The electrical power and energy requirements of future vehicles will be increased considerably due to both the electrical portion of the powertrain and to additional auxiliary systems. Furthermore, electrical systems for improving the energy efficiency of the vehicle such as start/stop, recuperation and energy management cause serious challenges in terms of Electrical Distribution System (EDS) complexity, cost, and stability, especially if future actuators with brief but high power consumption are also taken into account. The approach presented in this paper is a method for optimizing the topology of the EDS in combination with auxiliary storage devices and/or DC/DC converters, and the application of an appropriate power control strategy. The criteria are cost, robustness, sufficient power supply, and voltage stability. Due to the high number of possible EDS architectures, initially modeling and simulation are used to identify potential solutions. In a second step, the characteristics of these architectures are measured on a modular and HiL-based test bench. The test bench is built in modules in order to achieve maximum flexibility in representing variants of the architectures. Therefore, the components correspond to a large extent of the function blocks pre-conditioned lead-acid battery, a serial circuitry of ultracapacitors, a bi-directional DC/DC converter, two electronic loads that simulate the power consumption of the EDS, switches and diodes, and a alternator test bench, which allows the precise running of RPM profiles and the measuring of the torque. The alternator- and converter controls were developed specifically for this project, in order to realize the power management. Further components include the necessary instrumentation and data logging as well as computers to simulate and control the test scenarios. The following comparative analyses examine the ultracapacitor - DC/DC converter combination. For this purpose, the simulated current of high-power loads during a double lane-change maneuver were chosen as a test scenario. The final goal is a DoE and simulation-based optimization method providing the confidence level of experimental measurements. In addition to the theoretical description, initial measurement and simulation results are presented and the next steps discussed.


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