Configurable design approach for heavy-duty vehicle powertrain design

Abstract

Abstract

The design and fine-tuning of propulsion systems are facing significant challenges, considering the importance of maximizing energy efficiency and reducing carbon emissions. As internal combustion engines (ICEs) no longer exclusively control powertrains for heavy-duty vehicles (HDVs), the advent of emerging technologies in electrified powertrains and energy systems has presented a wide range of choices. None of the available concepts can satisfy all the requirements in different use case scenarios without compromising performance and energy efficiency. However, the number of available concepts for the powertrain increases the design flexibility while simultaneously elevating the challenge of design complexity. System-level simulation has provided great opportunities to predict system functionality at the very early stages of design. Considering a hybrid powertrain that includes different subsystems, simulation blocks representing each subsystem should be developed to predict the system behavior precisely. In this study, a configurable design approach is developed addressing the design complexity of an integrated e-axle in a truck use case. Different simulation methods for different subsystems of the powertrain are investigated, and a generic simulation structure is proposed for configurable simulations. Simulations of the subsystems are developed by cooperating with suppliers using different simulation tools. To implement a clear interface between the simulations, based on the generic structure of a hybrid powertrain with an e-axle, simulations for the different systems in the form of functional mockup units (FMUs) have been proposed. The simulations are separately compared against available measured data from a test truck with a conventional powertrain and suppliers’ data to be validated. After validation, different configurations of the system, component sizing, and different control strategies are investigated for driving cycles acquired from fleet owners to design the suitable system for the final use case scenario.