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SSppeecciiaall 22001100 FFEEDD EEddiittiioonn LLeeaadd ·· IInnnnoovvaattee ·· IInntteeggrraattee ·· DDeelliivveerr AALLpphhAA RREEVVEEAALLEEDD!! MMeeeettiinngg TToommoorrrrooww’’ss FFuueell--SSaavviinngg DDeessiiggnn aanndd EEnnggiinneeeerriinngg DDrriivvee AArrmmyy’’ss OOppeerraattiioonnaall EEnneerrggyy FFEEDD PPrrooggrraamm  PPaaggee 44 CChhaalllleennggeess TTooddaayy  IInnssiiddee FFrroonntt CCoovveerr SSyysstteemmss EEnnggiinneeeerriinngg AApppprrooaacchh CCrruucciiaall ffoorr FFEEDD VVeehhiicclleess  PPaaggee 2222 Report Documentation Page Form Approved OMB No. 0704-0188 Public reporting burden for the collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to a penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. 1. REPORT DATE 3. DATES COVERED 2010 2. REPORT TYPE 00-00-2010 to 00-00-2010 4. TITLE AND SUBTITLE 5a. CONTRACT NUMBER Accelerate 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) 5d. PROJECT NUMBER 5e. TASK NUMBER 5f. WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION US Army, TARDEC,6501 E. 11 Mile Road, Bldg 200A,RDTA-ST Mail REPORT NUMBER Stop #206,Warren,MI,48397 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S) 11. SPONSOR/MONITOR’S REPORT NUMBER(S) 12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited 13. SUPPLEMENTARY NOTES 14. ABSTRACT 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF 18. NUMBER 19a. NAME OF ABSTRACT OF PAGES RESPONSIBLE PERSON a. REPORT b. ABSTRACT c. THIS PAGE Same as 18 unclassified unclassified unclassified Report (SAR) Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18 Meeting Tomorrow’s Operational Energy Challenges Today Alan R. Shaffer Energy security theater of operations. At the tactical level, improved being the requirement to achieve the maximum fuel NASCAR and Le Mans series race cars. In racing, if is a national fuel economy will provide greater legs to our ground efficiency possible without degrading the performance a component can’t perform multiple tasks, it doesn’t challenge. Since forces, further enhancing their combat effectiveness. requirements or capabilities (i.e., reliability, survivability, go on the car. This exposure to new approaches World War I, every mobility, operations and sustainment costs, etc.) of the to design, manufacturing, system integration and The concept of increasing the fuel efficiency of our conflict in which M1114 uparmored High-Mobility Multipurpose Wheeled maintenance will raise the bar for overall government military equipment, thereby reducing energy usage the U.S. Military Vehicle (HMMWV). This approach should result in an fleet development. Industry also stands to gain from and distribution requirements, is not a new one. We has engaged has apples-to-apples comparison. this effort with increased awareness of military know that shrinking the military services’ dependence been shaped vehicle requirements. on fuel would reduce transportation requirements What made this initiative truly different is that TARDEC by the use and and decrease the number of Soldiers placed in harm’s used novel approaches to create an environment At the conclusion of this effort, the two FED movement of fuel. way. However, current operational contingencies in that promoted and fostered innovative ideas and demonstrators will not only show us what fuel Consequently, the Department of Defense (DoD) is committed to an era of persistent conflict have led to increased continually challenged the status quo in design efficiency is achievable, but will also inform new and reducing the demand for energy in the form of both vehicle weight for added armor protection and greater and manufacturing. By creating an environment existing programs (i.e., Joint Light Tactical Vehicle, conventional fuels and electricity, and increasing communications payloads which, in turn, increase fuel that enabled engineers and designers to focus on HMMWV recap, etc.) and provide decision makers the supply of assured or alternative energy sources consumption and drives down fuel efficiency across innovation and the art of the possible, they leveraged with additional insight regarding what is the art of the to reduce the Nation’s and military’s long-term the fleet. the various science and technology investments made possible in achieving improved fuel economy. by DoD and industry — such as advanced vehicle dependence on non-domestic energy sources. Make no mistake — keeping our warfighters safe is propulsion, composite materials and structures, Alan R. Shaffer the department’s top priority! Integrating systems Principal Deputy, Office of the Secretary of Defense In May 2006, the Office of the Secretary of Defense hybrid-electric power and energy, and modeling initiated an Energy Security Task Force to integrate engineered, energy-efficient capabilities into current and simulation. Equally as important was the fact (Acquisition, Technology and Logistics) and Director, Defense Research and Engineering disparate energy efforts across functional and and future combat and tactical vehicle fleets is a that these demonstrators would also draw from organizational lines. The Task Force assessed fuel close second. Both priorities will, ultimately, provide optimized design concepts and consumption of existing ground vehicle platforms our fighting force with unprecedented lethality and improved, lightweight materials and facilities, and then identified the largest energy survivability, and accelerate the delivery of overmatch currently used in specialty consumers. The Task Force also examined the validity capabilities that will serve as significant deterrents and performance and performance of on-going programs and assessed against potential combatants. vehicles such as the emerging needs for future programs to increase TARDEC’s FED program was conceived with the idea energy efficiency and develop novel technology- of demonstrating — using a systems engineering based alternatives. Using consumption rates as a approach — what fuel efficiency is achievable in key benchmark, the Task Force recommended 20 hardware operating in a realistic military environment programmatic options to reduce energy consumption and at what cost. To address this challenge, TARDEC across DoD. One such project was funded in the formed two teams comprised of the brightest and President’s Fiscal Year 2008 Budget Request — TARDEC’s best from government and industry. Expertise Fuel Efficient Ground Vehicle Demonstrator (FED). ranged from novel and non-traditional design, Since fuel is the second-highest battlefield throughput advanced automotive engineering and prototyping, commodity behind water, reductions in fuel to manufacturing expertise in military, specialty consumption by our combat and tactical vehicle and performance vehicles (e.g., motor sports). The fleets will provide operational commanders greater primary focus of these teams was to create a state- freedom of action and mobility, and reduce the of-the-art fuel-efficient tactical vehicle from a ‘clean vulnerability of warfighter logistics elements in the sheet of paper’ with the only design constraints II 1 Special 2010 FED Edition Lead · Innovate · Integrate · Deliver Innovative Systems-Engineered Designs Deliver Game-Changing Fuel-Efficient Tactical Vehicle Solutions EDITORIAL ADVISORY BOARD EXECUTIVE EDITORIAL STAFF CONTRIBUTING Dr. Grace Bochenek Dr. David Gorsich EDITORS Michael I. Roddin TARDEC Director Chief Scientist Editor-In-Chief The Fuel Efficient Ground Vehicle Demonstrator concept vehicle was evaluated. By using this collected Alan R. Shaffer DISCLAIMER: accelerate is published by TARDEC. MG Kurt Stein Paul Skalny Principal Deputy Beth Ann Locke (FED) Program was initiated by the Office of the data, the program management team was able to Articles express the written views of the authors and not TACOM LCMC Director, National Office of the Secretary Publications Manager necessarily official opinion of the Department of the Army Automotive Center of Defense (Acquisition, Secretary of Defense to address energy conservation accurately model, and then assess, the demonstrator (DOA). If articles are reprinted, please cite accelerate, the MG John Bartley Technology and Logistics) Rachel Ferhadson author and photographer. PEO Integration Dr. Jim Overholt Director, Defense Research Project Manager needs highlighted by the Defense Science Board’s vehicle’s potential mobility, performance, payload Senior Research and Engineering Reference herein to any specific commercial company, Scott J. Davis Scientist, Robotics Bob Van Enkenvoort Energy Security Task Force. The overarching program capacity and survivability capabilities against actual product, process or service by trade name, trademark, PEO GCS Thomas Mathes Managing Editor manufacturer or otherwise does not necessarily Teresa Gonda Executive Director goals are to improve military vehicle technology battlefield and environmental performance thresholds. constitute or imply its endorsement, recommendation, KPeEvOin CFaSh &ey CSS SDtirraetcetogric a Tnrdan JsCfoGrVmation of Product Development KSaetnhieorirn Pe uHb. lCicraawtifoonrds to reduce fuel consumption on the battlefield, The objective: demonstrate potential fuel efficiency oTrh efa ovpoirniniogn bsy o tfh teh eU anuittehdo Srst aetxeps rgeossveedrn hmereenitn o dro D nOoAt . William Taylor Development Lead CONTRIBUTING Manager and reduce U.S. ground and expeditionary forces’ achievement in hardware with an advanced, fuel- necessarily state or reflect those of the United States PEO Land Systems Marta Tomkiw EDITORS Chris Williams dependency on foreign oil for battlefield mobility. efficient, lightweight tactical vehicle demonstrator. government or DOA and shall not be used for advertising Chief of Staff Senior Writer/Editor or product endorsement purposes. Magid Athnasios Carl Johnson Executive Director Lynne Krogsrud Dan Desmond FED Team Leader POSTMASTER: Please send address changes to U.S. of Engineering Director of Strategy Editor/Writer Background Integrating Engineering Design and Innovation Army TARDEC, 6501 E. 11 Mile Road, Bldg. 200A, RDTA- Thomas Mathes and Communication Mike Seaton Matthew Sablan By forming a team of recognized government and The FED Program was designed to be innovative on ST, Mail Stop #206, Warren, MI, 48397-5000. Member, TARDEC Executive Director Michael I. Roddin Writer/Editor of Product Development Director of Strategic Systems Engineering industry subject-matter experts (SMEs), the FED a variety of levels, including how technology was Communications Group (SEG) Brian Ferencz To contact the Editorial Office, call Jennifer Hitchcock Nojae Kim Program Manager (PM) identified and engaged key selected, integrated and transitioned to the final (F5A8X6:) (758826-)4 823284- o23r 6(5086) 838-2294 Efoxre Rcuestievaer cDhir aenctdor JSiAmI CG,a rSdeinniior G raphic Design industry SMEs with demonstrated expertise in novel vehicle configurations. Key upfront decisions — use e-mail: [email protected] Technology Integration Sasyssitgenmesd Etongineer and innovative design configuration, advanced a ‘Monster Garage’ process to select candidate fuel- TARDEC SEG automotive engineering and systems integration. efficient technologies for possible transition; and have Additionally, innovators with prototyping and TARDEC engineers work side-by-side with industry manufacturing proficiency in military, specialty and innovators and automotive engineering experts — have high-performance vehicles (e.g., motor sports) were led us to potential technology solutions that will be actively recruited. The Tank Automotive Research, profiled in this special accelerate Magazine edition. Development and Engineering Center’s (TARDEC’s) crucial contributions were advanced computational This program has exposed our engineers and modelers and powertrain modeling expertise, and knowledge to novel and innovative design approaches, advanced 4 10 18 of future Army vehicle requirements, among others. automotive and systems engineering practices, and industry methodologies that are incorporated into The TARDEC PM then surveyed government and standard manufacturing processes. As anticipated, industry experts to identify and harvest potential the by-product of this experience was having our manufacturing and systems integration expertise engineers and designers approach the fuel-efficiency in existing fuel-efficient commercial-off-the-shelf challenge differently than they had on past tactical technologies, lightweight and composite materials, vehicle platforms. Once test and evaluation is and fuel-efficient vehicles and systems components. completed on both vehicle demonstrators in Fiscal His strategy was to quickly leverage government and Year 2011, I believe each vehicle’s fuel efficiency 22 28 industry modeling and simulation (M&S) capabilities performance data will speak for itself, providing the to build an aerodynamic virtual vehicle that would Army substantive engineering and M&S data for enable engineers to predict performance outcomes potential integration into future tactical vehicle systems. 3 Innovative Systems-Engineered Designs Deliver Game- 18 CCS Students Learn to Balance Aerodynamic and duty cycles, set objectives, refine design concepts and establish test criteria that would tap into the latest Please take a few moments to review the articles Changing Fuel-Efficient Tactical Vehicle Solutions Design and Functionality Thomas Mathes Chris Williams developments in fuel efficiency and power management. and information we have compiled about the FED Program for you, and learn how this collaborative 4 Fuel-Saving Design and Engineering Drive the 22 Systems Engineering Approach Crucial for Where Form Meets Function venture will potentially benefit our Army and U.S. Army’s FED Program FED Vehicles Using well-documented M1114 Up-armored High Marine Corps partners with innovative, advanced Carl Johnson Mike Seaton and Jim Gardini Mobility Multipurpose Wheeled Vehicle test data and technology solutions that will make the next generation 10 Modeling the FED — New Concepts, New Techniques 28 Hybrid FED Bravo Vehicle Uses ‘Monster analyses collected from extensive pre-deployment of military tactical vehicles more maneuverable, Chris Williams Garage’ Approach to Fuel Efficiencies ground testing and evaluation, and actual performance sustainable, survivable and fuel efficient. data compiled from the theater of operations, the 14 Fuel-Saving Design and Systems Engineering TARDEC FED Team government/industry team of engineers and designers Thomas Mathes Lead to Innovative Solutions 30 FED Alpha Vehicle Fact Sheet set baseline performance standards against which the FED Executive Director of Product Development TARDEC FED Team Rachel Agusti, TARDEC FED Team 16 FED Vehicle Timelines 2 3 TARDEC FED Team Fuel-Saving Design and Engineering Drive the Army’s FED Program Carl Johnson When engineers mount sacrificing vehicle payload, protection low-rolling-resistance or performance. To that end, OSD tires on a Fuel Efficient began programs to address fuel Ground Vehicle Demonstrator (FED), economy challenges. TARDEC’s FED the estimated miles-per-gallon program involves collaboration improvement is approximately 7 with automotive partners and percent. That may seem modest, suppliers, including companies but if the Army were to install such as Goodyear, which supplied low-rolling-resistance tires on its the custom-compounded, low- entire fleet of tactical vehicles, the rolling-resistance, 22.5-inch tires. resulting 7 percent jump in fuel The program has applied a systems economy could roughly translate engineering approach to military to approximately $45 million in vehicle technology design and saved fuel costs per year based on recent cost estimates. “It would “TARDEC is pay for itself in a year,” remarked the Nation’s Thomas Mathes, Executive Director for Product Development leading ground at the U.S. Army Tank Automotive vehicle systems Research, Development and Engineering Center (TARDEC). integrator, so it is vitally important The efficiency gains made by that we leverage switching to an energy-saving tire represents just one lesson derived technology, from the Office of the Secretary expertise and of Defense- (OSD-) funded FED research existing program, which has prompted Image above and below courtesy of AJ Mueller Photography/ Army engineers to think in new and outside our Ricardo North America. productive ways about fuel economy organization for solutions that can be applied across the Army’s ground vehicle fleet. the military”. It’s also one piece in a mosaic of ingredients, including lightweight development following two chassis and components, low-friction distinct and different intellectual parts and other high-efficiency approaches — one rooted in a technology that, when combined traditional, highly analytic using a systems engineering engineering process, and another approach, is expected to increase engaged in a more unconventional fuel economy by at least 70 percent. brainstorming method to promote innovation and foster creativity. Either As the owner of the world’s largest way, solutions tested and refined ground vehicle fleet, the U.S. Army on the demonstrator vehicles could has a significant stake in lowering be transitioned and integrated into its overall fuel consumption without other Army ground vehicle systems. 4 5 onto the team to provide automotive was completed in September 2010.  Performance friction low-drag and racing expertise. Employing a The vehicle will then go through aluminum brake calipers. “dual-track” approach to vehicle the contractor’s commissioning  REM Chemical Isotropic development and fabrication was just process and be delivered to the Superfinishing gears — a one unique FED Program aspect. government by year end. The finishing process often embedded engineers will facilitate used in racing vehicles to Embedded Engineers Assist this transition and be prepared to reduce friction and vibration With Development provide support when the vehicle and improve shifting. One team followed a more arrives at Aberdeen Proving  Continental Teves accelerator traditional development path. Ground (APG), MD, in early 2011. force feedback pedal, which TARDEC engineers Allen Rubel, cues the driver to accelerate the Richard Chase, Matt Collins and In addition to its Goodyear low- vehicle for optimal efficiency. Alan Cichosz were embedded with rolling-resistance tires, which  Carbon fiber body panels, the contractor-led team at Ricardo minimize the energy wasted as which reduce weight and to perform different roles within the heat between the tire and the road, increase rigidity. FED build team, including helping the FED Alpha vehicle is expected the contractor produce concepts, to boost fuel economy from ‘Monster Garage’ Brings designs and data to support a set of approximately 4 MPG to an average Together Top Experts military vehicle requirements. Rubel of 7.1 MPG on a typical urban patrol On a separate track, the second began working with the team early mission, using several designed team applied a ‘Monster Garage-’ in the design process to learn about components to achieve efficiencies: like process to build FED Bravo. Ricardo’s systems engineering  Optimized Cummins super/ This TARDEC-led government- processes, acquire TARDEC turbocharged 200-horsepower, industry team of subject- resources for the FED and share 4.5-liter, inline 4-cylinder matter experts (SMEs) sifted FED Systems Engineers vehicle systems integrator, so partnerships that assist TARDEC in knowledge gained in theater to diesel engine. through the most innovative Explore New Approach it is vitally important that we maintaining an elevated level of ensure the FED is a credible tactical  Alcoa Defense lightweight and compelling fuel-efficient To succinctly evaluate vehicle leverage the world’s intellectual systems engineering success.” military vehicle. Chase worked aluminum monocoque armored technologies available in industry. technologies that save fuel and keep capital for automotive ground closely with Ricardo’s electrical cab with underbody blast shield. The ‘Monster Garage’ process Soldiers safe, the FED Program vehicles to ensure the department’s FED Program objectives include: controls team in designing the FED tapped into the U.S. Army TACOM current and future needs are  Identifying and assessing vehicle’s user interface. Collins ENGINE ENERGY BALANCE VEHICLE ENERGY BALANCE Life Cycle Management Command’s met,” explained Mathes. “TARDEC new, fuel-efficient supported the design of interior Coolant Aero9% Drag Br6a%kes (LCMC’s) expertise, energy and designed the FED Program to vehicle technologies. components and managed the Exhaust 18% Rolling 3R3e%sistance enthusiasm, fully integrating employ automotive proficiency  Maintaining tactical receiving and cataloging of parts 38% Charged Air Driveline 10% 25% the collaborative community’s and aptitude for the benefit of vehicle capability while coming into the Ricardo garage. knowledge and capabilities. our Nation and its warfighters. At increasing fuel efficiency. Cichosz used computer-aided “TARDEC is the Department of the same time, we are building  Investing in developing the design (CAD) tools to complete Friction 3% Defense’s (DoD’s) leading ground crucial academic and industry next generation of government the final FED CAD package. M1114 scientists and engineers. Usable Power Accessories Estimates 31% 27%  Demonstrating promising Together, the team employed a “TARDEC did a marvelous job doing fuel-efficient technologies in rigorous modeling and simulation Driver Behavior incredible systems engineering and hardware against the baseline (M&S) approach to understand External Power Power Generation cost tradeoffs, coming out with two performance of an M1114 potential energy savings and High Efficiency Battery Technology High Mobility Multipurpose increase engine balance, which Turbo-Compounding Electric Parasitic Losses comparable vehicles that will get Turbo-Compounding Mechanical Wheeled Vehicle. reduces vibration and other Mass Reduction anywhere from 30 to maybe 50 to 70 stresses, to potentially enhance Thermal-Electronics Exhaust Heat Recovery Rankine Cycle Energy Recovery percent energy reduction… The FED has In 2009, the FED Program performance and reliability, Stirling Engines EFFICIENCY MEASURES issued contracts to two technical as illustrated in the figure. The Fuel Reformers been a tremendous success, bringing Cooling Heat Recovery engineering companies: Utah-based engineers used CAD and computer Regenerative Braking together various aspects of research, Select Engineering Services (SES) programming software, along Regenerative Damping and Maryland-based World Technical with wrenches, to help manage, This graphic illustrates the FED Program’s evolutionary systems engineering approach to industry and systems engineering to Services Inc. (WTSI). Subsequently, design and build the vehicles. improving engine balance to reduce vibration and other stressors that may hinder vehicle deliver two prototype vehicles.” performance, fuel consumption and reliability. (Image courtesy of Ricardo plc.) SES brought Detroit’s Ricardo plc Initial assembly on the FED Alpha 6 7 with multiple suppliers to delivering capabilities without pursue solutions that met FED hurting survivability or taking requirements and specifications capability away from our Soldiers? that would provide fuel-efficiency The FED has been a tremendous benefits. The collaboration between success, bringing together various TARDEC and WTSI also included aspects of research, industry and prime power engine and controller systems engineering to deliver development, computational fluid two prototype vehicles.” dynamics analysis, propulsion system M&S, and dynamic and TARDEC will begin testing the structural analysis performed by two demonstrator vehicles at several TARDEC engineers. “One APG in mid-2011. Thus far, M&S unique aspect of this government- evaluations are forecasting led collaborative effort is that By leveraging automotive systems engineering, the FED Program was able to improvements in fuel economy brought together the brightest ‘Monster Garage’ results and WTSI will be providing complete accelerate the traditional design process from concept to build in just 15 months. by approximately 70 percent and best government, industry continuing the collaborative source code for the hybrid system (Image courtesy of Ricardo plc.) without sacrificing payload, and academia representatives effort through partnerships with controller,” remarked WTSI protection or performance. from around the country to focus various technology industries. Engineer Brandon Card. “This is To deliver the best end-product feedback, V-shaped hulls, isotropic on the U.S. military’s ground In addition, engineers worked understood to be a first and will be possible, the FED Program finishes and remotely operated vehicle fuel consumption and directly with students from the the foundation for continuing the established a rigorous validation weapon stations, were investigated logistics burden to build FED College for Creative Studies (CCS), development of TARDEC engineers’ process to ensure that the to lower fuel consumption. Bravo. These experts examined Detroit, MI, through a sponsored knowledge and understanding of proposed vehicle designs and Carl Johnson is the FED Vehicle vehicle tradeoffs using a top-down, project to explore new ideas propulsion system optimization Program Team Leader. He has a B.S. technologies met the needs of The FED Program’s unique degree in electrical engineering from systems-level approach with fuel with tomorrow’s innovators. for fuel efficiency.” stakeholders and customers. This approach to addressing fuel Michigan Technological University. efficiency and performance as process was used to evaluate economy has been lauded by primary requirements. During the During the second phase, several A final design review was the six vehicle architectures that those throughout government for second phase, the government- companies’ technologies were conducted in September, with were considered by the teams. its innovative and collaborative led team worked hand-in-hand reviewed for each system within fabrication scheduled to begin in nature. “TARDEC did a marvelous to design the FED, leveraging the vehicle. The team worked late 2010, and vehicle assembly Propulsion systems studied job doing incredible systems slated for early 2011. Following included dual internal combustion engineering and cost tradeoffs, a summer of final calibration engine technology, series hybrid coming out with two comparable and tuning, the government- and parallel hybrid architectures, vehicles that will get anywhere led collaborative FED will and conventional, lightweight from 30 to maybe 50 to 70 percent begin shake-out testing and modern diesel engines with energy reduction,” remarked then launch into full test mode integrated starter generators. Alan R. Shaffer, Principal Deputy, during the following months. Transmission technologies — OSD (Acquisition, Technology such as 32-speed binary logic and Logistics)/Director, Defense M&S Capabilities Support transmissions and suspension Research and Engineering. Demonstrators concepts that use adjustable “That’s what this is all Both approaches incorporate height suspensions — were also about — how do we cutting-edge M&S capabilities, contemplated for the concept think about allowing teams to predict vehicle designs. Other technologies, such performance and optimize clean- as low-friction coatings, advanced sheet, systems-level engineering synthetic lubricants, Lithium- and design solutions. The FED ion batteries, advanced body Program also provided teams materials, ceramic brake TARDEC FED Team Leader Carl Johnson (right) explains the significance of the with critical support, including rotors, aluminum wiring, FED concept vehicle to TACOM LCMC Commanding General MG Kurt J. Stein (center) Lean Six Sigma tools, structured regenerative braking, while TARDEC National Automotive Center Director Paul F. Skalny looks on during innovation training and theory the Society of Automotive Engineers 2010 World Congress in April. Creating and central tire inflation of problem-solving historical improving the design for the FED concept vehicle has been a collaborative effort systems, driver benchmarking resources. across the TACOM LCMC, industry and academia. (U.S. Army TARDEC photo by Elizabeth Carnegie.) 8 9 Modeling the FED — at the Aberdeen Proving Ground necessary items without over- used to achieve high fuel efficiency. (APG), MD. The vehicle itself, a burdening SWAP-C requirements. At the program’s outset, few models New Concepts, New Techniques variation on the conventional In designing the vehicle, TARDEC existed to rank vehicle fuel efficiency military motif, will see action only engineers used the High Mobility standards or what available models on test tracks and in labs. As a Multipurpose Wheeled Vehicle would provide the greatest fuel demonstrator, it will help engineers (HMMWV) as their baseline, but economy improvement. For decades, Chris Williams validate systems and components, also maintained an awareness of military vehicles were designed for modeling and simulation (M&S) future Army vehicle requirements range, and fuel economy was rarely a tools and techniques, and identify to make the platforms relevant. consideration. The Advanced new technologies that can then be Concepts team leveraged the transitioned into the current and “The requirements that we came CASSI analytical team’s expertise future fleet of ground vehicles. up with were derived from the to obtain a better understanding While designing the new Fuel Efficient HMMWV, but we also looked at of fuel-efficient designs, concepts Ground Vehicle Demonstrator (FED), Meeting Mission-Effectiveness future programs like the Joint Light and powertrain technologies. U.S. Army engineers weren’t just Vehicle and Relevancy Challenges building a vehicle that would apply innovative TARDEC’s Advanced Concepts “We don’t normally design vehicles solutions for increasing fuel economy. They were team was involved with the FED also forging new systems design techniques. Program from the start. Engineers for fuel efficiency; we design vehicles used advanced computational For instance, cooling plays an important part in modeling to design the FED for protection or payload. What might system design and fuel efficiency for military vehicles. platforms, creating a demonstrator be very efficient from a space claim Shape also affects fuel efficiency. Consequently, the vehicle that uses the latest Army’s traditionally boxy vehicle designs would need developments in fuel efficiency and packaging standpoint, may not be a major makeover for the FED platforms to achieve and power management. true fuel efficiencies. To better understand cooling However, designing a fuel- very efficient from a fuel standpoint.” and aerodynamic concerns, engineers turned to the efficient and mission-effective U.S. Army Tank Automotive Research, Development vehicle posed some major and Engineering Center’s (TARDEC’s) Computational engineering challenges. Tactical Vehicle [JLTV] and said, Drafting the Most Fluid Dynamics team within the Concepts, Analysis ‘What growth happened between Promising Concepts Systems Simulation and Integration (CASSI) group. While proven solutions exist to HMMWV and JLTV?’ To keep the The CASSI Powertrain M&S team improve fuel efficiency, not all vehicles relevant, we designed the supported the FED Program “They basically do all the aerodynamics work in terms of are suitable to meet the power vehicle with a V-shaped hull because through the use of propulsion airflow and how to position things. They did some things needs of the Army’s fleet of heavy, of today’s threat,” Johnson explained. system models to guide the that helped us, particularly with under-the-hood cooling,” electronics-intensive ground “The other thing we knew we needed program through each phase. FED Team Leader Carl Johnson remarked. “They really vehicles. “You could use the was an integrated starter-generator Powertrain team members brought out a new capability that didn’t previously exist at University of Michigan’s solar [ISG], because onboard power is participated in the preliminary TARDEC and which none of our contractors had, either.” car to get 3,000 miles per gallon, very important. To paraphrase MG working group sessions, which but then it’s not mission-effective [James R.] Chambers, the Army has spawned a series of powertrain TARDEC’s CASSI group was fully involved in the design [for Soldiers],” Johnson stated. no intention of applying appetite architecture concepts that might of the two FED demonstrators. To do this required “We identified several vehicle suppressant to its power needs. So meet FED Program needs. The not just an understanding of vehicle space, weight, requirements, such as it should we made the conscious decision Powertrain M&S team then took power and cooling (SWAP-C) concerns, but also new be able to cross the terrain at APG to keep the FED relevant to current those concepts and fleshed research into fuel efficiency and aerodynamics. “We and be able to generate onboard and future vehicle needs, which them out to include individual don’t normally design vehicles for fuel efficiency; power. Our biggest concern was makes a direct comparison to a propulsion system components we design vehicles for protection or payload,” how to make the vehicle relevant.” HMMWV a little tricky because we and performance characteristics Johnson explained. “What might be very efficient have requirements beyond that.” before putting into action an M&S- from a space claim and packaging standpoint may As TARDEC associates designed based analysis plan to down-select not be very efficient from a fuel standpoint.” the FED, they worked from existing Filling Fuel-Efficiency Gaps the most promising concepts. The vehicle platform baselines to A challenge faced in creating analysis plan included deriving The first FED demonstrator, FED Alpha, to emerge from understand where to place seats, the FED’s computational models peacetime and wartime drive cycles this ambitious collaboration will go into testing in early 2011 engines, equipment and other concerned the vehicle technology to predict total fuel consumption. 10 11 The powertrain team also developed for a conventional powertrain with parallel hybrid system provided the preliminary concept models and an ISG, series hybrid powertrain, best opportunity for fuel savings established consistency throughout parallel hybrid powertrain, road- based on the drive cycles used for the concept evaluation in such coupled parallel hybrid powertrain the analysis. The team determined areas as gross vehicle weight, and a conventional powertrain that additional fuel savings might electrical (hotel) loads, fan power with ISG and Continuously be realized by optimizing the and auxiliary power requirements, Variable Transmission (CVT). projected control strategies. During to establish a level playing field Multiple simulations were run for the program’s final phase, as the for evaluating all concepts. each architecture to determine actual hardware for the propulsion the most favorable control system is selected, TARDEC will Next, the powertrain team strategies for fuel economy, update its models to reflect the populated the model templates while maintaining automotive as-built FED vehicle and validate with real-world performance performance required for the model with actual performance data for all components, trying to acceleration and speed on a grade. data. This will allow additional minimize assumptions whenever The various simulation results analysis to be performed over a possible. Models were developed indicated that the road-coupled wide variety of Army drive cycles that cannot be reproduced on “What we’re going to show is the the proving ground and further determine control strategies for best fuel efficiency you can expect in fuel economy maximization. a vehicle of this weight class while Johnson remarked that the still being military-relevant. I think it powertrain team’s contribution was invaluable to the program’s overall helped validate some of our internal success. “They looked at several M&S group’s skills and showed what powertrain concepts, including generic, series-type and parallel our teams are capable of. The work hybrids to determine which one was best and most fuel efficient.” that we’re going to do at Aberdeen will further validate those models.” “They did some of these generic tests for us and created FED drive cycles that we could run all of the concepts against to determine which vehicle concept would be the best to go forward with, giving us the powertrain layout Advanced Concepts’ space claim while still being military-relevant,” strides in designing a fuel-efficient, to meet layout,” Johnson commented. Johnson declared. “I think it helped mission-capable platform that “Powertrain modeling is very validate some of our internal M&S will further validate CASSI and strong here at TARDEC, and I group’s skills and showed what TARDEC’s modeling expertise. think it helped to validate that.” our teams are capable of. The work that we’re going to do at Aberdeen Editor’s Note: TARDEC “What we’re going to show is the will further validate those models,” Engineer Mike Pozolo best fuel efficiency you can expect Johnson concluded. APG testing contributed to this story. in a vehicle of this weight class will help validate the FED Program’s 12 13 Fuel-Saving Design and Systems Engineering SEATS Lead to Innovative Solutions The FED Alpha vehicle uses GSS Cobra Blast Attenuating Seats, which are designed with blast mitigation for military tactical vehicles. Systems have weight sensors to adjust the level of energy DRIVELINE absorption to the Soldier in the seat. The FED Alpha vehicle is powered by a modern CUMMINS 4.5L ISB engine optimized for fuel efficiency and designed to burn JP-8 fuel. The transmission is a 6-speed automatic from Aisin. A number of the driveline components, including the transmission, transfer case and differentials, were treated with a superfinishing process from REM Chemical. The superfinishing decreases the friction between gears and increases the fuel efficiency of the entire driveline. Ricardo also removed the wheel- end reduction units that are typically found on trucks. The absence of gear sets eliminates friction and losses in the entire system. LIGHTWEIGHT STRUCTURE The Lightweight Aluminum Monocoque Armored Cab and underbody blast shield on the FED Alpha vehicle is designed to be “lighter, faster and INTEGRATED STARTER-GENERATOR (ISG) stronger,” according to its supplier, Alcoa Defense. The Alcoa alloy increases strength, durability and ballistic performance while also reducing weight. Between the engine and transmission Ricardo included a Kollmorgen 24-volt ISG. This motor will start the vehicle and then produce up to 30kW of power for vehicle and military equipment loads. Because of high electrical power output requirements, most of the engine accessory drives have been removed from the engine belt and replaced with electric pumps and motors. Electric pumps and motors can be run only when needed, reducing parasitic losses, and can be more easily packaged away from the front of the engine. LIGHTING ACCELERATOR The lighting systems for both the FED Alpha vehicle as well as the FED Bravo feature LED headlamps, side markers, backup lighting and blackout lights. The FED vehicles use Truck-Lite systems, which are already DoD-approved components on several combat platforms. A Force Feedback Pedal sends cues when the driver LED headlamp systems typically feature longer life, increased pushes the accelerator too hard or too often. In the durability and minimal power consumption (about 4kW) when FED vehicles, the Continental Teves Accelerator Force compared to conventional truck lighting systems. Feedback Pedal will help the driver find the pedal position ensuring the highest possible fuel economy. This device is important because even the most advanced fuel economy systems can be undermined by a driver with a lead foot. TIRES BRAKES Rolling resistance is the term for the amount of drag force caused as The brake calipers on the FED Alpha vehicle use the tire treads press against the road while driving. Reducing drag leads Performance Friction Brakes Zero-Drag technology, to better fuel efficiency. The Goodyear Custom Compound Low Rolling which eliminates brake drag for fuel savings, increases Resistance Tires on the FED Alpha vehicle feature a tread design, depth pedal response and improves component life. These and compound to reduce this energy loss and boost miles-per-gallon brake systems have been proven in motor racing numbers. These new 22.5-inch military tires could account for 7.8 percent and are built with lightweight materials that maintain fuel economy gains over conventional military tires. stiffness and durability. 14 15