ELECTRICAL PRESENTATION

Jake Garrison and James Goin

Torque Vector Series PHEV

• Performance
– IVM-60 mph: 5.3s
– 50-70 mph: 2.9s
– Top Speed: 137 km/h (85
mph)
– EV Range: 80 km (50 miles)
– Power: 400 kW (536 hp)
– Torque: 4200 Nm (3098 lb
ft)
• Unique Characteristics
– Torque Vectoring
– Electric Drivetrain
LV SUBSYSTEM
LV CIRCUIT DIAGRAM
Added components
 LOAD CHARACTERIZATION
Accessory Draws (Added Parasitic Draws
Components) Component Nominal (mA) Max (mA)
Component Nominal (A) Radio 12 22
Air Pump 18 Powertrain Control Module 19 44
Unitek BamoCar D3 (2) 2.8 Keyless Entry Module 12 15
Radiator Motor 18 Oil Level Module 5 10
ETAS 2.5 Light Control Module 4 7
Coolant Pump 25 Illuminated Entry 13 22
Volt ACCM 0.125 HVAC Power Module 11 31
BCM 10 Heated Windshield Module 9 20
A123 Components (BMS CMS EDM) 2.35 Electronics Control Module 14 33
Centerstack 4.5 ETAS 20 44
HUD 3.5 Auto Door Lock 6 11
Anti-Theft System 6 8
Bosch SMG 180 Gen 1 0.5
Body Control Module 11 19
Bosch INVCON Gen 2.3 0.5
Multi-Function Chime 6 16
Retained Accessory Power (RAP) Module 6 22
Total 116.775 Twilight Sentinel Module 7 11
ON Star Module 8 16
Battery Specifications (Optima YellowTop)
Capacity (Ah) 75 Total 169 351
Reserve Capacity (min) 155
Minimum Cranking Voltage (V) 10.5
Minimum Cranking SOC (%) 20 Parasitic Depletion from 100% to 20% SOC
Cold-Cranking Amps (A) 900 Nominal at 115 mA 2.1 weeks
 LV SIMULATION OVERVIEW
Overview Limitations
• Cranking transient analysis • Lack of component specs and stock
vehicle benchmarks
• Steady state parasitic load analysis
• Only major loads accounted for
Features • Poorly defined duty cycle
• Impedance parameters
• Made in Simscape
• Adaptive physical battery and starter • 12V battery chemistry undecided
model • Runtime versus precision
• User-defined:
• Battery chemistry Assumptions
• Accessory loads
• Custom duty cycle • Stock Camaro loads
• Cranking load profile • Motor cranking load
• Efficiency
• Constant load duty cycles
• Constant ambient temperature
 LV BUS MODEL

Bosch INVCON 12V Battery Accessory Load Starter Motor

User Key-On
 CRANKING SIMULATION

Δ = 46A

Δ = 0.75V
HV SUBSYSTEM
HV CIRCUIT DIAGRAM
ESS DIAGRAM
ESS DEVELOPMENT
ESS DEVELOPMENT

Energy Storage System

Voltage 350 V

Capacity 18.9 kWh

Range 50 miles

Modules 7

Packaging 15s3p
Li-Ion
Chemistry
Phosphate
 HV SIMULATION OVERVIEW
Overview Limitations
• Bus ripple analysis • Lack of component specs
• Bus charge and discharge analysis • Impedance parameters
• Fuse melting analysis • Transient profiles
• No drive cycle support (yet)
Features
• Made in Simscape Assumptions
• Physical Li-Ion pack model • Component spec sheet parameters
• Compatibility with LV model • Worst case scenario
• User-defined: • Switching frequency bounds 8 to 24 kHz
• Battery parameters • Constant ambient temperature
• Switching frequencies • Constant motor torque (for now)
• Load impedance • Harness resistance is negligible
 HV MODEL
ESS TPIM

ACCM

Genset
APM
 HV BUS RIPPLE
Spectral Density
Magnitude

Frequency (Hz) 5,570.42 10,345.07 19,098.59

Ripple
Voltage Ripple (V) 5 6 4
Analysis
Current Ripple (A) 6 8 2
 HV BUS RIPPLE

Current Ripple Voltage Ripple

355V
65A

57A

349V

Frequency (Hz) 5,570.42 10,345.07 19,098.59

Ripple
Voltage Ripple (V) 5 6 4
Analysis
Current Ripple (A) 6 8 2
 BUS CHARGE AND DISCHARGE
BusCharging
Charge Bus Discharge
Discharging

350 350

300 300

250 250

200
Voltage (V)

200

150 150

100 100

45 s
50 50

0 0

0 2 4 6 0 10 20 30 40 50 60 70 80 90
Time (s) Time (s)
FUSE AND WIRE SELECTION
 FUSING OVERVIEW
Load Conditions
• Nominal and peak current
• Operating voltage
• Load Type (capacitive or resistive)

Source Conditions
• Power output
• Ambient temperature (derating)
• Short-circuit current (I2t analysis)
• Intended cycle life

Standards
• UL certified
• IEC 60269 standard
• Mersen design reviews
 WIRING OVERVIEW
Exrad XLE Cable Specifications
• High voltage and current
• Automotive grade
• High dielectric insulation
• High temperature tolerance
• High bend radius
• Shielded (reduce EMI)
• Orange

Conditions
• Fuse blows before cable fails
Standards
• UL 758 and ISO 6722 accordance
• SAE certified
• Champlain design reviews
 SELECTION OVERVIEW

Wire Gauge Wire Nominal Current Peak Current

Component Fuse Size (A) (AWG) Ampacity (A) (A) (A)

Charger 12 10 Shielded 80 12.25 12.75

Genset Inverter 300 1/0 Shielded 339 210 400

TPIM (Inverter) 200 1/0 Shielded 339 200 400

ACCM 20 10 Shielded 80 12.5 25.6

Junction Fuse 350 1/0 Shielded 339 250 500

ESS 350 1/0 Shielded 339 180 612

Note: load profiles approximated from supplier specification sheet

 GENSET INVERTER EXAMPLE
Source Load
ESS 1/0 Cable Fuse 1/0 Cable Genset
• V = 375 VDC • 300 A rated Inverter
• R = 0.05 Ω • Δtpeak >> 100 s • iavg = 210 A
• isc= 7.34 kA • Max V = 700 VDC • ipeak = 400 A
• Max isc = 100 kA • Δtpeak = 45 s

Requirements
• Capacitive load = time delay fuse to prevent nuisance blows
• 1.5 x 210 A (nominal) ≈ 300 A (rule of thumb)
• Allowed time at peak current:
• 45 s (Genset Δtpeak ) < 150 s (fuse) < 300 s (cable)
• Max voltage
• 375 VDC (ESS) < 700 VDC (fuse) < 1000 VDC (cable)
• Short circuit current
• 7.34 kA (ESS) < 100 kA (fuse)
 GENSET INVERTER FUSE
Nominal Peak Extreme
210A 400A 1500A
300 A Fuse Specification
Model: Mersen A70QS300
• Type: Time Delay
• Max Voltage: 700 VDC
• Impulse: 100 kA I.R
• Temperature: 25°C

3s

Parameter Current (A) Melt Time (s)

Nominal 210 >> 100

Peak 400 >> 100

Extreme 1500 3
Short
Circuit 7.3k < 0.01
CUSTOM EMBEDDED
CONTROLLER
 OUR OWN CAR CONTROLLER (O2C2)

O2C2
• CAN / RS232
• Configurable channels
• Real-time commands and
feedback
• Features:
• 8-channel 12-bit ADC
• 6-channel 12-bit DAC
• 16 digital IO
• 7 current drivers
• Pulse width modulation
• Custom driver set
 Current Current Current
Driver Driver Driver

Current
Driver
MPC4922
12-Bit
DAC

FOX20MHZ
Oscillator

Current
Driver
MCP3208 MPC4922 MPC4922
PIC32 12-Bit ADC 12-Bit DAC 12-Bit DAC

Current
Driver
Switch
Connector
PICKIT

MAX232
Switch

MCP2551
CAN

Current
Driver
LM317T LM317T
Regulator Regulator

DSUB 25 Connector

PCB Layout
 LV BENCH TESTING
Embedded Design Project
• Documentation
• Part sourcing
• Prototyping
• Harness design
• HIL harness
• In vehicle harness
• HIL validation
 APPLICATIONS

Examples
• Smarter MVEC + breakout
• Aerodynamic shutter
control
• Fail-safe motor speed
sensors
• Control non-CAN devices
• Smarter charge
management system
NON-POWERTRAIN EMBEDDED
CONTROL SYSTEM
 CHARGE MANAGEMENT SYSTEM
Reductions in energy consumption
Charge Options
• Direct 12V grid power
• Minimizing cooling pump use
Select Mode : Energy Efficiency
• Optimizing the charger
High level requirements Charge Complete : 6:00 am
• User input
• Charge complete
• Input modes
• Efficiency
• Fast
• Cost
• Operating requirements
• CAN communication
• 12V power
STANDARD SYSTEM - BLOCK DIAGRAM
Legend

12 V Line

350 V Line

120 V / 240 V Line

Charger Battery Pack
500K CAN Network

250K CAN Network

STANDARD SYSTEM - BLOCK DIAGRAM
Legend

12 V Line

350 V Line

120 V / 240 V Line

Accessory
Charger Battery Pack Power 12V Battery
Module 500K CAN Network

250K CAN Network

12V Loads
STANDARD SYSTEM - BLOCK DIAGRAM
Legend

12 V Line

350 V Line

120 V / 240 V Line

Accessory
Charger Battery Pack Power 12V Battery
Module 500K CAN Network

250K CAN Network

12V Loads

Battery
Supervisory Cooling Center
Management
Controller Pump Stack
System
OPTIMIZED SYSTEM - BLOCK DIAGRAM
Legend

12 V Line

350 V Line

120 V / 240 V Line

Accessory
Charger Battery Pack Power 12V Battery
Module 500K CAN Network

250K CAN Network

Relay
12 V AC/DC
Converter

12V Loads

Battery
Supervisory Cooling Center
Management
Controller Pump Stack
System
OPTIMIZED SYSTEM - BLOCK DIAGRAM
Legend

12 V Line

350 V Line

120 V / 240 V Line

Accessory
Charger Battery Pack Power 12V Battery
Module 500K CAN Network

250K CAN Network

Relay
12 V AC/DC
Converter

12V Loads

Battery
Supervisory Cooling Center
O2C2 Management
Controller Pump Stack
System
 OPTIMIZED SYSTEM - BLOCK DIAGRAM
Legend

12 V Line

350 V Line

120 V / 240 V Line

Accessory
Charger Battery Pack Power 12V Battery
Module 500K CAN Network

250K CAN Network

Relay
12 V AC/DC
Converter

12V Loads

Push Buttons

Battery
Supervisory Cooling Center
O2C2 Management
Controller Pump Stack
System
 CHARGER AND PUMP CONTROL STRATEGY
Standard Charge Cycle Optimized Charge Cycle

Results from 20% to 80% state of charge at 25°C ambient temperature

 NET EFFICIENCY GAIN

Percent Savings
Category Original Use (W) Modified Use (W) Per Category
Minimizing pump
use 192 115 25-40%
Direct 12V grid
power 264 243 8%
Charging
optimization 5100 4845 3-4%

Total power saved 5556 5083 6-7.7%

Total Energy Savings = 7.7%

 OPERATING LIMITATIONS
Component Rating
02C2
Input Voltage Range 4.2-30 V
ADC 12-bit accuracy O2C2
DAC 12-bit accuracy
Memory 256kB
Clock 20 MHz
CAN < 1 Mb/s
Temperature 0 - 120 C
Electromagnetic Interference > ~4 inches from high voltage

AC/DC Power Supply 12V Power Supply

Input Voltage 120/240 V +/- 12 V AC(50-65Hz)
Max Power 500 W

Relay
Control Voltage 8-17V VDC
Max Current 50A
Relay
 UTILIZED COMMUNICATION BUSSES
Used Network Data
RS232 Signal Name Type
Battery Pack
• Desktop development board State of Charge bcm_soc TX
• HIL validation Charger
Temperature getChargerTemp TX
Current Request setChargerCurrent RX
CAN Measured Current getChargerCurrent TX
Enable setEnable RX
• Slave controller Cooling Pump
• Simple master controller Measured Current CP1_current TX
• Receiving values for Coolant Temp CP1_temperature TX
optimization algorithm Pump Request setPumpSpeedRpm RX
Enable pumpOn RX
• Setting optimal values Center Stack
User Mode userMode TX
Charge By Time chargeByTime TX
 TOP 5 DFMEA LINE ITEMS
Failure Mode Effects Cause of Failure Prevention Detection RPN Action
Insufficient Unable to turn Poor or Durable and Not on CAN (7 * 3* 2) = 42 Get better
Power on damaged power high quality network power supply
supply supply
CAN Network Loss of Connection is Durable and No CAN (8 * 5 * 4) = 160 Disable all
Lost communication damaged or high quality Communication inputs and
unconnected wires outputs that
originated from
slave control
Improper CAN Improper or Improper Proper CAN Improper or (8 * 3 * 7) = 168 Throw flag and
Message unknown CAN device addressing, unknown CAN keep checking
message communication structure and message messages
received communication received
EMI Corruption Signal Too close to Shielding, metal Improper (9 * 3 * 5) = 135 Determine
corruption high voltage containers, keep messages, source of EMI,
away from high signals or increase
voltage corruption proximity from
and proper
shielding
Overpowered Fuse blown Power surge, Fuse and proper Fuse blown (8 * 3 * 3) = 72 Determine
short, or over power supply source of issue,
loaded correct it and
replace fuse

SEVERITY X OCCURRENCE X DETECTION = RISK PRIORITY NUMBER (RPN)

 IMPROPER CAN MESSAGE HANDLING
Checks Next
CAN Message Throws Error Flag
Message
1001..1100..1011

Begin Validate by Cyclic Redundancy

O2C2 Check:
1001..1100..1011

Structure Check: Structure Check:

ID Extension Field Data Field
1001..1100..1011 1001..1100..1011
 DESIGN TRADE-OFFS
Charge Management O2C2
• Charge time • Comfort and time
• Static parameters • Simplicity vs size
• Complexity • Precision and
features

Revision 1 Revision 3
Revision 2
 FUTURE EVALUATION

• Directly measure power

consumption with and
without the Charge
Management System

• Optimization based on real

parameters

• Dynamic parameters
KNOWLEDGE TRANSFER
 KNOWLEDGE TRANSFER
Collaboration Lessons Learned
• Slack • Time management
• Google Drive • Collaboration
• Wiki • Professionalism
• Safety Binder • Effective communication
• Priority setting
Training
• Weekly Design Review
• Training Workshops
• Extensive Lead training
• Weekly meetings
• Recruiting young members
• Capstone projects
HV HARNESS WORKSHOP
THANK YOU
QUESTIONS?