Training 

Part 1 
Overview

Sponsored by Lee Slezak

Sponsored by Lee Slezak

“This presentation does not contain any proprietary or confidential information”
PSAT Used to Support R&D and
Management Decisions
 After a thorough assessment, PSAT was selected in 2004 as the primary 
vehicle model for all FreedomCAR and 21 CTP activities by the U.S.DOE, 
stating that “All
stating that  All future code development and enhancements for OFCVT 
future code development and enhancements for OFCVT
shall focus on PSAT and PSAT‐PRO”
 PSAT was awarded a R&D100 Award in 2004 and a Technology Transfer 
Award in 2007
Award in 2007
 PSAT is currently used by more than 130 companies and 700 users 
worldwide, including GM, Ford, Chrysler, Hyundai, Toyota

2
Reliance on Modeling & Simulation is
Continuously Increasing
 Reduce cost and time to production
 Provides math‐based environment for more thorough multidisciplinary 
integration and testing in the virtual environment before hardware builds
 Sorts technologies quickly to reduce hardware build iterations
 Promotes parallel and integrated virtual development of control systems 
p g p y
and hardware
 Reduces/eliminates duplicate modeling and analysis work and activities
 Enables
Enables fast to market with new technologies and real fuel 
fast to market with new technologies and real fuel
economy
 Delivers better‐integrated, initial designs that balance 
Fuel Economy, Emissions and Drivability (FEED) requirements.
( )
 Provides common methods and tools for comparing/evaluating 
technologies.
 Facilitates efficient, seamless link from research to production 
to maximize reuse of work products and eliminate waste.
3
 AUTONOMIE
–
Taking it to the Next Level

The objective is to accelerate the development and 
j p
introduction of advanced technologies through a 
Plug&Play architecture that will be adopted by the 
entire industry and research community. 

4
Accelerating the Development and
I t d ti off Ad
Introduction AdvanceddT
Technologies
h l i
 Why is Autonomie Unique?
Why is Autonomie Unique?
 Develop/Evaluate Component/Control Technologies
 Develop/Evaluate Vehicle Architectures
Develop/Evaluate Vehicle Architectures

5
 AUTONOMIE/PSAT Comparison
p
Architecture
Capability PSAT PSAT‐PRO Autonomie
Plug & Play Architecture
Hierarchical Architecture Standards  (Vehicle, syst…)
Model Reusability through System Experts 
(Concept to Production)
Establish Standard Interfaces (Industry‐wide)

Features
Capability PSAT PSAT‐PRO Autonomie
Model/data Customization
Powertrain Configuration Customization 
Select Appropriate Level of Modeling
GUI Customization (process, post‐processing…) 
(p ,p p g )
Database Management
6
 AUTONOMIE/PSAT Comparison
p
Usage*
Capability PSAT PSAT‐PRO
PSAT PRO Autonomie
Evaluate Fuel Consumption Benefits
(technology, size, powertrain configuration…) 
Evaluate and Balance FEED in Simulation
(Fuel Economy, Emissions & Drivability)
Develop Component Requirements
Simulate Single Component
Develop System/Subsystem Requirements
Develop Vehicle Level Control
Develop System/Subsystem/Component Control
Develop System/Subsystem/Component Control 
Component‐in‐the‐Loop
Software‐in‐the‐Loop, Hardware‐in‐the‐Loop…

*Final usage depends on the level of details of the models available
7
Develop a Software Architecture & Environment to Plug-and-
Play Math-Based Models of Hardware & Control System
Software Early or Up Front in the Design & Analysis Process
Up-Front

Maximum  User Access
Reusability Database Control

Maximum  Enterprise
Flexibility
Flexibility  Wid S l ti
Wide Solution
Interface
Selectable  Version
Complexity Control

Code Models, Data Database

Neutralityy Search
Graphical User Interface
Models,  Database
Setup Generic Results Linkage with
Data
Simulation Processes Visualization Other Tools
Other Tools

8
Model & Data Requirements
■ Automated integration of existing models / controls / data 
Maximum ■ All models for a specific area of expertise in a single location
Reusability ■ Systems duplicated using Matlab API

■ Any system can be built automatically
Maximum ■ User can add their own configurations
Flexibility  ■ Single components or entire vehicles can be simulated

■ Common nomenclature (i.e., naming, I/O…)
Common nomenclature (i e naming I/O )
Selectable  ■ Common model organization (i.e, CAPS)
Complexity ■ Model compatibility checked

■ Matlab / Simulink main environment

Code ■ Use S‐functions
Neutrality ■ Co‐simulation (i.e., CoSimate*)
( , )

* Not yet implemented
9
 Graphical User Interface Requirements
■ Select architecture, model and data 
Setup ■ Check compatibilities 
Simulation ■ Select simulation outputs to Workspace
■ Select simulation type (i.e., fuel efficiency, performance…)
Select simulation type (i e fuel efficiency performance )

■ Calibration, Validation, Tuning
Generic  ■ Parametric study, including Monte Carlo analysis
Processes  ■ Optimization algorithms
■ Predefined set of simulations & report (i.e., Drive Quality)

■ Predefined calculations (i.e., fuel economy, efficiency, power…)
Predefined calculations (i e fuel economy efficiency power )
Results  ■ Predefined plots, both time based and lookup tables
Visualization ■ Energy balance
■ Specific plots available for different models (users defined)

■ Co‐simulation (i.e., CoSimate*)
Linkage with ■ Specialty Tools (i.e, GT‐Power, CarSim, AMESIM, AVL Drive*…)
Other Tools ■ Database Management (i.e., SourceSafe…)
g
■ Well‐to‐Wheel (i.e., GREET*)
* Not yet implemented
10
 Database Requirements
■ Prevent unauthorized users from accessing restricted or proprietary 
User Access data
Control ■ Allow authorized users to download all necessary files
■ Ensure model is documented before integration into database
Ensure model is documented before integration into database

■ Allow users to collaborate (i.e. share models)
Enterprise  ■ Main database accessible anywhere
Wide Solution  ■ Consistent process for interacting with files

■ Maintain traceability of all changes
Maintain traceability of all changes
Version  ■ Keep linked files together through entire vehicle process (i.e. 
Control design, simulation and test)

■ Use keywords to search data, models, controls related to    specific 
Database projects
Search ■QQuickly find the correct model with the correct fidelity of 
y y
modeling and all related files

11
Key Benefits
■ Flexibility & Reusability
■ Customizable architectures
Plug&Play ■ Common Nomenclature
■ Code Neutral

■ Common Methods to sort technologies quickly 
Reduces 
R d t
to reduce hardware build iterations
d h d b ild it ti
Cost &  ■ Reduces/eliminates duplicate modeling and 
Time to  analysis work
Production ■ Delivers designs that balance Fuel Economy, 
E i i
Emissions and Drivability (FEED) requirements
d D i bilit (FEED) i t

Enterprise 
Enterprise ■ Database Management
Wide  ■ Provides common methods and tools for 
Solution comparing/evaluating technologies

No other tool currently allows the linkage with any legacy code!
12
 Unique Feature – Plug & Play
Implement any language
Implement any language
Automated process to import 
Legacy Code
legacy code (data, model, 
,p )
control, process)…

Calibration CarSim
CarSim*
Validation Legacy Plug &  Specialty  GTPower*
Software 
Tuning Processes Play (COTS) Amesim*
Drive Quality…
Drive Quality… AVL Drive…

Database  Version Control
Management
Database Search

No other tool currently builds the model automatically!
13
* Already linked
 Key New Feature – Software Customization
Model organization
Model organization
Single or multiple plants
Model 
Configuration Controller location

Fuel economy
Fuel economy
Models
Validation
Data Proprietary  Customization Processes
Information Drive quality
Controls…
Control…

Post‐ Calculations
processing
Plots
R
Reports…
t

14
Integrate Legacy Code
Example: Integrate Legacy Simulink Models
Legacy Code

GUI Automatically Renames Variables, 
Creates Necessary Support Files
Creates Necessary Support Files

Ready for use in

15
Model Plug&Play Capability Provided by
“W
“Wrapper””
Legacy Plant

First block automatically built to select  Last block automatically built to change 

the required input parameters change
the required input parameters, change  units (SI) and data type before sending
units (SI) and data type before sending 
units and data type the information to a bus to make them 
available to other systems
16
Experts Develop Systems
1
1- Wh
Whatt iis a S t
System iin A t i T
Autonomie i l ?
Terminology?

Model
Expert System
Expert System
Documentation

Initialization 
File Test Data

Pre‐processing
File

Post‐processing
File

Report
File (HTML)

17
Experts Develop Systems
2 Each
2- E hSSystem
t C
Configuration
fi ti Can
C Be
B CCustomized
t i d

Each System is Optional

Each System is Optional

Controller Actuator Plant Sensor

Electric Machine #1 Example: GM 2 Mode HEV
Transmission Plant
Transmission Plant

Gearbox Any System can have 
Subsystems To 
Electric Machine #2
y p
Accurately Represent 
Hardware

18
Experts Systems Can Be Reused
3 How
3- H C
Can W
We R
Reuse it?
Expert #9
Vehicle
Expert #3
Battery
Expert #1 Expert #2
Expert #7
Expert #7
Controller Plant
Chassis

Expert #6 Expert #8
Engine
Expert #4
Expert #4 Expert #5
Expert #5
Driveline
Controller Plant

19
Autonomie Designed to Be Used For All Steps in the
Development Process
Build and compare Easy selection & implementation Run batch mode +
large number of of data, models, control or cycles Distributed
technology, computing
powertrain,
options

Analyze and
Ensure simulation compare
p test and
t bilit
traceability, simulation data
model compatibilities

Database Enables MIL, SIL,

Management
M t RCP, HIL, CIL
Generic Processes
20
Accelerating the Development and
I t d ti off Ad
Introduction AdvanceddT
Technologies
h l i
 Why is Autonomie Unique?
Why is Autonomie Unique?
 Develop/Evaluate Component/Control Technologies
 Develop/Evaluate Vehicle Architectures
Develop/Evaluate Vehicle Architectures

21
 Develop Plant Models with Different Level of
C
Complexity
l it
Steady State Model

Physical Model

Mean Efficiency Model

Highly Dynamic Model 
with Production Code

 Different models are necessary to study 
different phenomena
 Detailed models are required when technology 
Detailed models are required when technology
cannot be tested or does not exist!
22
Link with Commercial Off the Shelf Tools (COTS)
#1 – Develop Model in Native Environment

#2 – Integrate Model 
in Simulink
in Simulink

#3 – Use Model in Autonomie

COTS  
(1) can be used to generate maps
(2) can be run in the Simulink environment
(3) can be run in their own environment (co simulation)
(3) can be run in their own environment (co‐simulation)

GT Power, CarSim have already been linked
23
 Select the Appropriate Level of Modeling
Controlllers

or or or or

or
Plants

or
or or
or or
or

Engine Battery, Motor Transmission Chassis

Experts Experts Experts Experts
Vehicle Experts
24
Main Steps of Model Based Design
Software‐in‐the‐Loop Hardware‐in‐the‐Loop

Rapid Control Prototyping

Rapid Control Prototyping Component‐in‐the‐Loop
Component in the Loop

25
 Develop Control Algorithm
Software in the Loop
Software-in-the-Loop
 Specific configuration defined to develop and test 
new control algorithms
new control algorithms
New algorithm(s) 
Real Time Operating System (RTOS) 
Production Code to be tested
ensures call of functions at specific 
intervals (such as CAN)
intervals (such as CAN)

Sends and receives CAN  Hardware input/output
signals
26
Test Low Level Control Algorithm
Hardware in the Loop and Software-in-the-Loop
Hardware-in-the-Loop Software in the Loop
Hardware‐in‐the‐Loop
(Control Hardware / Emulated Plant)
Automatic building save days of development
Automatic building save days of development

All the lines connecting 
the blocks are built automatically

Block built 
automatically
‐Change units
‐Change data type
Change data type
‐Extract all the 
proper sensors

27
 Evaluate Fuel Consumption Benefits
Model in the Loop
Model-in-the-Loop
Example “Evaluation of HCCI Engine Fuel Savings for Various Powertrain”
EEngine maps from UofM
i f U fM

Vehicle & Control
Development
p
Fuel Consumption 
Analysis
Ratio Fuel Consumption of  HCCI vs Regular Engine 
1.000

0.950 Detailed Analysis of 
Unadjusted Fuel Consumption Ratio

0.900
Conventional
Micro_HEV
Mild_HEV
Reasons Behind Benefits
Split_HEV
HCCI Fuel Savings vs PI According to Hybridization Degree
Split_PHEV10 1.000
0.850
Split_PHEV20
Series_PHEV30
Series PHEV40
Series_PHEV40 0 950
0.950
U

0.800

Unadjusted Fuel Consumption Ratio 
0.900
0.750
1 UDDS
HWFET
0.850
Fuel Consumption Ratio (High Case) of HCCI vs PI
Combined

1.050

1.000
0.800

0.950

on Ratio
0.900

Unadjusted Fuel Consumptio
0.750
0.00% 10.00% 20.00% 30.00% 40.00%
0.850 50.00% 60.00% 70.00%
Hybridization Degree (%)
0.800

0.750

0.700

0.650

0.600
0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 28
120.00%
Percent of Time Engine is ON
Evaluate Non Modeled Phenomena With Hardware
Component-in-the-Loop

Example#1: Impact of 
battery cold start on 
PHEVs Fuel Consumption

Sensors Battery behaves as if in vehicle
Example #3: Engine and 
Battery are Coupled
y p

Rest of the Vehicle 
Modeled Example #2: Impact of 
emission and engine
emission and engine 
cold start on PHEVs Fuel 
Consumption

Engine behaves as if in vehicle

29
Evaluate Non Modeled Phenomena With Hardware
Component-in-the-Loop - Examples
Impact of Vehicle Level Control  Impact of Vehicle Level Control 
on Battery Life on Engine Emissions
vehicle speed
25 calculated
l l t d CO2 g/sec
/
engine torque/10 measured

20

O2 grams/second
15

10

CO
5

200 250 300 350 400

Time in seconds

Impact of Temperature on All  Impact of Charger Rating on 
100
Electric Range  Battery Roundtrip Efficiency
I nitia l te m p e rature 2 0 d e g re e s C 96 25
ve hic le s p e e d in m e te rs p e r s e c o nd 1.4, 95.5
90

ciency
I nitia l te m p e rature 0 d e g re e s C 2, 95.15

Ba ttery charging current -

95 6, 21.5
I nitia l te m p e rarture -7 d e g re e s C
20
eed

80 94
Batttery roundtrip effic
State of Charge, Vehicle spe

70 93 15

RMS (A)
(%)
60
92
91 10
50
90 2, 7
1.4, 5 5
40
89 6 89
6, 89.11
11
S

30 88 0
0 2 4 6 8
20
0 500 1000 1500 2000 2500 3000 3500
T im e in s e c o nd s Charger Pow er (kW)
30
 Define Component Requirements
Battery Electric Machine Accessories
ent Data 
D Teams

2004 Prius Camry A/C Power
Testing
Prius A/C Power
Prius A/C Power
from R&D
Compone

IL Ro

  OCV
VL
Model  

Rp1 Rp2

Ip1 Ip2

Vehicle Classes Sizing & Simulation
Simulaations
hicle

Vehicle  DOE / USABC

DOE / USABC 
Veh

Requirements  Requirements

Battery RCP Vehicle Testing
Validation
V

JCS VL41M

31
Accelerating the Development and
I t d ti off Ad
Introduction AdvanceddT
Technologies
h l i
 Why is Autonomie Unique?
Why is Autonomie Unique?
 Develop/Evaluate Component/Control Technologies
 Develop/Evaluate Vehicle Architectures
Develop/Evaluate Vehicle Architectures

32
 Validate Vehicle Models to Ensure Studies
I t
Integrity
it Analyze Data Develop Control

Collect Test Data
Validate Model
Engine Torque
APRF

Understand Gearbox
d d b Model Gearbox
d l b

Source : GM

Example of GM 2 Mode Tahoe
33
Develop Vehicle Control to Maximize Fuel Displacement
Gl b l O ti i ti
Global Optimization
Teng Tmc
ωmc P t  1, SOC ' t  1, J
0 0 0, 0' t 

ωeng X 0 
Pm t , SOCn t  U 0 t 
X T 
Optimal Control, 
Optimal Control
.
.
U M t  Minimal Fuel Cons.
. PM t  1, SOC M ' t  1., J M , M ' t 

Backward model
Backward model . p.
Bellman Principle
Control Design
Various Control 
Various 
St t i
Strategies
Control 
Principles Rule‐Based Control Design
Heuristic Optimization
p

Optimally tuned
Parameters

Existing Control Logic DIRECT Algorithm

34
 Develop Vehicle Control Taking into Account
N M
Non Modeled
d l dPParameters
t
Example: Impact of Vehicle Level Control on Engine Emissions for PHEVs
(collaboration with ORNL)
(collaboration with ORNL)
Step #1 – Evaluate Different Controls in Simulation
Vehicle Model Detailed After‐Treatment Model
Evaluation of
Evaluation of 
Different Vehicle 
Control Logic and 
Tuning

Step #2 – Verify the Trends with Engine‐in‐the‐Loop
Analyze Results

Rest of the Vehicle 
Modeled Engine behaves 
as if in vehicle
35
 Match Technologies, Configurations to
S
Specific
ifi AApplications
li ti
Impact of Aerodynamics for  Impact of Mild and Full HEV for 
Different Line Haul Applications Line Haul Applications
Comparison of Aerodynamic Fuel Savings for Drive Cycles vs Steady States
15 30.0
CONV MILD‐HEV FULL‐HEV

Fuel Conssumption (gal/100mi)
Drive Cycles
mprovement fromhigh to lowCd

Steady States 24.0

25.0 22.4
21.3
10
50% load 20.0 16.0
19.2
15.5 16.3 15.6 15.5
15.1 13.7 15.0 14.0
15.0 13.1
12.5
10.0
Percentage Im

5.0

0
0.0
HTUF Class 6/ UDDS Truck/ HHDDT Cruise/ HHDDT High Speed/
21 mph SS 26 mph SS 42 mph SS 53 mph SS HHDDT65  HHDDT Cruise HHDDT High  HHDDT  udds_truck
Speed Transient

The Sum of the Combined Technologies < The Sum of Each Technology 
h S f h C bi d h l i h S f h h l
Impact of All Technologies on Fuel Consumption
20.0%
18.0% Class 2B Pickup
Engine
16.0%
Transmission
Percent Fuel Savedd

14.0%
12.0% 8.9% RR
8.6%
10.0% Cd
8.0% 1.4% 15.9%
14.9% Weight
6.0% 1.7% 1.6%
1.2% Hybrid
Hybrid  
4 0%
4.0%
3.0% 3.8% improvements
2.0% Baseline 
1.4% 1.4% improvements
0.0%
Each  Combination Each  Combination
technology  (Conv) technology (Hybrid) 36
(Conv) (Hybrid)
 Evaluate Uncertainties Through Monte Carlo
A l i
Analysis
■ Uncertainty is modeled by a probability density function (pdf)
■ How is the uncertainty propagated? 

■ PHEV 10 miles All Electric Range (AER) midsize used as reference case
PHEV 10 miles All Electric Range (AER) midsize used as reference case
Inputs Sampling Results
Cd
Monte Carlo (MC), 
FA Latin hypercube (LHS),
Median Latin hypercube (MLHS)
Crr
Quasi Monte‐Carlo
Weight

37
 A f
A software environment and standard framework
i d d df k

Summary
 Unifies the entire engineering organization for efficient operation

 Focuses analysis on total system engineering and integration

 Provides complete user customization by an open architecture

 Simulates from single components, subsystems to entire vehicles

 Manages models, data, processes, results and control code 
from research to production by configuration and database management 

38