Exploring the Impact of Vehicle Lightweighting in Terms of Energy Consumption: Analysis and Simulation on Real Driving Cycle
<p>Location (<b>a</b>) of the GPS receiver (red circle), installed on the vehicle hood via magnetic connection, and (<b>b</b>) of the MoTeC ADL2 data acquisition unit, on the passenger mat, inside a protective box.</p> "> Figure 2
<p>Home-to-work commute real-world reference driving cycle.</p> "> Figure 3
<p>Acquired speed profile of the reference real driving cycle.</p> "> Figure 4
<p>Time spent at different vehicle speed ranges, as a percentage of total travel time (about 59.67 min).</p> "> Figure 5
<p>Altimetry profile obtained through the “GPS Visualizer” [<a href="#B46-energies-17-06398" class="html-bibr">46</a>] tool using GPS latitude and longitude vs. altimetry profile directly acquired from GPS on board the vehicle.</p> "> Figure 6
<p>Average energy consumption over the reference real driving cycle, as a function of vehicle weight, for the N1 category vehicle model (“N1”) and for the same model but with zero inertia contributions (“N1—NO inertias”); for the compact car model (“CompactCar”); and for the same model but with zero inertia contributions (“CompactCar—NO inertias”).</p> "> Figure 7
<p>Target speed and vehicle speed in the simulation vs. time elapsed since the beginning of the simulation itself for the N1 vehicle without moments of inertia and with a weight of 2950 kg: (<b>a</b>) for the entire simulation; (<b>b</b>) an enlargement relative to the green box in <a href="#energies-17-06398-f007" class="html-fig">Figure 7</a>a.</p> "> Figure 8
<p>Motor torque vs. time elapsed since the beginning of the simulation for the N1 vehicle without moments of inertia and with a weight of 2950 kg.</p> "> Figure 9
<p>Battery SOC (State of Charge) vs. time elapsed since the beginning of the simulation for the N1 vehicle without moments of inertia and with a weight of 2950 kg.</p> "> Figure 10
<p>Average energy consumption over the reference real driving cycle, as a function of vehicle weight, for the following vehicle models: the N1 vehicle (“N1”); compact car (“CompactCar”); compact car with the N1 battery pack on board (“CompactCar—N1 battery pack”); compact car with the aerodynamic coefficients of the N1 vehicle (“CompactCar—N1 aerodynamics”); compact car with the transmission efficiency equal to that of the N1 vehicle (“CompactCar—N1 transmission efficiency”); compact car with the rolling resistance coefficient equal to that of the N1 vehicle (“CompactCar—N1 rolling resistance”); and, finally, compact car with all the parameters previously mentioned equal to those of the N1 vehicle (“CompactCar—N1 values”).</p> "> Figure 11
<p>Average energy consumption over the reference real driving cycle, as a function of vehicle weight, for the following vehicle models: the vehicle of category N1 (“N1”); compact car (“CompactCar”); compact car with the battery pack of the N1 vehicle on board, with the aerodynamic coefficients, the efficiency of the transmission, and the rolling resistance coefficient of the N1 vehicle (“CompactCar—N1 values); compact car with the same moments of inertia as vehicle N1 (“CompactCar—N1 inertias”); compact car with the battery pack, aerodynamics, transmission efficiency, rolling resistance, and moments of inertia of the N1 vehicle (“CompactCar—N1 values (also inertia)”); compact car with the transmission ratios and wheel radii of the N1 vehicle (“CompactCar—N1 traction ratios”); and, finally, compact car with all the previously mentioned parameters equal to those of the N1 vehicle, i.e., the parameters relating to the battery pack, aerodynamics, transmission efficiency, rolling resistance, moments of inertia, transmission ratios, and wheel radii (“CompactCar—N1 values (all)”).</p> "> Figure 12
<p>Average energy consumption over the reference real driving cycle, according to the vehicle weight, for the following vehicle models: compact car without inertia (“CompactCar—NO inertias”); compact car with transmission ratios (and wheel radii) equal to those of the N1 vehicle and without inertia (“CompactCar—NO inertias—N1 traction ratios”).</p> "> Figure 13
<p>Average energy consumption over reference real driving cycle as a function of the vehicle weight. The curves relating to the results were obtained by means of the simulations (“Results”), and the curves were obtained thanks to the polynomial approximation of the first (“n = 1”), second (“n = 2”), and third degree (“n = 3”) for (<b>a</b>) the N1 vehicle and (<b>b</b>) the compact car.</p> "> Figure 14
<p>ERV index, calculated for the reference real driving cycle and calculated between a simulation performed at a given vehicle weight and the simulation with the vehicle weight immediately lower than that under examination (considering the set of simulations performed), as a function of the vehicle weight, for the following vehicle models: the N1 category vehicle (“N1”); N1 vehicle with zero inertia (“N1—NO Inertias”); compact car (“CompactCar”); compact car with the N1 battery pack on board (“CompactCar—N1 battery pack”); compact car with the aerodynamic coefficients of the N1 vehicle (“CompactCar—N1 aerodynamics”); compact car with the transmission efficiency equal to that of the N1 vehicle (“CompactCar—N1 transmission efficiency”); compact car with the N1 vehicle rolling resistance coefficient (“CompactCar—N1 rolling resistance”); and, finally, compact car with moments of inertia equal to those of the N1 vehicle (“CompactCar—N1 inertia”). In particular, in (<b>a</b>), the graph with all the ERV indexes calculated; in (<b>b</b>), the graph with the <span class="html-italic">y</span>-axis limited between 1 and 1.5 kWh/(100 km∙100 kg); and in (<b>c</b>), the legend valid for both graphs.</p> "> Figure 15
<p>Average energy consumption over the reference real driving cycle, as a function of vehicle weight, for the compact car, obtained through simulations with the TEST model (“Real consumption”) and considering the ERV obtained through polynomial interpolation, for the following vehicle models (lightweighting by 300 kg): CompactCar (“Calculated consumption”); CompactCar with the vehicle battery pack N1 on board (“Calculated consumption (ERV with N1 battery pack)”); CompactCar with the aerodynamic coefficients of vehicle N1 (“Calculated consumption (ERV with the N1 aerodynamics)”); CompactCar with the transmission efficiency equal to that of the N1 vehicle (“Calculated consumption (ERV with N1 efficiencies)”); CompactCar with the vehicle rolling resistance coefficient of N1 (“Calculated consumption (ERV with N1 rolling resistance)”); and, finally, CompactCar with the moments of inertia of vehicle N1 (“Calculated consumption (ERV with N1 inertias)”).</p> "> Figure 16
<p>Average energy consumption, for (<b>a</b>) the N1 category vehicle and (<b>b</b>) compact car, over the reference real driving cycle and the following standard driving cycles: WLTC (class 3b); US06; FTP75; HWFET; JC08; Artemis Urban Cycles; Artemis Rural Road Cycle; and Artemis Motorway Cycle (130) [<a href="#B28-energies-17-06398" class="html-bibr">28</a>].</p> "> Figure 17
<p>ERV index, obtained from the “polyfit” MATLAB function, for the reference real driving cycle, for the N1 vehicle, for the compact car, and for the compact car, with the following parameters, aspects, and components of the N1 vehicle: aerodynamics; moments of inertia; battery pack; transmission efficiency; and rolling resistance.</p> "> Figure 18
<p>ERV index, obtained from the “polyfit” MATLAB function, for different standard driving cycles, for the N1 vehicle and for the compact car [<a href="#B28-energies-17-06398" class="html-bibr">28</a>].</p> ">
Abstract
:1. Introduction
- Section 2 outlines the adopted methodology, detailing the reference vehicles used in this study, the reference real driving cycle, the simulation tool utilized, the vehicle parameters under investigation, and a brief description of the simulations conducted;
- Section 3 presents the results of this study and the considerations derived from them;
2. Materials and Methods
2.1. Reference Vehicles
2.2. Driving Cycle
- WLTC (Worldwide Harmonized Light-Duty Vehicles Test Cycle), class 3b, described in the WLTP (Worldwide Harmonized Light-Duty Vehicles Test Procedure) procedure [47];
- SFTP-US06, described in the “EPA Supplemental Federal Test Procedure” (SFTP) [48];
- FTP75 (EPA Federal Test Procedure) [49];
- HWFET (EPA Highway Fuel Economy Cycle);
- Japanese JC08 Emission Test Cycle [50], with a first additional phase equal to the phase corresponding to the last 172 s of the standard JC08 cycle itself;
- Artemis Urban, Rural Road, and Motorway (130) cycles [51].
2.3. Simulation Tool
2.4. Parameters of the Vehicle (And of Its Model) That Can Affect the Lightweighting Results
- Battery pack parameters (the nominal voltage, capacity, and internal resistance);
- Aerodynamic parameters;
- Transmission efficiency;
- Rolling resistance, in particular changing the rolling friction coefficient;
- Moments of inertia of the electric motor, of the rotating parts of the transmission, and of the wheels;
- Total transmission ratio (including the wheel ratio given by the wheel radius).
2.5. Set of Simulations
- Battery pack parameters (the nominal voltage, capacity, and internal resistance);
- Aerodynamics;
- Transmission efficiency;
- Rolling friction coefficient;
- Moments of inertia (of the motor, transmission, and wheels);
- All the previous parameters simultaneously;
- Motor reduction ratio, transmission ratio, and wheel radii;
- All of the above parameters simultaneously.
3. Results
3.1. Consumption Analysis
3.2. Polynomial Interpolation and ERV Index
3.3. Comparison Between the Reference Real-World Driving Cycle and Standard Cycles
4. Discussion
5. Conclusions
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
Nomenclature
Abbreviation | Description |
Af | Frontal area of the vehicle |
, , , | Coefficients of the polynomial |
Cx | Longitudinal aerodynamic coefficient (drag) |
DEM | Digital Elevation Model |
EPA | U.S. Environmental Protection Agency |
ERV | Energy Reduction Value |
EV | Electric vehicle |
FRV | Fuel Reduction Value |
FTP75 | Standard driving cycle (FTP75) described in the EPA Federal Test Procedure (FTP) |
GPS | Global Position System |
HWFET | EPA Highway Fuel Economy Cycle |
JC08 | Japanese Emission Test Cycle |
SFTP | EPA Supplemental Federal Test Procedure |
SFTP-US06 | Standard driving cycle (US06) described in the EPA Supplemental Federal Test Procedure (SFTP) |
TEST | Target-speed EV Simulation Tool |
WLTC | Worldwide Harmonized Light-Duty Vehicles Test Cycle |
WLTP | Worldwide Harmonized Light-Duty Vehicles Test Procedure |
Vehicle weight (expressed in 100 kg) | |
Polynomial interpolation function, energy consumption expressed in kWh/(100 km) |
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Analyzed Parameters | Compact Car Value | N1 Value |
---|---|---|
Transmission efficiency | 1 | 0.9409 |
Af ∙ Cx * | 1.034 m2 | 2.1 m2 |
Vertical aerodynamic coefficient | −0.026 m2 | 0 |
Rolling friction coefficient | 0.01 | 0.015 |
Total gear ratio | 9.6 | 6.22 |
Front wheel radius | 0.2987 m | 0.35 m |
Rear wheel radius | 0.3005 m | 0.35 m |
Moment of inertia of each wheel | 0.882 kg m2 | 1.09 kg m2 |
Moment of inertia of the motor | 0.02 kg m2 | 0.086 kg m2 |
Moment of inertia of the transmission | 0.0001 kg m2 | 0.01 kg m2 |
Battery capacity | 42 kWh (105 Ah) | 120 Ah |
Number of battery cells in series | 96 | 108 |
Number of battery cells in parallel | 2 | 1 |
Nominal battery pack voltage | 400.0 V | 356.1 V |
Internal resistance of the battery pack | 0.086 Ω | 0.097 Ω |
Driving Cycle | Maximum Speed [km/h] | Average Speed [km/h] | Maximum Acceleration [m/s2] | Idling Time [%] |
---|---|---|---|---|
Reference real driving cycle | 100.5 | 36.1 | 1.9 * | 6.7 |
WLTC—Class 3b | 76.6 | 27.7 | 1.7 | 13.1 |
US06 | 80.3 | 77.3 | 2.3 | 7.5 |
FTP75 | 91.2 | 12.2 | 1.5 | 19.1 |
HWFET | 96.4 | 77.7 | 1.4 | 0.8 |
JC08 | 81.6 | 27.0 | 1.7 | 27.1 |
Artemis—Urban Cycle | 57.7 | 17.7 | 2.9 | 28.4 |
Artemis—Rural Road Cycle | 111.5 | 57.5 | 2.4 | 3.0 |
Artemis—Motorway Cycle (130) | 131.8 | 96.9 | 1.9 | 1.5 |
Vehicle Model | Model Description | ||
---|---|---|---|
N1 | N1 model | 1.368 | 15.592 |
N1— NO inertias | N1 model without inertia contributions | 1.365 | 15.201 |
CompactCar | Compact car model | 1.141 | 9.782 |
CompactCar— NO inertias | Compact car model without inertia contributions | 1.141 | 9.406 |
CompactCar— N1 battery pack | Compact car model with the N1 battery pack on board | 1.172 | 9.633 |
CompactCar— N1 aerodynamics | Compact car model with the aerodynamic coefficients of the N1 vehicle | 1.109 | 15.149 |
CompactCar— N1 transmission efficiency | Compact car model with the transmission efficiency equal to that of the N1 vehicle | 1.211 | 10.110 |
CompactCar— N1 rolling resistance | Compact car model with the rolling resistance coefficient equal to that of the N1 vehicle | 1.250 | 9.875 |
CompactCar— N1 values | Compact car model compact car with all the above-mentioned parameters equal to those of the N1 vehicle | 1.339 | 15.862 |
CompactCar— N1 inertias | Compact car model with the same moments of inertia as vehicle N1 | 1.141 | 10.345 |
CompactCar— N1 values (also inertia) | Compact car model compact car with all the above-mentioned parameters (also moments of inertia) equal to those of the N1 vehicle | 1.342 | 16.385 |
CompactCar— N1 traction ratios | Compact car model with the transmission ratios and wheel radii of the N1 vehicle | 1.119 | 9.832 |
CompactCar— N1 inertias and traction ratios | Compact car model with the moments of inertia, the transmission ratios and wheel radii of the N1 vehicle | 1.118 | 10.031 |
CompactCar— N1 values (all) | Compact car model compact car with all the above-mentioned parameters equal to those of the N1 vehicle, including the moments of inertia, traction ratios, and wheel radii | 1.303 | 16.209 |
Driving Cycle | ||
---|---|---|
Reference real driving cycle | 1.368 | 15.592 |
WLTC—Class 3b | 0.852 | 25.995 |
US06 | 1.077 | 34.562 |
FTP75 | 0.946 | 15.229 |
HWFET | 0.630 | 24.647 |
JC08 | 0.944 | 15.362 |
Artemis—Urban Cycle | 1.426 | 13.082 |
Artemis—Rural Road Cycle | 0.929 | 18.344 |
Artemis—Motorway Cycle (130) | 0.835 | 44.654 |
Driving Cycle | ||
---|---|---|
Reference real driving cycle | 1.141 | 9.782 |
WLTC—Class 3b | 0.654 | 13.488 |
US06 | 0.809 | 16.549 |
FTP75 | 0.746 | 9.742 |
HWFET | 0.426 | 12.370 |
JC08 | 0.754 | 10.114 |
Artemis—Urban Cycle | 1.203 | 11.528 |
Artemis—Rural Road Cycle | 0.723 | 9.709 |
Artemis—Motorway Cycle (130) | 0.482 | 21.253 |
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Sandrini, G.; Chindamo, D.; Gadola, M.; Candela, A.; Magri, P. Exploring the Impact of Vehicle Lightweighting in Terms of Energy Consumption: Analysis and Simulation on Real Driving Cycle. Energies 2024, 17, 6398. https://doi.org/10.3390/en17246398
Sandrini G, Chindamo D, Gadola M, Candela A, Magri P. Exploring the Impact of Vehicle Lightweighting in Terms of Energy Consumption: Analysis and Simulation on Real Driving Cycle. Energies. 2024; 17(24):6398. https://doi.org/10.3390/en17246398
Chicago/Turabian StyleSandrini, Giulia, Daniel Chindamo, Marco Gadola, Andrea Candela, and Paolo Magri. 2024. "Exploring the Impact of Vehicle Lightweighting in Terms of Energy Consumption: Analysis and Simulation on Real Driving Cycle" Energies 17, no. 24: 6398. https://doi.org/10.3390/en17246398
APA StyleSandrini, G., Chindamo, D., Gadola, M., Candela, A., & Magri, P. (2024). Exploring the Impact of Vehicle Lightweighting in Terms of Energy Consumption: Analysis and Simulation on Real Driving Cycle. Energies, 17(24), 6398. https://doi.org/10.3390/en17246398