electric vehicle update - raindrop laboratories · 2013-08-04 · –trips: charging station...
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Electric Vehicle Update
Gary Graunke
Oregon Electric Vehicle Association
July, 2013
Agenda
• Electric vehicle benefits
• Costs vs gasoline vehicles
• Available manufactured EV’s
• Charging infrastructure update
– Battery swap technology
• Driving, charging, maintenance
• Electricity vs other alternative fuels
• Conclusion: a question of time and money
Benefits of Electric Vehicles• National security: electric power from
diverse, local sources
– 15% of US defense budget
just for Straights of Hormuz
• Economy: cost-effective EVs fueled locally
– Oil money leaves our economy
• United States: $1 Billion per day
• Oregon: $6-7 Billion per year
– $25000 Leaf saves $13000 in lifetime fuel
• Tires and wiper blade maintenance
• Fun to drive, home charging convenience
$$$
More EV Benefits
• Sustainability: electricity prices are stable
– Estimated life of our sun is 5.5 billion years
• Better grid utilization, stability
– Vehicles charge off-peak now
– Future potential to provide storage
for intermittent renewables
• Environment: EVs are cleaner
– Pollution reduction saves health care costs
– Reduce greenhouses gases affecting climate
Solar year house and EV’s
PV generated 5479 KWH
$406.48 electricity cost TOU
$121.20 base charge (grid
rental—a big battery)
non-TOU cost: $77.26 more
Time Direct Gen Used
OnPeak 435 771 796
MidPeak 1239 2196 1405
OffPeak 302 536 5067
PGE gained $25.76: peak KWH
traded for off-peak KWH
PV investment: $7000 returned
$709.68 electricity: 10% less
3.3% deprecition = 6.6% tax
free
risk: full faith and credit of sun
Nissan Leaf S Savings vs Versa
-10000
0
10000
20000
30000
40000
50000
60000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
6000
9000
12000
15000
Assumes 60 month loan, 8.5% gas inflation, 2% electric, replace
battery after 8 years, maintenance included
Spreadsheet available—provide your own data, assumptions
Cummulative savings for various annual miles driven
Lease price of $200/month is also available—less than many folks pay for gas
USDOE says $1.18 / gal equivalent vs $3.49 nationally:
http://energy.gov/articles/egallon-how-much-cheaper-it-drive-electricity
US-available 2013 Battery Electric Vehicles
Make / Model Description Range
Price
(USD)
Image
FordFocus Electric
The Focus Electric is based on Ford's next
generation Focus body. The vehicle is powered
by 23 kWh of Li-ion batteries with active liquid
cooling. J1772 charging only.
76 mi $39,20
0
Mitsubishi'i'
The Mitsubishi i is one of the most efficient
passenger vehicles in North America, rated at
112 MPGe. The 'i' is powered by a 47kW AC
synchronous motor and a 16-kWh Li-ion battery
pack... ChaDeMo DCQC available.
62 mi $29,12
5
NissanLEAF
The Nissan LEAF is a 5-seater, 4-door hatchback
based on Versa/Tida platform. The LEAF has an
80kW electric motor... ChaDeMo DCQC
available.
75 mi $28,80
0
SmartEV
An OEM conversion of the Smart Fortwo. Smart
began life as Swatch car in 1998, and was first
converted into EV form in 2006. The Smart ED
will have 16.5kWh of Li-ion batteries... J1772
charging only.
63 mi TBA
Tesla Motors
Model S
The Model S is a new ground-up 4-door,
7-seat sedan built by California EV
startup Tesla Motors. It's range will be
based on battery options of 230 mi and
300 mi. J1772, NEMA 240V/120V, and
Tesla Supercharger charging. 90 second
battery swap demonstrated.
300
mi $57,400
THINK
City
Two seater City car with 180km range
(based on MES DEA Zebra battery, US
model will use EnerDel LiFEPO4 batteries).
Body is ABS recycled plastic, steel...
111
mi
Was
$35,495
Toyota
2nd Gen.
RAV4 EV
The second generation Toyota RAV4 EV is
the result of the Toyota and Tesla Motors
collaboration. Based on the popular RAV4
compact SUV and powered by a Tesla
electric powertrain...
100
mi $49,800
Chevy Spark
EV
The 2014 Spark EV features a lithium-ion
battery , includes regenerative braking, offers
liquid thermal conditioning. SAE DC quick
charing is an option. Sold only in California and
Oregon.
82 mi
$19,185
Speed is (mostly) air speed (increase ground speed for headwinds, decrease for tailwinds)
Decrease in efficiency due to air speed applies to all vehicles regardless of fuel
Rule of thumb for elevation gain: 1000 ft gain = 5 miles of range
Level 2 (SAE
J1772)
adapter
240V 7.2 KW
22 miles/hour
Charging
Infrastructure
UpdateFully Operational
I5: Portland to Ashland
Coast: Astoria to Newport
Columbia River: Astoria to
the Dalles
Central OR: Sisters,
Redmond
TBD (as of 7/2013)
Madras, Warm Springs, Govt
Camp, Coos Bay, Mill City,
Marion Forks, Elkton, Aurora
Future: Tesla demonstrated
model S battery swap in 90 sec
Plugshare
Map of
NW
June
2013
Tesla Superchargers July 2013
Tesla 2 Year Plan
EV Maintenance• Tires, wiper blades same as gas car
• As car ages: suspension, seat covers
• No drive train maintenance
• Cooling system much lower temperature
• Battery maintenance automated
– Annual checkup for battery management system or (if
none) cell balancing (cost: $20)
• Vehicle is very durable
– Buy new battery instead of new vehicle/engine
– Thermal management optimizes life (Tesla, GM
Spark EV)
PV + EV is Sun-to-Wheels Champ
• PV/EV sun-to-wheels efficiency ~16%– PV cells 20% efficient sun-to-electricity
– EV >80% efficient electricity-to-wheels
• Bio-fuels sun-to-wheels efficiency <1%– Alcohol sun-to-fuel is 1-2% in practice
• Heat engine <20% fuel-to-wheels
– May require other resources (H2O, land)
– Bio-fuels still useful for PHEV long trips
• Fossil fuel sun-to-wheels efficiency 0%– Sun to fuel 10-10%, fuel to wheels <20%
– But utility generation + EV is more efficient than mobile heat engine with any fuel
• Example: >2X better for natural gas
3 KW of PV on an Oregon garage (12 KWH) is good for 36 to 72 miles/day
It’s Your Oregon
Carbon Footprint of Alternative Fuels
Fuel
Oregon
Carbon
Intensity*
(gCO2e/MJ)
Gasoline 92.34
Ultra Low Sulfur Diesel 91.53
Compressed Natural Gas (CNG) 70.22
Ethanol (Corn) 64.82
Electricity 37.80
Biodiesel (Midwest Soybeans) 19.99
Cellulosic Ethanol (NW Farmed
Trees) 15.54
Biodiesel (Yellow Grease) 10.28* Without indirect effects
Investing, Divesting• Live better, live sustainably—start now!
– Current fossil fuel reserves will create 2795 giga-
tons of CO2 if burned
– But only 565 giga-tons will create thermal runaway
with probability 0.2 (worse than Russian roulette)
• 2° C temp rise (industrial revolution to now: 0.8°C)
• About 14 years at present rate of increase in consumption
• The car you buy today determines your impact
for the life of the vehicle
• Coupling electric vehicles with sustainable
generation saves money, better vehicle
performance with comfort and convenience
Converting a Vehicle
(addendum to main talk)
Potential EV Safety Issues
• Professional vehicles
– Discharge, remove battery after damaging crash to
avoid slow heat buildup and fire
• Home conversions
– High voltage electrocutes
• Service disconnects reduce to <60V segments
– High current welds
– Short circuit may cause plasma fire
• Use contactors, DC-rated fuses, heater relays
– Loose connections cause heat—fires
– Use safe chemistries—LiFePO, LiMn, not LiCo
EV Myths
Long Tailpipe Myth: Pollution is worse for electric utility
than gas car
Fact: To do better than the grid your car would have
to get 75 mpg in Pacific NW
Fact: Cars get worse with age; EV’s get better as we
clean up the grid / use more renewables
Myth: EV’s are tiny cars unsuitable for most people’s needs
Fact: Any vehicle may be converted (e.g., Humvee)
Fact: VIA motors is building class 6, 7 trucks as
Plug-in Hybrids, Alt-E is converting Ford
F150/250/350s
More myths???
EV Driving Experiences• Limited range may require more planning
– Leaf battery sufficient for 2 hrs local driving
– Trips: charging station locations, charging power
• Charging stations may be unavailable
• GPS is your friend
– no energy to get lost / extra time to charge
• Bad weather (rain, headwinds) may require
significantly more (40%) energy
• Going slower stretches your range
Air Speed 35 45 55 65
Leaf Range 125 100 75 60
Gas Vehicle Conversions
• Select efficient vehicle, right size motor,
motor controller, battery charger
• Design adaptor plate, coupler shaft
– Check strength of motor mounts, drive train
• Accelerator speed control
• Power brake vacuum pumps
• Cooling for motor, controller, batteries
• Battery management or monitoring
Proper Tools for Safety
• Certified lineman gloves
to 1000V
• Fiberglass shaft
screwdrivers / nutdrivers
• Rubber handle wrenches
• Electrical tape on metal
sockets and other
wrenches
• Certified and isolated test
equipment (meters and
scopes)
Selecting an Electric Vehicle
• Lightweight
• Lightweight
• Lightweight
• Aerodynamic
• Can hold weight of batteries
– Rule of thumb: 30% of final weight is batteries
• Room for batteries
Where Does the Energy Go?
• Acceleration (hills) force = mass*acceleration
• Heating up tires (rolling resistance) force = mass*velocity
• Pushing air out of the way (esp. v > 40 mi/hr) force = frontal area * coefficient of drag * velocity2
Looks smooth on
Top, but rough
underside
creates turbulence
Square back
creates vacuum
that sucks vehicle
back (needs tail)
Wheel wells catch
cross-wind
Minimize
frontal area
!!!
Ideal vehicle is light, raindrop-shaped
Theoretical Energy Calculations
• Rolling resistance (Fr) is proportional to weight and velocity
• Wind resistance (Ftd) is proportional to frontal area, coefficient of drag,
and velocity squared
• Fh is acceleration (also hill climbing: 1 mph/sec is about 5% incline)
• Insight with LiIon batteries: 2200 lbs, 28 KWH, area 20.5 sq ft, Cd 0.25
V incline Fr Ftd Fh Ftotal HP KW Range mi/kwh
10 0 12.78 1.62 0.00 14.40 0.41 0.31 661.11 32.61
20 0 13.94 5.79 0.00 19.73 1.13 0.84 482.57 23.80
30 0 15.10 12.57 0.00 27.67 2.37 1.77 343.97 16.97
40 0 16.26 21.98 0.00 38.24 4.37 3.26 248.90 12.28
50 0 17.42 34.01 0.00 51.44 7.35 5.48 185.07 9.13
60 0 18.59 48.66 0.00 67.25 11.52 8.59 141.55 6.98
30 0 15.10 12.57 0.00 27.67 2.37 1.77 343.97 16.97
30 3 15.09 12.57 65.97 93.64 8.02 5.98 101.66 5.01
30 6 15.07 12.57 131.76 159.41 13.66 10.19 59.71 2.95
30 9 15.04 12.57 197.20 224.82 19.26 14.36 42.34 2.09
30 12 14.99 12.57 262.12 289.69 24.82 18.51 32.86 1.62
30 15 14.93 12.57 326.35 353.86 30.32 22.61 26.90 1.33
Electric Motor Torque and Power
Torque and mechanical power vs. rotation speed
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Shaft rotation speed, RPM
To
rqu
e (
ft/l
bs)
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
Mech
an
ical
po
wer
(K
W)
Max torque Rated torque Max power Rated power
Siemens 5105WS12 at 312 Volts
Insight torque 79 ft lbs at 1500 RPM Insight power 54.4 KW at 5700 RPM
Transmission
• EV’s have adequate torque at low RPM
• AC motors can go as high as 14,000 RPM
• Result: some EV’s don’t need gears, clutch
– Direct drive is common--saves weight
– Slower motor RPM is slightly more efficient
mph 40 50 60 65 70 80 90 100 110 120 130
3.461 1st 6923 8654 10385 11250 12116 13846 15577 17308 19039 20769 22500
1.750 2nd 3501 4376 5251 5688 6126 7001 7876 8751 9627 10502 11377
1.096 3rd 2192 2740 3289 3563 3837 4385 4933 5481 6029 6577 7125
0.857 4th 1714 2143 2571 2786 3000 3429 3857 4286 4714 5143 5571
0.710 5th 1420 1775 2130 2308 2485 2840 3196 3551 3906 4261 4616
Motor RPM
Adaptor Plate Design
Shaft Coupler Design
Adaptor Plate and Coupler
Shaft Coupler
Mount, Hanger, Motor, Adaptor
Plate
Mounting Motor Controller
Accelerator Pot Box
Power Brake Vacuum Pump
Cooling Motor and Inverter
Note: reversed inverter hose connections were fixed later
Questions?
Thank you!
Oregon Electric Vehicle Association www.oeva.org
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