C E N T E R F O R A U T O M O T I V E R E S E A R C H

ANNUAL REPORT 2014

Table of Contents

EDUCATION

pg4

Preparing future automotive industry

leaders.

RESEARCH pg10

Innovating solutions that affect future

transportation and mobility.

FUTURE PLANS pg28

Affecting tomorrow’s mobility—from energy

and environmental consequences to safety, information

and communication systems and lifestyle

and consumer choices.

APPENDIX pg30

ECONOMIC DEVELOPMENT

pg24

Cultivating teamwork and synergy among multiple disciplines, while responding to

the needs of our clients and partners.

1OVERVIEW

About CARThe Center for Automotive Research (CAR) is the pre-eminent research center in sustainable and safe mobility in the United States and an interdisciplinary research center in The Ohio State University’s College of Engineering. CAR research focuses on: energy, safety and the environment. CAR offers state-of-the-art facilities for students, faculty, research staff and industry partners. With a concentration on preparing the next generation of automotive leaders, CAR is recognized for: interdisciplinary emphasis on systems engineering, advanced and unique experimental facilities, collaboration on advanced product development projects with industry and a balance of government and privately sponsored research.

CAR offers advanced experimental facilities that include engine and vehicle dynamometers, vibration, noise and acoustics laboratories, intelligent and autonomous vehicle laboratories, engine fluid mechanics and combustion research facilities, and electric, hybrid-electric propulsion, fuel cell and electrochemical energy storage research facilities. In addition, CAR has access to the full-service proving grounds of the Transportation Research Center, Inc., located 45 miles northwest of the Ohio State Columbus campus.

CAR provides graduate education programs culminating in a Graduate Specialization in Automotive Systems Engineering for Ohio State students, and a certificate program for distance-learning industry practitioners. CAR also provides facilities and support for six automotive undergraduate student project teams.

Features of CAR include:

› Interdisciplinary emphasis on systems engineering

› Advanced and unique experimental facilities

› Collaboration on advanced product development projects with industry

› Balance of government and privately sponsored research

› Industry consortia, bringing top researchers together to work on pre-competitive projects, which often develop proprietary programs.

2 OVERVIEW

A Note from the DirectorWe have rarely seen in the history of the Center for Automotive Research such rapid transitions taking place so efficiently and successfully.

The first news that comes to mind is the expansion to CAR West, a facility that uses a building once part of the College of Engineering’s ElectroScience Laboratory. Our electro-chemical energy storage and autonomous vehicle laboratories have moved to CAR West. Although at the close of the fiscal year the official inauguration had yet to take place, our laboratories have been operating there since spring semester 2014, and the official ribbon cutting is scheduled for August 1, 2014.

Accompanying the expansion is an ongoing faculty search aimed at recruiting two senior faculty positions to add to the leadership team for the center. The research focus areas for each of the two positions are aligned with the activities of CAR West. See page 17 for more information.

In addition to these successes, Professor Umit Ozguner and a team of researchers from Ohio State and partner universities were awarded the U.S. Department of Transportation University Transportation Center Crash Imminent Safety, nicknamed CrIS. Learn more on page 16.

An educational development that affects CAR is the College of Engineering’s new Masters of Global Engineering Leadership, a professional degree for practicing engineers who want to enhance their management acumen, leadership skills and technical expertise. One of the three technical tracks offered in the program is based on the Automotive Systems Engineering Graduate Specialization that has been ongoing as a CAR educational program since 1995.

OSU Motorsports student teams had an extremely successful year. Notable were the top finishes of the Buckeye Current and EcoCAR 2 teams, in their respective international and national competitions. See page six for details.

Thanks to intellectual property developed by its faculty and research staff, CAR has spun-off a new startup, Simple-Fill. The company focuses on refueling solutions for compressed natural gas vehicles. Initial investments have been received and the next goal is to finish developing the first prototype of a natural gas compression system.

In summary this has been an exciting year for the Center for Automotive Research. Motivated from the past year’s successes, we look forward to more growth in FY2015. On our agenda is completing our faculty search task, and continuing to grow our research, graduate education and engineering services programs. It is truly a pleasure to be a part of this environment at The Ohio State University.

Cheers!

TEDxOhioStateUniversity // Rizzoni, 2013

Another significant area of growth has been our Testing, Engineering and Software Development Services, TESS, which experienced significant progress during FY2014. The team exceeded its target goal of securing $1.5 in new industry contracts. TESS supports companies in design and engineering tasks related to the commercialization of engineered products, and also provides testing and software services in support of companies that can benefit from CAR’s extensive expertise.

Director, Center for Automotive Research

3OVERVIEW

Giorgio Rizzoni

EDUCATION

MotorsportsStudents at The Ohio State University have the opportunity to participate in Motorsports/Student Projects. This program challenges students of all majors, backgrounds, skill levels and degrees of experience to compete in one of six student teams. Students apply research and classroom concepts, as well as learn hands-on skills for designing, fabricating, racing, managing and marketing competition vehicles. This experience includes machining, engine testing, battery testing, computer aided design and many other engineering tools.

BAJA BUCKEYESdesign | build | market

Baja Buckeyes SAE team is a student organization at The Ohio State University built to develop members’ understanding of the automotive and motorsports businesses, as well as provide hands-on experiences that expand knowledge of engineering and fabrication practices. As a student-managed off-road race team, the group strives to present challenges to members, enabling them to learn the important elements of project management, business management and engineering design. Learn more: osubaja.com

2013-2014 Vehicle: Weight: 450lbs; Track: 46” FR, 44.5” RR; Front tires: 23”x8”x10” ITP Mudlite; Rear tires: 23”x7”x10” Maxxis Razr 2; Engine: Briggs & Stratton 305; Suspension: 15” independent, front and rear; Advisor: Junmin Wang

FORMULA BUCKEYES SAEStudent Designed | Student Built | Student Raced

Formula Buckeyes is a volunteer student organization tasked with building a racecar to compete nationally and internationally. The team operates out of the Center for Automotive Research at The Ohio State University. Learn more: formulabuckeyes.com

2013 Car Statistics: Weight: 385lbs; Speed: 0-60 in 3.0 seconds; Power: 85 horsepower; Engine: 4 cylinder, 600cc; Advisor: Prasad Mokashi; Recent success: 24th place overall, Formula SAE-Michigan

BUCKEYE CURRENTWorld’s fastest collegiate electric motorcycle

Buckeye Current was founded as the Buckeye Electric Motorcycle Race Team by students in 2010. Through The Ohio State University’s Center for Automotive Research, the team’s goal is to provide students experience with electric vehicles and to construct a fully operable electric motorcycle to compete in races on both the national and international level. Learn more: current.osu.edu

Achievements: Third Place SES TT Zero 2014 Isle of Man; First Place Collegiate Team SES TT Zero 2014 Isle of Man; University Prize 2014 Isle of Man TT; Motul Award for Technical Performance; First Collegiate Team to Average 90 mph around the Isle of Man.

Goal: return to the Isle of Man to become the first collegiate team to average 100+ mph.

2013-2014 Vehicle: Driver: Rob Barber; Build time: 9 months; Batteries: 110 lithium ion cells; Volts: 453; Equivalent horsepower: 70; Frame: race prepped Honda CBR 1000 RR; Advisor: Marcello Canova

EDUCATION

BUCKEYE CURRENT // 2014 team

5EDUCATION

Competition Results › OSU EcoCAR 2

• First place overall in the national competition, among 15 universities; additionally the Ohio State team earned an award in every individual event category and brought home $32,000 in cash prizes.

• First place awards earned by the team include lowest petroleum consumption, Best Electrical Presentation, Best Controls Presentation, Best Technical Report, Best Vehicle Static Consumer Acceptability, Best Business Program Award, Best Business Presentation, Best Outreach Presentation, Best Communications Program, ETAS ECU Excellence Award, DSpace Embedded Success Award, Best Progress Reports, Best Modeling and Simulation Modeling White Paper, Best Pre-Competition Safety and Technical Inspection, Best Communications Plan, Best Influencer Campaign and Best Media Report.

› Buckeye Current• Team placed third—for the second year in a row—in the Isle of Man Tourist

Trophy (TT) Zero race. The only U.S. collegiate team to compete in the race, Buckeye Current earned a podium finish and set a new collegiate record with an average speed of 93.531 mph.

› Formula Buckeyes SAE• Out of 109 cars, from around the world, the Formula Buckeyes placed as

follows: Design Event - 5th, Presentation Event - 28th, Cost Event - 76th, Acceleration - 11th, Autocross - 23rd, Skidpad - 26th , Endurance – did not finish (completed 18 of 20 laps), Fuel Efficiency - 12th, Overall - 24th

› Venturi Buckeye Bullet, Baja Buckeyes SAE, and Supermileage SAE• Did not compete during FY14

OSU ECOCAR 2EcoCAR 2: Plugging In to the Future

EcoCAR 2: Plugging In to the Future is a three year collegiate automotive competition sponsored by the U.S. Department of Energy and General Motors that challenges 15 North American universities to redesign and rebuild a 2013 Chevrolet Malibu to reduce the environmental impact. The competition provides an unparalleled hands-on, real-world experience to educate the next generation of automotive engineers, business managers and public relations specialists. Learn more: ecocar2.osu.edu

Achievements: First place overall in national competition, multiple first place awards and $32,000 in cash prizes.

Vehicle Specs: Architecture: Parallel-Series Plug-in HEV; Fuel: Ethanol; Range: 50 miles all electric, 300 total miles; Engine: 1.8L Honda engine; Electric machines: 80kW peak front and rear motors; Battery: 18.9kW-hr, 340V; Advisor: Shawn Midlam-Mohler

VENTURI BUCKEYE BULLET 3World’s fastest electric vehicle

The mission of the Venturi Buckeye Bullet 3 team is to provide unique engineering challenges for students—valuable, hands-on experience—creating some of the best new engineers in the world. This student team pushes the envelope of electric vehicle technology and in so doing aims to change public perception of electric vehicles. Mission: prove that green technologies of the future will be both fun to drive and fast! Learn more: go.osu.edu/VBBullet

Vehicle specs: Target top speed: 400+ mph; Power: 1600kW (2200 HP); Weight: 8000lbs; Batteries: 2000 A123 Li-ion cells; Target records: FIA Category A group VIII Class 7 (international) and SCTA E3 (US); Driver: Roger Schroer; Battery packs: 8 packs, 825 V, 425 A each; Motors: 4 Venturi IPM Motors and 4 drives; Advisor: Giorgio Rizzoni

6 EDUCATION

OSU ECOCAR 2 // Driven by graduate student Matt Organiscak

Graduate Student Funding Sources

DEPARTMENT OF ENERGY CLEAN ENERGY RESEARCH CENTER (DOE CERC)Supported 13 graduate students at CAR during FY2014

The United States and China are the world’s largest energy producers, energy consumers and greenhouse gas emitters. The clean energy sectors in both countries are growing rapidly. The priorities of the U.S.-China Clean Energy Research Center reflect important areas of opportunity for both countries.

In the United States, more than three-quarters of electricity generated is used to operate buildings. In China, if present trends continue, floor space equal to the entire U.S. building stock will be built in the next 20 years. Both countries have large domestic coal reserves and use coal to generate the majority of their electricity (roughly 50% in the US and 80% in China). The two countries are also the world’s largest automobile markets and oil consumers, both importing more than half the oil they consume. Development and deployment of clean energy technologies will play a central role in helping both countries meet energy and climate challenges in the years ahead.

The CERC will also build a foundation of knowledge, technologies, human capabilities and relationships in mutually beneficial areas that will position the United States and China for a future with very low energy intensity and highly efficient multi-family residential and commercial buildings. Learn more: us-china-cerc.org

DEPARTMENT OF ENERGY GRADUATE AUTOMOTIVE TECHNOLOGY EDUCATION (DOE GATE), SINCE 1998Supported 20 graduate students at CAR during FY2014

This program trains future engineers to overcome technology barriers preventing the development and production of cost-effective, high-efficiency vehicles for the United States market. CAR has been involved in this program since its inception:

› 1998-2005: Hybrid Drivetrains and Control Systems

› 2005-2010: Advanced Propulsion Systems

› 2011-2016: Energy Efficient Vehicles for Sustainable Mobility

DOE’s Graduate Automotive Technology Education (GATE) initiative will award $6.4 million over the course of five years to support seven Centers of Excellence at American colleges, universities and university-affiliated research institutions. The awardees will focus on three critical automotive technology areas: hybrid propulsion, energy storage and lightweight materials. By funding curriculum development and expansion as well as laboratory work, GATE allows higher education institutions to develop multidisciplinary training. As a result, GATE promotes the development of a skilled workforce of engineering professionals who will overcome technical barriers and help commercialize the next generation of advanced automotive technologies.

The project at CAR is helping prepare a new generation of engineers to lead system integration projects in the following areas related to energy-efficient vehicles: efficient energy conversion, advanced energy storage, lightweight body and chassis systems, and vehicle systems control, including vehicle-grid and vehicle-infrastructure connectivity. Learn more: go.osu.edu/DOEgate

Professor Shawn Midlam-Mohler discusses a research project with a graduate student.

7EDUCATION

SPONSORED RESEARCH PROGRAMSSupported 40 graduate students at CAR during FY2014

CAR provides opportunities for graduate students to be employed as research assistants and to study among professionals in the automotive industry. The educational activities of CAR are therefore aimed at assisting engineers in industry, as well as College of Engineering students, in acquiring knowledge of automotive processes and systems to better prepare them for careers and career advancements in the automotive industry. This includes CAR’s industrial consortia, as well as 10 companies and four federal agencies.

GIFTS AND INTERNAL FUNDINGThere were six supported graduate students at CAR during FY2014

CAR, through its commitment to research, and in harmony with the educational mission of The Ohio State University, has formulated a strong program of educational activities to provide interdisciplinary education and training in the field of automotive systems. The College of Engineering offers a wide variety of masters and doctoral degree programs in most fields of engineering. Within CAR, student researchers of the various departments experience a strong interdisciplinary atmosphere, not only in their automotive-related coursework, but also in their specific areas of research. Funding for these students is used to explore new areas of research.

OSU ECOCAR 2 // Electric vehicle charging station at CAR

8 EDUCATION

Outreach and Events

TOURSThroughout the year CAR has had the opportunity to bring over 1,000 people through its doors—from facility tours for K-12 STEM students to distinguished guests and industry partners. Select groups included: Honda Manufacturing, Fuel Cell Seminar and Energy Exposition, Johnson Controls, GM Global R&D, Logan and Union Counties officials, Crown Battery, Toyota, Japan National Institute for Materials Science, Swagelock, Fisher College of Business Green Business Students, and Virtual tour with Academy of Green Technology at Douglas Byrd High School (North Carolina).

EVENTSIn addition to tours and visits, CAR held its first annual Alumni and Friends Open House September 28, 2013. This tailgate style event allowed guests to get an up-close look at motorsports and research projects, and to interact with CAR faculty, staff and students. The

second annual Alumni and Friends Open House will be held September 27, 2014. Email henley.53@osu.edu for more information.

Successful events continued and, in conjunction with Ohio State Office of Energy and Environment and OSU EcoCAR 2 team, CAR hosted the OSU Motorsports Statehouse Day April 17, 2014. During the event the OSU Motorsports teams displayed their vehicles on the West Plaza of the Statehouse. The highlight was the proclamation of OSU Motorsports Day by Reps. Michael Stinziano and Stephanie Kunze, along with Sen. Jim Hughes. Additional attendees included: Sen. Bill Coley; Staff member for Sen. Randy Gardner; Staff member for Sen. Joe Uecker; Staff member for Rep. Ryan Smith; Chancellor, University System of Ohio, Board of Regents John Carey.

Meet Graduate Student Ricky DehnerAdvised by Professor Ahmet Selamet, mechanical engineering PhD student Ricky Dehner has experienced much success in his research on turbochargers. His current work focuses on improving the understanding of compressor instabilities and acoustics through experiments and computational predictions.

Alongside the research team, Dehner is refining a methodology to predict compression system surge that can be utilized early in the engine design process. These developments will improve future turbocharged engine simulations. In the past year, Dehner has worked closely with BorgWarner and Ford Motor Company to gain a better understanding of compressor acoustics. Working directly with the fast-paced industry environment, he says, has been a great learning experience. Dehner plans to graduate in the spring of 2016.

L // OSU EcoCAR 2 team leads virtual tour of the team’s vehicle. R // 1st Annual CAR Alumni and Friends Open House

Ricky Dehner

RESEARCH

Research Highlights and SuccessesCAR currently has 170 active projects with 36 private industry and 16 government/non-profit agencies

Fiscal year 2014 was a strategic year for the Center for Automotive Research (CAR). In an era of rapidly evolving transportation technologies, changes in federal and state research funding structures, and increasing consumer demand for advanced products, CAR has focused on evolving to be responsive to both industry and government needs. During this year of building, the leadership team focused on partnering with automotive companies, heavy-duty engine manufacturers, Tier 1 Suppliers and government entities responsible for oversight and regulation of sustainable and safe transportation technologies.

Industry funding of direct sponsored research projects hit an all-time high at the center, comprising 42% of the research expenditures for the year. Companies such as Honda R&D Americas, Inc. (East Liberty, Ohio) committed to a second year of a new partnership to support further research, demonstration technology and prototyping of gas compression technology. The work not only supports Honda of America Manufacturing, Inc. as an original equipment manufacturer (OEM), it has created the opportunity for other Tier 1 and gaseous fuel system component manufacturers to participate in collaborative projects at CAR. Worthington Industries (Columbus, Ohio) and xperion (Newark, Ohio) are also participating in the gas compression demonstration projects with CAR. Honda R&D also continues to be involved in battery energy storage and simulation projects, along with DENSO, Ford, MIDAC and Renault, to name a few.

CAR also continues to serve federal agencies, non-profit organizations and national labs, which have relied on the institutional strength of the university system for advanced research. Federal funding comprised just over forty percent of the center’s research expenditures this year. The U.S. Department of Energy continues to be one of the largest federal participants, while the National Highway Traffic Safety Administration (NHTSA) has begun sponsoring new projects in injury biomechanics and trauma research, and the U.S. Department of Transportation has awarded a four year contract to the Control and Intelligent Transportation Research laboratory at CAR to develop the Crash Imminent Safety University Transportation Center (CrIS UTC), which will focus on the use of autonomous vehicle technology for crash avoidance capabilities and safety standards.

RESEARCH WITH INDUSTRY // (L-R) Professor Marcello Canova and graduate student Luke DeBruin pose with Honda R&D Americas’ Lara Minor.

CAR TOURS // (L-R) Parker Hannifin Corporation and Honda (Japan)

11RESEARCH

CHRYSLER/DEPARTMENT OF ENERGYIn response to the grand challenge of reducing the environmental impact of transportation systems, in 2010 the U.S. Department of Energy launched the Advanced Powertrain Technology - Light Duty Vehicles program, focused on demonstrating fuel efficient technologies for conventional automotive powertrains.

For this program, Chrysler launched the project “A MultiAir/MultiFuel Approach to Enhancing Engine System Efficiency”, demonstrating a 25% fuel economy improvement for a light-duty vehicle. CAR became a partner with Chrysler for this project, tasked to develop high-level supervisory controls for vehicle ancillary loads - namely the electrical, thermal management and air conditioning systems.

After comprehensive analysis, control development, implementation and rigorous verification, CAR demonstrated a 2.5% increase of vehicle fuel economy by integrating an optimal control for the vehicle’s ancillary loads and a novel powertrain thermal management strategy.

The control strategies developed by CAR have been transferred to Chrysler, and are currently being tested on the prototype vehicle. The goal is to demonstrate that the combination of engine and powertrain technology developed by Chrysler and the controls developed by CAR allow for reaching the 25% fuel economy improvement target.

This project enhanced the strong partnership and collaboration between Chrysler and CAR. Four researchers and seven graduate students focused on this project, with some of them hired directly by Chrysler upon graduation. Many new projects have been established with Chrysler based upon this work, making Chrysler one of our strongest partners in research and development.

MICROGRID IMPLEMENTATION PROJECTMicrogrids that leverage electric utility-independent means of power generation have become of great interest to the energy community with the onset of affordable renewable energy generation and electric vehicle charging. Through its SMART@CAR Consortium, CAR has been responsible for funding an AC microgrid project for the past four years. In the last year, CAR has expanded its research interests to include research and implementation of a DC microgrid. With its experience in energy storage technologies and its existing infrastructure that includes 10kW of photovoltaics and 8 electric vehicle charging stations, CAR has begun developing a flexible model and simulator for a DC microgrid that can be used to validate and test different sizing, scalability, control strategies and architectures.

Using the findings and data generated with the microgrid simulator, researchers and students at CAR plan to specify and implement a DC microgrid focused on leveraging 60+kWh of automotive lithium-ion battery packs, a grid tied inverter and photovoltaics. Once implemented, the DC microgrid will be used to explore research topics that include optimal control strategies, grid-specific battery management, battery aging, and electric vehicle charging strategies, and microgrid economics.

Through this research, CAR hopes to gain better understanding of not only the technical issues that surround DC microgrids, but also the economic and social aspects.

TURBOCHARGER RESEARCHTurbocharger technology is powering ahead and collaboration with industrial partners will play a key role in future developments. Under the direction of Professor Ahmet Selamet, multiple graduate students focus their research on increasing the power density of internal combustion engines, downsizing these engines, and improving part-load efficiency. Currently, the main focus for these students is to improve their understanding of compressor instabilities and acoustics through experiments and computational predictions, as well as to refine a methodology to predict compression system surge.

In order to achieve the ultimate goal of improving future turbocharged engine simulations and facilitating improved designs with fewer iterations, research students are collaborating closely with Ford Motor Company to focus on real-world applications of this technology, which in the past few decades, has become increasingly vital to fuel efficiency. Engineering students have shown enthusiasm toward this industrial experience, as it has enabled them to better understand and improve compressor acoustics.

12 RESEARCH

CAR RESEARCH AREASThe unique nature of being an interdisciplinary center allows CAR to address many research areas of automobile technology, unmatched worldwide. CAR is home to over 233 associates with a wide array of technical, cultural and demographic backgrounds which provides a thorough repository of skill sets to approach challenges from many perspectives. This talent pool is dedicated to studying innovative solutions that affect the safety and sustainability of

Systems Overview Of Research Areas

future transportation and mobility. Tomorrow’s mobility will be strongly affected by energy and environmental demands, safety, information and communication systems, and lifestyle/consumer choices.

CAR is able to perform work in each of these research areas through well-established working partnerships with government and industry. We serve a wide array of companies – from small businesses to international corporations – and contribute to their capabilities in several technical fields. Additionally, CAR actively engages, and is routinely awarded, competitive government projects. This tradition was continued this past year with new awards from the National Science Foundation and U.S. Department of Energy.

CONTROL AND SYSTEM INTEGRATION

Lightweight Body and Chassis

Vehicle Safety

Grid Connectivity

Aerodynamics

V2X and Cloud Computing

Occupant and Pedestrian Safety

Accessories, Thermal Management, Energy Recovery and Climate Control

Electrical Propulsion and Power ConversionEnergy Storage

Engines: Fuels, combustion, aftertreatment and turbocharging

13RESEARCH

Partnerships and CollaborationsIn addition to sponsored research, CAR has established throughout the years a very successful working partnership with a number of small, medium and large businesses nationwide. CAR aims to advance technology through precompetitive industrial consortia. Two such examples of this are the CAR Industrial Consortium and SMART@CAR Consortium. Both provide industry the opportunity to participate in original, leveraged research.

Other ways industry can be involved are through Testing, Engineering and Software Development Services. In this program resources which are not actively engaged in research or education are made available to outside clients at commercial rates which are competitive with comparable facilities. Numerous clients have used this program for tasks as widely varying as engine mapping, prototype sensor testing, and conducting technology searches. See the Industry page for additional information.

In additional to its work with industry, CAR actively engages in research projects with government agencies. The projects conducted with this mode of interaction are usually the result of a competitive process, in which potential research projects from several universities and research centers are evaluated and only the most promising receive funding. Current programs include the National Science Foundation; U.S. Department of Energy; U.S. Army Tank Automotive Research, Development, and Engineering Center; Ohio Development Services Agency; Ohio Third Frontier Wright Projects; and U.S. Department of Energy Clean Energy Research Center.

CAR COLLABORATIONS // TOP: Kenneth Dudek (L), CEO of CAR Technologies, and Donald Butler, CAR personnel, look over CAR’s AV900 machine. BOTTOM: CAR graduate student, Junbo Jing (L), discusses a project’s progress at CAR West.

14 RESEARCH

PersonnelIn the 2013-2014 academic year, there were a total of 233 Associates:

The Center also provided facilities and support, in collaboration with the college and Department of Mechanical and Aerospace Engineering, for six student project teams consisting of over 200 active undergraduate students and 45 FIRST (robotics project) high school students.

Administrative and Business

Development Staff

Graduate Students79

Visiting Scholars/Other

31

Secondary Faculty

25

Research Staff25

10

Research Support Staff

8

Primary Faculty

9

Student Assistants47

15RESEARCH

Fiscal

TOTAL EXPENDITURES: $9,616,775FY 14

(FY13 = $9.7M)

Research Expenses

Operating Expenses

Continuing Education

OSU Motorsports

$7,629,800 (79%)

$1,038,660 (11%)

$753,667 (8%)

$194,649 (2%)

RESEARCH EXPENDITURES: $7,629,800FY14

(FY13 = $6.9M)

Federal: Direct

Industry: Direct, Federal Flow-Through, Consortia, Testing and Engineering Services, Sponsored Programs

State: Direct, Ohio Third Frontier

Internal R&D: Graduate Fee Authorizations, Capital Improvements, Gifts

Industry $3,242,309

(43%)

Internal R&D $997,454

(13%)

Federal $3,210,849

(42%)

State $179,187 (2%)

16 RESEARCH

RESEARCH EXPENDITURES BY CATEGORY AND SPONSORFY14

FEDERALUS DoT

NSF

US DoE

AFRL

STATEOH Devt. Services Agency

Stoneridge (OHIO)

INDUSTRYOEM1

Smart@CAR Consortium

Industrial Consortium

OEM2

OEM3

OEM4

OEM5

Gas Compression Consortium (OEM4)

CERC Industrial Consortium

Supplier1

Supplier2

Supplier3

Flow-ThroughChrysler Group LLC (DoE)

American Electric Power (DoE)

Sandia Corp (DoE)

THOUSANDS$0 $500 $1,000 $1,500 $2,000 $2,500 $3,000 $3,500

OEM: Original Equipment Manufacturer

Supplier: Tier 1 Supplier

CTE (FTA)

UM (DOE) CFO (DOE)

17RESEARCH

SMART@CAR CONSORTIUM FY14 Updates

On-going projects:

Project Title DC Fast Charging: Impact and Economics

DC Microgrid Modeling/Simulation and Implementation at CAR

Secondary Life of Automotive Battery Packs: Aging and Economics

PEV Infrastructure: Standards and Deployment

Description Investigate optimal placement of DC fast chargers in a region, as well as study the impact on utility distribution systems. Investigate economics associated with installation and coupling with energy storage technologies

Development of a flexible model and simulator for a DC microgrid in order to appropriately size and investigate control strategies for the future implementation of a microgrid at CAR leveraging its 10kW of photovoltaic power, automotive battery packs and electric vehicle charging stations.

Exploration of usages for after-market plug-in electric vehicle battery packs in grid-tied energy storage applications and the economics associated with utilizing the packs as a utility asset.

Investigate the current state of the electric vehicle communication infrastructure industry and standards to evaluate current trends and opportunities for members in the consortium.

Pls Ramteen Sioshansi, Prof. ISE

Wei Zhang, Asst. Prof. ECE

Yann Guezennec, Prof. MAE

BJ Yurkovich, Research Specialist CAR

Current members:

ConsortiaThe mission of CAR’s consortia is to provide industry and government with opportunities to participate in original, pre-competitive leveraged research in diverse areas. CAR consortia: CAR Industrial Consortium, SMART@CAR Consortium and GasWorks@CAR.

Benefits include:

› Access to common pre-competitive research projects with leveraged sponsorship

› Interaction with other members on research projects in areas of mutual interest

› Opportunity to sponsor named graduate fellowships

› Significant leveraging of government–sponsored research programs

› Provide educational opportunities for graduate students, and therefore are an excellent source of potential employees for members

› Opportunities for teaming with partner members on bids for major government programs

18 RESEARCH

CAR INDUSTRIAL CONSORTIUM FY14 Updates

On-going projects:

Project Title Thermo-Electrochemical Modeling of Li-ion Battery Cells

PHEV Batteriews Life Estimation in PHEV Applications

Model-Based Investigation of Lean Gasoline PM and NOx Control

Light Duty Natural Gas Vehicle Characterization Study

Description Development of a reduced order thermo-electrochemical model of a Li-ion battery cell that is physics-based and suitable for control-orientated problems

Aging experiments of LG Chem batteries and development of an in situ capacity estimation technique for aging assessment during actual vehicle operation

Exploratory work to understand the design space of a GDI aftertreatment system designed to control both NOx and PM (in addition to the requisite HC and CO)

Developing experimental, modeling, and simulation capabilities especially suited for Natural Gas engines used in automotive transportation

PIs and Co-Pls Marcello Canova, Assist. Prof. MAE

Yann Guezennec, Prof. MAE

Shawn Midlam-Mohler, Assist. Prof. MAE

James Durand, Res. Scientist CAR

Fabio Chiara, Res. Scientist CAR

Giorgio Rizzoni, Prof. MAE

Current members:

®16FEB201120481109

GASWORKS@CAR CONSORTIUMFY14 Updates

Current members:

19RESEARCH

New Projects

UNIVERSITY TRANSPORTATION RESEARCH CENTER (UTC)Researchers at the Ohio State University’s Crash Imminent Safety (CrIS) University Transportation Center (UTC) hope to save lives and reduce the severity of human injuries in auto accidents by looking closely at what happens in the final seconds before vehicle collisions.

The goal of the CrIS UTC is to improve ground transportation safety through interdisciplinary research and development in the interplay of autonomous and intelligent vehicle systems, human factors, and injury biomechanics. Research will include developing advanced accident simulators, statistical modeling, analyzing past accidents and developing autonomous vehicles. The UTC research team includes over 20 faculty and researchers working at OSU and our partner Universities (IUPUI, NCA&T, UMass, UW).

The center and its research are funded by a grant from the U.S. Department of Transportation. The university will receive $1.41 million in 2014 and has requested an additional $1.5 million for 2015. The award and associated cost sharing total $4.3 million over the first two years of operation. Learn more: citr.osu.edu/CrIS/

DRIVING SIMULATOR // Electrical engineering graduate student, Danielle Fredette, demonstrates CAR’s desktop driving simulator.

20 RESEARCH

GLOBAL EDUCATION OUTREACH Drs. Rizzoni and Guezennec teach sustainable mobility at University of Stuttgart’s FKFS International Summer School

For the third consecutive summer, University of Stuttgart’s FKFS (Research Institute of Automotive Engineering and Vehicle Engines)—an independent institute providing research and development services for the international automotive industry—hosted International Summer School. Attended by 31 industry members from throughout the world, students learned about automotive engineering from experts from the two leading institutes of their kind.

Ohio State’s Drs. Giorgio Rizzoni and Yann Guezennec taught courses during the 2014 session, along with Dr. Simona Onori, Clemson University and Dr. Jochen Wiedemann, University of Stuttgart. Topics included Energy Analysis, Modeling and Simulation of Hybrid Electric Vehicles; Hybrid Electric Vehicles: Control and Optimization; Battery and Fuel Cell Systems for Electrified Vehicles; and Vehicle Aerodynamics and Aeroacoustics.

More information about International Summer School 2015 can be viewed here: go.osu.edu/ISS14-15

INTERNATIONAL SUMMER SCHOOL // Top: Yann Guezennec and his Battery and Fuel Cell Systems for Electrified Vehicles class. Bottom: Giorgio Rizzoni with students in the Energy Analysis, Modeling and Simulation of Hybrid Electric Vehicles class.

21RESEARCH

University Transportation Research CenterThe university’s new Crash Imminent Safety University Transportation Center (UTC) aims to increase understanding of technology design and improve the ways humans interact with intelligent, autonomous and semi-autonomous vehicles. Research objectives include developing advanced accident simulators, performing extensive modeling, analyzing past accidents and developing autonomous vehicles – all with the goal of making the U.S. transportation system the safest in the world.

The center and its research will be funded by a grant

Facilities ExpansionThe Center for Automotive Research is in the process of expanding facilities to accommodate a wider array of equipment, testing and engineering services. An interim expansion has taken place in the ElectroScience Laboratory (ESL) building to allow CAR to grow until new facilities are available. Over the past year the expansion into ESL has enabled CAR to move its Battery Laboratory and Intelligent Transportation research into “CAR West”, thus permitting an expansion of our Testing, Engineering, Software and Services (TESS) group at CAR.

With the completion of the CAR West facility, and repurposing of existing lab space at the main CAR building, in the near future we will have even more room for new areas of research to take place.

from the U.S. Department of Transportation. The university will receive $1.41 million in 2013 and has requested an additional $1.5 million for 2014. The award and associated cost sharing total $4.3 million over the first two years of operation.

Partner universities working with Ohio State on the UTC are Indiana University-Purdue University in Indianapolis; North Carolina A&T State University in Greensboro; University of Massachusetts in Amherst; and the University of Wisconsin in Madison.

A key component of the research will be development of a common, networked driver simulation that will allow researchers to experiment with pre-crash safety through simulated accidents.

Ohio State boasts world-class facilities, from a new driving simulator to resources at the Center for Automotive Research. Collectively, the university’s activity and expertise aligns extremely well with the development of autonomous ground vehicles, driver behavior, biomechanics and all automotive safety technologies.

ESL PHASE II // Phase two of construction for CAR West is to add a garage, to house the Intelligent Transportation group’s research vehicles

ESL PHASE I // Phase one of construction for CAR West was to move our Battery Lab from CAR to CAR West

New Faculty HiresEnabling Future Growth

Aligned with CAR’s expansion to CAR West, a faculty search aimed at recruiting two senior faculty positions to add to the leadership team for the center is underway. The research focus areas for each of the two positions will be aligned with the activities of CAR West.

CAR is pleased to announce it has extended an offer to one of two planned new faculty members. This hire is part of the plan to grow research activities at CAR, with the specific expansion being in the area of vehicle safety, vehicle autonomy, vehicle-infrastructure integration and vehicle systems and their control.

Professor Levent Guvenc will join both the Department of Mechanical and Aerospace Engineering and Department of Electrical and Computer Engineering for Academic Year 2014-2015. He is expert in

The center also will leverage extensive existing facilities and field experiments being conducted at Ohio State’s Transportation Research Center (TRC) with the common, networked driver simulation to create an unprecedented ability to experimentally address pre-crash safety.

The Department of Transportation said this type of research is critical in reducing deaths, injuries and property damage from accidents.

The award to Ohio State’s consortium was part of a $63 million transportation safety grant package announced from the U.S. Department of Transportation’s Research and Innovative Technology Administration (RITA). The grant package will fund projects at 33 UTCs nationwide. More than 142 applications were submitted to RITA for the grants.

mechatronics and control systems with application to automotive systems; robust and repetitive control; and AFM control.

Additionally Professor Guvenc has experience in managing major experimental facilities and staff and sizable research programs; and a deep understanding of needs and trends in the automotive and ground transportation industry.

Professor Guvenc’s research laboratories will be located at CAR West and he will support the activities of the Control and Intelligent Transportation Research laboratory with a focus on autonomous vehicles as well as vehicle fuel economy and control systems.

CAR PERSONNEL // Control and Intelligent Transportation Research laboratory personnel at CAR West.

UTC vehicle

ECONOMIC DEVELOPMENT

Engineering ServicesTesting, Engineering and Software Development Services

MISSIONWe provide high quality, cost effective, engineering analysis and development, testing, third party validation and software services. We couple the resources of The Ohio State University and the Center for Automotive Research with our highly trained and experienced engineering professionals to offer unique value to our clients.

BUSINESS MODELTarget market:

› Small to medium sized companies

› Companies in the need of engineering to bridge the gap between conceptual design and preproduction prototyping

› Companies not equipped for product development and innovation

› Companies in the need for 3rd party validation of their products

Products:

› Engine, vehicle and custom testing services

› Analysis services including a variety of computational codes

› Software development services

Our advantages:

› Offer high value services at a reasonable price

› Offer a high level of flexibility in all our services

› Cover a broad spectrum of services (one stop shop)

› Willing to consider custom or individual needs

Focus on our unique tools and capabilities:

› Heavy duty dynamometer

› Analytical capability

› We include capabilities of the larger university

Our passion:

› Be a catalyst for economic development

› Attracting new companies with new products

› Helping existing companies that want to develop new products

› Columbus2020 and TechColumbus helps businesses on the financial and business side, we work on the technical side

CONTRACTS: $1,472,119 FY14 (FY13 = $509,701)

Q1 subtotal

$394,695

Q2 subtotal

$103,305

Q3 subtotal

$813,685

Q4 subtotal

$160,434

25ECONOMIC DEVELOPMENT

CommercializationThe Testing, Engineering and Software Development group (TESS) has taken the lead at the Center for Automotive Research in providing a series of services to support industrial partners for the development and commercialization of their products and technologies. TESS couples the resources of Ohio State and CAR, with a number of highly trained, experienced and dedicated engineering professionals, to offer unique value to external customers, as well as to university faculty and staff in support of internal research projects.

The activities performed in the last year have covered a wide range of services. Some examples include:

› Providing experienced and specialized engineering support to move product designs all the way from conceptual ideation to the pre-production stage. Specific instances include: Simple-Fill liquid piston compressor development (Ohio State patents and technology), Cyclone Waste Heat Engine technology for micro-combined heat and power generation system optimization and Trilogy Engineered Solutions fueling system analysis

› Conducting in-depth design and engineering analyses of products in the market aimed at system optimization and performance enhancement. For example: Trilogy class 8 truck fueling system design and Myer snowplow design for light duty trucks

SPREAD PHOTOS // Testing, Engineering and Software Development Services (TESS) provided support for industrial partners throughout the fiscal year.

26 ECONOMIC DEVELOPMENT

Partnership WHE Generation Corporation accelerates commercialization of unique waste heat technologyCAR’s Testing, Engineering and Software Development Services group (TESS) provides contract engineering services for WHE Generation Corporation (WHE GEN), specifically, design analysis and testing of its unique Waste Heat Engine (WHE). These services are expected to assist WHE GEN transition its technology from prototype to commercial production over the following 12 months.

Its partnership with CAR, along with the support of Columbus2020/JobsOhio, convinced WHE GEN to move its operations from Florida to the State of Ohio. The company is planning a new manufacturing facility in Lancaster, Ohio with a forecast of approximately 80 new jobs over the next five years.

Christopher Nelson, CEO of WHE GEN, comments, “we chose to relocate to Ohio because of its deep technical employee pool, supply chain possibilities and proximity to our partners at CAR. We determined that with this team, we had the best chance of successfully launching our new technology into the market.”

› Testing and verification of new automotive powertrain components and systems. Examples include: Vanner hybrid bus, E-Now Solar system truck, Parker Hannifin’s new gasoline engine based powertrain system for medium duty trucks, Campbell diamond-like carbon coating for automotive parts and Cummins’ new E-85 based powertrain for box trucks

› Third party verification of new products ready to enter the market e.g. Stoneridge particulate matter sensor and BEX America over useful life class 8 truck EPA certification

› Marketing, technical and business case assessments of new and established products such as proprietary projects for Cummins and Worthington Industries, and a Honda European light duty natural gas vehicle market assessment.

TESS works primarily with small to mid-sized companies to accelerate technology development. This often becomes a force for economic development as clients are usually Ohio based, or, if not, due to the assistance we provide, relocate to mid-Ohio to take advantage of the many advantages available locally. Through these activities CAR has enhanced its role in central Ohio as a technical powerhouse and catalyst for economic development, directly attracting new companies and helping existing companies stay competitive by accelerating product development.

FUTURE PLANS

Goals for Five-Year Plan2012-2017

Target Growth Areas

ENERGY AND ENVIRONMENT › Fuel economy and emissions

› Fundamentals of engine gas dynamics, combustion and design

› New engine concepts

› Alternative fuels for engines

› Engine combustion and after-treatment control

› Waste heat recovery

› Accessory management

› Vehicle electrification

› Energy storage

› Vehicle system integration

› Powertrain and Vehicle Control and Diagnostic Systems

› Vehicle-grid and vehicle-building interactions

› Data analytics and cloud computing to improve fuel economy

SAFETY, INTELLIGENCE AND AUTONOMY › Crash imminent safety

› Cooperative highway-vehicle systems

› Electronic systems safety and cybersecurity

› Lane departure warning and lane-keeping assist

› Vehicle autonomy

› Vehicle-vehicle and vehicle-infrastructure communications

› Data analytics to improve maintenance and reliabilityLaunch a capital campaign to raise funds for a new facility7

1 Increase government sponsored research to exceed $6M per year (FY13 = $2.2M/FY14 = $3.4M)

2 Increase industry research projects to exceed $2M per year (FY13 = $1.4M/FY14 = $1.9M)

3 Partner with industry to secure federal flow-through of $1M per year (FY14 = $0.26M)

4 Grow industrial consortia to $1M per year (FY14 = $0.5M)

5 Increase engineering services to exceed $1M per year (FY13 = $0.5M/FY14 = $0.9M)

6 Increase graduate Student enrollment to 100 funded graduate students (FY14 = 79)

29FUTURE PLANS

Collaborating Faculty

Eylem Ekici

Computer networks, wireless and satellite systems, routing protocols and QoS provisioning

Vadim Utkin

Non-linear control theory

Andrea Serrani

Nonlinear control and systems theory, guidance and control of aerospace, underwater and terrestrial vehicles

Lisa Florentini

Control and systems theory with automotive application

Jin Wang

Power electronics circuits and control for renewable energy and hybrid electric and fuel cell vehicles

Fusun Ozguner

High performance parallel computing

Jiankang Wang

Emerging technologies of modern power system operation and planning, electricity markets, reconfiguration, demand side management, distributed generation and renewable energy

Umit Ozguner

Intelligent control of large, decentralized systems, automotive control, intelligent vehicle highway systems

Longya Xu

Power electronic converters, control of variable-speed drives, finite element analysis, solid state control of electric power, variable speed drives

Keith Redmill

Autonomous vehicles and robots, intelligent transportation systems, vehicle and bus tracking, wireless data communication, CDPD, GPS and GIS technologies

Wei Zhang

Control and estimation of hybrid dynamical systems

Bharat Bhushan

Nanomaterials characterization and scanning-probe techniques

Jim Gregory

Aerodynamics, flow control

Giorgio Rizzoni

System dynamics, measurements, control, and fault diagnosis with application to automotive systems

John Bolte

Injury biomechanics

Denny Guenther, emeritus

Vehicle dynamics and vehicle design

Ahmet Selamet

Internal combustion engines, acoustics, noise control, combustion, heat transfer and fluid dynamics

Marcello Canova

Energy conversion and energy storage systems for automotive applications, dynamic system modeling and optimization

Yann Guezennec

Energy conversion and storage systems for automotive applications Raj Singh

Machine dynamics; acoustics and vibrations; automotive noise, vibration, and harshness control; geared system dynamics and acoustics

Lei Cao

Nuclear instrumentation and detection methods for advanced materials characterization

Joseph Heremans

Thermal properties of matter and applications to energy conversion

Junmin Wang

Control modeling and estimation diagnosis of automotive systemsTerry Conlisk

Computational fluid dynamics with application to battery electrochemistry

Anthony Luscher

Mechanical assembly and fastening systems

Mei Zhuang

Computational air acoustics, computational fluid dynamics, and applications to aerospace and automotive engineering

Marcelo Dapino

Smart materials and systems, automotive and aerospace applications

Shawn Midlam-Mohler

Model-based design of complex systems, advanced automotive powertrain systems

ECE // Electrical and Computer Engineering

MAE // Mechanical and Aerospace Engineering

30 APPENDIX

Lisa Hall

Polymer nanochomposites

Ramteen Sioshansi

Operations research, energy systems

Jose Castro

Manufacturing, composite materials and structures

David McComb

Electron microscopy

Glenn Daehn

Impulse-based metal working and metallurgy; lightweight structures for automotive and aerospace applications Wolfgang Windl

Computational materials scienceAihua “Alan” Luo

Light metals and manufacturing research

MSE // Materials Science Engineering

ISE // Integrated Systems Engineering

CBE // Chemical and Biomolecular Engineering

Amanda Agnew

Human anatomy and biologic anthropology

Beth-Anne Schuelke-Leech

Public policy, engineering, business and technological innovation

Anne Co

Electrochemistry; electro catalysis for energy conversion and storage

Matthew Roberts

Commodity price analysis and risk management with application to automotive energy sources

HRS // School of Health and Rehabilitation Sciences

Glenn School //

John Glenn School of Public Affairs

ASC // College of Arts and Sciences

AEDE // Agricultural, Environmental and Development Economics

31APPENDIX

CAR ChampionsPrestigious Dwight Blaser Meritorious Service AwardA special citation presented annually to individuals whose sustained and extraordinary personal services have had a significant and lasting effect on the advancement of Ohio State’s Center for Automotive Research.

QUALIFICATIONSIndividual must have shown both extraordinary effort and sustained interest. Examples of activities which will be favorably considered are: fund raising, alumni organization work, substantial giving, participation in strategic and technical planning activities, support of research, extraordinary recruitment activities. Active Ohio State faculty and staff are not eligible. For emeritus faculty, the citation would be based principally upon activity performed after retirement. The recipient need not be an Ohio State alumnus.

BACKGROUND Dr. Dwight Blaser was an alumnus of The Ohio State University. He was also a retiree of the General Motors Corporation where he held the position of R&D Director, and he served on the CAR External Advisory Board since its establishment in the mid-1990s. To recognize Dr. Blaser’s generous gift of time, experience and wisdom, CAR created an award in his name.

PREVIOUS AWARDEES › Dave Tatman, General Motors Bowling Green Assembly Plant Manager,

General Motors Corporation

› 2012 Rick Renwick, Chief Engineer, Ford Motor Company Global Engine Engineering

› 2011 Kenneth P. Dudek, CEO, CAR Technologies, LLC

› 2010 Robert E. Lee, Senior Vice President, Chrysler Group, LLC

› 2009 James Wolever, Chief Engineer, Honda America Manufacturing

› 2008 Mark Schwabero, President, Mercury Marine

OHIO STATE FACULTY AND AWARDEE // (L-R) College of Engineering’s Dean David B. Williams, former Ohio State President E. Gordon Gee, 2013 awardee David Tatman of General Motors Corporation, and CAR Director Giorgio Rizzoni.

32 APPENDIX

2014 AWARDEE2014 Cyndy Bonsignore, The Ohio State University College of Engineering

Cyndy Bonsignore was a 1985 graduate of The Ohio State University and a senior sponsored program officer in the College of Engineering. One of her responsibilities in this capacity was CAR. In this position, Cyndy quickly became known as a facilitator and worked not only with CAR personnel, but also directly with many of CAR’s industry partners. No matter how difficult the negotiations on a research agreement, ‘no’ was not an option. Cyndy always found a way to get to ‘yes’.

Most important, Cyndy loved the students, especially the OSU Motorsports teams, in particular the Buckeye Bullet program. She worked very hard to assist and protect the Buckeye Bullet teams as they pursued higher and higher landspeed records. Cyndy had been there since the early years of CAR and few have done more or worked harder for CAR’s success. She truly showed both extraordinary effort and sustained interest in the Center for Automotive Research, for which CAR is forever grateful. Cyndy truly was a #BuckeyeForLife.

Cyndy passed away in February 2014 after a three year battle with lung cancer. In the weeks since, on several occasions, we have asked ourselves

“what would Cyndy do?”

// Cyndy was a champion for her continuous support of the center, its mission to collaborate with industry and the hardworking student motorsports teams.

During the April 25, 2014 CAR External Advisory Board meeting (picture right), we recognized Cynthia Bonsignore with the 2014 Dwight Blaser Meritorious Service Award. Cyndy was a champion for her continuous support of the center, its mission to collaborate with industry and the hardworking student motorsports teams. CAR Assistant Director Don Butler described Ms. Bonsignore’s unwavering commitment to CAR, while her husband, Tony Bonsignore (pictured top right, in red), talked about her love for the student teams. During the ceremony, Mr. Bonsignore presented CAR with a $5000 contribution in her memory. “Cyndy was always thinking of the students,” says Butler (also pictured top right). “Her generous gift will be used to support scholarly activities related to student projects at the center”.

33APPENDIX

Address: 930 Kinnear Road, Columbus, OH 43212 Phone: 614-292-5990 Fax: 614-688-4111 Email: henley.53@osu.edu Online: car.osu.edu go.osu.edu/CARLinkedIn Facebook.com/OSUCenterforAutomotiveResearch @OSUCtrAutoRsrch