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 Testing Effort Background& Motivation ADVANCEMENTS TEST ENVIRONMENTIN POWERTRAIN
As-is State Portfolio Product Expanding Technologies New
New Testing Effort Reuse Reuse Data Efficiency Gains Shift Shift & Expand Effectiveness
Reduced Testing Efforts in Strategic Environment Testing Effectiveness Four Levers 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 C] [deg 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 C] [deg 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 C] [deg 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
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