Natural Gas Engine with Variable Energy Adjustment: Difference between revisions

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==Opportunity==  
==Opportunity==  
[[File:HTS_Overrall System_Architecture_4.jpg|thumb |upright=1.5|alt=A system diagram of an aftermarket hybrid truck system.|Aftermarket EV/HEV System for Class 8 Trucks.]]
[[File:Arrow_Overrall_System_Architecture_4.jpg|thumb |upright=1.5|alt=A system diagram of a natural gas engine for stationary power generation.|Natural Gas Engine Control System for Stationary Power Generation]]


Develop an aftermarket Class 8 truck electric vehicle / hybrid electric vehicle system with [http://www.zeroemissionsystems.com/ Zero Emission Systems] to:
Develop the control system on a stationary natural gas engine for [http://www.arrowengine.com/en/ Arrow Engine Company]. The engine provides power generation in oil and gas exploration sites and must run on the fuel obtained directly from the field. The energy content of the fuel and the level of contaminants varies from site to site. The controls were required to automatically adjust to the variation of the fuel quality.
 
*Provide the electronic controls, control algorithm and system integration.  
 
*Operate in electric vehicle mode when in port to provide zero emissions while queuing.
 
*Operate in hybrid electric vehicle mode during normal operation to provide better fuel economy.
 
*Integrate the system on a vehicle to provide prototype demonstration of the benefits.
 
*Support vehicle performance testing.


==Solution==
==Solution==
New Eagle provided the vehicle integration module, the controller area network (CAN) relay box, HMI display and the vehicle integration module algorithm and software for an aftermarket EV/HEV system. We also provided extensive onsite vehicle support and system integration and verification.
New Eagle provided the engine control module, HMI display and the engine control algorithm and software for a natural gas engine for stationary power generation.


===Hardware===
===Hardware===
New Eagle selected the [http://www.neweagle.net/support/wiki/index.php?title=Controllers#112_Pin_5554_Engine_Control_Module ECM-5554-112-0904] calibratable electronic control module for the vehicle integration module (VIM) and the [http://www.neweagle.net/support/wiki/index.php?title=Controllers#Multiplexed_Power_Distribution_Module Multiplexed Power Distribution Module] (MPDM) for the CAN relay controller. The VIM interfaced with all of the components in the system through three independent CAN channels. In addition, the VIM read sensors such as pressure and steering position, and controled outputs such as the electric power steering input control and the various system relays. New Eagle used an electric vehicle test bench to test the CAN interfaces of the components prior to vehicle integration.
New Eagle selected the [] calibratable electronic control module for the engine control module (ECM). The ECM interfaced with all of the components in the system and adjusted the fuel and air mixture automatically.  
 
[[File:ZES_CAN_NETWORK.jpg|thumb |upright=1.5|alt=A CAN diagram of an aftermarket hybrid truck system.|CAN Diagram for Aftermarket Truck EV/HEV System]]


A [http://www.neweagle.net/support/wiki/index.php?title=CANvu#CANvu_350 CANvu 350] module was selected as the prototype display unit for the system. For future upgrades this display will be replaced by the more powerful and more cost effective [http://www.neweagle.net/support/wiki/index.php?title=VeeCAN_320_Display VeeCAN 320] display.
A [http://www.neweagle.net/support/wiki/index.php?title=CANvu#CANvu_350 CANvu 350] module was selected as for the HMI display unit for the system. For future upgrades this display will be replaced by the more powerful and more cost effective [http://www.neweagle.net/support/wiki/index.php?title=VeeCAN_320_Display VeeCAN 320] display.


===Toolchain===
===Toolchain===
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===Control Algorithm===
===Control Algorithm===
New Eagle has extensive experience developing controls and algorithms for [http://www.neweagle.net/support/wiki/index.php?title=%28EV%29_Electric_and_%28HEV%29_Hybrid_Vehicles EV and HEV Systems]. The Matlab / Simulink controls libraries were implemented with modifications for the specific components in the ZES system. Using the proven control libraries allowed rapid deployment of the system while also increasing confidence by using verified software components.


==Results==
==Results==
With New Eagle's help, Zero Emissions Systems was able to [http://www.zeroemissionsystems.com/Video successfully demonstrate the operation of the EV/HEV system] on a vehicle. The system was shown to:
*Provide electric vehicle (EV) operation while in port for up to 2-3 hours and at speeds up to 20mph.
*Supply auxiliary systems for up to 10 hours through the electrical system.
*Run in hybrid electric vehicle mode through the PTO during normal operation.
*Improve fuel economy by up to 25%.
*Charge through the engine and regenerative braking.
*Provide high voltage operation from 403 volts to 550 volts.
*Implement a J1939 compatible CAN 2.0 link.
*Provide a 1-1½ year return on investment in fuel savings.


==Customer==
==Customer==
[http://www.arrowengine.com/en/ Arrow Engine Company]
[http://www.arrowengine.com/en/ Arrow Engine Company]

Revision as of 14:53, 11 July 2012

__NOTITLE__

Opportunity

A system diagram of a natural gas engine for stationary power generation.
Natural Gas Engine Control System for Stationary Power Generation

Develop the control system on a stationary natural gas engine for Arrow Engine Company. The engine provides power generation in oil and gas exploration sites and must run on the fuel obtained directly from the field. The energy content of the fuel and the level of contaminants varies from site to site. The controls were required to automatically adjust to the variation of the fuel quality.

Solution

New Eagle provided the engine control module, HMI display and the engine control algorithm and software for a natural gas engine for stationary power generation.

Hardware

New Eagle selected the [] calibratable electronic control module for the engine control module (ECM). The ECM interfaced with all of the components in the system and adjusted the fuel and air mixture automatically.

A CANvu 350 module was selected as for the HMI display unit for the system. For future upgrades this display will be replaced by the more powerful and more cost effective VeeCAN 320 display.

Toolchain

The MotoHawk and New Eagle toolchain was employed to acclerate development. Using the Matlab / Simulink environment, the team was able to unit test and integrate the model in the simulation environment in parallel to the mechanical hardware development. The early start on algorithm development saved several weeks off of the timeline. New Eagle also utilized the Network Toolbox to quickly implement the CAN messaging strategy.Many of the actuators and sensors had defined DBC files for the CAN control commands and output feedback. By using the Network Toolbox, the messaging strategy was quickly implemented allowing more time for the critical algorithm development.

Control Algorithm

Results

Customer

Arrow Engine Company