GUIA DE PROCEDIMENTS PER AL TREBALL DE FI DE GRAU (TFG) I TREBALL DE FI DE 1 MASTER (TFM) Titulación: Grado en ingeniería en tecnologías industriales Alumne (nom i cognoms): Ignacio Vicente Basanta Enunciado TFG / TFM: Layout design of an electric vehicle p owertrain and simulation of energy deployment using torque vectoring techniques Director/a del TFG / TFM: Antoni García Espinosa Codirector/a del TFG / TFM: Convocatòria de lliurament del TFG / TFM: Junio 2019 Layout design of an electric vehicle powertrain and simulation of energy deployment using torque vectoring techniques. Bachelor’s degree in Industrial Technology Engineering Autor: Ignacio Vicente Basanta Director: Toni Garcia Espinosa Undergraduate degree: Grado en ingenier´ıa en tecnolog´ıas industriales Delivery date: June 2019 Abstract As every day passes, modelling and simulation tools gain importance and become rele- vance when it comes to the design and development stages. A prime example can be seen in the automotive industry, where such practices have become almost mandatory. Early design stages focus of energy-modelling, where many component dynamics are ig- nored and the models only compute the energy flow through the models. This allows for quick simulations and changing of component parameters, but as the design process pro- gresses, a need for more detailed models arises. This project will focus on modelling and simulations of subsystems that are unique electric vehicles, such as the battery, motors or inverters. The modelled systems are simplified, but retain fundamental parameters such as operat- ing principles, efficiencies and hardware limitations. Electrical models predict the battery voltage and state of charge. Physical models produce vehicle speed and tire slip estimates and give feedback to the system. Drive cycle inputs give the needed simulation parameters such as speed, incline and steering inputs to the model. The di↵erent model blocks are simulated as a unit using simulink, and results are analysed. Di↵erent parameters such as vehicle speed, energy consumption, battery SOC or wheel slip are logged a analysed and compared with real life examples. Di↵erent energy losses are located and plotted, and their causes explained. A dynamic wheel speed and slip control loop is developed and its performance studied. Finally, a study was carried where model fidelity was systematically and objectively evaluated, and improvements are proposed. 2 Declaration I declare that the work in this degree thesis is completely my own work, no part of this degree thesis is taken from other people’s work without giving them credit, all references have been clearly cited. I understand that an infringement of this declaration leaves me subject to the foreseen disciplinary actions by the Universidad Polit´ecnica de Catalu˜na - BarcelonaTECH. Ignacio Vicente June 10, 2019 Student Name Signature Date Title of the Thesis: Layout design of an electric vehicle powertrain and simulation of energy deployment using torque vectoring techniques. 3 Acknowledgements I want to thank everyone who helped me during this project and supported me in bringing it to fruition. In particular, I want to thank my tutor, professor Toni Garcia who helped in pointing me in the right direction when I wasn’t sure how to proceed. I would also want to acknowledge the helpful theoretical background learned during the optative course of Alternative Propulsion Vehicles imparted by professors David Gonzalez Diez and Joan Monta˜na Puig, which helped me better understand the various technological developments and system architecture of electric vehicles. It also has to be mentioned, that the developed model shown in this thesis, although with expensive modifications, has as it’s base, the model shown in in professor’s David Gonzalez’s class. As such I would like to thank both of them for their input. Finally, I also want to thank my sister for helping me during the revision or this paper and pointed out possible any grammar and spelling mistakes. 4 Contents 1 Introduction 11 1.1 Object....................................... 11 1.2 Scope ....................................... 11 1.3 Basicspecifications................................ 12 1.4 Justification.................................... 13 1.4.1 Chosen software . 13 1.4.2 Environmental advantages of electric vehicles and need to evaluate their efficiency .............................. 14 1.4.3 Cost and resource motivations . 15 2 State of the art 18 2.1 Energy storage devices . 18 2.1.1 Batteries ................................. 20 2.1.2 Fuelcells ................................. 23 2.1.3 Common batteries form factors . 25 2.1.4 Cooling and charge control . 26 2.2 DC-DCConverter ................................ 28 2.3 Inverters...................................... 28 2.3.1 Types of inverter control . 28 2.3.2 Energy regeneration . 29 2.4 Motors....................................... 29 2.4.1 DC vs AC motors . 30 2.4.2 Permanent magnet motors (PMAC) . 31 2.4.3 Rare earth magnets concerns . 32 2.4.4 Induction motor . 33 2.4.5 Switched reluctance motors . 33 2.4.6 Industrypreference. 34 2.5 Inverter and motor control strategies . 34 2.5.1 Field oriented control . 35 2.5.2 Space vector modulation (SVM) . 38 2.6 Sensors ...................................... 40 2.6.1 WheelSpeedsensors........................... 40 2.6.2 Steering angle sensor . 41 2.6.3 Yaw Angle Sensor . 41 2.7 Torquevectoring ................................. 41 5 6 CONTENTS 2.7.1 Basic operation . 42 2.7.2 Longitudinal dynamics . 44 2.7.3 Lateral dynamics . 45 2.7.4 Sensors .................................. 45 3 Proposed drivetrain components and layout 48 3.1 Vehiclelayout................................... 48 3.2 BatteryPack ................................... 49 3.3 Inverter and motor controllers . 51 3.4 Drivemotors ................................... 51 3.5 PMSMmotormodelling ............................. 51 3.5.1 Steady state model for a PMSM . 52 3.5.2 Steady state PMSM model including the core losses . 52 3.6 Reductiondriveandwheels . 53 3.7 Why evaluate di↵erent component layouts . 54 3.8 Simulation tools and environment . 55 4 Vehicle forces and Power Requirements 57 4.1 Rollingresistance................................. 57 4.2 Aerodynamic drag . 57 4.3 ResistanceduetoInclines . 58 4.4 Acceleration resistance . 58 4.5 Equation of motion . 59 4.6 Tractionlimit................................... 60 4.7 Longitudinal tyre force . 60 4.7.1 Slipratio ................................. 60 4.7.2 Magic formula . 62 4.8 Vehicle power and performance envelopes . 63 4.9 Electric motor and transmission ratings . 64 4.10 Modelling the contact forces . 65 4.10.1 Powerrequirements ........................... 68 5 Matlab Model 69 5.1 Di↵erentmodellingapproaches . 69 5.1.1 Causal and non-causal modelling . 69 5.1.2 How Simscape works . 69 5.2 Thechosenmodel ................................ 70 5.2.1 Limitations of the model . 71 5.2.2 Objectivesofthemodel ......................... 71 5.3 DriveCycleandsteeringinput . 71 5.4 Vehiclemodelblocks ............................... 72 5.4.1 Driver................................... 72 5.4.2 Battery .................................. 73 5.4.3 DC-DCpowerconverter . 73 CONTENTS 7 5.4.4 Inverter and motor controller . 73 5.4.5 PMSM motor . 74 5.5 Gearbox...................................... 74 5.5.1 Tyres ................................... 74 5.5.2 Traction control . 75 5.5.3 Torque vectoring . 75 5.6 Othermodelblocks................................ 75 5.6.1 Environment ............................... 75 5.6.2 Dynamic equations . 76 6 Results and Analysis 77 6.1 Drivetrain layout selector and initiation script . 77 6.1.1 Initiationscript.............................. 77 6.2 Basicsimulation ................................. 78 6.2.1 Intercommunication between blocks . 78 6.2.2 Requiredinputs.............................. 78 6.2.3 Obtained outputs . 79 6.3 Drivetrain layouts comparison and results analysis . 79 6.4 Longitudinal torque vectoring and traction control behaviour evaluation . 84 6.5 Efficiency testing and evaluation tools . 89 7 Conclusion 93 7.1 Mainconclussions ................................ 93 7.2 Economicviability ................................ 93 7.3 Enviromental impact and implications . 94 7.4 Recommendations for future development of the project . 94 7.5 Structure and planning for possible future development of the project . 95 Appendices 100 A Simulink blocks 101 A.1 Matlabmodelarchitecture. 101 A.1.1 Drivetrain................................. 101 A.1.2 Traction control Block . 102 A.1.3 Torque vectoring Block . 102 A.1.4 Inverter and motor controller . 103 A.1.5 PMAC motor . 104 A.1.6 Gearbox.................................. 104 A.1.7 Tires.................................... 105 A.2 Environmentmodelblocks. 105 B Matlab Code 106 B.1 MatlabInitiationCode.............................. 106 B.2 MatlabCodeforPlottingResults. 116 List of Figures 1.1 Oil total final consumption by sector, Mtoe. [34] . 15 1.2 Passenger transport in IEA countries: energy per passenger per kilometer, MJ/pkm.[34]................................... 15 2.1 Battery chemistries energy density comparison. [7] . 23 2.2 Lithium battery charge protocol. [9] . 27 2.4 Types of electric motors for electric vehicles. [36] . 30 2.5 Di↵erence in BEMF waveforms between BLDC and PMSM machines [4] . 32 2.6 Field oriented control scheme [43] . 36 2.7 Relationship of the ↵ β and d-q coordinate system [8] . 38 − 2.8 Space vector diagram with sectors . 40 2.9 Di↵erent dynamic states