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HYBRID TRANSIT BUS CERTIFICATION WORKGROUP Engine Certification Recommendations Report Northeast Advanced Vehicle Consortium NAVC0599-AVP009903 September 15, 2000 Submitted to U.S Department of Transportation U.S Environmental Protection Agency California Air Resources Board by Northeast Advanced Vehicle Consortium 112 South Street, Fourth Floor Boston, MA 02111 September 15, 2000 Agreement No.: NAVC0599-AVP009903 Prepared By M.J Bradley & Associates, Inc Manchester, NH Transient Operation Analysis By West Virginia University Department of Mechanical Engineering Morgantown, WV Copyright 2000, NAVC, DOT, All Rights Reserved HYBRID TRANSIT BUS CERTIFICATION About AVP and NAVC The NAVC Hybrid Transit Bus Certification Project was generously supported by the United States Department of Transportation’s Advanced Vehicle Technologies Program (AVP) The AVP combines the best in transportation technologies and innovative program elements to produce new vehicles, components, and infrastructure for medium- and heavy-duty transportation needs The primary objectives of AVP are to: • reduce vehicle emissions beyond 2004 standards, • improve vehicle fuel efficiency by 50 percent, • make the United States globally competitive in advanced vehicles, components and infrastructure, and • increase public acceptance of advanced transportation technology The AVP program continues the approach developed by the Defense Advanced Research Projects Agency (DARPA) Electric and Hybrid Vehicle (EHV) Technologies program of forming partnerships with other federal agencies, private companies, research institutions and state and local governments to expedite technology development vital to the nation’s interests The Northeast Advanced Vehicle Consortium (NAVC) is a public-private partnership of companies, public agencies, and university and federal laboratories working together to promote advanced vehicle technologies in the Northeast United States The NAVC Board of Directors includes a representative of the New England Governors’ Conference and the Northeast States for Coordinated Air Use Management and representatives appointed by the eight Northeast governors and the mayor of New York City Its participants have initiated numerous projects, spanning a wide range of technology areas including electric, hybrid-electric and fuel cell propulsion systems, electric and natural gas refueling, energy storage and management, and lightweight structural composites The NAVC receives funding from federal agencies and private members Agreement No.: NAVC0599-AVP009903 09/15/00 ii HYBRID TRANSIT BUS CERTIFICATION Acknowledgements The Northeast Advanced Vehicle Consortium (NAVC) thanks the U.S Department of Transportation (DOT) Advanced Vehicle Technologies Program for the funding and support of this project We recognize Shang Hsiung of DOT for his personal assistance The project was initiated by Sheila Lynch, NAVC Executive Director, and organized and lead by Thomas Webb, NAVC Project Director The NAVC thanks M.J Bradley & Associates for their excellent work on the project, particularly Thomas Balon, the lead author; Paul Moynihan, MJB&A staff engineer; and Amy Stillings, MJB&A staff analyst The NAVC thanks West Virginia University (WVU) for sharing and carrying forward the wealth of knowledge they possess with regard to engine certification testing We personally thank Dr Nigel Clark for his oversight and providing expertise on interactions between an engine’s operating conditions and emissions and the rest of the WVU staff for their participation In addition, the NAVC thanks the United States Environmental Protection Agency (EPA) and California Air Resources Board (CARB) for its participation In particular, we thank Dennis Johnson (EPA), Tom Stricker (formerly EPA), Jack Kitowski (CARB), Tom Chang (CARB) and Fernando Amador (CARB) for expressing a deep interest in the project from the beginning and a desire to explore alternate means to certify hybrid transit buses The NAVC would also like to thank the electric drive manufacturers, specifically Allison Transmission, Lockheed Martin Control Systems and ISE Research for allowing access to proprietary data that is at the heart of this report In addition, the ongoing participation of other interested parties and all workgroup participants was extremely valuable, including hybrid component suppliers, engine manufacturers, bus equipment manufacturers, environmental organizations and other governmental agencies Finally, the NAVC thanks the American Public Transportation Association for getting the hybrid bus certification ball rolling several years ago Frank Cihak and Jerry Trotter provided valuable insight and contacts Agreement No.: NAVC0599-AVP009903 09/15/00 iii HYBRID TRANSIT BUS CERTIFICATION Disclaimer The viewpoints expressed in this report are those of the authors While the report was prepared and reviewed by a broadbased and representative group of people from industry and government (listed in Appendix A), none of the participating organizations were asked to, nor have they necessarily, endorsed or adopted the findings and recommendations included in this report Agreement No.: NAVC0599-AVP009903 09/15/00 iv HYBRID TRANSIT BUS CERTIFICATION Executive Summary The purpose of this report is to help facilitate the introduction of hybrid-electric drive technology into the heavy-duty bus market in the United States today Recent chassis testing of hybrid buses by the Northeast Advanced Vehicle Consortium (NAVC) demonstrated the potential of hybrid technology to significantly reduce emissions and greenhouse gases compared to conventional drive buses However, hybrid buses can present a certification quandary for industry and regulators Historically, engines for heavy-duty transit buses have been certified using the federal transient procedure (FTP), but engines that may be optimized for today’s series hybrid buses may not be capable of following the behavior prescribed in the FTP cycle While chassis testing may ultimately resolve this dilemma, new rulemaking for certifying transit bus chassis (instead of engines) is a long way off A short-term, alternate engine certification procedure would help this viable, clean bus drive technology enter the market now Hybridelectric transit bus engines have to meet the same emission standards as conventional urban bus engines, however they should be tested on cycles that are representative of their actual operating characteristics The NAVC formed the Hybrid Transit Bus Certification Workgroup to help industry and regulators elect an appropriate existing engine cycle as an alternate to the FTP cycle During the course of several well-attended meetings, the government-industry group exchanged the latest information on hybrid-electric drive bus technology and identified an approach to near-term hybrid bus engine certification The group collected and analyzed data from a representative sample of state-of-the-art series hybrid buses operating in normal revenue service in New York, Boston and Los Angeles The data represents three leading electric drive manufacturers active in the market at this time This report summarizes the analysis of in-use hybrid-electric bus engine data and compares it to conventional bus, marine and off-road engine test cycles The analysis indicates that the hybrid engines have substantially less aggressive transient behavior than the FTP prescribes Since extreme transients cause the formation of particulate matter and carbon monoxide in diesel engines, and precipitate air/fuel ratio deviation in spark ignited engines, hybrid engine emissions are better represented by steady state operation A modal data analysis reveals that the Euro III 13-Mode Test Cycle is the most inclusive and representative cycle for hybrid engines Furthermore, it is widely used by regulators and engine manufactures, making it practical for implementation in the near term At this time, we recommend the use of the Euro III to certify engines for use in series hybrid buses only Additionally, we recommend a sunset date of 2004 to allow industry and regulators to reevaluate the cycle in light of advancements in hybrid technology and engine emission controls The recommended sunset date also coincides with the significantly reduced emission levels that will be instituted in California in 2004 Chapter provides an overview of the project, its goals and objectives and reason for focusing on near term alternate cycle for engine based certification of heavy-duty hybrid transit buses Chapter offers a more detailed discussion of hybrid drive systems including generator set operation and its affects on fuel economy, emissions and test procedures Chapter provides a description of existing transient and steady state cycles for certifying engines Chapter lays out a general in-use methodology for analyzing hybrid engine operation This chapter may be of use for future test programs Chapter provides the results of the analysis of three different hybrid engines in use in New York, Boston and Los Angeles Chapter draws conclusions and recommends the Euro III test cycle for near term certification of engines for series hybrid transit buses Agreement No.: NAVC0599-AVP009903 09/15/00 v HYBRID TRANSIT BUS CERTIFICATION Table of Contents About AVP and NAVC Acknowledgements Disclaimer Executive Summary 1.0 Hybrid Bus Overview 1.1 Introduction 1.2 Proven Hybrid Emissions Reductions 1.3 The Certification Challenge 1.4 The NAVC Hybrid Transit Bus Certification Workgroup 1.4.1 Special Test Procedures 2.0 Series Hybrid-Electric Buses 2.1 Hybrid-Electric Drive Definition 2.1.1 Drive System Design Variations 2.1.2 Engine Sizing 2.1.3 Batteries and Regenerative Braking 2.2 Engine Operation and Control 2.3 Emission Implications 3.0 Existing Engine Test Cycles 3.1 The FTP Transient Cycle 3.2 Steady-State Cycles 3.2.1 Generator Set Test Cycle 3.2.2 Off Road Equipment Test Cycle 3.2.3 Marine Engine Test Cycles 3.2.4 Other Steady-State Test Cycles 3.3 Conclusions Agreement No.: NAVC0599-AVP009903 09/15/00 vi HYBRID TRANSIT BUS CERTIFICATION 4.0 In-Use Data Collection 4.1 Data Collection Overview 4.2 Modal Data Analysis Methodology 4.3 Transient Data Analysis Methodology 4.4 Modal FTP Baseline 4.5 Conclusions 5.0 Manufacturers Data Analysis 5.1 NAVC Workgroup Data Collection 5.1.1 NAVC Workgroup Data Reduction 5.2 Engine Data—Transient Analysis 5.3 Engine Data—Modal Analysis 5.3.1 Modal Test Cycle Comparisons 5.4 Conclusions 6.0 Conclusions and Recommendations 6.1 Key Findings 6.2 Future Research Needs Appendix A: Attendance List for NAVC Hybrid Transit Bus Certification Workgroup Meetings Agreement No.: NAVC0599-AVP009903 09/15/00 vii HYBRID TRANSIT BUS CERTIFICATION List of Tables Table 1.1: Results of NAVC Hybrid Testing Project Table 1.2: Current Hybrid-Electric Engine and Turbine Applications Table 1.3: Hybrid Bus Certification Pathways Table 1.4: EPA Urban Bus Engine Standards Table 1.5: CARB Urban Bus Diesel Engine Standards Table 3.1: Steady State Test Cycles Table 5.1: Commercially Available Hybrid Buses Table 5.2: Hybrid Bus Specifications Agreement No.: NAVC0599-AVP009903 09/15/00 viii HYBRID TRANSIT BUS CERTIFICATION List of Figures Figure 1.1: U.S Hybrid Bus Market Figure 1.2: Comparison of Tailpipe Emissions between a Conventional and Hybrid Diesel Bus Figure 2.1: Vehicle Energy Requirements Figure 3.1: The FTP Transient Cycle Figure 3.2: Five-Mode Steady-State Test Figure 3.3: Eight-Mode Steady-State Test Figure 3.4: E4 and E5 Marine Cycles Figure 3.5: Thirteen-Step Japanese Steady-State Test Figure 3.6: Thirteen-Mode Euro III Test Figure 4.1: FTP Load-Point Analysis Figure 4.2: FTP Cycle Histogram Figure 4.3: FTP Horsepower Variations Figure 4.4: FTP Cycle Engine Torque Distributions Figure 5.1: LMCS Bus #6352 In-Use Speed Figure 5.2: Comparison of Speed Behavior on FTP Cycle and In-Use Hybrid Test Data Figure 5.3: Comparison of Horsepower on FTP Cycle and In-Use Hybrid Test Data Figure 5.4: Comparison of Torque on FTP Cycle and In-Use Hybrid Test Data Figure 5.5: Combined Hybrid Engine Torque Speed Hp-Hr Weighted, 1% Intervals Figure 5.6: Combined Hybrid Engine Torque Speed Hr-Hp Weighted, 10% Intervals Figure 5.7: Combined Hybrid Engine Torque Speed Hp-Hr vs 8178 5-Mode Figure 5.8: Combined Hybrid Engine Torque Speed Hp-Hr vs 8178 8-Mode Figure 5.9: Combined Hybrid Engine Torque Speed Hp-Hr vs 8178 Marine E4 and E5 Figure 5.10: Combined Hybrid Engine Torque Speed Hp-Hr vs 13 Step Japanese Figure 5.11: Combined Hybrid Engine Torque Speed Hp-Hr vs Euro III 13-Mode Figure 6.1: Comparison of Horsepower on FTP Cycle and In-Use Hybrid Test Data Figure 6.2: Combined Hybrid Engine Torque Speed Hp-Hr vs Euro III 13-Mode Agreement No.: NAVC0599-AVP009903 09/15/00 ix ... 5.7: Combined Hybrid Engine Torque Speed Hp-Hr vs 8178 5-Mode Figure 5.8: Combined Hybrid Engine Torque Speed Hp-Hr vs 8178 8-Mode Figure 5.9: Combined Hybrid Engine Torque Speed Hp-Hr vs 8178... Combined Hybrid Engine Torque Speed Hp-Hr vs 13 Step Japanese Figure 5.11: Combined Hybrid Engine Torque Speed Hp-Hr vs Euro III 13-Mode Figure 6.1: Comparison of Horsepower on FTP Cycle and In-Use Hybrid. .. economy and emissions 0.1 10 performance of state-of-the-art 0.05 0 hybrid- electric buses as well as NovaBUS RTS Orion Hybrid NovaBUS RTS Orion Hybrid conventional and alternatively (DDC50) VI