durchgängige antriebsstrangentwicklung vom ... durchgängige antriebsstrangentwicklung vom...
TRANSCRIPT
DLR 16.7.2013
H. Nonn
AVL Durchgängige Antriebsstrangentwicklung vom Verbrennungsmotor bis zum Brennstoffzellenantrieb
H.Nonn 2 2013
OUR EXPERIENCE FOR YOUR SUCCESS
AVL is world's largest privately owned company
for development, simulation and testing of:
Hybrid electrical vehicles
Combustion engines
Transmissions
Electric drives
Batteries
xCU software
AVL – more than 60 years’ experience
Involved in more than 2000 engine development projects
More than 4000 engine, powertrain and battery test bed installations
Passenger cars,
Trucks
Large engines
Offroad engines
H.Nonn 3 2013
AVL SERVES ALL AUTOMOTIVE SEGMENTS
passenger cars 2-wheelers racing
construction agriculture commercial vehicle
locomotive marine power plants
AVL
Advanced
Simulation
Technologies
AVL
Instrumentation &
Test Systems
AVL
Powertrain
Engineering
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Chassis Dyno
Driveline Test
Systems
Vehicle
Simulation
Powertrain
Simulation
Vehicle
Development
Vehicle Validation
Prod. Signoff
AVL PRODUCT PORTFOLIO FOR SUCCESSFUL
POWERTRAIN DEVLOPMENT
AVL-CRUISE
AVL-BOOST
AVL Software Tools for Powertrain Development
AVL-FIRE
AVL-DRIVE
AVL-EXCITE
Engine Test
Systems
Battery/Motor
Testing / HIL
Component
(Battery/ Engine)
Simulation
AVL
MicroSoot
AVL Instrumentation & Software for Systemvalidation & Optimimization
E-Storage
Tester
AVL PUMA,
LYNX AVL-INDICOM
AVL CAMEO
AVL iGEM
Instruments
(emissions,
consumption) AVL M.O.V.E.
2013 H.Nonn Public
Torque Vectoring Toyota
Hybrid Systems e CVT
TTR Hybrid (e4WD)
BUSINESS DRIVER
INCREASING POWERTRAIN DIVERSITY
1980 2000 2010
Pow
ert
rain
Co
mple
xity
Standard Configuration
20xx
Active 4WD Systems
Active Transmissions
Calendar Year
Electrical Driving
e-Motor for each Wheel
Inte
gra
tion &
Valid
ation E
ffort
Hybrid Systems
e-Motor on front Wheels
Porsche
Driver Assistant and
Vehicle Safety Systems
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AVL STRATEGY
INTEGRATING THE 5 ELEMENTS OF THE POWERTRAIN
Electrical energy
storage
(batteries, fuel cells)
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Test process
Test methods
Calibration Data
Evaluations
Models
ONE AUTOMOTIVE TEST PLATFORM SUPPORTING „FRONT LOADING“ IN THE DEVELOPMENT PROCESS
Common Requirement Management
Powertrain Testbed
Chassis Dyno
TestBed
Road Testing
Office Simulation
MIL/SIL Testing
Battery/ eMotor
TestBed
Engine Testbed
HIL Testing
Fuel Cell Testbed
R
ea
l w
orl
d
Vir
tua
l w
orl
d
Consistent and comparable results
Common Dataware, Modelware, Testware
Architecture Components Systems
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MANEUVER LIBRARY: VIRTUAL PROVING GROUND
+ x Roads goes Rig
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VEHICLE ELECTRICAL COMPONENTS
Mains supply
12V accessories
Mains supply
E-Motor
Inverter
Battery
DC/DC
converter On Board
Charger
Quick
charging unit
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POWER ELECTRONICS: INVERTER TESTING
Automation / Simulation
Mains Supply
Mains Supply
Power Measurement
T / P / U
Measurement
PUMA Open
Options:
- Climatic Chamber
- Switch Rack
Coolant
Conditioning
Test System
Cabinet
UUT-Inverter
U, I
AVL
InMotion™
e-Storage
Emulator
e-Motor-Emulator
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COUP-E TECHNICAL BATTERY INFORMATION
Battery Pack Details
nominal cell voltage 3,75 V
cell capacity 41 Ah
configuration 180s1p
number of cells 180
nominal pack voltage 675 V
installed pack energy 27,6 kWh
pack weight 242 kg
gravimetric pack energy density 114 Wh/kg
cooling method liquid
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SUPPLY CHAIN: INTERFACES DEFINES DEMAND FOR FC TESTBEDS
FC System
FC Powertrain
FCV
Fuel cell technology provider
OEM Car manufacturer
Chassis Dyno testbed
Powertrain testbed
FC system testbed
FC stack testbed
Fuel cell stack/module
Test S
yste
ms
2013 H.Nonn Public
3D-CFD Simulation
3D-CFD FIRE calculation of
of current/voltage
polarization cruves for
different operating
conditions
FUEL CELL PERFORMANCE & THERMAL MODELING
Scalable Fuel Cell Modeling
Surrogate Cell /
Stack Model
Surrogate fuel cell
model based on 3D-
CFD FIRE results
FC System /
Vehicle Modeling FC system model with
embedded surrogate fuel cell
model
Fuel C
ell
Sim
ula
tion
2013 H.Nonn
AVL SOFC APU FOR HD TRUCKS
Objective
Mobile SOFC generator fuelled with conventional
diesel
RTD Programme
System development, packaging & design
Component development (blowers, fuel processing, catalysts, burners,…)
Control system
Durability and reliability development
Vehicle integration
Benefit
3 kW continuous electric power
High efficiency >35%
Zero-emissions (limited & NVH)
AVL has successfully developed SOFC systems close to start-of-production level
Fuel C
ell
Applic
ations
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THDA - ONLINE FUEL CELL MONITORING
Background for Stack Monitoring
Usually critical operating status is monitored by measuring the cell
voltages individually. Large stacks thus require costly
instrumentation and elaborated wiring layouts.
Cost efficient solutions with less complexity are required.
AVL Approach THDA
On-line detection of critical FC operating conditions w/o
measuring individual cell voltages
Analysis of the effects of voltage drops instead of measuring
voltage drops itself
THDA technology analysis change in the harmonic distortion
content of a superimposed signal
Customer Benefits
Instrumentation effort is relatively small and of low complexity
2 channel measurement cost effective (no cell voltage
measurement required)
New extended functions enables identification of different
causes for critical conditions e.g.
water flooding / membrane drying / cathode- or anode effect
Dia
gnostics
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THDA - ONLINE FUEL CELL MONITORING EXAMPLE OF MEASUREMENT
Dia
gnostics
A3-FALCON ADVANCED 3D FUEL CELL ANALYSIS AND CONDITION DIAGNOSTICS
PROJECT DESCRIPTION The goal of A3-FALCON is to identify optimal operating strategies for fuel cells in terms of efficiency and lifetime. The
proposed solution comprises the first-time introduction of degradation models in a 3D CFD simulation, spatially resolved
experimental acquisition of critical cell states, a real-time data acquisition and signal analysis (based on AVL THDA) and the
correlation of results from simulation and experiment.
FUNDING PROGRAM FFG IV2Splus
PARTNERS TU Graz, S++, Intelligent Energy (assoc. Partner)
PROJECT TIME FRAME 05/2012 – 04/2014