kpit cummins infosystems ltd. capability overview in hev, ev and
TRANSCRIPT
© 2005 KPIT Cummins Infosystems Limited
We value our relationshipWe value our relationship
© 2003-09 KPIT Infosystems Limited
KPIT Cummins Infosystems Ltd.
Capability Overview in HEV, EV and Motor Control Areas
Version : 1.0
KPIT Cummins Involvement in HEV and EV Domain
Energy Storage Unit
Battery Management System Development
Battery Pack plant modeldevelopment
Functional validation of Production intent BMS
Pseudo – ABS development thro Motor Control for EV
Revolo™ -Hybrid Retrofit solution
Hybridization solutions
HEV/EV System Expertise
KPIT Initiative
Customer Program
Software development
MIL / SIL testing
Functional testing
Hardware in Loop testing
Integration and Testing
System / Vehicle Testing
Services
ECU HW development
ECU Virtualization
Rear Wheel Hybridization
Motor control IP for low power motors
AC drives commisioning toolUsing pocket PC
Technical Consultancy
Requirement Engineering
Motor controls
Battery Management System Consultancy
Battery charger boardprototype
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KPIT Product
Overview of KPIT’s Involvement in Battery Domain
Complete involvement in all Battery systems.
KPIT Initiative
Customer Program
Algorithm development
Software in Loop testing
Hardware in Loop testing
Unit Testing
Integration and Testing
System Testing
Services
Model-in Loop testing
ECU Virtualization & testing
Technical Consultancy
Requirement Engineering
Complete development Of BMS
Battery Pack plant modeldevelopment
Functional validation of Production intent BMS
Battery charger boardprototype
Battery characterizationExperiments and testing
Joint IP in SOC and SOH Algorithms for Li-Ion
Partnership for Development of complete
Battery Electronics & Electricals
CAD/ CAM / CAE for batterysystems
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Application Chemistry Status
Mild Hybrid Li-IonConcept Prototype
Full Hybrid Ni-MH In production
Mild Hybrid Lead acidProduction Prototype
Smart JBs Lead Acid In production
Product Development life Cycle @KPIT
Product Conceptualization
Requirement Analysis
Hardware Engineering
Product Certifications
Software Engineering Mechanical Engineering
Hardware Architecture
VLSI Design
Board circuit Design / simulation
PCB Fabrication, Assembly
Board V&V
Software Architecture
BSP development
RTOS Porting
Software V&V
Application development
Industrial Design
Engineering Design
CAD / CAM
Prototyping Fabrication(Rapid Prototypes only)
Mechanical QC
Product Integration
Reliability Analysis
Reliability Analysis
System testing & Product Testing
PCB Design
Device Drivers development
In house capability
Tie up with partners
Future Plan
Optional AUTOSAR flavor
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Battery Test Setup
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Battery Test setup
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Programmable load
ØD.A.S
Model Validation
DAS
Battery
Charger
Testing Setup
7
Case Study 1: Hybrid Control Unit ( HCU ) development
Our Role
• Complete requirement engineering and generation of documents as per SPICE standards and development of following features
• Pedal input sensing and redundant path development
• PRNDL inputs processing using finite state machines
• Immobilizer feature development• OBD-II for all electrical I/Os and CAN signals
• UDS implementation as per ISO 15765-3 specification for HCU
• Independent V & V arm for the entire right half of V cycle : MIL/ SIL / HIL and Vehicle testing,Low level Microcontroller core self tests
• Identification of various Hazards in PHEVs and working with customer to implement ISO 26262 functional safety compliance
Ø8
• Production intent project for MY 2011 PHEV
• US Tier-1 customer responsible for entire powertrain development for PHEV : Hybrid Control Unit, DC-DC converter, Plug-in charger and Inverters
DEVELOPMENT ENVIRONMENT
i. MATLAB / SIMULINK version R2009aii. RTW Embedded coder for Motorola
MPC5554iii. Woodward tool chains and OSiv. Clearcase / Clearquestv. ATI Vision
Case Study 2: eAWD System Overview
+
<Fu
nct
i
E C
on12 V
Battery
12 VBattery
V Batt 12 VDc
-
-+
+ +
Vehicle Altenator
Battery Pack Charging System
Vehicle Battery 12 V Lead Acid
-
-
-
36 ~ 42 VDc
Battery GND
+
CAN 1 Communications between Modules
Electro-Mechanical Load(for simulation substitute large resistor to provide loading on the Batteries )
ACM Control Module
Battery Box Ambient Temp .
Vehicle Signals
+A
ND
BMS Control
ModuleBattery Pack
(3 Lead Acid Batteries)
12 VBattery
12 VBattery
12 VBatteryPWM C
PWM B
PWM A
Ioc[ VDc]
I/O Signal
Hardwired Signals
FUSE
Contactor
+ I
T1~T5
PWM_FAN Ctrl
IGNITION
FAN on/off
KPIT Developed KPIT DevelopedKPIT Developed
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Case Study 3: BMS End to End solution
End to End Solution
Problem statement:• Development of end to end generic Battery
management system independent of variousbattery chemistries
Challenges:• SOC estimation based on various scenarios• Achieve goal of maximizing the battery life• Design of optimum battery charging algorithm• Estimation of battery ageing • Design of thermal management system for battery
and charger• Handholding the customer to complete the
specifications and algorithms
KPIT CUMMINS CONTRIBUTION:
• Coordination with Customer as well as Battery manufacturer• Leverage on in depth HEV technology expertise• Rapid prototyping to aid customer in selection of battery
chemistry and rating
Program phases:• Battery and charger requirement engineering• Implementation using MBD and validating using
rapid prototypes• HIL setup and validation• In-vehicle validation
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Case Study 4: Plant Modeling of Battery Pack
Problem statement:• Development of generic high-fidelity battery plant
models & validating the characteristics againstmanufacturer specification for future Analysis and
• V & V
Technologies:• SimPowerSystems toolbox• MATLAB scripts• SIMULINK report generator
Analytical high-fidelity modeling
Challenges:• In depth understanding of battery chemistries• Synthesizing the battery chemistries and
development of equivalent electrical circuit• Building all the fidelity to model to validate against
the Battery manufacturer provided characteristics.
KPIT CUMMINS CONTRIBUTION:
• Providing expert consultancy to the customer in coming up with virtual validation of control strategies by suggesting MIL /SIL testing relevance.
• Leverage on in depth Model based development expertise• Generation of plant model characteristics report in MATLAB User
interface environment.
Parametric Model( Exp. data + DoE)
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Case Study 5: HEV Software Validation – Ni-MH Chemistry
Challenges Faced:• Changes in the source code during course of the
activity• Limited and outdated availability of requirement
specifications• Limitation using RTRT for long instructions and
limitations in memory when large number of test cases are run
• Development of S-function wrapper function to accommodate various hand coding styles
Our Role:• To generate unit and functional test plan • To carryout unit testing for 16 sub features using RTRT• To perform feature testing for 14 sub feature using
Matlab environment.
Tools Used:i. RTRT version 2003ii. SDS single step Simulator for PowerPCiii. Matlab version 2006
Problem statement:• Functional validation of BMS legacy code in MATLAB
environment
KPIT CUMMINS VALUE ADDITION:
• Extensive experience in Testing projects, which helped recommend the unit testing tools and the decision to develop feature test tool in house
Verification and Validation12
Case study 6: ABS Control System for Electric Vehicle
Problem statement:Recover the maximum Regen braking energy while maintaining a good braking performance, under wheel locking scenario
Challenges faced• Algorithm development from scratch• Braking force algorithm tweaking• In-Vehicle Validation of the algorithm• Detecting wheel lock in absence of wheel speed
sensors and acceleration sensor. • Developing software in Curtis controller with limited
programming feature like Fixed point Math, Arrays and Pointers
• Developing software with limited debugging features (capture and timing).
• Calibration of algorithm in different road conditions• Ripple and noise issue in input variables RPM and Brake
KPIT Role: • Understanding of existing motor controller• POC of the control algorithm using MATLAB
simulation• Implementation of the ABS algorithm on the
Motor Controller• Validation of the control algorithm by
conducting in-vehicle testing• Support for Vehicle Track testing
Project Metrics 3 resources over 3 months of engineering effort
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Low Power Motor and Valve Control Related Experience
Motor Control Experience Summary
EPAS
PProduct DDesign and EEngineering SSolutions
Software Electronics
Mechanical Controls
Ø8/25/2010 Ø16
300+ vehicleprograms
3000+ projects
2000+Engineers
PDES - Offerings
Ø8/25/2010 Ø17
Technical Expertise
•Hardware Design•Software Development•Mechanical Design
Domain
•Automotive•Industrial Automation•Consumer Electronics•Bio-Medical
Offerings
•Prototype Building•Value Engineering•Reverse Engineering•Product V&V•Product Certification
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Abstract:
The goal of this project was to support the Electric Power Assisted Steering development for platform software and motor control.
Challenges:q First time Tier-1 was giving the work to
offshoreq Templates from Tier-1 was in evolving stageq Mismatch between design and implementationq Frequent Change in Requirementsq Multi location development
Our Role:q Platform software update and development (Review existing driver,
Design, Unit testing and Integration testing)q Motor control software development support (MATLAB Model update and
testing for Motor torque calculation and motor winding temperature calculation)
q Integration of platform software and motor control with the application
Tools and Technologies:V850E/PHO3 controllerGHS compiler, NEC MINICBE debuggerParasoft C++Test tool for unit test and static checkCANape and CANalyzerDOORS requirement management toolMATLAB
Metrics:q Approx. effort: 80
man months q Duration: 12 Monthsq On site and Off-shore
Customer Details:q European based Tier 1
for an European OEM
Electric Power Assisted Steering Design and Development
Motor Control Information:Permanent Magnet Synchronous Motor Control Peripheral was used PWM – specifically designed for motor control - for faster outputsFeedback Current read was achieved using Input Capture Unit of V850
Intelligent Wiper Control
SOLUTIONSOLUTION
OBJECTIVEOBJECTIVE
CHALLENGES & ACHIEVEMENTSCHALLENGES & ACHIEVEMENTS
Complete Redesign with Automotive Certifications
Ø Redesign with low cost 16-Bit microcontroller
Ø PID implementation
Ø Complete product development
Ø LIN 2.1 communication protocol
Ø Automotive Certification Testing in ARAI
Ø Cost Reduction
Ø First engagement in Chinese market for product development
Ø Supplier negotiations to get best quotation
Ø Partnership with ARAI
Ø Onsite product testing in actual vehicle
Ø Manufacturability aspects
SYSTEM DIAGRAMSYSTEM DIAGRAM
DC motor Drive, Improved EMC
Twin Wiper blades
PCB enclosure, Hall Effect position
encoder
Power Sunshade
SOLUTIONSOLUTION
OBJECTIVEOBJECTIVE
CHALLENGES & ACHIEVEMENTSCHALLENGES & ACHIEVEMENTS
Complete Redesign with reduced BOM cost with Automotive Certifications
Ø Redesign with Low Power AT tiny series
Ø Performance and Durability Testing
Ø Automotive Certification Testing in ARAI
Ø Cost Reduction
Ø Mass Production
Ø Maintaining existing mechanical constraints
Ø Supplier negotiations to get best quotation
Ø Partnership with ARAI
Ø Sustaining target BOM cost
Ø Product compliance to customer specified Performance & Durability tests
Ø Manufacturability aspects
SYSTEM DIAGRAMSYSTEM DIAGRAM
Improved EMC compliance,
Low Cost
Nylon Curtain
PCB and
Enclosure
Redesigning
Instrument Cluster (Dash Board)
SOLUTIONSOLUTION
OBJECTIVEOBJECTIVE
CHALLENGES & ACHIEVEMENTSCHALLENGES & ACHIEVEMENTS
To showcase new MCU capabilities for cluster applications
Ø Modular board design to drive digital dial gauges
Ø CAN Network interface
Ø Telltale and Chime simulation for automotive environment
Ø Segmented LCD drive for ODO and TRIP counts
Ø Product compliance to Automotive EMI EMC standards: ISO 11452 & CISPR-25 (Level-5)
Ø Software Layered architecture
Ø Configuration GUI for system trimming to 2 or 4 wheeler with required features
Ø Demonstration GUI for effective demonstration
SYSTEM DIAGRAMSYSTEM DIAGRAM
Thank You