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Copyright © 2016 Hino Motors, Ltd. All rights reserved.
1/15
Development of “Hino MELPHA Plug-in Hybrid bus“
with combination of Existing HIL and TruckMaker
To make the world a better
place to live by helping people
and goods get where they need
to go - safely, economically and
with environmental
responsibility - while focusing
on sustainable development.
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
2/15
Company Information
Company Name Hino Motors, Ltd.
Head Office 3–1–1, Hinodai, Hino-shi, Tokyo, Japan
Employees* 31,020
Products
Touring Coach Low-floor Bus
Heavy-Duty Trucks
HINO700 series
Medium-Duty Trucks
HINO500 series
Light-Duty Trucks
HINO300 series
Medium & Light-Duty Trucks
HINO600 series
Total lineup – Heavy / Medium / Light Duty Trucks and Buses
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
3/15
Sales company
Manufacturing company
Parts Depot company
Sales / Manufacturing company
HINO Motors location
ThailandPhilippines
Malaysia
USA
Taiwan
Australia
Indonesia
Vietnam
Canada
Pakistan
ChinaBelgium
Colombia
Russia
Mexico
About 80 Countries / Areas of Sales (FY2015)
Venezuela
UAE
India
HQ, Hino Plant
Nitta
Plant
Koga Plant
Hokkaido
Memuro
Proving Ground
Ibaraki
Proving
Ground
Hamura
Plant
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
4/15
EV:Short
mileage
FCV:middle
mileage
HV・pHV:Typical Low Emission VehicleLow Emission Diesel:long
mileage
We charge of this domain.
Range of low emission vehicle
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
5/15
Length・Width・Height
8.9m・2.3m・3.0 m
Passengers 32+1(Driver)
GVW 10,765kg
Engine Max 169kW
Motor Max 175kW
Battery 40kWh(Li-ion)
Charging
Normal : AC200V
Rapid : CHAdeMO
Max Speed 70 km/h
Specification of Plug-in Hybrid Bus
Hino Motors started pre-production of the Plug-in Hybrid bus in 2016
External view
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
6/15
Power train system
Specification of Plug-in Hybrid Bus
Drive mode(Hybrid)
Charge
Discharge
Drive mode(EV)
Charge
Discharge
Engine
stopped
Clutch
Disconnect
Clutch
Connect
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
7/15
System of Plug-in Hybrid Bus
CCU
TCU ECU
VCU PHV-ECU
AMTEngine
Clutch
plateMotor
inverterLi-ion
BatteryTransfer
Gear
Additional new devices for PHV-Bus Conventional system
First step : easy to build up HILS utilize already product devices.
To be realization above system is important to build up HILS.
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
8/15
How to build up effective the HILS
1st step: debug of software process
The 1st HILS have to debug huge algorithm of software.
2nd step: calibration of parameters process
The 2nd HILS is necessary to calibrate vehicle parameters.
Target system increases power efficiency and fuel efficiency.
Quicker performance of test maneuvers in
all possible conditions and repetition.
2nd HILS has been improved according to 1st HILS and the
added TruckMaker.
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
9/15
1st HILS for software debug process
CCU
VCUTCU
PHVDriver operation devices
ECUプラントモデル
TransmissionTransmissionTransmission
プラントモデルプラントモデル
Motor / Inverter
TransmissionTransmissionTransmission
プラントモデルプラントモデル
transfer batteryTransmission
Motor/
Inverter
Plant models
Control Desk
Target ECU
specification
coding
Verification on HILS
implementation
revise
・1st HILS description
・Work flow of create software
start
Product ECU
METER
CLUSTER
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
10/15
2nd HILS for calibration of parameters process
CCU
VCUTCU
PHV
ECUプラントモデル
TransmissionTransmissionTransmission
プラントモデルプラントモデル
Motor / Inverter
TransmissionTransmissionTransmission
プラントモデルプラントモデル
transfer batteryTransmission
Motor/
Inverter
Plant models
Additional TruckMaker
Target ECU
・2nd HILS description
Driver
Condition
Road
Data
Target
Vehicle
Speed
input
Acceleration pedal signal
Brake pedal signal
Gear position signalVehicle
speed
Product ECU
METER
CLUSTER
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
11/15
2nd HILS for calibration of parameters process
CCUPHVTruckMaker
Target ECUTarget vehicle speed profile
For Japanese regulation
The field road data profile
Same driver condition
Setting parameters
Result of evaluate
power efficiency
Mo
to
r T
orq
ue
N
m
Motor Speed rpm
Motor T
orque#5 N
m
Motor T
orque#4 N
m
Motor T
orque#3 N
m
Motor T
orque#2 N
m
Motor T
orque#1 N
m
Fuel or electricity
efficiency
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
12/15
2nd HILS for calibration of parameters process
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
13/15
Exemplary results for simulation precision
Shopping plaza
Station A Station B
Route of bus service
Shopping plaza→station A→shopping plaza→station B→shopping plaza
4.5km 4.5km 4.7km 4.7km total 18.4km
Plug-in Hybrid bus stared run service on the field.
Results of comparison : fuel & electricity efficiency.
Field data HILS
Fuel efficiency(km/L)
Field data HILS
Electricity efficiency(kWh/km)
6% 14%
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
14/15
Running of Plug-in Hybrid Bus on the field
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
15/15
Development time efficiency
Develop
Term
1
Month
2
Month
3
Month
4
Month
5
Month
6
Month
7
Month
8
Month
9
Month
Location
of
validation
Validation in the laboratory Validation on the vehicle
Previous
ProcessConsider
system
Specific
ation
Design Debug calibration of parameters General validation
Current
process
Consider
system
Specification→design→HILS
Calibration
of
parameters
General
validation3 months reduction
Stage of create software Stage of Evaluation
Exemplary development schedule for the prototype
Include calibration
Succeeded in reduction of 3 months thanks to
removed calibration process with combination of
Existing HIL and TruckMaker.
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
18/15
Shopping plaza
Station A Station B
3.走行データ解析
Route of bus service
Shopping plaza→station A→shopping plaza→station B→shopping plaza
4.5km 4.5km 4.7km 4.7km total 18.4km
Copyright © 2016 Hino Motors, Ltd. All rights reserved.
19/15
2nd HILS for adaption of parameters process
CCU
METER
CLUSTERVCUTCU
PHVDriver operation devices
ECU
プラントモデル
TransmissionTransmissionTransmission
プラントモデルプラントモデル
Motor / Inverter
TransmissionTransmissionTransmission
プラントモデルプラントモデル
transfer batteryTransmission
Motor/
Inverter
Plant models
Control Desk
Target ECU
specification
coding
Verification on HILS
implementation
revise
HILS description
Work flow for create software
start