ANNUAL SHOWCASE SPECIAL Heavyweight, technical papers written for the industry, by the industry! Audi proves that V engines are here to stay as it teams up with Bentley to create a 4-liter monster January 2012 ALL WRAPPED UP Coatings are finally making the automotive mainstream, but does this technology have a long-term future? LIQUID ENGINEERING The outlook is murky for those working on new fuels. We map out what the next decade holds LUX LOWDOWN GM’s head of powertrain for Opel/Vauxhall reveals what’s next after the Ampera www.enginetechnologyinternational.com // CASE STUDY // ROTOTEST Rethinking the test cell LINKÖPING UNIVERSITY CHOSE AN INNOVATIVE SOLUTION WHEN IT RECENTLY BUILT A NEW, STATE-OF-THE-ART POWERTRAIN TEST CELL FOR ADVANCED RESEARCH IN ENERGY OPTIMIZATION Total cost of ownership (TCO) is an economic term often used when describing the overall cost of an investment. For a passenger car, the TCO might involve aspects such as purchase price, maintenance costs, fuel costs and depreciation. The calculation is similar for test equipment, including purchase price, maintenance costs and running costs, but a few additional factors come into play. One is the cost of installing the equipment, another is the cost for any construction work necessary to house the equipment, and finally the projected lifetime of the test equipment and cell. For businesses that are based on project work, such as universities with fund-based research, the lifetime of any investment is of utmost importance. This is because the total lifespan might not be related to the test equipment, but rather the duration of the project work, as the next development program might be completely different. Traditional ways of designing test cells have in many cases prohibited investments for these businesses due to the TCO being prohibitively high for each individual project. Cost-effective test cell When Linköping University recently invested in test equipment for its department of electrical engineering and vehicular systems division, The test system can be controlled from inside the vehicle or from the purpose-built operator room 42 // January 2012 // Engine Technology International.com it chose an innovative and alternative route. By emphasizing flexibility, functionality and simplicity, it managed to create a cost-effective test cell with superior versatility. What is striking when visiting the university’s facility for the first time, is the entrance with large windows, offering a panoramic view into the new powertrain test cell, or laboratory for vehicle propulsion. The construction of the test cell is very generic in its design with a concrete floor and acoustic paneled walls, which makes it highly adaptable to different types of projects. The test equipment chosen for the cell was provided by Sweden-based company Rototest, which specializes in hub-mounted dynamometers. The company has supplied one of its regenerative chassis dynamometer models, the Rototest Energy, together with multiple options and accessories, such as a headwind // CASE STUDY // ROTOTEST View of the test cell through the panoramic window at the entrance “We have an exciting future ahead of us in terms of vehicle propulsion systems. This will in turn put demands on having test systems capable of keeping up with this development” The main power unit houses the regenerative motor drives fan with windspeed correlated to vehicle speed. One of the university’s criteria for selecting Rototest’s solution was that it should be flexible and multifunctional to cover a wide range of applications. It should also be upgradeable in terms of testing functionality and easy to relocate without extensive groundworks. Another key criterion was the overall cost. The chassis dynamometer arrived in a turnkey state and precommissioned. Excluding the installation of mains feed to the system, installation on-site took less than a day and was followed by a couple of days of training. With the complete cell installed, one of the first projects it will handle involves research into a method called ‘look ahead control’, where the geographical landscape is tracked to optimize driving in order to reduce energy consumption and CO 2. For a test system to be truly versatile, it needs to be able to switch swiftly between applications to minimize downtime. The ability of the system at Linköping to adapt quickly to different applications allows several research projects to be run in parallel, thereby lowering the cost of ownership for contractual research. One example is the university’s advanced turbocharging concepts project, which runs in parallel with the look ahead control research. Future EV projects With close cooperation with the automotive industry, future projects planned in the test cell include the development of gearbox control, as well as research into propulsion systems such as electrical and hybrid solutions. As the test system has a front-end mounted measurement system and is directly coupled to the vehicle’s wheel hubs, it can measure accurately the energy flow in both directions, such as during driving and braking (energy storage). The system can also be upgraded to include what Rototest calls a high-resolution torque system that would enable energy efficiency studies of bearings and engine auxiliaries. As a leading automotive supplier, Rototest closely monitors worldwide powertrain advances to continuously refine and update its technology to meet future demands. Feedback from Linköping University over the next five years will be important to Rototest and its future product evolution. “We have an exciting future ahead of us in terms of vehicle propulsion systems,” states Lars Nielsen, professor at the division of vehicular system, Linköping University. He adds: “This will in turn put demands on having test systems capable of keeping up with this development.” Engine Technology International.com // January 2012 // 43