CAR EXTERNAL ADVISORY BOARD MEETING
WELCOME WELCOME Welcome and Brett Roubinek
Introductions President & CEO Transportation Research Center
Giorgio Rizzoni Director Center for Automotive Research
CAR 2006
The Ohio State University Center for Automotive Research January 11th, 2006 Giorgio Rizzoni Director, Center for Automotive Research The Ohio State University
rizzoni.1@osu.edu http://car.eng.ohio-state.edu
Overview • Center for Automotive Research founded in 1991. • Center receives support from automotive industry and government agencies. • CAR receives partial support from Transportation Research Endowment Program (TREP), an endowment fund with market value around $50M. Endowment supports one third of operating expenses (5% of total budget). And provides matching funds for research programs. Annual contribution around $0.5M • FY05 expenditures: $5M. • Existing facilities include 35,000 ft2 of office and laboratory space with major research equipment including engine, powertrain and chassis dynamometers.
Research Areas VEHICLE SYSTEMS PERFORMANCE MEASURES Fuel Economy
PROPULSION SYSTEMS Powerplants
BODY & CHASSIS SYSTEMS Body Systems
INFORMATION SYSTEMS Communication Technology
Emissions Safety/Security
Drivetrains
Driveability /Ride/Handling
Human Biomechanics
Human/Vehicle Interaction
Noise/Vibration/Harshness Quality/Reliability/Durability Materials/Mfg/Cost
Controls
Chassis Systems
Interior Design
FutureTruck 2002-04 Hybrid Electric Explorer Supervisory Controller Rapid prototyping ETAS ES1000 CAN Bus
FT04 Gryphon
Traction Inverter Module (TIM) with built-in CAN controller
Engine module µC : Infineon C164CI , CAN compatible
Electric Machine
Engine
Driver module µC : Infineon C164CI, CAN compatible
Battery module µC : Infineon C164CI, CAN compatible
Cluster, transmission, accelerator pedal, etc
Battery pack
Buckeye Bullet • •
U.S. Land Speed Record e-III category: 315 mph, Oct. 2004 BNI International record: 272 mph, Oct. 2004
Energy Storage Systems Lab •
Performance, reliability and life cycle modeling of NiMH cells for HEV and highpower applications
Sponsored by CAR, CAR Industrial Consortium
Energy Storage Systems Lab •
Electrical and thermal characterization of double-layer (electrochemical) capacitors Sponsored by CAR, CAR Industrial Consortium
Electronics Lab before Denso Foundation gift
Electronics Lab after Denso Foundation gift
Personnel Summary
Personnel summary - 05-06 • 24 Faculty • 7 Research Scientists • 6 Research Engineers (M.S. and Ph.D.) • 40 Graduate Students • 13 Visiting Scholars • 5 Facility and Technical Support Staff • 5 Administrative Staff Total: 100 The Center also provided facilities and support, in collaboration with the College and ME department, for 4 student project teams consisting of over 300 undergraduate students and 60 FIRST (robotics project) high school students.
Personnel Trends 90 80 70 60 50 40 30 20 10 0 2000
Visiting Scholars
2001
SRA's
2002
2003
Research Staff
2004
2005
Facilities/Tech Support
Administrative Staff
Fiscal Summary
CAR growth Growth of CAR Expenditures $6,000,000 $5,000,000
$5,000,000
$3,800,000
$4,000,000
$3,000,000
$2,000,000
$2,600,000
$1,500,000
$1,500,000
$1,600,000
$1,000,000
$0 1 Year 2000
2001
2002
2003
2004
2005
Current Sponsors Private Government
• • • U.S. Army TARDEC • • U.S. Army Yuma Proving Ground • • U.S. Department of Energy • U.S. Department of Transportation • • • National Renewable Energy • Laboratory • • Oak Ridge National Laboratory • • National Science Foundation • • Ohio Board of Regents • • Ohio Department of Development • • • • Industrial Research Consortium OEMs • DaimlerChrysler, Ford, GM, Honda, • Oshkosh • Suppliers: ArvinMeritor, Bosch , Dana, Delphi, • Dow, Lear, ST MicroElectronics TRC • •
Battelle Bosch Caterpillar DaimlerChrysler Dana Denso Eaton Ford Motor Company General Motors Corporation Honda R&D Americas Hyundai International Truck and Engine Nissan Motor Co. Oshkosh Truck Corporation Owens Corning PSD Tech, Inc. Siemens SOFCo-EFS Tenneco Automotive TRC, Inc. TRW
The Future
Recent programs funded • DOE Freedom CAR : Graduate Automotive Technology Education Center of Excellence, Phase 2 • U.S. Army NAC: Advanced Power and Propulsion for Future Tactical Trucks • Tenneco Automotive: Exhaust after-treatment studies • Ford: Flow noise • General Motors: Powertrain Control and Electrical System Diagnostics
Building Expansion/Renovation • Current building has exceeded capacity – Need for new laboratories to support existing and new thrusts – Need for people space – Improve image
• Capital and program fund-raising campaign being planned • Architectural feasibility study started
Concept design
CAR 2012
Strategic Plan for OSU Center for Automotive Research
Giorgio Rizzoni The Ford Motor Company Chair in Electromechanical Systems Director and Senior Fellow, Center for Automotive Research Professor, Mechanical and Aerospace Engineering Professor, Electrical and Computer Engineering Adjunct Professor, Design Member of Graduate Faculty, Nuclear Engineering Program
Expertise areas: Sustainable and Safe Mobility Propulsion Systems • IC engine fluid, acoustic and thermal sciences • Exhaust emissions • Hybrid powertrains • Alternative fuels • Energy storage devices and systems • Electric drives and power conversion
Vehicle Systems • Vehicle dynamics and stability control • Autonomous vehicles • Communications networks, V2V and V2I • Occupant and pedestrian safety • Concept vehicle design
Transportation Systems • Vehicle-grid interaction • Alternative fuels – policy and infrastructure • Intelligent Transportation Systems
Cross cutting expertise • Computational modeling – fluid, thermal, electromechanical, electrochemical • Control and system sciences • Experimental facilities – materials, components, subsystems and systems testing
Research Partners and Sponsors • • • • • • • • • • • • •
Komatsu Lubrizol Magna Mercury Marine Nissan Motor Co. Novellus Design Oshkosh Truck Corporation Samsung Sentech TE Connectivity Toyota TRC, Inc. Venturi Automobiles
Automotive • A123 Systems • Battelle • Bosch • Caterpillar • CAR Technologies, LLC • Chrysler • Case-New Holland • Cummins • Denso • Eaton Electric Power • FIAMM • FilMore Express • American Electric Power • Firm Green • Buckeye Power • Ford Motor Company • Dayton Power and Light • General Motors Corporation • Duke Energy • GrafTech • Eaton • Henkel Corporation • Ecotality • Hi-Stat Manufacturing • FirstEnergy • Hitachi • Juice Technologies/PlugSmart • Honda • PJM Interconnection • Johnson Controls • Vanner
Government/Non-Profit • National Science Foundation • U.S. Department of Energy • U.S. Army TARDEC • U.S. Army Yuma Proving Ground • U.S. Department of Transportation • Office of Naval Research • Argonne National Laboratory • National Renewable Energy Laboratory • Oak Ridge National Laboratory • Sandia National Laboratory • Ohio Board of Regents • Ohio Department of Development • Ohio Department of Transportation • Clean Fuels Ohio • EWI – Edison Technology Center • MAGNET - Edison Technology Center • TechColumbus
Personnel Summary • 76 Graduate Students • 46 Student Assistants • 23 Visiting Scholars • 9 Primary Faculty • 22 Secondary Faculty • 17 Research Staff • 3 Post Doctoral Fellows • 6 Facility Support Staff • 7 Administrative Staff Total: 209 people The Center also provided facilities and support, in collaboration with the College and MAE department, for 6 student project teams consisting of over 150 active undergraduate students and 45 FIRST (robotics project) high school students.
Total Expenditures Operating Expenses $856,989 9%
Research Expenses $7,372,742 81%
Continuing Education $184,239 2%
OSU Motorsports $738,751 8%
$9,152,722
History – CAR Expenditures 10 Millions ($)
9.2
9 8
6.9
7
6.0
6
5.0
5
3.8
4 3 2 1 0
2.6 1.5
1.5
1.6
5.6 5.0
5.9
2. Five-year plan to achieve CAR vision:
To become the pre-eminent research center in sustainable and safe mobility in the United States
Milestones 1.
2.
3.
4. 5. 6. 7. 8. 9.
Grow SMART@CAR program into leading vehicle electrification research program in the country, in collaboration with ECE, ISE, and with the electric utility industry. Requires new faculty leadership Double advanced engines and alternative fuels research and establish strong connections with existing CAR research programs related to powertrain control, resulting in the leading powertrain systems research program in the U.S. Requires mid-career faculty hire Grow energy storage research group (CAR, MAE, MSE, ECE, Chemistry) and establish CAR and OSU as a leader in selected topics in basic and applied research in energy storage systems. Requires new faculty leadership Strengthen OSU capabilities in system fault diagnosis/prognosis. Requires junior or mid-career faculty hire Strengthen relationship with TRC, NHTSA and Honda in the vehicle safety area. Requires new faculty leadership Strengthen OSU leadership in vehicle autonomy, intelligence, and communications. Requires junior or mid-career faculty hire Establish CAR as a leader not only in technology development, but also in energy and mobility policy and planning. Requires new faculty leadership Establish new research area in big data/analytics with CSE focus. Requires midcareer faculty hire Expand UG, G, and professional educational programs
5. Obstacles to growth: Facilities
CAR 2018
CAR Today Electrification
Safety and Security
Autonomous and Connected Vehicles
Powertrain and Control
Innovative Materials and Solutions
STATE OF THE CENTER
2018 ANNUAL REPORT
Marcello Canova Associate Director for Research and Education Center for Automotive Research
Highlights Mobility21 •
Ohio State is a partner in the new Carnegie Mellon University led five-year national UTC award.
•
Focused on safely and efficiently improving the mobility of people and goods in the 21st century by investigating and deploying novel technologies, incentives, policies and training programs.
Sponsored Research •
Two PhD students help to solve a major problem with internal combustion engines, thanks to a National Science Foundation research grant.
CAR Champions Shawn Midlam-Mohler was awarded the NSF EcoCAR Outstanding Faculty Advisor Award
Matilde D’Arpino was presented with Best Paper Award at the 2017 IEEE International Transportation Electrification Conference
Qadeer Ahmed received the College of Engineering Lumley Engineering Research Award
Ahmet Selamet received the Ralph K. Hillquist NVH Lifetime Achievement Award
Smart Center An all-new, 540 acre, Smart Mobility Advanced Research and Test Center at the Transportation Research Center (TRC) to test connected and driverless vehicles for the future mobility of people and goods. This $45M project is funded by the State of Ohio and The Ohio State University.
Smart Center Status Update • Road bed preparation nearly complete for main intersection. Paving to start 10/7. • Earthwork on Urban center has begun. • Control building design is completed and foundation is being poured currently. • Traffic control system, Signals, and V2I hardware vendors have been selected. Detailed system design is underway.
Global Gateways Initiative
Shanghai
Columbus, OH
Mumbai
Sao Paolo
One of several identified initiatives by the President's and Provost's Council on Strategic Internationalization Students |
Faculty
|
Partners
|
Alumni
Primary Engagements for the India Gateway
290 70
Faculty engagement: science, technology and innovation, skill development programs
Industrial and institutional partnerships: sponsored research, trainings and certification courses
Healthcare
550 20
Engineering and Technology
Students: recruitment, internship, education abroad, exchange programs and alumni engagement
Government, international agencies and U.S. consulate partnerships
Business Management
RESEARCH AND FISCAL UPDATE David Cooke Assistant Director of Research Operations Center for Automotive Research
Personnel In the 2017-2018 academic year there were a total of 292 associates
Fiscal Year 2018:
Electrification Research By the Numbers in FY18
$5.1M 35
of research expenditures on electrification projects
Unique principal investigators leading electrification projects
64 61
Projects related to the electrification of the automotive and mobility industry
Graduate and undergraduate students as well as visiting scholars engaged in the projects
MEMBERSHIP CONSORTIUM: 2018
Platinum
Gold
Save the Date Membership Exploratory Research Project Year End Reporting Meeting
Friday, December 14 @Fiat Chrysler Automobiles Auburn Hills, MI
OUTREACH INITIATIVES Maryn Weimer Senior Associate Director Center for Automotive Research
CAMP CAR The Center for Automotive Research along with the Honda-Ohio State Partnership hosted 10 high school students at Camp CAR, a week long summer camp focused on automotive engineering.
Daily Themes Automotive Engineering Design and Simulation Manufacturing Autonomous and Connected Vehicles Future of Mobility
We welcome guest speakers from industry! Interested? See Matt Little or David Cooke during lunch.
“It was cool to apply what I learned in physics class last year to the simulations we worked on during Camp.� Isabel Delamater Marysville Early College STEM School
CAR INTERNSHIP PROGRAM Over the summer 13 high school and college students spent their summer at CAR, gaining experience in automotive engineering. Mary Cech worked under the direction of Research Scientist Greg Busch to model an automotive fuel system.
Four interns worked with Research Scientist, Jeff Chrstos on developing a Driver-in-the-Loop driving simulator.
High school student, Eddie Dominek worked closely with the Supermileage team, bending wood for the body of their vehicle and designing the steering column mount.
CAR Graduate Students Summer Internships This summer 15 of CAR’s graduate students gained real world experience as interns at some of the country’s top technology and automotive companies.
• • • •
Apple Bosch Cummins Delphi
• • • •
FCA Ford General Motors NASA Ames Research Center
“I enjoyed my work because it built on many of the principles I had learned during my projects with the Ohio State EcoCAR team, but with an industry perspective.” Evan Stoddart Bosch Intern
Congratulations to our Scholarship Recipients
Kerri Loyd (EcoCAR) Mason Hayes (Buckeye Current)
George Li (EcoCAR) Zach Salyer (Buckeye Current)
EcoCAR Formula Buckeyes Joseph Chiu (EcoCAR) Jackie Karl DeFrain (EcoCAR) Nick Kopycinski (Formula Buckeyes) Morgan Malencia (Formula Buckeyes)
RESEARCH STATE OF THE COLLEGE OF ENGINEERING Dorota Grejner-Brzezinska Associate Dean for Research College of Engineering
COE- an overview Dorota A. Grejner-Brzezinska Lowber B. Strange Endowed Professor Associate Dean for Research
CAR EAC, October 5, 2018
Engineering by the numbers
Engineering at Ohio State Graduate/Undergraduate programs ranked 16th/17th among public universities (USNWR) 360+ faculty members 12 departments 2017 enrollment: 10,552 students 98% of incoming students ranked in top 25% of their high school classes 40+ research centers and laboratories with state-of-the-art facilities Student national champs and record holders: EcoCAR 3 automotive engineering team & Spaceport America Cup rocket team Venturi Buckeye Bullet, world’s fastest electric vehicle (341mph) Autonomous drone world speed record (147mph over 28 miles)
More engineering quick facts 372 faculty members, 313 TT, 41 CT, 18 RT Students: Undergraduate 8,537, Graduate 2,015 = 10,552
More than 25 undergraduate student teams in COE
89% of engineering undergrads engage in engineering related experience
Research Expenditures: ~$153M
~$107M on campus
~$46M at the Transportation Research Center
Strong industry partnerships
COE: research expenditure analysis
OSU: industry sponsored research Source: INFORMATION TECHNOLOGY & INNOVATION FOUNATION, JANUARY 2018
COE: strategic priority areas
A History of Success: EcoCAR 3 at Ohio State
FIVE CONSECUTIVE FIRST-PLACE FINISHES OSU AVTC teams have finished in the top five teams for 10 years.
25+ YEARS OF PARTICIPATION The Ohio State University has been participating in AVTCs since 1990.
Source: Dr. Shawn Midlam-Mohler
AVTC - Advanced Vehicle Technology Competitions
66
Alumni Information Participation in AVTCs helps to prepare undergraduate and graduate-level students for the workforce, providing hands-on experiences that carry them through into their future careers. Employers are looking for students with these skills, leading to a 100% placement rate with above-average salaries.
Source: Dr. Shawn Midlam-Mohler
67
What is AVTC12? Provide a hands-on, real-world experience for the next generation of engineers and business leaders Focused on practical experience in: • Electrification • Autonomous Controls • Connected and Automated Vehicles AVTC12 COMPETITION
+ Powertrain and Energy Efficiency Source: Dr. Shawn Midlam-Mohler
Connected and Automated Vehicles
68
COE: Research Strengths Advanced Materials and Manufacturing • • • •
Lightweight metals and structures Materials joining Characterization ICME – integrated computational materials engineering
Aerospace and Aviation • Propulsion; flow control • Aviation; airport operations
Surface Transportation • Propulsion – fuel; electric; fuel cell; natural gas • Intelligent and autonomous transportation, smart mobility
Sensing, Simulation and Data Analytics • Electromagnetics and wireless systems • Data Analytics • Simulation and modeling
Engineering in Health • Cancer detection and imaging • Spine research • Sensors, drug delivery, etc.
COE: strategic priority areas COE: strategic priority areas
The College of Engineering strategic plan has four main research pillars: Manufacturing, Materials, Mobility and Medicine. The first three pillars are very well established and significant research centers and institutes already exist: Manufacturing centers/institutes: OMI, CDME, SIMCenter, ESL Materials centers/institutes: IMR, CEMAS, CAMM, CEM, CANPBD, FCC, ESL Mobility centers/institutes: CAR, ARC, CAS, TRC, PPC, DSL, ESL
Collaboration is the key to economic success Role of academic institutions in Primary stakeholders: local, regional, state, and federal government the economic growth of the organizations, private sector region is growing US innovation system is at the forefront of cutting-edge science, technology and innovation, through: educational system that fosters creative thinking world’s leading universities excellent research infrastructure solid venture capitalist presence, and strong support for regional innovation clusters.
Why forming industry-academia partnerships? Help industry to stay at the cutting-edge of innovation Offer the discovery process from the idea inception, through development to deployment Help faculty convert their innovation to application OSU framework Corporate Engagement Office and Technology Commercialization Office (TCO) established: 451 inventions disclosures in 2017 Industrial Liaison Office established under Office of Research Since FY14, Ohio State created 47 startup companies, bringing the active startup portfolio to 61 companies (only 12 in 2012), 89% are still active $3.5M invested in Ohio State startups has been leveraged to attract $175M of capital OSU is now 1st in invention disclosure per $$ spent among Big10 3rd nationwide in industry sponsored research
Smart city: example partnership
Smart Cities are those that have a base level of connectivity and integrated municipal services built on smart and intelligent solutions and technology Goal…to improve people’s lives
Smart Columbus Goals
Courtesy: Carla Bailo, OSU
Ohio State’s Engagement 1. Fill knowledge and skill gaps by leveraging faculty, staff and students 2. Act as a thought partner to extend work beyond the grant 3. Develop a Smart Campus strategic plan to leverage the university as a living laboratory
DRAFT Ohio State Smart Campus Framework
Mobility
Critical Components:
Energy & Sustainability
Community
Smart Campus
Education
Health Wellness
• R&D • Curriculum Development • Infrastructure • Big Data and IoT • Services • Policy and Regulation • External Engagement
Example opportunity: Engie-Axium energy partnership Energy partnership to support OSU’s sustainability and academic mission The Comprehensive Energy Management Project promises to modernize the university’s 485-building Columbus campus, create substantial academic benefits and establish a major center for energy research and technology commercialization The total value of $1.165 billion includes a $1.015 billion upfront payment to the university and a $150 million commitment to support academics in specific areas requested by students, faculty and staff during the bidding process. The proposal includes a $50 million Energy Advancement and Innovation Center for energy research and technology commercialization. hub where faculty members, students, alumni, ENGIE researchers, local entrepreneurs and industry experts work together on the next generation of smart energy systems, renewable energy and green mobility solutions within 10 years, conservation measures would improve our energy efficiency by 25 percent, reducing our carbon footprint
CAR’s expanding role in broader mobility space CAR – a recognized leader in automotive, transportation, energy and mobility research CAR had its strongest research year to date with research expenditures reaching $14M Develop and expand focused and intentional relationships with key partners aimed at the areas of CAR’s specific strengths: electrification advanced powertrain autonomous vehicles and safety CAR: FTA LoNo component testing center for Lo and No emission transit buses CAR will continue in its leadership role for all OSU’s mobility based initiatives in the future
CAR/COE news Maryn Weimer appointed Mobility Director for the College of Engineering advocate for mobility initiatives within CoE and amongst strategic business partners work to align centers, departments and Pis on mobility-related research and educational opportunities develop and implement strategy for increasing mobility-related research expenditures in alignment with the university and CoE strategic research plans Marcello Canova appointed CAR Associate Director for Research and Education focus on new federal relationships and how CAR can expand partnerships with industry, federal research, DOE, DOT, NASA, NSF and National labs in particular ensure alignment, collaboration and seek opportunities with internal and external partners to create solid cohesive relationships Lead graduate specialization in Automotive Engineering and expand specialized short course offerings in mobility and transportation
Thank you!
BREAK
ELECTRIFICATION RESEARCH PROJECTS Giorgio Rizzoni Director Center for Automotive Research
A History of Electrification Projects
1994: Formula Lightning
2000: GATE Program
1997: FutureCAR
2002: Buckeye Bullet
U.S.-China Clean Energy Research Center (CERC) Truck Research Utilizing Collaborative Knowledge (TRUCK) Program
Program Overview Vincent Freyermuth U.S. CERC TRUCK Consortium Deputy Director Argonne National Laboratory December 7th, 2016
CERC TRUCK Topic areas 1
Advanced Internal Combustion Engine/Powertrain System
2
Energy Management (System Level Efficiency Improvements)
3
Hybrid Electric Powertrain
4
Other Key Truck Technologies
5
Applied Research, Test, and Evaluation
Overall goal: Demonstrate 50% freight efficiency improvement over a 2016 baseline 85
CERC TRUCK Proposed Budget Split (Federal Funding) Topic 4
Topic 5
Consortium Management
Topic 3
Topic 2
Topic 1
DOE Funding: $12.5M over 5 years $12.5M cost share by project partners 86
TOPIC AREA 3: HYBRID ELECTRIC POWERTRAIN US-CHINA CERC TRUCK FACULTY: GIORGIO RIZZONI, MARCELLO CANOVA RESEARCH STAFF: QADEER AHMED, MA MATILDE D’ARPINO PHD STUDENTS: DANNY FREUDIGER, TONG ZHAO VISITING SCHOLAR: MINGJEI ZHAO
10/05/2018
ELECTRIFIED POWERTRAIN ARCHITECTURES Electric Truck with Range Extending Engine
DESIGN SPACE EXPLORATION FRAMEWORK
Components Architectures
Control (DP)
Energy Consumption Design Space
ELECTRIFIED POWERTRAIN ARCHITECTURES DP Analysis for Delivery Truck DP model of REHEV • Vehicle should follow the speed trajectory for a given driving cycle • Since the speed trajectory is given, a backward simulation model of the REHEV is implemented. • Optimal control strategy is found using Dynamic Programming • The goal is to compute optimal control strategies of different REHEV architectures and component sizes • Driving cycle: Columbus PnD (~1 hour)
REHEV Model states • • • •
State Of Charge Selected gear Engine on/off Torque converter lockup
Control inputs for the REHEV • • • •
Power split request Requested gear Requested engine on/off Requested torque converter lockup
GAUSSIAN PROCESS • Finding global optimal point(s) by minimizing a single objective function: Percentage of solutions that dominates the selected solution [0,1]
Q. Ahmed, D. Jung, X. Zhang, G. Rizzoni, “Mission-based Design Space Exploration for Powertrain Electrification of Series Plugin Hybrid Electric Delivery Truck”, American Control Conference 2018.
DESIGN SPACE EXPLORATION RESULTS COMPONENT SIZES
NREL Baltimore Parcel Delivery driving cycle
In-wheel
Direct drive
NREL PG&E Utility truck driving cycle
NREL PG&E Utility truck driving cycle
NREL Baltimore Parcel Delivery driving cycle
ENERGY STORAGE SYSTEM FOR MD/HD APPLICATIONS •
Develop novel, modular pack design for range-extender Class 6 HEV: •
•
Pack will integrate Li-ion modules of multiple chemistries; •
•
Energy and power capabilities can be configured “on-site” by the fleet manager based upon environmental conditions, route-specific requirements, and look-ahead capabilities;
This feature will require an active energy management strategy to optimize utilization of multi-chemistry modules to meet demand and reduce cooling requirements and aging;
Design a prototype BMS with fleet-level management and look-ahead capabilities. Battery power request Pb(t)
Powertrain Architecture Design Space Exploration
Flexible and Modular Battery Pack Design Considering: • Multi-chemistry pack • Vehicle specific mission • Fleet-level management • eHorizon information
Combination of energy and power cells
Battery pack macroscopic properties
VIRTUAL BATTERY PACK DESIGN PROCESS Powertrain Design Space Exploration • Output: Defining size of the battery pack and power requirements • Input: energy density and power limitations
Module chemistry A
Module chemistry D
Module chemistry B
Module chemistry C
Module chemistry E
Component level analysis (Cell/module model) • chemistry, weight, mass, • voltage, current, capacity, power limitation, • temperature, • aging properties
Battery design space exploration • Optimization problem solved with Particle Swarm techniques (PSO) or similar technique • Route information • Power profile
System level analysis and control • Hardware architecture • Energy management • Thermal management
VIRTUAL BATTERY PACK DESIGN PROCESS
Constraints • Max system mass • Max system volume • Power profile • Max power • Pack energy • Lifetime analysis horizon
Design Parameters • Module parameters • Voltage, current, capacity, chemistry, weight, mass, power limitation, temperature range
• Pack architecture • # of modules in series and parallel • Module configuration
• TMS • Air cooled, water cooled, convection, etc.
• BMS • Power split • Aging, SOC, temperature, etc.
Cost Functions • Total system cost • Modules, electronics, TMS, BMS, ….
• Module aging • Portion of used life of module (SOH) • Cell/module temperature
• Battery system weight
BATTERY CELL/MODULE MODEL FOR THE SYSTEM LEVEL ANALYSIS OSU is developing a modular battery pack model from database of commercially available battery technology OSU Cylindrical Cell Database •
84 total cells
•
Capacity range: 0.84 – 5.5 Ah
•
Power range: 6.22 – 165 W
•
Energy range: 3.11 – 20.35 Wh
•
Chemistries: LFP, NMC, NCA, LMO, LCO
đ?‘‰đ?‘‰ đ?‘Ąđ?‘Ą = đ?‘‰đ?‘‰đ?‘‚đ?‘‚đ?‘‚đ?‘‚ − đ?‘…đ?‘…0 đ??źđ??ź(đ?‘Ąđ?‘Ą)
đ?‘†đ?‘†đ?‘†đ?‘†đ?‘†đ?‘† = −
1
đ??śđ??śđ?‘›đ?‘›đ?‘›đ?‘›đ?‘›đ?‘›
đ?‘Ąđ?‘Ą
ďż˝ đ??źđ??ź đ?‘Ąđ?‘Ą đ?‘‘đ?‘‘đ?‘‘đ?‘‘ đ?‘Ąđ?‘Ą0
Using information from cell database, model parameters become independent of experimental data! đ?‘‰đ?‘‰đ?‘‚đ?‘‚đ?‘‚đ?‘‚ = đ?‘“đ?‘“(đ?‘†đ?‘†đ?‘†đ?‘†đ?‘†đ?‘†, đ??śđ??śđ??śđ??śđ??śđ??śđ??ś) đ?‘…đ?‘…0 = đ?‘“đ?‘“(đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰, đ??şđ??şđ??şđ??şđ??şđ??ş)
đ??śđ??śđ?‘›đ?‘›đ?‘›đ?‘›đ?‘›đ?‘› = đ?‘“đ?‘“ đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰, đ?‘‰đ?‘‰đ?‘›đ?‘›đ?‘›đ?‘›đ?‘›đ?‘›
Model parameters
Model has flexibility to calculate heat generation, include multiple chemistries, and include TMS model.
CONTACT car.osu.edu
Giorgio Rizzoni Professor, Director CAR Rizzoni.1@osu.edu Marcello Canova Associate Professor Canova.1@osu.edu
NASA ULI Electric Propulsion: Challenges and Opportunities Advanced Aerospace Battery R&D Matilde D’Arpino, PhD Senior Research Associate Center for Automotive Research
ULI Electric Propulsion: Challenges and Opportunities July 2017 – June 2022 Turbo electric system is one of the valuable architecture to bring a measurable CO₂ reduction impact on large commercial aircraft regional, single aisle and twin aisle. Felder, J.L., NASA Electric Propulsion System Studies, Report No. GRC-E-DAA-TN28410, 2015, Available at www.nasa.gov.
Generators
Electric smart motor
Two turbo-generators to supply electrical power to distributed motors. Eight motors with embedded power electronics Integrated Thermal Management Batteries are charged on the ground and kept charged by the generators during cruise. Thermal management is separate.
Challenge 1 System Integration Success Criteria: Vehicle energy and CO2 >20% improvement over existing solutions Challenge 2 Ultra-high Power Density Electric Machine and Power Electronics Success Criteria: Electric Machines > 14 kW/kg, Power Electronics > 25 kW/kg, Efficiency > 99%, Voltage >2kV without partial discharge Challenge 3 Energy Storage Success Criteria: Power density and reliability (desired 450 Wh/kg) Challenge 4 Advanced Control of Onboard Electrical Power Systems Success Criteria: system remaining stable at 20% voltage sag and 200% step load change Challenge 5 Research Infrastructure for More Electric Aircrafts Success Criteria: sub-system and component prototyping and testing tests at elevation, 2 kV, 1 MW, 20,000 RPM drive tests Though it is not listed as a separate challenge, research on thermal design and thermal management is integrated in every aspect of the project
Team Members and Roles in the Project Power Electronics
Electric Machine
Individual cell thermal analysis
Component Integration
Energy Storage
Temperature and Pressure Constraints
Integrate TMS and PGDS
Structural Machine Integration
Architecture Layout Performance Maps Power Densities
System Integration
• The interactions and impact each system has on each other • Total mass build up for each system and its effect on the aircraft • Aircraft’s volume availability • Redundancy strategies for each system architecture
Thermal Management PGDS – Power Generation and Distribution System
GT – HEAT NPSS Simulation Infrastructure The ULI project is using a Turbo -Hybrid Electric Propulsion system and is represented by GTHEAT’s power split hybrid architecture • Assuming “plug-in” hybrid mode of operation • Assessments assume ‘full scale’ performance • Numbers are still preliminary and will change as technology development ShL
Power Split hybrid Architecture
ShH InEngStart InEng
Cmp L
FusEng
B3
Brn
Cmp H
D22
OverBrd2
OverBrd9 D35
B13a
Inter-stage Bleed
B41
MotorCable
Inverter Motor
InFanStart InEng
ShF CmpF an
x Number of Fans D15
NozSec
D45
B45
TrbL
NozSecEnd
B41
D46
TrbG ShG
B14a
Batt
OverBrd7
TrbH
DCTrans
SupplyCable Bus
Generator
Generator Cable
D5
NozPri
NozPri End
Aerospace Battery R&D Design of a high-performance, multifunctional, smart structure-battery module to enable safe on-board, system-level distributed energy storage to power electric drive(s), comprised of structure-battery pack hardware and an advanced battery management system.
Cylindrical cells 240-270 Wh/kg
Pouch cells 300-500 Wh/kg
Battery Cells Requirements: • Assessment of high energy density Li-ion cell technologies: Wh/kg - Wh/L • Power density: kW/kg • Charging & discharging characteristics • Battery depth of discharge vs # of cycles • Permissible steady-state and transient temperature thresholds • Heat generation characterization • Cell level safety characterization
Pouch cells 170-260 Wh/kg
Battery Pack Requirements: • Electro-mechanical design of battery packs with elevate cell numbers • Modular architecture • Battery management • Thermal management • Safety and reliability @ system level HV Electrical System Requirements: • Max/min bus voltage • HV distribution (2kV) • Battery connectors/contactors availability
Battery Pack Design Process Design of a high-performance, multifunctional, smart structure-battery module to enable safe on-board, system-level distributed energy storage to power electric drive(s), comprised of structure-battery pack hardware and an advanced battery management system. OSU
GT, OSU, CWRU
Cell Experimental Characterization (Electrical, thermal)
Initialization step: Target energy density (pack level) 150-400 Wh/kg
OSU
GT, OSU, CWRU
Pack requirements: Volume, Mass, Energy, DC link volta ge (max, min, nom)
GT, OSU Virtual pack model (cell-to-pack)
GT, OSU Aircraft mission profile estimation
Performance Verification (pack-to-cell) Electrochemical-thermal coupled battery model
OSU, CWRU
Mechanical structure definition Task completed Work in progress Next steps
CWRU
Cell Experimental Characterization (Mechanical, safety)
OSU TMS and BMS specifications
Energy Density @ 23⁰C – Sample Variation The energy density was calculated through experimental testing for each cell model across 4-5 samples at multiple discharge rates. The error bars indicate the sample variation. ° C
Energy Density (Multi Rate) at 23 300
Dis Rate: C/3
Dis Rate: C
280 Dis Rate: 2C
Cell 1 shows the best performance with higher energy density.
260
240
220
Cell 6 has the highest capacity (12Ah) of all cells. Energy density is comparable to Cell 1 at low discharge rates.
200
Energy Density (Wh/kg)
Cell 2 shows minimal sample variation and has low energy density variation with the C-rate (up to 20A).
Dis Rate: Cmax (10A)
Dis Rate: 20A
The remaining cells show high capacity variation with C-rate, and also yield very low energy density at higher discharge rates
180
160
140
120
100 Efest
Cell 1
LGHG2
Cell 2
LGMJ1
Cell 3
Cell Model
Panasonic
Cell 4
Sanyo
Cell 5
Kokam
Cell 6
OSU DATA Cylindrical Cells
Pouch Cell
Preliminary Battery Pack Design The battery pack is a connection of several cells in series (đ?’Žđ?’Žđ?’†đ?’† ) and parallel (đ?’?đ?’?đ?’†đ?’† ) • đ?‘šđ?‘šđ?‘’đ?‘’ function of: • DC link voltage limits (1.7đ?‘˜đ?‘˜đ?‘˜đ?‘˜ − 2đ?‘˜đ?‘˜đ?‘˜đ?‘˜) • Cell voltage range • đ?‘›đ?‘›đ?‘’đ?‘’ function of: • Total mission energy đ??¸đ??¸đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘? = âˆŤ đ?‘ƒđ?‘ƒđ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘? đ?‘‘đ?‘‘đ?‘‘đ?‘‘ đ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘š • Peak power request đ?‘ƒđ?‘ƒđ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘? • Operating SoC range Δđ?‘†đ?‘†đ?‘†đ?‘†đ??śđ??śđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Ž = đ?‘†đ?‘†đ?‘†đ?‘†đ?‘†đ?‘† đ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘š − đ?‘†đ?‘†đ?‘†đ?‘†đ?‘†đ?‘† đ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘š • Cell temperature and thermal requirements Cylindrical
Pouch
Capacity @1C,23â °C [Ah]
3.25
10.87
10.24
Energy Density @1C, 23â °C [Wh/kg]
237
224
336
Experimentally Tested? Δđ?‘†đ?‘†đ?‘†đ?‘†đ??śđ??śđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Ž đ?‘šđ?‘šđ?‘’đ?‘’ đ?‘›đ?‘›đ?‘’đ?‘’ - Total Cell Number Heat Generation (kW) (Peak/Avg) Efficiency [%] (Min/Average) Pack Weight (Tons)
(10-95)% 176,472 51,816 54,752 (516s x 342p) (508s x 102p) (472s x 116p) 672 / 66
438 / 41
330 / 24
88 / 97
92 / 98
94 / 98
8.39
8.88
5.91
= meVcell ne I cell
Cruise BR=20%
đ?‘‡đ?‘‡đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?
đ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘š & đ?‘Łđ?‘Łđ?‘Łđ?‘Łđ?‘Łđ?‘Łđ?‘Łđ?‘Łđ?‘Łđ?‘Łđ?‘Łđ?‘Ł Landing BR=0%
30
20
10
0 0
Characterization in progress
Yes
= me ne Pcell
Climb BR=30%
Altitude (k ft)
Format
đ?‘†đ?‘†đ?‘†đ?‘†đ?‘†đ?‘†đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?
Ppack = V pack I pack
đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘? đ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘š
Cell 7 Li-Si
Cell 6
đ?‘‰đ?‘‰đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘? đ??źđ??źđ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?
��������
10
20
30
40
50
60
70
80
90
20 Total Power
15
Power (MW)
Cell 1
Battery pack model
đ?‘ƒđ?‘ƒđ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?
Battery Power
10
5
0 0
10
20
30
40
Time (min)
50
60
70
80
90
Summary and Next Steps Battery cell analysis • High energy density cells have been selected (250Wh/kg and 350 Wh/kg) • Next generation cell availability is limited and cost prohibitive • Characterization and model development is undergoing considering temperature and pressure effects Next steps: • define the protocol of the aging campaign • charging performance characterization System-level battery pack design • Challenges and constraints have been defined Next steps: • Architecture definition for a safe, reliable, and high voltage pack operation • Weight estimation including electrical, mechanical, and TMS components • BMS for high voltage systems
System-level analysis in collaboration with Georgia Tech • Power profiles have been developed by Georgia Tech • Preliminary battery packs were designed using the most promising cell technologies • Experimental verification on the mission power profile are undergoing Next steps: • define optimal power split control including high fidelity battery model • Cost analysis
CONTACTS car.osu.edu
Marcello Canova, PhD Associate Professor canova.1@osu.edu
Matilde D’Arpino, PhD Senior Research Associate darpino.2@osu.edu
10 MW RING MOTOR OSU-NNX14AL87A CODRIN-GRUIE (CG) CANTEMIR RESEARCH SCIENTIST CENTER FOR AUTOMOTIVE RESEARCH
This work was sponsored by NASA under the hybrid gas / electric propulsion subproject of the advanced air transport technology project, previously known as the fundamental aeronautics program fixed wing project. The purpose of this project is to significantly reduce the thrust specific fuel/energy consumption.
TARGET: CFM-56 The target is a 60 percent reduction relative to a baseline Boeing 737-800 aircraft with CFM56-7B engines in the 2030 to 2035 time frame.
WHY US?
• The study suggests 13 MW at 5400 rpm (max N1) for a total weight under 700 kg (1540 lbs). • This is already 11.2 hp / lbs some 40% better than required • However, there are 2-3 major issues which were revealed only towards the end of the study
PROJECT GOALS
• Direct driving of the LP shaft with no gears 10 MW continuously at 5000 rpm (20000 Nm continuous torque) 8 hp/lb
• No permanent magnets An induction motor will be way more forgiving in case of failure while flying
• No nacelle distortion
HOW? By marrying 3 new technologies in the same machine with the accent on fabrication and integration while optimization has only a marginal role
•Ring VCSWC or Variable Cross-Section Wet Coils (2 new technologies) •Cooling •Efficiency •Power Density
•Distributed Power Electronic (new technology) •Cooling •Power Level •Control
VARIABLE CROSS-SECTION TECHNOLOGY PATENT PENDING
• Ring Motor • Ring Coils • Reversed construction
VCS UNFOLDED
Just for the sake of facilitating intuition, the coil depicted is only formed in the first slot (with 4 turns) and unformed for the remaining 4 turns (which should fit in the adjacent slot). As shown, in order to form the coil, the winding process commences in the middle. Technologically the conductor is no longer of a wire type but moreover is a ribbon with some material removed for the portions of the coil located in the slot (it can be water or laser cut from a sheet). As visually presented, the last turns have a higher length outside of the slot obviously the increased cross section has subsequently a major impact in increasing the overall efficiency. In this specific design, the total stator resistance can be decreased 60% over conventional coils.
VCSWC AT ITS BEST
INDEPENDENTLY CONTROLLED COILS IMPLEMENTATION IN THE MID-BOX STRUCTURE
14 MW ELECTRIC BOOST 25 KW/KG
Grey =unmodified parts
HOW WE BUILT THE FIRST DEMONSTRATOR
TODAY APPLE TO APPLE TRACTION MOTORS
350 kW 11000 Nm 801 lbs
245 kW 7000 Nm 2130 lbs.
TODAY IN THE WORKS
10 KW/KG CONTINOUS AIRCRAFT GRADE 6 phases (asymmetric) TUNED INDUCTION (no PMs, no Cu) 1100 kW/103 kg or 1500 hp/227 lbs • • • • •
+3000 kW peak 5000 rpm 0.96% cold 2100-2400 Nm CONTINOUS 10 kW/kg CONTINOUS
World record held by SIEMENS with 260 kW/50 kg or 5.2 kW/kg
ONE STEP AT A TIME – WATER FIRST SPONSORS ARE WELCOME Testing on water is slightly more demanding than testing in air, however it will be way safer. Setting a record may be a low hanging fruit Needs only a battery, Anyone?
Actual record held by Jaguar 89mph (not sanctioned)
NEXT MOTORS
• 2 x 3-4 MW 3000 rpm / 15 kW/kg for STARC-ABL program • It would direct drive the tailcone thruster
Favorite Quote
“ The best way to predict the future is to invent it”
Henri-Marie COANDA
ARPA-E NEXTCAR Giorgio Rizzoni Director Center for Automotive Research
Fuel economy optimization with dynamic skip fire in a connected and automated vehicle An ARPA-E NEXTCAR program led by The Ohio State University with partners Delphi, Tula Technology and TRC Inc.
Advanced Powertrain Technologies
Connected and Automated Vehicle (CAV) Technologies
PROJECT OVERVIEW Objective: • • •
Develop an integrated control system to achieve 20% FE improvement by combining: CAV and look-ahead technology Mild hybridization Advanced cylinder deactivation
127
TARGET FUEL ECONOMY PERFORMANCE
20%
Powertrain: 9%
CAV and Look-Ahead Technologies: 7%
Intelligent Control: 4%
DSF(6.5%) + 48V mild Hybrid(2.5%)
V2V & V2X sensors provide surrounding environment and look-ahead information
Synergistic coupling between CAV information with powertrain control 128
POWERTRAIN OVERVIEW Configuration: • The prototype vehicle has a 1.8L Turbocharged GDI engine with 48V mild hybridization in P0 configuration (belt coupling between engine and electric motor), and an advanced cylinder deactivation strategy. Dynamic Skip Fire (DSF): • Advanced cylinder deactivation technology in which torque production is continuously modulated via selectively engaging or disengaging engine cylinders, rather than by throttling.
*Wilcutts, M., Switkes, J., Shost, M. and Tripathi, A., "Design and Benefits of Dynamic Skip Fire Strategies for Cylinder Deactivated Engines," SAE Paper 2013-010359, 2013.
129
ARPA-E NEXTCAR POWERTRAIN GROUP: SHRESHTA RAJAKUMAR DESHPANDE SHOBHIT GUPTA PUNIT TULPULE, PHD MARCELLO CANOVA, PHD GIORGIO RIZZONI, PHD
POWERTRAIN OVERVIEW Configuration: • The prototype vehicle has a 1.8L Gasoline Direct Injection Engine equipped with 48V mild hybridization in P0 configuration (belt coupling between engine and electric motor); Boosting is achieved through an exhaust gas turbocharger as well as an electric supercharger • The schematic and the low frequency quasi-static model of the P0 hybrid configuration, developed the PT team has been shown in the following figure;
Dynamic Skip Fire (DSF)*: • General Motors, Delphi Technologies and TULA have developed a cylinder deactivation technology. • The torque production is managed in response to the driver command, via selectively engaging or disengaging torque production from engine cylinders rather than by throttling. *Wilcutts, M., Switkes, J., Shost, M. and Tripathi, A., "Design and Benefits of Dynamic Skip Fire Strategies for Cylinder Deactivated Engines," SAE Paper 2013-01-0359, 131 2013.
ROUTES TESTED • There are 2 routes for which the various simulation and optimization studies are performed: • Route 15 • Route 19
• Route 15 is an urban route and has the following features: • Stop sign/s: 1 • Traffic lights: 14 • Length: ~7.5 km
• Route 19 is a mixed route and has the following features: • Stop sign/s: 1 • Traffic lights: 5 • Length: ~7 km 132
INTELLIGENT DRIVER MODEL : BASELINE • The Intelligent Driver Model (IDM) is a deterministic car-following model for one-lane situations: • In such models, the decision of the driver to accelerate or to brake depends only on his/her own speed, and on the position and speed of the "leading vehicle" immediately ahead. • Model parameters describe the driving style, i.e. the “aggressivenessâ€? of the simulated driver.
• The IDM model equations read as follows: Standard Formulation
Modified Formulation đ??ąđ??ąđ??žđ??žđ??žđ??žđ??žđ??ž
2  δ  *   v  s (v, ∆v )   dv  − = a 1 −    v  s dt  ďŁ 0 ďŁ ďŁ¸    Acceleration term: expresses the tendency to accelerate from an initial condition to a "desired speed" v0 (speed limit) in absence of traffic.
Braking term: expresses the tendency to brake, based on comparison between a "desired minimum gap" s*, and the actual gap s to the preceding vehicle:  2 δ  *   v   dv  −  s (v, ∆v )   = a 1−  dt
• • •
EGO
  
v  ďŁ 0
 ďŁ
s
    
Traffic and its impact on driver decisions not modeled. Not ideal for extension to case of traffic lights and stop signs along the route. SPaT information cannot be included.
đ??ąđ??ąđ??žđ??žđ??žđ??žđ??žđ??ž
EGO
đ??ąđ??ąđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľ
đ??Żđ??Żđ??žđ??žđ??žđ??žđ??žđ??ž
đ??Żđ??Żđ??žđ??žđ??žđ??žđ??žđ??ž
LEADER đ??Źđ??Ź đ??ąđ??ąđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľ
đ??Źđ??Ź
đ??ąđ??ąđ??žđ??žđ??žđ??žđ??žđ??ž
EGO
đ??Żđ??Żđ??žđ??žđ??žđ??žđ??žđ??ž
đ??ąđ??ąđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľ đ??Źđ??Ź
đ??Żđ??Żđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľ
đ??Żđ??Żđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľ = đ?&#x;Žđ?&#x;Ž
Car Following Braking term: đ?‘Łđ?‘Ł 2 đ?‘‘đ?‘‘đ?‘‘đ?‘‘ 2đ?‘ đ?‘ =− đ?‘‘đ?‘‘đ?‘‘đ?‘‘ đ?‘?đ?‘? Freeway Driving Acceleration term:
2
đ?‘‘đ?‘‘đ?‘‘đ?‘‘ = đ?‘Žđ?‘Ž 1 − đ?‘‘đ?‘‘đ?‘‘đ?‘‘ Braking term: đ?‘‘đ?‘‘đ?‘‘đ?‘‘ = −đ?‘?đ?‘? 1 − đ?‘‘đ?‘‘đ?‘‘đ?‘‘
đ?‘Łđ?‘Ł đ?‘Łđ?‘Ł0
Safe Gap at Stop
đ?‘Łđ?‘Ł0 đ?‘Łđ?‘Ł
��
��
SPaT Information 0 – GREEN LIGHT 1 – RED LIGHT
LEADER
đ??Żđ??Żđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľđ??Ľ = đ?&#x;Žđ?&#x;Ž
v0 - Desired velocity (Speed Limit), T - Safe time headway, a - Maximum acceleration, b - Maximum deceleration, δ - Driver Aggressiveness, s0 - Jam distance, s – Bumper to bumper distance gap Treiber, M., Hennecke, A., & Helbing, D., “Congested traffic states in empirical observations and microscopic simulations�. Physical review E, 62(2), 2000. Kesting, A., Treiber, M., & Helbing, D., “Enhanced intelligent driver model to access the impact of driving strategies on traffic capacity�. Philosophical Transactions of the Royal Society of London A: Mathematical, Physical and Engineering Sciences, 368(1928), 2010.
INTELLIGENT DRIVER MODEL: INTEGRATION WITH FORWARD MODEL Model Structure: • The block diagram below represents the sub-parts of the baseline vehicle model and their interaction with each other:
�� ������
đ?‘ đ?‘ đ?‘Łđ?‘Łđ?‘Łđ?‘Łđ?‘Ł
(presently)
IDM
������ �������
đ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Žđ?‘Ž
Conventional Driver
������� (feedback)
feedback from Plant
. . . . .
đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?
Simplified Delphi ECU
đ?‘‘đ?‘‘đ?‘‘đ?‘‘đ?‘‘đ?‘‘ đ?‘‡đ?‘‡đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’ đ?‘‘đ?‘‘đ?‘‘đ?‘‘đ?‘‘đ?‘‘ đ?‘‡đ?‘‡đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?đ?‘?
â‹Ž
Plant
other outputs (������� , ������ and so on)
134
INTELLIGENT DRIVER MODEL : RESULTS Results : • A full-factorial Design of Experiment (DOE) was performed to analyze the impact of the IDM model parameters on the travel time (TT) and fuel consumption (FC) for Route 19 and Route 15; • To compare the fuel consumption and travel time of a real-world driver, IDM was calibrated with driving data and the FC, TT values were compared with the DOE data as shown below: Route 19
Route 15
• It is seen that the the points obtained from the calibration with the driving data are closer to DOE curve. • From this analysis, an averaged driver behavior can be extracted which can further be used to benchmark the fuel economy for connected and automated driving. 135
Vehicle velocity and torque split optimization using dynamic programming
VD+PT OPTIMIZATION : OVERVIEW
Simulator
Optimizer
Test Vehicle 137
DYNAMIC PROGRAMMING: COST FUNCTION AND SAMPLE SOLUTIONS • The objective function used in the optimization includes the fuel consumed over the route, and a weighted penalty on travel time: đ?‘ đ?‘ đ?‘ đ?‘ Δđ?‘ đ?‘ đ??˝đ??˝ = min ďż˝ đ?›žđ?›ž. đ?‘šđ?‘šĚ‡ đ?‘“đ?‘“ đ?‘ đ?‘ đ?‘–đ?‘– + 1 − đ?›žđ?›ž â‹… đ?‘˘đ?‘˘ đ?‘‰đ?‘‰ďż˝đ?‘Łđ?‘Łđ?‘Łđ?‘Łđ?‘Ł đ?‘ đ?‘ đ?‘–đ?‘– đ?‘ đ?‘ đ?‘–đ?‘– =đ?‘ đ?‘ 0
• A few examples of the DP solution are computed w.r.t. Route 19:
138
COMPARISON OF OPTIMIZATION RESULTS WITH BASELINE MODEL Block Diagram of Baseline Model:
Block Diagram of Model with Integrated VD+PT Optimization and DSF:
139
COMPARISON OF OPTIMIZATION RESULTS WITH BASELINE MODEL • The forward-looking VD+PT model integrated with DP (DPIFM) and integrated with DSFDP (DSFDPIFM) was compared against the baseline model; • The baseline model (which includes the IDM) was run for different parameters, and the average behavior was considered. Real driver behavior obtained from IDM calibration was also highlighted in these results. • The following figure shows the comparison of the optimization results obtained with variable step size (5m – 25m) and the baseline over Route 19 and Route 15;
VEHICLE TESTING
VEHICLE TESTING Results:
Case
Travel Time [s]
Fuel Consumed [g]
Normal Driver
100.4
99.5
NEXTCAR Vehicle
108.3
84.1
For 7.8% increase in travel time, fuel consumption reduces by 15.1%!
ARPA-E NEXTCAR AUTOMATED DRIVING LAB GROUP: OZGENUR KAVAS SANTHOSH TAMILARASAN LEVENT GUVENC, PHD
CONNECTED VEHICLE FUEL ECONOMY EVALUATION ROUTE AND TEST MATRIX DETERMINATION
CV-BASED DETERMINISTIC CONTROLS
Dynamic Speed Harmonization
Eco-Cruise with DP speed
CV-Based Deterministic Control gives a recommended speed profile to the vehicle depending on whether there is a car in front of the ego vehicle, or an upcoming queue in the next mile, or a traffic light and STOP sign within the DSRC communication range.
HIL SIMULATOR AND IN-VEHICLE TESTING 3 stages of CAV control for energy management
dSPACE SCALEXIO
Simulink controls, Simulink powertrain model, Carsim RT with Traffic and Sensors vehicle dynamics and Level 2 autonomous driving simulation environment, SUMO traffic, real modems (OBU, RSU), real microautobox controls
Validated model running in Simulink-CarSim co-simulation with SUMO traffic objects
FUEL ECONOMY RESULTS Different routes with different levels of traffic from SUMO
Fuel economy studies with Monte Carlo simulations • • • •
Baseline Intelligent Driver Model Addition of the DP and DSF Addition of the Greenwave >20% fuel economy
ARPA-E NEXTCAR MACHINE LEARNING GROUP REINFORCEMENT LEARNING FOR CONNECTED AUTONOMOUS CARS ABHISHEK GUPTA, PHD GAURAV TENDOLKAR JAYANTH REGATTI (NOW AT APTIV) HAO CHEN JIANZONG PI
Simulator development: CATS
Adaptive routing for travel time minimization
Adaptive routing for min fuel consumption
Ongoing research: Learning how to drive
During learning
After learning is complete
FACILITY UPDATES David Cooke Assistant Director of Research Operations Center for Automotive Research
CAR 1ST FLOOR AND HIGH BAY Laboratory / Facility Upgrades In Progress CAR High Bay / HD Dyno
CAR Main Building 1st Floor
CAR 2ND FLOOR OFFICES
• Open floor plan functional area teams • • • •
Diagnostics Energy Storage HEV Powertrain
• Dedicated team rooms • NEXTCAR • CERC TRUCK
• New flex meeting space / small conference room
FACILITIES PROJECTS IN PROGRESS Lab Expansions Supporting Electrification • Advanced Powertrain Laboratory • High Power Traction Drive Laboratory • Energy Storage Systems Laboratory
Other Projects of Note: • Driver In The Loop Laboratory • Cybersecurity Laboratory • 2nd Floor Office Reconfiguration • EcoCar Office Complex • Lobby Renovation • Distance Learning Studio Upgrades • Student Project Machine Shop
THANKS APTIV!!!
Equipment Donation Including: •
Coin Cell Battery Cycler
•
Resistance Spot Welder with XY Table
•
Heat Treating Ovens
•
Large 600° Oven
•
Laboratory Water Chiller
•
Optical Comparator
•
Shop Flooring
•
Misc. Test Electronics
•
Any More!!!!!
STUDENT PROJECTS MACHINE SHOP
FUTURE ADVANCED POWERTRAIN LAB
Project: Complete Overhaul Of Current 200 HP DC Dyno Cell • Electric Machine Focused Test Stand • Considering Power of 200 – 400 kW • Target Speed 15,000 RPM • Support Equipment Including • • •
DC Power Supply / Battery Emulator Liquid Cooling Supply for Components Dedicated Power Analyzer
• Projects In Support of Research, Student Projects, and Engineering Services
HIGH POWER TRACTION DRIVE LABORATORY Announcing a new laboratory space, dedicated to the development and validation of electrification powertrain system components including drives, motors, and auxiliaries
Current Laboratory Equipment Available: • 30 kVA Variable Auto-transformer with rectifier • 300 kVA Variable Auto-transformer • (2) 1.5 MW Continuous Power Industrial Inverters • 1MW Traction Inverter • Ability to test up to 2MW machines Back to Back
Facility Enhancements Including: • Large Bedplate For Electric Machine Testing • New Dedicated 400A, 480V 3 Phase Power Service • Power Supplemented by Cummins Diesel Generator As needed • Completely Blasted / Epoxy Coated Floor Floor
ENERGY STORAGE SYSTEMS LAB Prashanth Ramesh Senior Design Engineer Center for Automotive Research
ENERGY STORAGE SYSTEMS FOR ELECTRIFIED VEHICLES Team Overview and Key Expertise: •
Over 10 years experience in experimental characterization, modeling, estimation and control of electrochemical energy storage systems for electrified powertrains;
•
Extensive facilities for electrochemical and thermal characterization of Liion batteries (from half-cell to full packs) and BMS prototyping tools;
•
Interface with CEMAS and Nanotech West for advanced microscopy and characterization techniques, and cell prototyping facilities;
•
Demonstrative projects with OSU Motorsports (EcoCAR, Bullet, Current).
Application Areas: •
Reduced-order electrochemical models for fast simulation;
•
Advanced model-based SOC/SOH estimation;
•
Thermal modeling and characterization of large-format cells;
•
Advanced thermal management and waste heat recovery;
•
BMS development and prototyping;
•
Battery prognosis, life estimation and life extension.
BATTERY TESTING FACILITIES AT CAR Battery Cycling, Aging, and Characterization Laboratory at CAR The testing facilities at CAR support research and development activities in electrochemical energy storage systems, ranging from coin cells to full-scale battery packs for electric vehicles: Cell, Module and Pack Testing and Characterization: • Cell cyclers, ~15 channels (<8V, up to 400A) • Module cyclers, 10 channels (up to 60V, 1200A) • Large pack cyclers, 2 channels (900V, 500A) • Environmental Chambers (5) Materials Characterization and Coin Cell Prototyping: • MBraun LABstar Glovebox Workstation • Arbin coin cell cycler (16 channels) • Branson Ultrasonic Cleaner and VWR Vacuum Oven • MTI Precision Disc Cutter, Compact Hydraulic Crimping Machine • Electrochemical Impedance Spectroscopy (EIS) Battery System and Electric Vehicle Systems Integration: • High-performance computing • Hardware-in-the loop software development systems • Electric, plug-in and hybrid vehicle prototypes
BATTERY LAB UPGRADE AND EXPANSION â&#x20AC;˘ Current battery testing facilities are split across two buildings and multiple labs.
Battery Testing Facilities
12V Module Lab
CAR
Battery Testing Facilities CAR
60V Module Lab
High Voltage lab
*Battery Lab Cell Testing
BMS/HIL Lab
High Voltage Lab
CAR West Glove Box Lab
Over 1000 sq.ft lab space
3ft. 1.50in.
2ft. 8.62in.
4ft. 0.00in.
Module Cycler (60V) 6 Channels
Movable Test Bench with DAQ
2ft. 0.00in.
3ft. 0.00in.
3ft. 2.81in. 4ft. 0.31in.
20V High Current Rack
4ft. 3.52in. 4 cu.ft. Temp Chamber
3ft. 2.81in.
161.28cm.
36ft. 0.00in.
PC/ Control Rack
12ft. 6.00in.
4ft. 6.00in.
Storage
Storage
2ft. 11.55in.
32 cu.ft Environmental Chamber
Module Cycler (60V) 4 Channels
Movable Test Bench with DAQ
Cell Cycler (5V) 8 Channels
6ft. 0.94in.
4ft. 0.23in.
2ft. 11.47in.
2ft. 4.27in.
Liquid Cooling Test Bench
10ft. 1.76in.
Electrical Panels
Liquid Chiller
1ft. 3.09in.
25ft. 5.66in.
1ft. 0.00in.
Pack Fabrication Lab
*Battery Lab: Floor plan of a new lab space serving as a one stop location for battery testing ranging from single cell (5V) to module level (48V) systems. The lab will include extensive thermal management capabilities and will be in close proximity to the pack fabrication and BMS Lab.
BATTERY LAB UPGRADE AND EXPANSION • A plan for the addition of a new battery lab is underway with the goal to upgrade and expand current capabilities in the area of energy storage. Battery Cycling • Flexible capabilities to support testing of batteries from cell level (5V) to modules (12V, 48V systems) in a single lab. • 40-50% Increase in channel count. • Wide current range capabilities – (µA to 1000A) • Higher charge power capability to support fast charging at the cell level. • State of the art equipment with higher accuracy and precision.
Cell/Module Cycler
Spot Welder
Thermal Management • Thermal Chambers • Thermoelectric Peltier Junction • Liquid Cooling Set-up Pack Fabrication • Dedicated area for pack fabrication and teardown. • Capabilities for fabricating prototype module architecture with integrated liquid cooling. BMS and HIL Testing • Upgraded Hardware-in-the-Loop (HIL) capabilities. • Battery Management System (BMS) development and testing.
Thermal Management
ELECTRIFICATION PARTNER
Center for High Performance Power Electronics Dr. Jin Wang
Professor and Center Co-Director
Oct. 5th, 2018
Center for High Performance Power Electronics Faculty: 10 Visiting Scholars: 12 PhD Students: 44 MS Students 30 Research Expenditures:>$4.8 Million/year
Major Research Areas
168
Semiconductors Power Electronics Electric Machines and Drives High Voltage Power Systems and Smart Grid
High Performance Power Electronics Lab a multi-million dollar center geared towards advanced power electronics circuits and devices; High Voltage Laboratory a 3600 square feet facility that hosts the biggest arcs and sparks in the U.S. universities; Distributed Real Time Simulation Platform a DoE sponsored real time simulation platform for both the electrical and communication systems within a smart grid, featured in the New York Times on Dec. 30, 2010. Integrated Power Electronic Packaging Lab an integrated cleanroom lab space, with the equipment for die handling, interconnection , and module encapsulation.
168
CHPPE Faculty Members 169
Dr. Mahesh Illindala
Dr. Jiankang Wang
Dr. Longya Xu, Center Director Dr. Jin Wang
Dr. Anant Agarwal
Dr. Siddharth Rajan
Dr. Julia Zhang
Dr. Wu Lu
Dr. Ayman Fayed
Dr. Hongping Zhao
169
CHPPE Research Facilities/Equipment 170
• 30,000 RPM • 350 kVA • Vehicle and aerospace applications
170
CHPPE Research Facilities/Equipment 171
One of the Test Benches
High Power Test Area
Student Lounge
Device Evaluation Bench 171
CHPPE Research Facilities/Equipment 172
The Fully Equipped Teaching/Research Platform.
One Simulation Tower with Surrounding Benches.
The new facility hosts two real time simulation towers, eight student computers, and eight digital oscilloscopes to enable 16 students to work in the hardware in the HIL lab at a time. Also, the new facility can be accessed remotely via internet.
172
CHPPE Packaging Lab
Wirebonder
MBE
Filpchip bonder
*Nanotech West Lab: 10,000 ft2 Cleanroom Space
Reflow belt
Power Curve-Tracer
173
Pull-Shear tester
Probe Station
173
Main Federal and State Funded Projects 174
Consortium for Advanced Electric Drive Technologies (CAEDT) , Department of Energy, Vehicle Technology, CHPPE lead: Anant Agarwal, $1.5 M, 2019~2024 Electrical Propulsion: Challenges and Opportunities, A $10 M NASA sponsored project, CHPPE lead: Jin Wang, $2.4M, 2017~2022 Electrical Brushless Doubly Fed Machine and Drive Systems for Aviation Application, PI: Julia Zhang, Ohio Federal Research Network, $2.1M, 2018~2020 Ohio/GE Electrification of Aircrafts, CHPPE Lead: Jin Wang, $5M ($2.5 M from State of Ohio and $2.5 OSU cost share), 2018~2023
Main Federal and State Funded Projects 175
Intelligent Power Systems, PI: Jin Wang, Air Force Research Lab, $680k, 2016~2018 Hybrid and Turbo Electric Propulsion System, PI: Julia Zhang, State of Ohio/Federal Research Network, $1.5M, 2016~2018 Medium Voltage Drive for Next Generation High Speed High Power Electric Machines, PI: Longya Xu, Department of Energy, $2.7 M, 2016~2018; Design and Synthesis of Resilient Microgrid Systems, PI: Mahesh Illindala, Office of Naval Research Young Investigator Award, $500 k, 2016~2018
$18.3 M Federal and State Funded Projects since 2016!
Awards in 2017-2018 Academic Year Student Awards
176
Li He, etc., IEEE Will Portnoy Award for Best Paper at ECCE 2017 (Co-authored with Liming Liu and Sandeep Bala from ABB), to be received at ECCE2018, Advisor: Jin Wang OSU CHPPE, Best Presentation Award at IEEE International Future Energy Challenge, July 2018. Advisor: Jin Wang Yue Zhang, 1st Place Winner of the Student Demonstration Competition at IEEE Energy Conversion Congress & Expo (ECCE), 2017, Advisor: Jin Wang Karun Potty, Outstanding presentation award in IEEE Applied Power Electronics Conference and Exposition (APEC), 2017, Advisor: Jin Wang Chengcheng Yao, Outstanding presentation award in IEEE Applied Power Electronics Conference and Exposition (APEC), 2017, Advisor: Jin Wang
22 students awards in leading power electronics conferences since 2010.
Faculty Awards
Longya Xu, IEEE Nicola Tesla Award, 2018. Jin Wang, Harrison Faculty Award for Excellence in Engineering Education, 2017.
CHPPE Sponsors
177
178
Thank You.
STUDENT MOTORSPORTS FACILITY An experiential automotive laboratory
By providing students hands-on experiences through motorsports teams and research opportunities, Ohio Stateâ&#x20AC;&#x2122;s Center for Automotive Research has created a uniquely integrated environment to accelerate pursuit of a career in the mobility industry.
First used as a student projects facility in 1997, the CAR Motorsports Garage is home to 7 student motorsports teams
Supermileage Team
Baja Buckeyes
Underwater Robotics
Formula Buckeyes
Buckeye Current
EcoCAR: National Champions
Venturi Buckeye Bullet 3: Worldâ&#x20AC;&#x2122;s Fastest
World-class experts mentor these exceptional student teams
Marcello Canova Buckeye Current
Giorgio Rizzoni Venturi Buckeye Bullet
Shawn Midlam-Mohler EcoCAR
CAR Associate Director for Research & Education
CAR Director & Ford Motor Company Chair
SIMCenter Director
“Originally, I thought I wanted to be a technical expert, someone who has really in-depth knowledge about a particular topic but doesn’t manage people. But my leadership roles on the EcoCAR team have really changed my career goals.” Andrew Huster ’17 | former EcoCAR team lead | current feature integration engineer at General Motors
First Robotics High School Student Team
Camp CAR
The Motorsports Garage also hosts a variety of K-12 STEM outreach programs
CAR Internship Program
CARâ&#x20AC;&#x2122;s integrated, immersive environment enables MS and PhD students to apply their research in the competition vehicles, while undergrad team members are exposed to a wide range of mobility R&D. Tomorrowâ&#x20AC;&#x2122;s talent is developed here.
If you (help us) build itâ&#x20AC;¦
We will develop and deliver more talent, more leaders and more innovation to you
A new, larger facility would mean more students gaining both knowledge and experience prior to entering the workforce.
Connector
New space
Current CAR facility with new facade
â&#x20AC;&#x153;The Ohio State Motorsports program has given me the unique opportunity of receiving hands-on engineering experience, connections to industry and leadership opportunities as I pursue a career in the automotive industry. A new facility would showcase the talent, hard work and accomplishments of the students on these teams, while giving them access to more space, equipment and room to grow. They will be equipped with the right tools to tackle the challenges of their projects, and will be able to directly transfer their skills to solving problems that face the industry.â&#x20AC;? Polina Brodsky Buckeye Current team member CAR Graduate associate
A new Motorsports Facility creates additional space for research facilities. Part of the project plan includes renovating the old Motorsports building to expend our physical facilities including: 1. Additional office space for graduate students (~20 seats) 2. Expanded garage space for vehicle programs 3. Additional space for high-voltage and other safety-sensitive projects
WELCOME David Williams Dean College of Engineering
LUNCH
MOTORSPORTS TEAM UPDATES
UNDERWATER ROBOTICS DIEGO QUEVEDO BLAINE MILLER
THE TEAM â&#x20AC;&#x201C; PAST VEHICLES
2010-2011
2015-2016
2011-2012
2016-2017
20122013
20172018
20132015
THE TEAM • Founded in 2010 • 52 current members • Represent 6 different engineering majors: • Mechanical • Computer Science • Electrical and Computer • Engineering Physics • Biomedical • Aerospace
THE TEAM - STUDENTS
• Primarily underclassmen • Focus on learning practical skills • Student-led and self-taught
THE Team TEAM â&#x20AC;&#x201C; COMPETITIONS Best Technical Spirit Paper Award 23rd out of 18th out of 50 23
Best Presenter 9th out of 47
2016
2013
2018
2015
2017
2019
17th out of 27
28th Place of 44
Finals?
Marine Advanced Technology Education International ROV competition
AUVSI RoboSub International AUV competition
ROBOSUB
• International Competition for Autonomous Underwater Vehicles • 47 teams from 10 countries in 2018 • Vehicles must navigate through a series of tasks
ROBOSUB â&#x20AC;&#x201C; COURSE LAYOUT
ROBOSUB – RESULTS
• 2018 RoboSub Performance • 9th overall (out of 47 teams) • Top 8 teams make it into finals • Best Presenter Award
• Problem: • Cannot accurately describe vehicle's position with current sensors
• Solution: DVL
MOVING FORWARD
• The team is going to RoboSub 2019 • Thanksgiving pool test • 9 cross-disciplinary projects planned to be completed • Testing acoustic system, HUD improvements, and more
• 22 projects completed by Christmas break
SPONSORS
BAJA BUCKEYES BEN MONINGER
WHO WE ARE
2017-2018 EVENTS SUMMARY Midnight Mayhem IX (Bedford Kentucky) -30/100 Overall â&#x20AC;&#x201C; 6 Hour Endurance Race -One of 3 teams to attend all 9 (2008-2017)
Baja SAE Kansas (Pittsburg, Kansas) -21/95 - Design Event (30 Points out of Design Finals -35/95 - Endurance Event ( Electrical Failure with 20 minutes remaining prevented top 20 finish) -44/95 â&#x20AC;&#x201C; Overall (Best team finish in 6 years)
2017-2018 DEVELOPMENTS Frame Development Weight Reduction â&#x20AC;&#x201C; 72lbs to 62lbs 15% Increase in Torsional Stiffness (Driven by Suspension Requirements) Increased skill in linear CAE allows for implementation of lightweight sheet metal structures Suspension Development Torsionally Integrated 3-Link IRS Custom Front and Rear Uprights (8 lbs. in weight savings)
2017-2018 DEVELOPMENTS
Drivetrain Development Custom 12:1 Final Reduction Gearbox Development of in house casting furnace for case components
2018-2019 PROJECTS/FOCUS
Overall Development -Target 350lb vehicle -Increased Low Speed Cornering Handling -Accelerate 100 feet in 3.7 seconds Suspension Development -Highlight Ackerman Steering Targets, Increase Roll stiffness, decrease ride frequency -Integrate driveshaft as 3rd suspension link Drivetrain Development eCVT will allow for programmable shifting modes catered to different events
2018-19 COMPETITIONS
Midnight Mayhem –Oct. 12-13 Baja SAE Rochester– June 6-9 Baja SAE Tenessee– April 14-17
MAJOR CONTRIBUTORS Thank you!
CONTACT car.osu.edu
Ben Moninger Chief Engineer moninger.6@osu.edu 419-956-1896
SUPERMILEAGE Mason Monter Thomas Clifford
WHAT IS SUPERMILEAGE? • Collegiate SAE Design Series • Construction of a one-person, fuel-efficient vehicle
SUPERMILEAGE AT OHIO STATE
The focus of Supermileage is to construct a oneperson, fuel-efficient vehicle from the ground up, and to help build students' experience in the automotive field.
FAIRING • Fabric stress skin fairing • Modularity • Rapid, affordable replacement • Laying ground work for future full-size wind tunnel testing
Tooling Board Buck
Fabric Over Frame
Carbon Fiber Mold
Tooling Board Mold
Carbon Fiber Canopy
Carbon Fiber Wheel Fairing
DRIVETRAIN • Capstone Team: High-efficiency drivetrain design and integration •
48-60v series-hybrid drivetrain
•
Preliminary GT-POWER engine model
•
Preliminary overall vehicle/performance run model
ENGINE DESIGN •
Address engine component improvements • Manufacture and assemble second engine • Implement internal thermal rejection and low friction coatings
• Dynamometer testing to verify operating points, EIVC valve lift profiles, cylinder offset, and compression ratio • GT-POWER optimized tables driving Ecotrons EFI kit
Valve Displacement (in)
Camshaft Valve Lift vs Rotational Travel 0.20 0.15 0.10
Splined Intake
0.05
Splined Exhaust OEM Exhaust
0.00 0 60 120 180 240 300 360 Rotational Travel (º)
ELECTRICAL •
Design and implementation of CAN-based vehicle DAQ system • Allow more information to be collected from testing • Model-driven HIL system to optimize drivecycle and vehicle path • Basis for future research
Picture: http://henrysbench.capn fatz.com/henrys-bench/
SPONSORS
THANK YOU
Thank You! CAR: For support and use of facilities Honda: For sponsorship and mentorship
CONTACT car.osu.edu
Mason Monter Supermileage Co-Captain Monter.13@osu.edu (330) 205-7519
CONTACTS car.osu.edu
Thomas Clifford Supermileage Co-Captain clifford.150@osu.edu (513) 658-7503 Matt Little Advisor Little.238@osu.edu
FORMULA BUCKEYES JAKOB MADGAR TIMOTHY LAING
THE PROJECT • Design • Build • Race! • A scale formula style race car • Static Events • Design • Cost • Business • Dynamic Events • Acceleration • Skidpad • Autocross • Endurance • Fuel economy
COMPETITION
SAE Collegiate Design Series: FSAE Michigan Formula North (Canada)
OBJECTIVE
• To provide students with real-world, hands on engineering experience, principles and application knowledge outside the classroom. • Excellent resume/qualification reinforcement • Increased chances of internship/job after graduating
INVOLVEMENT AND TEAM BREAKDOWN
• Approximately 20 dedicated members applying 20 or more hours per week • Very high involvement – Total involvement of approximately 50 members • High recruitment efforts at involvement fairs
2018 VEHICLE HIGHLIGHTS
• Carbon Fiber Wheels • Hybrid Chassis • Full Undertray Diffuser • 50 LBs Lighter and 10% more HP than last year
CURRENT STATUS â&#x20AC;˘ Aiming for competition in Michigan and Formula North â&#x20AC;˘ Depending on Funding we will be shooting for an overseas trip in the near future
2019 DESIGN UNDERWAY
• Metal 3D Printed Uprights • Reduces weight by more than 10% • Titanium or Aluminum
• High Downforce Aero Package • New manufacturing and packaging methods for increased stiffness
• Focused on producing our car as quickly as possible to increase testing time to increase points
COMPETITION HIGHLIGHTS
• FSAE Michigan (120 Teams) • 17th Design • 36th Overall
• • • •
Formula North (30 Teams) 11th Overall 4th Acceleration 6th Autocross
PARTNERSHIPS
• Monetary donations • Average annual sponsored by company: $3-7K
OTHER NOTABLE PARTNERS
• Algie Composites • Carbon fiber layups
• Huntsman • Tooling board
• Henkel • Adhesive
• Reese Machine • Part machining
• R and B Tool • Stock donations
BENEFITS
To Sponsors
To Students
• Generates more wellrounded students • Easy access to intern / co-op candidates • Publicity / advertisement
• Real-world, hands-on experience • Guarantees future of student organization • Professional experience from internship and being around industry professionals
CONTACTS car.osu.edu
Jakob Madgar Project Manager Madgar.2@osu.edu 330-780-9103 Timothy Laing Technical Director laing.43@osu.edu 231-383-2659
BUCKEYE CURRENT Mason Hayes
Team Overview
Buckeye Current is focused on designing, building, and racing electric motorcycles to develop electric vehicle technology, grow awareness of electric motorcycles, and educate members and the community about electric vehicle technology.
Team Demographics Grad, 2
Freshman, 2 Sophomore, 2
Annual participation is ~30 students, mostly undergraduate.
5 Female Senior, 11
25 Male Junior, 13
3 Other
The diverse 30student team represents both engineering and non-engineering majors.
Eng. Phys.
14
1
Mechanical
4
Aero 1 MSE
7 Elec/Comp
Industry Partnerships
â&#x20AC;Śand many more!
Team History
2013
2014
Pikes Peak International Hill Pikes Peak International Hillrace Climb For our last four seasons, we competed at Pikes Peak Climb • For our last four race seasons, we competed at Pikes Peak International Hill Climb, the International Hill Climb, the second-oldest motorsport even
• • •
second-oldest motorsports event in North America t in nd and 3rd place finishes with nd rd In 2015 and 2016 we podiumed in class with 2 respective 3 p In 2015 and 2016, we podiumed in class with 2 and North America. times of 11:12.0 and 11:16.0 lace th st In 2017 we had our best-ever finish placing 11finishes overall and 1 inofthe electric and times 11:12.0 andclass 11:16.0. posting a time of 10:55.0 In 2017, we had our best-ever finish, placing 11th overall a In 2018 we were set for a sub-10:30.0 time st
nd 1 in class with a time of 10:55.0, and, in 2018, we were set f or a sub-10:30.0 time.
PPIHC: 2018
Powertrain Overview
Battery pack
Power inverter
Electric motor
- 938 x 26650 cylindrical cells (134s7p) - Air-cooled (passive) - 495 Vdc (nominal) - 29.4 Ah, 14.6 kWh - In-house BMS
Rinehart PM150-DZR - Motor current: 300 Arms - Liquid-cooled - 320 kVA / 180 kVA peak/continuous - 800 Vdc - 600 Hz output (12 kHz PWM)
Enstroj EMRAX 268MV - 10 pole pair, axial-flux PMAC machine - Liquid-cooled - 360 Arms peak current capability - 20 kg, 5.13 L (â&#x152;&#x20AC;268 mm)
Future Vehicle Development
RW-4 Overview Custom Suspension - Double-link front suspension
Custom BEV Frame - Removable headstock -
Removable side rails
-
-
Removable rear upright
Rear swingarm with horizontal shock placement
Pack Bounding Volume
Overall Vehicle Geometry - Inverter, motor, and rear shock placement
RW-4 Design Focus • Modularity allows for tuning to all race conditions • Increased packaging volume and less restricted design space • Improved suspension accessibility and adjustability • Platform for future design • Enhanced aerodynamic characterization for more accurate energy approximation
T H A N K Contacts: Mason Hayes, hayes.893@osu.edu Aaronn Sergent, sergent.27@osu.edu
Y OU
EcoCAR Simon Trask
Advanced Vehicle Technology Competitions
For more than 28 years, the U.S. Department of Energy (DOE) has sponsored 11 Advanced Vehicle Technology Competitions (AVTC) in partnership with the North American auto industry.
More than 16,500 students have graduated from an AVTC 93 universities throughout North American have participated in an AVTC More than 165 corporations have contributed to an AVTC over 28 years 265
What was EcoCAR 3?
4-year Advanced Vehicle Technology Competition (AVTC) challenging 16 college teams to rebuild a 2016 Chevrolet Camaro Engineering Goals: Increase fuel economy Reduce emissions and energy consumption Maintain performance and consumer acceptability
Sponsored by the U.S. Department of Energy, General Motors, and many others.
EcoCAR 3 At Ohio State
Classic. Recharged.
Plug-In Hybrid-Electric Vehicle Architecture: Parallel-Series Plug-in Hybrid-Electric Engine: 2.0L Direct Injection - 120kW Electric Machine: Parker Hannifin - 112kW Transmission: Tremec 5-Speed Automated Manual Batteries: A123 Systems - 18.9kWh 340V LiFePO4 BAS: Denso - 32kW Fuel Type: E-85
A History of Success
FIVE CONSECUTIVE FIRST-PLACE FINISHES OSU AVTC teams have finished in the top five teams for 11 straight years.
25+ YEARS OF PARTICIPATION The Ohio State University has been participating in AVTCs since 1990.
ECOCAR 3 YEAR 4 2017-2018
Year 4 Activities • Vehicle Optimization • Dynamic Testing • Carbon Fiber Integration • Advanced Driver Assistance Systems
Year 4 Competition • May 10th through May 22th in Yuma, Arizona and Los Angeles, California • Static safety, dynamic events, and ADAS at General Motors Desert Proving Ground – Yuma • Consumer Appeal and Performance Events at Auto Club Speedway • Technical presentations in Los Angeles, California • Presented on integration, testing, and optimization of vehicle across all aspects of the team
Year 4 Competition Results Ohio State secured its fifth consecutive First Place finish!
2018 Scores (out of 1000) 1.
Ohio State University
895
4.
Virginia Tech
783
2.
West Virginia University
817
5.
Georgia Tech
771
3.
University of Alabama
784
6.
University of Tennessee
701
1st Place Consumer Appeal 1st Place Vehicle Design Review 1st Place Over-The-Road 1st Place Innovation NSF Diversity 1st Place dSpace Embedded Success 1st Place Communications TRC Best Energy Consumption Women In Engineering, Rookie Award
LOOKING FORWARD 2018-2019
What does the next year look like? Propulsion System Integration • Responsible for hardware and electrical system integration, thermal systems development, high voltage systems, calibration, and component testing.
Controls and Systems Modeling & Simulation • Responsible for design and implementation of a safe, robust, and functional propulsion control system and developing models used to simulate the vehicle and subsystems
Connected and Automated Vehicle Systems • Responsible for developing reliable and accurate multi-sensor vehicle perception systems, V2X communication systems, and autonomous control systems
Project Management & Systems Engineering • Responsible for managing the organization using Agile techniques, sponsor and supplier interface, and system engineering
27 4
CONTACT ecocar.osu.edu
Simon Trask Ohio State EcoCAR 3 Team Leader trask.29@osu.edu (248) 763-9843
LO OR NO EMISSION BUS TESTING PROJECT OVERVIEW Walt Dudek Manager Engineering Services
FEDERAL TRANSIT ADMINISTRATION LOW AND NO EMISSION OVERVIEW FTA LoNo Program • Provides funding to state and local governmental authorities for the purchase or lease of zero-emission and lowemission transit buses • Support transit infrastructure including the acquisition, construction, and leasing of required supporting facilities • FY13-18 FTA Bus Grants totaled $271MM • Under the FAST Act, $55MM per year is available until FY20 • There are currently 1,500 Zero emissions transit busses on order in the US
OHIO STATE’S FTA PROGRAMS Ohio State supports the FTA Low and No Emissions initiative through two programs: Bus Testing and Component Testing. Both programs produce public data to support the adoption of new low and no emissions transit busses and the integration of new component technologies into existing fleets. Low and No-Emission Bus Testing (LoNo-Bus) • Required testing for any buses acquired with FTA funding to provide public transportation service (49 CFR Part 665) • Full vehicle testing with a pass/fail criteria • Ohio State selected as a test center in 2018 Low and No-Emission Component Assessment Program (LoNo-CAP) • Voluntary program to promote the development and adaptation of new components and technologies intended to allow existing transit fleets to make more low and no emission improvements • Component, System, or full vehicle testing options • Test program content directed by industry and Ohio State
FTA IMPACT AT OHIO STATE Attracting both US and foreign manufacturers to Ohio for… • Research, Development, FTA Certification, Yearly Industry Technology Interchanges
Creation of an on-campus bus testing center • Scaled for the needs of the transit bus and commercial vehicle industry. • Focused on Low and No Emissions Technologies from research and development through testing and certification
Significant new funding opportunities • FTA Research opportunities for Bus Testing Program • OEM Manufacturer Research Funding for 20% bus testing cost share requirements • New Research and Development activities at OSU and TRC to support manufacturer product development Addition of new refueling infrastructure for electric and hydrogen vehicles • Supporting the Ohio State Bus Test Center and future OSU/Columbus/Public fleet needs
EXPANSION OF CAPABILITIES
Expansion of Ohio State and TRC’s Heavy-Duty Research Capabilities Ohio State’s test capacity will be enhanced and expanded to include… • Energy or fuel economy testing for electric vehicles, liquid, and gaseous fuels • Emissions certification testing • Individual system and component benchmarking for LoNo technologies including energy storage, hydrogen fuel systems, DC:DC converters, HVAC, and electric chargers
• Full life durability testing including braking, noise, towing, structural integrity, hoisting, and repair time tracking • Performance testing including acceleration, gradeability, and top speed
OHIO STATE CHASSIS TESTING EXPANSION
CONTACT car.osu.edu
Walt Dudek Director â&#x20AC;&#x201C; Commercial Vehicle Research and Test Laboratory Dudek.12@osu.edu 614-292-0380
CONTINUING EDUCATION OFFERINGS Marcello Canova Associate Director For Graduate And Continuing Education and Marianne Weber Continuing Education Manager
CAR CONTINUING EDUCATION • 2017-2018 Academic Year Highlights: • 66 engineers enrolled in 8 graduate automotive courses during the 17-18 academic year • New distance course on autonomous vehicles in Spring 2018 • 94 engineers enrolled in non-credit live short courses & online seminars
• • • •
4 live short courses at CAR for Honda, 1 for Yachiyo 5 live short courses delivered on site at FCA NAM and FCA Latam 22 automotive certificates completed at GM, FCA NAM, FCA Latam & Cesar Certificates completed in: • • • •
Powertrain Modeling & Control Advanced Propulsion IC Engine Control (customized/FCA) Modeling & Control of Advanced Vehicles (customized/FCA)
• Englearn.osu.edu/curriculum/certificates
ELECTRIFICATION COURSES ME7383: Electrochemical Energy Conversion and Storage Systems The course introduces the participants to energy storage systems for electrified vehicles based upon Lithium on battery technology. In addition, it provides a broad overview on the subject, covering multiple areas such as cell materials and fundamental properties, testing procedures for performance characterization, modeling and simulation, system integration, control, diagnostics and prognostics. Professor Marcello Canova, The Ohio State University Marcello Canova is associate professor of Mechanical and Aerospace Engineering at The Ohio State University, and associate director for Graduate and Continuing Education at the Center for Automotive Research. His research focuses on the optimization and control of propulsion systems, including internal combustion engines, hybrid-electric drivetrains, energy storage systems and thermal management.
ME7384: Simulation, Optimization & Control of HEVs This course introduces participants to HEV system integration and energy management concepts using modern simulation methods based on Matlab/Simulink tools. The participants will use a modular simulator compatible with software- and hardware-in-the-loop control development systems, describing the energy flows in conventional and hybrid vehicles and analyzing energy management strategies. Professor Giorgio Rizzoni, The Ohio State University Giorgio Rizzoni, the Ford Motor Company Chair in ElectroMechanical Systems, is a professor of Mechanical and Aerospace Engineering and of Electrical and Computer Engineering at The Ohio State University (OSU). He received his B.S. (ECE) in 1980, his M.S. (ECE) in 1982, his Ph.D. (ECE) in 1986, all from the University of Michigan. Since 1999 he has been the director of the Ohio State University Center for Automotive Research (CAR).
NEW IN 18-19 ACADEMIC YEAR ECE 5553: Autonomy in Vehicles
This graduate course provides an introduction to automated driving vehicles and their sub-systems with a focus on concepts, architectures, problems and solution approaches. Historical developments in automotive control and mechatronics that have led to the development of autonomous road vehicles are presented. Current research projects, including the Columbus Smart Cities program, provide relevant case studies in autonomous advancements. Professor Levent Guvenc, The Ohio State University Levent Güvenç is an assistant professor in Electrical and Computer Engineering and Mechanical Engineering. He leads the Automated Driving Lab at CAR. Güvenç received a B.S. in mechanical engineering from Bogaziçi University, Istanbul, Turkey, an M.S. in mechanical engineering from Clemson University, and his Ph.D. in mechanical engineering from The Ohio State University.
ECE5554: Powertrain Control This graduate course covers basic digital control concepts in the context of automotive powertrain control systems. A review of sampled data systems, particularly relevant to the implementation constraints common to production powertrain systems and subsystems, lays the foundation for subsequent control design discussions. A basic course in control systems and background in dynamic systems modeling and simulation are required. Professor Lisa Fiorentini, The Ohio State University Lisa Fiorentini is an assistant professor-clinical in Electrical and Computer Engineering and associate fellow at the Center for Automotive Research (CAR). Dr. Fiorentini received a BS and MS in Electrical Engineering from Universita’ Politecnica delle Marche, Italy, and her MS and PhD from The Ohio State University.
NEW IN 18-19 ACADEMIC YEAR
Certificate Program 2018-2019
Prep Seminars
Graduate Courses
Advanced Seminars
(August 2018)
(Autumn 2018 - Spring 2019)
(Spring 2019)
Modeling, Optim & Control of Advanced Vehicles
MATLAB/Simulink Prep System Dynamics Prep
Sim Opt Control of HEVs (ME7384) Autonomous Vehicles (ECE5553)
Energy Storage Systems
Powertrain Electrification
MATLAB/Simulink Prep System Dynamics Prep
Sim Opt Control of HEVs (ME7384) Energy Storage Systems (ME7383)
Power Electronics
• New customized certificates • New short course in Autonomous Vehicles • Updated online seminars in: • System Dynamics • Power Electronics • SIL-HIL for Control • Matlab for Data Analysis • Englearn.osu.edu/curriculum/seminar
NEW IN 18-19 ACADEMIC YEAR
Three-day workshop for engineers and managers in the automotive industry or businesses related to the transportation sector. Day 1: Electrification
Day 2: Connectivity and Automation
Day 3: Mobility and Cybersecurity
Location: Center for Automotive Research
Location: Transportation Research Center
Location: Smart Columbus Experience Center
Electrified Powertrains (Prof. Giorgio Rizzoni and Dr. Matilde Dâ&#x20AC;&#x2122;Arpino)
Technologies for Connected and Autonomous Vehicles (Prof. Levent Guvenc and Prof. Bilin Aksun-Guvenc)
Modeling of Urban Transportation and Forecasting of Consumer Choices in Multi-Modal Shared Mobility (Prof. Mark McCord, Prof. Rabi Mishalani, Prof. Andre Carrel)
Lunch & Networking
Lunch & Networking
Lunch & Networking
Energy Storage Systems for E-Mobility (Prof. Marcello Canova)
Verification and Testing Methods for Autonomous Vehicles (Prof. Shawn Midlam-Mohler and Dr. Joshua Every)
Cybersecurity in Connected and Autonomous Vehicles (Prof. Abhishek Gupta, Prof. Emre Koksal, Prof. Zhiquian Lin)
Tour of CAR: Energy Storage and e-Powertrain Testing Facilities
Tour of TRC Smart Center and CAV Testing Facilities
Tour of Smart Columbus Experience Center and Presentation by COTA
CONTACTS car.osu.edu
Marcello Canova Associate Director, Graduate and Continuing Education Canova.1@osu.edu
Marianne Weber Program Coordinator, Distance and Continuing Education Weber.305@osu.edu
NETWORKING Snacks available in the kitchen
Tomorrow! Join us for a tailgate party at CAR before cheering the Buckeyes on to victory! 1-3 p.m. Student Motorsports Garage