This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties. DENSO INTERNATIONAL EUROPE Electrified Vehicles as Platforms for Complex System Control DENSO INTERNATIONAL EUROPE Technical Research Department Hasan Esen 03.09.2012 HYCON2 WORKSHOP ON ENERGY
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This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
Electrified Vehicles as Platforms for Complex System Control
DENSO INTERNATIONAL EUROPETechnical Research Department
Hasan Esen03.09.2012HYCON2 WORKSHOP ON ENERGY
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
2 / 16AGENDA
1. DENSO Corporation Company Profile
2. Increasing Complexity of Automotive Systems
3. Example Studies
4. Outlook
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
3 / 16
global supplier of automotive technology, systems and components
1. DENSO Corporation Company Profile
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
4 / 16
global supplier of automotive technology, systems and components
1. DENSO Corporation Company Profile
� Established : 1949
� Employees (31.3.2010) : 120,812
� Subsidiaries and affiliates:
� Japan (80)
� Asia and Oceania (57)
� North & South America (39)
� Europe (36)
Headquarters: Nagoya, Japan
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
5 / 16
global supplier of automotive technology, systems and components
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
6 / 162. Increasing Complexity of Automotive Systems
Information &
Energy Grid
Integration
�More ECUs, larger program size, larger scale
� Powertrain Trend: Increasing diversity
Internal
Combustion
Engine
Electric
Vehicle (EV)
Efficiency Increase
Biofuels
Hybrid Vehicles, Plug-in Hybrids
Range extender
Battery electric vehicle
Fuel cells
Lowest Global
Emission
�Increasing powertrain diversity
Vehicle & Grid
IntegrationNetworked &
Integrated
System
� Vehicle System Trend:
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
7 / 162. Increasing Complexity of Automotive Systems
� Energy Flow (conventional vehicle):
Cabin Temperature
Electric Load
Driving
coolant
A/C
refrigant
Engine
Battery
fuel
Mechanical
Electrical
Thermal
1 function – 1 component
Heater Core (H/C)
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
8 / 162. Increasing Complexity of Automotive Systems
� Energy Flow (hybrid, low fuel consumption vehicle):
Rankine
coolant
Exhaustheat
recovery
recuperation
Motor /
Generator
refrigant
Mechanical
Electrical
Thermal
� 1 function – multi component
Cabin Temperature
Electric Load
Driving
fuel
Battery
A/C
Heater Core (H/C)
Engine
Elec. Heater(PTC)
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
9 / 162. Increasing Complexity of Automotive System
Architectural problems
High control freedom & optimality
Fault-tolerance
…
3.1 Functional Architecture
based Control System Design
3.3 Fault Tolerant Battery
Control in Electrified Vehicles
� DENSO Example Studies
3.2 Model Predictive Control
for Cabin Heat Thermal Man.”
Challenging control problems today as a result of increasing complexity & scale
New control design concept and methodology are necessary for automotive systems
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
Vehicle
Coordinator
Vehicle
Motion
Powertrain
・ ・ ・ElectricalEnergy,
Body,Information,
CabinClimate,・・・
TransmissionOutputshaftTorque
TransmissionOutputshaftTorque
・・・
・・・
Powertrain
Coordinator
PropulsionReference
ISG
Clutch
Trans-mission
Engine
Starter
Distribution
ISGTorque
TransmissionOutputshaftTorque
EngineTorque
EngineSpeed
StarterON/OFF
ClutchEngagementSignal
GearRatio
VehicleMotion
Coordinator
MotionReference
VehicleStability
Optimization
LongitudinalAcceleration Tire
ForcesLateralAcceleration
YAWRate
VehicleSpeed
Translation
VehicleStability
Coordinator
Diff.AWD
Steering
Brake
Distribution BrakeTorque
AWDTransferRatio
TireSteerAngle
DifferentialRatio
10 / 163.1 Functional Architecture based Control System Design*
*T. Tashiro, S. Akiyama (DENSO Corp.) Global Powertrain Conference 2003, Ann Arbor, MI, 2003
� Aim: structuring the control system that gets larger and more complex
Layer 0: Vehicle Domain Layer 1: Motion Domain
Layer 2: Stability Domain
Layer 1: Powertrain Domain
Main features:
- Restructure vehicle control
under simple rules.
- Redefine and allocate all of
control function appropriately
- Standardize interface of each
component.
- Hide localized information for
outside of the component.
- Parallel development of each
component
� This hierarchical structure serves as a framework. It has been gradually embodied
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
11 / 16
� Energy Flow (hybrid, low fuel consumption vehicle):
Rankine
coolant
Exhaustheat
recovery
recuperation
Motor /
Generator
refrigant
Mechanical
Electrical
Thermal
Cabin Temperature
Electric Load
Driving
fuel
Battery
A/C
Heater Core (H/C)
Engine
Elec. Heater(PTC)
distribute the workload between components to heat the cabin in order to achieve real-world (driving, electric and thermal domains) fuel efficiency
3.2 Model Predictive Control for Cabin Heat Thermal Man.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
12 / 16
Manipulate: Some options of engine, Electrical heater, (PTC), Heater Core (H/C)
Observe/Evaluate: Battery, engine, M/G, other electrical and thermal loads
3.2 Model Predictive Control for Cabin Heat Thermal Man.*
� Cabin Heat Problem Covering Range
Manipulated
Observed
Not included
* In collaboration with Prof. A. Bemporad (IMT Lucca) & his team
Rankine
coolant
Exhaustheat
recovery
recuperation
Motor /
Generator
refrigant
Cabin Temperature
Electric Load
Driving
fuel
Battery
A/C
Engine
Elec. Heater(PTC)
Heater Core (H/C)
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
13 / 16
� Control Problem
MPCCabin
Heat
Sys.
u1ym
routput
Complex relations are identified & simplified as linear-time variant (LTV) models
Multi-objective MPC is formulated s.t. LTV prediction models and constraints
For given measurements (ym) and references (r),
manipulate H/C (u1), PTC (u2), and engine power
(u3) to achieve the control objectives:
� heat power reference tracking
� maintaining battery SOC in its limits
� minimizing fuel consumption
u2
u3
� Simulation Results (NEDC, Ambient Temp 5oC)
0 200 400 600 800 1000 12000.3
0.4
0.5
0.6
0.7
0.8Battery SoC [%]
time [s]0 200 400 600 800 1000 12000
0.5
1
1.5
2
2.5
3
Sim Time [s]
He
at P
ow
er
[kW
]
Heat Power Tracking
Fuel savings
w.r.t. baseline:
~ 3%
Benefit:
Better competitiveness
3.2 Model Predictive Control for Cabin Heat Thermal Man.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
14 / 163.3 Fault Tolerant Battery Control in Electrified Vehicles*
� Different Battery Topologies
Type Single String Double String Multi-String
Complexity
Sensitivity to
1-cell failure
fuse
☺ �
� ☺
1 parallel x n series 2 parallel x n series m parallel x n series
improve the reliability of simpler topologies (single string) using
active fault detection and control mechanisms
* In collaboration with Prof. J. Stoustrup (Uni Aalborg) & his team. Published in Safeprocess’12 Conference
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
15 / 163.3 Fault Tolerant Battery Control in Electrified Vehicles
� Software modifications: Active Fault Detection (AFD)
1. State space battery model
Input : current I
Output : voltage Vo
States : voltage across bulk and
surface capacitorsVcb, Vcs
increase the sensitivity of parameter changes
Non-convex optimization problem
4. Compare the estimates with nominal values for fault detection
3. Design the input current signal I
2. Estimate the bulk capacity Cb and the terminal
resistance Rt using Extended Kalman Filter (EKF)
� Results
� Reliability of single-string topology increases with AFD
� Early warning to the driver, before severe failures occur
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE
16 / 164. Outlook
Zero emission, zero fatality
Utilizing advanced
computing technologies Standardization
Challenging control problems tomorrow as a result of increasing complexity & scale
cyber-physical systems, large-scale distributed systems, systems of systems
Vehicle as a component of
system of systems
Absolute fault-tolerance
Information management
DENSO EU Technical Research strategy: support and actively develop the technology together with
diversified EU partners
Secure V2G communication
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.DENSO INTERNATIONAL EUROPE