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Software development in an electric vehicle:
the TU/e Lupo EL
ir. Paul van OorschotMechanical Engineering, Dynamics and Control
October 3, 2011, Eindhoven
PAGE 1
TU/e Lupo EL
• picture + specs
PAGE 2
Donor vehicle: VW Lupo 3LVehicle mass: 1060 kg Battery capacity: 27 kWhTop speed: 130 km/hRange: up to 200km, 170km@100km/h0 – 100 km/h: 12 sec.4 seats
Carrying energy in batteries
energy density• batteries
weight: 273 kgvolume: 180 literscapacity: 27 kWh
• equivalent fossil fuel: 10 L petrol (8 kg), 7 L diesel (6 kg)
energy flow• normal fuel pump: 40 L/minute
• normal socket (Europe: 3.6 kW): approx. 1.5 L petrol/hour (1600x slower)
• DC fast charging (50 kW, CHAdeMO): approx. 20 L petrol/hour (120x slower)
PAGE 3
System overview
PAGE 4
Chassis 598 kg
ICE = 239 kgFocus points:
• Lightweight• Efficient• Flexible control• Extensive measurement abilities
Electric vehicle system diagram
Packaging
PAGE 5
• No interior space lost
• Weight distribution improved
Front compartment
PAGE 6
Aluminium mounting and battery box design
Charger
Inverter
DC-DC 12V
Controller
IFM CR0232 PLC
80x IO ports
4x CAN bus
Electric system layout
PAGE 7
VW systems fully functional (CAN)
PAGE 8
Controller
IFM CR2032, Industrial PLC• Infineon TriCore 1796, 32 bit CPU, 150 Mhz• 32 Inputs (analog/digital)• 48 Outputs (PWM, high/low side, current controlled)• 4 CAN bus interfaces (2.0 A/B, up to 1Mbit/s)
Software• CoDeSys v2.3 software development platform• IEC 61131-3 based, following languages available
• Instruction list (IL)• Structured text (ST)• Ladder diagram (LD)• Function block diagram (FBD)• Sequential function chart (SFC)
Control and safety features
PAGE 9
ABS active ? -> Disable regenerative braking
Airbags(crash) -> Disable systems and HV
Door opened ?• Initialize safety systems• Isolation monitoring• Brake booster vacuum
Data Aquisition
PAGE 10
Real-time logging via CAN bus
Extensive data on:• Energy flows• Battery condition• Vehicle dynamics
PAGE 11
PLC cycle setup
Cycle time ≈ 7 ms
Inputs read, values determined> 50 CAN identifiers> 200 parameters stored in structs
Sequential function execution• Functions in order of priority• Higher priority overrides
Outputs temporarily stored• Outputs sent at end of cycle
PAGE 12
Traction
Enable traction (start the vehicle)
Traction control
PAGE 13
Regenerative braking
Brake pressure
Current limit
Regenerative braking control• Based on brake system pressure• Torque controlled (better brake blending)
User interface
PAGE 14
Original VW console Touchscreen computer• Energy flows to components• Measured data per component• Errors and warnings• Charging control
Battery SOC
Power (-30 to +50 kW)
Energy consumption
Speed
Visual and audible indication• Ready to drive• Traction enabled while door open• System errors• HV disabled
Thank you for your attention!
PAGE 15
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