Hybrid HMMWV Applied Research Project for TARDEC - DRS TEM

1. Hybrid HMMWV Applied Research Project for TARDEC - DRS TEM ECE Advisory Board Meeting

2. Generation 1 HE HMMWV ECE Advisory Board Meeting

3. HE-HMMWV Project With TARDEC/DRS-TEM Project Goals: Support TARDEC in improvement of Technology Readiness Level of HE-HMMWV project with following actions: • Review the existing Performance Simulation Model. • Review current ATC test plan and recommend revision if needed. • Compare the intended test measurement items to the model outputs and identify gaps. • Review the field test data, compare results with design expectations and identify issues. ECE Advisory Board Meeting

4. HE-HMMWV Project With TARDEC/DRS-TEM Project Goals (cont.): • Develop possible corrective actions and recommend modifications to the Simulation model as appropriate. • Receive the test vehicle from TARDEC after completion of tests at ATC and conduct evaluation experiments of acceleration performance on AEI 4WD Vehicle Chassis Dynamometer. • Review the test results from the Dynamometer, develop improvement recommendations and propose block diagrams for high-level system model. • Prepare a Technical Report addressing the above efforts. ECE Advisory Board Meeting

5. Project Complexity Technical complexity of HE-HMMWV vehicle with extremely sophisticated control systems, engine, generator, wheel motors, battery, etc. Multi-discipline involvement due to complex knowledge residing in experts in inter-college disciplines. Project requires coordination of effort between: (2) Colleges (3) Departments (3) Project Principals (3) Research Associates (8) Research Assistants ECE Advisory Board Meeting

6. Major Program Events 12/10/04 LTU-TARDEC senior management meeting at LTU show- casing AEI capabilities. 1/14/05 Follow up to above meeting at LTU with discussions with team leaders at TARDEC on specific needs and potential projects. 4/13/05 Meeting at TARDEC for SOW development. 5/4& Trip to Aberdeen Test center in Maryland 5/5/05 6/30/05 HE-HMMWV proposal submitted to DRS-TEM at TARDEC’s request. 9/28/05 Purchase order received for the project. 10/18/05 Kick-off meeting at LTU for the project. ECE Advisory Board Meeting

7. Major Program Events (Cont.) 12/1/05 Meeting with Wilford Smith on CHPS Model 1/24/06 Project review status meeting with TARDEC and DRS-TEM and discussed scope of work issues. 2/23/06 Submitted options to address scope of work. 3/8/06 Trip to ATC for HE-HMMWV testing discussion ( Dr. Bansal and Mr. N. Bellovary) 5/5/06 TARDEC advises availability of additional funds to expand scope towards original intent under current year funding (ending 9/30/06). AEI to identify what can be accomplished with these additional funds. 6/13/06 Project review status, meeting with TARDEC and DRS-TEM and discussion on direction for future work. ECE Advisory Board Meeting

8. Project Goals Under Initial Funding Excel Model Simulink Model Verify Conversion Conversion of Existing Excel Model (Modular Construction) Deliver Report Dyno Testing & Validation Enhancements ECE Advisory Board Meeting

9. Excel Spreadsheet Model ECE Advisory Board Meeting

10. DRS Excel models • Slope Model – Maximum weight carrying capabilities for various grades • Velocity Model – Torque and maximum driving range capabilities at various velocities • Acceleration Model – Speed profile at maximum throttle. ECE Advisory Board Meeting

11. Limitations of current Excel model • Performance model only • Individual models of slope, constant velocity, and acceleration • Lack of flexibility • Difficult to change • No plug and play capability • Cannot modify numerical techniques for computation • Difficult to find errors • Easy to introduce errors • No hierarchical structure • No graphical user interface • Cannot create an executable version • Difficult to enhance for future model development ECE Advisory Board Meeting

12. Project Goals Under Initial Funding Excel Model Simulink Model Verify Conversion Conversion of Existing Excel Model (Modular Construction) Deliver Report Dyno Testing & Validation Enhancements ECE Advisory Board Meeting

13. Simulink Model ECE Advisory Board Meeting

14. Simulink GUI Interface ECE Advisory Board Meeting

15. Simulink Acceleration Performance Output Plots ECE Advisory Board Meeting

16. Project Goals Under Initial Funding Excel Model Simulink Model Verify Conversion Conversion of Existing Excel Model (Modular Construction) Deliver Report Dyno Testing & Validation Enhancements ECE Advisory Board Meeting

17. Analysis ECE Advisory Board Meeting

18. Numerical Analysis • Runge Kutta Methods • For a method of order , where is the stepsize • Local error is • Global error is • For the calculations modeling the HMMWV, • Excel Spreadsheet • Uses Euler’s method (order 1) • Local error is • Global error is • Matlab Simulink model • Allows a choice of the integration method. • Using ode45, based on the Dormand Prince formula (order 5) • Running the simulation with ode45 gives • Local error is • Global error is ECE Advisory Board Meeting

19. Project Goals Under Initial Funding Excel Model Simulink Model Verify Conversion Conversion of Existing Excel Model (Modular Construction) Deliver Report Dyno Testing & Validation Enhancements ECE Advisory Board Meeting

20. Enhancements with current Simulink model • Modular performance model leading to component based hierarchical model in future phases • Improved flexibility • Easy to change • Limited plug and play capability • Easily modifiable numerical techniques for more accurate computation • Easier to debug • Has a graphical user interface • Both source code and executable deliverables • Standard state-of-the-art simulation modeling language for complex control and mechanical system development • Compatible with Dyno testing ECE Advisory Board Meeting

21. Project Goals Under Initial Funding Excel Model Simulink Model Verify Conversion Conversion of Existing Excel Model (Modular Construction) Deliver Report Dyno Testing & Validation Enhancements ECE Advisory Board Meeting

22. OBJECTIVES OF DYNO TESTING • Acquire experimental data to assist in validating LTU Matlab/Simulink Model. • Conduct constant velocity tests with minimal vehicle loading. (Completed) • Conduct “flat top” and known velocity profile tests with minimal vehicle loading. (30 mph completed) • Conduct “flat top” and know velocity profile tests using full vehicle loading: aero drag, rolling resistance, and grade. (In planning stage) ECE Advisory Board Meeting

23. Example of Maintenance Unit Screen Print Data Collection ECE Advisory Board Meeting

24. 30 mph “Flat Top” Velocity Profile (Velocity Controlled Mode) ECE Advisory Board Meeting

25. Outlook Extension of current funding will help offset the additional effort for creation of Simulink Model from the existing Excel Spreadsheet Model and enhancements to the model as we incorporate the test experience in this Simulink Model. AEI Team is confident in our ability to handle this complex and sophisticated project. The Project provides our students unique opportunity for learning and employment due the unique learning experience in sophisticated skills. It also helps develop faculty with “state of the art” knowledge and skills and help create new knowledge. Our knowledge and base experience positions us to be more efficient and effective for future phases of the project. Expands AEI opportunities for serving TARDEC in additional projects in other areas of this and other vehicles. ECE Advisory Board Meeting

26. Roadmap for Immediately Available Additional Funding • Model Input as ATC track data (velocity and grade as a function of time) • Combine (3) individual models to one consolidated model • Correlate model with current Dyno test capability • Correlate model with ATC track data ECE Advisory Board Meeting

27. Roadmap for Future Funding Cycles(Multi-year) • Enhance Dyno capabilities with velocity and grade as a function of time • Fuel Economy measurement capability on Dyno • Hierarchical model development with limited Plug & Play a) Model Individual components (Motors, Generators, Battery, Controllers, Engine, Tires, Aerodynamics,….) – Additional Software & Commercial Licenses required. Experimental Verification of above (Instrumentation required) b) Model Subsystems (Motor, Generator & Controller Engine & Controller Battery & Controller) Experimental Verification of above c) Total Vehicle System Model Experimental Verification of above ECE Advisory Board Meeting