GVPM Powertrain OverviewJohn Tasdemir

UNCLASSIFIED: Dist A. Approved for public release

11 Aug 2011

UNCLASSIFIED: Dist A. Approved for public release

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1. REPORT DATE 10 AUG 2011

2. REPORT TYPE Briefing

3. DATES COVERED 10-08-2011 to 10-08-2011

4. TITLE AND SUBTITLE Ground Vehicle Power and Mobility (GVPM) Powertrain Overview

5a. CONTRACT NUMBER

5b. GRANT NUMBER

5c. PROGRAM ELEMENT NUMBER

6. AUTHOR(S) John Tasdemir

5d. PROJECT NUMBER

5e. TASK NUMBER

5f. WORK UNIT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) U.S. Army TARDEC ,6501 E.11 Mile Rd,Warren,MI,48397-5000

8. PERFORMING ORGANIZATIONREPORT NUMBER #22026

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) U.S. Army TARDEC, 6501 E.11 Mile Rd, Warren, MI, 48397-5000

10. SPONSOR/MONITOR’S ACRONYM(S)

11. SPONSOR/MONITOR’S REPORT NUMBER(S) #22026

12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited

13. SUPPLEMENTARY NOTES

14. ABSTRACT NA

15. SUBJECT TERMS

16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT Same as

Report (SAR)

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19a. NAME OFRESPONSIBLE PERSON

a. REPORT unclassified

b. ABSTRACT unclassified

c. THIS PAGE unclassified

Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18

Challenges we have: • Commercial Off-The Shelf (COTS) engines are not optimized for military applications• Emissions compatible engines are not compatible with military grade fuels (JP-8, JP-5, DF-2, etc…) • Availability of power dense and low heat rejecting engines for combat vehicles• Controls algorithms unique for military platforms targeting global fuel compatibility and fuel efficiency• Limited transmission technologies specific for the extreme demands and conditions of military vehicles

Solutions we are investigating:

Where we need your help:• Military fuel compatibility, fuel efficiency, electrical power generation, high efficiency low thermal burden cooling.• High power density low heat rejection engine designs, higher temp/low friction materials, improved cooling, efficient accessory

drives, advanced controls algorithms.• Improved torque capacity, better speed/load matching, reduced thermal loading, and improved control strategy for automatic

transmission applications.

Powertrain

UNCLASSIFIED: Dist A. Approved for public release

COTS Engine Optimization for JP8 Fuels• 48% Thermal Efficiency

• 0.6 kW/kW Heat Rejection

Efficient Powertrain Technologies• Combat Tracked Vehicles• Tactical Wheeled Vehicles

Research on the Ignition and Combustion Variances of JP-8 Fuel

• Fuel Characterizations • Controls Algorithims

Ultra High Pressure JP-8 Fuel Injection R&D

• Improve engine efficiency• Injector durability on low

lubricity fuels

600 900 1200 1500 1800 2100 2400 2700 3000 3300SPEED [rpm]

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Powertrain ProjectsCurrent & Future

Propulsion Technology

Current & Future

Combat Vehicle

Current & Future

Tactical Vehicle

Militarizing Commercial Diesel Engines and Transmissions for Tactical Vehicles:

Common Technology Development for Military Vehicles:

High Output Combat Vehicle Powertrain Development:

• Efficient, Integrated power pack• Increased Power Density• Quiet, efficient on-board electrical

power generation• Improved Fuel Efficiency• Thermoelectric Waste Heat Recovery

• Advanced Engine Cycle Demo• Increased Power Density• Enable Lighter Weight Structures• Decreased Heat Rejection• Efficient Binary-Logic Transmission• Quiet, efficient on-board electrical

power generation• Engine controls adapt engine for

variations in heavy fuels• Efficient, Integrated power pack

• Diesel Cold-start Research• Common military vehicle drive cycle

for fuel economy measurement• High Efficiency Power transfer

devices for military vehicle transmissions• Cabin Thermal Management• Militarized Power train Control Module

and strategies devices for militaryvehicle transmissions

FY11 FY12 FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21

Efficient Powertrain Technologies(Engine , Inline Generator, Transmission):- Medium Combat Application (20-40 tons)- Medium Tactical Application (15-30 tons)

Thermoelectric Waste Heat RecoveryEnergy Analysis

Next Generation Combat Engine Next Generation Combat Engine

High Operating Temperature High Engine Density (HOTHED)

Next Generation Combat Vehicle Engines and Transmissions

Independent Laboratory In house Research (ILIR) Combustion and JP-8 Research

Ultra High Capacity Launch Clutch for Tactical Transmission

Multi K Factor Torque converter

Powertrain Control and ECM Hardware Development

Military Vehicle Fuel Economy Measurement Cycle Development

CommonTechnology

Efficient Powertrain Integration(Engine , Inline Generator,Transmission):- Medium Combat Application- Medium Tactical Application

Thermoelectric Waste Heat Recovery

Energy Analysis

Cabin Thermal Management

UNCLASSIFIED

Laboratory CapabilityCurrent & Future

Propulsion Laboratory

GSPELGround Systems Power and Energy Laboratories

PowertrainRoadmap

Current Capability

P&E Vehicle Environmental Laboratory

9 Test Cells which include:• 6 “engine” test cells used for performance, endurance,

transmission or drive train testing• 2 vehicle test cells designed for steady-state tests to 44,000 ft-lbs

per side as well as transient tests and a Power & Inertia Simulator (PAISI)

• 1 vehicle test cell designed for wind speeds up to 20mph in eight possible directions, two 2500 hp dynamometers, 160F ambient temps

New Vehicle Environmental Lab:• 12 AC Dynamometers (2 for BFVS class combat vehicle and 10

for all tactical/wheeled vehicle torque/speed ratings)• Environmental capability from -60F to +160F with variable

wind, solar (desert) and humidity (global) control• Transient cycle (mission profile) test capability for repeatable /

controlled condition performance characterization, field failure root cause analysis and modeling and simulation validation data

Future Capability

UNCLASSIFIED

Advanced PowertrainTechnologies

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1975 1980 1985 1990 1995 1999 2001 2004 2007 2010

Year

Bra

ke S

peci

fic F

uel C

onsu

mpt

ion

(lbm

/hp-

hr)

1998 EPA Military Emissions Waiver

2004 EPA

2007 EPA

2010 EPA

Projected DevelopmentMilitary Engine Optimization

EfficiencyGap Transmission

-No Torque Converter- Multi-Cone clutches- Wide-spread, equallyprogressive gear ratios

- Low parasitic oil mgmt.- Variator technologies - Integrated controls-- Cooling system

Generator- Hardware- Controls

Engine- Multiple fuels- Integrated

Controls- Noise abatement- Cooling system

Commercial Heavy Duty Engine Manufacturers have Diverged from Military Engine Demands

Powertrain Integration and Optimization> 6 hp/ft3

High Engine Power Density

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0 1000 2000 3000 4000 5000 6000 7000 8000

BM

EP (P

SI) Cat 3600

Cat C-15

Heavy Duty, CommercialCat C-7

Navistar

GM Duramax

Pick-up Trucks

VW BMW

Euro Pass. Cars

Kawasaki, Army MotorcycleAVL, UAV

Cat C6C

MTU

HP/Liter of Displ. = BMEP X RPM / 12,984

RPM

100 hp/liter

150 hp/liter

200 hp/liter

FCS Combat EngineHigh

Speed Combustion

OPOC UAV

OPOC

Next Generation Combat Engine Binary Logic

Transmissions> 90% η

UNCLASSIFIED