Future Truck 4

1
Future Truck 4

• Donald Mattern
• Matt Rath
• Advisor Dr. Parten

2
Objective

• To determine and fix the problem of the motor
  controller system on the Ford Explorer for the
  Future Truck.
• Engine testing and tuning on Chassis dyno-meter.

Rath
3
Tasks

• System Background
• Electrical Assist
• Testing
• Motor Controller / Testing
• PXI Testing
• Chassis Dyno
• Setup
• Hydrogen Precautions
• Engine Tuning
• Injection Pump
• Argonne National Lab Dynamometer Testing
• Test 1
• Test 2
• Budget
• Gantt chart

Rath
4
Background

• FutureTruck is a unique four-year program that
  brings together the resources of industry
  government, and academia in a cooperative effort
  to address important environmental/ and
  energy-related issues posed by the growing demand
  for SUVs.
• Re engineer a conventional, mid-size Ford
  Explorer into a low-emissions vehicle with at
  least 25 higher fuel economy-without sacrificing
  the performance, utility, safety, and
  affordability consumers want.

Rath
5
What is a Hybrid?

• A hybrid electric vehicle combines two or more
  sources of power a fuel cell and a battery with
  an electric drive motor.
• Fuel cell is the primary source for the vehicle

• To conserve fuel, the engines have been downsized
  to meet that average power requirements of the
  vehicle.
• Used hydrogen fueled internal combustion engines
  as part of our hybrid strategy

Rath
6
Texas Tech Future Truck

• One of only 2 trucks in the nation that is a
  Hydrogen powered Hybrid.
• 2 Hydrogen tank fuel cells.

Rath
7
Vehicle Component Layout
Electric Motor
Battery Packs
Engine
Rath
8
Block Diagram
Labview Program
PXI
Field Point
Black Box
25 PIN
Motor Controller
Rath
9
Field Point

• The FPGA on the RIO board is configured with the
  LabVIEW FPGA software module rather than VHDL or
  Verilog.
• To generate fuel and ignition outputs, controller
  need index lots of look-up tables by input
  parameters and perform interpolation operations.

Rath
10
Main Field Point
Rath
11
System Configuration

• PXI, Driver Side Black Box, Field Point

Rath
12
Electrical Assist

• Electric Motor Control
• Assist based on
• Engine speed
• Engine load
• Throttle position
• Vehicle speed

Mattern
13
Black Box

• Black Box that is involved with the Electric
  Motor Assist System

25 Pin Connector to Motor Controller
Mattern
14
25 DIN Connector-PXI to Black Box
Observed a Pin that was not at proper position
and Repositioned
Mattern
15
25 DIN Connector

• Found and Inspected connector that was damaged
  during competition
• Observed a jammed male pin inside connector
• Repaired connector

Mattern
16
Solectria UMOC440TF Motor Controller
Mattern
17
Motor Controller- Hyper Terminal

• Control Program From RS-232 Connection
• Battery Voltage
• Motor Enabled (Power Stage)

Mattern
18
Hyper Terminal for Motor Controller
Enabled when Electric Motor is ON
Mattern
19
Vehicle Setup
Hydraulic Lift
Mattern
20
Testing Setup
DC Power Supply
Mattern
21
Testing

• First Test
• Tested motor controller for proper operation
• Used DC power supply
• Placed 3.5 V across motor enable pins on PXI
• Results
• Motor engaged
• Conclusions
• No problems with Black Box, Motor Controller, 25
  DIN connector

Mattern
22
PXI FPGA
Rath
23
PXI Wiring
Rath
24
Testing

• Second Test
• In order to test the proper operation of the
  Labview program the MAP and BAP sensors had to be
  working
• Inspected wiring of MAP and BAP connections to
  PXI
• Wiring Documentation and PXI wiring inconsistant
• Results
• Ran Truck and got correct readings from MAP BAP

Rath
25
Documentation Update

• MAP sensors changed to 85 and 86
• BAP sensors changed to 87 and 88

Rath
26
Electrical Assist Testing Completed

• Drove Future Truck to ensure Electrical Assist
  Engaged
• Power Stage Enabled while driving
• Confirmed by noticing when Assist engaged while
  driving
• Next Task
• Engine Tuning

Mattern
27
Chassis Dyno
Mattern
28
Testing Setup

• High Pressure Air
• Placing Rear Wheels on dyno
• Ensure Vehicle is Strapped Down
• Radiator Fan For Cooling While at High Loading
• Water
• Loading and Unloading dyno
• Dyno Control Box
• Hydrogen Considerations
• Filling Tanks
• While FT is operating

Mattern
29
Chassis Dyno

• Connections
• High Pressure Air
• Supply and Return Water
• Control Box which engages solenoids
• Loading and Unloading dyno

Mattern
30
Vehicle Setup and Testing
Straps Around Axel
Mattern
31
Testing Setup

• Exhaust fan
• Rear fan blowing excess hydrogen
• Blue tent

Mattern
32
Using the K tank

• Disconnected hose that went from tanks to engine.
• Connected hydrogen tank to truck

Mattern
33
Safety Setup

• Safety straps
• Front wheels jacked up for better results
• Radiator fan

Mattern
34
Hydrogen Concidrations

• Odorless but flammable gas
• Comparison
• Gasoline and diesel both have narrow flammability
  ranges between 1 and 7.6 percent and 0.6 and 5.5
  percent respectively.
• Hydrogen is capable of explosion between 15 and
  59 percent volumetric concentration of air.

Mattern
35
Hydrogen Precautions
Vents View from under Tent
Vents
Open Vent for Hydrogen
Mattern
36
Motec Testing Results

• Measures efficiency vs RPM
• Add or decrease fuel at certain RPM

Rath
37
MAPS of Fuel Menu

• Decide where fuel is needed
• Curves represent gear shifting and deceleration

Rath