Joseph P. Cunningham

Evaluation of the 2010 Toyota Prius Hybrid Synergy Drive System

Subsystems of the 2010 Toyota Prius hybrid electric vehicle (HEV) were studied and tested as part of an intensive benchmarking effort carried out to produce detailed information concerning the current state of nondomestic alternative vehicle technologies. Feedback provided by benchmarking efforts is particularly useful to partners of the Vehicle Technologies collaborative research program as it is essential in establishing reasonable yet challenging programmatic goals which facilitate development of competitive technologies. The competitive nature set forth by the Vehicle Technologies Program (VTP) not only promotes energy independence and economic stability, it also advocates the advancement of alternative vehicle technologies in an overall global perspective. These technologies greatly facilitate the potential to reduce dependency on depleting natural resources and mitigate harmful impacts of transportation upon the environment.

Evaluation of the 2007 Toyota Camry Hybrid Synergy Drive System

The U.S. Department of Energy (DOE) and American automotive manufacturers General Motors, Ford, and DaimlerChrysler began a five-year, cost-shared partnership in 1993. Currently, hybrid electric vehicle (HEV) research and development is conducted by DOE through its FreedomCAR and Vehicle Technologies (FCVT) program. The mission of the FCVT program is to develop more energy efficient and environmentally friendly highway transportation technologies. Program activities include research, development, demonstration, testing, technology validation, and technology transfer. These activities are aimed at developing technologies that can be domestically produced in a clean and cost-competitive manner. Under the FCVT program, support is provided through a three-phase approach [1] which is intended to: • Identify overall propulsion and vehicle-related needs by analyzing programmatic goals and reviewing industry’s recommendations and requirements, then develop the appropriate technical targets for systems, subsystems, and component research and development activities; • Develop and validate individual subsystems and components, including electric motors, emission control devices, battery systems, power electronics, accessories, and devices to reduce parasitic losses; and • Determine how well the components and subassemblies work together in a vehicle environment or as a complete propulsion system and whether the efficiency and performance targets at the vehicle level have been achieved. The research performed in this area will help remove technical and cost barriers to enable technology for use in such advanced vehicles as hybrid electric, plug-in hybrid electric, electric, and fuel-cell-powered vehicles.

Evaluation of the 2008 Lexus LS 600H Hybrid Synergy Drive System

Subsystems of the 2008 Lexus 600h hybrid electric vehicle (HEV) were studied and tested as part of an intensive benchmarking effort carried out to produce detailed information concerning the current state of nondomestic alternative vehicle technologies. Feedback provided by benchmarking efforts is particularly useful to partners of the Vehicle Technologies collaborative research program as it is essential in establishing reasonable yet challenging programmatic goals which facilitate development of competitive technologies. The competitive nature set forth by the Vehicle Technologies program not only promotes energy independence and economic stability, it also advocates the advancement of alternative vehicle technologies in an overall global perspective. These technologies greatly facilitate the potential to reduce dependency on depleting natural resources and mitigate harmful impacts of transportation upon the environment.

A Reduced-Part, Triple-Voltage DC-DC Converter for Electric Vehicle Power Management

Electrical power systems in future hybrid and fuel cell vehicles may consist of three voltage nets; 14 V, 42 V and high voltage (>200 V) buses. A soft-switched, bi-directional dc-dc converter using only four switches was proposed for interconnecting the three nets. This paper presents a reduced- part dc-dc converter, which decreases the converter cost while retaining all the favorable features of the original topology. Simulation and experimental data are included to verify a simple power flow control scheme.

Hybrid optics for the visible produced by bulk casting of sol-gel glass using diamond-turned molds

Recent combinations of diffractive and refractive functions in the same optical component allow designers additional opportunities to make systems more compact and enhance performance. This paper describes a research program for fabricating hybrid refractive/diffractive components from diamond-turned molds using the bulk casting of sol-gel silica glass. We use the complementary dispersive nature of refractive and diffractive optics to render two-color correction in a single hybrid optical element. Since diamond turning has matured as a deterministic manufacturing technology, techniques previoulsy suitable only in the infrared are now being applied to components used at visible wavelengths. Thus, the marriage of diamond turning and sol-gel processes offers a cost-effective method for producing highly customized and specialized optical components in high quality silica glass. With the sol-gel casting method of replication, diamond-turned mold costs can be shared over many pieces. Diamond turning takes advantage of all of the available degrees of freedom in a single hybrid optical element: aspheric surface to elimiate spherical aberration, kinoform surface for control of primary chromatic aberration, and the flexibility to place the kinoform on nonplanar surfaces for maximum design flexibility. We will discuss the critical issues involved in designing the hybrid element, single point diamond-turning the mold, and fabrication in glass using the sol-gel process.

Evaluation and Characterization of Magnets and Capacitors

Advanced vehicle, fuel cell, hybrid electric vehicle (HEV), and plug in hybrid research and development is conducted by the U.S. Department of Energy (DOE) through its FreedomCAR and Vehicle Technologies (FCVT) program. The mission of this program is to develop more energy efficient and environmentally safe highway transportation technologies. Program activities include research, development, testing, technology validation, and technology transfer. These activities are done at the system and component levels. This report will discuss component level testing of prototype capacitors and magnets. As capacitor and magnet technologies mature, it is important to ascertain the limitations of these new technologies by subjecting the components to standardized tests to evaluate their capabilities. Test results will assist in the determination of their ability to provide improvements in power electronics and motor designs to meet the FCVT goals.

Design, fabrication, and testing of micro-optical sensors containing multiple aspheres

The micro-sensor field is presently proliferating with designs and approaches. We have developed a micro-spectrometer for sensing applications containing five precision surfaces, including two off-axis aspheres. The entire monolith is less than six cubic centimeters in volume. This particular design contains a bandwidth of about 2 micrometers which is centered at 980 nm. Once an appropriate starting substrate was produced, the entire system was diamond turned to maintain the required surface figure, inter-surface spacing, and surface tilts. Only three diamond turned fixtures were needed to produce the monolith. The results proved to be more than adequate for many sensing applications. Slightly altered designs could easily be produced containing different bandwidths and resolutions as needed by the customer. Due to the spectrum of interest and the fabrication method, PMMA was the material chosen for this sensor. Other designs configurations incorporating BK7 and sapphire are presently being studied.