The University of Wisconsin-Madison Hybrid Vehicle Team designed a four-wheel drive, charge sustaining, split-parallel hybrid-electric crossover vehicle for entry into the ChallengeX competition. This multi-year project is built on a 2005 Chevrolet Equinox platform. Fuel economy results, greenhouse gas impact (GHGI), acceleration, component packaging, and consumer acceptability were appropriately weighted to establish Wisconsin’s vehicle technical specifications. Wisconsin’s Equinox, nicknamed the Moovada, is a split-parallel hybrid utilizing a General Motors 110 kW 1.9 L CIDI Diesel engine coupled to a GM F40 6-speed manual transmission. The rear axle is powered by a Ballard AC induction motor/gearbox powerlimited to 59 kW and powered by a 44-module (317 volts nominal) Johnson Controls nickel-metal hydride battery pack. The vehicle is fueled by B20 biodiesel, which has a lower GHGI impact than conventional diesel fuel. The engine control unit is a Motorola MPC555 based Powertrain Control Module (PCM) embedded controller with 38 inputs, 28 outputs and dual CAN bus capability, it has been specifically designed for automotive applications. Wisconsin is utilizing ANSI C language for code development and MotoTron development tools for programming the controller.

During the second year of the ChallengeX competition, the team integrated the powertrain into the stock Equinox. Year two focused on powertrain development and demonstration of the energy use and emissions goals of the competition. This was accomplished by finalizing the control strategy developed in the first year of the competition and physically mounting the powertrain components into the vehicle. The ChallengeX year two competition took place at the GM proving grounds in Mesa, AZ in June. Wisconsin took 2nd overall in points, highlighted with awards for the Dr. Donald Streit Sportsmanship Award, Best Engineering & Fabrication Workmanship Award, Outstanding Long-Term Faculty Advisor award, Best Technical Presentation, Best Vehicle Development Review, Best Acceleration, Most Improved Outreach Program, 3rd in Best Written Technical Reports, 1st place for Freescale Semiconductor: Silicon on the Move, and 3rd for Best realization of VTS.

During the third year of ChallengeX, the UW-Madison hybrid vehicle team concentrated on tuning and perfecting the design of Moovada. Aside from slightly reducing the battery voltage to 288 volts; the powertrain components remained the same for this phase of the competition. To reach a 99% buyoff in year three, the team is concentrated on perfecting and remaking the exhaust and catalyst system, they also refined the controls system and repackaged the batteries. Both the interior and exterior were modified to reflect a more “consumer acceptable” vehicle. Testing and calibration was also done to assure the occupants a smooth and flawless vehicle ride quality. In year three, team vehicles were judged extensively in categories such as towing capacity, and consumer acceptability. Teams were also required to give technical oral presentations and submit an SAE-style technical paper.  The ChallengeX year three competition took place at the GM proving grounds in Milford, MI in June; Wisconsin took second overall.

The fourth year of ChallengeX gave students the opportunity to further implement innovative technologies in their vehicles to help meet consumer demands for safety, security, entertainment, and convenience.  Wisconsin installed a Clarion entertainment package including new speakers and a GPS navigation system, as well as a rear backup camera and an infrared thermal imaging camera whichinterfaced with the Clarion system.  Wisconsin also further refined the exterior of the vehicle to improve its consumer acceptability.  The final year also allowed teams to focus on developing and implementing marketing plans for their vehicles to promote the goals of the ChallengeX program.  These marketing efforts culminated in a public relations road trip beginning at Raceway Park in New Jersey and ending in Washington D.C., with stops in New York and Baltimore en route for year four competition in May 2008.  Wisconsin earned second place overall in year four ChallengeX.

Source: Motor Authority