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2008 Advanced Vehicle Technology Analysis and Evaluation Activities

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annual progress report 2008V EHICLE T ECHNOLOGIES P ROGRAM ADVANCED VEHICLE TECHNOLOGY ANALYSIS AND EVALUATION ACTIVITIES AND HEAVY VEHICLE SYSTEMS OPTIMIZATION PROGRAM A Strong Energy Portfolio for a Strong America Energy efficiency and clean, renewable energy will mean a stronger economy, a cleaner environment, and greater energy independence for America. Working with a wide array of state, community, industry, and university partners, the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy invests in a diverse portfolio of energy technologies. For more information contact: EERE Information Center 1-877-EERE-INF (1-877-337-3463) www.eere.energy.gov U.S. Department of Energy Vehicle Technologies Program 1000 Independence Avenue, S.W. Washington, DC 20585-0121 FY 2008 Annual Progress Report for Advanced Vehicle Technology Analysis and Evaluation Activities and Heavy Vehicle Systems Optimization Program Submitted to: U.S. Department of Energy Energy Efficiency and Renewable Energy Vehicle Technologies Program Advanced Vehicle Technology Analysis and Evaluation Lee Slezak, Technology Manager FY 2008 Annual Report AVTAE Activities & HVSO Program ii AVTAE Activities & HVSO Program FY 2008 Annual Report CONTENTS I. INTRODUCTION.................................................................................................................................1 II. MODELING AND SIMULATION....................................................................................................9 A. PSAT Model Validation ...............................................................................................................9 B. Simulation Runs to Support GPRA/PDS....................................................................................14 C. DOE and FreedomCAR Technical Team Support .....................................................................24 D. PSAT Maintenance and Enhancements......................................................................................28 E. Plug-and-Play Software (Cooperative Research and Development Agreement with General Motors)..................................................................................................................31 F. Validation of the Through-the-Road (TTR) PHEV....................................................................34 G. Impact of Drive Cycles on PHEV Component Requirements....................................................36 H. Component Technology Impact on PHEV Fuel Efficiency .......................................................42 I. Comparison of Powertrain Configuration for Plug-in HEVs on Fuel Efficiency ......................46 J. Development of Models for Advanced Engines and Emission Control Components................51 K. PHEV Value Proposition Study..................................................................................................58 L. Enabling High Efficiency Ethanol Engines (Delphi PHEV CRADA).......................................65 M. Plug-In Hybrid Vehicle Systems Analysis .................................................................................70 N. Evaluating Route-Based Control of Hybrid Electric Vehicles (HEVs)......................................74 O. Renewable Fuel Vehicle Modeling and Analysis.......................................................................77 P. Integrated Vehicle Thermal Management Systems Analysis/Modeling ....................................81 Q. Medium-Duty Plug-in Hybrid Electric Vehicle Analysis ..........................................................87 R. PSAT Heavy-Duty Vehicle Modeling and Simulation ..............................................................91 S. Heavy Truck Duty Cycle (HTDC) Project .................................................................................94 III. INTEGRATION AND VALIDATION ........................................................................................105 A. Battery Hardware-in-the-Loop Testing ....................................................................................105 B. MATT/Component Hardware-in-the-Loop Testing.................................................................110 C. Active Combination of Ultracapacitors with Batteries for PHEV ESS....................................140 D. PHEV Development Platform — Through-the-Road Parallel PHEV......................................151 IV. LABORATORY TESTING AND BENCHMARKING .............................................................169 A. Benchmarking and Validation of Hybrid Electric Vehicles .....................................................169 B. Benchmarking of Plug-In Hybrid Electric Vehicles.................................................................177 C. PHEV Test Methods and Procedures Development.................................................................183 D. Advanced Hydrogen Vehicle Benchmarking ...........................................................................187 iii FY 2008 Annual Report AVTAE Activities & HVSO Program CONTENTS (CONT.) E. Maintain an On-Line HEV Test Results Database...................................................................193 V. OPERATIONAL AND FLEET TESTING ...................................................................................197 A. Hybrid Electric Vehicle Testing ...............................................................................................197 B. Plug-in Hybrid Electric Vehicle Testing by DOE’s Advanced Vehicle Testing Activity (AVTA) .........................................................................................................203 C. Hydrogen Internal Combustion Engine (ICE) Vehicle Testing ...............................................225 D. Neighborhood Electric Vehicle Testing ...................................................................................228 E. Advanced Technology Medium and Heavy Vehicles Testing .................................................231 VI. AERODYNAMIC DRAG REDUCTION ....................................................................................239 A. DOE Project on Heavy Vehicle Aerodynamic Drag ................................................................239 B. Investigation of a Trailer Underbody Fairing for Heavy Vehicle Aerodynamic Drag Reduction.........................................................................................................................241 VII. THERMAL MANAGEMENT ....................................................................................................251 A. Efficient Cooling in Engines with Nucleate Boiling ................................................................251 B. Erosion of Materials in Nanofluids...........................................................................................261 C. Integrated Underhood and Aerodynamic Analysis...................................................................265 D. CoolCab – Truck Thermal Load Reduction Project.................................................................268 VIII. FRICTION AND WEAR............................................................................................................277 A. Boundary Lubrication Mechanisms..........................................................................................277 B. Parasitic Energy Loss Mechanisms ..........................................................................................283 C. Superhard Coatings...................................................................................................................290 D. Residual Stresses in Thin Films................................................................................................295 iv AVTAE Activities & HVSO Program FY 2008 Annual Report I. INTRODUCTION On behalf of the U.S. Department of Energy’s Vehicle Technologies (VT) Program, I am pleased to submit the Annual Progress Report for fiscal year 2008 for the Advanced Vehicle Technology Analysis and Evaluation (AVTAE) team activities. Mission The AVTAE team’s mission is to evaluate the technologies and performance characteristics of advanced automotive powertrain components and subsystems in an integrated vehicle systems context, covering light to heavy platforms. This work is directed toward evaluating and verifying the targets of the VT technology R&D teams and to providing guidance in establishing roadmaps for achievement of these goals. Objective The prime objective of the AVTAE team activities is to evaluate VT Program targets and associated data that will enable the VT technology R&D teams to focus research on areas that will maximize the potential for fuel efficiency improvements and tailpipe emissions reduction. AVTAE accomplishes this objective through a tight union of computer modeling and simulation, integrated component testing and emulation, and laboratory and field testing of vehicles and systems. AVTAE also supports the VT Program goals of fuel consumption reduction by developing and evaluating the enabling of vehicle system technologies in the area of light vehicle ancillary loads reduction. The integration of computer modeling and simulation, hardware-in-the-loop testing, vehicle benchmarking, and fleet evaluations is critical to the success of the AVTAE team. Each respective area feeds important information back into the other, strengthening each aspect of the team. A graphical representation of this is shown in the figure below. Integration of AVTAE Computer Modeling and Testing Activities 1 FY 2008 Annual Report AVTAE Activities & HVSO Program
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