Virtual Vehicle Development Approach to Optimize Energy Efficiency and Vehicle Stability of Electrified Vehicles Using Brake Blending

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Virtual Vehicle Development Approach to Optimize Energy Efficiency and Vehicle Stability of Electrified Vehicles Using Brake Blending

Yan, Steven / Behnke, Ole / Ahlert, Alexander

Driving range and efficiency are two of the major influencing factors on current electric vehicle development efforts. While the focus is obviously on battery and powertrain technology, an optimized braking system can greatly contribute to achieving range and efficiency goals. Significant negative torque generation by the electric powertrain adds an important degree of freedom to modern electrified brake systems. It not only influences range and efficiency in general but also requires the engineers to tune the electric driving experience according to the specific OEM’s vehicle DNA.

This interdisciplinary challenge between brake, chassis and powertrain systems has to be continuously incorporated into the development process and solved by a cross-domain team collaboration. A full vehicle simulation environment is able to support these activities. Early on, virtual vehicle prototypes can be built up and used in a MIL/SIL environment to evaluate the performance regarding relevant optimization criteria. Further on in the process, component prototypes can be included for calibration and testing on HIL test systems. Later in the process, this is also possible for full powertrain and chassis prototypes.

In an application example, the energy efficiency and vehicle stability of an EV with a rear-wheel drive (RWD) powertrain are analyzed and optimized for different real driving scenarios. Due to the RWD architecture, the amount of regenerative braking (recuperation) directly influencing the energy efficiency is limited depending on the dynamic driving situation. The results from the MIL testing environment indicate that a careful calibration is necessary to ensure the vehicle’s driving stability, but also allow for the highest amount of recuperation at the rear axle. Future studies will take the driver behavior as well as driving and brake pedal force calibration into account.