u.s. department of energy’s vehicle technologies...
TRANSCRIPT
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U.S. Department of Energy’s Vehicle Technologies Program -
Sun Valley Community Forum, Plug-in Hybrid Electric Vehicles: Status and Testing Activities
Jim Francfort
Ketchum, IdahoSeptember 2008
This presentation does not contain any proprietary or sensitive information
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AVTA Background and Goal• The Advanced Vehicle Testing Activity (AVTA) is
conducted for DOE by the Idaho National Laboratory (INL) and Electric Transportation Engineering Corporation (ETEC), with Argonne National Laboratory providing testing support
• AVTA Goal– Provide vehicle and fueling infrastructure
benchmark data to technology modelers, research and development programs, and target and goal setters
– Assist fleet managers (often the early adaptors of alternative fuel vehicles) and the public in making informed vehicle purchase, deployment and operating decisions
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AVTA Testing History• Plug-in hybrid electric vehicles (PHEV)
– 9 models, ~75 vehicles• Hybrid electric vehicles (HEV)
– 14 models, 4 million test miles• Hydrogen ICE (internal combustion engine) vehicles
– 7 models, 400,000 test miles• Full-size electric vehicles
– 40 EV models, 5+ million test miles• Neighborhood electric vehicles
– 16 models, 200,000 test miles• Urban electric vehicles
– 3 models, 1 million test miles
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AVTA Testing Objectives• Benchmark and reduce operational uncertainties of
emerging technologies– Perform independent vehicle testing in track,
laboratory and on-road/fleet environments– Document battery life, charging patterns and
demand profiles, vehicle operations, and fuel use– Document fueling infrastructure requirements and
costs in real-world environments (both electricity and gasoline)
– Document life-cycle costs
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PHEV Definition• An electric grid recharged hybrid electric vehicle that is
powered by combinations of gasoline and electricity• Contain an internal combustion engine, electric motor,
and battery pack that allow more all-electric or electric-assist operations than a conventional HEV, someday with an all-electric range greater than 10 miles
• Currently recharged by plugging into standard 110 V, 15 amp (or greater) wall outlets
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Advanced Batteries are Improving, But• Consumer acceptance of HEVs due to the durability of
NiMH batteries• Gradual displacement of NiMH batteries is expected as
lithium ion promises increased performance/longer life• Cost of Li ion batteries for consumer electronics is now
below that of NiCd and NiMH batteries (<$500/kWh)• Li ion viewed as most viable energy storage option due
to potential for higher energy and power densities• Current Li ion batteries are 8X the DOE PHEV goal
($2000/kWh today vs. $250/kWh goal in 2015)• Further Li ion improvements are needed before a large
penetration of PHEVs can occur and a transition to EV’s can take place
• Projections of 10-15 year life are based on limited data, with questions on abuse tolerance and low-temperature performance
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9 PHEVs Models in Testing/Demonstrations • Most equipped with lithium
traction batteries• Hymotion Prius • Hymotion Escape• EnergyCS Prius• Electrovaya Escape• Hybrids Plus Escape• Hybrids Plus Prius• Manzanita Prius (lead acid)• Ford Escape• Renault Kangoo (NiCad)
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Hymotion Prius – UDDS Fuel Use• 5 kWh A123 lithium & Prius packs – AC 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 UDDS 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 & Prius packs – AC 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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PHEV Accelerated Testing• Accelerated testing in Phoenix over 5,440 miles• GPS units track distance, average and maximum speeds
188.357%43%Average5,4401621,3443,1002,340Total
11%2%60031218220011%4%6006128210012%5%640812628011%6%6001012426011%9%6001512404011%9%6001512224011%9%6001512044011%19%600308112011%37%6006040110(%)(%)(mi)(N)(hr)(10 mi)(10 mi)(mi)
MilesRepsTotalRepsChargeHighwayUrbanCycle
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Hymotion Prius – Accelerated Testing
101.1 6.0584.1060015120440
127.24.81
86.4 Weighted Average5,440167140431002540Total54.811.0215.060031218220073.28.4335.986006128210058.311.3643.99640812628068.98.9855.336001012426073.18.5479.8260015124040
106.95.7887.2260015122240
115.9 5.37122.026003081120136.336006040110
MPGGalskWh(mi)(N)(hr)(10 mi)(10 mi)(mi)
GasolineElectricityTotalRepsChargeHighwayUrbanCycle
Each total distance slightly greater than 600 and 640 miles. HEV version = 44 mpg
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EnergyCS Prius – Accelerated Testing
42.714.2925.00600*15120440
128.14.78115.586006040110
Weighted Average484014798425002340Total57.810.4612.9860031218220070.88.8122.676006128210065.810.0939.046408126280
103.75.9065.006001012426055.511.3632.44600*5124040
Testing600*5122240
77.9 7.95 86.216003081120
MPGGalskWh(mi)(N)(hr)(10 mi)(10 mi)(mi)
GasolineElectricityTotalRepsChargeHighwayUrbanCycle
*Software updated and cells replaced. Rerun. Each total distance slightly greater than 600 miles. HEV version = 44 mpg
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Hymotion Escape – Accelerated Testing
38.715.99
45.3
41.114.9157.5160015120440
Weighted Average5440162134431002340Total33.517.7226.0960031218220039.815.6958.646006128210041.316.0577.696408126280
13.7097.186001012426051.511.92114.1460015124040
76.2960015122240
45.713.51163.296003081120Testing6006040110
MPGGalsAC kWh(mi)(N)(hr)(10 mi)(10 mi)(mi)GasolineElectricityTotalRepsChargeHighwayUrbanCycle
Each total distance slightly greater than 600 miles. HEV version = 27 mpg
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Electrovaya Escape – Accelerated Testing
43.137.316.4271.360015120440
Weighted Average5440162134431002340Total600312182200
29.221.1720.856006128210040.816.3042.72640812628037.316.6444.796001012426029.820.7355.8460015124040
14.3469.860015122240
60030811206006040110
MPGGalsAC kWh(mi)(N)(hr)(10 mi)(10 mi)(mi)GasolineElectricityTotalRepsChargeHighwayUrbanCycle
Each total distance slightly greater than 600 miles. HEV version = 27 mpg
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* Testing ended when gasoline engine and inverter failed. Each total distance slightly greater than 600 miles.
Renault Kangoo – Accelerated Testing
Deleted*Deleted*
44.6257.9628.6033.2235.18
131.96
359.60AC kWh
Electricity
05.62005120440
0
3,04012387614801560Total60031218220060061282100
38.616.614.4640812628045.113.310.460010124260
07.0200512404006.02005122240
04.66003081120
1.76006040110MPGGalsMi/kWh(mi)(N)(hr)(10 mi)(10 mi)(mi)
GasolineTotalRepsChargeHighwayUrbanCycle
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Hymotion Prius – Fuel CostsHymotion PHEV Prius UDDS & HWFEDS 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$0.065
$0.070
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 HWFEDS and UDDS tests, uneven miles. Gas $4.00 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 Prius UDDS Combined $$ PER MILE
HYM Prius HWY Combined $$ PER MILE
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PHEV Vs. HEV and ICE Fuel Costs per MilePHEVs, HEV & ICEs - Fuel Costs per Mile
$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$0.18$0.19$0.20$0.21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Each data point labeled by HWFEDS and UDDS Tests, Uneven Miles. Gas $4.00 gallon & kWh $0.10
Fuel
Cos
t per
Mile
ECS UDDS Combined $$ PER MILEECS HWY Combined $$ PER MILEHYM Prius UDDS Combined $$ PER MILEHYM Prius HWY Combined $$ PER MILEHEV Prius 45 MPGICE Gas 30 MPGICE Gas 20 MPGECS Prius Accelerated TestingHYM Escape UDDS Combined $$ PER MILEHYM Escape HWY Combined $$ PER MILEHYM Prius Accelerated TestingEltro UDDS Combined $$ PER MILEEltro HWY Combined $$ PER MILE
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PHEV Fleet Testing Partners• With Hymotion, collecting onboard data from 50 PHEVs• Onboard, cellular V2Green data loggers collect vehicle
fuel use, performance, and charging and driving profiles– NYSERDA – original PHEV demos @ $100k per model– City of Seattle, King County, Port of Seattle, Puget
Sound Clean Air Agency and Tacoma Power, 15 PHEVs– Washington State, Port of Chelan lead, 14 PHEVs– UC Davis, with 70 public drivers, 13 PHEVs– National Rural Electric Coop Association, 7+ PHEVs– Maui and Oahu, HECO, MECO, State, University,
County, and Air Force, 6 PHEVs, Nov 2008
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Single Hymotion Prius Charging Profiles• 3 months, 2212 miles, 35 charges
Time at start of charging
0
2
4
6
8
10
12
140
- <2
2 - <
4
4 - <
6
6 - <
8
8 - <
10
10 -
<12
12 -
<14
14 -
<16
16 -
<18
18 -
<20
20 -
<22
22 -
<24
Time
# of
cha
rgin
g ev
ents
AC energy in per charging event (kWh)
0123456789
0.5 1
1.5 2
2.5 3
3.5 4
4.5 5
Mor
e
Kilowatt Hours
# of
cha
rgin
g ev
ents
Length of charging time per charging event
0
2
4
6
8
10
12
1 2 3 4 5 6 7 8 9 10 MoreHours
# of
cha
rgin
g ev
ents
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Single Hymotion Prius Charging Profiles
Plug-in battery SOC after charging
0
5
10
15
20
25
30
10 20 30 40 50 60 70 80 90 100SOC%
# of
cha
rgin
g ev
ents
Number of trips since last charging event
0
2
4
6
8
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0 1 2 3 4 5 6 7 8 9 10 MoreTrips since last charging event
Freq
uenc
y
Plug-in battery SOC prior to charging
0
2
4
6
8
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10 20 30 40 50 60 70 80 90 100SOC %
# of
cha
rgin
g ev
ents
Total distance since last charging event (mi)
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0 10 20 30 40 50 60 70 80 90 100 110 120MoreMiles
# of
cha
rgin
g ev
ents
• 3 months, 2212 miles, 35 charges
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26 Hymotion Prius - January thru May 2008• Below averages do NOT tell the whole PHEV energy-
use potential – see following May-only slides
48
40
49
59
Miles per Gallon
42,000
16,059
11,121
14,820
Distance Traveled (Miles)
1,358Charge Sustaining (CS)
4,835
404
3,073
Number of Trips
All trips combined
Mixed CD / CS
Charge Depleting (CD)
Charge / Operating Mode
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13 Hymotion Prius in May 2008 - MPG• Below averages do NOT tell the whole PHEV energy use
potential – see following slides
55.9
40.2
52.1
72.0
MPG
8.1
7.0
0.9
10.6
27.5
5.3
Average Trip Distance (miles)
6,291
6,417
127
1,411
1,840
3,040
Total Distance (Miles)
775CD, CS, CD/CS results (excludes EV results)
133Charge Sustaining (CS)
912
137
67
575
Number of Trips
Total
0.236Electric vehicle only (EV)
0.050Mixed CD / CS
0.138Charge Depleting (CD)
DC kWh per MileCharge / Operating Mode
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13 Hymotion Prius and MPGTrip Fuel Economy vs. Trip Average Speed - May 2008
0
50
100
150
200
250
300
0 10 20 30 40 50 60 70 80 90
Trip Average Speed (mph)
Trip
Fue
l Eco
nom
y (m
pg)
CD tripsCD/CS tripsCS trips
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13 Hymotion Prius and MPGTrip Fuel Economy vs. Trip Distance
0
50
100
150
200
250
300
0 5 10 15 20 25 30 35 40 45 50
Trip Distance (mi)
Trip
Fue
l Eco
nom
y (m
pg)
CD tripsCD/CS tripsCS trips
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13 Hymotion Prius and Aggressive DrivingMPG vs. Trip Aggressiveness (Percent of time above the 40% accelerator pedal position)
0%
10%
20%
30%
40%
50%
60%
0 25 50 75 100 125 150 175 200 225 250 275 300
Trip Fuel Economy (mpg)
Agg
ress
iven
ess
Fact
or
CD tripsCD/CS tripsCS tripsLog. (CD trips)Log. (CD/CS trips)
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14 - Canada
2
8+23
1
11
5
11+2
2
6
1+?
22+8
3+1
?
2+1 5+20
1
69 w/data loggers64 adding CY08? In discussion133 Total end of CY08
AVTA PHEV Demos with Data Loggers
1
1
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PHEV Charging Infrastructure• National Electric Code requires
– Dedicated branch circuit– GFCI (ground fault circuit interrupt)– “EV” extension cord– Unique connector “plug”
• NEC being updated
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PHEV Market Status - Converters• Hymotion: 100+ Prius ($9995) and 5 Escapes
– Prius only battery production ramp-up now, replaced all 67 Version I batteries. Recall Escapes
– Prius crash-tested and obtaining CARB certification– Conversions and warranty work in Boston, Los
Angeles, Minneapolis, San Francisco, and Seattle • Hybrids Plus: 35 Prius and Escapes, ($21,600 to $36,150).
Some operational issues• EnergyCS: ~30 Prius (~$40,000). Some past operational
issues, only doing custom conversions in future• Manzanita lead acid Prius conversions ($12,000) by
several groups. Some operational issues• Electrovaya: 2 Escapes. Some operational issues• Various single conversion “companies”
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PHEV Market Status - OEMs• Daimler Benz – 6 Sprinters late 2008, 1 to AVTA• Ford: 20 Escapes in 2008/2009. 2 currently • General Motors: Volt late 2010. Maybe Vue earlier• Chrysler: potential 1 of 3 PHEV / EV models in 2010• Renault Kangoo: ~1,200 NiCad range-extender PHEVs in
Europe (was 1 in U.S.), but shipped AVTA’s to Brussels for repair and sale
• Toyota: ~20 Prius NiMH PHEVs in U.S., France and Japan, gaining operational knowledge. To fleets in 2009
• Volvo and other OEMs have made various PHEV announcements
• DOE/s PHEV TADA solicitation: Ford, Chrysler/GE, and GM in negotiations. AVTA to test products
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AVTA Webpage Use and Gasoline CostsINL WWW Visitors & Gasoline Costs
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
May
'02
June
July
Aug
Sept
Oct
Nov
Dec
'02
Jan
'03
Feb
Mar
chAp
rilM
ay
June
July
Aug
Sept
Oct
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Dec
'03
Jan
'04
Feb
Mar
chAp
rilM
ayJu
neJu
lyAu
gSe
ptO
ctN
ovD
ec '0
4Ja
n '0
5Fe
bM
arch
April
May
June
July
Aug
Sept
Oct
Nov
Dec
'05
Jan
'06
Feb
Mar
chAp
rilM
ayJu
neJu
lyAu
gSe
ptO
ctN
ov
Dec
'06
Jan
'07
Feb
Mar
chAp
rilM
ayJu
neJu
lyAu
gSe
ptO
ctN
ovD
ec '0
7Ja
n '0
8Fe
bM
arch
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Num
ber o
f Mon
thly
Vis
itors
$1.25
$1.50
$1.75
$2.00
$2.25
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$2.75
$3.00
$3.25
$3.50
$3.75
$4.00
$4.25
All
Gra
des
Gas
olin
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osts
- E
nd o
f Mon
th
Visitors (left axis)Gasoline Cost (right axis) Linear (Gasoline Cost (right axis) )Linear (Visitors (left axis))
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http://avt.inl.gov or
http://www1.eere.energy.gov/vehiclesandfuels/avta/
Additional Information
INL/CON-08-14863