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Advancements in Powertrain Test Environment Delivering Productivity Through Strategic Choice of Test Environment

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Advancements in Powertrain Test Environment Delivering Productivity Through Strategic Choice of Test Environment ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT DELIVERING PRODUCTIVITY THROUGH STRATEGIC CHOICE OF TEST ENVIRONMENT Dr. Philip Lawson & Sulabh Dhingra 28 Jun 2018 – AVL Product Development in Motion ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Outline • Motivations Why? • Brief history of Powertrain Testing at JLR • Increasing Productivity through What? Shift & Expand • Key enablers to deliver Shift & Expand How? strategies Data • Emissions Test Use Case ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Background & Motivation Jaguar Land Rover Retail Sales Volumes by FY Jaguar E-Pace Jaguar F-Pace Land Rover Discovery Range Rover Velar ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Background & Motivation Since 2011: • Doubled internal Engine Test activity • Tripled internal Chassis-Dyno Test activity • 15x increase in outsourced test activity Testing Effectiveness Four Levers Internal capacity increase largely due to Testfield Efficiency Projects “Holistic Powertrain Development & Test Productivity Optimisation at Jaguar Land Rover” J. Houldcroft et. al. 5th International Symposium on Development Methodology, 2013 4 ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Background & Motivation – SAE 2016-01-0982 5 ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Background & Motivation Testing Effectiveness Four Levers Reuse Data New Efficiency Gains Technologies Effectiveness Shift & Expand Expanding Product Portfolio Testing Effort Testing New Testing Effort Testing New is State is - As Environment Reduced Testing Testing Reduced Efforts in Strategic in Strategic Efforts ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Shift and Expand Strategy 7 ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Key Enablers Adoption of Shift & Expand test methodologies requires significant investment in… People Test Field Effectiveness Facility Process 8 ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Process Investment - Operational Readiness “Customer” Relationship Management 9 ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Process Investment – Customer Relationship Management AVL Tech Centre Coventry AVL Graz 10 ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT People Investment – Importance of Training Team Growth & Development Team Size Ramp Skill Ramp Productive Facility TCC in Training Cell in Graz Coventry Project Timeline 11 Shift and Expand Use Case Study EMISSIONS TESTING ON A VEHICLE-IN-LOOP (VIL) TEST CELL 12 ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Chassis-Dyno to ViL Emission Test Comparison Fuel Type: CARCAL EU6 E10 Gasoline Engine Type: 3.0 V6 Supercharged Fuel Type: CARCAL EU6 Diesel Engine Type: 3.0 V6 Turbocharged ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Preparation of Unit Under Test 14 ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Design of Experiment ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Test Plan Overview Gasoline Diesel 101 104 102 103 CVS modal CVS modal RCD Soak RCD Soak CD3 CVS RCD Soak RCD Soak CD3 CVS RCD = Rapid Cool Down WLTC x3 NEDC x3 ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Diesel CO2 Comparison NEDC WLTC 190 Rapid cool down Soaked 185 Chassis Dyno 180 CO2 (g/km) CO2 175 170 165 102 103 102 103 Error bars represent 2σ modal modal ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Gasoline CO2 Comparison NEDC WLTC 250 Rapid cool down Soaked 240 Chassis Dyno 230 220 CO2 (g/km) CO2 210 200 101 104 101 104 Error bars represent 2σ modal modal ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Rapid Cool Down Issues T101 Gasoline 56 Gearbox Temperature - 54 NEDC 52 5050 48 46 44 42 4040 100 38 95 Gearbox TemperatureWLTC - Temp (ºC) Temp 36 90 WLTC Gbx_tTCMOil [deg C] 90 34 85 32 80 3030 75 28 70 26 65 24 6060 22 55 100 200 300 400 500 600 700 800 900 1000 1100 1200 200 400 600time [s] 800 1000 1200 50 Temp (ºC) Temp Gbx_tTCMOil [deg C] Time (s) 45 Rapid cool down 40 35 - Oil temperature 3030 Soaked - Driveline 25 20 - Coolant 15 Chassis Dyno 200 400 600 800 1000 1200 1400 1600 1800 400 800 time [s] 1200 1600 Time (s) ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Rapid Cool Down Issues T101 Gasoline Extended Correlation Activity - Fluid in RCD Unit reaches threshold and RCD switches off - Thermocouple data inside the vehicle is not checked ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Rapid Cool Down Issues T101 Gasoline 9090 Gearbox Temperature 85 80 12 hour soak 75 RCD + 2 hour RCD + 4 hour 70 RCD + 6 hour 65 RCD + 8 hour 6060 RCD + 12 hour 12 hour soak 55 50 45 Temp (ºC) Temp 40 Gbx_tTCMOil [deg C] 185 35 3030 180 25 20 15 175 10 5 (g/km) CO2 170 100 200200 300 400400 500 600600 700 800800 900 10001000 1100 Timetime [s] (s) 165 Tests ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Summary & Conclusions People Process Shift & Expand Level 4 Apprenticeship & Project process and Migration of Test Use Cases via Shift & Expand development of Technician common goal of operational delivers Efficiency benefits through increased population status effectiveness Established Technical Training Customer relationship A significant amount of effort (People, Process Team management & Facility) is required to unlock the potential Specialist training in the test Process oriented culture Successful demonstration of initial Use Cases field environment with “swim lane” processes has generated significant internal demand for developed in advance of additional applications Up-skilling existing population training and ramp-up While Technology changes can be “bought in”, it is essential to develop People and Teams 22 THANK YOU Dr. Philip Lawson Jaguar Land Rover Senior Manager Emissions Testing W/1/26 Abbey Road, Whitley Coventry CV3 4LF, UK M +44(0)7469 405229 jaguarlandrover.com [email protected] Sulabh Dhingra Lead Engineer Powertrain ViL/PiL Test & Methodology M +44(0)7341 074325 [email protected] 23.
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