u.s. department of energy - advanced vehicle …. department of energy - advanced vehicle testing...
TRANSCRIPT
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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
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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
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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
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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
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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
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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
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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)
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Hybrid Electric Vehicle (HEV) Testing
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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
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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
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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
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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
g-01
Sep-
01O
ct-0
1N
ov-0
1D
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1Ja
n-02
Feb-
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ar-0
2Ap
r-02
May
-02
Jun-
02Ju
l-02
Aug-
02Se
p-02
Oct
-02
Nov
-02
Dec
-02
Jan-
03Fe
b-03
Mar
-03
Apr-
03M
ay-0
3Ju
n-03
Jul-0
3Au
g-03
Sep-
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ct-0
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3D
ec-0
3Ja
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Feb-
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ar-0
4Ap
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May
-04
Jun-
04Ju
l-04
Aug-
04Se
p-04
Oct
-04
Nov
-04
Dec
-04
Jan-
05Fe
b-05
Mar
-05
Apr-
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ay-0
5Ju
n-05
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5Au
g-05
Sep-
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ct-0
5N
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5D
ec-0
5Ja
n-06
Feb-
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ar-0
6Ap
r-06
May
-06
Jun-
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l-06
Aug-
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p-06
Oct
-06
Nov
-06
Dec
-06
Jan-
07Fe
b-07
Mar
-07
Apr-
07M
ay-0
7
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)
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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
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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
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HEV Accelerated Testing• Monthly miles per gallon
HEV Monthly Miles per Gallon
15
20
25
30
35
40
45
50
55
Aug-
01Se
p-01
Oct
-01
Nov
-01
Dec
-01
Jan-
02Fe
b-02
Mar
-02
Apr-
02M
ay-0
2Ju
n-02
Jul-0
2Au
g-02
Sep-
02O
ct-0
2N
ov-0
2D
ec-0
2Ja
n-03
Feb-
03M
ar-0
3Ap
r-03
May
-03
Jun-
03Ju
l-03
Aug-
03Se
p-03
Oct
-03
Nov
-03
Dec
-03
Jan-
04Fe
b-04
Mar
-04
Apr-
04M
ay-0
4Ju
n-04
Jul-0
4Au
g-04
Sep-
04O
ct-0
4N
ov-0
4D
ec-0
4Ja
n-05
Feb-
05M
ar-0
5Ap
r-05
May
-05
Jun-
05Ju
l-05
Aug-
05Se
p-05
Oct
-05
Nov
-05
Dec
-05
Jan-
06Fe
b-06
Mar
-06
Apr-
06M
ay-0
6Ju
n-06
Jul-0
6Au
g-06
Sep-
06O
ct-0
6N
ov-0
6D
ec-0
6Ja
n-07
Feb-
07M
ar-0
7Ap
r-07
May
-07
Mile
s pe
r Gal
lon
Accord Insight
Gen I Civic Gen I Prius
Gen II Prius Silverado
Escape RX400h
Highlander Camry
Gen II Civic Vue
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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
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HEV Maintenance and Repairs Tracked
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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
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Plug-in Hybrid Electric Vehicle (PHEV) Testing
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• 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
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PHEV Baseline Performance Testing
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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
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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
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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
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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
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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
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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
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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
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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
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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
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Hydrogen Internal Combustion Engine (HICE) Vehicle Testing
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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
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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)
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Pilot Plant - Hydrogen SubsystemsOxygen
Water H2
Compressor High Pressure Storage
Low Pressure StorageDryerH2 Generator
Filter
Electricity
H2 Out
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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
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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)
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Pilot Plant - CNG Subsystem
Boost CompressorMain Compressor
CNG Output
Street Service Low
PressureNatural Gas
High Pressure Storage (3 levels)
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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
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Pilot Plant - Fueling Dispensers• Includes metering & electronic billing interface• Fully permitted for motor fuel dispensing• Public access
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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%
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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
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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
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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
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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)
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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)
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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.
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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