Within the ModulED project, the consortium developed an innovative virtual vehicle model to support a new energy management model and optimize vehicle performances.

To support the modular motor assembly and conditioning phases, numerical models, corresponding to physicals modules are developed. The aim is to compare the test’s results of the mechanical, electrical, thermal and control aspects of physical modules with simulation of virtual modules.

All this unit modules are integrated in a model of virtual vehicle to prepare assessment of vehicle-level performances of the powertrain, mitigation of physical integration risks, and evaluation of components correspondence for powertrain modularity: a Vehicle Energy Management (VEM) model. This model is unique thanks to the integration of all ModulED specific technologies models developed during the project in a unique system (innovative 6-phase motor, high-power GaN inverter, advanced regenerative braking control, …). This task was led by consortium partner SIEMENS.

The VEM model integrates each sub-system (gearbox and control aspects, cooling, and motor) into a full vehicle model. For its set up, interactions were needed with all the partners of the project. A focus is done on the control, especially in the integration of the regenerative braking and the powertrain controller defined by Chalmers. To reproduce some tests based on torque input, an enabler of a torque control mode is implemented. Indeed, the control of the vehicle, especially the regenerative braking is crucial for the range optimization, a major challenge in EV market today.

Article SIEMENS 1

Figure 1: Braking management

Article SIEMENS 2

Figure 2: Powertrain controller

Article SIEMENS 3

Figure 3: Torque control mode enabler

Today, obtained results are the first ones after the design phase: the integration of all modules inside the complete vehicle model. With the project going by, more data will be available to parametrize more accurately the models. A comparison with the measurements on test benches will be fundamental to test model’s predictability. This VEM model will be exploited to virtually expand the demonstration perimeter to non-physically testable operations in the project like driving cycles or weather conditions.