GREEN MOBILITY
System component sizing
- Satisfying performance requirements (driving range, speed, acceleration, efficiency, etc)
- Minimizing energy consumption
- Maximize packaging efficiency
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Powerplant system configuration examples for FCEV
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Packaging variants with various H2 tank and batteries
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Powerplant system (FC and Battery) power distribution strategies example
Vehicle conversion procedure
1. Packaging Design
- FC/PE system
- FC/PE Cooling system
- H2 supply system
- Wire harness
- HVCU
- Energy flow display
Packing design validates layout feasibility of vehicle components.
2. System Evaluation
-
FC system
- Performance
- Efficiency - HVCU control unit inspection test
- Battery/PE system
System level evaluation is executed to verify that each system satisfies the design specification.
3. Proto vehicle development
- Repainting
- Disassembly
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Components
installation - Filling hydrogen
After confirmation of systems, proto vehicle is built.
4. Proto vehicle test
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Calibration
- Driving control
- Power control -
Test
- Fuel economy test
- Drivability test
Vehicle level calibration is done and field test ensures the overall fulfillment of the vehicle development.
EV & FCEV platform development
EV > FCEV
Installation :
- Fuel cell system (FC stack & BOP)
- H2 tank
- Boost DC-DC converter
- Integrating junction box
- FC radiator
- etc
EV & FCEV platform development
ICEV > FCEV
Detachment :
- Engine
- Exhaust pipe
- Fuel tank
- Battery
- Motor
- Fuel cell system (FC stack & BOP)
- H2 tank
- Boost DC-DC converter
- Integrating junction box
- etc
BEV Thermal management system
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Define functions
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System build and simulation
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Rig test and validation
Hydrogen fuel supply system
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System modeling
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System strength simulation
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Vehicle installation and test
Vehicle control unit development
Controller for system integration (VCU, HVCU, HMU, TMS, FCU)
- Co-operative control (Traction control, regeneration, charging, TMS, …)
- Function limit considering system components
- Integrated E/E architecture
- Fail-safe
xEV Benchmarking
Vehicle electric economy, driving performance, TMS and charging strategies analysis
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Vehicle electric economy analysis
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Thermal management system analysis
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Charging control map analysis
Benchmarked vehicles list
HEV/PHEV
- BMW 330e PHEV
- Audi A3 PHEV
- Lexus UX250h HEV
- KIA Sorento HEV
EV
- Tesla Model 3
- Tesla Model Y
- HMC Ioniq 5
- KIA EV 6
- Audi E-tron 55 quarttro
- BMW i3
- XiaoPeng P7 4WD
- BYD tang 600D EV
- BYD song pro EV
- GM Bolt
FCEV
- Nexo FCEV
- Elec-city FCEV bus
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Benchmarking List (2019 ~ 2022)
Electric Component Test
E-PT, high-voltage battery and fuel cell system/BOP test is available
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Motor test
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E-PT test
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EV battery pack teardown and component analysis
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FC component test
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FC system test
Analysis system for
mobile data loggers with web interface
For testing and optimizing their utility vehicles, most O.E.M operates a fleet of vehicles equipped with measurement systems. Several hundred signals related to the vehicle’s operation are recorded over an entire shift: temperatures, pressures, rotation speeds, brake pedal operations, accelerations and shifting operations as well as a large number of controller parameters. Several gigabyte of raw data is collected per vehicle and shift and automatically transmitted to a central server.
