank you to Sabarish Gurusubramanian for his assistance with experimental testing and Quansheng Zhang for answering all my questions, no matter how simple. I would also like to thank Benjamin Grimm and Neeraj Agarwal for laying the foundation for my work. Finally, many thanks to Kyle Merical for keeping me sane during the more trying times. I appreciate you all. iv To my family. v Vita 2007................................................................Cloverleaf High School 2011................................................................B.S. Mechanical Engineering, Case Western Reserve University 2011 to present ..............................................Graduate Fellow, Department of Mechanical and Aerospace Engineering, Center for Automotive Research, The Ohio State University Fields of Study Major Field: Mechanical Engineering vi Table of Contents Abstract ............................................................................................................................... ii Acknowledgements ............................................................................................................ iv Vita ..................................................................................................................................... vi Table of Contents .............................................................................................................. vii List of Tables ..................................................................................................................... xi List of Figures ................................................................................................................... xv Nomenclature ................................................................................................................. xxiii Chapter 1: Introduction ....................................................................................................... 1 Section 1.1 Scope of Work .............................................................................................. 1 Section 1.2 Document Layout ......................................................................................... 2 Chapter 2: State of the Art .................................................................................................. 3 Section 2.1 Fuel Consumption in the Transportation Sector .......................................... 3 Section 2.2 Industry Response ........................................................................................ 7 2.2.1 Powertrain ........................................................................................................... 7 Powertrain Design ................................................................................................... 9 vii Energy Savings/Recovery ..................................................................................... 12 2.2.2 Ancillary Loads ................................................................................................ 18 Lubrication System ............................................................................................... 18 Cooling System ..................................................................................................... 20 AC System ............................................................................................................ 20 Alternator .............................................................................................................. 22 2.2.3 Electrical System Control ................................................................................. 23 Section 2.3 Equivalent Consumption Minimization Strategy ....................................... 26 2.3.1 The ECMS ........................................................................................................ 26 2.3.2 The Adaptive ECMS ........................................................................................ 29 Chapter 3: Model Development, Calibration and Validation ........................................... 32 Section 3.1 Experimental Setup .................................................................................... 32 3.1.1 Engine ............................................................................................................... 33 3.1.2 Vehicle .............................................................................................................. 35 3.1.3 Battery Testing ................................................................................................. 38 Section 3.2 Overview of the Vehicle Energy Simulator ............................................... 39 3.2.1 Driver ................................................................................................................ 40 3.2.2 Sensors .............................................................................................................. 40 3.2.3 Chrysler Control ............................................................................................... 41 viii 3.2.4 OSU Control ..................................................................................................... 41 3.2.5 Actuators ..........................................................................................................
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