February 2012

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Since 1988, students, faculty and volunteers at Penn State have participated in advanced vehicle technology competitions to design and build fuel efficient and safe vehicles. Now with 50 undergraduate students, three faculty advisors and three veteran volunteers in EcoCAR 2, Penn State’s team is aiming to train the next generation of automotive and energy professionals. Under the co-leadership of Luke Shepley and Eduardo Barrientos, the group is split into four subgroups: mechanical, controls, electrical and outreach/business. Many Penn State team members take jobs with industry sponsors such as A123, GM and AVL. The team enjoys watching this video to get them pumped up for working on CAD models and cleaning the garage in preparation for their upcoming facilities inspection!

 

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By Santhosh Jogi, Director of Engineering for dSPACE, Inc.

Being part of EcoCAR offers a fantastic opportunity to play a role in the development of new engineers who will take our industry through the next set of breakthroughs.  Automotive technology must transform to meet future needs, and creative engineers able to take on complex open-ended challenges, like the students in EcoCAR 2, will lead the way.

As a sponsor and judge in the competition, Winter Workshop afforded the chance to both assist teams and also assess their progress and strategy.  At this event, focus was on the HIL simulation environment, as it is critically important for teams to develop and test their supervisory control systems. The time my colleagues and I spent with teams during the HIL setup days and weekend training was invaluable.  We were able work with each team, discuss ideas and challenges, and determine what kind of help and mentoring is needed – I see a few tech talks in the near future!  It was also great for us to see all 15 teams able to run the requisite HIL demonstration for the judged event!

As a judge in the HIL Event, I had the opportunity to review the progress teams had made in development of their HIL test environment as well as their plans going forward.  As with any competition, there were some teams ahead of others, but overall I was thoroughly impressed.  The level of sophistication, creativity and maturity in what we saw during the presentation and HIL demonstration was outstanding.  It was evident that teams are taking the bull by the horns (we were in Texas after all!) and not underestimating the magnitude of challenges ahead.  Another objective during judging was to determine if any “course correction” was needed to help teams achieve their objectives.  While EcoCAR 2 is a competition, every sponsor and organizer has the same goal – for all teams to succeed and for every student to gain the best educational experience.  I feel Winter Workshop was highly successful in helping teams, organizers, and sponsors come together and align toward this goal.

A big thanks to my team (Jeff Warra, Tobias Eifler, Joe Cassar, and Vince Sabatini), who helped the teams during HIL setup days, held mentoring sessions, and provided training over the weekend. My thanks also to Freescale for co-hosting this event, and to the organizers for making it all happen!  I look forward to competition in Los Angeles, and best of luck to all the teams.

 

By Joe Cassar, Team Leader

I went to the EcoCAR Winter Workshop not knowing what to expect.  Although I had participated in EcoCAR: The NeXt Challenge as a mentor for a team, most of my interactions were limited to phone conferences and e-mail. So this was the first time that I actively participated in a competitive event.

I was very impressed with the level of sophistication and competency exhibited by all of the teams with regard to their design concepts.  Our mentoring sessions provided me the opportunity to meet with many teams and to hear why they selected their vehicle architectures.  As I answered their questions regarding dSPACE technology, I was also able to learn a lot about the various hybrid configurations that they plan on implementing. I was impressed with how rapidly they had adopted the specialized tools used to develop embedded control systems on their RCP boxes and drive train simulation on the HIL units.

During the technology presentations, we had a lot of positive feedback and participation so it was very obvious that the teams were very adept at processing the technical information provided to them and leveraging it to their own specific use cases.

 

By Tobias Eifler, Sr. Applications Engineer

I gained a lot of encouraging experiences from the 2012 EcoCAR 2 Winter Workshop. I’m proud to be the responsible mentor for the students regarding dSPACE’s Automotive Simulation Models (ASM). Many of the control team students were exposed to dSPACE tools for the first time, and I found it fascinating and very enjoyable to see the eagerness and willingness that these students showed.

The creativity that the students revealed in working with the given tools was outstanding. During this workshop, I was especially impressed by the great understanding the students have on the benefits of HIL simulation for their control software development. It was my first visit to Texas and I enjoyed it a lot. It’s true indeed that everything is bigger in Texas.

 

By Vivek Moudgal, Sales Director

Judging the HIL event was a very positive experience for me.  Compared to the first winter workshop from EcoCAR: The NeXt Challenge, all of the teams in EcoCAR 2 made significantly more progress − and I was most surprised by the new teams. Colorado and Purdue won over the judges with their presentation and understanding of HIL technology they were using and its application for the competition. Another aspect that struck me was the number of teams that were bunched close together in the final analysis of the judges’ scores. The maturity, systematic approach and understanding of the technology the students have at their disposal promises to make for a very close competition.

 

By Jeff Warra, Team Leader, HIL Applications Engineering

Teamwork is the fabric of our modern day technological revolution. Developing the next electromechanical innovation takes time and a lot of effort. Managing a team takes effort, so work out your communication breakdowns and manage your time. In the end, you will excel and you will meet the challenge as a team. Teams exist for one purpose … to reach an end goal, which would not be attainable individually. Team members may stumble: It’s unavoidable. Helping one another out will only strengthen your team, because each individual is a crucial member on the team.

“The strength of the team is in each individual member.  The strength of each member is the team.”  -Unknown Author

 

By Alicia Alvin, Marketing Manager

As an Advanced Vehicle Technology Competition, it’s only natural that engineering students receive the majority of the attention from the automotive industry, the media, policy makers, fellow students and the local community. But there is another segment of each EcoCAR team that is hard at work behind the scenes promoting EcoCAR … and that group is our Outreach Teams.  Without the contributions of outreach efforts, much of the work and success of the engineering teams would go unnoticed.

As an Outreach judge, I am absolutely amazed at the level of organization and accomplishments of this very special group. EcoCAR Outreach members are involved in so many aspects of promotion, from the creation of communications plans to organizing events, issuing media advisories, developing websites and social media outlets, networking on campus and off campus, educating youth and the public at large, etc. Outreach members capture the unique story of each team’s project and bring well-deserved attention to their goals, ambitions, and successes.  Way to go Outreach!

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Back in December, the Purdue EcoMakers attended the International Motorsports Industry Show (IMIS) which took place at the Indiana Convention Center. IMIS is in its third year and has actually increased in size despite the economic downturn!

The EcoMakers ran the Purdue University booth, which showcased both Purdue EcoCAR 2 and the Electric Vehicle Grand Prix, two progressive competitions in which Purdue takes part. The exhibitors at IMIS were very diverse, with everything from engine builders to safety equipment companies to university racing teams, and it was a great experience for EcoMakers to talk with these companies. Team members took the opportunity to tell other attendees about the EcoCAR 2 competition and get insights about high performance vehicle components.

EcoMakers also handed out promotional items to raise awareness about EcoCAR 2 with passing spectators. The team is happy to report that many attendees were interested in the project! As racing is typically done with high-powered gasoline engines, many people were intrigued to see the Purdue booth display an electric racing go-kart and the prospect of a reengineered Chevrolet Malibu.

This international event showcased companies from the UK, Japan, New Zealand and Germany who were very interested in hearing about the North American EcoCAR 2 competition. The EcoMakers that were able to attend the tradeshow enjoyed it immensely and benefitted greatly from the exposure to this side of the automotive world.

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Dr. Shawn Midlam-Mohler, a co-advisor for the Ohio State University EcoCAR 2 team, and Brian Benoy, an organizer from Argonne National Lab, will be the special guest speakers at a dSPACE webinar on March 16! The one-hour webinar is entitled “Adopting the Latest Industry Technology in Education” and  will address the benefits and issues surrounding the adoption of industry standard technology at academic institutions. From the webinar website:

Universities and research institutions across North America rely on real-time development systems from dSPACE for a wide variety of control applications … from high-speed robotics and rapid prototyping projects to complex vehicle development processes. Find out how the most cutting edge software tools support STEM theories and promote high-tech industries, such as automotive, aerospace and communications where electronic controls are vital to product development.

Educators, researchers, engineering students and other interested parties are all invited to join, so register now by clicking here!

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By Patrick Walsh, Engineer at Argonne National Laboratory

As an engineer who is passionate about sustainable transportation, I was very charged up to attend and speak at the SAE Hybrid Vehicle Technologies Symposium in San Diego this week. OEMs, suppliers and other companies at the forefront of hybrid vehicle engineering were all present to showcase their products and knowledge. I got the chance to speak for a few minutes about some electrifying results from EcoCAR, The NeXt Challenge, specifically how successful the top teams were in reducing the environmental impact of the stock vehicle, as well as educate the symposium attendees on our current EcoCAR 2 competition. Additionally, I helped staff our EcoCAR 2 booth display and educate anyone interested in advanced vehicle technology competitions.

As a competition graduate, it was also great to see the old EcoCAR: The NeXt Challenge vehicle from my alma mater, Virginia Tech, on display. The amount of interest in competitions, both at our EcoCAR 2 booth and at the vehicle display, was overwhelming. Based on what I saw this week, the industry definitely recognizes the incredible value of this competition, and the high level of experience of its graduates. I want to encourage all the teams to keep up the fantastic work, and continue to make the organizers proud!

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More Than $745M in Software, Hardware and Cash Donations from Sponsors to Build Highly-Efficient Vehicles

Detroit, Mich. (February 22, 2012) – Today, the 15 North American universities participating in EcoCAR 2: Plugging In to the Future announced the vehicle architectures they will implement in their General Motors-donated 2013 Chevrolet Malibu. The three-year EcoCAR 2 competition, which is sponsored by the U.S. Department of Energy (DOE), Argonne National Laboratory, General Motors, and 20 other government and industry leaders, gives students the opportunity to gain real-world, eco-friendly automotive engineering experience while striving to further improve the energy-efficiency of an already highly efficient vehicle – the Malibu.

But teams don’t get to stop there. Much like the challenges facing automakers, EcoCAR engineering students must balance the challenge of increasing the vehicle’s energy efficiency and reducing the vehicle’s greenhouse gas emissions and petroleum consumption with maintaining the performance, safety and overall consumer acceptability of the original Malibu.

To meet these technical challenges, each EcoCAR team designed its own unique Plug-In Hybrid Electric Vehicle (PHEV) architecture and utilized a crowd-sourcing format to select the powertrain components that it will integrate into its advanced technology vehicle over the three-year program. This technique mimics industry’s global vehicle development process, which focuses on advanced controls and software to develop future vehicles.  Hybrid vehicles on the road today already reach peak efficiency, so these teams must aim to get every last drop of energy possible out of the vehicle in order to reduce the environmental impact of a vehicle without compromising performance, safety and consumer acceptability. This hands-on experience is made possible by the numerous sponsor contributions to the 15 EcoCAR universities that exceed $745 million in software, hardware and cash donations.

“For this competition, we wanted to donate a vehicle that reflected today’s consumers’ needs, and the new 2013 Malibu made the most sense in terms of its size and flexibility,” said Kent Helfrich, executive director, electronic controls and software engineering, of General Motors. “EcoCAR 2 students will take our Malibu and re-engineer their vehicle to reduce its environmental impact, yet still deliver real-life, practical results. This is not an easy job, but it’s very rewarding. It’s what we do at GM every day.”

“The future in hybrid technology is happening now,” said Patrick Davis, program manager of DOE’s Vehicle Technologies Program. “It used to be that we were on the edge of this type of technology – now we are there, and these students are attempting to take it even further.”

All of the EcoCAR team vehicle designs are PHEVs, which use an on-board battery to reduce fuel use. The battery can be recharged using a standard wall outlet. Once the plug-in range of the battery is depleted, the vehicle can still operate as a regular hybrid. The diversity of architectures the teams have selected rests primarily in the power-flow, which teams will aim to improve upon by using various combinations of fuel, transmission, battery system, electric motor, generator or charger choices. Some teams are even developing their own engine controller.

The powertrain components that the teams have selected to drive the vehicle are five unique combinations:

Parallel through the Road (PTTR) Plug-in Hybrid vehicles utilize electrical energy to power one axle, while an engine drives another axle.  EcoCAR 2 teams using the PTTR architecture include: California State, Los Angeles; Purdue University; University of Washington; and Wayne State University.

Series Plug-in Hybrid vehicles consist of one or more electric motors driving the wheels, powered by a battery.  An engine-generator is decoupled from the wheels at all times and provides supplemental electrical power to drive the vehicle when needed. Teams building a Series PHEV are: Embry-Riddle Aeronautical University; North Carolina State University; Pennsylvania State University; and University of Waterloo.

Series-Parallel Plug-in Hybrid powertrains have the ability to couple and de-couple the engine from the wheels while still providing electric power from the on-board battery to drive a motor. EcoCAR 2 teams using the Series-Parallel architecture include: Mississippi State University; The Ohio State University; University of Tennessee, Knoxville; University of Victoria; Virginia Tech.

Hydrogen Fuel Cell Series Plug-in Hybrid vehicles use an onboard fuel cell to convert hydrogen into electricity and either propel the vehicle or recharge a battery pack. The battery pack can be charged using a standard wall outlet.  Colorado State University will build a Hydrogen Fuel Cell Series.

Split-Parallel Plug-in Hybrids utilize a motor connected to the engine’s accessory belt that can charge the on-board battery, start the engine and provide additional power for acceleration.  A separate motor provides additional power to the wheels. The EcoCAR 2 team using a Split-Parallel powertrain is Rose-Hulman Institute of Technology.

The various architectures will use B20, E85, or hydrogen to extend the range of the vehicles. B20 is a blend of 20% biodiesel and 80% petroleum diesel, and E85 is a blend of 85% ethanol and 15% gasoline.

The first year of EcoCAR 2 emphasizes the use of math-based design tools and simulation techniques for designing a successful vehicle foundation. Each team will receive a 2013 Malibu at the end of the first year of competition in May 2012. In years two and three, students will rebuild the vehicle based on their new architecture and continue to refine, test and improve the vehicle’s operation.

Additional information about EcoCAR 2 is available on the competition website, Flickr stream, Facebook page and Twitter stream. The sponsors contributing to the $745 million in software, hardware and cash donations include: U.S. Department of Energy; General Motors; Natural Resources Canada; MathWorks; California Air Resources Board; Clean Cities; dSPACE, Inc.; A123 Systems, Inc.; Freescale; AVL Powertrain Engineering, Inc.; National Science Foundation; ETAS; Snap-On Tools; Magna E-Car Systems; Magna Powertrain; Robert Bosch, LLC; FleetCarma; Siemens PLM Software; CD-adapco; Ventor CANtech, Inc.;  Woodward; Caterpillar.

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EcoCAR 2 is proud to announce it will host the Year One Competition in Los Angeles!

During the six day competition, held May 18-May 23, 2012, teams will present their final Electrical, Mechanical, Controls, Outreach, Business, Trade Show, Hardware-in-the-Loop and Project Initiation Approval presentations to industry leaders and judges. In the end, EcoCAR 2 will crown its Year One victor!

Students and sponsors will stay at the magnificent Renaissance Hollywood Hotel during the competition! Adjacent to the Hollywood and Highland Shopping Center, this hotel is just steps away from the Hollywood Walk of Fame and Madam Tussaud’s Wax Museum. The hotel is also surrounded by more than 20 restaurants and 60 retail shops and is near the famous Graumann’s Chinese 6 Theater and Kodak Theater.

Never visited Los Angeles? Here are some little known facts:

  • It is the only city in North America to host the Summer Olympics twice
  • It has hosted the Super Bowl seven times
  • It was the birthplace of the hula hoop, the Barbie doll and the chaise lounge
  • There are more than three million vehicle trips per day on freeways and surface streets
  • The LA Coastline stretches more than 75 miles long
  • There are more artists, writers, filmmakers, actors, dancers and musicians living and working in this city than any other city at any other time in the history of civilization.

Registration for Competition will open in March, but in the meantime, check out the hotel and learn some more about Los Angeles. As always, check back on the Green Garage Blog for blog posts about competition events and EcoCAR 2 updates!

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Welcome to Team Tuesdays: A new feature of Inside the Green Garage! From now until competition begins, we’ll highlight a new team video every Tuesday on the blog.

This week check out a great video from the Mississippi State University (MSU) EcoCAR 2 team, which is comprised of 84 members, spanning across 16 majors. The team is led by a mechanical engineering graduate student, serving as team leader, and five graduate group leaders, all of whom have significant experience in Advanced Vehicle Technology Competitions (AVTCs).

MSU first became involved in the AVTC series with the four-year Challenge X competition in 2004. The team is currently competing in its eighth year of AVTCs. In addition to Challenge X, Mississippi State also competed in EcoCAR: The NeXt Challenge which finished up in May of 2011. For EcoCAR 2, the MSU team will be recreating their 2013 Malibu into a Series-Parallel PHEV.

Currently the MSU team is broken into the following sub groups: Mechanical, Electrical, Controls, Business, Outreach and Emissions. Together these groups work collectively to achieve and exceed the standards set forth by the EcoCAR 2 competition – to create a vehicle that is more safe and fuel-efficient and that exceeds current consumer acceptability standards.

For more information on the MSU EcoCAR 2 team please visit the team website. MSU can also be found on Facebook, Twitter, and Tumblr.

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Who says work can’t be fun? The California State University Los Angeles (CSULA) EcoCAR 2 team recently attended its first green event with great success. Matthew Kirkwood and Matthew VanAtta from the Outreach/Business team attended the 2012 Eco-Resolutions Party, and the energy was, please excuse the pun, electric!

Carl Cole (right), founder of yourecoteam.com, a yellow pages for green organizations and investors, discusses his company

The event was located in Santa Monica’s  “Green Light District,” part of a national group of business committed to sustainable business practices that has helped make Santa Monica a green hub for Southern California. Events such as the Eco-Resolutions Party are held monthly all over the world by local chapters of Green Drinks International, a networking organization that allows for anyone working in the environmental field or that is concerned about environmental issues to get together to network, develop new ideas and create partnerships.

The team’s goals for the event were to inform the green community about EcoCAR 2 and generate interest, identify and network with key players in the green community, meet potential sponsors and event organizers and become better informed about the green community in order to gain insights into techniques that successfully reach the general public.

Organizations involved in the raffle quickly promote their message before announcing the winner

The event was not only a fun and engaging night, but a networking success for CSULA EcoCAR 2 as well. The team mingled with people from a wide variety of backgrounds, including heavy hitters such as Ken Spector, V.P. of Living Eco, who is heavily involved in the green community and is a potential link to media exposure and celebrity endorsement, and Carl Cole, the founder of a green business networking site, yourecoteam.com, which has a network of over 2,000 green businesses. Contacts were also made with event planners and community organizers, as well as people from the petroleum, solar and energy efficient construction industries.

Everyone attending the event was generous with their passion, excitement and advice. The green community has many diverse events and CSULA’s team generated several new ideas for its own public education campaign (as well as several eco-resolutions) by attending this one.

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Engineering is a highly iterative process.  Sometimes new data causes an entire redesign, often for the better. University of Washington EcoCAR 2 team members have devised several iterations of a battery cooling system, but with A123 Systems’ help, they’ve finally hit the mark.

Four engineers are designing a system to cool the battery pack for UW’s proposed vehicle architecture. Batteries generate heat when in use, so cooling via air or fluid is necessary to avoid damage. The main issue is that the ambient air at the final competition in Yuma, AZ is going to be about 40 degrees Celsius, and the A123 Systems batteries shut down at 50 degrees Celsius.  After much brainstorming, the team’s initial thought was to run coolant through battery cooling plates and then through a radiator to dissipate the heat. They crunched thermodynamic data and learned that, in order to be effective in Yuma, the system would have to pump approximately 100 gallons/minute… which is completely unrealistic! UW needed to find an alternative.

After further deliberation, the team decided to use a thermodynamic refrigeration cycle. This system is similar to a refrigerator: Coolant is compressed to raise pressure through the radiator, heat is dissipated, and then the coolant is allowed to expand to add a magnitude of cooling. The system is a little more complicated and requires more power, but the UW thought they were headed in the right direction.

However, things changed yet again. At the Winter Workshop in Austin, A123 Systems representatives showed the team that cooling is not going to be as critical as they had thought. The batteries won’t heat up as much as predicted so UW had grossly over-engineered the cooling system. With A123’s input, the team re-redesigned a cooling system that integrates the coolant and radiator of the Chevy Malibu’s existing A/C system. This is a much simpler, smaller and more elegant solution than UW’s original design. The team thanks A123 Systems’ representatives for being so helpful in guiding them towards a much more feasible and realistic design!

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