Next Generation HEV Powertrain Design Tools: Roadmap and Challenges

Hybrid electric vehicles (HEVs) represent a fundamental step in the global evolution towards transportation electrification. Nevertheless, they exhibit a remarkably complex design environment with respect to both traditional internal combustion engine vehicles and battery electric vehicles. Innovative and advanced design tools are therefore crucially required to effectively handle the increased complexity of HEV development processes. This paper aims at providing a comprehensive overview of past and current advancements in HEV powertrain design methodologies. Subsequently, major simplifications and limits of current HEV design methodologies are detailed. The final part of this paper defines research challenges that need accomplishment to develop the next generation HEV architecture design tools. These particularly include the application of multi-fidelity modeling approaches, the embedded design of powertrain architecture and on-board control logic and the endorsement of multi-disciplinary optimization procedures. Resolving these issues may indeed remarkably foster the widespread adoption of HEVs in the global vehicle market

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

A review of current and future powertrain technologies and trends in 2020

[EN] Fossil fuels are currently the most convenient on-board energy sources for vehicles in terms of energy density and refueling time. However, the increase in global temperature together with the increase in transported people and goods in recent years has forced regulatory authorities around the world to establish strict regulations on pollutant and CO2 emissions. These scenarios are challenging for vehicle manufacturers, but they also create opportunities for the development of new technologies and concepts. For example, automotive companies and researchers are currently exploring hybrid powertrains with either advanced internal combustion engine technologies and low levels of electrification, or with high levels of electrification combined with simpler internal combustion engines. While these hybridization approaches can provide significant improvements in efficiency and emissions. There is also a global movement at the, consumer, manufacturing and government level to accelerate the adoption of zero tailpipe emitting vehicles (e.g., battery electric vehicles and fuel cell electric vehicles). This paper reviews the current state of powertrain technologies, analyzing first the evolution of emissions regulations in major markets and emphasizing the future tighter measures that will be adopted in Europe and the US. After that, an analysis of current global vehicle sales considering the COVID situation is performed, followed by a forecast of future powertrain technology market share trends. Finally, reviews of internal combustion engine, hybrid, and battery electric vehicle technologies announced in 2020 are carried out.Conway, G.; Joshi, A.; Leach, F.; García Martínez, A.; Senecal, PK. (2021). A review of current and future powertrain technologies and trends in 2020. Transportation Engineering. 5:1-15. https://doi.org/10.1016/j.treng.2021.100080115

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

Module 1 : Engineering Trends

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Thermal Management of Electrified Propulsion System for Low-Carbon Vehicles

An overview of current thermal challenges in transport electrification is introduced in order to underpin the research developments and trends of recent thermal management techniques. Currently, explorations of intelligent thermal management and control strategies prevail among car manufacturers in the context of climate change and global warming impacts. Therefore, major cutting-edge systematic approaches in electrified powertrain are summarized in the first place. In particular, the important role of heating, ventilation and air-condition system (HVAC) is emphasised. The trends in developing efficient HVAC system for future electrified powertrain are analysed. Then electric machine efficiency is under spotlight which could be improved by introducing new thermal management techniques and strengthening the efforts of driveline integrations. The demanded integration efforts are expected to provide better value per volume, or more power output/torque per unit with smaller form factor. Driven by demands, major thermal issues of high-power density machines are raised including the comprehensive understanding of thermal path, and multiphysics challenges are addressed whilst embedding power electronic semiconductors, non-isotropic electromagnetic materials and thermal insulation materials. Last but not least, the present review has listed several typical cooling techniques such as liquid cooling jacket, impingement/spray cooling and immersion cooling that could be applied to facilitate the development of integrated electric machine, and a mechanic-electric-thermal holistic approach is suggested at early design phase. Conclusively, a brief summary of the emerging new cooling techniques is presented and the keys to a successful integration are concluded

Reactivity controlled compression ignition engine: Pathways towards commercial viability

© 2020 Elsevier Ltd. All rights reserved. This manuscript is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International Licence (http://creativecommons.org/licenses/by-nc-nd/4.0/).Reactivity-controlled compression ignition (RCCI) is a promising energy conversion strategy to increase fuel efficiency and reduce nitrogen oxide (NOx) and soot emissions through improved in-cylinder combustion process. Considering the significant amount of conducted research and development on RCCI concept, the majority of the work has been performed under steady-state conditions. However, most thermal propulsion systems in transportation applications require operation under transient conditions. In the RCCI concept, it is crucial to investigate transient behavior over entire load conditions in order to minimize the engine-out emissions and meet new real driving emissions (RDE) legislation. This would help further close the gap between steady-state and transient operation in order to implement the RCCI concept into mass production. This work provides a comprehensive review of the performance and emissions analyses of the RCCI engines with the consideration of transient effects and vehicular applications. For this purpose, various simulation and experimental studies have been reviewed implementing different control strategies like control-oriented models particularly in dual-mode operating conditions. In addition, the application of the RCCI strategy in hybrid electric vehicle platforms using renewable fuels is also discussed. The discussion of the present review paper provides important insights for future research on the RCCI concept as a commercially viable energy conversion strategy for automotive applications.Peer reviewe