EVS28 Korea, May 3-6, 2015

Model based adaptive controller

design and optimization for (L7)

electric vehicle

Chih-Ming Chang1, Kuang-Shine Yang2 EV Running Chassis , Metal Industries Research & Development Center,

1001 KAONAN HIGHWAY, KAOHSIUNG,TAIWAN 81160, Taiwan

Introduction (I)

I.

1.

2

Battery and BMS System

On-Board Charger

GearBox

Motor Drive

IM Motor

DC-DC Converter

Dry Double Pistons Vacuum Pump

3

Introduction (II)

SPEC.

4

Motor Performance Characteristic Target

L7-REEV-Vehicle Weight 480kg

0

10

20

30

40

50

60

70

80

0 1000 2000 3000 4000 5000 6000 7000 8000

Speed(rpm)

Tor

que(

N.m

)

0.0

2.5

5.0

7.5

10.0

12.5

15.0

17.5

20.0

Pow

er(k

W)

Tv-cruise Tm-peak Tm-con

Pv-cruise Pm-peak Pm-con

Motor Performance Target vs Vehicle Loading

L7-REEV-Vehicle Weight 480kg

0%

5%

10%

15%

20%

25%

30%

0

10

20

30

40

50

60

70

80

0 10 20 30 40 50 60 70 80 90

Vehicle Speed(kph)

Tor

que

@ M

otor

Sha

ft (

N.m

)

0

3

6

9

12

15

18

21

24

Acc

. Tim

e(se

c)

Tm-peak Tm-con

Tm-RE Acc. Time

Motor Performance Characteristic Target

L7-REEV-Vehicle Weight 480kg

0

10

20

30

40

50

60

70

80

0 1000 2000 3000 4000 5000 6000 7000 8000

Speed(rpm)

Tor

que(

N.m

)

0.0

2.5

5.0

7.5

10.0

12.5

15.0

17.5

20.0Po

wer

(kW

)

Tv-cruise Tm-peak Tm-con

Pv-cruise Pm-peak Pm-con

Motor Performance Target vs Vehicle Loading

L7-REEV-Vehicle Weight 480kg

0%

5%

10%

15%

20%

25%

30%

0

10

20

30

40

50

60

70

80

0 10 20 30 40 50 60 70 80 90

Vehicle Speed(kph)

Tor

que

@ M

otor

Sha

ft (

N.m

)

0

3

6

9

12

15

18

21

24

Acc

. Tim

e(se

c)

Tm-peak Tm-con

Tm-RE Acc. Time

5

Schematic Circuit

EV-L7 Control System

L7-xEV Battery System Structure

6

Battery System (BS)

Battery Management System (BMS)

Battery Pack

Battery Control Unit (BCU)

SOC/SOA/Safety/Power M’ment

…

Module #1

(BMU#1)

Packaging / Structure / Cooling / Sealing / Isolating / Vent

…

Tem

p.

Volt

In-Battery Network

Power Circuit HV

System

12V

Power

EV

Network

4~8-Cell-In-Series

Module #..

(BMU#..)

Module #n

(BMU#n)

4~8-Cell-In-Series 4~8-Cell-In-Series

Tem

p.

Volt

Tem

p.

Volt

Safety Detection

Control Circuit

Power Measurement

Cell

Module

Pack

Control

System

Battery Cell CHG Test @ 5C-0.2C

7

Battery Cell DCHG Test @ 5C-0.2C

8

9

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

73.00

73.50

74.00

74.50

75.00

75.50

76.00

76.50

77.00

77.50

78.00

78.50

79.00

79.50

80.00

80.50

0:00

:01

0:01

:54

0:03

:47

0:05

:40

0:07:33

0:09

:26

0:11

:19

0:13

:12

0:15

:05

0:16

:58

0:18

:51

0:20

:44

0:22

:37

0:24:30

0:26:23

0:28

:16

0:30

:09

0:32

:02

0:33

:55

0:35

:48

0:37

:41

0:39

:34

0:41

:27

0:43:20

0:45

:13

0:47

:06

0:48

:59

0:50

:52

0:52

:45

0:54

:38

0:56

:31

0:58

:24

1:00:17

1:02

:10

1:04

:03

1:05

:56

1:07

:49

1:09

:42

1:11

:35

1:13

:28

1:15

:21

1:17

:14

1:19:07

1:21

:00

1:22

:53

1:24

:46

1:26

:39

1:28

:32

1:30

:25

1:32

:18

1:34

:11

1:36:04

1:37

:57

1:39

:50

1:41

:43

VOLTAGE(V) CURRENT(A) ACCMAH(Ah)

MIRDC L7 Battery PACK DCHG TEST(1/2C,50A)

10

CELL_1~24 DCHG CURVE(I=50A)

11

CELL_1~24 CHG CURVE(I=25A)

Battery Pack Spec.

12

Type -Supplier: Lithium Iron Phosphate Oxide Battery

Battery Capacity(Ah): 7.86kWh(0~100% SOC)

Voltage Range(Volt): 87.6V~53V (Normal: 76.8V)

Battery Configuration: 2P-24S

Peak Power(kW): 76.8kW (300Sec)

Rated Power(kW): 7.68kW

HV Output

13

Purpose of Battery Management System

Battery Safety Protection

Temperature / Voltage / Short / Pressure / Leakage / Impact /

Battery Life Cycle Protection

Temperature / Voltage / Idchg & End of DCHG / Ichg & End of CHG / Cool

ing

Battery Energy Calculation

SOC / SOA(IR) / OCV

Battery Power Calculation

Idchg / Ichg vs. Voltage/Temperature / IR

System Reliability

Power Setup & Down / Power Devices Protection / Maintenance -Unbalanc

e & Self-Diagnosis / Communication

Cost Effective

Battery Optimum Matching / Modular Design / …..

L7-xEV IM Motor Controller Design (I)

14

Max. Power

• Flux Weak-less

Control(rpm Extend)

• Battery Limitation

• Continue Power

rpm

Tq

F-DrivingR-Driving

Regenerating

Max. Tq

• Short Period /

Low Speed

• Lock Tq

• F/R Drive &

Protection

Integrated M/G

• S/W Controlled for

Motor / Generator Mode

>90%

>90%

1xV2~3xV / Flux Weaken-less

>90%

>90%Map Control

• Efficiency Based

Output Control

• Electric Power Source

M’ment

• Tq Accuracy & Quality

L7-xEV IM Motor Controller Design (II)

15

Weight 22.7kg

Peak DC Current 323.6A @ 75.7V~81.7V

Peak Torque 61.6Nm @ 75.7V~81.7V

Peak Power 21.74kW @ 75.7V~81.7V

Continuous DC Current 14A @75.7V~81.7V

Continuous Torque 14Nm @ 75.7V~81.7V

Continuous Power 6.5kW @ 75.7V~81.7V

Motor Speed 0~8000rpm

DC-DC Converter

16

Size : 7.5 x 3 x 2.75

Weight : 2.5 lbs

Power : 300W

Nominal Input voltage : 72-80VDC

Output voltage 13.5VDC

Part Number 622/11204

No. Loading Output_Idcdc Output_12V Input_HV

1 25 21.2 11.67 ~72

2 20 17.2 11.78 ~72

3 15 14 11.9 ~72

4 10 9.9 12.02 ~72

5 5 3.6 12.15 ~72

6 0 1.1 12.3 ~72

7 0 ~0.2 12.35 ~74

17

Thank You