Professional Documents
Culture Documents
Vss030 Stutenberg 2014 o
Vss030 Stutenberg 2014 o
Project ID # VSS030
This presentation does not contain
any proprietary, confidential, or
otherwise restricted information.
Overview
Timeline DOE VSST barriers addressed:
– Benchmarking at ANL started in 1998 – Computational Models, Design and
– FY13 & FY14 Completed Testing: Simulation Methodologies (C)
• 10 vehicles tested in FY13, 4 in FY14 • Model development and validation
• Thermal impact study – Lack of Standardized Testing Protocols (D)
• Conventional vehicle study • Validating BEV and PHEV test procedures
– FY14 and FY15 Test Vehicles • Support of SAE committee (J2951 Drive
Metrics, J2907/2908 Powertrain rating,
• See Milestone on slide 6
J2263 Coast Down, etc…)
– Constant Advances in Technology (F)
• Public data generation from
benchmarking recent mass-produced
BEVs and PHEVs.
• Advances in HEVs and Alt Fueled Vehicles
Budget compared to previous models
2
Relevance: Objectives of the Advanced Powertrain
Research Facility (APRF)
Benchmark Codes and Standards
Objective Objective
“Assist in codes and
“Provide to DOE and Partners
standards development with
the Best Advanced Vehicle
public and independent
Test Data and Analysis”
research and data”
Laboratory Testing Mission Focus for FY14
Enable petroleum displacement through Establish technology benchmarks for HEV,
technology assessment & data dissemination PHEV, BEV, Conventional and Alternative
Establish the state-of-the-art automotive Fuel Vehicles.
technology baseline for powertrain Development of data management and
systems and components through test analysis tools for quicker data distribution
data generation and analysis Evaluation of thermal effects on energy
Provide independent and public data for consumption and powertrain behavior
evaluation of emerging technology
Generate data to support model creation
and validation, standards development,
and DOE target setting
3
Relevance: Advanced Technology Benchmark-
Matching Technology to Targets
Vehicle Research: Dynamometer Testing
Vehicle Technologies Office Plan
– Vehicle system testing
• Energy consumption (fuel + electricity) Hybrid and Vehicle
• Emissions Systems
• Performance Energy
• Vehicle operation and powertrain strategy Storage
Advanced Power
– ‘In-situ’ component and system testing
Electronics
• Component performance, efficiency and operation Materials
over drive cycles
Advanced Technology
• Component mapping
– Technology assessment and goal setting Combustion
Engines Fuels and
Lubricants
VSST Challenges and barriers
A. Risk Aversion
B. Cost.
C. Infrastructure.
D. Lack of standardized test protocols.
E. Computational models, design and
simulation methodologies.
F. Constant advances in technology.
4
Relevance: Purpose and Destination of Vehicle Testing
and Analysis
“Knowing how good you are requires an accurate picture of how good everybody else is”
Supporting DOE
Data
Independent technology evaluation
and
Baseline for technical targets and goal
Analysis
setting
• Vehicle efficiencies and energy use: average
over drive cycles at different temperatures
• Component behaviors from a vehicle system
perspective
Dynamometer • Charging profiles, battery capacities, battery
D3 Downloadable characterizations
Database
www.transportation.anl.gov/D3/ Technology challenge
Limited Public data sets Innovation opportunity
Heating , Thermal management, Accessory loads,….
US Drive
Codes and Standards Modeling Support
Tech Team Support Component mapping
Data for procedures
Full data sets Thermal analysis
development and
Climate control system
validation
Data for validation
Milestones: ARPF- Providing Data for a
2013 Prius
Wide Variety of Vehicle Technologies PHEV
AMR
2013-Q3
2013 Q4
2014 Q1
2014 Q2
2014 Q3
Milestones 2013 C-Max
Toyota Prius PHEV Hybrid
VW Jetta Hybrid
AVTA Test Cars
2013 C-Max
Nissan Leaf Energi
Ford Fusion Energi
Ford Focus Electric
Smart Fortwo ED
Dodge Ram Idle Stop
Honda Accord PHEV 2013 Civic
Hybrid
Level 2
2012
Development of D3 I-MiEV
Codes and Standards Support
6
2013 Jetta TDI 2013 Civic CNG 2013 Volt 2013 Malibu Eco 2013 Jetta Hybrid 2013 Leaf
Approach: Well-Established and Proficient Testing
Methods Adjusted to Individual Technologies
APRF expertise in testing
The vehicle benchmark activity has been refined during the Powertrains
past decade, which has resulted in: • Conventional
• Hybrid Electric (HEV)
Advanced and unique facilities and instrumentation • Plug-in HEV (PHEV)
Continuous improvement of testing procedures • Battery Electric (BEV or EV)
• Fuel Cell Vehicle
Standardization of test plans including instrumentation and Alternative fuels
drive cycles which are adjusted for individual vehicles • Hydrogen, Natural Gas
• Ethanol, Butanol
Significant knowledge of advanced vehicles and testing methods • Diesel (Bio, Fisher-Tropsch)
Data
New 1. Preparation and 2. Dyno testing 3. Analysis
vehicle instrumentation
Mileage
accumulation,
Data
track testing
& coast down
National Labs
USCAR (OEMs)
7
Approach: Purpose Built Research Laboratory for
Automotive Benchmark Activities
Level 1 testing: Basic and comprehensive Advanced Powertrain
instrumentation Research Facility
– Level 1 = non-intrusive instrumentation The right tools for the task:
– Vehicle characterization (fuel and energy • Two chassis dynamometer cells
consumption, emissions, performance) • Custom DAQ, flexible, module-
– Vehicle operation and strategy driven, used in both cells
– Component specific instrumentation for analysis • Thermal chamber which is 5-Cycle
and modeling (speed, temp, and other compliant (+)
technology specific removable instrumentation) 4WD chassis
Drive cycles and test conditions dyno with
– Standard drive cycles, technology specific cycles, thermal
performance tests, vehicle and component chamber
mapping cycles
– Thermal test conditions: 20⁰F, 72⁰F and 95⁰F
with 850 W/m2 radiant solar energy “5-Cycle”
– Additional testing at 0⁰F and 40 ⁰F as desired
2WD
chassis
dyno
8
Accomplishments: Revised Instrumentation,
Testing, and Data Management
Non-Invasive Vehicle Data
Instrumentation Dissemination
Data Management
0.34
0.34
12
2
0.34
0.3
Indicated Efficiency Map - 2012 Honda Civic CNG R18 0.36 0.34
11 0.4 11 0.36
0.36
0.38
0.38 0.38 0.35
0.38 0.38
0.36
10 0. 10
38
9
Natural Gas 0.3
8 0.38 0.35 9 Gasoline
0.3
0.4
0.4
0.4
8
8 8 0.3
0.
34 0.38 0.4 0.4 0.4
IMEP [bar]
7 0.38 0.3 7
0.
0.38
0.34
38
0.36
0.3
IMEP [bar]
6 0 6 6
.32
0.3
0.3 0.36 8
6 0.3
8
0.25
36
5 5 0. 0.36
0.
0.25 32 0.36
0.3 0.3 0.34
4 0.34
4 4
0.3
0.34 0.34
0.32
0.2 0.32 0.32 0.34
3
0. 8 0.3 3 0.32 0.32 0.32
2 0.3 0.3 0.2 0.2 0.2
0. 6 0.28 0.28 0.28
0.3 0.3 0.28 0.3
2
2 0.24 0.26 0.26 2 0.26 0.28 0.26
0.2 2
0.24 0.24 0.26 0.24
0. 0.24 0.24
0 18 0.22 0.22 0.22 0.22 0.22
0.2
1 0.1.16
4 0.2 0.2 1 0.160.18 0.2
0.2 0.15
0.
2 0.2
0 0 0.15
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Engine Speed [RPM] Engine Speed [RPM]
10
Accomplishments: Temperature Effects on BEV Range
100%
92.4 miles (84% of 72F)
2013 Nissan Leaf
100%
Range [miles]
90%
73% 69.2 miles (75% of 72F)
68%
81%
100%
90%
68%
54%
81%
60%
68%
60%
43%
Test Setup:
2014 Ford Cmax Energi Cabin temperature setting can save or cost
Charge depleting mode
almost 20% in city driving on a hot day
95F with 850 W/m2
Steady State Speed Results
AC off
78F
75F
68F
72F
AC max
Road
load
Test Cycle
curve
UDDS Steady
Phase State
1 Speeds Use the AC at high speeds, but at low speeds the
AC power outweighs the powertrain power
12
Accomplishments: “Blended” PHEV Fuel
Displacement Varies Heavily on Design and Controls
Both vehicles can drive a UDDS cycle in electric mode, but not the aggressive US06 cycle
EV power capability limits quick discharge of on-board battery energy, which limits fuel displacement
27.1 miles
5.7 kWh
~20 miles
Cmax Energi 5.7 kWh
= Periods of Engine-Assist
~20 miles
2.2 kWh
Prius PHV
13
Accomplishments: Assist in Codes and Standards
Level 1 Argonne Benchmarking Tests Are Prototypes
for Power Rating Procedures (SAE J2908)
1. Peak Powertrain
Power 3. Peak
Electric Drive
Power
4. Peak Regen Power
2. Peak Battery
Assist Power
14
Accomplishments: Data Analysis and Reporting
Data Management Tool
Test Summary Results D3
Vehicle Database Each test has a unique test ID
organized by
vehicle type
• Analysis presentation
(when available) 10Hz raw data files
• Test summary results Files named by unique test ID
• 10Hz data download
Bi-Monthly Update
• Images
• Brief description
• Key technologies
• Analysis presentation
(when available)
• Test summary results
• 10Hz data download
• Full Signal List
www.transportation.anl.gov/D3/
15
Coordination: Existing Collaborations with Other
Institutions J1711 HEV & PHEV test procedures International
J1634 EV test procedures - KATECH (Korea)
- ISO
AVTA (Advanced Vehicle - JARI (Japan)
Testing Activity) - IEA
Baseline dynamometer - Joint Research Centre (EU)
testing of vehicles
Autonomie
Support of modeling Chrysler – CTC
and simulation with data
GM – Powertrain, Milford
18
Technical Back-Up Slides
19
Advanced Powertrain Research Facility
4WD Chassis Dynamometer Thermal Test Cell
• Research aspects
Modular and custom DAQ with real
• Test cell features time data display
4WD chassis dynamometer Process water available for cooling
- Variable wheel base (180inches max) of experiment components
Available power in test cell
- 250 hp/axle
- 480VAC @ 200A
- 300 to 12,000 lbs.. inertia emulation - 208VAC @ 100A
Radiant sun energy emulation ABC 170 Power supply capable to
850W/m2 (adjustable) emulate electric vehicle battery
Variable speed cooling fan (0–62mph) Custom Robot Driver with adaptive
Gaseous fuel and hydrogen capable learning
Several vehicle tie downs
Diesel: Dilution tunnel, PM, HFID - chains, low profile, rigid,…
• Thermal chamber - 2, 3 and 4 wheel vehicle capable
EPA 5 cycle capable Expertise in testing hybrid and plug-
o o o
(20 F, 72 F and 95 F + 850W/m2 solar load) in hybrid electric vehicles, battery
Demonstrated as low as 0oF electric vehicles and alternative fuel
vehicles
Intermediate temperatures possible
• Special instrumentation
High precision power analyzers
(testing and charging)
CAN decoding and recording
OCR scan tool recording
Direct Fuel Flow metering
Infra Red Temperature camera
In cylinder pressure indicating
systems
In-situ torque sensor measurement
5 gas emissions dilute bench with
CVS (modal and bag emissions
analysis)
FTIR, Mobile Emissions unit
Raw and Fast HC and NOx bench
Aldehyde bench for alcohol fuels
• Special instrumentation
High precision power analyzers
(testing and charging)
• Test cell features CAN decoding and recording
2WD Light Duty / Medium Duty OCR scan tool recording
chassis dynamometer Direct Fuel Flow metering
- 300 hp Infra Red Temperature camera
- 300 to 14,000 lbs.. inertia emulation In cylinder pressure indicating
- 10,000 lbs.. max weight driven axle systems
Multiple cooling fans available In-situ torque sensor measurement
Vehicle lift (max 10,000 lbs..) SEMTECH-DS (Mobile Emissions
Remotely located control room with unit) with AVL DVE mass flow sensor
conference area
• Research aspects
Modular and custom DAQ with real
time data display
Flexible to adopt any drive cycle
Available power in test cell
- 480VAC @ 200A & 100A
- 208VAC @ 50A, 30A & 20A x3
ABC 170 power supply capable to
emulate electric vehicle battery
Custom Robot Driver with adaptive
learning
Expertise in testing hybrid and plug-in
hybrid electric vehicles, battery
electric vehicles and alternative fuel
vehicles