vehicle technologies program/media/others/events/... · aluminum engine block and . 45-55% lighter...

Program Name or Ancillary Text eere.energy.gov

Vehicle Technologies Program

Edwin OwensSupervisor - Hybrid Vehicle Systems & Advanced Materials

Vehicle Technologies Program eere.energy.gov

U.S. Petroleum Gap (2009)

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U.S. Production

Electric Utilities

Biofuels


U.S. Petroleum Production and Consumption, Transportation

• 240 million vehicles on the road• Approximately 9M new cars & light trucks for 2009. Average is 15.7 M/yr

2002-2007• 11.5 Million barrels of oil per day consumed by on-road vehicles• Light-duty vehicles consume 60% of transportation fuel, and account for 42%

of total US petroleum use.


Where are the opportunities for reducing transportation petroleum demand?

(In addition to walking more)

For Light-duty Passenger Vehicles


Vehicle Energy Consumption

Engine Losses = 62.4%

Aero-Dynamic Drag = 2.6%Inertia = 5.8% → Brakes

Drivesystem Friction = 5.6%

Rolling Resistance = 4.2%

Accessory Loads = 2.2%Idling = 17.2%

Vehicle Technologies• Advanced Engine Development

• Automotive Fuel Cells• Hybrid Electric Drivetrains

• Advanced Materials






Rolling Resistance

= 4.2%










Rolling Resistance = 4.2%






• Advanced Engine Combustion R&D• Materials Development• Batteries and Electric Drives• Fuel Cells

Program Overviews


Increasing engine efficiency a cost-effective approach to increasing fuel economy

Benefits All Vehicle Classes

Advanced Engine Combustion R&D

Heavy-Duty

Light-Duty

Class 2b-8Cars

Trucks• Power Rating: 100-300hp

• Power Rating: 200-400hp

• Power Rating: 250-600hp

Status and Targets

“Support improved mileage performance of internal combustion engines…” – Secretary of Energy Steven Chu

25-40% ImprovementUp to 20%

Improvement

Improve gasoline engine efficiency by advancing technologies such as lean-burn

operation, turbocharging, variable valve actuation, variable compression ratio

2015 Passenger Vehicle: Improve gasoline vehicle fuel economy by 25% and diesel vehicle fuel economy

by 40%; compared to 2009 gasoline baseline

2015 Commercial Engine: Improve commercial engine efficiency by more than 20%; compared to

2009 baseline

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Materials Development

Vehicle lightweighting is a effective way of reducing fuel consumption

Types of Materials and Benefits

MagnesiumCarbon Fiber25-35% Lighter than a

Aluminum Engine Block and 45-55% Lighter Compared

to Cast Iron

50-60% Lighter than a Standard Steel Body in White

Lightweighting improves fuel economy and reduces the demands on the powertrain and ancillary systems (e.g., braking)

Targets and Status

* Hypothetical Distribution

2015 Target: Validate cost-effective reduction of passenger vehicle body and chassis weight by 50% in high volume applications compared to 2002 vehicles.2015 Target: Commercial introduction of thermoelectric coolers/heaters to replace vehicle A/C systems

2009 Status: Modeling demonstrated that body and chassis weight reduction goal of 40% could be achieved, but not at cost parity.2009 Status: Thermoelectrics that convert engine waste heat directly to electricity which provides a 5% improvement in fuel economy on the highway


Hybrid Electric Drive OptionsPe

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Ford Fusion Hybrid

Toyota Prius-Hybrid

Chevy Volt –Plug-in Electric

Nissan Leaf- All Electric Honda Clarity – Fuel Cell

Ford F-150


Batteries and Electric Drive Technology

Drivetrain electrification is inherently efficient and a clear pathway to low-carbon transportation. Program targets focus on enabling market success

2009 Status: $8000-$12,000 for a PHEV 40-

mile range battery2009 Status: Current cost

of the electric traction system is ~$34/kW

2014 PHEV: Battery that has a 40-mile all-electric range and cost $3,400

2015 PEEM: Cost for electric traction system no greater than $12/kW peak by 2015

Types of Vehicles and Benefits

HEVToyota Prius 50 MPG• 1 kWh battery

• Power Rating: 80kW• System Cost: $3000

PHEVChevy Volt 100 MPGe

• 16 kWh battery• Power Rating: 170kW• System Cost: est. $16,000

EVNissan Leaf All Electric

• ≥ 40 kWh battery• Power Rating: ≥ 110kW• System Cost: est.$36,000

Potential Benefits• Potential oil savings in 2030 is ~1.25 million barrels per day (Mbpd)• Corresponding GHG emissions reduction is ~170 million metric tons of CO2 equivalent

(MMTCO2e)

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Power and Energy Storage

Relative Performance of Various Electrochemical Energy Storage Devices

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1000

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Ener

gy (W

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100 101 102 103 104

Specific Power (W/kg)

Lead-Acid

Capacitors

IC Engine

36 s0.1 h1 h

10 h

100 h

Ni-MH

Li-ion

Lead-Acid

Capacitors

New Battery Chemistry

IC Engine

36 s0.1 h1 h

10 h

100 h

Ni-MH

Li-ion

Acceleration

Ran

ge

Lead-Acid

Capacitors

IC Engine

EV goal

HEV goal

3.6 s36 s0.1 h1 h

10 h

100 h

Ni-MH

Li-ion PHEV-40 goal

PHEV-10 goal

Source: Product Data Sheets


Hybrid-Electric Systems

• Cell materials & fabrication represents about 3/4 the cost for PHEV batteries

• For significant cost reduction, new materials with increased energy density are needed to reduce: - material needs- cell count, and- cell/pack hardware

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Battery Cost Reduction

53%35%

12%

Prius Electric Traction Drive System Cost

DistributionPEEM

Battery

Generator

While Power Electronics & Electric Machine (PEEM) costs predominate in a HEV traction drive system, increased battery size in PHEV configurations will necessitate increased focus on battery cost reduction.


Fuel Cells — Where are we today?

Fuel Cells for TransportationIn the U.S., there are currently:

> 200 fuel cell vehicles > 20 fuel cell buses~ 60 fueling stations

Production & Delivery of Hydrogen

In the U.S., there are currently:

~9 million metric tons of H2 produced annually

> 1200 miles of H2 pipelines

Fuel Cells for Stationary Power, Auxiliary Power, and Specialty Vehicles

Fuel cells can be a cost-competitive option for

critical-load facilities, backup power, and forklifts.

The largest markets for fuel cells today are in stationary power, portable power, auxiliary power units, and forklifts.

~75,000 fuel cells have been shipped worldwide.

~24,000 fuel cells were shipped in 2009(> 40% increase over 2008).

Several manufacturers—including Toyota, Honda, Hyundai, Daimler, GM, and Proterra (buses) —have announced plans to commercialize vehicles by 2015.

GM

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GHG Emissions and Petroleum Consumption by Vehicle Technology

GHG Emissions (g CO2-eq / mi) Petroleum Consumption (gal gas-eq / mi)

Reference vehicle GHG

emissions: 430 g C02 eq/mi

50% reduction from reference vehicle GHG

emissions: 215 g CO2 eq/mi

What is the payoff? -- 2030


Car Technology Penetration Years afterFirst Significant Use


Vehicle and Systems Simulation and Testing

PHEV Market Introduction Study

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Current Policy Case (CPC) CPC Plus State Sales Tax ExemptionCPC Plus Plug-in Vehicle Tax Credit Extension CPC Plus Annual Operating Cost Allowance - $150CPC Plus "Progressive Feebate" Option - All Vehicles CPC Plus Federally - Backed Battery WarrantyCPC Plus Increased Charging Infrastructure - City & Suburb CPC Plus PHEV Federal Fleet Mandates

PHEV Market Introduction Study. ORNL, Sentech Inc, and University of Michigan Transportation Research Institute (UMTRI).


Prius sales are related to the price of gasoline.

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Investments


Fiscal Year 2010 Budget

Total – $311 MVehicle Technologies

Hybrid ElectricSystems$146M

Fuels$24M Technology

Integration$33M

Materials$51M

Advanced Combustion $57M

Vehicle Technologies and ARRATotal – $3.1 B

VTP

VTP ARRA

$311 M

$ 2.8 B


$30.7 M investment in Lightweight Materials Technology to accelerate the introduction of light weight materials and structures for vehicles in order to reduce transportation fuel consumption and greenhouse gas emissions.

$13 M investment in Propulsion Material Technology to develop high performance materials for automotive engine components, in order to improved the performance, efficiency, and emissions of internal combustion engines.

$5.7 M investment in High Temperature Materials Laboratory to make available to researchers a set of unique analytical tools and techniques for characterizing the behavior of materials at high temperatures and stresses.

$44 M investment in Power Electronics and Electric Machines to accelerate development of lower cost, compact, highly efficient electronic power management systems and electric motors for electric drive vehicles.

$76.3 M investment in Energy Storage for high performance, lower cost energy storage devices, including high capacity lithium-ion batteries and capacitors.

$22.3 M investment in Vehicle and Systems Simulation and Testing for modeling and field evaluation of hybrid, plug-hybrid, and electric vehicles, and development of the infrastructure to support large numbers of electric vehicles charged from the utility grids.

Materials and Energy Storage 2010 Budgets


$300 Million for Clean CitiesThe Recovery Act funding for state and local governments, and transit authorities will expand the nation’s fleet of clean, sustainable vehicles and the fueling infrastructure necessary to support them.$100 Million for SuperTruck and Advanced Combustion R&DHeavy-duty trucks are emphasized because they rapidly adopt new technologies and account for 20% of the fuel consumed in the United States.

$1.5 Billion to accelerate the manufacturing and deployment of the next generation of U.S. batteries

$500 Million for Electric-drive Components Manufacturing

$400 Million for Transportation ElectrificationRecovery Act money is funding 48 new projects in advanced battery and electric drive components manufacturing and electric drive vehicle deployment in over 20 states: Directly resulting in the creation tens of thousands of manufacturing jobs in the U.S. battery and auto industries

Vehicle Technologies Recovery Act Funding – 2.8 Billion


Thank you

Edwin Owens, SupervisorHybrid Electric Systems and Materials Technology

202-586-4830

www.annualmeritreview.energy.gov/

vehicle technologies program/media/others/events/... · aluminum engine block and . 45-55% lighter...

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