Modelling and Co-simulation of hybrid vehicles: A thermal management perspective

Thermal management plays a vital role in the modern vehicle design and delivery. It enables the thermal analysis and optimisation of energy distribution to improve performance, increase efficiency and reduce emissions. Due to the complexity of the overall vehicle system, it is necessary to use a combination of simulation tools. Therefore, the co-simulation is at the centre of the design and analysis of electric, hybrid vehicles. For a holistic vehicle simulation to be realized, the simulation environment must support many physical domains. In this paper, a wide variety of system designs for modelling vehicle thermal performance are reviewed, providing an overview of necessary considerations for developing a cost-effective tool to evaluate fuel consumption and emissions across dynamic drive-cycles and under a range of weather conditions. The virtual models reviewed in this paper provide tools for component-level, system-level and control design, analysis, and optimisation. This paper concerns the latest techniques for an overall vehicle model development and software integration of multi-domain subsystems from a thermal management view and discusses the challenges presented for future studies

Development and performance evaluation of a prototype electric hybrid powertrain system for automotive applications

Researchers at Universiti Teknologi Malaysia (UTM) have developed a dedicated hybrid power plant based on the parallel configuration using a gasoline engine coupled to a high performance electric motor, specifically targeted for automotive application. The aims are to achieve even lower exhaust emissions, better fuel economy and better performance than the conventional arrangement, demonstrating an alternative solution to the conventional power plant. The engine used is a 1.3 litre spark-ignition, coupled with a 27.5 kW Nexus electric motor. The control strategy developed in conjunction with the program is to use the electric drive motor for initial acceleration and for regeneration braking energy recovery, and for reducing the peak load and transients seen by the engine. A relatively small pack of advanced lead acid batteries is use for energy storage. The design, development and evaluation exercises are fully described giving a comprehensive insight of the prototype and its capabilities

Hydraulic Hybrid Powertrain-In-the-Loop Integration for Analyzing Real-World Fuel Economy and Emissions Improvements

The paper describes the approach, addresses integration challenges and discusses capabilities of the Hybrid Powertrain-in-the-Loop (H-PIL) facility for the series/hydrostatic hydraulic hybrid system. We describe the simulation of the open-loop and closed-loop hydraulic hybrid systems in H-PIL and its use for concurrent engineering and development of advanced supervisory strategies. The configuration of the hydraulic-hybrid system and details of the hydraulic circuit developed for the H-PIL integration are presented. Next, software and hardware interfaces between the real components and virtual systems are developed, and special attention is given to linking component-level controllers and system-level supervisory control. The H-PIL setup allows imposing realistic dynamic loads on hydraulic pump/motors and accumulator based on vehicle driving schedule. Application of fast analyzers allows characterization of the impact of dynamic interactions in the propulsion system on engine-out emissions. Therefore, the H-PIL facility allows optimization of the hybrid system for both high-efficiency and low emissions. The impetus is provided by previous work showing that more than half of the soot emissions from a conventional diesel powertrain over the urban driving schedule can be attributed to transients. The setup includes a 6.4L V-8 International diesel engine, highly dynamic dynamometer, Radial piston pump/motors supplied by Bosch-Rexroth and dSPACE real-time environment with in-house developed simulation of the virtual vehicle.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/89880/1/draft_01.pd

Effectiveness of hybrid powertrains to reduce the fuel consumption and NOx emissions of a Euro 6d-temp diesel engine under real-life driving conditions

[EN] Recent investigations demonstrated that the real-world driving conditions differ from those proposed in the homologation cycles. This provokes that the emissions levels in real-life conditions exceed the normative values, as shown in the recent scandal related to the NOx emissions from the passenger cars equipped with diesel engines. On the other hand, the upcoming emissions regulations will limit the CO2 emissions to very low levels, which demands a further optimization of the existing technology. One way to reduce the NOx and CO2 emissions is by electrifying the powertrain in a certain degree. The objective of this work is to evaluate the potential of implementing a parallel (P2) hybrid architecture in a compact car (class C) equipped with a diesel 1.6 Euro 6d-temp engine to reduce the emissions and fuel consumption in homologation and real-life driving cycles. This has been done using a OD numerical vehicle model and the experimental engine maps of fuel consumption and emissions measured at steady state conditions. After that, the transient conditions were simulated in homologation cycles and real-life driving cycles measured by the authors in Spain. The numerical model was validated against experimental tests carried out in an active engine test bench, evidencing differences below 4% under the worldwide harmonized light vehicles test cycle (WLTC). In the real-life cycles, the hybridization of the powertrains improves the fuel consumption for all types of driving cycles (urban, combined and highway). The major benefits are obtained in urban driving cycles, with gains up to 50% in fuel consumption and CO2 emissions. In addition, the improvements in real-life conditions are higher than in the urban phase of the homologation cycles. On the contrary, combined real-life cycles (urban + rural + highway) show lower benefits than the homologation cycle. This is due to different energy management strategy that needs to be adapted to each driving situation. Lastly, it was found that, contrarily to the case of the homologation cycle, the NOx emissions are not reduced with the hybridization of the diesel powertrain in real-life conditions. Thus, to achieve 2021 CO2 target (95 g/km) and to reduce aftertreatment systems in diesel engines, other vehicles technologies need to be added to the full hybridization.The authors acknowledge FEDER and Spanish Ministerio de Economia y Competitividad for partially supporting this research through TRANCO project (TRA2017-87694-R). The authors also acknowledge the Universitat Politecnica de Valencia for partially supporting this research through Convocatoria de ayudas a Primeros Proyectos de Investigacion (PAID-06-18).Luján, JM.; García Martínez, A.; Monsalve-Serrano, J.; Martínez-Boggio, S. (2019). Effectiveness of hybrid powertrains to reduce the fuel consumption and NOx emissions of a Euro 6d-temp diesel engine under real-life driving conditions. Energy Conversion and Management. 199:1-18. https://doi.org/10.1016/j.enconman.2019.111987S11819

Model Advancement And Hil Setup For Testing A P2 Phev Supervisory Controller

Teams participating in Advanced Vehicle Technology Competitions such as EcoCAR3 are often bound by limited time and resources. Moreover, vehicle and component downtime due to mechanical and electrical issues reduce the time available for testing activities demanded by the Controls/Systems Modeling and Simulation teams. Therefore, the teams would benefit from identifying new approaches and being more pragmatic and productive in order to achieve satisfactory progress in the competition. This thesis summarizes the approach taken to improve the simulation accuracy of the Wayne State University EcoCAR3 team’s Pre-transmission Parallel Hybrid Electric Vehicle plant model and HIL setup. Focus is on testing the Hybrid Supervisory Controller energy management and diagnostic functionality to be successful in the emissions and energy consumption event. After thorough literature research it is determined that a varying fidelity forward dynamic HEV plant model can produce accurate energy consumption simulation results. Initially, data obtained from manufacturers is used to model the components such as IC Engine, Electric Machine, Energy Storage System (ESS), transmission, differential, chassis and the ECUs. Later, test benches are setup to optimize and refine the individual model parameters by comparing the simulated results with the actual results obtained from component testing and on-road vehicle testing. Finally, the total vehicle plant model is validated by comparing the simulated results with the P2 PHEV on-road test data. The accuracy of the plant model determines the ability to optimize the Hybrid Supervisory Controller code to achieve maximum energy efficiency. Apart from model accuracy improvement, the Hardware In Loop (HIL) test setup is also discussed. HIL system is essential for validating the Hybrid Supervisory Controller’s functionalities in real time. The challenges during modeling and HIL setup are discussed and more improvements that can be done during the final year are recommended based on the research

A battery hardware-in-the-loop setup for concurrent design and evaluation of real-time optimal HEV power management controllers

Razavian, R. S., Azad, N. L., & McPhee, J. (2013). A battery hardware-in-the-loop setup for concurrent design and evaluation of real-time optimal HEV power management controllers. International Journal of Electric and Hybrid Vehicles, 5(3), 177. Final version published by Inderscience Publishers, and available at: https://doi.org/10.1504/IJEHV.2013.057604We have developed a battery hardware-in-the-loop (HIL) setup, which can expedite the design and evaluation of power management controllers for hybrid electric vehicles (HEVs) in a novel cost- and time-effective manner. The battery dynamics have a significant effect on the HEV power management controller design; therefore, physical batteries are included in the simulation loop for greater simulation fidelity. We use Buckingham's Pi Theorem in the scaled-down battery HIL setup to reduce development and testing efforts, while maintaining the flexibility and fidelity of the control loop. In this paper, usefulness of the setup in parameter identification of a simple control-oriented battery model is shown. The model is then used in the power management controller design, and the real-time performance of the designed controller is tested with the same setup in a realistic control environment. Test results show that the designed controller can accurately capture the dynamics of the real system, from which the assumptions made in its design process can be confidently justified.Financial support for this research has been provided by the Natural Sciences and Engineering Research Council of Canada (NSERC), Toyota, and Maplesoft

Study of the Potential of Electrified Powertrains with Dual-Fuel Combustion to Achieve the 2025 Emissions Targets in Heavy-Duty Applications

[ES] El transporte de personas, así como de carga ha evolucionado y crecido tremendamente en los últimos años. El desarrollo tecnológico debió ser adaptado a las diferentes medidas gubernamentales en términos de control de emisiones contaminantes. Desde el acuerdo de Paris en 2015 para mantener el crecimiento de la temperatura global por debajo de 1.5oC, se han impuesto también límites para las emisiones de CO2 por parte de vehículos de carretera. Para el sector del transporte pesado, se han impuesto límites de flota de 15% para 2025 y 30% para 2030 de reducción del CO2 con respecto a 2019. Por lo tanto, esta doble restricción de muy bajos niveles de emisiones contaminantes, así como de gases de efecto invernadero hacen que el sector del transporte este ante un gran desafío tecnológico. En 2022, el transporte de carga tiene un 99% de vehículos propulsados a motor de combustión interna con Diesel como combustible y sin ningún tipo de ayuda eléctrica en el sistema de propulsión. Los límites de emisiones contaminantes como Euro 6 son alcanzados con complejos sistemas de postratamiento que además agregan el consumo de Urea. Trabajos previos en la bibliografía, así como sistemas prototipo han demostrado que es posible alcanzar los objetivos de emisiones contaminantes con métodos avanzados de control de la combustión y así disminuyendo la complejidad del post tratamiento en la salida de gases. Con mayor éxito, el concepto de Reactivity Controlled Combustion Ignition puede alcanzar valores por debajo de Euro 6 con eficiencia similar a la combustión de Diesel. Sin embargo, no soluciona los problemas de emisiones de CO2. Por otro lado, en vehículos de pasajeros fue demostrado con suceso la aplicación de motores eléctricos en el sistema de propulsión para mejorar la eficiencia global del vehículo. El caso extremo son los vehículos puramente electicos donde se alcanza eficiencias por arriba del 70% contra 35% de los vehículos no electrificados. Sin embargo, limitaciones de autonomía, tiempo de carga y la no clara reducción global de la contaminación debido a las emisiones de la energía de la red eléctrica y la contaminación de las baterías de ion-litio hacen que este sistema de propulsión este bajo discusión. Para los vehículos con algún grado de electrificación, las emisiones de gases contaminantes siguen siendo un problema como para el caso no electrificado. Por lo tanto, esta tesis doctoral aborda el problema de emisiones contaminantes, así como de CO2 combinado modos avanzados de combustión con sistemas de propulsión electrificado. La aplicación de estas tecnologías se centra en el sector del transporte de carretera pesado. En particular, un camión de 18 toneladas de carga máxima que originalmente en 2022 equipa un motor seis cilindros de 8 litros con combustión convencional Diesel. El presente trabajo utiliza herramientas experimentales como son medidas en banco motor, así como en carretera para alimentar y validar modelos numéricos de motor, sistema de postratamiento, así como de vehículo. Este último es el punto central del trabajo ya que permite abordar sistemas como el mild hybrid, full hybrid y plug-in hybrid. Calibración de motor experimental dedicada a sistemas de propulsión hibrido es presentada con combustibles sintéticos y/o para llegar a los límites de Euro 7.[CA] El transport de persones, així com de càrrega ha evolucionat i crescut tremendament en els últims anys. El desenvolupament tecnològic degué ser adaptat a les diferents mesures governamentals en termes de control d'emissions contaminants. Des de l'acord de Paris en 2015 per a mantindre el creixement de la temperatura global per davall de 1.5oC, s'han imposat també límits per a les emissions de CO¿ per part de vehicles de carretera. Per al sector del transport pesat, s'han imposat limites de flota de 15% per a 2025 i 30% per a 2030 de reducció del CO¿ respecte a 2019. Per tant, aquesta doble restricció de molt baixos nivells d'emissions contaminants, així com de gasos d'efecte d'hivernacle fan que el sector del transport aquest davant un gran desafiament tecnològic. En 2022, el transport de càrrega té un 99% de vehicles propulsats a motor de combustió interna amb Dièsel com a combustible i sense cap mena d'ajuda elèctrica en el sistema de propulsió. Els limites d'emissions contaminants com a Euro 6 són aconseguits amb complexos sistemes de posttractament que a més agreguen el consum d'Urea. Treballs previs en la bibliografia, així com sistemes prototip han demostrat que és possible aconseguir els objectius d'emissions contaminants amb mètodes avançats de control de la combustió i així disminuint la complexitat del post tractament en l'eixida de gasos. Amb major èxit, el concepte de Reactivity Controlled Combustion Ignition pot aconseguir valors per davall d'Euro 6 amb eficiència similar a la combustió de Dièsel. No obstant això, no soluciona els problemes d'emissions de CO¿. D'altra banda, en vehicles de passatgers va ser demostrat amb succés l'aplicació de motors elèctrics en el sistema de propulsió per a millorar l'eficiència global del vehicle. El cas extrem són els vehicles purament electicos on s'aconsegueix eficiències per dalt del 70% contra 35% dels vehicles no electrificats. No obstant això, limitacions d'autonomia, temps de càrrega i la no clara reducció global de la contaminació a causa de les emissions de l'energia de la xarxa elèctrica i la contaminació de les bateries d'ió-liti fan que aquest sistema de propulsió aquest baix discussió. Per als vehicles amb algun grau d'electrificació, les emissions de gasos contaminants continuen sent un problema com per al cas no electrificat. Per tant, aquesta tesi doctoral aborda el problema d'emissions contaminants, així com de CO¿ combinat maneres avançades de combustió amb sistemes de propulsió electrificat. L'aplicació d'aquestes tecnologies se centra en el sector del transport de carretera pesat. En particular, un camió de 18 tones de càrrega màxima que originalment en 2022 equipa un motor sis cilindres de 8 litres amb combustió convencional Dièsel. El present treball utilitza eines experimentals com són mesures en banc motor, així com en carretera per a alimentar i validar models numèrics de motor, sistema de posttractament, així com de vehicle. Est ultime és el punt central del treball ja que permet abordar sistemes com el mild hybrid, full *hybrid i plug-in hybrid. Calibratge de motor experimental dedicada a sistemes de propulsió hibride és presentada amb combustibles sintètics i/o per a arribar als límits d'Euro 7.[EN] The transport of people, as well as cargo, has evolved and grown tremendously over the recent years. Technological development had to be adapted to the different government measures for controlling polluting emissions. Since the Paris agreement in 2015 limits have also been imposed on the CO2 emissions from road vehicles to keep global temperature growth below 1.5oC. For the heavy transport sector, fleet limits of 15% for 2025 and 30% for 2030 CO2 reduction have been introduced with respect to the limits of 2019. Therefore, the current restriction of very low levels of polluting emissions, as well as greenhouse gases, makes the transport sector face a great technological challenge. In 2021, 99% of freight transport was powered by an internal combustion engine with Diesel as fuel and without any type of electrical assistance in the propulsion system. Moreover, polluting emission limits such as the Euro 6 are achieved with complex post-treatment systems that also add to the consumption of Urea. Previous research and prototype systems have shown that it is possible to achieve polluting emission targets with advanced combustion control methods, thus reducing the complexity of post-treatment in the exhaust gas. With greater success, the concept of Reactivity Controlled Combustion Ignition can reach values below the Euro 6 with similar efficiency to Diesel combustion. Unfortunately, it does not solve the CO2 emission problems. On the other hand, in passenger vehicles, the application of electric motors in the propulsion system has been shown to successfully improve the overall efficiency of the vehicle. The extreme case is the purely electric vehicles, where efficiencies above 70% are achieved against 35% of the non-electrified vehicles. However, limitations of vehicle range, charging time, payload reduction and an unclear overall reduction in greenhouse emissions bring this propulsion system under discussion. For vehicles with some degree of electrification, polluting gas emissions continue to be a problem as for the non-electrified case. Therefore, this doctoral Thesis addresses the problem of polluting emissions and CO2 combined with advanced modes of combustion with electrified propulsion systems. The application of these technologies focuses on the heavy road transport sector. In particular, an 18-ton maximum load truck that originally was equipped with an 8-liter six-cylinder engine with conventional Diesel combustion. The present work uses experimental tools such as measurements on the engine bench as well as on the road to feed and validate numerical models of the engine, after-treatment system, and the vehicle. The latter is the central point of the work since it allows addressing systems such as mild hybrid, full hybrid, and plug-in hybrid. Experimental engine calibration dedicated to hybrid propulsion systems is presented with synthetic fuels in order to reach the limits of the Euro 7.This Doctoral Thesis has been partially supported by the Universitat Politècnica de València through the predoctoral contract of the author (Subprograma 2), which is included within the framework of Programa de Apoyo para la Investigación y Desarrollo (PAID)Martínez Boggio, SD. (2022). Study of the Potential of Electrified Powertrains with Dual-Fuel Combustion to Achieve the 2025 Emissions Targets in Heavy-Duty Applications [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/18883

High efficiency two stroke opposed piston engine for plug-in hybrid electric vehicle applications: evaluation under homologation and real driving conditions

[EN] The potential of plug-in hybrid electric vehicles (PHEV) to reduce greenhouse gas emissions highly depends on the vehicle usage and electricity source. In addition, the high costs of the battery pack and electric components suppose a challenge to the vehicle manufacturers. However, the internal combustion engine complexity can be reduced due to its lower use as compared to the no-hybrid vehicles. This work evaluates the use of a new opposed piston 2-stroke engine, based on rod-less innovative kinematics, in a series PHEV architecture based on rod-less innovative kinematics along different driving routes in Europe. A 0D-vehicle model fed with experimental tests is used. The battery size is optimized under homologation conditions for two different vehicle types. The optimum case is tested in several real driving conditions under different vehicle modes and battery states of charge. The main contribution of this work is the demonstration of the potential to reduce the vehicle CO2 emissions and cost with an innovative 2-stroke engine. The results show that 24 kWh is the optimum battery size for both vehicle platforms. Charge depleting mode shows 70% of CO2 tailpipe reduction in urban cycles and 22% in long travels compared to the no-hybrid version. Charge sustaining mode results show a CO2 tailpipe reduction of 20% in urban cycles and 2% in long distance travels with respect to the no-hybrid version. In spite of the CO2 contribution of the battery manufacturing, the results show a reduction of LCA CO2 emissions in 52% in charge depleting and 7% charge sustaining against the no-hybrid case.This work has been partially supported by "Conselleria de Innovacion, Universidades, Ciencia y Sociedad Digital de la Generalitat Valenciana" through grant number GV/2020/017. The authors acknowledge FEDER and Spanish Ministerio de Economia y Competitividad for partially supporting this research through TRANCO project (TRA2017-87694-R). The authors want to thank INNengine for providing the engine and the help in the experimental campaign. Lastly, acknowledge to Gamma Technologies for the numerical simulation support and provide the GT-RealDrive licensesSerrano, J.; García Martínez, A.; Monsalve-Serrano, J.; Martínez-Boggio, SD. (2021). High efficiency two stroke opposed piston engine for plug-in hybrid electric vehicle applications: evaluation under homologation and real driving conditions. Applied Energy. 282(Part A):1-17. https://doi.org/10.1016/j.apenergy.2020.116078S117282Part