DesignofHybridSystemofCommercial

VanforChineseMarket

areportdonefor

AUTOMOTIVEINSIGHT
Birmingham,Michigan

by
AndrewHerold
ChengjunLiang
HaoxiangSong
BradyStern
TingyuZhang

November16,2015

Inpartialfulfillmentoftherequirementsofthecourse

ME470
EngineeringDesign
ProfessorZ.ChambersPhD

DEPARTMENTOFMECHANICALENGINEERING
ROSEHULMANINSTITUTEOFTECHNOLOGY

ExecutiveSummary

OurgoalforthisprojectistocreateanexecutableAutonomiemodelofahybridcarthatwillbe
soldintheChinesemarket.ThisprojectissponsoredbyAutomotiveInsight,whichisan
engineeringcompanythatemployeesmanypeoplethathaveworkedinvarietyofpositionsat
Ford.Thisallowedthemtocreatealargenetworkofresourceswhichhelpstheirsmallcompany
deliverthesatisfactiontheirclientsexpect.

UsingHouseofQualityweareabletomakesureweourmeetingourcustomerneedsby
comparingtheirneedsandhowimportanttheyvaluedcertaincriteria.Usingthismethodwe
werealsoabletocomparecompetingvehiclestogiveussomebenchmarkingstandardswhen
testing.Basedoninformationprovidedtousbyourclientwewereabletocomeupwithtarget
specificationsfortheirneeds.

Tobetterexplainourdesign,weincludedtheconceptualdesignprocessandprojectlearning.
Bymakingthecomparisonbetweenfivedifferentcriteriaanddifferentconcepts,wefoundout
thatlargeengineandsmallbattery,mediumengineandmediumbattery,smallengineandlarge
batteryaresuitablesizesforthedesign.Afterevaluatingthesehighlevelconcepts,we
developedsomecontrolstrategiesinordertoobtainlowfuelconsumptionwiththemostefficient
waytocombinethemotorandtheengine.

SincewewereunabletogetAutonomieforthefallquarter,ourprototypeforthefallquarteris
usingtheReducedFactorialDesignmethodtofigureoutwhatcriteriaweshouldtestandwhich
onesweshouldnttest.Weusedabasicmodeltostartbutplanongoingintomoredetailwith
thislateraswereceiveandunderstandAutonomiebetter.

Autonomiehasbeenpromisedtousandweshouldbereceivingitearlyoninthewinterquarter.
Oncewereceivethissoftwarewewillbeabletomoveonwithourprojectandrunteststofind
theoptimalcombinationbetweenbatterysize,enginesize,andwhichcontrolstrategyworks
bestwiththiscombination.

TableofContents

1EXECUTIVESUMMARY.

2NOMENCLATURE...

3SCOPE...

4INTRODUCTION..

5QFD.
HOUSEOFQUALITY.
REVIEWOFSTANDARDS...
TARGETSPECIFICATIONS..............................

6DESIGNTODATE....
CONCEPTUALDESIGNPROCESS...
PROTOTYPE...
PROJECTLEARNING...

7WORKPLAN..

8APPENDIX..
ACKNOWLEDGEMENT..
REFERENCES.
SCHEDULE..
Nomenclature

DOEDesignofExperiments
RFDReducedFactorialDesign
QFDQualityFunctionDeployment

Scope

Thecontentsofthisreportwerepreparedbyseniormechanicalengineeringstudentsat
RoseHulmanInstituteofTechnology.Wefeelconfidentinourworkasstudents.However,all
materialshouldbereviewedbyanappropriateprofessionalbeforeimplementation.

Introduction

CompanyOverview

AutomotiveInsightwasfoundedbyMikeThomasin2004.Manyoftheiremployeeshave
workedforthemajorautomotivemanufacturingcompaniesdoingworkinavarietyofdifferent
positionsfromengineeringtomanagement.Theemployeeshelpeddesignthefirstgenerationof
hybridsatFord,whilealsohavingfullelectricvehicleengineeringandprogramexperience.This
givesthemalargenetworkofresources,whilebeingasmallcompany,thattheycanusetohelp
meettheneedsoftheirclients

WearedirectlyworkingwithSteveThomas,hehas37yearsexperienceinresearchfor
transmissionanddriveline,advancedengineering.WithalltheexperienceatAutomotiveInsight,
theycanprovidehelpwith,butnotlimitedto,design,development,execution,andprogram
management.Thisexperienceprovidestheirclientswithtrustthattheirgoalswillbe
accomplished[1].

ProblemHistory

Asbeingoneoftheworldsleadersinindustryandmanufacturing,Chinaisstilllacking
experiencewithsomeofthenewindustries.Oneofthesebeinghybridsystemdesign,which
therearelessthan200small,privatecompaniesthatareworkingondesigningtheirownhybrid
systems.
TheChinesegovernmentdesiresmorehybridvehicles[2].

WiththehelpofAutomotiveInsightandthedecadesofexperiencefromtheiremployees,they
havebeencontractedtoworkwithoneofthesesmallcompaniestodevelopahybridsystemfora
commercialvanthecorrectway.Withalltheuniquegovernmentrestrictionsandtheneedsofthe
Chineseautomotivemarket,thenewhybridsystemwillhavetobecarefullydone.

QFD

HouseofQuality

Inordertoensurethatwearemeetingourcustomersneeds,weusedourHouseofQualityas
showninfigure1toweightourcustomersneedsandcompareoursolutionstocompeting
vehicles.

Figure1:
HouseofQualityforHybridElectricdeliveryvan

Forexampleoneofourcustomersmostimportantneedswastoimprovefueleconomy.Inthe
ImproveFuelEconomyrowoftheHouseofQualityweweightedhowweanticipatedchanging
eachaspectofthevaluewouldactuallyimprovethevehiclesfueleconomy.Weanticipatedthat
BatterySize,Weight,RegenBraking,andEngineSizewouldallhaveamoderateeffectonthe
FuelEconomy,whiletheoverallcosthasnoeffect.Wealsoshowedhowcompetingvehicles
compareinfueleconomywiththeMercedesSprinterhavingthebestfueleconomy,theFord
TransithavingslightlylowerfueleconomyandtheChevyExpresshavingmuchlowerfuel
economy.


ReviewofStandards

CodeNumber

StandardDocuments

GB18352.52013

Limitsandmeasurementmethodsforemissionsfromlightduty
vehiclesCHINA5

GB/T197552005

Measurementmethodsforemissionsfromlightdutyhybridelectric
vehicles

GB/T125442012

Measurementofmaximumspeedofmotorvehicle

GB/T190552003

Reliabilitytestmethodsformotor

UNECER101

UnitedNationsagreementconcerningadoptionofuniformtechnical
prescriptionsforwheeledvehicles

TargetSpecifications

Basedonourclientsrequirement,theminimumtopspeedforthecommercialvanis80km/h
withthevehiclefullyloaded.Theaccelerationfrom0to100km/hneedstobelessthanorequal
to10seconds.TheEVrangeneedstobeatleast50kilometers,whilethebatterysizehastobe
greaterthan10kwhr,whichqualifiesforChineseincentiveprogramaimingtodecreasethe
environmentalimpactofautomobilesontheroadsinChina.Fromtheinformationgivenbythe
client,thetotalweightofafullyloadedcommercialvanneedstobebetween4500and4700
kilograms.Thecostforeachconceptdiffers,butourgoalistolowerthefuelconsumptionwhile
makingtheoverallcostaslowaspossible.Also,weshouldmaketheenginesizeofourdesign
reasonable,whichissimilartothecommondieselengineofcommercialvanonthemarket.

DesigntoDate

ConceptualDesignProcess

Powersavingsandreducingthecostsarethekeypointsinourproject.Inordertoachieve
thesetwogoals,severalideasarebroughtintothisproject.Wenarrowedourlistofpossible
conceptstothreedifferentconceptsthatrelatedtomotorandenginesizewhicharelarge
batterywithasmallengine,mediumbatterywithamediumengine,andsmallbatterywitha
largeengine.Inthesethreeconcepts,wecameupwithfivedifferentcriteriawhicharefuel
economy,cargocapacity,acceleration,EVrange,andtopspeedtorankthesethreeconcepts.
Table1showsthecomparisonbetweenthethreedifferentconceptsandthefivecriterion.

Table1:
Comparisonbetweendifferentconceptsandthefivecriterion
Criteria

LargeEngine
SmallBattery

MediumEngine
MediumBattery

SmallEngine
LargeBattery

FuelEconomy

CargoCapacity

Acceleration

EVRange

TopSpeed

Total

Weused1torepresentaboveaverage,1torepresentbelowaverage,and0torepresent
average.Finally,thetotalpointsforlargeenginewithsmallbatteryresultswere1,medium
enginewithmediumbatteryresultswere0,andsmallenginewithlargebatteryresultswere
1.

Afterevaluatingtheseconcepts,wedevelopedseveralcontrolstrategiesinordertoefficiently
combinethemotorandengineinthevehicleandachievethegoal.Forexample,amodethat

makestheengineandmotorcollaboratedifferentlyindifferenttrafficconditionssuchas
highwayandcityroads.Vehicleswilloperateatrelativelyconstantspeedsonthehighway,this
sustainstheenginerevolutionsperminuteatoraroundpeakperformance.Consequently,the
enginewillhavemuchbetterfuelefficiencyonthehighwaywherethemotorsupportedby
batteryislessefficient.Also,whenvehiclesaredriveninthecity,itwillinvolvemore
accelerationanddecelerationthanhighwaytraffic.Withtheelectricmotor,peoplecanhave
betteraccelerationresponseandlessfuelconsumption.Theefficiencyofthemotorinurban
trafficcombinedwiththeregenbrakingwillconserveenergyinthestopandgotrafficandallow
forhigheroverallvehicleefficiency.Theurbanmodewillallowvehiclestorunmostlyonengine
onthehighwayandrelymoreonthemotorduringcitydriving.

Prototype

TheprototypeforthefallquarterwillconsistofDOEusingtheRFDmethodtoshowthe
conceptsthatwewilleventuallytestwhenAutonomiearrives.Wewillaccomplishthisbyusing
theprogramMinitab,whichisastatisticalsoftwareprogram.Wewillloadintheconstraintsthat
wearelookingatandthenwewillreceivewhatcriteriaweshouldtest.Thiswillallowusto
connectthedotswiththeotherteststhatwecouldntdoduetotimeconstraintsandsmall
changesbetweentheseveralstudies.

WeusedtheDOEtoolinMinitabtocreateourRFDforprototypeshowninfigure2.

Figure2:
MinitaboutputofRFD

ThisprototypeshowsaRFDtothefourtoplevelconceptfactors.WithRFD,wecanonlydo
twolevelsofeachfactor,soallenginesizeswerearrangedintotwocategories,smallandbig.
Thesamethingwasdonewiththebatterysizes.Wehavetwooptionsforhybridsystem,series
orparallel,andregenbrakeiseitherusedornotused.Forthisparticulardesign,weuse
fractiondesigntohelpusgetthetestingtrialsfrom32downto16.Afterwehavedonefirst
testingrun,wewouldhaveoneoptimalcombinationof5facts.Theneachchoosingcategoryfor
enginesizeandbatterysizewillbeseparatedintotwonewcategoriesfordoinganotherRFD.
BydoingRFDiteratively,weshouldbeabletoreducetheoptionsforeachfactortoanarrower
range.OncewehavethedataandAutonomie,wewillbeabletorunthrougheachofthese
situationsandnarrowitdowntotheoptimalcombinationbetweenenginesizeandbatterysize
andfigureoutwhatcontrolstrategyworksthebestwiththiscombination.

SinceourprojectismostlydependantonusingAutonomieandthissoftwarehasnotbeen
availabletousyet,ourprototypeismoreabouthowwewillmanipulatetheavailablechoicesof
multiplefactors.

ProjectLearning

Basedontheconferencewithourclient,wecameupwiththeusersrequirementofthisproject.
Weaimtodesignadieselelectrichybridsystemwiththesameutilityandimprovedperformance
ofthecurrentmodel.Inordertoachievethegoalofthisproject,wehavelistedtheknowledge
thatweneedtobeawareof.Thatknowledgeisbutnotlimitedtodieselengine,electricmotor,
battery,varioushybridsystems,controlstrategy,governmentpolicy,RFD,regenbrakeand
Autonomie.

Ourmainfocuspointswillbethehybridsystemsandcontrolstrategy,sincethesetwomostly
affectthefuelconsumption.Bystudyingdifferenthybridsystems,wenarroweddownour
systemoptionstoaparallelsystem.Theparallelsystemcanrunonmotororengineseparately.
Thecontrolstrategywillbeappliedafterthesystemandpartshavebeenselected.Itwillbe
mainlyusedforbalancingthecollaborationoftheengineandmotor.

TherearethousandsofoptionsfortheengineandbatteryinAutonomie.However,wedonot
wanttosimulateeachsingleelement.BylookingattheDOE,wefoundthatRFDcouldhelpus
restricttheamountofoptionstoasmallernumber.RFDisadesigntocarefullychoosethe
fractionfromexperimentalrunsofthefullfactorialdesign.Technically,RFDwilleliminatethe
testtrialsthatwouldhavesimilartestresults.

Regenbrakeisanecessaryfeaturerequiredbyclients,wehavetoapplythatonourmodel.
Regenerativebrakeisamechanismthatwillslowdownthecarandtransferthekineticenergy
toelectricitywhichcanbeusedtorechargethebattery.Thiscanalsoextendthelifeofpartsin
thebrakesystemassomepartsdonotwearoutasquickly.

WedefineourultimatedesigngoalistohaveanexecutableAutonomiemodelofdieselelectric
hybridsystemwhichcanoutputadequatepowerwhilehavinglowfuelconsumption.

WorkPlan

OurplanformovingforwardnextquarteristostartrunningsimulationswithAutonomie.Wewill
usethedifferentbatteriesandenginesthatAutonomiehaspreloaded,andimplementtheminto
oursimulationstofindtheoptimumcombination.Wewillalsobeimplementingdifferentcontrol
strategieswiththesesimulationstofindtheoptimumstrategy.Sinceourprojectisusing
Autonomietofindtheoptimumcombinationandstrategyforadeliveryvanwewillnothavea
functionalprototypebytheendofthequarter.Insteadwewillhaveinformationonour
simulationsusingDOEandRFDtohelpfigureoutwhichcombinationsofbatteries,engines,
andcontrolstrategieswewilltest.

AppendixA

TheChinesegovernmenthasverystrictstandardsforhybridvehiclesthatdriveontheroadsin
China.BasedonThePeoplesRepublicofChinasstandards,Chinesegovernmentcreatedfive
stagestomakeandrunthestandardofemission.Forthevehiclethatwearedesigningforin
thisproject,itshouldbecompliantwiththefifthstageofthevehicleemissionanditisclarified
asthesecondtypeofvehicle.AccordingtoLimitsandmeasurementmethodsforemissions
fromlightdutyvehicles(CHINA5),tableA1intheappendixshowsChinesegovernments
emissionstandardforeverykindofvehicleinthefifthstage,andthefifthstagestandardis
goingtotakeeffectin20181.1.[3]

TableA1showstheChinesegovernmentemissionstandardsthatwasexaminedintheReview
ofStandardssection
.

TableA1:
Fifthstageemissionstandards

WiththestandardsthattheChinesegovernmentestablished,ourdesignneedstofitthese
requirementswhichhavegoodeffectonprotectingtheenvironment.

Therestdocumentisusedfortestingthemotor,inordertoachievetherequirementofChinese
governmentsmotorrequest.Topspeedisoneofourgoalthattheclientestablished,these
materialishelpfultobuildourfinaldesign.

Acknowledgements

Prof.ZacChambers,PhD

AutomotiveInsight,butespecially:
SteveThomas

RoseHulmanInstituteofTechnology

References

[1]
AutomotiveInsight
.AutomotiveInsight,n.d.Web.18Oct2015.
<http://www.automotiveinsight.net/>.

[2]Doggett,Scott.ChinaAnnouncesPlantoSubsidizeEVsandPluginHybridsin
FiveMajorCities.
AutoObserver
,Edmunds,1Jun2010.Web.18Oct2015.

[3]Chinesegovernment.Limitsandmeasurementmethodsforemissionsfromlightduty
vehicles
(CHINA5)17Sept2013

Schedule

Thescheduleintable3showsthetasksthatwerecompletedduringtheFallQuarteraswellas
thehoursworkedbyeachmemberofourteam.


Table3:
GanttChartforFallQuarterWork

DuringthefallquarterthetwomainaspectsofworkwereQFDandFunctionalModeling.We
alsomadeourteamcontractaswellasconductweeklyteammeetings,meetwithDr.
Chambersregularly,andspeakwithourclientacoupleoftimesonthephoneandinperson.

DesignChecklist

EngineeringStandards

OurprojectwillfollowtheclientsstandardswhichisdiscussedinTargetSpecifications
section.

Economic

DiscussedinTargetSpecificationssection,page#.

Environmental

Thegoalofthisprojectistoreduceemissionsandfuelconsumption,soitis
environmentallymindedbynature.DiscussedinAppendixA.


Manufacturability

Manufacturabilitywasnotinthemainfocusoftheproject,soitwasnotconsideredin
theanalysisabove.HybridelectricvehiclesarehardertoproducethananICvehicle
duetothecomplexityofitspowertrain.

Ethical

Standardengineeringethicalpracticeshavebeenusedinthisproject.Alltheengineers
involvedwiththeprojectoperatedwithintheircompetenciesanddidnotmissrepresent
theirskills.

HealthandSafety

Whileunderstandingoftheimportanceofthesafetyincarmanufacturingprocess,we
thinkmanufacturingwillnotbeinvolvedinourproject.However,makingsurethateach
teammemberisinagoodhealthconditionwhentheyareworkingisasubstantial
responsibilityforeveryoneintheteam.

Social/Political

DiscussedinTargetSpecificationssection,page#.

Calculations

Nocalculationsatthistime.

AlternateSolutions

Noalternatesolutionsatthistime

RawData

Norawdataatthistime

VendorInformation

ContactInformation


SteveThomas
email:sthomas@automotiveinsight.net
phone:2488928936

LessonsLearned

Capstonedesignisimportantforanengineeringstudenttodeveloptheirabilitiesfor
professionalpractice.AftergoingthroughourCapstoneDesignlessons,weknowhowto
approachanentrylevelproblem.Byapplyingestablishingaprojecttarget,benchmarking,and
houseofqualitywecanfindouthowimportanteachpartsare,sothatwecanmainlyfocuson
thosepartsandmakeabetterfinalizedproduct.

Theprojectmanagementtoolsalsoplayanimportantroleinourteam.Bylistingactionitems,
weknowwhatourteamneedstodospecifically.Usingganttchartsandquadcharts,wecan
recordwhichactionitemshavebeenassignedandcompletedaswellasmilestoneswehave
comingup.Theteamcontractalsohelpedourteamcollaboraterunsbetter.

Itisveryimportanttohaveagoodconnectionwiththeclientsandadvisor.Inthisproject,weare
supposedtogetthesoftwareAutonomie,wetriedtoconnectwithSIEMENSinitially,butwe
failedtogetit.ThenwetriedtoconnectwithourclientstoseeiftheycouldgetAutonomiefor
us,butourclientsalsowerentabletogetAutonomieforus.Thenwewentbacktotalkwithour
advisorDr.Chamberstoseeifhecouldgetussomehelp.Finally,withtheeffortsofDr.
Chambers,wewillbegettingAutonomienextquarter.IntheseweekswithoutAutonomie,we
neededtokeepourprojectgoing.ByworkingwithDr.Chambers,wecameupwithaideathat
helpedustonarrowdownourselectionofengineandbatterysizes,byusingRFDfromDOE.
Throughthisexperience,welearnedthatwhenwedonthavesomethingwereallyneed,westill
needtokeepourprojectgoing,bynevergivingup,andcomeupwithanideatosolvethisissue
orfindanotheralternativeway.

LetterofTransmittal
TO:SteveThomas
chamberz@rosehulman.edu

heroldaa@rosehulman.edu

liangc@rosehulman.edu

songh1@rosehulman.edu

sternba@rosehulman.edu

zhangt@rosehulman.edu

SteveThomas
PowertrainDirector
AutomotiveInsight

Mr.Thomas:

Accompanyingthisletteristheinterimdesignreportforthedieselelectrichybridstudy
thatyouaskedourgrouptolookat.Pleasereviewthisreportandletusknowifyouhave
anyfedbackontheproposedworkforthewinterandspringquarter.

Ourgrouphasenjoyedwithyouonthisprojectandwelookforwardtocontinuingthis
workforthenexttwoquarters.Ifyouhaveanyquestionsaboutthisdesignreport,please
feelfreetocontactoneofus.

Sincerely,

AndrewHerold(812)7655916
ChenjungLiang(812)2393235
heroldaa@rosehulman.edu
liangc@rosehulman.edu

HaoxiangSong(812)2233133
BradyStern(319)2900861
songh1@rosehulman.edu
sternba@rosehulman.edu

TingyuZhang(312)5135806
zhangt@rosehulman.edu