Model-based Development of Hybrid-specific ECU Software for a Hybrid Vehicle with Compressed- Natural-Gas Engine

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1 Model-based Development of Hybrid-specific ECU Software for a Hybrid Vehicle with Compressed- Natural-Gas Engine 5. Braunschweiger Symposium 20./21. Februar 2008 Dipl.-Ing. T. Mauk Dr. phil. nat. D. Kraft Dr.-Ing. J. Quarg Dipl.-Ing. M. Böhm Prof. Dr.-Ing. M. Bargende Prof. Dr.-Ing. H.-C. Reuss 1

2 Cooperative project Antriebskonzept mit Erdgashybrid Partners Universität Stuttgart in cooperation with Supported by 2

3 Outline Project Introduction Software Development Process Requirements Testing Process Tasks of the Hybrid Control Unit Software Summary and Outlook 3

4 Introduction 4

5 Introduction We build up a prototype hybrid vehicle Goals: based on an Astra Caravan using parallel hybrid configuration using a down-sized, highly turbo-charged natural-gas engine using an adaptive operating strategy minimize CO 2 emissions match EURO 5 5

6 Introduction (2) Hybrid Control Unit (HCU) Superordinate control unit Coordinates interaction between series and added (hybrid) components Rapid Prototyping ECU Natural-Gas Hybrid Engine Components Control Unit Astra series CAN bus Hybrid CAN bus + - 6

7 Software Development Process 7

8 Software Development Process Requirements Software development parallel to construction and assembly of the prototype vehicle Early software tests without prototype vehicle Safe testing without risk of damaging the vehicle Easy transfer to the real vehicle Real-time capability of the software Approach Model-based software development Automatic code generation Environment simulation (models of vehicle, driver, driving cycle, CAN bus) Strictly modular model structure 8

9 Stage 1: PC-based development and testing Development of the software functionality Testing the software with an environment model (faster than real-time) PC Hybrid Control Unit virtual bus CAN bus model driving cycle driver vehicle model driving resistance 9

10 Stage 2: HiL Simulation I Testing the real-time capability and CAN bus communication Rapid-prototyping ECU Hybrid Control Unit I/O virtual bus real CAN bus Real-time computer I/O virtual bus driving cycle driver vehicle model driving resistance 10

11 Stage 3: HiL Simulation II Code and parameter optimization based on real components Rapid-prototyping ECU Real components Hybrid Control Unit virtual bus TNG EM I/O real CAN bus Real-time computer I/O Test bench virtual bus driving cycle driver remaining vehicle driving resistance I/O I/O brake 11

12 Stage 4: Vehicle Testing / optimization based on the real vehicle Rapid-prototyping ECU Real vehicle Hybrid Control Unit I/O virtual bus real CAN bus 12

13 Software Development Process 4 stages of software testing PC Simulation HiL Simulation I HiL Simulation II Vehicle PC Real-time system Real-time system 30 driving cycle driver vehicle model CAN bus model driving cycle driver vehicle model remaining vehicle model Test bench TNG cycle driver EM 60 RP control unit RP control unit RP control unit Hybrid Control Unit (HCU) HCU HCU HCU 13

14 Hybrid Control Unit 14

15 Tasks of the Hybrid Control Unit Superordinate control unit coordinates interaction between different components contains hybrid operation strategy (hybrid mode, driving torque split-up, gear selection ) uses predictive information for strategy optimization translates CAN messages between buses (network gateway) CNG Engine ECU is incompatible to series Astra engine ECU 15

16 Tasks of the Hybrid Control Unit (2) Network Gateway HCU operating strategy Signals / messages are translated requantised rearranged virtual remaining powertrain translator virtual engine control unit battery power electronics vehicle sensors series components new components turbo naturalgas engine electric machine autom. manual transmission CAN buses 16

17 Tasks of the HCU (3) Reinterpretation of Signals Necessary as series components (esp. control units) are not modified signal engine speed engine transmission (MTA) needed by MTA, as engine speed = clutch input speed signal engine speed engine electric machine transmission (MTA) engine speed!= clutch input speed MTA does not know that there are two additional components (clutch and electric machine) 17

18 Tasks of the HCU (4) Reinterpretation of Signals signal electric machine speed Hybrid Control Unit forwarded to MTA as engine speed engine electric machine transmission (MTA) MTA interprets engine speed as clutch input speed 18

19 Summary and Outlook 19

20 Summary Introduction: Prototype hybrid vehicle with natural-gas engine Software development process with 4 stages of testing Stage 1: PC-based function development and fast simulation Stage 2: Real-time and bus communication aspects Stage 3: Optimization on real components Stage 4: Real Vehicle Tasks of the Hybrid Control Unit Choose optimal hybrid mode and torques, select gear Coordinate interaction of components Translate and reinterpret signals 20

21 Outlook HiL Simulation II (test bench) and testing in the vehicle in spring

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