Successful consortium meeting of the eTestHiL research project

  Second consortium meeting of the eTestHiL research project Copyright: © MSE



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On September 29, we held our second consortium meeting as part of the eTestHiL research project. This time we were guests of the Institute of Automotive Engineering (ika) in the imperial city of Aachen.

During the meeting, important progress in our work packages was presented. Among other things, the final topology of the eLKW powertrain was explained, which includes two powerful electric motors and modularly designed transmission sides with two gears. The focus of current simulation studies is on the investigation of various measures for further installation space and efficiency optimization and the finalization of the transmission concept for the purpose of later detailing for prototype production.

Another focus was on the further development of the chassis using an independent suspension. To this end, the chassis was designed in a detailed simulative process in order to improve handling compared with the conventional rigid axle. The energy efficiency of the tractor unit was increased by the optimized chassis geometry, thus generating an ecological and economic advantage.

The Model-Based System Engineering system model was expanded and modeled in close cooperation with drive experts from requirements through functions and solutions to contact levels. Initial simulation models from powertrain development were successfully integrated into the system model, thus forming a cornerstone for the model library. In addition, a comprehensive thermal management system (TMS) for the eTruck was modeled down to the level of the active surfaces and TMS solution modules were derived from this, which will soon be published as a publication.

The bidirectional converter system for battery emulation up to 1000 V was also addressed. Using simulation results on losses in semiconductors and transformers, the hardware design of the converter modules was explained. In addition, a concept for controlling the overall converter system was presented, in which up to four modular converters are connected in parallel.

In another part of the presentation, it was shown how simulation models can be transferred from the MBSE system model to a HiL model with the aid of transformation algorithms in order to reduce the modeling effort. In addition, a concept was presented on how test bench planning can be digitized using various model connections.

In the second part of our meeting, an interactive workshop was conducted. The aim was to elaborate the experiences and expectations of the eTestHiL consortium on a method guide for the development and testing of electrified heavy-duty drives.

We would like to express our sincere thanks to our eTestHiL colleagues for the good preparation of the presentations and the dedicated participation in the workshop. A big thank you also goes to the ika team for the great preparation and organization.

We are already looking forward to our next face-to-face meeting early next year and are excited to see the results we will have developed by then.

For more information please contact Patrick Jagla.