This document summarizes the process to generate full efficiency and power loss maps for the 8.5kW belt integrated starter generator (BISG) from a 2012 Hyundai Sonata with a 270V lithium polymer battery, using test data collected by Oak Ridge National Lab (ORNL). The generated BISG maps define the combined operating boundaries and electrical power consumption of the electric motor, inverter, and drive belt which are needed for ALPHA modeling. Hyundai refers to this BISG as a Hybrid Starter Generator (HSG).
SUGGESTED CITATION:
2012 Hyundai Sonata 8.5kW 270V BISG - ALPHA Map Package. Version 2023-03. Ann Arbor MI: US EPA National Vehicle and Fuel Emissions Laboratory, National Center for Advanced Technology, 2023.
BISG Physical Characteristics
The following table sets the key physical characteristics for the 2012 Hyundai Sonata 8.5kW 270V BISG used in the ALPHA model based on published information provided in 3d- Benchmarking State-of-the-Art Technologies Presentation by ORNL May 2013.pdf and 3e- FY2013 DOE Annual Progress Report Advanced Power Electronics and Electric Motors Program.pdf. The items in the table follow ALPHA’s code syntax for “emachines,” which is: emach.name_units = value; % comments.
The BISG is connected to the crankshaft through a belt drive. The ORNL test data provided in 3c- 2012 Hyundai Sonata 8.5kW 270V BISG - ORNL Test Data File.xlsx was referenced against the emotor speed but torque was measured at the BISG output (e.g., engine crankshaft). The belt pulley ratio between the BISG and the crankshaft was estimated by comparing the maximum torque value in the test data file 3c- 2012 Hyundai Sonata 8.5kW 270V BISG - ORNL Test Data.xlsx (110 Nm) with the maximum torque value in the reference plots provided in 3d- Benchmarking State-of-the-Art Technologies Presentation by ORNL May 2013.pdf and 3e- FY2013 DOE Annual Progress Report Advanced Power Electronics and Electric Motors Program.pdf (43 Nm) resulting in a belt pulley ratio of 110 Nm / 43 Nm or 2.56.
emach = class_REVS_emachine_geared; emach.name = '2012 Hyundai Sonata 8.5kW 270V BISG'; emach.type = enum_emachine_type.BISG; emach.inertia_kgm2 = 2 * (1/2*0.1604*1/2)^2; % Inertia = rotor mass *1/2 rotor diameter, rotor mass = 2kg, rotor diameter = 0.1604m. (0.01077 kg-m2) emach.max_speed_radps = 15000 * unit_convert.rpm2radps /2.56; % max value based on ORNL test data divided by the belt pulley ratio of 2.56 emach.max_torque_Nm = 43 * 2.56; % max value based on ORNL value shown on plots multiplied by the belt pulley ratio emach.max_motor_power_W = 8500; % published specification as noted by ORNL emach.max_generator_power_W = emach.max_motor_power_W;
Import BISG Data
The following code imports BISG efficiency data provided by ORNL found in 3c- 2012 Hyundai Sonata 8.5kW 270V BISG - ORNL Test Data.xlsx. EPA reviews the quality of the test data we import to ensure consistency with expected data trends and emotor system physics. Any data points considered significant outliers are removed from the dataset before generating the final efficiency map. In addition, since many of the datasets are missing low-speed and torque datapoints, occasionally a few “grounding” datapoints are added to help the curve fitting algorithm extrapolate the gradients near the map’s boundaries.
Specifically for this dataset, the test data points corresponding to 0 Nm and -80 Nm were removed before generating the final efficiency map.
% Read efficiency data for motor operation tbl_mot = readmatrix('data/3c- 2012 Hyundai Sonata 8.5kW 270V BISG - ORNL Test Data File.xlsx','Sheet','Motor Inverter Belt','Range','B6:R29'); data(1).name = 'Motor Data'; data(1).speed_rpm = tbl_mot(1,2:end)/2.56; %Adjust for pulley ratio data(1).torque_Nm = tbl_mot(3:end,1); data(1).efficiency_norm = tbl_mot(3:end,2:end)/100; % Read efficiency data for generator operation tbl_gen = readmatrix('data/3c- 2012 Hyundai Sonata 8.5kW 270V BISG - ORNL Test Data File.xlsx','Sheet','Regen Motor Inverter Belt','Range','B6:R22'); data(2).name = 'Generator Data'; data(2).speed_rpm = tbl_gen(1,2:end)/2.56; %Adjust for pulley ratio data(2).torque_Nm = -tbl_gen(3:end,1); data(2).efficiency_norm = tbl_gen(3:end,2:end)/100;
BISG Torque Limits
The following table sets the torque limits of the BISG input map based on test data collected by ORNL found in 3c- 2012 Hyundai Sonata 8.5kW 270V BISG - ORNL Test Data.xlsx. The maximum torque line is set by defining maximum torque (axis 2) at discrete speeds (axis 1) of the operating map.
emach.positive_torque_limit_Nm.axis_1.signal = 'emach_spd_radps'; emach.positive_torque_limit_Nm.axis_1.breakpoints = [0 data(1).speed_rpm] * unit_convert.rpm2radps; emach.positive_torque_limit_Nm.table = [110;110;110;105;100;95;90;90;75;60;50;40;35;30;25;25;15]; emach.negative_torque_limit_Nm.axis_1.signal = 'emach_spd_radps'; emach.negative_torque_limit_Nm.axis_1.breakpoints = [0 data(1).speed_rpm] * unit_convert.rpm2radps; emach.negative_torque_limit_Nm.table = -[80;80;80;75;75;75;65;60;50;45;35;30;25;25;20;20;5];
Build the emachine Object in Matlab
The script below creates an “emach” object which represents the emachine performance in power loss space (rather than efficiency space) for both the “drive” and "regen" quadrants, extrapolates to the emotor’s operational boundary based on the BISG torque limits defined above, and then scales for maximum power. The test data collected by ORNL in 3c- 2012 Hyundai Sonata 8.5kW 270V BISG - ORNL Test Data.xlsx contains both motoring and regen data which were utilized in this build.
emach = emach.load_data(data);
BISG Efficiency Map
The following code generates the Efficiency Map shown below for this BISG which includes combined efficiency data of the electric motor, inverter, and drive belt. The map represents the BISG Output Torque versus BISG Output Speed values, including the 2.56 belt pulley reduction ratio, to match the engine crankshaft speed. The efficiency data points used to generate the efficiency map are superimposed on this image.
A clean version of the efficiency map (without data points) is included in 4a- 2012 Hyundai Sonata 8.5kW 270V BISG – Efficiency.pdf. As reported by ORNL in 3d- Benchmarking State-of-the-Art Technologies Presentation by ORNL May 2013.pdf and 3e- FY2013 DOE Annual Progress Report Advanced Power Electronics and Electric Motors Program.pdf the BISG power levels operated above 20kW even though the published power level is only 8.5kW.
The 6- 2012 Hyundai Sonata 8.5kW 270V BISG - Electrical Power Consumption Data.xlsx file contains a sample data set extracted from this efficiency map.
REVS_plot_emachine(emach,'efficiency'); REVS_plot_emachine_data_overlay(data, 'efficiency');
ORNL’s Starter-Generator maps are shown below for reference and are based on the combined BISG efficiency data from the component’s electric motor, inverter, and drive belt. However, the data are plotted against electric motor output speed/torque scaled axes rather than the BISG output speed/torque scaled axes (engine crankshaft speed). These images are published in the technical documentation located in 3d- Benchmarking State-of-the-Art Technologies Presentation by ORNL May 2013.pdf and 3e- FY2013 DOE Annual Progress Report Advanced Power Electronics and Electric Motors Program.pdf.
Note that belt losses are included in the two ORNL efficiency maps (motor and regen modes), as well as the ALPHA BISG efficiency map above. Per ORNL, the belt losses “… contribute 1–2% of the loss at high power levels and about 3–6% of the loss at low and moderate load levels” as documented in 3e- FY2013 DOE Annual Progress Report Advanced Power Electronics and Electric Motors Program.pdf.
2012 Hyundai Sonata Starter-Generator – Combined (Motor) Efficiency Contours (Including Belt Losses)
2012 Hyundai Sonata Starter-Generator – Combined (Regen) Efficiency Contours (Including Belt Losses)
Power Loss Difference (%) Table
In addition, the table below shows the relative power loss difference by comparing the power loss data derived from the ORNL efficiency data found in 3c- 2012 Hyundai Sonata 8.5kW 270V BISG - ORNL Test Data.xlsx file and the ALPHA map power data. The relative power loss difference for these data points is calculated using the following formula and represented as a percentage in the table.
Where
In cases where the original ORNL data contain abrupt changes in curvature, the ALPHA curve-fitting function produces a smooth surface through the points, resulting in a noticeable difference between the values of the original ORNL points and the curve fit surface. Additionally, larger percentage values for power loss difference are typical where the magnitude of the power loss is small (for example, at low torques and speeds)
REVS_table_data_comparision_emachine(data,emach, 'loss_diff_pct');
Motor Data Power Loss Percent Difference
195 RPM 391 RPM 781 RPM 1172 RPM 1563 RPM 1953 RPM 2344 RPM 2734 RPM 3125 RPM 3516 RPM 3906 RPM 4297 RPM 4688 RPM 5078 RPM 5469 RPM 5859 RPM
__________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________
110.0 Nm -0.97 -3.03 NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN
105.0 Nm 2.23 6.86 -0.27 NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN
100.0 Nm -0.69 -3.5 0.88 0.76 NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN
95.0 Nm -2.37 3.62 -0.03 -1.91 -3.03 NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN
90.0 Nm 3.13 -4.55 -2.34 2.58 4.75 3.23 0.21 NaN NaN NaN NaN NaN NaN NaN NaN NaN
85.0 Nm -2.97 3.06 3.55 -1.92 -1.46 -1.79 0.3 NaN NaN NaN NaN NaN NaN NaN NaN NaN
80.0 Nm 4.17 -1.33 -2.14 0.26 -0.7 -1.62 -1.57 NaN NaN NaN NaN NaN NaN NaN NaN NaN
75.0 Nm -2.81 0.04 0.31 3.3 0.03 0.75 0.8 -0.98 NaN NaN NaN NaN NaN NaN NaN NaN
70.0 Nm -0.19 0.91 0.18 -3.17 1.16 0.32 1.14 0.3 NaN NaN NaN NaN NaN NaN NaN NaN
65.0 Nm 0.35 -0.37 0.59 0.04 -1.01 0.35 0.36 0.74 NaN NaN NaN NaN NaN NaN NaN NaN
60.0 Nm 0.37 0.05 -0.15 0.31 1.76 -0.02 -0.37 0.92 -1.21 NaN NaN NaN NaN NaN NaN NaN
55.0 Nm 0.01 -0.02 0.01 -0.11 -1.63 -1.29 -1.11 -0.73 1.27 NaN NaN NaN NaN NaN NaN NaN
50.0 Nm 0.19 -0.34 0.36 -0.02 0.25 2.97 0.62 -0.03 0.3 -0.81 NaN NaN NaN NaN NaN NaN
45.0 Nm -0.05 -0.14 0.69 -0.17 0.39 -2.41 -0.57 -0.2 -0.49 0.25 NaN NaN NaN NaN NaN NaN
40.0 Nm -0.17 0 -0.13 -0.28 -0.08 0.28 3.09 -0.59 -0.1 0.24 -0.69 NaN NaN NaN NaN NaN
35.0 Nm -0.04 0.21 -0.22 -0.16 0.11 0.06 -2.37 1.95 3.45 -0.28 -0.02 -1.37 NaN NaN NaN NaN
30.0 Nm -0.93 -0.76 1.52 -0.14 0.47 -0.29 0.01 -1.52 -3.47 3.85 4.08 0.33 -1.65 NaN NaN NaN
25.0 Nm 1.74 -1.3 -0.4 -0.32 -0.85 1.23 0.43 -0.02 0.14 -3.15 -3.36 5.04 4.93 2.97 -1.46 NaN
20.0 Nm 1.13 2.38 0.19 0.05 0.84 -1.34 -0.04 0.6 0.21 0.23 0.43 -3.69 -3.02 -3.07 7.41 NaN
15.0 Nm -1.64 -1.83 0.72 -0.1 0.44 1.24 0.11 -0.05 0.34 0.59 -0.03 0.64 0.4 0.81 -4.31 0.44
10.0 Nm 0.14 -0.26 1.01 -0.14 -0.69 -0.98 0.55 -0.04 -0.05 -0.01 -0.96 -2.42 -3.64 -5.19 -5.59 -6.53
5.0 Nm -3.85 -1.62 -1.65 -3.2 -0.75 -0.15 -1.45 -0.29 -0.55 -0.25 0.82 3.99 5.94 8.86 12.32 12.39
Generator Data Power Loss Percent Difference
195 RPM 391 RPM 781 RPM 1172 RPM 1563 RPM 1953 RPM 2344 RPM 2734 RPM 3125 RPM 3516 RPM 3906 RPM 4297 RPM 4688 RPM 5078 RPM 5469 RPM 5859 RPM
__________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________
-5.0 Nm 22.87 14.7 12.65 11.28 6.09 3.33 1.87 2.11 -0.7 1.14 0.87 -0.87 -0.96 -0.27 -3.31 -2.61
-10.0 Nm -10.28 -10.79 -9.1 -7.33 -5.16 -4.53 -0.46 -1.93 2.25 -0.83 -1.16 -0.36 -0.67 -2.56 0.35 NaN
-15.0 Nm 0.78 2.33 1.21 0.39 1.2 1.95 -0.68 0.39 -0.8 0.39 0.03 0.42 0.54 1.03 0.39 NaN
-20.0 Nm 0.46 0.15 0.87 0.82 0.19 -0.38 0.75 -0.63 -0.85 -0.29 0.8 0.1 -0.37 -0.07 0.15 NaN
-25.0 Nm -0.15 0.51 0.45 -0.4 0.46 -0.23 0.43 1.3 0.3 0.33 -0.75 -0.3 0.36 NaN NaN NaN
-30.0 Nm -0.12 -0.17 -0.31 -0.1 -0.37 0.17 -0.62 -0.27 0.17 -0.41 0.26 NaN NaN NaN NaN NaN
-35.0 Nm 0.2 0.23 0.09 0.41 0.04 0.32 0.3 -0.45 -0.35 0.25 NaN NaN NaN NaN NaN NaN
-40.0 Nm 0.03 -0.42 -0.12 -0.14 0.41 -0.39 -1.15 -0.53 -0.3 NaN NaN NaN NaN NaN NaN NaN
-45.0 Nm -0.09 0.11 0.01 0.07 -0.36 0.27 1 0.6 0.62 NaN NaN NaN NaN NaN NaN NaN
-50.0 Nm -0.15 0.27 0.13 -0.37 0.26 -0.68 -0.25 0.14 NaN NaN NaN NaN NaN NaN NaN NaN
-55.0 Nm -0.63 0.54 0.08 0.43 -0.76 0.52 1.45 NaN NaN NaN NaN NaN NaN NaN NaN NaN
-60.0 Nm 0.25 -0.56 0.23 0.32 0.81 0.15 -1.37 NaN NaN NaN NaN NaN NaN NaN NaN NaN
-65.0 Nm 0.42 0.1 -1.02 0.21 -0.67 -0.13 NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN
-70.0 Nm 0.98 -0.31 1.43 -1.74 1.48 NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN
-75.0 Nm -0.85 0.13 -0.43 0.91 -0.75 NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN
Power Loss Map
A clean version of the Power Loss map is shown below and in 5a- 2012 Hyundai Sonata 8.5kW 270V BISG - Power Loss.pdf. The additional plots show system losses, converted to effective torque loss, as a function of motor output torque and speed. Effective torque loss represents the total power loss in the system as a loss of mechanical power. The associated speed is kept constant, and thus the total loss is expressed as a loss of torque. Torque losses are presented on a log scale.
REVS_plot_emachine(emach,'power loss'); REVS_plot_emachine(emach,'torque loss curves');
Generate ALPHA .m file for ALPHA Model Simulations
This code generates and writes the created ALPHA emachine definition into an “.m file” for use in later ALPHA vehicle model simulations. The .m file is the actual input file used in ALPHA that defines power consumption over the speed and torque operating limits of the 2012 Hyundai Sonata 8.5kW 270V BISG.
emach.write_mscript('emachine_2012_Hyundai_Sonata_8p5kW_270V_BISG.m');
Motor Build: emachine_2012_Hyundai_Sonata_8p5kW_270V_BISG.m
% ALPHA ELECTRIC MOTOR DEFINITION % Generated 17-Mar-2023 11:31:47 % Constructor mg = class_REVS_emachine_geared(); mg.name = '2012 Hyundai Sonata 8.5kW 270V BISG'; mg.source_filename = mfilename; % Physical Description mg.electrical_source = 'propulsion'; mg.inertia_kgm2 = 0.0032160199999999996; mg.gear.ratio = 1; mg.gear.efficiency_norm = 1; % Capacity Limits mg.max_speed_radps = 613.59231515425643; mg.max_torque_Nm = 110.08; mg.max_motor_power_W = 8500; mg.max_generator_power_W = 8500; mg.positive_torque_limit_Nm = class_REVS_dynamic_lookup; mg.positive_torque_limit_Nm.axis_1.signal = 'emach_spd_radps'; mg.positive_torque_limit_Nm.axis_1.breakpoints = [ 0.0000000000000000 20.453077171808548 40.906154343617096 81.812308687234193 122.71846303085128 163.62461737446839 204.53077171808548 245.43692606170256 286.34308040531965 327.24923474893677 368.15538909255389 409.06154343617095 449.96769777978807 490.87385212340513 531.78000646702230 572.68616081063931 613.59231515425643 ]; mg.positive_torque_limit_Nm.table = [ 110.00000000000000 ; 110.00000000000000 ; 110.00000000000000 ; 105.00000000000000 ; 100.00000000000000 ; 95.000000000000000 ; 90.000000000000000 ; 90.000000000000000 ; 75.000000000000000 ; 60.000000000000000 ; 50.000000000000000 ; 40.000000000000000 ; 35.000000000000000 ; 30.000000000000000 ; 25.000000000000000 ; 25.000000000000000 ; 15.000000000000000 ]; mg.negative_torque_limit_Nm = class_REVS_dynamic_lookup; mg.negative_torque_limit_Nm.axis_1.signal = 'emach_spd_radps'; mg.negative_torque_limit_Nm.axis_1.breakpoints = [ 0.0000000000000000 20.453077171808548 40.906154343617096 81.812308687234193 122.71846303085128 163.62461737446839 204.53077171808548 245.43692606170256 286.34308040531965 327.24923474893677 368.15538909255389 409.06154343617095 449.96769777978807 490.87385212340513 531.78000646702230 572.68616081063931 613.59231515425643 ]; mg.negative_torque_limit_Nm.table = [ -80.000000000000000 ; -80.000000000000000 ; -80.000000000000000 ; -75.000000000000000 ; -75.000000000000000 ; -75.000000000000000 ; -65.000000000000000 ; -60.000000000000000 ; -50.000000000000000 ; -45.000000000000000 ; -35.000000000000000 ; -30.000000000000000 ; -25.000000000000000 ; -25.000000000000000 ; -20.000000000000000 ; -20.000000000000000 ; -5.0000000000000000 ]; % Losses & Efficiency mg.electric_power_W = class_REVS_dynamic_lookup; mg.electric_power_W.axis_1.signal = 'emach_spd_radps'; mg.electric_power_W.axis_1.breakpoints = [ 0.0000000000000000 40.906154343617104 81.812308687234207 122.71846303085125 163.62461737446841 204.53077171808553 245.43692606170251 286.34308040531965 327.24923474893683 368.15538909255395 409.06154343617089 449.96769777978807 490.87385212340519 531.78000646702230 572.68616081063931 613.59231515425643 ]; mg.electric_power_W.axis_2.signal = 'emach_trq_Nm'; mg.electric_power_W.axis_2.breakpoints = [ -75.000000000000000 -70.000000000000000 -65.000000000000000 -60.000000000000000 -55.000000000000000 -50.000000000000000 -45.000000000000000 -40.000000000000000 -35.000000000000000 -30.000000000000000 -25.000000000000000 -20.000000000000000 -15.000000000000000 -6.2096774193548381 0.0000000000000000 5.0000000000000000 10.000000000000000 15.000000000000000 20.000000000000000 25.000000000000000 30.000000000000000 35.000000000000000 40.000000000000000 45.000000000000000 50.000000000000000 55.000000000000000 60.000000000000000 65.000000000000000 70.000000000000000 75.000000000000000 80.000000000000000 85.000000000000000 90.000000000000000 95.000000000000000 100.00000000000000 110.00000000000000 ]; mg.electric_power_W.table = [ 1394.4092640792430 1156.4558323610688 956.62435313760841 798.12090159619845 671.22462685448784 559.39203988725194 459.88031855311834 372.02625153420541 296.14343383447982 231.85083729919782 176.26332860380549 127.54058348307873 85.021295673334862 19.318787226328549 32.527370934525649 62.898834981764480 94.669162681759403 129.57785203493657 168.99405414694854 225.40191155582653 302.65070513250646 388.72735761076154 484.08003312641557 590.40204435599378 712.85607128647814 858.29211993313788 1029.3465695671503 1227.8638120385988 1442.6392411794807 1648.1073636576532 1826.5305971845878 2109.8318849897378 2399.0292803460161 2792.6573576829674 3162.0002665473630 4032.7597263069906 ; -1453.0009944584237 -1457.6227586501971 -1440.7894126474616 -1397.1419241241140 -1342.4908256949036 -1264.9466182391407 -1164.5447626275786 -1048.7851125031900 -926.75636532829935 -793.02608343801114 -650.70065541779104 -497.27607326417217 -340.34340284849799 -99.933036625492079 164.92249261673362 420.30509907011827 675.58756501405514 929.86284311036036 1180.2052432568887 1463.2383583744738 1754.7854217800277 2042.5594059030143 2342.0707609124102 2656.1827367547071 2985.1282668166136 3330.4267492175377 3702.4519901154927 4109.6209277359167 4542.4473776029618 5005.9068393848238 5424.8811576657245 5871.7928184652665 6362.9098458363515 6706.0114605722711 7237.8900106884930 9134.6122445994934 ; 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mg.unpowered_torque_loss_Nm = class_REVS_dynamic_lookup; mg.unpowered_torque_loss_Nm.axis_1.signal = 'emach_spd_radps'; mg.unpowered_torque_loss_Nm.axis_1.breakpoints = [ -15000.000000000000 15000.000000000000 ]; mg.unpowered_torque_loss_Nm.table = [ 0.0000000000000000 0.0000000000000000 ];