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FEATURE AUTOMOTIVE ELECTRONICS


Developing electrified propulsion system concepts


power electronics. This is allowing it to assess electrified powertrain concepts, perform initial calibration and develop connected monitoring solutions under realistic constraints and real-world drive cycles within a virtual environment. To maximise life of batteries, battery


management systems should be designed with over the air updates in mind. The company can also represent these systems digitally and use in service monitoring in combination with a hybrid of physical and data driven modelling for prognostics, and to develop and test calibration updates virtually. Additionally, the ability of a Digital


Twin to store and process historical data and monitor state of health will allow for informed decision making on both recycling and second-life applications, which will lead to improved resource efficiency in the supply chain. In the Ricardo Digital Twin toolchain,


Ricardo’s Paul McGahan explores how digital twins can improve efficiency and performance of power electronics for electric vehicles


V


ehicle electronics systems are becoming ever more complex.


Vehicles are now defined by high levels of complexity driven in part by a significant growth in architecture solutions, and heavy reliance on the integration between multiple systems. Current passenger cars can have as many as 150 electronic control units – programmable computing elements – and hundreds of millions of lines of software code. With many governments around the


world announcing bans on the sale of new petrol and diesel cars within the next 10 years, automakers are looking for ways to hasten the take-up of battery electric vehicles. The biggest barrier to the mass adoption of electric vehicles is cost with vehicle attributes of range and durability in close second and third. A battery typically reaches 70% of its


nominal capacity at automotive end-of- life, meaning that significant capacity is still available for lower power applications. Digital Twin technology will bring a


8 MARCH 2021 | ELECTRONICS


significant reduction in electric powertrain development time, cost and risk: through up-front design analysis, optimisation and testing in a virtual environment, without the need for multiple prototypes. A Digital Twin is a representation of any physical product that can be used as testing grounds for monitoring, simulating and optimising design and operational performance. A current area of focus for Ricardo is


assessing the impact of Digital Twin techniques on product development and the application of Digital Twins to product maintenance to reduce time, cost and risk of electrified powertrain development, addressing the development of on-vehicle technology and speeding up its introduction to market.


DEVELOPMENT TECHNIQUES The company is developing its existing analytical modelling, simulation and model complexity reduction techniques for battery, e-machine, transmission and


the company has developed models to enable engineers to assess the performance of electronic components at different stages of the product delivery. Developing models that capture component physics requires access to quantities usually not available in component datasheets and therefore limits their usability. For that reason, the company uses behavioural modelling to generate the component models allowing for quick parametrisation through datasheet information. To support hardware engineers assess different components as well as system engineers assess the overall powertrain, different fidelity models have been developed to accommodate different simulation scenarios, without increasing the computational load. High-Fidelity Models capture the


switching behaviour of devices reporting the underlying conduction and switching losses as well as voltage drops at a timestep orders of magnitude smaller than the switching period. On the other hand, Medium-Fidelity models evaluate the average behaviour of the system by estimating power losses at a timestep equal to the switching frequency therefore allowing for longer simulation scenarios.


Ricardo www.automotive.ricardo.com


/ ELECTRONICS


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