The Challenge
Clemson University’s Advanced Powertrain Testing Laboratory (APTL) faced a critical need to significantly expand its research capabilities, particularly in the areas of efficient and clean engine concepts, alternative fuels, hybrid electric powertrains, and EV powertrain systems. Their existing facilities were insufficient for the rigorous R&D test of a diverse range of fuels, including gasoline, natural gas, medium-sized diesel, and electric powertrains, and medium-sized engines. This expansion was essential to support a growing body of graduate and PhD students, faculty, and commercial research partners, all vital for advancing Clemson University’s ambitious vision of becoming a global leader in automotive research and education, focusing on advanced powertrain solutions, including robust hybrid system development.
The Solution
ACS was engaged as Construction Manager at Risk (CM-R) to spearhead the expansion, providing a comprehensive solution that included the construction of two state-of-the-art EV powertrain design R&D test cells. This extensive project involved a two-story, 3,000-square-foot addition and renovation, specifically designed to enhance the laboratory’s capacity for advanced engine and alternative fuel research and to perform crucial R&D test activities. ACS’ involvement began with crucial preconstruction services, encompassing detailed constructability reviews, accurate construction estimates, and meticulous scheduling, all while actively participating in design reviews to optimize the project for advanced powertrain solutions, including those for hybrid and electric vehicles.
During the construction phase, ACS seamlessly managed subcontractor selection, bidding, and contracts while maintaining strict control over schedules and costs. We meticulously handled the installation, integration, and commissioning of all specialized test equipment crucial for EV powertrain design. This included significant upgrades to plant utilities like electrical power, natural gas, chilled water, heating hot water, compressed air, and sophisticated multi-fuel delivery systems. As a result, the facility is now fully equipped to support cutting-edge research across the entire spectrum of powertrain technologies and facilitate every R&D test.
The laboratory’s new capabilities include experimental investigations of efficient and clean engine concepts, alternative fuels, hybrid electric powertrains, and EV powertrain systems. It features a double-shaft 600KW regenerative AC-dynamometer, robust data acquisition, precise fuel balance measurement, FTIR emissions measurement, and an E-storage PDU emulator. Essential support infrastructure, such as a jacket water cooling system, oil cooler, isolated bed plate (21’-4” X 8’-3”), dedicated fuel farm, and a cooling tower, all bolster critical R&D test procedures and the development of future advanced powertrain solutions and EV powertrain design, with a strong emphasis on hybrid system validation.
The Outcome
The project successfully transformed Clemson University’s APTL, substantially enhancing its research capabilities for efficient and clean engine concepts, alternative fuels, and advanced powertrain solutions, including both hybrid electric and EV powertrain design. The newly constructed facility now offers unique flexibility for in-depth research and comprehensive powertrain systems integration, serving as an indispensable resource for graduate and PhD students, faculty, and commercial research partners. This strategic expansion firmly propels Clemson University closer to its goal of being the premier automotive research, innovation, and educational enterprise in the world.
Key Features
- Construction and renovation of engine and fuels research space within an active campus setting
- Two test cells for research of hybrid gasoline, natural gas, medium-size diesel, and electric powertrains
- Upgraded plant utilities systems, including electrical service, central chilled water, and clean agent fire suppression
- Advanced test equipment, including a 600KW regenerative AC-dynamometer, data acquisition, and emissions measurement
- Comprehensive test equipment support systems, such as a jacket water cooling system, oil cooler, and fuel farm
ACS Services
- Preconstruction services including consulting, project estimating, procurement strategies, and schedule control
- Construction phase services including the selection and coordination of subcontractors, construction schedule management and cost control, and test equipment installation, integration
- Commissioning services
