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

Gabe DiDomenico

Jacob Gover

Tanner Griffin

Hayden Jones
Ryan Moore
Jack Vulcani

ECE Team Members:

Jesus Garcia

Qingruo (Angela) Si

Problem Statement
To design the supervisory control strategy and low voltage
wiring system for the CSU EcoCAR3 plug-in hybrid electric
Camaro, in order to improve fuel and energy efficiency of
the vehicle while reducing well-to-wheel greenhouse gas
emissions.

CSU EcoCAR3 Project Background

SIL - Software In the Loop
Creates the controller program & vehicle model
No losses, instant shifts
Basic torque split strategy

HIL - Hardware In the Loop

Builds on the SIL model for real-time execution
Should be parallel to SIL
Develops and performs test cases

VIL Vehicle In the Loop

Implements low voltage electrical systems
All components connected
Sub-optimal wiring harness
Poorly documented wiring schematic

Technology

Matlab/Simulink
o

Design/simulation program

dSpace Real-Time Simulator

o

HIL development

ControlDesk
o

Real-time data acquisition

MotoHawk
o

Woodward automotive controller

MotoTune
o

Flash/read MotoHawk

Vector CANoe
o

Read CAN bus messages

Objectives
Objective

Subsystem Integration

Priority
Rating
(1-low) (5high)
5

Method of Measurement

Objective
Direction

Target

Number of Subsystems Fully

Integrated (Wiring/Data Transfer)

Increase

100%
Integration

Accuracy of SIL Model

Detrimental Signals

Decrease

Successful HIL Testing

Comparison to SIL results

Increase

100%

Refine Wiring Harness

# of Missing Wires/Faulty
Connections/Unnecessary Wiring

Decrease

CAN Bus Load

% Time of Controller
Communication

Decrease

30%

Simulated/Real World Gasoline

+ Battery Power Usage
Simulated/Real World Gasoline
Usage
Simulated/Real World

Increase

25 mpgge

Decrease

750 Wh
PE/km
250g GHG/km

EcoCAR3 VTS
UF-Weighted Total Energy
Consumption
UF-Weighted WTW Petroleum Energy
Use
UF-Weighted WTW Greenhouse Gas
Emissions

3
3

Decrease

Constraints
Constraints

Method of
Measurement

Limits

Baud Rate

kBaud

500

Access to Plant Controllers

Alteration of Plant
Controller Logic

Cannot Alter

Access to Brakes

Alteration of Brakes

Cannot Alter Brake

Specifications

Communication Protocol

Type of Protocol

CAN only

Architecture

Components

Pre-existing

Budget

Dollars

$10,000

Design Summary
Software-in-Loop (SIL)

o Includes a rudimentary CD/CS model

Engine only on when battery SOC is low
A switch that activates CS

o Basic transmission model

The spikes illustrate the gear changes

o Accounts for few losses

Has

Drag

Needs

Friction
Electric

o Monitors most of relevant data

Needs greenhouse gas output

Design Summary cont.

Hardware-in-Loop (HIL)

o HIL model is not in vehicle

More advanced than SIL

Currently does not run
Not monitoring all necessary points
Unorganized
Bad naming convention

HIL Setup

Design Summary cont.

Vehicle-In-Loop (VIL)

o Motohawk program is older than current HIL

Last version that works

o Mostly complete wiring

Inconsistent with schematics
Pin-outs
Wiring diagram
Components list

Final Concept
Modeling

o Account for all losses

o
o
o
o

Friction
Heat losses
Drag
Inefficiencies

Accurate Transmission Model

Effective torque split
Easily transferrable SIL to HIL
Overall efficient vehicle

Wiring

o Refinement for manufacturability

o Schematic update

Final Concept cont.

Feasibility Analysis
o Programming

Starting with basic model

Time
New computer- quicken simulations

o Wiring
Existing harness
Minimal cost for refinement

FMEA and Risk Analysis

FMEA and Risk Analysis

Item/Function
Failure Mode
Potential Effect(s) of Failure
E-Stop buttons Nonfunctional, does
System continues operating in
not stop High
unsafe conditions. Can't stop
Voltage/fuel flow when system in case of emergency. Loss
pressed
of vehicle or loss of life.
Transmission
Stuck in gear/ unable Run engine at high RPM
shifting while
to shift into certain
(overheating). Poor performance.
driving
gears
Effects on torque split strategies or
CD/CS strategies.
Vehicle velocity Incorrect or missing
While parked, will not allow PRNDL
sensor
measurements
switch. While in drive, overspeeding or over-torqueing of
components.
Accelerator
Acceleration pedal
Unintended acceleration. Lack of
pedal position signal failure
acceleration. Limp mode.
sensor
Brake pedal
Misread brake pedal
position sensor signal

Unintended braking.

Computer DAQ Ceases displaying or

reading data

Loss of ability to troubleshoot and

monitor vehicle control states.

Shift out of
Park/PRNDL
shifts

Immobile car. Loss of primary

function.

Unable to shift out of

park

12V disconnect 12V switch failure

switch

Car will not start.

Engine Switch

Driver is unable to turn the engine

on and must rely on the electric
motor.

Switch signal
nonfunctional

S Potential Cause(s) of Failure O Current Design Controls

10 Poor connection, incorrect
1 Preventative: High quality
wiring, loss of power
mechanical switches in use.
Redundancy with two
separate switches.
7 Improper TCU communication,
4 Control: Notify driver of
faulty model logic
transmission state through
CPU
7 Sensor malfunction, wheel slip,
broken shafts, signal
malfunction
10 Broken POT, short wire, wires
unplugged, signal malfunction

D RPN
Recommended Action
9
Regular, frequent checks of
the e-stop system. Introduce
90
notifications to driver for
problems with e-stop.
3
Regular wire connection
checks, simulate model
84
before flashing controller, fix
logic.
2 Control: Activate "Limp Mode" 5
If problems occur, run signal
logic operating condition
diagnostics. Create a way to
70
notify driver.
2 Preventative: High quality
3
components. Control: Activate
"Limp Mode"

8 Broken POT, short wire, wires

unplugged, signal malfunction

2 Preventative: Mechanical
3
brakes available. (No
complete loss of braking)
8 Broken connectors, wiring, or
5 Detect: Computer nofitication 1
faulty logic from the supervisory
of loss of data transfer.
controller
8 Dead battery, disconnected
3 Control: Diagnose error
wires, faulty model logic, sensor
malfunction, malfunctioning A/D
converter, user error, signal
malfunction
8 HV battery fail, dead battery,
3 Preventative: Shielded and
fuse, wire loose, poor
wear-resistant wires, battery
connection
redundancy (HV +12V)
7 Incorrect wiring, broken
2 No current design controls
connectors, faulty model logic

60

48

40

1
24
1
1

Extensive testing should be

done on these components
because severity is high.
Regular wire connection
checks
Regular wire connection
checks, regular chekcs for
the mechanical brakes.
Procure more robust wiring
and connectors to prevent
loss of information flow to the
computer.
Regular battery and wire
connection checks, simulate
model before flashing
controller.

Replace battery when

24 needed, regular wire
connection checks.
Simulate model to make sure
14 logic is correct. Regular wire
connection checks.

Design for X
Safety:
o Safety-critical functions prioritized by CAN ID
Lower Identification Number = higher priority
Emergency stops, PRNDM control, etc.

o Secure wiring
o Properly functioning models

Reliability:
o Kinematic states defined for state-flow subsystems
o Powertrain functionality communication given second priority
o Secure physical connections within wiring harness

Manufacturability:
o Efficient, functioning supervisory controller model
o Manageable wiring harness

Validation Plan
How we approach problems:
1.
2.
3.
4.

Define the desired functionality

Develop the necessary mathematical functions
Compile a list of relevant inputs and outputs
Apply it to the model and verify output

Example:
5. Driver Torque Request
6. Stock torque request map (vehicle speed vs pedal positions)
7. List inputs and outputs
a) Inputs: Vehicle Speed, Pedal Positions
b) Outputs: Driver Torque Request
8. Simulated drive trace vs. desired drive trace

Validation Plan cont.

Wiring Harness

o Communication and operation

Controllers and relays

o Audit of wiring harness

Correctness
Wire lengths
Accessibility
Efficient looming

Motohawk Programming
o Realistic and safe controls
Assertion blocks in model

o Test cases created by HIL

Efficient controls
Meets EcoCAR3 VTS
Ex. 25-30 mpg

Test Case Name

Version

<Updated version number> X.X

Updated

<Most recent date> XX/XX/XX

Author(s)

<Name 1, Name 2, >

Test Case Description

<A brief overview of what the test is looking to accomplish and

which components are involved>
Test Case Procedure

Test Initialization

<Step by step instructions for how to initialize the test>

Test Body

<Step by step instructions for how to execute the test>

Test Completion

<Step by step instructions for how to document the test

results and reset to the original pre-test state>
Test Case Summary

Pass/Fail Criteria

<Criteria 1, Criteria 2, >

Expected Results

<A short summary of what the tester should look for within
the results of the test>

Test Results

<Actual test results to be compared to expected results>

Pass/Fail

<Yes/No>

Comments

Test cases allow anybody to set up and

execute a test of a controlled vehicle function
Outlines the procedure and evaluation criteria
for functionality of modeled systems
Developed in order of priority:
1. Safety-critical functionality (eg.
emergency stops, airbags)
2. Powertrain functionality (eg. torque
command, transmission)
3. Deliverable functionality (eg. AC
system, qualitative assessments)
Should be developed for each domain:
simulated, real-time and in-vehicle

Term 2 Goals
SIL
Coordinate with HIL to match/update models
Model controllers separate from physical system
Implement robust CD/CS strategy
Torque splits for motor and engine
Incorporate losses
HIL
Coordinate with SIL to match/update models
Create testing plans and programs

VIL
Continue updating schematics
Continue working out current bugs
Improve the wiring harness
Unnecessary wire lengths
Inefficient looming
Rerouting
Dates
2/06/17 Match Model to Output
2/23/17 Spring Vehicle Evaluation
WOT 0-20
Hard Braking 0-20

Thank you
Questions?