Lotus - Esprit - Workshop Manual - (2010)

EVORA 414E HYBRID © Lotus Engineering 1 EVORA 414E HYBRID Phil Barker Chief Engineer - Hybrid and Electric Vehicles © Lotus Engineering AGENDA – EVORA 414E HYBRID • Lotus background • Project overview, aims and timing • Vehicle Package and System layout • Specification - Drive system, Battery, Range extender, Cooling systems • Driver interface and Sound Synthesis • Safety analysis & Control systems • Analysis & Performance © Lotus Engineering 3 LOTUS • HERITAGE – – – • LOTUS CARS – A DAWN OF A NEW ERA – – • The 4th most successful Formula 1 team of all time 60 year history of iconic sports cars A tradition of performance through innovation and great ride & handling New products expanding our range of cars - Esprit (2012), Elan (2013), Elite (2014), New Elise (2015), Eterne (2015) Return to motorsport - Indycar, GP2, GP3, GT2, GT3, GT4, LMP2, Lotus-Renault F1 LOTUS ENGINEERING MOVING FORWARD – New engineering technologies for sustainable transport - Range Extender, Omnivore © Lotus Engineering 4 WE UNDERSTAND ENGINEERING FOR PRODUCTION © Lotus Engineering 5 Lotus Engineering Today Group Lotus Shareholder: Proton Holdings Berhad (PROTON) Lotus Cars An automotive Lotus Engineering engineering consultancy and advanced technology company 70% of our work is for external clients © Lotus Engineering 6 GLOBAL ORGANISATION Europe Sales: £20m Headcount: 405 Hethel, UK - Headquarters Germany North America Sales: £9m Headcount: 85 Southfield, Michigan Ann Arbor, Michigan © Lotus Engineering Asia Sales: £23m Headcount: 145 Kuala Lumpur, Malaysia Shanghai, China 7 LOTUS - CORE COMPETENCIES Lightweight Architectures • Bespoke Platforms • Lightweight Concepts • Lotus Platforms • Range extender • Engine control • Omnivore Combined Offerings • Whole Vehicle Programmes • Total Hybrid Drivetrain EEI Products and Technologies • H&EV • HMI systems • Lotus controllers DD Products and Technologies Efficient Performance EP Products and Technologies LA Products and Technologies Driving dynamics • Attribute Development • Active Dynamics • Active Noise Control Electrical and Electronic Integration © Lotus Engineering 8 EVORA 414E HYBRID - PROJECT OVERVIEW • £19 million project supported by a UK Government’s Technology Strategy Board Award • Project partners – – – – – Lotus Engineering / Infiniti / Jaguar Land Rover – Vehicle design, integration, build and development Xtrac – Gearbox development Evo Electric – Motor & generator development Th!nk – Power Electronics development Axeon – Battery development © Lotus Engineering 9 EVORA 414E HYBRID – AIMS • Technology Strategy Board goal • – To develop UK supply base in the EV market place with three car manufacturers. OEM Partner Aims • – Lotus - 2 demonstrator vehicles – Nissan - 2 demonstrator vehicles – Jaguar Land Rover – 3 to 5 demonstrator vehicles Lotus development aims – – – – Integrated high power inverter, charger, DC/DC and axial flux motor/generator A high power, high energy battery pack with a high current draw capability Vehicle Control systems integration and torque vectoring control Simulated 7 speed paddle shift linked to HALOsonic Internal & External Electronic Sound Synthesis © Lotus Engineering 10 EVORA 414E HYBRID - PROJECT TIMING Concept Show car at Geneva Motor show - March 2010 Demonstrator project start - September 2010 Running vehicle planned - August 2011 Project completion - September 2012 © Lotus Engineering 11 VEHICLE HYBRID SYSTEM INSTALLATION Hybrid System Installed within current Lotus Evora Vehicle Package © Lotus Engineering 12 EVORA 414E HYBRID - SYSTEM LAYOUT Charge Port Traction Inverter Modules Battery Pack Range Extender Engine Power Control Unit DC/DC Converter Battery Charger Gearbox Generator Inverter Traction Motors © Lotus Engineering 13 SPECIFICATION – MOTOR & GEARBOX DRIVELINE – – – – Drive Motors, 2 x 150kW peak, 500Nm Axial flux synchronous motors – High power density / compact design Independent rear wheel control – Torque vectoring capability Integrated drive Motor / Inverter package – – – Gear Box, 4.58:1 (single speed transmission) Independent drive to each rear wheel Electrically operated park lock © Lotus Engineering 14 SPECIFICATION – HIGH VOLTAGE BATTERY • • • Pack details – Energy 14.8 kWh – Power 300 kW – Mass 230kg – Peak Current 1000A BMS – 7 Slave modules, controlled by a master. – Model based state of Charge estimation. – Continuous cell balancing – Earth leakage monitoring Cell – Configuration 112 series, 16 parallel. – Lithium iron phosphate (26650). – Liquid thermal management. © Lotus Engineering 15 EXTENDED RANGE ELECTRIC VEHICLE – WHY? • Optimum solution for drivers who typically use their vehicles for short distances but still require longer range capability • ‘Range Anxiety’ issue of electric vehicles resolved • Reduced dependence on an electric charging infrastructure • In EV mode provides Zero Vehicle Emissions Capability • Supports Low CO2 Strategies © Lotus Engineering 16 SPECIFICATION – RANGE EXTENDER Range Extender Engine (Generation 1) – – – – 1.2 litre, 35 kW, 3 cylinder engine Tri fuel - methanol, ethanol or gasoline. Aluminium mono block, integrating cylinder block, head & exhaust manifold. Close coupled Catalyst Range Extender Generator – – – – – © Lotus Engineering Axial flux synchronous motor / generator 162 kW peak, 54 kW continuous 120 Nm nominal torque (240 Nm peak) Engine flywheel integrated into generator rotor Generator rotor directly mounted to the crankshaft 17 SPECIFICATION - COOLING SYSTEMS This car requires 4 temperature management systems for • The IC engine cooling (90°C) • The High Voltage systems cooling (60°C) – – – – 2 x Motor Invertors 2 x Drive motors 1 x Generator 1 x DC Converter • HV Battery pack heating and cooling (40°C) • Cabin HVAC (20°C) • Each system has a dedicated water pump and radiator to ensure vehicle operation between -5°C and +30°C. © Lotus Engineering 18 DRIVER INTERFACE AND SOUND SYNTHESIS Infotainment System • Typical systems interface (music, video, sat nav etc) • Hybrid system status, and Halo Sonic Sound Synthesis System set up. HALOsonic Sound Synthesis • External sound synthesis for Pedestrian safety • Internal sound synthesis system providing active feedback and linked to the virtual Gear shift. Virtual Gear Shift • Simulated 7 speed paddle shift linked to HALOsonic Internal & External Electronic Sound Synthesis • Power interrupt / regenerative braking function to simulate gear change © Lotus Engineering 19 EVORA 414E HYBRID - SAFETY ANALYSIS • • • • • Lotus are developing the application of ISO 26262 (functional safety of road vehicles) to a hybrid vehicle, on the 414E project. Having set safety goals the drive system has been defined in physical and functional terms outlining the key interfaces between systems. A hazard analysis conducted using these interfaces to understand the risks associated with potential failures. Based on operational situations, hazards have been identified, which have resulted in preliminary ASIL for the vehicle systems (Automotive Safety Integrity Level) Driver interface system Cabin HVAC Range extender Driver interface wiring Acceleration demand Driver input (inc E-stop) High voltage wiring HVAC control wiring Temp sensor wiring HV power HVAC control HV power Cabin temperature Aircon/heater disable Lotus Vehicle Controller Vehicle immobiliser Vehicle coolant inlets Vehicle coolant outlets Coolant pump & fan wiring Cooling system temp sensor wiring Waste heat Coolant temperature Cooling demand Vehicle cooling system 12V power harness 12V electrical power Vehicle 12V system Vehicle Dynamic System High voltage wiring Powertrain CAN bus HV power Power demand Enable/disable Steering System Vehicle immobiliser wiring Vehicle activation Electric Drive System High voltage wiring Control wiring DC/DC control HV power Vehicle CAN bus Steering angle Vehicle hydraulic braking system Wheel speeds x 4 Transmission park lock Park lock wiring Park lock activation Park lock position Calibration test equipment RS232 Programming data Configuration data Crash sensor Crash sensor wiring Vehicle crash occurred HV Battery Pack Vehicle CAN bus fixings Secure EDS Control of vibration Manual handling Powertrain CAN bus Vehicle CAN bus Traction Drive System EM emissions Electric Drive System EM interference External Dust, water, salt No functionEnvironment Reduced function Heat Over Function Intermittent function Unintended function cold system in the vehicle, via hard wiring The driver interface system relays driver inputs to the appropriate P Torque demand F Zero torque demand E-stop F F Emergency shut-down not On/off, therefore N/A possible No mode change On/off, therefore N/A On/off, therefore N/A Sport/Eco switch On/off, therefore N/A Car dangerous/ N/A uncontrollable E-stop latches, theerefore False e-stop N/A Switch to wrong mode Get wrong mode Drive mode signal P F Car won't go into park On/off, therefore N/A On/off, therefore N/A Switch to wrong mode Get wrong mode Drive mode signal R F Car won't go into reverse On/off, therefore N/A On/off, therefore N/A Switch to wrong mode Get wrong mode Drive mode signal N F Car wont go into neutral On/off, therefore N/A On/off, therefore N/A Switch to wrong mode Get wrong mode Drive mode signal D F Car won't go into drive On/off, therefore N/A On/off, therefore N/A Switch to wrong mode Get wrong mode Ignition barrel - key in F N/A N/A N/A N/A N/A Ignition barrel - accessories F Can't progress to ignition N/A N/A Ignition barrel - ignition F N/A N/A Ignition barrel - crank F N/A N/A HMI F sound HV system not activiated Car too fast Maintenance personnel EDS development test equipment On-board charger, charge port Mitigation Physical interface Functional interface Driver interface system Driver interface wiring Car slow Diagnostic data Monitoring data Charging connection High voltage wiring Charge start/stop switch Charge flap open, cable connected HV battery charge Charge, drive enable/disable DC/DC Vehicle structure Second independent signal Cabin heating, ventilation and air-conditioning. Heating and A/C is provided by an electric heater and electric compressor, both running off the HV circuit. Cabin HVAC High Voltage wiring P HVAC control wiring P Similar to a DFMEA, the hazard assessment and risk analysis has been guiding systems design. © Lotus Engineering 20 EVORA 414E HYBRID - CONTROLS SYSTEMS Concept: Control Systems separated into three interdependent Controllers: Vehicle Controller – Energy, Power and Torque Management – Driver & Vehicle Interfaces Vehicle Dynamics Controller – Control Torque Split modes – Dedicated Private CANbus Safety Controller – Functional Safety monitoring – Parameter Error and Validation checking © Lotus Engineering 21 EVORA 414E HYBRID - CANBUS ARCHITECTURE Multiple CANbus Networks: © Lotus Engineering • TV-CANbus: Dynamic Control Signals to Power Inverters • SF-CANbus: Monitoring Dynamic controller & ESP sensors • VH-CANbus: HV Systems, Comfort, Info & Steering • PT-CANbus: Range Extender & Generator 22 EVORA 414E HYBRID - SOFTWARE Modular Vehicle & Dynamic Control Software The software is split into modular functions which are implemented in Simulink Models and application C code. Simulation Software (Lotus RAVEN and IPG CarMaker) is used for: – Vehicle Dynamic response to simulated Motor Faults – Develop Algorithms for Electronic Differential modes Independent Safety Control Software – Alternative Implementation of Strategy for functional safety monitoring – Focused on verifying Current output signal, Wheel Lock and Torque Feedback. – Monitoring the CANbus (Watchdogs, Checksum and Rolling Counters) The software modules are validated – – – © Lotus Engineering Separately As part of Software in the Loop (SIL) As part of Hardware in the Loop (HIL) test rigs or in the Vehicle 23 Lotus Vehicle Simulation - LVS EV and Series hybrid modelling and simulation • Model based design of Vehicle applications and electric architecture built within a Simulink environment • Energy management concepts defined early • Concept EV/HEV electrical device sizing and confirmation of programme targets at the concept stage – – – – – – – EV range EV launch acceleration times Vehicle maximum speeds Energy used over wide range of drive-cycles Drive-cycle CO2 predictions for HEVs Battery SoC investigations HEV control strategies for economy or performance 100 Battery State of Charge, % • 99.5 99 98.5 98 97.5 FTP Cycle 97 96.5 96 © Lotus Engineering 0 100 200 300 400 500 time, s 600 700 800 900 1000 24 EVORA 414E HYBRID - PERFORMANCE • Predicted Vehicle Performance – – – – 0-60 mph Electric only range EV max speed: CO2 emission © Lotus Engineering <4 Secs 35 miles (Total hybrid range 300 Miles) 130mph (Charge sustaining 60mph) 60g/km (ECE-R101 test schedule) 25 EVORA 414E HYBRID • A Platform for Whole Vehicle Integration Development Chassis/Body Structure Re-engineer for EV components Structural Crashworthiness Range Extender Required power at wheels Charge depleting / sustaining Drive cycle ‘Range’ definition NVH Motor Engine Exterior © Lotus Engineering Battery Cell Technology Characteristics ‘Quick-release’ pack Cooling Systems Motor Power electronics Battery IC Engine Driving Dynamics Ride & Handling Performance tuning UltraCapacitors Torque assist Peak current buffer Battery charging Charge rates Domestic charging Infrastructure charging Vehicle Systems Brakes Balancing friction brakes with regenerative braking Power steering HVAC In-car display Battery Management (BMS) Battery pack conditioning Battery pack charging Usually supplier recommended Controls HEV controller sits above other controllers: Motor Engine Transmission HVAC Stop/start Etc…etc… Motor Technologies AC / DC Brush / brushless Inboard Wheel motor Generator Regenerative braking 26 Summary: Benefits of Series Hybrid compared with pure EV • Total range of 300 miles would need more than 127kWh of battery capacity – Not possible to package in vehicle – Battery weight in the region of 1300kg (same as base vehicle) • For reference range extender weight is 58kg – Cost prohibitive: $76k based on $600/kWh Conclusion: • Series hybrid technology will be a useful ‘stepping stone’ until a breakthrough in battery technology will allow comparative range © Lotus Engineering 27 THANK YOU If you require further information please contact: Phil Barker Tel: +44 (0)1953 608333 E-mail: [email protected] WWW.LOTUSCARS.COM/ENGINEERING © Lotus Engineering