Advanced Technology Vehicle

Lab Benchmarking – Level 1 & 2

2015 U.S. DOE Vehicle Technologies Program
Annual Merit Review and Peer Evaluation Meeting

Kevin Stutenberg - Principal Investigator- L1

Eric Rask – Principle Investigator – L2

Argonne National Laboratory

June 9, 2015
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
– FY14 & FY15 Completed Testing: Simulation Methodologies (C)
• 10 vehicles thoroughly evaluated in • Model development and validation
FY14, 5 in FY15 (L1/L2) – Lack of Standardized Testing Protocols (D)
– FY14 and FY15 Test Vehicles • Validating BEV and PHEV test procedures
• See Milestone on slide 6 • Support of SAE committee (J2951 Drive
Metrics, J2907/2908 Powertrain rating,
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
compared to previous models
 Budget
– L1/L2 FY2014 $2.265k  Partners:
– L1/L2 FY2015 $1.925k – AVTA (Advanced Vehicle Testing Activity):
DOE, INL, ANL, Intertek
– Other Leveraged DOE Projects
(separate funding) – DOE, National Laboratories, USDrive, OEMs,
Component Suppliers, Vehicle Competitions
– EPA, CARB
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 Relevance: Objectives of the Advanced Powertrain
Research Facility (APRF)
Technology Assessment 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 FY15
Enable petroleum displacement through  Establish technology benchmarks for
technology assessment & data dissemination advanced technology powertrains,
 Establish the state-of-the-art automotive including: HEV, PHEV, BEV, Conventional
technology baseline for powertrain and Alternative Fuel Vehicles.
systems and components through test  Enhance instrumentation and signal
data generation and analysis capture through advanced analog
 Provide independent and public data for instrumentation and capture of vehicle
evaluation of emerging technology communications messaging.
 Generate data to support model creation  Continued evaluation of thermal effects
and validation, standards development, on energy consumption and powertrain
and DOE target setting behavior.
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
Dodge
Wide Variety of Vehicle Technologies Ram HFE

AMR
2014-Q3

2014 Q4

2015 Q1

2015 Q2

2015 Q3
Milestones Ford
Dodge Ram Idle Stop (CNG conversion) Focus
Ford Focus Electric (AVTA- Level 1) Electric
Chevrolet Cruze Diesel
Mazda 3 I-Eloop
Smart Fortwo ED
Level 1
AVTA

BMW i3 REx (AVTA- Level 1)

Chevy Cruze
BMW i3 BEV
Diesel
Honda Accord Hybrid
Chevrolet Impala Bi-Fuel
Chevrolet Spark EV
Kia Soul – Electric Mazda
VW E-Golf 3 - iEloop
Accord PHEV Instrumentation
Accord PHEV Testing
ANL L2

Accord PHEV Analysis

Level 2

BMW i3 Acquisition/Preparation Dodge Ram

BMW i3 Prelim Testing HFE w/ CNG
BMW i3 In Depth Instrumentation conversion
BMW i3 Testing

6
Smart ED L2 BMW i3 Rex 2014 L2 Accord Ford Fusion Energi Mitsubishi I-MiEV 2013 Leaf
 Approach: L1- 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)

APRF L1 Test Process:

Accelerated
Baseline Dynamometer Testing fleet testing

Data
New 1. Preparation and 2. Dyno testing 3. Analysis
vehicle instrumentation
Mileage
accumulation,

Data
track testing
& coast down

National Labs
USCAR (OEMs)
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Approach: Purpose Built Research Laboratory for
Automotive Benchmark Activities
 Level 1 and Level 2: Comprehensive Advanced Powertrain
instrumentation and evaluation Research Facility
– Level 2: invasive / Level 1: non-invasive 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
thermal
– Standard drive cycles, technology specific cycles,
chamber
performance tests, vehicle and component
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
Approach: L2- Extensive Vehicle Instrumentation
A wide mix of direct instrumentation (temperature, electrical, flow, pressure, etc.) as well as
CAN and Diagnostic bus information was used during testing

3-Phase AC Voltage and Current HV and LV Electrical Nodes

Thermal System Instrumentation

Cabin, low temp., and high temp. loops
EGR and Exhaust System

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 Accomplishments: Revised
Instrumentation Methods
 Development of Diagnostic Database
 Determination of message Id’s and scaling
– Historically- OCR used to capture / combine
– Now- database captured for streamlined logging
 Diagnostic messages are then:
– Utilized for broadcast CAN decoding
– Desired signal logging during testing
• Multiple Module / Multiple Modes
– Distributed to AVTA partnership for fleet testing

Old- OCR Module

New- Database Development

Data Collection / Merge

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Accomplishments: Idle Stop / NGV Vehicle
Evaluations
Idle Stop & CNG Operation
 HFE Idle Stop Impact
– Up to 14% improvement on NEDC/NYCC,
9% on UDDS
 Aftermarket CNG conversion
– CNG MPGe reduction of 2.5% to 8%
– Fuel economy consistently lower- as 72F- CNG

expected (lower energy density) Test Test #

Gasoline
Used (gal) CNG Use (GGE)
Combined Fuel Comined
Use (GGE) MPGe MPGe Impact
UDDS cold start 61409037 0.118 0.277 0.395 18.9 -2.7%

 Further NGV testing occurred on ANL UDDS

Highway
61409038
61409041
0.042
0.003
0.319
0.341
0.361
0.345
20.6
29.8
-3.4%
-6.7%

Bifuel 2012 VW Passat TSI Ecofuel US06

US06 City
61409042
61409042
0.088
0.067
0.336
0.075
0.424
0.142
18.9
12.5
-7.2%
-5.8%
US06 Highway 61409042 0.022 0.261 0.282 22.1 -7.9%

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Accomplishments: EV Energy Consumption vs. Ambient Temp.
All vehicles show dramatically higher impact due to heating versus A/C
• For aggressive cycles, A/C is a wash with other factors (improved losses)
• Cabin temp. trajectory from cycle-to-cycle makes direct impact assessment difficult
• HVAC is not the only contributor towards elevated “cold” energy consumption
Accomplishments: Understanding BEV Range
Variations Usable Capacity

Energy Consumption

• Although some clear trends exist,

recent vehicles show variations in
range due to:
• Useable battery capacity
• Energy consumption
• Drive cycle usage relative to maximum
capability

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Accomplishments: In-depth Blended PHEV Evaluation
• Honda Accord PHEV provides an
additional data point for blended
PHEV vehicle usage and capabilities

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Accomplishments: Aggressive Thermal Usage Assessment
55 mph steady-state operation @ 6-9% grade, 95F ambient + solar loading
Working Fluid Temperatures: Eng. Oil, Trans. Oil, Eng. Coolant, PE Coolant

Coolant Flows

Component Temps.
Generator and DC-DC
 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

APRF DOE technology evaluation

•DOE requests
•National Lab requests

AVTC (Advanced Vehicle

Technology Competition)
Universities USCAR, tech teams and OEMs
Shared test plans, data and
analysis

Autonomie
Support of modeling Chrysler – CTC
and simulation with data
GM – Powertrain, Milford

Ford – Powertrain, APTL

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Proposed Future Work: Level 1 & 2 Benchmark Will
Continue with Emphasis on BEVs
Upcoming AVTA Vehicles (as of Apr 2015):
 2014 BMW i3 BEV
 2015 Chevy Spark Electric
 2015 Kia Soul EV
 2015 Honda Accord Hybrid
 2015 Chevrolet Impala Bi-Fuel CNG
 2015 Mercedes Benz B-Class
Electric
 2015 Infiniti Q50 Hybrid FY2015 APRF L2 Research Vehicle: 2014 BMW i3 REx
 Further potential AVTA vehicles:
 2015 VW e-Golf Level 2 Vehicles + ANL Vehicles
 2016 Toyota Mirai  2014 Honda Accord PHEV (further testing)
 2016 Hyundai Sonata PHEV  2014 BMW i3 Rex (FY2015 L2 vehicle)
 2016 Mitsubishi Outlander PHEV  2012 VW Passat TSI EcoFuel (CNG bi-fuel)
 2016 Nissan E-NV200
 2016 Via Vtrux
 2016 Chevrolet Volt

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Summary
 APRF Vehicle Technology Evaluation Activity continues to provide precise
laboratory test data for a wide range of vehicle technologies that address DOE goals
– Establish the state-of-the-art automotive technology baseline for powertrain systems and
components through data collection and analysis
– Providing independent evaluation of technology and support for DOE target setting
– Generating test data for model development and validation to encourage speed-to-market of
advanced technologies
– Supporting codes and standards development for unbiased technology weighting

 Highlighted Accomplishments from Level 1 and Level 2 Testing

– Greatly enhanced data collection through non-invasive methods (CAN and Diagnostics)
– Continued evaluation of thermal impact on energy consumption and powertrain operation of
conventional, alt fuel, and electrified vehicle technologies
– AVTA vehicle testing in-progress in collaboration with INL and Interek
– Test results and raw data available publicly at the Downloadable Dynamometer Database
website (http://www.transportation.anl.gov/D3/)
– Continued collaboration with OEM & DOE Partners with resource of extended data sets of
level 1 and level 2 test vehicle.

 Continued Link to Industry is an important component of vehicle testing

– Sharing best test practices, facility hardware recommendations, data analysis methods
– Industry technology experts provide insight into what data is of interest, assisting in testing
direction
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Technical Back-Up Slides

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 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

APRF (Advanced Powertrain Research Facility) ver. Jan2012

 Advanced Powertrain Research Facility
2WD Chassis Dynamometer

• 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
 SEMTECH-DS (Mobile Emissions
 Vehicle lift (max 10,000 lbs..) unit) with AVL DVE mass flow sensor
 Remotely located control room
with 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

APRF (Advanced Powertrain Research Facility) ver. Jan2012