Advanced Powertrain Research Facility

Argonne's Advanced Powertrain Research Facility (APRF) is the principal U.S. Department of Energy (DOE) facility for assessing advanced and hybrid electric vehicle (HEV) technologies for the Vehicle Technologies Program. The APRF is an integrated multi-dynamometer vehicle and component test facility capable of testing conventional and hybrid vehicle propulsion systems and vehicles (two- or four-wheel drive) in a precise laboratory environment using a variety of fuels (including hydrogen). The facility is used to assess powertrain technology for light- and medium-duty propulsion systems with state-of-the-art performance and emissions measurement equipment and techniques.

Component, subsystem, and vehicle test facilities support hardware-in-the-loop testing, control system development, and technology validation. [Hardware-in-the-loop is a technique for performing system-level tests of components or subsystems in a virtual vehicle environment by using sophisticated computer models and control techniques.] The APRF allows researchers to test vehicles and components to provide configurations without building and then tearing apart an entire vehicle each time a component is changed. The facility is completely modular, so parts can be interchanged quickly, for rapid, standardized assessment. Components can be benchmarked individually or as part of a system.

Features of particular interest for testing and development of advanced propulsion systems include the following:

• Four-wheel-drive dynamometer for road load simulation, monitoring tractive effort, coastdown, and calibration for two- and four-wheel-drive vehicles up to 12,000 lb per axle
• Measurement of particulate and criteria emissions exhausts of Super Ultra Low Emissions Vehicle (SULEV) level for gasoline- and diesel-powered vehicles
• Data acquisition system to evaluate conventional, fuel cell, hybrid, and electric vehicles
• Safety system allows testing with all fuels (including hydrogen) and detects all hazardous gases, heat, and smoke/li>
• State-of-the-art air handling system cleans and conditions test air, as well as providing ventilation and cooling

The support equipment for the component dynamometers enables precise measurements in testing engines, transmissions, and advanced electric motors. All test cells in the building share extensive equipment for measuring exhaust emissions and fuel consumption, including a 150-kW battery tester-emulator.

• Powertrain Test Cell
• 4-Wheel Drive Chassis Dynamometer Test Cell

Research

Although similar instrumentation is in use at research facilities operated by vehicle manufacturers, the APRF is the only facility in North America that combines the best available emissions instrumentation with such a wide range of fuels including gasoline, hydrogen, natural gas, and diesel. In addition, the APRF has an expert staff with extensive industry experience who have tested more advanced technology vehicles than any other public sector group — more than 100 different hybrid electric vehicle configurations.

We have conducted vehicle- and component-level testing of commercially available and DOE-developed HEVs to characterize and enhance these technologies. The test data have also helped to evolve and validate DOE's vehicle simulation model, PSAT. The data are incorporated in the systems models to simulate advanced vehicles operated over standard and custom driving cycles, to study vehicle and powertrain efficiency and exhaust emissions characteristics.

We plan to continue testing high-efficiency electric motors, engines, transmissions, and vehicles, with particular attention to developing powertrain control strategies for increased fuel economy and reduced emissions.