development of a 55kw diesel powered auxiliary power …
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DEVELOPMENT OF A 55kW DIESEL POWERED AUXILIARY POWER UNIT
FOR HYBRID ELECTRIC VEHICLES
INTERIM REPORT TFLRF No. 328
By William E. Likos Daniel J. Podnar Jack A. Smith
Joe Steiber U.S. Army TARDEC Fuels and Lubricants Research Facility (SwRI)
Southwest Research Institute San Antonio, Texas
Prepared for Defense Advanced Research Projects Agency
3701 N. Fairfax Drive Arlington, Virginia 22203-1714
Under Contract to U.S. Army TARDEC
Petroleum and Water Business Area Warren, MI 48397-5000
Contract No. DAAK70-92-C-0059
Approved for public release; distribution unlimited
March 1998 mc «tonrnwoMD*
Disclaimers
The findings in this report are not to be construed as an official Department of the Army position unless so designated by other authorized documents.
Trade names cited in this report do not constitute an official endorsement or approval of the use of such commercial hardware or software.
DTIC Availability Notice
Qualified requestors may obtain copies of this report from the Defense Technical Information Center, Attn: DTIC-OCC, 8725 John J. Kingman Road, Suite 0944, Fort
Belvoir, Virginia 22060-6218.
Disposition Instructions
Destroy this report when no longer needed. Do not return it to the originator.
REPORT DOCUMENTATION PAGE Form Approved OMB No. 0704-0188
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1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE
March 1998
3. REPORT TYPE AND DATES COVERED
Interim September 1994 - September 1997
4. TITLE AND SUBTITLE
Development of a 55kW Diesel Powered Auxiliary Power Unit for Hybrid Electric Vehicles
6. AUTHOR(S)
Likos, W.E., Podnar, D.J., Smith, J.A., and Steiber, J.
5. FUNDING NUMBERS
DAAK70-92-C-0059; WD 36
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)
U.S. Army TARDEC Fuels and Lubricants Research Facility (SwRI) Southwest Research Institute P.O. Drawer 28510 San Antonio, Texas 78228-0510
8. PERFORMING ORGANIZATION REPORT NUMBER
TFLRFNo.328
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)
U.S. Army TARDEC Petroleum and Water Business Area U.S. Army TACOM Warren, MI 48397-5000
10. SPONSORING/MONITORIG AGENCY REPORT NUMBER
11. SUPPLEMENTARY NOTES
12a. DISTRIBUTION/AVAILABILITY STATEMENT
Approved for public release; distribution unlimited
12b. DISTRIBUTION CODE
13. ABSTRACT (Maximum 200 words)
Three auxiliary power units (APU) were developed for military hybrid vehicle applications with funding from DARPA. One APU was for the electric Ml 13 troop carrier originally converted to electric power in the 1960's. The other two APU's developed during this project were for hybrid electric High Mobility Multipurpose Wheeled Vehicle (HMMWV) projects. For this APU design a Volkswagen 1.5-1 diesel engine drives a permanent magnet generator, that with associated inverter produces 55 kW of DC power at 380 volts. Overall thermal efficiencies of 33 % were observed.
The controller for the APU's was based on the personal computer (PC) CPU. Basing the controller on the PC allowed flexibility in meeting the individual requirements of the different vehicles. Given a power level request from the vehicle controller, the APU controller set the engine speed for optimum thermal efficiency. The generator electronics adjusts the voltage and thus the current output from the inverter to deliver the requested power to the vehicle's electrical bus.
14. SUBJECT TERMS
APU Hybrid Permanent Magnet Electric Vehicle
15. NUMBER OF PAGES 30
16. PRICE CODE
17. SECURITY CLASSIFICATION OF REPORT
Unclassified
18. SECURITY CLASSIFICATION OF THIS PAGE
Unclassified
19. SECURITY CLASSIFICATION OF ABSTRACT
Unclassified
NSN 7540-01-280-5500Standard Form 298 (Rev. 2-89) Prescribed by ANSI Std. 239-18
298-102
20. LIMITATION OF ABSTRACT
EXECUTIVE SUMMARY
The initial purpose of this project was to develop an Auxiliary Power Unit (APU) for use in a High Mobility Multi-purpose Wheeled Vehicle (HMMWV) that was being converted to a hybrid electric configuration. Later, the project scope was increased to add an APU for another electric HMMWV and another APU for a hybrid electric Ml 13 Troop Carrier. The project involved selecting the engine and generator, developing the APU control system, and testing the completed APU. The project was divided into four phases: (1) selection of engine and generator, (2) design and construction of the APU, (3) APU control system development, and (4) APU testing.
The first phase involved reviewing the specifications of each vehicle integrator to select an appropriate engine and generator that would meet the size, weight, and power requirements and be able to operate underwater. The engine chosen, the new Volkswagen 1.9L, turbo-charged, direct injected diesel, is a state-of-the-art, high-efficiency, low emissions design. The generator selected is a permanent magnet alternator with inverter electronics to provide the requested power at the prevailing bus voltage. This electric machine is a state-of-the-art design with an overall efficiency in excess of 94 percent at most operating conditions.
The second phase involved the design and construction of the three APUs. Design of the APUs was a joint effort with SwRI and McKee Engineering. In order to fit the APU into the space available under the hood of the HMMWV, it was necessary to turn the engine on its side. Lubrication by means of the stock oil sump would no longer be functional, therefore the engine was modified to a dry sump configuration. McKee Engineering was selected for this task because of their extensive experience doing this engine modification.
The third phase of the project involved designing and developing an APU controller. The controller receives a power request from the vehicle and provides engine and generator management to meet the requested power. The APU controller was based on a personal computer (PC) platform. In order to meet the differing requirements of the Ml 13 and the HMMWV vehicle projects, individual software programs were developed for each vehicle.
The fourth phase of the project consisted of the debugging and performance testing of the APU in the laboratory. During this testing, the output of the generator was absorbed by a battery pack and a resistive load bank that simulated the vehicle power bus. Documentation of the complete control system was prepared to assist the vehicle integrators.
in
FOREWARD/ACKNOWLEDGMENTS
The U.S. Army TARDEC Fuels and Lubricants Research Facility (SwRI), San San Antonio, TX performed
this work, under contract no. DAAK70-92-C-0059. Work was funded by the Defense Advanced Research
Projects Agency (DARPA) with Mr. R. Rosenfeld (DARPA) and Mr. T. Bagwell (TARDEC) serving as
technical monitors, and Mr. L. Villahermosa (TARDEC) serving as the contracting officer's representative.
IV
TABLE OF CONTENTS Section Page
1.0 BACKGROUND 1
1.1 Technical Background 1 1.1.1 Engine 1 1.1.2 Generator 2 1.1.3 Controller 2
2.0 TECHNICAL DISCUSSION 2
2.1 APU Design and Development 2 2.1.1 Engine Selection 3 2.1.2 Generator Selection 3 2.1.3 Generator to Engine Coupling 6 2.1.4 Engine Dry Sump Lubrication System 9 2.1.5 Engine & Generator Cooling 10
2.2 APU Control System Development 10 2.2.1 Control Functions 10 2.2.2 Controller Hardware Platform 12 2.2.3 Control Software/Algorithm Descriptions 12
2.3 APU Testing ..14 2.3.1 Ml 13 APU controller Stand-Alone Testing 16
2.3.2 CTC Engine-Generator/Ml 13 APU Controller Integrated Testing 17 2.3.2.1 Heat Exchangers 18 2.3.2.2 Power Absorption 18 2.3.2.3 Fuel Supply 18 2.3.2.4 Power Measurement 19 2.3.2.5 Vehicle Control 19 2.3.2.6 HMMWV Controller/Ml 13 APU Start/Stop Testing 19 2.3.2.7 HMMWV Controller/Ml 13 APU Steady-State Testing 20 2.3.2.8 HMMWV Controller/Ml 13 APU Transient Testing 22
2.3.3 Testing of the HMMWV Engine Generator/HMMWV APU Controller ..27 2.3.3.1 Stand-Alone HMMWV Controller Testing 27 2.3.3.2 HMMWV APU Start/Stop Testing 29
TABLE OF CONTENTS (continued)
Section Page
2.4 APU Testing Conclusions 30
3.0 SUMMARY 30
APPENDICES
A Power System Research Engine Survey B Volkswagen 1.9L Engine Specifications C Steady-State Test Results D Complete APU Wiring Diagrams for the HMMWV APU E Complete Wiring Diagrams for the HMMWV APU
LIST OF ILLUSTRATIONS
Figure Page
1 HMMWV APU 4 2 M113APU 5 3 Original McKee Engine-to-Generator Coupling 7 4 Final Engine-to-Generator Coupling 8 5 Dry Sump Lubricant System 9 6 APU Test Setup 11 7 APU Controller 13 8 APU Control Functions 15 9 APU Efficiency vs. Electrical Power Out 21 10 Generator Efficiency vs. Electrical Power Out 21 11 Power/Ramp Up/Down 23 12 APU Power Transient Response 24 13 APU Power Transient Response 25 14 APU Power Transient Response 26
LIST OF TABLES
Table Page
1 APU Controller Signal I/O 16 2 APU Controller I/O Signals 28 3 Serial Link Protocol Specification 29
VI
1.0 BACKGROUND
1.1 Technical Background
Three hybrid vehicle auxiliary power units (APU) for hybrid vehicle applications were developed
with DARPA funding at Southwest Research Institute (SwRI) for use in military vehicles. One APU
design was for the electric Ml 13 Troop Carrier. This vehicle is an electric conversion of the diesel-
powered production Ml 13. The conversion was completed in the 1960's. The installation of the
SwRI APU was an upgrade funded by the Defense Advanced Research Projects Agency (DARPA).
The other two APUs are for hybrid electric High Mobility Multipurpose Wheeled Vehicle
(HMMWV) projects.
1.1.1 Engine
At the start of the APU development project, only one APU was to be delivered. The APU was for
a HMMWV being converted to a hybrid by Pentastar Electronics Corporation. Pentastar's APU
requirement became the basis for the initial APU design. Later in the project the second APU
request, again for a HMMWV, required changes in the mechanical design. Requirements for the
third APU for the Ml 13 troop carrier were much different from the HMMWV, requiring a different
engine/generator layout and APU controller hardware and software.
All three APUs used the Volkswagen 1.9L, direct injected, turbocharged, intercooled, four-cylinder
engine. This is a modern-design diesel engine selected for its high efficiency, good power-to-weight
ratio, quiet operation, and ability to maintain power with altitude. The engine also produces low
emissions, although this was not a requirement for the current application. The engine was modified
with a dry sump lubrication system, which allowed it to be mounted in the vehicle on its side. The
lower height permitted the APU to be located between the battery pack and the hood of the
HMMWV. The dry sump system also insured proper engine lubrication over the vehicle's extreme
grade and slope operating range.
1.1.2 Generator
All three APUs used a Unique Mobility SR218H Brushless DC motor, normally used as a vehicle
drive motor. For this application, the motor was operated in the regenerative braking mode. The
motor controller effectively served as a boost rectifier to elevate the generator's output voltage to
deliver the requested power to the vehicle bus. The generator also served as the engine starter under
the SwRJ APU controller. The APUs did not require the stock 12-volt starter motor, which resulted
in a weight and space claim reduction.
1.1.3 Controller
The controller for the APUs is based on a personal computer (PC) CPU. Basing the controller on the
PC allowed flexibility in meeting the requirements of the different vehicles. For example, the Ml 13
controller used discrete digital and analog lines for communication with the Ml 13 vehicle controller.
The HMMWV APU employed RS232 serial data link to communicate a list of commands and status
information. Different software environments were also required to meet the vehicle's
communication requirements.
Given a power request from the vehicle controller, the APU controller set the engine speed for
optimum thermal efficiency. The generator power electronics adjusted the voltage and current output
from the generator to deliver the developed power to the vehicle's electrical bus.
2.0 TECHNICAL DISCUSSION
2.1 APU Design and Development
The developmental process of the APUs consisted of the following components: design discussions
with Pentastar and McKee about fitting the APU into the hybrid HMMWV; converting the engine
to the dry sump lubrication system; mating the engine to the generator; providing mounting points
for the engine and generator assembly; providing adequate heat exchangers to cool the engine and
generator; designing and constructing the APU controller hardware; adapting existing SwRI software
code for the APU controller; and testing of the APU in the laboratory. The details of the APU
development are described in this section. Figure 1 and 2 show the HMMWV APU and the Ml 13
APU, respectively. The engine was mounted in the normal orientation for the Ml 13 application.
2.1.1 Engine Selection
The APU specifications, as given by Pentastar, provided the criteria for the engine selection. The
requirement for diesel or JP-8 operation (55 kW electrical output, high power density, quiet and
efficient operation) led to the selection of a turbo-charged, direct injected, water cooled diesel
engine. Other prime mover types such as diesel rotary engines (RPI), fuel cells or gas turbines
(Alturdyne) were not available as off-the-shelf items. Development of these different prime mover
types was beyond the scope of this project.
Power Systems Research (PSR) conducted a survey of their database of available engines (provided
in the appendix). The survey did not include the new Volkswagen turbo-charged, intercooled, 1.9L
engine, which was not available at the time of the survey. The Volkswagen engine had the lightest
weight of any engine in the upper-60 kilowatts of power output. Also, the double fuel injection
scheme reduced the noise and improved the efficiency. The engine specifications are given in the
appendix.
2.1.2 Generator Selection
The following manufacturers of permanent magnet motors and generators were contacted with the
request for a 55 kW continuous output generator: Onan, Kaman, Fisher Electric Motor, Unique
Mobility (UQM), and Overland Technology. Onan and Kaman did not have a suitable unit. The
Fisher design would have involved the development of a boost rectifier. SuperPower was contacted
for an estimate to develop the boost rectifier. The total Fisher/Kaman system was heavier and more
costly than the UQM system (an off-the-shelf item) with some modifications. The UQM system
could also serve as the engine starter. A design from Overland Technology, which consisted of an
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order to stepwise vary the output voltage as required) was also considered. However, it would have
been necessary to develop the controller for switching the windings. The UQM Model 218H was
selected because it did not require a development effort for the power controller.
2.1.3 Generator to Engine Coupling
The generator-to-engine coupling design and fabrication was tasked to McKee Engineering.
Discussions with Pentastar and McKee concluded that the adapter plate at the engine generator
interface would also serve as the rear mounting points for the APU. Since the Pentastar HMMWV
was located at the McKee facility, the design of the APU mounting was conducted there.
The original coupling supplied by McKee utilized a hard nylon disc as the coupling material. The
coupling was a KTR-BoWex model FLE-48-T. During APU testing, a torsional resonance was
discovered at 2200 RPM. This resonance fatally overloaded the nylon sline teeth of the coupling.
Figure 3 is a photograph of the fractured nylon slines after an hour of operation. McKee redesigned
the coupling by replacing the nylon disc with an all-steel disc. SwRI performed a torsional analysis
of the new design that predicted the second order critical speed to be 4200 rpm, which was below
the 4000 rpm maximum operating speed of the engine. During testing, torsional vibrations were
apparent at 1400 rpm and 2100 rpm, which corresponded to the fourth and sixth order excitations
of the coupling system. However, it was decided that the vibrations were not severe enough to
prohibit further debugging of the APU controller. Debugging of the APU controller continued with
the hard steel disc, avoiding the resonant conditions, while SwRI redesigned the coupling.
The final coupling was a KTR BoWex design (model 48 HE with a Shore 50 elastomer) utilizing
a compliant elastomer. The coupling is shown in Figure 4. McKee originally considered using this
coupling with the suffer Shore 60 elastomer, but discarded the design because KTR predicted a
torsional vibration in the operating speed range. SwRI determined that by going to a more compliant
elastomer and raising the idle setpoint to 1000 rpm, the resonance would drop below the operation
range of the engine.
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2.1.4 Engine Dry Sump Lubrication System
During the initial design discussions with Pentastar and McKee it was decided to lay the engine on
its side, which involved lowering the height of the APU, allowing it to be mounted in the space
available in the HMMWV. Because the oil sump was no longer located at the lowest point, a dry
sump lubrication system was required. This change produced the following advantages: an increase
in the oil capacity of the engine; reduced engine friction losses; and the ability of the engine to meet
the wide range of operating angles of the HMMWV.
Using the assembled engine generator with cardboard mockups of the UQM drive motors, and later
the Kaman drive motor in the case of the CTC APU, McKee determined that the best location for
the scavenge pumps, which are belt driven, to be the front of the engine. The system is shown in
Figure 5. A toothed belt drives two Bertel pumps on the front of the engine. These pumps draw oil
from the lowest points on the engine and return it to an external reservoir. An oil-air separator is
located at the inlet of the reservoir, and the air is directed to the vent system. The stock engine oil
pump draws oil from this reservoir and pressurizes the oil galleries in the normal manner.
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Figure 5. Dry Sump Lubrication System
9
2.1.5 Engine and Generator Cooling
Three heat exchangers were required for the APU, with each mounted behind the other in front of
the engine, as illustrated in Figure 6. The first heat exchanger (from the front) was for the electronics
cooling loop. This was an aluminum radiator, the core dimensions being 3-1/2" thick x 13" high x
24" wide. The stock Volkswagen intercooler was mounted behind the electronics heat exchanger.
Behind the intercooler, an aluminum core radiator was mounted which measured 3-1/2" thick x 15"
high x 24" wide. A 50/50 water/antifreeze mixture was used in both liquid cooling loops. A pump
in the electronics loop recirculated the coolant at 5 gallons per minute. A shroud was constructed
around the three heat exchangers and the engine-driven cooling fan.
2.2 APU Control System Development
An APU control system was developed to provide control of the engine operating point. SwRI
designed and constructed a PC-based APU control system to accomplish this function. The SwRI
controller design was based on its Rapid Prototyping Electronic Control System (RPECS) platform.
The RPECS is a highly flexible, PC-based prototyping tool used for real-time control in a variety
of applications, such as engine and power-train control and test-cell control.
2.2.1 Control Functions
The SwRI APU controller was designed to provide numerous control functions as related to the APU
components. Fundamentally, the APU controller provided control of the APU operating point
through manipulation of the throttle and control of the generator output via the voltage boost unit.
The APU controller was also responsible for the engine start and stop functions.
10
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11
2.2.2 Controller Hardware Platform
As previously noted , the APU controller platform was based on an industrial PC. The controller
utilized a commercially available 486, 66-Mhz CPU card, with a 1.44 Mb solid state RAM disk
emulator as the primary memory device. The controller utilized commercially available data
acquisition and control cards, as well as a commercial watchdog timer board for protection. The
controller enclosure for the APU is shown in Figure 7. In order to provide the necessary signal
conditioning and driver circuitry for interfacing with the APU hardware, a custom interface
enclosure was designed and constructed by SwRI. Electrical power for the control system was
provided via a converter that stepped the vehicle bus voltage down to 12 Vdc.
2.2.3 Control Software/Algorithm Descriptions
The APU control software was written in C language and executed in the MS DOS environment. The
control software was written to utilize floating point arithmetic to allow modifications to be made
to the algorithms with minimum development time. The 486 processor adequately executed all
control equations in a time-based interrupt drier routine operating at 100 Hz. Because the system was
built around the existing SwRI RPECS platform, built-in functions such as real-time plotting and
data logging were easily integrated into the control system. The following is a detailed description
of the APU control algorithms.
The APU controller's most fundamental function was to control the power output of the APU. APU
power output was commanded from the vehicle controller.
Given the desired APU power output, the engine speed and throttle set point were computed via a
programmable engine operation trajectory. The engine trajectory was calibrated to maximize the
APU efficiency. Therefore, the engine operation trajectory programmed into the APU controller
entailed transitioning the engine to the wide open rack point at the lowest engine speed and running
at the maximum rack up to the maximum power point of the engine (4000 rpm).
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Having computed the desired engine speed and throttle position, the APU controller first provided
the necessary rpm signal to the engine ECU. In order to achieve the desired engine speed, the APU
controller utilized information from an engine-speed sensor for the feedback control. In order to
control engine speed, the APU controller modulated the load applied to the engine via the generator.
The generator control was provided through the UQM inverter and its throttle signal. The APU
control functions are shown in Figure 8.
In addition to the APU power output control function the controller also provided control of the
engine start and stop functions. The engine start function was accomplished by using the generator
as a motor.
In conjunction with the control functions and algorithms previously described, the APU controller
was also designed with a limited set of diagnostics. Out-of-range diagnostics for each of the sensors
used by the APU controller were implemented to detect and react to sensor failures. Furthermore,
system level diagnostics and protection were built into the APU controller to detect and prevent APU
operation that could damage the unit (engine protection). The diagnostic functions of the APU were
designed to prevent operation that could cause permanent damage to the unit, and to provide
valuable information for diagnosing problems.
2.3 APU Testing
Testing was performed at SwRI to verify the performance of the HMMWV APU prior to shipment.
The Ml 13 APU controller was tested with the HMMWV engine-generator since the Ml 13 engine-
generator was located at the McKee Engineering facility. The testing was broken down into two
specific areas: stand alone testing of the APU controllers, and integrated testing of the APU
controllers and the engine generator. The performance of the APU controllers was found to be
satisfactory during all testing. Testing of the integrated APU package revealed problems with
limited transient response of the APU and over-heating of the generator rotor with prolonged
operation at full power. The following paragraphs detail the APU controller testing.
14
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2.3.1 Ml 13 APU Controller Stand Alone Testing
For the stand-alone testing, the APU controller was not interfaced with any other control systems
or sensors that make up the APU system. Rather, the APU controller was isolated on the test bench
with power supplied from a 12-VDC source and the first-stage, DC-to-DC converter bypassed.
Signals from sources such as adjustable power supplies and function generators were used as input
to the APU controller. Output signals were measured via oscilloscope and multi-meter
instrumentation. The purpose of the APU controller stand-alone testing was to verify that all analog
and digital signal I/O was functioning properly. This included all wiring and signal conditioning
circuitry between the APU control computer (the appropriate analog to digital converter [ADC],
digital to analog converter [DAC], digital input and digital output) and the interface connector on
the exterior of the APU controller enclosure. A list of the APU controller I/O signals (by signal
type) is shown in Table 1.
All controller I/O was tested on the bench environment and performed as expected. As a result of
the bench testing, the controller was installed in the test laboratory for APU-integrated testing. The
complete wiring diagram for the Ml 13 and HMMWV APUs is given in the appendix.
Table 1. APU Controller Signal I/O
Analog Input Signals
ADC channel #: Description: From:
0 APU Power Request Vehicle Controller
1 Coolant Temperature APU Sensors
2 Oil Temperature APU Sensors
3 Oil Pressure APU Sensors
4 Bus Voltage UQM Control
5 Generator Current UQM Controller
6 Engine Speed APU Sensors
7 Barometric Pressure APU Sensors
16
Table 1. APU Controller Signal I/O
Analog Output Signals
DAC Channel #: Description: To:
0 ECU Pedal Command Engine Controller
1 UQM Brake command UQM Controller
2 Coolant Temperature Signal Vehicle Controller
3 Engine Speed Signal Vehicle Controller
4 APU Power Output Vehicle Controller
5 UQM Accel Command UQM Controller
Digital Input Signals
Dig In Bit #: Description: From:
0 APU On/Off Vehicle Controller
1 UQM Over Temp UQM Controller
Digital Output Signals
Dig Out Bit #: Description: To:
0 Engine On/Off Vehicle Controller
1 APU Fault Vehicle Controller
2 UQM Enable UQM Controller
3 UQM Direction UQM Controller
4 Idle Validation Engine Controller
5 UQM Over Temp Vehicle Controller
6 ECU On/Off APU Power Relay
2.3.2 CTC Engine-Generator/ Ml 13 APU Controller Integrated Testing
The CTC engine-generator was mounted to a wooden pallet using three jackstands at the mounting
points provided by the McKee interface plate between the engine and generator and a bracket on the
front of the engine. The stock VW intake air filter assembly, which also houses the mass air flow
sensor, was used.
17
2.3.2.1 Heat Exchangers
Volumetric air flow through the heat exchanger was determined using a hand-held anemometer to
measure the air velocity at six points at the face of the heat exchanger pack. The six velocity
measurements were averaged, and the heat exchanger core area was used to calculate the volumetric
air flow. Using ambient temperature and pressure, the mass air flow was also calculated.
As shown in Figure 6, a centrifugal pump powered by the 120 VAC mains was used to circulate the
coolant through the Unique Mobility inverter and the generator. The pump output was measured to
be five gallons per minute by disconnecting the discharge line from the generator and timing the
filling of a one-gallon container. The capacity of the electronics cooling loop was 4.2 gallons of
water/anti-freeze mixture. The coolant was routed from the heat exchanger to the pump inlet, to the
inverter then the generator, and returned to the heat exchanger. The heat exchanger header space
served as the reservoir. Thermocouples were installed at the coolant flow into the inverter, and at the
coolant discharge at the generator.
2.3.2.2 Power Absorption
The electrical output of the inverter was connected to a switchable resistive load bank and to the
battery pack through a manual breaker. The battery pack consisted of twenty-four 12-volt, group-31
modules of lead acid batteries. Overall, battery pack and power cable DC impedance was determined
to be 0.9 ohms using the Thevenin equivalent method.
2.3.2.3 Fuel Supply
The engine was operated on a low-sulfur, number 2 diesel fuel. The fuel was assigned the number
AL-24507F at the TACOM Fuel and Lubricants Research Facility where the gross heat of
combustion was determined to be 19,571 BTU/lb, and the net heat of combustion was found to be
18,377 BTU/lb. Fuel flow rate to the engine was measured gravimetrically using a one-gallon
container on an electronic digital scale, and timed using a stopwatch.
18
2.3.2.4 Power Measurement
Direct current electric power output from the inverter was calculated from averaged current and
voltage measurements. The current was measured using a DC clamp-on-type current probe. The
voltage was measured with a digital voltmeter. Prior to these measurements the inverter output was
examined using an oscilloscope and found to be free of any large voltage variations. There were
voltage noise spikes of 30 volts and a few microsecond duration superimposed on the nominal 280
volt base DC voltage, which occurred at the inverter frequency of approximately 20 khz. The
absence of periodic voltage variations of significant duration permitted accurate power
measurements using the average values of voltage and current.
2.3.2.5 Vehicle Control
Since a vehicle controller was not part of the test setup, a potentiometer was installed to provide a
0-to-5v analog signal input to simulate the APU power request signal from the vehicle controller.
Similarly, a toggle switch was also installed to simulate the APU on/off signal from the vehicle
controller. The APU system was tested over a variety of operating conditions with various electrical
load settings on the load bank. Details of the final testing are contained in the following paragraphs.
2.3.2.6 HMMWV Controller/Ml 13 APU Start/Stop Testing
The APUs ability to respond to a normal start/stop command, as well as a mission disabling failure
condition was tested. In order to test the normal start/stop sequencing, the APU on/off switch was
toggled on, allowing the APU to start. Then, the switch was toggled off, stopping the APU.
Similarly, a loss of the APU start/stop signal was simulated by disconnecting the APU on/off switch
input to the APU controller. The APU, as expected, shut down immediately during this simulated
failure. The system was also tested for an open circuited APU power request signal. Removing the
APU power request signal connection to the APU controller simulated the failure. As expected, the
APU changed from its initial operating condition to an idle condition. Multiple conditions were
designed to shut down the APU to prevent damage. These engine protection faults included oil
19
pressure low/high, oil temperature high, coolant temperature high, and APU overspeed. APU
controller response to these fault conditions were also tested during the course of the APU
development effort.
2.3.2.7 HMMWV Controller/Ml 13 APU Steady-State Testing
APU steady-state performance tests were designed to verify acceptable system performance at
various power levels. Acceptable system performance was defined as stable operation at the desired
power level, resulting in no-fault conditions. During the test, data was collected at discrete APU
output power steps of 10, 25, 35,45 and 55 kW. A tabulation of the data and calculated results is
provided in the appendix. Figure 9 is plot of the APU efficiency versus the electrical power out.
Efficiency was calculated as the electrical power out over the fuel energy in (lower or net heating
value). The peak efficiency of 33.2 percent was observed at 25 kW, dropping to 30.7 percent at 55
kW. Figure 10 shows the efficiency of the generator/inverter only (based on the heat rejection to the
coolant) versus the electrical power out.
APU performance was found to be acceptable at all operating conditions except 55 kW. After
prolonged operation (greater than five minutes) at the 55kW point, the Unique Mobility controller
set a fault indicating excessively high rotor temperatures on the UQM generator. Under the fault
condition, the APU power output was reduced and the APU control system transitioned into an
overspeed protection mode, which dithered the ECU pedal command in order to prevent engine
overspeed. This condition remained until the rotor temperatures decreased below the fault threshold,
where normal operation was again restored.
20
10 15 20 25 30 35 40 45 50 55 Electric Power Out (kW)
Figure 9 APU Efficiency vs. Electrical Power Out
92.5
91.5-
I 90.5-r
is I 89.5-r c CD (3
88.54
87.5 10 15 20 25 30 35 40
Electric Power Out (kW) 45 50 55
Figure 10. Generator Efficiency vs. Electrical Power Out
21
2.3.2.8 HMMWV Controller/Ml 13 APU Transient Testing
APU performance data was gathered during power command transient conditions. The following
data are shown for four different transient conditions:
1. Power ramp up/ramp down from 0 kW to 55 kW to 0 kW over 60 seconds (Figures
11aand lib)
2. Power command step response from 0 kW to 30 kW to 0 kW over 30 seconds
(Figures 12a and 12b)
3. Power command step response from 27.5 kW to 55 kW to 27.5 kW over 30 seconds
(Figures 13a and 13b)
4. Power command step response from 0 kW to 55 kW to 0 kW over 30 seconds
(Figures 14a and 14b)
The "a" figures show the desired and measured APU power output and the DC bus voltage. The "b"
figures show the desired and measured engine speed, and the UQM brake command signal. It should
be noted that the desired APU power (labeled PwrCmd in the legend) is the command signal after
passing through the software rate limiter. Thus, even in a step response scenario, the maximum rate
of change of this signal is 6 kW/sec. As shown in the figures, adequate APU control performance
was obtained. Small overshoots in measured power of brief time duration (five seconds or less) were
observed during the step response tests. The responses were found to be adequately dampened on
achieving the desired output power level. As a result of the transient testing, it was determined that
the power command rate limiter within the APU controller must be set at 6 kW/sec in order to
achieve the responses shown in the figures. Rate limit values of more than 6 kW/sec produced
uncontrollable results on the 0-to-55 kW step response. Analysis of the results showed that the
UQM brake command signal from the APU controller (to the UQM controller) was reaching its
upper limit of 4.5V. This indicated that the UQM controller was applying the maximum torque to
the engine via the generator. Subsequent tests revealed that by lowering the APU power command
rate limiter to 6 kW/sec, adequate control could be maintained without saturation of the brake
command signal.
22
20 30 40 Time (Sec)
PwrCmd MsdPwr VBatt ]
5000
Figurella. Power Ramp Up/Down (Power and Bus Voltage)
30 Time (Sec)
40 50
-1.5
£ 5 -o c
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RPMCmd RPM BrakeCmd
Figure lib. Power Ramp Up/Down (Engine Speed & U.M. Brake Command)
23
10 15 20 Time (Sec)
25
400
360
-320
280
240
-200
CO
£0
30 160
PwrCmd MsdPwr VBatt 3 Figure 12a. APU Power Transient Response (Power and Bus Voltage)
5000
Time (Sec)
RPMCmd RPM BrakeCmd
£ C CÜ E E o Ü
2? CO
Figure 12b. APU Power Transient Response (Engine Speed & U.M. Brake Command)
24
10 15 20 Time (Sec)
25 30
PwrCmd MsdPwr VBatt ] Figure 13 a. APU Power Transient Response (Power and Bus Voltage)
5000
15 20 Time (Sec)
£ T3 C CO E E o ü
CO
RPMCmd RPM BrakeCmd
Figure 13b. APU Power Transient Response (Engine Speed and U.M. Brake Command)
25
QU-
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280 CD
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Figure 14a. APU Power Transient Response (Power and Bus Voltage)
5000
4500 H
10 15 20 Time (See)
25
c CO E E o ü
CD
30
RPMCmd RPM BrakeCmd 1 Figure 14b. APU Power Transient Response (Engine Speed and U.M. Brake Command)
26
2.3.3 Testing of the HMMWV Engine Generator/HMMWV APU Controller
Performance tests on the APU were conducted at SwRI prior to shipment. Testing was broken into
two phases: 1) verifying proper functionality of the individual hardware components, and 2)
verifying the integrated controller/engine/generator package. The performance of the APU controller
was found to be satisfactory during all phases of testing.
2.3.3.1 Stand-Alone HMMWV Controller Testing
Stand-alone testing was conducted to verify proper functionality of the PC hardware, analog and
digital I/O circuitry, and serial interface. I/O circuitry includes all wiring and signal conditioning
circuits between the APU computer and the interface connector on the exterior of the APU controller
enclosure. The APU controller was not interfaced with any of the other controller systems or sensors
that make up the APU package during this testing. Instead, the APU controller was isolated on a test
bench and powered by a 12-volt DC source. The first stage of the DC-to-DC converter was also
bypassed. A mock-up KEC Battery Regulator-to-APU Controller link was established via a laptop
computer and a standard RS-232 serial interface. The mock-up provided a means of verifying
message parsing correctness and controller logic.
Signals from adjustable power supplies and function generators were used as APU controller inputs.
APU controller outputs were measured with an oscilloscope and multi-meter. All I/O was tested
on the bench and performed as designed. The mock-up serial tests were conducted by simulating link
between the battery regulator and the SwRI APU controller. A list of the APU controller I/O signals
by signal type is provided in Table 2.
27
TABLE 2. APU Controller I/O Signals
Signal Type Channel Description From/To
Analog Input 0.00 Engine Coolant Temperature APU Sensor
1 Engine Oil Temperature APU Sensor
2 Engine Oil Pressure APU Sensor
3 Bus Voltage UQM Controller
4 Generator Current UQM Controller
5 Engine Speed APU Sensor
6 Barometric Pressure APU Sensor
Analog Output 0.00 ECU Pedal Command Engine Controller
1 UQM Brake Command UQM Controller
Digital In Bit 0.00 APU Silent Override Vehicle Controller
1 UQM Over Temperature UQM Controller
2 APU Kick Down Power Override Vehicle Controller
Digital Out Bit 2 UQM Enable UQM Controller
3 UQM Direction UQM Controller
4 Idle Validation Engine Controller
6 ECU On/Off APU Power Relay
PWM Output 2 UQM Accelerator Command UQM Controller
A program was written in QBasic for the mock-up serial link tests. The QBasic program utilized
a 13-byte message and the protocol specification listed in Table 3. The first two bytes (not listed
in Table 3) functioned as sync bytes to notify the APU controller that the succeeding 11 bytes
comprised a message following the format listed in Table 3. A value of 77 hex was given to the two
sync bytes for this version of the program and will be updated to a new value in each subsequent
version of the APU controller software. The APU power request is a 16-bit word and was therefore
broken into two bytes, the first byte indicating the most significant byte. The checksum, byte 9, was
calculated as an 8-bit unsigned summation of bytes 0 to 8, and overflow was ignored.
28
TABLE 3. SERIAL LINK PROTOCOL SPECIFICATION
BYTE DESCRIPTION MESSAGE SIZE UNIT/LSB LIMIT/RANGE
0.00 Message Header 1 Byte - 01 hex
1 Sequence Number 1 Byte - 0-255
2,3 APU Power Request:
Broken into 2 bytes; most significant
byte in byte #2
2 Bytes 10 Watts 0-120kW
4 APU Enable:
Bit 0 Enables if True.
Bits 1-7 are Spares.
1 Byte Off (False) = 0
On (True) = 1
5, 6, 7, 8 Spare 1 Byte - 0.00
9 Checksum 1 Byte - 0-255
10 End of Message 1 Byte - 03 hex
The QBasic program was installed on the laptop and simulated requests to enable the APU and
power requests. The power requests were incrementally increased/decreased and observed to change
as requested. All other bytes were visually monitored at each end of the serial link on either the
laptop or a monitor coupled to the APU controller and were correct. Serial link outputs from the
APU controller were analyzed with another program and computer that displayed the entire message
output from the APU controller. The message structure, message values, and sequence of the
messages were correct. As a result of the successful bench tests, the SwRI APU controller was
installed in the test laboratory and electronically integrated into the engine/generator package. The
KEC Battery Regulator simulation program and laptop were also coupled to the APU. The return
messages from the APU controller were not displayed.
2.3.3.2 HMMWV APU Start/Stop Testing
The APUs ability to respond to commands via the mock-up KEC Battery Regulator-to-APU
Controller link, as well as mission disabling conditions, was tested. The engine started appropriately
and quickly when the Enable APU byte of the simulator program was changed from 0 to 1 (byte #4)
via the laptop keyboard. The engine stopped when instructed to do so when the Enable APU byte
29
was changed from 1 to 0. Also, the engine stopped when the silent mode override was true (5 volts)
even though the APU was receiving Enable APU and power requests via the serial link.
Simply disconnecting the RS-232 cable between the APU controller and the laptop computer
simulated loss of communication between the KEC Battery Regulator-to-APU Controller mock-up.
If communication was not re-established after one second, a serial link fault was set and the engine
shut down. Other fault conditions, called engine protect faults, can also shut down the engine to
prevent damage. The engine protect faults included oil pressure high/low, oil temperature high,
engine coolant temperature high, and engine overspeed. APU controller response to these fault
conditions was also tested during the APU development effort.
2.4 APU Testing Conclusions
Based on these results, it was concluded that the APU and the APU controllers were functioning as
intended with the exception of the limited operating time at full power. The manufacturer of the
generator proposed that software changes to the inverter could be made to remedy this problem and
that the testing of these changes will be made at their test facility.
3.0 SUMMARY
Three different configurations of a state-of-the-art APU for hybrid electric vehicles were developed.
The APU utilized the following: the Volkswagen 1.91, direct injected, turbo-charged, intercooled,
electronically controlled, injected diesel engine; the UQM model 218H drive motor as a generator;
and an APU controller developed at SwRI. The APU develops 55 kW of DC output at 30.7 percent
between 130 and 380 volts for charging the vehicle power pack. The peak efficiency of 33.2 percent
(occurring at 25kW) is believed to be unprecedented.
A prototype APU control system was developed by SwRI for the control of the APU power output.
The prototype controller was designed around a personal computer platform for maximum flexibility
in control algorithm development, control system calibration, and sensor and actuator flexibility.
30
APPENDIX A Power System Research Engine Survey
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APPENDIX B Volkswagen 1.9L Engine Specifications
B-l
Specifications for Volkswagen Industrial Engine AFD 1.9 Itr. TDI-Diesel Engine
VOLKSWAGEN AG, WOLFSBORG
The Voikswagen AG reserves ,he „gh, to introduce modifications or improvements at any time
Th,s does no, emaii any obiigation to e.lec, such changes subsequently on engines aiready delivered.
Volksvagen Industrial Engines AFD
GOVERNED CONTROL UNIT 1000 to 4000 rpm 07.94
ft "3
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Volkswagen Industrial Engines AFD Technical dat
07.94
INTRODUCTION
r«nllHlkfWagen1In^UStrial En*ine vith the engine code AFD is a 1 9 ^r ,
Design: Direct valve operation via an overhead camshaft <mr\ HIHM U
nically regulated by control unit °thed beit and electro-
Diplacement Bore / stroke Compression ratio Firing order
Output with control unit (automotive version - Golf A3)
Nmax at 4000 rpm upper idling speed lower idling speed
cm3 1896 mm 79,5 / 95,5
19,5
1-3-4-2
Charging pressure
Installation angle
Distributor injection pump Control unit
Fuel
Cetan requirement as per
Fuel consumption
Alternator 12 V
Starter 12 V
Battery 12 V
Glow plugs
kV rpm rpm
bar (atmos)
¥:
66 (89/491/EVG) 5000...5200 (not adjustable) 860...940 (not adjustable)
0,60 - 0,80
20
' Manufacturer Manufacturer
Bosch Bosch
CN DIN
Diesel > 45 51601
g/ktf h see Page 2
A 90
kW 1,8
A (Ah) 380 (63) minimum capacity
V 12
Volksvagen Industrial Engines AFD
Instructions 07.94
FILLING CAPACITIES
Cooling system
For first filling, pour in coolant slowly up to Max.- marking vhile continuosly bleeding cooling system of air. Allow engine to warm up until thermostat is fully open. Switch off engine and allow to cool down before checking and correcting coolant level.
IMPORTANT ! Do not open radiator cap vhile engine is hot, as coolant system is pressurised. - DANGER OF SCALDING -
ltr. approx. 5-6 (depending on cooling system)
Oil circuit with filter change
Difference between Hin.- und Max.-marking on dipstick
ltr.
ltr.
4,5
approx. 1,0
TEMPERATURES
Coolant permissible temperature 'C (°F) 105 (221) continuous operation
'C (°F) 118 (244) absolute limit
Thermostat fully open starts opening at
»C (°F) 102 (216) 'C (°F) 87 (189)
Temperature contact switch switches on at C (°F) 110 ± 3 (230 ± 5)
Engine oil permissible max. temoerature »c er\ nn of,&\ in nil
B-M - Battery earth / engine earth L-M - EDC earth S-M - Sender earth
A - Battery B - Starter C - Alternator D - Starter switch G 28 - Engine speed sender G 80 - Needle lift sender K 2 - Alternator warning lamp Ki 2. ' SIS1"6 ■""?geTt Systeo and 8lov Period warning larap J 248 - EDC control unit y
Volksvagen Industrial Engines APD
Noise Capacity 10
07.94
Noise Capacity Level
120
1000 2000 3000
engine speed rpm 4000 5000
Full-load operation
Tracting operation
Volksvagen Industrial Engines AID
Viring diagr
KL1S KL30 KL15 KL15 I. JL
K3 IK28 00
P 14 F 22 G 70 G 149 N 18 M 75 N 108 N 109 J 52 J 317 K 3 E 28 S 39 Q 6
Coolant temperature control switch (110 °C) Oil pressure switch (0,25 bar) Air mass meter Control plunger travel sender Exhaust gas «circulation valve Boost pressure control solenoid valve Start of injection valve Fuel cut-off valve Glow plug relay Relay for voltage supply Oil pressure warning lamp Coolant temperature warning lamp Strip fuse (50 A) Glow plug
Volkswagen Industrial Engines AED
Exhaust gas back pressure 14
10.94
250
200 -•
M
■
3 (A «A « M
o 43
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150 H
100-
800 1200 1600 2000 2400 2800 3200 3600 4000 4400
engine speed rpm
engine speed rpm 1000 i
1200 | 1400 1600 1800 2000
1 I 2200 | 2400 2600 2800 3000 3200 3400 3600 3800 4000
temperature °C 501 484 483 469 471 479 493
511 535 542 560 575 576 582 608 627
Volksvagen Industrial Engines AFD
Air volumetric flov 16
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400
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engine speed rpm
engine speed rpm 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 volumetric (low kg/h 58.7 75 102 138 170 200 218 234 252 271 281 293 310 323 336 352
APPENDIX C Steady-State Test Results
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APPENDIX D Complete APU Wiring Diagrams for the M113 APU
D-l
SOUTHWEST RESEARCH INSTITUTE 622OCULEB*AHOAO . POSTO,RCEOR*WE«2.5,0 . SAN ANTON,0 TEXAS. USA 78228.05,0 . ,2,0,68<-5tn . TELEX 2<^e
ENGINE. FUEL. AND VEHICLE RESEARCH DIVISION
TELECOPIER: (210) SJ2-S720
March 17, 1997
Mr. Gordon Shafer United Defense LP Ground Systems Division P.O. Box 58123 Santa Clara. CA 95052-8123
Dear Mr. Shafer,
I am enclosing the documentation related to the HMMWV APU that SwRI recently sent you. It should include a number of wiring descriptions and wiring diagrams as described below:
1. UDC APU Controller External Wiring Description - These two paaes describe the signab and corresponding pin numbers associated to each of the five connectors on the SwRI-supplied APU Interface box.
2. UDC APU Controller External Wiring Description Diagram - In addition to the information described above, this diagram also illustrates the SwRI harnesses supplied with the APU. Please note that SwRI is NOT supplying the harnesses for connectors #1 and #2 as agreed earlier in the program. Also note that connector #3 connects to the Engine Harness via connector F2 and C2 described on a separate diagram.
3. Modified VW 1.9L Engine Harness Diagram - This diaeram illustrates the modifications that were made to the original stock VW engine harness #3Al-971-072 CD. Several connectors not used by the system were eliminated or hard-wired for clarity. Please note that connectors labeled B2 and D2 were shorted out (the connectors were actually removed). Also note that the ECU interface harness and relays connected to connector #3 of the APU Controller box were included in this diasram to illustrate the proper connection in case the relays or weather pack connector became separated dunne shipping. Connector Q2 should remain disconnected during normal operation It is intended to be used with a special VW engine diagnostic box during troubleshooting.
\. VW E07 68-Pin Connector Diagram - This is a VW-supplied diaeram that illustrates each of the pins being used. It is supplied as a reference only since not all of the sensors shown are connected to this connector. Please note that this diagram does not show the three adduional resistors attached to pins #10. #27, #33. #45. and #56 as shown in the Modified VW 1.9L Engine Harness Diagram."
SAN ANTONIO. TEXAS
HOUSTON. TEXAS • OETROIT. MICHIGAN • WASHINGTON OC
Mr. Gordon Shafer United Defense LP March 17, 1997 Page 2
VW 1.9LTDI Engine Harness Sketch - This sketch is supplied for future reference It provides a pictorial view of the physical location of the stock, VW-engine harness connectors before modifications were made to them. Note that the connectors are basically bundled into the sections: Section 1 (labeled from A to J), Section 2 (A to S) and Section 3 (A to E).
VW1.9L Engine Harness Diagram - This is a diagram of the original, stock VW engine harness before any modifications were made to it. It provides additional information not included in the sketch of the harness such as number of wires attached to each connector wire color codes, etc. Note that the numbering system list on the right side of the diagram (and half-way down the diagram) shows the sensors attached to the engine A separate sheet is provided that shows the same information more clearly. Please note that all the sensors are not being used as it was pointed out earlier.
VW and SwRI Numbering System List - This page duplicates the information provided in the diagrams described above (items #3 and #6). It more clearly shows the sensors illustrated in the previous diagrams.
6.
7.
ntm U^ulhave any questions regarding these diagrams, please do not hesitate to call me at
^twSK^"* " mCSSage 0steiber@SWn-or^ For vour convenience, my fax
Sincerely,
Joe Steiber Research Engineer Advanced Vehicle Technology
/krp
Enclosures
Page l of 2
UDC APU Controller External Wiring Description
Rev 0 - March 6, 1997
Connector #1 - Bus Power Interface
Pin R Desc.
Engine Ground f. VBus - U VBus +
Connector #2 - Vehicle Control Interface
fin Desc. APU Power Reguest + APU Power Reguest - Coolant Temperature 4 Coolant Temperature - Engine Speed + Engine Speed - Actual APU Power + Actual APU Power - APU On/Off + APU On/Off - Engine On/Off +
., Engine On/Off - " APU Fault + £J APU Fault -
18
1 2 3 4 5 6 7 8 9 10 11 12
Unigue Mobility Over Temp Unigue Mobility Over Temp
Connector #3 - Engine Control Interface Pin Desc. £ ECU Continuous Power J- ECU Switched Power " Idle Validation + 1 Pedal Command + 2 Idle Validation -
Pedal Command -
Page 2 of 2
Connector #4 - Unique Mobility Interface
Pin Desc. * VBus Signal ~ +12V :} IGen Signal !:, U.M. Over Temp + 7Z Brake Signal rf Accelerator Signal ±Z U.M. Enable ,„ U.M. Direction 30 U.M. Gnd
Connector #5 - APU Sensor Interface
Pin Desc. 1 Coolant Temperature
* Oil Temperature - jj Oil Pressure + * Oil Fressure - I Engine Speed + 8 Engine Speed - 9 +5V 10 Gnd ^2 Barometric Pressure
Barometric Pressure
* Coolant Temperature 3 Oil Temperature +
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APPENDIX E Complete Wiring Diagrams for the HMMWV APU
E-l
SOUTHWEST RESEARCH INSTITUTE 6220CL-LEBRAHOAO . POS' O.^CE DRAWER 385,0 . SAN ANTON.O. TEXAS. USA 78K.-0SI0 . ,2,0,684-5,:, . TELEX 244846
March 17. 1997
ENGINE. FUEL. ANO VEHICLE RESEARCH DIVISION
TELECOPIER: (210) S22-5720
1.
Ms. Kathy Bearden MARCAV Program Manager Concurrent Technologies Corporation 1450 Scalp Avenue Johnstown, PA 15902-3450
Dear Ms. Bearden,
I am enclosing the documentation related to the HMMWV APU that SwRI recently sent you. It should include a number of wiring descriptions and wiring diagrams as described below:
C7C APU Controller External Wiring Description - These two pages describe the signals and corresponding pin numbers associated to each of the five connectors on the SwRI-supplied APU Interface box.
CTC APU Controller External Wiring Description Diagram - In addition to the information described above, this diagram also illustrates the SwRI harnesses supplied with the APU. Please note that SwRI is NOT supplying the harnesses for connectors #1 and #2 as agreed earlier in the program. Also note that connector #3 connects to the Engine Harness via connector F2 and C2 described on a separate diagram.
Modified VW 1.9L Engine Harness Diagram - This diagram illustrates the modifications that were made to the original stock VW engine harness #3 Al -971-072 CD. Several connectors not used by the system were eliminated or hard-wired for clarity. Please note that connectors labeled B2 and D2 were shorted out (the connectors were actually removed). Also note that the ECU interface harness and relays connected to connector #3 of the APU Controller box were included in this diagram to illustrate the proper connecuon in case the relays or weather pack connector became separated during shipping. Connector Q2 should remain disconnected during normal operation It is intended to be used with a special VW engine diagnostic box during troubleshooting.
VW ECU 68-Pin Connector Diagram - This is a VW-supplied diagram that ülustrates each of the pins bemg used. It is supplied as a reference only since not all of the sensors shown are connected to this connector. Please note that this diagram does not show the
Sw^101*1 reSmorS attached t0 P™ #10' #27' #33- a45» ™* #56 as shown in the Modified VW 1.9L Engine Harness Diagram."
SAN ANTONIO, TEXAS
-OUSTON. TEXAS • 0ET30IT MICHIGAN • WASHINGTON. DC
Ms. Kathy Bearden Concurrent Technologies Corporation March 17, 1997 Page 2
5.
6.
7.
VWL9LTDI Engine Harness Sketch - This sketch is supplied for future reference It provides a pictorial view of the physical location of the stock, VW-engine harness connectors before modifications were made to them. Note that the connectors are basically bundled into the sections: Section 1 (labeled from A to J), Section 2 (A to S) and Section 3 (A to E).
VWL9L Engine Harness Diagram - This is a diagram of the orieinal, stock VW engine harness before any modifications were made to it. It provides additional information not included in the sketch of the harness such as number of wires attached to each connector wire color codes, etc. Note that the numbering system list on the right side of the dmgram (and half-way down the diagram) shows the sensors attached to the engine A separate sheet is provided that shows the same information more clearly. Please note that all the sensors are not being used as it was pointed out earlier.
VW and SwRI Numbering System List - This page duplicates the information provided in the diagrams described above (items #3 and #6). It more clearly shows the sensors illustrated in the previous diagrams.
nim <^y°",!re mquestions ^ding these diagrams, please do not hesitate to call me at
nuLber is (210) 522^"* * "^ Qs^bet&swLo^ For ^ convenience, my fax
Sincerely,
Joe Steiber Research Engineer Advanced Vehicle Technology
/krp
Enclosures
Page 1 of 2
CTC APU Controller External Wiring Description
Rev o - March 6, 1997
Main APU Control Enclosure Connectors:
Connector #1 - Bus Power Interface
lln Desc. s Gnd U
+5V v +12V (High Current) v xctr ' W ~ "
+12V (Low Current) V -12V * Gnd
Connector /2 - Vehicle Control Interface
Pin Desc.
Silent Run Mode +
6 Serial Port Rx
3 Pedal Kick Down Return
5 Serial Port Tx
4 Pedal Kick Down +
Silent Run Mode Return
7 ;
Serial Port Gnd
Connector #3 - Engine Control Interface
*in Desc. A C ECU Switched Power
ECU Continuous Power
£ Idle Validation"+" Pedal Command +
JJ Idle Validation - Pedal Command -
Page 2 of 2
Connector #4 - Unique Mobility Interface
Pin Desc. 1 VBus Signal 2 +12V 3 8 12 1 c
IGen Signal U.M. Over Temp + Brake Signal
15 18
Accelerator Signal U.M. Enable
20 U.M. Direction 30 U.M. Gnd
Connector #5 - APU Sensor Interface
Pin Desc. 1 2 3 4 5
Coolant Temperature + Coolant Temperature - Oil Temperature + Oil Temperature - Oil Pressure +
6 Oil Pressure - 7 8
Engine Speed + Engine Speed -
9 +5V 11 Barometric Pressure + 12 Barometric Pressure -
Power Converter Enclosure Connectors
"IN" Connector
Pin Desc. 3 VBUS - 8 VBus +
"OUT" Connector
Pin Desc. R S Engine Ground (from Engine)
Gnd U V
-KL2V (High Current) +5V w
X +12V (Low Current) -12V
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CItSUNI
•12 V CWiOM CUMCNT)
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Y I 0WJN3
CDNNECTDR ttl BUS POWER INTERFACE
( Harness not supplied by SwRI )
1 S:„ENT urn MOK ICTUIIN
2 SILENT HUM NODE •
3 PE3BM. K10O0WN RETURN
4 res«. WC<DOWN -
5 SEM«L P3*T T«
6 »Em«. p=tT ««
7 SCHIM. re*T GNB
CDNNECTDR #2 VEHICLE CDNTRDL INTERFACE
( Harness not supplied by SwRI )
CDNNECTDR #3
ECU rTNTINUOUS POWE» • CtCVKR)
ECU SWITCHES «WE» ♦ (ICVSCT)
ran. erwwn ♦ CM«-»/II>
ISLE v«L!B»TTON ♦ (PC TIO-IO/47)
PED*L COWMWD - <D»S IM8/W)
ENGINE CDNTRDL INTERFACE HARNESS
To Fuel Punp Relay ( Relay 103 - Pin #30 >
VV 357-911-253
D
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V
Weather Pack Connector
To the ECU Switched Power Connector of
VW Engine Harness ( Connector «■<#? )
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XLER EXTERNAL WIRING DESCRIPTION
CDNNECTDR *4 UNIQUE MOBILITY INTERFACE
ER INTERFACE
by SwRI )
CDNTRDL INTERFACE
i by SwRI )
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FUELS DISTRIBUTION LIST
Department of Defense
DEFENSE TECH INFO CTR ATTN: DTICOCC 8725 JOHN J KINGMAN RD STE 0944 FTBELVOIRVA 22060-6218
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TFLRF No. 328 Page 1 of5
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AMSTETCD AMSTE EQ
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TFLRF No. 328 Page 2 of5
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TFLRF No. 328 Page 3 of5
Department of the Navy
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TFLRFNo.328 Page 4 of5
Department of the Air Force
HQ USAF/LGSF ATTN: FUELS POLICY 1030 AIR FORCE PENTAGON WASHINGTON DC 20330-1030
HQ USAF/LGTV ATTN: VEH EQUIP/FACILITY 1030 AIR FORCE PENTAGON WASHINGTON DC 20330-1030
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TFLRF No. 328 Page 5 of 5