Hybrid

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With seven E85, six B20 biodiesel, two H2 fuel cell, and one full-electric vehicle at the Year Two Finals, the contest was fierce as each team showcased their unique vehicle architecture and competed for the first place trophy.

In the end, Mississippi State University took top honors with their plug-in series hybrid. The team won more than 15 awards during the Year Two Competition Finals, including 1st place in Energy Storage Design, 1st place in Outreach, 1st place in every Emissions and Energy Consumption event, and had the Best Controls, Mechanical, and Vehicle Design Review presentations.

In Year Two, the Mississippi team integrated a variety of components into their vehicle to decrease emissions and maintain consumer acceptability. The team’s plug-in range-extended hybrid included a well designed, translucent energy storage system cover with an inventive liquid cooling system. They had an innovative high-voltage wire routing, urea injection system, and maintained stock cargo space. They even bettered the baseline vehicle by more than two seconds in the Autocross Event.

MSU's EcoCAR on the road!

MSU also won every dynamic event in the Emission and Energy Consumption category. For the first time in Advanced Vehicle Technology Competition history, the Mississippi team received the highest fuel consumption score. The team utilized more than 90 percent of their 21 kWh battery pack and finished both the 22 mile and 44 mile schedule without using any biodiesel. The team was also able to significantly reduce their petroleum use by charge depleting for 60 miles and bettered the baseline vehicle’s greenhouse gas score by more than 30 percent in the Well-to-Wheel Greenhouse Gases event. In the end, Mississippi State achieved Tier 2, Bin 7 emissions over the EcoCAR drive schedule and averaged less than 2 Lge/100km in fuel consumption.

Taking home second place at the Year Two Finals, Virginia Tech won a combined eight trophies including Best Electrical Presentation and Best Braking, and was the runner up in Best Petroleum Energy Usage and Best Tailpipe Emissions. The team’s E85 engine with a 15 kilowatt belted alternator and 80 kilowatt rear traction drive successfully completed every dynamic event.  Virginia Tech’s vehicle stopped within mere seconds during the Braking event and won Best Static Consumer Acceptability with a clean engine compartment, five passenger seating, and a fully functional touch screen.

The Virginia Tech EcoCAR during emissions testing

Penn State University placed third overall with a 1.3L, B20 biodiesel series hybrid. At the Year Two Finals, the team took home eight awards, including Best AVL Drive Quality, Best Social Media, 2nd in A123 Battery Design, 3rd in Outreach, and was the runner up in Best Fuel Consumption and Best Tailpipe Emissions. The team’s fuel consumption averaged around 4.1 Lge/100 km and the EcoCAR displayed impressive acceleration linearity and quick throttle response during the Drive Quality dynamic tests. In addition, the team was able to host more than 50 outreach events and increase media relations by more than 400 percent in the outreach program.

The PSU team working under hood

Although Mississippi State, Virginia Tech and Penn State were the top three teams in Year Two, there was a variety of other awards given out during Finals. You can find the complete list of winners, here.

With only one year left, the EcoCAR competition will get fierce as all 16 EcoCAR teams fight for the number one spot in Year Three. Who will it be? Check back to the Inside the Green Garage blog throughout Year Three for team and competition updates!

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MSU recently had the pleasure of hosting Mississippi Senator Alan Nunnelee on its campus.  The senator lead a candid discussion with political science and business students, as well as members of the EcoCAR team. Nunnelee spoke about the benefits of hybrids, MSU’s participation in the EcoCAR program, and political attitudes toward hybrid adoption.

Regarding political attitudes toward hybrids, the senator talked about the benefits of hybrids in relation to the economy and environment.  He also touched on some of the ramifications for the state’s budget.  A current example of those ramifications is the state tax on every gas purchase that goes to the building and repair of roads in the state; if hybrids became widely adopted in the area, cars would still wear on the roads, but purchase significantly less gas.  This would compel the state government to find new ways to make up for the shortage of gas revenues.

It was inspiring to hear the influential viewpoint of Senator Nunnelee and his enthusiasm about the EcoCAR program!

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This week’s Mentor Monday post features Kerry Grand, an engineer working in the consulting services group at MathWorks‘ Michigan office. 

Before joining MathWorks and getting involved with EcoCAR, Kerry held various engineering positions at Ford and General Motors. During that time he focused on and gained extensive knowledge of hybrids and electric vehicles – experiences he brings to his EcoCAR teams. 

Kerry joined MathWorks in 2006, and soon after, was drawn to the student competitions. He was intrigued by EcoCAR’s green mission and the chance to help students become engineers. During his undergraduate studies, Kerry participated in an SAE electric vehicle challenge supporting his senior project; this competition was successful because of strong support from both advisors and sponsors. 

As an EcoCAR mentor, he is impressed by the professional growth of the students throughout the three years. Students are using industry standard processes to design their vehicles and he sees firsthand how much the teams develop their skills during the competition. “Questions they ask today are very different than the questions they asked in Year One. The students are really into learning about modeling with MathWorks’ Simulink technology. They now understand Simulink and are diving deeper into the complexities of their designs to focus on optimized control, rapid prototyping, and deployment.”

Kerry Grand with fellow MathWorks mentor, Pete Maloney, at the Year Two EcoCAR Fall Workshop hosted at MathWorks' headquarters in Natick, MA

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Dr. James Truchard, president and CEO of National Instruments (NI), visited the Virginia Tech Hybrid Electric Vehicle Team (HEVT) project bay, a few months back.  Dr. Truchard visited the Virginia Tech campus to see how HEVT is using NI equipment and software to design their EcoCAR.  HEVT demonstrated their vehicle controller interface on the computer using NI products. The HEVT members also had the opportunity to talk to Dr. Truchard about his work experiences and life story.

Since NI equipment and technology has played an intrical role in HEVT’s hybrid vehicle development, the team was thrilled to meet the brains behind the company.

HEVT team members posing with Dr. Truchard from National Instruments

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UWAFT team members talking about hybrid technology with local shoppers

The University of Waterloo Alternative Fuels Team (UWAFT) collaborated with Canadian Tire to engage with its local community on the technological advances happening in its garage. Although the weather was muggy, it didn’t affect the event – the team benefited from the high traffic and attention during a busy shopping weekend!

The majority of the public understood that hybrid technology is playing an increasingly important role in the auto industry. As a result, many people were interested in learning about the work being done by UWAFT and to discuss the merits and problems of various alternative fuels. In addition to educating people in the community, the team also had the opportunity to speak with Waterloo business owners and plant an early seed of interest with future students of UW.

The UWAFT team is passionate about developing new green technology and was delighted to have the opportunity to host the event at Canadian Tire.

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Steven Boyd first visited Virginia Tech as a junior in high school and had the opportunity to watch a group of engineers test an experimental hybrid electric vehicle.  That day sparked his love for engineering and changed his life forever. 

Fast forward 12 years and Steven works for the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy, managing projects in hybrid and electrical systems for the Vehicle Technologies program and serves as a technical advisor for the Advanced Vehicle Technology Competitions (AVTC) program.

Steven recalls attending his first “Hybrid Electric Vehicle Team” meeting at Virginia Tech as a freshman that focused on examining a new approach to improving vehicle efficiency. The team had just started a new collegiate AVTC series called FutureTruck. As an undergraduate, Steven volunteered in the Virginia Tech shop and worked on different kinds of hybrid vehicles including high voltage systems, electric traction drives, and hydrogen fuel systems in both hydrogen fuel cell and hydrogen internal combustion engine vehicles.  The unique engineering opportunities that Steven experienced through the FutureTruck competition series inspired him to do further graduate research in the field.

In pursuit of a master’s degree in mechanical engineering, Steven started his research as the team leader for Virginia Tech’s Challenge X team.  For two years he held that position and in 2006, the team took home the gold!

“Advanced vehicle technology competitions give students the opportunity to apply classroom skills to real-world applications that are critical to our nation’s energy security,” said Steven. “The competitions would not be possible without the active collaboration of government, industry, and academia partners.  Each brings something different to the table, but together, they offer so much more.”

Steven Boyd

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The University of Wisconsin hybrid team worked around the clock at the Kelly Moss Motorsports shop to give its vehicle a new paint job. Through the process, the team learned that the key to a successful paint job is the preparation. 
In the first week, the team completed the tear-down process. This involved careful disassembly and storage of drive train parts. The team made sure to label everything and document the process, so that the critical parts could be easily reassembled. Everything on the vehicle’s exterior that was not going to be painted was removed too. Kelly Moss Motorsports’ shop manager, Gary Kuehn, gave the team a tutorial on wet sanding a vehicle, which is critical to insure proper paint adhesion. Wet sanding is a bit messy, but results in a smooth flat finish that will readily accept automotive primer and paint.
 
 
In week two, the team completed the masking and cleaning part of the project. They even worked over Thanksgiving break to make sure the dust from the wet sanding process was cleaned off the vehicle and to tape off and mask the windows and trim. 
The finished product came out great!

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Earlier this month, the Rose-Hulman EcoCAR team participated in an Advanced Transportation Systems (ATS) open house on campus that featured the school’s automotive and aeronautical competition teams.  

At the ATS event, it was announced that the Rose-Hulman engineering departments have been awarded donations from several EcoCAR sponsors including: General Motors Company, The MathWorks, Freescale Semiconductor, Siemens, National Instruments, Snap On Tools, Vector CANtech and Woodward MotoTron Control Solutions.

The school’s EcoCAR team was also excited to learn that EnerDel Inc., an advanced lithium-ion battery maker, is donating an innovative, high-performance battery system for the team’s hybrid vehicle.  And the love doesn’t stop there! The Duke Energy Foundation, ON Semiconductor, Delphi, the Alcoa Foundation and ArcelorMittal are showing their love for the program by making financial donations to help with project development costs.  

The event generated significant exposure for Rose-Hulman’s ATS programs and as a result, coverage was secured in the following local outlets: WIBC-Indianapolis, Inside Indiana Business, Terre Haute Tribune-Star and WTHI-TV!

The Rose-Hulman team at the Advanced Transportation Systems open house

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Last month, the OSU EcoCAR team attended the 2009 SAE Powertrains, Fuels and Lubes meeting in San Antonio, Texas.

At the event, six EcoCAR students gave a presentation called, “Tomorrow’s Vehicles by Tomorrow’s Engineers: Design, Simulation, and HIL Results from Year 1 of the EcoCAR Challenge.” The students discussed the lessons they learned in Year 1 of the competition, including the rapid development of hybrid architectures and the implementation of hardware-in-the-loop simulation.

Brad Cooley and John Kruckenberg represented Ohio State at the meeting and students from Embry-Riddle, Georgia Tech and the University of Waterloo also participated. 

The OSU team was thrilled to be given the opportunity to attend the meeting and interact with industry experts. For more information about the students’ presentation and the other sessions at the SAE Powertrains, Fuels and Lubes meeting, click here!

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Fresh out of the Kelly Moss Motorsports garage, the University of Wisconsin EcoCAR team revealed its vehicle’s new paint design to the community last Saturday at an event held at Quaker Steak and Lube in Middleton, Wisconsin. The team’s EV1 vehicle and the Bucky Wagon also went along for the ride.

Formally a generic shade of tan, the hybrid team’s EcoCAR is now red, white and black. The vehicle’s colors matched the shirts the team wore at the event, creating a sea of Badger pride. Much to the team’s surprise, Kelly Moss Motorsports general manager Price Cobb, bodyshop manager Gary Kuehn, and body shop staff worker Justin Beach, dropped by to say hello.  

“I think it’s really cool that Kelly Moss stopped by for a visit,” said senior mechanical engineering student, Stacey Ley. “They put a lot of time and resources into this project, free of charge, and we are very thankful for their contributions.”

After three weeks at Kelly Moss Motorsports, the team is happy to have its EcoCAR back and is ready to get to work.

“The next step for us is to turn this rolling chassis into a fully functional hybrid electric vehicle,” said team leader and senior electrical engineering student, Adam Richards. “We have a  lot of work ahead of us, but we are building on a great foundation.”

At the Quaker Steak and Lube event, lunch-goers stopped by to ask questions about the EcoCAR and the University of Wisconsin team was on hand to provide answers.  

“Many people asked questions about the automotive industry,” said control team member and senior electrical engineering student, Ray Uhen. “They were excited about our technology and wanted to know why it’s not available today. We explained to them that at this point, our research and development is not cost-effective for full production.”

Please visit the University of Wisconsin Web site for a 360 view of the EcoCAR’s new paint design!

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