Before going into production, a conceptual vehicle powertrain is & can be tested on virtual environments for analyzing/optimizing performance of the vehicle in terms of its acceleration-torque characteristics, power regeneration, fuel economy & its accordance with emission norms which are governed by various legislative and no-legislative acts across the globe such as Comissions Regulations (R(EU) 2018/1832 . As a part of course work while studying MSc Automotive Engineering with Electric Vehicles at Oxford Brookes University, an opportunity was given to develop Real World Drive Cycles for Oxford city for the purpose of testing Real Driving Emissions. Along with this 2 different types of EURO 4 compliant vehicle numerical powertrain models were also developed using available literature & further those models were tested & validated based on fuel economy & greenhouse gas emissions by simulating the models on legislative drive cycles & the results were compared with developed Real World Drive Cycle.
Well-To-Wheel (W-T-W) analysis is a method of identifying total amount of pollutants generated in overall life-cycle of the fuel, stating from extraction of natural resources, generation of fuel, it's transportation & lastly pollutants emitted while actual usage of the fuel. If W-T-W emissions are considered, there is no such vehicle which can be said to be zero emissions, although a hydrogen fuel cell based vehicle, where hydrogen is purely made by electrolysis using wind turbine generates least emissions. Thus Hydrogen is the safest & most environmentally friendly fuel at the moment off-course along with carbon neutral fuels.
Stages of Well-To-Wheel analysis:
Well-to-Tank/Pump Analysis (W-T-T):
In this first stage pollutants generated from crude oil extrusion, generation & while transportation of fuel are taken into consideration. As some of the parameters are related to geographical location & different weather conditions while fuel generation-transportation, the results of W-T-T analysis vary country to country. Although 'GREET Life-Cycle Model' made by Argonne National Laboratory is a detailed & widely accepted tool used for this purpose.
Tank/Pump-to-Wheel Analysis (T-T-W):
2nd stage in W-T-W analysis is Tank-To-Wheel analysis in which emissions generated while the consumption of fuel is measured. This type of analysis can be done on model based powertrain simulations and also by actually coupling a Portable Emission Measurement System (PEMS) with the exhaust system of the vehicle and testing the vehicle in real world using legislative drive cycles.
There are multiple component based powertrain modelling software & some of the best widely used software in industry based on my knowledge are listed below:
Gamma Technologies GT-Suite - a versatile tool with applications from automotive to aeronautical industry, being literate in this & based on the availability of this software In my university I chose this software for the work which is further discussed on the page.
Open Modelica - This is an open source software available for free & possesses similar level of capabilities as of GT-Suite & it's FAQ forums are well explanatory for the usage.
Dassault Systems Dymola - It's a commercial software based on Open Modelica and equipped with more complex component based systems.
Matlab-Simulink - This is the most versatile software ever produced for model based system design as per my own experience.
Drive Cycle is a set of data points representing vehicle speed (acceleration / deceleration) with respect to time. These drive cycles are made by automotive legislative bodies across the globe for standardization of emission & fuel economy testing.
Following is the list of Legislative drive cycles with their respective year of implementation:
Economic Commision for Europe (ECE-15) Urban Drive Cycle : Year 1970
Japan: Mode 10: Year 1973
US: Environmental Protection Agency's Federal Test Procedure (FTP 72/75): Year 1978
Europe: Extra Urban Drive Cycle (EUDC): Year 1990
Japan: Mode 10-15 Drive Cycle: Year 1991
New European Drive Cycle (NEDC): Year 1997
US: Supplemental Federal Test Procedure (3 Drive Cycles): US06, SC03, Cold Cycle: Year 2007/2008
Further To make these drive cycles represent more realistic real world driving patterns in year 2015 NEDC has been replaced by new,
World Harmonized Test Procedure
more detailed information about these drive cycles can be found on DieselNet
Development of vehicle models can be done using different software but to validate those models one needs exact or nearly appropriate information about specific vehicle system.
Following is the list of Trusted Automotive & Standards related literature resources preferred by the author:
Despite of having legislative drive cycles which represent driving pattern of the driver, the real world driving scenario may vary drastically depending upon the weather conditions, amount of traffic & driver's mental-physical health. Due to such reasons, the vehicle will give different results for greenhouse gas emissions when tested on legislative drive cycle vs. when tested on real world drive cycle.
In order to tackle this problem, an attempt was made to develop Real World Drive Cycles for regular, relaxed & aggressive driving patterns. all the 3 drive cycles followed same route while following predefined test specifications as shown in Fig.1. Following a similar approach was used as of World Harmonized Test Procedure drive cycle, this drive cycles included road passing through Urban, Motorway & Rural areas.
Vehicle location & speed vs. time data was collected using SpeedView android application. once data was collected, .gdx file was then exported from the application which was converted to Microsoft Excel compliant file format using GPS Visualizer file conversion tool. The data was checked for identifying any errors due to GPS signal losses & unwanted halts. As it can be seen in Fig.1, these errors were then rectified by implementing a moving average data filter & data was made usable for Tank-to-Wheel Analysis for identifying greenhouse gas emissions & fuel economy using model based powertrain simulation.
Fig.1: Oxford Real World Drive Cycle
A complex model of power-split hybrid type of powertrain configuration was developed using existing GT-Suit libraries (Fig.2) & the model parameters were defined as per the specifications of EURO 4 compliant 2nd Toyota Prius THS-II powertrain. The required data was identified from the published literature & datasets available in the university. Model was validated against New European Drive Cycle while comparing the published & simulation results of Fuel Economy & Greenhouse Gas Emissions. This model is further being developed to equip a micro gas turbine range extender.
Supervisory Controller:
This is the mind of the vehicle which receives power demand from the driver and communicates with all the vehicle subsystems to propel the vehicle in efficient manner. In simple terms, it is a in-vehicle event manager which decides the vehicle propulsion mode such as pure electric, pure combustion or hybrid mode of operation based on the power demand from the driver & battery state of charge. (Fig.3)
Power-split Device (PSD):
This is the most important part of this type of powertrain configuration, as it enables vehicle to use multiple power sources to propel the vehicle at the same instance. PSD is a planetary gear set of which Sun gear is connected to Electric Motor 1 (EM1) & Internal Combustion Engine, whereas Ring gear is connected to Electric Motor 2 (EM2) & final drive differential. This allows EM1 to acts as a starter motor for the engine as well as power regeneration alternator. Also PSD allows supervisory controller to use IC engine & EM2 as a combined power source to meet the power demand from the driver in accelerating condition. (Fig.3)
Fig.2: Toyota Prius THS-II Powertrain Model & Validation Results
Fig.3: Power-Split Device Exploded View & Power-Split Hybrid Powertrain schematic diagram
A basic component based model of a conventional combustion vehicle was made using GT-Suite and component parameters were defined as per the specifications of Volkswagen Lupo car. Data for EURO 4 compliant engine's speed, torque, brake mean effective pressure & brake specific fuel consumption was obtained from available datasets from the university. The model was validated by comparing the results of fuel economy & CO2 emissions generated by the model when tested against NEDC drive cycle. Once validated the model was tested against all the major legislative drive cycles & also with real world drive cycle. (Fig.3)
It was observed that change in gear shifting time largely affects amount of CO2 emission for example early shifting caused higher CO2 emission in comparison to standard gear shifting strategy.
It was observed that CO2 & NOx emissions of real world passive and relaxed driving cycle was lower than most of legislative drive cycles whereas for CO2 emission was higher and NOx was lower than NEDC for aggressive driving. (Fig.2)
Real world CO emissions were extremely higher than all legislative cycles except US06 which is nearly 3 times of EURO 4 standard limit of 0.50g/km. (Fig.3)
Real world HC emissions were close to legislative cycles except aggressive driving, which has maximum amount of HC emissions.
It was proved that Real Driving Emissions & Fuel Economy vary drastically with driving pattern and legislative drive cycle cannot provide accurate results of emissions.
Fig.4: Volkswagen Lupo Model & Analysis Results
Fig.5: Volkswagen Lupo Model Validation
Fig.6: Volkswagen Lupo Model Fuel Economy Results