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U.S. Department of Energy -Advanced Vehicle Testing Activity
Hybrid Electric, Plug-in Hybrid Electric, and Hydrogen Internal Combustion Engine Testing Activities
Intermountain Conference on the Environment
Idaho State University, September 2007Jim Francfort
2
Presentation• INL and AVTA background, history and goal• Test methods• Testing Results
– Hybrid electric vehicles (HEVs) – Plug-in hybrid electric vehicles (PHEVs)– Hydrogen station and hydrogen internal
combustion engine (HICE) vehicles• Webpage address for this presentation and ~300 test
reports and fact sheets
3
Idaho National Laboratory• The INL is an Eastern Idaho
based U.S. Department of Energy (DOE) multi-program laboratory conducting research, development and demonstrations to help “ensure the nation’s energy with safe, competitive and sustainable energy systems…..”
• Managed for DOE by Battelle Energy Alliance
• 61 patent applications and 4 R&D 100 awards in 2006
• 890 square mile site with 3600 staff
Nuclear
Wind
Geothermal
Bio-mass
Hydropower
Fossil Energy
4
AVTA Background and Goal• The Advanced Vehicle Testing Activity (AVTA) is part
of the U.S. Department of Energy’s FreedomCAR and Vehicle Technologies Program
• The AVTA is primarily conducted by the Idaho National Laboratory (INL) and Electric Transportation Applications (ETA - Phoenix, AZ), with Argonne National Laboratory performing dynamometer testing
• AVTA Goal– Provide benchmark data to technology modelers,
research and development programs, and target setters
– Assist fleet managers in making informed vehicle purchase, deployment and operating decisions
5
AVTA Testing History• Plug-in hybrid electric vehicles
– 3 models tested, 4 more starting• Hybrid electric vehicles
– 12 models, 3 million test miles• Hydrogen ICE (internal combustion engine) vehicles
– 6 models, 400,000 test miles• Full-size electric vehicles
– 40 EV models, 5+ million test miles• Neighborhood electric vehicles
– 15 models, 200,000 test miles• Urban electric vehicles
– 3 models, 1 million test miles
6
Baseline Performance Testing • Initial closed track testing conducted near Phoenix, AZ
– Testing includes coastdown (determination of dynamometer coefficients), acceleration, top speed, charging, and durability tests
• Depending on vehicle technology, a two- to five-day dynamometer testing regime is used that includes:– Urban Dynamometer Driving Schedule (UDDS) and
Highway Fuel Economy Test (HWFET) primary dynamometer test cycles
– Charge depleting and sustaining test cycles– Includes air conditioning (AC) off and on cycles– Hot and cold starts for emissions testing– PHEV testing includes at least 26 drive cycle tests
7
Fleet and Accelerated Testing • Technology dependant
– PHEVs are onroad tested in defined 10-mile city and highway loops for 4,240 miles
– HEVs are tested for 160,000 miles and three years in high mileage fleets
– HICEs in tested in private and utility fleets (hydrogen infrastructure fueling limited)
8
Hybrid Electric Vehicle (HEV) Testing
9
HEV Baseline Performance Testing • 12 HEV models baseline performance tested to date
Baseline Performance MPG (J1634 With & W/O Air)
0
5
10
15
20
25
30
35
40
45
50
55
60
Insight Gen IPrius
Gen I Civic Gen IIPrius
Silverado Accord Escape Highlander RX400h Gen IICivic
Camry Vue Average
Mile
s pe
r Gal
lon
MPG SAE J1634 Air On MPG SAE J1634 Air Off
10
HEV Baseline Performance Testing • Percentage mpg decrease with air conditioning on
Percent MPG Difference (J1634 With & W/O Air)
-30%
-25%
-20%
-15%
-10%
-5%
0%
Insight Gen IPrius
Gen I Civic Gen IIPrius
Silverado Accord Escape Highlander RX400h Gen IICivic
Camry Vue Average
Perc
ent M
PG D
ecre
ase
11
HEV Accelerated Testing HEV Model Number Accelerated Tested Accelerated Testing Status
2001 Honda Insight 6 Completed
2002 Gen I Toyota Prius 6 Completed
2003 Gen I Honda Civic 4 Completed
2004 Chevrolet Silverado (2- & 4-WD) 2 Ongoing
2004 Gen II Toyota Prius 2 Completing
2005 Ford Escape (front & 4-WD) 2 Completing
2005 Honda Accord 2 Ongoing
2006 Lexus RX 400h (front & 2 AWD) 3 Ongoing
2006 Toyota Highlander (AWD) 2 Ongoing
2006 Gen II Honda Civic 2 Ongoing
200X GM 2-mode vehicles ? ?
2007 Saturn Vue 2 Ongoing
2007 Toyota Camry 2 Ongoing
200X Nissan Altima ? Obtaining
Total 35 to date
12
HEV Accelerated Testing• 2.9 million total accelerated testing miles
All HEVs - Miles Driven Monthly & Cumulative
0
250,000
500,000
750,000
1,000,000
1,250,000
1,500,000
1,750,000
2,000,000
2,250,000
2,500,000
2,750,000
3,000,000Au
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Mile
s
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
100,000
110,000
120,000
Mile
s
Monthly Mileage (right axis)
Cumulative Mileage (left axis)
13
HEV Accelerated Testing• Test miles per HEV model
Total HEV Fleet Test Miles
0
50,000
100,000
150,000
200,000
250,000
300,000
350,000
400,000
450,000
500,000
Civic Insight Gen I Prius Silverado Accord Gen IIPrius
Escape RX400h Highlander Camry Gen IICivic
Vue
Tota
l Tes
t Mile
s by
Mod
e
14
HEV Accelerated Testing• Miles per gallon by HEV model
HEV Fleet Testing MPG
37.6
45.2
41.0
17.8
28.3
44.2
27.3
24.0 24.8
33.2
40.1
29.0
0
5
10
15
20
25
30
35
40
45
50
Gen I Civic Insight Gen I Prius Silverado Accord Gen IIPrius
Escape RX400h Highlander Camry Gen IICivic
Vue
Mile
s pe
r Gal
lon
15
HEV Accelerated Testing• Monthly miles per gallon
HEV Monthly Miles per Gallon
15
20
25
30
35
40
45
50
55
Aug-
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p-01
Oct
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Accord Insight
Gen I Civic Gen I Prius
Gen II Prius Silverado
Escape RX400h
Highlander Camry
Gen II Civic Vue
16
HEV Accelerated Testing• AVTA accelerated testing and EPA miles per gallon
HEV Fleet Testing MPG
101214161820222426283032343638404244464850525456586062
Gen I Civic Insight Gen I Prius 4WDSilverado
2WDSilverado
AccordsGen II Prius 4WDEscape
2WDEscape
AWDRX400h
2WDRX400h
AWDHighlander
Camry Gen II Civic Vue
Mile
s pe
r Gal
lon
AVTA Fleet EPA New Combined EPA Old Combined
17
HEV Maintenance and Repairs Tracked
18
HEV Life-cycle Costs• Ownership, operating, and maintenance costs per mile
HEV Cost per Mile
$0.00
$0.10
$0.20
$0.30
$0.40
$0.50
$0.60
$0.70
$0.80
$0.9004
Priu
s 16
0k
04 P
rius
159.
9k
04 S
ilver
ado
88k
04 S
ilver
ado
85k
05 A
ccor
d 13
4k
05 A
ccor
d 13
8k
06 H
ighl
ande
r 124
k
06 H
ighl
ande
r 52k
05 E
scap
e 15
6k
05 E
scap
e 14
8k
06 R
X400
h 11
8k
06 R
X400
h 82
k
06 C
ivic
66k
06 C
ivic
81k
07 C
amry
82k
07 C
amry
50k
07 V
ue 5
4k
07 V
ue 1
2k
Wht
Ave
rage
Cos
t per
Mile
Maintenance Costs
Ownership Costs
Operating Costs
Operating costs = fuel, insurance & registration
19
Plug-in Hybrid Electric Vehicle (PHEV) Testing
• Can be a currently available HEV that has been converted to a PHEV by adding a second battery pack or using a larger replacement battery pack. Vehicle converters and OEMs are using both methods in series and parallel configurations
• Several OEMs have also announced future products • Different from HEVs in that PHEVs must be plugged
into the electric grid to charge, usually via a 110 volt, 15 amp circuit, the larger PHEV battery packs
PHEV Status and Brief Description
20
21
PHEV Baseline Performance Testing
22
EnergyCS Prius – UDDS Fuel Use• 9 kWh Valence lithium pack – A/C kWh
EnergyCS PHEV Prius MPG & kWh - UDDS Testing
0
1020
30
4050
60
7080
90
100110
120
130140
150
160170
180
7 15 22 30 37 45 52 60 67 75 82 90 97 105 112 120 127 135 142 150
Each Bar = 1 UDDS Test Cycle. Labeled by Cumulative Miles
MP
G
0
0.51
1.5
22.5
3
3.54
4.5
55.5
6
6.57
7.5
88.5
9
kWh
Drive Cycle MPG Cumulative AC kWh Cumulative MPG
23
EnergyCS Prius – HWFET Fuel Use• 9 kWh Valence lithium pack – A/C kWh
EnergyCS PHEV Prius MPG & kWh - HWFET Testing
0
1020
3040
50
6070
8090
100
110120
130
140150
160170
180
10 21 31 41 51 62 72 82 92 103 113 123 133 144 154
Each Bar = 1 HWFET Test Cycle. Labeled by Cumulative Miles
MPG
0
0.51
1.52
2.5
33.5
44.5
5
5.56
6.5
77.5
88.5
9
kWh
Drive Cycle MPG Cumulative AC kWh Cumulative MPG
24
Hymotion Prius – UDDS Fuel Use• 5 kWh A123 lithium and Prius packs – A/C kWh
Hymotion PHEV Prius MPG & kWh - UDDS Testing
01020
30405060
708090
100110
120130140150
160170180
7 15 22 30 37 45 52 60 67 75 82 90 97 105 112 119 127 134 142
MPG
0.00.51.0
1.52.02.53.0
3.54.04.55.05.5
6.06.57.07.5
8.08.59.0
Each Bar - 1 USSD Test Cycle, Labeled by Cumulative Miles
kWh
MPG per UDDS Test Cumulative AC kWh Cumulative MPG
25
Hymotion Prius – HWFET Fuel Use• 5 kWh A123 lithium and Prius packs – A/C kWh
Hymotion PHEV Prius MPG & kWh - HWFET Testing
0102030405060708090
100110120130140150160170180
10 21 31 41 51 62 72 82 92 103 113 123 133 144 154
MPG
0.00.51.01.52.02.53.03.54.04.55.05.56.06.57.07.58.08.59.0
Each Bar - 1 HWFET Test Cycle, Labeled by Cumulative Miles
kWh
MPG per FWHET Test Cumulative MPG Cumulative AC kWh
26
EnergyCS Prius – Fuel CostsEnergyCS PHEV Prius UDDS & HWFET Fuel Cost per Mile
$0.000
$0.005
$0.010
$0.015
$0.020
$0.025
$0.030
$0.035
$0.040
$0.045
$0.050
$0.055
$0.060
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Each Data Pioint Labeled by HWFET and UDDS Tests, uneven miles. Gas $3.25 gallon & kWh $0.10
Fuel
Cos
t per
Mile
ECS UDDS $ per Mile Gas
ECS UDDS $ per Mile kWh
ECS HWY $ per Mile Gas
ECS HWY $ per Mile kWh
ECS UDDS Combined $$ PER MILE
ECS HWY Combined $$ PER MILE
27
Hymotion Prius – Fuel CostsHymotion PHEV Prius UDDS & HWFET Fuel Cost per Mile
$0.000
$0.005
$0.010
$0.015
$0.020
$0.025
$0.030
$0.035
$0.040
$0.045
$0.050
$0.055
$0.060
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Each Data Pioint Labeled by HWFET and UDDS Tests, uneven miles. Gas $3.25 gallon & kWh $0.10
Fuel
Cos
t per
Mile
HYM UDDS $ per Mile Gas
HYM UDDS $ per Mile kWh
HYM HWY $ per Mile Gas
HYM HWY $ per Mile kWh
HYM UDDS Combined $$ PER MILE
HYM HWY Combined $$ PER MILE
28
EnergyCS Prius PHEV Accelerated TestingCycle Urban Highway Charge Reps Total Electricity Gasoline
(mi) (10 mi) (10 mi) (hr) (N) (mi) kWh Gals MPG10 1 0 4 60 60020 1 1 8 30 600 86.21 7.95 75.5 40 4 0 12 5 200 17.37 1.61 124.240 2 2 12 5 200 29.00 1.42 140.840 0 4 12 5 200 30.00 2.43 82.360 2 4 12 10 600 65.00 5.90 101.780 2 6 12 8 640 39.04 10.09 63.4
100 2 8 12 6 600 22.67 8.81 68.1200 2 18 12 3 600 12.98 10.46 57.4
Total 1740 2500 984 132 4240
29
Combined ECS and Hymotion Fuel CostsFuel Cost per Mile - Hymotion, EnergyCS (UDDS & HWFET) & Other Vehicles
$0.03
$0.04
$0.05
$0.06
$0.07
$0.08
$0.09
$0.10
$0.11
$0.12
$0.13
$0.14
$0.15
$0.16
$0.17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Each Data Point Labeled by HWFET and UDDS Tests, Uneven Miles. Gas $3.25 gallon & kWh - $0.10
Fuel
Cos
t per
Mile
ECS UDDS Combined $$ PER MILE
ECS HWY Combined $$ PER MILE
HYM UDDS Combined $$ PER MILE
HYM HWY Combined $$ PER MILE
PHEV Prius 45 MPG
ICE Gas 30 MPG
ICE Gas 20 MPG
ECS Prius Accelerated Testing
30
Other PHEV Test Vehicles and Partners• PHEVs to be tested
– Electrovaya Escape, Hymotion Civic and Escape, and HybridsPlus Escape (all lithium batteries)
• PHEV demonstration and testing partners– NYSERDA (New York State Energy Research and
Development Agency)– Seattle area: City of Seattle, Seattle City Light, King
County, Port of Seattle, Puget Sound Clean Air Agency
– Tacoma Public Utilities– Southern California Edison– State of Hawaii
31
Hydrogen Internal Combustion Engine (HICE) Vehicle Testing
32
APS Alternative Fuel (Hydrogen) Pilot Plant• Partners - Arizona Public Service (APS), Electric
Transportation Applications (ETA), INL, & DOE• First & longest operating hydrogen station in the
U.S. – since June 2002• Hydrogen produced onsite• Hydrogen & CNG fueling
33
Pilot Plant - Layout
Hydrogen Fuel Cell
2 H2 High psi tanks
H2 Low psi tank
H2 Compressor
2 CNG Compressors
6 CNG Tanks @ 3 psi levels)
34
Pilot Plant - Hydrogen SubsystemsOxygen
Water H2
Compressor High Pressure Storage
Low Pressure StorageDryerH2 Generator
Filter
Electricity
H2 Out
35
Pilot Plant – Hydrogen Subsystems cont’d• Proton Energy Systems’ HOGEN PEM stationary fuel
cell operating in reverse• Hydrogen Lectrodryer• Hydrogen compressor• Norman hydrogen filters• Hydrogen - 99.9997% purity
36
Pilot Plant - Hydrogen Subsystems cont’d• Low pressure hydrogen storage (lower tank)
– 8,955 SCF @ 150 psi• High pressure hydrogen storage (upper 2 tanks)
– 17,386 SCF @ 6,000 psi (total both tanks)
37
Pilot Plant - CNG Subsystem
Boost CompressorMain Compressor
CNG Output
Street Service Low
PressureNatural Gas
High Pressure Storage (3 levels)
38
Pilot Plant - CNG Subsystem cont’d• CNG Boost Compressor
– 300 scfm @ 60 psi • CNG Main Compressor
– 350 scfm @ 5,000 psi• CNG Storage/Pressure – 6 tanks
– 3 Low: 11,079 scf @ 3,600 psi– 2 Medium: 5,711 scf @ 4,500 psi– 1 High: 5,711 scf @ 5,000 psi
39
Pilot Plant - Fueling Dispensers• Includes metering & electronic billing interface• Fully permitted for motor fuel dispensing• Public access
40
15% HCNG Dodge Van Emissions Testing• 5.2 L CNG V8 (no modifications) with 71,000 HCNG test
miles - no problems - 15.5 miles/GGE
Percentage change in 15% HCNG emissions compared to 100% CNG emissions
Total hydrocarbons -34.7%
Carbon monoxide -55.4%
Oxides of nitrogen +92.1%
Carbon dioxide -11.3%
41
30% HCNG F150 Testing• 5.4 L V8 CNG base engine – added supercharger,
ignition modifications & exhaust gas recirculator• Fleet testing HCNG miles: 17.3 miles/GGE
Fuel Blend 0 to 60 mph (secs.) Miles/GGE Range (miles)
CNG 10.10 23.3 122
15% HCNG 10.97 22.6 110
30% HCNG 12.68 23.5 102
42
30% HCNG F150 Emissions TestingPercentage Change in Emissions TestingFuel
Type NMHC CH4 HC CO NOX CO2
Gasoline Base Base Base Base Base Base
CNG -80 +967 +35 -63 -34 -24
15% HCNG -78 +1000 +40 -70 -26 -27
30% HCNG -89 +1050 +37 -73 -25 -28NMHC=Non-Methane Hydrocarbons CH4=MethaneHC=Total Hydrocarbons CO=Carbon MonoxideNOx=Oxides of Nitrogen CO2=Carbon Dioxide
43
50% HCNG F150 Emissions Testing• Modifications
– SVO heads, exhaust intercooler & supercharger– Exhaust gas recirculator & ignition modification– Equipped with 3 Quantum hydrogen 3,600 psi tanks
with 9 kg total storage
Percent reduction in emissions (HCNG versus gasoline-fueled F-150)
HC CO NOX CO2
-3.5% -43.3% -97.0% -16.7%
HC = total hydrocarbonsCO = carbon monoxideCO2 = carbon dioxideNOx = oxides of nitrogen
44
5.4L 16-valve 100% Hydrogen ICE Vehicle• 5.4L V-8, 100% hydrogen 16-valve Ford/ETEC pickup• 5 speed transmission, supercharged (3 psi), lean-burn• Onboard hydrogen storage 3 Dynetek tanks @ 3,000
psi, 6.5 kg, aluminum vessel & fiberglass wrap• SAE J1634 fuel economy (AC on): 14.5 miles/GGE• SAE J1634 fuel economy (AC off): 18.0 miles/GGE• Fleet testing – 18.5 miles per GGE (120 miles range)
45
5.4L 32-valve 100% Hydrogen ICE Vehicle• 5.4L V-8, 100% hydrogen 32-valve Ford/ETEC pickup• 12 pounds supercharger boost, with hardened valves
& seats, and forged pistons with 11.5:1 compression• 13.0 miles per GGE in fleet testing• Onboard hydrogen storage 3 Dynetek tanks @ 5,000
psi, 15.3 kg (200-mile range)
46
6L V-8 100% Hydrogen ICE Vehicle• Base vehicle: Chevrolet 1500HD crew cab (4 door)
with 6L V8 CNG engine, converted by ETEC/Roush to 100% hydrogen
• 10.5 kg 100% hydrogen storage onboard @ 5,000 psi• 200 Horsepower & 260 lb-ft torque• 14 city & 20 highway miles per GGE - range of 140 to
200 miles• Eight vehicles in fleet testing in Vancouver B.C.
47
AcknowledgementThis work is supported by DOE’s
FreedomCAR and Vehicle Technologies ProgramVehicle Systems Team Leader, Tien Duong
AVTA DOE Lead, Lee Slezak
http://avt.inl.govAdditional Information
INL/CON-07-13004
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