“Vehicle in the Loop” Test Methodology for Tractor Efficiency … · Gap: Design already...
Transcript of “Vehicle in the Loop” Test Methodology for Tractor Efficiency … · Gap: Design already...
“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
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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
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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
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