Hydraulic Hybrid Vehicles Team Dumpster Divers - Design Review Snapshot March 8, 2005 Team Members: Michael Shurtliff - EE Seneca Bertovich - CompE Michael Amato - ME Joel Stobie - ME Andi Morey- EE Eric Hake - EE Controls Design Matrix FieldPoint ModulesFrame Assembly Detail Design Phase Target Completion Date: Jan. 31 st Excel ModelsPreliminary Design Size ComponentsDesign Components Solid Works ModelsOrder Parts Fabrication Target Completion Date: March 11 th System Components Take Apart F350 (Feb 7 th ) Complete Valve Logic (Feb 11 th ) Machine Components (Feb 25 st ) Have Reservoir Built (Mar 4 th ) Size Hoses (Mar 4 th ) Model Hydraulic Schematic in AMESim (Mar 5 th ) Assemble Components (Mar 11 th ) Tune System (Ready by March 21 st ) Develop Controls Install Computer (Feb 11 th ) Rough Code Development (Feb 18 th ) Defined Code Development (Mar. 11 th ) Wiring Diagram (Mar. 11 th ) Tested Program Ready to Run (by March 21 st ) Testing Target Completion Date: April 8 th  Jack Stand Testing (March 30 th )  Road Tests (April 8 th )  Gather necessary info for analysis Evaluation & EXPO! Target Completion Date: April 29 th  Data Analysis (April 22 nd )  Evaluate Results (April 22 nd )  Present at Engineering EXPO (April 29 th ) DDR – Deliverable DUE DATE: May 7 th Design Process for Spring SemesterFrame Assembly Buff Which Mode? System ON Assist Mode Regen Mode Inputs Correct? Break Pressure Accumulator Pressures, Transmission, Engine RPMs. Brake Pressure Accumulator Pressures, Transmission, Velocity, Throttle Pressure NO Throttle Pressure Open Valve YES Open Valve YES Swash Angle? Done ? NO Close Valve YES Accumulator Pressures, Velocity, Throttle Pressure Accumulator Pressures, Velocity, Brake Pressure Controls Flow DiagramAMESim Model Regen Mode Functional Requirements LabVIEW Simulation

DFMEA of Current System Team Dumpster Divers - Design Review Snapshot March 8, 20045

Drive Cycle Research Team Dumpster Divers - Design Review Snapshot March 8, 2005 Hydraulic Assist Cycle (ASSIST) Best efficiency range for hydrostat as a motor is 500 – 2000rpm (about 10 – 40 mph) For safety – we want to assist engine at lowest speed possible at higher speed, system must react more slowly due to high fluid flow, which could be dangerous in case of emergency Regenerative Cycle (REGEN) Best efficiency range for hydrostat as a pump is about 2000psi – 4500psi Goal is to fill accumulator –Approx. 370kJ to fill from 2000psi to 4500psi –Requires an initial regen speed of about 38 mph to obtain 370kJ in accumulator

Electric Charge Pump Team Dumpster Divers - Design Review Snapshot March 8, 2005 (Point 1 on figure) Diesel engine efficiency very low when at idle (Point 2) Add 10 N-m of torque from pump through alternator Efficiency increases due to that engine uses less fuel to do added operation Conclusion: Run e-pump whenever diesel engine is at idle

New Hydrostat Mounts Team Dumpster Divers - Design Review Snapshot March 8, 2005 After testing, we found the regenerative braking system was very noisy. Most of the system noise is machine borne noise. In an effort to reduce the noise of the system, we had to come up with a dampening scheme. Since the hydrostat acts as both a pump, and a motor, we had to design a mount that would have dampening ability in both directions. The hydrostat’s internal layout also puts forces in the axial direction; we needed to dampen vibrations in that direction as well. The solution was to use an omni- directional vibration dampener. We found the necessary spring rate, and matched it as closely as possible to production vibration dampeners, and came up with a dampener that could isolate the noise up to 77% when the hydrostat was operating at 2500 RPMs.

Scheduled Conferences Team Dumpster Divers - Design Review Snapshot March 8, 2005 ConferenceWhenWhereWhat ASME Conference April 1, 2 Tacoma, Washington Presentatio n SAE International Congress April Detroit, Michigan Poster, Fliers, Interaction Mathworks International Automotive Conference June 22, 23 Dearborn, Michigan Display Truck, Posters, Presentatio n

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