ELIN
efficient ELectric drive INverter control
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
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The Automotive challenge
Mechanics
Power
Electronics
Automotive
mechatronics
Power
Mechatronics
engineering
Volvo Car Group – Green, safe, premium cars!
Climate change; new legislations (often regional) …
Exponential increase of software in cars…
“80% of all new innovations in automotive are software”
Modern cars are product lines of complex distributed
software in moving, safety critical, (high voltage)
volume mechatronics.
Software
A trinity for sustainable automotive business!?
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
ELIN
Create a research and development platform in the
context of electric drive, to achieve
1. more efficient electric propulsion and
2. more efficient development of electric propulsion
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Software Center
Mission: Improve the software engineering capability of the
Nordic Software-Intensive industry with an order of
magnitude
Theme: Fast, continuous deployment of customer value
Success: Academic excellence
Success: Industrial impact
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
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Background: The Automotive challenge
Working with embedded software? Then you are
20 years behind!?
Why?
A modern premium car can have about 100 ECUs
(embedded computers) working in a complicated
network
So, the system is not 20 years behind! Can we solve this?
What will be required in the (near) future?
How fast must we get?
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
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R&D on mechatronics
ELIN: allow research and development on the
same platform!
Make software developers out of domain experts!
VCC invest in MDE
Researchers
To learn about and
develop on a system,
we must control the
software!
VCC invest in in-house Developers
development
Software
models
Controller
(ECU)
Power supply,
Network,…
Plant
Models
Environment
models
Device
Supplier(s)
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
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ELIN, piece for piece
VCC: engineering and demonstration vehicle
Construction of control software in-house (enabler for more advanced
control), construction of test vehicle with new inverter.
- Model driven development
- Inverter ECU construction (DSPACE environment with quasi AUTOSAR
platform)
- HIL-test
- Mechanical construction and test (one V60-hybrid is modified)
CTH: research and rig test
Applied research on motor control
- Model driven research (sharing models!)
- PWM algorithm design for efficient drive
- Rig construction and test
- Noise measurements etc.
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
4 triax for
blocked
force
8 mics for
Lw
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ELIN, status
2014-10-08
We have a 10 month delay. ELIN will finish in summer 2016
Andreas (PhD candidate) has published 2 papers [1,2] and built
one lab rig. Hence, great progress at CHT.
Niklas (VCC engineer) has developed an AUTOSAR application
layer for the ELIN-inverter. So far only tested in MIL (model based)
and currently being tested in HIL (picture).
We have struggled a lot with choosing inverter for ELIN, Tier1:s do
not always see benefits in this kind of research…
Solution: we use a dSPACE rapid prototyping-ECU and place this
in the car combined with a new inverter hardware.
The demonstrator (vehicle) is currently being tested. The
dSPACE ECU is on line, but the inverter and integration in the car
remains. Thus, good progress at VCC (according to plan)
Rig test -10
kHz, 20 Nm
Road test upwards driving
0-20 km/h
1) An Analysis of Inverter Switching Loss Minimization Based On Discontinuous
PWM for a Salient-pole PMSM, EPE2014, Lappeenranta, Finland
2) Inverter Losses Minimization Using Variable Switching Frequency Based On
Multi-objective, ICEM2014, Berlin, Tyskland
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
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ELIN, future work (2015)
Continuous Integration!!
•
•
CTH: a new inverter will be finalized
VCC: when finished, the new inverter is integrated in the ELIN
vehicle
When the hardware integration is done, continuous integration is
possible, both for CTH and VCC! Updates and new ideas can be
tested [verified] almost without any delay.
Some help will be appreciated from a VCC CI team.
•
•
CTH: continued development of the inverter control software
CTH: continued research on PWM pattern optimization vs noise,
etc.
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
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Notes
In line with R&D
•
•
ELIN sw is developed exactly as the in-house AUTOSAR software
in VCCs current projects.
However, ELIN can be used to test more advanced MDE, more
advanced Continuous Integration, etc.
This is extremely valuable to VCC, and links to other research
(several projects within Software center)
Learning advanced industrial software control development
• The CTH control software (algorithms) is developed in any way,
and goes deeper (closer to hardware) than VCC is usually
developing software.
Integrating this in a real vehicle is a way for both CTH and VCC to
learn how to optimize deeper, more holistic.
This is an enabler for new innovations.
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
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thanks!
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
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The Model Driven process
Re-invent the classical V-model!
High level
reqs.
System
System
MIL
HIL short loop 24h
System design tool
(database)
MIL
(SIL)
RIG
CAR test
HIL
ECU
Architecture
ECU integration
Simulink
code
gen
Simulink & Simscape
SW Component
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
SW
Design
Unit
test
Developed by Tier1 from
requirements
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… and in real life
Vehicle
ready!
ECU
ready!
High level
reqs.
System
RIG
CAR
test
System design tool
(database)
HIL
(continuous ECU-integration
possible)
Vehicle
integrations
ECU
ECU
integrations
Simulink & Simscape
SW Component
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
SW
Design
HW Assumptions made
Assumptions verified
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A use case: developing dog
clutch control software
function developers
CAE developers
Auto generated
AUTOSAR ECU model
test
developers
model
reference
library
Plant model (Simscape DSL)
Test bench
(combined with test tool)
ELIN 2014, Jonn Lantz, jonn.lantz@volvocars.com
automated
regression test
Results:
Although the first versions of the clutch model had
numerous faulty assumptions, these where easy to
correct – since the developers now understood the
system! (U. Eliasson et. al. MODELS 2014)
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