ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT DELIVERING PRODUCTIVITY THROUGH STRATEGIC CHOICE OF TEST ENVIRONMENT

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1 DELIVERING PRODUCTIVITY THROUGH STRATEGIC CHOICE OF TEST ENVIRONMENT Dr. Philip Lawson & Sulabh Dhingra 28 Jun 2018 AVL Product Development in Motion

2 Outline Why? What? How? Motivations Brief history of Powertrain Testing at JLR Increasing Productivity through Shift & Expand Key enablers to deliver Shift & Expand strategies Data Emissions Test Use Case

3 Background & Motivation Jaguar Land Rover Retail Sales Volumes by FY Jaguar E-Pace Jaguar F-Pace Land Rover Discovery Range Rover Velar

4 Background & Motivation Since 2011: Doubled internal Engine Test activity Tripled internal Chassis-Dyno Test activity 15x increase in outsourced test activity Internal capacity increase largely due to Testfield Efficiency Projects Testing Effectiveness Four Levers Holistic Powertrain Development & Test Productivity Optimisation at Jaguar Land Rover J. Houldcroft et. al. 5 th International Symposium on Development Methodology,

5 Background & Motivation SAE

6 As-is State Reduced Testing Efforts in Strategic Environment Testing Effort New Testing Effort ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Background & Motivation Testing Effectiveness Four Levers Reuse Data New Technologies Efficiency Gains Expanding Product Portfolio Effectiveness Shift & Expand

7 Shift and Expand Strategy 7

8 Key Enablers Adoption of Shift & Expand test methodologies requires significant investment in People Test Field Effectiveness Facility Process 8

9 Process Investment - Operational Readiness Customer Relationship Management 9

10 Process Investment Customer Relationship Management AVL Tech Centre Coventry AVL Graz 10

11 People Investment Importance of Training Team Growth & Development Team Size Ramp Skill Ramp Productive Facility Training Cell in Graz TCC in Coventry Project Timeline 11

12 Shift and Expand Use Case Study EMISSIONS TESTING ON A VEHICLE-IN-LOOP (VIL) TEST CELL 12

13 Chassis-Dyno to ViL Emission Test Comparison Fuel Type: CARCAL EU6 E10 Gasoline Engine Type: 3.0 V6 Supercharged Fuel Type: CARCAL EU6 Diesel Engine Type: 3.0 V6 Turbocharged

14 Preparation of Unit Under Test 14

15 Design of Experiment

16 Test Plan Overview Gasoline Diesel 101 CVS 104 modal 102 CVS 103 modal RCD Soak RCD Soak CD3 CVS RCD Soak RCD Soak CD3 CVS RCD = Rapid Cool Down WLTC x3 NEDC x3

17 CO2 (g/km) ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Diesel CO 2 Comparison 190 NEDC WLTC Rapid cool down 185 Soaked Chassis Dyno modal 103 modal Error bars represent 2σ

18 CO2 (g/km) ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Gasoline CO 2 Comparison 250 NEDC WLTC Rapid cool down 240 Soaked 230 Chassis Dyno modal 104 modal Error bars represent 2σ

19 Temp (ºC) Temp (ºC) ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Rapid Cool Down Issues T101 Gasoline Gearbox Temperature - NEDC Gbx_tTCMOil [deg C] Gearbox Temperature WLTC - WLTC Time (s) Rapid cool down time [s] Gbx_tTCMOil [deg C] Oil temperature - Driveline - Coolant Soaked Chassis Dyno Time (s) time [s]

20 Rapid Cool Down Issues T101 Gasoline Extended Correlation Activity - Fluid in RCD Unit reaches threshold and RCD switches off - Thermocouple data inside the vehicle is not checked

21 CO2 (g/km) Temp (ºC) ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Rapid Cool Down Issues T101 Gasoline Gearbox Temperature Gbx_tTCMOil [deg C] hour soak RCD + 2 hour RCD + 4 hour RCD + 6 hour RCD + 8 hour RCD + 12 hour 12 hour soak Time (s) time [s] Tests

22 Summary & Conclusions People Process Shift & Expand Level 4 Apprenticeship & development of Technician population Project process and common goal of operational status Migration of Test Use Cases via Shift & Expand delivers Efficiency benefits through increased effectiveness Established Technical Training Team Specialist training in the test field environment Up-skilling existing population Customer relationship management Process oriented culture with swim lane processes developed in advance of training and ramp-up A significant amount of effort (People, Process & Facility) is required to unlock the potential Successful demonstration of initial Use Cases has generated significant internal demand for additional applications While Technology changes can be bought in, it is essential to develop People and Teams 22

23 THANK YOU Dr. Philip Lawson Senior Manager Emissions Testing M +44(0) plawson1@jaguarlandrover.com Jaguar Land Rover W/1/26 Abbey Road, Whitley Coventry CV3 4LF, UK jaguarlandrover.com Sulabh Dhingra Lead Engineer Powertrain ViL/PiL Test & Methodology M +44(0) sdhingra@jaguarlandrover.com 23