EVORA 414E HYBRID - FH Joanneum · – Engine flywheel integrated into generator rotor ... Vehicle CAN bus Powertrain CAN bus On-board charger, charge ... 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


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


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


WE UNDERSTAND ENGINEERING FOR PRODUCTION


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


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


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


• £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


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


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 '


VEHICLE HYBRID SYSTEM INSTALLATION

Hybrid System Installed within current Lotus Evora Vehicle

Package


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


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


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.


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


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


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.


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


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 12V system


Vehicl e hydraul ic

braki ng system

EDS developm ent

test equipm ent


Cabi n HVAC




Vehi cle st ructure






12V power ha rness

fix ings

Ma nua l ha ndling

Vehicle CAN bus

Powertrain CAN bus


port



Monitoring da ta

Diag nostic da ta



Secure EDS



D ri ver i nput

( inc E -stop)


Vehicle CAN bus

Wheel speeds x 4

Range extender


Powertra in CAN bus

HV power


Exter nal

Environment

EM em issions

EM interferenc e

Dust, water, salt

Heat



HV power

Vehicle Dynamic

System

HV BatteryPack

Traction Drive

System



Vehicle Dynamic

System

Vehicle Dynamic

System

HV BatteryPack

HV BatteryPack

Traction Drive

System

Traction Drive

System


Lotus Vehicle ControllerLotus Vehicle Controller


Cooling dema nd

Pa rk lock wiring


RS 232

Prog ra mming da ta


sound

cold


HV power

HVAC control

Cabin tem perature



HVAC control wiring



Vehic le CAN bus









DC/DC


Park loc k position


HV power



Vehicle 12V system


Vehicl e hydraul ic

braki ng system

EDS developm ent

test equipm ent


Cabi n HVAC




Vehi cle st ructure






12V power ha rness

fix ings

Ma nua l ha ndling

Vehicle CAN bus

Powertrain CAN bus


port



Monitoring da ta

Diag nostic da ta



Secure EDS



D ri ver i nput

( inc E -stop)


Vehicle CAN bus

Wheel speeds x 4

Range extender


Powertra in CAN bus

HV power


Exter nal

Environment

EM em issions

EM interferenc e

Dust, water, salt

Heat



HV power

Vehicle Dynamic

System

HV BatteryPack

Traction Drive

System




Cooling dema nd

Pa rk lock wiring


RS 232

Prog ra mming da ta


sound

cold


HV power

HVAC control

Cabin tem perature



HVAC control wiring



Vehic le CAN bus





DC/DC


Park loc k position


HV power



Vehicle 12V system


Vehicl e hydraul ic

braki ng system

EDS developm ent

test equipm ent


Cabi n HVAC




Vehi cle st ructure






12V power ha rness

fix ings

Ma nua l ha ndling

Vehicle CAN bus

Powertrain CAN bus


port



Monitoring da ta

Diag nostic da ta



Secure EDS



D ri ver i nput

( inc E -stop)


Vehicle CAN bus

Wheel speeds x 4

Range extender


Powertra in CAN bus

HV power


Exter nal

Environment

EM em issions

EM interferenc e

Dust, water, salt

Heat



HV power

Vehicle Dynamic

System

HV BatteryPack

Traction Drive

System



Vehicle Dynamic

System

Vehicle Dynamic

System

HV BatteryPack

HV BatteryPack

Traction Drive

System

Traction Drive

System


Lotus Vehicle ControllerLotus Vehicle Controller


Cooling dema nd

Pa rk lock wiring


RS 232

Prog ra mming da ta


sound

cold


HV power

HVAC control

Cabin tem perature



HVAC control wiring



Vehic le CAN bus









DC/DC


Park loc k position


HV power


Electric Drive SystemNo function Reduced function Over Function Intermittent function Unintended function


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


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


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


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


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


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)


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

EVORA 414E HYBRID - FH Joanneum · – Engine flywheel integrated into generator rotor ... Vehicle CAN bus Powertrain CAN bus On-board charger, charge ... EVORA 414E HYBRID

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EVORA 414E HYBRID - FH Joanneum · – Engine flywheel integrated into generator rotor ... Vehicle CAN bus Powertrain CAN bus On-board charger, charge ... EVORA 414E HYBRID