Development of a range-extended electric vehicle powertrain for an integrated energy systems research printed utility vehicle

Chambon, Paul; Curran, Scott; Huff, Shean; Love, Lonnie; Post, Brian; Wagner, Robert; Jackson, Roderick; Green, Jr., Johney

doi:10.1016/j.apenergy.2017.01.045

Title: Development of a range-extended electric vehicle powertrain for an integrated energy systems research printed utility vehicle

Abstract

Rapid vehicle and powertrain development has become essential to for the design and implementation of vehicles that meet and exceed the fuel efficiency, cost, and performance targets expected by today's consumer while keeping pace with reduced development cycle and more frequent product releases. Recently, advances in large-scale additive manufacturing have provided the means to bridge hardware-in-the-loop (HIL) experimentation and preproduction mule chassis evaluation. This paper details the accelerated development of a printed range-extended electric vehicle (REEV) by Oak Ridge National Laboratory, by paralleling hardware-in-the-loop development of the powertrain with rapid chassis prototyping using big area additive manufacturing (BAAM). BAAM's ability to accelerate the mule vehicle development from computer-aided design to vehicle build is explored. The use of a hardware-in-the-loop laboratory is described as it is applied to the design of a range-extended electric powertrain to be installed in a printed prototype vehicle. The integration of the powertrain and the opportunities and challenges it presents are described in this work. A comparison of offline simulation, HIL and chassis rolls results is presented to validate the development process. Chassis dynamometer results for battery electric and range extender operation are analyzed to show the benefits of the architecture.

Authors:: Chambon, Paul; Curran, Scott; Huff, Shean; Love, Lonnie; Post, Brian; Wagner, Robert; Jackson, Roderick; Green, Jr., Johney

Publication Date:: Sat Apr 01 00:00:00 EDT 2017

Research Org.:: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Fuels, Engines and Emissions Research Center (FEERC); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). National Transportation Research Center (NTRC); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF); National Renewable Energy Lab. (NREL), Golden, CO (United States)

Sponsoring Org.:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office

OSTI Identifier:: 1390671

Alternate Identifier(s):: OSTI ID: 1342672; OSTI ID: 1352993

Report Number(s):: NREL/JA-4A00-68390
Journal ID: ISSN 0306-2619; S0306261917300533; PII: S0306261917300533

Grant/Contract Number:: AC05-00OR22725; AC36-08GO28308

Resource Type:: Published Article

Journal Name:: Applied Energy

Additional Journal Information:: Journal Name: Applied Energy Journal Volume: 191 Journal Issue: C; Journal ID: ISSN 0306-2619

Publisher:: Elsevier

Country of Publication:: United Kingdom

Language:: English

Subject:: 33 ADVANCED PROPULSION SYSTEMS; printed vehicle; range extender; additive manufacturing; rapid prototyping; hybrid vehicles; natural gas

Citation Formats


                    Chambon, Paul, Curran, Scott, Huff, Shean, Love, Lonnie, Post, Brian, Wagner, Robert, Jackson, Roderick, and Green, Jr., Johney. Development of a range-extended electric vehicle powertrain for an integrated energy systems research printed utility vehicle.  United Kingdom: N. p., 2017. 
Web.  doi:10.1016/j.apenergy.2017.01.045.

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                    Chambon, Paul, Curran, Scott, Huff, Shean, Love, Lonnie, Post, Brian, Wagner, Robert, Jackson, Roderick, & Green, Jr., Johney. Development of a range-extended electric vehicle powertrain for an integrated energy systems research printed utility vehicle.  United Kingdom.  https://doi.org/10.1016/j.apenergy.2017.01.045

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                    Chambon, Paul, Curran, Scott, Huff, Shean, Love, Lonnie, Post, Brian, Wagner, Robert, Jackson, Roderick, and Green, Jr., Johney. Sat .  
"Development of a range-extended electric vehicle powertrain for an integrated energy systems research printed utility vehicle".  United Kingdom.  https://doi.org/10.1016/j.apenergy.2017.01.045.

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@article{osti_1390671,

  title        = {Development of a range-extended electric vehicle powertrain for an integrated energy systems research printed utility vehicle},

  author       = {Chambon, Paul and Curran, Scott and Huff, Shean and Love, Lonnie and Post, Brian and Wagner, Robert and Jackson, Roderick and Green, Jr., Johney},

  abstractNote = {Rapid vehicle and powertrain development has become essential to for the design and implementation of vehicles that meet and exceed the fuel efficiency, cost, and performance targets expected by today's consumer while keeping pace with reduced development cycle and more frequent product releases. Recently, advances in large-scale additive manufacturing have provided the means to bridge hardware-in-the-loop (HIL) experimentation and preproduction mule chassis evaluation. This paper details the accelerated development of a printed range-extended electric vehicle (REEV) by Oak Ridge National Laboratory, by paralleling hardware-in-the-loop development of the powertrain with rapid chassis prototyping using big area additive manufacturing (BAAM). BAAM's ability to accelerate the mule vehicle development from computer-aided design to vehicle build is explored. The use of a hardware-in-the-loop laboratory is described as it is applied to the design of a range-extended electric powertrain to be installed in a printed prototype vehicle. The integration of the powertrain and the opportunities and challenges it presents are described in this work. A comparison of offline simulation, HIL and chassis rolls results is presented to validate the development process. Chassis dynamometer results for battery electric and range extender operation are analyzed to show the benefits of the architecture.},

  doi          = {10.1016/j.apenergy.2017.01.045},

  journal      = {Applied Energy},

  number       = C,

  volume       = 191,

  place        = {United Kingdom},

  year         = {Sat Apr 01 00:00:00 EDT 2017},

  month        = {Sat Apr 01 00:00:00 EDT 2017}

}

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Works referencing / citing this record:

Empirical Study on the Efficiency of an LPG-Supplied Range Extender for Electric Vehicles
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Lasocki, Jakub; Kopczyński, Artur; Krawczyk, Paweł
Energies, Vol. 12, Issue 18
DOI: 10.3390/en12183528

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Title: Development of a range-extended electric vehicle powertrain for an integrated energy systems research printed utility vehicle

Abstract

Citation Formats

Empirical Study on the Efficiency of an LPG-Supplied Range Extender for Electric Vehicles journal, September 2019

Empirical Study on the Efficiency of an LPG-Supplied Range Extender for Electric Vehicles
journal, September 2019