Platform To Accelerate

Your xEV Powertrain

Strategy
12th January’22

In Association with Automotive World

1
Whom are you listening to today?

Sandeep Agrawal Ashish Lodhi

Associate Vice President Technology Expert
Powertrain Controls &
Calibration
Agenda
1. About KPIT and xEV development overview

2. Scalable HCU Software Platform

3. Predictive Energy Management & Controls

4. Virtual Calibration Workflow

5. System Engineering for xEV Powertrain Architecture

6. Summary

7. Q&A

1/11/2022 3
1/11/2022 4
Software Autonomous eCockpit and
Electrification
solutions Driving & ADAS Connectivity

for new age

mobility Cloud & New age vehicle
Predictive
Virtualization Engineering &
Design Diagnostics

Common Middleware for new

E/E Architecture (AUTOSAR, Cybersecurity, OTA)

1/11/2022 5
 25
Strategic clients in
Mobility ecosystem
7000+
Multi domain KPITians passionate
about mobility &
expertise technology
700+
Vehicle production
Global scale program experience

World class
Quality systems
Dependability Worldwide footprint
Software centers of A-Spice L5 certified
excellence in
11 global locations
 DOMAIN
• Engine
• Transmission & driveline
Powertrain Overview
• Hybrid controls
• Exhaust after-treatment

30
• Battery Management OEMs & Tier1s rely on KPIT for
• Inverter
Powertrain technologies
• Charger

SOLUTION AREAS

15+
Years of
• Production software development
• Model based system engineering Experience in Powertrain
• Process & methods development domain
• Verification & validation
• Controls & calibration
• Engineering tools development

250+
Powertrain Features in
production across OEMs &
ACCELERATORS/ TOOLS Tier1s
• SysML model framework
• ECU virtualization framework
• Hybrid controls

1650+
• Predictive energy controls
Strong team of
• Model based calibration
• BMS platform and CDD passionate technologists working in
• CCS ISO 15118 stack powertrain domain
• EVCC digital platform

1/11/2022 7
KPIT xEV development overview

Engagement in Commercial Vehicle programs

KPIT engages with an American OEM for the development of System 10+
specifications for CV VCU involving coordination with multiple Years of Experience on
component suppliers xEV VCU Programs
Engagement in LV/HV Applications
KPIT engages with Asian OEM to develop entire VCU system
for double-decker bus with 400KW propulsion power output &
3+
electric bike application Ongoing EV VCU
Projects across
2021 Global Clientele
KPIT Validated its VCU
KPIT validated its electric vehicle system (144V
Electrical Architecture & 124KW Power Output in
2018 6+
production) Successful
KPIT Developed own VCU
2016 Engagements

KPIT designed and developed an electric

vehicle control system (144V Electrical 2010
Architecture & 124KW Power Output) 40+
Dedicated Engineers
working on EV VCU

1/11/2022 8
Agenda
1. About KPIT and xEV development overview

2. Scalable HCU Software Platform

3. Predictive Energy Management & Controls

4. Virtual Calibration Workflow

5. System Engineering for xEV Powertrain Architecture

6. Summary

7. Q&A

1/11/2022 9
 Typically, P2 & beyond or PxPy
Typically, P2 & PLUG-IN
Typical Hybrid Topologies Landscape beyond or PxPy HYBRID
STRONG External
Typically, P0 or P1 Charging
Hybridization with Add-ON Components: HYBRID

Hybrid Features & Types

MILD Limited Long
Conventional Vehicle(ICE) HYBRID Electric Drive Electric Drive

+ Regenerative
Braking
Regenerative
Braking
Regenerative
Braking

Thermal Sys
eMachine(s)
Inverter(s)

Batteries

DC/DC
Torque Assist Torque Assist Torque Assist
HCU

PDU
OBC
BMS

Engine Engine Engine

Stop Start Stop Start Stop Start

Voltage & Electric Machine Power

Series Hybrid Hybrid Topologies

Engine Generator Motor
F R
P2 – After Clutch, on the
P0 – Typically Transmission input shaft side
Battery P4 – Beyond
belt driven at
final drive
FEAD side of
reduction or
Parallel Hybrid engine P1 P2 P4
on the
wheels
Engine
Motor/ P1 – Mounted P3
Generator
at Crankshaft, P0
either inline P3 – At the transmission
or offset output shaft side
Battery

1/11/2022 10
Key Interfaces: HCU & Vehicle/Hybrid components
EMS
-Actual Engine state
-Engine speed, Actual
engine torque
-Engine torque limit
Inverter
-Requested Engine state -Actual Inverter state -Requested Inverter state
-Engine Start/Stop -EM speed, Actual -Desired Inverter generator Torque
command EM torque -Desired Inverter motor Torque
-Desired engine torque

HCU
-Actual Battery state
Driver

-Battery SOC
PowerUp and PowerDown Engine Stop Start -Battery Voltage
-KL15, KL50 state -Battery charging,
-Accelerator, Cutch, LV Supply and discharging power limit
Torque Arbitration

BMS
Brake, Gear input Accessories
-Vehicle speed
Diagnostics Thermal Management -Requested Battery
Battery

state
LV

Energy Management Transmission Interface

-LV Battery current Strategy Functions (Clutch & Gear)
and voltage

-Desired Gear -Requested DC/DC state

-Current Mode & Gear -Actual DC/DC state
-Shift Inhibit/Hold -Desired DCDC Voltage Setpoint
-Torque/Speed Request -Actual DCDC set point Voltage
-Desired Clutch
- I/P, O/P Shaft Speeds -Actual DCDC current, efficiency
State

TCU DC/DC

1/11/2022 11
A Scalable HCU Software platform architecture

Common HEV functions Variant HEV topologies. (Series / Parallel – P0/P1/P2/P3/P4) Base software modules

# HCU- Hybrid Control Unit 1/11/2022 12

Accelerate vehicle controls development using KPIT assets
Artifacts to cover entire development cycle

• Repository of Vehicle • Scalable Software • Test case repository for

Control software Platform Architecture.
Requirements • Modular architecture
• Rapid Prototyping for providing flexibility and
easier functionality customization to suit
verification. vehicle architecture &
OEM needs
most of the function
areas of xEV
• Automation framework to
generate requirement-
based tests for future
requirement changes
enabling ~30% effort
reduction in test design

1/11/2022 13
Ready to use Software libraries for HCU to accelerate
time to market • Driver demand wheel
torque
• BMS state manager • Vehicle level torque
• DC/DC state manager coordination
• EMS state manager • Desired torque
• Inverter state manager coordination
• Powertrain control • Torque limit
State Manager calculation
• Torque split strategy

• Engine Start Stop • Inverter, DC/DC &

Manager Engine Diagnostic
• Inverter Start Manager
Sequence control • HV & LV Battery
• BCM State manager Diagnostic Manager
• Hardware Diagnostic
Manager
• LV Supply State
manager • Desired upstream
• LV Accessories load setpoint temperature
calculation calculation
• Radiator Fan control
• Coolant Pump control
• Energy Management
start stop coordinator • Shift Coordination
• Battery Charge Control State Manager
• Desired Motor-Inverter • Shift Operation
Generator torque Sequence Control
• Converter Setpoint • Shift Point calculation
Calculation • Clutch Operation
• Engine operating point Sequence Control
determination • Clutch State Manager
Note : Libraries specifically for P0 Mild Hybrid topology as base

# HCU- Hybrid Control Unit 1/11/2022 14

HCU Software libraries reusability across multiple topologies
Reusability / Scalability Factors influencing Reusability
Additional powertrain components coordination and state
Powerup and Power down HIGH transitions management depending on the topology and
supplier variants

P1 - EM start
Engine Stop & Start MEDIUM P2 - Clutch start, Slip start (k0 clutch)
P4 - Through-the-road start.

Customized HV-LV concept, for example multiple DCDC

LV Supply and Accessories HIGH
converters in case of high accessories load.

Charge Sustain, Deplete modes based on Mild, Strong,

Plugin hybridization.
Energy Management Strategy MEDIUM
Variants in case of multiple Electrical energy sources
(example 2 Battery packs, 2 Motors)

Torque split based on topology, energy management

Torque Arbitration MEDIUM
strategy and component limits.

Additional powertrain components and specific

Diagnostics HIGH
diagnostics based on supplier variant.

Thermal circuit and additional thermal components to be

Thermal Management MEDIUM controlled
Note : Reusability considering P0 Mild Hybrid topology as base

# HCU- Hybrid Control Unit 1/11/2022 15

HCU Software Core Functions – Control flow
-Desired engine
torque Engine
Power Up and Engine start stop
-PT Ctrl State
Down -BMS state
coordinator Torque Arbitration
-Inverter Start
-DCDC state torque -Desired motor
Powertrain Ctrl Driver Demand torque Motor
-Engine state Engine start (+ ve )
State manager Wheel Torque
-Inverter trq ctrl state stop manager
-Batt SOC, Volt
BMS Ctrl State -Desired gear &
manager Vehicle Level clutch state Transmission
ESS Command
Torque Coord
EMS Ctrl State Inverter Start
manager sequence
control Desired Torque Vehicle
DCDC Cnv Ctrl
Coordinator -Driver input
State manager
Inverter Trq
Ctrl State Torque Split
manager Strategy

Energy Management DCDC

Torque Split
Strategy
-PT Ctrl State Calculation DC-DC LV side
-BMS state Engine operating -Inverter generation Setpoint Voltage
-Batt SOC, Voltage energy determination torque (- ve )
Torque Limit
-Engine trq/speed LV Supply and
Calculation
Charging allowed Accessories
Battery Charging Desired Gear &
Control Clutch State LV Accessory Load
Calculation
Desired charging
power Desired LV side Power
Desired HV side power
Desired Motor- Converter Setpoint
Generator torque -PT Ctrl State calculation
-DCDC state
-Engine state

1/11/2022 16
Agenda
1. About KPIT and xEV development overview

2. Scalable HCU Software Platform

3. Predictive Energy Management & Controls

4. Virtual Calibration Workflow

5. System Engineering for xEV Powertrain Architecture

6. Summary

7. Q&A

1/11/2022 17
A Scalable HCU Software platform architecture

Predictive Functions

Predictive Energy Management Interventions

Predictive Gear Shift offsets

Predictive Cruise Control

Common HEV functions Variant HEV topologies. (Series / Parallel – P0/P1/P2/P3/P4) Base software modules

# HCU- Hybrid Control Unit 1/11/2022 18

Predictive Controls
Energy management control strategies which optimize the system efficiency and reduce energy
consumption of the vehicle using environmental information through e-horizon map data.
Approach

Major functions used in Predictive driving
• Predictive Energy Management in Hybrid powertrain
• Predictive Gear Shift strategy
• Predictive Cruise Control
• many more
Typical Customer Benefits
• Real time energy management
• Enhanced Driver experience
• Improved Drivability
• Improved Safety Control
KPIT’s Ownership
• Functional Requirement generation
• Predictive function development
• Verification & Validation
• Model based Calibration & Validation

1/11/2022 19
Terrain Based Energy Management
Input required for Simulation

End point

Starting point

1/11/2022 20
Terrain Based Energy Management
Scenarios & actions
Sr.No Scenario Condition Action

Extended Battery charging

SOC is lesser than certain -When Uphill is predicted the battery
1 Uphill preview
threshold && Uphill Preview is charged in advance to have enough
battery power

If Current Grade & SOC are more Boost when actual uphill
2 Actual uphill
that certain threshold -Motor will give maximum power

Extended Boost / Batt discharging

SOC is greater than certain -When Downhill is predicted the
3 Down hill preview
threshold && Downhill Preview battery is discharged in advance to
store more regenerative power

Actual downhill - Current Grade is lesser that

4 Regeneration when actual downhill
Regeneration certain threshold

1/11/2022 21
Predictive Shift Strategy :
Scenarios & actions
Overview
High-Power Demands in Preview
• Shifting down upfront before an uphill maneuver
• Downshift before a cornering
• Shift to sports mode

Low-Power Demands in Preview

• Avoid possible down shift
• Upshift early for downhill preview

Benefits Vehicle Speed Constraints in Preview

• Avoid upshift, at a preview of a traffic congestion

etc
Reduce fuel
Better drive- Good average • Selection of appropriate gear with road speed
consumption &
ability speed limiter preview
emission

1/11/2022 22
Agenda
1. About KPIT and xEV development overview

2. Scalable HCU Software Platform

3. Predictive Energy Management & Controls

4. Virtual Calibration Workflow

5. System Engineering for xEV Powertrain Architecture

6. Summary

7. Q&A

1/11/2022 23
Virtual Calibration
Early feedback on requirements & negotiations
System
Model Options:
Attributes & First First Principles Complete
Requirements Principles + Data Model Data Model
1 2 3

Driver & Output guarded by

targets/constraints
Environment Plant Model (Single/Multi objective)Targets/
DOE Constraints
(Steady State & Cycle) (E.g.: FE, 0-100 kmph,

From

Model
Sensors

Actuators
Emissions, Jerk, etc.)

Model
Calibration
Allocation

To
Matured
Controls Base
Automated Tuning Calibration
Control Factors Controls Environment Options:
(E.g.: Selected gear, Smaller ASW in Bigger ASW in Multiple ECUs
Torque rate limit, etc.) MBD VECU in VECU
1 2 3

1/11/2022 24
Agenda
1. About KPIT and xEV development overview

2. Scalable HCU Software Platform

3. Predictive Energy Management & Controls

4. Virtual Calibration Workflow

5. System Engineering for xEV Powertrain Architecture

6. Summary

7. Q&A

1/11/2022 25
System Engineering for xEV Powertrain Architecture
• Application use-cases
• Typical drive cycle with
KPIT can deliver System Engineering services for xEV powertrain
stationary time details as a turnkey solution.
• Performance & Economy
Targets
• Architecture selection for a new platform to meet required
• Regulatory Targets & vehicle level performance and fuel economy targets.
Incentives opportunities
• Any base vehicle if any
• Existing hybrid architecture analysis/ improvement cues.
and its details

1 2 3 4
xEV FEATURE xEV ARCHITECTURE COMPONENT SYSTEM
SELECTION ANALYSIS SIZING ITERATIONS SIMULATIONS
Mild/ Strong/ Plug- • Electric Machine Functional Attributes
• Series
Speed vs Torque
in/ Pure EV: • Parallel Simulation:
• Engine Speed vs Meeting Yes
• Engine Stop/Start • Series-Parallel Torque • Acceleration
Targets
Reports
• Intelligent Alternator • P0, P1, P2, P3, P4 • Transmission ratios • Gradeability
• eAccessories • Px-Py • FDR • Max Speed
• Fuel Economy No
• Torque Assists • HV Battery capacity
• Regeneration • DC/DC converter size • EV Range
• EV creep & drive • LV battery, etc.

1/11/2022 26
Agenda
1. About KPIT and xEV development overview

2. Scalable HCU Software Platform

3. Predictive Energy Management & Controls

4. Virtual Calibration Workflow

5. System Engineering for xEV Powertrain Architecture

6. Summary

7. Q&A

1/11/2022 27
Requirements Architecture
Performance &
Selection &
FE Simulations
Component sizing

Vehicle
Calibration &
KPIT your partner for Scalable HCU
Validation xEV Development Control Software

Virtual Predictive Energy

Calibration & Management &
Validation Controls

Ready to use software assets for HCU to accelerate time to market

1/11/2022 28
 Reimagining Mobility with YOU

Q&A

If you would like to have detailed discussion on today’s topic,

do reach out to us on:
Sandeep.Agrawal@kpit.com | Ashish.Lodhi@kpit.com 1/11/2022 29