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EVS28 Korea, May 3-6, 2015
Model based adaptive controller
design and optimization for (L7)
electric vehicle
Chih-Ming Chang1, Kuang-Shine Yang2 EV Running Chassis , Metal Industries Research & Development Center,
1001 KAONAN HIGHWAY, KAOHSIUNG,TAIWAN 81160, Taiwan
Introduction (I)
I.
1.
2
Battery and BMS System
On-Board Charger
GearBox
Motor Drive
IM Motor
DC-DC Converter
Dry Double Pistons Vacuum Pump
3
Introduction (II)
SPEC.
4
Motor Performance Characteristic Target
L7-REEV-Vehicle Weight 480kg
0
10
20
30
40
50
60
70
80
0 1000 2000 3000 4000 5000 6000 7000 8000
Speed(rpm)
Tor
que(
N.m
)
0.0
2.5
5.0
7.5
10.0
12.5
15.0
17.5
20.0
Pow
er(k
W)
Tv-cruise Tm-peak Tm-con
Pv-cruise Pm-peak Pm-con
Motor Performance Target vs Vehicle Loading
L7-REEV-Vehicle Weight 480kg
0%
5%
10%
15%
20%
25%
30%
0
10
20
30
40
50
60
70
80
0 10 20 30 40 50 60 70 80 90
Vehicle Speed(kph)
Tor
que
@ M
otor
Sha
ft (
N.m
)
0
3
6
9
12
15
18
21
24
Acc
. Tim
e(se
c)
Tm-peak Tm-con
Tm-RE Acc. Time
Motor Performance Characteristic Target
L7-REEV-Vehicle Weight 480kg
0
10
20
30
40
50
60
70
80
0 1000 2000 3000 4000 5000 6000 7000 8000
Speed(rpm)
Tor
que(
N.m
)
0.0
2.5
5.0
7.5
10.0
12.5
15.0
17.5
20.0Po
wer
(kW
)
Tv-cruise Tm-peak Tm-con
Pv-cruise Pm-peak Pm-con
Motor Performance Target vs Vehicle Loading
L7-REEV-Vehicle Weight 480kg
0%
5%
10%
15%
20%
25%
30%
0
10
20
30
40
50
60
70
80
0 10 20 30 40 50 60 70 80 90
Vehicle Speed(kph)
Tor
que
@ M
otor
Sha
ft (
N.m
)
0
3
6
9
12
15
18
21
24
Acc
. Tim
e(se
c)
Tm-peak Tm-con
Tm-RE Acc. Time
5
Schematic Circuit
EV-L7 Control System
L7-xEV Battery System Structure
6
Battery System (BS)
Battery Management System (BMS)
Battery Pack
Battery Control Unit (BCU)
SOC/SOA/Safety/Power M’ment
…
Module #1
(BMU#1)
Packaging / Structure / Cooling / Sealing / Isolating / Vent
…
Tem
p.
Volt
In-Battery Network
Power Circuit HV
System
12V
Power
EV
Network
4~8-Cell-In-Series
Module #..
(BMU#..)
Module #n
(BMU#n)
4~8-Cell-In-Series 4~8-Cell-In-Series
Tem
p.
Volt
Tem
p.
Volt
Safety Detection
Control Circuit
Power Measurement
Cell
Module
Pack
Control
System
Battery Cell CHG Test @ 5C-0.2C
7
Battery Cell DCHG Test @ 5C-0.2C
8
9
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
73.00
73.50
74.00
74.50
75.00
75.50
76.00
76.50
77.00
77.50
78.00
78.50
79.00
79.50
80.00
80.50
0:00
:01
0:01
:54
0:03
:47
0:05
:40
0:07:33
0:09
:26
0:11
:19
0:13
:12
0:15
:05
0:16
:58
0:18
:51
0:20
:44
0:22
:37
0:24:30
0:26:23
0:28
:16
0:30
:09
0:32
:02
0:33
:55
0:35
:48
0:37
:41
0:39
:34
0:41
:27
0:43:20
0:45
:13
0:47
:06
0:48
:59
0:50
:52
0:52
:45
0:54
:38
0:56
:31
0:58
:24
1:00:17
1:02
:10
1:04
:03
1:05
:56
1:07
:49
1:09
:42
1:11
:35
1:13
:28
1:15
:21
1:17
:14
1:19:07
1:21
:00
1:22
:53
1:24
:46
1:26
:39
1:28
:32
1:30
:25
1:32
:18
1:34
:11
1:36:04
1:37
:57
1:39
:50
1:41
:43
VOLTAGE(V) CURRENT(A) ACCMAH(Ah)
MIRDC L7 Battery PACK DCHG TEST(1/2C,50A)
10
CELL_1~24 DCHG CURVE(I=50A)
11
CELL_1~24 CHG CURVE(I=25A)
Battery Pack Spec.
12
Type -Supplier: Lithium Iron Phosphate Oxide Battery
Battery Capacity(Ah): 7.86kWh(0~100% SOC)
Voltage Range(Volt): 87.6V~53V (Normal: 76.8V)
Battery Configuration: 2P-24S
Peak Power(kW): 76.8kW (300Sec)
Rated Power(kW): 7.68kW
HV Output
13
Purpose of Battery Management System
Battery Safety Protection
Temperature / Voltage / Short / Pressure / Leakage / Impact /
Battery Life Cycle Protection
Temperature / Voltage / Idchg & End of DCHG / Ichg & End of CHG / Cool
ing
Battery Energy Calculation
SOC / SOA(IR) / OCV
Battery Power Calculation
Idchg / Ichg vs. Voltage/Temperature / IR
System Reliability
Power Setup & Down / Power Devices Protection / Maintenance -Unbalanc
e & Self-Diagnosis / Communication
Cost Effective
Battery Optimum Matching / Modular Design / …..
L7-xEV IM Motor Controller Design (I)
14
Max. Power
• Flux Weak-less
Control(rpm Extend)
• Battery Limitation
• Continue Power
rpm
Tq
F-DrivingR-Driving
Regenerating
Max. Tq
• Short Period /
Low Speed
• Lock Tq
• F/R Drive &
Protection
Integrated M/G
• S/W Controlled for
Motor / Generator Mode
>90%
>90%
1xV2~3xV / Flux Weaken-less
>90%
>90%Map Control
• Efficiency Based
Output Control
• Electric Power Source
M’ment
• Tq Accuracy & Quality
L7-xEV IM Motor Controller Design (II)
15
Weight 22.7kg
Peak DC Current 323.6A @ 75.7V~81.7V
Peak Torque 61.6Nm @ 75.7V~81.7V
Peak Power 21.74kW @ 75.7V~81.7V
Continuous DC Current 14A @75.7V~81.7V
Continuous Torque 14Nm @ 75.7V~81.7V
Continuous Power 6.5kW @ 75.7V~81.7V
Motor Speed 0~8000rpm
DC-DC Converter
16
Size : 7.5 x 3 x 2.75
Weight : 2.5 lbs
Power : 300W
Nominal Input voltage : 72-80VDC
Output voltage 13.5VDC
Part Number 622/11204
No. Loading Output_Idcdc Output_12V Input_HV
1 25 21.2 11.67 ~72
2 20 17.2 11.78 ~72
3 15 14 11.9 ~72
4 10 9.9 12.02 ~72
5 5 3.6 12.15 ~72
6 0 1.1 12.3 ~72
7 0 ~0.2 12.35 ~74
17
Thank You