Real-time multi-domain optimization controller for multi-motor electric vehicles using automotive-suitable methods and heterogeneous embedded platforms

Los capítulos 2,3 y 7 están sujetos a confidencialidad por el autor. 145 p.In this Thesis, an elaborate control solution combining Machine Learning and Soft Computing techniques has been developed, targeting a chal lenging vehicle dynamics application aiming to optimize the torque distribution across the wheels with four independent electric motors.The technological context that has motivated this research brings together potential -and challenges- from multiple dom ains: new automotive powertrain topologies with increased degrees of freedom and controllability, which can be approached with innovative Machine Learning algorithm concepts, being implementable by exploiting the computational capacity of modern heterogeneous embedded platforms and automated toolchains. The complex relations among these three domains that enable the potential for great enhancements, do contrast with the fourth domain in this context: challenging constraints brought by industrial aspects and safe ty regulations. The innovative control architecture that has been conce ived combines Neural Networks as Virtual Sensor for unmeasurable forces , with a multi-objective optimization function driven by Fuzzy Logic , which defines priorities basing on the real -time driving situation. The fundamental principle is to enhance vehicle dynamics by implementing a Torque Vectoring controller that prevents wheel slip using the inputs provided by the Neural Network. Complementary optimization objectives are effici ency, thermal stress and smoothness. Safety -critical concerns are addressed through architectural and functional measures.Two main phases can be identified across the activities and milestones achieved in this work. In a first phase, a baseline Torque Vectoring controller was implemented on an embedded platform and -benefiting from a seamless transition using Hardware-in -the -Loop - it was integrated into a real Motor -in -Wheel vehicle for race track tests. Having validated the concept, framework, methodology and models, a second simulation-based phase proceeds to develop the more sophisticated controller, targeting a more capable vehicle, leading to the final solution of this work. Besides, this concept was further evolved to support a joint research work which lead to outstanding FPGA and GPU based embedded implementations of Neural Networks. Ultimately, the different building blocks that compose this work have shown results that have met or exceeded the expectations, both on technical and conceptual level. The highly non-linear multi-variable (and multi-objective) control problem was tackled. Neural Network estimations are accurate, performance metrics in general -and vehicle dynamics and efficiency in particular- are clearly improved, Fuzzy Logic and optimization behave as expected, and efficient embedded implementation is shown to be viable. Consequently, the proposed control concept -and the surrounding solutions and enablers- have proven their qualities in what respects to functionality, performance, implementability and industry suitability.The most relevant contributions to be highlighted are firstly each of the algorithms and functions that are implemented in the controller solutions and , ultimately, the whole control concept itself with the architectural approaches it involves. Besides multiple enablers which are exploitable for future work have been provided, as well as an illustrative insight into the intricacies of a vivid technological context, showcasing how they can be harmonized. Furthermore, multiple international activities in both academic and professional contexts -which have provided enrichment as well as acknowledgement, for this work-, have led to several publications, two high-impact journal papers and collateral work products of diverse nature

Real-time multi-domain optimization controller for multi-motor electric vehicles using automotive-suitable methods and heterogeneous embedded platforms

Los capítulos 2,3 y 7 están sujetos a confidencialidad por el autor. 145 p.In this Thesis, an elaborate control solution combining Machine Learning and Soft Computing techniques has been developed, targeting a chal lenging vehicle dynamics application aiming to optimize the torque distribution across the wheels with four independent electric motors.The technological context that has motivated this research brings together potential -and challenges- from multiple dom ains: new automotive powertrain topologies with increased degrees of freedom and controllability, which can be approached with innovative Machine Learning algorithm concepts, being implementable by exploiting the computational capacity of modern heterogeneous embedded platforms and automated toolchains. The complex relations among these three domains that enable the potential for great enhancements, do contrast with the fourth domain in this context: challenging constraints brought by industrial aspects and safe ty regulations. The innovative control architecture that has been conce ived combines Neural Networks as Virtual Sensor for unmeasurable forces , with a multi-objective optimization function driven by Fuzzy Logic , which defines priorities basing on the real -time driving situation. The fundamental principle is to enhance vehicle dynamics by implementing a Torque Vectoring controller that prevents wheel slip using the inputs provided by the Neural Network. Complementary optimization objectives are effici ency, thermal stress and smoothness. Safety -critical concerns are addressed through architectural and functional measures.Two main phases can be identified across the activities and milestones achieved in this work. In a first phase, a baseline Torque Vectoring controller was implemented on an embedded platform and -benefiting from a seamless transition using Hardware-in -the -Loop - it was integrated into a real Motor -in -Wheel vehicle for race track tests. Having validated the concept, framework, methodology and models, a second simulation-based phase proceeds to develop the more sophisticated controller, targeting a more capable vehicle, leading to the final solution of this work. Besides, this concept was further evolved to support a joint research work which lead to outstanding FPGA and GPU based embedded implementations of Neural Networks. Ultimately, the different building blocks that compose this work have shown results that have met or exceeded the expectations, both on technical and conceptual level. The highly non-linear multi-variable (and multi-objective) control problem was tackled. Neural Network estimations are accurate, performance metrics in general -and vehicle dynamics and efficiency in particular- are clearly improved, Fuzzy Logic and optimization behave as expected, and efficient embedded implementation is shown to be viable. Consequently, the proposed control concept -and the surrounding solutions and enablers- have proven their qualities in what respects to functionality, performance, implementability and industry suitability.The most relevant contributions to be highlighted are firstly each of the algorithms and functions that are implemented in the controller solutions and , ultimately, the whole control concept itself with the architectural approaches it involves. Besides multiple enablers which are exploitable for future work have been provided, as well as an illustrative insight into the intricacies of a vivid technological context, showcasing how they can be harmonized. Furthermore, multiple international activities in both academic and professional contexts -which have provided enrichment as well as acknowledgement, for this work-, have led to several publications, two high-impact journal papers and collateral work products of diverse nature

Efficient Neural Network Implementations on Parallel Embedded Platforms Applied to Real-Time Torque-Vectoring Optimization Using Predictions for Multi-Motor Electric Vehicles

The combination of machine learning and heterogeneous embedded platforms enables new potential for developing sophisticated control concepts which are applicable to the field of vehicle dynamics and ADAS. This interdisciplinary work provides enabler solutions -ultimately implementing fast predictions using neural networks (NNs) on field programmable gate arrays (FPGAs) and graphical processing units (GPUs)- while applying them to a challenging application: Torque Vectoring on a multi-electric-motor vehicle for enhanced vehicle dynamics. The foundation motivating this work is provided by discussing multiple domains of the technological context as well as the constraints related to the automotive field, which contrast with the attractiveness of exploiting the capabilities of new embedded platforms to apply advanced control algorithms for complex control problems. In this particular case we target enhanced vehicle dynamics on a multi-motor electric vehicle benefiting from the greater degrees of freedom and controllability offered by such powertrains. Considering the constraints of the application and the implications of the selected multivariable optimization challenge, we propose a NN to provide batch predictions for real-time optimization. This leads to the major contribution of this work: efficient NN implementations on two intrinsically parallel embedded platforms, a GPU and a FPGA, following an analysis of theoretical and practical implications of their different operating paradigms, in order to efficiently harness their computing potential while gaining insight into their peculiarities. The achieved results exceed the expectations and additionally provide a representative illustration of the strengths and weaknesses of each kind of platform. Consequently, having shown the applicability of the proposed solutions, this work contributes valuable enablers also for further developments following similar fundamental principles.Some of the results presented in this work are related to activities within the 3Ccar project, which has received funding from ECSEL Joint Undertaking under grant agreement No. 662192. This Joint Undertaking received support from the European Union’s Horizon 2020 research and innovation programme and Germany, Austria, Czech Republic, Romania, Belgium, United Kingdom, France, Netherlands, Latvia, Finland, Spain, Italy, Lithuania. This work was also partly supported by the project ENABLES3, which received funding from ECSEL Joint Undertaking under grant agreement No. 692455-2

Intelligent Torque Vectoring Approach For Electric Vehicles With Per-Wheel Motors

Transport electrification is currently a priority for authorities, manufacturers, and research centers around the world. The development of electric vehicles and the improvement of their functionalities are key elements in this strategy. As a result, there is a need for further research in emission reduction, efficiency improvement, or dynamic handling approaches. In order to achieve these objectives, the development of suitable Advanced Driver-Assistance Systems (ADAS) is required. Although traditional control techniques have been widely used for ADAS implementation, the complexity of electric multimotor powertrains makes intelligent control approaches appropriate for these cases. In this work, a novel intelligent Torque Vectoring (TV) system, composed of a neuro-fuzzy vertical tire forces estimator and a fuzzy yaw moment controller, is proposed, which allows enhancing the dynamic behaviour of electric multimotor vehicles. The proposed approach is compared with traditional strategies using the high fidelity vehicle dynamics simulator Dynacar. Results show that the proposed intelligent Torque Vectoring system is able to increase the efficiency of the vehicle by 10%, thanks to the optimal torque distribution and the use of a neuro-fuzzy vertical tire forces estimator which provides 3 times more accurate estimations than analytical approaches.The research leading to these results has been supported by the ECSEL Joint Undertaking under Grant agreement no. 662192 (3Ccar). This Joint Undertaking receives support from the European Union Horizon 2020 research and innovation program and the ECSEL member states

Intelligent Torque Vectoring Approach for Electric Vehicles with Per-Wheel Motors

Transport electrification is currently a priority for authorities, manufacturers, and research centers around the world. The development of electric vehicles and the improvement of their functionalities are key elements in this strategy. As a result, there is a need for further research in emission reduction, efficiency improvement, or dynamic handling approaches. In order to achieve these objectives, the development of suitable Advanced Driver-Assistance Systems (ADAS) is required. Although traditional control techniques have been widely used for ADAS implementation, the complexity of electric multimotor powertrains makes intelligent control approaches appropriate for these cases. In this work, a novel intelligent Torque Vectoring (TV) system, composed of a neuro-fuzzy vertical tire forces estimator and a fuzzy yaw moment controller, is proposed, which allows enhancing the dynamic behaviour of electric multimotor vehicles. The proposed approach is compared with traditional strategies using the high fidelity vehicle dynamics simulator Dynacar. Results show that the proposed intelligent Torque Vectoring system is able to increase the efficiency of the vehicle by 10%, thanks to the optimal torque distribution and the use of a neuro-fuzzy vertical tire forces estimator which provides 3 times more accurate estimations than analytical approaches.The research leading to these results has been supported by the ECSEL Joint Undertaking under Grant agreement no. 662192 (3Ccar).This Joint Undertaking receives support from the European Union Horizon 2020 research and innovation program and the ECSEL member states

Validation of a Real-Time Capable Multibody Vehicle Dynamics Formulation for Automotive Testing Frameworks Based on Simulation

The growing functionalities implemented on vehicles have increased the importance of simulation in the design process. This complexity is mainly driven by the introduction of electrified powertrains, Advanced Driver Assistance Systems (ADAS) and Automated Driving Systems (ADS). Additionally, the automotive industry must reduce development times and cost, while keeping flexible development capabilities and fulfilling demanding regulation standards for safety-critical systems. Existing testing frameworks based on simulation implement typically analytical models to ensure real-time performance, and provide limited flexibility to perform Hardware in the Loop (HiL) setup based tests. In this work a vehicle modelling approach which guarantees high accuracy and real-time capabilities is proposed. Moreover, the proposed approach is validated firstly with real vehicle data, demonstrating that it can fairly reproduce the behaviour of the vehicle tested; and secondly, in a HiL setup to demonstrate the real-time execution capabilities of the approach

Vehicle dynamics virtual sensing and advanced motion control for highly skilled autonomous vehicles

This dissertation is aimed at elucidating the path towards the development of a future generation of highly-skilled autonomous vehicles (HSAV). In brief, it is envisaged that future HSAVs will be able to exhibit advanced driving skills to maintain the vehicle within stable limits in spite of the driving conditions (limits of handling) or environmental adversities (e.g. low manoeuvrability surfaces). Current research lines on intelligent systems indicate that such advanced driving behaviour may be realised by means of expert systems capable of monitoring the current vehicle states, learning the road friction conditions, and adapting their behaviour depending on the identified situation. Such adaptation skills are often exhibited by professional motorsport drivers, who fine-tune their driving behaviour depending on the road geometry or tyre-friction characteristics. On this basis, expert systems incorporating advanced driving functions inspired by the techniques seen on highly-skilled drivers (e.g. high body slip control) are proposed to extend the operating region of autonomous vehicles and achieve high-level automation (e.g. manoeuvrability enhancement on low-adherence surfaces). Specifically, two major research topics are covered in detail in this dissertation to conceive these expert systems: vehicle dynamics virtual sensing and advanced motion control. With regards to the former, a comprehensive research is undertaken to propose virtual sensors able to estimate the vehicle planar motion states and learn the road friction characteristics from readily available measurements. In what concerns motion control, systems to mimic advanced driving skills and achieve robust path-following ability are pursued. An optimal coordinated action of different chassis subsystems (e.g. steering and individual torque control) is sought by the adoption of a centralised multi-actuated system framework. The virtual sensors developed in this work are validated experimentally with the Vehicle-Based Objective Tyre Testing (VBOTT) research testbed of JAGUAR LAND ROVER and the advanced motion control functions with the Multi-Actuated Ground Vehicle “DevBot” of ARRIVAL and ROBORACE.Diese Dissertation soll den Weg zur Entwicklung einer zukünftigen Generation hochqualifizierter autonomer Fahrzeuge (HSAV) aufzeigen. Kurz gesagt, es ist beabsichtigt, dass zukünftige HSAVs fortgeschrittene Fahrfähigkeiten aufweisen können, um das Fahrzeug trotz der Fahrbedingungen (Grenzen des Fahrverhaltens) oder Umgebungsbedingungen (z. B. Oberflächen mit geringer Manövrierfähigkeit) in stabilen Grenzen zu halten. Aktuelle Forschungslinien zu intelligenten Systemen weisen darauf hin, dass ein solches fortschrittliches Fahrverhalten mit Hilfe von Expertensystemen realisiert werden kann, die in der Lage sind, die aktuellen Fahrzeugzustände zu überwachen, die Straßenreibungsbedingungen kennenzulernen und ihr Verhalten in Abhängigkeit von der ermittelten Situation anzupassen. Solche Anpassungsfähigkeiten werden häufig von professionellen Motorsportfahrern gezeigt, die ihr Fahrverhalten in Abhängigkeit von der Straßengeometrie oder den Reifenreibungsmerkmalen abstimmen. Auf dieser Grundlage werden Expertensysteme mit fortschrittlichen Fahrfunktionen vorgeschlagen, die auf den Techniken hochqualifizierter Fahrer basieren (z. B. hohe Schlupfregelung), um den Betriebsbereich autonomer Fahrzeuge zu erweitern und eine Automatisierung auf hohem Niveau zu erreichen (z. B. Verbesserung der Manövrierfähigkeit auf niedrigem Niveau) -haftende Oberflächen). Um diese Expertensysteme zu konzipieren, werden zwei große Forschungsthemen in dieser Dissertation ausführlich behandelt: Fahrdynamik-virtuelle Wahrnehmung und fortschrittliche Bewegungssteuerung. In Bezug auf erstere wird eine umfassende Forschung durchgeführt, um virtuelle Sensoren vorzuschlagen, die in der Lage sind, die Bewegungszustände der Fahrzeugebenen abzuschätzen und die Straßenreibungseigenschaften aus leicht verfügbaren Messungen kennenzulernen. In Bezug auf die Bewegungssteuerung werden Systeme zur Nachahmung fortgeschrittener Fahrfähigkeiten und zum Erzielen einer robusten Wegfolgefähigkeit angestrebt. Eine optimale koordinierte Wirkung verschiedener Fahrgestellsubsysteme (z. B. Lenkung und individuelle Drehmomentsteuerung) wird durch die Annahme eines zentralisierten, mehrfach betätigten Systemrahmens angestrebt. Die in dieser Arbeit entwickelten virtuellen Sensoren wurden experimentell mit dem Vehicle-Based Objective Tyre Testing (VBOTT) - Prüfstand von JAGUAR LAND ROVER und den fortschrittlichen Bewegungssteuerungsfunktionen mit dem mehrfach betätigten Bodenfahrzeug ”DevBot” von ARRIVAL und ROBORACE validiert

Optimal handling characteristics for electric vehicles with torque vectoring.

Torque vectoring by virtue of independent electric motors is the focus of an increasing number of studies as electric vehicles gain prominence as the chosen direction for the automotive industry. Building on active yaw control systems developed over the past decades, torque vectoring benefits from the high-responsiveness and controllability of the electric motor actuator. Furthermore, and especially in the case of vehicles equipped with one independent motor per wheel, the overall performance envelope of the vehicle is significantly improved, as well as the ability to actively shape the vehicle handling. Much attention has been focussed on controller development and control allocation aspects of torque vectoring controllers, but little on the appropriate yaw rate reference. Optimal control studies have been successfully used to mimic the expert driver in both minimum-time circuit racing and high-sideslip rally driving, and can offer insight into how to optimally tune active chassis control systems, such as torque vectoring yaw control. The main aim of this thesis was to investigate the optimal handling characteristics of an electric vehicle with four independent electric motors at the limits of performance. A TV controller was first developed for a prototype sportscar with 4 independent motors, employing a model-based design process that encompassed real-time software in the loop testing. Real-world track testing demonstrated the controller was able to successfully modify the handling characteristic of the vehicle in both understeer and oversteer directions, achieving good controller performance in steady-state and transient manoeuvres. The limit performance of the TV-controlled vehicle was subsequently investigated in the simulation domain. Numerical techniques were used to solve optimal control problems for a single-track vehicle model with linear tyres and an external yaw moment term representing the overall yaw moment arising from the difference in torques at each wheel. For a U-turn manoeuvre, it was shown that torque vectoring significantly lowers manoeuvre time in comparison with the vehicle without TV active, and that modifying the passive understeer gradient does not affect manoeuvre time. The system dynamics were reformulated to include a feedback torque vectoring controller. The target yaw rate reference was varied and it was found that the manoeuvre time was highly sensitive to the yaw rate reference. For minimising laptime, the target understeer gradient should be set to the passive understeer gradient value. The methodology was repeated for a higher fidelity model including nonlinear tyres and lateral load transfer, and found that when the torque vectoring controller was included in the system dynamics, the manoeuvre time showed little sensitivity to the target understeer gradient. Following the contradictory results of the optimal control problems, the vehicle models were investigated next. Time optimal yaw rate gain surfaces were generated from further minimum-time optimal control problems. Open-loop manoeuvres investigating effects of tyre model, lateral load transfer and torque vectoring generation mechanism found that tyre modelling was the dominant differentiator and tyre nonlinearity is an essential modelling consideration. Optimal control techniques have been used for high sideslip manoeuvring for conventional vehicles but no studies have explored the effects of torque vectoring on agility. In the final chapter, an aggressive turn-around manoeuvre was simulated and it was found that torque vectoring can significantly increase agility and reduce the space taken for an aggressive turn-around manoeuvre. Reducing yaw inertia increased agility, as well as increasing longitudinal slips limits. A critique of agility metrics in this context was given.PhD in Transport System

Optimal Direct Yaw Moment Control of a 4WD Electric Vehicle

This thesis is concerned with electronic stability of an all-wheel drive electric vehicle with independent motors mounted in each wheel. The additional controllability and speed permitted using independent motors can be exploited to improve the handling and stability of electric vehicles. In this thesis, these improvements arise from employing a direct yaw moment control (DYC) system that seeks to adapt the understeer gradient of the vehicle and achieve neutral steer by employing a supervisory controller and simultaneously tracking an ideal yaw rate and ideal sideslip angle. DYC enhances vehicle stability by generating a corrective yaw moment realized by a torque vectoring controller which generates an optimal torque distribution among the four wheels. The torque allocation at each instant is computed by finding a solution to an optimization problem using gradient descent, a well-known algorithm that seeks the minimum cost employing the gradient of the cost function. A cost function seeking to minimize excessive wheel slip is proposed as the basis of the optimization problem, while the constraints come from the physical limitations of the motors and friction limits between the tires and road. The DYC system requires information about the tire forces in real-time, so this study presents a framework for estimating the tire force in all three coordinate directions. The sideslip angle is also a crucial quantity that must be measured or estimated but is outside the scope of this study. A comparative analysis of three different formulations of sliding mode control used for computation of the corrective yaw moment and an evaluation of how successfully they achieve neutral steer is presented. IPG Automotive’s CarMaker software, a high-fidelity vehicle simulator, was used as the plant model. A custom electric powertrain model was developed to enable any CarMaker vehicle to be reconfigured for independent control of the motors. This custom powertrain, called TVC_OpenXWD uses the torque/speed map of a Protean Pd18 implemented with lookup tables for each of the four motors. The TVC_OpenXWD powertrain model and controller were designed in MATLAB and Simulink and exported as C code to run them as plug-ins in CarMaker. Simulations of some common maneuvers, including the J-turn, sinusoidal steer, skid pad, and mu-split, indicate that employing DYC can achieve neutral steer. Additionally, it simultaneously tracks the ideal yaw rate and sideslip angle, while maximizing the traction on each tire[CB1] . The control system performance is evaluated based on its ability to achieve neutral steer by means of tracking the reference yaw rate, stabilizing the vehicle by means of reducing the sideslip angle, and to reduce chattering. A comparative analysis of sliding mode control employing a conventional switching function (CSMC), modified switching function (MSMC), and PID control (HSMC) demonstrates that the MSMC outperforms the other two methods in addition to the open loop system

Combining Sensors and Multibody Models for Applications in Vehicles, Machines, Robots and Humans

The combination of physical sensors and computational models to provide additional information about system states, inputs and/or parameters, in what is known as virtual sensing, is becoming increasingly popular in many sectors, such as the automotive, aeronautics, aerospatial, railway, machinery, robotics and human biomechanics sectors. While, in many cases, control-oriented models, which are generally simple, are the best choice, multibody models, which can be much more detailed, may be better suited to some applications, such as during the design stage of a new product