Case 3

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Automotive Research Center
Systems Engineering Methods Applied to

Hybrid Electric Vehicle Propulsion
Dennis Assanis
ARC Conference
May 19-20, 1998
Ann Arbor, Michigan
Case Study: Hybrid Electric Vehicle
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Presentation Outline
Introduction
Background and Objectives
Hybrid Electric Vehicle System Simulation
Engine System Simulation
Integration
HEV System Optimization
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What is a Hybrid Propulsion System?
Fuel
Tank
Fuel
Converter
Motor/Generator
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Series vs. Parallel HEV

Series HEV
Engine
Motor/Generator
Motor/Generator
Transmission
Electric
Power
Controller
Battery
Mechanical connection
Electrical connection
Parallel HEV
Engine
Motor/Generator
Electric
Power
Controller
Transmission
Battery
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Potential Benefits of the

Hybrid Electric Propulsion System
Fuel economy improvements due to engine operation
in a high efficiency region and power regeneration
during braking
Low speed acceleration improvements
Emission reduction during vehicle start and city
driving - electric motor provides power at low speeds
Electric drives silent operation important for army
reconnaissance vehicles
In case of parallel HEV either powerplant can provide
crawl home capability
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Need for System Simulation
HEV is a very complex system, simulation

needed to analyze component sizing
Need a simulation to quantify benefits,
explore options and new configurations
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OBJECTIVES
Develop a high fidelity, flexible, system
simulation of the HEV suitable for optimization
studies.
Demonstrate its application to mid-size
passenger car vehicle.
Optimize engine, motor and battery pack sizes
for best fuel economy, subject to PNGV
performance constraints.
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Foundation for HEV System Simulation
ADVISOR = quasi-steady model of a total vehicle

Developed by National Renewable Energy Laboratorys
Wipke, Cuddy and others (http://www.nrel.gov)
Matlab-SIMULINK, feed-backward simulation
Fuel
Engine
Look-up Table
RPM
Req Torque
Driving Cycle
Vehicle
Parameters
feed-backward
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HEV System Simulation Framework

Matlab-SIMULINK environment
FUEL (g/s)
ADVISOR
TORQUE
RPM
ENGINE FUEL DELIVERY

LOOK-UP TABLE
Parallel HEV
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Limitations of Using Engine

Look-up Tables
Look-up table has to be obtained on the test stand
and applies only to a given engine design.
Simple scaling of a look-up table for optimization
purposes can be unreliable.
Scaled look-up table
Scaled engine
300
250
240
Displacement=1.9L
Displacement=1.5L
Displacement=1.0L
BSFC (g/kW-h)
BSFC (gm/kW/hr)
280
260
240
220
All Displacements
230
220
210
200
200
1000
2000
3000
Engine Speed (RPM)
4000
1000
2000
3000
4000
Engine Speed (RPM)
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Remedy - Use an Engine Simulation

Maximum Torque Curves for Varying Engine Parameters
ADVISOR - only one engine
1.0 L
TINJ = 339
TIVC = 210-230
RPM
Torque
Torque
1.9 L
TINJ = 339
TIVC = 220
1.0 L
TINJ = 329-349
TIVC = 220
RPM
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Diesel Engine Simulation
Developed by the ARC (http://arc.engin.umich.edu)
FORTRAN, feed-forward simulation
Quasi-steady, thermodynamic model of the diesel engine

system, process-by-process in crank angle increments
RPM
Fuel
Engine
Simulation
Torque
feed-forward
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Forward to Backward Conversion

Fuel
Look-up
Table
RPM
Torque
feed-backward
Modified
Newton-Raphson
Method
RPM
Fuel
Engine
Simulation
Torque
feed-forward
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HEV Fuel Economy Predictions

Engine
Design
ENGINE
SIMULATION
Battery
Characteristics
Motor
Characteristics
Other Vehicle
Parameters
ADVISOR
driving
cycle
MPG
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Fuel Consumption Calculation

Over the Driving Cycle
mph
mph
SAE Test Procedure J1711

Urban Cycle
Highway Cycle
URBAN #1
URBAN #2
HWAY #1
HWAY #2
Simulation calculates one urban + one highway cycle for computational efficiency.
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Component Operating
Characteristics During a Driving Cycle
Actual Speed (mph)
Engine Power (W)
Power Regeneration
Motor Power (W)
Battery State
of Charge (-)
The effect of charge depletion

on fuel economy is accounted for.
TIME (s)
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HEV Performance Predictions

Engine
Design
ENGINE
SIMULATION
Battery
Characteristics
Motor
Characteristics
Other Vehicle
Parameters
ADVISOR
maximum
effort
acceleration
PERFORMANCE
METRICS
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Component Operating
Characteristics During a Performance Run
Actual Speed (mph)
Engine Power (W)
Motor Power (W)
Battery State
of Charge (-)
TIME (s)
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Example Results
Parameter Values used this cycle
--------------------------------------------Engine = 35 kW
Motor = 45 kW
Battery = 55 kW / 8 kW-h
Objective Function & Performance

--------------------------------------------Combined Fuel Economy = 57.3 mpg
Maximum speed
5 second distance
0-60mph time
0-85mph time
40-60mph passing time
=
=
=
=
=
93.10 mph
202.25 ft
9.26 sec
19.49 sec
4.91 sec
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Optimization Issues
Optimization problem statement

Optimization methodology
Results
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Problem Statement
Determine motor, battery and engine sizes

to maximize fuel economy
subject to
vehicle performance constraints.
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Optimization Methodology Flow-Chart

Start at
Initial Guess
Yes
Optimizer
Converged?
Done
No
New Design, i.e.
Component Sizes
ADVISOR
Diesel Engine
Simulation
Yes
New
Engine?
No
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Potential Integration Approaches

ENGINE
SIMULATION
ENGINE
SIMULATION
ENGINE
LOOK-UP
TABLE
ADVISOR
ADVISOR
OPTION A:
OPTION B:
Fully Integrated Simulation
Pre-generated look-up table

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Timing Issues One Driving Cycle

OPTION A: Fully Integrated Simulation
TOTAL TIME: ~ 50
minutes
OPTION B: Pre-generated look-up table

fi,j
TOTAL TIME: ~ 13
minutes
OPTION C: Pre-generated look-up table

with parallel computing
fi,j
fi,j
fi,j
TOTAL TIME: ~
3 minutes
fi,j
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Timing Issues
Complete Optimization Run
Assuming ~100 Calls per Optimization Run:
85
Option A
20
Option B
Option C
identical results!
TIME (hours)
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Example: Mid-size Passenger Car
Boundary values for component sizes are:

Batteries: 30 - 100 kW
Motor: 10 - 100 kW
Parallel
HEV
Diesel Engine: 35 - 70 kW (1.0 - 1.9 Liters)

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Vehicle Parameters Used in Model

Volkswagen DI Diesel Engine
Westinghouse Electric Motor / Controller
Electrosource Horizon Pb-Acid Batteries
Volkswagen 5-Speed Transmission
Modified Chevy Lumina Body
1000 kg shell mass
0.33 coefficient of drag
0.007 coefficient of rolling resistance
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Example Case Study

Maximize:
f(xADVISOR, xTDES) = mpg
xADVISOR = {motor size, battery size}
xTDES = {engine size}
Subject to:
0-60 time < 12 seconds
40-60 (passing time) < 5.3 seconds
maximum speed > 85 mph
0-85 time < 23.4 seconds
5 second distance > 140 feet
maximum acceleration > 0.5 gs
cruising (55 mph) grade > 6.5%
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Simulation Results
Stand-alone ADVISOR
ADVISOR + Turbocharged Diesel Engine
Simulation (TDES)
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Goals for Stand-Alone ADVISOR Problem

Quickly understand model behavior
Establish optimizer parameters
finite difference step size
convergence criteria
Identify potential problems

scaling / sensitivity
noise at the 0.1 kW level
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Design Space Response Surfaces

MPG
Specified engine
size: 1.0 Liter
MAX SPEED
motor
motor
battery
battery
motor
PASSING TIME
battery
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SQP - An Iterative Optimization Routine

1) Choose a starting point
2) Evaluate objective
function (mpg) and
constraints
(performance)
feasible
region
3) Calculate a search
direction
4) Do a line search along
that direction
5) Go back to (2) until
convergence
increasing
mpg
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Three-Variable Problem Results

Initial
Final
Run
motor
battery
engine
1
2
3
4
5
6
7
8
10
10
10
10
100
100
100
100
30
100
30
100
30
100
30
100
35
35
70
70
35
35
70
70
motor*
battery* engine*
3 9 .0 7
5 1 .5 2
35
4 3 .3 6
5 1 .4 2
35
10.04
15
60.07
4 0 .3 8
5 1 .4 2
35
did not converge
90
58.33
35
39.17
51.48
35
3 9 .1 5
5 1 .4 9
35
Final
mpg
5 8.45
5 8.36
50.44
5 8.43
**
56.92
58.45
5 8.45
fnc
calls
78
160
MAX
134
**
94
MAX
73
Motor* = 39 kW
Battery* = 51.5 kW
Engine* = 35 kW
f(x*) = 58.4 mpg

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HEV Component Sizing Study Using

Integrated ADVISOR - Engine Simulation
ATMOSPHERE
INTERCOOLER
I
M
E
M
FUEL
SYSTEM
4CYL ENGINE
.
W
TURBOCHARGED
DIESEL ENGINE
SIMULATION
ADVISOR
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Comparison of Results
Engine
Model
Motor*
Battery*
Engine* Fuel
Economy
ADVISOR
39.0 kW
51.5 kW
35 kW
(1 liter)
43.8 kW
56.3 kW
43.8 kW
56.3 kW
TDES
58.4 mpg
58.0 mpg
32.8 kW 51.5 mpg

(1 liter)
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Alternative Problem Statements

Optimize selected performance characteristic
subject to fuel economy > 50 mpg
Objective
Function
Motor*
Battery* Engine*
Results
minimize
40-60 time
48.4 kW 57.2 kW 54.3 kW 4.2 sec

(1.55 L)
maximize 25 40.6 kW 53.5 kW 55.2 kW 99.1

second speed
(1.58 L) mph
minimize
0-60 time
40.9 kW 53.8 kW 55.1 kW 8.3 sec

(1.57 L)
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Challenges - Optimization Group

Explore alternative optimization methods able to
better handle noise inherent to simulations
derivative-free / derivative-insensitive methods
surrogate modeling
Increase computational efficiency

Improve component models
Increase the number of optimization parameters
Investigate alternative problem statements
emissions characteristics
cost penalties
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Challenges - Engine Simulation Group

Continue to improve Engine Simulation /
ADVISOR handshake
Introduce emissions modeling capability
Explore the effect of engine design variables
other than displacement
Apply optimization techniques to engine
system alone prior to integration, e.g.
optimization of the injection timing
Validation of predictions with measurements
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Contributors
Optimization Group
Engine Group
Advisors
Dr. Panos Papalambros
Dr. Nestor Michelena
Advisors
Dr. Dennis Assanis
Dr. Zoran Filipi
Graduate Students
Ryan Fellini
Mike Sasena
Graduate Students
George Delagrammatikas
Jennifer Liedtke
David Reyes
Douglas Rosenbaum
Alejandro Sales

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arc

Automotive Research Center

Systems Engineering Methods Applied to

Automotive Research Center

Case Study: Hybrid Electric Vehicle

Automotive Research Center

What is a Hybrid Propulsion System?

Case Study: Hybrid Electric Vehicle

Automotive Research Center

Series vs. Parallel HEV

Case Study: Hybrid Electric Vehicle

Automotive Research Center

Potential Benefits of the

Case Study: Hybrid Electric Vehicle

Automotive Research Center

Need for System Simulation

HEV is a very complex system, simulation

Case Study: Hybrid Electric Vehicle

Automotive Research Center

Case Study: Hybrid Electric Vehicle

Automotive Research Center

Foundation for HEV System Simulation

ADVISOR = quasi-steady model of a total vehicle

Automotive Research Center

HEV System Simulation Framework

ENGINE FUEL DELIVERY

Automotive Research Center

Limitations of Using Engine

Engine Speed (RPM)

Engine Speed (RPM)

Case Study: Hybrid Electric Vehicle

Automotive Research Center

Remedy - Use an Engine Simulation

Automotive Research Center

Diesel Engine Simulation

Developed by the ARC (http://arc.engin.umich.edu)

FORTRAN, feed-forward simulation

Quasi-steady, thermodynamic model of the diesel engine

Automotive Research Center

Forward to Backward Conversion

Automotive Research Center

HEV Fuel Economy Predictions

Case Study: Hybrid Electric Vehicle

Automotive Research Center

Fuel Consumption Calculation

SAE Test Procedure J1711

Automotive Research Center

Actual Speed (mph)

Engine Power (W)

Motor Power (W)

The effect of charge depletion

Automotive Research Center

HEV Performance Predictions

Automotive Research Center

Engine Power (W)

Motor Power (W)

Automotive Research Center

Objective Function & Performance

Case Study: Hybrid Electric Vehicle

Automotive Research Center

Optimization problem statement

Case Study: Hybrid Electric Vehicle

Automotive Research Center