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Paper presented at the 4th International Modelica Conference, March 7-8, 2005,
Hamburg University of Technology, Hamburg-Harburg, Germany,
organized by The Modelica Association and the Department of Thermodynamics, Hamburg University
of Technology
Program Committee
Local Organization: Gerhard Schmitz, Katrin Prölß, Wilson Casas, Henning Knigge, Jens Vasel, Stefan
Wischhusen, TuTech Innovation GmbH
The PowerTrain Library: New Concepts and New Fields of Application
1 Introduction
The PowerTrain library [6] is a licensed Modelica
package providing components for modelling vehicle
powertrains. It is also used for the modelling of gear-
boxes with speed and torque dependent losses. The
available components range from simple, easy to use
parts to very sophisticated components. All the com-
ponents are open and can be extended and modified by
the user.
In December 2002, version 1.0 was finished and since Figure 1: Components of the PowerTrain library and
then several new developments have been incorporated some sublibraries
into the library. In addition, new concepts in the Mod-
elica language have been applied leading to improve- A very important property of the PowerTrain library is
ments aimed at delivering better interoperability be- the robust and efficient handling of speed and torque
tween the different automotive model libraries avail- dependent friction [8] as illustrated in Figure 2, which
able. These are described in Section 3. In Section 4, occurs when considering gear mesh efficiency (due to
new fields of application are described and new driver gear teeth friction) and bearing friction. This novel
models are presented in Section 5. type of friction handling was used in many compo-
nents in version 1.0, especially for planetary gears,
Ravigneaux gears, Lepelletier gears, extended Simp-
2 Previous library status son gears and differential gears.
Large system models often become difficult to under-
In the past, the library provided standard and planetary stand as there can be a large number of signals that
gearboxes with speed and torque dependent losses, need to be passed between the model’s top-level com-
table-based engine and simple driver models, and ponents. To overcome this problem, the PowerTrain
components required to model the longitudinal dy- library used a signal bus as shown in Figure 3. The
namics of vehicles, as well as a range of detailed exam- idea was that all the signals that have to be exchanged
ples. Version 1.0 of the library contained 45 reusable by the components are included on the bus. The com-
∆τ τΑ ∆τ
>0
ωA = 0 ∆τmax1, ωA
ωA ∆τ(ωΑ=0) τΑ
∆τ , ωA < 0
min2
τΑ
The gearbox and shaft components can be animated, 3.1 Incorporation of 3D effects
see Figure 4 for an example, which is useful for plau-
sibility checking and demonstration purposes. Ani- In [9], a concept for reproducing the three-dimensional
mation can be switched off by a parameter. In this (3D) mechanical effects of one-dimensionally (1D)
case, the complete animation code is removed from a modelled powertrains has been presented. The idea
model in order to get efficient simulation code, e.g., is to model transmission elements with their mostly
for hardware-in-the-loop simulations. 1D rotating behaviour in a convenient way with 1D
A number of control systems as shown in Figure 5 model components. Due to the simplicity of the
were included in the library. These are used to con- 1D equations, this results in very efficient simula-
trol the engine and transmission models. The control tion code. When these 1D components are mounted
on systems moving in 3D space using the Model- tiated and the connect statements referring to them are
ica.Mechanics.MultiBody [7] library a number of im- ignored. The advantage in comparison to simply set-
portant effects, such as support torques and gyroscopic ting the damping coefficient d of damper to zero is that
torques, are missing. By including adaptor models and the equations of the disabled components are removed
a 3D inertia component it is possible to incorporate from the model and from the generated code, leading
these missing effects. to more efficient simulations.
These 3D effects are incorporated in version 2.0 of This feature is now used to incorporate 3D effects into
the PowerTrain library. By default, 3D effects are the PowerTrain library. To include 3D effects into the
turned off to get fast simulations, which is especially components, a MultiBody connector is required but for
important for real-time purposes [3, 10]. The 3D ef- the simple 1D case, it is desirable to remove these con-
fects can be turned on through the use of a parameter. nectors. Therefore, the base class shown in Listing 2
This has been implemented using the new Modelica was implemented which is inherited by the affected
feature conditional declarations that have been intro- components of the PowerTrain library.
duced in version 2.2 of the Modelica language speci-
fication. The idea is illustrated using the example in
Listing 2: Base class for components with optional 3D
Listing 1 and the object diagram in Figure 6.
effects
partial model ThreeD
Listing 1: Example demonstrating conditional decla- import Modelica.Mechanics.MultiBody;
parameter Boolean enable3D=true;
rations MultiBody.Interfaces.Frame_a
model DampedInertia frame_a if effectiveEnable3D;
import Modelica.Mechanics.Rotational; protected
outer MultiBody.World world;
extends Rotational.Interfaces.TwoFlanges; parameter Boolean effectiveEnable3D=
world.enable3D and enable3D;
parameter Boolean damping=true; end ThreeD;
Rotational.Inertia inertia;
Rotational.Damper damper(d=10) if damping;
Rotational.Fixed fixed if damping; This base class allows the 3D effects to be switched on
equation or off in two ways:
connect(inertia.flange_a, flange_a);
connect(inertia.flange_b, flange_b);
connect(damper.flange_a, fixed.flange_b);
connect(damper.flange_b, flange_b);
• The base class provides a Boolean parameter en-
end DampedInertia; able3D, which can be used to disable the 3D ef-
fects for a particular component.
used throughout the PowerTrain library when 3D ef- sion 2.2 of the Modelica language specification. In
fects might be included. By default, only 1D behav- the simplest case, an expandable connector is merely
iour is modelled and all the code for the 3D effects is an empty connector, see Listing 3. This connector
removed during the code generation phase. By inher- class can be instantiated in different components, e.g,
iting from this class, it is easy to enable 3D effects and Source and Integrator in Listing 3, and it is possible to
then place the complete powertrain models onto 3D connect to components in the expandable connector,
moving parts without neglecting any 3D effects. even though they are not defined in the class defini-
Figure 7 shows a model which combines compo- tion of the bus. The various connect statements are
nents of the PowerTrain and the VehicleDynamics li- evaluated at compile time and the union of all refer-
brary [2]. The 3D effects are modelled in the pow- enced variables is used to build the actual bus connec-
ertrain. First investigations, see Figure 8, of such a tor. During translation a check is made to ensure that
model have been performed in [5]. every signal read from the bus is defined exactly once.
model Source
Bus bus;
Blocks.Sources.Sine sine;
equation
connect(sine.y, bus.dq);
end Source;
Figure 7: Powertrain model with 3D effects combined
with vehicle dynamics model model Integrator
Bus bus;
Blocks.Continuous.Integrator integrator;
equation
connect(integrator.u, bus.dq);
connect(integrator.y, bus.q);
end Integrator;
model Example
Bus bus;
Source source;
Integrator integrator;
equation
connect(bus, source.bus);
connect(bus, integrator.bus);
end Example;
end BusTest;
Figure 8: Animation of a joint powertrain and vehicle
dynamics model
In the previous version of the PowerTrain li- • At the input (axis A) a unit acceleration is applied
brary, the two components Gears.PlanetPlanet and for 1 s. This means that the speed of axis A starts
Gears.PlanetRing were provided so that any type of at zero, and rises linearly to 1 rad/s during the
planetary gearbox could be constructed. These ele- first 1 s of the simulation and then remains con-
ments have been improved so that speed and torque stant at 1 rad/s. Since the speed is constant, the
dependent losses are now taken into account. An ex- inertias inside the gear do not have an effect for
ample is shown in Figure 11 where a planetary gear of the power distribution.
the Wolfrom type, with losses, is constructed using the
PlanetPlanet and PlanetRing components. • To avoid possible problems with the non-
uniqueness of solutions of friction elements when
forcing the wheel to rotate according to the de-
sired acceleration, the forced movement of the
flange is not directly required. Instead, the ac-
celeration component drives a very stiff spring
which in turn drives the gear flange.
Figure 11: Object diagram of Wolfrom type planetary • The gear efficiency is the ratio of the cut-torques
gearbox with losses implemented using the improved of flange_A and flange_B divided by the gear ra-
PlanetPlanet and PlanetRing components tio.
The overall gear ratio and efficiency of a plan- • The above two numbers can most easily be deter-
etary gearbox constructed using these basic ele- mined from the simulation, in Dymola, by click-
ments can be calculated using the model Power- ing in the plot window on Advanced and then set-
Train.Examples.WolfromEfficiency shown in Fig- ting t = 2 in the input field Time. This displays the
ure 12, provided that the number of teeth on each of values of all variables in the variable browser at
the gearwheels and the efficiencies of each mesh (gear t = 2.
Figure 13: Screenshot of Dymola showing example model on Vehicle Model Architecture basis
It would not be possible to determine these values us- 4.1 Flexible driveline models
ing a static model where the gear shafts are not ro-
tating. This is because the friction between the teeth An area of increasing interest is the modelling of vi-
would be in the stuck mode and the friction torques brations and oscillatory responses within the whole
are then computed implicitly from the requirement powertrain. These effects are required when attempt-
that the shaft accelerations are zero. This is correctly ing to simulate driveability, shift quality or other sim-
described by the Modelica model and therefore does ilar effects that are likely to introduce oscillatory
not allow the efficiency to be calculated using a static torques into the powertrain system. The study of
model. these effects has required the development of addi-
tional driveline component models that include addi-
tional effects such as stiffness, damping and backlash.
The first key component required was the flexible
3.4 Vehicle Model Architecture
shaft, which introduces the ability to model the twist-
Within Ford Motor Company’s Powertrain Research ing of a shaft, such as the propshaft or driveshafts. In
Department an architecture for modelling of vehicles it’s simplest form the flexible shaft consists of two ro-
has been developed and reimplemented in Modelica. tational inertias connected by a linear spring-damper.
The resulting Modelica package was presented in [11] In this form the shaft can be used to model low fre-
and is freely redistributable in source code form. In quency effects such as shuffle, which occurs in the
order to promote interoperability with other libraries 2..10 Hz range.
in the automotive area, this architecture will be used in The flexible shaft can easily be adjusted to model
the PowerTrain library. An example model following higher frequency effects as it can contain a variable
this architecture is shown in Figure 13. number of spring-dampers and inertia components.
This is possible through the use of a parameter n to
specify how many spring-damper blocks the flexible
shaft model should contain. The effective stiffness
4 New fields of application and damping of each spring-damper block is adjusted
based on the parameter n. The flexible shaft contains
Version 2.0 of the PowerTrain library has been ex- n + 1 inertias and the total inertia of the shaft is evenly
tended by including a wider range of driver models distributed across these. The implementation of the
and new components in a number of new application flexible shaft is shown in Listing 4.
areas. Example models demonstrating the usage of the When developing a model to simulate driveability or
new components have also been included in the library shift quality it is important to include the reaction of
and these are described below. the powertrain within the vehicle. As the entire pow-
Figure 15: Some of the differential models available in the PowerTrain library. Clockwise from the top-left,
conventional differential, simple active differential, torque vectoring differential, viscous differential
possible ways to deliver an all-wheel drive vehicle and tial models available.
components have been included to enable the mod- For the simple active differential and the torque vec-
elling of the most common types and some of the most toring differential control systems have also been pro-
advanced. Available models include simple open dif- vided. An example of a four-wheel drive vehicle, that
ferentials, viscous differentials, and two types of active uses three of these simple active differentials, has been
differential. The various differential models have all added to the library. In this case, the control system
been implemented as 1D rotational systems with only has been designed to control each differential sepa-
the conventional differential described previously us- rately with the sole objective being to maximise trac-
ing a MultiBody approach. tion. Each differential controller looks at the output
All the differential models provided are based around shaft speeds from its differential and acts to reduce the
the use of an epicyclic differential unit. The differ- difference in speed. It should be possible for some slip
ent configurations of active and passive locking mech- to occur between the shafts to allow for cornering and
anisms are then placed around this core epicyclic unit this can be defined through the controller parameters.
and work in different ways to control the behaviour of In addition to the range of differential models, a power
the differential. Figure 15 shows four of the differen- take-off (PTO) style transfer box has been provided. In
some four wheel drive applications this type of transfer elled and this would limit the suitability of the library
box is used instead of a centre differential. The key for concept studies.
difference between using a differential and a PTO style
transfer box is that the ratio between the input and each
output shaft is fixed in the PTO style box whereas this 5 Other enhancements
ratio can vary when a differential is used.
This section describes the driver models, which have
been added to the library, and changes concerning ta-
4.3 Hybrid vehicles bles.
With several automotive manufacturers and suppliers
working on hybrid vehicles, there was a necessity to 5.1 New driver models
provide corresponding models in order to support con-
cept studies in this area. Models have been included The range of driver models provided with the Pow-
for batteries, motors and the associated controllers to erTrain library has been expanded to cover a wider
meet this need. range of tests. In addition to the existing cycle driver
The objective is to deliver models suitable for concept there are now driver models designed to carry out per-
study work so that minimal data is required to develop formance tests and driveability tests. There are also
a working model of a hybrid concept and to test out variants for use with both manual and automatic gear-
the functionality. Two hybrid vehicle examples have boxes.
been included, one based on a vehicle using an Inte- The cycle driver models are based around the use of a
grated Starter-Generator (ISG) and another based on a PI controller that actuates either the brake or accelera-
series-parallel hybrid style vehicle similar to the Toy- tor pedal to control the vehicle speed so that it follows
ota Prius. Both examples have been configured to run a defined speed-time profile. A number of drive cycles
drive cycle simulations. are included by default such as the NEDC, EPA City
The battery model included in the PowerTrain library and Highway cycles. It is possible to define your own
is based on the Saft capacitance model, which was additional drive cycles for use with the driver model.
originally developed in P-Spice [4] and has also been By varying the PI gains, the behaviour of the driver
used in the Advisor [1] simulation tool. Figure 16 can be altered allowing the driver model to be tuned
shows the circuit diagram used for the battery model. to match a range of different driving styles. The ver-
Capacitor Cb is very large and represents the ability of sion of the cycle driver used with manual gearboxes
the battery to store charge chemically, the capacitor Cc also controls the clutch pedal and gear lever. The shift
is small and represents the surface effects of a spiral- points are usually defined in the drive cycle to occur
wound cell. The three resistances represent the termi- at particular points in time and driver starts to change
nal resistance (Rt), end resistance (Re) and capacitor gear at these points.
resistance (Rc). The driveability driver models are used to perform tip-
in and tip-out tests in fixed gears, or fixed gearbox
mode in the case of automatic transmissions. The tests
start with the driver controlling the vehicle speed to an
initial value and then accelerating and decelerating the
vehicle between defined speeds using only the throttle.
The brakes will not be used to decelerate the vehicle.
For manual gearbox vehicles it is normal to define the
tip-in and tip-out speeds as engine speeds. Due to the
effect of the torque converter, it is more usual to de-
fine the tip-in and tip-out speeds using vehicle speed
Figure 16: Circuit diagram of the battery model for automatic gearbox equipped vehicles.
The performance driver is used to perform standing
The power electronics required to transfer energy from start acceleration tests. The version used with auto-
the battery to the electric motor have been simplified matic gearboxes can perform both an idle start or stall
so that the simulation performance is maintained. An start acceleration test. In both versions the accelera-
accurate model of the power electronics would require tor pedal position for the acceleration test can be de-
a large number of high frequency effects to be mod- fined so it is possible to assess the part-throttle accel-
eration performance as well as the wide open throt- [3] H. E LMQVIST, S. E. M ATTSSON , H. O LSSON ,
tle (WOT) performance. The version used with man- J. A NDREASSON , M. OTTER , C. S CHWEIGER , AND
ual gearboxes will change gear when a defined engine D. B RÜCK, Realtime Simulation of Detailed Vehicle
speed is reached. If in-gear acceleration times are re- and Powertrain Dynamics, in Electronics Simulation
and Optimization (SAE 2004 World Congress), De-
quired the driveability driver model should be used and
troit, USA, March 8–11, 2004, SAE International.
the tip-in and tip-out speeds set to be the minimum and Document Number: 2004-01-0768.
maximum speeds for the given gear.
[4] V. H. J OHNSON , A. A. P ESARAN , AND T. S ACK,
Temperature-Dependent Battery Models for High-
5.2 Replaceable tables Power Lithium-Ion Batteries, in 17th Electric Vehicle
Symposium, Montreal, Canada, October 16–18, 2000.
All tables in the library have now been declared as re-
[5] D. M AUERMANN, Echtzeitsimulation detaillierter
placeable. This change was made as many customers
Fahr- und Antriebsstrangdynamik, diploma thesis,
do not often have data in a form that is compatible with Hochschule für Technik, Wirtschaft und Kultur
the tables in the Modelica standard library. Instead, Leipzig (FH), Fachbereich Elektrotechnik und Infor-
they are forced to use their own, proprietary data for- mationstechnik, July 2004. Compiled at Deutsches
mat and their own table implementations. It was dif- Zentrum für Luft- und Raumfahrt e. V.
ficult for them to use these in combination with the [6] M. OTTER , M. D EMPSEY, AND C. S CHLEGEL, Pack-
PowerTrain library in the past. age PowerTrain. A Modelica Library for Modeling
and Simulation of Vehicle Power Trains, in Proceed-
ings of the 1st Modelica Workshop, Lund, Sweden,
6 Conclusions and Outlook October 2000, Modelica Association, pp. 23–32.
[7] M. OTTER , H. E LMQVIST, AND S. E. M ATTSSON,
Version 2.0 of the PowerTrain library offers several The New Modelica MultiBody Library, in Proceed-
new features, which open many new applications. ings of the 3rd International Modelica Conference,
New Modelica language elements allow a clean im- Linköping, Sweden, November 2003, Modelica As-
plementation of the new features and make it easier for sociation and Linköping University, pp. 311–330.
users to adapt the library to their own specific needs. [8] C. P ELCHEN , C. S CHWEIGER , AND M. OTTER,
Modeling and Simulating the Efficiency of Gearboxes
and of Planetary Gearboxes, in Proceedings of the
Acknowledgements 2nd International Modelica Conference, Oberpfaf-
fenhofen, Germany, March 2002, Modelica Asso-
For fruitful discussions, the authors would like to ciation and Institute of Robotics and Mechatronics,
thank Jochen Köhler and his colleagues from ZF Deutsches Zentrum für Luft- und Raumfahrt e. V.,
Friedrichshafen AG. pp. 257–266.
In addition, thanks to Michael Tiller from Ford Motor [9] C. S CHWEIGER AND M. OTTER, Modelling 3D
Company for pushing forward the concept of expand- Mechanical Effects of 1D Powertrains, in Proceed-
able connectors. ings of the 3rd International Modelica Conference,
This work was in parts supported by Bayerisches Linköping, Sweden, November 2003, Modelica As-
sociation and Linköping University, pp. 149–158.
Staatsministerium für Wirtschaft, Infrastruktur, Ver-
kehr und Technologie under contract AZ300-3245.2- [10] C. S CHWEIGER , M. OTTER , AND G. C IMAN -
3/01 for the project Test und Optimierung elektro- DER , Objektorientierte Modellierung mit Modelica
nischer Fahrzeug-Steuergeräte mit Hardware-in-the- zur Echtzeitsimulation und Optimierung von Antriebs-
strängen, in Steuerung und Regelung von Fahrzeugen
Loop-Simulation in the years 2001–2003.
und Motoren – AUTOREG 2004, VDI/VDE-GMA,
ed., no. 1828 in VDI-Berichte, Düsseldorf, Germany,
März 2004, VDI-Verlag, pp. 639–650.
References
[11] M. T ILLER , P. B OWLES , AND M. D EMPSEY, Devel-
[1] ADVISOR. URI http://www.ctts.nrel.gov/ opment of a Vehicle Model Architecture in Modelica,
analysis/advisor.html. in Proceedings of the 3rd International Modelica Con-
ference, Linköping, Sweden, November 2003, Model-
[2] J. A NDREASSON, VehicleDynamics library, in Pro- ica Association and Linköping University, pp. 75–86.
ceedings of the 3rd International Modelica Confer-
ence, Linköping, Sweden, November 2003, Modelica
Association and Linköping University, pp. 11–18.
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The Modelica Association 466 Modelica 2005, March 7-8, 2005