1 elin 2014, jonn lantz, [email protected] elin efficient electric drive inverter control
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2ELIN 2014, Jonn Lantz, [email protected]
The Automotive challenge
Software
Mechanics PowerElectronics
Volvo Car Group – Green, safe, premium cars!
Climate change; new legislations (often regional) …
Exponential increase of software in cars…
“80% of all new innovations in automotive are software”
Modern cars are product lines of complex distributed software in moving, safety critical, (high voltage) volume mechatronics.
A trinity for sustainable automotive business!?
Mechatronics
Automotivemechatronics
Power engineering
ELIN
Create a research and development platform in the context of electric drive, to achieve
1. more efficient electric propulsion and
2. more efficient development of electric propulsion
3ELIN 2014, Jonn Lantz, [email protected]
Mission: Improve the software engineering capability of the Nordic Software-Intensive industry with an order of magnitude
Theme: Fast, continuous deployment of customer value
Success: Academic excellenceSuccess: Industrial impact
Software Center
4ELIN 2014, Jonn Lantz, [email protected]
Background: The Automotive challenge
Working with embedded software? Then you are 20 years behind!?
Why?
A modern premium car can have about 100 ECUs (embedded computers) working in a complicated network
So, the system is not 20 years behind! Can we solve this? What will be required in the (near) future? How fast must we get?
5ELIN 2014, Jonn Lantz, [email protected]
R&D on mechatronics
Controller (ECU)
Device
Supplier(s)
Power supply, Network,…
Software models Plant
Models
Environment models
Make software developers out of domain experts! VCC invest in MDE
Developers
ResearchersTo learn about and develop on a system, we must control the software!
VCC invest in in-house development
ELIN: allow research and development on the same platform!
6ELIN 2014, Jonn Lantz, [email protected]
ELIN, piece for piece
VCC: engineering and demonstration vehicleConstruction of control software in-house (enabler for more advanced control), construction of test vehicle with new inverter.- Model driven development- Inverter ECU construction (DSPACE environment with quasi AUTOSAR
platform)- HIL-test- Mechanical construction and test (one V60-hybrid is modified)
CTH: research and rig testApplied research on motor control- Model driven research (sharing models!)- PWM algorithm design for efficient drive- Rig construction and test- Noise measurements etc.
4 triax for blocked force
8 mics for Lw
7ELIN 2014, Jonn Lantz, [email protected]
ELIN, status2014-10-08We have a 10 month delay. ELIN will finish in summer 2016
Andreas (PhD candidate) has published 2 papers [1,2] and built one lab rig. Hence, great progress at CHT.
Niklas (VCC engineer) has developed an AUTOSAR application layer for the ELIN-inverter. So far only tested in MIL (model based) and currently being tested in HIL (picture). We have struggled a lot with choosing inverter for ELIN, Tier1:s do not always see benefits in this kind of research… Solution: we use a dSPACE rapid prototyping-ECU and place this in the car combined with a new inverter hardware.The demonstrator (vehicle) is currently being tested. The dSPACE ECU is on line, but the inverter and integration in the car remains. Thus, good progress at VCC (according to plan)
Rig test -10 kHz, 20 Nm
Road test upwards driving 0-20 km/h
1) An Analysis of Inverter Switching Loss Minimization Based On Discontinuous PWM for a Salient-pole PMSM, EPE2014, Lappeenranta, Finland2) Inverter Losses Minimization Using Variable Switching Frequency Based On Multi-objective, ICEM2014, Berlin, Tyskland
8ELIN 2014, Jonn Lantz, [email protected]
ELIN, future work (2015)
Continuous Integration!!• CTH: a new inverter will be finalized• VCC: when finished, the new inverter is integrated in the ELIN
vehicle
When the hardware integration is done, continuous integration is possible, both for CTH and VCC! Updates and new ideas can be tested [verified] almost without any delay. Some help will be appreciated from a VCC CI team.
• CTH: continued development of the inverter control software• CTH: continued research on PWM pattern optimization vs noise,
etc.
9ELIN 2014, Jonn Lantz, [email protected]
Notes
Learning advanced industrial software control development• The CTH control software (algorithms) is developed in any way,
and goes deeper (closer to hardware) than VCC is usually developing software.
Integrating this in a real vehicle is a way for both CTH and VCC to learn how to optimize deeper, more holistic. This is an enabler for new innovations.
In line with R&D• ELIN sw is developed exactly as the in-house AUTOSAR software
in VCCs current projects. • However, ELIN can be used to test more advanced MDE, more
advanced Continuous Integration, etc.
This is extremely valuable to VCC, and links to other research (several projects within Software center)
11ELIN 2014, Jonn Lantz, [email protected]
The Model Driven processRe-invent the classical V-model!
ECU
SYS/MEC
H
High level reqs. CAR testRIG
HILSystem design tool
(database)
Developed by Tier1 fromrequirements
System
ECU
SW Component
MIL(SIL)
SystemMIL
Unittest
SWDesign
codegen
Simulink & Simscape
Architecture
Simulink
HIL short loop 24h
Continuous Deployment
short loop
Plant models
ECU integration
SW
MIL-SIL short loop 1h
12ELIN 2014, Jonn Lantz, [email protected]
… and in real life
ECU
SYS/MEC
H
SW
High level reqs.
ECU integrations
System design tool(database)
System
ECU
SW ComponentSW
Design
Simulink & Simscape
ECU ready!
Vehicle ready!
CAR test
Vehicle integra-tions
RIG
HIL(continuous ECU-integration possible)Plant models
Assumptions verifiedHW Assumptions made
13ELIN 2014, Jonn Lantz, [email protected]
A use case: developing dog clutch control software
Auto generated AUTOSAR ECU model
Test bench(combined with test tool)
Plant model (Simscape DSL)
Results:Although the first versions of the clutch model had numerous faulty assumptions, these where easy to correct – since the developers now understood the system! (U. Eliasson et. al. MODELS 2014)
modelreference library
function developers
CAE developers
test developers
automated regression test