Benchmarking and Teardown Activities Undertaken on Nissan Leaf ...
Transcript of Benchmarking and Teardown Activities Undertaken on Nissan Leaf ...
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Low Carbon Vehicle Technology Project
Benchmarking and Teardown Activities
Undertaken on
Nissan Leaf and Chevrolet Volt
Johnathan Breddy, Tata Motors European Technical Centre (TMETC) plc
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Agenda
• Benchmarking and teardown overview
• NVH challenges of alternative powertrains
Nathan Gabbott, TMETC
• Thermal benchmarking
David Bridge, MIRA
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Car Selection
US-specification Chevrolet Volt
UK-specification Nissan Leaf
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Timeline
2011 2012Jun Jul Aug Sep Oct Nov Dec Jan Feb
Leaf 1 Delivery u
Benchmarking2 Delivery u
BenchmarkingTeardown
Volt 1 Delivery u
BenchmarkingVehicle energy efficiency evaluation
2 Delivery u
BenchmarkingTeardown
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Benchmarking Activities
• Subjective Assessments
• Aerodynamics
• Braking and vehicle stability
• Parasitic losses
• Discharge behaviour
• Energy efficiency
• Thermal
• NVH
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Subjective Assessments
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Subjective Assessments – Leaf(Zytek)
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Energy Efficiency – Leaf(S Robinson JLR)
Energy Consumption by Vehicle State
(over 2 cumulative NEDCs)
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Energy Efficiency – Volt(Integral Powertrain)
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Braking Assessment – Volt(MIRA)
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Aerodynamics – Leaf Anti-Drag Lips
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Aerodynamics – Under body panels
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Teardown
• Completed at JLR Gaydon facility
• Primary objectives
> Permit viewing of EV and hybrid components in situ
> Liberate key components for teardown
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Teardown - Nissan Leaf
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Teardown - Chevrolet Volt
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Teardown - Nissan Leaf Motor
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Summary
• Partners able to subjectively evaluate two new to market cars
• In depth evaluations completed in a broad range of activities
• Teardown enabled component level benchmarking
• Cars available post project to support partners and University based tuition
and research
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NVH Challenges of Alternative Powertrains
Nathan Gabbott
Principal NVH Engineer
Tata Motors European Technical Centre
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NVH Challenges of Alternative Powertrains
Comparison of NVH characteristics of Electric and ICEngine driven vehicles
Specific Challenges in Electric Vehicles
Integration refinement of an APU into the vehicle
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Comparison of NVH characteristics of
Electric and IC Engine driven vehicles
EV vehicles bring many new challenges to the NVH engineer:
• Reduced low frequency noise
• Increased high frequency noise
• Reduced load dependency
• Increased road and wind noise sensitivity
However advantages can be found
• Reduced overall levels for improved passenger comfort
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Nissan Leaf exhibits strong whine orders fromtransmission spur gears
Comparison of NVH characteristics of
Electric and IC Engine driven vehicles
Strong lower order content found in the IC engine is absent in the EV drives, reducingoverall level at the cost of a less balanced overall sound quality
Interior NoiseWide Open Throttle
Nissan Leaf IC CompetitorChevrolet Volt
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• Both the Leaf and Volt exhibit noise from the power switchingelectronics between 8 and 12kHz
• These switching frequencies present a new challenge in thedevelopment of body sealing and trim packs due to their highfrequency
Comparison of NVH characteristics of
Electric and IC Engine driven vehicles
Interior NoiseWide Open Throttle
Nissan Leaf IC CompetitorChevrolet Volt
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Comparison of NVH characteristics of
Electric and IC Engine driven vehicles
Neither the Leaf or the Volt show significant load dependency, this leads to adisconnected feeling from the vehicle.
Interior Noise
Nissan LeafChevrolet VoltIC Competitor3rd Gear
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Comparison of NVH characteristics of
Electric and IC Engine driven vehicles
The Volt and Leaf have similar road and wind noise to traditional vehicles
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Nissan Leaf
Chevrolet Volt
IC Competitor
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NVH Challenges of Alternative Powertrains
Comparison of NVH characteristics of Electric and ICEngine driven vehicles
Specific Challenges in Electric Vehicles
Integration refinement of an APU into the vehicle
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Specific NVH Challenges
EV vehicles have a number of specific issues that require attention, for example:
• Auxiliary Devices
• Vacuum pumps for brake assist
• Battery contactor noise at key on/off
• Pedestrian Awareness
• Nissan Leaf exterior sound source
• Chevrolet Volt Active Warning
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The Volt has a strong multi order characteristicfrom the vacuum pump
Vacuum Pump Noise
Vacuum Pump RunningVacuum Pump Off
Specific NVH Challenges
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• The Nissan Leaf has significant noise from the batterycontactors at key on
• Nissan have created key on effects for the vehicle to helpminimise the disturbance from these noises
Contactor Noise
Key On Effect 1 OnKey On Effects Off
Specific NVH Challenges
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• The Nissan Leaf includes an exterior sound source system toimprove safety for pedestrian, particularly the blind and partiallysighted
• The majority of the additional energy is added between 200 and1000Hz with a swept tone up to 2300Hz
PedestrianAwareness
Exterior Sound Source OnExterior Sound Source Off
Specific NVH Challenges
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• The Volt does not have an ‘alwayson’ exterior sound source fitted
• However an additional warningmechanism is included - when theheadlight main beam is flashedthe vehicle horn is cycled rapidlyto provide a less intimidatingwarning than the main horn
• This warning is effective whilstbeing less aggressive to road usersnot isolated from the horn by avehicle body
PedestrianAwareness
Specific NVH Challenges
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NVH Challenges of Alternative Powertrains
Comparison of NVH characteristics of Electric and ICEngine driven vehicles
Specific Challenges in Electric Vehicles
Integration refinement of an APU into the vehicle
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Integration refinement of an APU
into the vehicle
ICE Generator Ring
Sun
CarrierIntermediate
shaft
WHEEL
Diff
TractionMotor
Planetary Gearset
Powertrain Layout of the Chevrolet Volt
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• The plot below shows how APU speed in range extended mode is a function of powerdemand
• The APU appears to be run at or near full load in all conditions with the speed beingaltered according to the power demand
• This causes an odd subjective feel during over run conditions, with the APU labouringwhilst the vehicle slows down
APU Speed vs. Road Speed
Integration refinement of an APU
into the vehicle
100% Throttle50% Throttle0% Throttle(Run Down)
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• The start up of the APU in the Volt is very well managed, imperceptible in normal drivingconditions
• The use of the second motor/generator unit allows the IC engine to be spun up to operatingspeed before it is fired, eliminating the kick usually experienced in IC only vehicles
• A similar strategy has been employed on shut down
APU Start Up
Integration refinement of an APU
into the vehicle
Road SpeedAPU rpmPT Vertical VibrationDrivers Seat Rail Vertical Vibration
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Thermal Benchmarking of the
Nissan Leaf and Chevrolet Volt
David Bridge – MIRA Ltd
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Tests Conducted
• Benchmarking covered
> Body Leakage
> Installed Airflows
> HMI
> Subjective Appraisals
> Climatic Wind Tunnel Tests
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CWT Testing
• Power performance
> WOT throttle tests
• Cooling system related
> Gradient climbs
> City drive cycles
> Vmax
• HVAC related
> AC system performance
> Heater system performance
> Screen (defrost) clearing
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LC Vehicle Testing Challenges
• Electric AC compressors & PTC heaters
• Independent cooling circuits
• Battery regeneration post test
• Battery temperature vs test time
• Heater performance test (1500rpm)
• Pre-conditioning
• PWM pumps and fans
• Auto vs ‘manual’ HVAC settings
• Amount of instrumentation (Volt)
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Volt Coolant Circuits
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Volt Coolant Circuits
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WOT Test
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Leaf vs Volt: Force at WOT
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WOT Test
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Leaf vs Volt: Developed Power at WOT
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Body Leakage
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Body Leakage
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Leaf vs Volt Cabin Pressure Drop Characteristics
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Body LeakageLeaf: 43.6 cm2
Volt: 29.0 cm2
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Installed Flows: Face Vents
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Leaf vs Volt Face Vent Characteristics
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Installed Flows: Floor Vents
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Leaf vs Volt Floor (Hot) Vent Characteristics
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Installed Flows: Defrost Vents
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Leaf vs Volt Defrost (Hot) Vent Characteristics
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HMI - Leaf
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HMI - Volt
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CWT Testing
• 45°C AC Pull Down
• 45°C Mumbai city drive
• 45°C Vmax and idle
• 49, 38, 25, -5°C EUCD drive cycles
• 45 & 25°C max acceleration cycles
• GL40 – 12% Gradient at 40kph (30°C) - GG
• GL100 – 7% at 100kph – (38°C) – DD
• GL60 – 8% at 60 kph (38°C)
• -20°C heater warm-up
• -8°C screen defrost
• WOT tests
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CWT Testing
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AC Pull-Down
• Vehicle soaked to 45°C
• Volt plugged in overnight but charger failed after 16miles
• Solar load at 1000W/m2 for 4 hours
• 60 kph 40 minutes
• 80 kph 30 minutes
• Static 20 minutes
• HVAC
> Full fans
> Full cold
> Face mode
> Recirculation
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AC Pull-Down
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Average Interior (GM Volt)
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AC Pull-Down
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Average Interior (Nissan Leaf)
Engine Speed
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AC Pull-Down
0
10
20
30
40
50
60
70
80
0 20 40 60 80 100
Tem
pe
ratu
re-
°C
Time - Minutes
Av Face Vent Outlet Temperatures - 45°C AC Pull-Down (Volt vs Leaf)
Average Face Vents (GM Volt)
Average Face Vents (Nissan Leaf)
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Heater Warm-Up
• Vehicle soaked to -20°C
• Volt plugged in overnight
• 50 kph 60 minutes
• 100 kph 30 minutes
• Static 20 minutes
• HVAC
> Full fans
> Full hot
> Foot vents
> Fresh air
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Heater Warm-Up
-20
-10
0
10
20
30
40
50
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Tem
pe
ratu
re-
°C
Time - Minutes
Average Interior - -20°C Heater Warm-Up (Volt vs Leaf)
Average Interior (GM Volt)
Average Interior (Nissan Leaf)
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Heater Warm-Up
-20
-10
0
10
20
30
40
50
60
70
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Tem
pe
ratu
re-
°C
Time - Minutes
Floor Outlet Temperatures - -20°C Heater Warm-Up (Volt vs Leaf)
LHS Floor Outlet (GM Volt)
RHS Floor Outlet (GM Volt)
LHS Floor Outlet (Nissan Leaf)
RHS Floor Outlet (Nissan Leaf)
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Heater Warm-Up
0
500
1000
1500
2000
2500
3000
3500
-20
-10
0
10
20
30
40
50
60
70
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Spe
ed
-rp
m
Tem
pe
ratu
re-
°C
Time - Minutes
Floor Outlet Temperatures - -20°C Heater Warm-Up (Volt vs Leaf)
LHS Floor Outlet (GM Volt)
RHS Floor Outlet (GM Volt)
LHS Floor Outlet (Nissan Leaf)
RHS Floor Outlet (Nissan Leaf)
Engine Speed
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Conclusions
• Testing of EV and HEV type vehicles offers uniquechallenges
• Both vehicles communicate to user impact of HVACchoice on energy use
• Close attention to sealing of body and FEM on Volt
• Leaf delivers more installed airflows
• AC performance similar
• Cabin warm-up for Leaf is very poor
• Cabin warm-up for Volt much better (temp) butdepends on engine switching and is subjectively poor