hoosier heavy hybrid center of excellence...

HOOSIER HEAVY HYBRIDCenter of Excellence (H3CoE) at

Purdue UniversityPI: Greg Shaver

Purdue UniversityJune 10th, 2015

Project ID #TI023

This presentation does not contain any proprietary, confidential, or otherwise restricted information

• Start – Oct 2011• Finish – Sept 2016 • Barriers addressed

– Lack of trained engineers and scientists: not enough trained in key areas of advanced energy efficiency vehicle technologies

– Lack of advanced technology curricula: curricula specific to advanced vehicle technologies not available at a sufficient number of universities.

• >$2,000,000 total– $1,000,000 from DOE– >$1,000,000 from Purdue, Industry Partners

• DOE funding to date– $1M received– $424K spent (travel + fellowship stipends)

• Purdue costshare– Tuition and stipend overhead

• Cummins funding to date– $515,000

Timeline

Budget

Barriers

• Purdue – lead• Industry – to date

Partners

Overview

Relevance - Objective

Establish a GATE Center of Excellence that provides multidisciplinary

engineering training for graduate students in advanced automotive

technology to overcome technology barriers preventing the development

and production of cost-effective vehicles for the US market.

Relevance - Motivation

• 21M barrels/day oil usage in U.S.• 7.6M barrels/day in China, but 9% annual growth

– Bus market: 11% annual growth rate– Heavy truck: 32% annual growth rate

• Heavy vehicle (average)– 6.2mpg (vs. 21 for auto/light truck)– 74,000 miles/year (vs. 11,000 for auto/light truck)– 12,000 gallons/year (vs. 570 for auto/light truck)

• Growth in fuel use tied to heavy vehicles…also target for reduction

Fuel consumption reduction possibilities for medium/heavy vehicle

Relevance - Motivation

Challenges:• Large braking energy rates• Engine stop/start (large start torque; aftertreatment management)• Packaging constraints• Sub-systems not optimized for hybrids use• Large diversity of vehicle sizes & duty cycles

Deployment Strategy• Provide H3CoE Research Fellowships & industry-

driven/funded projects to address challenges and unique opportunities for medium/heavy-duty hybrid vehicles– 14 current Fellowships students, from 5 Schools of Engr.– Biggest challenge: industry co-support of projects, resulting

in drop of requirement for this to award fellowships (still a preferred outcome)

• Deploy/enhance course content, and provide a Hybrid Vehicle Systems Certificate (HVSC).– New HEV course, offered in Fall ’12, ’13 & ‘14– Certificate program final approval in Fall 2012 (1st

interdisciplinary certificate at Purdue!)

Deployment Strategy• Partner with regional industry partners that manufacture

medium/heavy-duty hybrid vehicle components.– Strong partnership with Cummins

• Co-funding of two projects:– Enabling Plug-In Capability and Engine Optimization for a Heavy-Duty Hybrid

Vehicle System via Advanced Power Electronics ($158K)– Model-Based Heavy Hybrid Vehicle Design Optimization and Control ($25K)– Design and Control of Advanced Hybrid Powertrain Systems for Heavy Vehicles

($332K)

• $1M in support of “Cummins Power Lab” in new Purdue facility

– Converging on 3 co-funded projects with John Deere– Others developing more slowly

• Use the web to provide information, including fellowship and certificate program details, and research projects.– Website launched in Spring ‘13, used to advertise program

to current/future/pending students

• Final approval in Fall ’12

• 1st Interdisciplinary certificate program at Purdue!

• Students required to:– take 1 class in each area– attend one poster

show/workshop• Status

– 20 currently in program– 12 have completed program

Progress – Certificate Program

Fellow Professor Academic Area Project Title

Scott JohnsonRay Decarlo, Steve

PekarekElec. and Comp. Engr.

Switched System Observer for Fault Detection in Permanent Magnet Synchronous Machines

Aniruddha Jana Edwin Garcia Material Science Engr. Advanced Separators for Lithium-Ion Batteries

Rohinish Gupta Peter Meckl Mech. Engr.Evaluating Power Management Strategies for Parallel Through the Road

Diesel Hybrid Architecture

Xiaohui Liu Joe Pekny Chemical Engr.An Integrated Transportation, Electricity, and Drive Train Model for

Analyzing the Performance of Hybrid Vehicles

Michael Sprengel Monika Ivantysynova Ag. and Bio. Engr. Advanced high efficiency hydraulic power train architectures and controls

Paul Kalbfleisch Monika Ivantysynova Ag. and Bio. Engr.Investigation of Noise Reduction of Pumps and Motors Through

Computational Design Optimization

Dan Horvath Steve Pekarek Elec. and Comp. Engr. MEC-Based Design Optimization of Claw-Pole Alternator

Ruiyang Lin Scott Sudhoff Elec. and Comp. Engr. Asymmetric Salient PMSMs for Traction Applications

Sashankh Ravi Dionysios Aliprantis Elec. and Comp. Engr. Optimal Design of Asymmetric SR Motor Drives for Heavy Hybrids

Jagdish Hiremath Peter Meckl Mech. Engr. Development of a Urea Dosing Strategy for Diesel Hybrids

Ashish VoraGreg Shaver, Oleg

WasnyczukMech. Engr. Design and Control of Adv. Hybrid Powertrain Systems for Heavy Vehicles

Xing JinGreg Shaver, Oleg

WasnyczukMech. Engr. Design and Control of Adv. Hybrid Powertrain Systems for Heavy Vehicles

Jialiang Tang Vilas Pol Chemical Engr. Silicon-Carbon Hybrid Anodes for High Energy-Density Li-ion Batteries

Minyu Cai Oleg Wasnyczuk Elec. and Comp. Engr.Enabling Plug-In Capability and Engine Optimization for a Heavy-Duty

Hybrid Vehicle System via Advanced Power Electronics

• 14 active fellowship students, from 5 different schools of Engr.

Switched System Observer for Fault Detection in PMSMsFellow: Scott Johnson, Faculty: Ray Decarlo (ECE) & Steve Pekarek (ECE)

Progress – Fellowship Project Examples

• Objective:• Detect inter-turn short circuit faults in

PMSM stator windings• Solution

• Model faults as alternate “modes” of operation for online detection.

• Moving Horizon Observer (MHO): real time optimization for faults and states.

• Preliminary Results• Constructed observer structure and

verified observer feasibility.

Future Work• Complete PMSM fault model• Validate observer on PMSM model• Demonstrate real-time fault detection

on PMSM

Est. 24% of motor faults start as Inter-turn short circuit faults

Deere 644k Hybrid Wheel Loader uses 2 PMSM.

ControllerState Est.

Fault Est.

ControlInput

Meas.Output

MHO• PMSM Model• Fault Model

Advanced Separators for Lithium-Ion BatteriesFellow: Aniruddha Jana, Faculty: Edwin Garcia (MSE)

•Development of theories models to understand and engineer lithium dendrite growth (Fig. 1)• Identification of separator morphologies for fast recharging batteries (Fig. 2)• Identification of Thermodynamic and kinetic conditions to suppress dendrite nucleation (Fig. 3)


Fig.3Fig.2

Fig.1

Evaluating Power Management Strategies for Parallel Through the Road Diesel Hybrid Architecture

Fellow: Rohinish Gupta, Faculty: Peter Meckl (ME)

Challenge:• Optimizing fuel efficiency by fine tuning

the mode transition between EV and diesel

Solution: • Exploring power management

strategies with development of high fidelity models for powertrain

• Hardware in the loop testing• Validation on chassis dynamometer

Preliminary Results:• Prediction of battery State of charge

across a drive cycle with an accuracy of 99% (Fig. 2)

Future Work• Using reprogrammable ECM and TCM

for better control over powertrain

Fig 1. Electric Powertrain

Fig 2. SOC Prediction

Prediction error less than 1%



An Integrated Transportation, Electricity, and Drive Train Model for Analyzing the Performance of Hybrid Vehicles

Fellow: Xiaohui Liu, Faculty: Joe Pekny (ChemE)

Challenge• Understanding

transportationeffects on electricitydemand and batterydegradation

Solution• Integrate

transportationnetwork, drive trainmodel, andelectricity demandmodel into one multi-paradigm model

Future Work:• Transportation effects on power system• Develop battery degradation model• Use different drive cycles to study battery degradation characteristics• Impact on Battery Warranty Strategy• Apply to heavy hybrid vehicles

Opportunities:• Maximize efficiency and

performance of hydraulic hybrids

• Enhance industry/ public perception of technology

Solution:• Investigate novel

architectures and control schemes

• Construct technology demonstrator

Advanced High Efficiency Hydraulic Hybrid Powertrain Architectures and Controls

Fellow: Michael Sprengel, Faculty: Monika Ivantysynova (ABE, ME)


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Novel System Architectures Optimal Control via Dynamic Programming HIL Transmission Testing

Novel hydraulic hybrid architecture is currently being implemented in an SUV

demonstration vehicle (ready summer ’15)

Technology is easily transferred to Class 6+ vehicles

Enables ~100% energy recovery via regenerative

braking

Opportunities:• Design quieter fluid power

transmissions.

• Hybrid transmissions require new pump designs.

• Improve pump control system by reducing control effort and therefore improving efficiency.

Solution:• Investigate novel pump

designs through simulation.

• Verify simulation with state of the art measurements


Investigation of Noise Reduction of Pumps and Motors Through Computational Design Optimization

Fellow: Paul Kalbfleisch, Faculty: Monika Ivantysynova (ABE, ME)

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Different vehicles require different priority of hose/pump noise.

Optimizing the pump’s valve

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noise.

Measurement verifies the design strategies


MEC-Based Design Optimization of Claw-Pole AlternatorFellow: Dan Horvath, Faculty: Steve Pekarek (ECE)

• Challenge:• Meet demands of next-generation automotive

electrical systems such as starting capability, multiple battery systems

• Solution• Incorporate optimization techniques and

modeling methods such as genetic optimization and magnetic equivalent circuits (MECs) into a design utility for claw-pole alternators

• Utilize new topologies such as high phase-count and active rectifier

Future Work• Further Industry partnership with Remy International, Inc• Use Existing MEC Model to Create Design Utility• Optimize Machine Design using MEC Model• Incorporate Active Rectifier into Machine Model

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Claw-Pole Machine Coupled with Active Rectifier Operates as an Alternator or Starter

Asymmetric Salient PMSMs for Traction ApplicationsFellow: Ruiyang Lin, Faculty: Scott Sudhoff (ECE)


Around 17% cost reduction

• Challenge:• Improve Constant Power Speed Range

Performance of Permanent MagnetMachines For Traction Applications

• Solution• Asymmetric Salient Permanent Magnet

Synchronous Machine• Preliminary Results

• For the same requirements, the proposedmachine yields a 17% cost reduction

Future Work• Apply to Heavy Hybrid Vehicle Application• 3-D FEA Validation• Thermal Modeling• Investigate Pole Tapering

Optimal Design of Asymmetric SR Motors for Heavy HybridsFellow: Sashankh Ravi, Faculty: Dionysios Aliprantis (ECE)

• The Switched Reluctance Motor (SRMs) is a viable choice in traction applications due to its simple construction, ruggedness, and wide speed range.

• Challenge: torque ripple mitigation without reduction of average torque.

• Solution: asymmetric sculpting of stator and rotor tooth surfaces.

• Technical approach: multi-objective gradient descent and GA-based optimization with finite element analysis.

• Preliminary Results: ~5% improvements in both objectives (average torque increase and torque ripple decrease) obtained.

Future Work:• Apply to Heavy Hybrid Vehicle

application.• Co-optimize current waveforms

with geometric tooth shapes.• Experimental validation.


Development of a Urea Dosing Strategy for Diesel HybridsFellow: Jagdish Hiremath, Faculty: Meckl (ME)

Challenge:• Analyzing the implications of using the Urea-SCR

system for a Hybrid-Diesel platform.Solution: • Improved catalyst temperature sensing using

embedded thermocouples and downstream Ammonia-Sensor-based feedback control

Future Work:• Addressing transient operation during

drive cycles when temperatures and NOxconcentrations fall below operating region for conventional control


System-level optimization of heavy hybrid-electric powertrainsFellows: Ashish Vora, Xing Jin; Faculty: Greg Shaver (ME), Oleg Wasynczuk (ECE)

Objective:• To capture the impact of battery degradation

on fuel consumption, and battery replacement costs, over the lifecycle of the vehicle. Optimize net present valve (NPV) or payback period, and determine the corresponding optimal values for motor size, battery size, and control parameters

Solution:• Model battery degradation• Optimize control parameters that impact

battery utilization• Single economic metric (payback period) for

optimization over vehicle lifecycle, incorporating:• Initial system cost• Fuel consumption (varies over life)• Battery EOL replacement cost

Future Work:• To explore, analyze and optimize different powertrain architectures and power management control

strategies

Electrochemical ESS model capturing degradation mechanisms – AutoLion ST Autonomie 2013

NA transit bus – pre-trans. parallel HEV architecture

Results:

Min. Payback Period

Motor size Battery size

Silicon-Carbon Hybrid Anodes for High Energy-Density Li-ion Batteries for Electric Vehicles

Fellow: Jialiang Tang, Faculty: Vilas Pol (ChemE)


• Challenges: – Detrimental volumetric expansion of Si – Short cycling life & high synthesis cost

• Solutions:– Low cost carbon architecture to accommodate Si

volumetric expansion (Scheme 1 and Fig.1)– Electrolyte modification to stabilize battery cycling

• Preliminary Results – 30% Si/C anode exhibits twice the theoretical

capacity of graphite at much faster rates– Good coulombic efficiency of 99% (Fig. 2)

Schematic 1 (Left): low-cost Si/C hybrid anodedesign. Porous carbon with controlled pore sizeallow Si nanoparticles to expand freely duringlithiation.

Figure 1 (Below): SEM image of actual Si/C hybrid

Future Work:• Reducing initial capacity loss by

improving structure design• Completion of electrolyte

optimization• Full cell construction using

commercial cathodes• Pouch cell construction and

electrochemical evaluation

Figure 2: Rate performance of 30%Si / 70%C composite as an anodein Li-ion battery half cell. True C-rates are reported here.

Enabling Plug-In Capability via Adv. Power ElectronicsFellow: Minyu Cai, Faculty: Oleg Wasnyczuk (ECE)• Challenge

– Plug-in hybrid vehicles need a compact, highly efficient bi-directional dc–dc converter featuring with large voltage-conversion ratio and high power rating.

• Solution– High switching frequency (50 kHz)– Isolated converter with soft switching capability– SiC transistors

• Progress– Converter topologies compared via simulation: full-bridge active-

clamped isolated converter is chosen (Fig. 1)– Transformer & inductor designed (Fig. 2)– Converter prototype built and tested (Fig. 3)

• Current results– Converter tested under low power (<2 kW). Soft switching

realized with an average efficiency around 80%.– Further loss reduction by using SiC transistors verified via

simulation[1].


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• November 21st, 2014• 17 posters• Seminars by Professors Oleg Wasynczuk and Monika

Ivantysynova• Special visitors: Connie Bezanson and Adrienne Riggi

Progress – Poster Show & Workshop

Jagdish Hiremath (left) and Ashish Vora (right) discussing their research with Adrienne Riggi and Connie Bezanson

• Phase 1 (of 2)• 52,000 sq. ft.• Includes 4 powertrain test cells

for advanced medium & heavy duty hybrid powertrains

Progress -Opened New Herrick Labs

Layout for cells 1 and 2, the “Cummins Power Lab”

Spring 2014 Visit by Cummins’ (left to right: Prof. Greg Shaver, Tom Linebarger (CEO), John

Wall (CTO), Prof. Suresh Garimella)

Includes expanded Labs for:

• Power Magnetics• Vehicle Systems

Energy Conversion, and

• High Density Storage

Progress -Opened New Wang Hall

• Opened Fall 2014.• A key asset for projects focused on

hybrid electric vehicles

• Cummins– Co-sponsoring 3rd research projects (3 fellowship students)

• John Deere– Converging on 3 co-funded research projects (3 fellowship

students)

Collaborators & Coordination w/ Other Institutions

• Continue regular poster shows/workshops, and industry co-funded research projects.

• Continue growth of # of students in certificate program.

Future Work and Activities

• Purdue GATE Hoosier Heavy Hybrid Center of Excellence (H3CoE) project initiated in Oct. 2011.

• Focus on medium and heavy-duty hybrid vehicles.– Certificate program: 20 current students + 12 have that have

completed program– Industry co-funded research projects: 3 with Cummins– H3CoE Fellowship program: 14 current fellows

• New facilities will enhance/enable efforts of H3CoE– New Herrick Labs w/ 4 hybrid powertrain testcells opened

August 2013– Wang Hall opened Fall 2014

Summary

hoosier heavy hybrid center of excellence...

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