Concept design using vehicle system simulation : BEV / FCEV / Hybrid ICE

 
 

Work flow of development

1. Packaging Design

  • FC/PE system
  • FC/PE Cooling system
  • H2 supply system
  • Wire harness
  • HVCU
  • Energy flow display

2. System Evaluation

  • FC system
    - Performance
    - Efficiency
  • HVCU control unit inspection test
  • Battery/PE system

3. Proto vehicle development

  • Repainting
  • Disassembly
  • Components installation
  • Filling hydrogen

4. Proto vehicle test

  • Calibration
    - Driving control
    - Power control
  • Test
    - Fuel economy test
    - Drivability test

FCEV develop.

Tenergy solution :
COC (Constant Output Control) fuel cell hybrid system High vehicle system efficiency, Low FC degradation.
 
Hyundai [Nexo] TOYOTA [SORA] TENERGY (COC FC system) Remark
Motor 120kW 226kW 100kW -
Battery 1.6kWh 7.5kWh 24kWh QC, OBC charge
FC system 95kW 228kW 30kW High effi. const. output
H2 tank 157L 600L 153L (6.0kg) 700bar, Type 4
HEV type Full FC type COC type -
Pros. Low weight High effi., FC low degradation -
Cons. Low effi., FC degradation High weight -

HEV develop.

Tenergy solution :
Series and parallel multi mode system.
▶ Simple structure, High performance

Parallel

Architecture OEM
P0 / P1
  • Limited functionality of EV driving and regeneration
P2
  • Engine drag can be eliminated during EV driving to increase system efficiency
  • Limited PHEV functionality
  • 2 motor 1 clutch system is easier to turn engine on than 1 motor 2 clutch system
 
 

Multi Mode

Architecture OEM
Power-split / Parallel / Series
  • System efficiency depends on the configuration of gear and motor set
Series+ Parallel
  • Tenergy solution
  • Simple structure with high performance
 
 

Power-split

Architecture OEM
  • Simple and easy to control

EV develop.

Tenergy solution :
EV Conversion from ICE vehicle
Development of EV systems (TMS, ePT, Monitor, Controller, etc.)

Controller develop.

Expertise in custom crafting powertrain controllers for diverse vehicle types

  • Specialized feature implementation for Conventional Vehicle, EV, HEV and FCEV
  • Cooperative control with ECUs
  • Considering fail-safe operation
  • Employing diagnostic strategies
 
 

Automotive V-Model Process to design systematic development of software & system

  • Adopting AUTOSAR to enhance standardization, compatibility and reliability
  • Implementing Continuous Integration and Continuous Deployment (CI / CD)
  • Leveraging Model-Based Design (MBD) for improved system design and testing
  • Integrating Hardware-In-the-Loop Simulation for real-time testing and validation

Overview

1. Literature Survey

  • Patent
  • Maintenance manual
  • BM video
  • Public articles

2. Data Acquisition and Test Design

  • CAN reverse engineering
  • Installing sensor
  • Design test schedule

3. Vehicle Test

  • Coast down test
  • Chassis-dyno test
  • Real driving test

4. Vehicle Control Strategy Analysis

  • Analysis system
  • Analysis test results
  • Analysis control strategy
 
 

Vehicle test

Chassis dynamometer test

  • Simulate real road driving
    Driving, slope climbing & charging
  • Operating range: -20℃ ~ 55℃

Charging

Wheel dynamometer test

  • Direct measurement of PT output
    Performance
    Efficiency

Cold chamber test

  • Operation range: -30℃ ~ 0℃
    Thermal management
    Battery charging
    EV Charger(~100kW)
 
 

Test vehicle list

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