400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760 Web: www.sae.org SAE TECHNICAL PAPER SERIES 2002-01-3129 Vehicle Dynamometer for Hybrid Truck Development Gregory C. Nowell Eaton Corporation International Truck and Bus Meeting and Exhibition Detroit, Michigan November 18-20, 2002Downloaded from SAE International by Univ of California Berkeley, Saturday, August 04, 2018All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise,without the prior written permission of SAE. For permission and licensing requests contact: SAE Permissions 400 Commonwealth DriveWarrendale, PA 15096-0001-USAEmail: [email protected]: 724-772-4891Tel: 724-772-4028 For multiple print copies contact: SAE Customer ServiceTel: 877-606-7323 (inside USA and Canada)Tel: 724-776-4970 (outside USA)Fax: 724-776-1615Email: Customer [email protected] ISSN 0148-7191Copyright © 2002 SAE InternationalPositions and opinions advanced in this paper are those of the author(s) and not necessarily those of SAE.The author is solely responsible for the content of the paper. A process is available by which discussions will be printed with the pap er if it is publishe d in SAE Transactions. Persons wishing to submit papers to be considered for presentation or publication by SAE should send themanuscript or a 300 word abstract of a proposed manuscript to: Secretary, Engineering Meetings Board, SAE. Printed in USADownloaded from SAE International by Univ of California Berkeley, Saturday, August 04, 20182002-01-3129 Vehicle Dynamometer for Hybrid Truck Development Gregory C. Nowell Eaton Corporation ABSTRACT A special vehicle dynamometer has been developed that allows engineers to evaluate driveline components and control algorithms for advanced, electrically-assisted drive systems on commercial vehicles. This dynamometer allows objective measurements of performance, fuel economy, and exhaust emissions, while the full vehicle is operated over a specified driving cycle. This system can be used to exercise the electric motor, engine, transmission and battery systems on Medium Duty Hybrid Trucks - in regeneration as well as power mode - all indoors and in a controlled, repeatable environment. This paper will provide descriptions of the operating goals, control features, and results of testing with this dynamometer. Once the various parameters have been optimized for fuel and emissions performance in this facility, the vehicle can be evaluated where it counts - on the road. THE NEED FOR A VEHICLE DYNAMOMETER The design of Hybrid Electric Vehicles (HEVs) requires extremely intelligent controls that utilize communications among the Supervisory Powertrain Control Unit and the electric motor, engine, transmission, vehicle, and operator. Even though the control developers have extensive tools to design and debug the software in the simulation environment, the chances are remote that the new software will be absolutely correct upon the first implementation with real vehicle hardware. Hybrid control strategies need to be optimized with the functions and responses of the actual components in the system. Performance testing of different control strategies, on a full vehicle with a given system architecture and duty cycle, allows the control designers to develop the optimum performance potential for that hybrid system in the real operating environment. Evaluating the performance of different systems and different duty cycles allows the control developers to compare the robustness and relative benefits of proposed hybrid systems in actual vehicle operation, and tocompare their performance results against baseline results for a similar non-hybrid vehicle. Road testing is the most direct method for evaluating full vehicle performance, but the important variables thatinfluence the operating resul