1 © Lotus Engineering EVORA 414E HYBRID
1© Lotus Engineering
EVORA 414E HYBRID
© Lotus Engineering
EVORA 414E HYBRID
Steve Doyle
Chief Engineer - Hybrid and Electric Vehicle Integration
February 2011
3© Lotus Engineering
AGENDA – EVORA 414E HYBRID
• Lotus background
• Project overview, aims and timing
• Vehicle Package and System layout
• Specification - Drive system, Battery, Range extender, Cooling systems
• Driver interface and Sound Synthesis
• Safety analysis & Control systems
• Analysis & Performance
4© Lotus Engineering
LOTUS
• HERITAGE
– The 4th most successful Formula 1 team of all time
– 60 year history of iconic sports cars
– A tradition of performance through innovation and great ride & handling
• LOTUS CARS – A DAWN OF A NEW ERA
– New products expanding our range of cars - Esprit (2012), Elan (2013), Elite (2014), New Elise (2015)
– Returning to motorsport - Indycar, GP2, GP3, GT2, GT3, GT4, and LMP2
• LOTUS ENGINEERING MOVING FORWARD
– New engineering technologies for sustainable transport - Range Extender, Omnivore
5© Lotus Engineering
WE UNDERSTAND ENGINEERING FOR PRODUCTION
6© Lotus Engineering
Lotus Engineering Today
Lotus Cars Lotus Engineering
Group Lotus Shareholder: Proton Holdings
Berhad (PROTON)
An automotive engineering consultancy and
advanced technology company
70% of our work is for external clients
7© Lotus Engineering
GLOBAL ORGANISATION
North America
Sales: £9mHeadcount: 85
Southfield, Michigan
Ann Arbor, Michigan
Europe
Sales: £20m
Headcount: 405
Hethel, UK - Headquarters
Germany
Asia
Sales: £23m
Headcount: 145
Kuala Lumpur, MalaysiaShanghai, China
8© Lotus Engineering
LOTUS - CORE COMPETENCIES
Lightweight Architectures
Driving dynamicsEfficient Performance
• Range extender
• Engine control• Omnivore
Electrical and Electronic Integration
Combined Offerings• Whole Vehicle Programmes
• Total Hybrid Drivetrain
LA
Products and Technologies
EEI
Products and Technologies
EP
Pro
ducts
and T
echnolo
gie
sD
D
Pro
ducts
and T
echnolo
gie
s
• Attribute Development• Active Dynamics
• Active Noise Control
• H&EV• HMI systems
• Lotus controllers
• Bespoke Platforms
• Lightweight Concepts• Lotus Platforms
9© Lotus Engineering
• £19 million project supported by a UK Government’s Technology Strategy Board Award
• Project partners
– Lotus Engineering / Infiniti / Jaguar Land Rover – Vehicle design, integration, build and development
– Xtrac – Gearbox development
– Evo Electric – Motor & generator development
– Think – Power Electronics development
– Axeon – Battery development
EVORA 414E HYBRID - PROJECT OVERVIEW
10© Lotus Engineering
EVORA 414E HYBRID – AIMS
• Technology Strategy Board goal
– To develop UK supply base in the EV market place with three car manufacturers.
• OEM Partner Aims
– Lotus - 2 demonstrator vehicles
– Nissan - 2 demonstrator vehicles
– Jaguar Land Rover – 3 to 5 demonstrator vehicles
• Lotus development aims
– Integrated high power inverter, charger, DC/DC and axial flux motor/generator
– A high power, high energy battery pack with a high current draw capability
– Vehicle Control systems integration and torque vectoring control
– Simulated 7 speed paddle shift linked to HALOsonic Internal & External Electronic Sound Synthesis
11© Lotus Engineering
Concept Show car at Geneva Motor show - March 2010
Demonstrator project start - September 2010
Running vehicle planned - August 2011
Project completion - September 2012
EVORA 414E HYBRID - PROJECT TIMING
TaskName
%
Project Start 0%
Design and Procurement 33%
Vehicle design, analysis and procurement 70%
Design freeze 100%
Level 1 APU Programme (see WP4) 35%
HMI programme 30%
HALOSonic sound synthesis 10%
Vehicle build 0%
Vehicle Parts in Place (PIP) 1 (vehicle parts) 0%
Vehicle Parts in Place (PIP) 2 (battery) 0%
Build car 1 0%
Build car 2 0%
Shakedown and commission 2 vehicles 0%
Vehicles built and commissioned 0%
Vehicle Development 0%
01/09
01/04
17/12
22/08
30/12
01/03
19/05
24/05
06/06
16/08
16/08
34 36 38 40 42 44 46 48 50 52 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
' Sep ' Oct '1 Nov ' Dec ' Jan '1 Feb ' Mar ' Apr ' May ' Jun '1 Jul '1 Aug ' Sep ' Oct '1 Nov ' Dec ' Jan '1 Feb ' Mar ' Apr ' May ' Jun '1 Jul '1 Aug '
12© Lotus Engineering
VEHICLE HYBRID SYSTEM INSTALLATION
Hybrid System Installed within current Lotus Evora Vehicle
Package
13© Lotus Engineering
EVORA 414E HYBRID - SYSTEM LAYOUT
Battery Pack
Gearbox
Power Control Unit
DC/DC Converter
Battery Charger
Generator Inverter
Traction Motors
Traction Inverter Modules
Charge Port
Range Extender Engine
14© Lotus Engineering
SPECIFICATION – MOTOR & GEARBOX DRIVELINE
– Drive Motors, 2 x 150kW peak, 500Nm
– Axial flux synchronous motors – High power density / compact design
– Independent rear wheel control – Torque vectoring capability
– Integrated drive Motor / Inverter package
– Gear Box, 4.58:1 (single speed transmission)
– Independent drive to each rear wheel
– Electrically operated park lock
15© Lotus Engineering
SPECIFICATION – HIGH VOLTAGE BATTERY
• Pack details
– Energy 14.8 kWh
– Power 300 kW– Mass 230kg
– Peak Current 1000A
• BMS
– 7 Slave modules, controlled by a master.
– Model based state of Charge estimation.
– Continuous cell balancing– Earth leakage monitoring
• Cell
– Configuration 112 series, 16 parallel.
– Lithium iron phosphate (26650).
– Liquid thermal management.
16© Lotus Engineering
EXTENDED RANGE ELECTRIC VEHICLE – WHY?
• Optimum solution for drivers who typically use their vehicles for short distances but still require
longer range capability
• ‘Range Anxiety’ issue of electric vehicles resolved
• Reduced dependence on an electric charging infrastructure
• In EV mode provides Zero Vehicle Emissions Capability
• Supports Low CO2 Strategies
17© Lotus Engineering
Range Extender Engine
– 1.2 litre, 35 kW, 3 cylinder engine
– Tri fuel - methanol, ethanol or gasoline.
– Aluminium mono block, integrating cylinder block, head & exhaust manifold.
– Close coupled Catalyst
Range Extender Generator
– Axial flux synchronous motor / generator
– 162 kW peak, 54 kW continuous
– 120 Nm nominal torque (240 Nm peak)
– Engine flywheel integrated into generator rotor
– Generator rotor directly mounted to the crankshaft
SPECIFICATION – RANGE EXTENDER
18© Lotus Engineering
SPECIFICATION - COOLING SYSTEMS
This car requires 4 temperature management systems for
• The IC engine cooling (90°C)
• The High Voltage systems cooling (60°C)
– 2 x Motor Invertors
– 2 x Drive motors
– 1 x Generator
– 1 x DC Converter
• HV Battery pack heating and cooling (40°C)
• Cabin HVAC (20°C)
• Each system has a dedicated water pump and radiator
to ensure vehicle operation between -5°C and +30°C.
19© Lotus Engineering
DRIVER INTERFACE AND SOUND SYNTHESIS
Infotainment System
• Typical systems interface (music, video, sat nav etc)
• Hybrid system status, and Halo Sonic Sound Synthesis System set up.
HALOsonic Sound Synthesis
• External sound synthesis for Pedestrian safety
• Internal sound synthesis system providing active feedback and linked to the virtual Gear shift.
Virtual Gear Shift
• Simulated 7 speed paddle shift linked to HALOsonic Internal & External Electronic Sound Synthesis
• Power interrupt / regenerative breaking function to simulate gear change
20© Lotus Engineering
EVORA 414E HYBRID - SAFETY ANALYSIS
• Lotus are developing the application of ISO 26262
(functional safety of road vehicles) to a hybrid vehicle, on
the 414E project.
• Having set safety goals the drive system has been
defined in physical and functional terms out lining the key
interfaces between systems.
• A hazard analysis is then performed using these
interfaces to understand the risks associated with
potential failures.
• Based on operational situations, hazards have been
identified, which have resulted in preliminary ASIL levels
for the vehicle systems
• Similar to a DFMEA, the hazard assessment and risk
analysis has been guiding systems design.
Vehicle cooling system
Vehicle 12V system
T ransmissi on park lock
Vehicl e hydraul ic
braki ng system
EDS developm ent
test equipm ent
Vehicle im mobiliser
Cabi n HVAC
Driver interface system
Calibration test equipment
M ai ntenance personnel
Vehi cle st ructure
Vehicle imm obil iser wiring
Vehic le c oola nt inlets
Vehicle coolant outlets
Coola nt pump & fa n wiring
Cooli ng system temp sensor wiring
12V power ha rness
fix ings
Ma nua l ha ndling
Vehicle CAN bus
Powertrain CAN bus
On-board charger, charge
port
Cha rging connection
H V ba ttery cha rg e
Monitoring da ta
Diag nostic da ta
12V electri cal power
Control of vibration
Secure EDS
Vehicl e a ctiva ti on
D ri ver i nterfa ce wiring
D ri ver i nput
( inc E -stop)
Accelera ti on demand
Vehicle CAN bus
Wheel speeds x 4
Range extender
H igh volta ge wiri ng
Powertra in CAN bus
HV power
Power dem andEna ble/disa ble
Exter nal
Environment
EM em issions
EM interferenc e
Dust, water, salt
Heat
Crash sensorCra sh sensor wiring
Vehicle crash occ urred
HV power
Vehicle Dynamic
System
HV BatteryPack
Traction Drive
System
Electric Drive System
Lotus Vehicle Controller
Wa ste heatCoola nt tem perature
Cooling dema nd
Pa rk lock wiring
Pa rk lock a ctiva tion
RS 232
Prog ra mming da ta
Config ura tion data
sound
cold
Cha rge fl ap open, c able connected
HV power
HVAC control
Cabin tem perature
Aircon/hea ter disable
Hig h v olta ge wiring
HVAC control wiring
Tem p sensor wi ring
Steering System S teering ang le
Vehic le CAN bus
Physi cal interfa ce
Func ti ona l interface
High v ol ta ge wiring
Cha rge, drive ena bl e/disa ble
DC/DC
Hig h voltag e wiring
Park loc k position
Control wiringDC/DC c ontrol
HV power
Cha rg e sta rt/stop swi tc h
Vehicle cooling system
Vehicle 12V system
T ransmissi on park lock
Vehicl e hydraul ic
braki ng system
EDS developm ent
test equipm ent
Vehicle im mobiliser
Cabi n HVAC
Driver interface system
Calibration test equipment
M ai ntenance personnel
Vehi cle st ructure
Vehicle imm obil iser wiring
Vehic le c oola nt inlets
Vehicle coolant outlets
Coola nt pump & fa n wiring
Cooli ng system temp sensor wiring
12V power ha rness
fix ings
Ma nua l ha ndling
Vehicle CAN bus
Powertrain CAN bus
On-board charger, charge
port
Cha rging connection
H V ba ttery cha rg e
Monitoring da ta
Diag nostic da ta
12V electri cal power
Control of vibration
Secure EDS
Vehicl e a ctiva ti on
D ri ver i nterfa ce wiring
D ri ver i nput
( inc E -stop)
Accelera ti on demand
Vehicle CAN bus
Wheel speeds x 4
Range extender
H igh volta ge wiri ng
Powertra in CAN bus
HV power
Power dem andEna ble/disa ble
Exter nal
Environment
EM em issions
EM interferenc e
Dust, water, salt
Heat
Crash sensorCra sh sensor wiring
Vehicle crash occ urred
HV power
Vehicle Dynamic
System
HV BatteryPack
Traction Drive
System
Electric Drive System
Lotus Vehicle Controller
Vehicle Dynamic
System
Vehicle Dynamic
System
HV BatteryPack
HV BatteryPack
Traction Drive
System
Traction Drive
System
Electric Drive System
Lotus Vehicle ControllerLotus Vehicle Controller
Wa ste heatCoola nt tem perature
Cooling dema nd
Pa rk lock wiring
Pa rk lock a ctiva tion
RS 232
Prog ra mming da ta
Config ura tion data
sound
cold
Cha rge fl ap open, c able connected
HV power
HVAC control
Cabin tem perature
Aircon/hea ter disable
Hig h v olta ge wiring
HVAC control wiring
Tem p sensor wi ring
Steering System S teering ang le
Vehic le CAN bus
Physi cal interfa ce
Func ti ona l interface
Physi cal interfa ce
Func ti ona l interface
Physi cal interfa ce
Func ti ona l interface
High v ol ta ge wiring
Cha rge, drive ena bl e/disa ble
DC/DC
Hig h voltag e wiring
Park loc k position
Control wiringDC/DC c ontrol
HV power
Cha rg e sta rt/stop swi tc h
Vehicle cooling system
Vehicle 12V system
T ransmissi on park lock
Vehicl e hydraul ic
braki ng system
EDS developm ent
test equipm ent
Vehicle im mobiliser
Cabi n HVAC
Driver interface system
Calibration test equipment
M ai ntenance personnel
Vehi cle st ructure
Vehicle imm obil iser wiring
Vehic le c oola nt inlets
Vehicle coolant outlets
Coola nt pump & fa n wiring
Cooli ng system temp sensor wiring
12V power ha rness
fix ings
Ma nua l ha ndling
Vehicle CAN bus
Powertrain CAN bus
On-board charger, charge
port
Cha rging connection
H V ba ttery cha rg e
Monitoring da ta
Diag nostic da ta
12V electri cal power
Control of vibration
Secure EDS
Vehicl e a ctiva ti on
D ri ver i nterfa ce wiring
D ri ver i nput
( inc E -stop)
Accelera ti on demand
Vehicle CAN bus
Wheel speeds x 4
Range extender
H igh volta ge wiri ng
Powertra in CAN bus
HV power
Power dem andEna ble/disa ble
Exter nal
Environment
EM em issions
EM interferenc e
Dust, water, salt
Heat
Crash sensorCra sh sensor wiring
Vehicle crash occ urred
HV power
Vehicle Dynamic
System
HV BatteryPack
Traction Drive
System
Electric Drive System
Lotus Vehicle Controller
Wa ste heatCoola nt tem perature
Cooling dema nd
Pa rk lock wiring
Pa rk lock a ctiva tion
RS 232
Prog ra mming da ta
Config ura tion data
sound
cold
Cha rge fl ap open, c able connected
HV power
HVAC control
Cabin tem perature
Aircon/hea ter disable
Hig h v olta ge wiring
HVAC control wiring
Tem p sensor wi ring
Steering System S teering ang le
Vehic le CAN bus
Physi cal interfa ce
Func ti ona l interface
High v ol ta ge wiring
Cha rge, drive ena bl e/disa ble
DC/DC
Hig h voltag e wiring
Park loc k position
Control wiringDC/DC c ontrol
HV power
Cha rg e sta rt/stop swi tc h
Vehicle cooling system
Vehicle 12V system
T ransmissi on park lock
Vehicl e hydraul ic
braki ng system
EDS developm ent
test equipm ent
Vehicle im mobiliser
Cabi n HVAC
Driver interface system
Calibration test equipment
M ai ntenance personnel
Vehi cle st ructure
Vehicle imm obil iser wiring
Vehic le c oola nt inlets
Vehicle coolant outlets
Coola nt pump & fa n wiring
Cooli ng system temp sensor wiring
12V power ha rness
fix ings
Ma nua l ha ndling
Vehicle CAN bus
Powertrain CAN bus
On-board charger, charge
port
Cha rging connection
H V ba ttery cha rg e
Monitoring da ta
Diag nostic da ta
12V electri cal power
Control of vibration
Secure EDS
Vehicl e a ctiva ti on
D ri ver i nterfa ce wiring
D ri ver i nput
( inc E -stop)
Accelera ti on demand
Vehicle CAN bus
Wheel speeds x 4
Range extender
H igh volta ge wiri ng
Powertra in CAN bus
HV power
Power dem andEna ble/disa ble
Exter nal
Environment
EM em issions
EM interferenc e
Dust, water, salt
Heat
Crash sensorCra sh sensor wiring
Vehicle crash occ urred
HV power
Vehicle Dynamic
System
HV BatteryPack
Traction Drive
System
Electric Drive System
Lotus Vehicle Controller
Vehicle Dynamic
System
Vehicle Dynamic
System
HV BatteryPack
HV BatteryPack
Traction Drive
System
Traction Drive
System
Electric Drive System
Lotus Vehicle ControllerLotus Vehicle Controller
Wa ste heatCoola nt tem perature
Cooling dema nd
Pa rk lock wiring
Pa rk lock a ctiva tion
RS 232
Prog ra mming da ta
Config ura tion data
sound
cold
Cha rge fl ap open, c able connected
HV power
HVAC control
Cabin tem perature
Aircon/hea ter disable
Hig h v olta ge wiring
HVAC control wiring
Tem p sensor wi ring
Steering System S teering ang le
Vehic le CAN bus
Physi cal interfa ce
Func ti ona l interface
Physi cal interfa ce
Func ti ona l interface
Physi cal interfa ce
Func ti ona l interface
High v ol ta ge wiring
Cha rge, drive ena bl e/disa ble
DC/DC
Hig h voltag e wiring
Park loc k position
Control wiringDC/DC c ontrol
HV power
Cha rg e sta rt/stop swi tc h
Electric Drive SystemNo function Reduced function Over Function Intermittent function Unintended function
Driver interface system
Driver interfac e wiring P
Torque dem and F Zero torque demand Car slow Car too fas t Car dangerous/ uncontro llable
N/A S econd independent s ignal
E-stop F Emergenc y shut-down not possib le
On/off, therefore N/A On/off, therefore N/A E -stop latches, theerefore N/A
False e-stop
Sport/Ec o swi tch F No mode change On/off, therefore N/A On/off, therefore N/A S witch to wrong m ode Get wrong mode
Drive mode s ignal P F Car won't go into park On/off, therefore N/A On/off, therefore N/A S witch to wrong m ode Get wrong mode
Drive mode s ignal R F Car won't go into rever se On/off, therefore N/A On/off, therefore N/A S witch to wrong m ode Get wrong mode
Drive mode s ignal N F Car wont go into neutra l On/off, therefore N/A On/off, therefore N/A S witch to wrong m ode Get wrong mode
Drive mode s ignal D F Car won't go into drive On/off, therefore N/A On/off, therefore N/A S witch to wrong m ode Get wrong mode
Igni tion barr el - key in F N/A N/A N/A N/A N/A
Igni tion barr el - ac cess ories F Can't pr ogress to igni tion N/A N/A
Igni tion barr el - igni tion F N/A N/A
Igni tion barr el - crank F HV sys tem not activiated N/A N/A
HMI F
Cabin HVAC
High Voltage wiring P
HVAC control wiring P
Cabin he ati ng, ventila ti on a nd air-condi tio ning. Hea tin g a nd A/C is provi ded by a n e lectri c hea ter and ele ctric comp re sso r, both run ning off th e HV
circuit.
The drive r interface system rel ays driver inp uts to the appropri ate system in th e veh icle, via ha rd wi ri ng
21© Lotus Engineering
EVORA 414E HYBRID - CONTROLS SYSTEMS
Concept: Control Systems separated into three
interdependent Controllers:
Vehicle Controller
– Energy, Power and Torque
Management
– Driver & Vehicle Interfaces
Vehicle Dynamics Controller
– Control Torque Split modes
– Dedicated Private CANbus
Safety Controller
– Functional Safety monitoring
– Parameter Error and Validation checking
22© Lotus Engineering
EVORA 414E HYBRID - CANBUS ARCHITECTURE
Multiple CANbus Networks:
• TV-CANbus: Dynamic Control Signals to Power Inverters
• SF-CANbus: Monitoring Dynamic controller & ESP sensors
• VH-CANbus: HV Systems, Comfort, Info & Steering
• PT-CANbus: Range Extender & Generator
23© Lotus Engineering
EVORA 414E HYBRID - SOFTWARE
Modular Vehicle & Dynamic Control Software
The software is split into modular functions which are implemented in Simulink Models and
/or application C code.
Simulation Software (Lotus RAVEN and IPG CarMaker) is used for:
– Vehicle Dynamic response to simulated Motor Faults
– Develop Algorithms for Electronic Differential modes
Independent Safety Control Software
– Alternative Implementation of Strategy for functional safety monitoring
– Focused on verifying Current output signal, Wheel Lock and Torque Feedback.
– Monitoring the CANbus (Watchdogs, Checksum and Rolling Counters)–
The software modules are validated
– Separately
– As part of Software in the Loop (SIL)
– As part of Hardware in the Loop (HIL) test rigs or in the Vehicle
24© Lotus Engineering
Lotus Vehicle Simulation - LVS
• EV and Series hybrid modelling and simulation
• Model based design of Vehicle applications and
electric architecture built within a Simulink
environment
• Energy management concepts defined early in
programmes
• Concept EV/HEV electrical device sizing and
confirmation of programme targets at the concept
stage
– EV range
– EV launch acceleration times
– Vehicle maximum speeds
– Energy used over wide range of drive-cycles
– Drive-cycle CO2 predictions for HEVs
– Battery SoC investigations
– HEV control strategies for economy or
performance
0 100 200 300 400 500 600 700 800 900 100096
96.5
97
97.5
98
98.5
99
99.5
100
time, s
Battery State of Charge, %
FTP Cycle
25© Lotus Engineering
EVORA 414E HYBRID - PERFORMANCE
• Predicted Vehicle Performance
– 0-60 mph <4 Secs
– Electric only range 35 miles (Total hybrid range 300 Miles)
– EV max speed: 130mph (Charge sustaining 60mph)
– CO2 emission 55g/km (ECE-R101 test schedule)
26© Lotus Engineering
Chassis/Body Structure
Re-engineer for EV components
StructuralCrashworthiness
Range Extender
Required power at wheelsCharge depleting / sustaining
Drive cycle‘Range’ definition
NVH
MotorEngine
Exterior
Battery Management (BMS)
Battery pack conditioningBattery pack charging
Usually supplier recommended
ControlsHEV controller sits above other
controllers:Motor
EngineTransmission
HVACStop/start
Etc…etc…
Motor TechnologiesAC / DC
Brush / brushlessInboard
Wheel motorGenerator
Regenerative braking
EVORA 414E HYBRID
Battery
Cell TechnologyCharacteristics
‘Quick-release’ pack
Cooling SystemsMotor
Power electronicsBattery
IC Engine
Driving DynamicsRide & Handling
Performance tuning
UltraCapacitors
Torque assistPeak current buffer
Battery charging
Charge ratesDomestic charging
Infrastructure charging
Vehicle SystemsBrakes
Balancing friction brakes with regenerative braking
Power steeringHVAC
In-car display
• A Platform for Whole Vehicle Integration Development
© Lotus Engineering
THANK YOU
If you require further information please contact:
Steve Doyle
Tel: +44 (0)1953 608561 E-mail: [email protected]
WWW.LOTUSCARS.COM/ENGINEERING