Modeling, control and real time simulation of a four wheel drive ... - IPG
Modeling, control and real time simulation of a four wheel drive ... - IPG
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Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr<br />
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong><br />
<strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Pr<strong>of</strong>. Levent Güvenç , İsmail Meric Can Uygan, Özgür Tuncer<br />
İstanbul Technical University
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Outline <strong>of</strong> Presentation<br />
• About Mekar Labs <strong>and</strong> Autocom Center<br />
• Overview <strong>of</strong> Automotive Industry in Turkey<br />
(source: OSD, Automotive Manufacturers<br />
Association <strong>of</strong> Turkey)<br />
• Hybrid Electric Vehicles (HEV)<br />
• <strong>Modeling</strong> 4 WD HEV in Carmaker<br />
• HiL Simulation System<br />
• Conclusions<br />
2/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
We are İstanbul located in the from center Above <strong>of</strong> İstanbul.<br />
3/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
İSTANBUL TECHNICAL UNIVERSITY<br />
Oldest engineering school in<br />
Turkey, founded in 1773.<br />
4/36<br />
20,000 engineering students<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
İstanbul<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong><br />
Technical<br />
<strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong><br />
University<br />
<strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Gümüşsuyu-Taksim Campus<br />
5/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Background<br />
• We are the Mekar - Mechatronics Research<br />
Labs in the Department <strong>of</strong> Mechanical<br />
Engineering at İstanbul Technical University.<br />
• Automotive Control <strong>and</strong> Mechatronics has long<br />
been a part <strong>of</strong> our Mekar lab activities.<br />
• In 2004 the Autocom Automotive Control <strong>and</strong><br />
Mechatronics Research Center (AUTOCOM,<br />
INCO-16426) was selected as a center <strong>of</strong><br />
excellence <strong>and</strong> supported in EU FP6.<br />
6/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
• Project started <strong>of</strong>ficially on May 1, 2005.<br />
• Project Duration: 36 months<br />
• Project Budget: 600,000 Euro<br />
• Coordinator – one partner project<br />
• Three thrust areas <strong>of</strong> research:<br />
o Active <strong>and</strong> preventive safety – This is still our strongest thrust<br />
area. This is where we can collaborate with the automotive<br />
industry very easily.<br />
o Powertrain modeling, <strong>control</strong> <strong>and</strong> hardware in the loop<br />
<strong>simulation</strong>. We have improved considerably in this thrust area.<br />
o Hybrid electric vehicle modeling <strong>and</strong> <strong>control</strong>. We have finished<br />
two important projects <strong>and</strong> are in the middle <strong>of</strong> a followup<br />
project with a major OEM. We have become competitive in this<br />
thrust area.<br />
7/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
PEOPLE<br />
FACULTY<br />
Pr<strong>of</strong>.Dr. Levent Güvenç (İstanbul Technical University)<br />
Assoc.Pr<strong>of</strong>.Dr. Bilin Aksun Güvenç (İstanbul Technical University)<br />
Assist.Pr<strong>of</strong>.Dr. Ümit Sönmez (İstanbul Technical University)<br />
Assist.Pr<strong>of</strong>.Dr. Tankut Acarman (Galatasaray University)<br />
Assoc.Pr<strong>of</strong>.Dr. Emre Köse (Boğaziçi University)<br />
Assist.Pr<strong>of</strong>.Dr. Erdinç Altuğ (İstanbul Technical University)<br />
POST-DOCTORAL RESEARCHERS<br />
Dr. Ahu Ece Hartavi Dr. Vellupillai Sankaranarayanan<br />
GRADUATE STUDENTS<br />
Ali Boyalı Öncü Ararat Burcu Aytekin<br />
Bahadır Akyıldız Sinan Öncü Serhan Daniş<br />
Erkin Dinçmen Ercan Atam Mümin Aktaş<br />
Volkan Sezer İsmail Uygan ...<br />
Ayşe Tekeş Dinçer Özcan ...<br />
PROJECT MANAGEMENT ASSISTANT<br />
Zeynep Kayahan<br />
8/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
MVI in World – 2007 (x 1.000)<br />
1) JAPONYA<br />
2) ABD<br />
3) ÇHC<br />
4) ALMANYA<br />
5) G.KORE<br />
6) FRANSA<br />
7) İSPANYA<br />
8) BREZİLYA<br />
9) KANADA<br />
10) HİNDİSTAN<br />
11)MEKSİKA<br />
12) İNGİLTERE<br />
13) RUSYA<br />
14) İTALYA<br />
15) TAYLAND<br />
16) TÜRKİYE<br />
17) İRAN<br />
18) ÇEK CUMHURİYETİ.<br />
19)BELÇİKA<br />
20) POLONYA<br />
3.019<br />
2.890<br />
2.971<br />
2.578<br />
2.350<br />
2.095<br />
1.750<br />
1.660<br />
1.284<br />
1.238<br />
1.099<br />
997<br />
939<br />
844<br />
785<br />
4.086<br />
9/36<br />
6.213<br />
2 Million Units<br />
in 2015<br />
1.1 Million Units<br />
in 2007<br />
8.882<br />
Source: Automotive Manufacturers Assoc. <strong>of</strong> Turkey, OSD<br />
11.596<br />
10.781<br />
Ranking in EU (27)<br />
Total 6<br />
Buses 1<br />
LCV 2<br />
H.Trucks 6<br />
P.Cars 9<br />
2008<br />
Production 1.300.000<br />
Capacity 1.500.000<br />
Exports 950.000<br />
Market 675.000<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Development <strong>of</strong> MVI in Turkey: 1960/2010<br />
1960-1970<br />
1970-1980<br />
Free Market<br />
Global<br />
Competition<br />
Assembly<br />
1980-1990<br />
Development <strong>of</strong><br />
Component ınd.<br />
1990-1995<br />
1995-2000<br />
License<br />
Increase in<br />
Capacity<br />
Up-to-date<br />
Model Export<br />
2000-2012<br />
10/36<br />
Localization<br />
Modernization<br />
Full integration<br />
Manufacturing Base<br />
Up-to-date<br />
Model<br />
Protected<br />
Market<br />
Transition<br />
Period<br />
Research & Development, Design &<br />
Technology Management,<br />
Intellectual & Industrial Property<br />
TARGET FOR 2012 : CENTER <strong>of</strong> EXCELLENCE<br />
Source: Automotive Manufacturers Assoc. <strong>of</strong> Turkey, OSD<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
85 % <strong>of</strong><br />
Components<br />
Manufacturers<br />
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Istanbul<br />
Izmir<br />
MV Manufacturers in Turkey<br />
Izmit<br />
Gölcük<br />
Bursa<br />
Eskişehir<br />
Adapazarı ı<br />
Ankara<br />
11/36<br />
Aksaray<br />
Adana<br />
Source: Automotive Manufacturers Assoc. <strong>of</strong> Turkey, OSD<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Motor Vehicle Manufacturers (2008)<br />
Companies Ownership Partner<br />
TOFAŞ JV FIAT 400.000<br />
O.RENAULT JV RENAULT 360.000<br />
TOYOTA FDI TOYOTA P.Cars 150.000<br />
HYUNDAI ASSAN JV HYUNDAI 100.000<br />
HONDA FDI HONDA 50.000<br />
P.Cars Total<br />
1.060.000<br />
FORD OTOSAN JV FORD 295.000<br />
HYUNDAI ASSAN JV HYUNDAI 25.000<br />
KARSAN Local PEUGEOT 25.000<br />
B.M.C. Local Local 22.000<br />
OTOYOL JV IVECO 18.000<br />
M.BENZ TÜRK JV M.BENZ CV<br />
13.000<br />
ANADOLU ISUZU JV ISUZU 13.000<br />
TEMSA Local Local 11.000<br />
ASKAM Local Local 9.000<br />
OTOKAR Local LAND ROVER 8.000<br />
M.A.N. FDI MAN 4.000<br />
CV Total<br />
443.000<br />
Total<br />
1.503.000<br />
12/36<br />
Product<br />
Source: Automotive Manufacturers Assoc. <strong>of</strong> Turkey, OSD<br />
Capacity<br />
Vehicle/Year<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
History <strong>of</strong> the Production (x 1.000)<br />
1.200<br />
1.000<br />
800<br />
600<br />
400<br />
200<br />
0<br />
3<br />
Passenger Cars<br />
Total<br />
Total Production:<br />
3,000 in 1963<br />
1,100,000 in 2007<br />
110<br />
47<br />
1963<br />
1964<br />
1965<br />
1966<br />
1967<br />
1968<br />
1969<br />
1970<br />
1971<br />
1972<br />
1973<br />
1974<br />
1975<br />
1976<br />
1977<br />
1978<br />
1979<br />
1980<br />
1981<br />
1982<br />
1983<br />
1984<br />
1985<br />
1986<br />
1987<br />
1988<br />
1989<br />
1990<br />
1991<br />
1992<br />
1993<br />
1994<br />
1995<br />
1996<br />
1997<br />
1998<br />
1999<br />
2000<br />
2001<br />
2002<br />
2003<br />
2004<br />
2005<br />
2006<br />
2007<br />
13/36<br />
421<br />
348<br />
243<br />
213<br />
Source: Automotive Manufacturers Assoc. <strong>of</strong> Turkey, OSD<br />
431<br />
297<br />
1.100<br />
635<br />
271<br />
175<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
MVI Integration<br />
Number <strong>of</strong> Manufacturers 15<br />
Link With Non-EU 5 (26 % <strong>of</strong> 2007 production)<br />
* JV 4<br />
* License 1<br />
Link With EU 7 (72 % <strong>of</strong> 2006 production)<br />
* JV 6<br />
* License 1<br />
Local 3 (2 % <strong>of</strong> 2006 production)<br />
Link With EU Manufacturers<br />
Fiat Group JV<br />
Ford JV<br />
MAN FDI<br />
M. Benz JV<br />
Renault JV<br />
Rover Group L<br />
Peugeot L<br />
Source: Automotive Manufacturers Assoc. <strong>of</strong> Turkey, OSD<br />
14/36<br />
Link With Non-EU Manufacturers<br />
Isuzu JV<br />
Toyota FDI<br />
Mitsubishi L<br />
Honda FDI<br />
Hyundai JV<br />
Hino L<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Automotive Component Industry In Turkey<br />
Around 1.000 Component Suppliers: 350 Of Them Are Global Supplier<br />
International Accreditation:<br />
Quality – ISO 16949, Environment - ISO 14001<br />
Well Trained Work Force: Around 250.000<br />
Cost Advantage: High Productivity <strong>and</strong> Relatively Less Labor Wage<br />
Significant Experience In Their Field<br />
Able To Meet Global St<strong>and</strong>ards<br />
Able To Compete In Global Markets<br />
Experience In Export Activities<br />
Source: Automotive Manufacturers Assoc. <strong>of</strong> Turkey, OSD<br />
15/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
The Assets & Potential <strong>of</strong> MVI <strong>of</strong> Turkey<br />
Automotive Culture 50 years <strong>of</strong> production tradition<br />
High Sense <strong>of</strong> Quality TQM, Lean Production, 6 Sigma<br />
Labor Peace Unionized work force / collective bargaining since 1963<br />
Qualified, Well-Educated, Motivated Labor Force at Competitive Cost<br />
Flexible Working Hours 7.5 hours / shift - 3 shifts / day - 6 days / week;<br />
Rate <strong>of</strong> Absenteeism < 1.5 %<br />
Entrepreneurship $ 10 billion worth <strong>of</strong> Investment<br />
Partnership With World-Leading Manufacturers<br />
Experienced Local Component Industry / Supplier Base<br />
Unsaturated Domestic Market With High Potential <strong>of</strong> Dem<strong>and</strong><br />
More Incentives on R & D <strong>and</strong> New Investments<br />
Developed Infrastructure & Services in the Region<br />
Logistics, Energy, Transport, Banking, Communication<br />
Manufacturing Facilities With State-<strong>of</strong>-the-Art Technology<br />
Source: Automotive Manufacturers Assoc. <strong>of</strong> Turkey, OSD<br />
16/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
What is Hybrid Electric Vehicle (HEV)?<br />
• Internal Combustion Engine - The hybrid<br />
car has an internal combustion engine much<br />
like the one found in most cars. However, the<br />
engine on a hybrid is smaller <strong>and</strong> uses<br />
advanced technologies to reduce emissions<br />
<strong>and</strong> increase efficiency<br />
• Electric Motor - The electric motor on a<br />
hybrid car is very sophisticated. Advanced<br />
electronics allow it to act as a motor as well<br />
as a generator.<br />
• Generator - The generator is similar to an<br />
electric motor, but it acts only to produce<br />
electrical power. It is used mostly on series<br />
hybrids.<br />
• Controller: Manages the power flow <strong>and</strong><br />
determines the mode <strong>of</strong> action.<br />
• Batteries - The batteries in a hybrid car are<br />
the energy storage device for the electric<br />
motor. Unlike the gasoline in the fuel tank,<br />
which can only power the gasoline engine,<br />
the batteries on a hybrid car can put energy<br />
into the motor as well as draw energy from<br />
the motor.<br />
17/36<br />
HEV Main Components<br />
• Hybrid Electric Vehicle(HEV) is the vehicle which<br />
uses both electrical motor <strong>and</strong> gasoline engine<br />
to provide motive power<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Configuration <strong>of</strong> Series HEV<br />
•There is no mechanical connection between<br />
the ICE <strong>and</strong> the <strong>wheel</strong>s<br />
•Only electric motor <strong>drive</strong>s vehicle<br />
•Only serial charge works<br />
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
HEV Structures<br />
Configuration <strong>of</strong> Parallel HEV<br />
•There is always a mechanical connection<br />
between the <strong>wheel</strong>s <strong>and</strong> ICE<br />
•Electric motor <strong>and</strong> ICE can both <strong>drive</strong><br />
vehicle<br />
•Parallel charge works<br />
18/36<br />
Configuration <strong>of</strong> Series Parallel HEV<br />
•Combination <strong>of</strong> series<br />
<strong>and</strong> parallel HEV<br />
structure<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
CarMaker Graphical User Interface<br />
CarMaker Visualization<br />
CarMaker<br />
•CarMaker includes reliable vehicle models <strong>and</strong> detailed vehicle parameters can be integrated<br />
into vehicle models.<br />
•Vehicle movements can be easily observed with its visual interface.<br />
•Interacts with Simulink.<br />
19/36<br />
Vehicle Parameter Settings<br />
CarMaker Vehicle Model in Simulink<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Hybrid Powertrain in CarMaker<br />
20/36<br />
For the differential hanged on,<br />
the viscous coupling model is<br />
chosen with transferred torque<br />
equal to zero for all speed<br />
differences<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Hybrid Powertrain<br />
Actuating points for front <strong>and</strong> rear electrical motors<br />
on powertrain are the PT.GearBox.Trq_ext2GBout<br />
<strong>and</strong> PT.Gen.DL.HangOn.Trq_Cpl2B.<br />
The former is torque transferred from clutch to<br />
gearbox <strong>and</strong> the latter is torque from coupling model<br />
to shaft B.<br />
21/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Electrical Motor Model (Torque)<br />
EM Model Inputs <strong>and</strong> Outputs<br />
22/36<br />
EM Torque Map<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
EM Efficiency Map inputs <strong>and</strong> output<br />
Electrical Motor Model (Torque)<br />
23/36<br />
Torque [Nm]<br />
200<br />
150<br />
100<br />
50<br />
0<br />
0 100 200 300 400<br />
Speed [rad/s]<br />
500 600 700<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr<br />
0.9<br />
0.85<br />
0.8<br />
0.75<br />
0.7<br />
0.65<br />
0.6<br />
0.55<br />
0.5
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Battery Equivalent Circuit<br />
Model Equations<br />
Battery Model<br />
24/36<br />
Battery Model Inputs <strong>and</strong> Outputs<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Voc [V]<br />
325<br />
320<br />
315<br />
310<br />
305<br />
300<br />
295<br />
0.1 0.2 0.3 0.4 0.5<br />
SOC<br />
0.6 0.7 0.8 0.9<br />
V oc : Open circuit voltage [V]<br />
Battery Model<br />
25/36<br />
E − E<br />
SOC =<br />
E<br />
En<br />
Ec<br />
Rchg<br />
Rdchg<br />
n c<br />
n<br />
: Nominal charge capacity <strong>of</strong> battery in Ah<br />
: Discharge amount in Ah<br />
:<br />
Charge resistance [Ohm]<br />
: Discharge resistance [Ohm]<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
V des<br />
V veh<br />
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Model Block Diagram for Hybrid Controller<br />
Velocity<br />
Controller<br />
α brk<br />
Battery<br />
Regenerative<br />
Braking<br />
Controller<br />
Parameter<br />
Update<br />
g<br />
n<br />
α<br />
thr<br />
K ch<br />
K dch<br />
Per pch<br />
V veh<br />
S OC<br />
V<br />
bat<br />
I<br />
bat<br />
T EM<br />
T EM<br />
1 _ref<br />
2 _ref<br />
MOES<br />
CONTROLLER<br />
26/36<br />
,<br />
T EM<br />
1 _ref<br />
T EM 2 _ref<br />
α<br />
clt<br />
T EM<br />
3 _ref<br />
T IC E _ref<br />
EM1<br />
EM2<br />
EM3<br />
ICE<br />
TEM<br />
1<br />
TEM<br />
2<br />
T E M 3<br />
T ICE<br />
α<br />
clt<br />
ω ICE<br />
Vveh<br />
Autogear<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr<br />
g n<br />
Vveh
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
HiL Car Simulator Components<br />
• Carmaker/HiL S<strong>of</strong>tware<br />
• dSpace 1005<br />
• dSpace CLP 2210 I/O Card<br />
• dSpace microautobox (recent addition as<br />
the HEV <strong>control</strong>ler)<br />
• Force Feedback Steering Wheel <strong>and</strong><br />
Pedal System<br />
• PC<br />
27/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
HiL Simulator Block Diagram<br />
Steering<br />
Wheel<br />
Steering<br />
angle<br />
Force<br />
Feedback<br />
Gas&Brake<br />
Pedal<br />
DS 2210<br />
I/O Card<br />
28/36<br />
I/O<br />
Gas-Brake Signal<br />
PC<br />
Dspace<br />
1005<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Carmaker<br />
Simulation<br />
Dpace<br />
CLP2210<br />
Steering<br />
Wheel<br />
29/36<br />
Dspace<br />
1005<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
HiL Brake System<br />
30/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Animation<br />
31/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Real Time HiL Simulation with Driver in the Loop<br />
32/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Hybrid electric vehicle modeling <strong>and</strong> <strong>control</strong><br />
Project for a major OEM in Turkey. Goal: making a hybrid electric<br />
commercial van. Three research prototypes were built. We developed<br />
<strong>and</strong> implemented the <strong>control</strong> algorithm <strong>and</strong> integrated the <strong>control</strong><br />
hardware. Followup project in progress.<br />
33/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Hybrid electric vehicle modeling <strong>and</strong> <strong>control</strong><br />
34/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
Conclusions<br />
• A HiL HEV <strong>control</strong>ler development <strong>and</strong> testing<br />
environment based on CarMaker HiL was<br />
presented here.<br />
• The HEV <strong>control</strong>ler ECU is connected directly to<br />
this environment to check <strong>control</strong> algorithm<br />
problems ahead <strong>of</strong> <strong>time</strong>.<br />
• Problems that arise during actual testing are<br />
reduced.<br />
• Brake system <strong>of</strong> the vehicle is being integrated<br />
into the simulator as hardware for more <strong>real</strong>istic<br />
HiL <strong>simulation</strong>.<br />
35/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
Mechatronics Research Labs<br />
http://mekar.itu.edu.tr<br />
<strong>Modeling</strong>, <strong>control</strong> <strong>and</strong> <strong>real</strong> <strong>time</strong> <strong>simulation</strong> <strong>of</strong> a <strong>four</strong> <strong>wheel</strong> <strong>drive</strong><br />
hybrid electric vehicle in CarMaker<br />
In cooperation with: Dr. Ahu Ece Hartavi, Volkan Sezer, Pr<strong>of</strong>. Tankut Acarman<br />
Thanks to Ford Otosan (Dr. Murat Yıldırım, Varlık Kılıç <strong>and</strong> İlker Özelgin) for<br />
help with the HEV model, for donating the hydraulic brake system hardware<br />
<strong>and</strong> more.<br />
End <strong>of</strong> presentation ...<br />
Questions???<br />
36/36<br />
Automotive Control <strong>and</strong> Mechatronics Research Center<br />
http://www.autocom.itu.edu.tr
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