1. Hybrid-Electric HMMWV: Platform for Advanced Lead Acid Battery Testing Future Work Dr. Herb Hess Adapt the thermal management system to the advanced lead acid batteries Incorporate the battery monitoring system Test vehicle as portable generation device Develop battery monitoring and control Team Members Pictured From Left to Right: Linnea Anderson, Albert Whetstone, Daniel George Bryan Blakey, Chad Schierman, Matt Braley, Slade Klien, Matt Shaw Team Members Problem Definition This project focuses on converting a military HMMWV into a hybrid- electric vehicle. The HMMWV will serve as a test bed for the power-dense lead acid batteries that are being developed by Dr. Dean Edwards. We will concentrate on the design of the battery enclosure and thermal management system and make recommendations to future teams based on our results. Deliverables 1.Integrate the diesel generator for recharging the battery pack 2.Incorporate an electric propulsion system into the diesel HMMWV. 3.Design and build a battery enclosure 4.Implement a thermal management system to keep the temperature in the battery box between 80-120˚F. 5.Design and implement a data acquisition system that can be used to collect, display and store the temperature and voltage of the batteries during use. Faculty Advisor Add another propulsion unit and/ or a transmission to improve its performance Add 4 wheel drive capability Explore heating options for the thermal management design Integrate ground fault interruption system Data Acquisition Programmed using LabVIEW® Receives and displays 40 thermal readings Receives and displays 34 voltage readings Data retrieval via USB connection User Interface through a touch screen Research mode for data collection and display, see Fig4. Driver mode for normal operation, see Fig5. Versatile and reconfigurable system where interchangeable PXI cards can be purchased to expand the capabilities of the system.. Fig5: Driver Mode Fig4: Research Mode Electric Propulsion Unit Integration Battery Enclosure Design Implemented with National Instruments PXI based chassis system. 150kW electric propulsion system and motor in series configuration Calculated gear reduction ration for optimal performance 200 hp electric motor Used MatLAB® code developed by the Future Truck Team Top speed for good low end torque is 30 mph. Results are in Fig1. Design for mounting of gear reduction and electric motor can be found in Fig2. Fig1:Simulated Performance Thermal Management Fig2: Motor Mounting Design Located on the bed of the vehicle for easy maintenance Batteries are bolted to the frame and are surrounded with insulation Slides on tracks for access to recessed electric compartments. Fig3: Battery Enclosure Implemented with forced air system with three point flow control Baffling was added for uniform flow distribution Concentrated on the cooling system Implemented using the concepts presented in a design prepared by Aerovironrnent for a similar military vehicle, the J-TEV. Surrogate Batteries Foam Insulation Fans and Baffles Tracks Our Operation Point See Fig3 for our design Generator Charges the HMMWV while it is moving 550 hp diesel engine Volt/ Amp Alternator Controlled with a UQM control unit Started using a circuit designed and built by the team System Diagram