“Vehicle in the Loop” Test Methodology forTractor Efficiency Optimization

Claudia Pieke Test Engineer / PVV MannheimWaldemar Stark Test Engineer / PVV Mannheim

„Apply & Innovate 2016“ IPG Technology ConferenceKarlsruhe, September 2016

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Content

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• John Deere History

• Tractor Overview

• DLG PowerMix Test

• Test Bed Configuration

• Lab PowerMix Test

• Test Results

• Conclusion

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John Deere History

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70 Factories in 18 Countries - 57 000 Employees, Worldwide

2016: John Deere world’s leadingmanufacturer of farm equipment.

Mannheim, Germany

Richards Bay, South Africa

Pune, India

Jiamusi, China

Stadtlohn, GermanyGummersbach, Germany

Horst, NetherlandsEnschede, Netherlands

Bruchsal, GermanyZweibruecken, Germany

Arc-les-Gray, FranceSaran, France

Madrid,Spain

Santiago, ChileCatalao, Brazil

Horizontina, BrazilRosario, Argentina

Saltillo, MexicoMonterrey, Mexico

Torreon, Mexico

Valley City, NDFargo, ND

Minneapolis, MN

Dubuque, IAHoricon,WI

Waterloo, IA

Moline, ILEast Moline, IL

Welland, Ontario

Edmonton, Alberta

Davenport, IA

Des Moines,IA

Langley, British Columbia

Ottumwa, IASpringfield, MO

Coffeyville, KS

Fuquay-Varina, NC

Greeneville, TN

Augusta, GA

Kernersville, NC

Santo Angelo, Brazil

Joensuu, FinlandWoodstock, Ontario

Rock Valley, IA Klemme, IA

Tokoroa, New Zealand

Tianjin, China

Orenburg, Russia

1837: Blacksmith Shop- Self-Scoring Plow

Jonn Deere

Agricultural equipment, Commercial & Consumer Equipment,Construction & Forestry and Credit

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Agriculture Equipment

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TractorsLarge

(8R, 9R)

Mid(6M, 6R, 7R)

Utility(5er Serie)

Loader

CropHarvesting

CombinesFront-EndEquipment

CaneCotton

Crop Care

SeedingTillageApplicationEquipment

Turf andUtility

Utility VehiclesRiding LawnEquipmentCommercial

MowingGolf

Walk-BehindMowers

Hay andForage

Self-PropelledForage

HarvestersHeadsBalersMowing

Global Operating Model• 5 Global External Platforms• A platform consists of a portfolio of “like” product lines

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6R Tractor Overview

Cooling System

6210R Model

Transmissions:- Power Shift- Infinity Variable- Dual Clutch

Tires:RA: 650 / 85 R38FA: 600 / 70R28

Front Hitch &Front PTO

Rear Hitch &Rear PTO

Comfort View Cab

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Power TechEngine

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Agricultural Application Areas

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PTO Work TransportWork

Draw BarWork

Front LoaderWork

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DLG PowerMix Test Overview

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DLG:

• Deutsche Landwirtschafts-Gesellschaft (German Agricultural Society)• Independent organization with focus on agricultural and food testing

Basis of Test:

• 13 cycles representing work performed by a tractor• Tractor is loaded dynamically by drawbar, PTO and hydraulics• Allows comparison of fuel consumption between different tractors

Cycle Development:

• Field measurements carried out by DLG• Supplemented with field data from manufacturers and different

universities.

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Ploughing(Z1P,Z2P)

Cultivating(Z1G, Z2G)

Rotary Harrow(Z3K,Z4K, Z5K)

Mowing(Z3M, Z4M,Z5M)

Manure Spreading(Z6MS)

Baling(Z7PR)

DLG PowerMix Test Overview

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DLG PowerMix Test Overview

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Dynamic Load Profile (unscaled) - Manure Spreading Test Cycle

Total Load

Rela

tive

Load

[kW

/kW

PTO]

Drawbar Load(based on nominal speed)

PTO Load(based on nominal PTO speed)

Hydraulic Load

IPG / Apply & Innovate 2016 | 21/09/2016

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DLG PowerMix Test Overview

DLG test track and load truck inGroß-Umstadt

Tractor rear end and load truckattachment

400m Oval ConcreteTrack

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PTO LoadUnit

Hydraulic Load(SCV)

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• Today’s Tractor Development Programs:Clear focus on fuel economy (Market)Significant changes in powertrain area (Emissions)

• DLG PowerMixis a representative test method but ……requires fully functional prototype at DLG

Gap: Design already frozen, changes are difficult to implement!

Solution: PowerMix ReplicationPredict DLG PowerMix results early in development program (or evenconcept selection) with high level of repeatability (identify smalldifferences)

Motivation for DLG PowerMix Replication

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EarlyUnderstanding of

Fuel Economy

Late Results

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Test Bed Configuration

Visualization

Con

sum

ptio

nm

easu

rem

ent

SpeedTorqueRequest

Fuel Exact

InMotion

Pu

ma

Op

en

Test Rig

Test

Bed

Inte

rfac

e Road – Tire ContactManeuverSteps

GasBrakeShiftRequest

Vehicle ModelAxleTorqueSpeed

Driver Model

3D Road Test Control

CAN

Truck Maker

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Test Bed Configuration

Rear PTO drive

Front and Rear Axle drive

Hydraulic Load

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Vehicle Modeling

Vehicle structure:• Multi body system (Vehicle Body, Cab

Body, wheels-,…)• Data for the vehicle parametrization

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Road Measurement Online Visualization

IPG MovieGPS Data

Video Data

Test Run

Test Configuration

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Road SimulationDLG Test Track & Road Profile „Odenwald“

Google Earth

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Implement Model I: DLG Load Car

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Drawbar Force

Brake Torque

PID Control

PT2 Function

Load Profile

PTO Torque, Hydraulics Power

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Unscaled LoadProfile

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PowerMix Field

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Test Results: PowerMix Field

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Engine Speed [pm]Vehicle Speed [km/h]

PTO Power [kW]

Cycle Z3P – Rotary Harrow(Heavy PTO Work)

: DLG Results (1Hz): Test Rig Results (50Hz)

Accurate replication of DLGtest results

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Test Results: PowerMix Field (6215R DD)

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• Initial results integrated over cycle show less than 1%deviation from DLG test result

IPG / Apply & Innovate 2016 | 23/09/2016

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Implement Model II: DLG Trailer

• 3 Axle Drawbar• Variable Loads

Modular structure• Multi-body-system• Brake System• Tires• Hitch• Aerodynamics• Sensors

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Power Mix Transport

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Test Results: PowerMix Transport

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Odenwald Road : Hill Track #5

: DLG Results: Test Rig Results Vehicle Speed [km/h]

Engine Speed [rpm]

Full load acceleration on hilly road

Draw Bar Force [N]

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Test Results: Power Mix Transport (6215R DD)

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Delta BSFC (Hill Tracks): ~3.0 %

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Summary & Conclusion

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• Vehicle in the Loop test methodology provides powerful tool toreplicate DLG PowerMix

• The test results are showing good correlation between DLGPowerMix and Mannheim LabPowerMix Test

• Several influencing factors (ambient temp, steering,wheel/road interaction) eliminated or reduced

• High level of automation improve repeatability• Applicable at an early prototype stage or even concept

selection

IPG / Apply & Innovate 2016 | 21/09/2016