Lean Powertrain Development Tool

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Lean Powertrain Development Tool

• Sam Akehurst
• Powertrain Vehicle Research Centre
• Department of Mechanical Engineering
• University of Bath

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Presentation Outline

• What is a Powertrain?
• The problem current practice
• Project aim
• Project outcomes
• Method
• Beneficiaries
• Why me?

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Powertrain

• Sub-systems include
• Engine
• Transmission
• After-treatment Systems
• Electronic Control Units (ECU) and Control
  Software

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Powertrain RD - Current Industry Practice

• Separate sub-system development process- Little
  integration, compromised result
• Simulation tools used intensively, but at
  sub-system level Little integration to achieve
  optimisation
• New technologies selected off the shelf- Rarely
  optimised for required duty
• Lead time to market compromised by multiple
  iterations during development

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Project Aim

• To develop an integrated approach to Powertrain
  design, performance optimisation and rapid
  calibration, through a simulation and model based
  philosophy

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Project Aim
Realism
Vehicle Test
Rolling Road
Advanced Engine Test
Basic Engine Test
Powertrain Simulation
Cost Complexity
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Project Outcomes

• A practical method addressing complex Powertrain
  design, development and calibration
• A more integrated and better optimised Powertrain
  solution
• Reduction of intensive experimental and iterative
  modelling procedures
• Predictive methods developed for understanding
  the effects of emerging hardware
• Reduction in final product complexity

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Method
Validate with Advanced Test Methods
Phase 4
Assess Phase 3 Combinations Relative Performance
vs. Complexity
Phase 3
Select Technologies Capable of Achieving Phase 2
Requirements and Assess Interactions
Phase 2
Install in Vehicle as Proof of Concept
Calibrate Validate
Develop Requirements to Meet Phase 1
Targets Using Simulation Tools and Optimisation
Techniques
Model New Technologies and Integrate with
Existing Tools
Phase 1
Set Targets Select Baseline Powertrain for
Verification And Model
Develop Optimisation Techniques Black-Box
Engine Simulation
Integration of Different Simulation Tools
Prove Experimentally
Timeline in Years
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Methodology-Phase 1Target Setting/ Baseline
Selection
Set Performance Targets Select Baseline Powertrain
Model Baseline Powertrain in Software
Integration of Different Simulation Tools
Validate Experimentally
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Methodology-Phase 2Develop Technology
Requirements

• Novel Black-box Simulation approach
• Internal powertrain parameters optimised to
  achieve Phase 1 Targets
• Validated through hardware emulation
• No prototype components required

SET CONSTRAINTS/ TARGETS From Phase 1
Update Model Parameters
OPTIMISATION PROCESS
Assess Performance Against Constraints
Technology Performance Requirements
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Methodology-Phase 3Evaluate New Technologies
Select Technologies Capable To Achieve Phase 2
Requirements and Assess interactions
Development Of Technology Sub-system Models And
Integration With Existing Powertrain Models
Assess Performance and Interactions of Selected
Technologies
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Methodology-Final Phase Proof of Concept and
Validation
Assess Future Powertrain Combinations (Phase
3) Relative Performance vs. Cost And Complexity
Use Software to Undertake Initial Powertrain
Calibration
Install Selected Future Powertrain In Vehicle
Platform And Evaluate Performance on Rolling Road
Facility
Evaluate Performance of Future Powertrain
Demonstrate on Research Platform And In
Integrated Simulation Environment
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Beneficiaries

• Automotive Industry
• More refined optimised end product
• Better understanding of impact of emerging
  technologies
• Quicker time to market
• Industry at Large
• Methods and techniques will be transferable
• Academic Community
• Demonstrate the direct relevance of advanced
  simulation and optimisation techniques, promoting
  further research
• Demonstration of industry relevant research
  within Universities

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Community at Large

• Greener, cleaner and more healthy environment
• Reduced pollution from vehicles
• Improved fuel economy, reducing CO2
• Reduced fuel costs
• Cheaper transportation
• Extend life of petrochemical resources

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Why Me, at Bath?

• A launch pad to allow me and this work to become
  internationally recognised.
• Extensive expertise in Powertrain research.
• Significant experience in working with industry.
• State of the art experimental facilities.
• Supported by 5 Department of Mechanical
  Engineering

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Time Plan
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Emerging Technologies

• New combustion concepts (HCCI, CAI, etc)
• Advanced Common rail Multiple injection events
• Injection rate shaping?
• Fully flexible VVA
• Hybridisation
• Advanced air handling systems
• Sequential/ multiple turbochargers
• E-boost
• Variable compression ratio
• CVTs, IVTs, ASMs
• Future After-treatment systems

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Emerging Technology Issues

• Product Cost
• Development cost
• Over Specification, Technology Redundancy
• Control Calibration
• Complexity
• Reliability
• Development time
• Cost and time to market
• Optimisation!

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ACEA reduced CO2 Targets
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Clear Diesel Advantage