Abstract
Oak Ridge National Laboratory's Additive Manufacturing Integrated Energy (AMIE) demonstration project leverages rapid innovation through additive manufacturing to connect a natural-gas-powered hybrid electric vehicle to a highperformance building designed to produce, consume and store renewable energy. The AMIE demonstration project consists of a building and vehicle that were additively manufactured (3D-printed) using the laboratory's big area additive manufacturing (BAAM) capabilities and an integrated energy system with smart controls that connects the two via wireless power transfer. The printed utility vehicle features a hybrid electric powertrain with onboard power generation from a natural gas fueled auxiliary power unit (APU). The APU extends vehicle range through a series hybrid powertrain configuration that recharges the vehicle's lithium-ion energy storage system and acts as a mobile power generation system for the printed building. The development of the powertrain used for the printed range-extended electric vehicle was completed using a powertrain-in-the-loop development process and the vehicle prototype implementation was accelerated using BAAM. A flexible 3.2 kW solar photovoltaic system paired with electric vehicle batteries will provide renewable power generation and storage. Energy flows back and forth between the car and house using fast, efficient bidirectional wireless power transfer. The AMIE project marked the first demonstration of bidirectional level 2 charging through wireless power transfer. The accelerated creation and printing of the car and house will further demonstrate the program's function as an applied science tool to get products to market more quickly than what currently is possible with traditional manufacturing. This paper presents a case study that summarizes the efforts and technical details for using the printed research platforms. This paper explores the focuses on printing of the vehicle, powertrain integration, and possibilities for vehicles providing power to buildings in different scenarios. The ability for BAAM to accelerate the prototype development for the integrated energy system process is explored. Details of how this was successfully accomplished in 9 months with more than 20 industry partners are discussed.
| Original language | English |
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| Title of host publication | Emerging Technologies; Materials |
| Subtitle of host publication | Genetics to Structures; Safety Engineering and Risk Analysis |
| Publisher | American Society of Mechanical Engineers (ASME) |
| ISBN (Electronic) | 9780791850688 |
| DOIs | |
| State | Published - 2016 |
| Event | ASME 2016 International Mechanical Engineering Congress and Exposition, IMECE 2016 - Phoenix, United States Duration: Nov 11 2016 → Nov 17 2016 |
Publication series
| Name | ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE) |
|---|---|
| Volume | 14 |
Conference
| Conference | ASME 2016 International Mechanical Engineering Congress and Exposition, IMECE 2016 |
|---|---|
| Country/Territory | United States |
| City | Phoenix |
| Period | 11/11/16 → 11/17/16 |
Funding
The authors wish to thank the industry partners who made the success of this project possible: Alcoa/Kawneer; Cincinnati Incorporated; Clayton Homes; DowAksa; EPB of Chattanooga; General Electric; Hexagon Lincoln; IACMI-the Composites Institute; Johnson Controls; Knoxville Utilities Board; Liberty Utilities; Line-X; Mach Fuels; NanoPore; Skidmore, Owings & Merrill LLP; Spiers New Technologies; Techmer ES; Tru-Design; and University of Tennessee. The authors also thank these offices within the U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy: Building Technologies Office, Advanced Manufacturing Office, and the Vehicles Technologies Office. Lastly, the authors thank their numerous colleagues (>50 personnel) at Oak Ridge National Laboratory who worked on this project.