1. The Ohio State University
Center for Automotive Research (CAR)
Center for Automotive
C t f At ti
Research Overview
December 10, 2008
http://car.osu.edu
2. The Ohio State University
• The largest, most comprehensive
public research university in the
country
– 51,800 students at the Columbus
campus
– 19 different Colleges on the same
campus
• Ranked in the Top 25 of all public
universities overall in both
research and education
• Ohio State ranks 7th in public-university research expenditures
programs, 12th overall
– $708 million in 2007
– ranked 3rd among all American universities for private industry
sponsored research.
Endowment >$2 Billi (7th among public universities)
• Ed t $2 Billion bli i iti )
– OSU in first public university group (1999) to exceed $1Billion
3. College of Engineering
Ohio State University
College of Engineering is:
More than 7,000 students enrolled in
10 engineering departments and
Knowlton School of Architecture
Research expenditures: $113 million
Ranked #3 Nationally in Materials Research
Funding
Ohio State ranked 3rd in the country for
industry-financed research; 60% of industry
funding awarded for engineering research
f f
(NSF)
4. College of Engineering Enrollment
Ohio State has a competitive
admissions policy:
p y
Two-thirds of entering students from top quartile
of high school
Average incoming engineering
ACT score—27; national average 22
score 27; average—22
Only 8 universities in the top 25 have higher
GRE admit scores
Eighth-largest ndergrad ate
Eighth largest undergraduate
engineering enrollment in U.S.
Undergraduate Engineering 4,719
Graduate Engineering 1,299
Engineering Total 6,018
Architecture Total
A hit t Ttl 856
5. Graduate Degree Programs
Diverse Engineering Graduate Degree Programs:
• Aerospace Eng
• Architecture
• Biomedical Eng
• Chemical and Biomolecular Eng
• Civil and Environmental Eng
• Geodetic Science
• Computer Science and Eng
• Electrical and Computer Eng
• Food, Agricultural, and
ood, g cu tu a , a d • Industrial and Systems Eng
Biological Eng
• Materials Science and Eng
• Mechanical Eng
• Nuclear Eng
• Welding Eng
6. College of Engineering Faculty
Our faculty boast:
260 full-time faculty members
10 National Academy of Engineering
members
18:1 Undergraduate student/faculty ratio
14:1 First-Year Engineering program
First Year
student/faculty ratio:
12:1 First-Year Honors Engineering
s ude / acu y a o
student/faculty ratio:
40 research centers and laboratories provide
state-of-the art facilities for research and
teachingg
7. Interdisciplinary Research Centers
• Institute for Material Research
• Center for Automotive Research
• Nanoscale Science and Engineering Center
• Center for Multifunctional Polymer Nanomaterials and Devices
• Center for Advanced Polymer and Composite Engineering
• Institute for Energy and the Environment
gy
• Photovoltaic Innovation and Commercialization
• Smart Vehicles Concepts Center
• Collaborative for Enterprise Transformation and
p
Innovation
• Center for Precision Forming
• Center for Occupational Health in Automotive
Manufacturing
• Institute for Ergonomics
• Center for Energy, Sustainability and the Environment
• Center for Advanced Maturation of Materials
• ElectroScience Lab
• Institute for Sensing Systems
8. Materials Research Facilities
Molecular beam epitaxy:
to synthesize nanomaterials
(1st at an Ohio university - `94)
FEI Tit ™ 80-300
Titan™ 80 300
• World’s highest
structural resolution
microscope (
p (0.07 nm) )
• 1st in world - 2006
Nanofabrication cleanrooms:
• More than 7000 sqft of multi-
user processing capabilities
Leica EBPG 5000+
• 10 nm spot electron
beam nanopattern
capability
• less than 5 at US
universities, `05
9. Nanomaterials and Photonics
Commercialization of
the Speed of Light
Displays
Future Information
Technology
High T h D i
Hi h Tech Driven, Emerging Applications
E i A li ti Biosensing
Bi i
Optics
10. ElectroScience Laboratory
Major research areas:
• Graduated over 311 Ph.Ds. and Over 557 M.Sc. Degrees
• Graduate 17 Ph.Ds/M.Sc. degrees per year
12. Occupational Health in Auto
Manufacturing
• State-of- the Art Research
Facility Completed
• 3 funded projects
• $1M in donated equipment
13. Center for Energy, Sustainability
and the Environment
Advanced Nano-Engineered OSU Solar Cells on International Space Station
• Relatively low cost compound solar cells (
y p (III-V’s on silicon)
)
• Highest efficiency in the world for these Cells (20%)
• Recently retrieved from the Space Station
14. Ohio Supercomputer Center
• High performance computing resources for all
public and private higher education institutions
• Computational science education and
workforce development
• Renewed focus on economic development
through Blue Collar Computing and
networking for businesses
multi-scale,
Parallel CFD modeling of multi-physics models
Buckeye Bullet 2
15. The Ohi State University
Th Ohio St t U i it
Center for Automotive Research
16. Center of Automotive Research
The Center of Automotive Research is
a major Center of Excellence in the
College of Engineering
•24 faculty
•40 grad students
g
•350 undergrads
•Graduates 10 Ph.Ds/M.Sc. per year
Major research areas:
Hybrid Electric Vehicles
Automotive Safety
Electromechanical Systems
Diesel and Gas Engines
17. Key R&D Capabilities
Computational Experimental
Collaboration with Ohio Engine Combustion and Exhaust
Supercomputing Center After Treatment
After-Treatment
Solid Modeling, CAD, FEM Powertrain Control
Design Space Exploration Power and Energy
CFD • Fuel Cell Systems
Modeling and Simulation • HEV/PHEV Architectures
• Drive Cycle Analysis • Energy Storage
• Vehicle-Terrain Interaction and o Aging characterization
Mobility
o Modeling
• Chassis Dynamics
o Battery management systems
• Engine Combustion and Exhaust
Alternative Fuels
• Engine Flow Noise
Vehicle Dynamics (TRC)
• Fuel cells
Noise d
N i and acoustics
i
• Hybrid Electric Vehicles
ITS and V2V
• Batteries
18. CAR Testing Facilities
• Dynamometer test cells
– Engine ( )
g (4)
– Heavy-duty axle
– Chassis dynamometer
• Advanced Propulsion Systems research facilities
– PHEV and HEV test beds
– Fuel cell research laboratory
– Electrochemical energy storage aging and characterization laboratory
• Vibration, Noise and Acoustics laboratories
– hemi-anechoic chamber
• Intelligent and autonomous vehicle laboratories
• Engine fluid mechanics and combustion research facilities
• Hydrogen refueling station
19. Research Partners and Sponsors
Government
Private
• U.S. Army TARDEC
• American Electric Power
• U.S. Army Yuma Proving
• Battelle
Ground
• Bosch
• U.S. Department of Energy
• Caterpillar
• U.S. Department of
• Chrysler
y
Transportation (NHTSA)
• Cummins
• Argonne National Laboratory
• Dana
• National Renewable Energy
• Denso Laboratory
• Eaton • Oak Ridge National Laboratory
• Ford Motor Company
• National Science Foundation
• General Motors Corporation
• Ohio Board of Regents
• Honda
•O Ohio Department off
• Hyundai
Development
• Nissan Motor Co.
• Oshkosh Truck Corporation
• Tenneco Automotive
• Toyota
• TRC, Inc.
20. Personnel Summary - 2008
•5 Facility Support Staff
•4 Administrative Staff
• 19 Faculty
• 12 Research Staff
•4 Post Doctoral Fellows
• 45 Graduate Students
• 15 Visiting Scholars
• 40 Student Research Assistants
Total:
ota 144 peop e (84 peop e based on FTE)
people (8 people o )
The Center also provided facilities and support, in collaboration with
the College and ME department for 5 student project teams consisting
department,
of over 100 active undergraduate students and 45 FIRST (robotics
project) high school students.
21. Research Expenditures and Growth
• Balanced portfolio of government and private sector funding.
• Responsible for 13% of industry-funded research in the college of engineering.
• Industrial consortium is largest in the college
• Research expenditures have increased four-fold in 6 years.
7,000,000
6,000,000
6,000,000
$5,700,000
$5,000,000
5,000,000
5,000,000
3,800,000
4,000,000
3,000,000
2,600,000
2,000,000
1,500,000 1,600,000
1,500,000
1,000,000
FY06: $1,742,855
0
38%
2000 2001 2002 2003 2004 2005 2006 2007 2008
22. FY08 Research Revenue
Capital Improvements
Graduate Fee
$162,081 Consortium
Authorizations
3% $374,358
$374 358
$226,276
$226 276
8%
5%
In House Research
$516,222
11%
Sponsored Res. NON
F&A
$248,364
5%
Industrial
$1,944,525
42%
Total: $4,708,189
Government
$1,236,363
26%
23. Types of Engineering Services
o Testing
• Engine test cells (4)
• Chassis dynamometer
• Heavy-duty axle dynamometer
• Energy storage lab
• Flow lab
• Electronics Lab
• Machine shop
o Design
• Concept design
o Simulations, Optimizations, Solid Models, etc.
• Engineering design
o Mechanical, Electrical/Electronic
o Prototype
• Hardware for experimental confirmation
24. Customers to Date
• Testing • Design
– Caterpillar – Mercury Marine
– General Motors – Dana Italia
– Tenneco • Prototype
– Nextech – NETL
• Lab space access
– NHTSA/VRTC
26. Sustainable Mobility
• Advanced energy
storage
• Hybrid propulsion
systems
• Fuel cell systems
• Vehicle-building
Vehicle building
networks and PHEVs
ELECTROLYZE
R
Graduate Research Associates:
8-12 M.S. and Ph.D. students.
26
27. Advanced Powertrain Systems
• Diesel and gasoline engine
modelingg
• Control algorithm development
and validation
• Exhaust after-treatment systems
• Diagnostics
Graduate Research Associates:
6 M S 4 Ph D St dents
M.S., Ph.D. Students
28. Flow, Engine and Acoustics
• Flow noise and flow
performance
• Intake d h
I t k and exhaust system
t t
acoustics
• Engine combustion and
emissions
ii
Graduate Research Associates:
4 M.S., 2-4 Ph.D. Students
29. Control and Intelligent Transportation
• Control
• V2V communications
• Mobile sensor networks
• Vehicle dynamics and control
• Autonomous vehicles and
related sensing and sensor
fusion
Graduate Research Associates:
2-4 M.S., 4-6 Ph.D. Students
30. Vehicle Dynamics and Control
• Experimentally validated models
of advanced suspension,
braking, and vehicle stability
b ki d hi l t bilit
control systems, including CES,
ABS, ESC (YSC and RSC), and
related syste s
e ated systems.
• Advanced vehicle control
systems, such as automated test
drivers.
Graduate Research Associates:
3-5 M.S. and Ph.D. students.
31. Vehicle Duty Cycles and
Terrain Characterization
• On-road and off-road vehicle duty
cycles representing real-world
driving conditions for various
types of vehicles.
• Terrain surface profile
measurement using the latest
sensor technologies
technologies.
• Vehicle-based Terrain Severity
Measurement System.
Graduate Research Associates:
• Analysis of terrain surface profile
2 M.S., 1 Ph.D. student.
data
32. System Fault Diagnosis and Prognosis
• Theory of model-based Observatio Residual Decisio
RESIDUAL RESIDUAL
diagnosis and prognosis. n s n
GENERATOR EVALUATION
• Applications to:
– Exhaust after treatment
systems Input Outpu
Plant
s ts
– Engine systems
– Vehicle chassis systems
Model
– Vehicle electrical systems RESIDUAL
1
RESIDUAL S
L GENERATOR
M M
– Starter batteries Model
n
– HEV battery systems
Graduate Research Associates:
4-6 M.S. and Ph.D. students.
LNT System Schematic
33. Concept Design
• Aerodynamics
• Coolingg
• Electric Machines and
Drives
• Engines
• Powertrains and
transmissions.
transmissions
• Suspensions
• Vehicle Designs
g
34. Injury Biomechanics
• Human response to high
energy loading conditions
commonly found during
lf dd i
automobile collisions
• Injury criteria for various
aspects of the human body
t f th h bd
Graduate Research Associates:
5-7 M.S. and Ph.D. students and 4
medical students
35. CAR I d
Industrial Consortium
i lC i
Established in 1999
36. Consortium Benefits
• Provide industry and government leveraged automotive
research
• Interaction with other consortium members on research
projects in areas of mutual interest
• Opportunities for teaming with partner members on bids for
major program funding
• Significant leveraging of government sponsored research
• CAR laboratory, university support and the availability of the
Transportation Research Center (TRC)
• Access to all CAR reports that are not proprietary
• Reduced fees for test facility use at CAR
37. Additional Benefits
• Provides educational opportunities for g
pp graduate
students
• Access to CAR professors and research scientists
a for limited amount of free consulting
• Opportunity to sponsor graduate fellowships at
reduced fees
• Interaction with OSU students to enhance the
company’s recruiting
38. 2008-09 CAR Consortium Members
Consortium
Associate Members
• US Army Yuma Proving Ground
• US AArmy TARDEC
• NHTSA (VRTC) Vehicle Research and Test Center
39. Project Selection
• Participate in and steer the direction of these
projects.
projects
• Final project review are hosted by a member
companies in early September
September.
• Project reviews and deliverables available on
secure website
– Algorithms
– Data
– Simulation models
• For additional information visit
http://car.osu.edu .
40. 2008/09 Projects
Advanced Propulsion Systems
• PHEV Battery Aging studies
• Diesel NOX After-treatment Modeling and Diagnostics
• PHEV Energy Management
• Innovative HEV drive systems
Intelligent Transportation Systems/Vehicle 2 Vehicle
• Sensor Fusion and other IV technologies
• Wireless Intersection Simulator
• Hardware Test bed Development
p
Noise Vibration Dynamics
• Noise Path
41. 1998 to 2004 and 2006 to 2010
DoE Graduate Automotive Technology
Education (
(GATE) Programs
) g
Modeling, Control and System Integration of
Advanced Automotive Propulsion Systems
42. 1998-
1998-2004 GATE Program
Hybrid Drivetrains and Control Systems Projects
• Original funding from DOE
– 1998 through 2004 $550,000
– supported 22 Graduate-Student-years
• Additional funding from DOE
– 96 Graduate-Student-years
• GATE program at Ohio State graduated
– 38 M.S students
– 12 Ph.D. students
– 45 of these 50 professionals are now employed in the automotive sector
43. Program Success
Year M.S. Ph.D. Company Hires
1999 3 1 DaimlerChrysler 2
2000 2 0 Ford 7
2001 7 4 General Motors 7
2002 8 1 Hyundai 2
2003 3 0 Caterpillar 8
2004 6 3 Cummins 5
2005 7 5 Oshkosh Truck 2
TOTAL 36 14 DDC 2
Bosch 1
50 Delphi 2
Ballard 1
OSU CAR 2
Battelle (fuel cells) 1
Army (USMA) 1
Other automotive 2
45
TOTAL
44. 1998 to 2004 GATE Results
Research Programs Partners
– Advanced engine combustion, – Caterpillar
sensing, actuation and control – Cummins
– Advanced electrochemical – DaimlerChrysler
energy storage systems – Delphi
modeling and system
– Denso
integration
– Ford
– Fuel cell system modeling,
modeling
– General Motors, Honda
design and control
– Oshkosh Truck Corporation
– Research in smart materials
with application to sensing and – NREL
actuation in automotive – U.S. Army
systems
– TARDEC
– Modeling, design, integration
– NSF
and control of light- and heavy-
g y
– U.S DoT
duty hybrid-electric vehicles
.
45. GATE Success Metrics
• Number of graduates per year placed in auto industry
• Number of students in the program, including OSU graduate students
program
and industry participants
• Auto companies participating in internship and recruitment programs
• Funded
F d d research programs l
h leveraged f
d from GATE
• Publications and patents
• Number of specialty courses developed and taught and number of
team-taught courses
• Number of participating faculty
• Variety of courses across disciplines
• Outreach and societal impact
• International participation
46. GATE Past Achievements
• Design and built a Land
Speed Record vehicle
powered by fuel cells
• Neighborhood Electric
Vehicle (NEV) Full Cell
• Matlab-based “Personal Energy
Management
Ecosystem” simulator
• Battery electro-thermal
battery characterization
•NNew B tt
Battery Aging L b
A i Lab
• Fuel Cell Research
47. New GATE Program 2006-10
• The theme of the new program is System Integration.
• The program focus is on:
– advanced combustion engines,
– advanced energy storage systems,
– fuel cell systems,
– sensing and actuation technologies and
– advanced hybrid propulsion and related control systems,
• The DOE GATE program will continue to serve as a
catalyst
– Educating a new generation of automotive system engineers
– Strong emphasis on the integration
g p g
– Development of new generation of automotive propulsion concepts
48. Advanced Engines and Energy Storage
Systems Addressing Societal Needs
Emission reduction and
efficient energy conversion
Society
y
“Well-to-wheel” Vehicle
technology demonstrations
assessment Control-oriented
Real-time control
modeling
Hardware-in-the-loop
implementation
Optimization of g
p geometry,
y
operating conditions,
Sensor, actuator,
actuation
hardware
Multivariate implementation
optimization
Engine combustion models
Experiments
p
Control theoretics,
theoretics
Engine flow models,
models
Turbulent reacting flows
control policy, control
spray dynamics
Catalysis structure
Experiments
Product
Pollutant Formation,
Multi-dimensional
Electrochemistry Advanced sensing
simulations Energy Conversion and actuation
Engineering
Core Efficiency technology
Experiments
Chemical kinetics
Science Experiments
Fuel cell and battery
modeling
Engineering
g g Advanced
Engineering
Ei i
Science
50. SMART@CAR Research Thrusts
• Fleet Studies
Development of standards data formats and acquisition systems; Fleet data
standards, formats,
acquisition; data repository and data analysis
• PHEVs and their interaction with renewable energy sources and the grid
Model interdependencies between PHEVs and the grid
• Macroeconomics, Regulations, and Public Policy
Economic and public policy issues with significant role in the beneficial
p p y g
development of a viable PHEVs market.
• Power Electronics: Connecting the Vehicle and the Grid
From concept to realization power electronics needs for PHEV applications; on
realization,
board and off board applications, communication with battery management
system and vehicle control system
50
51. Current PHEV Research @ CAR
Vehicle and energy storage technology
• Battery aging and management
• Power electronics
V2G and V2B interface and communications
Vehicle design
Energy management and control strategies for PHEVs
Tools for PHEV vehicle design
Energy analysis
Energy management
52. Fleet Studies
10 kWh GAIA Lithium battery
pack
ChallengeX Equinox
g q
Soon to be PLUG-IN !!
Plug-in Prius
5 kWh Hymotion pack
Data related to real world duty
D ld l ld d
cycles, battery aging, and fuel
economy will be collected and
shared with consortium
members
Plug-in Hybrid Fuel Cell
Plug-in Saturn VUE..
Neighborhood Electric
Vehicle
V hi l
By 2009 a fleet of 10-20 PHEVs is expected to be available in the Columbus area
53. Data Clearinghouse
• Hardware:
• Use existing Web service provider (Google, others) to provide reliable hardware
reliable data archiving and accessibility for data collected on prototype or production
PHEVs/EVs.
• Aspects to consider:
• Storage space for growing data base
• Set-up
Set up and maintenance costs
• Security of data, archiving
• Always on-line
• Accessible with any Web browser/internet connection with no special hardware
y p
• Speed of access for convenient user upload and download of data
• Open Storage
• Define standards for data type, data format, data storage, data retrieval, data
mining, and data uploading.
• Definition of open standards documented and distributed to the user community
• Open and proprietary standards interoperability
• Defined web services and conformance standards
54. Vehicles part of the Energy Network
Grid power management – resource allocation (when, how much)
B2G Communication
network protocol
Collect info on power
demand/priority
V2B
Communication
network protocol
Information flow Power flow
55. Renewable based Ecosystem:
a case study
y
A renewable based ecosystem”
Matlab/Simulink® model
Main system components:
- residential load
- PV panels
- small scale wind turbine
small‐scale wind turbine
- battery pack for residential
Energy applications
Management
- plug‐in hybrid electric
plug in hybrid electric
vehicle
Detailed evaluation of:
- Energy
- Economics
- Emissions
55
56. Vehicles part of the
Energy Network
gy
RENEWABLE
ENERGY
ENERGY BUS:
STORAGE
MANAGEMENT AND CONTROL H2 REFUELING
DEVICES
STATION
H2 GENERATION
CAR PLUG IN
PLUG-IN
HYBRIDVEHICLES
FUEL CELL
GRID POWER
Smart control systems optimize
the energy management taking
into account time variations of
CENTER FOR AUTOMOTIVE RESEARCH,
the demand (homes and
OSU 56
drivers) and generation
57. Vehicles part of the
Energy Network
STORAGE
RENEWABLE DEVICES
ENERGY
ENERGY BUS:
H2 REFUELING
MANAGEMENT AND CONTROL
STATION
Battery
system tied to
10 kW of
the PV array
Installed
I t ll d PV
power within
6-8 weeks
CAR PLUG IN
PLUG-IN
HYBRIDVEHICLES
Real data will be
available soon
-PV system
PV
- Vehicles
- Batteries and Energy
GRID POWER
Management
Smart control systems optimize
- CAR load
the energy management taking
into account time variations of
CENTER FOR AUTOMOTIVE RESEARCH,
the demand (homes and
57
OSU
drivers) and generation
59. Battery Experience
• Over 10 years experience with advanced batteries
•AAccelerated aging of NiMH and Li i cells and modules.
l td i f d Li-ion ll d dl
• Multiple battery aging cyclers
• Programmable loads
• Supplies
• Temperature control environmental chamber
• Peltier junctions
• Individual system controller for each cycler
• Architecture mimicking parallel computer cluster
• Multiple cyclers in parallel for accelerated testing
• Safe operation with redundant control systems
p y
• Ethernet to supervisory safety controller and data archive
• Emergency operator paging system and accessible through VPN via the
Web.
• Electrochemical Impedance Spectroscopy (EIS) for non-intrusive
damage assessment 59
63. Autonomous City Transport (ACT)
TerraMax’04
ION’05
ACT 2007
• Lane tracking
• Car following
• Intersections,
traffic circles
• Passing
• Obstacle
avoidance
• Parking
• Dynamic route
Control and Intelligent Transportation Research Lab
planning
64. ACT Autonomous Car
• A hybrid vehicle
• Most drive by wire
drive-by-wire
aspects used
• Steering motor added
• Sensors added
66. V2V Research
• Vehicle-to-vehicle communication
– Simulator
– Testbed
– Protocols
• Intersection collision warning,
– V2V and Sensors
• Sensor fusion
• Simulation environments
• Energy savings using ITS
• In-vehicle networks
• Rollover
Control and Intelligent Transportation Research Lab
72. Student Motorsport Projects
First-Year Engineering Program
Team building training incorporated
Hands-on team design projects
Senior design
S i d i projects
jt
Multidisciplinary
year long
year-long
16 student-managed project teams
700 participants
p p
Intercollegiate competitions
73. Challenge X
3rd Pl
d Place Overall
O ll
1st Place, MATHWORKS: Crossover to model-based design
• model based
1st in Technical Paper Competition
•
1st in Control Strategy Presentation
•
2nd Place in Dynamic Consumer Acceptability
•
2nd Pl
d Place i T h i
• in Technical P
l Presentation
t ti
3rd Place Outreach competition
•
75. EcoCAR NeXt Challenge
Ohio State
selected for
EcoCAR
upcoming
competition
Highest
g
ranking out of
50 proposals
75
76. Land Speed Record
• Design and realization of a Land Speed Record
• Vehicle powered by fuel cells
• Designed and built by students (ME, ECE and Aero), and leadership of
two GATE fellows
• Strong partnership with Ford and Ballard and a host of other sponsors
• Set FIA record in October 2007 and fastest speed ever recorded for FC
vehicle: 225 mph.
77. Distance Education Programs
• Certificates:
o Powertrain modeling and Control
o Advanced Propulsion Systems
o Automotive NVH
• Graduate Specialization in Automotive Systems
Engineering
o Powertrain modeling and Control
o Advanced Propulsion Systems
oAt
Automotive NVH
ti
o Other specialty courses: Model-based diagnostics,
Powertrain packaging
• Seminars and short courses 77
78. Industry
and
Ohio State University
Center for Automotive Research
• Cutting edge research
• Development of new technology
• Industry trained graduates
A Winning Combination!
http://car.osu.edu