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www.springerlink.com/content/1738-494x
DOI 10.1007/s12206-012-0413-8
An innovative experimental on-road testing method and its demonstration on a prototype vehicle
Jos C. Pscoa1,*, Francisco P. Brjo2, Fernando C. Santos1 and Paulo O. Fael1
1
Electromechanical Engineering Department, Faculty of Engineering, University of Beira Interior, Covilh, 6201-001, Portugal 2 Aerospace Sciences Department, Faculty of Engineering, University of Beira Interior, Covilh, 6201-001, Portugal (Manuscript Received July 2, 2011; Revised February 9, 2012; Accepted February 9, 2012)
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Abstract
Ground vehicle drag coefficient is herein obtained using an unconventional on-road test in real scale. At low-Re numbers, and as a function of velocity variations, transition introduces changes on the vehicles drag coefficient. Therefore, the drag coefficient must be obtained as a function of velocity. Traditionally, only an average drag coefficient value is usually obtained using the coast down method. To obtain the on-road, velocity dependent, drag coefficients we introduce a new approach. The aerodynamic resistance coefficient is obtained by towing the vehicle with and without an aerodynamic shield, in order to eliminate the rolling resistance component. A detailed description of the method, its associated techniques, and related errors is presented. We conclude that the present experimental procedure is needed when comparing the experimental drag coefficient against computational results, since numerical computations are usually performed in a velocity dependent framework. Further, the same on-road test procedure is herein used to obtain the rolling and aerodynamic drag coefficient for a prototype vehicle working in the transition regime.
Keywords: Ground vehicle; On-road test; Experimental method; Aerodynamics ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1. Introduction
Generally speaking, for high-performing cars weight reduction and engine efficiency are usually the two most important bottlenecks affecting fuel consumption, considered typically more important than aerodynamic drag reduction. However, a reduction in drag coefficient remains an important matter to tackle when designing these vehicles. Actually, aerodynamic resistance will certainly result on a measurable gain in performance, even if the drive cycle does not comprise highspeed roads. Another consideration, even more important, is that the designer must insure that the aerodynamic performance improvements are transposed to the road conditions and not only achieved on controlled wind tunnel conditions, or in computational fluid dynamics (CFD) simulations. The experimental, or numerical, modeling of the flow around ground vehicles is inherently complex, in particular due to boundary layer separation and ground effects [1]. This triggered the need to develop the means to obtain an accurate drag coefficient in ground vehicles [2]. Most often, aerodynamic flow optimization for ground vehicles is usually performed in a wind tunnel, but this approach
Corresponding author. Tel.: +351 275 329 763, Fax.: +351 275 329 972 E-mail address: pascoa@ubi.pt Recommended by Editor Yeon June Kang KSME & Springer 2012
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is associated to a series of similarity and dimensionality problems. Even if we can ensure that the wind tunnel provides controlled and repeatable conditions, it cannot mimic in full the road conditions. Even in the most realistic case, when using a moving floor wind tunnel, the boundary layer is not completely representative of road conditions. The moving belt floor must be synchronized with free stream, and boundary layer suction must be performed in front of the vehicle. This must be carefully matched, which is very difficult and can introduce difficulties in achieving good dynamic similarity conditions. Besides, the vehicle tires must be rotating in order for taking into account the energy losses due to their rotation. Additionally, blockage effects in full-scale tests for these bluff bodies also strongly affect the achievement of similarity conditions. Very often, experimental results obtained in diverse wind tunnels, for the same geometry and at the same Reynolds number, result in a scatter of aerodynamic coefficients by around 5% [3]. Albeit these deficiencies we can still resort to wind tunnel testing in order to improve the aerodynamics of ground vehicles. Considering that the resultant on-road drag coefficient will be slightly different from wind tunnel, but that the performance trends are correlated to the real conditions. This introduces us to the problem of obtaining the drag coefficient from road testing. Track tests are complex, time consuming and introduce problems of controlling the environmental conditions. For this kind of testing, coastdown is the
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for on-road testing of ground vehicles. We can apply Newtons second law to establish an equation governing ground vehicle dynamics. Let us consider that the traction force is equal to the sum of all resistive forces,
FT = FD (v) + M e dv + Mg sin . dt
(1)
Fig. 1. Graphical representation of the main dynamic forces acting on the vehicle as a function of velocity. Here the aerodynamic drag is a quadratic function. Rolling force comprises a constant, a linear, and a quadratic zone.
The slope of the track, sin , can behave as a resistive or traction effect depending upon the road slope. It can even be eliminated by choosing a flat road. The effective vehicle mass M e comprises the actual mass M and the inertia of the rotating components,
Me = M + I 4 w I gbG fd + . Rr2 Rr2
(2)
most popular technique for studying aerodynamic performance of ground vehicles. The procedure has been continuously improved and was normalized by SAE [4-6]. A basic drawback of the procedure is that it requires very low, or no wind, conditions. Meanwhile, a new procedure was established, this is named J2263, and it improves the classic method by introducing an on-board anemometer. Using this approach it is possible to obtain acceptable results in low to moderate wind conditions, by applying corrections based on the readings obtained from the on-board anemometer. In addition, the J2264 standard complements the J2263 by introducing a chassis dynamometer, to simulate the rolling resistance to be then coupled to a classical coastdown procedure. However, J2264 only applies to two-wheel drive vehicle operation, since it is only based on a single axle electric roll dynamometer.
The inertia includes the inertia of four tires I 4 w and also the inertia of the gearbox I gb , with the corresponding final drive gear ratio being G fd . This later is related to the drivetrain chain for the traction tires. We have also included the tire rolling radius as Rr . We can consider a flat road, were sin = 0 . Then, in order to determine FD (v) we have to find the other two terms in Eq. (1) or, alternatively, eliminate one of them and determine the other one. This is the approach used in the coast-down technique, in which FT is eliminated by making the traction force equal to zero. In the coast-down technique the drag is related to the time rate of change of linear momentum,
FD (v) = M e dv . dt
(3)
As an alternative, the drag can also be obtained if we consider a vehicle moving in a steady velocity, thus eliminating M e ( dv dt ) . We get as a result an ordinary algebraic equation FT = FD (v ) . This equation is in the origin of the new method proposed in the present paper. The coastdown test is usually performed by driving the ground vehicle above the maximum velocity, then the traction force is removed. The vehicle coasts freely until it reduces the velocity to a definite specified value, or until zero. By recording the velocity over time we are able to determine the drag characteristics. Since we already pointed out that the time rate of change of momentum is equal to resistive forces. The technique requires that several tests be undertaken for the same conditions, in order to achieve an adequate level of statistical confidence on the results. Diverse approaches have been used to implement the coastdown test, most of them differing in the way measurements are made and, in particular, on the type of variables that are acquired [9]. The coast-down test can be performed by measuring the acceleration, the velocity, or displacement of the vehicle over a certain time. We can use any of the three cinematic variables. The tests made by measuring acceleration have the advantage of reducing the
J. C. Pscoa et al. / Journal of Mechanical Science and Technology 26 (6) (2012) 1663~1670
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complexity of the analysis procedure, because the acceleration can be readily applied to the differential equation, by using Eq. (1). However, in practice, the low levels of acceleration obtained on a coast-down experiment introduce errors that significantly affect this approach. Another alternative is thus to record velocity, but this introduces the need to differentiate the experimental curve in order to obtain the acceleration over time. In this method the accuracy of the differentiation procedure must be carefully monitored, since this differentiation step is prone to errors. Alternatively, the coastdown method can be performed by measuring the run distance over time. However, in this case the noisy integration procedure must be repeated twice. After decades of experience, experimentalists concluded that the best performance could be obtained with a velocity over time characteristic curve. In this case, the experimental values of several runs are fitted to an adequate analytical function, which can then be differentiated to obtain the acceleration over time. Using the coast-down approach we end up with a function representing resistive drag, see Eq. (3). The drag function comprises the mechanical and aerodynamic drag,
FD (v ) = FM + FA .
Fig. 2. Values of rolling resistance coefficient, as a function of velocity, for typical commercial vehicle tires, adapted from Ref. [10].
(4)
A major problem related to this method is the need to define an adequate analytical function able to interpolate the experimental results, see Fig. 1. This is usually made by fitting a curve to the experimental results, whose general shape is,
mechanical drag FD (v) = A0 + A1v + aerodynamic drag