Bringing Automotive Advanced Technologies to Market Faster with Objective Testing and Technology Validation
With implementation dates quickly approaching for federal mandates on fuel efficiencies and emission standards, the automotive industry no longer has the leisure of long development cycles. General Motors (GM) famously reduced their vehicle development process from 48 to 18 months. When it comes to testing and validating new automotive technology, some companies don’t have the internal capabilities and resources that GM has.That’s where companies such as Canada’s Advanced Testing and Validation Centre and Nevada Automotive Test Center play a role in speeding up the development process.
“More than ever before, objective testing and validation of technologies such as those found in alternate fuel vehicles are required to help address challenging technical issues, validate and bring products to world markets faster,” said Dr. Toby Astill, Marketing Officer of Canada’s National Research Council Institute for Fuel Cell Innovation (NRC-IFCI). He adds, “This involves rigorous testing under highly specific and variable operating conditions. A varied suite of test apparatus is required to allow a scale of testing from bench top testing of components to environmental testing of full driveline systems in conditions ranging from the harsh winters in the Northwest Territories to the tropical rainforests of the Amazon.”
When Westport Innovations, Inc. needed to develop strategies for starting their liquefied natural gas (LNG) vehicles at cold temperatures, they turned to NRC-IFCI to create tailored testing conditions to meet the precise requirements demanded of a product under development. At NRC-IFCI’s Advanced Testing and Validation Centre (ATVC) located at the University of British Columbia campus, they were able to test their systems under real-world conditions to demonstrate the robustness of the product and to identify any improvements necessary before deployment in the field. According to Westport Innovations’ senior product engineer Tim Lennox, “The facility has been a valuable development tool that will help us provide customers with a robust natural gas fuel system for their trucks, regardless of the climate.”
The ATVC provides the ability to test products under a range of electrochemical and environmental conditions including altitude (10,000’), humidity (5 % - 95 % RH) and temperature (-60 °C to +140 °C). The environmental test chamber is also hydrogen and natural gas-safe, which makes it a good fit for alternate fuel vehicles. As a result, technologies can be tested quickly, enabling companies to release their next generation products to the clean energy market more quickly.
On the opposite end of the environmental spectrum, Azure Dynamics turned to ATVC to help test their electric drive-train technologies in hot environments. With the chamber capable of a heat rejection capacity of 100kW at –40 °C, and a rolling road dynamometer accurate to speeds up to 100kph, Azure was able to test their Balance™ Hybrid trucks in hot temperatures in real world duty life cycles.
“As niche and mass-market opportunities open up for the [alternatively] fuelled vehicles and clean energy solutions being pioneered by cleantech companies, objective testing and validation services become an increasingly critical component of commercial success,” said Dr. Astill.
Cleantech companies are not the only ones striving for clean energy solutions. Now more than ever, the U.S. military is working to develop alternative fuels and advanced technologies to incorporate into their fleets, stateside and abroad. Hybrid technology and a solar-powered battery power management system are two projects that have been developed and tested by an independent third party to expedite market-readiness, with the market being the U.S. military.
Under U.S. Government contract, the U.S. military turned to the Nevada Automotive Test Center (NATC) to design a hybrid electric prototype 6x6 vehicle. NATC is a privately owned and independent test, evaluation, design and engineering facility offering development and certification testing to a broad range of vehicle manufacturers, users, developers, and government agencies.
NATC was responsible for the concept development, design, fabrication and shakedown testing of the prototype to verify vehicle compliance with the customer’s needs. The 6x6 hybrid electric vehicle platform was designed to be a recovery vehicle in different environments and to be used to demonstrate various technologies in the areas of transportability and mobility.
Located outside of Carson City in northern Nevada, “We can simulate 85 percent of the world’s terrain conditions where vehicles operate here at NATC,” said Henry C. Hodges Jr., the acting President and CEO of NATC in PEO LSMarine Corps magazine. “In addition, we can simulate beach heads, desert dunes, mountain trails and mud pits.” These conditions were very well suited for simulating where many of these vehicles would eventually be operating. “The vehicles tested here are exposed to the conditions found in Southwest Asia, focusing on Iraq and Afghanistan,” said Hodges.
NATC has been involved in the development and testing of hybrid and fully electric vehicles for military and commercial applications since 1999, when the need for battery power management to protect critical powertrain capabilities was recognized.The Capstart™ system, patented by NATC, was developed to meet this need. The Capstart™ system allows for the hybridization of the vehicle's power source by distributing and prioritizing power demands of the vehicle to maintain efficient operation of the vehicle. NATC continues to develop this advanced power control technology for use in alternative prototype vehicles for both commercial and military applications.One such development was adding a solar panel charger to maintain the capacitor of the system.
Working with both the government and private sector, NATC has logged more than 50 million vehicle test miles and evaluated more than 1,000 different vehicle systems from passenger hybrid electric cars to LNG Class 8 trucks to earth moving and agricultural equipment along with some 300 trailer systems.From structural analysis to prototype fabrication to production hardware certification, NATC meets these needs throughout the entire vehicle development cycle.NATC combines over 50 years of ground vehicle system development and test experience with analytical testing and practical real-world solutions to create customer-tailored test programs. This year NATC is performing third-party test evaluation and engineering support of several alternative vehicles, including evaluation of regenerative braking and accelerated durability tests of commercial electric vehicles.
“The team at NATC accelerates the integration of advanced technology in the field by performing real-time and real-world evaluation and accelerated life cycle cost analysis of system solutions to meet the customer's needs," said Kelley Hodges, test engineer.
Fleet-to-Fleet: AFVi Asks Fleet Managers about Policies or Initiatives to Green Their Fleets
Fleet managers who attended the Alternative Fuels & Vehicles National Conference + Expo 2010 were asked about one policy or initiative that their company is using to green their fleet. The top policy driving fleet managers’ greening practices were federal government mandates including EPA Executive Orders 13423 and 13514. Both of these executive orders mandate that petroleum consumption in fleet vehicles be reduced by two percent annually through 2015, compared to an FY 2005 baseline. From incorporating alternative fuel or advanced technologies to “right-sizing” vehicles, there were many initiatives implemented to green their fleets to comply with the mandate. Here’s how the green fleet initiatives broke down by category*:
18% said government executive orders (inclusive of all levels of government from federal to city) were the policy drivers behind their green fleet efforts
89% said incorporating, expanding and/or replacing existing vehicles with “alternative fuel vehicles” is their top strategy. See the chart below for a breakdown by fuel type for those responses that listed a specific fuel type of choice:
6% said they are downsizing or right-sizing their vehicles when possible
Less than 1% listed the following as an initiative they were currently using or considering using:
incorporating, expanding or replacing existing vehicles with neighborhood electric vehicles or low-speed vehicles
implementing a DOC exhaust system
vehicle conversions
driver education
propane fumigation system
Read about fuel saving strategies implemented by fleet managers here as reported in May's AFVConnection.
Tell us about policies or initiatives that have led you to green your fleet.
Second only to natural gas vehicles, plug-in electric vehicle are of most interest to people according to an informal AFVi poll. As the U.S. awaits the arrival of the first wave of electric vehicles this fall, the question still begs to be asked, “Are we ready?” AFVi had the opportunity to pose this and other concerns to Brian Wynne, President of Electric Drive Transportation Association (EDTA). EDTA is the preeminent industry association dedicated to advancing electric drive as a core technology on the road to sustainable mobility. In his two-part interview with AFVi, Mr. Wynne discusses some of the challenges the electrification of transportation will face from infrastructure to third-party technology to utilities. AFVi also had the opportunity to get a first look at two upcoming electric vehicles, the Th!nk City and the Toyota Plug-In Electric Hybrid Prius prototype. (Earlier this year, AFVi also had the chance to check out the new all-electric Nissan LEAF.) Lastly, AFVi learns about charging infrastructure produced by Coulomb Technologies. Fortunately, it looks like the U.S. is getting ready for electric vehicles to become part of our transportation norm and getting there fast!
Cutting Petroleum Dependence, Reduction Idling: Truckers Make a Big Impact By Greater Lansing Area Clean Cities
Modified from its original version by Falana White, AFVi
Core to each Clean Cities Coalition's mission is an effort to reduce petroleum consumption in the United States. The mission of Greater Lansing Area Clean Cities (GLACC) focuses on the mid-Michigan area. Our aim is to decrease petroleum dependence and improve air quality at a local level. We promote alternative fuel and vehicle usage and fuel economy practices.
A big benefit to reducing petroleum consumption is the opportunity to reduce air pollution that results from using petroleum fuels. Engine idle reduction is an easy method for reducing both petroleum consumption and air pollution.
In this issue of Greater Lansing Area Clean Cities’ Clean Transportation Awareness Campaign,
we’ll explore the role the trucking industry plays in petroleum reduction and air quality through idle reduction policies. While some of the tenets are specific to Michigan, the lessons learned can be applied across the United States. In fact, they are being applied through your local Clean Cities Coalition. Click here to find your local Clean Cities Coalition.
Learn More
What is engine idling? Engine idling is simply the act of running a vehicle's engine when the vehicle is not in motion, but parked in one place. Limiting idle time saves fuel, engine wear, and money while reducing emissions and noise. Idle reduction options typically refer to technologies and practices that reduce the amount of time vehicles idle their engines.
Why are truckers a key idle-reduction group? Trucking companies, like all vehicle fleets, are key because the impact of fuel use and emissions is greater when many vehicles stop idling. (That's not to say that individuals shouldn't worry about our own idling, too!) Private trucking companies can also often make changes in their fleets faster than public institution fleets, due to budget issues and procedural constraints. This quick decision-making puts long haul and local trucking companies in a great position to make a difference.
How much petroleum can be saved from trucker idle reduction? A lot - consider an example trucking fleet of 50 Class 8 trucks that reduce their idling by 8 hours per day. This fleet will save over 100,000 gallons of fuel per year! That's just one example fleet - if every trucking company operating in Michigan reduced their idling the impact on petroleum consumption would be huge!
Is there ever a good reason for truckers to idle? Truckers often idle to use the vehicle's engine to warm or cool the inside of the truck for comfort and safety. Long haul truckers are required to have 8 hours of rest for every 10 hours of work, for each 24-hour period. Truckers live in their trucks while on the road, with sleeper cabs and amenities like TV and internet. Heating/cooling the sleeper cab and running amenities takes power, and most often this comes from running the truck's main engine. There are equipment solutions that allow truckers to get power without idling their truck's main engine.
What's the bottom line - does trucker idling impact me? Are you a fleet manager or a trucker yourself? Do you live near a trucking distribution center or truck stop where vehicles idle for hours? Do you buy goods shipped by truck? Any of these situations make trucker idling important for you.
Fleet managers should care about the fuel and vehicle maintenance costs that can be saved by limiting idling
Truckers can get the good rest they need through idle reduction solutions, rather than being subjected to the noise, vibration, and exhaust from running the truck while trying to sleep
If you live near a place where trucks idle for hours you know too well the noise and pollution issues that result
All of us purchase goods shipped by truck - fuel and vehicle maintenance costs related to idling directly impact the cost you pay for goods you buy
There's a benefit for all of us for reducing idling
Tips
Trucking Industry Idle Reduction is Easy!
Fleet managers and truck drivers can use these warmer months to get used to idle reduction.
Notice: Truck drivers - how much do you idle? Fleet managers - how much does your overall fleet idle? Drivers - take note of when you're idling and for how long. Fleet managers - work with your drivers to get the data you need to measure idling and fuel loss associated with it.
Connect the Dots: How much can you save in the fuel budget by reducing idling? Can your company or organization get bonus points from customers and your community by creating, enforcing, and promoting idle reduction policies? There are many benefits to reducing idling.
Act: Knowing how much you or your fleet idle, and connecting the dots that reducing idling has benefits that matter to you, brings us to the next step - just stop idling. Talk to your management and drivers about the benefits of idle reduction. Find your local Clean Cities Coalition to learn about connecting with funding opportunities to get idle reduction equipment!
The results are in. The Alternative Fuels & Vehicles Conference + Expo 2010 (AF&V 2010) succeeded in bringing together leading industry manufacturers and service providers with fleet managers and other decision-makers. And, together, they are driving the new transportation paradigm. More than 1,200 people attended AF&V 2010. Besides government, educators, Clean Cities Coordinators, alternative fuel industry, media and foreign representatives, one of every three attendees were from companies interested in greening their fleets. Their company fleets ranged in size from as small as 7 vehicles to as many as 220,000 vehicles. The Conference took place May 9-12 in Las Vegas, Nevada.
The ambitious Conference brought together 150 experts who spoke about fuels, vehicles, advanced technologies, air quality, peak oil, government policies and automotive journalism. Keynote speakers included American financier T. Boone Pickens; EPA’s head of the Office of Transportation and Air Quality, Margo Tsirigotis Oge; R. James Woolsey, former CIA Director; Eric Cahill, Senior Director of the Automotive X Prize; U.S. Department of Energy Clean Cities Director Dennis Smith; and John Davis, the Host and Executive Producer of the award winning Motor Week.
The 100 exhibitors in the Expo Hall, the vehicles included in the Ride-n-Drive, the Guided Expo Tours and the Technology Showcase presentations are tough to capture in retrospect, but there are several ways to still engage. Photos, along with attendee, sponsor and exhibitor lists are all available by clicking here. Many of the vehicles that were on display can soon be found in the online Buyers’ Guide. And for those wanting to watch video of the keynote addresses or review speaker PowerPoint presentations, AFVi has a DVD available.
For those who missed AF&V 2010, there’s no time like the future. Mark your calendar and make plans to join us in Fort Worth, Texas, May 15-18, 2011.
Click here for pictures on our Facebook page. Click here for video on our YouTube page.
Introducing the new and improved, continuously updated AFV Buyers’ Guide. Created by AFVi in response to fleets’ requests. The Guide is designed to be the one reliable and complete source of currently available alternative fuel and advanced technologies to make purchasing decisions easier. Available exclusively online!
Natural Gas Training Classes Announced for Fall 2010
AFVi's own Leo Thomason is our resident natural gas expert. With over 20 years of experience, Leo has equipped more than 14,000 employees with the skills they need to safely implement, operate and maintain a NGV fleet. Four courses are currently open for registration, including:
NGV Driver and Mechanic Safety Training
- August 31: Charlotte, North Carolina
- September 14: Dallas, Texas
CNG Fuel System Inspector Training Course
- September 1-2: Charlotte, North Carolina
- September 15-16: Dallas, Texas
CNG Fueling Station Design Certification Course
- November 2-3: Downey, California
CNG Fueling Station Operation & Maintenance Certification Course
- November 4-5: Downey, California
Click here for course details and registration information.
Introducing the new and improved, continuously updated AFV Buyers’ Guide. Created by AFVi in response to fleets’ requests. The Guide is designed to be the one reliable and complete source of currently available alternative fuel and advanced technologies to make purchasing decisions easier. Available exclusively online!
Natural Gas Training Classes Announced for Fall 2010 
