Testing and Validation of a Series PHEV Control System

Abstract

EcoCAR 2: Plugging into the Future is an Advanced Vehicle Technology Competition managed by the U.S. Department of Energy at Argonne National Laboratory. The competition challenges 15 universities across North America to reduce the environmental impact of a production vehicle without compromising performance, safety and consumer acceptability. To meet this goal, the Pennsylvania State University Advanced Vehicle Team has designed a series plug-in hybrid electric vehicle (PHEV) capable of achieving a 40 mile all-electric range. An auxiliary power unit (750 cc two-cylinder engine converted to run on E85 fuel) provides extended range greater than 200 miles. A rigorous development process has been followed to provide a control system that meets the safety, performance and fuel economy targets, including fault mitigation. This paper summarizes the control system development strategy, starting with vehicle component selection. The strategies used to develop a control algorithm and plant model in parallel are described. Extensive testing is performed throughout the vehicle development process, including both software-in-the-loop (SiL), hardware-in-the-loop (HiL), and in-vehicle testing. In addition, it will be shown how pertinent testing data plays a crucial role in further plant model developments.