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Development of Electric Vehicle Controller by using MBD approach
ISSN: 0148-7191, e-ISSN: 2688-3627
To be published on November 21, 2019 by SAE International in United States
Event: NuGen Summit
The automobile industry is moving towards electrification of Vehicle to remove the exhaust gas emissions. A project was undertaken to develop Electric Vehicle control system from concept to vehicle trials in less than a year. The complete development cycle of an electronic controller required to be compressed to prepare mule electric vehicle within timeline. Agile methodology has been used for this project instead of waterfall as other control systems were in developing stage; system requirements were changing frequently. This paper presents the electric vehicle control unit development with agile methodology using model based development (MBD) in MATLAB and Simulink environment. The project flow consists of major phases like design of electrical architecture, system requirements specification, selection and setting up the simulation platform, EVCU strategy development, testing on Model in Loop (MIL)/ Hardware in Loop (HIL), vehicle trials. The electrical architecture of EV has been designed in Simulink for depicting the interfaces of EVCU with different sensors, battery management subsystem (BMS), and charging subsystem including both AC and DC, motor subsystem, relays and actuators. The strategies for controlling the battery, motor, charging, cooling etc. have been matured based on iterative and incremental development using agile methodology. Control modules of each subsystem has been developed in Simulink-Stateflow and integrated in one framework. An optimized code has been generated automatically which reduces time and errors. This integrated framework helped in effective functional unit testing; complete system testing and analysis of impacts on other systems as per incremental changes thereby reducing the complete development time. The challenges faced, solutions developed and lessons learnt are presented in this paper.