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, EindhovenPAGE 1

2. TU/e Lupo ELpicture + specsPAGE 2Donor vehicle: VW Lupo 3LVehicle mass: 1060 kg Battery capacity: 27 kWhTop speed: 130 km/hRange: up to 200km, 170km@100km/h0 – 100 km/h: 12 sec.4 seats

3. Carrying energy in batteriesenergy densitybatteries weight: 273 kgvolume: 180 literscapacity: 27 kWhequivalent fossil fuel: 10 L petrol (8 kg), 7 L diesel (6 kg)energy flownormal fuel pump: 40 L/minutenormal 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

4. System overviewPAGE 4Electric vehicle system diagramChassis 598 kgICE = 239 kgFocus points:Lightweight

5. Efficient

6. Flexiblecontrol

7. ExtensivemeasurementabilitiesPackagingPAGE 5No interior space lost

8. Weight distribution improvedFront compartmentPAGE 6Aluminium mounting and battery box designControllerChargerInverterDC-DC 12V

9. IFM CR0232 PLC80x IO ports4x CAN busElectric system layout PAGE 7VW systems fully functional (CAN)

10. PAGE 8ControllerIFM CR2032, Industrial PLCInfineonTriCore 1796, 32 bit CPU, 150 Mhz

11. 32 Inputs (analog/digital)

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

13. 4 CAN bus interfaces (2.0 A/B, up to 1Mbit/s)SoftwareCoDeSysv2.3 software development platform

14. IEC 61131-3 based, followinglanguagesavailable

15. Instruction list (IL)