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Innovative Electronic Systems for Vehicular and Nautical Applications

Innovative Electronic Systems for Vehicular and Nautical Applications. Roberto Saletti , Sergio Saponara, Luca Fanucci , Federico Baronti , Roberto Roncella , Pierangelo Terreni Dipartimento Ingegneria dell’Informazione University of Pisa, Italy E-mail : r.saletti@iet.unipi.it.

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Innovative Electronic Systems for Vehicular and Nautical Applications

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  1. Innovative Electronic Systems for Vehicular and Nautical Applications Roberto Saletti, Sergio Saponara, Luca Fanucci, Federico Baronti, Roberto Roncella, Pierangelo Terreni DipartimentoIngegneriadell’Informazione University of Pisa, Italy E-mail: r.saletti@iet.unipi.it APPLEPIES Roma June 11, 2012

  2. Outline • Motivations • Electronics for vehicle applications • Embedded systems for automotive applications • Electric and/or hybrid vehicles • Energy Storage Systems • Battery Management Systems • Electronic replacement of mechanical subsystems • AMDS (Advanced Mechatronic Door System) • Electronics for nautical applications • Superyacht market segment (Luxury yacht with LOA > 24m) • Integrated data acquisition systems • Innovative sensors for boat and seawater parameter measurement • Freeboard measurements • Seawater density measurement

  3. Motivations • Conference aim and scope • “defining the activities, topics, objectives and research areas of the applications of electronics” • “the application domain – which was once considered as a separate level over the technology – is now a part of the technology itself” • Show on-going activities in the electronic applications’ researchfield at the Universityof Pisa • Show applicationsystemswhere “hardware and software are the different faces of the same coin” • Show examples of applications where electronics is the key factor for progress and improvement

  4. Vehicular applications • The most significant improvements in last years vehicular market come from electronics • Control • Combustion control, Emission control, Traction control, Stability control, Drive-by-wire, steer-by-wire, X-by-wire • Safety • Active safety, Multiple Air-bags, Assisted braking systems, Intelligent seat belts, Parking aid and collision avoidance systems • Info-tainments • Vehicle-infrastructure communication, Traffic info, Navigational aids and info, Kids and passengers entertainment • Vehicles contains hundreds of ECUs, communication systems and multiple computer networks

  5. Trendsforpresent/future vehicles • Increasedenvironmentalsensibility • More stringentrules and lawsforpollutingemissions • Electric and/or hybrid vehicles • ZEV (Zero-Emission Vehicle) • Replacement of mechanical systems with mixed (mechanical/electronics) ones that give unexpected performance with affordable costs

  6. Electric/hybridvehicles • An energystoragesystemsismandatory • Properstorageofenergy • Allowsenergyrecoveryduringbraking • Rechargeablebatteries are the solution • Common rechargeable battery chemistries: • Lead acid • NiCd • NiMH • Li-ion • Li-polymer • Li-Iron-Phosphate (LiFePO4) • … dominant in automotive (engine starter) and industrial applications (power backup and grid-load leveling systems) current choice for hybrid vehicles battery of choice for portable applications:mobile phones, laptops, ecc.

  7. Comparison of battery energy densities Source: www.mpoweruk.com • Due to the excellent performance in energy density and power density Lithium chemistry is emerging also in high power applications

  8. Lithium chemistry • Very high energy density, no memory effect,very low self-discharge, very high efficiency, etc. • Very sensitive to overcharge and deep discharge and to exceeding specific temperature range • Cell life shortening, …, risk of explosion • Different technologies: • Different choices for electrodes and insulator materials • Lots of ongoing researches … • Battery cells safety is mandatory • Here comes Electronics • Safety is increased by an electronic management system (Battery Management System – BMS)

  9. Battery Management System (BMS) • Low-level functions: • Cell voltage and temperature monitoring • Current monitoring • Cell balancing • Communication with a host device • High-level functions: • Maintain each cell of the battery pack within its safe operating range • Estimate SoC (State-of-Charge) and SoH (State-of-Health) • Increase the battery pack lifetime • Manage thermal aspects …and of course very little power consumption(al least when the battery current is zero)

  10. BMS: hierarchical platform • Electric vehicle battery (300-400 V) up to 1 kV for distributed energy storage in smart-grids • Roughly 100 or more series-connected high-capacity elementary cells • Battery pack usually partitioned in modules • From 4 to 14 cells per module • BMS architecture reflects thephysical structure of the battery Cell Module Pack

  11. BMS: hierarchical platform (cont.) • High flexibility and scalability • Redundancysupport • Dynamic pack reconfigurationthrough the MBS • Module-levelactivebalancing • PMU (Pack Management Unit) • MMU (Module Management Unit) • CMU (CellMonitoringUnit) • PPS (Pack ProtectionSwitch) • MBS (Module Bypass Switch) Vehicle Management System PMU ... MMU MMU ... ... CMU CMU CMU CMU

  12. BMS: Cell Monitoring Unit • Benefits of an intelligent cell: • Local voltage and temperature measurement • Cell identification • Cell history (lifetime, cycle number, etc) • Second market application • Very simple design • A small 8-bit µC w/ 10-bit ADC • Few external components to provide isolated communication with the MMU

  13. BMS: CMU design example • CMU implementation with discrete off-the-shelf components CMU prototype applied to a 31 Ah LiPo cell

  14. BMS: MMU design example

  15. MMU: board prototype Connectors to the CMUs AuxCell Active charge equalizer based on a Buck-Boost Converter with super-capacitor

  16. BMS: MBS design example • Isolatedgatedriving • Very low dead-time • Liquidcooledheatsink

  17. BMS: MBS design example (cont.) • Battery pack for a fuel-cell hybrid small van(steady state current up to 160 A) • ΔT=70 °C &PDMBS=66W@ Ibattery=160 A • Little efficiencydegradation • e.g. N=11Vcell=3.7 V At maximum load!

  18. BMS: hierarchical platform prototype • Hydrogen Fuel Cell Hybrid Electric Vehicle (H2FC-HEV) which is being developed at University of Pisa • 14.4 kW hydrogen fuel cell • 155 V - 40 Ah LiPo battery pack M. Ceraoloet al., “Experiencesofrealisation and test of a fuel-cellbasedvehicle,” SPEEDAM 2010

  19. BMS: hierarchical platform prototype • Module implementation: • 11 40 Ah LiPo cells • FC-HEV battery built up of 4 modules • 11 CMUs • 1 MMU • 1 MBS • Electronic system with: • Hardware • 14 microcontrollers • FPGA • Power devices • Hall sensors • Temperature sensors • Software/firmware • 3 level hierarchical applications • Low level micro firmware • Medium level micro firmware • High level Labview application

  20. BMS: hierarchical platform prototype • Module implementation: • MMU connected to a PC by CAN bus • LabVIEW app emulates the PMU • Testing of BMS functionalities • Screenshot refers to an on-going balancing cycle (see the differences in cell voltages)

  21. Electronic replacement of mechanical parts • AdvancedMechatronicsDoor System • E-Latch • Fully electronic vehicle latch • Existingsensors • Electrical motor drive foractuation • Cincheddoor • Electricallyactivateddoorclosure • Electricalcrystalglasscontrolwithanti-pinchcontrol • A challenge for the stringentautomotivespecs

  22. Superyacht nautical market • Italy isby far the world largestproducerofsuperyachts • Nautical market hascollapsedbecauseof the global financialcrisis • New impulseisexpectedafter the crisis • New products and applications are expectedto come

  23. Electronicsapplicationto Superyacht test • Superyachts are complexsystemsembeddinghundredsofheterogeneous electronic controlled systems • Lack of integration and standardization • Extensive Test & Correction procedure before final delivery to customers • So far, manual registration of the data displayed on the dashboard, combined with feelings of expert drivers

  24. Dedicatedacquisition system for Ferretti • Multi-sensor, multi-protocolacquisition system • Integrated and synchronousacquisition @1 Hz from: • Enginesubsystems(CAN SAE-J1939, CANOpen) • Navigationsubsystem (RaymarineSeaTalk, NMEA-0183) • Flap and Trim subsystems (Analog, CANOpen, MODBUS TCP/IP) • Custom two-axis wireless inclinometer • Automaticconfigurationforhundredsof yacht models

  25. DAQ features • Unified user interface for data visualization • System guided automatic test procedure • Test results are stored and compared with references • Remote analysis of the test results

  26. Useful data

  27. Innovative sensorsfornauticalapplications • Freeboardsmeasurementstoprovide information about the yacht weight and trim • Wireless sensor network ofmagnetostrictivelineardisplacementsensors

  28. Freeboardsmeasurements

  29. Freeboardsmeasurementresults I Data acquiredfromdifferentnodes are strictlyrelated

  30. Freeboardsmeasurementresults II The operator’s weight (90 kg) causes a notnegligibleerror! ≈ 20 mm

  31. Electronic seawater density meter • Magnetostrictivedisplacementsensorstoread the immersion of a structuresemifloating in seawater • Immersion depends on seawater density

  32. Conclusions • Overviewofresearchactivities at the Universityof Pisa on the applicationofElectronics • Mainresearchfields are • Vehicularelectronics • Nauticalapplications • All the examples show a deepinteractionbetween • Hardware • Sensors and data conditioning and conversion • Controllers • Powerdevices • Software • Microcontrollerfirmware • Higherlevel software (C++, Labview, Web applications) • Knowledgeof the application domain ismandatory • Electronic engineers are ever more oftenaskedto tackle and solve multidisciplinary (mechanical, thermal, etc.) issues

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