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