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Title: Multi-Speed Transmission For Commercial Delivery Medium Duty PEDVs

Abstract

Successful completion of the proposed project will set a course for improving quality of life by overcoming key challenges in the gearbox for commercial-delivery, medium-duty, plug-in electric drive vehicles: It will reduce US dependency on foreign oil through the use of electric driven propulsion instead of fuel driven. It will reduce health risks by replacing tailpipe emissions in densely populated city centers. Finally, it will improve the performance-cost basis to meet or exceed the expectations of the targeted medium duty vehicle fleet owners and the independent customers. The proposed multi-speed transmission will narrow motor operation to the peak efficiency region, thereby increasing the electric powertrain efficiency to help close the range gap. Further, it will enhance customer satisfaction by improving vehicle acceleration, top speed and gradeability over the baseline. The project was conducted in three budget periods: In BP1: Technology Development, High-level vehicle powertrain models were used to optimize candidate transmission architectures and ratios along with a variety of traction motor characteristics for concept selection. The detailed driveline designs and component dynamics were investigated to meet medium-duty EV requirements; In BP2: Technology Development and Prototype Demonstration, The modeling and simulations with multi-speed transmissions were extended to other MD and HDmore » EV platforms. Clean sheet design of a compact, lightweight, flexible, and modular, four-speed transmission was completed. Development of novel shifting and controls strategies were started and procurement of the prototype transmission and the controller hardware was begun; In BP3: Technology Integration, Testing, and Demonstration, Prototyping the four-speed automated mechanical transmission was completed. The transmission controls system and software development and preliminary gearbox dyno tests were done at Eaton. ORNL conducted integrated powertrain HIL tests. One of the prototype units was fully integrated into a Proterra BE35 demonstration electric bus. The shift control strategy was fine-tuned on the integrated vehicle at Eaton Marshall Proving Grounds. NREL tested the vehicle and validated the performance gains. Simulations predicted up to 20% increase in system energy efficiency depending on drive cycles, a top speed of greater than70 mph on flat road, 40% faster acceleration and a doubled gradeability with four-speed transmission as compared to the baseline EVs. Chassis Dyno Tests at NREL verified the simulation results of Eaton team and the HIL test results of ORNL team. The new four-speed EV transmission is efficient, reliable, modular, scalable, light weight, small size, and will be affordable. Furthermore, four-speed transmission enables downsizing of motor, battery and final drive, thereby reducing the total system cost.« less

Authors:
 [1]
  1. Eaton Corp., Menomonee Falls, WI (United States)
Publication Date:
Research Org.:
Eaton Corp., Menomonee Falls, WI (United States); National Energy Technology Lab. (NETL), Pittsburgh, PA, and Morgantown, WV (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Vehicle Technologies Office (EE-3V); Proterra Inc., Burlingame, CA (United States)
OSTI Identifier:
1418158
Report Number(s):
DOE-EATON-0006843
DOE Contract Number:  
EE0006843
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
33 ADVANCED PROPULSION SYSTEMS; Medium duty electric vehicle (MD-EV); heavy duty electric vehicle (HD-EV); multi-speed transmission; 4-speed transmission; automated mechanical transmission; yy shifter; electric bus; electric delivery truck; HIL test; chassis dyno test; efficiency; efficiency gain; motor efficiency map; transmission efficiency; acceleration; gradeability; duty cycle; Altoona tests; Autonomie; simulation; modeling; regeneration; adaptive control strategy; transmission control unit; NVH; business case

Citation Formats

Chavdar, Bulent. Multi-Speed Transmission For Commercial Delivery Medium Duty PEDVs. United States: N. p., 2017. Web. doi:10.2172/1418158.
Chavdar, Bulent. Multi-Speed Transmission For Commercial Delivery Medium Duty PEDVs. United States. doi:10.2172/1418158.
Chavdar, Bulent. Sun . "Multi-Speed Transmission For Commercial Delivery Medium Duty PEDVs". United States. doi:10.2172/1418158. https://www.osti.gov/servlets/purl/1418158.
@article{osti_1418158,
title = {Multi-Speed Transmission For Commercial Delivery Medium Duty PEDVs},
author = {Chavdar, Bulent},
abstractNote = {Successful completion of the proposed project will set a course for improving quality of life by overcoming key challenges in the gearbox for commercial-delivery, medium-duty, plug-in electric drive vehicles: It will reduce US dependency on foreign oil through the use of electric driven propulsion instead of fuel driven. It will reduce health risks by replacing tailpipe emissions in densely populated city centers. Finally, it will improve the performance-cost basis to meet or exceed the expectations of the targeted medium duty vehicle fleet owners and the independent customers. The proposed multi-speed transmission will narrow motor operation to the peak efficiency region, thereby increasing the electric powertrain efficiency to help close the range gap. Further, it will enhance customer satisfaction by improving vehicle acceleration, top speed and gradeability over the baseline. The project was conducted in three budget periods: In BP1: Technology Development, High-level vehicle powertrain models were used to optimize candidate transmission architectures and ratios along with a variety of traction motor characteristics for concept selection. The detailed driveline designs and component dynamics were investigated to meet medium-duty EV requirements; In BP2: Technology Development and Prototype Demonstration, The modeling and simulations with multi-speed transmissions were extended to other MD and HD EV platforms. Clean sheet design of a compact, lightweight, flexible, and modular, four-speed transmission was completed. Development of novel shifting and controls strategies were started and procurement of the prototype transmission and the controller hardware was begun; In BP3: Technology Integration, Testing, and Demonstration, Prototyping the four-speed automated mechanical transmission was completed. The transmission controls system and software development and preliminary gearbox dyno tests were done at Eaton. ORNL conducted integrated powertrain HIL tests. One of the prototype units was fully integrated into a Proterra BE35 demonstration electric bus. The shift control strategy was fine-tuned on the integrated vehicle at Eaton Marshall Proving Grounds. NREL tested the vehicle and validated the performance gains. Simulations predicted up to 20% increase in system energy efficiency depending on drive cycles, a top speed of greater than70 mph on flat road, 40% faster acceleration and a doubled gradeability with four-speed transmission as compared to the baseline EVs. Chassis Dyno Tests at NREL verified the simulation results of Eaton team and the HIL test results of ORNL team. The new four-speed EV transmission is efficient, reliable, modular, scalable, light weight, small size, and will be affordable. Furthermore, four-speed transmission enables downsizing of motor, battery and final drive, thereby reducing the total system cost.},
doi = {10.2172/1418158},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2017},
month = {12}
}