POLITECNICO DI TORINO Automotive Engineering Master of Science [Class LM-33] Energy Management Strategy for a High-Performance Hybrid Vehicle Master Thesis Supervisors: Candidate: Chiar.mo prof. Stefano Malan Francesco Bertolini 1 Ing. Claudio Manzali “La vita è come il caffè. Puoi metterci tutto lo zucchero che vuoi, ma se lo vuoi far diventare dolce, devi girare il cucchiaino. A stare fermi non succede niente” (Alex Zanardi) 20 Luglio 2020 2 Table of Contents TABLE OF CONTENTS ..................................................................................................................................................... 3 NOMENCLATURE ........................................................................................................................................................... 5 1. INTRODUCTION ..................................................................................................................................................... 7 1.1 CONTEXT ................................................................................................................................................................. 7 1.1.1 Automobili Lamborghini: history and products................................................................................................ 7 1.1.2 2020 New Emission Standards and Automotive Industry Reaction ............................................................... 10 1.2 AIM OF THE STUDY .................................................................................................................................................. 13 2. HIGH-PERFORMANCE HYBRID VEHICLES: STATE-OF-THE-ART .............................................................................. 15 2.1 HYBRIDIZATION DEGREE: MILD, FULL AND PLUG-IN HYBRID VEHICLES .............................................................................. 15 2.2 POWERTRAIN CONFIGURATIONS: SERIES, PARALLEL AND POWER-SPLIT ............................................................................. 17 2.3 E-MOTOR LAYOUT: P1, P2, P3 AND P4 TOPOLOGIES .................................................................................................... 18 3. VEHICLE MODEL .................................................................................................................................................. 23 3.1 MODELLING APPROACH AND TOOLS ........................................................................................................................... 23 3.2 MODEL OVERALL STRUCTURE ..................................................................................................................................... 25 3.3 VEHICLE DASHBOARD ............................................................................................................................................... 26 3.4 VEHICLE COMMAND ................................................................................................................................................ 28 3.4.1 Vehicle speed tracing ..................................................................................................................................... 28 3.4.2 Driveline Control ............................................................................................................................................ 30 3.4.3 Strategy-related blocks: EM-ICE shift and Discharge Prevention Mode ........................................................ 31 3.5 TORQUE COMMAND ................................................................................................................................................ 32 3.4.4 In-gear torque command ............................................................................................................................... 33 3.4.5 ICE disconnected case .................................................................................................................................... 34 3.6 WHEELS ................................................................................................................................................................ 35 3.5.1 Cinematic path ............................................................................................................................................... 36 3.5.2 Dynamic path ................................................................................................................................................. 36 3.7 VEHICLE DYNAMICS ................................................................................................................................................. 37 3.6.1 Inner structure and brakes control ................................................................................................................. 38 3.6.2 AeroForce block.............................................................................................................................................. 38 3.8 THERMAL POWERTRAIN ............................................................................................................................................ 40 3.7.1 Two running modes: Hybrid and Charge Sustaining ...................................................................................... 40 3.7.2 Modes inner structure .................................................................................................................................... 41 3.7.3 ICE running case ............................................................................................................................................. 42 3.7.4 ICE in idle ........................................................................................................................................................ 44 3.7.5 Internal Combustion Engine ........................................................................................................................... 44 3.7.6 Fuel consumption ........................................................................................................................................... 45 3.9 ELECTRIC POWERTRAIN ............................................................................................................................................ 47 3.8.1 Overall structure ............................................................................................................................................ 47 3.8.2 EMs command ............................................................................................................................................... 48 3.8.3 Current control ............................................................................................................................................... 49 3.8.4 Regenerative braking command .................................................................................................................... 50 3.8.5 P4 unit: the front axle EM .............................................................................................................................. 51 3.8.6 P2.5 unit: the rear EM .................................................................................................................................... 53 3.8.7 P2.5: no propulsion case ................................................................................................................................ 54 3.8.8 P2.5: Hybrid Mode ......................................................................................................................................... 57 3.8.9 Battery ........................................................................................................................................................... 58 3 3.8.10 Energy consumption .................................................................................................................................. 60 3.10 BRAKES ................................................................................................................................................................. 60 3.11 MODELLING ISSUES .................................................................................................................................................. 62 4. ENERGY MANAGEMENT STRATEGY ..................................................................................................................... 65 4.1 STRATEGY FRAMEWORK ............................................................................................................................................ 65 4.3 POWERTRAIN CONFIGURATION CHOICE ........................................................................................................................ 69 4.3.1 Considerations over state-of-the-art vehicles and literature research .......................................................... 70 4.3.2 Considerations over project boundaries ........................................................................................................ 70 4.4 WORKING PRINCIPLE: TWO-LAYER CONTROL AND STATE MACHINE STRATEGY (MULTI-MODE STRATEGY) ................................. 71 4.5 TWO MAJOR OPERATING MODES ............................................................................................................................... 73 4.5.1 Hybrid Mode: working principles ................................................................................................................... 73 4.5.2 Charge Sustaining mode: working principles ................................................................................................