Since the evolution of the electric and hybrid vehicle, the analysis of batteries’ characteristics and influence on driving range has become essential. This fact advocates the necessity of accurate simulation modeling for batteries. Different models for the Li-ion battery cell are reviewed in this paper and a group of the highly dynamic models is selected for comparison. A new open circuit voltage (OCV) model is proposed. The new model can simulate the OCV curves of lithium iron magnesium phosphate (LiFeMgPO₄) battery type at different temperatures. It also considers both charging and discharging cases. The most remarkable features from different models, in addition to the proposed OCV model, are integrated in a single hybrid electrical model. A lumped thermal model is implemented to simulate the temperature development in the battery cell. The synthesized electro-thermal battery cell model is extended to model a battery pack of an actual electric vehicle. Experimental tests on the battery, as well as drive tests on the vehicle are performed. The proposed model demonstrates a higher modeling accuracy, for the battery pack voltage, than the constituent models under extreme maneuver drive tests.

A systematic simulation model is proposed in this research paper to estimate the energy consumption of electric vehicles. The main advantage of this model is that it is made in a generic and simplified way in order to be adaptable to different electric vehicles. The overall electrical power corresponding to the performed maneuver is estimated considering: a tabular form of electric motor efficiency, mechanical power losses, a generalized efficiency map of the power electronics, the auxiliary power losses, and an electro-thermal Lithium-Ion battery pack model. The battery model was developed in a previous work, which simulates the open circuit voltage curves at different temperatures and the alteration in the internal resistance of the battery cells. The proposed model is validated with experimental data from the maneuver tests. The battery model proved high accuracy in estimating the voltage values relevant to the WLTP2 driving cycle on the chassis roller test bench. Furthermore, the mechanical and electrical power were estimated with excellent matching compared to actual test field driving test measurements, giving only the measured vehicle speed and auxiliary power losses. Finally, the state of charge change is predicted accurately along the performed test field dynamic maneuver.

An identification technique is proposed to create a relation between the accelerator pedal position and the corresponding driving moment. This step is beneficial to replace the complex physical model of the vehicle control unit, especially when the sufficient information needed to model certain functionalities of the vehicle control unit are unavailable. We utilized the nonlinear autoregressive exogenous model to regenerate the electric motor torque demand, given the accelerator pedal position, the motor’s angular speed, and the vehicle’s speed. This model proved to be extremely efficient in representing this highly complex relationship. The data employed for the identification process were chosen from an actual three-dimensional route with sudden changes of a dynamic nature in the driving mode, different speed limits, and elevations, as an attempt to thoroughly cover the driving moment scope based on the alternation of the given inputs. Analyzing the selected route data points showed the widespread coverage of the motor’s operational scope compared to a standard driving cycle. The training outcome revealed that linear modeling is inadequate for identifying the targeted system, and has a substantial estimation error. Adding the nonlinearity feature to the model led to an exceptionally high accuracy for the estimation and validation datasets. The main finding of this work is that the combined model from the nonlinear autoregressive exogenous and the sigmoid network enables the accurate modeling of highly nonlinear dynamic systems. Accordingly, the maximum absolute estimation error for the motor’s moment was less than 10 Nm during the real-world driving maneuver. The highest errors are found around the maximum motor’s moment. Finally, the model is validated with measurements from an actual field test maneuver. The identified model predicted the driving moment with a correlation of 0.994.

The energy consumption of the electric test vehicle on the roller dynamometer test bench is thoroughly investigated in this work. Initially, we extensively examined the relevant testing approaches on chassis dynamometer test benches. Then, we presented the main issues and limitations of this type of testing facility. After that, an experimental analysis was performed by recording the NEDC and the WLTP-class 2 standard driving cycle test data. It was found that the power consumption associated with specific test maneuvers could be accurately simulated via the roller dynamometer system. However, the experimental test results showed some disparities compared to the expected results from the simulation models. These findings supported identifying the dynamic behavior resulting from the tire and roller contact. The LuGre friction model provided the solution, incorporating friction-related physical models such as stick-slip and the Stribeck effect. In addition, adjustments were made to the LuGre model to consider the dynamic influences of the roller on the tire. Finally, we created a systematic estimation model for energy consumption by integrating the boundary conditions of the test bench, a generic model for energy estimation of electric vehicles, and the proposed tire–roller contact model. The overall model requires only the measured traction speed of the test vehicle and the auxiliary energy losses as physical inputs. The results proved that the proposed model enabled the estimation of the total power consumption with high accuracy.

The regeneration of highly dynamic driving maneuvers on vehicle test benches is challenging due to several influences, such as power losses, vibrations in the overall system that involves the vehicle with the test bench, uncertainties in the model parameterization, and time delays from both the test bench and the measurement systems. In order to improve the dynamic response of the vehicle test bench and to overcome system disturbances, we employed different types of control algorithms for a mechanical multi-mass model. First, those controllers are extensively investigated in the frequency domain to analyze their stability and evaluate the noise rejection quality. Then, the expectations from the frequency analysis are confirmed in a time-domain simulation. Furthermore, sensitivity analysis tests were conducted to evaluate each controller’s robustness against the modeling parameters’ uncertainty. The linear quadratic controller with integral action demonstrated the best compromise between performance and robustness.