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With the introduction of plug-in electric vehicles (PEVs), the conventional mindset of “fill-up time” will be challenged as customers top off their battery packs. For example, using a standard 120VAC outlet, it may take over 10hrs to achieve 40-50 miles of EV range-making range anxiety a daunting reality for EV owners. As customers adapt to this new mindset of charge time, it is critical that automotive OEMs supply the consumer with accurate charge time estimates. Charge time accuracy relies on a variety of parameters: battery pack size, power source, electric vehicle supply equipment (EVSE), on-board charging equipment, ancillary controller loads, battery temperature, and ambient temperature. Furthermore, as the charging events may take hours, the initial conditions may vary throughout a plug-in charge (PIC). The goal of this paper is to characterize charging system sensitivities and promote best practices for charge time estimations.

This paper details the design and operating attributes of a triple input clutch, layshaft automatic transmission (TCT) with a torque converter in a rear wheel drive passenger vehicle. The objectives of the TCT design are to reduce fuel consumption while increasing acceleration performance through the design of the gearing arrangement, shift actuation system and selection of gear ratios and progression. A systematic comparison of an 8-speed TCT design is made against a hypothetical 8-speed planetary automatic transmission (AT) with torque converter using an energy analysis model based upon empirical data and first principles of vehicle-powertrain systems. It was found that the 8-speed TCT design has the potential to provide an approximate 3% reduction in fuel consumption, a 3% decrease in 0-100 kph time and 30% reduction in energy loss relative to a comparable 8-speed planetary AT with an idealized logarithmic ratio progression.

This investigation was aimed at measuring the relative performance of two spray-guided, single-cylinder, spark-ignited direct-injected (SIDI) engine combustion system designs. The first utilizes an outwardly-opening poppet, piezo-actuated injector, and the second a conventional, solenoid operated, inwardly-opening multi-hole injector. The single-cylinder engine tests were limited to steady state, warmed-up conditions. The comparison showed that these two spray-guided combustion systems with two very different sprays had surprisingly close results and only differed in some details. Combustion stability and smoke emissions of the systems are comparable to each other over most of the load range. Over a simulated Federal Test Procedure (FTP) cycle, the multi-hole system had 15% lower hydrocarbon and 18% lower carbon monoxide emissions.

Mid 2006 a study group at General Motors developed the concept for the electric vehicle with extended range (EREV),. The electric propulsion system should receive the electrical energy from a rechargeable energy storage system (RESS) and/or an auxiliary power unit (APU) which could either be a hydrogen fuel cell or an internal combustion engine (ICE) driven generator. The study result was the Chevrolet VOLT concept car in the North American Auto Show in Detroit in 2007. The paper describes the requirements, concepts, development and the performance of the battery used as RESS for the ICE type VOLTEC propulsion system version of the Chevrolet Volt. The key requirement for the RESS is to provide energy to drive an electric vehicle with “no compromised performance” for 40 miles. Extended Range Mode allows for this experience to continue beyond 40 miles.

Energy efficient HVAC system is becoming increasingly important as higher Corporate Average Fuel Economy (CAFE) standards are required for future vehicle products. The present study is a preliminary attempt at designing energy efficient HVAC system by introducing localized heating/cooling concepts without compromising occupant thermal comfort. In order to achieve this goal of reduced energy consumption while maintaining thermal comfort it is imperative that we use an analytical model capable of predicting thermal comfort with reasonable accuracy in a non-homogenous enclosed thermal environment such as a vehicle's passenger cabin. This study will primarily focus on two aspects: (a) energy efficiency improvements in an HVAC system through micro-cooling/heating strategies and (b) validation of an analytical approach developed in GM that would support the above effort.

Recent advancements in simulation software and computational hardware make it realizable to simulate a full vehicle system comprised of multiple sub-models developed in different modeling languages. The so-called, co-simulation allows one to develop a control strategy and evaluate various aspects of a vehicle system, such as fuel efficiency and vehicle drivability, in a cost-effective manner. In order to study the feasibility of the synchronized parallel processing in co-simulation this paper presents two co-simulation frameworks for a complete vehicle system with multiple heterogeneous subsystem models. In the first approach, subsystem models are co-simulated in a serial configuration, and the same sub-models are co-simulated in a parallel configuration in the second approach.

The sustainable use of energy and the reduction of pollutant emissions are main concerns of the automotive industry. In this context, Hybrid Electric Vehicles (HEVs) offer significant improvements in the efficiency of the propulsion system and allow advanced strategies to reduce pollutant and noise emissions. The paper presents the results of a simulation study that addresses the minimization of fuel consumption, NOx emissions and combustion noise of a medium-size passenger car. Such a vehicle has a parallel-hybrid diesel powertrain with a high-voltage belt alternator starter. The simulation reproduces real-driver behavior through a dynamic modeling approach and actuates an automatic power split between the Internal Combustion Engine (ICE) and the Electric Machine (EM). Typical characteristics of parallel hybrid technologies, such as Stop&Start, regenerative braking and electric power assistance, are implemented via an operating strategy that is based on the reduction of total losses.

General Motors' (GM) eAssist powertrain builds upon the knowledge and experience gained from GM's first generation 36Volt Belt-Alternator-Starter (BAS) system introduced on the Saturn VUE Green Line in 2006. Extensive architectural trade studies were conducted to define the eAssist system. The resulting architecture delivers approximately three times the peak electric boost and regenerative braking capability of 36V BAS. Key elements include a water-cooled induction motor/generator (MG), an accessory drive with a coupled dual tensioner system, air cooled power electronics integrated with a 115V lithium-ion battery pack, a direct-injection 2.4 liter 4-cylinder gasoline engine, and a modified 6-speed automatic transmission. The torque-based control system of the eAssist powertrain was designed to be fully integrated with GM's corporate common electrical and controls architectures, enabling the potential for broad application across GM's global product portfolio.

Conventional HVAC systems adjust the position of a temperature door, to achieve a required air temperature discharged into the passenger compartment. Such systems are based upon the fact that a conventional (non-hybrid) vehicle's engine coolant temperature is controlled to a somewhat constant temperature, using an engine thermostat. Coolant flow rate through the cabin heater core varies as the engine speed changes. EREVs (Extended Range Electric Vehicles) & PHEVs (Plug-In Hybrid Electric Vehicles) have two key vehicle requirements: maximize EV (Electric Vehicle) range and maximize fuel economy when the engine is operating. In EV mode, there is no engine heat rejection and battery pack energy is consumed in order to provide heat to the passenger compartment, for windshield defrost/defog and occupant comfort. Energy consumption for cabin heating must be optimized, if one is to optimize vehicle EV range.

The battery system in the Chevrolet Volt is very complex and must balance a variety of performance criteria, including the safety of vehicle occupants and other users. In order to assure a thorough approach to battery system safety, a system safety engineering process was applied and found to provide a useful framework. This methodical approach began with the preliminary hazard analysis and continued through requirements definition, design development and, finally, validation. Potentially hazardous conditions related directly to functional safety (for example, charge control) and primary physical safety (for example, short circuit conditions) can all be addressed in this manner. Typical battery abuse testing, as well as newly defined limit testing, supported the effort. Extensive documentation, traceability and peer reviews helped to verify that all issues were addressed.

Spot, or distributed, cooling and heating is an energy efficient way of delivering comfort to an occupant in the car. This paper describes an approach to distributed cooling in the vehicle. A two passenger CFD model of an SUV cabin was developed to obtain the solar and convective thermal loads on the vehicle, characterize the interior thermal environment and accurately evaluate the fluid-thermal environment around the occupants. The present paper focuses on the design and CFD analysis of the energy efficient HVAC system with spot cooling. The CFD model was validated with wind tunnel data for its overall accuracy. A baseline system with conventional HVAC air was first analyzed at mid and high ambient conditions. The airflow and cooling delivered to the driver and the passenger was calculated. Subsequently, spot cooling was analyzed in conjunction with a much lower conventional HVAC airflow.

With the rising cost of gasoline causing the adoption of the electric car into the lives of average consumers, new avenues of transportation cost control and consumer-vehicle interaction can be explored. Unlike a conventional ICE vehicle where a consumer cannot control the cost of what he or she pays for the fuel source, an electric vehicle provides a means for the consumer to directly impact the price for which they “fill-up”. GM's Programmable Charging feature offers a way for consumers to work directly with the power company to charge their electric vehicles during the most cost efficient hours. The consumer has the option to either start charging when plugging in the vehicle or utilizing the Programmable Charging feature to select a lower cost time to charge their vehicle's battery. Utilizing this feature also benefits the power companies by reducing demand on the Grid during peak usage hours when a customer would typically be charging her vehicle.

This paper examines Smart Electric Power Management as it pertains to when the vehicle charging system is active. Over the past decade there have been several factors at play which have stressed the demands placed upon the vehicle electrical power system. Many of these factors present challenges to electrical power that are at cross-purposes with one another. For example, demands of new and existing electrical loads, customer expectations about load performance and battery life, and the push by governments' world-wide for increased fuel economy (FE) and reduced CO2 emissions all have direct impact and can be directly impacted by decisions made in electric power design. As the electrification of the vehicle has progressed we now have much more specific vehicle state data available and the means to share this information among on-board computers through serial data link connectivity.

Current manufacture of alternative energy sources for automobiles, such as fuel cells and lithium-ion batteries, uses repeating energy modules to achieve targeted balances of power and weight for varying types of vehicles. Specifically for lithium-ion batteries, tens to hundreds of identical plastic parts are assembled in a repeating fashion; this assembly of parts requires complex dimensional planning and high degrees of quality control. This paper will address the aspects of dimensional quality for repeated, injection molded thermoplastic battery components and will include the following: First, dimensional variation associated with thermoplastic components is considered. Sources of variation include the injection molding process, tooling or mold, lot-to-lot material differences, and varying types of environmental exposure. Second, mold tuning and cavity matching between molds for multi-cavity production will be analyzed.

As vehicle fuel economy requirements continue to increase it is becoming more challenging and expensive to simultaneously improve fuel consumption and meet emissions regulations. The Passive Ammonia SCR System (PASS) is a novel aftertreatment concept which has the potential to address NOx emissions with application to both lean SI and stoichiometric SI engines. PASS relies on an underfloor (U/F) SCR for storage of ammonia which is generated by the close-coupled (CC) TWCs. For lean SI engines, it is required to operate with occasional rich pulses in order to generate the ammonia, while for stoichiometric application ammonia is passively generated through the toggling of air/fuel ratio. PASS serves as an efficient and cost-effective enhancement to standard aftertreatment systems. For this study, the PASS concept was demonstrated first using lab reactor results which highlight the oxygen tolerance and temperature requirements of the SCR.

Lean-burn SIDI engine technology offers improved fuel economy; however, the reduction of NOx during lean-operation continues to be a major technical hurdle in the implementation of energy efficient technology. There are several aftertreatment technologies, including the lean NOx trap and active urea SCR, which have been widely considered, but they all suffer from high material cost and require customer intervention to fill the urea solution. Recently reported passive NH₃-SCR system - a simple, low-cost, and urea-free system - has the potential to enable the implementation of lean-burn gasoline engines. Key components in the passive NH₃-SCR aftertreatment system include a close-coupled TWC and underfloor SCR technology. NH₃ is formed on the TWC with short pulses of rich engine operation and the NH₃ is then stored on the underfloor SCR catalysts.

In this paper, a low-cost means to improve fuel economy in conventional vehicles by employing ultracapacitor based Active Energy Recovery Buffer (AERB) scheme will be presented. The kinetic energy of the vehicle during the coast down events is utilized to charge the ultracapacitor either directly or through a dc-dc converter, allowing the voltage to increase up to the maximum permissible level. When the vehicle starts after a Stop event, the energy stored in the capacitor is discharged to power the accessory loads until the capacitor voltage falls below a minimum threshold. The use of stored capacitor energy to power the accessory loads relieves the generator torque load on the engine resulting in reduced fuel consumption. Two different topologies are considered for implementing the AERB system. The first topology, which is a simple add-on to the conventional vehicle electrical system, comprises of the ultracapacitor bank and the dc-dc converter connected across the dc bus.

To realize better fuel economy benefits from transmissions, car makers have started the application of torque converter clutch control in second gear and beyond, resulting in greater demand on the torque converter clutch (TCC) and its control system. This paper focuses on one aspect of the control of the torque converter clutch to improve fuel economy and faster response of the transmission. A TCC is implemented to control the slip between the pump and turbine of the torque converter, thereby increasing its energy transfer efficiency and increasing vehicle fuel economy. However, due to the non-linear nature of the torque converter fluid coupling, the slip feedback control has to be very active to handle different driver inputs and road-load conditions, such as different desired slip levels, changes in engine input torques, etc. This non-linearity requires intense calibration efforts to precisely control the clutch slip in all the scenarios.

Rechargeable energy storage systems with Lithium-ion pouch cells are subject to various ambient temperature conditions and go through thousands of charge-discharge cycles during the life time of operation. The cells may change their thickness with internal heat generation, cycling and any other mechanisms. The stacked prismatic cells thus experience face pressure and this could impact the pack electrical performance. The pack consists of stiff end plates keeping the pack in tact using bolts, cooling fins to maintain cell temperature and foam padding in between cells. The pack level thermal requirements limit the amount of temperature increase during normal operating conditions. Similarly, the structural requirements state that the stresses and the deflection in the end plates should be minimal. Uncertainties in cell, foam mechanical and thermal properties might add variation to the pack performance.

Hybrid high voltage battery pack is not only heavy mass but also large in dimension. It interacts with the vehicle through the battery tray. Thus the battery tray is a critical element of the battery pack that interfaces between the battery and the vehicle, including the performances of safety/crash, NVH (modal), and durability. The tray is the largest and strongest structure in the battery pack holding the battery sections and other components including the battery disconnect unit (BDU) and other units that are not negligible in mass. This paper describes the mass optimization work done on one of the hybrid batteries using CAE simulation. This was a multidisciplinary optimization project, in which modal performance and fatigue damage were accessed through CAE analysis at both the battery pack level, and at the vehicle level.