During the development of the hybrid system "HyperHybrid" a component test stand was erected. This was used for the initial commissioning of the main system components (ZV Generator HICE, HV battery and drive system) and to ensure the performance and efficiency values for the simulation. It consists of 3 separate cabins for the drive (electric motor), HV battery and CC Generator which can be operated individually or in a system network.

The test stands are indispensable for measuring and optimizing existing and developing new or improved components.

For the simulation, a system simulation tool was developed in Matlab / Simulink. With the aid of this tool, the components (ZV Generator, Li-Ion battery and traction motor) can be combined with the HyperHybrid control strategy with various variants (e.g. front, rear and four-wheel drive), with different control strategies (e.g. C-rate- Speed-based or purely electric), in various vehicles (e.g. Geely Emgrand EC7) and under different load profiles (e.g. driving cycles such as NEDC, WLTP or customer-specific driving profiles).

In principle, any vehicle with HyperHybrid components can be equipped and simulated to make the advantages / strengths of the developed concept visible. In addition, the tool forms the basis for the continuous further development and optimization of the system, the components and the control algorithm regarding fuel consumption and driving performance. The modular structure allows each component to be arbitrarily initialized and new components defined via tables or functions. For example, BEV A-segment vehicles can be equipped and simulated with the appropriate system components via the full-size SUV for long-haul routes, buses and trucks. The hybrid controller module allows the variation of the essential operating parameters, e.g. The charging strategy by the ZV generator, as well as the battery charge and discharge limit states.

After the simulation, numerous evaluation and analysis diagrams for internal system data (SOC curve, driving resistance characteristic etc.), system values (such as fuel consumption, CO2 emission, electrical range etc.) and performance parameters (such as required driving power, regenerative brake energy, battery currents etc.) to disposal. Thus, the operating strategy can be set optimally for each vehicle to achieve the respective simulation goal.

Simulation Testing area

Simulation Testing area

Key Facts

Simulation

  • BEV and Serial Hybrid Vehicles (of all classes: economy, luxury class, sports vehicles)
  • Misc. Vehicle Types (small cars, luxury sedans, SUVs, buses, trucks)
  • Misc. Drive Modes (FWD, RWD, AWD
  • All components Freely Parameterizable (from tire to battery - use of data sheet and measurement data)
  • Acceleration Tests (constant driving, downhill runs, standard driving cycles and also real driving with speed and height profile)

Testing

  • Component Tests (Battery, E-Drive and REX)
  • Operation of the Components (in the system network)
  • Actual State Analysis
  • Determination of Potential for Improvement
  • Implementation / Re-testing of Improvements

Simulation Target

Presentation of certain HyperHybrid system advantages 

  • Customer Request via Simulation Requirement Sheet
  • Detection of Real Vehicle Characteristics
  • Detection of the Components (to be replaced / added)
  • Installation and Mass Focal Point Investigation
  • Design HyperHybrid Vehicle
  • Supply of the Components
  • First Simulation Shot
  • Adjustment of the Components (according to the simulation goal)
  • Subsequent Simulation Loops
  • Documentation of the Results
  • Presentation Creation
  • Presentation and Discussion (with customers)

Extensive Test Possibilities

  • HV Battery Tests (battery discharges up to 96kW, 2x3.5kW chargers, water-glycol battery low temperature cooling circuit available)
  • REX Tests (fuel system, intake and exhaust air system available, feed possibility up to 100kW, water-glycol high temperature cooling circuit available)
  • E-Drive Tests (DC bus, low temperature cooling circuit available)