HEV Supervisory Control and
Fault Diagnosis
Module 3 Introduction
HEV Supervisory Control and
Fault Diagnosis
Module 3
Engine and Generator Control
Module Overview
• Controlling the engine and generator is key function of the
supervisory control:
– Dictates what operating mode
– Dictates the torque and speed operation of the engine and generator
– Review thermostatic control is the most basic control that could be
applied to operate the engine and generator
• Design of the supervisory control requires optimization
– What operating points give best efficiency while meeting power
demand?
Module Overview
• In this module, we will do the following:
– Review how the engine, generator, and battery operate together
– Review charge depleting and charge sustaining mode
– Examine how the supervisory control uses torque control to control
the engine
– Examine how the supervisory control uses speed control to control the
generator
– Discuss how thermostatic control can be used to operate the engine
and generator
– Demonstrate how to optimize engine and generator operating points
to achieve a minimum power request
AVTC Model Based Design
Curriculum Development
Project
HEV Supervisory Control and
Fault Diagnosis
Module 3-1
Module 3
Engine and Generator Control
Lesson 3-1
REVIEW OF ENGINE/GENERATOR
OPERATION
Introduction
• Review of basics of a series HEV
• Role of a Supervisory Control
• Role of Sub-Controllers
• Possible Control Modes for Series Operation
Engine/Generator Block Diagram
• All components electrically parallel
• Generator attached to engine
Governing Equations
𝐼𝐵𝐴𝑇𝑇 + 𝐼𝐺𝐸𝑁 = 𝐼𝑀𝑂𝑇 → 𝑃𝐵𝐴𝑇𝑇 + 𝑃𝐺𝐸𝑁 = 𝑃𝑀𝑂𝑇
𝑚ሶ𝑓𝑢𝑒𝑙 ∗𝑄𝐿𝐻𝑉 ∗𝜂𝐼𝐶𝐸 = 𝑃𝐼𝐶𝐸
𝑃𝐼𝐶𝐸 ∗𝜂𝐼𝐶𝐸 = 𝑃𝐺𝐸𝑁
𝑚ሶ𝑓𝑢𝑒𝑙 = 𝐹𝑢𝑒𝑙 𝑅𝑎𝑡𝑒
Where:
𝑄𝐿𝐻𝑉 = 𝐿𝑜𝑤𝑒𝑟 𝐻𝑒𝑎𝑡𝑖𝑛𝑔 𝑉𝑎𝑙𝑢𝑒 𝑜𝑓 𝐹𝑢𝑒𝑙
𝜂𝐼𝐶𝐸 = Engine Efficiency
Modes of Operation
• Two modes of operation
– Charge Sustaining
• Keep SOC (state of charge) within certain threshold
– Engine on
• Maximize efficiency while meeting driver torque request
– Charge Depleting
• Electric motor only (Engine off)
– Depletes SOC
• Can also have blended mode
– Not covered in this module
Modes of Operation
• Blended Mode
• EREV (Extended Range Electric Vehicle) Mode
Modes of Operation
• Charge sustaining
– All components in use
Modes of Operation
• Charge Depleting
– Option 1: All-Electric Mode (no engine usage)
– Option 2: Blended Mode (some engine usage)
Generator/Engine Operation
• Supervisory controls generally issue reference requests to
lower-level controls
– The Supervisory Control is the “brains” of the operation and doesn’t
get involved in the details
– The other controls follow orders and worry about achieving the
reference request
• For an Series HEV, a Supervisory control could request engine
torque and generator speed:
– Requests go to low-level controllers
• Engine torque - ECU
• Generator speed - Inverter
Generator/Engine Operation
Torque Control
Torque (Engine) Control
• Request Engine Torque (TREQ)
– From specified throttle
Speed Control
Speed (Generator) Control
• Request generator speed (NGEN)
– From specified throttle
AVTC Model Based Design
Curriculum Development
Project
HEV Supervisory Control and
Fault Diagnosis
Module 3-2
Module 3
Engine and Generator Control
Lesson 2
THERMOSTATIC CONTROL
Thermostatic Control
• This is one of the most basic type of control
– Characterized by operation in two states: Off or On
– Classic example is a typical home AC or heating system
– For heating, when the temperature falls below a set point the heating system
comes on a fixed heat deliver
– When the temperature surpasses the set point, the heat system is turned off
– There is usually a hysteresis band or delay that keeps the system from rapidly
cycling
• Pros:
– Very easy to code
– Easy to calibrate
• Cons:
– Very constrained
– Not much room to optimize
Thermostatic SOC Control for a Series HEV
• For example: SOC control
• Set SOC max and min limits
– Switch between an EV mode and a “recharge” mode
• Single generator speed and
engine torque pair
– Set point should be efficient for
both motor and engine
– Must be able to achieve charge
sustaining
• Must provide enough power
for all driving conditions
Thermostatic SOC Control for a Series HEV
• Stop-Start Issues:
– Noise and Vibration (NVH)
– Emissions – Catalyst thermal
– Emissions – Catalyst cooling
– Emissions – Catalyst chemistry
– Efficiency
• Upcoming Material:
– Module 3-3 shows how to use model-based optimization techniques
to select an operating point for a thermostatic control
– Module 4-2 is a demo on how a thermostatic control can be built in
Simulink
AVTC Model Based Design
Curriculum Development
Project
HEV Supervisory Control and
Fault Diagnosis
Module 3-3
Module 3
Engine and Generator Control
Lesson 3
OPTIMIZATION
Introduction
• One of the most basic (and useful) functions of model-based
design is the ability to use models for optimization
– It is possible to do optimization experimentally with actual plant
hardware
– This can be expensive, requires time, and is difficult to do on complex
systems
• An excellent example of this is the selection of operating
points for a series engine-generator
– Selection of gear/belt ratio between the two devices
– Selection of best possible operating point for thermostatic control
– Selection of a optimal power path for a more sophisticated control (we
will talk about this later)
Demonstration