Number range CHAPTER**RFP-PR-CI-08-10283**

**[Engineering Support for Design, Fabrication & Calibration of
Electronic Engine and Vehicle Controllers, Hydraulic Accumulators,
Hydraulic Pump Motors, and Powertrains For Advanced Hydraulic Hybrid
Vehicles]{.underline}**

**[Performance Work Statement]{.underline}**

**I. [Background]{.underline}**

The Environmental Protection Agency (EPA), Office of Transportation and
Air Quality (OTAQ), Advanced Technology Division (ATD) is continuing to
develop advanced clean and fuel efficient automotive technology to
better protect the environment and conserve energy. As part of the
Advanced Automotive Technology initiative, EPA continues researching and
testing hybrid vehicle technologies to examine their fuel economy and
reduced carbon dioxide emission potential. In particular, ATD is
investigating hydraulic hybrid vehicles and clean combustion engines. A
major goal of this program is to develop a vehicle that will be produced
to achieve up to three times the fuel efficiency of today's comparable
vehicle. It is EPA's responsibility to evaluate unique non-electric
hybrid vehicle designs. Currently these vehicle concepts involve large
package delivery vehicles as well as personal transportation concepts.
This contract will continue the development and evaluation of components
and hardware related to electronic engine and vehicle controls,
hydraulic accumulator systems, as well as advanced powertrain and engine
systems as required.

**II. [Overview of Requirements]{.underline}**

The primary purpose of this contract is to provide the Environmental
Protection Agency (EPA) with engineering support for the design,
development, modification, fabrication, testing, and installation of
electronic engine and vehicle control systems, and powertrain systems
and subsystems, for drivetrains of advanced hydraulic hybrid vehicles.
The engineering support required under this contract may include work on
vehicles such as large package delivery vehicles, as well as smaller
passenger and sport utility vehicles. The hydraulic hybrid vehicle
powertrain components contemplated here include hydraulic systems,
(pumps, motors, and accumulators) electrical and hydraulic control
valves and actuators, electronic control systems, internal combustion
engines, and transmissions.

Specific work direction will be defined and provided in each approved
work assignment. This direction may concern such topics as electronic
engine and vehicle control systems, electrical and hydraulic control
valves and actuators, hydraulic accumulators, and advanced Otto cycle or
Diesel cycle engines. This direction may also include test instructions,
procedures, data handling, and special reporting requirements.

The electronic control systems contemplated in this procurement may
include technologies such as the Rapid Prototyping Electronic Control
System (RPECS), used by ATD in prior technology efforts, or technologies
new to ATD. The contractor may be tasked to provide a flexible control
system specifically for a vehicle application, as well as support to
existing EPA control systems. Any engine controller required by EPA will
be required to function in a manner to ensure acceptable vehicle
driveability (as defined by EPA project management), fuel efficiency,
and an emissions profile comparable to that obtained in an engine
dynamometer test environment. All aspects of vehicle or chassis control
for a hydraulic hybrid power-train may also be required.

Advanced unique internal combustion engine configurations and
components, in support of a complete hydraulic hybrid powertrain, may
also be designed and fabricated under this contract. Engines that could
be developed or improved under this contract will be based on their
ability to perform at the highest possible efficiency and the least
possible cost. Some of the technologies that could be considered here
may have been evaluated under previous EPA contracts; these technologies
will be further developed and refined under this contract, as required.

The contractor shall provide personnel, materials, services, equipment
and facilities to perform work in response to written work assignments.
In many cases, individual work assignments will involve a combination of
one or more of the activities designated as tasks described below. All
electronic engine and vehicle control technologies, hydraulic systems,
engine, powertrain, and/or fuel system components required to perform
work will be obtained, designed, or fabricated by the contractor or
furnished by the Government.

The contractor shall provide capability in designing, evaluating,
fabricating, refining, calibrating, installing and testing electronic
engine and vehicle controllers. This capability shall also extend to
hydraulic systems and automotive components, including any components
used in vehicles, engines, powertrains, and fuel systems. The potential
exists that designs or prototypes submitted to EPA in the performance of
this contract may be subjected to further development by EPA or its
contractors. This may be necessary in order to customize the
component(s) for future unanticipated applications. The component(s) may
also be sent to another contractor for integration into a demonstration
vehicle, or other purposes, at the Government's discretion.

The contractor shall provide engineering and technical capability
available to perform all electronic engine and vehicle controller
diagnostics, in order to support these EPA control systems. This
diagnostic and support capability shall also extend to hydraulic
systems, internal combustion engines and their components. Work
contemplated as support might include diagnosing hydraulic accumulator
fluid motion problems, replacement or modification of power train
component, or diagnosing emission control equipment concerns.

The contractor shall also provide the appropriate equipment and the
ability to install modified components/subsystems in an EPA test
vehicle. These components and systems may include electronic engine and
vehicle controllers, as well as systems related to hydraulic hybrid
vehicle operation. Access to EPA facilities may be allowed for that
purpose or to familiarize EPA personnel with installation and operation
of the system(s), pursuant to work assignments approved by the
Contracting Officer.

**III. [Design and Specification Task]{.underline}**

The contractor shall provide technical support for design work, which
may include designing or specifying electronic engine and vehicle
control systems, hydraulic drivetrain systems and components, electrical
or hydraulic control valves and actuators, hydraulic accumulators,
hydraulic pumps and/or motors. Internal combustion engines and other
drivetrain components, as part of a hydraulic hybrid vehicle, may also
be considered as part of this task. This design effort may include
hardware and/or software designs for any electronic control systems
specified under the contract. Components or subsystems may be designed
either independently or as integrated units. The support for the design
effort required under this contract may include the following types of
tasks as set forth in specific work assignments:

--- Design or specify an electronic controller for a particular internal
combustion engine /hydraulic pump motor powertrain, as part of a
hydraulic hybrid vehicle application.

--- Design test equipment to evaluate hydraulic componentry such as
pumps, motors and other hydraulic components or systems.

--- Redesign existing hydraulic components and systems such as
accumulators, pumps, motors (and their internal parts such as pistons,
valves, bearings, and seals) to improve their efficiency or the speed at
which their displacement could be changed.

--- Design integrated hardware/software packages capable of monitoring
the state of hydraulic systems and adjusting system operations according
to external commands or rapidly changing vehicle conditions.

--- Design specialty high speed actuators for the control of hydraulic
components or systems.

--- Evaluate and/or redesign powertrain components or systems and their
internal parts such as pistons, valves, bearings, and seals to improve
their efficiency.

--- Design any electrical or non-electrical components or systems of a
vehicle or of an engine, powertrain, fuel system or related emission
control equipment.

--- Design prototype components, convert equipment to alternate fuel
operation, and/or incorporate new or changed performance requirements
into existing or proposed systems.

--- Produce preliminary design(s) including outline drawings of EPA
provided concepts as directed in individual work assignments. The
concepts provided may be in the form of hand-drawn sketches. The
contractor shall prepare a detailed design of the concept, including
materials, dimensions, specifications, blueprints and/or computer
assisted design and manufacturing (CAD/CAM) data. The detailed design
shall include all information required to fabricate, assemble and test
the functionality of the concept by the contractor or others.

**IV.** [**Development** **and** **Analysis** **Task**]{.underline}

The contractor shall provide development and analysis support under this
contract. The support may involve specific development, testing and
analysis tasks. Technical support considered here may include
modifications or adjustments made to electronic controller hardware or
software, hydraulic systems, powertrain components, other electronic
control systems and/or components listed in Task III, [Design and
Specification Task]{.underline}, to improve performance beyond the
normal operating range of such components. This effort may include the
requirement to develop actual working versions of new prototype designs.
The technical support for the development effort required under this
contract may include any of the following tasks as set forth in specific
work assignments:

---Development of electronic hardware or software to implement designs
as specified in Task III, [Design and Specification Task]{.underline}.
Modifications to existing control hardware, to optimize control rates,
handle more system inputs, and produce additional outputs may be
required.

---Redesign and improve the efficiency or performance of hydraulic
systems and powertrain components: redesign, and modify hydraulic pumps
or motor housings, seals or internal components to withstand greater
pressures, improve their efficiency or speed of actuation. Specific
examples of development work may include improved hydraulic accumulator
liners for accumulators containing bladder systems, improved fuel
injection systems, air charge systems, compressed air intercoolers,
variable control valves, and improved engine variable compression ratio
concepts.

The contractor shall develop customized data acquisition systems for
emissions and other data (e.g., vehicle/engine operating parameters for
hybrid vehicles), including necessary hardware and software development
for the specific tasks under consideration. As directed in individual
work assignments, the contractor shall program personal computers,
laptop computers, or other devices for the collection, manipulation and
logging of data, or for use together with electronic controllers for
vehicle engines, powertrains, or components thereof, and other
equipment.

**V.** **[Fabrication Task]{.underline}**

The contractor shall fabricate any hardware required as specified in
individual work assignments. This could include making design
modifications of new or existing components or fabrication of prototype
units incorporating design changes. Examples could include engine or
hydraulic system components; high pressure and high temperature
air-to-air heat exchangers; precision response hydraulic actuators;
modification of bent axis pump/motors to permit over-center operation;
and fabrication of unique pump/motor designs. The effort may include the
fabrication of electronic circuits including the use of circuit cards.
The contractor shall assemble required electronic components onto
circuit cards. The contractor shall fabricate the wiring and assembly of
sensors and signal conditioning components and software such as
displacement transducers and power supplies to support the requirements
of individual work assignments.

Fabrication of hardware may include procedures such as machining,
casting, drilling, tapping, grinding, honing, lapping, milling,
broaching, turning, heat treating, coating, curing, polishing,
finishing, surface treatment and welding. In addition, fabrication shall
include obtaining materials and commercially available parts required
for the fabrication of system components. The contractor may be required
to modify components furnished by EPA or others.

**VI. [Assembly Task]{.underline}**

Assembly tasks shall include assembling two or more fabricated
components into an assembly for delivery to EPA; installing a fabricated
component into an assembly provided by EPA; and/or modification of a
part or assembly furnished by EPA which would allow for inclusion of a
fabricated component. For example, if a work assignment involves
modifying a cylinder head, assembly work would involve complete assembly
of the cylinder head including the head, the valves, the cams, the
camdrive mechanism, the spark plugs, other parts as required, and the
complete valvetrain.

**VII. [Test Task]{.underline}**

Test tasks may include checking the physical dimensions and properties
of the fabricated and/or assembled hardware and performing functional
tests as appropriate to verify that the hardware will perform
adequately. For example, if a work assignment involves modifying a
cylinder head, checkout and test work would involve tests to verify that
all complete valvetrain, the cams, the camdrive mechanism, the spark
plugs, and other parts fit together and function properly.

The contractor shall provide technical testing support. The contractor
shall perform various types of electronic system, vehicle, hydraulic
system, or powertrain component tests as specified in specific work
assignments. These tests may include procedures such as extended tests
of current or prototype vehicles, engines, or powertrain components
considered by EPA to have an impact on vehicle emissions or fuel
consumption. As specified in individual work assignments, the contractor
may be tasked to perform tests using experimental apparatus designed to
simulate various phases of vehicle or engine operation.

**VIII.** [**Performance** **Task**]{.underline}

The contractor shall work on multiple work assignments concurrently.
Testing of prototype components, sub-systems, and prototype electronic
systems before installation on an EPA experimental vehicle shall occur
at the contractor\'s facilities. Work assignments involving component
and sub-system installation and operation on a government supplied
vehicle may occur at the contractor\'s facility or the EPA laboratory in
Ann Arbor, Michigan. Access to EPA facilities may be allowed if required
as part of a work assignment, or to familiarize EPA personnel with
installation and operation of the components and/or subsystems.

**IX. [Data Requirements]{.underline}**

The contractor shall provide all data generated in the performance of
work assignments, including design drawings and any results and
documents gathered during developmental tests, to the Project Officer.
The contractor shall distribute data and/or any information resulting
from work performed under this contract only to the Project Officer and
the Contracting Officer unless the Contracting Officer provides prior
written approval for other distribution of data. The required format for
the data will be set forth in the specific work assignments issued under
this contract.

**X. [Other]{.underline}** **[Requirements]{.underline}**

Weekly or bi-weekly meetings with the EPA Project Officer at the EPA
National Vehicle and Fuel Emissions Laboratory in Ann Arbor, Michigan
may be required for each work assignment.