EcoCAR3 Controls

Team
Mechanical Engineering Faculty Advisor: Dr. Thomas Bradley
Electrical Engineering Faculty Advisor: Dr. Sudeep Pasricha
Mechanical Engineering Graduate Advisors: Jamison Bair and David Baker
Electrical Engineering Graduate Advisor: Vipin Kukkala

ME Team Members:
Justin Cogswell Hayden Jones
Gabe DiDomenico Ryan Moore
Jacob Gover
Jack Vulcani
Tanner Griffin

ECE Team Members:

Jesus Garcia
Qingruo Si

Acknowledgements
Headline

Visionary
Leadership
Sustaining
Supporter

Contributor

Overview
EcoCAR 3 is the latest AVTC
Sponsored by GM and U.S. Department of Energy
Mission: Serve as North Americas premier training
ground for the next generation of automotive engineers.
CSU is one of 16 university teams to redesign the 2016
Chevrolet Camaro
Four year (2014-2018) process with a competition each
year
Year 3: Refinement, 65% functionality
Multiple workshops and resources
offered throughout the year

Overview
Where are we now?
Year 2 Completed Objectives
SoftECU development
Component startup
Software In the Loop (SIL) model
Hardware In the Loop (HIL) model
Vehicle Wiring
Project Continuation for Year 3
Vehicle In the Loop (VIL) model
Fuel economy optimization
Functional safety
Improvements to vehicle wiring

Background

Environment Issue
Air pollution & Shortages
of fossil fuels
Carbon monoxide, oxides of nitrogen, and
un-burnt hydrocarbons are all released by the
engines. They are all harmful to the
environment and peoples health.
The air quality pollutants cause heart
problems, acid rain, the depletion of Ozone
layer, the global warming and eutrophication.
Toxic chemicals present in the air also have
a bad effect on wildlife.
The fossil oil deposits will be gone by 2052,
the energy gap will be used up in 2060 and
the coal will be depleted by 2088.

"The End Of Fossil Fuels - Our Green Energy - Ecotricity".

Ecotricity.co.uk. N.p., 2016.

Benefits and Markets

Benefits of HEV
Cost less fuel use and maintaining high
performance
Protect Public Health and the environment
Increase Energy Security
Develop more frugal driving habits

HEV Markets
The HEV sales has a significant growth since
2005
In 2008, GM vehicles: roughly 2.6% of U.S.
HEV sales
Toyota vehicles: 77% of U.S. HEV
sales
In 2015, GM vehicles: 1.2% of U.S. HEV

What is the HEV

A hybrid electric vehicle (HEV) has two power
sources which are an internal combustion engine
and a chemical batteries plus an electric motor
drive. Typically, we have three kinds of
drivetrains. In our EcoCAR design, we use the
Parallel Hybrid Drivetrain.

Enang, W. et al. "Modelling And Heuristic Control Of A Parallel Hybrid

Electric Vehicle".

The modes of the Parallel Hybrid

Drivetrain are:
regenerative braking
power assist
motor only
trickle charge
engine only

http://ecocar3.org/colostate/architectureselection/

Driving Modes
Regenerative braking mode: the
electric motor has been used to recover
the kinetic braking energy
Power assist mode: the electric motor
is used to assist the engine
Motor-only mode: the HEV works
almost as an electric vehicle
Trickle charge mode: the engine is
used to drive the load, to keep the speed
request to recharge the chemistry
batteries
Engine-only mode: the internalcombustion engine works only

Enang, W. et al. "Modelling And Heuristic Control Of A Parallel

Hybrid Electric Vehicle".

The Control System

Manages and regulates behavior of other
components
In the Camaro: MotoHawk
Supervisory Controller manages the plant
The plant refers to a subsystem

Subsystems have their own subcontrollers

e.g. Cruise Control

Closed-Loop vs. Open-Loop

Closed-Loop
Feedback

Driving Mode
Focus on energy management and ideal operating
Strategies
line

Charge Depleting vs. Charge Sustaining

Balancing electronic and mechanical systems

Rapidly advancing technology

More advanced feedback loops
More advanced sensors and algorithms

https://cld.pt/dl/download/d14396fd-4148-4312-8830-7e9fa8ebae03/cvt/control/control.html

Control System
Control systems start with modelling and
Software
simulation

MATLAB and Simulink (by MathWorks)

dSpace Simulator for testing

Inside the vehicle: CAN Bus

Controller Area Network
Allows controllers to communicate

Control System
Software*

Evaluating the Control

There are three main components to evaluation:
System
SIL - Software In the Loop

Testing the software under expected conditions

HIL - Hardware In the Loop

Testing hardware applications in a simulated setting

VIL Vehicle In the Loop

Combines simulated and actual testing

Objectives and
Constraints

Objectives
Objective

Priority
Rating

Method of
Measurement

Objective
Direction

Target

Partial Vehicle
Functionality

VDP

increase

65%

SIL and HIL

Demonstration
Simulation

EcoCAR competetion
rules

Match

EcoCAR
Requirements

VIL Integration

Number of subsystems
integrated

Increase

100%

Improve Energy
Consumption

Emissions Measurement

Decrease

10%

Refine Wiring
Harness

Amount of wire used

Decrease

10%

SIL and HIL

Demonstration
Objective

Target Speed
(mph)

Target Time
(seconds)

Start and Idle

10

Acceleration

0-60

30

Drive at steady-state

60

30

Brake

60-0

10

VIL Integration
Subsyste
m

Objective

Gear Train

Cannot be shifted out of park unless brake pedal is depressed, and if 12V or
powertrain is enabled
Function Properly and shift smoothly through all positions

Ignition
Drivetrain
Battery

Cant be started unless in park

Intuitive push start
Effective transmission logic
Refine control strategies
Park/neutral safety switch prevents powertrain torque
Automatic, passive control strategy for charging
12V system is maintained while charging

Constraints

Constraint

Method of Measurement

Limits

System Safety Level

Compliance to Safety
Standards

100%

EcoCAR Rules

Compliance to Rules

100%

Controller Network

Data Transfer Rate

500 Kb/s

Budget

Dollars USD

$10,375

Defining Success

Budget
Projected Budget Needs
Category

Item

Description

Y2 Cost

Y3 Cost

Wires

Low voltage control wiring; 12AWG, 16AWG,

20AWG

$600

$600

Connector
Hardware

Adaptors, ports, and pins for connection to

ECUs and CAN bus

$200

$100

Soldering

Materials for soldering electric connections

$75

$50

Organization

Sleaving, tape, heat shrink, zip ties, tape, etc.

For organization of vehicle wire harness

$150

$100

Discrete
Components

Simple electrical components. Fuses,

switches, etc.

$125

$75

MotoHawk pins and connectors, PCAN

$1,100

$550

Desktop

Upgrade to current PC attached to dSpace

simulator

$800

Laptop

Upgrade to current laptop used for testing at

vehicle

$800

Camera

GoPro

Used for photographing and filming of vehicle

inspections and documentation

$400

Travel

Hotel/Gas/Essentials

Our travel expenses to go to and from

workshops/competition

$5,000

$2,250

$8,475

Signal Connection

Specialty Hardware
and Connectors

Computing Power

Total Cost

Defining Success
Success in Senior Design Deliverables
Fall Semester Deliverables
Fall Swimlane Report Nov. 17th
All vehicle integration work completed, vehicle
refinement work begins
Fall Vehicle Evaluation Dec. 6th
Evaluates functional safety of vehicle & powertrain
functionality

Defining Success*
Spring Semester Deliverables
Pre-Competition Safety/Tech Inspection Mar. 6-24th
Ensures safety of competition vehicles
Spring Vehicle Evaluation Apr. 13th
Video documentation of vehicle progress and
functionality
Ensure 65% project completion
Year 3 Competitions Milford, MI
Control success is vital to many events success

Thank you
Questions?