university of michigan challenge x team series hydraulic hybrid overview ricardo detroit technology...
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University of MichiganChallenge X Team
Series Hydraulic Hybrid OverviewRicardo Detroit Technology Campus, 08/24/06
The ChallengeX Competition
Challenge X is a 3 year student team competition sponsored by GM, ANL and the DOE along with a host of other sponsors.
17 schools from USA and Canada
The aim of the competition is to convert a stock Chevy Equinox into a hybrid to improve fuel economy and reduce emissions, while meeting or exceeding the stock vehicle performance characteristics
Team Overview Joint effort between the Ann Arbor and Dearborn campuses. Approximately 8 Core Team Members Faculty Leads
Prof. Dionissios Assanis Chair of the Mechanical Engineering Department, Ann Arbor [email protected]
Dr.Bruno Vanzieleghem Technical Program Manager, Automotive Research Center [email protected]
Prof. Keshav Varde Associate Dean of the Mechanical Engineering Department, Dearborn [email protected]
Student Leads Pavan Potluri (Mechanical) Steve Scott (E.E and Controls) Prasad Venkiteswaran (Vehicle Integration)
Series Hydraulic Hybrid: Motivation
Potential benefits: Full flexibility in controlling the engine High-power density of hydraulic components, dash-speed Hydraulics very efficient in regeneration (>70%*) Energy storage efficiency is independent of the temperature Allows downsizing of the engine
Engine Efficiency Considerations
Conventional Engine – FTP Cycle
Constant PowerMinimum BSFC Line
Conventional V8 - FTP 75
To
rqu
e (N
-m)
0
200
400
600
800
Engine Speed (rpm)600 1200 1800 2400 3000
To
rqu
e (
Nm
)
0
50
100
150
200
250
300
350
Speed (rpm)
875 1375 1875 2375 2875 3375 3875 4375
202
202
205
450450450
300
300
300
260
260
260
240
240
240
230
230
230
210210
210
237
229
218
210211
280
0
73
73
51
51
51
32
32
32
20
20
20
12
12
12
55
5
98
107
106
9867
16
FIAT ENGINE 1.9 JTD 16V 150CV EURO4
Conventional Engine – FTP Cycle
Constant PowerMinimum BSFC Line
Conventional V8 - FTP 75
To
rqu
e (N
-m)
0
200
400
600
800
Engine Speed (rpm)600 1200 1800 2400 3000
4
3.5
3
2.5
2
1.5
Engine Efficiency Considerations
Conventional Engine – FTP Cycle
Constant PowerMinimum BSFC Line
Conventional V8 - FTP 75
To
rqu
e (N
-m)
0
200
400
600
800
Engine Speed (rpm)600 1200 1800 2400 3000
4
3.5
3
2.5
2
1.5
To
rqu
e (
Nm
)
0
50
100
150
200
250
300
350
Speed (rpm)
875 1375 1875 2375 2875 3375 3875 4375
202
202
205
450450450
300
300
300
260
260
260
240
240
240
230
230
230
210210
210
237
229
218
210211
280
0
73
73
51
51
51
32
32
32
20
20
20
12
12
12
55
5
98
107
106
9867
16
FIAT ENGINE 1.9 JTD 16V 150CV EURO4
PI Control Series Hydraulic I4 Diesel Engine – FTP Cycle
Fuel Economy Benefit
Simulation Results
0
25
50
75
100
0 200 400 600 800 1000 1200 1400
Ve
loc
ity
(km
/hr)
Time (s)
FTP 75 Cycle
0 1 0 2 0 3 0 4 0
F u e l E c o n o m y ( m p g )
C o n v e n t io n a l
T h e r m o s t a t ic C o n t r o l S e r ie s H y d r a u l ic 77%
Emissions Benefit
0 20 40 60 80 100
Particulate Emissions Over FTP 75
Relative Cumulative Particulate Emissions
Conventional
Thermostatic ControlSeries Hydraulic
Modulated ControlSeries Hydraulic73.8% 60.9%
60.9%
73.8%
0 20 40 60 80 100
Particulate Emissions Over FTP 75
Relative Cumulative Particulate Emissions
Conventional
Thermostatic ControlSeries Hydraulic
Modulated ControlSeries Hydraulic73.8%73.8% 60.9%60.9%
60.9%60.9%
73.8%73.8%
0 20 40 60 80 100
Particulate Emissions Over FTP 75
Relative Cumulative Particulate Emissions
Conventional
Thermostatic ControlSeries Hydraulic
Modulated ControlSeries Hydraulic73.8% 60.9%
60.9%
73.8%
0 20 40 60 80 100
Particulate Emissions Over FTP 75
Relative Cumulative Particulate Emissions
Conventional
Thermostatic ControlSeries Hydraulic
Modulated ControlSeries Hydraulic73.8%73.8% 60.9%60.9%
60.9%60.9%
73.8%73.8%
Series Hydraulic Hybrid HMMWV Results
Engine-in-the-loop test resultsSource: 12th Automotive Research Center Conference, May 23rd, 2006
Hydraulic Hybrid – Unique Aspects
Existing technology, used in a novel way Cost efficient, with existing manufacturing base No conventional transmission system AWD system using one hydraulic pump/motor in the
front axle and a second hydraulic motor in the rear axle Ability to run the larger front pump/motor and the smaller
rear motor independently or together Drive cycle estimation logic in the powertrain control
algorithm Hydraulic engine starter to reduce the power draw from
the battery
Vehicle Design Schematic
Series hydraulic hybrid 1.9L GM Diesel Engine
80 cc/rev Front engine pump 55 cc/rev Front drive motor 80 cc/rev Rear drive motor 300 psi 12 gallon accumulator 5000 psi 12 gallon accumulator
Blue: High Pressure
Green: Low Pressure
Red: Pump/Motor
Intended Vehicle Operational Modes
Propulsion (FWD only) – Regular driving, highway cruising
Propulsion (AWD) – For Maximized acceleration, slippery/ low traction conditions
Regenerative Braking – Using front drive motor to recharge the accumulators
Engine Off – Hydraulic power only, when accumulator’s SOC is above a set level (0.4 – 0.55)
Control Strategy
Thermostatic Control SOC maintained over fixed region
(0.4 – 0.55) Deviation is compensated by moving
the Engine to desired location Results in larger engine transients
180kW
0.1
0.0kW
60kW
0.4 1.00.0 0.55
PI Control SOC maintained at fixed value (0.25) Engine Power demand is calculated
based on actual and target SOC Anticipates changes in SOC and
results in smoother engine operation
Role of Computer Based Modeling
Component Packaging: Powertrain packaging was done using the supplied
CAD data Vehicle modeling and simulation:
Equinox hydraulic hybrid model developed based on an existing ARC model
Vehicle performance with various component sizing simulated using this model
slope
driving cycle
VEHICLE DYNAMICS
Monitoring
Pump
Power Management
Driver
Load Input Data
DRIVELINE
DIESEL ENGINE
Accmulator/Reserver
AWD HYDRAULIC PM
1.9L GM TDCi Engine
Simplified Transmission
Additional components
AWD vehicle model
Role of Computer Based Modeling
VTS – Final Vs. Current
Category Final Design Current DesignVehicle Start Time (sec) < 5sec < 5secIVM-60 mph 10 sec <20sec50-70 mph 4 sec < 8 secVehicle Mass (lbs.) 4500 4500Mpg Combined EPA 34.5 35.4Highway Range (miles) 512 601Passenger Capacity 5 5Emissions Certification Level Tier 2 bin5/LEV2 ?Trailering Capacity (lbs.) 3500 3500
Conclusions
Hydraulic hybrid promises excellent fuel economy benefits
Hydraulic hybrid reduces soot emissions CAD & full-vehicle modeling aided significantly in
the design and build process Further work needed on powertrain and controls
integration
Sponsorship Benefits
Participation in a highly-visible, national engineering competition
Collaboration opportunities with team and competition sponsors (Sponsor social)
Collaboration opportunities with University of Michigan departments and faculty
Access to team vehicle for publicity purposes by Ricardo
Potential recruiting opportunities Team member recruitment, highly qualified graduates with
real-world experience
CX Sponsorship Guidelines
Competition-Level Sponsor Classification
Sponsorship Contribution Minimum Cash Support In-Kind Credit
Headline Sponsor $1 Million + $900,000 Up to $100,000
Platinum Sponsor $50,000 $40,000 Up to $10,000
Gold Sponsor $35,000 $30,000 Up to $5,000
Silver Sponsor $15,000 $10,000 Up to $5,000
Bronze Sponsor $3,000 $3,000 (cash or in-kind) N/A
Sponsor Socials
University of Michigan Challenge X Team
Altair Sponsorship Request – January 31st 2006
CX Official Sponsors
Headline Sponsors U.S. Department of Energy General Motors Corporation
Platinum Sponsors Natural Resources Canada The MathWorks National Instruments AVL North America, Inc. U.S. Environmental Protection Agenc
y U.S. Department of Transportation
Gold Sponsors National Science Foundation Freescale Semiconductor BP
Silver Sponsors
Cobasys
Chevron
Johnson Controls-SAFT Advanced Power Solutions
Ballard Power Systems, Inc.
Michelin North America
Sensors, Inc.
dSPACE, Inc.
Renewable Fuels Assocation
Current Vehicle Pictures
Installed Front Engine PumpGM 1.9L Diesel
Current Vehicle Pictures
GM 1.9L Diesel Engine
Current Vehicle Pictures
Rear Drive Motor
Current Vehicle Pictures
12 Gallon Accumulators
Questions?