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IFAC 2014, Design of Power Steering Systems for Heavy-Duty Long-Haul Vehicles

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Silvas Emilia

The document discusses the optimization of power steering systems in heavy-duty long-haul vehicles, focusing on the design of hybrid vehicles (HEVs) and the efficiency of auxiliary units, which can consume significant power. It outlines the project's goals, including the development of alternative steering system topologies and the use of a bi-level optimization problem to minimize fuel consumption. Specific models for various components, operational constraints, and efficiency metrics are introduced to improve overall system performance.

Engineering
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Why SDL? Designed Topologies Optimization Problem Results Conclusions Design of Power Steering Systems for Heavy-Duty Long-Haul Vehicles E. Silvas1, E. Backx1, T. Hofman1, H. Voets2 and M. Steinbuch1 1Control Systems Technology Group Dept. of Mechanical Eng., Eindhoven University of Technology, The Netherlands 2DAF Trucks NV, Eindhoven, The Netherlands Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Auxiliary Units "Belt driven auxiliary units can consume up to 4% of the total power for a long haul heavy duty truck... Power Steering Pump Air Brake Compressor Air Cond. Compressor... Silvas et al. (2013). Modeling for control and optimal design of a power steering pump and an air conditioning compressor used in heavy duty trucks. In the 9th IEEE VPPC Conf., pp. 218-223, 2013 Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Auxiliary Units Belt driven auxiliary units can consume up to 4% of the total power for a long haul heavy duty truck... Power Steering Pump Air Brake Compressor Air Cond. Compressor... Silvas et al. (2013). Modeling for control and optimal design of a power steering pump and an air conditioning compressor used in heavy duty trucks. In the 9th IEEE VPPC Conf., pp. 218-223, 2013 Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Auxiliary Units Belt driven auxiliary units can consume up to 4% of the total power for a long haul heavy duty truck... Power Steering Pump Air Brake Compressor Air Cond. Compressor... Silvas et al. (2013). Modeling for control and optimal design of a power steering pump and an air conditioning compressor used in heavy duty trucks. In the 9th IEEE VPPC Conf., pp. 218-223, 2013 Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Auxiliary Units Belt driven auxiliary units can consume up to 4% of the total power for a long haul heavy duty truck... Power Steering Pump Air Brake Compressor Air Cond. Compressor... Silvas et al. (2013). Modeling for control and optimal design of a power steering pump and an air conditioning compressor used in heavy duty trucks. In the 9th IEEE VPPC Conf., pp. 218-223, 2013 Engine Cooling Fan Water Pump Air Brake Compressor Air Brake Compressor Steering Pump Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Auxiliary Units Belt driven auxiliary units can consume up to 4% of the total power for a long haul heavy duty truck... Power Steering Pump Air Brake Compressor Air Cond. Compressor... Silvas et al. (2013). Modeling for control and optimal design of a power steering pump and an air conditioning compressor used in heavy duty trucks. In the 9th IEEE VPPC Conf., pp. 218-223, 2013 Starter Motor Air Conditioning Compressor Fuel Pump Alternator Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Losses of belt driven auxiliary units Output is dictated by engine speed Limited controllability Improvement Potential Pure electric driving Elimination of idling losses Matching auxiliaries operation to driver demand More efficient engine operation Different topology options Engine Transmission Final Drive + Wheels Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Losses of belt driven auxiliary units Output is dictated by engine speed Limited controllability Improvement Potential Pure electric driving Elimination of idling losses Matching auxiliaries operation to driver demand More efficient engine operation Different topology options Engine Transmission Final Drive + Wheels Auxiliary Units Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Losses of belt driven auxiliary units Output is dictated by engine speed Limited controllability Improvement Potential Pure electric driving Elimination of idling losses Matching auxiliaries operation to driver demand More efficient engine operation Different topology options Engine Transmission Final Drive + Wheels Auxiliary Units Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Losses of belt driven auxiliary units Output is dictated by engine speed Limited controllability Improvement Potential Pure electric driving Elimination of idling losses Matching auxiliaries operation to driver demand More efficient engine operation Different topology options Engine Transmission Electric Machine Battery Final Drive + Wheels Auxiliary Units Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Project Goal and Outline Project Goal: Steering System Design Optimal design of a steering system considering different topologies, component sizes and control. Outline Alternative Steering System Topologies Bi-level Optimization Problem Optimal Design Results Conclusions Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Project Goal and Outline Project Goal: Steering System Design Optimal design of a steering system considering different topologies, component sizes and control. Outline Alternative Steering System Topologies Bi-level Optimization Problem Optimal Design Results Conclusions Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Project Goal and Outline Project Goal: Steering System Design Optimal design of a steering system considering different topologies, component sizes and control. Outline Alternative Steering System Topologies Bi-level Optimization Problem Optimal Design Results Conclusions Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Project Goal and Outline Project Goal: Steering System Design Optimal design of a steering system considering different topologies, component sizes and control. Outline Alternative Steering System Topologies Bi-level Optimization Problem Optimal Design Results Conclusions Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Project Goal and Outline Project Goal: Steering System Design Optimal design of a steering system considering different topologies, component sizes and control. Outline Alternative Steering System Topologies Bi-level Optimization Problem Optimal Design Results Conclusions Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System 훿, 푇 Cylinder Steering wheel Torque Sensor Rack and Pinion Internal Combustion Engine Pinion Shaft Belt/Gear Pump ECU Including valve and reservoir Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System 훿, 푇 Cylinder Steering wheel Torque Sensor Rack and Pinion Internal Combustion Engine Pinion Shaft Belt/Gear Pump ECU Including valve and reservoir Hydraulic power Pump speed Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System 훿, 푇 Cylinder Steering wheel Torque Sensor Rack and Pinion Internal Combustion Engine Pinion Shaft Belt/Gear Pump ECU Including valve and reservoir Maximally required power Hydraulic power Pump speed Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System 훿, 푇 Cylinder Steering wheel Torque Sensor Rack and Pinion Internal Combustion Engine Pinion Shaft Belt/Gear Pump ECU Including valve and reservoir Delivered power Maximally required power Hydraulic power Pump speed Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System 훿, 푇 Cylinder Steering wheel Torque Sensor Rack and Pinion Internal Combustion Engine Pinion Shaft Belt/Gear Pump ECU Including valve and reservoir Delivered power Parasitic losses Actually required power Maximally required power Hydraulic power Pump speed Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Steering Converter – Transmitter (Topology Selection) System Source Internal Combustion Engine Fixed Displ. Hydraulic Pump (1) Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump (2) (1) Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Σ (3) (2) (1) Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Planetary Gear Set Σ (4) (3) (2) (1) Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Ball-screw Gear Planetary Gear Set Σ Σ (5) (4) (3) (2) (1) Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Ball-screw Gear Planetary Gear Set Σ Σ (6) (5) (4) (3) (2) (1) Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Ball-screw Gear Planetary Gear Set Σ Σ (6) (5) (4) (3) (2) (1) 1 2 i ,i e P z n h f , f l , A Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Modeling of Power Steering Topologies FD Hydraulic Pump: Analytical models that include both leakage losses and torque losses (! IEEE VPPC 2013) Electric Machine: Efficiency map, scaled linearly in torque. Alternator: Belt driven (b = 0:80), constant efficiency of a = 0:70. Gears: Spur, planetary and ball-screw gear sets. Driving Cycle: a mixed cycle, predominant (85%) highway driving, measured on a fully loaded tractor-trailer. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Modeling of Power Steering Topologies FD Hydraulic Pump: Analytical models that include both leakage losses and torque losses (! IEEE VPPC 2013) Electric Machine: Efficiency map, scaled linearly in torque. Alternator: Belt driven (b = 0:80), constant efficiency of a = 0:70. Gears: Spur, planetary and ball-screw gear sets. Driving Cycle: a mixed cycle, predominant (85%) highway driving, measured on a fully loaded tractor-trailer. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Modeling of Power Steering Topologies FD Hydraulic Pump: Analytical models that include both leakage losses and torque losses (! IEEE VPPC 2013) Electric Machine: Efficiency map, scaled linearly in torque. Alternator: Belt driven (b = 0:80), constant efficiency of a = 0:70. Gears: Spur, planetary and ball-screw gear sets. Driving Cycle: a mixed cycle, predominant (85%) highway driving, measured on a fully loaded tractor-trailer. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Modeling of Power Steering Topologies FD Hydraulic Pump: Analytical models that include both leakage losses and torque losses (! IEEE VPPC 2013) Electric Machine: Efficiency map, scaled linearly in torque. Alternator: Belt driven (b = 0:80), constant efficiency of a = 0:70. Gears: Spur, planetary and ball-screw gear sets. Driving Cycle: a mixed cycle, predominant (85%) highway driving, measured on a fully loaded tractor-trailer. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Modeling of Power Steering Topologies FD Hydraulic Pump: Analytical models that include both leakage losses and torque losses (! IEEE VPPC 2013) Electric Machine: Efficiency map, scaled linearly in torque. Alternator: Belt driven (b = 0:80), constant efficiency of a = 0:70. Gears: Spur, planetary and ball-screw gear sets. Driving Cycle: a mixed cycle, predominant (85%) highway driving, measured on a fully loaded tractor-trailer. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Problem Definition Optimization Problem Optimization objective The objective of each topology is to minimize the fuel consumption, = R tf 0 m_ f dt, over a given driving cycle of length tf . Bi-level optimization problem Z tf min xc ;xdX 0 c;d (xc(t); xd )dt; s:t: gd;c(xc(t); xd ) 0; hd;c(xc(t); xd ) = 0: xc = ffh; fng; xd = fi1; i2;Pe; z; l;Ag; fd;c = (xc; xd ) = m_ f : Optimization constraints and variables gd;c, hd;c, and xc;d are dictated by each topology. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Problem Definition Optimization Problem Optimization objective The objective of each topology is to minimize the fuel consumption, = R tf 0 m_ f dt, over a given driving cycle of length tf . Bi-level optimization problem Z tf min xc ;xdX 0 c;d (xc(t); xd )dt; s:t: gd;c(xc(t); xd ) 0; hd;c(xc(t); xd ) = 0: xc = ffh; fng; xd = fi1; i2;Pe; z; l;Ag; fd;c = (xc; xd ) = m_ f : Optimization constraints and variables gd;c, hd;c, and xc;d are dictated by each topology. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Problem Definition Optimization Problem Optimization objective The objective of each topology is to minimize the fuel consumption, = R tf 0 m_ f dt, over a given driving cycle of length tf . Bi-level optimization problem Z tf min xc ;xdX 0 c;d (xc(t); xd )dt; s:t: gd;c(xc(t); xd ) 0; hd;c(xc(t); xd ) = 0: xc = ffh; fng; xd = fi1; i2;Pe; z; l;Ag; fd;c = (xc; xd ) = m_ f : Optimization constraints and variables gd;c, hd;c, and xc;d are dictated by each topology. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Problem Definition Optimization Problem Topologies 2, 3 and 4 enable a controlled pump oil flow, . The minimum flow, at certain driving conditions, is restricted for safety reasons. Bi-level Optimization Sizing Optimization Variable Flow Control Outer Loop Inner Loop Variable Flow Control Cases (flow I): fh = 11; fn = 16 (flow II): fh = 6; fn = 16 (flow III): fh = 6; fn = 11 (flow IV): = r ; for r 6 L=min; 6 L=min for r 6 L=min; r = the required flow Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Problem Definition Optimization Problem Topologies 2, 3 and 4 enable a controlled pump oil flow, . The minimum flow, at certain driving conditions, is restricted for safety reasons. Bi-level Optimization Sizing Optimization Variable Flow Control Outer Loop Inner Loop Variable Flow Control Cases (flow I): fh = 11; fn = 16 (flow II): fh = 6; fn = 16 (flow III): fh = 6; fn = 11 (flow IV): = r ; for r 6 L=min; 6 L=min for r 6 L=min; r = the required flow Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Results Results Analysis Top. 1: Hydraulic Power Steering Infeasible Region Minimum Flow Constraint Fuel consumption, F Optimal gear ration, i1 (Scaled) Gear ratio, i1 [−] (Scaled) Average fuel consumption, F, [L/100km] 7.2 3.6 1,5 1,6 1,7 1,8 1,9 2,0 Boundary solution limited by min. No control flexibility Top. 2: Electro-Hydraulic Power Steering 3 constraints min , Te and !e not for conventional HD vehicles Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Results Results Analysis Top. 1: Hydraulic Power Steering Infeasible Region Minimum Flow Constraint Fuel consumption, F Optimal gear ration, i1 (Scaled) Gear ratio, i1 [−] (Scaled) Average fuel consumption, F, [L/100km] 7.2 3.6 1,5 1,6 1,7 1,8 1,9 2,0 Boundary solution limited by min. No control flexibility Top. 2: Electro-Hydraulic Power Steering 3 constraints min , Te and !e not for conventional HD vehicles EHPS optimization − 16 L/min Gear ratio i [−] Electric motor rated power PEM [kW] 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 15 10 5 Infeasible region Not simulated Motor speed constraint Motor torque constraint Fuel consumption 1.3 1.2 1.1 1 0.9 0.8 0.7 0.6 Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Results Results Analysis Top. 4: Split Electro-Hydraulic and Hydraulic Power Steering 1 2 3 4 5 6 0.4 0.3 0.2 0.1 0 Planetary gear ratio, z [−] Fuel consumption [L/100km] Pareto set Best solution Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Planetary Gear Set (4) 1 2 i ,i e P z n h f , f Flow IV: fuel consumption reduction up to 80% for hybrids and up to 35% for conventional trucks (max. 2.4 kW) The overall best topologies, 3 and 4, result in about the same reduction of about 80%. Added cost and complexity can be high. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Results Results Analysis Top. 4: Split Electro-Hydraulic and Hydraulic Power Steering 1 2 3 4 5 6 0.4 0.3 0.2 0.1 0 Planetary gear ratio, z [−] Fuel consumption [L/100km] Pareto set Best solution Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Planetary Gear Set (4) 1 2 i ,i e P z n h f , f Flow IV: fuel consumption reduction up to 80% for hybrids and up to 35% for conventional trucks (max. 2.4 kW) The overall best topologies, 3 and 4, result in about the same reduction of about 80%. Added cost and complexity can be high. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Results Results Comparison Top. 1 Top. 2 Top. 3 Top. 4 Top. 5 Top. 6 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Average fuel consumption, F, [L/100km] Fixed flow Variable flow I Variable flow II Variable flow III Variable flow IV lowering the minimum flow, hl , improves the fuel efficiency. top. 3,4,5 can also be suitable for conventional trucks Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Results Results Comparison Top. 1 Top. 2 Top. 3 Top. 4 Top. 5 Top. 6 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Average fuel consumption, F, [L/100km] Fixed flow Variable flow I Variable flow II Variable flow III Variable flow IV lowering the minimum flow, hl , improves the fuel efficiency. top. 3,4,5 can also be suitable for conventional trucks Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Conclusions Summary Nested optimization approach has resulted in optimal design and control of the power steering pump The electrification of the PSP can reduce fuel consumption by more than 80% when compared with hydraulic steering and enables Start/Stop and Zero Emission Driving; Future work Adress more auxiliaries and critical secondary aspects (e.g., cost, steering performance) for design. Integrate auxiliary design with powertrain components design for topology, sizing and control. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Conclusions Summary Nested optimization approach has resulted in optimal design and control of the power steering pump The electrification of the PSP can reduce fuel consumption by more than 80% when compared with hydraulic steering and enables Start/Stop and Zero Emission Driving; Future work Adress more auxiliaries and critical secondary aspects (e.g., cost, steering performance) for design. Integrate auxiliary design with powertrain components design for topology, sizing and control. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Conclusions Thank you! Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Conclusions Extra Slides Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Conclusions Optimization Problem Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump (2) (1) 1 i e P n h f , f Topology 1: xd = fi1g; xc = ; Topology 2: xd = fi1;Peg; xc = ffn; fhg Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
Why SDL? Designed Topologies Optimization Problem Results Conclusions Conclusions Optimization Problem Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Ball-screw Gear Planetary Gear Set (6) (4) 1 2 i ,i e P z n h f , f l Topology 4: xd = fi1;Peg; xc = ffn; fhg Topology 6: xd = fi2;Pe; lg; xc = ; Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV

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IFAC 2014, Design of Power Steering Systems for Heavy-Duty Long-Haul Vehicles

  • 1. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design of Power Steering Systems for Heavy-Duty Long-Haul Vehicles E. Silvas1, E. Backx1, T. Hofman1, H. Voets2 and M. Steinbuch1 1Control Systems Technology Group Dept. of Mechanical Eng., Eindhoven University of Technology, The Netherlands 2DAF Trucks NV, Eindhoven, The Netherlands Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 2. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Auxiliary Units "Belt driven auxiliary units can consume up to 4% of the total power for a long haul heavy duty truck... Power Steering Pump Air Brake Compressor Air Cond. Compressor... Silvas et al. (2013). Modeling for control and optimal design of a power steering pump and an air conditioning compressor used in heavy duty trucks. In the 9th IEEE VPPC Conf., pp. 218-223, 2013 Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 3. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Auxiliary Units Belt driven auxiliary units can consume up to 4% of the total power for a long haul heavy duty truck... Power Steering Pump Air Brake Compressor Air Cond. Compressor... Silvas et al. (2013). Modeling for control and optimal design of a power steering pump and an air conditioning compressor used in heavy duty trucks. In the 9th IEEE VPPC Conf., pp. 218-223, 2013 Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 4. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Auxiliary Units Belt driven auxiliary units can consume up to 4% of the total power for a long haul heavy duty truck... Power Steering Pump Air Brake Compressor Air Cond. Compressor... Silvas et al. (2013). Modeling for control and optimal design of a power steering pump and an air conditioning compressor used in heavy duty trucks. In the 9th IEEE VPPC Conf., pp. 218-223, 2013 Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 5. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Auxiliary Units Belt driven auxiliary units can consume up to 4% of the total power for a long haul heavy duty truck... Power Steering Pump Air Brake Compressor Air Cond. Compressor... Silvas et al. (2013). Modeling for control and optimal design of a power steering pump and an air conditioning compressor used in heavy duty trucks. In the 9th IEEE VPPC Conf., pp. 218-223, 2013 Engine Cooling Fan Water Pump Air Brake Compressor Air Brake Compressor Steering Pump Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 6. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Auxiliary Units Belt driven auxiliary units can consume up to 4% of the total power for a long haul heavy duty truck... Power Steering Pump Air Brake Compressor Air Cond. Compressor... Silvas et al. (2013). Modeling for control and optimal design of a power steering pump and an air conditioning compressor used in heavy duty trucks. In the 9th IEEE VPPC Conf., pp. 218-223, 2013 Starter Motor Air Conditioning Compressor Fuel Pump Alternator Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 7. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Losses of belt driven auxiliary units Output is dictated by engine speed Limited controllability Improvement Potential Pure electric driving Elimination of idling losses Matching auxiliaries operation to driver demand More efficient engine operation Different topology options Engine Transmission Final Drive + Wheels Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 8. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Losses of belt driven auxiliary units Output is dictated by engine speed Limited controllability Improvement Potential Pure electric driving Elimination of idling losses Matching auxiliaries operation to driver demand More efficient engine operation Different topology options Engine Transmission Final Drive + Wheels Auxiliary Units Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 9. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Losses of belt driven auxiliary units Output is dictated by engine speed Limited controllability Improvement Potential Pure electric driving Elimination of idling losses Matching auxiliaries operation to driver demand More efficient engine operation Different topology options Engine Transmission Final Drive + Wheels Auxiliary Units Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 10. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Motivation Losses of belt driven auxiliary units Output is dictated by engine speed Limited controllability Improvement Potential Pure electric driving Elimination of idling losses Matching auxiliaries operation to driver demand More efficient engine operation Different topology options Engine Transmission Electric Machine Battery Final Drive + Wheels Auxiliary Units Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 11. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Project Goal and Outline Project Goal: Steering System Design Optimal design of a steering system considering different topologies, component sizes and control. Outline Alternative Steering System Topologies Bi-level Optimization Problem Optimal Design Results Conclusions Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 12. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Project Goal and Outline Project Goal: Steering System Design Optimal design of a steering system considering different topologies, component sizes and control. Outline Alternative Steering System Topologies Bi-level Optimization Problem Optimal Design Results Conclusions Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 13. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Project Goal and Outline Project Goal: Steering System Design Optimal design of a steering system considering different topologies, component sizes and control. Outline Alternative Steering System Topologies Bi-level Optimization Problem Optimal Design Results Conclusions Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 14. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Project Goal and Outline Project Goal: Steering System Design Optimal design of a steering system considering different topologies, component sizes and control. Outline Alternative Steering System Topologies Bi-level Optimization Problem Optimal Design Results Conclusions Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 15. Why SDL? Designed Topologies Optimization Problem Results Conclusions Optimal Design on Hybrid Vehicles Project Goal and Outline Project Goal: Steering System Design Optimal design of a steering system considering different topologies, component sizes and control. Outline Alternative Steering System Topologies Bi-level Optimization Problem Optimal Design Results Conclusions Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 16. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System 훿, 푇 Cylinder Steering wheel Torque Sensor Rack and Pinion Internal Combustion Engine Pinion Shaft Belt/Gear Pump ECU Including valve and reservoir Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 17. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System 훿, 푇 Cylinder Steering wheel Torque Sensor Rack and Pinion Internal Combustion Engine Pinion Shaft Belt/Gear Pump ECU Including valve and reservoir Hydraulic power Pump speed Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 18. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System 훿, 푇 Cylinder Steering wheel Torque Sensor Rack and Pinion Internal Combustion Engine Pinion Shaft Belt/Gear Pump ECU Including valve and reservoir Maximally required power Hydraulic power Pump speed Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 19. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System 훿, 푇 Cylinder Steering wheel Torque Sensor Rack and Pinion Internal Combustion Engine Pinion Shaft Belt/Gear Pump ECU Including valve and reservoir Delivered power Maximally required power Hydraulic power Pump speed Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 20. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System 훿, 푇 Cylinder Steering wheel Torque Sensor Rack and Pinion Internal Combustion Engine Pinion Shaft Belt/Gear Pump ECU Including valve and reservoir Delivered power Parasitic losses Actually required power Maximally required power Hydraulic power Pump speed Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 21. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Steering Converter – Transmitter (Topology Selection) System Source Internal Combustion Engine Fixed Displ. Hydraulic Pump (1) Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 22. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump (2) (1) Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 23. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Σ (3) (2) (1) Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 24. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Planetary Gear Set Σ (4) (3) (2) (1) Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 25. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Ball-screw Gear Planetary Gear Set Σ Σ (5) (4) (3) (2) (1) Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 26. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Ball-screw Gear Planetary Gear Set Σ Σ (6) (5) (4) (3) (2) (1) Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 27. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Power Steering System Alternative Topologies Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Ball-screw Gear Planetary Gear Set Σ Σ (6) (5) (4) (3) (2) (1) 1 2 i ,i e P z n h f , f l , A Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 28. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Modeling of Power Steering Topologies FD Hydraulic Pump: Analytical models that include both leakage losses and torque losses (! IEEE VPPC 2013) Electric Machine: Efficiency map, scaled linearly in torque. Alternator: Belt driven (b = 0:80), constant efficiency of a = 0:70. Gears: Spur, planetary and ball-screw gear sets. Driving Cycle: a mixed cycle, predominant (85%) highway driving, measured on a fully loaded tractor-trailer. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 29. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Modeling of Power Steering Topologies FD Hydraulic Pump: Analytical models that include both leakage losses and torque losses (! IEEE VPPC 2013) Electric Machine: Efficiency map, scaled linearly in torque. Alternator: Belt driven (b = 0:80), constant efficiency of a = 0:70. Gears: Spur, planetary and ball-screw gear sets. Driving Cycle: a mixed cycle, predominant (85%) highway driving, measured on a fully loaded tractor-trailer. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 30. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Modeling of Power Steering Topologies FD Hydraulic Pump: Analytical models that include both leakage losses and torque losses (! IEEE VPPC 2013) Electric Machine: Efficiency map, scaled linearly in torque. Alternator: Belt driven (b = 0:80), constant efficiency of a = 0:70. Gears: Spur, planetary and ball-screw gear sets. Driving Cycle: a mixed cycle, predominant (85%) highway driving, measured on a fully loaded tractor-trailer. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 31. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Modeling of Power Steering Topologies FD Hydraulic Pump: Analytical models that include both leakage losses and torque losses (! IEEE VPPC 2013) Electric Machine: Efficiency map, scaled linearly in torque. Alternator: Belt driven (b = 0:80), constant efficiency of a = 0:70. Gears: Spur, planetary and ball-screw gear sets. Driving Cycle: a mixed cycle, predominant (85%) highway driving, measured on a fully loaded tractor-trailer. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 32. Why SDL? Designed Topologies Optimization Problem Results Conclusions Design Space Modeling of Power Steering Topologies FD Hydraulic Pump: Analytical models that include both leakage losses and torque losses (! IEEE VPPC 2013) Electric Machine: Efficiency map, scaled linearly in torque. Alternator: Belt driven (b = 0:80), constant efficiency of a = 0:70. Gears: Spur, planetary and ball-screw gear sets. Driving Cycle: a mixed cycle, predominant (85%) highway driving, measured on a fully loaded tractor-trailer. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 33. Why SDL? Designed Topologies Optimization Problem Results Conclusions Problem Definition Optimization Problem Optimization objective The objective of each topology is to minimize the fuel consumption, = R tf 0 m_ f dt, over a given driving cycle of length tf . Bi-level optimization problem Z tf min xc ;xdX 0 c;d (xc(t); xd )dt; s:t: gd;c(xc(t); xd ) 0; hd;c(xc(t); xd ) = 0: xc = ffh; fng; xd = fi1; i2;Pe; z; l;Ag; fd;c = (xc; xd ) = m_ f : Optimization constraints and variables gd;c, hd;c, and xc;d are dictated by each topology. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 34. Why SDL? Designed Topologies Optimization Problem Results Conclusions Problem Definition Optimization Problem Optimization objective The objective of each topology is to minimize the fuel consumption, = R tf 0 m_ f dt, over a given driving cycle of length tf . Bi-level optimization problem Z tf min xc ;xdX 0 c;d (xc(t); xd )dt; s:t: gd;c(xc(t); xd ) 0; hd;c(xc(t); xd ) = 0: xc = ffh; fng; xd = fi1; i2;Pe; z; l;Ag; fd;c = (xc; xd ) = m_ f : Optimization constraints and variables gd;c, hd;c, and xc;d are dictated by each topology. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 35. Why SDL? Designed Topologies Optimization Problem Results Conclusions Problem Definition Optimization Problem Optimization objective The objective of each topology is to minimize the fuel consumption, = R tf 0 m_ f dt, over a given driving cycle of length tf . Bi-level optimization problem Z tf min xc ;xdX 0 c;d (xc(t); xd )dt; s:t: gd;c(xc(t); xd ) 0; hd;c(xc(t); xd ) = 0: xc = ffh; fng; xd = fi1; i2;Pe; z; l;Ag; fd;c = (xc; xd ) = m_ f : Optimization constraints and variables gd;c, hd;c, and xc;d are dictated by each topology. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 36. Why SDL? Designed Topologies Optimization Problem Results Conclusions Problem Definition Optimization Problem Topologies 2, 3 and 4 enable a controlled pump oil flow, . The minimum flow, at certain driving conditions, is restricted for safety reasons. Bi-level Optimization Sizing Optimization Variable Flow Control Outer Loop Inner Loop Variable Flow Control Cases (flow I): fh = 11; fn = 16 (flow II): fh = 6; fn = 16 (flow III): fh = 6; fn = 11 (flow IV): = r ; for r 6 L=min; 6 L=min for r 6 L=min; r = the required flow Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 37. Why SDL? Designed Topologies Optimization Problem Results Conclusions Problem Definition Optimization Problem Topologies 2, 3 and 4 enable a controlled pump oil flow, . The minimum flow, at certain driving conditions, is restricted for safety reasons. Bi-level Optimization Sizing Optimization Variable Flow Control Outer Loop Inner Loop Variable Flow Control Cases (flow I): fh = 11; fn = 16 (flow II): fh = 6; fn = 16 (flow III): fh = 6; fn = 11 (flow IV): = r ; for r 6 L=min; 6 L=min for r 6 L=min; r = the required flow Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 38. Why SDL? Designed Topologies Optimization Problem Results Conclusions Results Results Analysis Top. 1: Hydraulic Power Steering Infeasible Region Minimum Flow Constraint Fuel consumption, F Optimal gear ration, i1 (Scaled) Gear ratio, i1 [−] (Scaled) Average fuel consumption, F, [L/100km] 7.2 3.6 1,5 1,6 1,7 1,8 1,9 2,0 Boundary solution limited by min. No control flexibility Top. 2: Electro-Hydraulic Power Steering 3 constraints min , Te and !e not for conventional HD vehicles Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 39. Why SDL? Designed Topologies Optimization Problem Results Conclusions Results Results Analysis Top. 1: Hydraulic Power Steering Infeasible Region Minimum Flow Constraint Fuel consumption, F Optimal gear ration, i1 (Scaled) Gear ratio, i1 [−] (Scaled) Average fuel consumption, F, [L/100km] 7.2 3.6 1,5 1,6 1,7 1,8 1,9 2,0 Boundary solution limited by min. No control flexibility Top. 2: Electro-Hydraulic Power Steering 3 constraints min , Te and !e not for conventional HD vehicles EHPS optimization − 16 L/min Gear ratio i [−] Electric motor rated power PEM [kW] 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 15 10 5 Infeasible region Not simulated Motor speed constraint Motor torque constraint Fuel consumption 1.3 1.2 1.1 1 0.9 0.8 0.7 0.6 Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 40. Why SDL? Designed Topologies Optimization Problem Results Conclusions Results Results Analysis Top. 4: Split Electro-Hydraulic and Hydraulic Power Steering 1 2 3 4 5 6 0.4 0.3 0.2 0.1 0 Planetary gear ratio, z [−] Fuel consumption [L/100km] Pareto set Best solution Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Planetary Gear Set (4) 1 2 i ,i e P z n h f , f Flow IV: fuel consumption reduction up to 80% for hybrids and up to 35% for conventional trucks (max. 2.4 kW) The overall best topologies, 3 and 4, result in about the same reduction of about 80%. Added cost and complexity can be high. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 41. Why SDL? Designed Topologies Optimization Problem Results Conclusions Results Results Analysis Top. 4: Split Electro-Hydraulic and Hydraulic Power Steering 1 2 3 4 5 6 0.4 0.3 0.2 0.1 0 Planetary gear ratio, z [−] Fuel consumption [L/100km] Pareto set Best solution Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Planetary Gear Set (4) 1 2 i ,i e P z n h f , f Flow IV: fuel consumption reduction up to 80% for hybrids and up to 35% for conventional trucks (max. 2.4 kW) The overall best topologies, 3 and 4, result in about the same reduction of about 80%. Added cost and complexity can be high. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 42. Why SDL? Designed Topologies Optimization Problem Results Conclusions Results Results Comparison Top. 1 Top. 2 Top. 3 Top. 4 Top. 5 Top. 6 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Average fuel consumption, F, [L/100km] Fixed flow Variable flow I Variable flow II Variable flow III Variable flow IV lowering the minimum flow, hl , improves the fuel efficiency. top. 3,4,5 can also be suitable for conventional trucks Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 43. Why SDL? Designed Topologies Optimization Problem Results Conclusions Results Results Comparison Top. 1 Top. 2 Top. 3 Top. 4 Top. 5 Top. 6 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Average fuel consumption, F, [L/100km] Fixed flow Variable flow I Variable flow II Variable flow III Variable flow IV lowering the minimum flow, hl , improves the fuel efficiency. top. 3,4,5 can also be suitable for conventional trucks Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 44. Why SDL? Designed Topologies Optimization Problem Results Conclusions Conclusions Summary Nested optimization approach has resulted in optimal design and control of the power steering pump The electrification of the PSP can reduce fuel consumption by more than 80% when compared with hydraulic steering and enables Start/Stop and Zero Emission Driving; Future work Adress more auxiliaries and critical secondary aspects (e.g., cost, steering performance) for design. Integrate auxiliary design with powertrain components design for topology, sizing and control. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 45. Why SDL? Designed Topologies Optimization Problem Results Conclusions Conclusions Summary Nested optimization approach has resulted in optimal design and control of the power steering pump The electrification of the PSP can reduce fuel consumption by more than 80% when compared with hydraulic steering and enables Start/Stop and Zero Emission Driving; Future work Adress more auxiliaries and critical secondary aspects (e.g., cost, steering performance) for design. Integrate auxiliary design with powertrain components design for topology, sizing and control. Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 46. Why SDL? Designed Topologies Optimization Problem Results Conclusions Conclusions Thank you! Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 47. Why SDL? Designed Topologies Optimization Problem Results Conclusions Conclusions Extra Slides Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 48. Why SDL? Designed Topologies Optimization Problem Results Conclusions Conclusions Optimization Problem Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump (2) (1) 1 i e P n h f , f Topology 1: xd = fi1g; xc = ; Topology 2: xd = fi1;Peg; xc = ffn; fhg Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV
  • 49. Why SDL? Designed Topologies Optimization Problem Results Conclusions Conclusions Optimization Problem Belt/ Gear Electric Machine Steering Converter – Transmitter (Topology Selection) System Internal Combustion Engine Alternator Source Fixed Displ. Hydraulic Pump Ball-screw Gear Planetary Gear Set (6) (4) 1 2 i ,i e P z n h f , f l Topology 4: xd = fi1;Peg; xc = ffn; fhg Topology 6: xd = fi2;Pe; lg; xc = ; Emilia Silvas (e.silvas@tue.nl) Multi-level optimal design of HEV