Neue Entwicklungen in AVL CRUISE und AVL CRUISE M und …

O. Knaus

AVL List GmbH (Headquarters)

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Neue Entwicklungen in AVL CRUISETM

und AVL CRUISETM M und AusblickAVL Germany Simulation Conference 2018

O. Knaus | AVL CRUISE & CRUISE M Product News | 16th Octt 2018 | 2Public

• CRUISE M Vehicle & Driveline

• RDE route generator

• New components: Semi trailer component, Planetary Gear Set and Double Pinion Gear

• CRUISE M Electric

• New Components: DC/DC converter,

• Improvements for E-machine and Battery

• CRUISE M Flow

• Cavitation in Hydraulic

• Pressure Drop Wizard

• CRUISE M Engine & Aftertreatment

• MOBEO Diesel Cylinder & MOBEO EAS Enhancements

• CRUISE M Interfaces & Utilities

• InTime 6.2 Support & Matlab/Simulink dll wrapper

• Data Bus Wizard

System SimulationProduct update CRUISE™ M v2018


▪ It is essential that engineer has a possibility to simulate driving using several RDE compliant driving cycles to assess the solution robustness.

▪ RDE cycles are usually hard to get but with integrated Virtual RDE Route Generator the engineer can easily generate random RDE compliant cycles according to the most recent RDE legislation.

▪ RDE routes are generated instantly in the form of a velocity and a height profile. For visualization purposes, the velocity profile is colored and divided in to three main regimes (the urban, rural and motorway operation).

System SimulationProduct update CRUISE™/ CRUISE™ M v2018

Virtual RDE (Real Driving Emissions) route generator


Visualization of E-Machine efficiency map and relevant data points

▪ CRUISE™ M introduces an enhanced pre-processing methodology supporting the assembly of scattered efficiency maps out of given data for motor and generator operating quadrants.

▪ Both quadrants are filled with additional point using interpolation, physically generated from the appropriate neighboring points.

▪ Extrapolation to zero-torque and speed lines considers the intuitive boundaries of zero efficiency, full load and drag-torque characteristics.


Questionable data

Appropriate data


CRUISE™ M Flow Cavitation in Hydraulic

▪ Cavitation takes place when local pressure drops below the vapor pressure

▪ Observed in components like pumps and pistons

▪ CRUISE™ M v2018 considers cavitation in the volume component like

▪ Expanding a liquid fluid

▪ pressure remains at the vapor pressure level

▪ while a cavitation volume builds up

▪ Compressing the fluid

▪ first the cavitation volume diminishes

▪ before the component pressure rises.

▪ Supports also realtime simulations

▪ stabilizes numerical solution procedures



Pressure Drop Wizard

▪ Fast parameterization of individual components.

▪ Accurate representation of given experimental data

▪ Pressure drop parameterization wizards available for restriction and throttle.

▪ Reference data are from measurement or 3D CFD simulations

▪ Wizard calculates a two-dimensional loss coefficient map

▪ The loss curve is displayed at the end of the parameterization process

▪ The steadiness of the curve and its principle trend gives feedback on provided data



MOBEO Diesel Cylinder Enhancements

New channels for improved diesel cylinder combustion control

▪ Quantity of second early post injection

▪ Timing of second early post injection

▪ Timing of late post injection

New inputs improve the parameterization of the diesel cylinder

▪ Global wall heat loss correction

▪ Post injection wall heat loss correction

▪ Post injection indicated power correction

▪ Gas exchange correction.



Data Bus Wizard

▪ Connecting hundreds of data bus channels can be time consuming.

▪ To ease-up data bus connections a dedicated data bus wizard is introduced which is tailored to speed up and facilitate the often error-prone work of data channel connection.

▪ Wizard offers a clear overview of existing connections which can also be disconnected in an efficient way.

▪ The new data bus wizard reduces the sources of manual mistakes and raises the efficiency in mastering complex models.



• New “share” feature

• Search module extension

• xlsCRUISE support for 64bit MS office

• Support for InTime 6.2

System SimulationProduct update CRUISE™ v2018


Single input data update for identical components - New “share” feature

▪ Within a single vehicle model certain components are completely the same (input parameter wise) like wheels or brakes on same axle. Repetition of loading or entering the same input data can be quite annoying and possibly leading to user errors.

▪ A new “share …” feature enable loading the input parameter data to multiple components within one step improving the usability and speeding up the data input process.

System SimulationProduct update CRUISE™ v2018


• CRUISE M Vehicle & Driveline

• Technical drawings / sketches

• Drawbar trailer

• CRUISE M Electric

• PEM Fuel Cell system model

• New Components (MOS-FET, IGBT, PWM Control)

• CRUISE M Flow

• Vapor–Liquid Equilibrium (VLE)

• Mass Flow Boundary

• CRUISE M Engine

• H2O Injection

• FFT analysis of cylinder and engine data

• Engine Model Generator

• CRUISE M Interfaces & Utilities

• XCP Slave

• and many others like

• New nD Table component

• Multi column map enhancements

• Delete case results

• Reduction of simulation turn-around time

System SimulationProduct outlook CRUISE™ M v2018.1


Technical drawings / sketches

▪ To guide the user and ease up the parameterization of individual components a technical drawings (sketches) have been introduced.

▪ The drawings can optionally be enabled and support the understanding of different input parameters especially in case of more complex component geometries.

▪ Technical Drawings help improving the fast setup models and reduce the potential of wrong parameterizations.



PEM Fuel Cell system model

▪ Within this release CRUISE™ M introduces a physical PEM Fuel cell system model based on analytical polarization curve supporting the following applications:

▪ Concept definition of FCEV(Fuel cell electric vehicle)

▪ Sizing of powertrain systems and core electric vehicle components

▪ Support control function development and vehicle energy management

▪ Re-use of FCEV models on theFuel cell testbed system



Switch, MOS-FET and IGBT with Diode

▪ In v2018.1 release, CRUISE™ M’s electric switch component was extended to a simple MOSFET and IGBT modules simplifying the modelling of detailed inverter configurations.

▪ The switching behaviour depends on the switch signal and the voltage level.

▪ Both MOSFET and IGBT feature an additional thermal model considering the impact of switching losses on the device temperature.



A new PWM (pulse-width modulation)signal generator

▪ It simplifies the setup of the detailed electrical network models for the Inverter and E-machines investigation.

▪ The PWM signals are applied to IGBTsor MOSFETs in DC/AC inverter controlling frequency and magnitude of the voltage, and the current applied to an AC load.

▪ From different PWM schemes such as sinusoidal, hysteretic, space vector, etc. latter one is integrated in this release as the most widely used scheme due to the reduced switching losses and a better utilization of the DC voltage source.



Flow

Vapor–Liquid Equilibrium (VLE)

System SimulationProduct outlook CRUISE™ v2018.1

▪ This new domain supports the simulation of refrigerant circuits e.g. air-conditioning systems.

▪ Essential for energy management system and electric and fuel cell powered vehicles.

▪ Joint development project AVL andTLK-Thermo GmbH.

▪ The media library offers properties for

▪ CO2

▪ Ethanol

▪ Variants of R134, R404, R507

▪ Water

▪ Operating point visualizations directly within the p-h diagram.


Thermodynamic – H2O Injection

▪ New functionality to handle water injection

▪ based on 6-species approach

▪ (initially for dual fuel engine SAE 2014-01-1094)

▪ Water can be injected in gas-path or directly into any cylinder.

▪ Correct treatment of evaporation heat and the thermal properties of water

▪ Allows e.g. to study impact of direct injected water

▪ on peak-firing pressure

▪ temperature

▪ knock



ThermodynamicFFT analysis of cylinder and engine data

▪ Analysis the crank-angle resolved behavior of individual cylinders

▪ FFT (Fast Fourier Transform) is applied on the crank-angle resolved torque signals.

▪ Calculated frequencies, amplitudes, and phases are exposed as data bus channels

▪ Impact of the crank-train optionally on the level of single cylinders

▪ Supports “artificial torque generators” used to excite drivetrain configurations



XCP Slave

▪ A new beta XCP slave feature as a new way to connect CRUISE™ M models using XCP,


the Universal Measurement and Calibration Protocol, standardized by ASAM.

▪ This enables monitoring and actuation of CRUISE™ M plant models out of any tool supporting XCP, such as ETAS INCA or CANape from Vector.

▪ With this new functionality calibration engineers can execute and control virtual CRUISE™ M plants out of the same front ends as they commonly used for calibration of ECU parameters.


Reduction of simulation turn-around time

▪ Latest release provides a major improvement in time needed to prepare the model for simulation.

▪ With a holistic optimization of the process we achieved approx. 10 times faster model preparation which was benchmarked on quite complex models consisting out of more than 1500 components. Enhancement will elevate the user experience when running the huge models case-studies resulting in significantly shorter overall simulation turnaround times.




• New Lifetime task

• Lifetime drive cycles @ load conditions

• Condensed workload diagram for Lifetime

• CRUISE™ Result Viewer utilizing MS Excel

• EU HD CO2 declaration - ACEA

• Loading data from VECTO declaration files

• Shifting logic according to ACEA/VECTO

• Component unique ID

• Presentation diagrams zoom

• Extending EFG to Macros

• Enhanced loading of Favorites

• Enabling Dataset Packages

• Velocity profile reducer



• A new Lifetime task provides relevant durability operating data for the entire component lifetime using a combination of different drive cycles & load conditions

• Result Viewer utilizing MS Excel

582,297,877.64 -48,275,373.42 7.88 428,000.91 33,730.82

Propelling Braking Propelling Braking

WLTC_Class_3a_automatic - Standard | Empty 1,380.00 22,358.55 -1,626.40 6.60 26.50 1,245.43 27,846,023.88 -2,025,568.44 6.60 33,000.18 2,178.01

WLTC_Class_3a_automatic - Standard | Half 1,625.00 25,290.48 -2,054.37 6.91 23.19 1,638.38 41,435,522.34 -3,365,847.31 6.91 38,000.68 2,625.85

WLTC_Class_3a_automatic - Standard | Full 1,870.00 18,976.40 -1,546.57 7.24 22.08 1,222.79 23,204,085.26 -1,891,124.88 7.24 27,000.35 1,954.83

RDE.pro - Standard | Empty 1,380.00 12,469.62 -1,323.55 6.28 20.54 1,071.08 13,355,956.89 -1,417,627.54 6.28 21,999.98 1,381.60

RDE.pro - Standard | Half 1,625.00 14,050.36 -1,619.47 6.70 18.56 1,293.49 18,173,946.40 -2,094,762.05 6.70 24,000.64 1,608.04

RDE.pro - Standard | Full 1,870.00 10,240.83 -1,206.72 7.06 17.97 890.25 9,116,868.10 -1,074,278.85 7.06 16,000.41 1,129.63

NEDC_aut - Standard | Empty 1,380.00 18,028.67 -1,149.41 7.47 13.65 1,831.23 33,014,588.18 -2,104,830.68 7.47 24,999.91 1,867.49

NEDC_aut - Standard | Half 1,625.00 14,828.14 -939.25 8.20 10.92 1,922.79 28,511,375.62 -1,805,979.01 8.20 21,000.69 1,722.06

NEDC_aut - Standard | Full 1,870.00 10,878.37 -806.86 9.95 8.19 1,831.23 19,920,765.40 -1,477,543.86 9.95 14,999.58 1,492.46

NEDC_aut - Standard | Empty 1,380.00 15,546.89 -1,257.48 9.05 9.10 2,746.84 42,704,828.27 -3,454,097.09 9.05 24,999.00 2,262.41

NEDC_aut - Standard | Half 1,625.00 14,807.45 -1,120.22 9.74 8.19 2,685.80 39,769,844.37 -3,008,686.51 9.74 21,999.39 2,142.74

NEDC_aut - Standard | Full 1,870.00 12,381.84 -868.54 11.06 7.28 2,334.81 28,909,299.42 -2,027,879.78 11.06 16,999.78 1,880.18

Ftp75 - Standard | Empty 1,380.00 37,372.98 -3,200.28 7.38 21.42 2,567.55 95,956,871.43 -8,216,868.35 7.38 54,999.42 4,058.96

Ftp75 - Standard | Half 1,625.00 30,909.99 -2,832.49 8.19 17.77 2,532.37 78,275,680.58 -7,172,926.37 8.19 45,000.30 3,685.52

Ftp75 - Standard | Full 1,870.00 31,605.09 -2,747.51 8.70 16.55 2,597.75 82,102,221.50 -7,137,352.70 8.70 43,000.61 3,741.05

Lifetime values

Driving Cycle Name | Load StateEngine Energy [MJ] Fuel Cons.

[l/100km]

Distance

[km]

Fuel Cons.

[l]

Lifetime values per CycleLIFETIME RESULTS

Values per Cycle

Vehicle

Mass

[kg]

Engine Energy

[MJ]

Fuel

Consumption

[l/100km]

Cycle

Distance

[km]

Yearly

Duration

Factor

[-]


• WAT (Workload Analysis Tool) diagram was extended to provide the accumulated diagram over entire lifetime and it is available in Lifetime task

• Additionally Workload Pivot Table can be presented also as normalized table for easier recognition of relative time spent at certain operating conditions



Loading data from VECTO declaration model <xml> files

Shifting logic according to ACEA/VECTO


• EU Heavy Duty commission regulation

• VECTO tool – used for the determination of CO2 emissions and fuel consumption of new heavy-duty vehicles to be sold, registered or put into service in the EU


▪ Visualization of Energy flow, Pie chart and Sankey has been extended and enabled for Macros as stand alone window.

▪ During the EFG results visualization user can now, rather easy take a look inside by clicking on Macro itself.

Extending EFG to Macros


Fuel CellConsumers

Vehicle


• Merging BOOST™ CSand CRUISE™ M

System Simulation


Vehicle modelDrivetrain, Road, Drive cycle

IC Engine Model integration

DriverEngine control

Thermal modelCooling & Lubrication

Electric modelE-Machine, Battery, Network

IC Engine model Air path, Combustion,

Emissions, Aftertreatment

Low & High Pressure Hydraulic One IC engine modeling

tool from office to HiL


Flexible Modelling Depth – Example Pipe

Let us have a look on the exhaust manifold modelling options

Each devlopmentphase may require it‘s specific model depth

Quasidimensional: 1D Species Transport / 1D Pressure

Quasidimensional: 1D Species Transport / 0D Pressure

1D CFD Gasdynamic Pipe (like in BOOST™ CS)

0D Mean Value Model / 0D Crank Angle Resolved


Engine Model Generator


ENGINE MODEL GENERATOR

FUELING - Ports

INTAKE -

Port

s

EXH

AU

ST -

Ports

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