Proposed Testing Procedure for Pre

-Transmission Hybrid PowerPack Certification 14 May 2011

Conventional On
- H ighway Engine Test Certification Procedure 1. Torque Curve Generation a. Warm e ngine to operating temperature (typically at a 75% power point ) b. Return e ngine to idle condition or at least 15 seconds. c. Snap throttle to 100% d. With throttle held at 100%, ramp engine speed from idle to the point above the max power point where 50% power is achieved. i. The speed should be ramped at the appropriate rate s uch that t he duration of the sweep is 4 to 6 minutes. e. At this point, there are alternatives to creating a negative/ motoring torque curve i. Repeat steps (b) through (d), but with throttle set to 0% (minimum operator demand). ii. Multiple the positive torque curve generated by

-40%. iii. Motor the engine at warm idle and at max speed, recording the motoring torque required. Interpolate between points to determine motoring torque. 2. Transient Cycle Generation a. A normalized engine speed and load cycle is defined (the FTP cycle) b. Using the torque curve defined in step 1 and defined calculations, denormalize the normalized test cycle into engine speed and torque commands i. The speed is defined in the normalized cycle as a percentage of the range between idle speed (0% speed) and a maximum test speed (100% speed) ii. The maximum test speed is defined as the speed at which the 100% load at that speed maximizes the length of the vector between that point and the idle point. iii. The torque is defined in the normalized cycle as a percentage of the maxim um torque at the corresponding test speed c. Some points in the normalized cycle are defined as motoring points. At the se points, the speed is defined as above, whereas the torque is defined as the value of the negative/motoring torque curve at the correspon ding speed 3. Running Transient Test Cycle a. Run the engine system over one or more conditioning FTP cycles, each separated by a 20 minute hot soak period, during which the keyswitch is turned off b. After the final conditioning cycle is run, turn off the engine keyswitch off and allow the engine to soak until the engine temperature has stabilized at ambient temperature (usually taken as oil temperature being less than 85degF)c. At this point, start the engine system and run it, without warm up, over the FTP cycle d. At the end of this “cold” cycle, soak the engine system for 20 minutes, during which the keyswitch is off e. At the end of this soak period, restart the engine system and run over the FTP cycle 4. Steady State Cycle Generation a. Using the engine torque curve defin ed in step 1, defined calculations and test schedule, generate the steady state cycle b. Calculate h igh and low test speeds, n hi and n lo, respectively, from the engine torque curve. c. Calculate i ntermediate speeds A, B and C based upon n hi and n lo . d. The test points are defined by the 100%, 75%, 50% and 25% load points at each one of these intermediate speeds, and the engine transitions between these test points according to the test schedule 5. Running Steady State Test Cycle a. The engine is warmed to operating co ndition b. The steady state test cycle is run twice back

-to - back c. The first cycle is used as a conditioning cycle, and the second as the certification cycle 6. Data collection and analysis a. Gaseous emissions data is collected and the total mass of the emissions is logged (in grams) b. The positive work of the engine is summed over the length of the cycle and logged (in hp

- hr) c. The brake specific emissions are determined by dividing the mass of the collected emissions by the total positive cycle work. 7. Criteria for Succe ssful Test Completion a. Speed, Torque and Power regressions must meet minimum targets after point omission rules are applied b. Determining emissions results i. The brake specific gaseous emissions for the conditioning cycles are ignored ii. The brake specific gaseous emissions for the transient cycle immediately following the cold soak period are multiplied by a weight factor of 1/7 iii. The brake specific gaseous emissions for the hot transient cycle (the next cycle run after the cold cycle) are multiplied by a weight factor of 6/7 iv. The weighted brake specific gaseous emissions of the two cycles are then summed to get a composite emissions value. This value must be less than the regulated limit. v. The brake specific gaseous emissions for the steady state cycle must also be l ess than the regulated limit.Proposed H ybrid Pre

-Transmission PowerPack On
- Highway Engine Test Certification Procedure

1. Steady State Torque Curve Generation

A positive torque curve is generated using only engine power to represent typical steady

-state system performance
. a. Warm powerpack to operating temperature (typically at a 75% power point)
. b. Return powerpack to idle condition or at least 15 seconds. c. Snap throttle to 100%
. d. Hold throttle at 100% until engine torque stabilizes (and power from the energy storage is near 0kW)
. e. With throttle held at 100%, ramp powerpack speed from idle to the point above the max power point where 50% power is achieved. i. The speed should be ramped at the appropriate rate such that the duration of the sweep is 4 to 6 minutes. f. M onitor energy storage power during sweep to ensure the torque curve produced is from engine only. 2. Transient Torque Curve Generation

A transient system torque curve, provided by the hybrid system manufacturer and covering the speed range from idle to maximum no load speed , is verified before the test. This torque curve is generated using both engine and battery power to represent typical transient system performance. a. Warm powerpack to operating temperature (typically at a 75% power point) b. Return powerpack to idle condition or at least 15 seconds. c. Set throttle to a position that achieves 50

-70% of the steady state torque curve value at this speed, and remain at this point for a time to be determined using good engineering judgment
. d. Snap throttle to 100% e. With throttle held at 100%, ramp powerpack speed from the current speed to the next incrememental speed. i. The speed should be ramped at a rate similar to that used to generate the steady state torque curve. ii. The next incremental speed should be determined using good engineering judgment, ensuring that the energy storage system is capable of meeting full power requirements through to that speed. f. Remaining at this speed, set throttle to a position that achieves 50

-70% of the steady state torque curve value at this speed, and remain at this point for a time to be determined using good engineering judgment
. g. Repeat steps (d) through (f) until a speed point above the max power point where 50% power is achieved.

3. Transient Cycle Generationa. A normalized engine speed and load cycle is defined (the FTP cycle) b. Using the torque curve defined in step 1 and defined calculations, denormalize the normalized test cycle into engine speed and torque commands i. The speed is defined in the normalized cycle as a percentage of the range between idle speed (0% speed) and a maximum test speed (100% speed) ii. The maximum test speed is defined as the speed at which the 100% load at that speed maximizes the length of the vector between that point and the idle point. iii. The torque is defined in the normalized cycle as a percentage of the maximum torque at the corresponding test speed iv. Some points in the normalized cycle are defined as motoring points. At these points, the speed is defined as above, whereas the torque is defined defined as follows : 1. An appropriate Vehicle FTP cycle is calculated based upon peak powerpack power. A braking torque from this Vehicle FTP cycle is provided as a normalized braking torque schedule. This normalize braking torque schedule is denormalized by multiplying the schedule by the peak system torque (plus a constant). These negative torqu e values are effectively a limit on regenerative braking torque. The regenerative braking energy captured by the powerpack during these motoring periods depends upon the state of the powerpack system, but is limited by the negative torque. 4. Running Transie nt Test Cycle a. Run the powerpack over one or more conditioning FTP cycles, each separated by a 20 minute hot soak period, during which the keyswitch is turned off b. After the final conditioning cycle is run, turn off the powerpack keyswitch off and allow the powerpack to soak until the engine temperature has stabilized at ambient temperature (usually taken as oil temperature being less than 85degF) c. At this point, start the powerpack and run it, without warm up, over the FTP cycle d. At the end of this “cold” cycl e, soak the powerpack for 20 minutes, during which the keyswitch is off e. At the end of this soak pe riod, restart the powerpack and run over the FTP cycle 5. Steady State Cycle Generation a. Using the steady state powerpack torque curve defined in step 1, defined calculations and test schedule, generate the steady state cycle b. Calculate high and low test speeds, n hi and n lo, respectively, from the steady state powerpack torque curve. c. Calculate intermediate speeds A, B and C based upon n hi and n lo . d. The test points are defined by the 100%, 75%, 50% and 25% load points at each one of these intermediate speeds, and the powerpack transitions between these test points according to the test schedule6. Running Steady State Test Cycle a. The powerpack is warmed to operati ng condition b. The steady state test cycle is run twice back

-to - back c. The first cycle is used as a conditioning cycle, and the second as the certification cycle 7. Data collection and analysis a. Gaseous emissions data is collected and the total mass of the emissio ns is logged (in grams) b. The positive work of the powerpack is summed over the length of the cycle and logged (in hp

- hr) i. Any difference in stored energy levels between the start and finish of the test cycle should be addressed a ccording to standards laid ou t in SAE J2711. c. The brake specific emissions are determined by dividing the mass of the collected emissions by the total positive cycle work. 8. Criteria for Successful Test Completion a. Speed, Torque and Power regressions must meet minimum targets after point omission rules are applied b. Determining emissions results i. The brake specific gaseous emissions for the conditioning cycles are ignored ii. The brake specific gaseous emissions for the transient cycle immediately following the cold soak period are multiplied by a weight factor of 1/7 iii. The brake specific gaseous emissions for the hot transient cycle (the next cycle run after the cold cycle) are multiplied by a weight factor of 6/7 iv. The weighted brake specific gaseous emissions of the two cycles are then summed to get a composite emissions value. This value must be less than the regulated limit. v. The brake specific gaseous emissions for the steady state cycle must also be less than the regulated limit. c. Energy storage management criteria met per J2711