This document summarizes the development of software for an electric vehicle called the TU/e Lupo EL. It describes the donor vehicle, a VW Lupo, and the modifications made including replacing the internal combustion engine with lithium-ion batteries. An overview is given of the electric vehicle system including the controller, inverter, charger and other components. Details are provided about the software architecture including the PLC used, programming languages, control features, data acquisition, and user interface.

1. Software developmentinan electric vehicle:the TU/e Lupo ELir. Paul van OorschotMechanical Engineering, Dynamics and ControlOctober 3, 2011, Eindhoven PAGE 1

2. TU/e Lupo EL picture + specs PAGE 2 Donor vehicle: VW Lupo 3LVehicle mass: 1060 kg Battery capacity: 27 kWhTop speed: 130 km/h Range: up to 200km, 170km@100km/h 0 – 100 km/h: 12 sec.4 seats

3. Carrying energy in batteries energy density batteries weight: 273 kgvolume: 180 literscapacity: 27 kWh equivalent fossil fuel: 10 L petrol (8 kg), 7 L diesel (6 kg) energy flow normal fuel pump: 40 L/minute normal socket (Europe: 3.6 kW): approx. 1.5 L petrol/hour (1600x slower) DC fast charging (50 kW, CHAdeMO): approx. 20 L petrol/hour (120x slower) PAGE 3

5. Efficient

6. Flexiblecontrol

9. IFM CR0232 PLC 80x IO ports 4x CAN bus Electric system layout PAGE 7 VW systems fully functional (CAN)

11. 32 Inputs (analog/digital)

12. 48 Outputs (PWM, high/low side, currentcontrolled)

14. IEC 61131-3 based, followinglanguagesavailable

15. Instruction list (IL)

16. Structuredtext (ST)

17. Ladder diagram (LD)

18. Functionblock diagram (FBD)

20. Isolation monitoring

21. Brake booster vacuumABS active ? -> Disable regenerative braking Airbags(crash) -> Disable systems and HV

23. Battery condition

26. PAGE 12 Traction Enabletraction (start the vehicle) Tractioncontrol

28. Torquecontrolled (betterbrakeblending)Current limit Brake pressure

30. Measured data per component

31. Errors and warnings

33. Tractionenabledwhile door open

34. System errors