Loss Minimization Algorithm Based Strategy for EV Hybrid Energy Storage System Optimization Alexander González Medina Facundo Aguilera Manuel Javier Vidal Cué Grupo de Electrónica Aplicada IITEMA, CONICET-UNRC, Argentina [email protected] Grupo de Electrónica Aplicada IITEMA, CONICET-UNRC, Argentina [email protected] Grupo de Electrónica Aplicada IITEMA, CONICET-UNRC, Argentina [email protected] Abstract—This work proposes an energy management strategy that optimizes an objective function evaluating losses and energy consumption in a hybrid energy storage system of an electric vehicle. This strategy is based on a loss minimization algorithm that iterates the objective function evaluated for the reference signals. Furthermore, supercapacitor voltage and temperature protection measures were implemented to avoid penalizing situations. The proposed strategy is validated by simulation using the electric vehicle model provided by the IEEE 2024 VTS Motor Vehicles Challenge (MVC). The results show that the strategy can improve the overall power distribution performance. Moreover, this proposal obtained the best final score among the 44 presented in MVC. Index Terms—energy management strategy, electric drive, loss minimization algorithm, supercapacitor, electric vehicle. I. I NTRODUCTION Climate change and global warming have become great concerns of our time. In relation, nearly 30% of carbon emissions are due to transportation, specifically due to combustion engines. This is why, recently, electric vehicles (EVs) have gained an incredible attraction as a secure alternative. However, EVs lack the reliability and efficiency that its predecessor has. To address these issues, the annual Motor Vehicle Challenge (MVC) was launched with the support of the IEEE Vehicular Technology Society in 2016. The challenge aimed to optimize a certain EV problem. In past editions, problems were centered on an energy management system (EMS) with different objectives, such as: reducing the operation cost of a hybrid vehicle, or battery state-of-charge (SoC) of a dualmotor all-wheel drive. Notwithstanding, models used in these editions did not consider or represent real power losses over an entire driving cycle [1]. In the MVC 2024 edition, the problem consisted of a simulation model that takes into consideration more accurate modeling of the losses and efficiency of the power electronics converters and electric machines. With this in mind, contest teams needed to satisfy two objectives: to propose an EMS to reduce energy consumption and to propose a suitable powertrain losses management strategy to reduce the losses of power electronics converters, inverters, and the e-machine. The EMS plays a major role in EV performance since it must provide proper control and distribution of energy to reach larger distances more efficiently [2]. Among the broad range of hybrid energy storage systems (HESS), one of the most widely used is the battery-supercapacitor configuration. Batteries have high energy density but lack power density, the opposite of a supercapacitor (SC); which means that a complementary architecture, if well controlled, can overcome weaknesses of both components [3]. In this regard, plenty of research work has been done to optimize battery-SC HESS. In general, works are divided into three main approaches depending on what they are based on: rules, frequency analysis, and optimization algorithms [4]. Rule-based EMS distributes overall power as defined by a set of rules. The low computational demand and reliability of this method make it suitable for real applications [5], [6]. A more intuitive approach is the Frequency-based (FB) EMS, which consists of dividing the demand of power according to its frequency components, considering that it is healthier for batteries to supply mean values (or DC component) and leave power peaks to the SCs [7], [8]. On the other hand, a better performance can be achieved by an Optimization-based (OB) EMS, where an objective function is minimized through an optimization algorithm or a combination of them. This method requires a lot of information which in real applications is difficult to collect [9]–[11]. Another issue that must be addressed in the performance of EVs is the minimization of losses throughout their propulsion system. Loss minimization control (LMC) has been extensively researched to achieve higher efficiency, less energy waste, and prevention of temperature rise [12], [13]. In general, LMC strategies can be classified into two groups: modelbased (loss-model and simple-state control) and physicalbased (search control) [14], [15]. Model-based methods are generally faster because they are simply the development of mathematical expressions and can be processed in real-time. A drawback of these techniques is that they depend closely on system parameters and may not consider the interrelation with no modeled coupled subsystems. In contrast, physicalbased methods do not strictly depend on system parameters because they focus on finding the set of inputs that results in minimum losses, making them very robust. However, this setsearch process can take a considerable amount of time, which is not of interest in fast dynamic drives. The simulation model presented in the MVC corresponds to a fast dynamic system, although processing time is not a restriction in this case. Due to the aforementioned, in this paper, a Loss Minimization Algorithm (LMA) based Coupling and EV chasis model Proposed strategy msc isc Energy management Temperature msc protection udc vve isc LMA usc Jbat (ĩ∗bat ) ibat mbat idc SC minv idc mbat ibat Battery M Drive cycle Measurements i∗bat Proposed ∗ strategy id ∗ vve Battery and SC control msc Motor control minv mbat Drive id control i∗q Fig. 1. Studied EV configuration ω strategy for optimizing both energy consumption and losses is proposed. This LMA is an iterative method that searches the set of battery and motor current references that minimizes two different condition-based cost functions that are partly based on the loss model of the electric subsystems of the vehicle. In addition, temperature protection and a flux weakening strategy are also developed. As a reference, this strategy earned 1st place as it obtained the best scores for this simulation model. The paper is organized as follows. Section II describes the challenge EV powertrain model and cost function. Section III presents the proposed strategy. Finally, the results of the applied strategy are shown in Section IV. II. C HALLENGE EV MODEL AND COST FUNCTION The configuration of the EV proposed as the platform for the MVC is illustrated in Fig. 1. This platform is based on a racing vehicle developed at the University of Nottingham which includes a battery-SC HESS [1]. Each energy storage source is connected to the DC-link through two bidirectional DC/DC power converters. Moreover, the traction permanent magnet synchronous machine (PMSM) is powered from the DC link through a three-phase inverter. The control laws for each of the three power converters are already provided by the MVC model, including vehicle speed, motor current, DC-link voltage, SC, and battery current controls. With this platform, the objective of the challenge is to design a strategy that generates the battery current reference, i∗bat , and the motor d current reference in the d-q reference frame, i∗d , which are left as two degrees of freedom in the model. The performance of the proposed strategy is scored by using the following cost function along a driving cycle: J = k1 ∆fsoc + k2 ∆fusc + k3 σcell + k4 Ereg + tot k5 Ploss + k 6 Nd + k 7 NT , (1) where k1 = k2 = k6 = 1, k3 = 10, k4 = 0.001, k5 = 0.1 and k7 = 50 represent weighting factors. ∆fsoc = 100 − SoCf is the percentage of the battery energy consumed throughout the driving cycle. SoCf is the final state of charge (SOC) and is obtained from the battery cells model included in the MVC model. ∆fusc = usc0 − uscf , where usc0 and uscf are the initial and final SC voltages, respectively. imax SC ch ĩ∗bat LMA Jd (ĩ∗d ) Field weakening − i∗ + SC ch + − + i∗bat + −1 ĩ∗d min(id1 , id2 ) i∗d i∗dF W Fig. 2. Proposed strategy diagram. σcell is the standard deviation of battery cell current measured throughout the driving cycle. Ereg is the regenerative energy of the battery and is obtained by integrating the negative battery power produced during deceleration intervals in the driving cycle. tot The fifth term accounts for the total losses Ploss , and is obtained as: tot bat SC inv em Ploss = P̄loss + P̄loss + P̄loss + P̄loss , (2) bat SC inv em where P̄loss , P̄loss , P̄loss and P̄loss are the mean losses of the DC-DC battery power converter, the DC-DC SC power converter, the inverter and the traction electric machine, respectively. Power converter losses are based on conduction and switching loss models of the EV power modules. The electric machine losses model includes copper, iron core, and stray losses. Nd is the total number of power modules. The number of power modules in parallel for each power converter is left as a design variable for the competition. A high number of modules in parallel may reduce the converter power losses, while a reduced number increases the junction temperature. NT is the number of power modules that exceed a junction temperature of 175° C at any time during the driving cycle. III. P ROPOSED STRATEGY The strategy developed to minimize the scoring function (1) is presented in this section. A simplified diagram of the strategy is shown in Fig. 2. The following subsections explain the two fundamental blocks that comprise this solution. A. Analysis of cost function for scoring The selection of the battery current reference and the d motor current references affect differently each of the terms defined in the cost function (1). In particular, an optimal battery current reference ĩ∗bat , in general terms, should: avoid a reduction of the battery SOC, avoid variations on the battery voltage at the end of the driving cycle, reduce variation in battery current, avoid charging the battery and reduce losses in the power converters of the SC and the battery. With respect to the losses in the power converters, they include switching and conduction losses and are modeled as: x x 2 Ploss = mx Ron ix + axsw |ix | , ibat <0 where ubat is the battery voltage. This term increases significantly due to the integration operation. In addition, during regenerative braking intervals, the penalization obtained if the battery is charged is much higher than the penalization of charging the SC, i.e. bat SC k4 Ereg + k5 Ploss ≫ k5 Ploss . , imin and δ definition imax j j = it imax j = it imin j it = imin + imax j j 2 (3) where index x ∈ {SC, bat} refers to SC or battery, respectively, mx is the modulation index, Ron is the on-state x power device resistance, and axsw = γsw fsw is a constant which models the switching losses linearly to the current. The x constant fsw denotes the switching frequency and γsw is the ratio between switching energy and current, obtained from the device datasheet [1]. bat SC Simulation model parameters shows that Ron < Ron and bat SC asw < asw . Therefore, it can be stated that a strategy that minimizes losses in these power converters will prioritize the battery as an energy source. With respect to the battery charging penalization (the fourth term in (1)), the regenerative energy of the battery is defined as: Z t , (4) ubat |ibat | dτ Ereg = 0 Start (5) Therefore, during regenerative braking, it is preferable to charge the SC instead of the batteries. Thus, it is necessary to discharge the SC according to the vehicle speed to avoid overvoltages during regenerative braking. Given the aforementioned, the following set of rules is proposed to define an optimal battery current reference ĩ∗bat : 1) Battery as an energy source is prioritized when idc > 0. 2) SC must store the energy if idc < 0 (ensuring Ereg = 0). 3) The SC should be discharged according to the EV kinetic energy. 4) The final SC voltage must be the same as the initial voltage. However, it is not necessary to enforce this condition throughout the entire driving cycle, but only towards the end. On the other hand, an optimal d motor current reference ĩ∗d should endeavor to reduce losses in the power converters and the PMSM and to implement a flux weakening strategy to allow high VE speeds. The energy management and id control strategies were designed based on this analysis, as described below. B. Energy management The energy management strategy consists of an LMA that generates the optimal ĩ∗bat , together with two mechanisms < 2δ imax − imin j j False True ĩ∗j = it Stop False Jj (it + δ) > Jj (it − δ) True Fig. 3. Loss minimization algorithm. that prevent hazardous situations, namely: charge/discharge (functioning inside the LMA) and temperature protection of the SC, as shown in Fig.2. The outputs are processed to obtain the final i∗bat . 1) LMA: The objective of the LMA block in Fig. 2 is to generate an optimal battery current reference ĩ∗bat based on system measurements. To this end, a new cost function for control is designed by selecting only the terms that depend on the battery currents in (1), as follows: if Fch = 1, Pb2 Jbat (ibat ) = Pb1 + Pb2 + Pb3 if vve ≥ kv ∆usc , Pb1 + Pb2 + Pb3 + Pb4 otherwise. (6) All terms in Jbat (ibat ) are evaluated in function of ibat with a binary search-based LMA to obtain the optimal ĩ∗bat for the actual condition [14]. The flowchart of the LMA is shown in Fig. 3. In this algorithm, a first definition of imin and imax j j fixes the initial search interval, where j ∈ {bat, d}, and δ defines the step amplitude. In each iteration, the midpoint it is calculated, and the cost function is evaluated in two points: if J(it +δ) > (it −δ) then imax = it , otherwise imin = it . The j j max iteration continues until ij − imin < 2δ, where the output j optimal current is defined as ĩ∗j = it . The initial minimum value is set as imin bat = 0 and therefore, no battery charging current is allowed as the output of the energy management LMA. The term Pb1 accounts for the battery discharge as: Pb1 = k1 ∆soc , (7) where ∆soc = 100 − SoC(ibat ). SoC(ibat ) represents the modeling of the battery SOC expressed in function of ibat . The term Pb2 is defined as: Pb2 = k2 |∆usc | , (8) where ∆usc = usc0 − usc (ibat ). usc (ibat ) is the SC voltage represented in function of ibat , by considering isc = idc −ibat . Similarly, power converter losses are considered with: bat Pb3 = k5 Ploss (ibat ), SC Pb4 = k5 Ploss (ibat ), (9) bat SC where Ploss (ibat ) and Ploss (ibat ) are the battery and SC power converter losses defined in function of ibat , respectively. From the provided EV model, it can be deduced that the four terms in (6) exhibit linear or quadratic behavior with positive coefficients. Therefore, the cost function Jbat (ibat ) is a concave function, with an absolute minimum. This allows the use of an LMA algorithm described in Fig. 3. The flag Fch and the coefficient kv in (6) are used to control the SC charge/discharge, as described below. 2) SC charge/discharge: From the condition described in (5), it can be concluded that the energy management LMA will prefer the use of the battery as an energy source if the four terms are used in the cost function defined in (6) (see rule 1 in Section III-A). Therefore, the discharge of the SC must be forced to fulfill rule 3 defined in Section III-A. The forced discharge is accomplished with the second condition in (6), where the coefficient kv is defined to reduce the SC voltage in function with the vehicle speed vve . Note that the term Pb4 is not taken into consideration in this second condition, and thus the SC will be preferred as the energy source when vve ≥ kv ∆usc , discharging the capacitor. This SC discharge must be high enough to store all the vehicle kinetic energy during braking intervals, avoiding SC overvoltage conditions. Given that the coefficient kv cannot be perfectly defined for all braking conditions, in general, ∆usc ̸= 0 when the vehicle reaches null speed. Therefore, the charging flag Fch in (6) is activated during low speeds to reduce the SC voltage variation at the end of the cycle. In this condition, Jbat = Pb2 giving maximum priority to the SC charging current. These forced SC charges cause additional losses in power converters. This is why the charging flag is only activated after a constant time tch is reached. Consequently, the charging flag is defined as: ( 1 if vve ≤ Vch and t > tch , Fch = (10) 0 otherwise, where Vch is a small constant speed, t is the current time, and tch is the time when low speed SC charging is activated. 3) Temperature protection: Power module junction temperature Tj in the DC-DC power converters can be estimated based on the modulation index mx , circulating current, and ambient temperature Ta . Therefore, given a maximum junction temperature Tmax = 175 ◦ C, the maximum current imax to x avoid over-temperature in any of the power modules (upper or lower) can be obtained by solving the following equation: x |mx − 0.5| Ron (imax )2 + axsw |imax |= x x 1 (Tmax − Ta ), Rth (11) where Rth is the junction-heatsink thermal resistance. The maximum is obtained for the SC power converter to generate saturation limits for the SC current reference i∗sc (see Fig. 2), as follows: usc imax Nsc imax (12) SC ch = SC − Im , udc where usc and udc are the SC and DC-link voltages, respectively, Nsc is the number of power devices in parallel in the SC power converter and Im is a constant security term. The SC current limit is used to avoid the penalization defined in the seventh term in (1). Finally, the output battery reference current from the Energy Management block is defined with the following equations: i∗SC ch = idc − ĩ∗bat , max iSC ch î∗SC ch = −imax SC ch ∗ iSC ch (13) if î∗SC ch > imax SC ch , ∗ if îSC ch < −imax SC ch , (14) otherwise. i∗bat = idc − î∗SC ch . (15) C. Drive id control The drive id control includes an LMA and a flux weakening strategy, as shown in Fig. 2. These systems generate the ĩ∗d and i∗dF W current references, and the minimum of them is used as the strategy i∗d reference. 1) LMA: The procedure described in Section III-B1 was used to generate the optimal reference signal ĩ∗d intended to reduce PMSM and inverter power losses. It should be noted that, for a given PMSM iq current and speed, a non-zero id reference can be used to reduce the motor losses. However, higher motor currents increase power converter losses. Consequently, in this case, the developed cost function involves the terms of expression (1) which depends on id , and is described as: Jd (id ) = Pd1 + Pd2 , (16) where Pd1 is defined as: bat SC inv Pd1 = Ploss (id ) + Ploss (id ) + Ploss (id ). (17) bat SC inv Terms Ploss (id ), Ploss (id ) and Ploss (id ) represent losses of the battery, SC and inverter power converters, respectively, expressed in function of id by considering fixed DC-link voltage, ibat and iq . The term Pd2 accounts for PMSM losses and is defined as: Pd2 = Pcu (id ) + Pf e (id ) + Pstr (id ), (18) where Pcu (id ) represents losses in copper, Pf e (id ) represents core losses, and Pstr represents stray losses. The ĩ∗d reference is obtained with the LMA described in Fig. 3, using the cost function (16). 2) Flux weakening: When the vehicle is operating at high speeds, the back emf of the PMSM may become too large, causing the inability of the inverter to follow current commands [16]. To avoid this situation, the following voltage conditions must be met: TABLE I S CORING OBTAINED FOR DIFFERENT DRIVING CYCLES . 2q vq2 + vd2 , (19) 3 where udc is the DC-Link voltage, vq and vd are the d-q voltages applied to the PMSM. From the PMSM and control models in [1], if current transients in d-q are neglected, the following approximation can be obtained: udc ≥ vq∗ ≈ Rs i∗q + ωr Ld i∗dF W + λm ωr , vd∗ ≈ Rs i∗dF W − ωr Lq i∗q , IV. R ESULTS The proposed strategy, illustrated in Fig. 2, was implemented in the MVC2024 EV simulation model [1]. The strategy parameters were defined as follows: imax bat = 250 A, m δ = 0.1 mA, kv = 1.9 , sV ∆fsoc (%) f ∆usc (mV) σcell (A) Total losses (W) Nd Ereg (W.s) NT Final score: MVC2024 (Submitted) 54.95 30.14 1.7906 578.62 13 4975 0 148.719 MVC2024 (Modified) 54.94 30.3 1.7899 576.64 14 784.7 0 145.318 ARTEMIS UDDS 21.86 2.635 1.281 431.24 13 11.36 0 90.711 10.58 0.002 1.034 223.18 13 6.779 0 56.251 (20) where vq∗ and vd∗ are the voltage reference control signals, i∗q is the q-current reference generated by the speed control, ωr , Rs , Lq and Ld are the motor rotor speed, winding resistance, and d-q inductances, respectively. i∗dF W denotes the d-current reference generated by the flux weakening algorithm, see Fig. 2. Based on this analysis, the d-current reference is set as i∗dF W = 0 when the obtained reference voltage from (20) does not violate the voltage condition (19). Otherwise, i∗dF W is solved to obtain the minimum d-current reference absolute value which meets the voltage condition. It is worth mentioning that DC-Link voltage is considered constant in the flux weakening algorithm. imin bat = 0 A, Description imin = −10 A, d imax = 1 A, d tch = 1800 s, Im = 2 A. With these parameters, the energy management LMA converges in a maximum of 21 iterations, while a maximum of 17 iterations was obtained for the id control LMA. The system was simulated for different driving cycles to define the number of power devices that minimize the cost function. The power devices configuration submitted to the MVC2024 was: 2 power modules for the battery power converter, 2 power modules for the SC power converter, and 9 power modules for the inverter. In addition, a modified configuration was selected after the MVC2024 score cycle was revealed to avoid the activation of the over-temperature protection, by using 3 power modules for the SC. Scoring results are presented in Table I for different driving cycles: the MVC2024 Score Cycle (with the submitted and with the modified power devices configuration), ARTEMIS and UDDS (both with the submitted configuration). Results show that no over-temperature penalty was obtained in any of the tests and that the final SC voltage variation is less than 31 mV. Regarding percentage, ∆fsoc was about 55% for the Score Cycle. To provide a comparison, it can be mentioned that the score obtained with the strategy presented as an example by the MVC for the Score Drive was 443.32. Therefore, the submitted strategy achieved a 66% improvement in the cost function. The results of the transient response for the Score Cycle with the submitted configuration are shown in Fig. 4. The obtained EV speed is shown in Fig. 4(a). Also, results show that the obtained ibat reference is almost always positive, see Fig. 4(b), while id reference is always negative, see Fig. 4(c). Moreover, because sufficiently high speeds are not reached during the entire cycle, the flux weakening strategy was unnecessary in this test. This is why the id reference remained around 0, as shown in Fig. 4(c). Fig. 4(d) shows that the SC is discharged according to the vehicle speed, and charged during regenerative braking intervals. In addition, near the end of the cycle (at approximately t = 1900 s), a positive battery current reference is obtained (see Fig. 4(b)), ensuring a reduced voltage variation ∆fsoc . The driving cycle presents abrupt braking intervals with high regenerative energy in 100 s < t < 350 s, see Fig. 4(a). As a consequence, as shown in Fig. 4(e), there are intervals where the SC current (black) reaches saturation limits (blue) near times t = 119.3 s, t = 215.8 s, and t = 314.9 s. Fig. 4(f) shows that due to the current saturation limits, none of the SC power modules reaches an over-temperature condition, reaching a maximum temperature of 153.95◦ C. In these intervals, unavoidable regenerative battery charging penalties (i.e. Ereg ) were applied resulting in the final 4975 Ws, see the negative ibat reference intervals in Fig. 4(b). However, note that a much greater penalty would have been incurred if an over-temperature had occurred. Fig. 5 shows the results obtained using 3 power modules for the SC. The current limits to avoid over-temperature are increased with the additional power module, see Fig. 5(a). For this reason, there are no intervals with negative current references in this test, see Fig. 5(b). Therefore, a better final score is obtained with this configuration due to the reduced regenerative battery charging penalties. V. C ONCLUSIONS An energy management system and a powertrain losses management strategy for a battery-supercapacitor hybrid electric vehicle were proposed in this paper. Both strategies are based on a loss minimization algorithm (LMA) that sets battery and motor direct current references for each sample time to obtain an optimal power distribution that minimizes ibat ref. (A) Speed (km/h) id ref. (A) usc (V) isc;lim (A) by comparing it with 43 other strategies during the 2024 VTS MVC, obtaining the best performance for the driving cycle used for scoring. 100 50 (a) 0 ACKNOWLEDGEMENT 200 This work was supported by Agencia Nacional de Promoción Cientı́fica y Tecnológica, Consejo Nacional de Investigaciones Cientı́ficas y Técnicas (CONICET), and Universidad Nacional de Rı́o Cuarto (UNRC), Argentina. 100 (b) 0 0 R EFERENCES -0.2 -0.4 (c) -0.6 160 (d) 140 120 100 (e) 0 -100 Tsc (/ C) 150 Peak temp.: 153.95°C 100 (f) 50 0 0 200 400 600 800 1000 1200 1400 1600 1800 Time (s) 100 (a) 0 -100 ibat ref. (A) isc;lim (A) Fig. 4. Results of submitted configuration. (a) Vehicle speed, (b) ibat reference, (c) id reference, (d) SC voltage, (e) SC current (black) and SC current saturation limits (blue), and (f) temperature of module 1 (black) and module 2 (blue) of the SC power converter. 200 (b) 100 0 0 50 100 150 200 250 300 350 400 Time (s) Fig. 5. Results of modified configuration. (a) SC current (black) and SC current saturation limits (blue), and (b) ibat reference designed cost functions. Also, some protection measures were required: over-temperature protection and supercapacitor charge/discharge. The results show that, although both strategies can handle the optimal power distribution, the protection measures were necessary to avoid large penalties. Moreover, a flux weakening was not required during the simulated driving cycles. Finally, the proposed strategy was validated [1] K. Li and T. 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