ELIN efficient ELectric drive INverter control

1. ELINefficientELectric drive INvertercontrol

2. The Automotive challenge Mechanics Power Electronics 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 Automotivemechatronics Power engineering Mechatronics ELIN Create a research and development platform in the context of electric drive, to achieve • more efficient electric propulsion and • more efficient development of electric propulsion A trinity for sustainable automotive business!?

3. 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

4. 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 yearsbehind! Canwesolvethis? Whatwill be required in the (near) future? Howfast must we get?

5. 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 development Software models PlantModels Developers Controller (ECU) Environment models Power supply, Network,… Device Supplier(s)

6. 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. 4 triax for blocked force 8mics for Lw

7. 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 upwardsdriving 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

8. 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.

9. 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.

10. thanks!

11. The Model Driven process Re-invent the classical V-model! Highlevel reqs. System MIL ContinuousDeployment short loop System RIG CAR test SW ECU MIL (SIL) Plant models System design tool (database) MIL-SIL short loop 1h HIL short loop 24h SYS/MECH HIL ECU Architecture Simulink ECU integration code gen Simulink& Simscape SW Design Unit test Developed by Tier1 from requirements SW Component

12. … and in real life Vehicle ready! ECU ready! Highlevel reqs. CAR test System RIG SW ECU System design tool (database) Plant models Vehicle integra- tions SYS/MECH HIL (continuous ECU-integration possible) ECU ECU integrations Simulink& Simscape SW Design SW Component HW Assumptionsmade Assumptionsverified

13. A use case: developing dog clutch control software functiondevelopers CAE developers Auto generated AUTOSAR ECU model model reference library Plant model (Simscape DSL) test developers Test bench (combined with test tool) Results: Although the first versions of the clutch modelhad numerous faulty assumptions, these where easy to correct – since the developers now understood the system! (U. Eliasson et. al. MODELS 2014) automated regression test