advancements in powertrain test environment - …keynote+dr... · 100 200 300 400 500 600 700 800...

ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENTDELIVERING PRODUCTIVITY THROUGH STRATEGIC CHOICE OF TEST

ENVIRONMENT

Dr. Philip Lawson & Sulabh Dhingra

28 Jun 2018 – AVL Product Development in Motion

ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT

Outline

• Motivations

• Brief history of Powertrain Testing at JLRWhy?

• Increasing Productivity through Shift & Expand

What?

• Key enablers to deliver Shift & Expand strategies

How?

• Emissions Test Use CaseData


Background & Motivation

Jaguar Land Rover Retail Sales Volumes by FY

Jaguar E-Pace Jaguar F-Pace

Land Rover Discovery Range Rover Velar



4

Since 2011:

• Doubled internal Engine Test activity

• Tripled internal Chassis-Dyno Test activity

• 15x increase in outsourced test activity

Internal capacity increase largely due to

Testfield Efficiency Projects

“Holistic Powertrain Development & Test Productivity Optimisation at Jaguar

Land Rover” J. Houldcroft et. al. 5th International Symposium on

Development Methodology, 2013

Testing Effectiveness Four Levers


Background & Motivation – SAE 2016-01-0982

5

As-i

s S

tate

Te

stin

g E

ffo

rt

New

Technologies

Expanding

Product

Portfolio

Ne

w T

estin

g E

ffo

rt

Reuse Data

Efficiency Gains

Effectiveness

Shift & Expand

Re

du

ced

Te

stin

g

Effo

rts in

Str

ate

gic

En

viro

nm

en

t

Testing Effectiveness Four Levers




Shift and Expand Strategy

7


Key Enablers

8

Test Field Effectiveness

People

ProcessFacility

Adoption of Shift & Expand test

methodologies requires significant

investment in…


Process Investment - Operational Readiness

9

“Customer” Relationship Management


Process Investment – Customer Relationship Management

10

AVL Tech Centre Coventry

AVL Graz


People Investment – Importance of Training

11

Team Growth & Development

Team Size

Ramp

Skill

Ramp

Productive

Facility

Training Cell in GrazTCC in

Coventry

Project Timeline

Shift and Expand Use Case StudyEMISSIONS TESTING ON A VEHICLE-IN-LOOP (VIL) TEST CELL

12


Chassis-Dyno to ViL Emission Test Comparison

Fuel Type: CARCAL EU6 E10 Gasoline

Engine Type: 3.0 V6 Supercharged

Fuel Type: CARCAL EU6 Diesel

Engine Type: 3.0 V6 Turbocharged


Preparation of Unit Under Test

14


Design of Experiment


Test Plan Overview

RCD = Rapid Cool Down

Gasoline

CD3 CVS

101CVS

104modal

RCD Soak RCD Soak

Diesel

CD3 CVS

102CVS

103modal

RCD Soak RCD Soak

WLTC

NEDC

x3

x3


Diesel CO2 Comparison

WLTCNEDC

CO

2 (

g/k

m)

102 102103

modal

103

modal

Rapid cool down

Soaked

Chassis Dyno

165

170

175

180

185

190

Error bars represent 2σ


Gasoline CO2 Comparison

WLTCNEDC

200

210

220

230

240

250

CO

2 (

g/k

m)

101 101104

modal

104

modal

Rapid cool down

Soaked

Chassis Dyno

Error bars represent 2σ


Rapid Cool Down Issues T101 Gasoline

WLTC

Rapid cool down

Soaked

Chassis Dyno

100 200 300 400 500 600 700 800 900 1000 1100 1200time [s]

Gbx_tT

CM

Oil

[deg C

]

22

24

26

28

30

32

34

36

38

40

42

44

46

48

50

52

54

56

200 400 600 800 1000 1200

50

40

30

200 400 600 800 1000 1200 1400 1600 1800time [s]

Gbx_tT

CM

Oil

[deg C

]15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100

Time (s)

Te

mp

(ºC

)

400 800 1200 1600

Time (s)

90

60

30

Te

mp

(ºC

)

Gearbox Temperature -

NEDC

- Oil temperature

- Driveline

- Coolant

Gearbox Temperature -

WLTC



Extended Correlation Activity

- Fluid in RCD Unit reaches threshold and RCD switches off

- Thermocouple data inside the vehicle is not checked



100 200 300 400 500 600 700 800 900 1000 1100time [s]

Gbx_tT

CM

Oil

[deg C

]

5

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

9090

60

30

Te

mp

(ºC

)

200 400 600 800 1000 Time (s)

12 hour soak

RCD + 2 hour

RCD + 4 hour

RCD + 6 hour

RCD + 8 hour

RCD + 12 hour

12 hour soak

165

170

175

180

185

CO

2 (

g/k

m)

Tests

Gearbox Temperature


Summary & Conclusions

22

People

Level 4 Apprenticeship &

development of Technician

population

Established Technical Training

Team

Specialist training in the test

field environment

Up-skilling existing population

Process

Project process and

common goal of operational

status

Customer relationship

management

Process oriented culture

with “swim lane” processes

developed in advance of

training and ramp-up

Shift & Expand

Migration of Test Use Cases via Shift & Expand

delivers Efficiency benefits through increased

effectiveness

A significant amount of effort (People, Process

& Facility) is required to unlock the potential

Successful demonstration of initial Use Cases

has generated significant internal demand for

additional applications

While Technology changes can be “bought in”, it

is essential to develop People and Teams

Jaguar Land RoverW/1/26 Abbey Road, WhitleyCoventry CV3 4LF, UK

jaguarlandrover.com

THANK YOU Dr. Philip LawsonSenior Manager Emissions Testing

M +44(0)7469 405229

[email protected]

23

Sulabh DhingraLead EngineerPowertrain ViL/PiL Test & Methodology

M +44(0)7341 074325

[email protected]

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